Honda 2010 CRF250R Service Manual Download Page 277

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Page 277

Summary of Contents for 2010 CRF250R

Page 1: ......

Page 2: ...es Only you can decide whether or not you should perform a given task AWARNING Failure to property follow instructions and precautions can cause you to be senously hurt or killed Follow the procedures...

Page 3: ...ow the source of the trouble go to Troubleshootmg section 18 Your safety and the safety of others is very Important To help you make Informed deCISions we have provided safety messages and other Infor...

Page 4: ...se molybdenum disulfide grease containing more than 3 molybdenum disulfide NLGI 2 or equivalent Example Molykole BR 2 plus manufactured by Dow Coming U S A Multi purpose M 2 manufactured by Milsubishi...

Page 5: ...STEM PGM FI COOLING SYSTEM ENGINE REMOVAL INSTALLATION CYLINDER HEADNALVES CYLINDER PISTON CLUTCH KICKSTARTERIGEARSHIFT LINKAGE ALTERNATOR CRANKCASE CRANKSHAFT TRANSMISSION BALANCER FRONT WHEEL SUSPEN...

Page 6: ...MEMO...

Page 7: ...PISTON SPECIFICATIONS 1 8 CLUTCH KICKSTARTERIGEARSHIFT LINKAGE SPECIFICATIONS 1 9 1 GENERAL INFORMATION CRANKCASE CRANKSHAFT TRANSMISSION BALANCER SPECiFiCATIONS 1 9 FRONT WHEEUSUSPENSION STEERING SPE...

Page 8: ...ding surfaces before reassembly 7 After reassembly check all parts for proper Installation and operation 8 Route all electrical wires as shown in Ihe Cable and Harness Routing page 1 21 9 00 not bend...

Page 9: ...ATION 10 shown SERIAL NUMBERS The Vehicle Idenltficallon Number yIN is stamped on the nght side of the steering head GENERAL INFORMATION The engme serial number is stamped on the lower left side of th...

Page 10: ...GENERAL INFORMATION The throttle body identification number is stamped on the right side of the throttle body LABEL The name plate is located on the right side of the frame 1 4 10 shown...

Page 11: ...9 in 2 181 mm 85 9 in 827 mm 32 6 in 1 273 mm 50 1 in 1 271 mm 50 0 in 1 493 mm 58 8 in 1 488 mm 58 6 in 1 489 mm 58 6 in 955 mm 37 6 in 951 mm 37 4 in 423 mm 16 7 in 422 mm 16 6 in 418 mm 16 5 in 32...

Page 12: ...Primary reduction 3 166 57 18 Final reduction 10 3 692 48 13 After 10 3 769 49 13 Gear ratio 2 357 33 14 20d 1 888 34 18 3cd 1 555 28 18 4th 1 333 24 18 5th 1 136 25 22 Gearshift pattern left foot op...

Page 13: ...0 Tip clearance 0 15 0 006 Body clea n cieC D t 5 O 2 lJ O O 06 O 008 Side clearance 0 15 0 22 0 006 0 009 0 20 0 008 FUEL SYSTEM PGM FI SPECIFICATIONS ITEM Throttle body identification number Idle sp...

Page 14: ...1 420 Valve lifter 0 0 Valve lifter bore 1 0 EX 25 524 25 764 1 0049 1 0143 __ 25 41 1 000 t 22 478 22 493 0 8850 0 8855 22 47 b 885 t 22 510 22 526 0 8862 0 8868 22 54 0 887_ _ CYLINDER PISTON SPECIF...

Page 15: ...030 0 8 0 03 0 006 0 018 0 0002 C O O O 07 J __ 02 0 5 0 002 M4 M5 C1 C2 C3 M4 M5 C1 C2 C3 M5 C1 C2 f C3 M4 M5 Cl C2 C3 at M5 bushing at C1 bushing at C2 bushing at C3 bushing M5 C1 C2 C3 0 05 0 002...

Page 16: ...r 2 0 0 08 2 0 0 08 453 17 8 0 2 0 01 __ 36 5 c cm 12 3 US oz 12 8 Imp oz __ 12 372 em 12 6 US OZ 13 1 Imp oz After 12 363 cm3 12 3 US oz 12 Blmp oz 0 195 cm3 6 6 US oz 6 9 Imp oz 1 12 240 cm3 8 1 US...

Page 17: ...ut from fun in damping adjuster standard II 1 1112 1 7112 turns out from full in _ __ 1 112 2 turns oul from full in After 12 1 3 4 2 1 41urns out f o m f inC position 12 I Low speed compressionCC d a...

Page 18: ...Torque specifications listed below are for specified fasteners Others should be tightened to standard torque values listed above FRAME BODY PANELS EXHAUST SYSTEM ITEM a TV THREAD TORQUE OIA mm N m kg...

Page 19: ...cable mounllng bolt frame 4 3 5 0 4 2 6 side Mud guard mounting screw 2 5 1 1 0 1 0 8 IAT sensor screw 2 5 1 1 0 1 0 8 Air cleaner housing mounting bolt 2 6 10 1 0 7 Air cleaner connecting boot band s...

Page 20: ...hreads and seating surfaces CKP sensor mounting bolt 4 5 5 2 0 5 3 8 Apply locking agent to the threads Coating width 4 5 1 0mm 0 18 0 04in Stator mounting socket bolt 3 5 5 2 0 5 3 8 Apply locking ag...

Page 21: ...TEERING ITEM a TV THREAD TORQUE t OIA mm N m kgf m IbHt REMARKS Front axle nut 16 88 9 0 65 Axle holder bolt 4 8 20 2 0 15 Front brake disc nut 6 6 16 1 6 12 U nut Front brake hose guide boll 6 5 2 0...

Page 22: ...eads and sealing surfaces U nul Shock link nut frame side 12 53 5 4 39 Apply engine oil to the threads and sealing surfaces U nut Shock absorber upper 10 44 4 5 32 U nul mounting nut Shock absorber lo...

Page 23: ...1 17...

Page 24: ...nnecting rod small end inner surface Mainshaft spline area and gear sliding surface Countershaft spline area and gear sliding surface Transmission gear sliding surfaces Shift fork claws and guide pins...

Page 25: ...e needle bearing rolling area Shock linkage dust seal lips Shock linkage side collar inside surfaces Steering head bearing rolling area Steering head dust seal lips Brake pedal dust seal lips Clutch c...

Page 26: ...sliding surface Rod guide case O ring rebound rubber oil seal lips dust seal lips Damper case inner surface Bladder lips Compression damping adjuster O rings Fuel pump O ring whole surface Fuel pump...

Page 27: ...CABLES 10 shown CLUTCH CABLE FRONT BRAKE HOSE GENERAL INFORMATION WIRE BANDS ENGINE STOP SWITCH WIRE CLUTCH CABLE ENGINE STOP SWITCH WIRE ENe NE STOP SWITCH WIRE FRONT BRAKE 1 1 _ 1 HOSE PROTECTOR fT...

Page 28: ...2 THROTTLE CABLES RADIATOR OVIERf LOW HOSE THROTTLE CABLES CLUTCH CABLE Ole FUEL PUMP SUB HARNESS 4P RED CONNECTOR GROUND WIRE eLlJ IeH CABLE ENGINE STOP SWITCH WIRE FRClNTBRI KE HOSE ENGINE STOP SWIT...

Page 29: ...NKCASE BREATHER HOSE THROTTLE CABLES FUEL PUMP SUB HARNESS GENERAL INFORMATION FUEL PUMP SUB HARNESS MAIN WIRE HARNESS SPARK PLUG WIRE FUEL HOSE FUEL TANK STOPPER CABLE MAP SENSOR 3P BLACK CONNECTOR F...

Page 30: ...GENERAL INFORMATION RADIATOR OVERFLOW HOSE UPPER RADIATOR HOSES LOWER RADIATOR HOSES FUEL HOSE FUEL PUMP SUB HARNESS 1 24...

Page 31: ...10 shown ECM 33P BLACK CONNECTOR CRANKCASE BREATHER HOSE GENERAL INFORMATION 10 12 IAT SENSOR 2P GRAY CONNECTOR After 12 IAT SENSOR 2P BLACK CONNECTOR 1 25...

Page 32: ...VACUUM HOSE INJECTOR MAP SENSOR WIRE ECT SENSOR 2P BLACK CONNECTOR After 12 MAP SENSOR VACUUM HOSE CRANKCASE BREATHER DRAIN HOSE 1 26 INJECTORfMAP SENSOR WIRE TP SENSOR 3P BLUE CONNECTOR ECT SENSOR W...

Page 33: ...NNECTOR TRANSMISSION BREATHER HOSE CLUTCH CABLE D o GENERAL INFORMATION ALTERNATORtCKP SENSOR 6P BLACK CONNECTOR CONDENSER2P BLACK CONNECTOR AlTERNATORlCKP SENSOR W IRE AlTERNATORlCKP SENSOR 6P BLACK...

Page 34: ...CRANKCASE BREATHER DRAIN HOSE After 12 TP SENSOR 3P CONNECTOR AlTERNATORlCKP SENSOR 6P BLACK CONNECTOR IAT SENSOR 2P BLACK CONNECTOR CRANKCASEBREAIHER DRAIN HOSE 1 28 o Eel SENSOR 2P BLACK CONNECTOR C...

Page 35: ...GENERAL INFORMATION REAR BRAKE HOSE No 2 CKP SENSOR CKP SENSOR WIRE No 1 CKP SENSOR 1 29...

Page 36: ...HOLDER 1 30 Standard Optional 10 After 10 10 After 10 REMARKS For maintenance Pin spanner A x 2 For shock absorber spring installed length preload adjustment two required For checking tire air pressu...

Page 37: ...0 US oz 13 6 Imp oz Minimum 301 em 10 2 US oz 10 6 Imp oz Standard No mark 4 4 N mm Standard 0 25 12 Ibflin 365 eml 12 3 US oz 12 81mp oz Maximum 380 eml 12 9 US oz t3 4 Imp oz Minimum 296 eml 10 0 US...

Page 38: ...12 7 Imp ozl Maximum 381 cm 12 9 US oz 13 4 Imp azl Minimum 298 cm3 10 1 USoz 10 5Impoz Standard 363 em3 12 3 US OZ 12 Blmp az Maximum 384 em 13 0 US oz 13 5 Imp azl Minimum 300 em 10 1 US oz 10 8 Imp...

Page 39: ...PANELS EXHAUST SYSTEM SERVICE INFORMATION 2 2 TROUBLESHOOTING 2 2 SEAT 2 3 SIDE COVER 2 3 RADIATOR SHROUD 2 4 ENGINE GUARD 2 4 NUMBER PLATE 2 5 FRONT FENDER 2 5 REAR FENDER 2 6 SUB FRAME 2 6 EXHAUST S...

Page 40: ...UES Seat mounting bolt Side cover bolt Radiator shroud bolt upper side Engine guard bolt Sub frame upper mounting bolt Sub frame right lower mounting bolt Sub frame lefllower mounting bolt Exhaust pip...

Page 41: ...CKET SIDE COVER REMOVAL INSTALLAnON Remove the seal mounting bolt Remove the side caver bolt and side cover 10 shown HOOK ECM STAY Be careful not 0 Install the side cover by inserting the side cover t...

Page 42: ...Tighten the upper side bolts to the specified torque TORQUE 5 0 N m 0 5 kgf m 3 7 IbHt Tighten the lower side bolts securely ENGINE GUARD REMOVALfINSTALLATION 2 4 Remove the bolt collar and engine gua...

Page 43: ...r plate by aligning its holes with the bosses on the steering stem Install and tighten the bolts Set the number plate band while positioning the clutch cable as shown FRONT FENDER REMOVALIINSTALLATION...

Page 44: ...3 kgf m 10 IbHt SUB FRAME REMOVAL Remove the following Seal page 2 3 Side covers page 2 3 Muffler page 2 9 10 2 Disconnect the tAT sensor 2P Gray connector After 12 Disconnecllhe tAT sensor 2P Black c...

Page 45: ...LS EXHAUST SYSTEM Remove the sub frame upper and lower mounting bolts Remove the connecting boot from the throttle body by iI pulling the sub frame backward Disconnect the crankcase breather hose from...

Page 46: ...nting bolts 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 tbHt Left lower 33 N m 3 4 kgf m 24 IbHt Hook the...

Page 47: ...d screw to the specified width as shown Install the following Muffler page 2 9 Side covers page 2 3 Seat page 2 3 EXHAUST SYSTEM MUFFLER REMOVAL INSTALLATION Remove the right side cover page 2 3 Loose...

Page 48: ...and with the cut out of the muffler Instalilhe washers and muffler mounting bolts Tighten the muffler mounting bolts to the specified torque TORQUE 26 N m 2 7 kgf m 19 IbHt TIghten the muffler joint b...

Page 49: ...rililhe rivet head with a 4 0 mm dnll to the specified depth as shown 2 Drililhe rivet head with a 10 mm drill so thallhe rivet can be removed into the muffler body then remove the rivet NOTE Be caref...

