Honda CBF190WH 2016 Shop Manual Download

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ELECTRICAL SYSTEM

4-15

DTC 29-1 (IACV)

IACV Diagram

• Fuel tank shroud



3-6

IACV2B

ECM

IACV

IACV1A

IACV2A

IACV1B

Bu/W

Br/W

Bl/Y

Bu/Bl

IACV 4P connector
(Wire side)

ECM 33P connector

IACV 4P connector
(IACV side)

Bu/W

Br/W

Bl/Y

Bu/Bl

Bu/W

Bu/Bl

Br/W

Bl/Y

1. IACV System Inspection

• Check the IACV with MCS.

• Is the DTC 29-1 is indicated?

►

• Intermittent failure

• Loose or poor contact at the connector

Yes

▼

2. IACV Circuit Inspection

• Check a open or short circuit in Bu/W, Br/W, Bl/Y

and Bu/Bl wires.

• Is there open or short circuit?

Yes

►

• Faulty Bu/W, Br/W, Bl/Y or Bu/Bl wire

▼

3. IACV Resistance Inspection

• Connection: A – D, B – C

• Is the resistance within 110 – 150

Ω

(25 °C)?

►

• Faulty IACV

Yes

▼

4. IACV Short Circuit Inspection

• Connection: A – B, C – D

• Is there continuity?

Yes

►

• Faulty IACV

▼

• Replace the ECM with a new one



4-19, and re-

check.

Summary of Contents for CBF190WH 2016

Page 1: ...nual CBF190WH G 2016 CBF190WH This book is Specific Shop Manual Refer to Basic Shop Manual for basic and common maintenance instructions 1 General Information 2 Fuel Engine 3 Frame Chassis 4 Electrical System ...

Page 2: ...TION A Few Words About Safety 1 2 How To Use This Manual 1 3 MODEL IDENTIFICATION 1 5 SPECIFICATIONS 1 6 TORQUE VALUE 1 11 SPECIAL TOOL LIST 1 14 CABLE HARNESS ROUTING 1 15 TECHNICAL FEATURES 1 22 MAINTENANCE SCHEDULE 1 23 ...

Page 3: ...iate clothing and using safety equipment When performing any service task be especially careful of the following Read all of the instructions before you begin and make sure you have the tools the replacement or repair parts and the skills required to perform the tasks safely and completely Protect your eyes by using proper safety glasses goggles or face shields any time you hammer drill grind pry ...

Page 4: ...essages and other information throughout this manual Of course it is not practical or possible to warn you about all the hazards associated with servicing this vehicle You must use your own good judgement You will find important safety information in a variety of forms including Safety Labels on the vehicle Safety Messages preceded by a safety alert symbol and one of three signal words DANGER WARN...

Page 5: ...pecified torque Replace with a new one before assembly Check the part for an inspection Measure the part for an inspection Turn ignition switch to OFF Turn ignition switch to ON Start the engine Measure a resistance or check continuity Measure a voltage Measure an ampere Use the Honda special tool Refer to Basic Service Manual for the instruc tion Use the recommend engine oil Apply molybdenum oil ...

Page 6: ...RAL INFORMATION 1 5 MODEL IDENTIFICATION Model name CBF190WH G Code Type Destination AG Argentina CO Colombia LA Latin America CL Chile PE Peru VEHICLE IDENTIFICATION NUMBER ENGINE SERIAL NUMBER COLOR LABEL ...

Page 7: ...rake Hydraulic single disc Caster angle 26 0 Trail length 100 mm Fuel tank capacity 12 0 liter Fuel tank reserve capacity 2 0 liter ENGINE Cylinder arrangement Single cylinder inclined 15 from vertical Bore and stroke 61 000 x 63 096 mm Displacement 184 40 cm3 Compression ratio 9 5 1 Valve train Chain driven OHC with rocker arm Intake valve opens 10 BTDC at 1 mm lift closes 35 ABDC at 1 mm lift Ex...

Page 8: ...ctric starter motor Charging system Triple phase output alternator Regulator rectifier SCR shorted triple phase full wave rectification Lighting system Battery ITEM SPECIFICATION ITEM SPECIFICATIONS Throttle body identification number GQMPA Idle speed 1 500 100 rpm Throttle grip freeplay 2 6 mm Fuel pressure at idle 263 316 kPa Fuel pump flow at 12 V 36 cm3 minimum 10 seconds ITEM STANDARD LIMIT E...

Page 9: ...spring free length INNER 35 59 34 88 OUTER 39 46 38 67 Cylinder head warpage 0 05 ITEM STANDARD LIMIT Cylinder I D 61 00 61 01 61 10 Warpage 0 10 Piston Piston O D 60 981 60 997 at 13 mm from bottom of skirt 60 900 Piston pin bore I D 14 002 14 008 14 020 Piston pin O D 13 994 14 000 13 980 Piston rings Piston ring end gap Top 0 07 0 17 0 27 Second 0 17 0 32 0 42 Oil side rail 0 10 0 35 0 55 Pisto...

Page 10: ...aft O D at M4 19 968 19 980 at M5 16 968 16 980 Countershaft O D at C1 16 966 16 984 at C2 19 978 19 989 at C3 19 988 20 000 Shift fork fork shaft Fork I D 10 000 10 018 Fork shaft O D 9 986 9 995 Claw thickness 4 93 5 00 4 83 ITEM STANDARD LIMIT Cold tire pressure Driver only 200 kPa Driver and passenger 200 kPa Axle runout 0 2 Wheel rim runout Radial 2 0 Axial 2 0 Wheel balance weight 60 g maxim...

