Honda NSA700A DN-1 2009 Service Manual Download Page 531 | Manualshive

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Remove the screw and fro nt brake light switch.

SCREW

HYDRAULIC BRAKE

Remove the boot.

Remove the snap ring and washer using a special

tool.

TOOL:
Snap ring pliers

07914-SA50001

Remove the master piston, piston cups and spring.

Clean the master cylinder, reservoir and master pis

ton in clean brake fluid.

INSPECTION

Check the piston cups for wear, deterioration or
damage.
Check the spring for fatigue or damage.
Check the master cylinder and piston for scoring,
scratches or damage.

Measure the master cylinder I.D.

SERVICE LIMIT: 14.055 mm (0.5533 in)

Measure the master piston O.D.

SERVICE LIMIT: 13.945 mm (0.5490 In)

SPRING

PISTON CUPS

MASTER CYLINDER

17-21

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Summary of Contents for NSA700A DN-1 2009

Page 1: ...7 2009...

Page 2: ...bdenum 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 J...

Page 3: ...fety alert symbol ds and one of three signal words DANGER WARNING or CAUTION These signal words mean You WILL be KILLED or SERIOUSLY HURT if you don t follow instructions You CAN be KILLED or SERIOUSL...

Page 4: ...ent 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 skill...

Page 5: ...ATOR STARTER CLUTCH SPECIFICATIONS 1 9 CRANKCASE CRANKSHAFT SPECIFICATIONS 1 9 FINAL DRIVE SPECIFICATIONS 1 10 FRONT WHEEL SUSPENSION STEERING SPECIFICATIONS 1 10 REAR WHEEL SUSPENSION SPECIFICATIONS...

Page 6: ...st control cables Damaged control cables will not operate smoothly and may stick or bind ABBREVIATION Throughout this manual the following abbreviations are used to identify the respective parts or sy...

Page 7: ...ATION SERIAL NUMBERS The Vehicle Identification Number V I N is stamoed on the right side of the steering head The engine serial number is stamped on the left side of the crankcase VEHICLE IDENTIFICAT...

Page 8: ...er is stamped on the throttle drum side of the throttle body THROTTLE BODY IDENTIFICATION NUMBER LABELS The Safety Certification Label is located on left side of the frame The Emission Control Informa...

Page 9: ...GENERAL INFORMATION EMISSION CONTROL INFORMATION LABEL...

Page 10: ...37 Imp gal ENGINE Cylinder arrangement 2 cylinders 52 V transverse Bore and stroke 81 0 x 66 0 mm 3 19 x 2 60 in Displacement 680 2 cm3 41 6 cu in Compression ratio 10 0 1 Valve train Silent cam chain...

Page 11: ...an type GQ6BC Idle speed 1 200 100 min 1 rpm Throttle grip free play 2 6 mm 0 1 0 2 in IAT sensor resistance at 20 C 68 F 1 4kQ ECT sensor resistance at 20 C 68 F 2 3 2 6 ki2 Fuel injector resistance...

Page 12: ...20 0 09 0 004 Valve guide projection IN 12 5 12 7 0 49 0 50 above cylinder head EX 16 7 16 9 0 66 0 67 Valve seat width IN EX 0 90 1 10 0 035 0 043 1 5 0 06 Valve spring Free length IN EX 44 91 1 768...

Page 13: ...68 F 14 17 Q ALTERNATOR STARTER CLUTCH SPECIFICATIONS Unit mm in ITEM STANDARD SERVICE LIMIT Starter driven gear I D 37 003 37 025 1 4567 1 4577 37 10 1 461 O D 57 743 57 768 2 2736 2 2743 57 73 2 27...

Page 14: ...___ J FRONT WHEEL SUSPENSION STEERING SPECIFICATIONS Unit mm in ITEM STANDARD SERVICE LIMIT Minimum tire tread depth 1 5 0 06 Cold tire Driver only 225 kPa 2 25 kgf cm2 33 psi pressure Driver and pass...

Page 15: ...disc warpage 0 30 0 012 Master cylinder I D r 15 870 15 913 0 6248 0 6265 15 925 0 6270 Master piston O D 15 827 15 854 0 6231 0 6242 pi578 15 0 6226 Caliper cylinder I D 27 000 27 050 1 0630 1 0650...

Page 16: ...ment light LED High beam indicator LED Neutral indicator LED Parking indicator LED Turn signal indicator LED ABS Indicator LED MIL LED Oil pressure level indicator LED Coolant temperature indicator LE...

Page 17: ...pe joint stud bolt 4 8 See page 3 18 Final drive cover socket bolt 2 6 9 0 9 7 Exhaust pipe joint nut 4 8 21 2 1 15 Exhaust pipe band bolt 2 8 17 1 7 13 Muffler band bolt 2 8 17 1 7 13 MAINTENANCE ITE...

Page 18: ...ear engine hanger plate bolt 4 8 26 2 7 19 Front engine mounting bolt 1 10 39 4 0 29 Rear engine mounting bolt 1 10 39 4 0 29 Lower engine mounting bolt 1 10 39 4 0 29 Step bracket mounting bolt 4 8 2...

Page 19: ...10 14 5 1 5 11 EOP sensor 1 10 22 2 2 16 Neutral oil pressure switch 1 PT 1 8 12 1 2 9 Apply sealant to the threads Neutral oil pressure switch bolt 1 4 1 9 0 19 1 4 washer ALTERNATOR STARTER CLUTCH I...

Page 20: ...seating sur face Side gear case stud bolt 165 mm 1 8 31 3 2 23 Apply engine oil to the threads and seating sur face FRONT WHEEL SUSPENSION STEERING ITEM Q TY THREAD DIA mm TORQUE N m kgf m Ibf ft REM...

Page 21: ...9 Rear brake caliper pin bolt 1 12 27 2 8 20 Front brake caliper mounting bolt 4 8 31 3 2 23 ALOC bolt replace with a new one Rear brake caliper mounting bolt 2 10 45 4 6 33 ALOC bolt replace with a...

Page 22: ...ft journals Cylinder 8 mm bolt threads and seating surface Each bearings rotating area Each gear tooth Each O rings Other rotating area and sliding surface Multi purpose Each oil seal lips grease Timi...

Page 23: ...r each bearing Molybdenum disulfide grease Drive shaft oil seal lip Drive shaft splines universal joint side Output shaft splines universal joint side Final drive pinion joint splines Cable lubricant...

Page 24: ...WIRE RIGHT HANDLEBAR SWITCH WIRE LEFT HANDLEBAR SWITCH WIRE BRAKE HOSE THROTTLE CABLES BRAKE FRON HOSE SIDE HEADLIGHT Lo 2P CONNECTOR HEADLIGHT Hi 2P CONNECTOR LEFT FRONT TURN SIGNAL 3P CONNECTOR RIG...

Page 25: ...GENERAL INFORMATION 1 21...

Page 26: ...GENERAL INFORMATION RIGHT HANDLEBAR SWITCH 8P GRAY CONNECTOR 85 95 t UPPER SIDE RIGHT SIDE LEFT HANDLEBAR SWITCH 12P GRAY CONNECTOR TURN SIGNAL RELAY 1 22...

Page 27: ...LEBAR SWITCH 3P GRAY CONNECTOR JUNCTION 24P CONNECTOR 1 JUNCTION 24P CONNECTOR 2 FRONT SIJR HARNESS 10P BLUE CONNECTOR FRONT WHEEL SPEED SENSOR 2P BLUE CONNECTOR HAZARD SWITCH 3P GRAY CONNECTOR FRONT...

Page 28: ...KE PIPE CRANKCASE BREATHER HOSE VACUUM HOSE EXCEPT CALIFORNIA TYPE AIR SUCTION HOSE AIR SUPPLY HOSE PARKING BRAKE CABLE LEFT SIDE REAR BRAKE PIPE UPPER SIDE PARKING BRAKE CABLE UPPER SIDE LEFT SIDE RE...

Page 29: ...SUCTION HOSE EVAP VACUUM HOSE AIR SUPPLY HOSE PARKING BRAKE CABLE CRANKCASE BREATHER HOSE VACUUM HOSE REAR BRAKE PIPE UPPER SIDE LEFT SIDE m PARKING BRAKE CABLE REAR BRAKE PIPE UPPER SIDE LEFT SIDE R...

Page 30: ...GENERAL INFORMATION FUEL TANK BREATHER HOSE FUEL TANK DRAIN HOSE FUEL HOSk t UPPER SIDE...

Page 31: ...GENERAL INFORMATION FUEL HOSE FUEL TANK DRAIN HOSE FUEL TANK BREATHER HOSE UPPER SIDE FUEL...

Page 32: ...GENERAL INFORMATION EXCEPT CALIFORNIA TYPE CALIFORNIA TYPE FUEL TANK 1 28...

Page 33: ...NERAL INFORMATION EVAP PURGE CONTROL SOLENOID VALVE TO THROTTLE BODY HOSE FUEL TANK BREATHER HOSE TO EVAP CANISTER EVAPPURGE CONTROL SOLENOID VALVE EVAP CANISTER TO EVAP PURGE CONTROL SOLENOID VALVE H...

Page 34: ...ADIATOR HOSfc f UPPER SIDE REAR BRAKE RESERVOIR REAR BRAKE LIGHT SWTCH WIRE REAR BRAKE PIPE SIDESTAND SWITCH WIRE STARTER MOTOR CABLE VS SENSOR WATER HOSES U PPER S SIDE VS SENSOR WIRE FRONT SIDE SIDE...

Page 35: ...RE SIDE STAND SWITCH WIRE RIGHT SIDE BATTERY GROUND CABLE FUEL HOSES FUEL PUMP FUEL LEVEL SENSOR WIRE REARWHEEL SPEEDSENSOR WIRE PARKING BRAKE CABLE BRAKE HOSE PARKING BRAKE CABLE UPPER SIDE SWASH PLA...

Page 36: ...GENERAL INFORMATION 1 32...

Page 37: ...GENERAL INFORMATION ENGINE SUB HARNESS 14P GRAY CONNECTOR ENGINE SUB HARNESS 14P CONNECTOR S A UPPER X SIDE CKP SENSOR WIRE SENS0R W RE v left cy 1 SIDE ALTERNATOR ENGINE SUB WIRE HARNESS 1 33...

Page 38: ...CM 5P BLACK CONNECTOR OIL LEVEL SWITCH RELAY NEUTRAL SWITCH RELAY MAIN FUSE 40 A NEGATIVE POSITIVE BANK ANGLE SENSOR HFT FUSE 10 A SIDE STAND SWITCH 2P GREEN CONNECTOR MAIN RELAY POSITIVE CABLE 2P WHI...

Page 39: ...GENERAL INFORMATION LEFT REAR TURN SIGNAL WIRE SEAT LOCK CABLE RIGHT REAR TURN SIGNAL WIRE TAILLIGHT WIRE 1 35...

Page 40: ...GENERAL INFORMATION r em o ve the LEFT SHROUD ENGINE GROUND TERMINAL FRAME GROUND TERMINAL 1 36...

Page 41: ...with the terms of the Distributor s Limited Warranty for Honda Motorcycle Emission Control Systems is necessary in order to keep the emissions system v arranty in effect SOURCE OF EMISSIONS Thecombus...

Page 42: ...lve prevents reverse air flow through the system The PAIR control valve is operated by the solenoid valve The solenoid valve is controlled by the Engine Control Module ECM and the fresh air passage is...

Page 43: ...ise control prior to its sale or delivery to the ultimate customer or while it is in use 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any...

Page 44: ...2 TECHNICAL FEATURE 2 HFT 2 2 2 1...

Page 45: ...on function the HFT also includes following components Starting clutch It operates according to engine speed Lockup mechanism It improves the transmission efficiency at higher speeds N D neutral drive...

Page 46: ...ed to hydraulic pressure within the HFT according to engine speed The hydraulic pressure drives the HFT output shaft The torque from the HFT output shaft is transmitted through the N D clutch which ca...

Page 47: ...s independent from engine lubrication Oil pump rotor for the HFT delivers oil into the oil filter each circuit of the automatic transmission lockup mechanism and N D clutch 2 4 LOCK UP SOLENOID VALVE...

Page 48: ...OIL FILTER FOR ENGINE LUBRICATION OIL PRESSURE RELIEF VALVE FOR ENGINE LUBRICATION HFT OIL PRESSURE SENSOR SPOOL VALVE NEUTRALOIL PRESSURE SWITCH OIL PUMP ROTOR FOR ENGINE LUBRICATION N D CLUTCH OIL...

Page 49: ...ar reduces sympathetic vibration between the engine and HFT by absorbing torque fluc tuations For example when the lifter rotation speed exceeds the speed of primary drive gear rotation when accelerat...

Page 50: ...the compact configu ration of system The starting clutch consists of a centrifugal governor and clutch valve The clutch valve opens closes a bypass between the high pressure cavity and the low pressu...

Page 51: ...il in the high pressure cavity starts to be pressurized The starting clutch transmits the engine power according to the generated oil pressure intermediate pressure When the clutch is fully engaged Wh...

Page 52: ...tor valves The HFT controls the output torque by adjusting the angle of the oil motor side swash plate DISTRIBUTOR VALVE OIL MOTOR SIDE SWASH PLATE OIL PUMP SIDE SWASH PLATE OIL MOTOR SIDE PISTON OIL...

Page 53: ...cts the piston cavity with the high pressure cavity During the suction stroke from the motor side to the pump side the valve connects the low pressure cavity with the piston cavity The oil motor side...

Page 54: ...e clutch valve end The rapid change of the clutch valve position is restricted by the oil flow into the damper cavity The incoming oil pressure is regu lated by the reducing valve incorporated in the...

Page 55: ...or side swash plate is great large amount of the oil is required to match the motor piston stroke To move the pump piston rapidly the difference of the revolution speed between the pump side swash pla...

Page 56: ...g is moved to a concentric posi tion As a result the distributor valve closes the circuit between the oil pump side cylinder high pressure and motor side cylinder low pressure causing the HFT to be oi...

Page 57: ...ts N on the drive mode select switch it is equivalent to the neutral position of a conventional geai driven transmission The output from the HFT shaft gear is transmitted to the N C clutch When the cl...

Page 58: ...is controlled by the N D solenoid valve In neutral position oil pressure is not applied to the clutch as the N D solenoid valve is closed In drive position the spool valve is pressurized as the N D s...

Page 59: ...il pressure indicator to illuminate Detecting condition of the oil level When the ignition switch is turned ON the TCM confirms that the oil level switch is ON or OFF to detect the engine oil level Oi...

Page 60: ...he neutral oil pressure switch detects the mode by the change in oil pressure The engine will stop if the throttle is opened during shift ing to prevent movement of the vehicle If the neutral oil pres...

Page 61: ...ash plate which determ ines the transm ission ratio is regulated by the swash plate control motor ENGINE THROTTLE VEHICLE OIL ANGLE OF N D RIDING SPEED OPENING SPEED TEMPEFATURE SW ASH PLATE POSITION...

Page 62: ...urned ON W hen the detection is com plete the ECM cuts off thecurrent in order to protect the contact point of the switch FLOAT C O N D ITIO N OF SW ITCH OPEN CLOSE H HIGH OIL LEVEL The neutral oil pr...

Page 63: ...HIGH PIEZOELECTRIC ELEMENT VCC 5V INPUT G N D G RO UN D V out O UTPUT TERM INAL SWASH PLATE ANGLE SENSOR The swash plate angle sensor is installed in the rear side of the crankcase The sensor and HFT...

Page 64: ...OOTING 3 3 UNDER C O W L 3 11 MAIN SEAT PILLION SEAT 3 4 FRONT FENDER 3 12 REARVIEW MIRROR 3 4 SEAT COWL 3 12 FRONT SIDE COWL 3 5 GRAB RAIL COVER 3 13 CENTER COWL 3 6 GRAB R A IL 3 13 HANDLEBAR COVER...

Page 65: ...oud page 3 8 19 Linder cowl cover page 3 9 20 M uffler protector page 3 10 21 U nder cowl page 3 11 22 M ain step page 3 9 23 Left side cover page 3 15 24 Inner low er cowl page 3 9 11 Front fender BO...

Page 66: ...tighten the exhaust pipe joint nuts first then tighten the m ounting fasteners Always inspect the exhaust system for leaks after installation Route the wires hoses and cables properly page 1 20 TORQUE...

Page 67: ...d m ain seat backward by releasing the four hooks Installation is in the reverse order of rem oval HOOKS BOLTS PILLION SEAT REARVIEW MIRROR REMOVAL INSTALLATION Rem ove the tw o socket bolts tw o coll...

Page 68: ...the side Rem ove a socket bolt three trim clips and front side cowl bosses cow Make sure the clips Release the five bosses and rem ove the left front of bosses are not side cowl left on the frame n th...

Page 69: ...ws and disconnect the hazard switch 4P Gray connector Rem ove the center cowl Installation is in the reverse order of rem oval 4P Gray CONNECTOR CENTER COWL HANDLEBAR COVER REMOVAL INSTALLATION Rem ov...

Page 70: ...the tw o hooks and tw o bosses Rem ove the rubber seals Rem ove the tw o trim clips and upper inner cowl Installation is in the reverse order of rem oval 3 DISASSEMBLY ASSEMBLY Rem ove the seven scre...

Page 71: ...the same m anner rem ove the right inner cowl Installation is in the reverse order of removal SHROUD REMOVAL INSTALLATION Remove the following left inner cowl page 3 8 left under cowl cover page 3 9 R...

Page 72: ...t under cowl cover Installation is in the reverse order of rem oval MAIN STEP REMOVAL INSTALLATION Rem ove the right under cowl cover page 3 9 Rem ove the tw o bolts and right m ain step In the sam e...

Page 73: ...er protector Installation is in the reverse order of removal EXHAUST PIPE PROTECTOR REMOVAL INSTALLATION Rem ove a socket bolt rubber washer and exhaust pipe protector Installation is in the reverse o...

Page 74: ...page 3 10 Rem ove th e tw o socket bolts and right under cowl by releasing the tw o hooks Installation is in the reverse order of rem oval LEFT UNDER COWL REMOVAL INSTALLATION Rem ove the left m ain s...

Page 75: ...the front fender dow nw ard Installation is in the reverse order of rem oval SEAT COWL REMOVAL INSTALLATION Rem ove the main seat page 3 4 Rem ove the six socket bolts and six trim clips Rem ove the...

Page 76: ...rab rail cover Installation is in the reverse order of rem oval i l GRAB RAIL REMOVAL INSTALLATION Rem ove the grab rail cover page 3 13 Rem ove the four socket bolts four screws and grab rail Disconn...

