Honda SH300 2006 Manual

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TYPE CODE

• Throughout this manual, the following abbreviations are used to identify individual model.

SH300/SH300A

CODE

AREA TYPE

EUROPEAN DIRECT SALES

U.K.

France

SH300II/AII

CODE

AREA TYPE

U.K.

France

SH300III/AIII

CODE

AREA TYPE

EUROPEAN DIRECT SALES

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Summary of Contents for Honda SH300 2006

Page 1 TYPE CODE • Throughout this manual, the following abbreviations are used to identify individual model. SH300/SH300A CODE AREA TYPE EUROPEAN DIRECT SALES U.K. France SH300II/AII CODE AREA TYPE U.K. France SH300III/AIII CODE AREA TYPE EUROPEAN DIRECT SALES...
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 WIRING DIAGRAMS THE TIME OF APPROVAL FOR PRINTING. Honda Motor Co., Ltd. RESERVES THE RIGHT TROUBLESHOOTING TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLI- INDEX GATION WHATSOEVER.
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 a locking agent. Use a middle strength locking agent unless otherwise specified.
Page 5: Table Of Contents
1. GENERAL INFORMATION SERVICE RULES ········································· 1-2 FRONT WHEEL/SUSPENSION/ STEERING SPECIFICATIONS ·················· 1-10 MODEL IDENTIFICATION··························· 1-3 REAR WHEEL/SUSPENSION SPECIFICATIONS ····································· 1-10 GENERAL SPECIFICATIONS······················ 1-5 HYDRAULIC BRAKE SPECIFICATIONS··· 1-10 LUBRICATION SYSTEM SPECIFICATIONS········································ 1-7 BATTERY/CHARGING SYSTEM SPECIFICATIONS ····································· 1-11 FUEL SYSTEM (PGM-FI) SPECIFICATIONS········································...
Page 6: Service Rules
SERVICE RULES GENERAL INFORMATION 1. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that don't meet Honda's design specifications may cause damage to the motorcycle. 2. Use the special tools designed for this product to avoid damage and incorrect assembly.
Page 7: Model Identification
GENERAL INFORMATION MODEL IDENTIFICATION SERIAL NUMBERS The Vehicle Identification Number (V.I.N.) is stamped on the right side of the frame near the rear shock absorber. VEHICLE IDENTIFICATION NUMBER The registered number plate is attached on the left side of the frame near the rear shock absorber.
Page 8 GENERAL INFORMATION The engine serial number is stamped on the final reduction case near the rear wheel. ENGINE SERIAL NUMBER The throttle body identification number is stamped on the lower side of the throttle body. THROTTLE BODY IDENTIFICATION NUMBER LABEL The color label is attached on the luggage box.
Page 9: General Specifications
GENERAL INFORMATION GENERAL SPECIFICATIONS STD TYPE: ITEM SPECIFICATION DIMENSIONS Overall length 2,096 mm (82.5 in) Overall width 730 mm (28.7 in) Overall height 1,187 mm (46.7 in) Wheelbase 1,430 mm (56.3 in) Seat height 785 mm (30.9 in) Ground clearance 136 mm (5.4 in) Curb weight 169 kg (372.6 lbs)
Page 10 GENERAL INFORMATION ABS TYPE: ITEM SPECIFICATION DIMENSIONS Overall length 2,096 mm (82.5 in) Overall width 730 mm (28.7 in) Overall height 1,187 mm (46.7 in) Wheelbase 1,430 mm (56.3 in) Seat height 785 mm (30.9 in) Ground clearance 136 mm (5.4 in) Curb weight 172 kg (379.2 lbs) Maximum weight capacity...
Page 11: Specifications
– After disassembly 1.7 liter (1.8 US qt, 1.5 lmp qt) – Recommended oil Honda "4-stroke motorcycle oil" or an equivalent API service classification: SG or higher (except oils labeled as energy conserv- – ing on the circular API service label)
Page 12 GENERAL INFORMATION CYLINDER HEAD/VALVES SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Cylinder compression at 450 min (rpm) 1,569 kPa (16.0 kgf/cm , 228 psi) – Camshaft Cam lobe height 39.325 – 39.485 (1.5482 – 1.5545) 39.295 (1.5470) 37.034 – 37.194 (1.4580– 1.4643) 37.034 (1.4580) Cylinder head warpage –...
Page 13: Specifications
0.28 liter (0.30 US qt, 0.25 lmp qt) After disassembly 0.30 liter (0.32 US qt, 0.26 lmp qt) Recommended final drive oil Honda "4-stroke motorcycle oil" or an equivalent API service classification: SG or higher (except oils labeled as energy conserving on the circular API service label)
Page 14 Fork Spring free length 263.5 (10.37) 257.5 (10.14) Pipe runout – 0.2 (0.01) Recommended fork Honda Ultra Cushion Oil 10W – fluid or equivalent Fluid level 90 (3.5) – 151 ± 2.5 cm (5.1 ± 0.08 US oz, 5.3 ±...
Page 15: Specifications
GENERAL INFORMATION BATTERY/CHARGING SYSTEM SPECIFICATIONS ITEM SPECIFICATIONS Battery Capacity 12 V – 11 (10) Ah Current leakage 1.5 mA max. Voltage Fully charged Above 12.8 V (20°C/68°F) Needs charging Below 12.3 V Charging Normal 1.1 A/5 – 10 h current Quick 5.5 A/1.0 h Alternator capacity...
Page 16: Standard 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 hex bolt and nut 5 (0.5, 3.6) 5 mm screw 4 (0.4, 2.9) 6 mm hex bolt and nut 10 (1.0, 7) 6 mm screw 9 (0.9, 6.5) 8 mm hex bolt and nut...
Page 17 GENERAL INFORMATION COOLING SYSTEM THREAD TORQUE ITEM Q'TY REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) Water pump impeller 12 (1.2, 9) Left-hand threads. CYLINDER HEAD/VALVES THREAD TORQUE ITEM Q'TY REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) Cylinder head bolt 38 (3.9, 28) Apply oil to the threads and seating surface.
Page 18 GENERAL INFORMATION FRAME FRAME/BODY PANELS/EXHAUST SYSTEM THREAD TORQUE ITEM Q'TY REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) Luggage box mounting bolt 10 (1.0, 7) Luggage box mounting washer 10 (1.0, 7) bolt Front fender mounting bolt 12 (1.2, 9) Rear view mirror lock nut 34 (3.5, 25) Exhaust pipe joint nut 29 (3.0, 21)
Page 19 GENERAL INFORMATION REAR WHEEL/SUSPENSION THREAD TORQUE ITEM Q'TY REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) Swingarm mounting bolt 49 (5.0, 36) Rear axle nut 118 (12.0, 87) U-nut. Rear brake disc socket bolt 42 (4.3, 31) ALOC bolt. Rear pulser ring torx bolt 8 (0.8, 5.9) ALOC bolt.
Page 20: Lubrication & Seal Points
GENERAL INFORMATION LUBRICATION & SEAL POINTS ENGINE MATERIAL LOCATION REMARKS Liquid sealant Oil pressure switch threads See page 5-5 (Three Bond 1207B or equiv- Final reduction case mating surface See page 12-12 alent) Crankcase mating surface See page 14-16 Liquid sealant Cylinder head semi-circular cut-out See page 9-24 (Three Bond 1211 or shell...
Page 21 GENERAL INFORMATION MATERIAL LOCATION REMARKS Grease Driven face boss inner surface Fill up 5 – 7 g (Shell ALVANIA R3 or SHIN- Movable driven face guide grooves (guide pin Fill up 4 – 5 g NIHON POWERNOC WB3 or areas) IDEMITSU AUTOREX B or equivalent) Multi-purpose grease...
Page 22 Japan), Shell Stamina EP2 or equivalent Engine oil Fuel pump rubber seal inner surface Apply 1.0 g maximum Honda bond A, Honda hand Handlebar grip rubber inside grip cement, Cemedine #540 Brake caliper bracket pad retainer or equivalent Silicone grease Throttle cable inside Apply 0.2 g minimum...
Page 23: Cable & Harness Routing
GENERAL INFORMATION CABLE & HARNESS ROUTING STD TYPE FRONT BRAKE REAR BRAKE HOSE HOSE THROTTLE CABLE HORN WIRE MAIN WIRE HARNESS 10 mm (0.4 in) RIGHT FRONT TURN SIGNAL/ maximum POSITION LIGHT WIRE IMMOBILIZER RECEIVER WIRE ACCESSORY SOCKET LEFT FRONT TURN WIRE MAIN RELAY/FAN SIGNAL/POSITION...
Page 24 GENERAL INFORMATION FRONT BRAKE HOSE REAR BRAKE HOSE THROTTLE CABLES HORN WIRE SEAT LOCK CABLE RIGHT FRONT TURN SIGNAL/ LEFT FRONT TURN POSITION LIGHT WIRE SIGNAL/POSITION LIGHT WIRE IGNITION SWITCH WIRE MAIN RELAY/FAN THROTTLE CABLES MOTOR RELAY WIRE THROTTLE CABLES ACCESSORY SOCKET WIRE FRONT BRAKE HOSE...
Page 25 GENERAL INFORMATION THROTTLE CABLES ACCESSORY SOCKET WIRE CONNECTORS: REAR BRAKE PIPE · IMMOBILIZER RECEIVER 4P · IGNITION SWITCH 2P · LEFT FRONT TURN SIGNAL/ /POSITION LIGHT 3P REAR (COMBINED) · RIGHT FRONT TURN SIGNAL/ BRAKE HOSE /POSITION LIGHT 3P (Black) RIGHT FRONT TURN SIGNAL/ POSITION LIGHT WIRE MAIN WIRE...
Page 26 GENERAL INFORMATION Front TURN SIGNAL RELAY WIRE HORN WIRE COMBINATION METER/ SEAT LOCK CABLE HANDLEBAR SWITCH WIRE ACCESSORY SOCKET WIRE FRONT BRAKE HOSE REAR BRAKE HOSE REAR BRAKE PIPE THROTTLE CABLES SEAT LOCK CABLE RADIATOR 5 mm FRONT BRAKE HOSE (0.2 in) Right maximum...
Page 27 GENERAL INFORMATION SEAT LOCK CABLE RIGHT FRONT TURN SIGNAL/POSITION LIGHT WIRE ACCESSORY SOCKET WIRE MAIN RELAY/FAN MOTOR RELAY WIRE REAR BRAKE HOSE 1-23...
Page 28 GENERAL INFORMATION BATTERY NEGATIVE STARTER RELAY STARTER RELAY (–) CABLE DLC WIRE WIRE BATTERY POSITIVE (+) CABLE STARTER RELAY WIRE BATTERY NEGATIVE FUSE BOX WIRE (–) CABLE STARTER RELAY WIRE FUSE BOX/DLC WIRE BATTERY NEGATIVE (–) CABLE DLC WIRE RADIATOR RESERVE RADIATOR UPPER TANK OVER FLOW HOSE THROTTLE CABLES...
Page 29 GENERAL INFORMATION IGNITION COIL CKP SENSOR/ PRIMARY WIRE ALTERNATOR WIRE PAIR AIR SPARK PLUG PAIR AIR SUCTION SUCTION HOSE WIRE HOSE CLIP PAIR CONTROL SOLENOID VALVE WIRE AIR CLEANER UPPER CONNECTING HOSE BAND ECT SENSOR WIRE Upper CRANKCASE BREATHER HOSE 7.0 ±...
Page 30 GENERAL INFORMATION FUEL PUMP WIRE Route the fuel feed hose on the fuel tank flange as shown. FUEL FEED HOSE FUEL FEED HOSE TANK FLANGE REAR BRAKE PIPE RADIATOR LOWER WATER HOSE 55 ± 5 ° FUEL TRAY DRAIN HOSE RADIATOR UPPER STARTER MOTOR WATER HOSE...
Page 31 GENERAL INFORMATION FUEL FEED HOSE FUEL PUMP WIRE FUEL TRAY DRAIN HOSE STARTER MOTOR CABLE Left Left BATTERY NEGATIVE SENSOR WIRE (–) CABLE Left GROUND CABLE (1) BATTERY NEGATIVE (–) CABLE (2) STARTER MOTOR CABLE 3 mm (0.1 in) (3) THROTTLE CABLE maximum (4) SIDESTAND SWITCH WIRE (5) O...
Page 32 GENERAL INFORMATION THROTTLE FINAL REDUCTION CASE CABLE BREATHER HOSE CRANKCASE PAIR AIR BREATHER HOSE SUCTION HOSE VS SENSOR WIRE THROTTLE 3 mm (0.1 in) CABLES maximum CKP SENSOR/ ALTERNATOR WIRE MAIN WIRE HARNESS INJECTOR WIRE RADIATOR UPPER WATER BATTERY NEGATIVE HOSE BAND (–) CABLE UPPER...
Page 33 GENERAL INFORMATION FUEL FEED HOSE FUEL PUMP WIRE Route the fuel feed hose on fuel tank flange as REGULATOR/ shown. RECTIFIER WIRE TANK FLANGE FUEL FEED HOSE The fuel feed hose clamp should be butted against the frame. CKP SENSOR/ CRANKCASE ALTERNATOR WIRE BREATHER HOSE...
Page 34 GENERAL INFORMATION REGULATOR/ RECTIFIER WIRE CKP SENSOR/ ALTERNATOR WIRE RADIATOR LOWER GROUND CABLE BYPASS WATER REAR BRAKE HOSE WATER HOSE HOSE (1) MAIN WIRE HARNESS CKP SENSOR/ (2) REAR BRAKE PIPE ALTERNATOR WIRE 1-30...
Page 35 GENERAL INFORMATION FINAL REDUCTION CASE IACV WIRE BREATHER HOSE PAIR CONTROL SOLENOID VALVE WIRE SENSOR UNIT WIRE IGNITION COIL PRIMARY WIRE ECT SENSOR WIRE FUEL FEED HOSE INJECTOR WIRE FRONT RADIATOR UPPER WATER BYPASS HOSE WATER HOSE CLIP SPARK PLUG WIRE BYPASS WATER HOSE UPPER...
Page 36 GENERAL INFORMATION SEAT LOCK CABLE BANK ANGLE SENSOR WIRE REAR TURN SIGNAL/ BRAKE/TAIL LIGHT WIRE ENGINE STOP RELAY/FUEL PUMP RELAY WIRE ECM WIRE LICENSE LIGHT WIRE 1-32...
Page 37 GENERAL INFORMATION ABS TYPE REAR BRAKE HOSE FRONT BRAKE HOSE THROTTLE CABLE HORN WIRE LEFT FRONT TURN SIGNAL/POSITION RIGHT FRONT TURN SIGNAL/ LIGHT WIRE POSITION LIGHT WIRE ACCESSORY SOCKET WIRE FRONT BRAKE HOSE FRONT WHEEL SPEED REAR (COMBINED) SENSOR WIRE BRAKE HOSE (1) COMBINATION METER/ HANDLEBAR SWITCH WIRE...
Page 38 GENERAL INFORMATION MAIN WIRE HARNESS ACCESSORY SOCKET WIRE LEFT FRONT TURN SIGNAL/POSITION ABS MODULATOR LIGHT WIRE WIRE ABS MODULATOR WIRE IMMOBILIZER RECEIVER WIRE 10 mm (0.4 in) maximum IGNITION SWITCH WIRE MAIN RELAY/FAN (1) LEFT FRONT TURN SIGNAL MOTOR RELAY WIRE /POSITION LIGHT WIRE (2) HORN WIRE (3) ACCESSORY SOCKET WIRE...
Page 39 GENERAL INFORMATION FRONT BRAKE HOSE REAR BRAKE HOSE THROTTLE CABLES HORN WIRE SEAT LOCK CABLE RIGHT FRONT TURN SIGNAL/ LEFT FRONT TURN POSITION LIGHT WIRE SIGNAL/POSITION LIGHT WIRE THROTTLE CABLES THROTTLE CABLES ACCESSORY SOCKET WIRE FRONT BRAKE HOSE FRONT WHEEL SPEED SENSOR REAR (COMBINED) BRAKE HOSE...
Page 40 GENERAL INFORMATION THROTTLE CABLES ACCESSORY SOCKET WIRE CONNECTORS: · IMMOBILIZER RECEIVER 4P · IGNITION SWITCH 2P · LEFT FRONT TURN SIGNAL/ /POSITION LIGHT 3P · RIGHT FRONT TURN SIGNAL/ /POSITION LIGHT 3P (Black) RIGHT FRONT TURN SIGNAL/ POSITION LIGHT WIRE MAIN WIRE 10 mm (0.04 in) HARNESS...
Page 41 GENERAL INFORMATION Front TURN SIGNAL RELAY WIRE FRONT WHEEL SPEED SENSOR HORN WIRE COMBINATION METER/ SEAT LOCK CABLE HANDLEBAR SWITCH WIRE ACCESSORY SOCKET WIRE REAR BRAKE HOSE FRONT WHEEL FRONT BRAKE HOSE SPEED SENSOR REAR BRAKE PIPE THROTTLE CABLES SEAT LOCK CABLE RADIATOR 5 mm FRONT BRAKE HOSE...
Page 42 GENERAL INFORMATION SEAT LOCK CABLE ABS MODULATOR WIRE ABS MODULATOR WIRE FRONT WHEEL SPEED SENSOR REAR (COMBINED) MAIN RELAY/FAN BRAKE HOSE MOTOR RELAY WIRE 1-38...
Page 43 GENERAL INFORMATION DLC/ABS SERVICE CHECK STARTER RELAY FUSE BOX A STARTER RELAY CONNECTOR WIRE WIRE BATTERY POSITIVE (+) CABLE FUSE BOX B STARTER RELAY WIRE BATTERY NEGATIVE (–) CABLE FUSE BOX B WIRE BATTERY NEGATIVE FUSE BOX A WIRE (–) CABLE STARTER RELAY WIRE FUSE BOX B/DLC/...
Page 44 GENERAL INFORMATION IGNITION COIL CKP SENSOR/ PRIMARY WIRE ALTERNATOR WIRE PAIR AIR SUCTION PAIR AIR SPARK PLUG HOSE CLIP SUCTION HOSE WIRE PAIR CONTROL Upper AIR CLEANER SOLENOID VALVE WIRE CONNECTING HOSE BAND ECT SENSOR WIRE Upper CRANKCASE BREATHER HOSE 7.0 ±...
Page 45 GENERAL INFORMATION FUEL PUMP WIRE Route the fuel feed hose on the fuel tank flange as shown. FUEL FEED HOSE FUEL FEED HOSE TANK FLANGE REAR BRAKE PIPE RADIATOR LOWER WATER HOSE 55 ± 5 ° FUEL TRAY DRAIN HOSE RADIATOR UPPER STARTER MOTOR WATER HOSE...
Page 46 GENERAL INFORMATION FUEL FEED HOSE FUEL PUMP WIRE FUEL TRAY DRAIN HOSE STARTER MOTOR CABLE Left Left BATTERY NEGATIVE SENSOR WIRE (–) CABLE Left GROUND CABLE (1) BATTERY NEGATIVE (–) CABLE (2) STARTER MOTOR CABLE 3 mm (0.1 in) (3) THROTTLE CABLE maximum (4) SIDESTAND SWITCH WIRE (5) O...
Page 47 GENERAL INFORMATION FINAL REDUCTION CASE BREATHER HOSE THROTTLE CABLE REAR WHEEL CRANKCASE PAIR AIR SPEED SENSOR BREATHER HOSE SUCTION HOSE WIRE THROTTLE VS SENSOR WIRE 3 mm (0.1 in) CABLES maximum BATTERY CKP SENSOR/ NEGATIVE (–) ALTERNATOR WIRE CABLE MAIN WIRE HARNESS INJECTOR WIRE...
Page 48 GENERAL INFORMATION FUEL FEED HOSE FUEL PUMP WIRE Route the fuel feed hose on fuel tank flange as REGULATOR/ shown. RECTIFIER WIRE TANK FLANGE FUEL FEED HOSE The fuel feed hose clamp should be butted against the frame. CKP SENSOR/ CRANKCASE ALTERNATOR WIRE BREATHER HOSE...
Page 49 GENERAL INFORMATION REGULATOR/ RECTIFIER WIRE CKP SENSOR/ ALTERNATOR WIRE RADIATOR LOWER GROUND CABLE BYPASS WATER WATER HOSE REAR BRAKE HOSE HOSE (1) MAIN WIRE HARNESS CKP SENSOR/ (2) REAR BRAKE PIPE ALTERNATOR WIRE 1-45...
Page 50 GENERAL INFORMATION FINAL REDUCTION CASE IACV WIRE BREATHER HOSE PAIR CONTROL SOLENOID VALVE WIRE SENSOR UNIT WIRE IGNITION COIL PRIMARY WIRE ECT SENSOR WIRE FUEL FEED HOSE INJECTOR WIRE FRONT RADIATOR UPPER WATER BYPASS HOSE WATER HOSE CLIP SPARK PLUG WIRE BYPASS WATER HOSE UPPER...
Page 51 GENERAL INFORMATION SEAT LOCK CABLE BANK ANGLE SENSOR WIRE REAR TURN SIGNAL/ BRAKE/TAIL LIGHT WIRE ENGINE STOP RELAY/FUEL PUMP RELAY WIRE ECM WIRE LICENSE LIGHT WIRE 1-47...
Page 52 Carbon monoxide does not react in the same way, but it is toxic. Honda Motor Co., Ltd. utilizes various systems to reduce carbon monoxide, oxides of nitrogen and hydrocarbons. CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere.
Page 53 GENERAL INFORMATION EXHAUST EMISSION CONTROL SYSTEM The exhaust emission control system is composed of a secondary air supply system and PGM-FI system, and no adjust- ments should be made. The exhaust emission control system is separate from the crankcase emission control system. SECONDARY AIR SUPPLY SYSTEM The secondary air supply system which introduces filtered air into the exhaust gases in the exhaust port.
Page 54 MEMO...
Page 55 2. TECHNICAL FEATURES HEATER-LESS O SENSOR························ 2-2 UNIT-SWING ENGINE LAYOUT················ 2-3...
Page 56 TECHNICAL FEATURES HEATER-LESS O SENSOR TECHNICAL FEATURES SUMMARY This model utilizes a heater-less O sensor. As O sensor does not function properly until it is warmed up, conventional O sensor is equipped with a heater. Heater-less O sensor is located near the exhaust port in order to make use of the heat from the exhaust gas, eliminating the need for a heater.
Page 57: Engine Hanger Bracket A
TECHNICAL FEATURES UNIT-SWING ENGINE LAYOUT SUMMARY This model utilizes the engine unit link located below the engine in order to provide enhanced riding comfort and stability. The engine unit link consists of engine hanger A, engine hanger B and swing rod. Needle bearings are installed on the unit link pivot in order to obtain smooth swing without sacrificing the rigidity of the unit link.
Page 58 MEMO...
Page 59 3. FRAME/BODY PANELS/EXHAUST SYSTEM BODY PANEL LOCATIONS ························ 3-2 FLOOR SIDE COVER ·································· 3-8 SERVICE INFORMATION ··························· 3-3 UNDER COVER··········································· 3-9 TROUBLESHOOTING ································· 3-3 FRONT UPPER COVER ······························ 3-9 SNAP FIT CLIP ············································ 3-4 FRONT INNER COVER ····························· 3-10 MAINTENANCE LID···································· 3-4 FRONT LOWER COVER ···························...
Page 60: Body Panel Locations
FRAME/BODY PANELS/EXHAUST SYSTEM BODY PANEL LOCATIONS FRAME/BODY PANELS/EXHAUST SYSTEM (15) (16) (11) (12) (14) (13) (10) (1) Maintenance Lid (page 3-4) (7) Rear Fender B (page 3-7) (13) Front Lower Cover (page 3-12) (2) Seat (page 3-4) (8) Front Fender (page 3-8) (14) Floor Panel (page 3-13) (3) Luggage Box (page 3-5) (9) Floor Side Cover (page 3-8)
Page 61: Service Information
FRAME/BODY PANELS/EXHAUST SYSTEM SERVICE INFORMATION GENERAL • This section covers removal and installation of the body panels and exhaust system. • When installing the covers, make sure the mating areas are aligned properly before tightening the fasteners. • Always replace the exhaust pipe gasket after removing the exhaust system. •...
Page 62: Snap Fit Clip
FRAME/BODY PANELS/EXHAUST SYSTEM SNAP FIT CLIP Separate the parts by pulling the snap fit clip Make sure that the INSERTION OF THE straight out of the hole, being careful not to tilt the insertion of the clip SNAP FIT CLIP insertion of the clip.
Page 63: Luggage Box
FRAME/BODY PANELS/EXHAUST SYSTEM LUGGAGE BOX Remove the maintenance lid (page 3-4). WASHER BOLTS MOUNTING BOLTS Remove the following: – four mounting bolts LUGGAGE BOX – two washer bolts – luggage box Installation is in the reverse order of removal. • Make sure that the fuel hose is routed on the fuel tank flange as shown.
Page 64: Body Cover
FRAME/BODY PANELS/EXHAUST SYSTEM BODY COVER Remove the following: SCREWS SNAP FIT CLIPS – maintenance lid (page 3-4) – luggage box (page 3-5) – grab rail (page 3-5) Remove the two special screws. Remove the center body cover by releasing the four Be careful not to snap fit clips (page 3-4) of the center body cover damage the tab on...
Page 65: Rear Fender
FRAME/BODY PANELS/EXHAUST SYSTEM REAR FENDER REAR FENDER A Remove the body cover (page 3-6). Remove the following: – license light 3P (black) connector – two special bolts – three washer bolts – rear fender A Installation is in the reverse order of removal. Route the license light wire properly SPECIAL BOLTS...
Page 66: Front Fender
FRAME/BODY PANELS/EXHAUST SYSTEM FRONT FENDER Remove the following: FRONT FENDER – three special bolts – front fender Installation is in the reverse order of removal. TORQUE: Front fender mounting bolt 12 N·m (1.2 kgf·m, 9 lbf·ft) BOLTS FLOOR SIDE COVER Remove the bolt and special bolt.
Page 67: Under Cover
