Honda PCX150 2013 Page 128 Service Manual Download

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Summary of Contents for PCX150 2013

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Page 3: ...equent pages give detailed procedure Your safety and the safety of others is very important To help you make informed decisions we have provided s fety messages and other information throughout this manual Of course it is not practical or possible to warn you about all the hazards associated with servicing this vehicle You must use your own good judgement You will find important safety information...

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Page 5: ...VALVES CYLINDER PISTON DRIVE PULLEY DRIVEN PULLEY CLUTCH FINAL REDUCTION ALTERNATOR STARTER CRANKCASE CRANKSHAFT ENGINE REMOVAL INSTALLATION en FRONT WHEEL SUSPENSION STEERING en REAR WHEEL BRAKE SUSPENSION c u HYDRAULIC BRAKE a BATTERY CHARGING SYSTEM WU aE LIGHTS METERS SWITCHES u w WIRING DIAGRAM INDEX ...

Page 6: ...MEMO ...

Page 7: ...ENTIFICATION 1 3 SPECIFICATIONS 1 6 TORQUE VALUES 1 11 LUBRICATION POINTS 1 17 1111 8 L _ HARNESS ROUTING 13 MODEL 1 19 CABLE HARNESS ROUTING AFTER 13 MODEL 1 TECHNICAL FEATURE AFTER 13 MODEL 1 34 EMISSION CONTROL SYSTEMS 1 35 1 ...

Page 8: ...l wires as shown in the Cable and Harness Routing page 1 19 9 Do not bend or twist 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 systems Abbrev term Full term CBS Combined brake system CKP sensor Crankshaft Position sensor DLC Data Link Connector OTC ...

Page 9: ... model SERIAL NUMBERS The Vehicle Identification Number V I N 1 is stamped on the seat stay as shown The engine serial number 1 is stamped on the lower left side of the crankcase 1 13 model After 13 model INFORMATION 1 1 ...

Page 10: ...throttle body LABELS The color label 1 is attached on the inner right side of luggage box When ordering color coded parts always specify the designated color code The Emission Control Information Label 1 is attached on the inner left side of luggage box 1 4 13 model 1 After 13 model 1 1 Canada only ...

Page 11: ...INFORMATION The Safety Certification Label 1 is attached on the inner cover 13 model 1 After 13 model 1 1 ...

Page 12: ...e 27 00 Trail length 86 mm 3 4 in Fuel tank capacity 5 9 liter 1 56 US gal 1 30 Imp gal ENGINE Bore and stroke 58 0 x 57 9 mm 2 28 x 2 28 in Displacement 153 cm3 9 3 cu in Compression ratio 10 6 1 Valve train 2 valve single chain driven SOHC Intake valve opens at 1 mm 0 04 in lift 5 BTDC closes at 1 mm 0 04 in lift 35 ABDC Exhaust valve opens at 1 mm 0 04 in lift 30 0 BBDC closes at 1 mm 0 04 in l...

Page 13: ...l length 86 mm 3 4 in Fuel tank capacity 8 0 liter 2 11 US gal 1 76 Imp gal ENGINE Bore and stroke 58 0 x 57 9 mm 2 28 x 2 28 in Displacement 153 cm3 9 3 cu in Compression ratio 10 6 1 Valve train 2 valve single chain driven SOHC Intake valve opens at 1 mm 0 04 in lift 5 BTDC closes at 1 mm 0 04 in lift 35 ABDC Exhaust valve opens at 1 mm 0 04 in lift 30 BBDC closes at 1 mm 0 04 in lift 0 ATDC Lub...

Page 14: ...ter 1 0 US qt 0 8 Imp qt Recommended engine oil Pro Honda HP4M 4 stroke oil U S A and Canada or equivalent motor oil API service classification SJ or higher JASO T 903 standard MB Viscosity SAE 1OW 30 Oil pump rotor Oil pump body 1 0 23 150 23 180 0 9114 0 9126 Outer rotor 0 0 22 970 23 000 0 9043 0 9055 Body to outer rotor clearance 0 15 0 21 0 0059 0 0083 0 35 0 014 Oil pump body depth 7 020 7 0...

Page 15: ...t point 6 5 0 26 from bottom of skirt pin Piston pin bore I D 14 002 14 008 0 5513 0 5515 14 04 0 553 Piston pin 0 0 13 994 14 000 0 5509 0 5512 13 96 0 550 Piston to piston pin clearance 0 002 0 014 0 0001 0 0006 0 02 0 001 Piston ring to ring Top 0 015 0 055 0 0006 0 0022 0 08 0 003 groove clearance Second 0 015 0 055 0 0006 0 0022 0 08 0 003 Piston ring end gap Top 0 10 0 25 0 004 0 0010 0 45 0...

Page 16: ...commended fluid Pro Honda Suspension Fluid SS 8 1 OW or equivalent Fluid level 75 2 95 Fluid capacity 122 0 2 5 cm3 4 13 0 05 US oz 4 29 0 05 Imp oz REAR WHEEL BRAKE SUSPENSION SPECIFICATIONS Unit mm in ITEM STANDARD SERVICE LIMIT Minimum tire tread depth 2 0 0 08 Cold tire Up to 90 kg 200 lbs load 225 kPa 2 25 kgf cm2 33 psi pressure Up to maximum weight capacity 250 kPa 2 50 kgf cm2 36 psi Wheel...

Page 17: ... model LED Rear turn signal light 13 model 12V 21 Wx2 After 13 model LED Instrument light LED PGM FI malfunction indicator lamp MIL LED High beam indicator LED Turn signal indicator LED Coolant temperature indicator LED Fuse Main fuse 1 13 model 10 A Main fuse 2 13 model 30A Main fuse After 13 model 25A Sub fuse 13 model 10 AX 3 15 AX 1 After 13 model 5 A 10 Ax 4 STANDARD TORQUE VALUES FASTENER TY...

Page 18: ... See page 2 28 Exhaust pipe stud bolt 2 7 See page 2 28 MAINTENANCE ITEM Q TY THREAD TORQUE REMARKS DIA mm N m kgf m lbMt Spark plug 1 10 16 1 6 12 Valve adjusting screw lock nut 2 5 10 1 0 7 Apply oil to the threads and seating surface Engine oil drain bolt 1 12 24 2 4 18 Engine oil strainer screen cap 1 30 20 2 0 15 Final reduction oil check bolt 1 8 23 2 3 17 Final reduction oil drain bolt 1 8 ...

Page 19: ... ITEM Q TY THREAD TORQUE REMARKS DIA mm N m kgf m lbf ft Radiator drain bolt 1 10 1 0 1 0 7 Radiator base screw 1 4 0 8 0 08 0 6 Radiator top cover screw 4 4 3 2 0 33 2 4 Radiator distance bolt 4 7 16 5 1 7 12 CYLINDER HEAD VALVES ITEM Q TY THREAD TORQUE REMARKS DIA mm N m kgf m lbf ft Camshaft stopper bolt 1 6 10 1 0 7 Rocker arm shaft stopper bolt 2 5 5 0 51 3 7 Apply oil to the threads and seat...

Page 20: ... 3 31 ALOC bolt replace with new ones Front axle nut 1 12 59 6 0 44 U nut Fork socket bolt 2 8 20 2 0 15 Apply locking agent to the threads Bottom bridge pinch bolt 4 10 49 5 0 36 Brake caliper mounting bolt 2 8 30 3 1 22 ALOC bolt replace with new ones Handlebar upper holder socket bolt 4 8 27 2 8 20 For tightening sequence See page 17 20 Right left handlebar switch housing screw 4 5 2 5 0 26 1 8...

Page 21: ...CBS master cylinder stay bolt 2 6 12 1 2 9 Knocker pivot screw 1 6 2 5 0 26 1 8 Left hand threads Knocker pivot nut 1 6 10 1 0 7 Left hand threads U nut CBS master cylinder mounting bolt 2 6 12 1 2 9 CBS master cylinder cover bolt 1 6 12 1 2 9 Brake caliper mounting bolt 2 8 30 3 1 22 ALOC bolt replace with new ones Brake caliper torque pin 1 8 22 2 2 16 Brake caliper pin 1 8 18 1 8 13 LIGHTS METE...

Page 22: ... DIA mm N m kgf m lbMt Sidestand pivot nut 1 10 29 3 0 21 Sidestand pivot bolt 1 10 10 1 0 7 Rear reflex reflector mounting nut 2 6 1 5 0 15 1 1 U nut Tail reflex reflector mounting nut 1 5 1 5 0 15 1 1 U nut Brake lock knob stopper nut 1 14 2 6 0 27 1 9 1 16 ...

Page 23: ...guide groove 1 7 2 2g IDEMITSU AUTOREX B or NIPPON OIL POWERNOC WB3 or equivalent Grease Driven face ball bearing sliding area NIPPON OIL P U N6B or N6C or equivalent Grease Driven face needle bearing sliding area Shell RETINEX LX2 or NIPPON OIL P U N6B or equivalent Engine oil Oil pump drive and driven gear teeth Without molybdenum Oil pump inner and outer rotor whole surface additives Oil pump s...

Page 24: ...iding area Centerstand pivot area Sidestand pivot area Silicone grease 1st 2nd rear brake cable cap boot inside Front brake lever to master piston contacting area Spread 0 1 g minimum Master cylinder piston boot inside Knocker to master piston contacting area Spread each 0 1 g Equalizer sliding area Spread each 0 1 g Knocker pivot bolt sliding area Front brake lever pivot sliding area Spread each ...

Page 25: ...FRONT TURN SIGNAL LIGHT 2P CONNECTOR HEADLIGHT 6P CONNECTOR MAIN RELAY 2nd REAR BRAKE CABLE INFORMATION REAR BRAKE LIGHT LEFT HANDLEBAR SWITCH WIRE SWITCH WIRE Front TURN SIGNAL RELAY MAIN WIRE HARNESS CONNECTORS FRONT BRAKE HOSE RIGHT HANDLEBAR SWITCH 1 ...

Page 26: ...R BRAKE CABLE 1 20 1 5 6 2 3 4 BATTERY CASE DRAIN HOSE 1 THROTTLE CABLE 2 LEFT HANDLEBAR SWITCH WIRE 3 RIGHT HANDLEBAR SWITCH WIRE 4 REAR BRAKE LIGHT SWITCH WIRE 5 1st REAR BRAKE CABLE 6 FRONT BRAKE HOSE 7 CBS BRAKE HOSE EVAP CANISTER to EVAP PURGE CONTROL SOLENOID VALVE HOSE 2nd REAR BRAKE CABLE _ ...

Page 27: ...IRE HARNESS FUEL FEED HOSE SEAT LOCK CABLE ENGINE SUB HARNESS IGNITION SWl H 2P CONNECT FRAME GROUND POINT SEAT LOCK CABLE CONNECTOR D VALVE 2P Black PIPE HOSE 1 EVAP PURG gg g g g ai ilDVALVE HOSE 2 EV 6 TER to E HOSE 3 EV CANISTER to F 4 EVAP CONNECTORS k CONNECTOR ECM 21 p Blac CONNECTOR ECM 21 p pray 1 1 ...

Page 28: ...NECTORS LICENSE LIGHT WIRE CONNECTORS MAIN WIRE HARNESS SEAT LOCK CABLE ENGINE SUB HARNESS ENGINE SUB HARNESS 1 22 ALTERNATOR WIRES RIGHT REAR TURN LEFT REAR TURN SIGNAL LIGHT WIRE SIGNAL LIGHT WIRE ALTERNATOR WIRES RIGHT REAR TURN SIGNAL LIGHT WIRE FRAME PIPE MAIN WIRE HARNESS ALTERNATOR WIRE SEATLOCK CABLE 7 MAINWIRE a ENGINESUB HARNESS CJ HARNESS SEAT LOCK CABLE ...

Page 29: ...L FEED HOSE EVAP PURGE CONTROL SOLENOID VALVE to INTAKE PIPE HOSE FUEL INJECTOR 2P Black CONNECTOR INFORMATION BATTERY POSITIVE CABLE STARTER CHARGING RELAY SP Black CONNECTOR DLC THROTTLE CABLE VS SENSOR WIRE FUSE BOX FINAL REDUCTION CASE BREATHER HOSE 02 SENSOR 1P Black CONNECTOR ENGINE GROUND POINT SPARK PLUG CAP Oz SENSOR CAP Set the ground cable against the crankcase 1 ...

Page 30: ...GENERAL INFORMATION Outside if 1 24 RADIATOR SIPHON HOSE ENGINE SUB HARNESS To ECT SENSOR WATER HOSES ECT SENSOR 2P Black CONNECTOR Center Center Front ...

Page 31: ...KE CABLE COMBINATION METER 16P CONNECTOR J THROTTLE CABLES FRONT BRAKE HOSE 1 _ LEFTHANDLEBAR SWITCH WIRE 1stREAR fl J BRAKE CABLE 7 Front II ACCESSORY SOCKET WIRE CONNECTORS RIGHT HANDLEBAR SWITCH 4P Red CONNECTOR RIGHT HANDLEBAR SWITCH 6P Black CONNECTOR RIGHT HANDLEBAR SWITCH Up 6P Red CONNECTOR t LEFT HANDLEBAR SWITCH 6P Blue CONNECTOR LEFT HANDLEBAR SWITCH 4P CONNECTOR LEFT HANDLEBAR SWITCH 4...

Page 32: ...ROTTLE CABLES SWITCH WIRE LEFT HANDLEBAR SWITCH WIRE FUEL LID CABLE GI IP THROTTLE CABLES __ FRONT BRAKE HOSE HORN WIRE CONNECTORS CBS BRAKE HOSE FRONT BRAKE HOSE SIDESTAND SWITCH WIRE EVAP CANISTER DRAIN HOSE AC type only BATTERY CASE DRAIN HOSE FUEL TRAY DRAIN TUBE 1 26 ...

Page 33: ...LOCK CABLE INFORMATION IGNITION SWITCH WIRE MAIN WIRE HARNESS ECM 3P Black CONNECTOR EVAP CANISTER to EVAP PURGE CONTROL SOLENOID VALVE HOSE AC type only EVAP PURGE CONTROL SOLENOID VALVE to INTAKE PIPE HOSE AC type only 1 ...

Page 34: ...MATION 18 mm maximum i r 2nd REAR BRAKE CABLE 5 mm maximum MAIN WIRE HARNESS q 1 m m v Ximum I SIDESTAND 1 SWITCH WIRE SIDESTAND SWITCH 3P Green CONNECTOR BATTERY DRAIN TUBE ENGINE SUB HARNESS ALTERNATOR WIRES 1 28 ...

Page 35: ...type only FUEL TRAY DRAIN TUBE EVAP PURGE CONTROL SOLENOID VALVE to INTAKE PIPE HOSE AC type only SENSOR UNIT 5P Black CONNECTOR IACV 4P Black CONNECTOR __ INFORMATION EVAP PURGE CONTROL SOLENOID VALVE to INTAKE PIPE HOSE AC type only RADIATOR SIPHON HOSE 1 ...

Page 36: ...GENERAL INFORMATION CABLE TERMINAL 1 30 BATTERY NEGATIVE CABLE TERMINAL DLC FUEL PUMP SP CONNECTOR ...

Page 37: ... INTAKE PIPE HOSE AC type only SPARK PLUG CAP THROTTLE CABLES 02 SENSOR 1p Black CONNECTOR 02 SENSOR WIRE GENERAL INFORMATION FINAL REDUCTION CASE BREATHER HOSE VS SENSOR 3P Black CONNECTOR IACV 4P Black CONNECTOR ENGINE GROUND POINT 1 1 ...

Page 38: ... GENERAL INFORMATION 1 32 ENGINE SUB HARNESS To ECT SENSOR RADIATOR SIPHON HOSE Left ECT SENSOR 2P Black CONNECTOR Front Fr m r 40 50 _ WATER HOSE ...

Page 39: ... HARNESS SEAT LOCK CABLE REAR COMBINATION LIGHT 9P CONNECTOR I I I I I LICENSE LIGHT 3P CONNECTOR RADIATOR SIPHON HOSE 8 mm maximum RADIATOR SIPHON HOSE INFORMATION MAIN WIRE HARNESS 5 mm maximum 8 mm maximum 1 ...

Page 40: ...ted in the upper inner side of fuel tank When the fuel is coi sumed to the point where the breather filter is exposed above the fuel level a certain amount of air will be drawn into the pump chamber via the breather filter and breather passage This incoming air produces a lack of fuel which impairs engine performance in order to notify the rider of the fuel filter blockage This symptom works as a ...

Page 41: ...ycle Emission Control Systems is necessary in order to keep the emissions system warranty in effect SOURCE OF EMISSIONS The combustion process produces carbon monoxide CO oxides of nitrogen NOx and hydrocarbons HC The control of hydrocarbons and oxides of nitrogen is very important because under certain conditions they react to form photochemical smog when subject to sunlight Carbon monoxide does ...

Page 42: ...A California Air Resources Board CARB and Environment Canada EC The fuel tank fuel hoses and fuel vapor charge hoses used on this scooter incorporate fuel permeation control technologies Tampering with the fuel tank fuel hoses or fuel vapor charge hoses to reduce or defeat the effectiveness of the fuel permeation technologies is prohibited by federal regulations NOISE EMISSION CONTROL SYSTEM TAMPE...

Page 43: ...E COVER 2 9 UNDER COVER 2 10 SEAT 2 11 CENTER COVER 2 11 METER PANEL COVER 13 MODEL 2 12 RIGHT INNER MAINTENANCE LID 13 MODEL 2 12 INNER OUTER AFTER 13 MODEL 2 13 RIGHT INNER OUTER COVER AFTER 13 MODEL 2 13 INNER COVER 4 HANDLEBAR FRONT COVER 2 15 REAR METER 2 15 FRONT COVER 2 16 FRONT LOWER COVER 2 18 PLUG MAINTENANCE LID 2 19 FLOOR STEP 2 20 GRAB RAIL COVER 2 21 GRAB RAIL BODY COVER 2 24 LUGGAGE...

Page 44: ...ITEM Q TY THREAD TORQUE REMARKS DIA mm N m kgf m lbMt Front reflex reflector mounting nut 2 6 1 5 0 15 1 1 U nut 13 model Front turn signal light unit mounting nut 2 6 8 8 0 9 6 5 U nut 13 model Tail brake light unit mounting screw 4 4 1 0 1 0 7 13 model Rear combination light unit mounting 5 5 1 2 0 12 0 9 screw After 13 model Luggage box nut After 13 model 2 6 3 0 3 2 2 Exhaust pipe joint nut 2 ...

Page 45: ...Seat page 2 10 13 Handlebar front cover page 2 14 14 Rear meter panel page 2 14 15 Front cover page 2 15 16 Front lower cover page 2 17 17 Plug maintenance lid page 2 18 18 Floor step page 2 19 13 This chart shows removal order of body panels by means of arrow 2 Front grille 5 Meter panel cover 3 Meter visor 13 Handlebar front cover 4 Front meter panel 11 Right inner maintenance lid 14 Rear meter ...

Page 46: ... Center cover page 2 10 18 Grab rail cover page 2 20 13 19 Grab rail page 2 21 20 Body cover page 2 23 21 Luggage box page 2 25 22 Battery box page 2 26 23 Seat page 2 10 24 Rear fender page 2 27 BODY PANEL REMOVAL CHART AFTER 13 MODEL This chart shows removal order of body panels by means of arrow 18 Grab rail cover 14 Left inner outer cover 2 Front grille 19 Grab rail 15 Right inner outer cover ...

Page 47: ...INSTALLATION AFTER 13 MODEL Remove the front wheel page 17 6 Two bolts 1 Two nuts 2 bolts 3 reflex reflectors 4 Front fender 5 Installation is in the reverse order of removal Tighten the nut while aligning the reflex reflector with the boss of the fork slider REMOVAL INSTALLATION 13 MODEL Remove the two screws 1 Release the snap fit clips 2 Pull the front grille 3 forward and release the hooks 4 t...

Page 48: ...n is in the reverse order of removal METER VISOR REMOVAL INSTALLATION 13 MODEL 2 6 Remove the front grille page 2 5 Remove the four bolts washers 1 plastic washers 2 and meter visor 3 Installation is in the reverse order of removal REMOVAL INSTALLATION AFTER 13 MODEL Remove the front grille page 2 5 Remove the four bolts 1 four plastic washers 2 and meter visor 3 Installation is in the reverse ord...

Page 49: ...l REMOVAL INSTALLATION MODEL Remove the front cover page 2 15 13 Release the holes 1 of the front meter panel 2 from the bosses of the front cover stay Remove the front meter panel by releasing the hooks 3 from the holes of the rear meter panel Installation is in the reverse order of removal REMOVAL INSTALLATION 13 MODEL Remove the floor mat 1 by releasing the bosses 2 of the reverse side from the...

Page 50: ...oltiwasher 3 Remove the side cover 4 by releasing the following Hook 5 from the slot of the under cover Three tabs 6 from the slots of the floor step Installation is in the reverse order of removal REMOVAL INSTALLATION AFTER 13 MODEL Remove the floor mat page 2 7 Place the scooter on its centerstand Open the passenger step and remove the special bolt 1 Remove the following Two trim clip 2 Five scr...

Page 51: ...rom the tabs 5 of the front lower cover Installation is in the reverse order of removal REMOVAL INSTALLATION 13 MODEL Remove the side covers page 2 8 Remove the four bolts washers 1 and trim clip 2 6 Release the battery case drain hose 3 and EVAP canister drain hose AC type only 4 from the under cover 5 Remove the under cover from the tabs 6 of the front lower cover Installation is in the reverse ...

Page 52: ...ts 1 and seat 2 Remove the seat hinge 3 and seat hinge pin 4 Install the seat and tighten the nuts so that the seat is completely centered NOTE Apply grease to the seat hinge sliding area if necessary CENTER COVER REMOVAL INSTALLATION 13 MODEL 2 10 Remove the seat page 2 10 Unlock and open the fuel lid Remove the special screw 1 Release the front side five tabs 2 Pull the center cover 3 rearward a...

