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Honda GOLDWING GL1800, Service Manual

The Honda GOLDWING GL1800 is a state-of-the-art motorcycle designed for exceptional cruising experiences. To get started swiftly, we offer a comprehensive Quick Start Manual that you can easily download for free from our website. This manual provides clear instructions and valuable insights for an enhanced riding experience.

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INDEX

26-2

I

IAT SENSOR ·································································· 5-68
IDLE AIR CONTROL (IAC) VALVE································· 24-2
IGNITION COIL ······························································ 18-7
IGNITION COIL WITH BUILT-IN IGNITER ·················· 24-12
IGNITION CRUISE RELAY··········································· 21-11
IGNITION PULSE GENERATOR···································· 18-9
IGNITION SWITCH ······················································ 20-34
IGNITION SYSTEM INSPECTION································· 18-5
IGNITION SYSTEM SPECIFICATIONS ························· 1-11
IGNITION TIMING ······················································· 18-14
INNER FAIRING ····························································· 2-10

K

KNOCK SENSOR ··························································· 5-69

L

LICENSE LIGHT ··························································· 20-15
LIGHTS/METERS/SWITCHES SPECIFICATIONS ········· 1-11
LUBRICATION & SEAL POINTS ··································· 1-19
LUBRICATION SYSTEM SPECIFICATIONS ··················· 1-6

M

MAIN JOURNAL BEARING········································· 11-14
MAINTENANCE SCHEDULE··········································· 3-4
METER PANEL································································· 2-7
MODEL IDENTIFICATION ··············································· 1-2
MULTI-DISPLAY CONTROL SWITCH························· 20-40

N

NEUTRAL INDICATOR ················································ 20-26
NUTS, BOLTS, FASTENERS········································· 3-21

O

O2 SENSOR ··································································· 5-69
OIL PRESSURE CHECK ··················································· 4-5
OIL PRESSURE INDICATOR ······································· 20-27
OIL PUMP ········································································ 4-7
OIL STRAINER/PRESSURE RELIEF VALVE···················· 4-6
OPEN AIR TEMPERATURE SENSOR ························· 20-33

P

PGM-FI (PROGRAMMED FUEL INJECTION) 
SYSTEM   ···········································································   5-8
PGM-FI IGNITION RELAY ··········································· 18-11
PGM-FI SELF-DIAGNOSIS MALFUNCTION 
INDICATOR FAILURE CODES······································· 5-13
PGM-FI TROUBLESHOOTING ······································ 5-16
PISTON/CONNECTING ROD INSTALLATION ··········· 11-17
PISTON/CONNECTING ROD REMOVAL······················ 11-7
POSITION LIGHT RELAY············································· 20-31
POWER CONTROL RELAY·········································· 19-31
POWER TRUNK LOCK SYSTEM································· 20-42
PRIMARY GEARS/OUTPUT SHAFT 
INSTALLATION···························································· 10-20
PRIMARY GEARS/OUTPUT SHAFT REMOVAL········· 10-13
PROPORTIONAL CONTROL VALVE (PCV) ················ 15-39

R

RADIATOR COOLANT··················································· 3-13
RADIATOR/COOLING FAN ············································· 6-8
REAR BRAKE CALIPER················································ 15-34
REAR CRANKCASE COVER INSTALLATION············· 10-24
REAR CRANKCASE COVER REMOVAL ····················· 10-11
REAR FENDER A···························································· 2-13
REAR FENDER B···························································· 2-16
REAR MASTER CYLINDER/BRAKE PEDAL················ 15-19
REAR WHEEL······························································· 14-14
REARVIEW MIRROR························································ 2-7
RELAY BOX ································································· 20-16
REVERSE OPERATION·················································· 3-20
REVERSE REGULATOR ASSEMBLY·························· 19-28
REVERSE RELAY ························································· 19-26
REVERSE RESISTOR ASSEMBLY ······························ 19-30
REVERSE SHIFT ACTUATOR······································ 19-36
REVERSE SHIFT MECHANISM··································· 19-42
REVERSE SHIFT RELAY ·············································· 19-34
REVERSE SWITCH······················································· 19-27

S

SADDLEBAG COMBINATION LIGHT ························· 20-14
SADDLEBAG/TRUNK STAY·········································· 2-17
SADDLEBAGS ······························································· 2-15
SEAT ················································································ 2-5
SECONDARY AIR SUPPLY SYSTEM ··················· 3-14,5-84
SECONDARY MASTER CYLINDER ···························· 15-24

SERVICE INFORMATION

AUDIO SYSTEM ························································22-3
BATTERY/CHARGING SYSTEM ·······························17-3
BRAKE SYSTEM (ABS) ·············································16-3
BRAKE SYSTEM (Standard) ·····································15-3
CLUTCH ·······································································9-4
COOLING SYSTEM ·····················································6-3
CRUISE CONTROL SYSTEM ····································21-3
CYLINDER HEAD/VALVE ············································8-3
CYLINDER/PISTON/CRANKSHAFT ··························11-3
ENGINE REMOVAL/INSTALLATION ··························7-3
FINAL DRIVE ······························································12-3
FRAME/BODY PANELS/EXHAUST SYSTEM·············2-2
FRONT WHEEL/SUSPENSION/STEERING ··············13-3
FUEL SYSTEM (Programmed Fuel Injection) ···········5-3
GEARSHIFT LINKAGE/TRANSMISSION··················10-4
IGNITION SYSTEM ···················································18-3
LIGHTS/METERS/SWITCHES ···································20-3
LUBRICATION SYSTEM ·············································4-3
MAINTENANCE ···························································3-2
REAR WHEEL/SUSPENSION ····································14-3
STARTER/REVERSE SYSTEM ··································19-4
WIRING DIAGRAM ····················································23-3

SERVICE RULES·······························································1-2
SHOCK ABSORBER ·····················································14-16
SIDE COVER ·····································································2-5
SIDE STAND···································································3-20
SIDE STAND SWITCH ·················································20-39
SPARK PLUG····································································3-8
SPEAKER ······································································22-12
SPECIFICATIONS ·····························································1-4
SPEED LIMITER RELAY ···············································19-33
SPEEDOMETER····························································20-20
STARTER RELAY SWITCH A·······································19-24
STARTER RELAY SWITCH B ·······································19-25
STARTER/REVERSE MOTOR ······································19-17
STARTER/REVERSE SYSTEM SPECIFICATIONS ········1-11
STEERING HEAD BEARINGS········································3-22
STEERING STEM ·························································13-41
SUSPENSION·································································3-21
SUSPENSION LEVEL RELAY ······································14-29
SUSPENSION LINKAGE··············································14-18
SWINGARM ·································································14-22
SYSTEM DIAGRAM

BATTERY/CHARGING SYSTEM ·······························17-2
FUEL SYSTEM (Programmed Fuel Injection) ···········5-7
IGNITION SYSTEM ···················································18-2
LUBRICATION ·····························································4-2
REVERSE SYSTEM····················································19-3
STARTER SYSTEM ···················································19-2

SYSTEM LOCATION

AUDIO SYSTEM ························································22-2
BATTERY/CHARGING SYSTEM ·······························17-2
BRAKE SYSTEM (ABS) ·············································16-2
BRAKE SYSTEM (Standard) ·····································15-2
CRUISE CONTROL SYSTEM ····································21-2
FUEL SYSTEM (Programmed Fuel Injection) ···········5-6
IGNITION SYSTEM ···················································18-2
LIGHTS/METERS/SWITCHES ···································20-2
STARTER/REVERSE SYSTEM ··································19-2

SYSTEM TESTING ···························································6-5
SYSTEM WIRING CONNECTIONS/LOCATIONS ·········16-4

T

TACHOMETER ·····························································20-21
THROTTLE BODY···························································5-58
THROTTLE OPERATION··················································3-5
TOP SHELTER ································································2-11
TORQUE VALUES

ENGINE & FRAME·····················································1-12
STANDARD································································1-12

Summary of Contents for GOLDWING GL1800

Page 1: ...fety equipment When performing any service task be especially careful of the following Read all of the instructions before you begin and make sure you have the tools the replacement or repair parts and the skills required to perform the tasks safely and completely Protect your eyes by using proper safety glasses goggles or face shields any time you hammer drill grind pry or work around pressurized...

Page 2: ...ree signal words DANGER WARNING or CAUTION These signal words mean You WILL be KILLED or SERIOUSLY HURT if you don t follow instructions You CAN be KILLED or SERIOUSLY HURT if you don t follow instructions You CAN be HURT if you don t follow instructions Instructions how to service this vehicle correctly and safely As you read this manual you will find information that is preceded by a symbol The ...

Page 3: ...denum disulfide grease containing more than 3 molybdenum disulfide NLGI 2 or equivalent Example Molykote BR 2 Plus manufactured by Dow Corning U S A Multi purpose M 2 manufactured by Mitsubishi Oil Japan Use molybdenum disulfide paste containing more than 40 molybdenum disulfide NLGI 2 or equivalent Example Molykote G n Paste manufactured by Dow Corning U S A Honda Moly 60 U S A only Rocol ASP man...

Page 4: ... SPECIFICATIONS 1 8 FINAL DRIVE SPECIFICATIONS 1 9 FRONT WHEEL SUSPENSION STEERING SPECIFICATIONS 1 9 REAR WHEEL SUSPENSION SPECIFICATIONS 1 9 BRAKE SYSTEM SPECIFICATIONS 1 10 BATTERY CHARGING SYSTEM SPECIFICATIONS 1 10 IGNITION SYSTEM SPECIFICATIONS 1 11 STARTER REVERSE SYSTEM SPECIFICATIONS 1 11 LIGHTS METERS SWITCHES SPECIFICATIONS 1 11 CRUISE CONTROL SYSTEM SPECIFICATIONS 1 11 STANDARD TORQUE ...

Page 5: ...ngs cotter pins and lock 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 sequence is specified 6 Clean parts in cleaning solvent upon disassembly Lubricate any sliding surfaces before reassembly 7 After reassembly check all parts for proper installati...

Page 6: ...ine serial number is stamped on the right side of the crankcase The Vehicle Identification Number VIN is located on the left side of the frame near the steering head The throttle body identification number is stamped on the rear of the throttle body ENGINE SERIAL NUMBER THROTTLE BODY IDENTIFICATION NUMBER ...

Page 7: ...urb weight No ABS 399 kg 880 lbs ABS model 402 kg 886 lbs Maximum weight capacity U S A type 189 kg 417 lbs Canada type 193 kg 425 lbs FRAME Frame type Diamond Front suspension Telescopic fork Front axle travel 122 mm 4 8 in Rear suspension Swingarm Rear axle travel 105 mm 4 1 in Front tire size 130 70R18M C 63H Rear tire size 180 60R16M C 74H Front tire brand D250F Dunlop G709 RADIAL Bridgestone ...

Page 8: ...mber FUEL DELIVERY SYSTEM Type Programmed Fuel Injection PGM FI Throttle bore 40 mm 1 6 in DRIVE TRAIN Clutch system Multi plate wet hydraulically assisted Clutch operation system Hydraulically operated Transmission Constant mesh 5 speeds with reverse Primary reduction 1 591 78 49 Secondary reduction output drive 1 028 36 35 Final reduction 2 750 33 12 Gear ratio 1st 2 375 38 16 2nd 1 454 32 22 3r...

Page 9: ...rottle grip free play 2 6 mm 1 12 1 4 Intake air temperature sensor resistance 20 C 68 F 2 2 2 7 kΩ Engine coolant temperature sensor resistance 20 C 68 F 2 3 2 6 kΩ Throttle sensor resistance 20 C 68 F 4 6 kΩ Fuel injector resistance 20 C 68 F 11 1 12 3 Ω Camshaft position sensor peak voltage 0 7 V minimum Ignition pulse generator peak voltage 0 7 V minimum Manifold absolute pressure at idle 400 ...

Page 10: ...143 Valve valve guide Valve stem O D IN 4 970 4 995 0 1957 0 1967 4 96 0 195 EX 4 955 4 980 0 1951 0 1961 4 95 0 195 Valve guide I D IN EX 5 000 5 012 0 1969 0 1973 5 04 0 198 Stem to guide clearance IN 0 005 0 042 0 0002 0 0017 0 075 0 0030 EX 0 020 0 057 0 0008 0 0022 0 085 0 0033 Valve guide projection above cylinder head IN EX 11 8 12 0 0 46 0 47 Valve seat width IN EX 0 9 1 1 0 035 0 043 1 5 ...

Page 11: ...t O D at M4 27 987 28 000 1 1018 1 1024 27 96 1 101 at M5 31 987 32 000 1 2593 1 2598 31 96 1 258 Bushing to shaft clearance 0 007 0 041 0 0003 0 0016 0 08 0 003 ITEM STANDARD SERVICE LIMIT Cylinder I D 74 000 74 015 2 9134 2 9140 74 10 2 917 Out of round 0 10 0 004 Taper 0 10 0 004 Warpage 0 05 0 002 Piston piston pin piston ring Piston O D at 10 mm 0 4 in from bottom 73 970 73 990 2 9122 2 9130 ...

Page 12: ...sure Up to 90 kg 200 lbs load 250 kPa 2 50 kgf cm2 36 psi Up to maximum weight capacity 250 kPa 2 50 kgf cm2 36 psi Axle runout 0 20 0 008 Wheel rim runout Radial 2 0 0 08 Axial 2 0 0 06 Wheel balance weight 60 g 2 1 oz max Fork Spring free length 335 3 13 20 328 6 12 94 Tube runout 0 20 0 008 Recommended fluid Pro Honda Suspension Fluid SS 8 Fluid level 128 5 0 Fluid capacity Left 529 2 5 cm3 17 ...

Page 13: ... 25 31 0 996 Lower 22 585 22 618 0 8892 0 8905 22 56 0 888 Rear Brake disc thickness 11 0 0 43 10 0 0 39 Brake disc runout 0 30 0 012 Pedal master cylinder I D 17 460 17 503 0 6874 0 6891 17 515 0 6896 Pedal master piston O D 17 417 17 444 0 6857 0 6868 17 405 0 6852 Secondary master cylinder I D 14 000 14 043 0 5512 0 5529 14 055 0 5533 Secondary master piston O D 13 957 13 984 0 5495 0 5506 13 9...

Page 14: ...6 0 mm 0 24 in Reverse resistor resistance 20 C 68 F Red and Black terminal 0 20 0 25 Ω White terminal 0 15 0 20 Ω ITEM SPECIFICATIONS Bulbs Headlight high beam 12 V 55 W x 2 Headlight low beam 12 V 55 W x 2 Brake taillight 12 V 21 5 W x 6 License light 12 V 3CP 5W Front turn signal running light 12 V 21 5 W x 2 Rear turn signal light 12 V 21 W x 2 Left panel switch light 12 V 1 4 W x 4 Left handl...

Page 15: ...d small flange 10 1 0 7 10 mm bolt and nut 34 3 5 25 12 mm bolt and nut 54 5 5 40 6 mm flange bolt 8 mm head large flange 12 1 2 9 6 mm flange bolt 10 mm head and nut 12 1 2 9 8 mm flange bolt and nut 26 2 7 20 10 mm flange bolt and nut 39 4 0 29 ITEM Q TY THREAD DIA mm TORQUE N m kgf m lbf ft REMARKS Spark plug 6 14 18 1 8 13 Timing hole cap 1 45 18 1 8 13 NOTE 2 Engine oil filter cartridge 1 20 ...

Page 16: ...ch center lock nut 1 22 127 13 0 94 NOTE 1 6 ITEM Q TY THREAD DIA mm TORQUE N m kgf m lbf ft REMARKS Shift drum stopper arm pivot bolt 1 6 12 1 2 9 Shift drum joint bolt 1 8 27 2 8 20 NOTE 3 Mainshaft bearing lock nut 1 30 186 19 0 137 NOTE 1 6 Countershaft setting plate bolt 3 6 12 1 2 9 NOTE 3 Mainshaft setting plate bolt 2 8 26 2 7 20 NOTE 3 Shift drum reverse lock cam bolt 1 6 12 1 2 9 NOTE 3 ...

Page 17: ...IA mm TORQUE N m kgf m lbf ft REMARKS Ignition pulse generator bolt 2 6 12 1 2 9 NOTE 3 ITEM Q TY THREAD DIA mm TORQUE N m kgf m lbf ft REMARKS Starter motor mounting bolt 3 8 29 3 0 22 Reverse switch 1 10 12 1 2 9 Shift drum lock arm bolt 1 6 12 1 2 9 NOTE 3 Reverse shifter shaft bolt 1 6 14 1 4 10 NOTE 3 Reverse shifter cable holder bolt 2 6 12 1 2 9 NOTE 3 Reverse switch terminal nut 1 4 2 0 2 ...

Page 18: ... Q TY THREAD DIA mm TORQUE N m kgf m lbf ft REMARKS Engine hanger bolt front rear 4 12 64 6 5 47 center 2 10 39 4 0 29 Left engine hanger adjusting bolt front 1 22 2 0 2 1 4 center 1 20 4 0 4 2 9 rear 1 22 4 0 4 2 9 Left engine hanger adjusting bolt lock nut front rear 2 22 54 5 5 40 center 1 20 54 5 5 40 ITEM Q TY THREAD DIA mm TORQUE N m kgf m lbf ft REMARKS Clutch master cylinder reservoir cap ...

Page 19: ... 26 2 7 20 Fork bottom bridge pinch bolt 4 8 29 3 0 22 Brake hose oil bolt anti dive 1 10 34 3 5 25 Steering bearing adjustment nut 1 26 27 2 8 20 NOTE 1 Steering bearing adjustment nut lock nut 1 26 See page 13 41 Steering stem nut 1 24 103 10 5 76 ITEM Q TY THREAD DIA mm TORQUE N m kgf m lbf ft REMARKS Rear wheel nut 5 12 108 11 0 80 Rear pulser ring bolt ABS model only 6 5 8 0 8 5 8 NOTE 7 Shoc...

Page 20: ...NOTE 3 Front brake caliper pin 2 8 23 2 3 17 Front brake caliper assembly bolt 6 8 32 3 3 24 NOTE 7 Left front brake caliper lower mounting bolt 1 8 31 3 2 23 NOTE 7 Left front brake caliper to secondary master cylinder joint bolt 1 8 25 2 6 19 NOTE 7 Right front brake caliper mounting bolt 2 8 31 3 2 23 NOTE 7 Rear brake caliper bracket pin 1 8 23 2 3 17 NOTE 3 Rear brake caliper pin bolt 1 12 27...

Page 21: ...olt 2 6 14 1 4 10 ITEM Q TY THREAD DIA mm TORQUE N m kgf m lbf ft REMARKS Bank angle sensor screw sensor to stay 2 4 2 0 2 1 4 Side stand pivot bolt 1 10 10 1 0 7 Side stand pivot lock nut 1 10 29 3 0 22 Side stand bracket bolt 2 10 44 4 5 33 1 8 26 2 7 20 Left center stand pivot bolt 1 10 54 5 5 40 NOTE 7 Right center stand pivot bolt 1 10 54 5 5 40 NOTE 7 9 Driver footpeg mounting bolt 4 8 26 2 ...

Page 22: ...idge threads and seating surface Engine oil Camshaft holder bolt threads and seating surface Cylinder head 9 mm bolt threads and seating surface Cylinder head 6 mm bolt threads and seating surface Ignition pulse generator rotor bolt threads and seating surface Clutch lifter joint piece sliding surface Clutch disc lining surface Clutch center lock nut threads and seating surface Piston pin outer su...

Page 23: ...riven sprocket bolt threads Primary driven gear bearing setting plate bolt threads rear crankcase cover Mainshaft setting plate bolt threads Countershaft setting plate bolt threads Shift drum reverse lock cam bolt threads Shift drum bearing setting plate bolt threads Ignition pulse generator bolt threads Shift drum lock arm bolt threads Reverse shifter shaft bolt threads Reverse shifter cable hold...

Page 24: ...seal lips Apply 0 5 g Final drive shaft splines output shaft and joint shaft Apply 1 g per each spline Throttle cable outer inside Cable lubricant Reverse control cable outer inside Trunk lid seal rubber seating surface Honda Bond A or equiva lent Trunk panel seal rubber seating surface Trunk light cover rubber seating surface Saddle bag cover seal rubber seating surface Saddle bag panel seal rubb...

Page 25: ... gear case cover bolt threads Final gear case stud bolt threads case side Fork center bolt threads Fork anti dive plunger case bolt threads Rear brake light cruise cancel switch holder screw threads Secondary master cylinder push rod joint lock nut threads LOCATION MATERIAL REMARKS ...

Page 26: ...R 3P 3P Gray IDLE AIR CONTROL IAC VALVE THROTTLE BODY THROTTLE POSITION TP SENSOR RADIATOR STAY No 5 FUEL INJECTOR No 3 FUEL INJECTOR No 1 FUEL INJECTOR 3P Blue REVERSE SHIFT ACTUATOR WIRE IGNITION PULSE GENERATOR WIRE REVERSE LIMIT SWITCH WIRE REVERSE SHIFT ACTUATOR PULSE SECONDARY AIR PAIR CONTROL SOLENOID VALVE 2P White 3P Gray MANIFOLD ABSOLUTE PRESSURE MAP SENSOR CONNECTORS Vehicle speed sens...

Page 27: ...purge control solenoid valve No 1 HOSE from fuel tank to EVAP canister No 15 HOSE to air cleaner housing CRUISE ACTUATOR CABLE THROTTLE CABLES AIR CLEANER HOUSING DRAIN HOSE CRANKCASE BREATHER HOSE to air cleaner housing PRESSURE REGULATOR VACUUM HOSE REVERSE SHIFT CABLE N side REVERSE SHIFT CABLE R side ...

Page 28: ...ERAL INFORMATION 1 25 No 5 No 2 No 1 2 IGNITION COIL No 3 4 IGNITION COIL No 5 6 IGNITION COIL SPARK PLUG WIRES No 4 No 6 No 2 No 5 No 1 No 3 45 45 10 45 No 1 2 No 3 4 Front No 5 6 View from the lower side ...

Page 29: ...RK PLUG WIRE No 5 SPARK PLUG WIRE No 4 HOSE from EVAP purge control soleniod valve to EVAP canister No 5 SPARK PLUG WIRE No 1 HOSE No 4 HOSE No 3 SPARK PLUG WIRE No 1 SPARK PLUG WIRE No 1 HOSE from fuel tank to EVAP canister No 3 No 1 5 3 1 No 5 No 3 No 5 ...

Page 30: ...URE SWITCH WIRE Left MAIN WIRE HARNESS knock sensor horn and fog light see page 1 31 HORN No 4 SPARK PLUG WIRE No 6 SPARK PLUG WIRE AIR CLEANER DRAIN HOSE No 6 SPARK PLUG WIRE No 2 SPARK PLUG WIRE CLUTCH HOSE No 2 SPARK PLUG WIRE AIR CLEANER DRAIN HOSE No 4 No 6 No 6 No 4 2 6 4 No 2 ...

Page 31: ...ay No 4 HOSE to EVAP canister EVAPORATIVE EMISSION EVAP PURGE CONTROL SOLENIOD VALVE 2P Black IGNITION PULSE GENERATOR WIRE REVERSE SHIFT ACTUATOR WIRE MODULATOR CONTROL MOTOR 2P Black REAR ABS MODULATOR No 5 6 IGNITION COIL CONNECTOR 5 No 3 4 IGNITION COIL CONNECTOR 3 MODULATOR CONTROL MOTOR 2P Black CONNECTORS Cruise cancel switch 2P Blue Ignition pulse generator 2P Red Reverse shift actuator 2P...

Page 32: ...lack No 4 HOSE from EVAP purge control soleniod valve EVAPORATIVE EVAP EMISSION CANISTER RIGHT HORN low GEARSHIFT LINKAGE COVER GEAR POSITION SWITCH Front KNOCK SENSOR left cylinder No 2 1P Black OIL PRESSURE SWITCH LEFT HORN high To open air Drain OPTIONAL 2P Gray for left and right fog lights ...

Page 33: ...No 1 FUEL HOSE to left fuel rail FUEL INJECTOR 2P Black Left side Front FUEL RAIL No 6 No 4 No 2 OIL PRESSURE SWITCH WIRE CAMSHAFT POSITION SENSOR FUEL INJECTOR 2P Black ENGINE CO0LANT TEMPERATURE ECT SENSOR FAN MOTOR CONDENSOR FUEL HOSE from right fuel rail PRESSURE REGULATOR VACUUM HOSE RADIATOR STAY FUEL PRESSURE REGULATOR ...

Page 34: ...TER HOSE IN side OUT side FRONT ABS MODULATOR Standard model CLIP From front master cylinder To front calipers BRAKE PIPES BRAKE PIPE to delay valve ABS Anti lock Brake System model ABS model IDENTIFICATION PAINT align paint color with color mark on modulator Blue White Brake pipe connection Yellow Green ...

Page 35: ...R IN side OUT side No 6 SPARK PLUG WIRE No 2 SPARK PLUG WIRE AIR CLEANER DRAIN HOSE No 4 SPARK PLUG WIRE BRAKE PIPE from rear master cylinder BRAKE PIPES to rear brake caliper WATER HOSE BY PASS HOSE BRAKE PIPE from PCV Front Front RADIATOR BREATHER HOSE to right radiator filler neck LEFT RADIATOR PROPORTIONAL CONTROL VALVE PCV ...

Page 36: ...ders 1 3 5 VEHICLE SPEED SENSOR WIRE WATER HOSE Right Front VEHICLE SPEED SENSOR Up REVERSE SHIFT CABLES REVERSE SWITCH CONNECTORS Vehicle speed sensor 3P White Right O sensor 4P White cylinders 1 3 5 Rear master cylinder brake light switch 3P White Rear master cylinder cruise cancel switch 2P Red Engine sub wire harness 4P Gray ...

Page 37: ... 34 SIDE STAND SWITCH WIRE WATER HOSE O2 SENSOR WIRE Left SIDE STAND SWITCH LEFT O2 SENSOR cylinders 2 4 6 ALTERNATOR TERMINALS 50 Up Front 20 50 mm 3P Green CONNECTOR 4P CONNECTOR ALTERNATOR O2 SENSOR WIRE BRAKE PIPES Left ...

Page 38: ... Rear Up Up Up Up Up Up Up A Up Up Up Rear HEAT GUARD RUBBER WATER HOSES CRANKCASE BREATHER HOSE SIPHON HOSE Engine ground point 4 places 45 Front 45 GROUND CABLE Frame ground point STARTER MOTOR CABLE FUEL TANK DRAIN HOSE WATER PUMP 45 WATER HOSES 3 places ...

Page 39: ...ETURN HOSE BRAKE PIPE standard model from rear master cylinder to rear brake caliper lower side BRAKE PIPE ABS model To front and rear modulators Standard model To rear brake caliper and delay valve CLIP standard model REAR WHEEL SPEED SENSOR 2P Gray ABS model FUEL TANK DRAIN HOSE ...

Page 40: ...2P White STARTER RELAY SWITCH B FENDER REVERSE RESISTOR STARTER MOTOR CABLE Inside BATTERY POSITIVE CABLE GROUND CABLES GROUND CABLE 20P White REVERSE REGULATOR FRAME Inside REVERSE RESISTOR 3P Brown STARTER MOTOR CABLE STARTER MOTOR CABLE REVERSE POWER CONTROL RELAY 1 REVERSE POWER CONTROL RELAY 2 1P White to starter relay switch REVERSE SPEED LIMITER RELAY Front ...

Page 41: ...NNA WIRE ACTUATOR CONTROL MOTOR 2P Blue ACTUATOR ANGLE SENSOR 3P Gray OIL HOSE to rear suspension REAR FENDER SUSPENSION LEVEL ACTUATOR To main wire harness To main wire harness ACTUATOR CONTROL MOTOR 2P Blue ACTUATOR ANGLE SENSOR 3P Gray PASSENGER HEADSET WIRE OIL HOSE to rear suspension REAR FENDER RADIO ANTENNA WIRE ...

Page 42: ... SENSOR WIRE BRAKE PIPE ABS model ABS Anti lock Brake System model REAR BRAKE CALIPER REAR WHEEL SPEED SENSOR WIRE clamp at white tape position BRAKE PIPE standard model REAR WHEEL SPEED SENSOR WIRE clamp at white tape position REAR WHEEL SPEED SENSOR Identification marks Yellow paint ...

Page 43: ...PER BRAKE HOSES REAR WHEEL SPEED SENSOR WIRE BRAKE HOSES REAR WHEEL SPEED SENSOR WIRE clamp at white tape position BRAKE PIPE standard model BRAKE PIPE ABS model Identification marks Yellow paint REAR WHEEL SPEED SENSOR WIRE clamp at white tape position BRAKE HOSE GUIDE BRAKE HOSE GUIDE Upper side PINS Lower side BRAKE HOSES ...

Page 44: ...41 01 02 To EVAP canister Front No 1 HOSE FUEL TANK DRAIN HOSE FUEL LEVEL SENSOR COVER 5P Gray FUEL PUMP FUEL LEVEL SENSOR WIRE FUEL RETURN HOSE FUEL HOSE 2P Gray FUEL LEVEL SENSOR WIRE clamp at black tape position FUEL HOSE ...

Page 45: ...INFORMATION 1 42 After 02 FUEL LEVEL SENSOR 2P Gray COVER 5P Gray FUEL PUMP FUEL LEVEL SENSOR WIRE PASSENGER HEADSET WIRE FUEL RETURN HOSE FUEL HOSE FUEL HOSE FUEL LEVEL SENSOR WIRE clamp at black tape position ...

Page 46: ...LIGHT RELA Y To meter 20P Blue connector SPEAKER 2P Blue OPTIONAL3P White for grip heater TURN SIGNAL RUNNINGLIGHT 3P Black 2P White OPEN AIR TEMPER A TURE SENSOR Front HEADLIGHT CONNECTOR high beam BANKANGLE SENSOR HEADLIGHTADJUSTINGMOTOR 3P Gray HEADLIGHTCONNECTORS lowbeam HEADLIGHTADJUSTINGMOTOR 3P Gray HEADLIGHT CONNECTOR high beam LEFTPANEL SWITCH14P CONNECTORS Driver headset 6P Red Auxiliary...

Page 47: ... only TURN SIGNAL RUNNING LIGHT 3P Black 2P White Front HEADLIGHT CONNECTOR high beam BANK ANGLE SENSOR HEADLIGHT ADJUSTING MOTOR 3P Gray HEADLIGHT CONNECTORS low beam HEADLIGHT ADJUSTING MOTOR 3P Gray HEADLIGHT CONNECTOR high beam LEFT FRONT SPEAKER WIRE AMBIENT AIR TEMPERATURE SENSOR RIGHT FRONT SPEAKER WIRE To meter 16P Black and 20P Black connectors LEFT PANEL SWITCH 14P CONNECTORS Driver head...

Page 48: ...otor 2P Black Left O sensor 4P Black cylinders2 4 6 Engine subwire harness4P Gray Optional 4P Black for fog light switch CONNECTORS Driver headset 6P Red Auxiliary input 3P White Optional 3P Red for accessory socket LEFT PANEL SWITCH 14P CONNECTOR Suspension level Hazard Headlight adjusting AIR DUCT LEFT PANEL SWITCHES Left MAIN WIRE HARNESS AUXILIARY INPUT WIRE LEFT PANEL SWITCH WIRE OPTIONAL 5P ...

Page 49: ...T 26P Black 26P Gray RADIOANTENNA CONNECTOR CRUISE REVERSE CONTROLMODULE 22P Black 6P Black ENGINECONTROL MODULE ECM see below 22P Gray 34P Black 34P Gray CONNECTORS Left fan motor 2P Black Left O sensor 4P Black cylinders2 4 6 Engine subwire harness4P Gray Optional 4P Black for fog light switch 0 1 ...

Page 50: ...ack 34P Gray 26P Black RADIOANTENNA CONNECTOR 26P Gray CRUISE REVERSE CONTROLMODULE 22P Black 6P Black ENGINECONTROL MODULE ECM DRIVERHEADSET 6P Red see below 22P Gray CONNECTORS Left fan motor 2P Black Left O sensor 4P Black cylinders2 4 6 Engine subwire harness4P Gray Optional 4P Black for fog light switch 0 1 2 ...

Page 51: ...Black for fog light switch 2P Black INTAKE AIR TEMPERATURE IAT SENSOR CONNECTORS Vehicle speed sensor 3P White Right O sensor 4P White cylinders 1 3 5 Rear master cylinder brake light switch 3P White Rear master cylinder cruise cancel switch 2P Red Engine sub wire harness 4P Gray 6P Black IGNITION SWITCH WIRE OPTIONAL 13P White for CB transceiver CONNECTORS Ignition switch 4P White Right fan motor...

Page 52: ...CH WIRE MAIN WIRE HARNESS IGNITION SWITCH WIRE CB TRANSCEIVER WIRE BARO SENSOR WIRE CRUISE ACTUATOR WIRE Front 1 2 3 4 C 1 Left handlebar switch 12P Green 2 Turn signal cancel unit 6P Gray 3 Audio switch 14P Blue 4 Right handlebar 18P Green A B C D TURN SIGNAL CANCEL UNIT WIRE SIPHON HOSE AIR DUCT RADIATOR BREATHER HOSE Clamp at white mark position Up Right Right Up Up Front RIGHT RADIATOR ...

Page 53: ...3P White Right O2 sensor 4P White cylinders 1 3 5 Rear master cylinder brake light switch 3P White Rear master cylinder cruise cancel switch 2P Red Engine sub wire harness 4P Gray OPTIONAL 13P White for CB transceiver PASSENGERHEADSET WIRE 6P Black 2P Black INTAKE AIR TEMPERATURE IAT SENSOR CONNECTORS Left fan motor 2P Black Left O2 sensor 4P Black cylinders 2 4 6 Engine sub wire harness 4P Gray O...

Page 54: ...ANDLEBAR SWITCH WIRE LEFT HANDLEBAR SWITCH WIRE MAINWIRE HARNESS C 1 Left handlebar switch 12P Green 2 Turn signal cancel unit 6P Gray 3 Audio switch 14P Blue 4 Right handlebar 18P Green IGNITION SWITCH WIRE PASSENGER HEADSET WIRE CBTRANSCEIVER WIRE BARO SENSOR WIRE CRUISE ACTUATOR WIRE SIPHON HOSE AIR DUCT RADIATOR BREATHER HOSE Clamp at white mark position Up Right Right Up Up Front RIGHT RADIAT...

Page 55: ...1 3 5 Rear master cylinder brake light switch 3P White Rear master cylinder cruise cancel switch 2P Red Engine sub wire harness 4P Gray OPTIONAL 13P White for CB transceiver PASSENGERHEADSET WIRE 6P Black 2P Black INTAKE AIR TEMPERATURE IAT SENSOR CONNECTORS Left fan motor 2P Black Left O2 sensor 4P Black cylinders 2 4 6 Engine sub wire harness 4P Gray Optional 4P Black for fog light switch IAT SE...

Page 56: ...HANDLEBAR SWITCH WIRE LEFT HANDLEBAR SWITCH WIRE MAINWIRE HARNESS C 1 Left handlebar switch 12P Blue 2 Turn signal cancel unit 6P Gray 3 Audio switch 14P Gray 4 Right handlebar 18P Blue IGNITION SWITCH WIRE PASSENGER HEADSET WIRE CB TRANSCEIVER WIRE BARO SENSOR WIRE CRUISE ACTUATOR WIRE SIPHON HOSE AIR DUCT RADIATOR BREATHER HOSE Clamp at white mark position Up Right Right Up Up Front RIGHT RADIAT...

Page 57: ...GENERAL INFORMATION 1 54 01 03 ...

