Xre300a (2017-2019)

Shop Manual
XRE300/A
1. General Information
2. Fuel & Engine
3. Frame & Chassis
4. Electrical System
5. XRE300/A
45?.;;75?<1/5/4;<-:A-8Ð
Refer to “Basic Shop Manual” for basic and
00X62-KWTM-002
common maintenance instructions. (2016 ~ 2019)
1. GENERAL INFORMATION
A Few Words About Safety ···················· 1-2 SPECIAL TOOL LIST····························· 1-16
How To Use This Manual························ 1-3 CABLE & HARNESS ROUTING ············ 1-17
MODEL IDENTIFICATION ······················· 1-5 EMISSION CONTROL SYSTEMS·········· 1-32
SPECIFICATIONS ···································· 1-6 TECHNICAL FEATURE ························· 1-33
TORQUE VALUE···································· 1-11 MAINTENANCE SCHEDULE················· 1-34
1-1
GENERAL INFORMATION
GENERAL INFORMATION
A Few Words About Safety

Service Information
The service and repair information contained in this manual is intended for use by qualified, professional technicians.
Attempting service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also
damage the vehicle or create an unsafe condition.
This manual describes the proper methods and procedures for performing service, maintenance and repairs. Some procedures
require the use of specially designed tools and dedicated equipment. Any person who intends to use a replacement part, service
procedure or a tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of
the vehicle.
If you need to replace a part, use genuine Honda parts with the correct part number or an equivalent part. We strongly recommend
that you do not use replacement parts of inferior quality.
For Your Customer’s Safety

Proper service and maintenance are essential to the customer’s safety and the reliability of the vehicle. Any error or oversight while
servicing a vehicle can result in faulty operation, damage to the vehicle, or injury to others.
Improper service or repairs can create an unsafe

condition that can cause your customer to be
seriously hurt or killed.
Follow the procedures and precautions in this
manual and other service materials carefully.
For Your Safety

Because this manual is intended for the professional service technician, we do not provide warnings about many basic shop safety
practices (e.g., Hot parts–wear gloves). If you have not received shop safety training or do not feel confident about your knowledge
of safe servicing practice, we recommended that you do not attempt to perform the procedures described in this manual.
Some of the most important general service safety precautions are given below. However, we cannot warn you of every
conceivable hazard that can arise in performing service and repair procedures. Only you can decide whether or not you should
perform a given task.
Failure to properly follow instructions and

precautions can cause you to be seriously hurt or
killed.
Follow the procedures and precautions in this
manual carefully.
Important Safety Precautions

Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and
using safety equipment. When performing any service task, be especially careful of the following:
• Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills
required to perform the tasks safely and completely.
• Protect your eyes by using proper safety glasses, goggles or face shields any time you hammer, drill, grind, pry or work around
pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye protection.
• Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe
burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.
• Protect yourself and others whenever you have the vehicle up in the air. Any time you lift the vehicle, either with a hoist or a jack,
make sure that it is always securely supported. Use jack stands.
Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will
help eliminate several potential hazards:
• Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine
• Burns from hot parts or coolant. Let the engine and exhaust system cool before working in those areas.
• Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way.
Gasoline vapors and hydrogen gases from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when
working around gasoline or batteries.
• Use only a nonflammable solvent, not gasoline, to clean parts.
• Never drain or store gasoline in an open container.
• Keep all cigarettes, sparks and flames away from the battery and all fuel-related parts.
1-2
GENERAL INFORMATION
How To Use This Manual

This manual is "Spec (Specific)" Service Manual. The service and repair information for this model is described in this
manual as specific information. Refer to “Basic" Service Manual for basic/common service information and
instructions.
Follow the Maintenance Schedule recommendations to ensure that the vehicle is in peak operating condition.
Performing the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the
break-in period.
Find the section you want on this page, then turn to the table of contents on the first page of the section.
Your safety, and the safety of others, is very important. To help you make informed decisions we have provided
safety messages and other information throughout this manual. Of course, it is not practical or possible to warn you
about all the hazards associated with servicing this vehicle.
You must use your own good judgement.
You will find important safety information in a variety of forms including:
• Safety Labels – on the vehicle
• Safety Messages – preceded by a safety alert symbol and one of three signal words, DANGER, WARNING,
or CAUTION. These signal words mean:
You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions.
You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions.
You CAN be HURT if you don’t follow instructions.
• Instructions – how to service this vehicle correctly and safely.
As you read this manual, you will find information that is preceded by a symbol. The purpose of this message
is to help prevent damage to your vehicle, other property, or the environment.
ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS

PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF
APPROVAL FOR PRINTING. Honda Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY
TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATSOEVER. NO PART OF THIS
PUBLICATION MAY BE REPRODUCED WITHOUT WRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR
PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTENANCE ON Honda MOTORCYCLES,
MOTOR SCOOTERS OR ATVS.
© Honda Motor Co., Ltd.

SERVICE PUBLICATION OFFICE
Date of Issue: October, 2015
1-3
GENERAL INFORMATION
SYMBOLS
The symbols used throughout this manual show specific service procedures. If supplementary information is required
pertaining to these symbols, it would be explained specifically in the text without the use of the symbols.
INSTRUCTION SYMBOL
Removal or Disassembly procedure. Installation or Assembly procedure.

Disconnect the connector. Connect the connector.
Order of installation/assembly with a point of

Order of removal/disassembly with a point of note.
note.
Tighten specified torque. Replace with a new one before assembly.
Check the part for an inspection. Measure the part for an inspection.
Turn ignition switch to OFF. Turn ignition switch to ON.
Start the engine. Measure a resistance or check continuity.
Measure a voltage. Measure an ampere.
Refer to “Basic” Service Manual for the instruc-

Use the Honda special tool.
tion.
LUBRICATION AND SEAL SYMBOL

Apply molybdenum oil solution (mixture of an
Use the recommend engine oil. engine oil and molybdenum grease in a ration of
1:1).
Apply a specified grease. Use a multi-purpose
Apply a liquid sealant.
grease unless otherwise specified.
Apply a locking agent. Use a medium strength

Use DOT 3 or DOT 4 brake fluid.
one unless otherwise specified.
Use a specified fork oil or suspension fluid.
1-4
GENERAL INFORMATION
MODEL IDENTIFICATION
• Model name: XRE300/A-G
DESTINATION
TYPE CODE ABS/CBS
XRE300-G IIBR –
IIILA –
VLA –
AG –
IIAG –
CO –
IICO –
XRE300A-G IIBR O
ENGINE SERIAL NUMBER VEHICLE IDENTIFICATION NUMBER
1-5
GENERAL INFORMATION
SPECIFICATIONS
GENERAL SPECIFICATIONS
ITEM SPECIFICATIONS
DIMENSIONS Overall length 2,171 mm
Overall width 838 mm
Overall height 1,181 mm
Wheelbase 1,417 mm
Seat height 860 mm
Footpeg height 345 mm
Ground clearance 259 mm
Curb weight XRE300 157 kg
XRE300A 163 kg
Maximum weight capacity 155 kg
FRAME Frame type Semi-double cradle
Front suspension Telescopic fork
Front axle travel 219 mm
Rear suspension Swingarm
Rear axle travel 225 mm
Front tire size 90/90-21M/C 54S
Rear tire size 120/80-18M/C 62S
Front tire brand METZELER ENDURO 3
Rear tire brand METZELER ENDURO 3
Front brake Hydraulic single disc
Rear brake Hydraulic single disc
Caster angle 26°48’
Trail length 109.7 mm
Fuel tank capacity 13.8 liters
Fuel tank reserve capacity 3.9 liters
ENGINE Cylinder arrangement Single cylinder 15° inclined from vertical
Bore and stroke 79.0 x 59.502 mm
Displacement 291.66 cm3
Compression ratio 9.0 : 1
Valve train Chain driven, DOHC
Intake valve opens 5° BTDC at 1 mm lift
closes 35° ABDC at 1 mm lift
Exhaust valve opens 40° BBDC at 1 mm lift
closes 0° TDC at 1 mm lift
Lubrication system Forced pressure and wet sump
Oil pump type Trochoid
Cooling system Air cooled
Air filtration Viscous paper filter
Engine dry weight 36.6 kg
Emission control system Crankcase emission control system
Three-way catalytic converter
FUEL SYSTEM Type PGM-FI
Throttle bore 36 mm
1-6
GENERAL INFORMATION
ITEM SPECIFICATIONS
DRIVE TRAIN Clutch system Multi-plate, wet
Clutch operation system Cable operating
Transmission Constant mesh, 5-speed
Primary reduction 2.875 (69/24)
Final reduction 3.000 (39/13)
Gear ratio 1st 3.166 (38/12)
2nd 1.941 (33/17)
3rd 1.380 (29/21)
4th 1.083 (26/24)
5th 0.884 (23/26)
Gearshift pattern Left foot operated return system
1-N-2-3-4-5
ELECTRICAL Ignition system Full transistorized ignition
Starting system Electric starter motor
Charging system Triple phase output alternator
Regulator/rectifier SCR shorted, triple phase full wave rectification
Lighting system Battery
FUEL & ENGINE SPECIFICATIONS

FUEL SYSTEM
ITEM SPECIFICATIONS
Throttle body identification number GQ3DA
Idle speed 1,400 ± 100 rpm
Throttle grip freeplay 2 – 6 mm
Fuel pressure at idle 317 – 374 kPa
Fuel pump flow (at 12 V) 232 cm3 minimum/10 seconds
CO concentration (IIBR only) 0.2% maximum
HC concentration (IIBR only) 100 ppm maximum
LUBRICATION SYSTEM
Unit: mm
ITEM STANDARD LIMIT
Engine oil capacity After draining 1.4 liters –
After draining/filter change 1.5 liters –
After disassembly 2.0 liters –
Recommended engine oil Honda “4-stroke motorcycle oil” or an
equivalent motor oil.
API service classification: SG or higher –
JASO T903 standard: MA
Viscosity: SAE 10W-30
Oil pump rotor Tip clearance 0.15 0.20
1-7
GENERAL INFORMATION
CYLINDER HEAD/VALVE
Unit: mm
ITEM STANDARD LIMIT
Cylinder compression 1,196 kPa at 400 rpm –
Valve clearance IN 0.12 ± 0.03 –
EX 0.15 ± 0.03 –
Camshaft Cam lobe height IN 37.000 – 37.240 36.94
EX 37.030 – 37.270 36.97
Oil clearance 0.020 – 0.062 0.10
Valve, Valve guide Valve stem O.D. IN 4.975 – 4.990 4.96
EX 4.955 – 4.970 4.94
Valve guide I.D. IN/EX 5.000 – 5.012 5.03
Valve seat width IN/EX 1.0 – 1.2 2.0
Valve spring free length Inner 33.77 32.36
Outer 36.64 34.84
Valve lifter Valve lifter O.D. IN/EX 25.978 – 25.993 25.97
Valve lifter bore O.D. IN/EX 26.010 – 26.026 26.06
Cylinder head warpage – 0.10
CYLINDER/PISTON
Unit: mm
ITEM STANDARD LIMIT
Cylinder I.D. 79.000 – 79.010 79.11
Warpage – 0.10
Piston, Piston pin Piston O.D. at 13 mm from
78.960 – 78.980 78.88
bottom of skirt
Piston pin bore I.D. 18.002 – 18.008 18.05
Piston pin O.D. 17.994 – 18.000 17.97
Piston rings Piston ring end gap Top 0.200 – 0.350 0.45
Second 0.40 – 0.55 0.65
Oil (side rail) 0.20 – 0.70 0.90
Piston ring-to-ring Top 0.030 – 0.065 0.135
groove clearance Second 0.015 – 0.045 0.115
Connecting rod small end I.D. 18.016 – 18.034 18.06
CLUTCH/GEARSHIFT LINKAGE
Unit: mm
ITEM STANDARD LIMIT
Clutch lever freeplay 10 – 20 –
Clutch Clutch spring free length 45.9 41.3
Disc thickness 2.92 – 3.08 2.69
Plate warpage – 0.30
Clutch outer guide I.D. 20.000 – 20.021 –
O.D. 27.980 – 27.993 –
Primary driven gear I.D. 33.000 – 33.025 –
Mainshaft O.D. at clutch outer guide 19.959 – 19.980 –
ALTERNATOR/STARTER CLUTCH
Unit: mm
ITEM STANDARD LIMIT
Starter driven gear I.D. 31.000 – 31.025 –
O.D. 51.660 – 51.673 –
1-8
GENERAL INFORMATION
CRANKCASE/CRANKSHAFT/BALANCER
Unit: mm
ITEM STANDARD LIMIT
Connecting rod Side clearance 0.05 – 0.50 0.60
Radial clearance 0.006 – 0.014 0.05
Crankshaft Runout – 0.05
TRANSMISSION
Unit: mm
ITEM STANDARD LIMIT
Transmission Gear I.D. M4, M5 23.000 – 23.021 –
C1 21.000 – 21.021 –
C2, C3 25.020 – 25.041 –
Gear bushing O.D. M4, M5 22.959 – 22.980 –
C1 20.959 – 20.980 –
C2, C3 24.979 – 25.000 –
Gear bushing I.D. M4 20.000 – 20.021 –
C1 18.000 – 18.018 –
C2, C3 22.000 – 22.021 –
Mainshaft O.D. at M4 bushing 19.959 – 19.980 –
Countershaft O.D. at C1 bushing 17.966 – 17.984 –
at C2, C3
21.959 – 21.980 –
bushing
Shift fork, Fork I.D. 13.000 – 13.021 –
Shift fork Fork shaft O.D. 12.966 – 12.984 –
shaft Claw thickness 4.93 – 5.00 4.5
FRAME & CHASSIS SPECIFICATIONS

FRONT WHEEL/SUSPENSION/STEERING
Unit: mm
ITEM STANDARD LIMIT
Cold tire pressure Driver only 150 kPa –
Driver and passenger 150 kPa –
Axle runout – 0.2
Wheel rim runout Radial – 1.0
Axial – 1.0
Fork Spring free length 506.3 496.2
Recommended fluid Honda Ultra Cushion Oil 10W –
Fluid level 143 –
Fluid capacity 547 ± 2.5 cm3 –
REAR WHEEL/SUSPENSION
Unit: mm
ITEM STANDARD LIMIT
Cold tire pressure Driver only 150 kPa –
Driver and passenger 200 kPa –
Axle runout – 0.2
Wheel rim runout Radial – 1.0
Axial – 1.0
Drive chain slack 20 – 30 60
Drive chain size/link DID520VD-104LE –
1-9
GENERAL INFORMATION
HYDRAULIC BRAKE
Unit: mm
ITEM STANDARD LIMIT
Front Specified brake fluid DOT 4 brake fluid –
Brake disc thickness 4.0 ± 0.2 3.5
Brake disc warpage – 0.3
Master cylinder I.D. 12.700 – 12.743 –
Master piston O.D. 12.657 – 12.684 –
XRE300 Caliper cylinder I.D. 27.000 – 27.050 –
Caliper piston O.D. 26.918 – 26.968 –
XRE300A Caliper cylinder I.D. Upper, lower 27.000 – 27.050 –
Middle 22.650 – 22.700 –
Caliper piston O.D. Upper, lower 26.918 – 26.968 –
Middle 22.585 – 22.618 –
Rear Specified brake fluid DOT 4 brake fluid –
Brake disc thickness 4.5 ± 0.2 4.0
Brake disc warpage – 0.3
XRE300 Master cylinder I.D. 12.700 – 12.743 –
Master piston O.D. 12.657 – 12.684 –
Caliper cylinder I.D. 27.000 – 27.050 –
XRE300A Master cylinder I.D. 17.460 – 17.503 –
Master piston O.D. 17.417 – 17.444 –
Caliper cylinder I.D. 38.18 – 38.23 –
ELECTRICAL SYSTEM SPECIFICATIONS