FRAME/BODY PANELS/EXHAUST SYSTEM UNDER COVER Remove the following: – floor side cover (page 3-8) HOSE – four washer bolts Release the radiator reserve tank over flow hose from the hose guide. Slide the under cover backward and release the front tabs to remove the under cover. Installation is in the reverse order of removal.
Page 68: Front Inner Cover
FRAME/BODY PANELS/EXHAUST SYSTEM FRONT INNER COVER REMOVAL/INSTALLATION Remove the following: – front upper cover (page 3-9) – rear handlebar cover (page 3-14) – two screws and luggage hook – four tapping screws Disconnect the accessory socket 2P connector. Release the six snap fit clips (page 3-4) of the front Be careful not to lower cover from the front inner cover slots.
Page 69 FRAME/BODY PANELS/EXHAUST SYSTEM DISASSEMBLY/ASSEMBLY Remove the seven tapping screws. Release the six tabs on the front upper inner cover from the front lower inner cover. Remove the tapping screw and pocket lid from the front upper inner cover. Remove the tapping screw and radiator mainte- nance lid from the front lower inner cover.
Page 70: Front Lower Cover
FRAME/BODY PANELS/EXHAUST SYSTEM FRONT LOWER COVER Remove the following: – front upper cover (page 3-9) – floor side cover (page 3-8) – front wheel (page 15-6) – front fender (page 3-8) – four screws – washer bolt – special bolt Release the two bosses from the grommets and six Be careful not to snap fit clips (page 3-4) of the front lower cover...
Page 71: Floor Panel
FRAME/BODY PANELS/EXHAUST SYSTEM FLOOR PANEL Remove the following: – body cover (page 3-6) – floor side cover (page 3-8) – front inner cover (page 3-10) – battery (page 19-6) – starter relay (page 21-15) Release the following: – fuse box A –...
Page 72: Front Handlebar Cover
FRAME/BODY PANELS/EXHAUST SYSTEM FRONT HANDLEBAR COVER Remove the front upper cover (page 3-9). Remove the following: – rear view mirrors – handlebar post lid (by sliding it forward) – four tapping screws Push the rear handlebar cover and release the four tabs of the front handlebar cover.
Page 73: Exhaust Pipe/Muffler
FRAME/BODY PANELS/EXHAUST SYSTEM EXHAUST PIPE/MUFFLER Remove the maintenance lid (page 3-4). Remove the two special bolts and exhaust pipe pro- tector. Loosen the exhaust pipe band bolt. Remove the two exhaust pipe joint nuts. Remove the three bolts and exhaust pipe/muffler then remove the gasket.
Page 74: Sidestand
FRAME/BODY PANELS/EXHAUST SYSTEM SIDESTAND Remove the following: NUT/BOLT – left floor side cover (page 3-8) – sidestand switch (page 22-21) Support the scooter securely using the centerstand. Unhook the return springs. Remove the pivot nut, bolt and sidestand. Installation is in the reverse order of removal. At installation, apply grease to the pivot bolt sliding surfaces.
Page 75 4. MAINTENANCE SERVICE INFORMATION ··························· 4-2 DRIVE BELT ·············································· 4-15 MAINTENANCE SCHEDULE ······················ 4-4 BELT CASE AIR CLEANER ······················· 4-16 FUEL LINE ··················································· 4-5 FINAL DRIVE OIL ······································ 4-17 THROTTLE OPERATION····························· 4-5 BRAKE FLUID ··········································· 4-18 AIR CLEANER·············································· 4-6 BRAKE PADS WEAR ································ 4-19 CRANKCASE BREATHER ···························...
Page 76: Service Information
0.16 ± 0.03 mm (0.006 ± 0.001 in) Valve clearance 0.22 ± 0.03 mm (0.009 ± 0.001 in) Recommended engine oil Honda "4-stroke motorcycle oil" or an equivalent API service classification: SG or higher (except oils labeled as energy conserving on the cir- cular API service label)
Page 77 MAINTENANCE TORQUE VALUES Spark plug 16 N·m (1.6 kgf·m, 12 lbf·ft) Air cleaner housing cover screw 1.5 N·m (0.2 kgf·m, 1.1 lbf·ft) Timing hole cap 6 N·m (0.6 kgf·m, 4.4 lbf·ft) Apply engine oil to the threads and seating sur- face Engine oil drain bolt 25 N·m (2.5 kgf·m, 18 lbf·ft)
Page 78: Maintenance Schedule
** STEERING HEAD BEARINGS 4-24 * 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 79: Fuel Line
MAINTENANCE FUEL LINE Remove the luggage box (page 3-5). FUEL FEED HOSE Check the fuel feed hose between the fuel pump and injector for deterioration, damage or leakage. Replace the fuel feed hose if necessary (page 6-44). Also, check the fuel feed hose fittings for damage or looseness.
Page 80: Air Cleaner
MAINTENANCE Major adjustments are made with the lower ADJUSTING NUT adjuster on the throttle body. Remove the luggage box (page 3-5). Loosen the lock nut, turn the adjusting nut as required and tighten the lock nut. After adjustment, recheck the throttle operation. LOCK NUT AIR CLEANER •...
Page 81: Crankcase Breather
MAINTENANCE CRANKCASE BREATHER • Service more frequently when ridden in rain, at full throttle, or after the scooter is washed or overturned. Service if the deposit level can be seen in the transparent section of the hose. Remove the crankcase breather drain plug and DRAIN PLUG drain the deposits into a suitable container, then reinstall it securely.
Page 82: Valve Clearance
MAINTENANCE Check the gap between the center and side elec- 0.8 – 0.9 mm trodes with a wire-type feeler gauge. (0.03 – 0.04 in) SPARK PLUG GAP: 0.8 – 0.9 mm (0.03 – 0.04 in) If necessary, adjust the gap by bending the side electrode carefully.
Page 83 MAINTENANCE Rotate the drive pulley (crankshaft) counterclock- T MARK wise and align the T mark on the flywheel with the index line in the crankcase cover. Make sure the piston is at TDC (Top Dead Center) of the compression stroke by moving the rocker arms. If the exhaust rocker arm is tight, rotate the crank- shaft one full turn (360 °) and align the T mark again.
Page 84: Engine Oil
MAINTENANCE Calculate the new shim thickness using the equa- Sixty-nine different tion below. thickness shims are A = (B – C) + D available from the A: New shim thickness thinnest 1.200 mm B: Recorded valve clearance thickness shim to C: Specified valve clearance the thickest 2.900 D: Old shim thickness...
Page 85 If the oil level is below or near the lower level line, add the recommended oil to the upper level line. OIL VISCOSITIES RECOMMENDED ENGINE OIL: Honda "4-stroke motorcycle oil" or an equivalent API service classification: SG or higher (except oils labeled as energy conserving on the circular API service label)
Page 86: Engine Oil Filter
MAINTENANCE Fill the crankcase with recommended engine oil O-RING (page 4-10). OIL CAPACITY: 1.2 liter (1.3 US qt, 1.1 Imp qt) after draining 1.4 liter (1.5 US qt, 1.2 Imp qt) after oil filter change 1.7 liter (1.8 US qt, 1.5 Imp qt) after disassembly Check that the O-ring on the oil filler cap/dipstick is in good condition, and replace it if necessary.
Page 87 MAINTENANCE Check that the oil filter boss protrusion from the OIL FILTER BOSS crankcase is specified length as shown. SPECIFIED LENGTH: 16 – 17 mm (0.6 – 0.7 in) When removing the oil filter boss, apply locking agent to the threads (page 1-16). Install and tighten the oil filter boss to the specified torque.
Page 88: Radiator Coolant
MAINTENANCE RADIATOR COOLANT Place the scooter on its centerstand on a level sur- face. “UPPER” LEVEL With the engine running at normal operating tem- perature and check the coolant level of the reserve tank. The level should be between the “UPPER” and “LOWER”...
Page 89: Secondary Air Supply System
MAINTENANCE Check the radiator air passage for clogs or damage. Straighten bent fins with a small, flat blade screw- RADIATOR FIN driver and remove insects, mud or other obstruc- tions with compressed air or low pressure water. Replace the radiator if the air flow is restricted over more than 20% of the radiating surface.
Page 90: Belt Case Air Cleaner
MAINTENANCE BELT CASE AIR CLEANER Remove the three socket bolts and screw. TABS SOCKET BOLTS SCREW Remove the belt case air cleaner housing from the left crankcase cover. BELT CASE AIR CLEANER HOUSING Release the three tabs of the air cleaner base cover TABS/SLOTS O-RING from the slots of the air cleaner base.
Page 91: Final Drive Oil
RECOMMENDED FINAL DRIVE OIL: CHECK BOLT Honda "4-stroke motorcycle oil" or an equivalent SEALING WASHER API service classification: SG or higher (except oils labeled as energy conserving on the circular API...
Page 92: Brake Fluid
MAINTENANCE BRAKE FLUID Spilling 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 93: Brake Pads Wear
MAINTENANCE BRAKE PADS WEAR FRONT BRAKE PADS Check the brake pads for wear. Replace the brake pads if either pad reaches the bot- tom of wear limit groove. Refer to front brake pad replacement (page 17-13). WEAR LIMIT GROOVES REAR BRAKE PADS Check the brake pads for wear.
Page 94: Headlight Aim
MAINTENANCE Inspect the brake hose and fittings for deterioration, cracks, damage or signs of leakage. Tighten any loose fittings. Replace hose and fittings as required. BRAKE HOSES COMBINED BRAKE SYSTEM INSPEC- TION This model is equipped with a Combined Brake Sys- tem.
Page 95: Clutch Shoes Wear
MAINTENANCE CLUTCH SHOES WEAR Remove the clutch assembly (page 11-11). Check the clutch shoe lining for wear or damage. Measure the thickness of each shoe. SERVICE LIMIT: 1.0 mm (0.04 in) Replace the clutch shoe linings if it is below a ser- vice limit.
Page 96: Nuts, Bolts, Fasteners
MAINTENANCE REAR Check the action of the shock absorber by com- pressing it several times. Check the entire shock absorber assembly for dam- age or loose fasteners. Replace damaged components which cannot be repaired. Tighten all fasteners. For rear shock absorber service (page 16-12). Raise the rear wheel off the ground by supporting the scooter on its centerstand.
Page 97 MAINTENANCE Support the scooter securely and raise the rear wheel. Check for worn final gear shaft bearings by grab- bing the rear wheel and attempting to move the wheel side to side. Replace the final gear shaft bearings if any loose- ness is noted (page 12-8).
Page 98: Steering Head Bearings
MAINTENANCE STEERING HEAD BEARINGS Support the scooter with its centerstand and raise the front wheel off the ground. Check that the handlebar moves freely from side-to- side. If the handlebar moves unevenly or binds, inspect the steering head bearings (page 15-27). Hold the scooter and check the steering head bear- ings for wear by moving the fork forward and back- ward.
Page 99 5. LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM ·········· 5-2 OIL STRAINER ············································ 5-6 SERVICE INFORMATION ··························· 5-3 OIL PRESSURE RELIEF VALVE ················· 5-7 TROUBLESHOOTING ································· 5-4 OIL PUMP ··················································· 5-8 OIL PRESSURE CHECK ······························ 5-5...
Page 100: Lubrication System Diagram
LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM LUBRICATION SYSTEM ROCKER ARM CAMSHAFT PISTON CRANKSHAFT OIL PRESSURE SWITCH OIL FILTER OIL PUMP OIL PRESSURE RELIEF VALVE REED VALVE OIL STRAINER...
Page 101 – After disassembly 1.7 liter (1.8 US qt, 1.5 lmp qt) – Recommended oil Honda "4-stroke motorcycle oil" or an equivalent API service classification: SG or higher (except oils labeled as energy conserv- – ing on the circular API service label)
Page 102: Troubleshooting
LUBRICATION SYSTEM TROUBLESHOOTING Engine oil level too low, high oil consumption • Normal oil consumption • External oil leak • Worn piston rings or incorrect piston ring installation (page 10-5) • Worn cylinder (page 10-5) • Worn valve guide or stem seal (page 9-12) Low oil pressure •...
Page 103 LUBRICATION SYSTEM OIL PRESSURE CHECK Remove the right floor side cover (page 3-8). OIL PRESSURE SWITCH RUBBER CAP If the engine is cold, the pressure reading will be abnormally high. Warm up the engine to normal operating temperature before starting this test. Stop the engine.
Page 104 LUBRICATION SYSTEM OIL STRAINER REMOVAL Drain the engine oil (page 4-11). Remove the right crankcase cover (page 13-4). Remove the oil strainer and screen mesh. STRAINER/SCREEN MESH INSPECTION Check the oil strainer screen mesh for damage or clogs. INSTALLATION Install the oil strainer into the crankcase as shown. STRAINER Install the screen mesh into the crankcase as shown.
Page 105 LUBRICATION SYSTEM OIL PRESSURE RELIEF VALVE REMOVAL Separate the crankcase (page 14-5). RELIEF VALVE Remove the oil pressure relief valve and O-ring from the left crankcase. O-RING INSPECTION • Be careful not to loose the disassemble parts. SNAP RING Check the operation of the oil pressure relief valve by pushing on the piston.
Page 106: Oil Pump
LUBRICATION SYSTEM OIL PUMP REMOVAL Remove the flywheel (page 13-9). COVER Remove the following: – bolt and sprocket cover BOLT – oil pump driven sprocket bolt The oil pump driven sprocket bolt has left-hand threads. BOLT (left-hand threads) – driven sprocket –...
Page 107 LUBRICATION SYSTEM DISASSEMBLY Remove the following: – dowel pins DOWEL PINS SCREW – screw – pump cover COVER – oil pump shaft – thrust washer WASHER – drive pin OIL PUMP SHAFT DRIVE PIN – inner rotor – outer rotor OUTER ROTOR Wash all parts with a high flash point or non-flam- mable solvent.
Page 108 LUBRICATION SYSTEM INSPECTION • Measure at several points and use the largest reading to compare the service limit. • If any portion of the oil pump is worn beyond the specified service limits, replace the oil pump as an assembly. Temporarily install the outer rotor, inner rotor, drive pin and oil pump shaft into the oil pump body.
Page 109 LUBRICATION SYSTEM ASSEMBLY OUTER ROTOR INNER ROTOR OIL PUMP SHAFT OIL PUMP COVER OIL PUMP BODY SCREW DRIVE PIN 2 N·m (0.2 kgf·m, 1.5 lbf·ft) WASHER Apply engine oil to the inner and outer rotor. DOWEL PIN GROOVE Install the outer rotor into the oil pump body. Install the inner rotor into the outer rotor with its drive pin groove facing the oil pump cover.
Page 110 LUBRICATION SYSTEM Install the oil pump cover onto the oil pump body by aligning the dowel pins on the body and hole of the DOWEL PINS SCREW cover. Install and tighten the oil pump cover screw to the specified torque. TORQUE: 2 N·m (0.2 kgf·m, 1.5 lbf·ft) Check that the oil pump shaft turns smoothly.
Page 111 6. FUEL SYSTEM (PGM-FI) COMPONENT LOCATION ·························· 6-2 FUEL TANK ··············································· 6-51 SERVICE INFORMATION ··························· 6-3 AIR CLEANER HOUSING ························· 6-52 PGM-FI SYMPTOM THROTTLE BODY ····································· 6-53 TROUBLESHOOTING ································· 6-5 INJECTOR ················································· 6-61 PGM-FI SYSTEM LOCATION ····················· 6-6 INTAKE PIPE ············································· 6-64 PGM-FI SYSTEM DIAGRAM ······················...
Page 112: Component Location
FUEL SYSTEM (PGM-FI) COMPONENT LOCATION FUEL SYSTEM (PGM-FI) 11 N·m (1.1 kgf·m, 8 lbf·ft) 5 N·m (0.5 kgf·m, 3.7 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft)
Page 113: 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 starting the engine with the fuel pump connector disconnected (page 6-44).
Page 114 FUEL SYSTEM (PGM-FI) TOOLS Fuel pressure gauge Pressure gauge manifold Fuel attachment hose 07406-0040004 07ZAJ-S5A0111 07ZAJ-S5A0120 ECM test harness 33P SCS connector Test probe 070MZ-MCA0100 070PZ-ZY30100 07ZAJ-RDJA110...
Page 115 FUEL SYSTEM (PGM-FI) PGM-FI SYMPTOM TROUBLESHOOTING When the scooter has one of these symptoms, check the DTC or MIL blinking, refer to the DTC index (page 6-15) and begin the appropriate troubleshooting procedure. If there are no DTC/MIL blinking stored in the ECM memory, do the diagnostic procedure for the symptom, in sequence listed below, until you find cause.
Page 116: Pgm-Fi System Location
FUEL SYSTEM (PGM-FI) PGM-FI SYSTEM LOCATION SENSOR UNIT FUEL PUMP – MAP SENSOR IGNITION SWITCH IACV – TP SENSOR ENGINE STOP – IAT SENSOR RELAY FUEL PUMP RELAY BANK ANGLE SENSOR VS SENSOR PAIR CONTROL SOLENOID VALVE INJECTOR CKP SENSOR SENSOR ECT SENSOR...
Page 117: Pgm-Fi System Diagram
FUEL SYSTEM (PGM-FI) PGM-FI SYSTEM DIAGRAM FUSE 15A MAIN RELAY Fuse 10A Bl/Br R/Bl IGNITION ENGINE STOP ENGINE STOP MAIN FUSE SWITCH SWITCH RELAY FUSE 10A R/Bl Bl/W R/Bu BATTERY BANK ANGLE SENSOR Bl/W P/Bu INJECTOR Bl/R Gr/R IACV SENSOR UNIT IACV1A Gr/R...
Page 118: Pgm-Fi Connector Locations
FUEL SYSTEM (PGM-FI) PGM-FI CONNECTOR LOCATIONS NOTE 1: Remove the luggage box (page 3-5). SENSOR UNIT 5P (Black) CONNECTOR IACV 4P CONNECTOR (NOTE 1) (NOTE 1) Wire side of Sensor side of Wire side of Sensor side of female terminal male terminal female terminal male terminal...
Page 119 FUEL SYSTEM (PGM-FI) NOTE 2: Remove the maintenance lid (page 3-4). Wire side of DLC 4P CONNECTOR female terminal (NOTE 2) NOTE 3: Remove the rear fender A (page 3-7). Wire side of female terminal ECM 33P CONNECTOR (NOTE 3)
Page 120 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 121 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 122 FUEL SYSTEM (PGM-FI) HDS POCKET TESTER INFORMATION • The HDS can readout the DTC, freeze data, current data and other ECM condition. How to connect the HDS Pocket Tester Turn the ignition switch to OFF. DUMMY CONNECTOR Remove the maintenance lid (page 3-4). Remove the dummy connector from the DLC.
Page 123 FUEL SYSTEM (PGM-FI) CLEARING DTC Connect the HDS Pocket Tester to the DLC (page 6-12). Clear the DTC with the HDS while the engine is stopped. To clear the DTC without HDS, refer to the following procedure. How to clear the DTC with SCS connector 1.
Page 124 FUEL SYSTEM (PGM-FI) TEST HARNESS CONNECTION Remove the rear fender A (page 3-7). Turn the ignition switch to "OFF". Disconnect the 33P connector from the ECM. 33P CONNECTOR Connect the ECM test harness between the main ECM TEST HARNESS wire harness and the ECM. TOOL: ECM test harness 33P 070MZ-MCA0100...
Page 125: Dtc Index
FUEL SYSTEM (PGM-FI) DTC INDEX Refer Refer Function Failure Symptom/Fail-safe function (MIL blinks) (DTC) (MIL) 1-1 (1) MAP sensor circuit low voltage (less than 0.195 V) • Engine operates normally 6-16 6-31 • MAP sensor or its circuit malfunction • Fail-safe value: 760 mmHg/ 1,013 hPa 1-2 (1) MAP sensor circuit high voltage (more than 3.848 V)
Page 126: Dtc Troubleshooting
FUEL SYSTEM (PGM-FI) DTC TROUBLESHOOTING DTC 1-1 (MAP SENSOR LOW VOLT- AGE) 1. MAP Sensor System Inspection Turn the ignition switch ON and engine stop switch " ". Check the MAP sensor with the HDS pocket tester. Is about 0 V indicated? –...
Page 127 FUEL SYSTEM (PGM-FI) 4. MAP Sensor Output Line Short Circuit Inspec- tion Turn the ignition switch "OFF". 33P CONNECTOR Disconnect the ECM 33P connector. (Wire side of female terminal) Check for continuity between the 33P connector of the wire harness side and ground with sensor unit connector disconnected.
Page 128 FUEL SYSTEM (PGM-FI) 2. MAP Sensor Inspection Turn the ignition switch "OFF". 5P (Black) CONNECTOR Disconnect the sensor unit 5P (Black) connector. (Wire side of female terminal) Connect the MAP sensor terminals at the wire harness side with a jumper wire. CONNECTION: Yellow/Orange –...
Page 129 FUEL SYSTEM (PGM-FI) DTC 7-1 (ECT SENSOR LOW VOLT- AGE) 1. ECT Sensor System Inspection Turn the ignition switch "ON" and engine stop switch " ". Check the ECT sensor with the HDS pocket tester. Is about 0 V indicated? –...
Page 130 FUEL SYSTEM (PGM-FI) DTC 7-2 (ECT SENSOR HIGH VOLT- AGE) • Before starting the inspection, check for loose or poor contact on the ECT sensor 3P (Gray) con- nector and recheck the DTC. 1. ECT Sensor System Inspection Turn the ignition switch "ON" and engine stop switch "...
Page 131 FUEL SYSTEM (PGM-FI) DTC 8-1 (TP SENSOR LOW VOLTAGE) • Before starting the inspection, check for loose or poor contact on the sensor unit 5P (Black) con- nector and recheck the DTC. 1. TP Sensor System Inspection Turn the ignition switch ON and engine stop switch "...