Page 58: ...GENERAL INFORMATION 1 55 After 03 BRAKE LIGHT CRUISE CANCEL SWITCH WIRE SWITCH WIRE BRAKE HOSE RIGHT HANDLEBAR SWITCH WIRE PIN THROTTLE CABLES THROTTLE CABLES BRAKE HOSE ...

Page 59: ...WITCH WIRE SWITCH WIRE CLUTCH HOSE CLUTCH CRUISE SWITCH WIRE CLUTCH HOSE CLUTCH SWITCH WIRE LEFTHANDLEBAR SWITCH WIRE CLUTCH CRUISE SWITCH WIRE CLUTCH HOSE CLUTCH SWITCH WIRE CLUTCH HOSE CLUTCH CRUISE SWITCH WIRE LEFTHANDLEBAR SWITCH WIRE CLUTCH SWITCH WIRE ...

Page 60: ... WIRE BAND white tape position TURN SIGNAL CANCEL UNIT WIRE CLUTCH HOSE BRAKE HOSE RIGHT HANDLEBAR SWITCH WIRE LEFT HANDLEBAR SWITCH WIRE TURN SIGNAL CANCEL UNIT 7P Green RIGHT HANDLEBAR SWITCH WIRE LEFT HANDLEBAR SWITCH WIRE ...

Page 61: ...rd model CLIP From secondary master cylinder To brake calipers To delay valve BRAKE PIPE from front ABS modulator Y OUT CLIP BRAKE HOSE FRONT WHEEL SPEED SENSOR WIRE clamp at white tape position BRAKE HOSE from front master cylinder BRAKE PIPE to PCV RADIATOR BREATHER HOSE BRAKE PIPE from rear master cylinder to rear modulator W IN BRAKE PIPE to front ABS modulator W IN Clamp at white tape positio...

Page 62: ...INFORMATION 1 59 ABS Anti lock Brake System model From secondary master cylinder CLUTCH HOSE THROTTLE CABLES RADIATOR BREATHER HOSE BRAKE PIPE from rear master cylinder to rear modulator W IN BRAKE PIPE to PCV ...

Page 63: ...e caliper lower side PROPORTIONAL CONTROL VALVE PCV TURN SIGNAL CANCEL UNIT To front ABS modulator W IN BRAKE PIPES From front ABS modulator Y OUT to front calipers SENSOR WIRE BRAKE PIPES BRAKE PIPE ABS model from front ABS modulator G OUT Standard model from rear master cylinder TURN SIGNAL CANCEL UNIT WIRE LEFT HANDLEBAR SWITCH WIRE RIGHT HANDLEBAR SWITCH WIRE From front master cylinder BRAKE H...

Page 64: ...FORMATION 1 61 ABS Anti lock Brake System model FRONT WHEEL SPEED SENSOR WIRE CLIP BRAKE HOSES FRONT WHEEL SPEED SENSOR STOPPER Clamp at white tape position DELAY VALVE CLAMPS RIGHT FRONT BRAKE CALIPER BRAKE HOSE ...

Page 65: ...GENERAL INFORMATION 1 62 ...

Page 66: ...HEADSET WIRE CONNECTORS Passenger headset 6P White Service check 3P Black Optional 4P Black for rear speaker Optional 14P White for CD changer Optional 2P Black for passenger talk switch RELAY BOX CONNECTORS Radio antenna Trunk lock control unit 12P Gray Optional 3P White for CB transceiver Diode CONTROL UNIT WIRE ANTENNA WIRE SUB HARNESS To radio antenna SUSPENSION LEVEL ACTUATOR WIRE ...

Page 67: ...l 4P Black for rear speaker Optional 14P White for CD changer Optional 2P Black for passenger talk switch PASSENGER HEADSET 6P White RELAY BOX CONNECTORS Radio antenna Trunk lock control unit 12P Gray Optional 3P White for CB transceiver Diode PASSENGER HEADSET WIRE CONTROL UNIT WIRE ANTENNA WIRE SUB HARNESS SUSPENSION LEVEL ACTUATOR WIRE To radio antenna OPTIONAL 5P CONNECTOR for passenger headse...

Page 68: ...GENERAL INFORMATION 1 65 SADDLEBAG OPENER CABLE TRUNK SUB HARNESS SADDLEBAG OPENER CABLE 5P Brown 5P Black 12P Black 14P White MAIN WIRE HARNESS SADDLE BAG FENDER LICENSE LIGHT ABS CONTROL UNIT ...

Page 69: ...HT SADDLEBAG WIRE LEFT SADDLEBAG WIRE CONNECTORS 2P and 3P Red left turn signal brake taillight and saddlebag open switches 2P and 3P Blue right turn signal brake taillight and saddlebag open switches License light 2P Brown RIGHT SADDLEBAG WIRE SADDLEBAG OPENER CABLE SADDLEBAG OPENER CABLE LICENSE LIGHT LICENSE LIGHT WIRE BOOT FRAME FRAME Front Front Front ...

Page 70: ...GHT BRAKE TAILLIGHT SADDLEBAG LID CATCHES SADDLEBAG OPEN SWITCH To main wire harness OPEN SWITCH 2P White Left saddlebag shown SADDLEBAG OPENER CABLE BRAKE TAILLIGHT CONNECTOR TURN SIGNAL BRAKE TAILLIGHT WIRE TURN SIGNAL CONNECTOR TRUNK ACTUATOR LOCK UNLOCK ACTUATOR TRUNK OPEN SWITCHES ...

Page 71: ...GENERAL INFORMATION 1 68 TRUNK LOCK CONTROL UNIT WIRE 01 After 01 TRUNK LOCK CONTROL UNIT WIRE ...

Page 72: ...s necessary in order to keep the emissions system warranty in effect SOURCE OF EMISSIONS The combustion process produces carbon monoxide hydrocarbons and oxides of nitrogen Control of hydrocarbons and oxides of nitrogen is very important because under certain conditions they react to form photochemical smog when subjected to sunlight Carbon monoxide does not react in the same way but is toxic Hond...

Page 73: ...nction of the Pulse Secondary Air Injection PAIR control valve This charge of fresh air promotes burning of the unburned exhaust gases and changes a considerable amount of hydrocar bons and carbon monoxide into relatively harmless carbon dioxide and water vapor The reed valve prevents reverse air flow through the system The PAIR solenoid control valve is controlled by the PGM FI unit and the fresh...

Page 74: ...tive by any person other than for the purposes of maintenance repair or replacement of any device or element of design incorporated into any vehicle for the purpose of noise control prior to its sale or delivery to the ultimate customer or while it is in use or 2 the use of any vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PR...

Page 75: ...on Control Information Label is located on the reverse side of the right engine side cover as shown It gives basic tune up specifications VACUUM HOSE ROUTING DIAGRAM LABEL The Vacuum Hose Routing Diagram Label is located on the reverse side of the right engine side cover ...

Page 76: ...2 5 ENGINE SIDE COVER 2 5 SEAT 2 5 FRONT FENDER COVERS 2 6 FRONT LOWER FAIRING 2 6 METER PANEL 2 7 REARVIEW MIRROR 2 7 WINDSHIELD 2 8 INNER FAIRING 2 10 FRONT FAIRING 2 10 TOP SHELTER 2 11 REAR FENDER A 2 13 TRUNK LOWER COVER 2 13 TRUNK 2 13 SADDLEBAGS 2 15 REAR FENDER B 2 16 SADDLEBAG TRUNK STAY 2 17 EXHAUST SYSTEM 2 18 ...

Page 77: ...UBLESHOOTING Excessive exhaust noise Broken exhaust system Exhaust gas leaks Poor performance Deformed exhaust system Exhaust gas leaks Clogged muffler Saddlebag trunk stay bolt 26 N m 2 7 kgf m 20 lbf ft Exhaust pipe joint nut 12 N m 1 2 kgf m 9 lbf ft Exhaust pipe mounting bolt 26 N m 2 7 kgf m 20 lbf ft Exhaust pipe band bolt 26 N m 2 7 kgf m 20 lbf ft Muffler band bolt 26 N m 2 7 kgf m 20 lbf ...

Page 78: ...HELTER page 2 11 3 REARVIEW MIRROR page 2 7 12 METER PANEL page 2 7 4 SEAT page 2 5 13 FRONT FAIRING page 2 10 5 SIDE COVER page 2 5 14 ENGINE SIDE COVER page 2 5 6 CENTER INNER FAIRING page 2 10 15 SADDLEBAG page 2 15 7 FRONT LOWER FAIRING page 2 6 16 TRUNK LOWER COVER page 2 13 8 FRONT FENDER COVER page 2 6 17 REAR FENDER A page 2 13 9 INNER FAIRING page 2 10 ...

Page 79: ...components FRONT FAIRING TOP SHELTER TRUNK SADDLEBAG 12 METER PANEL 6 CENTER INNER FAIRING 7 FRONT LOWER FAIRING 9 INNER FAIRINGS 3 MIRRORS 1 WINDSHIELD GARNISH 2 WINDSHIELD 13 FRONT FAIRING 4 SEAT 5 SIDE COVERS 12 METER PANEL 11 TOP SHELTER 4 SEAT 17 REAR FENDER A 16 TRUNK LOWER COVER 10 TRUNK 15 SADDLEBAG 5 SIDE COVER ...

Page 80: ...r side while aligning the slot with the tab of the injector cover and insert the bosses into the grommets properly SEAT Remove the four bolts and passenger grips Raise the rear of the seat and remove the seat by sliding it rearward Install the seat while inserting the tabs under the top shelter and the prong under the shelter setting stay Push down the rear of the seat install the passenger grips ...

Page 81: ...R FAIRING CENTER INNER FAIRING Remove the six trim clips two setting bolts and cen ter inner fairing Install the center inner fairing align the trim clip and bolt holes and install the six trim clips and two set ting bolts FRONT LOWER FAIRING Remove the center inner fairing Remove the four setting bolts and front lower fairing Installation is in the reverse order of removal CENTER INNER FAIRING TR...

Page 82: ...ts in the reverse order of removal REARVIEW MIRROR Remove the meter panel Remove the mirror boot from the front fairing Remove the trim clip screw and mirror cover Remove the three screws bracket and mirror Disconnect the turn signal light 3P connector Install the rearview mirror in the reverse order of removal Be careful not to dislodge the grommets SPEAKER COVERS TRIM CLIPS SETTING BOLTS 4P CONN...

Page 83: ...ndshield garnish Remove the bolt two nuts and windshield holder plate Make sure the windshield garnish locating tabs are hooked under the fairing tabs 01 02 Remove the four setting screws After 02 Remove the two setting screws Remove the two setting bolts and windshield Installation is in the reverse order of removal Be careful not to dislodge the grommets MOUNTING RUBBERS BOSSES GROMMETS WINDSHIE...

Page 84: ...he spring and steel ball into hole in the lever Install the lever onto pivot of the visor while align ing the slot with the pin of the lid Install the lever cover and screw Install the cover plate onto the lever cover Install the grommets into the holes in the visor Install the grille and visor onto the windshield by aligning the tab with the slot Install the four washers two socket bolts and cap ...

Page 85: ...removal FRONT FAIRING FAIRING MOLDING Carefully release the front tab first then release the other tabs and remove the fairing molding Install the fairing molding in the reverse order of removal being careful not to damage the tabs FRONT FAIRING Remove the following left and right fairing molding windshield page 2 8 left and right inner fairings Remove the two trim clips six 6 x 11 mm bolts two 6 ...

Page 86: ...nd connect the bank angle sensor and open air temperature sensor connectors Install the front fairing while inserting the two bosses into the grommets Install the removed parts in the reverse order of removal TOP SHELTER FAIRING POCKET LEFT FAIRING POCKET Push the opener button and open the fairing pocket lid Remove the four trim clips by pushing the center pins in and remove the fairing pocket 5 ...

Page 87: ...iring pockets meter panel page 2 7 left and right fairing molding page 2 10 seat page 2 5 left and right side covers page 2 5 Remove the headset connector from the holder Remove the two 5 x 18 mm four 5 x 12 mm two 5 x 19 mm and four 6 mm setting bolts Remove the two nuts and remove the rear ends of the top shelter from the studs Disconnect the left panel switch assembly antenna and audio unit con...

Page 88: ...Remove the two self tapping screws and trunk cen ter molding Remove the seven self tapping screws Release the four screw studs from the trunk by lightly pulling the trunk lower cover outward and remove the cover Installation is in the reverse order of removal TRUNK TRUNK LID Remove the seat page 2 5 Open the trunk lid Disconnect the 12P connector of the trunk control unit sub wire harness and remo...

Page 89: ...ddlebag opener cables and sub wire harness connectors and license light connector Disconnect the antenna connector and 12P connec tor of the trunk control unit sub wire harness and 14P connector of the trunk sub wire harness Remove the wire bands Remove the four mounting bolts three washers and trunk assembly from the stay Installation is in the reverse order of removal Route the wires and cables ...

Page 90: ...rs Remove the four bolts washer and the saddlebag Remove the four collars from the saddle bag Installation is in the reverse order of removal SADDLEBAG CATCH Perform the following procedure for both the left and right saddlebags Remove the saddlebag Remove the ten screws and inner cover Disconnect the saddlebag open switch connector and remove the saddlebag catch assembly Route the wires and cable...

Page 91: ...g from the rear fender two screws and relay box assembly starter relay switches A and B power control relays 1 and 2 speed limiter relay reverse regulator assembly connector holder band and ABS control unit Remove the four bolts release the hooks and remove rear fender B Installation is in the reverse order of removal ...

Page 92: ...llowing left and right footrest under covers trunk page 2 13 left and right saddlebags page 2 15 four bolts and guard pipes two rear fender bolts Remove the two nuts six bolts and saddlebag trunk stay Installation is in the reverse order of removal TORQUE Stay bolt 26 N m 2 7 kgf m 20 lbf ft REAR FENDER BOLTS SADDLEBAG TRUNK STAY 2P BROWN CONNECTOR STAY BOLTS NUTS GUARD PIPE BOLTS GUARD PIPES ...

Page 93: ...ght exhaust pipe protector top shelter page 2 11 Disconnect the left and right O2 sensor connectors Disconnect the wire bands and lay the O2 sensor leads aside Remove the right O2 sensor lead from the bracket and lay it aside Do not lose the hook rubbers on the tabs Remove the bolt and rear exhaust pipe protector while releasing the two hooks from the tabs Loosen the muffler band bolts and slide t...

Page 94: ...ts Remove both exhaust pipe joint nuts Do not damage the O2 sensors while removing the exhaust pipes Put on gloves then remove both exhaust pipe mounting bolts washers and exhaust pipes Remove the exhaust pipe joint gaskets Separate the exhaust pipes and remove the gasket ...

Page 95: ...T PIPE MUFFLER INSTALLATION Install both exhaust pipes with new gaskets Loosely tighten all nuts and bolts Tighten the exhaust pipe band bolts Tighten the exhaust pipe joint nuts TORQUE 26 N m 2 7 kgf m 20 lbf ft TORQUE 12 N m 1 2 kgf m 9 lbf ft ...

Page 96: ...skets Tighten the muffler band bolts Tighten the muffler mounting bolts Install the removed parts in the reverse order of removal TORQUE 26 N m 2 7 kgf m 20 lbf ft TORQUE 26 N m 2 7 kgf m 20 lbf ft TORQUE Rear exhaust pipe protector bolt 14 N m 1 4 kgf m 10 lbf ft BAND BOLTS MOUNTING BOLT PROTECTOR BOLT MUFFLER ...

Page 97: ...MEMO ...

Page 98: ...ILTER 3 12 RADIATOR COOLANT 3 13 COOLING SYSTEM 3 14 SECONDARY AIR SUPPLY SYSTEM 3 14 EVAPORATIVE EMISSION CONTROL SYSTEM 3 15 FINAL DRIVE OIL 3 15 BRAKE FLUID 3 16 BRAKE PAD WEAR 3 17 BRAKE SYSTEM 3 18 BRAKE LIGHT SWITCH 3 18 HEADLIGHT AIM 3 19 CLUTCH SYSTEM 3 19 CLUTCH FLUID 3 19 REVERSE OPERATION 3 20 SIDE STAND 3 20 SUSPENSION 3 21 NUTS BOLTS FASTENERS 3 21 WHEELS TIRES 3 22 STEERING HEAD BEAR...

Page 99: ...ded brake fluid DOT 4 brake fluid Recommended clutch fluid DOT 4 brake fluid Cold tire pressure Up to 90 kg 200 lbs load Front 250 kPa 2 50 kgf cm2 36 psi Rear 280 kPa 2 80 kgf cm2 41 psi Up to maximum weight capacity Front 250 kPa 2 50 kgf cm2 36 psi Rear 280 kPa 2 80 kgf cm2 41 psi Tire size Front 130 70R18 63H 130 70R18M C 63H Rear 180 60R16 74H 180 60R16M C 74H Tire brand Front D250F Dunlop G7...

Page 100: ...MAINTENANCE 3 3 TOOL Oil filter wrench 07HAA PJ70101 or 07HAA PJ70100 ...

Page 101: ...8 19 2 25 6 32 0 38 4 EMISSION RELATED ITEMS FUEL LINE I I I 3 5 THROTTLE OPERATION I I I 3 5 AIR CLEANER NOTE 2 R R 3 6 CRANKCASE BREATHER NOTE 3 C C C C C C 3 7 SPARK PLUG EVERY 16 000 mi 25 600 km R 3 8 VALVE CLEARANCE NOTE 4 EVERY 32 000 mi 51 200 km I 3 9 ENGINE OIL R R R 3 11 ENGINE OIL FILTER R R R 3 12 RADIATOR COOLANT NOTE 5 I I R 3 13 COOLING SYSTEM I I I 3 14 SECONDARY AIR SUPPLY SYSTEM...

Page 102: ...ate the cables and their pivot points with a commercially available cable lubricant or a lightweight oil If the throttle grip still does not return properly replace the throttle cables 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 idle speed increases check the throttle grip free play and the throttle cable connections ...

Page 103: ...us paper element type air cleaner can not be cleaned because the element contains a dust adhesive If the motorcycle is used in unusually wet or dusty areas more frequent inspections are required Remove the top shelter page 2 11 Remove the screws right and left intake air ducts Disconnect the following BARO sensor connector cruise control motor actuator connector cruise reverse control module conne...

Page 104: ... sively dirty or damaged Install a new air cleaner element and the cover Install the removed parts in the reverse order of removal CRANKCASE BREATHER Service more frequently when ridden in rain at full throttle or after the motorcycle is washed or overturned Service if the deposit level can be seen in the transparent section of the drain hose Remove the five rubber plugs five socket bolts and left...

Page 105: ... electrodes with a wire type feeler gauge If necessary adjust the gap by carefully bending the side electrode Thread each spark plug in by hand to prevent cross threading and tighten them with a spark plug wrench Connect the spark plug caps Install the cylinder head side covers page 3 7 TORQUE 10 N m 1 0 kgf m 7 lbf ft RECOMMENDED SPARK PLUGS Standard BKR6E 11 NGK K20PR U11 DENSO For cold climate ...

Page 106: ...ckwise and align the T1 2 mark on the ignition pulse generator rotor with the index mark in the front crankcase cover Make sure the No 1 cylinder cam lobes are facing out If they are facing in rotate the crankshaft coun terclockwise 360 one full turn and align the T1 2 mark with the index mark Measure the No 1 cylinder valve clearance by inserting a feeler gauge between the valve lifter and cam lo...

Page 107: ...he T5 6 mark with the index mark Check the No 6 cylinder valve clearance ADJUSTMENT Remove the valve lifters and shims page 8 10 Clean the valve shim contact area in the valve lifter with compressed air Measure the shim thickness and record it Sixty five different shim thicknesses are avail able in increments of 0 025 mm from 1 200 mm to 2 800 mm Calculate the new shim thickness using the equa tio...

Page 108: ...l the cylinder head side covers page 3 8 Coat a new O ring with grease and install it onto the timing hole cap Apply grease to the timing hole cap threads Install and tighten the timing hole cap ENGINE OIL OIL LEVEL CHECK Start the engine and let it idle for a few minutes Stop the engine place the motorcycle on its center stand on a level surface Remove the right engine side cover page 2 5 Wait fo...

Page 109: ...GINE OIL FILTER Change the oil with the engine warm and the motorcycle on its side stand to assure complete and rapid draining Warm up the engine Stop the engine and remove the following right engine side cover page 2 5 front lower fairing page 2 6 Remove oil filler cap dipstick and drain bolt and drain the oil Remove the oil filter cartridge and let the remaining oil drain out RECOMMENDED ENGINE ...

Page 110: ...e side cover page 2 5 Remove the reserve tank cap dipstick The level should be between the upper and lower level holes on the dipstick with the motorcycle on its center stand on a level surface If the level is low fill the tank to the upper level hole with a 1 1 mixture of distilled water and antifreeze coolant preparation page 6 6 Oil filter wrench 07HAA PJ70100 TORQUE 26 N m 2 7 kgf m 20 lbf ft ...

Page 111: ...ose clamps are tight Check the radiator air passage for clogs or damage Straighten bent fins with a small flat blade screw driver and remove insects 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 Install the radiator grilles and removed parts page 6 13 SECONDARY AIR SUPPLY SYSTEM Rem...

Page 112: ...ting page 1 23 for hose connections and routing FINAL DRIVE OIL OIL LEVEL CHECK Place the motorcycle on its center stand on a level surface Remove the oil filler cap from the final gear case Check that the oil level is to the lower edge of the oil filler hole Check for leaks if the oil level is low Pour the rec ommended oil through the oil filler hole until it reaches the lower edge of the hole Co...

Page 113: ...o not allow foreign material to enter the system when filling the reservoir When the fluid level is low check the brake pads for wear page 3 18 A low fluid level may be due to wear of the brake pads If the brake pads are worn and the caliper pistons are pushed out this accounts for a low reservoir level If the brake pads are not worn and the fluid level is low check the entire system for leaks pag...

Page 114: ... Check the fluid level in the rear brake reservoir If the level is near the LOWER level line remove the reservoir cap set plate and diaphragm and fill the reservoir with DOT 4 brake fluid from a sealed container to the UPPER level line Install the diaphragm set plate and reservoir cap Install the right engine side cover page 2 5 BRAKE PAD WEAR Check the brake pads for wear Replace the brake pads i...

Page 115: ...hoses pipes and fittings as required Place the motorcycle on its center stand stop the engine and shift the transmission into neutral Move the left front caliper assembly upward while slowly turning the rear wheel The brake system is normal if the rear wheel stops BRAKE LIGHT SWITCH The brake light switches cannot be adjusted If the brake light switch actuation and brake engagement are not synchro...

Page 116: ...t disengaged properly or the lever feels soft or spongy bleed the air from the system Refer to page 9 7 for air bleeding procedures Inspect the clutch hoses pipe and fittings for dam age deterioration cracks or leakage Tighten any loose fittings Replace hoses pipe and fittings as required CLUTCH FLUID When the fluid level is low check entire system for leaks Do not mix different types of fluid as ...

Page 117: ...r goes off and the reverse indicator comes on Check that the motorcycle moves in reverse while pushing the starter reverse switch For reverse system inspection see section 18 SIDE STAND Place the motorcycle on its center stand Check the side stand spring for damage or loss of tension Check the side stand assembly for freedom of movement and lubricate the side stand pivot if necessary Check the sid...

Page 118: ...eral times Check the entire shock absorber assembly for leaks damage or loose fasteners Replace damaged components which cannot be repaired Tighten all nuts and bolts Refer to section 14 for shock absorber service Place the motorcycle on its center stand Check for worn swingarm bearings by grabbing the rear wheel and attempting to move the wheel side to side Replace the bearings if any looseness i...

Page 119: ...its center stand Raise the front wheel off the ground by placing a jack under the engine Check that the handlebar moves freely from side to side Make sure the control cables do not interfere with the handlebar rotation If the handlebar moves unevenly binds or has ver tical movement inspect the steering head bearings section 13 RECOMMENDED TIRE PRESSURE Up to 90 kg 200 lbs load Front 250 kPa 2 50 k...

Page 120: ...4 1 4 4 LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM 4 2 SERVICE INFORMATION 4 3 TROUBLESHOOTING 4 4 OIL PRESSURE CHECK 4 5 OIL STRAINER PRESSURE RELIEF VALVE 4 6 OIL PUMP 4 7 ...

Page 121: ...LUBRICATION SYSTEM 4 2 LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM ...

Page 122: ... possible after handling used oil ITEM STANDARD SERVICE LIMIT Engine oil capacity After draining 3 6 liters 3 8 US qt 3 2 Imp qt After draining filter change 3 7 liters 3 9 US qt 3 3 Imp qt After disassembly 4 6 liters 4 9 US qt 4 0 Imp qt Recommended engine oil Pro Honda GN4 or HP4 without molybdenum additives 4 stroke oil or equivalent motor oil API service classification SG or higher JASO T 903...

Page 123: ...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 pump Internal oil leak High oil pressure Oil pressure relief valve stuck closed Clogged oil gallery or metering orifice Incorrect oil being used Oil contamination Oil or filter not changed often enough Worn piston rings Oil...

Page 124: ...nd check the oil pressure at 5 000 rpm 80 C 176 F Stop the engine Apply sealant to the oil pressure switch threads as shown and install it Connect the oil pressure switch wire and tighten the terminal screw Install the switch cover Start the engine Check that the oil pressure indicator turns off after 1 or 2 seconds If the oil pressure indicator stays on stop the engine immediately and determine t...

Page 125: ...r packing Clean the oil strainer thoroughly Apply engine oil to the new packing and install it onto the oil pump Apply locking agent to the oil strainer bolt threads Install the oil strainer onto the oil pump with the strainer bolt Tighten the bolt to the specified torque OIL PRESSURE RELIEF VALVE Remove the oil pressure relief valve and O ring TORQUE 12 N m 1 2 kgf m 9 lbf ft PACKING ...

Page 126: ... for fatigue or damage Assemble the relief valve in the reverse order of disassembly Apply engine oil to the new O ring and install it onto the relief valve Install the relief valve into the crankcase Assemble the crankcase page 11 22 OIL PUMP REMOVAL Remove the transmission page 10 26 Remove the strainer bolt and oil strainer from the oil pump Remove the oil strainer packing SNAP RING SPRING PIST...

Page 127: ...ee oil pump assembly bolts and oil pump cover B Remove the dowel pins from the oil pump body SCAVENGE PUMP SIDE Remove the drive pin from the oil pump shaft Remove outer rotor B and inner rotor B from oil pump cover B Remove the oil seal from oil pump cover B to avoid damaging the cover OIL PUMP OIL PUMP COVER B OIL PUMP COVER B ROTORS DRIVE PIN DOWEL PINS ...

Page 128: ...move the oil seal from the oil pump body to avoid damaging the pump body INSPECTION Temporarily assemble each inner rotor outer rotor and drive pin onto the pump shaft and install them into the pump body and pump cover B Measure the tip clearance for the feed and scavenge pumps Measure the pump body clearance for the feed and scavenge pumps OIL PUMP COVER A DOWEL PINS SERVICE LIMIT 0 20 mm 0 008 i...

Page 129: ... Drive the new oil seals into the oil pump body and oil pump cover B with the sealed side facing up until they are fully seated using the suitable collar 15 mm O D SERVICE LIMIT 0 12 mm 0 005 in OIL PUMP COVER A OIL PUMP COVER B OIL PUMP BODY DOWEL PINS DOWEL PINS DRIVE PIN DRIVE PIN PUMP SHAFT THRUST WASHER OUTER ROTOR B OUTER ROTOR INNER ROTOR B INNER ROTOR OIL SEAL ...

Page 130: ... the threaded hole end facing toward the pump body Install the outer rotor into the pump body Install the dowel pins as shown Assemble the oil pump body and pump cover A Install the drive pin into the pump shaft hole Install outer rotor B and inner rotor B into pump cover B Install the dowel pins as shown Assemble the pump body and pump cover B by aligning the drive pin with the groove in inner ro...

Page 131: ...he three mounting bolts Tighten the bolts securely Apply engine oil to the new packing and install it onto the oil pump Apply locking agent to the oil strainer bolt threads Install the oil strainer onto the oil pump with the strainer bolt Tighten the strainer bolt to the specified torque Install the transmission page 10 26 TORQUE 13 N m 1 3 kgf m 9 lbf ft OIL PUMP TORQUE 12 N m 1 2 kgf m 9 lbf ft ...

Page 132: ...LURE CODES 5 13 PGM FI TROUBLESHOOTING 5 16 FUEL LINE INSPECTION 5 52 FUEL PUMP 5 54 FUEL TANK 5 56 AIR CLEANER HOUSING 5 57 THROTTLE BODY 5 58 FUEL INJECTORS 5 61 FUEL PUMP RELAY 5 66 BARO MAP SENSORS 5 67 IAT SENSOR 5 68 CAMSHAFT POSITION SENSOR 5 68 O2 SENSOR 5 69 KNOCK SENSOR 5 69 VEHICLE SPEED SENSOR 5 70 ECM ENGINE CONTROL MODULE 5 71 SECONDARY AIR SUPPLY SYSTEM 5 71 EVAPORATIVE EMISSION EVA...

Page 133: ...FUEL SYSTEM Programmed Fuel Injection 5 2 FUEL SYSTEM Programmed Fuel Injection COMPONENT LOCATION ...

Page 134: ... is equipped with the self diagnostic system described on page 5 8 When checking the PGM FI system always follow the steps in the troubleshooting flow chart pages 5 16 through 5 55 The PGM FI system is provided with a fail safe function to secure a minimum running capability even when there is trouble in the system When any abnormality is detected by the self diagnosis function running capability ...

Page 135: ...ck valve cover bolt 5 N m 0 5 kgf m 3 6 lbf ft Knock sensor 31 N m 3 2 kgf m 23 lbf ft O2 sensor 25 N m 2 5 kgf m 18 lbf ft IgnitionMate peak voltage tester MTP07 0286 U S A only Peak voltage adaptor 07HGJ 0020100 not available in U S A with com mercially available digital multime ter impedance 10 MΩ DCV minimum Test harness set 07WMZ MBGA000 U S A only Fuel pressure gauge 0 100 psi 07406 0040003 ...

Page 136: ...ugh idling Restricted fuel feed hose Contaminated deteriorated fuel Intake air leak Faulty idle air control valve Restricted fuel tank breather tube Misadjusted idle adjusting screw Faulty ignition system section 17 Afterburn when engine braking is used Faulty pulse secondary air injection PAIR system Faulty PAIR control solenoid valve Faulty PAIR check valve Clogged hose of the PAIR system Faulty...

Page 137: ...E SPEED SENSOR GEAR POSITION SWITCH IGNITION PULSE GENERATOR CAMSHAFT POSITION SENSOR O2 SENSOR ECT SENSOR FUSE BOX KNOCK SENSOR FULL NAME ABBREVIATIONS FULL NAME ABBREVIATIONS Barometric pressure sensor BARO sensor Intake air temperature sensor IAT sensor Engine control module ECM Manifold absolute pressure sensor MAP sensor Engine coolant temperature sensor ECT sensor Oxygen sensor O2 sensor Idl...

Page 138: ...or 4 Pulse secondary air PAIR control solenoid valve 16 TP sensor 5 PAIR check valve 17 ECM 6 Camshaft position sensor 18 IAT sensor 7 Knock sensors 19 IAC valve 8 O2 sensors 20 Evaporative emission EVAP control solenoid valve 9 BARO sensor 10 Vehicle speed sensor 21 EVAP canister 11 Ignition pulse generator 22 Fuel pump 12 Gear position switch ...

Page 139: ...d record how many times the MIL blinks and determine the cause of the problem pages 5 13 through 5 55 The MIL will start blinking when the side stand is lowered and the engine speed is below 1 500 rpm If the side stand is retracted or the engine speed is above 1 500 rpm the MIL will illuminate and stay on To read the ECM memory of problem data perform the following Turn the ignition switch to OFF ...

Page 140: ...als 3P black connector with green and black leads with a jumper wire 3 Turn the ignition switch to ON 4 Remove the jumper wire from the service check connector 5 The MIL will light for approximately 5 seconds While the MIL lights short the service check con nector terminals again with the jumper wire The self diagnostic memory is erased if the malfunc tion indicator goes off and starts blinking Th...

Page 141: ...that the self diagnostic memory cannot be erased if the ignition switch is turned OFF before the MIL starts blinking If the MIL blinks 33 times the self diagnostic memory has not been erased PEAK VOLTAGE INSPECTION PREPARATION Use this procedure for the ignition pulse genera tor and camshaft position sensor inspection Use a commercially available digital multimeter impedance 10 M DCV minimum The d...

Page 142: ...to No 22 of the test pin box of the test harness are for terminals C1 to C22 of the ECM black connector Terminals No 31 to No 52 of the test pin box of the test harness are for terminals B1 to B22 of the ECM gray connector Example ECM terminals B8 C8 Test pin box terminals No 38 No 8 TOOLS Ignitionmate Peak voltage tester MTP07 0286 U S A only or Peak voltage adaptor with commercially available di...

Page 143: ... check as follows Remove the top shelter page 2 12 Turn the ignition switch to OFF disconnect the ECM 22P black connector Ground the White blue wire terminal of the wire harness side connector with a jumper wire Turn the ignition switch to ON the MIL should come on If the MIL comes on replace the ECM If the MIL does not come on check for open circuit in the White blue wire between the com bination...

Page 144: ...circuit in engine stop switch related wires Faulty ECM Blown FI IGN fuse 20 A Blown ST KILL fuse 10 A Engine does not start 5 71 No blinks Open circuit in MIL wire Faulty combination meter Faulty ECM Engine operates normally 5 12 Stays lit Short circuit in service check connector wire Short circuit in MIL wire Faulty ECM Engine operates normally 1 Blinks Loose or poorly connected MAP sensor connec...

Page 145: ...orly connected No 5 injector connector Open or short circuit in No 5 injector wire Faulty No 5 injector Engine does not start 5 31 17 Blinks Loose or poorly connected No 6 injector connector Open or short circuit in No 6 injector wire Faulty No 6 injector Engine does not start 5 33 18 Blinks Loose or poorly connected camshaft posi tion sensor connector Open or short circuit in camshaft position se...

Page 146: ... knock sensor Engine operates normally 5 44 29 Blinks Loose or poorly connected idle air control IAC valve connector Open or short circuit in IAC valve wire Faulty idle air control valve Engine stalls hard to start rough idling 5 45 33 Blinks Faulty E2 PROM in ECM Engine operates normally ECM does not hold the self diagnostic data 5 48 41 No blinks Loose or poorly connected connector in gear posit...

Page 147: ... or poorly connected ECM black connector YES GO TO STEP 2 2 MAP Sensor Line Voltage Inspection Measure the voltage between the main wire har ness side 8P gray connector terminals Is the voltage within 4 75 5 25 V NO Open circuit in the Green red wire of the main wire harness Loose or poorly connected ECM black connector YES GO TO STEP 3 3 MAP Sensor Line Voltage Inspection Measure the voltage betw...

Page 148: ...uity between the following wire terminal and ground at the wire harness side MAP sensor 3P connector Yellow red Green red Light green yellow Is there continuity YES Short circuit in the following wires of the engine sub wire harness Yellow red Green red Light green yellow NO GO TO STEP 6 6 MAP Sensor Voltage at ECM Connect the MAP sensor 3P connector and engine sub wire harness 8P gray connector I...

Page 149: ...or for loose contacts or cor roded terminals Turn the ignition switch to ON Measure the voltage between the wire harness side 3P connector terminal and ground Is the voltage within 4 75 5 25 V NO Open or short circuit in the Yellow blue wire Loose or poorly connected ECM gray connector or engine sub wire har ness 6P connector YES GO TO STEP 2 2 ECT Sensor Line Voltage Inspection Measure the voltag...