Page 50: ...ool to the inner pipe the punched area of assembly CENTER GLASS WOOL the inner pipe jIII UPt 45 45 0 THE RANGE TO START INSTALLING IINNER PIPE Apply 5 0 9 0 18 02 of muffler sealant hlgh temperature s...

Page 51: ...muffler page 2 9 GLASS WOOL REPLACEMENT After 10 Remove the muffler page 2 9 Set the muffler in a vise with pieces of wood or soft jaws to avoid damage Remove the rivets with a 4 0 mm and 10 mm drills...

Page 52: ...inner pipe Install new tail glass wool onto the inner pipe end as shown Be sure thaI the Install the end cover inside of end cover s filled evenly with the glass WOOl C Jmpielely cover Install new cen...

Page 53: ...fler sealant high temperature silicone to the front pipe assembly as shown Install the front pipe assembly into the muffler body assembly by inserting the inner pipe end into the fronl pipe end Align...

Page 54: ...T PIPE PROTECTOR 12 N m 1 2 kgf m 9Ibf ft EXHAUST PIPE PROTECTOR BAND Cj Align EXHAUST PIPE INSTALLATION 10 shown 26 N m 2 7 kgf m 19Ibf ft WASHER MUFFLER 26 N m 2 7 kgf m 191bHt C 7J GASKET EXHAUST P...

Page 55: ...ust pipe joint nuls to the specified torque TORQUE 21 N m 2 1 kgf m 15 1 bHt Always inspect the Tighten the muffler mounting fasteners exhaust system for leaks after installallon CYLINDER HEAD EXHAUST...

Page 56: ...MEMO...

Page 57: ...23 THROTTLE OPERATION 3 7 BRAKE PADS WEAR 3 24 AIR CLEANER 3 8 BRAKE SYSTEM 3 25 CRANKCASE BREATHER 3 10 CLUTCH SYSTEM 3 25 SPARK PLUG 3 10 CONTROL CABLES 3 27 RADIATOR COOLANT 3 11 EXHAUST PIPE MUFFL...

Page 58: ...0 001 in 0 67liler 0 70 US qt 0 59 Imp qt 0 69 liler 0 73 US qt 0 61 Imp qt _ 85Iiter 0 90 US ql 0 75 Imp qt 0 68liler 0 72 US ql 0 60 Imp qt I 0 75 liler 0 79 US qt 0 66 lmp qt Pro Honda GN4 4 stroke...

Page 59: ...Rim lock Plug bolt Drive chain adjuster lock nul TOOLS Spoke wrench 6 1 mm 07JMA MR60100 16 N m 1_6 kgf m 121bHt 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...

Page 60: ...3 16 RADIATOR COOLANT NOTE 2 I 3 11 I I 3 17 COOLING SYS T E M _ _ __ _ _ DRIVE CHAIN f I l R DRIVE CHAIN SLIDER _ I DRIVE CHAIN ROLLER I 10 11 3 21 I After 11 DRIVE SPROCKET DRIVEN SPROCK ET BRAKE F...

Page 61: ...ake pads Sub frame mounting bolts Chain guide Wear Minimum thickness 1 0 mm 0 04 In Side cover Number plate Front rear fender Clutch lever holder Brake lever Handlebar Throttle housing Handlebarlthrot...

Page 62: ...oll and collar Release the fuel lank band from the fuel tank band bracket screw Remove the fuel hose from the hose damp_ Check the fuel lank stopper cable for proper installation and deterioration kin...

Page 63: ...mage or leakage Check the quick connect fittings for dirt and clean if necessary FinING COVER Check Ihe cushk rubbees 1m p ope lostallalloo as ICUSHION RUBBER shown in the illustration L THROTTLE OPER...

Page 64: ...er turn it all the way in and then turn it out one turn Make the major adjustment with the throttle body side adjuster Major adjustment is made with the lower adjuster Hang the fuel tank to the left s...

Page 65: ...y a thin coat of Pro Honda While lithium Grease or an equivalent to the sealing surface Assemble the air cleaner element and element holder Hook the element holes onto the holder labs Apply 3 5 9 0 1...

Page 66: ...ase with compressed air before removing and be sure that no debris s allowed to enter he wmbuslion chamber Inspect or replace as described in the maintenance schedule page 3 4 INSPECTION Check the fol...

Page 67: ...the 0 8 mm 0 03 in diameter plug spark plug gap If gauge does nol Insert between the gap the gap IS out of If the gauge can be inserted mto the gap replace the speCificatIOn plug with a new one repla...

Page 68: ...ce Make sure the piston is at TDC Top Dead Center on the compression stroke This position can be obtained by confirming Ihallhere is slack in the rocker arm If there is no stack il is because the pist...

Page 69: ...nutes SlOp the engine and wait 3 minutes Support the motorcycle upright on a level surface Remove the oil filler cap dipstick and wipe the oil with a clean cloth tnsert the oil filler cap dipstick wit...

Page 70: ...o catch the engine oil then remove the engine oil drain bolt and sealing washer Drain the engine oil Operate the kicksiarter pedal five times or more while pressing the engine stop switch so the engin...

Page 71: ...and install them to the crankcase Tighten the engine oil drain bolt to the specified torque TORQUE 16 N m 1 6 kgf m 12 IbHt Fill the engine with the recommended engine oil page 3 13 ENGINE OIL CAPACIT...

Page 72: ...d IDLE SPEED 2 OOO 100 rpm TRANSMISSION OIL 3 16 OIL LEVEL INSPECTION 1 Start the engine and let it idle for 3 minutes 2 Stop the engine and wait 3 minutes 3 Support the motorcycle upright on a level...

Page 73: ...the transmission oil drain bolt to the specified torque TORQUE 16 N m 1 6 kgf m 12 IbHt Fililhe engine with the recommended transmission oil RECOMMENDED TRANSMISSION OIL Pro Honda GN4 4 stroke oil U...

Page 74: ...after every ride Perfonn the following service with the engine stopped and shift the transmission into neutral Place a worksland or equivalent under the engine Be careful nor to Release the alternator...

Page 75: ...er 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 DID 520DMA4 11...

Page 76: ...mm 2 2 in After 11 50 mm 2 0 in or more may damage the frame WARNING Amputation hazard Never inspect or adjust the drive chain while the engine is running ADJUSTMENT If the chain needs adjustment loos...

Page 77: ...E CHAIN SUDER Check the chain guide and chain guide slider for 10 shown alignment wear or damage CHAIN GUIDE SUDER Replace the chain guide if it is damaged or worn Replace the chain guide slider if th...

Page 78: ...n Replace the drive chain roller if necessary Install the drive chain upper roller with the _ mark facing out Install the drive chain lower roller as shown Install and tighten the drive chain roller b...

Page 79: ...EL INSPECTION When the fluid level is low check the brake pads for wear page 3 24 A low fluid level may be due to wear of the brake pads If the brake pads are worn the caliper piston is pushed out and...

Page 80: ...emove the bolts reservoir cover plate and diaphragm and fill the reservoir with DOT 4 brake fluid to the upper level tine Install the diaphragm plate and cover Inslall and lighten the bolts to the spe...

Page 81: ...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 CLUTCH SYSTEM CLUTCH LEVER POSITION LOCK NUT Make sure 1...

Page 82: ...L O C K N U T l adjuster so that the clutch lever freeplay is 10 20 mm 3 8 13 16 in at the tip of lever After adjustment tighten the adjuster lock nut securely while holding the adjuster H d idFl fIL...

Page 83: ...or dragging If proper freeplay cannot be obtained using both procedures or the clutch slips during the test ride disassemble and inspect the clutch page 10 9 CONTROL CABLES Remove the dust cover Remov...

Page 84: ...m 15Ibf ft Muffler joint band bolt 21 N m 2 1 kgf m 151bHt SUSPENSION FRONT SUSPENSION INSPECTION CABLE END ADJUSTER Check the action of the forks by operating the front brake and compressing it seve...

Page 85: ...with the front tire off the ground Loosen the plug bolts fully then lighten them to the specified to torque TORQUE 1 3 N m 0 1 kgf m 1 0 IbHt REAR SUSPENSION INSPECTION Check the action of the shock a...

Page 86: ...ect the swingarm and shock linkage pivot bearings and related seals every three races or about 7 5 hours of operation page 14 31 Lubricate and reassemble them NUTS BOLTS FASTENERS Check that all chass...

Page 87: ...IRE PRESSURE FRONT 100 kPa 1 0 kgflcm2 15 psi REAR 100 kPa 1 0 kgflcm2 15 psi Inspect the wheel rims and spokes for damage Tighten any loose spokes and rim locks to the specified torque using the spec...

Page 88: ...ly binds or has vertical movement inspect the steering head bearings page 13 52 Check for wom steering head bearing by grabbing the fork legs and attempting to move the front fork forward to backward...

Page 89: ...LUBRICATION SYSTEM DIAGRAM 4 2 SERVICE INFORMATION 4 3 TROUBLESHOOTING 4 3 4 LUBRICATION SYSTEM OIL STRAINER SCREEN 4 4 PRESSURE RELIEF VALVE 4 5 OIL PUMP 4 5 4 1...

Page 90: ...LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM PISTON MAINSHAFT OIL JET OIL PUMP PRESSURE OIL PUMP DRIVEN GEAR ONE WAY VALVE 4 2...

Page 91: ...I oil filter 0 69 liter 0 73 US qt 0 61 Imp qt change At draining 0 68 liter 0 72 US qt 0 60 Imp qt i Transmission all capacity Recommended engine oil __ iAcc 1 disassembly 0 85 liter 0 90 US qt 0 75...

Page 92: ...e oil strainer screen with non flammable or high g 4 4 flash point solvent and wipe it dry Check the oil strainer screen for damage or clogs INSTALLATION Install the oil strainer screen to the crankca...

Page 93: ...ary INSTALLATION Apply engine oil to a new O ring and install it to Ihe pressure relief valve Install the pressure relief valve into the left crankcase cover Inslalithe snap ring securely Inslallthe l...

Page 94: ...cing the oil seal install it into the left crankcase cover until it is fully seated After installing a Check Ihallhe washer and snap ring are installed in the snap ring always left crankcase cover sec...

Page 95: ...ASSEMBLY Install the one way valve onto the right crankcase as shown Install the oil pump shaft into the left crankcase Apply engine 011to the oil pump rotors sliding area Install the oil pump Innef...

Page 96: ...MEMO...

Page 97: ...ter 12 5 9 CONNECTOR LOCATION 5 10 PGM FI TROUBLESHOOTING INFORMATION 5 11 DTC INDEX 5 15 DTC TROUBLESHOOTING 5 16 MIL CIRCUIT INSPECTION 5 29 5 FUEL SYSTEM PGM FI FUEL LINE REPLACEMENT 5 30 FUEL PUMP...

Page 98: ...FUEL SYSTEM PGM FI COMPONENT LOCATION 10 shown After 12 only 10 N m 1 0 kgf m 7 Ibf ft 3AN m 0 3 kgf m 2 5Ibf ft 49N m __ 5 0 kgf m 36 IbHI tt 33 N m c 3 4 kgf m 24 IbHt 44 N m 4 5 kgf m 32 IbHt 5 2...

Page 99: ...olts and screws of the throttle body Loosening or tightening them can cause throttle valve and idle control failure SPECIFICATIONS ITEM Thro tle body idenllfication number 10 11 2 Afler 12 Idle speed...

Page 100: ...40004 r scs service connector 070PZ ZY30100 IP ss gauge man lf o d 107lAJ SSA0111 o I or 07406 0040006 U S A only NOI available in U S A Hose attachment 8 mm 9 Hose attachment 9 mm 9 mm Attachmentjoin...

Page 101: ...Adaptor female 07AAJ SBMASOO U S A only Battery harness 070MZ MEN0100 or 070MZ MENA100 U S A only FUEL SYSTEM PGM FI Battery harness adaptor 070MZ KRN01QO or070MZ KRNA100 U S A onIY I _ 5 5...

Page 102: ...le knob 3 Inspect the fuel line page 3 6 4 Inspect the regulator rectifier page 16 11 5 Inspect the condenser page 16 16 6 Inspect the ignition system page 16 5 Inspect the ignition system page 16 5 A...

Page 103: ...PGM FI SYSTEM LOCATION 10 shown FUEL PUMP DLe FUEL PUMP SUB HARNESS 4P RED CONNECTOR EeT SENSOR MAP SENSOR No 1 CKP SENSOR No 2 CKP SENSOR FUEL SYSTEM PGM FI EeM INJECTOR IAT SENSOR TP SENSOR 5 7...

Page 104: ...SS FEMAtE CONDENSER 23 25 OIBI 27 5r SCS CONNECTOR CONNECTION l IGNITION COIL FUEL PUMP u 191 IG f i c jll b 5 171 SENSOR SENSOR ENGINE STOP SWITCH 20 TA SG WARN INJ V WiBu A 24 PfY L o J BIJW 19 ENG...