Page 132 FUEL SYSTEM (PGM-FI) 5. TP Sensor Output Line Short Circuit Inspection Check for continuity between the sensor unit 5P 5P (Black) CONNECTOR (Black) connector terminal of the wire harness (Wire side of female terminal) side and ground with ECM connector discon- nected.
Page 133 FUEL SYSTEM (PGM-FI) DTC 8-2 (TP SENSOR HIGH VOLTAGE) 1. TP Sensor System Inspection Turn the ignition switch ON and engine stop switch " ". Check the TP sensor with the HDS pocket tester with the throttle fully closed. Is about 5 V indicated? –...
Page 134 FUEL SYSTEM (PGM-FI) DTC 9-1 (IAT SENSOR LOW VOLTAGE) 1. IAT Sensor System Inspection Turn the ignition switch ON and engine stop switch " ". Check the IAT sensor with the HDS pocket tester. Is about 0 V indicated? – GO TO STEP 2. –...
Page 135 FUEL SYSTEM (PGM-FI) DTC 9-2 (IAT SENSOR HIGH VOLTAGE) • Before starting the inspection, check for loose or poor contact on the sensor unit 5P (Black) con- nector and recheck the DTC. 1. IAT Sensor System Inspection Turn the ignition switch ON and engine stop switch "...
Page 136 FUEL SYSTEM (PGM-FI) 4. IAT sensor Ground line Inspection Turn the ignition switch "OFF". Disconnect the ECM 33P connector. 33P CONNECTOR (Wire side of female terminal) Check for continuity between the sensor unit connector of the wire harness side and ECM con- nector of the wire harness side.
Page 137 FUEL SYSTEM (PGM-FI) 3. Injector Resistance Inspection Turn the ignition switch OFF. Measure the resistance of the injector connector 2P CONNECTOR (Injector terminals. side of male terminals) Is the resistance within 11– 13 Ω (20°C/68°F)? – GO TO STEP 4. –...
Page 138 FUEL SYSTEM (PGM-FI) DTC 21-1 (O SENSOR) • Before starting the inspection, check for loose or poor contact on the O sensor cap connector and recheck the DTC. 1. O Sensor Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the ECM 33P connector and O sen- sor cap connector.
Page 139 FUEL SYSTEM (PGM-FI) DTC 29-1 (IACV) • Before starting the inspection, check for loose or poor contact on the IACV 4P connector and recheck the DTC. 1. Recheck DTC Clear the DTC. Start the engine and recheck the DTC. Is the DTC 29-1 indicated? –...
Page 140 FUEL SYSTEM (PGM-FI) 4. IACV Resistance Inspection Measure the resistance at the IACV 4P connector 4P CONNECTOR (IACV terminals of the IACV side. side of male terminals) Connection: A – D B – C STANDARD: 110 – 150 Ω (20 °C/68 °F) Is the resistance within 110 –...
Page 141: Mil Troubleshooting
FUEL SYSTEM (PGM-FI) MIL TROUBLESHOOTING MIL 1 BLINK (MAP SENSOR) • Before starting the inspection, check for loose or poor contact on the sensor unit 5P (Black) con- nector and recheck the MIL blinking. 1. MAP Sensor System Inspection Turn the ignition switch OFF. TEST HARNESS PIN BOX Connect the ECM test harness to ECM connector (page 6-14).
Page 142 FUEL SYSTEM (PGM-FI) 4. MAP Sensor Input Line Inspection Turn the ignition switch OFF. TEST HARNESS PIN BOX Connect the ECM test harness to ECM connector (page 6-14). Turn the ignition switch ON and engine stop switch " ". Measure the voltage between the test harness terminal and ground.
Page 143 FUEL SYSTEM (PGM-FI) 2. ECT sensor Output Voltage Inspection Turn the ignition switch OFF. 3P (Gray) CONNECTOR Disconnect the ECT sensor 3P (Gray) connector. (Wire side of female terminals) Turn the ignition switch ON and engine stop switch " ". Measure the voltage at ECT sensor connector of the wire harness side.
Page 144 FUEL SYSTEM (PGM-FI) 5. ECT Sensor Output Line Short Circuit Inspection Disconnect the test harness and ECM 33P con- 3P (Gray) CONNECTOR nector disconnected. (Wire side of female terminal) Check for continuity between the ECT sensor connector of the wire harness side and ground. Connection: Pink/white –...
Page 145 FUEL SYSTEM (PGM-FI) 2. TP Sensor Input Voltage Inspection Turn the ignition switch OFF. 5P (Black) CONNECTOR Disconnect the sensor unit 5P (Black) connector. (Wire side of female terminal) Turn the ignition switch ON and engine stop switch " ". Measure the voltage between the sensor unit 5P (Black) connector of the wire harness side.
Page 146 FUEL SYSTEM (PGM-FI) 5. TP Sensor Output Line Short Circuit Inspection Turn the ignition switch OFF. 5P (Black) CONNECTOR Disconnect the test harness and ECM 33P con- (Wire side of female terminal) nector disconnected. Check for continuity between the sensor unit 5P (Black) connector terminal of the wire harness side and ground.
Page 147 FUEL SYSTEM (PGM-FI) 3. IAT Sensor Resistance Inspection Turn the ignition switch OFF. 5P (Black) CONNECTOR Measure the resistance at the IAT sensor termi- (Sensor side of male terminals) nals. CONNECTION: White/blue – Green/orange STANDARD: 1 – 4 kΩ (20°C/68°F) Is the resistance within 1 –...
Page 148 FUEL SYSTEM (PGM-FI) MIL 12 BLINKS (INJECTOR) • Before starting the inspection, check for loose or poor contact on the injector 2P connector and recheck the MIL blinking. 1. Injector Input Voltage Inspection Disconnect the injector 2P connector. 2P CONNECTOR (Wire side of Turn the ignition switch ON and engine stop female terminal) switch to "...
Page 149 FUEL SYSTEM (PGM-FI) 3. Injector Circuit Resistance Inspection Connect the test harness to the ECM 33P connec- tor (page 6-14). Check for continuity between the test harness TEST HARNESS PIN BOX terminal and injector 2P connector of the wire harness side. Connection: A16 –...
Page 150 FUEL SYSTEM (PGM-FI) MIL 21 BLINKS (O SENSOR) • Before starting the inspection, check for loose or poor contact on the O sensor cap connector and recheck the MIL blinking. 1. O Sensor Open Circuit Inspection Turn the ignition switch OFF. Connect the test harness to the ECM 33P connec- tor (page 6-14).
Page 151 FUEL SYSTEM (PGM-FI) 3. O Sensor Inspection Replace the O sensor with a known good one (page 6-76). Clear the DTC (page 6-13). Start the engine and warm it up until the coolant temperature is 80 °C (176 °F). Test-ride the scooter. Stop the engine.
Page 152 FUEL SYSTEM (PGM-FI) 2. IACV Circuit Continuity Inspection Connect the ECM test harness to ECM connector. Check the continuities between the test harness 33P CONNECTOR and the IACV 4P connector. (Wire side of female Connection: A21 – Light green terminals) A20 –...
Page 153: Mil Circuit Inspection
FUEL SYSTEM (PGM-FI) MIL CIRCUIT INSPECTION When The Ignition Switch "ON", The MIL Does Not Come On Turn the ignition switch "OFF". 33P CONNECTOR Remove the rear fender A (page 3-7). (Wire side of female terminals) Disconnect the ECM 33P connector. Ground the ECM 33P connector terminal of the wire harness side connector with a jumper wire.
Page 154: Fuel Line Inspection
FUEL SYSTEM (PGM-FI) FUEL LINE INSPECTION FUEL PRESSURE RELIEVING/QUICK CONNECT FITTING REMOVAL • Before disconnecting fuel hose, relieve pressure from the system as following procedures. 1. Turn the ignition switch "OFF". FUEL PUMP 5P CONNECTOR Remove the luggage box (page 3-5). Disconnect the fuel pump 5P connector.
Page 155 FUEL SYSTEM (PGM-FI) 7. Hold the connector with one hand and squeeze RETAINER the retainer tabs with the other hand and release CONNECTOR TABS them from the locking pawls. Pull the connector off. • Prevent the remaining fuel in the fuel hose from flowing out using a shop towel.
Page 156 FUEL SYSTEM (PGM-FI) 2. Clean around the pipe and set the rubber cor- LOCKING PAWLS rectly. Align the quick connect fitting with the pipe and Do not bend or align the retainer locking pawls with the connec- twist fuel hose. tor grooves.
Page 157 FUEL SYSTEM (PGM-FI) FUEL PRESSURE TEST Relieve the fuel pressure and disconnect the quick FUEL FEED HOSE CLAMP BOLT connect fitting (page 6-44). Remove the bolt from the fuel feed hose clamp. Attach the fuel pressure gauge set and pressure FUEL PRESSURE GAUGE gauge.
Page 158: Fuel Pump
FUEL SYSTEM (PGM-FI) FUEL FLOW INSPECTION Relieve the fuel pressure and disconnect the quick FUEL ATTACHMENT HOSE connect fitting (page 6-44). Turn the ignition switch "OFF". Connect the fuel attachment hose to the fuel pump joint. TOOL: Fuel attachment hose 07ZAJ-S5A0120 Place the end of the hose into an approved gasoline Wipe off spilled out...
Page 159 FUEL SYSTEM (PGM-FI) REMOVAL • It is impossible to disassemble the fuel pump after removing it. Relieve the fuel pressure and disconnect the quick FUEL PUMP 5P CONNECTOR connect fitting (page 6-44). Clean around the fuel pump. Disconnect the fuel pump 5P connector. Remove the fuel pump mounting nuts.
Page 160 FUEL SYSTEM (PGM-FI) INSTALLATION Place a new packing onto the fuel tank and apply Always replace less than 1.0 g of engine oil to lip surface of the packing with a new packing. LIP SURFACE one. PACKING Install the fuel pump unit to the fuel tank. •...
Page 161: Fuel Tank
FUEL SYSTEM (PGM-FI) Connect the fuel pump 5P connector. FUEL PUMP 5P CONNECTOR Connect the quick connect fitting (page 6-45). FUEL TANK REMOVAL/INSTALLATION Remove the body cover (page 3-6). WASHER BOLTS Relieve the fuel pressure and disconnect the quick connect fitting (page 6-44). FUEL TANK Disconnect the fuel pump 5P connector.
Page 162: Air Cleaner Housing
FUEL SYSTEM (PGM-FI) AIR CLEANER HOUSING REMOVAL/INSTALLATION Remove the luggage box (page 3-5). BOLTS Remove the washer bolts and ignition coil cover. IGNITION COIL COVER Disconnect the following hoses from the air cleaner AIR SUCTION HOSE housing: – Crankcase breather hose –...
Page 163: Throttle Body
FUEL SYSTEM (PGM-FI) Installation is in the reverse order of removal. Route the hoses 7.0 ± 1.0 mm properly (page 1- TORQUE: Air cleaner housing mounting washer bolt 19). (0.28 ± 0.04 in) 11 N·m (1.1 kgf·m, 8 lbf·ft) • Tighten the connecting hose band screw until the clearance between the screw and band end is 7.0 ±...
Page 164 FUEL SYSTEM (PGM-FI) DISASSEMBLY • The throttle body is factory pre-set. Do not disas- semble in a way other than shown in this man- ual. • Do not snap the throttle valve from full open to full close after the throttle cable has been removed.
Page 165 FUEL SYSTEM (PGM-FI) ASSEMBLY SCREW WIRE CLAMP PLATE 3.4 N·m (0.3 kgf·m, 2.5 lbf·ft) THROTTLE CABLE BRACKET THROTTLE BODY TORX SCREWS O-RING 3.4 N·m (0.3 kgf·m, 2.5 lbf·ft) SCREW 3.4 N·m (0.3 kgf·m, 2.5 lbf·ft) SET PLATE TORX SCREWS SENSOR UNIT 2.1 N·m (0.2 kgf·m, IACV 1.5 lbf·ft)
Page 166 FUEL SYSTEM (PGM-FI) Turn the slide valve clockwise until lightly seated on IACV IACV. SLIDE VALVE Install the IACV by aligning the pin with the slide SLIDE VALVE valve slot. Align IACV Install the set plate by aligning the tab of the IACV TORX with the slot of set plate as shown.
Page 167 FUEL SYSTEM (PGM-FI) Tighten the connecting hose band screw until the clearance between the screw and band end is 7.0 ± 1.0 mm (0.28 ± 0.04 in). 7.0 ± 1.0 mm (0.28 ± 0.04 in) CONNECTING HOSE BAND SCREW Connect the throttle cable to the throttle drum and Be careful not to set the throttle cable onto the cable bracket, then damage the threads...
Page 168 FUEL SYSTEM (PGM-FI) TP SENSOR RESET PROCEDURE • Make sure that DTC is not stored in ECM. If the DTC is stored in ECM, TP sensor reset mode won’t start by following the procedure below. 1. Remove the maintenance lid (page 3-4). 2.
Page 169 FUEL SYSTEM (PGM-FI) 6. Turn the ignition switch "ON" then disconnect the jumper wire from the ECT sensor 3P (Gray) connector while the MIL is blinking (reset receiv- ing pattern) for 10 seconds. 3P (GRAY) CONNECTOR JUMPER WIRE 7. Check if the MIL blinks. After disconnection of the jumper wire, the MIL should start blinking (successful pattern).
Page 170 FUEL SYSTEM (PGM-FI) 10.Disconnect the SCS connector from the DLC. SCS CONNECTOR 11.Install the dummy connector to the DLC. DUMMY CONNECTOR 12.Support the scooter with its centerstand. Warm up the engine about ten minutes. Connect the tachometer and check the idle speed.
Page 171: Injector
FUEL SYSTEM (PGM-FI) INJECTOR REMOVAL Relieve the fuel pressure and disconnect the quick FUEL FEED HOSE CLAMP BOLT connect fitting (page 6-44). Disconnect the injector 2P connector. Remove the fuel hose clamp bolt. INJECTOR 2P CONNECTOR Before removal, clean around the injector. RUBBER FUEL FEED PIPE Pull the rubber off the fuel feed pipe.
Page 172 FUEL SYSTEM (PGM-FI) Remove the following: BOLTS FUEL FEED HOSE STAY – Bolts – Fuel feed hose stay – Fuel feed pipe/injector Seal the injector port with a shop towel or cover it with a piece of tape to prevent any foreign material from dropping into the engine.
Page 173 FUEL SYSTEM (PGM-FI) Insert a new retainer into the connector. • Always replace the retainer of the quick connect fitting when the fuel hose is disconnected. • If any retainer needs replacing, use the same manufacturer’s retainer as the ones being removed (The several manufacturers feature dif- ferent retainer specifications).
Page 174: Intake Pipe
FUEL SYSTEM (PGM-FI) INTAKE PIPE REMOVAL Remove the injector (page 6-61). BOLTS Loosen the insulator band screw. Remove the following: – Intake pipe mounting bolts – Intake pipe INTAKE PIPE BAND SCREW Remove the O-rings from the insulator. O-RINGS Seal the cylinder head intake port with a shop towel or cover it with a piece of tape to prevent any for- eign material from dropping into the engine.
Page 175: Ecm
FUEL SYSTEM (PGM-FI) REMOVAL/INSTALLATION Remove the rear fender A (page 3-7). Disconnect the ECM 33P connector. Remove the ECM from the rubber holder. Installation is in the reverse order of removal. RUBBER HOLDER 33P CONNECTOR Engine Does Not Start (MIL Does Not Come On) •...
Page 176 FUEL SYSTEM (PGM-FI) 3. Sensor Unit Power Input Line Short Circuit Inspection Turn the ignition switch "OFF". SENSOR UNIT 5P 5P (Black) Disconnect the ECM 33P connector. (Black) CONNECTOR CONNECTOR (Wire side of female Check for continuity between the sensor unit 5P terminals) (Black) connector of the wire harness side and ground.
Page 177: Engine Stop Relay
FUEL SYSTEM (PGM-FI) ENGINE STOP RELAY OPERATION INSPECTION Remove the rear body cover (page 3-6). ENGINE STOP Turn the ignition switch "ON". RELAY The engine stop relay coil is normal if the engine stop relay clicks. If you hear the engine stop relay "CLICK", but IACV and fuel pump does not operate for a few seconds, inspect the following: –...
Page 178 FUEL SYSTEM (PGM-FI) SWITCH LINE INSPECTION Turn the ignition switch OFF. RELAY CONNECTOR ENGINE STOP RELAY Remove the engine stop relay (page 6-69). Short the relay connector terminals of the wire har- ness side with a jumper wire. Connection: Red/Green – Black/White Disconnect the ECM 33P connector (page 6-65).
Page 179: Fuel Pump Relay
FUEL SYSTEM (PGM-FI) REMOVAL/INSTALLATION Remove the rear body cover (page 3-6). ENGINE STOP Remove the engine stop relay from the relay con- RELAY nector. Installation is in the reverse order of removal. FUEL PUMP RELAY OPERATION INSPECTION Remove the rear body cover (page 3-6). Turn the ignition switch "ON".
Page 180 FUEL SYSTEM (PGM-FI) CONTINUITY INSPECTION Turn the ignition switch OFF. RELAY Remove the fuel pump relay (page 6-71). Connect the ohmmeter to the switching side relay terminals. Connection: A – B Connect the 12 V battery to the coil side relay termi- nals.
Page 181 FUEL SYSTEM (PGM-FI) COIL LINE INSPECTION Turn the ignition switch "OFF". RELAY CONNECTOR ENGINE STOP RELAY Remove the fuel pump relay (page 6-71). Short the relay connector terminals of the wire har- ness side with a jumper wire. Connection: Black/White – Brown/Black Disconnect the ECM 33P connector (page 6-65).
Page 182: Bank Angle Sensor
FUEL SYSTEM (PGM-FI) BANK ANGLE SENSOR REMOVAL Turn the ignition switch "OFF". BANK ANGLE 3P CONNECTOR Remove the rear fender A (page 3-7). SENSOR Disconnect the bank angle sensor 3P connector. Remove the two screws and bank angle sensor. SCREWS INSTALLATION Install the bank angle sensor with its “UP”...
Page 183 FUEL SYSTEM (PGM-FI) SYSTEM INSPECTION Turn the ignition switch "OFF". BANK ANGLE Remove the rear fender A (page 3-7). SENSOR Remove the two screws and bank angle sensor. Do not disconnect the bank angle sen- sor connector dur- ing inspection. SCREWS Place the bank angle sensor in normal position as If you perform this...
Page 184: Ect Sensor
FUEL SYSTEM (PGM-FI) CIRCUIT INSPECTION Support the scooter with its centerstand on a level 3P CONNECTOR BANK ANGLE surface. (Wire side of male SENSOR 3P Remove the rear fender A (page 3-7). terminals) CONNECTOR Disconnect the bank angle sensor 3P connector. Turn the ignition switch "ON".
Page 185 FUEL SYSTEM (PGM-FI) INSPECTION Remove the ECT sensor (page 6-74). THERMOMETER Heat the coolant (1:1 mixture) with an electric heat- Wear insulated ing element. gloves and ade- Suspend the ECT sensor in heated coolant and quate eye protec- check the continuity through the sensor as the cool- tion.
Page 186: 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. REMOVAL Remove the maintenance lid (page 3-4). Replace the O sen- SENSOR CONNECTOR...
Page 187: Engine Idle Speed
FUEL SYSTEM (PGM-FI) ENGINE IDLE SPEED IDLE SPEED INSPECTION • Inspect the idle speed after all other engine main- tenance items have been performed and are within specifications. • Before checking the idle speed, inspect the fol- lowing items. – No DTC and MIL blinking. –...
Page 188: Secondary Air Supply System
FUEL SYSTEM (PGM-FI) Remove the IACV (page 6-53). IACV IACV SLIDE VALVE Check the IACV slide valve and IACV air passage in the throttle body for carbon deposits. Clean the IACV slide valve and IACV air passage if necessary. The IACV operation can be checked visually as fol- lows: IACV AIR PASSAGE Connect the 4P connector to the IACV, then turn the...
Page 189 FUEL SYSTEM (PGM-FI) INSPECTION Check air flow from A to B. Air should flow. Connect the 12 V battery to the solenoid valve side 2P connector terminals. Air should not flow from A to B when the battery is connected. SOLENOID VALVE Measure the resistance between the connector ter- SOLENOID VALVE...
Page 190 FUEL SYSTEM (PGM-FI) Check the reed valve for damage or fatigue. Replace VALVE STOPPER if necessary. Replace the PAIR check valve if the rubber seat is cracked, deteriorated or damaged, or if there is clearance between the reed and seat. Installation is in the reverse order of removal.
Page 191 7. COOLING SYSTEM SYSTEM FLOW PATTERN ························· 7-2 THERMOSTAT ············································ 7-9 SERVICE INFORMATION ··························· 7-3 WATER PUMP ·········································· 7-10 TROUBLESHOOTING ································· 7-4 RADIATOR COOLING FAN ······················ 7-13 SYSTEM TESTING······································ 7-5 RADIATOR ················································ 7-13 COOLANT REPLACEMENT ························ 7-6 RADIATOR RESERVE TANK ···················· 7-14...
Page 192: System Flow Pattern
COOLING SYSTEM SYSTEM FLOW PATTERN COOLING SYSTEM OVER FLOW HOSE RESERVE TANK RADIATOR SIPHON HOSE THERMOSTAT WATER PUMP...
Page 193: Service Information
COOLING SYSTEM SERVICE INFORMATION GENERAL Removing the radiator cap while the engine is hot can allow the coolant to spray out, seriously scalding you. Always let the engine and radiator cool down before removing the radiator cap. Using coolant with silicate inhibitors may cause premature wear of water pump seals or blockage of radiator passages. Using tap water may cause engine damage.
Page 194: Troubleshooting
COOLING SYSTEM TOOLS Bearing remover head, 14 mm Bearing remover shaft, 15 mm Remover weight 07WMC-KFG0100 07936-KC10100 07741-0010201 Driver Attachment, 24 x 26 mm Mechanical seal driver 07749-0010000 07746-0010700 07PMD-KBP0100 TROUBLESHOOTING Engine temperature too high • Insufficient coolant • Air in system •...
