2007ownermanualhondacbr600rr 151124204130 Lva1 App6891

HOW TO USE THIS MANUAL CONTENTS
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1. GENERAL INFORMATION
SERVICE RULES ·· .. ···· .. ············· ··· ...... ·· .. · .. ·· 1-2 REAR WHEELISUSPENSION

SPECIFICATIONS ........... ..... .. ....... ............ 1-10
MODEL IDENTIFICATION ········ ·.. ········ ··· ···· ·1-3
HYDRAULIC BRAKE SPECIFICATIONS···1-11
GENERAL SPECIFICATIONS · .. ········· ········· ·1 -5
BATIERY/CHARGING SYSTEM
SPECIFICATIONS .... ......... ..... .... ..... .......... 1-11
LUBRICATION SYSTEM
SPECIFICATIONS· ······· ···· ·· ·· ···· ············ ···· ····1-7
IGNITION SYSTEM SPECIFICATIONS ····1-11
FUEL SYSTEM (PGM-FI)
SPECIFICATIONS ····································.. ·1-7 ELECTRIC STARTER
SPECIFICATIONS ................... ...... ............ 1-11
COOLING SYSTEM SPECIFICATIONS ······1-7
LIG HTS/METERS/SWITCHES
SPECIFICATIONS ........................... ...... .... 1-12
CYLINDER HEADIVALVES
SPECIFICATIONS ································ ········ 1-8
STANDARD TORQUE VALUES· ···· ········ ·· 1-13
CLUTCH/STARTER CLUTCH/GEARSHIFT
LlNKAGE SPECIFICATIONS ········ ······· ········1-8 ENGINE & FRAME TORQUE VALUES ··· · 1-13
CRANKCASE/TRANSMISSION LUBRICATION & SEAL POINTS ······· ·· ··· ·· 1-19

SPECIFICATIONS··· ··············· ···················· .. 1-9
CABLE & HARNESS ROUTING ···············1-21
CRANKS HAFT /PISTON/CYLINDER
SPECIFICATIONS···· ·· ······················· ·· ·· ·· ····· 1-9 EMISSION CONTROL SYSTEMS ·· ···· ······ 1-36
FRONT WHEEL/SUSPENSION/STEERING
SPECIFICATIONS ···················· ··· ·· ······ .. ·.. ··1-10
1-1
GENERAL INFORMATION
SERVICE RULES
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 tor thi s product to avoid damage and incorrect assembly.
3. Use only metrie tools when servicing the motorcycle. Metrie bolts, nuts and screws are not interchangeable with
English lasteners.
4. Install new gaskets, O-rings, cotter pins, and lock plates when reassembling.
5. When tightening bolts or nuts, begin with the larger diameter or inne r bolt lirs!. Then tighten to the specilied torque
diagonally in incremental steps unless a particular sequence is specified.
6. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly.
7, After reassembly, check all parts tor proper installation and operation.
8. Route all electrical wires as shown in the Cable and Harness Routing (page 1-21) .
ABBREVIATION
Throughout this manual , the following abbreviations are used to identify the respective parts or systems.
Abbrev. tenn Full term

CKP sensor Cranks haft Position sensor
CMP sensor Camshaft Position sensor
DLC Data Link Connector
DTC Diagnostic Trouble Code
ECM Engine Control Module
ECT sensor Engine Coolant Temperature sensor
EEPROM Electrica lly Erasable Programmabie Read Only Memory
EGCV Exhaust Gas Control Valve
EG CV POT Exhaust Gas Control Valve Potentiometer
EOP switch Engine Dil Pressure switch
EVAP Evaporative Emission
HDS Honda Diagnostic System
HESD Honda Electronic Steering Damper
IACV Idle Air Control Valve
lAT sensor Intake Air Temperature sensor
MAP sensor Manifold Absolute Pressure sensor
MIL Mallunction Indicator Lamp
PAIR Pulsed Secondary Air Injection
PGM-FI Programmed Fuel Injectio n
SCS connector Service Check Short connector
TP sensor Throttle Position sensor
VS sensor Vehicle Speed sensor
1-2
GENERAL INFORMATION
MODEL IDENTIFICATION
SERlAL NUMBERS
The Vehiele Identifieation Number (VIN) is stamped on the right side of , - - - - - - - - - - - - - - - - - ,
the stee ring head.
The engine serial number is stamped on the upper side of the ENGINE SERlAL NUMBER
crankcase as shown .
/
/
1-~
GENERAL INFORMATION
The throttle body identification number is stamped on the right si de of
the throttle body as shown.
LABELS
The Safety Certification Label is located on lelt side of the frame . SAFETY CERTIFICATION LABEL
The color label is attached as shown. When orde ring color-coded parts, COLOR LABEL
always specify the designated color code.
The Emission Control Information Label is located on the rear fender B EM ISSION CONTROL INFORMATION LABEL
as shown.
1-4
GENERAL INFORMATION
GENERAL SPECIFICATIONS
ITEM SPECI FICATIONS
DIMENSIONS Overall length 2,010 mm (79.1 in)
Overall width 685 mm (27.0 in)
Overall height 1,105 mm (43.5 in)
Wheelbase 1,370 mm (53.9 in)
Se at height 820 mm (32.3 in)
Footpeg height 389 mm (15.3 in)
Ground clearance 135 mm (5.3 in)
Cu rb weight Except California type 186 kg (410 Ibs)
California type 187 kg (412 Ibs)
Maximum weight Except Canada type 166 kg (366 Ibs)
capacity Canada type 170 kg (375 Ibs)
FRAME Frame type ~iamond
Front suspension Telescopic fork
Front axle travel 110 mm (4.3 in)
Rear suspension Swingarm
Rear axle travel 129mm(5.1 in)
Front tire size 120nOZR17 M/C (58W)
Rear tire size 180/55ZR17 M/C (73W)
Front tire brand Bridgestone BT015F RADIAL E
Dunlop Qualifier PTG
Rear tire brand Bridgestone BT015R RADIAL E
Dunlop Qualifier PTG
Front brake Hydraulic double disc
Rear brake Hydraulic single disc
Caster angle 23" 55'
Trail length 98 mm (3.9 in )
Fuel tank capacity 18.0 liter (4.76 US gal, 3.96 Imp gal)
ENGINE Cylinder arrangement 4 cy linders in-line, inclined 38 Q trom ver-
t ical
Bore and stroke 67.0 x 42.5 mm (2.64 x 1.67 in)
Displacement 599 cm' (36. 5 cu-in)
Compression ratio 12.2 : 1
Va lve train Chain driven, DOHC
Intake valve opens at 1 mm (0.04 in ) lift 21 " BTDC
closes at 1 mm (0.04 in) lift 44" ABDC
Exhaust opens at 1 mm (0.04 in) lift 40" BBDC
valve closes at 1 mm (0.04 in) lift 5" ATDC
Lubrication system Force d pressure and wet sump
Oil pump type Trochoid
Cooling system Liquid coo led
Air filtration Paper element
Engine dry weight 57 kg (126 Ibs)
Firing order 1-2-4-3
FUEL DELIVERY Type PGM-FI
SYSTEM Throttle bore 40 mm (1.6 in )
DRIVE TRAIN Clutch system Multi-plate, wet
Clutch operation system Cable operating
Transm ission Constant mesh, 6-speeds
Primary reduction 2.111 (76/36 )
Final reduction 2.625 (42116)
Gear ratio lst 2.750 (33/12 )
2nd 2.000 (321 16 )
3rd 1.667 (30/18)
4th 1.444(26/18)
5th 1.304(30/23)
6th 1.208 (29/24)
Gearshift pattern Left foot operated return system,
1 -N-2-3- 4-5-6
1-5
GENERAL INFORMATION
ITEM SPECIFICATIONS
ELECTRICAL Ignition svstem Computer-controlled digita1 transistor-
ized with electric advance
Starting svstem Electric starter motor
Charging svstem Triple phase output altemator
Regulatorlrectifier FET shortedltriple phase, lull wave recti-
fication
Lighting svstem Battery
1-6
GENERAL INFORMATION
LUBRICATION SYSTEM SPECIFICATIONS
Unit· mm (in)
ITEM STANDARD SERVICE LIMIT
Engine oil capacity After draining 2.7 liter (2.9 US qt, 2.4 Imp qt) -
After oil filter change 2.8 lite r (3.0 US qt, 2.5 Imp qt) -
After disassembly 3.5 liter (3.7 US qt, 3.1 Imp qt) -
Recommended engine ail Pro Honda GN4 4-stroke oil (U.SA and
Canada) or equivalent motor ail
API service classification: SG or Higher -
JASO T 903 standard: MA
Viscosity: SAE 1OW-30
Oil pressure at EOP switch 505 kPa (5.1 kgf/cm', 73 psi)
-
at 6,000 rpm/(80°C/176°F)
Oi l pump Tip clearance 0.15 (0.006) 0.20 (0.008)
Body clea rance 0.15 - 0.21 (0.006 0.008) 0.35 (0.014)
Side clearance 0.04 0.09 (0.002 0.004) 0.17 (0.007)
FUEL SYSTEM (PGM-FI) SPECIFICATIONS

ITEM SPECIFICATIONS
Throttle body identifica- ) Except Califo rn ia type GQ64C
tian number I California type GQ64B
Idle speed 1,400 + 100 rpm
Throttle grip freeplay 2 4 mm (1/16 3/ 16 in)
lAT senso r resistance (a t 20°C/68°F) 1-4kl1
ECT sensor resistance (at 20°C/68°F) 2.3 - 2.6 kn
Fuet injector resistance ) Primary injector 11 13n
(at 20°C /68°F) I Seco ndary injector 11 13n
PA IR control solenaid valve resistance (at 20°C/68°F) 23 - 27 n
CMP sensor peak voltage (at 20°C/68°F) 0.7 V minimum
CKP sensor peak voltage (at 20°C/68°F) 0.7 V minimum
Fuel pressure at id le 343 kPa (3.5 kgf/cm' , 50 psi)
Fuel pump flow (at 12V) 167 cm ' (5.6 US oz, 5.9 Imp oz) minimum/10 seconds
COOLING SYSTEM SPECIFICATIONS

ITEM SPECIFICATIONS
Coolant capac ity I Radiator and engine 3.15 liter (3.33 US qt, 2.77 Imp qt)
I Reserve tan k 0.30 liter (0.32 US qt, 0.26 Imp qt)
Radiator cap relief pressure 108 - 137 kPa (1.1 - 1.4 kgf/cm', 16 - 20 psi )
Thermostat Begin to open 80 - 84°C (176 -183°F)
Full yopen 95°C (203°F)
Valve lift 8 mm (0.3 in) minimum
Recommended antifreeze Pro Honda HP Cao la nt or an equivalent high quality ethyl-
ene glycol antifreeze containing sllicate free corrosion
inhibitors
Standard coolant concent ratien 1:1 (mixtu re with distilled water)
1-7
GENERAL INFORMATION
CYLINDER HEAD/VALVES SPECIFICATIONS
Unit· mm (in)
Cylinder compression 1,226 kPa (12.5 kgf/cm', 178psi)
at 350 rpm
-
Valve clea rance IN 0.20 ± 0.03(0.008 + 0.001) -
EX 0.28 ± 0.03 (0.011 ± 0.001)
Ca m shaft Cam lobe height IN 36.36 - 36.60 (1.431 - 1.441) 36.34(1.431 )
EX 35.34- 35.58(1.391 -1.401) 35.32 (1.39 1)
Runout - 0.05(0.002)
Oil clea rance 0.020 0.062 (0.0008 0.0024) 0.10 (0.004)
Va lve lifter Valve lifter O.D. IN 25.978 - 25.993(1 .0228 - 1.0233) 25.97 (1.022 )
EX 22.478 - 22.493 (0.8850 - 0.8855) 22.47 (0.885)
Valve lifter bore I.D. IN 26.010 26.026(1.0240 1.0246) 26.04(1.025)
EX 22.510 - 22.526(0.8862 - 0.8868) 22.54 (0.887)
Valve, va lve Valve stem O.D. IN 3.975 - 3.990 (0. 1565 - 0.1571) 3.965(0.1561 )
guide EX 3.965 - 3.980 (0. 1561 0.1 567) 3.955 (0.1557)
Valve guide I.D. IN/EX 4.000 4.012(0.1575 0.1580) 4.04(0.159)
Stem·to-guide clearance IN 0.010 - 0.037(0.0004 - 0.0015) 0.075(0.0030)
EX 0.020 - 0.047 (0.0008 0.0019) 0.085 (0.0033)
Valve gu ide proje ction IN 17.1 17.4(0.67 0.69)
above cylinde r head EX 15.8 - 16.1 (0.62 - 0.63) -
Valve seat width IN/EX 0.90 - 1.10 (0.035 - 0.043) 1.5 (0.06)
Valve spring IN Inner 36.17 (1.424) 35.1 (1.38)
tree length Outer 40.38( 1.590) 39.2(1.54)
EX 40.80 (1.606) 39.6(1.56)
Cylinder head warpage 0.10 (0.004)
CLUTCH/STARTER CLUTCH/GEARSHIFT LlNKAGE SPECIFICATIONS

Unit" mm (in)
Clutch lever treepl ay 10 - 20 (3/8 13/ 16)
Clutch Spring tree length 46.7(1.84) 45.8 (1.80)
Disc thickness 2.92 - 3.08(0 .115 - 0.121) 2.6 (0. 10)
Plate w arpage - 0.30 (0.012)
Clutch outer guide I.D. 24.993 25.003(0.9840 0.9844) 25 .013(0.9848)
O.D. 34.996 - 35.004(1.3778 -1.378 1) 34.986(1.3774)
Primary driven gear I.D. 41.000 - 41.016(1.6142 - 1.6148) 41.026(1.6152)
Oil pump drive sprocket I I.D. 25.000 25.021 (0. 9843 0.9851 ) 25 .03 1 (0.9855)
guide O.D. 34.950 - 34.975(1.3760 - 1. 3770) 34.940 (1.3756)
Oil pump drive sprocket I.D. 35.025 - 35.145(1.3789 -1.3837) 35.155 (1.3841 )
Mainshaft O.D. at clutch outer guide 24.980 - 24.990 (0.9835 0.9839) 24.960 (0.9827)
Mainshaft O.D. at oil pump drive sprocket guide 24.980 - 24.990 (0. 9835 - 0.9839) 24.960 (0.9827)
Starter drive n gear boss O.D. 45.657 - 45.673(1.7975 -1.7981) 45.642 (1.7969)
1-8
GENERAL INFORMATION
CRANKCASE/TRANSMISSION SPECIFICATIONS
Unit· mm (in )
Shift lork I I.O. 12.000 12.018 (0.4724 0.4731 ) 12.03 (0.474)
Claw thickness 5.93 - 6.00 (0.233 - 0.236) 5.9 (0.23)
Shift lork shaft O.O. 11.957 - 11.968 (0.4707 - 0.4712 ) 11.95 (0.470)
Transmission Gear I.O. M5,M6 28.000 - 28 .021 (1.1024 1.1032) 28.04 (1.104)
Cl 24.000 24.021 (0.9449 0.9457 ) 24.04 (0.946)
C2, C3,C4 31.000 - 31.025 (1.2205 -1.2215) 31.04 (1.222)
Gear busing O.O. M5, M6 27.959 - 27.980 (1.1007 - 1.1016) 27.94 (1.100)
C2 30.955 - 30.980 (1.2 187 1.2197) 30.94 (1.218)
C3,C4 30.950 - 30.975 (1.2 185 -1.2195) 30.93 (1.218)
Gear-to-bushing M5, M6 0.020 - 0.062 (0.0008 - 0.0024) 0.10 (0.004)
clearance C2 0.020 - 0.070 (0.0008 0.0028) 0.10 (0.004)
C3,C4 0.025 0.075 (0.0010 0.0030) 0.11 (0.004)
Gear bushing I.O. M5 24.985 - 25.006 (0.9837 - 0.9845) 25.016 (0.9849)
C2 27.985 - 28.006 (1.1018 -1.1026) 28.021 (1.1032)
Mainshaft O.O. at M5 24.967 24.980 (0.9830 - 0.9835) 24.96 (0.983 )
Countershaft O.O. at C2 27.967 - 27.980 (1.1011 -1. 1016) 27.96 (1. 101 )
Sushing to shaft M5 0.005 - 0.039 (0.0002 - 0.0015) 0.06 (0.002)
clearance C2 0.005 0.039 (0.0002 0.0015) 0.06 (0.002)
CRANKSHAFT/PISTON/CYLINDER SPECIFICATIONS
Unit· mm (in)
Crankshaft Connecting rad side clearance 0.15 0.30 (0.006 0.012) 0.35 (0.014)
Crankpin bearing all clearance 0.028 0.052 (0.0011 0.0020) 0.06 (0.002)
Main journal bearing Dil clea ran ce 0.020 - 0.038 (0.0008 - 0.0015) 0.05 (0.002)
Run out 0.05 (0.002)
Pi ston, piston Piston O.O. at 6 mm (0.2 in ) lrom
66.965 - 66.985 (2.6364 - 2.6372 ) 66.90 (2.634)
rings bottom
Piston pin bare I.O. 15.030 - 15.044 (0.5917 - 0.5923) 15.07 (0.593)
Piston pin O.O. 14.994 - 15.000 (0.5903 0.5906) 14.98 (0.590)
Piston-ta-piston pin clearance 0.03 0.05 (0.001 0.002) 0.09 (0.004)
Piston ring end Top 0.10 - 0.20 (0.004 - 0.008) 0.4 (0.02)
gap Second 0.21 - 0.31 (0.008 - 0.012) 0.5 (0.02 )
Oil
0.2 - 0.7 (0.01 - 0.03) 1.0 (0.04)
(side rail)
Pi ston ring -ta - ring Top 0.030 - 0.060 (0.0012 - 0.0024) 0.10 (0.004)
groove clearance Second 0.115 - 0.150 (0.0045 - 0.0059) 0.08 (0 .003 )
Cylinder I.O. 67.000 67.015 (2 .6378 2.6384) 67.10 (2.642)
Out ol round - 0.10 (0.004)
Taper - 0.10 (0.004)
Warpage - 0.10 (0.004)
Cylinder-ta-piston clearance 0.015 - 0.050 (0.0006 - 0.0020) 0.10 (0.004)
Connecting rad small e nd I.O. 15.030 - 15.044 (0.591 7 - 0.5923 ) 15.05 (0.593 )
Connecting rad-ta-piston pin clea rance 0.03 0.05 (0.001 0.002) 0.07 (0.003)
1-9
GENERAL INFORMATION
FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS
Unit· mm (in)
ITEM STAN DARD SERVICE LIMIT
Minimum ti re tread depth - 1.5 (0.06)
Cold tire pres- ) Driver only 250 kPa (2.50 kgf/cm ' , 36 psi) -
sure Driver and passenger 250 kPa (2.50 kgf/cm ' , 36 psi) -
Axle runout 0.2 (0.01)
Wheel rim Radial - 2.0 (0.08)
runout ) Axia l - 2.0 (0.08)
Wheel balance weight 60 g (2. lal )
- ma x.
Fork Spring free length 243.4 (9.58) 238.5 (9.39)
Pipe runout - 0.20 (0.008)
Reco mmended fork fluid Pro Honda Suspension Flu id SS-47
(1OW)
-
Flu id level 93 (3.7) -
Fluid capacity 413 ± 2.5 cm ' (1 4.0 ± 0.08 US Ol, 14.5 ±
0.09 Imp Ol)
-
Pre-laad adjuster initial setting 5 turns from minimum
Rebound damping adjuster initial
setting
2-1 /2 turns out from full hard -
Compressien dam ping adjuster in i-
tial setting
2 turn s out from full hard -
Steering head bearing pre-laad 14.7 - 17.7 N (1.5 -1.8 kgf) -
REAR WHEEL/ SUSPENSION SPECIFICATIONS

Unit· mm (in)
Minimum tire tread depth - 2.0 (0.08)
Cold tire pres- I Driver only 290 kPa (2.90 kgf/cm ' , 42 psi)
sure Driver and passenger 290 kPa (2.90 kgf/cm' , 42 psi) -
Axle runout - 0.2 (0.01)
Wheel rim I Radial 2.0 (0.08)
runout ) Axial 2.0 (0.08)
Wheel ba lance weight 60 g (2.1 Ol)
-
max.
Dri ve chain Sile/link I OIO DID525HV KAI-11 2YB
I RK RK525ROZ6-112LJFZ
Slack 30 - 40 (1.2 - 1.6) -
Shock Spring pre-laad adjuster standard
absorber positien
Position 2 -
setting
2-1/2 turns out from full hard -
Compression damping adjuster ini-
22 clicks out from full hard -
tial setting
1-10
GENERAL INFORMATION
HYDRAULIC BRAKE SPECIFICATIONS
Unit· mm (in)
Front Specified brake fluid DOT 4 -
Brake disc th ickness 4.3 4.5 (0.17 0.18) 3.5 (0.14)
Bra ke disc runout - 0.30 (0.012)
Master cylinder I.O. 17.460 - 17.503 (0.6874 - 0.6891) 17.515 (0.6896)
Master piston O.O. 17.321 17.367 (0.6819 0.6837) 17.309 (0. 6815)
Caliper cylinder I.O . A 32.080 - 32.130 (1.2630 -1.2650) 32.140 (1.2654)
B 30.280 - 30.330 (1.1921 - 1.19411 30.340 (1. 1945)
Caliper piston O.O. A 31.967 - 32.000 (1.2585 1.2598) 31.957 (1.2581)
B 30.167 30.200 (1.1877 1.1890) 30.157 (1.1873)
Rear Specified brake fluid 00T4 -
Bra ke disc thickness 4.8 - 5.2 (0.19 - 0.20) 4.0 (0.16 )
8rake disc runout 0.30 (0.012)
Master cylinder I.O. 14.000 14.043 (0.5512 0.5529) 14.055 (0.5533)
Master piston O.O. 13.957 - 13.984 (0.5495 - 0.5506) 13.945 (0 .5490)
Caliper cylinder I.O. 30.230 30.280 (1 .1 902 1.1921) 30.290 (1.1925)
Caliper piston O.O. 30.082 30.115 (1.1843 1. 1856) 30. 140 (1.1866)
BATTERYICHARGING SYSTEM SPECIFICATIONS

ITEM SPECIFICATIONS
Battery Capacity 12V 8.6 Ah
Current leakage 2.0 mA max.
Voltage (20' C/68' F) Fully
13.0 - 13.2 V
charged
Needs
Below 12.4 V
charging
Charging current Normal 0.9 Al5 - 10 h
Ouick 4.5 All h
Alternator Capacity 0.342 kW/5.000 rpm
Charging cai I resistance (20' C/68' F) 0. 1 -1.0f!
IGNITION SYSTEM SPECIFICATIONS

ITEM SPECIFICATIONS
Spark plug (Iridium) I NGK IMR9C-9HES
I OENSO VUH270
Spark plug gap 0.80 0.90 mm (0.031 0.035 in )
CKP sensor peak vo ltage 0.7 V minimum
Ign ition timing (" F"mark) 7.8' BTOC at idle
ELECTRIC STARTER SPECIFICATIONS

Unit: mm (in)
Starter motor brush length 12.0 (0.47) 6.5 (0.26)
1-11
GENERAL INFORMATION
LlGHTS/METERS/SWITCHES SPECIFICATIONS
ITEM SPECIFICATIONS
Bulbs Headlight I Hi 12V-55W
I Lo 12 V 55W
Position light LED
Brake/tail/license lig ht LED
Front turn signallposi tion lig ht 12 V - 23/8 W x 2
Rea r turn signa l light 12 V 21 Wx 2
Instrument light LED
Turn signal indicator LED
High beam ind icator LED
Neutral indicator LED
MIL LED
HESD indicator LED
Eng ine oil pressure indicator LED
Engine coo lant tempe ratu re indicator LED
Fuse Ma in fuse 30 A
Sub f use 10 A x 4, 20 A x 3
Tachometer peak voltage 10.5 V minimum
Ee T sensor resistance I 80°C (176°F) 2.1 - 2.6 kn
I 120' C (248°F) 0.6 0.7 kn
1-12
GENERAL INFORMATION
STANDARD TORQUE VALUES
TORQUE TORQUE
FASTENER TVPE FASTENER TVPE
N·m (kgf·m, IbHt) N·m (kgf·m, IbHt)
5 mm bolt and nut 5.2 (0.5, 3.8) 5 mm screw 4.2 (0.4, 3.1 )
6 mm bolt and nut 10 (1.0, 7) 6 mm screw 9.0 (1.0, 6.6)
8 mm bolt and nut 22 (2.2, 16) 6 mm flange bolt (8 mm head, la rge flange) 12 (1.2, 9)
10 mm bolt and nut 34 (3.5, 25) 8 mm flange bolt and nut 27 (2.8, 20)
12 mm bolt and nut 54 (5.5, 40) 10 mm flange bolt and nut 39 (4.0, 29)
ENGINE & FRAME TORQUE VALUES

• Torque specifications listed below are for important fasteners.
• Others should be tightened to standard torque va lues listed above.
ENGINE
MAINTENANCE
THREAD TORQUE
ITEM Q'TV REMARKS
DIA. (mm) N·m (kgf·m, Ibf·ft)
Spark plug 4 10 16 (1.6, 12)
Timing hole cap 1 45 18 (1.8, 13) App[y,grease to t he
threads
Oil filter eartridge 1 20 26 (2.7,19) Apply oil to the
thrads and O,ring
Oil drain bolt 1 12 30(3.1,22)
Oil filter boss 1 20 - See page 4-18
Apply loeking agent
to the crankcase
side threads
LUBRICATION SYSTEM
THREAD TORQUE
ITEM Q'TV REMARKS
DIA. (mm) N ·m (kgf·m, Ibf·ft)
Oil pump assembly bolt 1 6 12 (1.2, 9) CT bolt
Oil pump driven spreeket bolt 1 6 15 (1.5,11) Apply loeking agent
to the threads
Oil cooler bolt 1 20 59 (6.0, 44) Apply oil to the
threads
Oil pipe A mounting bolt 2 6 12 (1.2, 9) Apply loeking agent
to the threads

THREAD TORQUE
ITEM Q'TV REMARKS
ECT sensor 1 12 23 (2.3, 17)
Primary fuel rail mounting bolt 4 5 5.1 (0.5,3.8)
Seeondary fuel rail mounting bolt 4 5 5.3 (0.5, 3.9)
IACV setting plate torx serew 2 4 2.1 (0.2, 1.5)
Knock sensor mounting bolt 1 8 22 (2.2, 16)
COOLING SYSTEM
THREAD TORQUE
ITEM Q'TV REMARKS
Water pump assembly bolt 4 6 12 (1.2, 9) CT bolt
Thermostat housing cover bolt 2 6 12 (1.2, 9) CT bolt
ENGINE REMOVALIINSTALLATION
THREAD TORQUE
ITEM Q'TV REMARKS
Drive spro eket bolt 1 10 54 (5.5, 40)
1-13
GENERAL INFORMATION
THREAD TORQUE
ITEM Q'TV REMARKS
DIA, (mm) N'm (kgl·m, Ibl·ft)
Cyli nder head bolt 10 9 47 (4.8, 35) Apply oil to the
threads and seating
surface
Camshaft holder bolt 20 6 12 (1.2, 9) Apply oil to the
threads and seating
surface
Cylinder head cover bolt 4 6 10 (1.0, 7)
PAIR check valve cover bolt 4 6 12 (1.2, 9) Apply locking agent
to the threads
Cam sprocket bolt 4 7 20 (2.0, 15) Apply locking agent
to the threads
CMP sensor rotor bolt 2 6 12 (1.2, 9) Apply locking agent
to the th reads
Cam chain tensioner A pivot bolt 1 6 12 (1.2, 9) Apply locking agent
to the threads
Cam chain tensioner B pivot bolt 1 10 20 (2.0, 15) Apply locking agent
to the threads
Cam chain guide A bolt 1 6 12 (1.2, 9)
Insulator mounting bolt 6 6 12(1.2, 9)
CLUTCH/ STARTER CLUTCH/ GEARSHIFT LlNKAGE

THREAD TORQUE
ITEM Q'TV REM ARKS
DIA. (mm ) N·m (kgl·m, Ibl·ft)
Clutch ce nter lock nut 1 22 128 (13.1, 94) Apply oil to the
threads and seating
surface, stake
Clu tch spri ng bolt 5 6 12 (1.2, 9)
Shift drum center bolt 1 8 23 (2.3, 17) Apply locking agent
to the threads
Shift drum stopper arm pivot bolt 1 6 12 (1.2, 9) Apply locking agent
to the threads
Gearshift spindie stopper pin 1 8 22 (2.2, 16)
Sta rter clutch mounting bolt 1 ~o 83 (8.5, 61) App ly oil to the
threads and seating
surface
ALTERNATOR
THREAD TORQUE
ITEM Q'TV REMARKS
DIA. (m m ) N·m (kgl ·m, Ibl ·ft)
Stator mounting bolt 4 6 12 (1.2, 9)
Flywheel bolt 1 10 103 (10.5, 76) Apply oil to the
threads and seating
surface
Stato r wi re clamp bo lt 1 6 12(1.2,9) CT bo lt
CRANKCASE/TRANSMISSION
THREAD TORQUE
ITEM Q'TV REMARKS
DIA. (mm) N·m (kgl·m, Ibl·ft)
Mainshaft bearing set plate bolt 3 6 12 (1.2, 9) Apply locking agent
to the threads
Shift drum bearing set bolt 2 6 12 (1.2,9) App ly locki ng agent
to the threads
Crankcase 6 mm bo lt 10 6 12(1.2, 9)
8 mm bolt 6 8 24 (2.4, 18)
8 mm bo lt (main journal bolt) 10 8 15 (1.5, 11 ) + 120" See page 12-1 7
Replace with a new
one
10 mm bolt 1 10 39 (4.0, 29)
1-14
GENERAL INFORMATION
CRANKSHAFT/ PISTON/ CYLINDER
THREAD TORQUE
ITEM Q'TV REMARKS
Crankpin bearing cap bolt (new) 8 7 20 (2.0, 15) + 90' Apply oil to the
threads and seating
surface
Crankpin bearing cap bolt (retightening) 8 7 1411.4, 10) + 90' Apply oil to the
threads and seating
surface
Oil iet pipe mounting bolt 2 6 12 (1.2, 9) App ly locking agent
to the threads
ELECTRIC STARTER
THREAD TORQUE
ITEM Q'TV REMARKS
DIA. (mm) N·m Ikgf·m, Ibf·ft)
Starter motor terminal nut 1 6 1011.0, 7)
LlGHTS/METERS/SWITCHES
THREAD TORQUE
ITEM Q'TV REMARKS
EOP switch 1 PT 1/8 12 (1.2, 9) Apply sealant to the
threads
EOP switch wire terminal bolt 1 4 2.010.2, 1.5)
Neutral switch 1 10 1211.2,9)
1-15
GENERAL INFORMATION
FRAME
FRAME/ BODY PANELS/ EXHAUST SYSTEM
THREAD TORQUE
ITEM Q'TV REMARKS
DIA. (mm) N·m (kgl·m , Ibf.ft)
Lower cowlM to-middle cowl screw 4 5 1.5 (0.2, 1. 1)
Windscreen mounting screw 6 5 0.45 (0.05, 0.3)
Seat rail mounting nut 2 10 54 (5.5, 40)
Seat rai l m ounting bolt 2 10 44 (4.5, 32)
Seat rail assem bly bolt 2 8 30 (3.1 , 22)
Muffler ba nd bolt 1 8 17 (1.7, 13)
Exhau.st pipe joint nut 8 7 12( 1. 2, 9)
Fron t fender moun ti ng screw 6 6 12( 1.2,9)
Rearview mi rror mounting bolt 4 6 7.0 (0.7,5.2)
Exhaust pipe mounting bolt 1 8 17 (1.7, 13)
Main step bracket mounting bolt 4 8 37 (3.8, 27)
Passenger step bracket mounting bolt 4 8 26 (2.7, 19)
Exhaust pipe stud 8 8 - See page 3-26
Position light mounting screw 2 5 1.8 (0.2, 1.3)
Rea r lender bracket mounting bolt 4 6 12 (1.2, 9)
Air duet mounting bolt 4 6 12(1.2, 9) ALOC bolt; replace
with a new one
MAINTENANCE
THREAD TORQUE
ITEM Q'TY REMARKS
Air clea ner element mounting screw 3 5 4.2 (0.4, 3.1)

THREAD TORQUE
ITEM Q'TV REMARKS
Fuel pump mounting nut 6 6 12( 1.2, 9)
EG CV pu lley nut 1 6 5.0 (0.5, 3.7)
Bank angle sensor mounting screw 2 4 1. 5 (0.2, 1.1 )
Fuel tank mounting bolt 2 8 30(3.1 , 22)
Air funne i/lower housing mounting screw 6 5 4.2 (0.4, 3.1)
lAT sensor moun ting screw 2 5 1.1 (0.1, 0.8)
MAP senso r mounting screw 1 5 1. 1 (0.1, 0.8)
ECM setting pla te screw 2 4 0.7 (0.07, 0.5)
COOLING SYSTEM
THREAD TORQUE
ITEM Q'TV REMARKS
Fa n m otor nut 3 5 4.9 (0.5, 3.6)
Fan mo tor shroud mou nti ng bolt 3 6 8.4 (0.9, 6.2)
ENG INE REMOVALlINSTALLATION

THREAD TORQUE
ITEM Q'TV REMARKS
DIA. (mm) N·m (kgl·m , Ibl·ft)
Front engine hanger bolt 2 12 54 (5.5, 40)
Upper engine hanger adjusting bolt 1 20 10 (1.0, 7)
Upper engine hanger loek nut 1 20 54 (5.5, 40)
Upper engine hanger nut 1 12 59 (6.0, 44)
Lower engine hanger adjusting bolt 1 20 10 (1 .0, 7)
Lower engine hanger loek nut 1 20 54 (5.5, 40)
Lower angine hanger nut 1 12 59 (6.0, 44)
1-16
GENERAL INFORMATION
FRONT WHEELISUSPENSION/STEERING
THREAD TORaUE
ITEM a'TV REMARKS
DIA. (mm) N ·m (kgf·m, IbHt)
Handlebar weight mounting screw 2 6 9.8 (1.0, 7) A LOC screw; rep lace
with a new one
Fron t brake disc bolt 12 6 20 (2.0, 15) ALOC screw; rep lace
with a new one
Front axle bolt 1 14 59 (6.0, 44)
Front axle holder bolt 4 8 22 (2.2, 16)
Fork socket bolt 2 10 34 (3.5, 25)
Fork damper rod loek nut 2 10 20 (2.0, 15)
Fork bolt 2 44 34 (3.5, 25 )
Handlebar pinch bolt 2 8 27 (2 .8, 20)
Top bridge pinch bolt 2 8 22 (2.2, 16)
Bottom bridge pinch bolt 2 8 27 (2.8, 20 )
Steering stem adjusting nut 1 26 - See page 14-41
Steering stem adjusting loek nut 1 26 - See page 14-41
Steering stem nut 1 24 103 (10.5, 76)
Compression adjuster plug bolt 2 14 17 (1.7, 13)
Stee ring damper mounting bolt 4 6 10 (1.0, 7)
Second arm nut 2 6 12 (1.2, 9) U-nut
REAR WHEEL/SUSPENSION
THREAD TORaUE
ITEM a 'TV REMARKS
Rear brake disc bolt 4 8 42 (4.3, 31) A LO C bolt; replace
with a new one
Oriven sprocket nut 6 10 64 (6.5, 47) U-nut
Rear axle nut 1 22 113 (11.5, 83) U-n ut
Rear shock absorber mounting nut 2 10 44 (4.5, 32) U-nut
Shock arm-to-swingarm nut 1 10 44 (4.5, 32) U-nut
Dri ve chain case bolt 3 6 12 (1.2, 9)
Dri ve chain slider bolt 3 6 9.0 (0.9, 6.6) ALOC bolt; rep lace
with a new one
Swingarm pivot adjusting bolt 1 30 12 (1.2, 9) Appl y oil to the
threads
Swingarm pivot loek nut 1 30 64 (6.5, 47)
Swingarm pivot nut 1 18 93 (9.5, 69)
Shock link nut 2 10 44 (4. 5, 32) U-nut
1-17
GENERAL INFORMATION
HYDRAULIC BRAKE
THREAD TORQUE
ITEM Q'TV REMARKS
DIA. (mm) N·m (kgl·m, IbHt)
Front master cylinder reserve tank stopper
plate screw 1 4 1.2 (0.1 , 0.9)
Front brake lever pivot bolt 1 6 la (0. 1, 0.7) ApplV silicone
grease to the slid-
ing surface
Front brake lever pivot nut 1 6 6.0 (0.6, 4.4 )
Front brake light switch screw 1 4 l2 (0.1, 0.9)
Front master cvlinder holder bolt 2 6 12 (l 2, 9)
Front brake caliper assemblv torx bolt 8 8 22 (2.2, 16) App lV locking agent
to the threads
Front brake caliper mounting bolt 4 10 45 (4.6, 33) ALOC bolt; replace
with a new one
Front brake reserve tank stav bolt 1 6 12 Il 2,9)
Rear master cyli nder push rad loek nut 1 8 18 11.8, 13)
Rear master cylinder reserve tan k cap screw 2 4 l5 (0.2, 1.1)
Rear master cylinder mounting bolt 2 6 10 (la, 7)
Rear brake reserve tank mounting bolt 1 6 12 Il2,9)
Rear brake hose joint screw 1 4 l5 (0.2, 1.1) ApplV locking agent
to th e threads
Front brake caliper pad pin 2 10 15 Il5, 11)
Rear brake caliper pad pin 1 10 18 (l8, 13)
Brake hose oil bolt 5 10 3413.5,25)
Front brake hose clamp bolt 1 6 9.0 10.9, 6.6)
Front brake hose clamp nut 1 6 10 IlO, 7)
Front brake hose 3-waV j oi nt bolt 1 6 10 (1.0, 7)
Front brake ca liper bleed valve 2 8 8.0 10.8, 5.9)
Rear brake caliper bleed va lve 1 8 6.0 10.6, 4.4 )
THREAD TORQUE
ITEM Q'TV REMARKS
DIA. (mm) N·m (kgl·m , Ibl·ft)
Combination meter screw 9 5 la 10.1, 0.7)
Ignition switch mounting bo lt 2 8 24 (2.4, 18) Replace with a new
one
Headl ight mounting screw 2 5 l8 10 .2, l3)
Sidestand switch mounti ng bolt 1 6 10 IlO, 7) ALOC bolt; repla ce
with a new one
Right handlebar switch housi ng screw 2 4 0.9 (0.09, 0.7)
Mirror stay mounting bolt 6 6 12 11.2, 9) ALOC bolt; repla ce
with a new one
OTHERS
THREAD TORQUE
ITEM Q'TV REMARKS
Sidestand pivot bolt 1 10 10 (1.0, 7)
Sidestand pivot nut 1 10 29 (3.0, 21)
1-18
GENERAL INFORMATION
LUBRICATION & SEAL POINTS
ENGINE
MATERlAL LOCATI ON REM ARKS
Liquid sealant (Th ree Crankcase mating surface See page 12-16
Bond 1207B or equiva- Dil pan mating surface See page 5-7
lent) Right crankcase cover mating surface See page 10-26
Alternator cover mating surface See page 11-6
EOP switch threads
Alternator cover wire grommet
Right crankcase cover wire grommet
Cylinder head semi-circular cut-out See page 9-34
Molybdenum disulfide Main journal bearing sliding surface
oil (a mixture of 1/2 Piston pin sliding surface
eng i ne oil and 1/2 Crankpin bearing sliding surface
molybdenum disu lfide Connecting rad small end inner surface
grease) Crankshaft thrust surface
Camshaft lobes and journals
Va lve stem (va lve guide sliding surface)
Valve lifter sliding surface
Dil pump drive sproeket guide sliding surface
Water pump shaft and thrust washer sliding surface
Cluteh outer sliding surface
Cluteh outer guide sliding surface
M3/4, C5, C6 shifter gear (shift fork grooves)
Starter reduction gear sliding surface
Starter id le gear shaft sliding surface
Cylinder head bolt threads and seating surface
Engine oil Piston and piston ring sliding surface
Cluteh dise surface
Starter one-way clutch slid ing surface
Crankpin bearing cap bolt threads and seating surface
Flywheel bolt threads and seating surface
CJutch center loek nut threads and seating surface
Dil filter eartridge threads and O-ring
Dil cooler bolt threads and sealing washer seating surface
Camshaft holder bolt threads and seating surface
Each gear teeth and ratating surface
Eaeh bearing
Eaeh O-ring
Eaeh sea I ri ng
Other ratating area and sliding surface
St arter cluteh mounting bolt threads and seating surface
Multi-purpose grease Timing hole cap threads
Eaeh oil seal lips
Loeking agent CMP sensor rotor bolt threads
Dil pump driven sproeket bolt threads Coating w idth : 6.5 ± 1 mm
Shift drum bearing set plate bolt threads Coating w idth: 6.5 ± 1 mm
Mainshaft bearing se t plate bolt thread s Coating width: 6.5 ± 1 mm
Cam sproeket bolt threads Coating width : 6.5 ± 1 rnm
Shift drum center bolt threads Coating width : 6.5 ± 1 mm
Cam ehain tensioner A pivot bolt threads Coating w idth : 6.5 ± 1 mm
Cam ehain tensi o ner B pi vot bo lt threads Coating width: 6.5 ± 1 mm
Shift drum stopper arm pi vot bolt threads Coating width : 6.5 ± 1 mm
Dil pump drive ehain guide mounting bolt threads Coating w idth : 6.5 ± 1 mm
Shift spindie setting plate bolt threads Coating width: 6.5 ± 1 mm
Dil jet pipe mounting bolt threads Coating width: 6.5 ± 1 mm
Dil leve l plate bolt threads Coating w idth : 6.5 ± 1 mm
Dil pipe AlB mounti ng bolt threads Coating width: 6.5 ± 1 mm
PAIR check v alve cover bolt threads
Dil filter boss threads (cra nkcase side) Coating width: 6.5 + 1 mm
1-19
GENERAL INFORMATION
FRAME
MATER lAL LOCATION REMARKS
Multi-purpose grease Passenger seat catch hook sliding area
Front wheel dust seal lips
Rear wheel dust seal lips
Throttle pipe sliding surface
Clutch lever pivot bolt sliding surface
Rear brake pedal pivot sliding surface
Gearshift peda I link tie rod bali joints
Gearshift pedal pivot sliding surface
Sidestand pivot sl iding surface
Axle surface
Swingarm pivot bolt surface
Urea based multi-pur- Steering head bearing sliding surface 3 5g
pose grease with Steering head dust seal lips 3-5g
extreme pressu re Steering stem adjusting nut threads 0.' - 0.3 g
(example: EXCELITE
EP2 manufactured by
KYODO YUSHI, Japan)
or equivalent
Multi-purpose grease Swingarm pivot bearings
(Shell Alvania EP2 or Swingarm pivot dust seallips
equiva lent) Shock lin k needie bearings
Shock link dust seal lips
Shock absorber needie bearing
Shock absorber dust seal lips
Cable lubricant Throttle cable inside
Clutch cable inside
EGCV control cable inside
Honda bond A or Pro Handlebar grip rubber inner surface
Honda hand grip
cement (U.S.A. only)
Engine oil Swingarm pivot adjusting bolt threads
Each a -ring
Silicone grease Front brake push rod-tc-master piston contact surface
Front brake push red tip
Front brake lever pivot bolt sliding surface 0.' g
Rear brake master piston-ta-push rod contacting area 0.' g
Rear brake caliper pin sliding surface 0.4 g
Rear brake caliper pad pin a -ring
DOT 4 brake fluid 8rake master piston and cups
8rake caliper piston and piston saais
Fork fluid Fork a-ring
Fork dust seal and oil seal lips
Locking agent Front brake calipe r assembly torx bolt threads
Cooling fan nut threads
'-20
GENERAL INFORMATION
CABLE & HARNESS ROUTING
COMBINATION METER 20P (Blaek) CONNECTOR
POSITION
LlGHTWIRE
BANKANGLE
SENSOR WIRE
BANK ANGLE SENSOR

3P (Blaek) CONNECTOR
HEADLIGHT 2P
(Natural ) CONNECTOR
HEADLIGHT 2P
(Natural) CONNECTOR
LEFTTURN SIGNAL WIRE
e e
1-21
GENERAllNFORMATION
THROTILE CAB LES CLUTCH CABLE
SWITCH WIRE
FRONT BRAKE LIGHT

SWITCH WIRE
HEADLIGHT/ BANKANGLE
SENSOR WIRE
FRONT BRAKE HOSE

HORNWIRE
CLUTCH CABLE
THROTILE CABLES
LEFT HANDLEBAR SWITCH WIRE
1-22
GENERAL INFORMATION
CLUTCH CABLE
LEFT HANDLE BAR

SWITCH WIRE
HEADLIGHT/BANKANGLE
SENSOR WIRE
FRONT BRAKE HOSE
'-23
GENERAL INFORMATION
THROTILE CABLES
CLUTCH CABLE
FRONT BRAKE HOSE

MAINWIRE
HARNESS
'-24
GENERAL INFORMATION
BANK ANGLE SENSOR

3P (Black) CONNECTOR .--""",_ _-
HEADLIGHT 2P (Natura l)
CONNECTOR
LEFTHANDLEBAR SWITCH
12P (Gray) CONNECTOR
POSITION LIGHT 2P
IGNITION SWITCH 2P (Black) CONNECTOR
(Bro wn) CONNECTOR
HEADLIGHT 2P
RIGHT SWITCH CLUTCH CABLE (Natu ral) CONNECTOR
8P (Gray) CONNECTOR
1-25
GENERAL INFORMATION
lAT SENSOR 2P (Gray) CONNECTOR ECM

ECM 33P (G ra y) CONNECTOR
ECM 33P (Blaek) CONNECTOR
FUEL HOSE
(
Ij
REGULATOR/RECTIFIER MAIN WIRE HARNESS
lAT SENSOR 2P (Gray) CONNECTOR

