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Honda FourTrax Foreman Rubicon 2005, Service Manual

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Honda FourTrax Foreman Rubicon 2005 Service Manual Download Page 249

Summary of Contents for FourTrax Foreman Rubicon 2005

Page 1: ......

Page 2: ...ow the procedures and precautions in this manual and other servICE matenals carefully AWARNING Failure to properly IoIlow instructions and precautions can cause you to be seriously hurt or killed Foll...

Page 3: ...Of system illustration serYlCft In Qrmalion ana troubleshoOllng for the sactlOn The subsequent pagH give 08lailed procedure II you don know the IiQl llca 01 the IJOObIe go 10 sectlOIl 26 T rbc I CAN...

Page 4: ...m disulfide grease containing more than 3 molybdenum disulfide NlGI 2 or equivalent Example Molykote BA 2 plus manufactured by Dow Corning U S A Multi purpose M 2 manufactured by Milsubishi Oil Japan...

Page 5: ...HIFT LINKAGE SPECIFICATIONS CRANKSHAFT AUTOMATIC TRANSMISSION SPECIFICATIONS FRONT WHEEL SUSPENSION STEERING SPECIFICATIONS 2 REAR WHEEL SUSPENSION SPECIFICATIONS 2 BRAKE SYSTEM SPECIFICATIONS 2 FRONT...

Page 6: ...k plates when reassembling 5 When tightening bolts or nuts begin with the larger diameter or inner bolt first Then tighten to the specified torque diagonally in incremental steps unless a particular s...

Page 7: ...ATION Throughout this manual the following abbreviations are used to identify the respective parts or systems DESTINATION CODE Throughout this manual the following codes are used to identify individua...

Page 8: ...he engine serial number is stamped on the right side of the crank case The name plate is attached on the front frame pipe U type only U type only I P LA TE The vehicle safety certification label is at...

Page 9: ...information label is attached on the right side of the frame U S A only U S A only p CONTROL LABEL After 07 The vehicle emission control information label is attached on the rear fender near the bane...

Page 10: ...GENERAL INFORMATION The color label is attached on the front side of the frame When order ing color coded parts always specify the designated color code 1 6...

Page 11: ...170 mm 6 7 in Double tube Swingarm 170 mm 6 7 in Double tube AT25 x 8 2 AT25xl0 12 12 x 6 0 AT 12 x 7 5 AT KT1 S1 DUNLOP KT185 DUNLOP Hydraulic disc brake Mechanical drum brake l eading trailing 2 8 m...

Page 12: ...Reverse automatic non stage speed with sub transmission constant mesh 1 045 70 67 2 000 40 20 3 231 42 13 3 154 41 13 0 93 3 47 1 583 38124 2 500 45 18 3 222 29118 x 28114 0 N R L Sub transmission D...

Page 13: ...qt 4 6 Imp qt Honda GN4 4 stroke oi o qu v o 1 1 lent motor oil API service classification SG or Higher JASO T 903 standard MA lll i ii i l l 0 W 3 O Jl _ j Oil pressure 80 C 176 F Oil pump rotor FUE...

Page 14: ...UGAL CLUTCH SPECIFICATIONS Unit mm lin rclUlch ITEM STANDARD SERVICE LlMIT_ mt D 150 0 150 2 5 906 5 913 150 4 5 92 ht lining thickness 3 0 0 12 2 010 08 Clutch spring height 3 72 0 146 3 6 0 14 Clutc...

Page 15: ...0 553 27 979 28 000 1 1015 1 10 24 27 93 1 100 t ii Reverse idle Gear bushing 0 0 D lR Gear bushing 1 0 D lR Reverse idle shaft 0 0 27 984 28 005 1 1017 1 1026 27 93 1 100 1_ 0 020 0 062 0 0008 0 002...

Page 16: ...GENERAL INFORMATION FRONT WHEEL SUSPENSION STEERING SPECIFICATIONS pres sure only After 08 REAR WHEEL SUSPENSION SPECIFICATIONS STANDARD sure BRAKE SYSTEM SPECIFICATIONS I 1 12 I I...

Page 17: ...ear ta stop pin clearance 0 3 0 6 0 01 0 02 BATIERY CHARGING SYSTEM SPECIFICATIONS Fully en Qulc IGNITION SYSTEM SPECIFICATIONS ITEM Spark plug Standard I For cold climate below 5 C 41 F Spark plug ga...

Page 18: ...Assist headlight 12V 45W r Brakeltaillight i5 06 12V 2115Wx 2 After 06 LED f Neutral indicator LED Reverse indicator LED Coolant oil temperature indicator LED 4WD indicator LED r PS indicator EPS mod...

Page 19: ...ng surface 4 ALoe bolt screw replace with a new one 5 Lock nut replace with a new one 6 Castle nut tighten to the specified torque and further tighten until its grooves aligns with the cotter pin hote...

Page 20: ...1 SUB TRANSMISSION GEARSHIFT LINKAGE THREAD TORQUE ITEM a TV DIA mm N m kgf m Ibf ft REMARKS Gearshift drum center bolt 1 8 27 2 8 20 NOTE 1 Gearshift drum stopper arm pivot bolt 1 6 12 1 2 9 NOTE 1 C...

Page 21: ...Cylinder stud bolt Exhaust pipe stud bolt Insulator band GENERAL INFORMATION r 23 r O 5mm _ 0 9 1 0 02 in 236 O B mm 9 29 0 03 in ___ 50 mm 2 0 in i l 1 5 3 Omm I 0 06 0 12 in 1 17...

Page 22: ...lt Lower engine hanger nut teft and right Upper engine hanger bracket nut frame side Upper engine hanger bracket bolt engine side SUB TRANSMISSION GEARSHIFT LINKAGE ITEM Gearshift lever box cover bolt...

Page 23: ...ont master cylinder holder bolt Front brake caliper mounting bolt Front brake disc plate bolt Front brake caliper slide pin boll Splash guard bolt Rear brake arm pinch bolt Rear wheel hub nut Rear bra...

Page 24: ...TE 5 Differential case mounting nut 8 mm 1 8 22 2 2 16 Final drive clutch assembly mounting bolt 3 8 25 2 6 19 NOTE 4 Front vehicle speed sensor cover bolt 2 6 10 la 7 Clutch cover stay bolt 3 6 10 la...

Page 25: ...seating surface Starter sprag clutch whole surface Sub transmission gear teeth Sub transmission mainshah and countershah journals Shih fork shah Shih drum guide grooves Primary driven gear bolt thread...

Page 26: ...ulti purpose Throttle cable adjuster threads lever side grease NlGI 2 Throttle lever pivot and dust seal lips Rear parking brake lever pivot Parking lock arm pivot screw Steering shah dust seal lips S...

Page 27: ...r dust seal EPS motor O ring Throttle cable outer inside Choke cable outer inside Rear brake cable pedal and lever outer insid e_ _ _ Master cylinder piston cups and oil seal Front brake caliper pisto...

Page 28: ...T CONNECTOR se VALVE CABLE THROITLE CABLE ASSIST HEADLIGHT CONNECTOR STARTING ENRICHMENT SE VALVE CABLE FRONT BRAKE HOSE GP CONNECTOR GPS model only HAND CABLE FRONT HOSE EPS model only If the cables...

Page 29: ...IlE CABLE GENERAL INFORMATION REAR FINAL GEAR CASE BREATHER HOSE FRONT FINAL GEAR CASE BREATHER HOSE REAR FINAL GEAR CASE RRFA r R HOSE Pi Ff RONTFINAL GEAR CASE 1 I F 1r n P BREATHER REAR BRIIKE BREA...

Page 30: ...RIGHT HANDLEBAR SWITCHWIAE STARTING ENRICHMENT SE VALVE CABLE THl oTTlE CABLE 2W J 4V1iD SELECT WITCHWIRE STARTING ENRICHMENT SE VALVE CABLE HOSE FR NTSRA KE HOSE EPS model onlv If the cables and har...

Page 31: ...CH MODE SELECT SWITCH WIRE LEFT HANDLEBAR SWITCH WIRE After 06 HANO BRAKE CABLE MODE SEI ECTSWITCH LEFT HANDLE SWITCH WIRE MODE NOTE EPS model only If the cables and harness around handlebar were repl...

Page 32: ...TCH 4P BLACK CONNECTOR ASSIST HEADLIGHT 2P BLACK CONNECTOR 4WD 2P GRAY CONNECTOR FRONT 4P GREEN CONNECTOR 1 28 ECM 5P BLACK MAIN WIRE HARNESS HANDLE SWITCH 10P GREEN CDr CTOR I METER 14P GRAY CONNECTO...

Page 33: ...CH 4P BLACK CQNNECTOR 4WD SWITCH 2P GRAY CONNECTOR IGNITION SWITCH 4P NATURAL CONNECTOR MAIN WIRE HARNESS HANDLE SWITCH 14P GREEN CONNECTOR COMBINATION METER 14P GRAY CONNECTOR COMBINATION METER 4P YE...

Page 34: ...HER HOSE Headlight wire REVERSE SWITCH WIRE FRONT FINAL GEAR CASE BREATHER HOSE Thermo switch wire Fan motor wire After 06 MAIN WIRE HARNESS FAN MOTOR WIRE BAND Accessory socket wire Headlight wire Ca...

Page 35: ...CABLE HAND BRAKE CABLE REAR FINAL GEAR CASE BREATHER HOSE REAR BRAKE BREATHER HOSE CLIP Rear final gear case breather hose Rear brake breather hose FAN MOTOR Radiator reserve tank siphon hose BREATHE...

Page 36: ...HEATER SWITCH WIRE BAND Front speed sensor wire Front fjnal clutch wire i 6_ p Rear speed sensor wire IGNI nON COIL CONTROL MOTOR 2P NATURAL LEFT FRONT BRAIKE HOSE REAR SPEED SENSOR 3P YELLOW CONNECTO...

Page 37: ...inal clutch wire Rear speed sensor wi re LEFT FRONT BRAKE HOSE REVERSE SWITCH WIRE REAR SPEED SENSOR 3P YELLOW CONNECTOR GENERAL INFORMATION I I COil r mRnl MOTOR 2P N TUIRAllCONNECTOR ANGLE SENSOR WI...

Page 38: ...ront speed sensor wire Front final clutch wire Rear speed sensor wire REAR SPEED SENSOR 3P YELLOW CONNECTOR FRONT DIFFERENTIAL CASE BREATHER HOSE IGNITION COIL CONTROL MOTOR 2P NATURAL CONNECTOR ANGLE...

Page 39: ...speed sensor wire REVERSE SWITCH WIRE REAR SPEED SENSOR 3P YELLOW CONNECTOR FRONT FINAL CLUTCH 2P GREEN CONNECTOR GENERAL INFORMATION FRONT DIFFERENTIAL CASE BREATHER HOSE IGNITION COil r 7F EPS MOTOR...

Page 40: ...SS EPS ECU AA RNESS EOl SENSe R WIRE 1 36 CLIP Rear final gear case breather hose Rear brake breather hose Radiator breather hose Hand brake cable RIGHT FRONT BRAKE HOSE CLIP Rear final gear case brea...

Page 41: ...TING AREA r 05 06 SPARK PLUG WIRE THROTILE IGNITION COil CRANKCASE BREATHER PIPE I SENSOR CONTROL MOTOR 2P NATURAL1 CONNECT O R __ CONTROL MC rCIR WIRE CONTROL MOTOR WIRE ANGLE SENSOR WIRE ANGLE SENSO...

Page 42: ...R WIRE AUTOMATIC TRI NS MI SI N CONTROL MOTOR SPARK PLUG WIRE CRANKCASE BREATHER PIPE CARBURETOR HEATER WIRE EPS MOTOR 2P GREY CONNECTOR CONTROL MOTOR 2P NATURAL 1J2 CONNECTOR J T 1 J CONTROL MOTOR WI...

Page 43: ...07 SPARK 0 3 mm 0 0 1 in SPARK WIRE CA BU RElrOR HEATER WIRE THROTTLE CABLE WIRE FUEL HOSE STARTING ENRICHMENT SE VALVE CABLE CARBURETOR HEATER WIRE GENERAL INFORMATION CRANKCASE BREATHER PIPE THROTT...

Page 44: ...ain wire harness Hand brake cable FUEL HOSE Rear brake breather hose CRANKCASE Rear final gear case breather hose BREATHER HOSE Radiator reserve tank siphon hose SEI VALVE CABLE FUEL HOSE CJ THROTTLE...

Page 45: ...er hose CRANKCASE Rear final gear case breather hose BREATHER HOSE Radiator reserve siphon hose STARTER Mr m RCABLE WATER PUMP BYPASS HOSE GENERAL INFORMATION STARTING ENRICHMENT SE VALVE CABLE THROTI...

Page 46: ...POSITION SWITCH 4P NATURAL SIPHON HOSE GROUND CABLE Engine te frame From HARNESS HAND BRAKE CABLE CARBURETOR HEATER 2P NATURAL CO NECTC R PEDAL BRAKE CABLE 1 42 GROUND CABLE Engine te frame From HARNE...

Page 47: ...sition switch wire Carburetor drain hose GEAR POSITION SWITCH WIRE RADIATOR RESERVE TANK SIPHON HOSE REAR FINAL GEAR CASE BREATHER HOSE GENERAL INFORMATION GROUND CABLE Engine la frame HAND BRAKE CABL...

Page 48: ...05 07 U type CLIPS Horn wire Front speed sensor wire Front final clutch wire Rear speed sensor wire Front final gear case breather hose FRONT FINAL GEAR CASE HOSE RIGHT FRONT BRAKE HOSE 1 44 BRAKE HO...

Page 49: ...t speed sensor wire Front final clutch wire Rear speed sensor wire Front final gear case breather hose FRONT FINAL GEAR CASE BREATHER HOSE GENERAL INFORMATION LEFT FRONT BRAKE HOSE BANO Front speed se...

Page 50: ...GENERAL INFORMATION Reverse side of the front fender HEAD LIGHT WIRE ACCESSORY SOCKET WIRE ACCESSORY SOCKET 05 06 Reverse side of the rear fender TAIUBRAKE LIGHT WIRE 1 46...

Page 51: ...BRAKE LIGHT Except EPS BATTERY 2P CONNECl OR GENERAL INFORMATION TAIUBRAKE LIGHT WIRE STARTER RELAY SWITCH 2P CO NEC TOR BOX STARTER MOTOR CABLE I I ______ _1 BATTERY BATTERY GROUND CABLE STARTER RELA...

Page 52: ...GENERAL INFORMATION EPS only STARTER AELAYSW1TCH BAnoRY2PCOINNI CTOR BOX EPS FUSE BATIERY GROUND CABLE STARTER RElAY SWITCH 1 48...

Page 53: ...ide does not react in the same way but it is toxic Honda Motor Co ltd utilizes various systems to reduce carbon monoxide oxides of nitrogen and hydrocarbon EXHAUST EMISSION CONTROL SYSTEM The exhaust...

Page 54: ...hicle or parts of the exhaust or intake system with parts other then those speci fied by the manufacturer NOISE EMISSION CONTROL SYSTEM U type only TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITE...

Page 55: ...RECOIL STARTER COVER 2 4 ENGINE GUARD 2 5 GEARSHIFT LEVER KNOB 2 5 SIDE COVER 2 5 FUEL TANK COVER 2 6 CENTER MUD GUARD 2 7 INNER COVER 2 7 FRONT MUD GUARD 2 8 INNER FENDER 2 9 FRONT CARRIER 2 9 FRONT...

Page 56: ...ts after removing the exhaust system Always inspect the exhaust system for leaks after installation TORQUE VALUES Front carrier carry pipe bolt Gearshift lever knob screw Rear carrier bolt Muffler ben...

Page 57: ...ner Cover page 2 8 12 Right Front Mud Guard page 2 8 13 left Front Mud Guard page 2 8 23 24 2 FRAME BODY PANELS EXHAUST SYSTEM i 6 9 7 11 13 12 1 4 Inner Fender page 2 9 15 Front Carrier page 2 9 16 C...

Page 58: ...at by turning the release lever upward S E A T B O S S E S P R O N G S Pull the seat back and remove it Install the seat by inserting the prongs into the seat retainer on the frame Push the seat forwa...

Page 59: ...R KNOB Remove the two screws and gearshift lever knob Installation is in the reverse order of removal TORQUE Knob screw 2 N m 0 2 kgf m 1 4 Ibf ft SIDE COVER RIGHT SIDE COVER BOLTS SCREWS Remove the s...

Page 60: ...shift lever knob page 2 5 left side cover page 2 6 fuel fill cap eight trim clips fuel tank cover assembly release two tabs of cover by sliding the cover forward Installation is in the reverse order o...

