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Honda 2009 crf 450r, Service Manual

The Honda 2009 CRF 450R Service Manual is an essential tool for all CRF 450R owners. This comprehensive manual provides detailed instructions and specifications for servicing and maintaining your bike. Download this invaluable manual for free from manualshive.com and ensure hassle-free maintenance of your Honda 2009 CRF 450R.

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Summary of Contents for 2009 crf 450r

Page 1: ......

Page 2: ...ures Only you can decide whether Of not you should perform a given task AWARNING Failure to property follow instructioos and precautions can cause you to be senously hurt Of killed Follow the procedures and precautions in thiS manual carefully Important Safety Precautions Make sure you have a dear understanding of all baSIC shOp safety practices and thai you are weanng appropnate clothing and USin...

Page 3: ... read Technical Features In Section 2 If you don t know the source of the trouble go to Troubleshooting Section 19 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 Y...

Page 4: ...ybdenum disulfide grease containing more than 3 molybdenum disulfide NLGI 2 or equivalent Example M04ykote BR 2 plus manufactured by Dow Coming U S A Multi purpose M 2 manufactured by Mltsubishj Oil Japan Use molybdenum disulfide paste containing more than 40 molybdenum disulfide NLGI 2 or equivalent Example Molykote G n Paste manufactured by Dow Corning U S A Honda Moly Paste M77 U S A only Rocol...

Page 5: ... FI F C O O LI N G S y 7 S T E M UJ ENGINE REMOVAL INSTALLATION F CYLINDER HEADNALVES F CYLINDER PISTON F CLUTCH KICKSTARTERIGEARSHIFT LINKAGE Z F UJ ALTERNATOR CRANKCASE CRANKSHAFTITRANSMISSION BALANCER FRONT WHEEL SUSPENSION STEERING REAR WHEEL SUSPENSION G HYDRAULIC BRAKE ELECTRICAL SYSTEM WIRING DIAGRAM TROUBLESHOOTING INDEX ...

Page 6: ...MEMO ...

Page 7: ...STON SPECIFICATIONS 1 9 CLUTCH KICKSTARTER GEARSHIFT LINKAGE SPECiFiCATIONS 1 10 1 GENERAL INFORMATION CRANKCASEICRANKSHAFTI TRANSMISSION BALANCER SPECIFICATIONS 1 10 FRONT WHEEL SUSPENSION STEERING SPECIFICATIONS 1 11 REAR WHEEL SUSPENSION SPECiFiCATiONS 1 12 HYDRAULIC BRAKE SPECiFiCATIONS 1 13 ELECTRICAL SYSTEM SPECiFiCATIONS 1 13 TORQUE VALUES 1 13 LUBRICATION SEAL POINTS 1 20 CABLE HARNESS ROU...

Page 8: ...n to the specified torque diagonally in Incremental steps unless a particular sequence is specified 6 Clean parts in cleaning solvent upon disassembly Lubricate any sliding surfaces before reassembly 7 After reassembly check all parts for proper installation and operation 8 Route all electrical wires as shown in the Cable and Harness Routing page 1 23 g Do not bend or twist control cables Damaged ...

Page 9: ...GENERAL INFORMATION MODEL IDENTIFICATION 09 shown After 15 shown 1 3 ...

Page 10: ...on the right side of the steering head The engine serial number is stamped on the left side of the lower 0 crankcase The throttle body identification number is stamped on the right side of the iiI I throttle body NUMBER LABEL The name plate is located on the right side of the frame 1 4 ...

Page 11: ... I Overaillengih 1 09 9l3 t 8 6 3li n _ 10 191 mm 86 3in 1 12 fE tt BB mm B6 Ii n O erall width on I i U ITEM I DIMENSIONS Overall heigh 09 1 27B mm 50 3 Imm 50 ler I mm 50 1w t 09 E 493mm Bin Seat height I Foolpeg height I Ground clearance 1 5 ...

Page 12: ...7 Trail length 115 l mm 1 55 1 0 14 2 mm 1 50 r i 4f f 12 Fuellaok 5J11ler I 1 25 Imp gal D US gal 1 39 Imp gal 2 n I T27 Hallo 09 12 12 0 1 I I 12 5 Valve train 15 Wlth rocker oem Intake valve I 6 m 1 09 opens i lift I 20 BTOC closes 6 7 ft SO ABDC fo opeos i 6 m 09 valve In 11ft After doses at 1 0mm IS ATOC nSvStem 004 i 11ft rocho and weI I type Eng e dry we ghl I kg 59 71bs i 11 I I 13 1 2 i A...

Page 13: ...N SPECIFICATION Multi plate wet Cable operated r _ Constant mesh S speed _r 2 7 39 6312 3t _ _ 3 692 48 13 i 1st _ 1 7 0 800 27 15 f 2 n i d__ 1c 4 70 2Sf17 I 3rd 1 235 21117 ___ 4th 1 050 211 20 5 lht t O 9 09 20f2i2 Left foot operated return system 1 N 2 3 4 S C o m puler controned digital ______ I n sistoriZed with electric advance Single phase output alternator S C R shorted single phase full ...

Page 14: ... or higher JASO MA i 10W 30 I 4 slroke all Canada or equivalent molor API service classification SG or higher JASO T903 standard MA SAE 10W 30 FUEL SYSTEM PGM FI SPECIFICATIONS ITEM Throttle body identification number i 09 t 10 09 I 75 rpm After 4 r O 12 1C OOoo rp m j Th orue g n p t 09 E E 1 3 I er 2 Hmm 1i 6 1i4 nl ei ce a 576 2 3 _2 6 1 0 Fue l 3 F pump now al 2 VI 50 em 5 US OZ limp COOLING S...

Page 15: ... 977 11 985 0 4715 0 4718 11 97 0 471 Rocker arm la shaft clearance 0 015 0 041 0 0006 0 0016 ro 055 0 0022 Cam tobe heighl IN 37 540 37 780 1 4779 1 4874 I 37 52 1 477 EX 28 598 28 838 1 1259 1 1354 I 28 58 1 125 Rocker arm Camshaft Valve lifter 0 0 Valve lifter bore 1 0 25 978 25 993 1 0228 1 0233 25 97 1 022 26 010 26 026 1 0240 1 0246 26 04 1 025 CYLINDERlPISTON SPECIFICATIONS Cylinde Piston p...

Page 16: ...16 _ 09 10 47 9 1 89 _ j J 11 12 43 3 70 3 51 7 2 04 _ __ _ STANDARO ___ _ tSERVICE LIMIT j cc __ Afta 3 _ _4 9 7 i 96 c i s C IU ch di SC IIl ick ne SS __ t 2 9 2 _3 08 O 115 O 121 ii 33 i CRANKCASE CRANKSHAFTITRANSMISSION BALANCER SPECIFICATIONS ___ unit mm STANDARD SERVICE LIMIT c mkShaft 11 e f I Transmission 1 10 bushing clearance Fork shaft ...

Page 17: ...tandard cold air I 13 2 3 0 kPa 2 3 kgffcm2 33 psi 7 p ei s isu c e ___ After 1 3 i2ii4c 0ikPa 2 4 kgf cm 2 35 psi r Compression 09 10 14 13 clicks out from full in damping 11 12 12 clicks oul from full in __ adjuster 13 14 clicks out from full in standard 15 High speed ___ i 1clicks oul from full in position low speed 12 clicks oul from full in i H 9 h S pe dC I 2 Oclicks out from full in After 1...

Page 18: ... 0 D ive h ln 09 11 35 roller 0 0 12 35 _owe 3 5 Jppe I Lowe M 33 Shock MPa 10 2 145 psi absorber gas ga shock oil KYB KHV10 K2C 2m ed 1i0ice i B 4 k9 40 6 49 4 IbD standard 5 94 2 B 5U un H i h speed I 09 _ 11 IumS ull position c lI 2 1 5 2 turns oull lin tuIIln 4 516 I leks oul wm ull In Low_ _ i I adjuster standard position 2 4 ClickS lull I Clicks oullrom lull in n I position 0 I aJuilln oul w...

Page 19: ...IFICATIONS I TEM SPECIFICATION S pa pl ug C S ta ndard NGK t QPiiOnal NG K lu9 L ______ _ _____ SILMAR9A 9S SILMAR10A 9S _ _ _ 0 8 0 9 mm 0 031 0 035 in __ Ignition coil resistance at 20 C 6aQ F ____ Ignition coil peak voltage 1____ C I 20 C 6S0F 09 12 1 13 2 6 3 100Vminlmum 0 7Vmini 0 1 3 0n S BTDC at idle 10 BTDC at idle ____ 12 BTDC at idle iAft 13 Alternator 1 Capacity__ TORQUE VALUES STANDARD...

Page 20: ...I I I bOil IAHer 5 C 36 Air i 2 6 1C JI Sea 3 Muffler i bOil 19 3 Muffler ininl I bOil 15 ipe join nu 2 I i pe 2 1 Mud guard screW _ 121 55 5 6 1 Upper step i c je 5 Lowerslep 2 30 i c 2 29 2 S screw yn i MAINTENANCE ITEM Q TY DIA lmm N m Ibf ft REMARKS I Engine oil drain bolt 1 10 1 0 I I iI e threads d sealing surface 1oil arain DOli 1 10 1 121 I oilt the d seating r b Olt_ 12 2 9 1 JU 15 TS ll1...

Page 21: ...ew 1 5 3 4 0 3 2 5 Air cleaner housing coverscrew 09 12 1 5 1 1 0 1 0 8 engine mode select switchfindicator After 1 1 I 4 t 1 5 0 2 1 1 L_ COOLING SYSTEM ITEM left radiator air bleed bolt After 12 Water pump impeller Radiator connecting hose band screw Radiator hose band screw ENGINE REMOVAUINSTALLATION THREAD TORO ue OIA mm N m kgf m Ibf ftl L 12 I 1 6 0 2 1 2 I a TV REMARKS 1 7 12 1 2 9 2 r See ...

Page 22: ... 5 47 Apply engine oil to the threads and seating surfaces CKP sensor mounting boll 4 5 5 2 0 5 3 81 AlOe bolt replace with a new one Stator mounting socket bolt 3 5 5 2 0 5 3 81 Al Oe bolt replace Left crankcase cover boll t t f t with a new one 09 10 _ 8 6 12 1 2 9 After 10 8 6 10 1 0 7 1 _ ______ J CRANKCASE CRANKSHAFTfTRANSMISSIONIBALANCER ITEM Q TY REMARKS Gearshift drum bearing set iI iI Oil...

Page 23: ...per tj O 9 t 14 _2 Fork protector mounting 6 30 See page 14 78 1 8 22 2 2 8 20 2 0 15 j 42 28 2 9 21 51 45 4 6 33 22 55 5 6 41 ti pply locking agent to I the threads 14 43 4 4 32 Apply locking agent to the threads 12 29 3 0 21 12 29 3 0 21 i 5 2 10 0 9 8 8 5 8 0 6 4 3 8 5 5 0 6 4 1j 51 30 3 1 22 1 I Fronl brake disc cover bolt 09 12 1 1 S J 7 0 0 7 5 2 AlOC bolt replace with a new one 6 137 1 3 1 ...

Page 24: ...ock nut 1 18 14 O TY 5 8 50 14 12 TOIRO UE r R EMARK S I and seating surfaces I 12 t S3 5 4 39 mOIYbdenUmOil solution to lhe threads I I T53 5 4 39 f i I solution to the threads and seating surfaces I U nut d 1 10 44 3Z U nut 1 10 44 1 60 28 3 5 4 2 e 6 z U nul I 1 7 1 12 1 I 30 3 1 22 1 28 1 ZB 30 3 ZZ j THREAD TORQUE O TY DIA mm N m kgf m IbUt REMARKS j 4 10 34 3 5 Z5 1 5 5 9 0 6 4 4 6 5 9 0 6 4...

Page 25: ...ELECTRICAL SYSTEM ITEM Timing hole cap Q TY 1 GENERAL INFORMATION THREAD I TORQUE REMARKS I CIA mm N m kgf m IbHt _ 14 Y S O 0 6 4 4 Apply grease to the __ threads __ 1 19 ...

Page 26: ...oil and molybdenum grease with the ratio 100 g 70 eel Pro GN44 stroke oil U S A Canada or equivalent motor oil API service classification SG or higher JASO T903 standard MA Viscosity SAE 10W 30 I purpose grease NLGI 2 or equivalent f oa ic rtnFB1wIB i C 1i t dcover 1 20 area ...

Page 27: ...n a ct a e a Brake lever spring both endS _ _ _____ _ Rear master cylinder push rod rounded surface and boot _ fi ttlng area onda DOT 4 brake fluid rake caliper piston seal lips Brake caliper piston outer SUrface t Masler piston outer surface I MaSle yl nde inne urtace Honda Bond A or Pro Handlebar grip rubber inner surface Honda Handgrip Cement Air cleaner connecting boot contacting surface U S A...

Page 28: ...ATION iI 55 19 After 10 Honda GN4 4 stroke oil U S A Canada or equivalent motor oil API service dassification SG or higher JASO T903 standard MA Viscosity SAE 10W 30__ h Muffler sealant high temperature silicone 1 22 ...

Page 29: ...SS ROUTING 09 12 ENGINE STOP SV ITC H 13 14 30 50mm 1 2 2 0in CLUTCH CABLE 10 20mm 0 4 O S in GENERAL INFORMATION FRONT BRAKE HOSE T Un CABLES FUEL TANK BREATHER HOSE FRONT BRAKE HOSE FUEL TANK BREATHER HOSE 1 23 ...

Page 30: ...er 14 THROTTLE CABLES ENGINE MODE SELECT SWITCHI INDICATOR WIRE FUEL TANK BREATHER HOSE CLUTCH CABLE 20 40 mm 1 24 ENGINE SELECT SWITCH INDICATOR WIRE THROTTLE CABLES f d i 10 20mm 0 8 1 6in 0 4 0 8 in I ENGINE STOP SWITCH WIRE CLUTCH CABLE FRONT BRAKE HOSE ...

Page 31: ...LE CABLES RADIATOR OVIERF lOW HOSE 13 14 THROTTLE CABLES RADIATOR OVERFLOW HOSE GENERAL INFORMATION CLUTCH CABLE ENGINE STOP SWITCH WIRE FRONT BRAKE HOSE CLUTCH CABLE 1 ENGINE STOP SWITCH WIRE FRONT BRAKE HOSE 1 25 ...

Page 32: ...GENERAL INFORMATION After 14 THROTILE CABLES f THROTILE CABLES H D 09 12 THROTILE CABLE CLUTCH CABLE ENGINE STOP SWITCH WIRE FRONT BRAKE HOSE 1 26 ...

Page 33: ...1 F CABLES CLUTCH FRONT BRAKE After 14 FRONT BRAKE HOSE ENGINE STOP SWITCH 4P BLACK CONNECTOR Arr Y ENGINE MODE SElECT SWITCH INDICATOR WIRE GENERAL INFORMATION ENGINE STOP SWITCH 4P BLACK CONNECTOR CLUTCH CABLE 1 27 ...

Page 34: ...NITION COIL PRIMARY WIRE CONDENSER2P BLACK CONNECTOR ECl SENSOR 2P BLACK CONNECTOR 1 28 CONDENSER 3P BLACK CONNECTOR ALTERNATORlCKP SENSOR WIRE CRANKCASE BREATHER DRAIN HOSE GEAR SWITCH WIRE MAP SENSOR VACUUM HOSE ALTERNATORlCKP SENSOR 6P BLACK CONNECTOR ALTERNATORlCKP SENSOR WIRE CRANKCASE BREATHER DRAIN HOSE ...

Page 35: ...E After 14 ECl SENSOR 2P BLACK CONNECTOR CLUTCH CABLE GENERAL INFORMATION CONDENSER CRANKCASE BREATHER DRAIN HOSES CONDENSER WIRE CONDENSER WIRE AllTEf A ORi CKP SENSOR WIRE CRANI KC E BREATHER DRAIN HOSES CONDI E ER WIRE Al rE W TC Ri OKP SENSOR WIRE 1 29 ...

Page 36: ...EL PUMP SUB HARNESS CRANKCASE HOSE 1 30 OLe THROTIlE CABLES ENGINE STOP SWITCH WIRE THROTILE CABLES FUEL PUMP SUB HARNESS 2P NATURAL CONNECTOR MAIN WIRE HARNESS ALTERNATORlCKP SENSOR WIRE GEAR POSITION SWITCH WIRE MAIN HARNESS ECM 33P BLACK CONNECTOR ...

Page 37: ...THER HOSE FUEL PUMP SUB HARNESS CRANKCASE BREATHER HOSE EeM GENERAL INFORMATION ENGINE STOP SWITCH WIRE SPARK PLUG WIRE MAIN WIRE HARNESS THROITLE CABLES MAIN WIRE HARNESS ECM 33P BLACK CONNECTOR FUEL PUMP SUB HARNESS 1 31 ...

Page 38: ...S FUEL HOSE RADIATOR OVERFLOW HOSE ENGINE MODE SELECT SWITCHIINOICATOR 4P Black CONNECTOR FUEL HOSE o RADIATOR OVERFLOW HOSE CLUTCH CABLE THROTTLE CABLES ii t Jli THROTTLE II CABLES CLUTCH CABLE PLUG WIRE SPARK PLUG WIRE ALTERNATORI CKP SENSOR WIRE THRonLE J CABLES 1 32 __ MAINWIRE HARNESS ...

Page 39: ...er 15 ENGINE MODE SELECT SWITCH INDICATOR 4P Black CONNECTOR ALTERNATOR CKP SENSOR WIRE FUEL HOSE MAIN WIRE HARNESS GENERAL INFORMATION RADIATOR OVERFLOW HOSE SPARK PLUG WIRE CUP FUEL PUMP SUB HARNESS 1 33 ...

Page 40: ...GENERAL INFORMATION 09 RADIATOR CONNECTING HOSE LOWER RAIJlA roR HOSES 1 34 UPPER RADIATOR HOSES RADIATOR OVERFLOW HOSE LUV cK RADIATOR HOSE ...

Page 41: ...GENERAL INFORMATION 10 12 RADIATOR CONNECTING HOSE 8 RADIATOR OVERFLOW HOSE UPPER RADIATOR RADIATOR OVERFLOW HOSE LOWER RADIATOR HOSE LOWER RADIATOR HOSES 1 35 ...

Page 42: ...IATOR OVERFLOW HOSE UPPER RADIATOR HOSE I RADIATOR CONNECTING HOSE After 14 RADIATOR OVERFLOW HOSE UPPER RADIATOR HOSE RADIATOR CONNECTING HOSE 1 36 UPPER RADIATOR HOSES LOWER RADIATOR HOSE UPPER RADIATOR HOSES LOWER RADIATOR HOSE ...

Page 43: ...ORJCKP SENSOR WIRE GENERAL INFORMATION ENGINE STOP SWITCH 4P NATURAL CONNECTOR GEAR POSITION SWITCH 2P GREEN CONNECTOR GROUND WIRE 10 12 THROTTLE CABLES MAIN WIRE HARNESS _ o OLCfFUEL PUMP SUB HARNESS OLCIFUEL PUMP SUB HARNESS 4P REO CONNECTOR ENGINE STOP SWITCH 4P NATURAL CONNECTOR GR OU D WIRE 1 37 ...

Page 44: ...PUMP SUB HARNESS 4P RED CONNECTOR After 14 IGNITION COIL WIRE BLACK GROUND WIRE l lr MAIN WIRE HARNESS CLUTCH CABLE j ENGINE MODE t _ SELECT SWITCH INDICATOR WIRE _____ Q u 0 20mm 0 0 8 in OLC FUEL PUMP SUB HARNESS 4P RED CONNECTOR 1 38 RADIATOR OVERFLOW HOSE IGNITION COIL WIRE YELLOW BLUE f 1 IGNITION COIL WIRE BLACK GROUND WIRE ...

Page 45: ...PUMP HARNESS 10 12 MAP SENSOR 3P BLACK CONNECTOR FUEl PUMP HARNESS CRANKCASE BREATHER HOSE FUEL INJECTOR GRAY CONNECTOR CRANKCASE BREATHER HOSE FUEL INJECTOR 2P GRAY CONNECTOR GENERAL INFORMATION FUEL PUMP HARNESS 2P NATURAL CONNECTOR 1 39 ...

Page 46: ... PUMP SUB HARNESS 2P BLACK CONNECTOR MAP SENSOR 3P BLACK CONNECTOR CRANKCASE 1 BREATHER HOSES THROTILE CABLES FUEl HOSE MAP SENSOR 3P BLAC K CONNECTOR ALTERNATORlCKP SENSOR 6P BLACK CONNECTOR II FUEL PUMP SUB HARNESS 3 2P BLACK CONNECTOR ___ 1 40 FUEL INJECTOR 2P GRAY CONNECTOR CRANKCASE I jJ BREATHER HOSES THROTTLE CABLES ...

Page 47: ...SOR WIRE 10 12 CRANKCASE BREATHER HOSE TP SENSOR 3P BLUE CONNECTOR REGULATOR RECTIFIER WIRE REGULATOR RECTIFIER 5P BLACKjCONNECTOR IAT SENSOR WIRE GENERAL INFORMATION MAIN WIRE HARNESS CLUTCH CABLE EeT SENSOR WIRE 11J lib CRANKCASE BREATHER DRA N HOSE TRANSM SSION BREATHER HOSE MAIN WIRE HARNESS CLUTCH CABLE ECT SENSOR WIRE TRANSMISSION BREATHER HOSE 1 41 ...

Page 48: ...P SENSOR WIRE IAT SENSOR WIRE ECM 33P BLACK CONNECTOR ALTERNATORJCKP SENSQRWIRE 6P CONNECTOR JjI CRANKCASE BREATHER HOSE f CLUTCH CABLE CRANKCASE BREATHER DRAIN HOSE REGULATOR RECTIFIER 6P CONNECTOR TRANSMISSION BREATHER HOSE CRANKCASE BREATHER HOSE Eer SENSOR WIRE CRANKCASE BREATHER DRAIN HOSE TRANSMISSION BREATHER HOSE ...

Page 49: ...ENSOR 3P BLACK MAP SmSOR VACUUM HOSE TP SENSOR3P BLUE CONNECTOR GEAR POSITION SWITCH WIRE GENERAL INFORMATION AlTERNATORlCKP SENSOR WIRE IAT SE SOR 2F GRAY CONNECTOR REGULATOR RECTIFIER 5P BLACK CONNECTOR ALTERNATOR CKP SENSOR WIRE CONDENSER WIRE JAT SENSOR 2P GRAY CONNECTOR Eel SENSOR WIRE REGULATOR RECTIFIER SP BLACK CONNECTOR 1 43 ...

Page 50: ...R 2P BLACK CONNECTOR ALTERNATORlCKP SENSOR WIRE After 14 ALTERNATORlCKP SENSORWJRE FUEL INJECTOR WIRE MAPSENSOR WIRE CONDENSER WIRE CRANKCASE BREATHER HOSE CRANKCASE BREATHER DRAIN HOSES JAT SENSOR 2P BLACK CONNECTOR CONDENSER 2P BLACK CONNECTOR TP SENSOR 3P CRANKCASE BREATHER BLUE CONNECTOR DRAIN HOSES 1 44 ECM WIRE ...

Page 51: ... 09 14 After 14 FUEL HOSE II II I 1 FUEL PUMP 5P BLACK CONNECTOR FUEL PUMP SUB HARNESS GENERAL INFORMATION FUEL PUMP SUB HARNESS _ FUEL PUMP 5P BLACK CONNECTOR iL FUEL HOSE 1 45 ...

Page 52: ...OWER HOLDER SPARK PLUG 1 46 Standard Optional Standard Optional BREATHER HOSE REAR BRAKE HOSE REMARKS For maintenance Pin spanner A x 2 For shock absorber spring installed length preload adjustment two required For checking tire air pressure 48T Aluminum J116 47T Alumlnum 116 49T Aluminum J116 DID 520DMA4 120RB RK 520TXZ 120RJ 3 mm offset no offset SILMAR9A 9S NGK SILMAR10A 9S NGK ...

Page 53: ...Ibflin 345 em 11 7 US OZ 12 1 Imp OZ Maximum 357 em 12 1 US oz 12 Slmp oz Minimum 300 em 10 1 US CI 10 61mp Ol FORK 10 11 Spring TYPE I SPRING RATE OIL CAPACITY I Ughl 2 scribe marks 4 4 N mm Standard 25 12 Ibflin 352 em 11 9 US OZ a 12 4 Imp oz Maximum 359 emJ 12 1 US OZ 12 6 Imp oz Minimum I Standard 303 eml 10 2 US OZ 10 7 Imp oz No mark factory products 4 6 N mm Standard CO or 4 scribe marks a...

Page 54: ... USoz 12 6 Imp oz USoz 355 12 0 US OZ 12 5 Imp oz Maximum 362 em 12 2 US OZ 12 7 Imp OZ Minimum 305 em3 10 3 US OZ 1 I 350 em 11 8 US OZ 12 3 Imp oz Maximum 357 cm3 12 1 US oz 12 6 Imp 02 Minimum 300 em3 10 1 US OZ 10 Slmp oz MARK The standard fork and shock springs mounted on the motorcycle when it leaves the factory are not marked Before replacing the springs be sure to mark them so they can be ...

Page 55: ...FI SYSTEM 2 2 RESIN FUEL TANK WITH A BUILT IN FUEL PUMP 2 4 BATTERY LESS PGM FI KICKSTARTING SYSTEM 2 3 PSF PNEUMATIC SPRING FORK 13 14 2 5 ENGINE STOP SWITCH INCLUDING THE MIL 2 3 PSF2 PNEUMATIC SPRING FORK 2 After 14 2 6 2 1 ...

Page 56: ...perature and sends the information to the ECM with variations in voltage MAP sensor detects changes in the intake air pressure and sends the information to the ECM with variations in voltage TP sensor detects the opening angle of the throttle and sends the information to the ECM with variations in voltage ECT sensor detects changes in the coolant temperature with a thermistor CKP sensors send cran...

Page 57: ...CONDfN Oft To FUEL PU P IGNITION COIL To ad nior EeM ENGINE STOP SWITCH INCLUDING THE MIL OUTLINE The engine stop switch on this motorcycle includes a MIL incorporated Into this housing The condition of the PGM FI system can be easily checked Pre ride MIL I FUNCTION D C power supply is applied to the Mil when the engine is running TOJ ENGI STOI WI CH If a problem is not detected in the system the ...

Page 58: ...ank against the insert ring press fitted into the resin fuel tank The pump is secured with conical spring washers and bolts Fuel pump unit consists of the following parts 1 Fuel tank 2 Insert ring 3 Two O rings 4 Fuel pump 5 Fuel pump plate 6 Six conical spring washers 7 Six collars 8 Four washers 9 Six M6 bolts to Stopper cable guide 09 10 shown 8 2 4 9 3 _ 4 5 10 6 7 5 i i 9 ...

Page 59: ...per Pistons compresslonfrebound control the damping of the fork Rebound spring compresses when the fork is fully extended Balance spring balances the resistant force air spring by generating an extensive force when the fork is in neutral to fully extended stale The room for the air becomes less under compression stroke The resistant force increases as the sealed chamber decreases in volume The oil...

Page 60: ...extensive force when the fori is in neutral to fully extended slate Fork cap High speed adjuster to adjust oil flow at high speed Low speed adjuster to adjust oil flow at low speed Check valve to lubricate the outer tube and fork slider utilizing the change of the volume in the inner damper when compressing the fork The room for the air becomes less under compression stroke The resistant force inc...

Page 61: ...Left fork with compression damping adjuster When compressed LOW SPEED HIGH SPEED ADJUSTER When extended CHECK VALVE CHECK VALVE TECHNICAL FEATURE REBOUND REBOUND 2 7 ...

Page 62: ...MEMO ...

Page 63: ...AME BODY PANELS EXHAUST SYSTEM SERVICE INFORMATION 3 2 TROUBLESHOOTING 3 2 SEAT 3 3 SIDE COVER 3 3 RADIATOR SHROUD 3 4 ENGINE GUARD 3 6 NUMBER PLATE 3 6 REAR FENDER 3 7 SUB FRAME 3 7 EXHAUST SYSTEM 3 11 3 1 ...

Page 64: ...ower mounting bolt Sub frame left lower mounting bolt 09 12 After 12 Air cleaner housing mounling boll After 12 Exhaust pipe protector bolt Exhaust pipe protector band Exhaust pipe joint nut Muffler mounting bolt Muffler Joint band bolt Mud guard screw After 12 Exhaust pipe stud bolt Air cleaner connecting boot band bolt After 10 screw throttle body side Rear fender mounting bolt 09 12 TROUBLESHOO...

Page 65: ... bracket on the fuel tank and seal prong with the ECM stay Install and lighten the seat mounting bolts to the specified torque TORQUE 26 N m 2 7 kgf m 191bHt SIDE COVER REMOVAL INSTALLATION 09 12 Remove the seal mounting bolt Remove the side cover bolt and side cover HOOK PRONG BRACKET L MS_ T _ AY________ 1 09shown SEAT MOUNTING BOLT ISIDE COVER COVER BOLT 3 3 ...