Page 105: ...when detecting DTC I MIL rl Short terminals for 1 P reading DTC I MIL LgN 32 VIG 33 Gr Bu p 20 22 0 PB T TA TW vee so U G OLe LABEL 0 811251 l lJ L_ _ J j 8 127 ses SERVICE CONNECTOR OLCiFUEL PUMP SUB...

Page 106: ...ge 2 6 10 shown G J MAP SENSOR 3P BLACK CONNECTOR NOTE 1 INJECTOR 2P GRAY CONNECTOR NOTE 1 OLe FUEL PUMP SUB HARNESS 4P RED CONNECTOR cn rl l l TP SENSOR 3P BLUE CONNECTOR NOTE 3 5 10 W Eel SENSOR 2P...

Page 107: ...unning capability is maintained by pre programmed values in the simulated program map When any abnormality IS detected in the injector and or CKP sensor the fail safe function stops the engine to prot...

Page 108: ...70MZ MEN0100 or 070MZ MENA100 U S A only Connect the battery harness positive cable and battery harness cable 10 the 12 V battery NOTE Before connecting the battery harness cables to the 12 V battery...

Page 109: ...resent the MIL will come on and Will start blinking the oTC when running the engine Of connecting the 12 V battery to the fuel pump sub harness ECM selector switch is ON page 5 12 In the case that the...

Page 110: ...or rOLC labeled connector using the special tooL Connection Brown Green TOOL SCS service connector 070PZ ZY30100 3 Turn the ECM selector switch ON 4 Remove the special tool from the OLC labeled connec...

Page 111: ...leration 8 1 8 Loose or poor contact of the TP sensor connector Pre programmed value O TP sensor or its circuit malfunction 8 2 8 T p csensor circuit high voltage more than 4 93 V TP sensor or jts cir...

Page 112: ...Disconnect the ECM 33P Black connector Check for continuity at the Red yellow wire between the MAP sensor 3P Black connector and ECM 33P Btack connector Connection 14 Red yellow TOOL Test probe 07ZAJ...

Page 113: ...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 s...

Page 114: ...nsor with the HDS at idle speed Is the readjng changed YES Intermittent 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...

Page 115: ...3 3 ECl Sensor Resistance Inspection Turn the ECM selector switch OFF Measure the resistance at the ECT sensor terminals Standard 2 3 2 6 kO 20 C 68 F Is the resistance within 2 3 2 6 If YES Replace t...

Page 116: ...er wire Connection Pink Green red Turn the ECM selector switch ON Check the EeT sensor with the HOS Is about 0 V indicated YES Inspect the Eel sensor page 5 57 NO GO TO STEP 3 3 Eer Sensor Open Circui...

Page 117: ...ensor 3 TP Sensor Input Voltage Inspection Turn the ECM selector switch OFF Disconnect the TP sensor 3P Blue connector Turn the ECM selector switch ON Measure the voltage at the wire side Connection R...

Page 118: ...E CONNECTOR Wire sideffemale terminals 33 Q 33P BLACK CONNECTOR Wire side female terminals I YIG Check for continuity between the TP sensor 3P 3 P B L U E C O N N E C T O R Blue connector of the wire...

Page 119: ...ltage al the wire side Connection Redfyellow Green red Is the voltage within 4 75 5 25 V YES GO TO STEP 4 NO Open circUit In Green red wire Open circuit in Red yellow wire 4 TP Sensor Inspection 2 Rep...

Page 120: ...eck for loose or poor contact on the tAT sensor 2P connector and ECM 33P connector then recheck the OTC 1 tAT Sensor System Inspection Connect the 12 V battery ECM selector switch is ON page 5 12 Chec...

Page 121: ...ck the OTC 1 Injector System Inspection Erase the oTC s page 5 14 Connect the 12 V battery ECM selector switch is ON page 5 12 _ Check the injector with the HDS Is DTC 12 1 indicated YES GO TO STEP 2...

Page 122: ...5 Black blue TOOL Test probe Is there continuity YES GO TO STEP 5 07ZAJ ROJA110 NO Open circuil in Black blue wire 5 Injector Signal Line Short Circuit Inspection Connect the ECM 33P Black connector C...

Page 123: ...NO Intermittent failure 2 CKP Sensor Peak Voltage Inspection Turn the ECM selector switch OFF Disconnect the allerna orlCKP sensor 6P Black connector Crank the engine and measure the CKP sensor peak v...

Page 124: ...ignal line Signal line GROUND LINE Connection 10 12 After 12 TOOL Test probe Is there continuity 10 Ground line Ground tine ground 07ZAJ RDJA110 YES Short circuit in Signal line NO Open circuil in Sig...

Page 125: ...ide of the frame page 3 6 Disconnect the ECM 33P Black connector Ground the While blue 10 12 15 After 12 18 wire O 12 terminal of the wire harness side connector with a After 12 jumper wire TOOL Test...

Page 126: ...BLACK CONNECTOR Wire sidelfemale terminals Check for continuity between the ECM 33P Black connector of the wire harness side and ground Connection 27 Ground TOOL Test probe 07ZAJ ROJA110 If there is c...

Page 127: ...r tabs with the other hand to release the locking pawls pun the connector off then remove the retainer from Ihe fuel joint Absorb the remaining fuel in the fuel hose with a shop towel Be careful not t...

Page 128: ...CONNECT FITTING TOWEL 4 Hold the connector with one hand and squeeze the 5 32 retainer tabs with the other hand to release the locking pawls Puilihe connector off then remove the retainer from the in...

Page 129: ...ing removed The various manufactures feature different retainer specification FUEL PUMP SIDE 1 Insert a new retainer into the connector Align the retainer locking pawls with the connector grooves 2 Al...

Page 130: ...kage in fuel supply system page 3 6 INJECTOR SIDE 1 Insert a new retainer into the connector NOTE Align new retainer locking pawls with the connector grooves 2 Set a new joint rubber to the injector j...

Page 131: ...re and check that there is no leakage in fuel supply system page 3 6 FUEL PRESSURE INCREASING 1 Connect the 12 V battery to the fuel pump sub harness page 5 12 2 Temporarily install the fuel tank onto...

Page 132: ...battery to the fuel pump sub harness page 5 12 Support the fuel tank in an upright position onto the frame then remove the hose damp from the breather hose Turn the PUMp selector switch ON Read the f...

Page 133: ...he end of the hose into an approved gasoline gasolme container Turn the PUMP selector switch ON for 10 seconds Measure the amount of fuel flow Perform this inspection three times and take the average...

Page 134: ...f the wires are normal replace the fuel pump unit page 5 38 If there is no battery vollage check for open circuit in Black or Green wire between the regulator rectifier connector and fuel pump sub har...

Page 135: ...ump unit holder from the damage the hooks grooves on the fuel pump base tabs while pushing the and tabs holder against the base and slightly spreading the base tabs HOOK FUEL PUMP BASE Wipe up any spI...

Page 136: ...the strainer counterclockwise until its hook is damage the hook completely seated 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 p...

Page 137: ...oloration If the hooks and tabs are damaged or discolored replace the fuel pump unit as an assembly Be careful not 10 Release the hooks of the fuel pump umt holder from the damage the hooks grooves on...

Page 138: ...l pump assembly ASSEMBLY After 10 Clean the fuel pump joint area with compressed air Install a new fuel strainer onto the fuel pump assembly joint aligning its hook with the oint boss completely Apply...

Page 139: ...Ihan I Omm O D4 n 86 careful no to damage the fuel pump wiles Connect the fuel pump wires to the fuel pump base terminals completely as shown Install the fuel pump unit page 5 43 INSTALLATION Apply e...

Page 140: ...collars the shown dlffiction Four washers 5 44 Stopper cable to the stopper cable guide Stopper cable guide Six fuel pump mounting bolts Tighten the fuel pump mounting bolts to the specified torque in...

Page 141: ...e page 5 31 Remove the fuel pump wire clamp from the stopper cable guide Hold the fuel tank and disconnect the stopper cable from the frame stay Remove the fuel tank For fuel pump unit removal page 5...

Page 142: ...eleasing air cleaner housing cover tabs from the sub frame 10 N m 1 0 kgf m 7 Ibf ttl AIR CLEANER HOUSING INSPECTIONIINSTALLATION Check that the connecting boot is sealed properly al the air cleaner h...

Page 143: ...f m O 8IbHI 0 7 N m 0 1 kgf m 0 5 IbUt _ Apply Honda Bond A or Honda Handgnp Cement or equivalent Apply cemedlne 366 or eqUivalent INJECTOR REMOVAL FUEL SYSTEM PGM FI RETAINING BOLT AIR CLEANER ELEMEN...

Page 144: ...not to damage them Be careful no to Install the injector into the injector joint damage the O nng Align the boss of the injector with the injeclor terminals as shown 5 48 Install the injector jointJi...

Page 145: ...g from the injector side page 5 32 Disconnect the injector 2P Gray and MAP sensor 3P Black connectors Raise the rear wheel off the ground by placing a worksland or equivalent under the engine Remove t...

Page 146: ...throttle body from the insulator Remove the clamp of the MAP sensor and injector wire harness Remove the boll Remove the throttle drum cover while releasing its slot from the throttle body lab loosen...

Page 147: ...idle control allure Always clean the throttle body before disassembly to prevent dl 1 and debns from en anog the passages Do not remove the TP sensor LEFT VIEW 34 N m 0 3 Kgfm 2 5lbf tt FUEL SYSTEM P...

Page 148: ...orque TORQUE 4 0 N m 0 4 kgf m 3 0 IbHt Install the throttle drum cover while aligning its slol with the tab of the throttle body Instatt and lighten the bolt to the specified torque TORQUE 3 4 N m 0...

Page 149: ...rectifier stay to the throttle body install and tighten the bolts FUEL SYSTEM PGM FI 0 12 lmm 0 5 0 04 in 11 11 lmm 0 4 0 04 in I 11 1 mm 0 4 0 04 in Install the rear shock absorber upper mounting bol...

Page 150: ...45 FAST IDLE KNOB REMOVAL 5 54 Remove Ihe throttle body page 5 49 Clean around the fast idle knob with compressed air before removing the fast idle knob Loosen the lock nut and remove the fast idle kn...

Page 151: ...er 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 an...

Page 152: ...ther hose Install the fuel tank page 3 6 IAT SENSOR REMOVAL INSTALLATION 5 56 Remove the left side cover page 2 3 1 0 _ 12 Disconnect the fAT sensor 2P Gray connector After 1 2 Disconnect the fAT sens...

Page 153: ...esult in incorrect readings Do not lei the thermometer or Eel sensor touch the pan Temperature Resistance 40 C 1040F 1 1000C 212 F l 1 0 1 3 kG 0 14 0 17 kO Replace the Eel sensor if it is out of spec...

Page 154: ...e stop switch 2 ECM Power Input Line Inspection Disconnect the ECM 33P Black connector page 3 3p C B LA CC C K C O NNECTOR 5 58 _ Wire side female terminals Check for continuity at the ECM 33P Black c...

Page 155: ...SYSTEM FLOW PATTERN 6 2 SERVICE INFORMATION 6 3 TROUBLESHOOTING 6 4 SYSTEM TESTING 6 5 6 COOLING SYSTEM COOLANT REPLACEMENT 6 6 RADIATOR 6 7 WATER PUMP 6 10 6 1...

Page 156: ...COOLING SYSTEM SYSTEM FLOW PATTERN UPPER RADIATOR HOSES t 1 RADIATORS LOWER RADIATOR HOSES WATER PUMP 6 2...

Page 157: ...cooling system tester SPECIFICATIONS ITEM Coolant capacity Radiator cap relief pressure Recommended antifreeze TORQUE VALUES Water pump impeller TOOLS Attachment 32 x 35 mm 07746 0010100 Remover head...

Page 158: ...d in radiator hoses or water jacket Radialor air passage clogged with dirt Air in system Faulty waler pump Bent or worn water pump shaft Damaged water pump shaft bearings Coolant leak Faulty oil seal...

Page 159: ...e C OF _ 15 20 25 30 35 40 45 113 0 999 1 007 1 014 1021 1 028 32 41 5 1 009 1009 10 t 018 1 017 5 1 028 1 027 20 1 036 I 1 035 g 25 1 045 1 044 30 3 1 052 35 I 1 063 1062 ro 8 40 1 072 1 070 u 45 1 0...

Page 160: ...psi Repair or replace components if the system will not hold the specified pressure for al least 6 seconds After checking the pressure install the radiator cap securely COOLANT REPLACEMENT PREPARATIO...

Page 161: ...surface cool down before removing the radiator cap 1 f Fill the system with the recommended coolant through I the filler opening up to the filler neck CAPACITY 1 03 liter 1 09 US qt 0 91 Imp ql at ch...

Page 162: ...bolt ground wire and connector stay boss from the right side radiator lower mount Remove the right side radiator upper mounting boll washer and then remove the right side radiator Remove the left side...