Page 61: ...f removal LEFT CENTER MUD GUARD Remove the following left side cover page 2 6 two bolts and footpeg screw socket bolt eight trim clips left center mud guard Installation is in the reverse order of rem...

Page 62: ...8 RIGHT FRONT MUD GUARD Remove the right side cover page 2 5 Remove the nine trim clips and right guard front mud Installation is in the reverse order of removal LEFT FRONT MUD GUARD Remove the left s...

Page 63: ...ts two trim dips two tapping bolts left inner fender Installation is in the reverse order of removal FRONT CARRIER Be careful nor to sera ell the front fender Remove the following two 6 mm bolts and t...

Page 64: ...bolts front skid plate Installation is in the reverse order of removal CARRY PIPE Remove the following front carrier page 2 9 carry pipe guard page 2 10 front skid plate page 2 10 two 6 rnm bolts four...

Page 65: ...of removal REAR CARRIER 05 06 model shown Remove the seat page 2 4 Remove the two trim clips and rear fender lid Remove the following fuel tank cover page 2 6 taillight grilles page 2 14 or rear corne...

Page 66: ...S fuse box Remove the following fuel tank cover page 2 6 rear carrier page 2 11 bolt two socket bolts six trim clips tail light connector 05 06 only Remove the starter motor and battery H cables out o...

Page 67: ...der of removal OUTER FENDER HEADLIGHT GRILLE Remove the following two screws four trim clips headlight grille Installation is in the reverse order of removal FRONT OUTER FENDER Remove the following se...

Page 68: ...R FENDER After 06 Remove the following six trim clips rear corner outer fender Install the rear corner outer fender in the reverse order of removal REAR OUTER FENDER Remove the following bolt and coll...

Page 69: ...ts Remove the joint nuts and pull the exhaust pipe for ward gradually to disconnect it from the muffler Remove the joint gasket and muffler gasket Release the crankcase breather pipe clips from the st...

Page 70: ...LY ASSEMBLY 3 2 N m 0 3 kgf m 2 4 Ibf ft BANO B BAND FRONT EXHAUST PIPE COVER 5 4 N m 0 6 kgf m 4 0 Ibf tt 5 4 N m 0 6 kgf m 4 0 Ibf ft END BAND 2 16 END BAND CENTER BAND 5 4 N m 0 6 kgf m 4 0 Ibf ft...

Page 71: ...tightening all fasteners Tighten the joint nuts first then tighten the mount ing bolt and band bolts Set the breather pipe onto the stay and install the clip TORQUE M uffler band bolt 23 N m 2 3 kgf m...

Page 72: ...MEMO...

Page 73: ...CH 3 21 AIR CLEANER 3 6 BRAKE SYSTEM 3 22 AIR CLEANER HOUSING DRAIN HOSE 3 8 SKID PLATE ENGINE GUARD 3 23 SPARK PLUG 3 9 SUSPENSION 3 23 VALVE CLEARANCE 3 10 SPARK ARRESTER 3 24 ENGINE OIL 3 12 NUTS B...

Page 74: ...d before starting any work The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and may lead to death Run the engine in an open area or with an exhaust evacuation sy...

Page 75: ...nal gear case oil drain bolt Tie rod lock nut Spark arrester bolt Front master cylinder reservoir cap screw 22 N m 2 2 kgf m 16Ibf ft 17 N m 1 7 kgf m 13 fbf h 10 N m 1 0 kgf m 7 IbHt 25 N m 2 5 kgf m...

Page 76: ...ADIATOR COOLANT NOTE 3 I I 3 16 COOLING SYSTEM NOTE 2 I I 3 16 DRIVE SHAFT BOOTS I I 3 17 REAR FINAL GEAR CASE OIL R Every I 3 18 AND DIFFERENTIAL OIL 2 years BRAKE FLUID NOTE 3 I I 3 20 BRAKE SHOES W...

Page 77: ...he throttle lever still does not return properly replace the throttle cable With the engine idling turn the handlebar all the way to the right and left to ensure that the idle speed does not change If...

Page 78: ...r other damage AIR CLEANER Remove the seat page 2 4 If tha vehicle IS used in dusty areas Release the retaining clips from the air cleaner sandor snow more housing cover and remove the cover frequent...

Page 79: ...lent oil from the inside of the element Place the element into a plastic bag and spread the oil evenly by hand Install the clip and sub air cleaner filter Install the element core into the air cleaner...

Page 80: ...tab with the air cleaner element end be faced ro forward Secure the air cleaner housing cover with the retain ing clips Install the seat page 2 4 AIR CLEANER HOUSING DRAIN HOSE Remove the drain hose...

Page 81: ...age 3 4 INSPECTION Check the following and replace if necessary rec ommended spark plug page 3 2 Insulator for damage Electrodes for wear Burning condition coloration This motorcycle s If the electrod...

Page 82: ...mm 0 04 in plug gauge does not insert between the gap If the gauge can be inserted into the gap replace the plug with a new one INSTALLATION Install the spark plug in the cylinder head and hand tighte...

Page 83: ...e crankshaft one full turn and match up the T mark again Check the clearance of each valve by inserting a feeler gauge between the adjusting screw and valve stem VALVE CLEARANCES IN 0 15 mm 0 006 in E...

Page 84: ...ant on a dry sump engine due to the comparatively large vol ume of oil Do not snap the throttle while idling or the oil level reading will be inaccurate Before checking the oil level remove the dipsti...

Page 85: ...rature in your riding area is within the indicated range Reinstall the oil filler cap and dipstick Oil level che k when engine is running NOTE The oil pump adjusts the oil level so that the oil tank i...

Page 86: ...in bolt with a new sealing washer and tighten it TORQUE 25 N m 2 5 kgf m 18 Ibf ft Pour the recommended engine oil page 3 13 into the oil tank up to the upper level mark on the dip stick ENGINE OIL CA...

Page 87: ...ank with the recommended engine oil page 3 14 ENGINE IDLE SPEED Inspect and adjust idle speed aher alt other engine maintenance items have been performed and are within specifications The engine must...

Page 88: ...on inhibitors I NOTICE I Using coo ant with silicate corrosion inhibitors may cause premature wear of water pump seals or blockage of radiator passages Using tap water may cause engine damage LOWER LE...

Page 89: ...ts mud or other obstruc tions with compressed air or low pressure water Replace the radiator if the air flow is restricted over more than 20 of the radiating surface Installation is in the reverse ord...

Page 90: ...ve the oil filler cap and pour the oil slowly through the filler hole until the oil starts to flow out of the check bolt hole RECOMMENDED OIL HVpoid gear oil SAE 80 Install the check bolt with a new s...

Page 91: ...Z 3 5 Imp oz at disassembly InSlall the oil filler cap with a new O ring page 3 18 DIFFERENTIAL OIL lEVEL CHECK Place the vehicle on a level surface Remove the oil filler cap Check that the oil level...

Page 92: ...material to enter the system when filling the reservoir I NOTICE I Spilled fluid can damage painted plastic or rubber parts Place 8 rag over fhese pans whenever the system is s8lViced FRONT BRAKE Tur...

Page 93: ...k Refer to page 16 13 for brake pads replacement BRAKE LIGHT SWITCH INSPECTION Adjust the rear brake light switch after adjusting the brake pedal freeplay The front brake light switch can not be adjus...

Page 94: ...r other damage Replace or repair if necessary For cable lubrication Disconnect the brake cables at the brake lever or pedal ends Thoroughly lubricate the cables and their pivot points with commerciall...

Page 95: ...S sealed on Ihe brake arm JOint SKID PLATE ENGINE GUARD Check the skid plates and engine guard for cracks damage or looseness Tighten any loose fasteners Replace the skid plates and engine guard as re...

Page 96: ...ttempting to move the swingarm side to side Replace the pivot bearings if any looseness is noted page 15 9 SPARK ARRESTER 3 24 Remove the three bolts and the spark arrester with the gasket Use a brush...

Page 97: ...xcept EPS Front 25 kPa 0 25 kgflcm2 3 6 psi Rear 25 kPa 0 25 kgflcm2 3 6 psi RECOMMENDED TIRE PRESSURE EPS only Front 32 5 kPa 0 33 kgf cm2 4 7 psi Rear 25 kPa 0 25 kgf cm2 3 6 psi Check the tires for...

Page 98: ...vertical movement inspect the steering shaft holder bushing and bearing page 14 28 STEERING SYSTEM Place the vehicle on a level ground with the front wheels facing straight ahead Mark the centers of t...

Page 99: ...r 06 Using a 22 mm wrench hold the tie rod ends so that the relative angle of both tie rods may turn into 16 degrees 30 minutes Then using a suitable torque wrench tighten the tie rod lock nuts making...

Page 100: ...MEMO...

Page 101: ...4 LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM 4 2 SERVICE INFORMATION 4 3 TROUBLESHOOTING 4 5 OIL PRESSURE CHECK 4 6 OIL COOLER 4 7 OIL STRAINER 4 8 OIL PUMP 4 12 4 1...

Page 102: ...ATION SYSTEM LUBRICATION SYSTEM DIAGRAM OIL PRESSURE CHECK VALVE OIL COOLER CAMSHAFT CENTRIFUGAL CLUTCH ROCKER ARMS 1 tb Oil PRESSURE I h REUEFVALVE EDT SENSOR OIL STFIA ERSCAEEN Oil FILTER OIL STFIA...

Page 103: ...rvice limits replace the oil pump as an assembly After oil pump oil cooler and or oil hoses have been installed check that there are no oil leaks and that oil pressure is correct SPECIFICATIONS _____...

Page 104: ...t available in U S A Pressure gauge attachment 07KPJ VD60100 or 07KPJ VD601OA U S A only 4 4 Oil pressure gauge Q7YAJ 0010300 Not available in U S A Oil pressure gauge 0 160 psi 07ZMJ HN2Al00 U S A on...

Page 105: ...p Internal oil leak Incorrect oil being used No oil pressure Oil level too low Oil pressure relief valve stuck open Broken oil pump drive chain Broken oil pump drive or driven sprocket Damaged oil pum...

Page 106: ...auge for 1 400 rpm min Oil pressure gauge for 5 000 rpm min ll Pressure gauge hose Pressure gauge attachment U S A only 01YAJ 0010100 07YAJ 0010300 07FPJ 7520100 07KPJ VD60100 07ZMJ HN2A100 Oil pressu...

Page 107: ...QUE 34 N m 3 5 kgf m 25 Ibf tt OIL COOLER INSPECTION Remove the radiator grille plate page 3 16 Check the oil cooler pipe joints and seams for leaks Check the oil cooler air passage for clogging or da...

Page 108: ...r pipe joints Install the pipe joints onto the oil cooler Install the removed parts in the reverse order of removal Check the oil level and add the recommended engine oil if the level is low page 3 12...

Page 109: ...ts from the front oil tank LUBRICATION SYSTEM OIL FRONT Oil TANK Remove the seven bolts and remove the rear oil tank from the front oil tank REAR I TANK Remove the oil strainer screen from the front o...

Page 110: ...oil tank 111 a RING Install the rear oil tank onto the front oil tank and tighten the seven bolts securely REAR OIL TANK 4 10 Install the five bolts and tighten them securely Install the joint collar...

Page 111: ...ely Install the engine oil temperature IEOT sensor with a new sealing washer and tighten it TORQUE 18 N m l B kgf m 13 Ibf ftl Connect the EDT sensor connector Install the inner fender page 2 9 and fr...

Page 112: ...screen thoroughly Install the oil strainer screen and tighten the bolt securely_ Coat a new O ring with oil and install it onto the oil strainer Install the oil strainer and tighten the bolt securely...

Page 113: ...ng seat spring and relief valve Check the valve for wear sticking or other damage Check the spring for fatigue or damage Remove outer inner rotors C and drive pin Remove the oil pump spacer Remove out...

Page 114: ...oughly INSPECTION Temporarily assemble each inner rotor outer rotor and drive pin onto the pump shaft and install them into each pump body individually Measure the rotor tip clearance SERVICE liMIT 0...

Page 115: ...toward pump body A Install inner rotor A onto the shaft with the drive pin grooves facing Qut Install outer rotor A Install the drive pin into the pump shaft hole and set the drive pin in the inner r...

Page 116: ...ligning the pin grooves with the drive pin Install outer rotor C Install the relief valve spring and spring seat Install the pump body C and tighten the three bolts INSTALLATION Coat new O rings with...

Page 117: ...Install the oil pump onto the front crankcase and tighten the five bolts securely Assemble the crankcases page 13 16 LUBRICATION SYSTEM 4 17...

Page 118: ...MEMO...

Page 119: ...5 13 SERVICE INFORMATION 5 3 CARBURETOR INSTALLATION 5 18 TROUBLESHOOTING 5 4 PILOT SCREW ADJUSTMENT 5 19 AIR CLEANER HOUSING 5 5 HIGH ALTITUDE ADJUSTMENT except U type 5 20 CARBURETOR REMOVAL 5 6 FU...

Page 120: ...FUEl SYSTEM SYSTEM COMPONENTS 2 3 N m 0 2 kgf m 1 7 Ibf ft 5 2...

Page 121: ...connected perform the initial setting page 24 6 after all carburetor adjustments have been completed If the vehicle is to be slored for more than one month drain the float chamber Fuel left in the flo...

Page 122: ...e air leak Faulty vacuum piston Faulty throttle valve Rich mixture SE valve open ON Clogged air jets Faulty float valve Float level too high Dirty air deaner Clogged slow circuit Clogged SE valve circ...

Page 123: ...n the muffler Disconnect the crankcase breather pipe from the air cleaner housing Disconnect the air cleaner hose from the carburetor hose jOint Loosen the band screw and remove the air intake duct fr...

Page 124: ...using page 5 5 Release the carburetor heater wire from the wire clip and disconnect the heater 2P connector Remove the carburetor drain hose from the clamp Do nolloosen the Disconnect the throttle pos...

Page 125: ...tha thronle cable adjuster Loosen the throttle cable lock nut and remove the adjuster from the carburetor body and disconnect the cable from the throttle drum Loosen the carburetor insulator band scr...

Page 126: ...CTION Check the SE valve face for scores scratches or wear Check the SE valve seat at the tip of the valve for stepped wear Check the seal ring for wear or damage HOSES Remove the following air vent h...

Page 127: ...crews and clamps while holding the vacuum chamber cover Remove the vacuum chamber cover compression spring and diaphragmlvacuum piston from the car buretor body Be careful not 10 Turn the needle holde...

Page 128: ...mooth operation up and down in the carburetor body Air will leak out of the vacuum chamber if the dia phragm is damaged in any way even with just a pin hole Remove the screw set plate air joint and O...

Page 129: ...ove the four screws and the float chamber Remove the baffte plate Drive out the float pin from the throttle stop screw side using a pin driver Remove the float and float valve Check the float for dama...

Page 130: ...seat Will ber of turns until it seats lightly Make a note of this occur If the Pilot to use as a reference when reinstalling the pilot screw IS ttghtened screw agamst the seat Remove the pilot screw...

Page 131: ...TOR HEATER THROTTLE POSITION SENSOR ONE WAY VALVE 0 CHAMBER DRAIN HOSE Damage to the pilot Install the pilot screw with the spring washer and screw seat Will new O rings and return it to its original...

Page 132: ...eck the float level after checking the float valve valve seat and float With the float velve seated and the float arm just touching the valve measure the float level with the float level gauge TOOL Ca...

Page 133: ...body and tighten the screw Install the needle clip onto the jet needle 05 STANDARD CLIP POSITION 2nd groove from top After OS Aher 05 model can not adjust the needle clip posi tion Install the washer...

Page 134: ...cover while lifting the piston in place Align the dl8phragm under tab of the cover with the air passage and secure the rhechambercover cover with at least two screws before releasing the and 0 keep t...

Page 135: ...etor body Install and tighten the screw CARBURETOR HEATER Install the collar and carburetor heater with the stepped side of the collar facing the carburetor and tighten carburetor heater HOSES Connect...

Page 136: ...temporarily lighten the lock nut Install the throttle drum cover and tighten the screw I TORQUE 1 5 N m 0 2 kgf m 1 1Ibf ft Install the starting enrichment SE valve and tighten the SE valve nut TORQU...

Page 137: ...ew clockwise until it seats lightly then back it out to the specification given This is an initial sening prior to the final pilot screw adjustment TOOL Pilot screw wrench 07KMA MN90101 or 07KMA MN9A1...

Page 138: ...use will meet each emission standard throughout its useful life The high altitude carburetor adjustment is per formed as follows Remove the carburetor page 5 6 and the float chamber Replace the stand...

