Honda SH300I 2006 Manual Download Page 382 | Manualshive

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HYDRAULIC BRAKE

17-24

Install the snap ring into the groove in the master
cylinder.

• Install the snap ring with the chamfered edges

facing the thrust load side.

• Check that the snap ring is seated in the grooves.

Apply silicone grease to the piston boot inner sur-
face.

Install the piston boot into the master cylinder and
the groove in the piston.

Instal the brake light/inhibitor switch and tighten the
screws to the specified torque.

Apply 0.1 g of silicone grease to the contact sur-
faces of the brake lever, piston tip and brake lever
pivot bolt sliding surface.
Install the brake lever.

Install the pivot bolt and tighten it to the specified
torque.

Install the pivot nut and tighten it to the specified
torque.

TOOL:
Snap ring pliers

07914-SA50001

SNAP RING

SNAP RING PLIERS

PISTON BOOT

TORQUE: 1.2 N·m (0.1 kgf·m, 0.9 lbf·ft)

BRAKE LIGHT/INHIBITOR SWITCH

SCREWS

TORQUE: 1 N·m (0.1 kgf·m, 0.7 lbf·ft)

TORQUE: 6 N·m (0.6 kgf·m, 4.4 lbf·ft)

PIVOT BOLT

PIVOT NUT

BRAKE LEVER

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Summary of Contents for SH300I 2006

Page 1: ...l the following abbreviations are used to identify individual model SH300 SH300A SH300II AII SH300III AIII CODE AREA TYPE ED EUROPEAN DIRECT SALES E U K F France CODE AREA TYPE E U K F France CODE ARE...

Page 2: ...ty equipment When performing any service task be especially careful of the following Read all of the instructions before you begin and make sure you have the tools the replacement or repair parts and...

Page 3: ...ee signal words DANGER WARNING or CAUTION These signal words mean You WILL be KILLED or SERIOUSLY HURT if you don t follow instructions You CAN be KILLED or SERIOUSLY HURT if you don t follow instruct...

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

Page 5: ...CTION SPECIFICATIONS 1 9 ALTERNATOR STARTER CLUTCH SPECIFICATIONS 1 9 CRANKCASE CRANKSHAFT SPECIFICATIONS 1 9 FRONT WHEEL SUSPENSION STEERING SPECIFICATIONS 1 10 REAR WHEEL SUSPENSION SPECIFICATIONS 1...

Page 6: ...icate any sliding surfaces before reassembly 7 After reassembly check all parts for proper installation and operation 8 Route all electrical wires as shown in the Cable and Harness Routing page 1 19 A...

Page 7: ...e Vehicle Identification Number V I N is stamped on the right side of the frame near the rear shock absorber The registered number plate is attached on the left side of the frame near the rear shock a...

Page 8: ...rear wheel The throttle body identification number is stamped on the lower side of the throttle body LABEL The color label is attached on the luggage box When ordering color coded parts always specif...

Page 9: ...gal ENGINE Cylinder arrangement Single cylinder inclined 81 from vertical Bore and stroke 72 0 x 68 5 mm 2 83 x 2 70 in Displacement 279 cm3 17 0 cu in Compression ratio 10 5 1 Valve train Chain driv...

Page 10: ...Cylinder arrangement Single cylinder inclined 81 from vertical Bore and stroke 72 0 x 68 5 mm 2 83 x 2 70 in Displacement 279 cm3 17 0 cu in Compression ratio 10 5 1 Valve train Chain driven OHC with...

Page 11: ...rotor Tip clearance 0 15 0 006 0 20 0 008 Body clearance 0 15 0 22 0 006 0 009 0 35 0 014 Side clearance 0 02 0 09 0 001 0 004 0 12 0 005 ITEM SPECIFICATIONS Throttle body identification number GQB4A...

Page 12: ...19 0 09 0 004 Valve guide projection above cylinder head IN 11 20 11 50 0 441 0 453 EX 12 20 12 50 0 480 0 492 Valve seat width IN EX 0 90 1 10 0 035 0 043 1 5 0 06 Valve spring free length IN EX 37 0...

Page 13: ...il capacity After draining 0 28 liter 0 30 US qt 0 25 lmp qt After disassembly 0 30 liter 0 32 US qt 0 26 lmp qt Recommended final drive oil Honda 4 stroke motorcycle oil or an equivalent API service...

Page 14: ...3 psi Wheel Rim runout Radial 2 0 0 08 Axial 2 0 0 08 Balance weight 70 g 2 5 oz maximum ITEM STANDARD SERVICE LIMIT Front Specified brake fluid DOT 4 Brake disc thickness 4 3 4 7 0 17 0 19 3 5 0 14 B...

Page 15: ...0 04 in Ignition coil primary peak voltage 100 V minimum Crankshaft position CKP sensor peak voltage 0 7 V minimum Ignition timing F mark 10 BTDC at idle ITEM STANDARD SERVICE LIMIT Starter motor bru...

Page 16: ...N m kgf m lbf ft Spark plug 1 10 16 1 6 12 Timing hole cap 1 14 6 0 6 4 4 Apply oil to the threads and seating surface Engine oil drain bolt 1 12 25 2 5 18 Apply oil to the threads and seating surface...

Page 17: ...8 5 61 Apply oil to the threads and seating surface UBS bolt ITEM Q TY THREAD TORQUE REMARKS DIA mm N m kgf m lbf ft Final reduction case bolt 7 8 24 2 4 18 ITEM Q TY THREAD TORQUE REMARKS DIA mm N m...

Page 18: ...unting washer bolt 4 6 12 1 2 9 Air cleaner housing mounting washer bolt 2 6 11 1 1 8 Bank angle sensor mounting screw 2 4 1 2 0 1 0 9 ITEM Q TY THREAD TORQUE REMARKS DIA mm N m kgf m lbf ft Cooling f...

Page 19: ...Brake lever pivot bolt 2 6 1 0 1 0 7 Brake lever pivot nut 2 6 6 0 6 4 4 Brake light switch screw 1 4 1 2 0 1 0 9 Brake light inhibitor switch screw 2 4 1 2 0 1 0 9 Master cylinder holder bolt 4 6 12...

Page 20: ...Engine oil drain bolt threads and seating surface Cylinder head mounting bolt threads and seating surface Oil filter cartridge threads and O ring Oil pump rotors and shaft sliding surface Oil pump dri...