Page 163: ...everse order of removal Tighten the radiator hose band screws as shown_ Fill the radiator with the recommended coolant mixture to the filler neck and bleed the air page 6 7 After installation check th...

Page 164: ...amount of weeping from the bleed hole is normal Make sure that there is no continuous coolant leakage from the bleed hole while operating the engine REMOVAL Drain the coolant page 6 7 Remove the drai...

Page 165: ...e cover Remove the water pump shaft bearing using 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...

Page 166: ...ht crankcase cover as shown Drille in a new Drive in a new bearing into the right crankcase cover bearing squarely using the special tools as shown with the marliing sIde facing up TOOLS 6 12 Driver A...

Page 167: ...draulic press and special tool MECHANICAL SEAL INSTALLER BASE TOOL Attachment 32 x 35 mm 07746 0010100 ATTACHMENT Check the mechanical seal for proper installation using J J the straight edge and feel...

Page 168: ...QUE 12 N m 1 2 kgf m 9lbHt Instalilhe dowel pins Install a new D ring to the water pump cover Install the water pump cover Install and tighten the bolts securely Install the coolant drain bolt with a...

Page 169: ...7 ENGINE REMOVAUINSTALLATION COMPONENT LOCATION 7 2 SERVICE INFORMATION 7 3 ENGINE REMOVAL 7 4 ENGINE INSTALLATlON 7 6 7 1...

Page 170: ...E REMOVAUINSTALLATION COMPONENT LOCATION 0 shown 88 N m 9 0 kgf m 651bHt 33 Nm 3 4 kgf m 24 Ibf ft 54 N m 5 5 kgf m 40 Ibf ft 54 N m 5 5 kgfm 40 Ibnt 54 N m 5 5 kgf m 40 IbHt 26 N m 2 7 kgf m 191bf ft...

Page 171: ...stroke oil U S A and Canada or equivalent motor oil API service classification SG or Higher JASO T 903 standard MA Viscosity SAE 10W 30 Recommended transmission oil Pro Honda GN4 4 stroke oil U S A a...

Page 172: ...age 15 29 Condenser page 16 16 Regulator rectifier page 16 11 After 2 only Drive sprocket cover page 3 18 Dnve chain page 3 18 Disconnect the allernatorlCKP sensor 6P Black connector Disconnect the EC...

Page 173: ...rm pivot nul washer and bolt Remove the lower engine hanger bolt nut and washer Remove the engine from the right side of the frame Note the direction of the engine hanger plates and mounting bolts Tem...

Page 174: ...bolts and nuts to the specified torque Route the wires hoses and cables properly page 1 21 Sel the engine into the frame in the reverse order of r i r l I removal Apply thin coat of grease to the swin...

Page 175: ...54 N m 5 5 kgf m 40 IbHt Cylinder head hanger bolt 54 N m 5 5 kg m 40 Ibf ft Cylinder head hanger plate bolt 33 No m 3 4 kgf m 24 Ibf ft Front engine hanger plate nut 26 N m 2 7 kgf m 19 IbUt Connect...

Page 176: ...oil page 16 13 Throttle body page 5 52 Exhaust pipe page 2 16 Fuel lank page 5 45 Engine guard page 2 4 Fill the radiator with the recommended coolant mixture to the filler neck and bleed the air page...

Page 177: ...GUIDE REPLACEMENT 8 22 CYLINDER COMPRESSION TEST 8 7 VALVE SEAT INSPECTION REFACING 8 23 CYLINDER HEAD COVER 8 7 CYLINDER HEAD ASSEMBLY 8 26 CAMSHAFT ROCKER ARM REMOVAL 8 10 CYLINDER HEAD INSTALLATION...

Page 178: ...CYLINDER HEADNALVES COMPONENT LOCATION 10 N m 1 0 kgl m 7lbHl 22 Nm 2 2 kgfm t6lbHt 33 N m 3 4 kgf m 24 IbHt 8 2 o o ____ v 16 Nm 1 6kgf m 121bHt 45 N m 4 6 kgf m 33 IbUt 54 N m 5 5 kgl m 40 IbUt...

Page 179: ...0 047 0 0008 0 0019 Valve guide projection above cylinder head Valve seat wid h 15 4 15 6 0 606 0 614 21 3 21 5 0 839 0 847 0 90 1 10 0 035 0 043 n 7 0 07 42 50 1 673 42 1 p 66 46 71 1 839 46 3 1 82...

Page 180: ...e reamer 5 0 mm 07984 MASOOO1 Not available in U S A Valve guide reamer 4 5 mm 07HMH MlOO101 or 07984 MA6000D U S A only I or 07HMH ML0010B U S A only Valve seal cutter 24 5 mm Flat cutler 33 mm 32 IN...

Page 181: ...on gauge attachment 07AMJ MENA200 U S A only Interior cutter 26 mm 60 EX 07780 0014500 or equivalent commercially available in U S A CYLINDER HEADNALVES Cutter holder 5 0 mm 07781 0010400 or equivalen...

Page 182: ...lty decompressor plunger Faulty decompressor weight Compression too high over heating or knocking Excessive carbon build up on piston head or combustion chamber ExcessIve smoke Worn valve stem or valv...

Page 183: ...s until the gauge needle stops moving COMPRESSION 598 kPa 6 1 kg em 87 psi at cranking Low compression can be caused by Improper valve adjustment Valve leakage Blown cylinder head gasket Worn piston r...

Page 184: ...he breather plate bolt threads as shown Inslall and lighten the breather plale bolts to the specified torque TORQUE 12 N m 1 2 kgf m 9lbHt INSTALLATION Check the plug hole seal ring and packing for da...

Page 185: ...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 7lbHt Connect the spa plug cap and cr...

Page 186: ...ion stroke This position can be obtained by confirming that there 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 cranks...

Page 187: ...olts camshaft holders and sel rings drop the set rings mlo the crankcase Slide the cam sprocket side camshaft bearing to the cam sprocket Remove the camshaft by removing the cam chain from the cam spr...

Page 188: ...ARM SHAFT Inspect the rocker arm shaft for wear or damage Measure the rocker arm shaft D D SERVICE LIMIT 12 97 mm 0 511 in Calculate the rocker arm to shaft clearance SERVICE LIMIT 0 055 mm 0 0022 in...

Page 189: ...ove the decompressor weight outward with your finger 2 Release the decompressor weight The decompressor weight should move inward automatically If the decompressor weight operation is abnormal disasse...

Page 190: ...ng INSPECTION CLEANING Check the decompressor weight for bends or damage Check the decompressor cam surface for wear or damage Check the camshaft bearing for wear or damage Check the decompressor spri...

Page 191: ...he decompressor weight stopper pin Into the camshaft Instalilhe camshaft page 8 33 VALVE CLEARANCE ADJUSTMENT Adjust the valve clearance while the engme is rold below 3S CI95 F Remove the camshaft pag...

Page 192: ...mm In Iflcrements A New shim thickness of 0 025 mm B Recorded valve clearance C Specified valve clearance D Old shim thickness Make sure of the correct shim thickness by measuring the shim using a mi...

Page 193: ...following Exhaust pipe page 2 15 Sub frame page 2 6 Camshaft page 8 10 Rocker arm page 8 12 Valve lifters shims page 8 15 Drain the coolant page 6 7 Remove Ihe shock absorber upper nut and bolt Turn t...

Page 194: ...cylinder head hanger plates Remove the cylinder head 6 mm bolts Loosen the cylinder bolt loosen the cylinder head bolts in a crisscross paltern in two or three sleps Be careful not to let Remove the...

Page 195: ...LE PROTECTOR lifter bore TOOL Tappet hole protector 07JMG KY20100 not available in U S A U SA only An equivalent tool can easily be made from a plastic 35 mm film container as shown 5mm 5mm TOP VIEW 1...

Page 196: ...ombustion scratch the chamber or exhaust port combustion Check the spark plug hole and valve area for cracks chamber or head gasket surface Replace the cylinder head if necessary SPRING SEAT VALVE RET...

Page 197: ...are shorter than the service limits VALVENALVE GUIDE Inspect each valve for out of round burns scratches or abnormal stem wear Check the valve movement in the guide Measure and record the valve stem...

Page 198: ...er depth see specification page 8 22 using a marker Chill a new valve guides in a freezer for about 1 hour Heal the cylinder head to 100 150 C 212 302 F with a hot plate or oven Do not heat the cylind...

Page 199: ...xhaust valves thoroughly to remove carbon depOSits Apply a light coating of Prussian Blue to the valve seal Tap the valves and seats using a rubber hose or olher hand lapping 1001 Remove the valve and...

Page 200: ...ct area is too high on the valve the seal must be lowered using a 32 flat culler If the contact area is too low on the valve the seal must be raised using a 60 interior cutler Reface the seal Use a 45...

Page 201: ...EATWIDTH 32 cJ Use a 60 interior cutter remove 1f4 of the existing valve seat material TOOLS IN Interior cutter 34 mm Cutter holder 5 0 mm EX Interior cutter 26 mm Cutter holder 4 5 mm 07780 0014700 0...

Page 202: ...he exhaust valve face and tap 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 defonn or damag...

Page 203: ...ombustion chamber side Install the spring retamers NOTE Do not confuse the intake spring retainers and exhaust spnng retainers Intake spring retainer Two grooves Exhaust spring retainer One groove CYL...

Page 204: ...the intake and exhaust valve cotters The inside radius of intake valve cotler is larger than that of the exhaust valve cotter Suppon he cylinder Tap the valve stems with a hammer and shaft as shown he...

Page 205: ...ng to the water hose jOint Install the water hose joint to the cylinder head Instal and tighten the bolt securely Install the following ECT sensor page 5 57 Spark plug page 3 11 Cylinder head page 8 3...

Page 206: ...ith Ihe washers crankcase Tighten the cylinder head bolts in a crisscross pattern in two or three steps to the specified torque 8 30 TORQUE 45 N m 4 6 kgf m 33 1bHt Install and tighten Ihe cylinder he...

Page 207: ...6 9 Connect the ECT sensor 2P Black connector Apply molybdenum oil solution to the valve lifter outer surface Be careful not to let Install the shims and valve lifters the shims drop into the left cr...

Page 208: ...4 5 kgf m 32Ibf ft Install the following Rocker arm page 8 32 Camshaft page 8 32 Sub frame page 2 8 Exhaust pipe page 2 16 Fill the radiator with the recommended coolant mixture to the filler neck an...

Page 209: ...ft cam lobes Install the camshaft Instalilhe camshaft while installing the cam chain onto with the inrake cam the cam sprocket making sure thai the index line on the lobes facing up cam sprocket is al...

Page 210: ...ers with their IW marks facing the intake side Apply engine oil to the camshaft holder mounting bolt threads Align the rocker arm Install and tighten the camshaft holder mounting bolt to shaft cut out...

Page 211: ...t Afrer 12 only Instalilhe condenser page 16 16 Install the cylinder head cover page 8 8 CAM CHAIN TENSIONER CAM CHAIN TENSIONER LIFTER REMOVAL After 12 only Remove the condenser page 16 16 Remove the...

Page 212: ...sert the cam chain tensioner holder Into the cam r chain tensioner lifter Turn the cam chain tensioner holder clockwise fully and lock the cam chain tensioner lifter by pushing the handle TOOL Cam cha...

Page 213: ...11 5 Remove the bolt collar and cam chain tensioner INSPECTION Inspect the cam chain tensioner and cam chain guide for excessive wear or damage replace them if necessary INSTALLATION Clean and apply l...

Page 214: ...tensioner bolt to the specified torque TORQUE 12 N m 1 2 kgf m 9lbHt Install the following Flywheel page 11 5 Left crankcase cover page 11 8 Installihe cam chain guide by aligning its tabs with the ii...

Page 215: ...NENT LOCATION 9 2 SERVICE INFORMATION 9 3 TROUBLESHOOTING 9 3 CYLINDER REMOVAL 9 4 9 CYLINDER PISTON PISTON REMOVAL 9 4 CYLINDER PISTON INSPECTION 9 5 PISTON INSTALLATION 9 7 CYLINDER INSTALLATION 9 8...

Page 216: ...CYLINDER PISTON COMPONENT LOCATION 9 2...

Page 217: ...002 Top ring mark __ 1_ R N M mark side facing up Piston ring to ring groove clearance Piston ring end gap Cylinder to piston clearance Connecting rod small end 1 0 Connecting rod to piston pin clear...

Page 218: ...rs towel over the crankcase to prevent the piston pin clip from dropping into the crankcase Pis on rings are easily broken take care nollo damage Ihemdun ng removal 9 4 Press the piston pin out of the...

Page 219: ...9 6 SERVICE LIMIT 0 085 mm 0 0033 in Calculate the taper and aut af round at three levels in the X and Y axis Take the maximum reading to determine the cylinder condition SERVICE LIMITS Taper 0 010 m...

Page 220: ...IT 76 740 mm 3 0213 in If the 0 0 is under the service limit or nearly 15 0 hours of running lime have elapsed replace the piston with a new one Measure the piston pin bore 1 0 SERVICE LIMIT 16 03 mm...