Page 139: ...screw wrench 07KMA MN90101 or 07KMA MN9Al00 U S A only LOW ALTITUDE PILOT SCREW OPENING 114 tum out from the high altitude setting Warm up the engine and adjust the idle speed at low altitude with th...

Page 140: ...o the backward and disconnect the fuel level sensor 2P Red connector Remove the fuel tank Install the fuel tank in the reverse order of removaL After connecting the fuel hose turn the fuel valve ON an...

Page 141: ...flash point solvent Dry the strainer screen thoroughly Install a new Q ring onto the fuel valve Install the fuel valve into the fuel tank with the two collars and bolts and tighten the bolts securely...

Page 142: ...MEMO...

Page 143: ...FLOW PATTERN 6 2 SERVICE INFORMATION 6 3 TROUBLESHOOTING 6 3 SYSTEM TESTING 6 4 COOLANT REPLACEMENT 6 5 6 COOLING SYSTEM RADIATOR RESERVE TANK 6 7 RADIATOR COOLING FAN 6 7 THERMOSTAT 6 10 WATER PUMP 6...

Page 144: ...COOLING SYSTEM SYSTEM FLOW PATTERN RESERVE TANK WH R PUMP 6 2...

Page 145: ...in the system All cooling system service can be done with the engine in the frame Avoid spilling coolant on painted surfaces After servicing the system check for leaks with a cooling system tester Ref...

Page 146: ...tor cap lid from the S CR E W front fender Remove the radiator cap COOLANT HYDROMETER TEST Test the coolant gravity using a hydrometer STANDARD COOLANT CONCENTRATION 1 1 look for contamination and rep...

Page 147: ...ts if the system will nor hold specified pressure for at least 6 seconds Remove the tester and install the radiator cap Install the radiator cap lid and tighten the screw COOLANT REPLACEMENT PREPARATI...

Page 148: ...ealing washer Install the fuel tank cover page 2 6 Disconnect the Siphon hose and drain the coolant IIIIIII I11111 IIIIIIIIIIIIIIIIII I11111 _ from the radiator reserve tank Connect the siphon hose to...

Page 149: ...iphon hose from the reserve tank and drain the coolant Install the reserve tank in the reverse order of removal Fill the reserve tank to the upper level line RADIATOR COOLING FAN RADIATOR REMOVAL Remo...

Page 150: ...OLING FAN DISASSEMBLY Remove the radiator Free the fan motor wire and breather hose from the clamp and disconnect the breather hose from the motor Remove the three bolts and fan shroud molor assembly...

Page 151: ...l the fan motor onto the shroud and tighten the three nuts securely Install the cooling fan onto the motor shaft aligning the flat surfaces Apply locking agent to the motor shaft threads Install and t...

Page 152: ...ghten the hose band screws Connect the fan motor breather hose _ Il Iq ASSEMBLY BREATHER Route the fan motor wire and breather hose prop L arty page 1 24 Connect the fan molor 2P connector Install the...

Page 153: ...ace the thermostat if the valve stays open at room temperalure ar the rubber seal is damaged Heat the water with an electric heating element to operaling temperature for 5 minutes Suspend the thermost...

Page 154: ...eed the cooling system page 6 5 WATER PUMP 6 12 MECHANICAL SEAL INSPECTION Check the inspection hole for signs of coolant leak age If there is leakage the water pump mechanical seal is defective and t...

Page 155: ...ver and water pump body Install and tighten the two bolts INSTALLATION WATER PUMP fJ O RING BOLTS Do not apply OJ to Install a new O ring onto the pump side of the water the D rmgs joint pipe I 1 Inst...

Page 156: ...nd tighten them securely Connect the bypass hoses to the water pump Connect the lower radiator hose to the water pump and tighten the band screw securely Install the fuel tank cover page 2 6 Fill and...

Page 157: ...7 ENGINE REMOVAL INSTALLATION SYSTEM COMPONENTS 7 2 ENGINE REMOVAL 7 4 SERVICE INFORMATION 7 3 ENGINE INSTALLATION 7 8 7 1...

Page 158: ...NE REMOVAL INSTALLATION SYSTEM COMPONENTS 54 N m 5 5 kgf m 40 Ibf h 54 N m 5 5 kgf m 40 Ibf ft 18 N m 0 8 kgf m 13 IbUt 54 N m 5 5 kgf m 40 Ibf ft 7 2 32 N m 3 3 kgf m 24 Ibf ft 32 N m 3 3 kgf m 24 Ib...

Page 159: ...p qt TORQUE VALUES left lower engine hanger bracket bolt Lower engine hanger nut Upper engine hanger bracket bolt Upper engine hanger bracket nut Engine oil temperature EOT sensor Gearshift lever link...

Page 160: ...t system page 2 15 carburetor page 5 6 heat guard page 8 6 bolt and ground cable terminal Remove the rubber cap terminal nut and starter r motor cahle Remove the bolt and ground cable Disconnect the c...

Page 161: ...ion is into neutral Remove the pivot bolt washer pinch bolt and the gearshift arm from the gearshift spindle Pivot the tie rod up out of the way Remove the following from the stays and discon nect the...

Page 162: ...ensor connector Remove the bolts and oil pipes from the oil tank BOLTS Oil PIPES Disconnect the engine oil temperature EDT sensor 1 fs 1 connector and remove the EDT sensor and sealing washer 7 6 Remo...

Page 163: ...spacer and mounting rubbers Move the engine forward and disconnect the output shah from the universal joint Remove the engine from the frame toward the leh side Remove the engine hanger bushings and d...

Page 164: ...engine in the frame from the left side Engage the output shaft with the universal joint Install the mounting rubbers on the right lower hanger bushing with the large 1 0 side facing in Install the sp...

Page 165: ...he engine side upper hanger bolts TORQUE 32 N m 3 3 kgf m 24 Ibf ft Tighten the frame side upper hanger nut TORQUE 54 N m 5 5 kgf m 40 Ibf ft Install the universal joint boot onto the engine Install t...

Page 166: ...ews securely Install the spark plug cap onto the plug Connect the following alternator ignition pulse generator connector gear position switch connector Install the connectors onlO the stays and clamp...

Page 167: ...il the stopper ring seats in the groove Make sure that the stopper ring is seated properly by pulling on the propeller shaft lightly Install the boot over the pinion joint securely and the boot bands...

Page 168: ...ber cap over the terminal properly Install the ground cable terminal onto the engine and tighten the bolt Adjust the tie rod length of the gearshift lever link age page 12 18 Install the following hea...

Page 169: ...TION REFACING 8 13 TROUBLESHOOTING 8 5 CAMSHAFT REMOVAL 8 15 CYLINDER COMPRESSiON 8 6 CAMSHAFT INSTALLATION 8 17 CYLINDER HEAD COVER REMOVAL DISASSEMBLY 8 6 CYLINDER HEAD ASSEMBLy 8 19 CYLINDER HEAD R...

Page 170: ...CYLINDER HEADIVALVE CAMSHAFT SYSTEM COMPONENTS 53 N m 5 4 kgf m 391bf ft 32 N m t3 3 kgf m 24 Ibf h 10 N m 1 0 kgf m 7Ibf ft 16Ibf ft 8 2...

Page 171: ...th I Valve spring Free length Rocker arm Arm I D Shaft 0 0 EX 5 455 5 470 0 2148 0 2154 5 43 0 214 IN EX IN EX IN EX IN EX Inner Outer IN EX IN EX 5 500 5 512 0 2165 0 010 0 037 0 0004 0 030 0 057 0 0...

Page 172: ...A 8 4 Valve guide driver 5 5 mm 07742 0010100 Fla cutter 36 mm IN 32Q 07780 0013500 or equivalent commercially avail able in U S A Seat cutter 33 mm EX 45 07780 0010800 or equivalent commercially avai...

Page 173: ...inder head leaking or damaged cylinder head gasket loose spark plug Warped or cracked cylinder head Cylinder piston problem page 9 5 Compression too high overheating or knocking Excessive carbon build...

Page 174: ...PRESSURE 608 902 kPa 6 2 9 2 kgf cm2 88 131 psi at 450 rpm min Check that there is no leakage at the gauge connec tion Low compression can be caused by blown cylinder head gasket improper valve adjus...

Page 175: ...ns so that they can be placed baclc in their OTlgmallOCBfJOns DISASSEMBLY Remove the two setting bolts and sealing washers Push the rocker arm shah with the small screw driver through the bolt hole un...

Page 176: ...ain the rocker arm lo shaft clearance SERVICE LIMITS 0 08 mm 0 003 in PUSH ROD Check the push rods for wear or damage If the push rod is worn or damaged check the cam follower and camshaft CYLINDER HE...

Page 177: ...four bolts and the cylinder head cy meier head 100 hard Remove the gasket and dowel pins CYLINDER HEAD DISASSEMBLY To prevenr loss of Remove the valve spring cotters using the valve tension do not sp...

Page 178: ...its from the combustion chamber being careful not to damage the gasket surface Check the spark plug hole and valve areas for cracks Check the cylinder head for warpage with a straight edge and feeler...

Page 179: ...E GUIDE Check that the valve moves smoothly in the guide Check the valve for bending burning or abnormal wear Measure each valve stem 0 0 and record it SERVICE LIMITS IN 5 45 mm 0 215 in EX 5 43 mm 0...

Page 180: ...Heat the cylinder head 10 130 140 C 275 290G F with a hot plate or oven Do not heat the cylinder head beyond 150 C 300 F Use temperature indica tor sticks available from welding supply stores to be su...

Page 181: ...eat contact Remove the valve and inspect the valve seat face The valve seat contact should be within the speci fied width and even all around the circumference STANDARD 1 0 1 1 mm 0 039 0 043 in SERVI...

Page 182: ...b d 09 60 01 0 co 32 CONTACT TOO LOW T 60 D Using a 45 seat cutter remove any roughness or irregularities from the seat TOOLS Valve seat cutter 35 mm IN 07780 0010400 Valve seat cutter 33 mm EX 07780...

Page 183: ...es are removed Excessive lappmg After cutting the seat apply lapping compound to pressure may the valve face and lap the valve using light pres deform or damage sure the seal Change the angle of lappi...

Page 184: ...cam sprocket and suspend the cam chain with a piece of wire to pre vent it from falling into the crankcase Remove the camshaft assembly and holder plate 00 nor forcibly Remove the dowel pins from the...

Page 185: ...the camshaft assem bly Install the dowel pins if they were removed Remove the timing hole cap page 3 10 Rotate the crankshaft using the recoil starter knob and align the T mark on the flywheel with th...

Page 186: ...and tighten the four camshaft holder bolts Apply molybdenum oil solution to the cam lobes Remove the stopper tool from the cam chain ten sioner lifter and install the sealing bolt with a new sealing w...

Page 187: ...ls lubricate the valve stem sliding surface with molyb denum oil solution Insert the valve into the guide while turning it slowly to avoid damage to the stem sea1 Install the inner and outer valve spr...

Page 188: ...pport the cylinder head so that the valve heads will not contact anything that cause damage Tap the valve stems gently with two plastic ham mers as shown to seat the cotters firmly CYLINDER HEAD INSTA...

Page 189: ...Install the mounting rubbers on the upper engine hanger bushing with the large 1 0 side facing in Install the upper engine hanger bracket and bolts Tighten the engine side hanger bolts TORQUE 32 N m...

Page 190: ...tall them onto the rocker arm shaft grooves Apply molybdenum oil solution to the rocker arm shaft sliding surface t I a RINGS 8 22 Install the rocker arms and shafts into the cylinder head cover Align...

Page 191: ...sure to seat the rocker arm followers on the push rods properly by turning the crankshaft slowly with the recoil starter Apply oil to the cap nut threads and sealing sur faces Install the four washer...

Page 192: ...8 24 Install the wire clamp 10 the fuel tank heat guard Install the fuel tank heat guard Install the upper radiator hose choke and throttle cables onto the fuel tank heat guard properly Install the fu...

Page 193: ...SYSTEM COMPONENTS 9 2 SERVICE INFORMAnON 9 3 TROUBLESHOOTING 9 4 9 CYLINDER PISTON CYLINDER PISTON REMOVAL 9 5 CYLINDER PISTON INSTALLATION 9 9 9 1...

Page 194: ...CYLINDER PISTON SYSTEM COMPONENTS o 9 2...

Page 195: ...1 0 piston ring Piston pin 0 0 Piston to piston pin clearance Piston ring end gap Piston ring to ring groove clearance Cylinder to pisto nclearance Connecting rod small end I D Connecting rod to pisto...

Page 196: ...inder and piston Compression too high overheating or knocking Excessive carbon built up on piston head or combustion chamber E cessive smoke Worn cylinder piston or piston rings Improper installation...

Page 197: ...the stopper fully to hold the tensioner in the fully retracted posi tion TOOL Cam chain tensioner stopper 07NMG MY90101 or 07ZMG MCAA400 U S A only Remove the two bolts Remove the cam chain tensioner...

Page 198: ...move the piston pin clips with the pliers Push the piston pin out of the piston and connecting rod and remove the piston Donordamage he Spread each piston ring and remove it by lifting up PIston nng b...

Page 199: ...cylinder must be rebored and an oversize pis ton fitted jf the service limits are exceeded The 0 25 mm 0 010 in and 0 50 mm 0 020 in over size pistons are available The cylinder must be rebored so tha...

Page 200: ...ment against the maxim um cylinder 1 0 measurement and calculate the piston to cylinder clearance page 9 7 Measure piston pin hole Take the maximum read ing to determine the 1 0 SERVICE LIMIT 20 04 mm...

Page 201: ...aps as shown PISTON INSTALLATION Place a clean shop towel over the crankcase to pre vent the piston pin clip from falling into the crank case Apply molybdenum oil solution to the piston pin outer surf...

Page 202: ...own Install the dowel pins and a new gasket Apply engine oil to the cylinder wall piston outer surface and piston rings 88 ClIreful not 10 Install the cylinder over the piston while compress damage th...

Page 203: ...stopper tool TOOL Cam chain tensioner stopper 07NMG MY90101 or 07ZMG MCAA400 U S A only Install the cam chain tensioner lifter into the cylin der with a new gasket Install the camshaft page B 17 Insta...

Page 204: ...MEMO...

Page 205: ...10 CENTRIFUGAL CLUTCH COMPONENT LOCATION 10 2 SERVICE INFORMATION 10 3 TROUBLESHOOTING 10 4 FRONT CRANKCASE COVER 10 5 CENTRIFUGAL CLUTCH 10 9 0...

Page 206: ...CENTRIFUGAL CLUTCH COMPONENT LOCATION 8 N m 12 0 kgf m B7Ibf ft 18 N m 1 8 kgf m 13Ibf ft 10 2...

Page 207: ...clutch disengagement Oil additives of any kind are not recommended When the clutch does nOI disengage or the vehicle creeps with the clutch disengaged inspect the engine oil viscosity and level before...

Page 208: ...0400 TROUBLESHOOTING Clutch slips when accelerating Worn clutch weight linings Worn clutch drum Improper oil additive used The vehicle creeps with clutch disengaged Weak clutch weight springs 10 4 Dri...

Page 209: ...cover stay Remove the setting cap and oil feed pipe from the front crankcase cover Remove the O rings from the setting cap and feed pipe Remove the fourteen crankcase cover bolts Remove the two bolts...

Page 210: ...race of the bearing fits tightly in the front crankcase cover TRANSMISSION BEARINGS Replace the bearing if the inner race does not turn smoothly quietly or if the outer race fits loosely in the front...

Page 211: ...Drive new transmission bearings in using the spe cial tools TOOLS Inner bearing Driver Attachment 42 x 47 mm Pilot 22 mm Outer bearing Driver Hub bearing driver INSTALLATION 07749 0010000 07746 001030...

Page 212: ...Clean the crankcase and cover mating surfaces Apply liquid sealant to the mating surface of the front crankcase cover Install the front crankcase cover and lighten the fourteen bolt in a crisscross p...

Page 213: ...S oil tank page 4 8 j gearshift linkage page 7 10 I inner fenders page 2 9 front mud guards page 2 8 Adjust the tie rod length of the gearshift lever link age page 12 8 SOCKET BOLTS CENTRIFUGAL CLUTCH...

Page 214: ...ise Remove the drive plale assembly from the clutch drum by turning it counterclockwise CLUTCH DRUM Check the one way clutch sprag for abnormal wear damage or irregular movement Remove the sprag clutc...

Page 215: ...lining thickness of the weight weights as a sel SERVICE LIMIT 2 0 m m 0 08 in Check the sprag clutch contacting surface of the drive plate boss for abnormal wear or damage Compress the clutch cone sp...