Page 150: ...inking NO Temporary failure the system is normal YES Replace the ECM with a new one and inspect again MIL 8 BLINKS TP SENSOR 1 TP Sensor Input Voltage Inspection Remove the top shelter page 2 12 Turn the ignition switch to OFF Disconnect the engine sub wire harness 8P gray connector Check the connector for loose contacts or cor roded terminals Turn the ignition switch ON Measure the voltage betwee...

Page 151: ...EP 4 4 TP Sensor Line Continuity Inspection Check for continuity between Light green wire terminals of the 8P gray connector and ECM 22P connector Is there continuity NO Open circuit in the Light green wire of the main wire harness YES GO TO STEP 5 5 TP Sensor Harness Continuity Inspection Turn the ignition switch to OFF Remove the air cleaner housing page 5 57 Disconnect the TP sensor 3P connecto...

Page 152: ...e when the input voltage reading page 5 19 shows 5 V If the reading shows other than 5 V derive a voltage range at the test harness as follows Example In the case of a input voltage of 4 75 V 0 4 x 4 75 5 0 0 38 V 0 6 x 4 75 5 0 0 57 V Thus the valid range is 0 38 0 57 V for throttle fully closed Replace this calculation using 4 2 and 4 8 to get the resulting range for the throttle fully open Is v...

Page 153: ...n the wire harness side 2P connector terminal and ground Is the voltage within 4 75 5 25 V NO Open or short circuit in the Gray blue wire Loose or poorly connected ECM gray connector YES GO TO STEP 3 3 IAT Sensor Signal Line Voltage Inspection Measure the voltage between the wire harness side 2P connector terminals Is the voltage within 4 75 5 25 V NO Open circuit in the Green red wire Loose or po...

Page 154: ...e voltage between the wire harness side 3P connector terminal and ground Is the voltage within 4 75 5 25 V NO Open or short circuit in the Yellow red wire Loose or poorly connected ECM black connector YES GO TO STEP 3 3 BARO Sensor Line Voltage Inspection Measure the voltage between the wire harness side 3P connector terminals Is the voltage within 4 75 5 25 V NO Open circuit in the Green red wire...

Page 155: ...cts or cor roded terminals Connect the vehicle speed sensor 3P connector and install the removed parts Run the motorcycle with the engine speed more than 2 100 rpm for 20 seconds or more Let the engine idle and lower the side stand Check that the MIL blinks Is the MIL blinking NO Temporary failure the system is normal YES GO TO STEP 2 2 Vehicle Speed Sensor Input Line Voltage Inspection Turn the i...

Page 156: ...etween the White black wire terminals of the vehicle speed sensor 3P connector and ECM 22P connector Is there continuity NO Open circuit in the White black wire YES GO TO STEP 6 6 Vehicle Speed Sensor Pulse Signal Voltage Inspection Connect the vehicle speed sensor 3P connector Connect the test harness set to the ECM gray connectors page 5 11 Shift the transmission into neutral and turn the igniti...

Page 157: ...ion switch to OFF Disconnect the No 1 injector 2P connector Measure the resistance between the No 1 injec tor terminals Is resistance within 11 1 12 3Ω at 20 C 68 F NO Faulty No 1 injector YES GO TO STEP 3 3 No 1 Injector Short Circuit Inspection Check for continuity between the No 1 injector terminal and ground Is there continuity YES Faulty No 1 injector NO GO TO STEP 4 4 No 1 Injector Power Inp...

Page 158: ... 1 Injector Connection Inspection Remove the left injector cover page 5 61 Turn the ignition switch to OFF Disconnect the No 2 injector 2P connector Check the connector for loose contacts or cor roded terminals Connect the No 2 injector 2P connector Place the motorcycle on its side stand Turn the ignition switch to ON Check that the MIL blinks Is the MIL blinking NO Temporary failure the system is...

Page 159: ...ircuit in the Red yellow wire NO GO TO STEP 6 6 No 2 Injector Control Line Continuity Inspection Check for continuity between Red yellow wire terminals of the No 2 injector 2P connector and ECM 6P black connector Is there continuity NO Open circuit in the Red yellow wire YES Replace the ECM with a new one and inspect again MIL 14 BLINKS No 3 INJECTOR 1 Injector Connection Inspection Remove the rig...

Page 160: ...njector and ground Does battery voltage exist NO Open circuit in the Brown wire YES GO TO STEP 5 5 No 3 Injector Control Line Short Circuit Inspection Turn the ignition switch to OFF Disconnect the ECM 6P black connector Check for continuity between the Red black wire terminal of the wire harness side 6P connector and ground Is there continuity YES Short circuit in the Red black wire NO GO TO STEP...

Page 161: ...ion switch to OFF Disconnect the No 4 injector 2P connector Measure the resistance between the No 4 injector terminals Is resistance within 11 1 12 3Ω at 20 C 68 F NO Faulty No 4 injector YES GO TO STEP 3 3 No 4 Injector Short Circuit Inspection Check for continuity between the No 4 injector terminal and ground Is there continuity YES Faulty No 4 injector NO GO TO STEP 4 4 No 4 Injector Power Inpu...

Page 162: ...16 BLINKS No 5 INJECTOR 1 Injector Connection Inspection Remove the right injector cover page 5 61 Turn the ignition switch to OFF Disconnect the No 5 injector 2P connector Check the connector for loose contacts or cor roded terminals Connect the No 5 injector 2P connector Place the motorcycle on its side stand Turn the ignition switch to ON Check that the MIL blinks Is the MIL blinking NO Tempora...

Page 163: ...t Inspection Turn the ignition switch to OFF Disconnect the ECM 6P black connector Check for continuity between the Pink white wire terminal of the wire harness side 6P connector and ground Is there continuity YES Short circuit in the Pink or Pink white wire NO GO TO STEP 6 6 No 5 Injector Control Line Continuity Inspection Check for continuity between the Pink wire ter minal of the No 5 injector ...

Page 164: ...on switch to OFF Disconnect the No 6 injector 2P connector Measure the resistance between the No 6 injector terminals Is resistance within 11 1 12 3Ω at 20 C 68 F NO Faulty No 6 injector YES GO TO STEP 3 3 No 6 Injector Short Circuit Inspection Check for continuity between the No 6 injector terminal and ground Is there continuity YES Faulty No 6 injector NO GO TO STEP 4 4 No 6 Injector Power Input...

Page 165: ...with a new one and inspect again MIL 18 BLINKS CAMSHAFT POSITION SENSOR 1 Camshaft Position Sensor Peak Voltage Inspection at ECM Remove the top shelter page 2 12 Turn the ignition switch to OFF Disconnect the ECM 22P gray connector Check the connector for loose contacts or cor roded terminals Connect the peak voltage adaptor to the digital multimeter page 5 10 Connect the test harness set to the ...

Page 166: ... Is the MIL blinking NO GO TO STEP 4 YES Replace the ECM with a new one and inspect again 4 Camshaft Position Sensor Peak Voltage Inspection Turn the ignition switch to OFF Remove the left injector cover page 5 61 Disconnect the camshaft position sensor 2P connector Check the connector for loose contacts or cor roded terminals Turn the ignition switch to ON Crank the engine with the starter motor ...

Page 167: ...voltage at least 0 7 V NO GO TO STEP 4 YES GO TO STEP 2 2 Ignition Pulse Generator Connection Inspection Turn the ignition switch to OFF Remove the ECM test harness and connect the ECM connectors Reset the self diagnostic memory page 5 9 Check that the engine can be started by cranking it with the starter motor for 10 seconds or more Does the engine start YES Temporary failure the system is normal...

Page 168: ...the top shelter page 2 12 Turn the ignition switch to OFF Disconnect the right O2 sensor 4P connector Check the connector for loose contacts or cor roded terminals Connect the right O2 sensor 4P connector Place the motorcycle on its side stand Start the engine and warm it up until the radiator fan comes on Snap the engine from idle to 5 000 rpm then let it idle and check that the MIL blinks Is the...

Page 169: ...rcuit in the Green red wire YES GO TO STEP 5 5 Right O2 Sensor Output Voltage Inspection Connect the right O2 sensor 4P connector Start the engine snap it from idle to 5 000 rpm and measure the voltage between the test pin box terminals Is the voltage within the standard value NO Faulty right O2 sensor YES Check the fuel supply system If the sys tem is normal replace the ECM with a new one and ins...

Page 170: ...4P connector and ECM 22P connectors Check for continuity between the Black orange wire terminal of the wire harness side 4P con nector and ground Is there continuity YES Short circuit in the Black orange wire NO GO TO STEP 3 3 Left O2 Sensor Signal Line Continuity Inspection Connect the test harness set to the ECM connec tors page 5 10 Check for continuity between the wire harness side O2 sensor 4...

Page 171: ...Connect the right O2 sensor 4P connector Place the motorcycle on its side stand Turn the ignition switch to ON Check that the MIL blinks Is the MIL blinking NO Temporary failure the system is normal YES GO TO STEP 2 2 Right O2 Sensor Heater Resistance Inspection Turn the ignition switch to OFF Disconnect the right O2 sensor 4P connector Measure the resistance between the O2 sensor side connector t...

Page 172: ...ween the wire harness side O2 sensor 4P connector terminals Is voltage present YES Short circuit in the White wire NO GO TO STEP 6 6 Right O2 Sensor Heater Control Line Continuity Inspection Turn the ignition switch to OFF Connect the test harness set to the ECM black connectors page 5 10 Check for continuity between the wire harness side O2 sensor 4P connector and test pin box terminals Is there ...

Page 173: ...FF Disconnect the left O2 sensor 4P connector Measure the resistance between the O2 sensor side connector terminals Is the resistance within 10 40Ω NO Faulty left O2 sensor YES GO TO STEP 3 3 Left O2 Sensor Heater Short Circuit Inspection Check for continuity between the White wire ter minal of the O2 sensor side connector and ground Is there continuity YES Faulty left O2 sensor NO GO TO STEP 4 4 ...

Page 174: ... 4P connector and test pin box terminals Is there continuity NO Open circuit in White wire YES Replace the ECM with a new one and inspect again MIL 25 BLINKS RIGHT KNOCK SENSOR 1 Right Knock Sensor Connection Inspection Remove the right front exhaust pipe protector page 2 18 Turn the ignition switch to OFF Disconnect the right knock sensor 1P connector Check the connector for loose contacts or cor...

Page 175: ...a new one page 5 69 Place the motorcycle on its side stand Start the engine and hold the engine speed above 2 500 rpm for 10 seconds or more Check that the MIL blinks Is the MIL blinking NO Original knock sensor is faulty YES Replace the ECM with a new one and inspect again MIL 26 BLINKS LEFT KNOCK SENSOR 1 Left Knock Sensor Connection Inspection Remove the left front exhaust pipe protector page 2...

Page 176: ...lace the motorcycle on its side stand Start the engine and hold the engine speed above 2 500 rpm for 10 seconds or more Check that the MIL blinks Is the MIL blinking NO Original knock sensor is faulty YES Replace the ECM with a new one and inspect again MIL 29 BLINKS IAC VALVE 1 IAC Valve Power Input Line Voltage Inspection Remove the top shelter page 2 12 Turn the ignition switch to OFF Disconnec...

Page 177: ...P 4 4 IAC Valve Signal Line Continuity Inspection Check for continuity between the Light blue wire terminals of the main wire harness side 8P con nector and ECM 22P black connector Is there continuity NO Open circuit in the Light blue wire of the main wire harness YES GO TO STEP 5 5 IAC Valve Harness Continuity Inspection Remove the fuel tank page 5 56 Disconnect the IAC valve 3P connector Check t...

Page 178: ...lve 3P connector and the engine sub wire harness 8P connector Install the fuel tank page 5 56 Turn the ignition switch to ON Measure the voltage between the ECM 22P black connector terminal and ground Does battery voltage exist NO Faulty IAC valve YES GO TO STEP 8 8 IAC Valve Connection Inspection Turn the ignition switch to OFF Connect the ECM 22P black connector Place the motorcycle on its side ...

Page 179: ...linking 33 times YES Faulty ECM NO GO TO STEP 3 3 Recheck MIL Blinks Turn the ignition switch to OFF Remove the jumper wire from the service check connector Place the motorcycle on its side stand Turn the ignition switch to ON and check that the MIL blinks Is the MIL blinking NO No problem or check other failure YES GO TO STEP 4 4 Recheck MIL Blinks Turn the ignition switch to OFF Short the servic...

Page 180: ...system section 20 YES GO TO STEP 3 3 Gear Position Switch 2nd Gear Line Continuity Inspection Place the motorcycle on its center stand Remove the top shelter page 2 12 Turn the ignition switch to OFF Disconnect the ECM 22P gray connector Shift the transmission into 2nd gear Check for continuity between the Black yellow wire terminal of the wire harness side connector and ground Is there continuity...

Page 181: ...k yellow wire of the main wire harness NO GO TO STEP 7 7 1st Gear Selected Clutch Engaged Side Stand Retracted Line Continuity Inspection Shift the transmission into 1st gear and retract the side stand Check for continuity between the Blue red wire terminal of the wire harness side connector and ground with the clutch lever squeezed When there is continuity a small resistance value will register I...

Page 182: ...mbly Short circuit in the Green red wire of the main wire harness between the reverse regulator assembly and clutch switch Faulty clutch switch NO GO TO STEP 9 9 Side Stand Switch Line Short Circuit Inspection Extend the side stand Check for continuity between the Blue red wire terminal of the wire harness side connector and ground with the clutch lever squeezed Recheck with reverse connections Is...

Page 183: ...he fuel pressure gauge to the banjo bolt Start the engine let it idle and read the fuel pressure If the pressure is higher than the specified pressure inspect the following clogged fuel return hose pressure regulator fuel pump page 5 54 Do not loosen or remove the banjo bolt If it is loos ened or removed replace the sealing washer with a new one and tighten it to the specified torque TOOL Fuel pre...

Page 184: ...r inspection remove the fuel pressure gauge Install the sealing bolt with a new sealing washer and tighten it Turn the ignition switch to ON and check that there is no fuel leakage Remove the hose clamp from the pressure regulator vacuum hose Install the left injector cover and tighten the two bolts securely Install the front fairing page 2 10 TORQUE 12 N m 1 2 kgf m 9 lbf ft ...

Page 185: ...t inspect the following clogged fuel feed hose and or fuel return hose clogged fuel filter pressure regulator fuel pump After inspection connect the fuel return hose to the hose joint Turn the ignition switch to ON and check that there is no fuel leakage Install the seat page 2 5 FUEL PUMP INSPECTION Remove the seat page 2 5 Make sure the engine stop switch is turned to 1 Turn the ignition switch ...

Page 186: ...check the fuel pump relay cir cuit page 5 66 REPLACEMENT Be sure to wear safety glasses while performing this procedure Pull off the rubber cap Disconnect the 5P connector and fuel return hose from the fuel pump Remove the two fuel feed hose joint bolts Cover the fuel feed hose joint with a rag or shop towel Hold the flats of the hose joint and pull it up straight being careful not to damage the f...

Page 187: ... fuel pump by pushing it straight being careful not to damage the fuel pump joint Do not over tighten the joint bolts Install and tighten the hose joint bolts Connect the fuel return hose and 5P connector to the fuel pump Turn the ignition switch to ON and check that there is no fuel leakage Install the rubber cap over the fuel pump properly FUEL TANK REMOVAL INSTALLATION Remove the following top ...

Page 188: ...l tank Install the fuel tank in the reverse order of removal AIR CLEANER HOUSING REMOVAL INSTALLATION Remove the following air cleaner element page 3 6 fuel tank page 5 56 Disconnect the crankcase breather hoses from the air cleaner housing Remove the four screws attaching the air funnels and air cleaner housing from the throttle body The screws cannot be removed from the air fun nels at this time...

Page 189: ... insulator band screws and remove the throttle body from the insulators Disconnect the following Evaporative emission EVAP No 5 hoses pressure regulator vacuum hose MAP sensor connector TP sensor connector IAC valve connector Remove the cruise actuator cable from the cable stay and disconnect it from the actuator drum Remove the throttle cables from the cable stay and disconnect them from the thro...

Page 190: ...ing them can cause throttle and idle valve synchronization failure The parts of the throttle body not shown in this manual should not be disassembled IAC VALVE Remove the two screws IAC valve and seal rubber Install a new seal rubber into the throttle body groove Install the IAC valve and tighten the screws IAC VALVE SCREWS TORQUE 4 N m 0 4 kgf m 2 9 lbf ft SEAL RUBBER ...

Page 191: ...the insulators and bands are installed properly as shown Connect the throttle cables to the throttle drum and install them onto the cable stay Screw in the throttle cable end bolts fully and tighten them Connect the cruise actuator cable to the actuator drum and install it onto the cable stay Adjust the cable position with the nuts so that the distance between the cable cap screw end and stay is 3...

Page 192: ...ws so that the distance between the band tabs is 12 1 mm 0 47 0 04 in Check the following and adjust if necessary throttle cable page 3 5 cruise actuator cable page 21 16 FUEL INJECTORS INSPECTION Remove the injector covers page 5 61 Start the engine and let it idle Confirm proper injector operation with a sounding rod or stethoscope If any injector does not operate replace it REMOVAL Remove the r...

Page 193: ...he fuel pressure Remove the two bolts and radiator stay Disconnect the injector connectors Left side Remove the four bolts fuel feed hose joint and pressure regulator stay from the fuel rail Right side Remove the four bolts and fuel feed hose joints CONNECTORS FEED HOSE JOINT BOLTS PRESSURE REGULATOR STAY FEED HOSE JOINTS BOLTS ...

Page 194: ...e Remove the injector clips and injectors from the fuel rail Remove the O rings from the injectors INSTALLATION Coat new O rings with oil and install them into the injector grooves Install the injectors into the fuel rail Install the injector clips Coat new O rings with oil and install them into the injector grooves Install the fuel rail assembly onto the intake mani fold while inserting the injec...

Page 195: ...ll them into the fuel feed hose joints Left side Install the fuel feed hose joint and pressure regula tor stay onto the fuel rail Install and tighten the joint bolts Right side Install the fuel feed hose joints onto the fuel rail Install and tighten the joint bolts TORQUE 10 N m 1 0 kgf m 7 lbf ft FUEL RAIL ASSEMBLY BOLTS O RINGS TORQUE 10 N m 1 0 kgf m 7 lbf ft FEED HOSE JOINT BOLTS PRESSURE REGU...

Page 196: ...tor Remove the O rings from the joint pipe Coat the new O rings with oil and install them onto the joint pipe Install the joint pipe into the pressure regulator stay Connect the fuel return hose and vacuum hose onto the pressure regulator Install the pressure regulator onto the stay and tighten the nut by hand Align the index lugs on the pressure regulator and stay and tighten the nut while holdin...

Page 197: ...e GO TO STEP 2 2 Turn the ignition switch to OFF and remove the fuel pump relay Turn the ignition switch to ON Measure the voltage between the Black yellow wire terminal of the relay connector and ground There should be battery voltage If there is no voltage GO TO STEP 3 If there is battery voltage GO TO STEP 4 3 Turn the ignition switch to OFF and remove the PGM FI ignition relay Check for contin...

Page 198: ...nnectors There should be continuity If there is no continuity repair the open circuit in the Brown black wire If there is continuity replace the ECM with a new one and inspect again BARO MAP SENSORS OUTPUT VOLTAGE INSPECTION Connect the ECM test harness to the ECM connec tors page 5 11 Turn the ignition switch to ON and engine stop switch to Measure the voltage at the ECM test harness con nector t...

Page 199: ...page 5 58 and replace the sensor page 5 68 IAT SENSOR REPLACEMENT Remove the control unit holder page 3 6 Disconnect the IAT sensor 2P connector Remove the IAT sensor from the grommet Installation is in the reverse order of removal CAMSHAFT POSITION SENSOR REPLACEMENT Remove the injector cover page 5 61 Disconnect the camshaft position sensor 2P connec tor Remove the bolt and camshaft position sen...

Page 200: ... 18 Remove the O2 sensor from the exhaust pipe Install an new O2 sensor and tighten it Connect the O2 sensor connector page 2 20 Install the top shelter page 2 12 KNOCK SENSOR REPLACEMENT Remove the front exhaust pipe protector page 2 18 Remove the front lower fairing page 2 6 Disconnect the knock sensor 1P connector Remove the knock sensor from the cylinder Install a new knock sensor and tighten ...

Page 201: ...ector Remove the two bolts and the vehicle speed sensor from the crankcase Coat a new O ring with engine oil and install it onto a new vehicle speed sensor Install vehicle the speed sensor and tighten the bolts securely Route the vehicle speed sensor wire properly page 1 23 and connect the connector Install the following right front exhaust pipe protector page 2 18 top shelter page 2 12 3P CONNECT...

Page 202: ...h the engine stop switch turned to Measure the voltage between the test pin box No 1 terminal and ground There should be battery voltage If there is no voltage check for an open circuit in Black yellow wire between the ECM and PGM FI ignition relay If the wire is OK check the PGM FI ignition relay cir cuits page 18 11 SECONDARY AIR SUPPLY SYSTEM SYSTEM INSPECTION Start the engine and warm it up to...

Page 203: ...2P connector and air supply hoses from the PAIR control solenoid valve and remove the solenoid valve Check air flow from hose fitting A input port to hose fitting B output port Air should flow out Connect a 12 V battery to the solenoid valve connector Air should not flow when the battery is connected Install the PAIR control solenoid valve in the reverse order of removal PAIR CHECK VALVE REPLACEME...

Page 204: ... necessary Replace the PAIR check valve if the seat rubber is cracked deteriorated or damaged or if there is clearance between the reed and seat Install the PAIR check valve and cover onto the cylinder Install and tighten the bolts Install the intake manifold with new gaskets and tighten the bolts securely Install the engine section 7 HOSES COVERS BOLTS PAIR CHECK VALVE TORQUE 5 N m 0 5 kgf m 3 6 ...

Page 205: ...P canister in the reverse order of removal EVAP PURGE CONTROL SOLENOID VALVE INSPECTION Remove the center inner fairing page 2 10 Disconnect the 2P connector No 4 and No 5 hoses from the EVAP purge control solenoid valve Remove the EVAP purge control solenoid valve from the stay Check the air flow from hose fitting A input port to hose fitting B output port Air should not flow Connect a 12 V batte...

Page 206: ...nnectors If there is continuity GO TO STEP 2 If there is no continuity repair the black wire 2 Remove the air cleaner housing page 5 57 Temporarily install the fuel tank Connect the ECM IAT sensor and BARO sensor connectors 3 Start the engine warm it up to normal operating temperature and let it idle Disconnect the idle air control IAC valve 3P connector Block the air passages in the throttle body...

Page 207: ... securely Connect the loose hose securely or replace the damaged hose with a new one as necessary Connect the loose hose securely or replace the damaged hose with a new one as necessary 4 Disconnect the IAC valve 3P connector Temporarily install the fuel tank Connect the ECM IAT sensor and BARO sensor connectors Start the engine warm it up to normal operating temperature and let it idle Block the ...

Page 208: ...of specification replace the IAC valve If the idle speed is within the specification GO TO STEP 7 7 Stop the engine and connect the IAC valve 3P connector Start the engine and check the idle speed If the idle speed is higher than specification replace the IAC valve If the idle speed is within specification the system is OK IDLE SPEED 1 500 1 600 rpm IDLE SPEED 700 70 rpm ...

Page 209: ...MEMO ...

Page 210: ...6 1 6 6 COOLING SYSTEM COMPONENT LOCATION 6 2 SERVICE INFORMATION 6 3 TROUBLESHOOTING 6 4 SYSTEM TESTING 6 5 COOLANT REPLACEMENT 6 6 RADIATOR COOLING FAN 6 8 WATER PUMP THERMOSTAT 6 17 ...

Page 211: ...COOLING SYSTEM 6 2 COOLING SYSTEM COMPONENT LOCATION LEFT RADIATOR RIGHT RADIATOR RESERVE TANK THERMOSTAT WATER PUMP DRAIN BOLT ...

Page 212: ...omiting gargle and consult a doctor immediately If any coolant get on your skin or clothes rinse thoroughly with plenty of water Refer to section 19 for coolant temperature indicator SPECIFICATIONS TORQUE VALUES Removing the radiator cap while the engine is hot can allow the coolant to spray out seriously scalding you Always let the engine and radiator cool down before removing the radiator cap IT...

Page 213: ...ocked in radiator hoses or water jacket Air in system Faulty cooling fan motor Faulty water pump Engine temperature too low Faulty temperature gauge or ECT sensor Thermostat stuck open Coolant leaks Faulty water pump mechanical seal Deteriorated O rings Faulty radiator cap Damaged or deteriorated cylinder head gasket Loose hose connection or clamp Damaged or deteriorated hoses ...

Page 214: ... 013 1 011 1 009 1 007 1 005 15 1 028 1 027 1 026 1 025 1 024 1 022 1 020 1 018 1 016 1 014 1 012 20 1 036 1 035 1 034 1 033 1 031 1 029 1 027 1 025 1 023 1 021 1 019 25 1 045 1 044 1 043 1 042 1 040 1 038 1 036 1 034 1 031 1 028 1 025 30 1 053 1 052 1 051 1 047 1 046 1 045 1 043 1 041 1 038 1 035 1 032 35 1 063 1 062 1 060 1 058 1 056 1 054 1 052 1 049 1 046 1 043 1 040 40 1 072 1 070 1 068 1 066...

Page 215: ...r and install the radiator cap Install the right fairing pocket page 2 12 COOLANT REPLACEMENT PREPARATION Using coolant with silicate corrosion inhibitors may cause premature wear of water pump seals or blockage of radiator passages Using tap water may cause engine damage The effectiveness of coolant decreases with the accumulation of rust or if there is a change in the mixing proportion during us...

Page 216: ...in the coolant from the system by removing the drain bolt and sealing washer Reinstall the drain bolt with a new sealing washer Remove the reserve tank mounting bolt and collar Remove the reserve tank from the frame Disconnect the siphon hose and overflow hose from the reserve tank Empty the coolant and rinse the inside of the reserve tank with water Connect the siphon hose and overflow hose Insta...

Page 217: ...the radiator cap Remove the reserve tank cap dipstick Fill the reserve tank to the upper level hole of the dipstick with the motorcycle on its center stand on a flat level surface Install the following left engine side cover page 2 5 front lower fairing page 2 6 right fairing pocket page 2 12 RADIATOR COOLING FAN REMOVAL Drain the coolant from the system page 6 6 Remove the front fairing page 2 10...

Page 218: ...the three trim clips and air duct Remove the radiator grille from the radiator by releasing the four hooks from the tabs Disconnect the siphon hose Loosen the band screws and disconnect the radiator hose and bleed hose Loosen the bolt and remove the filler neck from the radiator shroud TRIM CLIPS ...

Page 219: ... two mounting bolts and the right radia tor assembly LEFT RADIATOR Be careful not to damage the radiator fins while servicing the radiator Disconnect the left radiator fan motor 2P black connector Remove the two screws attaching the connector holder to the air duct BOLTS 2P BLACK CONNECTOR AIR DUCT TRIM CLIP SCREWS ...

Page 220: ...leasing the four hooks from the tabs Loosen the band screws and disconnect the bleed hose drain hose upper and lower radiator hoses Remove the two mounting bolts and the left radia tor assembly DISASSEMBLY Remove the three bolts condenser and the fan shroud motor assembly from the radiator BOLTS BOLTS CONDENSER ...

Page 221: ...COOLING SYSTEM 6 12 Remove the nut and cooling fan from the fan motor Remove the three bolts and fan motor from the shroud ASSEMBLY ...

Page 222: ...urely Install the cooling fan onto the motor shaft aligning the flat surfaces Apply locking agent to the fan nut threads Install the nut and tighten it securely Install the fan shroud motor assembly and con denser and tighten the three bolts securely INSTALLATION RIGHT RADIATOR Install the right radiator by inserting the boss into the grommet in the stay FAN MOTOR BOLTS DRAIN HOSE BOLTS CONDENSER ...

Page 223: ...d and tighten the bolt securely Connect the radiator hose and bleed hose and tighten the band screws securely Connect the siphon hose and secure it with the clip Install the right radiator grille onto the radiator The right radiator grille has an R mark TORQUE 14 N m 1 4 kgf m 10 lbf ft BOLTS UPPER RADIATOR HOSE LOWER RADIATOR HOSE DRAIN HOSE BLEED HOSE FILLER NECK BOLT RADIATOR HOSE SIPHON HOSE ...

Page 224: ...nnector holder onto the air duct and tighten the screws securely Connect the right fan motor 2P white connector LEFT RADIATOR Install the left radiator by inserting the boss into the grommet in the stay Install the two mounting bolts and tighten them AIR DUCT TRIM CLIPS 5 4 95 2P WHITE CONNECTOR TORQUE 14 N m 1 4 kgf m 10 lbf ft BOLTS ...

Page 225: ... the left air duct and secure it with the three trim clips The left air duct has an L mark Install the connector holder onto the air duct and tighten the screws securely Connect the left fan motor 2P black connector Install the top shelter page 2 11 Install the front fairing page 2 10 Fill and bleed the cooling system page 6 6 BLEED HOSE UPPER RADIATOR HOSE DRAIN HOSE LOWER RADIATOR HOSE TRIM CLIP...

Page 226: ...ced REMOVAL The water pump and thermostat can be removed with the engine in the frame Drain the coolant from the system page 6 7 Remove the starter reverse motor page 19 17 Remove the alternator page 17 10 Loosen the hose band screws and disconnect the three water hoses from the water pump Remove the three pump cover bolts and three water pump mounting bolts Remove the water pump cover Remove the ...

Page 227: ... Suspend the thermostat in the heated water to check its operation Replace the thermostat if the valve opens at a tem perature other than those specified INSTALLATION Install the pump shaft joint and secure it with a new lock pin LOCK PIN PUMP SHAFT JOINT Wear insulated gloves and ade quate eye protection Keep flammable materials away from the electric heating element Do not let the thermostat or ...

Page 228: ...he starter clutch bolt Install a new O ring onto the water pump groove Install a new rubber seal onto the thermostat flange Install the thermostat into the water pump cover with the hole facing upward while aligning the lug with the cover groove as shown Install the water pump cover onto the pump Install the three cover bolts and three mounting bolts and tighten them O RING O RING TORQUE Cover bol...

Page 229: ...EM 6 20 Connect the water hoses to the water pump and tighten the hose band screws securely Install the alternator page 17 18 Install the starter reverse motor page 19 23 Fill and bleed the cooling system page 6 6 ...

Page 230: ...7 1 7 7 ENGINE REMOVAL INSTALLATION COMPONENT LOCATION 7 2 SERVICE INFORMATION 7 3 ENGINE REMOVAL 7 5 ENGINE INSTALLATION 7 11 ...

Page 231: ...ENGINE REMOVAL INSTALLATION 7 2 ENGINE REMOVAL INSTALLATION COMPONENT LOCATION ...

Page 232: ...e lock nut wrench use a deflecting beam type torque wrench 20 inches long The lock nut wrench increases the torque wrench s leverage so the torque wrench reading will be less than the torque actually applied to the lock nut The specification given on the next page is the actual torque applied to the lock nut not the reading on the torque wrench when used with the lock nut wrench The procedure late...

Page 233: ...ENGINE REMOVAL INSTALLATION 7 4 TOOLS Lock nut wrench 07908 ME90000 or 07GMA KT7A200 U S A only Lock nut wrench 20 mm 07VMA MBB0101 ...

Page 234: ...ank page 6 8 throttle body page 5 58 both injector covers and radiator stay page 5 61 Wrap the intake ports with a shop towel or cover them with a piece of tape to prevent any foreign material from dropping into the engine Disconnect the ignition pulse generator 2P red connector Disconnect the reverse shift actuator 3P red and 2P white connectors Disconnect the gear position switch 6P black connec...

Page 235: ...tand switch 3P green connec tor and remove the wire band Slide the rubber cap off the alternator terminal and remove the terminal nut and alternator cable Disconnect the alternator 4P connector Disconnect the evaporative emission EVAP purge control solenoid valve connector Remove the EVAP purge control solenoid valve from the stay Remove the spark plug wires from the ignition coils Remove the wire...

Page 236: ...e band Remove the two bolts EVAP canister bracket and coolant drain joint from the engine Drain the clutch fluid from the hydraulic system page 9 7 Remove the clutch slave cylinder oil bolt and seal ing washers Remove the gearshift pedal pivot bolt and washer Remove the pinch bolt and gearshift pedal arm from the gearshift spindle WIRE BAND EVAP CANISTER BRACKET OIL BOLT AND SEALING WASHERS ...

Page 237: ...gs Remove the two bolts and fuel feed hose joint from the right fuel rail Place a floor jack or other adjustable support under the engine The jack height must be continually adjusted to relieve stress for ease of bolt removal Loosen the three left sub frame mounting bolts ENGINE GUARD BOLTS FOOTPEG FEED HOSE JOINT BOLTS SUB FRAME ...

Page 238: ...ut Remove the left front engine hanger bolt and nut Remove the left rear engine hanger bolt Loosen the left center engine hanger adjusting bolt lock nut using the special tool Remove the lock nut Loosen the left center engine hanger adjusting bolt TOOL Lock nut wrench 20 mm 07VMA MBB0101 LOCK NUT WRENCH LOCK NUT ADJUSTING BOLT ...

Page 239: ...rear engine hanger adjusting bolt lock nut using the special tool Remove the lock nut Loosen the left rear engine hanger adjusting bolt Remove the three bolts and left sub frame Remove the right center engine hanger bolt and nut Remove the right front engine hanger bolt and nut TOOL Lock nut wrench 07908 ME90000 or 07GMA KT7A200 U S A only TOOL Lock nut wrench 07908 ME90000 or 07GMA KT7A200 U S A ...

Page 240: ...ing the engine route the wires hoses and cables properly page 1 23 When tightening the lock nut with the lock nut wrench refer to torque wrench reading informa tion on page 7 3 SERVICE INFORMATION A hoist or equivalent is required to support the motorcycle when installing the engine Be sure to use the engine hanger adjusting bolts adjusting bolt lock nuts hanger bolts and hanger nuts in their corr...

Page 241: ...th the output shaft splines Install the joint boot over the output gear case securely Temporarily install the sub frames front and rear engine hanger bolts and nuts then tighten the engine mounting fasteners to the specified torque in the correct sequence 1 Tighten the right sub frame mounting bolts 2 Install and tighten the right rear engine hanger bolt Be careful not to damage the wire harnesses...

Page 242: ...center engine hanger bolt 5 Tighten the left sub frame mounting bolts 6 Tighten the left rear engine hanger adjusting bolt until it contacts the engine TORQUE 64 N m 6 5 kgf m 47 lbf ft TORQUE 39 N m 4 0 kgf m 29 lbf ft LEFT SUB FRAME BOLTS TORQUE 4 N m 0 4 kgf m 2 9 lbf ft LEFT REAR ADJUSTING BOLT ...

Page 243: ... lock nut onto the left center engine hanger adjusting bolt Hold the adjusting bolt and tighten the lock nut using the special tool 10 Remove the left front engine hanger bolt Tighten the left front engine hanger adjusting bolt until it contacts the engine TOOL Lock nut wrench 07908 ME90000 or 07GMA KT7A200 U S A only TORQUE 54 N m 5 5 kgf m 40 lbf ft TORQUE 4 N m 0 4 kgf m 2 9 lbf ft LEFT CENTER ...