Page 77: ...STALLATION Rem ove the left under cowl page 3 11 Rem ove the three socket bolts three collars and left side cover Installation is in the reverse order of rem oval TORQUE Left side cover socket bolt 10...

Page 78: ...STALLATION Rem ove a socket bolt bolt washer collar and m ounting rubbers Release the boss on the final drive cover from the final drive grum m et and rem ove the final drive cover Installation is in...

Page 79: ...ten the m uffler band bolts to the specified torque TORQUE 17 N m 1 7 kgf m 13 Ibf ft Install the m uffler protector page 3 10 NOTE Inspect the exhaust system for leaks after installa tion EXHAUST PIP...

Page 80: ...TEM Loosen the exhaust pipe band bolts and rem ove the exhaust pipe Rem ove the gasket Rem ove the exhaust pipe joint nuts Rem ove the rear exhaust pipe Rem ove the front and rear exhaust pipe gaskets...

Page 81: ...m 15 Ibf ft MUFFLER 17 N m 1 7 kgf m 13 Ibf ft EXH A UST PIPE GASKET If the exhaust pipe stud bolts are loose tighten them Be sure to verify the distance from the top of the stud to the cylinder head...

Page 82: ...nuts but not tighten yet Install a new exhaust pipe gasket to the rear exhaust pipe Install the exhaust pipe Install the exhaust pipe joint nuts but not tighten yet Joint the exhaust pipe and rear ex...

Page 83: ...f m 15 Ibf ft Tighten the exhaust pipe band bolts to the specified torque TORQUE 17 N m 1 7 kgf m 13 Ibf ft Tighten the m ounting nut securely Install the following m uffler page 3 16 exhaust pipe gua...

Page 84: ...AIR CLEANER 4 6 BRAKE PADS W EA R 4 20 CRANKCASE BREATHER 4 6 BRAKE SYSTEM 4 20 SPARK PLUG 4 7 BRAKE LIGHT SW ITCH 4 22 VALVE CLEARANCE 4 8 BRAKE LOCK OPERATION 4 22 ENGINE OIL 4 11 HEADLIGHT A IM 4 2...

Page 85: ...haust 0 20 0 02 m m 0 008 0 001 in Recom m ended engine oil Pro Honda GN4 4 stroke oil U S A and Canada or an equivalent m otor oil API service classification SG or higher JASO T 903 standard M A Visc...

Page 86: ...26 N m 2 7 kgf m 20 Ibf ft 25 N m 2 5 kgf m 18 Ibf ft 12 N m 1 2 kgf m 9 Ibf ft 12 N m 1 2 kgf m 9 Ibf ft 1 5 N m 0 2 kgf m 1 1 Ibf ft 59 N m 6 0 kgf m 44 Ibf ft 22 N m 2 2 kgf m 16 Ibf ft 108 N m 11...

Page 87: ...SPEED I I I I 4 14 RADIATOR COOLANT NOTE 5 I I R 4 15 L U COOLING SYSTEM I I I 4 15 SECONDARY AIR SUPPLY SYSTEM I I I 4 16 EVAPORATIVE EM ISSIO N CONTROL SYSTEM NOTE 4 I I 4 17 C O FINAL DRIVE OIL I R...

Page 88: ...their upper ends Thoroughly lubricate the cables and their pivot points w ith a com m ercially available cable lubricant or a light w eig ht oil If the throttle grip still does not return properly rep...

Page 89: ...left front side cowl page 3 5 Remove the screws air cleaner cover and air cleaner elem ent Replace the air cleaner elem ent in accordance with the m aintenance schedule or any tim e it is exces sivel...

Page 90: ...he spark plug bases w ith compressed air before rem oving the plugs and be sure that no debris is allowed to enter into the com bustion cham ber Rem ove the spark plugs INSPECTION Check the follow ing...

Page 91: ...d side electrodes with a w ire type feeler gauge M ake sure that the t 1 0 m m 0 04 in plug gauge does not insert between the gap If the gauge can be inserted into the gap replace the plug with a new...

Page 92: ...the rocker arms If there is no slack rotate the crankshaft clockwise one full turn and align the FT m ark w ith the index notch again Check the valve clearances by inserting a feeler gauge betw een t...

Page 93: ...INTAKE 0 15 0 02 mm 0 006 0 001 in EXHAUST 0 20 0 02 mm 0 008 0 001 in Adjust by loosening the lock nut and turning the adjusting screw until there is a slight drag on the feeler gauge Hold the adjus...

Page 94: ...mark on the dipstick add the recom m ended oil to the upper level mark Other viscosities RECOMMENDED ENGINE OIL shown in the char may be used when the average temperature in you riding area is within...

Page 95: ...t Fill the crankcase w ith the recom m ended engine oil page 4 11 OIL CAPACITY 2 9 liters 3 06 US qt 2 55 Imp qt at draining 3 3 liters 3 49 US qt 2 90 Imp qt at filter change 4 0 liters 4 23 US qt 3...

Page 96: ...t 2 55 Imp qt at draining 3 3 liters 3 49 US qt 2 90 Imp qt at filter change 4 0 liters 4 23 US qt 3 52 Imp qt at disassembly Check the engine oil level page 4 11 Install the oil filler cap dipstick p...

Page 97: ...r cleaner condition page 4 6 Ignition system condition page 20 5 Spark plug condition page 4 7 PAIR system condition page 4 16 No DTC and M IL blinking The engine m ust be warm fo r accurate idle spee...

Page 98: ...very rapidly If the reserve tank becom es com pletely em aty there is a possibility of air getting into the coo ing system Be sure to rem ove any air from the cooling system page 7 6 COOLING SYSTEM Ch...

Page 99: ...le am ount of hydrocar bons and carbon m onoxide into relatively harm less carbon dioxide and w ater If the hoses show any signs o f heat damage inspect the PAIR check valve in the cylinder head cover...

Page 100: ...HECK Place th e motorcycle on its sidestand Rem ove the oil filler cap from the final gear case Check that the oil level is up to the low er edge of the oil filler hole Check fo r leaks if the oil lev...

Page 101: ...fter disassembly BRAKE FLUID NOTICE Spilled fluid can damage painted plastic or rubber parts Place a rag over these parts whenever the system is serviced Do net m ix different types of fluid as they a...

Page 102: ...2 kgf m 1 1 Ibf ft REAR Place the motorcycle on a level surface Check the rear brake reservoir fluid level Rem ove the right front side cowl page 3 5 If the fluid level is near the LOWER level mark re...

Page 103: ...S Check the brake pad for w ear Replace the brake pads if either pad is worn to the w ear limit groove Always replace the For brake pad replacem ent page 17 15 brake pads as a set to assure even disc...

Page 104: ...ures page 17 7 Inspect the brake hose and fittings for deterioration cracks dam age or signs o f leakage Tighten any loose fittings Replace the hose and fittings as required BRAKE LEVER ADJUSTMENT The...

Page 105: ...If the light fails to come on adjust the switch so that the light com es on at the proper tim e Hold the 3witch body end turn the adjusting nut as required Recheck the brake light switch operation BRA...

Page 106: ...a level surface Adiust the headlight Adjust the headlight beam s vertically by turning the beam as specified vertical beam adjusters by local laws and Adjust t e headlight beam s horizontally by turn...

Page 107: ...s dam age or loose fasteners Loose worn or damaged suspension parts impair motorcycles stability and control Replace dam aged com ponents which cannot repaired Tighten all nuts and bolts For fork serv...

Page 108: ...to see if the w heel bearings are w orn For front w heel service page 15 10 I Support the m otorcycle secure y and raise the rear w heel off the ground Hold the sw ingarm and m ove the rear w heel sid...

Page 109: ...NG HEAD BEARINGS Support the motorcycle securely and raise the front w heel off the ground Check that the handlebar m oves freely from side to side Make sure the control cables do not interfere w ith...

Page 110: ...LUBRICATION SYSTEM LUBRICATION SYSTEM DIA G R AM 5 2 OIL PUMP DRIVEN GEAR 5 5 SERVICE INFORMATION 5 3 OIL P U M P 5 6 TROUBLESHOOTING 5 4 OIL COOLER 5 13 OIL PRESSURE INSPECTION 5 5 EOP SW ITC H 5 14...

Page 111: ...LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM CAM SHAFT 1 PISTON CRANKSHAFT OIL PRESSURE SWITCH HFT U N IT PRESSURE RELIEF VALVE OIL SIKAINbH N D CLUTCH OIL FILTER 5 2...

Page 112: ...ction page 22 15 SPECIFICATIONS Unit m m in ITEM STANDARD SERVICE LIM IT Engine oil capacity After draining 2 9 liters 3 06 US qt 2 55 Im p qt After draining filter change 3 3 liters 3 49 US qt 2 90 I...

Page 113: ...being used No oil pressure Oil level too low Oil pressure relief valve stuck open Broken oil pum p drive chain Broken oil pum p drive and or driven sprocket Dam aged oil pum p Internal oil leak High...

Page 114: ...the engine oil level page 4 11 Warm the engine to norm al operating tem perature approximately 80 C 176 F and increase the engine speed to 5000 rpm and read the oil pressure STANDARD 530 kPa 5 4 kg f...

Page 115: ...l REMOVAL Separate the crankcase page 13 5 Rem ove the bolts and oil pum p assem bly from the right crankcase Rem ove the dow el pins and gasket DISASSEMBLY OIL PUM P BODY Rem ove the bolt and oil str...

Page 116: ...he oil pum p cover Remove the dowel pins drive pin and washer Remove the inner rotor outer rotor pressure relief valve A Remove the oil pum p base from the oil pum p body OIL PUM P ASSEM BLY DRIVF PIN...

Page 117: ...valve spring for w ear or fatigue Check the relief valve body for clogging or dam age Clean all parts and assemble the relief valve in the reverse order of disassembly NOTE Install the snap ring with...

Page 118: ...Y drive pin and pum p shaft into the pum p body BODY M easure the body clearance SERVICE LIMIT 0 35 m m 0 014 in TIP CLEARANCE M easure the tip clearance SERVICE LIMIT 0 20 m m 0 008 in SIDE CLEARANC...

Page 119: ...o the oil pum p body Install the inner rotor into the outer rotor w ith its drive pin groove facing the drive pin Install the oil pum p shaft through the inner rotor and oil pum p body Install the dri...

Page 120: ...e pressure relief valve A Install the pressure relief valve A to the oil pump cover Install the inner and outer rotor to the oil pum p cover 7 g PUM P BODY BASE PRESSURE RELIEF VALVE A O RING OIL PUM...

Page 121: ..._______________ Apply engine oil to a new seal ring and install it onto the oil strainer Install the oil strainer to the oil pump body Install and tighten the bolt to the specified torque TORQUE 12 N...

Page 122: ...ge 4 12 Loosen the band screws then disconnect the water hoses from the water pump Remove the bolt washer and oil cooler Check the oil cooler for damage INSTALLATION Install a new O ring into the oil...

Page 123: ...s securely page 7 10 Fill the crankcase with the recommended oil page 4 11 and check that there are no oil leaks Fill the cooling system and bleed any air page 7 6 BAND SCREWS EOP SWITCH INSPECTION Re...

Page 124: ...nstall a new O ring into the oil cooler groove Remove the dust cover Remove the bolt washer and disconnect the EOP switch wire Remove the EOP switch Apply sealant to the EOP switch threads DUST COVER...

Page 125: ...al and tighten the bolt w ith washer to the specified torque TORQUE 1 9 N m 0 19 kgf m 1 4 Ibf ft Install the dust cover Start the engine and check that there are no oil leaks Install the left under c...

Page 126: ...SPECTION 6 36 FUEL LINE INSPECTION 6 37 FUEL PUMP 6 41 FUEL CUT RELAY 6 43 UPPER FUEL TANK 6 44 BREATHER SEPARATOR 6 47 LOWER FUEL TANK 6 48 AIR CLEANER HO USING 6 50 INSULATOR 6 53 THROTTLE BODY 6 54...

Page 127: ...FUEL SYSTEM PGM FI _________ COMPONENT LOCATION 6 2...

Page 128: ...e connections before proceeding The VS sensor sends digital pulse signal to the ECM and computation Refer to procedures for VS sensor inspection DTC troubleshooting page 6 15 When disassembling the PG...

Page 129: ...digital m ultim eter impedance 10 MQ DCV m inim um ECM test harness 33P 070MZ MCA0100 SCS connector 070PZ ZY30100 Inspection adaptor 07GMJ ML80100 Test probe 07ZAJ RDJA110 Pressure gauge manifold 07ZA...

Page 130: ...system page 6 37 Open circuit in the power input and or ground wire of the ECM Faulty bank angle sensor or related circuit Faulty FI IGN relay or related circuit Faulty engine stop switch or related c...

Page 131: ...STEM PGM FI PGM FI SYSTEM LOCATION FRONT INJECTOR IAT SENSOR BANK ANGLE SENSOR IACV VS SENSOR CKP SENSOR MAP SENSOR PAIR CONTROL SOLENOID VALVE REAR INJECTOR CMP SENSOR O2 SENSOR FUSE RELAY BOX ECTSEN...

Page 132: ...CONTROL VALVE IACV FANC11FLR IVSP B28 B31 THj ECM 1EVKIN 830 B13 nTl IEN6INH B25 JNL IN____ B27 B20 o T T I ITACO B17 A18 S G B2 HTCNTI I warT A20 11M OID BI2 B33 CYLPl I M TNr A30 S C o B19 m r R 4 B...

Page 133: ...nter cowl page 3 6 B1 s B1 A ll 1 m 1 v 1 _____1 ______ At y r f r A12 r f V B33 BJ3 A33 A23 ECM 33P GRAY ECM 33P BLACK CONNECTOR Note 1 CONNECTOR Note 1 Note 2 Remove the air cleaner housing page 6 5...

Page 134: ...nter cowl page Note 4 Remove the left under cowl page 3 11 ECTSENSOR CONNFCTOR 3P GRAY Note 3 VS SENSOR 3P BLACK CONNECTOR Note 4 FRONT INJECTOR 2P GRAY IACV 4P BLACK CONNECTOR CMP SENSOR 2P BLACK CON...

Page 135: ...FUEL SYSTEM PGM FI Note 5 Remove the seat page 3 4 Note 6 Remove the right seat cowl page 3 12 CKP SENSOR 2P RED CONNECTOR Note 6...

Page 136: ...ed by the self diagnosis function running capability is maintained by pre programed value in the simulated program map When any abnorm ality is detected in the injector s crankshaft position CKP senso...

Page 137: ...e to readout the MIL blink pattern as the cur rent DTC In case the ECM does not detect any problem at present but has a problem stored in its memory the MIL w ill not light and blink If it is necessar...

Page 138: ...before the MIL starts blinking CIRCUIT INSPECTION INSPECTION AT ECM CONNECTOR Always clean around and keep any foreign mate rial away from the ECM connector before discon necting it A faulty PGM FI s...

Page 139: ...erates normally Fail safe value 25 C 77 F 6 23 11 1 11 VS sensor no signal Loose or poor contact of the VS sensor connector VS sensor or its circuit malfunction Engine operates normally 6 24 12 1 12 N...

Page 140: ...f female terminal KyP 3 MAP Sensor Input Line Inspection Turn the ignition switch OFF Disconnect the ECM 33P connectors Check for continuity at the Yellow red wire between the MAP sensor 3P Black conn...

Page 141: ...V indicated YES GO TO STEP 2 NO Interm ittent failure Loose or poor contact on the MAP sensor connector 2 MAP Sensor System Inspection 2 Turn the ignition switch OFF Disconnect the MAP sensor 3P Blac...

Page 142: ...rt the engine and check the MAP sensor with the HDS pocket tester at idle speed Is the voltage w ithin 1 6 1 8 V YES Intermittent failure NO GO TO STEP 2 2 Manifold Absolute Pressure Test Turn the ign...

Page 143: ...P 4 3 ECT Sensor Resistance Inspection Turn the ignition switch OFF Measure the resistance at the ECT sensor term i nals CONNECTION Pink white Green orange STANDARD 2 3 2 6 k 2 20 C 68Q F Is the resis...

Page 144: ...CONNECTION Pink white Green orange Turn the ignition switch ON and engine stop switch o Check the ECT sensor with the HDS pocket tester Is about 0 V indicated YES Faulty ECT sensor NO G O TO STEP 3 3...

Page 145: ...STEP 3 TP SENSOR 3P BLACK CONNECTOR Wire side of female terminal k v p 3 TP Sensor Circuit Inspection Disconnect the ECM 33P connectors Check for continuity at the Yellow red wire between the TP senso...

Page 146: ...r w ith the HDS pocket tester Is DTC 8 1 indicated YES Replace the ECM with a known good one and recheck NO Faulty original TP sensor DTC 8 2 TP SENSOR HIGH VOLTAG E 1 TP Sensor System Inspection Turn...

Page 147: ...0 V indicated YES GO TO STEP 2 NO Intermittent failure Loose or poor contact on the IAT sensor connector 2 IA T Sensor Inspection Remove the center cowl page 3 6 Turn the ignition switch OFF Disconne...

Page 148: ...ction Gray blue Green orange Turn the ignition switch ON and engine stop switch Q Check the IAT sensor with the HDS pocket tester Is about 0 V indicated YES Faulty IAT sensor NO G O TO STEP 3 3 IAT Se...

Page 149: ...op switch O Check the VS sensor with the HDS pocket tester Is the DTC 11 1 indicated YES Replace the ECM with a new one and recheck NO Loose or poor contact on the ECM connectors Interm ittent failure...

Page 150: ...ONNECTION B28 Pink TOOL Test probe 07ZAJ RDJA110 Is there continuity NO Open circuit in Pink wire YES GO TO STEP 6 VS Sensor Pulse Line Short Circuit Inspection Disconnect combination meter connector...

Page 151: ...mittent failure Loose or poor contact on the injector 2P Gray connector YES GO TO STEP 2 2 Injector Input Voltage Inspection Turn the ignition switch ON and engine stop switch O Measure the voltage be...

Page 152: ...e continuity NO Open circuit in SIGNAL line wire YES GO TO STEP 5 5 Injector Signal Line Short Circuit Inspection Check for continuity between the injector 2P Gray connector and ground CONNECTION SIGN...

Page 153: ...OLS Imrie diagnosis tester model 625 or Peak voltage adaptor 07HGJ 0020100 w ith commercially available digital m ultim eter impedance 10 MQ DCV minimum Is the voltage more than 0 7 V 20 C 68 C F YES...