Page 195: System Testing
COOLING SYSTEM SYSTEM TESTING COOLANT (HYDROMETER TEST) Remove the screw and radiator maintenance lid. SCREW RADIATOR MAINTENANCE LID Remove the radiator cap. The engine must be cool before removing the radiator cap. RADIATOR CAP Test the coolant gravity using a hydrometer. STANDARD COOLANT CONCENTRATION: 1:1 (distilled water and the recommended antifreeze)
Page 196: Coolant Replacement
COOLING SYSTEM RADIATOR CAP/SYSTEM PRESSURE INSPECTION Remove the radiator cap (page 7-5). Wet the sealing surfaces of the cap, then install the RADIATOR CAP cap onto tester. Pressurize the radiator cap using the tester. Replace the radiator cap if it does not hold pressure, or if relief pressure is too high or too low.
Page 197 COOLING SYSTEM REPLACEMENT/AIR BLEEDING Place the scooter on its centerstand on a level sur- The engine must be face. cool before WATER PUMP servicing the Remove the following: cooling system. – maintenance lid (page 3-4) – luggage box (page 3-5) –...
Page 198 COOLING SYSTEM Remove the reserve tank cap. Pump out the coolant with a fluid evacuator to drain TANK CAP the reservoir tank. RESERVE TANK Remove the bolt and sealing washer. BOLT HOLE Fill the coolant from the filler neck until the coolant WASHER starts dripping from the bolt hole.
Page 199: Thermostat
COOLING SYSTEM THERMOSTAT REMOVAL/INSTALLATION Remove the following: COVER – maintenance lid (page 3-4) – luggage box (page 3-5) – floor side cover (page 3-8) – under cover (page 3-9) Drain the coolant from the system (page 7-7). Remove the following: –...
Page 200: Water Pump
COOLING SYSTEM WATER PUMP MECHANICAL SEAL INSPECTION Check for signs of seal leakage. A small amount of "weeping" from the inspection hole is normal. INSPECTION HOLE MECHANICAL SEAL REPLACEMENT Remove the right crankcase cover (page 13-4). DOWEL PINS O-RING Remove the following: –...
Page 201 COOLING SYSTEM Remove the mechanical seal using the special tools. MECHANICAL SEAL WEIGHT TOOLS: Bearing remover head, 14 mm 07WMC-KFG0100 Bearing remover shaft, 15 mm 07936-KC10100 Remover weight 07741-0010201 BEARING REMOVER Remove the oil seal. INSPECTION HOLE Blow the inspection hole in the crankcase cover with compressed air to clean it.
Page 202 COOLING SYSTEM Install the thrust washer to the shaft. Install thrust SHAFT Install the pump shaft into the right crankcase cover. washer with the chamfered (rolled) Check the pump shaft for smooth rotation. edge facing the pump shaft tab. Install the washer and impeller. The impeller has Hold the pump shaft tab and tighten the impeller.
Page 203: Radiator Cooling Fan
COOLING SYSTEM RADIATOR COOLING FAN REMOVAL/INSTALLATION Remove the following: 2P CONNECTOR – floor side cover (page 3-8) – front inner cover (page 3-10) – floor panel (page 3-13) Disconnect the cooling fan motor 2P (black) connec- tor and release the wire from the three wire bands. WIRE BANDS Remove the two mounting bolts and fan motor Be careful not to...
Page 204: Radiator Reserve Tank
COOLING SYSTEM RADIATOR RESERVE TANK REMOVAL/INSTALLATION Remove the following: OVER FLOW HOSE – floor side cover (page 3-8) BOLTS – front inner cover (page 3-10) – floor panel (page 3-13) Drain the coolant from the system (page 7-7). Disconnect the over flow hose and siphon hose from the reserve tank.
Page 205 8. ENGINE REMOVAL/INSTALLATION COMPONENT LOCATION ·························· 8-2 ENGINE REMOVAL ···································· 8-4 SERVICE INFORMATION ··························· 8-3 ENGINE INSTALLATION···························· 8-9...
Page 206 ENGINE REMOVAL/INSTALLATION COMPONENT LOCATION ENGINE REMOVAL/INSTALLATION 30 N·m (3.1 kgf·m, 22 lbf·ft) 78 N·m (8.0 kgf·m, 58 lbf·ft) 10 N·m (1.0 kgf·m, 7 lbf·ft)
Page 207 ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION GENERAL • When removing/installing the engine, tape the frame around the engine beforehand for frame protection. • A hoist or equivalent is required to support the frame when removing and installing the engine. Support the engine using a jack or other adjustable support to ease engine mounting bolt removal.
Page 208 ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL Remove the following: PROTECTOR CALIPER – maintenance lid (page 3-4) – luggage box (page 3-5) – grab rail (page 3-5) – body cover (page 3-6) – rear fender A (page 3-7) – floor side cover (page 3-8) –...
Page 209 ENGINE REMOVAL/INSTALLATION Disconnect the PAIR control solenoid valve 2P (Black) connector. 2P CONNECTOR BAND Release the three wire bands from the wire band stay. Release the main wire harness, alternator and CKP sensor wires from the two wire guides. GUIDES BANDS Disconnect the ECT sensor 3P (gray) connector and injector 2P (black) connector.
Page 210 ENGINE REMOVAL/INSTALLATION Remove the starter motor mounting bolts and release the battery negative (–) cable and frame BOLT/CLAMP MOTOR CABLE ground cable from the starter motor. Remove the terminal nut and release the starter motor cable form the starter motor. Remove the bolt and cable clamp.
Page 211: Engine Hanger
ENGINE REMOVAL/INSTALLATION Remove the engine pivot nut and bolt. Make sure the wires and cables do not interfere with The jack height the engine components, and separate the frame must be adjusted to from the engine. relieve stress for ease of bolt removal.
Page 212: Bearing
ENGINE REMOVAL/INSTALLATION Remove the engine hanger bracket nut, bolt and separate the engine hanger bracket B from the BRACKET A engine hanger bracket A. NUT/BOLT BRACKET B INSPECTION Remove the dust seals and inner collar from the DUST SEAL BEARINGS engine hanger bracket B.
Page 213: Engine Hanger Bracket B
ENGINE REMOVAL/INSTALLATION Pack the new needle bearings with grease. Drive the needle bearings into the engine hanger DRIVER bracket B with the marked side facing up until it is fully seated, using the special tools. TOOLS: Driver 07749-0010000 Attachment, 24 x 26 mm 07746-0010700 Pilot, 20 mm 07746-0040500...
Page 214 ENGINE REMOVAL/INSTALLATION Apply 1.0 – 2.0 g of grease to the inner collar, needle DUST SEAL BEARINGS bearings and dust seal lips. Install the inner collar and dust seals to the engine hanger bracket B. INNER COLLAR DUST SEAL Install the engine hanger bracket B to the engine hanger bracket A and tighten the bolt/nut to the BRACKET A specified torque.
Page 215 ENGINE REMOVAL/INSTALLATION Coat new O-rings with molybdenum disulfide paste (SUMICO MOLYPASTE 500 or equivalent) and install MOUNTING BUSING them to the engine mounting bushing grooves. Apply 0.5 – 0.7 g of molybdenum disulfide paste O-RINGS (SUMICO MOLYPASTE 500 or equivalent) to the cen- ter groove of the engine mounting bushing and install it.
Page 216 MEMO...
Page 217 9. CYLINDER HEAD/VALVES COMPONENT LOCATION ·························· 9-2 CYLINDER HEAD DISASSEMBLY ··········· 9-12 SERVICE INFORMATION ··························· 9-3 VALVE GUIDE REPLACEMENT ··············· 9-14 TROUBLESHOOTING ································· 9-5 VALVE SEAT INSPECTION/REFACING ·· 9-15 CYLINDER COMPRESSION TEST·············· 9-6 CYLINDER HEAD ASSEMBLY ················· 9-18 CYLINDER HEAD COVER REMOVAL ········ 9-6 CYLINDER HEAD INSTALLATION···········...
Page 218: Component Location
CYLINDER HEAD/VALVES COMPONENT LOCATION CYLINDER HEAD/VALVES 22 N·m (2.2 kgf·m, 16 lbf·ft) 16 N·m (1.6 kgf·m, 12 lbf·ft) 10 N·m (1.0 kgf·m, 7 lbf·ft) 38 N·m (3.9 kgf·m, 28 lbf·ft)
Page 219: Service Information
CYLINDER HEAD/VALVES SERVICE INFORMATION GENERAL • This section covers service of the rocker arms, camshaft, valves and cylinder head. These parts can be serviced with the engine installed in the frame. • When disassembling, mark and store the disassembled parts to ensure that they are reinstalled in their original loca- tions.
Page 220 CYLINDER HEAD/VALVES TOOLS Valve spring compressor Valve spring compressor attach- Valve guide reamer, 4.5 mm 07757-0010000 ment 07HMH-ML00101 07959-KM30101 Valve guide driver, 4.3 mm Cutter holder, 4.5 mm Seat cutter, 27.5 mm (45° IN) 07HMD-ML00101 07781-0010600 07780-0010200 Seat cutter, 24 mm (45° EX) Flat cutter, 29 mm (32°...
Page 221: Troubleshooting
CYLINDER HEAD/VALVES TROUBLESHOOTING • Engine top-end problems usually affect engine performance. These problem can be diagnosed by a compression test, or by tracing top-end noise with a sounding rod or stethoscope. • If the performance is poor at low speeds, check for white smoke in the crankcase breather hose. If the hose is smoky, check for a seized piston ring (page 10-5).
Page 222: Cylinder Compression Test
CYLINDER HEAD/VALVES CYLINDER COMPRESSION TEST Remove the maintenance lid (page 3-4). COMPRESSION GAUGE Warm up the engine to normal operating tempera- ture. Stop the engine and remove the spark plug cap and spark plug (page 4-7). Install a compression gauge into the spark plug hole.
Page 223: Camshaft/Rocker Arm Removal
CYLINDER HEAD/VALVES CAMSHAFT/ROCKER ARM REMOVAL CAM SPROCKET REMOVAL Remove the following: – cylinder head cover (page 9-6) – belt case air cleaner housing (page 4-16) Remove the timing hole cap and O-ring from the right crankcase cover. TIMING HOLE CAP Rotate the drive pulley (crankshaft) counterclock- wise and align the "T"...
Page 224 CYLINDER HEAD/VALVES Place a shop towel into the cylinder head opening to BOLTS prevent fasteners from falling into the crankcase. Remove the two bolts while holding the drive pulley (crankshaft), and the cam sprocket off of the cam- shaft. Remove the cam sprocket from the cam chain. Attach a piece of wire to the cam chain to prevent it from falling into the crankcase.
Page 225 CYLINDER HEAD/VALVES Remove the rocker arm shafts, rocker arms and ROCKER ARM springs. SHAFT SPRING INSPECTION CAM SPROCKET Check the cam sprocket for wear or damage. CAMSHAFT Check the camshaft bearing for wear or damage. Turn the bearing outer race with your finger. BEARING The bearing should turn smoothly and quietly.
Page 226 CYLINDER HEAD/VALVES Check the camshaft boss for wear or damage. CAMSHAFT BOSS Check the camshaft holder hole for wear or damage. CAMSHAFT HOLE ROCKET ARM/SHAFT Inspect the sliding surfaces of the rocker arms and shafts for wear or damage. Check the oil holes for clogs. Measure the O.D.
Page 227: Cylinder Head Removal
CYLINDER HEAD/VALVES CYLINDER HEAD REMOVAL Remove the following: STAY – exhaust system (page 3-15) – intake manifold (page 6-64) – thermostat (page 7-9) – ECT sensor (page 6-74) – O sensor (page 6-76) – cylinder head cover (page 9-6) – cam sprocket (page 9-7) –...
Page 228: Cylinder Head Disassembly
CYLINDER HEAD/VALVES CYLINDER HEAD DISASSEMBLY Remove the following: SPRING COMPRESSOR – cylinder head (page 9-11) – camshaft/rocker arm (page 9-7) Remove the valve spring cotters using the spring To prevent loss of compressor. tension, do not compress the valve TOOLS: springs more than Valve spring compressor 07757-0010000...
Page 229 CYLINDER HEAD/VALVES VALVE SPRING Check the valve springs for fatigue or damage. Measure the valve spring free length. SERVICE LIMIT: IN/EX: 35.6 mm (1.40 in) VALVE/VALVE GUIDE Check that the valve moves smoothly in the guide. Check the valves for bending, burning or abnormal wear.
Page 230: Valve Guide Replacement
CYLINDER HEAD/VALVES CAM CHAIN GUIDE/TENSIONER SLIDER Check the cam chain tensioner slider in the crank- TENSIONER SLIDER case for excessive wear or damage. Check the cam chain guide for excessive wear or damage. CHAIN GUIDE VALVE GUIDE REPLACEMENT Mark new valve guides at the specified height indi- cated below, using a marker.
Page 231: Valve Seat Inspection/Refacing
CYLINDER HEAD/VALVES Ream the new valve guides. Use cutting oil on Insert the reamer from the combustion chamber the reamer during VALVE GUIDE side of the cylinder head and always rotate the this operation. Take REAMER reamer clockwise. care not to tilt or learn the reamer in TOOL: the guide while...
Page 232 CYLINDER HEAD/VALVES • Contact area (too high or too low) – Reface the valve seat. TOO LOW TOO HIGH REFACING Valve seat cutters/grinders or equivalent valve seat Follow the refacing refacing equipment are recommended to correct manufacturer's worn valve seats. operating instruc- tions.
Page 233 CYLINDER HEAD/VALVES Using a 32° flat cutter, remove 1/4 of the existing valve seat material. TOOLS: Flat cutter, 29 mm (32° IN) 07780-0013400 OLD SEAT WIDTH Flat cutter, 25 mm (32° EX) 07780-0012000 Cutter holder, 4.5 mm 07781-0010600 or equivalent commercially available 32°...
Page 234: Cylinder Head Assembly
CYLINDER HEAD/VALVES CYLINDER HEAD ASSEMBLY SPRING COTTERS SPRING RETAINER VALVE SPRING SPRING SEAT STEM SEAL VALVE GUIDE EXHAUST VALVE INTAKE VALVE Blow out the oil passages in the cylinder head with compressed air. STEM SEAL Apply engine oil to the fitting area of new stem seals.
Page 235: Cylinder Head Installation
CYLINDER HEAD/VALVES Install the valve spring cotters using the valve To prevent loss of SPRING COMPRESSOR spring compressor. tension, do not compress the valve TOOLS: springs more than Valve spring compressor 07757-0010000 necessary. Valve spring compressor attach- 07959-KM30101 ment COTTERS Tap the valve stems gently with two plastic ham- Support the cylin- mers to seat the cotters firmly.
Page 236 CYLINDER HEAD/VALVES Route the cam chain through the cylinder head and BOLTS/WASHERS install the cylinder head. Apply molybdenum oil solution to the thread and seating surface of the cylinder head 9 mm bolts and washers. Install the 9 mm bolts, washers and tighten the bolts in a crisscross pattern in 2 or 3 steps to the specified torque.
Page 237: Camshaft/Rocker Arm
CYLINDER HEAD/VALVES CAMSHAFT/ROCKER ARM INSTALLATION CAMSHAFT/ROCKER ARM INSTALLA- TION Apply molybdenum oil solution to the sliding sur- Do not exchange face of the rocker arms and shafts. the intake and exhaust rocker arm shafts. Clean the rocker arm shaft holes and camshaft bear- ROCKER ARM ing mating area.
Page 238 CYLINDER HEAD/VALVES Shift the rocker arms to the spring side and install Be careful not to let the shims in their original locations on the valve the shims fall into SHIMS retainer. the crankcase. CAM SPROCKET INSTALLATION Rotate the drive pulley (crankshaft) counterclock- Be careful not to wise and align the "T"...
Page 239: Cylinder Head Cover
CYLINDER HEAD/VALVES Retract the push rod while pushing the tab and release the tab to lock it. TENSIONER LIFTER PUSH ROD Install a new gasket and cam chain tensioner lifter TENSIONER LIFTER onto the cylinder head. Install and tighten the mounting bolts. BOLTS GASKET Install the spring, new sealing washer and sealing...
Page 240 CYLINDER HEAD/VALVES CYLINDER HEAD COVER INSTALLATION Check that the rubber seal is in good condition, replace it if necessary. Install the rubber seal. RUBBER SEAL Apply liquid sealant (Three Bond 1211 or shell KE45T or equivalent) to the cylinder head semi-cir- cular cutout as shown.
Page 241 10. CYLINDER/PISTON COMPONENT LOCATION ························ 10-2 CYLINDER/PISTON REMOVAL ··············· 10-4 SERVICE INFORMATION ························· 10-3 CYLINDER/PISTON INSPECTION ··········· 10-5 TROUBLESHOOTING ······························· 10-3 PISTON/CYLINDER INSTALLATION······· 10-7 10-1...
Page 242 CYLINDER/PISTON COMPONENT LOCATION CYLINDER/PISTON 10-2...
Page 243 CYLINDER/PISTON SERVICE INFORMATION GENERAL • This section covers maintenance of the cylinder and piston. • The cylinder and piston can be serviced with the engine installed in the frame. • Be careful not to damage the mating surfaces when removing the cylinder. •...
Page 244 CYLINDER/PISTON CYLINDER/PISTON REMOVAL CYLINDER REMOVAL Remove the cylinder head (page 9-11). BOLTS BOLT/CLAMP Remove the two bolts, oil pressure switch wire clamp and PAIR check valve (page 6-79). Remove the bolt and O sensor wire clamp PAIR CHECK VALVE CLAMP Release the water hose from the clamp.
Page 245 CYLINDER/PISTON Spread each piston ring and remove it by lifting up Do not damage the at a point opposite the gap. piston ring by spreading the ends too far. Clean carbon deposits from the ring grooves with a Never use a wire ring that will be discarded.
Page 246 CYLINDER/PISTON Check the cylinder for warpage with a straight edge and feeler gauge in the directions shown. SERVICE LIMIT: 0.05 mm (0.002 in) PISTON/PISTON RING Inspect the piston rings for movement by rotating the rings. The rings should be able to move in their grooves without catching.
Page 247 CYLINDER/PISTON Measure the piston O.D. at the point 10 mm (0.4 in) from the bottom and 90° to the piston pin hole. 90° SERVICE LIMITS: 71.90 mm (2.831 in) Calculate the cylinder-to-piston clearance (cylinder 10 mm (0.4 in) I.D.: page 10-5). SERVICE LIMIT: 0.10 mm (0.004 in) Measure the connecting rod small end I.D.
Page 248 CYLINDER/PISTON Apply molybdenum oil solution to the piston pin Place a shop towel PISTON PIN and piston pin hole. at the opening of the crankcase to Install the piston with the "IN" mark facing the intake prevent the piston side. pin clips from falling Install the piston pin and new pin clips.
Page 249 CYLINDER/PISTON Install the O sensor wire clamp and tighten the bolt. BOLTS BOLT/CLAMP Install the PAIR check valve (page 6-79), oil pressure switch wire clamp and tighten the two bolts. Install the cylinder head (page 9-19). CLAMP PAIR CHECK VALVE 10-9...
Page 250 MEMO...
Page 251 11. DRIVE AND DRIVEN PULLEYS/CLUTCH COMPONENT LOCATION ························ 11-2 DRIVE BELT ·············································· 11-7 SERVICE INFORMATION ························· 11-3 DRIVE PULLEY ········································· 11-8 TROUBLESHOOTING ······························· 11-4 CLUTCH/DRIVEN PULLEY····················· 11-11 LEFT CRANKCASE COVER ······················ 11-5 11-1...
Page 252 DRIVE AND DRIVEN PULLEYS/CLUTCH COMPONENT LOCATION DRIVE AND DRIVEN PULLEYS/CLUTCH 83 N·m (8.5 kgf·m, 61 lbf·ft) 74 N·m (7.5 kgf·m, 55 lbf·ft) 11-2...
Page 253 DRIVE AND DRIVEN PULLEYS/CLUTCH SERVICE INFORMATION GENERAL • This section covers maintenance of the drive pulley, driven pulley and clutch. • These services can be done with the engine installed in the frame. • Avoid getting grease and oil on the drive belt and drive/driven pulley faces in order to prevent belt slippage. •...
Page 254 DRIVE AND DRIVEN PULLEYS/CLUTCH Bearing remover set, 25 mm Remover weight Attachment, 32 x 35 mm 07936-ZV10100 07741-0010201 07746-0010100 Attachment, 42 x 47 mm Pilot, 20 mm Pilot, 25 mm 07746-0010300 07746-0040500 07746-0040600 Pilot, 28 mm Driver 07746-0041100 07749-0010000 TROUBLESHOOTING Engine starts but scooter won’t move •...
Page 255 DRIVE AND DRIVEN PULLEYS/CLUTCH LEFT CRANKCASE COVER REMOVAL Remove the belt case air cleaner housing (page 4- 16). BOLT/CLAMP BOLTS Remove the following: – bolt (10 mm head) and wire clamp (from the left crankcase cover) – eleven bolts (8 mm head) –...
Page 256 DRIVE AND DRIVEN PULLEYS/CLUTCH Apply engine oil to new bearing cavity. Drive the bearing into the left crankcase cover DRIVER squarely until it is fully seated, using the special tools. TOOLS: Driver 07749-0010000 Attachment, 42 x 47 mm 07746-0010300 Pilot, 20 mm 07746-0040500 ATTACHMENT /PILOT...
Page 257 DRIVE AND DRIVEN PULLEYS/CLUTCH DRIVE BELT REMOVAL Remove the following: DRIVE BELT – left crankcase cover (page 11-5) – drive pulley face (page 11-8) – clutch outer (page 11-11) Remove the clutch/driven pulley assembly with the drive belt from the driveshaft. Remove the drive belt from the driven pulley.
Page 258 DRIVE AND DRIVEN PULLEYS/CLUTCH DRIVE PULLEY REMOVAL Remove the left crankcase cover (page 11-5). BOLT/WASHER DRIVE PULLEY FACE Hold the drive pulley face with special tool and loosen the drive pulley face bolt. TOOL: Universal holder 07725-0030000 Remove the bolt, washer and drive pulley face. UNIVERSAL HOLDER Remove the drive belt from the crankshaft.