Page 244: ... and tighten the left rear engine hanger bolt 13 Install and tighten the left front engine hanger bolt 14 Install and tighten the left center engine hanger bolt TOOL Lock nut wrench 07908 ME90000 or 07GMA KT7A200 U S A only TORQUE 54 N m 5 5 kgf m 40 lbf ft TORQUE 64 N m 6 5 kgf m 47 lbf ft TORQUE 64 N m 6 5 kgf m 47 lbf ft TORQUE 39 N m 4 0 kgf m 29 lbf ft LEFT CENTER ENGINE HANGER BOLT ...

Page 245: ...unting bolts Install both engine guards onto the frame and tighten the mounting bolts securely Apply grease to the gearshift pedal link tie rod ball joints and gearshift pedal pivot Install the gearshift arm onto the gearshift spindle by aligning the slit of the arm with the punch mark on the spindle Install the pinch bolt and tighten it securely Install the washer and gearshift pedal onto the sub...

Page 246: ...P canister bracket onto the engine with the two mounting bolts Connect the No 4 and No 1 hoses to the EVAP canister Install the wire band Connect the connectors to both horns Connect both knock sensor connectors Install the wire clamp onto the No 2 and No 5 spark plug wires and install it onto the stay Connect the spark plug wires to the ignition coils Install the EVAP purge control solenoid valve...

Page 247: ...e motor terminal and tighten the nut securely Install the rubber cap onto the starter reverse motor terminal Do not over tighten the terminal nut Install the reverse switch wire and nut onto the reverse switch terminal and tighten the nut Install the rear brake master cylinder reservoir stay by aligning the stay tab with the hole in the crankcase Install the stay bolt and tighten it securely Conne...

Page 248: ...3P red and 2P white connectors Connect the gear position switch 6P black connector Install the following radiator stay and both injector covers throttle body page 5 60 radiator reserve tank page 6 7 exhaust system page 2 20 center inner fairing page 2 6 both engine side covers page 2 5 both side covers page 2 5 Fill the crankcase with the recommended engine oil if drained page 3 11 CONNECTORS ...

Page 249: ...MEMO ...

Page 250: ...OVER REMOVAL 8 6 CAMSHAFT REMOVAL 8 7 CAM CHAIN REMOVAL 8 12 CYLINDER HEAD REMOVAL 8 14 CYLINDER HEAD DISASSEMBLY 8 16 VALVE GUIDE REPLACEMENT 8 19 VALVE SEAT INSPECTION REFACING 8 19 CYLINDER HEAD ASSEMBLY 8 22 CYLINDER HEAD INSTALLATION 8 24 CAM CHAIN INSTALLATION 8 26 CAMSHAFT INSTALLATION 8 28 CYLINDER HEAD COVER INSTALLATION 8 32 ...

Page 251: ...CYLINDER HEAD VALVE 8 2 CYLINDER HEAD VALVE COMPONENT LOCATION ...

Page 252: ... guide Valve stem O D IN 4 970 4 995 0 1957 0 1967 4 96 0 195 EX 4 955 4 980 0 1951 0 1961 4 95 0 195 Valve guide I D IN EX 5 000 5 012 0 1969 0 1973 5 04 0 198 Stem to guide clearance IN 0 005 0 042 0 0002 0 0017 0 075 0 0030 EX 0 020 0 057 0 0008 0 0022 0 085 0 0033 Valve guide projection above cylinder head IN EX 11 8 12 0 0 46 0 47 Valve seat width IN EX 0 9 1 1 0 035 0 043 1 5 0 06 Valve spri...

Page 253: ...mm 45 EX 07780 0010300 or equivalent commercially available in U S A Flat cutter 35 mm 32 IN 07780 0012300 or equivalent commercially available in U S A Flat cutter 33 mm 32 EX 07780 0012900 or equivalent commercially available in U S A Interior cutter 30 mm 60 IN EX 07780 0014000 or equivalent commercially available in U S A Cutter holder 6 6 mm 07781 0010400 or equivalent commercially available ...

Page 254: ...inder head Leaking or damaged cylinder head gasket Warped or cracked cylinder head Loose spark plug Cylinder piston problem section 11 Compression too high Excessive carbon build up on piston head or combustion chamber Excessive smoke Worn valve stem or valve guide Damaged stem seal Cylinder piston problem section 11 Excessive noise Incorrect valve clearance Sticking valve or broken valve spring W...

Page 255: ... rising The maximum reading is usually reached within 4 7 seconds Low compression can be caused by blown cylinder head gasket improper valve adjustment valve leakage worn piston ring or cylinder High compression can be caused by carbon deposits in combustion chamber or on piston head CYLINDER HEAD COVER REMOVAL Remove the following five rubber plugs five socket bolts cylinder head side cover bolt ...

Page 256: ...ner body Push the special tool into the tensioner so the blade of the tool is in the tensioner and the tabs are just above the slots in the tensioner There should be space between the bottom of the tool and the ten sioner body do not engage the teeth on the special tool with the slots in the tensioner body Unscrew the rod from the tool and pull the ring until the tool stops turning the tensioner l...

Page 257: ...st above the slots in the tensioner There should be space between the bottom of the tool and the tensioner body do not engage the teeth on the special tool with the slots in the tensioner body Turn the tool clockwise until it stops turning the tensioner lifter shaft is fully secured with the special tool Remove the timing hole cap Rotate the crankshaft counterclockwise and align the 1 2 TF mark on...

Page 258: ... Remove the camshaft holder Remove the cam chain off the cam sprocket being careful not to damage the cylinder head and cam shaft and then remove the camshaft Be careful not to jam the removed cam chain into the timing sprocket of the crankshaft when rotating the crankshaft Rotate the crankshaft counterclockwise 360 one full turn and align the 1 2TF mark on the ignition pulse generator rotor with ...

Page 259: ... shims to fall into the cyl inder head Mark all valve lifters and shims to ensure correct reassembly in their original locations The valve lifters can be easily removed with a valve lapping tool or magnet The shims can be easily removed with tweezers or a magnet INSPECTION CAMSHAFT Check the cam sprocket for wear or damage Check the cam and journal surfaces of the camshaft for scoring scratches or...

Page 260: ...es Install the dowel pins and camshaft holder onto the cylinder head being careful not to drop the plastigauge Apply oil to the threads and seating surfaces of the camshaft holder bolts and install them Tighten the holder bolts in several steps according to the numerical order cast on the camshaft holder 1 thru 8 Remove the camshaft holder and measure the compressed plastigauge at its widest point...

Page 261: ...eft camshaft with the OUT mark on the rotor facing out Apply locking agent to the threads of the sprocket bolts Install the bolts and tighten them CAM CHAIN REMOVAL Remove the camshaft page 8 7 Remove the following twelve crankcase cover bolts front crankcase cover two dowel pins two bolts and wire retainer ignition pulse generator grommet gasket pulse generator bolt and washer ignition pulse gene...

Page 262: ...olts left cam chain tensioner right cam chain guide washer bolt and left cam chain guide right and left cam chains timing sprocket key INSPECTION TIMING SPROCKET CAM CHAIN Check the sprocket teeth and chain for wear or damage CAM CHAIN TENSIONER GUIDE Check the tensioner and guide for excessive wear or damage ...

Page 263: ...and the left and right radi ator stays Remove the following from the cylinder head two bolts and guide plate spark plug caps spark plugs when the cylinder head is to be disassembled Left cylinder head only camshaft position sensor 2P black connector bolt and camshaft position sensor O ring engine coolant temperature ECT sensor 3P gray connector bolt and water hose joint pipe O ring FUEL RAIL COVER...

Page 264: ...e crankcase and mani fold to support it Remove the following from the cylinder head manifold gasket Left cylinder head only ECT sensor and sealing washer cylinder head bolts three 6 mm bolts and eight 9 mm bolts Remove the cylinder head while disconnecting the water hose joint pipe being careful not to damage the mating surface of the manifold and cylinder head GASKET ...

Page 265: ...d side wall of the container Install the protector into the valve lifter bore To prevent loss of tension do not compress the valve spring more than necessary to remove the cotters Remove the valve spring cotters using the valve spring compressor Mark all parts so they can be placed back in their original locations Remove the following spring retainer valve spring valve stem seal spring seat TOOL V...

Page 266: ...valve areas for cracks Check the cylinder head for warpage with a straight edge and feeler gauge Check the valve lifter bore for scoring scratches or damage Measure each valve lifter bore I D VALVE LIFTER Check the valve lifter for scoring scratches or damage Measure each valve lifter O D SERVICE LIMIT 0 10 mm 0 004 in SERVICE LIMIT 29 04 mm 1 143 in SERVICE LIMIT 28 97 mm 1 141 in ...

Page 267: ...ding guide I D to obtain the stem to guide clearance If the stem to guide clearance exceeds the service limit determine if a new guide with standard dimensions would bring the clearance within tolerance If so replace any guides as necessary and ream to fit If the stem to guide clearance exceeds the service limit with a new guide also replace the valve SERVICE LIMITS IN EX 37 0 mm 1 46 in SERVICE L...

Page 268: ... the reamer clockwise Clean the cylinder head thoroughly to remove any metal particles after reaming and refacing the valve seat page 8 19 VALVE SEAT INSPECTION REFACING INSPECTION Clean all intake and exhaust valves thoroughly to remove carbon deposits Apply a light coat of Prussian Blue to each valve seat Tap the valve against the valve seat several times without rotating the valve to check for ...

Page 269: ...nce If the valve seat width is not within specification reface the valve seat Inspect the valve seat face for Damaged face Replace the valve and reface the valve seat Uneven seat width Replace the valve and reface the valve seat Contact area too low or too high Reface the valve seat REFACING Follow the refacer manufacturer s operating instructions Be careful not to grind the seat more than necessa...

Page 270: ...t material Using a 60 interior cutter remove 1 4 of the exist ing valve seat material TOOLS Valve seat cutter 33 mm IN 07780 0010800 Valve seat cutter 29 mm EX 07780 0010300 Cutter holder 5 0 mm 07781 0010400 or equivalent commercially available in U S A ROUGHNESS TOOLS Flat cutter 35 mm IN 07780 0012300 Flat cutter 33 mm EX 07780 0012900 Cutter holder 5 0 mm 07781 0010400 or equivalent commercial...

Page 271: ...ure Change the angle of the lapping tool frequently to prevent uneven seat wear After lapping wash any residual compound off the cylinder head and valve and recheck the seat contact CYLINDER HEAD ASSEMBLY Excessive lapping pressure may deform or damage the seat Do not allow lap ping compound to enter the guides VALVE VALVE LIFTER SHIM COTTERS SPRING RETAINER VALVE SPRING STEM SEAL SPRING SEAT VALV...

Page 272: ...id damaging the stem seal Install the valve springs with the tightly wound coils facing the combustion chamber Install the spring retainer Install the lifter bore protector made from a film container into the valve lifter bore Install the valve spring cotters using the valve spring compressor Grease the cotters to ease installation To prevent loss of tension do not compress the valve springs more ...

Page 273: ...event interference the cylinder head with the manifold Install the two dowel pins and a new gasket Coat a new O ring with coolant and install it onto the water joint pipe Install the cylinder head while connecting the joint pipe Apply engine oil to the threads and seating sur faces of the 9 mm cylinder head bolts Install the eight 9 mm bolts and three 6 mm bolts and tighten them in a crisscross pa...

Page 274: ...olts Tighten the bolts in a crisscross pattern in several steps Coat a new O ring with coolant and install it onto the water hose joint pipe Install the joint pipe into the cylinder head and tighten the bolt Left cylinder head only Coat a new O ring with engine oil and install it into the groove in the camshaft position sensor Install the camshaft position sensor and tighten the bolt Connect the 2...

Page 275: ... right fuel rail covers with the socket bolts Install the following left and right radiators page 6 8 air cleaner housing page 5 57 exhaust pipe page 2 18 camshaft s page 8 28 CAM CHAIN INSTALLATION Install the following key timing sprocket align the groove with the key cam chains cam chain guides left chain guide washer bolt TORQUE 18 N m 1 8 kgf m 13 lbf ft The cylinder num bers are printed on e...

Page 276: ...oil to the threads and seating surface Clean the gasket mating surfaces of the crankcase and cover thoroughly being careful not to damage them Install the following onto the crankcase cover ignition pulse generator two bolts with retainer apply locking agent to the threads grommet Apply liquid sealant to the mating areas of the crankcase as shown TORQUE 12 N m 1 2 kgf m 9 lbf ft TORQUE 59 N m 6 0 ...

Page 277: ...er cylinder head cover must be removed and the other camshaft position must be checked Install the valve shims in their original locations Coat the outer surfaces of the valve lifters with molybdenum oil solution Install the valve lifters in their original lifter bores being careful not to damage the sliding surfaces of the lifters and bores TORQUE 12 N m 1 2 kgf m 9 lbf ft SHIMS VALVE LIFTER ...

Page 278: ...head cover and check the cam shaft position as shown in the next step If the crankshaft has not been rotated since the camshaft was removed it should not be neces sary to rotate it i e it should still be in the proper position However check the other cam shaft s position as described in the next step to ensure proper camshaft positioning Then install the camshaft The timing marks on the cam sprock...

Page 279: ...am sprocket in its proper location so that the timing marks on the sprocket are flush with the cylinder head surface Make sure the M mark is facing in and the rear end cam lobe is facing out Make sure the guide rails of the cam chain tensioner and guide are positioned over the cam chain properly Be careful not to damage the cylinder head and camshaft GUIDE CHAIN TENSIONER ...

Page 280: ...am sprocket are flush with the cylinder head surface when the 1 2 TF mark on the ignition pulse generator rotor is aligned with the index mark in the front crankcase cover Apply grease to the timing hole cap threads and coat a new O ring with engine oil Install the timing hole cap with the O ring and tighten it Install the cylinder head cover s page 8 32 Install the following left horn with bolt h...

Page 281: ...edges of the cyl inder head as shown Be careful not to damage the semi circular area of the gasket Install the head cover by aligning the semi circular areas of the cylinder head and gasket properly then install the cover bolts left side six bolts right side five bolts by aligning them with the bolt holes in the cylinder head Tighten the head cover bolts in a crisscross pattern in several steps In...

Page 282: ... VALVE 8 33 Install the cylinder head side cover and tighten the five bolts Install the five rubber plugs Fill and bleed the cooling system if the cylinder head was removed page 6 6 TORQUE 10 N m 1 0 kgf m 7 lbf ft ...

Page 283: ...MEMO ...

Page 284: ...9 1 9 9 CLUTCH COMPONENT LOCATION 9 2 SERVICE INFORMATION 9 4 TROUBLESHOOTING 9 6 CLUTCH FLUID REPLACEMENT AIR BLEEDING 9 7 CLUTCH MASTER CYLINDER 9 8 CLUTCH SLAVE CYLINDER 9 12 CLUTCH 9 14 ...

Page 285: ...CLUTCH 9 2 CLUTCH COMPONENT LOCATION ...

Page 286: ...CLUTCH 9 3 ...

Page 287: ...creeps with the clutch disengaged inspect the engine oil viscosity and level before servicing the clutch system SPECIFICATIONS Unit mm in TORQUE VALUES ITEM STANDARD SERVICE LIMIT Specified clutch fluid DOT 4 brake fluid Clutch master cylinder Cylinder I D 14 000 14 043 0 5512 0 5529 14 055 0 5533 Piston O D 13 957 13 984 0 5495 0 5506 13 945 0 5490 Clutch Clutch spring free height 4 8 0 19 4 6 0 ...

Page 288: ...pliers 07914 SA50001 Driver 07749 0010000 Attachment 32 x 35 mm 07746 0010100 Pilot 17 mm 07746 0040400 Shaft holder 07PAB 0010200 or 07924 PJ40001 U S A only Clutch outer holder 07JMB MN50100 Lock nut wrench 46 mm 07JMA MN50100 ...

Page 289: ... system Discs worn Weak clutch spring Clutch regulator valve stuck open section 10 Low oil pressure section 4 Clutch will not disengage or motorcycle creeps with clutch disengaged Air in hydraulic system Low clutch fluid level Stuck piston Leaking hydraulic system Warped plates Oil level too high improper oil viscosity or oil additive used ...

Page 290: ...bleeder to the bleed valve Pump the brake bleeder and loosen the bleed valve Add brake fluid when the fluid level in the reservoir is low Check the fluid level often while bleeding the clutch to prevent air from being pumped into the system When using a brake bleeding tool follow the manufacturer s operating instructions Repeat the above procedures until new fluid flows out of the bleed valve and ...

Page 291: ...bubbles do not appear in the bleed hose Tighten the bleed valve Fill the reservoir to the casting ledge with DOT 4 brake fluid from a sealed container Install the diaphragm set plate and reservoir cap and tighten the cap screws Install the EVAP canister page 5 74 CLUTCH MASTER CYLINDER DISASSEMBLY Drain the clutch fluid from the hydraulic system page 9 7 Disconnect the clutch switch and cruise swi...

Page 292: ...itch pivot nut pivot bolt clutch lever push rod piston boot snap ring spring seat master piston primary cup spring Clean the master cylinder and master piston in clean brake fluid INSPECTION Check the piston cups for wear deterioration or damage Check the spring for damage TOOL Snap ring pliers 07914 SA50001 SPRING CUP MASTER PISTON SPRING SEAT ...

Page 293: ...e master piston O D ASSEMBLY Coat the master piston and piston cups with clean brake fluid Install the primary cup onto the spring Install the spring master piston and spring seat into the master cylinder SERVICE LIMIT 14 055 mm 0 5533 in SERVICE LIMIT 13 945 mm 0 5490 in Do not allow the piston cup lips to turn inside out ...

Page 294: ...he clutch lever pivot Insert the push rod into the hole in the joint piece to install the clutch lever assembly onto the master cylinder Install and tighten the pivot bolt Install and tighten the pivot nut Install the clutch switch and cruise switch with the screws Install the master cylinder and holder by aligning the end of the master cylinder with the punch mark on the handlebar Tighten the upp...

Page 295: ...bolt Connect the clutch switch and cruise switch connectors Fill and bleed the clutch hydraulic system page 9 7 CLUTCH SLAVE CYLINDER DISASSEMBLY Drain the clutch fluid from the hydraulic system page 9 7 Disconnect the clutch hose from the slave cylinder by removing the oil bolt and sealing washers Remove the following three mounting bolts slave cylinder dowel pins lifter rod oil seal 2 TORQUE 34 ...

Page 296: ...ston for scoring or damage Check the clutch lifter rod for bends or damage ASSEMBLY Apply a small amount of silicone grease to the lifter rod contacting area of the piston Apply grease to the lips of a new oil seal and install it into the piston Install a new piston seal into the piston groove Install the piston spring onto the piston Coat the piston and piston seal with clutch fluid and install t...

Page 297: ...oove in the slave cylinder Tighten the oil bolt Fill and bleed the clutch hydraulic system page 9 7 CLUTCH CLUTCH COVER REMOVAL Drain the engine oil page 3 16 Remove the exhaust system page 2 18 Remove the radiator reserve tank page 6 8 Remove the following fuel tank drain tube from clamp eleven bolts and clamp clutch cover two dowel pins oil through pipe and O ring scavenge oil strainer TORQUE 34...

Page 298: ...ke the clutch center lock nut Shift the transmission into any gear except neutral Loosen the lock nut while applying the rear brake If the engine was removed from the frame hold the output shaft with the special tool and loosen the lock nut Remove the following lock nut STOPPER RING LIFTER PLATE A Unstake TOOL Shaft holder 07PAB 0010200 or 07924 PJ40001 U S A only ...

Page 299: ...CLUTCH 9 16 lock washer spring guide clutch spring spring seat clutch center assembly from clutch outer splined washer stopper ring lifter spring clutch lifter plate B ...

Page 300: ... plates While pressing the clutch plate push the clip wire ends from the inside of the clutch center to remove them off the wire hole in the clutch center Continuously press the clutch plate and remove the clip wire from the clip groove in the clutch center Remove the following clutch plate clutch disc B judder spring spring seat CLUTCH PISTON PRESSURE PLATE O RING DISCS AND PLATES DISC B JUDDER S...

Page 301: ...ng and drive the bearing out of the lifter plate Drive a new bearing into the plate with its mark side facing up Install the snap ring into the lifter plate groove securely Install the lifter joint piece into the bearing and secure it with the snap ring CLUTCH DISC Replace the clutch discs and plates as a set Check the clutch discs for signs of scoring or discoloration Measure the clutch disc thic...

Page 302: ...distortion Measure the height of the clutch spring Measure the height of the lifter spring CLUTCH CENTER Check the clutch center for nicks indentations or abnormal wear made by the plates PRESSURE PLATE Clean the inner side of the pressure plate Check the pressure plate for abnormal wear and the oil passages for debris SERVICE LIMIT 4 6 mm 0 18 in SERVICE LIMIT 2 5 mm 0 10 in ...

Page 303: ...he lock nut Remove the special washer and clutch outer CLUTCH OUTER INSTALLATION Clean the primary driven gear boss threads thoroughly Apply molybdenum oil solution to the friction spring cone spring on the reverse side of the clutch outer Install the clutch outer and the special washer with the OUTSIDE mark facing out Be careful not to damage the pri mary driven gear boss threads TOOLS Clutch out...

Page 304: ... clutch outer with the special tool and tighten the lock nut Be careful not to damage the primary driven gear boss threads Stake the lock nut into the driven gear boss groove LOCK NUT TOOLS Clutch outer holder 07JMB MN50100 Lock nut wrench 46 mm 07JMA MN50100 TORQUE 186 N m 19 0 kgf m 137 lbf ft Stake ...

Page 305: ...nto the hole in the clutch center While pressing the clutch plate set the clip wire into the groove in the clutch center firmly and install the other end into the hole to secure it LIFTER SPRING LIFTER PLATE B CLUTCH PISTON O RING PRESSURE PLATE CLUTCH DISC B CLIP WIRE CLUTCH CENTER SPRING SEAT JUDDER SPRING CLUTCH DISCS A 01 03 CLUTCH DISCS C After 03 CLUTCH DISCS A CLUTCH DISC C O RING STOPPER R...

Page 306: ...lates Coat a new O ring with engine oil and install it into the groove in the clutch center boss Install the pressure plate by aligning its convex areas with the grooves in the clutch center Coat a new O ring with engine oil and install it into the groove in the clutch piston Install the clutch piston evenly until it is fully seated Install lifter plate B by aligning the tabs with the oil holes in...

Page 307: ...outside clutch disc into the shal low slots in the clutch outer Line up the disc tabs carefully and install the clutch center assembly by aligning the disc tabs with the slots in the clutch outer Install the spring seat with the concave side facing out Install the clutch spring and spring guide with the concave side of the spring facing in Install the lock washer Make sure the stop per ring is sea...

Page 308: ...oove Apply engine oil to the sliding surface of the lifter joint piece Install lifter plate A and secure it with the stopper ring CLUTCH COVER INSTALLATION Apply grease to the lips of a new lifter joint piece oil seal Install the oil seal into the clutch cover with the flat side facing up until the snap ring groove is visible Install the snap ring into the cover groove securely TORQUE 127 N m 13 0...

Page 309: ... gasket Install the clutch cover being careful not to damage the oil seal in the cover Install the 11 cover bolts with the clamp and tighten them in a crisscross pattern in several steps Install the radiator reserve tank page 6 8 Install the fuel tank drain tube and reserve tank breather tube into the clamp on the clutch cover properly page 1 23 Install the exhaust system page 2 18 Fill the crankc...

Page 310: ...SHOOTING 10 7 GEARSHIFT LINKAGE 10 8 REAR CRANKCASE COVER REMOVAL 10 11 PRIMARY GEARS OUTPUT SHAFT REMOVAL 10 13 CRANKCASE COVER BEARING REPLACEMENT 10 19 PRIMARY GEARS OUTPUT SHAFT INSTALLATION 10 20 REAR CRANKCASE COVER INSTALLATION 10 24 TRANSMISSION DISASSEMBLY 10 26 TRANSMISSION ASSEMBLY 10 33 ...

Page 311: ...GEARSHIFT LINKAGE TRANSMISSION 10 2 GEARSHIFT LINKAGE TRANSMISSION COMPONENT LOCATION ...

Page 312: ...GEARSHIFT LINKAGE TRANSMISSION 10 3 ...

Page 313: ...Do not overtighten the lock nut The specification later in the text gives both actual and indicated SPECIFICATIONS Unit mm in ITEM STANDARD SERVICE LIMIT Output shaft Damper spring free length 66 0 2 60 64 0 2 52 Shaft O D 22 008 22 021 0 8665 0 8670 21 99 0 866 Gear bushing I D 22 026 22 041 0 8672 0 8678 22 05 0 868 O D 25 959 25 980 1 0220 1 0228 25 95 1 022 Driven gear I D 26 000 26 013 1 0236...

Page 314: ...ft spindle return spring pin 25 N m 2 5 kgf m 18 lbf ft Final drive gear lock nut 186 N m 19 0 kgf m 137 lbf ft Apply engine oil to the threads and seating surface left hand threads stake the nut Alternator drive gear bolt 25 N m 2 6 kgf m 19 lbf ft Apply engine oil to the threads and seating surface Oil pump driven sprocket bolt 18 N m 1 8 kgf m 13 lbf ft Apply locking agent to the threads Starte...

Page 315: ...m 07746 0040500 Pilot 25 mm 07746 0040600 Pilot 28 mm 07746 0041100 Pilot 30 mm 07746 0040700 Driver 22 mm I D 07746 0020100 Bearing remover 12 mm 07936 1660110 Remover shaft 07936 1660120 or 07936 166010A U S A only Remover weight 07741 0010201 or 07936 371020A or 07936 3710200 U S A only Shaft holder 07PAB 0010200 or 07924 PJ40001 U S A only ...

Page 316: ...ft cam Broken drum stopper arm spring Worn gear dogs Worn gear shifter groove Bent shift fork shaft Broken shift drum stopper arm Worn or bent shift forks Broken gearshift spindle return spring Excessive engine noise Worn or damaged transmission gears or bearing Worn or damaged primary drive and driven gears or bearing Worn or damaged alternator drive and driven gears or bearing Worn or damaged fi...

Page 317: ...e bolts and clutch slave cylinder two dowel pins To keep the slave cylinder piston from being forced out of the cylinder squeeze the clutch lever and tie it to the handlebar Remove the following seven cover bolts gearshift linkage cover two dowel pins grommet from cover two bolts and gear position switch gasket bolt and shift drum joint four dowel pins Do not disconnect the clutch hose Support the...

Page 318: ...in into the shift drum Lift the stopper arm with a screwdriver and install the shift drum cam by aligning the pin groove with the dowel pin Install the four dowel pins into the shift drum cam Apply locking agent to the threads of the shift drum joint bolt Install the shift drum joint by aligning the holes with the dowel pins Install the bolt and tighten it Check the gearshift linkage operation and...

Page 319: ...nt to the mating areas of the crankcase as shown Install the two dowel pins and a new gasket Make sure the pin groove in the shift drum joint faces down transmission is in neutral Align the long end of the switch pin with the tab on the switch Install the linkage cover being careful not to dam age the switch pin Install the seven bolts and tighten them ...

Page 320: ...7 alternator page 17 10 water pump page 6 17 clutch outer page 9 20 Remove the three bolts and the output shaft bearing holder Remove the O ring and oil seal Be careful that metal particles do not enter the bearing and that the output shaft threads are not damaged Unstake the lock nut with a drill or grinder Hold the output shaft and loosen the lock nut using the special tools and breaker bar Remo...

Page 321: ...h bearing with your finger The bearings should turn smoothly and quietly Also check that the bearing outer race fits tightly in the cover CLUTCH REGULATOR VALVE CHECK Remove the following snap ring spring seat valve spring piston Check the piston for wear unsmooth movement or other damage Check the spring for fatigue or damage Install the piston spring and spring seat and secure them with the snap...

Page 322: ...e pri mary driven gear boss Hold the clutch outer with the special tool and loosen the starter clutch bolt Remove the clutch outer Remove the following starter clutch bolt washer starter clutch assembly Replace the starter clutch as an assembly Make sure the starter driven gear rotates smoothly The gear should only rotate clockwise and lock up in the other direction Remove the starter driven gear ...

Page 323: ... teeth of the scissor gears primary drive gear and sub gear by inserting a screwdriver into the gear holes and prying the scissor gear spline washer primary drive gear six bolts alternator drive gear reverse shifter and shift drum lock arm page 19 46 output shaft assembly OUTPUT SHAFT ASSEMBLY ...

Page 324: ...set two bolts and oil separation plate if necessary Check the driven gear boss bearing for wear or damage Be careful not to damage the countershaft threads Unstake the final drive gear lock nut with a drill or grinder The final drive gear lock nut has left hand threads Shift the transmission into any forward gear except neutral Hold the mainshaft with the special tool and loosen the lock nut Remov...

Page 325: ...ools OUTPUT SHAFT DISASSEMBLY INSPECTION Turn the bearing outer race with your finger The bearing should turn smoothly and quietly Remove the following snap ring retainer cotters Press the output shaft out of the bearing using a suitable collar about 20 mm O D and remove the following bearing gear bushing final driven gear TOOLS Driver 07749 0010000 Attachment 28 x 30 mm 07946 1870100 Pilot 28 mm ...

Page 326: ...l driven gear for abnormal wear or damage Measure the driven gear I D Measure the bushing O D and I D Measure the shaft O D OUTPUT SHAFT ASSEMBLY SERVICE LIMIT 64 0 mm 2 52 in SERVICE LIMIT 26 03 mm 1 025 in SERVICE LIMIT O D 25 95 mm 1 022 in I D 22 05 mm 0 868 in SERVICE LIMIT 21 99 mm 0 866 in OUTPUT SHAFT DAMPER LIFTER WASHER COTTERS RETAINER SNAP RING BEARING BUSHING REVERSE DRIVEN GEAR FINAL...

Page 327: ...fter lugs gear bushing apply engine oil Install the bearing with the sealed side facing up Press a new bearing onto the output shaft using the special tool Install the cotters into the cotter groove Install the retainer by aligning its tab with the groove in the shaft and turn it to set the tab in the opposite position of the groove Secure the retainer with the snap ring TOOL Driver 22 mm I D 0774...

Page 328: ...to the crankcase cover with the markings facing up Use new bearings TOOLS Bearing remover 12 mm 07936 1660110 Remover shaft 07936 1660120 or 07936 166010A U S A only Remover weight 07741 0010201 or 07936 371020A or 07936 3710200 U S A only REVERSE SHIFTER SHAFT ALTERNATOR DRIVEN GEAR PRIMARY DRIVEN GEAR OUTPUT SHAFT TOOLS Driver 07749 0010000 Attachment 42 x 47 mm 07746 0010300 Pilot 20 mm 07746 0...

Page 329: ...nd sliding surface Install the final drive gear and lock washer onto the countershaft with the OUTSIDE mark on the washer facing out The final drive gear lock nut has left hand threads Apply engine oil to the threads and seating surface of a new lock nut and install it Hold the mainshaft with the special tool and tighten the lock nut TOOLS Driver 07749 0010000 Attachment 78 x 90 mm 07GAD SD40101 T...

Page 330: ...boss Install the oil pump driven sprocket drive chain and driven gear boss as a set with the OUT mark of the sprocket facing out Apply locking agent to the threads of the driven sprocket bolt and install it Temporarily install the clutch outer on the driven gear boss Hold the clutch outer with the special tool and tighten the sprocket bolt Stake OIL SEPARATE PLATE DRIVEN GEAR BOSS SPROCKET OUT CHA...

Page 331: ... cap and hold the ignition pulse generator bolt which is located on the oppo site side of the crankcase and tighten the bolts Install the shift drum lock arm and reverse shifter page 19 43 Install the primary drive gear and spline washer Install the primary driven gear with the long boss side facing out while aligning the scissors gears primary drive gear and sub gear by inserting the screwdriver ...

Page 332: ...install the clutch outer on the primary driven gear boss Hold the clutch outer with the special tool and tighten the starter clutch bolt Install the alternator driven gear assembly while aligning the scissors gears alternator drive gear and sub gear by inserting the screwdriver into the gear holes Install the friction spring and washer with the con cave side of the spring facing in TOOL Clutch out...

Page 333: ... side facing out REAR CRANKCASE COVER INSTALLATION Clean the gasket mating surfaces of the crankcase cover and crankcase thoroughly being careful not to damage them Install the orifice into the crankcase Coat a new O ring with engine oil and install it Install the two dowel pins Apply sealant to the mating areas of the crankcase as shown Install a new gasket ORIFICE O RING GASKET ...

Page 334: ...he transmission into any gear except neutral Hold the output shaft and tighten the lock nut using the special tools Be careful not to damage the output shaft threads Stake the lock nut into the output shaft groove TORQUE 24 N m 2 4 kgf m 17 lbf ft REAR CRANKCASE COVER TOOLS Shaft holder 07PAB 0010200 or 079249 PJ40001 U S A only Lock nut wrench 30 x 64 mm 07916 MB00002 or 07916 MB00001 Refer to to...

Page 335: ... lips Install the three bolts and tighten them Install the following clutch page 9 20 water pump page 6 18 alternator page 17 18 starter reverse motor page 19 17 reverse shift arm cables page 19 49 engine section 7 TRANSMISSION DISASSEMBLY Separate the crankcase page 11 6 RIGHT CRANKCASE SHIFT FORK AND SHIFT DRUM Remove the following two bolts shift drum setting plate TOOLS Driver 07749 0010000 At...

Page 336: ...SSION 10 27 fork shaft shift forks shift drum assembly COUNTERSHAFT Remove the three bolts and countershaft setting plate Slide the countershaft off the crankcase and remove the rear side bearing FORK SHAFT SHIFT FORKS BEARING ...

Page 337: ... Remove the front side bearing and oil pass plate Disassemble the countershaft Clean all disassembled parts in solvent thoroughly LEFT CRANKCASE MAINSHAFT Remove the following two bolts mainshaft setting plate mainshaft assembly dowel pin Disassemble the mainshaft Clean all disassembled parts in solvent thoroughly Check the needle bearing for abnormal wear or damage ...

Page 338: ... A oil seal INSPECTION Check the gearshift spindles for bends Check the spindle arm and spindle plates for wear or damage Check the spindle return spring for fatigue or damage Check the shift fork guide pins for abnormal wear or damage Measure the shift fork I D Measure the shift fork claw thickness ARM PLATE PLATE SPRING SERVICE LIMIT 14 04 mm 0 553 in SERVICE LIMIT 5 6 mm 0 22 in ...

Page 339: ...ring Install the front side bearing Install the dowel pin and the lock cam by aligning the hole in the lock cam with the dowel pin Apply locking agent to the lock cam bolt threads Install the bolt and tighten it Install the rear side bearing Check the gear shifter groove for abnormal wear or damage Check the gear dogs and teeth for abnor mal wear or damage If there is damage to the gear dogs check...

Page 340: ...learance Turn the ball bearing race with your finger The bearing should turn smoothly and quietly Replace the bearing if the race does not turn smoothly or quietly SERVICE LIMITS M4 31 04 mm 1 222 in M5 35 04 mm 1 380 in C2 C3 33 04 mm 1 301 in SERVICE LIMITS M4 30 93 mm 1 218 in M5 34 93 mm 1 375 in C2 C3 32 93 mm 1 296 in SERVICE LIMITS 0 10 mm 0 004 in SERVICE LIMITS M4 28 04 mm 1 104 in M5 32 ...

Page 341: ...ine oil to the threads of a new lock nut Install the collar and the lock nut Hold the mainshaft and tighten the lock nut using the special tools TOOLS Shaft holder 07JMB MN50200 Lock nut wrench 30 x 64 mm 07916 MB00002 or 07916 MB00001 MAINSHAFT BEARING TOOLS Driver 40 mm I D 07746 0030100 Attachment 30 mm I D 07746 0030300 DRIVER ATTACHMENT TOOLS Shaft holder 07JMB MN50200 Lock nut wrench 30 x 64...