Page 66: ...kgf m 7 IbHt Install and lighten the seal mounting bolt 10 the specified torque TORQUE 26 N m 2 7 kgf m 19 IbHt REMOVAUINSTALLATION After 12 SEAT BOLT TABS SIDE COVER COVER BOLT Remove the seat page 3 3 J iJr E OO Ei Remove the bolts side cover and air cleaner housing cover Inslallation is in the reverse order of removal TORQUE Side cover bolt 10 N m 1 0 kgf m 7lbHt RADIATOR SHROUD REMOVAUINSTALLA...

Page 67: ...TALLATION After 12 Remove the seat page 3 3 Remove the two upper bolts lower bolt and collar Slide the radiator shroud forward to release the labs then slide it rearward until its hook is aligned with the fuel tank recess Remove the radiator shroud by releasing the hook from the recess Installation IS in the reverse order of removal TORQUE Radiator shroud bolt upper side 5 2 N m 0 5 kgf m 3 8 IbH ...

Page 68: ...hooking its tab onto the frame TORQUE Engine guard bolt 10 N m 1 0 kgf m 7Ibf ft NUMBER PLATE REMOVAL INSTALLATION 3 6 Remove the number plate tab from the handlebar pad Remove the bolts and number plate Install the number plale by aligning its holes with the tabs on the steering stem Installation is in the reverse order of removal ENGINE GUARD TAB BOLT 09 shown NW BE R PLATE BOLTS TABS ...

Page 69: ...der Installation is in the reverse order of removal TORQUE Rear fender mounting bolt 09 12 13 N m 1 3 kgf m 10 IbHt SUB FRAME FRAME BODY PANELS EXHAUST SYSTEM 09 12 REAR FENDER After 12 REAR FENDER BOLTS REMOVAL INSTALLATION 09 1 2 Remove the following Seal page 3 3 Side covers page 3 3 Muffler page 3 11 Disconnect the tAT sensor 2P Grav connector 3 7 ...

Page 70: ...the slay of damagfJ the ECM the sub frame and wires Be careful not to damage the mud guard 3 8 Unhook the fuel tank band from the fuel tank band bracket Remove the sub frame upper and lower mounting bolts r i J Remove the connecting boot from the throttle body by i il ri r l pulling the sub frame backward I Disconnect the crankcase breather hose from the air cleaner housing and then remove the sub...

Page 71: ...rame upper mounting bolls first then tighten the lower mounting bolts to the specified torque TORQUE Upper 33 N m 3 4 kgf m 24 IbHt Right lower 49 N m 5 0 kgf m 36 IbHtj Left lower 33 N m 3 4 kgf m 24 IbHtj Hook the fuel lank band to the fuel lank band bracket Connect the tAT sensor 2P GRAY connector ECM FUEL TANK BAND UPF ER MOUNTING BOLTS BRIEAl HER HOSE LEFT MOUNTING BOLT 2P GRAY CONNECTOR TAB ...

Page 72: ...ing Muffler page 3 11 Side covers page 3 3 Seat page 3 3 REMOVALIINSTALLAnON AFTER 12 Remove the following Seat page 3 3 Side covers page 3 4 Muffler page 3 12 Remove the air cleaner housing mounting bolls Unhook the fuel lank band from the fuel lank bracket band Remove the mounting bolts and pull the rear fender backward page 3 7 Release the air cleaner housing holes from the sub frame bosses 4 5...

Page 73: ...kgf m 24 IbHt 49 N m S O kgf m 36 IbHt Install the removed parts in the reverse order of removal TORQUE Air cleaner housing mounting bolt 10 N m 1 0 kgf m 7lbHt EXHAUST SYSTEM MUFFLER REMOVAL INSTALLATION 09 12 Remove the right side cover page 3 3 Loosen the muffler joint band boll Remove the muffler mounting bolts washers muffler jji gasket and muffler joint band Inslall the muffler joint band an...

Page 74: ...6 N m 2 7 kgf m 191bHt Tighten the muffler joint band bolt to the specified torque TORQUE 21 N m 2 1 kgf m 15Ibf ft Install the right side cover page 3 3 MUFFLER REMOVAUINSTALLATION After 12 09 shown BOLT MUFFLER CUT OUT JOINT BAND BOLT Remove the side covers page 3 4 r 11 Loosen the right muffler joint band bolt Remove the right muffler mounting bolt washer right muffler gasket and muffler joint ...

Page 75: ...uffler rear mounting bolt and washer Remove the left muffler front mounting bolt spacer left muffler gasket and muffler joint band Install a new left muffler gasket to the exhaust pipe Install the left muffler by aligning the tab of the muffler joint band with the cut Qul of the muffler 3 13 ...

Page 76: ...pecified torque TORQUE 26 N m 2 7 kgf m 191bHt Install the mud guard and screws then tighten them to the specified torque TORQUE 1 5 N m 0 2 kgf m 1 1IbHt Install a new right muffler gasket Install the right muffler to the left muffler Install the right muffler mounting bolt and washer Tighten the muffler joint band bolt to the specified torque TORQUE 20 N m 2 0 kgf m 151bHt Tighten the muffler mo...

Page 77: ...page 3 11 Aher 12 page 3 12 Remove the exhaust pipe joint nuts eKhaust pipe and gasket EXHAUST PIPE DISASSEMBLY ASSEMBLY 09 shown EXHAUST PIPE PROTECTOR 12 N m 1 2 kgf m 9Ibf ft 09 12 3 5 N m 0 4 kgf m 2 6IbHt After 12 2 8 N m 0 3 kgr m 2 1 Ibr ft EXHAUST PIPE PROTECTOR BAND 3 15 ...

Page 78: ...ION 09 12 26 N m 2 7 11 2 After 12 13 shown 5 N m o 2 kg m MUDGUARD l 26 N m 2 7 kgf m 19 LEFT MUFFLER RIGHT MUFFLER fI GASKET 20 N m 2 0 kgf m 15 3 16 fI GASKET 21 N m 2 1 kgf m 15 26 N m 2 7 kgf m 19 SPACER 20 N m 2 0 kgf m 15 j 21 N m 2 1 15 EXHAUST PIPE ...

Page 79: ...ighten the exhaust pipe Joint nuts to the specifted torque TORQUE 21 N m 2 1 kgf m 1S IbHtj Always Inspect Ille Tighten the muffler mounting fasteners exhaust system for leaks aner Installation CYLINDER HEAD EXHAUST PIPE STUD BOLT REPLACEMENT Thread two nuts onto the stud and tighten them together then use a wrench on them to turn the stud bolt out Install new stud bolts into the cylinder head as ...

Page 80: ...MEMO ...

Page 81: ...7 THROTTLE OPERATION 4 8 BRAKE PAD WEAR 4 28 AIR CLEANER 4 9 BRAKE SYSTEM 4 29 CRANKCASE BREATHER 4 11 CLUTCH SYSTEM 4 29 SPARK PLUG 4 11 CONTROL CABLES 4 31 RADIATOR COOLANT 4 13 EXHAUST PiPE MUFFLER 4 32 VALVE CLEARANCE 4 13 SUSPENSION 4 39 ENGINE OIUOIL FILTER 4 16 SWINGARMISHOCK LINKAGE 4 41 ENGINE IDLE SPEED 4 19 NUTS BOLTS FASTENERS 4 41 TRANSMISSION OIL 4 19 WHEELSITIRES 4 41 COOLING SySTEM...

Page 82: ...hrottle grip freeplay Spark plug ITEM Spark plug gap rValve clearance Engine oil capacity Recommended engine Recommended transmission oil equivalent motor oil API service classification SG or higher I JASO s ao d a rd M AOil u SJ l5Imaaaj 1 equivalent motor oil API service classification SG or higher I _________________ JA S 0 T Ois3 As E ao d a ro QM A Idl speed ____ I 09 a 750 t OO t rpm11 6 __ ...

Page 83: ...gf m 12Ibf ft 16 N m 1 6 kgf m 12Ibf ft 12 N m 1 2 kgf m 9Ibf ft 15 N m 1 5 kgf m 11Ibf ft 22 N m 2 2 kgf m 16Ibf ft 5 9 N m 0 6 kgf m 4 4 IbUt 5 9 N m 0 6 kgf m 4 4 Ibf ft 128 N m 13 1 kgf m 94lbf ft 12 N m 1 2 kgf m 9Ibf ft 12 N m 1 2 kgf m 9Ibf ft 12 N m 1 2 kgf m 9Ibf ft 31 N m 3 2 kgf m 23 Ibf ft 32 N m 3 3 kgf m 24 Ibf fl 1 0 N m 0 1 kgf m 0 7Ibf ft 1 0 N m 0 1 kgf m 0 7Ibf ft 21 N m 2 1 kgf...

Page 84: ... I R 4 19 RADIATOR COOLANT NOTE 2 1 4 13 COOLING SYSTEM I 4 20 DRIVE CHAIN I L R 4 21 IDRlVE CHAIN SLIDER 4 24 r DRIVE CHAIN ROLLER 1 4 24 tORIVE SPROCKET I 4 26 DRIVEN SPROCKET I 4 26 BRAKE FLUID NOTE 2 I 4 27 BRAKE PADS WEAR I 4 28 BRAKE SYSTEM r 4 29 CLUTCH SYSTEM I NOTE 5 I 4 29 ICONTROL CABLES I L 4 31 I EXHAUST PIPE MUFFLER 1 4 32 ISUSPENSION I 4 39 SWINGARMISHOCK LINKAGE L 4 41 FORK Oil EXC...

Page 85: ...rake pads Sub frame mounting bolts Chain guide _ C ause Wear Minimum thickness 1 0 mm 0 04 in Side cover Number plale Front rear fender Clutch lever holder Brake lever Handlebar Throttle housing Handlebarlthrottle grip Gearshift pedal Brake pedal Drive chain adjusting bolVadJuster lock nut Air cleaner NOTE Fattgue or damage Wear or damage Damage Damage Damage Freeplay or damage Freeplay or damage ...

Page 86: ...ose with the hose damp Remove the fuel tank breather hose from the steering slem Remove the bolt collar and fuel tank band Aner Hi Remove the clip from the thronle cable and fuel pump sub harness Remove the fuel hose from the hose damp Check the fuel lank stopper cable for proper installation and deterioration kinks or other damage BREATHER HOSE 1 HOSE ClAMP ...

Page 87: ...over and rubber cover for proper installation Remove the fuel pump SIde quick connect fitting cover Check the qUIck connect fittIngs for looseness 0 I Check the fuel line for deterioration damage or leakage FiniNG COVER Check the fuel connect fillings for dirt and clean if necessary After 14 Check the fuel pump side quick connect fitllng cover and rubber cover for proper installation Remove the fu...

Page 88: ...utomatically to the fully closed position from any open position and from any steering position Check the throttle cables and replace them if they are deteriorated kinked or damaged Lubricate the throttle cables if throttle operation is not smooth Measure the freaplay at the throttle grip flange FREEPLAY 09 12 3 5mm 1f8 3 16In AFTER 12 2 6 mm 1116 114 In 09 12 3 5 mm t18 3 16 in After 12 2 6 mm 11...

Page 89: ...n Make the major adJustment with the throttle body side of the adjuster Major adjustment is made with the lower adjuster Hang the fuel tank to the left side of the frame page 4 6 Adjust the freeplay by loosening the adjuster lock nut and turning the adjuster After adjustment tighten the adjuster lock nut to the specified torque while holding the adjuster TORQUE 4 0 N m 0 4 kgf m 3 0 IbNt Recheck t...

Page 90: ...r element and element holder After 09 Assemble the air cleaner element and element holder while aligning with their flat surfaces Hook the element hole After 09 holes onto the holder tab After 09 tabs HOLE ELEMENT HOLDER Hook 09 J2 Apply 3 5 g 0 1 0 2 oz of grease to the air cleaner O 9 how T A B assembly contacting area of the air cleaner housing Af er 12 Apply 1 5 5 5 g 0 05 0 19 oz of grease to...

Page 91: ...irt from the crankcase breather hoses into a proper container Reinstall the drain plugs SPARK PLUG REMOVAL Clean around the spark plug base wIth compressed ai before removing and be sure that no debris is allowed 0 en erlhe combustion chamber Hang the fuel tank to the left side of the frame page 4 6 Disconnect the spark plug cap Remove the spark plug and inspect it for damage Inspect or replace as...

Page 92: ... To prevent Check the gap between the center and side electrodes damaging the with a wire type feeler gauge IridIUm center electrode use 8 SPARK PLUG GAP 0 8 0 9 mm 0 031 0 035 In wire type feeler gauge 10 check the sparlf plug gap DonoliJdjustthe Make sure that the 1 0 mm 0 04 in diameter plug spark plug gap If gauge does not insert between the gap the gap Is out of If the gauge can be inserted i...

Page 93: ...punch mark on the primary drive gear with the S mark on the right crankcase oover Check that the index line on the cam sprocket aligns with the cUI oul of the camshaft holder Make sure the piston is al TDC Top Dead Center on the compressIOn stroke This position can be obtained by confirming thatlhere is slack in the rocker arms If there is no slack it is because the piston is moving through the ex...

Page 94: ... shim Record tile Check the valve clearance for the exhaust valves using dearance foreach a feeler gauge va WJ for reference In shIm selection if VALVE CLEARANCE adjustment is 0 28 t 0 03 mm 0 011 t 0 001 in required 4 14 VALVE CLEARANCE ADJUSTMENT Remove the camshaft page 9 10 Remove the valve lifters The shims may slick to the inside of the valve lifter Do not allow the shims to drop into the cr...

Page 95: ...Recorded valve clearance C Specified valve clearance D Old shim thickness Make sure of the correct shim thickness by measuring the shim using a micrometer Reface the Intake valve seat if carbon deposits result in a calculated dimenSion of over 2 450 mm Reface the exhaust valve seal if carbon deposits result in a calculated dimension of over 3 000 mm Ins all the shIms In Inslall the newly selected ...

Page 96: ... 3 minutes Stop the engine and walt 3 minutes Support the motorcycle upright on a level surface Remove the oil filler cap dipstick and wipe the oil with a clean cloth Insert the all filler cap dipstick without screwing it in remove it and check the oil level If the oil level is below or near the lower level line on the oil filler capfdipslick and add the recommended engine oil to the upper level l...

Page 97: ...l drain bolt and sealing washer Drain the engine oil Operate the kicl starter pedal five limes or more while opening the throttle fully so the engine oil r 1111 completely drains Oil fitter cflange Remove the engine guard page 3 6 Remove the following Bolts Oil filter cover O ring Oil filter Spring SPRING MAINTENANCE DRAIN BOLT SEALING WASHER D RING OIL FILTER BOLTS Apply grease to the oil filler ...

Page 98: ...n bolt and install them to the left crankcase cover Tighten the engine oil drain bolt to the specified torque TORQUE 16 N m 1 6 kgf m 12 Ibf ftj l T Fill the engine with the recommended engine oil page liliiiiiiiii iiir ri l 4 16 I 4 18 ENGINE OIL CAPACITY 0 58 liter 0 61 US qt 0 51 Imp qt at draining 0 62 liter 0 66 US qt 0 55 Imp qt at 011 filter change 0 17 liter 0 81 US qt 0 68 Imp qt at disas...

Page 99: ...2 1 800 100 rpm After 12 2 000 100 rpm TRANSMISSION OIL OIL LEVEL INSPECTION 1 Start the engine and lei it idle for 3 minutes 2 Stop the engine and wait 3 minutes 3 Support the motorcycle upright on a level surface 4 Remove the oil filler cap Remove the transmission oil check bolt and sealing washer from the right crankcase cover A small amount of oil should flow out of the check bolt hole 5 If no...

Page 100: ...cified torque TORQUE 16 N m 1 6 kgf m 121bHt Fililhe engine with Ihe recommended Iransmission oil RECOMMENDED TRANSMISSION OIL Pro Honda GN4 4 stroke oil U S A Canada or equivalent motor oil API service classification SG or higher JASO T903 standard MA Viscosity SAE 10W 30 TRANSMISSION OIL CAPACITY 09 12 0 59 liter 0 62 US qt 0 52 Imp qt at draining 0 67 liter 0 71 US qt 0 59 Imp qt at disassembly...

Page 101: ...de Perform the following service with the engine stopped and shift the transmission into neutraL Place a wort sland or equivalent under the engine Except 13 14 Remove the bolls drive sprocket cover and drive chain F I_ Be careful not to guide by releasing the allernalorlCKP sensor wire from _ damage the the harness guide harness guide ofthe drive sprocket cover 13 14 Remove the bolts drive sprocke...

Page 102: ...6 r pitches from pin center to pin center with the chain held taut and any kinked joint straightened SERVICE LIMIT 259 mm 10 2 in If the measurement exceeds the service limit replace the chain REPLACEMENT CHAiN 010 5200MA4I116RB RK 520TXZl116RJ SERVICE LIMIT 259 mm 10 2 in lubricate the drive chain with 80 90 gear oil or drive L U B R C A T E chain lubricant Wipe off any excess oil or chain lubric...

Page 103: ...y between the sprockets 11 CHAIN SLACK 09 11 30 40 mm 1 2 1 6In 12 15 25 35mm 1 0 1 4in After 15 30 40mm 1 2 1 6In NOTICE Excessive chain slack 55 mm 2 2 in or more may damage the frame ADJUSTMENT If the chain needs adjustment loosen the tear axle nul li and drive chain adjusler lock nuts and tum the adjusting bolts Check that the adjusting block index marks are in the same position on each side t...

Page 104: ...HAIN SUDER Check the chain guide and chain guide slider for 0 9 O hOW O alignment wear or damage Replace the chain guide if it is damaged or worn Replace the chain guide slider if the slider Is worn to the bottom of the wear limit indicator DRIVE CHAIN ROLLER 09 11 CHAIN GUIDE SUDER CHAIN GUIDE WEAR LIMIT INDICATOR Inspect the drive chain rollers for excessive wear or r binding Measure the upper a...

Page 105: ...oller it necessary MAINTENANCE CHAIN ROLLERS MARK UPPER lO 1 Upper Green Install the upper drive chain roller with the r marl J j facing away from the frame MARK CHAIN ROLLERS Lower Black Install the lower drive chain roller with the stepped side facing oul as shown Install and lighten the drive chain rolier bolt and nut to the specified torque TORQUE Drive chain upper roller bott 12 N m 1 2 kgf m...

Page 106: ... 31 mm 1 2 in Replace the drive chain roller if necessary upper Groen Install the upper drive chain roller with the mark facing away from the frame Install and lighten a new drive chain upper bolt to the specified torque TORQUE 12 N m 1 2 kgf m 9lbHt Lower Black Install the lower drive chain roller with the stepped side facing out as shown Install and tighten the drive chain lower roller nut to th...

Page 107: ...oir FLUID LEVEL INSPECTION When the fluid level is low check the brake pads for wear page 4 28 A tow fluid tevel may be due to wear of the brake pads If the brake pads are worn the caliper piston is pUShed out and this accounts for a low reservoir tevel If the brake pads are nol worn and the fluid level is low I check the entire system for leaks page 4 28 II FRONT Turn the handlebar so that the re...

Page 108: ...d REAR Remove the bolts reservoir cover plale and diaphragm and fill the reservoir with Honda DOT 4 brake fluid to the upper level line Inslallths diaphragm plale and cover Install and lighten the bolts to the specified torque TORQUE 1 0 N m 0 1 kgf m 0 7 IbHt Check the entire system for leaks Inspect the brake hose and fittings for deterioration cracks or signs of leakage Tighten any loose fittin...

Page 109: ...e brake pedal to the desired height by r P U S H R O O loosening the push rod lock nut and turning the push md STANDARD LENGTH 79 6 mm 3 13 in Tighten the push rod lock nut to the specified torque TORQUE 5 9 N m 0 6 kgf m 4 4 IbHt LOCK NUT L CLUTCH SYSTEM Make sure to adjust the clutch lever fraepJay after the clutch lever position adjustmefll or when the clutch cable IS dIsconnected CLUTCH LEVER ...

Page 110: ...ble L OC K N U T adjuster to adjust the clutch lever freeplay 10 20 mm 3 8 13116 in at the tip of lever After adjustment lighten the adjuster lock nut securely while holding the adjuster ADJUSTER Adjust the clutch cable end adjuster for minor adjustment CLUTCH LEVER FREEPLAY Measure the clutch lever freeplay at the lever end FREEPLAY 10 20 mm 318 13116 in CABLE END ADJUSTER 10 20 mm 3 8 13 16 in ...

Page 111: ...g both procedures or the clutch slips during the test ride disassemble and inspect the clutch page 11 10 CONTROL CABLES Remove the dust cover Remove the throttle housing bolts Disconnect the throttle cables from the throttle pipe and remove the throttle housing I Is not necessary Thoroughly lubricate Ihe cable ends with a 10 lubncate the commercially available cable lubricant entire cable If the t...

Page 112: ...ust pipe joint nut 21 N m 2 1 kgf m 15Ibf ft Muffler joint band bolt 09 12 21 N m 2 1 kgf m 151bHt After 12 20 N m 2 0 kgf m 1S Ibf ft GLASS WOOL REPLACEMENT 09 10 Remove the muffler page 3 11 Set the muffler in a vise with pieces of wood or soft jaws to avoid damage Remove the rivels with a 4 0 mm and 10 mm drill bits using the following procedures 1 Drill the rivet head with a 4 0 mm bit to the ...

Page 113: ...ipe end cover and inner pipe Install new glass wool B into the front pipe as shown ISTAINLESS WOOL FRONT PIPE CENTER GLASS WOOL INNER PIPE FRONT PIPE MAINTENANCE MUFFLER BODY END COVER TAil GLASS WOOL GLASS WOOL B t THE RANGE TO START INSTALLING 45 45 Install new stainless wool onto the inner pipe W O O L N N E R Install new center glass wool to the inner pipe PIPE assembly 4 33 ...

Page 114: ...4 shown Install the Inner pipe assembly into the muffler body assembly by inserting the inner pipe end into the front pipe end Install new tail glass wool into the end cover as shown Apply 5 0 9 0 18 oz of muffler sealant high temperature silicone to the end cover as shown Install the end cover between the inner pipe assembly and muffler body assembly Align each rivet hole and install new riveIs I...

Page 115: ...ified depth as shown 2 Drill the rivet head with a 10 rnm bit so that the rivet can be removed into the muffler body then remove the rivet NOTE MAINTENANCE IMUFFLER Be careful not to damage the band muffler body and muffler assembly 1 Remove the following Bands Front pipe Muffler body End cover Tail glass wool Center glass wool Stainless wool Inner pipe Clean off the sealant from the muffler body ...

Page 116: ...pe as shown Install new center glass wool to the inner pipe assembly as shown THE RANGE TO TAIL GLASS WOOL II END COVER fI CENTER GLASS WOOL v THE RANGE TO START INSTALliNG Apply 5 0 g 0 18 oz of muffler sealant high temperature silicone to the inner pipe assembly as shown Install the muffler body to the inner pipe assembly MUFFLER BODY INNER PIPE ASSEMBLY ...

Page 117: ...2 Remove the muffler page 3 12 Set the muffler in a vise With pieces of wood or soft jaws to avoid damage Remove the nvets with a 4 0 mm and 10 mm drill bits using the following procedures 1 Drill the rivet head with a 4 0 mm bit to the specified depth as shown 2 Drill the rivet head with a 10 rnm bit so that the rivet can be removed into the muffler body then remove the rivet NOTE Be careful not ...

Page 118: ...ipe assembly Install a new center glass wool onto the inner pipe area of front pipe as shown Apply 5 0 9 0 18 oz of muffler sealant high temperature silicone to the front pipe as shown Instatl the muffler body onlo the front pipe CENTER GLASS WOOL MUFFLER BODY END PIPE TAIL GLASS WOOL THE RANGE TO START INSTALLING 45 45 END PIPE TAIL GLASS WOOL rS END COVER Fill the cover equally THE RANGE TO STAR...

Page 119: ...d and dirt Remove any dirt that has accumulated on the bottom of the fork seals Replace damaged components which cannol be repaired Tighten all nuts and bolts For fork service page 14 17 MAINTENANCE RIVETS SIJ 1 MUFFLER BODY ASSEMBLY END COVER ASSEMBLY 09 12 Air pressure acts as a progressive spring and affects the entire range of fork travel Air is an unstable gas it increases in pressure as it i...

Page 120: ...r pump to the air valve Apply the following air pressure to the fork assembly and check that there is no air leakage TEST AIR PRESSURE 300 kPa 3 1 kgflcm2 44 psi If there is no leakage adjust the PSF air pressure to the standard value Replace the air valve if necessary REAR SUSPENSION INSPECTION Check the action of the shock absorber by compressing il several times 09 12 Remove the sub frame page ...

Page 121: ...swingarm and shock linkage pivot bearings and related seals every three races or about 7 5 hours of operation page 15 38 Lubricate and reassemble them NUTS BOLTS FASTENERS Check thai atl chassis nuts and bolts are lightened to their correct torque values page 1 13 Check thai all safety clips hose clamps and cable stays are in place and properly secured WHEELSITIRES Raise the front wheel off the gr...

Page 122: ...the tires are cold FRONT 100 kPa 1 0 kgflcml 15 psi REAR 100 kPa 1 0 kgflcmZ 15 psi Inspect the wheel rims and spokes for damage Tighten any loose spokes and rim locks to the specified torque using the special loot TOOLS FRONT Spoke wrench 6 1 mm REAR Spoke wrench 6 6 mm TORQUE 07JMA MR60100 070MA KZ30100 Spoke Rim lock 3 7 N m 0 4 kgf m 2 7IbHt 12 N m 1 2 kgf m 9lbHt STEERING HEAD BEARINGS Raise ...

Page 123: ...vertical movement inspect the steering head bearings page 14 75 Check for worn steering head bearing by grabbing the fork legs and attempting to move the front fork forward to backward Replace the bearing if any looseness is noted MAINTENANCE 4 43 ...

Page 124: ...MEMO ...

Page 125: ...5 LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM 5 2 OIL STRAINER SCREEN 54 SERVICE INFORMATION 5 3 PRESSURE RELIEF VALVE 5 5 TROUBLESHOOTING 5 3 OIL PUMP 5 5 5 1 ...

Page 126: ...LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM OIL JET OIL CRANKSHAFT PRESSURE RELIEF VALVE CAMSHAFT OIL JMp DRIVEN GEAR 5 2 PISTON ONE WAY VALVE Oil STRAINER SCREEN COUNTERSHAFT ...

Page 127: ...pacity At oil filter change 0 62 liter 0 66 US qt 0 55 Imp qt h T T o __ A I dtis aSSembJY O 77 1i H1l fE Transmission AI draining Og 12 0 59 it oil capacity After 12 __ 0 64 liler 0 68 US ii i At disassembly 09 12 0 67 liter 0 71 US ccc After 12 1 0 72 liter 0 76 US Pro Honda GN4 it Recommended engine oil Canada or equivalent motor oil API service classification SG or higher JASO T903 standard MA...

Page 128: ...rainer screen Clean the oil strainer screen with non flammable or high flash point solvent and wipe it dry Check the oil strainer screen for damage or clogs INSTALLATION Install the oil strainer screen to the crankcase as shown Install the left crankcase cover page 12 10 Fill the engine with the recommended oil page 4 16 ...

Page 129: ...LUBRICATION SYSTEM SNAP RING Apply engine oil to a new D ring and install it to the r 7It O R N G pressure relief valve ill OIL PUMP Install the pressure relief valve into the left crankcase cover S Install the snap ring securely Inslallthe left crankcase cover page 12 10 OISASSEMBLY Remove the engine from the frame page 8 6 Separate the crankcase halves page 13 10 Remove the dowel pins and gasket...

Page 130: ...mage or deterioration replace it if necessary After installing a Check Ihallhe washer and snap ring are installed in the snap ring always left crankcase cover securely rotate it in Its groove ro be sure if Is fully seated 5 6 Temporarily install the oil pump shaft and inner outer rotors into the left crankcase Measure the lip clearance SERVICE LIMIT 0 20 mm 0 008 in ONE WAY VALVE PUMP SHAFT ...

Page 131: ...SEMBLY Install the one way valve onto the right crankcase as shown Instalilhe oil pump shaft into the left crankcase Apply engine oil to the oil pump rotors sliding area Instafl the oil pump inner rotor while aligning its cut out with the cut out of the oil pump shaft Install the oil pump outer rolor Install the dowel pins and new gasket Assemble the crankcase halves page 13 12 Inslallthe engine t...

Page 132: ...MEMO ...

Page 133: ...ER 12 6 61 PGM FI SYSTEM LOCATION 6 7 FUEL INJECTOR 6 63 PGM FI SYSTEM DIAGRAM 6 11 THROTTLE BODy 6 64 CONNECTOR LOCATION 6 15 FAST IDLE KNOB 6 69 PGM FI TROUBLESHOOTING INFORMATION 6 18 MAP SENSOR 6 70 DTC INDEX 6 24 IAT SENSOR 6 71 DTC TROUBLESHOOTING 6 25 ECT SENSOR 6 72 MIL CIRCUIT INSPECTION 6 38 ECM 6 73 FUEL LINE REPLACEMENT 6 40 ENGINE MODE SELECT SWITCHI INDICATOR After 14 6 75 6 1 ...