Page 216: ...rings from the drive plate WEIGHTS Replace rhe clurch Measure the clutch weight spring free length wBlght springs 8S 8 ser 10 12 SERVICE liMIT 24 1 mm 0 95 in ASSEMBLY DRIVE PLATE SPRINGS J CLUTCH DRU...

Page 217: ...ith locating pins facing up Install the E clips into the pin grooves of the drive plate with their gaps facing towards the locating pins while compressing the cone spring with pliers Apply oil to the...

Page 218: ...assembly onto the crankshaft while aligning the splines of the drive plate boss and crankshaft Engage the primary drive gear of the clutch drum with the driven gear of the automatic transmission unit...

Page 219: ...8e CiJreful no to Stake the clutch lock nut into the crankshaft groOlle damage he crankshaf hreads Install the front crankcase cOlier page 10 7 CENTRIFUGAL CLUTCH 10 15...

Page 220: ...MEMO...

Page 221: ...11 ALTERNATORISTARTER CLUTCH SYSTEM COMPONENTS 2 SERVICE INFORMATION 3 TROUBLESHOOTING 4 RECOIL STARTER 5 ALTERNATOR STATOR 8 FLYWHEEL STARTER CLUTCH 2 11 1...

Page 222: ...ALTERNATOR STARTER CLUTCH SYSTEM COMPONENTS 108 N m 11 0 k gf m 80 Ibf ft 11 2...

Page 223: ...icing SPECIFICATIONS Unit mm in ITEM 51 705 51 718 2 0356 2 0 3661 iIl t 5 7 O 5 1 2 Q03 5 6t l j STANDARD SERVICE LIMIT Starter driven gear boss 0 0 TORQUE VALUES Starter clutch outer bolt Recoil sta...

Page 224: ...201 or 07936 3710200 or 07936 371020A U S A only TROUBLESHOOTING Bearing remover shaft 10 mm 07936 GE00100 Starter motor turns but engine does not turn Faulty starter clutch Damaged reduction gear or...

Page 225: ...olt and ratchet cover Remove the ratchet and spring Untie the starter rope and remove the starter grip Release the starter rope slowly prQtecl Of and use Remove the starter drive pulley cafe when remo...

Page 226: ...a new one if it is damaged or broken ASSEMBLY Install the spring by hooking the outer end onto the starter housing hook as shown Install the starter rope into the drive pulley and tie the rope end in...

Page 227: ...d through the starter hous ing and grip holes while the pulley remains held in place Tie the starter rope end in a square knot Install the ratchet return spring onto the drive pul ley inserting the en...

Page 228: ...k that the recoil starter for smooth operation by pulling the grip INSTALLATION Install the recoil starter assembly and tighten the four bolts Install the air cleaner housing page 5 5 ALTERNATOR STATO...

Page 229: ...TOOL Recoil pulley holder 07SMB HM70100 Remove the bolt O ring and the driven pulley Remove the nine bolts three sealing washer and alternator cover Remove the dowel pins and O ring IGNITION PULSE GEN...

Page 230: ...or and tighten the two bolts TORQUE 6 N m 0 6 kgf m 4 3 IbUt Connect the ignition pulse generator connector ALTERNATOR COVER INSTALLATION Install the dowel pins and a new O ring Check that the starter...

Page 231: ...stall the bolt Hold the starter driven pulley using the special tool and tighten the bolt TOOL Recoil pulley holder 07SMB HM70100 TORQUE 108 N m 11 0 kgf m 80 Ibf ft Install the recoil starter page 11...

Page 232: ...C starter reduction shaft Remove the flywheel and starter driven gear using the special tool TOOL Flywheel puller 07933 3950000 Remove the needle bearing washer and woodruff key_ STARTER CLUTCH DISAS...

Page 233: ...the starter clutch outer and sprag clutch for abnormal wear or damage Check the starter driven gear teeth and needle bear ing for wear or damage Measure the starter driven gear boss 0 0 SERVICE LIMIT...

Page 234: ...e bearing with molybdenum oil r l Install the washer and needle bearing onto the crankshaft Clean any oil from the tapered portions of the crank shaft and flywheel Install the woodruff key into the cr...

Page 235: ...ead 10 mm Remo ler weight 0793 GEOOI00 07936 GE00200 07741 0010201 or 07936 371020A or 07936 3710200 U S A only Be sure to press Drive a new bearing in the cover using the special the bearing in tools...

Page 236: ...MEMO...

Page 237: ...TRANSMISSION GEARSHIFT LINKAGE SYSTEM COMPONENTS 12 2 SERVICE INFORMATION 12 3 TROUBLESHOOTING 12 5 REAR CRANKCASE COVER 12 6 GEARSHIFT LINKAGE 12 8 SUB TRANSMISSION 12 12 GEARSHIFT LEVER LINKAGE 12 1...

Page 238: ...SUB TRANSMISSION GEARSHIFT LINKAGE SYSTEM COMPONENTS 12 2...

Page 239: ...ugh the oil passage in the rear crankcase cover Clean the oil passage before installing the rear crankcase cover SPECIFICATIONS TORQUE VALUES Gearshift lever box cover bolt Gearshift lever linkage arm...

Page 240: ...0201 or 07936 371020A U S A only or 07936 3710200 Attadlment 42 x 47 mm 07746 0010300 Pilot 25 mm 07746 0040600 12 4 Bearing remover 20 mm 01936 3710600 Driver 07749 0010000 Attachment 52 x 55 mm 0774...

Page 241: ...rooves Improperly adjusted tie rod length of gearshift lever linkage Bent tie rod of gearshift lever linkage Improperly installed gearshift spindle and drum Transmission jumps out of gear Worn gear do...

Page 242: ...and shafts page 11 12 starter motor page 21 6 vehicle speed sensor page 23 1 1 gear position switch page 24 39 engine side cover stay page 10 5 eleven bolts and rear crankcase cover dowel pins oil jo...

Page 243: ...rive new mainshaft and countershaft bearings in with the sealed side facing down using the special tools TOOLS Mainshaft bearing Driver Attachment 37 x 40 mm Pilot 17 mm Countershaft bearing Driver At...

Page 244: ...n the crankcase and cover mating surfaces Apply liquid sealant to the mating surface of the rear crankcase cover Install the rear crankcase cover and tighten the eleven bolts in a crisscross pattern i...

Page 245: ...hift drum while lowering the stopper arm with a screwdriver boll and setting plate gearshift spindle pivot bolt stopper arm washer and spring INSPECTION Check the shift fork guide pins for abnormal we...

Page 246: ...or damage Remove the bolt center plate shifter gear and dowel pin if necessary Install the dowel pin drum shifter gear and center plate Apply locking agent to the drum center bolt threads Install and...

Page 247: ...the setting plate and lighten the bolt Apply oil to the shift drum guide grooves lower t he stopper arm and installing the shih drum by aligning the index lug of the shift drum with the index line on...

Page 248: ...Remove the shift fork shaft and shift forks page 12 81 Remove the washers from the countershaft and reverse idle shaft Pull out the mainshaft from the automatic transmis sion unit Remove the countersh...

Page 249: ...SERVICE LIMIT D R l 0 10 mm O 004 inl Measure the gear bushing 1 0 SERVICE LIMIT D lR 25 04 mm 0 986 in Check the countershaft for abnormal wear or dam age Check the gear shifter for smooth operation...

Page 250: ...ushings Do not for J8 to Assemble the countershaft Install the washer onto the crankcase end of the shaft 12 14 Coat a new O ring with oil and install it into the groove in the automatic transmission...

Page 251: ...e crankcase Install the washers onto the reverse idle gear shaft and countershaft Install the shift forks and shaft page 12 8 GEARSHIFT LEVER LINKAGE GEARSHIFT LEVER BOX DRAINING Remove the fuel tank...

Page 252: ...bolt O ring and washer pinch bolt and gearshift arm from the spindle screw and reverse switch shift lever boot two mounting bolts and gearshift lever assem bly_ loosen the lock nuts and remove the tie...

Page 253: ...pivot and both mat ing surfaces of lever box and dust seal lips Assemble the base bracket gearshift lever box return spring and cover and tighten the two bolts TORQUE 5 N m 0 5 kgf m 3 6 IbUt Apply mo...

Page 254: ...IT U iiiiiil and tighten the two bolts L 12 18 Install the shift lever boot Install the reverse switch onto the base bracket and tighten the screw Put the gearshift lever in the neutral position Insta...

Page 255: ...ot centered loosen the lock nuts on the tie rod B and adjust the slide shaft position by turning the tie rod 8 Install the washer and secure the slide shaft with a new cotter pin Tighten all the tie r...

Page 256: ...MEMO...

Page 257: ...TRANSMISSION SYSTEM COMPONENTS 13 2 AUTOMATIC TRANSMISSION UNIT AND CRANKSHAFT 13 10 SERVICE INFORMATION 13 3 CRANKCASE BEARING TROUBLESHOOTING 13 6 REPLACEMENT 13 13 CRANKCASE SEPARATION 13 8 CRANKC...

Page 258: ...CRANKSHAFTIAUTOMATIC TRANSMISSION SYSTEM COMPONENTS 12 Ibf ft 12 N m 1 2 kgf m 9lbf ftl 13 2...

Page 259: ...ction lubricating oil is fed through the oil passage in the crankcase Clean the oil passages before assembling the crankcase halves Do not disassemble the automatic transmission unit Replace the autom...

Page 260: ...7 mm 07746 0010300 Pilot 17 mm 07746 0040400 13 4 Remover handle 07936 3710100 Driver 07749 0010000 Attachment 52 55 mm 07746 0010400 Pilot 20 mm 07746 0040500 Remover weight 0774 0010201 or 07936 371...

Page 261: ...I AUTOMATIC TRANSMISSION Pilot 32 mm 07MAD PR90200 Thread shaft 07965 VM00200 or Puller shaft 07931 ME40108J and Special nut 07931 HB3020A U S A only Universal bearing puller 07631 0010000 or equivale...

Page 262: ...l pressure page 4 6 Is the oil pressure correct NO Faulty lubrication system page 4 5 YES GO TO STEP 3 3 Centrifugal clutch inspection 1 Test drive the vehicle to check the engine speed and vehicle sp...

Page 263: ...he faulty part YES GO TO STEP 7 5 Sub transmission inspection 2 Check the operating condition in each sub transmission range Does the engine speed rise and stop both ranges YES GO TO STEP 6 NO Faulty...

Page 264: ...24 41 angle sensor joint two bolts and oil separate plate sprocket bolt oil pump driven sprocket and drive chain cam chain pivot bolt and cam chain tensioner washer and collar Temporarily install the...

Page 265: ...e them loosen the twelve front crankcase bolts in a criss cross pattern in several steps and remove them Place the crankcase assembly with the rear crank case down The dowel pin hole in the automatic...

Page 266: ...e the crankshaft and balancer from the rear damage rhe crankcase using a hydraulic press Be sure to hold crankcase fI1811fl J the crankshaft and balancer while pressing them surface and Qut of the cra...

Page 267: ...CE LIMIT 0 15 mm 0 006 in Measure the side clearance between the connecting rod big end and crank weight with a feeler gauge SERVICE LIMIT 0 8 mm 0 03 in Measure the radial clearance at the connecting...

Page 268: ...e page 13 13 Engage the balancer and crankshaft by aligning the index lines on the side surfaces of the balancer drive and driven gears and install the crankshaft and balancer together into the fear c...

Page 269: ...ssembly rotation of the pump motor shaft movement of the motor swash plate assembly and ball nut Install the dowel pin into the rear crankcase Install the automatic transmission unit and tighten the f...

Page 270: ...new bearings Drive the following bearings in with the marking side facing up using the special tools TOOLS Mainshaft bearing Driver Attachment 52 x 55 mm Pilot 30 mm Countershaft bearing Driver Attach...

Page 271: ...n with the marking side facing up using the special tools TOOLS Crankshaft bearing Driver Attachment 78 C 90 mm Pilot 40 mm Balancer bearing Driver Attachment 37 40 mm Pilot 17 mm Output shaft bearing...

Page 272: ...liquid sealant to the mating surface of the crankcase Install the two dowel pins Install the front crankcase over the fear crankcase Install the twelve front crankcase bolts and tighten them in a cris...

Page 273: ...t facing to the crankcase and by aligning the flats of the sprocket and pump shaft driven sprocket bolt apply locking agent to the threads TORQUE 12 N m 1 2 kgf m 9Ibf ft oil separate plale with two b...

Page 274: ...MEMO...

Page 275: ...HUB 14 18 SERVICE INFORMATION 14 4 SUSPENSION ARM 14 20 TROUBLESHOOTING 14 6 STEERING SHAFT Except EPS model 14 28 HANDLEBAR 14 7 STEERING SHAFT EPS UNIT THROTILE HOUSING 14 13 EPS model 14 34 FRONT...

Page 276: ...f m 29 bf tt 25 N m 2 6 kgf m 19Ibf ft 32 N m 3 3 kgf m 24 Ibf h 54 N m 5 5 kgf m 40 Ibf h 108 N m 11 0 kgf m 80 Ibf ft 78 N m 8 0 kgf m 58 Ibf ft 14 2 44 N m 4 5 kgf m 33 IbUt 44 N m 4 5 kgf m 33Ibf...

Page 277: ...Ibf ft 39 N m 4 0 kgf m 29Ibf h 54 N m 5 5 kgf m 40 Ibf h 108 N m 11 kgf m 8 O b f ft I 78 N m 8 0 kgf m 58 Ibf h FRONT WHEEL SUSPENSION STEERING 44 N m 4 5 kgf m 33 Ibf h 29 N m 3 0 64 N m 6 5 kgf m...

Page 278: ...ight case mounting nut Steering shaft end nut Steering shaft holder bolt Front master cylinder holder bolt EPS unit output shaft nut EPS model EPS unit mounting bolt EPS model EPS unit mounting nut EP...

Page 279: ...mm 07746 0010400 Pilot 30 mm 07746 0040700 FRONT WHEEL SUSPENSION STEERING Ball joint remover installer 07WMF HNOOtOO Attachment 28 x 30 mm 07946 1870100 Attachment 22 x 24 mm 07746 0010800 Pilot 22...

Page 280: ...nment Unequal tire pressure Bent tie rod suspension arm or frame Worn or damaged knuckle bearing Weak shock absorber Front wheel wobbling Bent rim Worn or damaged knuckle bearing Faulty tire Wheel hub...

Page 281: ...wo bolts master cylinder holder Keep the brake front brake master cylinder master cylmder upflght to prevent air from entering rhe hydraulic s ystem two screws bracket holder feaf parking brake lever...

Page 282: ...p ends HANDLEBAR GRIP BOLT handlebar grips GRIP After 07 grip ends turn the grip end to release the setting G R P tabs from the holes in the handlebar and pry it using a screwdriver handlebar grips HO...

Page 283: ...ebar upper holders handlebar INSTALLATION Place the handlebar onto the lower holders and align the punch mark on the handlebar with the top of the lower holder Install the upper holders with the bolt...

Page 284: ...SION STEERING Install the handlebar rear cover and tighten the two bolts Install the handlebar front cover and tighten the two g nuts 14 10 Install the handlebar upper cover and tighten the screw HAND...

Page 285: ...nstall the grip Rotate the 0 dry for an hour grip for even application of the adhesive before using 05 07 Install the grip ends and tighten the bolts After 07 Install new grip ends by aligning their t...

Page 286: ...nstall the front brake master cylinder and holder with the UP mark facing up Align the edge of the master cylinder with the punch mark on the handlebar and tighten the upper bolt first then tighten th...

Page 287: ...sing bottom ASSEMBLY Coal a new dust seal lip with grease and install it into the throttle housing until it is fully seated Apply grease to the throttle lever pivot Apply grease to the throttle cable...

Page 288: ...er adjustment the freeplay FRONT WHEEL REMOVAL Do nor Interchange the left and right tlfes 14 14 Loosen the wheel nuts Place the support block under the frame to raise the front wheel off the ground R...

Page 289: ...ust the bottom rim supports to the proper rim size Align the flat side of the support with the corre sponding rim size indicator l ube the bead area of the tire with water pressing down on the tire si...

Page 290: ...NOTE Use the manufacturer s instructions for the tire repair kit you are using If your kit does not have instructions use the procedures provided hear Check the tire for puncturing objects Chalk mark...

Page 291: ...tire page 14 15 and apply a cold patch to the inside of the tire as described If a plug has been inserted trim it even with the inner tire surface Temporarily place a rubber patch that is at least twi...

Page 292: ...t 1 hour and inflate the tire to the specified pressure RECOMMENDED TIRE PRESSURE 05 07 Front Standard 25 kPa 0 25 kgf cm2 3 6 psi Minimum 22 kPa 0 22 kgf cm2 3 2 psi Muimum 28 kPa 0 28 kgf cm2 4 0 ps...