Page 221: ...om entering the crankcase Clean the piston ring grooves thoroughly Apply engine oil to the piston rings and install them as shown Do not damage the piston ring by spreading the ends too far Be careful...

Page 222: ...g used piston pin clips may lead to serious engine damage CYLINDER INSTALLATION Be careful not to damage the pis on ring and cylmder wall Ttghten the boll after ins ailing the cylmder Mad 9 8 Install...

Page 223: ...10 CLUTCH KICKSTARTERIGEARSHIFT LINKAGE COMPONENT LOCATION 10 2 CLUTCH 10 7 SERVICE INFORMATION 10 3 KICKSTARTER 10 16 TROUBLESHOOTlNG 10 4 GEARSHIFT LINKAGE 10 20 RIGHT CRANKCASE COVER 10 5 10 1...

Page 224: ...CLUTCH KICKSTARTERlGEARSHIFT LINKAGE COMPONENT LOCATION 10 22 N m 2 2 kgf m 16 Ibf ft 12 N m 1 2 kgf m 91bHI 69 N m 7 0 kgf m 38Nm 281bHt 10 2 12 N m 1 2 9lbHt 12 N m 1 2 kgf m 9 Ibf ft...

Page 225: ...652 16 466 16 484 0 6483 0 6490 16 46 0 648 19 000 19 021 0 7480 0 7489 19 050 0 7500G 15 000 15 018 0 5906 0 5913 15 037 0 5920 18 959 18 980 0 7464 0 7472 18 941 0 7457 Counlershaft 0 0 al kickstar...

Page 226: ...s out of gear Worn shift drum stopper arm Weak or broken shift arm return spnng Loose stopper plate bolt Gearshift pedal will not return Weak or broken gearshift spindle relurn spring Benl gearshift s...

Page 227: ...the radiator hose from the right crankcase cover Loosen the right crankcase cover bolts in a criss cross TI ijlii D pattern in two or three sleps Remove the bolts and right crankcase cover Remove the...

Page 228: ...ghten the right crankcase cover bolts in a crisscross pattern in two or three steps Connect the radiator hose to the right crankcase cover and lighten the band screw securely page 6 9 Apply locking ag...

Page 229: ...ross pattern in two or three steps Remove the clutch springs Remove the clutch pressure plate Remove the clutch tifter assembly and clutch lifter rod 10 Remove the eight clutch discs and seven clutch...

Page 230: ...cially available in U S A Remove the lock washer and thrust washer Remove the special tool and clutch center Remove the thrust washer and clutch outer Remove the needle bearing and clutch Quter gUide...

Page 231: ...s should Measure the thickness of each disc be replaced as a sel if one or more is less than the service limit SERVICE liMIT 2 85 mm 0 112 in CLUTCH PLATES Check the plates for excessive warpage or 1...

Page 232: ...d or damage JUOOER SPRING SPRING SEAT After 10 Check the judder spring and spring seat for deformation warpage or damage replace them if necessary A damaged or warped spring seat will cause the judder...

Page 233: ...rings as follows LIFTER LEVER BEARING REPLACEMENT Remove the engine from the frame page 7 4 Remove the cam chain tensioner lifter page 8 35 Remove the clutch page 10 7 Remove the lifter lever needle b...

Page 234: ...010000 07746 0041300 07AMO MENA200 Install new oil saallo the specified depth as shown Install the following Clutch page 10 12 Cam chain tensioner lifter page 8 36 Engine page 7 6 INSTALLATION 7J IJ L...

Page 235: ...f m 9lbHt SPRING PRESSURE PLATE Apply molybdenum oil solution to the clutch lifter lever cam area Instalilhe dutch lifter lever into the left crankcase Connect the clutch cable end to the litter lever...

Page 236: ...W lock washer by aligning its groove with the clutch center rib Apply engine oil to the threads and sealing surface of the clutch center lock nul then install it onto the malnshaft I Tighten Ihe lock...

Page 237: ...il Install the clutch disc A large I D seven clutch plates and seven clutch discs B Insert the dutch lifter rod into the malnshaft Inslalilhe clutch lifter assembly Instalilhe clulch pressure plate In...

Page 238: ...ks KICKSTARTER REMOVAL Remove the right crankcase cover page 10 5 Remove the clutch page 10 7 Remove the idle gear and bushing Unhook the kickstarter return spring from the crankcase Remove the kicksl...

Page 239: ...Measure the kickstarter spindle 0 D SERVICE LIMIT 16 46 mm 0 648 in Check the kickstarter idle gear for wear or damage Measure the klckstarter idle gear 1 0 SERVICE LIMIT 19 050 mm 0 7500 in Measure...

Page 240: ...lthe sharp edge of the snap ring facing out 10 18 KleKSTAR ER SPINDLE RET URN SPRING Instalilhe thrust washer to the kickstarter spindle THRUST WASHER KICKSTARTER SPINDLE Apply molybdenum oil solution...

Page 241: ...KS Align the punch marks and install the starter ratchet Install the end washer to the kickstarter spindle INSTALLATION Install the ratchet spring Apply engine oil to the kickstarter spindle journal B...

Page 242: ...nd starter idle gear onto the counlershaft Inslallthe clutch page 10 12 Install the right crankcase cover page 10 6 GEARSHIFT LINKAGE REMOVAL Remove the right crankcase cover page 10 5 Remove the clut...

Page 243: ...move the bolts guide plate and drum shifter as an ratchet pawls fall assembly when removing the gUide plate and drum shifter Remove the shift drum center pin and shift drum center Remove the bolt stop...

Page 244: ...ase surface RATCHET PAWL Remove the following Guide plale Drum shifter Ratchet pawls Plungers Springs Clean the ratchet pawls plungers springs and drum shifter with engine oil Check each part for wear...

Page 245: ...TORQUE 12 N m 1 2 kgf m 9lbHt Check the stopper arm for proper operation Move the stopper arm oul of the way using a screwdriver Align the shift drum center groove with the drum pin and install it to...

Page 246: ...rshift spindle serration area Do not forget 10 Install Ihe washer and gearshift spindle assembly into install the washer the crankcase while aligning the spring ends with the onlo Iha gearshift crankc...

Page 247: ...11 ALTERNATOR COMPONENT LOCATION 11 2 FLYWHEEL 1 1 5 SERVICE INFORMATION 11 3 STATOR CKP SENSOR 11 6 LEFT CRANKCASE COVER REMOVAL 11 4 LEFT CRANKCASE COVER INSTALLATION 11 8 11 1...

Page 248: ...ALTERNATOR COMPONENT LOCATION 10 shown After 12 12 N m 1 2 kgf m 9Ibf ft 10 N m 1 0 kgf m 7 Ibf ft 64 N m 6 5 kgf m 47Ibf ft 12 N m 1 2 kgf m 9lbHt 11 2...

Page 249: ...case cover bolt TOOLS Flywheel holder 07725 0040001 F 64 N m 6 5 kgf m 47 Ibf ft 5 2 N m 0 5 kgf m 3 8 IbUt 5 2 N m 0 5 kgf m 3 8 Ibf ft 12 N m 1 2 kgf m 9lbHt Flywheel puller 07QMC HP1 01 00 o or 07A...

Page 250: ...ase the wire clamp from the connector holder Disconnect the alternator CKP sensor 6P Black connector Loosen the left Remove Ihe left crankcase cover bolls and left cran case cover crankcase cover bolt...

Page 251: ...uller adapter TOOL U S A only 070MG KSE0100 Not available in U S A Thread protector 07AMC MEBA110 This thread protector is included with 07AMC MEBA100 or can be ordered separately Attach the special t...

Page 252: ...he special tool and lighten the nul to the specified torque TOOL Flywheel holder 07725 0040001 or 07AMB MENA100 U S A only TORQUE 64 N m 6 5 kgf m 471bHt Install the left crankcase cover page 11 8 STA...

Page 253: ...unting socket bolts to the specified torque TORQUE 5 2 N m 0 5 kgf m 3 8 JbHt NO 2 CKP SENSOR Install the CKP sensors and wire clamp into the left crankcase cover Apply locking agent to the CKP sensor...

Page 254: ...he oil seal of the left crankcase cover Tighten the left crankcase cover bolts to the specified torque In a crisscross pattern in two or three sleps TORQUE 12 N m 1 2 kgf m 9 lbHt Route 1M wire Connec...

Page 255: ...T LOCATION 12 2 CRANKCASE 12 13 SERVICE INFORMATION 12 3 TRANSMISSION 12 18 TROUBLESHOOTING 12 6 CRANKSHAFT 12 24 PRIMARY DRIVE GEAR BALANCER CRANKCASE BEARING DRIVE GEAR 12 7 REPLACEMENT 12 26 BALANC...

Page 256: ...CRANKCASE CRANKSHAFTITRANSMISSION BALANCER COMPONENT LOCATION 22 N m 2 2 kgf m 16Ibf ft 12Nm 1 2 10 Nm 1 0 gf m 7Ibf Il 12 N m 12 kgf m 9lbHt 16 N m 1 6 kgf m 121bHt 12 2...

Page 257: ...case mating surfaces when servicing Clean the oil passages before assembling the crankcase halves SPECIFICATIONS Crankshaft Transmission ITEM Side clearance Radial clearance Runout Gear 1 0 Unit mm in...

Page 258: ...ft 16 N m 1 6 kgf m 121bHt 10 N m 1 0 kgf m 7lbHt Remover handle 07936 3710100 Attachment 72 x 75 mm 07746 0010600 Apply locking agent to the threads Pro Honda Hondalock 3 or equivalent high strength...

Page 259: ...2 S 07724 0010100 i I Pilot 17 mm 07746 0040400 Pilot 30 rnm 07746 0040700 Universal holder 07725 0030000 0 O 7 72 4 O O 1 A 2 00 iU S A 0 Y __ 0 07724 001A100 U S A only Valve guide driver 8 0 mm Bea...

Page 260: ...cylinder piston or piston rings page 9 5 Transmission jumps out of gear Worn gear dogs Worn gear shifter groove Bent shift fork shaft Broken gearshift drum stopper arm page 10 20 Broken gearshift drum...

Page 261: ...ve and driven gears TOOL Gear holder M2 5 07724 0010100 or 07724 001 A100 U S A only Remove Ihe primary drive gear bolt and washer then remove Ihe gear holder Remove the clutch outer needle bearing an...

Page 262: ...ch outer guide needle bearing and clutch ouler to the mainshaft Insert the gear holder between the primary drive and driven gears TOOL Gear holder M2 5 07724 0010100 or 07724 001A100 U S A only Apply...

Page 263: ...ven I r gear and O ring I Check the water pump drive gear and balancer driven gear for wear or damage Turn the balancer shaft as shown and remove it from i i the left side i Check the balancer shaft f...

Page 264: ...rt the gear holder between the balancer drive and i driven gears r TOOL Gear holder M1 5 07724 010200 or 07724 001A200 U S A only Apply engine oil to the balancer shaft lock nut threads Install and ti...

Page 265: ...hment 32 x 35 mm Pitot 15 mm 07749 0010000 07746 0010100 07746 0040300 After inslallation apply engine oil 10 the bearing Install the snap ring into the groove in the right crankcase Apply grease to n...

Page 266: ...e snap ring and left needle bearing Dn ve in a new Drive in a new balancer shaft needle bearing using the bearing squarely special tools with the marked side facing up TOOLS 12 12 Driver Attachment 32...

Page 267: ...PARATION For removal of necessary parts before separating the crankcase page 12 3 Remove the bolt and hose guide Disconnect the transmission breather hose from the right crankcase Loosen the drive spr...

Page 268: ...ring oil pump driven gear and drive pin Remove the transmission oil drain bolt and sealing washer Loosen the crankcase bolts in a crisscross pattern in two or three steps Remove the crankcase bolts an...

Page 269: ...ting surfaces before assembly and check for wear or damage If there is minor roughness or irregularities on the crankcase mating surfaces dress them with an oil stone Install the one way valve to the...

Page 270: ...crisscross pattern in two or three progressive sleps After lightening Ihe crankcase bolts lighten the transmission oil drain bolt to the specified torque TORQUE 16 N m 1 6 kgf m 12 1bHt Check that the...

Page 271: ...counlershaft O ring and install it to the counlershaft collar Install them to the countershaft Install the drive sprocket to the countershaft with its flat side facing out as shown Install the washer...

Page 272: ...ase does not interfere Place Ihe right crankcase facing down and separate Ihe with the oil jet right and left crankcase halves Remove the shift fork shafts Remove the shift forlc guide pins from Ihe g...

Page 273: ...each gear SERVICE LIMITS M4 M5 23 07 mm 0 908 in C1 20 07 mm 0 790 in C2 27 07mm 1 066in C3 25 07 mm 0 987 in BUSHING Check the bushings for damage or excessive wear Measure the 0 0 of each bushing SE...