Page 154: ...able digital multimeter impedance 10 MS2 DCV minimum Is the voltage more than 0 7 V 20 C 68 F 7 YES GO TO STEP 2 NO Faulty CKP sensor 2 CKP Sensor Circuit Inspection Turn the ignition switch OFF Disco...

Page 155: ...of the w ire harness side CONNECTION A18 Green orange B20 Blue black TOOL Test probe 07ZAJ RDJA110 Is there continuity YES GO TO STEP 3 NO Open circuit in Green orange wire Open circuit in Blue black...

Page 156: ...Is the DTC 23 1 indicated YES GO TO STEP 2 NO Loose or poor contact on the O2 sen sor 4P Black connector Interm ittent failure 2 O2 Sensor Heater Resistance Inspection Turn the ignition switch OFF Dis...

Page 157: ...l ECM 33P LIGHT GRAY CONNECTOR Wire side of female terminal O2 SENSOR 4P WHITE CONNECTOR Wire side of female terminal DTC 29 1 IACV Before starting the inspection check for loose or poor contact on th...

Page 158: ...ue or Green white wire Open or loose contact in Green or Green yellow wire 4 IACV Resistance Inspection Measure the resistance at the IACV 4P Black connector terminals CONNECTION Yellow blue Green yel...

Page 159: ...ntinuities YES GO TO STEP 2 NO Open circuit in Brown wire 2 TCM Signal Line Short Circuit Inspection Check the continuity between the TCM 33P Black connector of the w ire harness side and ground CONNE...

Page 160: ...there continuity YES G O TO STEP 2 NO Open circuit in Brown Black wire 2 Engine Inhibitor Signal Line Short Circuit Inspection Check the continuity between the TCM 33P Black connector of the wire harn...

Page 161: ...9 If they function properly check the follows Turn the ignition switch OFF Disconnect the ECM 33P connectors Ground the A20 terminal of the wire harness side connector with a jum per wire TOOL Test pr...

Page 162: ...r dirt and clean if necessary Place a shop towel over the quick connect fitting 6 Slide and release the rubber cap 7 Hold the connector with one hand and squeeze the retainer tabs with the other hand...

Page 163: ...t or twist fuel feed hose If any retainer needs replacing use the same manufacturer s retainer as the ones being removed The various manufactures feature dif ferent retainer specification 1 Insert a n...

Page 164: ...ressure gauge attachment and manifold TOOLS 1 Fuel pressure gauge 07406 0040004 2 Pressure gauge manifold 07ZAJ S5A0111 3 Hose attachment 8 mm 9 mm 07ZAJ S7C0100 4 Hnsp attachm ent 9 m m 9 m m 07Z A J...

Page 165: ...pe spilled Place the end of the hose into an approved gasoline gasoline out o f the container container connecnhe pump 3P Black connector Turn the ignition switch ON engine stop switch O for 10 second...

Page 166: ...There should be battery voltage for a few seconds If there is battery voltage replace the fuel pump If there is no battery voltage inspect the following Main fuse 40 A Fuse FI 20 A Fuse ST IGN 10 A E...

Page 167: ...PACKING INSPECTIO N Check the fuel pump assembly for damage Replace the fuel pump if it necessary Clean the fuel strainer screen STRAINER SCREEN INSTALLATIO N Always replace Place a new packing onto t...

Page 168: ...38 Install the seat page 3 4 FUEL CUT RELAY INSPECTION Remove the seat page 3 4 Open the fuse relay box and remove the fuel cut relay Connect an ohmmeter to the fuel cut relay term i nals Connect a 1...

Page 169: ...ct the upper fuel level sensor 2P Blue connector Release the fuel tank tray drain hose from the clamp on the upper fuel tank Remove the fuel tank tray Disconnect the upper and lower fuel tank breather...

Page 170: ...fuel tank washers collars and bolts Tighten the bolts securely Remove the bolts washers collars and upper fuel I BOLTS WASHERS COLLARS tank INSTALLATION UPPER FUEL TANK BOLTS COLLARS BREATHER HOSE UPP...

Page 171: ...ower fuel lank brealher hose to the upper fuel tank Install the fuel tank tray Install the fuel tank tray drain hose to the clamp on the upper fuel tank Connect the upper fuel level sensor 2P B ue con...

Page 172: ...parator retainer and O ring INSTALLATION Install a new O ring onto the breather separator Install the breather separator and retainer by align ing the fuel tank boss and retainer cut out Install and t...

Page 173: ...he fuel pressure and disconnect the quick connect fitting page 6 37 Remove the m uffler page 3 16 Disconnect the following CKP sensor 2P Red connector O2 sensor 4P Black connector PGM FI sub harness 4...

Page 174: ...and tighten the pivot nut securely Install and tighten the lower fuel tank pivot bolt nut mounting bolt securely with washers NUT WASHER SUB FRAME PIVOT NUT BOLTS WASHERS PIVOT BOLT Install and tighte...

Page 175: ...l level sensor 3P Black connector Install the m uffler page 3 16 Connect the quick connect fitting page 6 3S Install the upper fuel tank page 6 45 AIR CLEANER HOUSING REM O VAL Remove the following Up...

Page 176: ...nect the crankcase breather hose and PAIR air supply hose Remove the air cleaner housing Seal the throttle body intake ports with tape or a clean cloth to keep dirt and debris from entering the intake...

Page 177: ...CLEANER ELEMENT MIDDLE CASE Connect the crankcase breather hose and PAIR air supply hose to the air cleaner housing Connect the air cleaner housing connecting tube to the throttle body then tighten th...

Page 178: ...um hose Connect the IAT sensor 2P connector Install the following ECM page 6 68 Upper fuel tank page 6 45 INSULATOR REMOVAL INSTALLATION Remove the air cleaner housing page 6 50 Remove the bolts and i...

Page 179: ...fuel tank page 6 44 Air cleaner housing page 6 50 California type only Disconnect the vacuum hoses Relieve the fuel pressure and disconnect the quick connect fitting at the throttle body page 6 37 Dis...

Page 180: ...PGM FI Loosen the lock nuts and remove the throttle cables Loosen the insulator band screws Lift up the throttle body and release the injector wire from the clamp Remove the throttle body I I SCREWS...

Page 181: ...operation Do not damage the throttle body It may cause incorrect throttle valve operation Do not loosen or tighten the white painted bolts nuts and screws of the throttle body Loosening or tightening...

Page 182: ...M FI INSTALLATION Install the injector wire to the c amp Install the throttle body and tighten the insulator band screws CLAMP Connect the throttle cable ends to the throttle drum THROTTLE CABLES THRO...

Page 183: ...le body page 6 38 California type only Connect the vacuum hoses Install the follow ing A ir cleaner housing page 6 52 Upper fuel tank page 6 45 Adjust the throttle grip free play page 4 5 INJECTOR SOU...

Page 184: ...injector base and fuel hose quick connector with compressed air before removing the injector and De sure that no debris is allowed to enter into the throttle body Disconnect the injector 2P Gray conne...

Page 185: ...seal ring and O ring SEAL RING O RINGS INSTALLATION Coat a new O ring and new seal ring with engine oil m SEAL RING INJECTOR Install a new O ring and new seal ring being careful H not to damage Insta...

Page 186: ...ORQUE 5 4 N m 0 55 kgf m 4 1 Ibf ft INJECTOR FRONT BOLTS FRONT INJECTOR 2P GRAY CONNECTOR FRONT I e a r T H r ear INJECTOR 2P t k s I 4 i I S GRAY CONNECTOR INJECTOR HOLDER INJECTOR THROTTLE BODY r e...

Page 187: ...on switch turned ON NOTE The IACV operation can be checked visually as fol lowing 1 Remove the IACV page 6 62 2 Connect the IACV 4P Black connector and turn the ignition switch ON REMOVAL Always clean...

Page 188: ...plate IACV I INSTALLATION Turn the slide valve clockwise until lightly seated on IACV Install the IACV aligning slide valve groove w ith the pin Install the setting plate while aligning the cut out wi...

Page 189: ...to the throttle body Install and tighten the screw to the specified torque TORQUE 3 4 N m 0 35 kgf m 2 5 Ibf ft Install the air cleaner housing page 6 52 MAP SENSOR REMOVAL INSTALLATION Remove the air...

Page 190: ...nt page 7 6 senso while the jsconnect the ECT sensor 3P Gray connector engine is co pemove ECT sensor and sealing washer Always replace a Install the new sealing washer and ECT sensor sealing washer w...

Page 191: ...ALLATION Apply oil to a new O ring and install it onto the CMP sensor Install the CMP sensor into the cylinder head Install and tighten the bolt securely Route the wire Connect the CMP sensor 2P Black...

Page 192: ...on Place the bank angle sensor is normal position as shown and ignition switch ON and engine stop switch O ther bank angle sensor is normal if the engine stop relay clicks and power supply is closed I...

Page 193: ...UMP relay connector terminals Connect a 12 V battery to the follow ing FI IGN PUMP relay connector terminals as shown There should be continuity only when the 12 V bat tery is connected If there is no...

Page 194: ...switch OFF Check for continuity between the ECM 33P con nector terminals and ground CONNECTION A23 Ground B4 Ground TOOL Test probe 07ZAJ RDJA110 Is there continuity YES GO TO STEP 3 NO Open circuit...

Page 195: ...Red Black White black and or Red green wires RERAY TERMINAL 5 FI IGN PUMP Relay Inspection 2 Turn the ignition switch OFF Jum p the FI IGN PUMP relay connector term i nals CONNECTION Black white Red y...

Page 196: ...page 4 6 Check that the secondary air intake port is clean and free of carbon deposits Check the PAIR check valves if the port for carbon fouling page 6 73 Start the engine and open the throttle slig...

Page 197: ...in the reverse order of removal INSPECTION Remove the PAIR solenoid valve page 6 72 Check that air does not flow A to B when a 12 V battery is connected to the PAIR control solenoid valve terminals Ai...

Page 198: ...seat is cracked deteriorated or damaged or if there is clearance between the read and seat Installation is in the reverse order of removal TORQUE PAIR check reed valve cover bolt 5 2 N m 0 53 kgf m 3...

Page 199: ...mpact wrench while removing or installing the O2 sensor Be careful not to damage the sensor wire INSTALLATION Install the O2 sensor and tighten it securely TOOL O2 sensor wrench 07LAA PT50101 Connect...

Page 200: ...2P connector Fuel tank breather hose to fuel tank Canister to purge control solenoid valve hose EVAP canister hose EVAP canister drain hose Purge control solenoid valve to throttle valve hose Remove t...

Page 201: ...t low A to B only when a 12V battery is connected to the EVAP purge con trol solenoid valve terminals Check the resistance betv een the term inals of the EVAP purge control solenoid valve STANDARD 30...

Page 202: ...PATTERN 7 2 SERVICE INFORMATION 7 3 TROUBLESHOOTING 7 4 SYSTEM TESTING 7 5 COOLANT REPLACEMENT 7 6 THERMOSTAT 7 8 THERMOSTAT HOUSING 7 9 RADIATOR COOLING FAN 7 10 WATER PUMP 7 15 RADIATOR RESERVE TAN...

Page 203: ...COOLING SYSTEM SYSTEM FLOW PATTERN RESERVE TANK RADIATOR CAP RADIATOR WATER PUMP 7 2...

Page 204: ...se engine damage Add coolant at the reserve tank Do not remove the radiator cap except to refill or drain the system All cooling system service can be done w ith the engine in the frame Avoid spilling...

Page 205: ...adiator hoses or water jacket A ir in system Faulty cooling fan motor Faulty fan m otor switch Faulty water pump Engine temperature too low Thermostat stuck open Faulty EOT sensor Coolant leaks Faulty...

Page 206: ...side cowl page 3 5 Remove the radiator cap COOLANT GRAVITY CHART STANDARD COOLANT CONCENTRATION 1 1 distilled w ater and the recommended antifreeze Test the coolant specific gravity ter using a hydrom...

Page 207: ...or at least 6 seconds Remove the tester and install the radiator cap COOLANT REPLACEMENT PREPARATION RADIATOR CAP COOLING SYSTEM TESTER NOTE The effectiveness of coolant decreases with the accumulatio...

Page 208: ...oolant Empty the coolant and rinse the inside of the reserve tank with water Connect the siphon hose to the reserve tank Fill the system with the recommended coolant through the filler opening up to t...

Page 209: ...he recommended coolant Install the following Left under cowl page 3 11 Right front side cowl page 3 5 THERMOSTAT REMOVAL Drain the coolant from the system page 7 6 Remove the right front side cowl pag...

Page 210: ...IFT 8 mm 0 3 in minimum at 95 C 203 F INSTALLATION Install the therm ostat by aligning it w ith the therm o stat housing slot Install the therm ostat housing to the cover and tighten the bolts to the...

Page 211: ...pecified range 0 1 0 mm 0 0 0 4 in RADIATOR COOLING FAN NOTE Be carefu not to damage the radiator fins while ser vicing the radiator and fan motor REMOVAL Drain the coolant from the system page 7 6 Re...

Page 212: ...se Remove the radiator upper bolt and collar Remove the radiator lower bolt and collar Release the radiator grom met from the frame boss and remove the radiator DISASSEMBLY Remove the bolts and fan m...

Page 213: ...EM FAN MOTOR Remove the nut and cooling fan NUT COOLING FAN SHROUD FAN MOTOR ASSEMBLY Release the fan m otor wire from the clamp Remove the nuts and fan m otor from the shroud NUTS CLAMP RADIATOR COOL...

Page 214: ...he clamp NUTS SHROUD CLAMP FAN MOTOR Install the cooling fan unto the motor shaft aligning the flat surfaces Clean and apply locking agent tc the cooling fan nut threads Tighten the cooling fan nut BO...

Page 215: ...ommet with the frame boss Install the radiator lower bolt and collar Install the radiator upper bolt and collar Connect the upper radiator hose and tighten the hose band screw securely 0 1 0 mm 0 0 0...

Page 216: ...CAL SEAL INSPECTION Remove the left under cowl page 3 11 Check for signs of seal leakage A small amount of weeping from the bleed hole normal Route the hoses Connect the fan m otor 2P Black connector...

Page 217: ...water hoses Remove the bolts sealing washer and water pump cover Remove the Remove the O RING WATER PUMP COVER INSTALLATION Install a new O ring into the water pump cover groove Install the dowel pins...

Page 218: ...ses and tighten the hose band screw securely Fill and bleed the cooling system page 7 6 0 1 0 mm 0 0 04 in RADIATOR RESERVE TANK REMOVAL INSTALLATION Disconnect the siphon hose and hoses from the rese...

Page 219: ...otor relay con nector terminals as shown There should be continuity when a 12 V battery is connected If there is no continuity when a 12 V battery is con nected replace the fan m otor relay FAN MOTOR...

Page 220: ...8 ENGINE REMOVAL INSTALLATION COMPONENT LOCATION 8 2 ENGINE REMOVAL 8 4 SERVICE INFORMATION 8 3 ENGINE INSTALLATION 8 9...

Page 221: ...ENGINE REMOVAL INSTALLATION COMPONENT LOCATION...

Page 222: ...er motor page 21 6 The following components require engine removal for servicing Crankshaft page 13 6 HFT page 11 89 Oil pump page 5 6 SPECIFICATIONS ITEM SPECIFICATIONS Engine dry weight 80 0 kg 176...

Page 223: ...6 Right shroud page 3 8 Left shroud page 3 8 Right under cowl page 3 11 Left under cowl page 3 11 Right side cover page 3 14 Left side cover page 3 15 Oil filter page 4 12 PAIR control solenoid valve...

Page 224: ...e bolt and disconnect the ground cable Release the wires from the clamp Disconnect the oil reserve sensor connectors Pink blue and Yellow red wires Remove the wire clamp PAIR AIR SUPPLY HOSE REAR PAIR...

Page 225: ...or Remove the bolt and disconnect the neutral switch wires Release the wires from the clamp Disconnect the EOT switch 2P Black connector and swash plate angle sensor 3P Brown connector Remove the bolt...

Page 226: ...ar engine mounting nut and bolt Remove the engine hanger plate bolts and rear engine hanger olates Remove the front engine mounting nut and bolt Remove the engine hanger nuts bolts and front engine ha...

Page 227: ...nd be careful not to damage the frame and engine Release the joint boot from the side gear case Move the engine forward and release the output shaft from the universal joint in the swingarm Turn the e...

Page 228: ...n the frame Apply of molybdenum grease to the output shaft splines Carefullyalign the Engage the output shaft w ith the universal joint mountingpoints Install and tighten the lower engine mounting bol...

Page 229: ...kgf m 19 Ibf ft Install and tighten the rear engine mounting bolt and nut to the specified torque TORQUE 39 N m 4 0 kgf m 29 Ibf ft Connect the ground cable and lighten the bolt Connect the water hos...

Page 230: ...sor 3P Brown connector Connect the following Neutral drive solenoid 2P Black connector Lock up solenoid 2P Gray connector Oil pressure sensor 3P Black connector Connect the neutral switch wi es and ti...

Page 231: ...t PAIR check valve and PAIR check valve cover Install and tighten the bolts to the specified torque TORQUE 5 2 N m 0 53 kgf m 3 8 Ibf ft Connect the PAIR air supply hose to the rear PAIR check valve c...

Page 232: ...r motor page 21 14 Right shroud page 3 8 Left shroud page 3 8 Right under cowl page 3 11 Left under cowl page 3 11 Right side cover page 3 14 Left side cover page 3 15 Oil filter page 4 12 PAIR contro...

Page 233: ...COVER REMOVAL 9 6 CAMSHAFT REMOVAL 9 7 CYLINDER HEAD REMOVAL 9 13 CYLINDER STUD BOLT REPLACEMENT 9 15 CYLINDER HEAD DISASSEMBLY 9 15 VALVE GUIDE REPLACEMENT 9 18 VALVE SEAT INSPECTION REFACING 9 20 C...

Page 234: ...CYLINDER HEAD VALVE________ COMPONENT LOCATION 23 N m 2 3 kgf m 17 Ibf ft...

Page 235: ...rance 0 020 0 062 0 0008 0 0024 0 10 0 004 I Rocker arm rocker arm Rocker arm shaft O D Rocker arm I D IN EX IN EX 11 983 11 994 0 4718 0 4722 12 006 12 024 0 4726 0 4734 11 92 0 469 12 05 0 474 shaft...

Page 236: ...available Valve seat cutter 27 5 mm 45 EX 07780 0010200 jgj or equivalent commercially available Valve seat cutter 33 mm 45 IN 07780 0010800 or equivalent commercially available Flat cutter 27 mm 32 E...