PGM-FI SYSTEM
ITEM SPECIFICATIONS
IAT sensor resistance (25°C) 1.8 – 2.4 kȍ
EOT sensor resistance (20°C) 2.5 – 2.8 kȍ
Fuel injector resistance (24°C) 11 – 13 ȍ
O2 sensor heater resistance (20°C) 6.7 – 9.5 ȍ
IACV resistance (25°C) 90 – 130 ȍ
IGNITION SYSTEM
ITEM SPECIFICATIONS
Spark plug SILMAR7D9DS (NGK)
Spark plug gap 0.8 – 0.9 mm
Ignition coil peak voltage 100 V minimum
CKP sensor peak voltage 0.7 V minimum
Ignition timing ("F"mark) 8° BTDC at idle speed
BATTERY/CHARGING SYSTEM
ITEM SPECIFICATIONS
Battery Type YTZ7S
Capacity 12 V – 6 Ah (10 HR)
Voltage (20°C) Fully charged 12.8 V minimum
Needs charging Below 12.3 V
Charging Normal 0.6 A/5 – 10 h
current Quick 3 A/1 h
Current leakage 0.05 mA maximum
Alternator Capacity 0.275 kW/5,000 rpm
Charging coil resistance (20°C) 0.1 – 1.0 ȍ
1-10
GENERAL INFORMATION
LIGHTS/METERS/SWITCHES
ITEM SPECIFICATIONS
Bulb Headlight Hi/Lo 12 V – 60/55 W
Brake/taillight 12 V – 21/5 W
Turn signal light 12 V – 16 W x 4
Fuse Main fuse 30 A
Sub fuse 10 A x 3, 15 A
ABS fuse (XRE300A) 30 A x 2, 10 A
Fuel level sensor resistance Full 6 – 10 ȍ
Empty 75 – 81 ȍ
TORQUE VALUE
• Each fastener should be tightened to the standard torque value except the fasteners specified torque value.
• Q’TY: Quantity, DIA: Thread diameter (mm), TRQ: Tightening torque (N·m)
STANDARD TIGHTENING TORQUE
FASTENER TYPE TRQ FASTENER TYPE TRQ
5 mm hex bolt and nut 5.2 5 mm screw 4.2
6 mm hex bolt and nut 10 6 mm screw 9.0
8 mm hex bolt and nut 22 6 mm flange bolt 12
10 mm hex bolt and nut 34 8 mm flange bolt and nut 27
12 mm hex bolt and nut 54 10 mm flange bolt and nut 39
FUEL TANK
ITEM Q'TY DIA TRQ REMARKS
Fuel filler cap socket bolt 3 4 1.8
AIR CLEANER
Air cleaner cover screw 4 4 1.1
THROTTLE BODY
Throttle cable A lock nut (throttle body side) 1 6 4.5
Throttle cable B lock nut (throttle body side) 1 6 4.5
Sensor unit torx screw 3 5 3.4
IACV setting plate torx screw 2 4 2.1
Throttle cable stay screw 2 5 3.4
Injector joint bolt 2 5 5.1
Fuel hose clamp stay screw 1 5 3.4
LUBRICATION SYSTEM
Oil drain bolt 1 12 30
Oil pump relief valve cap 1 14 19
Oil pipe joint bolt (oil cooler side) 4 6 13
1-11
GENERAL INFORMATION
CYLINDER HEAD
Crankshaft hole cap 1 30 8.0 Apply grease.
Timing hole cap 1 14 10 Apply grease.
Cylinder head cover bolt 3 6 12
Camshaft holder bolt 8 6 12 Apply engine oil.
Cam chain tensioner lifter plug screw 1 6 4.0
Cylinder head nut 4 10 45 Apply engine oil.
Oil pass pipe bolt 1 7 12
2 8 12
Throttle body insulator bolt 2 6 12
CYLINDER/PISTON
Cylinder stud bolt 4 10 – Î2-26
Clutch center lock nut 1 16 108 Apply engine oil. Stake.
Clutch spring bolt 5 6 12
Primary drive gear lock nut 1 16 108 Apply engine oil.
Shift drum stopper arm bolt 1 6 12
Flywheel bolt 1 12 103 Apply engine oil.
Starter clutch outer socket bolt 6 7 21 Apply locking agent.
CKP sensor socket bolt 2 5 5.2 Pre-coated (ALOC) bolt,
replace with a new one.
Alternator stator socket bolt 3 6 10
Alternator stator wire clamp socket bolt 1 6 10
Gearshift return spring pin 1 8 24 Apply locking agent.
ENGINE UNIT
Front upper engine hanger nut 1 10 49
Front upper engine hanger bracket nut 2 8 26
Front engine hanger nut 1 10 49
Front engine hanger bracket nut 2 8 26
Front lower engine hanger nut 1 10 49
Rear engine hanger nut 1 10 49
Rear engine hanger bracket bolt 2 8 26
Rear lower engine hanger nut 1 10 49
Upper engine hanger nut 1 10 49
Upper engine hanger bracket nut 2 8 26
Drive sprocket fixing plate bolt 2 6 10
BODY PANELS
Drive chain slider screw 1 5 4.2 Pre-coated (ALOC) bolt,
Driver footpeg bolt 2 12 84
Gearshift pedal bolt 1 6 12 Pre-coated (ALOC) bolt,
1-12
GENERAL INFORMATION
SIDESTAND
Sidestand pivot bolt 1 10 10 Î3-18
Sidestand pivot nut 1 10 39 U-nut
EXHAUST PIPE/MUFFLER
Muffler mounting bolt (front) 1 8 26
Muffler mounting nut (rear) 1 8 30
Muffler band bolt 1 8 20
Muffler protector bolt 3 6 14
Exhaust pipe joint nut 2 8 18
Exhaust pipe protector bolt 2 6 14
FRONT WHEEL
Front axle 1 12 59
Front axle holder nut 4 6 12 U-nut
Front brake disc bolt 4 8 42 Pre-coated (ALOC) bolt,
Front pulser ring bolt (XRE300A) 3 5 7.0 Pre-coated (ALOC) bolt,
FORK
Top bridge pinch bolt 4 8 21
Bottom bridge pinch bolt 4 8 32
Front brake hose clamp bolt 2 6 12
Fork bolt 2 37 22
Fork socket bolt 2 8 20 Apply locking agent.
HANDLEBAR
Left handlebar switch screw 2 5 2.5
Right handlebar switch screw 2 5 2.5
Clutch lever pivot bolt 1 6 1.0
Clutch lever pivot nut 1 6 5.9
Throttle cable A adjuster lock nut 1 7 3.8
Throttle cable A lock nut (grip side) 1 10 3.0
Throttle cable B lock nut (grip side) 1 12 3.0
STEERING STEM
Steering stem nut 1 24 103
Steering stem adjusting nut 1 26 – Î3-26
REAR WHEEL
Rear axle nut 1 16 88 U-nut
Driven sprocket nut 6 10 45 U-nut
Rear brake disc bolt 4 8 42 Pre-coated (ALOC) bolt,
Rear pulser ring bolt (XRE300A) 4 5 7.0 Pre-coated (ALOC) bolt,
1-13
GENERAL INFORMATION
REAR SUSPENSION
Shock absorber upper bolt 1 10 54 U-nut
Shock absorber lower nut 1 10 44 U-nut
Shock link nut (frame side) 1 10 44 U-nut
Shock link nut (shock arm side) 1 10 44 U-nut
Shock arm nut 1 12 78 U-nut
Swingarm pivot nut 1 14 88 U-nut
Drive chain slider screw 1 5 4.2 Pre-coated (ALOC) bolt,
FRONT BRAKE
Front master cylinder reservoir cover screw 2 4 1.5
Front brake master cylinder holder bolt 2 6 12
Front brake hose oil bolt (XRE300) 2 10 34
Front brake hose oil bolt (XRE300A) 3 10 34
Brake lever pivot bolt 1 6 1.0
Brake lever pivot nut 1 6 5.9
Front brake light switch screw 1 4 1.2
Front brake pad pin 1 10 17
Front brake pad pin plug (XRE300) 1 10 2.5
Front brake caliper bolt 2 8 30 Pre-coated (ALOC) bolt,
Front brake caliper pin bolt (XRE300) 1 8 22
Front brake caliper bleed valve (XRE300) 1 8 5.4
Front brake caliper bleed valve (XRE300A) 2 8 5.4
REAR BRAKE
Rear master cylinder reservoir cover screw 2 4 1.5
Rear master cylinder reservoir bolt 1 6 12
Brake hose oil bolt 2 10 34
Rear master cylinder bolt 2 6 12
Rear master cylinder hose joint screw 1 4 1.5 Apply locking agent.
Rear master cylinder push rod lock nut 1 8 17
(XRE300)
Rear brake pad pin 1 10 17
Rear brake pad pin plug (XRE300) 1 10 2.5
Rear brake caliper bolt (XRE300A) 1 8 22 Pre-coated (ALOC) bolt,
Rear brake caliper bleed valve 1 8 5.4
Rear brake caliper pin bolt 1 12 27
Rear brake caliper bracket pin bolt 1 6 12 Apply locking agent.
(XRE300)
PGM-FI SYSTEM
EOT sensor 1 10 15
O2 sensor 1 12 25
Bank angle sensor bolt 2 4 2.0
IGNITION SYSTEM
Spark plug 1 10 16
1-14
GENERAL INFORMATION
ELECTRICAL STARTER
Starter motor terminal nut 1 6 12
Neutral switch 1 10 12
ABS SYSTEM (XRE300A)
Brake pipe joint nut 12 10 14 Apply brake fluid to the
threads.
SPEEDOMETER
Combination meter screw 3 5 1.0
ELECTRICAL COMPONENT
Ignition switch bolt 2 8 27 One-way bolt, replace with a
new one.
Sidestand switch bolt 1 6 10 Pre-coated (ALOC) bolt,
OTHERS
Front wheel spoke nipple 36 6 3.7
Rear wheel spoke nipple 36 6 3.7
1-15
GENERAL INFORMATION
SPECIAL TOOL LIST

TITLE TOOL No. TOOL NAME
07406-0040004 Fuel pressure gauge
070MJ-K260100 Fuel pressure gauge attachment set
070MF-KVS0300 Fuel pump case remover
070PZ-ZY30100 SCS connector
070MG-0010100 Cam chain tensioner lifter stopper
Fuel & Engine 07757-0010000 Valve spring compressor
07959-KM30101 Valve spring compressor attachment
07984-MA60001 Valve guide reamer, 5.0 mm
07942-MA60000 Valve guide driver, 5.0 mm
07724-0010100 Gear holder
07724-0050002 Clutch center holder
07725-0040001 Flywheel holder
07733-0020001 Flywheel puller
07631-0010000 Universal bearing puller
07965-VM00100 Assembly collar
07965-VM00300 Assembly adaptor
07965-VM00200 Assembly shaft
07749-0010000 Driver
07746-0041300 Pilot, 16 mm
07746-0050400 Remover head, 15 mm
07746-0050100 Bearing remover shaft
07741-0010201 Bearing remover weight
07749-0010000 Driver
07746-0010100 Attachment, 32 x 35 mm
07746-0040300 Pilot 15 mm
07747-KA50100 Fork seal driver weight
07947-KF00100 Driver attachment, 41 mm I.D.
07916-3710101 Lock nut wrench, 5.7 x 37.5 mm
07948-4630100 Ball race remover
07946-4300101 Driver
Frame & Chassis
07746-0010300 Attachment, 42 x 47 mm
07746-0050500 Remover head, 17 mm
07GGD-0010100 Bearing remover shaft
07746-0010200 Attachment, 37 x 40 mm
07746-0040400 Pilot 17 mm
07946-1870100 Attachment, 28 x 30 mm
07746-0010700 Attachment, 24 x 26 mm
07746-0040500 Pilot 20 mm
07946-0010800 Attachment, 22 x 24 mm
07931-MA700000 Needle bearing remover, 20 mm
07914-SA50001 Snap ring pliers
070PZ-ZY30100 SCS connector
Electrical System
07HGJ-0020100 Peak voltage adapter
1-16
GENERAL INFORMATION
CABLE & HARNESS ROUTING
XRE300:
2 ± 1 mm
10° ± 5°
RIGHT FRONT RIGHT FRONT

TURN SIGNAL WIRE TURN SIGNAL WIRE
HANDLE PIPE
CENTER
90° ± 5°
BRAKE HOSE
MAIN WIRE HARNESS

LEFT FRONT
TURN SIGNAL WIRE
IGNITION SWITCH WIRE
1-17
GENERAL INFORMATION
XRE300A:
2 ± 1 mm
10° ± 5°
RIGHT FRONT RIGHT FRONT

TURN SIGNAL WIRE TURN SIGNAL WIRE
HANDLE PIPE
CENTER
90° ± 5°
BRAKE HOSE
MAIN WIRE HARNESS

LEFT FRONT
TURN SIGNAL WIRE
IGNITION SWITCH WIRE
1-18
GENERAL INFORMATION
BRAKE HOSE
FRONT
Contact.
FRONT RIGHT HANDLEBAR
SWITCH WIRE
LEFT HANDLEBAR
SWITCH WIRE
LEFT HANDLEBAR
SWITCH WIRE
FRONT
LEFT HANDLEBAR
SWITCH WIRE
RIGHT HANDLEBAR
THROTTLE CABLE B SWITCH WIRE
CLUTCH CABLE
THROTTLE CABLE A
1-19
GENERAL INFORMATION
XRE300:
BRAKE HOSE
VS SENSOR WIRE
Contact.
1-20
GENERAL INFORMATION
XRE300A: FRONT BRAKE HOSE
FRONT
FRONT WHEEL SPEED

SENSOR WIRE
Contact.
FRONT
Contact.
FRONT BRAKE HOSE
FRONT
VS SENSOR WIRE
1-21
GENERAL INFORMATION
FUEL PUMP WIRE FUEL HOSE (Return)
FUEL HOSE (Feed)
7 ± 2 mm
18 mm
FUEL TANK
BREATHER HOSE
20 mm
FUEL TANK
DRAIN HOSE
FUEL LEVEL SENSOR WIRE
1-22
GENERAL INFORMATION
XRE300: BANK ANGLE SENSOR

3P CONNECTOR
HEAT PROTECTOR
(IIBR only)
VS SENSOR WIRE
REGULATOR/RECTIFIER
5P CONNECTOR
STARTER MOTOR CABLE
MAIN WIRE
HARNESS
O2 SENSOR WIRE
BATTERY
NEGATIVE (–)
CABLE
HORN WIRE SIDESTAND
SWITCH WIRE
ALTERNATOR WIRE
SIDESTAND
SWITCH WIRE
1-23
GENERAL INFORMATION
BRAKE PIPE FRONT WHEEL

XRE300A:
SPEED SENSOR
2P CONNECTOR
HEAT PROTECTOR
(IIBR only)
VS SENSOR WIRE
BANK ANGLE SENSOR

3P CONNECTOR
REGULATOR/RECTIFIER
5P CONNECTOR
BRAKE PIPE
BRAKE PIPE
STARTER MOTOR CABLE
MAIN WIRE
HARNESS
O2 SENSOR WIRE
BATTERY
HORN WIRE NEGATIVE (–)
SIDESTAND CABLE
SWITCH WIRE
ALTERNATOR WIRE
SIDESTAND
SWITCH WIRE
1-24
GENERAL INFORMATION
12 ± 1 mm
SENSOR UNIT
BATTERY 5P CONNECTOR
NEGATIVE (–)
CABLE FUEL TANK
DRAIN HOSE
FRONT
STARTER MOTOR CABLE

AIR CLEANER HOUSING ALTERNATOR WIRE
FUEL TANK BREATHER HOSE DRAIN HOSE
XRE300A: REAR BRAKE PIPE B FRONT BRAKE PIPE C
FRONT BRAKE PIPE B REAR BRAKE PIPE A

MAIN WIRE HARNESS
ABS FUSE BOX
ABS FUSE BOX

1P CONNECTOR
STARTER MOTOR
CABLE
1-25
GENERAL INFORMATION
FUEL PUMP 2P CONNECTOR
STARTER MOTOR CABLE
BRAKE PIPE
(XRE300A)
ALTERNATOR WIRE
SIDESTAND
SWITCH WIRE
FUEL HOSE (Feed)