Page 342: ...es Always install the thrust washer and snap ring with the chamfered rolled edge facing away from the thrust load see the illustration on page 10 34 Install the snap ring so its end gap aligns with the groove in the splines page 10 33 Make sure the snap ring is fully seated in the shaft groove after installing it Stake LOCK WASHER SNAP RING Gap aligned with spline Gap aligned with groove Incorrect...

Page 343: ...ply engine oil to the gear teeth sliding surfaces bushings and bearing Apply molybdenum oil solution to the gear shifter grooves Assemble the countershaft except the C1 gear front end gear Install the oil pass plate and front side bearing into the right crankcase ...

Page 344: ...he C1 gear onto the countershaft Install the countershaft assembly into the bearing in the crankcase Support the countershaft assembly and install the rear side bearing onto the countershaft and into the crankcase Apply locking agent to the setting plate bolt threads Install the setting plate and tighten the three bolts COUNTERSHAFT ASSEMBLY 4 BEARING TORQUE 12 N m 1 2 kgf m 9 lbf ft ...

Page 345: ...shift fork C center shift fork R rear shift fork Apply engine oil to the outer surface of the shift fork shaft Install the shift forks into the gear shifter grooves front and rear forks and into the shift drum guide grooves with the identification marks facing toward the front side of the engine then insert the fork shaft Apply locking agent to the setting plate bolt threads Install the setting pl...

Page 346: ...eeth sliding surfaces bushings and bearing Apply molybdenum oil solution to the gear shifter groove Assemble the mainshaft Install the dowel pin into the crankcase Install the mainshaft assembly by properly aligning the hole in the needle bearing with the dowel pin See NOTE on page 10 33 ...

Page 347: ...ing careful not to dam age the oil seal lips Install the thrust washer onto gearshift spindle B Place the spindle arm through the notch in spindle A with the flat surface of the arm facing in Then insert spindle B through the crankcase and spindle A align the spring ends with the spring pin Align the bolt holes in the spindle arm and spindle B and install a new lock washer and the bolt Tighten the...

Page 348: ... INFORMATION 11 3 TROUBLESHOOTING 11 5 CRANKCASE SEPARATION 11 6 PISTON CONNECTING ROD REMOVAL 11 7 CRANKPIN BEARING 11 11 CRANKSHAFT REMOVAL 11 13 MAIN JOURNAL BEARING 11 14 CRANKSHAFT INSTALLATION 11 16 PISTON CONNECTING ROD INSTALLATION 11 17 CRANKCASE ASSEMBLY 11 22 ...

Page 349: ...CYLINDER PISTON CRANKSHAFT 11 2 CYLINDER PISTON CRANKSHAFT COMPONENT LOCATION ...

Page 350: ...0 2 917 Out of round 0 10 0 004 Taper 0 10 0 004 Warpage 0 05 0 002 Piston piston pin piston ring Piston O D at 10 mm 0 4 in from bottom 73 970 73 990 2 9122 2 9130 73 85 2 907 Piston pin hole I D 18 010 18 016 0 7091 0 7093 18 03 0 710 Piston pin O D 17 994 18 000 0 7084 0 7087 17 99 0 708 Piston to piston pin clearance 0 010 0 022 0 0004 0 0009 0 05 0 002 Piston ring end gap Top 0 15 0 30 0 006 ...

Page 351: ...AF 0010400 or 07JGF 001010A U S A only Pilot collar 18 mm 07PAF 0010640 or 07KMF MT20200 U S A only Adjustable piston pin driver head 07PAF 0010700 or 07973 6570210 U S A only Adjustable piston pin driver shaft 07PAF 0010800 or 07973 6570300 Piston ring compressor 07JMG MN5000B U S A only or 07JMG MN5000A U S A only Piston base A 07ZMG MCAA100 U S A only Piston base B 07ZMG MCAA200 U S A only ...

Page 352: ...linder and piston Compression too high overheating or knocking Excessive carbon build up on piston head or combustion chamber Excessive smoke Worn cylinder piston or piston rings Improper installation of piston rings Scored or scratched piston or cylinder wall Abnormal noise Worn piston pin or piston pin hole Worn cylinder piston or piston rings Worn main journal bearings Worn crankpin bearings ...

Page 353: ...ace the engine with the left side down Loosen the eleven 6 mm bolts and eight 10 mm bolts in a crisscross cross pattern in several steps Remove the bolts and washers Be careful not to damage the crankcase mating surfaces Lift the right crankcase and separate the crankcase halves and set suitable wooden blocks between them to support the right crankcase To prevent the pistons from falling and from ...

Page 354: ...necting rod Recheck and if it is still out of specification replace the crankshaft PISTON CONNECTING ROD REMOVAL Mark the bearing caps bearings connecting rods and pistons as you remove them to indicate the correct cylinders Remove the bearing cap nuts bearing caps and pis ton connecting rod assemblies of the right cylinder No 1 3 and 5 DOWEL PINS OIL PIPE SERVICE LIMIT 0 40 mm 0 016 in Tap the si...

Page 355: ...r Spread each piston ring and remove it by lifting up at a point opposite the gap Never use a wire brush it will scratch the groove Clean carbon deposits from the ring grooves with a used piston ring that will be discarded Never use a wire brush it will scratch the groove PISTON INSPECTION Inspect the piston rings for movement by rotating the rings The rings should be able to move in their grooves...

Page 356: ...er to piston clearance Calculate the cylinder taper and out of round at three levels on the X and Y axes Take the maximum reading to determine the taper and out of round The cylinder must be rebored and an oversize pis ton fitted if the service limits are exceeded The following oversize pistons are available 0 25 mm 0 010 in 0 50 mm 0 020 in 0 75 mm 0 030 in 1 00 mm 0 040 in SERVICE LIMITS Top 0 5...

Page 357: ...NSPECTION Measure the piston pin O D at piston pin hole areas Measure the piston pin hole I D Calculate the piston to piston pin clearance SERVICE LIMIT 0 05 mm 0 002 in TOOLS Piston base 07973 6570500 Piston base spring 07973 6570600 Piston pin pilot 07PAF 0010300 or Pilot base insert 07973 6570400 U S A only Piston base head 07PAF 0010400 or 07JGF 001010A U S A only TOOLS Pilot collar 18 mm 07PA...

Page 358: ...bearing tabs for damage OIL CLEARANCE INSPECTION Do not rotate the crankshaft and con necting rod during inspection Clean off any oil from the bearing inserts and crankpins Set the connecting rods onto the crankpins Put strips of plastigauge lengthwise on the crank pins being sure to avoid the oil hole Carefully install the bearing caps by aligning the I D code Apply engine oil to the bearing cap ...

Page 359: ...the crankshaft are the codes for the crankpin O D in the sequence from the No 1 crankpin front to rear Record the crankpin O D code letters Cross reference the connecting rod and crankpin codes to determine the replacement bearing color code MAIN JOURNAL BEARING SELECTION TABLE After selecting new bearings recheck the oil clear ance with plastigauge Incorrect oil clearance can cause major engine d...

Page 360: ...der connecting rod page 11 7 Before loosening the bearing cap bolts punch each bolt flange and main journal bearing cap at the same position to indicate the aligning point for tightening the bolts during reassembly Mark the bearing cap bolts and bearings as you remove them to indicate the correct journals Remove the bolts and the main journal bearing caps Move the left crankcase pistons to the top...

Page 361: ...se and main journal bearing caps for unusual wear or peeling Check the bearing tabs for damage Check the thrust bearings on the rear end bearing support of the left crankcase for wear scoring or discoloration and replace them if necessary OIL CLEARANCE INSPECTION Do not rotate the crankshaft during inspection Clean off any oil from the bearing inserts and main journals Carefully install the cranks...

Page 362: ...into the correct bolt holes in the bearing caps Tighten the bolts in a crisscross pattern in several steps to the specified torque Remove the bearing caps and measure the com pressed plastigauge at its widest point on each main journal to determine the oil clearance If the oil clearance exceeds the service limit select the correct replacement bearings BEARING SELECTION Letter A B or C on the front...

Page 363: ... can cause major engine damage BEARING INSTALLATION Clean the bearing outer surfaces bearing caps and crankcase bearing supports Install the main journal bearing inserts onto the bearing caps and crankcase bearing supports align ing each tab with each groove CRANKSHAFT INSTALLATION Install the thrust bearings onto the rear end bearing support of the left crankcase with the groove side facing the c...

Page 364: ...h a dot mark that is aligned with the journal number 1 2 3 and 4 as viewed from the front of the engine Install the dowel pins and main journal bearing caps onto the correct journals with the arrows facing toward the upper side of the engine Apply engine oil onto the bearing cap bolt threads and seating surfaces Install the bolts into the correct bolt holes in the bearing caps Tighten the bolts in...

Page 365: ...piston pin into the connecting rod through the piston until the hydraulic press stops gauge rises slightly using the adjustable piston pin driver assembly Place a 12 mm flat washer on the top of the adjustable piston pin driver head Have the crown of the piston facing the arrow on the piston base head TOOLS Pilot collar 18 mm 07PAF 0010640 or 07KMF MT20200 U S A only Piston base 07973 6570500 Pist...

Page 366: ...p Do not confuse the top and second rings To install the oil ring install the spacer first then install the side rails On the upper side rail of the left cylinder pistons No 2 4 and 6 align the end stopper with the stopper groove Stagger the top and second piston ring end gaps 60 degrees apart L or R mark as shown Stagger the side rail end gaps as shown LEFT CYLINDER PISTON STOPPER AND GROOVE ...

Page 367: ...ool Apply molybdenum oil solution to the crankpin bearing sliding surfaces on the connecting rods Set the connecting rods onto the crankpins Apply molybdenum oil solution to the crankpin bearing sliding surfaces on the connecting rods Install the bearing caps by aligning the I D code on the connecting rod and bearing cap Be sure each part is installed in its correct position as noted dur ing remov...

Page 368: ... bearing caps Install the right piston connecting rod assemblies and bearing caps No 1 3 and 5 onto the corre sponding crankpins with the R mark toward the intake side by aligning the I D code Be sure each part is installed in its correct position Apply engine oil to the bearing cap nut threads and seating surfaces and install the them Tighten the nuts in several steps alternately Assemble the cra...

Page 369: ...ging them Place the support blocks lengthwise onto the left crankcase mating surfaces Hold the right crankcase over the left crankcase and set the front cylinder No 1 straight onto the No 1 piston while aligning the center shift fork with the transmission gear shifter groove The right crank case will rest on the support blocks Carefully pull the wires of the No 1 piston ring com pressor to separat...

Page 370: ...s No 3 and 5 of the right crank case straight onto the pistons and let the crankcase rest onto the support blocks Remove piston base A Pull the cords of the piston ring compressors to sep arate the two halves and remove the remaining compressors Remove the shop towels Install the two dowel pins and oil pipe ...

Page 371: ...mm bolts into the right crankcase Tighten bolts in a crisscross cross pattern in several steps Install the four 8 mm bolts and new washers into the left crankcase and tighten them in a crisscross pattern in several steps Install a new O ring into the water hose joint Install the water hose joint with the large spout fac ing the rear of the engine and tighten the two bolts Install the following pri...

Page 372: ... COMPONENT LOCATION 12 2 SERVICE INFORMATION 12 3 TROUBLESHOOTING 12 6 FINAL DRIVE REMOVAL 12 7 FINAL DRIVE DISASSEMBLY INSPECTION 12 9 CASE BEARING REPLACEMENT 12 14 FINAL DRIVE ASSEMBLY 12 17 FINAL DRIVE INSTALLATION 12 22 ...

Page 373: ...FINAL DRIVE 12 2 FINAL DRIVE COMPONENT LOCATION ...

Page 374: ...l drive gear assembly preload 0 2 1 N m 2 10 kgf cm 1 7 8 7 lbf in Pinion retainer 147 N m 15 0 kgf m 108 lbf ft Apply engine oil to the threads and seating surface Pinion retainer lock tab bolt 10 N m 1 0 kgf m 7 lbf ft Pinion joint nut 108 N m 11 0 kgf m 80 lbf ft Apply locking agent to the threads Final side flange screw 9 N m 0 9 kgf m 6 5 lbf ft ALOC screw replace with a new one Gear case cov...

Page 375: ... I D 07746 0030100 Attachment 25 mm I D 07746 0030200 Bearing remover 20 mm 07936 3710600 Bearing remover 30 mm 07936 8890300 or 07736 A01000B or 07736 A01000A U S A only with slide hammer 3 8 x 16 mm thread Remover handle 07936 3710100 Bearing remover weight 07741 0010201 or 07936 371020A or 07936 371020 U S A only or equivalent commer cially available in U S A Pinion holder 07924 ME40010 ...

Page 376: ... U S A only Puller shaft 07931 ME40000 or 07931 ME4010B and 07931 HB3020A U S A only Retainer wrench 07910 4630100 Oil seal driver 07948 SC20200 or 07749 0010000 07946 ME90200 and 07947 KA50100 Assembly base 07ZMF MCAA300 Bearing clip compressor 35 mm 07ZME MCAA100 Driver 07949 3710001 Attachment 32 x 35 mm 07746 0010100 Pilot 20 mm 07746 0040500 ...

Page 377: ...NG Excessive noise Worn or scored pinion and splines Worn pinion and ring gears Excessive backlash between pinion and ring gears Oil level too low Oil leakage Clogged breather Oil level too high Damaged seals Loose case cover bolts ...

Page 378: ...ter 03 two bolts brake hose guide and wheel speed sensor 01 03 only bolt and brake hose clamp bolt and brake pipe clamp from swingarm two bolts and brake caliper Support the brake caliper so it does not hang from the brake hose Do not twist the brake hose Do not operate the brake pedal after removing the caliper two screws using an impact driver be careful not to damage the screw head brake disc 0...

Page 379: ...r damage Check the splines of the joint shaft for wear or damage If the splines are damaged check the pinion joint and drive shaft splines To remove the drive shaft remove the swingarm page 14 22 Turn the pinion joint and check that the pinion and ring gears turn smoothly and quietly without binding If the gears do not turn smoothly or quietly the gears and or bearing may be damaged or faulty They...

Page 380: ...he three measurements If the difference between the three measurements exceeds the service limit it indicates that the bear ing is not installed squarely or the case is deformed Inspect the bearings and case If the backlash is excessive replace the right ring gear shim with a thicker one If the backlash is too small replace the right ring gear shim with a thinner one Fifteen different shim thickne...

Page 381: ...e ring gear needle bearing in the gear case for wear or damage GEAR TOOTH CONTACT PATTERN CHECK Keep dust and dirt out of the case and cover Clean the sealing material off the mating surfaces of the gear case and cover being careful not to dam age them Apply a thin coat of Prussian Blue to the pinion gear teeth for the tooth contact pattern check RIGHT RING GEAR SHIMS A thinnest 1 82 mm 0 072 in D...

Page 382: ... face If the patterns are not correct remove and change the pinion shim with a suitable one Replace the pinion gear shim with a thicker one if the contact pattern is too high toward the face Replace the pinion gear shim with a thinner one if the contact pattern is too low toward the flank Seven different shim thicknesses from A to G are available in increments of 0 06 mm 0 002 in For pinion gear s...

Page 383: ...ase cover Heat the case cover to 80 C 176 F and drive the bearing out of the case cover Install a new bearing while the cover is still heated Install the snap ring into the cover groove with the chamfered rolled edge facing away from the bear ing properly Install the ring gear page 12 19 When the gear set pinion bearing and or gear case has been replaced use a 2 00 mm 0 079 in thick shim for initi...

Page 384: ...gear assembly out of the gear case Check the pinion needle bearing in the gear case for wear or damage Place the washers under the holder plate on the top and bottom stud bolts on the oil drain bolt side to compensate for the angle of the pinion shaft TOOLS Pinon holder 07924 ME40010 Collar set C 07924 ME40020 Holder plate modified 07924 9690103 or 07924 9690101 modified TOOL Retainer wrench 07910...

Page 385: ...ar When the gear set ring gear bearing and or gear case has been replaced use a 1 50 mm 0 059 in thick shim for initial reference Drive the bearing using the special tools CASE BEARING REPLACEMENT RING GEAR NEEDLE BEARING Remove the snap ring from the gear case PINION SHIM PINION GEAR INNER RACES BEARING TOOLS Driver 40 mm I D 07746 0030100 Attachment 25 mm I D 07746 0030200 DRIVER ATTACHMENT BEAR...

Page 386: ...e needle bearing by using the special tools Remove the bearing cage and bearings from the inside of the pinion bearing to allow the special tool to grip the bearing TOOLS Bearing remover 30 mm 07936 8890200 Remover handle 07936 3710100 Remover weight 07741 0010201 or 07936 371020A or 07936 3710200 U S A only U S A only Adjustable bearing puller 20 40 mm 07736 A01000B or 07736 A01000A Slide hammer ...

Page 387: ...F Remove the needle bearing from the freezer and drive it into the gear case using the special tools Make sure the stopper ring is securely set in the groove of the gear case TOOLS Driver 07949 3710001 Attachment 32 x 35 mm 07746 0010100 Pilot 20 mm 07746 0040500 Differential bearing ring compressor 35 mm 07ZME MCAA100 DRIVER COMPRESSOR ...

Page 388: ... DRIVE ASSEMBLY PINION GEAR INSTALLATION Drive the pinion gear assembly into the gear case using the special tool TOOL Oil seal driver 07948 SC20200 Main bearing driver attachment 07946 ME90200 U S A only Driver 07749 0010000 ...

Page 389: ...nding on the position of the pinion retainer grooves in relation to the lock tab and tighten the bolt Clean the threads of the pinion gear shaft and pin ion joint nut thoroughly Apply locking agent to the joint nut threads and install the pinion joint and joint nut onto the pinion gear shaft TOOLS Driver 07749 0010000 Attachment 52 x 55 mm 07746 0010400 PINION RETAINER OIL SEAL O RING TOOL Retaine...

Page 390: ...clean their threads with contact cleaner then install using locking agent After installing be sure to measure the distance from the top of each stud to the ring gear surface as shown Install the right side shim onto the ring gear Support the bearing inner race with the special tool and press the ring gear into the case cover TOOLS Pinon holder 07924 ME40010 Collar set C 07924 ME40020 Holder plate ...

Page 391: ...nto the bearing Coat a new O ring with grease and install it into the groove in the ring gear boss Pack grease into the oil seal lip cavity Install the oil seal into the case cover until it is flush with the cover edge page 12 19 Never allow foreign materials to get into the clearance between the side flange and ring gear boss Apply grease to the inner side wall of the side flange as shown Install...

Page 392: ...ar case Install the case cover onto the gear case Apply locking agent to the threads of the case cover bolts Install the bolts and tighten them 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 pattern in sev eral steps Check that the gear assembly turns smoothly with out binding Measure the g...

Page 393: ...ack molybdenum disulfide grease into the seal lip cavity Apply molybdenum disulfide grease to the pinion joint splines Install the joint shaft assembly into the pinion joint until the stopper ring on the shaft seats in the pinion joint groove Make sure the stopper ring is seated properly by pulling on the joint shaft lightly Clean the mating surfaces of the swingarm and final gear case Install the...

Page 394: ...se clamp onto the gear case and tighten the bolt 01 03 Install the wheel speed sensor and tighten the bolts After 03 Install the wheel speed sensor brake hose guide and tighten the bolts Install the following rear wheel page 14 14 right muffler page 2 20 Fill the gear case with the recommended oil if it was disassembled page 3 16 TORQUE 9 N m 0 9 kgf m 6 5 lbf ft 5 4 95 TORQUE 45 N m 4 6 kgf m 33 ...

Page 395: ...MEMO ...

Page 396: ...13 1 13 13 FRONT WHEEL SUSPENSION STEERING COMPONENT LOCATION 13 2 SERVICE INFORMATION 13 3 TROUBLESHOOTING 13 6 HANDLEBAR 13 7 FRONT WHEEL 13 16 FORK 13 24 STEERING STEM 13 41 ...

Page 397: ...FRONT WHEEL SUSPENSION STEERING 13 2 FRONT WHEEL SUSPENSION STEERING COMPONENT LOCATION ...

Page 398: ... Handlebar mounting bolt 26 N m 2 7 kgf m 20 lbf ft Front brake disc bolt 20 N m 2 0 kgf m 14 lbf ft ALOC bolt replace with a new one Front pulser ring bolt ABS model only 8 N m 0 8 kgf m 5 8 lbf ft ALOC bolt replace with a new one Front axle bolt 59 N m 6 0 kgf m 43 lbf ft Front axle holder bolt 22 N m 2 2 kgf m 16 lbf ft Fork center bolt 20 N m 2 0 kgf m 14 lbf ft Apply locking agent to the thre...

Page 399: ...achment 42 x 47 mm 07746 0010300 Pilot 20 mm 07746 0040500 Fork seal driver 07KMD KZ30100 07KMD KZ3010A U S A only Needle bearing remover 07946 KA50000 Steering stem socket 07916 3710101 or 07916 3710100 Main bearing driver attachment 07946 ME90200 Fork seal driver weight 07947 KA50100 Oil seal driver 07965 MA60000 Installer shaft 07VMF KZ30200 ...

Page 400: ...EERING 13 5 Installer attachment A 07VMF MAT0100 Remover attachment A 07VMF MAT0300 Remover attachment B 07VMF MAT0400 Installer attachment B 07ZMF MCAA100 Inner driver handle 40 mm 07746 0030100 Attachment 35 mm 07746 0030400 ...

Page 401: ...rings Bent front axle Worn swingarm pivot component section 14 Front wheel wobbling Bent rim Worn wheel bearings Faulty tire Unbalanced tire and wheel Soft suspension Weak fork spring Low fluid level in fork Insufficient fluid weight low viscosity Low tire pressure Hard suspension High tire pressure Bent fork tube Fork slider binds High fluid level in fork leg Incorrect fluid weight high viscosity...

Page 402: ...eight and remove the mount ing screw and the weight Remove the holder cap from the clutch master cylin der holder bolts Disconnect the clutch switch connectors Disconnect the clutch cruise switch connectors Remove the two bolts holder and the clutch master cylinder assembly Keep the clutch res ervoir upright to prevent air from entering the hydrau lic system BOLTS HOLDER ...

Page 403: ... handlebar mounting bolts Remove the two screws and handlebar setting plate Remove the two screws from the left handlebar switch Remove the screw setting plate and the left handle bar switch Remove the left handlebar grip SCREWS PLATE 5 4 95 PLATE SCREW ...

Page 404: ...and to the outside surface of the left handlebar Wait 3 5 minutes and install the grip Rotate the grip for even application of the adhesive Install the left handlebar switch aligning its locating pin with the hole in the left handlebar Install the setting plate and tighten the screw Install the left handlebar switch screws Tighten the forward screw first then the rear screw Allow the adhesive to d...

Page 405: ...lts and tighten them to the speci fied torque Install the clutch master cylinder and holder Align the end of the master cylinder with the punch mark on the handlebar and tighten the upper bolt first then the lower bolt Connect the clutch switch connectors Connect the clutch cruise switch connectors Install the holder cap onto the clutch master cylin der holder bolts SCREWS PLATE TORQUE 26 N m 2 7 ...

Page 406: ... Install the meter panel page 2 7 RIGHT HANDLEBAR REMOVAL Remove the meter panel page 2 7 Remove the handlebar center cover page 13 7 Hold the handlebar weight and remove the mount ing screw and weight Remove the holder cap from the brake master cylin der holder bolts Disconnect the brake light cruise cancel switch connectors Loosen the two brake master cylinder holder bolts but do not remove them...

Page 407: ...bar clamp Remove the right handlebar mounting bolts Remove the two screws and handlebar setting plate Keep the brake reservoir upright to prevent air from entering the hydraulic system Remove the two bolts holder and the brake master cylinder assembly BOLTS SCREWS PLATE HOLDER BOLTS ...

Page 408: ...grip flange Remove the throttle grip from the throttle pipe RIGHT HANDLEBAR INSTALLATION Clean the inside surface of the throttle grip and the outside surface of the throttle pipe Apply Honda Bond A or equivalent to the inside sur face of the throttle grip and to the outside surface of the throttle pipe Wait 3 5 minutes and install the grip Rotate the grip for even application of the adhesive 5 4 ...

Page 409: ...tch aligning its locat ing pin with the hole in the right handlebar Install the setting plate and tighten the screw Install the right handlebar switch screws Tighten the forward screw first then the rear screw Install the brake master cylinder and holder Align the end of the master cylinder with the punch mark on the handlebar and temporarily tighten the holder bolts Route the cables properly page...

Page 410: ...rely Then install the han dlebar mounting bolts and tighten them to the spec ified torque Securely clamp the throttle cables with the handle bar clamp Make sure the end of the master cylinder aligns with the handlebar and tighten the upper bolt first then the lower bolt Connect the brake light cruise cancel switch connectors SCREWS PLATE TORQUE 26 N m 2 7 kgf m 20 lbf ft BOLTS TORQUE 12 N m 1 2 kg...

Page 411: ...nd pulse ring Remove the front fender covers and front fender A page 2 6 Support the motorcycle securely using a hoist or equivalent and raise the front wheel off the ground Do not operate the brake lever and pedal after removing the brake caliper Cover both sides of the front wheel with protective tape or an equivalent to prevent damaging it Remove the two mounting bolts lower pivot and upper joi...

Page 412: ...er mounting bolts and right front brake caliper Loosen the right axle holder bolts Remove the front axle bolt Loosen the left front axle holder bolts Remove the front axle and the front wheel Remove the side collars Support the brake caliper so that it does not hang from the brake hoses Do not twist the brake hoses ...

Page 413: ...ndicator Actual runout is 1 2 the total indicator reading WHEEL BEARING Replace the wheel bearings in pairs 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 hub Remove and discard the bearings if the races do not turn smoothly and quietly or if they fit loosely in the hub DISASSEMBLY Remove...

Page 414: ...lts and brake disc from the left wheel hub Replace the wheel bearings in pairs Do not reuse old bearings Install the bearing remover head into the bearing From the opposite side of the wheel install the bearing remover shaft and drive the bearing out of the wheel hub Remove the distance collar and drive out the other bearing TOOLS Bearing remover shaft 07746 0050100 Bearing remover head 20 mm 0774...

Page 415: ...collar Drive in a new left bearing squarely with the marked side facing up until it is fully seated Install the brake discs with the arrow mark facing out Install new disc bolts and tighten them in a criss cross pattern in two or three steps TOOLS Driver 07749 0010000 Attachment 42 x 47 mm 07746 0010300 Pilot 20 mm 07746 0040500 TORQUE 20 N m 2 0 kgf m 14 lbf ft ...

Page 416: ...ocated next to the valve stem Remount the tire if necessary Mount the wheel tire and brake discs and pulser ring ABS model only assembly on an inspection stand Spin the wheel allow it to stop and mark the lowest heaviest part of the wheel with chalk Do this two or three times to verify the heaviest area If the wheel is balanced it will not stop consistently in the same position To balance the whee...

Page 417: ...ing Install the side collars The right side collar is longer than the left side collar Place the front wheel between the fork legs Insert the front axle from the left side until it is fully seated Make sure the index line on the axle is aligned with the fork leg Install the axle bolt and tighten it to the specified torque while holding the axle Tighten the right axle holder bolts to the specified ...

Page 418: ...er pivot collar Install the pivot collars into the fork and caliper bracket Install the left front brake caliper with new mounting bolts lower pivot and upper joint bolts and tighten them Remove the protective tape With the front brake applied pump the forks up and down several times to seat the axle and check brake operation Tighten the left axle holder bolts to the specified torque TORQUE 31 N m...

Page 419: ...er installing the wheel apply the front and rear brakes several times and recheck the caliper clear ances between each surface of the brake disc and the brake caliper Failure to provide clearance will damage the brake disc and affect braking efficiency Check the front wheel speed sensor air gap page 16 29 Install front fender A page 2 6 Install the front fender side covers page 2 6 FORK REMOVAL Re...

Page 420: ...he brake caliper and secondary master cylinder from the brake hoses The fork cap is under spring pres sure use care when loosening it Loosen the fork top bridge pinch bolts When the fork is ready to be disassembled loosen the fork caps but do not remove them Be careful not to drop the fork legs when loosening the bolts Loosen the bottom bridge pinch bolts and remove the fork tubes from the fork br...

Page 421: ...damage or loose fit If the needle bearings are damaged replace them page 13 32 The fork cap is under spring pres sure use care when removing it Remove the fork cap from the fork tube Remove the O ring from the fork cap Remove the following spacer spring seat fork spring Pour out the fork fluid by pumping the fork tube up and down several times AXLE HOLDER BOLTS PLATE NEEDLE BEARINGS DUST SEALS JOI...

Page 422: ...l and remove the center bolt and sealing washer Remove the dust seal Remove the stopper ring being careful not to scratch the fork tube sliding surface Using quick successive motions pull the fork tube out of the fork slider Remove the following stopper ring oil lock valve oil lock spring spring seat stopper ring Remove the fork piston and rebound spring from the fork tube FORK CENTER BOLT DUST SE...

Page 423: ...nd fork piston for score marks and excessive or abnormal wear Check the rebound spring for fatigue or damage Check the fork piston ring for wear or damage Replace any damaged component if necessary Set the fork tube in V blocks and measure the fork tube runout with a dial indicator Actual runout is 1 2 the total indicator reading Do not remove the slider bushing unless it is neces sary to replace ...

Page 424: ...oring or scratching or if the teflon is worn so that the copper surface appears on more than 3 4 of the entire surface Check the back up ring replace it if there is any dis tortion at the points shown LEFT FORK LEG ASSEMBLY Before assembly wash all parts with a high flash point or non flammable solvent and wipe them off completely ...

Page 425: ... fork tube Install the following stopper ring spring seat oil lock spring oil lock valve stopper ring Install the fork tube into the fork slider If the fork piston turns with the cen ter bolt tempo rarily install the fork spring spring seat spacer and fork cap Hold the fork slider in a vise with soft jaws or a shop towel Apply locking agent to the center bolt threads Install the center bolt with a...

Page 426: ...to the fork tube Slowly pump the fork tube several times to remove any trapped air from the lower portion of the fork tube Compress the fork tube fully Measure the oil level from the top of the fork tube Pull the fork tube up and install the fork spring with the tightly wound coil side facing down DUST SEAL STOPPER RING RECOMMENDED FORK FLUID Pro Honda Suspension Fluid SS 8 FORK FLUID CAPACITY 529...

Page 427: ...m the fork slider Press the needle bearings out of the fork slider using the special tools and a hydraulic press Apply grease to the needle rollers of the new bearings Carefully press the needle bearings in the fork slider until the depth from the fork slider outer surfaces is specified value using the same tool and a hydraulic press Apply grease to the new dust seal lips and install the seal unti...

Page 428: ...holder bolts Remove the fork cap from the fork tube Hold the fork damper lock nut and remove the fork cap from the fork damper Remove the O ring from the fork cap Remove the following spacer spring seat fork spring Pour out the fork fluid by pumping the fork tube up and down several times AXLE HOLDER BOLTS PLATE FORK CAP LOCK NUT ...

Page 429: ...jaws or a shop towel and remove the center bolt and sealing washer Remove the dust seal Remove the stopper ring being careful not to scratch the fork tube sliding surface Using quick successive motions pull the fork tube out of the fork slider Remove the fork damper and rebound spring from the fork tube Remove the oil lock piece FORK CENTER BOLT DUST SEAL STOPPER RING OIL LOCK PIECE FORK DAMPER ...

Page 430: ...eck the fork tube slider and fork damper for score marks and excessive or abnormal wear Check the rebound spring for fatigue or damage Replace the component if necessary Set the fork tube in V blocks and measure the fork tube runout with a dial indicator Actual runout is 1 2 the total indicator reading Do not remove the slider bushing unless it is neces sary to replace it with a new one OIL SEAL G...

Page 431: ...ble solvent and wipe them off completely Be careful not to damage the coat ing of the bushing Do not spread open the bushing more than necessary Install a new slider bushing if the bushing has been removed Remove the burrs from the bushing mating sur face being careful not to peel off the coating Install the guide bushing and install the back up ring with its chamfered surface side facing down App...

Page 432: ... with a new sealing washer and tighten it to the specified torque Drive the oil seal into the fork slider until the stopper ring groove is visible using the special tool Install the stopper ring into the groove in the fork slider being careful not to scratch the fork tube slid ing surface Apply fork fluid to the lip of a new dust seal and install the dust seal FORK DAMPER OIL LOCK PIECE TORQUE 20 ...

Page 433: ...n of the fork tube Compress the fork tube fully Measure the oil level from the top of the fork tube Pull the fork tube up and install the fork spring with the tightly wound coil side facing down Install the spring seat and spacer RECOMMENDED FORK FLUID Pro Honda Suspension Fluid SS 8 FORK FLUID CAPACITY 485 2 5 cm3 16 4 0 08 US oz 17 1 0 09 Imp oz FORK FLUID FORK FLUID LEVEL 128 mm 5 0 in OIL LEVE...

Page 434: ...he fork cap to the specified torque Tighten the fork cap after installing the fork tube into the fork bridges Screw the fork cap into the fork tube INSTALLATION Route the wires cables and hoses properly page 1 23 Install the fork tubes into the fork bridges Align the top of the fork tubes with the upper sur face of the top bridge as shown O RING TORQUE Fork damper lock nut 20 N m 2 0 kgf m 14 lbf ...

Page 435: ...n the bolt Clean the mating areas of the plunger case and front fork with compressed air and be sure that no foreign materials are allowed Apply silicone grease to the anti dive plunger tip Install the anti dive plunger case with new socket bolts and tighten them TORQUE 29 N m 3 0 kgf m 22 lbf ft BOTTOM BRIDGE PINCH BOLTS TORQUE 23 N m 2 3 kgf m 17 lbf ft TORQUE 26 N m 2 7 kgf m 20 lbf ft FORK CAP...

Page 436: ...l the front wheel page 13 16 STEERING STEM REMOVAL Remove the combination meter page 20 17 Remove the handlebar center cover page 13 7 Remove the two bolts and hydraulic hose clamp Remove the handlebar mounting bolts TORQUE Delay valve mounting bolt 12 N m 1 2 kgf m 9 lbf ft TRIM CLIP FENDER TOP COVER BOLTS Keep the brake and clutch reservoir upright to prevent air from entering the hydraulic syst...

Page 437: ... disconnect the turn signal cancel unit connector Loosen the steering stem nut Remove the fork legs page 13 24 Remove the steering stem nut and top bridge Remove the following two bolts two screws three screws turn signal cancel unit wind protector CAP CONNECTOR BOLTS SCREWS ...

Page 438: ... bearing adjustment nut lock nut and lock washer Remove the steering bearing adjustment nut using the special tool Remove the following dust seal upper bearing inner race steering stem upper bearing TOOL Steering stem socket 07916 3710101 or 07916 3710100 DUST SEAL INNER RACE UPPER BEARING ...

Page 439: ...holding the installer shaft with the wrench turn the upper nut gradually to remove the upper bearing outer race TOOLS Main bearing driver attachment 07946 ME90200 Fork seal driver weight 07947 KA50100 Oil seal driver 07965 MA60000 Installer shaft 07VMF KZ30200 Installer attachment A 07VMF MAT0100 Remover attachment A 07VMF MAT0300 Remover attachment B 07VMF MAT0400 Installer attachment B 07ZMF MCA...

Page 440: ...t gradually to remove the lower bearing outer race Install a new upper bearing outer race and the spe cial tools as shown While holding the installer shaft with the wrench turn the lower nut gradually until the outer race bot toms on the steering head pipe UPPER NUT INSTALLER ATTACHMENT A UPPER BEARING OUTER RACE INSTALLER SHAFT INSTALLER ATTACHMENT B OIL SEAL DRIVER FORK SEAL DRIVER WEIGHT MAIN B...