Page 237: ...ing Uneven valve seating Valve stuck open Cylinder head Leaking or damaged cylinder head gasket Warped or cracked cylinder head Loose sparkplug Cylinder piston problem page 10 3 Compression too high E...

Page 238: ...ter m otor until the gauge reading stop rising The maximum reading is usually reached within 4 7 seconds Compression pressure 1 569 98 kPa 16 0 1 0 kgf cm 2 227 6 14 psi at 400 m in 1 rpm Low compress...

Page 239: ...ness and mating surfaces when removing the cylinder head cover CAMSHAFT REMOVAL NOTE The camshaft can be serviced w ith the engine in the frame The front camshaft uses the same service proce dure as t...

Page 240: ...ke when removing the camshaft holder Measure the cam chain tensioner wedge B length as shown SERVICE LIMIT 6 mm 0 2 in Replace the cam chain with a new one if the projec tion exceeds the service limit...

Page 241: ...n stroke Loosen the bolts in a crisscross pattern in several steps then rem ove them and cam shaft holder assembly Remove the camshaft INSPECTION CAMSHAFT RUNOUT Support both end journals of the cam s...

Page 242: ...AL Check the cam shaft journal surfaces for scoring or evidence of insufficient lubrication M easure the O D of each cam shaft journal SERVICE LIMIT 21 90 mm 0 862 in NOTE Check the oil passages and c...

Page 243: ...que in a crisscross pattern in several steps TORQUE 23 N m 2 3 kgf m 17 Ibf ft Rem ove the cam shaft holder and m easure tne width of each plastigauge The w idest thickness determ ines the oil clearan...

Page 244: ...screw for w ear or damage M easure the I D o f each rocker arm SERVICE LIMIT 12 05 mm 0 474 in Check the shaft for w ear or dam age M easure each rocker arm shaft O D SERVICE LIMIT 11 92 mm 0 469 in C...

Page 245: ...the bolts and insulator Rem ove the O ring from the insulator Rem ove the bolts and w ater hose joints Rem ove the 0 rings from the w ater hose joints Rear cylinder head Rem ove the bolt and C M P se...

Page 246: ...careful not to damage the mating surface when removing the cylinder head Remove the follow iny cylinder head bolts and nuts 8 m m bolts 10 m m nuts washers Rem ove the cylinder head Rem ove the gasket...

Page 247: ...kcase surface Adjust the height if necessary CYLINDER HEAD DISASSEMBLY Rem ove the spark plug 12 m m S TU D BOLT 12 m m S TU D BOLT 10 m m S TU D BOLT c ES E 9 o r CM CO iJ A 7Z Mark all parts Rem ove...

Page 248: ...em ove the carbon deposits from the com bustion cham ber and clean off the head gasket surface Check the spark plug hole and valve areas for cracks INSPECTION CYLINDER HEAD Check the cylinder head for...

Page 249: ...cing Insert the ream er from the com bustion cham ber side of the head and always rotate the ream er clockwise TOOL Valve guide reamer 5 510 mm 07984 2000001 or 07984 2000001D U S A only M easure each...

Page 250: ...valve guides in a freezer for aDOut an hour Using a torch to Heat the cylinder head to 130 140 C 275 heat the cylinder 290 F with a hot plate or oven Do not heat the cyl head may cause inder head bey...

Page 251: ...guides until the marks are parallel with the cylinder head Check that the valve guides are at the proper depth adjust the height if necessary Let the cylinder head cool to room tem perature then ream...

Page 252: ...is burned or badly w orn or if it contacts the seat unevenly replace the valve Inspect the valve seat face for Uneven seat width Replace the valve and reface the valve seat Damaged face Replace the v...

Page 253: ...seat m ust be raised using a 60 interior cutter CONTACT TOO HIGH OLD SEAT W IDTH CONTACT TOO LOW Using a 45 cutter rem ove any roughness or irregu larities from the seat TOOLS Seat cutter 33 mm IN Sea...

Page 254: ...that all pitting and irregularities are rem oved NOTE Excessive lapping pressure m ay deform or d am age the seat Change the angle of lapping tool frequently to prevent uneven seat wear Lapping com p...

Page 255: ...de oil Install the valve into the valve guide NOTE To avoid dam age to the stem seal turn the valve slow ly w hen valve installing Install the valve spring w ith tightly w ound coils fac ing the com b...

Page 256: ...OTE Compressing the valve springs m ore than neces sary w ill cause loss of valve spring tension Support the cylinder head so the valve heads will not contact anything and possibly get dam aged Tap th...

Page 257: ...e cylinder opening to prevent dust or dirt from entering the engine Clean the gasket m ating surfaces of the cylinder and cylinder head thoroughly being careful not to d am age them Install the cam ch...

Page 258: ...d tight then torque the larger fasteners before tightening the sm aller fasteners Tighten the bolts and nuts in a crisscross pattern in several steps Install the cam chain tensioner aligning its end w...

Page 259: ...nstall the insulator and tighten the bolts securely Install the following Cam shaft page 9 27 Cylinder head cover page 9 32 CAMSHAFT INSTALLATION CAMSHAFT HOLDER ASSEMBLY O RING BOLTS W ATER HOSE JO I...

Page 260: ...intake rocker arm shaft holes w ith the holder holes Align the exhaust rocker arm shaft grooves w ith the holder holes CAMSHAFT INSTALLATION NOTE The cam shafts are identified by the stam ped marks F...

Page 261: ...lyw heel w ith the index notch and begin installation of the front camshaft If the R m ark faces dow n cannot be seen turn the crankshaft clockwise 16 45 128 turn align the FT m ark w ith the index no...

Page 262: ...using the follow ing proce dure CAMSHAFT INSTALLATION Lubricate the cam shaft lobe and journal surfaces w ith m olybdenum disulfide oil Install the cam shaft w ith the cam shaft identification m ark...

Page 263: ...o the cam sprocket bolt threads Align the cam sprocket bolt holes in the cam sprocket and camshaft T em porarily install the cam sprocket bolt Turn the crankshaft clockwise 360 and tighten the other s...

Page 264: ...roove and cylinder head mating surface o the cylinder head cover Install the gasket into the groove Apply liquid sealant Three Bond 5211C or equiva lent to the cylinder head sem i circular cut outs as...

Page 265: ...ead cover mating surface of the cylinder head Install the rear cylinder head cover on the rear cylin der Install th e rubber seals and washers Install and tighten the cylinder head cover bolts to the...

Page 266: ...10 CYLINDER PISTON COMPONENT LOCATION 10 2 SERVICE INFORMATION 10 3 CYUNDER PISTON REMOVAL 10 4 CYUNDER PISTON INSTALLATION 10 9 TROUBLESHOOTING 10 3 10 1...

Page 267: ...CYLINDER PISTON_____________ COMPONENT LOCATION...

Page 268: ...1886 80 90 3 185 Piston pin bore I D 18 002 18 008 0 7087 0 7089 18 05 0 711 Piston pin O D 17 994 18 000 0 7084 0 7087 17 98 0 708 Piston to piston pin clearance 0 002 0 014 0 0001 0 0006 0 04 0 002...

Page 269: ...lips Slide the cylinder joint collar tow ard either the front or rear cylinder Lift the cylinder and rem ove it being careful not to dam age the piston w ith the stud bolts NOTE Attach a piece of w ir...

Page 270: ...rom falling into the crankcase PISTON REMOVAL Rem ove the piston pin clip w ith pliers Push the piston pin out of the piston and connecting rod and rem ove the piston Rem ove the oil jet and O ring fr...

Page 271: ...g is nearly flush w ith the piston and m easure the ring to ring groove clearance SERVICE LIMITS Top Second 0 07 mm 0 003 in Insert the piston ring into the bottom of the cylinder squarely using the p...

Page 272: ...o piston p ir clearance SERVICE LIMIT 0 04 mm 0 002 in CONNECTING ROD M easure the connecting rod small end I D SERVICE LIMIT 18 047 mm 0 1705 in Calculate the connecting rod to piston pin clear ance...

Page 273: ...three levels on the X and Y axes Take the m axim um reading to determ ine the taper and out of round SERVICE LIMITS Taper 0 06 mm 0 002 in Out of round 0 06 mm 0 002 in The cylinder m ust be rebored a...

Page 274: ...Do not confuse the top and second rings To install the oil ring install the spacer first then install the side rails Stagger the piston ring end gaps 120 apart from each other Stagger the side rail en...

Page 275: ...rooves in the piston pin hole NOTE M ake sure the piston pin clip is seated securely Do not align the clip end gap w ith the piston cut out CYLINDER INSTALLATION Install new O rings to the joint colla...

Page 276: ...the piston w hile compressing the piston rings with your fingers Slide the joint collar into the hole in the cylinder and connect it Install the retaining clips into the joint collar grooves Frontcyl...

Page 277: ...ANKCASE COVER 11 62 CAM DAMPER PRIMARY DRIVE GEAR 11 66 PRIMARY DRIVEN GEAR 11 67 RIGHT CRANKCASE COVER 11 69 N D Neutral Drive CLUTCH 11 77 HFT 11 89 HFT INITIALIZATION TCM RESET 11 93 SWASH PLATE CO...

Page 278: ...HFT COMPONENT LOCATION 11 2...

Page 279: ......

Page 280: ...0 2 0 3 kft Oil level switch resistance Close 0 0 01 kLl Open 1 5 1 7 kQ N D Neutral drive solenoid valve resistance at 20 C 68 F 14 17 Q Lock up solenoid valve resistance at 20 C 68 F 14 17 Q TORQUE...

Page 281: ...AJ RDJA110 Oil pressure gauge 07YAJ 0010200 Oil pressure hose 07KPJ VD60210 Gear holder M2 5 07724 0010100 able or 07724 001A100 U S A only able Universal holder 07725 0030000 Bearing rem over shaft 0...

Page 282: ...PL50100 Bolt set 07GAE PG40200 Driver 07749 0010000 Not available in U S A or 07GAE PGAA200 U S A only Attachment 42 x 47 mm 07746 0010300 Pilot 20 m m 07746 0040500 Bearing rem over handle 07936 3710...

Page 283: ...arting clutch irspection 3 HFT oil pressure inspection 4 HFT inspection with the engine installed in the fram e Faulty engine oil Low HFT oil pressure Faulty HFT Faulty TCM Start the motorcycle w ith...

Page 284: ...l passage or inspect the oil pum p page 5 8 4 N D Clutch Inspection Inspect the N D clutch page 11 82 Is the N D clutch correct YES GO TO STEP 5 NO Faulty N D clutch 5 N D Solenoid valve Inspection In...

Page 285: ...T correct YES Replace the engine oil then perform the HFT initialization procedure page 11 93 and recheck NO Faulty HFT START THE MOTORCYCLE WITH NEUTRAL POSITION 1 Engine Oil Level and Condition Insp...

Page 286: ...m m ended engine oil page 4 11 2 N D Clutch Inspection Inspect the N D clutch page 11 82 Is the N D clutch correct YES GO TO STEP 3 NO Faulty N D clutch 3 N D Solenoid valve Inspection Inspect the N D...

Page 287: ...clutch correct YES GO TO STEP 4 NO Faulty N D clutch 4 N D Solenoid valve Inspection Inspect the N D solenoid valve page 11 107 Is the N D solenoid valve correct YES GO TO STEP 5 NO Faulty N D soleno...

Page 288: ...vailable Oil pressure hose 07KPJ VD60210 or equivalent commer cially available W arm the engine to norm al operating tem perature and read the oil pressure following Standard At idle P lore than 127 k...

Page 289: ...wash plate and ball nut m ovem ent The reduction gear should turn sm oothly Check the swash plate angle sensor shaft is turned w hen the reduction gear is turning If the reduction gear and swash plate...

Page 290: ...T nine tim es per turn If the HFT operation is abnorm al split the crankcase and inspect the HFT page 11 91 Install the following Prim ary driven gear page 11 68 N D clutch page 11 88 TURNING INSPECTI...

Page 291: ...N SW ASH PLATE CONTROL M OTOR VS SENSOR NEUTRAL OIL PRESSURE SW ITCH OIL LEVEL SW ITCH EOP SENSOR LOCK UP SOLENOID VALVE SWASH PLATE ANGLE SENSOR N D SOLENOID VALVE EOT SENSOR OIL LEVEL SW ITCH RELAY...

Page 292: ...AM DOWN SIDESTAND SWITCH 0 Nunber of MIL blinks Theengine does not start if there is malfunction A1 w a B l Blade Y Yellow Bu Blue G Green R Red W White Br Brown 0 Orange Lb Light blue Lg Light green...

Page 293: ...HFT CONNECTOR LOCATIONS Note Remove the pillion seat page 3 4 Note Remove the left side cover page 3 15 BLACK CONNECTOR 11 17...

Page 294: ...JECTOR SUB HARNESS 20P BLACK CONNECTOR RIGHT HANDLEBAR SW ITCH 6P GRAY CONNECTOR LEFT HANDLEBAR SW ITCH 3P GRAY CONNECTOR Note Rem ove the right under cowl page 3 11 OIL LEVEL SW ITCH W IRE TERMINAL P...

Page 295: ...HFT Note Rem ove the right side cover page 3 14 Note Remove the radiator reserve tank page 7 17 11 19...

Page 296: ...HFT Note Rem ove the center cowl page 3 6 ECM 33P GRAY CONNECTOR ECM 33P BLACK CONNECTOR Note Rem ove the upper cowl page 3 7 11 20 CO M BINATIO N METER 20P GRAY CONNECTOR...

Page 297: ...7 SYSTEM DESCRIPTION SELF DIAGNOSIS SYSTEM The HFT system includes a fail safe function to secure a m inim um running capability even w hen there is trouble in the sys tem When any abnorm ality is de...

Page 298: ...ks plus four short blinks DTC 8 Eight sho rt blinks 2 5 sec 0 4 sec DTC 14 1 cycle Pattern repeated W hen there isn t a DTC the shift i n d i c a t o r g o e s off and starts blinking as follows 2 sec...

Page 299: ...READOUT S tart the engine and check the shift indicator If the shift indicator blinks connect the HDS Pocket Tester to the DLC page 11 23 Read the DTC freeze data and follow the trouble shooting index...

Page 300: ...e the en gire is stopped To clear the DTC w ithout HDS refer to the following procedure H ow to clear th e DTC w ith o u t HDS 1 Turn the ignition switch to OFF 2 Remove the pillion seat page 3 4 3 Re...

Page 301: ...at the self diagnostic memory cannot be erased if the ignition switch is turned to OFF before the shift i n d i c a t o r s t a r t s blinking CIRCUIT INSPECTION INSPECTION AT TCM CONNECTOR Always cle...

Page 302: ...up solenoid valve or its circuit malfunction Drivable but does not lock up system operate 11 37 19 1 19 Engine speed input line no signal ECM or Engine speed input circuit malfunction Won t switch ne...

Page 303: ...sensor circuit low voltage less than 0 137 V EOT sensor or its circuit malfunction Engine power low 11 52 44 2 44 EOT sensor circuit high voltage more than 4 941 V Loose or poor contact of the EOT sen...

Page 304: ...owing TCM 33P Black connector engine sub harness 20P Black connector Check for continuity between the engine sub harness 20P Black connector terminal and TCM 33P Black connector terminal of the main w...

Page 305: ...nector terminal of the wire harness side and ground Connection A31 Yellow red Ground TOOL Test probe 07ZAJ RDJA110 Is there continuity YES Short circuit in Yellow red wire NO Replace the TCM with a n...

Page 306: ...nnect the EOP sensor 3P connector Turn the ignition switch ON and engine stop switch O Measure the voltage between the wire harness side connector terminal and ground Connection Black blue Ground Is t...

Page 307: ...TCM 33P Black connector then check the DTC 1 EOP Sensor System Inspection Turn the ignition switch ON and engine stop switch O Check the EOP sensor with the HDS Is about 5 V indicated YES GO TO STEP 2...

Page 308: ...terminals Connection A15 Yellow black Yellow black A27 Green black Green black 07ZAJ RDJA110 TOOL Test probe Is there continuity YES Replace the TCM with a new one and recheck HFT initialization proc...

Page 309: ...n procedure page 11 93 IMO Open circuit in Pink wire 3 VS Sensor Input Voltage Inspection Turn the ignition switch OFF Disconnect the VS sensor 3P Black connector Check for continuity at the VS sensor...

Page 310: ...will be indicated when the shift switch position and the N D status of neutral oil pressure switch are not synchronized for more than ten seconds Before starting inspection Check for loose or poor con...

Page 311: ...w A to B Does the N D solenoid valve operate YES GO TO STEP 4 NO Faulty N D solenoid valve 4 Spool Valve and HFT Oil Passage Inspection Inspect the following Spool valve page 11 71 HFT oil passage pag...

Page 312: ...then check the DTC 1 N D Solenoid Valve System Inspection Start the engine and select the D of the N D select switch Check the N D solenoid valve with the HDS Is DTC 17 1 indicated YES GO TO STEP 2 N...

Page 313: ...tion Check for continuity between the wire harness side N D solenoid valve 2P Black connector ter minal and ground Connection White black Ground Brown Ground Is there continuity YES Short circuit in W...

Page 314: ...Light green TOOL Test probe 07ZAJ RDJA110 Is there continuity YES GO TO STEP 4 NO Open circuit in Yellow wire Open circuit in Light green wire 4 Lock Up Solenoid Valve Line Short Circuit Inspection C...

Page 315: ...tor terminal Connection A7 Yellow green Yellow green TOOL Test probe 07ZAJ RDJA110 Is there continuity YES GO TO STEP 2 NO Open circuit in Yellow green wire 2 Engine Speed Line Short Circuit Inspecti...

Page 316: ...Plate Angle Sensor Resistance Inspection Inspect the resistance of the swash plate angle sensor shaft groove turning CONNECTION A B Is there resistance w ithin 0 to 1 6 2 4 k 20 C 68 F YES GO TO STEP...

Page 317: ...itialization proce dure page 11 93 SWASH PLATE ANGLE SENSOR 3P CONNECTOR Wire side of female terminal L j j Pink SWASH PLATE ANGLE SENSOR 3P CONNECTOR Wire side of female terminal Wire side of female...

Page 318: ...rcuit in Green black wire SWASH PLATE ANGLE SENSOR 3P CONNECTOR Wire side of female terminal crtg Green black 4 DTC 26 1 SWASH PLATE CONTROL MOTOR LOCK Before starting inspection Check for loose or po...