FUEL HOSE (Feed)
FUEL HOSE (To injector) FUEL HOSE (To injector)
FUEL HOSE (Return)
FUEL HOSE (Return)
1-26
GENERAL INFORMATION
ABS SERVICE CHECK

XRE300A: 2P CONNECTOR
10 mm maximum
FRAME
MAIN WIRE HARNESS
BRAKE PIPE
AIR CLEANER HOUSING

DRAIN HOSE
FUEL TANK BREATHER HOSE FUEL TANK DRAIN HOSE
FUEL TANK DRAIN HOSE FUEL TANK BREATHER HOSE
1-27
GENERAL INFORMATION
ALTERNATOR WIRE
NEUTRAL SWITCH WIRE
XRE300A shown: LEFT HANDLEBAR O2 SENSOR WIRE

SWITCH WIRE
THROTTLE CABLE B
RIGHT HANDLEBAR MAIN WIRE HARNESS

THROTTLE CABLE A
SWITCH WIRE
CLUTCH CABLE
THROTTLE CABLE B BRAKE PIPE

VS SENSOR WIRE (XRE300A)
THROTTLE CABLE A
CLUTCH CABLE
MAIN WIRE HARNESS
BRAKE PIPE
(XRE300A)
CLUTCH SWITCH
2P CONNECTOR
LEFT HANDLEBAR RIGHT HANDLEBAR

9P CONNECTOR 9P CONNECTOR
1-28
GENERAL INFORMATION
XRE300A shown: REAR WHEEL SPEED SENSOR WIRE
REAR BRAKE LIGHT 90° ± 5°

SWITCH WIRE
Contact.
XRE300A shown:
MAIN WIRE HARNESS

MAIN WIRE HARNESS
(To rear wheel speed sensor)
(To IACV)
REAR WHEEL SPEED

SENSOR WIRE
35°
CRANKCASE
BREATHER HOSE
9 mm
5 – 6 mm
1-29
GENERAL INFORMATION
INSIDE BOOT CONNECTORS

· BRAKE/TAILLIGHT 3P
· REAR TURN SIGNAL LIGHT
90° ± 5°
10 mm maximum
FRAME
10 mm maximum
(XRE300)
MAIN WIRE HARNESS
XRE300A: Into the groove.
BRAKE PIPE
FRONT WHEEL SPEED

FRONT BRAKE HOSE SENSOR WIRE
1-30
GENERAL INFORMATION
XRE300: Contact.
REAR BRAKE HOSE
Contact.
1-31
GENERAL INFORMATION
EMISSION CONTROL SYSTEMS

This motorcycle complies with the requirements of the Air Pollution Control Program for Motorcycles and Similar
Vehicles-PROMOT (Resolution no.297 dated 02/26/2002 of CONAMA-Environmental National Council).
POLLUTANT OF EMISSIONS
The combustion process produces carbon monoxide, oxides of nitrogen and hydrocarbons among other elements.
Control of hydrocarbon and oxides of nitrogen is very important because, under certain conditions, they react to form
photochemical smog when subjected to sunlight. Carbon monoxide does not react in the same way, but it is toxic.
Moto Honda da Amazonia Ltda. utilizes various systems to reduce carbon monoxide, oxides of nitrogen and
hydrocarbons.
CRANKCASE EMISSION CONTROL SYSTEM
The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the
atmosphere. Blow-by gas is returned to the combustion chamber through the air cleaner and throttle body.
EXHAUST EMISSION CONTROL SYSTEM
The exhaust emission control system is composed of a three-way catalytic converter and PGM-FI system.
No adjustment should be made for the exhaust emission control system. The exhaust emission control system is
separate from the crankcase emission control system.
1-32
GENERAL INFORMATION
TECHNICAL FEATURE
FUEL FILLER CAP BREATHER
The fuel tank breather function of this model is controlled by the two one-way valves (positive and negative pressure
valves) in the fuel filler cap as a substitute for a conventional vapor-liquid separator in the fuel tank.
COMPONENT FUNCTION
VALVES
They regulate the internal pressure of the fuel tank (they are closed with the spring until each specified pressure). In
addition, spilling fuel to the outside is reduced when a fall-down has occurred.
BREATHER SEAL
It is the connecting section of the fuel filler cap and breather passage of the tank, and it is prevented from leaking.
VALVE OPERATION
POSITIVE PRESSURE VALVE:
When the tank internal pressure is increased by fuel vapor, the positive pressure valve opens to release excess
pressure out of the tank.
NEGATIVE PRESSURE VALVE:
When the tank internal pressure is decreased (fuel consumption etc.), the negative pressure valve opens and
introduces air into the tank.
When increasing pressure: FUEL FILLER CAP
BREATHER PIPE
(in the fuel tank)
POSITIVE PRESSURE
VALVE (Open) BREATHER SEAL
(Close)
When decreasing pressure:
(Close)
NEGATIVE PRESSURE
VALVE (Open)
1-33
GENERAL INFORMATION
MAINTENANCE SCHEDULE
s 0ERFORMTHE0RE RIDEINSPECTIONINTHE/WNERS-ANUALATEACHSCHEDULEDMAINTENANCEPERIOD
s ))NSPECTAND#LEAN!DJUST,UBRICATEOR2EPLACEIFNECESSARY##LEAN22EPLACE!!DJUST,,UBRICATE
s 4HEFOLLOWINGITEMSREQUIRESOMEMECHANICALKNOWLEDGE#ERTAINITEMSPARTICULARLYTHOSEMARKED
AND
MAY
REQUIREMORETECHNICALINFORMATIONANDTOOLS#ONSULTADEALER
s 2EFERTOh"ASIC3ERVICE-ANUALFOREACHMAINTENANCEINSTRUCTIONEXCEPTTHEINSTRUCTIONSDESCRIBEDINTHIS
MANUAL
FREQUENCY (NOTE 1)
REFER
ITEMS NOTE X1,000 km 1 6 12 18 24 30 36 ANNUAL REGULAR TO
X1,000 mi 0.6 4 8 12 16 20 24 CHECK REPLACE PAGE

&5%,,).% ) ) ) )

&5%,&),4%2 ./4% 2 2 2

4(2/44,%/0%2!4)/. ) ) ) )

!)2#,%!.%2 ./4% 2 2
#2!.+#!3%"2%!4(%2 ./4% # # # # # # #
%VERYKM)

30!2+0,5'
%VERY2

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%.').%/), 2 2 2 2 2 2 2 2
%.').%/),&),4%2 2 2 2 2

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$2)6%#(!).3,)$%2 ./4% ) ) )
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"2!+%0!$37%!2 ) ) ) ) ) ) )
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"2!+%,)'(437)4#( ) ) ) )
(%!$,)'(4!)- ) ) ) )
#,54#(3934%- ) ) ) ) ) ) )
3)$%34!.$ ) ) ) )

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.543"/,43&!34%.%23 ./4% ) ) ) )

7(%%,34)2%3 ./4% ) ) ) ) ) ) )
34%%2).'(%!$

) ) ) )
"%!2).'3
s
3HOULDBESERVICEDBYADEALERUNLESSTHEOWNERHASPROPERTOOLSANDSERVICEDATAANDISMECHANICALLYQUALIlED
s
)NTHEINTERESTOFSAFETYWERECOMMENDTHESEITEMSBESERVICEDONLYBYADEALER
s (ONDARECOMMENDSTHATADEALERSHOULDROADTESTTHEVEHICLEAFTEREACHPERIODICMAINTENANCEISCARRIEDOUT
NOTES:
!THIGHERODOMETERREADINGSREPEATATTHEFREQUENCYINTERVALESTABLISHEDHERE
3ERVICEMOREFREQUENTLYWHENRIDINGINUNUSUALLYWETORDUSTYAREAS
3ERVICEMOREFREQUENTLYWHENRIDINGINRAINORATFULLTHROTTLE
3ERVICEMOREFREQUENTLYWHENRIDING/&&2/!$
2EPLACEMENTREQUIRESMECHANICALSKILL
))"2TYPEONLY
1-34
2. FUEL & ENGINE
FUEL LINE················································ 2-2 CYLINDER HEAD ·································· 2-19
FUEL PUMP UNIT ···································· 2-4 CYLINDER/PISTON ······························· 2-26
AIR CLEANER·········································· 2-7 CLUTCH/GEARSHIFT LINKAGE ·········· 2-27
FUEL TANK·············································· 2-9 ALTERNATOR/STARTER CLUTCH······ 2-29
THROTTLE BODY·································· 2-10 CRANKCASE/CRANKSHAFT/

BALANCER ············································ 2-31
LUBRICATION SYSTEM························ 2-14
TRANSMISSION ···································· 2-34
COOLING SYSTEM································ 2-18
ENGINE UNIT ········································· 2-36
2-1
FUEL & ENGINE
FUEL & ENGINE
FUEL LINE
FUEL PUMP
FUEL TANK
FUEL FILTER INJECTOR
• This vehicle uses resin for the part of materials in the fuel
hose. Do not bend or twist the fuel hose.
• Fuel pump 2P connector Î2-9
• Let the engine idle until it stops.
• Battery negative (–) cable Î4-45
• Do not use tools in removal. If the connector does not

move, alternately pull and push the connector until it
comes off easily.
• Check the fuel quick connect fitting for dirt, and clean if
necessary.
• Place a shop towel over the quick connect fitting.
• Push the retainer tab forward.
• Press down the retainer and disconnect the connector
from the fuel joint.
• Check the retainer condition and replace the fuel hose if
necessary.
• To prevent damage and keep foreign matter out, cover the
disconnected connector and pipe end with the plastic
bags.
• Press the connector onto the fuel joint until the retainer
locks with a “CLICK”. If it is hard to connect, put a small
amount of engine oil on the pipe end.
• Make sure the connection is secure; check visually and by
pulling the connector.
• After installing the removed parts, turn the ignition switch
ON. (Do not start the engine.)
The fuel pump will run for about 2 seconds, and fuel
pressure will rise. Repeat 2 or 3 times, and check that
there is no leakage in the fuel supply system.
2-2
FUEL & ENGINE
FUEL PRESSURE TEST
FUEL FEED HOSE
(Fuel pump to fuel filter) FUEL PUMP
FUEL TANK
FUEL FILTER INJECTOR
FUEL FEED HOSE

(Fuel filter to threeway joint)
• Quick connect fitting (fuel filter side)

[A] from FUEL PUMP
• Attach the fuel pressure gauge and attachment.

[A] Fuel pressure gauge: 07406-0040004
[B] Pressure gauge attachment set: 070MJ-K260100
• Temporarily connect the negative cable to the battery and
fuel pump 5P connector.
Start the engine and let it idle, and read the fuel pressure
at the fuel feed hose (fuel filter to threeway joint side).
Standard: 317 – 374 kPa
• If the fuel pressure is higher than specified, replace the
pressure regulator. Î2-5
[B]
• If the fuel pressure is lower than specified, measure the
[A]
fuel pressure at the fuel feed hose (fuel pump to fuel filter
side).
– If the fuel pressure is within specification, replace the fuel
filter (outside). Î2-5
from FUEL PUMP
[B]
FUEL FLOW INSPECTION

• Quick connect fitting (injector side)
from FUEL PUMP • Place the end of the hose into an approved gasoline con-
tainer. Wipe off spilled out gasoline.
• The fuel pump operates for 2 seconds. Repeat 5 times to
meet the total measuring time.
Standard: 232 cm3 minimum / 10 seconds
• If fuel flow is less than specified, inspect the following:
– Clogged fuel hose
– Fuel pump unit
– Fuel filter (fuel pump side)
2-3
FUEL & ENGINE
FUEL PUMP UNIT
• Quick connect fittings (fuel pump side) Î2-2

• Fuel tank Î2-9
• Loosen the nuts in a crisscross pattern in several steps.
• Carefully remove the fuel pump from the fuel tank to prevent damage the fuel hose.
• Check the clog in the passage of the mesh filter. If it is clogs, clean the mesh filter with gasoline.
• Install a new outer packing onto the fuel pump hole by aligning the tab.
• Fuel pump malfunction and inspection
2-4
FUEL & ENGINE
FUEL FILTER
• Fuel clog or excessively damaged

• If the fuel pump filter is clogged, clean the mesh filter with gasoline.
• To prevent dirt and debris from entering the fuel pump, always clean it before disassembly.
• Clean the fuel pump and fuel pump filter with clean gasoline. Never use commercially available
carburetor cleaners.
• Before installing the fuel pump filter, check the fuel pump for dirt. If necessary, clean the fuel pump with com-
pressed air. Do not blow into the fuel pump.
2-5
FUEL & ENGINE
• Left side cover Î3-6

• Quick connect fittings (fuel filter side) Î2-2
• Replace the fuel filter in accordance with the maintenance schedule. Î1-34
• Install the fuel filter with its direction marks facing up.
2-6
FUEL & ENGINE
AIR CLEANER
35°
9 mm 5 – 6 mm
AIR CLEANER HOUSING

DRAIN HOSE
1.1 N·m
Air cleaner element:

• Seat Î3-3
• Replace the air cleaner element in accordance with the maintenance schedule. Î1-34
• Replace the element any time if it is excessively dirty or damaged.
Air cleaner housing:
• Battery box Î3-17
• Muffler Î3-19
• Mud guard Î3-5
2-7
FUEL & ENGINE
1.1 N·m
2-8
FUEL & ENGINE
FUEL TANK
• Fuel tank shroud Î3-7

• Side cover Î3-6
• Quick connect fitting (fuel pump side) Î2-2
• A pressure release can be heard when opening the fuel

cap, but this is not blockage of the passage. If checking for
clog in the passage of the fuel tank side is necessary, ap-
ply air pressure to the breather hose end with the fuel filler
cap opened.
• If the fuel filler cap is removed, replace the breather seal
1.8 N·m with a new one.
2-9
FUEL & ENGINE
THROTTLE BODY
12 ± 1 mm
4.5 N·m
4.5 N·m
• Air cleaner housing Î2-7

• Quick connect fitting (throttle body side) Î2-2
• Align the lug with the slot.
• Throttle body cleaning and inspection
2-10
FUEL & ENGINE
2.1 N·m
5.1 N·m
3.4 N·m
3.4 N·m
3.4 N·m
• The throttle body is factory pre-set. Do not disassemble in a way other than shown in this manual.
• Do not loosen or tighten the white painted fasteners. Loosening or tightening them can cause throttle body
malfunction.
Sensor unit
• Throttle body Î2-10
• Align the clip with the boss.

• Perform the TP sensor reset procedure. Î2-12
IACV
• Turn the slide valve clockwise until lightly seated on IACV.

• Align the slot with the pin.
• Align the groove with the lug.
2-11
FUEL & ENGINE
TP SENSOR RESET PROCEDURE
• Make sure that DTC is not stored in ECM. If the DTC is
stored in ECM, TP sensor reset mode won’t start by
[A] following the procedure below.
• Connector cover from the DLC [A]
• Connect the special tool to the DLC.
SCS connector: 070PZ-ZY30100
[A]
• EOT sensor 2P connector [B]

[B]
• Short the EOT sensor terminals with jumper wire.
[B]
Connection: Y/Bu – G/W
Y/Bu G/W
• Turn the ignition switch ON then disconnect the

jumper wire from the EOT sensor 2P connector [B] within
10 seconds while the MIL is blinking (reset receiving pat-
[B] tern).
• Check for the MIL blinks.
After disconnecting the jumper wire, the MIL should start
short blinking. (reset completed pattern)
If the jumper wire is connected for more than 10 seconds,
within 10 sec. the MIL will stay ON (unsuccessful pattern). Try again from
the first.
• Check the engine idle speed.
Reset procedure and MIL blinking pattern
0.3 sec.
within 10 sec.
0.3 sec.
0.1 sec.
1.3 sec.
Reset receiving Reset completed
2-12
FUEL & ENGINE
INJECTOR
5.1 N·m
• Quick connect fitting (throttle body side) Î2-2

• IACV Î2-10
2-13
FUEL & ENGINE
LUBRICATION SYSTEM
SYSTEM DIAGRAM
OIL COOLER
OIL FILTER
OIL PUMP
2-14
FUEL & ENGINE
ENGINE OIL LEVEL CHECK
• Place the vehicle on the level ground.
• Let the engine idle for 3 – 5 minutes.
• Wait for 2 – 3 minutes.
UPPER • Hold the vehicle in an upright position.