Page 21: ...p Cam stopper plate bolt threads Coating width 6 5 1 0 mm 0 26 0 04 in from its tip Cam sprocket bolt threads Coating width 6 5 1 mm 0 26 0 04 in from its tip to 2 0 3 0 mm 0 08 0 12 in down Cylinder...

Page 22: ...head bearings Apply 3 5 g each Steering head dust seal lips Engine oil Fuel pump rubber seal inner surface Apply 1 0 g maximum Honda bond A Honda hand grip cement Cemedine 540 or equivalent Handlebar...

Page 23: ...COMBINED BRAKE HOSE RIGHT FRONT TURN SIGNAL POSITION LIGHT WIRE IMMOBILIZER RECEIVER WIRE REAR BRAKE HOSE 2 3 10 mm 0 4 in maximum LEFT FRONT TURN SIGNAL POSITION LIGHT WIRE ACCESSORY SOCKET WIRE POS...

Page 24: ...E HOSE SEAT LOCK CABLE RIGHT FRONT TURN SIGNAL POSITION LIGHT WIRE MAIN RELAY FAN MOTOR RELAY WIRE LEFT FRONT TURN SIGNAL POSITION LIGHT WIRE HORN WIRE RADIATOR SIPHON HOSE THROTTLE CABLES THROTTLE CA...

Page 25: ...LIGHT 3P RIGHT FRONT TURN SIGNAL POSITION LIGHT 3P Black THROTTLE CABLES IGNITION SWITCH WIRE RIGHT FRONT TURN SIGNAL POSITION LIGHT WIRE ACCESSORY SOCKET WIRE MAIN WIRE HARNESS FANMOTOR WIRE 10 mm 0...

Page 26: ...RELAY WIRE RADIATOR RESERVE TANK OVER FLOW HOSE REAR COMBINED BRAKE HOSE FRONT BRAKE HOSE Right RADIATOR Front LOWER WATER HOSE CLIPS RADIATOR LOWER WATER HOSE RADIATOR UPPER WATER HOSE SEAT LOCK CAB...

Page 27: ...GENERAL INFORMATION 1 23 MAIN RELAY FAN MOTOR RELAY WIRE REAR BRAKE HOSE RIGHT FRONT TURN SIGNAL POSITION LIGHT WIRE ACCESSORY SOCKET WIRE SEAT LOCK CABLE...

Page 28: ...IRE BATTERY NEGATIVE CABLE BATTERY POSITIVE CABLE STARTER RELAY WIRE BATTERY NEGATIVE CABLE DLC WIRE BATTERY NEGATIVE CABLE FAN MOTOR WIRE SIDESTAND SWITCH WIRE SIDESTAND SWITCH WIRE REAR BRAKE PIPE F...

Page 29: ...ES CKP SENSOR ALTERNATOR WIRE INJECTOR WIRE IGNITION COIL PRIMARY WIRE FUEL FEED HOSE STARTERMOTOR CABLE FINAL REDUCTION CASE BREATHER HOSE PAIR AIR SUCTION HOSE UPPER PAIR AIR SUCTION HOSE CLIP CRANK...

Page 30: ...ring to direction of this figure 10 mm 0 4 in maximum RADIATOR LOWER WATER HOSE RADIATOR UPPER WATER HOSE 1 BATTERY NEGATIVE CABLE 1 1 BATTERY NEGATIVE CABLE STARTER MOTOR CABLE 2 2 2 STARTER MOTOR CA...

Page 31: ...AND SWITCH WIRE FUEL TRAY DRAIN HOSE BATTERY NEGATIVE CABLE STARTER MOTOR CABLE O2 SENSOR WIRE FUEL FEED HOSE GROUND CABLE FUEL PUMP WIRE 5 O2 SENSOR WIRE 6 OIL PRESSURE SWITCH WIRE 6 5 6 5 Right PAIR...

Page 32: ...NSOR ALTERNATOR WIRE THROTTLE CABLES CRANKCASE BREATHER HOSE PAIR AIR SUCTION HOSE THROTTLE CABLE MAIN WIRE HARNESS FUEL FEED HOSE RADIATOR UPPER WATER HOSE BAND UPPER O2 SENSOR WIRE PAIR AIR SUPPLY H...

Page 33: ...CKP SENSOR ALTERNATOR WIRE REAR BRAKE HOSE CRANKCASE BREATHER HOSE PAIR AIR SUCTION HOSE REGULATOR RECTIFIER WIRE Route the fuel feed hose on fuel tank flange as shown TANK FLANGE FUEL FEED HOSE The f...

Page 34: ...MATION 1 30 1 2 2 1 1 MAIN WIRE HARNESS 2 REAR BRAKE PIPE 2 1 GROUND CABLE BYPASS WATER HOSE RADIATOR LOWER WATER HOSE REGULATOR RECTIFIER WIRE CKP SENSOR ALTERNATOR WIRE REAR BRAKE HOSE CKP SENSOR AL...

Page 35: ...E BYPASS WATER HOSE CLIP UPPER UPPER RADIATOR LOWER WATER HOSE RADIATOR LOWER WATER HOSE BAND BYPASS WATER HOSE ECT SENSOR WIRE SENSOR UNIT WIRE IACV WIRE PAIR CONTROL SOLENOID VALVE WIRE IGNITION COI...

Page 36: ...GENERAL INFORMATION 1 32 BANK ANGLE SENSOR WIRE SEAT LOCK CABLE ENGINE STOP RELAY FUEL PUMP RELAY WIRE ECM WIRE LICENSE LIGHT WIRE REAR TURN SIGNAL BRAKE TAIL LIGHT WIRE...

Page 37: ...NT BRAKE HOSE 1 HORN WIRE REAR COMBINED BRAKE HOSE RIGHT FRONT TURN SIGNAL POSITION LIGHT WIRE REAR BRAKE HOSE 2 3 LEFT FRONT TURN SIGNAL POSITION LIGHT WIRE ACCESSORY SOCKET WIRE 1 COMBINATION METER...

Page 38: ...mum POSITION LIGHT WIRE 1 LEFT FRONT TURN SIGNAL 2 HORN WIRE IGNITION SWITCH WIRE IMMOBILIZER RECEIVER WIRE LEFT FRONT TURN SIGNAL POSITION LIGHT WIRE MAIN RELAY FAN MOTOR RELAY WIRE ACCESSORY SOCKET...

