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Honda CBR125R, Owner'S Manual

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Honda CBR125R Owner'S Manual Download Page 217

CYLINDER/PISTON

9-5

Remove the dowel pins and gasket.

PISTON REMOVAL

Place a clean shop

towel over the

crankcase to

prevent the piston

pin clips from falling

into the crankcase.

Remove the piston pin clips with pliers.

Push the piston pin out of the piston and connecting
rod, and remove the piston.

Spread each piston ring and remove it by lifting up
a point opposite the gap.

 • Do not damage the piston ring by spreading the

ends too far.

 • Be careful not to damage the piston when the

piston ring removal.

GASKET

DOWEL PINS

PISTON PIN CLIPS

PISTON PIN

PISTON

PISTON RING

Summary of Contents for CBR125R

Page 1: ...abbreviations are used to identify individual model CODE AREA TYPE E U K Ireland F France ED EUROPEAN DIRECT SALES Austria Switzerland Belgium Germany Portugal Italy Spain Israel U Australia II G Ger...

Page 2: ...ty 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...

Page 3: ...es preceded by a safety alert symbol and one of three signal words DANGER WARNING or CAUTION These signal words mean You WILL be KILLED or SERIOUSLY HURT if you don t follow instructions You CAN be KI...

Page 4: ...molybdenum disulfide grease containing more than 3 molybdenum disulfide NLGI 2 or equivalent Example Molykote BR 2 plus manufactured by Dow Corning U S A Multi purpose M 2 manufactured by Mitsubishi...

Page 5: ...FICATIONS 1 9 CRANKSHAFT BALANCER TRANSMISSION SPECIFICATIONS 1 9 FRONT WHEEL SUSPENSION STEERING SPECIFICATIONS 1 10 REAR WHEEL SUSPENSION SPECIFICATIONS 1 10 HYDRAULIC BRAKE SPECIFICATIONS 1 10 BATT...

Page 6: ...ing surfaces before reassembly 7 After reassembly check all parts for proper installation and operation 8 Route all electrical wires as shown in the Cable and Harness Routing page 1 18 9 Do not bend o...

Page 7: ...istered number plate is located on the right side of the frame Except CM and U type The engine serial number is stamped on the lower left side of the crankcase The throttle body identification number...

Page 8: ...color coded parts always specify the designated color code The Safety Certification Label is located on the right side of the frame CM type only The Emission Control Information Label is located on t...

Page 9: ...acity 10 0 liter 2 64 US gal 2 20 lmp gal ENGINE Cylinder arrangement Single cylinder inclined 40 from vertical Bore and stroke 58 0 x 47 2 mm 2 28 x 1 86 in Displacement 125 cm3 7 6 cu in Compression...

Page 10: ...r controlled digital transistor ized with electric advance Starting system Electric starter motor Charging system Triple phase output alternator Regulator rectifier SCR shorted triple phase full wave...

Page 11: ...002 0 004 0 12 0 005 ITEM SPECIFICATIONS Throttle body identification number GQ16A Engine idle speed 1 450 100 min 1 rpm Throttle grip freeplay 2 6 mm 1 16 1 4 in Fuel injector resistance 20 C 68 F 9...

Page 12: ...0 05 0 002 ITEM STANDARD SERVICE LIMIT Cylinder I D 58 000 58 010 2 2835 2 2839 58 05 2 285 Out of round 0 010 0 0004 Taper 0 010 0 0004 Warpage 0 05 0 002 Piston piston pin piston ring Piston O D at...

Page 13: ...0 10 0 004 C2 0 015 0 057 0 0006 0 0022 0 10 0 004 Bushing I D M5 17 000 17 018 0 6693 0 6700 17 04 0 671 C1 15 000 15 018 0 5906 0 5913 15 10 0 594 C2 20 020 20 041 0 7882 0 7890 20 10 0 791 Mainsha...

Page 14: ...cargo 225 kPa 2 25 kgf cm2 33 psi Axle runout 0 2 0 01 Wheel rim runout Radial 2 0 0 08 Axial 2 0 0 08 Wheel balancer weight 60 g max Drive chain Size link 428 124 Slack 25 35 1 0 1 4 ITEM STANDARD SE...

Page 15: ...rd CR8E NGK or U24ESR N DENSO Optional CR9E NGK or U27ESR N DENSO Spark plug gap 0 70 0 80 mm 0 028 0 031 in Ignition coil peak voltage 100 V minimum CKP sensor peak voltage 0 7 V minimum Ignition tim...

Page 16: ...er bolt 3 6 13 1 3 10 Exhaust pipe stud bolt 2 8 See page 2 17 ITEM Q TY THREAD TORQUE REMARKS DIA mm N m kgf m lbf ft Spark plug 1 10 16 1 6 12 Tappet adjusting nut 2 5 10 1 0 7 Apply engine oil to t...

Page 17: ...ne oil to the threads and seating surface Cam sprocket mounting bolt 2 5 9 0 0 9 6 6 Rocker arm shaft stopper bolt 2 5 9 0 0 9 6 6 Cam chain tensioner lifter plug 1 6 4 0 0 4 3 0 ITEM Q TY THREAD TORQ...

Page 18: ...er lower mounting nut 1 10 44 4 5 32 U nut Swingarm pivot nut 1 12 88 9 0 65 U nut Drive chain slider screw 1 6 5 9 0 6 4 4 Brake hose guide screw 1 5 4 2 0 4 3 1 Driven sprocket stud bolt 4 10 28 2 9...

Page 19: ...WITCHES ITEM Q TY THREAD TORQUE REMARKS DIA mm N m kgf m lbf ft Turn signal light lens screw 4 4 0 9 0 1 0 7 Turn signal light mounting nut 4 6 8 8 0 9 6 5 License light cover screw 2 4 1 0 0 1 0 7 Li...

Page 20: ...ing Multi purpose grease Each oil seal lips clutch lifter arm gearshift spindle countershaft Molybdenum oil solution a mixture of 1 2 engine oil and 1 2 molybdenum disulfide grease Valve stem sliding...

Page 21: ...a Driven flange bearing rotating area Each dust seal lips Each O ring Engine oil Fuel tank contacting area fuel pump unit Silicone grease Throttle cable boot inside Brake caliper pin bolt sliding surf...

Page 22: ...ANDLEBAR SWITCH WIRE FRONT BRAKE LIGHT SWITCH WIRE RIGHT HANDLEBAR SWITCH WIRE IGNITION SWITCH WIRE COMBINATIONMETER SUB HARNESS BANK ANGLE SENSOR 3P GRAY CONNECTOR CLUTCH SWITCH WIRE SPEEDOMETER CABL...

Page 23: ...GENERAL INFORMATION 1 19 HEADLIGHT 4P NATURAL CONNECTOR POSITION LIGHT 3P NATURAL CONNECTOR HEADLIGHT BULB CONNECTORS FRONT SUB HARNESS FRONT SUB HARNESS Front POSITION LIGHT WIRE...

Page 24: ...BINATION METER 9P NATURAL CONNECTOR COMBINATION METER 3P NATURAL CONNECTOR DLC 4P NATURAL CONNECTOR FRONT BRAKE HOSE BANK ANGLE SENSOR 3P GRAY CONNECTOR COMBINATION METER SUB HARNESS RIGHT HANDLEBAR S...

Page 25: ...SPEEDOMETER CABLE CLUTCH SWITCH WIRE RIGHT TURN SIGNAL LIGHT WIRE BANK ANGLE SENSOR 3P GRAY CONNECTOR HORN WIRE LEFT TURN SIGNAL LIGHT WIRE CONNECTORS BANK ANGLE SENSOR WIRE Front View from the botto...

Page 26: ...R 6P NATURAL CONNECTOR SIDESTAND SWITCH 3P GREEN CONNECTOR FUEL TANK BREATHER HOSE COOLANT RESERVE TANK OVERFLOW HOSE SIDESTAND SWITCH WIRE AIR CLEANER HOUSING DRAIN HOSE FUEL TANK DRAIN HOSE REGULATO...

Page 27: ...SWITCH 9P NATURAL CONNECTOR COOLING FAN MOTOR 2P NATURAL CONNECTOR IGNITION SWITCH 2P NATURAL CONNECTOR RIGHT HANDLEBAR SWITCH 6P NATURAL CONNECTOR ECM 33P CONNECTOR ECT SENSOR 3P GRAY CONNECTOR INJE...

Page 28: ...RAKE LIGHT SWITCH AIR CLEANER HOUSING DRAIN HOSE WATER PUMP INSPECTION HOSE FUEL FEED HOSE SIPHON HOSE GROUND CABLE STARTER MOTOR CABLE MAIN WIRE HARNESS FUEL TANK BREATHER HOSE CLUTCH CABLE AIR CLEAN...

Page 29: ...ER HOSE GROUND CABLE SIPHON HOSE WATER HOSE O2 SENSOR 2P NATURAL CONNECTOR STARTER MOTOR CABLE RIGHT HANDLEBAR SWITCH WIRE IGNITION SWITCH WIRE CLUTCH CABLE THROTTLE CABLE CLUTCH CABLE THROTTLE CABLE...

Page 30: ...GENERAL INFORMATION 1 26 FUEL PUMP 5P NATURAL CONNECTOR FUEL FEED HOSE FUEL TANK BREATHER HOSE FUEL FEED HOSE IACV 4P BLACK CONNECTOR INJECTOR 2P BLACK CONNECTOR SENSOR UNIT 5P BLACK CONNECTOR...

Page 31: ...ABLE MAIN FUSE 30 A BATTERY POSITIVE CABLE 1 3 4 FUN MOTOR BRAKE TAIL LIGHT TURN SIGNAL LIGHT TURN SIGNAL INDICATOR LICENSE LIGHT MIL INSTRUMENT LIGHT NEUTRAL INDICATOR POSITION LIGHT HORN FUEL PUMP I...

Page 32: ...GENERAL INFORMATION 1 28 REAR BRAKE HOSE REAR BRAKE RESERVOIR HOSE DIODE MAIN WIRE HARNESS STARTERMOTOR CABLE GROUND CABLE REAR BRAKE LIGHT SWITCH 2P NATURAL CONNECTOR REAR BRAKE LIGHT SWITCH WIRE...

Page 33: ...LAY REAR TURN SIGNAL 2P ORANGE AND LIGHT BLUE CONNECTORS BRAKE TAIL LIGHT 3P NATURAL CONNECTOR LICENSE LIGHT WIRE LICENSE LIGHT WIRE BRAKE TAIL LIGHT 3P NATURAL CONNECTOR REAR TURN SIGNAL 2P ORANGE AN...

Page 34: ...en subject to sunlight Carbon monoxide does not react in the same way but it is toxic Honda Motor Co Ltd utilizes various systems page 1 31 to reduce carbon monoxide oxides of nitrogen and hydrocarbon...

Page 35: ...the ultimate customer or while it is in use 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITU...

Page 36: ...tributor s Limited Warranty for Honda Motorcycle Emission Control Systems is necessary in order to keep the emissions system warranty in effect SOURCE OF EMISSIONS The combustion process produces carb...

Page 37: ...y prohibit the following acts or the causing there of 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of desi...

Page 38: ...MEMO...

Page 39: ...S 2 2 SERVICE INFORMATION 2 3 TROUBLESHOOTING 2 3 PILLION SEAT 2 4 SINGLE SEAT 2 4 GRAB RAIL 2 5 REAR COWL 2 5 FUEL TANK COVER 2 6 INNER COWL 2 7 LOWER COWL 2 8 MIDDLE COWL 2 9 UPPER COWL 2 10 FRONT F...

Page 40: ...EM 2 2 BODY PANELS EXHAUST SYSTEM BODY PANEL LOCATIONS EXCEPT CM AND U TYPE shown WINDSCREEN SINGLE SEAT LOWER COWL FRONT FENDER UPPER COWL PILLION SEAT REAR FENDER MIDDLE COWL REAR COWL GRAB RAIL INN...

Page 41: ...install all of the exhaust pipe fasteners Always tighten the exhaust pipe joint nuts first then tighten the mounting bolts Always inspect the exhaust system for leaks after installation TORQUE VALUES...

Page 42: ...at retainers Push the pillion seat down to lock it SINGLE SEAT REMOVAL INSTALLATION Remove the pillion seat page 2 4 Remove the mounting bolt and collar on the frame and fuel tank Install the collar a...