• Clean and insert the oil filler cap/dipstick without screwing
it in, and then remove it and check the oil level.
• If the oil level is below or near the lower level line on the
dipstick, add the recommended oil to the upper level.
• Check that the O-ring on the oil filter cap is in good condi-
tion, and replace If it necessary.
LOWER • RECOMMENDED ENGINE OIL:
Honda “4-stroke motorcycle oil” or an equivalent mo-
tor oil.
API service classification: SG or higher
JASO T903 standard: MA
Viscosity: SAE 10W-30
ENGINE OIL CHANGE

• Drain oil completely.
• Fill the crankcase with the recommended engine oil.
• ENGINE OIL CAPACITY:

1.4 liter after draining
1.5 liter after filter change
2.0 liter after disassembly
30 N·m
2-15
FUEL & ENGINE
ENGINE OIL FILTER CHANGE
• Install the oil filter with the "OUT-SIDE" mark facing outside.
• Discard the oil filter in accordance with the maintenance schedule. Î1-34
• Engine oil filter inspection
2-16
FUEL & ENGINE
ENGINE OIL STRAINER SCREEN/OIL PUMP
19 N·m
• Right crankcase cover Î2-27
• Align with the cutouts of the oil pump drive shaft and inner rotor.
• Oil pump inspection
2-17
FUEL & ENGINE
COOLING SYSTEM
SYSTEM DIAGRAM
OIL COOLER
13 N·m
• Right fuel tank shroud Î3-7
2-18
FUEL & ENGINE
CYLINDER HEAD
• Following services can be serviced with the engine installed in the frame.
VALVE CLEARANCE
INSPECTION
• Inspect while the engine is cold (below 35°C).

• Cylinder head cover Î2-21
8.0 N·m
10 N·m
• Rotate the crankshaft counterclockwise and align the "T"
mark on the flywheel with the index notch on the left crank-
case cover.
• The index lines on the cam sprocket must be flush with the
cylinder head surface.
• Make sure that the timing marks (index lines) on the cam
sprockets are flush with the cylinder head surface and the
"IN" and "EX" marks are facing up as shown.
• If the "IN" and "EX" marks are facing down, turn the crank-
shaft counterclockwise one full turn (360°) and realign the
"T" mark with the index notch.
• Valve clearance (Insert a feeler gauge between each valve

lifter and cam lobe).
IN: 0.12 ± 0.03 mm, EX: 0.15 ± 0.03 mm
2-19
FUEL & ENGINE
ADJUSTMENT
• Adjust while the engine is cold (below 35°C).

• Do not allow the shims to fall into the crankcase.
• Mark all shims to ensure correct reassembly in their origi-
nal locations.
• The shims can be easily removed with a tweezers or
magnet.
• Camshaft Î2-21
• Shims
• Clean the shim contact area in the valve lifter with com-
pressed air.
• Shim thickness and record it.
• Calculate the new shim thickness using the equation

below.
A = (B – C) + D
A: New shim thickness
B: Recorded valve clearance
C: Specified valve clearance
D: Old shim thickness
• Sixty-nine different thickness shims are available from the
1.80 mm 1.825 mm 1.85 mm 1.875 mm thinnest 1.200 mm shim to the thickest 2.900 mm shim in
intervals of 0.025 mm.
• Make sure of the correct shim thickness by measuring the
shim by micrometer.
• Reface the valve seat if carbon deposit result in a calculat-
ed dimension of over 2.900 mm.
• Newly selected shim on the valve spring retainer.
• Camshafts
• Rotate the camshaft by rotating the crankshaft counter-
clockwise several times.
• Recheck the valve clearance Î2-19
2-20
FUEL & ENGINE
CYLINDER HEAD COVER
12 N·m

• Spark plug cap Î4-26
• Apply liquid sealant (Three bond 5211C, SS KE45, or equivalent) to the rubber seal as shown.
CAMSHAFT
• Cylinder head cover Î2-21
• Set the piston to the TDC (Top Dead Center) on the
compression stroke Î2-19
• Install the special tool into the tensioner body and turn the
tool clockwise until it stops. Hold the tensioner lifter by
pushing the tool while aligning the tabs of the tool with the
grooves of the tensioner lifter.
Tensioner stopper: 070MG-0010100
4.0 N·m
2-21
FUEL & ENGINE
12 N·m
• Install each camshaft holder to the correct location in accordance with the identification mark.
• Camshaft inspection
• Camshaft oil clearance inspection
2-22
FUEL & ENGINE
45 N·m 16 N·m
12 N·m
12 N·m
• Engine Î2-36
• Camshaft Î2-21
• EOT sensor Î4-19
• Remove the cylinder head bolts.
• Loosen the cylinder head nuts in a crisscross pattern in two or three steps.
• Align the pins with the grooves in the cylinder and the end with the groove in the right crankcase.
2-23
FUEL & ENGINE
• Remove the valve cotters.

Valve spring compressor: 07757-0010000
Valve spring compressor attachment: 07959-KM30101
• Ream the valve guide to remove any carbon build up before measuring the guide. Insert the reamer from
the combustion chamber side of the cylinder head and always rotate the reamer clockwise.
Valve guide reamer, 5.0 mm: 07984-MA60001
• Support the cylinder head and drive the valve guides out of the cylinder head from the combustion
chamber side.
Valve guide driver, 5.0 mm: 07942-MA60000
• Drive new valve guides into the cylinder head until it is fully seated.
Valve guide driver, 5.0 mm: 07942-MA60000
• Valve and valve spring inspection
• Valve guide inspection
• Valve seat inspection
2-24
FUEL & ENGINE
CAM CHAIN TENSIONER
• Exhaust pipe/muffler Î3-19
• Install the special tool into the tensioner body and turn the
tool clockwise until it stops. Hold the tensioner lifter by
pushing the tool while aligning the tabs of the tool with the
grooves of the tensioner lifter.
Tensioner stopper: 070MG-0010100
4.0 N·m
• Check the cam chain tensioner lifter operation:
– The tensioner shaft should not go into the body when it
is pushed.
– When it is turned clockwise with the tensioner stopper,
the tensioner shaft should be pulled into the body. The
shaft should protrude from the body as soon as the
tensioner stopper is released.
2-25
FUEL & ENGINE
CYLINDER/PISTON
Left crankcase:
136.5 ± 1 mm
Right crankcase:
132.5 ± 1 mm
• Cylinder head Î2-19

• Cam chain tensioner Î2-25
• Spread each piston ring and remove it by lifting up at a point opposite the gap.
• Carefully install the piston ring ends into the piston ring ends grooves with its markings facing up.
• Install the piston with the “IN” mark facing the intake side.
• Do not align the piston pin clip end gap with the piston cut-out.
• Piston and piston rings inspection
• Cylinder inspection
2-26
FUEL & ENGINE
• Engine oil Î2-15

• Oil pass pipe Î2-21
• Oil cooler pipe Î2-18
2-27
FUEL & ENGINE
108 N·m
12 N·m
Disc
12 N·m
108 N·m
• Gearshift pedal Î3-17

• Loosen the primary drive gear lock nut.
Gear holder: 07724-0010100
• Hold the clutch center and loosen the lock nut.
Clutch center holder: 07724-0050002
• Install the tabs of the clutch disc (outside) into the shallow slots in the clutch outer.
• Stake the clutch center lock nut into the mainshaft groove.
• Clutch inspection
2-28
FUEL & ENGINE
• This service can be serviced with the engine installed in the frame.
Align.
103 N·m
• Engine oil Î2-15

• Fuel tank Î2-9
• Drive sprocket cover Î3-13
• Hold the flywheel with the special tool for the bolt removal.
Flywheel holder: 07725-0040001
• Flywheel
Flywheel puller: 07733-0020001
• Clean any oil and grease from crankshaft and flywheel contact areas. Apply engine oil to the starter driven
gear sliding surface of the crankshaft. Install the flywheel onto the crankshaft by aligning the key way with the
woodruff key.
2-29
FUEL & ENGINE
Coating width:
6.5 ± 1 mm from the tip
21 N·m
10 N·m 10 N·m 5.2 N·m
2-30
FUEL & ENGINE
• Engine Î2-36
• Cylinder/piston Î2-26
• Clutch/gearshift linkage/Primary drive gear Î2-27
• Flywheel/starter clutch Î2-29
• Starter motor Î4-29
• Engine oil strainer screen/oil pump Î2-17
• Loosen the crankcase bolts in a crisscross pattern in 2 – 3 steps.
• Place the crankcase with the left side facing down and separate.
• Bearing from the crankshaft
Universal bearing puller: 07631-0010000
2-31
FUEL & ENGINE
• Install the spring washer as shown.
• Balancer inspection
CRANKSHAFT RUNOUT INSPECTION

• Set the crankshaft on V-blocks and measure the runout us-
ing a dial indicator.
Limit: 0.05 mm
5 mm 8 mm
2-32
FUEL & ENGINE
: Gear sliding surfaces and shifter grooves

12 N·m
: Shift drum guide grooves
: Gear teeth
: Shift fork shaft sliding surfaces
24 N·m
2.8 ± 0.1 mm
• Align the balancer driven gear punch marks with the drive gear mark.
• Pull the crankshaft into the bearing until it is fully seated while positioning the connecting rod in the cylinder
sleeve opening in the left crankcase. After pulling the crankshaft, check that the index marks of the balancer
gear and crankshaft are aligned.
Assembly collar: 07965-VM00100
Assembly adaptor: 07965-VM00300
Assembly shaft: 07965-VM00200
• Drive a new shift drum needle bearing into the left crankcase with the marked side facing up to the spec-
ified depth, using the special tools.
Driver: 07749-0010000
Pilot, 16 mm: 07746-0041300
Specified depth: 2.8 ± 0.1 mm
• Crankshaft inspection
• Connecting rod inspection
• Shift fork/shift drum/drum journal inspection
2-33
FUEL & ENGINE
TRANSMISSION
MAINSHAFT
Washers and snap rings direction:
• Transmission inspection
2-34
FUEL & ENGINE
COUNTERSHAFT
Washers and snap rings direction:
• Transmission inspection
2-35
FUEL & ENGINE
ENGINE UNIT
49 N·m 26 N·m
26 N·m
26 N·m
10 N·m
49 N·m
12 N·m
49 N·m
26 N·m
26 N·m 49 N·m

• Oil cooler Î2-18
• Drive chain slipper Î3-15
• Rear brake pedal Î3-16
• Gearshift pedal Î3-17
• Heel guard Î3-13
• Footpeg Î3-15
• Install the drive sprocket with its OUT mark facing outside.
• Install the fixing plate with its chamfer edge facing inside.
2-36
3. FRAME & CHASSIS
BODY PANELS ········································ 3-2 STEERING STEM··································· 3-26
SIDESTAND ··········································· 3-18 REAR WHEEL ········································ 3-28
EXHAUST PIPE/MUFFLER···················· 3-19 REAR SUSPENSION ····························· 3-30
FRONT WHEEL······································ 3-21 FRONT BRAKE ······································ 3-34
FORK ······················································ 3-23 REAR BRAKE ········································ 3-39
HANDLEBAR ········································· 3-25
3-1
FRAME & CHASSIS
FRAME & CHASSIS
BODY PANELS
XRE300A shown: [4] [6]
[3] [7]
[8]
[2] [5]
[9]
[1]
[10]
[11]
[12]
[16] [13]
[15] [14] [19]
[18]
[17]
[22] [21] [20]
[1] Lower front fender Î3-10 [12] Drive chain guide Î3-14
[2] Upper front fender Î3-9 [13] Battery box Î3-17
[3] Front visor Î3-8 [14] Tool rid Î3-5
[4] Rearview mirror Î3-16 [15] Gearshift pedal Î3-17
[5] Fuel tank shroud Î3-7 [16] Drive sprocket cover Î3-13
[6] Seat Î3-3 [17] Muffler cover Î3-3
[7] Grab rail Î3-11 [18] Side cover Î3-6
[8] Rear cowl Î3-11 [19] Meter lower cover Î3-9
[9] Rear fender Î3-12 [20] Brake pedal Î3-16
[10] ABS modulator cover (XRE300A) Î3-4 [21] Heel guard Î3-13
[11] Drive chain case Î3-14 [22] Mud guard Î3-5
3-2
FRAME & CHASSIS
SEAT
MUFFLER COVER
3-3
FRAME & CHASSIS
ABS MODULATOR COVER (XRE300A)
OUTER MODULATOR COVER
INNER MODULATOR COVER
• Seat Î3-3
• Outer modulator cover Î3-4
3-4
FRAME & CHASSIS
TOOL LID
MUDGUARD
3-5
FRAME & CHASSIS
SIDE COVER
• Seat Î3-3
• (Left side) Tool lid Î3-5
• (Right side) Muffler cover Î3-3
3-6
FRAME & CHASSIS
FUEL TANK SHROUD
3-7
FRAME & CHASSIS
FRONT VISOR
3-8
FRAME & CHASSIS
METER LOWER COVER
UPPER FRONT FENDER
• Meter lower cover Î3-9

• Front turn signal light Î4-45
3-9
FRAME & CHASSIS
LOWER FRONT FENDER
XRE300
XRE300A
3-10
FRAME & CHASSIS
REAR COWL
GRAB RAIL
• Seat Î3-3
• Rear cowl Î3-11
3-11
FRAME & CHASSIS
REAR FENDER
• Seat Î3-3
• Grab rail Î3-11
3-12
FRAME & CHASSIS
DRIVE SPROCKET COVER
HEEL GUARD
3-13
FRAME & CHASSIS
DRIVE CHAIN CASE
DRIVE CHAIN GUIDE
3-14
FRAME & CHASSIS
DRIVE CHAIN SLIPPER
4.2 N·m
FOOTPEG
84 N·m
3-15
FRAME & CHASSIS
REARVIEW MIRROR
BRAKE PEDAL
• Right footpeg Î3-15
3-16
FRAME & CHASSIS
GEARSHIFT PEDAL
12 N·m
• Align with the punch marks.
BATTERY BOX
• Battery Î4-45
• Fuel filter (Outside) Î2-5
3-17
FRAME & CHASSIS
SIDESTAND
Sliding surface
10 N·m
39 N·m
• Sidestand switch Î4-54
• Tighten the sidestand pivot bolt to the specified torque and return it 45° – 90°. Then tighten the U-nut while
holding the pivot bolt to the specified torque.
3-18
FRAME & CHASSIS
EXHAUST PIPE/MUFFLER
30 N·m
26 N·m
20 N·m
14 N·m
• Muffler cover Î3-3
• Align the tab with the groove.
3-19
FRAME & CHASSIS
22 ± 0.5 mm
18 N·m
14 N·m
• Fuel tank Î2-9
3-20
FRAME & CHASSIS
FRONT WHEEL
12 N·m
59 N·m
• (XRE300A) Wheel speed sensor Î4-42
• Wheel inspection
3-21
FRAME & CHASSIS
XRE300A shown:
42 N·m
Install the bearing according

to the number of the figure.
(XRE300A)
7.0 N·m
• Install the bearing remover head into the bearing. From the opposite side, install the bearing remover shaft
and drive out the bearing from the wheel hub.
Remover head, 15 mm: 07746-0050400
Bearing remover shaft: 07746-0050100
• Drive in a new bearing squarely with its marked side facing outside until it is fully seated.
Driver: 07749-0010000
Attachment, 32 x 35 mm: 07746-0010100
Pilot, 15 mm: 07746-0040300
• Install the distance collar.
• Wheel disassembly and inspection
3-22
FRAME & CHASSIS
FORK
32 N·m
21 N·m
12 N·m
• Lower front fender Î3-10