Page 293: ...brake disc Remove the dust seal ASSEMBLY Apply grease to a new dust seal lip and install it to the hub BOLTS Install the brake disc and tighten the new disc plate A bolts to the specified torque S BOL...

Page 294: ...ll a new cotter pin Install the front brake caliper page 16 14 Install the front wheel page 14 14 SUSPENSION ARM REMOVAL 14 20 Remove the wheel hub page 14 18 Remove the brake disc guard bolts and bra...

Page 295: ...not damage the ball joint boot If necessary apply Adjust the jaw spacing by turning the pressure bolt penetrating rype lubricant to loosen the oolljoml To prevent the tool from dropping tie the strap...

Page 296: ...rd if necessary Remove the following front shock absorber lower mounting nut and bolt pivot nut bolt and upper arm pivot nuts bolts and lower arm INSPECTION UPPER LOWER ARM Remove the dust seal caps a...

Page 297: ...e with your finger The bearing should turn smoothly and quietly Also check that the bearing ouler race fits tightly in the knuckle Inspect the knuckle for damage or cracks Inspect the ball joint boot...

Page 298: ...de of the remover installer facing to the ball joint as shown Press the ball joint into the upper arm until it is fully seated TOOLS Ball joint removerlinstaller Attachment 15 mm 1 0 07WMF HNOO100 077...

Page 299: ...joint in a vise as shown Press the ball joint into the knuckle until it is fully 1 _ __ _ 1 seated TOOLS Ball joint remover installer Attachment 15 mm 1 0 07WMF HNOO100 07746 0020200 If you feel stro...

Page 300: ...x 55 mm Pilot 30 rnm 07749 0010000 07746 0010400 07746 0040700 Install the snap ring into the knuckle groove with the chamfered edge faci ng Apply grease to a new outer dust seal lip and install it us...

Page 301: ...f m 25 Ibf ft Connect the shock absorber to the upper arm with the lower mounting bolt and a new nut and tighten the nut TORQUE 44 N m 14 5 kgf m 33 Ibf ft Install the lower arm into the frame with th...

Page 302: ...uard and tighten the brake disc guard bolts Install the wheel hub page 14 8 Install the front wheel page 14 14 then place the vehicle on level ground Tighten the lower arm pivot nuts to the specified...

Page 303: ...shah cylmder reservoir upflgh Remove the cotter pins Remove the tie rod ball joint nuts while holding the joint stud flats with an open end wrench Remove the tie rods from the steering shaft arm Remo...

Page 304: ...8 and shaft INSPECTION Check the steering shaft bushing for wear or dam age Check the steering shaft for distortion or damage Turn the inner race of the steering shaft bearing with your finger The be...

Page 305: ...rive the steering shaft bearing out of the frame Drive in a new bearing squarely with the marked side facing up until it is tully seated TOOLS Driver Attachment 42 C 47 mm Pilot 22 mm 07749 0010000 07...

Page 306: ...t with the Harrow Hmark facing up Install steering shaft holder B onto the frame Install the steering shaft into the shaft bearing Install steering shaft holder A Install and tighten the two bolts TOR...

Page 307: ...s Install the handlebar assembly onto the steering shaft with the washers and new lower holder nuts and tighten the nuts TORQUE 39 N m 4 0 kgf m 29 Ibf ft Install the meter assist headlight assembly o...

Page 308: ...Remove the control motor 2P connector from the frame and position it to allow room for EPS unit removal Remove the following bott and brake hose clamp cable and wire harnesses from the guide clip Kee...

Page 309: ...NSION STEERING loosen mounting bolts and nuts Remove the following brake hose from the hose dip two bolts steering shaft holder A steering shaft bolt steering shaft steering shaft bushing steering sha...

Page 310: ...WHEEL SUSPENSION STEERING 14 36 coner pin nut washer steering shaft arm mounting bolts and nuts Remove the EPS unit from the frame to teh side INSPECTION Check the steering shaft bushing for wear or d...

Page 311: ...unit input shaft and output shaft for wear or damage Turn the inner race of the output shaft bearing with your finger The bearing should turn smoothly and quietly Also check that the bearing outer rac...

Page 312: ...orm gear splines with 0 5 9 of specified grease page 24 Coat a new D ring with silicone grease and install it Install the EPS motor onto the EPS unit Install the bolts and tighten them TORQUE 20 N m 2...

Page 313: ...facing up until it is fully seated using the spe COMPRESSOR cial tools and a 10 mm washer as shown BOLT TOOLS Clutch compressor attachment 01LAE PX40100 Compressor bolt assembly 07GAE PG40200 Attachme...

Page 314: ...pecified torque TORQUE 108 N m 11 0 kgf m 80 Ibf ft Install a new cotter pin Apply 2 3 9 of grease to the shaft bushing inner surface Install the shaft bushing onto the steering shaft with the arrow m...

Page 315: ...to the specified torque TORQUE BOLTS 22 N m 12 2 kgf m 16 Ib ftl NUTS 22 N m 1 2 2 kgf m 161bf ftl Install the tie rods into the steering shaft arm Install new ball joint nuts and tighten them by hol...

Page 316: ...page 22 4 Refer omfom18 10f Perform the Torque Sensor Initialization for the torque page 25 13 sensor InitJallzatlOl1 chan page 2 13 TIE ROD 14 42 REMOVAL Remove the inner fenders page 2 9 Remove the...

Page 317: ...for toe adjust ment side of the tie rod and the left hand threads nut and l marked ball joint on the opposite side TheballJOmr Hand tighten the lock nuts and measure the dis posItions afe IBO tance b...

Page 318: ...ehicle with a support block to raise the front wheels off the ground Support the suspension arm or front wheel and remove the upper and lower mounting nuts bolts and shock absorber INSPECTION Check th...

Page 319: ...e needle bearing in the lower pivot side facing up until the depth from the lower pivot outer surface is 5 4 5 5 mm 0 21 0 22 in using the special tools TOOLS Driver Attachment 22 x 24 mm Pilot 16 rnm...

Page 320: ...rease to new dust seal lips and install the dust seals into the lower pivot until they are flush with the pivot surfaces Install the pivot collar INSTALLATION Install the front shock absorber in the f...

Page 321: ...15 REAR WHEEL SUSPENSION SYSTEM COMPONENTS 15 2 REAR WHEEL 15 6 SERVICE INFORMATION 15 3 REAR SHOCK ABSORBER 15 6 TROUBLESHOOTING 15 5 SWINGARM 15 9 15 1...

Page 322: ...YSTEM COMPONENTS f __ 34 N m 3 5 kgf m 25 Ibf ft 64 N m 6 5 kgf m 47 Ibf ft 44 N m 4 5 kgf m 32 Ibf ft 112 N m 11 4 kgf m 82Ibf ft 05 06 10 N m 7 Ibf ft After 06 3 9 N m 0 4 kgf m 0 9 Ibf ft 2 N m 11...

Page 323: ...torque wrench reading will be less than the torque actually applied to the lock nut The specification given is the actual torque applied to the lock nut not the reading on the torque wrench Do not ove...

Page 324: ...B0200 15 4 Attachment 37 x 40 mm 07746 0010200 Lock nut wrench 07908 4690003 Driver shaft 07949 3710001 Attachment 22 x 24 mm 07746 0010800 Adjustable bearing remover 20 x 40 mm 07JAC PH80100 or 07736...

Page 325: ...side or does not track straight Unequal tire pressure Bent swingarm or frame Weak shock absorber Soft suspension Weak shock absorber spring Faulty shock absorber damper Hard suspension Bent shock abs...

Page 326: ...tire removal installation and repair refer to page 14 15 INSTALLATION Install the wheel with the arrow mark facing in the normal rotating direction Install the wheel nuts and tighten them TORQUE 64 N...

Page 327: ...d lower pivot collar for wear or damage After 06 Check the lower pivot bushing for wear or damage BEARING REPLACEMENT 05 06 Remove the lower pivot collar Remove the dust seals Press the needle bearing...

Page 328: ...mm 07949 3710001 07746 0010800 07746 0041300 Apply grease to new dust seal lips and install them into the lower pivot Install the lower pivot collar BUSHING REPLACEMENT After 06 Press the bushing out...

Page 329: ...ll the rear shock absorber onto upper mounting stud of the frame Install the lower mounting bolt and tighten it TORQUE 44 N m 4 5 kgf m 33 Ibf ft Install the washer and upper mounting nut and tighten...

Page 330: ...light switch Remove the left and right swingarm pivot caps Remove the right pivot lock nut using the special tooL TOOL lock nut wrench 07908 4690003 Remove the left and right pivot bolts Remove the u...

Page 331: ...and for wear or damage grease holders must be replaced as 8 sellf any pan IS damaged 0 wom After 06 Remove the dust seals from the swingarm Check the dust seals for wear or damage REAR WHEEL SUSPENSIO...

Page 332: ...bearing remover 20 x 40 mm 07JAC PH80100 Adjust able bearing remover shaft 07JAC PH80200 Remover weight 07741 0010201 U S A only Adjustable bearing puller 24 x 40mm 3 8 x 16 Slide hammer 07736 A01000B...

Page 333: ...nd bearing cavities with 3 r 9 of molybdenum disulfide grease After 06 Apply molybdenum disulfide grease to the dust seal lips and install the dust seals in the swingarm using the special tools TOOLS...

Page 334: ...kgf m 7 Ibf ft After OS 3 9 N m 0 4 kgf m 0 9 IbUt Move the swingarm up and down several times to seat the pivot bearings Retighten the pivot bolts to the same torques Tighten the right pivot lock nut...

Page 335: ...Route the breather hoses properly page 1 24 and secure them with the clamps Install the final drive assembly page 18 21 REAR WHEEL SUSPENSION 15 15...

Page 336: ...MEMO...

Page 337: ...NENT LOCATION 16 2 FRONT MASTER CyLINDER 16 8 SERVICE INFORMATION 16 3 BRAKE PAD DISC 16 13 TROUBLESHOOTING 16 5 FRONT BRAKE CALIPER 16 14 BRAKE FLUID REPLACEMENT REAR BRAKE 16 19 AIR BLEEDING 16 6 BR...

Page 338: ...BRAKE SYSTEM COMPONENT LOCATION 20 N m 2 0 kgf m 14 Ibf h 137 N m 1 4 0 kgf m 101 IbUt 34 N m 3 5 kgf m 11 N m 1 1 kgf m 8Ibf ft 16 2...

Page 339: ...V C E L M T DOT 4 brake flui 14 000 14 043 0 55 2 0 55 9ii 1__ _ 4Ci 0i 5 5 ii10 i 5 5 331 13 957 13 984 0 5495 0 55061 __ i 3 i 94i 5TiI O 54 i 9iiO 1 3396 34 01 1337 339 34 02 1 3394 Master cylinder...

Page 340: ...BRAKE SYSTEM TOOLS Snap ring pliers 07914 SA50001 Pilot 28 mm 07746 0041100 16 4 Driver 07749 0010000 Oit seal driver attachment 07JAO PH80101 Anachment 78 x 80 mm Q7NAD PX40100...

Page 341: ...operly adjusted brake Worn brake shoe drum Contaminated brake shoe drum Warped deformed brake drum Bent brake lever pedal Front brake lever hard Clogged restricted hydraulic system Sticking worn calip...

Page 342: ...types of fluid They are not compatible BRAKE FLUID DRAINING With the fluid reservoir paraliel to the ground remove the reservoir cover diaphragm plate and diaphragm Connect a bleed hose to the bleed...

Page 343: ...ith Teflon tape If a brake bleeder is not available fill the master cylinder and operate the brake lever to fill the system Close the bleed valve Next perform the available BLEEDING procedure see belo...

Page 344: ...g over these parts whenever the system IS servICed 16 8 Remove the reservoir cover diaphragm plate dia phragm and f108t and soak up the brake fluid from the reservoir page 16 6 Disconnect the brake sw...

Page 345: ...ever Remove the screw brake switch bracket and brake light switch Remove the master piston boot BOOT BR E LEVER SCREW BOOT Remove the snap ring from the master cylinder using the special tool SNAP RIN...

Page 346: ...ston cups spring snap ring and boot as a set do not substitute individual parts Coat all parts with clean brake fluid before assem bly Install the secondary cup into the master piston groove Install t...

Page 347: ...light switch Install the bracket onto the brake light switch Install the brake light switch by aligning the hole of the bracket and boss of the brake switch BOOT Align Align Apply locking agent to th...

Page 348: ...the pivot bolt and tighten the pivot nut to the specified torque TORQUE 5 9 N m 0 6 kgf m 4 4 Ibf ft Install the brake lever boot Place the master cylinder on the handlebar Install the master cylinde...

Page 349: ...ated pads and clean a contaminated disc with a high quality brake degreasing agent Be careful that the master cylinder does not over flow when the caliper pistons are compressed Brake fluid can cause...

Page 350: ...12 in Replace the brake disc if the smallest measurement is less than the service limit page 14 18 Check the brake disc for warpage SERVICE LIMIT 0 30 mm 0 012 in Check the front wheel hub bearings f...

Page 351: ...hose from the brake caliper Remove the mounting bolts and brake caliper OISASSEMBLY Remove the brake caliper slide pin bolts Remove the caliper bracket pad spring and boots Remove the pad spring BRAKE...

Page 352: ...h excessive force that could cause injury Use the air in short spurts Be careful not to damage the piston sliding surface Push the piston seal in and lift it out Clean the seal grooves caliper piston...

Page 353: ...with silicone grease Install the piston seal and dust seal into the groove of the caliper body Coat the caliper piston with clean brake fluid and install it into the caliper cylinder with its closed e...

Page 354: ...N m 4 5 kgf m 33 Ibf ft BOLTS Install the brake hose eyelet to the caliper body with rs j E H OSE new sealing washers and oil bolts 16 18 Push the brake hose eyelet to the stopper on the cal iper then...

Page 355: ...emove the right rear hub nut and wheel hub Remove the bolts and brake drum cover Remove the brake drum cover D ring Remove the brake drum INSPECTION Measure the brake drum J D SERVICE LIMIT 181 mm 7 1...

Page 356: ...ove the dust seal from the wheel hub Apply grease to a new seal lips and install it into the wheel hub with the flat side facing in until it is fully seated Install a new dust seal into the drum cover...

Page 357: ...es to indICate and shoe springs their original POSlflons before removing them Remove the adjusting nuts brake cables springs and joint pins from the brake arm Remove th e brake arm pinch bolt nut and...

Page 358: ...ve the a ring from the brake panel groove BRAKEPANEL BEARING REPLACEMENT Turn the inner race of the bearing with your finger The bearing should turn smoothly and quietly Also check that the outer race...

Page 359: ...l tools as shown TOOLS Driver Oil seal driver attachment Pilot 28 mm 07749 0010000 07JAD PH80101 07746 0041100 Install the snap ring into the groove Pack a new dust seal lips with grease Install the d...

Page 360: ...KE CAM tI BRAKE DRUM conER Coat a new O ring with grease and install it in the brake panel groove Install the brake panel onto the axle housing Donor reuse fila Install and tighten the new nuts nuts C...

Page 361: ...ide groove on the brake cam Install the brake arm aligning the punch marks on the brake arm and cam Hook the return spring end onto the brake arm Tighten the brake arm pinch bolt nut to the specified...

Page 362: ...n install the brake cables and springs InSlalithe adjusting nuts BRAKE DRUM INSTALLATION Apply molybdenum disulfide grease to the axle splines and install the brake drum Apply grease to a new O ring a...

Page 363: ...until its grooves align with the cotter pin hole in the axle shaft Install a new cotter pin and secure the hub nut Install the rear wheel page 15 6 Adjust the rear brake lever and pedal freeplay page...

Page 364: ...rom the pedal iiiAiiHiER pivot shaft then remove the brake pedal from the shaft Remove the dust seals INSTALLATION Apply grease to the brake pedal pivot shaft sliding surface and dust seal lips Instal...

Page 365: ...Install and connect the brake cable Hook the return spring Install the brake light switch Hook the brake light switch spring Install the brake light switch guard and lighten the bolt Adjust the rear...

Page 366: ...MEMO...

Page 367: ...TS 17 2 SERVICE INFORMATION 17 3 TROUBLESHOOTING 17 6 FRONT DRIVE SHAFT 17 7 DIFFERENTIAL REMOVAL 17 14 DIFFERENTIAL DISASSEMBLYI INSPECTION 17 17 CASE BEARING REPLACEMENT 17 24 DIFFERENTIAL ASSEMBLy...