Page 53: ...upper cover with the slots of the inner lower cover 13 REMOVAL INSTALLATION Release the both upper side hooks 1 Remove the meter panel cover 2 by releasing the two snap fit clips 3 and lower side hook 4 Installation is in the reverse order of removal 13 REMOVAL INSTALLATlON Remove the meter panel cover page 2 11 Remove the right inner maintenance lid 1 by releasing 1 the snap fit clips 2 Installat...

Page 54: ...four snap fit clips 2 and hooks 3 Installation is in the reverse order of removal RIGHT INN OUTER COVER AFTER 13 MOD L 2 12 REMOVAL INSTALLATION Remove the left inner outer cover page 2 12 Remove the two screws 1 and right inner outer cover 2 by releasing the four snap fit clips 3 and hooks 4 Installation is in the reverse order of removal 1 ...

Page 55: ...Snap fit clips 4 Boss 5 from the grommet of the front cover stay Hooks 6 from the slots of the front cover Brake lock knob rubber cover hole 7 from the brake lock knob Installation is in the reverse order of removal REMOVAL INSTALLATION AFTER 13 MODEL Remove the following Rear meter panel page 2 14 Luggage box page 2 25 Remove the special screw 1 bolt 2 and inner cover 3 Pull up the inner cover an...

Page 56: ... dust cover and disconnect the speedometer 20P connector 1 Remove the four screws 2 Remove the rear meter panel 3 by releasing the bosses 4 from the grommets of the front cover stay Installation is in the reverse order of removal REMOVAL INSTALLATION AFTER 13 MODEL Remove the following Front meter panel page 2 7 Handlebar front cover page 2 14 Disconnect the combination meter 16P connector 1 Remov...

Page 57: ...eft front turn signal light 2P Black connector 1 Right side Disconnect the right front turn signal light 2P connector 2 Remove the six screws 3 and two screws washers 4 Remove the front cover 5 by releasing the following Tab 6 from the groove of the headlight unit Hooks 7 from the slots of the floor step Installation is in the reverse order of removal Left side Right side 6 3 ...

Page 58: ...rim clips 2 and fourteen screws silver 3 Remove the right front cover 4 and left front cover 5 by releasing the following Snap fit clip 6 from the slots of the inner cover Hooks 7 from the slots of the rear meter panel Hooks 8 from the slots of the floor step Tabs 9 from the slits of the center cover Remove the two screws black 1 O and combination light under cover 11 Installation is in the revers...

Page 59: ...ove the three screws 9 and front turn signal light unit stay 1 O from the front cover Assembly is in the reverse order of disassembly TORQUE Front turn signal light unit mounting nut 8 8 N m 0 9 kgf m 6 5 lbMt REMOVAL INSTALLATION 13 MODEL Remove the front cover page 2 15 Remove the four screws 1 bolt washer 2 and trim clip 3 Remove the front lower cover 4 by releasing the tabs 5 from the slots of...

Page 60: ...verse order of removal PLUG MAINTENANCE LID REMOVAL INSTALLATION 13 MODEL 2 18 Remove the left floor mat page 2 7 Remove the screw 1 Remove the maintenance lid 2 by releasing the tabs 3 Installation is in the reverse order of removal REMOVAL INSTALLATION AFTER 13 MODEL Remove the left floor mat page 2 7 Remove the screw 1 Remove the maintenance lid 2 by releasing the tabs 3 Installation is in the ...

Page 61: ...ree special bolts 2 Open the passenger step 3 and remove the floor step 4 Installation is in the reverse order of removal REMOVAL INSTALLATION AFTER 13 MODEL Remove the following Side cover page 2 8 Front cover page 2 15 Remove the screw 1 trim clip 2 and three special bolts 3 Remove the floor step 4 Installation is in the reverse order of removal 4 3 ...

Page 62: ...ull up the front side of grab rail cover 2 and release the two snap fit clips 3 Push the grab rail cover to outside and release the grooves 4 from the bosses 5 of the grab rail as shown Carefully pull up the rear side of grab rail cover and release the snap fit clip 6 and remove the grab rail cover Installation is in the reverse order of removal Releasing the grooves procedure 2 3 ...

Page 63: ...l up the front side of grab rail cover 4 and release the two snap fit clips 5 and remove the grab rail cover Installation is in the reverse order of removal L REMOVAL INSTALLATION 13 MODEL Remove the grab rail cover page 2 20 Remove the four bolts 1 Remove the grab rail 2 by releasing the bosses 3 from the grooves of the body cover as shown Installation is in the reverse order of removal 1 l 2 3 1...

Page 64: ...8B0DYPANEL EXHAUSTSYSTEM 2 22 REMOVAL INSTALLATION AFTER 13 MODEL Remove the grab rail cover page 2 20 Remove the four bolts 1 two screws 2 and grab rail 3 Installation is in the reverse order of removal 2 ...

Page 65: ...de the body cover 3 backward and release the following Lower side holes 4 from the cone plugs 5 of the frame Hooks 6 from the slots Groove 7 from the stopper of the tail brake light unit Pull the body cover backward and disconnect the brake tail light 6P connector 8 then remove the body cover Installation is in the reverse order of removal PANELS EXHAUST SYSTEM 7 ...

Page 66: ...7 from the slots of the floor step Tabs 8 from the slits of the center cover Bosses 9 from the grommets of the rear fender Pull the body cover backward and disconnect the rear combination light 9P connector 1 O then remove the body cover Installation is in the reverse order of removal DISASSEMBLY ASSEMBLY 13 MODEL Remove the following Four tapping screws 1 Right left body covers 2 Tail brake light...

Page 67: ...ssy 5 Assembly is in the reverse order of disassembly TORQUE Rear comb light unit mounting screw 1 2 N m 0 12 kgf m 0 9 lbMt REMOVAL INSTALLATION 13 MODEL Remove the following Center cover page 2 10 Body cover page 2 23 Battery maintenance lid page 20 7 Release the battery band 1 Remove the following Two bolts washers 2 Four special bolts 3 Luggage box 4 Installation is in the reverse order of rem...

Page 68: ...uggage box Installation is in the reverse order of removal TORQUE Luggage box nut 3 N m 0 3 kgf m 2 2 lbf ft BATTERY BOX REMOVAL INSTALLATION 13 MODEL 2 26 Remove the following Luggage box page 2 25 Battery page 20 7 Remove the wire band boss 1 and disconnect the battery box drain hose 2 from the joint Release the EVAP canister to intake pipe hose 3 from the case grooves Remove the two special bol...

Page 69: ... 2 23 Disconnect the following connectors Turn signal light Light blue Orange Green wire connectors 1 License light Brown Green wire connectors 2 Release the radiator siphon hose 3 from the hose groove 4 Remove the three bolts washers 5 Remove the rear fender 6 from the frame bosses 7 and boss 8 of the radiator reserve tank Installation is in the reverse order of removal REMOVAL INSTALLATION AFTER...

Page 70: ...t 29 N m 3 0 kgf m 21 lbMt Muffler mounting bolt 49 N m 5 0 kgf m 36 lbMt EXHAUST PIPE STUD BOLT REPLACEMENT Thread two nuts to the stud bolt and tighten them together then use a wrench on them to turn the stud bolt out Install the stud bolts Install and tighten new stud bolts into the cylinder head with their rounded to the specified torque end t facing out TORQUE 9 N m 0 92 kgf m 6 6 lbMt After ...

Page 71: ...erstand 4 Apply thin coat of grease to the centerstand pivot shaft 1 surface Install the centerstand 2 and insert the pivot shaft while aligning its hole with the crankcase boss Install the washer 3 and a new cotter pin 4 Install the centerstand spring in the reverse order of removal ...

Page 72: ...MEMO ...

Page 73: ... OIL STRAINER SCREEN 3 12 ENGINE IDLE SPEED 3 13 RADIATOR COOLANT 3 13 COOLING SYSTEM 3 14 EMISSION CONTROL SYSTEM fl U l fl 13 MODEL CM TYPE 3 15 DRIVE 3 15 FINAL DRIVE OIL 3 16 FLUID 3 17 BRAKE SHOES PADS WEAR 3 17 BRAKE SYSTEM 3 18 BRAKE LIGHT SWITCH 3 20 BRAKE LOCK OPERATION 3 21 HEADLIGHT AIM 3 22 CLUTCH SHOES WEAR 3 23 SIDESTAND 3 23 SUSPENSION 3 23 NUTS BOLTS FASTENERS 3 24 WHEELS TIRES 3 2...

Page 74: ...pacity After disassembly 0 9 liter 1 0 US qt 0 8 Imp qt After oil strainer removal 0 9 liter 1 0 US qt 0 8 Imp qt Engine idle speed 1 700 100 rpm Recommended antifreeze Pro Honda HP Coolant or an equivalent high quality ethylene glycol antifreeze containing silicate free corrosion inhibitors Drive belt width 13 model Service limit 21 0 mm 0 83 in After 13 model Service limit 21 6 mm 0 85 in Recomm...

Page 75: ...ver screw 1st rear brake cable lock nut Brake lock cable lock nut TOOL Valve adjusting wrench 07908 KE90000 r or Tappet wrench 3 mm 07908 KE90200 U S A only Q TY 1 2 1 1 1 1 7 1 2 THREAD TORQUE REMARKS DIA mm N m kgf m lbHt 10 16 1 6 12 5 10 1 0 7 Apply oil to the threads and seating surface 12 24 2 4 18 30 20 2 0 15 8 23 2 3 17 8 23 2 3 17 5 1 1 0 11 0 8 8 6 5 0 66 4 8 6 3 0 31 2 2 ...

Page 76: ...VERY 5 000 mi 8 000 km I CJ EVERY 15 000 mi 24 000 km R 2 FINAL DRIVE OIL NOTE4 w t BRAKE FLUID NOTE4 I I I 0 BRAKE SHOES PADS WEAR I I I w BRAKE SYSTEM I I I I J BRAKE LIGHT SWITCH I I I w 0 BRAKE LOCK OPERATION I I I I z HEADLIGHT AIM I I I 0 u5 CLUTCH SHOES WEAR I CJ SIDESTAND I I I w SUSPENSION I I I I NUTS BOLTS FASTENERS I I z 0 WHEELS TIRES I I I z STEERING HEAD BEARINGS I I Should be servi...

Page 77: ...CONTROL NOTE4 SYSTEM I J DRIVE BELT I I FINAL DRIVE OIL NOTE5 w l BRAKE FLUID NOTE5 I I I I I 0 BRAKE SHOES PADS WEAR I I I I I w BRAKE SYSTEM I I I I I I BRAKE LOCK OPERATION I I I I I I w er HEADLIGHT AIM I I I I I z CLUTCH SHOES WEAR I I 0 u5 SIDESTAND I I I I I J SUSPENSION I I I I I w NUTS BOLTS FASTENERS I I I I WHEELS TIRES I I I I I z 0 STEERING HEAD BEARINGS I I z Should be serviced by a ...

Page 78: ... Check that the throttle opens and automatically closes in all steering positions If the throttle grip does not return properly overhaul and lubricate the throttle grip housing If the throttle grip still does not return properly replace the throttle cable With the engine idling turn the handlebar all the way to the right and left to ensure that the idle speed does not change If idle speed increase...

Page 79: ... dust adhesive If the scooter is used in unusually wet or dusty areas more frequent inspections are required 13 model Remove the screws 1 and air cleaner housing cover 2 Remove the air cleaner element 1 from the air cleaner housing cover 2 Discard the air cleaner element in accordance with the maintenance schedule page 3 4 Replace the element any time if it is excessively dirty or damaged Install ...

Page 80: ...se order of portions of the air removal cleaner housing 4 TORQUE and air cleaner element Air cleaner housing cover screw 1 1 N m 0 11 kgf m 0 8 lbf ft CRANKCASEBREATH R 3 8 NOTE Service more frequently when ridden in rain at full throttle or after the scooter is washed or overturned Service if the deposit level can be seen in the transparent section of the drain plug Remove the crankcase breather ...

Page 81: ...he maintenance schedule page 3 4 Clean the spark plug electrodes with a wire brush or special plug cleaner Check the insulator for cracks or damage and the electrodes for wear fouling or discoloration Always use the SPECIFIED SPARK PLUG CPR7EA 9 NGK specified spark plug on this motorcycle Measure the spark plug gap between the center and side electrodes with a wire type feeler gauge If necessary a...

Page 82: ... and align the cut out T mark 4 of the cooling fan with the index mark 5 on the crankcase Make sure the mark 1 of the camshaft and index line 2 of the cylinder head are aligned Make sure the piston is at TDC Top Dead Center on the compression stroke This position can be confirmed by checking that there is slack in the rocker arm If there is no slack it is because the piston is moving through the e...

Page 83: ...od condition and replace it if necessary Install the left crankcase cover duct by aligning the holes with bosses of the left crankcase cover Install and tighten the three bolts 1 Install the following Cylinder head cover page 10 7 Four radiator mounting bolts page 9 7 Radiator cover page 9 4 Side cover page 2 8 OIL LEVEL CHECK Support the scooter with its centerstand on a level surface Start the e...

Page 84: ...fter oil strainer removal Check that the 0 ring on the oil filler cap is in good condition and replace it if necessary Install the oil filler cap dipstick and check the oil level page 3 11 ENGIN OIL STRAINER SCRE N 3 12 Drain the engine oil page 3 12 Remove the oil strainer screen cap 1 0 ring 2 spring 3 and oil strainer screen 4 Wash the strainer screen thoroughly in non flammable or high flash p...

Page 85: ...e 10 5 IACV operation page 7 23 13 model Support the scooter with its centerstand Unlock and open the seat Check the coolant level of the reserve tank with the engine running at normal operating temperature The level should be between the UPPER level line 1 and LOWER level line 2 with the scooter upright on a level surface If the level is low fill as follows Remove the radiator reserve tank lid pa...

Page 86: ...e reserve tank becomes completely empty there is a possibility of air getting into the cooling system Be sure to remove all air from the cooling system page 9 5 Install the radiator reserve tank lid COOLING SYSTE 3 14 Remove the following Luggage box page 2 25 Radiator cover page 9 4 Check the radiator 1 for leakage Check for coolant leakage from the water pump 2 water hoses 3 and hose joints 4 Ch...

Page 87: ... damage Install the floor step page 2 19 Remove the left crankcase cover page 12 6 Check the drive belt 1 for cracks separation or abnormal or excessive wear and replace it if necessary page 12 8 Using the suitable two flat plates measure the drive belt 1 width as shown SERVICE LIMITS 13 model 21 0 mm 0 83 in After 13 model 21 6 mm 0 85 in Replace the drive belt if it is less than the service limi...

Page 88: ...it to the specified torque TORQUE 23 N m 2 3 kgf m 17 lbHt Oil CHANGE Place an oil drain pan under the final reduction case to collect the oil then remove the oil check bolt 1 oil drain bolt 2 and sealing washers 3 Slowly turn the rear wheel and drain the oil After draining the oil completely install the oil drain bolt with a new sealing washer and tighten the drain bolt to the specified torque TO...

Page 89: ...the brake pads are not worn and fluid level is low check entire system for leaks page 3 18 FRONT LINE Support the scooter with its centerstand Turn the handlebar to the left so the reservoir is level and check the front brake reservoir fluid level through the sight glass If the level is near the LOWER level mark 1 check the brake pads for wear page 3 17 CBS BRAKE LINE Support the scooter with its ...

Page 90: ... or spongy when operated bleed the air from the system For air bleeding procedures page 19 7 Remove the front meter panel page 2 7 Inspect the brake hoses 1 and fittings for deterioration cracks or signs of leakage Tighten any loose fittings Replace the hoses and fittings as required Install the front meter panel page 2 7 REAR DRUM BRAKE Check the brake cable and brake lever for loose connections ...

Page 91: ...pplied If it is abnormal inspect as follows Inspect and adjust the CBS with the steering positioned straight Adjust the CBS after removing the CBS master cylinder and or rear brake cable Remove the front meter panel page 2 7 Measure the distance between the equalizer 1 and boss 2 of the master cylinder body as shown STANDARD 13 model 2 3 mm 0 08 0 12 in After 13 model 3 4 mm 0 12 0 16 in If the di...

Page 92: ...e system adjustment is normal but the front wheel rotates abnormally check for other malfunction parts Install the front meter panel page 2 7 Adjust the rear brake lever freeplay page 3 18 Check that the rear wheel turns freely without brake dragging BRAKE LIGHT SWITCH 3 20 NOTE The brake light switch on the brake lever cannot be adjusted If the brake light switch actuation and brake engagement ar...

Page 93: ... position 2 and the rear wheel is locked completely Squeeze and hold the rear brake lever Press the brake lock knob while pushing in the center button 3 check that the brake lock knob is in the released position 4 and the rear brake is fully released so there is no drag on the rear wheel If there is an abnormality in the above inspection inspect the following To apply the brake lock 2 To release t...

Page 94: ...adjuster TORQUE 3 N m 0 31 kgf m 2 2 lbMt Apply and release the brake lock then recheck the distance between the brake lock lever and brake lock stay STANDARD 2 0 3 0 mm 0 08 0 12 in If the brake lock system adjustment is normal but the rear wheel is not locked completely check for other malfunctioning parts Install the front meter panel page 2 7 AIM NOTE Adjust the headlight beam as specified by ...

Page 95: ... 6 13 FRONT Loose worn or Check the action of the forks by operating the front damaged brake and compressing the front suspension several suspension parts times impair scooter Check the entire assembly for signs of leaks damage stability and control or loose fasteners Replace damaged components which cannot be repaired Tighten all nuts and bolts For fork service page 17 8 REAR Check the action of ...

Page 96: ...and attempting to move the wheel side to side Replace the front wheel bearings if any looseness is noted Turn the wheel and check that it rotates smoothly with no unusual noises If any abnormal conditions are suspected inspect the front wheel bearings page 17 6 Support the scooter securely and raise the rear wheel Check for worn final gear shaft bearings by grabbing the rear wheel and attempting t...

Page 97: ...14M C 57P TIRE BRAND 13 model FRONT SS 560F IRC TT900F DUNLOP REAR SS 560R IRC TT900A DUNLOP After 13 model FRONT SS 560F IRC REAR SS 560R o IRC Measure the tread depth at the center of the tires Replace the tires when the tread depth reaches the following limits MINIMUM TIRE TREAD DEPTH FRONT 1 5 mm 0 06 in REAR 2 0 mm 0 08 in NOTE Check that the control cables do not interfere with handlebar rot...

Page 98: ...NTENANCE 3 26 Hold the scooter and check the steering head bearings for wear by moving the fork forward and backward If the steering stem has vertical movement inspect the steering head bearing page 17 24 ...

Page 99: ... 9 PGM FI TROUBLESHOOTING INFORMATION 13 MODEL 4 10 PGM FI TROUBLESHOOTING INFORMATION AFTER 13 MODEL 4 13 OTC INDEX 13 MODEL 4 15 INDEX AFTER 13 MODEL 4 16 OTC TROUBLESHOOTING 13 MODEL 4 17 SENSOR UNIT POWER LINE INSPECTION AFTER 13 MODEL 4 33 OTC TROUBLESHOOTING AFTER 13 MODEL 4 34 MIL CIRCUIT INSPECTION 13 MODEL 4 47 MIL CIRCUIT INSPECTION AFTER 13 MODEL 4 48 ECM 4 49 ECT SENSOR 4 52 02 SENSOR ...

Page 100: ... I PGM FI SYSTEM PGM FI SYSTE LOCATION 13 model ECM DLC FUEL PUMP SIDESTAND SWITCH ECT SENSOR 4 2 FUEL INJECTOR 02 SENSOR IACV VS SENSOR SENSOR UNIT MAP IAT TP SENSORS ...

Page 101: ... After 13 model IGNITION SWITCH FUEL PUMP STAND SWITCH SIDE ECM 02SENSOR PGM FI SYSTEM DLC INJECTOR ECT SENSOR CKP SENSOR ENSOR UNIT S NSORS MAP IAT TP SE ...

Page 102: ...ASE 01 VPHASE 02 WPHASE 03 STARTER CHARGING RELAY EVAP PURGE CONTROL SOLENOID VALVE BI Bu BI W Br Y Y Bu P Bu Lg R Gr R Br R BI R FUEL PUMP BI W 29 IACV SPEEDOMETER Br Lg R Br COOLANT TEMPERATURE INDICATOR G 0 G BI Br Bu w ST SW B1 Y G ALTERl S ARTER rco STARTER SWITCH l OTC MIL number 18 Engine does not start when detecting OTC MIL cl Short terminals for reading OTC MIL Bl Black Y Yellow Bu Blue ...

Page 103: ...ine does not start when detecting MIL cl Short terminals for reading MIL Bl Black Y Yellow Bu Blue G Green R Red W White Br Brown 0 Orange Lg Light green P Pink Gr Gray INJ A2 A14 A26 A27 A16 A15 A4 U PHASE C3 V PHASE C2 W PHASE C1 A33 33P Black CONNECTOR A ECM side male terminal R Y BIIW STARTER CHARGING RELAY R Y Ell EVAP PURGE CONTROL SOLENOID VALVE Bu W BIIW Br Y Y Bu P Bu BIIW 12 INJECTOR Lg ...

Page 104: ... a minimum running capability even when there is any trouble in the system When any abnormality is detected by the self diagnosis function running capability is secured by making use of the numerical values of a situation preset in the simulated program map It must be remembered however that when any abnormality is detected in fuel injector the fail safe function stops the engine to protect it fro...

Page 105: ...k Contaminated deteriorated fuel Faulty fuel injector IACV stuck Faulty ignition system Engine stalls hard to start 1 Check the idle speed page 3 13 Restricted fuel feed hose rough idling 2 Check the IACV page 7 23 Contaminated deteriorated fuel 3 Inspect the fuel supply system Intake air leak page 7 6 Restricted fuel tank cap breather Faulty ignition system Backfiring or misfiring during Check th...