• Front wheel Î3-21
• Front brake caliper Î3-36
• Align the cap mating surface with the top surface of the top bridge.
3-23
FRAME & CHASSIS
143 mm 22 N·m
20 N·m
• Pull the fork tube out of the bottom case using quick successive motions,.
• Drive the oil seal until the stopper ring groove is visible.
Fork seal driver weight: 07947-KA50100
Driver attachment, 41 mm I.D.: 07947-KF00100
• Pour the specified amount of recommended fork fluid into the fork pipe.
RECOMMENDED FORK FLUID: Honda Ultra Cushion Oil 10W or equivalent
FORK FLUID CAPACITY: 547 ± 2.5 cm3
• Compress the fork leg fully and measure the fluid level from the top of the fork pipe.
FORK FLUID LEVEL: 143 mm
• Pull the fork pipe up and install the fork spring with its tightly wound coil side facing down.
• Fork disassembly and inspection
3-24
FRAME & CHASSIS
HANDLEBAR
Sliding surface
Bolt: 1.0 N·m
Nut: 5.9 N·m
2.5 N·m
2.5 N·m
• Front brake master cylinder Î3-35

• Rearview mirror Î3-16
• Align the punch mark with the top surface of the top bridge.
• Align the locating pin with the hole.
• Align the punch mark with the mating surface.
3-25
FRAME & CHASSIS
STEERING STEM
TOP BRIDGE
103 N·m
21 N·m
• Handlebar Î3-25
3-26
FRAME & CHASSIS
BOTTOM BRIDGE
[A]
12 N·m
Multi-purpose extreme pressure grease NLGI #2

12 N·m (EXCELITE EP2 manufactured by KYODO YUSHI CO., LTD.
or equivalent)
• Fork Î3-23
• Steering stem
Lock nut wrench, 5.7 x 50 mm: 07916-3710101
• Steering stem
[A] Lock nut wrench, 5.7 x 50 mm: 07916-3710101
• Install the adjusting nut. Hold the steering stem and tighten the adjusting nut to the initial torque.
TORQUE: 25 N·m
• Turn the steering stem lock-to-lock several times to seat the bearing. Completely loosen the adjusting nut,
and then tighten the adjusting nut to the specified torque.
TORQUE: 3.5 N·m
• Steering disassembly/assembly and inspection
3-27
FRAME & CHASSIS
REAR WHEEL
88 N·m
• (XRE300A) Rear wheel speed sensor Î4-42
• Wheel inspection
3-28
FRAME & CHASSIS
XRE300A shown:
45 N·m
42 N·m
(XRE300A)
7.0 N·m
Install the bearing according

to the number of the figure.
• Install the bearing remover head into the bearing. From the opposite side, install the bearing remover shaft
and drive out the bearing from the wheel hub.
Remover head, 17 mm: 07746-0050500
Bearing remover shaft: 07GGD-0010100
• Drive in a new bearing squarely with its marked side facing outside until it is fully seated.
Driver: 07749-0010000
Attachment, 37 x 40 mm: 07746-0010200
Pilot, 17 mm: 07746-0040400
• Install the distance collar.
• Install the driven flange collar in the bearing until it is fully seated.
Driver: 07749-0010000
Attachment, 28 x 30 mm: 07946-1870100
Pilot, 17 mm: 07746-0040400
• Drive in the driven flange bearing/collar with the collar side facing down until it is fully seated.
Driver: 07749-0010000
Attachment, 42 x 47 mm: 07746-0010300
Pilot, 17 mm: 07746-0040400
• Wheel disassembly and inspection
3-29
FRAME & CHASSIS
REAR SUSPENSION
SHOCK ABSORBER/LINKAGE
54 N·m
44 N·m
78 N·m
• Fuel tank Î2-9

• Mudguard Î3-5
3-30
FRAME & CHASSIS
Molybdenum 44 N·m
grease
6.0 ± 0.2 mm (3 places) Molybdenum

grease
6.0 ± 0.2 mm
Molybdenum
grease
Molybdenum
grease
3-31
FRAME & CHASSIS
SWINGARM
88 N·m
44 N·m
78 N·m
• Rear wheel Î3-28

• Drive chain case Î3-14
• Drive chain guide Î3-14
3-32
FRAME & CHASSIS
8.0 ± 0.5 mm
4.2 N·m
• Carefully press the needle bearing into the pivot until it is 8 mm below the outer surface.
3-33
FRAME & CHASSIS
FRONT BRAKE
BRAKE FLUID REPLACEMENT
Front brake: Rear brake:

1.5 N·m 1.5 N·m
Upper line
Upper line
• Add the reservoir with brake fluid from a sealed container to the upper line.
RECOMMENDED BRAKE FLUID: DOT 4
3-34
FRAME & CHASSIS
BRAKE MASTER CYLINDER
34 N·m
12 N·m
• Rearview mirror Î3-16
• Install the brake master cylinder and holder with the "UP" mark facing up. Align the edge of the master
cylinder with the punch mark on the handlebar.
1.0 N·m
Silicon grease
(0.1 g minimum)
Silicon grease (0.1 g minimum)
1.2 N·m
5.9 N·m
• Brake fluid Î3-34

• Remove the snap ring.
Snap ring pliers: 07914-SA50001
• Master cylinder inspection
3-35
FRAME & CHASSIS
BRAKE CALIPER
BRAKE PAD REPLACEMENT
XRE300
2.5 N·m
17 N·m
XRE300
34 N·m
30 N·m
3-36
FRAME & CHASSIS
XRE300 Silicon grease 22 N·m 5.4 N·m
Silicon grease
Silicon grease
• Brake caliper inspection
XRE300A
17 N·m
3-37
FRAME & CHASSIS
XRE300A
30 N·m
34 N·m
34 N·m
XRE300A
Silicon grease 5.4 N·m
Silicon grease
Silicon grease
3-38
FRAME & CHASSIS
REAR BRAKE
BRAKE MASTER CYLINDER
XRE300A shown:
34 N·m
12 N·m
12 N·m
1.5 N·m

• Heel guard Î3-13
3-39
FRAME & CHASSIS
XRE300
Silicon grease (0.1 g)
17 N·m
XRE300A
Silicon grease (0.1 g)
• Remove the snap ring.

Snap ring pliers: 07914-SA50001
• Master cylinder inspection
3-40
FRAME & CHASSIS
BRAKE CALIPER
BRAKE PAD REPLACEMENT
XRE300
17 N·m
2.5 N·m
XRE300
34 N·m

3-41
FRAME & CHASSIS
XRE300
Silicon grease
5.4 N·m
Silicon grease
27 N·m
12 N·m
Silicon grease
XRE300A
Silicon grease
17 N·m
22 N·m
3-42
FRAME & CHASSIS
XRE300A
34 N·m

XRE300A
Silicon grease
5.4 N·m
Silicon grease
27 N·m
Silicon grease
Silicon grease
3-43
MEMO
4. ELECTRICAL SYSTEM
PGM-FI SYSTEM······································ 4-2 BATTERY/CHARGING SYSTEM··········· 4-44
ETHANOL INDICATOR FUNCTION ······ 4-21 LIGHTING SYSTEM ······························· 4-45
IGNITION SYSTEM ································ 4-25 SPEEDOMETER ···································· 4-49
ELECTRICAL STARTER ······················· 4-27 ELECTRICAL COMPONENT ················· 4-54
ABS························································· 4-31
4-1
ELECTRICAL SYSTEM
ELECTRICAL SYSTEM
PGM-FI SYSTEM
• Refer to "Basic Shop manual" for the following information.
– PGM-FI technical feature and each sensor function.
– Symptom troubleshooting for the PGM-FI system.
– MCS (Motorcycle Communication System) information.
DTC CODE INDEX

DTC Function Failure Symptom/Fail-safe function Page
MAP sensor malfunction • Engine operates normally
1-1 Î4-5
• MAP sensor low voltage
MAP sensor malfunction • Engine operates normally
1-2 Î4-6
• MAP sensor high voltage
EOT sensor malfunction • Hard start at a low temperature
7-1 Î4-7
• EOT sensor low voltage
EOT sensor malfunction • Hard start at a low temperature
7-2 Î4-8
• EOT sensor high voltage
TP sensor malfunction • Poor engine acceleration
8-1 Î4-9
• TP sensor low voltage
TP sensor malfunction • Poor engine acceleration
8-2 Î4-10
• TP sensor high voltage
IAT sensor malfunction • Engine operates normally
9-1 Î4-11
• IAT sensor low voltage
IAT sensor malfunction • Engine operates normally
9-2 Î4-12
• IAT sensor high voltage
Injector malfunction • Engine does not start
12-1 Î4-13
• Injector, fuel pump and ignition coil shut down
21-1 O2 sensor malfunction • Engine operates normally Î4-14
23-1 O2 sensor heater malfunction • Engine operates normally Î4-15
29-1 IACV malfunction • Engine stalls, hard to start, rough idling Î4-16
Bank angle sensor malfunction • Engine operates normally
54-1 Î4-17
• Bank angle sensor low voltage • Engine stop function does not operate
Bank angle sensor malfunction • Engine operates normally
54-2 Î4-18
• Bank angle sensor high voltage • Engine stop function does not operate
4-2
ELECTRICAL SYSTEM
PGM-FI SYSTEM LOCATION
FUEL PUMP
IGNITION SWITCH
INJECTOR
IACV
BANK ANGLE SENSOR
O2 SENSOR
ECM
CKP SENSOR
DLC
EOT SENSOR
SENSOR UNIT
· MAP SENSOR
· IAT SENSOR
· TP SENSOR
4-3
ELECTRICAL SYSTEM
PGM-FI SYSTEM DIAGRAM
R/W R Bl Bl/R Bl/R Bl

MAIN FUSE (30 A) IGNITION SWITCH TAIL/STOP/HORN/
METER FUSE (10 A)
Bl/R Bl/Bu
ECU/FUEL PUMP FUSE (15 A)

W Bl/Br
BATTERY
(12 V - 6 Ah)
Bl/Br Bl/Br
ENGINE STOP SWITCH
Bl/Br
Bl/Br
O2 SENSOR Bl/Br 1 IGP
(21) K-LINE 30 Y
Bl Bl/W 3 O2SENS.
SCS 15 Bu
O2 SENSOR HEATER Gr G/W 4 SG G/Bl
(23) DLC SCS CONNECTOR

W 22 HTCNTL
Bl/Br
FUEL INJECTOR
INJ 16 P/W (12)
MAP SENSOR
Lg/Y 27 PB
(1)
Bl/Bu
ECM
G/W
IGPLSE 11 P/Bu
SENSOR UNIT TP SENSOR SPARK
Y 5 THL IGNITION PLUG
(8) COIL
Y/R Y/R 6 VCC

FLR 8 Br
IAT SENSOR
(9) Gr/Bu 14 TA Br/R
G
FUEL PUMP
EOT SENSOR RELAY
Y/Bu 24 TO FUEL PUMP
(7) G/W
MIL
FI-IND 18 W/Bu
Bl
G/W
BANK ANGLE SENSOR
R/Bu 26 BA R/Bl
(54) Y/R TACHO 7 Bu/R
Bl/G
TACHOMETER
Lg/R G/R 29 NL SW
NEUTRAL SWITCH COMBINATION METER
Up IACV1A 21 Bu/W
G
IACV1B 32 Bu/Bl IACV
G/O 25 SSTAND
Down IACV2A 20 Br/W (29)
IACV2B 31 Br/Bl
SIDESTAND SWITCH
VSP 17 W/R VS
Bu/Y 12 PCP SENSOR
W/Y 23 PCM Bl/G
CKP SENSOR R/Bl
G 10 PG2
G 9 PG1 LG 2 G/Bl
( ) : MIL blink
: Engine does not start 1 2 3 4 5 6 7 8 9 10 11
when MIL blinks 12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
: Short terminals for
reading MIL
ECM 33P CONNECTOR
4-4
ELECTRICAL SYSTEM
DTC TROUBLESHOOTING
DTC 1-1 (MAP SENSOR LOW VOLTAGE)
MAP Sensor Diagram
Sensor unit 5P connector ECM 33P connector
Y/R
G/W Lg/Y Y/R Lg/Y G/W
5V
VCC
Y/R 5V
Sensor unit PB ECM
(MAP sensor) Lg/Y
SG
G/W
1. MAP Sensor System Inspection
• Measure the MAP sensor voltage with MCS. No • Intermittent failure

• Is the voltage about 0 V indicated? Ź • Loose or poor contact at the connector
Yes ź
2. Sensor unit Power Input Voltage Inspection
• Faulty Y/R or G/W wires

• Connection: Y/R (+) – G/W (–) No
• If there is no open or short circuit, replace the ECM
• Is the voltage within 4.75 – 5.25 V? Ź
with a new one Î4-19, and recheck.
Yes ź
3. MAP Sensor Output Voltage Inspection
• Connection: Lg/Y (+) – G/W (–) Yes • Replace the sensor unit (MAP sensor) with a new
• Is the voltage within 3.80 – 5.25 V? Ź one Î2-10, and recheck.
No ź
4. MAP Sensor Output Line Inspection
• Check for a short circuit in Lg/Y wire.

• If there is no short circuit, replace the ECM with a
new one Î4-19, and recheck.
4-5
ELECTRICAL SYSTEM
DTC 1-2 (MAP SENSOR HIGH VOLTAGE)
MAP Sensor Diagram
Y/R
G/W Lg/Y Y/R Lg/Y G/W
5V
VCC
Y/R 5V
Sensor unit PB ECM
(MAP sensor) Lg/Y
SG
G/W
1. MAP Sensor System Inspection
• Measure the MAP sensor voltage with MCS. No • Intermittent failure

Yes ź
2. MAP Sensor System Inspection 2
• Install a jumper wire between the terminals.

Connection: Lg/Y – G/W Yes • Replace the sensor unit (MAP sensor) with a new
• Measure the MAP sensor voltage with MCS. Ź one Î2-10, and recheck.
• Is the voltage about 0 V indicated?
No ź
3. MAP Sensor Output Line Inspection
• Check for an open circuit in Lg/Y and G/W wire.

• If there is no open circuit, replace the ECM with a
4-6
ELECTRICAL SYSTEM
DTC 7-1 (EOT SENSOR LOW VOLTAGE)
EOT Sensor Diagram
EOT sensor 2P connector ECM 33P connector
Y/Bu G/W
G/W Y/Bu
5V
TO
Y/Bu
ECM
EOT sensor
SG
G/W
1. EOT Sensor System Inspection
• Measure the EOT sensor voltage with MCS. No • Intermittent failure

Yes ź
2. EOT Sensor Inspection
• Measure the EOT sensor voltage with MCS. No • Replace the EOT sensor with a new one Î4-19,
• Is the voltage about 0 V indicated? Ź and recheck.
Yes ź
3. EOT Sensor Output Line Inspection
• Check for a short circuit in Y/Bu wire.

4-7
ELECTRICAL SYSTEM
DTC 7-2 (EOT SENSOR HIGH VOLTAGE)
EOT Sensor Diagram
EOT sensor 2P connector ECM 33P connector
Y/Bu G/W
G/W Y/Bu
5V
TO
Y/Bu
ECM
EOT sensor
SG
G/W
1. EOT Sensor System Inspection
• Measure the EOT sensor voltage with MCS. No • Intermittent failure

Yes ź
2. EOT Sensor Inspection

Connection: Y/Bu – G/W Yes • Replace the EOT sensor with a new one Î4-19,
• Measure the EOT sensor voltage with MCS. Ź and recheck.
No ź
3. EOT Sensor Output Line Inspection
• Check for an open circuit in Y/Bu and G/W wire.