Page 43: ...e 2 4 Grab rail page 2 5 Remove the bolts collars spacers and screws Release the bosses from the grommets of the fuel tank Carefully pull out both sides of the rear cowl then remove it rearward Instal...

Page 44: ...in the reverse order of disassembly Install the rear center cowl A and B by aligning its tabs with the slits of the both rear cowls FUEL TANK COVER REMOVAL INSTALLATION Remove the screws and fuel tank...

Page 45: ...REMOVAL INSTALLATION Remove the screws and inner cowl by pulling it rearward Install the inner cowl in the reverse order of removal Insert the tabs of the inner cowl to the slits of the middle cowl an...

Page 46: ...owl to middle cowl screws Install and tighten the lower cowl special screws DISASSEMBLY ASSEMBLY Remove the screws and lower center cowl Remove the screws and separate the right and left lower cowls A...

Page 47: ...s Release the boss from the grommet of the frame and remove the middle cowl by pulling it forward Release the speedometer cable from the cable guide Install the middle cowl in the reverse order of rem...

Page 48: ...le cowl page 2 9 Disconnect the headlight position light 4P Natural connector Remove the bolts and release the bosses from the grommets of the upper cowl stay Disconnect the bank angle sensor 3P Gray...

Page 49: ...removal FRONT FENDER REMOVAL INSTALLATION Be careful not to damage the fork legs Remove the bolts collars front fender and front fender stay from the fork legs Pull the front fender up and then pull i...

Page 50: ...oxes and retaining washer from the rear fender Remove the bolts and rear fender by pulling it rear ward Install the rear fender in the reverse order of removal Insert the hooks of the rear fender into...

Page 51: ...d license light assembly Grommet Nuts and number plate bracket CM type Assemble is in the reverse order of disassembly EXHAUST PIPE MUFFLER REMOVAL Remove the lower cowl page 2 8 Remove the exhaust pi...

Page 52: ...ffler mounting bolt collar rubber and nut Remove the exhaust pipe mounting bolt nut washer collar and rubbers Remove the exhaust pipe muffler as assembly Remove the exhaust pipe gasket BOLT COLLAR RUB...

Page 53: ...and gasket Assembly is in the reverse order of disassembly Always replace the muffler gasket with a new one whenever the muffler is removed from the exhaust pipe TORQUE Muffler joint bolt 13 N m 1 3...

Page 54: ...emoved Install the exhaust pipe muffler then temporarily install the all mounting fasteners Tighten the exhaust pipe joint nuts securely EXHAUST PIPE MUFFLER NUT NUT WASHER WASHER COLLAR COLLAR RUBBER...

Page 55: ...system for leaks STUD BOLT REPLACEMENT Remove the exhaust pipe muffler page 2 13 Thread two nuts onto the stud and tighten them together and use a wrench on them to turn the stud bolt out Install new...

Page 56: ...MEMO...

Page 57: ...G 3 9 VALVE CLEARANCE 3 11 ENGINE OIL 3 13 ENGINE OIL STRAINER SCREEN 3 14 RADIATOR COOLANT 3 15 COOLING SYSTEM 3 15 DRIVE CHAIN 3 16 BRAKE FLUID 3 21 BRAKE PADS WEAR 3 22 BRAKE SYSTEM 3 23 BRAKE LIGH...

Page 58: ...as energy conserving on the circular API service label JASO T 903 standard MA Viscosity SAE 10W 30 CM type only Pro Honda GN4 4 stroke oil or equivalent motor oil API service classification SG or Hig...

Page 59: ...threads and seat ing surface Water hose band screw See page 6 14 Rear axle nut 59 N m 6 0 kgf m 44 lbf ft U nut Drive sprocket fixing plate bolt 10 N m 1 0 kgf m 7 lbf ft Driven sprocket nut 64 N m 6...

Page 60: ...ment requires mechanical skill FREQUENCY WHICHEVER COMES FIRST ODOMETER READING NOTE 1 REFER TO PAGE x 1 000 km 1 4 8 12 x 1 000 mi 0 6 2 5 5 7 5 ITEMS NOTE MONTHS 6 12 18 FUEL LINE I I I 3 6 THROTTLE...

Page 61: ...TEMS x 1 000 km 1 4 8 12 EMISSION RELATED ITEMS FUEL LINE I I I 3 6 THROTTLE OPERATION I I I 3 7 AIR CLEANER NOTE 2 C C R 3 8 CRANKCASE BREATHER NOTE 3 C C C 3 9 SPARK PLUG I R I 3 9 VALVE CLEARANCE I...

Page 62: ...ort it using a suitable support as shown INSPECTION Check the fuel line for deterioration damage or leakage Replace the fuel line if necessary Check the fuel pump mounting area for leakage Replace the...

Page 63: ...on Measure the throttle grip freeplay at the throttle grip flange Throttle grip freeplay can be adjusted at either end of the throttle cable Minor adjustment is made with the upper adjuster at throttl...

Page 64: ...ge 3 8 Clean the air cleaner element using a compressed air as follows 1 Blow off the dust from the throttle body side Position the air blow gun 30 mm 1 2 in away from the air cleaner element Move the...

Page 65: ...the crankcase breather hose for deterioration damage or loose connection Make sure that the hoses are not kinked pinched or cracked Replace the crankcase breather hose if necessary Service if the dep...

Page 66: ...ce the spark plug if necessary Measure the gap between the center and side elec trodes with a feeler gauge If necessary adjust the gap by bending the side electrode carefully INSTALLATION Install and...

Page 67: ...wise and align the T mark on the flywheel with the index notch on the left crankcase cover The index line on the cam sprocket must be flush with the cylinder head surface as shown Make sure the piston...

Page 68: ...nces Install the cylinder head cover page 8 7 Apply engine oil to new O rings and install them to each hole cap Install and tighten the timing hole cap and crank shaft hole cap to the specified torque...

Page 69: ...e temperature in your riding area is within the indicated range Check that the O ring is in good condition replace it if necessary Apply engine oil to the O ring and install it to the filler cap dipst...

Page 70: ...Make sure there are no oil leaks ENGINE OIL STRAINER SCREEN REMOVAL INSTALLATION Remove the right crankcase cover page 10 5 Pull the oil strainer screen out of the crankcase Wash the oil strainer scre...

Page 71: ...ny coolant leaks when the coolant level decreases very rapidly If the reserve tank becomes completely empty there is a possibility of air getting into the cooling system Be sure to remove any air from...

Page 72: ...ut Loosen the lock nuts and turn the adjusting nuts until the correct drive chain slack is obtained Make sure the index lines on both adjusting plates are aligned with the rear end of the axle slots i...

Page 73: ...kly Inspect and replace sprocket as necessary Lubricate the drive chain with 80 90 gear oil or drive chain lubricant designed specifically for use with O ring chains Wipe off the excess oil or drive c...

Page 74: ...a drive chain with a staked master link Loosen the drive chain page 3 16 Assemble the special tool as shown TORQUE Drive sprocket fixing plate bolt 10 N m 1 0 kgf m 7 lbf ft Driven sprocket nut 64 N...

Page 75: ...ver reuse the old drive chain master link master link plate and O rings Assemble the new master link O rings and plate Assemble and set the drive chain tool set TOOL Drive chain tool set 07HMH MR10103...

Page 76: ...by mea suring the diameter of the staked area using a slide caliper A drive chain with a clip type master link must not be used After staking check the staked area of the master link for cracks If the...

Page 77: ...liper pis tons are pushed out this accounts for a low fluid level If the brake pads are not worn and fluid level is low check the entire system for leaks page 3 23 FRONT BRAKE Turn the handlebar so th...

Page 78: ...l the bolt BRAKE PADS WEAR FRONT BRAKE PADS Check the brake pads for wear Replace the brake pads if either pad is worn to the bottom of wear limit grooves For brake pad replacement page 15 8 REAR BRAK...

Page 79: ...BRAKE PEDAL HEIGHT ADJUSTMENT Loosen the lock nut and turn the push rod until the correct pedal height is obtained After adjustment tighten the lock nut securely BRAKE LIGHT SWITCH The front brake li...

Page 80: ...ustment is made with the lower adjusting nut at the clutch lifter lever Loosen the lock nut and turn the adjusting nut to adjust the freeplay Tighten the lock nut while holding the adjusting nut If pr...

Page 81: ...n of the forks by operating the front brake and compressing the front suspension several times Check the entire assembly for signs of leaks dam age or loose fasteners Replace damaged components which...

Page 82: ...s page 1 12 Check that all cotter pins safety clips hose clamps and cable stays are in place and properly secured WHEELS TIRES Support the motorcycle using a safety stand or hoist raise the front whee...

Page 83: ...ff the ground Check that the handlebar moves freely from side to side Make sure the control cables do not interfere with the handlebar rotation Check for steering stem bearings by grabbing the fork le...

Page 84: ...MEMO...

Page 85: ...4 1 4 4 LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM 4 2 SERVICE INFORMATION 4 3 TROUBLESHOOTING 4 3 OIL PUMP 4 4...

Page 86: ...LUBRICATION SYSTEM 4 2 LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM OIL STRAINER SCREEN OIL PUMP CAMSHAFT COUNTERSHAFT ROCKER ARM MAINSHAFT CRANKSHAFT...

Page 87: ...roperly installed piston rings From coolant mixing with oil Faulty head gasket Water leak in crankcase Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged p...

Page 88: ...BLY Remove the E clip from the oil pump shaft Remove the oil pump driven gear assembly and dis assemble them Remove the dowel pins bolts and oil pump cover Remove the inner and outer rotors from the o...

Page 89: ...over securely OIL PUMP Measure each clearance at several points and use the largest reading to compare the service limit If any portion of the oil pump is worn beyond the specified service limit repla...

Page 90: ...ide clearance using a straight edge and feeler gauge ASSEMBLY SERVICE LIMIT 0 26 mm 0 010 in BODY CLEARANCE SERVICE LIMIT 0 12 mm 0 005 in SIDE CLEARANCE OIL PUMP BODY INNER ROTOR OIL PUMP SHAFT OUTER...

Page 91: ...the oil pump driven gear groove with lock pin Install the oil pump cover Install the oil pump driven gear assembly into the oil pump body aligning the flats of the oil pump shaft and inner rotor Insta...

Page 92: ...f the E clip is upward Install the E clip to the oil pump shaft INSTALLATION Install the oil pump assembly Install and tighten the mounting bolts securely Install the right crankcase cover page 10 8 O...

Page 93: ...S 5 8 PGM FI TROUBLESHOOTING INFORMATION 5 10 DTC INDEX 5 14 SENSOR UNIT POWER LINE INSPECTION 5 15 DTC TROUBLESHOOTING 5 17 MIL TROUBLESHOOTING 5 33 MIL CIRCUIT TROUBLESHOOTING 5 44 FUEL LINE INSPECT...

Page 94: ...FUEL SYSTEM PGM FI 5 2 FUEL SYSTEM PGM FI COMPONENT LOCATION 1 2 N m 0 1 kgf m 0 9 lbf ft...

Page 95: ...g The PGM FI system is equipped with the Self Diagnostic System described page 5 10 If the MIL blinks follow the Self Diagnostic Procedures to remedy the problem When checking the PGM FI system always...

Page 96: ...0040004 Pressure gauge manifold 07ZAJ S5A0111 Hose attachment 9 mm 9 mm 07ZAJ S5A0120 Hose attachment 6 mm 9 mm 07ZAJ S5A0130 Attachment joint 6 mm 9 mm 07ZAJ S5A0150 ECM test harness 33P 070MZ MCA010...

Page 97: ...o start rough idling 1 Check the idle speed 2 Check the IACV 3 Inspect the fuel supply system page 5 44 4 Inspect the battery charging system page 16 6 Restricted fuel feed hose Contaminated deteriora...

Page 98: ...M FI SYSTEM LOCATION IGNITION SWITCH INJECTOR BANKANGLE SENSOR DLC O2 SENSOR SENSOR UNIT MAP SENSOR IAT SENSOR TP SENSOR CKP SENSOR IACV ECT SENSOR FUEL PUMP ECM THROTTLE BODY MAP SENSOR SENSOR UNIT T...