Page 134: ...FUEL SYSTEM PGM FI COMPONENT LOCATION 09 12 10 N m 1 0 kgf m 7lbHt 3 4 N m 0 3 2 5IbHt 33 N m 3 4 kgf m 24Ibf ft 44 N m 4 5 kgf m 32 Ibf ft 6 2 ...

Page 135: ...After 12 1 3 4 N m 0 3 kgf m 2 5IbHt FUEL SYSTEM PGM FI 10N m 1 0kgfm 7lbUt 32 N m 3 3 kgf m 24 IbHt 44 N m 4 5 kgf m 321bHt 6 3 ...

Page 136: ... SPECIFICATIONS ITEM SPECIFICATIONS tion number 09 GOOOA I Throttle body identifica 10 GOD3A 11 12 G025A 13 14 G027A After 14 G02BA 09 1 750 100 rpm f 10_ 12 1 800 100 rpm tdle speed After 12 2 000 100 rpm Throttle grip freeplay 09 12 3 5 mm 118 3116 in After 12 2 6mm 1f16 114 in ECT sensor resistance at20i C 6 8 Ficl_______ 2 3 2 6 kO Fuel injector resistance at 2 0 C 6 8 F I i rt 66 2 4 O j Fuel...

Page 137: ...i Pressure gauge manifold minimum h Q7ZAJ ROJA11Q 07406 0040004 07ZAJ S5A0111 Hose attachment 8 mm 9 mm 07ZAJ S7C0100 Not available in U S A r pressure manifold hose 07AMJ HW3A100 U S A only or 07406 0040008 U S A only Not available in U S A _ O O 7406 004000C U S A onIY c __ Hose attachment 9 mml9 mm 07ZAJ S5A0120 t Not available in U S A Adaptor C male 07AAJ SBMA300 U S A only Attachment joint 8...

Page 138: ... pump circuits I t k I k na ealr ea Contaminated deteriorated fuel Faulty fuel injector 1 ECM power ground circuits malfunction Faulty engine stop switch or related page 6 74 circuit 2 tnspect the fuel supply system page 6 40 1 Inspect the idle speed Clogged fuel strainer screen 2 Inspect the fast idle knob Restricted fuel hose 3 Inspect the fuel line page 4 6 Contaminated deteriorated fuel 4 Insp...

Page 139: ...FUEL SYSTEM PGM FI PGM FI SYSTEM LOCATION 09 MAP SENSOR FUEL PUMP ECM FUEL INJECTOR ECl SENSOR No 2 CKF SENSClR IAlSENSOR lPSENSOR 6 7 ...

Page 140: ...FUEL SYSTEM PGM FI 10 12 OLe MAP SENSOR FUEL PUMP FUEL INJECTOR EeT SENSOR No 1 CKP SENSOR tAT SENSOR TP SENSOR 6 8 ...

Page 141: ...FUEL SYSTEM PGM FI 13 14 FUEL PUMP MAP SENSOR oLC FUEL INJECTOR IAT SENSOR TP SENSOR ECT S sCIR No 1 CKP SENSOR No 2 SENSOR 6 9 ...

Page 142: ...FUEL SYSTEM PGM FI After 14 Eer SENSOR 6 10 ENGINE MODE SELECT SWITCHI INDICATOR FUEL INJECTOR No 1 CKP SENSOR No 2 SENSOR IAT SENSOR ...

Page 143: ... 6 _ Il9 p StNSOII _ B M 2nd G CED DTC MIL number Engine does not start when detecting DTC I Mil Short terminals for reading DTC I MIL W M N J Y IS ENG STOI 0 I to I12 I I 0 1 0 ECM lJP IBL O KI CONNECTOR EeM 0 01 molt erm o FUEL SYSTEM PGM FI fUElI UMf if OOf fOll i 1121 81 8fOW Y lIow 0 Of Blue Ugh Ureen G M W n 6 11 ...

Page 144: ...NE STOP 81m 19 ENG STOP PC PCP 01111251 J L___J 1 Brim SCSSERVICE CONNECTOR IGP K UNE scs WARN OlCifUEL PUMP SVB IiAANESSlF MALE SE 23 25 0181 27 Br WIBu 6 15 SCS SERVICE CONNECTOR CONNECTION fUEl PUMP FUEllNJECTQR Im INJE Y3 i F 12 lli J 5 BII8u GlP I G L OTC I MIL number ts J Engine does not start 12 when detecting OTC I MIL b Short terminals for reading OTe I MIL 6 12 23 ECM 331 BLACK CONNECTOR...

Page 145: ...FEMALE CONDENSER 25 0 111 27 SCS CONNECTOI CONNECTION f J 1 IGNITION COil FUEl PUMP 9 20 m t l l c L 7 SENSOR 69 1 9 J 1 I DTC MIL number G 9 20 ENGINE STOP SWITCH TA TW vee so 19 ENG STOP OM __ N N 29 co PCP2 f PCP1 WARN INJ V NJ 12 PG GW 24 PN 5 B Bu Engine does not start 12 when detecting DTC I MIL Il Short terminals for LP reading DTC I MIL ECM 33P IBlACK CONNECTOR IECM Ie Qr Ie 1efmInII 1 FlI...

Page 146: ... fl Short terminals for l P reading Drc 6 14 ID BATTERY HARI IESS _ REGlJl ATORJRECnFIER CO DlCIFUEL PUMP SUB HARNESS MAlE FUEL PUMP D BATTERY _ n G OLe lABEL 1 l1ll J l l DLClFUEL PUMP SCSS RVICE CONNECTOR SUB KAANESS FEMAlE SCS SERVICE CONN CTOR CONNECTION fUEl PUMP IGNITION COIl ENGINE STOP SWlTCH FUEt INJECTOR 12 23 w 33 2 EeM 33P BlACK CONNECTOR feM MIlt or 3J G W ...

Page 147: ... fuel tank to the left side of the frame page 4 61 NOTE 6 Remove the right radiator shroud page 3 4 rID MAP SENSOR 3P BLACK CONNECTOR 5 ALTERNATORlCKP SENSOR 6P NATURAL CONNECTOR NOTE 6 FUEL INJECTOR 2P GRAY CONNECTOR NOTE 5 E83 Eel SENSOR 2P BLACK CONNECTOR FUEL SYSTEM PGM FI ECM 33P BLACK CONNECTOR NOTE 5 DLC 83 1 2 v IAT 2P GRAY CONNECTOR NOTE 3 OJ TP SENSOR 3P BLUE CONNECTOR NOTE4 8 Cli 6 15 ...

Page 148: ...el lank to the left side of the frame page 4 6 6 16 MAP SENSOR 3P BLACK CONNECTOR 3 FUEL INJECTOR 2P GRAY CONNECTOR NOTE 3 I nl8lIn I ECM 33P BLACK CONNECTOR NOTE 3 Eel SENSOR 2P BLACK CONNECTOR OJ IAT SENSOR 2P GRAY CONNECTOR NOTE 1 TP 3P BLUE CONNECTOR NOTE 2 ern AlTERNATORlCKP SENSOR rr fi 1 6P BLACK CONNECTOR ICl ClJ e ...

Page 149: ... 3 Hang the fuel tank to the left side of the frame page 4 6 MAP SENSOR 3P BLACK CONNECTOR NOTE 3 DID Eer SENSOR 2P BLACK CONNECTOR NOTE 2 W FUEL INJECTOR 2P GRAY CONNECTOR NOTE 3 ALTERNATORlCKP SENSOR 6P BLACK CONNECTOR NOTE 3 IATSENSOR2P BLACK CONNECTOR NOTEt ECM 33P BLACK CONNECTOR TP SENSOR 3P BLUE CONNECTOR 6 17 ...

Page 150: ...he self diagnosis function running capability is maintained by pre programmed values in the simulated program map When any abnormality is detected in the fuel injector andlor CKP sensor the fail safe function stops the engine to protect it from damage DTC Diagnostic Trouble Code The DTC is composed of a main code and a sub code and it is displayed as a hyphenated number when relrieved from the ECM...

Page 151: ...y harness positive cable and battery harness cable to the 12 V battery NOTE Before connecting the battery harness cables to the 12 V battery make sure the battery harness selector switches are OFF Select the power delivery by operating the selector sWitches as follows ECM selector switch ON Power to ECM only PUMP selector switch ON Power to fuel pump only Both selector switches ON Power to ECM and...

Page 152: ... ECM selector switch is ON page 6 19 The MIL will slay ON when the engine speed is ovef 4 000 rpm The MIL has two types of blinks a long blink and short blink The long blinking lasts for 1 2 seconds the short blinking lasts for 0 4 seconds One long blink is the equivalent of ten short blinks For example when two long blinks are followed by five short blinks the Mil is 25 two long blinks 20 blinks ...

Page 153: ...ons when the first malfunction was detected r ECM RESET The MeS can reset the ECM data including the DIG stored data and some learning memory NOTE After 14 Before starting the EGM reset check and record the selection mode After the EGM reset select the previous mode Stored using the HRC data setting tool optional parts the setting of the mode 2 and mode 3 are erased DTC READOUT 09 Start the engine...

Page 154: ...for 2 seconds then go off o If the engine can nol be started connect the 12 V battery ceCM selector switch is ON page 6 19 If the MIL stays on or blinks connect the MCS to the DLC page 6 21 read the DTC freeze data and follow the troubleshooting index page 6 24 To read the OTC with the MIL blinking refer to Reading OTC with the Mll page 6 22 Reading OTC with the Mil Stop the engine Disconnect the ...

Page 155: ...d or 12 V battery is disconnected before Ihe MIL starts blinking ERASING DTC After 09 NOTE Start the erasing procedure with the engine stopped Connect the MCS to the battery harness adaptor OLe labeled connector Erase Ihe OTC with the MCS To erase the DIG without MCS use to the following procedure How to clear the OTe with ses service connector FUEL SYSTEM PGM FI 1 Disconnect the DLClfuel pump sub...

Page 156: ...ts circuit f i Eel sensor circuit high voltage more than 4 93 loose or poor contact of the Eel sensor 00 01 EeT sensor or its circuit malfunction P connector Pre programmed value 09 90 C 194 F After 09 120 C 248 F Ii Pre programmed value 09 90 CI194 F After 09 120 C 24S F Ii i Pre programmed value O 6 27 6 29 6 30 FP 6 31 I IIU lI IIUII value 6 32 09 tAT sensor circuit high voltage more than 4 93 ...

Page 157: ...e ECM 33P Black connector Check for continuity al the Red yellow wire between the MAP sensor 3P Black connector and ECM 33P Black connector Connection 14 Red yellow TOOL Test probe 2 pack 07ZAJ RDJA110 Is there continuity YES Replace the ECM with a known good one and recheck NO Open circuit in Red yellow wire 4 MAP Sensor Output Line Short Circuit Inspection Tum the ECM selector switch OFF Check f...

Page 158: ...Is about 5 V Indicated YES GO TO STEP 2 NO Intermittent failure 2 MAP Sensor System Inspection 2 Turn the ECM selector switch OFF Disconnect the MAP sensor 3P Black connector Connect the MAP sensor 3P Black connector terminals at the wire side with a jumper wire Connection Light greenfyellow Green red Turn the ECM selector switch ON Check the MAP sensor with the MCS Is about 0 V indicated YES Faul...

Page 159: ...ine Check the MAP sensor with the MCS at idle speed Is the reading changed YES Inlermittent failure NO GO TO STEP 2 2 Manifold Absolute Pressure Test Stop the engine Hang the fuel tank to the left side of the frame page 4 6 Remove the screw and stay Check for connection and installation of the MAP sensor vacuum hose Is the MAP sensor vacuum hose connection correct YES GO TO STEP 3 NO Correct the h...

Page 160: ...4 NO GO TO STEP 3 3 Eer Sensor Resistance Inspection Turn Ihe ECM selector switch OFF Measure the resistance at the Eer sensor terminals Standard 2 3 2 6 kO 20 C 68 F Is the resistance within 2 3 2 6 kO YES Replace the ECM with a known good one and recheck NO Faulty Eer sensor 4 ECT Sensor Output Line Short Circuit Inspection 2P BLACK CONNECTOR Sensor side male terminals Q Turn the ECM selector sw...

Page 161: ...n Pink Green red Turn the ECM selector switch ON Check the Eel sensor wilh the MeS Is about 0 V indicated YES Inspect the EeT sensor page 6 72 NO GO TO STEP 3 3 ECl Sensor Open Circuit Inspection Turn the ECM selector switch OFF Remove the jumper wire Disconnect the ECM 33P BlaCk connector Check for continuity between the ECT sensor 2P Black and ECM 33P Black connectors Connection 20 Pink 22 Green...

Page 162: ...ntermittent failure NO Faulty TP sensor 3 TP Sensor Input Voltage Inspection Tum the ECM selector switch OFF Disconnect the TP sensor 3P Blue connector Tum the ECM selector switch ON Measure the voltage at the wire side Connection Red yellow Green red Is the voltage withIn 4 75 5 25 V YES GO TO STEP 5 NO GO TO STEP 4 4 TP Sensor Circuit Inspection Tum the ECM selector switch OFF Disconnect the ECM...

Page 163: ...inuity between the TP sensor 3P Blue connector of the wire side and ground 3P BLUE CONNECTOR Wire side female terminals Connection Yellow green Ground Is there continuity YES Short circuit in Yellow green wire NO GO TO STEP 7 7 TP Sensor Inspection Replace the throttle body with a known good one page 6 64 Erase the OTC s page 6 23 Turn the ECM selector switch ON Check the TP sensor with the MCS Is...

Page 164: ...hrottle body with a known good one page 6 64 Erase the oTG s page 6 23 Turn the ECM selector switch ON Check Ihe TP sensor with the MeS Is DTe 8 2 indicated YES Replace the ECM with a known good one and recheck NO Faulty original throttle body TP sensor OTe 9 1 IAT SENSOR LOW VOLTAGE 1 IAT Sensor System Inspection Connect the 12 V battery ECM selector switch is ON 09 page 6 19 After 09 page 6 19 C...

Page 165: ... battery ECM selector switch is ON 09 page 6 19 After 09 page 6 19 Check the tAT sensor with the MeS Is about 5 V Indicated YES GO TO STEP 2 NO Intermittent failure 2 IAT Sensor Inspection Turn the ECM selector switch OFF Disconnect the IAT sensor 2P 09 12 Gray After 12 Black connector Connect the IAT sensor 2P 09 12 Gray After 12 Black connector terminals with a jumper wire Connection Gray blue G...

Page 166: ...n circuil in Gray blue wire Open circuit in Green red wire DTC 12 1 FUEL INJECTOR Before starting the inspection check for loose or poor contact on the fuel injector 2P Gray connector and ECM 33P Black connector then recheck the OTG 1 Fuel Injector System Inspection Erase the OTC s page 6 23 Connect the 12 V battery ECM selector switch is ON 09 page 6 19 After 09 page 6 19 Check the fuel injector ...

Page 167: ...uel injector 2P connector terminals Is the resistance within 11 6 12 4 n 20 C 68 F YES GO TO STEP 4 NO Faulty fuel injector 4 Fuel Injector Signal Line Open Circuit Inspection Disconnect the ECM 33P Black connector Check for continuity between the ECM 33P Black connector and fuel injector 2P Gray connector Connection 5 Black blue TOOL Test probe 2 pack Is there continuity YES GO TO STEP 5 07ZAJ RD...

Page 168: ...12 29 1 CKP Sensor System Inspection Erase the DTC s page 6 23 Connect the 12 V battery rECM selector switch is ONI 09 page 6 19 After 09 page 6 19 Crank the engine and check the CKP sensor with the MCS Is orc 19 1 indicated YES GO TO STEP 2 NO Intermittent failure 2 CKP Sensor Peak Voltage Inspection Turn the ECM selector switch OFF Disconnect the alternatorfCKP sensor 6P NO 1 CKP SENSOR connecto...

Page 169: ...ne 11 Signal line Connection 09 12 10 Ground line After 12 Ground line ground TOOL Test probe 2 pack 07ZAJ ROJA110 Is there continuity YES Short circuit in Signal line NO Open circuit in Stgnalline Open cirCUit In Ground line DTC 69 1 No 2 CKP SENSOR See page 6 36 ISIGNAL LINE 09 12 11 7 FUEL SYSTEM PGM FI No 2 LINE Wf BWY Q J J No 1 LINE After 12 No 2 LINE Wf 11 29 Bof No 1 LINE GROUND LINE 09 12...

Page 170: ...Black connector If the connector connection properly check as follows Stop the engine 09 12 Hang the fuel tank to the left side of the frame page 4 6 After 12 Remove the ECM page 6 74 Disconnect the ECM 33P Black connector Ground the Whilelblue 09 12 15 After 12 18 wire terminal of the wire harness side connector with a jumper wire TOOL Test probe 2 pack 07ZAJ RDJA110 Connect the 12 V battery ECM ...

Page 171: ...blue Ground If there is continuity check for short circuit in the Whitefblue wire between the ECM and MIL If there is no continuity check the Ole circuit as follow 4P 09 12 NATURAL After 12 BLACK CONNECTOR WIre side female terminals W Bu Q Connect the engine stop switch 4P 09 12 Natural After 12 Black connector ECM 33P BLACK CONNECTOR Disconnect the ECM 33P Black connector Wire sldelfemale termina...

Page 172: ...from the system as follows 1 Hang the fuel tank to the left side of the frame page 4 6 2 09 Disconnect the fuel pump sub harness 2P Natural connector 10 12 Disconnect the fuel pump 5P Black connector After 12 Disconnect the fuel pump sub harness 2P Black connector 3 Start the engine and let it idle until the engine stalls ...

Page 173: ...ng pawls pun the connector off then remove the retainer from the fuel joint NOTE Absorb the remaining fuel in the fuel hose with a shop towel Be careful not to damage the hose or other parts Do nOI use lools If the connector does nol move keep the retainer tabs pressed down and alternately pull and push the connector until it comes off easily 4 To prevent damage and keep foreign matter out cover t...

Page 174: ...th one hand and squeeze the retainer tabs with the other hand to release Ihem from the locking pawls Pull the connector off then remove the retainer from the fuel in ector joint NOTE Absorb the remaining fuel in the fuel feed hose with a shop toweL Be careful not to damage the hose or other parts Do not use tools If the connector does nol move keep the retainer tabs pressed down and alternately pu...

Page 175: ... and clean if necessary 4 Place a shop towel over the quick connect fitting FUEL SYSTEM PGM FI PLASTIC BAGS I COVER SHOP 5 Unlock the slide retainer of the quick connect fitting R E T A N E R by completely pulling it up 6 Release the quick connect fitting from the fuel joint while holding the connector housing Prevent the remaining fuel in the fuel hose from JOINT flowing out using a shop towel Be...

Page 176: ...ver the disconnected connector and pipe end with plastic bags FUEL INJECTOR SIDE 1 Relieve the fuel pressure page 6 40 Check the fuel quick connect fitting for dirt and clean if necessary Remove the boll clamp and setting rubber 2 Place a shop towel over the quick connect fitting CONNECTOR PIPE END SHOP TOWEL ...

Page 177: ...NECT FITTING INSTALLATION 09 14 Always replace the retainer of the quick connect fitting and JOint rubber when the fuel hose is disconnected If the rubber cover and fitling cover are damaged or cut replace them with a new one Do not bend or twist the fuel hose If any relainer needs replacing use the same manufacturer s retainer as the ones being removed The various manufactures feature different r...

Page 178: ... locked into place check visually and by pulling the connector 4 Make sure the rubber cover is in place between the quick connect fitting and fuel pump plale 5 Install the quick connect fitting cover securely Sel the rubber cover tab into the quick connect fitting cover groove 6 Increase the fuel pressure and check that there is no leakage in fuel supply system page 4 6 FUEL INJECTOR SIDE 1 Insert...

Page 179: ...R U B B E R pawls are firmly locked into place check visually and by pulling the connector Make sure the joint rubber is in place between the flange and retainer tab CONNECTOR I 5 Install the selting rubber and clamp NOTE IFLA _T A B C O N N E C TO R SETIING RUBBER Install the fuel feed hose stay aligning its tab with the groove of the fuel feed hose stay Install and tighten the bolt securely 6 In...

Page 180: ...hile holding the connector housing If it is hard 1 0 connect put a small amount of engine oil on the pipe end CONNECTOR FUEL PIPE 3 Lock the slide retainer by pushing it until you hear R E T A INER the ClICK Make sure the connection is secure and that the slide retainer is firmly locked into place check visually and by pulling the connector 4 Install the quick connect fitting cover securely 5 Incr...

Page 181: ...QUE 3 4 N m 0 3 kgf m 2 5 IbHt 4 Increase the fuel pressure and check that there is no leakage in fuel supply system page 6 49 FUEL PRESSURE INCREASING 1 Connect the 12 V battery 09 page 6 19 After 09 page 6 19 2 09 Temporarily install the fuel lank onlo the frame 10 12 Connect the fuel pump 5P Black connector and install the fuel lank page 6 59 After 12 Connect the fuel pump 2P Black connector an...

Page 182: ... HW3A100 07AAJ S6MA300 07AAJ 5SMASOO CLAMP Support the fuel tank in an upright position onto the L _________________ J frame then remove the hose clamp from the breather hose Tum the PUMp selector switch ON Read the fuel pressure Standard 333 360 kPa 3 4 3 7 kgflcm 48 52 psi If the fuel pressure is higher than specified replace the fuel pump assembly faulty fuel pump or fuel pressure regulator If ...

Page 183: ...l tank in an upright position onto the frame then remove the hose clamp from the breather hose Place the end of the hose into an approved gasoline container Turn the PUMP selector sWitch ON for 10 seconds Measure the amount of fuel now Amount of fuel flow 150 em 5 1 US OZ 5 3 Imp oz minlmuml10 seconds at 12 V If the fuel flow is less than specified inspect the fOllowing Pinched or clogged fuel hos...

Page 184: ...55 If the wires are normal replace the fuel pump unit page 6 52 If there is no battery voltage open circuit in Black or Green wire between the regulator rectifier connector and fuel pump sub harness connector REMOVAL Remove the fuel tank page 6 59 Remove the following After 14 Fuel pump 5P Black connector Six fuel pump mounting bolts Stopper cable guide Stopper cable Four washers Six collars Six c...

Page 185: ...n the fuel pump base tabs while pushing the and labs holder against the base and slightly spreading the base labs Wipelhespilledout Remove the fuel pump unit holder assembly from the rue Immediately fuel pump base Remove the O ring FUEL SYSTEM PGM FI FUEL PUMP WIRES FUEL PUMP BASE UNIT HOLDER TAB HOOK FUEL PUMP BASE a RING FUEL PUMP BASE Check the fuel strainer for clog damage or deterioration and...

Page 186: ...he strainer counterclockwise until its hook is damage the hook completely sealed on the joint boss boss and clip Apply small amount of silicone grease to a new O ring Install the O ring to the fuel pump base Be sure thaI the Install the fuel pump unit holder assembly into the fuel hooks are pump base while aligning its hooks with the grooves in completely sealed the pump base tabs In the grooveS R...

Page 187: ...it as an assembly Be careful not 10 Release the hooks of the fuel pump unit holder from the damage the hooks grooves on the fuel pump base tabs while pushing the and labs holder against the base and slightly spreading the base tabs FUEL SYSTEM PGM FI FUEL PUMP WIRES FUEl PUMP BASE TABS GROOVES FUEL PUMP BASE Wipe the spilled oul Remove the fuel pump unit holder assembly from the F U E L P U M P U ...

Page 188: ...sembly joint aligning its hook with the cints boss completely 11 12 Apply small amount of siticone grease to a new O ring Afler 12 Apply small amount of engine oil to a new O ring 6 56 Install the C ring to the fuel pump assembly Install the fuel pump assembly into the fuel pump unit holder while routing the fuel pump wires through the holder grooves as shown Install a damper joint rubber to the f...

Page 189: ...en the hook and tab is more than 1 0 mm O D4m FUEL SYSTEM PGM FI FUEL PUMP UNIT HOLDER 61 _ O RING Ii Be careful not to damage the fuel pump wires FUEL PUMP BASE Connect the fuel pump wires to the fuel pump base terminals completely as shown Instal the fuel pump unit page 6 57 INSTALLATION Apply engine oil 10 a new O ring Install a new D ring onto the fuel pump unit Apply engme oil to a new O flng...

Page 190: ...ection Four washers 6 58 Stopper cable to Ihe stopper cable guide Stopper cable guide Six fuel pump mounting bolts Tighten the fuel pump mounting bolts to the specified torque in the specified sequence as shown TORQUE 11 N m 1 1 kgf m 8lbHt Install the fuel lank page 6 59 MARK FUEL PUMP PLATE SPRING WASHERSlCOLLARSfGUIDElBOl TS CABLE o J 0 0 o _ J SPRING WASHERSI COLLARSI vVASHERS BOLTS 1 6 3 SPRI...

Page 191: ...unit removal page 6 52 Inslallation is in the reverse order of removal STAY FUEL TANK REMOVAL INSTALLATION After 12 Relieve the fuel pressure page 6 40 Oisconnecllhe quick connect fitting from the fuel pump side page 6 41 Hold the fuel tank and disconnect the stopper cable from the frame stay Remove the fuel tank For fuel pump unit removal page 6 52 Installation is In the reverse order of removal ...

Page 192: ...er housing while releasing air cleaner housing cover labs from the sub frame 7Ib J C TAB AIR CLEANER HOUSING INSPECTIONIINSTALLATION Check Ihallhe connecting boot is sealed properly at the air cleaner housing Check the air cleaner housing for damage Installation Is In the reverse order of removal TORQUE Mud guard mounting screw 1 1 N m 0 1 kgf m Q 8IbHt Air cleaner housing mounting bolt 10 N m 1 0...

Page 193: ...5Ibf ft 1 1 N m 0 1 kgf m a 8Ibf ft _ Apply Honda Bond A or Honda Handgrip Cement or equivalent Apply cemedine 366 or equivalent AIR CLEANER HOUSING AFTER 12 REMOVAUINSPECTIONI INSTALLATION Remove the sub frame page 3 10 Release the crankcase breather drain hose from the clamp Disconnect the crankcase breather hose from the air deaner housing Disconnect the tAT sensor 2P Black connector RETAINING ...

Page 194: ... air cleaner housing for damage Install the removed parts in the reverse order of removal Tighten the air cleaner connecting boot band screw to the specified width as shown OISASSEMBLY ASSEMBLY Remove the air cleaner housing page 6 61 AIR CLEANER HOUSING CONNECTING BOOT 6 62 1 5 N m 0 2 kgf m 1 1 rbf ft 0 7 N m 0 1 kgf m a Slb t BAND SCREW AIR CLEANER HOUSING 7 5 1 5 mm 0 30 0 06 in O RING 11 1 AI...

Page 195: ...ove the a ring cushion ring and seal ring INSTALLATION Coat a new O ring and seal ring With engine oiL Install a new D ring cushion ring and seal ring being careful nol to damage them Be careful not to Install the fuel injector into the injector joint damage the a ring Align the boss of the fuel injector with the injector terminals as shown FUEL SYSTEM PGM FI INJECTOR JOINT INJECTOR INJECTOR e INJ...

Page 196: ...EMOVAL 6 64 Relieve the fuel pressure page 6 40 09 12 Remove the sub frame page 3 7 After 12 Remove the air cleaner hOUSing page 6 61 Disconnect the TP sensor 3P Blue connector Ane 12 Remove the bolts and release the condenser slay from the throttle body Disconnect the quick connect fitting from the fuel injector side page 6 42 Disconnect the fuel injector 2P Gray and MAP sensor 3P Black connector...

Page 197: ...ck absorber upper mounting bolt and nut Loosen the insulator band screw Release the throttle body from the insulator wire harness ClAMP Remove the clamp of the MAP sensor and fuel injector I Remove the bolt Remove the throWe drum cover while releasing its sial from the throttle body tab FUEL SYSTEM PGM FI 6 65 ...

Page 198: ...peration Do not damage the throttle body It may cause incorrect throttle valve operaUon Do not loosen or tighten the whffe painted bolts nuts and screws of the throttle body Loosening or tightening them can cause throttle valve and idle control fai ure A ways clean the throttle body before disassembly to prevent dirt and debris from entering the passages Do not remove the TP sensor LEFT VIEW ____ ...

Page 199: ...LATION Connect the throttle cables to the throttle drum and throttle body_ Adjust the throttle grip freeplay page 4 8 Install the throttle drum cover while aligning its slot with the tab of the throttle body Install and tighten the bolt to the specified torque TORQUE 3 4 N m 0 3 kgf m 2 5 Ibf ttl FUEL SYSTEM PGM FI J Route the wire Install the clamp of the MAP sensor and fuel Injector CLAMP hamess...

Page 200: ...ith the insula or tab 6 68 Install the rear shock absorber upper mounting bolt by aligning cut outs of the frame and upper mounting bolt Install and tighten the rear shock absorber upper mounting nut to the specified torque TORQUE 44 N m 4 5 kgf m 321bHt Route the wire harness and hoses properly page 1 23 Connect the fuel injector 2P Gray and MAP sensor 3P Black connectors Connecllhe quick connect...

Page 201: ...rottle body page 6 64 Clean around the fast idle knob with compressed air before removing the fast idle knob loosen the lock nul and remove the fast idle knob INSPECTION Check the fast idle knob operation Turn the fast idle knob counterclockwise then the valve should be pulled into the valve body Turn the fast idle knob clockwise then the valve should be come out from the valve body Check the fast...