Page 368: ...ENTS 44 N m 4 5 kgf m 33 Ibf h j 7 N m 0 7 kgf m 5 1 tbf h 10 N m 1 0 kgf m 7 Ibf ft 22 N m 2 2 kQf m 16Ibf ft 10 N m 1 0 kgf m 7Ibf ft 22 N m 2 2 kgf m 1Slbf tt 17 2 44 N m 4 5 kgf m 33 Ibf ft kgf m...

Page 369: ...height 2 8 0 11 2 6 0 10 TORQUE VALUES Upper and lower arm ball joint nut Front wheel hub nut Differential ring gear bolt Differential case cover 10 mm bolt Differential case cover 8 mm bolt Differen...

Page 370: ...07MAC SL0202 U SAonly or 07MAC SLQ0200 and 07MAC SLOA300 U S Aonly 17 4 Attachment 22 x 24 mm 07746 0010800 Pilot 15 mm 07746 0040300 Remover shah 07936 KC10100 Bearing remover head 30 mm 07936 889030...

Page 371: ...A only Differential bearing clip compressor 07YME HN4010A U S A only Press attachment 07LME GE20100 o Driver 40 mm I D 07746 0030100 Driver shaft 07949 3710001 FRONT DRIVING MECHANISM Anachment 30 mm...

Page 372: ...h contact between ring gear and pinion gear Gear noise while coasting Chipped or damaged gears Abnormal noises when turning Worn or damaged ring gear bearing Worn or damaged face cams and cam follower...

Page 373: ...pin Remove the tie rod ball joint nut while holding the joint stud flats with an open end wrench Remove the tie rod from the knuckle Remove the two bolts and splash guard Remove the cotter pins and l...

Page 374: ...ard joint Support the wheel hublknuckle assembly so that it does not hang from the brake hose Hold the inboard joint of the drive shaft and tug firmly to force the stopper ring in the drive shaft end...

Page 375: ...ove the boot band B emovlng them Remove the boot from the inboard joint RemOve the following stopper ring inboard joint snap ring bearing inboard boot boot band C Replace the Check the following for w...

Page 376: ...outboard side Remove boot band A Remove the boot from the outboard joint ASSEMBLY DRIVE SHAFT c OUlrBO RD BOOT INBOARD JOINT I BAND C OUTBOARD BOOT RING BEARING CAGE INBOARD BOOT BAND C I The outboard...

Page 377: ...the bearing with the small 0 0 facing the drive shaft Install the snap ring with the chamfered side facing the bearing Pack the inboard joint with 55 75 9 05 06 40 60 9 After 06 of molvbdenum disulfid...

Page 378: ...e inboard joint boot direction Bend down the band end and secure it with the lock tabs Tap the lock tabs with a plastic hammer Install a new boot band C and a new outboard boot band onto the outboard...

Page 379: ...pension arms linmgs Install hub nut and temporarily tighten the nut Install and tighten each joint nut to the specified torque and further tighten until its grooves align with the cotter pin holes Do...

Page 380: ...ub nut to the specified torque and fur ther tighten until its grooves align with the cotter pin hole TORQUE 78 N m 8 0 kgf m 58 Ibf ft Install a new cotter pin Install the front wheel page 14 14 DIFFE...

Page 381: ...vehicle speed sensor Disconnect the front final clutch 2P Green connec tor Disconnect the front differential case breather hose Remove the differential case mounting 8 mm bolt and nUl Remove the bolt...

Page 382: ...er shaft joint and engine Pull the propeller shaft joint out of the output shaft of the engine Remove the O ring Remove the boot band and propeller shaft boot from the pinion joint Pull the propeller...

Page 383: ...e the propeller shaft joint and spring Check the splines of the propeller shaft and joint for wear or damage If damaged check the output shaft and the pinion jOint also Check the seal rubbers for fati...

Page 384: ...backlash Repeat this procedure once more Compare the difference of the three measure ments SERVICE LIMIT 0 2 mm 0 01 in If the difference in measurements exceeds the ser vice limit it indicates that t...

Page 385: ...sing a screwdriver and remove the cover Remove the differential assemblv and shims Remove the O ring BEARING INSPECTION Turn the inner race of each bearing in the gear case and cover with your finger...

Page 386: ...everal steps until the cover evenly touches the gear case Then while rotating the pinion gear tighten the bolts to the specified torque in a crisscross pattern in several steps TORQUE 10 mm bolt OS 01...

Page 387: ...TION Install the inspection tools into both sides of the dif ferential TOOL Slip torque inspection tool 07KMK HC50101 or 07KMK HC5010A U S A only Hold the flat surface of the tool with a vise Attach a...

Page 388: ...am followers B right face cam DIFFERENTIAL COMPONENTS INSPECTION RING GEAR SIDE CONE SPRING RING GEAR SHIM CAM FOLLOWERS A AND B LEFT FACE RIGHT FACE CAM Check the sliding surface of the ring gear for...

Page 389: ...rily assemble the differential housing face cams and cam followers page 17 29 1 47 kN 150 kgf Measure the height of the face cam from the hous ing mating surface as shown while applying a load of 1 47...

Page 390: ...m bly using the special lools TOOLS Driver Pilot 15 mm 07749 0010000 07746 0040300 Heal the final clutch to about 100 C 212 F Remove the pinion gear bearing from the final dutch using the special tool...

Page 391: ...nch to bent the end upward Grasp the end of the ring with needle nosed pliers and pull the stopper ring out through the access hole Be sure to wear Heat the gear case to about BO C 176 F and heavy glo...

Page 392: ...aring and tool assembly into a freezer L __ C _ O _ M _PR _E _S _S _O _ R ___N _ E_ E_ D_ L_ E_ B _ E _ A _R _ _ N_ G __ for 81 least 30 minutes Heat the gear case to 80 C 1760 Fl Take out the bearing...

Page 393: ...INION BEARING PINION SHIM 05 07 49 N m 5 0 kgf m 36Ibf f1 RING GEAR PINION GEAR Aher 07 46 5 N m 14 7 kgf m 34 Ibf ft D RING RING GEAR SHIM DIFFERENTIAL CASE RING GEAR SHIM STOPPER RING GEAR CASE ijji...

Page 394: ...ARING Be careful no 10 Press the pinion gear bearing assembly into the damage the 01 seal front final clutch using the special tools ATIACHMENT lips If the mal clutch TOOLS Universal bearing puller Pr...

Page 395: ...ring gear page 17 22 and the height of the housing la cam page 17 23 and record them Calculate the shim thickness using the equation below The correct shim is nearly this dimension A B C 1 Bmm A New s...

Page 396: ...lv when the replacement shim is changed by 0 3 mm or more from the selected shim page 17 29 DIFFERENTIAL CASE ASSEMBLY When the gear set bearing differential housing andlor gear case has been replaced...

Page 397: ...m 34Ibf ft 8 mm bolt 25 N m 2 6 kgf m 19 Ibf ftJ Make sure that the gear assembly rotales smoothly without binding PROPELLER SHAFT ASSEMBLY PINION JOINT SEAL RUBBER 15 89 Apply molybdenum disulfide gr...

Page 398: ...fferen tial until the stopper ring seats in the pinion joint groove Make sure that the stopper ring is seated properly by pulling on the pinion joint lightly Install the propeller shaft boot over the...

Page 399: ...d nut Install the mounting bracket 8 mm bolts 8 mm r mounting bolt and nut i First tighten the differential case mounting bracket bolts to the specified torque TORQUE 22 N m 2 2 kgf m 16Ibf ft Tighten...

Page 400: ...rear speed sensor wire and front final clutch wire Install the clutch cover while hooking it on the boss um Hcc v jl on the case and install and tighten the two bolts to the specified torque TOROUE 7...

Page 401: ...FORMATION 18 3 TROUBLESHOOTING 18 6 REAR AXLE REMOVAL 18 7 FINAL DRIVE REMOVAL 18 9 FINAL DRIVE DISASSEMBLYI INSPECTION 18 10 FINAL GEAR CASE BEARING REPLACEMENT 18 16 FINAL DRIVE ASSEMBLy 18 18 FINAL...

Page 402: ...REAR DRIVING MECHANISM SYSTEM COMPONENTS 137 N m 14 0 kgf m 101 Ibf ft 54 N m 5 5 kgf m 40 IbHt 44 N m 4 5 33 Ibf ft 44 N m 4 5 kgf m Ibf ft 32 N m 3 3 kgf m 24 Ibf ftl 18 2...

Page 403: ...set SPECIFICATIONS Unit mm in ITEM STANDARD SERVICE LIMIT Axle runout 3 0 0 12 Rear final Oil capacity After draining 75 cm 2 5 US oz 2 6 Imp oz drive After disassembly 100 cms 3 4 US oz 3 5 Imp oz Re...

Page 404: ...earing compressor clip 07YME HN4010A U S A only 18 4 Attachment 52 55 mm 07746 0010400 Pilot 32 mm 07MAD PR90200 Pilot 14 mm 07746 0041200 Lock nut wrench 30 x 64 mm 0791S MB00002 Attachment 62 x 68 m...

Page 405: ...ng remover head 14 mm 07WMC KFG0100 Oil seal driver 07965 KE8020a or 07947 KA50100 U S A only Driver 40 mm J D 07746 0030100 Remover shaft 07936 KC10100 REAR DRIVING MECHANISM Attachment 30 mm I D 077...

Page 406: ...rn or damaged drive shaft propeller shaft or universal joint Worn pinion and ring gears Excessive backlash between pinion and ring gears Oil level too low Wobble or vibration in vehicle Axle not tight...

Page 407: ...rings brake cables four nuts discard them Do nor get grease brake panel assembly on the shoe Immgs D ring cotter pin hub nut left wheel hub three bolts and skid plate left shock absorber lower mountin...

Page 408: ...and brake panel Turn the inner race of each bearing with your finger The bearings should turn smoothly and quietly Also check that the bearing outer race fits tightly in the housing or panel BEARING R...

Page 409: ...upport the swingarm and remove the right shock absorber lower mounting bolt Remove the eight nuts four bolts and right axle housing Remove the D ring from the final drive gear case Disconnect the brea...

Page 410: ...y and quietly without bind ing If the gears do not turn smoothly or quietly the gears and or bearing may be damaged or faulty They must be checked after disassembly replace faulty partsJ assemblies as...

Page 411: ...rings and case If the backlash is excessive replace the ring gear right side shim with a thinner one If the backlash is too small replace the ring gear right side shim with a thicker one Backlash chan...

Page 412: ...ring gear bearing replacement see page 18 12 GEAR TOOTH CONTACT PATTERN CHECK Keep dUSf anddlrr Clean sealing material off the mating surfaces of the ourofrhecas8and gear case and cover being careful...

Page 413: ...on Contact is normal if the Prussian Blue is transferred to the approximate center of each tooth but slightly to the heel side and to the flank side If the patterns are not correct remove and change t...

Page 414: ...d past the groo e in the pinion jOint Remove the oil seal from the gear case Be careful rhat Unstake the pinion gear bearing lock nut with a drill metal partICles do or grinder nor enter the beanng an...

Page 415: ...e pinion gear bearing from the shaft with a commercially available bearing puller Remove the pinion gear shim Install the shim and bearing onto the pinion gear When the gear set ring gear bearing and...

Page 416: ...cover Drive new bearings in the case and cover using the special tools TOOLS Driver Attachment 62 x 68 mm Pilot 35 mm 07749 0010000 07746 0010500 07746 0040800 ApplVgrease to new oil seal lips Drive t...

Page 417: ...tool TOOLS Bearing remover head 14 mm 01WMC KFG0100 Remover shaft 07936 KC10100 gear case may cause warpage Remover weight 07741 0010201 07936 3710200 or 07936 371020A U S A only USing rape attach the...

Page 418: ...E ASSEMBLY GEAR CASE PINION NEEDLE BEARING OIL SEAL DRAIN BOLT BEARING STOPPIN Ir PINIONGEAA i SHIM O RING STOPPER RING PINION JOINT BEARING mm 18 18 PINION BEARING LOCK NUT BEARING G007 NEEDLE BE R G...

Page 419: ...al r wrench reading tool mformalion on page 18 3 Service TOOL Information lock nut wrench 30 x 64 mm 07916 MB00002 TORQUE Actual 98 N m 10 0 kgf m 72 Ib tt Indicated 89 N m 9 1 kgf m 66 Ib ft Be caref...

Page 420: ...ing gear If the clearance is without the standard value heat the case cover to approximately BOaC 176 F and remove the stop pin by tapping the cover Install a stop pin shim to obtain the correct clear...

Page 421: ...stall the case cover and tighten the bolts in several steps until the cover evenly touches the gear case Then while rotating the pinion gear tighten the bolts to the specified torque in a crisscross p...

Page 422: ...e NUTS Coat a new O ring with grease and install it into the groove in the gear case 11 _ 8 11 o Install the right axle housing onto the gear case and 5wingarm with the four bolts and eight new nuts T...

Page 423: ...Install the side collar onto the rear axle with the tapered side facing inward Install the left axle housing with four new nuts and tighten the nuts TORQUE 44 N m 4 5 kgf m 33 Ibf ft Install the left...

Page 424: ...ease and install it into the P I111 brake panel groove Do not gel grease Install the brake panel assembly onto the axle on the brake shoe Immgs 18 24 Install new brake panel nuts and lighten them TORQ...

Page 425: ...CHARGING SYSTEM COMPONENT LOCATION 19 2 BATTERy 19 6 SYSTEM DIAGRAM 19 2 CHARGING SYSTEM INSPECTION 19 7 SERVICE INFORMATION 19 3 ALTERNATOR CHARGING COIL 19 8 TROUBLESHOOTING 19 5 REGULATOR RECTIFIER...

Page 426: ...BATIERY CHARGING SYSTEM COMPONENT LOCATION BATTERY FUSE RECTIFIER SYSTEM DIAGRAM 51 y y y y Y Y R G I I I I I REWTM RECT tFIER 19 2 ALTF NAT n R e IlATTERY G Green A Red Y Yellow...

Page 427: ...ll drop quickly and eventually die out For this reason the charging system is often suspected as the problem Battery overcharge often results from problems in the battery itself which may appear to be...

Page 428: ...BATIERY CHARGING SYSTEM TOOLS Motorcycle battery analyzer Micro 404XL U S A only 19 4 Christie battery charger MC1012J2T U S A only...

Page 429: ...orted wire harness Faulty ignition switch 4 Charging Vottage Inspection Measure and record the battery voltage using a digital multimeter page 19 6 Start the engine Measure the charging voltage page 1...

Page 430: ...dielectric grease Install the terminal cover to the position terminal securely VOLTAGE INSPECTION Remove the seat page 2 4 Measure the battery voltage using a commercially available digital multimete...

Page 431: ...shorted circuit is likely Locate the short by disconnecting connections one by one and measuring the current CHARGING VOLTAGE INSPECTION Remove the seat page 2 4 Be sure the battery is in good conditi...

Page 432: ...ARD 0 1 1 0 n at 20 C 68 F Check for continuity between each Yellow wire ter minal of the alternator side connector and ground There should be no continuity Replace the alternator stator if resistance...

Page 433: ...k connector and ground There should be continuity at all times CHARGING COil LINE Measure the resistance between the Yellow wire terminals of 3P GRAY connector STANDARD 0 1 1 0 n at 20 C 68 F Check fo...

Page 434: ...MEMO...

Page 435: ...20 IGNITION SYSTEM COMPONENT LOCATION 20 2 IGNITION SYSTEM INSPECTION 20 5 SYSTEM DIAGRAM 20 2 IGNITION COIL 20 7 SERVICE INFORMATION 20 3 IGNITION TIMING 20 8 TROUBLESHOOTING 20 4 20 1...

Page 436: ...ENGINECONTAOL MODULE EeM ocP PLUG IGNITION PULSE GENERATOR R U G lY llBl BI R TIfl JTTLE ENGIMf WiTRIl mu EeM 20 2 e POSITlI BATTERY BIIY Bu Y G BI 1 8I G 4P R lm l 3 I 1 111111 roll Sf It 1 I L _ _...

Page 437: ...results in a slower engine cranking speed as well as no spark at the spark plug This vehicle s spark plug is equipped with iridium type electrode Do not use any spark plug other than specified 11 8 f...

Page 438: ...ing of the tester and measured pulse were not synchronized System is normal if measured voltage is over the standard voltage at least once 5 Poorly connected connectors or an open circuit in the ignit...

Page 439: ...before this inspec tion Poor connected connectors can cause incor rect readings Check the cylinder compression and check that the spark plug is installed correctly in the cylin der head Disconnect the...

Page 440: ...w termi ExceptEPS ECM CONNECTOR Viewed bend the conll9ClOf nal of the wire harness side and ground model from the terminal side terminals EPS model Disconnect the 21 P Grey EPS ECU connector 20 6 Conn...