Page 441: ...ower bearing inner race from the stem Remove the lower bearing inner race with a chisel or equivalent tool being careful not to damage the stem Remove the dust seal Apply grease to a new dust seal lip and install it onto the steering stem Press a new lower bearing inner race onto the steer ing stem using the special tools UPPER NUT MAIN BEARING DRIVER ATTACHMENT FORK SEAL DRIVER WEIGHT INSTALLER A...

Page 442: ...he steering head pipe Install the upper bearing and inner race DUST SEAL TURN SIGNAL CANCEL CONTROL UNIT STEERING STEM WIND PROTECTOR LOWER INNER RACE LOWER BEARING LOWER OUTER RACE TOP BRIDGE HYDRAULIC HOSE CLAMP UPPER INNER RACE UPPER OUTER RACE CONNECTOR STEM NUT CAP STEERING STEM NUT LOCK NUT LOCK WASHER STEERING BEARING ADJUSTMENT NUT DUST SEAL UPPER BEARING INNER RACE UPPER BEARING ...

Page 443: ...ng bearing adjustment nut to the specified torque 2 Loosen the steering bearing adjustment nut and retighten it to the same torque 3 Turn the steering stem left and right lock to lock at least four times to seat the bearings Retighten the adjustment nut to the same torque 4 Repeat step 3 DUST SEAL TOOL Steering stem socket 07916 3710101 or 07916 3710100 TORQUE 27 N m 2 8 kgf m 20 lbf ft ...

Page 444: ...o align its grooves with the tabs of the lock washer Bend up the lock washer tabs into the grooves of the lock nut Put the turn signal cancel unit wire through the steering stem Install the following wind protector turn signal cancel unit three screws Tighten the screws Install the two screws and two bolts and tighten them Install the top bridge and steering stem nut Temporarily install the fork l...

Page 445: ...ombination meter page 20 17 STEERING BEARING PRE LOAD Remove the front fairing page 2 10 Support the motorcycle securely using safety stands or a hoist and raise the front wheel off the ground Position the steering stem to the straight ahead position Hook a spring scale to the fork tube between the fork top and bottom bridges Make sure there is no cable wire harness or hose interference Pull the s...

Page 446: ... 14 14 REAR WHEEL SUSPENSION COMPONENT LOCATION 14 2 SERVICE INFORMATION 14 3 TROUBLESHOOTING 14 5 REAR WHEEL 14 14 SHOCK ABSORBER 14 16 SUSPENSION LINKAGE 14 18 SWINGARM 14 22 SUSPENSION LEVEL RELAY 14 29 ...

Page 447: ...REAR WHEEL SUSPENSION 14 2 REAR WHEEL SUSPENSION COMPONENT LOCATION ...

Page 448: ...31 Refer to section 15 for hydraulic brake system service The angle sensor digital pulse signal is sent to the suspension level control unit in the combination meter For combina tion meter servicing see section 19 The following color codes are indicated throughout this section SPECIFICATIONS Unit mm in TORQUE VALUES Bl Black G Green Lg Light Green R Red Br Brown W White Bu Blue Y Yellow ITEM STAND...

Page 449: ...47 mm 07746 0010300 Attachment 24 x 26 mm 07746 0010700 Attachment 22 x 24 mm 07746 0010800 Attachment 28 x 30 mm 07946 1870100 Pilot 17 mm 07746 0040400 Pilot 20 mm 07746 0040500 Driver 07749 0010000 Driver 07949 3710001 Remover weight 07741 0010201 or 07936 371020A or 07936 3710200 U S A only Remover handle 07936 3710100 Bearing remover 20 mm 07936 3710600 ...

Page 450: ...erly tightened swingarm pivot Bent damper rod Tire pressure too high Rear suspension noise Faulty rear shock absorber Loose rear suspension fasteners Worn rear suspension pivot bearings Rear wheel wobbling Bent rim Faulty rear tire Unbalanced rear tire and wheel Insufficient rear tire pressure Faulty swingarm pivot bearings Axle fastener not tightened properly Low tire pressure Rear wheel turns ha...

Page 451: ...ll blink for 3 sec onds The spring pre load system has 26 positions from 0 to 25 for different road or riding conditions CIRCUIT DIAGRAM BEFORE TROUBLESHOOTING Check that the battery is fully charged and in good condition Check for a blown No 20 fuse Check that the audio system functions properly Check that the neutral indicator comes on when the ignition switch is turned to ON with the transmissi...

Page 452: ...icator Inspection Turn the ignition switch to ON or ACC and operate the manual height switch Check that the SUS ADJ ERROR indication blinks on the multi display Does SUS ADJ ERROR blink on the multi display YES GO TO STEP 5 NO GO TO STEP 2 2 Manual Height Switch Operation Inspection Turn the ignition switch to OFF Remove the left fairing pocket page 2 11 Disconnect the panel switch 14P gray connec...

Page 453: ...t in the fairing sub wire harness YES Loose or poor contact of the switch 14P gray connector and meter 16P black connector Faulty combination meter replace the meter gauge assembly page 20 15 5 Angle Sensor Power Input and Ground Line Inspection at Combination Meter Turn the ignition switch to OFF Remove the combination meter page 20 17 Measure the angle sensor resistance between the Black red and...

Page 454: ... or more Connect the battery positive terminal to the UP relay connector Brown white wire ter minal and the battery negative terminal to the DOWN relay connector Green wire termi nal within 3 seconds max 3 seconds If the angle sensor resistance measured on the previous step is 2 5 kΩ or less Connect the battery positive terminal to the DOWN relay connector Green wire termi nal and the battery nega...

Page 455: ... the right saddlebag page 2 15 Disconnect the angle sensor connector Measure the angle sensor resistance between the Yellow red and Blue green wire terminals of the sensor side connector Is the resistance within the specified value NO Faulty angle sensor replace the shock absorber assembly page 14 16 YES Open or short circuit in the Yellow red wire between the combination meter 16P black connector...

Page 456: ... motor operation by connect ing the fully charged 12 V battery If the angle sensor resistance is 2 5 kΩ or more Connect the battery positive terminal to the Light green red wire terminal of the actua tor motor connector and the battery negative terminal to the Green wire terminal within 3 seconds max 3 seconds If the angle sensor resistance is 2 5 kΩor less Connect the battery positive terminal to...

Page 457: ...st between the color coded wires as follows Is there continuity between the wires as shown in the charts NO Faulty memory switch replace the panel switch assembly page 20 32 YES GO TO STEP 2 2 Memory Switch 1 and 2 Control Line Short Circuit inspection Remove the combination meter page 20 17 Check the following wires for continuity to ground at the panel switch 14P gray connector Brown yellow Brow...

Page 458: ...nnector and combi nation meter 16P black connector Brown yellow Brown blue Is there continuity NO Open circuit in the fairing sub wire harness YES Loose or poor contact of the switch 14P gray connector and meter 16P black connector Faulty combination meter replace the meter gauge assembly page 20 19 METER 16P BLACK CONNECTOR viewed from the terminal side Lg Y Br W ...

Page 459: ... brake disc ABS model only six bolts and pulser ring if necessary Install a new pulser ring with new bolts and tighten them Clean the mating surfaces of the final drive assem bly and brake disc and make sure that no foreign materials are allowed Install a new brake disc onto the stud bolts Install new screws and tighten them Install the brake caliper with new bolts and tighten them Install the bra...

Page 460: ...e the tire balance mark a paint dot on the side wall must be located next to the valve stem Remount the tire if necessary Mount the wheel and tire assembly on an inspection stand Spin the wheel allow it to stop and mark the lowest heaviest part of the wheel with chalk Do this two or three times to verify the heaviest area If the wheel is balanced it will not stop consistently in the same position ...

Page 461: ...ghten the five axle nuts to the specified torque while applying the rear brake Perform the air gap inspection if the rear brake disc was removed page 16 29 Install rear fender A page 2 6 SHOCK ABSORBER REMOVAL Remove the right saddlebag page 2 17 Remove the fuel tank page 5 56 Remove the rear wheel page 14 14 Disconnect the angle sensor connectors from the suspension level actuator and disconnect ...

Page 462: ... 8 in drill bit Do not use a dull drill bit which could cause a build up of excessive heat and pressure inside the damper leading to an explosion and severe injury The shock absorber contains nitrogen gas and oil under high pressure Do not drill any further down the damper case than the measurement given above or you may drill into the oil cham ber Then high pressure oil may cause serious injury A...

Page 463: ...bolts Tighten the mounting bolt and the two 8 mm bolts to the specified torque Connect the angle sensor connector to the suspen sion level actuator and connect the control motor connector Clamp the control motor connector onto the clamp Install the rear wheel page 14 14 Install the fuel tank page 5 56 Install the right saddlebag page 2 15 SUSPENSION LINKAGE SHOCK ARM REMOVAL Remove the exhaust sys...

Page 464: ...le rollers of new bearings Carefully press the needle bearing in the shock arm pivot until the depth from the shock arm outer sur face is at specification using the special tools and a hydraulic press TOOLS Bearing remover set 07936 3710001 not available in U S A remover weight 07741 0010201 or 07936 371020A or 07936 3710200 U S A only remover handle 07936 3710100 remover 20 mm 07936 3710600 TOOLS...

Page 465: ...d torque Install the rear wheel page 14 16 Install the exhaust system page 2 20 SHOCK LINK REMOVAL Remove the exhaust system page 2 18 Remove the rear wheel page 14 14 Remove the shock arm to shock link nut and bolt Remove the shock link to frame nut and bolt Remove the shock link Shock absorber side Driver 07749 0010000 Attachment 24 x 26 mm 07746 0010700 Pilot 17 mm 07746 0040400 TORQUE Shock ab...

Page 466: ... needle bearings into the shock link pivot until the depth from the shock link outer surface is at specification using the special tools and a hydraulic press SHOCK LINK INSTALLATION Apply grease to new dust seal lips and install them into the shock link pivot until they are fully seated Install the pivot collar into the shock link pivot TOOLS Bearing remover set 07936 3710001 not available in U S...

Page 467: ...WINGARM REMOVAL Remove the final gear case page 12 10 Remove the shock absorber page 14 16 Remove the mounting bolts and each swingarm pivot bolt cover Remove the bolt and brake pipe clamp Remove the left pivot lock nut with the special tool TORQUE Shock arm to frame nut 64 N m 6 5 kgf m 47 lbf ft Shock arm to shock link nut 64 N m 6 5 kgf m 47 lbf ft NUTS AND BOLTS PIPE CLAMP BOLT TOOL Lock nut w...

Page 468: ...Remove the shock arm to shock link nut and bolt Remove the two screws and brake light cruise can cel switch assembly from the rear master cylinder Remove the joint boot off the engine Separate the drive shaft from the output shaft of the engine then remove the swingarm LEFT PIVOT BOLT ...

Page 469: ...ingarm nut and bolt and shock arm from the swingarm INSPECTION Both bearings outer races and grease holders must be replaced as a set if any part is damaged or worn Remove the tapered roller bearings from the swing arm pivots Check the bearings and dust seals for damage or wear Check the outer races for damage or wear Check the grease holders for damage or deformation NUT AND BOLT SHOCK ARM ...

Page 470: ...uter race and grease holder with the installed tools Insert a suitable driver through the swingarm and drive out the other side grease holder and bearing using a suitable hydraulic press Install the new grease holders into the swingarm pivot Carefully press the new outer races into the swing arm pivots until they are fully seated using the spe cial tools and a hydraulic press TOOLS Attachment 32 x...

Page 471: ...rm onto the swingarm by insert ing the mounting bolt Install the shock arm to swingarm nut and tighten the nut to the specified torque Apply 1 g 0 04 oz of molybdenum disulfide grease to the output shaft side splines of the drive shaft Place the drive shaft into the swingarm with the short shaft facing the front of the motorcycle SEAL LIPS ROLLERS TORQUE 64 N m 6 5 kgf m 47 lbf ft ...

Page 472: ...age the splines of the drive and output shafts securely Align the frame pivot bolt hole with the swingarm securely Install and tighten the right pivot bolt to the speci fied torque Align the frame pivot bolt hole with the swingarm securely Install and tighten the left pivot bolt to the specified torque Move the swingarm up and down several times to seat the pivot bearings Route the wires hoses and...

Page 473: ...s Install the brake light cruise cancel switch assembly with the screws Adjust the switch position so that the brake light comes on when pushing the brake pedal slightly and the push rod moves 0 7 1 7 mm Tighten the holder screws Install the brake pipe clamp with the bolt and tighten the bolt to the specified torque TORQUE 108 N m 11 0 kgf m 80 lbf ft Refer to torque wrench reading information on ...

Page 474: ...relay with a new one If the suspension level actuator does not operate go to step 2 2 Turn the ignition switch to OFF and exchange the suspension level UP relay with a known good one Turn the ignition switch to ON or ACC and operate the manual height switch If the suspension level actuator operates replace the suspension level UP relay with a new one and check again using the original suspension l...

Page 475: ...e go to step 6 If there is no voltage check for an open circuit in the Light green black wire between the suspen sion level main relay and ACC relay 6 Turn the ignition switch to OFF Remove the suspension level UP and DOWN relays Check the Red black wires for continuity between the suspension level main relay and UP relay and between the main relay and DOWN relay If there is continuity go to step ...

Page 476: ...reen black wire terminal of the suspension level UP and DOWN relay connectors and ground If there is battery voltage follow the trouble shooting flow chart on page 14 10 If there is no voltage check for an open circuit in the Light green black wire between the suspen sion level UP and DOWN relay and ACC relay ...

Page 477: ...MEMO ...

Page 478: ...BLESHOOTING 15 5 BRAKE FLUID REPLACEMENT AIR BLEEDING 15 6 BRAKE PAD DISC 15 13 FRONT MASTER CYLINDER 15 15 REAR MASTER CYLINDER BRAKE PEDAL 15 19 SECONDARY MASTER CYLINDER 15 24 FRONT BRAKE CALIPER 15 27 REAR BRAKE CALIPER 15 34 DELAY VALVE 15 38 PROPORTIONAL CONTROL VALVE PCV 15 39 ...

Page 479: ...BRAKE SYSTEM Standard 15 2 BRAKE SYSTEM Standard SYSTEM LOCATION ...

Page 480: ...ng dust regardless of material composition could be hazardous to your health Avoid breathing dust particles Never use an air hose or brush to clean brake assemblies Use an OSHA approved vacuum cleaner ITEM STANDARD SERVICE LIMIT Specified brake fluid DOT 4 Front Brake disc thickness 4 5 0 18 3 5 0 14 Brake disc runout 0 30 0 012 Master cylinder I D 14 000 14 043 0 5512 0 5529 14 055 0 5533 Master ...

Page 481: ...r bracket pin 13 N m 1 3 kgf m 9 lbf ft Apply locking agent to the threads Front brake caliper pin 23 N m 2 3 kgf m 17 lbf ft Front brake caliper assembly bolt 32 N m 3 3 kgf m 24 lbf ft ALOC bolt replace with a new one Left front brake caliper lower mounting bolt 31 N m 3 2 kgf m 23 lbf ft ALOC bolt replace with a new one Left front brake caliper to secondary master cylinder joint bolt 25 N m 2 6...

Page 482: ...icking worn master piston Bent brake lever pedal Brake lever pedal hard Clogged restricted hydraulic system Sticking worn caliper piston Sticking worn master piston Caliper not sliding properly Bent brake lever pedal Brake drag Contaminated brake pad disc Misaligned wheel Badly worn brake pad disc Warped deformed brake disc Caliper not sliding properly Clogged restricted fluid passage Sticking cal...

Page 483: ...d Use only DOT 4 brake fluid from a sealed container Do not mix different types of fluid They are not compatible Once the hydraulic system has been opened or if the brake feels spongy the system must be bled When using a commercially available brake bleeder follow the manufacturer s operating instructions BRAKE FLUID DRAINING LEVER BRAKE LINE Remove front fender A and the fender covers page 2 6 Su...

Page 484: ...o more fluid flows out of the bleed valve Tighten the bleed valve Perform the above procedure at the other front caliper PEDAL BRAKE LINE Remove the following right engine side cover page 2 5 front fender A and fender covers page 2 6 Support the motorcycle on its center stand Remove the rear master cylinder reservoir cap UPPER BLEED VALVE LOWER BLEED VALVE Right front caliper Left front caliper ...

Page 485: ...re at each remaining valve of the brake pedal brake line LEVER BRAKE LINE FLUID FILLING AIR BLEEDING FLUID FEEDING It is not a problem if the fluid flowing out from the bleed valve contains air bubbles because the lines will be bled in next steps Air Bleeding Fill the reservoir with DOT 4 brake fluid from a sealed container Operate the brake lever several times to bleed air from the master cylinde...

Page 486: ...bleed valve of the front caliper Pump the brake lever several 5 10 times quickly then squeeze the brake lever all the way and loosen the bleed valve 1 4 turn Wait several seconds and close the bleed valve Release the brake lever slowly and wait several seconds after it reaches the end of its travel Repeat above procedure until sufficient amount of fluid flows out of the bleed valve 2 Perform step ...

Page 487: ...g ledge with DOT 4 brake fluid from a sealed container Install the diaphragm set plate and reservoir cap and tighten the screws Install the fender covers and front fender A page 2 6 PEDAL BRAKE LINE FLUID FILLING AIR BLEEDING Before performing this service have at least 500 cc 16 9 US oz 14 1 Imp oz of brake fluid Feed fluid and bleed air from the pedal brake line in the following sequence 1 Left ...

Page 488: ...t used add brake fluid when the fluid level in the reservoir is low Repeat above procedure until sufficient amount of the fluid flows out of the bleed valve Close the bleed valve When using a brake bleeding tool follow the manufacturer s operating instructions Perform step 1 at each bleed valve in the sequence as follows 2 Right front caliper lower side bleed valve 3 Rear caliper lower side bleed ...

Page 489: ...i dive plunger bleed valve 5 Rear caliper upper side bleed valve Next perform the air bleeding AIR BLEEDING Note that you may feel strong resistance on the brake pedal during pumping to bleed air from the right front caliper This symptom is caused by the delay valve function Be sure to depress the brake pedal fully to the bottom Air bleeding procedure must be performed in the same way as in the fl...

Page 490: ...spring Remove the brake pads Coat the stopper ring on the pad pin end with sili cone grease Make sure the pad spring is installed correctly Install new brake pads into the caliper body with the shim facing toward the wheel side so that their ends rest into the pad retainer on the bracket properly Install the pad pin by pushing in the pads against the pad spring to align the pad pin holes in the pa...

Page 491: ...retainer on the bracket properly Install the pad pin by pushing in the pads against the pad spring to align the pad pin holes in the pads and caliper body Tighten the pad pin Install the pad pin plug securely Operate the brake pedal and right front caliper to seat the caliper piston against the pads BRAKE DISC INSPECTION Visually inspect the disc for damage or cracks Measure the brake disc thickne...

Page 492: ... system page 15 6 Disconnect the brake light cruise cancel switch connectors Disconnect the brake hose from the master cylinder by removing the oil bolt and sealing washers Remove the holder cap Remove the master cylinder holder bolts holder and the master cylinder Remove the following from the master cylinder screw and brake light cruise cancel switch pivot nut pivot bolt and brake lever SERVICE ...

Page 493: ...rake fluid INSPECTION Check the piston cups and boot for wear deteriora tion or damage Check the spring for damage Check the master cylinder and piston for scoring scratches or damage Measure the master cylinder I D Measure the master piston O D TOOL Snap ring pliers 07914 SA50001 SERVICE LIMIT 14 055 mm 0 5533 in SERVICE LIMIT 13 945 mm 0 5490 in ...

Page 494: ...n cups with clean brake fluid Install the primary cup onto the spring Install the spring and master piston into the master cylinder Make sure the snap ring is firmly seated in the groove Install the snap ring into the groove in the master cylinder using the special tool TOOL Snap ring pliers 07914 SA50001 SNAP RING PLIERS ...

Page 495: ...aster cylinder and holder by aligning the end of the master cylinder with the punch mark on the handlebar Tighten the upper bolt first then tighten the lower bolt Install the holder cap into the holder bolts Connect the brake hose to the master cylinder with the oil bolt and new sealing washers Be sure to rest the hose joint pin against the stopper Tighten the oil bolt Connect the brake light crui...

Page 496: ...the reservoir hose joint from the master cylinder Remove the O ring Disconnect the brake hose by removing the oil bolt and sealing washers Remove the pinch bolt and the brake pedal Remove the two bolts and right footpeg Unhook the spring end to remove the return spring from the frame and pivot arm Remove the master cylinder mounting bolts Remove the pedal pivot arm off the frame while pushing the ...

Page 497: ... master cylinder and master piston in clean brake fluid INSPECTION Check the piston cups and boot for wear deteriora tion or damage Check the spring for damage Check the master cylinder and piston for scoring scratches or damage Measure the master cylinder I D Measure the master piston O D TOOL Snap ring pliers 07914 SA50001 SPRING CUP PISTON SERVICE LIMIT 17 515 mm 0 6896 in SERVICE LIMIT 17 405 ...

Page 498: ...the spring Install the spring and piston push rod assembly into the master cylinder Make sure the snap ring is firmly seated in the groove Install the snap ring into the groove in the master cylinder using the special tool Apply silicone grease to the boot groove in the push rod and install the boot into the master cylinder and boot groove TOOL Snap ring pliers 07914 SA50001 BOOT ...

Page 499: ...stance from the center of the lower mounting bolt hole to the center of the joint pin hole is 106 mm 4 2 in After adjustment tighten the joint nut Install the pivot arm into the master cylinder push rod joint with the joint pin and a new cotter pin INSTALLATION TORQUE 18 N m 1 8 kgf m 13 lbf ft 106 mm ...

Page 500: ...r pin Apply brake fluid to a new O ring and install it onto the reservoir joint Install the reservoir hose joint into the master cylin der and secure it with the snap ring Connect the brake hose to the master cylinder with the oil bolt and new sealing washers and tighten the oil bolt Install the brake pedal by aligning the slit with the punch mark on the pivot arm Install the pinch bolt and tighte...

Page 501: ...0 7 1 7 mm Tighten the switch holder screws Fill and bleed the pedal brake hydraulic system page 15 7 SECONDARY MASTER CYLINDER DISASSEMBLY Drain the brake fluid from the pedal brake hydraulic system page 15 6 Remove the following front fender B page 13 16 oil bolt and sealing washers upper side brake hose caliper to master cylinder joint bolt mounting bolts TORQUE 26 N m 2 7 kgf m 20 lbf ft FOOTP...

Page 502: ...pring Clean the master cylinder and master piston in clean brake fluid INSPECTION Check the piston cups and boot for wear deteriora tion or damage Check the spring for damage Check the master cylinder and piston for scoring scratches or damage Measure the master cylinder I D Measure the master piston O D OIL BOLT MASTER CYLINDER TOOL Snap ring pliers 07914 SA50001 SPRING CUP PISTON SERVICE LIMIT 1...

Page 503: ...aster cylinder using the special tool Apply silicone grease to the boot groove in the push rod and install the boot into the master cylinder and boot groove If the push rod joint is reinstalled adjust the push rod length so the distance from the center of the lower mounting bolt hole to the center of the joint pin hole is 69 mm 2 7 in After adjustment tighten the joint nut SPRING CUP PISTON Make s...

Page 504: ...inder with the oil bolt and new sealing washers and tighten the oil bolt Install front fender B page 13 39 Fill and bleed the pedal brake hydraulic system page 15 10 FRONT BRAKE CALIPER REMOVAL Drain the brake fluid from the lever and pedal brake hydraulic systems page 15 6 LEFT CALIPER Remove the brake pads page 15 13 Disconnect the brake hoses from the brake caliper by removing the oil bolts and...

Page 505: ...ALIPER Remove the brake pads page 15 13 Disconnect the brake hoses from the brake caliper by removing the oil bolts and sealing washers ABS model only Remove the following bolt and wire clamp from fork leg two bolts clamp and wheel speed sensor from caliper bracket Remove the two mounting bolts and brake caliper DISASSEMBLY Remove the following caliper bracket boots pad spring OIL BOLTS Being care...

Page 506: ...sh the dust and piston seals in and lift them out Clean the seal grooves caliper cylinders and pis tons with clean brake fluid INSPECTION Check the caliper cylinders and pistons for scoring scratches or damage Measure the caliper cylinder I D BODY B BODY A Do not use high pressure air or bring the nozzle too close to the inlet SEALS SERVICE LIMITS Left caliper Upper lower 22 71 mm 0 894 in Center ...

Page 507: ...ndard 15 30 Measure the caliper piston O D ASSEMBLY RIGHT CALIPER SERVICE LIMITS Left caliper Upper lower 22 56 mm 0 888 in Center 26 91 mm 1 059 in Right caliper Upper center 25 31 mm 0 996 in Lower 22 56 mm 0 888 in ...

Page 508: ...nstall them into their correct seal grooves in the caliper Coat the caliper pistons with clean brake fluid and install them into their correct caliper cylinders with the opening toward the pads Assemble the caliper body halves with new assem bly bolts and tighten them TORQUE 32 N m 3 3 kgf m 24 lbf ft ...

Page 509: ...er body Install the brake pads page 15 13 INSTALLATION RIGHT CALIPER Install the right brake caliper so the disc is posi tioned between the pads being careful not to dam age the pads Install new mounting bolts and tighten them Install the wheel speed sensor with the wire clamp and tighten the bolts Install the wire clamp onto the fork leg and tighten the bolt Tighten the pad pin after installing t...

Page 510: ...o the lower pivot bearing and dust seal lips and to the outer surface of the upper pivot collar Install the pivot collars into the fork and caliper bracket Install the left brake caliper so the disc is positioned between the pads being careful not to damage the pads Install new mounting bolts lower pivot and upper joint bolts and tighten them TORQUE 34 N m 3 5 kgf m 25 lbf ft TORQUE 18 N m 1 8 kgf...

Page 511: ...15 8 and 15 11 REAR BRAKE CALIPER DISASSEMBLY Remove the rear wheel page 14 14 Drain the brake fluid from the pedal brake hydraulic system page 15 6 Remove the brake pads page 15 13 Disconnect the brake hoses from the brake caliper by removing the oil bolts and sealing washers Remove the two mounting bolts and brake caliper Remove the following caliper bracket boots pad spring TORQUE 34 N m 3 5 kg...

Page 512: ...essure to the fluid inlets to remove the pistons Push the dust and piston seals in and lift them out Clean the seal grooves caliper cylinders and pis tons with clean brake fluid INSPECTION Check the caliper cylinders and pistons for scoring scratches or damage Measure the caliper cylinder I D BODY A BODY B SEALS SERVICE LIMITS Upper lower 22 71 mm 0 894 in Center 27 06 mm 1 065 in ...

Page 513: ...t seals with clean brake fluid and install them in the seal grooves in the caliper Coat the caliper pistons with clean brake fluid and install them into the caliper cylinders with the open ing toward the pads SERVICE LIMITS Upper lower 22 56 mm 0 888 in Center 26 91 mm 1 059 in PISTONS SEALS ...

Page 514: ...ed or damaged Install the boots into the caliper and bracket Apply silicone grease to the inside of the boots and install the caliper bracket over the caliper body Install the brake pads page 15 13 Install the brake caliper so the disc is positioned between the pads being careful not to damage the pads Install new mounting bolts and tighten them TORQUE 32 N m 3 3 kgf m 24 lbf ft PAD SPRING BRACKET...

Page 515: ...y valve INSTALLATION Route the speed sensor wire prop erly page 1 23 Install the delay valve onto the fork leg and tighten the mounting bolts Apply brake fluid to the joint nut threads on the brake pipe Connect the brake pipe by tightening the joint nut Install the 3 way joint and tighten the bolt Connect the brake hoses with the oil bolts and new sealing washers and tighten the oil bolts Secure t...

Page 516: ...wo mounting bolts and the PCV INSTALLATION Install the PCV and tighten the bolts Apply brake fluid to the joint nut threads on the brake pipes Connect the brake pipes by tightening the joint nuts Fill and bleed the pedal brake hydraulic system page 15 11 Install the left radiator page 6 15 When removing the joint nut cover the ends of the brake pipes to prevent brake fluid leakage TORQUE 12 N m 1 ...

Page 517: ...MEMO ...

Page 518: ...M ABS SYSTEM LOCATION 16 2 SERVICE INFORMATION 16 3 SYSTEM WIRING CONNECTIONS LOCATIONS 16 4 BEFORE STARTING TROUBLESHOOTING 16 5 BEFORE TROUBLESHOOTING 16 8 TROUBLESHOOTING 16 10 WHEEL SPEED SENSOR 16 29 ABS MODULATOR 16 31 ...

Page 519: ...BRAKE SYSTEM ABS 16 2 BRAKE SYSTEM ABS SYSTEM LOCATION ABS CONTROL UNIT REAR ABS MODULATOR FRONT WHEEL SPEED SENSOR FRONT ABS MODULATOR REAR WHEEL SPEED SENSOR ...

Page 520: ... sure that the ABS indicator is operating normally Be careful not to damage the wheel speed sensor and pulser ring when removing and installing the wheel or speed sensor When the wheel speed sensor and or pulser ring is replaced check the clearance air gap between both components The ABS control unit ECU may be damaged if dropped Also if a connector is disconnected when current is flowing the exce...

Page 521: ... WIRING CONNECTIONS LOCATIONS Refer to page 16 5 for the parts that must be removed for service For example REAR MODULATOR CONTROL MOTOR 2P Electric component Center inner fairing page 2 6 The part that must be removed for service ...

Page 522: ...rmal and it completes the pre start self diagnosis When the ABS is normal the ABS indicator goes off just after a road speed of 10 km h 6 mph indicating that the diagnosis is completed If a problem is detected the ABS indicator blinks or comes on and stays on to notify the rider of the problem The self diagnosis is also made while the motorcycle is running and the indicator blinks when a problem i...

Page 523: ... After diagnostic troubleshooting erase the problem code s and perform the pre start self diagnosis to be sure that there is no prob lem in the ABS indicator indicator is operating normally RETRIEVAL 1 Remove the No 3 and 4 control motor fuses with the ignition switch turned to OFF to be sure that each fuse is not burned out If either fuse is burned out perform the troubleshooting of problem code ...

Page 524: ...BRAKE SYSTEM ABS 16 7 PROBLEM CODE INDICATION PATTERN When the problem code is not stored ...

Page 525: ... Fuse Modulator Wheel speed sensor Pulser ring Power circuit charging Wire harness ABS control unit ABS indicator Tire Wheel Riding conditions NOTE ABS main Modulator control motor Control motor Crank angle sensor Front Rear Front Rear Front Rear Front Rear Front Rear Front Rear Front Rear 2 Front wheel speed sensor system O O O O O O O 16 10 3 Rear wheel speed sensor system O O O O O O O 16 12 4 ...

Page 526: ... pre start self diagnosis to be sure that the ABS indicator is operating normally The ABS indicator might blink in the following cases Correct the faulty part Incorrect tire pressure Tires not recommended for the motorcycle were installed incorrect tire size Deformation of the wheel or tire The ABS indicator might blink while riding under the following conditions Erase the problem code and perform...

Page 527: ...tion of the pulser ring and speed sensor for looseness Does pulser ring and speed sensor fit properly NO Install properly or replace the faulty part YES GO TO STEP 4 4 Speed Sensor Pulser Ring Damage Inspection Check the pulser ring for deformation or damage e g chipped teeth and the speed sensor tip for damage Is pulser ring or speed sensor deformed or damaged NO GO TO STEP 5 YES Replace the faul...

Page 528: ...ort circuit between the ABS control unit and speed sensor YES Faulty front wheel speed sensor 8 Wire Harness Continuity Inspection Disconnect the front wheel speed sensor con nector 1 Short the terminals of the connector 1 with a jumper wire Check for continuity between the Black white and Green orange ter minals of the connector 8 Is there continuity YES GO TO STEP 9 NO Open circuit in the wire b...

Page 529: ...eed sensor for looseness Did pulser ring and speed sensor have proper fit NO Install properly or replace the faulty part YES GO TO STEP 4 4 Speed Sensor Pulser Ring Damage Inspection Check the pulser ring for deformation or damage e g chipped teeth and the speed sensor tip for damage Was deformation or damage found NO GO TO STEP 5 YES Replace the faulty part 5 ABS Indicator Function Inspection Ret...

Page 530: ...y NO Short circuit in the wire between the ABS control unit and speed sensor YES Faulty rear wheel speed sensor 8 Wire Harness Continuity Inspection Disconnect the rear wheel speed sensor connec tor 6 Short the terminals of the connector 6 with a jumper wire Check for continuity between the Black orange and Blue yellow ter minals of the connector 8 Is there continuity NO Open circuit in the wire b...

Page 531: ...ndicator Function Inspection Retrieve the problem code and erase it Perform the pre start self diagnosis and check the ABS indicator Is indicator blinking YES GO TO STEP 4 NO Normal temporary failure Fine foreign matter in modulator or the ABS unit has been disrupted by and extremely powerful radio wave Check the connec tor and wire harness for loose connection 4 ABS Control Unit Battery Voltage I...

Page 532: ...w terminal of the connector 2 and ground and between the Green yellow terminal of the connector 2 and ground Is there continuity NO GO TO STEP 8 YES Short circuit in the wire between the ABS control unit and modulator control motor 7 Open Circuit Inspection Between ABS Control Unit and Front Modulator Short the Brown yellow and Green yellow termi nal of the connector 9 with a jumper wire Check for...

Page 533: ...O TO STEP 3 YES GO TO STEP 2 2 Short Circuit Inspection Between Fuse Box and ABS Control Unit Disconnect the ABS control unit 5P connector 7 Check for continuity between the Red green terminal of the connector 7 and ground with the No 4 fuse removed Is there continuity YES Short circuit in the wire between the fuse box and ABS control NO Temporary failure install a spare fuse and recheck 3 ABS Ind...

Page 534: ...pection at ABS Control Unit Check for continuity between the Green terminal of the connector 7 and ground Is there continuity NO Open circuit between in the Green wire YES GO TO STEP 6 6 Modulator Motor Short Circuit Inspection at Modulator Connector Disconnect the rear modulator control motor connector 5 Check for continuity between the Brown light green terminal of the connector 5 and ground and...

Page 535: ...odulator and the 5 and 4 connectors to the front modulator con versely Perform the pre start self diagnosis and retrieve the problem code and record it Is there a problem code 4 or 5 CODE 4 Faulty rear modulator assembly CODE 5 Faulty ABS control unit Problem Code 6 Front modular crank angle sensor system 1 ABS Indicator Checking Turn the ignition switch ON and check the ABS indicator Is the indic...

Page 536: ...ctor Disconnect the ABS control unit 12P connec tor 8 Check for continuity between the White red terminal of the connector 3 and ground Is there continuity NO GO TO STEP 5 YES Short circuit in the wire between the ABS control unit and modulator angle sensor 5 Open Circuit Inspection Between ABS Control Unit and Angle Sensor Modulator Ground the White red terminal of the connector 8 with a jumper w...

Page 537: ...rol Unit and Angle Sensor Modulator Disconnect the ABS control unit 12P connector 8 Check for continuity between the Orange green terminal of the connector 3 and ground and between the Pink black terminal of the con nector 3 and ground Is there continuity NO GO TO STEP 8 YES Short circuit in the wire between the ABS control unit and modulator angle sensor 8 Open Circuit Inspection Between ABS Cont...