Page 202: ...above is measured under the standard atmosphere 1 aim 1 013 hPa The MAP sensor output voltage is affected by the distance above sea level because the output voltage is changed by atmospheric pressure Check the altitude and be sure that the measured voltage falls within the specified value REMOVALIINSTALLATION Hang the fuel tank to the left side of the frame page 4 6 Disconnect the MAP sensor 3P Bl...

Page 203: ... m 3 6IbHt Connect the MAP sensor 3P Black connector Instatl the fuel tank page 4 6 IAT SENSOR REMOVAUINSTALLATION 09 12 Remove the left side cover page 3 3 Disconnect the IAT sensor 2P Gray connector Remove the screws IAT sensor and O nng Apply engine oil to a new O ring and install it to the tAT sensor tnstall ihe tAT sensor and screws Tighten the screws to the specified torque TORQUE 1 1 N m 0 ...

Page 204: ...c heating element Suspend the Eel sensor in heated coolant and measure the resistance through the sensor as the coolant heats up Soak the EeT sensor in coolant up to its threads with at least 40 mm 1 6 in from the bottom of the pan to the bottom of the sensor Keep temperature constant for 3 minutes before testing A sudden change of temperature will result in incorrect readings 00 not let the therm...

Page 205: ...Connect the Eel sensor 2P Black connector Inslallthe exhaust system page 3 11 Fill and bleed the cooling system page 7 8 REMOVAL INSTALLATION 09 12 Hang the fuel lank to the left side of the frame page 4 6 Disconnect the ECM 33P Black connector Remove the ECM from the ECM stay Installation is in the reverse order of removal FUEL SYSTEM PGM FI 6 73 ...

Page 206: ...ly YES GO TO STEP 2 NO Faulty engine stop switch 2 ECM Power Input Line Inspection Disconnect the ECM 33P Black connector page 6 73 Check for continuity at the ECM 33P Black connector terminals and ground Connection 23 Ground TOOL Test probe 2 pack 07ZAJ RDJA110 Is there continuity YES Short circuit in Black wire NO GO TO STEP 3 3 ECM Ground Line Inspection Check for continuity between the ECM 33P...

Page 207: ...ODE Start the engine and push the engine mode select switch with your CRF stopped The engine mode select switch indicator indicate a selected mode by the number of times the indicator blinks Mode 1 1 blink Mode 2 2 blinks Mode 3 3 blinks If the indicator does not blink with the engine mode select switch pushed inspect the following Engine idle speed page 4 19 Switch inspection page 6 76 Switch cir...

Page 208: ...elect switchl indicator and holder Installation is in the reverse order of removal TORQUE Engine mode select switchfindicator 1 5 N m 0 2 kgf m 1 1Ibf ft SWITCH INSPECTION Disconnect the engine mode select switch indicator 4P Black connector page 6 76 Check for continuity between the Ughl green and Red wire terminals of the engine mode select switchl indicator side connector There should be contin...

Page 209: ...lace the ECM with a known good one page 6 74 INDICATOR CIRCUIT INSPECTION INPUT VOLTAGE FUEL SYSTEM PGM FI 4P Black CONNECTOR Q 33P Black CONNECTOR L __ Connect a 12 V battery to the fuel pump sub harness page 6 19 Turn the ECM selector switch OFF Disconnect the engine mode select SWItch indicator 4P Black connector page 6 76 Turn the ECM selector switch ON Measure the voltage between the engine m...

Page 210: ...ck connector terminals Connection White green Whitefgreen TOOL Test probe 07ZAJ ROJA110 If there is no continuity check for open circuit In the White green wire If there is continuity replace the engine mode select switchlindicator with a known good one and recheck page 6 76 If the indicator does nol blink when replaced with a known good engine mode select switchlindicalor replace the ECM with a k...

Page 211: ...SYSTEM FLOW PATTERN 7 2 SERVICE INFORMATION 7 4 TROUBLESHOOTING 7 6 SYSTEM TESTING 7 7 7 COOLING SYSTEM COOLANT REPLACEMENT 7 8 RADIATOR 7 10 WATER PUMP 7 13 7 1 ...

Page 212: ...COOLING SYSTEM SYSTEM FLOW PATTERN 09 12 RADIATOR CONNECTING HOSE UPPER RADIATOR HOSE LOWER RADIATOR HOSE 7 2 ...

Page 213: ...After 12 13 shown WATER WATER PUMP COOLING SYSTEM UPPER RADIATOR HOSES RADIATOR QVERI Le W HOSE LOINEI DI TCIR HOSE RADIATOR CONNECTING HOSE 7 3 ...

Page 214: ... system All cooling system services can be done with the engine installed in the frame After servicing the system check for teaks with a cooling system tester SPECIFICATIONS ITEM it 11 3 c OO ra n t ca pa C C f A t ch a ng 09 2E t After 12 At disassembly 09 12 After 12 R ad a w r ca p re r fgpgr ss u re 108 _ Recommended antifreeze Pro Honda HP c iiiii ii q glycol antifreeze containing 1 1 mixture...

Page 215: ...371020A U S A only Remover handle 07936 3710100 U S A only Not available in U S A Driver Not available in U S A cc lnstaller collar I n SI al c e L b e I 07749 0010000 070MF MEN0210 070MF MEN0220 8EJ ____ o 070MF MENA210 U S A only I 0 070MF MENA220 U S A only I Mechanical seal installer set Bearing remover 12 mm Pilot 12 mm 070MF MEN0200 07936 166010A U S A only 07746 0040200 EJ C38 or 070MF MENA...

Page 216: ...ater jacket Radiator air passage clogged with dirt Air in system Faulty water pump Bent or worn water pump shaft Damaged water pump shaft needle bearings Coolant leak Faulty oil seal and mechanical seal Deteriorated oil seal and mechanical seal Damaged 01 detenorated O ring Loose hose connection 01 clamp Damaged or deteriorated hose Faulty radiator cap Damaged radiator 7 6 ...

Page 217: ...c 35 40 8 1 45 I 50 f 55 60 0 32 1 009 1 018 1 028 1 036 1 045 1 053 1 063 Coolant temperature C OF 5 10 15 25 1 30 35 40 41 SO 59 cW ll L1J86 95 1 04 1 009 1 008 1 008 1007 1006 1005 1 003 1 001 1 01f 101ijij 016 1 011 1 1 009 26 1 025 1 018 1 016 34 1 033 1 02511 023 043 1 042 1 034 1 031 l 51 1 049 1 041 1 038 1 027 1 0 1 035 1 0 1 044 1 1 052 1 0 1 062 1 060 f 1 058 1 049 1 046 1 072 1 070 1 0...

Page 218: ...kgflcnT 20 psi Repair or replace components if the system will not hold the specified pressure for alleas 6 seconds After checking the pressure install the radiator cap securely COOLANT REPLACEMENT PREPARATION 7 8 The effectiveness of coolant decreases with the accumulation of rust or if there is a change in the mixing proportion during usage Therefore for best performance change the coolant regul...

Page 219: ...cycle in an upngh POSlllon on a flal eV l surface FiU the system with the recommended coolant through the filler opening up to the filler neck CAPACITY 09 12 1 04 liter 1 10 US qt 0 92 Imp qt at change After 12 0 94 Iller 0 99 US qt 0 83 Imp qt at change lean the machine approximately 20 to the right and left several times to bleed any air trapped in the cooling system If the coolant level drops a...

Page 220: ...hose clamp Be carefuf not to damsgethe radiator core 7 10 Disconnect the following from the right side radiator Overflow hose Connecting hose Right side upper radiator hose radiator to 3 way joint Left side upper radiator hose radiator to 3 way joint Disconnect the right side lower radiator hose from the radiator Remove the bolt and connector stay boss from the right side radiator lower mount ...

Page 221: ...nnect the left side lower radiator hose from the radiator COOLING SYSTEM Remove the left side radiator mounting bolts washers g and left side radiator REMOVAL After 12 Drain the coolant page 7 9 Remove the radiator shrouds page 3 5 Be careful not ro Remove the radiator grills damage the radiator W 9 7 11 ...

Page 222: ... the following from the right side radiator Overflow hose Upper radiator hose lower radiator hose Disconnect the connecting hose and upper radiator hose from the left side radiator Release the wire damp and Ole from the left side radiator Remove the radiator mounting bolts washers and then remove the radiators ...

Page 223: ...of coolant leakage If waler leaks through the bleed hole replace the mechanical seal page 7 14 If oil leaks through the bleed hole replace the oil seal page 7 14 Make sure that there is no continuous coolant leakage from the bleed hole while operating the engine NOTE A small amount of coolant weeping from the bleed hole is normal REMOVAL Drain the coolant page 7 9 Remove the drain bolt sealing was...

Page 224: ... O ring and dowel pins loosen the impeller Remove the right crankcase cover page 11 7 Remove the impeller and plain washer BEARING MECHANICAL SEAUOIL SEAL REPLACEMENT OIL SEAL MECHANICAL SEAL 7 14 WATER PUMP SHAFT BEARING s r PLAIN WASHER ...

Page 225: ...ft TOOLS U S A only Bearing remover 12 mm Remover handle Remover weight 07936 1660101 not available in U S A 07741 010201 07936 1660110 not available in U S A 07936 1660120 not available in U S A 07936 166010A 07936 3710100 07936 371020A Remove the mechanical seal and oil seal from the right C AL crankcase cover Apply grease to a new oil seal lips Inslall the oil seat into the right crankcase cove...

Page 226: ...er pump shaft as shown TOOLS Mechanical seal installer set Installer collar Installer base TOOLS U S A only Mechanical seal Installer set Installer collar Installer base 070MF MEN0200 070MF MEN0210 070MF MEN0220 070MF MENA200 070MF MENA210 070MF MENA220 Press the mechanical seal until it is fully seated to the right crankcase cover using the hydraulic press and special tool TOOL Attachment 32 x 35...

Page 227: ... to the specified torque TORQUE 12 N m 1 2 kgf m 9 IbHt Install the dowel pins Inslall a new O ring to the water pump cover Install the water pump cover Install and lighten the bolts securely Install the coolant drain bolt With a new sealing washer Tighten the coolant drain bolt securely Connect the lower radiator hose and lighten the hose band screw securely page 7 13 Fill the radiator with the r...

Page 228: ...MEMO ...

Page 229: ...8 ENGINE REMOVAUINSTALLATION COMPONENT LOCATION 8 2 SERVICE INFORMATION 8 5 ENGINE REMOVAL 8 6 ENGINE INSTALLATION 8 9 8 1 ...

Page 230: ...N COMPONENT LOCATION 09 12 09 shown 44 N m 4 5 kgf m 32 Ibf ft 88 N m g O kgf m 65Ibf fl 33 N m 3 4 kgf m 24 IbUt r V I 54 N m 5 5 kgf m 40 IbUt 54 N m 5 5 kgl m 40 Ibf ft 54 N m 5 S kgf m 40 Ibf fl 26 N m 2 7 kgf m 19 IbUt 8 2 ...

Page 231: ...ION 13 14 44 N m 4 5 kgf m 32 lbUt is 32 N m 3 3 kgf m 24 Ibf ft 32 N m 3 3 kgf m 24 lbHt 2 2 j 88 N m 9 0 kgf m 651bHt J 10 N m 1 0 kgf m 7Ibf ft 54 N m 5 5 kgf m 40 lbUt 54 N m 5 5 kgf m 40 bUt 26 N m 2 7 kgf m 19Ibf ft 8 3 ...

Page 232: ...GINE REMOVAUINSTALLATION After 14 32 N m 3 3 kgf m 24 bHt 32 N m 3 3 kgf m 24 bHt Z 88 N m 9 0 kgf m 65 bHt 54 N m 5 5 kgf m 40 bHt 7 bHt 54 N m 5 5 kgf m 40 bHt 54 N m 5 5 kgf m 40 bf ft kgf m 19 bNI 8 4 ...

Page 233: ... Honda GN4 4 stroke oil U S A Canada or equivalent motor oil JASO T903 standard MA API service classification SG or higher Viscosity SAE lOW 3 At draining 0 58 liter 0 61 US iq 0f 51 m p q 1 _ At oil and filter change 0 62 titer 0 66 U t 0 55 Imp qt At disassembly 0 77 liter 0 81 US qt 0 68 Imp qtl Engine oil capacity Transmission oil capacity AI draining 09 1 2 0 59 liter 0 62 USql 0 52 Imp qt Co...

Page 234: ...dal page 11 25 Brake pedal pivot bolt page 16 29 09 14 Ignition coil page 17 16 Drive chain page 4 2 1 After 12 Regulator rectifier page 17 14 12 1 4 Right side radlalor page 7 11 After 14 Right and left radiators page 7 1 1 09 Disconnect the alternator CKP sensor 6P Natural and c _ gear position switch 2P Green connectors Remove the wire band 09 12 Remove the wire band and release the wire harnes...

Page 235: ...e alternator CKP sensor 6P Black connector Remove the wire band and release the wire harness 09 4 Rernove the bolt and clutch cable stay and disconnect the clutch cable from the clutch lifter lever Aller 4 Remove the bolts and clutch cable stay and disconnect the clutch cable from the clutch lifter lever 8 7 ...

Page 236: ...hose and upper radiator hose After 12 Loosen the hose band screw and disconnect the upper radiator hose Remove the cylinder head hanger bolls Remove the bolts and cylinder head hanger plates Remove the front engine hanger bolt and nut Remove the bolts nuts and front engine hanger plates I HANGER BOLT ...

Page 237: ...direction of the engine hanger plates and mounting bolts Temporarily install the swingarm pivot bolt so the frame can be moved and stored safely ENGINE INSTALLATION NOTE Install all the engine mounting fasteners loosely then tighten the bolts and nuts 10 the specified torque Route the wires hoses and cables properly page 1 23 ENGINE REMOVAUINSTALLATION 8 9 ...

Page 238: ...ints fo removal prevent damage to loosely install the lower engine hanger boll washer engm6 frame wire and nul and cables 8 10 Apply a thin coal of grease to the swingarm pivot bolt sliding surface Loosely inslalilhe swingarm pivot bolt washer and nul Loosely install the front engine hanger plates bolls and nuts ...

Page 239: ... IbHt Cylinder head hanger bolt 54 N m 5 5 kgf m 40 IbHt Cylinder head hanger plate bolt 09 12 33 N m 3 4 kgf m 241bHt After 12 32 N m 3 3 kgf m 24Ibf ft Front engine hanger plate nut 26 N m 2 7 kgf m 19Ibf ft 09 12 Connect the lower radiator hose to the water pump cover Connectlhe upper radiator hose to the cylinder head Tighten the hose band screws securely page 7 13 09 14 Connect the clutch cab...

Page 240: ...utch cable slay and bolts Tighten the bolts to the specified torque TORQUE 10 N m 1 0 kgf m 7lbHt Connect the ECT sensor 2P Black connector 09 Instalilhe wire clamp 10 1 2 Connect the alternator CKP sensor 6P Black connector After 12 Connect the alternator CKP sensor 6P Black connector Install the wire band ...

Page 241: ... 17 22 After 12 Regulator rectifier page 17 14 13 14 Righi side radiator page 7 11 After 14 Right and left radiators page 7 11 Fill the radiator With the recommended coolant mixture to the filler neck and bleed the air page 7 9 Fill the engine with the recommended oil page 4 16 Fill the transmission with the recommended oil page 4 20 After installing the engine perform the following Inspections an...

Page 242: ...MEMO ...

Page 243: ...ESHOOTING 9 6 CYLINDER HEAD INSPECTION 9 21 CYLINDER COMPRESSION TEST 9 7 VALVE GUIDE REPLACEMENT 9 23 CYLINDER HEAD COVER 9 7 VALVE SEAT INSPECTION CAMSHAFT ROCKER ARM REMOVAL 9 10 REFACING 9 24 DECOMPRESSOR SYSTEM 9 13 CYLINDER HEAD ASSEMBLy 9 27 CYLINDER HEAD REMOVAL 9 16 CYLINDER HEAD INSTALLATION 9 30 CAMSHAFT ROCKER ARM INSTALLATION 9 32 9 1 ...

Page 244: ...S COMPONENT LOCATION 10 N m 1 0 kgf m 7lbHt 14 N m kgf m 10 IbHt 12 N m 1 2 9lbHt 54 N m 5 5 kgf m 40 IbHt 51 Nm 38IbHt After 12 After 12 f 09 12 33 N m 3 4 kgf m 24Ibf ft After 12 32 N m 3 3 kgf m 24 Ibf ft After 14 9 2 ...

Page 245: ... 0 0 IN Valve guide 1 0 Stem to guide clearance above Valve EX 195 Valve spring free length EX Rocker arm Rocker arm 1 0 Rocker arm shaft 0 0 c _ ROCker arm to shaft clearance cam Sh a n t_ c _a_ m lobe height F NX i i 5 ii 97 0 471 0 055 OO221 37 52 1 477 1 125I R Valve lifter O D Valve lifter bore I D TORQUE VALUES Breather plate bolt Cylinder head cover bolt Camshaft holder mounting bolt Cylind...

Page 246: ...r Valve seal cutler 35 mm 45 IN v a v e s e a t cu t te 3 3 mm 45 EX Flat cutter 33 mm 32 EX 07780 0010400 07780 0010800 07780 0012900 or equivalent commercially available in U S A Flat cu tt e o 3co6 m m 3 2 I N 0778 OO13500 or equivalent commercially available In U S A 9 4 or equivalent commercially available in U S A Inlerior culler 37 5 mm 60 IN 07780 0014100 or equivalent commercially availab...

Page 247: ...lly available in U SA Compression test adaptor 07AMJ MENA200 U S A only Cam chain tensioner holder 070MG 0010100 1 r or 07AMG 001Al00 U S A only CYLINDER HEADNALVES Compression gauge aUachment 07RMJ MY5010Q y or equivalent commercially available in U S A 9 5 ...

Page 248: ...ty decompressor plunger Faulty decompressor weight Compression too high over heating or knocking Excessive carbon build up on piston head or oornbustion chamber Excessive smoke Worn valve stem or valve guide Damaged stem seal Faulty cylinder piston or piston rings page 10 6 Excessive noise Incorrect valve adjustment Sticking valve or broken valve spring Worn or damaged camshaft Worn or damaged val...

Page 249: ...lly several times until the gauge needle stops moving COMPRESSION 09 12 392 kPa 4 0 kg em 57 psi at 600 rpm After 12 647 kPa 6 6 kg em 94 psi at 600 rpm Low compression can be caused by Improper valve adjustment Valve leakage Blown cylinder head gasket Worn piston rings or cylinder page 10 6 High compression can be caused by Carbon deposits on piston head or combustion chamber Faulty decompressor ...

Page 250: ...own Install the breather plale to the cylinder head cover Install and tighten new breather plate bolls to the specified torque TORQUE 12 N m 1 2 kgf m 9 lbHt INSTALLATION Check the plug hole seal ring and packing for damage or deterioration and replace them jf necessary Apply engine oil to the plug hole seal ring outer surface and install it Install the packing to the cylinder head cover Install t...

Page 251: ... Install the rubber seals onto the cylinder head cover with their UP marks facing up Install and lighten the bolts to the specified torque TORQUE 10 N m 1 0 kgf m 7 lbHt Connect the spark plug cap and crankcase breather hose Install the fuel tank page 4 6 CYLINDER HEADNALVES PLUG HOLE SEAL RING CYLINDER HEAD COVER UP MARKS I RUBBER SEAL 9 9 ...

Page 252: ...troke This position can be obtained by confirming thallhere is slack in the rocker arm If there is no slack it is because the piston is moving through the exhaust stroke to TDC Rotate the crankshaft clockwise one full turn and match up the punch mark on the primary drive gear with S mark on the right crankcase cover again PUNCH MARK Remove the cam chain tensioner lifter bolt and sealing washer Ins...

Page 253: ...he camshaft bearings Slide the cam sprocket side camshaft bearing to the cam sprocket Remove the camshaft by removing the cam chain from the cam sprocket ROCKER ARM CYLINDER HEADNALVES Thread a 6 mm bolt into the rocker arm shaft and pull r 7 r out the rocI er arm shaft from the cylinder head Remove the rocker arms 9 11 ...

Page 254: ...in Calculate the rocker arm to shaft clearance SERVICE LIMIT 0 055 mm 0 0022 in CAMSHAFT L L Turn the ouler race of the camshaft bearings with your r 09 shown finger The bearing should turn smoothly and quielly Also check that the bearing inner race fils tightly on the camshaft Replace the camshaft assembly if the cam sprocket side bearing does not turn smoothly quietly or if they fit loosely on t...

Page 255: ... The plunger operation is normal if II is protruded If the decompressor weight and plunger operation is abnormal disassemble and dean the derompressor system and camshaft page 9 13 Replace the damaged parts jf necessary CAMSHAFT HOLDER Check the set ring grooves for scoring or scratchers Check the camshaft holder for installalion of the dowel pins DECOMPRESSOR SYSTEM DISASSEMBLY Remove the camshaf...

Page 256: ... Check the decompressor plunger for wear or damage Check the decompressor spring for fatigue Replace the damaged parts if necessary Clean the decompressor weight plunger and spring Blow the oil passage in the camshaft with compressed air ASSEMBLY 09 CAMSHAFT DECOMPRESSOR PLIJNClER STOPPER PIN OECOMPRESSOR SPRING 09 shown PLUNGER PIN STCIPPloR PIN DECOMPRESSOR WEIGHT CAMSHAFT BEARING SPRING DECOMPR...

Page 257: ...t but do not hook the spring end to the decompressor weight yet Install the plunger with its cut out facing the decompressor side Install the decompressor weight by aligning the lower side spring end with the camshaft nange and deoompressor weight end with the plunger cut out Check the plunger operation by moving the decompressor weight with your finger CAMSHAFT BEARING DECOMPRESSOR WEIGHT PLUNGER...

Page 258: ...ge 6 64 Camshaft page 9 10 Rocker arm page 9 11 Drain the coolant page 7 9 Be sure o mark the Remove the valve lifters from the cylinder head valve liflers so they can be installed m their anginal posllions The shims may slick to the inside of the valve lifters Do not allow the shims to drop into the crankcase Be careful no to Remove the shims drop the shtms into the cronkcase 9 16 The shims can b...

Page 259: ...r 2P Black connector 09 14 Loosen the hose band screw and disconnect the upper radiator hose CYLINDER HEADNALVES After 14 Loosen the hose band screws and disconnect the i upper radiator hose and radiator connecting hose I 9 17 ...

Page 260: ...late bolts and cylinder head hanger plates Remove the cylinder head 6 mm bolt Loosen the cylinder head bolls in a crisscross pattern in two or three steps Be careful noI to leI Remove the bolts washers and cylinder head the washers drop into the Cf8nkcsS8 Remove the dowel pins and gasket 9 18 ...

Page 261: ...kcase cover page 12 5 Flywheel page 12 7 Remove the cam chain guide Remove the boll collar and cam chain tensioner INSPECTION CYLINDER HEADNALVES Inspect the cam chain tensioner and cam chain guide r C A M C HA N G U O E for excessive wear or damage replace them if necessary CAM CHAIN TENSIONER 9 19 ...

Page 262: ...the groove in the crankcase Install the following Flywheel page 12 8 left crankcase cover page 12 10 Cylinder head page 9 30 CYLINDER HEAD DISASSEMBLY Remove the following Spark plug page 4 11 Eel sensor page 6 72 Cylinder head page 9 16 loosen the insulator band screw and remove the insulator from the cylinder head Remove the bolt water hose joint and D ring O R I N G Install the tappet hole prot...

Page 263: ...ing disassembly so they can be installed In thelf origma Iocations TOOLS Valve spring compressor Valve spring compressor aUachment Remove the following Spring retainer Valve spring Valve Stem seal Spring seat 07757 0010000 07959 KM30101 CYLINDER HEAD INSPECTION CYLINDER HEAD Disassemble the cylinder head page 9 20 USJJ care not to Remove the carbon deposits from the combustion scratch the chamber ...

Page 264: ...E LIMIT 26 04 mm 1 025 in VALVE LIFTER Check the valve lifter for scoring scratches or damage Measure each valve lifter 0 0 SERVICE LIMIT 25 97 mm 1 022 in VALVE SPRING Check the valve springs for fatigue or damage Measure the free length of the intake and exhaust valve springs SERVICE LIMITS IN Orange paint EX Gray paint 40 6 mm 1 60 In 42 1 mm 1 66 in Replace the springs if they are shorter than...

Page 265: ...019 in RefBCB the valve If the stem lo guide clearance exceeds the service se Jls whenever Ihe limils determine if a new guide with standard valwJ guides are dimensions would bring the clearance within tolerance rep aced If so replace the guides as necessary and ream 10 fit page g 24 If the slem to guide clearance e ceeds Ihe service limits with new guides also replace the valves and guides VALVE ...

Page 266: ...nder head and always rotate the reamer care not to tilt or dockwise lean the reamer in the guide while reaming TOOL Valve guide reamer 5 0 mm 07984 MA60001 or 07984 MA6000D U S A only Clean the cylinder head thoroughly to remove any metal particles after reaming and reface the valve seats page 9 24 VALVE SEAT INSPECTION REFACING 9 24 Clean the intake and exhaust valves thoroughly to remove carbon ...

Page 267: ...e seat Contact area too high or 100 low Reface the valve seal VALVE SEAT REFACING Valve seat cUllersfgrinders or equivalent valve seat retacing equipment are recommended to correct worn valve seats If the contact area is too high on the valve the seat must be lowered using a 32 nat cutter If the contact area is too Iowan the valve the seat must be raised using a 60 interior culler CYLINDER HEADNAL...

Page 268: ... EX Flat cutter 33 mm Cutter holder 5 0 mm 07780 0013500 07781 0010400 07780 0012900 07781 0010400 or equivalent commercially available in U S A Use a 60 interior cutter remove 1 4 of the existing valve seat material TOOLS IN Interior cutter 37 5 mm IN Cutter holder 5 0 mm IN EX Interior cutter 34 mm EX Cutter holder 5 0 mm EX 07780 001 4100 07781 0010400 07780 014700 07781 010400 or equivalent co...

Page 269: ...the exhaust valve face and lap the exhaust valve using light pressure After lapping wash any residual compound off the cylinder head and valves I NOTICE I ExceSSIVe lapping pressure may deform or damage the seat Change the angle of the lapping tool frequently to prevent uneven seal wear Do not allow any lapping compound to enter the guides CYLINDER HEAD ASSEMBLY 09 4 shown VALVE COTTERS SPRING RET...

Page 270: ...valve springs with the lightly wound coils facing the combustion chamber Install the spring retainer Install the tappet hole protector into the valve lifter bore TOOL Tappet hole protector TOOL U S A only See Instructions on page 9 20 07HMG MR70002 not available in U S A SPRING SEAT VALVE INTAKE VALVE I J TAPPET EXHAUST J PROTECTOR To preVfJnt loss of Install the valve cotters using the special to...

Page 271: ... TB UP mark facing toward the throttle body side Align the insulator band hole with the insulator tab Tighten the insulator band screw to the specified range as shown Install a new a ring to the water hose joint Install the water hose jOint to the cylinder head Inslall and tighten the bolt securely Install the following EeT sensor page 6 73 Spark plug page 4 12 Cylinder head page 9 30 09 shown CYL...

Page 272: ...he washers crankcase Tighten the cylinder head bolts in a crisscross pattern in two or three steps to the specified torque 9 30 TORQUE 51 N m 5 2 kgf m 38 IbHt Install and tighten the cylinder head 6 mm bolt Install the cylinder head hanger plates and bolts Tighten the cylinder head hanger bolts to the specified torque TORQUE 54 N m 5 5 kgf m 40 IbHt Tighten the cylinder head hanger plate bolts to...

Page 273: ...d valve lifters in their original location Tighten the hose band screws securely page 7 13 Connect the ECT sensor 2P Black connector Apply molybdenum oil solution to the valve lifter bore ouler surface Inslallthe shims and valve lifters Install the following Rocker arm page 9 32 Camshaft page 9 32 Throttle body page 6 64 Exhaust pipe page 3 16 09 14 Ignition coil page 17 16 Fill the radiator with ...

Page 274: ...lipper surface Install the rocker arms onlo the camshaft holder base Inslall the rocker arm shaft while aligning the camshaft holder bolt holes with the rocker arm shaft cui outs CAMSHAFT Turn the crankshaft clockwise to align the punch mark on the primary drive gear with the S mark on the right PUNCH MARK MARK crankcase cover Apply molybdenum oil solution to the camshaft cam lobes Install the cam...

Page 275: ... with the set rings and dowel pins with the camshaft holder base holes CYLINDER HEADNALVES Apply engine oil to the camshaft holder mounting bolt M O U N T N G B O LT S threads Rotate the rocker Install and tighten the camshaft holder mounting bolt 10 arm shah to align its the specified torque cut outs for mounting bolt TORQUE 14 No m 10 4 kgfo m 10 IbHt instal ation ARM SHAFT CUT OUTS 9 33 ...

Page 276: ...ensioner lifter boll with a new sealing washer Tighten the cam chain tensioner lifter bolt securely Apply engine oil to a new O ring and install it to the r crankshaft hole cap Apply grease to the crankshaft hole cap threads Install the crankshaft hole cap and tighten it to the specified torque TORQUE 15 N m 1 5 kgf m 111bHt InslaUthe cylinder head cover page 9 8 After 12 Install the condenser pag...