IGNITION SWITCH WIRE
~0
~~~~rtr RIGHT HANDLE BAR

-;; SWITCH W IRE
FUEL HOSE COVER MAIN WIRE HARNESS
1-26
GENERAL INFORMATION
ALTERNATOR 3P (Natural ) SIDESTAND SWITCH 2P

CONNECTOR (Green) CONNECTOR
HORNWIRE REGULATOR/RECTIFIER
2P (Natural) CONNECTOR
FAN MOTER 2P (Blaek)

CONNECTOR
CMP SENSOR WIRE
CLUTCH CABLE
SI PH ON HOSE
'-27
GENERAL INFORMATION
FUEL TANK DRAIN HO SE
FUEL HOSE FUEL PUMP 2P I Brow n) CONNECTOR
FUEL TANK BREATHER HOSE

ICalilornia type: to EVAP eanister)
FUEL LEVEL SENSOR

2P IBlaek) CONNECTOR
KNOCK SENSOR GROUND CABLE

3P IBlaek) CONNECTOR
STARTER MOTOR CABLE
ALTERNATOR WIRE
NEUTRAL SWITCH WIRE
SIDESTAND SWITCH WIRE
FUEL TANK DRAIN HOSE
~--,
LOWER COWL
'-28
GENERAL INFORMATION
MAP SENSOR 3P
(Blaek) CONNECTOR
CKP SENSOR 2P
(Blaek) CONNECTOR
IACV 4P (Blaek)
CONNECTOR
Max
22 .5°
GROUND CABLE
PAINTMARKS
PAINTMARK
KNOCK SENSOR
'-29
GENERAL INFORMATION
PAIR CONTROL SOLENOID

HESD 2P I Brown ) CONNECTOR
VALVE 2P IBlaek) CONNECTOR
PAIR CONTROL SOLENOID VALVE
IGNITION SUB HARNESS THROTILE CAB LES

6P I Blaek) CONNECTOR
IGNITION SUB HARNESS
TP SENSOR 3P IBlaek)
CONNECTOR
DIRECT IGNITION COIL
DIRECT IGNITION COIL 2P IWhi!e) CONNECTOR
IACV 4P IBlaek) CONNECTOR
IACV 4P IBlaek) CONNECTOR
TP SENSOR 3P
IBlaek) CONNECTOR
No. 4 PRIMARY INJECTOR

2P IGray) CONNECTOR
No. 1 PRIMARY INJECTOR

2P IGray) CONNECTOR No. 3 PRI INJECTOR
2P IGray) CONNECTOR
KNOCK SENSOR 3P No. 2 PRIMARY INJECTOR

IBlaek) CONNECTOR 2P I Gray) CONNECTOR
1-30
GENERAL INFORMATION
EGCV 6P (Natu ra l) CONNECTOR
FUSE/RELA Y BOX
STARTER RELAY SWITCH
REAR BRAKE LIGHT SWITCH

DLC
TURN SIGNAL RELAY
EGCV CONTROL CABLES

REAR BRAKE LIGHT SWITCH WIR E
1-31
GENERAL INFORMATION
REAR BRAKE LIGHT

SWITCH WIRE
REAR BRAKE HOSE ~-4~~ r-_-'"
J'"
'\
EGCV CONTROL CABLES
'-32
GENERAL INFORMATION
LEFT TURN SIGNAL LIGHT WIRE
RIGHTTURN
SIGNAL LIGHT WIRE BRAKEfTAIULlCENSE
LlGHTWIRE
LEFTTURN SIGNAL
LIGHT W IR E
RIGHTTURN SIGNAL
LIGHT WIRE
BRAKEfTAIULlCENSE -r~L-;;;;;;~~~~;:::-
LlGHTWIRE
1-33
GENERAL INFORMATION
CALIFORNIA TYPE:
NOTE : Face the paint marks upward.
EVAP PURGE CONTROL SOLENOID VALVE (ta fuel tank )
CANISTER-TO-PURGE CONTROL
SOLENOID VALVE HOSE
PAINTMARK EVAP CANISTER
PAINTMARK
EVAP CANISTER DRAIN HOSE

CLAMP
'-34
GENERAL INFORMATION
CALIFORNIA TYPE:
VACUUM HOSES
5-WAY JOINT

Ito EVAP caniste r)
EVAPPURGECONTROL
SOLE NOID VALVE
EVAP PURGE CONTROL SOLENOID VALVE
2P I Blaek) CONN ECTOR
EVAP CANISTER
1-35
GENERAL INFORMATION
EMISSION CONTROL SYSTEMS
EXHAUST EMISSION REQUIREMENT
The U.S. Environmental Protection Agency (EPA), Calilornia Air Resources Board (CARB) and Transport Canada require
manufacturers to certify that their motorcycles comply with applicable exhaust emissions standards during their useful
life, when operated and maintained according to the instructions provided.
NOISE EMISSION REQUIREMENT
The EPA also requires that motorcycles built after January 1, 1983 comply with applicable noise emission standards lor
one year or 3,730 miles (6,000 km) after the time of sale to the ultimate purchaser, when operated and maintained
according to the instructions provided.
WARRANTY COMPLIANCE
Compliance with the terms of the Distributor's Limited Warranty for Honda Motorcycle Emission Control Systems is
necessary in order to keep the emissions system wa rranty in effect.
SOURCE OF EMISSIONS
The combustion process produces carbon monoxide (COl. oxides ol nitrogen (NOx) and hydrocarbons (HC). Control ol
carbon monoxide, oxides of nitrogen and hydrocarbons is very important because, under certain conditions, they rea ct to
form photochemical smog when subject to sunlight. Carbon monoxide does not react in the same way, but it is toxic.
Honda Motor Co., Ltd. utilizes various systems to reduce carbon monoxide and hydrocarbons.
CRANKCASE EMISSION CONTROL SYSTEM
Th e engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere.
Blow-by gas is returned to the combustion chamber through the air cleaner housing and throttle body. (
AIR CLEANER HOU SING
<== FRESH AIR
• BLOW-BY GAS
'-36
GENERAL INFORMATION
EXHAUST EMISSION CONTROL SYSTEM
The exhaust emission contral system is composed of a pulse secondary air supply system , an oxidation catalytic converter
and PGM-FI system.
SECONDARY AIR SUPPL Y SYSTEM
The pulse secondary air supply system introduces filtered air into the exhaust gases in the exhaust port. Fresh air is drawn
into the exhaust port by the function of the PAIR control valve.
This charge of fresh air promotes burning of the unburned exhaust gases and changes a considerable amount of
hydrocarbons and carbon monoxide into relatively harmiess carbon dioxide and water vapor.
The reed valve prevents reverse air flow through the system. The PAIR control valve is operated by the solenoid valve. The
solenaid valve is controlled by the PGM-FI unit, and the fresh air passage is opened/closed according to running conditions
(ECT/IATfTP/MAP senso r and engine revolution).
No adjustments to the secondary air supply system should be made, although periodic inspection of the components is
recommended.
AIR CLEANER HOUSING
BODY
PAIR CONTROL VALVE
PAIR CHECK VALVE
PORT
<== FRESH AIR
• EXHAUST GAS
OXIDATION CATALYTIC CONVERTER

This motorcycle is equipped with an oxidation catalytic converter.
The oxidation cataJytic converter is in the exhaust system . Through chemical reactions, it converts He and CO in the
engine's exhaust to carbon dioxide (CO,) and water vapor.
'-37
GENERAL INFORMATION
EVAPORATIVE EMISSION CONTROL SYSTEM (CALIFORNIA TYPE)
This model complies with California Air Resources Board (CAR B) evaporative emission requirement. Fuel vapor trom the
fuel tank is routed into the evaporative emission (EVAP) canister where it is absorbed and stored while the engine is
stopped . When the engine is running and the evaporative emission (EVAP ) purge contral solenaid valve is open, tuel vapor
in the EVAP canister is drawn into the engine through the throttle body.
EVAP CANISTER
EVAPPURGECONTROL
SOLEN OIO VALVE ~FRESHAIR
THROTILE BODY • FUEL VAPOR
NOISE EMISSION CONTROL SYSTEM

TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: U.S. Federallaw prohibits, or Canadian provincial law
may prohibit the following acts or the causing there of: (1) The remaval or rendering inoperative by any person, other than
for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any vehicle for
the purpose of noise contral prior to its sale or delivery to the ultimate customer or while it is in use; (2) the use of the
vehicle after such device or element of design has been removed or rende red inoperative by any person.
AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS L1STED BELOW:
1. Removal of, or puncturing of the muffler, baffles, header pipes or any other component which conducts exhaust gases.
2. Remaval of, or puncturing of anv part of the intake svstem.
3. Lack of proper maintenance.
4. Replacing anv moving parts of the vehicle, or parts of the exhaust or intake svstem, with parts other than those
specified bV the manufacturer.
1-38
2. TECHNICAL FEATURES
111
IACV· ·············· ············ ········ ·· ··· ······ ········· ····· · 2-2 KNOCK SENSOR .......... ........ .................... .. 2-4
2-1
TECHNICAL FEATURES
IACV
SUMMARY
This motorcycle adopts an electronic Idle Air Control system for the inline-four engine, this system is composed the IACV
and distribution hoses on the throttle body. The IACV consists of a step motor and a slide v alve to control the amount of air
bypassed around the closed throttle valve. With the i9nition switch on, the amount of inlet air is determined trom informa·
tion detected by the ECT sensor. During engine start up or while maintaining idle (throttle valve closed). the amount of
1nlet air is corrected by various sensors' information .
This system eJiminates the need for manual idle speed adjustment and air screw adjustment for throttle body synchroniza-
tion.
DISTRIBUTION HOSES
IACV ------dLc
- -......~ Idle air flow
2-2
TECHNICAL FEATURES
OPERATION
The ECM contrals the IA CV during engine idling, also the ECM stops controlling the IACV operation and closes the valve
when the ECM detects the following conditions:
• Throttle valve open
• Neutral switch OFF (in gear) and clutch switch OFF (release clutch lever)
During engine id ling , from ignition switch ON to warming up, the ECM controls the IACV step motor as follows:
With the ignition switch ON
When the ignition switch is turned ON , the IACV activates initial func-
tion , idle - open - idle position. There wil! be a step motor operating
STEP MOTOR
sound.
Engine start - warming up
This optimizes the bypass opening with the throttie valve closed, and
the correct amount of inlet air passes through, allowing proper engine
start up.
After the engine has started, the ECM controls the IACV slide valve
position and adjusts the amount of inlet air in response to the engine
coolant temperature.
VALVE
After warming up - idling

When the ECM denotes the engine warming up by the engine coolant
temperature, it operates the step motor to move the slide valve to the STEP MOTOR
closed position. This results in a reduced amount of bypassed air com-
pared to the amount during engina warm-up, which allows proper
engina idle to be maintained,
;1
c:>c:>~ VALVE
2-3
TECHNICAL FEATURES
KNOCK SENSOR
SUMMARY
Under certain conditions the mixture in the perimeter of the combustion chamber can self-ignite due to the expansion of
the combusting gas ignited by the spark plug. At this point there are !wo flame-lronts colliding within the combustion
chamber.
As aresui!, the pressure and temperature În the cylinder increase at a time different trom normal-combustion conditions,
causing damage to the piston and/or the combustion chamber. Such a phenomenon is ca lied knocking.
Deteriorated or low-octane gasoline may cause the knocking more frequently, resulting in engine damage.
To detect knocking, the knock sensor is attached in the rear ol NO.3 cylinder block. Monitoring signals Irom the knock sen-
sor, the ECM detects knocking, and prevents engine damage by regulating ignition timing.
In th is model, a non-resonating type knock sensor is employed. With the voltage signa Is tree of resanant characteristics
and the convergence period short, the responsiveness is superb, the knocking signals do not overlap in the high rpm zone,
allowing detection ol knocking.
The non-resonating type knock sensor consists of the base, which is mounted on the cylinder bloek, the weight, and the
piezoelectric element.
The vibrations lrom the cylinder block are directly transmitted to the base. The weight applies the pressure occurring Irom
its inertia force to the piezoelectric element. The pressure is converted to voltage by the piezoelectric element, and trans-
mitted to the ECM. The ECM modilies the voltage signa I wavelorm, separates knocking signals lrom engine naise signais,
and detects knocking.
WEIGHT
PIEZO ~rT",r ELEMENT

FROM CYLINDER
(1) Convecting motion ol the engine to the weight
(2) Pressure Irom the weight
(3) Converted voltage signa I by the piezo electric element
When the ECM determines that the voltage signa I is higher than the prescribed level (knock occurring), it retards the igni-
tion timing. When the ECM determines that the voltage signal is lower than the prescribed level (no knocking) during the
retarded ignition timing period, it gradually advances the ignition timing back to normal.
The ECM has self-diagnostic functions for the knock sensor circuit. It can detect a sensor output line short, failure of the
integrated circuit (IC) within the ECM, and a connector coming aft.
2-4
TECHNICAL FEATURES
IGNITION COILS
~
I Adjusted ignition timing signal
_. KNOCK
SENSOR
(7)
-+- ECM
KNOCK IC CPU
I--
ENGINE Cl
(8)
FILTER
(2)
Y (4)
(5)
- ,---
Y
..
(9)
(1 ) (3) (6)
ECM monitors engine condition

through PGM-FI sensors (ECT .MAP .TP sensor etc .. ,)
(1) Regulate the input voltage signal wave
(2) Noise signal pi ek up circuit
(3) Knock signal piek up circuit
(4) Detect the knock
(5) Calculate proper ignition timing
(6) Detect the fail safe
(7) Input voltage line (for open circuit detection)
(8) Open circuit detection line
(9) Output vo ltage line
2-5
MEMO
(
3. FRAME/BODY PANELS/EXHAUST SYSTEM
..
BODY PANEL LOCATIONS .. ··· .......... ·.... ···· 3-2 REARVIEW MIRROR ·.. ·· ····· ······· ·· ·· ···········3-10
SERVICE INFORMATION ············ ····· ··········3-3 WINDSCREEN ·.. ··········· ····························3-10
TROUBLESHOOTING ................................. 3-3 UPPER COWL/FRONT SPOILER ...... .. ..... 3-11
SEAT················································ ············3-4 AIR DUCT ················· .. ··············· .. ··············3-12
PASSENGER SEAT· .... ·...... ··············· .. ····· .. · 3-4 FRONT FENDER ................ .. .. ...... ............. 3-13
REAR COWL .. ··· .. ······· .. ················ .. ············ .. 3-5 REAR FENDER A· ···· .... ········ .. ······· .. ·········· 3-13
LOWER COWL ··········· .. ······ .. ········ .. ·············3-6 REAR FENDER B······· .. ·.. ········ .. ······· .. ···· ···· 3-14
UPPER INNER COWL/HEADLIGHT REAR FENDER C........ ·.. ·.. ·............ ·.... ·...... 3-16
COVER· .. ·.... ·.... ·...... ·· .. ·........ ·.... ·................ ·· 3-7
SEAT RAIL ............................................... . 3-16
MIDDLE COWL ...... ·.. ·.... ·...................... ·...... 3-8
MUFFLER .... ·.. ·...... · .......................... ·.... ·.. ·3-19
FUEL TANK COVERISIDE COVER ........ ·.... 3-9
EXHAUST PIPE ......................................... 3-24
3-1
FRAME/BODY PANELS/EXHAUST SYSTEM
BODY PANEL LOCATIONS
REARVIEW MIRROR
WINDSCREEN
UPPER COWL
\ FUEL TANK COVER
PASSENGER SEAT
REAR FENDER B
HEADLIGHT COVER
FRONT FENDER
REAR FENDER C
SI DE COVER
,
, , --::::==~ LOWER COWL
MIDDLE COWL
UPPER INNER COWL
3-2
SERVICE INFORMATION
GENERAL
• This section covers remaval and installation of the body panels, exhaust system and seat rail.
• Serious burns may result if the exhaust system is not allowed to cool betore components are remo ved or servieed.
• A lways replace the exhaust pipe gas kets with new ones after removing the exhaust pipe trom the engine.
• When installing the exhaust system, loosely install all of the exhaust pipe fasteners. Always t ighten the exhaust clamps
tirst, then tighten the mounting fasteners .
• A lways inspeet the exhaust system for [eaks after installation.
TORQUE VALUES
Lower cowl-to-middle cowl screw 1.5 N·m 10.2 kgf·m, 1.1 Ibf.ft)
Rearview mirror mounting bolt 7.0 N'm 10.7 kgl·m, 5.2 Ibl·ft)
Windscreen mounting screw 0.45 N'm 10.05 kgl·m, 0.3 Ibf·ft )
Front brake hose damp nut 10 N' m 11.0 kgf·m, 7 Ibl·ft)
Front brake hose 3-way joint bolt 10 N·m 11.0 kgf·m, 7 Ibf·ft)
Front fender mounting screw 12 N·m 11.2 kgf·m , 9Ibf.ft)
Seat rail mounting nut 54 N' m 15.5 kgl·m , 40 Ibf·ft)
Seat ra il mounting bolt 44 N·m 14.5 kgf·m, 32 Ibf.ft)
Seat rail assembly bolt 30 N·m 13.1 kgf·m, 22 Ibf·ft)
Exhaust pipe joint nut 12 N·m 11.2 kgf.m, 9 Ibf.ft)
Exhaust pipe mounting bolt 17 N·m (1.7 kgf.m, 13 Ibl·ft)
Main step bracket mounting bolt 37 N·m (3.8 kgf.m, 27 Ibl·ft)
Passenger step bracket mounting bolt 26 N·m (2.7 kgf.m, 19 Ibl·ft)
Rear master cylinder mounting bolt 12 N'm (1.2 kgf·m, 9Ibf·ft)
Position light mounting screw 1.8 N 'm (0.2 kgf·m, 1.3 Ibl·ft)
Rea r fender bracket mounting bolt 12 N·m (1.2 kgf.m, 9 Ibf·ft)
MuIlIer band bolt 17 N·m (1.7 kgf.m, 13 Ibf·ft)
Air duet mounting bolt 12 N·m (1.2 kgf·m, 9Ibf·ft) ALOC bolt; replace with a new one
TROUBLESHOOTING
Excessive exhau st noise
• Braken exhaust system
• Exhaust gas leak
Poor performance
• Deformed exhaust system
• Exhaust gas leak
• Clogged muIlIer
3-3
SEAT
REMOVAL/INSTALLA TION
Remove the screws, washers and seat rearward .
Install the seat by inserting the prang and aligning SCREWS/WASHERS
its holes with the se at rail bosses.
Tighten the screws securely.
PASS ENGER SEAT

REMOVAL/INSTALLA TlON
Unhook t he passenger seat loek using the ignition
key, IGN ITION KEY PASSENGER SEAT
~
Remove the passenger seat by pulling it forward,
Install the passenger seat in the reverse order of
removal and push down it to loek.
3-4
REAR COWL
REMOVALIINSTALLA TION
Remave the lol lowing :
SCR EWS
- Seat (page 3-4)
- Passenger seat (page 3-4)
Remove the screws, special screws and rear cowl
upward.
Installation is in the reverse order of remaval.
1\
3-5
LOWERCOWL
REMOVALlINSTALLA TION
Remove the lower cowl-to-middle cowl screws.
Release the hoses from the lower cowl.
Be careful not to Aemove the lower cowl screw, collar and special
damage the tabs screws then remove the lower cowl downward.
and graoves.
Ca{ifornia type: Remove the lower cowl screw, col lar, special screws
and clamp then remove the lower cowl downward.
Installation is in the reverse order of removal.
• A lign the midd le cowl tabs with the lower cowl
grooves.
TORQUE:
Lower cowl-to-middle cowl screw:
1.5 N·m (0.2 kgf·m, 1.1Ibf.ft)
Route the hoses properly:
- Except Ca lifornia type (page 1-21)
- California type (page '-34)
COLLAR
NUT
SPECIAL SCREW
SCREW
RIGHT LOWER COWL
Align
3-6
UPPER INNER COWL/HEADLIGHT
COVER
REMOVALlINSTALLATION
Remave the middle cowl (page 3-8) .
Remove the trim clips and upper inner cow!.
TRI M CLIP S
Remave the screw and headlight cover. SCR EW
Route the wires Instal lation is in the reverse order of remaval.

properfy
(page 1-21!.
HEA DLI GHT COVER UPPER IN NER COWL
3-7
MIDDLE COWL
Be careful nor ra Remove the screws, trim clips and middle cowl.
damage the tabs.
Disconneet the turn signallight 3P connector.
Route the wires Installation is in the reve rse order of removal.
properly
TORQUE:
(page 1-21).
Be careful not ta Lower cowl-to-middle cowl screw:
pinch the wires. 1.5 N ·m (0.2 kgf·m, 1.1Ibf.ft)
MIDDLE COWL
SCREWS
3P CONNECTOR
DISASSEMBLY / ASSEMBL Y
MIDDLE COWL A
,/ "
/ FRONT TURN SIGNAL LIGHT
MIDDLE COVER B
MIDDLE COWL B
INNER COWL
3-8
FUEL TANK COVER/SIDE COVER
Remove the following :
FUEL TAN K COVER!
- Seat (page 3-4) SIOE COVER ASSEMBL Y
- M iddle cowls (page 3-8)
- Upper inner cowls (page 3-7) TRIM CLIPS
Remove the screws, grommets, trim clips, collars
and fuel tank cover/side cover assembl y.
Be careful not to Installation is in the reverse order of removal.
pinch rhe wires.
COLLARS
DISASSEMBL Y/ ASSEMBL Y
FUEL TANK COVER

SCREWS
/
RIGHT SIDE COVER
LEFT SIDE COVER
3-9
REARVIEW MIRROR
Remove the balts and rearview mirror.
BOLTS REAR VIEW MIRROR
Install the rearview mirror and tighten the bolts to
the specified torque.
TOROUE: 10 N·m (0.7 kgf·m , 5.2IbHt)
WINDSCREEN
REMOVALIINSTALLATION
Remove t he rearview mirror (page 3-10).
Remove the screws, plastic wa s hers, rubber wash-
j
ers , windscreen and nuts.
Installation is in the reverse order of removal. PLASTIC WASHER
TOROUE: SCREW
RUBBER~~
Windscreen mounting screw:
0.45 N·m (0.05 kgf·m, 0.3 IbHt)
WASH~~ ~ "\i~
..
,.,.\
\,:.
:::,:
.
.
§
WINDSCREEN
3-10
UPPER COWL/FRONT SPOILER
Remove the lollowing:
- Middle cowls (page 3-8)
- Headlight covers (page 3-7)
- Upper inner cowls (page 3-7)
- W indscreen (page 3- 10)
Disconneet the position light 2P (Black) connector.
Remove the mai n wire harness 20P (Gray) connec-
to r trom the front spoiler.
Remove the screws and upper cowl/front spoiler ~=====~~~~~~~~==.

assembly.
Insta llation is in the reverse order of removal.
U PPER COWUFRONT
SPOILER ASS EMBLY
3-11
DISASSEMBLY/ ASSEMBL Y
Remove the screws and position light trom the
upper eow!.
UPPER COWL
Be careful not ra Remove the front spoil er trom the upper cowl.
damage the labs. Assembly is in the reverse order of disassembly.
TOROUE:
Position light mounting screw:
1.8 N·m (0.2 kgf·m , 1.3 IbHt)
SCREWS f!1\...,==~='l~
FRONT SPOILER
AIR DUeT
REMOVAL/INSTALLATION
Remove the combination meter (page 20-8).
Remave the duet attachment and grill trom the air
duet.
Straighten the loek was her tabs.
S ~
BàLT
LOCK WASHER S~
Remove the balts, loek washers and air duet.
Install the air duet and new loek washers then
tighten new balts to the specified torque.
TOROUE: 12 N·m (1.2 kgf·m , 9 IbHt)
Bend the loek was her tabs up against the air duet
mounting balts securely.
Install the grill and duet attaehment seeurely.
Install the combination meter (page 20-10) .
DUCT AITACHMENT
3-12
FRONT FENDER
Remave the front brake hose 3-way joint bolt and
hose clamp nut.
Remove the screws, grommets, collars , reflectors
and front fender from the fork legs.
NUT
NOTE : FRONT FENDER
o Pull the front fender up and then pull it forward
between the fork legs.
o Be careful not to damage the fork legs .

TORQUE:
Front fender mounting screw:
12 N·m (1.2 kgf·m, 9 Ibf·ft)
Front brake hose clamp nut:
10 N·m (1 .0 kgf·m, 7 Ibf·ft)
Front brake hose 3-way joint bolt:
10 N·m (1.0 kgf·m, 7 Ibf·ft)
REFLECTOR
SCREWS/GROMMETS
REAR FENDER A
REMOVALlINSTAlLATION
Remave the rear cow l (page 3-5).
Disconneet the brakeltail and turn signal light con-
nectors.
Remave the balts, reflectors and rear fender A
assembly rearward .
InstaJlation is in the reverse order of removal.
REAR FENDER A ASSEMBLY

DISASSEMBL Y/ ASSEMBLY
BRAKEfTAIULlCENSE LIGHT
HEAT GUARD
REA R FENDER A
REAR TUR N SIGNAL LIGHT

FENDER STAY
REAR FENDER B
REMOVAL
Remove the follow ing :
- Rear cowl (page 3-5)
- Battery (page 17-6)
- Fu el tank (page 6-50)
- EGCV servomotor (page 6-80)
- Starter relay switch (page 19-14)
Remave the balts, passenger seat hooks and pas-
senger seat bracket.
Remove the heat gua rd mou nting screw.

SCREW
3-14
Release the rear brake light switch 2P (Black) con-
nector trom the rear fender 8.
Release the wire harnesses trom the rear fender 8.
Remave the trim clips, screw and rear fender B.
INSTALLATION
Route the wires Installation is in the reverse ord er of remaval.
properly
(page 1-21).
REAR FENDER B
PASSENGER SEAT BRACKET
SCREW
/
3-15
REAR FENDER C
REMOVAL/INSTALLA TlON
Remave Ihe special screws, rear fend e r C and brake ' S-P-E-C-IA
- L-S-C-RE- W
- S- - - - - - - - - - - - - ,
hose guide trom the swingarm.
Inslall Ihe brake hase guide by aligning ils lab la Ihe ~
swingarm hole.
Inslall Ihe rear fender C and lighlen Ihe special
screws securely,
REAR FENDER C BRAKE HOSE GUlDE
SEAT RAIL
REMOVAL
Remave Ihe fallawing:
- Fu el lank (page 6-50)
- Muftier (page 3- 19)
- Rear fender A (page 3-13)
- Rea r fender B (page 3-14)
Remave Ihe balls and left passenger slep bracket.
LEFT PASS ENGER STEP BRACKET

Remave Ihe baiIs, nuls and se al rail.
3-16
DISASSEMBL Y
Remave the balts.
BOLTS
Remave the balts and rear fender bracket.

Separate the seat rail.
REAR FENDER BRACKET BOLTS

Remove the dowel pin from the seat rail.
DOWELPIN
3-17
ASSEMBLY
30 N'm (3.1 kgf.m , 22 IbHt)
REAR FENDER BRACKET
lEFT PASSENGER
54 N·m (5.5 kgf·m , 40 IbHt)
STEP BRACKET
12 N·m (1.2 kgf·m , 9 Ibf·ft) 44 N·m (4.5 kgf·m, 32 Ibf.ft)
Install the dowel pi n onto the seat rail and assem bie
the seat rail.
BOlTS
Tighten the seat rail assembly balts to the specified

torque.
TORQUE: 30 N·m (3.1 kgf·m, 22 Ibf·ft)
DOWEl PIN
Install the rear fender bracket and balts temporarily.
REAR FENDER BRACKET BOlTS
3-18
INSTALLATION
Install the seat rail, balts and nuts.
Tighten the balts and nuts to the specified torque.
-
TORQUE:
Seat rail mounting bolt:
44 N·m (4.5 kgf·m, 32 Ibf·ft)
Seat rail mounting nut:
54 N ·m (5 .5 kgf·m , 40 Ibf·ft)
Tighten th e rear fender bracket mounting balts to

t he specified t orque.
TORQUE: 12 N ·m (1 .2 kgf· m , 9Ibf·ft)
Install the left passenger step bracket and t ighten

the balts to the specified torque.
TORQUE: 26 N·m (2.7 kgf.m, 19 Ibf·ft)

Install th e following:
- Rear fender B (page 3-15)
~ I
- Rea r fender A (page 3- 13)
Muftier (pag e 3-22)
- Fuel ta nk (page 6-50)
LEFT PASS ENG ER STEP BRACKET
MUFFLER
REMOVAL
Remove th e foll owing:
- Rea r fender A (page 3-13)
- Right passenge r step b racket (page 16-19)
Un hook th e rear brake light switch spring from th e
brake pedal.
Remove the rea r brake light switch.
SPRI NG BRAKE PEDAL
3-1 9
Keep the rear Remove the bolt and rear brake reserve tank.
reserve tank upright SCREW
Remove the heat guard mounting screw and
to prevent air from
washer.
entering the RESERVE
hydraufic system. Remove the bolts and right main step/heat guard TANK
assembly as shown .
RIGHT MAIN STEP/HEAT

GUARD ASSEMBl Y
BOlTS
Remave the screws, muffler rear cover, rubber

washers and collars.
REAR COVER
Remove the screW5 and muffler rear cap.
3-20
leesen the muftier band belt.
Remeve the beits and muftier.

BOlTS
MUFFlER
Remove the screw, bolt and heat guard.
3-21
INSTALLATION
HEAT GUARD
REAR COVER
MUFFLER REAR CAP
26 N·m (2.7 kgl·m, 19Ibl·ft)
MUFFLER
37 N·m (3.8 kgl·m, 27 Ibl·ft)
Install th e heat guard and tighten the screw and bolt

securely.
Install a new gasket onto the exhaust pipe and ~~;:;

install the muffler anto th e exhaust pip e.
3-22
Install the muftier and bolts.
BOLTS
Tighten the bolts securely.
Tighten the muftier band bolt to the specified

torque.
TORQUE: 17 N·m (1 .7 kgf·m , 13Ibf.ft)
Install the muftier rear cap and tighten the screws

securely.
Install the rubber washers and collars onto the muf-

fier rear cover.
Install the muffler rear cover and tighten the screws
securely.
REAR COVER
3-23
Install the right main step/heat guard assembly as
shown and tighten the main step mounting balts to
the specified torque. SCREW/WASHER
TOROUE: 37 N·m (3.8 kgf·m , 27 Ibf.ft)
Install the heat guard mounting screw and washer,
then tighten it securely.
Install th e rear brake reserve tank and tighten the
bolt to the specified torque.
TOROUE: 12 N·m (1 .2 kgf·m, 9 Ibf·tt)
RIGHTMAIN STEP/HEAT
BOlTS GUARD ASSEMBl Y
Route the wires Install the rear brake light switch.

properly
Hook the rear brake light switch spring to the brake
(page 1-2 11.
pedal.
Install the following:
- Rig ht passenger step bracket (page ' 6-24)
- Rea r fende r A (page 3-'3)
SPRING BRAKE PEDAl
EXHAUST PIPE
REMOVAL
Remove the following:
- l ower cowl (page 3-6)
_ Right main step/heat guard assembly (page 3-19)
Lift and support the fuel tank (page 4-5).
Remove the nut, bolt and washer.
Move the radiator forward.
3-24
Loosen the muffler band bolt.
Remo ve the exhaust pipe joint nuts .
Remove the nuts, bolts and EGCV cove r.

' .;;j
Loosen the loek nuts tully and disconneet the EGCV .
control cables trom the pulley.
COVER CONTROL CABLES
Remove the bolt, washer, collar and exhaust pipe.
3-25
Remove the exhaust pipe gaskets.
INSTALLATION
EXHAUST PIPE
12 N·m (1.2 kgf·m, 9 IbHt)
17 N'm (1.7 kgf·m, 13 Ibf·ft )

Check the exhaust pipe stud protrusion from th e
EXHAUST PIPE STUD
exhaust port.
SPECIFIED LENGTH: 45.0 - 46.0 mm (1.77 - 1.81 in) ~ r

I I1 I 11 1 ~
l
45.0 - 46.0 mm
(1.77 -1.81 in)
-
3-26
A/ways replace the Install new exhaust pipe gaskets anto the exhaust
exhaust pipe ports of the cylinder head.
gaskets with new
ones.
Install a new gasket onto the exhaust pipe and

install the exhaust pipe into the muffler and cylinder
head.
Loosely install the exhaust pipe, colla r and mount-

ing bolt/was her.
Tighten the exhaust pipe joint nuts to the specified

torque.
TORQUE: 12 N·m (1.2 kgf·m, 9 IbHt)
3-27
Tighten the exhaust pipe mounting bolt to the spec-
ilied torque.
Tighten the muIlIer band bolt to the specilied

torque.
TORQUE: 17 N·m (1 .7 kgf·m, 13 Ibf·ft)
Con neet the EGCV control cables to the pulley and

tighten the loek nuts securely.
Adjust the EGCV control cab le (page 4-23).
Install the EGCV cover, balts and tighten the nuts
securely.
PULLEY CONTROL CABLES COVER

Install the radiator lower mounting bolt, washer and
nut.
Tighten the nut securely.
Remave the suitable support and close the luel tank
(page 4-6).
Install the lollowing:
- Lower cowl (page 3-6)
- Right main step/heat guard assembly (page 3-24)
3-28
4. MAINTENANCE
•
SERVICE INFORMATION ···························4·2 EGCV CABLE ............................. ......... ...... 4·22
MAINTENANCE SCHEDULE ........ .............. 4·4 DRIVE CHAIN .. ·· ··· ······ ····· ········ ·· ········ ········ 4·23
FUEL LlNE ............ .... .......... ..................... .... 4·5 BRAKE FLUID .... .... .... ..... ......... ........ ..... .... 4·28
THROTTLE OPERATION· .. ·························· 4·8 BRAKE PADS WEAR ... .. ....... .... .. .............. 4·29
AIR CLEANER···················· ·························· 4·8 BRAKE SYSTEM ..... ...... ............. ..... .......... 4·30
SPARK PLUG ············································· ·4·9 BRAKE LIGHT SWITCH ... ........ .... ..... ........ 4·31
VALVE CLEARANCE··························· ······ 4·13 HEADLIGHT AlM .... .................................. 4·31
ENGINE OIL/OIL FILTER ·· ························ 4·17 CLUTCH SYSTEM ········ ·· ··········· ····· ··········4·31
RADIATOR COOLANT .............................. 4·19 SIDESTAND ........... .. ..... .. ......... ................. 4·32
COOLING SYSTEM .. ································· 4·20 SUSPENSION ........................................... 4·32
SECONDARY AIR SUPPLY SYSTEM·······4·20 NUTS, BOLTS, FASTENERS· .. ················· 4·35
EVAPORATIVE EMISSION CONTROL WHEELS/TIRES ..... ........ .. .. ........ ............... 4·35

SYSTEM (CALIFORNIA TYPE) ......... ........ 4·21
STEERING HEAO BEARINGS ....... ........... 4·36
4-1
MAINTENANCE
SERVICE INFORMATION
GENERAL
• Place the motorcycle on level ground befere starting any work .
• The exhaust contains poisonous carbon monoxide gas that may cause 1055 of consciousness and may lead to death .
Run the engine in an open area or with an exhaust evacuation system in and enclosed area.
SPECIFICATIONS
ITEM SPECIFICATIONS
Throttle grip freeplay 2 4mm(1 / 16 3/ 16 in)
Spark plug ) NGK IMR9C-9HES
) OENSO VUH270
Spark plug gap 0.80 0.90 mm (0.03 1 0.035 in )
Valve clearance IN 0.20 ± 0.03 mm (0.008 + 0.001 in )
EX 0.28 ± 0.03 mm (0.011 + 0.001 in )
Engine Dil capacity After draining 2.7 liter (2.9 US qt, 204 Imp qt)
After oil filter change 2.8 liter (3.0 US qt, 2.5 Imp qt)
Recomm ended engine oi! Pro Honda GN4 4-stroke oil (U.S.A. and Canada) or equiv-
alent motor Dil
APr service classification: SG or Higher
JASO T 903 standard: MA
Recommended antifreeze Pro Honda HP Coolant or an equivalent high quality ethyl-
ene glycol antifreeze contain ing silicate free corrosion
inhibitors
Drive chain Size/link OIO OIO 525HV KAI- 112YB
) RK RK 525ROZ6 - 112LJFZ
Slack 30 - 40 mm (1.2 1.6 in )
Reco mmended brake fluid DOT4
Clutch lever freeplay 10 - 20 mm (3/8 - 13/16 in)
Tire slze Front 120/70 ZR 17 M/C (58W)
Rear 180/55 ZR 17 M/C (73W)
Tire brand Bridgestone Front BT015F RADIAL E
Rear BT015R RADIAL E
Ounlop Front Oualifier PTG
Rear Oualifier PTG
eold ti re pressure Dri ver only Front 250 kPa (2 .50 kgf/cm ', 36 psi)
Rear 290 kPa (2.90 kgf/cm ' , 42 psi)
Driver and Front 250 kPa (2.50 kgf/cm ' , 36 psi)
passenger Rear 290 kPa (2.90 kgf/cm ' , 42 psi)
Minimum tire tread depth Front 1.5 mm (0.06 in)
Rear 2.0 mm (0.08 in)
TORQUE VALUES
Spark plug 16 N'm (1.6 kgfm, 12Ibf·ft)
Timing hole cap 18 N·m (1.8 kgfm, 13 Ibfft) Apply grease to th e threads
Oil drain bolt 30 N·m (3. 1 kgf·m, 22 Ibf·ft)
Oil filter cartridge 26 N'm (2.7 kgfm, 19 Ibf·ft) Apply oil to the a-ring
Rear axle nut 113 N·m (11.5 kgf·m , 83 Ibf·ft) U-nut
Drive sprocket bolt 54 N·m (5.5 kgf·m, 40 Ibf·ft)
DrÎ ven sproeket nut 64 N'm (6.5 kgfm, 47 Ibf·ft) U-nut
Rear master cylinder push rod loek nut 18 N·m (1.8 kgfm, 13 Ibfft)
Fuel tank mounting bolt 30 N·m (3. 1 kgf·m, 22 Ibf·ft)
Air cleaner element mounting screw 4.2 N·m (004 kgfm, 3.1 Ibf·ft)
Sidestand pivot bolt 10 N'm (1.0 kgfm, 7 Ibf·ft)
Sidestand pivot nut 29 N·m (3.0 kgf·m, 21 Ibf·ft)
ECM setting plate screw 0.7 N·m (0.07 kgf'm, 0.5 Ibf·ft)
4-2
MAINTENANCE
TOOLS
Oil filter wrench Dri ve chain tooi set SCS connector

07HAA-PJ70101 07HMH-MR10l03 070PZ-ZY30100
or 07AAA-PLCA100 (U.S.A. only) or 07HMH-M R101OC (U.S.A. only)
4-3
MAINTENANCE
MAINTENANCE SCHEDULE
Perform the Pre-ride inspection in the Owner 's ManuaJ at each scheduled maintenance periad.
I: Inspeet and Clean , Adjust, lubricate or Replace if necessary. C: Clean . R: Replace. A: Adjust. l: lubricate .
The following items require some mechanica! knowiedge. Certain items (particularly those marked * and **) may require
more technical information and tools. Consult an authorized Honda dealer.
FREQUENCY WHICHEVER
COMES FIRST q ODOMETER READING (NOTE 1) REFERTO
ITEMS 0 Xl,OOO mi 0.6

Xl00 km 10
4 8 12 16 20
64 128 192 256 320 384
24 PAGE
* FUEl LlNE I I I 4-5

* THROTTlE OPERATION I I I 4-8
* AIR CLEANER NOTE2 I I 4-8
Ul
~ * SPARK PLUG EVERY 16,000 mi (25,600 km)l,
4-9
LJ.J EVERY 32,000 mi (51,200 km) R
t:: * VAlVE CLEARANCE I 1 4-13
0
LJ.J ENGINE Oll INITIAl = 600 mi (1,000 km) or
~
LJ.J
1 month : R,
REGUlAR = EVERY 8,000 mi
4-17
a: (12,800 km) or 12 months: R
z ENGINE Oll FilTER R R R R 4-17
0
Ul RADIATOR COOLANT NOTE4 I I R 4-19
Ul COOLING SYSTEM
* I I I 4-20
~
LJ.J * SECONDARY AIR SUPPlY SYSTEM I I I 4-20
* EVAPORATIVE EMISSION
NOTE3 I I 4-21
CONTROL SYSTEM
** EGCV CABlE EVERY 16,000 mi (25,600 km)1 4-22
Ul DRIVE CHAIN EVERY 500 m i (800 km)l, l 4-23
~ BRAKE FlUID NOTE4 4-28
I I R I I R
~ BRAKE PADS WEAR I I I I I I 4-29
0
BRAKE SYSTEM I I I I 4-30
~
LJ.J
* BRAKE LI GHT SWITCH I I I 4-31
a: * HEADLIGHT AlM I I I 4-31
Z ClUTCH SYSTEM I I I I I I I 4-31
0
üi SIDESTAND I I I 4-32
Ul
:;, * SUSPENSION I I I 4-32
"I * NUTS, BOlTS, FASTENERS I I I I 4-35
z ** WHEElSfTlRES I I I 4-35
0
z •• STEERING HEAD BEARINGS I I I I 4-36
* Should be serviced by an authorized Honda dealer, unless th e owner has proper tools and service data and is
mechanically qualified.
** In the interest of safety, we recommended these items be servi ced only by an authorized Honda dealer
NOTES:
1. At higher odometer reading, repeat at the frequency interval established here.
2. Service more frequently when riding in unusually wet or dusty areas.
3. California type only.
4. Replace every 2 years, or at indicated odometer interval, whichever comes fjrst. Replacement requi re s mechanical ski lI .
4-4
MAINTENANCE
FUEL L1NE
FUEL TANK LlFTING
Remove the fuel tank cover (page 3-9).
Except cafifornia Release the tuel tank breather and drain hoses. DRAIN HOSE
type:
Ca/ifornia type: Release the tuel tank drain hose .
Remove the tuel tank mounting balts and washers.
Ca/ilorni. type: Disconnect the fuel tank breather hose (to EVAP r--:______- - - - - - - - - - - - - - - - ,
canister) from the hose joint. California type shown:
BREATHER HOSE
HOSE JOINT
4-5
MAINTENANCE
Lift the lront end ol the luel tank and support it
using a suitable support as shown.
INSPECTION
Check the luel lines lor deterioration, damage or
leakage. Replace the luel line il necessary. FUEL RAIL
Check the luel rails and luel line joint lor damage or
leakage. Replace them il necessary.
Check the luel pump mounting area lor leakage.
Replace the luel pump packings il necessary.
Check the primary/secondary injectors lor damage
or leakage. Replace them il necessary.
FUEL HOSE
FUEL TANK LOWERING
Remave a suitable support.
Guide the breather Lower the luel tank, leading the breather hose and
hose and drain drain hose to downward. Then close the luel tank
hose 50 as not to and route the breather and drain hoses.
be kinked or bound.
NOTE:
• Route the hoses properly Ipage 1-21).
• Be careful not to damage the harness and hoses.
• After installing the luel tank, make sure the
breather, drain and fuel hoses are not kinked or
bound.
4-6
MAINTENANCE
Californ ia type: Conneet the tuel tank breather hose (to EVA? canis-
ter) to the hose joint securely. California type shown:
BREATHER HOSE
HOSE JOINT
Install the washers and fuel tank mounting bolts.

Tighten the bolts to the specified torque.
TORQUE: 30 N ·m (3.1 kgf'm, 22 Ibf·ft)
Route the hoses Install the removed parts in the reverse order of
BREATHER HOSE
properly removal. DRAIN HOSE
(page 1-27).
4-7
MAINTENANCE
THROTTLE OPERATION
Check for smooth throttle grip full opening and
au tomatic full dasing in all stee ring positions.
Check the throttle cables and replace them if they
are deteriorated, ki nked or dam ag ed.
Lubricate the throttle cables, if throttle operation is
not smooth.
Measure the f reeplay at the throttle grip flange.
FREEPLAY: 2 - 4 mm (1 / 16 - 3116 in)
Throttle g rip freeplay can be adjusted at either end

of the throttle cabie.
Minor adjustment is made with the upper adjuster.
Adjust the freeplay by loosening the loek nut and
turning the adjuster.
After adjustment, tighten the loek nut securely.
Major adj ustment is made with the lower adjuster.

Remove the air cleaner housing (page 6-52).
Adjust the freeplay by loosening the loek nut and
turn ing the adjuster.
After adjustment, t ighten the loek nut securely.
Recheek th e throttl e operation.
Replace any damaged parts, if necessary.
In sta ll the removed parts in the reverse order of
removal.
AIR CLEANER
Remove the fuel tank cove r (page 3-9).
Di scon neet the lAT sensor 2P (Gray) connector.
Remove the screws and ECM setting plate.
4-8
MAINTENANCE
Be careful not to Remave the screws and air cleaner housing upper
damage 'he ECM cover by pulling up the ECM with connectors con-
and wires. nected .
Loasen the screws and remove the air cleaner ele-

ment as shown. AIR CLEANER ELEMENT SCREWS
Clean th e air cleaner element using compressed air

trom the throttle body si de any tim e it is excessively
dirty.
Installation is in th e reverse order of remaval.
TORQUE:
Air cleaner element mounting screw:
4.2 N·m (0.4 kgf·m. 3.1 Ibf·ft)
ECM setting plate screw:
0.7 N·m (0.07 kgf·m. 0.5 Ibf·ft)
SPARK PLUG
REMOVAL
Remove the middle eowls (page 3-8).
Remave the screw and water pipe guard.
Remave the hom wire clamp and disconnect the fan
motor 2P (Blaek) connector.
4-9
MAINTENANCE
Remove the radiator lower mounting bolt, was her
and nut.
Remave the radiator upper mounting bolt and

washer.
8e careful not to Rel ease the radiator grom met trom the frame boss
damage the radiator by moving the radiator to the rig ht, then move the
fins and radiator rad iato r downward .
hOSBS.
Disconneet the direct ig nition coil 2P (White) con-

nectors.
Remove the direct ignition coils trom the spa rk
plugs.
Clean around the Remove th e spark plug using the equipped spark
spark plug bases plug wrench or an equivalent.
with compressed
air betore Inspeet or replace as described in the maintenance
schedule (page 4-4).
removing, and be
sure thar no debris
is allo wed to enter
the combustion
chamber.
4-10
MAINTENANCE
INSPECTION
Check the following and repla ce if necessary Irec- ~C-
E-N-T-E-R-----------S-
ID
-E---~
ommended spark plug: page 4-2) ELECTRODE ---";;:1)..."'- ELECTRODE

• Insulator tor damage
• Electrodes tor wear
• Burning condition, coloration
This motorcycle 's If the electrodes are contaminated with accumu-
spark plug is lated objects or dirt, replace the spark plug . INSULATOR
equipped wirh an
iridium center
electrode. Rep/ace
the spark plug if the
e/ectrodes are
conraminared.
A/ways USB Replace the plug if the center electrode is rounded

specified spark as shown in the illustration.
ROUNDED ELECTRODE
plugs on this
motorcycle. SPECIFIED SPARK PLUG:
NGK: IMR9C-9HES
DENSO: VUH27D
To pre vent Check the spark plug gap between the center and
WIRE TYPE FEELER GAUGE
o x
damaging the si de electrodes with a wire type teeier gauge.
iridium center
Make sure th at the $ 1.0 mm 10.04 in ) plug gauge
electrode, use a
does not insert between the gap.
wirs type fee/er
gauge to check the
spark plug gap.
Do not adjust the If the gauge can be inserted ;nto the gap, replace the
spark plug gap. If plug with a new one.
the gap is out of
specificarion,
rep/ace with a new
one.
INSTALLATION
Install and hand tighten the spark plug to the cylin-
der head, then tighten the spark plug to the speci-
fied torque.
TORQUE: 16 N·m (1 .6 kgf·m, 12Ibf.ft)
,
4-11
MAINTENANCE
Install the direct ignition coils.
Connect the direct ignition coil 2P (White) connec-
tors correctly.
Be carefuJnot to Install the radiator by aligning the grommet and

damage the radiator frame boss.
fins.
Install the washer and radiator upper mounting bolt.
Install the radiator lower mounting bolt, washer and

nut.
Install the water pipe guard and tighten the screw

securely.
~~~~ii~i~
Install the horn wire clamp and connect the fan
motor 2P (Black) connector.
Install the middle cowls (page 3-8).
4-12
MAINTENANCE
VALVE CLEARANCE
INSPECTION
NOTE:
Check the engine idle speed (page 6-67) after the
valve cleara nce inspection.
Inspeet and adjust Remave the cylinder head cover (page 9-7).
the va/ve clearance
Remave the timing hole cap and O-ring .
while the engine is
co/d (be/ow 35"C/
95°F).
Turn the crankshaft clockwise, align the "T" mark

with the index ma rk on the right crankcase cover.
The timing marks ("IN" and "EX ") on the cam

sprockets must be I lush with the cylinder head CYLINDER HEAO UPPER SURFACE
upper surface and facing outward as shown ,
If the ti ming ma rks on th e cam sp rockets are facing
inward, turn the crankshaft clo ckwise one tuil turn
(360°) and realign the timing marks with the cylin-
der head surface sa they are fa cing outward.
TIMING MARKS
Insert the Ieeier gauge between the valve lifter and

cam lobe. NO.3 INTAKE VALVES
Record the Check the valve clearance lor the NO.1 and NO.3 cyl -
clearance for eacll inder intake valves using a tee ier gauge.
va/ve for reference
in shim se/ection if VALVE CLEARANCE:
adjustment is IN: 0.20 ± 0.03 mm (0.008 ± 0.001 in)
required.
4-1 3
MAINTENANCE
Turn the crankshaft clockwise 1/2 turn (180' ). align
the index line sa that it is facing up as shown.
Record the Check t he va lve clea rance fo r the NO.2 and NO.4 cyl-
clearance foreach inder exhaust va lves usi ng a teeier gauge.
va/ve for reference
in shim selection if VALVE CLEARANCE:
adjustment is EX: 0.28 ± 0.03 mm (0.011 ± 0.001 in )
required.
NO.2 EXHA UST VALVES
Tu rn the cra nks haft cloc kwise 1/2 t urn (180' ). alig n
th e "T" m ark with the index m ark on th e right crank-
case cove r.
Record rhe Check the valve clea rance for the NO.2 and NO.4 cyl-
cfearance foreach inder intake va lves using teeier gauge.
vafve for reference
in shim selection if VALVE CLEARANCE:
adjustment is IN: 0.20 ± 0.03 mm (0.008 ± 0.001 in)
required.
4-14
MAINTENANCE
Turn the crankshaft clockwise 1/2 turn (180' !. align
the index !ine 50 that it is facing up as shown.
Rocord the Check the valve clearance tor the NO.1 and NO.3 cyl- ~~~~~~~~~~~~~~~~~~~~
clearance foreach inder exhaust valves using a teeier gauge.
va/va for reference
in shim seloc/lon if VALVE CLEARANCE:
adjustment is EX: 0.28 ± 0.03 mm (0.011 ± 0.001 in)
required.
NO .1 EXHAUST VALVES
ADJUSTMENT
It is not necessary Remove the camshafts (page 9-9) .
ra remove the cam
Remove the valve lifters and shims.
sprocket (rom the
camshah except • The shim may stick to the inside of the valve
when replacing the lifter. Do not allow the shims to tall into the
camshafr and/or crankcase.
cam sprocket. • Mark all valve lifters and shims to ensure correct
reassembly in their original locations.
• The valve lifter can be easily removed with a
valve lapping taal or magnet.
• The shims can be easily removed w ith a twee-
zers or mag net.
Clean the va lve shim contact area in the va lve lifter

with compressed air. VALVE LIFTER
4-15
MAINTENANCE
Sixty·nine different Measure the shim thickness and record it.
thickness shims are SHIM
Calculate the new shim thickness using the equa-
avaiJable trom the
t ion bel ow.
thinnest 1.200 mm
A~(B-CI+D
thickness shim ta
A: New shim thickness
the thickest 2.900
B: Reco rd ed valve clearance
mm thickness shim
C: Specified valve clearance
in increments of
D: aid shim thickness
0.025 mmo
• Make sure of the co rrect shim thickness by mea-
su ri ng the shim by micrometer .
• Reface the va lve seat if carbon deposit result in a
calculated dimension of over 2.900 mm o
eeee
1.80 mm 1.825 m m 1. 85 mm 1.875 mm
Insta!! rhe shims In stall the newJy selected shim on the valve spring
and va/ve lifters in reta i ner.
theiroriginal App ly molybdenum disu lfide Di l t o th e valve lifters
loeations. sliding surface.
Instal! the valve lifters into the valve li fter holes.
Instal! the camshafts (page 9-28).
Rotate the ca mshafts by rotating the crankshaft
clockwise several times.
Recheek the va lve clea rance.
Apply oi l to a new a-ring and instal! it to the timing

hole cap.
Apply grease to the timing hole cap threads.
Tig hten the timing ho le cap to the specified torque.
TORQUE: 18 N·m (1.8 kgf·m , 13 Ibl·ft)
Instal! the removed parts in the reverse order of

removal.
4-16
MAINTENANCE
ENGINE Oll/Oll FilTER
Dil lEVEL INSPECTIDN
Start the engine and let it idle for 3 - 5 minutes.
UPPER lEVEL L1NE
Stop the engine and wait 2 - 3 minutes.
Ho ld the motorcycle in an upright position. ij'/
Check the oi llevel t hrough the inspection window.

If the level is below the lower level line, remove the
oil filler cap and fill the crankcase with the recom -
mended o il up to the upper lev el line as following
procedures:
Remove the oil filler cap and fill the recommended
engine oi l up to the upper level line.
Oll FlllER CAP

Other viscosities RECOMMENDED ENGINE Oll:
shown in the chart Pro Honda GN4 4-stroke oil (U.S.A. and Canada) or
may be used when equivalent motor oil
the average API service classification: SG or Higher
temperature in your JASO T 903 standard: MA
riding Brea is within Viscosity: SAE 10W-30
the indicated range.
Reinstall the oil filler cap.
120· F
ENGINE Dil & FilTER CHANGE

Remove the lower cowl (page 3-6).
Ho ld the motorcycle in an upright position.
Remove the oi l filler cap.
Remave th e drain bo lt and sealing washer, d rain the

oil completely.
SEALING WASHER DRAIN BOLT
4-17
MAINTENANCE
Remove the Dil filter cartridge using the special taal.
TOOl:
Dil filter wrench 07HAA-PJ70101 or
07AAA·PLCA100
(U.S.A. only)
Install a new sealing washer onto the drain bolt.

Tighten the drain bolt to the specilied torque.
TORQUE: 30 N·m (3.1 kgl·m, 22 Ibl·ft)
....
~~
SEALING WASHER DRAIN BOLT
Check that the oil lilter boss protrusion Irom the ,-
O-Il- F-I l-T-E-R- B
-O-S
- S- - - - - - - n - - - - - - ,
crankcase is specified length as shown. ~
SPECIFIED LENGTH: 16.0 -17.0 mm (0.63 - 0.67 in)
16.0-17.0mm
(0.63 - 0.67 in)
Apply oil to new oil lilter cartridge threads and 0- ~:::;;:----:;;;;;::=:;=::::::::::~~:;:,
ring.
4-18
MAINTENANCE
Install the oil li lter cartridge and tighten it to the
specified torque.
TOOl:
Oil lilter wrench 07HAA-PJ70101 or
07AAA-PlCA 100
(U .S.A. only)
TORQUE: 26 N ·m (2.7 kgl·m, 19 Ibl·ft)
Fill the crankcase with recommended engine oil.
ENGINE Oll CAPACITY:

2.7 liter (2.9 US qt, 2.41mp qt) after draining
2.8 liter (3.0 US qt, 2.51mp qt) after oil lilter change
Check th at the O-ring on the oil lil Ier cap is in good
condit ion, and replace it if necessary.
Install the oil lil Ier cap.
Sta rt the engine and let it idle lor 3 - 5 minutes.
Stop th e eng in e and wait 2 - 3 m inutes and recheek
the oil level.
Check that there are no oil leaks.
Insta ll the lower cowl (page 3-6).
RADIATOR COOLANT
Check the coo lant level ol the reserve tank with the
engine running at narmal operating temperature.
Left si de:
The level shou ld be between the "U PPER " and

"LOWER " level !ines.
If necessary, add recommended coo lant.
RECOMMENDED ANTIFREEZE:
Pro Honda HP Coolant or an equivalent high qual-
ity ethylene glycol antifreeze containing silicate
tree corrosion inhibitors
Remave the lower cowl (page 3-6).

Remave the reserve tank filler cap and lill to the
"UPPER" levelline with 1:1 mixture of distilled water FllLER CAP l OWER lEVEL lINE
and antifreeze. " - - - - - - - - - - - -- ------'
Reinstall the lilier cap.

Install the lower cowl (page 3-6).
4-19
MAINTENANCE
COOLING SYSTEM
Remave the following:
Check the radiator air passages for clogging or dam-
age.
Straighten bent fins , and re move insects, mud or
other obstructions with compressed air or low
water pressure.
Replace the radiator if the air flow is restricted over
more than 20 % ot the radiating surface.
Inspect the water hoses tor cracks or deterioration,

and replace them it necessary.
Check the tightness of all hose clamps and fasten-
ers.
SECONDARY AIR SUPPLY SYSTEM

• This model is equipped with a built-in secondary
air supply system. The pulse secondary air sup- CYLINDER HEAO COVER
ply system is located on the cylinder head cover. PAIR CHECK VALVE
• The secondary air supply system introduces fil-
tered air inta exhaust gases in the exhaust port.
The secondary air is drawn into the exhaust port
whenever there is negative pressure pulse in the
exhaust system. This charged secondary air pro-
motes burning of the unburned exhaust gases
and changes a considerable amount of hydrocar-
bons and carbon monoxide inta relatively harm-
less carbon dioxide and water.
Remave the air cleaner housing (page 6-52).
11 ,he hoses show Check th e PAIR hoses between the PAIR control
any signs of heat solen aid valve and cylinder head cove r for deterio-
damage, inspeet ration , damage or loose connections. Make sure
the PAIR check th at the hoses are not cracked.
vafves for damage.
EXHAUST PORT
4-20
MAINTENANCE
Check the air suction hose between th e air cleaner
housing and PAIR control solenaid valve for deteri o-
ration, damage or loose connections.
Check th at the hoses are not kinked, pinched or
cracked.
EVAPORATIVE EMISSION CONTROL

SYSTEM (CALIFORNIA TYPE)
Check the hoses between the luel tank, EVAP canis-
ter, EVA P purge control solenoid va lve for deteriora-
tion, damage or loase connection.
Check the EVAP canister lor clacks or other damage.
Reler to th e Cable & Harness Routing lor hose con-
nectio ns (page 1-34).
SOLENO ID VALVE
EVAP CANISTER
4-21
MAINTENANCE
EGCV CABLE
OPERATING INSPECTION
Remave the lollowing:
- Seat (page 3-4)
- lower cowl (page 3-6)
Remave the balts, nuts and EGCV cover.
Remave the dummy connector and short the DlC ,-- - - - - - - -- - - ----:--- ---,
terminals using the special taal.
TOOL:
SCS connector 070PZ-ZY30100
~
~SCONNECTOR
Turn the ignition switch ON and make sure th at the ~=================~
pulley index line is aligned with the EGCV housing
projecting portien as shown . o
II the pulley index line is not within the toleranee,
adjust the EGCV control cable (page 4-23) .
Turn the i9nition switch OFF and remave the SCS
connector.
securely.
.T
--.l 2.0 mm
(0.08 in)
BEARING INSPECTION
Move the exhaust valve pulley to ths rotative direc-
tian with your hand, check the exhaust valve shaft PUllEY
tor excessive play.
If there is excessive play to the rotative direction,
replace the exhaust pipe (page 3-24).
4-22
MAINTENANCE
CABLE ADJUSTMENT
1. Short the DLC using the special tooi (page 6-15).
2. Loosen the adjusting nut and adjust the pulley
position by turning the adjusting nut.
3. Tighten the loek nut securely.
4. Remove the SCS connector trom the DLC, then

reinstall it.
Make sure that the pulley index line is aligned
w ith the EGCV housing toleranee as shown.
I
T
--'- 2.0 mm
(0.08 in )
DRIVE CHAIN
DRIVE CHAIN SLACK INSPECTION
Never inspeer and Turn the ignition switch OFF, plaee the motoreycle
adjust the drive on lts sidestand and shift the transmission into neu-
chain whife the tral.
angina is running.
Check the slack in the drive chain lower run midway
between the sprockets.
DRIVE CHAIN SLACK: 30 - 40 mm (1 .2 - 1.6 in)
I NOTICE I
Exeessive ehain slaek, 50 mm (2.0 in ) or more, may
damage the frame.
Lubri eate the drive ehain with #80 - 90 gear oil or
chain lubricant designed specifically tor use with D-
ring chains. Wipe aft the excess Dil or chain lubri-
cant.
4-23
MAINTENANCE
ADJUSTMENT
Laasen the rear axle nut.
loosen the loek nuts and turn the adjusting bolts
until the correct drive chain slack is obtained.
Make sure the index marks on both adjusting plates
are aligned with the swingarm index mark.
Tighten the rear axle nut to the speeilied torque.
Hold the adjusting bolts and tighten the loek nuts.
Recheek the drive chain slack and tree wheel rota·

tion .
Lubricate the drive chain with #80 - 90 gear Dil or
drive chain lubricant designed specifically for use
with O-ring chains. Wipe off the excess oil or chain
lubricant.
Check the drive ehain wear indicator label attaehed
on the left swingarm .
If the drive chain adjusting plate index mark reaches
red zone ol the indicator label, replaee the drive
ehain with a new one (page 4-26).
CLEANING AND LUBRICATION

Clean the ehain with non-flammable or high Ilash
point solvent and wipe 1t dry. SOLVENT SOFT BRUSH
Be sure the ehain has dried eompletelv belore lubri-
cating.
Inspeet the drive chain for possible damage or wear.
Replaee anv ehain th at has damaged rollers, loose ClEANINJ(G~~~~~~~~~;~;~::§l@;:
~ oo ~ 0000000000
fitting links, or otherwise appears unserviceable. ~
Installing a new ehain on badlV worn sproekets will
cause the new chain to wear quickly. WIPE ANDDRY ~
Inspeet and replace sprocket as necessary. ::@: ~.2..- 0 0
o
o
lUBRICATE 0
:@~~
Lubricate the drive chain with #80 - 90 gear oil or

drive chain lubricant designed specifically for use
lUBRICATE
with O-ring chains. Wipe aft the excess oil or chain
lubricant.
#80 - 90 GEAR Oll OR

DRIVE CHAIN LUBRICANT
4-24
MAINTENANCE
SPROCKET INSPECTION
Remave the drive sp racket cover (page 8-5).
Inspeet the drive and driven sprocket teeth tor wear
or damage, replace if necessary.
Never use a new drive chain on wern sprockets.
Bath chain and sprockets must be in good condi-
tion, or the new replacement chain will wear rap-
idly.
NORMAL
Check the attaching balts and nuts on the drive and

d riven sprockets.
If any are loose, torque them .
TORQUE:
Drive sprocket bolt: 54 N·m (5.5 kgf·m, 40 Ibl·ft)
Driven sprocket nut: 64 N·m 16.5 kgl·m, 47 Ibl·ft)
4-25
MAINTENANCE
REPLACEMENT
This motorcycle uses a drive chain w ith a staked
master li nk.
Loosen the d rive ehain (page 4-24).
When using the Assembie the special taa l as shown .
special roo f. fol/ow
rhe manufacturer's
TOOl:
instruction. Drive chain tooi set 07HMH-MR10103 or
07HMH-MR1010C
(U.S.A. only)
DRIVE CHAIN TOOL SET
Locate the crimped pin ends of th e ma ster link trom

th e ou tside of t he chain , and remove the link w ith MASTE R LI NK
t he drive chain taa l set.
TOOl:
Drive chain tooi set 07HMH-MR10103 or
07HMH-MR1010C
(U.S.A. only)
Remave the drive chain.
DRIVE CHAIN TOOL SET
Include the mas ter Remave the excess d rive chain links t rom the new ~=================~
link when you d rive chain wit h t he d rive chain taa l set.
counc the drive
eh.in links. STANOARO liNKS: 112 LINKS
REPLACEMENT CHAIN
OIO: 0 10525HV KAI-112YB 1 LINK
RK: RK525ROZ6-112WFZ
..
. f - - -- - - 11 2 LINKS ..
-----~
4-26
MAINTENANCE
• Never reuse th e c id drive chain, master link,
master link plate and O-rings.
(nsen the master Assembie t he new master li nk, O-rings and plate.
link. trom the inside
of the drive chain,
and Înstall the plate
with the
identification mark
facing the outside.
MASTE R LI NK
Assembie and set t he d rive ehain taal set.
DRI VE CHA IN TOO l SET
TOOl:
Drive chain tooI set 07HMH-MR10l03 or
07HMH-MR10l0C
IU.S.A. only)
Make sure t hat t he master link pin s are insta lled

MASTER LI NK PI NS
properly.
M easure t he master link pin length projected t rom
the plate.
STANOARO LENGTH:
OIO: 1.15 - 1.55 mm 10.045 - 0.061 in)
RK: 1.2 - 1.4 mm 10.05 - 0.06 in)
Stake t he master link pins.
Make sure t hat the pins are staked properl y by mea-

SLi DE CALIPER
suring th e d iameter of the staked area usin g a slide
ca li per.
DIAMETER OF THE STAKEO AREA:

OIO: 5.50 - 5.80 mm 10.217- 0.228 in)
RK: 5.30 - 5.70 mm 10.209 - 0.224 in)
4-27
MAINTENANCE
A drive chain with a After staking, check the staked area of the master
cli{Hype master link link tor cracks.
must nor be used. If there is any cracking, replace the master link, 0-
rings and plate. GOOD NO GOOD
~v CRACKED
DRIVE CHAIN SLiDER

Inspeet the drive chain slider tor excessive wear or , - - - - - - - - - - - - - - - - - - - ,
damage.
If it is warn to the wear indicator, replace the drive
ehain slider (page 15-22).
WEAR INDICATO R
BRAKE FLUID
I NOTICE
Spil/ed fluid can damage painted, plastic or rubber
parts. Place a rag over these pans whenever the
system ;s servieed.
• 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 reserve tank.
When the fluid level is low, check the brake pads for
wear (page 4-29). A low fluid level may be due to
wear of the brake pads.
If the brake pads are wam, the ealiper piston is
pushed out, and th is accounts for a low fluid level.
If the brake pads are not wam and the fluid level is
low, check entire system for leaks (page 4-30).
FRONT BRAKE
Turn the handlebar sa that the reserve tank is level 1------=:;;:;;;:;;:;;;;;---- - - - - - 1
and check the front brake fluid level.
If the level is near the low er level line, check the
brake pad wear (page 4-29).
4-28
MAINTENANCE
REAR BRAKE
Place the motorcycle on a level surface, and support r----------------~
it an upright pos ition. LOWEA LEVEL LlNE
Check the rear brake fluid level.
If the level is near the lower level line, check the
brake pa d wear (page 4-29).
BRAKE PADS WEAR

FRONT BRAKE PADS
Check the brake pads for wear.
Aeplace the brake pads if either pad is worn to the WE AA LIMIT GAOOVE
bettam of wear lim it groove .
For brake pad replacement (page 16-9).
I;-,
REAR BRAKE PADS

Check the brake pads for wear.
Aeplace t he brake pads if eit her pad is w orn to the
bettam of wea r limit groove .
For brake pad replacement (page 16-11).
W EAA LIMIT GAOOVE
4-29
MAINTENANCE
BRAKE SYSTEM
INSPECTION
Firm ly apply the brake lever or peda I, and check that
no air has entered the system.
If the lever or peda I feels soft or spongy when oper-
ated, bleed the air from the system (page 16-8).
In speet the brake hose and fittings tor deterioratio n,
cracks and signs of leakage.
Tighten any loose fittings.
Replace hoses and fitti ngs as required.
For brake air bleeding (page 16-8).
BRAKE LEVER ADJUSTMENT

Align the • t:::: mark
The distance between the brake lever and the grip
on the brake {ever can be adjusted by turning the adjuster.
with rhe index
number on the
adjuster.
BRAKE PEDAL HEIGHT ADJUSTMENT

Loosen the loek nut and turn the push rad until the
correct peda I heig ht is obtained .
• When adjusting the push rod length, do not

extend it more than 5.5 mm (0.22 in ).
After adjustment, tighten the loek nut to the speci-
fied torqu e.
TORQUE: 18 N·m (1 .8 kgf·m, 13Ibf.ft)
5.5 mm (0.22 in )
MAXIMUM
LoeK NUT
4-30
MAINTENANCE
BRAKE LIGHT SWITCH
The front brake Adjust the brake light switch so th at the brake light
light switch does cames on just prior to the brake actuall y being
not (equire engaged .
adjustment. If the light fails to come on, adjust the switch so th at
the light comes on at the proper time.
Hold the switch body and turn the adjuster. Do not
turn the switch body.
ADJUSTER
HEADLIGHT AlM
Place the motorcycle on a levelsurface.
VERTICAL BEAM ADJUSTING SCREWS
Adjust the headlight Adjust the headlight aim vertically by turning the
aim as specified by vertical bearn adjusting screw.
locallaws and A clockwise rotatian moves the bearn up and coun-
regufations. terclockwise rotatien moves the bearn down.
Adjust the headlight aim horizontally by turning the
horizontal bearn adjusting screw.
Left Headlight: A clockwise rotatien moves the bearn toward the
right and counterclockwise rotatian moves the
beam toward the left side of the rider.
Right Headfight: A clockwise rotatian moves the bearn toward the
left and counterclockwise rotatian moves the bearn
loward the right side of the riaer. HORIZONTAL BEAM ADJUSTING SCREWS
CLUTCH SYSTEM
Measure the clutch lever freeplay at the end of the , - - - - - - - - - - - - - - - - - - - ,
clutch lever. 10 - 20 mm (3/8 - 13/16 in )
FREEPLAY: 10 - 20 m m (3/8 - 13/1 6 in)
The adjuster may Minor adjustment is made with the upper adjuster ~L=O=C=K=N=U=T===============
be damaged if it is at the clutch lever.
positioned too far Loosen the lock nut and turn the adjuster.
out, leaving minÎmal
If the adjuster is threaded out near its limit and the
rhread
correct freeplay cannot be obtained, turn the
engagement.
adjuster all the way in and back out one turn .
Tighten the loek nut while holding the adjuster and
make a major adjustment as described as follows:
ADJUSTER
4-31
MAINTENANCE
Major adjustment is performed at the clutch lifter
lever. LOCK NUT
Loosen the lock nut and turn the adjusting nut to
adjust the Ireep lay.
Tighten the lock nut while holding the adjusting nut.
Il proper Ireeplay cannot be obtained, or the clutch
slips during test ride, disassembie and inspeet the
clutch (page 10-7).
ADJUSTING NUT
SIDESTAND
Support the motorcycle on a level ground.
Check the sidestand spring lor damage or loss ol
ten sion.
Check t he sidestand assembly lor Ireedom ol move-
ment and lubricate the sidestand pivot jf necessary.
TORQUE:
Sidestand pivot bolt: 10 N·m (1.0 kgl·m, 7Ibl·ft)
Sidestand pivot nut: 29 N·m (3.0 kgl·m , 21 Ibl·ft)
Check the sidestand ignition cut-aft system:

- Sit astride the motorcycle and raise the
sidestand.
- Start the engine with the transmission into neu-
tral, then shift the transmission ;nto gear, with
the clutch leve r squeezed.
- Move the sidestand l ull down .
- The engine should stop as the sidestand is low-
ered.
Il there is a problem with the system, check the
sidesta nd switch (page 20-20).
SUSPENSION
FRONT SUSPENSION INSPECTION
Check the action ol the lorks by operating the Iront
brakes and compressing the front suspension sev-
era l times.
Check the entire assembly lor signs olleaks, dam-
age or loose fastene rs.
Loase. wom or Replace damaged components which cannot be
damaged repaired.
suspension parts Tigh ten all nuts and bolts.
impair motorcycles
For lork service (page 14-22).
stabifityand
control.
4-32
MAINTENANCE
FRONT SUSPENSION ADJUSTMENT
SPRING PRE-LOAD ADJUSTER
Spring pre-laad can be adjusted by turning the r-- - - - - - - - - - - - - - - - - - ,
adjuster.
TURN CLOCKWISE:
Increase the spring pre-laad
TURN COUNTERCLOCKWISE:
Decrease the spring pre-Ioad
PRE-LOAD ADJUSTER ADJUSTABLE RANGE:

15 tums
PRE-LOAD ADJUSTER STANDARD POSITION :

5 tums clockwise trom minimum
PRE -LOAD ADJUSTER
COMPRESSION AND REBOUND DAMPING

ADJUSTERS
I NOTICE I
Do not turn the adjusters more than the given posi-
tions or the adjusters ma y be damaged.
• All dampi ng adjustments are referenced trom the
full hard position.
To adjust bath Th e comp ression and rebound damping can be , - - - - - - - - , , - - - - - - - - - - ,
sides equalfy, set adjusted by turning th e adjusters.
the right and left
damping adjus ters DIRECTION H: Increase the damping force
to the same DIRECTION S: Decrea se t he dam ping torce
position.
Turn the compression adjuster clockwise until it
stops (fu ll hard position), then turn the adjuster
co unterclockwise.
COMPRESSION ADJUSTER STANDARD POSITION:
2 tums out t rom tuil hard
COMPRESSION ADJUSTER
Tu rn the rebound adjuster clockwise unti l 1t stops ~===============~

(ful l hard position), then turn the adjuster counter-
cJockwise.
REBOUND ADJUSTER STANDARD POSITION :

2-1 / 2 tums out trom full hard
REBOUND ADJUSTER
4-33
MAINTENANCE
REAR SUSPENSION INSPECTION
Support the motorcycle securely and raise the rear
whee l aft the ground.
Check for wam swingarm bearings by grabbing the
rear end of the swingarm and attempting to move
the swingarm side to side.
Replace the bearings if any are looseness is noted.
Check the action of the shock absorber by com-

pressing it several times.
Check the entire shock absorber assembly for signs
of [eaks , damage or loose fasteners .
Replace damaged components which cannot be
repaired .
Tighten all nuts and balts.
For shock absorber service (page 15-14).
REAR SUSPENSION ADJUSTMENT

COMPRESSION AND REBOUND DAMPING
ADJUSTERS
I NOTICE I
Do not turn the adjusters more than the given posi-
tions or the adjusters may be damaged .
• All damping adjustments are referenced trom the
full hard position .
• Be sure that the compression adjuster is firmly
loeated in a detent and not between positions.
The compression and rebound damping can be
adjusted by turning the adjusters.
DIRECTION H: Increase the damping force
DIRECTION S: Decrease the damping force
Turn the compression adjuster clockwise until it
stops (full hard position ). then turn the adjuster
counterclockwise.
COMPRESSION ADJUSTER STANDARD POSITION:

22 clicks out from full hard
4-34
MAINTENANCE
Turn the rebound adjuster clockwise until it stops
(full hard posit ion), th en turn the adjuster counter-
clockwi se.
REBOUND ADJUSTER STANDARD POSITION :

2-1/2 tums out trom tuil hard
REBOU ND ADJUSTER
NUTS, BOLTS, FASTENERS

Check th at all chassis nuts and balts are tightened to
their correct torque values (page 1-13).
Check th at all safety clips, hose clamps and cable
stays are in place and properly secured.
WHEELS/TIRES
Support th e motorcycle securely and raise the front
wheel aft the ground .
Hold the front fork leg and move the front wheel
si deways with force to see if the wheel bearings are
worn.
For front wheel service (page 14-16).
Support th e motorcycle secureJy and raise the rear

whee l aft th e ground .
Hold the swingarm and move the rear wheel si de-
ways with force to see if the wheel bearings are
worn.
For rear whee l service (page 15-7).
4-35
MAINTENANCE
Tire pressure should be checked when the tires are
CO LD.
RECOMMENDED TIRE PRESSURE AND TIRE SIZE:
FRONT REAR
Tire pressure kPa
250 (2.50, 36) 290 (2.90, 42)
(kgf/cm', psi )
120170ZR 17 180/55ZR 17
Tire size
M/C (5aW) M/C (73W)
BT015F BT015R
Tire Bridgestone
RADIAL E RADIAL E
bland
Dunlap Oual ifier PTG Oual ifier PTG
Check the tires for cuts, embedded nails, or other

damage.
Measure the tread depth at the center of the tires.
Replace the tires when the tread depth reaches the
following limits.
MINIMUM TIRE TREAD DEPTH:
FRONT: 1.5 mm (0.06 in)
REAR: 2.0 mm (0.08 in)
STEERING HEAO BEARINGS

Check th at the control cables do not interfere with
handlebar rotation.
Support the motorcycle securely and raise the front
wheel aft the ground.
Check that the handlebar moves freely from si de to
side.
It the handlebar moves unevenly, binds, or has ver-

tical movement, inspeet the steering head bearing s
(page 14-34).
Check tor worn steering stem bearings by grabbing
the front fork leg and attempting to move the front
fork side to side.
Replace the bearings if any looseness is noted .
4-36
5. LUBRICATION SYSTEM
LUBRICATION SYSTEM DIAGRAM ···· ······ 5-2 Oll STRAINER/PRESSURE RELIEF

VAlVE ····· ······················ ········ ···· ········· ··· ······ 5-5
SERVICE INFORMATION ........................... 5-3
Oll PUMP ................................................... 5-7
TROUBlESHOOTING ................................ . 5-4
Oll COOLER ...... .. .................. ................... 5-13
Ol l PRESSURE INSPECTION .. .. .. .. .......... ·.. 5-5
5-1
LUBRICATION SYSTEM
LUBRICATION SYSTEM DIAGRAM
CAMSHAFTS
,
"
PISTON
OIL JET PIPE
CRANKSHAFT
MAINSHAFT
OIL COOLER
COUNTERSHAFT
OIL FILTER CARTRIDGE OIL P
PRESSURE RELIEF VALVE

OIL STRAINER
5-2
LUBRICATION SYSTEM
SERVICE INFORMATION
GENERAL
ACAUTION
Used engine oil may cause skin cancer if repeatedly left in contact w ith the skin for prolonged periods. Although th is is
unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and
water as soon as possible after handling used oil.
• T his section covers service of the Dil pump and EOP switch .
• T he Dil pump can be serviced with the engine instalied in the frame.
• T he service procedures in this section must be performed with the engine Di l drained.
• When remoying and installing the Dil pump, use care not to allow dust or dirt to enter the engine.
• If any portion of the Dil pump is warn bevond the specified service limits, replace the oil pump as an assembly.
• After the Dil pump has been insta lied, check that there are no oil leaks and that oil pressure is correct.
SPECIFICATIONS
Unit· mm (in )
Engine Di l capacity After draining 2.7 liter (2.9 US qt, 2.41mp q t)
After oil f ilter change 2.8 liter (3.0 US qt, 2.5 Imp qt) -
After disassembly 3.5 liter (3.7 US qt, 3.1 Imp qt) -
Recommended engine Dil Pro Honda GN4 4-stroke oil (U.S.A. and
Canada) or equivalent motor oil
API service classification : SG or Higher -
JAS 0 T 903 standard: MA
Oi l pressure at EOP switch 505 kPa (5.1 kgf/c m ', 73 psi)
-
at 6,000 rpm/(80' C/ 176' F)
Oil pump Tip clearance 0.15 (0.006) 0.20 (0.008)
Body clearance 0.15 - 0.2 1 (0.006 - 0.008) 0.35 (0.014)
Side clearance 0.04 - 0.09 (0.002 - 0.004) 0.17 (0.007)
TORQUE VALUES
EOP switch 12 N·m (1.2 kgf·m , 9Ibf-ft) Apply sealant to the threads
EOP switch wire terminal bolt 2.0 N·m (0.2 kgf-m, 1.5 Ibf-ft)
Oil pump assembly bolt 12 N·m (1.2 kgf-m, 9 Ibf·ft ) CT bolt
Oil pump driven sp racket bolt 15 N·m (1.5 kgf·m, 11 IbHt) Apply locking agent to the threads
Oil cooler bolt 59 N·m (6.0 kgf·m , 44 Ibf·ft) App ly oil to the threads
Oil pipe A mounting bolt 12 N·m (1.2 kgf·m , 9 Ibf-ft) Apply locking agent to the threads
5-3
LUBRICATION SYSTEM
TOOLS
OH pressure gauge set OH pressure ga uge attachment

07506-3000001 07406-0030000
or equivalent commercially avail- or equiva lent comme rcia lly avail-

able in U.SA (MT37A) able in U.SA(AT77AH)
TROUBLESHOOTING
Oil level toa low
• Oil consumption
• External oil leak
• Warn piston rin gs
• Improperfy insta lied piston rings
• Wam cyli nde rs
• Warn va lve stem seals
• Warn va lve guide
Low Dil pressure
• Oil leve l low
• Clogged Dil strainer
• Internal ail leak
• Incorrect Dil being used
No oil pressure
• Dil level toa low
• Dil pressure reliet valve stu ck open
• Braken Dil pump drive chain
• Broken ail pump drive or dri ve n sprocket
• Damaged oil pump
• Internal Dil leak
High oil pressure
• Dil pressure relief va lve stuck closed
• Clogged oil filter, oil cooler ga llery or metering orifice
• Incorrect oil being used
Oil contaminatio"
• Oil or filter not changed aften eno ugh
• Warn piston rings
Oil emulsification
• Blown cylinder head ga.ket
• Leaky coolant passage
• En try of water
5-4
LUBRICATION SYSTEM
Oll PRESSURE INSPECTION

Remave the EOP switch (page 20-15).
Install the oil pressure gauge an achment to the
switch base.
Conneet the Dil pressure gauge to the oil pressure
gauge attachment.
TOOlS:
Oil pressure gauge set 07506-3000001 or
equivalent commer-
eially available in
U.S.A. (MT37A)
Oil pressure gauge attaehment 07406-0030000 or
equivalent cam mer-
eially available in
U.S.A. (AT77AH)
Check the engine o ill evel (page 4-17).

Warm the engine to normal operati ng tem perature
(app roxim ately 80°C/176° F) and increase th e engine
speed to 6,000 rpm and read the oil pressure.
Standard:
505 kPa (5.1 kgf/cm' , 73 psi) at 6,000 rpm
(80°C/176°F)
Stop the engine and remave the toois.
Install the EOP switch (page 20-15).
Oll STRAINER/PRESSURE RELIEF

VAlVE
REMOVAL
Dra in the engine oil (page 4-17) .
STAY
Remave the following:
- Ex haust pipe (page 3-24)
- Radiator rese rve tank (page 7-20)
Loosen the balts in Remove th e balts, stay and oil pan.
a crisscross pattern
in two or rhree
steps.
BOlTS
Remove the oil strainer and seal ring .

Clean the Dil strainer screen and check for damage,
replace it if necessary.
5-5
LUBRICATION SYSTEM
Remave the pressure relief valve and O-ring.
INSPECTION
Check t he operation of the pressure relief valve by
pushing on the piston .
Disassembie the relief valve by removing the snap
ring.
Inspeet the piston for wear, unsmooth move ment or
damage.
Ins peet the spring for fatigue or damage.
Assembie the pressure relief valve in the reverse
order of disassembly.
INSTALLATION
Apply oil to a new O-ri ng and install it onto the pres-
sure reHef valve.
Install the pressure relief valve to the crankcase.
App ly oi l to a new seal ring and install it onto the oil

strainer.
Insta ll the oil strainer to the crankcase while align-
ing the Di l strainer boss with the groove of the Dil
pump.
5-6
LUBRICATION SYSTEM
Clean the oil pan mating surface thoroughly.
Donotapplymore Apply sealant (Three Bond 1207B or an equivalent)
sea/ant than to the mating surface.
necessary.
Install the oil pan, stay and balts .

Tighten th e balts in a crisscross pattern in two or STAY
three ste ps.
Install the follow ing :
- Radiator reserve tan k (page 7-20)
- Exhaust pipe (page 3-26)
Fill the crankcase with the recommended oil (page
4-17) .
After installation, start the engine and check th at
there are no oil leaks.
. \
BOLTS
Oll PUMP
REMOVAL
Drain the engine oi l (page 4-17).
Rem ave th e follow ing:
- Right cran kcase cove r (page 10-5)
- Oil strainer (page 5-5)
Remave the water pump (page 7-17), if you remave
the oi l pipe B.
Remave the bolt, wash er and oil pump driven
sprocket . .
Remave the balts, oil pipe A and seal rings .

Clean the oil pipe A thoroughly and check for dam-
age.
5-7
LUBRICATION SYSTEM
Remave the balts, oil pipe Band O-rings.
Clean the oil pipe B thoroughly and check lor dam- e:~
age.
Remave the balts and oil pump assembly.
Remove the dowel pins.
DISASSEMBL Y
Remove the balts and separate the oil pump assem-
bly. BOlTS
5-8
LUBRICATION SYSTEM
DOWEL PINS
Remove the th rust washer, drive pin, Dil pump
shaft, outer rotor and inner rotor trom the oil pump
OUTER ROTOR
body.
WASHER
Clean all disassembied parts thoroughly.
DIL PUMP
SHAFT
INN ER ~mr,,~ PIN

INSPECTION
• If any portion of the ail pump is warn bevond the
service limit, repla ce th e oil pump as an assem- TIP CLEARANCE:
bly.
Temporarily install the outer and inner rotors into
the oil pump body.
Temporarily install the drive pin and oil pump shaft.
Measure the rotor tip clearance.
SERVICE LIMIT: 0.20 mm (0.008 in)
Measure t he pump body clearance.
5-9
LUBRICATION SYSTEM
Measure the side clearance using a straight edge
and Ieeier gauge. SI DE CLEARANCE:
SERVICE l iMIT: 0.17 mm (0.007 in)
ASSEMBLY
Dip all parts in clean engine ail.
OUTER ROTOR
INNER ROTOR
Oll PUMP SHAFT
DOWEl PIN
I
DRIVE PIN
THRUST WASHER
12 N·m (1.2 kgl·m, 9 Ibl·ft)
Install the outer rotor into the Dil pump body.

OUTER ROTOR
Install the inner rotor into the outer rotor with its
drive pin groove facing the drive pin. THRUST
Install the Dil pump shaft through the inner rotor WASHER
and Dil pump body.
Install the drive pin into the Dil pump shaft hole and OllPUMP
arign it with the inner rotor groove. SHAFT
Install the thrust washer.
INNER ROTOR DR IVE PIN
5-10
LUBRICATION SYSTEM
Install the dowel pins.
DOWEL PINS
Assembie the oil pump and tighten the balts to the

specified to rque. BOLTS
TORQUE: 12 N ·m (1 .2 kgf·m , 9 Ibl·ft)
INSTALLATION
Install the dowel pins to the crankcase.
Install the oi l pump assembly and tighten the balts

securely.
5-11
LUBRICATION SYSTEM
Apply oil to new O-rings and install them onto the
oil pipe B.
Apply locking agent to the oil p ipe B mounting bolt
threads (page 1-19).
Install the oil pipe Band tighten the balts securely.
Apply oil to new seal rings and install them onto the
oil pipe A.
Apply locking agent to the oil pipe A mounting bolt
Install the oil pipe A and tighten the balts to the
specified torque in the order as shown .
lORQUE: 12 N·m (1.2 kgl·m, 9 IbHt)
• First tighten the No. 1 bolt, then tighten the No . 2

bo lt.
Apply oil to the oil pump driven sprocket and drive

chain.
Install the driven sprocket with its "OUT" mark lac-
ing out by aligning the Ilat surfaces.
Apply locking agent to the oil pump driven sprocket

bolt threads (page 1-19).
lighten the driven sprocket bolt/was her to the spec-
ified torque.
lORQUE: 15 N ·m (1 .5 kgl·m, 11 IbHt)
II the oil pipe B was removed , install the water
pump (page 7-18).
- Dil strainer (page 5-6)
- Right crankcase cover (page 10-26)
After installation, lill the crankcase with the recom-
mended oil (page 4-17) and check the oil pressure
(page 5-5).
Check th at there are na oil leaks.
5-12
LUBRICATION SYSTEM
Oll COOLER
REMOVAL
Dra in the engine oil (page 4-17).
Drain the coola nt trom the system (page 7-7).
Loasen the hose clamp screws and disconneet the
water hoses trom the oil cooler.
Remave th e bolt, sealing washer and oi l cooler.