Page 39: ...IGNAL POSITION LIGHT WIRE LEFT FRONT TURN SIGNAL POSITION LIGHT WIRE HORN WIRE THROTTLE CABLES THROTTLE CABLES THROTTLE CABLES THROTTLE CABLES FRONT BRAKE HOSE REAR COMBINED BRAKE HOSE FRONT WHEEL SPE...

Page 40: ...ITION LIGHT 3P RIGHT FRONT TURN SIGNAL POSITION LIGHT 3P Black THROTTLE CABLES RIGHT FRONT TURN SIGNAL POSITION LIGHT WIRE ACCESSORY SOCKET WIRE MAIN WIRE HARNESS FANMOTOR WIRE 10 mm 0 04 in maximum S...

Page 41: ...RVE TANK OVER FLOW HOSE REAR COMBINED BRAKE HOSE FRONT BRAKE HOSE Right RADIATOR Front RADIATOR LOWER WATER HOSE RADIATOR UPPER WATER HOSE SEAT LOCK CABLE REAR BRAKE PIPE Upper Upper FRONT WHEEL SPEED...

Page 42: ...GENERAL INFORMATION 1 38 MAIN RELAY FAN MOTOR RELAY WIRE REAR COMBINED BRAKE HOSE SEAT LOCK CABLE FRONT WHEEL SPEED SENSOR ABS MODULATOR WIRE ABS MODULATOR WIRE...

Page 43: ...BLE STARTER RELAY WIRE BATTERY NEGATIVE CABLE DLC WIRE ABS SERVICE CHECK CONNECTOR WIRE FUSE BOX B DLC ABS SERVICE CHECK CONNECTOR WIRE FUSE BOX B WIRE FUSE BOX B FUSE BOX A BATTERY NEGATIVE CABLE FAN...

Page 44: ...ALTERNATOR WIRE INJECTOR WIRE IGNITION COIL PRIMARY WIRE FUEL FEED HOSE STARTERMOTOR CABLE FINAL REDUCTION CASE BREATHER HOSE PAIR AIR SUCTION HOSE PAIR AIR SUCTION HOSE CLIP CRANKCASE BREATHER HOSE U...

Page 45: ...ring to direction of this figure 10 mm 0 4 in maximum RADIATOR LOWER WATER HOSE RADIATOR UPPER WATER HOSE 1 BATTERY NEGATIVE CABLE 1 1 BATTERY NEGATIVE CABLE STARTER MOTOR CABLE 2 2 2 STARTER MOTOR CA...

Page 46: ...AND SWITCH WIRE FUEL TRAY DRAIN HOSE BATTERY NEGATIVE CABLE STARTER MOTOR CABLE O2 SENSOR WIRE FUEL FEED HOSE GROUND CABLE FUEL PUMP WIRE 5 O2 SENSOR WIRE 6 OIL PRESSURE SWITCH WIRE 6 5 6 5 Right PAIR...

Page 47: ...CRANKCASE BREATHER HOSE PAIR AIR SUCTION HOSE THROTTLE CABLE MAIN WIRE HARNESS FUEL FEED HOSE RADIATOR UPPER WATER HOSE BAND UPPER O2 SENSOR WIRE BATTERY NEGATIVE CABLE STARTERMOTOR CABLE GROUND CABLE...

Page 48: ...CKP SENSOR ALTERNATOR WIRE REAR BRAKE HOSE CRANKCASE BREATHER HOSE PAIR AIR SUCTION HOSE REGULATOR RECTIFIER WIRE Route the fuel feed hose on fuel tank flange as shown TANK FLANGE FUEL FEED HOSE The f...

Page 49: ...MATION 1 45 1 2 2 1 1 MAIN WIRE HARNESS 2 REAR BRAKE PIPE 2 1 GROUND CABLE BYPASS WATER HOSE RADIATOR LOWER WATER HOSE REGULATOR RECTIFIER WIRE CKP SENSOR ALTERNATOR WIRE REAR BRAKE HOSE CKP SENSOR AL...

Page 50: ...E BYPASS WATER HOSE CLIP BYPASS WATER HOSE CLIP UPPER BYPASS WATER HOSE ECT SENSOR WIRE SENSOR UNIT WIRE IACV WIRE PAIR CONTROL SOLENOID VALVE WIRE IGNITION COIL PRIMARY WIRE FINAL REDUCTION CASE BREA...

Page 51: ...GENERAL INFORMATION 1 47 BANK ANGLE SENSOR WIRE SEAT LOCK CABLE ENGINE STOP RELAY FUEL PUMP RELAY WIRE ECM WIRE LICENSE LIGHT WIRE REAR TURN SIGNAL BRAKE TAIL LIGHT WIRE...

Page 52: ...Honda Motor Co Ltd utilizes various systems to reduce carbon monoxide oxides of nitrogen and hydrocarbons CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped with a closed crankcase system to pr...

Page 53: ...ee way catalytic converter The three way catalytic converter is in the exhaust system Through chemical reactions they convert HC CO and NOx in the engine s exhaust to carbon dioxide CO2 dinitro gen N2...

Page 54: ...MEMO...

Page 55: ...2 1 2 2 TECHNICAL FEATURES HEATER LESS O2 SENSOR 2 2 UNIT SWING ENGINE LAYOUT 2 3...

Page 56: ...erly until it is warmed up conventional O2 sensor is equipped with a heater Heater less O2 sensor is located near the exhaust port in order to make use of the heat from the exhaust gas eliminating the...

Page 57: ...are installed on the unit link pivot in order to obtain smooth swing without sacrificing the rigidity of the unit link Furthermore the swing rod controls restricts to and fro and vertical travel of t...

Page 58: ...MEMO...

Page 59: ...NANCE LID 3 4 SEAT 3 4 LUGGAGE BOX 3 5 GRAB RAIL 3 5 BODY COVER 3 6 REAR FENDER 3 7 FRONT FENDER 3 8 FLOOR SIDE COVER 3 8 UNDER COVER 3 9 FRONT UPPER COVER 3 9 FRONT INNER COVER 3 10 FRONT LOWER COVER...

Page 60: ...l page 3 13 3 Luggage Box page 3 5 9 Floor Side Cover page 3 8 15 Front Handlebar Cover page 3 14 4 Grab Rail page 3 5 10 Under cover page 3 9 16 Rear Handlebar Cover page 3 14 5 Body Cover page 3 6 1...