Page 106: ...ignition system Engine stalls hard to start 1 Check the idle speed page 3 13 Restricted fuel feed hose rough idling 2 Check the IACV page 7 22 Contaminated deteriorated fuel 3 Inspect the fuel supply system Intake air leak page 7 6 Restricted fuel tank cap breather Faulty ignition system Backfiring or misfiring during Check the ignition system page 5 6 acceleration Poor performance Inspect the fue...

Page 107: ...ove the right side cover page 2 8 NOTE 5 Remove the left side cover page 2 8 NOTE 6 Refer to page 4 53 l j SENSOR UNIT 5P Black CONNECTOR ___ _ _i___J NOTE 3 View from the right side CKP sensor 6P Black tr t CONNECTOR NOTE 3 ECM 5P CONNECTOR NOTE 2 IACV 4P Black CONNECTOR rr NOTE 5 UJ FUEL INJECTOR 2P Black CONNECTOR NOTE 3 View from the left side F 9 ECT SENSOR 2P Black lLLJJ CONNECTOR NOTE 4 02 ...

Page 108: ...he hyphen are the main code they indicate the component of function failure The digits behind the hyphen are the sub code they detail the specific symptom of the component or function failure For example in the case of the TP sensor OTC 8 1 TP sensor voltage lower than the specified value OTC 8 2 TP sensor voltage higher than the specified value The MAP ECT TP and IAT sensor diagnosis will be made...

Page 109: ...e learning memory OTC READOUT Support the scooter with its centerstand Turn the ignition switch ON and engine stop switch 0 check the MIL When the ignition switch is turned ON the MIL will stay on for a few seconds then go off If the MIL stays on or blinks connect the MCS Tester to the OLC page 4 11 Crank the engine for more than ten seconds and check the MIL MIL 52 blinks CKP sensor is indicated ...

Page 110: ...arts blinking successful pattern The DLC must be jumped while the MIL lights If not the MIL will not start blinking In that case turn the ignition switch OFF and try again from step 3 Note that the self diagnostic memory cannot be erased if the ignition switch is turned OFF before the MIL starts blinking CIRCUIT INSPECTION INSPECTION AT ECM CONNECTOR Always clean around and keep any foreign materi...

Page 111: ...he specific symptom of the component or function failure For example in the case of the TP sensor OTC 08 1 TP sensor voltage lower than the specified value OTC 08 2 TP sensor voltage higher than the specified value The ECT and TP sensor diagnosis will be made according to the voltage output of the affected sensor If a failure occurs the ECM determines the Function Failure compares the sensor volta...

Page 112: ...om the OLC 2 and short the OLC terminals using the special tool TOOL 3 SCS connector 070PZ ZY30100 Connection Brown Green black 4 Turn the ignition switch ON read and note the MIL blinks and refer to the OTC index page 4 16 NOTE If the ECM has any OTC in its memory the MIL will start blinking ERASING DTC 1 Turn the ignition switch OFF 2 Remove the battery maintenance lid page 20 7 3 Remove the dum...

Page 113: ... V TP sensor or its circuit malfunction 9 1 9 IAT sensor circuit low voltage less than 0 078 V IAT sensor or its circuit malfunction IAT sensor circuit high voltage more than 4 922 V 9 2 9 Loose or poor contact of the sensor unit 5P Black connector IAT sensor or its circuit malfunction Fuel injector malfunction 12 1 12 Loose or poor contact of the fuel injector connector Fuel injector or its circu...

Page 114: ...unction 8 2 TP sensor circuit high voltage more than 4 89 V Poor engine acceleration 4 39 TP sensor or its circuit malfunction Pre program value 0 9 1 IAT sensor circuit low voltage less than 0 08 V Engine operates normally 4 40 IAT sensor or its circuit malfunction Pre program value 35 C IAT sensor circuit high voltage more than 4 91 V Engine operates normally 9 2 Loose or poor contact of the sen...

Page 115: ...tion switch OFF Disconnect the sensor unit 5P Black connector Turn the ignition switch ON Measure the voltage between the sensor unit 5P Black connector 1 of the wire harness side and ground CONNECTION Yellow orange Green orange STANDARD 4 75 5 25 V Is the voltage within 4 75 5 25 V YES GO TO STEP 3 NO GO TO STEP 4 3 MAP Sensor Output Voltage Inspection Measure the voltage between the sensor unit ...

Page 116: ... continuity YES Replace the ECM with a new one and recheck NO Open circuit in the Yellow orange wire Open circuit in the Green orange wire 5 MAP Sensor Output Line Open Circuit Inspection Turn the ignition switch OFF Disconnect the ECM 21 P Gray connector Check for continuity between the ECM 21 P Gray connector 1 of the wire harness side and sensor unit 5P Black connector 2 of the wire harness sid...

Page 117: ... NO GO TO STEP 3 3 MAP Sensor Output Line Open Circuit Inspection Turn the ignition switch OFF Disconnect the ECM 21 P Gray connector Check for continuity between the sensor unit SP Black connector 1 and ECM 21 P Gray connector 2 of the wire harness side 1 Green orange 2 1 CONNECTION Yellow Red 811 Yellow red STANDARD Continuity Yellow red Is there continuity YES GO TO STEP 4 NO Open circuit in th...

Page 118: ...e ignition switch OFF Measure the resistance at the 2P connector 1 terminals of the ECT sensor side CONNECTION A B STANDARD 2 3 2 6 kQ 20 C 68 F Is the resistance within 2 3 2 6 kD YES Replace the ECM with a new one and rech eck NO Faulty ECT sensor 4 ECT Sensor Output line Short Circuit Inspection Turn the ignition switch OFF Disconnect the ECM 21 P Gray connector Check for continuity between the...

Page 119: ...s side with a jumper wire 2 CONNECTION Pink white Green orange Turn the ignition switch ON Check the ECT sensor with the MCS tester Is about OVindicated YES Inspect the ECT sensor page 4 52 NO GO TO STEP 3 3 ECT Sensor Output ground Line Inspection Turn the ignition switch OFF Disconnect the jumper wire Disconnect the ECM 21 P Gray connector Check the continuity between the ECT sensor 2P Black con...

Page 120: ...it SP Black connector NO Replace the sensor unit with a new one and recheck Faulty TP sensor 3 TP Sensor Resistance Inspection Turn the ignition switch OFF Disconnect the sensor unit SP Black connector Measure the resistance at the SP connector 1 of the sensor unit side CONNECTION B C STANDARD 0 5 0 7 kO 20 C 68 F Is the resistance within 0 5 0 7 k l YES GO TO STEP 4 NO Replace the sensor unit wit...

Page 121: ...nit SP Black connector 1 of the wire harness side and ground CONNECTION Yellow orange Ground STANDARD 4 75 5 25 V Is the voltage within 4 75 5 25 V YES Replace the sensor unit with a new one and recheck Faulty TP sensor NO GO TO STEP 7 7 TP Sensor Input Line Open Circuit Inspection Turn the ignition switch OFF Disconnect the ECM 21 P Gray connector Check for continuity between the sensor unit SP B...

Page 122: ...th a new one and recheck Faulty TP sensor 3 TP Sensor Resistance Inspection Turn the ignition switch OFF Disconnect the sensor unit SP Black connector Measure the resistance at the SP connector 1 of the sensor unit side CONNECTION B C STANDARD 0 5 0 7 kO 20 C 68 F Is the resistance within 0 5 0 7 k l YES GO TO STEP 4 NO Replace the sensor unit with a new one and recheck Faulty TP sensor 4 TP Senso...

Page 123: ...cated YES GO TO STEP 3 NO Replace the sensor unit with a new one and recheck Faulty IAT sensor 3 IAT Sensor Output Line Short Circuit Inspection Turn the ignition switch OFF Disconnect the ECM 21 P Gray connector Check for continuity between the ECM 21 P Gray connector 1 of the wire harness side and ground with sensor unit qP Black connector disconnected CONNECTION B12 White blue Ground STANDARD N...

Page 124: ...tor 1 terminals of the wire harness side with a jumper wire 2 CONNECTION White blue Green orange Turn the ignition switch ON Check the IAT sensor with the MCS tester Is about OVindicated YES Replace the sensor unit with a new one and recheck Faulty IAT sensor NO GO TO STEP 3 3 IAT Sensor Output Line Open Circuit Inspection Turn the ignition switch OFF Disconnect the jumper wire Disconnect the ECM ...

Page 125: ...or and recheck the OTC 1 Fuel injector System Inspection Clear the DTC s page 4 12 Turn the ignition switch ON and engine stop switch 0 then start the engine and check the fuel injector with the MCS tester Is the DTC 12 1 indicated YES GO TO STEP 2 NO Intermittent failure Loose or poor contact on the fuel injector 2P Black connector 2 Fuel injector Input Voltage Inspection Turn the ignition switch...

Page 126: ...tor 2P Black connector 1 of the wire harness side and ECM 21 P Black connector 2 of the wire harness side CONNECTION Pink Blue A14 Pink Blue STANDARD Continuity TOOL Test probe 2 pack 07ZAJ RDJA110 Is there continuity YES GO TO STEP 5 NO Open circuit in the Pink blue wire 5 Fuel injector Signal Line Short Circuit Inspection Check for continuity between the fuel injector 2P Black connector 1 and gr...

Page 127: ... the Black or Black orange wire 2 02 Sensor Line Short Circuit Inspection With the ECM 21 P Gray connector disconnected check for continuity between the 02 sensor cap terminal 1 and ground CONNECTION 02sensor cap terminal Ground STANDARD No continuity TOOL Test probe 2 pack 07ZAJ RDJA110 Is there continuity YES Short circuit in the Black or Black orange wire NO GO TO STEP 3 3 02 Sensor Inspection ...

Page 128: ...wn red Ground Gray red Ground Black red Ground STANDARD No continuity Are there continuities YES Short circuit in the Light green red or Brown red wire Short circuit in the Gray red or Black red wire NO GO TO STEP 3 3 IACV Circuit Continuity Inspection Disconnect the ECM 21 P Black connector Check the continuity between the ECM 21 P Black connector 1 terminals and IACV 4P Black connector 2 termina...

Page 129: ...0 150 2 20 C 68 F YES GO TO STEP 5 NO Faulty IACV Replace the IACV with a new one and recheck 5 IACV Short Circuit Inspection Check for continuity at the IACV 4P Black connector 1 terminals of the IACV side CONNECTION A B C D STANDARD No continuity Is there continuity YES Faulty IACV Replace the IACV with a new one and recheck NO Replace the ECM with new one and recheck PGM FI SYSTEM 1 1 ...

Page 130: ...connector Check the connector for loose contacts or corroded terminals Measure the voltage at the CKP sensor 6P Black connector 1 of the wire harness side CONNECTION White red Ground White blue Ground White black Ground Blue yellow Ground STANDARD 5 10 V CONNECTION Brown black Blue green STANDARD Battery voltage Does the standard voltage exist YES GO TO STEP 3 NO Open circuit in wire harness betwe...

Page 131: ...or and start the OTC troubleshooting page 4 34 NO GO TO STEP 2 2 Sensor Unit Input Voltage Line Short Circuit Inspection Turn the ignition switch OFF Check for continuity between the sensor unit SP Black connector 1 of the wire harness side and ground Connection Yellow white Ground Is there continuity YES Short circuit in the Yellow white wire NO GO TO STEP 3 3 Sensor Unit Power Line Open Circuit ...

Page 132: ...age Inspection Turn the ignition switch OFF Disconnect the sensor unit 5P Black connector page 7 15 Turn the ignition switch ON Measure the voltage at the sensor unit 5P Black connector 1 of the wire harness side Connection Yellow red Green orange Standard 4 75 5 25 V Is the voltage within 4 75 5 25 V YES GO TO STEP 5 NO GO TO STEP 4 4 MAP Sensor Output Line Short Circuit Inspection Turn the ignit...

Page 133: ...GO TO STEP 2 NO Intermittent failure Loose or poor contact on the sensor unit 5P Black connector 2 Sensor Unit Power Line Inspection Check the sensor unit power line inspection page 4 33 Is the sensor unit power line normal YES GO TO STEP 3 NO Replace or repair the abnormal circuit 3 MAP Sensor System Inspection 2 Turn the ignition switch OFF Disconnect the sensor unit 5P Black connector page 7 15...

Page 134: ... Sensor System Inspection Turn the ignition switch ON Check the ECT sensor with the MCS Is about OVindicated YES GO TO STEP 2 NO Intermittent failure 2 ECT Sensor Inspection Turn the ignition switch OFF Disconnect the ECT sensor 2P Black connector page 4 52 Turn the ignition switch ON Check the ECT sensor with the MCS Is about OVindicated YES GO TO STEP 3 NO Faulty ECT sensor 3 ECT Sensor Output L...

Page 135: ...Pink white Green orange Turn the ignition switch ON Check the ECT sensor with the MCS Is about OVindicated YES Replace the ECT sensor with a known good one and recheck NO GO TO STEP 3 3 ECT Sensor Open Circuit Inspection Turn the ignition switch OFF Remove the jumper wire Disconnect the ECM 33P Black connector page 4 49 Check for continuity between the ECM 33P Black connector 1 and ECT sensor 2P B...

Page 136: ...eplace or repair the abnormal circuit 3 TP Sensor Output Line Short Circuit Inspection Turn the ignition switch OFF Disconnect the sensor unit 5P Black connector page 7 15 Check for continuity between the sensor unit 5P Black connector 1 of the wire harness side and ground Connection Yellow blue Ground Is there continuity YES Short circuit in the Yellow blue wire NO GO TO STEP 4 4 TP Sensor Output...

Page 137: ...2 2 TP Sensor Inspection Check that the TP sensor voltage increases continuously when moving the throttle from fully closed to fully opened using the data list menu of the MCS Does the voltage increase continuously YES Intermittent failure NO Replace the TP sensor sensor unit with a known good one and recheck 3 TP Sensor Resistance Inspection Turn the ignition switch OFF Disconnect the sensor unit...

Page 138: ...ensor System Inspection Turn the ignition switch ON Check the IAT sensor with the MCS Is about OVindicated YES GO TO STEP 2 NO Intermittent failure 2 IAT Sensor Inspection Turn the ignition switch OFF Disconnect the sensor unit 5P Black connector page 7 15 Turn the ignition switch ON Check the IAT sensor with the MCS Is about OVindicated YES GO TO STEP 3 NO Faulty sensor unit IAT sensor 3 IAT Sens...

Page 139: ...isconnect the sensor unit 5P Black connector 1 page 7 15 Connect the IAT sensor terminals at the wire harness side with a jumper wire 2 Connection White blue Green orange Turn the ignition switch ON Check the IAT sensor with the MCS Is about OVindicated YES Faulty sensor unit IAT sensor NO GO TO STEP 4 4 IAT Sensor Voltage Input Line Open Circuit Inspection Turn the ignition switch OFF Disconnect ...

Page 140: ...de and ground Connection Black white Ground Standard Battery voltage Does the standard voltage exist YES GO TO STEP 3 NO Open circuit in the Black white wire 3 Fuel Injector Signal Line Open Circuit Inspection Turn the ignition switch OFF Disconnect the ECM 33P Black connector page 4 49 Check for continuity between the ECM 33P Black connector 1 and fuel injector 2P Black connector 2 of the wire ha...

Page 141: ...itch OFF Disconnect the 02 sensor 1P Black connector page 4 53 Disconnect the ECM 33P Black connector page 4 49 Check for continuity between the ECM 33P Black connector 1 of the wire harness side and 02 sensor 1P Black connector 2 of the wire harness side TOOL Test probe 2 pack 07ZAJ RDJA110 Connection A9 Black orange Is there continuity YES GO TO STEP 2 NO Open circuit in the Black orange wire 2 ...

Page 142: ...C 1 Recheck DTC Erase the DTC s page 4 12 Turn the ignition switch ON Check the IACV with the MCS Is the DTC 29 1 indicated YES GO TO STEP 2 NO Intermittent failure Loose or poor contact on the IACV 4P Black connector 2 IACV Short Circuit Inspection Turn the ignition switch OFF Disconnect the IACV 4P Black connector 1 Check for continuities between the IACV 4P Black connector of the wire harness s...

Page 143: ...istance Inspection Measure the resistance of the IACV side 4P Black connector 1 terminals Connection light green black Gray red Brown red Black red Standard 11o 150 n 25 C 77 F Is the resistance within 110 150 Q 25 C 77 F YES GO TO STEP 5 NO Faulty IACV 5 IACV Short Circuit Inspection Check for continuity of the IACV side 4P Black connector 1 terminals Connection Gray red Black red Brown red light...

Page 144: ...ts or corroded terminals Measure the voltage between the CKP sensor 6P Black connector 1 of the wire harness side and ground Connection White red Ground White blue Ground White black Ground Blue yellow Ground Standard 5 10 V Connection Brown black Blue green Standard Battery voltage Does the standard voltage exist YES GO TO STEP 2 NO Open circuit in the wire harness between the ECM and CKP sensor ...

Page 145: ...URNED ON THE MIL DOES NOT GO OFF WITHIN A SECONDS ENGINE STARTS Turn the ignition switch OFF Disconnect the ECM 21 P Black connector Turn the ignition switch ON and engine stop switch O the MIL should stay off If the MIL comes on check for short circuit in the White blue wire between the speedometer and ECM If the MIL turns off check the following Disconnect the ECM 21 P Gray connector Check for c...

Page 146: ...the Light green wire between the combination meter and ECM WHEN THE IGNITION SWITCH IS TURNED ON THE Mil DOES NOT GO OFF WITHIN A FEW SECONDS ENGINE STARTS Turn the ignition switch OFF Disconnect the ECM 33P Black connector page 4 49 Turn the ignition switch ON the MIL should stay off If the MIL comes on check for a short circuit in the Light green wire between the combination meter and ECM If the...

Page 147: ...ECM 3P Black connector 5 Remove the three bolts 1 and ECM 2 Installation is in the reverse order of removal REMOVAL INSTALLATION AFTER 13 MODEL Remove the inner cover page 2 13 Pull off the dust cover 1 Disconnect the following ECM 33P Black connector 2 ECM 3P Black connector 3 ECM 5P connector 4 Remove the three bolts 5 and ECM 6 Installation is in the reverse order of removal PGM FI SYSTEM ...

Page 148: ...tor Check for continuity between the ECM 5P connector 1 of the wire harness side and ground TOOL Test probe 2 pack 07ZAJ RDJA110 CONNECTION Green Ground Green black Ground Is there continuity YES GO TO STEP 3 NO Open circuit in the Green wire Open circuit in the Green black wire 3 Sensor Unit Power Input Line Short Circuit Inspection Turn the ignition switch OFF Disconnect the sensor unit 5P Black...

Page 149: ... 13 MODEL MIL DOES NOT COME ON AND FUEL PUMP DOES NOT OPERATE ECM DOES NOT OPERATE Before starting the inspection check for loose or poor contact on the ECM connectors and recheck the MIL blinking Make sure that the battery is fully charged 1 Fuse Inspection Check for a blown IGN INJ F_PUMP fuse 10 A Is the fuse blown YES Replace the fuse NO GO TO STEP 2 2 ECM Ground Line Inspection Turn the ignit...

Page 150: ...lated gloves and adequate eye protection Keep flammable materials away from the burner 4 52 Tighten the ECT sensor to the specified torque TORQUE 12 N m 1 2 kgf m 9 lbMt Fill the cooling system with recommended coolant page 9 5 Install the right side cover page 2 8 INSPECTION Remove the ECT sensor page 4 52 Heat the coolant with an electric heating element Suspend the ECT sensor 1 in heated coolan...

Page 151: ...e band boss 1 from the stay engine is cold Release the 02 sensor 1P Black connector 2 from the stay and disconnect it Hold the center of the 02 sensor cap 1 as shown Disconnect the cap from the sensor while slightly turning it less than 1 2 of a turn Remove the 02 Remove the 02 sensor 1 from the cylinder head sensor while the engine is cold Do not use an impact wrench when removing or installing t...

Page 152: ...nnect the 02 sensor cap 1 to the 02 sensor 2 by pushing it straight l NOTICE I Be careful not to tilt the 02 sensor cap when connecting the cap to the 02 sensor Connect the 02 sensor 1P Black connector 1 and set it to the stay Set the wire band boss 2 to the stay After installation make sure the exhaust gas does not leak Install the left side cover page 2 8 ...

Page 153: ...are Be careful not to damage the sensor wire Do not use an impact wrench while removing or installing the 02 sensor Remove the side cover page 2 8 Disconnect the 02 sensor 1P Black connector 1 and release the wire 2 from the clamp 3 Remove the 02 sensor 1 using the special tool TOOL FRXM17 Snap on or equivalent 2 Installation is in the reverse order of removal TORQUE 02 sensor 24 5 N m 2 5 kgf m 1...

Page 154: ...MEMO ...

Page 155: ...SYSTEM LOCATION SYSTEM DIAGRAM 5 3 SERVICE INFORMATION 5 4 TROUBLESHOOTING 5 5 IGNITION SYSTEM INSPECTION 5 6 IGNITION COIL 5 7 IGNITION TIMING 5 7 ...

Page 156: ...IGNITION SYSTEM SYSTEM LOCATION 13 model IGNITION SWITCH After 13 model FUSE BOX MAIN RELAY STARTER CHARGING RELAY MAIN FUSE 25 A SUB FUSE 5 A 10 Ax 4 CKP SENSOR ECM SPARK PLUG IGNITION COIL 5 2 ...