Remave the O-ring trom the oil cooler.
INSPECTION
Check the oil coo ler tor damage.
INSTALLATION
Apply oi l to a new O-ring and install it into the oil
cooler groove.
App ly oi l to the oil coo ler bolt threads and a new
sealing washer seating surface.
Install the oil cooler to the cran kcase by aligning the
oil cooler groove with the crankcase boss.
In stall the sealing washe r and oil coole r bolt.
5-13
LUBRICATION SYSTEM
Hold the oil cooler bV Vour hand and tighten th e bolt
to the specified torq ue.
TORQUE: 59 N·m (6.0 kgf·m , 44lbf.ft)
Conneet the wate r hoses and tighten the hose

clamp screws securelv (page 7-19) .
Fill th e cooling svstem and bleed anv ai r (pa ge 7-7) .
Fill the crankcase with the recommended oil (page
4-17) and check that there are na oilleaks.
5-14
6. FUEL SYSTEM (PGM-FI)
COMPONENT LOCATION ......... .. .. .. .. .. ....... 6-2
SERVICE INFORMATION ······ ····· ···· ·· ·· ··· ····· 6-3

THROTTLE BODy ····· ··· ······· ·········· ····· ·· .. .. · 6-60
PRIMARY INJECTOR ···· ······· ···· ······ ··· ······ ·· 6-65

•
PGM-FI SYMPTOM ENGINE IDLE SPEED ·· ·· ·· · .. ······ ········· ········ 6-67
TROUBLESHOOTING ........ .... .... .. ..... .. ....... . 6-7
IACV ... ... .. ... .. ... ... ......... .. ............... ......... ···· 6-68
PGM-FI SYSTEM LOCATION ················· ···· 6-8
KNOCK SENSOR ......... ....... ..... ........ .. ... .... 6-69
PGM-FI SYSTEM DIAGRAM .. ......... ... ........ 6-9
MAP SENSOR········· ········ ········· ············· ···· 6-70
CONNECTOR LOCATION···· ······· ·· ···· ·· ······ 6-10
lAT SENSOR ·.. ·· ··· ····· ·· ··· ········ ··· ···· ········ ····6-71
PGM-FI TROUBLESHOOTING
INFORMATION · .. ······ ········ ·· ······················ 6-13 ECT SENSOR ·.. ··········· ····· ··· ······ ···· ······· ····· 6-71
DTC INDEX ······· ·· ······ ·· ········· ········ ·············· 6-16 CMP SENSOR· .. ·············· ··· ······················· 6-71
DTC TROUBLESHOOTING ··· ·· ·················· 6-18 BANK ANGLE SENSOR .. ... ............ ..... .... . 6-72
MIL CIRCUIT TROUBLESHOOTING ········ 6-42 ENGINE STOP RELAY· .. ····· ·········· ··· ········ · 6-74
FUEL LlNE INSPECTION ··············· ·· ·········6-42 ECM·········· ·················· ·· ·· ········ ·· ······· ··········6-74
FUEL PUMP UNIT ........... .............. .. .......... 6-47 SECONDARY AIR SUPPL Y SYSTEM .. .... 6-77
FUEL PUMP RELAY ..... ................... .......... 6-49

EVAP PURGE CONTROL SO LENOID VALVEI
CANISTER (CALIFORNIA TYPE)·· ·········· ·· 6-79
FU EL TAN K .... ...... ... ...... ........ ........ ............ 6-50
EG CV SERVOMOTOR ··········· ··········· ····· ··· 6-80
AIR CLEANER HOUSING ·············· ···········6-52
EGCV············· ····· ····················· ············· ·····6-83
SECONDARY INJECTOR ····· ·· ··················· 6-56
6-1
COMPONENT LOCATION
5.3 N·m 10.5 kgf.m, 3.9 IbUt)
30 N·m 13. 1 kgf·m, 22 IbUt )
6-2
SERVICE INFORMATION
GEN ERAL
• Be sure to re lieve the tuel pressure while the engine is OFF.
• Bending or twisting the contral cables will impair smooth operation and could cause the cables to stick or bind, result~
in9 in 1055 of vehicle contro!.
• Work in a weil ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can
cause a fire or explosion.
• Do not snap the throttle valve trom tuil open to tuil close after the throttle cable has been removed. It may cause incar·
reet idle operation.
o Seal the cylinder head intake parts with tape or a clean clath ta keep dirt and debris Iram entering the intake parts after
the thrattle body has been remaved .
o Do not apply excessive l arce ta the luel rail on the thrattle body while remaving or installing the throttle body.
o Do not damage the throttle body. It may cause incorrect thrattle and idle valve synchranizatian.
• Prevent dirt and debris trom entering the engine, clean the throttle bore and tuel hose with compressed air.
o The throttle body is lactary pre-set. Do not disassembie in a way ather than shawn in this manual.
o Do not push the luel pump base under the luel tank wh en the luel tank is stared.
o Always replace the packing when the luel pump is remaved.
o The PGM-FI system is equipped with the Sell-Diagnastic System described. II the mallunctian indicator lamp (MIL)
blinks, lallaw the Sell-Diagnastic Procedures ta remedy the problem.
o When checking the PGM-FI, always lallaw the steps in the troubleshaating Ilaw chart (page 6-18) .
• The PGM-FI system is provided with a fail-safe function to secure a minimum running capability even when there is any
trouble in the system. When any abnormality is detected by the self-diagnosis function, running capability is secured by
using numerical values preset in advance in the program map. It must be remembered, however, that when any abnor-
mality is detected in 8 injectors andl ar the CKP and CMP sensor, the lail sale lunctian stops the engine ta protect it Iram
damage.
o Far PGM-FI system lacatian (page 6-8).
• A faulty PGM-FI system is often related to poorly connected or corroded connectors. Check those connections before
proceeding.
o Far luellevel sensor inspectian (page 20-16).
o When disassembl ing the PGM-FI parts, nate the lacatian ol the O-rings. Replace them with new anes upan reassembly.
• Before disconnecting the tuel hose, relieve fuel pressure from the system by disconnecting the quick con neet fitting
(page 6-42).
o Use a digital tester lor PGM-FI system inspectian.
• Do not loosen or tighten the white painted bolts and screws of the throttle body. Loosening or tightening them can
cause throttle valve and idle control failure .
6-3
SPECIFICATIONS
ITEM SPECIFICATIONS
Throttle body identilica- I Except Calilornia type G064C
tian number I Calilornia type G064B
Idle speed 1,400 ± 100 rpm
Thrattle grip Ireeplay 2 - 4 mm (1 /16 - 3/16 in)
lAT sensor resistance (at 20' C/68' F) 1-4 kn
ECT sensor resistance (at 20' C/68' F) 2.3 - 2.6 kn
Fuel injector res istance I Primary injector 11 - 13 n
(at 20' C /68' F) I Secandary injector 11 -13 n
PAIR control solenaid va lve resistance (at 20' C/68' F) 23 - 27 n
CMP sensar peak voltage (at 20' C/68' F) 0.7 V minimum
CKP sensor peak voltage (at 20' C/68' F) 0.7 V minimum
Fuel pressure at idle 343 kPa (3 .5 kgl/cm' , 50 psi )
Fuel pump Ilow (at 12V) 167 cm' (5.6 US oz, 5.9 Imp oz) minimum/10 seconds
TORQUE VALUES
EeT sensor 23 N·m (2.3 kgl·m, 17 Ibf.ft)
Primary luel rail mounting bolt 5.1 N·m (0.5 kgl·m, 3.8Ibl·ft)
Secondary luel rail mounting bolt 5.3 N·m (0.5 kgl·m, 3.9 Ibl·ft)
Fuel tank mounting bolt 30 N·m (3.1 kgf.m, 22 Ibl·ft)
Fuel pump mounting nut 12 N·m (1.2 kgl·m , 9 Ibl·ft) For tightening sequence (page 6-49)
Air funnei/lower housing mounting screw 4.2 N·m (0.4 kgf.m, 3. 1 Ibl·ft)
Bank angle sensor mounting screw 1.5 N·m (0.2 kgl·m , 1.1 Ibl·ft)
IACV setting plate torx screw 2.1 N·m (0.2 kgl·m, 1.5 Ibl·ft)
EGCV pulley nut 5.0 N·m (0.5 kgl·m, 3.7 Ibf.ft)
Knock sensor mounting bolt 22 N·m (2.2 kgl·m, 16 Ibl·ft)
lAT sensor mounting screw 1.1 N·m (0.1 kgf.m, 0.8 Ibl·ft)
MAP sensor mounting screw 1.1 N·m (0.1 kgl·m , 0.8 Ibl·ft)
ECM setting plate screw 0.7 N·m (0.07 kgl·m, 0.5 Ibl·ft)
6-4
TOOLS
Peak voltage adaptor SCS connector Test probe

07HGJ-0020100 (Not available in 070PZ-ZY30100 07ZAJ-RDJA 110
U.S.A.)
with commercially available digital

multimeter (impedance 10 MnJDCV
minimum)
IgnitionMate peak voltage tester Fuel pressure gauge Pressure gauge manifold
MTP07-0286 (U.S.A. only) 07406-0040004 07ZAJ-S5A0111
or 07406-004000B Not available in U.S.A.

or 07406-004000A (U.S.A. on ly)
Hose attachment, 8 mm/9 mm Hose anachment, 9 mm/9 mm Attachment joint, 8 mm/9 mm

07ZAJ-S7C0100 07ZAJ-S5A0120 07ZAJ-S7C0200
Not available in U.S.A.
6-5
Pressure manifold hose Adaptor, male Adaptor, female

07AMJ-HW3Al00 (U.S.A. only) 07AAJ-S6MA200 (U.SA only) 07AAJ-S6MA400 (U.SA only)
Inspection adaptor HDS pocket tester

07GMJ-ML80100 TDS3557-0112-01 (U.SA only)
6-6
PGM-FI SYMPTOM TROUBLESHOOTING
When the motoreveIe has one of these svmptoms, check the DTC or MIL blinking, refer to the DTC index Ipage 6-16) and
begin the appropriate troubleshooting procedure. If there are na DTC/MIL blinking sta red in the ECM memory, do the diag-
nestie procedure for the symptom , in sequence listed below, until you find the cause .
Symptom Diagnosis procedure Also check for

Engine cranks but won 't 1. Crank the starter for more than • No fuel to injector
start 10 seconds and check the DTC - Clogged tuel strainer screen
INo DTC and MIL blinking) Ipage 6-14) and execute the - Pinched or e10gged fuel hose
troubleshooting according to - Pinched or clogged fuel tank breather
the DTC. hose
2. Inspeet the fuel supplV svstem - Faulty fuel pump
Ipage 6-42). - Faultv fuel pump circuits
• Intake air leak
• Contaminated/deteriorated fuel
• Faultv injector
• IACV stuck closed
• Faulty ignition svstem
Engine cranks but won 't 1. ECM power/ground circuits • Open circuit in the power input and/or
start malfunction Ipage 6-75) ground wire of the ECM
INo fuel pump operation 2. Inspeet the fuel supplV svstem • Faulty bank angle sensor or related circuit
sound when the turning the Ipage 6-42). • Faulty engine stop relay or related circuit
ignition ON) • Faulty engine stop switch or related circuit
Engine sta lis, hard to start, 1. Check the idle speed. • Restricted fuel hose
rough idling 2. Check the IACV. • Contaminated/deteriorated fuel
3. Inspect the fuel supplV svstem • Intake air leak
Ipage 6-42). • Faulty IACV
4. Inspeet the baltery charging • Restricted fuel tank breather hose
svstem Ipage 17-7). • Faultv ignition svstem
• Fau ltv balterv charging svstem
Afterburn when engine Check the PAIR svstem Ipage 6-77). • Faultv PAIR svstem
braking is used - Faultv PAIR control solenaid va lve
- Faultv PAIR check valve
- Clogged hose of the PAIR svstem
• Faulty ignition system
Backfiring or misfiring dur- Check the ignition system. • Faulty ignition system
ing acceleration
Poor performance 1. Inspeet the fuel supplV svstem • Pinched or e10gged fuel hose
(driveabilitv) and paar fuel Ipage 6-42). • Faulty pressure regulator
economy 2. Inspect the air cleaner element • Faultv injector
Ipage 4-8). • Faulty ignition system
• Clogged air cleaner element
Idle speed is bel ow specifi- 1. Check the idle speed • IACV stuck e10sed
cations or fast idle too low 2. Check the IACV • Faultv fuel supplV svstem
INo DTC and MIL blinking) • Faulty ignition system
Idle speed is above speci fi - 1. Check the idle speed • IACV stuck opened
cations or fast idl e toa high 2. Check the throltle operation • Faulty ignition svstem
INo DTC and MIL blinking) and freeplav • Intake air leak
3. Check the IACV • Engine top end problem
• Air cleaner condition
MIL stays ON but na DTCs Troubleshaat the MIL circuit (page • Faultv MIL circuit
set, or MIL never comes ON 6-42).
at all
MIL stavs ON at all Inspeet the DLC circuit. • Short circuit in the DLC related wire
(No DTC set)
6-7
(PGM-FI)
FUEL SYSTEM M LOCA TION
PGM-FI SYSTE
SECONDARYINJECTOR
MAP SENSOR lAT SENSOR