Page 61: ...lways inspect the exhaust system for leaks after installation TORQUE VALUES TROUBLESHOOTING Excessive exhaust noise Broken exhaust system Exhaust gas leak Poor performance Deformed exhaust system Exha...

Page 62: ...e parts by inserting the snap fit clip straight into the hole being careful not to tilt the insertion of the clip MAINTENANCE LID Unlock the seat lock with the ignition key and open the seat Remove th...

Page 63: ...on the fuel tank flange as shown GRAB RAIL Unlock the seat lock with the ignition key and open the seat Remove the three bolts washers and grab rail Installation is in the reverse order of removal TOR...

Page 64: ...g two tapping screws two special screws two bolts and collars Raise the front portion of the body cover slightly and release its tabs from the floor panel Remove the body cover and disconnect the rear...

Page 65: ...ther rear shock absorber page 16 12 Remove the ECM page 6 65 Remove the fuel pump engine stop relays page 6 69 from the rear fender B Release the main wire harness and fuel tank over flow hose from th...

Page 66: ...cover from the tab on the floor panel Release the three hooks and three tabs on the floor side cover from the grooves on the floor panel Remove the floor side cover by releasing the two tabs on the fl...

Page 67: ...is in the reverse order of removal FRONT UPPER COVER Remove the two special screws Release the two snap fit clips page 3 4 of the front upper cover from the front lower cover slots Remove the front u...

Page 68: ...six snap fit clips page 3 4 of the front lower cover from the front inner cover slots Raise the lower portion of the inner cover and release the six tabs from the floor panel Remove the front inner co...

Page 69: ...m the front lower inner cover Remove the tapping screw and pocket lid from the front upper inner cover Remove the tapping screw and radiator mainte nance lid from the front lower inner cover Assembly...

Page 70: ...ket wire band from the front lower cover Release the left turn signal position wire from the wire band While supporting the front lower cover and discon nect the turn signal position light 3P connecto...

Page 71: ...o screws four washer bolts and spe cial bolt Remove the tapping screw and wire holder Pull out the electric cables wire harness fuse box A fuse box B ABS type only DLC and ABS service check connector...

Page 72: ...EBAR COVER Remove the front handlebar cover page 3 14 Remove the following two tapping screws front side screw rear side Remove the rear handlebar cover from the handle bar and disconnect the handleba...

Page 73: ...ust pipe stud bolt protrusion from the cylinder head is specified length as shown Tighten the exhaust pipe joint nuts exhaust pipe band bolt and muffler mounting bolts in the sequence as shown After i...

Page 74: ...s CENTERSTAND Retract the centerstand and support the scooter securely Remove the following from the right side spring cotter pin Remove the following from the left side spring mounting bolt mounting...

Page 75: ...ENGINE OIL 4 10 ENGINE OIL FILTER 4 12 RADIATOR COOLANT 4 14 COOLING SYSTEM 4 14 SECONDARY AIR SUPPLY SYSTEM 4 15 DRIVE BELT 4 15 BELT CASE AIR CLEANER 4 16 FINAL DRIVE OIL 4 17 BRAKE FLUID 4 18 BRAK...

Page 76: ...1 1 lmp qt After draining filter change 1 4 liter 1 5 US qt 1 2 lmp qt After disassembly 1 7 liter 1 8 US qt 1 5 lmp qt Engine idle speed 1 500 100 min 1 rpm Drive belt width Service limit 25 5 mm 1...

Page 77: ...ft Apply engine oil to the threads and seating sur face Oil filter cartridge 26 N m 2 7 kgf m 19 lbf ft Apply engine oil to the threads and seating sur face Oil filter boss 18 N m 1 8 kgf m 13 lbf ft...

Page 78: ...y 2 years Replacement requires mechanical skill FREQUENCY WHICHEVER COMES FIRST ODOMETER READING NOTE 1 REFER TO PAGE x 1 000 km 1 6 12 18 24 30 36 x 1 000 mi 0 6 4 8 12 16 20 24 ITEMS Months 6 12 18...

Page 79: ...rip housing For cable lubrication disconnect the throttle cable at its upper end Thoroughly lubricate the cable and its pivot point with a commercially available cable lubricant or a light weight oil...

Page 80: ...pections are required Remove the following belt case air cleaner housing page 4 16 seven screws air cleaner housing cover air cleaner element Replace the element in accordance with the mainte nance sc...

Page 81: ...e maintenance lid page 3 4 Disconnect the spark plug cap and remove the spark plug Check the insulator for cracks or damage and the electrodes for wear fouling or discoloration Replace the plug if nec...

Page 82: ...e tab of the cylinder head cover Install the maintenance lid page 3 4 VALVE CLEARANCE INSPECTION Inspect and adjust the valve clearance while the engine is cold below 35 C 95 F Check the engine idle s...

Page 83: ...of each valve by inserting the feeler gauge between the rocker arm and shim Move the rocker arm to the spring side and remove the shim Do not allow the shims to fall into the crankcase Mark all shims...

Page 84: ...Check that the O ring is in good condition replace if necessary Apply engine oil to the timing hole cap O ring Apply engine oil to the timing hole threads and seating surface Tighten the timing hole...

Page 85: ...Remove the oil filler cap dipstick Remove the oil drain bolt and sealing washer then drain the engine oil completely Replace the sealing washer with new one Apply engine oil to the oil drain bolt thr...

Page 86: ...itch and clock switch for more than 2 seconds while odd meter indicated at ignition switch The indicator will disappear If the oil is changed before the oil change indicator appears be sure to reset t...

Page 87: ...boss protrusion from the crankcase is specified length See above Apply clean engine oil to new oil filter cartridge threads and O ring Install the oil filter and tighten it to the specified torque Re...

Page 88: ...and antifreeze coolant preparation page 7 6 Check to see if there are any coolant leaks when the coolant level decreases very rapidly If the reserve tank becomes completely empty there is a possibili...

Page 89: ...cleaner housing and pulse secondary air injection PAIR check valve for cracks deterioration damage or loose connections If the air supply hoses show any signs of heat dam age inspect the PAIR check va...

Page 90: ...aner base cover is in good condition replace if necessary Remove the air cleaner element from the base core Wash the element in non flammable or high flash point solvent Squeeze out the solvent and le...

Page 91: ...ompletely drained install the drain bolt M8 x 12 with a new sealing washer and tighten it to the specified torque Fill the final reduction case with recommended oil up to the correct level page 4 17 R...