Page 157: ...MAIN FUSE 1 r 10 A W R W BI Bu Y G BI W Bu Br Bl Bu G ECM G CKP SENSOR COMBINATION SWITCH G R I I BATTERY Bl Black Y Yellow Bu Blue G Green R Red W White Br Brown 10A R o v RN BI W t11 BI W BI W BI G ENGINE STOP SWITCH CKP SENSOR Y Bu Bl Black Y Yellow Bu Blue W R G Green W Bu IGNITION R Red W BI W White ECM COIL Br Bl Br Brown Bu Y G Bu G l SPARK PLUG ...

Page 158: ...cannot 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 Using the starter with a weak battery results in a slower engine cranking speed as well as no spark at the spark plug Inspect the following Spark plug page 3 9 Ignition switch page 21 22 CKP sensor pag...

Page 159: ...ystem is by 2 4 V while cranking the engine normal if measured voltage is over the specifications with reverse connections 2 Battery is undercharged Voltage drops largely when the engine is started 3 Loose or poor connection or an open circuit in the Yellow blue wire between the ignition coil and ECM 4 A short circuit in the ignition primary coil 5 Faulty CKP sensor Check the OTC page 4 15 6 Fault...

Page 160: ...port the scooter with its centerstand on a level surface Disconnect the plug cap from the spark plug page 3 9 Connect a known good spark plug 1 to the spark plug cap and ground it to the cylinder head stay bolt as done in a spark test With the ignition coil primary wires connected connect the imrie diagnostic tester or peak voltage adaptor probes to the ignition coil primary terminal 2 and ground ...

Page 161: ...cooling fan is visible page 9 7 water hoses from the radiator Start the engine warm it up to normal operating temperature and stop it Read the instructions for timing light operation Never allow the cooling fan to come in contact with the radiator while the engine is running or the radiator will be severely damaged Connect the timing light 1 to the spark plug wire Start the engine and let it idle ...

Page 162: ...MEMO ...

Page 163: ...SYSTEM LOCATION SYSTEM DIAGRAM 6 3 SERVICE INFORMATION 6 4 TROUBLESHOOTING 6 5 STARTER CHARGING RELAY 6 8 STARTER SYSTEM INSPECTION 6 11 SIDESTAND SWITCH 6 13 ...

Page 164: ...ELECTRIC STAR ION SYSTEM LO FRONTBRAKE 13 model REAR BRAKE LIGHT SWITCH IGNITION SWITCH ECM BATTERY 6 2 LIGHT SWITCH ECM BATTERY ENGINE STOP SWITCH ALTERNATOR CKP SENSOR ...

Page 165: ...BI G B 1 W 1 ECM ENGINE STOP SWITCH G W G G BI Bu G G I e BATTERY Bl Black Y Yellow G Green R Red W White Br Brown ALTERNATOR CKP SENSOR SIDESTAND SWITCH Bu Blue STARTER After 13 model G 1 G Bl Black Y Yellow G Green R Red W White Br Brown P Pink Bu Blue C O_M_B IN_A_T_IO N SW IT_C_H __ R BATTERY R e rr R W BI W BI W 10 A 10A Br Bl G G Y STARTER SWITCH REAR BRAKE LIGHT SWITCH MAIN RELAY I G J_ G S...

Page 166: ...rter When checking the starter system always follow the steps in the troubleshooting page 6 5 If the current is kept flowing through the alternator starter to turn it while the engine is not cranking over the alternator starter may be damaged Refer to the following component information Ignition switch page 21 21 Brake light switch page 21 25 Starter switch page 21 24 Refer to the alternator start...

Page 167: ... connector Open circuit in the Black brown wire between the fuse box and front or rear brake light switch Faulty front or rear brake light switch page 21 25 Open circuit in the Green yellow wire between the front or rear brake light switch and starter switch Open circuit in the Yellow green wire between the starter switch and ECM Faulty starter switch page 21 24 4 Sidestand Inspection Turn the ign...

Page 168: ...Red white Red yellow Red blue Red white Red blue Is the resistance within 0 03 0 20 Q 20 C 68 F YES GO TO STEP 8 NO Replace the alternator starter with a new one and recheck 8 CKP Sensor Circuit Inspection Turn the ignition switch OFF Disconnect the CKP sensor 6P Black connector Turn the ignition switch ON Measure the voltage at the 6P Black connector of the ECM ide and ground CONNECTION White red...

Page 169: ...nnected connector Open circuit in the Black white wire between the ignition switch and engine stop switch Open circuit in the Black green wire between the engine stop switch and starter charging relay Open circuit in the Yellow wire between the starter charging relay and ECM Faulty engine stop switch page 21 24 Alternator starter turns engine slowly Low battery voltage Poorly connected battery ter...

Page 170: ...val OPERATION INSPECTION Remove the battery maintenance lid page 20 7 Turn the ignition switch ON and engine stop switch 0 Retract the sidestand Squeeze the brake lever and push the starter switch The system is normal if the starter charging relay 1 clicks If you hear the relay CLICK but the starter does not turn inspect the following Relay switch line page 6 9 Stator page 6 11 CKP sensor line pag...

Page 171: ...ng relay and ECM RELAY COIL LINE INSPECTION 13 MODEL Disconnect the ECM 21 P Black connector page 4 49 Turn the ignition switch ON and engine stop switch 0 Squeeze the rear brake lever and push the starter switch Measure the voltage between the ECM 21 P Black connector 1 of the wire harness side and ground TOOL Test probe 2 pack 07ZAJ RDJA110 CONNECTION Yellow ground STANDARD Battery voltage If th...

Page 172: ...ltage inspect the following Loose or poorly connected connector Open circuit in the Black white wire between the ignition switch and starter charging relay Open circuit in the Yellow wire between the starter charging relay and ECM CONTINUITY INSPECTION Remove the starter charging relay page 6 8 Connect an ohmmeter to the following relay 1 connector terminals CONNECTION A C Connect a 12 V battery t...

Page 173: ...e CKP sensor lines are normal If there is no voltage inspect the following Loose or poor contacts of related terminal Open circuit in the wire harness between the ECM and CKP sensor connector Faulty ECM STATOR INSPECTION Disconnect the ECM 3P Black connector page 4 49 Measure the resistance at the ECM 3P Black connector 1 CONNECTION Red yellow Red white Red yellow Red blue Red white Red blue STAND...

Page 174: ...starter switch and ECM Faulty starter switch page 21 24 STARTER SWITCH LINE INSPECTION AFTER 13 MODEL Disconnect the ECM 33P Black connector page 4 49 Turn the ignition switch ON Squeeze the rear brake lever fully and push the starter switch Measure the voltage between the ECM 33P Black connector 1 of the wire harness side and ground TOOL Test probe 2 pack 07ZAJ RDJA110 CONNECTION Yellow green gro...

Page 175: ...ied torque TORQUE Sidestand switch bolt 10 N m 1 0 kgf m 7 lbMt INSPECTION 13 MODEL Disconnect the ECM 21 P Gray connector page 4 49 Check for continuity between the following terminals of the ECM 21 P Gray connector 1 of the wire harness side TOOL Test probe 2 pack 07ZAJ RDJA110 CONNECTION Green white Blue green There should be continuity with the sidestand retracted and there should be no contin...

Page 176: ...de TOOL Test probe 2 pack 07ZAJ RDJA110 CONNECTION A31 A23 There should be continuity with the sidestand retracted and there should be no continuity with the sidestand applied If there is no continuity with the sidestand retracted the Continuity Sidestand retracted I ___________________ _______ r wire harness is broken or the sidestand switch is faulty No continuity Sidestand applied 1 A23 A31 6 1...

Page 177: ...UEL SUPPLY TEST AFTER 13 MODEL 7 9 FUEL PUMP UNIT 7 10 FUEL TANK 7 13 AIR CLEANER HOUSING 7 13 THROTTLE BODY 7 15 IACV 7 22 FUEL INJECTOR 7 24 INTAKE PIPE 7 25 EVAP PURGE CONTROL SOLENOID VALVE EXCEPT 13 MODEL CM TYPE 7 27 EVAP CANISTER EXCEPT AFTER 13 MODEL CM TYPE 7 28 ...

Page 178: ...FUEL SYSTEM COMPON NT LOCATION 13 model 12 N m 1 2 kgf m 9 lbf ft 11 N m 1 1 kgf m 8 lbf ft 7 2 ...

Page 179: ...FUEL SYSTEM 1 1 N m 1 1 kgf m 8 lbMt ...

Page 180: ...an cause throttle valve and idle control failure The parts of the throttle body not shown in this manual should not be disassembled For fuel level sensor inspection page 21 19 SPECIFICATIONS ITEM SPECIFICATIONS Throttle body identification number 13 model GQMHA After 13 model GQMNA Throttle grip freeplay 2 6 mm 0 1 0 2 in Fuel pressure at idle 13 model 294 kPa 3 0 kgf cm2 43 psi After 13 model 263...

Page 181: ...e 07AAJ S6MA200 U S A only Pressure gauge manifold 07ZAJ S5A0111 Not available in U S A Attachment joint 6 mm 9 mm 07ZAJ S5AO150 Not available in U S A Adaptor B female 07AAJ S6MA400 U S A only SYSTEM Hose attachment 9 mm 9 mm 07ZAJ S5A0120 Not available in U S A Pressure manifold hose 07AMJ HW3A100 U S A only SCS connector 070PZ ZY30100 ...

Page 182: ...essure from the system by following the procedures above This scooter uses resin for the part of materials in the fuel feed hose Do not bend or twist the fuel feed hose 1 Check the fuel quick connect fitting 1 for dirt and clean if necessary Place a shop towel over the quick connect fitting Push the retainer tab 2 forward 2 Press down the retainer 1 and hold Disconnect the connector 2 from the fue...

Page 183: ...mall amount of engine oil on the pipe end 2 Make sure the connection is secure check visually and by pulling the connector FUEL PRESSURE NORMALIZATION 1 Connect the fuel pump SP connector 1 2 Set the battery box 2 in position then install and tighten the two special bolts 3 3 Connect the negative cable 4 to the battery and tighten the bolt 5 4 Turn the ignition switch ON and engine stop switch 0 N...

Page 184: ...00 07AAJ S6MA400 Temporarily connect the positive cable and negative cable to the battery and fuel pump 5P connector Start the engine and let it idle Read the fuel pressure STANDARD 13 model 294 kPa 3 0 kgf cm2 43 psi After 13 model 263 316 kPa 2 7 3 2 kgf cm2 38 46 psi If the fuel pressure is higher than specified replace the fuel pump unit page 7 10 If the fuel pressure is lower than specified i...

Page 185: ... 98 cm3 3 31 US oz 3 45 Imp oz minimum 10 seconds After 13 82 cm3 2 77 US oz 2 89 Imp oz model minimum 10 seconds If fuel flow is less than specified inspect the following Clogged fuel hose Fuel pump unit page 7 10 Clogged fuel filter page 7 10 Connect the quick connect fitting and normalize the fuel pressure page 7 7 13 1 Fuel Pressure Test 1 Perform the fuel pressure test page 7 8 Standard 263 3...

Page 186: ...the fuel pump 5P connector page 7 6 Turn the ignition switch ON and measure the voltage at the fuel pump 5P connector 1 terminals of the wire harness side CONNECTION Black white Brown yellow STANDARD Battery voltage There should be standard voltage for a few seconds If there is standard voltage replace the fuel pump unit If there is no standard voltage inspect the following Open circuit in the Bla...

Page 187: ...el pump unit page 7 10 Release the hooks 1 of the fuel filter 2 from the stoppers 3 by slightly spreading the hooks then turn the filter clockwise Pull up the filter and remove it from the fuel pump Remove the 0 ring 1 Apply a small amount of engine oil to a new 0 ring and install it Install a new fuel filter 1 in the correct direction so that the triangle marks on the filter and fuel pump body wi...

Page 188: ...nit 1 to the fuel tank hole NOTE Insert the fuel level sensor into the tank while bending the fuel filter 2 Push the fuel pump unit 1 into the fuel tank so that the pump tabs 2 are positioned between the ribs as shown NOTE Make sure the dust seal is installed properly Install the set plates 1 with their UP marks 2 facing up while pushing down the fuel pump unit Install and tighten the fuel pump se...

Page 189: ...l tank Disconnect the fuel tank breather hose 4 EXCEPT After 13 Release the EVAP solenoid valve to intake pipe hose model CM type 1 from the hose guide 2 Disconnect the fuel tray drain hose 3 from the fuel tray 4 Remove the fuel tank cap 5 and fuel tray Install the fuel tank cap Remove the following Two bolts 1 Bolt washers 2 Collar 3 Fuel tank 4 Installation is in the reverse order of removal IN ...

Page 190: ...isconnect the connecting hose 3 from the throttle body by holding the throttle body and pulling the air cleaner housing backward Remove the air cleaner housing Installation is in the reverse order of removal Set the connecting hose band with its band screw 1 facing left side as shown Tighten the air cleaner connecting hose band screw until the band seat on the collar 2 TORQUE Air cleaner housing m...

Page 191: ...al the intake pipe with a shop towel or cover it with a piece of tape to prevent any foreign material from dropping into the engine REMOVAL AFTER 13 MODEL Remove the luggage box page 2 25 Loosen the throttle cable nuts 1 Disconnect the throttle cables 2 from the cable bracket 3 and throttle drum 4 Disconnect the sensor unit SP Black connector 5 and IACV 4P Black connector 6 Loosen the connecting h...

Page 192: ...white painted nut 1 of the throttle drum Loosening or tightening it can cause throttle body malfunction 13 model Always clean around the throttle body before the sensor unit removal to prevent dirt and debris from entering the air passage Remove the torx screws 1 sensor unit 2 and 0 ring 3 Remove the IACV page 7 22 After 13 model Always clean around the throttle body before the 7 1 sensor unit rem...

Page 193: ...ge in the throttle body TORX SCREWS 1 with compressed air Do not use high pressure air or bring the nozzle too close to the throttle body 13 MODEL 0 RING 3 4 N m 0 35 kgf m 2 5 lbf ft IACV 3 4 N m 0 35 kgf m 2 5 lbf ft 2 1 N m 0 21 kgf m 1 5 lbf ft ...

Page 194: ...to assemble the sensor unit and throttle body in the correct position If you cannot assemble them easily the clip may be misaligned Do not attempt to force them together and make sure that the clip is aligned Install and tighten the torx screws 1 to the specified torque TORQUE 3 4 N m 0 35 kgf m 2 5 lbf ft After installing the throttle body perform the TP sensor reset procedure page 7 21 ASSEMBLY ...

Page 195: ...t the clip is aligned Do not hold the throttle drum when installing the sensor unit Install and tighten the screws 1 to the specified torque TORQUE 2 1 N m 0 21 kgf m 1 5 lbMt After installing the throttle body perform the TP sensor reset procedure page 7 21 INSTALLATION 13 MODEL Install the throttle body 1 between the connecting hose 2 and insulator band 3 Align the throttle body tab with the ins...

Page 196: ...ntake pipe 3 Tighten the intake pipe bolts 4 Posit ion the connecting hose band with its connecting hose band screw 5 facing the left side as shown Tighten the connecting hose band screw until the band seats the collar 6 Connect the sensor unit 5P Black connector 1 and IACV 4P Black connector 2 Connect the lower throttle cable 3 first then connect the upper throttle cable 4 to the throttle drum 5 ...

Page 197: ...stop switch O then disconnect the jumper wire from the ECT sensor 2P Black connector within 10 seconds while the MIL is blinking reset receiving pattern 6 Check if the MIL blinks After disconnection of the jumper wire the MIL should start blinking successful pattern If the jumper wire is connected for more than 10 seconds the MIL will stay ON unsuccessful pattern Try again from the step 4 ijf ij__...

Page 198: ... slide valve 1 clockwise until lightly seated on IACV 2 2 Install the set plate 3 by aligning the tab of the IACV with the slot of set plate as shown Install the IACV 1 by aligning the pin with the slide valve slot Install and tighten the torx screws 1 to the specified torque TORQUE 2 1 N m 0 21 kgf m 1 5 lbMt Connect the IACV 4P Black connector 2 Install the left side cover page 2 8 1 1 Align ...

Page 199: ...operating sound with the ignition switch turned ON Remove the IACV page 7 22 Check the IACV slide valve 1 and IACV air passage in the throttle body for carbon deposits Clean the IACV slide valve and IACV air passage if necessary Temporarily connect the IACV 4P Black connector 2 Turn the ignition switch ON The slide valve should move back and forth Turn the ignition switch OFF Disconnect the IACV 4...

Page 200: ...njector Check the removed parts for wear or damage and replace them if necessary INSTALLATION Coat new 0 ring 1 and seal ring 2 with engine oil Install a new 0 ring and seal ring to the fuel injector 3 being careful not to damage them Install the fuel injector joint 4 to the fuel injector by aligning the both tabs Install the fuel injector joint injector 1 into the intake pipe Install and tighten ...

Page 201: ...nd 4 from the throttle body Remove the insulator 1 from the intake port Remove the 0 rings 2 from the insulator Remove the insulator band 1 from the intake pipe 2 Seal the cylinder head intake port with a shop towel or cover it with a piece of tape to prevent any foreign material from dropping into the engine INSTALLATION 13 MODEL Install the insulator band 1 to the intake pipe 2 by aligning the t...

Page 202: ... intake pipe mounting bolts 1 Tighten the insulator band bolts 2 to the specified torque TORQUE 5 N m 0 51 kgf m 3 7 lbHt Connect the EVAP canister to intake pipe hose 3 to the intake pipe joint Install the fuel injector page 7 24 REMOVAL INSTALLATION AFTER 13 MODEL Remove the luggage box page 2 25 Disconnect the following Quick connect fitting 1 page 7 6 Injector 2P Black connector 2 Remove the i...

Page 203: ...ter cover page 2 10 Disconnect the following EVAP purge control solenoid valve 2P Black connector 1 EVAP purge control solenoid valve to intake pipe hose 2 EVAP canister to EVAP purge control solenoid valve hose 3 Remove the two screws 4 and EVAP purge control solenoid valve 5 Installation is in the reverse order of removal INSPECTION Remove the EVAP purge control solenoid valve page 7 27 Check th...

Page 204: ...pecification replace the EVAP purge control solenoid valve REMOVAL INSTALLATION Remove the front cover page 2 15 R 13 Disconnect the following from the EVAP canister 1 EVAP canister drain hose 2 EVAP canister to fuel tank hose 3 Canister to EVAP purge control solenoid valve hose 4 Remove the EVAP canister by releasing the groove from the frame Installation is in the reverse order of removal 1 ...

Page 205: ...LUBRICATION SYSTEM DIAGRAM 8 2 TROUBLESHOOTING 8 4 SERVICE INFORMATION 8m3 OIL PUMP 8 5 ...

Page 206: ...LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM ROCKER ARM SHAFT J PISTON i j 1 t CRANKSHAFT OIL STRAINER SCREEN 8 2 ...

Page 207: ...ck that there are no oil leaks SPECIFICATIONS Engine oil capacity Recommended engine oil Oil pump rotor TORQUE VALUE ITEM Oil pump mounting bolt TOOLS Driver 07749 0010000 ITEM STANDARD After draining 0 8 liter 0 8 US qt 0 7 Imp qt After disassembly 0 9 liter 1 0 US qt 0 8 Imp qt After oil strainer removal 0 9 liter 1 0 US qt 0 8 Imp qt Pro Honda HP4M 4 stroke oil U S A and Canada or equivalent mo...

Page 208: ...ternal oil leak Worn piston rings page 11 8 Incorrect piston ring installation page 11 9 Worn cylinder page 11 5 Worn valve guide page 10 16 Worn valve stem seal page 10 14 Oil contamination Oil not changed often enough Faulty cylinder head gasket Worn piston rings page 11 8 8 4 ...

Page 209: ...he stator page 14 4 Remove the bolts 1 and stator base 2 Remove the 0 ring 1 from the stator base groove Remove the dowel pins 2 from right crankcase Remove the oil pump driven gear 3 Remove the oil pump mounting bolts 1 and oil pump 2 Remove the dowel pins 3 Remove the outer rotor 1 from the oil pump assembly 2 2 ...

Page 210: ...easure at several points and use the largest reading OUTER ROTOR Check the oil pump outer rotor sliding surface for wear or damage Measure the 0 0 and height of outer rotor STANDARD OUTER ROTOR O D 22 970 23 000 mm 0 9043 0 9055 in OUTER ROTOR HEIGHT 6 960 6 980 mm 0 2740 0 2748 in Measure at several points and use the smallest reading Calculate the oil pump body to outer rotor clearance SERVICE L...

Page 211: ...ase surface as shown using the special tools TOOLS 2 Driver 3 Attachment 32 x 35 mm INSTALLATION 07749 0010000 07746 0010100 Apply engine oil to the entire surface of the inner 1 and outer 2 rotors and to the oil pump shaft 3 sliding surface Install the outer rotor to the oil pump assembly 4 Install the dowel pins 1 Install the oil pump 2 to the crankcase Install and tighten the oil pump mounting ...

Page 212: ... pump driven gear by aligning its groove with the oil pump shaft pin Install the dowel pins 1 to the right crankcase Apply engine oil to a new 0 ring 2 Install the 0 ring to the stator base groove Apply engine oil to the right crankshaft oil seal 3 lips Install the stator base 1 and tighten the bolts 2 Install the stator page 14 6 Fill the engine oil page 3 12 ...

Page 213: ...SYSTEM FLOW PATTERN 9 2 COOLANT 9 5 SERVICE INFORMATION 9 3 RADIATOR 9 6 TROUBLESHOOTING 9 3 RADIATOR RESERVE 9 7 COOLING SYSTEM TESTING 9 4 WATER PUMP THERMOSTAT 9 8 ...

Page 214: ...COOLING SYSTEM When the engine is cold When the engine is hot 13 model shown 9 2 RADIATOR RESERVE TANK DRAIN HOSE SIPHON HOSE RADIATOR WATER PUMP THERMOSTAT RESERVE TANK WATER HOSE THERMOSTAT ...