4-8
ELECTRICAL SYSTEM
DTC 8-1 (TP SENSOR LOW VOLTAGE)
TP Sensor Diagram
Y/R Y
G/W Y
Y/R G/W
5V
VCC
Y/R
Sensor unit THL ECM
(TP sensor) Y
SG
G/W
1. TP Sensor System Inspection
• Measure the TP sensor voltage with MCS. No • Intermittent failure

Yes ź
2. Sensor unit Power Input Voltage Inspection
• Faulty Y/R wire

• Is the voltage within 4.75 – 5.25 V? Ź
Yes ź
3. TP Sensor Output Line Inspection
• Check for an open or short circuit in Y wire. Yes

• Faulty Y wire
• Is there open or short circuit? Ź
No ź
4. TP Sensor Inspection
• Replace the sensor unit (TP sensor) with a new

one Î2-10
• Erase the DTCs.
• Check the TP sensor with MCS.
• If DTC 8-1 is indicated, replace the ECM with a
4-9
ELECTRICAL SYSTEM
DTC 8-2 (TP SENSOR HIGH VOLTAGE)
TP Sensor Diagram
Y/R Y
G/W Y
Y/R G/W
5V
VCC
Y/R
Sensor unit THL ECM
(TP sensor) Y
SG
G/W
1. TP Sensor System Inspection
• Measure the TP sensor voltage with MCS when

operating the throttle from fully closed to fully
• Measure the TP sensor voltage with MCS when
No opened.
the throttle fully closed.
Ź • If the voltage is not increase continuously, replace
the sensor unit (TP sensor) with a new one Î2-
10, and recheck.
Yes ź
2. TP Sensor Ground Line Inspection
• Check for an open circuit in G/W wire. Yes

• Faulty G/W wire
• Is there open circuit? Ź
No ź
3. TP Sensor Inspection
• Replace the sensor unit (TP sensor) with a new

one Î2-10
• Erase the DTCs.
• Check the TP sensor with MCS.
4-10
ELECTRICAL SYSTEM
DTC 9-1 (IAT SENSOR LOW VOLTAGE)
IAT Sensor Diagram
Gr/Bu G/W
G/W Gr/Bu
5V
TA
Gr/Bu
Sensor unit ECM
(IAT sensor)
SG
G/W
1. IAT Sensor System Inspection
• Measure the IAT sensor voltage with MCS. No • Intermittent failure

Yes ź
2. IAT Sensor Inspection
• Measure the IAT sensor voltage with MCS. No • Replace the sensor unit (IAT sensor) with a new
• Is the voltage about 0 V indicated? Ź one Î2-10, and recheck.
Yes ź
3. IAT Sensor Output Line Inspection
• Check for a short circuit in Gr/Bu wire.

4-11
ELECTRICAL SYSTEM
DTC 9-2 (IAT SENSOR HIGH VOLTAGE)
IAT Sensor Diagram
Gr/Bu G/W
G/W Gr/Bu
5V
TA
Gr/Bu
Sensor unit ECM
(IAT sensor)
SG
G/W
1. IAT Sensor System Inspection
• Measure the IAT sensor voltage with MCS. No • Intermittent failure

Yes ź
2. IAT sensor Inspection

Connection: Gr/Bu – G/W Yes • Replace the sensor unit (IAT sensor) with a new
• Measure the IAT sensor voltage with MCS. Ź one Î2-10, and recheck.
No ź
3. IAT Sensor Voltage Input Line Inspection
• Check for an open circuit in Gr/Bu and G/W wire.

4-12
ELECTRICAL SYSTEM
DTC 12-1 (INJECTOR)
• Fuel tank Î2-9

Injector Diagram
Injector 2P connector Injector 2P connector

ECM 33P connector
(Injector side) (Wire side)
A B Bl/Br P/W
P/W
Bl/Br
Injector ECM
INJ
P/W
1. Fuel Injector System Inspection
• Check the fuel injector with MCS. No • Intermittent failure

• Is the DTC 12-1 is indicated? Ź • Loose or poor contact at the connector
Yes ź
2. Fuel Injector Input Voltage Inspection
• Faulty Bl/Br wire

• Connection: Bl/Br (+) – Ground (–) No
• Does the battery voltage exist? Ź
Yes ź
3. Fuel Injector Signal Line Inspection
• Check for an open or short circuit in P/W wire. Yes

• Faulty P/W wire
No ź
4. Fuel Injector Resistance inspection
• Connection: A – B No
• Faulty fuel injector
• Is the resistance within 11 – 13 ȍ (24°C)? Ź
Yes ź
• Replace the ECM with a new one Î4-19, and re-

check.
4-13
ELECTRICAL SYSTEM
DTC 21-1 (O2 SENSOR)
• Fuel tank Î2-9
O2 Sensor Diagram
O2 sensor 4P connector ECM 33P connector
G/W Bl/W
W Bl/Br W G/W Bl/W Bl/Br
W W HTCTL
W Bl/Br IGP ECM
O2 sensor
Bl Bl/W O2
Gr G/W
SG
1. O2 Sensor System Inspection
• Test-ride the vehicle and check the O2 sensor with

No • Intermittent failure
MCS.
Ź • Loose or poor contact at the connector
• Is the DTC 21-1 is indicated?
Yes ź
2. O2 Sensor Circuit Inspection
• Check for an open or short circuit in Bl/W and G/

Yes
W wire. • Faulty Bl/W or G/W wire
Ź
• Is there open or short circuit?
No ź
3. O2 Sensor Inspection
• Replace the O2 sensor with a new one. Î4-20

• Erase the DTCs.
• Test-ride the vehicle and check the O2 sensor with
MCS.
4-14
ELECTRICAL SYSTEM
DTC 23-1 (O2 SENSOR HEATER)
• Fuel tank Î2-9
O2 Sensor Diagram
O2 sensor 4P connector O2 sensor 4P connector

ECM 33P connector
(Sensor side) (Wire side)
G/W Bl/W
A B W G/W Bl/W Bl/Br

W Bl/Br
W W HTCTRL
O2 sensor W Bl/Br IGP ECM
Bl Bl/W O2
Gr G/W
SG
1. O2 Sensor Heater System Inspection
• Erase the DTCs, and check the O2 sensor heater

No • Intermittent failure
with MCS.
Ź • Loose or poor contact at the connector
• Is the DTC 23-1 is indicated?
Yes ź
2. O2 Sensor Heater Input Voltage Inspection
• Connection: Bl/Br (+) – Ground (–) No

• Faulty Bl/Br wire
Yes ź
3. O2 Sensor Heater Circuit Inspection
• Check for an open or short circuit in W wire. Yes

• Faulty W wire
No ź
4. O2 Sensor Heater Resistance inspection
• Connection: A – B No
• Faulty O2 sensor
• Is the resistance within 6.7 – 9.5 ȍ (20°C)? Ź
Yes ź

check.
4-15
ELECTRICAL SYSTEM
DTC 29-1 (IACV)
IACV Diagram
IACV 4P connector IACV 4P connector

ECM 33P connector
(IACV side) (Wire side)
Br/W Br/Bl Bu/W Br/W
A B C D
Bu/W Bu/Bl
Bu/Bl Br/Bl
Bu/W IACV1A
Bu/Bl IACV1B ECM
IACV
Br/W IACV2A
Br/Bl IACV2B
1. IACV System Inspection
• Check the IACV with MCS. No • Intermittent failure

• Is the DTC 29-1 is indicated? Ź • Loose or poor contact at the connector
Yes ź
2. IACV Circuit Inspection
• Check for an open or short circuit in Bu/W, Br/W,

Yes
Br/Bl, and Bu/Bl wires. • Faulty Bu/W, Br/W, Br/Bl, or Bu/Bl wire
Ź
• Is there open or short circuit?
No ź
3. IACV Resistance Inspection
• Connection: A – D, B – C No
• Faulty IACV
• Is the resistance within 90 – 130 ȍ (25°C)? Ź
Yes ź
4. IACV Short Circuit Inspection
• Connection: A – B, C – D Yes
• Faulty IACV
• Is there continuity? Ź
No ź

check.
4-16
ELECTRICAL SYSTEM
DTC 54-1 (BANK ANGLE SENSOR LOW VOLTAGE)
• Fuel tank Î2-9
Bank Angle Sensor Diagram

Bank angle sensor
ECM 33P connector
3P connector
G/W R/Bu Y/R
Y/R R/Bu G/W
5V
VCC
Y/R 5V
Bank angle BA ECM
R/Bu
sensor SG
G/W
1. Bank Angle Sensor System Inspection
• Measure the bank angle sensor voltage with MCS. No • Intermittent failure
Yes ź
2. Bank Angle Sensor Power Input Voltage In-

spection
• Faulty Y/R wire

• Is the voltage about 5 V indicated? Ź
Yes ź
3. Bank Angle Sensor Output Line Inspection
• Check a short circuit in R/Bu wire. Yes

• Faulty R/Bu wire
• Is there short circuit? Ź
No ź
4. Bank Angle Sensor Inspection
• Replace the bank angle sensor with a new one.

Î4-20
• Erase the DTCs.
• Check the bank angle sensor with MCS.
4-17
ELECTRICAL SYSTEM
DTC 54-2 (BANK ANGLE SENSOR HIGH VOLTAGE)
• Bank angle sensor (Connector is connected.) Î4-20
Bank Angle Sensor Diagram

Bank angle sensor
ECM 33P connector
3P connector
G/W R/Bu Y/R
Y/R R/Bu G/W
5V
VCC
Y/R 5V
Bank angle BA ECM
R/Bu
sensor SG
G/W
1. Bank Angle Sensor System Inspection
• Measure the bank angle sensor voltage with MCS. No • Intermittent failure
Yes ź
2. Bank Angle Sensor Power Input Voltage In-

spection

• Faulty G/W wire
• Is the voltage about 5 V indicated? Ź
Yes ź
3. Bank Angle Sensor Output Line Inspection
• Check for an open circuit in R/Bu wire. Yes

No ź
4. Bank Angle Sensor Inspection
• Replace the bank angle sensor with a new one.

Î4-20
• Erase the DTCs.
• Check the bank angle sensor with MCS.
4-18
ELECTRICAL SYSTEM
ECM
• ECM power circuit and ground circuit inspection
EOT SENSOR
15 N·m
• EOT sensor inspection
4-19
ELECTRICAL SYSTEM
O2 SENSOR
25 N·m
• Fuel tank Î2-9

• Remove the O2 sensor.
Flare nut socket: FRXM17 (Snap on) or equivalent
BANK ANGLE SENSOR
2.0 N·m
• Fuel tank Î2-9
• Bank angle sensor inspection
4-20
ELECTRICAL SYSTEM
ETHANOL INDICATOR FUNCTION

ETHANOL INDICATOR
• When turning the ignition switch ON, the ethanol indicator
should come on 2 seconds, then go off.
• If the ethanol indicator blinks when the ignition switch is
turned ON, the engine is hard to start under the following
conditions.
– The air temperature is below 15°C
– The ratio of ethanol is approximately 80 – 100%
– If the engine does not start, add 3 litters amount of gaso-
line to the fuel tank and let it idle for 2 minutes.
• If the engine does not start without ethanol indicator comes
on or is hard to start, add 2 liters amount of gasoline to the
fuel tank and let it idle for 2 minutes.
ECM FUEL CONDITION DATA INDEX

• The ECM fuel condition data readout is same as procedure of DTC readout.
Unit: sec.
Approximate
Code Ethanol indicator blinking pattern
ratio of ethanol
• Pattern A
0.3 1 cycle
1 0 to 40%
Pattern repeated
1.3
• Pattern B
0.3 0.3 1 cycle
2 30 to 70%
Pattern repeated
1.3 0.3
• Pattern C
0.3 0.3 0.3 1 cycle
3 60 to 90%
Pattern repeated
1.3 0.3 0.3
• Pattern D
0.3 0.3 0.3 0.3 1 cycle
4 80 to 100%
Pattern repeated
1.3 0.3 0.3 0.3
4-21
ELECTRICAL SYSTEM
ECM FUEL CONDITION DATA RESET PROCEDURE
• Perform following for the proper ECM initialization.
• Before performing the ECM fuel condition data re-
set, replace the fuel in the fuel tank with 100% of
gasoline or blinking pattern A.
• Connect the special tool to the DLC.

SCS connector: 070PZ-ZY30100
• Open the throttle all the way.
• Turn the ignition switch ON.
– The ethanol indicator comes on for 2 seconds

Pattern B and goes off, then starts blinking of pattern B af-
ter few seconds (approx. 4 seconds).
• Close the throttle fully within 5 seconds.
Pattern C • The ethanol indicator starts blinking of pattern C,

Disconnect the SCS connector within 10 seconds.
Pattern D • The ethanol indicator starts blinking of pattern D,

Connect the SCS connector within 5 seconds.
No
Is stay on?
(Indicator is blinking)
Yes • If the ethanol indicator comes on and remain on,

the ECM is reset.
Turn the ignition switch OFF.
ECM is reset.
(Blink pattern A)
• After resetting the ECM, check the ECM condition

data.
4-22
ELECTRICAL SYSTEM
ETHANOL INDICATOR TROUBLESHOOTING
ENGINE CAN BE STARTED, BUT IT IS HARD TO START OR POOR PERFORMANCE
• Loose or poor contacts of related terminal/connector

• Battery condition
• DTC (PGM-FI system)
• Initial function of the meter
1. ECM Fuel Condition Data Reset Inspection
• Reset the fuel condition data in the ECM. Î4-22

• Test-ride for 5 minutes. No
• Inferiority of original fuel
• Does the ethanol indicator display show the condi- Ź
tion of the gasoline in the fuel tank?
Yes ź
2. Fuel System Troubleshooting
• Inspect the fuel pressure. Î2-3 No

• Replace or repair the abnormal parts.
• Is the fuel pressure within specification? Ź
Yes ź
3. Fuel Inspection (Gasoline)
• Fuel supply system (fuel pump, air cleaner, throttle

• Replace the fuel in the fuel tank with gasoline. body, cylinder head, exhaust pipe/muffler, or etc.)
• Test-ride for 5 minutes. No • Replace the O2 sensor with a new one Î4-20, and
• Read the ECM fuel condition data. Ź recheck.
• Does the ethanol indicator blink in pattern A? If problem is not solved, replace the ECM with a
Yes ź
4. Fuel Inspection (Ethanol)
• Fuel supply system (fuel pump, air cleaner, throttle

• Replace the fuel in the fuel tank with ethanol. body, cylinder head, exhaust pipe/muffler, or etc.)
• Test-ride for 5 minutes. No • Replace the O2 sensor with a new one Î4-20, and
• Read the ECM fuel condition data. Ź recheck.
• Does the ethanol indicator blink in pattern D? If problem is not solved, replace the ECM with a
Yes ź
• Intermittent failure
4-23
ELECTRICAL SYSTEM
ETHANOL INDICATOR CIRCUIT INSPECTION
• Before starting this troubleshooting, check the initial function of the meter.
• Fuel tank Î2-9
• Front visor Î3-8
Ethanol Indicator Diagram
ECM 33P connector
From Battery
METER ECM
P ALC
The ethanol indicator does not come on (Ignition switch turned ON)
1. Ethanol Indicator Inspection
• Install the jumper wire.

Yes • Replace the ECM with a new one Î4-19, and re-
Connection: P – Ground
Ź check.
• Does the ethanol indicator come on?
No ź
• Check for an open circuit in P wire.

• If there is no open circuit, replace the meter with
a new one Î4-49, and recheck.
The ethanol indicator does not go off (Ignition switch turned ON with air temperature above 15°C)
1. Ethanol Indicator Inspection
No • Replace the ECM with a new one Î4-19, and re-

• Does the ethanol indicator come on?
Ź check.
Yes ź
• Check for a short circuit in P wire.