Page 92: ...low check the brake pads for wear page 4 19 A low fluid level may be due to wear of the brake pads If the brake pads are worn the caliper pis ton is pushed out this accounts for a low reser voir leve...

Page 93: ...R BRAKE PADS Check the brake pads for wear Replace the brake pads if either pad reaches the bot tom of wear limit groove Refer to rear brake pad replacement page 17 14 BRAKE SYSTEM HYDRAULIC SYSTEM IN...

Page 94: ...eration as follows Place the scooter on its centerstand Jack up the scooter to raise the front wheel off the ground Apply the rear brake lever Make sure that the front wheel does not turn while the re...

Page 95: ...nd Check the sidestand spring for damage or loss of tension Check the sidestand assembly for freedom of move ment and lubricate the sidestand pivot if necessary SUSPENSION FRONT Check the action of th...

Page 96: ...FASTENERS Check that all chassis nuts and bolts are tightened to their correct torque values page 1 12 Check that all cotter pins safety clips hose clamps and cable stays are in place and properly se...

Page 97: ...ssure gauge when the tires are cold Check the tires for cuts embedded nails or other damage Check the front and rear wheels for trueness Measure the tread depth at the center of the tires Replace the...

Page 98: ...hat the handlebar moves freely from side to side If the handlebar moves unevenly or binds inspect the steering head bearings page 15 27 Hold the scooter and check the steering head bear ings for wear...

Page 99: ...5 1 5 5 LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM 5 2 SERVICE INFORMATION 5 3 TROUBLESHOOTING 5 4 OIL PRESSURE CHECK 5 5 OIL STRAINER 5 6 OIL PRESSURE RELIEF VALVE 5 7 OIL PUMP 5 8...

Page 100: ...LUBRICATION SYSTEM 5 2 LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM CRANKSHAFT PISTON OIL PUMP REED VALVE CAMSHAFT ROCKER ARM OIL STRAINER OIL PRESSURE RELIEF VALVE OIL FILTER OIL PRESSURE SWITCH...

Page 101: ...l ITEM STANDARD SERVICE LIMIT Engine oil capacity After draining 1 2 liter 1 3 US qt 1 1 lmp qt After oil filter change 1 4 liter 1 5 US qt 1 2 lmp qt After disassembly 1 7 liter 1 8 US qt 1 5 lmp qt...

Page 102: ...sure Oil level too low Oil pressure relief valve stuck open Broken oil pump drive chain Broken oil pump drive and driven sprocket Damaged oil pump Internal oil leak High oil pressure Oil pressure reli...

Page 103: ...the engine Do not apply seal ant to the thread head 3 4 mm 0 1 0 2 in Apply sealant Three Bond 1207B or equivalent to the oil pressure switch threads as shown and tighten it to the specified torque C...

Page 104: ...er and screen mesh INSPECTION Check the oil strainer screen mesh for damage or clogs INSTALLATION Install the oil strainer into the crankcase as shown Install the screen mesh into the crankcase as sho...

Page 105: ...e body for clogging or damage Clean all parts and assemble the relief valve in the reverse order of disassembly Install the snap ring with the chamfered edge facing the thrust load side Do not reuse w...

Page 106: ...eel page 13 9 Remove the following bolt and sprocket cover oil pump driven sprocket bolt driven sprocket drive chain two bolts oil pump The oil pump driven sprocket bolt has left hand threads COVER BO...

Page 107: ...following dowel pins screw pump cover oil pump shaft thrust washer drive pin inner rotor outer rotor Wash all parts with a high flash point or non flam mable solvent COVER SCREW DOWEL PINS DRIVE PIN...

Page 108: ...worn beyond the specified service limits replace the oil pump as an assembly Temporarily install the outer rotor inner rotor drive pin and oil pump shaft into the oil pump body Measure the tip cleara...

Page 109: ...ne oil to the oil pump shaft and insert the drive pin into the hole in the oil pump shaft Install the oil pump shaft through the inner rotor and oil pump body by align the drive pin with the groove in...

Page 110: ...stall the sprocket with its OUT mark facing out while aligning the flat surfaces of the sprocket and pump shaft Apply engine oil to the threads of the oil pump driven sprocket bolt Install and tighten...

Page 111: ...INFORMATION 6 10 DTC INDEX 6 15 DTC TROUBLESHOOTING 6 16 MIL TROUBLESHOOTING 6 31 MIL CIRCUIT INSPECTION 6 43 FUEL LINE INSPECTION 6 44 FUEL PUMP 6 48 FUEL TANK 6 51 AIR CLEANER HOUSING 6 52 THROTTLE...

Page 112: ...FUEL SYSTEM PGM FI 6 2 FUEL SYSTEM PGM FI COMPONENT LOCATION 12 N m 1 2 kgf m 9 lbf ft 5 N m 0 5 kgf m 3 7 lbf ft 12 N m 1 2 kgf m 9 lbf ft 11 N m 1 1 kgf m 8 lbf ft...

Page 113: ...tightening it can cause incorrect throt tle valve operation Always replace the packing when the fuel pump is removed A faulty PGM FI system is often related to poorly connected or corroded connectors...

Page 114: ...PGM FI 6 4 TOOLS Fuel pressure gauge 07406 0040004 Pressure gauge manifold 07ZAJ S5A0111 Fuel attachment hose 07ZAJ S5A0120 ECM test harness 33P 070MZ MCA0100 SCS connector 070PZ ZY30100 Test probe 07...

Page 115: ...Engine stalls hard to start rough idling 1 Inspect the idle speed page 6 77 2 Inspect the IACV page 6 77 3 Inspect the fuel supply system page 6 44 4 Inspect the ignition system page 20 5 Restricted...

Page 116: ...SYSTEM LOCATION ENGINE STOP RELAY O2 SENSOR ECT SENSOR ECM FUEL PUMP DLC FUEL PUMP RELAY BANKANGLE SENSOR PAIR CONTROL SOLENOID VALVE IGNITION SWITCH SENSOR UNIT MAP SENSOR TP SENSOR IAT SENSOR IACV...

Page 117: ...O G O TP SENSOR Y R W R G O FI 8 9 FI G O W Bu G O IAT SENSOR P W G Bu METER TEMPERATURE FROM COOLANT Bl O 2 FI 29 Y O W R W Bu P W Bl O IMMOBILIZER RECEIVER Y R G O O Bu P FI 7 ECT SENSOR P O Bu CKP...