Page 99: ...IACV2B 32 IACV1B IACV P Bl Br Y Bu R Bu Bl IGNITION SWITCH MAIN RELAY 10A 10A STARTER SWITCH BATTERY STARTER RELAY SWITCH 30A 10A 10A Y R Bl W R Bl ENGINE STOP SWITCH CM AND U TYPE Lg Bl Bl Bl Lg R G...

Page 100: ...STEM PGM FI 5 8 PGM FI CONNECTOR LOCATIONS NOTE 1 Remove the upper cowl page 2 10 NOTE 2 Remove the right middle cowl page 2 9 BANK ANGLE SENSOR 3P GRAY CONNECTOR NOTE 1 O2 SENSOR 2P NATURAL CONNECTOR...

Page 101: ...nd support the fuel tank page 3 6 NOTE 2 Open the rubber sheet page 6 10 ECM 33P CONNECTOR NOTE1 NOTE 2 ECT SENSOR 3P GRAY CONNECTOR NOTE 1 IACV 4P BLACK CONNECTOR NOTE 1 SENSOR UNIT 5P BLACK CONNECTO...

Page 102: ...en there is trouble in the system When any abnormality is detected by the self diagnosis function running capability is maintained by pre programed value in the simulated program map When any abnormal...

Page 103: ...w seconds then go off If the MIL does not come on troubleshoot the MIL circuit page 5 44 CURRENT DTC FREEZE DTC The DTC is indicated in two ways according to the failure status In case the ECM detects...

Page 104: ...linking CLEARING DTC Connect the HDS pocket tester to the DLC page 5 11 Clear the DTC with the HDS pocket tester while the engine is stopped To clear the DTC without HDS pocket tester refer to the fol...

Page 105: ...ch the digital multimeter probe to the test probe TEST HARNESS CONNECTION Lift and support the fuel tank page 3 6 Open the rubber sheet page 6 10 Turn the ignition switch OFF Disconnect the ECM 33P co...

Page 106: ...engine acceleration Pre program value 0 5 22 9 1 9 IAT sensor circuit low voltage less than 0 07 V IAT sensor or its circuit malfunction Engine operates normally Pre program value 35 C 95 F 5 23 5 37...

Page 107: ...pection Turn the ignition switch OFF Check for continuity between the sensor unit 5P connector of the wire side and ground Is there continuity YES Short circuit in White red wire NO GO TO STEP 3 3 Sen...

Page 108: ...t Power Input Voltage Inspection 2 Turn the ignition switch OFF Disconnect the sensor unit 5P connector Turn the ignition switch ON and engine stop switch CM and U type Measure the voltage at the wire...

Page 109: ...ontact on the sensor unit 5P connector 2 Sensor Unit Power Line Inspection Check the sensor unit power line inspection page 5 15 Is the sensor unit power line normal YES GO TO STEP 3 NO Replace or rep...

Page 110: ...nsor with the HDS pocket tester Is DTC 1 1 indicated YES Replace the ECM with a known good one and recheck NO Faulty original sensor unit MAP sensor DTC 1 2 MAP SENSOR HIGH VOLTAGE 1 MAP Sensor System...

Page 111: ...h a known good one and recheck NO Open circuit in Light green yellow wire DTC 7 1 ECT SENSOR LOW VOLTAGE 1 ECT Sensor System Inspection Turn the ignition switch ON and engine stop switch CM and U type...

Page 112: ...lue wire NO Replace the ECM with a known good one and recheck DTC 7 2 ECT SENSOR HIGH VOLTAGE Before starting the inspection check for loose or poor contact on the ECT sensor 3P connector and recheck...

Page 113: ...O Open circuit in Yellow blue wire Open circuit in Green orange wire DTC 8 1 TP SENSOR LOW VOLTAGE 1 TP Sensor System Inspection Turn the ignition switch ON and engine stop switch CM and U type Check...

Page 114: ...s page 5 12 Connect the sensor unit 5P and ECM 33P connec tors Turn the ignition switch ON and engine stop switch CM and U type Check the TP sensor with the HDS pocket tester Is DTC 8 1 indicated YES...

Page 115: ...type Check the IAT sensor with the HDS pocket tester Is about 0 V indicated YES GO TO STEP 2 NO Intermittent failure Loose or poor contact on the sensor unit 5P connector 2 Sensor Unit Power Line Ins...

Page 116: ...sor unit 5P connector 2 Sensor Unit Power Line Inspection Check the sensor unit power line inspection page 5 15 Is the sensor unit power line normal YES GO TO STEP 3 NO Replace or repair the abnormal...

Page 117: ...the engine and check the injector with the HDS pocket tester Is the DTC 12 1 indicated YES GO TO STEP 2 NO Intermittent failure Loose or poor contact on the injector 2P connector 2 Injector Input Volt...

Page 118: ...ulty injector 5 Injector Signal Line Open Circuit Inspection Disconnect the ECM 33P connector Check the continuity at the Pink green wire between the ECM 33P and injector 2P connec tors Is there conti...

Page 119: ...icated YES GO TO STEP 2 NO Intermittent failure 2 O2 Sensor Short Circuit Inspection Turn the ignition switch OFF Disconnect the O2 sensor 2P connector page 7 5 Check for continuity between the O2 sen...

Page 120: ...ion check for loose or poor contact on the IACV 4P connector and recheck the DTC 1 Recheck DTC Clear the DTC s page 5 12 Turn the ignition switch ON and engine stop switch CM and U type Check the IACV...

Page 121: ...eck NO Faulty IACV DTC 33 2 EEPROM 1 Recheck DTC Clear the DTC s page 5 12 Turn the ignition switch ON and engine stop switch CM and U type Recheck the ECM EEPROM Is the DTC 33 2 indicated YES Replace...

Page 122: ...n switch ON and engine stop switch CM and U type Measure the voltage at the bank angle sensor connector of the wire side Is the voltage within 4 75 5 25 V YES GO TO STEP 4 NO GO TO STEP 3 3 Bank Angle...

Page 123: ...CM and U type Check the bank angle sensor with the HDS pocket tester Is DTC 54 2 indicated YES Replace the ECM with a known good one and recheck NO Faulty original bank angle sensor DTC 54 2 BANK ANGL...

Page 124: ...t in White red wire Open circuit in Green orange wire 4 Bank Angle Sensor Output Line Open Circuit Inspection Turn the ignition switch OFF Disconnect the ECM 33P connector Check the continuity between...

Page 125: ...Disconnect the sensor unit 5P connector Turn the ignition switch ON and engine stop switch CM and U type Measure the voltage at the sensor unit 5P con nector of the wire side Is the voltage within 3...

Page 126: ...tor Turn the ignition switch ON and engine stop switch CM and U type Measure the voltage at the ECT sensor connec tor of the wire side and ground Is the voltage within 4 75 5 25 V YES GO TO STEP 3 NO...

Page 127: ...Yellow blue wire Open circuit in Green orange wire 5 ECT Sensor Output Voltage Inspection Connect the ECT sensor 3P connector Turn the ignition switch ON and engine stop switch CM and U type Measure...

Page 128: ...Inspection Turn the ignition switch OFF Disconnect the sensor unit 5P connector Check for continuity between the sensor unit 5P connector of the wire side and ground Is there continuity YES Short circ...

Page 129: ...Inspection 2 Turn the ignition switch OFF Disconnect the sensor unit 5P connector Turn the ignition switch ON and engine stop switch CM and U type Measure the voltage at the sensor unit 5P con nector...

Page 130: ...ensor unit IAT sensor MIL 12 BLINKS INJECTOR Before starting the inspection check for loose or poor contact on the injector 2P connector and recheck the MIL blinking 1 Injector Input Voltage Inspectio...

Page 131: ...20 C 68 F YES GO TO STEP 4 NO Faulty injector 4 Injector Signal Line Open Circuit Inspection Connect the ECM test harness to the ECM 33P connector Check the continuity between the ECM test har ness a...

Page 132: ...k the MIL blinking Does the MIL blink 21 times YES GO TO STEP 2 NO Intermittent failure 2 O2 Sensor Short Circuit Inspection Turn the ignition switch OFF Disconnect the O2 sensor 2P connector page 7 5...

Page 133: ...V 4P connector and recheck the MIL blinking 1 IACV Resistance Inspection Turn the ignition switch OFF Disconnect the IACV 4P connector Measure the resistance at the IACV 4P connector terminals Is the...

Page 134: ...le sensor 3P connector Turn the ignition switch ON and engine stop switch CM and U type Measure the voltage at the bank angle sensor connector of the wire side Is there within 4 75 5 25 V YES GO TO ST...

Page 135: ...e sensor 3P connector of the wire side and ground Is there continuity YES Short circuit in Red blue wire NO GO TO STEP 5 5 Bank Angle Sensor Output Line Open Circuit Inspection Connect the ECM test ha...

Page 136: ...on replace the ECM with a known good one and recheck the MIL indication If the MIL does not come on check for open cir cuit in the White black wire between the MIL and ECM 33P connector If the wire i...

Page 137: ...nector off and remove the retainer Absorb the remaining fuel in the fuel feed hose from flowing out with a shop towel Be careful not to damage the hose or other parts Do not use tools If the connector...

Page 138: ...eed hose 1 Insert a new retainer into the connector Align new retainer locking pawls with the con nector grooves 2 Set the rubber cap as shown Then press the quick connect fitting onto the pipe until...

Page 139: ...rn the ignition switch ON and engine stop switch CM and U type Start the engine and let it idle Read the fuel pressure If the fuel pressure is higher than specified replace the fuel pump assembly If t...

Page 140: ...n the first fuel is flowed If fuel flow is less than specified inspect the follow ing Fuel pump unit page 5 48 Clogged fuel filter Assembly of the fuel pump unit Connect the quick connect fitting page...

Page 141: ...CM and U type Open circuit in Black white or Brown white wire ECM page 5 66 REMOVAL Do not disassemble the fuel pump Clean around the fuel pump Relieve the fuel pressure and disconnect the quick conne...

Page 142: ...the fuel tank When installing the setting plate onto the fuel pump unit align the following Slots of the fuel pump setting plate and tabs of the fuel pump unit marks of the fuel pump setting plate an...

Page 143: ...5 44 Release the fuel feed hose and fuel pump wire from the clamps Disconnect the fuel tank breather hose Remove the bolt and fuel tank Install the fuel tank in the reverse order of removal Connect th...

Page 144: ...the hose guides of the air cleaner housing Remove the bolts and air cleaner housing Installation is in the reverse order of removal THROTTLE BODY REMOVAL Relieve the fuel pressure and disconnect the...

Page 145: ...manual Do not snap the throttle valve from full open to full close after the throttle cable has been removed It may cause incorrect idle operation Do not damage the throttle body It may cause incorrec...

Page 146: ...ve the IACV Check the IACV for wear or damage Replace if necessary The IACV operation can be checked visually as fol lows 1 Connect the IACV 4P Black connector 2 Turn ignition switch ON and engine sto...

Page 147: ...th the boss of the throttle valve IAT sensor of the throttle body with the hole Install and tighten the sensor unit torx screws to the specified torque Perform the throttle valve fully closed reset pr...

Page 148: ...stall the setting plate while aligning the cut out with the lug on the IACV as shown Install and tighten the IACV setting plate torx screws to the specified torque INSTALLATION Connect the throttle ca...

Page 149: ...injector 2P Black connector Connect the injector side of the quick connect fitting page 5 61 Connect the sensor unit 5P Black connector If the sensor unit is removed reset the throttle valve fully cl...

Page 150: ...ort the DLC using a special tool 6 Disconnect the ECT sensor 3P connector Short the ECT sensor 3P connector terminals of the wire harness side using a jumper wire 7 Turn the ignition switch ON and eng...

Page 151: ...removal to prevent dirt and debris from entering the injector passage Relieve the fuel pressure and disconnect the quick connect fitting page 5 44 Disconnect the injector joint quick connect fitting...

Page 152: ...tools If the connector does not move keep the retainer tabs pressed down and alternately pull and push the connector until it comes off easily 3 To prevent damage and keep foreign matter out cover the...

Page 153: ...NECT FITTING INSTALLATION Always replace the retainer of the quick connect fitting when the fuel feed hose is disconnected If any retainer needs replacing use the same manufacturer s retainer as the o...