PRIMARY INJECTOR
EGCV SERVOMOTOR
KNOCK SENSOR
DlC
(Remov e the seat.)
TP SENSOR ECT SENSOR
IACV VSSENSOR CKPSENSOR
GE CONTROL
~~~~~~I~ VAlVE
6-8
PGM-FI SYSTEM DIAGRAM
ENGINE STOP ENGINE STOP

SWITCH RELAY
w""
BANKANGlE
SENSOR
CONTROl
~~=t:~fI=~=:
SOlENQID
@( SENSOR lb
MAP1,2) VALVE
@ (8)
TP SENSOR ~~
@ (9)
LAT SENSOR
@ (7)
ECTSENSOR
@( 34,35)
'OCV
HEse I'ND,eATOR
@ (25,56)
KNOCK
SENSOR
@l:><:)
@ (18) {)::::::::;---"~~~
l:><:)~~~SOR@
INJECTORS
(19) ~
l:><:)~~~soR0
'ACV
DLC
c
CLUTCH
SWITCH
Br: 8rown
BI : Blaek
NEUTAAL
SWITCH Y:Yeliow
Su: Blue
G : Green
R : Red
, 2 :J 4 5 6 7 8 9 10 11 , 2 3 4 5 , 7
•2<)"
9 10 11 W:White
@( )=DTC / MIL nu m ber 0 : Orange
12' 314151e 17 la 19 2 21 22 2 13'4 1516 1718 19 2
Lg : light green
~32 252627 2829~O31 J2J3 3 425 627 82930 31/3233
P : Pink
~
Gr: Gray
ECM 33P (BLACK) CONNECTOR A ECM 33P (LIGHT GRAY) CONNECTOR B
ECM sida of mlle terminals
6-9
CONNECTOR LOCATION
NOTE: Remove the tuel tank cover (page 3-9).
ECM 33P (Blaek) CONNECTOR

'2--17"A,
lAT SENSOR 2P (Gray) CONNECTOR
8
SECONDARY INJECTOR 2P (Gray) CONNECTOR
m HESD 2P (Brown) CONNECTOR
NOTE: Remove the lelt middle eowl (page 3-8).
CMP SENSOR 2P (Blaek) CONNECTOR
m
6-10
NOTE: Lift and support the tuel tank (page 4-5).
MAP SENSOR
CU)
CKP SENSOR
CD 2P (Blaek) CONNECTOR
PRIMARY INJECTOR
2P (Gray) CONNECTOR m
f1i'=)
[ft KNOCK SENSOR
f1i'=)
[ft VS SENSOR
ECT SENSOR
3P (Gray) CONNECTOR
NOTE: Remove the air cleaner housing (page 6-52).
-========IRÀ
/------.-!-)
TP SENSOR
CU) IACV 4P (Blaek) CONNECTOR
oTo
6-11
NOTE : Remove the seat (page 3-4) .
EG CV 6P (Natural) CONNECTOR
EEB
6-12
PGM-FI TROUBLESHOOTING INFORMATION
GENERAL TROUBLESHOOTING
Intermittent Failure
Th e term "i ntermittent failure" means a system may have had a failure, but it checks OK now. Ifthe MIL does not come on,
check for paar contact or loose pins at all connectors related to the circuit that of the troubleshaating . If the MIL was on,
but then went out, the original problem may be intermittent.
Opens and Shorts
"Opens" and "Shorts" are cemmon electrical terms. An open is a break in a wi re or at a con nection. A short is an accidental
co nn ection of a wire to ground or to another wire. In simple electronics, th is usuall y means something wil! not work at all.
With ECMs this can mean someth ing may wo rk, but not the way irs supposed to.
If the MIL has come on
Refer to DTC READOUT (page 6-14).
If the MIL did not stay on
If the MIL did not stay on, but there is a driveability problem, do the SYMPTOM TROUBLESHOOTING (page 6-7).
SYSTEM DESCRIPTION
SELF-DIAGNOSIS SYSTEM
Th e PGM-FI system is equipped with th e self-diagnostic system. When any abnormal ity occurs in the system, the ECM
turns on the MIL and stores a DTC in its erasab le memory.
FAIL-SAFE FUNCTION
Th e PGM-FI system is provided with a fail -safe fun ction ta secure a minimum running capability even when there is trouble
in the system. When any abnormality is detected by the self-diagnosis function , running capa bility is maintained by pre-
programmed va lue in the simulated program map . When any abnormality is detected in the injecto r(s), CKP sensor and/or
CM P sensor, the fail-safe fun ction stops the engin e to proteet it from damage.
DTC (Diagnostic Trouble Code)
• Th e DTC is composed of a maln code and a su b code and it is displayed as a hyphenated number when retrieved trom
the ECM with the HDS pockettester.
The digits in front of the hyphen are the main code, they i ndicate the component of fun ction failure .
The digits behind the hyphen are the sub code, th ey detail th e specific symptom of th e componen t or function failure.
Far example, in the case of the TP sensor:
- DTC 08 - 1 = (TP sensor vo ltage) - (Iower than the specified value)
- DTC 08 - 2 = (TP sensor voltage) - (higher than the specified va lue)
• The MAP, ECT, TP and lAT sensor diagnosis w ill be made according to the voltage output of the aftected sensor.
If a failure occurs, the ECM determines the Function Failure, compares the sensor voltage output to the standard value,
and then outputs the corresponding DTC to th e HDS Pocket Tester.
For example:
- If the in put voltage line (A) on the MAP sensor is opened, the ECM detects the output voltage is about 5 V, then the
DTC 1-2 (MAP sensor ci rcuit high voltage) will be displayed.
- If the input voltage line (B) on the TP sensor is opened, the ECM detects the output voltage is 0 V, th en the DTC 8-' (TP
sensor circuit low voltage) will be displayed .
5V
MAP SENSOR 5V
5V TP SENSOR
r - - _ - o - - (A) - -Ç.......... r----<r-- (B)- -Q--'

~.~~>- ______-<~__O~U~T~PUTVOLTAG E
OUTPUT VOLTAGE
5V 5V
ECTSENSOR lAT SENSOR
OUTPUT VOLTAGE OUTPUT VOLTAGE
6-13
MIL Blink Pattern
• It the HDS pocket te ster is not availab le, DTC can be read trom the , -- - - - - - - -- - - - - - - - - - ,
ECM memory by the MIL blink pattern ,
• The number ol MIL blinks is the equivalent the main code ol the
DTC (the sub code cannot be displayed by the MIL),
• The MIL will blin k the current DTC, in case the ECM detects the
problem at present, when the ignition switch ON or idling with the
sidestand down, The MIL will stay ON when the engine speed is
over 5,000 rpm or with the sidestand up,
• The MIL has two types ol blinks, a long blink and short blink, The
long blinking lasts lor 1.3 seconds, the short blinking lasts lor 0,5
seconds, One long blink is the equivalent ol ten short blinks, For
example, when two long blinks are lollowed by live short blinks, the
MIL is 25(two long blinks = 20 blinks, plus live short blinks) ,
• When the ECM stores more than one DTC, the MIL will indicate
them by blinki ng in the order lrom the la west number to highest L _ _ _ _ _ _ _ _ _ _ _ _ _ _ _M _ IL_ _. l
number.
MIL Check
When the ignition switch is turned ON and engine stop switch "0", the MIL will stay on lor a lew seconds, then go aft, Il the
MIL does not come on, troubleshaat the MIL circuit (page 6-42),
CURRENT DTC/FREEZE DTC
The DTe is indicated in twa ways according to the failure status.
• In case the ECM detects the problem at present, the MIL will come on and the MIL will start to blink when the sidestand
is lowered, It is possible to readout the MIL blink pattern as the current OTC,
• In case th e ECM does not detect any problem at pre se nt but has a problem sta red in its memory, the MIL will not light
and blink, Il it is necessary to retrieve the past problem, readout the Ireeze DTC by lollowing the DTC readout proce-
dure.
HDS POCKET TESTER INFORMATION

• The HDS can readout the DTC, Ireeze data, current data and other ECM co ndition,
How to conneet the HDS Pocket Tester
Remave the se at (page 3-4) ,
DLC
Turn the ignition switch OFF,
Remave the dummy connector trom the DLC,
Conneet the HDS pocket tester to the DLC,
Turn the ignition switch ON, check the DTC and freeze data,
NOTE:
• Freeze data indicates the engine conditions when the first maIfunc-
tion was detected .
ECM reset
The HDS can reset the ECM data including the DTC, Ireeze data and
same learning memory. DUMMY CONNECTOR
DTC READOUT
Start the engine and che ck th e MIl.
• If the engine wil! not start, turn the starter motor tor more than 10
seconds and check that the MIL blinks,
• When the ignition switch is turned ON , the MIL will stay on lor a lew
seconds, then go oft.
Il the MIL stays on or blinks, conneet the HDS Pocket Tester to the DLC
(page 6-14), read the DTC, freeze data and lollow the troubleshooting
index (page 6-16),
Ta read the DTC with the MIL blinking, reler to the lollowing proce-
dure.
MIL
6-14
Reading DTC with the Mil
Turn the ign ition switch OFF.
Remave the seat (page 3-4).
Remave the dummy connector and short DLC terminals using the spe·
cial taal.
Connectio": Brown - Green
TOOl:
/~
Make sure the engine stop switch is turned to "0".
Turn the ignition switch ON, read, note the Mil blinks and refer to the
troubleshooting index (page 6-16) .
SCS CONNECTOR
NOTE:
II the ECM has any DTC in its memory, th e Mil will start blinking .
CLEARING DTC
Conneet the HDS Pocket Teste r to the DlC (page 6-14).
Clear the DTC with the HDS while th e engine is stopped.
Ta clear the DTC wi th ou t HDS, refer to the lollowing procedure.
How to cle_r the DTC with SCS connector
1. Remave the seat (page 3-4).
2. Turn the ignition swit ch OFF.
3. Make sure the engine stop switch is turned to "0".
Remave the dummy connector and short the 8rown and Green w ire
termin als ol the DlC using the specia l taal.
Connectio": Brown - Green
TOOl:
/~
4. Turn the ignit ion swi tch ON .
5. Remave the special taal from the DlC.
SCS CONN ECTOR
6. The Mil wililight for approximately 5 seconds. While the Millights,
short the DLC terminals aga ln with the special taal. The self-d iagnostic memory is erased if the ma lfunction indicator
goes of! and starts blinking.
NOTE:
• The DlC must be j umped whi le the Millights. II not, the Mil will not start blinking .
• Note that the self-diagnostic memory cannot be erased if the i9n ition switch is turned OFF betore the MIL starts blink-
ing .
CIRCUIT INSPECTION
INSPECTION AT ECM CONNECTOR
• Always clean around and keep any foreign material away trom the
ECM connector betore disco nnecting it.
• A faulty PGM-FI system is often related to poorly connected or cor-
roded connections. Check those connections betore proceeding.
• In te5tin9 at EC M connector (wire harness side) terminal, always
use th e test probe . Insert th e test probe in ta the connector terminal,
then attach th e digital multim eter probe to the test probe.
TOOl:
Test probe 07ZAJ-RDJA 110
TEST PROBE
DTCINDEX
DTC(MIL
blinks)
Function Failure Symptom/Fail-safe function Refer to
1-1 (1)
MAP sensor circuit low voltage (less than 0.2 V) • Engine operates normally
6-18
• MAP sensor or its circu it malfunction
MAP sensor circuit high voltage (more than 3.9 V) • Eng ine operates normally
1-2 (1 ) •
La ase or poor contact of the MAP sensor connector 6-19
•
MAP sensor or its circuit malfunction
MAP sensor performance problem • Engine operates normally
2-1 (2) • Laa se or poor connection of th e MAP sensor vac· 6-20
uum hose
• MAP senso r malfunction
ECT sensor circuit low voltage (Ie ss than 0.07 V) • Hard start at a low temperature
7-1 (7) • EeT sensor or its circuit malfunction • Pre-program value: 90°C/ 194°F 6-21
• Caoling fan turns on
ECT sensor circuit high voltage (more than 4.93 V) • Hard start at a low temperature
7-2 (7) • Laase or poor contact of the EeT sensor connector • Pre-program value: 90°C/ 194°F 6-22
• EeT senso r or its circuit malfunction • Cooling fan turns on
TP sensor circ uit low voltage (Iess than 0.3 V) • Poor engine acceleration
8-1 (8) • Laase or paar contact of the TP sensor connector • Pre-program value: 0° 6-23
• TP sensor or its circuit malfunction
8-2 (8)
TP sensor circuit high voltage (more than 4.93 V) • Poor engine acceleration
6-25
• TP sensor or it s circuit malfunction • Pre·program value: 0°
9-1 (9)
lAT sensor ci rcuit low voltage (Iess than 0.07 V) • Engine operates norm ally
6-26
• lAT sensor or its circuit malfunction • Pre-program value: 25°Cn7°F
lAT sensor circuit high voltage (more than 4.93 V) • Engine operates normally
9-2 (9) • Laase or poor co ntact of the lAT sensor connecto r • Pre-program va lue: 25°CnrF 6-27
• lAT sensor or its circuit malfunction
VS sensor na signa I • Engine operates narmally
11-1 (11) • Loose or poor contact ofthe VS sensor connector 6-28
• VS sensor or its circuit malfunction
No. 1 primary injector circuit malfunction • Engine does not start
12-1 (12) • Loose or poor contact of the injector connector • Injectors, fuel pump and ignition shut 6-29
• Injector or its circuit malfunction down
13-1 (13) • Loo se or poor contact of the inj ector connector • Injectors, fue l pump and ignition shut 6-31
No. 3 primary injector circuit malfunction • Engine does not sta rt
14-1 (14) • Loose or paar contact of the inj ector connector • Injectors, fu el pump and ignition shut 6-31
• Injector or its ci rcuit malfunction down
15-1 (15) • Loose or paar contact of the injector con nector • Injectors, fuel pump and ignition sh ut 6-31
N o. 1 secondary injector circuit malfunction • Engine does not start
16-1 (16) • Loo se or paar contact of the injector connector • Injectors, fu el pump and ignition shut 6-31
No. 2 secondary injector circuit malfunction • Engine does not start
17-1 (17) • Loose or paar contact of the injector connector • Injectors, fuel pump and ignition shut 6-31
CMP sensor na signal • Engine does not start
18-1 (18) • Loos e or poor contact of the CMP sensor connector • Injectors, fuel pump and i9nition shut 6-31
• CMP sensor or its ci rcuit malfunction down
CKP sensor na signa I • Engine does not start
19-1 (19) • Loose or paar contact of the CKP sensor connector • Inj ectors, fuel pump and ignition shut 6-32
• CKP sensor or its circuit malfunction down
Knock sensor circuit malfunction • Engine operates normally
25-2 (25) • Loo se or poor contact of the Knock sensor connector 6-33
• Knock sensor or its circuit malfunction
25-3 (2 5)
Knock sensor circuit malfunction • Eng ine operates normally
6-34
• Knock sensor or its circuit malfunctio n
IACV circuit malfunction • Engine stalIs, hard to start, rough
29-1 (29) • Loose or paar contact of the IACV connector idling 6-36
• IACV or its circuit malfunction
33-2 (-) ECM EEPROM malfunction • Engine operates normally 6-37
6-16
DTC (Mil
Function Failure Symptom/Fail-safe function Refer to
blinks)
EGCV POT low voltage malfunetion • Engine operates normally
34-1 (34) • Loase or poor contact of the EGCV connector 6-38
• EG CV or its circuit malfunction
34-2 (34)
EGCV POT high voltage malfunetion • Engine operates normally
6-39
• EGCV or its circuit malfunction
EGCV servomotor malfunetion • Engine operates normally
35-1 (3 5) • Laase or poor contact of the EG CV connector
6-40
• EG CV or its circuit malfunction
• EG CV servomotor loek
48-1 (48) • Laase or poor contact of the injector connector • Injectors. tuel pump and ignition shut 6-31
• Injector its circuit malfunction down
49-1 (49) • Laase or poor contact of the injector connector • Injectors, tuel pump and ignition shut 6-3 1
• Injector its circuit malfunction down
HESD linear solenoid malfunction • Engin e operates normally
51-1 (51) • Loose or poor contact of the HESD solenoid connec- • HESD does not function
14-9
tor
• HESD solenoid or its circuit
56-1 (56)
Knock sensor IC malfunction • Engine operates normall y
6-41
• Knock sensor or its circuit malfunction
6-17
DTC TROUBLESHOOTING
DTC ,-, (MAP SENSOR LOW
VOLTAGE)
• Betore starting the inspection, check tor loose or
paar contact on the MAP sensor 3P (Black) con-
necto r and ECM 33P connectors, then recheck
the DTC.
1. MAP Sensor System Inspection
T urn the ignition switch ON and engine stop
switch "0".
Check the MAP se nsor w ith the HDS.
Is about 0 V indicated?
YES - GO TO STEP 2.
NO - Intermittent failure
2. MAP Sensor Input Voltage Inspection
Turn the ignition switch OFF.
Disconnect the MAP sensor 3P (Black) connec- 3P CONNECTOR
tor. (W ire side/female terminals)
Turn the ignition switch ON and engine stop

switch "0" .
Measure the voltage at the wire side. Gray/ black Yellow/ red
Connection: Yellow/red (+) - Gray/black H
Is the voltage within 4.75 - 5.25 V?
YES - GO TO STEP 4.
e
NO - GO TO STEP 3.
3. MAP Sensor Input Line Inspection

Disconnect the ECM 33P (Black) connector. 3P CONNECTOR
(Wire side/female term inals)
Check for continuity between the MAP sensor 3P Yellow/red (A9 )
(Black) connector and ECM 33P (Black) connec- ~±~gf8!E~
tor. F~h Yellow/
Connection: A9 - Yellow/red ........i-4J red
TOOL:
Test probe 07ZAJ-RDJA110
Is there continuity7
YES - Replace the ECM with a known good 33P (Black) CONNECTOR
one, and recheek
(Wire side/female terminals )
NO - Open circuit in Yellow/ red wire
6-18
FUEL SYSTEM (PGM -FI)
4. MAP Sensor Output Line Short Circuit
Inspection
Connect the ECM 33P (Black) connector.
Check for continuity between the MAP sensor 3P 3P CONNECTOR
(Black) connector at the wire side and ground. (Wire side/female terminals)
~.iFl9'"
Connection : Light green / yellow - Ground
YES - Short circuit in Light green/yellow wire Light green/
NO - GO TO STEP 5. yellow
5. MAP Sensor Inspect ion

Replace the MAP sensor w ith a known good one
(page 6-70) .
Clear the DTC's (page 6-15).
switch "0".
Check the MAP sensor with the HDS .
Is DTC 1- 1 indicated?
YES - Replace the ECM with a known good
one, and recheek
NO - Faulty original MAP sensor
DTC '-2 (MAP SENSOR HIGH

VOLTAGE)
• Before starting the inspection, check tor loose or
poor contact on the MAP sensor 3P (Black) con-
nector and ECM 33P connectors, then recheck
the DTC.
1. MAP Sensor System Inspection 1
switch "0" .
Check the MAP sensor with the HDS.
Is abou t 5 V indicated?
YES - GO TO STEP 2.
2. MAP Sensor System Inspect ion 2
3P CONNECTOR
Disconneet the MAP sensor 3P (Blaek) connec- (Wire side/femal e terminal s)
tor.
Connect the MAP sensor 3P (Blaek) connector at
the wire side with a jumper wire.
Connection: Li ght green/yell ow - Gray/blaek
switch "0" ,
Check the MAP sensor with the HDS.
YES - Faulty MAP sensor
NO - GO TO STEP 3. JUMPER WIRE
6-19
FUEl SYSTEM (PGM-FI)
3. MAP Sensor Input Voltage Inspection
Remove the jumper wire. 3P CONN ECTOR
(Wire side/female terminals)
switch "0".
Measure the voltage at the wire side.
Conneetion: Yel/ow/red (+)- Gray/ black H Gray/ black Yel/ow/ red
/5 the voltage within 4.75 - 5.25 V7

YES
NO
- GO TO STEP 4.
- Open ci rcuit in Gray/black wi re
e
4. MAP Sensor Output line Open Circuit

Inspection
Discon neet th e ECM 33P (Gray) connector. 3P CONNECTOR
Check for continuity between the MAP sensor 3P (Wire side/female terminals)
(Black) connector and ECM 33P (G ray) connec-
tor.
Conneetion: 89 - Light green/yel/ow
I
Taal: Light green/
Test probe 07ZAJ-RDJA 110 Light greenl yel/ow
ye l/ow (B9)
Is there continuity? L...-_-{ Q
YES - Replace the ECM with a know n good
one, and recheek 33P (Gray) CONNECTOR
(Wi re side/female terminal s)
NO - Open circuit in Light green /yel/ow wire
DTC 2-1 (MAP SENSOR)

• Betore starting the inspection, check tor 10058 or
paar contact on the MAP sensor 3P (Black) con-
nector and ECM 33P connectors, th en re check
the DTC.
1. MAP Sensor System Inspeetion
switch "0".
Start the engine and check the MAP sensor with
the HDS at idle speed .
Is the reading changed7
YES - Intermittent failure
NO - GO TO STEP 2.
6-20
2. Manifold Absolute Pressure Test
Check for connect ion and installation of the MAP
sensor vacuum hose.
Is the MAP sensor vacuum hose connection cor-
rect?
YES - GO TO STEP 3.
NO - Correct the hose installation
VACUUM HOSE MAP SENSOR

3. MAP Sensor System Inspection
Replace the MAP sensor with a known good one
(page 6-70).
switch "0".
Start the engine and check the MAP sensor with
the HDS at idle speed.
Is the reading changed?
YES - Fau lty original MAP sensor
NO - Repla ce the ECM with a known good
one, and recheek
DTC 7-1 (ECT SENSOR LOW

VOLTAGE)
• Betore starting the inspectien, check tor loose or
poor contact on the ECT sensor 3P (Gray) con-
nector and ECM 33P connectors, then recheek
the DTC.
,. EeT Sensor System Inspection
switch "0".
Check the ECT sensor with the HDS.
YES - GO TO STEP 2.
2. EeT Sensor Inspection
Disconneet th e ECT sensor 3P (Gray) connect or.
Turn th e ignition switch ON and engine stop
switch "0" ,
Check t he ECT sensor with the HDS.
YES - GO TO STEP 4.
NO - GO TO STEP 3.
6-21
3. EeT Sensor Resistance Inspection
Measure the resistance at the EeT sensor termi-
nals. 3P CONNECTOR
(Senso r side/ male terminals)
Connection: Blue/ yellow - Gray/blaek
Standard: 2,3 - 2,6 kn (20°C/68°F)
Is the resistanee within 2,3 - 2,6 kil?

~
YES - Rep lace the ECM with a known good
one, and recheek
NO - Faulty ECT sensor
4, ECT Sensor Output Line Short Circuit Inspection

Turn the ignit ion switch OFF, .3
-P- C-O- N
-N- EC
-T-O
- R- - - - - - - - - - - - - ,
Check for continuity between the ECT sensor 3P (Wire side/female terminals)
(Gray) connector at the wire side and ground, "'"
Connection: Blue/yellow - Ground ~
Is there eontinuity?
YES - Short circui t in Blue/yellow wire Blue/ye llow
NO - Replace the ECM with a known good
one, and recheek
DTC 7-2 (ECT SENSOR HIGH

VOLTAGE)
• Beto re starting th e inspectio n, check tor loose or
paar contact on the ECT sensor 3P (Gray) co n-
nect or an d ECM 33P connectors, th en recheck
the DTC,
1, ECT Sensor System Inspection
Turn the 19 nition switch ON and engine stop
switch "0" .
Check the ECT sensor with the HDS,
Is about 5 V indieated?
YES - GO TO STEP 2,
2, ECT Sensor Inspection
Turn the ignition switch OFF,
Di scon nect the ECT sensor 3P (Gray) co nnector,
Connect the ECT sensor 3P (G ray) connector at Blue/ye llow Gray/black
the wire side with a jumper wire.
Connection: Blue/yellow - Gray/bl.ek
Turn the i9nition switch ON and engine stop

switch "0" .
Check the ECT sensor with the HDS,
Is about 0 V indieated? JUMPER WIRE
YES - Inspect th e ECT sensor (page 20-14)
3P CONNECTOR
NO - GO TO STEP 3,
(Wire side/female termina ls)
6-22
3. ECT Sensor Output Line Inspection
Remave the jumper wire.
3P CONNECTOR
(Wire side/lemale terminals )
Disconneet the ECM 33P connectors.
Check lor continuity between the ECT sensor 3P
(Gray) connector and ECM 33P connectors.
Connection: 813 - 8lue/yellow
A 18 - Gray/black
TOOl: Blue/yellow
(813)
Is there continuity?
YES - Replace the ECM with a known good 33P (Gray) CONNECTOR
one, and recheek (Wire side/lemale terminals)
NO _. Open circuit in Blue/yellow wire

• Open circuit in Gray/black wi re
3P CONNECTOR
(Wi re side/lemale terminals)
Gray/black Gray/black
(A18)
L-----{ Q
33P (Black) CONNECTOR
(Wire side/lemal e terminals)
DTC 8-' (TP SENSOR LOW VOLTAGE)

paar contact on the TP senso r 3P (Black) co nnec-
tor and ECM 33P connectors, then recheck t he
DTC.
1. TP Sensor System Inspection
switch "0 ".
Check the TP sensor with the HDS when the
throttle is lully closed.
YES - GO TO STEP 3.
NO - GO TO STEP 2.
2. TP Sensor Inspection
Check that the TP sensor voltage increases con-
tinuously when moving the throttle trom fully
closed to lully opened using the data list menu
ol the HDS.
Does the voltage increase continuously?
YES - Intermittent lailure
NO - Faulty TP sensor
6-23
3. TP Sensor Input Voltage Inspection
Disconnect the TP sensor 3P (Black) connector. 3P CONN ECTO R
(Wire side/female te rmina ls)
switch "0".
Measure the voltage at the wi re side. ~?='I""I'=I"
Yell ow/red Gray/black
Connection: Yell ow/ red (+) - Gray/ black H
/s the voltage within 4.75 - 5.25 V7
YES - GO Ta STE P 5. e
NO - GO Ta STEP 4.
4 . lP Sensor Circuit Inspection

Turn the ignit ion switch OFF.
Disconnect the ECM 33P (Black) connector. 3P CONN ECTOR
Check for continuity between the T P senso r 3P (Wire side/female te rminals)
(Black) con nector and ECM 33P (Black) connec-
to r.
Connection: A9 - Yellow/ red
TOOl:
Yell ow/red
(A9)
YES - Replace t he ECM with a known good
one, and recheek 33P (Blaek) CONNECTOR
NO - Open circuit in Yellow/red w ire
(Wire side/fe m ale termina ls)
5. lP Sensor Output line Open Circuit Inspection

T urn the ig nition switch OFF.
Disconnect the ECM 33P (G ray) connector. 3P CONN ECTOR
Check fo r con tinui ty betwee n the T P sensor 3P (Wi re side/fema le te rmina ls)
(Black) connecto r and ECM 33P (G ray) connec-
tor.
Connect ion : B31 - Blue/yellow
Blue/yellow
TOOl:
Blue/yellow
Test probe 07ZAJ -RDJA110
(B3 1)
Is th ere continuit y7 '-------{ Q
YES - GO Ta STEP 6.
33P (G ray) CONN ECTOR
NO - Ope n circuit in Blue/yellow w ire
(Wire side/fem ale term inals)
6. lP Sensor Output Line Short Circuit Inspection

Disconnect the TP sensor 3P (Black) co nn ector.
Co nn ect the ECM 33P (G ray) co nnecto r. 3P CONNECTOR
Check f or continuity between the T P senso r 3P
connector at the wire side and ground.
Connection: Blue/yellow - Ground ~~
Is there continuity? Bl ue/yellow
YES - Short circuit in Blue/yellow w i re
NO - GO TO STEP 7.
6-24
7. TP Sensor Inspection
Replace the throltle body (page 6-60).
Clear the DTC's (page 6-15 ).
switch "0".
Check the TP sensor with the HDS.
Is DTC 8-1 indicated7
one, and recheek
NO - Faulty original TP sensor
DTC 8-2 (TP SENSOR HIGH VOLTAGE)

• Before starting the inspection, check for loose or
poor contact on the TP sensor 3P (Black) connec-
tor and ECM 33P connectors, then recheck the
DTC.
1. TP Sensor System Inspection
switch "0".
Check th e TP sensor with the HDS.
Is about 5 V indicated7
YES - GO TO STEP 3.
NO - GO TO STEP 2.
2. TP Sensor Inspectio"
Check that the lP sensor voltage increases con-
tinuously when moving the throttle Irom f ully
closed to lully opened using the data list menu
ol the HDS.
Does the voltage increase continuously7
YES - Inte rm ittent lailure
3 . TP Sensor Resistance Inspection
3P CONNECTOR
Disconnect the TP sensor 3P (Black) connector. (Sensor side/male terminals)
Measure the resistance at the lP sensor side.
Connection: Blue/yellow - Gray/blaek
Gray/black
\~
Is the resistance within 0.5 - 1.5 kfl7
YES - GO TO STEP 4.
6-25
4. TP Sensor Input Voltage Inspection
switch "0".
3P CONNECTOR
Measure the voltage at the wi re si de. (Wire side/female terminals )
"'~
Connection: Yellow/red (+) - Gray/black H
Is the voltage within 4.75 - 5.25 V7 Yellow/ red Gray/ blaek
one, and recheck
NO - Open circuit in Gray/black wire e
DTC 9-' (lAT SENSOR LOW VOLTAGE)

• Befare starting the inspectien, check for loose or
poor contact on the lAT sensor 2P (Gray) connec-
tor and ECM 33P co nnectors, then recheck the
DTC.
1. lAT Sensor System Inspection
switch "0".
Check the lAT sensor with the HDS.
YES - GO TO STEP 2.
NO - Inte rm ittent failure
2. lAT Sensor Inspection
Disconnect the lAT sensor 2P (Gray) connector.
Turn th e i9nition switch ON and eng ine stop
switch "0".
Check the lAT sensor with the HDS .
YES - GO TO STEP 3.
NO - Faulty lAT sensor
3. lAT Sensor Output line Short Circuit Inspection
Tu rn the ignition switch OFF.
Check for conti nuity between the lAT sensor 2P 2P CONNECTOR
(Gray) co nnector at the wire side and grou nd. (Wire side/female termina ls)
Connection: Gray/blue - Ground
Is there continuity7 Gray/ blue
YES - Short circuit in Gray/ blue wire

NO - Replace th e ECM with a know n good
one, and recheek
Q
6-26
DTC 9-2 (lAT SENSOR HIGH VOLTAGE)
paar contact on the lAT sensor 2P (Gray) connec-
tor and ECM 33P connectors, then recheek the
DTC.
1. lAT Sensor System Inspection
Turn the ignition switch ON and eng ine stop
switch "0".
Check the lAT sensor with the HDS.
Is about 5 V indieated7
YES - GO TO STEP 2.
2. lAT Sensor Inspection
2P CONNECTOR
Disconneet the lAT sensor 2P (Gray) connector. (Wire side/female terminals )
Conneet the lAT sensor 2P (Gray) connector at
the wire side with a jumper wire. Gray/blue
Connection : Gray/blue - Gray/blaek
Turn th e ign ition switch ON and engine stop
switch "0 ".
Check the lAT sensor with the HDS .
Is about 0 V indieated7
YES - Faulty lAT sensor
NO - GO TO STEP 3.
JUMPER WIRE
3. lAT Sensor Line Inspection
Disconneet th e ECM 33P connectors. 2P CONNECTOR
Check for conti nuity between the lAT sensor 2P (Wire side/female terminals)
(Gray) connector and ECM 33P connectors.
Connection: B29 - Gray/blue
A18 - Gray/blaek Gray/
H'----l b Iu e
TOOL:
Test probe 07ZAJ-RDJA 110 Gray/blue
(B29)
Is there continuity? ,--------{ Q
one, and recheek 33P (Gray) CONNECTOR
NO _. Open ci rcuit in Gray/blue wire (Wire side/f emale terminals)
• Open circuit in Gray/black wire
2P CONNECTOR
(Wi re side/female terminals )
Gray/
f----l black
Gray/black
(A 1S)

6-27
DTC ,,-, (VS SENSOR)
paar contact on the VS sensor 3P (Black) connec-
tor and ECM 33P connectors, th en recheek the
DTC.
1. VS Sensor System Inspection
Support the motorcycle s8cu rely, raise the rear
wheel aft the ground.
Start the engine and shift the transmission ;nto
gear.
Check the VS sensor with the HDS at 6 mph (10
km/hl.
/s 6 mph (10 km/ hl indicated?
YES - Intermittent lailure
NO - GO TO STEP 2.
2. Combination Meter Inspection
Check tor operation of speedometer.
Does the speedometer opera te normally?
YES - Open or short ci rcuit in Pink/green wire
NO - GO TO STEP 3.
3. VS Sensor Input Vo ltage Inspection
3P CONNECTOR
Disconneet the VS sensor 3P (Black) co nnector. (Wire side/lemale terminals)
~~
Turn th e ignition switch ON and eng ine stop
switch "0 ".
Measure the voltage at the wire si de.
Violet
Connection: Violet (+) - Green/black H
/s there battery voltage?
YES - GO TO STEP 4. e
NO _. Open circuit in Violet wire
• Open circuit in Green/ black w i re
4. VS Sensor Signal Line Open Circuit Inspection

Turn th e ign ition switch OFF.
33P (G ray ) CONNECTOR
Disconneet the ECM 33P (Gray) connector.
(Wire side/lemale t erminal s)
Check the continuity between the ECM 33P
(Gray) connector and VS sensor 3P (Black) con- Pink/green
nector.
Connection : 828 - Pink/ green
r
TOOL: Pin k/g reen
Test probe 07ZAJ-RDJA 110 (B28)
Is there continuity? Q
YES - Open circuit in Pink/green wire
3P CONNECTOR
NO - GO TO STEP 5. (Wire side/lemale terminals)
6-28
5. VS Sensor Signal Line Short Circu it Inspection
Turn the igniti on switch OFF.
Conneet the EC M 33P (Gray) connector. 3P CONNECTOR
Check for continuity between the VS sensor 3P
(Blaek) connector at the wire side and ground.
Connection: Pink/ green - Ground
Pink/green
YES - Short circuit in Pink/green wire
NO - Inspeet VS sensor (page 20-11 )
DTC 12-1 (No.1 PRIMARY INJECTOR)

• Betore starting the inspection, check for loose or
poor contact on the injector 2P (Gray) connectors
and ECM 33P connectors, then recheek the DTC.
INJEC- POWER SIGNAL SIGNAL
DTC
TOR INPUT LlNE LlNE ATECM
No.l
12-1 Blaek/white Pink/yellow A17
Primary
NO.2
13-1 Blaek/white Pink/blue A6
Primary
NO.3
14-1 Blaek/white Pink/green AS
Primary
No.4
15-1 Blaek/white Pin k/blaek A7
Primary
NO .l
16-1 See- Blaek/wh ite Yellow A13
ondary
NO.2
17-1 See- Blaek/white Ye llow/blue AlS
ondary
No.3
Ye llow/
48-1 See- Blaek/white A26
green
ondary
No.4
Yellow/
49-1 See- Blaek/white A14
blaek
ondary
1. Injector System Inspection

Clear the DTC's (page 6-15) .
Start the engine and check the injector with the
HDS.
Is the DTC 12-1 indieated?
YES - GO TO STEP 2.
6-29
2. Injector Input Voltage Inspection
2P CONN ECTOR
Disconneet the injector 2P (Gray) connector. (Wire side/female terminals )
switch "0".
Measure the voltage between the injector 2P
(Gray) connector at the wire side and ground.
\
Connection: Black/white (+) - Ground H
Is there battery voltage ?
YES - GO TO STEP 3.
NO - Open ci rcuit in Black/white wire
3. Injector Resistance Inspection

2P CONN ECTOR
Measure the resistance of the injector 2P con- (Injecto r side/male terminals)
nector terminals.
Is the resistance within 11- 13 IJ (20 ' C/ 68' F) ?
YES - GO TO STEP 4.
~
NO - Faulty injector
4. Injector Signal line Open Circuit Inspection

Disconneet the ECM 33P (B lack) connector.
NO.1 primary shown:
Check fo r continuity between the ECM 33P
(Black) connector and injector 2P (Gray) connec- 33P (Black) CONN ECTOR
tor. (Wire side/female termina ls)
Connection : SIGNAl llNE - SIGNAl AT ECM Pink/yellow
Taal:
Test probe
YES
NO
- GO TO STEP 5.
07ZAJ-RDJAll0
- Open circ uit in SIG NAl LlN E wi re

Pink/yellow
(A17)
,----{ Q \
2P CON NECTOR
(Wi re side/female
term inals)
5. Injector Signa I Line Short Circuit Inspection

Conneet the ECM 33P (Black) connector.
2P CONNECTOR
Check for continuity between the injector 2P
(Gray) connector at the wire side and ground.
Connecti on : SIGNAl LlNE - Ground
Is there continuity7 SIGNAl LlNE
YES _. Short circuit in SIGNAl LlNE wire
• Faul ty injector
NO - Replace the ECM with a known good
one, and ree heek
6-30
(pag e 6·29)
(p age 6-29)
(pa ge 6-29)
DTC 16-1 (No.1 SECONDARY
INJECTOR)
(page 6-29)
INJECTOR)
(page 6-29)
INJECTOR)
(page 6-29)
INJECTOR)
(page 6-29)
DTC 18-1 (CMP SENSOR)

• Beto re st arting th e inspectio n, check tor loose or
paa r co ntact on t he CMP senso r 2P (Black) con-
nector and ECM 33P co nnectors. then recheek
t he DTC.
1. CMP sensor Peak Voltage Inspection
Turn t he igniti on switch OFF.
Disconneet lh'e CM P sensor 2P (Black) connector. 2P CO N NECTOR
(Senso r side/fema le te rminals)
Turn the ign ition switch ON.
Crank th e en gi ne and m easure t he CM P se nsor
peak vo ltage at the CM P sensor 2P (Blaek) con-
nectar.
Connection : Gray (+) - Wh ite H

TOOlS:
IgnitionMate peak voltage MTP07-0286
tester (U.S.A. only) or
Peak voltage adaptor 07HGJ-0020100
(Not available in PE AK VOLTAG E ADAPTE R
U.S.A.)
with commercially available digital multimeter
(impedance 10 M n /DCV minimum)
/s the voltage more t han 0.7 V (20 C/ 68 F) ?
Q Q
YES - GO TO STEP 2.
NO - Faulty CM P sensor
6-31
FUEl SYSTEM (PGM-FJ)
2. CMP sensor Circuit Inspection
Disconneet the ECM 33P connectors. 2P CONNECTOR
(Wire side/male terminals)
Check for continuity between the CMP sensor 2P
(Black) connector and ECM 33P connectors.
Connection: B33 - Gray
A32 - White/black
Gray
TOOL: Gray (B33)
'-----{ Q )---'
YES - Short circuit in Gray wire 33P (Gray) CONNECTOR
NO _. Open circuit in White/bJack wire (Wire side/female t erminals)
• Open circuit in Gray wire
2P CONNECTOR
White/black
'-----i Q
DTC 19-1 (CKP SENSOR)

paar contact on the CKP sensor 2P (Blaek) con-
nector and ECM 33P connectors, then ree heek
the DTC.
1. CKP sensor Peak Voltage Inspection
Disconneet the CKP sensor 2P (Black) connector. 2P CONNECTOR
(Sensor side/female terminals)
Turn the ignition switch ON.
Crank the engine and measure the CKP sensor
peak voltage at the CKP sensor 2P (Black) con- '\ ~
nector.
Connection: Yellow (+) - White/yellow H
TOOLS:
IgnitionMate peak voltage MTP07-0286
tester (U.S.A. only) or
(Not available in PEAK VOLTAGE ADAPTER
U.S.A.)
(impedance 10 M fl/ DCV minimum)
/s the voltage more than 0.7 V (20 "C/68 OF) ?
YES - GO TO STEP 2.
NO - Faulty CKP sensor
6-32
2. CKP sensor Circuit Inspection
Disconnect the ECM 33P connectors. 2P CONNECTOR
Check for continuity between the CKP sensor 2P
(Black) connector and ECM 33P connectors.
Connection: B22 - Yell ow
\
A32 - White/black
Yellow
Yellow (B22 )
TOOl:
Test probe 07ZAJ·RDJA 110
L---_ _--{ Q }------.J
YES - Short circuit in Yellow wire 33P (Gray) CONNECTOR
NO _. Open circuit in Yellow wire (Wire side/female terminals)
• Open circuit in White/black wire
2P CONNECTOR
(Wire side/male term inals)
Whitel
White/black black
(A32)

(Wire side/fema le termina ls)
DTC 25-2 (KNOCK SENSOR NO INPUT

VOLTAGE)
poor contact on the Knock sensor 3P (Black) con-
nector and ECM 33P connectors, then reche ck
the DTC.
1. Knock Sensor System Inspection
Place the motorcycle on its sidestand.
Start the engine and ree heek the Knock sensor
with the HDS.
/s the DTC 25-2 indicated?
YES - GO TO STEP 2.
2. Knock Sensor Input Voltage Inspection
3P CONNECTOR
Disconnect the Knock sensor 3P (Black) connec-
tor.
switch "0".
~~ ~ I· 1 ~ Yellow/red
Connection: Yellow/red (+)- Ground H
/s the voltage within 4.75 - 5.25 V?
YES - GO TO STEP 4.
v
NO - GO TO STEP 3.
6-33
3. Knock Sensor Input Line Inspection
Turn the ignitio n switch OFF.
Disconneet th e ECM 33P (Blaek) connector. 3P CONN ECTOR
(Wi re side/female terminals )
Check tor continuity between the Knock sensor
3P (Blaek) connector and ECM 33P (Blaek) con-
nector.
Connection: AS - Vellow/red
Vellaw/
TOOL: Vellaw/ red red
Test probe 07ZAJ-RDJA 110 (A9)
Is there continuity7 '-------1 Q
YES - Replaee th e ECM with a known good
on9, and recheek
33P (Bl aek) CONNECTOR
NO - Open circuit in Ye ll ow/red w ire
4 . Open Circuit Detection Llne Inspection
Turn the ign iti on switch OFF.
Discon neet the ECM 33P (G ra y) connectar. 33P (B laek) CONNECTOR
Check tor cont inuity between the Knock sensor
3P (Blaek) conn ectar and ECM 33P (G ray) con- Blaeklyellaw
nector.
Connection : 85 - Black/yellow
TOOL: Blaeklyellaw
Test probe 07ZAJ-RDJA110 (B5)
YES - GO TO STEP 5.
3P CONN ECTOR
NO - Open ci rcuit in Blaeklyell aw wi re (Wire side/female terminals)
5. Knock Sensor Inspection

Check far eantinuity at the Knaek sensar 3P
(Blaek) con nectar terminals. 3P CONN ECTO R
(Sensar side/male t erminal s)
Connection: Yellow/red - Black/yellow
Is there confinuity?
YES - Replaee the ECM with a known good
one, and recheek
\~
NO - Faulty Knaek sensa r
Ve llaw/red Blaeklyellow
6-34
DTC 25-3 (KNOCK SENSOR LOW
VOLTAGE)
poor contact on the Knock sensor 3P (Black) con-
nector and ECM 33P connectors, then recheek
the DTC.
1. Knock Sensor System Inspectio"
Place the motorcycle on its sidestand .
Start the engine and recheck the Knock sensor
with the HDS.
Is DTC 25-3 indicated?
YES - GO TO STEP 2.
2. Knock Sensor Output line Short Circuit
Inspection 1
3P CONNECTOR
Disconnect the Knock sensor 3P (Black) connec- (Wire side/female terminals)
tor.
Check
ground.
tor continuity between the Knock sensor
3P (Black) connector of the wire side and \ Blue
Connectio": Blue - ground
YES - Short circuit in blue wire
NO - GO TO STEP 3.
3. Knock Sensor Output line Short Circuit

Inspection 2
Check for continuity between the Knock sensor r-
3-P-C-0- N
-N- EC
- T-0 -R- - - - - - - - - - - - - ,
3P (Blaek) connector of the sensor si de and
ground. (Sensor side/male terminals)
Connection: Blue - ground \
Blue
YES - Faulty Knoek sensor
NO - Replaee the ECM with a known good
one, and recheek
6-35
DTC 29-' (IACV)
paar contact on the IA CV 4P (Black) connector
1. Recheek DTC
Start the engine and check the IA CV with the
HDS.
Is the DrC 29-1 indicated?
YES - GO TO STEP 2.
2. IACV Short Circuit Inspection
Disconneet the IACV 4P (Black) connector. 4P CONNECTOR
Check for continuity between the IACV 4P (Blaek) (Wire side/female terminals)
connector at the wire si de and ground.
Connection : Blaek/blue - Ground
Blaek/orange - Ground
Blaek/yellow - Ground
Blaek/red - Ground
YES - . Short circuit in Blacklblue or Blackl
orange wire
• Short circuit in Blacklyellow or Blackl
red wire
NO - GO TO STEP 3.
6-36
3. IACV Circuit Continuity Inspection
Disconneet the IACV 4P (Black) connector.
Check for continuity between the ECM 33P 33P (Blaek) CONN ECTOR
(Black) connector and IACV 4P (Blaek) connector. (Wire side/female terminals )
Connection : A16 - Blaek/blue
A29 - Blaek/ orange
A 19 - Blaek/ yel/ow
A27 - Blaek/red
TOOl:
Is there continuity? (A27) (A16) (A29)
(A19)
YES - GO TO STEP 4.
NO - . Open circuit in Black/b lue or Black/
orange wire
• Open circuit in 81acklyellow or Black/
red w ire
4P CONNECTOR
4. IACV Resistance Inspection

Measure the resistance at the IACV motor side.
4P CONNECTOR
Connection: Blaek/yel/ow - Blaek/orange (Motor side/ma le terminals)
Blaek/red - Black/blue
",,"o,,~
Standard: 99 - 121 n (20' C/68' F)
Is the resistance within 99- 121 Q (20"C/68 ' F)?
Blaek/yellow
one, and recheek ~l=r""f""r1f. ____
NO - Fa ulty IACV
Black/blue Black/red
DTe 33-2 (EEPROM)

1. Recheek DTC
switch "0".
Recheek the ECM EEPROM .
Is the DTC 33-2 indicated7
one, and recheek
6-37
DTC 34-1 (EGCV POT LOW VOLTAGE)
• Betore starting the inspection, check for loose or
paar contact on the EGCV 6P (Natural) connector
1. EGCV POT System Inspection
switch "0".
Check the EGCV POT with the HDS provided
EGCV closed.
Is the indieated voltage within 2.0 - 2.1 V7
YES - Intermittent failure
NO - GO TO STEP 2.
2. EGCV POT Input Voltage Inspection
Di sconneet the EGCV 6P (Natural) connector. 6P CONNECTOR
switch "0 ".
Connection: Yellow/red (+) - Gray/blaek (-)
Gray/black Yellow/red
Is the voltage within 4.75 - 5.25 V7
YES - GO TO STEP 4.
NO - GO TO STEP 3.
8
3. EGCV POT Circuit Inspection

6P CONNECTOR
Disconneet the ECM 33P (Slaek) connector. (Wire side/female terminals)
Check for conti nuity between the EGCV 6P (Nat-
ural) connector and ECM 33P (Slaek) connector.
Connection : A9 - Yellow/red
YeIIOW~
(A9) Ir/ r~e~d~q~~~:j:::n \
TOOl: Yellowl
Test probe 07ZAJ-RDJA 110 red
Is there continuity? L-_--{ Q )----l

YES - R~place the ECM with a known good
one, and recheek
NO - Open circuit in Yel low/ red wire (Wire side/female terminals)
4. EGCV POT Output line Open Circuit Inspection

6P CONNECTOR
Disconneet the ECM 33P (Gray) connector. (Wire side/female terminals)
Check for continuity between the EGCV 6P (Nat-
ural) connector and ECM 33P (Gray) connector.
Connection: S18 - Light green/blaek
TOOl: Lig ht 9 reent

Test probe 07ZAJ-RDJA 110 Light g reen/black black
(S18)
Is there continuity? '--------1 Q
YES - GO TO STEP 5.
NO - Open ci rcuit in light green/black wire 33P (Gray) CONN ECTOR
6-38
5. EGCV POT Output line Short Circuit Inspection
Conneet the ECM 33P connectors.
3P CONNECTOR
Check for continuity between the EGCV 6P (Nat- (Wire side/female terminals)
ural ) connector at the wire side and ground.
Connection: light green/black - ground
Light green/black
YES - Short circuit in Light green/black wire
NO - GO Ta STEP 6.
6. EGCV POT Inspection

Replace the EGCV servomotor with a known
good one.
switch "0".
Check the EGCV POT with the HDS .
Is DTC 34-1 indicated?
one, and recheek
NO - Faulty original EGCV servomotor
DTC 34-2 (EGCV POT HIGH VOLTAGE)

• Betare starting the inspection, check for loose or
poor contact on the EGCV 6P (Natura l) connector
and ECM 33P connecto rs, then recheek the DTC.
1. EGCV POT System Inspection
Turn the ignition switch ON and angine stop
switch "0" .
Check the EGCV POT with the HDS.
YES - GO TO STEP 2.
NO _. Intermittent failure
• Lo ase or poor contact on the EGCV
6P (Natu ral) connector
2. EGCV POT Resistance Inspection
6P CONNECTOR
Disconneet the EGCV 6P (Natural) connector. (EGCV side/male terminals)
Measure the resistance at the EGCV POT side.
Connection: Yell ow/red (+) - Green H
Is the resistance within 4.75 - 5.25 kil (20 °C/
68°F)?
YES - GO TO STEP 3.
NO - Faulty EGCV servomotor
6-39
3. EG CV POT Input Voltage Inspection
switch "0", 6P CONNECTOR
Measure the voltage at the wire side. (Wire side/female terminals)
Connection: Yellow/red (+) - Gray/ black H
/5 the voltage within 4.75 - 5.25 V?
Gray/black Yellow/red
one, and recheek
NO - Open circuit in Gray/black wi re
e
DTC 35-1 (EGCV SERVOMOTOR LOCK)

paar contact on the EGCV 6P (Natural) connector
and ECM 33P connectors, then recheek the Mil
blinking.
1. EGCV Operating Inspection
Disconneet the EGCV control cables from the
exhaust valve pulley (page 6-83).
Check the EGCV servomotor pulley rotation
when shorting the DlC (page 6-15).
Does the EGCV servomotor pulley opera te cor-
rect/y?
YES - . Check the EGCV co ntrol cables bind-
ing, sticking or loek (
• Check the EGCV at exhaust pipe si de
NO - GO TO STEP 2.
2. EG CV Servomotor Inspection
Remove the EGCV servomotor (page 6-80). 6P CONNECTOR
(Motor side/male terminals)
Conneet a 12 V battery to the EGCV 6P (Natural)
connector terminals and check the servomotor
function. . Red~Blue
Connection: Red (+) - Blue H
Does the EGCV servomotor operate normally7 - -
YES - GO TO STEP 3. EB e
NO - Faulty EGCV servomotor
e:l e
6-40
3. ECM Output Line Inspection
Disconneet the ECM 33P (Blaek) connector.
Check for continuity between the EGCV 6P (Nat- 6P CONN ECTOR
ura l) connector and ECM 33P (Black ) connector. (Wire sid e/fema le terminal s)
Connection: Red - AlO
TOOl:
Blue - All
Red (A lO )
\ r--t---t+1 Red
Is there confinuity?
YES - Replace th e ECM wi th a known good '----__---{ Q I-----.J
one, and recheek
NO - . Open circuit in Red wire 33P (Black) CONNECTOR
• Open circuit in Blue wire (Wire side/fema le terminals )
6P CONNECTOR
Blue (Al')
Bl ue ~
33P (Bl ack) CONNECTOR

DTC 56-' (KNOCK SENSOR IC)

1. Knock Sensor System Inspection
Clear th e DTC's (page 6-15) .
Pl ace the motorcycle on its sidestand.
Start the engi ne and recheek th e Knock sensor
with the HDS .
Is about DTC 56-1 indicated?
one, and recheek
NO - Interm ittent failure
6-41
MIL CIRCUIT TROUBLESHOOTING
II the engine can be started but the Mil does not , - - - - - - - - - - - - - - - - - - - ,
come on when the ignition switch is ON and engine 33P (Black) CONNECTOR
stop switch "0", check as lollows: (Wire side/lemale terminals)
• II they do not lunetion, check the combination
meter power input line (page 20-7).
• II they lunetion properly, check as lollows:
Turn the ignition switch OFF, disconneet the ECM
33P (blaek) connector. White/ blue
TOOl: (A20)
Test probe 07ZAJ-RDJA 110 -
-
Ground the White/blue wire terminal ol the wire
side connector with a jumper wire.
Turn the ignition switch ON, the Mil should come ' -
J_
U_M_P_E_R_W
_ IR_E_ _ _ _ _ _ _ _ _ _ _--'
on.
- II the Mil comes on, replace the ECM.
- II the Mi l does not come on, check lor open cir-
cuit in the White/blue wire between the combina-
tion meter and ECM .
It the wire is OK, replace the combination meter
(page 20-8) .
FUEL LlNE INSPECTION

FUEL PRESSURE RELIEVING/QUICK
CONNECT FITTING REMOVAL
• Befare disconnecti ng the tuel hose, relieve pres-
sure trom the system as follows .
1. Turn the ignition switch OFF.
2P (Brown) CONNECTOR
Lilt and support the luel tank (page 4-5) .
2. Disconneet the luel pump 2P (Brown) connector. \
3. Start the engine, and let it idle until the engine
stalls .
4. Turn the ignition switch OFF.
5. Disconneet the battery negative H cable (page
17-6) .
6. Check the luel quick conneet l itti ng lor dirt, and ~=============:::::::=FI:n
::::::IN=G~
clean if necessary.
Place a shop towel over the quick conneet fitting .
6-42
7. Pull and release the rubber cap trom the retainer.
RUBBER CAP RETAINER TABS
8. Hold the connector with one hand and squeeze
the retainer tabs with the ether hand to release
them trom the locking pawls.
Pull the connector oft, then rem ave the rubber
cap and retainer trom the tuel joint.
• Absorb the remaining tuel in the tuel hose trom
tlowing out with a shop towel.
• Be careful not to damage the hose or other parts.
• 00 not use tools.
• If the co nnector does not move, keep the retainer
tabs pressed down, and alternately pull and push LOCKING PAWLS
the connector until it comes oft easily.
CONNECTOR
9. Ta prevent damage and keep toreign matter out,

cover the disconnected connector and fuel joint PLASTIC BAGS
with plastic bags.
QU ICK CON NECT FITTING

INSTALLATION
• Always replace the retainer of the quick connect
fitting when the fuel hose is disconnected.
• If the rubber cap is damaged or cut, replace it
with a new one.
• Do not bend or twist the tuel hose.
• If any reta iner needs replacing, use the same
manufacturer's retainer as the ones being
removed (The various manufactures feature dif·
ferent retainer specjfication) .
1. Insert a new retainer lnto the connector.
~
• Align new retainer locking pawls with the con·
nector 9 rooves .
.....
RETAINER . .
CONNECTOR
6-43
2. Install the rubber cap and seat it onto the fuel
~
RUBBERCAP
joint as shown.
Align the quick connect fitting with the fuel joint.
Then press the quick connect f itting onto the CONNECTOR
pipe until both retainer pawls lock with a
"CLICK", RUBBER CAP ~,
If it is hard to connect, put a small amount of
engine Dil on the pipe end. '\-----, - 1""
FUEL JOINT LOCKING PAWLS

3. Make sure the connection is secure and that the
pawls are firmly locked into place; check visually CONNECTOR
and by pulling the connector.
4. Make sure the rubber cap is in pi ace (between
the flange and retainer tab).
RUBBER CAP
FLANGE RETAINER
5. Connect the f uel pump 2P (Brown) connector.
6. Connect the battery negative (-) cable to the bat-
tery (page 17-6).
7. Turn the ignition switch ON and engine stop
switch "0 ".
The fuel pump will run for about 2 seconds, and
fuel pressure wil! rise.
Repeat 2 or 3 times, and check that there is no
leakage in the fuel supply system.
Remove the suitable support and close the fuel
tank (page 4-6) .
FUEL PRESSURE TEST

Relieve the tuel pressure and disconneet the quick
connect fitting (page 6-42).
6-44
Attach the tue! pressure gauge, hoses, attachment
joint and manila Id.
TOOlS:
(1): Fuel pressure gauge 07406-0040004
(2): Pressure gauge manffold 07ZAJ-S5A0111
(3): Hose attachment,
9 mm/9mm 07ZAJ-S5A0120
(4): Hose attachment,
8mm/9 mm 07ZAJ-S7C0100
(5): Attachment joint,
8mm/9 mm 07ZAJ-S7C0200
U.S.A. TOOlS:
(6): Fuel pressure gauge 07406-0040008 or
07406-004000A
(7): Pressure manilold hose 07AMJ-HW3A 100
(8) : Adaptor, male 07AAJ-S6MA200
(9): Adaptor, lemale 07 AAJ-S6MA400
Temporarily con neet the battery negative H cable
to the battery.
Conneet the luel pump 2P (Brown) connector.
Start the engine and let it idle .
Read the tuel pressure.
Stan dard: 343 kPa (3.5 kgflcm', 50 psi)
II th e luel pressure is higher than speeilied, replace
the luel pump assembly (Iaulty luel pump or luel
press ure reg ulator). (2)
If the tuel pressure is lowe r than specified, inspeet (3)
the lollowing:
- Fuelline leaking U.S.A. TOOlS:
- Pinched or clogged luel hose or luel tank
breather hose
- Fu el pump (page 6-47)
- Clogged luel strainer screen (Assembly ol the
luel pump: page 6-47)
Wrap a shop tawel After inspection, re lieve the tue! pressure by discon-
around the neeting the quick conneet fitting (page 6-42).
attachment to soak
up any spilled fuel. Remave the fuel pressure gauge, ho ses attachment
joint and manilold.
Connect the quick con neet litting (page 6-43).
6-45
FUEL FLOW INSPECTION
Remove the seat (page 3-4).
Open the fuse/ relay box and re move the fuel pump
relay.
Jump the Brown and Black/white wire terminal s ~=======~~~~-~~~~~~

using a jumper wire as shown. RELAY TERMINALS
JUMPER W IRE
Disconneet the quick conneet fitting (page 6-42).
• Place an approved gasoline container and drain
the gasoline .
• Wipe of! spilled gasoline.
Conneet the fuel pump 2P (Brown) connector
(page 6-44).
Conneet the battery negative H cable (page 17-6).
Turn the ignition switch ON and engine stop switch

"0" for 10 seconds.
Measure the amount of fuel flow.
Amount of fuel flow :
167 cm' (5.6 US OZ, 5.9 Imp oz) minimum/10 sec-
ond. at 12 V
I1 the luel flow is less than specilied, inspeet the 101-
lowing :
- Pinched or clogged fuel hose
- Fuel pump unit (page 6-47)
Conneet the quick con neet litting (page 6-43).
6-46
FUEl SYSTEM (PGM-FI)
FUEL PUMP UNIT
INSPECTION
Turn the ignit ion switch ON and engine stop switch
"0" th en confirm th at the fuel pump operates for a
2P (Brown ) CONN ECTOR
tew seconds.
If the fuel pump does not operate, inspeet as fol-
lows:
\
Lift and support the fue l tank (page 4-5).
Discon neet th e fu el pump unit 2P (Brown) connec-
tor.
Turn the ignition switch ON and engine stop switch ~2=P=C=O=N=N=E=C=T=O=R=============

"0", measure the voltage between the terminals on
the wire side. (Wire side/female terminals )
Connection: Brown (+) - Green H

Th ere should be battery vo ltage for a few seconds.
If th ere is battery voltage tor a tew seconds, replace
the fue l pump unit.
If there is na battery vol tage, inspeet the follawing: 8
- Main fuse 30A
- Sub fuse (BANK ANGLE 10A)
- Sub fu se (FI 20A)
- Engine stop switch (page 20-18)
- Fu el pump relay (page 6-49)
- Engine stop relay (page 6-74)
- Bank angle sensar (page 6-72)
- ECM (page 6-75)
REMOVAl
Remave the fuel tank (page 6-50).
Disconneet the breather and drain hoses trom the
fuel tank.
6-47
Remove the fuel pump unit mount ing nuts and
clamps.
Be c8reful nor co Remov e the tuel pump unit and packings.

damage (he pump
FUEL PUMP UN IT
wire and tue/level
gauge.
INSPECTION
Check the fuel pump unit for wear o r damag e,
repl ace it if necessary. FUEL STRAINER SCREEN
Clean the tuel strainer screen with non-flammable

or high flash point solvent.
INSTALLATION
A/ways rep/ace the Place new packings o nto the tuel pump unit.
packing with a new
one.
Be careful nor co Install the tuel pump unit t o the tu el tank.

damage rh e pump
wire and fuellevel
gauge.
6-48
Instal l the clamps and ti ghten the luel pump mount-
ing nuts ta the specified torque in the specified
sequence as shown .
TORQUE: 12 N·m (1 .2 kgl·m, 9Ibl·ft)
Route the hoses Conneet the breather and dra in hoses to the lue l
properly tank securely.
(page 1-21).
Insta ll the luel tank (page 6-50).
FUEL PUMP RELA Y

INSPECTION
Open the luse box and rem ave th e luel pump relay.
Conneet the ohmmeter to the luel pump relay term i- ~F:::U:::E:::L:P:U::M=P:R::E::LA::::Y~~~~=-~~~~~~

nals.
Connect a 12 V battery to th e luel pump relay term i-
nals as shown.
There should be continuity o nl y when the 12 V bat-
tery is connected. If the re is no continui ty when the
12 V battery is connected, replace the luel pump
re lay.
6-49
FUEL SYSTEM (PGM -FI)
FUEL TANK
REMOVAL
Remove the qu ick conneet fitting cover.
QUICK CONN ECT FITTING
Relieve the fuel pressure (page 6-42 ) and disconneet
the quick conneet fitting from the fuel tank.
Disconneet the fue l level sensor 2P (Black) connec-
tor.
COVER 2P (Black) CONNECTO R

Remove the fuel tank pivot bolts, washers and fuel
tank.
For fuel pump unit remova l (page 6-47).
INSTALLATION
FUEL TANK
30 N·m (3.1 kgf·m, 22 Ibrlt)
6-50
Install the luel tank, washers and pivot bolts into the
Irame and tighten the bolts seeurely.
Support the luel tank using a suitable support.
Route the hoses Conneet t he l uellevel sensor 2P (Blaek) connector.

properly
QUICK CONNECT FITIING
Con neet t he quiek conneet litting (page 6-43) .
(page 1-21).
In5ta1l the quick conneet fitting cover securely.
COVER 2P (Bla ek) CONN ECTOR

ENGINE GUARD RUBBER REMOVALI
INSTALLATION
Remove the luel tank (page 6-50) .
Remave the wire harness covers farm the air
cleaner housing . WIRE HARNESS COVERS
Unhook the engi ne guard rubber Irom the wire har-
ness gulde then remove it.
Installation is in the reverse order of rem aval.
WIRE HARNESS GUlDE
6-51
AIR CLEANER HOUSING

REMOVAL
• For MAP sensor remo vallinsta llatio n (page 6-70)
• Far secondary injector removal /installation (page
6-57)
Remove the air cleaner element (page 4-8).
Disconneet the secondary injector 2P (G ray) connec-
tors.
Relieve the tuel pressure and disconneet the quick

conneet fitting from the fuel rail joint (page 6-42) .
Remove the wire harness cover trom the air cleaner
housing.
Remave the screws and middle hou sing.
Remave the screws and remave the air tunnels trom

the lower housing .
6-52
Left slde: Disconneet the PAIR air suction hose trom the lower
Left side: Right si de:
housing.
LOWER HOUSING
Righr side: Disconneet the crankcase breather hose trom the I
lower housing.
PAIR AIR SUCTION HOSE BREATHER HOSE

Disconneet the MAP sensor 3P (Black) connector
and vacuum hose.
~=================~
3P CONNECTOR
VACUUM HOSE
Be careful not ro let Remave the lower housing and air intake joint.
dirt into the intake
port. Be careful not AIR INTAKE JOINT
to damage the
lower housing at
IACV contact area.
LOWER HOUSING
6-53
INSTALLATION
AIR FUNNELS UPPER COVER

AIR INTAKE JOINT
MIDDLE HOUSING
LOWER HOUSING
Install the air intake joint to the frame securely by

aligning its bosses with the frame holes as shown .
AIR INTAKE JOINT
" "
-------
Conneet the MAP sensor 3P (Black) connector and
vacuurn hose.
VACUUM HOSE
6-54
Right side: Connect the crankcase breather hose to the lower
Left side: Right side :
housing .
LOWER HOUSING
Laft side: Conneet the PAIR air suction hose to the lower
housing.
Be care/ui not to let Install the lower housing onto the throttle body.
debris into the
intake port.
PAIR AIR SUCTION HOSE BREATHER HOSE

Set the lower housing to the air intake joint
securely.
Push the lower housing forward against the air
intake joint, then push it down onto the throttle
body.
• Be careful not to damage the lower housing at
IACV contact area .
o Align the air i ntake joint bosses with the lower
housing grooves.
LOWER HOUSING AIR ,"'"".·0JOINT

InstaJl the air tunnels onto the lower hou sing.
Install and tighten the air tunnel/lower housing
mounting screws to the specified torque.
TORQUE: 4.2 N·m (0.4 kgf·m, 3.1Ibf·ft)
6-55
Roure the w ires Install the middle housing and screws.
properly T igh ten the sc rews securely.
(page 1-211.
Install the wire harn ess cover securely.

Connect the fuel hose secu rely.
Con neet the secondary injector 2P (G ray) connec-

tors.
Insta ll the air cleaner element (page 4-8)_
SECONDARYINJECTOR
INSPECTION
Lift and support the fuel tank (pa ge 4-5)_
SOUNDIN G ROD
Start the eng ine and let it idle.
Confirm the injector operating sounds with a sound-
ing rad or stethoscope.
NOTE:
The secon dary injecto rs operate with foll owing con-
di tions.
- Engine speed is over 4,400 rpm
- Thrott le opening is over 10°
INJ ECTOR
6-56
REMOVAL
Remave the air cleaner cover (page 4-8).
Disconneet the secondary injector 2P (Gray) connec-
tors.
Relieve the fuel pressure and disconneet the quick

con neet fitting trom the fuel rail joint (page 6-42).
Remove the wire harness cover.
Remave the balts and fuel rail assembly from the air rF'UiE'L'R,;j[:A;;'Si;iBLY
cleaner housing .
Remave the injector plate trom the fuel rail.

INJECTOR PLATE
6-57
Remave the injectors from the fuel rail.
INJECTOR
Remave the Q-ring and seal ring .
SEAL RING
O-RING
Remave th e fuel rail s and O-rings from the fuel rail
joint. FUEL RAIL
~l . O-RING
O-R ING
FUEL RAIL JOINT

INSTALLATION
Apply oi l to new O-rings and inst al! them to the fuel
rail joint.
FUEL RA IL
Install the fuel rails to the fuel rail joint.
, O-RING
, O-RING e~
ti FUEL RAIL JOINT
6-58
....
Apply oil to a new O-ring and install it to the injec-
tor, being carelul not to damage the O-ring. SEALRING . .~
Rep/ace the dusr Install a new seal ring to the injector. INJ ECTOR
seal and Q-ring with
new ones as a set.
Install the injectors to the luel rail , being carelul not

to damage the O-rings.
INJECTOR
Install the injector plate to the luel rail assembly.
Install the luel rail assembly onto the air cleaner

housing and tighten the balts to the specilied
torque.
TORQUE: 5.3 N·m (0.5 kgl·m, 3.9 IbHt)
6-59
Connect the quick connect fitting (page 6-43).
Install the wire harness cover securely.
Connect the secondary injector 2P (Gray) connec-

tors.
Install the air cleaner cover (page 4-8).
THROTTLE BODY
REMOVAL
California type shown: 5-WAY JOINT
- Fuel tank (page 6-50)
- Air clea ner housing (page 6-52)
California type: Discon neet the vacuum hose trom the 5-way joint.
VACU UM HOSE
Disconneet the tollowing:
TP SENSOR CONNECTOR IACV CONNECTOR
- IACV 4P (Black) connector
- TP sensor 3P (Bl ack) co nnector
- Knock senso r 3P (B lack) connector
- Primary injector 2P (Gray) connectors
INJECTOR KNOCKSENSOR
CONNECTORS CONNECTOR
6-60
Loosen the insulator band screW5 using a long type
phill ips screwdriver.
Do not hold the fuel Remave the throttle body Irom the cylinder head.
rail on the throttle
body to remove rhe
throttle body, or it
may be damaged.
\\, ~
INSULATOR BAND SCREWS
Do nor snap the Loosen the lock nut, adjusting nuts and disconneet I
throttle va/ve trom the throttle cables Irom the throttle drum.
fully open to fully
• Seal the cylinder head intake ports with tape or a
cfosed after the
clean cloth to keep dirt and debris from entering
throttle cable has
the intake ports after the throttle body has been
been removed. Ir
removed. If debris is allowed to enter the ports
maycause
the engine may be damaged.
incorrect idle
• The throttle body is lactory pre-set. Do not disas-
operation.
sembIe in a way other than shown in th is man-
ual.
• Do not loosen or tighten the white painted balts
and screws ol the throttle body . Loosening or
tightening them can cause throttle valve and idle
control failure .
PAINTED WHITE PAINTED WHITE
PAINTED WHITE
6-61
Do not loosen
PA INTED W HITE PAINTED W HITE
PA INTE D WHITE PAINTED W HITE
5.1 N·m (0.5 kg/·m, 3.8 IbHt)

2.1 N·m (0.2 kg/·m, 1.5 IbHt)
6-62
PAINTED WHITE
THROTTLE BODY VACUUM HOSE ROUTING (CALIFORNIA TYPE)
6-63
INSTALLATION
Route the throttle Conneet the throttle cabla ends to the throttJe drum.
cab/es properly
(page 1-2 1).
00 not hold the luel Install the throttle body onto the cylinder head.
raif on the throttle
Tighten the engine si de insulator band so that the
body to ins tall the
insulator band distance is 12 ± 1 mm (0.5 ± 0.04 in) .
throttle body.
• Align the insulator band hole with the insulator
boss.
\\"- ~
INSULATOR BAND SCREWS
12 ± 1 mm
(0.5 ± 0.04 in)
Conneet the following :

TP SENSOR CONNECTOR IACV CONNECTOR
- Primary injector 2P (Gray) connectors
- Knock sensor 3P (Black) connector
- TP sensor 3P (Black) connector
- IACV 4P (Blaek) connector
INJECTOR
CONNECTORS
6-64
Califomia type: Conneet the vacuum hose to the 5·way joint
California type shown : 5-WAY JOINT
securely.
Adjust the throttle grip freeplay (page 4-8).
Install the removed parts in the reverse order of
remaval.
VACUUM HOSE
PRIMARY INJECTOR
INSPECTION
Lift and support the fuel tank (page 4-5).
PRIMARY INJECTOR
Start the engine and let it idle.
Confirm the injector operating sounds with a sound-
ing rod or stethoscope.
SOUNDING ROD
REMOVAL
Remove the throttle body (page 6-60).
Remove the balts and tuel rail/primary injector
assembly.
FUEL RAIL
Remove the injectors trom the tuel rail.
INJECTOR
6-65
Remove the seal ring and a -ring .
SEAL RING
~
a-RING
Remove the fuel rails and O-rings from the fuel rai l
joint. FUEL RAIL JOINT FUEL RAIL
~~
INSTALLATION
Apply oil to new O-rings and install them to the fuel
rail joint.
Install the fuel rails to the fuel rail joint.
r\ .
FUEL RAIL O-RINGS ~,
Apply oil to a new a -ring and install it to the injec-
tor, being careful not to damage the a-ring.
Rep/ace the seal Install a new seal ring to the injector.
ring and O-ring with
new ones as a set.
Install the injectors to the fuel rail, being careful not

INJECTOR
\1
a-RING S
FUEL RAIL
to damage the a-ring.
INJECTOR
6-66
Install the luel raillprimary injector assembly onto
the throttle body , being carelul not to damage the FUEL RAIL IPRIMARY INJECTOR ASSEMBLY
seal rings.
Tighten the luel rai l mounti ng balts to the specilied

torque.
TORQUE: 5.1 N·m (0.5 kgf·m, 3.8 IbHt)

Install the throttle body (page 6-64).
ENGINE IDLE SPEED

IDLE SPEED INSPECTION
• In speet the idle speed afte r all ather engine main-
tenance items ha ve been performed and are
within specifi catio ns.
• Bel are checki ng t he idle speed, inspeet the 101-
lowing items.
- No DTC and MIL blinking
- Spark plug co ndition (page 4-9)
- Air clea ner condition (page 4-8)
• The engine must be warm tor accurate idJe speed
inspection .
• Thi s system eliminates the need tor manual id le
speed adjustment compared to previous
desig ns.
• Use a tachometer w ith graduations of 50 rpm or
sma ller that wi ll accurately indicate a 50 rpm
change.
Lift and support the l uel tank (page 4-5).
Start the engine and warm it up to coolant tempera-
ture 80°C (176°F).
Stop the eng ine and conneet a tachometer accord-
1n9 to the tachometer manufacturer's operating
instructions.
Start the engine and let it idle. Check the idle speed .
ENGINE IDlE SPEED: 1,400 ± 100 rpm
II the idle speed is out ol the specilication , check the
lollowing:
• Throttle operation and throttle grip I reeplay
(page 4-8)
• Intake air leak or engine top-end problem (page
9-6)
• IACV operation (page 6-68)
6-67
IACV
INSPECTION
The IACV is installed on the throttle body and is
operated by the step motor. When the ignition
switch is turned ON, the IACV operates lor a lew
seconds.
Check the step motor operating (beep) sound with
the ignition switch turned ON.
NOTE:
The IACV operation can be checked visua"y as 101-
lows:
• Remove the IACV (page 6-68). Connect the 4P
(Black) co nnector to the IACV, then turn the igni-
tion switch ON .
REMOVAL
• Always clean the throttle body belore the IACV
removal to prevent dirt and debris trom entering SETIING PLATE
the IACV passage.
Remove the throttle body (page 6-60).
Remove the torx screws and setting plate.
Remove the IACV motor.
INSTALLATION
Turn th e slide valve clockwise untillightly seated on
IACV.
6-68
FUEL SYSTEM (PGM-FJ)
Install the IACV motor, aligning slide valve groove
with the pin.
Install the setting plate while aligning the cut-out

with the lug on the IACV motor.
Install the torx screws and tighten them to the spec-

ified torque.
TORQUE: 2.1 N·m (0.2 kgf·m, 1.5 Ibf·ft)
Install the throttle body (page 6-64) .
KNOCK SENSOR
- Starter motor (page 19-6)
- Th ermostat housing (page 7-8)
Remove the bolt and knock sensor.
Rou te the wire Installation is in the reverse order of removal.
properly
TORQUE:
(page 1-211.
Knock sensor mounting bolt:
22 N·m (2.2 kgf.m, 16Ibf·ft)
6-69
MAP SENSOR
OUTPUT VOLTAGE INSPECTION
Conneet the HDS pocket tester (page 6-14).
View the vo ltage with HDS pocket tester.
(VI
Standard: 2 .7 - 3.1 V
3.5
Th e M A P sensor outp ut voltage (abave) is mea-
su red unde r the standard atmosphere (1 atm =
1,013 hPa) . 3.1
Th e MAP sensor output voltage is aftected by the 3.0
di sta nce above sea level, because the output volt- 2.763
age is changed by atmospheric pressure. 2.7
2.6
Check the altitude and be sure that the measured 2.5 2 .46 2.5
voltage lalls withi n the specil ied value.
2.1
2.0
1.5
1.0
0.5
o 500 1,000 1,500 2,OOO :m

(1 ,650) (3,300) (4,950) (6,600) (teet)
Altitude
Remave the air cleane r housi ng (page 6-52) .
Remove the screw and MAP sensor from th e air
cleaner hou sing.
In sta ll the removed parts in the reverse order of
removal.
!ORQUE:
MAP sensor mounting screw:
1.1 N ·m (0.1 kgf·m , 0.8 Ibl·ft)
6-70
lAT SENSOR
Remave th e tue l tank cover (page 3-9).
Discon neet th e lAT se nso r 2P (Gray) connector.
Remove the screws and lAT sensor trom the air
cleane r housin g cover.
Insta llati on is in the reverse order of removal.
TORQUE:
lAT sensor m ounting screw:
1.1 N'm (0.1 kgl·m, 0.8 Ibl·ft )
ECT SENSOR
REMOVAL
Rep/ace the ECT Dra in t he coo lan t trom the system (page 7-7).
sensor while the
Lift and support th e t uel t ank (page 4-5) .
engine is cold.
Disco nneet t he ECT sensor 3P (Gray) connector.
Remove th e Ee T sensor an d sealing washer.
INSTALLATION
Afways rep/ace a Insta ll a new seali ng was her and EeT sensor.
sealing washer wirh Ti ghten the EeT se nsor to th e speci fied torqu e.
a newone.
TORQUE: 23 N·m (2.3 kgl·m , 17 Ibl·ft)
Conneet t he ECT senso r 3P (Gray) co nnecto r.
Rem ave th e suitabl e sup po rt and close th e luel ta nk 3P CONNECTOR
(page 4-6).
Fil l th e coo ling system wi th recommended coola nt
(page 7-7).
CMPSENSOR
REMOVAL
Remave th e left m id dle cowl (page 3-8).
Disconneet the CMP sensor 2P (Black) con nect or.
6-71
Remove the bolt, wire clamp CMP sensor and D-
ring from Ihe cylinder head .
INSTALLATION
Apply oil la a new a-ring and inslall il onlo Ihe CMP
sensor.
Inslall Ihe CMP sensor inlo Ihe cyl inder head.
Route the w ire Install the wire clamp and tighten the mounting bolt
properly secu rely .
(page 1-27).
Roule Ihe CMP sensor wire properly, connecl Ihe 2P

(Black) conneclor.
Inslall Ihe lett middle cowl (page 3-8).
BANK ANGLE SENSOR

INSPECTION
Remave Ihe upper cowl/fronl spoiler (page 3-11).
Connecl Ihe special 1001 belween Ihe bank angle
sensor and wire harness.
TOOL:
Inspection adaptor 07GMJ-ML80100
Turn the îgnition switch ON and engine stop switch

"0".
Measure Ihe vollage between Ihe following lermi-
nals of Ihe special 1001.
TERMINAL STANDARD
While (+ ) - Green (-) Banery vollage
INSPECTION ADAPTOR
Red (+) - Green (-) 0- 1 V
6-72
Do not disconneer Turn the ignition switch OFF.
the bank angfe
Remove the screws, washers and bank angle sen·
sensor connector
during inspection. sor.
Place the bank angle sensor horizontal as shawn,

60· BANK ANGLE POSITION
and turn the ignitian switch ON.
6
The bank angle sensor is normal if the engine stop
relay clicks and power supply is closed.
Incline the bank angle sensor approximately 60° to
the left or right with the ignitian switch ON.
The bank angle sensor is normal if the engine stop NORMAL
relay clicks and power supply is open. POSITION
If you repeat th is test, tirst turn the ignition switch
OFF, then turn the ignitian switch ON. ~
~ :\ 60° (approximately)
Remave the upper cawllfrant spoiler (page 3-11).
Disconneet the bank angle sensor 3P (Black) con-
nector.
Remave the screws and bank angle sensor.
Instafl rhe bank In sta ll ation is in the reverse order of removal.

angle sensor with
its "UP" mark T ighten the bank angle sensor mounting screws to
the specified tarque.
facing up.
TORQUE: 1.5 N·m (0.2 kgf·m, 1.1 IbHt )
6-73
ENGINE STOP RELA Y
INSPECTION
Open the luse/relav box and remove the engine
stop relav.
Con neet the ohmmeter to the engine stop relav con- ~E:N:G:I:N:E:S:T:O=P:R:E:LA=Y~~~:"'~~~~~~
nector terminals.
Conneet a 12 V battery to the engine stop re lav con-
nector terminals as shown .
There should be continuitv on IV whe n the 12 V bat-
tery is connected.
II there is no continuity when the 12 V battery is
connected, replace the engine stop relay.
ECM
Remove the l uel tank cover (page 3-9) .
Remove the screws, setting plate and ECM.
Disconneet the ECM 33P (Black) and 33P (Grav) con-
necto rs,
Remove the ECM.
TORQUE:
ECM s ettin g plate s crew:
0.7 N·m (0.07 kgf· m, 0.5 Ibl·ft)
6-74
POWER/GROUND LlNE INSPECTION
ENGINE DOES NOT START (MIL DOES NOT BLINK)
1. ECM Power Input Voltage Inspect ion
Disco nneet the ECM 33P connectors (page 6-74).
33P (Black) CONN ECTOR
Tu rn the ignition switch ON and engine stop (Wire side/female terminals)
switch "0",
Measure the voltage at the ECM 33P (Black) con-
nector terminals and ground.
Connection: A4 (+) - Ground H
\
A5 (+) - Ground H
TOOL: (A5) (A4)

Test pro be 07ZAJ-RDJA 110
EB
Is there battery voltage?
YES - GO TO STEP 2.
NO - GO TO STE P 3.
2. ECM Ground Line Inspection
Turn t he ign itian switch OFF.
(A25) (A24) (A23) (B4)
Check fa r cantinu ity between the ECM 33P con-
nector term inal and ground. c:J..~
Connection: 84 - Ground
A23 -Ground
A24- Ground
A25 - Ground
TOOL:
YES - Replace the ECM with a knawn gaod 33P CONNECTORS
one, and recheek (Wire side/female terminals )
NO - Open circuit in Ground line
6-75
3. Engine Stop Relay Inspection I
Open the fuse/relav box and remave the engine
stop relav.
Turn the ign ition switch ON and engine stop
switch "0".
Measure the vo lta ge at the engine stop relay ter-
minals.
Connection: Blaek 1+) - Red/blue I-l
YES - GO TO STEP 4.
NO - . Inspeet the bank ang le sensor Ipage
6-72)
• Inspeet the engine stop switch (page
20-18)
• Blown luse (BANK ANGlE 10A)
8
Red/ blu e
RElAY TERMINALS
4. Engine Stop Relay Inspection 2
Jump the engine stop relay connector terminals.
RELA Y TERMINALS
Connection: Red - Blaek/white
Measure the voltage at the ECM con necto r ter-
minals and ground.
Connection: A4 1+) - Ground I-l
A5 1+) - Ground I-l
TOOl:
Test probe 07ZAJ-RDJAll0 JUMPER WIRE
YES - Inspeet the eng ine stop relav Ipage 6-
74) 33P (Blaek) CONNECTOR
NO - Open circ uit in power input line IB laek/ (Wire side/lemale terminals )
whi te or Red) between the battery and
ECM
IA5) (A4)
EB
6-76
SECONDARY AIR SUPPL Y SYSTEM

SYSTEM INSPECTION
Start the engine and warm it up to coolant tempera-
ture is 80°C (176°F) .
Stop the engine.
Remave the air cle aner middle housing (page 6-52).
Check that the secondary air intake port is clean and
tree of ca rban deposits.
Check the PAIR check valves if the port for carbon
fouling (page 9-8).
Start the engine and open the throttle sli ghtly to be ~~~~~~~~~~~~::::::::=--=----,
certain that air is sucked in through th e air intake
port.
If the air is not drawn in , check the air suction hoses
for clogs and PAIR solenaid valve.
EXHAUST PORT
<===0 FRESH AIR
~ EXHAUST GAS
6-77
PAIR CONTROL SOLENOIO VALVE
REMOVAl/INSTAlLA TION
Remove the air cleaner housing (page 6-52).
Remave the air intake joint trom the frame.
Disco nnect the PAIR control solenoid valve 2P r;:iQ;;E';;

(Black) connector.
Discon neet the PAIR air suction hoses.
INSPECTION
Remove the PAIR control solenoid valve.
Check th at air does not flow (A) to (B) when a 12 V
battery is connected to the PAIR control solenoid
valve terminals. Air should flow (A) to (B) when
there is no voltage applied to the PAIR valve termi -
nals.
(B)_ F=~~:l:!:!:yJ-!!==I __ (B)
Check the resistance between the terminals of the

PAIR control solenoid valve. 2P CONNECTOR
(Solenoid valve sidel male terminals)
n (20°C/68°F)
\
Standard : 23 - 27
If the reslstance is out of specjfjcation , replace the
PAIR control solenoid valve.
6-78
EVAP PURGE CONTROL SOLENOID

VALVE/CANISTER (CALIFORNIA TYPE)
Remove the shock absorber (page 15-14).
Disconneet the following:
- EVAP purge control solenoid valve 2P (Black)
connector
- Fuel tank breather hose (to fuel tank )
- Canister-to-purge control solenaid valve hose
- EVAP canÎster drain hose
Remove the bolts, collars, EVAP canister and Canis-
ter bracket.
Remove the bolts, collars, EVAP purge control sole-
noid valve and solenoid valve bracket.
Route the hoses Installation is in the reverse order of rem aval.
properly
(page 1-341.
EVAP PURGE CONTROL SOLENOID VALVE

2P CONNECTOR
SOLENOID VALVE BRACKET
BOLT
_ _
~ANISTER-TO-PURGE
~ ~OLENOID VALVE HOSE
. CONTROL
.~~~
COLLAR

CANISTER BRACKET BOLT
6-79
INSPECTION
Remove the EVAP purge control solenoid va lve ,-- - - - - - - -- - - - - - - - - ,
(page 6-79).
Check that air should not flow (A) to (B), only when
a 12 V battery is connected to the EVAP pu rge con-
tro l solenoid valve te rmina ls.
Check the resistance between the te rminals of the ~=================~

EVAP pu rge co ntrol solenoid valve. 2P CONN ECTOR
(Solenoid va lve side/male terminals)
STANDARD: 30 - 34 Q (20°C/ 68°F)
If the resista nce is out of specification, repl ace the
EVAP purge con t ro l solenoid val ve.
EGCV SERVOMOTOR
REMOVAL
Remove t he followin g:
- l ower cow l (page 3-6)
- Seat (page 3-4)
Remove th e bolts, nuts and EGCV cover.
loose n the loek nuts and discon neet the EGCV con-
tro l cables from th e pu lley.
BOlTS/NUTS CON TR OL CABLE S

Remove the bolt and wire clamp, th en release the
EGCV contro l cables.
6-80
Disconnect the servomotor 6P (Natura!) connector.
Remove the balts, co llar, cover and servomotor.
Disconnect the EGCV control cables trom the servo-

SERVOMOTOR PULLEY
motor pulley.
'\
CONTROL CABLES
INSPECTION
Connect a 12 V battery to the se rvomotor 6P (Natu-
ral) connector terminals and check th at the motor
operation.
Connection: Red (+l- Blue H
lf the servomotor does not turn , replace the servo-

motor with a new one.
•I
Measure the resistance between the servomotor 6P

(Natura l) connector terminals.
Connection: Yellow/red - Green

Standard: 5 kQ
Connection : Brown - Green

Standard: 0 - 5 kQ
lf the resistance is out of range , replace the servo-
motor. • I
6-81
INSTALLATION
SERVOMOTOR
COVER
COVER
Connect the battery and servomotor 6P (Natural) r------------------~

connector. 3 x 18 mmSCREW
/f you use a new Short the DLC (page 6-15).
servomotor, ie ;s not
Turn the ignition switch ON .
necessary to do
The servomotor turns, then stops.
this procedure.
Secure the servomotor pulley at this position using
a 3 x 18 mm screw as shown .
Connect the EGCV control cables to each positi on.

3 x 18 mm SCREW
Remave the 3 x 18 mm screw trom the servomotor
pulley.
CONTROL CABLES
6-82
Install the servomotor, cover, collar and tighten the
balts securely.
Conneet the servomotor 6P (Natural ) connector.
Route rhe cab/es Install the wire clamp and tighten the bolt securely.
properly
(page 1-2/1.
Conneet the EGCV control cables to the pulley and

tighten the loek nut securely.
Adjust the E.GCV control cable (page 4-22) .
securely.
Install the lollowing :
- Seat (page 3-4)
CONTROL CABLES COVER
EGCV
DISASSEMBL Y
Remave the lower cowl(page 3-6).
Remave the balts, nuts and EGCV cover.
Loosen the loek nuts and disconneet the EGCV con -
trol cables Irom the pulley.
BOLTSI NUTS CONTROL CABLES
6-83
Bend the tabs of the loek was her away from the pul -
ley nut. SPRING COLLAR LOCKWASHER
Hold the pulley and remave the pulley nut.

Remave the loek washer, pulley, spring collar and
return spring .
RETURN SPRING PULLEY

ASSEMBLY
Install the return spring onto the housing while
aligning its end with the housing boss.
Install the spring collar as shown.
RETU
Install the pulley and a new loek was her while align- ~L=O=C=K=W=A=S=H=E=R===N=U=T========~
ing its tabs with the pulley as shown.
Tighten the pulley nut to the specified torque. ~ \~
Bend the tabs of th e loek washer up against the pul-
ley nut.
PULLEY
Conneet the EGCV control cables to the pulley and
tighten the loek nuts securely.
Adjust the EGCV control cable (page 4-22).
securely.
Install the lo wer cowl (page 3-6).
CONTROL CABLES COVER
6-84
7. COOLING SYSTEM
SYSTEM FLOW PATTERN ····· ······ ···· ··········7-2 THERMOSTAT HOUSING .. ············ ······ ······ 7-8
SERVICE INFORMATION ...... ... .... .. ...... ...... 7-3 RADIATOR ..... ............... .. ............ .... .... ... ... 7-11
TROUBLESHOOTING ..... ............... ...... .... .. . 7.-4 WATER PUMP ................ .. ................ .. ...... 7-16
SYSTEM TESTING .. ······ ······ ····· ·· ················· 7-5 RAD IATOR RESERV E TANK ··· ·· ···· ··· ······ ·· 7-20
COOLANT REPLACEMENT ········ ·· ··············7-6 FAN MOTOR RELAY ···· ··· ·········· ······· ········7-20
7-1
COOLING SYSTEM
SYSTEM FLOW PATTERN
RADIATOR CAP
~~
RADIATOR
THERMOSTAT
RADIATOR RESERVE TANK
7-2
COOLING SYSTEM
SERVICE INFORMATION
GENERAL
Removing the radiator cap while the engine is hot can allow the coola nt to spray out, seriously scalding you.
Always Jet the engine and rad iator cool down before removing the radiator cap.
I NOTICE I
Using coo/ant with silicate inhibitors may cause premature wear of water pump seals or blockage of radiator passages.
Using tap water may cause engine damage.
• Add coolant at the reserve tank. Do not remove the radiator cap ex cept to retill or drain the system .
• All cooling system services can be done with the engine instalied in the frame.
• Avoid spilling coo lant on painted surfaces.
• Afte r servicing the system, check for leaks with a cooling system tester.
• Refer to the ECT sensor inspection (page 20-14).
SPECIFICATIONS
ITEM SPECIFICATIONS
Coolant capacity Radiator and engine 3. 15 liter (3.33 US qt, 2.77 Imp qt)
Reserve tank 0.30 liter (0.32 US qt, 0.26 Imp qt)
Radiator cap relief pressure 108 -137 kPa (1.1 -1.4 kgf/cm', 16 - 20 psi)
Th ermostat Begin to open 80 84°C (176 183°F)
Fullyopen 95°C (20 3°F)
Valve lift 8 mm (0.3 in) minimum
Recommended antifreeze Pro Honda HP Coolant or an equivalent hi gh quality ethyl-
ene glycol antifreeze contain ing silicate tree corrosion
inhibitors
Standard coo lant concentration 1:1 (m ixture with distilled water)
TORQUE VALUES
Water pump assem bly bolt 12 N'm (1.2 kgf.m, 9Ibf·ft) CT bolt
Water pump drain bolt 12 N·m (1.2 kgf·m, 9 Ibf·ft) CT bolt
Thermostat housing cover bolt 12 N·m (1.2 kgf.m, 9 Ibf·ft) CT bolt
ECT sensor 23 N·m (2.3 kgf·m , 17 Ibf·ft)
Fan motor sh roud mounting bolt 8.4 N·m (0.9 kgf·m, 6.2 Ibf·ft)
7-3
COOLING SYSTEM
TROUBLESHOOTING
Engine temperature too high
• Faulty engine coolant temperature meter or EeT sensor
• T hermostat stuck closed
• Fa u lty ra d iator ca p
• Insufficient coolant
• Passage blocked in radiator, hoses or water jacket
• Ai r in system
• Faulty cao ling fan motor
• Fault y fan motor relay
• Fau lty wate r pump
Engine temperature too low
• Fault y t emperature gauge or EeT sensor
• Thermost at stuck open
• Faulty fan motor relay
Coolant leak
• Fau lty water pump mechanical sea l
• Det eriorated O-rings
• Fau lty rad iator cap
• Damaged o r deteriorated cy linder head gasket
• Loase hose connect ion or cia mp
• Damage d or deteriorated hose
7-4
COOLING SYSTEM
SYSTEM TESTING
COOLANT (HYDROMETER TEST)
Remove the right middle cowl (page 3-8).
Remove the radiator cap.
Test the coolant gravity using a hydrometer (see

below for "Coolant gravity ehart") .
For maximum corrosion protection , a 1:1 solution of
ethyl ene glycol and disti lled water is reeommended
(page 7-6).
Look tor contamination and replace the coolant if
necessary.
COOLANT GRAVITY CHART

Coolant temperature °C (OF)
0 5 10 15 20 25 30 35 40 45 50
(32) (41) (50) (59) (68) (77) (86 ) (95) (104) (113) (122)
5 1.009 1.009 1.008 1.008 1.007 1.006 1.005 1.003 1.001 0.999 0.997
10 1.018 1.017 1.017 1.016 1.015 1.014 1.013 1.011 1.009 1.007 1.005
15 1.028 1.027 1.026 1.025 1.024 1.022 l020 1.018 1.016 1.014 1.012
?f. 20 1.036 1.035 1.034 1.033 1.031 1.029 1.027 1.025 1.023 1.021 1.019
.9 25 1.045 1.044 1.043 1.042 1.040 1.038 l036 1.034 1.031 1.028 1.025
'"
E
~
~ 30
35
1.053 1.052 l051
1.063 1.062 1.060
1.049
1.058
1.047 1.045 1.043 1.041
1.056 1.054 1.052 1.049
1.038
1.046
1.035
1.043
1.032
1.040
0 40 1.072 1.070 1.068 1.066 1.064 1.062 1.059 1.056 1.053 1.050 1.047
0
u 45 1.080 1.078 1.076 1.074 1.072 1.069 1.066 1.063 1.060 1.057 1.054
50 1.086 1.084 l082 l080 1.077 1.074 l071 1.068 1.065 1.062 l059
55 1.095 1.093 1.091 1.088 1.085 1.082 1.079 1.076 1.073 1.070 1.067
60 1.100 1.098 1.095 1.092 1.089 1.086 1.083 1.080 1.077 1.074 1.071
7-5
COOLING SYSTEM
RADIATOR CAP/SYSTEM PRESSURE
INSPECTION
Remav e the radiator cap (page 7-5 ).
Pressure test the radiator cap.
Before instal/ing the
Replace the radiator cap if it does not hold pressure,
cap in the tester,
wet the sealing or if relief pressure is too high or too low.
surfaces. It must hold specified pressure for at least 6 sec-
onds.
RADIATOR CAP RELlEF PRESSURE:
108 -137 kPa (1 .1 - 1.4 kgf/ cm ', 16 - 20 psi)
Pressure the radiator, engine and hoses, and check

for leaks.
I NOTICE I
Excessive pressure can damage the cooling system
components. Do not exceed 137 kPa (1.4 kgf/cnr, 20
ps;).
Repair or replace components if the system will not
hold specified pressure for at least 6 seconds.
COOLANT REPLACEMENT
PREPARATION
• The effeetiveness of coolant decreases with the
accumulation of rust or i1 there is a change in the
mixing proportion during usage. Therefore, for
best performance change the coolant regularly
as specified in the maintenance schedule.
ANTIFREEZE
SOLUTION D~I
r 6V
• Mix only distilled, low mineral water with the
antifreeze.
RECOMMENDED ANTIFREEZE: (ETHYLENE LOWMINERAL
Pro Honda HP Coolant or an equivalent high qua 1- GLYCOL BASE '''' OR DISTILLED
ity ethyl ene glycol antifreeze containing silicate SOLUTION) 10 WATER
free corrosion inhibitors
RECOMMENDED MIXTURE:
1:1 (mixture with dislilled water) COOLANT
7-6
COOLING SYSTEM
REPLACEMENT/AIR BLEEDING
When fiIIing the Remove the lollowing:
system or reserve
- Right middle cowl (page 3-8)
tank with a coofant
(checking cao/ant
level), place the Remove th e radiator cap (page 7-5 ).
motorcycle in a
vertical position on
a flat. level surface.
Remove the water pump drain bolt, sealing washer

and drain the coolant.
,.-----."""'!i":;
Remove the cylinder drain bolt and drain the cool -

ant trom the cylinder.
Reinstall the drain balts with new sealing washers .
Tighten the cylinder dra in bolt securely.
Tighten the water pump drain bolt 10 Ihe specilied
torque.
TORQUE: 12 N·m (1.2 kgl·m. 9 Ibl·ft)
Di sconneet the siphon hose trom th e radiator 1Jjii1::;;;~~"""

reserve ta nk.
Drain the reserve tank coolant.
Empty the coola nt and rinse the inside ol the
reserve tank with water.
Con neet the radiato r siphon hose.
7-7
COOLING SYSTEM
Fill the system with the recommended coolant
through the filler opening up to filler neck.
Remove the radiator reserve tank cap and fil! the

reserve tank to the upper level line.
Bleed air trom the system as follows:
1. Shift the transmission into neutra I. Start the
engine and let it idle for 2 - 3 minutes.
2. Snap the throttle three or four times to bleecl air
from the system.
3. Stop the engine and add coolant up to the filler
neek if necessary. Install the radiator cap.
4. Check the level of coolant in the reserve tank and
fill to the upper level if it is low.
Install the radiator reserve tank cap.
After installation, check that there are no coolant
leaks.
THERMOSTAT HOUSING
REMOVAL
Drain the coolant (page 7-7).
Remave the throttle body (page 6-60).
Remove the balts and thermostat housing cover.
7-8
COOLING SYSTEM
Remave the thermostat trom the housing .
Disconneet the ECT sensor 3P (Gray) connector.
Laasen the hose damp screw and disconneet the
water hose.
Remave the balts, thermostat

from the cy linder head.
INSPECTION
Visually inspeet the thermostat for damage.
Check for damage of the seal rin g. THERMOSTAT SEAL RING
Wear insulated gloves and adequate eye protection.
Keep flammable materials away trom the electric
heating element.
Do not let che Heat the water with an electric heating element to
thermostat or operating temperature tor 5 minutes.
thermometer touch Suspend the thermostat in heated water to check its
the pan, or you will operation .
get fa/se rea ding.
Replace the thermostat if the valve stays open at
room temperature, or if it responds at temperatu re s
other than those specified .
THERMOSTAT BEGIN TO OPEN:
80 - 84°C (176 - 183°F)
VALVE LIFT:
8 mm (0.3 in) minimum at 95°C (203°F)
THERMOSTAT
7-9
COOLING SYSTEM
INSTALLATION
Install a new O-ring to the thermostat housing
groOV9 .
Install the thermostat housing to the cylinder head

and tighten the bolts securely.
Con neet the ECT sensor 3P (Gray) connector.

Install the thermostat into the housing by align ing
the th ermostat air bleed hole with the housing boss.
Install the thermostat housing cover onto the hous- ,........,."""

ing .
TORQUE: 12 N·m (1 .2 kgf·m, 9lbHt)
Fill the system with the recommended coolant and
bleed any air (page 7-6).
7-10
COOLING SYSTEM
RADIATOR
REMOVAL
Drain the coolant (page 7-7).
Disconneet the fan motor 2P (Black) connector.
Remove the horn wire ctamp from the left heat
guard plate.
Remove the radiator lower mounting bolt, washer

and nut.
Remave th e radiator upper mounting bolt and

washer .
Be careful not co Release th e radiator upper grommet trom the frame
damage the radiator boss.
fins.
Laasen the hose damp screw and disconneet the

left radiator hose.
7-11
COOLING SYSTEM
Loasen the hose damp screw and disconneet the
right radiator hose.
Remove the radiator to the right side.
Be careful not to Remove the trim clip and right heat guard plate
damage the radia tor trom the radiator.
fins.
DISASSEMBL Y
Remave the trim clip and lef! heat guard plate from
LEFT HEAT GUARD PLATE
the radiator.
TR IM CLIP
Rem ave the balts and fan motor assembly f rom the
radiator.
7-12
COOLING SYSTEM
Remave the nut and cooling fan.
NUT
Release the fan motor 2P (Black) connector from the

shroud.
SHROUD
Remove the nuts and fan motor trom the shroud.

For fan motor relay information (page 7-20).
NUTS
FAN MOTOR
2P CONNECTOR
ASSEMBLY
RADIATOR
o
•
COOLING FAN
FAN MOTOR
TRIM CLIP
8.4 N·m (0.9 kgf.m, 6.2 Ibf·ft )

SHROUD
7-13
COOLING SYSTEM
Install the fan motor onto the sh roud and tighten
the nuts securely. SHROUD
Install th e fan motor 2P (Black) connector onto the

shroud.
NUTS
FAN MOTOR
2P CONNECTOR
Install the cooling fan onto the fan motor shaft by

aligning the flat surfaces.
Apply locking agent to th e cooling fan nut threads.

NUT .cu
Install the fan motor assembly onto the radiator.

Tighten the balts to the specified torque.
TORQUE: 8.4 N·m (0.9 kgf·m. 6.2 IbHt)
7-14
COOLING SYSTEM
Install the left heat guard plate and trim clip onto the
radiator left side. LEFT HEAT GUARD PLATE
TRIM
INSTALLATION
ae care lul not to Install the right heat guard plate and trim clip onto
damage the radiator the radiator right side.
fins.
Connect the right radiator hose and t ighten th e hose

clamp screw securely (page 7-19).
Connect the left radiator hose and tighten the hose

clamp screw securely (page 7-19).
7-15
COOLING SYSTEM
Install the radiator assemblv, aligning its upper
grommet with the frame boss.
Install the upper mounting bolt and washer, th en
tighten the bolt secure IV.
Install the radiator lower mounting bolt, washer, nut

and tighten the nut securely.
Insta ll the horn wire clamp to the lelt heat guard

plate.
Conneet the fan motor 2P (Blaek) connector.
Fill the svstem with the recommended coolant
(page 7-6).
WATER PUMP
MECHANICAL SEAL INSPECTION
Check for signs of seal leakage.
A sma ll amount of "weeping" from the bleed hole is
normal.
SLEED HOLE
7-16
COOLING SYSTEM
REMOVAL
Remove the tollow ing :
- Lower cowl (p age 3-6)
- Gearshift arm (page 8-4)
- Drive sprocket cover (page 8-5)
Drain the coolant (page 7-7 ).
Loasen the hose clamp screws and disconneet the
hoses.
Remove the bolt. joint pipe and O-ring .
Remave the balts and water pump cover.
Remove the O-ring trom the water pump body.

Do not disassembIe Remave th e wa ter pump body and O-ring trom the
the water pump crankcase.
body.
7-17
COOLING SYSTEM
INSTALLATION
12 N 'm (1.2 kgf.m, 9Ibf.ft)
Apply oil to a new O-ring and install it onto the

stepped portion of th e water pump body.
Install the water pump body into the crankcase
while aligning the water pump shaft groove with the
oil pump shaft end by turning the water pump
impeller.
Install a new O-ring into t he groove in the water

pump body.
7-18
COOLING SYSTEM
Install the water pump cover and bolts.
Install a new O-ring to the joint pipe.

Install the joint pipe to the water pump cover and
tighten the bolt securely.
Con neet the hoses and tighten the hose clamp

screws.
~;~~~~~jjiii
r'
Fill the system with the recommended coolant
(page 7-6).
Start the engine and check for coolant leaks.
Install the following :
- Drive sprocket cover (page 8-15)
- Gearshift arm (page 8-15)
I
--1-_. __
I
- - '
0-1 mm (0-0.04in)
7-19
COOLING SYSTEM
RADIATOR RESERVE TANK

REMOVAL
- Lower cowl (p age 3-6)
- Righ t middle cowl (page 3-8)
Disconneet the siphon hose and drain the coolant
trom the reserve tank .
Disconneet the coolant over flow hose trom the
reserve tank .
Remove the bolt and rad iato r reserve tank.
INSTALLATION
Route the hos es Conneet the siphon hose and coolant over flow
properly hose to the reserve tank.
(page 1-2 1J. SIPHON HOSE
Install the reserve tank while aligning the reserve
tank boss with the mounting stay hole.
Tighten the bolt securelv.
Fiil the svstem with the recommended coolant
(page 7-6).
FAN MOTOR RELA Y

INSPECTION
Remove the s_eal (page 3-4).
Open the fuse/rela y box and rem ave the fan motor
relav·
Conneet the ohmmeter to the fan motor relay con-

nector terminals. FAN MOTOR RELAY
Connecl a 12 V battery to the fan motor relav con-

nector terminals as shown .
There should be continuity onlv when 12 V batterv
is connected ,
\
If there is no conlinuity on IV when the 12 V batterv
is connected, replace the fan motor relay .
(j) e
7-20
8. ENGINE REMOVAL/INSTALLATION
COMPONENT LOCATION .. ........................ 8-2 ENGINE REMOVAL ........ .... ......... .. ........ ..... 8-4
SERVICE INFORMATION .... .. .................. .. · 8-3 ENGINE INSTALLATION ...... .. .......... .......... 8-9
8-'
ENGINE REMOVALlINSTALLATION
COMPONENT LOCATION
54 N·m (5.5 kgf.m , 40 IbHt )
10 N·m (1.0 kgf.m , 7lbHt)

54 N·m (5.5 kgl·m , 40 IbHt)
54 N·m (5.5 kgl·m, 40 IbHt)

10 N·m (1.0 kgl·m, 7 Ibf.ft)
10 N·m (1.0 kgf.m , 7Ibf.ft)
54 N·m (5.5 kgl·m, 40 IbHt)
20 N·m (0.2 kgl·m, 1.5 Ibl·ft)
8-2
ENGINE REMOVAl/lNSTAllATION
SERVICE INFORMATION
GENERAL
• A heist or equivalent is required to support the motorcycle when removing and installing the engine.
• A floar jack or other adjustable support is required to support and maneuver the engine.
• Do not use the Dil filter and Dil cooler as a jacking point.
• When using the lock nut wrench for the engine hanger lock nut, use a deflecting beam type torque wrench 20 inches
long. The loek nut wrench increases the torque wrench 's leverage, so the torque wrench reading will be less than the
torque actually applied to the lock nut. The specification given is the actual torque applied to the lock nut, not the read-
ing on the torque wrench. Do not overtighten the loek nut. The specification later in the text gives bath actual and indi-
cated.
• The following components can be servieed with the engine instalied in the frame .
- Alternator (page 11 -4)
- Clutch (page 10-7)
- Camshaft (page 9-9)
- Cylinder head (page 9-14)
- Gearshift Iinkage (page 10-23)
- Dil cooler (page 5-13)
- Dil pump (page 5-7)
- Water pump (page 7-16)
• The following components require engine rem aval for service.
- Crankshaft (page 13-5)
- Piston/cylinder (page 13-14)
- Shift fork/shift drum/transmission (page 12-6)
• Wh en installing the engine, be sure ta tighten the eng ine maunting fasteners ta the specified torque in the specified
sequence. If you mistake the torqu e or sequence, loosen all mounting fasteners, then tighten them again to the speci-
fied torque in the correct sequence.
SERVICE DATA
ITEM SPECIFICATIONS
Engine dry weight 57 kg (126 Ibs)
Engine oil capacity (After disassembly) 3.5 liter (3.7 US qt, 3.1 Imp qt)
Coolant capacity (Radiator and engine) 3.15 liter (3.33 US qt, 2.77 Imp qt)
TORQUE VAlUES
Front engine hanger bolt 54 N·m (5.5 kgf·m, 40 Ibf·ft)
Upper engine hanger adjusting bolt 10 N·m (lO kgf·m, 7 Ibf·ft)
Upper engine hanger loek nut 54 N·m (5.5 kgf.m , 40 Ibf·ft)
Upper engine hanger nut 59 N·m (6.0 kgf.m, 44 Ibf·ft)
Lower engine hanger adjusting bolt 10 N·m (1.0 kgf·m, 7 Ibf.ft)
Lower engine hanger loek nut 54 N·m (5.5 kgf·m , 40 Ibf·ft)
Lower engine hanger nut 59 N·m (6.0 kgf·m, 44 Ibf·ft)
Drive sprocket bolt 54 N·m (5.5 kgf·m, 40 Ibf·ft)
Starter motor terminal nut 10 N·m (1.0 kgf'm, 7 Ibf·ft)
EOP switch wire terminal bolt 2.0 N·m (0.2 kgf·m, 1.5 Ibf·ft)
TOOl
Loek nut wreneh
07VMA-MBB0100
8-3
ENGINE REMOVAL
Middle cowls (page 3-8)
Exhaust pipe (page 3-24)
Radiator (page 7-11)
Radiator reserve tank (page 7-20)
Engine guard rubber (page 6-51)
Throttle body (page 6-60)
PAIR control solenoid va lve (page 6-78)
• W ith the ignition switch OFF, disconneet the bat-
tery negative H cable (page 17-6).
Disconneet the alternator 3P (Natu rai ), sidestand
switch 2P (Green ) and CMP sensor 2P (B lack) con - ~tr:'(;j~/~~~:::
nectors.
Disconneet the ignition sub harness 6P (Black) con- , . . . . - - - - -..
nectar.
Remove the sidestand switch wire from the wi re

clamps.
Remove the bo lt and gearshift arm from th e gear- I""""'''''illr':

shift spindie.
D isconneet the neutral switch connector.
8-4
Remove th e balts, w ire clamp, drive sprocket cover
and guide plate.
Laasen the rea r axle nut.

Turn the drive chain adjusting balts and make the
drive chain slack lully (page 4-24).
Remove the bolt, was her and drive sprocket.
Disconneet the CKP sensor 2P (Black) connector.
Disconneet th e joint hose and ECT sensor 3P (Gray)

co nnector.
8-5
ENGINE REMOVAL/INSTALLATION
Remave the bolt and disconneet the ground cabie.
Remove the nut and disconneet the starter motor
cable.
Disconnect the VS sensor 3P (Black) connector.
Di sconneet the water hoses from the engine.
Remave th e bolt and radiator bracket.
Remave the dust cover, terminal bolt and EOP ~~~;;;;~;

switch wire .
Remave the EOP switch wire clamp trom the
engine.
DUSTCOVER
8-6
Remave the bolt and clutch cable guide plate, then
disconnect the clutch cable end from the clutch lifter
lever.
Support the engine using a jack or other adjustable

support.
Remave the ri ght front engine hanger bolt and col-
lar.
Remave th e left front engin e hanger bolt and co ll ar.
Remave the upper engine hanger nut while holding

the engine hanger bolt.
ENGIN E REMOVALlINSTALLATION
Laasen the upper engine hanger loek nut using the
special tooI.
TOOl:
Loek nut w rench 07VMA-MBB0100
Turn the upper engine hanger adjusting bolt coun-

terclockwise lully by turning the upper engine
hanger bolt.
Remave the lower engine hanger nut while holdi ng

the engine hanger bolt.
Laasen the lowe r engine hanger loek nut using the

special tooI.
TOOl :
Loek nut w rench 07VMA-MBB0100
8-8
Turn the lower engine hanger adjusting bolt coun-
terclockwise fully by turning the lower engine
hanger bolt.
Support the engine using a jack or other adjustable
support to ease removal of the engine hanger balts.
- Lower engine hanger bolt
- Upper engine hanger bolt and collars
Carefully lower the adjustable support, th en re move
the engine from the frame .
Remove the engine hanger lock nuts and adjusting
bolts.
ENGINE INSTALLATION
UPPER ENGINE HANGER

NG BOLT
UPPER ENGINE HANGER
UPPER ENGINE LOCK NUT
HANGER BOLT
LOWER ENGINE
HANGER BOLT
UPPER ENGINE
HANGER NUT
LOWER ENGINE
HANGER NUT
COLLARS
LOWER ENGINE HANGER

ADJUSTING BOLT
FRONTENGINE
HANGER BOLT
8-9
o Note the direction ol the hanger bolts/collars.
o When tightening the loek nut with the loek nut
wrench, refer to the torque wrench reading infor~
mation in "SERVICE INFORMATION" (page 8-3).
o The jack height must be continually adjusted to
relieve stress trom the mounting fasteners.
o Route the wires, hoses and cables properly (page
1-21 ).
• Be sure to tighten all engine mounting fasteners
to the speci fied torque in th e specified sequence
described on the lollowi ng pages. II you mistake
th e tightening torq ue or sequence, loosen all
mounting fa steners, then tighten them again to
the specified torqu e in the specified sequence.
Install the upper and lower engine hanger adjusting

bolts lully Irom the inside ol the Irame. ADJUSTING BOLT
Carefully install the engine into the Irame.

Install the lower engine hanger bolt Irom the right
side.
Align the straight portion ol the engine hanger bolt
head with the adjusting bolt boss.
Loosely install the lower engine hanger loek nut.
Install the collars and upper engine hanger bolt

Irom the right side.
Align the straig ht portion ol the engine hanger bolt
head with the adjusting bolt boss.
Loosely install the upper engine hanger loek nut.
8-10
loosely install the collar and left front engine
hanger bolt.
loosely install the collar and right front engine

hanger bolt.
Turn the upper and lower engine hanger adjusting

bolt by turning the hanger bolt unti l the adjusting
bolt is seated on the engine.
Tighten the lower engine hanger adjusting bolt to
the specified torque by turning the lower engine
hanger bolt.
Hold the adjusting bolt by holding the hanger bolt

and tighten the loek nut to th e specilied to rq ue.
TOOl:
Loek nut wrench 07VMA-MBB0100
TORQUE:
Actual: 54 N·m (5.5 kgl·m, 40 Ibl·ft)
Indicated: 49 N·m (5.0 kgl·m, 36 Ibl·ft)
8-11
Tighten the lower engine hanger nut to the specified
torque while holding the hanger bolt.
Tighten the upper engine hange r adjusting bolt to

the specified torque by turning th e upper engine
hanger bolt.
TORQUE: 10 N·m (1 .0 kgf·m, 7 Ibl·ft)
Hold the adjusting bolt by holding the hanger bolt

and tighten the loek nut to the speeilied torque.
TOOL:
Loek nut wrench 07VMA-MBB0100
TORQUE:
Aetu.l: 54 N·m (5.5 kgl·m, 40 Ibl·ft)
Indie.ted: 49 N·m (5.0 kgl·m, 36 Ibl·ft)
Tighten the upper engine hanger nut to the speci-

lied torque while holding the hanger bolt.
8-12
ENGINE REMOVALIINSTALLATION
Tighten th e lelt lront engine hanger bolt to the spec-
ified torque.
TOROUE: 54 N ·m (5.5 kgf·m, 40 Ibf.lt)
Tighten the right front engine hanger bolt t o the

specified torque.
TOROUE: 54 N·m (5.5 kgf·m , 40 Ibl·ft)
Connect the cl utch cable to the clutch lilter lever.

Install the clutch cab le gu ide plate by aligning its
hole with the right crankcase cover bos s and tighten
th e bolt securely.
Route the wire In stall the EOP switch wire to the w ire clamp ~~~~~~~~~~
properly securely.
(pag e 1-21).
Connect th e wire to the EOP switch and tighten the
t erminal bolt to the specilied torque.
TOROUE: 2.0 N ·m (0.2 kgl·m, 1.5 Ibl·ft)
In sta ll the dust cover securely.
DUSTCO VER
8-13
Install the radiator bracket as shown and tighten the
bolt securely.
Con neet the water hoses and tighten the hose

cia mp screws securely (page 7-19).
Con neet the VS sensor 3P (Black) connector.

Route the wires Install the ground cable and tighten the bolt
properly securely.
(page 7-27 J.
Conneet the stater motor cable and tighten the nut
to the specilied torque.
TORQUE: 10 N·m (1 .0 kgl·m, 7Ibl·ft)
Conneet the ECT sensor 3P (Gray) connector.

Conneet the joint hose and tighten th e hose clamp
screw securely (page 7-19).
8-14
Conneet the CKP sensor 2P (Blaek) connector.
Install the drive sprocket with its marks facing out.

Install the washe r and bolt, then tighten the bolt to
TORaUE: 54 N·m (5.5 kgf·m, 40 Ibf.ft)
Install th e guide plate, drive sprocket cover, wi re I"'!~~

clamp and tighten the balts securely.
Install the gearshifl arm aligning its slit with the I"'!~"!"ir
punch mark on the gearshifl spindie.
Tighten the bolt securely.
Conneet the neutral switch connector.
8-15
Route (he w ire Insta ll the sidestand switch wire to the wire clamps
properly
(page 1 ~21) .
Connect the ignition sub harness 6P (Black) connec~ , . . . . - - - - -..

tor.
Connect the alternator 3P (Naturai), sidestand

switch 2P (Green) and CMP sensor 2P (Black) co n~
neetars.
- PAIR control solenoid valve (page 6~78)
- Throttle body (page 6~64)
- Engine guard rubber (page 6~51)
- Radiator re serve tank (page 7~20)
- Radiator (page 7~ 15)
- Exhaust pipe (page 3~26)
- Middle cowls (page 3~8)
- Lower cowl (page 3~6)
Adjust the drive chain slack (page 4~24).
Check the engine oillevel (page 4~17).
Connect the battery negative H cable (page 17 ~6).
Fill the cooling svstem and bleed anv air (page 7~71.
Check the clutch lever freeplav (page 4~31).
Check the exhaust svstem for leaks.
Check for coolant leaks.
8-16
9. CYLINDER HEAD/VALVES
COMPONENT LOCATION ......... ................ . 9-2 CYLINDER HEAO INSPECTION ......... ... .. . 9-17
SERVICE INFORMATION . ····· ······· ····· ·· ·······9-3 VALVE GUlDE REPLACEMENT .. ............ ·9-20
TROUBLESHOOTING ................ ................ . 9-6 VALVE SEAT INSPECTIONI

REFACING ...... .. .. ...... .. ... .... ... ... .................. 9-21
CYLINDER COMPRESSION TEST .. ............ 9-7
CYLINDER HEAO ASSEMB LY .. ........ ....... 9-24
CYLINDER HEAO COVER REMOVAL ........ 9-7
CYLINDER HEAO INSTALLATION .......... · 9-26
CYLINDER HEAO COVER
DISASSEMBLY .......... ........................ .... ..... 9-8 CAMSHAFT INSTALLATION ................ .. . 9-28
CAMSHAFT REMOVAL .......... ...... ........ ...... 9-9 CYLINDER HEAO COVER ASSEMBL Y .... 9-33
CYLINDER HEAO REMOVAL ........ .... .. ... .. 9-14 CYLINDER HEAO COVER
INSTALLATION ........ ...... .. ...... .................. 9-34
CYLINDER HEAO DISASSEMBL Y.... ........ 9-16
CAM CHAIN TENSIONER LIFTER ...... ..... 9-35
9-1
COMPONENT LOCATION
10 N·m (1.0 kgf·m, 7lbHt)
12 N·m (1.2 kgf·m, 9 lbHt)
12 N·m (1 .2 kgf·m, 9 IbHt)
20 N·m (2.0 kgf·m, 151bHt)
16 N·m (1.6 kgf·m, 12Ibf·ft)

12 N·m (1 .2 kgf.m, 9Ibf.ft)
9-2
CYLINDER HEAD/VALVES
SERVICE INFORMATION
GENERAL
• This section covers service of the cylinder head, valves and camshaft.
• The cylinder head services can be done with the engine insta lied in the frame .
• When disassembling, mark and store the disassembied parts to ensure that they are reinstalled in the ir original loca-
tions.
• Clean all disassembied parts with clea n ing so lvent and dry them by blawing them aft with campressed air belare
inspectien.
• Camshaft lubricating ail is led thraugh ail passages in the cylinder head. Clean the ail passages belare assembling the
cylinder head.
• Be careful not to damage the mating surfaces when removing the cylinder head cover and cylinder head .
SPECIFICATIONS
Uni!" mm (in)
Cylinder compression 1,226 kPa (12.5 kgl/cm ' , 178psi) -
at 350 rpm
Valve clearance IN 0.20 ± 0.03 (0.008 ± 0.001)
EX 0.28 + 0.03 (0.011 + 0.001) -
Camshaft Cam labe height IN 36.36 - 36.60 (1 .431 -1.441) 36.34 (1. 431 )
EX 35.34 35.58 (1.391 1.401 ) 35.32 (1.391)
Aunout - 0.05 (0.002)
Oil clearance 0.020 - 0.062 (0.0008 - 0.0024) 0.10 (0.004)
Va lve lifter Valve lifter O.O. IN 25.978 25.993 (1.0228 - 1.0233) 25.97 (1 .022)
EX 22.478 22.493 (0.8850 0.8855) 22.47 (0.885)
Valve lifter bare I.O . IN 26.010 - 26.026 (1.0240 -1 .0246) 26.04 (1.025)
EX 22.510 22.526 (0.8862 - 0.8868) 22.54 (0.887)
Va lve, valve Valve stem O.O. IN 3.975 3.990 (0.1565 0.1571) 3.965 (0.1561)
guide EX 3.965 - 3.980 (0 .1561 - 0.1567) 3.955 (0.1557)
Valve guide I.O. IN/EX 4.000 4.012 (0.1575 0.1580) 4.04 (0.159)
Stem-to-guide clearance IN 0.010 0.037 (0.0004 0.0015) 0.075 (0.0030)
EX 0.020 - 0.047 (0.0008 - 0.0019) 0.085 (0.0033)
Valve guide projectien IN 17.1 17.4 (0. 67 - 0.69) -
abave cylinder head EX 15.8 16.1 (0.62 0.63)
Valve seat width IN/EX 0.90 - 1.10 (0.035 - 0.043) 1.5 (0.06)
Valve spring IN Inner 36.17 (1.424) 35.1 (1.38)
Iree length Outer 40.38 (1.590) 39.2 (1.54)
EX 40.80 (1.606) 39.6 (1.56)
Cylinder head warpage 0.10 (0.004)
TORQUE VALUES
Cylinder head bolt 47 N·m (4.8 kgf.m, 35 Ibl·ft) Apply malybdenum ail solution ta the
threads and seating surface
Camshaft holder bolt 12 N'm (1.2 kgl·m, 9 Ibl·ft) Apply ail ta the thread s and seating surface
Cylinder head cover bolt 10 N·m (1.0 kgl·m , 7 Ibl·ft)
PAIR check valve cover bolt 12 N'm (1.2 kgf.m, 9Ibl·ft) Apply lacking agent ta the thread s
Cam sprocket bolt 20 N'm (2.0 kgl·m, 15 Ibf.ft) Apply lacking agent to the threads
CMP sensor rotor bolt 12 N'm (1.2 kgl·m, 9Ibl·ft) Apply lacking agent ta the threads
Cam chain tensioner A pivot bolt 12 N'm (1.2 kgf.m, 9Ibl·ft) Apply lacking agent ta the threads
Cam chain tensioner B pivot bolt 20 N'm (2.0 kgl·m, 15 Ibl·ft) Apply lackin g agent ta the threads
Cam chain guide A bolt 12 N 'm (1.2 kgl·m, 9 Ibl·ft)
Spark plug 16 N·m (1.6 kgl·m , 12 Ibl·ft)
Insulator maunting bolt 12 N·m (1.2 kgl·m, 9 Ibf.ft)
9-3
TOOLS
Compression gauge attachment Valve spring compresso.r Valve spring compressor attach-
07RMJ-MY50100 07757-0010000 ment (IN)
07959-KM30101
or equivalent commercially avail-

able in U.SA
Valve spring compressor attach- Tappet hole protector (IN) Tappet hole protector (EX)
ment (EX) 07HMG-MR70002 07JMG-KY20100
07JME-KY20100
8
Not available in U.S.A. Not available in U.S.A.
Valve guide driver Valve gulde driver Valve guide ream er, 4.008 mm
07JMD-KY20100 07743-0020000 07MMH-MV90100
Not available in U.SA or 07MMH-MV9010A (U.SA only)
Valve seat cutter, 29 mm (45 0 IN) Valve seat cutter, 24 mm (45 0 EX) Flat cutter, 29 mm (32 0 IN )
07780-0010300 07780-0010600 07780-0013400
or equivalent commercially avalI- or equivalent comme rcially aval]- or equivalent commercially avail-
abie in U.SA able in U.SA able in U.SA
9-4
Flat cutter, 24 mm (32 0 EX) Interior cutter, 30 mm (60 0 IN ) Interior cutter, 24 mm (60 0 EX)
07780-0012500 07780-0014000 070PH-ZOD0100
or equ ivalent commercially avail- or equivalent commercially avail- or equivalent commercially avail-
able in U.SA able in U.SA able in U.S.A.
Cutter holder, 4.0 mm Tensioner stopper

07781 -0010500 070MG-0010100
, \
or equivalent commercially avai l-

able in U.S.A.
9-5
TROUBLESHOOTING
• En gine top-end pro bi ems usually affect engine performance . These problems can be diagnosed by a compress ion test
or by tra cing engine noises to the top-end with a sounding red stethoscope.
• If the performance is poor at lew speeds, check for white smoke in the crankcase breather hose. If the hose is smoky,
check for a seized piston ring (page 13-15).
Compression too low, hard starting or paor performance at low speed
• Va lves:
- Inco rrect valve clearance adjustment
- Burn ed or bent valve
- Incorrect va lve timing
- Broken valve spring
- Uneven va lve seating
• Cylinder head:
- Leaking or damaged cyli nder head gasket
- Warped or cracked cylinde r head
- Loose spa rk plug
• Worn cy linder, pisto n or piston rings (page 13-15)
Compression toa high, overheating or knocking
• Excess ive ca rbon build-up on piston crown or on combustion chamber
Excessive smoke
• Cylinder head:
- Worn va lve stem or valve gulde
- Damaged stem sea l
• Worn cyli nder, pist on or piston rings (page 13- 15)
Excessive noise
• Cylinder head:
- In correct valve clearance adjustment
- Stlcklng va lve or braken valve spring
- Dama ged or wa rn ca mshaft
- La ase or wo rn cam chal n
- Wa rn or damaged ca m chain
- Worn or dam aged cam cha ln tensianer
- Worn cam spracket teeth
• Worn cy linder, piston or piston rings (page 13-15)
Rough idle
• Law cylinder compresslon
9-6
CYLINDER COMPRESSION TEST
Wa rm the eng ine to normal operating temperature.
Stop the engine and re move the all direct ignition
coill spark plu g caps and spark plugs (page 4-9).
lift and suppo rt th e fu el tank (page 4-5).
Disco nneet the f uel pump unit 2P (Blaek) connector.
2P (Black) CONN ECTO R
Insta ll a comp ression gauge into the spa rk plug

hole.
TOOL:
Compression gauge 07RMJ-MY50100 or
attachment equivalent commer-
cially available in
U.S.A.
Open th e throttle all t he way and crank t he engin e
w ith th e starter moto r until the ga uge readi ng stops
risi ng.
Th e maxim um rea din g is usually reached wi th in 4-
7 seco nds.
Standard:
1,226 kPa (12.5 kgf/cm', 178 psi) at 350 rp m
Low com pressio n can be caused by:
- Bl own cy linder hea d gasket
- Impra per va lve clea ran ce adju stment
- Val ve leakage
- Wa rn pi ston ring or cyli nder
Hig h co mpression ca n be ca used by:
- Carbon deposits in co m bustion chamber or on
piston hea d
CYLINDER HEAO COVER REMOVAL

Remove the followi ng:
- Air cleane r housing (page 6-52)
- PAI R cont rol solenoid valve (page 6-78)
- Direct ignition coils (page 4-9)
Disconneet the breather hose from the cylinder
head cove r.
Remave t he trim clip and right heat guard plate.
Remave the cylinder head cover balts and was hers,

BOLTSIWASHERS
8e carefu/ not ta Remove th e cylin der head cover from the cyl inder
damage the radiator head.
fins.
CYLINDER HEAO COVER

DISASSEMBLY
Remove the cylinder head cover packing.
PACKING
9-8
Remave the balts and PAIR check valve cover.
COVER
Remave the PAIR check valves fram the cylinder

head cover.
Check the PAIR check valve far wear or damage,
replace if necessary.
Remave the baftle plates fram the cylinder head

cover.
CAMSHAFT REMOVAL
Remave the fallawing :
- CMP sensor (page 6-71)
- Cylinder head cover (page 9-7)
Remove the timing hole cap and O-ring.
9-9
Turn the crankshaft clockwise and align the "T"
mark with the index mark on the right crankcase
cover.
The timing marks I"IN " and "EX") on the ca m

sprockets must be flush with the cylinder head sur-
face and facing outward as shown.
If the tim ing marks on th e cam sprocket are fa cing
inward, turn the crankshaft clockwise one full turn
1360°) and rea lign the timing marks with the cylin-
der head surface sa they are facing outward .
Remave the cam cha in tensio ner lifter sealing bolt

and washer.
Use a 1.5 mm hex Remave the screw and end piece from the tensioner ;::::::::::::::::~::~~~~~~~~~~
wrench ra remave stopper.
the screw.
TOOl:
Tensioner stopper 070MG-0010l 00
9-10
Turn the tensioner lifter shaft ful ly in (clockwisel
and secure it using the tensioner stopper to prevent
damaging the cam chain.
TENSIONER STOPPER
It is nor necessary If you plan to replace the camshaft and/ or cam
to remove the cam sprocket, loosen the cam sprocket balts as follows:
sprocket trom the
- Remave the cam sprocket balts from the intake
camshaft except
and exhaust camshafts.
when replacing the
camshaft andlor NOTE :
cam sprocket. • Be careful not to drop the cam sprocket balts and
cam sp racket into the crankcase.
- Turn the crankshaft clockwise one full turn

(360°). remave the other cam sprocket balts from
the camshafts.
- Remave the balts and cam chain guide B.
- Remave the cam sp rackets from the camshafts .
- Remave the balts and CMP sensor rotor from the

exhaust camshaft.
9-11
CYLINDER HEADIVAL VES
Remove the bolts and cam chain guide B.
Suspend rhe cam Loosen and remove the camshaft holder bolts!
chain with a piece washers, then remove the camshaft holders and BOLTSIWASHERS
of wire to prevent camshafts.
the chain trom
falling inta the NOTE:
crankcase. From outside to inside, loosen the balts in a cri 55-
cross .pattern in several steps or the camshaft holder
might brea k.
Do not forcibly remove the dowel pins from the
camshaft holders.
Remove the valve lifters and shims.

SHIM LIFTER I
• Be careful not to damage the valve lifter bore.
• Shim may stick to the inside of the valve lifter.
Do not allow the shims to fall into the crankcase.
• Mark all valve lifters and shims to ensure co rrect
reassembly in their original locations.
• The valve lifter can be easily removed with a
va lve lapping taal or magnet.
• The shims can be easily removed with a twee-
zers or mag net.
INSPECTION
CAMSHAFT
Check the cam and jou rna I surfaces of the camshaft
for seoring, scratehes or evidence of insufficient
lubrication.
Check the oil holes in the camshaft for clogging.
Support bath sides of the camshaft (at jou rna Is)
with V-blocks and check the camshaft runout with a
dial gauge .
9-12
Using a micrometer, measure eaeh eam lobe height.
SERVICE lIMITS:
IN: 36.34 mm (1.431 in)
EX: 35.32 mm (1 .391 in)
CAMSHAFT HOLDERS
In speet the bearing surfaee of eaeh eamshaft holder
for seoring , seratehes, or evidenee of insuffieient CAMSHAFT HOLDER A
lubrieation.
Inspeet th e oil oriliees ol the holders lor clogging. ,/ CAMS HAFT HOLDER B
I
CAMSHAFT HOLDER C
CAM CHAIN GUlDE B
Inspeet the cam ehain slipper surfaee of the eam
chain guide B for wear or damage.
CAM CHAIN GUlDE B

CAMSHAFT Oll CLEARANCE
Do not rotate the Wipe any oil from the journals of the eamshaft, eyl-
camshaft when inder head and eamshaft holders.
PLASTIGAUGE
using pfastigauge. Lay a strip of plastigauge lengthwise on top of eaeh
eamshaft journal.
9-13
Be sure the dowe! Install each camshaft holder to the correct locations
pins in the with the identification marks.
SEALING WASHERS
camshaft holder
- No mark: right camshaft holder
afign the holes in
- "R" mark: center camshaft holder
the cylinder head.
- "L" mark: left camshaft holder
Apply oil to the threads and seating surfaces ol the
camshaft holder balts.
Install the holder balts with the eight sealing wash-
ers.
Finger tighten the balts.
IDENTIFICATION MARKS
Gradually tighten the camshaft holder balts until the

camshaft holders lightly contact the cylinder head
surface.
I NOTICE
Fai/ure to tighten the camshaft holder in a criss-
cross pattern might cause a camshaft holder to
break.
Tighten all camshaft holder balts in the numerical
order cast on the camshaft holders.
TORQUE: 12 N·m (1 .2 kgl·m, 9 Ibl·ft)
Remove the camshaft holders and measure the

width ol each plastigauge.
The widest thickness determines the Dil clearance.
When the service limits are exceeded, replace the
camshaft and recheek the Dil clearance.
Replace the cy li nder head and cams haft holders as
a set jf the clearance still exceeds the service limit.
CYLINDER HEAO REMOVAL

- Th ermosta! housing (page 7-8)
- Camshaft (page 9-9)
Remave the balts, cam chain tens ioner lifter and
gasket.
9-14
Remove the two 6 mm bolts.
Loosen the 9 mm Remave the ten 9 mm bolts/washers.
bolts În a crisscross
Remove the cylinder head.
pattern in two or
three steps.
Remove the gasket and dowel pins.
Rem ove th e following:

- Right crankcase cover (pag e 10-5)
- Starter clutch (page 10-17)
Remove the bolt, cam chain tensioner A and collar.
Remo ve the bolt, washer and cam chain guide A.
Rema ve the cam chain and timing sprocket trom the

crankshaft.
CYLINDER HEAO DISASSEMBL Y
Remave the cylinder head (page 9-14).
Remave the balts, insulators and O-rings.
\
\
, ,, , ,
\
\ , , ,
\~/ .... '
Q-R INGS
Remove the bolt, sealing washer and cam chai n

tensioner B from the cylinder head.
Remave th e spa rk plugs t rom t he cylinder head .

Install the tappel hole p rotector into the va lve lifter
ba re.
TOOLS:
Tappet hole protector (IN) 07HMG-MR70002
Tappet hole protector (EX) 07JMG-KY20100
Not available in
U.S.A .
An equ ival en t taal ca n easil y be made tro m a plastic ~~~~~~~~====-=~=-~~~,

35 mm fil m container as shown.
TOP VIEW
9-16
Ta prevent 1055 of Remove the valve spring cotters using the special
tension. do not tools as shown.
compress the va/VB
springs more than TOOLS :
necessary to Valve spring compressor 07757-0010000
remove the cotters. Valve spring compressor
attachment (IN) 07959-KM30101
Valve spring compressor
attachment (EX) 07JME-KY20100
Mark all parts Remave the following :

during disassembly
- Spring retainer
50 they can be
- Inner/outer valve springs (IN)
pfaced back in their
- Valve spring (EX)
originallocations.
- Valve
- Stem seal STEM SEAL
- Valve spring seat
SPRING SEAT
;.),1, ;
VALVE SPRINGS
RETAINER
CYLINDER HEAO INSPECllON

CYLINDER HEAO
Avoid damaging the Remove carbon deposits trom the combustion . .
gasker surface. chambers.
Check the spark plug hole and valve areas for
cracks.
Check the cylinder head for warpage with a straight

edge and feeier gauge.
9-17
VALVE LIFTER BORE
Ins peet each valve lifter bare for scratehes or abnor-
mal wear.
Measure each valve lifter bare I.O.
SERVICE lIMITS:
IN: 26.04 mm (1 .025 in)
EX: 22.54 mm (0.887 in)
VALVE LIFTER
Inspeet each valve lifter for scratehes or abnormal
wear.
M easu re the each valve lifter O.O.
SERVICE lIMITS:
IN : 25.97 mm (1.022 in)
EX: 22.47 mm (0.885 in)
VALVE SPRING
Measure the tree length of th e inner and outer va lve
springs. IN:
SERVICE LIMITS:
IN: Inner: 35.1 mm (1 .38 in)
Outer: 39.2 mm (1 .54 in)
EX: 39.6 mm (1 .56 in)
Replace the springs if they are sharter than the ser-
vice limits.
EX:
9-18
CAM CHAIN TENSIONER/CAM CHAIN
GUlDE
Inspeet the cam chain tensioner A and cam chain
guide A for excessive wear or damage, replace
CAM CHAIN TENSIONER A
them if necessary.
Inspeet the cam chain tensioner 8 for excessive

\
CAM CHAIN GUlDE A
CAM CHAIN TENSIONER B

wear or damage, replace it if necessary.
VALVEIVALVE GUlDE
Check that the valve moves smoothly in the guide.
Inspeet each valve for bending, burning or abnor-
mal stem wear.
Measure and re cord each valve stem O.O.
SERVICE lIMITS :
IN: 3.965 mm (0.1561 in)
EX: 3.955 mm (0.1557 in)
Ream the guides to re move any carbon deposits

before checking clearances.
Insert the rea mer trom the combustion chamber
side of the cylinder head and always rotate the
rea mer clockwise.
TOOL:
Valve guide reamer, 4.008 mm 07MMH·MV90100 or
07MMH·MV9010A
(U.S.A. only)
a .. a
Measure and record each valve guide I.O.
SERVICE LIMIT: IN/EX: 4.04 mm (0.159 in)
Subtract each valve stem O.O. trom the correspond-

ing gu ide I.O. to obtain the stem-to-guide cl ea rance.
SERVICE L1MITS:
IN: 0.075 mm (0.0030 in)
EX: 0.085 mm (0.0033 in)
Reface the va/ve It the stem-ta-guide clearance is out of standard,

seats whenever the determine if a new guide with standard dimensions
va/ve guides are would bring the clearance within tolerance. It sa,
repfaced replace any guides as necessary and ream to fit.
(page 9-22). It the stem-ta-guide clearance exceeds the service
limit with the new guides, replace the valves and
guides.
VALVE GUlDE REPLACEMENT

Chili the replacement valve guides in the freezer
section of a refrigerator tor about an hour.
Do not use a toreh
Heat the cylinder head to 100 -150°C (212 - 302° F)
with a hot plate or oven.
to heat the cylinder
head;itmaycause To avoid burns, wear heavy gloves when handling
warping. the heated cy linder head.
Support the cylinder head and drive out the valve
guides trom combustion chamber side ot the cylin-
der head.
TOOl:
Valve guide driver 07JMD-KY20100
Drive in the va lve guides to the specitied depth trom

the top ot the cylinder head.
SPECIFIED DEPTH:
IN: 17.1 - 17.4 mm (0.67 - 0.69 in)
EX: 15.8 -16.1 mm (0.62 - 0.63 in)
TOOL:
Valve guide driver 07743-0020000
Not available in
U.S.A.
Let the cylinder head cool to room temperature.
VALVE GUlDE DRI

Use cutting oil on Ream new valve guides after installation.
the reamerduring Insert the reamer from the combustion chamber
this operation. side of the head and also always rota te the reamer
clockwise.
TOOL:
Valve guide reamer, 4.008 mm 07MMH-MV90100 or
07MMH-MV9010A
(U.S.A. onlv)
Clean the cylinder head thoroughly to remave any

metal particles.
Retace the valve seat (page 9-22).
9-20
VALVE SEAT INSPECTION/REFACING
Clean the intake and exhaust valves thoroughly to
remove carbon deposits.
Apply a light coating of Prussian Blue to the valve
seats.
Tap the valves and seats using a rubber hose or
other hand-Iapping taa l.
Remove the valve and ins peet the valve seat face.
The valve se at contact should be within the speci-
fied width and even all around the circumference.
Standard:
IN/EX: 0.90 - 1.10 mm (0.035 - 0.043 in)
SERVICE LIMIT:
IN/EX: 1.5 mm (0.06 in)
If the seat width is not within specification, reface
the valve seat (page 9-22).
SEATWIDTH
Inspeet the valve seat face for:

• Uneven seat width:
- Replace the valve and reface the valve seato
• Oamaged face:
- Replace the va lve and reface the valve seato
- - =--=- - -
DAMAGED FACE UNEVEN SEAT WIDTH
The va/yes cannot • Contact area (toa high or too low)

be ground. If a - Reface the valve seat.
va/ve face is burned
or badly wam or if it
contacts the seat
unevenly, rep/ace
the va/va.
TOO LOW TOO HIGH

VALVE SEAT REFACING
Follow the refacing Varve seat cutters/grinders or equivalent valve sea I
manufacturer's refacing equ ipment are recommended to correeI
operating warn varve seats.
instructions.
I -I ';
45'
'\ / ~
Qj 32'
D '" 60'
Ir
II Ihe conlacl area is 100 high on Ihe valve, Ihe seal

must be lowered using a 32° flat cutter. CONTACT TOO HIGH ,OlO SEAT WIOTH
~ ..~ ~".
ft the contact area is toa [ow on the varve, the se at
must be raised using a 60° interior cutter.
CONTACTTOO lOW OlO SEAT WIOTH
~ ~ .. L 60'
Reface the seat Use a 45° cutter to rem ave any roughness or irregu-
wÎth a 45 cutter
Q
lariti es trom the seat. ROUGHNESS
whenever a va/va
guide is replaced. TOOlS:
Seat cutter, 29 mm (IN) 07780-0010300 "
Seat cutter, 24 mm (EX) 07780-0010600 '.
Cutter holder, 4.0 mm 07781-0010500
or equivalent com-
mercially available
in U.S.A.
Use a 32' cutter la rem ave Ihe lap 1/4 ol Ihe exisling
valve seat materiaL
TOOlS: "
Flat cutter, 29 mm (IN) 07780-0013400 OlO SEAT WIOTH

Flat cutter, 24 mm (EX) 07780-0012500
Cutter holder, 4.0 mm 07781 -0010500
or equivalent com-
~ <
merciallyavailable
in U.S.A_ 32' I
9-22
Use a 60 0 cutter to rem ave the bottom 1/4 ol the aid
seat o
TOOLS: / '
OlO SEAT WIDTH
Interior cutter, 30 mm (IN) 07780-0014000
Interior cutter, 24 mm (EX)
Cutter holder, 4.0 mm
070PH-Z000100
07781-0010500
~
or equivalent cam-
mercially available
in U.S.A.
60
0
L
Using a 45° seat cutter, cut the seat to the proper ~=================~
width.
Make sure that all pitting and irregularities are
removed. / ~o mm (0.04 in)
Aefin ish if necessary.
----------' 45°L
After cutting the seat, apply lapping compound to
the valve lace, and lap the valve using light pres- HAND-lAPPING TOOl
sure.
• Excessive lapping pressure may deform or dam-
age the sea!.
• Change the angle ol lapping taal Irequently to
prevent uneven se at wear.
• 00 not allow lapping compound to enter the
guides.
After lapping, wash all residual compound aft the
cylinde r head an·d valve.
CYLINDER HEAO ASSEMBL Y
INNER VALVE SPRING

(9
~STEMSE~
, VALVE LIFTER
SHIM-
___ ~ o
FAC"',""NO
" Q
~
6\'J
":::N~~ Q-RING ~
VALVE SPRING
SPRING SEAT /
VALVE GUlDE
, INTAKE VALVE
12 N·m 11.2 kgf·m, 9Ibf·ft)
Blow through all oil passages in the cylinder he.ad

with compressed air.
Install the tappet hole protector into the valve lifter
bare.
TOOLS:
Tappet hole protector (IN) 07HMG-MR70002
Tappet hole protector lEX) 07JMG-KY20100
Not available in
U.S.A .
Install the valve spring seats.

Insta!! new stem seals.
Lubricate the valve sterns with molybdenum oil
solution.
Insert the valve into the valve guide while turning it s ~
slowly to avoid damage to the stem sea l.
l S2
M
SEAL
•
1. 0
SPRING SEAT
"a
~! ;
VALVE SPRINGS
RETAINER
9-24
Install the valve springs with the tightly wound coils
facing the combustion chamber. IN: INNER VALVE SPRING
• The valve springs have pa int marks OUTER VALVE SPRING

- IN (inner): Red
- IN (outer): Pink
- EX: Pink
Install the valve spring retainer.
COMBUSTION CHAMBER SIDE
EX:
I•
COMBUSTION CHAMBER SIDE
Grease rhe cotters Install the valve cotters using the special taal as
to ease instaflarion. shown .
NOTE:
To prevent 1055 of tension, do not compress the
valve spring more than necessary.
TOOLS:
Valve spring compressor 07757·0010000
attachmen! (IN) 07959·KM30101
attachmen! (EX) 07JME·KY20100
Support 'he Tap the valve stems gently with two plastic ham·
ey/inder head above mers as shown to seat the cotters firmly.
the work bench
surface ra prevent
possible va/ve
damage.
9-25
Apply loeking agent to the cam ehain tensioner B
pivot bolt threads (page 1-19).
Install the sealing washer, bolt and cam eha in
tens ioner B as shown .
Tighten the cam ehain tensioner B pivot bolt to the
specified to rque.
TORQUE: 20 N·m (2.0 kgf·m, 1Slbf·ft)
Install new O-rings to the insulato r grooves.

INSULATOR
Install the insulators to the cylinder head and
tighten t he balts to the speeified torque.
TORQUE: 12 N·m (1 .2 kgf·m, 9 Ibf.ft)
For spark plug installation (page 4-11).
CYLINDER HEAO INSTALLATION

Install t he timin g sproeket by alig ning the wide teeth
between t he crankshaft and sproeke!.
Install th e cam ehai n.
9-26
Install the cam chain guide A, bolt and washer.
CAM CHAIN GUlDE A
\.,
BOLT/WASHER
Apply locking agent to the cam chain tensioner A
Install the collar, cam chain tensioner A and bolt.
COLLAR
"" '"' ' ""~"" ,Iv

_ B OLT
Tighten the cam chain guide A bolt to the specified

torque.
TORQUE: 12 N·m (1.2 kgl·m, 9 IbHt)

Tighten the cam chain tensioner A pivot bolt to the
specified t orqu e.
Install th e following :
- Right cra nkcase cover (page 10-26)
Install the dowel pins and a new cylinder head gas-

ket as shown.
n ~..,
Install the cyli nder head onto the cylinder block
while aligning the cam chain tensioner A and B as
CAM CHAIN TENSIONER B
r====iI~
shown.
CAM CHAIN TENSIONER A

Apply molybdenum oil solution to the 9 mm bolts!
washers threads and seating surface and install
them.
Install the two 6 mm flange bolts.
Tighten the 9 mm balts in a crisscross pattern in two
or three steps to the specified torque.
TORQUE: 47 N·m 14.8 kgf·m, 35 IbHt)
Tighten the 6 mm flange bolts.
Install the cam chain tensioner lifter onto the cylin- ...-~
der head with a new gasket.
- Camshaft Ipage 9-28)
- Th ermostat housing Ipage 7-10)
CAMSHAFT INSTALLATION
Apply molybdenum oil so lution to the sliding sur-
face of each valve lifter.
Install the shims Install the shims and valve lifters to the cylinder
and valve lifters in head.
their original
locations.
9-28
Ea ch camshaft has an identification mark.
"IN " MARK
• "IN"; Intake camsha ft
• "EX"; Exhaust camshaft
"EX" MARK
If the cam sprockets are removed, install the cam

sprockets onto th e camshafts . NO.1 CYLINDER CAM lOBES
• Install th e intake cam sprocket with the timing

mark (IN ) facin g outward and the No.1 cam lobes
facing up and out as show n.
• Install the exhaust cam sprocket with the timing
mark (EX) facing outward and the No.1 ca m
lobes facing up and out as shown.
EXHAUST CAM SPROCKET

INTAKE CAM SPROCKET
Clean and apply locking agent to the ca m sp racket

Temporarily install the cam sprockets and balts.
o
UW BOlTS
Exhaustcamshaft Clean and apply locking agent to the CMP sensor
"OUT" MARK
on/v: rotor bolt threads .
Install the CMP Install the CMP sensor rotor and balts.
s ensor rotor with
the No. 1 cylinder
cam lobes facing
down and rotor
'our m ark facing
up as shown.
.o.uw BOlTS
Turn the crankshaft clockwise and align the "T"
mark with the index mark on the right crankcase
cover.
Apply molybdenum oil solution to the camshaft

journalof the cylinder head.
Make sure the cam Install the cam cha in over the cam sprockets and
chain tensionBr is then in stall the intake and exha ust camshafts. INTAKE CAMSHAFT
fuJly rerracred with
Ea ch camshaft has an identification mark.
the rensioner
stopper (page 9-711. • "IN ": Intake camshaft
• "EX"; Exhaust camshaft
• Make sure that the timing marks on the cam

spreekels are facing outwa rd and flush with Ihe CYLINDER HEAO UPPER SURFACE
cylinder head upper surface as shown.
TIMING MARKS
9-30
Coat new O-rings with oil and install them into the
grooves in the camshaft holders.
Apply mo lybdenum oil solution to the camshaft
jou rna Is of the camshaft holders.
~, O-RINGS
Note the correct locations with the identification . - - - - - - - - - - - - - - - - - - ,
marks as shown.
- No mark: right camshaft holder
"R" mark: center camshaft holder
- "L" mark: left camshaft holder
IDENTIFICATION MARKS
Be sure to align the Instal1 each camshaft holder anto the camshafts.
dowel pins in the
camshaft holder
with the holes in
the cvlinder head.
Apply oil to the threads and seating surfaces of the

-;71!1 BOLTS/SEALING WASHERS !1lt!~
camshaft holder balts.
Install the twenty holder balts with new eight seal - lil ""..
ing washers as shown.
Finger tighten the balts.
Gradually tighten the camshaft holder balts until the
camshaft holders lightly contact the cylinder head BOlTS
surface.
I NOTICE I
Fai/ure ta tighten the camshaft holder in a criss-
cross pattern m ight cause a camshaft holder ta
break.
Tighten all camshaft holder balts in the numerical
order cast on the camshaft holders.
TOAQUE: 12 N·m (1.2 kgl·m, 9 Ibl·ft)
Install the cam chain guide B, and tighten the balts.

Tighten the cam sp racket balts to the specilied
torque.
TOAQUE: 20 N·m (2.0 kgl·m, 15Ibl·ft)
Turn the crankshaft clockwise one full turn (360°)
and tighten the other cam sprocket balts.
In case the CMP sensor rotor was removed , tighten

the CMP sensor rotor bolt to the specified torque.
TOAQUE: 12 N·m (1.2 kgl·m, 9 Ibl·ft)

Turn the crankshaft clockwise one full turn (360°)
and tighten the other CMP sensor rotor bolt.
Remave the tensioner stopper trom the cam chain

tensioner lifter.
TENSIONER STOPPER
9-32
Install a new sealing washer and tighten the bolt
secu rel y.
Recheck the va lve timing.
Install the CMP sensor (page 6-72 ).
CYLINDER HEAO COVER ASSEMBL Y

Install the PAIR check valve battle plates into the cyl-
inder head cover. BAFFLE PLATES
Install the PAIR check va lves into the cylinder head

cover.
Apply locking agent to the PAIR check va lve cove r

bolt threads. COVER
~
Install the PAIR check valve cover and tighten the
balts to the specified torque.
TOROUE: 12 N ·m (1 .2 kgf·m, 9 IbHt)
9-33
CYLINDER HEAO COVER

INSTALLATION
Install a new cylinder head packing into the groove
e~ PACKING
ol the cylinder head cover.
......
Apply sealant to the cylinder head semi-circula r cut- , - - - - - - - - - - - - - - - - - - - - ,

outs as shown. JI~
Be carefuf not to Install the cylinder head cover onto the cylinder
damage the radiator head.
fins.
Instal! new washers to the cylinder head cover with ~::==-:.:.:===-::-=-:-=-~-~-----,

their "UP" ma rk lacing up . -""
......
""",. "UP" MARK
9-34
Install and tighten the cylinder head cover bolts to
the specified torque. BOlTS
Install the right heat guard plate and trim clip.
Conneet the breather hose securely.

- Direct ignition coils (page 4-11)
- PAIR control solenoid va lve (page 6-78)
- Air cleaner housing (page 6-54)
CAM CHAIN TENSIONER LIFTER

REMOVAL
Lift and support the luel tank (page 4-5).
Rem ove the cam chain tensioner sealing bolt and
sealing washer.
9-35
Use a 1.5 mm hex
wrench ro remove
the screw.
Remove the screw and end pieee trom the tensloner
stopper. 1.5
SCREW-
mm' Ill--
,
TOOL:
Tensioner stopper 070MG,0010100
Turn the tensioner shaft lully in (clockwise) and

secure it using the tensioner stopper to prevent
damaging the cam chain.
TENSIONER STOPPER
Remove the bolts, cam chain tensioner lifter and

gasket.
INSTALLATION
Nore the instaJ/ation Install a new gasket onto the cam chain tensioner ,..--......
direction of rhe lifter.
gasket.
Install the cam cha in tensioner lifter into the cylin-
der head .
9-36
Install and tighten the balts securely.
Remove the tensioner stopper.
Install a new sealing washe r and tighten the sealing

bolt securely.
Remave the suitable support and close the fuel tank
(page 4-6) .
9-37
MEMO
10. CLUTCH/STARTER CLUTCH/GEARSHIFT LlNKAGE
COMPONENT LOCATION ........ ················ 10-2 CLUTCH ... .. ..... .......... ................ .... ......... ... 10-7
SERVICE INFORMATION · ............ ······ ······10-3 STARTER CLUTCH ..... ....... ........... .......... 10-17
TROUBLESHOOTING ·············· ............ ·····10-4 GEARSHIFT L1NKAGE· .............. ·........ ·.. · 10-23
RIGHT CRANKCASE COVER RIGHT CRANKCASE COVER

REMOVAL · .. ·· ······ ·.... ·· ········ ········· .. ·· .. ········ 10-5 INSTALLATION ................ ... ......... .......... 10-26
10-1
CLUTCH/STARTER CLUTCH/GEARSHIFT LlNKAGE
COMPONENT LOCATION
~~ \\ \ \
\~>
\ ~"
i 0
83 N·m (8.5 kgf·m,Sl IbHt )
23 N' m (2.3 kgf·m ,17 IbHt)
. ~
~~~L. 15 N·m (1.5 kgf·m , lllbHt)
128 N·m (13.1 kgf·m, 94Ibf.ft)
12 N' m (1.2 kgf.m , 9 Ibf·ft)
10-2
SERVICE INFORMATION
GENERAL
• This section covers service of the clutch, starter clutch and gearshift linkage. All service can be done with the engine
installed in the Irame.
• Engine oil viscosity and level have an effect on clutch disengagement. When the clutch does not disengage or the
motorcycle creeps with clutch disengaged, inspeet the engine Dil level betore servicing the clutch system.
SPECIFICATIONS
Unit· mm (in)
Cluteh lever Ireeplay 10 - 20 (3/8 - 13/ 16) -
Cluteh Spring Iree length 46.7(1.84) 45.8(1.80)
Dise th iekness 2.92 3.08(0.115 0.121) 2.6(0.10)
Plate warpage - 0.30 (0.012)
Cluteh outer guide I.O. 24.993 - 25.003 (0.9840 - 0.9844) 25.013(0.9848)
O.O. 34.996 - 35.004(1.3778 -1.3781) 34.986 (1.3774)
Primary driven gear I.O. 41.000 - 41.016(1 .6142 1.6148) 41.026 (1.6152)
Dil pump drive sproeket I.O. 25.000 - 25.021 (0.9843 - 0.9851) 25.031 (0.9855)
guide I O.O. 34.950 34.975 (1.3760 1.3770) 34.940 (1.3756)
Dil pump drive sproeket I.O. 35.025 - 35.145(1.3789 - 1.3837) 35.155(1.3841)
Mainshaft O.O. at cluteh outer guide 24.980 - 24.990 (0.9835 - 0.9839) 24.960 (0.9827)
Mainshaft O.O. at oil pump drive sp racket guide 24.980 - 24.990 (0.9835 - 0.9839) 24.960 (0.9827)
Starter driven gear boss O.O. 45.657 45.673(1.7975 -1 .7981) 45.642 (1.7969)
TORQUE VALUES
Cluteh center loek nut 128 N'm (13. 1 kgfm, 94Ibf·ft) Apply oil to the thread and seating surface,
stake
Cluteh spring bolt 12 N·m (1.2 kgl·m, 9Ibf·ft)
Dil pump driven sproeket bolt 15 N·m (1.5 kgl·m , 11 Ibl·ft) Apply loeking agent to the threads
Shift drum center bolt 23 N·m (2.3 kgl·m, 17 Ibl·ft) Apply loeking agent to the threads
Shift drum stopper arm pivot bolt 12 N·m (1.2 kgfm, 9 Ibfft) Apply loeking agent to the threads
Gearshift spindie stopper pin 22 N·m (2.2 kgfm, 16Ibl·ft)
Starter eluteh mounting bolt 83 N·m (8.5 kgf·m, 61 Ibl·ft) Apply oil to the threads and seating surface
10-3
TOOLS
Clutch center holder Gear holder, M2 .5