Page 277: ...ONENT LOCATION 10 2 PISTON REMOVAL 10 6 SERVICE INFORMATION 10 3 CYLINDER PISTON CAM CHAIN TENSIONER LIFTER INSPECTION 10 6 TROUBLESHOOTING 10 4 PISTON INSTALLATION 10 10 CYLINDER REMOVAL 10 5 CYLINDER INSTALLATION 10 11 10 1 ...

Page 278: ...CYLINDERJPISTON COMPONENT LOCATION U Q O 0 G o 0 10 2 ...

Page 279: ...le do not use a screwdriver to pry the cylinder Clean all disassembled parts with cleaning solvent before inspection use compressed air to dry the parts Under racing conditions the piston and piston rings should be replaced after every 6 races or about 15 hours of operation Replace the piston pin after every 12 races or about 30 hours of operation SPECIFICATIONS piston ring TOOL Cam chain tensione...

Page 280: ...on too low hard starting or poor performance at low speeds leaking or damaged cylinder head gasket Worn stuck or broken piston rings Worn or damaged cylinder and piston loose spark plug Compression too high over heating or knocking Excessive carbon build up in on piston head or combustion chamber Abnormal noise Worn cylinder and piston Worn piston pin or piston pin hole Worn connecting rod small e...

Page 281: ...ove the bolts and water hose Joint and D ring CYLINDER PISTON Remove the cam chain tensioner holder Remove the bolts cam chain lensioner lifter and gasket TOOL Cam chain tensloner holder Remove the cylinder Remove the dowel pins and gasket 070MG Q10100or 07AMG 01A100 U S A only 10 5 ...

Page 282: ...te the gap care not to damage them during removal CYLINDER PISTON CAM CHAIN TENSIONER LIFTER INSPECTION CYLINDER Inspect the cylinder bore for wear or damage Measure the cylinder 1 0 in the X and Y axis al three levels Take the maximum reading to determine the cylinder wear SERVICE LIMIT 96 025 mm 3 7805 In Calculate the cylinder to piston clearance Take a maximum reading to determine the clearanc...

Page 283: ...nspect the piston ring for free movement by rotating it in its grooves The ring should be able to move freely without catching Push the ring until the outer surface of the piston ring is nearly flush with the piston and measure the piston ring to groove clearance SERVICE LIMIT 0 12 mm 0 004 in CYLINOERIPISTON Measure the diameter of the piston at 7 0 mm 0 30 in IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII...

Page 284: ...e cyfinder with the rop of the PIS on 1 0 be sure the ring is squarely in the cylinder 10 8 Calculate the piston la piston pin clearance SERVICE LIMIT 0 04 mm 0 002 in Insert each piston ring into the cylinder and measure the ring end gap SERVICE LIMITS Top 0 32 mm 0 013 in Oil side rail 0 71 mm 0 028 in If the ring end gap under the service limit or near1y 15 0 hour of running time have elapsed r...

Page 285: ...ly minimum 2 cc of engine oil to the groove portion of a new cam chain tensioner lifter 2 Remove Ihe stopper while holding the lifter portion not to pop out the lifter portion suddenly 3 Turn the cam chain tensioner holder clockwise fully and lock the cam chain tensioner lifter by pushing the handle Tum Ihe cam chain tensioner while holding the lifter portion not to pop out the lifter portion sudd...

Page 286: ...il ring end 90 apart After installation the rings should rotate freely in the piston ring grooves Clean any gasket material from the cylinder mating surfaces of the crankcase Apply molybdenum oil solution to the connecting rod small end inner surface Apply engine oil to the piston pin outer surface and piston pin hole of the piston Apply molybdenum oil solution to the piston pin outer surface Appl...

Page 287: ...er and install the cylinder while compressing the piston rings Install a new gasket cam chain tensioner lifter Install and lighten the bolts securely Insert the cam chain tensioner holder into the cam chain tensioner lifter Turn the cam chain tensioner holder clockwise fully and lock the cam chain tensioner lifter by pushing the handle TOOL Cam chain tensioner holder 070MG o010100 or 07AMG 001A100...

Page 288: ... the water hose joint groove Set the waler hose joint to Ihe cylinder Install and lighten Ihe bolts securely Install Ihe cam chain guide by aligning its tabs with the grooves in the cylinder and guide end with Ihe groove in Ihe crankcase Inslalithe cylinder head page 9 30 ...

Page 289: ...11 CLUTCH KICKSTARTERIGEARSHIFT LINKAGE COMPONENT LOCATION 11 2 CLUTCH 11 10 SERVICE INFORMATION 11 4 KICKSTARTER 11 22 TROUBLESHOOTING 11 6 GEARSHIFT LINKAGE 11 25 RIGHT CRANKCASE COVER 11 7 11 1 ...

Page 290: ...CLUTCHIKICKSTARTERIGEARSHIFT LINKAGE COMPONENT LOCATION 09 12 12 N m 1 2 kgf m 9 12 N m 1 2 kgf m 9 80 N m 8 2 59Ibf fl 38 N m 3 9 kgf m 28 12 N m 1 2 kgf m 9 10 N m 1 0 kgf m 7 11 2 ...

Page 291: ...CLUTCH KICKSTARTERIGEARSHIFT LINKAGE After 12 12 N m 1 2 kgf m 9 22 N m 2 2 kgf m 16 bHt 12 N m 1 2 kgf m 9 80 N m 8 2 kgf m 59Ibf ft 38 N m 3 9 kgf m 28 12N m 1 2kgf m 9 to N m 1 0 kgf m 7 11 3 ...

Page 292: ...ch system The clutch discslplates can be serviced without removing the right crankcase cover Replace the transmission oil if the clutch discs and plates are replaced SPECIFICATIONS TORQUE VALUES Clutch center lock nut Clulch spring bolt Clutch cover boll Gearshift drum center pin Gearshift drum stopper arm bolt Kickstarter pedal bolt Gearshift pedal pinch bolt l eft crankcase cover bolt 11 4 80 N ...

Page 293: ...Remo v e w e g h 1 07741 0010201 or 07936 371020A U SA only Remover handle 07936 3710100 Needle bearing driver 07AMO MENA200 U S A only 07936 166010A U S A only 07936 1660101 Remover head 12 mm 07936 1660110 Not available in U SA Remover shaft 07936 660120 Not available in U S A ________ 1 iN 0 C a va b e n u S A __________ 1 Pilot 16 mm Driver 07746 0041300 07749 0010000 i 11 5 ...

Page 294: ...tch lever is too hard to pullin Damaged dutch lifter mechanism Faulty clutch lifter needle bearing Clutch lifter piece installed improperly Transmission jumps out of gear Worn gearshift drum stopper arm Weak or broken gearshift arm return spring Loose stopper arm bolt Bent shift fork shaft page 13 18 Damaged gearshift drum guide grooves page 13 18 Damaged or bent shift fork page 13 17 Worn gear en...

Page 295: ...l positIOn to ensure correct reassembly in its original location loosen the hose band screw and disconnect the lower r r T iiij 1i i i radiator hose from the water pump cover Remove the water hose jOint bolls from the cylinder Loosen the right crankcase cover bolts in a crisscross pattern in two or three steps Clean off any dirt Remove the bolts and right crankcase cover from the kickstarter spind...

Page 296: ...se joint Remove the kickslarter spindle oil seal Apply grease to a new oil seat lips and install it to the right crankcase cover INSTALLATION OllSEAl Apply engine oil to a new D ring and install it to the r RiNc 7I water hose joint Instalilhe dowel pins and new gasket 11 8 ...

Page 297: ...and screw securely page 7 13 Install and lighten the water hose joint bolts securely Install the kickslarter pedal on its original position as i ii mar1 ed during removal Install and tighten a new kickstarter pedal boll to the specified torque TORQUE 38 N m 3 9 kgf m 28 IbHt Install the brake pedal pivot boll page 16 30 Fill the radiator with the recommended coolant mixture to the filler neck and ...

Page 298: ...move the brake pedal pivot bolt page 16 29 Remove the bolts clutch cover and O ring Remove the clutch spring bolts in a crisscross pattern in two or three steps Remove the clutch springs and clutch pressure plate 09 12 Remove the following Thrust washer Needle bearing Clutch lifter piece Clutch lifter rod 11 10 ...

Page 299: ... Seven clutch disc B Seven clutch plates Clutch disc A Judder spring Spring seal Bend the tab of the lock washer away from the lock nut Remove the clutch center lock nut while holding the clutch center using the Special tool TOOL Clutch center holder 07724 050002 or equivalent commercially available in U S A Remove the lock washer and thrust washer Remove the special tool and clutch center 11 11 ...

Page 300: ...e the clutch dISCS and plates as 8 sat 11 12 CLUTCH SPRING CLUTCH DISCS Check the clutch discs for signs of scoring or 1cW C OD S CC i discoloration Measure the thickness of each dutch disc SERVICE LIMIT 2 85 mm 0 112 in CLUTCH PLATES Check the plates for excessive warpage or discoloration Measure the warpage of each plate SERVICE LIMIT 0 15 mm 0 006 in CLUTCH CENTER Check the clutch center groove...

Page 301: ...Replace the needle bearing and thrust washer as a set if necessary CLUTCH LIFTER ROD Check the clutch lifter rod for damage and straightness Replace it if necessary JUDDER SPRING SPRING SEAT After 10 THRUST WASHER ROO LIFTER PIECE NEEDLE BEARING LIFTER PIECE NEEDLE BEARING THRUST WASHER Check the udder spring and spring seat for After 10 deformation warpage or damage replace them if necessary A da...

Page 302: ...es eight pieces THRUST WASHER fILOCK WASHER CLUTCH CENTER LIFTER PIEC I NEEDLE BEARING WASHER 12 N m 1 2 kgf m 9lbf ftj PRESSURE PLATE SPRING SEAT JUDOER SPRING 80 N m 8 2 I CLUTC D C A seven pieces LOCK WASHER R c 1 ERPIEC NEEDLE BEARIN 1 CLUTCH DISC B seven pieces THRUST WASHER 12 N m 1 2 kgf m 9 PRESSURE PLATE 11 14 ...

Page 303: ...llthe thrust washer SPRING Install a new lock washer by aligning its groove with the dutch center rib PRESSURE PLATE Apply engine oil to the threads and seating surface of the clutch center lock nut then install it to the mainshaft Tighten the clutch center lock nul to the specified torque while holding the clutch center using the special tool TOOL Clutch center holder 07724 OSO002 or equivalent c...

Page 304: ... shown Coat the clutch discs lining surfaces with clean engine oil Install the clutch disc A large 1 0 seven clutch plates and seven clutch discs B After 10 C L U T CH DISCS 7 JUDDER SPRING SPRING SEAT eUJ 1L H DISC A 7 C LU T C H DISCS 7J 09 12 Apply molybdenum oil solution to the dutch lifter lever Dii iiiiiiiiiiii iiiiiiiiiiii cam contact area of clutch lifter rod Insert the clutch lifter rod i...

Page 305: ... surface 7JI Inslall the needle bearing and thrust washer to the NEEDLE BEARING riI clutch lifter piece n all Ihe nap ing into Ihe lift piece gcoo e 0 SNAP RING LIFTER PIEC THRUST WASHER After 12 Apply molybdenum oil solution to the clutch lifter lever i 7 o iiIi cam contact area of clutch lifter rod Insert the clutch lifter rod into the mainshaft Apply engine oil to the clutch lifter assembly who...

Page 306: ...cover O ring is in good condition replace it if necessary Apply engine oil to the D ring and install it to the clutch cover Instalilhe clutch cover Install and tighten the clutch cover bolls to the specified torque in a crisscross pattern in two or three steps TORQUE 10 N m 1 0 kgf m 7lbHt Install the brake pedal pivot bolt page 16 30 Adjust the clutch lever freeplay page 4 30 FiU the transmission...

Page 307: ...nicks indentations or c L U T C H O U TE R abnormal wear made by the clutch discs Check the serrated teeth of the primary driven gear for wear or damage Replace the clutch outer if necessary CLUTCH OUTER GUIDE PRIMARY L 4 O I _ r __ GEAR Check the clutch outer guide for abnormal wear or Ic c L uiTT c HIOu ERGiJiO E 1 damage Replace it if necessary NEEDLE BEARING Check the needle bearing for wear o...

Page 308: ...t washer Install the following Clutch center clutch discs clutch plates page 11 14 Righi crankcase cover page 11 8 LIFTER LEVER REMOVAL Remove the clutch lifter rod page 11 10 Disconnect the clutch cable and remove the clutch lifter lever from the left crankcase Remove the oil seal LIFTER LEVER INSPECTIONI INSTALLATION Check the clutch lifter lever for bends or damage Check the needle bearings for...

Page 309: ...ng the special tools TOOLS Bearing remover set 12mm Remover weight Remover head 12 mm Remover shaft TOOLS U S A only Bearing remover 12 mm Remover handle Remover weight 07936 1660101 not available in U S A 07741 0010201 07936 1660110 not available in U S A 07936 1660120 not available in U S A 07936 166010A 07936 3710100 07936 371020A Apply engine oil to new needle bearings Drive in new needle bear...

Page 310: ... INSPECTION Check the relum spring and ratchet spring for fatigue or damage Check the ratchet for wear or damage Replace them if necessary Check the pinion gear for wear or damage Check the spindle for bends wear or damage Check the pinion gear bushing for damage or excessive wear Measure the pinion gear 1 0 SERVICE LIMIT 22 05 mm 0 868 in Measure the pinion gear bushing 1 0 and 0 0 SERVICE LIMITS...

Page 311: ...ARTER PINION GEAR THRUST WASHER Install the snap ring with the chamfered edge facing the trust road side Check thaI the snap ring is sealed in the spindle groove THRUST WASHER Inslalilhe snap ring in the groove of the spindle Install the thrust washer Apply molybdenum oil solution to the spindle gear rolling area SNAP RING KICKSTAR rER RATCHET KICKSTARTER SPINDLE THRUST WASHER 11 23 ...

Page 312: ... aligning the gap of the coliar with the spring GEAR BUSHING 09 12 shown THRUST 09 12 shown Apply molybdenum oil solution to the spindle spline P U N C H MA R K S area 09 12 shown 11 24 Align the punch marl s and install the ratchet INSTALLATION Install the ratchet spring Apply engine oil 10 the spindle journal Install the kickslarter assembly to the crankcase and rotate the spindle clockwise unti...

Page 313: ...rshafl facing toward the outside 01 the crankcase Installihe clutch outer page 11 20 Inslall the right crankcase cover page 11 8 GEARSHIFT LINKAGE REMOVAL Remove the following Right crankcase cover page 11 7 Clutch ouler page 11 19 Clean off any dirt from the gearshift spindle serration When remoVing the Remove the bolt and gearshift pedal gearshlff pedal mark the pedal position to ensure correct ...

Page 314: ...ukJe plate and drum shifter Remove the gearshift drum center pin and gearshift iiiiii iiii drum center I 11 26 Remove the bolt stopper arm return spring and washer Remove the drum pin from the gearshift drum INSPECTION GEARSHIFT SPINDLE Check the gearshift spindle for bends wear or damage Check the return spring for fatigue or damage Replace them if necess81 GEARSHIFT SPINDLE ...

Page 315: ...n the guide plate as shown L _ _____ ____ __ GEARSHIFT SPINDLE OIL SEAL Remove the gearshift spindle oil seal InS 8 a new oil seal Apply grease to a new gearshift spindle oil seal lips and with its marlfed side install ilia the right crankcase facing out INSTALLATION Install the drum pin into the hole on the gearshift drum Inslall the relurn spring washer and stopper arm and tighten the stopper ar...

Page 316: ...er collar onlo the drum shifter Apply engine oil 1 0 the gearshift spindle serration area Do not forgel 0 Install the washer and gearshift spindle assembly Into install the washer the crankcase while aligning the spring ends with the onto the gearshift crankcase stopper pin and gearshift spindle end with spindle the shifter collar 11 28 Wipe off any oil from the gearshift spindle serration area In...

Page 317: ...12 ALTERNATOR COMPONENT LOCATION 12 2 FLYWHEEL 12 7 SERVICE INFORMATION 12 4 STATORlCKP SENSOR 12 9 LEFT CRANKCASE COVER LEFT CRANKCASE COVER REMOVAL 12 5 INSTALLATION 12 10 12 1 ...

Page 318: ...ALTERNATOR COMPONENT LOCATION 09 14 09 shown 12 2 64 N m 6 5 kgf m 471bHl 09 10 12 N m 1 2 kgf m 9lbHt After 10 10 N m 1 0 kgf m 7lbHt 12 N m 1 2 kgf m 9Ibf ft ...

Page 319: ...ALTERNATOR After 14 12 N m 1 2 kgf m 9lbHt 10 N m 1 0 kgf m 7Ibf ft 12 3 ...

Page 320: ... Left crankcase cover bolt TOOLS 09 10 After 10 64 N m 6 5 kgf m 47 IbHt 6 0 N m 0 6 kgf m 4 4 IbHt 5 2 N m O S kgf m 3 8IbHt 5 2 N m 0 5 kgf m 3 8IbHt 12 N m 1 2 kgf m 9lbHt 12 N m 1 2 kgf m 9Ibf ft 10 N m 1 0 kgf m 7 Ibf ft r Flywheel hold e F ywtl e e p u e 07725 0040001 070MC HP10100 or 07AMB MENA100 U S A only Thread protector 07AMC MEBA110 U S A only U OTE This thread protector is included w...

Page 321: ...uard page 3 6 Gearshift pedal page 11 25 Drain the engine oil page 4 17 09 Remove the wire banet Disconnect the altematorJCKP sensor 6P Natural connector Remove the wire band and release the allernator CKP sensor wire ALTERNATOR 09 SENSQRWIRE 10 12 Disconnect the alternator CKP sensor 6P Black 1IIII1IIII I1111 IIIIIIIIII IIIIIIIIIIIIIIIIIIII connector P BLACK CONNECTORJ 12 5 ...

Page 322: ... the alternalor CKP sensor wire from the drive sprocket cover 09 14 Remove the left crankcase cover bolts and left crankcase cover NOTE loosen the left crankcase cover bolts in a crisscross pattern in two or three steps The left crankcase cover stator is magnetically attracted to the flywheel be careful during removal ...

Page 323: ...AL Remove the left crankcase cover page 12 5 Hold the flywheel with the special tool and remove the nul and washer TOOL Flywheel holder 07725 0040001 or 07AMB MENA100 U S A only Be careful not to Screw the special tool onlo the crankshaft bottom lhe adapter against the crankshaft Jeft end TOOL Flywheel puller adapter 070MG KSE0100 or it may damage not available in the oil control U S A orifice TOO...

Page 324: ...odruff key in the groove in the crankshaft damage he crankshaft 12 8 Inslall the flywheel to the crankshaft by aligning the groove in the flywheel with the woodruff key Apply engine oil to the flywheel nul threads and sealing surface Install the washer and nul Hold the flywheel with the special tool and lighten the nut to the specified torque TOOL Flywheel holder 07725 0040001 or 07AMB MENA100 U S...

Page 325: ...over page 12 5 Remove the grommet from the left crankcase cover Remove the bolls wire damp and CKP sensors Remove the mounting socket bolts and stator INSTALLATION t 5 2 N m 0 5 WIRE CLAMP STATOR NO 1 SENSOR ALTERNATOR 3 8 GROMMET tt fill NO 2 SENSOR 12 9 ...

Page 326: ... wire grommet seating surface and install the grommet into the left crankcase cover Install the left crankcase cover page 12 10 LEFT CRANKCASE COVER INSTALLATION Install the dowel pins and a new gasket OQ 14 Install the left crankcase cover and left crankcase cover 12 10 bolts Be careful not to damage the oil seal of the left crankcase cover The left crankcase cover stator is magnetically attracte...

Page 327: ... crankcase cover stator is magnetically attracted to the flywheel be careful during installation Tighten the left crankcase cover bolls to the specified torque in a crisscross pattem in two or three steps TORQUE 10 N m 1 0 kgf m 7 Ibf ft After 14 Route and secure the altemator CKP sensor wire with the drive sprocket cover 09 Connect the altemator CKP sensor 6P Natural connector Install the wire ba...

Page 328: ...onnector Install the wire bands NOTE Routs the wire proper1y page 1 23 Inslallthe following Gearshift pedal page 11 28 Engine guard page 3 6 V9 12 Insla1l the drive sprocket cover page 4 23 09 af er 12 Install the fuel lank page 4 6 Fililhe engine with the recommended oil page 4 16 12 12 10 12 6P BLACK CONNECTOR WIRE BAND ...

Page 329: ...NSMISSION BALANCER COMPONENT LOCATION 13 2 TRANSMISSION 13 15 SERVICE INFORMATION 13 3 CRANKSHAFT 13 22 TROUBLESHOOTING 13 6 CRANKCASE BEARING REPLACEMENT 13 24 BALANCER GEAR BALANCER SHAFT 13 7 OIL JET 13 30 CRANKCASE 13 10 13 1 ...

Page 330: ...N BALANCER COMPONENT LOCATION 09 shown 108 N m 1 0 kgf m 80 36 N m 3 7 kgf m 27 Ibf ft 12 N m 1 2 kgf m 9lbHt 10 N m 1 0 kgf m 7 Ibf ft 13 2 12 N m 1 2 kgf m 9Ibf ft 16 N m 1 6 kgf m 12 Ibf ft 23Ibf ft 9 IbUt 10 N m 1 0 kgf m 7Ibf ft ...

Page 331: ...ame The following parts must be removed before separating the crankcase Cylinder head page 9 16 Cylinder page 10 5 1Piston page 10 6 Clutch page 11 10 lKickstarter page 11 22 Gearshlft linkage page 11 25 Balancer page 13 7 Flywheel page 12 7 Gear position switch page 17 19 09 model only Engine page 8 6 Be careful not to damage the crankcase mating surfaces when servicing Clean the oil passages bef...

Page 332: ...m 3 2 kgf m 23 IbHt 108 N m 11 0 kgf m 80 Ibf ft 36 N m 3 7 kgf m 271bHt 12 N m 1 2 kgf m 9lbHt 16 N m 1 6 kgf m 12lbf ft 10 N m 1 0 kgf m 7Ibf ft Bearing remover set 20 mm 07936 3710600 ALoe bolt replace with a new one AlOC screw replace with a new one Aloe screw replace with a new one Aloe bolt replace with a new one Aloe bolt replace with a new one Apply engine 011 to the threads Apply engine o...

Page 333: ...m 07746 0040400 Gear holder M2 S 07724 0010100 Universal holder 07725 0030000 or 07724 001A200 U S A only or 07724 001A100 U S A only oP iIO o 15 m mC hSearing remover shaft 10 mm Bearing remover head 10 mm I 07936 GE00200 07746 0040300 07936 GE00100 Valve guide driver 8 0 mm Q7ZMD MCH0100 or 07ZMD MCHA100 U S A only or 07936 GEOAOOO U S A _ _o _n c Y c __ 13 5 ...

Page 334: ... cylinder piston or piston rings page 10 6 Transmission Jumps out of gear Worn gear dogs Worn gear shifter groove Benl shift fork shaft Broken gearshift drum stopper arm page 11 25 Broken gearshift drum stopper arm spring page 11 25 loose gearshift drum stopper arm bolt page 11 25 Worn or bent shift forks Weak or broken gearshift spindle return spring Hard to shift Improper dutch lever freeptay ad...

Page 335: ... 001A100 U S A only Remove the primary drive gear bolt and washer then 2 remove the gear holder Remove the clutch Quter needle bearing outer guide and primary drive gear Check the primary drive gear for wear or damage Replace the primary drive gear if necessary Insert the gear holder between the balancer drive and driven gears TOOL Gear holder M1 5 07724 0010200 or 07724 01A200 U S A only Remove t...

Page 336: ...th oil pump dn ven gear Check the oil seal for wear or damage replace it if necessary page 13 24 InSlal1 the balancer Install the balancer drive gear while aligning liS wide drive gear with the cut out in the splines with the punch mark on the flat side facing crankshaft toward the outside of the crankcase Check the oil seal for wear or damage replace it if J necessary page 13 26 Aner lO Apply eng...

Page 337: ...he primary drive gear by aligning its wide cul out drive gear with the in the splines with the punch mark on the crankshaft Punch mark side facing OUI Temporarily install the clutch ouler guide needle bearing and clutch ouler to the mainshaft Insert the gear holder between the primary drive and driven gears TOOL Gear holder M2 S 07724 0010100 or 07724 001 A100 U S A only Apply engine oil 1 0 the p...

Page 338: ...ose from the right crankcase Loosen the drive sprocket bolt while holding the rn sprocket with the special 1001as shown TOOL Universal holder 07725 0030000 Remove the drive sprocket bolt coliar washer and drive sprocket Be careful tJOt 0 Remove the countershaft coliar and O ring damage the collar and countershan 13 10 Remove the bolt coliar and cam chain tensioner Remove the bolt stopper plate and...

Page 339: ... washer 09 shown STAY Loosen the crankcase bolls in a crisscross pattern in two or three steps Remove the crankcase botts balancer shaft bearing set plate and stay Place the left crankcase facing down and separate the left and right crankcase halves Remove the dowel pins and gasket Remove the oil pump inner outer rotors and oil pump shaft PINS 13 11 ...

Page 340: ...nor roughness or irregularities on the crankcase mating surfaces dress them with an oil slone lnstalilhe one way valve to the righl crankcase halves Install the dowel pins and new gasket Apply engine oil to the oil pump inner outer sliding area rotors Install the oil pump inner outer rotors and oil pump shaft in the left crankcase Install the right crankcase on the left crankcase ONE WAY VALVE DOW...

Page 341: ...g the crankcase bolls tighten the transmission oil drain bolt first then lighten the balancer shaft bearing set plate bolts to the specified torque TORQUE Transmission oil drain bolt 16 N m 1 6 kgf m 121bHt Balancer shaft bearing set plate bolt 10 N m 1 0 kgf m 7lbHt 09 shown STAY Carefully trim the protruding gasket material from the r C U TT C N G A R EA cylinder base gasket surface NOTE 00 not ...

Page 342: ...hain tensioner bolt to the specified torque TORQUE 12 N m 1 2 kgf m 9 IbHt Apply grease to a new counlershaft Q ring and install it to the countershaft collar Instalilhem to the countershaft Install the drive sprocket to the countershaft as shown OLLAR Install the washer and collar with the OUT SIDE k 13 14 marks facing out Install and tighten the drive sprocket bolt to the specified torque while ...

Page 343: ...t crankcase Place the right crankcase facing down and separate the right and left crankcase halves Remove the shift fork shafts Remove the shift fork guide pins from the gearshift drum grooves and remove the gearshift drum Remove the shift forks HOSE Remove the mainshaft and countershaft assembly from the right crankcase r Disassemble the transmission Keep track of the disassembled parts gears bus...

Page 344: ...gs for wear or damage replace them if necessary page 13 26 Also check Ihallhe needle bearings fil tightly in the left crankcase TRANSMISSION NEEDLE BEARING Check the C1 gear needle bearing for damage Replace the needle bearing if necessary GEAR LEFT CRANKCASE Check the gear dogs dog holders and teeth for damage or excessive wear ...

Page 345: ...m 1 065 in C3 25 02 mm 0 985 In MAINSHAFT COUNTERSHAFT 0 Check the spline grooves and sliding surfaces for damage or abnormal wear Measure the 0 0 of the mainshaft and countershaft at the bushing sliding areas SERVICE LIMITS Mainshaft at MS bushing 24 94 mm 0 982 In Countershaft at C2 bushing 26 94 mm 1 061 in at C3 bushing 24 94 mm 0 982 in Calculate the bUShing to shaft clearance SERVICE LIMITS ...

Page 346: ...ck that the bearing outer race fit tightly in the crankcase Replace the bearings if necessary page 13 26 ASSEMBLY DRUM Apply molybdenum oil solution to the mainshaft and countershaft spline area and transmission gear sliding surface Assemble aU parts into their original positions Check the gears for freedom of movement or rolation on the shaft Install the washers and snap rings with the chamfered ...

Page 347: ...5T M2 GEAR 17T THRUSTWASH RS After 12 MAINSHAFT Ml GEAR 1ST M2 GEAR 17T SNAP RINGS M3 GEAR 17T spi N WASH R M4 BUSHING M4 GEAR 20T SNAP RINGS M3 GEAR 17T M4 BUSHING M4 GEAR 20T LOCK WASHER THRUST WASHER MS BUSHING MS GEAR 22T SPLINE WASHER MS BUSHING MS GEAR 22T SPLINE WASHER 13 19 ...

Page 348: ...COUNTERSHAFT 13 20 C2 25T THRUST WASHER INSTALLATION Apply molybdenum oil solution to each transmission MA N S H A FT gear teeth ASSEMBLY Engage the mainshaft and countershaft gears ASSEMBLY EACH GEAR TEETH Install the mainshaft and countershaft assembly into the l right crankcase I Make sure the three thrust washers are installed mainshaft left onlylcountershaft both ends ...