Page 259 DRIVE AND DRIVEN PULLEYS/CLUTCH INSPECTION WEIGHT ROLLER Check each roller for wear or damage. Measure the weight roller O.D. SERVICE LIMIT: 22.5 mm (0.89 in) MOVABLE DRIVE FACE Check the drive face boss for wear or damage. Measure the face bushing I.D. SERVICE LIMIT: 30.08 mm (1.184 in) Measure the boss O.D.
Page 260 DRIVE AND DRIVEN PULLEYS/CLUTCH Clean any oil and grease from the weight rollers. RAMP PLATE Install the weight rollers on the movable drive face. Install the slide piece and ramp plate. WEIGHT ROLLERS SLIDE PIECES Clean any oil and grease from the drive face and the drive belt.
Page 261 DRIVE AND DRIVEN PULLEYS/CLUTCH CLUTCH/DRIVEN PULLEY REMOVAL Remove the drive pulley face (page 11-8). FLYWHEEL HOLDER COLLAR/O-RINGS Hold the clutch outer with the special tool and loosen the clutch outer nut. TOOL: Flywheel holder 07725-0040001 Remove the nut, bearing collar and clutch outer. Remove the O-rings from the bearing collar.
Page 262 DRIVE AND DRIVEN PULLEYS/CLUTCH Hold the clutch spring compressor in a vise and To prevent loss of remove the clutch/driven pulley nut using the spe- tension, do not cial tool. compress the clutch spring more TOOL: than necessary to Socket wrench, 39 x 41 mm 07GMA-KS40100 remove the clutch/ driven pulley nut.
Page 263 DRIVE AND DRIVEN PULLEYS/CLUTCH – three rubber dampers RUBBER DAMPERS DRIVE PLATE DRIVEN PULLEY Remove the following: – seal collar SEAL COLLAR – guide pins and rollers MOVABLE DRIVEN FACE – movable driven face GUIDE PINS/ROLLERS – two O-rings OIL SEALS –...
Page 264 DRIVE AND DRIVEN PULLEYS/CLUTCH DRIVEN FACE BEARING REPLACE- MENT Remove the driven face needle bearing using the special tools. BEARING REMOVER TOOLS: Bearing remover set, 25 mm 07936-ZV10100 Remover weight 07741-0010201 WEIGHT NEEDLE BEARING Remove the snap ring and remove the ball bearing. SNAP RING BALL BEARING...
Page 265 DRIVE AND DRIVEN PULLEYS/CLUTCH Apply grease to a new needle nearing rollers. Install the needle bearing into the driven face squarely with the sealed side facing up so that the NEEDLE BEARING depth from the driven face surface is 0.8 mm (0.03 DRIVER in) using the special tool.
Page 266 DRIVE AND DRIVEN PULLEYS/CLUTCH ASSEMBLY • Apply specified quantity of grease to the inside of the driven face and the guide grooves in the movable driven face. • Avoid getting grease or oil on the clutch shoe lin- ings and driven pulley faces. Discard contami- nated clutch shoes and clean contaminated pulley faces with a high quality degreasing agent.
Page 267 DRIVE AND DRIVEN PULLEYS/CLUTCH Clean any oil and grease from the pulley face. MOVABLE DRIVEN FACE Install the movable driven face onto the driven face. Install the rollers and guide pins. Apply 4 – 5 g of grease (Shell ALVANIA R3 or SHIN- NIHON POWERNOC WB3 or IDEMITSU AUTOREX B or equivalent) to the guide grooves.
Page 268 DRIVE AND DRIVEN PULLEYS/CLUTCH Install the clutch side plate and secure it with the E- clips CLUTCH SIDE PLATE E-CLIPS CLUTCH/DRIVEN PULLEY Assemble the following: COLLAR A – driven pulley assembly COLLAR B – spring collar A – driven face spring –...
Page 269 DRIVE AND DRIVEN PULLEYS/CLUTCH INSTALLATION Install the clutch/driven pulley assembly with the drive belt (page 11-7). COLLAR Clean any oil and grease from the clutch outer. Install the clutch outer onto the driveshaft by align- ing the spline. Apply grease to the new O-rings and install its to the bearing collar grooves.
Page 270 MEMO...
Page 271 12. FINAL REDUCTION COMPONENT LOCATION ························ 12-2 FINAL REDUCTION DISASSEMBLY/ INSPECTION ············································· 12-6 SERVICE INFORMATION ························· 12-3 BEARING REPLACEMENT ······················· 12-8 TROUBLESHOOTING ······························· 12-5 FINAL REDUCTION ASSEMBLY ··········· 12-11 12-1...
Page 272 FINAL REDUCTION COMPONENT LOCATION FINAL REDUCTION 24 N·m (2.4 kgf·m, 18 lbf·ft) 10 N·m (1.0 kgf·m, 7 lbf·ft) ABS type only: 12-2...
Page 273 0.28 liter (0.30 US qt, 0.25 lmp qt) After disassembly 0.30 liter (0.32 US qt, 0.26 lmp qt) Recommended final drive oil Honda "4-stroke motorcycle oil" or an equivalent API service classification: SG or higher (except oils labeled as energy conserving on the circular API service label)
Page 274 FINAL REDUCTION Remover weight Driver Attachment, 22 x 24 mm 07741-0010201 07749-0010000 07746-0010800 Attachment, 42 x 47 mm Attachment, 48.2 x 51.5 mm Attachment, 52 x 55 mm 07746-0010300 07946-3290000 07746-0010400 Pilot, 14 mm Pilot, 15 mm Pilot, 20 mm 07746-0041200 07746-0040300 07746-0040500...
Page 275 FINAL REDUCTION TROUBLESHOOTING Engine does start but scooter won’t move • Damaged final reduction • Seized final reduction • Faulty drive pulley and driven pulley/clutch (page 11-4) Abnormal noise • Worn, seized or chipped gears • Worn or damaged final reduction bearing Oil leak •...
Page 276 FINAL REDUCTION FINAL REDUCTION DISASSEMBLY/ INSPECTION Remove the following: – clutch/driven pulley (page 11-11) – rear wheel (page 16-5) – sensor protector (page 18-25) – rear wheel speed sensor (page 18-25) ABS type only. Drain the final drive oil (page 4-17). Remove the following from the left crankcase: –...
Page 277 FINAL REDUCTION Check the final gear shaft and driveshaft ball bear- ings in the left crankcase. COUNTERSHAFT BEARING Turn the inner race of each bearing with your finger. The bearing should turn smoothly and quietly. Check the counter shaft needle bearing in the left crankcase for wear or damage.
Page 278 FINAL REDUCTION If the bearing is left on the driveshaft, remove it using a hydraulic press. DRIVESHAFT BEARING Check the countershaft, counter gear, final gear COUNTERSHAFT DRIVESHAFT shaft and driveshaft for wear or damage. FINAL GEAR SHAFT COUNTER GEAR BEARING REPLACEMENT Be careful not to damage the mating surfaces of the crankcase and final reduction case.
Page 279 FINAL REDUCTION LEFT CRANKCASE Remove the driveshaft bearing if it remains in the Be careful not to FINAL GEAR COUNTERSHAFT crankcase. damage the final SHAFT BEARING BEARING Remove the countershaft and final gear shaft bear- reduction case ings using the special tools. mating surface.
Page 280 FINAL REDUCTION Drive the final gear shaft bearing out of the reduc- Be careful not to COUNTERSHAFT DRIVESHAFT BEARING tion case. damage the final BEARING reduction case mat- Remove the driveshaft and countershaft bearings ing surface. using the special tools. WEIGHT TOOLS: Driveshaft bearing:...
Page 281 FINAL REDUCTION FINAL REDUCTION ASSEMBLY Clean the mating surfaces of the final reduction case and left crankcase. Install the driveshaft into the bearing. Position the assembly collar against the driveshaft ASSEMBLY COLLAR bearing inner race and pull the driveshaft into the bearing until it is fully seated.
Page 282 FINAL REDUCTION Install the two dowel pins. DOWEL PINS Apply sealant (Three Bond 1207B or equivalent) to the final reduction case mating surface as shown. Install the final reduction case to the left crankcase. FINAL REDUCTION CASE Install and tighten the seven bolts in a crisscross pattern in 2 or 3 steps to the specified torque.
Page 283 13. ALTERNATOR/STARTER CLUTCH COMPONENT LOCATION ························ 13-2 RIGHT CRANKCASE COVER ··················· 13-4 SERVICE INFORMATION ························· 13-3 STATOR/CKP SENSOR···························· 13-8 TROUBLESHOOTING ······························· 13-3 FLYWHEEL/STARTER CLUTCH ·············· 13-9 13-1...
Page 284 ALTERNATOR/STARTER CLUTCH COMPONENT LOCATION ALTERNATOR/STARTER CLUTCH 103 N·m (10.5 kgf·m, 76 lbf·ft) 13-2...
Page 285 ALTERNATOR/STARTER CLUTCH SERVICE INFORMATION GENERAL • This section covers the removal and installation of the flywheel, starter clutch and alternator/crankshaft position (CKP) sensor. • These service can be done with the engine installed in the frame. • For alternator inspection (page 19-8). •...
Page 286 ALTERNATOR/STARTER CLUTCH RIGHT CRANKCASE COVER REMOVAL Remove the following: 2P CONNECTOR 3P CONNECTOR – luggage box (page 3-5) – floor side cover (page 3-8) – under cover (page 3-9) – exhaust pipe/muffler (page 3-15) Drain the engine oil (page 4-11). Drain the coolant (page 7-7).
Page 287 ALTERNATOR/STARTER CLUTCH Loosen the hose band screw and disconnect the lower radiator hose from the water pump cover. BYPASS HOSE Disconnect the bypass hose from the water pump cover. LOWER RADIATOR HOSE Loosen the twelve bolts in a crisscross pattern in 2 The right crank- or 3 steps, then remove the bolts and right crank- case cover (stator)
Page 288 ALTERNATOR/STARTER CLUTCH Align the groove on the oil pump bolt with the index mark on the oil pump cover while aligning the tab WATER PUMP SHAFT OIL PUMP SHAFT on the water pump shaft with the cutout on the case as shown.
Page 289 ALTERNATOR/STARTER CLUTCH Install the ignition coil stay washer bolts and tighten them. WASHER BOLTS Install ignition coil cover and tighten the two washer bolts. WASHER BOLTS IGNITION COIL COVER Install the alternator/CKP sensor wire into the wire Route the wires guide and install the wire band onto the stay.
Page 290 ALTERNATOR/STARTER CLUTCH STATOR/CKP SENSOR REMOVAL Remove the right crankcase cover (page 13-4). GROMMET CKP SENSOR BOLTS Remove the following from the right crankcase cover: – four bolts and stator – two bolts and CKP sensor – wire grommet BOLTS STATOR INSTALLATION Install the stator and tighten the four bolts.
Page 291 ALTERNATOR/STARTER CLUTCH FLYWHEEL/STARTER CLUTCH REMOVAL Remove the right crankcase cover (page 13-4). BOLT Remove the bolt and starter driven gear guide. GEAR GUIDE Hold the flywheel with the special tool and loosen FLYWHEEL BOLT/WASHER the flywheel bolt. TOOL: Flywheel holder 07725-0040001 Remove the flywheel bolt and washer.
Page 292 ALTERNATOR/STARTER CLUTCH Remove the starter reduction gear shaft and reduc- tion gear. REDUCTION GEAR SHAFT Remove the woodruff key from the crankshaft. WOODRUFF KEY DISASSEMBLY Check the operation of the sprag clutch by turning the driven gear. STARTER DRIVEN GEAR You should be able to turn the driven gear clock- wise smoothly, but the gear should not turn coun- terclockwise.
Page 293 ALTERNATOR/STARTER CLUTCH Remove the starter clutch outer and sprag clutch from the flywheel. SPRAG CLUTCH FLYWHEEL CLUTCH OUTER INSPECTION Check the starter driven gear and reduction gear teeth for wear or damage. REDUCTION GEAR Measure the starter driven gear bushing I.D. SERVICE LIMIT: 25.100 mm (0.9882 in) Measure the starter driven gear boss O.D.
Page 294 ALTERNATOR/STARTER CLUTCH Install the starter clutch assembly onto the flywheel. STARTER CLUTCH ASSEMBLY FLYWHEEL Clean the starter clutch socket bolt threads. FLYWHEEL HOLDER Apply locking agent to the socket bolt threads. Align the bolt holes on the starter clutch outer and flywheel.
Page 295 ALTERNATOR/STARTER CLUTCH Apply engine oil to the starter reduction gear and shaft. REDUCTION GEAR Set the starter reduction gear properly and insert the shaft. SHAFT Clean any oil from the tapered portions of the crank- shaft and flywheel. Align Install the flywheel onto the crankshaft, aligning the groove with the woodruff key.
Page 296 MEMO...
Page 297 14. CRANKCASE/CRANKSHAFT COMPONENT LOCATION ························ 14-2 CRANKSHAFT/CONNECTING ROD ········ 14-6 SERVICE INFORMATION ························· 14-3 CRANKPIN BEARING ······························· 14-8 TROUBLESHOOTING ······························· 14-4 MAIN JOURNAL BEARING ··················· 14-10 CRANKCASE SEPARATION····················· 14-5 CRANKCASE ASSEMBLY ······················ 14-14 14-1...
Page 298 CRANKCASE/CRANKSHAFT COMPONENT LOCATION CRANKCASE/CRANKSHAFT 12 N·m (1.2 kgf·m, 9 lbf·ft) 33 N·m (3.4 kgf·m, 24 lbf·ft) 14-2...
Page 299 CRANKCASE/CRANKSHAFT SERVICE INFORMATION GENERAL • This section covers the crankcase separation to service the crankshaft. • The following parts must be removed before separating the crankcase. – engine (page 8-4) – cylinder head (page 9-11) – cylinder and piston (page 10-4) –...
Page 300 CRANKCASE/CRANKSHAFT TOOLS Driver, 40 x 42.7 mm Driver base, 48.4 x 56 mm Metal installer set 07965-VM00100 07946-KM90600 070MF-KTWR100 TROUBLESHOOTING Abnormal noise • Worn crankshaft bearing • Worn connecting rod big end bearing • Worn connecting rod small end 14-4...
Page 301 CRANKCASE/CRANKSHAFT CRANKCASE SEPARATION Refer to Service Information (page 14-3) for removal of necessary parts before separating the crankcase. PIVOT BOLT TENSIONER SLIDER Remove the cam chain and oil pump chain from the drive sprocket. Remove the cam chain tensioner pivot bolt and tensioner slider from the crankcase.
Page 302 CRANKCASE/CRANKSHAFT – water joint pin and O-ring – three oil joint pins and O-rings OIL JOINT PINS/O-RINGS – reed valve WATER JOINT PIN/ REED VALVE O-RING – crankshaft/connecting rod CRANKSHAFT/ CONNECTING ROD – snap ring – oil seal OIL SEAL SNAP RING CRANKSHAFT/CONNECTING ROD SIDE CLEARANCE INSPECTION...
Page 303 CRANKCASE/CRANKSHAFT CONNECTING ROD REMOVAL Remove the crankpin bearing cap nuts, bearing cap Tap the side of the and connecting rod from the crankshaft. cap lightly if bearing BEARING CAP CONNECTING ROD cap is hard to For the connecting rod small end inspection, refer to remove.
Page 304 CRANKCASE/CRANKSHAFT CRANKPIN BEARING BEARING INSPECTION Remove the connecting rod (page 14-7). Check the bearing inserts for unusual wear, damage BEARINGS or peeling and replace them if necessary. Select the replacement bearing (page 14-9). OIL CLEARANCE INSPECTION Clean off any oil from the bearing insert and crankpin.
Page 305 CRANKCASE/CRANKSHAFT BEARING SELECTION Record the connecting rod I.D. code number. • Number 1, 2 or 3 on the connecting rod is the code for the connecting rod I.D. CONNECTING ROD I.D. CODE NUMBER Record the crankpin O.D. code letter. CRANKPIN O.D. CODE LETTER •...
Page 306 CRANKCASE/CRANKSHAFT MAIN JOURNAL BEARING BEARING INSPECTION Remove the crankshaft (page 14-5). Clean off any oil from the bearings. MAIN JOURNAL INDEX MARK BEARING Check the bearings for unusual wear, damage or peeling and replace them if necessary. Measure the main journal bearing I.D. at between the bearing groove and crankcase outer side end of the bearing, and 90 degrees to the index mark.
Page 307 CRANKCASE/CRANKSHAFT Measure and record the crankcase main journal I.D. at between the main journal groove and crankcase outer side end, and 90 degrees to the index mark. SERVICE LIMIT: 45.060 mm (1.7740 in) INSIDE 90° OUTSIDE Depending upon the results of the above measure- BEARING SUPPORT I.D.
Page 308 CRANKCASE/CRANKSHAFT In case the crankshaft and crankcase are replaced: MAIN JOURNAL O.D. CODE 39.994 – 40.000 mm 39.988 – 39.994 mm 39.982 – 39.988 mm (1.5746 – 1.5748 in) (1.5743 – 1.5746 in) (1.5741 – 1.5743 in) 45.000 – 45.006 mm BEARING (1.7717 –...
Page 309 CRANKCASE/CRANKSHAFT BEARING THICKNESS: IDENTIFICATION COLOR O.S. E (Blue-Blue): Thick O.S. F (Black-Black): O.S. G (Brown-Brown): O.S. H (Green-Green): Middle A (Blue): B (Black): C (Brown): D (Green): Thin BEARING INSTALLATION Set a new bearing onto the metal installer so that the clearance between the end of the tool and bear- BOLTS ing is about 1.0 mm (0.04 in) on the inserting side.
Page 310 CRANKCASE/CRANKSHAFT Press the new bearings until the metal installer INSTALLER SET flange fully seat. BEARING DRIVER BASE Make sure the bearing mating line aligns with the INDEX MARK index mark on the crankcase. Check the oil clearance (page 14-8). • After selecting new bearings, recheck the clear- ance.
Page 311 CRANKCASE/CRANKSHAFT Install the snap ring into the groove in the left crank- SNAP RING case securely. Apply molybdenum disulfide oil to the main journal bearing inserts and install the crankshaft/connecting CRANKSHAFT/ rod into the left crankcase. CONNECTING ROD Install the reed valve of the left crankcase as shown. REED VALVE Install the water joint pin and new O-ring.
Page 312 CRANKCASE/CRANKSHAFT Install the two dowel pins. DOWEL PINS Apply sealant (Three Bond 1207B or equivalent) to the right crankcase mating surface. Install the right crankcase over the left crankcase. RIGHT CRANKCASE LEFT CRANKCASE Install the crankcase bolts and tighten them in a CRANKCASE BOLTS crisscross pattern in 2 or 3 steps.
Page 313 CRANKCASE/CRANKSHAFT Install the cam chain tensioner slider and tighten the pivot bolt to the specified torque. TENSIONER SLIDER TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft) PIVOT BOLT Apply engine oil to the timing sprocket teeth, cam TIMING chain and oil pump chain then install the cam chain CAM CHAIN and oil pump chain onto the timing sprocket.
Page 314 MEMO...
Page 315 15. FRONT WHEEL/SUSPENSION/STEERING COMPONENT LOCATION ························ 15-2 FORK ······················································· 15-12 SERVICE INFORMATION ························· 15-3 HANDLEBAR··········································· 15-20 TROUBLESHOOTING ······························· 15-5 STEERING STEM···································· 15-27 FRONT WHEEL ········································· 15-6 15-1...
Page 316: Component Location
FRONT WHEEL/SUSPENSION/STEERING COMPONENT LOCATION FRONT WHEEL/SUSPENSION/STEERING 12 N·m (1.2 kgf·m, 9 lbf·ft) 128 N·m (13.1 kgf·m, 94 lbf·ft) 49 N·m (5.0 kgf·m, 36 lbf·ft) 30 N·m (3.1 kgf·m, 22 lbf·ft) 36 N·m (3.7 kgf·m, 27 lbf·ft) 98 N·m (10.0 kgf·m, 72 lbf·ft) 15-2...
Page 317: Fork
Fork Spring free length 263.5 (10.37) 257.5 (10.14) Pipe runout – 0.2 (0.01) Recommended fork Honda Ultra Cushion Oil 10W – fluid or equivalent Fluid level 90 (3.5) – 151 ± 2.5 cm (5.1 ± 0.08 US oz, 5.3 ±...
Page 318 FRONT WHEEL/SUSPENSION/STEERING TOOLS Bearing remover shaft Bearing remover head, 15 mm Driver 07746-0050100 07746-0050400 07749-0010000 Attachment, 42 x 47 mm Attachment, 52 x 55 mm Pilot, 15 mm 07746-0010300 07746-0010400 07746-0040300 Fork seal driver weight Fork seal driver attachment, Socket wrench 07747-0010100 37.2 mm I.D.
Page 319 FRONT WHEEL/SUSPENSION/STEERING Remover weight Attachment, 35 mm I.D. 07741-0010201 07746-0030400 TROUBLESHOOTING Hard steering • Insufficient tire pressure • Faulty tire • Steering stem adjusting nut too tight • Worn or damaged steering head bearings • Worn or damaged steering head bearing races •...
Page 320 FRONT WHEEL/SUSPENSION/STEERING FRONT WHEEL REMOVAL Remove the axle nut and loosen the axle holder AXLE socket bolts. Support the scooter securely using a hoist or equiv- alent and raise the front wheel off the ground. Pull the axle out and remove the front wheel. Do not operate the brake levers after removing the...
Page 321 FRONT WHEEL/SUSPENSION/STEERING WHEEL Check the rim runout by placing the wheel in a tru- ing stand. Spin the wheel slowly and read the runout using a dial indicator. Actual runout is 1/2 the total indicator reading. SERVICE LIMITS: Radial: 2.0 mm (0.08 in) Axial: 2.0 mm (0.08 in) WHEEL BEARING...
Page 322 FRONT WHEEL/SUSPENSION/STEERING To balance the wheel, install a balance weight on the lightest side of the rim, on the side opposite the BALANCE WEIGHT chalk marks. Add just enough weight so the wheel will no longer stop in the same position when it is spun.
Page 323 FRONT WHEEL/SUSPENSION/STEERING Install the remover head into the bearing. Replace the wheel REMOVER SHAFT From the opposite side of the wheel, install the bearings in pairs. bearing remover shaft and drive the bearing out of Do not reuse old the wheel hub. bearing.
Page 324 FRONT WHEEL/SUSPENSION/STEERING Apply grease to a new dust seal lips and install the dust seals until it is flush with the hub. DUST SEALS Install the brake disc on the wheel hub with the Do not get grease MARK BRAKE DISC marked side facing out.