Page 274: ...C3 bushing 21 94 mm 0 864 in Calculate the bushing la shaft clearance SERVICE LIMITS M5 0 12 mm O OOSln C1 0 07 mm 0 003 In C2 C3 0 12 mm 0 005 In SHIFT FORK M5 C2 C3 C1 Check the shift forks for abno...

Page 275: ...ge 12 28 ASSEMBLY DRUM Apply molybdenum oil solution to the mainshaft and countershaft spline area and transmission gear sliding surface Assemble all parts into their original positions Check the gear...

Page 276: ...SSION BALANCER MAINSHAFT MAINSHAFTfM1 GEAR 14T M4 BUSHING THRUST WASHERS COUNTERSHAFT THRUST WASHER THRUST WASHER 12 22 C2 BUSHING SNAP RINGS M4 GEAR 18T C4 GEAR 24T THRUST WASHER C2 GEAR 34T M5 BUSHI...

Page 277: ...ty countershafl both ends MAINSHAFT ASSEMBLY COUNTERSHAFT ASSEMBLY I Each gea eelh MAINSHAFT COUNTERSHAFT ASSEMBLY Each shift fork has an identification mark RNM R is for the nght shift fork RNM L is...

Page 278: ...crankcase on the right connecting rod crankcase does not Interfere with the oil jet Place the left crankcase facing down and separate the left and right crankcase halves Assemble crankcase halves pag...

Page 279: ...cting rod big end radial clearance in both X and Y directions SERVICE LIMIT 0 05 mm 0 002 in Measure the connecting rod big end side clearance using a feeler gauge SERVICE LIMIT 0 8 mm 0 03 in INSTALL...

Page 280: ...T CRANKCASE LEFT COUNTERSHAFT BEARING 22 x52 x 14 OIL SEAL LEFT MAINSHAFT BEARING 17 x40 x 11 28 x RIGHT MAINSHAFT BEARING 22 x 47 x 14 RIGHT COUNTERSHAFT RIGHT CRANKSHAFT BEARING 17 x40 x 11 BEARING...

Page 281: ...010000 Attachment 72 x 75 mm 07746 0010600 Pitot 30 mm 07746 0040700 Left crankshaft bearing Driver 07749 0010000 Attachment 62 x 68 mm 07746 0010500 After installation apply engine oil to the cranksh...

Page 282: ...lips Install the left Install the left crankshaft oil seal to the specified depth crankshaft oil seal below the crankcase surface as shown with its flat side facing up 12 28 TRANSMISSION OIL PUMP GEAR...

Page 283: ...tlools TOOLS Oil pump shaft needle bearing Bearing remover shaft 10 mm 07936 GE00100 Bearing remover head 10 mm 07936 GE00200 Not available in U S A Remover weight TOOLS U S A only Remover handle 0774...

Page 284: ...0 mm 07749 0010000 07746 0010200 Drive in a new oountershaft bearing until it is fully seated using the special tools TOOLS Drive n a new bearing squarely with its sel plale groove side facing up Coun...

Page 285: ...ment 37 x 40 mm Pilot 17 mm 07749 0010000 07746 0010300 07746 0041000 07749 0010000 07746 0010200 07746 0040400 After installation apply engine oil to each bearing Install a new gearshift drum bearing...

Page 286: ...mage and replace it if necessary OIL JET Clean and apply a locking agent to the oil jet bolt i z IIII J threads as shown I Install the oil jet and lighten the boll to the specified torque TORQUE 10 N...

Page 287: ...FRONT WHEEUSUSPENSION STEERING COMPONENT LOCATION 13 2 SERVICE INFORMAnON 13 3 TROUBLESHOOTING 13 6 FRONT WHEEL 13 7 FORK 13 14 HANDLEBAR 13 36 HPSD 13 41 STEERING STEM 13 52 CLUTCH LEVER 13 56 EI 13...

Page 288: ...80 IbUt 22 N m 2 2 kgf m 16 IbUt 44 N m 4 5 kgf m 321bHt 20 N m 2 0 kgf m 15Ibf ft 20 N m 2 0 kgl m 1Slbf ft 30 N m 3 1 kgf m 22 IbHt 88 N m 9 0 kgf m 65lbnt 5 2 N m 0 5 kgf m 3 8Ibf ft 20 N m 2 0 kgf...

Page 289: ...e brake lever SPECIFICATIONS ITEM Cold tire p e e _______ _ STANDARD 100 kPa 1 0 kgf cm2 15 psi I Axle shaft runout Wheel rim R a d ia I runout Axi ia I Wheel hub to rim d i ta ce _ _____ Fork Spring...

Page 290: ...rm 121bHt 4 0 N m 0 4 kgf m 3 0 IbHt 9 9 N m 1 0 kgf m 7 3IbHt See page 13 57 10 N m 1 0 kgf m 7 IbHt 1 5 N m 0 2 kgf m 1 1 IbHt 30 N m 3 1 kgf m 22 IbHt 30 N m 3 1 kgf m 22 IbHt 69 N m 7 0 kgf m 511b...

Page 291: ...ng race installer 2 required 070MF MEN0100 Bearing remover shaft 07GGD 001D100 Installer shaft Q7VMF KZ30200 40r070MF_MENA100 U S A O O IY __ ______________________ Fork rod stopper Collar 07AMB KZ3A1...

Page 292: ...l quantity in each fork tube Faulty steering head bearings Bent frame Worn wheel bearings Worn swingarm pivot components Unevenly adjusted right and left fork legs Front wheel wobbling Bent rim Worn w...

Page 293: ...disc cover bolt After 12 Raise the front wheel off the ground by placing a fr 1T jr j workstand or equivalent under the engine Remove the bolts and brak e disc cover Remove the axle nul and loosen the...

Page 294: ...r finger The bearings should turn smoothly and Quietly Also check thatlhe bearing outer race fits tightly in the wheel hub Rep ace the Replace the wheel bearing if necessary page 13 8 bearings in pair...

Page 295: ...nd nuts Brake disc Dust seal Replace the wheel Install the remover head into the wheel bearing j r f 1 bearings in pairs From the opposite side install the remover shaft and r Do not reuse old drive t...

Page 296: ...nd begin the lacing with new spokes Adjusllhe hub position so the distance from the hub left end surface to the side of the rim is 28 0 1 0 mm 1 10 0 04 in as shown RIM LOCK 12 N m 1 2 kgl m 9 IbHt a...

Page 297: ...place then drive a new right wheel bearing using the same speciallools Pack the lips of a new right dust seal with grease and install it to the wheel hub Pack the lips of a new left dust seal with gre...

Page 298: ...clamping surface of Ihe axle shaft and axle holders Install the front wheel between the fork legs so that the brake disc is positioned between the pads being careful nollo damage the pads Apply a thi...

Page 299: ...the fork legs are parallel then lighten the right axle holder bolts to the specified torque TORQUE 20 N m 2 0 kgf m 151bHt 10 12 lnstalilhe brake disc cover bolt Tighten the bolt to the specified tor...

Page 300: ...front wheel To do so will cause difficulty in fitting the brake disc between the brake pad Remove the fork protector mounting bolls and fork protector 10 shown loosen the fork top bridge pinch bolts W...

Page 301: ...he fork Measure the length between the axle holder and outer tube and record it before disassembling the fork Turn the rebound and compression damping adjusters counterclockwise to the softest positio...

Page 302: ...n the fork center bolt Push the fork damper out from the slider unlil the fork center bolt lock nut is fully exposed and install the piston base or mechanic s stopper 1001 between the axle holder and...

Page 303: ...ll nOI be able 10 reassemble the fori damper Remove the push rod from the piston rod Be careful JO to Remove the piston base or mechanic s stopper tool damage the fork between the axle holder and fork...

Page 304: ...der bushings for wear or damage page 13 20 SPRING BACK UP RING DUST SEAL STOPPER RING Using quick successive motions pull the fork slider oul Do not damage the sJider bushing especially the slK1mg sur...

Page 305: ...lation If the lock nut was removed the piston rod will fall into the fork damper and you will not be able to reassemble the fork damper After 10 Set the fork damper in a vise with a piece of wood or r...

Page 306: ...d Be careful not to damage the fork cap bushings 10 BACK UP RING BUSHINGS After 10 Pis rON RING BUSHINGS Empty the fork oil from the fork damper by pumping the F O R K D A M P E R piston rod several l...

Page 307: ...sive wear or scratches replace them if necessary Check the compression damping adjuster for clicks FORK CENTER BOLT Check the fork center bolt for damage Check the rebound damping adjuster for clicks...

Page 308: ...f Ihe service limit is exceeded or Ihere are fork slider if it is scratches or nicks that will allow fork oil to leak past the bent seals FORK SPRING OUTER TUBE FORK SLIDER FORK Measure the fork sprin...

Page 309: ...eck the fork damper operation again page 13 29 ASSEMBLY FORK DAMPER FORK SPRING FQRKDAMPER FORK SLIDER I SLIDER BUSHING BACK UP RING 8 0ILSEAL 34 N m 3 5 kgf m 2Slbf ft OUTER TUBE PISTON ROD PLUG BOLT...

Page 310: ...N G or non flammable solvent and wipe them dry Be careful not 10 damage the sJidef bushing coaling Do not open Ihe slider bushing more than necessary 13 24 OUTER TUBE AND SLIDER ASSEMBLY Wrap the end...

Page 311: ...ring into the outer tube using the special 1001 BACK UP RING Drive the oil seal into the outer lube using the special tool TOOL Fork seal driver 48 2 x 58 mm 070MO MEN0100 or 070MO MENA100 U S A only...

Page 312: ...k cap bushings new O rings and piston ring Install the O rings and piston ring to the fork cap assembly Extend the piston rod to its maximum length Pour the recommended fork oil into the fork damper R...

Page 313: ...while holding the fork damper TOOL Fork cap bolt holder 36 mm 070MB MEN0100 or 070MB MENA100 U S A only TORQUE 30 N m 3 1 kgf m 22 IbHt BOLT HOLDER After 10 Set the fork damper in a vise with a piece...

Page 314: ...2 Imp azl of fork oil will be drained from the fork damper through the oil hole This will cause 195 emJ 6 6 US OZ 6 9 Imp ozl 11 12 240 cmJ 8 1 US OZ 8 4 Imp oz After 12 243 emJ 8 2 US oz 8 6 Imp oz...

Page 315: ...e piston rod then check that it extends to its maximum length If the piston rod does not extend to maximum bleed the fork damper again Wipe off any oil completely from the fork damper Compress the pis...

Page 316: ...___ S 6 S 2 7 9 7 6 1 7 3 _ 6 8_ 6 0 If the fork damper has not been disassembled from the outer lubeffork slider turn it upside down for 20 minutes and drain the fork oil from the inside of the outer...

Page 317: ...the fork assembly Apply recommended fork oil page 13 26 to a new 0 ring and install it to the fork damper Temporarily install the fork damper assembly into the fork assembly RING COLLAR BACK UP RING S...

Page 318: ...boll lock nut and fork center bolt clearance STANDARD 1 5 2 0 mm 0 06 0 08 in If the clearance is out of specification check the fork center bolt lock nut and fork center bolt installation 1 5 2 0mm...

Page 319: ...ure the oil Pour the recommended fork oil into the outer tube I 10 shown OUTER TUBE capacity is the same in both fork legs RECOMMENDED FORK OIL Pro Honda HP Fork Oil 55 19 STANDARD FORK OIL CAPACITY 1...

Page 320: ...to the original positions as noted during removal COMPRESSION ADJUSTER REBOUND ADJUSTER INSTALLATION install the fork leg and lighten the bottom bridge pinch bolts to the specified torque TORQUE 20 N...

Page 321: ...hten the bottom bridge pinch bolts to the specified torque TORQUE 20 N m 2 0 kgf m 15Ibf ft Tighten the top bridge pinch bolts to the specified torque TORQUE 22 N m 2 2 kgf m 161bHt NOTICE I Over tigh...

Page 322: ...que TORQUE 30 N m 3 1 kgf m 22 IbHt Inslall the brake hose clamp and bolts Tighten the bolls securely Install the fronl wheel page 13 12 Inspect the wear rings for wear or damage Replace the wear ring...

Page 323: ...the hydraulic Ime and master cylinder Keep the brake master cylinder upright to prevent air from entering the hydraulic system Remove the throll e housing as an assembly as follows Loosen the throttle...

Page 324: ...ove the throttle grip from the throttle pipe Loosen the handlebar lower holder nuts Remove the bolls upper holders and handlebar Remove the lower holder nuts washers bushings and lower holders INSTALL...

Page 325: ...lders aligning the O h o w a U P P E R H O L D E R S paint marl on the handlebar with the top surface of the lower holders Inslall the upper holders with its punch mark facing r iiii iiiiiiiil forward...

Page 326: ...ighten the throttle 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 t...

Page 327: ...screw on the handlebar Align the center of each holder with the paint mark on the handlebar as shown Tighten the engine stop switch screw to the specified torque TORQUE 1 5 N m 0 2 kgf m 1 11bHtJ Cla...