Page 349: ...ork marks 10 the left crankcase Apply engine oil to the gearshift drum guide grooves i l 1 Install the gearshift drum by aligning the guide pins on I the shift forks with the guide grooves in the gearshift drum Apply molybdenum oil solution to the shift fork shaft outer surface Slide the shift fork shafts through the shift forks into the crankcase Temporarily install the left crankcase on the righ...

Page 350: ...uietly Also check that the bearing Quter race fits tightly in the crankcase Replace the bearings if necessary page 13 24 Be careful not 0 Place the crankshaft on a stand or V blocks damage the main Set the dial indicator as shown journal Rotate the crankshaft two revolutions 720 and read the runout 13 22 SERVICE LIMIT 0 05 mm 0 002 in Measure the connecting rod big end radial clearance in both X a...

Page 351: ...necting rod big end side clearance FEELER GAUGE SERVICE LIMIT 0 6 mm 0 02 in INSTALLATION Coat the oil seal contacting surface of the crankshaft IC RANKSHAF i with engine oil and install it into the left crankcase Assemble the crankcase halves page 13 12 13 23 ...

Page 352: ...in OIL SEAL 14x22x5 RIGHT CRANKCASE OIL SEAL 31 x40x7 LEFT MAINSHAFT BEARING 09 _ 12 6203U OIL SEAL After 12 17x40x 11 38x52x7 LEFT BALANCER SHAFT BEARING 20 x32 x 14 RIGHT COUNTERSHAFT BEARING RIGHT MAINSHAFT RIGHT BALANCER SHAFT 1 0 0 5 mm 0 04 0 02 in BEARING 6205U BEARING 6202 RIGHT CRANKSHAFT BEARING 63G6 Oil SEAL 09 2 6203U After 2 17 x 40 x 11 OIL SEAL 22 x36 x7 5 39 x56 x 7 5 CRANKSHAFT BE...

Page 353: ... 68 mm Pilot 30 mm Left crankshaft bearing Driver 07749 0010000 07746 0010500 07746 0040700 07749 0010000 07746 0010500 DRIVER Atta chment 62 x 68 mm After installation apply engine oil to the crankshaft I bearings I Il D T Install new T30 torx screws with the set plates and lighten the torx screws to the specified torque TORQUE 22 N m 2 2 kgf m 16 IbHt Apply grease to a new right crankshaft 011 s...

Page 354: ...CASE Remove the counlershaft oil seal Remove the balancer shaft bearing using the special tools TOOLS Balancer shaft bearing Bearing remover set 20 mm Remover handle Remover weight 07936 3710600 07936 3710100 07741 0010201 or 07936 371020A U S A only Remove the mainshaft bearing and balancer shaft bearing using the special tools TOOLS Malnshaft bearing Bearing remover set 17 mm 07936 3710300 Remov...

Page 355: ...0100 07746 0040500 Remove the oil pump shaft needle bearing retainer and needles out from the bearing case Remove the oil pump shaft needle bearing cases using the spacial tools TOOLS Oil pump shaft needle bearing Bearing remover shaft 10 mm 07936 GE00100 Bearing remover head 10 mm 07936 GE00200 TOOLS U S A only Remover handle 07936 3710100 Remover weight 07741 0010201 Remover weight 07936 371020A...

Page 356: ...rum needle bearing using the special tools TOOLS Gearshift drum needle bearing Driver 07749 0010000 Attachment 37 x 40 mm 07746 0010200 Drive In a new countershafl bearing using the special tools TOOLS Countershaft bearing Driver Attachment 52 55 mm 07749 0010000 07746 0010400 After installation apply engine oil 10 each bearing Install new T30 lorx screws with the set plates and tighten the screws...

Page 357: ...ht crankcase using the special tools WIth rhe sealed side facing down TOOLS Drive in new bearmgs squarely wI II tIla marked side fecing up Mainshaft bearing Driver Attachment 52 x 55 mm Pilot 25 mm Countershaft bearing Driver Attachment 37 x 40 mm Pilot 17 mm 07749 0010000 07746 0010400 07746 0040600 07749 0010000 07746 0010200 07746 0040400 Drive in new balancer shaft bearing crankcase using the ...

Page 358: ...ainshaft bearing set plate bolts 12 N m 1 2 kgf m 9lbHt BOLTS SET PLAlES I MAINSHAFT BEARING Make sure the snap Inslall the snap ring into the groove of the right ring is firmly seated crankcase securely In the groove Instailihe balancer shan 0 1 seal with its metal side facing do_ OIL JET 13 30 Apply grease to new balancer shaft oil seal lips Install the balancer shaft oil seal to the specified d...

Page 359: ... Check the oil jet for clogs wear or damage and replace it if necessary OIL JET Install the oil jet and tighten new bolt to the specified 1IIIIII1IIIIII1III II1IIIIII1IIIIII I111111 I111111 torque TORQUE 10 N m 1 0 kgf m 7lbHt Install the following Crankshaft page 13 23 Transmission page 13 20 13 31 ...

Page 360: ...MEMO ...

Page 361: ...SUSPENSION STEERING COMPONENT LOCATION 14 2 SERVICE INFORMATION 14 5 TROUBLESHOOTING 14 9 FRONT WHEEL 14 10 FORK 09 14 14 17 FORK After 14 14 45 HANDLEBAR 14 59 HPSD 14 64 STEERING STEM 14 75 CLUTCH LEVER 14 80 14 1 ...

Page 362: ...ERING COMPONENT LOCATION 09 12 22 N m 2 2 kgf m 161bHt 108 N m 11 0 kgf m 80 IbNI 22 N m 2 2 kgf m 16 IbHI 44 N m 4 5 kgf m 32 IbHt 5 2 N m 0 5 kgf m 3 8IbHt 151bHt kgf m 7 0 N m 0 7 kgf m 5 2IbHt 13 N m 1 3 kgf m 10 IbNt 14 2 ...

Page 363: ... CJ 1ft aJ 1 08 N m 11 0 kgf m 80 fbf t ft 1m 2 2 kgf m 16 fbf n 44 N m 4 5 kgf m 32 IbUt J JCJ t J 0 m 20 kgfm 151bfn r r 20 N m 2 0 kgf m 151bHI 7 0 N m 0 7 kgl m 5 2IbHt l IJIJ 20 N m 2 0 kgf m 15 IbUt 5 2 N m 0 5 kgf m 3 8IbHt 13 N m 1 3 kgf m 10 Ibf ft 14 3 ...

Page 364: ... STEERING After 14 22 N m 2 2 kgf m 16 Ibf ft vr I5rJ t iJ 108 N m 11 0 kgf m 80 IbHt 22 16 Ibf ft 44 N m kgf m 32Ibf ft 14 4 5 2 N m 0 kgl m 3 8IbHt 30 N m 3 kgf m 22Ibf ft 88 N m 9 0 kgf m 651bHt 13 N m 1 3 kgf m 10 IbHt ...

Page 365: ...ut Recommend ed O O ilr r KYB KYB 01M 451 17 BI __ 0 2 0 01 Oil level 09 12 2 47 1 6 5 _ 1 B 51 r Oil level 15 92 3 6 Oil level A_ e r 1 j5I b c 87 3 4 Oil capacitY Fork L 09 12 350 cm e B U S oz 2 3 Imp oz I j lube L 10 11 355 cm j 12 0 US Ol 12 5ImP T0z I__ j_ 13 t 245 cm3 8 3 US OZ a 6lmp oz _ _ 4 242 em3 8 2 US OZ 8 5Imp o z I Fork 09 10 201 em3 6 8 US OZ 7 1 Imp oz t damper 11 12 205 em3 6 9 ...

Page 366: ...f m 15Ibf ft 88 N m 9 0 kgf m 65Ibf ft 16 N m 1 6 kgf m 12Ibf ft 4 0 N m OA kgf m 3 0 Ibf ft 9 9 N m 1 0 kgf m 7 3Ibf ft See page 14 80 10 N m 1 0 kgf m 7Ibf ft 1 5 N m 0 2 kgf m 1 1Ibf ft 30 N m 3 1 kgf m 22 Ibf ft 28 N m 2 9 kgf m 21 Ibf ft 45 N m 4 6 kgf m 33 Ibf ft 55 N m 5 6 kgf m 41 Ibf ft 43 N m 4 4 kgf m 32 Ibf ft 29 N m 3 0 kgf m 21 Ibf ft 29 N m 3 0 kgf m 21 Ibf ft 1 2 N m 0 1 kgf m 0 9I...

Page 367: ...Ol A200 or 070MO MENA100 U S A only f D n e Sase collar 31 mm 1 0 A ac h m e n 3 7ccxCC4 O mOcm i 07749 0010000 07GAJ PG2Q120 07746 0010200 Pilot 20 mm 07746 0040500 C I l 8eanng remover head 20 mm 07746 0050600 Bearing remover shaft 07GGD 0010100 Piston ba e 07958 2500001 f DB eari ng ce ln a e OCI 2 eq ed I n aller h a ft 1 070MF MEN0100 07VMF KZ30200 or 070MF MENA100 U S A only ______________L ...

Page 368: ... only 070MB MEN0100 07AMD MENA100 U S A only t or 070MB MENA100 U S A only Remover weight Ball race remover shaft 07741 0010201 07JAC PH80200 or 07936 371 020A U S A only Air Fork Pump 0 60 psi U S A only 07AMJ MENA300 or07AMJ KRNA100 Not available in U S A Fork Damper Holder Handle 07TMB 001010A Adapter 3 8 in x 16 thread 07YAC 001A200 Used with 07YAC OQ10102 Holder Attachment 30 mm 070MB MEN0200...

Page 369: ...d left forks After 12 Front wheel wobbling Bent rim Worn wheel bearings Benl spokes Faulty lire insufficient lire pressure Axle nol tightened properly Unbalanced tire and wheel Wheel hard to turn Faulty wheel bearings Benl axle shaft Brake drag page 16 6 Soft suspension Weak fork springs 09 12 Insufficient fork oil in fork Incorrect fork oil weight Insufficient PSF air pressure After 12 Insufficie...

Page 370: ...disc cover bolt After 12 Raise the front wheel off the ground by placing a workstand or equivalent under the engine Remove the bolts and brake disc cover After 12 Remove the axle nul and loosen the left axle holder i rj bolts I Do not operata the loosen the right axle holder bolts brake evar after Remove the axle shaft and front wheel removing the front wheel 14 10 ...

Page 371: ...r I finger The bearings should tum smoothly and quietly Also check that the bearing ouler race fils tightly in the wheel hub Replace rhe Replace the wheel bearing if necessary page 14 11 bearings In pairs WHEEL RIM RUNOUT Check the rim runout by placing the wheelan a truing stand Spin the wheel by hand and read the runout uSing a dial indicator SERVICE LIMITS Radial 2 0 mm 0 08 in Axial 2 0 mm 0 0...

Page 372: ...ke disc bolts and nuts Brake disc Dust seal RepJace the wheel Instalilhe remover head into the wheel bearing beanngs in pairs From the opposite side install the remover shaft and Do not reuse okJ drive the wheel bearing out of the wheel hub beanngs Remove the distance collar and drive out the other bearing 14 12 TOOLS Bearing remover head 20 mm Bearing remover shaft 07746 OS0600 07GGO 01 01 00 ...

Page 373: ... 1 6 FRONT WHEEUSUSPENSION STEERING 121bUt 12 N m 1 2 kgf m 9 lbHt u lEFT WHEEL BEARING 6904 BRAKE DISC COVER LEFT OUST SEAL 16 N m 1 6 kgf m 121bHt S 12 N m 1 2 kgf m 9lbHt RIGHT SIDE COLLAR RIGHT WHEEL BEARING 6904 DISTANCE COLLAR lEFT DUST SEAL s v LEFT WHEEL BEARING 6904 LEFT SIDE COLLAR BRAKE DISC 14 13 ...

Page 374: ...ee progressive steps liiii r C l page 4 42 I Inslallths rim lock setting rubber tube and lire Tighten the rim lock page 4 42 Pack each wheel bearing cavity with grease i l Drive a new left wheel bearing in the wheel hub until it is fully seated using special tools Instatl the wheel bearing with the sealed side toward the outside TOOLS Driver AHachment 37 x 40 mm Pilot 20 mm 07749 0010000 07746 001...

Page 375: ...uts to the specified torque TORQUE 16 N m 1 6 kgf m 121bHt 09 12 Ched the left side collar for wear or damage Replace it if necessary Install the side collar to the right wheet hub 09 12 Check the brake disc cover for wear or damage Replace it if necessary Install the brake disc cover to the left wheel hub After 12 Check the side collars for wear or damage Replace them if necessary Pack the lips o...

Page 376: ...the axle shaft from the right side Install and lighten the axle nut to the specified torque j j while holding the axle shaft I TORQUE 88 N m 9 0 kgf m 651bHt Tighten the left axle holder bolts to the specified torque TORQUE 20 N m 2 0 kgf m 151bHt With the front brake applied pump the front suspension up and down several times to seal the axle shaft and check the front brake operation Be sure the ...

Page 377: ...VAL Remove the front wheel page 14 10 Remove the holts and brake hose clamp Remove the brake caliper mounting bolts and front brake caliperlbracket assembly Do not suspend the brake caliperlbracket assembly from the brake hose Do not twist the brake hose Do not operate the brake lever after removing the caliper bracket assembly and front wheel To do so will cause difficulty in fitting the brake di...

Page 378: ...around the center bolt Remove the valve cap Check the fork air pressure SPECIFIED AIR PRESSURE 13 230 kPa 2 3 kgf emi 33 psi 14 240 kPa 2 4 kgf cmZ 35 psi With specified air pressure applied measure the length between the axle holder and outer tube and record it Release the air pressure by depressing the valve center III I 13 14 loosen the inner damper while holding the fork damper iI Iiiiii 7 1 u...

Page 379: ... oosen the fork bottom bridge pinch boilS and pull the fork leg down and out DISASSEMBLY Cle n Ihe fo k a embly the lldlng unace of the fo I 09 12 slider and bottom of the slider around the center bolt before disassembling the fork Measure the length between the axle holder and Quter lube and record it before disassembling the font FORK DAMPER Tum the rebound and compression damping adjusters 09 h...

Page 380: ...per Do not over tighten the vise 011 the axle Set the axle holder of the fork slider in a vise with a piece of wood or soft Jaws to avoid damage BOLT Loosen the fork center bolt 09 12 Push the fork damper oul from the slider until the fork center bolt lock nut is fully exposed and install the piston base or mechanic s stopper 1001 between the axle holder and fork center botllock nut If 9 Jiston ba...

Page 381: ... damper Remove the O ring and sealing washer from the fork center boll 13 14 Push Ihe fork damper Qut from Ihe slider unlillhe fork center bolt lock nut is fully exposed Hold the fork center bolt lock nul using the 15 mm 9 16 in open end wrench and remove the fork center bolt from Ihe fork damper Remove Ihe O ring and sealing washer from the fork center bolt Remove the push rod from Ihe piston rod...

Page 382: ...centerbolt Jock nut and fork center bolt ho a Remove the fork damper assembly from the fork assembly Remove the D ring from the fork damper assembly Remove the fork assembly from the vise 09 12 Remove the fork spring from the fork assembly 1 12 Remove the snap ring and collar 14 22 09 12 FORK DAMPER ASSEMBLY SPRING 13 14 FORK DAMPER ASSEMBLY 11 PISTON BASE D RING FORK ASSEMBLY D RING FORK ASSEMBLY...

Page 383: ... AND FORK SLIDER DISASSEMBLY Remove the dust seal and stopper ring Check that the fork slider moves smoothly in the outer tube If it does not check the fork slider for bends or damage and slider bushings for wear or damage page 14 26 Using quick successive motions pull the fork slider oul of the outer tube 09 12 SPRING DUST SEAL STOPPER RING 14 23 ...

Page 384: ... GUIDE BUSHING SLIDER BUSHING 11 1 4 BACK UP RING GUIDE BUSHING COLLAR SUDER BUSHING 09 12 Set the fork damper in a vise with a piece of wood or soft jaws to avoid damage 09 12 FORK DAMPER Hold the fork damper using the special tool TOOL Fork cap bolt holder 36 mm 070MB MEN0100 or 010MB MENA100 U S A only loosen the fork cap assembly using the special tool while holding the fork damper TOOL Lock n...

Page 385: ...not disassemble the fork cap assembly Replace the fork cap as an assembly if it IS damaged Be careful not to damage the fork cap bushings 09 0 09 shown FORK _ tPISTON ROD 09 shown O RINGS BUSHINGS C09 10 13 14 O RINGS 13 14 Remove the air valve and O ring from the fork cap 3 4 assembly AIR VALVE If the air valve is removed replace the air valve and O ring as a sel 14 25 ...

Page 386: ... Replace Ihe spring seat collar as an assembly if necessary FORK CAP ASSEMBLY Check Ihe fork cap assembly for damage Check the spring for fatigue or damage Replace the fork cap as an assembly if necessary 09 10 Check the fork cap bushings for excessive wear or scratches replace them if necessary Check the compression damping adjuster for clicks 14 26 09 12 09 shown 09 shown FORK DAMPER SPRING SEAT...

Page 387: ... score marks scratches and excessive or abnormal wear Check the outer lube for damage or bends Replace the outer tube if necessary Sellhe fork slider on V blocks and measure the runout Tum the fork slider and measure the runout using a dial indicator Actual runout is 1 2 of the lotal indicator reading SERVICE LIMIT 0 2 mm 0 01 in Do not reuse the Replace if the service limit is exceeded or there a...

Page 388: ...e replace the slider and guide bushings Replace the back up ring if there is distortion al the points shown Remove any metal powder from the fork slider and guide bushings with a nylon brush and fork oil FORK DAMPER Check the fork damper for bends or damage Check the piston rod for bends wear or damage Check the fork damper operation by pumping the piston rod If the operation is not smooth fill th...

Page 389: ...G fORK CENTER BOLT II IIDUST SEAL 11 12 I GUIDE BU SHIING 8BACK UP PUSH ROD 1ftQILSEAL 8 O R NG FORK SPR lNG OUTER TUBE FORK DAMPER PLUG BOLT RING I FORK CAP ASSEMBLY O RINGS 1118 LJ O RIN GS a SPRING SEAT COLLAR PLUG BOLT RINGI1I FORKCAP g ASSEMBLY O RINGS 1118 O RING 8 SEALING WA SHER 1IIJf __ SPRING SEAT COLLAR _ FORK CENTER BOLT RING WEAR RING 8S DUST SEAL RING 14 29 ...

Page 390: ...fork oil seal and dust seal lips with recommended fork oil page 14 33 Install the dust seal and stopper ring onto the fork slider Install Ihe oil seal onto the fork slider with its marked side facing the dust seal Remove Ihe tape from Ihe end of the 011 slider I g DUST OIL SEAL 09 10 Install the bad up ring guide bushing and slider z M bushing GUIDE 14 30 NOTE Be careful not to damage the slider b...

Page 391: ...E BUSHING Coat the guide bushing and slider bushing with 09 10 shown recommended fork oil page 14 33 and install the fon slider into the outer tube Drive in the guide bushing together with the back up O Il S EA L ring 11 14 back up ring and collar into the outer tube using the special tool Drive the oil seal into the outer lube using the special tool TOOL Fork seal driver 48 2 x 58 mm 070MO MEN010...

Page 392: ...L Fork seal driver 48 2 x 58 mm 070MD MEN0100 or 070MD MENA100 U S A only FORK DAMPER REFILLING ASSEMBLY RING Jr Fs t RKSEAL DRIVE1 13 14 Apply fork fluid to a new O ring and install it into a new 1 3 3 1 l air valve groove I AIR VALVE Inslalilhe air valve to the fork cap and lighten it to the fII specified torque TORQUE 5 8 N m 0 6 kgf m 4 3 IbHt 14 32 1 ...

Page 393: ...end the piston rod to its ma imum length Pour the recommended fork oil into the fork damper RECOMMENDED FORK Oil KYB 01M KYB STANDARD OIL CAPACITY 09 10 211 cml 7 1 USaz 7 4 Imp oz 11 12 215cml 7 3 USoz 7 6Impoz 13 353 eml 11 9 US OZ 12 4 Imp 0 14 355 cml 12 0 US OZ 12 51mp oz 09 12 a RIN GS It _ 71 II BU H GS 09 10 a 13 14 _____ a R NGS a FORK FORK DAMPER Pump the piston rod slowly several times ...

Page 394: ...fork cap assembly to the specified torque using the special 1001 while holding the fork damper TOOL ForX cap bolt holder 36 mm 070MB MENDi00 or FORK CAP frY BOlTHOlDER 070MB MENA100 LOCK NUT WRENCH U S A only TORQUE 28 N m 2 9 kgf m 211bHt 13 14 Hold the fork damper using the special tool 13 14 FORK CAP 14 34 TOOL Lock nut wrench 49 mm 070MA MENDi00 or 070MA MENA100 U S A only Temporarily tighten ...

Page 395: ...e The following amount of fork oil will remain in the fork damper REMAINING OIL AMOUNT 09 10 201 em 6 8 US oz 7 1 Imp oz 11 12 205 cml 6 9 US oz 7 2 Imp oz 13 343 cml 11 6 US OZ 12 1 Imp oz 14 345 cml 11 7 US OZ 12 1 Imp oz Blowout the oil off completely from the fork damper Drain the extra fork oil from the oil holes of the fork damper FORK DAMPER OPERATION INSPECTION Make sure the compression da...

Page 396: ...ound and release the piston rod then check that the piston rod extends to its maximum length 13 14 Wipe off any oil complelely from the fork damper Compress the piston rod and stroke so that the protruding length of piston rod is 50 150 mm 2 0 5 9 in as shown There should be no oil leaking from the fork damper and piston rod If oil leaks from the fork damper or piston rod replace the fork damper a...

Page 397: ...C 32 F 30 C a6 F i f 120 1 minutes 13 14 00C 320F J to C 50 F 1 2O C 68 F _ _ 3D C B6 F r t 20 1 120 _ Invef1ed lime minutes If the fork damper has nol been disassembled from the r outer tubelfork slider tum it upside down for FORK DAMPER OUTER TUBE FORK SUDER 09 12 20 minutes and drain the fork oil from the inside of the Quter tube and fork slider completely Og 12 15 8 cc at 20 C 68 FI 13 14 21 6...

Page 398: ...lock nut fully and measure LO C K N U T the length between the fork center bolt lock nut end and piston rod end as shown STANDARO 16 18 mm 0 6 0 7 in Wipe off any oil completely from the fork damper 09 I I Apply recommended fork oil page 14 33 to the bushing 09 shown BUSHING 6 09 11 II Install the spring seal rollar to the fork damper SPRING SEAT COLLAR 11 12 Instalilhe coliar and snap ring 11 14 ...

Page 399: ...stall the piston base or mechanic s stopper tool between the axle holder and fork center bolt lock nul TOOL Piston base Fork rod stopper 07958 2500001 or 07AMB KZ3A100 U S A only 13 14 Push the fork damper oul from the slider untillhe fork center bolt lock nut is fully exposed Install the push rod into the piston rod until it stops Measure the length between the fork center bolt lock nut end and p...

Page 400: ...olt by hand unlillhey touch Tighten the fork center bolt lock nul to the specified torque using the 15 mm 9f16 in open end wrench TORQUE 29 N m 3 0 kgf m 21 IbHt 09 12 Remove the piston base or mechanic s stopper tool Be careful not to damage Ina fori centerbolt lock nut and fori center bolt hole 14 40 between the axle holder and fork center bolt lock nut while pushing the fork damper Clean and ap...

Page 401: ...Pour the recommended fork oil into the outer tube capacity is the same in both forlc legs RECOMMENDED FORK OIL KYB 0iM KYB STANDARD FORK Oil CAPACITY 09 12 350 em 11 8 US OZ 12 31mp oz 10 11 355 em 12 0 US OZ 12 5 Imp oz 13 245 em 8 3 US OZ 8 6 Imp oz 14 242 em 8 2 US OZ 8 Slmp oz MaXirnum fork oil capacity 09 11 Slighily sliffer near 362 em 12 2 US oz 12 7 Imp oz full compression j 12 357eml 12 1...

Page 402: ...wrench 0 tight9ll the fork TOOL damper it cookJ be Lock nut wrench 49 mm 070MA MEN0100 or 070MA MENA100 U S A only damaged Refer to torque wrench reading information in SERVICE INFORMA nON page 14 5 13 14 TORQUE Actual 30 N m 3 1 kgf m 22 IbHt Indicated 27 N m 2 8 kgf m 20 IbHt When the fork cap was removed from the damper tighten the fork cap to the specified torque while holding the damper with ...

Page 403: ...nd disassembly they should be same length If the length at assembly is longer than al disassembly check the fork center boll and fork center bolt lock nut installation STANDARO POSITiON Loosen the bottom bridge pinch bolts 09 12 For ease when releasing the air pressure after the forks are installed position the fork outer tubes so the plug bolts are in front of the compression adjusters 13 14 For ...

Page 404: ...fork protector mounting bolts Tighten the fork protector mounting bolts to the specified torque TORQUE 7 0 N m 0 7 kgf m 5 2IbHt Install the front brake caliperlbracket assembly and new brake caliper mounting bolls Tighten the front brake caliper mounting bolts to the specified torque TORQUE 30 N m 3 1 kgf m 22 IbHt Instalilhe brake hose clamp and bolts Tighten the bolts securely Instalilhe front ...

Page 405: ...ose Do not twist Ihe brake hose Do not operate the brake lever after removing Ihe caliperlbrackel assembly and front wheel To do so will cause difficulty in fitting the brake disc between Ihe brake pads Remove Ihe fori protector mounting bolls and fork i i jiiiii protector loosen the fork lop bridge pinch bolts When the fork is ready to be disassembled tum Ihe rebound and compression damping adjus...

Page 406: ...A only Air Fork Pump 0 60 psi 07AMJ MENA300 With specified air pressure applied measure the length between the axle holder and outer tube and record it Remove the valve cap and release the air pressure by depressing the valve center Loosen the fori cap but do not remove it yet Loosen the fork bottom bridge pinch bolts and pull the fork leg down and out DISASSEMBLY Remove the fork cap from the oute...

Page 407: ... fork oil from the fork assembly by pumping the piston rod several times Set the axle holder of the fork slider in a vise with a piece of wood or soft jaws to avoid damage Remove the fork center bolt TOOLS Fork Damper Holder Handle Holder Attachment 30 mm 07TMB 001010A 070MB MEN0200 or 070MB MENA200 U S A only LOCK NUT ATTACHMENT HOLDER HANDLE CENTER BOLT 14 47 ...

Page 408: ...age and slider bushings for wear or damage page 14 26 DUST FORK DAMPER STOPPER RING Using quick successive motions pull the fork slider oul of the outer tUbe FORK SLIDER OUTER Do 001 damage the Carefully remove the slider bushing by prying the slot D U S T S E A L sJiderbushing with a screwdriver untillhe slider bushing can be pulled BACK UP RING especially the off by hand sJK1ing surface To Remov...

Page 409: ...ssary Check the adjuster for clicks Replace the fork cap as an assembly jf necessary Apply fork oil to a new O ring and install it into a new air valve groove Inslall the air valve to the fork cap and tighten it to the specified torque TORQUE 5 5 N m 0 6 kgf m 4 1 Ibf ft FORK SLIDER OUTER TUBE Check the outer lube and fork slider for score marks scratches and excessive or abnormal wear Check the o...

Page 410: ... BUSHING GUIDE BUSHING BACK UP RING FORK SUDER Check the slider and guide bushings for excessive wear r B U S H N G or scratches 14 50 If copper appears on the surface replace the slider and guide bushings Replace the back up ring if there is distortion at the points shown Remove any metal powder from the fork slider and guide bushings with a nylon brush and fork oil FORK DAMPER Check the fork dam...

Page 411: ...slider and oil passage with tape Coat new fork oil seal and dust seal lips with recommended fork oil page 14 33 Install the dust seal scraper and stopper ring onto the r fork slider Install the oil seal onto the fork slider with its marked side facing the dust seal Remove the tape from the end of the fork slider DUST SEAL SIDE t RING SCRAPER O LSEAl 8 Inslall the collar back up ring guide bushing ...

Page 412: ... into the outer lube using the special tool TOOL Fork seal driver 48 2 58 mm 070MD MEN0100 or 070MO MENA100 COLLAR U S A only BACK UP RING GUIDE BUSHING Inslallthe stopper ring into the groove in the outer tube l rF O R K S EAfL D R V E R l Drive the dust seal with the scraper into the outer tube I using the special tool TOOL Fork seal driver 48 2 II 58 mm 070MD MEN0100 or 070MD MENA100 U S A only...

Page 413: ...n the fork center bolt fully by hand Hold the fork damper using the special tools and tighten the fork center boll to the specified torque TOOLS Fork Damper Holder Handle Holder Attachment 30 mm 07TMB 001010A 070MB MEN0200 or 070MB MENA200 U S A only TORQUE 43 N m 4 4 kgf m 321bHt FORK OIL LEVEL OIL CAPACITY ADJUSTMENT HOLDER HANDLE Lower the outer tube slowly untillhe dust seal seats the 0 U T E ...