Page 325 FRONT WHEEL/SUSPENSION/STEERING Set the axle holder with the "F" mark facing forward Right fork only: and temporarily install the new axle holder socket "F" MARK bolts and washers. SOCKET BOLTS/ HOLDER WASHERS Install the front wheel between the fork legs while Be careful not to inserting the brake disc between the pads in caliper.
Page 326 FRONT WHEEL/SUSPENSION/STEERING Tighten the front side axle holder socket bolt, then tighten the rear side axle holder socket bolt to the specified torque. TORQUE: 36 N·m (3.7 kgf·m, 27 lbf·ft) SOCKET BOLTS Measure the clearance (air gap) between the sensor ABS type only.
Page 327 FRONT WHEEL/SUSPENSION/STEERING DISASSEMBLY Hold the bottom case in a vise with soft jaws or shop towels. SOCKET BOLT Loosen the fork socket bolt. Remove the socket bolt after draining the fork fluid. Remove the fork pipe cap. FORK PIPE CAP Press the spring seat using a hydraulic press and SPRING SEAT remove the stopper ring.
Page 328 FRONT WHEEL/SUSPENSION/STEERING Remove the following: – socket bolt SOCKET BOLT – sealing washer SEALING WASHER – fork piston Do not remove the – rebound spring fork piston ring, FORK PISTON unless it is neces- sary to replace with a new one. REBOUND SPRING –...
Page 329 FRONT WHEEL/SUSPENSION/STEERING – oil lock piece OIL LOCK PIECE – oil seal – back-up ring OIL SEAL GUIDE BUSHING – guide bushing BACK-UP RING INSPECTION FORK SPRING Measure the fork spring free length. SERVICE LIMIT: 257.5 mm (10.14 in) FORK PIPE/BOTTOM CASE/PISTON Check the fork pipe and bottom case for score marks, and excessive or abnormal wear.
Page 330 FRONT WHEEL/SUSPENSION/STEERING Check the fork piston for score marks, and excessive PISTON RING or abnormal wear. Check the fork piston ring for wear or damage. Check the rebound spring for fatigue or damage. REBOUND SPRING Replace any damaged component if necessary. FORK PISTON Set the fork pipe in V-blocks and measure the fork pipe runout with a dial indicator.
Page 331 FRONT WHEEL/SUSPENSION/STEERING ASSEMBLY Before assembly, wash all parts with a high flash point or non-flammable solvent and wipe them off completely. FORK PIPE CAP DUST SEAL FORK PIPE PISTON RING STOPPER RING STOPPER RING OIL SEAL SPRING SEAT FORK BACK-UP RING PISTON O-RING GUIDE BUSHING...
Page 332 FRONT WHEEL/SUSPENSION/STEERING Install the rebound spring to the fork piston, then install them into the fork pipe. FORK PISTON REBOUND SPRING Install the oil lock piece to the fork piston end. Install the fork pipe assembly into the bottom case. FORK PISTON BOTTOM CASE OIL LOCK PIECE...
Page 333 Coat a new dust seal lip with fork fluid and install it. Pour the specified amount of the recommended fork fluid into the fork pipe. RECOMMENDED FORK FLUID: Honda Ultra Cushion Oil 10W or equivalent FLUID FLUID CAPACITY: LEVEL 151 ± 2.5 cm (5.1 ±...
Page 334: Handlebar
FRONT WHEEL/SUSPENSION/STEERING Install the fork pipe cap on to the fork pipe. FORK PIPE CAP INSTALLATION Install the fork leg into the steering stem and align the fork pipe groove with the bolt hole, then install Align the upper pinch bolt. BOLTS Tighten the upper/lower pinch bolts to the specified torque.
Page 335 FRONT WHEEL/SUSPENSION/STEERING Disconnect the inhibitor switch and rear brake light REAR BRAKE LIGHT switch connectors. SWITCH CONNECTORS INHIBITOR SWITCH CONNECTORS Remove the following: REAR MASTER CYLINDER – two bolts Keep the rear mas- – holder ter cylinder upright, – rear brake master cylinder to prevent air from entering the hydrau- lic system.
Page 336 FRONT WHEEL/SUSPENSION/STEERING Remove the following: FRONT MASTER CYLINDER – two bolts Keep the front mas- – holder ter cylinder upright, – front brake master cylinder to prevent air from entering the hydrau- lic system. Do not twist the brake hose. HOLDER BOLTS –...
Page 337 Disconnect the throttle cables from the throttle pipe. LOWER HOUSING INSTALLATION When removing the right handlebar grip from the throttle pipe, apply Honda Bond A or equivalent to the inside of the grip and to the clean surfaces of the throttle pipe. HANDLEBAR GRIP Wait 3 –...
Page 338 FRONT WHEEL/SUSPENSION/STEERING Install the handlebar by aligning the locating pin on the handlebar and cut-off of the steering stem. HANDLEBAR Align STEERING STEM Align the groove of the steering stem with the upper bolt hole in the handlebar, then install a new upper handlebar bolt.
Page 339 Clean the inside surface of the left handlebar grip and the outside surface of the handlebar. HANDLEBAR GRIP Apply Honda Bond A or equivalent to the inside sur- face of the handlebar grip and to the outside surface of the handlebar.
Page 340 FRONT WHEEL/SUSPENSION/STEERING Install the left handlebar weight and tighten the new screw. SCREW HANDLEBAR WEIGHT Set the rear master cylinder by aligning the end of REAR MASTER CYLINDER PUNCH MARK the master cylinder with the punch mark on the han- dlebar.
Page 341: Steering Stem
FRONT WHEEL/SUSPENSION/STEERING STEERING STEM REMOVAL • Always replace the bearings and races as a set. Remove the following: BOLT/CLAMP BOLT/CLAMP – front upper cover (page 3-9) – front handlebar cover (page 3-14) – rear handlebar cover (page 3-14) – front inner cover (page 3-10) –...
Page 342 FRONT WHEEL/SUSPENSION/STEERING Remove the following: DUST SEAL – steering stem UPPER BEARING – dust seal – upper inner race – upper steering bearing – lower steering bearing UPPER INNER RACE LOWER BEARING STEERING STEM Remove the upper outer race using the special tools.
Page 343 FRONT WHEEL/SUSPENSION/STEERING Remove the dust seal. DUST SEAL Remove the lower inner race with a chisel or equiv- alent tool, being careful not to damage the stem. INNER RACE Press a new lower bearing inner race using a special tool and hydraulic press. TOOL: DUST SEAL Attachment, 35 mm I.D.
Page 344 FRONT WHEEL/SUSPENSION/STEERING INSTALLATION • Urea based multi-purpose grease with extreme pressure agent (example: EXCELITE EP2 manufac- tured by KYODO YUSHI, Japan), Shell Stamina EP2 or equivalent LOWER LOCK NUT OUTER RACE UPPER DUST SEAL ADJUSTING LOWER BEARING LOWER UPPER INNER RACE INNER RACE LOWER UPPER BEARING...
Page 345 FRONT WHEEL/SUSPENSION/STEERING Tighten the steering stem adjusting nut to the speci- Refer to torque fied torque using the specified tool. ADJUSTING NUT wrench reading information, on ser- TOOL: vice information Pin spanner 07702-0020001 (page 15-3). TORQUE: Actual: 25 N·m (2.5 kgf·m, 18 lbf·ft) Indicated: 18 N·m (1.8 kgf·m, 13 lbf·ft) PIN SPANNER Turn the steering stem left and right, lock-to-lock...
Page 346 FRONT WHEEL/SUSPENSION/STEERING Install the brake hose clamps and tighten the bolts. BOLT/CLAMP BOLT/CLAMP Install the following: – handlebar (page 15-23) – fork (page 15-20) – front inner cover (page 3-10) – rear handlebar cover (page 3-14) – front handlebar cover (page 3-14) –...
Page 347 16. REAR WHEEL/SUSPENSION COMPONENT LOCATION ························ 16-2 REAR WHEEL/SWINGARM ····················· 16-5 SERVICE INFORMATION ························· 16-3 REAR SHOCK ABSORBER ····················· 16-12 TROUBLESHOOTING ······························· 16-4 16-1...
Page 348 REAR WHEEL/SUSPENSION COMPONENT LOCATION REAR WHEEL/SUSPENSION 49 N·m (5.0 kgf·m, 36 lbf·ft) 30 N·m (3.1 kgf·m, 22 lbf·ft) 118 N·m (12.0 kgf·m, 87 lbf·ft) 16-2...
Page 349 • When servicing the rear wheel and suspension, support the scooter using a safety stand or hoist. • Use only tires marked “TUBELESS” and tubeless valve stems on rims marked "TUBELESS TIRE APPLICABLE". • Use genuine Honda replacement bolts and nuts for all suspension pivot and mounting point. • For brake system service (page 17-4).
Page 350 REAR WHEEL/SUSPENSION TROUBLESHOOTING Rear wheel wobbles • Bent rim • Faulty tire • Axle nut and/or engine mounting bolt not tightened properly • Unbalanced tire and wheel • Loose or worn final gear shaft bearing • Insufficient tire pressure Soft suspension •...
Page 351 REAR WHEEL/SUSPENSION REAR WHEEL/SWINGARM REMOVAL Remove the exhaust pipe/muffler (page 3-15). Support the scooter securely on its centerstand. Lower the rear wheel and ground it, then loosen the rear axle nut. REAR AXLE NUT Support the left crankcase and remove the follow- ing: PROTECTOR –...
Page 352 REAR WHEEL/SUSPENSION – axle nut BOLTS – two mounting bolts – swingarm AXLE NUT SWINGARM – inside collar INSIDE COLLAR – outside collar OUTSIDE COLLAR – rear wheel INSPECTION WHEEL Check the wheel rim runout using dial indicators. Actual runout is 1/2 the total indicator readings. SERVICE LIMITS: Radial: 2.0 mm (0.08 in) Axial:...
Page 353 REAR WHEEL/SUSPENSION DISASSEMBLY Remove the following: PULSER RING – three torx bolts ABS type only. – pulser ring Do not reuse the torx bolts. TORX BOLTS – six socket bolts Do not reuse the – brake disc SOCKET BOLTS socket bolts. BRAKE DISC SWINGARM BEARING INSPECTION/ REPLACEMENT...
Page 354 REAR WHEEL/SUSPENSION Turn the inner race of the bearing with your finger. The bearing should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the swingarm. Replace the bearing if the inner race does not turn smoothly and quietly, or if the outer race fits loosely.
Page 355 REAR WHEEL/SUSPENSION ASSEMBLY BRAKE DISC ABS type: TORX BOLTS 8 N·m (0.8 kgf·m, 5.9 lbf·ft) PULSER RING SOCKET BOLTS 42 N·m (4.3 kgf·m, 31 lbf·ft) Install the brake disc onto the wheel hub with the Do not get grease marked side facing out. MARK on the brake disc or SOCKET BOLTS...
Page 356 REAR WHEEL/SUSPENSION INSTALLATION Install the rear wheel onto the final gear shaft, align- ing the spline. Apply 0.03 – 0.04 g grease to the groove of the final gear shaft. Apply grease to bearing fitting area of the final gear shaft.
Page 357 REAR WHEEL/SUSPENSION Install the rear brake caliper to the swingarm and tighten the new rear brake caliper mounting bolts to the specified torque. TORQUE: 30 N·m (3.1 kgf·m, 22 lbf·ft) Install the brake hose clamp to the swingarm and tighten the bolt. BOLT/CLAMP MOUNTING BOLTS CALIPER...
Page 358 REAR WHEEL/SUSPENSION REAR SHOCK ABSORBER REMOVAL/INSTALLATION Remove the following: SHOCK ABSORBER – maintenance rid (page 3-4) – luggage box (page 3-5) – grab rail (page 3-5) – body cover (page 3-6) – rear fender A (page 3-7) Support the engine with a jack or adjustable support to relieve stress from the shock absorber.
Page 359 17. HYDRAULIC BRAKE COMPONENT LOCATION ························ 17-2 FRONT MASTER CYLINDER·················· 17-16 SERVICE INFORMATION ························· 17-4 REAR MASTER CYLINDER ···················· 17-21 TROUBLESHOOTING ······························· 17-6 DELAY VALVE (STD TYPE) ··················· 17-25 BRAKE FLUID REPLACEMENT/ DELAY VALVE (ABS TYPE) ··················· 17-26 AIR BLEEDING ·········································· 17-7 FRONT BRAKE CALIPER························...
Page 360: Component Location
HYDRAULIC BRAKE COMPONENT LOCATION HYDRAULIC BRAKE FRONT: 12 N·m (1.2 kgf·m, 9 lbf·ft) 34 N·m (3.5 kgf·m, 25 lbf·ft) STD type: 34 N·m (3.5 kgf·m, 25 lbf·ft) 30 N·m (3.1 kgf·m, 22 lbf·ft) ABS type: 34 N·m (3.5 kgf·m, 25 lbf·ft) 30 N·m (3.1 kgf·m, 22 lbf·ft) 17-2...
Page 361 HYDRAULIC BRAKE REAR: 12 N·m (1.2 kgf·m, 9 lbf·ft) 34 N·m (3.5 kgf·m, 25 lbf·ft) STD type: 14 N·m (1.4 kgf·m, 10 lbf·ft) ABS type: 14 N·m (1.4 kgf·m, 10 lbf·ft) 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) 17-3...
Page 362: 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 and OSHA-approved vacuum cleaner. Spilled brake fluid will severely damage instrument lenses and painted surfaces.
Page 363 HYDRAULIC BRAKE TORQUE VALUES Caliper bleed valve 5.4 N·m (0.6 kgf·m, 4.0 lbf·ft) Pad pin 17 N·m (1.7 kgf·m, 13 lbf·ft) Master cylinder reservoir cap screw 1.5 N·m (0.2 kgf·m, 1.1 lbf·ft) Brake hose oil bolt 34 N·m (3.5 kgf·m, 25 lbf·ft) Brake pipe joint nut 14 N·m (1.4 kgf·m, 10 lbf·ft) Apply brake fluid to the threads...
Page 364: Troubleshooting
HYDRAULIC BRAKE TROUBLESHOOTING Brake lever soft or spongy • Air in hydraulic system • Leaking hydraulic system • Contaminated brake pad/disc • Worn caliper piston seal • Worn master cylinder piston cups • Worn brake pad/disc • Contaminated caliper • Contaminated master cylinder •...
Page 365: Brake Fluid Replacement
HYDRAULIC BRAKE BRAKE FLUID REPLACEMENT/AIR BLEEDING Spilled fluid can damage painted, plastic, or rubber parts. Place a rag over these parts whenever the system is serviced. • Do not allow foreign material to enter the system when filling the reservoir. •...
Page 366 HYDRAULIC BRAKE Connect a commercially available brake bleeder to LOWER BRAKE BLEEDER the front brake caliper lower bleed valve. BLEED VALVE Loosen the lower bleed valve and operate the air bleed tool. Drain the brake fluid. Tighten the front caliper lower bleed valve. Connect a bleed hose to the rear brake caliper bleed BRAKE BLEEDER REAR BLEED VALVE...
Page 367 HYDRAULIC BRAKE If the brake bleeder is not available, perform the fol- lowing procedure: Fill the reservoir with DOT 4 brake fluid from a sealed container. Operate the front brake lever several times to bleed Check the fluid level air from the master cylinder. often while bleed- ing the brakes to prevent air from...
Page 368 HYDRAULIC BRAKE REAR (COMBINED) BRAKE FLUID FILL- ING/AIR BLEEDING • Use only DOT 4 brake fluid from a sealed con- tainer. • Do not mix different types of fluid. There are not compatible. BRAKE FLUID FEEDING Fill the reservoir with DOT 4 brake fluid from a BRAKE BLEEDER FRONT LOWER sealed container.
Page 369: Air Bleeding
HYDRAULIC BRAKE If the brake bleeder is not available, perform the fol- lowing procedure: Fill the reservoir with DOT 4 brake fluid from a sealed container. Operate the rear brake lever several times to bleed Check the fluid level air from the master cylinder. often while bleed- ing the brakes to prevent air from...
Page 370 HYDRAULIC BRAKE Connect a bleed hose to the front caliper lower bleed valve. Repeat step 1 and 3 for front caliper bleed valve. • Note that you may feel strong resistance on the rear (combined) brake lever during pumping to bleed air from the caliper.
Page 371: Brake Pad/Disc
HYDRAULIC BRAKE BRAKE PAD/DISC BRAKE PAD REPLACEMENT FRONT Push the caliper pistons all the way in to allow Check the fluid installation of new brake pads. level in the master cylinder reservoir as this operation causes the fluid level to rise. Loosen the pad pin.
Page 372 HYDRAULIC BRAKE REAR Remove the following: – exhaust pipe/muffler (page 3-15) – brake hose protector (page 16-5) Push the caliper piston all the way in to allow instal- Check the fluid level lation of new brake pads. in the master cylin- der reservoir as this operation causes the fluid level to...
Page 373 HYDRAULIC BRAKE Hold the rear caliper pin and tighten the rear caliper bolt to the specified torque. CALIPER BOLT CALIPER PIN TORQUE: 22 N·m (2.2 kgf·m, 16 lbf·ft) Install the caliper to the swingarm so that the disc is positioned between the pads, being careful not to damage the pads.
Page 374: Front Master Cylinder
HYDRAULIC BRAKE FRONT MASTER CYLINDER REMOVAL Remove the following: – front upper cover (page 3-9) SEALING WASHERS BRAKE HOSE – front handlebar cover (page 3-14) – rear handlebar cover (page 3-14) Drain the brake fluid from the front brake line hydraulic system (page 17-7).
Page 375 HYDRAULIC BRAKE – screw – brake light switch SCREW BRAKE LIGHT SWITCH – piston boot SNAP RING/WASHER – snap ring/washer TOOL: Snap ring pliers 07914-SA50001 PISTON BOOT SNAP RING PLIERS – master piston – spring Clean the master cylinder, reservoir and master pis- MASTER PISTON ton in clean brake fluid.
Page 376 HYDRAULIC BRAKE Measure the master cylinder I.D. SERVICE LIMIT: 11.055 mm (0.4352 in) Measure the master cylinder piston O.D. SERVICE LIMIT: 10.945 mm (0.4309 in) ASSEMBLY PIVOT BOLT SNAP RING 1 N·m (0.1 kgf·m, 0.7 lbf·ft) BOOT SCREWS WASHER 1.5 N·m (0.2 kgf·m, 1.1 lbf·ft) SPRING DIAPHRAGM PLATE DIAPHRAGM...
Page 377 HYDRAULIC BRAKE Install the washer and snap ring into the groove in the master cylinder. WASHER SNAP RING TOOL: Snap ring pliers 07914-SA50001 • Install the snap ring with the chamfered edges facing the thrust load side. • Check that the snap ring is seated in the grooves. SNAP RING PLIERS Apply silicone grease to the piston boot inner sur- face.
Page 378 HYDRAULIC BRAKE INSTALLATION Install the master cylinder and the holder with the FRONT MASTER CYLINDER PUNCH MARK "UP" mark facing up. Align the edge of the master cylinder with the HOLDER punch mark on the handlebar and tighten the upper bolt first, then tighten the lower bolt to the specified torque.
Page 379: Rear Master Cylinder
HYDRAULIC BRAKE REAR MASTER CYLINDER REMOVAL Remove the following: BRAKE HOSE SEALING WASHERS – front upper cover (page 3-9) – front handlebar cover (page 3-14) – rear handlebar cover (page 3-14) Drain the brake fluid from the rear (combined) brake line hydraulic system (page 17-7).
Page 380 HYDRAULIC BRAKE – two screw – brake light/inhibitor switch SCREWS BRAKE LIGHT/INHIBITOR SWITCH – piston boot – snap ring SNAP RING PISTON BOOT TOOL: Snap ring pliers 07914-SA50001 SNAP RING PLIERS – master piston – piston cup – spring Clean the inside of the cylinder and reservoir with MASTER PISTON clean brake fluid.
Page 381 HYDRAULIC BRAKE Measure the master cylinder I.D. SERVICE LIMIT: 12.755 mm (0.5022 in) Measure the master cylinder piston O.D. SERVICE LIMIT: 12.645 mm (0.4987 in) ASSEMBLY PIVOT BOLT 1 N·m (0.1 kgf·m, 0.7 lbf·ft) SCREWS 1.5 N·m (0.2 kgf·m, 1.1 lbf·ft) BOOT SNAP RING SPRING...
Page 382 HYDRAULIC BRAKE Install the snap ring into the groove in the master cylinder. SNAP RING TOOL: Snap ring pliers 07914-SA50001 • Install the snap ring with the chamfered edges facing the thrust load side. • Check that the snap ring is seated in the grooves. SNAP RING PLIERS Apply silicone grease to the piston boot inner sur- face.
Page 383: Delay Valve (Std Type)
HYDRAULIC BRAKE INSTALLATION Install the master cylinder and the holder with the PUNCH MARK REAR MASTER "UP" mark facing up. CYLINDER Align the edge of the master cylinder with the HOLDER punch mark on the handlebar and tighten the upper bolt first, then tighten the lower bolt.
Page 384: Delay Valve (Abs Type)
HYDRAULIC BRAKE INSTALLATION Install the delay valve and tighten the delay valve mounting bolts. JOINT NUT OIL BOLTS/ SEALING WASHERS Connect the brake hoses to the delay valve with the oil bolts and new sealing washers. Tighten the brake hose oil bolts to the specified torque while setting the hose joints against the stoppers on the delay valve.
Page 385: Front Brake Caliper
HYDRAULIC BRAKE INSTALLATION Install the delay valve and tighten the delay valve DELAY VALVE mounting bolts. Connect the brake hose to the delay valve with the oil bolt and new sealing washers. Tighten the brake hose oil bolt to the specified torque while setting the hose joint against the stop- per on the delay valve.
Page 386 HYDRAULIC BRAKE Disconnect the brake hoses from the brake caliper When removing the by removing the oil bolts and sealing washers. oil bolts, cover the BRAKE end of the hoses to HOSES Remove the following: prevent contamina- – brake pads (page 17-13) tion.
Page 387 HYDRAULIC BRAKE Push the dust and piston seals in and lift them out. Be careful not to damage the piston DUST SEALS PISTON SEALS Clean the seal grooves, caliper cylinders and pis- sliding surface. tons with clean brake fluid. INSPECTION Check the caliper cylinder for scoring or other dam- age.
Page 388 HYDRAULIC BRAKE ASSEMBLY RETAINER CALIPER BRACKET BRACKET PIN BOOT CALIPER PISTON BRACKET PIN BOLT 12 N·m (1.2 kgf·m, 9 lbf·ft) CALIPER PIN BOLT 22 N·m (2.2 kgf·m, 16 lbf·ft) DUST SEAL CALIPER BLEED VALVES 5.4 N·m (0.6 kgf·m, 4.0 lbf·ft) CALIPER BODY PISTON SEAL PAD SPRING...