Page 11: ... 080 Caliper piston O D 31 948 31 998 ITEM SPECIFICATIONS EOT sensor resistance 20 C 2 5 2 8 kΩ Fuel injector resistance 24 C 11 13 Ω EVAP purge control solenoid valve resistance 20 C 37 44 Ω ITEM SPECIFICATION Spark plug CPR8EA 9 NGK Spark plug gap 0 80 0 90 mm Ignition coil peak voltage 100 V minimum CKP sensor peak voltage 0 7 V minimum Ignition timing F mark 8 BTDC at idle ITEM SPECIFICATIONS ...

Page 12: ... 4 5 Throttle cable B nut throttle body side 1 6 4 5 Sensor unit screw 2 4 2 1 IACV screw 3 4 2 1 Throttle cable stay torx screw 1 5 5 1 Throttle body insulator bolt 2 6 12 ITEM Q TY DIA TRQ REMARKS Engine oil drain bolt 1 12 30 Oil pump cover screw 1 4 3 0 ITEM Q TY DIA TRQ REMARKS Timing hole cap 1 14 10 Crankshaft hole cap 1 32 15 Apply grease Valve adjusting lock nut 2 6 18 Apply engine oil Ca...

Page 13: ...r engine hanger nut 2 10 54 Drive sprocket bolt 2 6 12 ITEM Q TY DIA TRQ REMARKS Rearview mirror lock nut 2 10 34 Rearview mirror adaptor bolt 2 10 34 Rear fender A screw 2 4 1 0 Rear garnish screw 10 4 1 0 Fuel tank shroud screw 28 4 1 0 Rear fender B screw 2 4 1 0 Taillight bolt 2 6 7 5 Taillight side cover screw 4 4 1 0 Battery box bolt 3 6 7 0 Rear master cylinder bolt 2 6 12 ITEM Q TY DIA TRQ...

Page 14: ...ock absorber upper nut 1 10 44 Shock absorber lower nut 1 10 44 Swingarm pivot nut 1 14 54 Apply grease ITEM Q TY DIA TRQ REMARKS Brake hose oil bolt 2 10 34 Master cylinder reservoir cap screw 2 4 1 5 Front brakelight switch screw 1 4 1 2 Brake lever pivot bolt 1 6 1 0 Brake lever pivot nut 1 6 6 0 Pad pin 2 10 18 Pad pin plug 2 10 2 5 Brake caliper bolt 2 8 26 Pre coated ALOC bolt re place with ...

Page 15: ...00 Locknut wrench 10 x 12 mm 07908 KE90000 Tappet adjusting wrench 3 x 4 mm 070MG 0010100 Tensioner stopper 07757 0010000 Valve spring compressor 07984 MA60001 Valve guide reamer 5 0 mm 07942 MA60000 Valve guide driver 4 8 mm 07724 0010200 Gear holder 07GMB KT70101 Clutch center holder 07725 0040001 Flywheel holder 07933 KM10001 Flywheel puller Frame Chassis 07746 0050400 Remover head 15 mm 07746 ...

Page 16: ...FT HANDLEBAR SWITCH 3P INSIDE BOOT CONNECTORS HEADLIGHT 6P POSITION LIGHT 3P TURN SIGNAL LIGHT WIRE CONNECTORS 25 THROTTLE CABLE A THROTTLE CABLE B To be butted To be butted Left Right MAIN WIRE HARNESS MAIN WIRE HARNESS to HEADLIGHT POSITION LIGHT and TURN SIGNAL LIGHT MAIN WIRE HARNESS to HANDLEBAR SWITCH Frame Left Right ...

Page 17: ...GENERAL INFORMATION 1 16 LEFT REAR TURN SIGNAL WIRE RIGHT REAR TURN SIGNAL WIRE HEADLIGHT WIRE POSITION LIGHT WIRE THROTTLE CABLE A THROTTLE CABLE B To be butted To be butted ...

Page 18: ...5 mm MAIN WIRE HARNESS MAIN WIRE HARNESS BANK ANGLE SENSOR 2P CONNECTOR ECM 33P CONNECTOR MAIN WIRE HARNESS 15 mm Maximum 15 mm Maximum MAIN WIRE HARNESS MAIN WIRE HARNESS DLC EVAP PURGE CONTROL SOLENOID VALVE 2P CONNECTOR EVAP PURGE CONTROL SOLENOID VALVE WIRE EVAP PURGE CONTROL SOLENOID VALVE WIRE ...

Page 19: ...GENERAL INFORMATION 1 18 NEUTRAL SWITCH WIRE CKP SENSOR WIRE ALTERNATOR WIRE ...

Page 20: ...RMATION 1 19 NEUTRAL SWITCH WIRE MAIN WIRE HARNESS MAIN WIRE HARNESS MAIN WIRE HARNESS SENSOR UNIT 5P CONNECTOR REGULATOR RECTIFIER WIRE THROTTLE CABLE B THROTTLE CABLE A To be butted IACV 4P CONNECTOR To be butted ...

Page 21: ...GENERAL INFORMATION 1 20 BATTERY POSITIVE CABLE 15 mm Maximum MAIN WIRE HARNESS MAIN WIRE HARNESS INJECTOR 2P CONNECTOR FUEL TANK BREATHER HOSE ...

Page 22: ...IGHT WIRE LICENSE LIGHT WIRE RIGHT REAR TURN SIGNAL WIRE LEFT REAR TURN SIGNAL WIRE LICENSE LIGHT WIRE RIGHT REAR TURN SIGNAL WIRE LEFT REAR TURN SIGNAL WIRE LICENSE LIGHT WIRE LICENSE LIGHT WIRE RIGHT REAR TURN SIGNAL WIRE LEFT REAR TURN SIGNAL WIRE LEFT REAR TURN SIGNAL WIRE RIGHT REAR TURN SIGNAL WIRE 5 mm Maximum 10 mm Maximum ...