Page 154: ...eed after all other engine main tenance items have been performed and are within specifications Before checking the idle speed inspect the fol lowing items No DTC and MIL blinking Spark plug condition...

Page 155: ...the ECT sensor to the specified torque Connect the ECT sensor 3P Gray connector Remove the suitable support and close the fuel tank page 3 6 Fill the cooling system with recommended coolant page 6 6...

Page 156: ...angle sensor horizontal as shown Turn the ignition switch ON and engine stop switch CM and U type Read the voltage with the HDS pocket tester Incline the bank angle sensor approximately 60 to the left...

Page 157: ...ness at its terminals If you repeat this test first turn the ignition switch OFF then turn the ignition switch ON and engine stop switch CM and U type ECM REMOVAL INSTALLATION Lift and support the fue...

Page 158: ...exist YES GO TO STEP 2 NO Open or short circuit in Black white wire Faulty ignition switch Blown main or sub fuse Faulty engine stop switch CM and U type 2 ECM Ground Line Inspection Turn the ignition...

Page 159: ...ted replace the O2 sensor cord with a new one do not reuse O2 sensor cord REMOVAL Handle the O2 sensor with care Do not service the O2 sensor while it is hot Remove the right middle cowl page 2 9 Disc...

Page 160: ...r cap by installing a new O2 sensor cord Take care not to tilt the O2 sensor cap when con necting the cap to the O2 sensor Do not turn the O2 sensor cap after connecting it Install the O2 sensor cover...

Page 161: ...TEM FLOW PATTERN 6 2 SERVICE INFORMATION 6 3 TROUBLESHOOTING 6 4 SYSTEM TESTING 6 5 COOLANT REPLACEMENT 6 6 THERMOSTAT 6 8 THERMOSTAT HOUSING 6 9 RADIATOR 6 10 WATER PUMP 6 15 RADIATOR RESERVE TANK 6...

Page 162: ...COOLING SYSTEM 6 2 COOLING SYSTEM SYSTEM FLOW PATTERN RADIATOR SIPHON HOSE THERMOSTAT WATER PUMP RESERVE TANK WATER HOSES WATER HOSES...

Page 163: ...SPECIFICATIONS Coolant capacity Radiator and engine 0 70 liter 0 74 US qt 0 62 lmp qt Reserve tank 0 28 liter 0 30 US qt 0 25 lmp qt Radiator cap relief pressure 93 2 122 6 kPa 0 95 1 25 kgf cm2 13 5...

Page 164: ...ump Engine temperature too low Faulty temperature gauge or ECT sensor Thermostat stuck open Faulty fan control relay Coolant leak Faulty water pump mechanical seal Deteriorated O ring Faulty radiator...

Page 165: ...001 0 999 0 997 10 1 018 1 017 1 017 1 016 1 015 1 014 1 013 1 011 1 009 1 007 1 005 15 1 028 1 027 1 026 1 025 1 024 1 022 1 020 1 018 1 016 1 014 1 012 20 1 036 1 035 1 034 1 033 1 031 1 029 1 027 1...

Page 166: ...e 6 5 COOLANT REPLACEMENT PREPARATION The effectiveness of coolant decreases with the accumulation of rust or if there is a change in the mixing proportion during usage Therefore for best performance...

Page 167: ...he reserve tank with water Install the siphon hose to the clamps and connect it to the radiator When filling the system or reserve tank with a coolant checking coolant level support the motorcycle on...

Page 168: ...Lower cowl page 2 8 THERMOSTAT REMOVAL Drain the coolant page 6 7 Lift and support the fuel tank page 3 6 Remove the bolts and thermostat housing cover Remove the thermostat from the thermostat hous i...

Page 169: ...ecified torque Remove the suitable support and close the fuel tank page 3 6 Fill the system with the recommended coolant and bleed any air page 6 6 THERMOSTAT HOUSING REMOVAL INSTALLATION Drain the co...

Page 170: ...the trim clip Open the rubber sheet Disconnect the fan motor 2P Natural connector Disconnect the siphon hose from the radiator Loosen the water hose band screw and disconnect the lower water hose Loos...

Page 171: ...y Release the radiator upper grommet from the frame boss by moving the radiator to the right then remove the radiator assembly DISASSEMBLY Remove the bolts and fan motor assembly from the radiator Rem...

Page 172: ...e fan motor shroud Install and tighten the screws to the specified torque FAN MOTOR SHROUD SCREWS WASHERS 8 4 N m 0 9 kgf m 6 2 lbf ft RADIATOR 1 0 N m 0 1 kgf m 0 7 lbf ft COOLING FAN FAN MOTOR SHROU...

Page 173: ...nstall and tighten the bolts to the specified torque INSTALLATION Be careful not to damage the radiator fins Install the radiator assembly aligning its upper grommet with the frame boss Install the ho...

Page 174: ...the upper water hose and tighten the water hose band screw Connect the lower water hose and siphon hose Tighten the water hose band screws as shown After installation check the radiator and radiator h...

Page 175: ...N Remove the lower cowl page 2 8 Check for signs of seal leakage If water leaks through the bleed hose replace the mechanical seal page 6 15 If oil leaks through the bleed hose replace the oil seal pa...

Page 176: ...s semble them Check the water pump driven gear water pump shaft and lock pin for wear or damage replace them if necessary Remove the mechanical seal using the special tools IMPELLER PLAIN WASHER DRIVE...

Page 177: ...g the special tool as shown OIL SEAL 10 N m 1 0 kgf m 7 lbf ft MECHANICAL SEAL WASHER LOCK PIN WASHER PUMP SHAFT OIL SEAL PLAIN WASHER SEALING WASHER WASHER PUMP COVER WASHER PUMP DRIVEN GEAR IMPELLER...

Page 178: ...pump shaft outer sur face Install the water pump driven gear assembly into the right crankcase cover Install the plain washer and impeller to the water pump shaft Hold the water pump shaft and tighten...

Page 179: ...ge 5 52 Drain the coolant from the reserve tank page 6 7 Remove the bolt and reserve tank Disconnect the overflow and siphon hoses from the reserve tank Connect the overflow and siphon hoses to the re...

Page 180: ...e fan control relay con nector terminals Connect a 12 V battery to the fan control relay con nector terminals as shown There should be continuity only when 12 V battery is connected If there is no con...

Page 181: ...7 1 7 7 ENGINE REMOVAL INSTALLATION COMPONENT LOCATION 7 2 SERVICE INFORMATION 7 3 ENGINE REMOVAL 7 4 ENGINE INSTALLATION 7 6...

Page 182: ...ENGINE REMOVAL INSTALLATION 7 2 ENGINE REMOVAL INSTALLATION COMPONENT LOCATION 60 N m 6 1 kgf m 44 lbf ft 60 N m 6 1 kgf m 44 lbf ft 10 N m 1 0 kgf m 7 lbf ft...

Page 183: ...ensor page 11 6 Flywheel page 11 7 Starter motor page 18 6 The following components require engine removal for service Cylinder head valves page 8 15 Cylinder piston page 9 4 Crankshaft balancer page...

Page 184: ...clutch cable from the clutch lifter arm Disconnect the alternator CKP sensor 6P Natural connector and neutral switch wire connector Release the alternator CKP sensor and neutral switch wires from the...

Page 185: ...otor terminal nut and starter motor cable Remove the starter motor mounting bolt and ground cable The jack height must be continually adjusted to relieve stress for ease of bolt removal Support the en...

Page 186: ...ied torque Route the water hose wires and cables properly page 1 18 During engine installation hold the engine securely and be careful not to damage the frame and engine Place the engine in the frame...

Page 187: ...al connector If the O2 sensor cap is disconnected replace the O2 sensor cord with a new one Connect the water hoses and tighten the water hose band screws page 6 14 Install the drive chain over the dr...

Page 188: ...t cover page 11 5 Exhaust pipe muffler page 2 16 Throttle body page 5 56 Gearshift arm and left step holder page 10 19 Middle cowl page 2 9 Inspect the following Drive chain slack page 3 16 Throttle g...

Page 189: ...8 1 8 8 CYLINDER HEAD VALVES COMPONENT LOCATION 8 2 SERVICE INFORMATION 8 3 TROUBLESHOOTING 8 5 CYLINDER COMPRESSION 8 6 CYLINDER HEAD COVER 8 6 CAMSHAFT 8 8 CAMSHAFT HOLDER 8 12 CYLINDER HEAD 8 15...

Page 190: ...CYLINDER HEAD VALVES 8 2 CYLINDER HEAD VALVES COMPONENT LOCATION 4 0 N m 0 4 kgf m 3 0 lbf ft 29 N m 3 0 kgf m 21 lbf ft 9 N m 0 9 kgf m 6 6 lbf ft 10 N m 1 0 kgf m 7 lbf ft...

Page 191: ...EX 0 27 0 02 0 011 0 001 Valve valve guide Valve stem O D IN 4 975 4 990 0 1959 0 1965 4 863 0 1915 EX 4 965 4 980 0 1955 0 1961 4 853 0 1911 Valve guide I D IN EX 5 000 5 012 0 1969 0 1973 5 04 0 198...

Page 192: ...8920000 Seat cutter 24 mm 45 EX 07780 0010600 Seat cutter 29 mm 45 IN 07780 0010300 Flat cutter 27 mm 32 EX 07780 0013300 Flat cutter 30 mm 32 IN 07780 0012200 Interior cutter 26 mm 60 EX 07780 001450...

Page 193: ...r head gasket Warped or cracked cylinder head Loose spark plug Faulty cylinder piston or piston rings page 9 4 Compression too high over heating or knocking Excessive carbon build up on piston head or...

Page 194: ...ression can be caused by Blown cylinder head gasket Improper valve adjustment Valve leakage Worn piston ring or cylinder High compression can be caused by Carbon deposits in combustion chamber or on p...

Page 195: ...l the cylinder head cover onto the cylinder head Check the rubber seals are in good condition replace them if necessary Install the rubber seals to the cylinder head cover with their UP marks facing u...

Page 196: ...ner lifter shaft fully in clockwise and secure it using a tensioner stopper to prevent damaging the cam chain Be careful not to let the cam sprocket bolts fall into the crankcase Remove the cam sprock...

Page 197: ...ly and quietly Also check that the bearing inner race fits tightly on the camshaft Replace the camshaft assembly if the bearings do not turn smoothly quietly or if they fit loosely on the camshaft CAM...

Page 198: ...make a good access for camshaft installation Make sure the snap ring is firmly seated in the groove Install the snap ring into the groove of the camshaft holder Be careful not to jam the cam chain and...

Page 199: ...case Install and tighten the cam sprocket mounting bolts to the specified torque by holding the crankshaft Remove the tensioner stopper from the cam chain tensioner lifter Apply engine oil to a new O...

Page 200: ...washers and camshaft holder assembly Remove the dowel pins from the cylinder head DISASSEMBLY Remove the camshaft page 8 8 Remove the rocker arm shaft stopper bolts Push the rocker arm shafts from th...

Page 201: ...arm I D Measure the rocker arm shaft O D at three points Calculate the rocker arm to shaft clearance Clean the oil passages of the camshaft holder using a compressed air Check the oil passage for clo...

Page 202: ...e 8 10 INSTALLATION Install the dowel pins to the cylinder head Install the camshaft holder onto the cylinder head Apply engine oil to the camshaft holder mounting nut threads and seating surface Inst...

Page 203: ...into the crankcase Do not strike the cylinder too hard and do not damage the mating surface with a screwdriver Remove the dowel pins and gasket DISASSEMBLY Remove the following Spark plug page 3 9 O2...

Page 204: ...AD Use care not to scratch the combustion chamber or head gasket surface Remove the carbon deposits from the combustion chamber or exhaust port Check the spark plug hole and valve area for cracks Repl...

Page 205: ...build up before measuring the guide I D Use cutting oil on the reamer during this opera tion Take care not to tilt or lean the reamer in the guide while reaming Otherwise the valves may be installed s...

Page 206: ...ever the valve guides are replaced to prevent uneven seating Chill new valve guides in a freezer section of refrig erator for about an hour Heat the cylinder head to 130 140 C 266 284 F with a hot pla...