Page 538: ... wave Check the connector and wire harness for loose connection YES GO TO STEP 3 3 Crank Angle Sensor Input Voltage Inspection Disconnect the rear modulator crank angle sensor connector 4 Measure the voltage between the Orange white and Pink white terminals of the connector 4 with the ignition switch turned to ON Standard 4 5 5 5V Is voltage within standard value NO GO TO STEP 6 YES GO TO STEP 4 4...

Page 539: ... and rear modulators Connect the 2 and 3 connectors to the rear modulator and the 5 and 4 connectors to the front modulator con versely Perform the pre start self diagnosis and retrieve the problem code and record it Is any problem code indicated CODE 6 Faulty rear modulator assembly CODE 7 Faulty ABS control unit 7 Short Circuit Inspection Between the ABS Con trol Unit and Angle Sensor Modulator ...

Page 540: ...electromagnetic interference This is just a temporary symptom Erase the prob lem code and the ABS control unit is normal unless the symptom occurs again Turn the ignition switch to ON and check the ABS indicator Is the indicator blinking NO GO TO STEP 2 YES GO TO STEP 3 2 ABS Indicator Function Inspection Retrieve the problem code and erase it Perform the pre start self diagnosis and check the ABS...

Page 541: ...radio wave electromagnetic interference This is just a temporary symptom Erase the prob lem code and the ABS control unit is normal unless the symptom occurs again Turn the ignition switch to ON and check the ABS indicator Is the indicator blinking NO GO TO STEP 2 YES GO TO STEP 3 2 ABS Indicator Function Inspection Retrieve the problem code and erase it Perform the pre start self diagnosis and ch...

Page 542: ...dio wave electromagnetic interference This is just a temporary symptom Erase the prob lem code and the ABS control unit is normal unless the symptom occurs again Turn the ignition switch to ON and check the ABS indicator Is the indicator blinking NO GO TO STEP 2 YES GO TO STEP 3 2 ABS Indicator Function Inspection Retrieve the problem code and erase it Perform the pre start self diagnosis and chec...

Page 543: ...ON GO TO STEP 3 NO OFF Normal temporary failure The ABS control unit has been disrupted by an extremely powerful radio wave Check the connector and wire harness for loose connection YES GO TO STEP 4 3 Input Voltage Inspection Disconnect the ABS control unit 5P connector 9 and 7 Measure the voltage between the Red blue and Green terminals of the connector 9 and between the Red green and Green termi...

Page 544: ...nector 7 Check for continuity between the Red blue terminal of the connector 7 and ground with the No 13 fuse removed Is there continuity NO Temporary failure install a spare fuse and recheck YES Short circuit in the wire between the fuse box and ABS control unit 4 Open Circuit Inspection Between Fuse Box and ABS Control Unit Install the fuse Disconnect the ABS control unit 7 Measure the voltage b...

Page 545: ...9 Disconnect the front and rear wheel speed sensor connectors 1 and 6 Measure the voltage between each con nector 1 and 6 terminal and ground as shown with the ignition switch turned to ON Is there voltage NO Open or short circuit in the wire between the ABS control unit and front or rear wheel speed sensor YES GO TO STEP 7 7 Open Circuit Inspection Between ABS Control and Wheel Speed Sensor Disco...

Page 546: ...PECTION Front sensor Raise the front wheel off the ground Remove the rear fender A page 2 13 Measure the clearance air gap between the sensor and pulser ring at several points by turning the wheel slowly It must be within specification The sensor air gap cannot be adjusted If it is not within specification check each installation part for deformation looseness and damage REPLACEMENT FRONT SENSOR R...

Page 547: ...emove the following right saddle bag page 2 15 fuel tank page 5 56 Disconnect the sensor 2P gray connector Remove the sensor wire from the clamps and clips Remove the two bolts and the speed sensor Installation is in the reverse order of removal After installation check the air gap page 16 29 Route the wire properly page 1 23 TORQUE 12 N m 1 2 kgf m 9 lbf ft Route the wire properly page 1 23 TORQU...

Page 548: ...ectors from each modulator Loosen the joint nuts to disconnect the brake pipe from each modulator Remove the following spark plug wire clip from stay two stay bolts Be careful not to bend or damage the brake pipe and stay modulator stay assembly from frame three mounting bolts and each modulator from the stay When loosening the joint nuts cover the ends of the brake pipe to pre vent contamination ...

Page 549: ...pes into the modulator ports and make sure that the paint color on the brake pipes are aligned with the marks on the modulators Be careful not to cross thread the joint nuts Apply brake fluid to the joint nut threads on the brake pipes Tighten the joint nuts to connect the brake pipes Connect the connectors to the modulators properly Install the ignition coils page 18 8 Fill and bleed the hydrauli...

Page 550: ...17 1 17 17 BATTERY CHARGING SYSTEM SYSTEM LOCATION 17 2 SYSTEM DIAGRAM 17 2 SERVICE INFORMATION 17 3 TROUBLESHOOTING 17 5 BATTERY 17 6 CHARGING SYSTEM INSPECTION 17 9 ALTERNATOR 17 10 ...

Page 551: ...BATTERY CHARGING SYSTEM 17 2 BATTERY CHARGING SYSTEM SYSTEM LOCATION SYSTEM DIAGRAM ...

Page 552: ...ng the motorcycle The battery will self discharge when the motorcycle is not in use For this reason charge the battery every 2 weeks to prevent sulfation from occurring Filling a new battery with electrolyte will produce some voltage but in order to achieve its maximum performance always charge the battery Also the battery life is lengthened when it is initially charged When checking the charging ...

Page 553: ...mal 1 8 A x 5 10 h Quick 9 0 A x 1 0 h Alternator Capacity 1 kW 2 400 min 1 rpm Stator coil resistance 20 C 68 F 0 07 0 09 Ω Rotor coil resistance 20 C 68 F 2 5 2 9 Ω Rotor coil slip ring O D 22 7 mm 0 89 in 21 2 mm 0 83 in Alternator mounting bolt 29 N m 3 0 kgf m 22 lbf ft Alternator terminal nut 8 N m 0 8 kgf m 5 8 lbf ft Driver 07749 0010000 Pilot 20 mm 07746 0040500 Driver 22 mm I D 07746 002...

Page 554: ...harging Voltage Inspection Measure and record the battery voltage using a digital multimeter page 17 6 Start the engine Measure the charging voltage page 17 7 Compare the measurements to the result of the following calculation Do the battery and charging voltages satisfy the calculation YES Faulty battery NO GO TO STEP 5 5 Wire Harness Inspection Perform the wire harness inspection page 17 10 Is b...

Page 555: ... disconnect the positive cable Remove the battery from the battery case Install the battery in the reverse order of removal Connect the positive cable first then connect the negative cable After connecting the battery cables coat the ter minals with grease VOLTAGE INSPECTION Remove the left side cover page 2 5 Measure the battery voltage using a commercially available digital multimeter VOLTAGE 20...

Page 556: ... result from overheating when The test button is pushed in for more than 3 seconds The tester is used without being allowed to cool for at least 1 minute when testing more than one battery More than ten consecutive tests are performed without allowing at least a 30 minute cool down period The result of a test on the meter scale is relative to the amp hour rating of the battery Any battery reading ...

Page 557: ...on indicated by the Honda Battery Tester RED 3 RED 2 or YELLOW 1 If you are charging a new battery set the switch to the NEW BATT position 4 Attach the clamps to the battery terminals red to positive black to negative Connect the battery cables only when the POWER switch is turned to OFF 5 Turn the POWER switch to ON 6 The charger will automatically switch to the Trickle mode after the set chargin...

Page 558: ...robable cause Locate the short by disconnecting connections one by one and measuring the current CHARGING VOLTAGE INSPECTION Make sure the battery is in good condition before performing this test Remove the left side cover page 2 5 Start the engine and warm it up to the operating temperature then stop the engine Connect the multimeter between the positive and negative terminals of the battery To p...

Page 559: ...t all times BATTERY VOLTAGE LINE Measure the voltage between the Black yellow wire terminal of the alternator 4P connector and ground There should be battery voltage with the ignition switch turned to ON and the engine stop switch turned to Install the removed parts in the reverse order of removal ALTERNATOR REMOVAL Remove the left engine side cover page 2 5 Remove the fuel tank page 5 56 Disconne...

Page 560: ... to identify their original position Remove the four bolts and separate the front hous ing rotor from the rear housing stator Remove the four screws and separate the rotor from the front housing Remove the oil seal from the front housing Remove the terminal cap nut and terminal set from the rear housing O RING OIL SEAL ROTOR SCREWS ...

Page 561: ... assembly from the rear housing INSPECTION ROTOR COIL Inspect the slip rings for discoloration Measure the O D of the slip rings Measure the rotor coil resistance between the slip rings Check for continuity between the slip ring and rotor shaft There should be no continuity SPRING WASHER SCREWS SERVICE LIMIT 21 2 mm 0 83 in SLIP RINGS STANDARD 2 5 2 9 Ω ...

Page 562: ...etly or if they fit loosely on the shaft page 17 15 BRUSH LENGTH Always replace the brushes in pairs Replace the brushes if they are worn to or near the wear lines If replacement is necessary remove the insulator and cap melt the solder securing the brushes and pull the brushes out of the brush holder Install new brushes in the brush holder with their marked side facing to the front housing Set th...

Page 563: ... as shown Cut off the surplus brush wires STATOR COIL Melt the solder and separate the stator coil from the regulator rectifier Measure the resistance between the stator coil wires Put the tester probe on the silver color part of the core Check for continuity between the stator coil wire and stator core There should be no continuity For stator coil assembly see page 17 14 Work quickly to avoid hea...

Page 564: ...ace the regulator rectifier assembly ROTOR BEARING REPLACEMENT Remove the front and rear rotor bearings using a bearing puller Be sure to center the attachment with the bearing Drive a new front bearing onto the rotor shaft using the special tools Drive a new rear bearing onto the rotor shaft using the special tools 2 2 2 TOOLS Driver 22 mm I D 07746 0020100 Attachment 20 mm I D 07746 0020400 TOOL...

Page 565: ...ad content solder join the stator and regulator rectifier by sol dering the stator coil wires on the diode terminals Push the brushes in the brush holder and insert an appropriate pin into the brush holder to hold the brushes Work quickly to avoid heat damage to the regulator rectifier Join with solder STATOR COIL REGULATOR RECTIFIER ...

Page 566: ...shes into the hole in the housing Align the marks on the rear housing and stator Install the three screws and tighten them securely Install the terminal and nut and tighten the nut Install the terminal cap Apply grease to a new oil seal lip and install it into the front housing REAR HOUSING PIN HOLE 5 4 95 TORQUE 8 N m 0 8 kgf m 5 8 lbf ft OIL SEAL ...

Page 567: ... on the front hous ing and stator Remove the pin holding the brushes from the rear housing Install the four bolts and tighten them securely Make sure the bolt holes in the rear housing align with the gaps between the stator core ridges Make sure the bolt holes in the rear housing align with the gaps between the stator core ridges INSTALLATION Coat a new O ring with oil and install it into the alte...

Page 568: ...three mounting bolts Connect the alternator cable and tighten the termi nal nut securely Install the rubber cap properly Connect the alternator 4P connector Install the fuel tank page 5 56 Install the left engine side cover page 2 5 TORQUE 29 N m 3 0 kgf m 22 lbf ft NUT CABLE 4P CONNECTOR ...

Page 569: ...MEMO ...

Page 570: ... LOCATION 18 2 SYSTEM DIAGRAM 18 2 SERVICE INFORMATION 18 3 TROUBLESHOOTING 18 4 IGNITION SYSTEM INSPECTION 18 5 IGNITION COIL 18 7 IGNITION PULSE GENERATOR 18 9 PGM FI IGNITION RELAY 18 11 BANK ANGLE SENSOR 18 13 IGNITION TIMING 18 14 ...

Page 571: ...IGNITION SYSTEM 18 2 IGNITION SYSTEM SYSTEM LOCATION SYSTEM DIAGRAM ...

Page 572: ...ly charged Using the starter motor with a weak battery results in a slower engine cranking speed as well as no spark at the spark plugs This motorcycle s ignition coil is equipped with an ignitor The ignition coil signal voltage from the ECM is converted to the high voltage in the ignition coil For spark plug inspection see section 3 See section 19 for the following components Ignition switch Engi...

Page 573: ...position neutral switch 5 An open circuit or loose connection in No 4 related circuit wires Side stand switch line Green white wire Neutral switch line Blue red and Light green red wires 6 Open or short circuit in the ignition coil signal wire No 1 2 Yellow white No 3 4 Yellow blue No 5 6 Yellow red 7 Faulty peak voltage adaptor 8 Faulty engine control module ECM when No 1 through 7 are normal Pea...

Page 574: ...GNITION COIL SIGNAL PEAK VOLTAGE Check all system connections before performing this inspection Loose connectors can cause incorrect readings Check that the cylinder compression is normal for each cylinder and the spark plug is installed correctly in the cylinder head Remove the center inner fairing page 2 10 Disconnect the ignition coil 4P connector TOOLS Peak voltage tester U S A only or Peak vo...

Page 575: ... the cylinder head Connect the test harnesses set to the ECM connec tors page 5 11 Connect the peak voltage tester or adaptor probes to the test pin box terminals Shift the transmission into neutral Turn the ignition switch to ON Crank the engine with the starter motor and mea sure the ignition pulse generator peak voltage If the voltage measured at the ECM connector is abnormal measure the peak v...

Page 576: ... voltages are abnormal follow the checks described in the troubleshooting chart on page 18 4 IGNITION COIL POWER GROUND LINE INSPECTION If the ignition coil signal voltage is normal but there is no spark at the plug perform this inspection Remove the center inner fairing page 2 10 Turn the ignition switch OFF Disconnect the ignition coil 4P connector POWER INPUT LINE 1 Make sure the engine stop sw...

Page 577: ...connector and ground There should be continuity If there is no continuity repair the open circuit in the Green wire between the ignition coil and ground terminal REPLACEMENT Remove the center inner fairing page 2 10 Remove the evaporative emission EVAP purge control solenoid valve from the stay Disconnect the ignition coil 4P connectors Disconnect the spark plug wires from the ignition coils Remov...

Page 578: ...age 3 8 Remove the bolts front lower inner cover wire clamps and the spark plug wires Route the spark plug wires properly page 1 23 and install the removed parts in the reverse order of removal IGNITION PULSE GENERATOR REPLACEMENT Remove the following front lower fairing page 2 6 air cleaner housing page 5 57 Disconnect the ignition pulse generator 2P red connector Remove the 12 bolts and the cran...

Page 579: ... surface of a new ignition pulse generator Apply locking agent to the bolt threads Install the ignition pulse generator grommet and wire retainer onto the crankcase cover and tighten the bolts Install the dowel pins and a new gasket Apply sealant to the mating surface of the crankcase as shown Install the front crankcase cover and tighten the 12 bolts TORQUE 12 N m 1 2 kgf m 9 lbf ft WIRE RETAINER...

Page 580: ...is no ignition coil input volt age perform this inspection Remove the seat page 2 5 Remove the two screws and remove the relay box Remove the relay blocks from the relay box 1 Turn the ignition switch to OFF and exchange the PGM FI ignition relay with the other good one Turn the ignition switch to ON and check the MIL If the MIL comes on for a few seconds and goes off replace the PGM FI ignition r...

Page 581: ...lay box If the fuse is blown replace it with a new one install the PGM FI ignition relay and turn the igni tion switch to ON If the fuse blows again check for a short circuit in the related wires 4 Measure the voltage between the Black white wire terminal of the relay connector and ground There should be battery voltage If there is no battery voltage check the Black white wire at the engine stop s...

Page 582: ...ween the White wire ter minal of the wire harness side connector and ground There should be battery voltage If there is no voltage check for an open circuit in the White wire If there is battery voltage go to step 4 4 Remove the two screws and the bank angle sen sor assembly from the right headlight 5 Turn the ignition switch to OFF Connect the bank angle sensor connector Measure the voltage betwe...

Page 583: ... ignition pulse generator rotor aligns with the index mark on the front crankcase cover Connect the timing light to the No 3 or No 4 spark plug wire and check the ignition timing as previ ously described by observing the F3 4 mark Check the No 5 or No 6 cylinder ignition timing in the same way using the F5 6 mark Remove the timing light and install the following cylinder head side cover page 3 7 t...

Page 584: ...RTER REVERSE MOTOR 19 17 STARTER RELAY SWITCH A 19 24 STARTER RELAY SWITCH B 19 25 REVERSE RELAY 19 26 REVERSE SWITCH 19 27 REVERSE REGULATOR ASSEMBLY 19 28 REVERSE RESISTOR ASSEMBLY 19 30 POWER CONTROL RELAY 19 31 SPEED LIMITER RELAY 19 33 REVERSE SHIFT RELAY 19 34 REVERSE SHIFT ACTUATOR 19 36 CRUISE REVERSE CONTROL MODULE 19 39 REVERSE SHIFT MECHANISM 19 42 ...

Page 585: ...STARTER REVERSE SYSTEM 19 2 STARTER REVERSE SYSTEM SYSTEM LOCATION STARTER SYSTEM DIAGRAM ...

Page 586: ...STARTER REVERSE SYSTEM 19 3 REVERSE SYSTEM DIAGRAM ...

Page 587: ...indicator goes out To use reverse again it is necessary to push the reverse shift switch to OFF then push it to ON See section 10 for starter clutch servicing See section 19 for following components ignition switch engine stop switch starter reverse switch reverse shift switch clutch switch side stand switch gear position switch SPECIFICATIONS TORQUE VALUES ITEM STANDARD SERVICE LIMIT Starter reve...

Page 588: ... x 35 mm 07746 0010100 Attachment 37 x 40 mm 07746 0010200 Attachment 20 mm I D 07746 0020400 or equivalent commercially avail able in U S A Pilot 20 mm 07746 0040500 Pin driver 3 5 mm 07744 0010300 or equivalent commercially avail able in U S A Fork seal driver 07947 4630100 Assembly collar 07965 VM00100 ...

Page 589: ...elay switches A and B Are all connections between starter relay switches A and B good NO Poorly connected terminals Open circuit in the starter relay switch cable YES GO TO STEP 4 4 Starter Relay Switches A B Operation Inspection With the ignition switch turned to ON and the engine stop switch to push the starter reverse switch and check for a click sound from starter relay switches A and B Both s...

Page 590: ... Is battery voltage present when the starter reverse switch is pushed in NO Open circuit in the Yellow red wire between starter relay switch A and right handlebar switch Loose or poor contact of the handlebar switch connector Faulty right handlebar starter reverse switch page 20 35 Open circuit in the White wire between the right handlebar switch and fuse box No 8 ST KILL fuse YES GO TO STEP 9 9 S...

Page 591: ... NO Open circuit in the Red wire between starter relay switch A and the fuse box No 12 reverse fuse B Open circuit in the Yellow red wire between starter relay switch B and the fuse box No 12 reverse fuse B Faulty starter relay switch A YES GO TO STEP 12 12 Starter Relay Switch B Operation Inspection Check the operation of starter relay switch B page 19 25 Is there continuity between the cable ter...

Page 592: ...rse Shift Relay 1 Coil Control Line Voltage Inspection Check the reverse shift relay 1 coil No 40 circuit at the cruise reverse control module page 19 39 Is battery voltage present when tested as described NO Open circuit in the Blue black wire between the control module and reverse shift relay 1 YES GO TO STEP 5 5 Reverse Shift Relay 2 Coil Voltage Control Line Continuity Inspection Check the rev...

Page 593: ... circuit at the cruise reverse control module page 19 39 Is there continuity NO Open circuit in the Light green red wire between the control module and gear position switch YES GO TO STEP 11 11 Reverse Shift Switch Line Voltage Inspection Check the reverse shift switch No 23 circuit at the cruise reverse control module page 19 39 Is battery voltage present NO Open circuit in the Yellow white wire ...

Page 594: ...se reverse control module Reverse shift actuator operates but the reverse indicator does not come on 1 Oil Pressure and Side Stand Indicator Operation Inspection Check for blown speed limiter fuse 70 A Check that the oil pressure and side stand indicators function properly Do the oil pressure and side stand indicators function properly NO Check the combination meter power input line page 20 17 YES...

Page 595: ...mechanism page 19 42 Turn the ignition switch to ON and push the reverse shift switch to ON position Check that the reverse actuator turns to the reverse position and the reverse indicator comes on Does the reverse actuator turn to the reverse position and the reverse indicator light come on NO Perform the troubleshooting on page 19 9 YES GO TO STEP 3 3 Reverse Shift Relay 3 Coil Control Line Cont...

Page 596: ...re switch Faulty oil pressure switch diode D18 page 20 13 YES GO TO STEP 3 3 Starter Relay Switch B Cable Continuity Inspection Remove the left saddlebag page 2 15 Check for continuity between the cable terminals at starter relay switch B There should be continuity Is there continuity NO Open circuit in the Red wire between starter relay switch B and reverse resistor assembly Open circuit in the B...

Page 597: ...ue wire between the reverse regulator assembly and reverse position switch in the reverse shift actuator Open circuit in the Brown red wire between the reverse regulator assembly and starter relay switch A Loose or poor contact of the related connectors YES GO TO STEP 7 7 Reverse Regulator Inspection Replace the reverse regulator assembly with a known good one and check the regulated voltage again...

Page 598: ...y cruise reverse control module Speed limiter system will not works when the reverse running speed is above 1 6 mph 2 5 km h 1 Speed Limiter Relay System Inspection Check the speed limiter relay system page 19 33 Does the speed limiter relay system test OK NO Faulty speed limiter relay circuits Faulty speed limiter relay YES GO TO STEP 2 2 Speed Limiter Line Continuity Inspection Check the Yellow ...

Page 599: ...or contact of the cruise reverse control module connectors Faulty cruise reverse control module System enters the reverse mode before all reverse running conditions are satisfied 1 Side Stand Switch and Oil Pressure Switch Signal Line Continuity Inspection Check the side stand switch No 11 and oil pressure switch No 48 circuits at the cruise reverse control module page 19 39 Is the continuity corr...

Page 600: ...minal nut and starter reverse motor cable Remove the three starter reverse motor mounting bolts Remove the starter reverse motor from the rear crankcase cover as shown and remove the O ring from the starter motor DISASSEMBLY INSPECTION Remove the three starter reverse motor case bolts Remove the following reduction gear case seal ring gear base washer gear base washer SEAL RING GEAR CASE GEAR BASE...

Page 601: ...he commutator bars of the armature for discoloration Do not use emery or sand paper on the commutator Check for continuity between pairs of commutator bars There should be continuity Check for continuity between each commutator bar and the armature shaft There should be no continuity ...

Page 602: ...gth Check for continuity between the insulated brush and cable terminal There should be continuity Check for continuity between the insulated brush and motor case There should be no continuity Remove the following if necessary brush holder SERVICE LIMIT 6 0 mm 0 24 in ...

Page 603: ... Remove the snap ring and washers from the starter shaft Remove the reduction gears and dowel pin Check the starter reduction gears for excessive or abnormal wear Remove the three screws Separate the starter and reverse reduction gear cases Remove the seal ring Remove the gear holder Check the reverse reduction gears for excessive or abnormal wear GEAR HOLDER REDUCTION GEARS SEAL RING ...

Page 604: ...oove with the dowel pin Install a new seal ring Assemble the reduction gear cases aligning the groove with the dowel pin Install the three screws and tighten them securely Install the dowel pin and starter reduction gears aligning the groove in the large outer gear with the pin Apply molybdenum disulfide grease to the starter reduction gears ...

Page 605: ...res The coil may be damaged if the magnet pulls the armature against the case Push and hold the brushes inside the brush holder and install the armature through the motor case and brush holder When installing the armature into the motor case hold the armature tightly to prevent the magnet of the case from pulling the armature against it Install the washer and a new seal ring Install the rear cover...

Page 606: ...curely INSTALLATION Coat a new O ring with oil and install it into the starter reverse motor groove Install the starter reverse motor into the rear crank case cover as shown Install the three mounting bolts and tighten them Connect the starter motor cable Install and tighten the terminal nut securely Pull the rubber cap onto the terminal securely Install the following reverse shift arm page 19 49 ...

Page 607: ...here is continuity when the transmission is in neutral or when the clutch is disengaged and the side stand is retracted the ground line is normal There is a slight resistance due to the diode RELAY COIL INPUT VOLTAGE LINE Turn the ignition switch to ON Measure the voltage between the Yellow red wire terminal of the wire harness side connector and ground If battery voltage is present only when the ...

Page 608: ...rminal of the wire harness side con nector and ground If there is continuity the ground line is normal There is a slight resistance due to the diode RELAY COIL INPUT VOLTAGE LINE Turn the ignition switch to ON Measure the voltage between the Yellow red wire terminal of the wire harness side connector and ground If battery voltage is present only when the starter reverse switch is pushed in the inp...

Page 609: ...to ON Measure the voltage between the Yellow red wire terminal of the relay connector and ground There should be battery voltage If there is battery voltage GO TO STEP 3 If there is no voltage check the following open circuit in the Yellow red and Black red wires between the reverse relay and reverse shift switch loose or poor contact of the related connector faulty diode D7 in the reverse regulat...

Page 610: ...en circuit in the Green red wire between the reverse regulator assembly and clutch switch faulty clutch switch open circuit in the Green white between the clutch switch and side stand switch faulty side stand switch REVERSE SWITCH REMOVAL INSTALLATION Remove the right engine side cover page 2 5 Pull the rubber cap off the reverse switch Remove the terminal nut and reverse switch wire Remove the re...

Page 611: ...r assembly page 19 28 The 11 diodes are integrated in the assembly They are used in the following circuits REVERSE REGULATOR ASSEMBLY 20P CONNECTOR D1 Ground of starter relay switch B coil D2 Ground of reverse relay neutral position side Gear position neutral signal of engine control module ECM D3 Ground of reverse relay clutch switch and side stand switch side D4 Ground of reverse relay coil reve...

Page 612: ...2P red connector with the connector connected Push the starter reverse switch The voltage should be approximately 0 V for the first 0 3 second then a minimum of 4 0 V should register Push the reverse shift switch to OFF and stop the engine REVERSE REGULATOR CIRCUIT INSPECTION Remove the reverse regulator assembly page 19 28 Check the following at the wire harness side con nector of the reverse reg...

Page 613: ...ARTER RELAY SWITCH LINE Turn the ignition switch to OFF Disconnect the 2P red connector of starter relay switch A Check for continuity between the Brown red wire terminals of the reverse regulator and starter relay switch A connectors There should be continuity CONTROL MODULE LINE Remove the top shelter page 2 11 Turn the ignition switch to OFF Disconnect cruise reverse control module 26P gray con...

Page 614: ... switch to ON Push the reverse shift switch to ON and check that the reverse indicator comes on Turn the ignition switch to OFF and disconnect the cruise reverse control module 26P gray connector POWER CONTROL RELAY 1 1 Ground the Orange wire terminal of the control module connector with a jumper wire Turn the ignition switch to ON and check that power control relay 1 clicks If the relay clicks th...

Page 615: ...en circuit in Red and Black wires between power control relay 1 and reverse resistor POWER CONTROL RELAY 2 1 Ground the White wire terminal of the control module connector with a jumper wire Turn the ignition switch to ON and check that power control relay 2 clicks If the relay clicks the relay coil is normal go to step 3 If the relay does not click go to step 2 2 Turn the ignition switch to OFF E...

Page 616: ... be continuity while the battery is connected and no continuity when the battery is disconnected SPEED LIMITER RELAY SYSTEM INSPECTION Remove the following top shelter page 2 11 left saddlebag page 2 15 Shift the transmission into neutral and turn the igni tion switch to ON Push the reverse shift switch to ON and check that the reverse indicator comes on Turn the ignition switch to OFF and disconn...

Page 617: ...tor Check for continuity between the White wire ter minals of the speed limiter relay and reverse resistor connectors There should be continuity OPERATION CHECK Remove the speed limiter relay Connect an ohmmeter and a fully charged 12 V bat tery to the relay terminals as shown There should be continuity while the battery is connected and no continuity when the battery is disconnected REVERSE SHIFT...

Page 618: ...ne Turn the ignition switch to ON and push the reverse shift switch to ON If the reverse shift actuator operates replace reverse shift relay 3 with a new one and check again using original reverse shift relays 1 and 2 If the reverse shift actuator does not operate go to step 4 4 Turn the ignition switch to OFF and remove reverse shift relay 1 Measure the voltage between the Red black wire terminal...

Page 619: ... If the actuator operates check the following open circuit in the Blue wire between reverse shift relay 2 and the actuator open circuit in the Blue red wire between reverse shift relay 3 and the actuator If the actuator does not operate go to step 4 4 Disconnect the reverse shift actuator cables from the actuator page 19 38 and check again If the actuator operates check the reverse shift mechanism...

Page 620: ...he Brown and Black white wire terminals of the actuator side 3P connector There should be continuity Turn the actuator to the reverse position by con necting a fully charged 12 V battery to the actuator side 2P connector terminals Check for continuity between the Brown and White blue wire terminals of the actuator side 3P connector There should be continuity REMOVAL INSTALLATION Remove the followi...

Page 621: ... cables Install the following ABS modulators page 16 31 right engine side cover page 2 5 REVERSE SHIFT ACTUATOR CABLE ADJUSTMENT Remove the following right engine side cover page 2 5 center inner fairing page 2 10 Check that the reverse shift actuator pulley is in the neutral position as shown Check the N cable clearance between the cable outer end and cable holder Check the R cable clearance betw...

Page 622: ...e reverse actuator pulley to the neutral position Turn the ignition switch to OFF and install the following center inner fairing page 2 6 right engine side cover page 2 5 CRUISE REVERSE CONTROL MODULE SYSTEM INSPECTION Remove the top shelter page 2 11 Turn the ignition switch to OFF and disconnect the 26P black and gray connectors from the cruise reverse control module Check the reverse system cir...

Page 623: ...ty 12 Starter reverse motor Pink white and starter reverse motor cable termi nal of starter relay switch B Remove the left saddlebag page 2 15 There should be continuity 17 Reverse switch Green orange and ground Reverse shift actuator in the neutral position There should be continuity Reverse shift actuator in the reverse position There should be no continuity 18 Starter reverse switch Yellow red ...

Page 624: ...ls There should be continuity 40 Reverse shift relay 1 Blue black and ground Ignition switch ON There should be battery voltage 43 Reverse relay Yellow red and ground Ignition switch ON There should be battery voltage 46 Power control relay 2 White and ground Reverse shift actuator in the reverse position Ignition switch ON There should be battery voltage 47 Neutral switch Light green red and grou...

Page 625: ...inder page 15 19 Remove the two bolts ground cable and reverse shift actuator cable holder Remove the following bolt washer collar lost motion spring reverse shift arm with the cables and holder lost motion plate reverse shift arm spring bushing spring collar O ring from the collar needle bearing washer oil seal ...

Page 626: ...he rear crankcase cover page 10 11 Remove the following starter reduction gear and shaft washer reverse idle gear reverse shifter shaft assembly three bolts starter drive gear holder two dowel pins bolt shift drum lock arm assembly GEAR SHAFT WASHER REDUCTION GEAR REVERSE IDLE GEAR ...

Page 627: ...eck the drive gear teeth for wear or damage Turn the drive gear and check the bearing condition The bearing should turn smoothly and quietly Also check that the outer race of the bearing fits tightly in the holder Replace the bearing if the drive gear does not turn smoothly quietly or if the outer race fits loosely in the holder Check the reverse shifter shaft bearing for wear or damage Check the ...

Page 628: ...aring inner race with the special tool and press the starter drive gear into the bearing REVERSE SHIFTER SHAFT BEARING Remove the starter drive gear Drive the reverse stopper shaft and collar out of the gear holder TOOLS Pilot 20 mm 07746 0040500 Assembly collar 07965 VM00100 TOOLS Driver 07749 0010000 Attachment 32 x 35 mm 07746 0010100 Fork seal driver 07947 4630100 TOOLS Driver 07749 0010000 At...

Page 629: ...IFTER INSTALLATION Apply molybdenum disulfide grease to the lock arm pivot Apply locking agent to the shift drum lock arm bolt threads Install the shift drum lock arm assembly and tighten the bolt Apply oil to the starter drive gear bearing and install the drive gear into the gear holder Apply oil to the reverse shifter shaft bearing Apply molybdenum oil solution to the reverse stop per shaft and ...

Page 630: ...curely Apply oil to the needle bearings Apply molybdenum oil solution to the shifter guide holes groove and shifter gear splines Install the washer needle bearings shifter gear and washer onto the reverse shifter Install the snap ring with the chamfered side facing in Check that the shifter gear turns smoothly SNAP RING SHIFTER GEAR SNAP RING ...

Page 631: ...um lock arm while aligning the flat on the shaft end with the flat in the lock arm hole Further insert the shifter shaft assembly while align ing the shifter groove with the stopper shaft Install the reverse idle gear with the OUT mark facing out Install the washer Coat the starter reduction gear shaft with molybde num oil solution and install it into the gear holder Install the starter reduction ...

Page 632: ...l and install the seal into the rear crankcase cover Coat the needle bearing with molybdenum oil solu tion and install the washer and needle bearing onto the reverse shifter shaft Coat a new O ring with oil and install it into the spring collar Install the spring collar onto the reverse shifter shaft ...

Page 633: ...pply locking agent to the reverse shifter shaft bolt threads Install the collar washer and shaft bolt and tighten the bolt Apply locking agent to the cable holder bolt threads Install the cable holder ground cable terminal and holder bolts and tighten the bolts Check the reverse shift actuator cables and adjust them if necessary page 19 38 Install the rear brake master cylinder page 15 19 LOST MOT...

Page 634: ...HOMETER 20 21 COOLANT TEMPERATURE GAUGE ECT SENSOR 20 22 FUEL GAUGE LOW FUEL INDICATOR 20 24 NEUTRAL INDICATOR 20 26 OIL PRESSURE INDICATOR 20 27 TURN SIGNAL RELAY 20 27 TURN SIGNAL CANCEL UNIT 20 28 POSITION LIGHT RELAY 20 31 HAZARD SWITCH 20 32 OPEN AIR TEMPERATURE SENSOR 20 33 IGNITION SWITCH 20 34 HANDLEBAR SWITCH 20 35 BRAKE SWITCH 20 37 CLUTCH SWITCH 20 37 GEAR POSITION SWITCH 20 38 SIDE STA...

Page 635: ...LIGHTS METERS SWITCHES 20 2 LIGHTS METERS SWITCHES SYSTEM LOCATION ...

Page 636: ...stalled on the motorcycle When checking the turn signal hazard system always follow the steps in the troubleshooting flow chart page 20 5 The following color codes used are indicated throughout this section SPECIFICATIONS TORQUE VALUES TOOL Bl Black G Green Lg Light Green R Red Br Brown Gr Gray O Orange W White Bu Blue Lb Light Blue P Pink Y Yellow ITEM SPECIFICATIONS Bulbs Headlight high beam 12 ...

Page 637: ... Loose or poor contact of related connectors Both high beam headlights do not light with the dimmer switch pushed to Faulty dimmer switch page 20 36 Open circuit in the Blue white wire between the starter reverse switch and dimmer switch Left high beam headlight does not light with the dimmer switch pushed to Faulty bulb Open circuit in the Blue wire between the left headlight and dimmer switch Lo...

Page 638: ... 3 Turn Signal Light Inspection Connect the Light green black and Gray wire ter minals of the meter 3P connector with a jumper wire Turn the ignition switch to ON and operate the turn signal switch Do the turn signal lights come on NO Open circuit in the Gray wire between the turn signal relay and turn signal switch Loose or poor contact of the related connectors YES GO TO STEP 4 4 Turn Signal Rel...