Page 23: ...his incoming air produces a lack of fuel which impairs engine performance in order to notify the rider of the fuel filter blockage This symptom works as a reminder for the filter replacement This system eliminates the need of fuel filter replacement according to a fixed interval as the rider will experience the symptom and notice the filter blockage during vehicle usage The driveability remains no...

Page 24: ...iding in unusually wet or dusty areas 3 Service more frequently when riding in rain or at full throttle 4 Replacement requires mechanical skill Refer to Basic Service Manual for each maintenance instruction except the instructions described in this manual ITEMS NOTE FREQUENCY NOTE 1 ANNUAL CHECK REGULAR REPLACE REFER TO PAGE X1 000 km 1 4 8 12 X1 000 mi 0 6 2 5 5 7 5 FUEL LINE I I I I THROTTLE OPE...

Page 25: ...MEMO ...

Page 26: ...L TANK 2 6 AIR CLEANER 2 7 THROTTLE BODY 2 8 EVAP SYSTEM 2 11 LUBRICATION SYSTEM 2 13 CYLINDER HEAD 2 15 CYLINDER PISTON 2 21 CLUTCH GEARSHIFT LINKAGE 2 22 ALTERNATOR STARTER CLUTCH 2 25 CRANKCASE CRANKSHAFT BALANCER 2 27 TRANSMISSION 2 29 ENGINE UNIT 2 31 ...

Page 27: ...ss down the retainer and disconnect the connector from the fuel pump joint injector joint Check the retainer condition and replace the fuel hose if necessary To prevent damage and keep foreign matter out cover the disconnected connector and pipe end with the plastic bags Press the connector onto the fuel joint until the retainer locks with a CLICK If it is hard to connect put a small amount of eng...

Page 28: ...the fuel pressure is lower than specified inspect the following Fuel line leaking Any erratic swing or vibration of the gauge needle in the pressure gauge reading If the needle is swing or vibration replace the fuel fil ter 2 5 If the needle is stable replace the fuel pump unit 2 4 from FUEL PUMP to INJECTOR fuel feed hose B A Quick connect fitting injector side 2 2 Place the end of the hose into ...

Page 29: ...nstall a new outer packing onto the fuel pump unit groove by aligning the tab with the boss Set the setting plate onto the fuel pump by aligning the hole and boss Install the fuel pump into the fuel tank by aligning the fuel pump 5P connector with the triangle mark Tighten the fuel pump setting plate nuts in the specified sequence as shown Make sure that the outer packing tab can see in the settin...

Page 30: ...rs by slightly spreading the hooks and then turn it clockwise Fuel filter clog or excessive damage If the fuel filter is clogged replace it with a new one Before installing the fuel pump filter check the fuel pump unit for dirt If necessary clean the fuel pump unit with compressed air Do not blow into the fuel pump unit If the R or Bl wire connector is disconnected replace the fuel level sensor wi...

Page 31: ...FUEL ENGINE 2 6 FUEL TANK Quick connect fitting fuel pump side 2 2 ...

Page 32: ... ENGINE 2 7 AIR CLEANER Seat 3 3 Discard the air cleaner element in accordance with the maintenance schedule 1 23 Replace the element any time if it is excessively dirty or damaged Rear shock absorber 3 25 ...

Page 33: ...EL ENGINE 2 8 THROTTLE BODY 4 5 N m 4 5 N m 12 N m Quick connect fitting injector side 2 2 If the throttle body is changed perform the TP sensor reset procedure 2 10 Throttle body cleaning and inspection ...

Page 34: ...rum when installing the sensor unit Sensor unit IACV 2 1 N m 2 1 N m 5 1 N m A Throttle body 2 8 Install the sensor unit to the throttle body by aligning the clip of the sensor unit and boss of the throttle valve Perform the TP sensor reset procedure 2 10 Fuel tank shroud 3 6 Check the IACV for wear or damage The IACV operation can be checked visually as follows 1 Connect the IACV 4P connector 2 T...

Page 35: ... G W Turn the ignition switch ON and then disconnect the jumper wire from the EOT sensor 2P connector within 10 seconds while the MIL is blinking reset receiving pattern Check for the MIL blinks After disconnecting the jumper wire the MIL should start blinking reset completed pattern If the jumper wire is connected for more than 10 seconds the MIL will stay ON unsuccessful pattern Try again from t...

Page 36: ...FUEL ENGINE 2 11 INJECTOR EVAP SYSTEM Quick connect fitting injector side 2 2 Side cover 3 4 ...

Page 37: ...FUEL ENGINE 2 12 Fuel tank shroud 3 6 ...

Page 38: ...Clean and insert the oil filler cap dipstick without screwing it in remove it and check the oil level If the oil level is below or near the lower level line on the dipstick add the recommended oil to the upper level Check that the O ring on the oil filler cap is in good condition and replace it if necessary RECOMMENDED ENGINE OIL Honda 4 stroke motorcycle oil or an equivalent mo tor oil API servic...

Page 39: ...Drain oil completely Fill the crankcase with the recommended engine oil ENGINE OIL CAPACITY 1 0 liter after draining 1 2 liter after disassembly 30 N m 3 0 N m Right crankcase cover 2 22 Align with the cutouts of the oil pump drive shaft and inner rotor Oil pump inspection ...

Page 40: ...ign with the cyl inder head tabs A Make sure that the mark B on the cam sprocket is in the position shown TDC If the cam sprocket mark is not in position shown rotate the crankshaft one full turn Valve clearance Insert a feeler gauge between the valve adjusting screw and valve stem IN 0 08 0 02 mm EX 0 24 0 02 mm Locknut wrench 10 x 12 mm 07708 0030200 Tappet adjusting wrench 3 x 4 mm 07908 KE9000...