Page 207: ...oughly to remove any metal particles after reaming and reface the valve seat page 8 20 VALVE SEAT INSPECTION Clean the intake and exhaust valves thoroughly to remove carbon deposits Apply thin coat of...

Page 208: ...ng manufacturer s operating instructions Reface the valve seat whenever the valve guide has been replaced Be careful not to grind the seat more than neces sary If the contact area is too high on the v...

Page 209: ...to proper width Make sure that all pitting and irregularities are removed Refinish if necessary TOOLS Seat cutter 24 mm 45 EX 07780 0010600 Seat cutter 29 mm 45 IN 07780 0010300 Cutter holder 5 0 mm...

Page 210: ...the seat contact after lapping ASSEMBLY Clean the cylinder head assembly with solvent and blow through all oil passages with compressed air Install the spring seats and new valve stem seals Lubricate...

Page 211: ...nder head above the work bench surface to prevent valve damage Tap the valve stems gently with two plastic hammer Install the throttle body insulator by aligning the groove of the throttle body insula...

Page 212: ...stall the dowel pins and new gasket Route the cam chain through the cylinder head and install the cylinder head onto the cylinder Loosely install the cylinder head bolts Install the following Camshaft...

Page 213: ...9 1 9 9 CYLINDER PISTON COMPONENT LOCATION 9 2 SERVICE INFORMATION 9 3 TROUBLESHOOTING 9 3 CYLINDER PISTON 9 4...

Page 214: ...CYLINDER PISTON 9 2 CYLINDER PISTON COMPONENT LOCATION...

Page 215: ...n rings Scored or scratched piston or cylinder wall Abnormal noise piston Worn piston pin or piston pin hole Faulty cylinder piston or piston ring Worn connecting rod small end ITEM STANDARD SERVICE L...

Page 216: ...ket Loosen the water hose band screw and disconnect the water hose Lift the cylinder and remove it being careful not to damage the piston with the stud bolts Attach a piece of wire to the cam chain to...

Page 217: ...e the piston pin clips with pliers Push the piston pin out of the piston and connecting rod and remove the piston Spread each piston ring and remove it by lifting up a point opposite the gap Do not da...

Page 218: ...der taper and out of round at three levels on the X and Y axis Take the maximum reading to determine the taper and out of round The cylinder must be rebored and an oversize pis ton fitted if the servi...

Page 219: ...the piston pin O D at three points Calculate the piston to piston pin clearance Always replace the piston rings as a set Inspect the piston rings for smooth movement by rotating them The rings should...

Page 220: ...ain tensioner lifter body The cam chain tensioner lifter shaft should spring out of the cam chain tensioner lifter body as soon as the tensioner stopper is released STUD BOLT REPLACEMENT Thread two nu...

Page 221: ...s as shown Apply engine oil to the piston outer surface When cleaning the cylinder mating surface place a shop towel over the cylinder opening to prevent dust or dirt enter the crankcase Clean any gas...

Page 222: ...t CYLINDER INSTALLATION Install the dowel pins and a new gasket Apply engine oil to the cylinder inner surface and piston outer surface Route the cam chain through the cylinder and install the cylinde...

Page 223: ...hem to the cylinder Install and tighten the cam chain tensioner mount ing bolts Install the cam chain guide aligning its tabs with the cylinder grooves and its end with the left crank case groove Inst...

Page 224: ...MEMO...

Page 225: ...10 CLUTCH GEARSHIFT LINKAGE COMPONENT LOCATION 10 2 SERVICE INFORMATION 10 3 TROUBLESHOOTING 10 4 RIGHT CRANKCASE COVER 10 5 CLUTCH 10 9 GEARSHIFT LINKAGE 10 15 GEARSHIFT PEDAL 10 18 PRIMARY DRIVE GEA...

Page 226: ...CLUTCH GEARSHIFT LINKAGE 10 2 CLUTCH GEARSHIFT LINKAGE COMPONENT LOCATION 64 N m 6 5 kgf m 47 lbf ft 74 N m 7 5 kgf m 55 lbf ft 12 N m 1 2 kgf m 9 lbf ft 12 N m 1 2 kgf m 9 lbf ft...

Page 227: ...pring free length 40 0 1 57 38 3 1 51 Disc thickness 2 92 3 08 0 115 0 121 2 85 0 112 Plate warpage 0 15 0 006 Clutch outer I D 30 000 30 021 1 1811 1 1819 30 54 1 202 Clutch outer guide O D 22 959 22...

Page 228: ...k nut Clutch slips Clutch lifter sticking Worn clutch discs Weak clutch springs No clutch lever freeplay Engine oil level too low or oil additive used Hard to shift Misadjusted clutch cable Damaged or...

Page 229: ...utch cable from the clutch lifter arm Loosen the water hose band screws and disconnect the water hoses Loosen the right crankcase cover bolts in a criss cross pattern in 2 or 3 steps and remove the bo...

Page 230: ...lifter arm Return spring Remove the bolts and plate from the right crankcase cover Remove the rubber from the right crankcase cover INSPECTION Check the clutch lifter arm oil seal for wear or dam age...

Page 231: ...or wear or damage Return spring for fatigue or damage ASSEMBLY Install the rubber to the right crankcase cover Install the plate to the right crankcase cover Apply locking agent to the right crankcase...

Page 232: ...return spring to the right crankcase cover by aligning the spring upper end with the hole of the clutch lifter arm Install the lifter piece to the clutch lifter arm groove while aligning the groove w...

Page 233: ...er freeplay page 3 24 Fill the engine with the recommended engine oil page 3 13 Fill the recommended coolant mixture to the filler neck and bleed the air page 6 6 CLUTCH REMOVAL Remove the right crank...

Page 234: ...the clutch center lock nut and washer Remove the following Clutch center Clutch disc Clutch plates Pressure plate Remove the clutch outer TOOLS Clutch center holder 07GMB KT70101 Lock nut wrench 20 x...

Page 235: ...n the lifter plate Replace the bearing if the inner race does not turn smoothly quietly or if the outer race fits loosely in the lifter plate CLUTCH SPRING Replace the clutch springs as a set Check th...

Page 236: ...ent the clutch from disen gaging properly CLUTCH OUTER OUTER GUIDE Check the slots of the clutch outer for nicks cuts or indentations made by the clutch discs Check the primary driven gear teeth for w...

Page 237: ...guide outer surface and install it to the mainshaft Install the clutch outer 12 N m 1 2 kgf m 0 9 lbf ft BEARING LIFTER PLATE CLUTCH SPRING CLUTCH PLATE four pieces CLUTCHDISC five pieces WASHER CLUT...

Page 238: ...ter and pressure plate Install the tabs of the clutch disc out side into the shallow slots in the clutch outer Install the clutch center assembly into the clutch outer Install the washer Apply engine...

Page 239: ...L Remove the following Right crankcase cover page 10 5 Clutch assembly page 10 9 Gearshift arm page 10 18 Clean the gearshift spindle end Remove the shift drum stopper arm bolt and shift drum stopper...

Page 240: ...and spindle arm spring for fatigue or damage replace them if necessary Check the gearshift spindle for wear or bend Check the spindle arm for wear damage or defor mation Replace the gearshift spindle...

Page 241: ...o the crank case by aligning the return spring ends with the spring pin while pushing down the spindle arm and set the spindle arm to the shift drum pins Apply 6 5 1 0 mm 0 26 0 04 in from tip of lock...

Page 242: ...from the gearshift pedal and gearshift arm Apply grease to the gearshift tie rod sliding area and install the gearshift pedal and gearshift arm Install the washers and new cotter pins Apply grease to...

Page 243: ...holder mounting bolts tighten the bolts to the spec ified torque Install the gearshift arm on its original position as marked during removal Install and tighten the pinch bolt securely Standard pedal...

Page 244: ...e gear holder between the primary drive and driven gears Loosen the primary drive gear lock nut using the special tools Remove the clutch outer clutch outer guide lock nut and washers Remove the prima...

Page 245: ...h outer Insert the gear holder between the primary drive and driven gears Tighten the primary drive gear lock nut to the speci fied torque using the special tools Install the following Oil pump page 4...

Page 246: ...RIMARY DRIVE GER SELECTION TABLE If the primary drive gear is replaced with a new one select the same colored gear as the original gear If the crankcase is replaced with a new one select the blue mark...

Page 247: ...TERNATOR STARTER CLUTCH COMPONENT LOCATION 11 2 SERVICE INFORMATION 11 3 TROUBLESHOOTING 11 3 LEFT CRANKCASE COVER 11 4 STATOR CKP SENSOR 11 6 FLYWHEEL REMOVAL 11 7 STARTER CLUTCH 11 8 FLYWHEEL INSTAL...

Page 248: ...ALTERNATOR STARTER CLUTCH 11 2 ALTERNATOR STARTER CLUTCH COMPONENT LOCATION 64 N m 6 5 kgf m 47 lbf ft...

Page 249: ...ne does not turn Faulty starter clutch Damaged reduction gear shaft Faulty starter driven gear ITEM STANDARD SERVICE LIMIT Starter driven gear I D 22 010 22 031 0 8665 0 8674 22 08 0 869 O D 45 660 45...

Page 250: ...ase the alternator CKP sensor wire from the clamp The left crankcase cover stater is magnetically attracted to the flywheel be careful during removal Loosen the left crankcase cover bolts in a crisscr...

Page 251: ...tracted to the flywheel be careful during installation Install the left crankcase cover bolts and washer Tighten the bolts in a crisscross pattern in 2 or 3 steps Connect the alternator CKP sensor 6P...

Page 252: ...liquid sealant TB 1215 or equivalent to the wire grommet sealing surface and install the grom met into the groove Install the wire guide and CKP sensor Apply 6 5 1 0 mm 0 26 0 04 in from tip of lock...

Page 253: ...eel nut and washer Remove the flywheel using a special tool Remove the collar starter reduction gear and shaft Check the starter reduction gear and shaft for wear or damage TOOL Flywheel holder 07725...

Page 254: ...he flywheel page 11 7 Remove the starter driven gear while turning it counterclockwise Hold the flywheel with a special tool and remove the starter clutch torx screws Remove the starter clutch assembl...

Page 255: ...damage Starter clutch should replaced as an assembly if the starter clutch and springs are damaged or worn Check the starter driven gear teeth for wear or dam age Check the roller contact surface for...

Page 256: ...uides and rollers into the starter clutch outer Apply engine oil to the starter clutch rolling surface Install the plate ROLLER SPRING GUIDE SPRING STARTER DRIVEN GEAR FLYWHEEL 16 N m 1 6 kgf m 12 lbf...

Page 257: ...crews to the specified torque Install the starter driven gear while turning it coun terclockwise Make sure that the starter driven gear turns counter clockwise smoothly and does not turn clockwise Ins...

Page 258: ...l the flywheel while aligning the woodruff key on the crankshaft with flywheel keyway Apply engine oil to the flywheel nut threads and seating surface Install the washer and nut Hold the flywheel with...

Page 259: ...HAFT BALANCER TRANSMISSION COMPONENT LOCATION 12 2 SERVICE INFORMATION 12 3 TROUBLESHOOTING 12 5 CRANKCASE SEPARATION 12 6 CRANKSHAFT BALANCER 12 8 TRANSMISSION 12 12 BEARING REPLACEMENT 12 18 CRANKCA...

Page 260: ...CRANKSHAFT BALANCER TRANSMISSION 12 2 CRANKSHAFT BALANCER TRANSMISSION COMPONENT LOCATION...

Page 261: ...7087 0 7095 18 07 0 711 C2 23 020 23 041 0 9063 0 9071 23 09 0 909 C3 C4 22 020 22 041 0 8669 0 8678 22 10 0 870 Bushing O D M5 M6 19 959 19 980 0 7858 0 7866 19 91 0 784 C1 17 959 17 980 0 7070 0 707...

Page 262: ...mm 07936 1660120 Bearing remover head 15 mm 07936 KC10200 Bearing remover shaft 07936 KC10100 Remover weight 07741 0010201 Driver 07749 0010000 Pilot 12 mm 07746 0040200 Pilot 15 mm 07746 0040300 Pilo...

Page 263: ...guide pin Bent shift fork claw Damaged gearshift spindle Loose shift drum stopper arm bolt Transmission jumps out of gear Worn gear dogs or dog holes Damaged shift drum guide groove Worn shift fork gu...