Page 328: ...e the steering damper page 13 41 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 dam...

Page 329: ...using the special tool b STOPPER RING TOOL Collar 07KPF V060100 Install a new stopper ring into the groove of the damper mounts securely SPHERICAL BEARING Set a 7 mm bolt and nut to the spherical bea...

Page 330: ...e to gently press the bearing into place 0 shown 10 shown SPHERICAL BEARING SPHERICAL BEARING REMOVER Inslall the stopper ring into the groove of the damper l I 0 shown mount securely Install the stee...

Page 331: ...mm screw to the free piston then remove the free piston and O ring Drain the damper oil from the damper case Remove the plug bolt and O ring Remove the adjuster piece from the damper case 8 mm SCREW...

Page 332: ...own SNAP SNAP RING DAMPER ROD Carefully puilihe damper rod and rod guide with the 0 O h O W P S T O N R N G o A M P E R R O o ring oul of the damper case Check the following Rod guide for abnormal scr...

Page 333: ...OD ROD DAMPER CASE FREE PISTON O RING t f O RING n RETURN SPRING I S SNAP RING O RING f Check that the Pour recommended damper oil into a suitable container D A M P E R C A S E damperoii until the ste...

Page 334: ...per rod sliding surface Bleed any air out from the damper case and damper piston following the procedure below 1 Install the damper piston into the damper case pump the damper rod quickly_ NOTE To ope...

Page 335: ...noil SNAP RING In oil O RING f1I Fully seated I F R E E P ST O N Koop the damper Install the adjuster piece into the threads of the damper In oil assy submerged in case and thread it one turn oil Chec...

Page 336: ...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 13 50 SHOULDERED END If the measured depth is other than the sta...

Page 337: ...pped air reassemble the steering damper Install the damper rod side spherical bearing page 13 43 Out of oil DAMPER ROD Measure the Measure the length between the spherical bearings as r damper rod len...

Page 338: ...E A T H E R H O S E stem Remove the steering stem nut and washer TOP BRIDGE Remove the fork legs page 13 14 Remove the fork top bridge NUTIWASHER Remove the steering stem adjusting nut using the 111...

Page 339: ...TOOLS U S A Remover weight 07936 371020A Adjustable Bearing Puller 45 75mm 07YAC 0010102 Adapter Smm x 31 8 x 16 07YAC 001A200 and thread commercially available slide hammer 3 8 x 16 thread Install a...

Page 340: ...A F T Temporarily install the steering stem nul onto the stem 1 10 shown STEERING STEM to prevent the threads from being damaged when removing the lower tapered roller bearing from the LOWER BEARINI3...

Page 341: ...Ihe sleering slem into the sleering head pipe and install the following while holding the slem Upper tapered roller bearing Upper dust seal Install the sleering stem adjusting nut Tighten Ihe steerin...

Page 342: ...hly without play or binding Install the following Fork top bridge Fork legs page 13 34 Washer and steering stem nut Tighten the sleering stem nut to the specified torque TORQUE 108 N m 11 0 kgf m 80 I...

Page 343: ...g surface Install and tighten the clutch lever pivot boll to the specified torque TORQUE 2 0 N m 0 2 kgf m 1 5IbHt Loosen the clutch lever pivot bolt 45 90 Install and tighten the clutch lever pivot n...

Page 344: ...MEMO...

Page 345: ...14 REAR WHEEUSUSPENSION COMPONENT LOCATION 14 2 SERVICE INFORMATlON 14 3 TROUBLESHOOTING 14 6 REAR WHEEL 14 7 SHOCK ABSORBER 14 13 SHOCK LINKAGE 14 31 SWINGARM 14 36 14 1...

Page 346: ...ENSION COMPONENT LOCATION 10 shown 44 N m 4 5 kgf rn 32 Ibf ft 88 N m 9 0 kgf m 65 IbHI 12 N m 1 2 kg m 9lbHt 44 N m 4 5 kgf m 32 IbUt 53 N m 5 4 kgf m 391bHt 53 N m 5 4 kgf m 391bHt 128 N m 13 1 kgf...

Page 347: ..._t _ _________ j 2 0 0 08 h i ino t c Ai iOia __________ c oc ________ 2 0 0 08 Wheel rim Radial Wheel hub to rim distance See page 14 10 __ 1 I D i i ach a ini rs i Z lin kk l D I D t go10 520DMA4 1...

Page 348: ...frame side Swingarm pivot nut Drive chain guide mounting bolUnul Drive chain slider front side screw Drive chain slider rear side screw Rear brake hose guide screw Drive chain adjuster lock nut TOOLS...

Page 349: ...20 mm 07746 0040500 Bearing remover head 25 mm 07746 0050800 Retainer wrench body 07710 0010401 Conar 23 x 17 mm 07GMD KT8Al10 U S A only Remover Handle 07936 3710100 REAR WHEEUSUSPENSION Pilot 22 mm...

Page 350: ...spension adjustment Tire pressure 100 high Steers to one side or does not track straight Benl axle shaft Axle alignmenVchain adjustment nol equal on both sides Rear wheel wobbling Benl rim Worn wheel...

Page 351: ...wheel forward to derail the drive chain from the driven sprocket Do not operate the Remove the axle shaft adjusting blocks and rear brake pedal after wheel removing the rear wheel INSPECTION AXLE SHAF...

Page 352: ...e the wheel bearing if necessary page 14 8 bearings as a set 14 8 WHEEL RIM RUNOUT Check the rim runout by placing the wheelan a truing stand Spin the wheel by hand and read the runoul using a dial in...

Page 353: ...07HMA KS70100 U S A only 07710 0010401 Replace the wheel Instalilhe remover head into the bearing bearings as a set From the opposite side install the remover shaft and Do not reuse old drive the bea...

Page 354: ...SPROCKET DRIVEN SPROCKET m LEFT DUST SEAL Q BEARINGS 6905RS SIDE COLLAR 14 10 Place the rim on a work bench Place the hub in the center of Ihe rim and begin lacing with new spokes Adjust the hub posit...

Page 355: ...the sealed side facing down REAR WHEEL SUSPENSION Drive the outside left wheel bearing with the sealed r l side facing up Install and tighten a new bearing retainer to the rR ET e i RE r JNlERWieEj CH...

Page 356: ...TORQUE 16 N m 1 6 kgf m 12Ibf ft Check the right and left side collars for wear or damage 1 mi Replace them if necessary t Install the right and left side collars INSTALLATION Place the rear wheel int...

Page 357: ...ground by placing a worksland or equivalent under the engine Remove the upper mounting bolt and nut Remove the shock absorber lower mounting bolt nul and shock absorber DISASSEMBLY REAR WHEEL SUSPENS...

Page 358: ...SEAT compressing the shock absorber spring Remove the shock absorber spring SPRING BLADDER REPLACEMENT Replace the bladder when oil leaks around the chamber cap or oil spills out when releasing the n...

Page 359: ...on which to seat securely To remove the stopper ring first push one end of the stopper ring oul of its groove then slip the second screwdnver between the stopper flng and reservoir to act as a ramp No...

Page 360: ...ten the vise and distort the damper case Remove the compression damping adjuster plale and O rings 3 Fill the damper case and reservoir with HP Fork Oil 25 through the compression damping adjuster hol...

Page 361: ...ay around or the chamber cap can come apart when riding Ihe motorcycle Temporarily fill Ihe reservoir with air slowly until Ihe chamber cap seats against Ihe stopper ring REAR WHEEUSUSPENSION x NO GOO...

Page 362: ...Before disposal of the shock absorber release the nitrogen by pressing the valve core Then remove the valve core from the chamber cap COMPRESSION ADJUSTER Drain most of the shock oil from the damper...

Page 363: ...pulling the damper rod the damper rod out of the damper case piston ring Carefully pull the damper rod assembly out of the damper case PISTON RING REPLACEMENT Inspect the piston ring If the piston rin...

Page 364: ...t to over file Turn the damper rod end nut back and forth in 1 4 turn increments until it loosens then rolale another 1 4 turn and repeat turning back and forth until the damper rod end nut loosens co...

Page 365: ...shown is typical and may not represent this model exactly Remove the compression valves valve stopper and washer Chase the threads with a die and clean with shock oi1 Wrap the threads of the damper ro...

Page 366: ...melal is worn so that the copper surface appears replace the rod guide case with a new one REBOUND SPRING INSPECTION Inspect the rebound spring for weakness or damage COMPRESSION ADJUSTER INSPECTION M...

Page 367: ...d blow them dry with compressed air before assembly Use care to avoid geffing solvent on the piston ring L _ _____ V _ A _L _ V _ E _S _T _O _P _P _E_R_S_____ and O rings The valve arrangement and num...

Page 368: ...he damper rod sliding surface with shock oi Carefully install the rod guide case assembly with the rebound spring facing up over the damper rod Remove the special tool Check the rod guide case assembl...

Page 369: ...ric with the damper rod Install the valve stopper o REBOUND VALVES Set the shock absorber lower mount in a vise with a END NUT f END NUT piece of wood or soft jaws to avoid damage r Install and tighte...

Page 370: ...per ring by damper case pulling the damper rod ai the way our STOPPER RING Drive the end plate squarely and evenly Into the damper T 7l case with a plastic hammer Fill the damper case and reservoir wi...

Page 371: ...neck Apply shock oil to new O rings and install them to the compression damping adjuster Dip the compression damping adjuster in clean shock oil Slowly install the plate and compression damping adjust...

Page 372: ...rn the spring adjusting nut until the spring length adJusling nut measurement recorded al disassembly is reached or changes the spring until the spring length is as specified below length by 1 5 mm 0...

Page 373: ...damage If it is worn or damaged it must be replaced Press the spherical bearing to get the clearance necessary to remove the stopper ring using the special tool TOOL Coliar 23 x 17 mm Remove the stopp...

Page 374: ...osite side using the special tool until it seats againsllhe stopper ring TOOL Collar 23 x 17 mm 07GMD KTSA110 U S A only Be sure 10 install Apply grease to new dust seal lips and inslalilhem with the...

Page 375: ...stalilhe sub frame page 2 8 SHOCK LINKAGE REMOVAL Remove the nut and lower drive chain roller Remove the following Shock absorber lower mounting bolUnut Shock arm bolUnutJwasher shock link side Shock...

Page 376: ...r wear damage or fatigue Check the shock arm for cracks or damage Replace them jf necessary Check the needle bearings for damage or loose fit If the needle bearings are damaged replace them page 14 33...

Page 377: ...Press the needle bearings into the shock link side pivot iliiilffi bearing into the with the special lools and a hydraulic press so that the L shock arm with the needle bearing surface is 6 0 6 5 mm...

Page 378: ...cified grease page 1 19 to new needle bearings Press the needle bearings into the frame side pivot with the special lools and a hydraulic press so that the needle bearing surface is 4 4 4 7 mm 0 17 0...

Page 379: ...ls with the marking side facing out INSTALLATION Apply engine oil to the shock link and shock arm nut threads and seating surface Loosely instalilhe following Shock link Shock link boltlnutlwasher fra...

Page 380: ...ed torque TORQUE 12 N m 1 2 kgf m 9lbHt SWINGARM REMOVAL Raise the rear wheel off the ground by placing a r T B O L T N U T N A S H ER workstand or equivalent under the engine SWINGARM SIDE 14 36 Remo...

Page 381: ...pedal after removing the rear wheel Remove the swingarm pivot nut and washer Remove the swingarm pivot bolt and swingarm DISASSEMBLY Check the chain guide slider and chain guide for wear or damage pa...

Page 382: ...m for cracks or damage Replace any damaged parts if necessary BEARING REPLACEMENT Press the needle bearings out of the swingarm using the special tools and a hydraulic press TOOLS Driver Attachment 24...

Page 383: ...lips Install the following ew th t 1 5 _2 0 mm 0 06 _0 08 I Thrust washers Thrust needle bearings Pivot collars Dust seals Side collars Instailihe inner side dust seals so that the dust seal surface i...

Page 384: ...m Install and lighten the bolts nuts to the specified torque TORQUE 12 N m 1 2 kgf m 9 bHt INSTALLATION Apply a thin coat of grease to the swingarm pivot bolt sliding surface Install the swingarm betw...

Page 385: ...to the specified torque TORQUE 1 2 N m 0 1 kgf m 0 9 IbHt Apply engine oil to the shock arm nut swingarm side threads and seating surface Install the shock arm bolt washer and nul swlngarm side Tight...

Page 386: ...MEMO...

Page 387: ...2 FRONT MASTER CYLINDER 15 14 SERVICE INFORMATION 15 4 REAR MASTER CYLINDER 15 19 TROUBLESHOOTING 15 6 FRONT BRAKE CALIPER 15 22 BRAKE FLUID REPLACEMENT AIR REAR BRAKE CALIPER 15 25 BLEEDING 15 7 BRAK...