Page 118: ...OR 2P Natural CONNECTOR NOTE 1 INJECTOR 2P CONNECTOR NOTE 1 SENSOR UNIT 5P Black CONNECTOR NOTE 1 Wire side of female terminal Sensor side of male terminal Wire side of female terminal Sensor side of...

Page 119: ...STEM PGM FI 6 9 NOTE 2 Remove the maintenance lid page 3 4 NOTE 3 Remove the rear fender A page 3 7 DLC 4P CONNECTOR NOTE 2 Wire side of female terminal ECM 33P CONNECTOR NOTE 3 Wire side of female te...

Page 120: ...y is detected by the self diagnosis function running capability is maintained by pre programed value in the simulated program map When any abnormality is detected in the injector and or crankshaft pos...

Page 121: ...the MIL is 25 two long blinks 20 blinks plus five short blinks When the ECM stores more than one DTC the MIL will indicate them by blinking in the order from the lowest number to highest number MIL C...

Page 122: ...t start turn the starter motor for more than 10 seconds and check that the MIL blinks 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 bl...

Page 123: ...indicator goes off and starts blinking The DLC must be jumped while the MIL lights If not the MIL will not start blinking Note that the self diagnostic memory cannot be erased if the ignition switch...

Page 124: ...n the main wire harness and the ECM TEST HARNESS TERMINAL LAYOUT The ECM connector terminals are numbered as shown in this illustration The ECM test harness terminals are same layout as for the ECM co...

Page 125: ...t connec tor TP sensor or its circuit malfunction Poor engine acceleration Fail safe value 0 6 21 6 34 8 2 8 TP sensor circuit high voltage more than 4 922 V TP sensor or its circuit malfunction Poor...

Page 126: ...oltage within 4 75 5 25 V YES GO TO STEP 4 NO GO TO STEP 3 3 MAP sensor Input line Open Circuit Inspection Turn the ignition switch OFF Disconnect the ECM 33P connector Check for continuity between th...

Page 127: ...S pocket tester Is about 0 V indicated YES Faulty ECM Replace it with new one and recheck refer to Key Registration Procedures page 23 4 NO Faulty original sensor unit Faulty origi nal MAP sensor DTC...

Page 128: ...circuit in the Yellow Orange wire 4 MAP sensor Ground line Open Circuit Inspection Turn the ignition switch OFF Check for continuity between the sensor unit 5P Black connector of the wire harness sid...

Page 129: ...e resistance within 2 3 2 6 k YES Replace the ECM with a new one and recheck refer to Key Registration Proce dures page 23 4 NO Faulty ECT sensor 4 ECT Sensor Output Line Short Circuit Inspection Turn...

Page 130: ...sor with the HDS pocket tester Is about 0 V indicated YES Inspect the ECT sensor page 6 74 NO GO TO STEP 3 3 ECT Sensor Output ground Line Inspection Turn the ignition switch OFF Disconnect the jumper...

Page 131: ...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 5P Black connector Measure the resistance at the senso...

Page 132: ...a new one and recheck NO GO TO STEP 7 7 TP Sensor Input line Open Circuit Inspection Turn the ignition switch OFF Disconnect the ECM 33P connector Check for continuity between the sensor unit 5P Blac...

Page 133: ...sistance Inspection Turn the ignition switch OFF Disconnect the sensor unit 5P Black connector Measure the resistance at the sensor unit side Is the resistance within 0 5 0 7 k YES GO TO STEP 4 NO Rep...

Page 134: ...Is about 0 V indicated YES GO TO STEP 3 NO Faulty IAT sensor 3 IAT Sensor Output Line Short Circuit Inspection Turn the ignition switch OFF Disconnect the ECM 33P connector Check for continuity betwe...

Page 135: ...IAT sensor with the HDS pocket tester Is about 0 V indicated 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...

Page 136: ...nd engine stop switch then start the engine and check the injector with the HDS pocket tester Is the DTC 12 1 indicated YES GO TO STEP 2 NO Intermittent failure Loose or poor contact on the injector 2...

Page 137: ...nuity YES GO TO STEP 5 NO Open circuit in Pink Blue wire 5 Injector Signal Line Short Circuit Inspection Check for continuity between the injector 2P con nector and ground with the ECM connector dis c...

Page 138: ...een the ECM 33P con nector of the wire harness side and ground Is there continuity YES Short circuit in the Black Orange wire NO GO TO STEP 3 3 O2 Sensor Inspection Replace the O2 sensor with a known...

Page 139: ...ire Short circuit in Gray red or Black Red wire NO GO TO STEP 3 3 IACV Circuit Continuity Inspection Disconnect the ECM 33P connector Check the continuity between the ECM 33P con nector terminals and...

Page 140: ...YES Faulty IACV Replace the IACV with a new one and recheck NO Replace the ECM with new one and recheck refer to Key Registration Proce dures page 23 4 DTC 33 2 EEPROM 1 Recheck DTC Clear the DTC Turn...

Page 141: ...e sensor unit 5P Black connector Turn the ignition switch ON and engine stop switch Measure the voltage at the wire harness side Is the voltage within 4 75 5 25 V YES Replace the sensor unit with a ne...

Page 142: ...ide and ground Is there continuity YES Short circuit in Yellow Orange wire NO Replace the sensor unit with a new one and recheck Faulty MAP sensor MIL 7 BLINKS ECT SENSOR Before starting the inspectio...

Page 143: ...d recheck refer to Key Registra tion Procedures page 23 4 NO Faulty ECT sensor 4 ECT Sensor Output Ground Line Open Circuit Inspection Turn the ignition switch OFF Check the continuity between the tes...

Page 144: ...stop switch Measure the TP sensor output voltage at the test harness terminals A voltage marked refers to the value of the ECM output voltage Step 2 when the volt age reading shows 5 V When the ECM o...

Page 145: ...ss termi nals Is the voltage within 4 75 5 25 V YES Open circuit in Yellow Red wire Open circuit in Green Orange wire NO Replace the ECM with new one and recheck refer to Key Registration Proce dures...

Page 146: ...harness to ECM connector page 6 14 Turn the ignition switch ON and engine stop switch Measure the voltage at the test harness termi nals Is the voltage within 2 7 3 1 V YES Intermittent failure Loose...