Page 319: ...le terminal 4 Swash Plate Movable Inspection at HFT Oil Motor Side Inspect the swash plate movable inspection at HFT oil motor side page 11 13 Do the reduction gear and swash plate angle sensor shaft...

Page 320: ...con nector terminals of the wire harness side and ground CONNECTION Red black Ground Yellow Ground Is there continuity YES Short circuit in Red black wire Short circuit in Yellow wire NO GO TO STEP 8...

Page 321: ...HFT initialization procedure page 11 93 NO Faulty control motor MOTOR 2P Bla Motor side of U S ck CONNECTOR male terminal r n LZ J 1n i i n DTC 28 1 SWASH PLATE CONTROL MOTOR Before starting inspecti...

Page 322: ...n nector terminals and the swash plate control motor 2P Black connector terminals of the wire harness side CONNECTION Red black Red black Yellow Yellow Is there continuity YES GO TO STEP 4 NO Open cir...

Page 323: ...at the control motor operation Does the control m otor turn Clockwise YES GO TO STEP 7 NO Faulty control motor 7 Swash Plate Control Motor Operate Inspection Counterclockwise Apply battery voltage to...

Page 324: ...ntermittent failure DTC 32 1 FAIL SAFE RELAY 1 Failure Reproduction Reset the self diagnosis memory data from the TCM page 11 24 Perform the HFT initialization procedure page 11 93 Test ride the motor...

Page 325: ...with a new one NO GO TO STEP 2 2 TCM Sub Power Input Voltage Inspection Install the TCM fuse 30 A Disconnect the TCM 33P Black connector Measure the voltage between the wire harness side TCM 33P Black...

Page 326: ...ground Connection Black blue Ground Does the battery voltage exist YES GO TO STEP 3 NO Open circuit in Black blue wire If Black blue wire is rormal replace the TCM with a new one and recheck HFT ini...

Page 327: ...tion Turn the ignition switch OFF Disconnect the left handlebar switch 3P Gray connector Check for continuity at the switch side left han dlebar switch 3P Gray connector terminals in each switch posit...

Page 328: ...een the left handlebar switch 3P Gray connector terminals of the main wire harness side and ground Connection White blue Ground White yellow Ground Is there continuity YES Short circuit in White blue...

Page 329: ...ose or poor connectors on the EOT sensor 2P connector and TCM 33P Black connector then check the DTC 1 EOT Sensor System Inspection Turn the ignition switch ON and engine stop switch O Check the ECT s...

Page 330: ...terminal Wire side of female terminal DTC 45 1 NEUTRAL OIL PRESSURE SWITCH Before starting inspection Check for loose or poor connectors on the neutral oil pressure switch wire terminals and TCM 33P...

Page 331: ...EP 2 NO Fill the engine oil properly page 4 11 2 Oil Level Switch Input Voltage Inspection Turn the ignition switch OFF Disconnect the oil level switch wire terminals Turn the ignition switch ON and e...

Page 332: ...switch OFF Remove the oil level switch relay Turn the ignition switch ON Measure the volt age between the oil level switch relay 4P Gray connector terminals of the wire harness side and ground Connect...

Page 333: ...d JUMPER WIRE OIL LEVEL SWITCH WIRE TERMINAL 8 Oil Level Switch Relay Drive Circuit Inspection Turn the ignition switch OFF Disconnect the jumper wire Install the oil level switch relay Disconnect the...

Page 334: ...page 11 17 Check for continuity between the combination meter 20P Gray connector and TCM 33P Black connector Connection A28 Pink white Is there continuity YES GO TO STEP 2 NO Open circuit in Pink whit...

Page 335: ...ground line before troubleshooting page 22 9 1 Neutral Indicator Signal Line Open Circuit Inspection Turn the ignition switch OFF Disconnect the TCM 33P Black connector page 11 17 Turn the ignition s...

Page 336: ...switch pushed 0 V switch released Is there standard voltage YES Replace the TCM with a new one and recheck HFT initialization procedure page 11 93 NO GO TO STEP 2 2 Mode Select Switch Input Voltage I...

Page 337: ...with a jumper wire Turn the ignition switch ON and engine stop switch O Measure the voltage between the test harness terminal and ground Connection A14 Ground Is there battery voltage YES Inspect the...

Page 338: ...WATER HOSES Loosen the hose clamp screws and disconnect the lower radiator hose from the left crankcase Remove the bolts in a crisscross pattern in several steps and clamp Remove the left crankcase co...

Page 339: ...nd bearing set plates Remove the bolts and oil separator Remove the HFT bearings using the special tools TOOLS Clutch spring compressor attachment 07LAE PX40100 Bearing remover shaft 07JAC PH80200 Rem...

Page 340: ...agent to the oil separator bolt threads page 1 18 Install the oil separator and tighten the bolts securely INSTALLATION Clean the mating surfaces of the left crankcase and cover Install the dowel pins...

Page 341: ...r pump cover Tighten the band screw to the specified range page 11 65 Install the left side cover page 3 15 Add the recommended engine oil page 4 121 and check that there are no oil leaks Fill and ble...

Page 342: ...ION Check the primary drive gear teeth for wear or dam age INSTALLATION Apply engine oil to the spline of the cam damper primary drive gear and crankshaft Install the cam damper primary drive gear ali...

Page 343: ...t crankcase cover page 11 64 Add the recommended engine oil page 4 12 and check that there are no oil leaks Fill and bleed the cooling system with the recom mended coolant page 7 6 PRIMARY DRIVEN GEAR...

Page 344: ...N Install the dowel pin Install the primary driven gear to the HFT aligning its hole with the dowel pin Align the orimary drive gear teeth using a fa t blade screwdriver with primary driven gear teeth...

Page 345: ...ng Right side cover page 3 14 Exhaust pipe page 3 16 Disconnect the following EOP senscr 3P connector N D solenoid valve 2P Black connector Lock up solenoid valve 2P Gray connector Oil level switch co...

Page 346: ...and HFT shaft bearing with your finger The bearings should turn smoothly and qu etly Also check that the bearing outer races fit tightly in the right crankcase cover Remove and discard the bearings i...

Page 347: ...de HFT HYDRAULIC PIPE Remove the feed pipe set bolt and O ring from the right crankcase cover Remove the hydraulic pipe and O ring SPOOL VALVE Remove the bolts and spool valve body from the right cran...

Page 348: ...lenoid valve page 11 107 Lock up solenoid valve page 11 109 Neutral oil pressure switch page 11 106 Clean al HFT oil passages in the right crankcase cover check them for clogs or other obstructions NO...

Page 349: ...ecurely HFT HYDRAULIC PIPE Coat a new O ring with engine oil and install it to the hydraulic pipe Install the hydraulic pipe by aligning the pipe flange with the right crankcase groove Coat a new O ri...

Page 350: ...Coat a new O ring with engine oil and install it into inside of the guide Install the guide to the hydraulic pipe Coat a new O ring with engine oil and install it to the guide Install the hydraulic pi...

Page 351: ...IGHT N D CLUTCH BEARING Install the N D clutch hydraulic pipe page 11 74 HFT SHAFT BEARING Remove the HFT shaft hydraulic pipe page 11 71 Remove the HFT shaft bearing using the special tools TOOLS Rem...

Page 352: ...as oil passages Be careful not to pinch the O rings between the right crankcase and the cover HFT___________________________________________ Apply liquid sealant Three Bond 1207B or equiva lent to th...

Page 353: ...14 Exhaust pipe page 3 18 Add the recommended engine oil page 4 12 and check that there are no oil leaks Warm up the engine and check that the shift indica tor is not blinking Test ride the motorcycle...

Page 354: ...de gear page 14 23 Remove the N D clutch bearing using the special tools TOOLS Remover handle 07936 3710100 Bearing remover 20 mm 07936 3710600 Remover weight 07741 0010201 or 07936 371020A U S A only...

Page 355: ...the N D clutch assembly Remove the needle bearing and washer NEEDLE BEARING WASHER Remove the N D clutch shaft and O rings Remove the stopper ring and end plate N D CLUTCH ASSEMBLY WASHER SFCONDARY G...

Page 356: ...ompressor attachment A Clutch spring compressor attachment B Bolt set Clutch spring compressor attachment is must be set the spring retainer flat surface DISCS CLUTCH PLATES WAVE SPRING CLUTCH DRUM cl...

Page 357: ...ing spring retainer and return spring Place a shop towel over the piston Do not use high Position the clutch drum with the piston down and pressure air or bring apply small squirts of air pressure to...

Page 358: ...for clogs Check the secondary gear teeth for wear or damage NEEDLE BEARING Check the needle bearing turns smoothly and qui etly Replace the bearing if necessary NEEDLE BEARING N D CLUTCH SHAFT Check...

Page 359: ...place the clutch Replace the clutch discs if they are worn to the discs and plates as clutch disc grooves a set Check the clutch plates for discoloration CLUTCH DRUM PISTON Check the clutch drum oil h...

Page 360: ...oil holes and clutch pis ton check valve with small squirts of air pressure OIL HOLES CHECK VALVE CLUTCH DRUM CLUTCH PISTON ASSEMBLY END PLATE STOPPER RING WASHER NEEDLE BEARING SECONDARY GEAR N D CLU...

Page 361: ...l the spec al tools to the clutch drum TOOLS Clutch spring compressor attachment A Clutch spring compressor attachment B Bolt set 07LAE PX40100 Two required in U S A 07HAE PL50100 Not available in U S...

Page 362: ...cessary w ill cause loss o f tension HFT_______________________________________ Remove the special tools Remove the wave spring from the clutch drum SNAP RING WAVE SPRING Install the three clutch disc...

Page 363: ...ect the clearance between the end plate and clutch disc of top as following Set a dial indicator on the end plate at bottom posi tion Lift the end plate to the stopper ring Measure the clearance and r...

Page 364: ...LATE NUMBER THICKNESS 1 2 1 mm 0 083 in 2 2 2 mm 0 087 in 3 2 3 mm 0 091 in 4 2 4 mm 0 094 in 5 2 5 mm 0 098 in 6 2 6 mm 0 102 in 7 2 7 mm 0 106 in 1 11 1 9 mm 0 075 in __________ 12___________ 2 0 mm...

Page 365: ...Engine page 8 4 Right crankcase cover page 11 69 N D clutch assembly page 11 77 Remove the snap ring and HFT shaft gear from the HFT shaft Remove the collar Separate the crankcase page 13 5 Remove the...

Page 366: ...ins with O rings have two purposes to fix the position of the HFT and to act as oil pas sages INSPECTION REDUCTION GEAR SHAFT Check the reduction gear and reduction gear shaft for wear or damage REDUC...

Page 367: ...ne times per turn TURNING INSPECTION AT HFT OIL MOTOR SIDE Incline a little the swash plate and hold the HFT at the motor side Turn the HFT shaft and check the HFT rotation at the oil motor side The f...

Page 368: ...age 13 16 Install the collar to the HFT shaft Install the HFT shaft gear and a new snap ring NOTE Install the snap ring with its rolled edge facing the engine side Install the following N D clutch ass...

Page 369: ...propriate troubleshooting procedure Inspect the battery voltage and check it the cor rectly Warm the engine to the normal operating tem perature before HFT initialization service INITIALIZATION PROCED...

Page 370: ...switch ON while pushing the shift switch IGNITION SWITCH 6 Check the shift indicator blinks to 1 7 Release the shift switch Start the engine Check the shift indicator blinks to 2 V m i SHIFT INDICATOR...

Page 371: ...HFT th e sw ash p ate to p p o sitio n 10 Check that the shift indicator blinks to 5 The TCM writes the measurement memory 11 Turn the ignition switch OFF The shift indicator goes off 11 95...

Page 372: ...line Start the engine Check the PGM FI DTC and refer to the DTC index page 6 14 Inspect the wire harness Not blinking to 3 Faulty Swash plate mov able range Swash plate stuck or worn Open circuit TAC...

Page 373: ...EMOVAL Remove the left side cover page 3 15 Disconnect the swash plate control motor 2P Black connector Remove the bolts and swash plate control motor Remove the O ring SWASH PLATE CONTRO MOTOR 2P BLA...

Page 374: ...control motor is turning when 12 V battery is connected If the swash plate control motor is not turning replace the swash plate control motor INSTALLATION Coat a new O ring with engine oil and install...

Page 375: ...h ON and engine stop switch O Measure the voltage between the swash plate angle sensor 3P connector of the wire harness terminal Connection Black blue and Green black Standard 4 75 5 25 V If the volta...

Page 376: ...place the swash plate angle sensor REMOVAL Remove the radiator reserve tank page 7 17 Disconnect the swash plate angle sensor 3P connec tor Remove the bolts Remove the swash plate angle sensor and O r...

Page 377: ...r 3P connector Install the radiator reserve tank page 7 17 Perform the HFT initialization procedure page 11 93 SWASH PLATE ANGLE SENSOR SHAFT REMOVAL INSTALLATION Remove the swash plate angle sensor p...

Page 378: ...g with engine oil and install it to the shaft holder Install the shaft holder and tighten the bolts to the specified torque TORQUE 12 N m 1 2 kgf m 9 Ibf ft Install swash plate angle sensor page 11 10...

Page 379: ...Do not let the thermometer or EOT sensor touch the pan If the resistance is out of range replace the EOT sensor HFT Temperature 20 C 68 F 100 C 212 F I Resistance 2 5 2 8 kQ 0 2 0 3 kli INSTALLATION I...

Page 380: ...que TORQUE 22 N m 2 2 kgf m 16 Ibf ft Connect the EOP sensor 3P connector Install the right side cover page 3 14 OIL LEVEL SWITCH REMOVAL Drain the engine oil page 4 12 Remove the right step bracket p...

Page 381: ...0 0 01 kil Open contact point 1 5 1 7 k 2 If the resistance is out of range replace the oil level switch INSTALLATION Coat a new O ring with engine oil and install it to the oil level switch Install t...

Page 382: ...eutral oil pressure switch wire Remove the neutral oil pressure switch Do not apply sealant to the thread head 3 4 m m 0 1 0 2 in Apply liquid sealant Three Bond 1270B or equiva lent to the neutral oi...

Page 383: ...P Black con nector Remove the bolts and N D solenoid valve Remove the O rings INSPECTION Measure the resistance between the N D solenoid valve 2P connector terminals Standard 14 17 ft 20 C 68 F If the...

Page 384: ...ings with engine oil and install them to the N D solenoid valve NOTE Keep the foreign matter and sealant out of the HFT oil passages as they could cause HFT mal function Install the N D solenoid valve...

Page 385: ...n nector Remove the bolts and lock up solenoid valve Remove the O rings INSPECTION Measure the resistance between the lock up sole noid valve 2P connector terminals Standard 14 17 Q 20 C 68 F If the r...

Page 386: ...e oil and install them to the lock up solenoid valve NOTE Keep the foreign matter and sealant out of the HFT oil passages as they could cause HFT mal function Install the lock up solenoid valve and ti...

Page 387: ...ove the oil level switch relay page 11 111 Connect an ohmmeter to the oil level switch relay connector terminals Connect a 12 V battery to the following oil level switch relay connector terminals as s...

Page 388: ...t handlebar switch 6P Gray connector Check for continuity between the wire terminals of the right handlebar switch 6P Gray connector Continuity should exist between the color coded wire terminals as f...

Page 389: ...r switch 3P Gray con nector _____________________________________________ HFT Check for cont nuity between the wire terminals of the left handlebar switch 3P Gray connector Continuity should exist bet...

Page 390: ...sconnect the right handlebar switch 6P Gray connector HFT__________________________________________ Check for continuity between the wire terminals of the right handlebar switch 6P Gray connector Cont...

Page 391: ...and engine stop switch O Measure the voltage between the TCM 33P Black connector and ground Connection A13 Ground Is there battery voltage YES GO TO STEP 2 NO GO TO STEP 3 2 Ground Line Open Circuit...

Page 392: ...4 NO Inspcct the bonk angle sensor page 6 67 Blown fuse ST IGN 10 A Inspect the engine stop switch page 22 21 Open circuit in Red yellow White black Red green wires Red Green E Red Orange FI IGN PUMP...

Page 393: ...and engine stop switch O Measure the voltage between the TCM 33P Black connector and ground Connection A3 Ground Is there battery voltage YES Inspect the FI IGN PUMP relay page 6 68 NO Open circuit in...

Page 394: ...12 ALTERNATOR STARTER CLUTCH COMPONENT LOCATION SERVICE INFORMATION TROUBLESHOOTING 12 2 CKP SENSOR STATOR REMOVAL 12 4 12 3 FLYWHEEL STARTER CLUTCH 12 5 12 3 CKP SENSOR STATOR INSTALLATION 12 11 12 1...

Page 395: ...ALTERNATOR STARTER CLUTCH COMPONENT LOCATION...

Page 396: ...mm in ITEM STANDARD SERVICE LIMIT Starter driven gear I D 37 000 37 025 1 4567 1 4577 37 10 1 461 O D 57 749 57 768 2 2736 2 2743 57 73 2 273 Starter clutch outer I D 74 412 74 420 2 9296 2 9299 74 40...

Page 397: ...mp and alternator f TCDMAxrtD rr cD a crisscross pattern cover ALTERNATOR COVER in several steps NOTE The alternator cover stator is magnetically attracted to the flywheel be careful during removal Be...

Page 398: ...L Remove the alternator cover page 12 4 Remove the flywheel bolt and washer while holding the flywheel using a special tool TOOL Flywheel holder 07725 0040001 or equivalent com mercially available Rem...

Page 399: ...k the starter reduction gear and shaft for wear or damage STARTER DRIVEN GEAR STARTER CLUTCH REMOVAL Remove the starter driven gear from the flywheel while turning the driven gear clockwise FLYWHEEL C...

Page 400: ...NE WAY CLUTCH CLUTCH OUTER Check the one way clutch sprag for abnormal wear damage or irregular movement NOTE Do not remove the one way clutch from the clutch outer unless it is necessary to replace w...

Page 401: ...STARTER DRIVEN GEAR STARTER CLUTCH INSTALLATION CLUTCH OUTER DRIVEN GEAR ONE WAY CLUTCH FLYWHEEL r am 30 N m 3 1 kgf m 22 Ibf ft Clean the one way clutch and apply engine oil to the sprag Install the...

Page 402: ...reads Install and tighten the bolts to the specified torque TORQUE 30 N m 3 1 kgf m 22 Ibf ft Install the starter driven gear to the flywheel while turning the driven gear clockwise Recheck the one wa...

Page 403: ...ff the mating surface of the flywheel with crankshaft Install the flywheel to the crankshaft aligning the key groove of the flywheel with the woodruff key on the crankshaft Hold the flywheel using a s...