• If there is no short circuit, replace the meter with
a new one Î4-49, and recheck.
4-24
ELECTRICAL SYSTEM
IGNITION SYSTEM
IGNITION SYSTEM LOCATION
IGNITION SWITCH
IGNITION COIL
FUSE BOX 15 A MAIN FUSE 30 A
SPARK PLUG
CKP SENSOR ECM
IGNITION SYSTEM DIAGRAM
W/Y
CKP SENSOR
Bu/Y
Bl/Br Bl/Bu Bl/Bu Bl/R

ENGINE STOP 15 A IGNITION
SWITCH SWITCH
Bl/Bu
P/Bu
G R/W
30 A
IGNITION
COIL
ECM SPARK
PLUG BATTERY
4-25
ELECTRICAL SYSTEM
SPARK PLUG REPLACEMENT
• Spark plug inspection
16 N·m
• Discard the spark plug in accordance with the mainte-
nance schedule. Î1-34
INSPECTION
IGNITION COIL PRIMARY PEAK VOLTAGE
• Refer to "Basic Shop Manual" for the detail information of

ignition coil primary peak voltage inspection.
• Disconnect the spark plug cap from the spark plug.
• Connect a known-good spark plug to the spark plug cap

and ground it to the cylinder head as done in a spark test.
• With the ignition coil primary wires connected, connect
the peak voltage adaptor probes to the ignition coil
primary terminal and ground.
CONNECTION: P/Bu (+) – Ground (–)
• Check the initial voltage at this time.

STANDARD VOLTAGE: Battery voltage
• Shift the transmission into neutral.
• Crank the engine with the starter and measure the
ignition coil primary peak voltage.
PEAK VOLTAGE: 100 V minimum
IGNITION TIMING
• Warm up the engine to normal operating temperature.

• Timing hole cap Î2-19
• Connect the timing light to the spark plug wire.
• Start the engine and let it idle
IDLE SPEED: 1,400 ± 100 rpm
• The ignition timing is correct if the "F" mark on the
flywheel aligns with the index notch on the left crankcase
cover.
4-26
ELECTRICAL SYSTEM
ELECTRICAL STARTER
ELECTRICAL STARTER SYSTEM LOCATION
ENGINE STOP SWITCH STARTER SWITCH
BATTERY ECM
FUSE BOX
· DIODE
· 15 A
CLUTCH
SWITCH
IGNITION SWITCH
STARTER MOTOR
STARTER RELAY SWITCH
NEUTRAL SWITCH
SIDESTAND SWITCH
ELECTRICAL STARTER SYSTEM DIAGRAM
Bl
STARTER
RELAY R/W Bl
SWITCH 30 A BATTERY
Bl
R Bl Bl/R Bl/Bu
IGNITION SWITCH 15 A
STARTER Y/R Bl/Br Bl/Br

MOTOR STARTER SWITCH ENGINE STOP SWITCH
G/R Lg/R
NEUTRAL SWITCH
DIODE
G/R G/R Bl Bl G/O G/W SIDESTAND

SWITCH
CLUTCH SWITCH
4-27
ELECTRICAL SYSTEM
ELECTRICAL STARTER TROUBLESHOOTING
STARTER MOTOR DOES NOT TURN

• Battery condition
• Burned fuse
• DTC (PGM-FI system)
Connector Diagram
Starter relay switch

4P connector
G/R Y/R
1. Starter Relay Coil Input Circuit Inspection
• Inspect the following.

• Connection: Y/R (+) – Ground (–)
– Ignition switch
(Connector connected) No
– Engine stop switch
• Push and hold the start switch. Ź
– Starter switch
• Does the battery voltage exist?
– Starter relay coil input circuit
Yes ź
2. Starter Relay Coil Ground Circuit Inspection
• Inspect the following.

• Connection: G/R – Ground – Diode
• Squeeze the clutch lever and retract the sidestand No – Clutch switch
or shift the transmission in neutral position. Ź – Neutral switch
• Is there continuity? – Sidestand switch
– Starter relay coil ground circuit
Yes ź
3. Starter Relay Switch Inspection
• Replace the starter relay switch with a new one,

Yes
and recheck. • Faulty original starter relay switch
Ź
• Does the starter motor turn?
No ź
• Check for a short or open circuit in starter motor

cable.
• If there is no faulty circuit, replace the starter motor
with a new one, and recheck.
4-28
ELECTRICAL SYSTEM
STARTER MOTOR
12 N·m
• Electric starter inspection
4-29
ELECTRICAL SYSTEM
NEUTRAL SWITCH
12 N·m
4-30
ELECTRICAL SYSTEM
ABS
• Refer to "Basic Shop manual" for the following information.
– ABS technical feature and each function.
– MCS (Motorcycle Communication System) information.
DTC CODE INDEX

Detection
*A *B
ABS indicator malfunction • ABS indicator never come
Î4-35
• ABS modulator voltage input line ON at all
• Indicator related wires • ABS indicator stays ON
–
• Speedometer
Î4-35
• ABS modulator
• ABS fuses
Front wheel speed sensor circuit inspection • Stops ABS operation
1-1 Î4-37
• Wheel speed sensor or related wires
Front wheel speed sensor malfunction • Stops ABS operation
• Wheel speed sensor, pulser ring or related
1-2 Î4-37
wires
• Electromagnetic interference
Rear wheel speed sensor circuit malfunction • Stops ABS operation
1-3 Î4-38
• Wheel speed sensor or related wires
Rear wheel speed sensor malfunction • Stops ABS operation
• Wheel speed sensor, pulser ring or related
1-4 Î4-38
wires
• Electromagnetic interference
Front pulser ring • Stops ABS operation
2-1 Î4-37
• Pulser ring or related wires
Rear pulser ring • Stops ABS operation
2-3 Î4-38
• Pulser ring or related wires
3-1 Solenoid valve malfunction (ABS modulator) • Stops ABS operation
3-2
3-3
Î4-39
3-4
3-7
3-8
Front wheel lock • Stops ABS operation
4-1
• Riding condition
Î4-37
Front wheel lock (Wheelie)
4-2
Rear wheel lock • Stops ABS operation
4-3 Î4-38
Pump motor lock • Stops ABS operation
• Pump motor (ABS modulator) or related
5-1 Î4-40
wires
• ABS MOTOR 30 A fuse
Pump motor stuck OFF • Stops ABS operation
• Pump motor (ABS modulator) or related
5-2 Î4-40
wires
Pump motor stuck ON • Stops ABS operation
5-3 • Pump motor (ABS modulator) or related Î4-40
wires
Power supply relay malfunction • Stops ABS operation
• Power supply relay (ABS modulator) or re-
5-4 Î4-40
lated wires
4-31
ELECTRICAL SYSTEM
Detection
*A *B
Power circuit under voltage • Stops ABS operation
6-1 • Input voltage (too low) Î4-41
• ABS MAIN 10 A fuse
Power circuit over voltage • Stops ABS operation
6-2 Î4-41
• Input voltage (too high)
Tire malfunction • Stops ABS operation
7-1 Î4-41
• Tire size
ABS control unit • Stops ABS operation
8-1 • ABS control unit (ABS modulator) malfunc- Î4-41
tion
*A: Pre-start self-diagnosis
*B: Ordinary self-diagnosis: diagnoses while the vehicle is running (after pre-start self-diagnosis)
How To Erase the DTC Without MCS
• Short the service check connector.

• Squeeze the brake lever.
• The ABS indicator should come on 2 seconds and go off.
• After the ABS indicator is off, release the brake lever imme-
diately.
• After the ABS indicator is on, squeeze the brake lever im-
mediately.
• After the ABS indicator is off, release the brake lever imme-
diately.
– When code erasure is complete, the ABS indicator blinks
2 times and stay on.
– If the ABS indicator is not blink, the data has not been
erased, so try again.
4-32
ELECTRICAL SYSTEM
ABS LOCATION
DLC
ABS MODULATOR
FRONT WHEEL
SPEED SENSOR
FUSE BOX
· ABS MOTOR FUSE 30 A
· ABS FSR FUSE 30 A REAR WHEEL
· ABS MAIN FUSE 10 A SPEED SENSOR
4-33
ELECTRICAL SYSTEM
ABS DIAGRAM
Combination Meter
ABS INDICATOR
Bl
BRAKE/TAIL LIGHT
IGNITION TAIL STOP

G/Y
SWITCH HORN METER
FUSE 10 A
Bl BI/R BI/R Bl Bl Bl G/Y 4 STOP
LAMP SW
R REAR BRAKE ABS CONTROL UNIT

LIGHT SWITCH
(Modulator assembly)
R/W Bl G/Y G
ABS WARN 21 W/Bl
MAIN ABS MAIN FRONT BRAKE IND
FUSE FUSE LIGHT SWITCH
30 A 10 A
R/Bu 16 IGN (6-1, 6-2)
ABS MOTOR
FUSE
30 A
Bl R/W R 9 MOTOR+
PUMP
ABS FSR
FUSE
30 A
R/W R 8 FSR (5-1, 5-2, 5-3)
(5-4)
FRONT WHEEL SPEED SENSOR
BATTERY SOLENOIDS
(1-1, 1-2)
P 12 FR SP+
FRONT PULSER RING
(2-1, 4-1, 4-2) G/Bu 3 FR SP-
REAR WHEEL SPEED SENSOR

(1-3, 1-4) (3-1, 3-2, 3-3, 3-4, 3-7, 3-8)
P/W 2 RR SP+
REAR PULSER RING
TIRE SIZE
(2-3, 4-3) G/R 18 RR SP-
(7-1)
Gr/R 13 SCS CPU

ABS SERVICE CHECK
O/Bu 10 DIAG (8-1)
CONNECTOR
G
ABS MODULATOR 25P CONNECTOR

(Modulator side/male terminals)
G 25 MOTOR
GND
1 2 3 4 5 6 7 8 9 G 24
LOGIC
GND
10 11 12 13 14 15 16
24 25
17 18 19 20 21 22 23
( ) : DTC
4-34
ELECTRICAL SYSTEM
DTC TROUBLESHOOTING
• Before starting this troubleshooting, check the burned fuse and initial function of the meter.
• Use a fully charged battery. Do not diagnose with a charger connected to the battery.
• Perform inspection with the ignition switch OFF, unless otherwise specified.
• All connector diagrams in the troubleshooting are viewed from the terminal side.
• When the ABS modulator assembly is detected to be faulty, recheck the wire harness and connector connections
closely before replacing it.
• After diagnostic troubleshooting, erase the DTC and test-ride the vehicle to check that the ABS indicator operates
normally during pre-start self-diagnosis.
ABS indicator malfunction

ABS indicator does not come ON (When the ignition switch ON)
Meter 16P connector ABS modulator 25P connector
W/Bl W/Bl
From Battery
IGNITION
METER ABS W/Bl IND ABS MODULATOR
1. ABS Indicator Inspection
• Check the ABS indicator. Yes

• Faulty ABS modulator
• Does not the ABS indicator come on? Ź
No ź
2. ABS indicator Line Inspection
• Check for a short circuit in W/Bl wire. No

• Faulty meter
Yes ź
• Faulty W/Bl wire
4-35
ELECTRICAL SYSTEM
ABS indicator stays ON (Indicator does not go off when the motorcycle is running, but DTC is not stored)
ABS modulator 25P connector
R/Bu Gr/R
G W/Bl
From Ignition switch
DLC R/Bu IGN

Gr/R SCS
ABS MODULATOR
ABS W/Bl IND

METER G GND
1. Service Check Line Inspection
• Check for a short circuit in Gr/R wire. Yes

• Faulty Gr/R wire
No ź
2. ABS Indicator Line Inspection
• Install a jumper wire between the terminal and

ground. No • Faulty W/Bl wire
Jumper terminal: W/Bl Ź • If wire is ok, faulty meter.
• Does the ABS indicator go off?
Yes ź
3. ABS Modulator Ground Line Inspection
• Check for an open circuit in G wire. Yes

• Faulty G wire
No ź
4. ABS Modulator Power Line Inspection
• Connection: R/Bu (+) – Ground (–) No

Yes ź
4-36
ELECTRICAL SYSTEM
DTC 1-1, 1-2, 2-1, 4-1, 4-2
• Fuel tank Î2-9

(Front wheel speed sensor circuit / Front wheel speed sensor / Front pulser ring / Front wheel lock)
Front wheel speed sensor ABS modulator 25P connector

2P connector
G/Bu
G/Bu P
P
FRONT WHEEL Bu G/Bu FR VSP (–)

SPEED SENSOR W P FR VSP (+)
ABS MODULATOR
1. Air Gap Inspection
• Measure the air gap. No • Check each part for deformation, looseness and
• Is the air gap correct? Ź correct accordingly. Recheck the air gap.
Yes ź
2. Speed Sensor and Pulser Ring Inspection
• Check the speed sensor and pulser ring.

No • Remove any deposits.
• Are the sensor and pulser ring in good condition
Ź • Install properly or replace faulty part.
and properly installed?
Yes ź
3. Speed Sensor Line Inspection

Jumper terminal: G/Bu and P No
• Faulty G/Bu or P wire
• Check the continuity between the above wires. Ź
• Is there continuity?
Yes ź
4. Failure Reproduction
• Replace the speed sensor with a new one. Î4-42

• Erase the DTC and test-ride the vehicle above 30 No
• Faulty original speed sensor
km/h, then recheck the DTC. Ź
• Is the DTC 1-1, 1-2, 2-1, 4-1, 4-2 indicated?
Yes ź
4-37
ELECTRICAL SYSTEM
DTC 1-3, 1-4, 2-3, 4-3
(Rear wheel speed sensor circuit / Rear wheel speed sensor / Rear pulser ring / Rear wheel lock)
Rear wheel speed sensor ABS modulator 25P connector

2P connector
P/W
G/R P/W G/R
REAR WHEEL Bu G/R RR VSP (–)

SPEED SENSOR W P/W RR VSP (+)
ABS MODULATOR
1. Air Gap Inspection
• Measure the air gap. No • Check each part for deformation, looseness and
• Is the air gap correct? Ź correct accordingly. Recheck the air gap.
Yes ź
2. Speed Sensor and Pulser Ring Inspection
• Check the speed sensor and pulser ring.

No • Remove any deposits.
• Are the sensor and pulser ring in good condition
Ź • Install properly or replace faulty part.
and properly installed?
Yes ź
3. Speed Sensor Line Inspection

Jumper terminal: G/R and P/W No
• Faulty G/R or P/W wire
• Check the continuity between the above wires. Ź
• Is there continuity?
Yes ź
• Replace the speed sensor with a new one. Î4-42

• Erase the DTC and test-ride the vehicle above 30 No
• Faulty original speed sensor
km/h, then recheck the DTC. Ź
• Is the DTC 1-3, 1-4, 2-3, 4-3 indicated?
Yes ź
4-38
ELECTRICAL SYSTEM
DTC 3-1, 3-2, 3-3, 3-4, 3-7, 3-8
(Solenoid valve)
From Battery
SOLENOID
VALVE
ABS FSR 30 A ABS MODULATOR
• Erase the DTC and test-ride the vehicle above 30

No
km/h, then recheck the DTC. • Intermittent failure
Ź
• Is the DTC 3-1, 3-2, 3-3, 3-4 indicated?
Yes ź
4-39
ELECTRICAL SYSTEM
DTC 5-1, 5-2, 5-3, 5-4
(Pump motor lock/Power supply relay)
ABS modulator 25P connector
From Battery
R BAT
ABS MOTOR 30 A
ABS MODULATOR
PUMP
MOTOR
1. ABS Modulator Power Line Inspection
• Connection: R (+) – Ground No

• Faulty R wire
Yes ź

No
Ź
• Is the DTC 5-1, 5-4 indicated?
Yes ź
4-40
ELECTRICAL SYSTEM
DTC 6-1, 6-2
(Power Circuit)
From Ignition switch
R/Bu IG
ABS MAIN 10 A
ABS MODULATOR
R BAT
ABS MOTOR 30 A
1. Charging Voltage Inspection
• Measure the charging voltage. No

• Faulty regulator/rectifier
• Is the charging voltage below 15.5 V? Ź
Yes ź

No
Ź
• Is the DTC 6-1, 6-2 indicated?
Yes ź
DTC 7-1
• Check the following and correct the faulty part.