Page 41: ...FUEL ENGINE 2 16 CYLINDER HEAD COVER Fuel tank shroud 3 6 ...

Page 42: ...he tensioner lifter Tensioner stopper 070MG 0010100 4 0 N m 9 0 N m 12 N m 5 0 N m B A Install the camshaft with its flange tab facing up Insert the rocker arm shafts into the cylinder head in the position shown using a flat tip screwdriver while aligning the bolt holes of the shaft with the bolt holes on the cylinder head The index lines on the cam sprocket are align with the cylinder head tabs A...

Page 43: ...ross pattern in several steps Remove the left side stud bolts Loosen the right side stud bolts then pull and remove the stud bolts together with the cylinder head Install the cam chain guide while aligning its pins with the grooves on the cylinder and its end with the groove on the left crankcase After tightening the cylinder head nuts check that the length from the cylinder stud bolt head to the ...

Page 44: ... clockwise Valve guide reamer 5 0 mm 07984 MA60001 Support the cylinder head and drive the valve guides out of the cylinder head from the combustion chamber side Valve guide driver 4 8 mm 07942 MA60000 Drive new valve guides into the cylinder head to the specified height from the cylinder head Valve guide driver 4 8 mm 07942 MA60000 VALVE GUIDE PROJECTION Reference 16 8 17 0 mm Valve and valve spr...

Page 45: ...s of the tool with the grooves of the tensioner lifter Tensioner stopper 070MG 0010100 Check the cam chain tensioner lifter operation The tensioner shaft should not go into the body when it is pushed When it is turned clockwise with the tensioner stopper the tensioner shaft should be pulled into the body The shaft should protrude from the body as soon as the tensioner stopper is released 4 0 N m ...

Page 46: ...emove it by lifting up at a point opposite the gap Carefully install the piston rings into the piston ring grooves with the markings facing up Top ring 1R or TOP 1 mark Second ring RN or TOP 2 mark Install the piston with the IN mark facing the intake side Do not align the piston pin clip end gap with the piston cut out Piston and piston rings inspection Cylinder inspection ...

Page 47: ...FUEL ENGINE 2 22 CLUTCH GEARSHIFT LINKAGE Engine oil 2 14 0 5 1 0 mm ...

Page 48: ... tooth Coating width 6 5 1 mm from the tip Each bearing Gearshift pedal 3 13 Loosen the oil filter rotor lock nut Gear holder 07724 0010200 Loosen the clutch center lock nut Clutch center holder 07GMB KT70101 Align with the punch marks of the balancer driven gear and drive gear ...

Page 49: ...tion A 22201 KRE G01 B 22201 KTT 900 Assemble clutch discs clutch plates and pressure plate onto clutch center while aligning marks of clutch center and pressure plate Install the tabs of the clutch disc outside into the shallow slots in the clutch outer Clutch inspection ...

Page 50: ... Drive sprocket cover 3 9 Hold the flywheel with the special tool for the nut removal Flywheel holder 07725 0040001 Flywheel Flywheel puller 07933 KM10001 Clean any oil and grease from crankshaft and flywheel contact area Install the flywheel onto the crank shaft by aligning the key way on the flywheel with the woodruff key ...

Page 51: ...FUEL ENGINE 2 26 16 N m Coating width 6 5 1 mm from the tip 12 N m 12 N m 12 N m Coating width 6 5 1 mm from the tip Apply sealant TB 1141G 1215 1207B or equivalent to the sealing surface ...

Page 52: ...e Temporarily install the balancer drive gear and loosen the right side of the balancer driven gear lock nut Gear holder 07724 0010200 Install the gear holder A and loosen the left side of the balancer nut B Gear holder 07724 0010200 Align with the cut outs of the crankshaft and balancer shaft Install the push plug by aligning its flat surface with the crankshaft bearing outer race Temporarily ins...

Page 53: ...FUEL ENGINE 2 28 CRANKSHAFT RUNOUT INSPECTION Balancer inspection Set the crankshaft on V blocks and measure the runout us ing a dial indicator Limit 0 03 mm 45 0 mm 47 5 mm ...

Page 54: ... m 0 5 1 0 mm 0 5 1 0 mm Coating width 6 5 1 mm from the tip Each bearing Separate the crankcase 2 27 Each shift fork has an identification mark R L right and left C center Install the oil seal to the left crankcase so that the depth as shown ...

Page 55: ...FUEL ENGINE 2 30 MAINSHAFT COUNTERSHAFT Each gear tooth Transmission inspection Each gear tooth Transmission inspection ...

Page 56: ...FUEL ENGINE 2 31 ENGINE UNIT 12 N m 39 N m 54 N m 12 N m Exhaust pipe muffler 3 15 Drive sprocket cover 3 9 Side cover 3 4 ...

Page 57: ...MEMO ...

Page 58: ... CHASSIS BODY PANELS 3 2 CENTERSTAND 3 14 SIDESTAND 3 14 EXHAUST PIPE MUFFLER 3 15 FRONT WHEEL 3 16 FORK 3 18 HANDLEBAR 3 20 STEERING STEM 3 21 REAR WHEEL 3 23 REAR SUSPENSION 3 25 FRONT BRAKE 3 26 REAR BRAKE 3 29 ...

Page 59: ...er A 3 10 2 Front visor 3 7 11 Rear fender B 3 11 3 Front fender 3 8 12 Drive chain cover 3 11 4 Fuel tank shroud 3 6 13 Pillion step 3 4 5 Brake pedal 3 13 14 Step holder 3 12 6 Side cover 3 4 15 Gearshift pedal 3 13 7 Seat 3 3 16 Drive sprocket cover 3 9 8 Fuel tank center cover 3 7 17 Battery box 3 12 9 Rear cowl 3 5 ...