Page 215: ...alve lift 13 model After 13 model Recommended antifreeze Standard coolant concentration TORQUE VALUES ITEM QTY Radiator drain bolt 1 Radiator base screw 1 Radiator top cover screw 4 Engine temperature too high Thermostat stuck closed Faulty radiator cap Insufficient coolant Passage blocked in radiator hoses or water jacket Air in system Faulty water pump Engine temperature too low Thermostat stuck...

Page 216: ... the radiator cap if it does not hold pressure or if relief pressure is too high or too low The cap must hold the specified pressure for at least 6 seconds RADIATOR CAP RELIEF PRESSURE 108 137 kPa 1 1 1 4 kgf cm2 16 20 psi Pressurize the radiator engine and hoses using the tester and check for leaks Repair or replace components if the system will not hold the specified pressure for at least 6 seco...

Page 217: ... radiator and tighten it to the specified torque TORQUE 1 N m 0 1 kgf m 0 7 lbMt When filling the Fill the system with the coolant through the filler system or reserve opening to the filler neck 1 tank with coolant or checking the RECOMMENDED ANTIFREEZE coolant level Pro Honda HP Coolant or an equivalent high support the scooter quality ethylene glycol antifreeze containing with its centerstand si...

Page 218: ...ll as follows Remove the radiator reserve tank lid 1 Remove the reserve tank cap 2 and fill the tank to the UPPER level line with a recommend antifreeze RECOMMENDED ANTIFREEZE High quality ethylene glycol antifreeze containing silicate free corrosion inhibitors Check if there are any coolant leaks when the coolant level decreases very rapidly If the reserve tank becomes completely empty there is a...

Page 219: ...nk 2 Remove the special bolt 3 Remove the reserve tank 1 by releasing the boss 2 from the groove 3 of the rear fender Open the reserve tank cap 4 and drain the coolant into an approved pan Disconnect the siphon hose 5 from the reserve tank Installation is in the reverse order of removal After installation fill the reserve tank with the coolant page 9 6 REMOVAL INSTALLATION AFTER 13 MODEL Remove th...

Page 220: ...ater pump as an assembly A small amount of weeping from the bleed hole is normal Make sure that there is no continuous coolant leakage from the bleed hole while operating the engine 9 8 REMOVAL DISASSEMBLY The water pump can be serviced with the engine installed on the frame Drain the coolant page 9 5 Remove the right side cover page 2 8 Disconnect the water hoses 1 from the water pump and thermos...

Page 221: ...amage Replace the thermostat if it stays open at room temperature Heat a container of water with an electric heating element for 5 minutes Suspend the thermostat in heated water to check its operation VALVE BEGINS TO LIFT OPEN 13 model 74 78 c 165 172 F After 13 model 84 88 c 183 190 F VALVE LIFT 13 model 8 mm 0 3 in minimum at 100 c 212 F After 13 model 5 3 mm 0 2 in minimum at 95 C 203 F Replace...

Page 222: ...t oil to this 0 ring 2 Install the thermostat to the water pump cover and tighten the bolts 3 Do not apply engine Install a new 0 ring 1 into the groove of the water oil to this 0 ring pump 2 9 10 Install the two dowel pins 3 to the water pump cover Install the water pump cover thermostat 4 to the water pump e 0 RING Do not apply engine oil to these 0 rings 2 3 4 1 3 2 ...

Page 223: ...water pump shaft mating area with the camshaft Install the water pump thermostat assembly 2 to the cylinder head while aligning the pin on the water pump shaft with the groove on the camshaft Install and tighten the three water pump mounting bolts 1 then tighten the water pump cover bolt 2 Make sure that the Connect the water hoses 1 to the water pump and hoses and clips are thermostat installed i...

Page 224: ...MEMO ...

Page 225: ...COMPONENT LOCATION 1 CYLINDER COVER 10 6 SERVICE INFORMATION 10m3 CAMSHAFT 1Oa8 TROUBLESHOOTING 10 5 CYLINDER 10 13 CYLINDER COMPRESSION TEST 10 6 CAM CHAIN TENSIONER 10m23 1 ...

Page 226: ...CYLINDER HEADNALVES CO PONENT 8 N m 0 82 kgf m 5 9 lbf ft I 27 N m 2 8 kgf m 20 lbf ft 10 2 ...

Page 227: ...ylinder head warpage 0 05 0 002 Rocker arm shaft 0 0 IN EX 9 960 9 972 0 3921 0 3926 C amshaft Cam lobe height IN 33 616 33 856 1 3235 1 3329 EX 33 393 33 633 1 3147 1 3241 Valve Valve clearance IN 0 10 0 02 0 004 0 001 valve EX 0 24 0 02 0 009 0 001 guide Valve stem O D IN 4 975 4 990 0 1959 0 1965 4 90 0 193 EX 4 955 4 970 0 1951 0 1957 4 90 0 193 Valve guide I D IN EX 5 000 5 012 0 1969 0 1973 ...

Page 228: ...guide adjusting driver 07743 0020000 Not available in U S A Seat cutter 27 5 mm EX 45 07780 0010200 or equivalent commercially available in U S A Interior cutter 30 mm IN 60 07780 0014000 or equivalent commercially available in U S A Valve guide reamer 5 0 mm 07984 MA60001 or 07984 MA6000D U S A only Tensioner holder 070MG 0010100 or 07AMG 001A100 U S A only Flat cutter 30 mm IN 32 07780 0012200 o...

Page 229: ...Uneven valve seating Valve stuck open Weak valve spring Cylinder head Leaking or damaged cylinder head gasket Warped or cracked cylinder head Loose spark plug Worn cylinder page 11 5 Worn piston or piston rings page 11 8 Compression too high overheating or knocking Excessive carbon build up on piston head or on combustion chamber Excessive smoke Worn valve stem or valve guide Damaged stem seal Wor...

Page 230: ...0 rpm If compression is high it indicates that carbon deposits have accumulated on the combustion chamber and or the piston crown If compression is low pour 3 5 cm3 of clean engine oil into the cylinder through the spark plug hole and recheck the compression If the compression increases from the previous value check the cylinder piston and piston rings Leaking cylinder head gasket Worn piston ring...

Page 231: ...Bond 5211C or 1215 or SHIN ETSU SILICONE KE45T or LOCTITE 5060S or 5020 or equivalent to the cylinder head and rubber seal mating surface as shown Install the cylinder head cover 1 onto the cylinder 2 head Install the bolts 2 and tighten them Set the hose guide 1 then install and tighten the bolt 2 Connect the crankcase breather hose 3 Install the battery box page 2 26 HEADNALVES __ l 5 10 mm 0 2 ...

Page 232: ...cylinder head and that the KWN mark 2 on the cam sprocket is facing up as shown TDC on the compression stroke If the cam sprocket KWN mark is not facing up rotate the crankshaft one full turn and realign the index lines on the cam sprocket Remove the cam chain tensioner lifter screw 1 and 0 ring 2 Install the special tool 3 into the tensioner body and turn the tool clockwise until it stops turning...

Page 233: ...MPRESSORSYSTEM Turn the decompressor 1 with your finger Make sure that the decompressor operates smoothly and that the weight returns back in position If the decompressor is faulty replace the camshaft as an assembly CAMSHAFT Turn the outer race of each camshaft bearing 1 with your finger The bearing should turn smoothly and quietly Also check that the bearing inner race fits tightly on the camsha...

Page 234: ...r damage Turn the rocker arm rollers 4 with your finger The rollers should turn smoothly and quietly Measure the 0 0 of each rocker arm shaft STANDARD IN EX 9 960 9 972 mm 0 3921 0 3926 in Temporarily install the rocker arm shaft 1 to the rocker arm 2 Check the rocker arm needle bearing for excessive play and rocker arm shaft for smooth movement INSTALLATlON Apply engine oil to the camshaft bearin...

Page 235: ...per bolt 2 to the specified torque TORQUE 10 N m 1 0 kgf m 7 lbMt Apply engine oil to the rocker arm 1 roller surface Apply molybdenum oil solution to the sliding surface of the rocker arm needle bearing 2 and rocker arm shaft 3 Intake and exhaust rocker arms have identification marks I 1 is for the intake rocker arm and E 2 is for the exhaust rocker arm 2 2 CYLINDER HEADNALVES 3 1 1 1 ...

Page 236: ...h the index mark 2 on the crankcase Apply engine oil to the cam chain 1 whole surface and cam sprocket 2 teeth Install the cam chain on the cam sprocket Install the cam sprocket to the camshaft so that the index lines 3 on the cam sprocket is flush with the cylinder head and KWN mark 4 is facing forward as shown TDC on the compression stroke Align Place a shop towel Apply engine oil to the seating...

Page 237: ...ll and bleed the coolant page 9 5 Fill the engine oil page 3 12 REMOVAL Remove the following Engine page 16 4 Camshaft page 10 8 Exhaust pipe muffler page 2 28 Intake pipe page 7 25 Spark plug page 3 9 02 sensor page 4 53 ECT sensor page 4 52 Remove the two bolts 1 and water joint 2 from the cylinder head Remove the 0 ring 3 from the water joint Remove the bolts 1 and wire guides 2 from the cylind...

Page 238: ...g disassembly so they can be placed back in their original locations 10 1 DISASSEMBLY Remove the bolts 1 and water pump holder 2 Remove the valve cotters 1 using the special tool TOOLS 2 Valve spring compressor 3 Valve spring compressor attachment 07757 0010000 07959 KM30101 Remove the valve spring compressor and remove the following Valve spring retainers 1 Valve springs 2 Valve spring seats 3 Va...

Page 239: ... for cracks Check the cylinder head for warpage with a straight edge and a feeler gauge SERVICE LIMIT 0 05 mm 0 002 in VALVE SPRING Measure the free length of the valve springs STANDARD IN EX 36 94 mm 1 454 in VALVE VALVE GUIDE Check that the valve moves smoothly in the guide Check each valve for bends burns scratches or abnormal wear Measure each valve stem O D and record it SERVICE LIMITS IN EX ...

Page 240: ...he valve SERVICE LIMITS IN EX 5 03 mm 0 198 in guides are replaced Subtract each valve stem O D from the corresponding page 10 17 guide I D to obtain the stem to guide clearance 10 16 SERVICE LIMITS IN 0 08 mm 0 003 in EX 0 10 mm 0 004 in If the stem to guide clearance exceeds the service limit determine if a new guide with standard dimensions would bring the clearance within tolerance If so repla...

Page 241: ...ber side TOOL 2 Valve guide driver 5 0 mm 07942 MAGOOOO Take out new valve guides 1 from the freezer Drive new valve guides into the cylinder head to the specified height from the cylinder head TOOL 2 Valve guide adjusting driver 07743 0020000 Not available in U S A VALVE GUIDE PROJECTION IN EX 11 05 11 35 mm 0 435 0 447 in Let the cylinder head cool to room temperature Ream new valve guides after...

Page 242: ... using a hand lapping tool without rotating the valve to make a clear pattern Remove the valve and inspect the valve seat face The valve seat contact should be within the specified width and even all around the circumference STANDARD 0 90 1 10 mm 0 035 0 043 in SERVICE LIMIT 1 5 mm 0 06 in If the valve seat width is not within specification reface the valve seat Inspect the valve seat face for Dam...

Page 243: ... 0012200 Flat cutter 27 mm EX 32 07780 0013300 Cutter holder 5 0 mm 07781 0010400 or equivalent commercially available in U S A Use a 60 interior cutter remove the bottom 1 4 of the existing valve seat material TOOLS Interior cutter 30 mm IN 60 07780 0014000 Interior cutter 24 mm EX 60 070PH ZOD0100 Cutter holder 5 0 mm 07781 0010400 or equivalent commercially available in U S A Using a 45 seat cu...

Page 244: ...bf ft INTAKE VALVE INTAKE ROCKER ARM SHAFT la Blow through the oil passage in the cylinder head with compressed air Apply engine oil to the inner surface of new valve stem seals 1 Install the valve spring seats 2 and new valve stem seals Apply molybdenum oil solution to the valve stem sliding surface and stem end Insert the valves 3 into the valve guides while turning them slowly to avoid damage t...

Page 245: ...mly using a to prevent valve damage hammer Apply liquid sealant Three Bond 1207B or 1215 or LOCTITE 5060S or 5020 or equivalent to the mating surface of the cylinder head and water pump holder 1 as shown Install the water pump holder while aligning its pins with the holes on the cylinder head Install and tighten the water pump holder bolts 1 to the specified torque TORQUE 10 N m 1 0 kgf m 7 lbHt A...

Page 246: ... cylinder 10 22 Route the cam chain 1 through the cylinder head 2 and install the cylinder head onto the cylinder Apply engine oil to the seating surface and threads of the cylinder head nuts 3 whole surface of the washers 4 and cylinder stud bolt upper threads 5 Install the cylinder head nuts and washers then tighten them in a crisscross pattern to the specified torque TORQUE 27 N m 2 8 kgf m 20 ...

Page 247: ...3 Tensioner holder 070MG 0010100 or 07AMG 001A100 U S A only Remove the bolts 4 and cam chain tensioner lifter 5 Remove the gasket 6 from the tensioner lifter INSPECTION Remove the cam chain tensioner lifter 1 page 10 23 Check the cam chain tensioner lifter operation The tensioner shaft 2 should not go into the body when it is pushed When it is turned clockwise with the tensioner holder 3 the tens...

Page 248: ... 10 24 Apply engine oil to a new 0 ring 1 Install a new 0 ring to the cam chain tensioner lifter Install and tighten the screw 2 to the specified torque TORQUE 4 N m 0 41 kgf m 3 0 lbMt Install the throttle body page 7 19 ...

Page 249: ...COMPONENT LOCATION 11 SERVICE INFORMATION 11 3 TROUBLESHOOTING 11 4 CYLINDER 11 PISTON 11 7 11 ...

Page 250: ...CYLINDER PISTON COMPON NT LOCATION 11 2 ...

Page 251: ...970 57 990 2 2822 2 2831 rings piston Piston O D measurement point 6 5 0 26 from bottom of skirt pin Piston pin bore I D 14 002 14 008 0 5513 0 5515 14 04 0 553 Piston pin O D 13 994 14 000 0 5509 0 5512 13 96 0 550 Piston to piston pin clearance 0 002 0 014 0 0001 0 0006 0 02 0 001 Piston ring to ring Top 0 015 0 055 0 0006 0 0022 0 08 0 003 groove clearance Second 0 015 0 055 0 0006 0 0022 0 08 ...

Page 252: ...on build up on piston head or on combustion chamber Excessive smoke Worn cylinder piston or piston ring Improper installation of piston rings Scored or scratched piston or cylinder wall Cylinder head valve problem page 10 15 Abnormal noise Worn piston pin or piston pin hole Worn connecting rod small end Worn cylinder piston or piston rings Piston ring sticking scuffing bearing damage Clogged oil g...

Page 253: ... mating surface Attach a piece of wire to the cam chain 2 to prevent it from falling into the crankcase Disconnect the water hose 3 from the cylinder Do not reuse the Remove the gasket 1 and dowel pins 2 old gasket Clean off any gasket material from the cylinder mating surface of the crankcase INSPECTION Check the cylinder for warpage with a straight edge and feeler gauge in the directions shown S...

Page 254: ...rance for the oversize piston must be 0 01 0 04 mm 0 0004 0 0016 in STUD BOLT REPLACEMENT Thread two nuts onto the stud and tighten them together and use wrench on them to turn the stud bolt out Install the stud bolts Install new stud bolts A 1 into the right crankcase with their larger Install new stud bolts B 2 into the left crankcase thread end o o 3 Tighten the stud bolts to the specified torq...

Page 255: ...t the ignition coil wire connectors 3 Install the 02 sensor 1P Black connector 4 to the ignition coil stay Install the cylinder head page 10 22 REMOVAL Be careful not to let Remove the cylinder page 11 5 the piston pin clips Remove the piston pin clips 1 with pliers fall into the opening Push the piston pin 2 out of the piston 3 and of the crankcase connecting rod then remove the piston Spread eac...

Page 256: ...ck the piston outer surface for scratches or damage Measure the piston pin hole Take the maximum reading to determine 1 0 SERVICE LIMIT 14 04 mm 0 553 in Measure the piston pin 0 0 at piston and connecting rod sliding areas SERVICE LIMIT 13 96 mm 0 550 in Calculate the piston to piston pin clearance SERVICE LIMIT 0 02 mm 0 001 in Measure the piston 0 0 at the point 6 5 mm 0 26 in from the bottom a...

Page 257: ...oil ring install the spacer 5 first then install the side rails 6 Stagger the piston ring end gaps 120 apart from each other Stagger the side rail end gaps as shown Apply engine oil to the connecting rod 1 small end inner surface Apply engine oil to the piston pin 1 outer surface and piston pin hole inner surface Install the piston 2 with the IN mark 3 facing the intake side Install the piston pin...

Page 258: ...all the new pin clips 1 the piston pin clips NOTE fall into the opening of the crankcase Make sure the piston pin clips are seated securely 11 10 Do not align the piston pin clip end gap with the piston cut out 2 Install the cylinder page 11 6 ...

Page 259: ...1 COMPONENT LOCATION 1 SERVICE INFORMATION 12 3 TROUBLESHOOTING 12 5 LEFT CRANKCASE COVER 12 6 DRIVE 12 8 DRIVE PULLEY 12 9 CLUTCH DRIVEN PULLEY 12 12 1 ...

Page 260: ...DRIVE PULLEY DRIVEN PULLEY CLUTCH NT LOCATION 59 N m 6 0 kgf m 44 lbf ft 49 N m 5 0 kgf m 36 lbf ft 12 2 ...

Page 261: ... Movable drive face Bushing I D 23 989 24 052 0 9444 0 9469 24 08 0 948 Boss O D 23 960 23 974 0 9433 0 9439 23 93 0 942 Weight roller O D 19 92 20 08 0 784 0 791 19 5 0 77 Clutch Lining thickness 2 0 0 08 Clutch outer I D 125 0 125 2 4 92 4 93 125 5 4 94 Driven pulley Face spring free length 151 1 5 95 146 6 5 77 Driven face O D 33 965 33 985 1 3372 1 3380 33 94 1 336 Movable driven face I D 34 0...

Page 262: ...2 4 Bearing remover shaft 10 mm 07936 GE00100 or 07936 GEOAOOO U S A only Bearing remover 15 mm 07936 KC10500 U S A only Driver 07749 0010000 Clutch spring compressor 07LME GZ40201 or 07960 KM1000B U S A only Bearing remover head 15 mm 07936 KC10200 Not available in U S A Attachment 32 x 35 mm 07746 0010100 Clutch center holder 07725 0030000 Socket wrench 39 x 41 mm 07GMA KS40100 or equivalent com...

Page 263: ...946 1870100 Worn or damaged clutch shoes and or clutch outer Broken driven face spring Engine stalls or scooter creeps Broken clutch shoe spring Poor performance at high speed or lack of power Worn drive belt Weak driven face spring Worn weight rollers Contaminated pulley faces LLEY DRIVEN PULLEY CLUTCH Remover weight 07741 0010201 or 07936 371020A U S A only Pilot 20 mm 07746 0040500 1 ...

Page 264: ...nkcase BEARING INSPECTION REPLACEMENT INSPECTION Turn the inner race of the bearing with your finger The bearing should turn smoothly and quietly Also check that the bearing outer race fits tightly in the left crankcase cover Replace the bearing if the inner race does not turn smoothly quietly or if the outer race fits loosely in the left crankcase cover REPLACEMENT Remove the snap ring 1 from the...

Page 265: ...OLS 6 Bearing remover head 15 mm 07936 KC10200 7 Bearing remover shaft 15 mm 07936 KC10100 5 Remover weight 07741 0010201 U S A TOOLS Bearing remover 15 mm Remover weight Apply engine oil to the bearing cavity 07936 KC10500 07936 371020A Drive a new drive shaft bearing bushing 1 into the left crankcase cover squarely until it is fully seated using the special tools TOOLS 2 Driver 3 Attachment 32 x...

Page 266: ...en the bolts 3 Install the left side cover page 2 8 DRIVE LT Do not get grease on the drive shaft splines from the driven face inside 12 8 REPLACEMENT Remove the following Drive pulley face page 12 9 Clutch outer page 12 12 Slide off the clutch driven pulley assembly 1 from the drive shaft 2 Remove the drive belt 3 and replace it with a new one Install the clutch driven pulley assembly onto the dr...

Page 267: ...0 Release the drive belt 5 from the drive pulley boss Remove the movable drive face assembly 1 while holding the back of the face ramp plate 2 and drive face boss 3 DISASSEMBLY ASSEMBLY 13 MODEL Remove the following Drive face boss 1 Ramp plate 2 Slide pieces 3 Weight rollers 4 Assembly is in the reverse order of disassembly PULLEY DRIVEN PULLEY CLUTCH Clean any oil and grease from the weight roHe...

Page 268: ...ing Drive face boss 1 Oil seal 2 Ramp plate 3 Slide pieces 4 Weight rollers 5 Assembly is in the reverse order of disassembly Clean any oil and grease from the weight rollers and movable drive face 6 6 2 INSPECTION DRIVE PULLEY FACE Check the drive pulley face 1 for scratches scoring or damage 5 1 ...

Page 269: ... D SERVICE LIMIT 23 93 mm 0 942 in MOVABLE DRIVE FACE Check the movable drive face for scratches scoring or damage Measure the drive face bushing I D SERVICE LIMIT 24 08 mm 0 948 in INSTALLATION Clean any oil and grease from the drive face and drive belt Install the movable drive face assembly 1 onto the crankshaft while holding the ramp plate 2 and drive face boss 3 PULLEY DRIVEN PULLEY CLUTCH 1 ...