– Incorrect tire pressure
– Tires not recommended for the motorcycle were installed (incorrect tire size).
– Deformation of the wheel or tire.
(Incorrect Tire Size)

No
Ź
• Is the DTC 7-1 indicated?
Yes ź
DTC 8-1
(ABS Control Unit)

No
Ź
• Is the DTC 8-1 indicated?
Yes ź
4-41
ELECTRICAL SYSTEM
WHEEL SPEED SENSOR
FRONT
• Fuel tank Î2-9
• Wheel speed sensor inspection
REAR
• Right side cover Î3-6
• Wheel speed sensor inspection
4-42
ELECTRICAL SYSTEM
ABS MODULATOR
Brake pipe joint nut: 14 N·m

• ABS modulator cover Î3-4
4-43
ELECTRICAL SYSTEM
BATTERY/CHARGING SYSTEM
BATTERY/CHARGING SYSTEM LOCATION
BATTERY
MAIN FUSE 30 A
IGNITION SWITCH
REGULATOR/
RECTIFIER
ALTERNATOR
BATTERY/CHARGING SYSTEM DIAGRAM
Y R/W
30 A
Y
Y G Bl
REGULATOR/RECTIFIER
ALTERNATOR Bl
BATTERY
• Battery/charging system information, troubleshooting and inspection
4-44
ELECTRICAL SYSTEM
BATTERY
LIGHTING SYSTEM
• Headlight aim Î4-49
4-45
ELECTRICAL SYSTEM
• Rear fender Î3-12
4-46
ELECTRICAL SYSTEM
• Rear cowl Î3-11
BULB REPLACEMENT
4-47
ELECTRICAL SYSTEM
4-48
ELECTRICAL SYSTEM
HEADLIGHT AIM
• Loosen the visor bolts. After the adjustment, tighten the visor bolts.
SPEEDOMETER
1.0 N·m

• Meter lower cover Î3-9
4-49
ELECTRICAL SYSTEM
4-50
ELECTRICAL SYSTEM
CLOCK ADJUST
• Push and hold both the SEL button and SET button for
more than 2 seconds.
• The clock will be set in the adjust mode with the hour dis-
play flashing.
• The time is advanced by one hour, each time the button is

pushed.
• The time advances fast when the button is pushed and
held.
• The minute display will start flashing.
• The time advances by one minute, each time the button is

pushed.
• The time advances fast when the button is pushed and
held.
• To end the adjustment, push the SET button or turn the ig-
nition switch to OFF.
• The display will stop flashing automatically and the
adjustment will be cancelled if the button is not pushed for
about 30 seconds.
4-51
ELECTRICAL SYSTEM
FUEL LEVEL SENSOR
• Fuel pump unit Î2-4
4-52
ELECTRICAL SYSTEM
FUEL METER TROUBLESHOOTING
FUEL GAUGE FAILURE INDICATION
• Fuel level sensor Î4-52
Open circuit indication:
Short circuit indication:
FULL
EMPTY
1. Fuel Level Sensor Circuit Inspection
• Check the Y/W and G wire. No • Faulty Y/W or G wire

• Is there no open or short circuit? Ź
Yes ź
2. Fuel Level Sensor Inspection
• Standard: FULL 6 – 10 ȍ, EMPTY 75 – 81 ȍ. No • Replace the fuel level sensor with a new one Î4-
• Is there standard resistance? Ź 52, and recheck.
Yes ź
• Replace the meter with a new one Î4-49, and re-

check.
4-53
ELECTRICAL SYSTEM
ELECTRICAL COMPONENT
IGNITION SWITCH
27 N·m
• Fuel tank Î2-9
SIDESTAND SWITCH
10 N·m
• Align the pin with the hole.
4-54
ELECTRICAL SYSTEM
HORN
4-55
MEMO
INDEX
dummytext
INDEX
A Few Words About Safety ·············································1-2 FUEL LINE ····································································· 2-2
A
ABS ···············································································4-31 FUEL PUMP UNIT·························································· 2-4

AIR CLEANER ································································2-7 FUEL TANK ···································································· 2-9
ALTERNATOR/STARTER CLUTCH·····························2-29 HANDLEBAR································································ 3-25
H
BATTERY BOX ·····························································3-17 HORN ··········································································· 4-55

B
BATTERY/CHARGING SYSTEM ·································4-44 How To Use This Manual ··············································· 1-3

BODY PANELS·······························································3-2 IGNITION SYSTEM ······················································ 4-25
I
BRAKE FLUID REPLACEMENT···································3-34 INJECTOR···································································· 2-13

BULB REPLACEMENT·················································4-47 LIGHTING SYSTEM ····················································· 4-45
L
CABLE & HARNESS ROUTING ···································1-17 LUBRICATION SYSTEM·············································· 2-14

C
CLUTCH/GEARSHIFT LINKAGE ·································2-27 MAINTENANCE SCHEDULE ······································· 1-34

M
COOLING SYSTEM······················································2-18 MODEL IDENTIFICATION ············································· 1-5

CRANKCASE/CRANKSHAFT/BALANCER ··················2-31 OIL COOLER································································ 2-18
O
CYLINDER HEAD ·························································2-19 PGM-FI SYSTEM ··························································· 4-2

P
CYLINDER/PISTON······················································2-26 REAR BRAKE ······························································ 3-39

R
ECM FUEL CONDITION DATA RESET REAR SUSPENSION ··················································· 3-30

E
PROCEDURE ·······························································4-22 REAR WHEEL ······························································ 3-28

ELECTRICAL COMPONENT········································4-54 SIDESTAND ································································· 3-18
S
ELECTRICAL STARTER ··············································4-27 SPARK PLUG REPLACEMENT··································· 4-26

EMISSION CONTROL SYSTEMS································1-32 SPECIAL TOOL LIST ··················································· 1-16
ENGINE OIL CHANGE ·················································2-15 SPECIFICATIONS·························································· 1-6
ENGINE OIL FILTER CHANGE····································2-16 SPEEDOMETER ·························································· 4-49
ENGINE OIL LEVEL CHECK········································2-15 STEERING STEM ························································ 3-26
ENGINE UNIT ·······························································2-36 TECHNICAL FEATURES ············································· 1-33
T
ETHANOL INDICATOR FUNCTION·····························4-21 THROTTLE BODY························································ 2-10

EXHAUST PIPE/MUFFLER ··········································3-19 TORQUE VALUE·························································· 1-11
FORK ············································································3-23 TP SENSOR RESET PROCEDURE ···························· 2-12
F
FRONT BRAKE·····························································3-34 TRANSMISSION ·························································· 2-34

FRONT WHEEL ····························································3-21 VALVE CLEARANCE ··················································· 2-19
V
FUEL LEVEL SENSOR·················································4-52
5-1
XRE300/A-G (BR,LA,AG,CO) ENGINE
STOP
SWITCH
FRONT FRONT REAR
BRAKE WHEEL WHEEL
COMBINATION METER LIGHT SPEED SPEED
STARTER SWITCH IGNITION SENSOR SENSOR
SWITCH SWITCH O2 SENSOR
ABS
IG
BAT1
only
BAT
ALC IND
ABS only
FUEL REAR BRAKE
LIGHT SWITCH
ST
HL
IG
BAT2
BAT4
LEVEL FUEL ABS
V+
V-
V+
V-
VS SENSOR PUMP only ABS MODULATOR

SENSOR
R
W
W
Bl
Bl
Bl
W
W
Gr
Bu
Bu
Y/R
G/Y
STARTER
R/Bl
Bl/Br
Bl/Br
Bl
Bl
Bl
Bl
Bl
Bl
Bl
Bl/Bu
Bu/W
FUEL PUMP RELAY JOINT
FUEL
TACHO SIGNAL
FUEL PULSE
ALC
/
SPEED GND
GND
BATT BACKUP
WINKER RELAY
ABS
HIGH BEAM
ENG
NEUTRAL
SPEED SIGNAL
SPEED VCC
IGN
JOINT JOINT JOINT
VCC
GND
OUT
RELAY SWITCH DUMMY
Bl
Bl
16P STARTER 30A MOTOR GND
LOGIC GND
2P 2P
STOP LAMP SW
MOTOR(+)
FSR
IGN
ABS WARN IND
DIAG
SCS
RR SP(-)
RR SP(+)
FR SP(-)
FR SP(+)
G
Gr M O Gr 3P
Br/R
MOTOR
BATTERY 25P Bl
P
R
R
G
G
Bl
Bl
W
Gr
Bu
Y/W
R/Bl
Y/W
Bl/G
W/R
W/Bl
Bu/R
Lg/Bl
Bl
Lb/W
P
W/Bu
G
Bl
12V 6AH
R
R
R
R
G
G
G
G
G
G
G
G
2P
G/R
P/W
Gr/R
G/Y
G/Y
G/Bu
O/Bu
R/W
R/W
4P
Bl/Br
Bl/Br
Bl/Br
Bl/Br
R/Bu
R/Bu
3P 2P 9P 2P 4P 2P R Bl
P
R
R
G
G
Bl Bl Bl Bl
G/Y
G/R
4P
P/W
W/Bl
Gr/R
R/Bu
O/Bu
G/Bu
GROUND
Bl
GROUND
G/Y
G
G
G
Bl
W
Br
ABS
Y/R
Y/R
G/Y
G/R
R/Bl
Y/W
R/Bl
Bl/R
R/W
R/W
R/W
Br/R
Bl/G
W/R
R/W
G/W
Br/R
Bl/W
Bl/Br
Bl/Br
Bl/Bu
Bl/Bu
Bl/Bu
Bu/W
only
REAR RIGHT TURN

Lb Lb Lb SIGNAL LIGHT
G G G
G 12V 16W
O O
G/Y G/Y G/Y STOP/TAILLIGHT
G G G
Bl Br Br 12V 5/21W
3P
REAR LEFT TURN
G SIGNAL LIGHT
O
12V 16W
FRONT RIGHT
TURN SIGNAL Lb Lb Lb
LIGHT G G G
12V 16W G
O O
G
LO
Bu
Bu
W
3P
HEADLIGHT Bl
12V 60/55W
ABS
FRONT LEFT only
TURN SIGNAL G
LIGHT O
12V 16W
Bl
1P
W
Y
Y
R
R
R
G
O
Bl
Bl
Lg
Lb
Lg
Gr
Bu
Bu
Y/R
G/R
G/R
G/O
R/Bl
Bl/R
R/Bl
R/Bl
Bl/R
R/W
R/W
R/W
G/Bl
G/W
Lg/Y
Lg/R
Bl/Br
R/Bu
Lg/Bl
Bl/Bu
Bl/Bu
Bu/W
Gr/Bu
4P
9P R 5P
2P Bl
Bl
10A
10A
10A
15A
10A
30A
30A
TA
PB
SG
TPS
VCC
DUMMY
Y
Y
Y
Y
Y
Y
G
G
G
G
G
G
G
G
G
G
G
G
G
G
Y/R
G/O
W/Y
P/W
R/W
G/Bl
G/Bl
G/W
G/W
Lg/R
Bu/Y
Br/Bl
Y/Bu
P/Bu
Bl/Br
Br/W
R/Bu
Bu/Bl
Bl/Bu
Bu/W
HORN
SENSOR 4P 2P 2P 3P 2P 3P 3P 5P
CLOCK ABS MOTOR Bl Bl Bl
UNIT Bl Bl Bl Bl
O
Bl
Bl
W
Lb
Lg
Gr
Bu
Bu
R/Bl
Bl/Br
STOP, TAIL
Bu/W
ABS FSR
ABS
ABS only
TURN SIGNAL
Y
Y
Y
only
OUT
VCC
GND
W/Y
G/W
METER, HORN
Lg/R
Bu/Y
HI
W
HL
HO
BAT
BAT
BANK ANGLE, F/P EOT
ECM, INJ, IGN COIL
IACV BANK GROUND
SENSOR
HI
H/L
L
R
LO
ANGLE
only
ABS
P INJECTOR REGULATOR/
Y
Y
G
G
W
Br
SENSOR
Bu
Y/R
G/R
G/O
W/Y
P/W
G/Bl
W/R
G/W
Lg/Y
Bl/W
Bu/Y
Bl/Br
P/Bu
Y/Bu
Br/Bl
TURN
Bu/R
R/Bu
Br/W
Lb/W
Bu/Bl
W/Bu
Bu/W
Gr/Bu
CLUTCH RECTIFIER
G
SIGNAL
G/W
SWITCH 33P IGNITION

SWITCH Bl COIL ALTERNATOR
W/Y
Lg/R
Bu/Y
/
/
TA
LG
PB
TO
SG
INJ
IGP
THL
FLR
ALC
VSP
PG1
PG2
PCP
SCS
VCC
PCM
DIMMER HORN
NLSW
FLCNT
K-LINE
TACHO
IACV1A
IACV2A
IACV1B
IACV2B
IGPLSE
SWITCH UP DOWN
SSTAND
O2SENS
FI WARN
SWITCH
O2HTCTL
BANK ANGLE
PASSING SIDE
SWITCH ECM
STAND CKP SENSOR
SWITCH
ALC IND
ALC IND
NEUTRAL
SWITCH
Bl Black Br Brown
Y Yellow O Orange
Bu Blue Lb Light Blue
SWITCH CONTINUITY G Green Lg Light Green
ENGINE R Red P Pink
IGNITION SWITCH STARTER SWITCH STOP SWITCH TURN SIGNAL SWITCH DIMMER SWITCH HORN SWITCH PASSING SWITCH W White Gr Gray
BAT1 BAT2 IG ST BAT HL BAT4 IG W R L HL LO HI BAT5 HO BAT3 HI
ON FREE OFF R LO FREE FREE TWO COLORED WIRE (EXAMPLE:YELLOW/RED)
OFF PUSH RUN N (N) PUSH PUSH
L HI

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Shop Manual

2. Fuel & Engine

3. Frame & Chassis

MODEL IDENTIFICATION ······················· 1-5 EMISSION CONTROL SYSTEMS·········· 1-32

SPECIFICATIONS ···································· 1-6 TECHNICAL FEATURE ························· 1-33

TORQUE VALUE···································· 1-11 MAINTENANCE SCHEDULE················· 1-34

A Few Words About Safety

For Your Customer’s Safety

Improper service or repairs can create an unsafe

For Your Safety

Failure to properly follow instructions and

Important Safety Precautions

How To Use This Manual

You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions.

You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions.

You CAN be HURT if you don’t follow instructions.

• Instructions – how to service this vehicle correctly and safely.

ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS

© Honda Motor Co., Ltd.

Removal or Disassembly procedure. Installation or Assembly procedure.

Order of installation/assembly with a point of

Tighten specified torque. Replace with a new one before assembly.

Turn ignition switch to OFF. Turn ignition switch to ON.

Start the engine. Measure a resistance or check continuity.

Measure a voltage. Measure an ampere.

Refer to “Basic” Service Manual for the instruc-

LUBRICATION AND SEAL SYMBOL

Apply a locking agent. Use a medium strength

Use a specified fork oil or suspension fluid.

ENGINE SERIAL NUMBER VEHICLE IDENTIFICATION NUMBER

FUEL & ENGINE SPECIFICATIONS

FRAME & CHASSIS SPECIFICATIONS

ELECTRICAL SYSTEM SPECIFICATIONS

SPECIAL TOOL LIST

RIGHT FRONT RIGHT FRONT

MAIN WIRE HARNESS

IGNITION SWITCH WIRE

RIGHT FRONT RIGHT FRONT

MAIN WIRE HARNESS

IGNITION SWITCH WIRE

XRE300A: FRONT BRAKE HOSE

FRONT WHEEL SPEED

FRONT BRAKE HOSE

FUEL PUMP WIRE FUEL HOSE (Return)

FUEL HOSE (Feed)

FUEL LEVEL SENSOR WIRE

XRE300: BANK ANGLE SENSOR

STARTER MOTOR CABLE

BRAKE PIPE FRONT WHEEL

BANK ANGLE SENSOR

STARTER MOTOR CABLE

STARTER MOTOR CABLE

XRE300A: REAR BRAKE PIPE B FRONT BRAKE PIPE C

FRONT BRAKE PIPE B REAR BRAKE PIPE A

ABS FUSE BOX

ABS FUSE BOX

FUEL PUMP 2P CONNECTOR

STARTER MOTOR CABLE

FUEL HOSE (Feed)

FUEL HOSE (To injector) FUEL HOSE (To injector)

FUEL HOSE (Return)

FUEL HOSE (Return)

ABS SERVICE CHECK