Page 60: ...FRAME CHASSIS 3 3 REARVIEW MIRROR SEAT 34 N m 34 N m ...

Page 61: ...FRAME CHASSIS 3 4 SIDE COVER PILLION STEP ...

Page 62: ...FRAME CHASSIS 3 5 REAR COWL 1 0 N m Seat 3 3 Side cover 3 4 Pillion step 3 4 1 0 N m ...

Page 63: ...FRAME CHASSIS 3 6 FUEL TANK SHROUD Rear cowl 3 5 1 0 N m ...

Page 64: ...FRAME CHASSIS 3 7 FUEL TANK CENTER COVER FRONT VISOR Fuel tank shroud 3 6 Speedometer 4 34 ...

Page 65: ...FRAME CHASSIS 3 8 FRONT FENDER Except CL type CL type Front wheel 3 16 Front wheel 3 16 ...

Page 66: ...FRAME CHASSIS 3 9 DRIVE SPROCKET COVER Left side cover 3 4 ...

Page 67: ...FRAME CHASSIS 3 10 REAR FENDER A 1 0 N m 7 5 N m Rear cowl 3 5 1 0 N m Brake tail light unit 4 28 ...

Page 68: ...FRAME CHASSIS 3 11 REAR FENDER B DRIVE CHAIN COVER Rear fender A 3 10 ...

Page 69: ...FRAME CHASSIS 3 12 BATTERY BOX STEP HOLDER 7 0 N m ECM 4 19 Battery 4 28 12 N m Side cover 3 4 ...

Page 70: ...FRAME CHASSIS 3 13 BRAKE PEDAL GEARSHIFT PEDAL Step holder 3 12 ...

Page 71: ...FRAME CHASSIS 3 14 CENTERSTAND SIDESTAND Muffler cover 3 15 39 N m 10 N m ...

Page 72: ...FRAME CHASSIS 3 15 EXHAUST PIPE MUFFLER 26 N m 10 N m 20 5 22 5 mm 11 N m ...

Page 73: ...FRAME CHASSIS 3 16 FRONT WHEEL 64 N m 23 N m ...

Page 74: ...earing remover shaft and drive out the bearing from the wheel hub Remover head 15 mm 07746 0050400 Bearing remover shaft 07746 0050100 Drive in a new bearing squarely with its marked side facing outside until it is fully seated Driver 07749 0010000 Attachment 42 x 47 mm 07746 0010300 Pilot 15 mm 07746 0040300 Install the distance collar Wheel disassembly and inspection ...

Page 75: ...FRAME CHASSIS 3 18 FORK 23 N m 23 N m 33 5 mm Handlebar 3 20 Front fender 3 8 Brake caliper 3 28 Install the front fork so that the length from the top bridge surface is 33 5 mm ...

Page 76: ...cified amount of recommended fork fluid into the outer tube RECOMMENDED FORK FLUID MX4 FORK FLUID CAPACITY 395 cm3 Bleed air from the fork pipe by pumping the outer tube Compress the fork pipe fully and measure the fluid level from the top of the outer tube FORK FLUID LEVEL 70 mm Hold the fully seated fork rod nut A and tighten the fork cap B Fork disassembly and inspection ...

Page 77: ...lever bracket and holder with the UP mark facing up Align the edge of the clutch lever bracket with the punch mark on the handlebar Install the left handlebar switch housing while aligning the locating pin in the housing with the hole in the handlebar Install the throttle pipe housing while aligning its locating pin with the hole on the handlebar ...

Page 78: ...FRAME CHASSIS 3 21 STEERING STEM TOP BRIDGE 74 N m 23 N m Handlebar 3 20 Front visor 3 7 ...

Page 79: ...RING STEM BEARING C Steering stem driver 07946 4300101 STEERING STEM A Steering stem socket wrench 07916 3710101 Install the steering stem adjusting nut Hold the steering stem and tighten the steering stem adjusting nut to the initial torque using the special tool TORQUE 24 5 N m Turn the steering stem lock to lock several times to seat the bearing Completely loosen the top thread Tighten the stee...

Page 80: ...FRAME CHASSIS 3 23 REAR WHEEL 88 N m Wheel inspection ...

Page 81: ... 07746 0050500 Bearing remover shaft 07746 0050100 Drive in a new bearing squarely with its sealed side facing outside until it is fully seated Driver 07749 0010000 Attachment 40 x 42 mm 07746 0010900 Pilot 17 mm 07746 0040400 Install the distance collar Drive in a new bearing squarely with its marked side facing outside until it is fully seated Driver 07749 0010000 Attachment 42 x 47 mm 07746 001...

Page 82: ...FRAME CHASSIS 3 25 REAR SUSPENSION 44 N m 54 N m 44 N m 1 0 g 1 0 g Rear cowl 3 5 Drive chain cover 3 11 Rear wheel 3 23 ...

Page 83: ...RAKE BRAKE FLUID REPLACEMENT 7 0 8 0 mm Set line 1 5 N m Front brake Rear brake 1 5 N m Upper line Add the reservoir with brake fluid from a sealed container to the set line and upper line RECOMMENDED BRAKE FLUID DOT 3 or DOT 4 ...

Page 84: ...aster cylinder and holder with the UP mark facing up Align the edge of the master cylinder with the punch mark on the handlebar 1 5 N m 1 0 N m 1 2 N m 6 0 N m Silicone grease 0 1 g Silicone grease Remove the snap ring Snap ring pliers 07914 SA50001 Master cylinder inspection ...

Page 85: ...FRAME CHASSIS 3 28 BRAKE CALIPER BRAKE PAD REPLACEMENT 18 N m 2 5 N m 26 N m Install brake pads so that they are set on the brake caliper bracket and bracket pin 34 N m 26 N m ...