07724-0050002 07724-0010100
or equiva lent comme rcially avai l-

able in U.S .A. or 07724-001A 100 (U.S.A. only)
TROUBLESHOOTING
Clutch lever is too hard to pull in
• Dam aged cl utch lifte r mechani sm
• Faulty clutch lifter bearing
• Clutch lifter piece insta lied improperly
Clutch slips when accelerating
• Warn cl utch disc
• Weak clutch springs
• Engi ne Dil m ixed wit h molybdenu m or graphi te additive
Clutch will not disengage or motorcycle creeps with clutch disengaged
• Clutch plate warped
• Laase clutch center loek nut
• Oil level too hig h
• Improper oi l viscosity
• Damaged cl utch lifter mechanism
• Clutch lifter piece insta lled im properly
Hard to shift
• Improper cl utch operation
• Improper oil viscosity
• Bent sh ift lork
• Bent shift l ork shaft (page 12-8)
• Bent lork claw (page 12-8)
• Damaged gea rshift ca m
• Loose sto pper plate bolt
• Damaged stopper plate and pin
• Damaged gearshift spi ndie
Transm ission jumps out of gear
• Warn shift drum stopper arm
• Weak or braken shift drum stopper arm return spring
• Loose stopper plate bo lt
• Bent shift l ork shaft
• Oamaged gearshift cam
• Damaged or be nt shift lorks (page 12-8)
• Worn gea r engagement dogs or slots (page 12-9)
Gearshift pedal will not retu rn
• Weak o r braken gearshift spindie return spring
• Bent gea rsh ift spindie
Engine does not turn
• Faulty starte r clutch
• Damaged reduction gearlshaft
• Damaged id le gearl shaft
10-4
RIGHT CRANKCASE COVER REMaVAL
Remove the lollowing :
2P CONNECTOR
- Radiator reserve tank (page 7-20)
Drain the engine oil (page 4-17).
Lift and support the luel tank (page 4-5) .
Disconnect the CKP sensor 2P (Black) connector.
Remove the bolt and clutch cable gu ide plate, then

disconnect the clutch cable end lrom the clutch lifter
lever.
Remove the right crankcase cover balts and stays.
The liher lever Remove the right crankcase cover while turning the
spindie is engaged clutch lifter lever counterclockwise to disengage the
with the c1utch lifter lifter lever spindie lrom the lifter piece.
piece inside of the
right crankcase NOTE :
cover. Be careful not to drop th e thrustJwave washers into
the Dil pan wh en removing the right crankcase
cover.
10-5
CLUTCH/STARTER CLUTCH/GEARSHIFT L1NKAGE
Be careful not to Remave the th rust washer and wave washer from
drop the thrust/ the starter idle gear.
wave washers inca
the oil pan.
Remave the four dowel pins.

Clean oft any sealant trom the right crankcase cover
mating surfaces.
NOTE:
Do not turn the crankshaft counterclockwise after
removin g the rig ht crankcase cover to prevent the
starter reduction gear trom damage.
CLUTCH LIFTER LEVER

Remave the clutch lifter lever, return spring and
LIFTER LEVER
washer trom the right crankca se cover.
Check the lifter lever spindie for wear or damage.
Check the return spring for fatigue or damage.
WASHER
SPRING
Check the lifter lever oil seal and needie bearings for
wear or da m age.
Install the clutch lifter lever with the washer and
spring in the reverse order of remaval.
BEARINGS GIL SEAL
10-6
CLUTCH
REMOVAL
Remove the right crankcase cover (page 10-5).
Remove the starter idle gear and shaft.
Remave the cl utch spring balts, springs in a cri ss-

cross pattern in two or th ree steps, then remove the
pressure plate.
Remave the clutch lifter pieee from the lifter bear-
ing .
Remove th e following:
- Clutch disc A
- Six clutch discs C
- Seven clutch plates
- Clutch disc B
- Judder spring
- Spring sea t
Be careful not ta Unstake the clutch center loek nut.

damage the
mainshaft threads.
10-7
Ho ld the cluteh center with th e special taal and
remove the clutch center loek nut.
TOOl:
Clutch center holder 07724-0050002 or
equivalent comme r-
cially available in
U.S.A.
Diseard the loek nut.
Rem ave the loek was her, thrust washer and cluteh
center.
Remove th e thrust washer.
Remave the cluteh outer guide and needie bearing .
10-8
Remave the clutch outer.
Be careful not to Remave the balts, oil pump drive chain guide A and ~~ ~~BI.
drop the parts into chain guide B.
the oil pan.
Be careful not to Remave the oil pump driven sprocket bolt and
drop the parts in to washer.
the oil pan. Remave the ail pump drive/driven sprocket and
drive chain as an assembly.
Remave the ail pump drive sprocket guide.
10-9
INSPECTION
Clutch lifter bearing
Turn the inner race of the lifter bearing with your
finger.
The bearing should turn smoothly and quietly.
Also check th at the outer race of the bearing fits
tightly in the pressure plate.
Repla ce the bearing if the inner race does not turn
smoothly, quietly, or if the outer race fits loosely in
the pressure plate.
Clutch spring
Rep/ace rhe clutch Measure the clutch spring tree length .
springs as a set.
Clutch center
Check the grooves of the clutch center for damage
or wear caused by the clutch plates.
Repla ce it if necessary.
Clutch lifter piece

Check the clutch lifter piece for damage or abnormal
wear.
10-10
Clutch disc
Rep/ace the clutch Replace the clutch discs jf they show signs of scor·
discs and plates as ing or discoloration .
a set.
Measure the disc thickness of each disco
Clutch plate
Rep/ace the cfutch Check th e plates for discoloration.
discs and plates as Check the prate warpage on a surface plate using a
a set. teeier gauge.
Judder spring/spring seat

Check Ihe judder spring and spring seal for defor-
matien, warpage or d amage; rep lace th em if neces·
sary .
• A damaged or warped spring seat wil! cause th e
judder spring to be pressed unevenly .
• A damaged judder spring al50 ca uses the weak
co ntact betwee n the discs and plate s or uneven
diselplale conlacl.
SPRING SEAT
\
JUDDER SPRING
Clutch outer/primary driven gear

Check Ihe slols of I he clulch ouler for damage or
CLUTCH OUTER SLOT
wear caused by the clutch discs.
Check the primary driven gear for abnormal wear o r
damage.
Measure the I.O . of the primary driven gear.
SERVICE LIMIT: 41 .026 mm (1.6152 in)
Repla ce Ihe clulch ouler assembly if necessary.
PRIMARY GEAR
10-11
Clutch outer guide/needle bearing
Measure the O.O. and I.O. of the clutch outer guide.
SERVICE LlMITS:
O.O.: 34.986 mm (1 .3774 in)
I.O.: 25.013 mm (0.9848 in)
Check the needie beari ng turns smoothly and qui-

etly.
Replace the bearing jf necessary.
Dil pump drive sprocket guide

Measure the O.O. and I.O. of the oil pump drive
sp racket guide.
SERVICE LlMITS:
O.O.: 34.940 mm (1 .3756 in)
I.O.: 25.031 mm (0.9855 in)
Dil pump drive sprocket

Check the oil pump drive sprocket for abnormal
wear or damage.
Measure the I. O. of the oil pump drive sp racket.
SERVICE LIMIT: 35.155 mm (1 .3841 in)
Dil pump drive ehain guide A/B

Check th e oil pump drive ehain guide A and 8 for
abnormal wear or damage. CHAIN GUlDE A
Replace them if necessary.
\
CHAIN GUlDE 8
10-12
Mainshaft
Measure the mainshaft o .O. at clutch outer guide
and oil pump drive sprocket guide slid ing surfaces.
SERVICE LlMITS: 24.960 mm (0.9827 in)
Starter idle gear/idle gear shaft

Check the starter idle gear and shaft for wea, 0'
STARTER IDLE GEAR
damage, rep lace them if necessary.
STARTER IDLE GEAR SHAFT
INSTALLATION
o
-
_ 12 N·m (1.2 kgf m, 9Ibf·ft)
10-13
Apply molybdenum oil solution to the oil pump
drive sprocket guide sliding surface and install it to
the mainshaft.
Apply oil to the oil pump drive/driven spreeket teeth

and drive chain.
Install the ail pump Install the oil pump drive/driven sproeket and drive
driven sprocker chain as an assembly.
with its 'our mark
App ly locking agent to the oi l pump driven sp racket
facing out.
bolt threads (page 1-19) .
Be carefu/ not ra Install the ail pump driven sprocket bolt, washer
drop rhe pans inta and tighten the bolt to the specified to rque.
the Dil pan.
Be careful not to Apply locking agent ta the oil pump drive chain
drep 'he pans into gu ide mounting balts threads (page 1-19).
the Dil pan.
Install the oil pump drive ehain guide A and tighten
the bolt seeurely.
Install the oil pump drive ehain guide Band tighten
the bolt seeurely.
Apply molybdenum oil solution to the eluteh outer :::::-~:.~;;:::::::~;::;;~.:~:::~

sliding surfac8.
Make sure 'he Install the cluteh outer by aligning th e tabs ol the oi l
starter reduction pump drive sprocket with the holes of the clutch
gear is installed inca outer.
the crankcase
(page 10-22) before
instaffing rhe clutch
outer.
10-14
Apply molybdenum oil solution to the clutch outer
guide sliding surface.
Install the c1utch Install the clutch outer guide and needle bearing
outerguide w ith its onto the mainshaft.
grooves facing out.
Install the th rust washer,
Install the clutch center and thrust washer,

Install the lock washer with its "OUT" mark facing
out.
Apply oil to a new clutch center lock nut threads and

seati ng surface the n insta!! it onto the mainshaft.
Hold the clutch cente r w ith the special taa l and
tighten the lock nut to the specified torque,
TOOl:
Clutch center holder 07724-0050002 or
equival ent cammer-
cially available in
U,S,A,
TORQUE: 128 N'm (13,' kgt'm, 94 Ibf·ft)
10-15
Be careful not to Stake the loek nut into the mainshaft grOQve w ith a
damage the punch.
mainshaft threads.
Install the spring seat and judder spring onto the

clutch center as shown.
Coat the clutch discs and plates with cl ean engine

CLUTCH DISC B CLUTCH DISCS C - ,
ail.
Install the clutch disc 8 (larger I.o. disc) into the
clutch outer.
Stack the seven clutch plates and six discs C alter-
nately.
Install the clutch disc A.
• Clutch disc 8 has a larger I.o. than the other
discs.
-,
CLUTCH PLATES CLUTCH DISC A
Install the tabs of outside clutch disc A into the shal - ~::::::~::;:.;;;;;;;;;;;;;,;;;;;;;;;;::::;~
low slots of the clutch outer.
10-16
Install the lifter bearing into the pressure plate.
LIFTER PIECE
Install the clutch lifter piece into the lifter bearing .
Install the pressure plate.

Install the clutch springs and spring balts.
Tighten the balts to the specified torque in a criss-
cross pattern in two or three steps.
TORQUE: 12 N·m (1.2 kgf·m. 9 Ibf·ft)
Apply molybdenum oil solution to the starter idle

gear shaft sliding surface.
Install the starter idle gear and shaft.
Install the right crankcase cover (page 10-26).
STARTER CLUTCH
REMOVAL
Remave the clutch (page 10-7).
Remove the starter reduction gear trom the crank-
case.
10-17
CLUTCH/STARTER CLUTCH/GEARSHIFT L1NKAGE
Temporarily install the following :
- Starter idle gear
- Starter idle gear shaft
Insert the gear holder between the starter idle gear
and drÎven gear as shown.
TOOl:
Gear holder, M2.5 07724-0010100 or
07724-001 A 100
(U.S.A. only)
Rem ove th e starter clutch mounting bolt and
washer.
Remove the temporarily insta lied parts.
Remove the starter clutch assembly.
Rem ove the th ru st washer.
INSPECTION
Check th e operation of th e one-way clutch by turn -
ing the driven gear.
NEEDLE BEA RING
Vou should be able to turn the driven gear clock-
wise smoothly, but the gea r should not turn eoun-
terclockwise.
DISASSEMBL Y
Remove the starter driven gear by turning it cloek-
wise.
Remove the needie bea rin g.
STARTER DRIVEN GEAR
10-18
CLUTCH/STARTER CLUTCH/GEARSHJFT L1NKAGE
Remove the snap ring and one·way clutch.
SNAP RING ONE-WAY CLUTCH
Check the starter clutch outer inner surface and one·

way clutch for abnormal wear or damage and
ONE-WAY CLUTCH
replace them if necessary.
STARTER CLUTCH OUTER
Check the needie bearing for abnormal wear or

damage.
Replace it if necessary.
NEEDLE BEARING
Check the starter driven gear for abnormal wear or

damage.
Measure the starter driven gear boss O.O.
10-19
Check the starter reduction gear tor wear or damage
and replace it if necessary. REDUCTION GEAR
ASSEMBLY
STARTER DRIVEN GEAR
~ , ONE-WAY CLUTCH
NEEDLE BEARING
SNAP RING
Apply oil to the one-way clutch sliding surface.

PAINTMARK ONE-WAY CLUTCH ,
Install the one-way clutch into the starter clutch
outer with its paint mark facing out.
10-20
After ins ralling the In stall the snap ring inta the starter clutch outer
SNAP RING STARTER CLUTCH OUTER
snap ring, a/ways groove securely.
rotate it in its
groove ro be sure it
is fully seated.
Install the starter driven gear and needie bearing

into the starter clutch outer while turning the starter NEEDLE BEARING
driven gear clockwis8.
Recheck Ihe one-way clulch operalion (page 10-18).
STARTER DRIVEN GEAR
INSTALLATION
Insla ll Ihe Ihrusl washer 10 Ihe crankshaft.
Inslall Ihe slarter clulch assembly 10 Ihe cranks haft

while aligning Ihe wide leelh of Ihe crankshaft wilh
Ihe slarter clulch assemb ly.
10-21
Apply oil to the starter clutch mounting bolt threads
and seating surfac8.
Install the was her and starter clutch mounting bolt.
Temporarily install the following:

- Oil pump drive sp racket guide
- Oil pump drive sprecket gear
- Clutch outer
- Clutch outer guide
- Clutch outer needie bearing
Be careful not to Attach the gear holder between the primary drive
drop (he gear gear and driven gear.
holder inco rhe Dil
pan.
TOOl:
Ge.r holder, M2.5 07724-0010100 or
07724-001A 100
(U.S.A. on/y)
Tighten the starter clutch mounting bolt to the spec-
jfied torque.
Remave the temporarily insta lied parts.
Apply molybdenum oil solution to the starter reduc- .........,...,.-
tian gear sliding surfac8.
Install the starter reduction gear into the crankcase.
Inslall the clutch (page 10-13).
10-22
CLUTCH/STARTER CLUTCH / GEARSHIFT LlNKAGE
GEARSHIFT lINKAGE
REMOVAL
Remave the lollowing :
Aemove the bolt and disconneet the gearshift arm
lrom the gearshift spindie.
Remave the bolt and setting plate.
Pull the gearshift spindie and thrust washer out ol

the crankcase .
Be careful not to Remave the lol lowing:

drop the parts inca
- Stopper arm pivot bolt
the oil pan.
- Stopper arm
- Return spring
- Washe r
- Shift drum center bolt
- Gearshift cam
- Dowel pin
10-23
INSPECTION
Check the gearshift spindie for wear, damage or
bending . GEARSHIFT SPINDLE
Check the return spring for fatigu e or damage.
RETURN SPR ING

INSTALLATION
Apply locking agent to the shift drum stopper arm
Be carelul not to Install the following :
drop the parts inro _ Washer
the aiJ pan.
- Return spring
- Stopper arm
- Stopper arm pivot bolt
Tighten the stopper arm pi vot bolt to the specified
torque.
TORQUE: 12 N·m (1 .2 kgl·m , 9 Ibl·ft)
Install the dowel pin onto the shift drum .

Align the dowel pin Install the gearshift cam while holding the stopper
on the shift drum arm using a screwdriver as shown ,
with the wide
groove on the
gearshift cam.
App ly locking agent to the shift drum center bolt

Tighten the shift drum center bolt to the specified
torque.
10-24
CLUTCH/STARTER CLUTCH/ GEARSHIFT LlNKAGE
Install the thrust washer and gearshift spindie into
the crankcase while aligning the spring ends with
the stopper pin .
Apply locking agent to the setting plate bolt threads

(page 1-19).
Install the setting plate and tighten the bolt securely.
Install the gearshift arm to the gearshift spindie,

aligning the arm slit with the punch mark on the
gearshift spin die.
Install and tighten the pinch bolt.
10-25
CLUTCH/START ER CLUTCH/GEARSHIFT LlNKAGE
RIGHT CRANKCASE COVER

INSTAllATION
Apply sealant (TB 1207 B or equivalent) to the mat- , - - - - - - - - - - - - - - - - - ,
ing surface of the right crankcase cover as shown. Cover side:
Crankcase side:
10- 15mm
(0.4 - 0.6 in)
10-15mm
(0.4 - 0.6 in)
Install the four dowe l pins.
Install the wave washer and th rust washer anto the

starter idle gear.
10-26
Install the right crankcase cover while turning the
lifter lever clockwise to en gage the lifter lever spin-
die groove with the lifter piece tlange.
Route the EOP Install the stays and right crankcase cover balts.
switch wire
Tighten the right crankcase cover balts crisscross
properly
pattern in tWQ or three steps.
(page 7-211.
Route rhe c/urch Conneet the clutch cable to the clutch lifter lever.
cable properly
Install the clutch cable guide plate by aligning its
(page 7-27).
hole with the right crankcase cover boss and tighten
the bolt securely.
Route the CKP Connect the CKP sensor 2P (Black) connector.

sensor wire
Add the recommended engine oil (page 4-17) and
properly
check th at there are na oilleaks.
(page 7-27).
Remave the suitable support and close the tuel tank
(page 4-6) .
removaJ.
Adjust the clutch leve r treeplay (page 4-31) .
10-27
MEMO
(
11. ALTERNATOR
COMPONENT lOCATION ······· ············ ·· ··· 11-2 STATOR ....... ... ... .. ..... ... .... .. .. ... ............ ... ... 11-4
SERVICE INFORMATION ........................ · 11-3 Fl YWHEEl ................ .. .. .. ................ ·........ · 11-5
ALTERNATOR COVER REMOVAL ...... · .... 11-4 ALTERNATOR COVER

INSTALlATION .......... .............. .. .............. 11-6
,,-,
ALTERNATOR
COMPONENT LOCATION
103 N·m (10.5 kgf.m, 76Ibf.ft)
11-2
ALTERNATOR
SERVICE INFORMATION
GENERAL
• This section covers service of the stator and flywheel. All service can be done with the engine instalied in the frame.
• Refer to procedures for stator inspection (page 17-8).
TORQUE VALUES
Stator mounting bolt 12 N·m (1.2 kgf·m, 9 Ibf.ft)
Flywheel bolt 103 N·m (10.5 kgf.m, 76 Ibf.ft) Apply oil to the threads and seating surface
Stator wire eiamp bolt 12 N·m (1.2 kgf·m, 9 Ibf.ft) CT bolt
TOOLS
Flywheel holder Flywheel holder Rotor puller

070MB-MELC100 07AMB-MELA100 (U.SA only) 07733-0020001
or 07933-3950000 (U.SA only)
11-3
ALTERNATOR
ALTERNATOR COVER REMOVAL
Remove the lollowing:
- lower cowl (page 3-6)
- lelt middle cowl (page 3-8)
Oisconnect the alternator 3P (Natural) connector.
The alternatorcover Remove the alternator wire clamp, balts, stays and
(seator) is alternator cover.
magnerically •
Engine Dil will run out when the alternator cover
atrracted to the
is removed . Set a Dil pan under the engine and
f1ywheef, be careful
during removal.
add the recommended oil to the specilied level
alter installation.

Clean off any sealant trom the alternator cover mat-
ing surfaces.
STATOR
REMOVAL
Remove the bolt, wire cia mp and grommet trom the
BOLT GROMMET
alternator cover.
Remove the balts and stator.
BOlTS STATOR
11-4
ALTERNATOR
INSTALLATION
12N·m(1.2
12 N·m (1.2 kgf·m, 9Ibf.ft)
STATO R
Cl AMP
A LTER NATOR COVER
Insta ll the stator to the alternato r cover.

Tighten the bal ts to the specified torque.
A pply seala nt to the w i re grommet, then insta ll it
in to the alternato r cover g roove securely.
Install th e w ire c1amp and tighten the bolt to the
specified torque.
TORQUE: 12 N·m (1.2 kgf·m , 9 Ibf·ft)
BOLTS STATOR
FLYWHEEL
REMOVAL
Remave t he altemator cover (page 11-4).
Hold the flywheel using the special taal and rem ave
the f lywhee l bolt.
TOOl:
Flywheel holder 070MB-MElCl00 or
07AMB-MELA 100
(U.S.A. only)
Remove the was her.
11 -5
ALTERNATOR
Remove the flywheel using the special tooI.
TOOl:
Rotor puller 07733-0020001 or
07933-3950000
(U.S.A. only)
INSTALLATION
Clean any oil from the tapered area of the crank- ~~=~~~~'R::;'''
shaft and flywheel thoroughly.
Install the flywheel to the crankshaft.
App ly oil 10 Ihe flywheel boll threads and sealing
surface.
Install the washer and flywheel bolt.
Hold the fl ywheel usi ng the special tooi and lighten
the bolt to the specified torque.
TOOl:
Flywheel holder 070MB-MElCl00 or
07AMB-MELA100
(U.S.A. only)
TORQUE: 103 N·m (10.5 kgf·m , 76Ibf·ft)
ALTERNATOR COVER INSTALLATION

Apply sea lant (TB 1207B or equivalent) to the mat-
Cover side:
ing surface of the alternator cover.
Crankcase side:
10-15mm
(0.4 - 0.6 in )
10-15mm
(0.4 - 0.6 in)
11-6
ALTERNATOR
The a/temator cover Install the alternator cover, stays and bolts.
(stator) is
T ighten the bolts in a criss cross pattern in two or
magnstÎcafly
three steps securely.
attracred to (he
flywheel, be careful
during installation.
Connect the alternator 3P INatural) connecto r.

After installation, add the recomm ended engine oil
to the speci f ied level.
Check the engine oil level Ipage 4-17 ).
- Lef! middle cowl Ipage 3-8)
- Lower cowllpage 3-6)
11-7
MEMO
12. CRANKCASE/TRANSMISSION
COMPONENT LOCATION ··· .. ·.... ·.. ·.... ·.... ·12-2 CRANKCASE SEPARATION ................ .... 12-5
SERVICE INFORMATION ........................ · 12-3 SHIFT FORK/SHIFT DRUM/

TRANSMISSiON ·.. ·.. ··· .......... ·.... ·.. .... ·· ...... 12-6
TROUBLESHOOTING ........ .. .................. ... 12-4
CRANKCASE ASSEMBL Y ...................... 12-16
12-1
COMPONENT LOCATION
15 N·m (1.5 kgf·m, 11lbf·ftl + 120·
12 N·m (1 .2 kgf.m, 9 Ibf·ftl
~~
12-2
SERVICE INFORMATION
GENERAL
• The crankcase must be separated to service the following:
- Transmission
• The following components must be removed betore separating the crankcase:
- Engine (page 8-4)
- Clutch (page 10-7)/gearshift linkage (page 10-23)
- Flywheel (page 11-5)
- Cylinder head (page 9-14)
- Dil strainer/pressure reliel valve (page 5-5), oil pump (page 5-7), oil lilter (page 4-17) and oil cooler (page 5-13)
- Starter motor (page 19-6)
- Water pump (page 7-17)
- EOP switch (page 20-15)
- VS sensor (page 20-11)
- Neutra l switch (page 20-20)
• Be careful not to damage the crankcase mating surfaces when servicing.
• Prior to assembling the crankcase halves, apply sealant to their mating surfaces. Wipe aff excess sealant thoroughly.
SPECIFICATIONS
Unit· mm (in)
Shift lork I I.O. 12.000 -12.018 (0.4724 - 0.4731) 12.03 (0.474)
I Claw thickness 5.93 6.00 (0.233 0.236) 5.9 (0.23)
Shift lork shaft O.O. 11.957 - 11.968 (0.4707 - 0.4712) 11.95 (0.470)
Transmission Gear I.O. M5,M6 28.000 - 28.021 (1. 1024 - 1.1032) 28.04 (1.104)
C1 24.000 24.021 (0.9449 0.9457) 24.04 (0.946)
C2,C3,C4 31.000 - 31.025 (1.2205 - 1.2215) 31.04 (1.222)
Gear busing O.O. M5,M6 27.959 - 27.980 (1.1007 - 1.1016) 27.94 (1.100)
C2 30.955 30.980 (1.2187 1.2197) 30.94 (1.218)
C3, C4 30.950 - 30.975 (1.2185 -1.2195) 30.93 (1.218)
Gear-to-bushing M5,M6 0.020 - 0.062 (0.0008 - 0.0024) 0.10 (0.004)
clearance C2 0.020 0.070 (0.0008 0.0028) 0.10 (0.004)
C3, C4 0.025 - 0.075 (0.0010 - 0.0030) 0.11 (0.004)
Gear bushing I.O. M5 24.985 - 25.006 (0.9837 - 0.9845) 25.016 (0.9849)
C2 27.985 28.006 (1.1018 1.1026) 28.021 (1.1032)
Mainshaft O.O. at M5 24.967 - 24.980 (0.9830 - 0.9835 ) 24.96 (0.983)
Countershaft O.O. at C2 27.967 - 27.980 (1.101 1 - 1.1016) 27.96 (1.101)
Bushing to shaft M5 0.005 0.039 (0 .0002 0.0015) 0.06 (0 .002 )
clearance C2 0.005 - 0.039 (0.0002 - 0.0015) 0.06 (0.002)
TORQUE VALUES
Mainshaft bearing set plate bolt 12 N·m (1.2 kgl·m, 9 Ibl·ft) Apply locking agent to the
threads
Shift drum bearing set bolt 12 N ·m (1.2 kgl·m, 9Ibl·ft) Apply locking agent to the
threads
Crankcase 6 mm bolt 12 N ·m (1.2 kgl·m, 9 Ibl·ft)
8 mm bolt 24 N·m (2.4 kgf.m, 18 Ibl·ft)
8 mm bolt (main journal bolt) 15 N'm (1.5 kgl·m, 11 Ibl·ft) + 120' See page 12-17
Replace with a new one
10 mm bolt 39 N·m (4.0 kgl' m , 29 Ibl·ft)
12-3
TOOLS
Bearing remov er set, 20 mm Remover weight Remover handle

07936-3710600 07741-0010201 07936-3710100
or 07936-371020A (U.S.A. only)
Ori ve r Attachment, 42 x 47 mm Pilot, 20 mm

07949-3710001 07746-0010300 07746-0040500
TROUBLESHOOTING
Hard to shift
• Impra per clutc h operation
• Inco rrect eng in e Di l weight
• Bent shift lork
• Bent sh ift lork shaft
• Bent sh ift lork ciaw
• Damaged sh ift drum groove
• Bent gearshift spindie (page 10-24)
Transmissio" jumps out of gear
• Warn gear dogs
• Wam gear shifter groQve
• Bent shift lork shaft
• Braken shift drum stopper arm
• Braken shift drum stopper arm spring
• Warn or bent shift forks
• Braken gearshift spindie return spring (page 10-24)
Excessive engine noise
• Warn or damaged transmission gear
• Warn or damaged transmi ssion bearings
12-4
CRANKCASE SEPARATION .
For Service Information tor removal of necessary
parts belare separating the crankcase (page 12-3).
Remave the balts, water hose joint and O-ring.
Remave the bolt, oil level plate and oil level linder ~~~~
trom the crankcase.
Remove th e balts and sealing washers.
12-5
Place the engine upside down.
Laasen the 10 mm and 6 mm balts in a crisscross
6 mm BOlTSI
pattern in two or three steps.
SEALING WASHERS
loosen the 8 mm balts (main jou rna I balts) in a
crisscross pattern in two or three steps. 6 mm BOLTS
Remave the beits and sealing washers .
Separate the lower crankcase from the upper crank-
case.
6 mm BOlTS
8 mm BOlTS 10 mm BOLT
(MAIN JOURNAl BOLTS)
Remave the dowel pins and oil orifices.

DOWEl PINS
Clean any sealant oft trom th e crankcase mating
surface.
Clean the oil orifices in solvent thoroughly.
Check the oil orifices for clogs, and replace them if
necessary.
SHIFT FORK/SHIFT DRUM/

TRANSMISSION
REMOVALIDISASSEMBL Y
Separate the crankcase halves (page 12-5).
Remave the countershaft assembly.
Disassembie the countershaft assembly.
Clean all disassembied parts in solvent thorough ly.
ASSEMBlY
12-6
CRAN KCASE/TRANSMISSION
Remove the dowel pin and countershaft bearing set
ring .
Remave the shift drum bearing set balts and wash-

ers.
Remave the lork shaft and shift lorks.
Remave the shift drum and shift drum bearing.
BEARING
12-7
Remove the bolts and mainshaft bearing set plate.
Remave the mainshaft bearing from the crankcase.
Remove the mainshaft assembly.

Disassembie the mainshaft assembly.
Clean all disassembied parts in solvent thoroughly.
SHIFT DRUM/SHIFT FORK

INSPECTION
Check the shift fork guide pin for abnormal wear or
damage.
Measure the shift fork I.o.
Measure the shift fork ciaw thickness.
12-8
Measure the shift fork shaft O.O.
I
I
/ /~
Inspeet the shift drum guide grOQves for abnormal
wear or damage.
Turn the outer race of the shift drum bearing with
your tinger.
Also check that the inner race of the bearing fits
tightly on the shift drum.
Replace the hearing if the inner race does not turn
smoothly, quietly, or if the inner race fits loosely on
the shift drum.
TRANSMISSION INSPECTION
Check the shifter groove and gear dogs for abnor-
mal wear or damage.
Check the dog holes and teeth for abnormal wear or

damage.
Measure the I.O. of each gear.
SERVICE LlMITS:
M5, M6: 28.04 mm (1 .104 in)
Cl : 24.04 mm (0.946 in)
C2, C3, C4: 31.04 mm (1.222 in)
-0--
12-9
Measure the O.O. ol each gear bushing .
SERVICE lIMITS:
M5, M6: 27.94 mm (1.100 i n)
C2: 30.94 mm (1 .218 in)
C3, C4: 30.93 mm (1 .218 in)
Measure the I.D. ol each gear bush ing .

SERVICE LIMITS:
M5: 25.016 mm (0.9849 in )
C2: 28.021 mm (1.1032 in )
Calculate the gear-to-bushing clearance.

SERVICE L1MITS:
M5, M6: 0.10 mm (0.004 in)
C2: 0.10 m m (0.004 in)
C3, C4: 0.1 1 mm (0.004 in)
Check the mainshaft and countershaft lor abnormal
wear or damage .
Measure the mainshaft D.D. at the M5 gear. M5
Measure the counte rshaft D.D . at the C2 gear.
Calculate t he gear bushing-to-shaft clearance.
SERVICE L1MITS:
M5: 0.06 mm (0.002 in)
C2: 0.06 mm (0.002 in) C2
Countershaft bearing
Turn the outer race of countershaft bearing with
your tinger.
Th e bearing should turn smoothlv and quietlv.
Also check that the bearing inner race lits tightlV on
the countershaft.
Replace the countershaft, collar, and bearing as an
assemblv, il the race does not turn smoothlv, qui-
et IV, or il the inner race lits looselv on the
countershaft .
• The countershaft bearing cannot be replaced. II
the countershaft bearing is laultv, replace the
countershaft as an assembly.
BEARING
M ainshaft beari ng
Temporarilv install the left mainshaft bearing onto
the mainshaft.
Turn the outer race of the left mainshaft bearing
with your finger.
The bearing should turn smoothlv and quietlv.
Also check th at the inner race ol the bearing lits
tightiV on the mainshaft.
Replace the bearing if the inner race does not turn
smoothly, quietly, or if the inner race fits loosely on
the mainshaft.
12-10
Turn the inner race of the right mainshaft bearing
with your finger.
Also check th at the outer ra ce of the bearing f its
tightly in the crankcase.
Replace the bearing if the inner race does not turn
smoothly, quietly, or if the outer race fits loosely in
the crankcase.
BE AAING
MAINSHAFT BEARING REPLACEMENT

Aemove the following :
- Piston (page 13-14)
Remave t he mainshaft bearing using the special
tools as shown.
TOOlS:
Bearing remove r s et, 20 mm 07936-3710600
Remover weight 07741-0010201 or
07936-371020A
(U.S.A.only)
Aemover handle 07936-3710100
Drive in a new Drive a new bearing into the left crankcase using the
bearing squarely special tools.
with the marks
facing toward the TOOLS:
inside of the Driver 07949-3710001
crankcase. Attachment, 42 x 47 mm 07746-0010300
Pilot, 20 mm 07746-0040500
12-11
SMISSION
CASE/TRAN SEMBLY
CRANK NSMISSION AS sliding surface
TRA . e oil to t he gear teeth ,
Apply engm shift lork
and bushmgs. "I solution to the
Apply ma Iy bdenum Ol
grooves. .
Assem bie the mamsha
ft and countershaft.
MAINSHAFT/ MI GEAR (12T)

M5 GEAR (23T)
M4/3 GEAR (IS/ I ST)
M6 GEAR (24T)
Cl GEAR (33T)
C5 GEAR (30T)
C4 GEAR (26T)
C3 GEAR (30T)
" G'" '''Ol /

COUNTERSHAFT C2 GEAR (32T)
12-12
Assembie the transmi ssion gear and shafts.

Ali n
• Coat each gear with clean engi ne oil and check
tor smooth movement.
o Align the loek washer tabs with th e spline
washer grooves.
• Always install the th rust washers and snap rings

with the ehamlered (rolled ) edge laeing away
lrom the thrust laad. CORRECT INCORRECT
o Install the snap rings sa that th em end gap aligns
with the groove ol the splines.
• Make su re th at the-snap rings are fully seated in
the shaft groove after installing them.
SNAP RING
12-13
INSTALLATION
Install the mainshaft assembly inta the crankcase.
Install the bearing In stall th e mainshaft bea ring into th e crankcase.

inca the crankcase
with the marked
side facing out.
Apply lacking agent ta the set plate bolt threads

(page 1-19).
Install th e mainshaft bearing set plate with its "OUT
SIDE" mark facing out.
Tighten the set plate balts ta the specified tarque.
TORQUE: 12 N·m (1 .2 kgf·m. 9 Ibf·ft)
Install the shift drum and shift drum bearing inta the
crankcase.
BEARING
12-14
The shift forks have the following identification
marks:
- liL" tor left
- "Ril tor right
- "c"tor center
"L" "C" "R"
Install the shift forks into the shift drum guide

grooves with the identification marks facing toward
the right "ide of the eng ine and insert the fork shaft.
Apply locking agent to the shift drum bearing set

Tighten the bolts/washers to the specified torque.
TOROUE: 12 N·m (1 .2 kgl·m, 9 Ibl·ft)
Install the dowel pin onto the upper crankcase hole.

Install the countershaft bearing set ring anto the
upper crankcase groove.
12-15
Install the countershaft assembly by aligning the
countershaft bearing groove with the set ring on the
crankcase , and bearing cap hole with the dowel pin.
Also align the countershaft bearing stopper pin with

the groQve in the crankcase.
CRANKCASE ASSEMBL Y
Applya light, but thorough, coating of liqu id sealant
(TB 1207B or equivalent) to the crankcase mating
surface. Do not apply sealant to the crankcase 8 mm
bolt (main journal bolt) area and the oil passage o
area as shown.
o
o

Install the oil orifices in the upper crankcase . DOWELPINS
NOTE:
Align the orifice cut-out with the cran kcase.
12-16
o Tighten the crankcase 8 mm balts (main jou rna I
8 mm BalTS (MAIN JOURNAl BalTS ) !$!~
balts) using the Plastic Region Tightening
Methad described below. .....
• Do not reuse the crankcase 8 mm balts (main
journal balts), beca use the correct axial tension
will not be obtained .
o The cran kcase 8 mm balts (main journal balts)
are pre-coated with an Dil additive for axial ten-
sion stability. Do not remove the oil additive
from the new 8 mm balts (main journal balts)
surfac8.
lnstaB th e lawer crankcase onto the upper crank-
case.
Install new crankcase 8 mm balts (main jou rna I 8
mm balts).
loosely install all the crankcase balts.
PLASTIC REGION TIGHTENING METHOD:

Make sure the upper and lawer crankcase are
seated securely.
Tighten th e crankcase 8 mm balts (main journal
balts) as f ollows:
Tighten the crankcase 8 mm balts (main jou rna I
balts) in numerical order as shown in the illustration
in twa or three steps to the specified torque.
Further tighten the cra nkcase 8 mm balts (main
jou rna I balts) 120' .
TORQUE: 15 N·m (1 .5 kgf·m, 11 Ibf·ft) + 120'
Tighten the 10 mm bolt to the specified torque.
TORQUE: 39 N·m (4.0 kgf·m, 29 Ibf·ft) 6 mm BalTS! "-
From the inside to outside, tighten the 6 mm balts!