Page 389 HYDRAULIC BRAKE INSTALLATION Install the front brake caliper onto the left fork leg. MOUNTING BOLTS Install new mounting bolts and tighten them to the specified torque. TORQUE: 30 N·m (3.1 kgf·m, 22 lbf·ft) BRAKE CALIPER Connect the brake hoses to the front brake caliper with the oil bolts and new sealing washers.
Page 390: Rear Brake Caliper
HYDRAULIC BRAKE Support the scooter securely using a hoist or equiv- ABS type only. alent and raise the wheel off the ground. Measure the clearance (air gap) between the sensor and pulser ring at several points by turning the wheel slowly. It must be within specification.
Page 391 HYDRAULIC BRAKE Place a shop towel over the piston. Position the caliper body with the piston down and Do not use high apply small squirts of air pressure to the fluid inlet pressure air or bring to remove the piston. the nozzle too close the inlet.
Page 392 HYDRAULIC BRAKE ASSEMBLY CALIPER PIN BOLT 22 N·m (2.2 kgf·m, 16 lbf·ft) CALIPER BOLT 22 N·m (2.2 kgf·m, 16 lbf·ft) DUST SEAL PISTON SEAL PIN BOOT CALIPER BRACKET CALIPER BODY CALIPER PISTON BLEED VALVE 5.4 N·m (0.6 kgf·m, 4.0 lbf·ft) CALIPER PIN PIN BOOT RETAINERS...
Page 393 HYDRAULIC BRAKE INSTALLATION Install the rear brake pads (page 17-14). REAR BRAKE CALIPER Install the caliper to the swingarm so that the disc is positioned between the pads, being careful not to damage the pads. Hold the caliper and install new brake caliper mounting bolts then tighten them to the specified torque.
Page 394 MEMO...
Page 395 18. ANTI-LOCK BRAKE SYSTEM (ABS; SH300A/AII/AIII) ABS SYSTEM LOCATION ························ 18-2 ABS INDICATOR PROBLEM CODE INDEX······················································ 18-10 ABS SYSTEM DIAGRAM ························· 18-3 TROUBLESHOOTING····························· 18-11 SERVICE INFORMATION ························· 18-4 FRONT WHEEL SPEED SENSOR ·········· 18-23 ABS CONNECTOR LOCATIONS ·············· 18-5 REAR WHEEL SPEED SENSOR ············· 18-25 BEFORE STARTING TROUBLESHOOTING ·······························...
Page 396: Abs System Location
ANTI-LOCK BRAKE SYSTEM (ABS; SH300A/AII/AIII) ABS SYSTEM LOCATION ANTI-LOCK BRAKE SYSTEM (ABS; SH300A/AII/AIII) FRONT BRAKE MASTER CYLINDER REAR BRAKE MASTER CYLINDER REAR BRAKE CALIPER ABS MODULATOR DELAY VALVE FRONT WHEEL SPEED SENSOR REAR PULSER RING FRONT PULSER RING REAR WHEEL FRONT BRAKE CALIPER SPEED SENSOR 18-2...
Page 397: Abs System Diagram
ANTI-LOCK BRAKE SYSTEM (ABS; SH300A/AII/AIII) ABS SYSTEM DIAGRAM ABS INDICATOR Bl/Br IGNITION MAIN Bl/Br SWICTH FUSE BRAKE LIGHT R/BI SWITCHES Bl/Br 4 STOP LAMP SW R/Bl REAR METER ELECTRONIC FUSE CONTROL UNIT Bl/Br (ABS-ECU) FRONT MAIN ABS MAIN R/Bl RELAY FUSE ABS WARN IND 1 Bl/Y...
Page 398: Service Information
ANTI-LOCK BRAKE SYSTEM (ABS; SH300A/AII/AIII) SERVICE INFORMATION GENERAL • This section covers service of the Anti-lock Brake System (ABS; SH300A/AII/AIII). For conventional brake service, refer to section 17. • Pre-start self-diagnosis starts when the ignition switch is turned "ON". ABS modulator control unit receives signals and detects if the ABS system functions normally.
Page 399: Abs Connector Locations
ANTI-LOCK BRAKE SYSTEM (ABS; SH300A/AII/AIII) ABS CONNECTOR LOCATIONS NOTE 1: Remove the front upper cover (page 3-9). Wire side of female terminal ABS MODULATOR 25P CONNECTOR (NOTE 1) NOTE 2: Remove the front inner cover (page 3-10). Sensor side of Wire side of male terminal female terminal...
Page 400 ANTI-LOCK BRAKE SYSTEM (ABS; SH300A/AII/AIII) NOTE 3: Remove the maintenance lid (page 3-4). Wire side of female terminal ABS SERVICE CHECK CONNECTOR (NOTE 3) NOTE 4: Remove the luggage box (page 3-5). Sensor side of Wire side of male terminal female terminal REAR WHEEL SPEED SENSOR 6P CONNECTOR (NOTE 4)
Page 401 ANTI-LOCK BRAKE SYSTEM (ABS; SH300A/AII/AIII) BEFORE STARTING TROUBLESHOOTING SUMMARY OF ABS PRE-START SELF-DIAGNOSIS SYSTEM The ABS pre-start self-diagnosis system diagnoses the electrical system as well as the operating status of the modulator. When there is any abnormality, the problem and the problematic part can be detected by outputting the problem code. When the vehicle is running, pulse signals generated at the front/rear wheel speed sensor are sent to the ABS control unit.
Page 402 ANTI-LOCK BRAKE SYSTEM (ABS; SH300A/AII/AIII) PROBLEM CODE INDICATION PATTERN • The ABS indicator indicates the problem code by blinking a specified number of times. The ABS indicator denotes the problem codes from 11 to 81. The indicator has two types of blinks, a long blink and short blink.
Page 403 ANTI-LOCK BRAKE SYSTEM (ABS; SH300A/AII/AIII) 2. Turn the ignition switch "ON". The ABS indicator starts problem code indica- tion. Note how many times the ABS indicator blinks, and determine the cause of the problem (page 18-10). 3. Turn the ignition switch "OFF" and remove the jumper wire.
Page 404 ANTI-LOCK BRAKE SYSTEM (ABS; SH300A/AII/AIII) ABS INDICATOR PROBLEM CODE INDEX • The ABS indicator denotes the problem codes from 11 to 81. The indicator has two types of blinks, a long blink and short blink. The long blink lasts for 1.3 seconds, the short blink lasts for 0.3 seconds. •...
Page 405: Troubleshooting
ANTI-LOCK BRAKE SYSTEM (ABS; SH300A/AII/AIII) TROUBLESHOOTING • Perform inspection with the ignition switch turned "OFF", unless otherwise specified. • All connector diagrams in the troubleshooting are viewed from the terminal side. • Use a fully charged battery. Do not diagnose with a charger connected to the battery.
Page 406 ANTI-LOCK BRAKE SYSTEM (ABS; SH300A/AII/AIII) ABS INDICATOR STAYS ON (–Indicator does not go off when the scooter is running, –Problem code is not indicated by the retrieval procedure) 1. Fuse Inspection Check the "ABS MAIN" fuse (10 A) in the fuse box.
Page 407 ANTI-LOCK BRAKE SYSTEM (ABS; SH300A/AII/AIII) 4. Service Check Line Short Circuit Inspection Turn the ignition switch "OFF". Brown/White Check for continuity between the ABS modulator connector of the wire harness side and ground. CONNECTION: Brown/White – Ground Is there continuity? –...
Page 408 ANTI-LOCK BRAKE SYSTEM (ABS; SH300A/AII/AIII) PROBLEM CODE 11, 12, 21, 41 or 42 (Front Wheel Speed Sensor) • The ABS indicator might blink under unusual riding or conditions (page 18-10). This is tempo- rary failure. Erase the problem code (page 18-9) then test ride the scooter above 30 km/h (18 mph) and check the problem code by retrieving the self-diagnosis system (page 18-8).
Page 409 ANTI-LOCK BRAKE SYSTEM (ABS; SH300A/AII/AIII) 4. Speed Sensor Line Short Circuit Inspection (at sensor side) Check for continuity between each terminal FRONT WHEEL SPEED SENSOR (Black and White) of the sensor side 2P connec- 2P (ORANGE) CONNECTOR tor and ground in the same manner as the previ- Black ous step.
Page 410 ANTI-LOCK BRAKE SYSTEM (ABS; SH300A/AII/AIII) PROBLEM CODE 13, 14, 23 or 43 (Rear Wheel Speed Sensor) • The ABS indicator might blink under unusual riding or conditions (page 18-10). This is tempo- rary failure. Erase the problem code (page 18-9) then test ride the scooter above 30 km/h (18 mph) and check the problem code by retrieving the self-diagnosis system (page 18-8).
Page 411 ANTI-LOCK BRAKE SYSTEM (ABS; SH300A/AII/AIII) 4. Speed Sensor Line Short Circuit Inspection (at sensor side) Check for continuity between each terminal (Pink REAR WHEEL SPEED and Green/Red) of the sensor side 6P connector SENSOR 6P CONNECTOR and ground in the same manner as the previous step.
Page 412 ANTI-LOCK BRAKE SYSTEM (ABS; SH300A/AII/AIII) PROBLEM CODE 31, 32, 33, 34, 37 or 38 (Solenoid Valve) 1. Failure Reproduction Erase the problem code (page 18-9). Test ride the scooter above 30 km/h (18 mph). Retrieve the problem code (page 18-8). Does the indicator blink 31, 32, 33, 34, 37 or 38 times? –...
Page 413 ANTI-LOCK BRAKE SYSTEM (ABS; SH300A/AII/AIII) 3. Motor Power Input Line Open Circuit Inspection (at control unit side) Install the "ABS MOTOR" fuse. Disconnect the ABS modulator 25P connector. Measure the voltage between the ABS modula- tor 25P connector from the wire harness side. There should be battery voltage at all times.
Page 414 ANTI-LOCK BRAKE SYSTEM (ABS; SH300A/AII/AIII) 2. Relay Power Input Line Short Circuit Inspection Disconnect the ABS modulator 25P connector. Check for continuity between the ABS modulator 25P connector of the wire harness side and ground with "ABS FSR" fuse removed. CONNECTION: Black –...
Page 415 ANTI-LOCK BRAKE SYSTEM (ABS; SH300A/AII/AIII) PROBLEM CODE 61 or 62 (Power Circuit) 1. Fuse Inspection Check the "ABS MAIN" fuse (10 A) in the fuse box. Is the fuse blown? – GO TO STEP 2. – GO TO STEP 3. "ABS MAIN"...
Page 416 ANTI-LOCK BRAKE SYSTEM (ABS; SH300A/AII/AIII) 4. Failure Reproduction Turn the ignition switch "OFF". Connect the ABS modulator 25P connector. Erase the problem code (page 18-9). Test ride the scooter above 30 km/h (18 mph). Retrieve the problem code (page 18-8). Does the indicator blink 61 or 62 times? –...
Page 417: Front Wheel Speed Sensor
ANTI-LOCK BRAKE SYSTEM (ABS; SH300A/AII/AIII) FRONT WHEEL SPEED SENSOR INSPECTION Support the scooter securely using a hoist or equiv- alent and raise the wheel off the ground. Measure the clearance (air gap) between the sensor and pulser ring at several points by turning the wheel slowly.
Page 418 ANTI-LOCK BRAKE SYSTEM (ABS; SH300A/AII/AIII) Remove the wire clamp bolts and wire guide. CLAMP BOLT GUIDE Remove the two bolts and front wheel speed sen- sor. FRONT WHEEL BOLTS SPEED SENSOR Check that there is iron or other magnetic deposits between the pulser ring and wheel speed sensor.
Page 419: Rear Wheel Speed Sensor
ANTI-LOCK BRAKE SYSTEM (ABS; SH300A/AII/AIII) REAR WHEEL SPEED SENSOR INSPECTION Place the scooter on its centerstand. Measure the clearance (air gap) between the sensor and pulser ring at several points by turning the wheel slowly. It must be within specification. STANDARD: 0.2 –...
Page 420 ANTI-LOCK BRAKE SYSTEM (ABS; SH300A/AII/AIII) Remove the four socket bolts and sensor protector. SENSOR PROTECTOR SOCKET BOLTS Remove the two bolts and rear wheel speed sensor. BOLTS Check that there is iron or other magnetic deposits between the pulser ring and wheel speed sensor. Remove any deposits.
Page 421: Abs Modulator
ANTI-LOCK BRAKE SYSTEM (ABS; SH300A/AII/AIII) ABS MODULATOR REMOVAL/INSTALLATION Drain the brake fluid from the front and rear hydrau- lic systems (page 17-7). Remove the following: – front lower cover (page 3-12) – front inner cover (page 3-10) Disconnect the ABS modulator 25P connector (pull the lock lever up to disconnect it).
Page 422 MEMO...
Page 423 19. BATTERY/CHARGING SYSTEM SYSTEM LOCATION································· 19-2 BATTERY ·················································· 19-6 SYSTEM DIAGRAM·································· 19-2 CHARGING SYSTEM INSPECTION········· 19-7 SERVICE INFORMATION ························· 19-3 ALTERNATOR··········································· 19-8 TROUBLESHOOTING ······························· 19-5 REGULATOR/RECTIFIER ························· 19-8 19-1...
Page 424: System Location
BATTERY/CHARGING SYSTEM SYSTEM LOCATION BATTERY/CHARGING SYSTEM REGULATOR/ RECTIFIER MAIN FUSE 30 A BATTERY ALTERNATOR SYSTEM DIAGRAM MAIN FUSE 30A BATTERY REGULATOR/RECTIFIER ALTERNATOR YELLOW GREEN WHITE 19-2...
Page 425 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 426 BATTERY/CHARGING SYSTEM SPECIFICATIONS ITEM SPECIFICATIONS Battery Capacity 12 V – 11 (10) Ah Current leakage 1.5 mA max. Voltage Fully charged Above 12.8 V (20°C/68°F) Needs charging Below 12.3 V Charging Normal 1.1 A/5 – 10 h current Quick 5.5 A/1.0 h Alternator capacity 0.368 kW/5,000 min (rpm)
Page 427 BATTERY/CHARGING SYSTEM TROUBLESHOOTING BATTERY IS DAMAGED OR WEAK 1. BATTERY TEST Remove the battery (page 19-6). Check the battery condition using the recommended battery tester. RECOMMENDED BATTERY TESTER: BM210 or BATTERY MATE or equivalent Is the battery in good condition? –...
Page 428 BATTERY/CHARGING SYSTEM BATTERY REMOVAL/INSTALLATION Remove the maintenance lid (page 3-4). Always turn the BATTERY HOLDER PLATE ignition switch OFF Remove the bolts and battery holder plate. before removing the battery. BOLTS Remove the bolt and disconnect the negative (–) Disconnect the NEGATIVE (–) BATTERY cable.
Page 429: Charging System Inspection
BATTERY/CHARGING SYSTEM CHARGING SYSTEM INSPECTION CURRENT LEAKAGE INSPECTION Remove the maintenance lid (page 3-4). (+) PROBE (–) PROBE Turn the ignition switch "OFF" and disconnect the negative (–) cable from the battery. Connect the ammeter (+) probe to the battery (–) cable and the ammeter (–) probe to the battery (–) terminal.
Page 430: Alternator
BATTERY/CHARGING SYSTEM ALTERNATOR INSPECTION Remove the luggage box (page 3-5). ALTERNATOR 3P CONNECTOR Disconnect the alternator 3P connector. Measure the resistance between each Yellow wire terminals. STANDARD: 0.1 – 1.0 Ω (at 20°C/68°F) Check for continuity between each wire terminal of the alternator/stator side connector and ground.
Page 431 20. IGNITION SYSTEM SYSTEM LOCATION································· 20-2 IGNITION SYSTEM INSPECTION············ 20-5 SYSTEM DIAGRAM·································· 20-2 IGNITION COIL ········································· 20-8 SERVICE INFORMATION ························· 20-3 IGNITION TIMING ···································· 20-8 TROUBLESHOOTING ······························· 20-4 20-1...
Page 432 IGNITION SYSTEM SYSTEM LOCATION IGNITION SYSTEM ENGINE STOP RELAY IGNITION SWITCH BANK ANGLE SENSOR ENGINE CONTROL MODULE (ECM) IGNITION COIL SIDESTAND SWITCH SUB FUSE MAIN FUSE CKP SENSOR 10 A BATTERY 30 A SYSTEM DIAGRAM MAIN FUSE FUSE R/Bl : Black BATTERY : Blue : Green...
Page 433 IGNITION SYSTEM SERVICE INFORMATION GENERAL • Some electrical components may be damaged if terminals or connectors are connected or disconnected while the igni- tion switch is turned to ON and current is present. • When servicing the ignition system, always follow the steps in the troubleshooting sequence on page 20-4. •...
Page 434 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) • "Initial voltage" of the ignition primary coil is the battery voltage with the ignition switch turned to ON (The engine is not cranked by the starter motor).
Page 435 IGNITION SYSTEM IGNITION SYSTEM INSPECTION • If there is no spark present at the plug, check all connections for loose or poor contact before measuring the peak voltage. • Use a commercially available digital multimeter (impedance 10 MΩ/DCV minimum). • The display value differs depending upon the internal impedance of the multimeter.
Page 436 IGNITION SYSTEM With the ignition coil primary wire connected, con- nect the Imrie diagnostic tester or peak voltage adaptor probes to the ignition coil primary terminal and ground. TOOLS: PROBE (–) Imrie diagnostic tester (model 625) or PROBE (+) Peak voltage adaptor 07HGJ-0020100 with commercially available digital multimeter (impedance 10 MΩ/DCV minimum)
Page 437 IGNITION SYSTEM Turn the ignition switch "OFF". Disconnect the CKP sensor 2P (Red) connector. Connect the Imrie diagnostic tester or peak voltage adaptor probes to the CKP sensor side connector terminals. In the same manner as at the ECM connector, mea- sure the peak voltage and compare it to the voltage measured at the ECM connector.
Page 438 IGNITION SYSTEM IGNITION COIL REMOVAL/INSTALLATION Remove the maintenance lid (page 3-4). SPARK PLUG CAP WIRE BAND BOSS Disconnect the spark plug cap. Remove the spark plug wire clamp bolt. Remove the wire band boss from the wire stay. BOLT/WIRE CLAMP Disconnect the ignition coil wire connectors.
Page 439 IGNITION SYSTEM The ignition timing is correct if the “F” mark on the flywheel aligns with the index mark on the right crankcase cover at idle. Increase the engine speed and make sure the “F” INDEX MARK mark begins to move. "F"...
Page 440 MEMO...
Page 441 21. ELECTRIC STARTER SYSTEM LOCATION································· 21-2 TROUBLESHOOTING······························· 21-4 SYSTEM DIAGRAM·································· 21-2 STARTER MOTOR ···································· 21-6 SERVICE INFORMATION ························· 21-3 STARTER RELAY ···································· 21-14 21-1...
Page 442 ELECTRIC STARTER SYSTEM LOCATION ELECTRIC STARTER REAR BRAKE LIGHT/ FRONT BRAKE INHIBITOR SWITCH LIGHT SWITCH STARTER SWITCH IGNITION SWITCH ENGINE STOP RELAY FUSE 10 A BANK ANGLE SENSOR SIDE STAND SWITCH STARTER RELAY STARTER MOTOR BATTERY /MAIN FUSE 30 A SYSTEM DIAGRAM Bl: Black IGNITION...
Page 443 ELECTRIC STARTER SERVICE INFORMATION GENERAL • Always turn the ignition switch to OFF before servicing the starter motor. The motor could suddenly start, causing seri- ous injury. • A weak battery may be unable to turn the starter motor quickly enough, or supply adequate ignition current. •...
Page 444 ELECTRIC STARTER TROUBLESHOOTING Starter motor does not turn 1. Standard Inspection Check the following: – Battery condition – Burned fuse Are the above items in good condition? – Replace or repair the malfunction part(s). – GO TO STEP 2. 2. Starter Relay Operation Retract the sidestand.
Page 445 ELECTRIC STARTER 6. Starter Relay Coil Ground Line Inspection Check the starter relay coil ground line inspection (page 21-15). Is the ground line normal? – Replace the starter relay with a new one, and recheck. – • Loose or poorly connected connector. •...
Page 446 ELECTRIC STARTER STARTER MOTOR REMOVAL Remove the following: RUBBER CAP STARTER MOTOR CABLE – Belt case air cleaner cover (page 4-16) – Air cleaner housing (page 6-52) TERMINAL NUT Open the rubber cap and remove the terminal nut. Disconnect the starter motor cable. Remove the two mounting bolts, ground cables.
Page 447 ELECTRIC STARTER Remove the starter motor case/armature from the O-RING ARMATURE rear cover. Remove the O-ring from the starter motor case. Remove the armature from the motor case. REAR COVER STARTER MOTOR CASE Remove the brushes and springs from the brush holder.
Page 448 ELECTRIC STARTER Remove the screw and negative brushes. SCREW NEGATIVE BRUSHES Remove the terminal nut. Remove the washer, insulator, terminal stopper and O-RING O-ring. INSULATOR WASHER TERMINAL STOPPER Remove the terminal bolt, positive brushes and brush holder. BRUSH HOLDER POSITIVE BRUSHES TERMINAL BOLT 21-8...
Page 449 ELECTRIC STARTER INSPECTION Measure each brush length. SERVICE LIMIT: 6.5 mm (0.26 in) Check the commutator for damage or abnormal ARMATURE wear. Check the commutator bar for discoloration. Do not use emery Clean the metallic debris off between commutator or sand paper on bars.
Page 450 ELECTRIC STARTER Check the dust seal and needle bearing for wear or DUST SEAL damage. BALL bearing Check the ball bearing rotates smoothly. Check the bushing of the rear cover for wear or BUSHING damage. REAR COVER ASSEMBLY BOLT 4.9 N·m (0.5 kgf·m, 3.6 lbf·ft) FRONT COVER O-RING MOTOR CASE...
Page 451 ELECTRIC STARTER Install the brush holder, positive brushes and termi- nal bolt. BRUSH HOLDER POSITIVE BRUSHES TERMINAL BOLT Install a new O-ring, terminal stopper, insulator and O-RING washer. INSULATOR WASHER TERMINAL STOPPER Install and tighten the terminal nut securely. Install the negative brushes and tighten the screw to SCREW the specified torque.
Page 452 ELECTRIC STARTER Install the brush springs to the brush holder grooves. SPRINGS Install the brushes to the brush holder. BRUSHES Install the armature to the starter motor case. STARTER MOTOR CASE The coil may be damaged if the magnet pulls the armature against the case.