Page 441: ...l and the one measured at the alternator connector is normal the Blue yellow wire has an open or short circuil or loose con nection If both peak voltages are abnormal follow the checks described below...

Page 442: ...et it idle 1 400 rpm min and check the ignition timing The ignition timing is correct if the F mark on the flywheel aligns with the index mark on the rear crankcase cover at idle Increase the engine s...

Page 443: ...COMPONENT LOCATION 21 2 SYSTEM DIAGRAM 21 2 SERVICE INFORMATION 21 3 TROUBLESHOOTING 21 4 21 ELECTRIC STARTER STARTER MOTOR 21 6 STARTER RELAY SWiTCH 21 12 DIODE 21 13 21 1...

Page 444: ...NGINE STOP SWITCH ECM BATTERY FUSE 130 AI f lrl STARTER SWITCH STARTER MOTOR SYSTEM DIAGRAM L l lOA SlITIlt RIB Y 0 STNITER OOtJ sur 11 SlITIlt SlIT I 1 y R O o II1 O III S Gr l VIR I I I I cAe 1 l c...

Page 445: ...er motor quickly enough or supply adequate ignition current If the current is kept flowing through the starter motor to turn it while the engine is not cranking over the starter motor may be damaged 1...

Page 446: ...GO TO STEP 4 NO GO TO STEP 5 4 Starter Motor Inspection Turn the ignition switch to OFF Apply battery voltage to the starter motor directly Does the starter motor turn YES Poorly connected starter mo...

Page 447: ...ter relay switch connector terminal Starter motor turns engine slowly Low battery voltage Poorly connected battery cable Poorly connected starter motor cable Faulty starter motor Poorly connected grou...

Page 448: ...tarter motor terminal and remove the terminal nut and starter motor cable Remove the two mounting bolts and ground cable and the starter motor from the rear crankcase cover Remove the O ring from the...

Page 449: ...ge Check the dust seal and needle bearing in the fronl cover for deterioration wear or damage Check the commutator bars of the armature for dis coloration Do not use emery or sand paper on the commu t...

Page 450: ...en each commutator bar and the armature shaft There should be no continuity Check for continuity between the insulated brush and cable terminal There should be continuity Check for continuity between...

Page 451: ...Remove the brushes from the brush holder Measure the brush length SERVICE LIMIT 9 0 mm 0 35 in ASSEMBLY D RING BRUSH HOLDER U WASHER ULATOR WASHERS O RING WASHER BRUSH SPRING SEAL RING SEAL RING MO rO...

Page 452: ...m pulling the armature against it armature agamst the case 21 10 Install a new seal ring onto the motor case Install the same number of shims in the same loca tions as noted during disassembly Install...

Page 453: ...o the starter motor shaft splines Install the starter motor into the rear crankcase cover with the two mounting bolts and ground cable and tighten the mounting bolts Install the starter motor cable an...

Page 454: ...o neutral Turn the ignition switch ON and push the starter switch The coil is normal if the starter relay switch clicks If you don t hear the switch CLICK inspect the relay switch using the procedure...

Page 455: ...al and negative terminal to the light green red wire terminal of the relay switch side 2P connector There should be continuity between the cable termi nals while the battery is connected and no contin...

Page 456: ...MEMO...

Page 457: ...CH 22 10 CARBURETOR HEATER 22 11 CARBURETOR HEATER SWITCH 22 12 COMBINATION METER REAR VEHICLE SPEED SENSOR VSS 22 13 FUEl GAUGE FUEl LEVEL SENSOR 22 15 TEMPERATURE INDICATOR 22 17 ENGINE OIL TEMPERAT...

Page 458: ...RS SWITCHES COMPONENT LOCATION HA uc e H SWITCH REVERSE SWITCH EeT SENSOR CARBURETOR HEA TER 22 2 COMBINATION METER EOT SENSOR AUTO ESP SWITCH FRONT BRAKE INHIBITOR SWITCH SPEED SENSOR REAR VEHICLE SP...

Page 459: ...CA T lg O N S J Bulb Headlight high tow beam 12V 30 3 O WCifx 2 ____ 1 Assist headlight 12V 45 W t B k h a I li9 h t O 5i O 6 _ E 12V 2115W x 2 _ After 06 LED Neutral in d ca t o c ______ __________ i...

Page 460: ...a new bulb and removed parts in the reverse order of removal REMOVALIINSTALLATION Remove the assist headlight bulb page 22 4 Remove the two trim clips 8 rnm nuts and the assist headlight meter bracket...

Page 461: ...t case cover cap Remove the dust cover Remove the bulb socket and bulb Install a new bulb in the case aligning the bulb tab with the case groove Install the bulb socket Install the dust cover with its...

Page 462: ...ci liii screw REMOVALIINSTALLATION Remove the front side outer fender page 2 13 Remove the screws trim clip bolt and headlight cover unit assembly Remove the headlight unit from the cover Installation...

Page 463: ...ve the taillight unit from the cover Align rhe bosses Install the taillight in the reverse order of removal and grommets properly TAIL BRAKE LIGHT After 06 REMOVALIINSTALLATION Open the storage box Pu...

Page 464: ...tween the White black wire terminal of the socket side 2P Natural connector and bottom canter terminal of the socket and between the Green wire terminal and side wall ter minal There should be continu...

Page 465: ...y should exist between the color coded wires as follows IGNITION SWITCH BAT2 DC BAn BAT ON re OfF m REMOVALIINSTALLATION Remove the following front fender page 2 11 combination meter page 22 14 Remove...

Page 466: ...disconnect it Check for continuity between the switch side con nector terminals in each switch position Continuity should exist between the color coded wires as shown below UGHTING SwrrOl OIMMER SWITC...

Page 467: ...the ignition switch turned to ON If there is no voltage check for an open circuit in the wire harness Measure the resistance between the heater side connector terminals STANDARD 13 15 n at 20 C 68 F...

Page 468: ...r Remove the clips and carburetor heater switch cover Remove the clip and carburetor heater switch Check for continuity between the switch side con nector terminals of the carburetor heater switch 2P...

Page 469: ...rcuit in the wire harness SPEEDOMETER REAR VSS Check that the hour meter and odometer trip meter function properly If they do not function check the power ground line page 22 13 If they function prope...

Page 470: ...ellow connector and combination meter 14P Gray connector If the Pink green wire is OK replace the combination meter COMBINATION METER REMOVAL INSTALLATION Remove the front fender page 2 1 Remove the c...

Page 471: ...ws Remove the left inner fender page 2 9 Turn the ignition switch to OFF and disconnect the fuel level sensor 2P connector Turn the ignition switch to OFF Connect the meter side connector terminals wi...

Page 472: ...auge Segment RES should blink If the fuel gaugB does nOI function properly check the fuel level sensor page 22 17 If the fuel level sensor is OK replace the combina tion meter If all segments blink du...

Page 473: ...t at the top FULLM and bottom RESERVE posi tion FLOAT POSITION Resistance 20 C 68cF TOP FULL 5 7 n B 0 TT 0 M R ES E R V E 20 4 2 O n O TEMPERATURE INDICATOR SYSTEM INSPECTION The oil coolant temperat...

Page 474: ...ops Remove the following recoil starter cover page 2 4 fuel tank caver page 2 6 air intake duct page 6 10 Oisconnect the connector from the engine coolant temperature EeT sensor and check the tempera...

Page 475: ...r Fan motor does not start Remove the following recoil starter cover page 2 4 fuel tank cover page 2 6 air intake duct page 6 10 Disconnect the engine coolant temperature ECT sensor connector and grou...

Page 476: ...emperature EDT sensor Suspend the EOT sensor in a pan of engine oil on an electric heating element and measure the resistance THERMOMETER 22 20 through the sensor as the oil heats up NOTE Soak the EOT...

Page 477: ...the ECT sensor Keep the temperature constant for 3 minutes before testing A sudden change of temperature will result in incorrect readings 00 not let the thermometer or ECT sensor touch the pan LIGHTS...

Page 478: ...con nector terminals There should be continuity with the gearshift lever in reverse position and no continuity with it in except reverse REPLACEMENT Remove the screw and the reverse switch Install a...

Page 479: ...rning OFF When transporting the vehicle with the ignition switch OFF for over lOa km 60 mil When the battery is disconnected If the GPS indicator is blinking and the antenna mark and all segments do n...

Page 480: ...een orange Ground Is therB continuity YES GO TO STEP 4 NO _ Open circuit on the Green orange wire Inspect the combination meter page 22 13 4 GPS RECEIVER REPLACEMENT Replace the receiver with a known...

Page 481: ...ter page L_________________ J 22 13 REMOVALIINSTALLATION Remove the combination meter assembly and remove the meter bracket page 22 14 Remove the bolls and lift the GPS receiver Disconnect the GPS 6P...

Page 482: ...t the rear brake pedal switch 2P Yellow connector and check for continuity between the switch side connector terminals There should be continuity with the rear brake pedal depressed and no continuity...

Page 483: ...tinuity when the horn switch is pushed and be no continuity when the switch is released HORN U type only Disconnect the wire connectors from the horn Connect a 12V battery to the horn terminals The ho...

Page 484: ...MEMO...

Page 485: ...TABLE 4WD SYSTEM COMPONENT LOCATION 23 2 PROBLEM CODE INDEX 23 4 SYSTEM DIAGRAM 23 2 TROUBLESHOOTING 23 5 SERVICE INFORMATION 23 3 REAR VEHICLE SPEED SENSOR VSS 23 11 BEFORE STARTING TROUBLESHOOTING 2...

Page 486: ...OO IIIIIC I HJij 23 2 G BI 81 1 Q GIY P PIG BI O G 1 PjI G Bi j I I rn Br BI r t BllB rn sr l COMBINATION METER 4WDI E NG IIIE CDHIIIl IKlDllE ECM 2WD 4WD SWITCH ENGINE CONTROL MC ULE IECM V55 G Sr BI...

Page 487: ...ctable 4WD system always follow the steps in the troubleshoot ing page 23 5 See page 17 3 for front final clutch information A faulty selectable 4WD system is often related to poorly connected or corr...

Page 488: ...more problems occur Once the ECM detects a problem it stores the problem code in the erasable memory It can be indicated as freeze code by retrieval of problem code Retrieval and erasure procedure are...

Page 489: ...n Turn the ignition switch ON Measure the voltage between the wire harness side front VSS 3P Black connector terminals Connection Black orange Green yellow H Does the battery voltage exist NO Open or...

Page 490: ...for any object on the sensor tip or ring gear sur face also check for damage on the sensor tip Is it installed correctly NO Clean the front VSS and ring gear cor rectly install the front VSS or repla...

Page 491: ...Measure the voltage between t he wire harness side rear VSS 3P Yellow connector terminal and ground Connection Blacklorange Green yellow H Does the battery voltage exist NO Open or short circuit in th...

Page 492: ...r any object on the sensor lip or ring gear surface also check for damage on the sensor tip Is if Installed correctly NO Clean the rBar VSS and ring gear cor rectly install the rear VSS or replace the...

Page 493: ...ltage between the wire harness side connector terminal and ground Connection Black green t 1 Ground Standard 11 16 V 20 C 68 F Is the voltage within the standard value NO Open or short circuit in wire...

Page 494: ...ck wires for continuity between the wire harness side clutch 2P Green connector terminals and ground Is there continuity YES Short circuit in the White red wire Short circuit in White black wire NO GO...

Page 495: ...over stay mounting bolts and stay Release the rear VSS wire from the wire clamp Remove the front fina l clutch 2P Green connector INSTALLATION Install the front final clutch 2P Green connector Apply e...

Page 496: ...housing then install and tighten the three mounting bolts Clamp the rear VSS wire with the wire clamp Install the front final clutch cover onto the housing while aligning its hole with the boss on th...

Page 497: ...38 CONNECTOR LOCATION 24 4 MODE SELECT SWITCH 05 08 only 24 39 CIRCUIT DIAGRAM 24 5 THROTTLE POSITION INITIAL SETTING PROCEDURE 24 6 TP SENSOR 24 40 BEFORE STARTING ANGLE SENSOR 24 41 TROUBLESHOOTING...

Page 498: ...OR BATTERY GEAR POSITION SWITCH 24 2 cm e ATION METER DRIVE MODE SElECT SWITCH 05 08 only ESP SHIFT SW ITCH IGNITICINSWITCH AUTO ESP SWITCH After 08 only ENGINE CONTROL M UUIL IECMI FRONT VSS REAR VSS...

Page 499: ...hen the Engine Control Module ECM detects a problem with the Hondamatic system it stops the automatic trans mission function and the gear position indicator blinks After perlorming troubleshooting inc...

Page 500: ...ECM 5P BLACK front fender page 2 11 f1I NI B R SWITCH lOP or 14P GREEN ESP SHIFT SWITCH Front fender page Front fender page 2 11 2 11 FRONT VSS 3P BLACK Inner fender page 2 9 f bnrC THROTILE posmON S...

Page 501: ...tch Main b VB_M attery volt ___I go Drive s D_SW witch L_SW N5W R_SW SEl_UP SEl DOWN VSP FA_VWP itch Low sw NeulraI switch e switch P rdown Revers Selecto Selecto Vehicle sor vol Front V speed sen tag...

Page 502: ...at the procedure from the step 2 INITIAL SETTING Make sure 10 cfIedc 1 the OII evel befOf6 executlflg the Ins raj 2 Senmg procedure Start the engine and let it idle about 30 seconds with the sub trans...

Page 503: ...constant should be displayed on the gear position indicator Usten for the control motor operation sound the control motor should function at this time to adjust the angle sensor tum the Ignmon SWltdJ...

Page 504: ...the ECM detects a problem it stores the problem code in the erasable memory It can be indicated as freeze code by retrieval of problem code page 24 9 I P f 83 1 I CD 1 J I 0 1 1 1 8 Q I I The shift fu...

Page 505: ...ches imme diately then push the UP and DOWN shift switches simultaneously again for 2 seconds or more 4 The problem code is displayed by a number of blinks on the gear position indicator page 24 81 If...

Page 506: ...ds or more while the problem code is being displayed i e blinking on the gear position indicator 2 When the erasure is completed the blinking pat tern changes to the erasure confirmation blink 3 Turn...

Page 507: ...ore Fuses Relevant connectors components for water or loose contact After troubleshooting erase the problem code and test drive the vehicle to be sure that the sys tem Is normal When connecting the EC...

Page 508: ...the EPS EeU 21P Gray A connector YES GO TO STEP 2 2 Ground Cable Connection Inspection Check for loose or poor camact on the ground cable Is the connection no 17 NO loose or poor contact on the ground...

Page 509: ...body ground TOOL Pin probe Male 07ZAJ ROJA110 Is there continuity NO Short ci rcuit in the Violetlwhite wire YES GO TO STEP 5 5 System Failure Reproduction Connect all connectors Test ride the veh icl...

Page 510: ...TEP 2 2 Speedometer Indication Inspection Check the indication of the speedometer when driving at a low speed Is the indication accurate NO YES Perform the troubleshooting of meter speed sensor page 2...

Page 511: ...heck the Pink green wire for continuity between the ECM 21P Gray connector terminal and ground Check the Pink wi re for continuity between the rear VSS side 3P Yellow connector terminal and ground Is...

Page 512: ...y failure Erase the problem code page 24 9 YES Faulty ECM After replacement per form initial setting procedure page 24 6 PROBLEM CODE 3 GEAR POSITION SWITCH SYSTEM 1 Gear Position Switch Connection In...

Page 513: ...l continuity NO Faulty gear position switch Open or short circuit in engine sub harness YES _ Open or short circuit in wire between the ECM and junction box connector Open or short circuit in w ire be...

Page 514: ...sure the resistance at the TP sensor termi nals of the sensor side Connection Black red J Green vellow H Is the resistance within 4 0 6 0 kfl 20 CI68 F 7 NO Faulty TP sensor perform initial setting pr...

Page 515: ...nition switch OFF Disconnect the ECM 21 P Gray connector and the TP sensor 3P Black connector Check for continuity at the 81ackJred wire and Green yellow wire between the ECM connector and sensor conn...

Page 516: ...DE 5 ANGLE SENSOR SYSTEM MOTOR LOCK 1 Angle Sensor Connection Inspection Check for loose or poor contact on the ECM 21 P Gray and 5P Black connectors Check for loose or poor contact on the angle sen s...

Page 517: ...ilure code page 24 9 4 Control Motor Power Input Line Inspection Turn the ignition switch OFF Disconnect the ECM 5P Black connector Measure the voltage between the wire harness side connector terminal...

Page 518: ...otor connector Is there continuity NO Open in wire between the ECM and the control motor YES GO TO STEP 7 7 Control Motor Circuit Inspection Disconnect the control motor 2P Natural con nector Check fo...