SEALING WASHERS g
sealing washers to the specified torque. 6 mm BalTS
TORQUE: 12 N·m (1.2 kgf·m, 9Ibf·ft)
6 mm BalTS
10 mm BOLT
12-17
Place the engine with the lower side down .
The sealing washer Install the 6 mm bolts with a new sealing washer.
locations are
Tighten the 6 mm bolts securely.
indicated on the
uppercrankcase Install the 8 mm bolt with a new sealing washer,
using the • 6.' mark.
Tighten the 8 mm bolt to the specilied torque.
TORQUE: 24 N'm (2.4 kgl·m, 18 Ibl·ft)
When installing a Install a new Dil level finder into the crankcase
nBw ai/level finder, securely.
do not press the
Apply locking agent to the oil level plate bolt
elear surface.
Align the aillevel Install the oil level plate and tighten the bo lts
plate groove with securely.
the crankcase tab.
Install a new a -ring into the groove ol the water

hose joint.
Insta ll the water hose joint to the cylinder bloek.
remaval.
12-18
13. CRANKSHAFT/PISTON/CYLINDER
COMPONENT LOCATION ...... ·· .... ············13-2 MAIN JOURNAL BEARING ..................... 13-8
SERVICE INFORMATION ........................ ·13-3 CRANKPIN BEARING ............................. 13-11
TROUBLESHOOTING .............................. ·13-4 PISTON/CYLINDER ................................ 13-14
CRANKSHAFT .... ·· .. ·· .. · .......... · ...... ·· .. ·· .. · .... 13-5
13-1
CRANKSHAFTIPISTON/CYLINDER
COMPONENT LOCATION
I r- 20 N·m (2.0 kgl·m , 15 Ibl·ft ) + 90°
~
~
~~
~~~
12 N·m (1.2 kgl·m, 9Ibl·ft)
12 N·m (1.2 kgl·m, 9 Ibl·ft)
13-2
SERVICE INFORMATION
GENERAL
• The crankcase must be separated to service the following :
- Cranks haft (page 13-5)
• Mark and store the connecting rads, bearing caps and bearing inserts to be sure of their correct locations for reassem ·
bly.
• The crankpin and main journal bearing inserts are select fit and are identified by color codes. Select replacement bear-
in9S trom th e code tables. After selecting new bearings, recheek the Dil clearance with a plastigauge. Incorrect oil clear-
ance can cause major engine damage.
• Clean the ail passages in the upper crankcase with compressed air before installing the pistons.
SPECIFICATIONS
Unit· mm (in)
Crankshaft Connecting rod side clearance 0.15 0.30 (0.006 0.012) 0.35 (0.014)
Crankpin bearing oil clearance 0.Q28 - 0.052 (0.0011 - 0.0020) 0.06 (0.002)
Main jou rna I bearing oil clearance 0.020 0.038 (0.0008 - 0.0015) 0.05 (0.002)
Runout - 0.05 (0.002 )
Piston, piston Piston O.O. at 6 mm (0.2 in) from
66.965 - 66.985 (2.6364 - 2.6372 ) 66.90 (2.634)
rings bottom
Pi ston pin bare I.o. 15.030 15.044 (0.5917 0.5923) 15.07 (0.593)
Piston pin O.O. 14.994 - 15.000 (0.5903 - 0.5906) 14.98 (0.590)
Piston-to-p iston pin clearance 0.03 - 0.05 (0.001 - 0.002) 0.09 (0.004)
Piston ring end Top 0.10 0.20 (0 .004 0.008) 0.4 (0.02)
gap Second 0.21 0.31 (0.008 0.012) 0.5 (0.02)
Oil
0.2 - 0.7 (0.01 - 0.03) 1.0 (0.04)
(si de raill
Piston ring-to-ring Top 0.030 - 0.060 (0 .0012 0.0024) 0.10 (0 .004)
groove clearance Second 0.115 0.150 (0.0045 0.0059) 0.08 (0.003)
Cylinder I.o. 67.000 - 67.015 (2 .6378 - 2.6384) 67.10 (2.642)
Out of round 0.10 (0.004)
Taper 0.10 (0.004)
Warpage - 0.1 0 (0.004)
Cyl inder-to-piston clearance 0.D15 - 0.050 (0.0006 - 0.0020) 0.10 (0.004)
Connecting rod small end I.o. 15.030 - 15.044 (0.5917 0.5923) 15.05 (0.593)
Connecting rod-to-piston pin clearance 0.03 - 0.05 (0 .001 - 0.002) 0.07 (0.003)
TORQUE VALUES
Crankpin bearing cap bolt
(new) 20 N·m (2.0 kgf·m, 15 Ibf·ft ) + 90' Apply oil to the threads and sea ting surface
Crankpin bearing cap bolt
(retightening) 14 N·m (1.4 kgf·m, 10 Ibf·ft) + 90' Apply oil to the threads and seating surface
Crankcase 8 mm bolt
(mai n journal bolt) 15 N·m (1.5 kgf.m, 11 Ibf·ft) + 120' See page 13-9
Replace with a new one
Oil jet pipe mounting bolt 12 N·m (1.2 kgf·m, 9 Ibf·ft) Apply locking agent to the threads
13-3
CRANKSHAFT /PISTON/CYLINDER
TROUBLESHOOTING
Cylinder compression is toa low, hard to starting or poar performance at low speed
• Leaking cyli nder head gasket
• Warn, stuck or braken piston ring
• Warn or damaged cylinder and piston
Cylinder compressio" toa high, overheating or knocking
• Excessive carbon bui lt-up on piston head or combustion chamber
Excessive smoke
• Warn cylinder, piston o r piston ring
• Improper installation of piston rings
• Scored or scratched piston or cyl inder wall
Abnormal "aise
• Warn piston pin or piston pin hole
• Warn connecting rad smal! end
• Warn cylinder, piston or piston rings
• Warn main j ourna l bearings
• Warn crankpin bearings
Engine vibratio"
• Excessive crankshaft runout
13-4
CRANKSHAFT
Separate t he crankcase halves (page 12-5).
SIDE CLEARANCE INSPECTION
Measure the connecting rad side clearance .
If the clearance exceeds th e service limit, replace

the connecting red .
Recheek and if still out of limit, replace the crank-
shaft.
REMOVAL
I NOTICE
• Before rernoval, position all the pistons at TOC
(Top Oead Center) to prevent darnaging the
crankpin with the connecting rad.
• Do not interchange the bearing inserts. They
must be instafled in their origina! locations or the
correct bearing oil cleara nce may not be
obtained, resuJting in engine damage.
Mark the bearing caps and bearings as you rem ave
them to indicate th e correct cylinder for reassembly .
Remave the crankpin bearing cap balts and bearing
caps .
Remave the cranksha ft.
Remave th e main jou rna I bearings from bath crank-

case hal ves.
- --,- --- --
MAIN JOURNAL BEARI NGS
I NOTICE
Do not interchange the bearing inserts. Th ey must
be instal/ed in their original locations or the correct
bearing. Dil clearance may not be obtained, resulting
in engine damage.
13-5
CRANKS HAFTIPISTON/CYLINDER
Remave the balts, oil iet pipes and O-rings from the
upper crankcase. O-RING O-RING
Clean the oil iet pipes thorough ly.
INSPECTION
Support the crankshaft on bath end iournals.
Set a dial gauge on the center main journalof the
MEASURE POINT
crankshaft.
Rotate the crankshaft two revolutions and read the
runout.
Check the primary drive gear teeth for abnormal
wear or damage.
PRIMARY DRI VE GEAR

Always rep/ace the Inspect th e oil iet pipes for clogs, bending or dam- Right side: RIGHT OIL JET PIPE
O-rings when the age.
~
aif jet pipes are
Replace them if neces sary.
removed.
Left side:
INSTALLATION
LEFT OIL JET PIPE ~
~ !lt!" •-
Apply oil to new O-rings and install them to the oil
iet pipes. O-RING
Install the oil iet pipes into the upper crankcase. lil .......
13-6
CRANKSHAFT/PISTON/CYLINDER
Apply locking agent to the oil jet pipe mounting bolt
threads (page 1-19) and t ighten them to the speci-
lied torque.
TORQUE: 12 N ·m (1.2 kgl·m. 9Ibf.ft)
Apply molybdenum oil solution to the main jou rna I

bearing sliding surfaces on the upper crankcase and
crankpin bearing sliding surfaces on the connecting
rods .
The bearing tabs Install the main journal bearings into the original
should ba aligned locations.
with the grooves in
ehe crankcase. NOTICE
Do not interchange the bearing inserts. They must
be instaIJed in their original locations or the correct
bearing oil clearance may not be obtained, resulting
in engine damage.
Apply molybdenum oil solution to the main jou rna I

thrust surfaces of the crankshaft as shown.
NOT!CE
Position all the pistons at TOC (Top Oead Center) to
pre vent damaging the crankpin with the connecting
rad.
Install the crankshaft onto the upper crankcase.
Set the connecting rods to the crankpins.
13-7
Apply molybdenum oil solu tion to the crankpin
bea ri ng sliding surfaces on the crankpin bearing BEARING CAP
~
caps.
In stall the crankpin bearing caps, aligning the dowel
pins with th e holes in the connecting rods .
Be su re each part is installed in its original position,
as noted during removal.

The crankpin Apply oil to new crankpin bearing cap bolt threads
bearing cap balts
cannot be reused.
and seating surfaces, and insta ll th em.
Ti ghten th e balts in two or three steps alternately.
oS~/I!IfiiI
Once the balts have BOLTS
been foosened Furth er ti ghten th e balts 90°,
repface them wÎth
newones. TORQUE: 20 N·m (2.0 kgl·m, 15 Ibl·ft) + 90"
Assembie the crankcase halves (page 12-16).
MAIN JOURNAL BEARING

I NOTICE I
Do not interchange the bearing inserts. Th ey must
be insta lied in their originalloca tio ns or the correct
bearing Dil clearance may not be obtained, resulting
in engine damage.
Rem ave the crankshaft (page 13-5).
BEARING INSPECTION
Inspeet the maln journal bearing inserts on the
upper and lower crankcase halves tor unusual wear
"' - -
MAIN JOURNAL BEARINGS
--
or peeling .
Check the bearing tabs for damage.
13-8
Oll CLEARANCE INSPECTION
Clean off any oil from the bearing inserts and main
journais.
Install the crankshaft onto the upper crankcase.
Pu t a strip of plastigauge lengthwise on each main
jou rna I avoiding the oil hole.
• Do not retate the crankshaft during inspection .
In stall the dowel pins and oi l orifices onto the upper

crankcase. DOWELPINS
NOTE :
AUgn the orifice cut-out with the crankcase ,
Instal! th e lower crankcase onto the upper crank-
case.

Install the crankcase 8 mm bolts (main journal 8 mm
balts).
Make sure the upper and lower crankcase are
seated secu rely.
Tighten the crankcase 8 mm balts (main jou rna I
balts) as follows:
Tighten the crankcase 8 mm balts (main journal
balts) in numeri cal o rder in the illustration in two or
three steps to the specified torque.
Further tighten the crankcase 8 mm balts (main
jou rna I bolts) 120' .
TORQUE: 15 N·m (1 .5 kgf·m , 11 Ibf·ft) + 120'
Remave the crankcase 8 mm balts (main journal
bolts) and lower crankcase, measure th e com-
pressed plastigauge at its widest point on each
main journal to determine the Dil clearan ce.

If the oi! clearance exceeds the service limit, select a
replaeement bearing .
13-9 I
BEARING SELECTION
Letters IA. BorG) Record Ihe crankcase bearing support LD. code lel-
on the lefr side of Iers from Ihe pad on Ihe left side of Ihe upper crank-
upper crankcase case as shown.
are the codes for
the bearing support
/.0.5 (rom left (0
right.
CRANKCASE LD. CODE

Numbers (7, 2 or 3) Record the corresponding main journal O.O. code
on (he crank weight numbers trom the crank we ight. MAIN JOURNAL O.D. CODE
are the codes for
rhe main journal
0.0.5 trom left to
right.
Cross reference the main journal and bearing sup~

port codes to determine the replacement bearing
color code.
MAIN JOURNAL BEARING SELECTION TABLE:
BEARING SUPPORT I.D. CODE
A B C
34.000-34.006 mm 34.006 - 34.012 mm 34.012 - 34.018 mm
(1 .3386 - 1.3388 in) (1.3388 - 1.3391 in) (1.3391 - 1.3393 in)
MAIN JOURNAL 1 30.999 - 31.005 mm
Pink Yellow Green
O.D. CODE (1.2204 - 1.2207 in)
2 30.993 - 30.999 mm
Yellow Green Brown
(1.2202 - 1.2204 in)
3 30.987 - 30.993 mm
Green Brown Black
(1.2200 -1.2202 in)
BEARING THICKNESS : IDENTIFICATION COLOR

Bloek: Thickest
Brown:
Green: I
Yellow:
Pink: Thinnest
NOTICE
After se/eeting new bearings, recheek the clearance
with a plastigauge. Incorrect clearance ean cause
severe engine damage.
13-10
BEARING INSTALLATION
Clean the bearing outer surfaces and crankcase .. _ -
MAIN JOURNAL BEARINGS
--
bearing supports.
Apply molybdenum oil solution to the main journal
bearing sliding surfaces on the upper crankcase.
Install the main jou rna I bearing inserts onto the
crankcase bearing supports, aligning each tab with
each groove.
CRANKPIN BEARING
I NOTICE I
Do not interchange the bearing inserts. They must
be instal/ed in their origina' locations or the correct
bearing oil cleara nce may not be obtained, resulting
in engine damage.
Remove the cran ks haft (page 13-5) .
BEARING INSPECTION
Check the be ari ng inserts tor unusual wear or peel-
BE ARIN GS
ing .
Check th e bearing tabs for damage.
A lign
OIL CLEARANCE INSPECTION

Clean aft any Dil trom the bearing inserts and crank-
pi ns.
PLASTIGAUGE
Carefully install the crankshaft onto th e upper crank-
case.
Set th e connecting rods onto the crankpins.
Put a strip of plast igauge lengthwise on each
crankpin avoiding the oil hole .
• Do not rota te the crankshaft during inspection.
13-11
Carefullv install the crankpin bearing caps, aligning
the dowel pins with the holes in the connecting
rods.
Use the removed ApplV oil to the crankpin bearing cap bolt threads
crankpin bearing and seating surfaces and install the balts.
cap balts when Tighten the balts in two or three steps alternatelv.
checking the oil
Further tighten the balts 90°.
clearance.
TORQUE: 14 N·m (1 .4 kgf·m , 10 IbHt) + 90°
Remave the bearing caps and measure the com-

pressed plastigauge at its widest point on the crank-
pin to determine the Dil clearance.

If the Dil clearance exceeds the service limit, select
the correct replacement bearings.
BEARING SELECTION
Numbers (1 or 2) on Record the connecting rad I.O. code number (1 or 2)
the connecting rods or measure the I.O. with the crankpin bearing cap
are (he codes for instalied without bearing inserts.
the connecting rad
/.D.
I.O. CODE
Letters fA or Bl on If you are rep lacing the crankshaft, record the cor re-
the crankweight are sponding crankpin O.O. code letter (A or Bl.
the codes tor the
lf you are reusing the crankshaft, measure the
crankpin O.O.s
cra nkpin O.O. with a micrometer.
trom left to right.
CRAN
13-12
CRANKSHAFT /PISTON/CYLIN DER
Cross-reference the connecting rad and crankpin
codes to determine the replacement bearing colar
code.
CRANKPIN BEARING SELECTION TABLE:
CONNECTING ROD I.o. CODE
1 2
33.500 - 33.508 mm 33.508 - 33.516 m m
(1.3189 -1.3192 in ) (1.3192 - 1.3195 in)
CRANK PIN O.O. CODE A 30.995 - 31.003 mm Green
Yellow
(1.2203 - 1.2206 in)
B 30.984 - 30.995 mm Brown
Green
(1.2198 - 1.2203 in)
BEARING THICKNESS: 10ENTIFICATION COLOR

Brown: Thickest
Green: !
Yell ow: Thinn est
NOTICE
After se/eeting new bearings, recheek the clearance
with a plastigauge. Incorrect clearance can cause
severe engine damage.
BEARING INSTALLATION
Clean the bea ring outer surfaces, crankpin bearing
BEARINGS
cap and connecting rad .
Install the crankpin bearing inserts onto the bearing
cap and connecting rod, aligning each tab with each
groove.
Align
13-13
PISTON/CYLINDER
PISTON/CONNECTING ROD
REMOVAL
NOTICE
• This motorcycle is equipped with aluminum cyl-
inder sJeeves. Betore piston removaJ, place a
clean shop ta wel around the connecting rod to
pre vent damaging the cylinder sleeve.
• Do not try to remave the piston/connecting rod
assembly from bottom of the cylinder; the
assembly will get stuck in the gap between the
cylinder !iner and the upper crankcase.
• Do not interchange the bearing inserts. They
must be instal/ed in their originallocations or the
correct bearing Dil clearance may not be
obtained, resulting in engine damage.
Mark all pans as Remove the balts and crankpin bearing caps.
vou remove them
co indicare the
correct cylinder for
reassembly.
Do not try to Remave the piston/connecting rad assembly trom

remove the the top ofthe cylinder.
connecting rod!
piston assembly
trom the bottom ot
the cylinder; the
assembly will be
locked when the oil
ring expands in the
gap between the
cylinder liner and
the upper
crankcase.
PISTON REMOVAL
Remove the piston pin clip with pliers.
Push the piston pin out of the piston and connecting
PISTON PIN CLIP
rad , and rem av e the piston.
13-14
PISTON DISASSEMBL Y
Be careful not to Spread each piston ring ends and remave them by
damage rhe p iston lifting up at a point opposite the gap.
ring by spreading
the ends toa faro
Never use a wire Clean carbon deposits trom the piston ring grooves
brush; it w ill scratch with a ring th at will be discarded.
the groove.
PISTON INSPECTION
Inspeet the piston rings for movement by rotating
Ihe rings. The rings should be able la move in Iheir
grooves without catching.
Push Ihe rin g unlil Ihe ouler surface of Ihe pision
ring is nearly flush with the piston and measure the
ring-ta-ring groove clearance.
SERVICE LIMITS:
Top: 0.10 mm (0.004 in)
Second: 0.08 mm (0.003 in)
Push the rings inta Insert Ihe pisIon ring squarely inlo Ihe lap of Ihe cyl-
the cylinder with inder and measure the ring end gap.
the top of the
piston to be sure SERVICE LlMITS:
theyare squarely in Top: 0.4 mm (0.02 in)
the cylinder. Second: 0.5 mm (0.02 in)
Dil (side rail): 1.0 mm (0.04 in)
13-15
CRANKS HAFTIPISTON/CYLINDER
Measure the piston pin bare I.O.
Measure the O.O. of the piston pin .

Calculate the piston-ta-piston pin clearance.
Measure the diameter of the piston at 6 mm (0.2 in)

from th e bottom and 90° to the piston pin hole.
CONNECTING ROD INSPECTION

Measure the connecting rad small end I.O.

Calculate the connecting rad-ta -piston pin clear-
ance.
13-16
CRANKS HAFTI PISTON/CYLINDER
CYLINDER INSPECTION
Inspeet the cyli nder ba re for wear or damage.
Measu re the cylinder I. o. in X and Y axis at three
levels.
Take the maximum reading to determi ne the cylin·
der wea r.
Calcu late the cyli nde r to piston clea rance.
T ake a maximum reading to determine the clea r-
ance.
For p iston O.O. measurement (page 13-16).
<:> .; .
Calculate t he taper and ou t-ol-round at three levels
in X and Y axis. T ake the maximum reading to
determi ne th em.
SERVICE LlMITS: ,
Taper: 0.10 mm (0.004 in)
TOP
.~
- "- " .. _- --
..
/
Out-of-round : 0.10 mm (0.004 in) / '...... "-"- ~".

T he cylinder m ust be re bored and an oversize pis- M IDDLE .,
ton fi tted if the se rvice lim its are exceeded.
.~
"- "- " . - ..

- '- '
- _/
The following oversize piston is available: / ~.

0.25 mm (0.010 in) BonOM ., ...,../
T he cy li nder to piston clearance to r the oversize pis-
.~
-"-,.
ton must be: 0.015 - 0.050 mm (0 .0006 - 0.0020 in).
Inspeet t he top ol the cy linder lor warpage.
13-17
CRANKSHAFTIPISTONICYLINDER
PISTON ASSEMBL Y
Clean the piston ring grooves thoroughly and install
the piston rings.
o Apply oil to the piston rings . SECOND RING - , TOP RING - ,
• Avoid piston and piston ring damage during
installation .
o Install the piston rings with the marking (R: top
ring , RNE: second ring ) facing up.
o Ta install the oil ring , install the spaeer first, then
install the side rails.
Stagger the piston ring end gaps 120· apart from
each other.
Stagger the si de rail end gaps as shown.
After installation, the rings should rotate freely in
the ring groove.
SI DE RAILS - ,
PISTON INSTALLATION
Apply molybdenum oil solution to the connecting
red small end inner surfaces and piston pin sliding
CONNECTING ROD
surfaces.
"IN " MARK
Assembie the piston and connecting rad with the
journal bearing tab facing to the piston "IN " mark.
PISTON
.....
Apply molybdenum oil solution to the piston pin
sliding surface. CLIP !$!~
In stall the piston pin and secure it using new piston

pin clips.
• Make sure that the piston pin clips are seated
securely.
o Do not align the piston pin clip end gap with the
piston cut-out.
13-18
Coat the cylinder walls, pistons and piston rings
with engine oil. PISTON RING COMPRESSOR
Install the piston/ Install the piston/connecting rod assemblies into the
connecting rod cylinders using a commercially ava ilable piston ring
assembfy with the compressor taal.
piston 'IN' mark When reusing the connecting rods, they must be
facing the intake installed in their originallocations.
side.
NOTICE
• While installing the piston; be careful not to dam-
age the top surface of the cylinder, especially
around the cylinder bore.
• Be careful not to damage the cylinder sleeve and
crankpin with the connecting rad.
Make $ure the Use the handle of a plastic hammer or equivalent
piston ring taal to tap the piston into the cylinder.
compressor taal
Install the crankshaft (page 13-6).
sits flush on the top
surface of the
cyfinder.
Apply molybdenum oil solution to the crankpin

bearing slidi ng surface on the bearing caps . ,
Install the crankpin bearing caps, aligning the dowel
pins with the holes in the connecting rods.

The crankpin Apply oil to new crankpin bearing cap bolt threads
bearing cap balts and seating surfaces, and install the balts.
cannat be reused.
Once the balts have
been laasened
rep/ace them with
newanes.
Tighten the balts in two or three steps alternately.

Further tighten the balts 90' .
TORQUE: 20 N·m (2.0 kgf·m, 15 Ibf.ft) + 90'
Assembie the cra nkcase halves (page 12-16).
13-19
MEMO
14. FRONT WHEEL/SUSPENSION/STEERING
COMPONENT LOCATION ······· .. ·· ...... ··· ····14-2 FRONT WHEEL .................... ..... .... .......... 14-16
SERVICE INFORMATION ···· ··············· ··· ··· 14-3 FORK .. .............. .......... ... .............. ............ 14-22
TROUBLESHOOTING .................... ... ........ 14-7 HESD ....................................................... 14-33
HESD TROUBLESHOOTING .................... 14-8 STEERING STEM .. · .. ·.... ·...... ·.. ...... .. ........ 14-34
HANDLEBARS······························ ···········14-10
14-1
COMPONENT LOCATION
27 N·m (2.8 kgl·m, 20 IbHt)
12 N·m (1.2 kgl·m, 9Ibf.ft)
10 N·m (1.0 kgf.m, 7 Ibl·ft)
~
27 N·m (2.8 kgl·m, 20 Ibl·ft)
10 N·m (1. 0 kgf.m, 7 lbHt)
7 Ibl·ft)
59 N·m (6.0 kgl·m, 44 Ibf.ft)

45 N'm (4.6 kgl'm, 33 Ibl·ft)
14-2
SERVICE INFORMATION
GENERAL
• When servicing the front wheel, fork or stee ring stem , support the motorcycle using a safety stand or hoist.
• A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc
with a high quality brake degreasing agent.
• After the Iront wheel installation, check the brake operation by applying the brake lever.
• For brake system inlormation (page 16-4).
• Use only tires marked "TUBELESS" and tubeless valves on rim ma rked "TUBELESS TIRE APPLICABLE ".
SPECI FICATIONS
Unit· mm (in )
ITEM STANDARD SERVICE LIM IT
Minimum tire tread depth 1.5 (0.06)
Cold ti re pres-
I Driver only 250 kPa (2.50 kgf/cm', 36 psi) -
sure I Driver and passenger 250 kPa (2.50 kgf/cm ', 36 psi)
Axle runout - 0.2 (0.01)
Wheel rim L Radial - 2.0 (0.08)
runout I Axial - 2.0 (0.08)
Whee l balance weight 60 9 (2.10z)
- max.
Fork Spring I ree length 243.4 (9.58) 238.5 (9.39)
Tube runout - 0.20 (0.008)
Recommended lork fluid Pro Honda Suspension Fluid SS-47
(1QW) -
Fl u id level 93 (3.7) -
Fluid capac ity 413 ± 2.5 cm' (14.0 ± 0.08 US oz, 14.5 ±
0.09 Imp oz) -
Pre-laad adjuster initial setting 5 turns t rom minimum
2-1 /2 turns out f rom full hard -
setting
Compression damping adjuster inl-
tial setting
2 turns out from full hard -
Steering head bearing pre-Ioad 14.7 17.7 N (1.5 1.8 kgl)
TORQUE VALUES
Handlebar weight mounting screw 9.8 N·m (1.0 kgf·m , 7 Ibl·ft) ALGe screw; replace with a new one
Front brake disc bolt 20 N·m (2.0 kgf·m, 15Ibf-ft) ALOC bolt; replace with a new one
Front axle bolt 59 N·m (6.0 kgf·m, 44lbf-ft)
Front axle ho lder bolt 22 N·m (2 .2 kgf·m, 16 Ibf·ft)
Fo rk socket bolt 34 N·m (3.5 kgf·m, 25 Ibf-ft) Apply locking agent to the threads
Fork bo lt 34 N·m (3.5 kgf'm, 25 Ibf-ft)
Handlebar pinch bolt 27 N·m (2.8 kgf·m, 20 Ibf-ft)
Top bridge pinch bolt 22 N·m (2.2 kgf·m, 16 Ibf·ft)
Bottom b ridge pinch bolt 27 N·m (2.8 kgf·m, 20 Ibf-ft)
Stee ri ng stem adjusting nut See page 14-41
Stee ring stem adjusting loek nut See page 14-41
Steering stem nut 103 N·m (10.5 kgl·m, 76Ibl·ft)
Front brake hose clamp bolt 9.0 N·m (0.9 kgf·m, 6.6 Ibl·ft)
Front brake hose clamp nut 10 N·m (1.0 kgf·m, 7 Ibf·ft)
Front brake hose 3-way joint bolt 10 N·m (1.0 kgf·m, 7 Ibf-ft)
Front master cyli nder holder bolt 12 N·m (1.2 kgf·m, 9Ibf·ft)
Front brake caliper mounting bo lt 45 N·m (4.6 kgf·m, 33 Ibf·ft) A Loe bolt; replace with a new one
Second arm nut 12 N·m (1.2 kgf'm, 9 Ibl·ft)
Compression adjuster plug bolt 17 N·m (1.7 kgf·m, 13 Ibf-ft)
Stee ring damper mounting bolt 10 N'm (1.0 kgf·m , 7 Ibf·ft)
Right handlebar switch housing screw 0.9 N·m (0.09 kgf·m , 0.7 Ibf·ft)
Fork damper rod loek nut 20 N·m (2.0 kgf·m, 15 Ibl·ft )
14-3
TOOLS
Bearing remover shaft Bearing remover head, 20 mm Dri ver

07GGD-0010100 07746-0050600 07749-0010000
Attachment, 42 x 47 mm Pilot, 20 mm Fork seal driver

07746-0010300 07746-0040500 07KMD-KZ30100
or 07NMD-KZ3010A (U.SA only)
Fork seal driver attachment Steering stem soeket Driver attachment (upper)
07RMD-MW40100 07916-3710101 070MF-MCJ0100
or 07916-3710100 (U.SA only) Not available in U.S.A.
Driver attachment (lower) Driver shaft assembly Bearing remover, A

070MF-MCJ0200 07946-KM 90301 07946-KM90401
Not available in U.SA

e~
Not available in U.S.A. Not available in U.S.A.
14-4
Bearing remover, B Assembly base Altachment, 30 mm LD.

07NMF-MD0110 07946-KM90600 07746-0030300
~
.'d..
. "<=:;,
..
Not available in U.SA Not available in U.SA
Fork damper holder Spring collar hol der Damper rad holder
07YMB-MCF0101 070MF-MBZC110 070MF-MBZC120
or 07YMB-MCFA100 (U.SA only) NOTE NOTE

This taal is a part ol lork damper Thi s taal is a part ol fork damper
install set (PIN 070MF-MBZC100) install set (PIN 070MF-MBZC100)
Stopper plate Test probe HDS pocket tester

070MF-MBZC130 07ZAJ-RDJA 110 TOS 3557-0112-01 (U.SA only)
NOTE
This taal is a part of lork damper
install set (PIN 070MF-MBZC100)
Main bearing driver attachment Fork seal driver weight Oil seal driver
07946-ME90200 07947-KA50100 07965-MA60000
14-5
InstalIer shaft Insta lIer attachment A InstalIer attach m ent B

07VMF-KZ30200 07VMF-MAT0100 07VM F-MAT0200
Remover attachment C Remover attachment 0

07AMF-MEEA100 07AMF-MEEA200
14-6
TROUBLESHOOTING
NOTE:
II there is any problem at steering, remove the HESD (page 14-33) and inspeet the steering condition. Check the HESD by
using the Function Test (page 14-8) in case ol no laulty parts at steering.
Hard steering
• Faulty HESD
• Steering stem adjusting nut too tight
• Warn or damaged steering head bearings
• Bent steering stem
• Insufficient tire pressure
Steers to one side or does not track straight
• Fau lty HESD .
• Damaged or loose steering head bearings
• Bent forks
• Bent axle
• Bent frame
• Warn or damaged wheel bearings
• Warn or damaged swingarm pivot bearings
Front wheel wobbling
• Bent dm
• Warn or damaged front wheel bearings
• Faulty tire
• Unbalanced front tire and w heel
front wheel turns hard
• FauJty front whee l bearings
• Bent front axle
• Front brake drag
Soft suspensio"
• Insufficient fluid in fork
• Incorrect lork Iluid weight
• Weak lork springs
• Insufficient tire pressure
Stift suspensio"
• Bent fork tubes
• TOD rnuch fluid in fork
• Incorrect fork fluid weight
• Clogged lork Ilu id passage
Front suspension noise
• Insufficient fluid in fark
• Loase fork fasteners
14-7
HESD TROUBLESHOOTING
• The HESD system is equipped with a Self-Diagnostic System th at is linked to the PGM-FI system (page 6-13). If the MIL
blinks, follow the Self-Diagnostic Procedures to remedy the problem (Refer to DTC troubleshooting: page 6-18).
The HESD system is also equipped with a Function Test Mode to check the HESD under maximum damping character-
istics. If there is anv abnormal condition in the HESD system without MIL blinking , follow the HESD function test and
check the HESD function.
• The HESD syste m includes a fail-safe function to secure a minimum runn ing capability even when there is any trouble
in the svstem . When anV abnormality is detected bV the self-diagnosis function, the ECM stops the HESD svstem control
bV shutting oft the current supplV to the linear solenoid and the HESD will operate under m in imum damping character-
istics accordingl y.
• For PGM-FI system diagram (page 6-9).
• For HDS pocket tester information (page 6-14).
• For DTC readout (page 6-14).
• For DTC index (page 6-16).
• A faulty HESD system is often related to poorly con nected or corroded connectors . Check those connections betore pro-
ceedi ng.
HESD FUNCTION TEST
NOTE :
• The HESD system is also equipped with a Function Test Mode so that a technician can cempare the minimum with max-
imum damping characteristics without riding. The HESD system is set to minimum damping at no vehicle speed under
narmal conditions. By using the Functie n Test Mode, the ECM operates the linear solenaid with ma xi mum current sa
the HESD system is temporarily set to maximum damping.
• It is not possible to use the HESD Function Test Mode when anv problem occur.
• Before performing the HESD function test, re move the HESD (page 14-33) and check the following .
- Steering head bearing pre-Ioad (page 14-44)
- Wear or damage of steering head bearings (page 4-36)
- HESD-to-steering linkage
HESD FUNCTI ON T EST PROCEDURE
• Support the motorcvele using a hoist or equivalent and raise the front wheel oft the ground.
• Before function test, check the feel for minimum damping characteristics with moving the steering right and left quickly
several times. Operate the steering qu ickly and at a uniform force any time of the te st.
Perform the HESD function test as follows:
1. Lower the sidestand (sidestand switc~ OFF) .
2. Shift the transmission into any gear other than neutra!.
3. Open the throttle grip full\,-
4. Turn the ignition switch ON while keeping the state of 1 - 3.
The HESD indicator starts blinking and the HESD svstem enters the Function Test Mode for 10 seconds.
Make sure that the dam ping characteristics (force) changes, by means of comparing the minimum dam ping characteris-
tics before Functio n Test with the max imum damping characteristics under the Function Test.
If the HESD damping characteristics (force ) in Function Test Mode does not change at all, replace the HESD unit with a
new one (page 14-33).
14-8
DTC TROUBLESHOOTING
Refer
DTC Causes Symptoms
to
• Laase or poor contact on VS sensor • Engine operates normally
connector • HESD does not function
11-1 • VS sensor or its circuit malfunction - ECM does not control the
6-28
linear solenaid
- Minimum damping char-
acteristics
• Loose or poor contact of the HESD • Engine operates normally
solenaid connector • HESD does not fun ction
51-1 • HESD solenaid or its circuit malfunc- - ECM does not control the
14-9
tian linear solenaid
- Minimum damping char-
acteristics
DTC 51 -1 (LiNEAR SOLENaiD)

Before starting the inspection , check for loose or poor contact on the linear solenoid connector and
recheek the DTC.
1. Linear Solenoid Circuit Inspectio"
Disconneet the ECM 33P (Gray) connector. 33P (Gray) CONNECTOR
Measure the resistance at the ECM 33P (Gray) (Wire side/female terminals )
connector terminals of the wire si de.
Connection: B8 - B10 \ I ~
TaaL:
Is the resistance within 10 - 15 n (20'C/68 "F)7
YES
NO
- GO TO STEP 3.
- GO TO STEP 2.
(B10) -
White/green --@-- '--- (B8)
White/ Blue
2. Linear Solenoid Resistance Inspectio"

Remove the HESD (page 14-33).
Measure the resistance at the linear solenaid ter- 2P CONNECTOR
minals. (Linear solenaid side/male terminals)
Is the resistance within 10 - 15 n (20'C/68°F)7

YES - Open circuit in White/green or Whitel
Blue wire
NO - Faulty linear solenoid
14-9
3. Linear Solenoid Short Circuit Inspection
Check lor continuity between the ECM 33P
(Gray) connector terminals at the wire side and 33P (Gray) CONNECTOR
ground. (Wi re side/lemale terminals )
Connection: B8 - body ground
BlO - body ground
Taal:
(BlO)
YES - Short circuit in White/green or White/
blue wire
NO - Rep lace the ECM with a known good
one, and recheek
HANDLEBARS
REMOVAL
Remove the screw and right handlebar weight.
n" "c'c~o".n WEIG HT
Disco nneet the front brake light switch wire connec-

tors trom the switch .
Keep rhe brake Remove the balts, holder and master cylinder
master cylinder assembly.
reserve tank
upright to prevent
air trom entering
the hydraulic
system.
Remove the screws and right handlebar switch.
14-10
Remove the screws and separate the throttle hous~
ing.
Remave the screw, left handlebar weight and grip

trom the handlebar.
Remove the screws and left handlebar switch hous~

ing.
Disconnect the clutch switch connectors from the
clutch switch.
Loosen the clutch lever bracket pinch bolt.
14-11
Remove the nut and disconneet the second arm
Irom the top bridge.
Remave the screws and steering damper cover.
Remave the stee ring stem cap, top bridge pinch

balts, handlebar pinch balts and cable guide.
Remave the steering stem nut, washer and top
bridge with ignition switch wire connector con·
neeted.
Remave the handlebars Irom the lork sliders.
Remave the clutch lever bracket and throttle pipe
lrom the handlebars.
INSTALLATION
Install the clutch lever bracket to the left handlebar.
Install the left handlebar onto the lork slider.
LEFT HANDLEBAR
Apply grease to the sliding surface ol the throttle

pipe.
Install the throttle pipe to the right handlebar.
Install the right handlebar onto the lork slider.
14-12
Install the top bridge while aligning its holes with
the hand leba r stopper pins.
Install the washer and steering stem nut.

Tighten the steering stem nut to the specified
torque.
Insta!! the stee ring stem cap.

Install the cable guide top bridge pinch balts and
handlebar pinch balts.
Tighten the top bridge pinch balts to the specified
torque.
Tighten the handlebar pinch balts to the specified
torque.
TORQUE: 27 N ·m (2.8 kgf·m, 20 Ibf·ft)
Install the stee ring damper cover to the top bridge IsCREV\/S
and tighten the screws securely.
Connect the second arm to the top bridge and
tighten the nut to the specified torque .
14-13
Install the clutch lever bracket aligning the punch
mark on the left handlebar and clutch lever bracket. BRACKET
Tighten the clutch lever bracket pinch bolt securelv.
Install the left handlebar switch housing aligning its

locating pin with the hole in the handlebar.
Tighten the forward screw first, then the rear screw.
Conneet the cl utch switch connectors securely,
ApplV Honda Bond A or Pro Honda hand grip

cement (U .SA onlV) to the inner surface ol the grip
and to the clean surfaces ol the left handlebar and
throttl e pipe.
Wait 3 - 5 minutes and install the grip.
AI/ow rhe adhesive Rotate th e grip tor even application of th e adhesive. GRIP
to dry for an hour
before using.
Install the left handlebar we ight and t ighten a new

mounting screw ta the specified torque.
TORQUE: 9.8 N·m (1.0 kgl·m, 7 IbUt)
14-14
Install the throttle housing by aligning its locating
pin with the hole on the handlebar.
Ti ghten the upper screw first, then the lower screw.
Install the right handlebar switch housing by align-

ing its locating pin with the hole in the handlebar.
Ti ghten th e forward screw first, then the rear screw
to the specilied torque.
TORQUE: 0.9 N·m (0.09 kgl·m, 0.7 Ibf·ft)
Install the master cyli nder by alig ning the end ol the
master cylinder with the punch mark on the handle-
bar.
Install the master cylinder holder with its "UP" ma rk
lacing up.
Ti ghte n the upper bolt l irst, then the lower bolt.
TORQUE: 12 N ·m (1 .2 kgl·m, 9 Ibf·ft)
Con neet th e front brake switch wire connectors.
Install the right handlebar weight and t ig hten a new

mounting screw to the specified torque.
TORQUE: 9.8 N·m (1 .0 kgf·m , 7 Ibf·ft)
14-15
HANDLEBAR WEIGHT REPLACEMENT
Remave the left grip and throttle pipe trom the han-
diebar. RETAINER TAB RETAINER RING
,"",,~,",o~
Straighten the weight retainer tab by the screw-
driver or punch.
App/y lubricam Temporarily install the handlebar w8ight and screw,
spray through the then remove the inner weight by turning the handle-
~~
tab focking hole ta bar weight.
the rubber for easy
removal.
INNER WEIGH~ /""..,.,~
HANDLEBAR WEIGHT
Remove the handleba r weight trom the inner ~=================~

weight. INNER WEIGHT
Discard the retainer ring.
Install a new retainer ring onto the inner weight.
Install the handlebar we ight onto the inner weight HANDLEBAR WEIG HT
while aligning the bosses and grOQves each other.
In stall a new mounting screw.
Install the left grip and throttle pipe onto the handle-
bars. RETAINER TAB RETAINER RING
Insert the handlebar weigh t assembly into th e han-
diebar.
Turn the handlebar weight and hook the retainer
RUBBER ~SHION~
ring tab with the hole in the handle bar.
~~
INNER WEIGH~ .
RETAINER HOLE
HANDLE BAR WE IGHT
FRONT WHEEL
REMOVAL
Remave the balts and brake calipers.
Do not operate the Support the brake caliper with a piece of w ire so
brake {ever after the that it does not hang trom the brake hose. Do not
brake caliper is tw ist the brake hose.
removed.
14-16
Loosen the right axle holder bolts.
Remove the axle bolt.
Support the motorcycle securely and raise the front
wheel oft the ground using a safety stand or ahoist.
Loosen the left axle holder bolts.

Remove the axle and front wheel.
Remove the right and left side collars.
INSPECTION
Axle
Set the axle on V-blocks and measure the runout.
Actual runout is 1/2 the total indicator reading .
14-17
Wheel bearing
Turn the inner race of each bearing with your tinger.
The bearings should tu rn smoothly and quietly.
Also check that the outer race of the bearing fits
tightly in the hub.
Rep/ace the Replace the bearings if the inner race do not turn
bearings in pairs. smoothly, quietly, or if th e outer race fit loosely in
the hub.
Replace the wheel bearings, if necessary (page 14-
19).
W HE EL BEARING
Wheel rirn runout

Check t he rim runout by placing the wheel in a
t ru ing stand.
Spin the wheel by hand, and read the runout using a
dial indicator.
Act ual runout is 1/2 the tata I indicator reading.
SERVICE LIMlTS:
Radia l: 2.0 mm (0.08 in)
Axia l: 2.0 m m (0.08 in)
Wheel balanee
• Wheel balance di rectly affects the stability, han-
dling and overa ll safet y of the motorcycle. BALANC E MARK
A lways check ba lance when the tire has been
removed t rom th e rirn .
• Far optimum balance, t he tire balance mark (a
paint dot on the side wall) must be located nex!
to the va lve stem. Remou nt the tire if necessary.
Note the rotating direction marks on t he wheel and

tire.
14-18
Remave the dust seals from the wheel.
Mount the wheel , tire and brake discs assembly in
an inspection stand.
Spi n th e w hee l, allow it to stop, and mark the lowest
(heaviest) point of the wheel with achalk.
Do this !wO or three times to verify the heaviest
area.
If the wheel is balaneed, it wil l not stop eonsistently
in the same position.
Ta balanee the wheel, install the wheel weights on
the highest side of the rim, the side opposite the
ehalk marks. Add just enough weight sa the wheel
wil! no longer stop in the same position when it is
spun. Do not add more than 60 grams to the wheel. INSPECTION STAND
DISASSEMBL Y
Remave the balts and brake discs.
Remave the dust seals.
Install the bearing remove r head into the bearing .

From the opposite side, Înstall the bearing remover
shaft and drive the bearing out of the wheel hub.
Remove the distance collar and drive out the ather
bearing.
TOOLS:
Bearing remover head, 20 mm 07746-0050600
Bearing remover shaft 07GGD-0010l00
14-19
FRONT WHEEL/SUSPENSION/ STEERING
ASSEMBLY
RIGHT BRAKE DISC
~ RIGHTWHEEL BEARING (6004UU )
~ LEFT WHEEL BEARING (6004UU)
S~
LEFT BRAKE Dise
-~
RIGHT DUST SEAL
DISTANCE eOLLA R
~
~~
.....
_~ LEFT DUST SEAL
20 N'm (2.0 kgf·m, 15 Ibf.ft)
Never install the old Drive in a new right bearing squarely until it is fully
bearings.Once the sea ted . ~~~~~~~~~~
bearings have been Install the distance collar, then drive in a new left ..
removed, the bearing using the special tools.
bearings must ba
replaced with new
TOOLS:
ones. Driver 07749-0010000
Attachment, 42 x 47 m m 07746-0010300
Pilot, 20 mm 07746-0040500
Check the spokes Install the brake discs with the arrow mark facing in
on the wheel for the direction of rotatian.
the direction mark. Install new disc balts and tighten them in a criss-
cross pattern in two or th ree steps.
TOROUE: 20 N·m (2.0 kgf·m, 15Ibf.ft)
Apply grease ta new dust seallips, then install th em
inta the wheel hub.
14-20
INSTALLATION
Install the right and left side eollars.
Install the Iront wheel between the lork legs.

Apply a thin layer ol grease to the Iront axle surface.
Install t he Iront axle lrom the left side.
Hold the axle and tighten the axle bolt to the speei-
lied torque.
lOROUE: 59 N·m (6.0 kgl·m, 44 Ibl·ft)
lighten the right axle ho lder bolts to the speeified
torque.
Install both brake ealipers and tighten new mount-

ing bolts to the speeilied torque.
14-21
Check the brake operation bV applving the brake
lever.
With the Iront brake applied, pump the lork up and
down several times to seat the axle.
Tighten the left axle holder bolts to the specilied

torque.
FORK
REMOVAL
- Front wheel (page 14-16)
- Front lender (page 3-13)
Loosen the handlebar pinch bolt and top bridge
pinch bolt.
When the lork leg will be disassembied, loosen the
lork bolt, but do not remove it vet.
Keep 'he front While holding the lork leg, loosen the lork bottom
brake master bridge pinch beits and remove the fork slider trom
cylinder reserve the handlebar and fork bridges.
tank uprighr.
14-22
When disasse m bli ng Ihe lork leg, lurn Ihe pre-laad,
rebound and compression damping adjusters coun- REBOUN D ADJUSTER
terclockwise to the seftest positien (be sure to
record the number of turns from the starting posi-
lion).
PRE-WAD ADJUSTER
DISASSEMBL Y
Be careful nor to Remove th e ha ndlebar stopper ring ,
scra tch the {ark FORK BOLT
Remave Ihe lork balI Irom Ihe lo rk slider.
slider.
FORK SliDE R STOPPER RING

Push Ihe lork slider slowly down, and genlly seal
Ihe dusl seal onlo Ihe axle holder.
8e careful nor to Set the spring collar hol der to the spri ng coll ar
damage rhe spring holes.
colfar holes.
TOOl:
Spring colla, holde, 070MF-MBZCll0
Compress Ihe spring col lar wilh Ihe spring collar
ho lder.
14-23
Insert the stopper plate between the loek nut and
spring seat stopper.
TOOL:
Stopper plate 070MF-MBZC130
Loos en the loek nut wh ile holding the lork bolt.
SPRINGSEAT
STOPPER LOCK NUT
Remove the lork bolt.
Remove the stopper plate and spring eollar holder.
SPRING CO LLAR HOLt ER1

SPR ING SEAT STOPPER
- Spring seat stopper
- Spring eollar
- Rubber seal
- Fork spring SPR ING COLLAR
RUBBER SEAL G
Pour out the lork Iluid by pumping the lork tube sev-
eral times.
Pour out the lork Iluid lrom the lo rk damper by
pumping the damper rod several times.
14-24
Remove the compression damping adjuster trom
the axle holder.
COMPRESSI
Remave the adjuster piece Irom the plug bolt.

ADJUSTER PIECE PLUG BOLT
Remove the Q-ri ngs.
O-RINGS
Ho ld the axle holder in a vise with soft jaws or a

shop towel.
Hold the lork damper with the special taal, then
re move the tork socket bolt and sealing washer.
TOOL:
Fork damper holder 07YMB-MCF0101
Remave the lork damper assembly Irom the lork

FORK DAMPER ASSEMBL Y
slider.
FORK SLiDER
14-25
Remave the dust seal.
Do not scratch the Remove the oil seal stopper ring.
(ork tube sliding
surfac8.
DUST SEAL G
Pull the tork tube out until you teel resistance trom ....
the slider bush ing. Then move it in and out, tapping
the bushing lightly until the tork tube separates ,
trom the tork slider.
The slider bushing will be torced out by the tork
tube bushing.
Remave the tork tube bushing, slider bushing, back-

up ring, oil seal, stopper ring and dust seal trom the SLiDER BUSHING
tork tube.
DIL SEAL
Remave the tollowing :
-
-
-
-
-
Fork tube bushing
Slider bushing
Back up ring
Dil seal
Stopper ring
/
- Dust seal
BACK-UP RING
INSPECTION
Fork spring
Measure the tork spring tree length.
14-26
Fork tube/ slider/ damper
Check the fork slider for damage or deformation.
Check the fork damper for bend or damage. FORK DAMPER
\
Replace any components which are damaged .
FORK SLiDER
Check the oil loek valve for wear or damage.
Replace the fork damper assemblv, if anV compo- OIL LOCK VALVE
nents are damaged .
Check the fork tube for score marks, scratch es, or , - - - - - - - - - - - - - - - - - - - ,

excessive or abnormal wear.
Place the fork tube on V-blocks and measure the
runout.
Actual runout is 1/2 the tota l indicator reading.
FORK TUBE
Fork tube bushing

Visuallv inspeet the slider and fork tube bushings.
Replace the bushings if there is excessive seoring or
scratchi ng, or if the teflon is warn 50 t hat the copper BUS HI NG
surface appears on more than 3/4 of the entire sur-
face. BACK-UP RING
'f 1
Check the back-up ring; replace it if there is anv dis-
tortion at the points shown. ("=:ol :..
CHECK POINTS
COPPER SURFACES
14-27
ASSEMBLY
STOPP~2 .0 kgf.m, 15Ibf.ft)
n
FORK TUBE
FORK TUBE BUSHING
SLiDER BUSHING
~.,
"";;00
\,,1 7,
.. !
34 N·m (3.5 kgf.m, 25 Ibf.ft)
~SPRINGSEAT
~ ~ STOPPER
~.,
"";;00
-.-
- STOPPER
# RUBBER SEAl
Oll SEAl ~ RING SPRING COllAR

~ ~~"b,O ~
~-;J
34 N·m (3.5 kgl·m, 25 Ibl·ft) S
;,r
17 N·m (1.7 kgl·m, 13Ibf.ft)
LJ~ '------'
DUST SEAl
~ .. FORK SPRING
• Belore assembly, wash all parts with a high Ilash

or non-Ilammable solvent and blow them dry .
• When insta lling the lork dust sea l and oil seal,
wrap the edge and groove ol the lork tube with
tape.
TAPE
Apply lork Iluid to new dust seal and oil seal lips_
FORK TUBE BUSHING
Insta" the oil seal Install the dust seal, stopper ring and oil seal.
with its marked
side facing roward
the axle holder,
Remove any burrs Install the back-up ring, slider bushing and lork tube
(rom the slider bush ing.
bushing mating Instal l the lork tube into the lork sl ider.
surface, being
careful not to peel SLiDER BUSHING
off the coating.
~"OllSEAl
14-28
Drive the oil seal in using the special tooI.
TOOlS:
Fork seal driver 07KMD-KZ30100
Fork seal driver attachment 07RMD-MW40100
U.S.A. TOOl:
Fork seal driver 07NMD-KZ3010A
SLIDING I
Do not 5cra tch the

(ork tube sliding
Install the stopper ring into the lork slider groove
securely.
.
ATTACHM ENT
.. . .
BUSHING I
DUST SEAL
.I \
5urface.
Install the dust seal into the lork slider.
\~.
~- -..:" ~ /
Install the lork damper assembly into th e lork slider.

FORK DAMPER ASSEMBLY
FORK SLiDER
Install the soeket bolt with a new sealing washer.
BOLT
14-29
FRONT WHEElISUSPENSION/STEERING
Hold the axle holder in a vise with soft jaws or a
shop towel.
Hold the lork damper with the special tooi, then
tighten the lork soeket bolt to the speeilied torque.
TOOL:
Fork damper holder 07YMB-MCF010l or
07YMB-MCFA 100
(U.S.A . only)
TOROUE: 34 N·m (3 .5 kgl·m, 25 Ibl·ft)
Apply lork fluid to new O-rings, then install them to

the plug bolt and adjuster pieee. ADJUSTER PIECE PLUG BOLT
Install t he adjuster pieee into the axle holder.

Tighten the plug bolt to the speeilied torque.
TOROUE: 17 N·m (1.7 kgl·m, 13 Ibl·ft)
Pour the specified amount of recommended fork

Iluid into the lork slider.
RECOMMENDED FORK FLUID:

Pro Hond. Suspension Fluid 55-47 (10W)
FORK FLUID CAPACITY:
413 ± 2.5 cm' (14.0 ± 0.08 US OZ, 14.5 ± 0.09 Imp oz)
14-30
Bleed the air from the fo rk leg as follows:
FORK DAMPER
1. Exten d the fork, cover the top of the fork slider
with yo ur hand and compress the fork leg slowly.
2. Remove your hand and extend the fork slowly.
Repeat above procedure 2 or 3 times.
3. Pump the fork damper rod slowly 8 - 10 times.
Slowly push the fork slider, and gently seat the dust
seal anto the axle hol der and leave it for 5 minutes.
Be sure the oillevel After the oil leve l stabilizes, measure the aiJ level
is the same in the trom the top of the fork slider.
bath lorks.
FORK FlUID lEVEL: 93 mm (3.7 in) 93mm
(3.7 in)
Install the fork spring into the fork slider with the
tapered end lacing up . TAPERED END
,
DAMPER ROD HOLDER
-
I ------....
Extend the lork damper full y and install the damper
rod holder onto th e damper rod. ~ SPRINGSEAT
STOPPER
TOOl: I
Damper rad holder
stopper.
070MF-MBZC120
Install the spri ng col lar, rubber sea l and sp ri ng sea t
ti~ SPRING COLLAR

I~ ·
RUBBER SEAL
I
FORK SPRING
• • d
Set th e spring collar holder to th e spring co ll ar

I
holes. LOCK NUT
TOOl:
Spring collar hol der 070MF-MBZC110
Compress the spring co llar with the spring collar

holder whi le pu lling th e dam per red hol der up.
Insert the stopper plate between the loek nut and
spring se at stopper.
TOOl:
Stopper plate 070MF-MBZC130
Remove the damper rod holder.
14-31
Apply lork Iluid to a new O-ring and install it to the
lork bolt. FORK BOLT
Tighten the (ark Install the lork bolt to the lork damper. !II!~
bolt after instafling
Tighten the loek nut to the speeilied torque with ""...
the (ark slider into
holding the lork bolt.
the {ark bridges.
Remave the stopper plate and spring eollar holder.

/
/
/
/
LOCK NUT SPRING COLLAR HOLDER

Tighten the (ark Install the lork bolt to the lork sl ider.
bolt after installing
FORK BOLT
Install the handlebar stopper ring .
the fark.
FORK SLiDER STOPPER RING

INSTALLATION
Return the pre-laad, rebound and compression
damping adjusters to the original positions as noted
during disas sembly.
Install the lork leg through the bottom bridge, han-
diebar and top bridge.
Position the fork so that the first groove trom the
top is Ilush with the upper surface ol the top bridge
as shown.
Tighten the bottom bridge pineh balts to the speei-

lied torque.
14-32
If the fork bolt is loosened, tighten it to th e specified
torque.
Tighten the top bridge pinch bolt to the specified
torque.
TORQUE: 22 N·m (2.2 kgf.m, 16 Ibf·ft)
Tighten the handlebar pinch bolt to the specified
torque.
TORQUE: 27 N'm (2.8 kgf·m, 20 Ibf.ft)
- Front fender (page 3-13)
- Front wheel (page 14-21)
HESD
REMOVAL
Remave the fuel tank cover (page 3-9).
Remove the screws and steering damper cover.
Remove the nut and disconneet the second arm
from the top bridge.
Remave the balts and steering damper trom the

fram e.
Disconneet the HESD 2P (Brown) connector trom
the steering damper.
14-33
INSTALLATION
Connect the HESD 2P (Brown) connector to the
steering damper securely.
Install the steering damper onto the frame and
tighten the bolts to the specified torqu e.
TORQUE: 10 N·m (1.0 kgf·m , 7 Ibf·ft)
Con neet the second arm to the top bridge and "~
' ~~:::::::~=
tig hten th e nut to the speci f ied torqu e.
TORQUE: 12 N·m (1 .2 kgf·m , 9 Ibf·ft)
Install the steering damper cover and tighten th e

screws securely.
Install th e fuel tan k cover (page 3-9).
STEERING STEM
REMOVAL
- Front fend er (page 3-13)
- Fuel tank cover (page 3-9)
- Upper in ner cowls (page 3-7)
- Front wh eel (page 14-16)
Remave the nut and disconneet the secon d arm
from the top bridge.
Disconnect the ignition switch 2P (Brown) connec- ~~~ .~~~~~

tor.
Remave the bolt and wire damp.
Remove the steering stem cap.
14-34
FRONT W HEELISUSPENSION/STEERING
Remove the screws and steering damper cover.
Remove th e steering stem nut.
Remove the forks (page 14-22).
Remove t he bolt and front brake hose clamp.
Straighten tabs loek washer tabs.

lOCK NUT
Remove the adjusting loek nut and loek washer.
Remove the steering stem adjusting nu t using the

specia l tooI. STEE RING STEM "SOCKET
TOOl:
Steering stem socket 07916-3710101 or
07916-3710100
(U.S.A. only)
14-35
- Dust seal
- Upper bearing inner race
- Upper bearing
- Stee ring stem
- Lower bearing
BEARING REPLACEMENT
Always rep/ace the Repl ace th e races using the special tools as , - - - - - - - - - - - - - - - - - - - - ,
bearings and races described in the following procedure.
as a set.
Except U.S.A.: (6)
TOOLS: (Not available in U.S.A.)
(1) Driver attachment (upper) 070MF-MCJ0100
(2) Driver attachment (lower) 070MF-MCJ0200
(3) Driver shaft assembly 07946-KM90301
(4) Bearing remover, A 07946-KM90401
(5) Bearing remover, B 07NMF-MT70110
(6) Assembly base 07946-KM90600
NUTA (3 )
NUTB
(1) (4)
DRIVER
SHAFT
(2) (5)
14-36
Note the instalfation Install the special tools into the steering head as
direction of the shown. DRIVER UPPER OUTER
assembly base; the ATIACHMENT RACE
Align the bearing remover A with the grooves in the (upper)
smal/l.O.side
steering head.
facing the upper
Lightl y tighten the nut B with a wre nch. NUTA
attachment.
Holding the driver shaft with a wrench , turn the nut
A gradually to re move the upper outer race.
ASSEMBLY
BASE
BEA RIN G
REMOVER A t
NUTB
DRIVER SHAFT
DRIVER
ATIACHMENT
(lower)
Nore the installation In stall the specia l tool s into the steering head as
direction of the shown and re move the lower outer race using the DRIVER DRIVER SHAFT
assemblybase; the same procedure as for the upper outer race . ATIACHMENT
large I.D. side (upper)
facing the lower
attachment.
BEARING
REMOVER B
NUTB
~ G
••
ASSEMBLY
BASE
_____
==-
>Ç~"":I
NUTA
LOWER
OUTER RACE DRIVER
ATIACHMENT
(lower)
1'/L~7
Aemove any burrs trom the outer race installation
surface of the stee ring head. DRIVER DRIVER SHAFT
ATIACHMENT
Nore the insralfation Install a new upper outer race with the special tools
(upper)
direction of (he as shown .
assemblybase; (he Hold the driver shaft with a wrench and turn the nut
large /.D. sid. A gradually until upper outer race is fully seated.
facing the lower
atrachment.
S~
UPPER OUTER
RACE
DRIVER
ATIACHMENT
(lower)
ASSEMBLY
BASE NUTA
Remove any burrs trom the outer race installation

surface of the stee ring head. NUTA
Note the installation Install a new lower outer race with the special tools
direction of the as shown .
assembJy base; the Hold the driver shaft with a wrench and turn the nut
smaff I.O. side A gradually until lower outer race is fully seated.
ASSEMBLY
facing the upper
BASE
attachmenr.
DRIVER
ATIACHMENT
(upper)
~
LOWER
OUTER RACE
DRIVER
ATIACHMENT
DRIVER SHAFT
(Iower)
14-38
U .S.A. only:
TOOLS:
Main bearing driver attachment 07946-ME90200 UPPER NUT
Fork seal driver weight 07947-KA50100
Oil seal driver 07965-MA60000
MAIN BEARING
InstalIer shaft 07VMF-KZ30200
DRIVER ATIACHM ENT
InstalIer attachment A 07VMF-MAT0100
Insta lier attachment B 07VMF-MAT0200
Remover attachment C 07AMF-MEEA 100
Remover attachment D 07AMF-MEEA200 FORK SEAL
DRIVER WEIGHT
Install the special tools into the steering head pipe
as shown.
Align the remover attachment C with the grOQve in
the steering head. UPPER BEARING
While holding the instalier shaft with the wrench, OUTER RACE
turn the upper nut gradually to remove the upper
bearing outer race.
REMOVER
ATIACHM ENTC
LOWER NUT
INSTALLER SHAFT
INSTALLER
ATIACHM ENTB
Install the special tools into the steering head pipe ~=================~
as shown. INSTAL LER
Align the remover attachment D with the groove in ATIACH
the steering head.
While holding the insta lier shaft with the wrench,
INSTALLER SHAFT
turn the lower nu t gradua ll y to remove th e Jower
bearing outer race.
UPPER NUT
REMOVER
ATIACHM ENT D
LOWER BEARING --~01""1

OUTER RACE
MAIN BEARING
DRIVER ATIACHMENT
LOWER NUT
14-39
Instal! a new upper bearing outer race and the spe-
cial toals as shown . UPPER NUT
turn the lower nut gradually until the groove in the INSTALLER
steering head. This will allow you to install the
ATIACHMENT A - _.....
upper bearing outer race .
UPPER BEARING
OUTER RACE
INSTALLER SHAFT
INSTALLER
ATIACHMENT B
OIL SEAL DRIVER -~.....
FORK SEAL
DRIVER WEIGHT --~
MAIN BEARING
DRIVER ATIACHMENT
LOWER NUT
Instal! a new lower bearing outer race and the spe-

cial tools as shown. UPPER NUT
turn the upper nut gradually until the groove in the
instalIer attachment B aligns with the lower end of MAIN BEARING
the stee ring head. This will allow the installation of DRIVER A
the lower bea ring outer race.
FORK SEAL
DRIVER WEIGHT
INSTALLER
ATIACHMENT A ----I
INSTALLER SHAFT _ _!--!.~
LOWER BEARING
OUTER
INSTALLER
ATIACHMENT B - - -
LOWE NUT
14-40
LOWER INNER RACE REPLACEMENT
Temporarily install the steering stem nut onto the
stem to prevent the threads trom being damaged DUST SEAL
when removing the lower bearing inner race from
the stem.
Remove the lower bearing inner race with a chisel
or equivalent taal , being careful not to damage the
stem.
Remove the dust seal.
LOWER INNER RACE
Apply grease to a new dust seal lips and install it

over the stee ring stem .
Install a new lower bearing inner race using a spe-
cial taal and a hydraulic press.
TOOL:
Attachment, 30 mm I.O. 07746-0030300
INSTALLATION
: BEARINGS
LOCK NUT ------=-
~
...-"
...
: BEARING RACES ADJUSTING NUT ~ LOCK WASHER
: DUST SEALS
UPPER INNER R~
~ UPPER DUST SEAL
STEE RING STEM
~ UPPER BEARING
~~UPPER OUTER RACE

~~KJr--,
~
~
~ LOWER OUTER RACE
~
~.. LOWER BEARING
~ LOWER INNER RACE
LOWER DUST SEAL
14-41
Apply the speeified grease (page 1-19) to the upper
and lower bearings and bearing races.
Install the lower bearing onto the steering stem.
Inser! the stee ring stem into the steering head pipe.
Install the upper bearing, inner race and dust seal.
Apply the speeified grease to the steering stem

adjusting nut threads (page 1-19).
Tighten the steering stem adjusting nut to the initial
torque.
TOOL:
Steering stem socket 07916-3710101 or
07916-3710100
(U.S.A . only)
Move the steering stem right and left, loek-ta-loek,

five times to seat the bearings .
Retighten the stee ring stem adjusting nut to the

speeified torque.

Recheek that the steering stem moves smoothly
without play or binding.
14-42
Install a new loek washer onto the steering stem ,
LOCKWASHER
Align the tabs of the loek washer with the groov es in ~
the adjusting nut and bend !wo oppos ite tabs dow n S
inta the adjusting nut groove.
Install and fi nger t ighten the loek nut.
Hold the adjusting nut and further tighten the loek
nut within 1/4 turn (90°) enough to align its groov es
with the loek was her tabs ,
8end the loek washer tabs up into the loek nut
grooves.
LOCK NUT
Route the brake Install the front brake hose clamp and tighten the
hose properly bolt to the speeified torque,
(page 1-211.
TOROUE: 9,0 N·m (0.9 kgf'm. 6,6 Ibf.ft)
Install the forks (page 14-32).
Install the top bridge and steering stem nut.

Install the steering damper cover and tighten the
screws securely.
14-43
Tighten the steering stem nut to th e specified
torque ,
TORQUE: 103 N·m 110.5 kgf·m, 76 Ibl·ft)

Move th e steering stem right and left, lock-to-Iock,
several times.
Make sure the steering stem moves smooth ly w ith-
out play or binding .
Install the steering stem ca p.

Connect the ignition switch 2P IBrown) connector.
Route the wires Install the wire clamp and tighten the bolt secu rel y.
properly
(page 1-21).
Con neet the second arm to the top bridge and

tighten the nut to th e specil ied torqu e.
TORQUE: 12 N·m 11.2 kgl·m, 9 Ibl·ft)
- Front wheellpag e 14-21 )
- Upper inner cowls Ipage 3-7)
- Fuel tank cover Ipag e 3-9)
- Front lender Ipage 3-13)
STEERING HEAO BEARING PRE-LOAD

Jack up the motorcycle to raise the Iront wheel olf ,-----;:-:::;-:;;;::::::::::-<0;;-:-----1
the ground.
Position the steering stem to the straight ahead
position.
Make sure thar Hook a spring scale to th e lork slider and measure
there is na cabfe or th e steering head bearing pre-Ioad .
wire harness
interference.
Standard: 14.7 -17.7 N 11.5 -1.8 kgl)
14-44
If the readings do not fa I! within the standard value,
disconneet the second arm and recheek.
Standard: 10.8 -12.7 N (1 .1 -1.3 kgf)

If the readings do not fal! within the standard value,
adjust the steering stem adjusting nut (page 14-34).
If the readings fal! w ithin the standard value, check
the HESD (page 14-8).
14-45
MEMO
15. REAR WHEEL/SUSPENSION
COMPONENT LOCATION ························15-2 SHOCK ABSORBER ................................ 15-14
SERVICE INFORMATION ...... .. ................ · 15-3 SUSPENSION LlNKAGE ...... .. ................ 15-19
TROUBLESHOOTING ........ .. .................... ·15-6 SWiNGARM .... ·· .. ·.. ·· ·........ ·.......... · .. ·...... · 15-20
REAR WHEEL ............................................ 15-7
15-1
COMPONENT LOCATION
64 N·m (6.5 kgl·m, 47 Ibfft)
54 N·m (5.5 kgl·m, 40 Ibl·ft)
44 N·m (4.5 kgl·m, 32 Ibl·ft)
93 N·m (9.5 kgfm, 69 Ibl·ft)

/
15-2
REAR WHEELISUSPENSION
SERVICE INFORMATION
GENERAL
• A contaminated brake disc or pad redu ces stopping power. Discard conta minated pads and cl ean a contam inated disc
with a high quality brake degreasing agent.
• After the rear wheel installation, check the brake operation by applying the brake pedal.
• The shock absorber contains nitrogen under high pressure. Do not allow tire or heat near the shock absorber.
• Befare disposal of the shock absorber, release the nitrogen (page 15-18).
• When servicing the rear wheel and suspension, support the motorcycle using a safety stand or hoist.
• Use only tires marked "TUBELESS " and tubeless valves on rim marked "TUBELESS TIAE APPLICABLE".
• Use genuine Honda replacement balts and nuts for all suspension pivot and mounting point.
• When installing the swingarm, be sure to tighten the swingarm pivot fasteners to th e specified torque in the specified
sequence. It you mistake the tightening torque or sequence, loosen all pivot fasteners, then tighten them again to the
specified torque in the correct sequence.
• For brake system information (page 16-4).
• When using the loek nut wrench for the swingarm pivot loek nut, use a dellecting beam type torque wrench 20 inches
long. The loek nut wrench increases the torque wrench 's leverage, sa the torque wrench reading will be less than the
torque actually applied to the loek nut. The specification given is the actual torque applied to the loek nut, not the read-
ing on the torque wrench. Do not overtighten the loek nut, The specification later in the text gives both actual and indi·
cated .
SPECIFICATIONS
Unit· mm (in )
Minimum tire tread depth 2.0 (0.08)
Cold tire pres- I Driver only 290 kPa (2.90 kgf/cm ' , 42 psi)
sure Driver and passenger 290 kPa (2.90 kgf/cm ' , 42 psi) -
Axle runout 0.2 (0.01)
Wheel rim I Aadial 2.0 (0.08)
runout Axial - 2.0 (0.08)
Wheel balance weight 60 9 (2.1 oz)
- ma x.
Drive chain Size/link ) DID DID525HV KAI-112YB -
I AK AK525AGZ6-112LJFZ -
Slaek 30 - 40 (1.2 -1.6)
Shock Spring pre-laad adjuster standard -
Position 2
absorber position
Aebound dam ping adjuster initia I
setting
2- 1/2 turns out from full hard -
Compression damping adjuster in;-
22 clicks out from full hard -
tial setting
TORQUE VALUES
Aear brake disc bolt 42 N·m (4.3 kgf-m, 31 Ibf·ft) ALGC bolt; replace with a new one
Dri ven sprocket nut 64 N·m (6.5 kgf-m, 47 Ibf·ft) U-nut
Rear axle nut 113 N·m (11.5 kgf-m, 83Ibf·ft ) U-nut
Shock absorber mounting nut 44 N·m (4.5 kgf·m, 32 Ibl·ft) U-nut
Shock link nut 44 N·m (4.5 kgf·m, 32 Ibf·ft) U-nut
Shock arm·to-swingarm nut 44 N·m (4.5 kgf·m, 32 Ibf·ft) U-nut
Drive chain slider bolt 9.0 N·m (0.9 kgf·m, 6.6Ibf·ft) ALGC bolt; replace with a newone
Drive ehain case bolt 12 N·m (1.2 kgf·m, 9 Ibl·ft)
Swingarm pivot nut 93 N·m (9.5 kgf-m, 69 Ibf·ft)
Swingarm pi vot adjusting bolt 12 N·m (1. 2 kgf·m, 9Ibf·ft) Apply oil to the threads
Swingarm pivot loek nut 64 N·m (6.5 kgf·m, 47 Ibf-ft)
Drive sproeket bolt 54 N·m (5.5 kgf·m, 40 Ibf·ft)
15-3
REAR WHEEL/SU SPENSION
TOOLS
Bearing remover shaft Bearing remover head, 25 mm Driver

07GGD-0010100 07746-0050800 07749-0010000
"
~
<_.-: "
--'
~~~
. "-~.
Driver Driver shaft Driver head

07949-3710001 07946-MJ00100 07946-MJ00201
,,
;) , I
or 07946-MJOA100 (U,SA only)
Attachment, 42 x 47 mm Attachment, 52 x 55 mm Attachment, 24 x 26 mm

07746-0010300 07746-0010400 07746-0010700
~
® ,
......,..
",-, -~
\'",,,, ~ __,I
Attachment, 22 x 24 mm Attachment 40 x 42 mm Attachment, 28 x 30 mm

07746-0010800 07746-0010900 07946-1870100
~
,e
--~
~~;$f'

or 07746-001A800 (U,SA only)
15-4
Pilot, 17 mm Pilot, 20 mm Pilot, 25 mm

07746·0040400 07746-0040500 07746-0040600
Pilot, 28 mm Pilot, 28 mm Altachment, 37 mm

07746-0041100 07JAO-PH80400 07ZMO-MBW0200
Altachment, 30 mm I.O. Loek nut wrench Bearing driver

07746-0030300 07908-4690003 07GMO-KT80100
15-5
TROUBLESHOOTING
Soft suspensio"
• Weak shock absorbe r spring
• Incorrect suspension adjustment
• Dil leakage trom damper unit
• Insufticient tire pressure
Hard suspension
• Incorrect suspension adjustment
• Damaged rear suspension pivot bearings
• Bent damper rad
• Bent swinga rm pivot
• Ti re p ress ure toa high
Rear wheel wobbling
• Bent rirn
• Warn or damaged rear wheel bearings
• Faulty rear tire
• Unbalanced rear tire and wheel
• Insufficient rear tire pressure
• Faulty swingarm pivot bearings
Rear wheel turns hard
• Faulty rear wheel bearings
• Bent rea r axle
• Rear brake drag
• Drive chain toa tight
Rear suspension noise
• Faulty rear shock absorber
• Lease rear sus pension fasteners
• Warn rear sus pension pivot bearings
Steers to one side or does not track straight
• Bent rear axle
• Axle ali gnmentlchain adjustment not equal on both sides
15-6
REAR WHEEL
REMOVAL
Remove the serew and brake hose clamp .
Support the motoreyele seeurely, raise the rear 1"":""'.........-:.

wheel olf the ground .
Fully slaeken the drive ehain (page 4-24).
Remove the rear axle nut, washer and adjusting
plate.
Push the rear wheel forward.

Remove the rear axle and adjusting plate.
Oerail the drive chain from the driven sprocket.
Do not hang the Remove the rear brake caliper bracket and rear
cal/per by the brake wheel.
hose. Do not twÎst
the brake hose. Do
nor operate the
brake peda' after
removing the rear
wheel.
15·7
REAR WHEEl/SUSPENSION
Remove the side collars.
DISASSEMBLY
Remove the bolts and brake disco
Remove the right dust seal.
If you rep lace the driven sprocket, loosen the driven

sprocket nuts before removing the driven flange
trom the wheel hub.
Remove the dust seal.
Remove t he driven tlange assembly trom the left

wheel hub.
If you replace the dri ven spro cket, rem ave the nuts,
DRIVEN SPROCKET
washers, driven sprocket and balts.
NUTS/WASHERS/BOLTS
Remave the wheel rubber dampers.

Remave the O-ring.
INSPECTION
Axle
Place the axle on V-bloeks and measure the runout.
Actual runout is 1/2 the total indicator reading .
Wheel balance
For wheel balance servicing (page 14-18).
• When checking wheel balance, install the brake
disc onlo the wheel (page 15-12).
Wheel/driven tlange bearings

Turn the inner race of each bearing with your finger.
The bearings should turn smoothly and quietly.
Also check th at the outer ra ce ot the bearing fits
tightly in the hub or driven tlange.
Rep/ace the wheel Replace the bearings if th e ra ces do not turn
bearings in pairs. smoothly, quietly, or if the outer race fit loosely in
the hub or driven tlange.
WHEEL BEARING
15-9
Wheel rirn runout
Check the rim runout by placing the wheel in a
truing stand.
Spin the w heel slowly and read th e runout using a
dial indicator.
Actual runout is 1/2 th e tota l indicator reading.
SERVICE LIMlTS:
Radial: 2.0 mm (0.08 in)
Axial: 2.0 mm (0.08 in)
Driven sprocket
Check the condition of the final driven sprocket , - - - - - - - - - - - - - -- -- - ,
teeth.
Replace the sprocket if worn or damaged .
GOOD REPLACE
• If the fina t driven sprocket requires replacement,
inspeet the drive chain and drive sprocket.
• Never install a new drive chain on a warn
sprocket or a warn chain on new sprockets. Bath
o X
~~
chain and sprocket must be in good condition or
the replacement cha in or sprocket will wear rap-
idly. .
DRIVEN FlANGE BEARING

REPLACEMENT
Press the driven flange colla r out of the driven
flange bea rings . DRIVER SHAFT
TOOLS:
Driver shaft 07946-MJ00100 or
DRI VER HEAD
07946-MJOA 100
(U .S.A. only)
Driver head 07946-MJ00201
Drive out the driven flange bea rings using the spe-
cial toois.
TOOLS:
Driver 07749-0010000
Attachment, 40 x 42 mm 07746·0010900
Pilot, 28 mm 07JAD-PH80400
15-10
Press the d riven f lange collar inta the new driven
DRIVEN FLANGE COLLAR
Ilange bearings until it is l ull y seated .
TOOlS:
Driver 07749-0010000
Attachment, 28 x 30 mm 07946-1870100
Pilot, 25 mm 07746-0040600
5~
DRI VEN FLANGE BEARINGS
Press t he d riven Ilange bea rings/collar into the

dri ven fla nge using t he special tools.
TOOlS:
Driver 07749-0010000
Attachment, 52 x 55 mm 07746-0010400
Pilot , 25 mm 07746-0040600
WHEEL BEARING REPLACEMENT

Insta ll the bea ri ng remover head inta t he bea ring.
From the opposite side, install the bearing remover
s haft and drive th e bearing o ut ol the w heel hu b.
Remove t he dist ance collar an d d ri ve o ut t he other
bearing .
TOOlS:
Bearing remover head, 25 mm 07746-0050800
Bearing remover shaft 07GGD-0010100
Never install the aid Dri ve in a new right bea ring sq uarely until it is fu ll y
bearings, once the seated.
bearings has been
removed. the TOOlS:
bearings must be Driver 07749-0010000
repfaced with new Attachment, 52 x 55 mm 07746-0010400
ones. Pilot, 25 mm 07746-0040600
15-1 1
Inslall Ihe dislance collar.
Drive in a new left bearing squarely.
TOOLS:
Driver 07749·0010000
Attachment, 42 x 47 mm 07746·0010300
Pilot, 25 mm 07746·0040600
ASSEMBLY
~S~
.. ..ûiiIi
LEFT DUST SEAL
DRIVEN SPROCKET
BRAKE DISC
64 N·m (6.5 kgf·m, 47 Ibf·ft)
...... ..u;:;.;"
!$!~
RIGHT DUST SEA L
DISTANCE COLLAR
S
~ LEFTWHEEL S~
BEARING (6005) .. ..u;:;.;" O·R I N G DRIVEN FLANGE
Inslall Ihe wheel rubber dampers inlo Ihe wheel ...

hub.
---=.-......
App ly grease la a new O·ring and inslall il inlo Ihe
groove of Ihe w heel hub.
15-12
If the driven sprocket is removed , install the driven
sprocket bolts, sprocket, washers and nuts onto the
driven Ilange.
Instal! th e driven Ilange assembl y into the left wh eel
hub.
If the driven sprocket is removed , tighten the driven
sprocket nuts to the specified torque.
TORQUE: 64 N·m (6.5 kgl·m, 47 Ibf·ft)
Apply grease to a new dust seal lip, th en install it
into the driven tlange.
Instal! the brake dise with its rotating direction mark r-~-~~~
laeing out.
Tighten new brake dise balts to the speeilied torque.
Apply grease to a new dust seal lip, then instal! it
into the wheel hub.
INSTALLATION
Instal! the side eollars .
Be careful not to Install the rear brake caliper bracket onto the guide
damage the brake rail of the swingarm while placing the rear wheel
pads. into the swingarm.
15-13
Instal! the drive chain over the driven sp racket.
Applya thin coat of grease to the rear axle surface.
Install the adjusting plate and rear axle from the left
side.
Install the adjusting plate, washer and rear axle nut.