Page 86: ...FRAME CHASSIS 3 29 REAR BRAKE BRAKE MASTER CYLINDER 8 0 N m Silicone grease Silicone grease 0 4 g minimum Silicone grease 0 4 g minimum Brake caliper inspection 34 N m Step holder 3 12 ...

Page 87: ...IS 3 30 BRAKE CALIPER BRAKE PAD REPLACEMENT 1 5 N m 1 5 N m 17 N m Silicone grease 0 1 g Remove the snap ring using the special tool Snap ring pliers 07914 SA50001 Master cylinder inspection 17 N m Silicone grease ...

Page 88: ...FRAME CHASSIS 3 31 34 N m Rear wheel 3 23 5 4 N m Silicone grease 0 4 g minimum Silicone grease Silicone grease 0 4 g minimum Brake caliper inspection ...

Page 89: ...MEMO ...

Page 90: ...4 1 4 ELECTRICAL SYSTEM PGM FI SYSTEM 4 2 IGNITION SYSTEM 4 21 ELECTRICAL STARTER 4 23 BATTERY CHARGING SYSTEM 4 27 LIGHTING SYSTEM 4 28 SPEEDOMETER 4 34 ELECTRICAL COMPONENT 4 38 ...

Page 91: ...cceleration 4 9 8 2 TP sensor malfunction TP sensor high voltage Poor engine acceleration 4 10 9 1 IAT sensor malfunction IAT sensor low voltage Engine operates normally 4 11 9 2 IAT sensor malfunction IAT sensor high voltage Engine operates normally 4 12 12 1 Injector malfunction Engine does not start Injector fuel pump and ignition coil shut down 4 13 21 1 O2 sensor malfunction Engine operates n...

Page 92: ...ELECTRICAL SYSTEM 4 3 PGM FI SYSTEM LOCATION IGNITION SWITCH INJECTOR BANK ANGLE SENSOR DLC O2 SENSOR SENSOR UNIT MAP SENSOR IAT SENSOR TP SENSOR CKP SENSOR IACV EOT SENSOR FUEL PUMP ECM ...

Page 93: ...ONNECTOR Bl Bl Bl Bl R Bl R Bl R Bl R Bl R R W R Bl Bl W Br Bu Br Bu Br Bu Br Bu Br R G Bl W Bu Br W Bu W Bl Y Bu Bl P Bl Bu Y G G R Bu Y R Gr Bu Y Bu G W Bu Y Bl W W Y Y G Lg Y 21 1 O2 SENSOR IACV1A IACV2A 1 IGP 26 BA 6 VCC 27 PB 5 THL 14 TA 24 TO 4 SG 12 PCP 23 PCM 3 O2 10 PG2 9 PG1 18 FI IND 2 LG 16 INJ 8 FFP 21 32 20 K LINE SCS 30 15 31 IACV1B IACV2B ECM BATTERY 20A 10A 10A 1 1 1 2 8 1 8 2 9 1...

Page 94: ... or poor contact at the connector Yes 2 Sensor unit Power Input Voltage Inspection Connection Y R G W Is the voltage within 4 75 5 25 V No Open or short circuit in Y R wire If there is no open or short circuit replace the ECM with a new one 4 19 and recheck Yes 3 MAP Sensor Output Voltage Inspection Connection Lg Y G W Is the voltage within 3 80 5 25 V Yes Replace the sensor unit MAP sensor with a...

Page 95: ... Is the voltage about 5 V indicated No Intermittent failure Loose or poor contact at the connector Yes 2 MAP Sensor Inspection Install a jumper wire between the terminals Connection Lg Y G W Check the MAP sensor voltage with MCS Is the voltage about 0 V indicated Yes Replace the sensor unit MAP sensor with a new one 2 8 and recheck No 3 MAP Sensor Output Line Inspection Check an open circuit in Lg...

Page 96: ... sensor voltage with MCS Is the voltage about 0 V indicated No Intermittent failure Loose or poor contact at the connector Yes 2 EOT Sensor Inspection Check the EOT sensor voltage with MCS Is the voltage about 0 V indicated No Replace the EOT sensor with a new one 4 19 and recheck Yes 3 EOT Sensor Output Line Inspection Check a short circuit in Y Bu wire If there is no short circuit replace the EC...

Page 97: ...tage about 5 V indicated No Intermittent failure Loose or poor contact at the connector Yes 2 EOT Sensor Inspection Install a jumper wire between the terminals Connection Y Bu G W Check the EOT sensor voltage with MCS Is the voltage about 0 V indicated Yes Replace the EOT sensor with a new one 4 19 and recheck No 3 EOT Sensor Output Line Inspection Check an open circuit in Y Bu and G W wire If the...

Page 98: ...he connector Yes 2 Sensor unit Power Input Voltage Inspection Connection Y R G W Is the voltage within 4 75 5 25 V No Open or short circuit in Y R wire If there is no open or short circuit replace the ECM with a new one 4 19 and recheck Yes 3 TP Sensor Output Line Inspection Check a open or short circuit in Y G wire Is there open or short circuit Yes Faulty Y G wire No 4 TP Sensor Inspection Repla...

Page 99: ...ut 5 V indicated No Check the TP sensor voltage with MCS Operate the throttle from fully closed to fully opened If the voltage is not increase continuously replace the sensor unit TP sensor with a new one 2 8 and recheck Yes 2 TP Sensor Ground Line Inspection Check a open circuit in G W wire Is there open circuit No Faulty G W wire Yes 3 TP Sensor Inspection Replace the sensor unit TP sensor with ...