Page 388: ...HYDRAULIC BRAKE COMPONENT LOCATION FRONT 0 shown 9 9 N m 1 0 kgf m 7 3IbHt 34 N m 3 5 kgf m 251bHt 34 N m 3 5 kgf m 25 Ibf ft 18 N m 1 8 kgf m 131bHt 30 N m 3 1 kgf m 22 IbUt 15 2...

Page 389: ...HYDRAULIC BRAKE REAR 10 shown 18 N m 1 8 kgf m 131bHt 34 N m 3 5 kgf m 25 IbHt 9 34 N m 3 5 kgf m 251bHt s 13 N m 1 3 kgf m 10 IbHt i t 36 N m 3 7 kgf m 271bHt 15 3...

Page 390: ...ted disc with high quality brake degreasing 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 reservo...

Page 391: ...Snap ring pliers 07914 SAS0001 34 N m 3 5 kgf m 25 IbHl 5 9 N m 0 6 kgf m 4 4 IbH 1 0 N m 0 1 kgf m O 7IbHt 5 9 N m 0 6 kgf m 4 4 IbHt 1 0 N m 0 1 kgf m O 7IbU I 9 9 N m 1 0 kgf m 7 3 IbUI 30 N m 3 1...

Page 392: ...ston Contaminated master cylinder Benl brake lever pedal Brake lever pedal hard Cloggedlfestricted brake system Sticking worn caliper piston Caliper bracket not sliding properly rear Clogged restricte...

Page 393: ...d When using a commercially available brake bleeder follow the manufacturer s operating instruction BRAKE FLUID DRAINING HYDRAULIC BRAKE Do nor allow foreign Check the master cylinder parallel to the...

Page 394: ...of fluid They are not compatible Fill the master cylinder with DOT 4 brake fluid from a sealed container Connect a commercially available brake bleeder to the bleed valve Operate the brake bleeder an...

Page 395: ...ith DOT 4 brake fluid from a sealed container Connect a bleed hose to the bleed valve Pressurize the system with the brake lever or pedal until there are no air bubbles in the brake fluid flowing out...

Page 396: ...diaphragm and reservoir cover Tighten the reservoir cover screws to the specified torque TORQUE 1 0 N m 0 1 kgf m 0 7 Ibf ft COVER DIAPHRAGM Rear Straighten the diaphragm and install it to the rear ma...

Page 397: ...w brake pads ro assure even disc pressure NOTE Check the brake fluid level in the brake master cylinder reservoir as this operation causes the level to rise After 12 only Remove the front brake disc c...

Page 398: ...Discard contaminated pads and clean a contaminated disc with high quality brake degreasing agent Push the brake pads against the pad spring Ihen install the pad pin Apply locking agent to the brake c...

Page 399: ...ke operation REAR BRAKE PADS REPLACEMENT HYDRAULIC BRAKE Always replace the Push the caliper piston all the way in to allow r _ _ brake pads in pairs installation of new brake pads to assure even disc...

Page 400: ...crometer SERVICE LIMITS 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 limil Measure the brake disc warpage with a dial indicator...

Page 401: ...the pivot nut and bolt Release the boot from the knocker arm Remove the brake lever assembly spring and push rod from the master cylinder Remove the boot Remove the snap nng from the master cyhnder us...

Page 402: ...atigue or damage 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 SER...

Page 403: ...to the master piston cups do not allow Install the master piston assembly into the master the lips 0 tum cylinder inside ouf Install the washer Be certain the snap ring is firmly seated in the groove...

Page 404: ...rm groove securely PUSH ROD PUSH ROD BRAKE LEVER ASSEMBLY BOOT Apply silicone grease to the spring both ends and B RA K E LE V E R A S S E M B L Y install it between the master cylinder and brake leve...

Page 405: ...Oint against the stopper then tighten the brake hose oil boll to the specified torque TORQUE 34 N m 3 5 kgf m 25 IbHt Fililhe reservoir to the upper level and bleed the front brake system page 15 8 RE...

Page 406: ...r 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...

Page 407: ...ing to the master piston cups do not allow Install the master piston assembly into the master the lips to tum cylinder inside oul If the push rod is disassembled adjust he brake pedal heigh page 3 25...

Page 408: ...rque TORQUE 34 N m 3 5 kgf m 25 IbHt Install the brake pedal page 15 29 Fill the reservoir to the upper level and bleed the brake system page 15 8 FRONT BRAKE CALIPER REMOVAL 15 22 Drain the front bra...

Page 409: ...eful not to damage the pis on sliding surface Push the dust seals and piston seals in and lift them P S T O N S E A L S out Clean the seal grooves caliper pistons and caliper piston sliding surfaces w...

Page 410: ...clean brake fluid and install them into the caliper cylinder with their open ends facing the pad Install the brake pad retainer onto the caliper bracket Note the installation Install the pad spring in...

Page 411: ...to the upper level and bleed the hydraulic system page 15 8 REAR BRAKE CALIPER REMOVAL Drain the rear brake hydraulic system page 15 7 Remove the brake pads page 15 13 loosen the brake hose oil bolt R...

Page 412: ...to cushion the piston when it is expelled Do not hold the air Apply short bursts of air pressure to the fluid inlet to nozzle too close to remove the piston the inlet Excessive air pressure could forc...

Page 413: ...SERVICE LIMIT 22 712 mm 0 8942 in HYDRAULIC BRAKE Check the caliper pistons for scoring scratches or damage Measure the caliper piston 0 0 SERVICE LIMIT 22 573 mm 0 8887 in ASSEMBLY PAD SPRING 5 4 N m...

Page 414: ...stall the pad spring into the caliper directIOn of the pad spnng Replace the caliper and bracket pin boots jf there is wear deterioration or damage Install the caliper and bracket pin boots Apply sili...

Page 415: ...m 3 5 kgf m 25 IbHt Inslall the brake pads page 15 13 Fill Ihe reservoir to Ihe upper level and bleed the hydraulic system page 15 8 BRAKE PEDAL REMOVAL HYDRAULIC BRAKE 10 shown CALIPERIBRACKET ASSEMB...

Page 416: ...pply grease page 1 19 to the dust seal lips r iiiii l Installihe dust seals to the brake pedal with its lip side 15 30 facing oul as shown Install the relurn spring Set the washer to the frame Apply g...

Page 417: ...RMATION 16 3 TROUBLESHOOTlNG 16 4 IGNITION SYSTEM INSPECTION 16 5 ALTERNATOR COIL 16 9 16 ELECTRICAL SYSTEM REGULATOR RECTIFIER 16 10 IGNITION COIL 16 13 IGNITION TIMING 16 14 ENGINE STOP SWITCH INSPE...

Page 418: ...M SYSTEM LOCATION 10 2 ENGINE STOP SWITCH IGNITION COIL ECM REGULATOR RECTIFIER No 1 CKP SENSOR ALTERNATOR No 2 SENSOR After 12 ENGINE STOP SWITCH IGNITION COIL REGULATOR RECTIFIER No 1 CK S N OR No 2...

Page 419: ...ECM is factory preset A faulty ignition system is often related to poor connections Check connections before proceeding This motorcycle s ICM is built into the ECM For PGM FI troubleshooting informat...

Page 420: ...ition coil secondary voltage If there Is no spark al cylinder temporarily exchange the ignition coli with a known good one and perform the spark test If there is spark the original ignition coil Is fa...

Page 421: ...ly or peak vollage adapter to the digital multimeter TOOLS IgnitionMate peak voltage tester TMNTS91 H U S A only or Peak voltage adaptor 07HGJ 0020100 not available in U S A with commercially availabl...

Page 422: ...llow the checks in the troubleshooting table page 16 4 Disconnect the 12 V battery page 5 12 Shift the transmission into neutral Crank the engine with the kickstarter and read the ignition coil primar...

Page 423: ...terminals TOOLS IgnitionMate peak voltage tester TMNTS91 H U S A only or Peak voltage adaptor 07HGJ 0020100 ELECTRICAL SYSTEM 1 0 12 No 1 CKP SENSOR 11 t 1iO 33P BLACK CONNECTOR wire side female term...

Page 424: ...al the ECM connector measure the peak voltage and compare 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 alte...

Page 425: ...iiii II I III terminals Sensor side female terminal Connection Yellow White y STANDARD 0 1 3 0 D at 20 CI68 F Check for continuity between each wire terminal of the alternator side connector and groun...

Page 426: ...the connector cover and disconnect the regulator rectifier 5P Black connector Remove the bolts nut and regulatorlrectifier Release the wire harness from the clamp Remove the following Bolts Nuts Clam...

Page 427: ...the following Bolts Nuts Regulatorlrectifier Connector holder Regulator rectifier stay Installation is in the reverse order of removal INSPECTION 10 12 Disconnect the regulatOf rectifier 5P Black conn...

Page 428: ...K CONNECTOR wire side female terminal connector TOOLS Test probe 07ZAJ RDJA110 There should be continuity at all times I BI 23 Q 5P BLACK CONNECTOR wire side female terminal After 12 BI 33P BLACK CONN...

Page 429: ...fier IGNITION COIL INSPECTION ELECTRICAL SYSTEM 0 12 After 12 5P BLACK 6P NATURAL CONNECTOR CONNECTOR y w w y Q wire side female terminal Disconnect the ignition coil wires IC m Measure the ignition c...

Page 430: ...according to its manufacturer s instructions Connect the timing light to the spark plug wire Read the instruction for timing light operation Start the engine and let it idle IDLE SPEED 2 OOO 100 rpm P...

Page 431: ...ITCH BIIW RfY Hang the fuel tank to the left side of the frame page 3 P EE C M 33 P e CX c c l 61 Disconnect the ECM 33P Black connector Check for continuity between the ECM 33P Black and 313P B LA C...

Page 432: ...here is no voltage check for open circuit in Black or Green wires If there is voltage check the condenser as follows e 1 Turn the ECM selector switch OFF and connect I i ___ the condenser 2P Black con...

Page 433: ...17 WIRING DIAGRAM WIRING DIAGRAM 10 12 17 2 WIRING DIAGRAM After 12 17 3 17 1...

Page 434: ......

Page 435: ...3 L N 2 N j r I I I1 o I i o FRAME GROUND o II IGNITION COIL 1SPARK PCUG I Po INJECTOR 0 il 3 Eel SENSOR NO 1eKP SE eKPSENSCR AlTERNATOR O d a lAT SENSOR 81 BLACK Y YELLOW Bu BLUE G GREEN R RED W WHIT...

Page 436: ...I u 1 G G NN NNNNNN 1 II lil l h ii l i h Hi h IIJ Uri i l i l n l llili g i FRAME GROUND l i m I o ii5 IGNITION COIL 1SPARK PlUG IL iii a lie M l I I I Ii 1 IiII II 2P INJECTOR 3 3 0 C1 II i3 3 ECT S...

Page 437: ...18 TROUBLESHOOTING ENGINE DOES NOT START OR IS POOR PERFORMANCE AT HARD TO START 18 2 HIGH SPEED 18 6 ENGINE LACKS POWER 18 3 POOR HANDLING 18 7 POOR PERFORMANCE AT LOW AND IDLE SPEED 18 5 18 1...

Page 438: ...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...

Page 439: ...tch springs Sticking clutch lifter Additive in engine oil YES GO TO STEP 4 4 Engine Peliormance Inspection Accelerate lightly Did the engine speed increase NO Dirty air cleaner Restricted fuel flow Cl...

Page 440: ...System normal YES GO TO STEP 10 NO Faulty PGM FI system 10 Spark Plug Inspection Remove and inspect spark plug Is the spark plug fouled or discolored YES _ Spark plug nol serviced frequently enough In...

Page 441: ...Broken or shorted spark plug wire Faulty CKP sensor s Faully alternator coil Faulty engine slop button Faulty ECM NO GO TO STEP 3 3 Fuel Pump Inspection Inspect the fuel now Is the fuel pump unit norm...

Page 442: ...system normal YES GO TO STEP 3 NO Faulty PGM FI system 3 Ignition Timing Inspection Check ignition liming Is the ignition timing correct NO Faulty ECM faufty CKP sensor s YES GO TO STEP 4 4 Valve Tim...

Page 443: ...g 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 fork spr...

Page 444: ...MEMO...

Page 445: ...IVE CHAIN SUDER 3 21 DRIVE DRIVEN SPROCKET 3 22 DTC INDEX 5 15 DTC TROUBLESHOOTING 5 16 ECM 5 56 ECT SENSOR 5 57 ELECTRICAL SYSTEM SPECIFICATIONS 1 12 ENGINE GUARD 2 4 INDEX ENGINE IDLE SPEED 3 16 ENG...

Page 446: ...FLOW PATTERN 6 2 SYSTEM LOCATION 16 2 SYSTEM TESTING 6 5 THROTTLE BODy THROTTLE OPERATION TORQUE VALUES TRANSMISSION TRANSMISSION OIL TROUBLESHOOTING 5 49 3 7 1 12 12 18 3 16 CLUTCH KICKSTARTERIGEARSH...

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Honda 2010 CRF250R, Service Manual

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