Page 264: ...the crank case Remove the tensioner guide plate bolt plate and cam chain tensioner Remove the cam chain Check the cam chain tensioner for excessive wear or damage replace if necessary Remove the snap...

Page 265: ...n a crisscross pat tern in 2 or 3 steps and remove the bolts and washer Place the crankcase assembly with the right side down Carefully separate the left crankcase from the right crankcase while tappi...

Page 266: ...NSPECTION CRANKSHAFT RUNOUT Place the crankshaft on V blocks Set the dial indicator on the crankshaft Rotate the crankshaft two revolutions 720 and read the runout BIG END SIDE CLEARANCE CRANKSHAFT BA...

Page 267: ...nd discard the bearing if the races do not turn smoothly quietly or if they fit loosely in the crankcase and crankshaft For crankshaft bearing replacement page 12 18 BALANCER BEARING Turn the inner ra...

Page 268: ...s balancer gear springs and balancer driven gear Check the rubbers and springs for damage replace it if necessary Check the balancer driven gear for excessive or damage replace it if necessary BALANCE...

Page 269: ...red gear as the original gear INSTALLATION Be careful not to out of alignment Install the crankshaft and balancer assembly together into the right crankcase WASHER SNAP RING THRUST SPRING ID COLOR P N...

Page 270: ...e the shift forks and shift drum Be sure to remove the three end washers mainshaft left only countershaft both ends Remove the mainshaft assembly and countershaft assembly together PUNCH MARKS SHIFT F...

Page 271: ...shifter groove dogs dog holes and teeth for damage or excessive wear Measure the I D of each gear Check the bushings for wear or damage Measure the O D of each bushing Calculate the gear to bushing c...

Page 272: ...journal I D Calculate the shift drum to shift drum journal clear ances SHIFT FORK Check the shift forks for deformation or abnormal wear Check the shift fork guide pin for abnormal wear or damage Meas...

Page 273: ...19 ASSEMBLY INSTALLATION Clean all parts in solvent and dry them thoroughly Apply molybdenum oil solution to the gear rotating surface M5 M6 C1 C2 C3 C4 bushing entire sur face M5 M6 C1 C2 shift fork...

Page 274: ...R THRUST WASHER M6 GEAR BUSHING SPLINE WASHER M5 GEAR BUSHING WASHER M2 GEAR 17T SNAP RINGS C1 GEAR BUSHING THRUST WASHER THRUST WASHER SPLINE WASHER SNAP RING C1 GEAR 38T SPLINE WASHER C2 GEAR 33T C2...

Page 275: ...ether into the right crankcase Each shift fork has an identification marks R is for the right shift fork L is the left shift fork and C is for the center shift fork Install the shift forks into the sh...

Page 276: ...g with a new one whenever the crankshaft is removed Remove the transmission page 12 12 Drive out the right crankshaft bearing from the right crankcase Install new left crankshaft bearing to the cranks...

Page 277: ...ission page 12 12 RIGHT CRANKCASE SIDE Remove the bolts and mainshaft bearing setting plate Drive out the mainshaft and balancer bearings Remove the countershaft bearing using the special tools TOOLS...

Page 278: ...earings Remove the mainshaft bearing using the special tools TOOLS Mainshaft bearing marked side facing up Driver 07749 0010000 Attachment 37 x 40 mm 07746 0010200 Pilot 17 mm 07746 0040400 Countersha...

Page 279: ...logs TOOLS Mainshaft bearing sealed side facing down Driver 07749 0010000 Attachment 32 x 35 mm 07746 0010100 Pilot 12 mm 07746 0040200 Countershaft bearing marked side facing up Driver 07749 0010000...

Page 280: ...t crankcase and check for misaligned parts Install the left crankcase on the right crankcase being careful not to damage the oil seal lips Install the right crankcase bolts and washer and tighten the...

Page 281: ...all the snap ring and remove the screw Install the cam chain through the crankcase Install the cam chain over the timing sprocket Install the cam chain tensioner and tensioner guide plate Install and...

Page 282: ...MEMO...

Page 283: ...13 1 13 13 FRONT WHEEL SUSPENSION STEERING COMPONENT LOCATION 13 2 SERVICE INFORMATION 13 3 TROUBLESHOOTING 13 5 HANDLEBARS 13 6 FRONT WHEEL 13 13 FORK 13 18 STEERING STEM 13 27 CLUTCH LEVER 13 31...

Page 284: ...EERING 13 2 FRONT WHEEL SUSPENSION STEERING COMPONENT LOCATION 88 N m 9 0 kgf m 65 lbf ft 27 N m 2 8 kgf m 20 lbf ft 23 N m 2 3 kgf m 17 lbf ft 59 N m 6 0 kgf m 44 lbf ft 30 N m 3 1 kgf m 22 lbf ft 27...

Page 285: ...0 g max Fork Spring free length 412 4 16 24 404 1 15 91 Pipe runout 0 20 0 008 Recommended fork fluid Except CM type Honda ULTRA CUSHION OIL 10W or equivalent CM type only Pro Honda Suspension Fluid S...

Page 286: ...ent 42 x 47 mm 07746 0010300 Pilot 12 mm 07746 0040200 Driver 07749 0010000 Bearing remover shaft 07746 0050100 Bearing remover head 12 mm 07746 0050300 Oil seal remover 07748 0010001 Steering stem dr...

Page 287: ...tem adjusting nut Front wheel wobbling Bent rim Worm wheel bearing Faulty tire Insufficient tire pressure Axle not tightened properly Unbalanced tire and wheel Wheel hard to turn Faulty wheel bearing...

Page 288: ...d remove the screw then remove both handlebar weights Disconnect the brake light switch connectors Keep the brake master cylinder upright to prevent air from entering the hydraulic system Remove the b...

Page 289: ...hrottle cable from the throttle pipe then remove the throttle pipe Remove the grip rubber replace it if necessary Disconnect the clutch switch connectors Remove the bolts holder and clutch lever brack...

Page 290: ...gs from both fork pipes Loosen the handlebar pinch bolts and remove the handlebars INSTALLATION Route the wires hose and cable properly page 1 18 Install the handlebars to both fork pipes while align...

Page 291: ...the grips and to the clean surface of the left handlebar and throttle pipe Wait 3 5 minutes and install the grip Rotate the grips for even application of the adhe sive Install the left handlebar switc...

Page 292: ...onnect the clutch switch connectors Apply grease to the throttle pipe sliding area of the right handlebar Install the throttle pipe to the right handlebar Connect the throttle cable end to the throttl...

Page 293: ...up and bolts Align the end of the master cylinder with the punch mark on the handlebar and tighten the upper bolt first then the lower bolt Connect the brake light switch connectors Install the handle...

Page 294: ...ght assembly by turning the handlebar weight Remove the screw handlebar weight retainer ring and rubber cushions from the inner weight Install the rubber cushions and new retainer onto the inner weigh...

Page 295: ...motorcycle using a safety stand or hoist raise the front wheel off the ground Disconnect the speedometer cable while pushing the tab of the cable Remove the axle nut Remove the axle and front wheel R...

Page 296: ...easure the runout using a dial indicator Actual runout is 1 2 of the total indicator reading WHEEL BEARING Turn the inner race of each bearing with your finger The bearings should turn smoothly and qu...

Page 297: ...he wheel with chalk Do this 2 or 3 times to verify the heaviest area If the wheel is balanced it will not stop consistently in the same position To balance the wheel install a new balance weight on th...

Page 298: ...y with its marked side facing up until it is fully seated Install the distance collar Drive in a new left side bearing squarely with its marked side facing up until it is seated on the dis tance colla...

Page 299: ...lts to the speci fied torque in a crisscross pattern in 2 or 3 steps Apply grease to a new dust seal lips Install the dust seal until it is flush with the wheel hub surface to the right wheel hub INST...

Page 300: ...ht side Install and tighten the axle nut to the specified torque Connect the speedometer cable to the speedometer gear box by aligning the tab of the cable with the hole of the gear box FORK REMOVAL R...

Page 301: ...and remove the handlebars Loosen the top bridge pinch bolts Hold the fork leg and loosen the bottom bridge pinch bolt and lower the fork leg then remove it DISASSEMBLY Remove the following Fork bolt O...

Page 302: ...fork socket bolt and sealing washer Remove the fork pipe and oil lock piece from the fork slider Do not remove the piston ring unless it is to replace with a new one Remove the fork piston and rebound...

Page 303: ...Check the fork spring for fatigue or damage Measure the fork spring free length FORK PIPE SLIDER PISTON Check the fork pipe slider and for score marks scratches or excessive or abnormal wear Check th...

Page 304: ...fork pipe and measure the runout using a dial indicator Actual runout is 1 2 of the total indicator reading ASSEMBLY PISTON RING FORK PISTON REBOUND SPRING SERVICE LIMIT 0 20 mm 0 008 in 20 N m 2 0 k...

Page 305: ...ve is visible using the special tools Install the stopper ring into the groove of the fork slider securely Install a new dust seal Install the rebound spring to the fork piston and install them into t...

Page 306: ...fluid into the fork pipe Slowly pump the fork pipe several times to remove any trapped air from the lower portion of the fork pipe Compress the fork pipe fully and measure the fluid level from the top...

Page 307: ...r surface to the fork pipe end is 32 mm 1 3 in Tighten the bottom bridge and top bridge pinch bolts to the specified torque If the fork bolt is loosened tighten the fork bolt to the specified torque T...

Page 308: ...r rings to the grooves of both fork pipes LEFT SIDE Install the wire band to the fork pipe Route the wire properly page 1 18 Install the brake caliper bracket assembly and tighten new brake caliper mo...

Page 309: ...emove the suitable support and close the fuel tank page 3 6 Loosen the steering stem nut Remove the fork legs page 13 18 Remove the steering stem nut washer and top bridge Loosen the steering stem adj...

Page 310: ...ving the lower inner race from the steering stem Remove the lower inner race with a chisel or equiv alent tools being careful not to damage the steering stem Remove the steering head bearing dust seal...

Page 311: ...TOOLS Driver 07749 0010000 Attachment 42 x 47 mm 07746 0010300 OUTER RACE DRIVER ATTACHMENT TOOLS Driver 07749 0010000 Attachment 42 x 47 mm 07746 0010300 OUTER RACE ATTACHMENT DRIVER STEERING STEM U...

Page 312: ...ified torque using a special tool Move the steering stem left and right lock to lock five times to seat the bearings Loosen the adjusting nut to torque of 0 N m 0 kgf m 0 lbf ft Retighten the adjustin...

Page 313: ...ay or binding Route the wires hose and cable properly page 1 18 Install the stay and bolts tighten the bolts Install the wire harness clamps and brake hose to the stay Lift and support the fuel tank C...

Page 314: ...tch lever pivot bolt sliding surface page 1 17 Install and tighten the clutch lever pivot bolt to the specified torque Install and tighten the clutch lever pivot nut to the specified torque while hold...

Page 315: ...14 1 14 14 REAR WHEEL SUSPENSION COMPONENT LOCATION 14 2 SERVICE INFORMATION 14 3 TROUBLESHOOTING 14 4 REAR WHEEL 14 5 SHOCK ABSORBER 14 11 SWINGARM 14 12...

Page 316: ...NSION 14 2 REAR WHEEL SUSPENSION COMPONENT LOCATION 59 N m 6 0 kgf m 44 lbf ft 88 N m 9 0 kgf m 65 lbf ft 39 N m 4 0 kgf m 29 lbf ft 44 N m 4 5 kgf m 32 lbf ft 4 2 N m 0 4 kgf m 3 1 lbf ft 27 N m 2 8...

Page 317: ...imum tire thread depth 0 8 0 03 Cold tire pressure Standard 225 kPa 2 25 kgf cm2 33 psi With cargo 225 kPa 2 25 kgf cm2 33 psi Axle runout 0 2 0 01 Wheel rim runout Radial 2 0 0 08 Axial 2 0 0 08 Whee...

Page 318: ...d to turn Brake drag Faulty wheel bearing Faulty driven flange bearing Bent axle Drive chain too tight page 3 16 Soft suspension Weak shock absorber spring Oil leakage from damper unit Insufficient ti...