Page 270: ...er holder 07725 0030000 TORQUE 59 N m 6 0 kgf m 44 lbf ft Install the left crankcase cover page 12 8 CLUTCH DRIVEN PULLEY REMOVAL Use the special tool when loosening the lock nut Holding the rear wheel or rear brake will damage the final reduction system 12 12 Remove the left crankcase cover page 12 6 Hold the clutch outer 1 with the special tool TOOL 2 Flywheel holder 07725 0040001 Remove the nut...

Page 271: ... driven pulley by turning the clutch spring compressor clockwise Hold the clutch spring compressor in a vise Remove the clutch driven pulley nut 1 using the special tool TOOL 2 Socket wrench 39 x 41 mm 07GMA KS40100or equivalent commercially available in U S A 1 Align BOSSES HOLES 2 Loosen the clutch spring compressor gradually and remove the following 2 Clutch assembly 1 Spring seat 2 Driven face...

Page 272: ...r rubbers 1 from the drive plate 2 DRIVEN PULLEY Remove the seal collar 1 Remove the guide pins 2 and guide rollers 3 from the driven face 4 Remove the movable driven face 5 from the driven face 2 1 Remove the 0 rings 6 and oil seals 7 from the movable driven face 5 12 14 INSPECTION NOTE For clutch shoes inspection page 3 23 4 2 1 1 7 ...

Page 273: ...iven face spring free length SERVICE LIMIT 146 6 mm 5 77 in DRIVEN FACE Check the driven face for scratches scoring or damage Measure the driven face boss O D SERVICE LIMIT 33 94 mm 1 336 in MOVABLE DRIVEN FACE Check the movable driven face for scratches scoring or damage Check the guide grooves for stepped wear or damage Measure the movable driven face I D SERVICE LIMIT 34 06 mm 1 ...

Page 274: ...2 out of the driven face Pack new ball bearing 1 with grease NIPPON OIL P U N6B or N6C or equivalent Install the ball bearing into the driven face squarely until it is fully seated with its sealed side facing down using the special tools TOOLS 2 Driver 3 Pilot 28 mm 07749 0010000 07746 0041100 Install the snap ring 1 to the groove on the driven face securely Apply 7 3 8 3 g of grease Shell ALVANIA...

Page 275: ...flush with the driven face surface as shown TOOLS 2 Driver 3 Attachment 28 x 30 mm 4 Pilot 20 mm ASSEMBLY SEAL COLLAR DRIVEN PULLEY 07749 0010000 07946 1870100 07746 0040500 Apply engine oil to new oil seal 1 lips and install them into the movable driven face Apply engine oil to new 0 rings 2 and install them into the movable driven face grooves DRIVEN FACE MOVABLE DRIVEN FACE CLUTCH SHOES S 1 PLA...

Page 276: ... 2 2 g of grease Shell ALVANIA R3 or IDEMITSU AUTOREX B or NIPPON OIL POWERNOC WB3 or equivalent to each guide groove Install the seal collar 1 to the driven pulley CLUTCH Install the damper rubbers 1 onto the drive plate 2 Install the clutch shoes 1 to the drive plate bosses 2 Turn the clutch shoes so that the damper rubbers 3 are positioned in the grooves of the clutch shoes 3 4 2 1 1 2 1 3 2 1 ...

Page 277: ... the following Driven pulley assembly 1 Driven face spring 2 Spring seat 3 Clutch assembly 4 Set the clutch spring compressor 1 over the clutch driven pulley assembly aligning the bosses of the compressor with the holes of the clutch TOOL 1 Clutch spring compressor 07LME GZ40201 or 07960 KM10008 U S A only Be careful not to Compress the driven face spring while aligning the damage the driven cutou...

Page 278: ... assembly 2 and compress the drive face spring by turning movable driven face 3 clockwise until it stops Set the drive belt onto the pulley groove while holding the movable driven face Do not get grease Install the clutch driven pulley assembly onto the drive on the drive shaft shaft splines from the driven face inside 12 20 Clean any oil and grease from the clutch outer 1 Install the clutch outer...

Page 279: ...T LOCATION 13 2 SERVICE INFORMATION 13 3 TROUBLESHOOTING 13 5 FINAL REDUCTION CASE SEPARATION 13 6 1 FINAL REDUCTION INSPECTION 13 6 FINAL REDUCTION BEARING REPLACEMENT 13 8 FINAL REDUCTION CASE ASSEMBLY 13 12 1 ...

Page 280: ...FINAL REDUCTION COMPONENT LOCATION 23 N m 2 3 kgf m 17 lbf ft 13 2 ...

Page 281: ... ITEM SPECIFICATIONS Final reduction oil capacity I After draining 0 12 liter 0 13 US qt 0 11 Imp qt I After disassembly 0 14 liter 0 15 US qt 0 12 Imp qt Recommended final reduction oil Pro Honda HP4M 4 stroke oil U S A and Canada or equivalent motor oil API service classification SJ or higher JASO T 903 standard MB Viscosity SAE 1OW 30 TORQUE VALUES ITEM Q TY THREAD TORQUE REMARKS DIA mm N m kgf...

Page 282: ... 40 mm 07746 0010200 13 4 Bearing remover shaft 12 mm 07936 1660120 Not available in U S A Remover weight 07741 0010201 or 07936 371020A U S A only Bearing remover 15 mm 07936 KC10500 U S A only Pilot 12 mm 07746 0040200 Bearing remover 12 mm 07936 166010A U S A only Bearing remover head 15 mm 07936 KC10200 h t A Wf 1 ti Not available in U S A Driver 07749 0010000 Attachment 42 x 47 mm 07746 00103...

Page 283: ...y clutch page 12 14 Abnormal noise Worn seized or chipped gears Worn or damaged final reduction bearing Oil leak Oil level too high Worn or damaged oil seal Case puller 07SMC 0010001 or 07HAC PK4010B U S A only Assembly shaft 07965 1660200 Attachment 51 5 mm 07946 3290000 Cracked crankcase and or final reduction case FINAL REDUCTION Pilot 20 mm 07746 0040500 Assembly collar attachment 07965 GM0020...

Page 284: ...l gear shaft 5 D CTION INS BEARING LEFT CRANKCASE Check each bearing for wear or damage Turn the inner race of the countershaft 1 and final gear shaft 2 bearings with your finger The bearing should turn smoothly and quietly Also check that the bearing outer race fits tightly in the crankcase Replace the bearings if they do not turn smoothly quietly or if they fit loosely in the crankcase Turn the ...

Page 285: ... finger The bearing should turn smoothly without friction Check that there is no clearance between the outer race and final reduction case GEAR SHAFT DRIVESHAFT Check the driveshaft 1 for bend wear or damage COUNTER GEAR COUNTERSHAFT FINAL GEAR SHAFT Check the countershaft 1 counter gear 2 and final gear shaft 3 for wear or damage FINAL REDUCTION 1 1 ...

Page 286: ...110 07936 1660120 07741 0010201 07936 KC10200 07936 KC10100 07741 0010201 Bearing remover 12 mm Remover handle Remover weight 07936 16601 OA 07936 3710100 07936 371020A Final gear shaft bearing Bearing remover 15 mm Remover weight 07936 KC10500 07936 371020A Apply engine oil to each bearing 1j cavity Set the bearings Drive each new bearing into the left crankcase squarely with their marked until i...

Page 287: ...t side If the bearing remains on the driveshaft remove the bearing using a hydraulic press Remove the driveshaft oil seal 1 Apply engine oil to the bearing cavity Set the bearing with Drive a new driveshaft bearing 1 into the left its marked side crankcase squarely until it is fully seated using the facing up special tools TOOLS 2 Driver 3 Attachment 42 x 47 mm 4 Pilot 20 mm 07749 0010000 07746 00...

Page 288: ...t 07965 1660200 5 Assembly collar attachment 07965 GM00200 Apply engine oil to a new driveshaft oil seal 1 lip Do not insert the oil Install the driveshaft oil seal so that the depth from the seal too far left crankcase surface is 0 2 0 8 mm 0 01 0 03 in 1 using the special tools TOOLS 2 Assembly shaft 07965 1660200 3 Assembly collar 07965 GM00100 4 Assembly collar attachment 07965 GM00200 Assembl...

Page 289: ...t oil seal 6 and bearing 7 Apply engine oil to the driveshaft bearing 1 and countershaft bearing 2 cavity Set the bearings Drive a new countershaft bearing and driveshaft with their marked bearing into the final reduction case squarely until they sides facing up are fully seated using the special tools TOOLS Driveshaft bearing 3 Driver 4 Attachment 32 x 35 mm 5 Pilot 15 mm Countershaft bearing Dri...

Page 290: ...final gear shaft 1 Install the countershaft 2 into the counter gear 3 while aligning the countershaft splines with the counter gear splines and install them to the left crankcase Install the dowel pins 4 and a new gasket 5 Set the rear brake cable 1 in position Install the final reduction case 2 case bolts 3 drain bolt 4 and a new sealing washer 5 Tighten the final reduction case bolts and drain b...

Page 291: ...1 COMPONENT LOCATION 14 2 AlTERNATOR STARTER 1 SERVICE INFORMATION 14 3 1 ...

Page 292: ...ALTERNATOR STARTER COMPON NT LOCATION 10 N m 1 0 kgf m 7 lbf ft 1ON m 1 0 kgf m 7 lbf ft 69 N m 7 0 kgf m 51 lbf ft 14 2 26 5 N m 2 7 kgf m 20 lbf ft 8 5 N m 0 87 kgf m 6 3 lbf ft ...

Page 293: ...ces can be done with the engine installed in the frame For charging system inspection page 20 8 For starter system inspection page 6 11 TORQUE VALLI ITEM Stator mounting socket bolt CKP sensor mounting special bolt Flywheel nut Cooling fan mounting bolt Passenger step mounting bolt TOOLS Clutch center holder 07725 0030000 1 Q TY THREAD DIA mm 3 6 1 6 1 12 3 6 4 8 Flywheel puller 07733 0010000 TORQ...

Page 294: ...sub harness 2 from the frame clamp 3 Release the two wire band bosses 4 Release the three wire band bosses 1 Disconnect the CKP sensor 6P Black connector 2 It is not necessary Remove the four radiator mounting bolts and move the to disconnect the radiator so that the cooling fan is accessible page 9 7 water hoses from the radiator Remove the three bolts 1 and cooling fan 2 14 4 ...

Page 295: ...eel 1 using the special tool TOOL 2 Flywheel puller 07733 0010000 or 07933 0010000 U S A only Remove the two bolts 1 and wire holder plate 2 Release the grommets 3 from the right crankcase groove Do not forget to Remove the three mounting socket bolts 1 CKP remove the special sensor mounting special bolt 2 and stator 3 from the bolt stator base ALTERNATOR STARTER 1 ...

Page 296: ...d grease from the crankshaft Set the stator assembly 1 onto the stator base Install and tighten the stator mounting socket bolts 2 and CKP sensor mounting special bolt 3 to the specified torque TORQUE 10 N m 1 0 kgf m 7 lbMt Route the wire properly and set the wire grommets 1 into the right crankcase grooves Set the wire holder plate 2 as shown and tighten the holder plate bolts 3 ...

Page 297: ...pecial tool and tighten the nut to the specified torque TOOL 3 Clutch center holder 07725 0030000 TORQUE 69 N m 7 0 kgf m 51 lbMt Install the cooling fan 1 while aligning its boss with the hole on the flywheel Install the cooling fan mounting bolts 1 and tighten them to the specified torque TORQUE 8 5 N m 0 87 kgf m 6 3 lbMt Install the radiator back in position page 9 7 1 ...

Page 298: ... Install the two wire band bosses 1 and secure the engine sub harness 2 into the frame clamp 3 Connect the ECM 3P Black connector 4 Set the right passenger step 1 then install and tighten the mounting bolts 2 to the specified torque TORQUE 26 5 N m 2 7 kgf m 20 lbMt Install the right floor step page 2 19 ...

Page 299: ...COMPONENT LOCATION 15 2 CRANKCASE SEPARATION 1 SERVICE INFORMATION 15 3 CRANKSHAFT INSPECTION 15 7 TROUBLESHOOTING 1 CRANKCASE ASSEMBLY 15 8 1 ...

Page 300: ...CRANKCASE C COMPON RANKSHAFT ENT LOCATION _ 15 2 ...

Page 301: ...n addition to the parts listed above remove the following parts when the right crankcase must be replaced Oil pump page 8 5 Be careful not to damage the crankcase mating surfaces when separating and assembling the crankcase halves Clean all disassembled parts with clean solvent and dry them using compressed air before inspection When installing the crankshaft be sure to use the special tools posit...

Page 302: ...ise Worn crankshaft bearing Worn connecting rod big end bearing Universal bearing puller 07631 0010000 or equivalent commercially available in U S A Pilot 35 mm 07746 Q040800 Assembly collar B 07931 KF00100 Driver attachment 35 mm 07HMD MR70100 Worn connecting rod small end page 11 8 15 4 Driver 07749 0010000 Assembly shaft adaptor 07WMF KFF0200 Assembly shaft 07965 VM00200 ...

Page 303: ...e Remove the bolt 1 and set plate 2 Remove the pivot 3 and cam chain tensioner slider 4 Remove the spring 5 and plunger 6 from the right crankcase Remove the cam chain 7 from the crankshaft Remove the crankcase bolts 1 from the right crankcase Be careful not to Place the crankcase with the left crankcase 1 facing damage the down and separate the left and right 2 crankcase crankcase mating surface ...

Page 304: ...l tool TOOL 2 Case puller 07SMC 0010001 Remove the left crankshaft bearing 1 using the special tool TOOL 2 Universal bearing puller 07631 0010000 or equivalent commercially available in U S A If the left crankshaft bearing remains in the crankcase drive it out to the right side 2 If the left crankshaft bearing remains in the crankcase 1 ...

Page 305: ...the right crankshaft Replace the crankshaft as an assembly if the bearing does not turn smoothly quietly or if it fits loosely on the right crankshaft If the timing Check the oil pump drive gear 1 and timing sprocket sprocket teeth are 2 teeth for wear or damage worn or damaged check the cam chain tensioner and cam sprocket Measure the connecting rod big end side clearance with a feeler gauge 1 SE...

Page 306: ...n CAM CHAIN TENSIONER SLIDER INSPECTION Check the cam chain tensioner slider 1 for excessive wear or damage Replace if necessary If the cam chain tensioner slider is worn or damaged also check the condition of cam chain guide CRANKCASE ASSEMBLY Be careful not to Clean the insides and mating surface 1 of the damage the crankcases crankcase mating Check for cracks or other damage 15 8 surface Remove...

Page 307: ...e assembly shaft adaptor while aligning the center of the assembly collar B with the assembly shaft 5 NOTE When pulling the crankshaft into the bearing be careful not to damage the connecting rod 5 Pull the crankshaft into the bearing until it is fully seated while positioning the connecting rod in the cylinder sleeve opening on the left crankcase TOOLS 1 Assembly shaft adaptor 2 Assembly collar A...

Page 308: ...se mating surface Inject minimum 3 cm3 of engine oil to the connecting rod 7M 2 big end bearing 1 Ii Apply 2 cm3 minimum of engine oil to right crankshaft bearing 2 Install the dowel pins 3 to the left crankcase Assemble the left 1 and right 2 crankcase Install the crankcase bolts 1 and tighten them in a crisscross pattern in 2 3 steps ...

Page 309: ... to the timing sprocket Install the cam chain tensioner slider 3 pivot 4 and set plate 5 Install and tighten the bolt 6 Install the rear inner fender 1 to the crankcase Set the ground cable 2 against the crankcase then install and tighten the bolt 3 Install the stay 4 and tighten the bolt 5 Refer to service information page 15 3 for installation of parts removed to perform crankcase service CRANKC...

Page 310: ...MEMO ...

Page 311: ...1 COMPONENT LOCATION 16 2 ENGINE LINK 16 6 SERVICE INFORMATION 16 3 ENGINE INSTALLATION 16 7 ENGINE REMOVAL 16 4 1 ...

Page 312: ...ENGINE REMOVAL INSTALLATION COMPONENT LOCATION 59 N m 6 0 kgf m 44 lbf ft 24 N m 2 4 kgf m 18 lbf ft 16 2 ...

Page 313: ...ge 12 3 Final reduction page 13 3 Alternator starter page 14 4 Camshaft page 10 8 Water pump page 9 8 Throttle body page 7 15 Oil pump page 8 5 SPECIFICATIONS ITEM SPECIFICATIONS Engine dry weight 30 1 kg 66 4 lbs 1 Coolant capacity Radiator and engine 0 48 liter 0 51 US qt 0 42 Imp qt Engine oil capacity After draining 0 8 liter 0 8 US qt 0 7 Imp qt After disassembly 0 9 liter 1 0 US qt 0 8 Imp q...

Page 314: ...1 and cable clamp 2 Remove the rear brake adjusting nut 1 Pull out the brake cable 2 from the joint pin 3 and cable holder 4 Remove the joint pin from the brake arm EXCEPT After 13 Disconnect the EVAP canister to intake pipe hose 1 model CM type from the intake pipe joint and pull it out from the clamps 2 Loosen the throttle cable lock nut 1 Disconnect the throttle cable 2 from the cable bracket 3...

Page 315: ... harness 6P Black connector 3 Release the engine sub harness 4 from the frame clamp 5 Remove the bolt 6 and ground cables Release the four wire band bosses 1 Disconnect the CKP sensor 6P Black connector 2 Support the frame in upright position Hold the front wheel Remove the both rear shock absorber upper mounting nuts 1 and washers 2 Release the both rear shock absorber upper mount from the frame ...

Page 316: ...ge 2 28 Remove the engine hanger link nut 1 bolt 2 and engine hanger link 3 Install the engine hanger link bolt and nut then temporarily tighten the nut Install the removed parts in the revers order of removal NOTE 1 2 After installing the engine to the frame tighten the engine hanger link nut to the specified torque page 16 7 Ir111r21 3 16 6 INSPECTION Check the hanger link bushings 1 and stopper...

Page 317: ...t Install the inside washers 1 then set the both rear shock absorber upper mount to the frame Install the outside washers 2 and both rear shock absorber upper mounting nuts 3 then tighten them to the specified torque TORQUE 24 N m 2 4 kgf m 18 lbHt When you replace or remove the engine hanger linkage tighten the engine hanger link pivot nut engine side 1 to the specified torque while holding the p...

Page 318: ...r 4 Engine sub harness 6P Black connector 5 Set the ground terminals then install and tighten the bolt 6 Connect the siphon hose 1 to the radiator and remove the clamp 2 Install the siphon hose to the hose guide 3 Install the cable clamp 1 then install and tighten the bolt 2 Connect the throttle cable 3 to the throttle drum 4 and cable bracket 5 then adjust the throttle grip freeplay page 3 6 Set ...

Page 319: ... the 2nd rear brake cable 2 into the cable holder 3 and joint pin then install the adjusting nut 4 Install the cable clamp 1 and tighten the bolt 2 Adjust the rear brake lever freeplay page 3 18 Connect the fuel injector side quick connect fitting and normalize the fuel pressure page 7 7 Install the following Floor step page 2 19 Luggage box page 2 25 ENGINE REMOVAL INSTALLATION 1 ...

Page 320: ...MEMO ...

Page 321: ...1 COMPONENT LOCATION 1 SERVICE INFORMATION 17 3 TROUBLESHOOTING 17 5 FRONT WHEEL 17 6 17 8 HANDLEBAR 17 17 HANDLEBAR P0ST 17 23 STEERING STEM 17 24 1 ...

Page 322: ... j j FRONT WHEEL SUSPENSION STEERING 39 N m 4 0 kgf m 29 lbf ft 1 49 N m 5 0 kgf m 36 lbf ft ...

Page 323: ...ommended fluid Pro Honda Suspension Fluid SS 8 1 OW or equivalent Fluid level 75 2 95 Fluid capacity 122 0 2 5 cm3 4 13 0 05 US oz 4 29 0 05 Imp oz TORQUE VALUES ITEM Q TY THREAD TORQUE REMARKS DIA mm N m kgf m lbMt Front brake disc socket bolt 4 8 42 4 3 31 ALOC bolt replace with new ones Front axle nut 1 12 59 6 0 44 U nut Fork socket bolt 2 8 20 2 0 15 Apply locking agent to the threads Bottom ...

Page 324: ...emover shaft 07746 0050100 Pilot 12 mm 07746 0040200 Pin spanner 07702 0020001 Ball race remover 34 5 mm 07948 4630100 or 07736 A010008 U S A only and a 3 8 x 16 thread slide hammer commercially available in U S A Driver 07749 0010000 Oil seal remover 07748 0010001 or equivalent commercially available in U S A Socket wrench 07916 KM10000 Attachment 35 2 mm I D 07947 KA20200 Not available in U S A ...

Page 325: ...ged engine mounting bushings Bent frame Faulty steering head bearing Front wheel wobbles Loose front axle fasteners Bent rim Worn or damaged front wheel bearings Front wheel turns hard Front brake drag Bent front axle Faulty front wheel bearings Soft suspension Low tire pressure Deteriorated fork fluid Incorrect fork fluid weight Insufficient fluid in fork Weak fork spring Hard suspension High tir...

Page 326: ...icator SERVICE LIMIT 0 2 mm 0 01 in Actual runout is 1 2 of the total indicator reading WHEEL BEARING Turn the inner race of each bearing with your finger the bearing should turn smoothly and quietly Also check that the bearing outer race fits tightly in the hub Replace the Remove and discard the bearings if the races do not bearings in pairs turn smoothly quietly or if they fit loosely in the hub...

Page 327: ...ring out of the wheel hub Remove the distance collar and drive out the other bearing TOOLS 1 Remover head 12 mm 2 Bearing remover shaft 07746 0050300 07746 0050100 Pack all bearing cavities with grease Never install the old Drive in a new left bearing 1 squarely with its sealed bearings Once the side facing up until it is fully seated bearings have been TOOLS removed the bearings must be 2 Driver ...