Page 404: ...age 1 18 Install and tighten the stator socket bolts to the specified torque TORQUE 12 N m 1 2 kgf m 9 Ibf ft Clean and apply sealant to the wire grommet seat ing surface and install the grommets into...

Page 405: ...d sealant Three Bond 1207B or equiva lent to the alternator cover mating surface Coat a new O ring with engine oil and install It to the right crankcase Blow open oil passage in the oil jet with com p...

Page 406: ...y page 1 20 Connect the CKP sensor 2P Red connector Install the wires to the clamps Connect the regulator rectifier 3P Dlack connector Install the right seat cowl Check the engine oil level page 4 11...

Page 407: ...ANKSHAFT COMPONENT LOCATION 13 2 CRANKSHAFT CONNECTING ROD 13 6 SERVICE INFORMATION 13 3 CRANKPIN BEARING 13 9 TROUBLESHOOTING 13 4 MAIN JOURNAL BEARING 13 11 CRANKCASE SEPARATION 13 5 CRANKCASE ASSEM...

Page 408: ...CRANKCASE CRANKSHAFT COMPONENT LOCATION Q 42 N m 4 3 kgf m 31 Ibf ft 12 N m 1 2 kgf m 9 Ibf ft 13 2...

Page 409: ...r page 21 6 VS sensor page 22 12 Oil pump driven sprocket page 5 5 Swash plate control motor page 11 97 Side gear case page 14 22 Be careful not to damage the crankcase mating surfaces when servicing...

Page 410: ...0 0015 0 07 0 003 Crankshaft runout 0 03 0 001 Main journal O D 52 976 52 994 2 0857 2 0864 52 976 2 0857 Main journal I D 58 010 58 022 2 2839 2 2843 58 070 2 2862 TORQUE VALUES Crankcase bolt 6 mm C...

Page 411: ...n uses the same service pro cedure as the front side cam chain Loosen the 6 mm bolts in several steps Loosen and remove the 8 mm bolts in a crisscross pattern in several steps then remove the 6 mm bol...

Page 412: ...t and connecting rod service be careful not to damage the main journal or crank pin bearing inserts Mark and store the connecting rods bearing caps and bearing inserts to be sure of their cor rect loc...

Page 413: ...d SERVICE LIMIT 0 30 mm 0 012 in CONNECTING ROD REMOVAL Tap the side o f the Remove the crankpin bearing cap nuts and the bear cap lightly if bearing ing caps cap is hard to remove Mark the rods beari...

Page 414: ...bearing oil clearance may not be obtained resulting in engine damage Wipe any oil from the connecting rod cap and bear ing inserts Install the bearing inserts on the connecting rods and caps by aligni...

Page 415: ...r original locations o r the correct bearing oil clearance may not be obtained resulting in engine damage BEARING INSPECTION Remove the connecting rod page 13 7 Check the bear ng inserts for unusual w...

Page 416: ...r 2 on the connecting rod is the code for the connecting rod I D Remove the bearing caps and measure the com pressed plastigauge at its widest point on each crankpin to determine the oil clearance SER...

Page 417: ...ct a rod with the same weight code as the original CONNECTING ROD WEIGHT CODE A B WEIGHT 400 0 407 5 g 14 11 14 37 oz 407 5 412 5 g 14 37 14 55 oz I C 1412 5 417 5 g 14 55 14 73 oz Install the followi...

Page 418: ...03 in If the clearance exceeds the service limit select the bearing page 13 10 BEARING SELECTION Set a special tool and hydraulic press on the outside of the crankcase TOOL Driver 57 mm 070MF MEG0100...

Page 419: ...G SUPPORT I D CODE LETER A 58 016 58 022 mm 2 284 2 2843 in C Brown B Black A Blue B 58 010 58 016 mm 2 2839 2 2841 in D Green C Brown B Black In case the crankcase only is replaced MAIN JOURNAL O D 5...

Page 420: ...wnl Black Blue Blue 58 010 58 016 mm D C B A 2 2839 2 2841 in Green Brown Black Blue BEARING THICKNESS O S E Yellow Thick O S F Pink O S G Red A Blue Middle B Black C Brown D Green Thin BEARING INSTAL...

Page 421: ...the metal installer flange fully seats BEARING Make sure the bearing mating line aligns with the f index mark on the crankcase Check the oil clearance page 13 11 After selecting new bearings recheck...

Page 422: ...all parts are installed in the right crankcase Apply liquid sealant Three Bond 1207B or equiva lent to the crankcase mating surfaces Coat new O rings with engine oil and install them to the oil pipe B...

Page 423: ...steps TORQUE 23 N m 2 3 kgf m 17 Ibf ft Tighten the 6 mm bolts to the specified torque TORQUE 12 N m 1 2 kgf m 9 Ibf ft Install the front side cam chain to the crankshaft Apply locking agent to the bo...

Page 424: ...OMPONENT LOCATION 14 2 FINAL DRIVE DISASSEMBLY INSPECTION 14 9 SERVICE INFORMATION 14 4 FINAL DRIVE ASSEMBLY 14 17 TROUBLESHOOTING 14 7 FINAL DRIVE INSTALLATION 14 21 FINAL DRIVE REMOVAL 14 8 SIDE GEA...

Page 425: ...FINAL DRIVE__________________ COMPONENT LOCATION 14 2...

Page 426: ...FINAL DRIVE...

Page 427: ...Final drive gear backlash 0 05 0 15 0 002 0 006 0 30 0 012 Backlash difference between measurements 0 10 0 004 Final drive gear assembly preload 0 3 1 1 N m 0 C3 0 11 kgf cm 0 2 0 8 Ibf ft Side gear D...

Page 428: ...ver 07749 0010000 Attachment 32 x 35 mm 07746 0010100 Driver 40 mm I D 07746 0030100 Base 105 x 1115 x 65 mm 07ZMF MCA0200 Retainer wrench 07910 MA10100 Pinion puller base 07HMC MM80110 07HMC MM8011A...

Page 429: ...3710600 07936 371020A U S A only Bearing remover 30 mm 07936 8890300 Remover handle 07936 3710100 Puller shaft nut 07931 ME40000 07931 MEA010B and 07931 HB3020A U S A only Pilot 17 mm 07746 0040400 Ho...

Page 430: ...el too low Worn or damaged pinion gear and or pinion joint splines Oil leak Clogged breather Oil level too high Damaged seals Loose case cover bolts Excessive rear wheel backlash Worn drive shaft spli...

Page 431: ...final drive gear case assembly from the swingarm Remove the drive shaft from the gear case by gently turning the drive shaft and pulling it Remove the spring oil seal and stopper ring from the drive...

Page 432: ...NOTE Perform the backlash inspection and contact pattern check whenever you replace the pinion gear ring gear bearings and gear case The extension lines from the gear engagement surfaces should inter...

Page 433: ...For ring gear shim replacement page 14 12 For shaft shim replacement page 14 15 RING GEAR SHIMS SHAFT SHIMS A 1 82 mm 0 072 in A 1 73 mm 0 068 in B 1 88 mm 0 074 in B 1 76 mm 0 069 in C 1 94 mm 0 076...

Page 434: ...ches the gear case Install and tighten the two 10 mm bolts to the speci fied torque in several steps alternately TORQUE 47 N m 4 8 kgf m 35 Ibf ft Tighten the six 8 mm bolts to the specified torque in...

Page 435: ...y 0 1 mm 0 004 in Too Low PINION GEAR A 1 32 mm 0 B 1 38 mm 0 C 1 44 mm 0 D 1 50 mm 0 E 1 56 mm 0 F 1 62 mm 0 G 1 68 mm 0 SHIMS 052 in 054 in 057 in 059 in 061 in 064 in 066 in DRIVE FLANK SIDE For pi...

Page 436: ...the ring gear remove it as follows Remove the ring gear bearing using a commercially available bearing puller Select the replacement shim page 14 10 PINION GEAR REMOVAL Hold the gear case in a vise wi...

Page 437: ...the special tools onto the pinion gear shaft and gear case TOOLS Pinion puller base 07HMC MM80110 or 07HMC MM8011A U S A only Puller shaft nut 07931 ME40000 or 07931 ME4010B and 07931 HB3020A U S A on...

Page 438: ...g with the marked side facing up TOOLS Driver 40 mm I D 07746 0030100 Attachment 25 mm I D 07746 0030200 CASE BEARING REPLACEMENT RING GEAR BEARING Heat the gear case to 80 C 175 F evenly using a heat...

Page 439: ...Heat the gear case to 80 C 176 F and remove the needle bearing using the special tools NOTE Do not use a torch to heat the gear case it may cause warping TOOLS Bearing remover 20 mm 07936 3710600 Remo...

Page 440: ...E ASSEMBLY PINION GEAR INSTALLATION 14 17 DRIVER INNER RACES SHIM PINION GEAR O RING RETAINER LOCK PLATE A or B Drive the pinion gear assembly into the gear case using the special tool TOOLS Oil seal...

Page 441: ...e and install it into the p N nM retainer groove Hold the gear case in a vise with soft jaws Install the retainer into the gear case anc tighten it to the specified torque using a special tool TOOL Re...

Page 442: ...nt and joint nut onto the pinion gear shaft Hold the pinion joint with the special tools and tighten the pinion joint nut to the specified torque TOOLS Pinion holder 070MB 0010110 Pinion holder attach...

Page 443: ...using a hydraulic press TOOL Base 105 x 1115 x 65 mm 07ZMF MCA0200 Apply grease to a new oil seal lips Install a new oil seal until it is flush with the cover surface using the special tools TOOL Base...

Page 444: ...load STANDARD 0 3 1 1 N m 0 03 0 11 kgf cm 0 2 0 8 Ibf ft If the preload reading does not fall within the speci fication check the bearings for proper installation FINAL DRIVE INSTALLATION Check that...

Page 445: ...molybdenum disulfide grease to the universal joint side splines of the drive shaft Insert the final drive assembly into the swingarm and align the drive shaft splines with the universal joint splines...

Page 446: ...ear case page 14 8 Release the clamp and disconnect the VS sensor 3P Black connector Remove the side gear case mounting bolts NOTE When removing the side gear case mounting bolts 65 mm note the locati...

Page 447: ...move and discard the bearing if the races do not turn smoothly quietly or if they fit loosely in the crankcase BEARING REPLACEMENT Remove the side gear case assembly page 14 22 Remove the final driven...

Page 448: ...older assembly Shim Dowel pin O ring Set the special tools to the final shaft assembly TOOLS Bearing separator set 07931 4630000 Recoil pulley holder 07SMB HM70100 Compress the damper spring and remov...

Page 449: ...R COLLAR Check the damper collar slot for damage or exces sive wear Measure the I D of damper collar SERVICE LIMIT 18 05 mm 0 711 in FINAL SHAFT Measure the O D of the final shaft at the damper collar...

Page 450: ...ving the side gear case bolts 60 mm note the location of the bolts Turn the final shaft and check that the final shaft and output shaft turn smoothly and quietly without binding If the shafts do not t...

Page 451: ...HAFT SHAFT HOLDER Remove the dial indicator and special tools Turn the final shaft 120 and measure backlash Repeat this procedure once more Compare the difference of the three measurements Backlash di...

Page 452: ...he selected shim Install the final shaft bearing holder assembly into the gear case Apply engine oil to the bolts threads and seating surface and tighten the bolts to the specified torque TORQUE 31 N...

Page 453: ...n is not correct remove and replace the output shaft shim Replace the shim with a thinner one if the contact pattern is too high toward the face Replace the shim with a thicker one if the contact patt...

Page 454: ...threads and seating surface and tighten the bolts to the specified torque TORQUE 31 N m 3 2 kgf m 23 Ibfft Recheck the contact pattern page 14 29 FINAL SHAFT DISASSEMBLY Hold the side gear case in a v...

Page 455: ...and final shaft bearing holder assembly from the side gear case NOTE When removing the side gear case bolts 60 mm note the location of the bolts Remove the shim O ring and dowel pin Press the drive g...

Page 456: ...inal shaft threads STOPPER RING OUTPUT SHAFT DISASSEMBLY Hold the side gear case in a vise with soft jaws Remove the stopper ring and oil seal OIL SEAL Hold the output shaft and remove the inner lock...

Page 457: ...tool TOOL Lock nut wrench 36 x 47 8 mm 07916 MB00002 Remove the bolts and output shaft bearing holder assembly from the side gear case BOLTS Remove the shim and O ring O RING SHIM Press the output sh...

Page 458: ...ilot 30 mm 07749 0010000 07746 0010500 07746 0040700 TOOLS Bearing remover 17 mm Remover handle Remover weight 07936 3710300 07936 3710100 07741 0010201 or 07936 371020A U S A only DRIVER ATTACHMENT P...

Page 459: ...g into the gear case with marked side facing up TOOLS Driver 07749 0010000 Attachment 42 x 47 mm 07746 0010300 Pilot 17 mm 07746 0040400 Press a new bearing into the bearing holder with the marked sid...

Page 460: ...16 in shim for initial referencs page 14 30 O RING Hold the side gear case in a vise with soft jaws Install the bearing holder into the side gear case aligning with the bolt holes Apply engine oil to...

Page 461: ...U S A 07916 MB00002 07KMK HC50101 Stake the inner lock nut to the output shaft groove Stake the outer lock nut to the bearing holder groove Apply grease to the oil seal lip of a new oil seal and inst...

Page 462: ...T Press a new bearing into the bearing holder with the marked side facing up DR VER TOOLS Driver Attachment 62 x 68 mm Pilot 30 mm 07749 0010000 07746 0010500 07746 0040700 ATTACHMENT PILOT If the fin...

Page 463: ...Hold the gear case in a vise with soft jaws Apply engine oil to the threads and seating surface of a new outer lock nut and tighten it to the speci fied torque using a specia tool TOOL Lock nut wrench...

Page 464: ...e side gear case bolts 60 mm note the location of the bolts Remove the following Final shaft bearing holder assembly Shim Dowel pin Install the following to the final shaft assembly Damper spring Damp...

Page 465: ...ters are seated in the groove Coat a new O ring with engine oil and install it into the final shaft assembly groove Install the following Dowel pin Shim Final shaft assembly Apply engine oil to the bo...

Page 466: ...de gear case mounting bolt threads Tighten the 65 mm bolts to the specified torque TORQUE 31 N m 3 2 kgf m 23 Ibf ft Tighten the 60 mm bolts to the specified torque again TORQUE 31 N m 3 2 kgf m 23 Ib...

Page 467: ...IVE Install the final driven gear and new snap ring NOTE Install the snap ring with its rolled edge facing the engine side Install the following N D clutch assembly page 11 88 Right crankcase cover pa...

Page 468: ...15 FRONT WHEEL SUSPENSION STEERING COMPONENT LOCATION 15 2 FRONT WHEEL 15 10 SERVICE INFORMATION 15 3 FORK 15 16 TROUBLESHOOTING 15 5 STEERING STEM 15 25 HANDLEBAR 15 6 15 15 1...

Page 469: ...FRONT WHEEL SUSPENSION STEERING COMPONENT LOCATION 15 2...

Page 470: ...or equivalent Fluid level 105 4 1 Fluid capacity 475 2 5 cm3 16 1 0 08 US oz 16 7 0 09 Imp oz Steering head bearing preload 11 9 15 6 N 1 2 1 6 kgf TORQUE VALUES Handlebar mounting nut 55 N m 5 6 kgf...

Page 471: ...aring remover shaft 07GGD 0010100 Ball race remover C7953 MJ10000 Attachment 42 x 47 mm 07746 0010300 Bearing remover head 20 mm 07746 0050600 Driver attachment 07947 KF00100 Driver shaft 07949 371000...

Page 472: ...n wheel bearings Faulty tire Unbalanced tire and wheel Axle fastener not tightened properly Wheel hard to turn Faulty wheel bearings Bent axle Brake drag page 17 6 Soft suspension Low fluid level in f...

Page 473: ...the screws and left handlebar switch hous ing Disconnect the front brake light switch wire connec tors from the switch Remove the bolts holder and master cylinder assembly NOTE Keep the reservoir upr...

Page 474: ...TE Route the cable hose and wires properly page 1 20 If the throttle grip was removed clean the inside surface of the right handlebar grip and the outside surface of the throttle pipe Apply Honda bond...

Page 475: ...ROTTLE HOUSING Install the handlebar and nuts Tighten the nuts to the specified torque TORQUE 55 N m 5 6 kgf m 41 lbf ft Install tha clamps and bolts Tighten the bolts securely Install the switch thro...

Page 476: ...and tighten the upper bolt first then tighten the lower bolt Connect the front brake light switch connectors Clean the inside surface of the right handlebar grip and the outside surface of the throttl...

Page 477: ...d left front side cowls page 3 5 Install the upper and lower handlebar covers page 3 6 FRONT WHEEL Do nor operate the brake lever and peoal after removing the wheel To do so will cause difficulty in f...

Page 478: ...e runout using a dial indicator Actual runout is 1 2 the total indicator reading SERVICE LIMIT 0 2 mm 0 008 in WHEEL BEARING Replace the wheel bearings in pairs Turn the inner race of each bearing wit...

Page 479: ...next to the valve stem Remount the tire if necessary Mount the tire with the arrow mark facing in the direction of rotation Remove the dust seals from the wheel Mount the wheel tire and brake disc as...

Page 480: ...r head into the bearing bearings in pairs From the opposite side of the wheel install the Do not reuse old remover shaft and drive the bearing out of the bearing wheel hub Remove the distance collar a...

Page 481: ...left bearing squarely with the marked side facing up until it is seated on the collar TOOLS Driver Attachment 42 x 47 mm Pilot 20 mm 07749 0010000 07746 0010300 07746 0040500 NOTE Replace the wheel be...

Page 482: ...t and left side collars Place the front wheel between the fork legs so the brake disc is positioned between the brake pads Apply thin coat of grease to the axle shaft sliding surface Insert the axle s...

Page 483: ...he axle and check brake operation Tighten the left axle pinch bolts to the specified torque TORQUE 22 N m 2 2 kgf m 16 lbf ft REMOVAL Remove the following Front wheel page 15 10 Front fender page 3 12...

Page 484: ...the dust seal Do not scratch the Remove the oil seal stopper ring fork tube sliding surface The fork cap is Remove the fork cap from and O ring under spring pressure use care when loosening it FORK P...

Page 485: ...n Remove the fork center socket bolt and turns with the fork washer center socket bolt temporarily install the fork spring spring seal collar and fork cap Do not remove the Remove the fork piston and...