Adjust the drive ehain slaek Ipage 4-24) .
Install the brake hose clamp between rear fender C

and swingarm, aligning its tab with the swingarm
hole.
Tighten the screw securely.
SHOCK ABSORBER
REMOVAL
- Lower eowllpage 3-6)
- Rear fender C Ipage 3-16)
Support the motorcycle using a hoist or equivalent,
and rise the rear wheel aft th e ground.
Support the rear Remave the shock absorber lower mounting nut
wheel secure/y. and bolt.
15-14
Remave the shock absorber upper mounting nut
and bolt, then remave the shock absorber upward.
INSPECTION
Visually ins peet the shock absarber far damage.
Check the fallawing:
DAMPER UNIT
- Damper rad for bends or damage
- Damper unit for deformation or oil leaks
- Rubber bumper for wear or damage
Inspeet all the ather parts far wear or damage.
It necessary, replace the shock absorber as an
assembly.
,,
DAMPER RaD RUBBER BUMPER
UPPER BEARING REPlACEMENT

Remave the dust seals.
DUST SEAlS
Press the spherical bearing to get the clearance nec-

essary to remave the stopper ring using the special STOPPER RING COLLAR
taal.
TOOl:
Bearing driver
(Use only 17 mm eollar) 07GMD-KT80100
Remave the stopper ring .
15-15
Pre ss the spherical bearing out of the upper mount
using the special tools . COLLAR
TOOLS:
Searing driver
(Use only 17 mm colla r) 07GMO-KT80100
Attachment, 30 mm I.O. 07746-0030300
ATIACHMENT
Drive the bearing in Press a new spherical bearing into the upper mount ~=================~
evenly; do not al/ow using the special tooI. COLLAR
it to tift.
Taal:
Sealin g driver
(Use only 17 m m co llar) 07GMO-KT80100
Install a new stopper ring into the groove of the

upper mount securely. CO LLAR
Press the spherical bearing into the upper mount
using the special too i, until it seats against the stop-
per ring.
TOOl:
Searing driver
(Use only 17 mm collar) 07GMO-KT80100
STOPPER RI NG
The lelt dust seal Apply grease to new dust sea l lips and insta ll them.
o.O. is largef than
righ t dus t s9a/ D.D.
$I .. - DUST SEALS
15-16
LOWER BEARING REPLACEMENT
Remave the dust seals and co lla r.
OU ST SEALS
Press the needie bearing out of the lower mount

using the special tools . DRIVER
TOOLS: / ATTAC HM ENTI

Driver 07949-3710001 PILOT
Attachment, 22 x 24 mm 07746-0010800
Pilot, 17 mm 07746-0040400
Attachment, 30 mm I.O. 07746-0030300
Pack a new needie bea ring with multi ~ purpose

DRIVER
grease.
Press the needie bea ring into the lower mount using
th e specia l toois. ATTACHM ENTI
PI LOT
TOOLS:
Driver 07949-3710001
Attachment, 22 x 24 mm 07746-0010800
Pilot,17 mm 07746-0040400
App ly grease to new dust sea ll ips.

Install the collar and new dust seals.
e~
DUST SEALS _ Ii.iijiij.,
15-17
SHOCK ABSORBER DISPOSAL
PROCEDURE
Release the nitrogen trom the reservoir by pushing
PACKING 2 mm(0.07 in ) SHAFT
and dropping the reservoir cap packing with the 2
mm (0.07 in) shaft.
• Put on safety glasses.
• Betore disposal of the shock absorber, release
L
..
th e nitrogen trom the reservoir.
Push
RESERVOIR CAP
INSTALLATION
Support the rear Set the shock absorber with the compression damp-
whee/securely. ing adjuster facing left.
Install the upper mounting bolt.
lighten the upper mounting nut to the specified
torque.
lORQUE: 44 N·m (4.5 kgl·m, 32 Ibl·ft)
Install the lower mounting bolt.

lighten the lower mounting nut to the specilied
torque.
- Rear fender C (page 3-16)
15-18
SUSPENSION LlNKAGE
REMOVAL
Remov e t he lower cowl (page 3-6).
Support t he motorcycle using a hoist or equivalent,
and raise the rear wheel oft the ground.
Support the rear Remove the l ollowi ng :
wheel s8curely.
- Shock link bolts/nuts
- Shock link
- Shock arm
SHOCK LINK BEARING REPLACEMENT

Remove th e pivot co llar and du st sea ls.
o
()
COLLAR
Press the needie beari ngs out ol the shock link
usi ng th e special tools.
TOOLS:
Driver 07949-3710001
Attachment, 22 x 24 mm 07746-0010800 or ATIACHM ENT/
07746-001A800 PILOT
(U.S.A. only)
Pilot, 17 mm 07746-0040400 - - - BEA RING
Attachment, 30 mm I.O. 07746-0030300
Press the nead/e Pack new needie bea rings with multi-purpose
bearing into the grease.
shock link with the
Press t he needie bearings into the shock link so th at
marked side facing 5.2- 5.7 mm
t he needie bearing surface is 5.2 - 5.7 mm (0.20 -
out. 0.22 i n) below th e end ol th e shock link using the (0.20 - 0.22 in)
specia l too is.
TOOLS:
Driver 07949-3710001
Attachment, 22 x 24 mm 07746-0010800 or
07746-001 A800
(U.S.A. only)
Pilot. 17 mm 07746-0040400
15-19
App ly grease to new dust sea l li ps, th en install the
dust seals and col lar into the shock link.
- ~ !$."
..... DUST SEALS
o
IJ
INSTALlATION
Suppon the rear Loosely install th e fo llowing:
wheel secure/v· _ Shock arm
- Shock lin k
- Shock link bo lts/nuts
Ti g hte n the nut s to t he specified t orque.
In stall t he lowe r cowl (page 3-6).
SWINGARM
REM OVAl
Remave the fo ll owing:
- Rear wheel (page 15-7)
- Shock absorber (page 15-14)
Remove th e shock arm bolt/nut (swi ngarm side).
Remove t he bo lt and gea rshift arm f ro m the gear-