Page 328: ...egs while inserting the disc between the pads Apply thin coat of grease to the front axle 1 sliding surface and install it from the right side Install the axle nut 2 and tighten it to the specified torque TORQUE 59 N m 6 0 kgf m 44 lbHt REMOVAL Remove the following Front fender page 2 5 Front wheel page 17 6 Support the front Remove the mounting bolts 1 and front brake caliper brake caliper with a...

Page 329: ... 1 in a vice with soft jaws or a shop towel Loosen the fork socket bolt 2 To prevent loss of Put a suitable tool 1 on the spring seat 2 tension do not Press the spring seat into the fork pipe using a suitable compress the fork tool and hydraulic press then remove the stopper ring spring more than 3 using a small screwdriver necessary The spring seat is under spring pressure Use care when removing ...

Page 330: ... 1 and fork spring 2 from the fork pipe 3 Remove the 0 ring 4 from the spring seat Pour out the fork fluid by pumping the fork pipe several times Remove the socket bolt 1 and sealing washer 2 Remove the fork piston 1 and rebound spring 2 from the fork pipe 2 1 2 ...

Page 331: ...l the fork pipe 1 out from the fork slider 2 Remove the dust seal 1 Remove the oil seal stopper ring 1 Remove the oil seal 1 using the special tool TOOL 2 Oil seal remover 07748 0010001 or equivalent commercially available in U S A 2 1 1 ...

Page 332: ...R PISTON Check the fork pipe 1 fork slider 2 and fork piston 3 for score marks and excessive or abnormal wear Check the fork piston ring 4 for wear or damage Check the rebound spring 5 for fatigue or damage Replace the components if necessary Place the fork pipe on V block and measure the runout Actual runout is 1 2 the total indicator reading SERVICE LIMIT 0 2 mm 0 01 in 1 1 I I 5 77 3 4 ...

Page 333: ...f the entire surface Check the back up ring 2 and replace it if there is any distortion at the points indicated by arrows on the figure ASSEMBLY FORK PIPE DUST SEAL STOPPER R I N G O I L S E A L BACK UP RING 20 N m 2 0 kgf m 15 lbf ft SEALING WASHER FORK PISTON REBOUND SPRING Before assembly wash all parts with high flash point or non flammable solvent and wipe them dry Install the back up ring 1 ...

Page 334: ... ring 1 into the stopper ring groove on the fork slider Apply fork fluid to a new dust seal 2 lip Do not tap the dust Install the dust seal until it is fully seated seal lip too hard Install the fork pipe 1 into the fork slider 2 If removing the fork piston ring 1 from the fork piston 2 install a new fork piston ring to the fork piston groove Make sure that the Install the rebound spring 3 and for...

Page 335: ... or equivalent FORK FLUID CAPACITY 122 0 2 5 cm3 4 13 0 05 US oz 4 29 0 05 Imp oz Pump the fork pipe several times to remove trapped air from the lower portion of the fork pipe Be sure the oil level Compress the fork leg fully and measure the fluid level is same in the both from the top of the fork pipe forks FORK FLUID LEVEL 75 mm 2 95 in Pull the fork pipe 1 up and install the fork spring 2 with...

Page 336: ...ing more than necessary 17 16 Hold the fork slider 1 in a vise with soft jaws or a shop towel Tighten the fork socket bolt 2 to the specified torque TORQUE 20 N m 2 0 kgf m 15 lbMt INSTALLATION Install the fork into the steering stem and align the groove of the fork pipe with the upper bolt hole of the stem then install the upper bottom bridge pinch bolt 1 Tighten the upper and lower bottom bridge...

Page 337: ... Install the brake hose clamp and bolt 3 to the left fork leg Install the following Front wheel page 17 8 Front fender page 2 5 REMOVAL The rearview mirror Remove the rearview mirrors 1 lock nuts have left hand threads Remove the wire bands 2 Remove the two socket bolts 1 holder 2 and rear brake lever bracket 3 Remove the two screws 1 from the left handlebar switch housing 2 2 3 1 2 1 ...

Page 338: ... 1 and remove it from the handlebar Remove the screw 1 left handlebar weight 2 and left handlebar grip 3 Disconnect the front brake light switch connectors 1 Remove the two socket bolts 2 holder 3 and front master cylinder 4 Remove the screw 1 and right handlebar weight 2 1 ...

Page 339: ...Separate the right handlebar switch 1 and disconnect the throttle cable 2 from the throttle grip 3 Remove the right handlebar switch and throttle grip Remove the four caps 1 Remove the four socket bolts 1 upper holders 2 and handlebar 3 WHEEL SUSPENSION STEERING 2 1 1 ...

Page 340: ...acing forward Install the socket bolts 5 and tighten them to the specified torque in the specified sequence as shown TORQUE 27 N m 2 8 kgf m 20 lbMt Install the four caps 1 Install the throttle grip 1 onto the handlebar Apply 0 1 0 2 g of grease to the cable end and cable rolling area Connect the throttle cable 2 to the throttle grip Install the right handlebar switch 3 by aligning the locating pi...

Page 341: ... 1 and holder 2 with 1 the UP mark 3 facing up Align the edge of the master cylinder with the punch mark 4 on the handlebar and tighten the upper bolt 5 first to the specified torque then tighten the lower bolt 6 to the specified torque TORQUE 12 N m 1 2 kgf m 9 lbMt Connect the front brake light switch connectors 7 If the handlebar grip 1 was removed apply Honda Bond A or Honda Handgrip Cement U ...

Page 342: ...e handlebar Install the two screws 1 and tighten the front side screw first to the specified torque then tighten the rear side screw to the specified torque TORQUE 2 5 N m 0 26 kgf m 1 8 lbHt Install the rear brake lever bracket 1 and holder 2 with the UP mark 3 facing up Align the edge of the rear brake lever bracket with the punch mark 4 on the handlebar and tighten the upper bolt 5 first to the...

Page 343: ...ve the following Handlebar page 17 17 Inner cover page 2 13 Socket bolts 1 Plastic washers 2 Handlebar front cover 3 Handlebar rear cover 4 Temporarily install the handlebar 1 then remove the lower holder nuts 2 and washers 3 Remove the handlebar and lower holders 4 Release the following from the clamps 1 Throttle cable 1st rear brake cable Right handlebar switch wire Left handlebar switch wire Re...

Page 344: ...llowing Fork page 17 8 Handlebar post page 17 23 Hold the top thread using the pin spanner 1 and loosen the steering stem lock nut 2 using the socket wrench 3 TOOLS 1 Pin spanner 3 Socket wrench Remove the steering stem lock nut 07702 0020001 07916 KM10000 Hold the steering stem and loosen the top thread 1 using the pin spanner 2 TOOL 2 Pin spanner 07702 0020001 Remove the top thread while holding...

Page 345: ...Remove the lower bearing outer race 1 using the following tools TOOLS 2 Ball race remover 34 5 mm 07948 4630100 or 07736 A01 OOOB U S A only and a 3 8 x 16 thread slide hammer commercially available in U S A 3 Ball race remover shaft 07GMD KS40100 Remove the dust seal 1 from the steering stem lower bearing inner race 2 Remove the lower bearing inner race with a chisel or equivalent tool being care...

Page 346: ...reme pressure agent recommended EXCELIGHT EP2 manufactured by KYODO YUSHI japan or Shell ALVANIA EP2 or equivalent to a new dust seal 1 lip then install it to the lower bearing inner race Drive a new upper bearing outer race 1 into the head pipe using the following tools TOOLS 2 Driver 07749 0010000 3 Bearing driver attachment 07946 3710701 Drive a new lower bearing outer race 1 into the head pipe...

Page 347: ...ELIGHT EP2 manufactured by KYODO YUSHI japan or Shell ALVANIA EP2 or equivalent to the lower bearing races Attach the steel balls 29 balls 1 to the lower bearing outer race Insert the steering stem 2 into the steering head pipe being careful not to drop the steel balls Apply 3 5 g of grease with extreme pressure agent recommended EXCELIGHT EP2 manufactured by KYODO YUSHI japan or Shell ALVANIA EP2...

Page 348: ...o seat the bearing Completely loosen the top thread Tighten the top thread 2 fully by hand while holding the steering stem then turn the top thread counterclockwise about 45 degrees Hold the top thread using the pin spanner and tighten the steering stem lock nut 1 to the specified torque TOOLS 2 Socket wrench 3 Pin spanner 07916 KM10000 07702 0020001 TORQUE 74 N m 7 5 kgf m 55 lbMt Make sure the s...

Page 349: ...1 COMPONENT LOCATION 18 2 WHEEL SWINGARM 18 5 SERVICE INFORMATION 18 3 REAR DRUM BRAKE 18 8 TROUBLESHOOTING 18 4 REAR SHOCK ABSORBER 18 12 1 ...

Page 350: ...REAR WHEEL BRAKE SUSPENSION COMPONENT LOCATION 3 5 N m 0 36 kgf m 2 6 lbf ft 1ON m 1 0 kgf m 7 lbf ft 24 N m 2 4 kgf m 18 lbf ft 118 N m 12 0 kgf m 87 lbf ft 18 2 ...

Page 351: ...225 kPa 2 25 kgf cm2 33 psi pressure Up to maximum weight capacity 250 kPa 2 50 kgf cm2 36 psi Wheel rim Radial 2 0 0 08 runout Axial 2 0 0 08 Brake Brake lever freeplay 10 20 0 4 0 8 Brake drum 1 0 130 0 130 2 5 12 5 13 131 0 5 16 TORQUE VALUES ITEM Q TY THREAD TORQUE REMARKS DIA mm N m kgf m lbMt Rear axle nut 1 16 118 12 0 87 U nut Apply oil to the threads and seating surface Shock absorber upp...

Page 352: ...mm 07936 KC10200 U S A only Collet only from 07936 KC10500 Axle nut and or engine mounting bolt nut not tightened properly Loose or worn final gear shaft bearing Insufficient tire pressure Soft suspension Weak rear shock absorber spring Oil leakage from damper unit Low tire pressure Stiff suspension Bent damper rod High tire pressure Rear suspension noisy Loose mounting fasteners Faulty shock abso...

Page 353: ...rstand and remove the following Axle nut 1 Right rear shock absorber lower mounting bolt 2 Remove the swingarm mounting bolts 1 washers 2 and swingarm 3 Remove the two socket bolts 1 Slightly pull up the rear inner fender 1 and remove the rear wheel 2 WHEEL BRAKE SUSPENSION 1 ...

Page 354: ...Install and tighten the two socket bolts 2 to the specified torque TORQUE Engine side 10 N m 1 0 kgf m 7 lbHt Air cleaner side 3 5 N m 0 36 kgf m 2 6 lbMt Apply 0 03 0 04 g of grease to the final gear shaft grease groove 1 Apply grease to the swingarm bearing fitting area of the final gear shaft Install the swingarm 1 onto the final gear shaft Install the washers 2 and swingarm mounting bolts 3 th...

Page 355: ...icator readings SERVICE LIMITS Radial 2 0 mm 0 08 in Axial 2 0 mm 0 08 in SWINGARM REPLACEMENT INSPECTION Remove the swingarm page 18 5 Remove the side collars 1 and dust seals 2 from the swingarm 3 Turn the inner race of the bearing 1 with your finger The bearing should turn smoothly and quietly Also check that the bearing outer race fits tightly in the swingarm If the inner race does not turn sm...

Page 356: ...with the chamfered side facing the bearing Apply grease to the new dust seal 2 lips Install each dust seals until they are flush with the swingarm surfaces Install the swingarm page 18 6 REAR DRUM BRAKE INSPECTION 18 8 Remove the rear wheel page 18 5 Measure the rear brake drum I D SERVICE LIMIT 131 0 mm 5 16 in DISASSEMBLY Remove the rear wheel page 18 5 Remove the adjusting nut 1 and brake cable...

Page 357: ...2 and remove the brake arm 3 then remove the brake arm Remove both dust seals 1 Remove the sleeve 1 using the special tools TOOLS 2 Bearing remover shaft 15 mm 07936 KC10100 3 Bearing remover head 14 mm 07WMC KFG0100 4 Remover weight 07741 0010201 U S A TOOLS Bearing remover shaft 14 mm 07YMC 00101 OA Bearing remover collet 15 mm 07936 KC10200 collet only from 07936 KC10500 Remover handle 07936 37...

Page 358: ...OLS 2 Driver 3 Pilot 20 mm 07749 0010000 07746 0040500 Apply grease to the both new dust seals Install the left dust seal 1 into the final reduction case until it is fully seated Install the right dust seal 2 so that the depth from the final reduction case surface is 0 5 1 1 mm 0 02 0 04 in Install the dust seals in the correct direction as shown Apply each 0 2 0 3 g of grease ____ 4 3 4 9 mm 0 17...

Page 359: ... tighten it to the specified torque TORQUE 10 N m 1 0 kgf m 7 lbMt Apply 0 2 0 3 g grease to the anchor pin and brake cam sliding surface Always replace the Assemble the brake shoes 1 and springs 2 in the brake shoes as a direction as shown set Wipe any excess grease from the brake cam and When not replacing anchor pin the brake shoes install to the original Install the rear wheel page 18 6 direct...

Page 360: ... mounting bolt 1 Upper mounting nut 2 Washers 3 Rear shock absorber 4 Installation is in the reverse order of removal TORQUE Shock absorber upper mounting nut 24 N m 2 4 kgf m 18 lbMt INSPECTION Check the damper unit 1 for leakage or other damage 2 Check the shock absorber bushing 2 for wear or damage Replace the shock absorber 3 if necessary Check the rear shock absorber mount bushings 1 for wear...

Page 361: ...1 COMPONENT LOCATION 19 2 PAD DISC 19 10 INFORMATION 19 3 TROUBLESHOOTING 19 4 CBS MASTER CYLINDER 19 16 BRAKE FLUID REPLACEMENT BRAKE CALIPER 19 23 AIR BLEEDING 19 5 1 ...

Page 362: ...HYDRAULIC BRAKE COMPON NT LOCATION 12 N m 1 2 kgf m 9 lbf ft 34 N m 3 5 kgf m 25 lbf ft 12 N m 1 2 kgf m 9 lbf ft 12 N m 1 2 kgf m 9 lbf ft 30 N m 3 1 kgf m 22 lbf ft 19 2 ...

Page 363: ... 0 004 0 30 0 001 Front brake Cylinder I D 12 700 12 743 0 5000 0 5017 12 755 0 5022 master cylinder Piston O D 12 657 12 684 0 4983 0 4994 12 645 0 4978 CBS master Cylinder I D 11 000 11 043 0 4331 0 4348 11 055 0 4352 cylinder Piston O D 10 957 10 984 0 4314 0 4324 10 945 0 4309 Caliper Cylinder I D Upper 25 400 25 450 1 0000 1 0020 25 460 1 0024 Center 22 650 22 700 0 8917 0 8937 22 710 0 8941 ...

Page 364: ...sc Contaminated caliper Contaminated master cylinder Caliper not sliding properly Low brake fluid level Clogged fluid passage Warped deformed brake disc Sticking worn caliper piston Sticking worn master cylinder piston Bent brake lever Brake lever hard Clogged restricted brake system Sticking worn caliper piston Caliper not sliding properly Worn caliper piston seal Sticking worn master cylinder pi...

Page 365: ...KE LINE CBS BRAKE LINE FRONT BRAKE LINE Turn the handlebar until the reservoir is parallel to the ground before removing the reservoir cap Remove the screws 1 reservoir cap 2 diaphragm plate 3 and diaphragm 4 Be careful not to Connect a commercially available brake bleeder 1 to confuse with the the front brake line bleed valve 2 CBS brake line Loosen the bleed valve and operate the bleeder bleed v...

Page 366: ...der reservoir as shown Remove the reservoir cap 1 diaphragm plate 2 and diaphragm 3 Be careful not to Connect a commercially available brake bleeder 1 to confuse with the the CBS brake line bleed valve 2 front brake line Loosen the bleed valve and operate the bleeder bleed valve Drain the brake fluid Tighten the CBS brake line bleed valve 19 6 2 3 ...

Page 367: ...re until the system is completely bled After bleeding the system completely tighten the front brake line bleed valve to the specified torque TORQUE 5 4 N m 0 55 kgf m 4 4 lbMt If the brake bleeder is not available perform the following procedure Fill the master cylinder reservoir with DOT 3 or DOT 4 brake fluid from the sealed container to the upper level Pump up the system pressure with the brake...

Page 368: ...valve Connect a commercially available brake bleeder 1 to 19 8 the CBS brake line bleed valve 2 Operate the brake bleeder and loosen the CBS brake line bleed valve If an automatic refill system is not used add brake fluid when the fluid level in the reservoir is low Check the fluid level often while bleeding the brake to prevent air from being pumped into the system When using a brake bleeder foll...

Page 369: ...rake to prevent air from being pumped into the system 1 Push the knocker arm all the way and loosen the bleed valve 1 2 of a turn Wait several seconds and then close the bleed valve 2 Release the knocker arm slowly and wait several seconds after it reaches the end of its travel 3 Repeat the steps 1 and 2 until there are no air bubbles in the bleed hose After bleeding the system completely tighten ...

Page 370: ...l the inner cover page 2 13 BRAKE PAD DISC BRAKE PAD REPLACEMENT Remove the pad pin 1 from the brake caliper Remove the 0 ring 2 from the pad pin Remove the brake pads 1 from the brake caliper Always replace the Install new brake pads 1 so that they are set on the brake pads in pairs brake caliper bracket and bracket pin 2 to assure even disc pressure 19 10 ...

Page 371: ...ed torque replacement check the brake operation TORQUE 18 N m 1 8 kgf m 13 lbMt by applying the brake lever BRAKE DISC INSPECTION Visually inspect the brake disc for damage or cracks Measure the brake disc thickness at several points SERVICE LIMIT 3 0 mm 0 12 in Check the brake disc for warpage SERVICE LIMIT 0 30 mm 0 001 in If the warpage exceeds the service limit check the wheel bearings for exc...

Page 372: ... connectors 2 When removing the Remqve the brake hose oil bolt 1 sealing washers 2 brake hose oil bolt and brake hose 3 eyelet cover the end of the hose to prevent contamination Secure the hose to prevent the fluid from leaking out 19 12 Remove the master cylinder holder socket bolts 1 holder 2 and master cylinder 3 DISASSEMBLY Remove the pivot nut 1 pivot bolt 2 and brake lever 3 3 3 2 2 1 ...

Page 373: ...50001 Remove the master piston 1 and spring 2 Clean the master cylinder reservoir and master piston INSPECTION Check the piston cups for wear deterioration or damage Check the master cylinder inner surface and piston outer surface for scratches or damage Measure the master cylinder I D SERVICE LIMIT 12 755 mm 0 5022 in Measure the master piston O D SERVICE LIMIT 12 645 mm 0 4978 in HYDRAULIC 1 1 3...

Page 374: ...luid Install the spring 3 onto the master piston Do not allow the Install the spring and master piston into the master piston cup lips to cylinder turn inside out Be sure that snap Install the snap ring 1 into the groove in the master ring is firmly seated cylinder in the groove 19 1 TOOL 2 Snap ring pliers 07914 SA50001 Apply silicon grease to the inside of the piston boot 3 Install the piston bo...

Page 375: ...t Install the pivot nut 3 and tighten it to the specified torque while holding the pivot bolt TORQUE 6 N m 0 61 kgf m 4 4 lbMt INSTALLATION Install the master cylinder 1 and holder 2 with the UP mark 3 facing up Align the end of the master cylinder with the punch mark 4 on the handlebar and tighten the upper bolt 5 first then tighten the lower bolt 6 to the specified torque TORQUE 12 N m 1 2 kgf m...

Page 376: ...page 19 7 CBS MASTER CYLIND R REMOVAL Drain the brake fluid from the CBS brake line hydraulic system page 19 6 Remove the following Inner cover page 2 13 Front meter panel page 2 7 Loosen the adjusting nut 1 to the maximum When removing the Remove the brake hose oil bolt 1 sealing washers 2 brake hose oil bolt and brake hose 3 eyelet cover the end of the hose to prevent contamination Secure the ho...

Page 377: ...3 Loosen the lock nut 4 and adjuster 5 Release the 1st rear brake cable 6 from the equalizer Remove the bolt 1 and CBS master cylinder 2 DISASSEMBLY Remove the snap ring 1 and reservoir hose joint 2 from the CBS master cylinder TOOL Snap ring pliers 07914 SA50001 Remove the 0 ring 3 from the reservoir hose joint 1 ...

Page 378: ...screw 3 pivot screw have knocker arm 4 and equalizer 5 left hand threads 19 18 Remove the two bolts 1 and CBS master cylinder stay 2 Remove the piston boot 3 from the CBS master cylinder and master piston Remove the snap ring 1 using the special tool TOOL 2 Snap ring pliers 07914 SA50001 Remove the washer 3 2 Do not loosen 1 2 3 ...

Page 379: ...ratches or damage Measure the master cylinder I D SERVICE LIMIT 11 055 mm 0 4352 in Measure the master piston 0 0 SERVICE LIMIT 10 945 mm 0 4309 in HYDRAULIC 2 ASSEMBLY BOLTS STAY CBS MASTER CYLINDER SNAP RING RESERVOIR HOSE JOINT KNOCKER ARM 1 Apply 0 1 g of silicone grease to the knocker contact area with piston 2 Apply 0 1 g of silicone grease to the sliding surface MASTER PISTON ON CUPS SNAPRI...

Page 380: ...the groove in ring is firmly seated the master cylinder in the groove 19 TOOL 3 Snap ring pliers 07914 SA50001 Install the CBS master cylinder stay 1 Install the two bolts 2 and tighten them to the specified torque TORQUE 12 N m 1 2 kgf m 9 lbMt Apply silicone grease to the inside of the piston boot 3 Install the piston boot into the master cylinder and groove of the piston Apply 0 1 g of silicone...