Page 486: ...N FORK SPRING Measure the fork spring free length SERVICE LIMIT 435 6 mm 17 15 in BACK UP RING OIL SEAL SLIDER BUSHING FORK TUBE SUDER PISTON Check the fork ube and fork slider for score marks and exc...

Page 487: ...ork tube runout with a dial indicator Actual runout is 1 2 the total indicator reading SERVICE LIMIT 0 20 mm 0 008 in Visually inspect the slider and guide bushings Replace the bushings if there is ex...

Page 488: ...LING WASHER OIL SEAL 3 351 SLIDER BUSHING FORK PROTECTOR DUST SEAL t i l l STOPPER RING FORK Install the fork tube bushing being careful not to damage the coating of the bushing if it has been removed...

Page 489: ...ld the fork slider in a v se with soft jaws Apply a locking agent to the fork center socket bolt threads Install the socket bolt with a new sealing washer Tighten the fork center socket bolt to the sp...

Page 490: ...ss the fork tube fully Measure the fluid level from the top of the fork tube FORK FLUID LEVEL 105 mm 4 1 in Pull the fork tube up and install the fork spring with the tapered side tightly wound coil s...

Page 491: ...eering stem and top bridge Align the top end of the fork tube with the upper surface of the top bridge Tighten the fork bottom bridge pinch bolts to the specified torque TORQUE 40 N m 4 1 kgf m 30 Ibf...

Page 492: ...ve the fork legs page 15 16 Straighten the lock washer tats Remove the steering top thread lock nut and lock washer Loosen the steering top thread using the special tool TOOL Steering stem socket 0791...

Page 493: ...ver shaft 07949 3710001 Install the stem nut ontc the stem to prevent the threads from being damaged when removing the lower bearing inner race Remove the lower bearing inner race with a chisel or equ...

Page 494: ...TOP THREAD UPPER DUST SEAL STEM UPPER STEERING BEARING v LOWER OUTER RACE LOWER STEERING BEARING LOWER INNER RACE LOWER DUST SEAL STEERING Apply 3 5 g 0 1 0 2 oz of specified grease to each new steer...

Page 495: ...ighten the top thread to the specified torque TOOL Steering stem socket 07916 3710101 TORQUE 34 N m 3 5 kgf m 25 Ibf ft Recheck that the steering stem moves smoothly without play or binding Install a...

Page 496: ...ring stem moves smoothly wi hout play or binding Install the following Front wheel page 15 15 Front fender page 3 12 Handlebar page 15 7 STEERING BEARING PRE LOAD NOTE Make sure there is no cable wire...

Page 497: ...16 REAR WHEEL SUSPENSION COMPONENT LOCATION SERVICE INFORMATION TROUBLESHOOTING 16 2 REAR WHEEL 16 6 16 3 SHOCK ABSORBER 16 6 16 5 SWINGARM 16 8...

Page 498: ...REAR WHEEL SUSPENSION COMPONENT LOCATION 44 N m 4 5 kgf m 32 Ibf ft 127 N m 13 0 kgf m 94 Ibf ft 44 N m 4 5 kgf m 32 Ibf ft 80 Ibf ft 16 2...

Page 499: ...less than the torque actually applied to the lock nut The specification given is the actual torque applied to the lock nut not the read ing on the torque wrench Do not overtighten the lock nut The spe...

Page 500: ...REAR WHEEL SUSPENSION...

Page 501: ...aged shock absorber rubber mounts Damaged swingarm pivot bearings High tire pressure Rear suspension noise Loose suspension fasteners Worn shock absorber rubber mounts Faulty rear shock absorber Rear...

Page 502: ...ified torque TORQUE 108 N m 11 0 kgf m 80 Ibf ft Install the m uffler page 3 16 INSPECTION WHEEL RIM Check the rim runout by placing the wheel in a true ing stand Spin the wheel slowly and read the ru...

Page 503: ...otor with a sharp 30 8 mm 1 21 in drill bit NOTE Point the valve away from you to prevent debris getting in your eyes Before disposal of the shock absorber release the nitrogen by pressing the valve c...

Page 504: ...Rear wheel page 16 6 Final drive gear case page 14 8 Remove the bolts and clamps Remove the shock absorber lower mounting nut and bolt Release the joint boot from the side gear case Check the boot for...

Page 505: ...plires for wear or damage If damaged check the splines of the output driven gear shaft and drive shaft also Remove the richt and left pivot collar and dust seals from the swingarm pivot Check the dust...

Page 506: ...nd pivot needle bearing from the left swingarm pivot using the spe cial tool and a hydraulic press TOOLS Driver handle Attachment 28 x 30 mm 07949 3710001 07946 1870100 TOOLS Driver Attachment 37 mm P...

Page 507: ...ARING SNAP Pack new needle bearing with specified grease Press the right needle bearing in right swingarm pivot with the marking side facing up using the spe cial tools and a hydraulic press TOOLS Dri...

Page 508: ...1 Attachment 22 x 24 mm 07746 0010800 Pilot 17mm 07746 0040400 A SSEM BLY JOINT BOOT NEEDLE BEARING NEEDLE BEARING DUST SEAL PIVOT COLLAR PIVOT COLLAR DUST SEAL _55S b DUST SEAL SHOCK ARM COLLAR Insta...

Page 509: ...the pivot nut to the specified torque TORQUE 127 N m 13 0 kgf m 94 lbf ft Tighten the pivot pinch bolts to the specified torque TORQUE 34 N m 3 5 kgf m 25 lbf ft Apply 1 g 0 04 oz of molybdenum disulf...

Page 510: ...wer ing bolt to the spccificd torque TORQUE 44 N m 4 5 kgf m 32 Ibf ft Install and tighten the clamps and bolts securely Install the following Final drive gear case page 14 21 Rear wheel page 16 6 Rig...

Page 511: ...TING 17 6 BRAKE FLUID REPLACEMENT AIR BLEEDING 17 7 BRAKE PAD DISC 17 14 FRONT MASTER CYLINDER 17 20 REAR MASTER CYLINDER 17 24 PROPORTIONAL CONTROL VA LV E 17 29 FRONT BRAKE CALIPER 17 30 REAR BRAKE...

Page 512: ...HYDRAULIC BRAKE COMPONENT LOCATION FRONT...

Page 513: ...HYDRAULIC BRAKE REAR 45 N m 4 6 kgf m 33 lbf ft PARKING 23 lbf ft 17 3...

Page 514: ...ngy the system must be bled Always check brake operation before riding the motorcycle SPECIFICATIONS Unit mm in ITEM STANDARD SERVICE LIMIT Front Specified brake fluid DOT 4 Brake disc thickness 3 9 4...

Page 515: ...unting bolt Brake pipe joint nut Front brake caliper pin Front brake caliper bracket pin Rear brake caliper pin Rear brake caliper bracket pin 5 4 N m 0 6 kgf m 4 0 lbf ft 17 2 N m 1 8 kgf m 12 7 lbf...

Page 516: ...ston Sticking worn master piston Contaminated master cylinder Bent brake lever pedal Brake lever pedal hard Clogged restricted hydraulic system Sticking worn caliper piston Caliper not sliding properl...

Page 517: ...linder reservoir is level before removing the reservoir cap Remove the screws and reservoir cap Remove the set plate and diaphragm Connect a commercially available brake breeder to the front brake cal...

Page 518: ...ke fluid Connect a commercially available brake bleeder to the rear brake caliper bleed valve Loosen the bleed valve and operate an air bleed tool Drain the brake fluid BRAKE FLUID FILLING BLEEDING Br...

Page 519: ...eeder to the front brake saliper upper bleed valve Operate the brake bleeder and loosen the bleed valve If an automatic refill system is not used add brake fluid when the fluid level in the reservoir...

Page 520: ...cially available brake bleeder to the left front brake caliper bleed valve Loosen the bleed valve and operate an air bleed tool If an automatic refill system is not used add brake fluid when the fluid...

Page 521: ...valve 1 4 turn and then close it 2 Release the brake pedal slowly and wait several seconds after it reaches the end of its travel 3 Repeat steps 1 and 2 until a sufficient amount of the fluid flows ou...

Page 522: ...the system again Connect a commercially available brake bleeder to the left front brake caliper bleed valve Loosen the bleed valve and operate an air bleed tool If an automatic refill system is not u...

Page 523: ...te that you may feel strong resistance on the rear brake pedal during pumping to bleed air from the caliper This symptom is caused by the proportional control valve function Be sure to push the rear b...

Page 524: ...luid level in the lation of new brake pads reservoir as this operation causes the level to rise Loosen the pad pin Pull the pad pin out of the caliper body while push ing in the pads against the pad s...

Page 525: ...ORQUE 17 2 N m 1 8 kgf m 12 7 Ibfft Operate the brake lever to seat the caliper piston against the pads REAR Remove the muffler page 3 16 Check the brake Push the caliper piston all the way in to allo...

Page 526: ...all the brake pads into the caliper so their ends brake pads in pairs 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...

Page 527: ...m 0 26 kgf m 0 18 lbf ft Operate the brake pedal to seat the caliper piston against the pads PARKING Remove the bolts and clamps Remove the pad pins and brake pad of the wheel side Do not reuse the Re...

Page 528: ...the brake pad final drive side Install the parking brake caliper Do not reuse the Install and tighten new mounting bolts to the speci bolts fied torque TORQUE 31 N m 3 2 kgf m 23 Ibf ft Install the br...

Page 529: ...warpage with a dial indica tor SERVICE LIMITS FRONT REAR 0 30 mm 0 012 in Check the bearing for excessive play if the warpage exceeds the service limit Replace the brake disc if the bearings are norma...

Page 530: ...the brake fluid from the hydraulic system page 17 7 Remove the oil bolt and sealing washers and dis connect the brake hose SEALING WASHERS Disconnect the front brake light switch connectors Remove th...

Page 531: ...Clean the master cylinder reservoir and master pis ton in clean brake fluid INSPECTION Check the piston cups for wear deterioration or damage Check the spring for fatigue or damage Check the master cy...

Page 532: ...ke fluid Install the spring onto the piston end Do not allow the Install the master piston spring into the master cyl piston cup lips to inder turn inside out 1 5 N m 0 2 kgf m 1 1 Ibf ft SET PLATE DI...

Page 533: ...0 1 kgf m 0 9 lbf ft Apply silicone grease to the brake lever pivot and brake piston contacting surface of the lever Install the brake lever and pivot bolt and tighten it to the specified torque TORQU...

Page 534: ...17 8 I SEALING WASHERS REAR MASTER CYLINDER NOTE When removing the pipe joint nut cover the end of the pipe to prevent contamination REMOVAL Drain the brake fluid from the hydraulic system page 17 7...

Page 535: ...BLY Remove the snap ring reservoir hose joint Remove the O ring from the hose joint JOINT PIN Remove the boot from the master cylinder body Remove the snap ring from the master cylinder body using the...

Page 536: ...Check the piston cups and boot for wear deteriora tion or damage Check the spring for fatigue or damage Check the master cylinder and piston for scoring scratches or damage Measure the master cylinder...

Page 537: ...sembly into the master cylin der and snap ring into the groove in the master cyl inder using a special tool TOOL Snap ring pliers 07914 SA50001 Install the snap ring with the chamfered edges facing th...

Page 538: ...he bolt securely Install the rear master cylinder and tighten the bolts securely Connect the brake pipe to the rear master cylinder Apply brake fluid to the brake pipe joint nut threads and tighten it...

Page 539: ...ination REMOVAL INSTALLATION Remove the right front side cowl page 3 5 Drain the brake fluid from the hydraulic system page 17 7 Loosen the brake pipe joint nuts and disconnect the brake pipe Remove t...

Page 540: ...m page 17 7 Remove the brake pads page 17 14 Remove the oil bolts and sealing washers Do not reuse the Remove the mounting bolts and caliper assembly bolts DISASSEMBLY Disassemble the bracket from the...

Page 541: ...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 right caliper cylinder I...

Page 542: ...caliper Coat the caliper pistons with clean brake fluid and install them into the caliper cylinders with the open ing toward the pads Apply Honda bond A or equivalent to the installing surface of the...

Page 543: ...ts to the specified torque TORQUE 35 N m 3 6 kgf m 26 lbf ft Install the brake pads page 17 14 Fill and bleed the hydraulic system page 17 8 REAR BRAKE CALIPER REMOVAL NOTE When removing the oil bolt...

Page 544: ...ing Caliper bracket Pad retainer Pad spring Pin boots Place a shop towel over the pistons Position the caliper body with the piston facing down and apply small squirts of air pressure to the fluid inl...

Page 545: ...m 4 0 Ibf ft DUST SEAL PAD REATAINER S l H CALIPER PIN BOOT 2 5 N m 0 26 kgf m 1 8 Ibf ft CALIPER BRACKET BRACKET PIN PAD SPRING BOOT H I Ufl PISTON SEAL 17 2 N m 1 8 kgf m 13 Ibf ft Coat new piston s...

Page 546: ...ting bolt to the speci fied torque TORQUE 45 N m 4 6 kgf m 33 lbf ft Install the brake hose eyelet to the caliper body with new sealing washers and oil bolt Push the brake hose eyelet to the stopper o...

Page 547: ...e caliper pin bolt Remove the following Caliper bracket Pad retainer Pad spring Pin boots Collar Remove the brake arm while holding the brake arm Remove the brake arm Remove the brake shaft boot BOOTS...

Page 548: ...e dust seal Clean the caliper cylinder and brake shaft sliding surface INSPECTION Check the caliper cylinders and pistons for scoring scratches or damage Measure the caliper cylinder I D SERVICE LIMIT...

Page 549: ...age Check the adjust bolt for wear or damage ADUST BOLT BOOT CALIPER BRAKE SHAFT ASSEMBLY BARKE PAD BRACKET SNAP RING WASHER PAD PIN DUST SEAL PIN BOOT BRAKE SHAFT ADUST BOLT Apply silicone grease to...

Page 550: ...ts convex side facing snap ring side Install the snap ring into the adjust bolt groove Apply silicone grease to the parking brake shaft threads Install the parking brake shaft to the caliper Make sure...

Page 551: ...Install the brake shaft boot to the caliper groove Install the brake arm aligning with the punch marks Install and tighten the lock nut Install the following Pad retainer Pad spring Pin boots Collar C...

Page 552: ...he following Rear wheel speed sensor page 18 22 Brake pads page 17 17 PARKING BRAKE INSPECTION Release the parking brake lever lock Pull the parking brake lever slowly and check the parking brake leve...

Page 553: ...ever slowly and check the parking brake lever stroke STANDARD 3 6 notches ALL STROKE 9 notches If the parking brake lever stroke is out of specifica tion adjust again REMOVAL INSTALLATION PARKING BRAK...

Page 554: ...p bracket Release the rear brake light switch spring and return spring Remove the cotter pin and joint pin Remove the push rod from the brake pedal Remove the nut washer socket bolt and brake pedal fr...

Page 555: ...lar sliding surface Install the dust seals and collar to the brake pedal Install the brake pedal socket bolt washer and nut Install the push rod and joint pin to the brake pedal Secure the joint pin u...

Page 556: ...C BRAKE Hook the rear brake light switch spring and return spring Install the right step bracket and tighten the bolts Install the following Right under cowl page 3 11 Right shroud page 3 8 STEP RRACK...

Page 557: ...ABS ABS SYSTEM LOCATION 18 2 ABS SYSTEM DIAGRAM 18 3 SERVICE INFORMATION 18 4 ABSTROUBLESHOOTING INFORMATION 18 5 ABS INDICATOR PROBLEM CODE INDEX 18 8 TROUBLESHOOTING 18 9 WHEEL SPEED SENSOR 18 21 AB...

Page 558: ...2P BLUE CONNECTOR For each parts inspection and service refer to the following 1 Front wheel speed sensor 2P Blue connector Right front side cowl page 3 5 2 Rear wheel speed sensor 2P Orange connecto...

Page 559: ...WITCH R i R o R BI SV01 front 71 PULSER ring TIRE SIZE 0 41 FRONT WHEEL LOCK X43 REAR WhEEL LOCK 0 2 3 REAR ABS SERVICE CONNECTORy3P SCS GD GD S 2D Number of ABS indicator blinks Bl Black Y Yellow Bu...

Page 560: ...one Write down the problem code and proba ble faulty part before starting diagnosis and troubleshooting ABS control unit ECU can record only the first problem data detected while the ignition switch...

Page 561: ...If the ABS indicator blinks because problem is detected during the pre start self diagnosis See page 18 5 If the ABS indicator does not come on when the ignition switch is turned ON or the ABS indica...

Page 562: ...eing output Note that turning the ignition switch to ON again does not indicate the problem code To show the problem code again repeat the problem code retrieval procedures from the beginning Do not a...

Page 563: ...for 2 seconds and go off 2 Release the brake lever immediately after the ABS indicator is off The ABS indicator should come on 3 Squeeze the brake lever immediately after the ABS indicator is on The...

Page 564: ...nuously run bumpy roads The front wheel leaves the ground for a long time when riding wheelie Only either the front or rear wheel rotates The ABS operates continuously The ABS control unit has been di...

Page 565: ...6 NO PROBLEM CODE FAILURE ABS INDICATOR DOES NOT COME ON when the ignition switch turned ON 1 Combination M eter Power ground Line Inspection Check the combination meter power and ground lines page 22...

Page 566: ...lue wire between the fuse box and ABS modulator NO Intermittent failure Replace the ABS MAIN fuse 10 A with a new one and recheck 3 ABS Power Input Line Open Circuit Inspection Install the ABS MAIN fu...

Page 567: ...onnector con nected short the Red black wire terminal o the combination meter and ground with a jumper wire Check the ABS indicator with the ignition sv itch turned ON CONNECTION Red black Ground Does...

Page 568: ...d the front wheel speed sensor Check that there is no iron or other magnetic deposits between the pulser ring and wheel speed sensor and check the pulser ring slots for obstructions Check installation...

Page 569: ...eck for continuity at the front wheel speed sensor 2P connector terminals of the wire har ness side Is there continuity NO Open circuit in wire between the ABS modulator and speed sensor YES GO TO STE...

Page 570: ...ea around the rear wheel speed sensor Check that there is no iron or other magnetic deposits between the pulser ring and wheel speed sensor and check the pulser ring slots for obstructions Check insta...

Page 571: ...inals of the wire harness side rear wheel speed sensor 2P con nector Is there continuity NO Open circuit in wire between the ABS modulator and speed sensor YES GO TO STEP 6 ABS MODULATOR 25P CONNECTOR...