sh ift spin die.
~~~=:
15-20
Remove the bolts, wire clamp, drive sprecket cover
and guide plate.
Remave the bolt, washer and drive sproeket.
Remove the swingarm pivot nut and washer.
Leosen th e swingarm pivot loek nut using the spe·

eial taal.
TOOL:
Loek nut wreneh 07908-4690003
Turn th e swingarm pivot adjusting bolt counte r·
eloekwise fully by turning th e swingarm pivot bolt.
Remave the pivot bolt, loek nut, adjusting bolt and
swingarm .
15-21
DISASSEMBLY IINSPECTION
Remove the balts and drive chain case.
DRIVE CHAIN CASE
BOlTS
Remove the balts, washers and drive chain slider.
Check the drive chain slider for wear or damage.
BOLT/WASHER BOlTS/WASHERS
Remave the dust seals and collar from the
swingarm.
Check the collar for wear or damage.
Remove the pivot collars, dust seals and distance

coJlar trom the swin ga rm pivot. PIVOT COllAR
Check the pivot collars for wear or damage. \
/
""'"";
DISTANCE COLLAR
,...........
PIVOT COllAR
I
\
15-22
Turn the inner race of righ t side pivot bali bea ring
with your finger.
The bearing should turn smoothly and quietly. Also
check that the bea ring outer race fits tightl y in the
swinga rm pivot.
Rem ave and disca rd the bearing if the races do not
tu rn sm ooth ly and quietly, or if they fit loosely in the
swingarm pivot.
BEARING
Pivot bearing replacement

Right side: Remove the snap ring trom the swingarm right side
SNAP RING
pivot.
Right side: Press the right pivot needie and bali bearings out of
the swingarm pivot using the special tools .
TOOlS:
Driver 07949-3710001
Attachment, 24 x 26 mm 07746-0010700
Pilot, 20 mm 07746-0040500
Lelt sida: Press the left pivot n~e d le bearing out of the
swi ngarm pivot usi ng th e special tools .
TOOlS:
Driver 07949-3710001
Attach m ent, 28 x 30 mm 07946- 1870100
15-23
Righr side: Pack a new bali bearing w ith multi-purpose grease.
Press the bali Press the bali bearing into the swingarm right pivot
bearing inta the until it is fu lly seated using th e special tool s.
....."
swingarm w Îth the TOOlS:
marked side facing
out. Driver 07749-0010000
Attachment, 37 mm 07ZMD-MBW0200
Pilot, 20 mm 07746-0040500
BAll BEARING
- ~ "'
Right side:
Press the needIe

Pa ck a new need ie bearing with multi-purpose
greaS8.
Pre ss the needie bearing into the swingarm right
oe,,," I
..
bearing into the pivot until it seats using the speci al too ls.
swingarm w ith the rOOlS:
marked side facing - _ . ATIACHMENTI
out. Driver 07749-0010000 PilOT
Attachment, 37 mm 072MD-MBW0200
Pilot, 28 mm 07746-0041100 - NEED lE
BEARING
Left side: Pack a new needie bea ring with multi-purpose

grease.
Press the naad/a Press the needie bearing into th e swingarm left 5.0 - 6.0 mm
bearing into the pivot sa that the needie bearing surface is 5 .0 - 6.0 (0.02 - 0.24 in )
swingafm w irh rhe mm (0.20 - 0.24 in) below the end of the swingarm
marked side facing pivot surface usin g the special tools.
our.
TOOlS:
Driver 07749-0010000
Attachment, 37 mm 072MD-MBW0200
Pilot. 28 mm 07746-0041100
Righr side: A fref Insta" t he snap ri ng into the groove securely.

SNAP RING
installing a snap
ring, always rorate
it in irs groove ro be
sure it is fully
seated.
1~_74
SHOCK ARM -TO-SWINGARM BEARING
REPLACEMENT
Press the needie bearing out of the swingarm using
the special toois.
TOOLS:
Driver 07949-3710001
•
07746-001A800
(U.S.A. onlyJ
Pilot, 17 mm 07746-0040400
Attachment. 30 m m I.O. 07746-0030300
Pack a new needie bearing with multi-pu rpose

grease.
Press the needie bearing inta the swing arm sa that
5.5 - 6.0 mm
t he need ie bearing surface is 5.5 - 6.0 mm (0.22 -
(0.22 - 0.24 in)
0.24 in ) below the end ol th e swinga rm using the
special too ls.
TOOLS:
Driver 07949-3710001
07746-001A800
Pilot, 17 mm
(U .S.A . only)
07746-0040400 I~
.~
,
NE ED LE BEAR ING
~-------'
ASSEMBLY
.~ ~~ NEEDLE BE ARING SNAP RING
....
~~ BA LL BEARI NG ..... -$IDW ~ ,~ól 12 N·m (1.2 kgl·m , 9lbHt)
DISTA NCE CO LLAR
~~ NEEDLE BEARING
.... • !fjijjjffi
DRIVE CHA IN CAS E
S~
9.0 N·m (0.9 kgf.m, 6.6 IbHt)
NEE DLE BEARING • --
.,!!IifJmJ{ S~
15-25
Apply grease to new dust seal lips.
Install the distance collar, dust seals and pivot col-
lars to the swingarm.
COLLAR
, /OJ
DUST SEAL I
~~
DISTANCE COLLAR s-
Apply grease to new dust seal lips, then install the
dust seals and coJlar inta the swingarm. SEALS .. -$jiiffi
s ~
Install the drive chain slider aligning its slit with the
boss on the swingarm.
Install a new drive chain slider mounting balts and

washers.
Tighten the balts to the specified torque.
S., S~
BOLTIWASHER BOLTSIWASHERS
15-26
Install the drive chain case, and tighten the balts to
DRIVE CHAIN CASE
BOlTS
INSTALLATION
Apply oil to the swingarm pivot adjusting bolt
threads and install it to the Irame.
Make sure th at the swingarm pivot adjusting bolt
does not protrude from the inside pivot.
Apply grease to the swingarm pivot bolt.

Install the swingarm and pivot bolt to the frame.
Loosely install the swingarm pivot loek nut.
Tighten the swingarm pivot adjusting bolt to the
specified torque by turning the swingarm pivot bolt.
Hold the swingarm pivot bolt and tighten the

swingarm pivot loek nut using the special taal.
TOOl:
Loek nut wrench 07908-4690003
TORQUE:
Actual: 64 N·m (6.5 kgl·m, 47 Ibl·ft)
Indicated: 58 N·m (5.9 kgl'm, 43 Ibl·ft)
15-27
REAR WHEElISUSPENSION
Install the washer and swingarm pivot nut.
Tighten the nut to th e speeified torque.
TOROUE: 93 N·m (9.5 kgf·m, 69 IbHt)
Install the drive spreeket with its marks faeing out.

Install the washer and bolt, th en tighten the bolt to
the speeified torque.
Route the Install the guide plate, drive sp rocket cover, w ire
sidestand s witch damp and beits, then tighten the bolts securely.
wirs properly
(page 1-211.
Install the gearshift arm aligning its slit with the

punch mark on the gearshift spin die.
Tighten the bolt seeurely.
15-28
Install the shock arm bolt/nut (swingarm side) and
tighten the nut to the specified torque.

- Shock absorber (page 15-18)
- Rea r wheel(page 15-13)
15-29
MEMO
16. HYDRAULIC BRAKE
COMPONENT LOCATION .......... ···· .. ········ 16-2 FRONT MASTER CyLINDER· .. .. · ............ 16-13
SERVICE INFORMATION .. ...... .. .. .. .......... · 16-4 REAR MASTER CYLINDER .......... .. ........ 16-19
TROUBLESHOOTING ............................. .. 16-6 FRONT BRAKE CALIPERS ........ .... .. ....... 16-25
BRAKE FLUID REPLACEMENTI REAR BRAKE CALIPER ...... ............ ........ 16-28
AIR BLEEDING .. .... .. ............................ ·.. · .. 16-7
BRAKE PEDAL ........ · ............ ...... ...... .... .. · 16-31
BRAKE PAD/DISC .. ...... .. ...................... .. · .. 16-9
16-1
HYDRAULIC BRAKE
COMPONENT LOCATION
FRONT:
12 N·m (1.2 kgf·m, 9 lbHt)
\
\
\
\ 34 N·m (3.5 kg f ·m, 25 IbHt)
45 N·m (4.6 kgf.m, 33 IbHt)
- 10 N·m (1.0 kgf·m, 7 IbHt)
34 N·m (3.5 kg f ·m, 25 Ibf·ft)
16-2
HYDRAULIC BRAKE
REAR:
34 N·m (3.5 kgl·m, 25 Ibl·ft)
18 N'm (1.8 kgf.m, 13Ibl·ft) --~
~
~ 34 N'm (3.5 kgl·m, 25 Ibl·ft)
10 N'm (1.0 kgl·m, 7Ibl·ft)
12 N'm (1.2 kgl·m, 9 Ibl·ft)

~
16-3
HYDRAULIC BRAKE
SERVICE INFORMATION
GENERAL
ACAUTION
Frequent inhalation ol brake pad dust, regardless ol material composition, could be hazardous to your health .
• Avoid breathing dust partjcles.
• Never use an air hose or brush to clean brake assem blies. Use an OSHA·approved vacuum cleaner.
NOTICE I
Spil/ed brake fluid wil/ severely damage instrument lenses and painted surfaces. ft is also harmful to some rubber parts. Be
careful whenever you remove the reserve tank cap; make sure the reserve tank ;s horizontal first.
• A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc
with a high quality brake deg reasing agent.
• Check the brake system by applying the brake lever or pedal after the air bleeding.
• Never allow contaminants (dirt, water, etc.) to get into an open reserve tank.
• Once the hydraulic system has been opened, or il the brake leels spongy, the system must be bied.
• Always use fresh DOT 4 brake fluid trom a sealed container when servicing the system. Do not mix different types of
Iluid; they may not be compatible.
• Always check brake operation betere rid ing the motoreycIe.
SPECIFICATIONS
Unit· mm (in)
Front Specilied brake I luid DOT4 -
8 rake disc thickness 4.3 - 4.5 (0. 17 - 0.18) 3.5 (0.14)
8rake disc runout - 0.30 (0.012)
Master cy linder I.D. 17.460 - 17.503 (0.6874 - 0.6891) 17.515 (0.6896)
Master piston O.D. 17.321 -17.367 (0.6819 - 0.6837) 17.309 (0.6815)
Caliper cy li nder I. D. A 32.080 - 32.1 30 (1.2630 - 1.2650) 32. 140 (1.2654)
B 30.280-30.330 (1.1921-1.1941) 30.340 (1.1945)
Cal iper piston O.D. A 31.967 - 32.000 (1.2585 - 1.2598) 31.957 (1.2581)
B 30.167 - 30.200 (1. 1877 - 1.1 890) 30. 157 (1.1873)
Rear Specilied brake Iluid DOT 4
Brake disc thickness 4.8 - 5.2 (0.19 - 0.20) 4.0 (0. 16)
8rake disc runout - 0.30 (0.012)
Master cy li nder I.D. 14.000 - 14.043 (0,5512 - 0.5529) 14.055 (0.5533)
Master piston O.D. 13.957 -13.984 (0.5495 - 0.5506) 13.945 (0.5490)
Caliper cylinder I.D. 30.230 - 30.280 (1.1902 - 1.1921 ) 30.290 (1.1925)
Caliper piston O.D. 30.082 - 30.115 (1.1843 - 1.1856) 30.140 (1.1866)
16-4
HYDRAULIC BRAKE
TORQUE VALUES
Front master cylinder reserve tank stopper
plate screw 1.2 N'm 10.1 kgl·m, 0.9 Ibf.ft)
Front brake lever pivot bolt 1.0 N'm 10.1 kgl·m, 0.7 Ibl·ft) Apply silicon grease la the sliding
surface
Front brake lever pivot nut 6.0 N'm 10.6 kgl·m , 4.4 Ibl·ft)
Front brake light switch screw 1.2 N'm 10.1 kgf.m, 0.9 Ibf.ft)
Front master cylinder holder bolt 12 N'm 11. 2 kgl·m, 9 Ibl·ft)
Front brake caliper assembly torx bolt 22 N'm 12.2 kgf.m, 16 Ibl·ft) Apply locking agent la Ihe threads
Front brake caliper mounting bolt 45 N·m 14.6 kgl·m, 33 Ibl·ft) ALOe bolt; replace with a new one
Rear master cylinder reserve tank cap screw 1.5 N·m 10.2 kgl·m, 1.1 Ibl·ft)
Rear master cylinder push rod loek nut 18 N·m 11.8 kgl·m, 13Ibl·ft)
Rear master cylinder mounting bolt 10 N'm 11.0 kgf.m, 7 Ibl·ft)
Front brake reserve tank stay bolt 12 N'm 11.2 kgf.m, 9 Ibl·ft)
Rear brake caliper mounting bolt 23 N'm 12.3 kgl·m, 17 Ibf.ft) ALoe bolt; replace with a new one
Front brake ca liper pad pin 15 N·m 11.5 kgf.m, 11 Ibf.ft)
Rear brake caliper pad pin 18 N·m 11.8 kgl·m, 13 Ibl·ft)
Brake hose oil bolt 34 N'm 13.5 kgl·m, 25 Ibl·ft)
Front brake hose 3-way joint bolt 10 N·m 11.0 kgf.m, 7 Ibl·ft)
Rear brake hose joint screw 1.5 N·m 10.2 kgl·m, 1.1 Ibl·ft) Apply locking agent la the threads
Front brake caliper bleed valve 8.0 N·m 10.8 kgl·m, 5.9 Ibf.ft)
Rear brake ca lipe r bleed valve 6.0 N'm 10.6 kgl·m, 4.4 Ibf.ft)
Main step bracket mounling bo lt 37 N·m 13.8 kgl·m, 27 Ibl·ft)
Rear brake res erve tank mounting bolt 12 N·m 11.2 kgl·m, 9 Ibl·ft)
TOOL
Snap ring pliers

07914-SA50001
16-5
HYDRAULIC BRAKE
TROUBLESHOOTING
Brake lever/peda I soft or spongy
• Air in hydraulic system
• Leaking hydraulic system
• Cantaminated brake pad/disc
• Warn caliper piston seal
• Warn master cylinder piston cups
• Warn brake pad/disc
• Contaminated caliper
• Caliper not sliding properly (rea r)
• Clagged fluid passage
• Warped/deformed brake disc
• Sticking/worn caliper piston
• Sticking/worn master cylinder piston
• Contaminated master cylinder
• Bent brake lever/peda I
Brake lever/peda I hard
• Caliper not sliding properly (rear)
• Clagged/restricted fluid passage
• Warn caliper piston seal
• Sticking/worn master cylinder piston
• Bent brake lever/peda I
• Sticking rear brake pedal sliding surface (pillaw bali)
Brake drags
• Contaminated brake pad/disc
• Misaligned wheel
• Warped/deformed brake disc
• Caliper not sliding properly (rear)
• Clagged/ restricted hydraulic system
• Sticking master cylinder piston
• Sticking rear brake pedal sliding surface (pillaw bali)
16-6
HYDRAULIC BRAKE
BRAKE FLUID REPLACEMENTI AIR
BLEEDING
I NOTICE
Spil/ed fluid can damage painted, plastic, or rubber
parts. Place a rag over these parts whenever the
system is serviced.
• 00 not allow foreign material to enter the system
when lilling the reserve tank.
BRAKE FLUID DRAINING
Front: Turn the handlebar until the reserve tank is parallel r:--;..- - - .
to the ground, betore removing the reserve tank
cap.
Remave the screw, stopper plate and reserve tank
cap.
Remave the set plate and diaphragm .
Rear: Remave the screws and reserve tank cap.

Remave the set plate and diaphragm.
Conneet a bleed hose to the caliper bleed valve.

Loosen the bleed valve and pump the brake lever or
pedal.
Stop pumping the lever or pedal when na more
Iluid Ilows out ol the bleed valve.
16-7
HYDRAULIC BRAKE
BRAKE FLUID FILLINGIAIR BLEEDING
Fill the reserve tank with DOT 4 brake fluid from a
sealed container.
NOTE:
• Use only DOT 4 brake fluid from a sealed con-
tainer.
• Do not mix different types of fluid . There are not
compatible.
Con neet a commercially available brake bleeder to
the caliper bleed valve.
Operate the brake bleeder and loosen the bleed
valve.
If not using an automatic refill system, add brake
fluid when the flu id level in the reserve tank is low.
• Check the fluid level aften w hil e bleeding the
brakes to prevent air trom being pumped into the
system.
• When using a brake bleeding taal, follow the
manufacturer's operating instructions.
Perform the bleeding procedure until the system is
completely flushed/bled .
• If air is entering the bleeder trom around the
bleed valve threads, seal the threads with teflon
tape.
For the front brake, close the bleed va lve and per-
farm air bleeding for the other side bleed valve.
Operate the brake lever or pedal. If it still feels
spongy, bleed the system again.
If th e brake bleeder is not available, perfo rm the fol -
lowing procedures:
Conneet a clear bleed hose to the bleed valve.
Pressurize the system wit h the brake lever or pedal
until there are na air bubbles in the fluid flowing out
of the reserve tank sma ll hole and lever or peda I
resistance is feit.
1. Squeeze the brake lever or push the brake peda!,
open the bleed valve 1/2 turn and then close th e
va lve.
NOTE:
• Do not release the brake lever or pedal until the
bleed valve has been closed .
2. Release the brake lever or pedal slowly and wait
several seconds after it reaches the end of its
trave!.
3. Repeat steps 1 and 2 until bubbles cease to
appear in the fluid coming out of the bleed va lve.
4. Tighten the bleed valve to the specified torque.
TORQUE:
Front: 8.0 N·m (0.8 kgf·m, 5.9 Ibf·ft)
Rear: 6.0 N·m (0.6 kgf·m, 4.4 Ibf·ft)
16-8
HYDRAULIC BRAKE
Front: Perform air bleeding for the other side bleed valve.
Front:
Fill each reserve tank to the upper level with DOT 4
brake fluid from a sealed container.
CAP
Reinstall the diaphragm and set plate.
On the front brake, install the reserve tank cap, stop-
per plate and tighten the screw to the specified
torque.
TORQUE: 1.2 N·m (0.1 kgf·m, 0.9IbHt)
SET PLA TE C§:)
DIAPHRAGM
SCREW
Rear: Install the reserve tank cap and tighten the screws ~R=ea=r=:= = = = =S=C=R=E=W=S==
~:::;.=~=_=_=..=...=..===~
to the specified torque. -
CAP
SET PLATE
BRAKE PAD/DISC
FRONT BRAKE PAD REPLACEMENT
Loosen the pad pins.
Remove the caliper mounting bolts and brake cali -
per.
Discard the brake caliper mounting balts.
16-9
HYDRAULIC BRAKE
Check 'he brake Push the ealiper pistons all the way in
fJuid level in the installation of new brake pads.
brake master
cylinder reserve
tank as this
operation causes
rhe level to riSB.
Remave the pad pins, pad spring and brake pads .
Clean the inside of the ealiper espeeially around the

caliper pistons.
Install the pad spring with its bent side downward.
16-10
HYDRAULIC BRAKE
Afways rep/ace the Install new brake pads to the brake ca li per.
brake pads in pairs
Install the pad pins while push ing in the bra ke pads
ra assure even disc
against the pad spring .
pressure.
Install the brake caliper to the fork leg so that the

disc is positioned between the pa ds.
NOTE:
• Make sure th at the dowel pins are installed into
the caliper bracket properly.
• Be careful not to damage the brake pa ds.
Tighten new brake caliper mounting bolts to the

specified torque.
TOROUE: 45 N·m (4.6 kgf·m. 33 IbHt)

Tighten the pad pins to the specified torque.
TOROUE: 15 N·m (1.5 kgf·m. 11 IbHt)
Check the brake operation by applying the brake
lever.
REAR BRAKE PAD REPLACEMENT

Check the brake Push the caliper piston all the way in by pushing the
caliper body inward to allow installation of new
fluid levelin the
brake master brake pads.
cylinder reserve
tank as this
operation causes
the level to rise.
16-11
HYDRAULIC BRAKE
Remave the pad pin .
Remave the brake pads and clean the inside of the

caliper especially around the ca liper piston.
Apply si licone grease to a new O-ring and install it

to the pad pi n groove.
A/ways rep/ace the Make sure the pad spring is in place and install new
brake pads in pairs brake pads securely. p-=~.!
to assure even disc
pressure.
Tighten the pad pin to the specified torque.
TORQUE: 18 N·m (1 .8 kgf·m, 13 IbHt )
16-12
HYDRAULIC BRAKE
BRAKE DISC INSPECTION
Visuallv ins peet the brake discs for damage or
cracks.
Measure the brake disc thickness with a microme·
ter.
SERVICE LlMITS:
FRONT: 3.5 mm (0.14 in)
REAR: 4.0 mm (0.16 in)
Replace the brake disc jf the smallest measurement
is less than the service limit.
Measu re the brake disc runout with a dial indicator.
SERVICE lIMITS:
FRONT: 0.30 mm (0.012 in)
REAR: 0.30 mm (0.012 in)
Check the wheel bearings for excessive plav (page
14-17), ifthe warpage exceeds the service limit.
Replace th e brake disc if th e wheel bearings are nor-
mal.
FRONT MASTER CYLINDER

I NOTICE I
Spifled fluid can damage painted, plastic, or rubber
system is servieed.
REMOVAL
Drain the front hvdrauli c svstem (page 16-7 ).
Disconneet the brake light switch wire connectors.
Remave the brake hose oil bolt, sealing washers
and brake hose evelet joint.
16-13
HYDRAULIC BRAKE
Remove the bolts trom the master cylinder hol der
and remave the master cylinder assembly.
DISASSEMBL Y
Remove the dust cover and snap ring .
TOOL:
Snap ring pliers 07914-SA50001
Remove the bolt and reserve tank from the master

cylinder.
Remove the O-ring trom the reserve tank hose joint.
Remove the pivot bolt, nut and brake lever assem-

bly.
PIVOT NUT
Remove the screw and brake light switch.
BRAKE LIGHT SWITCH
SCREW
16-14
HYDRAULIC BRAKE
Be careful not to Remove the boot and push rod.
damage the boot.
PUSH ROD
Remove the snap ring from the master cylinder

body using the special taal as shown . SNAP RING
TOOL:
Remove the master piston, spring and spring guide
from the master cylinder body.
INSPECTION
Clean th e inside of the cylinder and reserve tank
with clean brake fluid . SPRING GU lDE
Check the master cylinder and piston for abnormal
scratch es.
Check the spring for fatigue or damage.
/ M""'" ""0'
M""'" m"o,"~ I
SPRING ,
o
Measure the master cylinder I.O .
16-15
HYDRAULIC BRAKE
Measure the master cylinder piston O.O.
•
, ... 'I'
I
I
/
ASSEMBLY
1.0 N'm (Q,l kgf'm, 0,7IbHt)
1,2 N'm (0 .1 kgf·m , 0.9 IbHt)
1.2 N·m (0 .1 kgf'm, 0 ,9 IbHt)
12 N·m (1.2 kgf·m, 9lbHt)
• Keep the piston, cups, spring, snap ring and boot

MASTER CYLINDER
as a set; do not substitute individual parts.
Coat new piston caps with clean brake fluid and
install them to the master piston . SPRING
-.>- /
Coat the master piston and piston cups with clean
brake fluid,
Install the spring guide into the spring. MASTER
/' PISTON
~
When installing the Install the spring guide/spring and master piston
cups, do not a/low into the master cylinder.
the tips to turn ""NGGU'"
inside out.
ftt 0
16-16
HYDRAULIC BRAKE
Be cenain ths snap Inslall Ihe snap ring wilh Ihe specia l 1001.
ring is firmly seated SNAP RING
in the grOOV8 . TOOl:
SNAP RING PLiERS
Apply silicone grease 10 conlacl s urfa ces ol Ihe

BOOT/PUSH ROD
pu sh rad and master piston.
Inslall a new bool wilh Ihe push rod.
S~
Inslall Ihe brake lighl swilch by aligning ils boss

wilh Ihe hole.
Tighlen Ihe screw 10 Ihe specilied lorque.
TORQUE: 1.2 N·m (0.1 kgl·m, 0.9 Ibl·ft)
Apply silicone grease 10 push rod li p.

Inslal l Ihe brake 'Ieve r by aligni ng Ihe ho le of Ihe
brake leve r wilh Ih e push rod.
16-17
HYDRAULIC BRAKE
Apply silicone grease to the brake lever pivot bolt
sliding surface. BRAKE LEVER
Install the brake lever pivot bolt and nut.
Tig hten the pivot bolt to the specilied torqu e.
TORQUE: 1.0 N·m (0.1 kgl·m, 0.7Ibl·ftl
Hold the pivot bolt and tighten the pivot nut to the
specified torque.
TORQUE: 6.0 N·m (0.6 kgl·m, 4.4 Ibl·ftl
.....
PIVOT NUT
Apply brake Iluid to a new a -ring and install it to the

reserve tank hose joint. al ~., a-RING
After installing a Install the reserve tank hose joint into the master
snap ring, a/ways cylinder and secure the joint with the snap ring . BOLT DUSTCOVER
rorate it in its
groove ro be sure it TOOL:
is fully seated. Snap ring pliers 07914-SA50001
Install the dust cover.
Install the reserve tank stay onto the master cylinde r
and tighten the mounting bolt to the specilied
torqu e.
TORQUE: 12 N·m (1.2 kgl·m, 9 Ibl·ftl
INSTALLATION
Insta" the master Install the master cylinder assembly, master cylin-
cylinder ho/der w;th der holder and balts.
its 'UP' mark facing
Align the end ol the master cylinder with the punch
up. mark on the handle bar.
Tighten the upper bolt lirst, then the lower bolt to
the specilied torque.
TORQUE: 12 N·m (1.2 kgl·m, 9 Ibl·ftl
16-18
HYDRAULIC BRAKE
Install the brake hose evelet joint with new sealing
washers and oil bolt.
Push the evelet joint aga inst the stopper then
tighten the o il bolt to the specified torque.
TORQUE: 34 N·m (3 .5 kgf·m, 25 Ibf·ft)
Connect the brake light switch connectors.
Fill bra ke fluid and bleed air the rear brake hvdraulic
svstem (page 16-8).
REAR MASTER CYLINDER

I NOTICE I
Spilled flu id ca n damage painted, plastic, or rubber
system is serviced.
REMOVAL
Drain the re ar hvd raulic svstem (page 16-7).
Remave the balts and right passenger step bracket.
Remove the bolt and rear master cylinder reserve

tank.
16-19
HYDRAULIC BRAKE
Avoid spil/ing fluid Remove the brake hose oil bolt, sealing washers
on painted, plastic, and brake hose eyelet joint.
or rubber parts.
Place a rag over
these parts
whenever the
system is serviced.
Remove the cotter pin, nut. washers and bolt.
Remove the rear master cylin der mounting balts

and master cylinder guard plate.
DISASSEMBLY
Remove th e screw and hose joint from the master
cylinder. HOSE JOINT/O-RING
Remove the O-ring trom the hose joint.
16-20
HYDRAULIC BRAKE
Be careful not to Remave the boot from t he master cylinder body.
damage the boot. BOOT SNAP RING
Remave the snap ring from the master cylinder
body using the special taal as shown.
TOOl:
Snap ring pHers 07914-SA50001
SNAP RING PLiERS
Remove the push rod assembly, master piston and

spring. SPRING PRIMARY CUP
Clean the inside of the cylinder with clean brake

fluid .
Check the pillow bali movement.
Replace the tie rad if the pillow bali does not move
smoothly. PlllOW BAll
MASTER PISTON /~
PUSH ROD ASSEMBl Y "
TIE ROD
INSPECTION
Check the piston boot, primary cup and secondary
cup for fatigue or damage.
Check the master cylinder and piston for abnormal
scratches.
Measure th e master l. O.
Measure the master cylinder piston O.O.
16-21
HYDRAULIC BRAKE
ASSEMBLY
"11 oS~ O-RING
MASTER CYLINDER
SPRING
....~~I
PRIMARY CUP
SET PLATE o
•
1.5 N'm (0.2 kgf·m, 1.1 Ibf.lt)
DIAPHRAGM
PUSH ROD ASSEMBLY
Keep the piston, Coat all parts w ith clean brake fluid betore assem ~
cups, spring, snap
ring and boot as a
set; do not
biV.
Etl I
substitute individual
parts.
When insrafling the Dip the piston in brake fluid .

-. ~
. ..
PR/IMARY CUP
~~
SECONDARY CUP
.
cups, donotallow Install the spring to the primary cup. SPRING / BOOT
~
the Nps ta turn Instal! the spring/primary cup and master piston
inside out. assembly into the master cylinder.
Apply silicone grease to the piston co nta ct area of
the push rad .
MASTER PISTON PUSH ROD ASSEMBL Y
Install the push rod assembly into the master cylin-

SNAP RING
der.
Be certain the snap Install the snap ring w ith the special taal.
ring is firmly seated
TOOL:
in the groove.
Install the boot.
SNAP RING PLiERS
16-22
HYDRAULIC BRAKE
Apply brake fluid to a new O-ring and install it onto
the hose joint.
Install the hose joint into the master cylinder.
Apply locking agent to the hose joint screw threads.

Tighten the screw to the specified torque. HOSE JOINT
TORQUE: 1.5 N·m (0.2 kgf.m, 1.1Ibf.ft)
o
UiIil3 SCIREIN
INSTALLATION
Install the master cylinder and guard plate, tighten
th e bolts to the specified torque.
Connect the bra ke pedal to the push rod lower joint.

Install the bolt, washers, nut and tighten the nut
securely.
Install a new cotter pin.
16-23
HYDRAULIC BRAKE
Install the brake hose w ith the oil bolt and new seal-
ing washers .
Push the evelet joint against the stopper, then
tighten the oil bolt to the specified torque.
Route the brake Insta ll the reserve tank and tighten the bolt to the
hose properly specified torque.
(page 1-21).
TORQUE: 12 N·m 11.2 kgf·m, 9lbHt)
Install th e right passenger step bracket and tighten

the balts to the specified torque.

Adjust th e rear brake pedal height Ipage 4-30).
Fill brake fluid and bl eed air the rear brake hvdraulic
svstem Ipage 16-8).
16-24
HYDRAULIC BRAKE
FRONT BRAKE CALIPERS
t NOTICE I
Spil/ed fluid can damage painted, plastic, or rubber
system is serviced.
REMOVAL
Drain the front brake hydraulic system (page 16-7).
Remave the brake hase ail bolt, sealing washers
and brake hase eyelet joint.
Remave the brake pads (page 16-9).
DISASSEMBL Y
Place a shop towel over the piston.
Do not use high App ly small squirts of air pressure ta the fluid inlet
pressure air or bring to remove the pistons.
the nozzls toD close
to the in/et.
Remave the torx balts and separate the caliper

BOLTS
halves.
16-25
HYDRAULIC BRAKE
Mark the pistons ta Remove the following:
ensure correct PISTON 8
- Joint sea l
reassembly.
- Caliper piston A
- Caliper piston 8
JOINT SEAL PISTON A

Be careful not to Push the dust seals and piston seals in and lift them
damage the piston out.
sliding surface. Clean the seal grooves with clean brake fluid.
II\ISPECTION
Check the caliper cylinder for searing or other dam-
age. CYLINDER A CYLINDER 8
Measure the caliper cylindér I.O.
SERVICE LIMITS:
Cylinder A: 32.140 mm (1.2654 in)
Cylinder B: 30.340 mm (1.1945 in)
Check the caliper pistons for scratch es, searing or

other damage.
Measure the caliper piston O.O.
SERVICE LIMITS:
Piston A: 31.957 mm (1.2581 in)
Piston B: 30.157 mm (1.Ï873 in)
16-26
HYDRAULIC BRAKE
ASSEMBLY
(\
PAD SPRING
iW 22 N'm (2.2 kgf·m, 16Ibf·ft)
CAL/PER PISTONS
8.0 N·m (0.8 kgf·m, 5.9 Ibf·ft)
15 N·m (1.5 kgf·m, 11Ibf·ft)

..
.....~I
PISTON SEAL
S~
~ 0::0;;::.,
DUST SEAL
BRAKE PADS
Coat new piston seals with clean brake f1uid .

PISTON SEAL
Coat new dust seals with silicone grease .
Install each piston Install the piston and dust seals into the grooves of
seal, dust seal and the caliper body.
caliper piston În Coat the caliper pistons wÎth clean brake fluid and
"
liS~
theirproper install them into the caliper cylinder with their open
Jocation's. ends toward the pad.
PISTON B
Install a new joint seal into the fluid passage on the

PISTON B
caliper.
PISTON A
16-27
HYDRAULIC BRAKE
Assembie the caliper halves.
Apply locking agent to the caliper assembly torx
bolt threads.
Install and tighten the torx bolts to the specified
torqu e.
INSTALLATION
Install the brake pads (page 16-9).
lighten new caliper mounting bolts to the specified
torque.
Install the brake hose eyelet joint to the caliper body
with new sea ling washers and Dil bolt.
Push the brake hose eyelet joint to the stopper on
the ca liper, then tighten the oil bolt to the speci f ied
torque.
Fill brake fluid and bleed air from the front brake l~~~!,.':;~!!:!!::.n"
hydraulic system (page 16-7).
REAR BRAKE CALIPER

I NOTICE I
Spil/ed ffuid can damage painted, plastic, or rubber
system is serviced.
REMOVAL
Drain the rear brake hydraulic system (page 16-7).
Rem ove the rear brake pads (page 16-11) .
Remove the oil bolt. sealing washers and brake
hose eyelet joint.
Remove the rear wheel (page 15-7).
HYDRAULIC BRAKE
DISASSEMBL Y
Remove the caliper bracket and pad spring from the
caliper body. CALIPER BRACKET
Remove the retainer trom the caliper bracket.

Remove the caliper pin boot and bracket pin boot.
RETAINER
BOOT BOOT
Place a shop towel over the piston .
Do not use high Position the caliper body with the piston down and
pressure Bir or bring apply small squirts of air pressure to the fluid inlet
the nozzJe toa close to re move the piston.
to the in/er.
Be careful not to Push the dust seal and piston seal in and lift them
damage the piston out.
sliding surface.
Clean the seal grooves with clean brake fluid .
INSPECTION
Check the caliper cylinder for scoring or other dam-
age.
Measure the caliper cylinder I.O.
16-29
HYDRAULIC BRAKE
Check the caliper piston lor scratch es, scoring or
other damage.
Measure the caliper piston D.D.
SERVICE LIMIT: 30.140 mm (1 .1 866 in)
ASSEM13LY
I PISTON
BRAKE PADS
Coat a new piston seal with clean brake fluid.

Coat a new dust seal with silicone grease. A ..~ PISTON SEAL
Install the piston seal and dust seal into the groove
14 .....
ol the caliper body.
Coat the ca liper piston with clean brake Iluid and
install it into the caliper cylinder with its open end
towa rd the pad.
16-30
HYDRAULIC BRAKE
Install the retainer onto the caliper bracket.
CALIPER BRACKET
Install the pad spring into the caliper body.
II boot is hard or deteriorated, repla ce it with a new
one.
Apply silicone grease to the inside of the boot and RETAINER
its sliding surface.
Install the calipe r cylinder onto the caliper bracket.
INSTALLATION
Install the rear wheel (page 15-13).
Install the brake hose eyelet joint to the caliper body
with new sealing washers and Dil bolt.
Push the brake hose eyelet joint to the stopper on
the caliper, then tighten the oil bo lt to the specified
torque.
TORQUE: 34 N'm (3.5,kgf·m, 25Ibf·.ft)
Install the rear brake pads.
Fill brake fluid and bljled air from the rear ·liJrake
I
hydraulic system (page) 6-8).
BRAKE PEDAL
REMOVAL
Unhook the rear brake light switch spring from th ~ r------------------,
brake pedal.
Remove the rear brake light switch from tlle ,main
step bracket.
SPRING BRAKE PEDAL ----

Remave the muffler ,guard bolt, heat guard .9.olt, ~:;:;:;~:-:::;;:~~--_;;:::::;:;;::::~
washer, main step bracket ,mounting balts and
bracket assembly Irom the fram e.
I
16-31
HYDRAULIC BRAKE
Remove the cotter pin, nut, bolt, washers and dis-
cannect the push rad from the brake peda!.
Unhaak the brake pedal return spring .
Remove the snap ring , th rust washer, and wave - -........~

washer.
Remave the brake pedal from the main step bracket.
INSTALLATION
STEP BRACKET ASSEMBL Y
SNAP RING
THRUST WAS HER
RETURN SPRING
WAVEWASHER BRAKE PEDAL
16-32
HYDRAULIC BRAKE
Apply g rease to the brake peda I sliding surface.
Install the brake peda I, wave washer, and th rust
washer onto the main step bracket.
After installing a Install the snap ring securely.

snap ring, a/ways
Hook the brake pedal return spring.
rotate ft in fts
groove ta be sure it Install the bolt, washers, nut and tighten the nut
is fully seated. securely.
Install a new cotter pin securely.
Install the main step bracket assembly onto the

frame.
Tighten the main step bracket mounting balts to the
specified torque.
TORQUE: 37 N ·m (3.8 kgf·m, 27 IbHt)
Tighten the muftier guard bolt securely.

Install the was her and heat guard bolt, tighten the
heat guard bolt securely.
Install the rear brake light switch .

Hook the rear brake light switch spring to the brake
pedal.
Adjust the rear brake light switch operation
(page 4-31 ).
--.....
SPRING BRAKE PEDAL
16-33
MEMO
17. BATTERY/CHARGING SYSTEM
SYSTEM DIAGRAM· ...... ··· ····· ···· .. ·.. ·····.. ··· 17-2 CHARGING SYSTEM INSPECTION· ········ 17-7
SERVICE INFORMATION ····················· ····17-3 ALTERNATOR CHARGING COIL············· 17-8
TROUBLESHOOTING .... :.. ························17-5 REGULATOR/RECTIFIER ...... .. ................. 17-8
BATTERY· .. ········· ················· ······················17-6
EI
17-1
BATTERY/CHARGING SYSTEM
SYSTEM DIAGRAM
MAIN FUSE
BATIERY
REGULATOR/RECTIFIER
,----<Lro-----R-------.
MAIN FUSE
e EB
BATTERY
30A
Y Y Y Y Y Y
REGULATOR/RECTIFIER Y: Yellow
G: Green
A: Red
ALTERNATOR
17-2
BA TIERY /CHARGING SYSTEM
SERVICE INFORMATION
GENERAL
AWARNING
• The battery gives alf explosive gases; keep sparks, flames and eigarettes away. Provide adequate ventilation when
charging.
• The battery contains sulfurie acid (electrolytel. Contact with skin or eyes ma y cause severe burns. Wear protective
clothing and a face shield.
- If electrolyte gets on your skin, flush with water.
- If electrolyte gets in you r eyes, flus h with water for at least 15 minutes and ca ll a physician immediately.
• Elect rolyte is poisonous,
- If swallowed, drink large quantities of water or milk and call your local Poison Control Center or a call a physieian
immediately.
NOTICE
• A/ways turn OFF the ignition switch befare disconnecting any e/ectrical component.
• Some e/ectrical components may be damaged if terminals or connectors are cannected or disconnected while the igni-
tion switch is ON and CUffent is present.
• Far extended stora98, re move the battery, give it a tuil charge, and store it in a cool, dry space. Far ma xim um service
life, charge the sta red battery every!Wo weeks.
• Far a battery remaining in a sto red motorcycle, di sco nneet the negative battery cable trom the battery terminal.
• Th e maintenance free battery must be replaced when it reaches the end of its service life.
• The battery can be damaged if overcharged or undercharged, or if left to discharge for a long periad. These same con-
ditions con tribu te to shortening the "li fe span" of the battery. Even under normal use, the performance of the battery
deteriorates after 2-3 years.
• Battery vol tage may recover after battery cha rging, but under heavy laad, battery voltage will drop quickly and eventu-
ally die out. For th is reason , the charging system is aften suspected as the problem . Battery overcharge aften results
from problems in the battery itself, wh ich may appear to be an overcharging symptom. If one of the battery cells is
shorted and battery voltage does not increase, the regulator/rectifier supplies ex ce ss voltage to the battery. Under these
cond itio ns, the electrolyte level goes down quickly.
• Befare troubleshooting the charging system, check for proper use and maintenance of the battery. Check if the battery
is frequently under heavy laad, such as having the headlight and taillight on for long periods of time without riding the
motoreycIe.
• The battery will self-discha rg e when the motorcycle is not in use. For this reason , charge the battery every tWQ weeks to
prevent sulfatio n from occurring .
• When checking the charging system, always follow the steps in the troubleshooting flow chart (page 17-5).
• For battery chargi ng, do not exceed the charging current and time specified on the battery. Use of excessive current or
cha rging time may damage th e battery.
• For alternator remaval (page 11-4).
BATTERV CHARGING
• Turn power ON/OFF at the charger, not at the battery terminal.
• For battery charging, do not exceed the cha rging current and time specified on the battery. Using excessive current or
extending the charging time may damage the battery.
• Qui ck charging should only be done in an emergency; slow charging is preferred.
BATTERV TESTING
Refer to the instru ction in the Operation Manual for the recommended battery tester for details about battery testing. The
re commended battery tester puts a "Ioad" on the battery 50 that the actual battery condition ca n be measured .
Recommended battery tester: Micro 404XL (U.S.A. on IV), BM-210 or equivalent
SPECIFICATIONS
ITEM SPECIFICATIONS
Battery Ca pa city 12V 8.6Ah
Current leakage 2.0 mA max.
Vol tage (20°C/68° F) Fully
13.0 - 13.2 V
charged
Needs
Below 12.4 V
charging
Charging current Normal 0.9 Al5 - 10 h
Quick 4.5 Al1 h
Alternator Capacity 0.342 kW/5,OOO rpm
Charging coil resistance (20°C/68° F) 0.1 1.0 n
17-3
BATTERY /CHARGING SYSTEM
TOOLS
Motoreyele battery analyzer Christie battery eharger
Micro 404XL IU.S.A. only) MC101212T IU.S.A. only)
17-4
BA TIERYICHARGING SYSTEM
TROUBLESHOOTING
BATTERY IS DAMAGED OR WEAK
1. BA TTERY TEST
Remave the battery (page 17-6).
Check the battery condition using the recommended battery tester.
Recommended battery tester: Micro 404Xl (U.S.A. only), BM-210 or equivalent
Is the battery in good condition ?
NO - Faulty battery
YES - GO TO STEP 2.
2. CURRENT lEAKAGE TEST
Install the battery (page 17-6).
Check the battery current leakage test (page 17-7).
Is the current leakage below 2.0 mA?
YES - GO TO STEP 4.
NO - GO TO STEP 3.
3. CURRENT lEAKAGE TEST WITHOUT REGULATOR/RECTIFIER CONNECTED
Disco nneet th e regulator/ rectitier connector and ree heek th e battery current leakage.
Is the current leakage below 2.0 mA?
YES - Faulty regulator/recti!ier
NO - . Shorted wire harness
• Faulty i9nition switch
4. AlTERNATOR CHARGING COll INSPECTION
Check the alternator charging coil (page 17-8).
Is the alternator charging coil resistance within 0.1- 1.0 n (20"C/68°F)?
NO - Faulty charg ing coil
YES - GO TO STEP 5.
5. CHARGING VOLTAGE INSPECTION
Measure and record the battery vo ltage using a digital multimeter (page 17-6).
Start the engine.
Measure the charging vol tage (page 17-7).
Compare the measurement to resuJt of the following calculation .
Standard:
Measured BV < Measured CV < 15.5 V
• BV = Battery Voltage (page 17-6)
• CV = Charging Voltage (page 17-7)
Is the measured charging voltage within the standard voltage?
YES - Faulty battery
NO - GO TO STEP 6.
6. REGULATOR/RECTIFIER SYSTEM INSPECTION
Check the voltage and resistance at the regulator/ reeti!ier connector (page 17-8) .
Are the results of checked voltage and resistance correct7
YES - Faul ty regulator/recti!ier
NO - . Open circuit in related wire
• Lo ase or paor cantacts of related terminal
17-5
BATTERY /CHARGING SYSTEM
BATTERY
Always turn rhe Remave the se at (page 3-4) .
ignition switch OFF NEGATIVE
Disconneet the negative cable and then the positive
before removing
cable.
the battery.
Remove the battery holder band and battery.
Conneet the Install the battery in the reve rse order of removal.
positive terminal
After installi ng the battery, coat the t erminals with
first and then the
clean grease.
nega tive cabie.
VOLTAGE INSPECTION
Measure the battery voltage us ing a digital
multimeter.
VOLTAGE:
Fully charged: 13.0 - 13.2V
Under charged: Below 12.4V
TOOl:
Oigital multimeter Commercially available
BATTERY TESTING
Reter to the instructions that are appropriate to the
battery testing equipment available to you.
TOOl:
Battery tester Micro 404Xl (U.S.A . only),
BM-210 or equivalent
BATTERY CHARGING (U.S.A. only)

Refer to the instructi ons that are appropriate to the
battery charging equipment available to you.
TOOl:
Christie battery charger MC1012/2T (U.S.A. o nly)
17-6
CHARGING SYSTEM INSPECTION

CURRENT LEAKAGE INSPECTION
Remave Ihe seal (page 3-4).
Turn Ihe ignilion swilch OFF and disconnecl Ihe bal-
lery negalive cable Irom Ihe battery.
Connecl Ihe ammeler (+) probe la Ihe negalive H
cable and ammeler H probe la Ihe battery H lermi-
nal.
Wilh Ihe ignilion swilch OFF, check lor currenl leak-
ag8 .
• When measuring current using a tester, set it to a
high range, and Ihen bring Ihe range down la an
a ppropriale level. Currenl flow higher Ihan Ihe
range selecled may blow oul Ihe luse in Ihe
tester.
• While measuring current, do not turn the ignition
swilch ON. A sudden surge ol currenl may blow
out the fuse in the tester.
SPECIFIED CURRENT LEAKAGE: 2.0 mA max.
Il currenl leakage exceeds Ihe specilied value, a
short circuit is li kely.
Lo cate the shorted circuit by disconnecting connec-
tions one by one and mea suring the current.
CHARGING VOLTAGE INSPECTION

Be su re the battery is in good conditio n betore per-
lorming Ihis lest.
Do not disconneet Warm the engine to narmat operating temperature .
the battery or any Stop the engine, and con neet th e multimeter
cable in the between the positive and negative terminals of the
charging system battery.
without first
• To prevent a short, make absolutely certain
switching OFF the
which are th e positive and negative terminals or
ignition switch.
cable.
Faifure ra fol/ow this
precaution can Reslart Ihe engi ne.
damage the tester Wilh Ihe headlighl on Hi beam, measure Ihe vollage
or e/eerriesl on th e multimeter when th e engine runs at 5,000
components. rpm .
Standard:
Measured BV < Measured CV < 15.5 V
at 5,000 rpm
=
BV Battery Voltage (page 17-6)
=
CV Charging Voltage
ALTERNATOR CHARGING COIL
INSPECTION
Remave the left middle cowl (p age 3-8).
ft is not necessary Disconneet the alternator 3P (Natural) connector.
to remove the
stator coi! to make
this test.
Measure th e resistance between all Yellow termi-

nals.
Standard: 0.1 - 1.0 n (at 20°C/68°F)

Check lo r continu itv between all Yellow terminals
and ground .
There should be na continuitv.
II readings are lar bevond the standard, or il anv
wire has contin uity to ground, repla ce the stator.
For alternator remaval (page 11 -4).
REGULATOR/RECTIFIER
SYSTEM INSPECTION
It is not necessary Remave the left middle cowl(page 3-8).
to remove the
Disconneet the regulator/rectilier 2P (Natural ) con-
stator coil to
nector and alternator 3P (Natural) connector, and
perform this test.
check it tor loose contact or corroded terminals.
II the regulated voltage reading (page 17-3) is out ol
the specification, measure the voltage between con-
nector terminals (wire side) as follows:
ITEM TERMINAL SPECIFICATION

Batterycharging Red (+)and Battery vo ltage
line ground (-) should appear
Charging coi l Yellow and Ye l- 0.1 la n at
Hne low (20°C/68°F)
Ground Hne Green and Continuity
ground should exist
If all compone nts of the cha rging system are narmal

and there are no loose connections at the reguiatorI
rectifier co nnecto rs , repla ce the regulator/rectifier
unit.
17-8
BATTERY/ CHARGING SYSTEM
REMOVAL/INSTALLA TION
Remave the left middle cowl (page 3-8).
Disconneet the alternator 3P (Natural) connector.
Disconnect the regulatorlrectifier 2P (Natural) con-
nector.
Remove the balts, washers, wire damp and regula-
tor/rectifier unit stay.
Remave the balts, nuts and regulator/rectifier unit

from the stay.
17-9
MEMO
18. IGNITION SYSTEM
SYSTEM DIAGRAM···· .. ·.. ·........ ·.. ···· ········· 18-2 IGNITION SYSTEM INSPECTION ··· ········· 18-5
SERVICE INFORMATION ···· ····· ·········· ······ 18-3 CKP SENSOR····· ····························· ·········· 18-7
TROUBLESHOOTING ········· ·· ·· ··············· .. · 18-4 IGNITION TIMING .................................... 18-7
18-1
IGNITION SYSTEM
SYSTEM DIAGRAM
ECM
KNOCK SENSOR
DIRECT IGNITION COIL
NEUTRAL SWITCH
CLUTCH swrra. SIOESTANO SWITCH FUse IGNITION MAlN FUSE
r~ WN-[-~O-O-R18I
lIlA
___ R
SWlTOi 3QA
~~----,
'''~ .
"
WN1[ W1B1
l ENGINE STOP
SWlTCloI
r~----4~
To Bink Angll BI 81.J
s._
""'L-I- - - " ' "
ENGINESTOP
AElA"
FUSE ZOA
T [)I(lO(' 8P
WN R~_
WN - +----+-f-J
+" ...
WI8I
G,
y
r~" ~
g'w,,"
~e-c"~g 0 R: Rld
G: Or. .n
V: .,.lIow
L,,:LlIl/llg,.. n
Gr:Grly
81: ElI.cIc
DIRECT IGNITION COIl C!CP SENSOR CMP SENSOR Bu: 8h••
W: Whlt.
18-2
IGNITION SYSTEM
SERVICE INFORMATION
GENERAL
NOTICE
• The ECM may be damaged if dropped. Also if the connector is disconnected when current is flowing, the excessive volt-
age may damage the module. A/ways turn aft the ignition switch before servicing.
• Use spark plug of the correct heat range. Using spark plug with an incorrect heat range ean damage the engine.
• Some electrical components may be damaged if terminals or connectors are connected or disconnected while the igni-
tion switch is ON and current is present.
• When servicing the ignition svstem , alwavs follow the steps in the troubleshooting sequence (page 18-4).
• This motorcvcle's lCM is built into th e ECM.
• The ignition timing does not normallv need to be adjusted since the ECM is factory preset.
• A faulty ignition system is often ref ated to poor connections. Check those connections betore proceeding. Make sure the
battery is adequatelv charged. Using the starter motor with a weak battery results in a slower engine cranking speed as
weil as no spark at the spark plug.
• This motorcycle features direct ignition coils, where the ignition coil and spark plug cap are integrated. There are four
direct 19n1tion eoils.
• For PGM-FI troubleshoating information (page 6-13).
• The folJowing components information
- Ignition switch (page 20-17)
- Sidestand switch (page 20-20)
- Clutch switch (page 20-19)
- Neutral switch (page 20-20)
SPECIFICATIONS
ITEM SPECIFICATIONS
Spark plug (Iridium) L NGK IMR9C-9HES
) OENSO VUH270
Spark plug gap 0.80 0.90 mm (0.031 0.035 in)
CKP sensor peak voltage 0.7 V minimum
Ignition timing ("F"mark) 7.8° BTOC at idle
TORQUE VALUE
Timing hole cap 18 N·m (1.8 kgf·m, 13 IbHt) ApplV grease to the threads
TOOLS
Peak voltage adaptor Test probe IgnitianMate peak voltage tester

07HGJ-0020100 (Not avai lable in 07ZAJ-ROJAll0 MTP07-0286 (U.S.A. onlV)
U.S.A.)
with commerciallv available digital

multimeter (impedance 10 MnJOCV
minimum )
18-3
IGNITION SYSTEM
TROUBLESHOOTING
• Inspect the lollowing belare diagnosing the system.
- Faulty spark plug
- Lease direct ignition coil and spark plug connection
- Loase direct ignition coil connectors
- Water gat into the direct ignition coil (shorting the ignition coil secondary voltage)
• II there is na spark at one cylinder, temporarily exchange the direct ignition coil with the other good one and perform
the spark test. II there is spark, the original direct ignition coil is laulty.
• "Initial voltage " of the ignition primary coil is battery voltage with the ignition switch turned ON and engine stop switch
turned "0 " (The engine is not cranked by the starter motor).
No spark at all plugs
Unusual condition Probable cause (Check in numerical order)
19nition coil No initial voltage with the ignition 1. Faulty engine stop switch
primary volt- switch ON and engine stop switch 2. Lease or poor connect of the direct ignition coil pri-
age turned "0 " (other electrical compo- mary wire terminal, or an open circuit in primary coil
nents are normal) (Check at the ECM connector)
3. Faulty ECM (in case when the initial voltage is normal
while disconnecting ECM connector)
Initial voltage is normal, but it drops l. Undercharged battery
down to 2 - 4 V while cranking the 2. An open circuit or loose connection in ECM Green wire
engine. 3. An open circuit or loose connection in Blue/ black, Yel-
low/white, Red/ blue and Red/yellow wires between the
direct ignition coils and ECM
4. Faulty sidestand switch, clutch switch or neutral switch.
5. An open circuit or loo se connection in No. 4 related cir-
cuit wires
- Clutch switch line: Green/white wire
- Sidestand switch line: Green/w hite wire
- Neutra l switch line: Light green wire
6. Faulty CKP sensor (measure the peak voltage).
7. Faulty ECM (in case when above No. 1 - 7 are normal).
B. Faulty direct ignition coil
Initial voltage is normal, but does l. Faulty spark plug or leaking ignition coil secondary cur-
not spark. rent ampere.
2. Faulty direct ignition coil (s)
CKP sensor Peak voltage is lower than standard l. The multimeter impedance is toa low; below 10 Mnt
value . DCV.
2. Cranking speed is toa low (battery under charged).
3. The sampling timing olthe tester and measured pulse
were not synchronized Isystem is normal if measured
voltage is over the standard voltage at least once).
4. Faulty CKP sensor (in case when above No. 1 - 3 are
normal)
No peak voltage. l. Faulty peak voltage adaptor
2. Faulty CKP sensor
3. Faulty CMP sensor
18-4
IGNITION SYSTEM
IGNITION SYSTEM INSPECTION
• II there is na spark at any plug , check all connec-
tians for /oose or poor contact betore measuring
each peak voltage.
• Use the recommended digital multimeter or
com mercia lly avai lable digital multimeter with
an impeda nce ol 10 MnJDCV minimum.
• Th e display val ue dillers depending upon the
inte rnal im peda nce of th e multimeter.
• II t he peak voltage tester IU. S.A. only) is used,
fo llow the m anufactu rer' s instruction.
Connect the peak voltage tester or peak voltage
adaptor to t he digital mult imeter. DIGITAl MULTIMETER
.............. .
TOOl:
IgnitionMate peak voltage tester MTP07-0286
IU.S.A. only) or
INot uvailable in
U.S.A.)
l impedunce 10 Mn /DCV minimum)
PEAK VOLTAG E ADAPTOR
IGNITION COIL INITIAL VOLTAGE

• Check all system connections betore inspection.
If the system is disconnected, incorrect initial
vo ltage might be measured .
• Check cyli nder compression and check t hat the
spark plugs are insta lied correctly.
Disconneet the direct ignition eoils trom the spark 12p(:oi~iË'ë'Tciii
plugs Ipage 4-9).
Con nect the direct ignition coil 2P IWhite) connec-
tors to the direct ig ni tion coil.
Shift the tra nsmission into neutra I.
Connect a known-good spark plu g to the di rect ig ni-
tion coil and ground the spark plug to the cylinder
head as do ne in a spark test.
Disconnect th e di rect ig nition coi l 2P IWh ite) con-

2P CONNECTOR
necto r.
IWire side/lema le terminals)
Turn the ignition switch ON and engine stop switch
"0".
Measure the initi al vo ltage. Black
Connection: Blaek 1+)- Ground 1-)
Standard: Battery voltage
18-5
IGNITION SYSTEM
CKP SENSOR PEAK VOLTAGE
• Check all system connections before inspection .
Ifthe system is disconnected, incorrect peak volt-
age might be measured.
• Check cylinder compression and check th at the
spark plugs are insta lied correctly.
Remove the luel tank cover (page 3-9).
Disconnect the ECM 33P (G ray ) connector lrom the
ECM.
Connect the peak voltage tester or peak voltage

adaptor pro bes to the connector terminal ofthe wire 33P (Gray) CONNECTOR
si de. (Wire side/lemale terminals)
Yellow ~g~
Connection: Vellow tenninal (+) - Ground (-)
TOOLS:
(822) ti
(U.S.A . only) or
(Not available in
U.S.A.)
(impedance 10 Mfl/DCV minimum)
Test probe 07ZAJ-RDJA 110 PEAK VOLTAGE ADAPTOR
Crank the engine and read the peak voltage.

PEAK VOLTAGE: 0.7 V minimum
II the peak voltage measured at ECM connector is
abnormal, measure the peak voltage at the CKP sen-
sor connector.
Lift and support the luel tank (page 4-5).
2P CONNECTOR
Disconnect the CKP sensor 2P (Black) connector and
connect the tester probes to the terminal (Vellow
and White/yellow).
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.
• II the peak voltage measured at the ECM is
abnormal and the one measured at the CKP sen-
sor is normal, check the 2P (Black) connector lor
loose connection and the wire harness for an
open circuit or loose connection .
• II both peak voltage measured are abnormal,
check each itèm in the troubleshooting chart
(page 18-4).
II all items are normal, the CKP sensor is laulty.
For CKP sensor replacement (page 18-7).
18-6
IGNITION SYSTEM
CKP SENSOR
Remove the right crankcase cover (page 10-5).
",'m.ID GROMMET
Remove the wire grommet trom the cover.
Remove the bolts and CKP sensor.
Apply sealant to the grommet seating surface.
Install the CKP sensor and grommet to the cover
groove properly.
Install the right crankcase cover (page 10-26).
CKP SENSOR
IGNITION TIMING
Warm up the angine.
Stop the engine and remove the timing hole cap.
Read the Conneet the timing light to the NO.1 direct i9nition
coil connector wire.
instructions for
timing light
Start the engine, let it idle and check the ignition
operation. timing.
IDLE SPEED: 1,400 ± 100 rpm
The i9nit10n timing is correct if the index mark on

the right crankcase cover aligns the "F" mark on the
CKP sensor rotor as shown.
18-7
IGNITION SYSTEM
Apply oil to a new O-ring and install it to the timing
ho le cap.
Apply grease to the timing hole cap threads and
tighten the timing hole cap to the specified torque.
TORQUE: 18 N·m (1 .8 kgf·m, 13 IbHt)
18-8
19. ELECTRIC STARTER
SYSTEM DIAGRAM·· ·.... ·.. ························ 19-2 STARTER MOTOR ········ ···················· ········ 19-6
SERVICE INFORMATION ··········· ··············19-3 STARTER RELAV SWITCH ........ ·.. ·.. · ...... 19-14
TROUBLESHOOTING ····· ···· ······· ·· ······ ·· ·· .. ·19-4 DIODE .................. · ............ ·.. ·.. ·· ...... · .. · .... · 19-16
19-1
ELECTRIC STARTER
SYSTEM DIAGRAM
STARTER SWITCH
IGNITION SWITCH
BATTER Y
CLUTCH SWITCH
STARTER MOTOR
NEUTRAL SWITCH
SIDESTAND SWITCH
STARTER RELAY SWITCH
STARTER EB 8
MOTOR MAIN BATTERV
FUSE
30A
L rn
CLUTCH
SWITCH
BI
BI
G/R - - - - -....
GNJ
-
G/R
t
G/R
V/R
IGNITION
./'
SWITCH
R---o--'" 0 - - RlBI
FUSE 20A
DIODE
12P
"-ill"~
Up Down
R: Red
SIDESTAND W: White
SWITCH NEUTRAL V: Vellow
2P SWITCH G: Green
G
BI: Blaek
~ Lg: Light green
19-2
ELECTRIC STARTER
SERVICE INFORMATION
GENERAL
I NOTICE
If current is kept flowing through the starter motor to turn it while the engine is not cranking over, the starter motor may be
damaged.
• Always turn the ignition switch OFF betore servicing the starter motor. The motor could suddenly start, causing serious
injury.
• The starter motor can be servieed with the engine in the frame.
• When eheeking the starter system, always follow the steps in the troubleshooting flow ehart (page 19-4).
• A weak battery may be unable to turn the starter motor quickly enough, or supply adequate ignition current.
• For the starter elutch servieing (page 10-17).
• Reter to the following components information.
- Ignition switch (page 20-17)
- Starter switch (page 20-17)
- Neutral switch (page 20-20)
- Sidestand switch (page 20-20)
- Clutch switch (page 20-19)
S PECIFICATION
Unit: mm (in)
Starter motor brush length 12.0 (0.47) 6.5 (0.26)
TORQUE VA LUE
Starter motor terminal nut 10 N'm (lO kgf.m, 7 IbHt)
19-3
ELECTRIC STARTER
TROUBLESHOOTING
Starter motor does not turn
1. Fuse Inspection
Check for blown main fuse or sub fuse (HEADLIGHT 20 A).
Is the fuse blown?
YES - Replace the fuse
NO - GO TO STEP 2.
2. Battery Inspection
Make sure the battery is fullV charged and in good condition.
Is the battery in good condition ?
YES - GO TO STEP 3.
NO - Replace the battery
3. Starter Relav Switch Operation
Check the starter relav switch operation.
You should hear the relav "CLICK" when the starter switch button is depressed.
Is there a "CLICK"?
YES - GO TO STEP 4.
NO - GO TO STEP 5.
4. Starter Motor Inspection
ApplV battery voltage to the starter motor directlv and check the operation.
Does the starter motor turn 7
YES _. Pao riv connected starter motor cable
• Faultv starter relav switch (page 19-14)
NO - Faultv starter motor (page 19-6)
5. Relay Coil Ground Wire lines Inspection
Disconneet the starter relay switch connector, and check the relay coil ground wire Hnes as below for
continuity:
1. Green/red terminal - diode - neutra I switch Hne (with the transmission in neutral and clu tch lever
released).
2. Green/ red terminal - clutch switch - sidestand switch line (in anv gear except neutral, and with
the clutch lever pulled in and sidestand up.
NO • Faulty neutral switch (page 20-20)
• Faultv diode (page 19-16)
• Faulty clutch switch (page 20-19)
• Faultv sidestand switch (page 20-20)
• Lease or poor contact connector
• Open circuit in wire harness
YES - GO TO STEP 6.
6. Starter Relay Voltage Inspection
Connect the starter relay switch connector.
With the ignition switch ON and starter switch pushed, measure the voltage at the starter relav
switch connector (between Yellow/red (+) and body ground (-)).
Js the starter relay switch operation correct?
NO - . Fau lty ignition switch (page 20-17)
• Faulty starter switch (page 20-17)
• Lease or poor contact connector
• Open circuit in wire harness
YES - GO TO STEP 7.
19-4
ELECTRIC STARTER
7. Starter Relay Switch Continuity Inspection
Conneet the starter relay switch connector.
Tu rn th e ignition switch ON and check fo r co ntinuity at the starter relay switch terminals when the
starter switch is pushed .
Is there continuityl
NO - Faulty sta rter relay switch
YES - Lease or poor contact starter rel ay switch connector
The starter motor turns when the transm ission is in neutral, but does not turn w ith the transmission in
any position except neutra I, with the sidestand up and clutch lever pulled in .
1. Clutch Switch Inspection
Ch eck th e clutch switch operation.
Is the clutch switch operation normall
NO - Fa ulty clu tch switch
YES - GO TO STE P 2.
2. Sidestand Switch Inspection
Check th e sidestand switch operation.
Is the sidestand switch operafion normal7
NO - Faulty sidestand switch (page 20-20)
YES - . Open ci rcuit in wire harness
• Lease or poor contact con necto r
Starter motor turns engine sJowly
• Low battery voltage
• Poorly connected battery cables
• Poorly co nnected starter motor cable
• Fa ul ty starter motor
Starter motor turns, but engine does not t urn
• Starter motor is running backwards
- Case assem bied improperly
- Terminals connected imp roperlv
• Faultv starter clutch
• Damaged or faulty starter d rive gear, driven gea r. idle gear and/or reduction gear
Starter relav switch "CLICK", but engine does not turn over
• Cranks haft does not turn due to engine problems
19-5
ELECTRIC STARTER
STARTER MOTOR
REMOVAL
• With the ignition switch OFF, disconneet the bat-
tery negative (-) cable belore servicing the
starter motor.
Remove the thermostat housing (page 7-8).
Open the rubber cap, th en remave the terminal nut
and starter motor cable trom the starter motor.
Remave the starter motor mounting balts and
ground cab Ie.
Remave the starter motor trom the crankcase.
Remave the Q·ring trom the starter motor.
DISASSEMBL YIINSPECTION
Remove the bolts.
BOlTS
19-6
ELECTRIC STARTER
Remave the front cover and seal ring.
FRONT COVER SEAL RING
Remove the starter motor case and seal ring .

Remove the armature from the rear cover. STARTER MOTOR CASE
ARMATURE SEAL RING
Remave the brushes and springs trom the brush

holder.
BRUSHES/SPRINGS
Check tor continuity between starter motor cable

terminal and positive brushes. Continuity:
STARTER MOTOR CABLE TERMINAL
There should be continuity.
POSITIVE BRUSHES
19-7
ELECTRIC STARTER
Check lor continuity between positive brushes (ter-
minal bolt side) and rear cover. Nocontinuity: NEGATIVE BRUSHES
There should be no continuity.

Check for continuity between positive and negative
brushes.
There should be no continuity.
REAR CO'liER POSITIVE BRUSHES
Remave the screw and negative brushes.

NEGATIVE BRUSHES
SCREW
Remove the terminal nut.

NUT
Remave the washer, insulator, terminal stopper and

a-ring .
o
TERMINAL STOPPER WASHER
19-8
ELECTRIC STARTER
Remove the terminal bolt, positive brushes and
brush holder. POSITIVE BRUSHES
BRUSH HOLDER
Y"/
TERMINAL BOLT
INSPECTION
Measure each brush length .
ti
Check the commutator tor damage or abnormal

ARMATURE
wear.
Do not use emery Check the commutator bar tor discoloration.
or sand paper on Clean th e metallic debris aft between commutator
the commutator. bars.
Repl ace the armature with a new one if necessary.
COMMUTATOR
Check tor continuity between pairs of commutator

bars. Continuity:
There should be continuity.
19-9
ELECTRIC STARTER
Check for continuity between each individual com-
mutator bar and armature shaft. No continuity:
There should be na continuity.
Check the dust seal for de.tefloration, wear or dam-

age. DUSTSEAL
Turn the inner race of the starter motor bearing with

your finger.
Also check that the out.er race of the bearing fits
tightly in the front cover.
BEARING
Check the bushing of the rear cover for wear or
damage. BUSHING
19-10
ELECTRIC STARTER
ASSEMBLY
FRONT COVER
MOTOR CASE
ARMATURE
TERMINAL BOLT
POSITIVE BRUSHES
NEGATIVE BRUSHES
BRUSH HOLDER
REAR COVER
Install the brush holder, positive brushes and termi-

POSITIVE BRUSHES
nal bolt.
BRUSH HOLDER
Y'r
TERMINAL BOLT
In stall a new O-ring, terminal stopper, insulator and

washer.
INSULATOR
/
TERMINAL STOPPER WASHER
19-11
ELECTRIC START ER
Tighten the terminal nut securely.
NUT
Install the negative brushes and tighten the screw

NEGATIVE BRUSHES
securely.
SCREW
Install the brush springs to the brush holder.

SPRINGS
Install the brushes to the brush hol der.

BRUSHES
19-12
ELECTRIC STARTER
Install the armature to the rear cover.
ARMATURE
Install a new seal ring to the starter motor case.

SEAL RING !$!~
Install the starter motor case with its groove with
the tab on the rear cover. ......
I NOTICE I
The coil may be damaged if the mag net pulls the
armature against the case.
Align
Insta ll a new seal ring to the starter motor case.

Install the front cover to the starter motor case. FRONT COVER
NOTE:
When installing the front cover, take care to prevent
damaging the oil seallip with the armature shaft.
!$!~
SEAL RING ......
Align the index marks on the front cover, starter
motor case and rear cover.
INDEXMARKS
19-13
ELECTRIC STARTER
Instal! new bolts and tighten them securely.
~
eBOLTS
INSTALLATION
Apply oil to a new a-ring and instal! it to the starter
motor groove.
Instal! the starter motor into the crankcase.

Route the wires Install the ground cable and mounting bolts, and
properly tighten the bolts securely.
(page 1-211. Instal! the starter motor cabie, then tighten the ter-
m inal nut to the specified torque.
TORQUE: 10 N·m (1 .0 kgf·m, 7 Ibf.ft)
Instal! the rubber cap securely.
Instal! the thermostat housing (page 7-10).
Connect the battery negative H cable (page 17-6).
STARTER RELA Y SWITCH

Remove the se at (page 3-4).
Disconnect the battery negalive H cabie.
Disconnect the starter relay switch 4P (Red) connec-
tor.
Remove the bolts and disconnect the starter relay
switch wires.
Aemove the starter relay switch .
19-14
ELECTRIC STARTER
OPERATION INSPECTION
Shift the transmission into neutra I.
Turn the ignition switch ON and press the starter
switch button.
The coil is narmat if the starter relay switch clicks.
It you don 't hear the switch "CLICK", inspect the
relay switch using the procedure below.
GROUND L1NE INSPECTION

Disconnect the starter relay switch 4P (Red) connec-
4P CONNECTOR
tor.
Check for continuity between the Green/red wire
(ground line) and ground.
If there is continuity when the transmission is in
neutra I and clutch lever released or when the clutch
lever pulled and the sidestand up, the ground circuit
is narmal (In neutral, there is a slight resistance due
to the diode).
INPUT VOLTAGE INSPECTION

Connect the starter relay switch 4P (Red) connector.
Shift the transmission into neutral.
Measure the voltage between the Yellow/red wire
terminal (+) and ground (-).
It the battery voltage appears wh en the starter
switch button is pushed with the ignition switch ON,
it is normal.
CONTINUITY INSPECTION
Remove the starter relay switch (page 19-14).
Connect an ohmmeter to the starter relay switch
large terminals .
Connect a tully charged 12 V battery positive (+)
wire to the starter relay switch Yellow/red terminal
and negative (-) wire to the Green/red terminal.
There should be continuity between the large termi-
nals while the battery is connected, and no continu-
ity when the battery is disconnected.
EB
BATTERY
19-15
ELECTRIC STARTER
DIODE
Remove Ihe se al (page 3-4).
Open Ihe tuse box and re move Ihe diode.
INSPECTION
Check tor conlinuily between Ihe diode Iermina is.
Wh en there is continuity, a smal! resistance value
wil l register.
If there is contin uity, in one direction, the diode is
normal.
19-16
20. LIGHTS/METERS/SWITCHES
SYSTEM LOCATION· .... · .. ·························20-2 FUEL LEVEL SENSOR ··························· · 20-16
SERVICE INFORMATION ·························20-3 IGNITION SWITCH ................................ . 20-17
TROUBLESHOOTING .......... .. ................... 20-5 HANDLEBAR SWiTCHES······················· 20-17
HEADLIGHT····································· ·· ·· ·· ····20-6 BRAKE LIGHT SWITCH .......................... 20-19
TURN SIGNAL L1GHT··················· ············ 20-7 CLUTCH SWITCH ................................... 20-19
BRAKE/TAllILlCENSE LIGHT·················· 20-7 NEUTRAL SWiTCH ................................ · 20-20
COMBINATION METER····· ·· ·· ···· ·········· ·····20-7 SIDESTAND SWITCH ............................ ·20-20
SPEEDOMETER/VS SENSOR ................ 20-11 HORN ............ ............ .............................. 20-23
TACHOMETER ........................................ 20-12 TURN SIGNAL RELAY ........................... 20-23
ECT SENSOR ·.. ····································· ·· 20-14 HEADLIGHT RELAY ................................ 20-24
EOP SWITCH···· ····································.. ·20-14
20-'
SYSTEM LOCATION
RIGHT HANDLE BAR SWITCH

IGNITION SWITCH
FUEL LEVEL SENSOR
CLUTCH
SWITCH ~=--7~~~!~~~~
LEFT HAI~UL.t:""H
SWITCH
HORN
ECT SENSOR
EOP ~IAIiTrU
SIDESTAND SWITCH
NEUTRAL SWITCH
20-2
SERVICE INFORMATION
GENERAL
I NOTICE
• Ahalog en headlight bulb becomes very hot while the headlight is on, and remains hot for a while after it is turned off.
Be sure to let it cool down before servicing.
• Note the fol/owing when replacing the halogen headlight bulb.
- Wear clean gloves while replacing the bulb. Do not put finger prints on the headlight bulb, as they may create hot
spots on the bulb and cause is to fail.
- If you touch the bulb with your bare hands, clean it with a cia th moistened with denatured alcohol to prevent its ear/y
fai/ure.
• Use an electric heating element to heat the water/coolant mixture tor the EeT sensor inspection . Keep flammable mate-
ria Is away trom the electric heating element. Wear protective clothing, insulated gloves and eye protection.
• Check the battery condition belare performing anv inspection th at requires proper battery voltage.
• A continuity test can be made with the switches installed on the motoreycIe.
• Position light removal/installation (page 3-11).
• The following celor codes are used throughout this section .
Bu = Blue G = Green Lg = Light Green R = Red

BI = Black Gr = Grav 0= Orange W=White
Sr:;; Brown Lb = Light Blue P = Pink Y = Yellow
SPECIFICATIONS
ITEM SPECIFICATIONS
Bulbs Headlight I Hi 12 V 55 W
I La 12V- 55W
Position light LED
Brake/taililicense light LED
Front turn signallposition light 12 V 23/8 W x 2
Rear turn signa I light 12V-21 Wx2
Instrument light LED
Turn signa I indicator LED
High beam indicator LED
Neutral ind icator LED
MIL LED
HESD indicator LED
Engine Dil pressure ind icator LED
Engine coolant temperature indicator LE D
Fuse Main fuse 30A
Sub luse 10 A x 4, 20 A x 3
Tachomete r peak voltage 10.5 V minim um
ECT sensor resistance L 80' C (176' F) 2.1-2.6 kQ
I 120' C (248' F) 0.6 0.7 kQ
TORQUE VALUES
19nition switch mounting bolt 24 N'm (2.4 kgl·m, 18 IbHt) Replace with a new one
EOP switch 12 N·m (1.2 kgl·m, 9lbHt) ApplV sealant to the threads
EOP switch wire terminal screw 2.0 N·m (0.2 kgf·m, 1. 5 IbHt)
Neutral switch 12 N'm (1.2 kgl·m, 9 IbHt)
Combination meter screw 1.0 N·m (0.1 kgl·m, 0.7 Ibl·ft)
Sidestand switch mounting bolt 10 N'm (1.0 kgl·m, 7 IbHt) ALOC bolt; replace with a new one
Mirror stay mounting bolt 12 N'm (1.2 kgl·m, 9 Ibl·ft) A LOC bolt; replace with a new one
20-3
TOOLS
Peak voltage adaptor Test probe IgnitionMate peak voltage tester

07HGJ-0020100 07ZAJ-RDJA 110 MTP07-0286 (U. SA only)
Not ava ilable in U.S .A.

with commercially available digital
multimeter (impedance 10 MnlDCV
minimum)
20-4
TROUBLESHOOTING
VS SENSOR/SPEEDOMETER
The speedometer and odometer/trip meter indicates "- - - _" ,
Faulty EEPROM in ECM
The odometer/ trip meter operate normally, but the speedometer does not operate
Faulty speedometer in combination meter
The speedometer operates normally, but the odometer/trip meter does not operate
Faulty odometer/trip meter in combinatien meter
The speedometer operates abnormally
1. Fuse Inspection
Check lor blown main luse or sub luse (CLOCKfTURN 10 A).
Is the fuse blown?
YES - Replace the luse
NO - GO TO STEP 2.
2. Battery Inspection
Make sure th e battery is lully charged and in good cond ition.
Is the battery in good condition?
YES - GO TO STEP 3.
NO - Replace the battery
3. VS Sensor Power Input Voltage Inspection (VS Sensor Side)
Discon neet the VS sensor 3P (Black ) connector and measure the voltage at the VS sensor connector
Violet terminal with the ignition switch ON.
Is there Battery Voltage?
NO _. Lease or poor contact of reJated terminals
• Open ci rcuit in Violet wires betwee n the combinatien meter and VS sensor
YES - GO TO STEP 4.
4. VS Sensor Power Input Voltage Inspection (Combination Meter Side)
Conneet th e VS sensor 3P (Bla ck) connector and check for loose or poor contact of the combination
meter 20P (Black) connector.
With the ignition switch ON, and measure the vo ltage at bottom of the combination meter 20P
(Black) connector Violet terminal.
Is the Voltage more than 10 V (20 °C/ 68"F)?
NO _. Lo ose or poor contact of related terminals
• Faulty combination meter
YES - GO TO STEP 5.
5. VS Sensor Signal Line Inspection
With the ignition swi tch OFF, check lor continuity ol the Pink/green wire between the terminals ol the
VS sensor and speedometer.
NO - Open circuit in Pink/gree n wire
YES - GO TO STEP 6.
6. VS Sensor Signallnspection
Support the motorcycle using a hoist or other support to raise the rear w heel oft the ground.
Measure the output voltage (sensor signal) at the speedometer with the ignition switch ON while
slowly turning the rear w heel with your hand (page 20-").
Standard: Repeat 0 to 5 V
Is the voltage as specified?
NO - Faulty VS sensor
YES - Faulty speedometer
20-5
HEADLIGHT
BULB REPLACEMENT
Remove the dust cover.
Disconneet the headlight bulb connector.
Unhook the bulb retainer and remave the headlight
bulb.
I NOTICE I
Avoid to uching the ha/ogen head/ight bu/b. Finger
prints can create hot spots that cause a bulb to
break.
Install a new headlight bulb aligning its tab with the
groove in the headlight unit.
II vou touch the bulb with vour bare hands, clean it
with a cloth moistened with denatured alcohol to
prevent earlv bulb lailure.
Hook the bulb retainer securelv.
Conneet the headlight bulb connector.
remaval.
DUST COVER aULa RETAINER
Remave the upper cowltlront spoi ler (page 3-11).
Disconneet the headlight 2P (Natura l) con nector.
Remove the collar, screw and headlight unit.

Rout ths wire Installatio n is in the reverse order of removal.
harnsss propsrly TORQUE:
(page 7-27 J.
Headlight mounting screw:
1.8 N·m (0.2 kgl·m, 1.3 IbHt)
20-6
LlGHTS/M ETERS/SWITCHES
TURN SIGNAL LIGHT

BULB REPLACEMENT
Remove the screw , turn si gnal lens and rubber seal. r-- - - - - -- - -- - - - - - - - - ,
LE N S
While pushi ng in, turn the bulb counterclockwise to
remove it and replace with a new one.
Install t he rubber seal, len s and tighten the screw
securely.
• For front turn signal light removal/installation
(page 3-8) ,
• For rear turn signal light remova llinsta llation
(page 3-13),
SCREW RUBBER SEAL
BRAKE/TAIL/LiCENSE LIGHT
INSPECTION
Turn the ignition switch ON, and check the tail light
operation.
Check that all LED in t he brakeltaili license light unit
ill uminate wi th the front brake lever and/or rea r
b ra ke peda l applied,
I/ any LED does not tu rn on, replace t he brakel taill
lice nse light assem bly (page 3-13),
COMBINATION METER
POWER/GROUND LlNES INSPECTION
Remove the w indscreen (page 3- 10),
Check the fo llowing at the wire side connector te r-
minals of the combination meter with the 20P
(Black) connector connected ,
20-7
Power input line
Measure the voltage between the White/blaek wire
terminal (+) and ground (-) . 20P CONNECTOR
There should be battery voltage with the ignition (Wire side/lemale terminals)
switch ON .
II there is na voltage, check the METER ILLUMI ~ White/blaek
(1OA) and White/blaek wire lor aloase connection or
an open circuit.
Backup line
Measure the voltage between the White/green wire
terminal (+) and ground (-) . 20P CONNECTOR
There should be battery voltage. (Wire side/lemale terminals)
II there is na voltage, check the CLOCKITURN (10A)
and White/green wire tor aloase connection or an
open circuit.
White/green
EB
Ground line
Measure the eontinuity between the Green/blaek r-::-=-=--::-::--:---------------,
wi re terminal and body ground . 20P CONNECTOR
There should be eo ntinuity. (Wire side/lemale terminals)
If th ere is no continuity, check tor open circuit in
Green/blaek w ire.
Green/blaek
REMOVAL
- Upper eowl (page 3-11)
- Front spoi ler (page 3-11)
- Head lights (page 20-6)
- Bank angle sensor (page 6-73)
Remove the minor stay mounting balts.
20-8
Disconneet the combination meter 20P (Black) con-
nector.
Remave the balts and mirror stay assembly.
Remove the screws, washers and combination

mete r trom th e mirror stay. MIRRDRSTAY COMBINATION METER
DISASSEMBLYI ASSEMBL Y
Remave th e screws and separate the front cover
trom the rear cover.
SCREWS
AssembIe the combination meter in the reverse

order of removal. PRINT BOARD
TORQUE:
Combination meter screw:
1.0 N·m (0.1 kgf·m, 0.7Ibf.ft)
REAR COVER FRONT COVER

lIGHTS/METERS/SWITCHES
INSTALLATION
Install the combinatien meter, was hers and screws
ta the mirror stay. MIRROR STAY COMBINATION METER
nghten the screws securelv.
Install the mirror sta V assernblv and tighten bolts; to ....- -

the specified torque in the specified sequence as
shown.
TOROUE: 12 N·m (1.2 kgf·m , 9 Ibf· ft)

Conoe.ct the combination meter 20P (Blaek) conrlec-
tor.
Tighten the mirror sta V mounting bolts to the speci-

fied torque.
TOROUE: 12 N·m (1 .2 kgf·m, 9 Ibf· ft)

- Bank angle sensor (page 6-73)
Head light (page 20-6)
- Fron t spoiler (page 3-11)
- Upper cowl (page 3-11)
20-10
SPEEDOMETER/VS SENSOR
SYSTEM INSPECTION
Check that the tachometer and coolant temperature
meter function properly,
• Check for loose or poor contact terminals at the
combination meter 20P (Black) and sub harness
20P (Gray) connectors,
• If they do not function , perform the power and
ground line inspection of the com bination meter
(page 20-7) ,
• It they functien, shift the transmission into neu-
tral and turn the ignition switch ON ,
Measure the voltage between the Pink/green (+)
and body ground (-),
Slowly turn the rear wheel by hand,
There should be 0 to 5 V pulse voltage,
- It purse voltage appears, replace the combination
meter print circuit board.
- If pulse voltage does not appear, check for open
or short circuit in Pink/green wire.
If th e Pink/green wire is OK, check the VS sensor
(page 20-11),
VS SENSOR INSPECTION
Lift and support the fuel tank (page 4-5),
(Wire side/lemale
Disconneet the VS sensor 3P (Black) connector and terminals)
check for loose or poar contact of the connector.
Turn th e i9nition switch ON and measure the volt-
\
age at the 3P (Black) connector at the wire harness
side,
Connection: Violet (+) - Green/blaek (-)
Standard: Battery voltage 8
If there is no voltage, check the following:
- Violet wire open circuit
- Green/black wire open circuit
- Combination meter (page 20-7)
Lift and support the fuel tank (page 4-5),
Disconneet the VS sensor 3P (Black) connector,
Remove the bolt, VS sensor and O-ring,
20-11
Apply oil to the O-ring and install it 10 the VS sen-
sor.
Install the VS sensor into the upper crankcase.
Tighten the VS sensor mounting bolt securely and

conneet the VS sensor 3P (Black) connector.
Remove Ihe suitable support and close the fuel tank
(page 4-6).
TACHOMETER
SYSTEM INSPECTION
• Check tor loose or poor con tact terminals at th e , - - - - - - - - - - - - - - - - - - ,
combination meter 20P (Black) and sub harness
20P (Gray) connectors.
Turn the ignition switch ON, check th at the tachom -
eter needie moves to tuil scale and then returns to
zero. F_
iE_I=
.-
-
If the needie does not show initial function , check
the combination meter power input line (page 20-7).
20-12
Remave the windscreen (page 3-10) and expose the
combination meter 20P (Black) connector. X IX IX
Conneet the peak voltage adaptor to the combina-
tian meter termina l and ground.
lX lX
Yellow/green
Connection: Yellow/green (+) and Ground H 20P CONNECTOR
TOOl:
(Wire side/lemale terminals ) EB
(U.S.A. only) or Vr. 'I
(Not available in
U.S.A.) -
-
-
with commercially available digital multimeter -
PEAK VOLTAGE ADAPTOR
(impedance 10 M Q/DCV minimum)
Start the engine and measure the tachometer input
peak voltage.
PEAK VOLTAGE: 10.5 V minimum
II the peak voltage is normal, replace the combina-
tion meter assembly (page 20-8) .
II the measured value is below 10.5 V, replace the
ECM (page 6-74).
II the value is 0 V, check lor co ntinuity between the
combination meter 20P (Black) connector and ECM 20P CONNECTOR
33P (Gray) connector Yellow/green terminals. (Wire side/le\ale terminals)
TOOl:
Test probe 07ZAJ-RDJA 110 I I I I IXJ I I rxJXI
It there is no continuity, check the wire harness and I IXJ I I I I,IXJ I
combination meter sub harness for an open circuit. Yellow/
If there is continuity, replace the combination meter
printed circuit board (page 20-8).
\ ""ow,
green green
33P (Gray) CONNEC~R

(Wire side/lema le terminals)
20-13
ECT SENSOR
INSPECTION
Remave the ECT sensor (page 6-71).
Suspend the ECT sensor in a pan of coolant (1:1
mixture) on an electric heating element and mea-
sure the resistance through the sensor as ths cool-
ant heats up.
• Soak the EeT sensor in coolant up to its threads
with at least 40 mm (1.6 in) from the bottom of 1I I1
the pan to the bottom of the sensor.
• Keep the temperature constant tor 3 minutes
betore te5t1n9. A sudden change of temperature
will result in incorrect readings. Do not let the
thermometer or EeT sensor touch the pan.
Replace the sensor if it is out of specification by
more than 10% at any temperature li sted.
Temperature BO' C (176' F) 120' C (24B' F) ECT SENSOR

Resistance 2.1 - 2.6 kQ 0.6 - 0.7 kQ
Install the ECT sensor (page 6-71).
ECT SENSOR TERMINAL
EOP SWITCH
INSPECTION
If the Dil pressure warning indicator stays on while r - - - - - - - - - - - - - - - - - - - - - ,
the engine is running, check the engine oil level
before th is inspection.
Make sure that the Dil pressure warning indicator
cames on with the ignition switch ON,
OIL PRESSURE WARNING INDICATOR
20-14
If the indicator does not come on , inspect as fol-
lows:
Remove the dust cover, terminal screw and wire .
Short the EOP switch w ire to ground .
Th e engine oil pressure indicator comes on when
the ignition switch is ON.
II the light does not come on, check the sub luse
(C LOCKfTURN 10 A) and wires lor a loose connec-
tion or an open circuit.
Start th e engine and make sure the indicator goes
out.
II th e indicator does not go out, check the oil pres-
su re (pa ge 5-5).
II the oil pre ssure is normal, replace the EOP switch
(page 20-15).
Instal l the lower cowl (page 3-6).
If rhe oil pressure Remove the lower cowl (page 3-6).
indicator light
Remove th e dust cover.
remains on a few
seconds, check the Remove the bolt and disconnect the EOP switch
indicator system w ire.
bofaro chocking 'ho Remove th e EOP switch while holding the switch
oi/ pressure. base.
Apply sealant to th e EOP switch threads.

Tighten the EOP switch to the specilied torque whi le
Aolding the switch base.
Connect the EO? switch wire terminal and tighten

the bolt to the specilied torque.
TOROUE: 2.0 N·m (0.2 kgf·m, 1.5 Ibf·ft)

Install the dust cover.
Start the engine and check that there are no Dil
leaks.
Install the lower cowl (page 3-6).
20-15
FUEL LEVEL SENSOR
, .,
If the tuel meter cycles the pattern as shown, check _ _
for an open circuit in wire harness and the tuellevel
sensor.
ij.-••.- ij..•• - ij.•••
.-
, , ~ ... 1 ... F.-
-
~
If the wire harness and fuel level sensor are good,

,"
~.::-.
, ' -+ -+ -+
replace the combination meter printed circuit board
(page 20-8). E Cl E Cl
, ' (--
,= s.-_
,. '
_ t
-- --- -.•
-...
~
••L::::i
--
ij +- iJ +- il +- il
~
E Cl E Iïïi E E
FUEL LEVEL SENSOR INSPECTION

Remave the fuel pump unit (page 6-47).
Con neet an ohm meter to the fuel pump unit 3P
(Blaek) connector Brown/blaek and Green terminals.
Inspeet the resistanee of the float at the top (fu II )
and bottom (empty) positions.
TOP (FULL) BonOM (EMPTY)
Resistanee 12 14 n 119 121 Q
TOP (FULL)
FUEL METER INSPECTION

Remave the fuel pump unit (page 6-47).
Conneet the fuel pump unit 2P (Blaek) connector.
FLOAT POSITION: FULL
ft takes abour 1 Turn the ignition switch ON and move the float from F
minute for the bottom (empty) to top (fuII) to check the fuel meter
display to reflect a display indication .
change in floa t
position.
" ,_"
E-C-
I
FLOAT POSITION: EMPTY
20-16
IGNITION SWITCH
INSPECTION
Remave the right middle cowl (page 3-8).
Disconneet the ignition switch 2P (Brown) connec-
tor.
Check for continuity between the wire terminals of

the ignition switch connector in each switch posi-
tian.
Continuity should exist between the color coded
wires as follow :
IGNITION SWITCH
.~ BAT1 IG KEY
ON KEVON
OFF KEY OFF

KEY OFF
LOCK LoeK PIN
COLOR R RIB ~
REMOVAL/I NSTALLATION
Remave the top bridge (page 14-34).
IGNITION SWITCH
Remave the balts and ignition switch .
Install the ignition switch to the top bridge.
Tighten new ignition switch mounting balts to the
specified torque.
TORQUE: 24 N·m (2.4 kgl·m, 18 Ibl· ft)
Installation is in the reverse order of remaval.
HANDLEBAR SWITCHES
Remave the middle cowls (page 3-8).
Disconneet the handlebar switch co nnectors.
20-17
RIGHT SIDE
Check for continuity between the wire terminals of r - - - - - -- - -E
-N- G-I-N-E-S-T-O-P- S-W
- I-T-C-H'
the handlebar switch connector.
Continuity should exist between the color coded
wire terminals as follows:
ENGINE STOP SWITCH
~ IG BAT4
8
0 0- -Q
COlOR BI W/BI
STARTER SWITCH
STARTER SWITCH
~ BAT5 ST H/l
FREE \.
PUSH n- Hl
COlOR BIIR VIR BuNV
LEFT SIDE
Check for continuity between the wire terminals of r D
--IM- M
-E-R
- S-W-IT
-C- H- - - - - - - - - - '
the handlebar switch connector.
Continuity should exist between the ce lor coded
wire terminals as follows:
TURN SIGNAL SWITCH
~ W R l P PR Pl
~ 0- --0 0 -0
N 0- ro- -n
~ 0 .J 0- f--<)
COlOR Gr lb 0 W/BI lbNV ONV
TURN SIGNAl SWITCH HOAN SWITCH
HORNSWITCH
~ Ho BAT2
FREE
PUSH
COlOR BI BrNV
DIMMER SWITCHES
~ Hl la Hi
ID
IN) '-
10 ( .J
COlOR BufW Bu
20-18
BRAKE LIGHT SWITCH
FRONT
Oisconneet the front brake light switch connectors
and check for continuity between the terminals.
There should be continuity with the brake lever
applied, and there should be no continuity with the
brake lever is released.
REAR
Remove the fuel tank (page 6-50).
Disconnect the rear brake light switch 2P (Black)
connector.
Check for continuity between the terminals.
There should be continuity with the brake pedal
brake peda l is relea sed .
CLUTCH SWITCH
Disconneet the clutch switch connectors.
There should be continuity with the clutch lever
clutch lever is released.
20-19
NEUTRAL SWITCH
INSPECTION
Disconneet the neutral switch connector from the I"""~~~""~~
switch.
Shift the transmission into neutral and check for
continuity between the neutral switch terminal and
ground.
There should be continuity with the transmission in
neutra I, and no continuity wh en the transmission is
in gear.
Di sconneet the ne utral switch connecto r.
Remove the neutral switch and sea lin g washer.
In stall a new sea li ng washer and tig hten the neutra l
swi tch to the speci f ied torque.
TORQUE: 12 N·m (1 .2 kgf· m, 9lbf· ft)
Con neet th e neutral swi tch connector securely.
SIDESTAND SWITCH
INSPECTION
Remove the left middl e cowl (page 3-8).
Disco nneet t he sidestand switch 2P (Green) connec-
tor.
20-20
Check tor continuity between the wire term inals of
the sidestand switch 2P (Green) connector.
Conti nuity should exist on ly when the sidestand is
up.
2P (Green) CONN ECTOR

(Switch side ollema le terminals)
REMOVAL
- Lelt middle cowl (page 3-8)
Disconnect the sidestand switch 2P (Green) connec-
tor.
Remave th e wire clamps and release the sidestand

switch w ire.
20-21
Remove the bolt and sidestand switch.
INSTALLATION
Install the rubber onto the sidestand pin securely.
Insta ll the sidestand switch by aligning the switch
pin with the sidestand hole and switch groove with
the return spri ng holding pin.
Secure the si destand switch w ith a new bolt.
TOROUE: 10 N·m (1.0 kgf·m, 7 Ibf.ft)
Route the wire Con neet the sidestand switch ZP (Green) co nnector.
properly
(page 1-21).
20-22
HORN
INSPECTION
Remave the right middle cowl (page 3-8).
Disconneet the horn connectors trom the horn.
Conneet a 12 V baltery to the horn terminal directly.
The horn is normei if it sounds when the 12 V bat-
tery is connected across the horn terminals.
Install the right middle cowl (page 3-8).
Remave the right middle cowl (page 3-8) .
Disconneet the horn connectors.
Remove the nut and horn.
Route the wire Installation is in the reverse order of removal.
proper/y
(page 1-2 1).
TURN SIGNAL RELA Y

INSPECTION
1. Related Circuit Inspection
Remave the seat (page 3-4) .
Check the following:
- Burned bulb or non-specified wattage
- Blown fuse (CLOCKITURN 10 A, STOP/HORN
10 A)
- Ignition switch (page 20-17) and turn signal
switch (page 20-18) function
- Laase connector
Are the above items in good condition?
NO - Repl ace or repair the failed part(s)
YES - GO TO STEP 2.
20-23
LlGHTS/M ETERS/SWITCHES
2. Turn Signa 1 Circuit Inspecti on
Short the 8rown/white and Gray terminals ol the
turn signal relay with a jumper wire. Turn the
i9nition switch ON and check the turn signal
light by turning the turn signal switch on.
Does the light come on?
YES - . Faulty turn signa I relay
• Laase or poor contact of the connec-
tor terminals
NO - Open circuit in White/green or Gray
wires
HEADLIGHT RELA Y
INSPECTION
Open the luse/relay box and remave the headlight
relay.
Conneet the ohmmeter to the headlight relay con-

nector terminals. HEADLIGHT RELAY
Conneet a 12 V battery to the headlight relay con-

nector terminals as shown.
There should be continuity only when the 12 V bat-
tery is connected.
II there is na continuity when the 12 V battery is
connected, replace the headlight re lay.
20-24
21. WIRING DIAGRAM
WIRING DIAGRAM ............. ......... .. ....... .... 21 -3
?1-1
\
WIRING DIAGRAM
WIRING DIAGRAM
PAIR CONTROL
SOLENOID VALVE KNOCK
SENSOR
ENGINE STOP 0 "'"
COMBINATION METER ' STARTER SWITCH "W '"
\ ~i
~ FRONT BRAKE
LIGHT SWITCH
rMl ~
W~ IACV EGCV
~ ~ ~. ~ ~~ DLC
I::::=====E~~
l :. ~I ni!ilnn~
IGNITION SWITCH n
~
11 !5~iin~
>~ ~~ mm~jO~ :: U J
• I
BI Black B, 8rown
I e~~ J
Y Yellow 0 Dran e
HESO Bu Blue Lb Li ht blus
~~ ::c • u~. 1 G Green L U ht green
.~" i~~ ~Jr

R Red Pink
EVAP PURGE CONTROL
a. W Wh ite G, Gray
~ ~~
~ l4=ïl
-, ~ ~
SOLENOID VALVE
V Violet
RIGHT FRONT TURN
SIGNAL LIGHT
l2V 23 / BW f"i"lt 'ol ~
iI
~$$~
i1! jii ll-
SENSOR
8
r
lAT
\..B--.-Ju.w ===ïl l SENSOR • ECT
~o, SENSOR FUEL LEVEL
TP
~~ nLl SENSOR
j,j, SENSOR
r~'
FUEL
HEADLIGHT (LOl ~o, IGNITION COILS
l2V 55W H7
PUMP
.:.1 <:I-
c:: a 11 U> ::nl=: U> ~ RIGHT REAR TURN
POSITION LIGHT ~
0lf w~WI! BRAKEfTAIIJLICENSE

LIGHT
t::: g =?J= g-t=;::V

o
~ LEFT REAR TURN
SIGNAL LIGHT
l2V 23W
STARTER RELAY MAIN FUSE

SW~TCH
30A
• e 0
STARTER M
MOTOR w • BATTERY
iij · l2V B.BAh
~~
HEAOLIGHT (HII
l2V 55W H7
SWITCH CONTINUITY
IGNITION SWITCH
BANKANGLE
SENSOR
.~~
o ALTERNATOR
FAN MOTOR •• REGULATOAIRECTIFIER
Ö
o "
CLUTCH SWITCH
FUSE BOX
A (1OAI METER ' ILLUMINAnON
r
CMP SENSOR B (10AI BANKANGLE SENSOR
G SIDESTAN D SWITCH
TURN SIGNAL RELAY C (20AI HEADLIGHT
DIMMER HORN ENGINE STOP STARTER
SWITCH SWITCH SWITCH SWITCH D (1 0AI FRONT, REAR BRAKE ' HORN ' TURN SIGNAL
PRIMARY FU EL SECONDARY FUEL E (1 0AI CLOCK
~
'" l"', o
"- Hl '" ,,,.
HL Lo H. BA" JO SAT. BATS ST HA.
INJECTOR INJECTOR F (20AI FAN MOTOR
~ FIlE' IS FREEIO - [Q G (20AI FI
I" kî PIJ" 10 KJ
811R 'r1R
""" FAN MOTOR
RELAY
ENGINE STOP
RELAY
0030Z-M FJ-AOOO
0030Z-MFJ-LOOO
21-3
MEMO
22. TROUBLESHOOTING
ENGINE DOES NOT START OR POOR PERFORMANCE AT

IS HARD TO START ·.. ··············· ········ ·· ·· ·· ·· 22-2 HIGH SPEED ........................ .. .. .. ............... 22-6
ENGINE lACKS POWER .... · .. .. .......... ...... ·22-3 POOR HANDlING ................ ..... .. ............ . 22-6
POOR PERFORMANCE AT
lOW AND IDlE SPEED ...... ...................... 22-5
22-1
TROUBLESHOOTING
ENGINE DOES NOT START OR IS HARD TO START

1. Spark Plug Inspection
Remave and in speet spark plug .
Are the spark plugs in good condition ?
NO _. Incorrect spark plug heat range
• Incorrect spark plug gap
• Dirty air cleaner
YES - GO TO STEP 2.
2. Spark Test
Perform spark test.
Are there good sparks?
NO _. Loase or disconnected i9n1tion system wire
• Faulty direct 19nit10n coil
• Braken or shorted direct 19n1t10n coit connector wire
• Faulty CKP sensor
• Faulty engine stop switch
• Faulty ECM
YES - GO TO STEP 3.
3. Fuel Pump Inspection
Check for operation ot the tuel pump and inspeet the tuel flow.
Is the fuel pump unit normal?
NO - Faulty tu el pump un it (page 6-47)
YES - GO TO STEP 4.
4. Programmed Fuellnjection System Inspection
Check the tuel injection system .
Is the fuel injection system norma/?
NO - Faulty tuel injection system (primary: page 6-65, secondary: page 6-56)
YES - GO TO STEP 5.
5. Cylinder compression Inspection
Test the cylinder compression . (
Is the compression specified7

NO _. Va lve stuck open
• Warn cylinder and piston ring s
• Damaged cylinder head gasket
• Seized va Ives
• Impraper valve timing
YES - GO TO STEP 6.
6. Engi ne Start Condition
Start by following normal procedure.
Did the engine start but stops?
YES - . Leaking intake manifold
• Leaking intake pipes
• Faulty IACV
• Improper ignition timing (Faulty ECM or CKP sensor)
• Contaminated fuel
l
22-2
TROUBLESHOOTING
ENGINE LACKS POWER
1. Drive Train Inspectio"
Raise wheel aft the graund and spi n by hand.
Did the wheel spin freely?
NO _. Bra ke dragging
• Warn or damaged wheel bearings
YES - GO TO STEP 2.
2. Tire Pressure Inspection
Check the tire pre ssure.
Is the tire pressure correct?
NO _. Faulty tire valve
• Punctured tire
YES - GO Ta STEP 3.
3. Clutch Inspection
Accelerate rapidly, shift Iram lirst ta secand.
Did the engine speed change accordingly when clutch is released?
NO _. Clutch slipping
• Warn clutch discs/plates
• Warped clutch discs/plates
• Weak clutch spring
• Addlti ve in en gin e Di l
YES - GO TO STEP 4.
4. Engine Performance Inspectio"
Accelerate lig htly.
Did the Eng;ne speed increase7
NO _. Dirty air cleaner
• Restricted luel flow
• Clagged muftier
YES - GO Ta STEP 5.
5. Spark Plug Inspection
Remove and inspeet spa rk plugs.
Are the spark plugs in good condition7
NO _. Plugs not serviced Irequently enough
• Incorrect spa rk plug heat rang e
• Incorrect spa rk plug gap
YES - GO TO STEP 6.
6. Engine Oillnspeetion
Check the oillevel and condition.
Is the engine oil in good condition7
NO _. Oil level toa high
• Oillevel toa low
• Contaminated Dil
YES - GO Ta STEP 7.
22-3
TROUBLESHOOTING
7. Ignition Timing Inspectio"
Check the ignition timing.
Is the ignition timing as specified7
NO -. Faulty ECM
• Faul ty CMP sensor
• Faulty knock sensor
• lmproper valve timing
YES - GO TO STEP 8.
8. Cylinder compression Inspection
Te st th e cylinde r compression.
Is the compression as specified?
NO _. Valve clearance toa small
• Valve stuck open
• Warn cylinder and piston rings
• Damaged cylinder head gasket
• Improper valve timing
YES - GO TO STEP 9.
Inspect the fuel flow .
Is the tuef pump unit narmal?
NO - Faulty fuel pump unit (page 6-47)
YES - GO TO STEP 10.
10. Programmed Fuellnjection System Inspection
Check the fuel injection system.
Is the (uel injection system narmat?
NO - Faulty fuel injection system (primary: page 6-65, secondary: page 6-56)
YES - GO TO STEP 11 .
11 . lubrication Inspectio"
Remove cylinder head cover and inspeet lubrication.
Is the valve train lubricated proper/v?
NO _. Faulty oil pump
• Faul ty pressure relief valve
• Clogged oil strainer
• Clogged oil passage
YES - GO TO STEP 12.
12. Over Heating Inspection
Check for engine over heating .
Is the engine over heating?
YES - . Coolant level too low
• Fan motor not working
• Thermostat stuck closed
• Excessive carbon build-up in comb ustion chamber
• Use of poor quality fuel
• Wrong type of fuel
• Clutch slipping
NO - GO TO STEP 13.
22-4
TROUBLESHOOTING
13. Engine Knocking Inspection
AcceJerate or run at high speed.
Is the engine knocking?
YES - . Warn piston and cylinder
• Wrong type of fuel
• Excessive carbon build-up in com bu stion chamber
• Ignition timing toa advance (Fau lty ECM )
• Faulty CMP sensa r
• Faulty knock sensor
NO - Engine does not knack
POOR PERFORMANCE AT LOW AND IDLE SPEED

1. Spark Plug Inspectian
Remave and inspeet spark plugs.
Are the spark plugs in good condition?
NO _. Plugs not serviced frequently enough
• Incorrect spark plug heat range
• In correct spa rk plug gap
YES - GO TO STEP 2.
2. Ignition Timing Inspection
Check the ign itian timing.
Is the ignition timing as specified7
NO _. Faulty ECM
• Fau lty CKP sensar
• Faulty CMP sensar
• FauJ ty VS sensor
• Faulty knock senso r
• Improper valve timing
YES - GO TO STEP 3.
3. Fuel Pump Inspectian
Inspeet th e fuel flaw.
/5 the luel pump unit narmal7
YES - GO TO STEP 4.
4 . Programmed Fuellnjection System Inspection
Check the fuel injectian system .
Is the tuel injection system narmal?
NO - Faulty fuel injectian system (primary: page 6-65, secandary: page 6-56)
YES - GO TO STEP 5.
5. Intake Pipes Leaking Inspection
Ch eck far leaks at the intake manifold pipes.
Are there leak.?
YES _. Laase insulator
• Damaged insulator
22-5
TROUBLESHOOTING
paaR PERFORMANCE AT HIGH SPEED
1. Ignition Timing Inspectio"
Check the ignition timing.
Is the ignition timing as specified?
NO _. Faulty ECM
• Faulty CMP sensor
• Faulty VS sensor
• Faultv knock sensor
• Imprope r valve timing
YES - GO TO STEP 2.
Ins peet th e f uel fl ow.
Is the fuet pump unit operation normal7
YES - GO TO STEP 3.
3. Programmed Fuellnjection System Inspectio"
Check th e f uel injection svstem.
Is the fuel injection system normal7
NO - Faultv fuel injection svstem (primarv: page 6-65, secondarv: page 6-56)
YES - GO Ta STEP 4.
4. V.lve Timing Inspection
Check th e va lve tim ing.
Is the va/ve timing correct?
NO - Ca m shahs not insta lied properlv
YES - GO TO STEP 5.
5. Valve Spring Inspectio"
Check for the valve springs.
Is the valve spring free length as specified7
NO - Faulty va lve springs
YES - Not weak
paaR HANDLING
Stee ring is heavy
• Steering stem adjusti ng nut too tight
• Dam age d steerin g head bearings
• Low tire pressure
• Faulty HESD
Either w heel is wobbling
• Excessive w heel bearing play
• Bent rim
• Swinga rm pivot bearing excessively warn
• Bent frame
The motorcycle pulls to one side
• Front and rea r wheel not aligned
• Faulty shock absorber
• Bent fork
• Bent swi ngarm
• Bent axle
• Bent frame
22-6
23. INDEX
AIR CLEANER· ······ ····· .. ····· ····· ···· .. ···· .. ··· .. ······· ········ .. ···· .. ·4-8 DTC INDEX ............................. .. .............. ...... ............... 6-16
AIR CLEANER HOUSING ........ ·...... ·............................ 6-52 DTC TROUBLESHOOTING ...... ·.. · ........ ·.. ·.................. ·6- 18
AIR DUCT ........ .. .... ........ ·...... ·.......... ·...... ·.................. ·.. 3-12 ECM· ····· .. ·· ····· ·· .. ·························· ··········· .. ····· ······ ········· 6-74
ALTERNATOR CHARGING COIL ·........ ·...................... 17-8 ECT SENSOR
ALTERNATOR COVER INSTALLATION .................... ·11-6 FUEL SYSTEM (PGM-FI) .... .. ............. .. ........ .... .. ..... 6-71
ALTERNATOR COVER REMOVAL .......... ·.... ·........ ·.... ·11-4 LlGHTS/METERS/SWITCHES .. ·.... .... ·.... · .............. 20-14
BANK ANGLE SENSOR .. .. .. .. ...................................... ·6-72 EGCV ····· ···· .. ············································ ······· ···· ··········6-83
BATIERY ·· .. · .. .. .... ·.... ·.......... .. .. ·...... ·.... ·· .................... ·.. 17-6 EGCV CABLE ............................................................... 4-22
BATIERY/CHARGING SYSTEM SPECIFICATIONS .. · 1- 11 EGCV SERVOMOTOR ............ .... .... .. .. ......................... 6-80
BODY PANEL LOCATIONS .... .. .. · ................ ·.... ·.. ·.. · ...... 3-2 ELECTRIC STARTER SPECIFICATIONS .. ...... ............. 1-1 1
BRAKE FLUID ········ ···· ······ ······ ····.. ·········· .. ·········· .. ·· .. ·· .. ·4-28 EMISSION CONTROL SYSTEMS .. ..... .. .. .... ... ............. 1-36
BRAKE FLUID REPLACEMENT/AIR BLEEDING ........ · 16-7 ENGIN E & FRAME TORQUE VALUES ...................... · 1-13
BRAKE LIGHT SWITCH ENGINE DOES NOT START OR IS HARD TO
LlGHTS/METERS/SWITCHES .... ·...... ·.. ·.... ·· ........ .. 20-19 START ·· .. ········· .. ······················ ····· ······ ···· .. ····· ··· ··· ···· .. ···22-2
MAINTENANCE··· ·· ·········· .. ········ ··· .. ·· .. ·· .. ·· ·· ····· ···· ·· ··4-31 ENGINE IDLE SPEED .................. .. ...... .. .. .. ·............ ·.... · 6-67
BRAKE PAD/DISC .. ·.. .......... .... .. .... ·........ ·.... ·............ ·· .. 16-9 ENGINE INSTALLATION .. · .................... ·.... · .................. 8-9
BRAKE PADS WEAR··············· ············· ·.. ··· .. ···· .. ··········4-29 ENGINE LACKS POWER ............................................ . 22-3
BRAKE PEDAL ...... ·.............. .. .... .... ...... ·.. ·· .. ·.............. · 16-31 ENGINE OIUOIL FILTER .... .. .... ·.. ·................................ 4-17
BRAKE SYSTEM ......................................................... ·4-30 ENGINE REMOVAL ........ · .................................... ·........ ·8-4
BRAKEITAI ULlCENSE LlGHT ············ ···· ···· ···· ···· ··········20-7 ENGINE STOP RELAY .. ·.................... ·.... .. ...... ·...... ·.... · 6-74
CABLE & HARNESS ROUTING .. .. .... ·.. ·............ .. .. ·.. .. .. 1-21 EOP SWITCH .. ...... .. ... ................... ............................. 20-14
CAM CHAIN TENSIONER LlFTER .... .......... · ................ 9-35 EVAP PURGE CONTROL SOLENOID VAL VEI
CAMSHAFT INSTALLATION ........ ·.......................... ·.. ·9-28 CANISTER (CALIFORNIA TYPE) .... · .... ·.... .. .... ·............ 6-79
CAMSHAFT REMO VAL .... .... ·.. ...... · ........ · .... ·........ ·.. .... .. 9-9 EVAPORATIVE EMISSION CONTROL SYSTEM
CHARGING SYSTEM INSPECTION ............................ 17-7 (CALIFORNIA TYPE) .. ·.. ·...... ·.. ·· ...... ·· ...... ·........ ·.. .. .. .... · 4-21
CKP SENSOR .. · ........ ·...... · .............. ·.... ·.... .... .. .. ............ 18-7 EXHAUST PIPE· ...... ·.. ·........ ...... ·............ ·...... · .... ·.. ·...... 3-24
CLUTCH ............................................. ·· .... ····················· 10-7 FAN MOTOR RELA Y .. .. ·................................ ·.......... .. ·7-20
CLUTCH SWITCH .................................. ... .. ................ 20-19 FLYWHEEL ........ ·.. · .. ·............ · ........ .. ...... .. .. ·.............. ·.. ·11-5
CLUTCH SYSTEM ····· .. ·········· ···· .. ····· ··· ···· .. ·.. ···· .. ···· ····· ·4-31 FORK · .. ······· ··········· .. ········· .. ·.... ··· .. ······ ··· ······· .. ·.. ··· ··· .. · 14-22
CLUTCH/STARTER CLUTCH/GEARSHIFT LlNKAGE FRONT BRAKE CALIPERS .... .... .. .... ..... .. ................... 16-25
SPECIFICATIONS ...... ·...... · .... .... .... ··.................... ·.......... 1-8 FRONT FENDER ............... .. .. ..... .. ..................... ........ ... 3- 13
CMP SENSOR .. ·...... .. ·.. ·· ...................... · ...................... ·6-71 FRONT MASTER CyLINDER ...... ·.. ·.............. · .. ·.. ·.. .... 16-13
COMBINATION METER .. .. ·.......... ·...... · ................ ·.. · .. .. 20-7 FRONT WHEEL .. ·........ .. ·.... .......... ·.. ·· ........ ·.... ·.... .. .. .. · 14-16
COMPONENT LOCATION FRONT WHEEUSUSPENSION/STEER ING
ALTERNATOR ........ · .......................... ·.. .. ...... ·.......... 11-2 SPECIFICATIONS ·........................ ··· ...... .. .... .. .. ............ 1-10
CLUTCH/STARTER CLUTCHI FUEL LEVEL SENSOR ..................................... ....... ... 20- 16
GEARSHIFT LlNKAGE .. ...... .. ........ ·.. ·.. ·· ............ ·.. .. .. 10-2 FUEL LlNE ········· .. ·· .. ······· ·· .. ···· ····· ·· ···· ·· ··· .... ·· .... ··· ···· .. ····· 4-5
CRANKCASEITRANSMISSION ........ ·............ · ........ 12-2 FUEL LlNE INSPECTION .. .. ......................................... 6-42
CRANKSHAFT/PISTON/CY LINDER ...... ·.............. .. ·13-2 FUEL PUMP RELA Y .......... ·.. .. .. .. ........................ .......... 6-49
CYLINDER HEADNALVES ·.... ·.................. ·· .......... ·.. ·9-2 FUEL PUMP UN IT ..................................................... .. 6-47
ENGINE REMOVAUINSTALLATION .. · ...... · .. .. .... ...... 8-2 FUEL SYSTEM (PGM -FI ) SPECIFICATIONS ..... .. ......... 1-7
FRONT WHEEUSUSPENSION/STEER ING .. ...... .. .. 14-2 FUEL TANK·· ·· ··· .. ·.. ···· .. ····· .. ···· ····· ··· ··· ··· ······· .. ·.. ······ .. ··· 6-50
FUEL SYSTEM (PGM-FI)··· ···.. ····· ··· ··· ·.. ·.... ·· .. ··· ···· ···· ·6-2 FUEL TANK COVERISIDE COVER .... ...... ...................... 3-9
HYDRAULIC BRAKE .. .... .. .... .. .... · ........................ ·.. .. 16-2 GEARSHIFT LlNKAGE .... ........................................... 10-2 3
REAR WHEEL SUSPENSION .......................... ·.... ·.. 15-2 GENERAL SPECIFICATIONS ........................................ 1-5
CONNECTOR LOCATION .. ·.... · ........ ·.. · ................ ·...... ·6- 10 HANDLEBAR SWiTCHES .......................................... 20-17
COOLANT REPLACEMENT .................. ·.. ·· .. · .......... ...... ·7-6 HANDLEBARS ...................... ·.... ·.... ·.. · ...... .. ........ · ...... 14-10
COOLING SYSTEM ····· .... ·· .. ······················· .. ···· .. ·········· 4-20 HEADLIGHT ........................... ... ...... ....... .. .... .... .... .... ····20-6
COOLING SYSTEM SPECIFICATIONS .... .. ........ ·.... · .... · 1-7 HEADLIGHT AlM ........ .. .. .. .. .. ....................................... 4-31
CRANKCASE ASSEMBLY .. .. ·...... .. ·.... ·........ ·.......... · .. 12-16 HEADLIGHT RELA Y .. .. .. ·.... ··· .... · ...... · .................. ·.. ·.. · 20-24
CRANKCASE SEPARATION .... ·.. · .... .. .. .. .. · ...... · .. ·.. ·.. .. .. 12-5 HESD .. .... · ........ ·.... · .. ·.... · ........................ ·.. ·.. ·.............. 14-33
CRANKCASEITRANSMISSION SPECIFICATIONS ...... 1-9 HESD TROU BLESHOOTING ...................... ·...... ·...... ·.. 14-8
CRANKPIN BEARING .......................... ·.............. .. ·.... 13-11 HORN .............................. ...... .. ......... ........ .. .. .··· ·.. ·.. ····20-23
CRANKSHAFT ······ .. ·.. ················ .. ·· ··.... ········· ········· .. ··· .. 13-5 HYDRAULI C BRAKE SPECIFICATIONS .. ·...... ·.... ·.... ·.. 1-11
CRANKSHAFT/PISTON/CYLINDER IACV
SPECIFICATIONS ··· ··· .. ······· ······· .. ····· ·········· .. ··· .. ·········· .. ·1-9 FUEL SYSTEM (PGM -FI ) ........................................ 6-68
CYLINDER COMPRESSION TEST .. ·.... ·.................. · ...... 9-7 TECHNICAL FEATURES ........................................... 2-2
CYLINDER HEAD ASSEMBL Y· ...... ·.................... ·.. · .... ·9-24 lAT SENSOR ...... ·.............. .. ·.......... .. .. .. .. ·.................... · 6-71
CYLINDER HEAD COVER ASSEMBLY ·.......... .... .. ...... 9-33 IGNITION SWITCH ................ .. .... ..... .. .............. .... ..... 20-17
CYLINDER HEAD COVER DISASSEMBLY · .. ·.............. ·9-8 IGNITION SYSTEM INSPECTION ............ .. .. .......... ·.... 18-5
CYLINDER HEAD COVER INSTALLATION .. .. .. ·.......... 9-34 IGN ITION SYSTEM SPECIFICATIONS ........ · .............. 1-11
CYLINDER HEAD COVER REMOVAL ·.. ·...... ·................ 9-7 IGNITION TIMING .. .............................. ·.. ·.............. ·.. .. 18-7
CYLINDER HEAD DISASSEMBLY ...................... ·........ 9-16 KNOCK SENSOR
CYLINDER HEAD INSPECTION .. .. .. ·.................. ·.. ·...... 9-17 FUEL SYSTEM (PGM-FI) ........................................ 6-69
CYLINDER HEAD INSTALLATION ...... ·.................... ·.. 9-26 TECHNICAL FEATURES ............ ........... ..... .. ........... .. 2-4
CYLINDER HEAD REMOVAL .. ·· .. ·........ · .... ·.............. · .. ·9-1 4 LlGHTS/ METERS/SWITCHES SPECIFICATIONS .. ·.... 1-12
CYLINDER HEADNALVES SPECIFICATIONS .. ·........ ·.. 1-8 LOWER COWL .. ·.. · .... ·.. · ........ ·.. ·.......... ·.............. ·.... ·.... ·· 3-6
DIODE· .. ·...... · .............. · .......... ...... .. ·.......... · ............ ·.... 19-16 LUBRICATION & SEA L POINTS ·...... · .... ·................ ·.. · 1-19
DRI VE CHAIN ........ .......... ... ............................... ...... ··· .. 4-23 LUBRICATION SYSTEM DIAGRAM ...... ....................... 5-2
23-'
INDEX
LUBRICATION SYSTEM SPECIFICATIONS .. .... ........ ·.. 1-7 IGNITION SYSTEM ....... .... ...................................... 18-3
MAIN JOURNAL BEARING .......... ...... ........................ 13-8 LlGHTS/METERS/SWITCHES .......... ......... .. ............ 20-3
MAINTENANCE SCHEDULE ............ ...... .. ............ .. .... .. 4-4 LUBRICATION SYSTEM ...... .. .. ................................. 5-3
MAP SENSOR ................................................... .......... 6-70 MAINTENANCE ............ .. ... .... .. ....... .... ..... ............. ... ·4-2
MIDDLE COWL ...... .. ·.............. ·.. ·........ ·.... .......... ...... · .... · 3-8 REAR WHEEL SUSPENSION ...... ............ .............. ·15-3
MIL CIRCUIT TROUBLESHOOTING ...... ...... ............ ·.. 6-42 SERVICE RULES ...................... ... .... ............ ...... .......... .. . 1-2
MODEL IDENTIFICATION ...... .. · ........ .... ............ ........ .. .. 1-3 SHIFT FORKISHIFT DRUM/TRANSMISSION ........ ·.... 12-6
MUFFLER··· .. ······ ·.. ····· ···· ·.. ··· .. ···· .. ········ ·· ···· ·· ··· ··.. ···· ·· ·· ·3-19 SHOCK ABSORBER ........ .. ........................ .... ...... ...... · 15-14
NEUTRAL SWITCH .. .. ..... ........ .. ................................ 20-20 SIDESTAND .. ..... ....................... ... .................... .. .... ·.. ··· 4-32
NUTS, BOLTS, FASTENERS ...................................... 4-35 SIDESTAND SWITCH ........ .... .................................... 20-20
OIL COOLER ... .... .. .. ............. .... ............ ...... .. ...... .......... 5- 13 SPARK PLUG ...................... ................... .................. ···· ··4-9
OIL PRESSURE INSPECTION ... ........................ ............ 5-5 SPEEDOMETERNS SENSOR ................................... 20- 11
OIL PUMP .............................. ........................................ 5-7 STANDARD TORQUE VALUES ................................. . 1-13
OIL STRAINER/ PRESSURE RELIEF VALVE ................. 5-5 STARTER CLUTCH ...... .. ............................................ 10-17
PASSENGER SEAT ............ .. .... .... ................................ · 3-4 STARTER MOTOR ............ ....... .......... ........ ............ .... .. 19-6
PGM - FI SYMPTOM TROUBLESHOOTING ........ ........ .. 6-7 STARTER RELA Y SWITCH .... ........... .... ..................... 19- 14
PGM -FI SYSTEM DIAGRAM ...................................... ·.. 6-9 STATOR .............................. ....................... ...... .... ........ 1 1-4
PGM -FI SYSTEM LOCATION .. .................... ................. 6-8 STEERING HEAD BEARINGS ........ ............ .. .. ............ ·4-36
PGM -FI TROUBLESHOOTING INFORMAITON .. .. .... · 6-13 STEERING STEM ........ ... .......................... .. ... .. .. ......... 14-34
PISTON/CYLINDER .. ................................................ ·13-14 SUSPENSION .... ....................................... .......... .... ····· 4-32
POOR HANDLING ........ ............................. .................. 22-6 SUSPENSION LlNKAGE .. ......................................... 1 5-19
POOR PERFORMANCE AT HIGH SPEED ·.... ·.. ·.......... 22-6 SWINGARM ......... .................................. .. .. .......... ...... 15-20
POOR PERFORMANCE AT LOW AND SYSTEM DIAGRAM
IDLE SPEED ........................................ ......................... 22-5 BATTERY/CHARGING SYSTEM ............................ · 17-2
PRIMARY INJECTOR ...................... ............................ 6-65 ELECTRIC STARTER .... ........................................... 19-2
RADIATOR ...... .... .......................... .............................. · 7-11 IGNITION SYSTEM .................................... ............. 18-2
RADIATOR COOLANT ............................................ .. .. 4-19 SYSTEM FLOW PATTERN ............................................ 7-2
RADIATOR RESERVE TANK ...... .. .......................... .. .. · 7-20 SYSTEM LOCATION .... .. · .. ........ ·........ .. ...................... ·20-2
REAR BRAKE CALIPER ... .... ............................ .......... 16-28 SYSTEM TESTING .. ............................ ... .... ... ... ....... ...... 7-5
REAR COWL ....................... .................................. ......... 3-5 TACHOMETER ............................... ........................ .... 20- 12
REAR FENDER A ............ .... ...... .................. ·.......... ·.... · 3-13 THERMOSTAT HOUSING ................................ ............. 7-8
REAR FENDER B ......................................................... 3-14 THROTTLE BODy · ............................................ ·.. · ...... · 6-60
REAR FENDER C .... .. .. .. ·.................... ·.... .. ·.............. ·.. ·3-16 THROTTLE OPERATION ............ .......... ......................... 4-8
REAR MASTER CyLINDER ............ .. ...................... ·.. 16-19 TROUBLESHOOTING (
REAR WHEEL .............................................................. 15-7 BATTERY/CHARGING SYSTEM .......................... ·.. 17-5
REAR WHEEUSUSPENSION SPECIFICATIONS ...... · 1-10 CLUTCH/STARTER CLUTCH/
REARVIEW MIRROR ........ ............ .......... .. ................... 3-10 GEARSHIFT LlNKAGE .......... .... .. ............................ 10-4
REGULATOR/RECTIFIER···· ············· .. ··· ······ ······ ··· ........ 17-8 COOLING SYSTEM ........ .......... ................................. 7-4
RIGHT CRANKCASE COVER INSTALLATION ........ · 10-26 CRANKCASE/TRANSMISSION ...... .. ...................... 12-4
RIGHT CRANKCASE COVER REMO VAL .................. ·10-5 CRANKSHAFT/PISTON/CYLINDER ........................ 13-4
SEAT .................................................. .... ....... ·· .... ···········3-4 CYLINDER HEADNALVES ............................ ·.......... · 9-6 (
SEAT RAIL .. ·........................................ ........................ 3-16 ELECTRIC STARTER .... ................ .. ......................... 19-4
SECONDARY AIR SUPPL Y SYSTEM FRAME/BODY PANELS/EXHAUST SYSTEM .... .... .. 3-3
FUEL SYSTEM (pGM-FI) ...................... .............. .... 6-77 FRONT WHEEUSUSPENSION/STEERING ............ 14-7
MAINTENANCE ···· .. ·.. ··· ··· .. ·· ···· ·.... ·.. ········ .. ·· ·.. ···· ···· 4-20 HYDRAULIC BRAKE ...... .......................................... 16-6
SECONDARY INJECTOR .... ........................ ............ .. .. 6-56 IGNITION SYSTEM ...... ........ .... ............................... 18-4
SERVICE INFORMATION LIG HTS/METERS/SWITCHES ......... ........................ 20-5
ALTERNATOR ........................................................ · 11-3 LUBRICATION SYSTEM ...................... .............. .. .... · 5-4
(
BATTERY/CHARGING SYSTEM ............ ·.............. · 17-3 REAR WHEEL SUSPENSION ...... ...... .... .......... ...... · 15-6
CLUTCH/STARTER CLUTCH/ TURN SIGNAL LIGHT .......... ·· .. .. .................................. 20-7
GEARSHIFT LlNKAGE ............................................ 10-3 TURN SIGNAL RELAY ·.......... .......... ·........ .. .............. · 20-23
COOLING SYSTEM .......................... ..... ............ ....... 7-3 UPPER COWUFRONT SPOILER .............................. .. ·3-11
CRANKCASE/TRANSMISSION··· ···· .. ···· .. ·········· .. ··· 12-3 UPPER INNER COWUHEADLIGHT COVER .. .... ...... .... ·3-7
CRANKSHAFT/PISTON/CYLINDER ................ .. .. ... 13-3 VALVE CLEARANCE .................................................... 4-13
CYLINDER HEADNALVES ....................................... 9-3 VALVE GUlDE REPLACEMENT .... .. ............................ 9-20
ELECTRIC STARTER .... ...... ........ · ...... .... .. .......... .. .... 19-3 VALVE SEAT INSPECTION/REFACING ........ .. ............ 9-21
ENGINE REMOVAUINSTALLATION ........... ............ 8-3 WATER PUMP .. .. · .................... .. .............. · .................. ·7-16
FRAME/BODY PANELS/EXHAUST SYSTEM .... ·.. ·.. 3-3 WHEELS/TIRES ............ ..... ....... .... ....... ........ ... ... .. ..... ... . 4-3 5
FRONT WHEEUSUSPENSION/STEERING ........... 14-3 WiNDSCREEN··· ·········· .. ············· .. ·· ··· ·...... ·········· .. ··· .... ·3-10
FUEL SYSTEM (PGM-FI) .............. .. .......................... 6-3 WIRING DIAGRAM ...... .. · .......................................... .. ·2 1-3
HYDRAULIC BRAKE ........... ...... ...... ................ .. ...... 16-4
i.
23-2

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""""""'" ...... _ , - . . . ................. :":,:.:

--_..... _....'--_........... ,."' - - - -

SERVICE RULES ·· .. ···· .. ············· ··· ...... ·· .. · .. ·· 1-2 REAR WHEELISUSPENSION

CRANKCASE/TRANSMISSION LUBRICATION & SEAL POINTS ······· ·· ··· ·· 1-19

Abbrev. tenn Full term

FUEL SYSTEM (PGM-FI) SPECIFICATIONS

COOLING SYSTEM SPECIFICATIONS

CLUTCH/STARTER CLUTCH/GEARSHIFT LlNKAGE SPECIFICATIONS

REAR WHEEL/ SUSPENSION SPECIFICATIONS

BATTERYICHARGING SYSTEM SPECIFICATIONS

IGNITION SYSTEM SPECIFICATIONS

ELECTRIC STARTER SPECIFICATIONS

ENGINE & FRAME TORQUE VALUES

FUEL SYSTEM (PGM-FI)

CLUTCH/ STARTER CLUTCH/ GEARSHIFT LlNKAGE

FUEL SYSTEM (PGM-FI)

ENG INE REMOVALlINSTALLATION

BANK ANGLE SENSOR

LEFTTURN SIGNAL WIRE

THROTILE CAB LES CLUTCH CABLE

FRONT BRAKE LIGHT

FRONT BRAKE HOSE

LEFT HANDLEBAR SWITCH WIRE

LEFT HANDLE BAR

FRONT BRAKE HOSE

FRONT BRAKE HOSE

BANK ANGLE SENSOR

lAT SENSOR 2P (Gray) CONNECTOR ECM

REGULATOR/RECTIFIER MAIN WIRE HARNESS

lAT SENSOR 2P (Gray) CONNECTOR

~~~~rtr RIGHT HANDLE BAR

FUEL HOSE COVER MAIN WIRE HARNESS

ALTERNATOR 3P (Natural ) SIDESTAND SWITCH 2P

FAN MOTER 2P (Blaek)

CMP SENSOR WIRE

FUEL TANK DRAIN HO SE

FUEL HOSE FUEL PUMP 2P I Brow n) CONNECTOR

FUEL TANK BREATHER HOSE

FUEL LEVEL SENSOR

KNOCK SENSOR GROUND CABLE

SIDESTAND SWITCH WIRE

FUEL TANK DRAIN HOSE

FUEL TANK BREATHER HOSE

PAIR CONTROL SOLENOID

PAIR CONTROL SOLENOID VALVE

IGNITION SUB HARNESS THROTILE CAB LES

IGNITION SUB HARNESS

IACV 4P IBlaek) CONNECTOR

No. 4 PRIMARY INJECTOR

No. 1 PRIMARY INJECTOR

KNOCK SENSOR 3P No. 2 PRIMARY INJECTOR

EGCV 6P (Natu ra l) CONNECTOR

STARTER RELAY SWITCH

REAR BRAKE LIGHT SWITCH

TURN SIGNAL RELAY

EGCV CONTROL CABLES

REAR BRAKE LIGHT

REAR BRAKE HOSE ~-4~~ r-_-'"

REAR BRAKE LIGHT SWITCH

LEFT TURN SIGNAL LIGHT WIRE

PAINTMARK EVAP CANISTER

EVAP CANISTER DRAIN HOSE