Page 639: ...al switch operating properly NO Faulty turn signal switch YES GO TO STEP 2 2 Turn Signal Off Signal Line Inspection Check the turn signal off signal line of the turn signal cancel unit page 20 28 Is there continuity NO Open circuit in the Light green white wire between the turn signal cancel unit and turn signal switch Loose or poor contact of the related connectors YES Faulty turn signal cancel u...

Page 640: ...ss side panel switch 14P connector and ground Is there continuity NO Open circuit in the Green wire between the hazard switch and ground terminal YES GO TO STEP 3 3 Hazard Switch Line Continuity Inspection Disconnect the combination meter 3P connector page 20 17 Check for continuity of the following wires between the panel switch 14P connector and meter 3P connector Gray Blue green Is there contin...

Page 641: ...oth moistened with alcohol to prevent an early failure Install the bulb socket into the headlight and hook the bulb retainer properly as shown Install the dust cover properly onto the headlight with the arrow mark facing up Connect the headlight connector Install the fairing pocket page 2 11 REMOVAL INSTALLATION Remove the front fairing page 2 10 Remove the two screws and bank angle sensor assembl...

Page 642: ... loose contacts or corroded terminals 3 Check for continuity between the Green wire ter minal and ground There should be continuity If there is continuity go to step 4 If there is no continuity check for an open cir cuit in the Green wire between the headlight adjuster and ground terminal 4 Start the engine and let it idle Measure the voltage between the Brown red wire terminal and ground There sh...

Page 643: ...Turn the adjuster clockwise Left headlight adjuster Turn the adjuster counter clockwise Turn the adjusting bolt counterclockwise and remove the headlight adjuster from the headlight Install the headlight adjuster in the reverse order of removal Adjust the headlight beam page 3 19 HEADLIGHT ADJUSTING SWITCH SYSTEM INSPECTION 1 Turn the ignition switch to OFF Remove the left fairing pocket page 2 11...

Page 644: ...oltage between the Brown red wire terminal and ground There should be battery voltage If there is battery voltage the system is OK If there is no battery voltage check for open circuit in the Brown red wire between the panel switch connector and headlight adjuster relay headlight adjuster relay system HEADLIGHT ADJUSTER RELAY SYSTEM INSPECTION 1 Turn the ignition switch to ON and check that the oi...

Page 645: ...heck for continuity between the Blue white wire terminal of the relay connector and ground Start the engine and let it idle There should be no continuity If there is no continuity go to step 5 If there is continuity check for short circuit in the Blue white wire between the headlight adjuster relay and oil pres sure switch diode D17 faulty diode D17 5 Stop the engine then turn the ignition switch ...

Page 646: ...IGHT BULB REPLACEMENT Remove the screw and mirror from the rearview mirror housing by releasing the two tabs Remove the bulb socket from the turn signal light by turning it counterclockwise Pull the bulb out of the socket and replace it with a new one Install the removed parts in the reverse order of removal REPLACEMENT Remove the rearview mirror cover page 2 7 Disconnect the turn signal light con...

Page 647: ...ght by turning it counterclockwise Pull the turn signal light bulb out of the socket and replace it with a new one Install the removed parts in the reverse order of removal BRAKE TAILLIGHT Remove the bulb socket from the combination light by turning it counterclockwise Pull the brake taillight bulb out of the socket and replace it with a new one Install the removed parts in the reverse order of re...

Page 648: ... taillight by turning it counterclockwise Pull the bulb out of the socket and replace it with a new one Install the removed parts in the reverse order of removal LICENSE LIGHT BULB REPLACEMENT Remove the two screws and license light lens Pull the bulb out of the socket and replace it with a new one Install the license light lens and tighten the two screws BULB SOCKET SCREWS LENS BULB ...

Page 649: ... 4 terminal There should be continuity while the battery is connected There should be no continuity when the battery is disconnected 5 TERMINAL RELAY CHECK Check for continuity between the No 1 and No 2 terminals and between No 1 and No 4 terminals Connect the fully charged 12 V battery terminal to the relay No 3 terminal and the terminal to the No 5 terminal There should be continuity between the...

Page 650: ...UND LINE INSPECTION Remove the combination meter page 20 17 Check the following at the wire harness side con nector terminals POWER SOURCE LINE Measure the voltage between the Brown white wire terminal of the 20P blue connector and ground There should be battery voltage with the ignition switch turned to ON If there is no voltage check for open circuit in the Brown white wire between the combinati...

Page 651: ...nd fuse box No 22 fuse blown No 22 fuse loose or poor contact of related connectors GROUND LINE Check for continuity between the Green wire termi nal of the 20P black connector and ground There should be continuity at all times If there is no continuity check for open circuit in the Green wire between the combination meter and ground terminal SENSOR GROUND LINE Check for continuity between the Gre...

Page 652: ...nnector and remove the LCD assembly Remove the eight tapping screws and remove the meter gauge assembly from the lower case Remove the three terminal screws and turn signal relay circuit board Remove the tapping screw wire clamp and turn sig nal relay wire METER LENS SCREWS LCD ASSEMBLY SCREWS 5 4 95 WIRE CLAMP TAPPING SCREW TERMINAL SCREWS ...

Page 653: ...des go to step 3 3 Remove the combination meter page 20 17 Place the motorcycle on its center stand shift the transmission into neutral and turn the ignition switch to ON Measure the voltage between the White black and Green wire terminals of the combination meter 20P black connector There should be 0 V to 5 V pulse voltage while slowly turning the rear wheel by hand If the pulse voltage appears r...

Page 654: ... value is more than 10 5 V replace the meter gauge assembly page 20 19 If the measured value is less than 10 5 V replace the engine control module ECM If there is no voltage go to step 3 3 Remove the top shelter page 2 12 Disconnect the engine control module ECM 22P gray connector 4 Check the Yellow green wire for open or short circuit as follows Check for continuity between the combination meter ...

Page 655: ...sconnect the ECT sensor 3P connector 3 Ground the Green black wire terminal of the ECT sensor connector with a jumper wire Turn the ignition switch to ON and check the coolant temperature gauge The gauge needle should move to H If the needle moves check the ECT sensor If the needle does not move go to step 4 4 Remove the combination meter page 20 17 Check the Green black wire for continuity betwee...

Page 656: ... pan to the bottom of the sensor Keep the temperature constant for 3 minutes before testing A sudden change of temperature will result in incorrect readings Do not let the thermometer or ECT sensor touch the pan Replace the ECT sensor if it is out of specifications by more than 10 at any temperature listed Install the ECT sensor with a new sealing washer and tighten it Connect the ECT sensor conne...

Page 657: ...with a jumper wire Turn the ignition switch to ON and check the low fuel indicator and fuel level gauge The indicator should not come on and the gauge needle should move to F If the indicator and gauge function properly check the fuel level sensors If one of the indicator or gauge functions properly but the other does not function replace the meter gauge assembly page 20 19 If the indicator and ga...

Page 658: ...onnector terminals with the float at top FULL and bottom EMPTY positions Install a new base gasket Install the fuel level sensor in the fuel tank and align the lugs on the sensor base with grooves in the fuel tank Install the retainer and turn it clockwise with the special tool until it stops Install the removed parts in the reverse order of removal TOOL Fuel sender pump wrench 07ZMA MCAA201 or 07...

Page 659: ...nd ground There should be battery voltage If there is no battery voltage go to step 3 If there is voltage check for reverse position switch page 19 30 reverse shift switch page 20 35 open circuit in the Black white Black red and Black brown wires between the combi nation meter and reverse position switch loose or poor contact of related connectors 3 Check for continuity between the Light green wir...

Page 660: ...he oil pressure switch and combination meter Indicator stays on while the engine is running Check for continuity between the oil pressure switch wire terminal and ground There should be no continuity If there is continuity check for short circuit in the Blue red wire between the oil pressure switch and combination meter If there is no continuity check the oil pressure page 4 6 If the oil pressure ...

Page 661: ...y at all times If there is no continuity check for an open circuit in the Green wire between the 6P gray connector and ground terminal TURN SIGNAL ON SIGNAL LINE Check for continuity between the Pink wire terminal and ground There should be continuity when the turn signal switch is turned to or If there is no continuity check for an open circuit in the Pink wire between the 6P gray connector and l...

Page 662: ...tor and combina tion meter loose or poor contact in related connectors CANCEL SIGNAL LINE Make sure the ground turn signal on off signal and power input lines are OK before inspection Connect the 6P gray connector and turn the ignition switch to ON Measure the voltage between the Blue black wire terminal and ground There should be no voltage when the turn signal switch is pushed to or There should...

Page 663: ... by turning the angle sensor plate Install and tighten the screw securely REMOVAL INSTALLATION Remove the meter panel page 2 7 Remove the two screws and handlebar center cover Remove the steering stem nut cap and disconnect the turn signal cancel unit 7P connector Remove the three screws and turn signal cancel unit from the steering stem Installation is in the reverse order of removal CAP 7P CONNE...

Page 664: ...he Light blue white wire terminal and ground There should be battery voltage and no voltage when the turn signal switch is pushed to If the measurements are normal go to step 3 If there is no voltage check the following faulty turn signal switch open circuit in the Light blue white wire 3 Measure the voltage between the Orange white wire terminal and ground There should be battery voltage and no v...

Page 665: ...h assembly 14P gray connector Check for loose contacts or corroded terminals Check for continuity between the switch side con nector terminals Continuity should exist between the color coded wires as shown in the chart LEFT PANEL SWITCH REPLACEMENT Disconnect the left panel switch assembly 14P gray connector page 20 32 Remove the left fairing molding page 2 10 Remove the screw attaching the switch...

Page 666: ...the Yellow blue and Green black wire terminal of the wire harness side sensor connector There should be approximately 5 V If there is approximately 5 V go to step 2 if there is no voltage check for an open circuit in the Yellow blue and Green black wires between the sensor and combination meter connectors 2 Turn the ignition switch to OFF and measure the resistance between the sensor side connec t...

Page 667: ...t Install the open air temperature sensor in the reverse order of removal IGNITION SWITCH INSPECTION Remove the top shelter page 2 11 Disconnect the ignition switch 4P white connector Check for continuity between the switch side con nector terminals in each switch position Continuity should exist between the color coded wires as shown in the chart AIR DUCT GROMMET AND BOSS Color LOCK R Bl Lg Bl OF...

Page 668: ...t handlebar switch 14P blue connector After 03 right handlebar switch 18P blue connector left handlebar switch 12P blue connector left handlebar switch 14P gray connector Check for continuity between the connector termi nals in each switch position Continuity should exist between the color coded wires as shown below RIGHT HANDLEBAR SWITCH For cruise control switch inspection see section 21 Starter...

Page 669: ... SWITCH Color LO Bu W N HI Position Bu Color FREE W G Lg PUSH Position Color R Gr Lb O L PUSH Position Br W Lb W O W G P G Lg W LEFT HANDLEBAR SWITCH BULB A BULB C BULB C BULB C BULB B ORNAMENT PLATE A ORNAMENT PLATE C ORNAMENT PLATE D LOWER LENS UPPER LENS A UPPER LENS B AUDIO LENS ORNAMENT PLATE A ORNAMENT PLATE B UPPER LENS LOWER LENS A LOWER LENS B BULB C BULB B BULB B RIGHT HANDLEBAR SWITCH ...

Page 670: ...AR Remove the top shelter page 2 11 There should be continuity with the rear brake pedal depressed and no continuity with the pedal released Disconnect the rear brake light switch 3P white con nector and check for continuity between the switch side connector terminals CLUTCH SWITCH The upper switch is the clutch switch Disconnect the clutch switch wire connectors and check for continuity between t...

Page 671: ...ct the gear position switch connector Remove the gear position switch from the gearshift linkage cover page 10 8 Install a new gear position switch onto the gearshift linkage cover and install the cover page 10 9 Connect the gear position switch connector Install the air cleaner housing page 5 65 GEAR POSITION SWITCH CONNECTOR GEAR POSITION CONTINUITY Neutral Light green red to ground 1st 2nd Blac...

Page 672: ...ide cover page 2 5 Disconnect the side stand switch 3P connector Remove the side stand switch bolt and the switch Install a new side stand switch by aligning the switch pin with the hole in the side stand and the switch groove with the bracket pin Install the side stand switch bolt and tighten it Connect the side stand switch 3P connector Install the left engine side cover page 2 5 3P CONNECTOR BO...

Page 673: ...when the MODE switch is depressed TRIP SWITCH There should be continuity between the Brown yellow and Green yellow wire terminals when the TRIP switch is depressed DISP SWITCH There should be continuity between the Blue yellow and Green yellow wire terminals when the DISP switch is depressed HORN Remove the front lower fairing page 2 6 Disconnect the wire connectors from the horn Connect a 12 V ba...

Page 674: ...heck the following blown No 7 fuse open circuit in the Black blue wire 3 Turn the ignition switch to OFF and connect the Blue and Black blue wire terminals with a jumper wire Turn the ignition switch to ON The cooling fan should start If the cooling fans start go to step 4 If the cooling fans do not start check the following faulty cooling fan open circuit in the Blue and Green wires 4 Exchange th...

Page 675: ... stored the code which was registered first will be erased Make sure to keep the timing between 1 and 4 seconds for each action Too fast or too slow will cause the control unit to lose the stored codes 1 Turn the ignition switch to ON Between 1 and 4 seconds press the trunk opener button on the transmitter while aiming transmitter at the trunk Between 1 and 4 seconds turn the ignition switch to OF...

Page 676: ...4 4 Register the good known transmitter and check that the system functions properly If the system functions properly replace the transmitter If the system does not function go to step 5 5 Remove the trunk lid inner cover and disconnect the trunk lock control unit 18P white connector page 20 46 Check for continuity between the Green wire ter minal and ground There should be continuity at all times...

Page 677: ...ed replace the trunk lock control unit page 20 46 Trunk opener unit can be unlocked but cannot be locked with the transmitter Make sure all trunk and saddlebag lids are closed completely 1 Remove the trunk lid inner cover and disconnect the trunk lock control unit 18P white connector page 20 46 2 Check for continuity between the Brown red wire terminal and ground There should be no continuity If t...

Page 678: ...ed wires between the trunk control unit and open switches Loose or poor contact of related connectors Faulty trunk control unit Trunk opener unit can be locked and unlocked with the transmitter but the turn signal lights do not blink Make sure that the turn signal hazard system functions properly ignition switch is turned to OFF or LOCK 1 Remove the trunk lid inner cover and disconnect the trunk l...

Page 679: ...uit in the Blue wire between the trunk control unit and opener actuator Open circuit in the Green wire between the opener actuator and ground terminal Loose or poor contact in related connectors Faulty trunk control unit Trunk and saddlebag lid open indicator does not function when one of the lids is open Faulty trunk or saddlebag open switch pages 20 48 and 20 49 Open circuit in the following wir...

Page 680: ... and terminal to the Yellow wire terminal momentarily The trunk opener unit should be unlocked LOCK UNLOCK SWITCH Check for continuity between the White and Green wire terminals There should be continuity with the opener unit locked and no continuity with the unit unlocked Check for continuity between the Black and Green wire terminals There should be continuity with the opener unit unlocked and n...

Page 681: ...tinuity with the lid closed TRUNK OPENER UNIT REMOVAL INSTALLATION Remove the trunk lower cover page 2 14 Remove the trunk and saddlebag opener rods from the snap joints of the opener unit Remove the two bolts and the trunk saddlebag lid opener lever assembly Disconnect the trunk opener unit 8P connector Remove the three screws and the trunk opener unit from the trunk 5 4 95 ...

Page 682: ...eck for continuity between the Brown red and Green wire terminals of the saddlebag side connectors There should be continuity with the saddlebag lid open and no continuity with the lid closed OPEN SWITCH DIODE INSPECTION Remove the seat page 2 5 Remove the trunk saddlebag open switch diode from the wire harness Check for continuity between the diode terminals When there is continuity a small resis...

Page 683: ...MEMO ...

Page 684: ...ONTROL SYSTEM SYSTEM LOCATION 21 2 SERVICE INFORMATION 21 3 TROUBLESHOOTING 21 4 CRUISE REVERSE CONTROL MODULE 21 9 IGNITION CRUISE RELAY 21 11 CRUISE CONTROL SWITCH 21 13 CRUISE CANCEL SWITCH 21 14 CRUISE ACTUATOR 21 16 ...

Page 685: ...CRUISE CONTROL SYSTEM 21 2 CRUISE CONTROL SYSTEM SYSTEM LOCATION ...

Page 686: ...e electric cruise actuator is used to control the throttle valve in this cruise control system The cruise control module is integrated with the reverse control module When checking the cruise control system always follow the steps in the troubleshooting flow chart page 21 4 SPECIFICATIONS ITEM STANDARD SERVICE LIMIT Cruise actuator coil resistance 20 C 68 F Clutch coil 35 45 Ω Step motor coil 3 7 ...

Page 687: ...ndicator Line Check the cruise ON indicator No 13 line at the cruise reverse control module page 21 9 Does the cruise ON indicator No 13 line function as specified NO GO TO STEP 7 YES GO TO STEP 4 4 Cruise Main Switch Line Check the cruise main switch No 9 line at the cruise reverse control module page 21 9 Does the cruise main switch No 9 line function as specified YES Faulty cruise reverse contr...

Page 688: ... enter the fail safe mode and the cruise ON indicator will blink when the cruise main switch is pushed to ON with the ignition switch turned to ON and the engine stop switch to Check the cruise actuator relay coil No 50 line at the cruise reverse control module Does the relay coil No 50 line function as specified NO Faulty cruise actuator relay page 21 16 Open circuit in the Black yellow wire betw...

Page 689: ...osition switch No 2 line function as specified NO Faulty gear position switch page 20 38 Open circuit in the Green orange wire between the cruise reverse control module and gear position switch YES GO TO STEP 2 2 Gear Position 4th Switch Line Check the gear position 4th switch No 3 line at the cruise reverse control module page 21 9 Does gear position 4th switch No 3 line function as specified NO ...

Page 690: ... 9 Does the brake light No 35 line unction as specified NO Faulty brake light system YES GO TO STEP 10 10 Cruise Actuator Motor A Line Check the cruise actuator motor A No 33 line at the cruise reverse control module page 21 9 Does the cruise actuator motor A No 33 line function as specified NO Faulty cruise actuator motor page 21 16 Open circuit in the Blue wire between the cruise reverse control...

Page 691: ...tch Cruise control cannot be cancelled 1 Clutch Cruise Cancel Switch Line Make sure that the brake lights operate properly Check the clutch cruise cancel switch No 4 line at the cruise reverse control module page 21 9 Does the clutch cruise cancel switch No 4 line function as specified NO Faulty clutch cruise cancel switch page 21 14 Open circuit in the Green blue wire between the cruise reverse c...

Page 692: ...ied NO Faulty cruise reverse control module YES GO TO STEP 2 2 Combination Meter and Cruise Reverse Control Module Remove the combination meter page 20 17 Check the Blue white wire for continuity between the meter 20P blue connector and cruise reverse control module 26P black connector Is there continuity NO Open circuit in the Blue white wire Loose or poor contact of the related connectors YES Fa...

Page 693: ...ack and ground Ignition switch turned to ON Rear wheel turned slowly 0 to 5 V pulse voltage should appear 9 Cruise main switch Black yellow and ground Ignition switch turned to ON Cruise main switch turned to ON There should be battery voltage 13 CRUISE ON indicator Blue orange Ground wire with a jumper wire and turn the ignition switch to ON CRUISE ON indicator should come on 14 Cruise power inpu...

Page 694: ...e no voltage Ignition switch turned to ON Brake lever squeezed or brake pedal depressed There should be battery voltage 39 Cruise actua tor motor B Yellow and No 32 Brown white There should be 3 7Ω 45 Cruise actua tor motor C Light green and No 32 Brown white There should be 3 7Ω 50 Cruise actua tor relay coil Green black and ground Ignition switch turned to ON There should be battery voltage 52 G...

Page 695: ...e is continuity go to step 5 If there is no continuity repair the open circuit in the green wire 5 Measure the voltage between the Yellow wire terminal of the relay connector and ground There should be battery voltage If there is battery voltage go to step 6 If there is no voltage check for an open circuit in the Yellow wire between the ignition cruise relay and fuse box No 19 fuse 6 Turn the igni...

Page 696: ...lue connector Check for continuity between the connector termi nals in each switch position Continuity should exist between the color coded wires as shown in the charts below CRUISE MAIN SWITCH SET DECEL SWITCH RESUME ACCEL SWITCH 18P CONNECTOR Color FREE White yellow Black yellow PUSH Position Color FREE White blue Black yellow PUSH Position ...

Page 697: ...inuity with the front brake lever squeezed and continuity with the lever released Turn the ignition switch to ON and push the cruise main switch to ON Measure the voltage between the Black blue wire terminal and ground There should be battery voltage THROTTLE GRIP Remove the air cleaner housing page 5 57 Disconnect the throttle grip cruise cancel switch 2P blue connector Check for continuity betwe...

Page 698: ...e from the cable stay and disconnect it from the throttle drum Remove the left radiator page 6 10 Remove the two bolts and proportional control valve PCV from the stay Remove the stay mounting bolt Remove the two socket bolts and stay from the can cel switch Remove the center bolt and switch cover 2P BLUE CONNECTOR RETURN SIDE THROTTLE CABLE STAY PCV ...

Page 699: ...ON and push the cruise main switch to ON Measure the voltage between the Green white wire terminal of the wire harness side connector and ground There should be battery voltage CRUISE ACTUATOR INSPECTION Remove the top shelter page 2 11 Disconnect the cruise actuator 6P black connector Check the connector for loose contacts or corroded terminals ACTUATOR CLUTCH Connect a 12 V battery terminal to t...

Page 700: ...trol unit holder and tighten the three tapping screws Connect the cruise actuator cable to the actuator drum and install it onto the cable stay Adjust the cable position with the nuts so that the distance between the cable cap screw end and stay is 34 mm 1 34 in as shown Install the air cleaner housing page 5 57 ACTUATOR CABLE ADJUSTMENT Remove the top shelter page 2 11 Check that the projection o...

Page 701: ...CRUISE CONTROL SYSTEM 21 18 Loosen the lock nut and adjust the cruise actuator cable by turning the adjusting nut as required Install the top shelter page 2 11 ...

Page 702: ...22 1 22 22 AUDIO SYSTEM SYSTEM LOCATION 22 2 SERVICE INFORMATION 22 3 TROUBLESHOOTING 22 4 AUDIO UNIT 22 6 AUDIO SWITCH 22 9 ANTENNA 22 11 SPEAKER 22 12 HEADSET JUNCTION WIRE 22 12 ...

Page 703: ...AUDIO SYSTEM 22 2 AUDIO SYSTEM SYSTEM LOCATION ...

Page 704: ...onnected The AM frequency moves in sequence in 10 kHz steps The FM frequency moves in sequence in 0 2 MHz steps The ambience AMB circuit blends and boosts certain frequencies from both channels for a live performance effect AMB may be used for stereo programs from the FM radio However the ambience circuit may make weak FM stereo signals sound worse TORQUE VALUE Antenna base mounting bolt 14 N m 1 ...

Page 705: ...P 2 2 Audio Back up Line Inspection Check the audio back up line page 22 6 Is battery voltage present NO Open circuit in the Red yellow wire between the audio unit and fuse YES GO TO STEP 3 3 Accessory Power Line Inspection Check the accessory power line page 22 6 Is battery voltage present NO Open circuit in the Light green black wire between the audio unit and relay YES GO TO STEP 4 4 Audio Grou...

Page 706: ...ns good NO Correct the faulty part YES GO TO STEP 2 2 Antenna Base Inspection Check the antenna base page 22 11 Is continuity correct NO Faulty antenna base YES Loose or poor related connection Faulty condenser in the alternator or cooling fan motor Faulty audio unit AVC Auto Volume Control does not work at all 1 Speedometer Inspection Check that the speedometer operates properly Is the speedomete...

Page 707: ...There should be battery voltage with the ignition switch turned to ON or ACC GROUND LINE Check for continuity between the Green wire termi nal and ground There should be continuity at all times SPEAKER OUTPUT VOLTAGE INSPECTION Remove the speakers page 22 12 Select the AC range on the tester Measure the voltage between the connector termi nals at each speaker There should be voltage with the radio...

Page 708: ...ndlebar audio switch 12P connector and ground There should be continuity AUDIO DISPLAY SIGNAL LINES Remove the combination meter page 20 17 Check for continuity between the audio unit 34P black and meter 16P connectors There should be continuity between the same color wire terminals Also check for a short circuit between each connec tor terminal and ground There should be no continuity 14P CONNECT...

Page 709: ...the voltage between the Yellow red wire terminal of the audio unit 34P gray connector and ground with the ignition switch turned to ON and the engine stop switch turned to There should be battery voltage when the starter reverse switch is pushed If there is no voltage check the following open or short circuit in the Yellow red wire loose or poor contact in related connectors REMOVAL INSTALLATION R...

Page 710: ...TERMINAL ARRANGEMENT AND SWITCH LOCATION CB VOL SWITCH CB CH SWITCH CB SQL SWITCH VOLUME SWITCH 14P CONNECTOR 12P CONNECTOR 14P Viewed from the terminal side 12P No 1 Orange No 2 White No 3 Black No 5 Light green 01 03 No 7 Red No 8 Yellow No 9 Brown No 10 Green2 No 3 Light green After 03 No 5 Green1 TALK VOLUME TUNE DISC MUTE CB SQL CB CH CB VOL Color Up Black Orange Red Free Down Position Color ...

Page 711: ...AUDIO SYSTEM 22 10 TUNE DISC SWITCH MUTE SWITCH TALK SWITCH Color Up Black White Yellow Free Down Position Color Free Green1 Light green Push Position Color Free Green2 Yellow Push Position ...

Page 712: ...ated under the frame cross member and remove the antenna wire out of the frame Remove the three bolts stay and antenna base assembly Installation is in the reverse order of removal INSPECTION Remove the seat page 2 5 Disconnect the antenna connector Remove the antenna from the antenna base page 22 11 Check for continuity between the antenna connector and base as shown Route the wires properly page...

Page 713: ...l if the speaker clicks at the moment when the ohmmeter probes are connected to the speaker terminals HEADSET JUNCTION WIRE INSPECTION Remove the left fairing pocket page 2 11 Remove the seat page 2 5 Disconnect the junction wire 6P red connector Check for continuity between the same color num ber wire terminals of the 6P connector and junction connector There should be continuity Select smallest ...

Page 714: ... SYSTEM 23 5 ABS 23 7 FUEL SYSTEM Programmed Fuel Injection 23 9 COOLING CHARGING IGNITION SYSTEM 23 11 STARTER REVERSE SYSTEM 23 12 LIGHTING SYSTEM 23 13 TURN SIGNAL LIGHTS HORN 23 14 COMBINATION METER 23 15 ACC TRUNK LOCK CONTROL SYSTEM 23 17 CRUISE CONTROL SYSTEM 23 20 AUDIO SYSTEM 23 22 ...

Page 715: ...E INFORMATION GENERAL The following abbreviations are used to identify wire colors in this section FUSE BOX FUSE NUMBER Bl Black Gr Gray P Pink Y Yellow Br Brown Lb Light blue R Red Bu Blue Lg Light green S Shield wire G Green O Orange W White ...

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Page 737: ...NTROL IAC VALVE 24 2 HYDRAULICALLY ASSISTED CLUTCH 24 4 BRAKE SERVO PRESSURE SENSING ANTI DIVE SYSTEM 24 5 ELECTRIC REAR SUSPENSION SPRING PRELOAD ADJUSTMENT SYSTEM 24 6 ANTI LOCK BRAKE SYSTEM ABS 24 7 IGNITION COIL WITH BUILT IN IGNITER 24 12 ...

Page 738: ...hrottle valves When the coolant temperature is low the IAC valve functions as the fast idle valve too STRUCTURAL PRINCIPLE As the IAC valve shaft rotates the IAC valve opens and closes the air passage to control the air flow volume A magnet is mounted at the end of the shaft i e in the oval hole in the iron core Because the magnet is set at the center of the oval hole the magnetic force from the N...

Page 739: ...ng its valve angle the digital drive signal turns the voltage on and off at a constant frequency with the signal being a PWM Pulse Width Modulation type that changes the on time ratio per cycle This is referred to as the duty ratio duty cycle The average current changes smoothly just as the analog type does in accordance with the changes of the duty ratio The IAC valve has a built in drive circuit...

Page 740: ... center are fixed by the lock nut via the spring guide oil pressure moves the pressure plate towards the clutch center The clutch spring is forced against the pressure plate via lifter plate B Therefore the clutch plates and discs are pressed together by oil pressure and spring force When the clutch is disengaged The oil outlet ports in the pressure plate are sealed by lifter plate B Lifter plate ...

Page 741: ...er cylinder The secondary master cylinder responds to braking forces generated by the lever and or pedal When either brake is applied the plunger is pushed by pressure from the secondary master cylinder and the anti dive piston valve in the fork oil passage moves to block the passage As the flow of the fork fluid is reduced by movement of the piston valve the system reduces compression of the fron...

Page 742: ...e piston in the actuator is operated by the control motor while the shock absorber piston is operated by hydraulic pressure The piston stroke is detected by the angle sen sor and the motor is controlled with the control unit ECU inside the combination meter Preload can be adjusted by operating the Up and Down switch while monitoring the preload condition on the multi display Two preload settings c...

Page 743: ... which in turn controls the brake fluid Therefore in comparison with other ABSs the modulator size number of parts and weight are all substantially reduced In addition the fluid pressure can be regulated continuously unlike ABSs which have staged control This ABS has a higher accuracy of control in a more simplified system COMPONENT LOCATIONS 1 ABS indicator Blinks or stays on when a problem occur...

Page 744: ...consists of the following parts Control piston Operates in accordance with the change of the crankshaft angle and adjusts the caliper fluid pressure Because each modulator must provide simultaneous control over two separate systems each features two sets of control pistons Crankshaft Turns with the control motor via the reduction gears to change the piston position Back up spring Pushes the contro...

Page 745: ...the orifice valve to the brake caliper Stage 3 The control piston returns to its normal uppermost position opening both the cut off valve and orifice valve and restoring full hydraulic pressure for conventional brake operation WHEEL SPEED SENSOR PULSER RING The wheel speed sensor is a contactless sensor that detects front and rear wheel speed The sensor consists of a perma nent magnet and Hall ele...

Page 746: ... and modulator crank angle sensor signals The wheel speed sensors send signals to the control unit after the motorcycle starts to move approximately 10 km h or above then the control unit evaluates the system condition by activating the modulator control motors and receiving signals from the crank angle sensors The ABS indicator goes off when the system is found to be normal The control unit monit...

Page 747: ...ressure hold position which permits the slipping wheel to recover its rotational speed Pressure INCREASE Once the ABS control unit detects full wheel speed recovery it rotates the crankshaft back into its highest position This rapid cycle of pressure DECREASE HOLD and INCREASE makes possible nearly instantaneous correction of changes in wheel rotation while ensuring highly accurate control of hydr...

Page 748: ...NICAL FEATURES 24 12 IGNITION COIL WITH BUILT IN IGNITER Each ignition coil has a built in igniter that boosts the ignition signal 5V from the engine control module ECM to gener ate the primary side voltage ...

Page 749: ...25 1 25 25 TROUBLESHOOTING ENGINE DOES NOT START OR IS HARD TO START 25 2 ENGINE LACKS POWER 25 3 POOR PERFORMANCE AT LOW AND IDLE SPEED 25 5 POOR PERFORMANCE AT HIGH SPEED 25 6 POOR HANDLING 25 6 ...

Page 750: ...M FI IGNITION relay Faulty engine control module ECM YES GO TO STEP 3 3 Programmed Fuel Injection System Inspection Check the fuel injection system Is the fuel injection system normal NO Faulty fuel injection system section 5 YES GO TO STEP 4 4 Cylinder Compression Inspection Test the cylinder compression Is the compression as specified NO Valve stuck open Worn cylinder and piston rings Damaged cy...

Page 751: ...ulty hydraulic assist system Additive in engine oil YES GO TO STEP 4 4 Engine Performance Inspection Accelerate lightly Does the engine speed increase NO Clogged air cleaner Restricted fuel flow Clogged muffler YES GO TO STEP 5 5 Spark Plug Inspection Remove and inspect spark plugs Are the spark plugs in good condition NO Plugs not serviced frequently enough Incorrect spark plug heat range YES GO ...

Page 752: ...head cover and inspect lubrication Is the valve train lubricated properly NO Clogged oil passage YES GO TO STEP 11 11 Overheating Inspection Check for engine overheating Is the engine overheating YES Coolant level too low Fan motor not working Faulty fan motor or ECM Thermostat stuck closed Excessive carbon build up in combustion chamber Use of poor quality fuel Clutch slipping Wrong type of fuel ...

Page 753: ...lty spark plug Fouled spark plug Loose ignition system wires Broken or shorted spark plug wire Faulty ignition pulse generator Faulty ignition coil Faulty engine control module ECM YES GO TO STEP 3 3 Ignition Timing Inspection Check the ignition timing Is the ignition timing as specified NO Faulty engine control module ECM Faulty ignition pulse generator YES GO TO STEP 4 4 Programmed Fuel Injectio...

Page 754: ... Timing Inspection Check the valve timing Is the valve timing correct NO Camshafts not installed properly YES GO TO STEP 4 4 Valve Spring Inspection Check the valve springs Is the valve spring free length as specified NO Faulty valve spring YES Not weak POOR HANDLING Steering is heavy Steering bearing adjustment nut too tight Damaged steering head bearings Either wheel is wobbling Excessive wheel ...

Page 755: ...1 13 CRUISE ACTUATOR 21 16 CRUISE CANCEL SWITCH 21 14 CRUISE CONTROL SWITCH 21 13 CRUISE CONTROL SYSTEM SPECIFICATIONS 1 11 CRUISE REVERSE CONTROL MODULE CRUISE CONTROL SYSTEM 21 9 STARTER REVERSE SYSTEM 19 39 CYLINDER COMPRESSION 8 6 CYLINDER HEAD ASSEMBLY 8 22 CYLINDER HEAD COVER INSTALLATION 8 32 CYLINDER HEAD COVER REMOVAL 8 6 CYLINDER HEAD DISASSEMBLY 8 16 CYLINDER HEAD INSTALLATION 8 24 CYLI...

Page 756: ... SHIFT MECHANISM 19 42 REVERSE SHIFT RELAY 19 34 REVERSE SWITCH 19 27 S SADDLEBAG COMBINATION LIGHT 20 14 SADDLEBAG TRUNK STAY 2 17 SADDLEBAGS 2 15 SEAT 2 5 SECONDARY AIR SUPPLY SYSTEM 3 14 5 84 SECONDARY MASTER CYLINDER 15 24 SERVICE INFORMATION AUDIO SYSTEM 22 3 BATTERY CHARGING SYSTEM 17 3 BRAKE SYSTEM ABS 16 3 BRAKE SYSTEM Standard 15 3 CLUTCH 9 4 COOLING SYSTEM 6 3 CRUISE CONTROL SYSTEM 21 3 ...

Page 757: ...INKAGE TRANSMISSION 10 7 IGNITION SYSTEM 18 4 LIGHTS METERS SWITCHES 20 4 LUBRICATION SYSTEM 4 4 REAR WHEEL SUSPENSION 14 5 STARTER REVERSE SYSTEM 19 6 TRUNK 2 13 TRUNK BRAKE TAILLIGHT 20 15 TRUNK LOWER COVER 2 13 TURN SIGNAL CANCEL UNIT 20 28 TURN SIGNAL RELAY 20 27 V VALVE CLEARANCE 3 9 VALVE GUIDE REPLACEMENT 8 19 VALVE SEAT INSPECTION REFACING 8 19 VEHICLE SPEED SENSOR 5 81 W WATER PUMP THERMO...

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