Page 100: ...AT sensor voltage with MCS Is the voltage about 0 V indicated No Intermittent failure Loose or poor contact at the connector Yes 2 IAT Sensor Inspection Check the IAT sensor voltage with MCS Is the voltage about 0 V indicated No Replace the sensor unit IAT sensor with a new one 2 8 and recheck Yes 3 IAT Sensor Output Line Inspection Check a short circuit in Gr Bu wire If there is no short circuit ...

Page 101: ...ge about 5 V indicated No Intermittent failure Loose or poor contact at the connector Yes 2 IAT sensor Inspection Install a jumper wire between the terminals Connection Gr Bu G W Check the IAT sensor voltage with MCS Is the voltage about 0 V indicated Yes Replace the sensor unit IAT sensor with a new one 2 8 and recheck No 3 IAT Sensor Voltage Input Line Inspection Check an open circuit in Gr Bu a...

Page 102: ...s indicated No Intermittent failure Loose or poor contact at the connector Yes 2 Fuel Injector Input Voltage Inspection Connection Br Bu Ground Does the battery voltage exist No Open circuit in Br Bu wire Yes 3 Fuel Injector Signal Line Inspection Check an open or short circuit in P W wire Is there open or short circuit Yes Faulty P W wire No 4 Fuel Injector Resistance inspection Connection A B Is...

Page 103: ...CS Is the DTC 21 1 is indicated No Intermittent failure Loose or poor contact at the connector Yes 2 O2 Sensor Circuit Inspection Check an open or short circuit in Bl W wire Is there open or short circuit Yes Faulty Bl W wire No 3 O2 Sensor Inspection Replace the O2 sensor with a new one 4 20 Erase the DTC s Test ride the vehicle and check the O2 sensor with MCS If DTC 21 1 is indicated replace th...

Page 104: ...s the DTC 29 1 is indicated No Intermittent failure Loose or poor contact at the connector Yes 2 IACV Circuit Inspection Check a open or short circuit in Bu W Br W Bl Y and Bu Bl wires Is there open or short circuit Yes Faulty Bu W Br W Bl Y or Bu Bl wire No 3 IACV Resistance Inspection Connection A D B C Is the resistance within 110 150 Ω 25 C No Faulty IACV Yes 4 IACV Short Circuit Inspection Co...

Page 105: ... 4 16 DTC 33 2 EEPROM 1 EEPROM System Inspection Check the EEPROM with MCS Is the DTC 33 2 is indicated No Intermittent failure Loose or poor contact at the connector Yes Replace the ECM with a new one 4 19 and re check ...

Page 106: ... Intermittent failure Loose or poor contact at the connector Yes 2 Bank Angle Sensor Power Input Voltage In spection Connection Bl R Ground Does the battery voltage exist No Faulty Bl R wire Yes 3 Bank Angle Sensor Output Line Inspection Check a open or short circuit in R Bu wire Is there open or short circuit Yes Faulty R Bu wire No 4 Bank Angle Sensor Inspection Replace the bank angle sensor wit...

Page 107: ...gle sensor From Battery Bl R R Bu R Bu Bl R R Bu Bank angle sensor 2P connector ECM 33P connector 1 Bank Angle Sensor System Inspection Check the bank angle sensor voltage with MCS Incline the bank angle sensor Is the voltage decrease Yes Replace the ECM with a new one 4 19 and recheck No Replace the bank angle sensor with a new one 4 20 and recheck ...

Page 108: ...ELECTRICAL SYSTEM 4 19 ECM EOT SENSOR Fuel tank shroud 3 6 ECM power circuit and ground circuit inspection 15 N m Side cover 3 4 Engine oil 2 14 EOT sensor inspection ...

Page 109: ...ELECTRICAL SYSTEM 4 20 O2 SENSOR BANK ANGLE SENSOR 25 N m Fuel tank shroud 3 6 Remove the O2 sensor Flare nut socket FRXM17 Snap on or equivalent 10 N m Fuel tank shroud 3 6 Bank angle sensor inspection ...

Page 110: ...YSTEM DIAGRAM IGNITION SWITCH IGNITION COIL ECM CKP SENSOR SPARK PLUG BATTERY FUSE BOX FI 10 A MAIN FUSE 20 A IGNITION SWITCH SPARK PLUG CKP SENSOR ECM BATTERY MAIN 20 A Bl IGNITION COIL G G G Bl Bl FI 10 A R W Bl Bu Bl W Bl R P Bu W Y Bu Y Br Bu Bl R ENGINE STOP SWITCH R Bl ...

Page 111: ...nd it to the cylinder head as done in a spark test With the ignition coil primary wires connected connect the peak voltage adaptor probes to the ignition coil primary terminal and ground CONNECTION P Bu Ground Check the initial voltage at this time STANDARD VOLTAGE Battery voltage Shift the transmission in neutral and then crank the engine with the starter and measure the ignition coil primary pea...

Page 112: ... SWITCH NEUTRAL SWITCH STARTER SWITCH STARTER RELAY SWITCH CLUTCH SWITCH BATTERY STARTER MOTOR MAIN FUSE 20 A FUSE BOX FI 10 A Y R IGNITION SWITCH NEUTRAL SWITCH CLUTCH SWITCH STARTER MOTOR BATTERY STARTER RELAY SWITCH G Lg R STARTER SWITCH G R Bl Bl Bl Bl R W Bl R MAIN 20 A FI 10 A Bl ENGINE STOP SWITCH Bl Bu Bl W R Bl ...

Page 113: ...n switch Starter switch Engine stop switch Starter relay coil input related circuit Yes 2 Starter Relay Coil Ground Circuit Inspection Connection G R Ground Squeeze the clutch lever or shift the transmis sion in neutral position Is there continuity No Inspect the following Diode Clutch switch Neutral switch Starter relay coil ground related circuit Yes 3 Starter Relay Inspection Replace the starte...