Page 414: ...4 0 08 in If the clearance is out of specification check the fork cap and lock nut installation Apply fork oil to a new 0 rin9 and install it to the fork cap groove Tighten the lock nul to the fork cap closely by hanc Hold the fork cap and tighten the lock nullo the specified torque TORQUE 29 N m 3 0 kgf m 21 IbHt Pull the outer tube up slowly and install it to the fork cap Temporarily install the...

Page 415: ...psi 07AMJ MENA300 or 07AMJ KRNA100 Cover the fork leg with shop towel to prevent fork damage Compress the outer tube 150 mm 5 9 in from fully extended position Repeat above procedure about 10 times Release the P F air pressure Remove the fork cap using the following procedures Temporarily install the fork leg through the bottom and top bridges Tighten the bottom bridge pinch bolts to the specified...

Page 416: ...m 4 4 inqsli9htlYSOfter 630 6 cm3 2 1 3 US oz near full 22 2 Imp oz compression After 15 108 mm 4 3 in 636 0 em 21 5 US OZ 22 4 Imp oz Be sure the oil level is the same in both fork legs Always use the after market syringe while adjusting the all level If it Isn t used air may get Into the fork If a syringe is not available first set the all level somewhat lower than the normal level then add smal...

Page 417: ... pinch bolts to the specified torque TORQUE 20 N m 2 0 kgf m 151bHt FORK CAP ILOCK NUT When the fork leg has been disassembled perform the following Tighten the fork cap to the specified torque TORQUE 45 N m 4 6 kgf m 33 IbHt Adjust the PSF air pressure as specified SPECIFIED AIR PRESSURE 240 kPa 2 4 kgf cm2 35 psi TOOL U S A only Air Fork Pump O fiO psi 07AMJ MENA300 or 07AMJ KRNA100 Measure the ...

Page 418: ...e lop surface of the lop bridge with the outer lube upper surface as shown Tighten the bottom bridge pinch bolts to the specified torque TORQUE 20 N m 2 0 kgf m 151bHt Tighten the top bridge pinch bolls to the specified torque TORQUE 22 N m 2 2 kgf m 161bHt I NOTICE I Over tightening the pinch bolts can deform the outer tube A deformed outer tube must be rep sced Install the foOt protector and new...

Page 419: ...per surface of the clamp Tighten the bolts securely Inslall the front wheel page 14 16 Inspecllhe wear rings for wear or damage Replace the wear ring if it is 1 5 mm 0 06 in or flat with the Quter lube Make sure the wear ring end gaps face rearward HANDLEBAR REMOVAL Remove the number plale page 3 6 After 14 Remove the engine mode select switch indicator page 6 76 from the handlebar Remove the hand...

Page 420: ...master cylinder holder l the hydraulic line and master cylinder I Keep the brake master cylinder upright to prevent air from entering the hydraulic system 14 60 Remove the throttle housing as an assembly as follows Loosen the throttle housing bolts turn the handlebar to the right fully then remove the throttle housing If you will disassemble the throttle housing remove the throttle housing dust co...

Page 421: ...handlebar lower holder nuts FRONT WHEEUSUSPENSION STEERING PIPE THROTIlE Remove the bolls upper holders and handlebar Remove the lower holder nuts washers bushings and rBOLTS UPPER lower holders INSTALLATION Install the bushings lower holders washers and lower L O W E R H O L O E R holder nuts as shown standard position Jj r rc F ORWARD BUSHINGS WASHER 14 61 ...

Page 422: ...on the handlebar with the top surface of the lower holders Install the upper holders with its punch mark facing forward Install and lighten the front side bolls first then the rear side bolts to the specified torque TORQUE 22 N m 2 2 kgf m 161bHt Tighten the lower holder nuts to the specified torque TORQUE 44 N m 4 5 kgf m 32 IbHt If the handlebar grips are removed apply Honda Bond A or Pro Honda ...

Page 423: ... cable bolt to the specified torque TORQUE 4 0 N m 0 4 kgf m 3 0 IbHt Install the throttle housing aligning the end of the housing with the paint mark on the handlebar Tighten the throttle housing upper boll first then the lower bolt Adjust the throttle grip freeplay page 4 8 Inslall the brake master cylinder and holder with the M A S T E R l UP mark on the holder facing up I Align the end of the ...

Page 424: ...with the paint mark on the handlebar as shown Tighten the engine slop switch screw to the specified torque TORQUE 1 5 N m 0 2 kgf m 1 1IbHt Clamp the engine stop button wire with the wire bands After 14 Install the engine mode select swilchlindicalor page 6 76 Install the handlebar pad Adjust the clutch lever freeplay page 4 30 REMOVALIINSTALLATION Remove the number plate page 3 6 09 12 Remove the...

Page 425: ...ge 14 64 Visually inspect the steering damper for wear or damage Check the follOWIng Damper case for deformation or oil leakage Damper rod for bending or damage Replace the damper case or damper rod if necessary Fully extend and compress the damper rod by hand Release the damper rod then check that it extends to its maximum length STANDARD maximum length 117 55 118 35 mm 4 628 4 659 In Check the d...

Page 426: ...the damper mounts C O LLA R C S T O P P E R R N G evenly do not allow using the special 1001 it atilt 14 66 TOOL Collar 07KPF VD60100 Install a new stopper ring into the groove of the damper mounts securely SPHERICAL BEARING Set a 7 mm boll and nut to the spherical bearing as 7 m m BO LT shown Check for smooth operation of the spherical bearing Install the steering damper page 14 64 U S A only Rem...

Page 427: ... pressure of the ise to gently press the bearing back into place Install the stopper ring into the groove of the damper mount securely lnslalilhe steering damper page 14 64 HPSO DISASSEMBLY ReconJ the Remove the steering damper page 14 64 damping force adjuster position Clean the damper assembly thoroughly Install a 4 mm screw to the end cap Remove the snap ring while pushing the end cap and then ...

Page 428: ...crew 10 Ihe free piston then remove the free piston and O ring Drain the damper oil from Ihe damper case Remove the plug bolt and O ring Remove Ihe adjuster piece from the damper case 8mmSCREW 09 shown O RING 09 shown t O RING FREE PISTON PLUG BOLT PIECE ...

Page 429: ...arefully pull the damper rod and rod guide with the O ring out of the damper case Check the following Rod guide for abnormal scratches Damper piston ring for fatigue or damage Damper case inner surface for abnormal scratches Replace the damper case jf necessary Replace the damper rod as an assembly if necessary 09 shown SNAP RING SNAP RING DAMPER ROD 09 shown ROO a RING ROO GUIDE 14 69 ...

Page 430: ...11 FREE PISTON SNAP RING O RING fI 1 RETURN SPRING 1111 IISNAP RING O RING f l l Check thai the Pour recommended damper oil into a suitable container damperol until the steering damper is fully submerged temperature Is 2O C 68 F RECOMMENDED DAMPER OIL 14 70 09 10 Pro Honda HP Fork Oil5W or equivalent After 10 Pro Honda HP Fork 0 11 55 19 Check the damper oil for contamination Do not allow foreign ...

Page 431: ...round the damper rod sliding surface DAMPER ROD O RING S Bleed any air out from the damper case and damper piston following the procedure below In oil DAMPER PISTON I 1 Install the damper piston into the damper case pump the damper rod quickly NOTE To open the piston valve pump the piston rod quickly 2 Remove the damper piston from the damper case 3 Bring any air out from the damper case by using ...

Page 432: ...mper case In oil In oil O RING f 1 F R E E P IS T O N Keep the damper Install the adjuster piece into the threads of Ihe damper r In oil assy submerged in case and thread it one turn oil 1 turn ADJUSTER PIECE Check that the damper rod is fully extended to its In oil maximum length Bleed any trapped Install a new O ring to Ihe plug bolt air aI he O n ng seating surface by turning the O ring Make su...

Page 433: ... 31 9 mm 1 23 1 26 in at oil temperature 20 C 68 F Measure the oil temperature If measured temperature is other than 20 C 68 F refer to the oil chart page 14 73 If the measured depth is other than the standard length disassemble the steering damper and start over The depth of the free piston wiJl change according to the oillemperature as shown 09 10 unit mm in Depth Max Standard Min 0 32 2B B 1 13...

Page 434: ...y trapped air reassemble the steering damper Install the damper rod side spherical bearing page 14 66 Out of oil DAMPER ROD Measure the Measure the length between the spherical bearings as 0 0 0 damper rod length shown 4 659 In wi hlhelnsklejaws S35f 1f11l4 62S ofa vemiercaliper STANDARD Fully compressed damper rod length 1 55 _1 3 _ 3 1 5 I 93 55 94 35 mm 3 683 3 715 in 9435f11f11l 3 6 14 74 Full...

Page 435: ...B R D G E Ii stem Remove the steering stem nut and washer Remove the fork legs page 14 17 Remove the fork top bridge Remove the steering stem adjusting nut using the I11111 I11111 IIIIIIIIIIIIIIIIIIIIIIII special tool TOOL Steering stem socket 07916 3710101 or 07702 020001 U S A only Remove the upper dust seal upper tapered roller l bearing and steering stem I Check the bearings and outer races fo...

Page 436: ...x 16 thread 07741 0010201 or 07936 371020A U S A only 07JAC PHB0200 not available In U S A 07YAC 010102 07YAC 001A200 and Commercially available slide hammer 318 In x 16 thread Install a new lower outer race bearing race installers LO W E R O U T E R RA C E and installer shaft as shown Hold the shaft with a wrench and tum the installer to install the lower outer race TOOLS Bearing race Installer 2...

Page 437: ... nul onto the stem to prevent the threads from being damaged when removing the lower tapered rolier bearing from the steering stem Remove the lower tapered roller bearing with a chisel or equivalent lools being careful nol to damage the steering stem Remove the dust seal Apply specified grease page 1 21 to the lips of a new dust seal and install it over the steering stem Install a new lower tapere...

Page 438: ...steering head bearing rolling area and new upper dust ii Insert the steering stem into the steering head pipe and install the following while holding the stem Upper tapered roller bearing Upper dust seal Inslallthe steering stem adjusting nut Tighten the steering stem adjusting nut to the specified torque using the special tool while holding the steering stem TORQUE 29 5 N m 3 0 kgf m 221bHt TOOL ...

Page 439: ...tem socket 07916 3710101 or 07702 0020001 U S A only Recheck Ihallhe steering slem moves smoothly without play or binding InslaUthe following Fork top bridge Fork legs page 14 42 Washer and steering stem nul Tighten the steering stem nul to the specified torque TORQUE 108 N m 11 0 kgf m 80 Ibf ft Recheck the steering stem adjustment before installing the removed parts Install the remaining removed...

Page 440: ... lever to the clutch lever bracket Apply grease to the clutch lever pivot bolt sliding surface Install and lighten the dutch lever pivot bolt to the specified torque TORQUE 2 0 N m 0 2 kgf m 1 5 IbHt loosen the clutch lever pivot bolt to 450 go Install and lighten the clutch lever pivot nul to the specified torque while holding the clutch lever pivot bolt TORQUE 10 N m 1 0 kgf m 7lbHt Adjust the c...

Page 441: ...15 REAR WHEEUSUSPENSION COMPONENT LOCATION 15 2 SHOCK ABSORBER 15 14 SERVICE INFORMATION 15 3 SHOCK LINKAGE 15 38 TROUBLESHOOTING 15 7 SWINGARM 1543 REAR WHEEL 15 8 15 1 ...

Page 442: ...REAR WHEEUSUSPENSION COMPONENT LOCATION 09 shown 44 N m 4 5 32IbHt 12 N m 1 2 9 lbHt 53 N m 5 4 39 IbHt 53 N m 5 4 kgf m 391bHt Nm Ifm 39 lbfftl 128 N m 13 1 15 2 ...

Page 443: ...nal rear wheel sprockets drive chain shock springs and pin spanners are available For optional parts page 1 46 For brake system information page 16 4 Use genuine Honda replacement bolts and nuts for all suspension pivot and mounting points After the rear wheel installation check the brake operation by applying the brake pedal SPECIFICATIONS t mm in I gp 5 L iMiT 2 I m Radial 0 chain 2 0 0 08 Slack...

Page 444: ...5 4 128 N m 13 1 kgf m 94 IbUt 32 N m 3 3 kgf m 24Ibf ft 16 N m 1 6 kgf m 12Ibf ft 44 N m 4 5 kgf m 32 IbUt 44 N m 4 5 kgf m 32 tbHt 44 N m 4 5 kgf m 32 Ibf ft 26 N m 2 7 kgf m 191bHt 30 N m 3 1 kgf m 221bHt 30 N m 3 1 kgf m 22Ibf ft 28 N m 2 9 kgf m 21 tbf ft 12 N m 1 2 kgf m 9Ibf ft 53 N m 5 4 kgf m 39 IbHI 53 N m 5 4 kgf m 39 Ibf ftl 53 N m 5 4 kgf m 39 IbUt 88 N m 9 0 kgf m 65 IbHt 12 N m 1 2 ...

Page 445: ...ent 40 x 42 mm 07946 1870100 07746 0010900 EJ Pilot 19 mm 07746 0041400 j L pilot 25 m m I 774S 0040600 C Pilot 20mm 07746 0040500 Bearing remover head 25 mm 07746 0050800 REAR WHEEUSUSPENSION Driver 07749 0010000 Attachment 24 x 26 mm 07746 0010700 fl Pilot 22 rnm 07746 0041000 Bearing remover shaft 07GGD OO10100 i 15 5 ...

Page 446: ... available in U S A Bearing Remover 20 mm 07936 3710600 15 6 Retainer wrench body 07710 01Q401 Collar 23 x 17 mm 07GMD KTBA110 U S A only Remover Handle 07936 3710100 Pin spanner 2 required 07702 020001 or Pin spanner A 89201 KSS 810 2 required Attachment 30 mm 1 0 07746 0030300 Remover Weight 07741 0010201 07936 3710200 U S A only ...

Page 447: ...sufficient lire pressure Steers to one side or does not track straight Bent axle shaft Axle alignmenUchain adjustment not equal on both sides Rear wheel wobbling Bent rim Worn wheel bearings Bent spokes Unbalanced lire and wheel Faulty tire Insufficient tire pressure Faulty swingarm pivot bearings loose axle nul loose suspension fasteners Rear wheel turns hard Faulty wheel bearings Bent axle shaft...

Page 448: ...l forward to derail the drive chain from the driven sprocket Do not operata the Remove the axle shaft adjusting blocks and rear bnJke pedal after wheel remoVing the resr wheel 15 8 INSPECTION AXLE SHAFT RUNOUT Set the axle shaft on V blocks and measure the runout Tum the axle shaft and measure the runout using a dial indicator Actual runout is 1 2 of the lotal indicator reading SERVICE LIMIT 0 2 m...

Page 449: ...ry page 15 9 bearings as B sel WHEEL RIM RUNOUT REAR WHEEUSUSPENSION I I I S Check the rim runout by placing the wheel on a truing stand Spin the wheel by hand and read the runDut using a dial indicator SERVICE LIMITS Radial 2 0 mm 0 08 in Axial 2 0 mm 0 08 in Check the spokes and tighten any that are loose DISASSEMBLY Remove the right and left side coliars Remove the following Brake disc bolts an...

Page 450: ...body 07YMA KZ40100 or 07HMA KS70100 U S A only 07710 0010401 Replace the wheel lnstalilhe remover head into the bearing bearings 8S a sal From the OPPosite side Install the remover shaft and Do not reuse old drive the bearing out of the wheel hub bearing Remove the distance collar and drive out the other bearings 15 10 TOOLS Bearing remover head 25 mm Bearing remover shaft 07746 0050800 07GGD 0010...

Page 451: ...on a work bench Place the hub in the center of the rim and begin lacing with new spokes Adjust the hub position so the distance from the hub left end surface to the side of the rim is as specified 09 12 45 5 1 0 mm 1 79 0 04 in After 12 50 0 1 0 mm 1 97 0 04 i _ 1 _ J Tighten the spoke in two or three progressive steps iiiii r page 4 42 Install the rim lock setting rubber tube and tire Tighten the...

Page 452: ...e tools Drive the inside left wheel bearing with the sealed side facing down Drive the outside left wheel bearing with the sealed side facing up Install and lighten a new bearing retainer to the specified torque using Ihe special toots TOOLS Retainer wrench 48 mm Retainer wrench body 07YMA KZ40100 or 07HMA KS70100 U S A only 07710 010401 TORQUE 44 N m 4 5 kgf m 321bHt Peen the edge of the retainer...

Page 453: ...ft REAR WHEEUSUSPENSION Check the right and left side collars for wear or damage 1 Replace them if necessary Install the right and left side collars INSTALLATION Place the rear wheel into the swingarm carefully r aligning the brake disc between the brake pads Install the drive chain over the driven sprocket Apply a thin coat of grease to the axle shaft sliding surface Install the adjusting blocks ...

Page 454: ...assemble the shock absorber loosen the spring adjuster lock nut TOOLS Pin spanner Pin spanner A 07702 0020001 2 required or 89201 KS6 810 2 required Raise the rear wheel off the ground by placing a workstand or equivalent under the engine Remove the upper mounting boll and nut Remove the shock absorber lower mounting bolt nut and shock absorber LOCK NUT ...

Page 455: ...o record the number of turns from the COMPRESSION l OW ADJUSTER starting position Set the shock absorber upper mount in a vise with a piece of wood or soft jaws to avoid damage l oosen the spring lock nul and spring adjusting nut TOOLS Pin spanner Pin spanner A 07702 020001 2 required or 89201 KS6 810 2 required Slide the rubber stopper while it is fully sealed to the damper case REBOUND ADJUSTER ...

Page 456: ...s Oul when releasing the nitrogen from the reservoir Perform this procedure before draining the oil from the damper Point the valve Depress the valve core to release the nitrogen from the awa from you to reservoir prevent debris getting inyoureyes 15 16 AWARNING The chamber cap will be under significant pressure and could cause serious injury Release all nitrogen pressure before disassembly Wear p...

Page 457: ...eservoir to act as a ramp Now use the other screwdriver to pull the stopper ring completely oul Check the stopper ring groove for burrs STOPPER RING SHOP TOWEL Remove any burrs with a fine emery cloth before L _________________ removing the chamber cap out of the reservoir Set the shock absorber upper mount in a vise with a r S H O C K O l piece of wood or soft jaws to avoid damage Using a suitabl...

Page 458: ...e compression damping adjuster hole while slowly pulling the damper rod oul 4 Reinstall the compression damping adjuster after filling the damper NOTE The damper must be kept upright to prevent shock oil from leaking oul 5 Place the damper with the reservoir chamber cap facing up 6 Repeat steps 1 to 5 until the chamber cap is removed from the reservoir Remove the bladder from the chamber cap I NOT...

Page 459: ...pper ring is sealed in the groove all the way around or the chamber cap can come apart when riding the motorcycle Temporarily fill the reservoir with air slowly until the chamber cap seats against the stopper ring Make sure the chamber cap face is level with the reservoir face If the chamber cap does not seat fully the chamber cap may fly out when filling the reservoir with nitrogen Release the ai...

Page 460: ...on damping adjuster and O rings 12 Remove the compression damping adjuster collar spring and O rings Remove the spring seat 13 Remove the compression damping adjuster washers spring and D rings Remove the spring seal After 14 Remove the damping adjuster washer and O ring 15 20 NOTE Before disposal of the shod absorber release the nitrogen by pressing the valve core Then remove the valve core from ...

Page 461: ... and reservoir by pumping the damper rod In and out several times Sel the damper case in a vise with a piece of wood or soft jaws to avoid damage Remove the end piaIe and tape or tie it to the rubber stopper so it will nol get in the way Push in the rod guide case until you have good access to the stopper rlng REAR WHEEL SUSPENSION 15 21 ...

Page 462: ...ine emery cloth before pulling tile damper rod the damper rod out of the damper case piston ring 15 22 Carefully pull the damper rod assembly out of the damper case PISTON RING REPLACEMENT Inspect the piston ring If the piston ring is damaged cut the piston ring and replace it along with a new O rings DAMPER CASE ROD ASSEMBLY O RINGS PISTON RING Apply recommended shock oil page 15 31 to new 0 ring...

Page 463: ... damper rod end nut by hand so thai the 0 0 of the rod end is about 10 mm 0 4 in Be careful not to over file Tum the damper rod end nul back and forth in 1f4 turn increments until illoosens then rotate another 1f4 turn and repeallurning back and forth until the damper rod end nul loosens completely If the damper rod is cracked or damaged when removing the damper rod end nut replace the damper rod ...

Page 464: ... rings and piston ring The valve arrangement and number of valves shown is typical and may not represent this model exactly Remove the compression valves and valve stopper Chase the threads with a die and clean with shock oil Wrap the threads of the damper rod with tape Remove the rod guide case assembly from the damper cd Remove the O ring from the rod guide case PISTON VALVE STOPPER VALVES WASHE...

Page 465: ... Inspect the rod guide case metal If the metal is worn so that the copper surface appears replace the rod guide case with a new one COMPRESSION DAMPING ADJUSTER INSPECTION OIL SEAL DUST SEAL Inspect the compression damping adjuster After 14 r damping adjuster for wear scratches or damage 09 shown COMPRESSION ADJUSTER DAMPER ROD INSPECTION Inspect the damper rod sliding surface for damage or r dist...

Page 466: ...ess Disassemble them thoroughly dean them with solvent and blow them dry with compressed a r before assembly Use care to avoid getting so vent on the piston ring L V__ A LV __ E S T O P P E R ______W A S__ H E__ R S and O rings The valve arrangement and number of valves may differ from those shown 09 11 14 COMPRESSION VALVES LOCK NUT ADJUSTING NUT COMPRESSION ADJUSTER tEND NUT __ VE WASHERS VALVE ...

Page 467: ...RING r END PLATE Q _ 1n _SPRINGSEAT H WASHER LI SPRING SEAT wlRUBBER STOPPER 6 PISTON II D RIN S PIS roN RING DAMPER ROD I RUBBER SEAT LOCK NUT END NUT COMPRESSION VALVES VALVE STOPPER f ADJUSTING NUT VALVE STOPPER II COMPRESSION ADJUSTER WASHERS _ e REBOUND RUBBER WASHERS IoROD GUIDE CASE L CS Ie 0 e DUST SEAL 0 O D RING l e S 0 9 O STOPPER RING SPRING SEAT a RINGS e8 BLADDER d Q DAMPER CASE O VA...

Page 468: ...topper and end plate Apply recommended shock oil page 15 31 to a new O ring and install it 10 the rod guide case Apply recommended shock oil page 15 31 to rebound rubber oil seal lips and dust seal lips 09 shown II REBOUND RUBBER ROO i ASE DUST SEAL 0 O RING af I L _ STOPPER RING r END PLATE SPRING SEAT WASHER SPRING SEAT RUBBER STOPPER DAMPER Rool RUBBER SEAT RUBBER STOPPER RUBBER SEAT END PLATE ...

Page 469: ...on of the piston valves Do noI oller lighten the vise and dlstOft the shock mount Install the piston onlo the damper rod with its punch mark side facing up Install the rebound valves with their polished surfaces facing down I NOTICE Be careful not to bind the valves when installing the piston onto the damper rod Also check that thay are concentric with the damper rod Install the valve stopper and ...

Page 470: ...e with a piece of wood or soft jaws to avoid damage Coat the damper case inner surface and piston ring with recommended shock oil page 15 31 and insert the damper rod assembly carefully Sel the damper case in a vise with a piece of wood or M J soft Jaws to avoid damage I Install the stopper ring into the groove in the damper case After assembly check that the stopper ring is sealed in the groove o...

Page 471: ...OCK OIL KHV10 K2C KYB STANDARD OIL CAPACITY 09 12 420 emJ 14 2 US OZ 14 8 Imp oz After 12 400 em 13 5 US oz 14 1 Imp oz Slowly pump the damper rod until there are no bubbles in the shock oil that overflows from the damper case Do not leI oil flow Remove the damper unit from the vise while holding the out of fhe reservoir compression damping adjuster hole facing up After 14 Coat a new O rings with ...

Page 472: ...om the reservoir completely When bleeding air from the reservoir be careful to hold the damper at the angles shown so the filler hole points up Temporarily charge the reservoir with 49 kPa 0 5 kgf cm2 7 1 psi of air slowly to inflate the bladder Check for any shock oil thai may leak out of the valve while pressurizing Replenish oil as necessary SHOCK OIL ...

Page 473: ...mpression damping adjuster Slowly install the spring and washers After 14 Apply shOCk oil to a new D ring and install It to a new damping adjuster Slowly install the washer 09 11 14 Dip the compression damping adjuster After 14 12 damping adjuster in clean shock all II filii Slowly Install the compression damping adjuster After 14 damping adjuster Tighten the compression damping adjuster After 14 ...

Page 474: ...ze the shock absorber Install the valve cap VALVE CAP Install the shock absorber spring with its paint mark side C j j S E A T I 09 shown small 0 0 side facing toward the lower mount 15 34 Install the spring seat washer Install the spring seat while compressing the shock absorber spring Slide the rubber stopper while it is fully seated to the rubber seat Tum the shock absorber lower mount so the r...

Page 475: ...ow STANDARD SPRING LENGTH 09 12 249 5 mm 9 82 In 13 251 0 mm 9 88 in 14 15 252 5 mm 9 94 in After 15 251 0 mm 9 88 In Hold the spring adjusting nut and lighten the spring adjuster lock nut to the specified torque TORQUE 28 N m 2 9 kgf m 211bHt Use this standard spring length as the baseline See the Owner s Manual for detailed instructions on adjusting preload and damping for riding conditions and ...

Page 476: ...t seals from the upper mount Check the spherical bearing for wear or damage If it is worn or damaged it must be replaced 09 shown COMPRESSION LOW ADJUSTER After 14 COMPRESSION lOW ADJUSTER DUST SEALS Press the spherical bearing to get the clearance S TO P P E R R N G l necessary to remove the stopper ring using the special I tool TOOL Coliar 23 x 17 mm 07GMD KTSA110 Remove the stopper ring 15 36 ...

Page 477: ...ling area Press the spherical bearing into the upper moun TOOL Collar 23 x 17 mm 07GMD KT8A110 Install a new stopper ring into the groove of the upper S T O P P E R R N G l mount securely I Press the spherical bearing into the upper mount using the special tool until it seats against the stopper ring TOOL Collar 23 x 17 mm 07GMD KT8A110 86 sure to mstall Apply grease to new dust seal lips and insl...

Page 478: ... by aligning the flat side of the bolt with groove of the frame Install and lighten the shock absorber upper mounting nul to the specified torque TORQUE 44 N m 4 5 kgf m 32 IbHl 09 12 Install the sub frame page 3 7 After 12 Install the air cleaner housing page 6 61 SHOCK LINKAGE REMOVAL Remove the nut and lower drive chain roller Remove the following Shock absorber lower mounting bolt nul Shock ar...

Page 479: ...T COLLAR Remove the side collars pivot coliar and dust seals S H O C K L N K from the shock link SIDE COLLAR TOOLS Bearing Remover 20 mm Remover Handle Remover Weight INSPECTION 07936 3710600 07936 3710100 07741 010201 or 07936 371020 U S A only Check the collars for wear damage or fatigue Check the shock arm for cracks or damage Replace them if necessary Check the needle bearings for damage or lo...

Page 480: ... Attachment 30 mm 1 0 07949 3710001 07746 0010700 07746 0040500 07746 0030300 DRIVER SIDE COLLARS SHOCK LINK Press Ihe needle bearing shock absorber side out of iiii iii l the shock link using the special tools and a hydraulic I press TOOLS Driver Attachment 24 x 26 mm Pilot 19 mm Attachment 30 mm 1 0 07749 0010000 07746 0010700 07746 0041400 07746 0030300 Apply specified grease page 1 21 to new n...

Page 481: ...t the needle bearing surface is 3 0 3 2 mm 0 12 0 13 in below the end of the shock arm surface TOOLS Driver Attachment 24 26 mm Pilot 19 mm SHOCK LINK NEEDLE BEARING 07749 0010000 07746 0010700 07746 0041400 Remove the needle bearings from the shock link TOOLS Bearing Remover 20 mm Remover Handle Remover Weight 07936 3710600 07936 3710100 07741 0010201 or 07936 3710200 U S A only j 3 0 3 2 mm 0 12...

Page 482: ...de surfaces Inslall the pivot collars and side collars to the shock arm 0i swingarm side shock link side The shock link side pivot coliar is longer than the swingarm side pivot collar Q SHOCK ARM Apply specified grease page 1 21 to new dust seal lips O U S T S EA L and side collars Install the dust seals pivot collar and side collars rId Make sure the needle bearing rollers are in position before ...

Page 483: ...ng out After 11 Instat the lower drive chain roller with the slepped side facing out as shown Install and tighten the nullo the specified torque TORQUE 12 N m 1 2 kgf m 9lbHt SWINGARM REMOVAL Raise the rear wheel off the ground by placing a r l7 eKil Tir U r l workstand or equivalent under the engine I SWINGARM SIDE Remove the following Rear wheel page 15 8 Drive chain page 4 21 Brake pedal pivot ...

Page 484: ...s tnslallthe following Thrust washers Thrust needle bearings Pivot collars Dust seals Side collars Install the dust seal so thai the dust seal surface is 1 5 2 0 mm 0 06 0 08 In below the end of the swlngarm pivot surface as shown Inslalithe chain slider so its hole fits over the tab on the swingarrn DUST SEAL _ THRUSTNEEDILE BEARING g 1 5 2 0 mm 0 06 0 08 in 111 DUST SEALS g DUST SEAL g THRUST NE...