Page 319: ...ive chain from the driven sprocket Remove the axle nut Remove the axle and rear wheel Remove the side collars INSPECTION AXLE Place the axle on V blocks Turn the axle and measure the runout using a di...

Page 320: ...ely in the wheel hub and driven flange WHEEL BALANCE For wheel balance servicing page 13 15 DRIVEN SPROCKET For driven sprocket inspection page 3 17 DISASSEMBLY Remove the dust seal from the right whe...

Page 321: ...Install the bearing remover head into the bearing From the opposite side install the bearing remover shaft and drive out the bearing from the wheel hub Remove the distance collar and drive out the ot...

Page 322: ...ease to the driven flange bearing rotating area Drive in a new driven flange bearing squarely with its sealed side facing up until it is fully seated BEARING 6301UU BEARING 6003 DAMPER RUBBER O RING D...

Page 323: ...sprocket to the driven flange Loosely install the driven sprocket nuts Apply grease to a new O ring Install the O ring and wheel damper rubbers into the left wheel hub Install the driven flange assem...

Page 324: ...with the stamped mark MIN TH 3 5 mm facing outside Install and tighten new brake disc bolts to the speci fied torque in a crisscross pattern in 2 or 3 steps INSTALLATION Install the right side collar...

Page 325: ...axle washer swingarm rear wheel and collar Install the axle washer Install and tighten the axle nut to the specified torque Adjust the drive chain slack page 3 16 SHOCK ABSORBER REMOVAL Support the mo...

Page 326: ...lt Tighten the shock absorber upper mounting nut to the specified torque Install the shock absorber lower mounting bolt and nut Tighten the lower mounting nut to the specified torque Install the rear...

Page 327: ...the screw and brake hose guide Release the brake hose from the clamp Remove the shock absorber lower mounting bolt and nut Remove the rear brake caliper bracket assembly from the swingarm BOLTS COVER...

Page 328: ...rm DISASSEMBLY Remove the drive chain adjusters and rubber collar Remove the screw and collar Remove the drive chain slider by releasing the slider slits from the swingarm tab Check the drive chain sl...

Page 329: ...in slider while aligning the swin garm tabs with the slider slits Install the collar and drive chain slider screw then tighten the screw to the specified torque BUSHINGS COLLAR DRIVE CHAIN SLIDER RUBB...

Page 330: ...n onto the swingarm and install the swingarm to the frame Install the swingarm pivot bolt from the left side Install the swingarm pivot nut and loosely tighten it Install the brake caliper bracket ass...

Page 331: ...clamp Install the brake hose guide and brake hose guide screw tighten the screw to the specified torque Install the chain cover to the swingarm with aligning the boss of the chain cover with the groov...

Page 332: ...14 10 Lift down the motorcycle from the safety stand or hoist and support the motorcycle by your hands as be preload to the shock absorber and rubber bush ings Tighten the swingarm pivot nut to the sp...

Page 333: ...TION 15 2 SERVICE INFORMATION 15 3 TROUBLESHOOTING 15 4 BRAKE FLUID REPLACEMENT AIR BLEEDING 15 5 BRAKE PAD DISC 15 8 FRONT MASTER CYLINDER 15 11 REAR MASTER CYLINDER 15 15 FRONT BRAKE CALIPER 15 20 R...

Page 334: ...HYDRAULIC BRAKE 15 2 HYDRAULIC BRAKE COMPONENT LOCATION 34 N m 3 5 kgf m 25 lbf ft 34 N m 3 5 kgf m 25 lbf ft 30 N m 3 1 kgf m 22 lbf ft 34 N m 3 5 kgf m 25 lbf ft 27 N m 2 8 kgf m 20 lbf ft...

Page 335: ...Master cylinder I D 11 000 11 043 0 4331 0 4348 11 055 0 4352 Master piston O D 10 957 10 984 0 4314 0 4324 10 945 0 4309 Caliper cylinder I D 25 400 25 450 1 0000 1 0020 25 460 1 0024 Caliper piston...

Page 336: ...cking worn caliper piston Sticking worn master cylinder piston Bent brake lever pedal Brake lever pedal hard Clogged restricted hydraulic system Sticking worn caliper piston Caliper not sliding proper...

Page 337: ...REAR BRAKE Support the motorcycle in an upright position Remove the bolt and reservoir Remove the reservoir cover screws reservoir cover set plate and diaphragm Connect a bleed hose to the caliper bl...

Page 338: ...n the bleed valve 1 2 turn Wait several sec onds and then close the bleed valve Do not release the brake lever pedal until the bleed valve has been closed 2 3 Repeat the steps 1 and 2 until there are...

Page 339: ...d torque REAR BRAKE Install the diaphragm set plate reservoir cover and reservoir cover screws then tighten the screws to the specified torque Install the reservoir and bolt CASTING LEDGE FRONT REAR U...

Page 340: ...the brake pad hanger pin and brake pads Check that the O ring is in good condition replace if necessary Install new brake pads to the brake caliper so their ends seat against the retainer and brake c...

Page 341: ...per pistons all the way in to allow installation of new brake pads Check the brake fluid level in the brake master cylin der reservoir as this operation causes the level to rise Remove the rubber plug...

Page 342: ...n the hanger pin holes in the pads and brake caliper Tighten the brake pad hanger pin to the specified torque Install the rubber plug Operate the brake pedal to seat the caliper pistons against the pa...

Page 343: ...ove the right rearview mirror Remove the brake hose oil bolt sealing washers and brake hose eyelet Disconnect the brake light switch connectors Remove the bolts holder and master cylinder DISASSEMBLY...

Page 344: ...n the inside of the master cylinder reservoir and master piston with brake fluid INSPECTION Check the master cylinder for scoring scratches or damage Check the master piston for scoring scratches or d...

Page 345: ...pring into the master cyl inder Install the washer SERVICE LIMIT 11 055 mm 0 4352 in SERVICE LIMIT 10 945 mm 0 4309 in SNAP RING RESERVOIR COVER DIAPHRAGM MASTER PISTON 1 0 N m 0 1 kgf m 0 7 lbf ft BO...

Page 346: ...pply silicone grease to the brake lever contacting area of the master piston and brake lever pivot bolt sliding surface page 1 17 Install the brake lever to the master cylinder Install and tighten the...

Page 347: ...ed torque Install the right rearview mirror Fill the reservoir to the upper level and bleed the front brake system page 15 6 REAR MASTER CYLINDER REMOVAL Drain the brake fluid from the hydraulic syste...

Page 348: ...the right step holder assem bly DISASSEMBLY Remove the hose joint screw O ring and reservoir hose joint Be careful not to damage the boot Remove the boot Remove the snap ring using a special tool MAST...

Page 349: ...scoring scratches or damage Check the piston cups for wear deterioration or damage Measure the master cylinder I D Measure the master piston O D Check the following Push rod for bent Boot for damage R...

Page 350: ...master cylinder Make sure the snap ring is firmly seated in the groove Install the snap ring into the groove of the master cylinder using a special tool RESERVOIR COVER O RING DIAPHRAGM MASTER PISTON...

Page 351: ...ten the push rod lock nut to the specified torque Install a new O ring to the reservoir hose joint and install them to the master cylinder Apply locking agent to the hose joint screw threads and insta...

Page 352: ...ll the reservoir to the upper level and bleed the rear brake system page 15 6 FRONT BRAKE CALIPER REMOVAL Drain the brake fluid from the hydraulic system page 15 5 Remove the brake pads page 15 8 Remo...

Page 353: ...e Push the dust and piston seals in and lift them out Clean the seal grooves caliper cylinder and pistons with clean brake fluid INSPECTION Check the caliper cylinders for scoring scratches or damage...

Page 354: ...e caliper cylinders with the opening side toward the pad Install the pad spring onto the caliper body Apply silicone grease to the brake caliper pin bolt sliding surface page 1 17 Install the caliper...

Page 355: ...stem page 15 6 REAR BRAKE CALIPER REMOVAL Drain the brake fluid from the hydraulic system page 15 5 Remove the brake pads page 15 9 Remove the brake hose oil bolt and sealing wash ers Remove the rear...

Page 356: ...piston seals in and lift them out Clean the seal grooves caliper cylinder and piston with clean brake fluid INSPECTION Check the caliper cylinder for scoring scratches or damage Measure the caliper cy...

Page 357: ...e caliper cylinder with the opening side toward the pad Install the pad spring onto the caliper body Apply silicone grease to the brake caliper pin bolt sliding surface page 1 17 Install the caliper b...

Page 358: ...l and breed the rear brake system page 15 6 BRAKE PEDAL REMOVAL Remove the step holder mounting bolts and right step holder assembly Unhook the brake light switch spring from the brake pedal return sp...

Page 359: ...the brake pedal to the push rod lower joint Install the joint pin and new cotter pin Install the brake light switch spring to the brake pedal return spring as shown STEP HOLDER COTTER PIN 27 N m 2 8...

Page 360: ...assembly Install and tighten the step holder mounting bolts to the specified torque After the installation check the brake operation and adjust the rear brake light switch operation page 3 23 TORQUE 2...

Page 361: ...BATTERY CHARGING SYSTEM SYSTEM LOCATION 16 2 SYSTEM DIAGRAM 16 2 SERVICE INFORMATION 16 3 TROUBLESHOOTING 16 4 BATTERY 16 5 CHARGING SYSTEM INSPECTION 16 6 ALTERNATOR CHARGING COIL 16 7 REGULATOR RECT...

Page 362: ...CHARGING SYSTEM SYSTEM LOCATION SYSTEM DIAGRAM BATTERY ALTERNATOR REGULATOR RECTIFIER MAIN FUSE 30A G Bl Bu 6P R Y Y Y Bl R Bl Bl Bl Bl MAIN FUSE 30A REGULATOR RECTIFIER ALTERNATOR Bl Bu Red Green Yel...

Page 363: ...r long periods of time without riding the motorcycle The battery will self discharge when the motorcycle is not in use For this reason charge the battery every 2 weeks to prevent sulfation from occurr...

Page 364: ...TION Measure and record the battery voltage using a digital multimeter page 16 5 Start the engine Measure the charging voltage page 16 6 Compare the measurements to the results of the following calcul...

Page 365: ...Measure the battery voltage using a commercially available digital multimeter If the battery voltage is below 12 4 V charge the bat tery BATTERY TESTING Refer to the instructions that are appropriate...

Page 366: ...s likely Locate the short by disconnecting connections one by one and measuring the current CHARGING VOLTAGE INSPECTION Remove the single seat page 2 4 Open the battery case cover page 16 5 Be sure th...

Page 367: ...the ignition switch OFF Disconnect the regulator rectifier 6P Black connec tor and check it for loose contacts or corroded ter minals If the charging voltage reading page 16 6 is out of the specificat...

Page 368: ...ove the left middle cowl page 2 9 Disconnect the regulator rectifier 6P Black connec tor Remove the bolts and regulator rectifier from the frame Install the regulator rectifier in the reverse order of...

Page 369: ...17 1 17 17 IGNITION SYSTEM SYSTEM LOCATION 17 2 SYSTEM DIAGRAM 17 2 SERVICE INFORMATION 17 3 TROUBLESHOOTING 17 4 IGNITION SYSTEM INSPECTION 17 5 IGNITION TIMING 17 7 IGNITION COIL 17 8...

Page 370: ...IN FUSE 30 A ECM SUB FUSE 33P 9P 2P Bl W W Y Bu Y G G Bl R Bl G W G R P Bu P G Lg R R Bl Bl W R P G Y Lg Bl Bu W Red Pink Green Yellow Light Green Black Blue White SPARK PLUG IGNITION COIL MAIN FUSE 3...

Page 371: ...g according to the engine speed The TP sensor signals the ECM to compensate the igni tion timing according to the throttle opening Make sure the battery is adequately charged Using the starter motor w...

Page 372: ...the ECM connector or loosen ECM con nection 4 An open circuit or loose connection in Green wire at the ECM 5 An open circuit or loose connection in Pink blue wire between the ignition coils and ECM 6...

Page 373: ...N COIL PRIMARY PEAK VOLTAGE Check all system connections before performing this inspection Loose connectors can cause incorrect readings If the system is disconnected incorrect peak volt age might be...

Page 374: ...adaptor probes to the ECM 33P connector terminals of the wire har ness side Shift the transmission into neutral Turn the ignition switch ON Crank the engine with the starter motor with the throttle gr...