Page 114: ...ELECTRICAL SYSTEM 4 25 STARTER MOTOR Electric starter inspection ...

Page 115: ...ELECTRICAL SYSTEM 4 26 NEUTRAL SWITCH Drive sprocket cover 3 9 Engine oil 2 14 ...

Page 116: ...Y CHARGING SYSTEM LOCATION BATTERY CHARGING SYSTEM DIAGRAM ALTERNATOR REGULATOR RECTIFIER BATTERY MAIN FUSE 20 A R W G Bl Y Y Y Y Y BATTERY REGULATOR RECTIFIER ALTERNATOR Y Bl Bl MAIN 20 A Battery charging system information troubleshooting and inspection ...

Page 117: ...LIGHTING SYSTEM 9 0 N m Left side cover 3 4 1 0 N m 7 5 N m When LEDs headlight flickering replace the regulator rectifier with a known good one and recheck If the headlight still flickering replace the headlight unit Front visor 3 7 ...

Page 118: ...ELECTRICAL SYSTEM 4 29 Rear fender A 3 10 19 N m Front Front visor 3 7 Rear Seat 3 3 ...

Page 119: ...ELECTRICAL SYSTEM 4 30 HEADLIGHT AIM 1 0 N m Seat 3 3 Beam up Beam down ...

Page 120: ...ay 3P connector G Bl Gr 1 Turn Signal Light Relay Input Voltage Inspection Connection Bl G Does the battery voltage exist No Faulty Bl or G wire Yes 2 Turn Signal Light Relay Inspection Connection Gr G Connector connected Peak voltage adapter 07HGJ 0020100 Battery voltage Measured voltage 1 5 V max No Replace the turn signal light relay with a new one and recheck Yes Check an open or short circuit...

Page 121: ...t light replace the handlebar switch with a known good one 3 20 and recheck Speedometer Connector connected 4 34 Loose or poor contacts of related terminal connector Battery condition Burned fuse Right handlebar switch 9P connector G Br Bl Left handlebar switch 9P connector G Br Bl 1 Handlebar Switch LED Input Voltage Inspection Turn the lighting switch ON1 or ON2 Connection Br Bl G Does the volta...

Page 122: ...condition Burned fuse Speedometer 16P connector G Br Br Bl 1 Handlebar Switch LED Circuit Inspection Check an open or short circuit in Br Bl or G wire Is there an open or short circuit No Faulty Br Bl or G wire Yes 2 Speedometer Input Voltage Inspection Turn the lighting switch ON1 or ON2 Connection Br G Does the battery voltage exist No Faulty Br wire Yes Replace the meter with a new one 4 34 and...

Page 123: ...ELECTRICAL SYSTEM 4 34 SPEEDOMETER ...

Page 124: ...ushed The time advances fast when the button is pushed and held The minute display will start flashing The time advances by one minute each time the button is pushed The time advances fast when the button is pushed and held To end the adjustment push the SEL button or turn the ig nition switch to OFF The display will stop flashing automatically and the adjustment will be cancelled if the button is...

Page 125: ...ELECTRICAL SYSTEM 4 36 VS SENSOR FUEL LEVEL SENSOR R R Bl Y G Bl Fuel pump unit 2 4 Route the fuel level sensor wires to the guide and terminals properly ...

Page 126: ...ation Short circuit indication 1 Fuel Level Sensor Circuit Inspection Check the Y W and G wire Is there open or short circuit Yes Faulty Y W or G wire No 2 Fuel Level Sensor Inspection Connection A B Standard FULL 6 10 Ω EMPTY 90 100 Ω Does the standard resistance exist No Replace the fuel level sensor with a new one 4 36 and recheck Yes Replace the meter with a new one 4 34 and recheck ...

Page 127: ...ELECTRICAL SYSTEM 4 38 ELECTRICAL COMPONENT IGNITION SWITCH HORN Fuel tank center cover 3 7 Fuel tank shroud 3 6 ...

Page 128: ...CREEN 2 14 ENGINE UNIT 2 31 EVAP SYSTEM 2 11 EXHAUST PIPE MUFFLER 3 15 F FORK 3 18 FRONT BRAKE 3 26 FRONT WHEEL 3 16 FUEL LEVEL SENSOR 4 36 FUEL LINE 2 2 FUEL PUMP UNIT 2 4 FUEL TANK 2 6 H HANDLEBAR 3 20 HORN 4 38 How To Use This Manual 1 3 I IGNITION SYSTEM 4 21 INJECTOR 2 11 L LIGHTING SYSTEM 4 28 LUBRICATION SYSTEM 2 13 M MAINTENANCE SCHEDULE 1 23 MODEL IDENTIFICATION 1 5 P PGM FI SYSTEM 4 2 R ...

Page 129: ... Lg R Bl Bl Br Bl G Bu R W R Bl Bl W R Br Bl Bl Bl Bl Bl R W Bl W R W R Bl R W R W R W R W Y R G R G R G R G R Lg R Lg R Lg Y Gr Bu G W Y R Y G Bu Bl Br W Bl Y Bu W G Bl Bu Bl R Y Bl O Lb G R W Br Bu Bl Bu Bl G Y Bl G Y G R Lg Y W Y R Y R Bu Y Bu W Bu Gr Bu P Bu Bu G G P Bl Bu Bl Bu W Bu Y Bu R Y R Y G G W G Bl Bl W Br R Br Bu Br W Y Bl Y R Bu Bl R R W Bl W Bl R Bl R R Bl R Bl Bl G Lb Lb G Y Br G ...

Page 130: ... Honda Motor Co Ltd 2016 Published by Honda Motor Co Ltd Printed in Japan Book 62K70M0 A 2016 03 ...

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