Page 381: ...vot nut 3 then tighten it to left hand threads the specified torque while holding the pivot screw TORQUE 10 N m 1 0 kgf m 7 lbMt Install the delay spring 1 Coat a new 0 ring 1 with clean DOT 3 or DOT 4 brake fluid Install the 0 ring onto the reservoir hose joint Be sure that snap Install the reservoir hose joint 1 and snap ring 2 onto ring is firmly seated the CBS master cylinder in the groove TOO...

Page 382: ...e guide 5 Set the brake lock stay 1 and temporarily install the right side CBS master cylinder mounting bolt 2 Install the CBS master cylinder cover 3 by aligning the slot with the boss of the CBS master cylinder Set the collar 4 and temporarily install the brake lock stay mounting bolt 5 Tighten the both side CBS master cylinder mounting bolts to the specified torque TORQUE 12 N m 1 2 kgf m 9 lbH...

Page 383: ...er cover page 2 13 REMOVAL Drain the brake fluid from the following lines of the hydraulic systems Front brake line page 19 5 CBS brake line page 19 6 Remove the brake pads page 19 10 When removing the Disconnect the brake hoses 1 from the brake caliper oil bolts cover the by removing the oil bolts 2 and sealing washers 3 end of the hoses to Remove the front brake caliper mounting bolts and front ...

Page 384: ...sh the dust seal 1 and piston seals 2 in and lift damage the piston them out sliding surface Clean the seal grooves caliper cylinders and pistons 19 24 INSPECTION Check the caliper cylinder for scoring scratches or damage Measure the caliper cylinder I D SERVICE LIMIT Upper Center lower 25 460 mm 1 0024 in 22 710 mm 0 8941 in Check the caliper piston for scoring scratches or damage Measure the cal...

Page 385: ...all them into the caliper cylinders with the open side toward the pads Check the pin boots 1 and replace them if they are hard deteriorated or damaged Install the boot and pad spring 2 into the caliper 3 Apply 0 4 g minimum of silicone grease to the inside of the boots and install the caliper bracket 4 over the caliper body Make sure the boot ribs are seated into the boot grooves in the slide pins...

Page 386: ...3 1 kgf m 22 lbMt Connect the brake hoses 1 to the brake caliper with the oil bolts 2 and new sealing washers 3 Set the hose eyelet joints onto the stoppers of the brake caliper and tighten the oil bolts to the specified torque TORQUE 34 N m 3 5 kgf m 25 lbMt Install the brake pads page 19 10 Fill and bleed the following lines of hydraulic systems Front brake line page 19 7 CBS brake line page 19 ...

Page 387: ...SYSTEM LOCATION TROUBLESHOOTING 20 6 SYSTEM DIAGRAM 20 3 20 7 SERVICE INFORMATION 20 4 CHARGING SYSTEM 20 8 ...

Page 388: ...BATTERY CHARGING SYSTEM SYSTE 13 model STARTER CHARGING RELAY FUSE BOX MAIN RELAY STARTER CHARGING RELAY MAIN FUSE 25 A SUB FUSE 5 A 10 Ax 4 ECM 20 ...

Page 389: ...TERNATOR STARTER BI G BI G I BI W R W G J_ MAIN RELAY BI W IGNITION L J SWITCH R W MAIN 1 FUSE 10 A I crv R MAIN 2 FUSE 30 A __ T l l R BI G BI W ENGINE ECM STOP SWITCH G G BI I I COMBINATION SWITCH G G Green R Red W White Bl Black Y Yellow Bu Blue BATTERY 10 A R W BI W BI W ca R Bu R Y R W ENGINE STOP SWITCH MAIN BI W RELAY G BI G 1 ECM f t R Y y STARTER CHARGING RELAY ...

Page 390: ...ry voltage will drop quickly and eventually die out For this reason the charging system is often suspected as the problem Battery overcharge often results from problems in the battery itself which may appear to be an overcharging symptom If one of the battery cells is shorted and battery voltage does not increase the regulator rectifier supplies excess voltage to the battery Under these conditions...

Page 391: ...zer Micro 404XL After 13 model Fully charged Needs charging Normal Quick 13 model After 13 model 13 model After 13 model Christie battery charger MC1012 2T or OptiMate 4 PROS U S A only BATTERY CHARGING SYSTEM SPECIFICATIONS YTZ7S GTZSV 12 V 6 Ah 10HR 12 V 7 Ah 10HR 0 1 mA max 0 4 mA max 13 0 13 2 V Below 12 4 V 0 6 A 5 10 h 0 5 A 5 10 h 3 A 1 h 2 5 A 1 h 0 343 kW 5 000 rpm ...

Page 392: ...easure the charging voltage page 20 9 Compare the measurements to result of the following calculation STANDARD Measured BV Measured CV 15 5 V BV Battery Voltage CV Charging Voltage Is the measured charging voltage within the standard voltage YES Faulty battery NO GO TO STEP 5 5 Starter charging Relay Operation Inspection Check the starter charging relay operation page 20 10 Is the operation normal...

Page 393: ... the luggage box After 13 model Unlock and open the seat Press the tabs 1 and remove the battery maintenance lid 2 Release the battery band 1 Remove the bolt 2 and disconnect the negative cable 3 Remove the bolt 4 and disconnect the positive cable 5 Remove the battery 6 Connect the Install the battery in the reverse order of removal positive terminal first and then the negative terminal ...

Page 394: ...S charger U S A only CHARGING SYSTEM 20 8 CURRENT LEAKAGE TEST Remove the battery maintenance lid page 20 7 Turn the ignition switch to OFF and disconnect the negative cable 1 from the battery Connect the ammeter probe 2 to the negative cable and ammeter probe 3 to the battery terminal With the ignition switch turned to OFF check for current leakage NOTE When measuring current using a tester set i...

Page 395: ...eam restart the engine Measure the voltage on the multimeter when the engine runs at 5 000 rpm STANDARD Measured BV Measured CV 15 5 V BV Battery Voltage page 20 8 CV Charging Voltage CHARGING LINE INSPECTION Disconnect the ECM 5P connector page 4 49 Turn the ignition switch ON and engine stop switch 0 Measure the voltage between the ECM 5P connector 1 of the wire harness side and ground CONNECTIO...

Page 396: ...erminals CONNECTION A B Connect a 12 V battery to the following relay connector terminals CONNECTION D E There should be no continuity when the battery is connected and there should be continuity only when the battery is disconnected If the above inspection is abnormal replace the starter charging relay E D E B A STARTER CHARGING RELAY C STARTER CHARGING RELAY ...

Page 397: ...13 MODEL 21 10 COMBINATION METER AFTER 13 MODEL 21 12 FUEL GAµGE AFTER 13 MODEL 21 15 AVERAGE FUEL MILEAGE AFTER 13 MODEL 15 VS SENSOR 21 16 COOLANT INDICATOR 18 FUEL METER FUEL SENSOR 21 19 IGNITION SWITCH 21 21 HANDLEBAR SWITCHES 21 24 BRAKE LIGHT SWITCH 21 25 HORN 21 25 ACCESSORY SOCKET AFTER 13 MODEL 21 26 MAIN RELAY 21 TURN SIGNAL LIGHT RELAY 13 MODEL 21 28 CONTROL UNIT AFTER 13 MODEL 28 ...

Page 398: ...LIGHTS METERS SWITCHES LECTRICAL SYSTEM LOCATION 13 model DIMMER SWITCH 21 2 MAIN RELAY FRONT BRAKE LIGHT SWITCH FUEL LEVEL SENSOR FUSE BOX ...

Page 399: ... After 13 model REAR BRAKE LIGHT SWITCH E STOP SWITCH ENGIN COMBINATION METER FRONT BRAKE LIGHT SWITCH LEFT HANDLEBAR SWITCH CONTROL UNIT LED HORN FUEL LEVEL SENSOR FUSE BOX VS SENSOR ...

Page 400: ... made with the switches installed on the scooter The following color codes are used throughout this section Bu Blue Bl Black G Green Gr Gray Lg Light Green O Orange SPECIFICATIONS ITEM Bulbs Headlight 13 model After 13 model Position light After 13 model Tail brake light 13 model After 13 model License light 13 model After 13 model Front turn signal light 13 model After 13 model Rear turn signal l...

Page 401: ...rew 13 model Speedometer screw 13 model VS sensor protector socket bolt Fuel lid seat opener lower cover screw Key shutter socket bolt Ignition switch mounting screw TOOL Test probe 2 pack 07ZAJ RDJA110 Q TY 4 2 2 2 2 4 7 4 8 2 1 1 2 LIGHTS METERS SWITCHES THREAD TORQUE REMARKS DIA mm N m kgf m lbMt 4 0 9 0 09 0 7 6 8 8 0 9 6 5 U nut 4 1 0 1 0 7 5 4 3 0 44 3 2 U nut 4 1 2 0 12 0 9 5 1 2 0 12 0 9 4...

Page 402: ...of the wire harness side and ground CONNECTION Green orange ground STANDARD Battery voltage If there is battery voltage the headlight line is normal If there is no voltage inspect the following Blown HEADLIGHT fuse 10 A Loose or poor contacts of related terminal Open circuit in the Green orange wire between the headlight and ECM Open circuit in the Blue or White wire between the headlight and dimm...

Page 403: ... check the LED control unit page 21 28 If the position light does not turn on replace the combination light unit 13 BULB REMOVAL INSTALLATION The bulb replacement procedure is the same for front and rear turn signal light Remove the screw 1 and turn signal light lens 2 by releasing the hook 3 from the turn signal light unit 4 Remove the rubber seal 5 Slightly push and turn the turn signal light bu...

Page 404: ...ve the rear turn signal light unit 5 by pulling out the wire 6 from the holes of the rear fender Installation is in the reverse order of removal TORQUE Rear turn signal light unit mounting nut 8 8 N m 0 9 kgf m 6 5 lbMt Right side shown 4 TAIL BRAKE LIGHT 13 MODEL BULB REMOVAL INSTALLATION 21 8 Remove the grab rail cover page 2 20 Turn the tail brake light bulb socket 1 cqunter clockwise and pull ...

Page 405: ...wn and Green wire connectors 2 Remove the two nuts 3 and license light unit 4 Installation is in the reverse order of removal TORQUE License light unit mounting nut 4 3 N m 0 44 kgf m 3 2 lbMt LICENSE LIGHT UNIT REMOVAL INSTALLATION AFTER 13 MODEL Remove the body cover page 2 23 Disconnect 3P connector 1 Release the wire clamp 2 Remove the two screws 3 and license light unit 4 Installation is in t...

Page 406: ... replace the license light page 21 9 13 REMOVAl lNSTAlLATION Remove the rear meter panel page 2 14 Remove the four screws 1 and speedometer 2 from the rear meter panel 3 Installation is in the reverse order of removal TORQUE Speedometer mounting screw 1 1 N m 0 11 kgf m 0 8 lbHt DISASSEMBLY ASSEMBLY Remove the four screws 1 and speedometer lens 2 Remove the meter packing 1 1 2 3 1 2 1 ...

Page 407: ...nd line is normal If there is no voltage inspect the following Blown SPEEDOMETER TAIL fuse 10 A Loose or poor contacts of related terminal Open circuit in the Brown wire between the fuse box and speedometer Open circuit in the Green red wire between the speedometer and ground BACK UP LINE Remove the front meter panel page 2 7 Disconnect the mater 20P connector 1 Measure the voltage between the spe...

Page 408: ... combination meter 16P connector page 2 14 Check the following at the combination meter 16P connector of the wire harness side POWER INPUT LINE Turn the ignition switch ON Measure the voltage between the combination meter 16P connector 1 and ground CONNECTION Brown Ground There should be battery voltag e If there is no voltage check the following Open circuit in the Brown wire Blown IGN INJ F_PUMP...

Page 409: ...bnormal if the MIL 1 stays on Check the serial communication line in the following sequence 1 Serial Communication Line Short Circuit Inspection Turn the ignition switch OFF Disconnect the following Combination meter 16P connector page 2 14 ECM 33P Black connector page 4 49 Check for continuity between the combination meter 16P connector 1 of the wire harness side and ground Connection Light green...

Page 410: ...Remove the rear meter panel page 2 14 Remove the four screws 1 and combination meter 2 from the rear meter panel 3 Installation is in the reverse order of removal TORQUE Combination meter mounting screw 1 2 N m 0 12 kgf m 0 9 lbMt DISASSEMBLY ASSEMBLY Remove the two screws 1 meter lens 2 and meter packing 3 Remove the seven screws 1 and combination meter panel 2 from the lower case 3 Assembly is i...

Page 411: ...TION Check the combination meter initial operation page 21 12 1 Fuel Pulse Line Open Circuit Inspection Turn the ignition switch OFF Remove the rear meter panel page 2 14 Disconnect the following Combination meter 16P connector page 2 14 ECM 33P Black connector page 4 49 Check the continuity between the ECM 33P Black connector 1 and combination meter 16P connector 2 of the wire harness side TOOL T...

Page 412: ...otector 2 Remove the sensor protector while releasing the grommet 3 of the protector from the boss 4 of the left crankcase Release the wire band bosses 5 from the sensor protector When installing the socket bolt clean the threads and apply locking agent to the bolt threads TORQUE VS sensor protector socket bolt 10 N m 1 0 kgf m 7 lbMt Disconnect the VS sensor 3P Black connector 1 Remove the bolt 2...

Page 413: ...n the Black white wire between the ignition switch and VS sensor Open circuit in the Blue green wire between the ECM and VS sensor Turn the ignition switch OFF Disconnect the speedometer 20P connector 1 Check the continuity between the speedometer 20P connector and VS sensor 3P Black connector 2 of the wire harness side Check the continuity between the VS sensor 3P Black connector of the wire harn...

Page 414: ...or an internal short circuit If the indicator goes off with the connector disconnected check the following Short the ECM 21 P Black connector 1 terminal of the wire harness side and ground with the jumper wire 2 CONNECTION Light green red Ground TOOL Test probe 2 pack 07ZAJ RDJA110 Turn the ignition switch ON and check the indicator The indicator should come on If the indicator does not come on ch...

Page 415: ...uel level sensor and ECM for an open circuit If the wire is normal replace the speedometer panel with a new one and recheck WHEN THE FUEL METER BLINKS SLOWLY Disconnect the fuel pump 5P connector page 7 6 Turn the ignition switch ON and engine stop switch 0 check the fuel meter The fuel meter blinks rapidly if the system circuit is normal In that case check the fuel level sensor page 21 19 If the ...

Page 416: ...CE 5 11 n 265 275 n Replace the fuel level sensor if it is out of specification page 21 20 FUEL LEVEL SENSOR REMOVAL INSTALLATION Remove the fuel pump unit page 7 10 Disconnect the fuel level sensor Red and Black wire connectors Release the wires from the guides 1 of the fuel pump unit Remove the fuel level sensor 1 from the fuel pump unit by releasing the three hooks 2 Installation is in the reve...

Page 417: ...sconnect the fuel lid cable 1 and seat opener cable 2 from the cable levers 3 Remove the two screws 4 and fuel lid seat opener 5 from the ignition switch Installation is in the reverse order of removal IGNITION SWITCH REMOVAL Remove the steering stem page 17 24 Disconnect the ignition switch 2P connector 1 Remove the screws 1 and ignition switch 2 Remove the socket bolt 3 and key shutter 4 LIGHTS ...

Page 418: ...ket bolt 5 to the specified torque TORQUE 5 1 N m 0 52 kgf m 3 8 lbMt Install the ignition switch 1 by aligning the boss and hole of the frame Install and tighten a new screws 2 to the specified torque TORQUE 9 N m 0 9 kgf m 6 6 lbMt Connect the ignition switch 2P connector 1 Install the steering stem page 17 27 INSPECTION Remove the front meter panel page 2 7 Disconnect the ignition switch 2P con...

Page 419: ...uity at the terminals of the switch side connector in each switch position Continuity should exist between the color coded wires as follows LIGHTS METERS SWITCHES IGNITION SWITCH BAT1 BAT2 ON Cr OFF LOCK COLOR R W BI W ...

Page 420: ...andlebar switch 9P Black connector Check for continuity between the terminals of the starter switch and engine stop switch connector in each switch position Continuity should exist between the color coded wires as follows DIMMER SWITCH COLOR BI R W Bu HORN SWITCH BAT HO FREE PUSH COLOR Bl Br Lg TURN SIGNAL LIGHT SWITCH L N COLOR Lb Gr 0 ENGINE STOP SWITCH BAT ECM 0 COLOR BI W BI G STARTER SWITCH S...

Page 421: ... switch wire connectors 1 and check for continuity at the wire connector terminals of the switch side CONNECTION Black brown Green yellow There should be continuity with the rear brake lever squeezed and there should be no continuity when the rear brake lever is released REMOVAL INSTALLATION Remove the left front cover page 2 15 Disconnect the horn connectors 1 from the horn 2 Remove the bolt 3 an...

Page 422: ...if it sounds when the 12 V battery is connected to the horn terminals ACCESSORY SOC MODEL AFTER 13 REMOVAL INSTALLATION Remove the front meter panel page 2 7 Disconnect the wire connector 1 Remove the following Accessory socket 2 Accessory socket cover 3 Align the locating Installation is in the reverse order of removal lug on the socket with the cutout in the inner cover 21 26 ...

Page 423: ...nd main relay 2 Installation is in the reverse order of removal CONTINUITY INSPECTION Turn the ignition switch OFF Remove the main relay page 21 27 Connect an ohmmeter to the following relay 1 terminals CONNECTION A B Connect the 12 V battery to the following relay terminals CONNECTION C D There should be continuity between the relay terminals while the battery is connected and no continuity when ...

Page 424: ...rminals of the wire harness side with a jumper wire CONNECTION Black brown Gray Turn the ignition switch ON and engine stop switch 0 Check the turn signal light by turning the switch ON If the light comes on the turn signal light relay is faulty or connector has poor connection If the light does not come on the wire harness is broken LED CONTR MOD L UNIT 13 21 28 REMOVAL INSTALLATION Remove the fr...

Page 425: ... Disconnect the front combination light 8P connector page 21 7 Turn the ignition switch ON Use the special tool Measure the voltage between the front combination only for turn signal light 8P connector 1 terminals of the wire harness side light voltage and ground inspection TOOL Imrie diagnostic tester model 625 or Peak voltage adaptor O HGJ 0020100 with commercially available digital multimeter i...

Page 426: ...l 9P connector 1 terminals of the wire harness side and light voltage ground inspection TOOL 21 30 Imrie diagnostic tester model 625 or Peak voltage adaptor 07HGJ 0020100 with commercially available digital multimeter impedance 10 MO DCV minimum Connection Left turn signal light Orange white Green Right turn signal light Light blue white Green If there is voltage replace the rear combination light...

Page 427: ......

Page 428: ...MEMO ...

Page 429: ...WIRING DIAGRAM 13 MODEL WIRING DIAGRAM AFTER 13 MODEL 22 3 ...

Page 430: ......

Page 431: ... TURN SIGNALLIGHT SWITCH DIMMER SWITCH GNmGN Y G Y G BI G BI G B IW BliW BUBr Bl Br GfY GfY 1s m 11r w w BI R BI R Lb Lb Gr Gr 0 0 lg Lg Bl Sr BV8r TURN HORN SIGNAL SWITCH LIGHT SWITCH R g 1P u i I r I A MAIN 1 B MAIN 2 C BACK UP D HEAD LIGHT E WINKER STOP HORN F SPEEDOMETER TAIL FUSE BOX cc 0 I _g Q if Q m I mm m e ell I Ji CONTROL SOLENOID VALVE IGNITION SWITCH BAT1 BAT2 ON 0 l 0 OFF LOCK COLOR ...

Page 432: ......

Page 433: ...i 1P I t J 1 J v BI P l DBI B r w Br r I t lt 1 1 1 L mnt lt I SWITCH DIMMER g W H L ____ REAR GRNNAL UEL FUEL BRAKE LIGHT LEVEL PUMP SWITCH LIGHT SWITCH SENSOR TURN SIGNAL l G II COMBINATION SWITCH Ip 1 a 0 o I I Ft _ _ I J I IIU tea_ I II I II I IA I II 11 n H __ M _ ULI II I 11 _fillJII 10111111 iiiIll llllllillliillnl Ill 1BD1 Pffll L ro 1 t t Q i IVAL ___ _J 1 11Til11J1lf mnml g J g iM i FT e...

Page 434: ...MEMO ...

Page 435: ...LLEY 1 2 9 OTC INDEX 13 MODEL 4 15 OTC INDEX AFTER 13 MODEL 4 16 OTC TROUBLESHOOTING 13 MODEL 4 17 OTC TROUBLESHOOTING AFTER 13 MODEL 4 34 I ECM 4 49 ECT SENSOR 4 52 ELECTRICAL SYSTEM LOCATION 21 2 EMISSION CONTROL SYSTEMS 1 35 ENGINE HANGER LINK 16 6 ENGINE IDLE SPEED 3 13 ENGINE INSTALLATION 16 7 ENGINE OIL 3 11 ENGINE OIL STRAINER SCREEN 3 12 ENGINE REMOVAL 16 4 EVAP CANISTER EXCEPT AFTER 13 MO...

Page 436: ...ION SYSTEM 5 4 LIGHTS METERS SWITCHES 21 4 LUBRICATION SYSTEM 8 3 MAINTENANCE 3 2 PGM FI SYSTEM 4 6 REAR WHEEL BRAKE SUSPENSION 18 3 SERVICE RULES 1 2 SIDE COVER 2 9 SIDESTAND 3 23 SIDESTAND SWITCH 6 13 SPARK PLUG 3 9 SPECIFICATIONS 1 6 SPEEDOMETER 13 MODEL 21 10 STARTER SYSTEM INSPECTION 6 11 STARTER CHARGING RELAY 6 8 STEERING HEAD BEARINGS 3 25 STEERING STEM 17 24 SUSPENSION 3 23 SYSTEM DIAGRAM...

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