Page 375: ...ide is lower than standard value follow the checks described in the troubleshooting table page 17 4 For CKP sensor replacement page 11 6 Install the removed parts in the reverse order of removal IGNIT...

Page 376: ...ATION Lift and support the fuel tank page 3 6 Remove the ECM page 5 65 Disconnect the spark plug cap page 3 9 Disconnect the wire connectors from the ignition coil Remove the bolts and ignition coil I...

Page 377: ...18 1 18 18 ELECTRIC STARTER SYSTEM LOCATION 18 2 SYSTEM DIAGRAM 18 2 SERVICE INFORMATION 18 3 TROUBLESHOOTING 18 4 STARTER MOTOR 18 6 STARTER RELAY SWITCH 18 14 DIODE 18 15...

Page 378: ...CH CLUTCH SWITCH NEUTRAL SWITCH SUB FUSE DIODE 9P Bl Bl Bl Y R G R R 6P Bl W Lg R G W R Bl G 4P R G Y Lg Bl W Red Green Yellow Light Green Black White SUB FUSE 10A 12V 6AH UP DOWN IGNITION SWITCH STAR...

Page 379: ...using serious injury A weak battery may be unable to turn the starter motor quickly enough or supply adequate ignition current When servicing the starter system always follow the steps in the troubles...

Page 380: ...ter relay switch connector and check the relay coil ground wire line as below for continuity 1 Green red terminal diode neutral switch line with the transmission in neutral and clutch lever released 2...

Page 381: ...h switch YES GO TO STEP 2 2 Sidestand Switch Inspection Check the sidestand switch operation page 19 19 Is the sidestand switch operation normal NO Faulty sidestand switch page 19 19 YES Open circuit...

Page 382: ...he O ring DISASSEMBLY INSPECTION Remove the starter motor case bolts and O rings Record the location and number of shim s Remove the front cover insulator shim s and seal ring Remove the lock washer f...

Page 383: ...Check the needle bearing for wear or damage Replace the starter motor as an assembly if neces sary Do not use emery or sand paper on the commutator Clean the metallic debris off between commutator bar...

Page 384: ...mature shaft There should be no continuity Check for continuity between the positive brush and cable terminal There should be continuity Check for continuity between the positive brush and rear cover...

Page 385: ...he rear cover Remove the insulator plates from the rear cover Remove the following Nut Washer Insulators O ring Remove the positive brush and set plate REAR COVER NEGATIVE BRUSH BRUSH HOLDER SCREWS WA...

Page 386: ...rter motor as an assembly if neces sary ASSEMBLY SERVICE LIMIT 3 5 mm 0 14 in BUSHING O RING O RING NUT WASHER MOTOR CASE SHIM S FRONT COVER O RING SNAP RING ARMATURE BRUSH HOLDER SPRING REAR COVER IN...

Page 387: ...nd nut Tighten the nut securely Install the insulator plates onto the rear cover Install the brush holder negative brush washers and screws into the rear cover as shown Tighten the screws SET PLATE BR...

Page 388: ...ture against the motor case Install the springs and brushes to the brush holder Install a new seal ring to the motor case Install the shim s onto the armature shaft Install the rear cover while pushin...

Page 389: ...ten the starter motor case bolts securely INSTALLATION Apply engine oil to a new O ring and install it into the starter motor groove Route the cable properly page 1 18 Install the starter motor into t...

Page 390: ...stand is retracted the ground circuit of the relay coil is normal In neutral there is a slight resistance due to the diode STARTER RELAY INPUT VOLTAGE Connect the starter relay switch 4P Red connector...

Page 391: ...itch from the stays with the shock rubber Remove the starter relay switch from the shock rub ber Installation is in the reverse order of removal DIODE INSPECTION Remove the rear cowl page 2 5 Remove t...

Page 392: ...MEMO...

Page 393: ...TAIL LIGHT 19 6 LICENSE LIGHT 19 7 COMBINATION METER 19 8 TACHOMETER 19 11 COOLANT TEMPERATURE GAUGE ECT SENSOR 19 12 IGNITION SWITCH 19 13 HANDLEBAR SWITCHES 19 14 BRAKE LIGHT SWITCHES 19 16 NEUTRAL...

Page 394: ...SYSTEM LOCATION COMBINATION METER FRONT BRAKE LIGHT SWITCH FUEL PUMP UNIT TURN SIGNAL RELAY NEUTRAL SWITCH REAR BRAKE LIGHT SWITCH IGNITION SWITCH RIGHT HANDLEBAR SWITCH LEFT HANDLEBAR SWITCH ECT SEN...

Page 395: ...battery voltage A continuity test can be made with the switches installed on the motorcycle The following color codes are used throughout this section SPECIFICATIONS TORQUE VALUES Bu Blue G Green Lg L...

Page 396: ...facing up Connect the headlight connector REMOVAL INSTLATION Remove the upper cowl page 2 10 Remove the headlight mounting screws clamps and headlight unit Install the headlight unit headlight mountin...

Page 397: ...ignal light Install the screw and washer CM type only Tighten the screw to the specified torque REMOVAL INSTALLATION FRONT Disconnect the turn signal light connectors Remove the turn signal light moun...

Page 398: ...brake tail light assembly bosses from the rear fender grommets Disconnect the brake tail light 3P Natural connec tor and remove the brake tail light Turn the bulb socket counterclockwise and remove it...

Page 399: ...ion and is in good condition replace it with a new one if neces sary Install the license light cover and screws Tighten the screws to the specified torque REMOVAL INSTALLATION Remove the following Rea...

Page 400: ...tighten the nut Install the removed parts in the reverse order of removal COMBINATION METER BULB REPLACEMENT Remove the combination meter assembly page 19 9 Remove the meter bulb sockets Remove the bu...

Page 401: ...y while releas ing the boss from the grommet Disconnect the speedometer cable from the combi nation meter assembly Install the combination meter assembly in the reverse order of removal When connectin...

Page 402: ...er Fuel gauge mounting screws and fuel gauge Sub harness band screw Bulb sockets and combination meter sub harness Assemble the combination meter in the reverse order of disassembly UPPER COVER FUEL G...

Page 403: ...low green and Green wire terminals There should be at least 6 V pulse voltage If there is pulse voltage replace the tachometer page 19 10 If there is no pulse voltage check for following Open or short...

Page 404: ...lowing Open or short circuit in Yellow green wire Open or short circuit in White green line Blown main fuse Blown sub fuse Faulty main relay page 19 22 Open circuit in Green wire If the wires and ECT...

Page 405: ...ECT senor if it is out of specification by more than 10 at any temperature listed Install the ECT sensor page 5 63 IGNITION SWITCH INSPECTION Lift and support the fuel tank page 3 6 Open the rubber s...

Page 406: ...age 3 6 Open the rubber sheet page 6 10 Disconnect the right handlebar switch 6P Natural connector Check for continuity between the switch side con nector terminals in each switch position Continuity...

Page 407: ...tch position Continuity should exist between the color coded wire as shown in the tables DIMMER SWITCH TURN SIGNAL SWITCH HORN SWITCH Close the rubber sheet page 6 15 Remove the suitable support and c...

Page 408: ...ver squeezed and no continuity with the brake lever released REAR Remove the rear cowl page 2 5 Disconnect the rear brake light switch 2P Natural connector Check for continuity between the switch side...

Page 409: ...ral switch wire connector Check for continuity between the switch side Light green red terminal and ground There should be continuity with the transmission is in neutral and no continuity when the tra...

Page 410: ...necessary Bend the spring cap by force or crush the contact point will cause poor electricity connection Install the spring into the spring cap and install them into the shift drum Apply engine oil t...

Page 411: ...tween the switch side con nector terminals There should be continuity with the sidestand retracted and no continuity with the sidestand low ered REMOVAL INSTALLATION Disconnect the sidestand switch 3P...

Page 412: ...the fuel pump unit 5P connector Turn the ignition switch ON Move the float from empty to full then check the fuel gauge needle If the needle does not move check for following Open or short circuit in...

Page 413: ...nit page 5 50 HORN INSPECTION Disconnect the connectors from the horn Connect a 12 V battery to the horn terminals The horn is normal if it sounds when the 12 V bat tery is connected across the horn t...

Page 414: ...and Gray terminals of the turn signal relay connector with a jumper wire Start the engine and check the turn signal light by moving the turn signal switch all the way in the right side or left side Is...

Page 415: ...lay connector terminals There should be continuity only when 12 V battery is connected If there is no continuity only when the 12 V battery is connected replace the main relay CONNECTION Red Red CONNE...

Page 416: ...MEMO...

Page 417: ...20 1 20 20 WIRING DIAGRAMS ED E F II G type 20 3 CM type 20 4 U type 20 5...

Page 418: ...Gray Pink Light Green Light Blue Orange Brown W R G Bu Y Bl Gr P Lg Lb O Br R WR L Lo Hi COLOR LOCK OFF ON COLOR N COLOR N PUSH FREE COLOR BAT ST PUSH FREE COLOR Y R BAT Ho Bu Gr Lb O HL Lg Br W G W R...

Page 419: ...ight Green Light Blue Orange Brown W R G Bu Y Bl Gr P Lg Lb O Br R WR L Lo Hi COLOR LOCK OFF ON COLOR N COLOR N PUSH FREE COLOR BAT ST PUSH FREE COLOR Y R BAT Ho Bu Gr Lb O HL Lg Br W G W Bl R Bl Bl B...

Page 420: ...ight Green Light Blue Orange Brown W R G Bu Y Bl Gr P Lg Lb O Br R WR L Lo Hi COLOR LOCK OFF ON COLOR N COLOR N PUSH FREE COLOR BAT ST PUSH FREE COLOR Y R BAT Ho Bu Gr Lb O HL Lg Br W G W Bl R Bl Bl B...

Page 421: ...21 1 21 21 TROUBLESHOOTING ENGINE DOES NOT START OR IS HARD TO START 21 2 ENGINE LACKS POWER 21 3 POOR PERFORMANCE AT LOW AND IDLE SPEED 21 5 POOR PERFORMANCE AT HIGH SPEED 21 6 POOR HANDLING 21 7...

Page 422: ...pe YES GO 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 NO Faulty fuel pump unit YES GO TO STEP 4 4 PGM FI System Inspect...

Page 423: ...utch discs plates Warped clutch discs plates Weak clutch spring Sticking clutch lifter mechanism Additive in engine oil Incorrect clutch lever adjustment YES GO TO STEP 4 4 Engine Performance Inspecti...

Page 424: ...Is the PGM FI system normal NO Faulty PGM FI system YES GO TO STEP 11 11 Lubrication Inspection Remove cylinder head cover and inspect lubrication Is the valve train lubricated properly NO Clogged oil...

Page 425: ...ECM Faulty CKP sensor Improper valve timing YES GO TO STEP 3 3 Fuel Pump Inspection Inspect the fuel flow Is the fuel pump unit normal NO Faulty fuel pump unit YES GO TO STEP 4 4 PGM FI System Inspec...

Page 426: ...GO TO STEP 3 3 PGM FI System Inspection Check the PGM FI system Is the PGM FI system normal NO Faulty PGM FI system YES GO TO STEP 4 4 Valve Timing Inspection Check the valve timing Is the valve timi...

Page 427: ...head bearings Insufficient tire pressure Faulty tire Either wheel is wobbling Excessive wheel bearing play Bent rim Improperly installed wheel hub Excessively worn swingarm pivot bushings Bent frame M...

Page 428: ...MEMO...

Page 429: ...MISSION CONTROL SYSTEMS CM type only 1 32 EMISSION CONTROL SYSTEMS Except CM type 1 30 ENGINE FRAME TORQUE VALUES 1 12 ENGINE IDLE SPEED 5 62 ENGINE INSTALLATION 7 6 ENGINE OIL 3 13 ENGINE OIL STRAINE...

Page 430: ...ING STEM 13 27 SUSPENSION 3 25 SWINGARM 14 12 SYSTEM DIAGRAM BATTERY CHARGING SYSTEM 16 2 ELECTRIC STARTER 18 2 IGNITION SYSTEM 17 2 SYSTEM FLOW PATTERN 6 2 SYSTEM LOCATION BATTERY CHARGING SYSTEM 16...

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