Page 572: ...ion Check the ABS MOTOR fuse 30 A in the fuse box for blown Is the fuse b lo w n YES GO TO STEP 2 NO GO TO STEP 3 2 M otor Power Input Line Short Circuit Inspection Disconnect the ABS modulator 25P co...

Page 573: ...STEP 4 4 Failure Reproduction Turn the ignition switch OFF Connect the ABS modulator 25P connector Erase the problem code page 18 7 Test ride the motorcycle above 10 km h 6 mph Retrieve the problem c...

Page 574: ...e ABS modulator 25P connector Measure the voltage between the ABS modula tor 25P connector from the wire harness side There should be battery voltage at all times CONNECTION Black Green Orange Is ther...

Page 575: ...ween the fuse box and ABS modulator NO Intermittent failure Replace the ABS MAIN fuse 10 A with a new one and recheck 3 ABS Power nput Line Open Circuit Inspection Install the ABS MAIN fuse Disconnect...

Page 576: ...orrect tire size Deformation of the wheel or tire 1 Failure Reproduction If the above items are normal recheck the prob lem code indication Erase the problem code page 18 7 Test ride the motorcycle ab...

Page 577: ...cification STANDARD 0 2 1 2 mm 0 01 0 05 in The sensor air gap cannot be adjusted If it is not within specification check each installa tion part for deformation looseness and damage REMOVAL INSTALLAT...

Page 578: ...and pulser ring page 18 21 REAR Remove the rear brake pads page 17 15 Remove the main seat page 3 4 Disconnect the rear wheel speed sensor 2P lOrange connector Remove the bolts and rear wheel speed s...

Page 579: ...he pipe joint nut cover the end of the pipe to prevent contamination Be careful not to bend or damage the brake pipes Drain the brake fluid from the front and rear hycrau lic systems page 17 7 Loosen...

Page 580: ...NSTALLATION Install the modulator to the bracket and tighten the mounting bolts Apply brake fluid to the brake pipe joint nut threads Connect the brake pipe and tighten the brake pipe joint nut to the...

Page 581: ...ake pipes and tighten the brake pipe joint nuts to the specified torque TORQUE 14 N m 1 4 kgf m 10 Ibf ft Connect the ABS modulator 25P connector and push down the ABS modulator connector lock Fill an...

Page 582: ...HARGING SYSTEM COMPONENT LOCATION 19 2 BATTERY 19 6 SYSTEM DIAGRAM 19 2 CHARGING SYSTEM INSPECTION 19 7 SERVICE INFORMATION 19 3 ALTERNATOR CHARGING COIL 19 8 TROUBLESHOOTING 19 5 REGULATOR RECTIFIER...

Page 583: ...BATTERY CHARGING SYSTEM COMPONENT LOCATION REGULATOR RECTIFIER SYSTEM DIAGRAM MAIN FUSE 4 0 A...

Page 584: ...ntually die out For this reason the charging system is often suspected as the problem Battery overcharge often results from problems in the battery itself which may appear to be an overcharging sympto...

Page 585: ...BATTERY CHARGING SYSTEM TOOLS Motorcycle battery analyzer Micro 404XL U S A only Christie battery charger MC1012 2T U S A only...

Page 586: ...ition switch 4 ALTERNATOR CHARGING COIL INSPECTION Check the alternator charging coil page 19 8 Is the alternator charging coil resistance w ithin 0 1 1 0 Q 20 C 68 F NO Faulty charging coil YES GO TO...

Page 587: ...BLE BATTERY VOLTAGE INSPECTION Remove the side cover pillion seat page 3 4 Measure the battery voltage using a commercially available digital multimeter VOLTAGE 20 C 68 F Fully charged 13 0 13 2 V Und...

Page 588: ...uit is the probable cause Locate the short by disconnecting connections one by one and measuring the current NEGATIVE CABLE PROBE CHARGING VOLTAGE INSPECTION Do not disconnect the battery or any cable...

Page 589: ...ack connec tor and alternator 3P Black connector and check it for loose contact or corroded terminals If the regulated voltage reading page 19 7 is out of the specification measure the voltage between...

Page 590: ...NITION SYSTEM COMPONENT LOCATION SYSTEM DIAGRAM 20 2 20 2 IGNITION SYSTEM INSPECTION IGNITION COIL 20 5 20 8 SERVICE INFORMATION 20 3 IGNITION TIMING 20 8 TROUBLESHOOTING 20 4 SIDESTAND SWITCH 20 9 20...

Page 591: ...TEM DIAGRAM SID E STAND SWITCH J T MAIN FUSE IG N IT IO N 40A SWITCH SUB FUSE 20A cr _o SUB FUSE 10A cr _o F I IGN PUMP RELAY l BI o m ENGINE STOP SWITCH BATTERY CMP CKP SENSOR SENSOR 0 O r Y NEUTRAL...

Page 592: ...eed to be adjusted since the ECM is factory preset A faulty ignition system is often related to poor connections Check those connections before proceeding Make sure the battery is adequately charged U...

Page 593: ...ircuit in Blue black or Yellow white wire between the ignition coils and ECM 6 Faulty side stand switch or neutral switch 7 Loose or poor connection or an open circuit in No 7 related wires Side stand...

Page 594: ...ltimeter or use the peak voltage tester TOOLS Imrie diagnostic tester model 625 or Peak voltage adaptor 07HGJ 0020100 with commercially available digital multimeter impedance 10 MQ DCV minimum IGNITIO...

Page 595: ...page 20 4 Check the neutral position of neutral drive clutch Crank the engine with the starter motor and mea sure the ignition coil primary peak voltage PEAK VOLTAGE 100 V minimum NOTE Although measu...

Page 596: ...the ECM connector is abnormal measure the peak voltage at the CKP sen sor connector Disconnect the CKP sensor 2P Red connector and connect the peak voltage tester or adaptor probes to the connector t...

Page 597: ...is in the reverse order of removal plug wires properly page 1 20 IGNITION TIMING Start the engine warm it up to normal operating temperature and then stop it Remove the timing hole cap COIL FRONT IGN...

Page 598: ...ct inspect the ECM and CKP sensor Stop the engine and connect the timing light to the front cylinder spark plug wire Check the ignition timing at the front cylinder Coat a new O ring with engine oil a...

Page 599: ...sidestand retracted and no continuity with the sidestand low ered REMOVAL Remove the following Main seat page 3 4 Left side cover page 3 15 Disconnect the sidestand switch 2P Green connec tor Release...

Page 600: ...ove with the side stand switch spring shaft Install the sidestand switch bolt and tighten it to the specified torque TORQUE 10 N m 1 0 kgf m 7 Ibf ft Install the sidestand switch wire to the clamps Co...

Page 601: ...21 ELECTRIC STARTER COMPONENT LOCATION 21 2 STARTER MOTOR 21 6 SYSTEM DIAGRAM 21 2 NEUTRAL SWITCH RELAY 21 15 SERVICE INFORMATION 21 3 STARTER RELAY SWITCH 21 15 TROUBLESHOOTING 21 4 21 21 1...

Page 602: ...ELECTRIC STARTER COMPONENT LOCATION ENGINE STOP SWITCH SYSTEM DIAGRAM 21 2...

Page 603: ...motor could suddenly start causing serious injury The starter m otor can be serviced w ith the engine in the frame When checking the starter system always follow the steps in the troubleshooting flow...

Page 604: ...or cable Faulty starter relay switch page 21 15 NO Faulty starter m otor page 21 61 5 Relay Coil Ground Lines Inspection Disconnect the starter relay switch connector and check the continuity between...

Page 605: ...tarter relay switch connector Starter motor turns slowly Low battery voltage Poorly connected battery term inal cable Poorly connected starter m otor cable Faulty starter m otor Poorly connected batte...

Page 606: ...rter motor Remove the left under cov l page 3 11 Remove the rubber cap terminal nut and discon nect the starter m otor cable Remove the bolts Remove the starter motor Remove the O ring from the starte...

Page 607: ...Remove the armature from the starter m otor case Remove the brushes and springs from the brush holder Check for continuity between starter m otor cable term inal and positive brushes There should be...

Page 608: ...ontinuity Check for continuity between positive and negative brushes There should be no continuity Remove the screw and negative brushes Remove the term inal nut Remove the washer insulator term inal...

Page 609: ...h SERVICE LIMIT 6 5 mm 0 26 in i i Check the ccm m utator for damage or abnormal wear Check the com mutator bar for discoloration Clean the metallic debris off between commutator bars Replace the arma...

Page 610: ...dual com m utator bar and the armature shaft There should be no continuity Check the dust seal and bearing for wear or dam age Check the bearing rotates smoothly Check the bushing of the rear cover fo...

Page 611: ...HOLDER O RING TERMINAL STOPPER INSULATOR REAR COVER Install the brush holder positive brushes and termi nal bolt POSITIVE BRUSHES BRUSH HOLDER TERMINAL BOLT Install a new O ring terminal stopper insu...

Page 612: ...the term inal nut securely Install the negative brushes and tighten the screw securely Install the brush springs to the brush holder grooves TERMINAL STOPPER NEGATIVE BRUSHES SCREW SPRINGS Install the...

Page 613: ...may be damaged if the magnet pulls the armature against the case Install a new seal ring to the m otor case Install the motor case aligning its groove with the stopper on the rear cover assembly Inst...

Page 614: ...m otor groove Install the starter m otor to the crankcase and tighten the bolts Route the cable Connect the starter m otor cable properly Install and tighten the terminal nut to the specified page 1...

Page 615: ...lay terminals There should be continuity Installation is in the reverse order of removal STARTER RELAY SWITCH INSPECTION Remove the left seat cowl page 3 12 Operate the neutral drive clutch to the neu...

Page 616: ...voltage between the yellow red wire term inal and ground If the battery voltage appears when the starter switch button is pushed the power supply circuit of the relay coil is normal OPERATION CHECK D...

Page 617: ...move the socket bolts and cables Remove the starter relay switch Installation is in the reverse order of removal ______________________________ ELECTRIC STARTER i SOCKET BOLTS mmasBt STARTER RELAY SWI...

Page 618: ...AKE TAILLIGHT 22 9 COMBINATION METER 22 9 SPEEDOMETER VS SENSOR 22 12 TACHOMETER 22 13 OIL PRESSURE LEVEL WARNING INDICATOR 22 15 ECT SENSOR 22 16 FUEL LEVEL SENSOR 22 17 IGNITION SWITCH 22 19 HANDLEB...

Page 619: ...LIGHTS METERS SWITCHES COMPONENT LOCATION RIGHT 22 2...

Page 620: ...nuity test can be made w ith the switches installed on the motorcycle The following color codes used are indicated throughout this section Bu Blue G Green Lg Light Green R Red Bl Black Gr Gray O Orang...

Page 621: ...GHTS METERS SWITCHES TOOLS Imrie diagnostic tester model 625 Test probe or Peak voltage adaptor 07ZAJ RDJA110 07HGJ 0C20100 with com nercially available digital m ultim eter impedance 10 M12 DCV minim...

Page 622: ...an create hot spots that cause a bulb to break NOTE Wear clean gloves w hile replacing the bulb If you touch the bulb w ith your bare hands clean it with a cloth moistened with alcohol to prevent earl...

Page 623: ...clockwise then remove it from the turn signal light Remove the bulb from the bulb socket and replace it w ith a new one Check the O ring on the bulb socket is in good con dition and replace it if nece...

Page 624: ...d con dition and replace it if necessary Installation is in the reverse order of removal LICENSE LIGHT BULB REPLACEMENT Remove the tw o socket bolts and three nuts collars Remove the license light bra...

Page 625: ...e the license light bracket Remove the four nuts rear side reflector rubber m ount and license light case from license light bracket Remove the screws case bracket and nuts collars then separate the l...

Page 626: ...22 9 REMOVAL INSTALLATION Remove the grab rail page 3 3 Disconnect the turn signal light 2P and taillight 3P connectors Release the tabs and remove the brake taillight unit Route the taillignt Install...

Page 627: ...terminal of the combination meter 20P Gray connector and ground There should be battery voltage at all times If there is no voltage check the following Open circuit in the Red green wire Blown fuse CL...

Page 628: ...rd assembly from the rear cover Assembly is in the reverse order of disassembly INSTALLATION Install the com bination meter washers and screws Tighten the screws securely Connect the combination meter...

Page 629: ...a tion meter If pulse voltage does not appear check for open or short circuit in Pink wire If the Pink wire is OK check the VS sensor page 22 12 20P CONNECTOR VS SENSOR INSPECTION Remove the left unde...

Page 630: ...ge 1 20 Install the wires to the clamp Install the left jn d e r cowl page 3 11 TACHOMETER SYSTEM INSPECTION Check for loose or poor contact term inals at the combination meter 20P Gray and sub harnes...

Page 631: ...re the tachometer input peak voltage PEAK VOLTAGE 10 5 V minimum If the peak voltage is normal replace the com bina tion meter print board assembly page 22 11 If the measured value is below 10 5 V rep...

Page 632: ...witch Check the oil level page 4 11 Inspect the oil level switch page 11 105 5 se 5 se INDICATOR RESET PROCEDURE 1 Warm up the engine until the engine oil tempera ture reached 50 C when the cooling fa...

Page 633: ...page 6 65 Suspend the ECT sensor in a pan of coolant 1 1 mixture on an electric heating element and mea sure the resistance through the sensor as the cool ant heats up NOTE Soak the ECT sensor in coo...

Page 634: ...l sensor damage the sen Remove the O ring from the uoper fuel level sensor Install a new O ring to the upper fuel level sensor Be careful not to Install the upper fuel level sensor damage the sensor a...

Page 635: ...2 14 a 110 130 Q Replace the fuel pump assembly if fuel level sensor is out of specification LOWER FUEL LEVEL SENSOR INSPECTION Remove the fuel pump page 6 41 Connect the ohmmeter to the fuel pump 3P...

Page 636: ...cate properly check for open or short circuit in wire harness If the wire harness is good replace the fuel meter with a new one page 22 10 OPEN CIRCUIT FULL POSITION EMPTY POSITION F w m m F F i V_ J...

Page 637: ...S METERS SWITCHES Remove the socket bolts and ignition switch plate Disconnect ignition switch 2P Brown connector Remove the bolts and ignition switch Installation is in the reverse order of removal 2...

Page 638: ...rminals in each switch position Continuity should exist between the color coded wires as shown in the chart ENGINE STOP SWITCH BAT4 ENG STOP o o O COLOR W BI RJG STARTER SWITCH BAT5 HL IGN ST FREE o o...

Page 639: ...inuity w ith the brake lever squeezed and no continuity w ith the lever released o Rear Remove the right front side cowl page 3 5 Disconnect the rear brake light switch 2P White connector and check fo...

Page 640: ...nectors from the horn Remove the bolt and horn Route the horn wire Installation is in the reverse order of removal properly page 1 20 TURN SIGNAL RELAY INSPECTION Remove the right front side cowl page...

Page 641: ...or and ground CONNECTION Green Ground There should be continuity at all times SIGNAL LINE INSPECTION Short the turn signal relay 4P Natural connector terminals at the wire side CONNECTION Gray Black r...

Page 642: ...12 V battery is connected replace the headlight relay Installation is in the reverse order of removal MAIN RELAY INSPECTION Remove the left seat cowl page 3 12 Remove the main relay Connect an ohmmet...

Page 643: ...24 TROUBLESHOOTING ENGINE DOES NOT START OR POOR PERFORMANCE IS HARD TO START 24 2 AT HIGH SPEED 24 6 ENGINE LACKS POWER 24 3 POOR HANDLING 24 7 POOR PERFORMANCE AT LOW AND IDLE SPEED 24 5 24 24 1...

Page 644: ...or shorted spark plug wire Faulty CKP sensor Faulty CMP sensor Faulty ignition coil Faulty bank angle sensor or FI ignition relay Faulty ECM Faulty TCM Faulty engine stop switch Faulty HISS NO GO TO...

Page 645: ...ke dragging Worn or damaged wheel bearings Final gear bearing damaged YES G O TO STEP 3 3 Tire Pressure Inspection Check tire pressure Are the tire pressures low YES Faulty tire valve Punctured tire N...

Page 646: ...fuel pump page 6 41 Is the fuel pum p normal NO Faulty fuel pump YES G O TO STEP 10 10 Programed Fuel Injection System Inspection Check the fuel injection system page 6 5 Is the fuel injection system...

Page 647: ...ulty CMP sensor Faulty knock sensor POOR PERFORMANCE AT LOW AND IDLE SPEED 1 Spark Test Perform spark test Is there weak or interm ittent spark YES Faulty spark plug Fouled spark plug Loose or disconn...

Page 648: ...TEP 3 3 Programmed Fuel Injection System Inspection Check the fuel injection system page 6 5 Is the fuel injection system normal NO Faulty fuel injection system YES GO TO STEP 4 4 Valve Timing Inspect...

Page 649: ...ing head bearings Low tire pressure Either wheel is wobbling Excessive wheel bearing play Bent rim Improperly installed wheel hub Excessively worn swingarm pivot bearings Bent frame Motorcycle pulled...

Page 650: ...CRANKSHAFT CONNECTING ROD 13 6 CYLINDER COMPRESSION 9 6 CYLINDER HEAD ASSEMBLY 9 23 CYLINDER HEAD COVER INSTALLATION 9 32 CYLINDER HEAD COVER REMOVAL 9 6 CYLINDER HEAD DISASSEMBLY 9 15 CYLINDER HEAD I...

Page 651: ...G INFORMATION 6 11 PRIMARY DRIVEN GEAR 11 67 PROPORTIONAL CONTROL VALVE 17 29 RADIATOR COOLANT 4 15 RADIATOR RESERVE TANK 7 17 RADIATOR COOLING FAN 7 10 REAR BRAKE CALIPER 17 33 REAR FENDER 3 14 REAR...

Page 652: ...6 IGNITION SYSTEM 20 4 LUBRICATION SYSTEM 5 4 POOR HANDLING 24 7 POOR PERFORMANCE AT HIGH SPEED 24 6 POOR PERFORMANCE AT LOW AND IDLE SPEED 24 5 REAR WHEEL SUSPENSION 16 5 TURN SIGNAL LIGHT 22 6 TURN...

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Page 654: ...R G E L C C N TW X SOEMOO rtL t muiL TWO COLCflEOWIRS IEXAMPL YELLOWflEDl COLOR C0W 8 G RO UNO VARKING TUWSWTCH fuseros AVW EKS w ft I FO RfO lK o O O O PC S O J o o I o o OH o cacfi Q U 0 EiB i A ow...

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