Page 147: ...O Open circuit in White Blue wire Open circuit in Green Orange wire 5 IAT Sensor Output Line Short Circuit Inspection Disconnect the test harness and ECM 33P con nector disconnected Check for continui...

Page 148: ...voltage between the injector 2P connector of the wire harness side and ground Does the battery voltage exist YES GO TO STEP 2 NO Open circuit in Black white wire 2 Injector Resistance Inspection Turn...

Page 149: ...gnal Line Short Circuit Inspection Disconnect the test harness and ECM 33P con nector disconnected Check for continuity between the injector 2P con nector of the wire harness side and ground Is there...

Page 150: ...harness terminal and the O2 sensor connector terminal of the wire harness side Is there continuity YES GO TO STEP 2 NO Open circuit in Black Orange wire 2 O2 Sensor Short Circuit Inspection Disconnect...

Page 151: ...rting the inspection check for loose or poor contact on the IACV 4P connector and recheck the MIL blinking 1 IACV Short Circuit Inspection Turn the ignition switch OFF Disconnect the IACV 4P connector...

Page 152: ...place the IACV with a new one and recheck 4 IACV Short Circuit Inspection Check for continuity at the IACV 4P connector terminals of the IACV side Is there continuity YES Faulty IACV Replace the IACV...

Page 153: ...n the ignition switch OFF Remove the rear fender A page 3 7 Disconnect the ECM 33P connector Turn the ignition switch ON the MIL should turn off If the MIL comes on check for short circuit in the Blue...

Page 154: ...the luggage box page 3 5 Disconnect the fuel pump 5P connector 2 Turn the ignition switch ON 3 Start the engine and let it idle until the engine stalls 4 Turn the ignition switch OFF 5 Check the fuel...

Page 155: ...ely pull and push the connector until it comes off easily 8 To prevent damage and keep foreign matter out cover the disconnected connector and pipe end with the plastic bags QUICK CONNECT FITTING INST...

Page 156: ...il on the pipe end 3 Make sure the connection is secure and that the pawls are firmly locked into place check visually and by pulling the connector 4 Connect the fuel pump 5P connector 5 Do not start...

Page 157: ...owing Fuel line leaking Fuel pump page 6 48 Clogged fuel filter Assembly of the fuel pump After inspection relieve the fuel pressure by starting the engine and let it idle until it stalls Remove the f...

Page 158: ...the ignition switch ON and confirm that the fuel pump operates for a few seconds If the fuel pump does not operate inspect as fol lows Turn the ignition switch OFF Remove the luggage box page 6 45 Di...

Page 159: ...nnector Remove the fuel pump mounting nuts Remove the set plate and fuel pump unit from the fuel tank Remove the packing from the fuel pump unit INSPECTION Check for fuel pump unit for wear or damage...

Page 160: ...sensor when installing the fuel pump unit Be careful not to allow the dirt and debris between the fuel pump and packing Install the set plate by aligning the allow marks and its holes with the tabs on...

Page 161: ...P connector Disconnect the fuel tray drain hose Remove the bolts and frame plate Remove the four mounting washer bolts and fuel tank Installation is in the reverse order of removal Route the fuel tank...

Page 162: ...washer bolt from the air cleaner housing Disconnect the final reduction case breather hose from the air cleaner housing Remove the two mounting washer bolts from the air cleaner housing Loosen the con...

Page 163: ...body Loosen the throttle cable lock nuts Release the throttle cable from the cable bracket Disconnect the throttle cables from the throttle drum Loosen the connecting hose band screw and insula tor b...

Page 164: ...cause incorrect throttle valve operation Do not loosen or tighten the white painted nut of the throttle drum Loosening or tightening it can cause throttle body malfunction Remove the following Torx sc...

Page 165: ...eir 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 Perform the TP sensor reset procedure pa...

Page 166: ...tall and tighten the torx screws to the specified torque INSTALLATION Install the throttle body between the connecting hose and insulator band by aligning the throttle body tab with insulator band gro...

Page 167: ...hrottle cable onto the cable bracket then adjust the throttle grip free play page 4 5 Connect the sensor unit 5P Black connector and IACV 4P connector Set the wire clamp boss from the throttle body In...

Page 168: ...lid page 3 4 2 Turn the ignition switch OFF 3 Remove the dummy connector from the DLC 4 Connect the special tool to the DLC and short the DLC terminals 5 Disconnect the ECT sensor 3P Gray connector S...

Page 169: ...the ECT sensor Gray 3P connector JUMPER WIRE 3P GRAY CONNECTOR within 10 sec 0 1 sec MIL ON MIL OFF RESET RECEIVING PATTERN SUCCESSFUL PATTERN TP SENSOR IS RESET SUCCESSFULLY If the jumper wire is con...

Page 170: ...h its centerstand Warm up the engine about ten minutes Connect the tachometer and check the idle speed If the idle speed is out of the specification check the following Throttle operation and throttle...

Page 171: ...lease them from the locking pawls Pull the connector off Prevent the remaining fuel in the fuel hose from flowing out using a shop towel Be careful not to damage the hose or other parts Retainer tabs...

Page 172: ...he new O ring and seal ring with engine oil Install the O ring and seal ring to the injector Replace the O ring and seal ring with new ones as a set Be careful not to damage the O ring and seal ring I...

Page 173: ...Then press the quick connect fitting onto the pipe until both retainer pawls lock with a CLICK If it is hard to connect put a small amount of engine oil on the pipe end Make sure the connection is sec...

Page 174: ...t any for eign material from dropping into the engine INSTALLATION Install new O rings to the groove on the insulator Install the insulator as shown Install the intake pipe by aligning the intake pipe...

Page 175: ...between the ECM 33P con nector of the wire harness side and ground Is there continuity YES GO TO STEP 2 NO Open circuit in Green White wire Open circuit in Green Black wire 2 ECM Power Line Inspection...

Page 176: ...ge between the ECM 33P con nector of the wire harness side and ground Does the battery voltage exist YES Inspect the engine stop relay coil line page 6 68 Inspect the engine stop relay conti nuity pag...

Page 177: ...l replace the ECM with a new one and recheck If you do not hear the relay CLICK inspect the fol lowing Engine stop relay coil line inspection page 6 68 Engine stop relay continuity inspection page 6 6...

Page 178: ...e engine stop relay page 6 69 Short the relay connector terminals of the wire har ness side with a jumper wire Disconnect the bank angle sensor 6P connector Turn the ignition switch ON Measure the vol...