Page 453 ELECTRIC STARTER Install a new O-ring to the starter motor case. Install the front cover to the starter motor case. FRONT COVER When installing the front cover, take care to prevent damaging the oil seal lip with the armature shaft. O-RING Align the index marks on the front cover, starter motor case and rear cover.
Page 454 ELECTRIC STARTER Connect the ground cables and tighten the two RUBBER CAP mounting bolts. STARTER MOTOR CABLE Connect the starter motor cable. TERMINAL NUT Install and tighten the terminal nut to the specified torque. TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft) Install the rubber cap properly.
Page 455 ELECTRIC STARTER GROUND LINE Remove the maintenance lid (page 3-4). Ground (–) Turn the ignition switch to OFF. Release the connector cover and disconnect the starter relay 4P (Red) connector. Check for continuity between the wire harness side connector terminal and ground. CONNECTION: White/Green –...
Page 456 MEMO...
Page 457 22. LIGHTS/METERS/SWITCHES SYSTEM LOCATION································· 22-2 OIL PRESSURE INDICATOR ·················· 22-15 SERVICE INFORMATION ························· 22-3 IGNITION SWITCH ································· 22-16 HEADLIGHT··············································· 22-4 HANDLEBAR SWITCH ··························· 22-18 FRONT TURN SIGNAL/ INHIBITOR SWITCH ······························· 22-19 POSITION LIGHT ······································ 22-5 BRAKE LIGHT SWITCH ·························· 22-20 REAR TURN SIGNAL/BRAKE/ TAILLIGHT·················································...
Page 458: System Location
LIGHTS/METERS/SWITCHES SYSTEM LOCATION LIGHTS/METERS/SWITCHES TURN SIGNAL SWITCH DIMMER COMBINATION METER SWITCH HORN SWITCH ENGINE STOP SWITCH REAR BRAKE LIGHT/ FRONT BRAKE INHIBITOR SWITCH LIGHT SWITCH TURN SIGNAL RELAY STARTER HORN SWITCH IGNITION SWITCH ACCESSORY SOCKET FUEL LEVEL SENSOR (in the fuel pump) VS SENSOR FAN MOTOR RELAY ECT SENSOR...
Page 459: Service Information
LIGHTS/METERS/SWITCHES SERVICE INFORMATION GENERAL Note the following when replacing the halogen headlight bulb. – Wear clean gloves while replacing the headlight bulb. Do not put fingerprints on the headlight bulb, as they may create hot spots on the bulb and cause it to fail. –...
Page 460: Headlight
LIGHTS/METERS/SWITCHES HEADLIGHT BULB REPLACEMENT Remove the front handlebar cover (page 3-14). CONNECTOR Release the dust cover and disconnect the bulb con- Be careful not to nector. scratch the headlight lens during servicing. Avoid touching a new halogen bulb. Finger prints can create hot spots that cause a bulb to break.
Page 461: Position Light
LIGHTS/METERS/SWITCHES FRONT TURN SIGNAL/POSITION LIGHT BULB REPLACEMENT TURN SIGNAL LIGHT BULB Remove the front upper cover (page 3-9). TURN SIGNAL Remove the bulb socket by turning it counterclock- LIGHT BULB wise. While pushing the bulb in, turn it counterclockwise to remove it, and replace it with a new one. Check the rubber seal is in good condition and replace it with a new one if necessary.
Page 462: Rear Turn Signal/Brake
LIGHTS/METERS/SWITCHES Release the wire band boss from the wire guide. TURN SIGNAL/ WIRE BAND Remove the three screws and turn signal/position POSITION LIGHT BOSS light unit. UNIT Installation is in the reverse order of removal. Route the wires properly (page 1-19). SCREWS REAR TURN SIGNAL/BRAKE/ TAILLIGHT...
Page 463: License Light
LIGHTS/METERS/SWITCHES REAR TURN SIGNAL LIGHT BULB Remove the following: SCREW – brake/taillight lens (page 22-6) – screw(s) – turn signal light lens(es) TURN SIGNAL LIGHT LENS While pushing the turn signal light bulb in, turn it GASKETS counterclockwise to remove it, and replace it with a new one.
Page 464: Combination Meter
LIGHTS/METERS/SWITCHES COMBINATION METER BULB REPLACEMENT Remove the front handlebar cover (page 3-14). BULB Remove the rubber cap. Remove the bulb by turning it counterclockwise and replace it with a new one. Installation is in the reverse order of removal. METER INSPECTION INITIAL FUNCTION When the ignition switch turns ON, check that the speedometer, fuel gauge and coolant temperature...
Page 465 LIGHTS/METERS/SWITCHES GROUND LINE Remove the front handlebar cover (page 3-14). 16P CONNECTOR Disconnect the combination meter 16P connector. (Wire side of female terminal) Check for continuity between the Green wire termi- nal of the 16P connector of the wire harness side and ground.
Page 466 LIGHTS/METERS/SWITCHES DISASSEMBLY/ASSEMBLY Remove the combination meter (page 22-9). Remove the following: – harness clamp screw and meter harness – four screws and meter lens – eight screws and under case – reflecting plate – meter assembly Assembly is in the reverse order of disassembly. METER LENS SCREW METER ASSEMBLY METER LENS...
Page 467: Speedometer/Vs Sensor
LIGHTS/METERS/SWITCHES SPEEDOMETER/VS SENSOR SYSTEM INSPECTION Speedometer gauge does not move Check the combination meter initial function (page 22-8). 16P CONNECTOR (Connector If the speedometer needle shows initial function but connected) speedometer does not move at running, check the following: Support the scooter its centerstand and rise the rear wheel off the ground.
Page 468 LIGHTS/METERS/SWITCHES Check for continuity between the combination COMBINATION METER 16P CONNECTOR meter connector of the wire harness side and ground. CONNECTION: Pink/Green (+) – Ground (–) There should be no continuity. If there is continuity, check for short circuit in Pink/ Green wire.
Page 469: Fuel Gauge/Fuel Level Sensor
LIGHTS/METERS/SWITCHES FUEL GAUGE/FUEL LEVEL SENSOR • The fuel level sensor is mounted on the fuel pump (the fuel pump with the built-in level sen- sor). Do not disassemble the fuel pump. Replace the fuel pump as an assembly when the it is faulty.
Page 470: Coolant Temperature Gauge
LIGHTS/METERS/SWITCHES COOLANT TEMPERATURE GAUGE/ ECT SENSOR CIRCUIT INSPECTION When engine is hot but gauge needle does not move Check the combination meter initial function (page ECT SENSOR 3P 22-8). (Gray) CONNECTOR If the coolant temperature gauge needle shows ini- tial function but coolant temperature gauge does not move at engine is hot, check the following: Remove the luggage box (page 3-5).
Page 471: Oil Pressure Indicator
LIGHTS/METERS/SWITCHES OIL PRESSURE INDICATOR INSPECTION Indicator does not come on with the ignition switch turned to "ON" Check the combination meter initial function (page RUBBER CAP 22-8). If the all needles show initial functions but oil pres- WIRE sure indicator does not came on, check the follow- TERMINAL ing: Slide the rubber cap, and disconnect the oil pres-...
Page 472: Ignition Switch
LIGHTS/METERS/SWITCHES IGNITION SWITCH INSPECTION Remove the front upper cover (page 3-9). STD type: STD type shown: Remove the front inner cover (page 3-10). ABS type: Disconnect the ignition switch 2P connector. Check for continuity between the switch side con- nector terminals in each switch position. Continuity should exist between the color coded wire terminals as follows: 2P CONNECTOR...
Page 473 LIGHTS/METERS/SWITCHES REMOVAL/INSTALLATION Remove the following: 2P CONNECTOR – Front inner cover (page 3-10) – Immobilizer (page 23-14) Disconnect the ignition switch 2P connector. Loosen the seat lock cable joint nut and disconnect the seat lock cable from the ignition switch. JOINT NUT SEAT LOCK CABLE Remove the ignition switch mounting bolts and...
Page 474: Handlebar Switch
LIGHTS/METERS/SWITCHES HANDLEBAR SWITCH INSPECTION RIGHT HANDLEBAR Remove the rear handlebar cover (page 3-14). Check for continuity between the switch terminals in each switch position. Continuity should exist between the terminals of the corresponding color coded wire as follows: STARTER SWITCH FREE PUSH COLOR...
Page 475: Inhibitor Switch
LIGHTS/METERS/SWITCHES LEFT HANDLEBAR Remove the rear handlebar cover (page 3-14). Check for continuity between the switch terminals in each switch position. Continuity should exist between the terminals of the corresponding color coded wire as follows: DIMMER SWITCH PASSING SWITCH FREE PUSH COLOR Bl/R...
Page 476: Brake Light Switch
LIGHTS/METERS/SWITCHES BRAKE LIGHT SWITCH INSPECTION Remove the front handlebar cover (page 3-14). FRONT: Disconnect the brake light switch connectors. Check for continuity between the switch terminals. There should be continuity with the brake lever squeezed, and there should be no continuity when the brake lever is released.
Page 477 LIGHTS/METERS/SWITCHES REMOVAL/INSTALLATION Remove the following: SIDESTAND SWITCH 2P – Floor side cover (page 3-8) (BLACK) CONNECTOR – Floor panel (page 3-13) Support the scooter securely using the centerstand. Disconnect the sidestand switch 2P (Black) connec- tor. Release the sidestand switch wire from the wire WIRE BAND bands.
Page 478: Fan Motor Relay
LIGHTS/METERS/SWITCHES FAN MOTOR RELAY INSPECTION Fan motor does not stop Remove the rear fender A (page 3-7). Disconnect the ECM 33P connector. Turn the ignition switch "ON" and check the fan motor does stop. • If the fan motor does not stop, check the follow- ing: –...
Page 479 LIGHTS/METERS/SWITCHES Turn the ignition switch OFF. RELAY CONNECTOR Short the relay connector terminals of the wire har- ness side with a jumper wire. Connection: Black – Blue Remove the front inner cover (page 3-10). Disconnect the fan motor 2P (Black) connector. Turn the ignition switch "ON".
Page 480: Main Relay
LIGHTS/METERS/SWITCHES REMOVAL/INSTALLATION Remove the front upper cover (page 3-9). STD type: FAN MOTOR RELAY STD type shown: Remove the front Lower cover (page 3-12). ABS type: Remove the fan motor relay from the relay connec- tor. Installation is in the reverse order of removal. ABS type shown: FAN MOTOR RELAY MAIN RELAY...
Page 481 LIGHTS/METERS/SWITCHES Turn the ignition switch OFF. Short the relay connector terminals of the wire har- JUMPER WIRE ness side with a jumper wire. Connection: Red/Yellow – Red Remove the maintenance lid (page 3-4). Disconnect the fuse 10 A. Turn the ignition switch "ON". Measure the voltage between the fuse box terminal connector of the wire harness side and ground.
Page 482: Turn Signal Relay
LIGHTS/METERS/SWITCHES REMOVAL/INSTALLATION Remove the front upper cover (page 3-9). STD type: STD type shown: Remove the front lower cover (page 3-12). ABS type: Remove the main relay from the relay connector. Installation is in the reverse order of removal. MAIN RELAY ABS type shown: MAIN RELAY TURN SIGNAL RELAY...
Page 483: Horn
LIGHTS/METERS/SWITCHES HORN INSPECTION Remove the front upper cover (page 3-9). HORN Disconnect the horn connectors. Connect a 12V battery to the horn terminals. The horn is normal if it sounds when the 12V battery is connected across the horn terminals. CONNECTORS REMOVAL/INSTALLATION Remove the front upper cover (page 3-9).
Page 484 MEMO...
Page 485 23. IMMOBILIZER SYSTEM (HISS) SYSTEM LOCATION································· 23-2 DIAGNOSTIC CODE INDICATION ··········· 23-7 SYSTEM DIAGRAM·································· 23-2 TROUBLESHOOTING······························· 23-9 SERVICE INFORMATION ························· 23-3 IMMOBILIZER INDICATOR ···················· 23-12 KEY REGISTRATION PROCEDURES ······· 23-4 IMMOBILIZER RECEIVER······················· 23-13 23-1...
Page 486 IMMOBILIZER SYSTEM (HISS) SYSTEM LOCATION IMMOBILIZER SYSTEM (HISS) ENGINE STOP SWITCH ENGINE STOP IGNITION SWITCH RELAY IMMOBILIZER RECEIVER BANK ANGLE SENSOR FUSE 10 A BATTERY MAIN RELAY CKP SENSOR MAIN FUSE (30A) SYSTEM DIAGRAM FUSE R/Bl R/Bl FUSE R/Bl Bl/Br ENGINE STOP MAIN IGNITION...
Page 487 IMMOBILIZER SYSTEM (HISS) SERVICE INFORMATION GENERAL • When checking the immobilizer system (HISS), follow the steps in the troubleshooting flow chart (page 23-9). • Keep the immobilizer key away from the other vehicle's immobilizer key when using it. The jamming of the key code signal may occur and the proper operation of the system will be obstructed.
Page 488 IMMOBILIZER SYSTEM (HISS) KEY REGISTRATION PROCEDURES When the key has been lost, or additional spare key is required: 1. Obtain a new transponder key. 2. Grind the key in accordance with the shape of the original key. 3. Apply 12 V battery voltage to the CKP sensor lines of the ECM using the special tool (page 23-7). 4.
Page 489 IMMOBILIZER SYSTEM (HISS) When the ignition switch is faulty: 1. Obtain a new ignition switch and two new transponder keys. • Remove the ignition switch (page 22-17). 2. Apply 12 V battery voltage to the CKP sensor lines of the ECM using the special tool (page 23-7). 3.
Page 490 IMMOBILIZER SYSTEM (HISS) 13.Turn the ignition switch OFF and remove the key. 14.Turn the ignition switch ON with a second new key. (Never use the key registered in previous step.) The indicator comes on for four seconds then it blinks four times repeatedly. •...
Page 491 IMMOBILIZER SYSTEM (HISS) DIAGNOSTIC CODE INDICATION Disconnect the CKP sensor 2P (Red) connector. 2P (Red) CONNECTOR Connect the inspection harness to the wire harness side connector. Connect the red clip of the adaptor to the 12 V bat- tery positive (+) terminal and green clip to the nega- tive (–) terminal.
Page 492 IMMOBILIZER SYSTEM (HISS) When the system (ECM) enters the diagnostic mode from the registration mode: BLINKING PATTERN SYMPTOM PROBLEM PROCEDURE Registration is The key is Use a new key or overlapped already regis- cancelled key tered properly Code signals Communication Follow the trouble- cannot send or fails...
Page 493 IMMOBILIZER SYSTEM (HISS) TROUBLESHOOTING The immobilizer indicator comes on for approx. two seconds then it goes off, when the ignition switch is turned ON with the properly registered key and the immobilizer system (HISS) functions normally. If there is any problem or the properly registered key is not used, the indicator will remains on. Immobilizer indicator does not come on when the ignition switch is turned ON 1.
Page 494 IMMOBILIZER SYSTEM (HISS) Immobilizer indicator remains on with the ignition switch ON 1. Immobilizer Receiver Jamming Inspection Check that there is any metal obstruction or the other vehicle’s transponder key near the immobilizer receiver and key. Is there any metal obstruction or the other key? –...
Page 495 IMMOBILIZER SYSTEM (HISS) Diagnostic code is indicated (Code signals cannot send or receive) 1. Immobilizer Receiver Power Input Line Inspection Check the power input line (Yellow/Red) at the immobilizer receiver connector (page 23-13). Is there approx. 5 V? – GO TO STEP 2. –...
Page 496 IMMOBILIZER SYSTEM (HISS) IMMOBILIZER INDICATOR INSPECTION Check the combination meter initial function (page 33P CONNECTOR 22-8). (Wire side of If the all needles show initial functions but immobi- female terminal) lizer indicator does not stay on, check the following: Remove the rear fender A (page 3-7). Disconnect the ECM 33P connector.
Page 497 IMMOBILIZER SYSTEM (HISS) IMMOBILIZER RECEIVER POWER INPUT LINE INSPECTION Remove the front inner cover (page 3-10). IMMOBILIZER 4P CONNECTOR Disconnect the immobilizer receiver 4P connector. RECEIVER 4P (Wire side of female CONNECTOR terminals) Measure the voltage between the Yellow/red wire terminal (+) of the wire harness side connector and ground (–).
Page 498 IMMOBILIZER SYSTEM (HISS) Check for continuity between the Orange/Blue wire terminal and ground. 4P CONNECTOR (Wire side of female terminals) There should be no continuity. O/Bu REPLACEMENT Remove the front inner cover (page 3-10). IMMOBILIZER RECEIVER Disconnect the immobilizer receiver 4P connector Remove the two screws and immobilizer receiver.
Page 499 24. WIRING DIAGRAMS STD type: ·················································· 24-3 ABS type:·················································· 24-4 24-1...
Page 502 25. TROUBLESHOOTING ENGINE DOES NOT START OR IS POOR PERFORMANCE AT HARD TO START ······································ 25-2 HIGH SPEED ············································· 25-6 ENGINE LACKS POWER ·························· 25-3 POOR HANDLING ···································· 25-7 POOR PERFORMANCE AT LOW AND IDLE SPEED··············································· 25-5 25-1...
Page 503 TROUBLESHOOTING ENGINE DOES NOT START OR IS HARD TO START TROUBLESHOOTING 1. Spark Plug Inspection Remove and inspect spark plug. Is spark plug in good condition? – GO TO STEP 2. – • Plug not serviced frequently enough • Incorrect spark plug heat range •...
Page 504 TROUBLESHOOTING ENGINE LACKS POWER 1. Engine Oil Inspection Check the oil level and condition. Is the oil level correct and the oil in good condition? – GO TO STEP 2. – • Oil level too high • Oil level too low •...
Page 505 TROUBLESHOOTING 7. Fuel Flow Inspection Inspect the fuel flow (page 6-48). Is the fuel flow within specification? – GO TO STEP 8. – • Clogged fuel feed hose • Faulty fuel pump 8. Drive Train Inspection Check the drive train Is the drive train normal? –...
Page 506 TROUBLESHOOTING POOR PERFORMANCE AT LOW AND IDLE SPEED 1. Inlet Pipe Leaking Inspection Check for leaks at the inlet pipe. Does it leak? – • Loose inlet pipe mounting nut • Damaged inlet pipe O-ring – GO TO STEP 2. 2.
Page 507 TROUBLESHOOTING 7. Fuel Flow Inspection Inspect the fuel flow (page 6-48). Is the fuel flow within specification? – • Perform the TP sensor reset procedure (page 6-58). • Clogged IACV passage – • Clogged fuel feed hose • Faulty fuel pump POOR PERFORMANCE AT HIGH SPEED 1.
Page 508 TROUBLESHOOTING POOR HANDLING Steering is heavy • Steering stem adjusting nut too tight • Damaged steering head bearings • Low tire pressure Either wheel is wobbling • Excessive wheel bearing play • Faulty tire • Bent rim • Excessively worn engine mounting bushings •...
Page 509 MEMO...
Page 510 26. INDEX ABS CONNECTOR LOCATIONS ·································18-5 DIAGNOSTIC CODE INDICATION ······························ 23-7 ABS INDICATOR PROBLEM CODE INDEX ··············18-10 DRIVE AND DRIVEN PULLEYS/ ABS MODULATOR ····················································18-27 CLUTCH SPECIFICATIONS ··········································· 1-9 ABS SYSTEM DIAGRAM ············································18-3 DRIVE BELT ABS SYSTEM LOCATION ···········································18-2 DRIVE AND DRIVEN PULLEYS/CLUTCH··············· 11-7 ACCESSORY SOCKET···············································22-27 MAINTENANCE ······················································...
Page 511 INDEX IMMOBILIZER INDICATOR ······································· 23-12 FRAME/BODY PANELS/EXHAUST SYSTEM ·········· 3-3 IMMOBILIZER RECEIVER·········································· 23-13 FRONT WHEEL/SUSPENSION/STEERING ············ 15-3 INHIBITOR SWITCH ·················································· 22-19 FUEL SYSTEM (PGM-FI) ·········································· 6-3 INJECTOR···································································· 6-61 HYDRAULIC BRAKE················································ 17-4 INTAKE PIPE································································ 6-64 IGNITION SYSTEM ················································· 20-3 KEY REGISTRATION PROCEDURES ························· 23-4 IMMOBILIZER SYSTEM (HISS) ······························...

This manual is also suitable for:

Sh300a 2006 Sh300i 2006 Sh300aii 2006 Sh300ii 2006 Sh300iii 2006 Sh300aiii 2006 ... Show all

Honda SH300 2006 Manual

General Information

Technical Features Unit-Swing Engine Layout

Maintenance

Lubrication System

Fuel System (Pgm-Fi)

Cooling System

Cylinder Head/Valves

Front Wheel/Suspension/Steering

Hydraulic Brake

Anti-Lock Brake System (Abs; Sh300A/Aii/Aiii)

Battery/Charging System

Lights/Meters/Switches

Quick Links

Chapters

Troubleshooting

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Summary of Contents for Honda SH300 2006