Page 519: ...the crankcase to move the ball nut The ball nut of the automatic transmission unit can strike the shaft end and lock up This is just a temporary symptom In this case be sure that the motor shaft join...

Page 520: ...ntinuity NO Open in wire between the ECM and the angle sensor YES GO TO STEP 13 13 Angle Sensor Input Voltage Inspection Turn the ignition switch ON Measure the voltage between the wire harness side c...

Page 521: ...ctor Is there normal condition NO loose or poor contact on the ECM con nector and the angle sensor connector YES GO TO STEP 2 2 Angle Sensor Resistance Inspection 1 Turn the ignition switch OFF Discon...

Page 522: ...connector Check for continuity on the Yellow blue wire between the ECM connector and main harness side angle sensor connector Is there continuity NO Open in wire between the ECM and angle sensor YES...

Page 523: ...re page 24 6 YES GO TO STEP 8 8 System Failure Reproduction HONDAMATIC JOINT Install the angle sensor and connect all connec tors GEAR POSITION INDICATOR Turn the ignition switch ON Check the gear pos...

Page 524: ...O STEP 2 2 ESP Shift Switch line Inspection ECM side Check for continuity at the ECM 21P Black con nector terminals in each shift switch position page 24 38 r WhiteJ Black while Black Position blue d...

Page 525: ...nition switch ON Check the gear position indicator Is problem code 7 indicated NO _ No problem Temporary failure Erase the failure code YES Faulty ECM After replacement per form initial setting proced...

Page 526: ...k page 24 9 Is II problem code indicated NO Perform the necessary diagnostic trou bleshooting of the output problem code YES Faulty ECM After replacement per form initial setting procedure page 24 6 P...

Page 527: ...und Connection Green Ground 1 1 Is there continuity NO Open in wire between the EeM and ground YES GO TO STEP 4 4 Control Motor line Inspection Disconnect the EeM 5P Black connector and the control mo...

Page 528: ...form initial setting procedure page 24 6 PROBLEM CODE 13 MODE SELECT SWITCH SYSTEM 01 02 AND ESP Mode Select Switch Connection Inspection Check for loose or poor contact on the ECM 21 P Black connecto...

Page 529: ...nuity at the mode select switch side 4P Black connector in the same manner as the STEP 2 page 24 33 r Orange Blue Siadt Green Position blact green 01 02 0 ESP Is there normal continuity NO Faulty mode...

Page 530: ...or Is there the gear position D L N RJindication NO Perform troubleshooting of problem code 3 gear position switch system page 24 16 YES Perform troubleshooting of problem code 7 ESP shift switch syst...

Page 531: ...ear position switch wire terminal of the ECM connector and ground u W DRIVE NEUTltAl REVERSE Is there normal continuity NO GO TO STEP 3 YES GO TO STEP 4 3 Gear Position Switch Line Inspection 2 Check...

Page 532: ...Check for continuity at the switch side 4P Black connector in the same manner as the STEP 4 page 24 36 Is there continuity NO Faulty mode select switch YES Open or short circuit in wire between the E...

Page 533: ...of the ECM connector and ground There should be continuity only at the terminals that correspond to the gear positions shown below and there should be no continuity at the other terminals You must te...

Page 534: ...Engine is running INSPECTION Turn the ignition switch OFF Disconnect the ECM 21P Black connector Check for continuity between the ECM connector terminals in each switch position Continuity should exis...

Page 535: ...ctor and perform the inspection at the 4P Black connector in the same manner as the previous step If the continuity at the ECM is abnormal and con tinuity at the 4P connector is normal check for an op...

Page 536: ...e carburetor body Improper Install a new TP sensor assembly by aligning the mstallanon can tabs of the sensor with the flat of the shaft as cause damage to shown the TP sensor Install the screws and t...

Page 537: ...NCE Turn the ignition switch OFF Disconnecl lhe angle sensor 3P connector Measure the resistance at the angle sensor 3P con nector Connection Black red GreenlVeliow H Standard 1 6 2 4 kO 20 C 68 F Cle...

Page 538: ...and crankcase base cavity and be sure that no foreign material is allowed Align the tabs of the sensor with the flat of the sen sor joint and set the angle sensor onto the crank case in the position a...

Page 539: ...over page 10 5 Remove the two mounting boils and control motor Coat a new O ring with engine oil and install it into the control motor groove Apply molybdenum oil solution to the motor shaft splines a...

Page 540: ...Natural can WIth the clamp nector Install the removed parts in the reverse order of removal ENGINE CONTROL MODULE ECM REMOVALIINSTALLATION Remove the front fender page 2 11 24 44 Disconnect the ECM 21...

Page 541: ...LESHOOTING INDEX 25 15 SYSTEM DIAGRAM 25 3 SYMPTOM TROUBLESHOOTING INDEX 25 17 EPS CONNECTOR LOCATION 25 4 DTC TROUBLESHOOTING 25 18 SERVICE INFORMATION 25 7 SYMPTOM TROUBLESHOOTING 25 34 GENERAL TROU...

Page 542: ...ENT LOCATION ENGINE CONTROL MODULE ECM DATA LINK CONNECTOR OLe 25 2 CRANKSHAFT POSITION SENSOR CKP SENSOR EPS INDICATOR EP MOTOR ElECTRIC POWER STEERING ELECTRONIC CONTROL UNIT EPS ECU TORQUE SENSOR R...

Page 543: ...ENSOR GK AEAA I I 1 11 24 PJG vs SENSOR L_ _ eKP 0 SENSOR 1 9 4 NEGNO ECM L9 r eN DLe G L A5 WLP All 4WOtNOO AI24 M INOl Al VSt A3 VS2 A2 TIS GNO A17 VSP 4 19 NEP A20 NEP2 A14 K LiNE 9 SCS EPS ECU BI...

Page 544: ...Note 2 Remove the right inner fender Note 3 Remove the left inner fender ECM 21P GREY CONNECTOR NOle 1 I j ECM 21P BLACK CONNECTOR Nole 1 EPS ECU 2P BROWN C CONNECTOR Nota 2 EPS ECU 2P GRAY 8 CONNECTO...

Page 545: ...EPS MOTOA 2P CONNECTOR Note 3 REAR VS SENSOR 3P YEllOW CONNECTOR Note 3 ELECTRIC POWER STEERING EPS TORQUE SENSOR 3P CONNECTOR Note 3 25 5...

Page 546: ...ELECTRIC POWER STEERING EPS 25 6 MIDDLE REAR CONNECTOR LOCATIONS Note 1 Behind the rear fender ALTERNATOR 5P NATURAL CONNECTOR Note 1...

Page 547: ...cedure page 13 34 Before disconnecting any connector of the EPS system always turn the ignition switch OFF and disconnect the negative cable from the battery The following color codes are indicated th...

Page 548: ...res to clear OTCs page 25 11 SELF DIAGNOSIS DTC Self diagnosis can be classified into three categories Initial diagnosis performed right after the engine starts and until the EPS indicator goes off Re...

Page 549: ...zed whenever the EPS unit the motor the EPS ECU etc is serviced page 25 3 Perform the Torque Sensor Initialization when you service the following contents page 25 13 MAINTENANCE LOCATION Cables and ha...

Page 550: ...the seat page 2 4 Remove the insulator rubber Remove the dummy connector Connect the HOS Pocket Tester to the OLe Make sure the engine stop switch is turned to 0 turn the ignition switch to ON check t...

Page 551: ...the ignition switch to OFF 4 Remove the dummy connector and sholl the Brown red and Green wire term inals of the DLC using the special tool TOOL SCS connector 070PZ ZV30100 CONNECTION Brown red Green...

Page 552: ...AR EPS EPS I 11 Within 4 seconds afterthe EPS indicator goes off release the handlebar The EPS indicator blinks HANDLEBAR EPS INDICATOR twice 4 seconds after releasing the handlebar NOTE If the EPS in...

Page 553: ...while the engine is slopped Follow the instructions on the HDS display How to Initialize the Torque Sensor with Ole NOTE The OTe will be erased when initializing the torque sensor 1 Remove the seat pa...

Page 554: ...r Leh The rorque sensor 11 Within 4 seconds after the EPg indicator goes off IS mltlallzed of thiS return the handlebar within 1 second to straight HANDLEBAR 25 14 rime ahead and release the handlebar...

Page 555: ...stuck ON VM Volt Indicator ON Halt steering assist age Motor immediately Regular diagnosis 13 05 EPS ECU internal circuit FET stuck ON over cur Indicator ONIHalt steering assist rent accumu lated imme...

Page 556: ...t k o I diagnosis internal circuit 1M2 ON Halt e e ng jReSei t15 261 35 01 ImTiiiiVoii ge to sensor initial diagnosis torque sensor I sensor I i the Ole is erased the Specified ON Halt assist 1 m mffi...

Page 557: ...TOM TROUBLESHOOTING INDEX Symptom Symptom F8i l safe f un c t o n____ EPS indicator does not come o n d Symptom Troubleshooting EPS indicator does not go off and no DTCs Symptom Troubleshooting are st...

Page 558: ...en Circuit Inspection Remove the following front fender page 2 1 1 left inner fender page 2 9 Disconnect the EPS ECU 21 P gray A connector and rear VS sensor 3P yellow connector Check for continuity b...

Page 559: ...U 21 P gray A connector and the ECM 33P black connector TOOL Pin probe Malel 07ZAJ RDJA110 Is there continuity NO Open circuit in the Violet white wire YES GO TO STEP 7 7 CKP Sensor line ECMj Short Ci...

Page 560: ...em is normal at this time YES GO TO STEP 2 2 Motor line Short Circuit Inspection Remove the front fender page 2 11 Disconnect the EPS ECU 2P gray B connector Check for continuity between the Black and...

Page 561: ...GNOSIS Refer to EPS EeU INTERNAL CIRCUIT LOWER FET STUCK ON troubleshooting page 25 20 DTC 13 04 EPS ECU INTERNAL CIRCUIT FET STUCK ON VM VOLTAGE MOTOR REGULAR DIAGNOSIS Refer to EPS EeU INTERNAL CIRC...

Page 562: ...curs there are some of problem of selectable 4WD system Question the customer about the conditions when the problem occurred and try to reproduce the same conditions for troubleshooting Find out when...

Page 563: ...k the EPS indicator DaBs the indicator come on NO System is normal at this time YES GO TO STEP 3 3 4WO indicator Inspection 1 Turn the ignition switch ON 2 Start engine 3 2WD 4WD select switch to 4WD...

Page 564: ...nection Brown white Body ground H TOOL Pin probe Male 01ZAJ RDJA110 Is there continuity YES Replace the combination meter with a new one meter short circuit page 22 13 NO Short circuit in the Brownlwh...

Page 565: ...Light green black Body ground H TOOL Pin probe Male 07ZAJ RDJA110 Is there continuity NO Recheck for poor contact or loose con nection in the wire harness If they are OK replace the ECM with a new one...

Page 566: ...diagnosis 18 0 I SECU Jntem 1 lrcUit Motor current deflection T8 G Regular diagnosis S CUlnternaIclrCiiit lM2 Regular diagnosis I u rrcu internal circuit EEPROlvl Regular diagnosis 1 35 01 IEPS ECU nt...

Page 567: ...nector Check for continuity between the Black and Red wire harness side of the EPS ECU 2P gray B con nector Connection Black Red H Is there continuity YES Recheck for poor contact or loose con nection...

Page 568: ...LAR DIAGNOSIS Refer to EPS ECU INTERNAL CIRCUIT CURRENT SENSOR LOW STUCK INITIAL DIAGNOSIS trou bleshooting page 25 27 DTC 22 01 FAILURE TO INITIALIZE THE TORQUE SENSOR INITIAL DIAGNOSIS NOTE The EPS...

Page 569: ...on Yellowlred Green orange 1 Vellowlred White blue J White blue 1 Green orange 1 TOOL Pin probe Male 07ZAJ RDJA110 Is the resistance less than 10 fllat 20 CI68 F 7 YES GO TO STEP 3_ NO GO TO STEP 4 3...

Page 570: ...und Connection A Terminal i Body ground C Terminal 1 Body ground Is there continuity7 YES Replace the EPS unit Torque sensor coil short circuit page 13 34 NO Short circuit in the torque sensor line c...

Page 571: ...5 11 2 Start the engine 3 Fully turn the handlebar to the left or right and hold it 10 seconds 4 Check the EPS indicator Does the EPS indicator come on NO System is normally in this time YES GO TO STE...

Page 572: ...Black green wire termi nal of the wire harness side of the EPS ECU 21 P gray A connector and body ground Connection Black green l Body ground H TOOL Pin probe Male 07ZAJ RDJA110 Is there battery volt...

Page 573: ...e voltage between the Red wire terminal of the wire harness side of the EPS ECU 2P C brown connector and body ground Connection Red Body ground Is there banery voltags7 NO Open circuit in the Red wire...

Page 574: ...page 2 1 Disconnect the EPS EeU 2t P gray A connector Turn the ignition switch 10 ON Does the indicator come on YES Recheck for poor contact or loose con nection in the wire harness If they are OK re...

Page 575: ...e the front fender page 2 11 Disconnect the EPS ECU 21 P gray A connector Ground the Gray blue wire terminal of the wire harness side of the EPS ECU 21 P gray A connec tor and with a jumper wire TOOL...

Page 576: ...EPS EeU 21P gray A connector and body ground Connection Black green I Body ground TOOL Pin probe Malel 07ZAJ ROJA110 EPS EeU 21P A CONNECTOR Viewed from terminal side Brown red EPS ECU 21 P A CONNECTO...

Page 577: ...ARGING SYSTEM in good condition YES Recheck for poor contact or loose con nection in the wire harness If they are OK replace the EPS ECU with a new one page 25 37 NO Repair the BATTERY CHARGING SYS TE...

Page 578: ...MEMO...

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Page 581: ...del lA CM type 26 8 05 06 FA model IU type 26 4 After 08 FA modellA type 26 9 05 06 FGA model 26 5 After 08 FA modellU type 26 10 06 08 FA model lA CM type 26 6 After 08 FGA modellCM type 26 11 06 08...

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Page 593: ...27 TROUBLESHOOTING ENGINE DOES NOT START OR POOR PERFORMANCE IS HARD TO START 27 2 AT HIGH SPEED 27 6 ENGINE LACKS POWER 27 3 POOR HANDLING 27 6 POOR PERFORMANCE AT LOW AND IDLE SPEED 27 5 27 1...

Page 594: ...g Fouled spark plug loose or disconnected ignition system wires Broken or shorted spark plug wire Faulty ignition coil Faulty ignition pulse generator Faulty engine stop switch Faulty ignition switch...

Page 595: ...ner Restricted fuel flow Clogged muffler Restricted fuel tank breather hose YES GO TO STEP 4 4 Engine Condition Inspection Accelerate or run at high speed Is there knocking YES _ Worn piston and cylin...

Page 596: ...l le lel and condition Is there correct level and good condition NO _ Oil level too high Ojl level too low Contaminated oil YES GO TO STEP 10 10 lubrication Inspection Remove cylinder head cover and i...

Page 597: ...form spark test Is there weak or intermittent spark YES Faulty spark plug Fouled spark plug Loose or disconnected ignition system wires Broken or shorted spark plug wire Faulty ignition coil Faulty ig...

Page 598: ...gnition timing Is the ignition timing correct NO _ Faulty engine control module ECM Faulty ignition pulse generator YES GO TO STEP 5 5 Valve Spring Inspection Check valve springs Are the valve springs...

Page 599: ...OVER REMOVAU DISASSEMBLY 8 6 CYLINDER HEAD DISASSEMBLY 8 9 CYLINDER HEAD INSTALLATION 8 20 28 INDEX CYLINDER HEAD REMOVAL CYLINDER HEADNALVE 8 8 CAMSHAFT SPECiFiCATIONS 1 10 CYLINDER PISTON INSTALLATI...

Page 600: ...EERING EPS 25 7 ELECTRIC STARTER 21 3 ENGINE REMOVAUINSTALLATION 7 3 FRAME BODY PANELS EXHAUST SySTEM 2 2 FRONT DRIVING MECHANISM 17 3 28 2 FRONT WHEEUSUSPENSION STEERING 14 4 FUEL SYSTEM 5 3 HONDAMAT...

Page 601: ...BRICATION SYSTEM 4 5 POOR HANDLING 27 6 POOR PERFORMANCE AT HIGH SPEED 27 6 INDEX POOR PERFORMANCE AT LOW AND IDLE SPEED 27 5 REAR DRIVING MECHANISM 18 6 REAR WHEEUSUSPENSION 15 5 SU8 TRANSMISSIONfGEA...

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