Page 485: ...swingarm Inslall and tighten the bolts nuls to the specified torque TORQUE 12 N m 1 2 kgf m 9 IbHt INSTALLATION Apply a thin coat of grease to the swingarm pivot bolt sliding surface Install the swingarm between the engine and frame install the swingarm pivot bolt from the right side through the frame swingarm pivot and engine Install the washer and swingarm pivot nut Tighten the swingarm pivot nu...

Page 486: ...rews Tighten the screws to the specified torque TORQUE 1 2 N m 0 1 kgf m 0 9 IbHt Apply molybdenum oil solution to the shock arm nut swingarm side threads and seating surface Install the shock arm bolt washer and nul swingarm side Tighten the nul to the specified torque TORQUE 53 N m 5 4 kgf m 39 IbHt Install the following Brake pedal pivot bolt page 16 30 Drive chain page 4 21 Rear wheel page 15 ...

Page 487: ... 2 FRONT MASTER CYLINDER 16 14 SERVICE INFORMATION 16 4 REAR MASTER CYLINDER 16 19 TROUBLESHOOTING 16 6 FRONT BRAKE CALIPER 16 22 BRAKE FLUID REPLACEMENT AIR REAR BRAKE CALIPER 16 25 BLEEDING 16 7 BRAKE PEDAL 16 29 BRAKE PADSIDISC 16 11 16 1 ...

Page 488: ...HYDRAULIC BRAKE COMPONENT LOCATION FRONT 9 9 N m 1 0 kgf m 7 3Ibf ft 34 N m 3 5 kgf m 25Ibf ft 09 shown 2 5 t 8IbHt 18N m 1 8 13Ibf tt 30 N m 3 1 kgf m 221bHt 16 2 ...

Page 489: ...HYDRAULIC BRAKE REAR 09 shown 18 N m 1 8 13lbnt 34 N m 3 5 25Ibf ft 34 N m 3 5 kgf m 251bHt 13 N m 1 3 kgf m 10 IbUt 36 N m 3 7 kgf m 271bHt 16 3 ...

Page 490: ... front reservoir is horizontal first A contaminated brake disc or pad reduces stopping power Oiscard contaminated pads and clean a contaminated disc with high quality brake degreaslng agent Check the brake system by applying the brake lever or pedal after the air bleeding Never allow contaminants dirt water etc to get into an open reservoir Once the hydraulic system has been opened or if the brake...

Page 491: ... ring pliers 07914 SASOOO1 34 N m 3 5 kgf m 25Ibf ft 5 9 N m 0 6 kgf m 4 4 IbUt 1 0 N m 0 1 kgf m 0 7 tbf ft 5 9 N m 0 6 kgf m 4 4lbHt 1 0 N m 0 1 kgf m O 7IbHt 9 9 N m 1 0 kgf m 7 3IbHt 30 N m 3 1 kgf m 22Ibf ft 5 4 N m 0 6 kgf m 4 0 Ibf ft 13 N m 1 3 kgf m 10 Ibf ft 1 0 N m 0 1 kgf m O 7Ibf ft 13 N m 1 3 kgf m 10 Ibf ft 22 N m 2 2 kgf m 16Ibf ft 12 N m 1 2 kgf m 9Ibf ft 22 N m 2 2 kgf m 16Ibf ft...

Page 492: ...piston Contaminated master cylinder Bent brake lever pedal Brake lever pedal hard Clogged restricted brake system Slickinglwom caliper piston Caliper bracket nol sliding properly rear Clogged restricted fluid passage Worn caliper piston seals Stickinglworn master cylinder piston Bent brake lever pedal Brake drags Contaminated brake pads disc Misaligned wheel Clogged restricted brake hose joint bol...

Page 493: ... be bled When using a commercially available brake bleeder follow the manufacturer s operating instruction BRAKE FLUID DRAINING Do not allow foreign Check the master cylinder parallel to the ground before meterial to enter the removing the reservoir cover system when filling the reservoir Front Remove the screws reservoir cover and diaphragm Rear Remove the bolts reservoir cover set plate and diap...

Page 494: ...id They are nol compatible Fill the master cylinder with DOT 4 brake fluid from a FRC PER 2l J sealed container I Connect a commercially available brake bleeder to the bleed vatve Operate the brake bleeder and loosen the bleed valve If an automatic refill system is not used add brake fluid when the fluid level in the reservoir is low Check the fluid level often while bleeding to prevent air from b...

Page 495: ...Connect a bleed hose to the bleed valve towel around the Pressurize the system with the brake lever or pedal until reservoir 0 pteV9n1 there are no air bubbles in the brake fluid flowing out of brake nuld spilling the small hole in the reservoir and lever or pedal resistance is felt 1 Squeeze the brake tever or push the brake pedal open the bleed valve 112 tum and then close the bleed valve NOTE D...

Page 496: ...nslallths diaphragm and reservoir cover Tighten the reservoir cover screws to the specified torque TORQUE 1 0 N m 0 1 kgf m O 71bHt Rear Straighten the diaphragm and install it to the rear master cylinder Check the diaphragm installation as shown Install the set plate and reservoir cover Tighten the reservoir cover bolls to the specified torque TORQUE 1 0 N m 0 1 kgf m O 7IbHt ...

Page 497: ...o assure even disc pressure NOTE Check the brake fluid level in the brake master cylinder reseNOir as this operation causes the level to rise After 12 Remove the brake disc cover page 14 10 Remove the pad pin plug and loosen the pad pin HYDRAULIC BRAKE Remove the brake caliper mounting boils and brake caliper bracket assembly Remove the pad pin and brake pads 16 11 ...

Page 498: ...the pad retainer securely NOTE Discard contaminated pads and clean a contaminated disc with high quality brake degreasing agent Push the brake pads against the pad spring then install the pad pin Instal Ihe brake caliper bracket assembly to Ihe fork leg Inslall and tighten new brake caliper mounting bolls to Ihe specified torque TORQUE 30 N m 3 1 kgf m 22 Ibf tt PAD SPRING ...

Page 499: ...r page 14 17 REAR BRAKE PADS REPLACEMENT HYDRAULIC BRAKE Always replace the Push the caliper piston all the way in to allow 1 07 brake pads in pairs installation of new brake pads to assure even disc pressure NOTE Check the brake fluid level in the brake master cylinder reservoir as this operation causes the level to rise Remove the pad pin and brake pads Install new brake pads to the pad retainer...

Page 500: ...FRONT 2 5 mm 0 10 In REAR 3 5 mm 0 14 In Replace the brake disc if the smallest measurement is less than the service limit Measure the brake disc warpage wilh a dial indicator SERVICE LIMIT 0 3 mm 0 01 in Check the wheel bearings for excessive play if the warpage exceeds the service limit Replace the brake disc if the wheel bearings are normal FRONT MASTER CYLINDER REMOVAL Drain the front brake hy...

Page 501: ...t from the knocker arm damage the boot Be careful nollo damage the boot Remove the brake lever assembly spring and push rod from the master cylinder Remove the boot Remove the snap ring from the master cylinder uSing the special tool TOOL Snap ring pliers 07914 SA50001 HYDRAULIC BRAKE MASTER CYLINDER ASSEMBLY BRAKE LEVER SPRING j BOLT NUT BOOT 16 15 ...

Page 502: ...age Replace the master piston primary cup and secondary cup as an assembly jf necessary Measure the master cylinder 1 0 SERVICE LIMIT 11 050 mm 0 4350 in Measure the master piston 0 0 SERVICE LIMIT 10 840 mm 0 4268 In Check the brake lever for bends or damage Move the knocker arm with your finger The knocker arm should move smoothly and without excessive play freely Replace the brake lever and kno...

Page 503: ...r inner surface ring and bool 8S 8 set do not replace the parts individually Whtm ins ailing the nslallthe spring to the master piston cups do nat allow Inslall the master piston assembly Into the master the lips to rum cylinder Inside out Inslalithe washer c Be certain the snap ring is firmly saaled in the groove MASTER CYLINDER I Install the snap ring to the master cylinder using the i iiiiC n B...

Page 504: ...cker arm groove securely MASTER PISTON PUSH ROD BRAKE lEVER ASSEMBLY Apply silicone grease to the spring both ends and install it between the master cylinder and brake lever BRAKE LEVER ASSEMBLY 16 18 assembly Apply silicone grease to the pivot bolt sliding surface Install and lighten the pivot boll to the specified torque TORQUE 1 0 N m 0 1 kgf m O 71bHt Tighten the pivot nul to the specified tor...

Page 505: ...the stopper then lighten the brake hose oil bolt to the specified torque TORQUE 34 N m 3 5 kgf m 25 Ibl ft Fill the reservoir to the upper level and bleed the front brake system page 16 8 After 4 Inslalithe engine mode select switch indicator page 6 76 REAR MASTER CYLINDER REMOVAL Drain the rear brake hydraulic system page 16 7 Remove the brake pedal page 16 29 When removing the Remove the brake h...

Page 506: ...der with brake fluid INSPECTION Check the master cylinder for abnormal scratches Check the master piston for abnormal scratches Check the piston boot primary cup and secondary cup for fatigue or damage Replace the master piston primary cap and secondary cap as an assembly if necessary Measure the master piston 0 0 SERVICE LIMIT 9 465 mm 0 3726 in Measure the master cylinder 1 0 SERVICE UMIT 9 575 ...

Page 507: ...ow the ips to tum Inside our If the push rod is disassembled adjust the brake pedal height page 4 29 Be certain the snap ring is firmly seatad in the groove Install the spring to the master piston Install the master piston assembly into the master cylinder Apply silicone grease to the push rod rounded surface and boot fitting area Install the push rod into the master cylinder Install the snap ring...

Page 508: ...5 kgf m 25 IbHt Install the brake pedal page 11 30 Fill the reservoir to the upper level and bleed the brake system page 16 8 FRONT BRAKE CALIPER REMOVAL After 12 Remove the brake disc cover page 14 10 16 22 Drain the front brake hydraulic system page 16 7 Remove the brake hose oil boll sealing washers and brake hose eyelet Remove the brake pads page 16 11 DISASSEMBLY Remove the caliper bracket fr...

Page 509: ...use injury Be careful not 10 damage the piston sliding surface Push the dust seals and piston seals in and lift them l out Clean the seal grooves caliper pistons and caliper piston sliding surfaces with clean brake fluid INSPECTION OUST Check the caliper cylinder for scoring scratches or damage Measure the caliper cylinder 1 0 SERVICE LIMIT 27 060 mm 1 0654 in Check the caliper pistons for scoring...

Page 510: ... and install them Into the caliper cylinder with their open ends facing the pad Inslalithe brake pad retainer onto the caliper bracket Note the ins allation Inslall the pad spring into the caliper dime ion ofthe pad spring Replace the caliper and bracket pin boots If there is wear deterioration or damage Install the caliper pin boot and bracket pin boot Apply silicone grease to the caliper and bra...

Page 511: ...7 Fill the reservoir to the upper level and bleed the hydraulic system page 16 8 REAR BRAKE CALIPER REMOVAL Drain the rear brake hydraulic system page 16 7 Remove the brake pads page 16 13 Remove the bolts and rear brake caliper guard Loosen the brake hose oil bolt Remove the rear wheel page 15 8 HYDRAULIC BRAKE Remove the brake caliperlbracket assembly to the slide C A LI P E RI B RA C K E T A S ...

Page 512: ...r to cushion the piston when it is expelled Do not Dring the air Apply short bursts of air pressure to the fluid inlet to nozzlflloo close to remove the pistons the inlel or the piston may be forced out with excessive force that couki cause injury Be carsful 1101 to damage the pistOfl sliding surface 16 26 Push the dust seal and piston seal in and lift them out Clean the seal grooves caliper pisto...

Page 513: ...E LIMIT 22 712 mm 0 8942 in Check the caliper pistons for scoring scratches or 09 shown damage Measure the caliper piston 0 0 SERVICE LIMIT 22 573 mm 0 8887 In ASSEMBLY A PISTON SEAL 5 4 N m 0 6 kgf m 4 0 PAD SPRING __ PINBOOT BRACKET PIN BOOT iiSioIPINS I_ CALIPER PISTON DUST SEAL BRAKE PAD RETAINER BRACKET DISC COVER 16 27 ...

Page 514: ...e brake pad retainer onto the caliper bracket Install the pad spring into the caliper Replace the caliper and bracket pin boots if there is wear deterioration or damage Inslall the caliper and bracket pin boots Apply silicone grease to the caliper and bracket pins sliding area When assembling Assemble the caliper and bracket the caliper ami bracket set the bool into the side pin groove 16 28 Insta...

Page 515: ... stopper then tighten the brake hose oil bott to the specified torque TORQUE 34 N m 3 5 kgf m 25Ibf ft Inslalithe rear brake caliper guard and bolts Tighten the bolts Inslalithe brake pads page 16 13 Fill the reservoir to the upper level and bleed lhe hydraulic system page 16 8 BRAKE PEDAL REMOVAL Remove the brake pedal pivot bolt washer and dust r seals Remove the return spring HYDRAULIC BRAKE AS...

Page 516: ... new cotter pin Apply grease to the dust seal lips Install the dust seals to the brake pedal with its lip side facing oul as shown Install the return spring Sel the washer to the frame Apply grease to the brake pedal pivot bolt sliding surface Install the brake pedal Install and tighten a new brake pedal pivot bolt to the specified torque TORQUE 36 N m 3 7 kgf m 27 lbHt ...

Page 517: ...ION COIL 17 16 SERVICE INFORMATION 17 4 IGNITION TIMING 17 17 TROUBLESHOOTING 17 6 GEAR POSITION SWITCH 09 17 18 IGNITION SYSTEM INSPECTION 17 7 ENGINE STOP SWITCH INSPECTION 17 21 ALTERNATOR COIL 17 12 CONDENSER 17 22 REGULATOR RECTIFIER 17 13 17 1 ...

Page 518: ...ELECTRICAL SYSTEM SYSTEM LOCATION 09 12 09 shown EN ilNE STOP SWITCH SPARK PLUG NO 1 CKP SENSOR 17 2 IGNrnON COIL REGULATOR RECTIFIER ECM CONDENSER GEAR PO TI N SWITCH 09 No 2 CKP SENSOR ALTERNATOR ...

Page 519: ...After 12 13 shown ENGINE STOP SWITCH SPARK PLUG IGNITION COil No 1 CKP SEt SCH No 2 ALTERNATOR ELECTRICAL SYSTEM ECM CONDENSER SENSOR 17 3 ...

Page 520: ... the engine before serviCing Use a sparle plug of the correct heat range Using 8 sperl plug with an incorrect heal range can damage the engine When servicing the ignition system always follow the steps in the troubleshooting sequence page 17 6 The ignition timing does not normally need to be adjusted since the ECM is factory preset A fautty ignition system is often related to poor connections Chec...

Page 521: ...or 07HGJ 0020100 Not available in U S A with commercially available digital multimeter impedance 10 MOIDCV minimum IgnillonMate peak voltage tester MTPQ7 0286 U S A only ELECTRICAL SYSTEM Test probe 2 pack 07ZAJ RDJA11 0 17 5 ...

Page 522: ...l voltage is no rm O a b U I h e i n o 1 i1 Incorrect peak voltage adaptor connections System is normal peak voltage while cranking the if measured voltage is over the specifications with reverse engine connections 2 Faulty peak voltage adaptor 3 Faulty engine stop switch Check the engine stop switch operation 4 An open circuit or loose connection in ground wire 09 12 Green After 12 Greenlwhite at...

Page 523: ...ak voltage adapter to the digital multimeter TOOLS IgnitionMate peak voltage tester MTP07 0286 U S A only or Peak voltage adaptor 07HGJ 020100 Not available in U S A with commercially available digital muttimeter impedance 10 MOJOCV minimum IGNITION COIL PRIMARY PEAK VOLTAGE Check all system connections before inspection If the system is disconnected incorrect peak voltage might be measured Ched c...

Page 524: ...h the ignition coil primary wire connected connect the peak voltage adaptor to the ignition coil TOOLS IgnilionMate peak voltage tester MTP07 0286 U S A only or Peak voltage adaptor 07HGJ 0020100 Not available In U S A with commercially available digital multlmeter impedance 10 MOIOCV minimum Connection Yellow blue Ground Connect the 12 V battery turn Ihe ECM selector switch is ON 09 pageI 19 Afte...

Page 525: ... NOTE When reconnecting the ECM connector check that there is no dirt and oil in the connector 09 12 Connect the peak voltage lester or adaptor probes to the wire harness side connector terminals TOOLS IgnitionMate peak voltage tester MTP07 0286 U S A only or Peak voltage adaptor 07HGJ 0020100 Not available in U S A with commercially available digital multimeter Impedance 10 MOJDCV minimum Test pr...

Page 526: ...ound H No 2 CKP sensor White yellow 29 Ground Shift the transmission into neulral Crank the engine with the kickstarter and measure the CKP sensor peak voltage PEAK VOlTAGE O 7 V minimum If the voltage measured at the ECM connector is abnormal measure the peak voltage al the alternatorl CKP sensor connector 09 12 Disconnect the alternatorlCKP sensor 6P connector 17 10 After 12 No 1 CKP SENSOR 33P ...

Page 527: ...e it to the voltage measured at the ECM connector If the peak voltage measured at the ECM connector is abnormal and the one measured at the alternator CKP sensor connector is normal the Blue yellow or White yellow or Greenlwhite wire has an open or short circuit or loose connection If both peak voltages are abnormal follow the checks described in the troubleshooting chart page 17 6 If the CKP sens...

Page 528: ...NNECTOR Measure the resistance at the alternator side connector terminals Wire side of male terminals 17 12 Connection Yellow White STANDARD 0 1 3 0 a at 20 CI68 F Check for continuity between each wire terminal of the alternator side connector and ground Connection Yellow Ground White Ground There should be no continuity Replace the alternator stator if resistance Is oul of 6P CONNECTOR specifica...

Page 529: ...tifier 5P Black connector Remove the bolls nut and regulator rectifier Release the wire harness from the clamp Remove the following Bolts Nuts Clamp Slay Route lhe wires Installation is in the reverse order of removal proporly page 1 23 ELECTRICAL SYSTEM REGULATOR RECTIFIER II f J CLAMP STAY BOL CLAMP 17 13 ...

Page 530: ...nnect the regulator rectifier 6P Natural connector BOLTS STAY 6P CONNECTOR CLAMP Remove the nuts bolts regulator rectifier and R E G U LA T O Rl R E C T IF E R connector stay Roule the wims Installation is in the reverse order of removal properly page 1 23 17 14 INSPECTION Disconnect the regulator rectifier connector Check the connectors for loose contacts or corroded terminals STAY NUTSIBOLTS ...

Page 531: ...CTOR wire sidelfemale terminal After 12 BI 33P BLACK CoNNECTOR wire side female terminal 23 Q 6P NATURAL CONNECTOR wire side female terminal 09 12 5P BLACK CONNECTOR After 12 6P NATURAL CONNECTOR G Q wire side female terminal Measure the resistance at the alternator side connector r O _ 2 A ft e 2 terminals 5P BLACK 6P NATURAL Connection Yellow White STANDARD 0 1 _ 3 0 Q at 20 CI68 F If resistance...

Page 532: ...fication replace the ignition coil REMOVAUINSTALLATION 09 12 Remove the spark plug cap page 4 11 Disconnect the ignition coil primary wire connectors and release them from the clamp Remove the bolt and washer Remove the bolt ground wire and ignition coil with the stay Remove the following Bolts Nuts Clamp Stay Route the wires Installation is in the reverse order of removal properly page 1 23 17 16...

Page 533: ...e a tachometer with graduations of 50 rpm or smaller that will accurately indicate 50 rpm change Warm up the engine to normal operating temperature Stop the engine and remove the timing hole cap CONNECTOR BLACK WIRE Attach a tachometer according to its manufacture s instructions Connect the liming light to the sparl plug wire Read the instruction for timing light operation Start the engine and let...

Page 534: ...connect the ECM 33P Black connector Check for continuity between the ECM 33P Black IIIIIIIIIIIIIIIIIIIIIIII connector and ground at each corresponding gear 33P BLACK CONNECTOR 17 18 position wire side female terminal Connection 1st and N position 30 Ground 2nd position 31 Ground TOOL Test probe 2 pack 07ZAJ RDJA110 There should be continuity only at each corresponding gear position If the continui...

Page 535: ...pond to the gear positions shown below and there should be no continuity at the other terminals GEAR GROUND G LgiR N 2 0 Gr Gray LglR Light greenfred If the continuity is abnormal replace the gear position switch REMOVAL Hang the fuel tank to the left side of the frame page 4 6 Remove the drive sprocket cover page 4 21 Remove the wire band gear position switch 2P Green connector Remove the wire ba...

Page 536: ...tch INSTALLATION Apply oil to a new D ring and install it to the gear position switch groove Insta 1lhe gear position switch while aligning its tab with the groove of the shift drum Install the wire band Install the gear position switch 2P Green connector and wire band Inslalilhe following Fuel lank page 4 6 Drive sprocket cover page 4 23 ...

Page 537: ...itch pushed and no continuity with the switch released SWITCH LINE INSPECTION Disconnect the ECM 33P Btack connector 09 12 page 6 73 After 12 page 6 74 Check for continuity between the ECM 33P Black and engine stop switch 4P connectors of the wire hamess side TOOL Test probe 2 pack 07ZAJ RDJA110 Connection Blacklwhite BlackJwhite 19 BIIW ENGINE STOP SWITCH BIIW 33P BLACK CONNECTOR wire side female...

Page 538: ...nector Remove the condenser from the regulator rectifier stay Installation is in the reverse order of removal REMOVAUINSTALLATION AFTER 12 Disconnect the oondenser 2P Black connector Release the condenser from the slay Installation is in the reverse order of removal After 2 STAY 2P BLACK CONNECTOR CONDENSER u ...

Page 539: ...FF and connect the condenser 3P After 09 2P Black connector 2 Turn the ECM selector switch ON for a few seconds and charge the condenser 3 Turn the ECM selector switch OFF and discharge the condenser 4 Disconnect the condenser 3P After 09 2P connector and check the resistance between the condenser side terminals The condenser is normal if the resistance comes near 00 once and eventually becomes DO...

Page 540: ...MEMO I 1 I I ...

Page 541: ...18 WIRING DIAGRAM WIRING DIAGRAM 18 2 EI 18 1 ...

Page 542: ...o iii m II II IiIlii1 1 11 II 2P 2PG 1 GEAR POSITION SWITCH ENGINE STOP SWITCH E IG FREE PUSH 0 C COlOR BIIW RN 06 m FRAME t SPARK GROUND1 UG 6P ECT SENSOR FUEL INJECTOR NO 1 CKP SENSOR NO 2 CKP SENSOR ALTERNATOR a o IAT SENSOR BI BLACK Y YELLOW Bu BLUE G GREEN R RED W WHITE V VIOLET II Q j TP SENSOR Br 0 Lb Lg P Gr to MAP SENSOR BROWN ORANGE LIGHT BlUE UGHTGREEN PINK GRAY TWO Ca OREDWIRE E X M1PL...

Page 543: ...z 0 0 J en l Q g I I ______ ___1 p3P 8 t P I ___ _ _ N N NNN N NM M I I I I I II I nnI I h I i I h I I I I h i i i iii I nu 1I1 n to I C a iii FRAME n I I IGNITION GROUND to COil 1SPARK PLUG Ii III FUEL INJECTOR m t l Eel SENSOR ALTERNATOR ft MAPSENSQR tAT SENSOR TP SENSOR BI BLACK Br BROWN Y YELLOW 0 ORANGE Su BLUE L b LIGHT BLUE G GREEN Lg LIGHT GREEN R RED P PINK W WHITE Gr GRAY TWO COLOREDWIRE...

Page 544: ... I G DIAGRA M _ _ _ _ _ w I 18 4 z P illR R1Y illR YIG BIIW R1Y INJ lO TA PCP1 PO ...

Page 545: ... iii m q 1 i ECM N b z 0 I Cl i O Z 0 I __ I J UJ w 8 i C 1 33P nnTrn MTTnOT TnTT m Of g g H II I I II Ii Hi iiI 0 FRAME GROUND IGNITION COIL SPARK rLUG FUEL INJECTOR No 1 CKP SENSOR lillll p Ol ALTERNATOR ECTSENSOR No 2CKP SENSOR MODE CHANGE SWITCH INDICATOR l _ J PJl p Of iii IATSENSOR BI Stack Y Yellow Su Blue G Green R Red W White TP SENSOR MAP SENSOR Sr Brown o Orange Lb Light Blue Lg Light G...

Page 546: ...MEMO ...

Page 547: ...19 TROUBLESHOOTING ENGINE DOES NOT START OR IS HARD POOR PERFORMANCE AT HIGH TO START 19 2 SPEED 19 6 ENGINE LACKS POWER 19 3 POOR HANDLING 19 7 POOR PERFORMANCE AT LOW AND IDLE SPEED 19 5 19 1 ...

Page 548: ...O TO STEP 3 3 Fuel Pump Inspection Check for operation of the fuel pump and inspect the fuel flow Is the fuel pump unit normal YES GO TO STEP 4 NO Faulty fuel pump unit 4 PGM FI System Inspection Check the PGM FI system Is the PGM FI system normal YES GO TO STEP 5 NO Faulty PGM Ft system 5 Engine Starting Condition Start engine by normal procedure Does the engine start then stops YES Improper fast...

Page 549: ...eeplay Worn clutch discs plates Warped clutch discs plates Weak clutch springs Slicking clutch lifter Additive in engine oil YES GO TO STEP 4 4 Engine Performance Inspection Accelerate tighlly Did the engine speed increase NO Dirty air cleaner Restricted fuel flow Clogged muffler Clogged fuel tank breather hose Fast idle knob stuck open or damaged Excessive carbon build up in combustion chamber YE...

Page 550: ...d head gasket Improper valve timing Faulty decompressor system NO GO TO STEP 9 9 Fuel pump Inspection Inspect the fuel flow Is the fuel pump unit normal YES GO TO STEP 10 NO Faulty fuel pump unit 10 PGM Fl System Inspection Check the PGM FI system Is the PGM FI System normal YES GOTOSTEP11 NO Faulty PGM FI system 11 Spark Plug Inspection Remove and inspect spark plug Is the spark plug fouled or di...

Page 551: ...rk lest Is there weak or intermittent spark YES Faulty spark plug Fouled spark plug Faulty ignition coil Broken or shorted spark plug wire Faulty CKP sensor s Faulty alternator coil Faulty engine stop button Faulty ECM NO GO TO STEP 3 3 Fuel Pump Inspection Inspect the fuel flow Is the fuel pump unit normal YES GO TO STEP 4 NO Faulty fuel pump unit 4 Ignition Timing Inspection Check the ignition t...

Page 552: ...I system normal YES GO TO STEP 3 NO Faulty PGM FI system 3 Ignition Timing Inspection Check ignition timing Is the ignition timing correct NO Faulty ECM Faulty CKP sensor s YES GO TO STEP 4 4 Valve Timing Inspection Check valve timing Is the valve timing correct NO Camshaft not installed properly YES GO TO STEP 5 5 Camshaft Inspection Remove and inspect the camshaft Is the cam lobe height within s...

Page 553: ...nual for spring preload adjustment Make only one change at a time in the sequence of remedies given below Front End Oversteers It Cuts Too Sharply such as In sand Increase the fork oil capacity Use stiffer for1c spring 09 12 Front End Understeers It Washes Out Or Pushes such as on at tight track with hard ground l ower fork oil capacity Use softer fork spring 09 12 Front End Hunts At High Speed It...

Page 554: ...MEMO ...

Page 555: ...DRIVE CHAIN 4 21 DRIVE CHAIN ROLLER 4 24 DRIVE CHAIN SLlDER 4 24 DRIVE DRIVEN SPROCKET 4 26 DTC INDEX 6 24 DTC TROUBLESHOOTING 6 25 ECM 6 73 INDEX ECT SENSOR 6 72 ELECTRICAL SYSTEM SPECIFICATIONS 1 13 ENGINE GUARD 3 6 ENGINE IDLE SPEED 4 19 ENGINE INSTALLATION 8 9 ENGINE MODE SELECT SWITCHIINDICATOR After 14 6 75 ENGINE OIUOIL FILTER 4 16 ENGINE REMOVAL 6 6 ENGINE STOP SWITCH INCLUDING THE MIL 2 3...

Page 556: ...12 9 STEERING HEAD BEARINGS 4 42 STEERING STEM 14 75 SUB FRAME 3 7 SUSPENSiON 4 39 SW1NGARM 15 43 WINGARM SHOCK LINKAGE 4 41 SYSTEM FLOW PATTERN 7 2 SYSTEM LOCATION 17 2 SYSTEM TESTING 7 7 THROTTLE BODy 6 64 THROTTLE OPERATION 4 8 TORQUE VALUES 13 TRANSMISSION 13 15 TRANSMISSION OIL 4 19 TROUBLESHOOTING CLUTCHIKICKSTARTER GEARSHIFT LINKAGE 11 6 COOLING SYSTEM 7 6 CRANKCASEICRANKSHAFTfTRANSMISSIONI...

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