Page 179: ...s If you hear the fuel pump relay CLICK but fuel pump does not operate for a few seconds inspect the following Fuel pump relay continuity inspection page 6 70 Fuel pump relay switch line inspection pa...

Page 180: ...connector terminals of the wire har ness side with a jumper wire Disconnect the fuel pump 5P connector page 6 48 Turn the ignition switch ON Measure the voltage at the fuel pump connector of the wire...

Page 181: ...rmal If the battery voltage does not appear inspect the following Open circuit in Black White wire between the engine stop relay and fuel pump relay Open circuit in Brown Black wire between the fuel p...

Page 182: ...sensor INSTALLATION Install the bank angle sensor with its UP mark fac ing up Install and tighten the two screws to the specified torque Connect the bank angle sensor 3P connector Install the followin...

Page 183: ...ates that circuit is closed Incline the bank angle sensor approximately 49 4 to the left or right while the ignition switch is ON The bank angle sensor is normal if the engine stop relay clicks which...

Page 184: ...Measure the voltage at the bank angle sensor 3P connector terminals of the wire harness side If there is no voltage check the open circuit in Red Blue wire ECT SENSOR REMOVAL Drain the coolant page 7...

Page 185: ...t the ther mometer or ECT sensor touch the pan Replace the ECT sensor if it is out of specifications INSTALLATION Always replace a sealing washer with a new one Install the new sealing washer and ECT...

Page 186: ...cold Remove the maintenance lid page 3 4 Remove the O2 sensor connector Remove the O2 sensor from the cylinder head INSTALLATION Install and tighten the O2 sensor to the cylinder head to the specified...

Page 187: ...rately indicate a 50 min 1 rpm change Start the engine and warm it up to coolant tempera ture 80 C 176 F Stop the engine and connect a tachometer accord ing to the tachometer manufacturer s operating...

Page 188: ...pport the scooter with its centerstand Warm up the engine about ten minutes Stop the engine Remove the air cleaner element page 4 6 Check that the PAIR air suction hose port of air cleaner is clean an...

Page 189: ...resistance between the connector ter minals If it is out of the standard replace the PAIR control solenoid valve PAIR CHECK VALVE INSPECTION Remove the body cover page 3 6 Remove the bolts and PAIR ch...

Page 190: ...ge or fatigue Replace if necessary Replace the PAIR check valve if the rubber seat is cracked deteriorated or damaged or if there is clearance between the reed and seat Installation is in the reverse...

Page 191: ...SYSTEM SYSTEM FLOW PATTERN 7 2 SERVICE INFORMATION 7 3 TROUBLESHOOTING 7 4 SYSTEM TESTING 7 5 COOLANT REPLACEMENT 7 6 THERMOSTAT 7 9 WATER PUMP 7 10 RADIATOR COOLING FAN 7 13 RADIATOR 7 13 RADIATOR RE...

Page 192: ...COOLING SYSTEM 7 2 COOLING SYSTEM SYSTEM FLOW PATTERN THERMOSTAT RESERVE TANK WATER PUMP SIPHON HOSE RADIATOR OVER FLOW HOSE...

Page 193: ...r information page 22 14 SPECIFICATIONS TORQUE VALUES Removing the radiator cap while the engine is hot can allow the coolant to spray out seriously scalding you Always let the engine and radiator coo...

Page 194: ...ure too low Thermostat stuck open Faulty cooling fan motor or fan motor circuit Faulty coolant temperature gauge circuit or ECT sensor page 22 14 Coolant leaks Faulty water pump mechanical seal Deteri...

Page 195: ...1 005 1 003 1 001 0 999 0 997 10 1 018 1 017 1 017 1 016 1 015 1 014 1 013 1 011 1 009 1 007 1 005 15 1 028 1 027 1 026 1 025 1 024 1 022 1 020 1 018 1 016 1 014 1 012 20 1 036 1 035 1 034 1 033 1 03...

Page 196: ...ssure for at least 6 seconds Remove the tester and install the radiator cap Install the radiator maintenance lid and tighten the screw COOLANT REPLACEMENT PREPARATION The effectiveness of coolant decr...

Page 197: ...under cover page 3 9 radiator maintenance lid page 7 5 Drain the coolant from the system by removing the drain bolt sealing washer and the radiator cap then disconnect the lower radiator hose and com...

Page 198: ...he filler neck Fill the reserve tank to the upper level line and install the tank cap Bleed air from the system as follows 1 Start the engine and let it idle for 2 3 minutes 2 Snap the throttle 3 4 ti...

Page 199: ...ally inspect the thermostat for damage Check for damage of the seal ring Replace the thermostat if the valve stays open at room temperature Do not let the ther mostat or ther mometer touch the pan or...

Page 200: ...Turn the water pump impeller with your finger The pump shaft should turn smoothly and quietly Replace the faulty part if the shaft do not turn smoothly or quietly Hold the pump shaft tab securely and...

Page 201: ...ew mechanical seal Degrease the pump shaft thoroughly and apply molybdenum oil solution to the shaft journal and thrust washer Do not apply molybdenum oil solution to the mechanical seal sliding area...

Page 202: ...r Check the pump shaft for smooth rotation Install the two dowel pins to the right crankcase cover Install a new O ring to the water pump cover Install the water pump cover to the right crankcase cove...

Page 203: ...page 3 10 floor panel page 3 13 cooling fan motor page 7 13 Drain the coolant from the system page 7 7 Disconnect the four water hoses Disconnect the radiator siphon hose Remove the two bolts and wat...

Page 204: ...anel page 3 13 Drain the coolant from the system page 7 7 Disconnect the over flow hose and siphon hose from the reserve tank Remove the mounting bolts and reserve tank Installation is in the reverse...

Page 205: ...8 1 8 8 ENGINE REMOVAL INSTALLATION COMPONENT LOCATION 8 2 SERVICE INFORMATION 8 3 ENGINE REMOVAL 8 4 ENGINE INSTALLATION 8 9...

Page 206: ...ENGINE REMOVAL INSTALLATION 8 2 ENGINE REMOVAL INSTALLATION COMPONENT LOCATION 78 N m 8 0 kgf m 58 lbf ft 30 N m 3 1 kgf m 22 lbf ft 10 N m 1 0 kgf m 7 lbf ft...

Page 207: ...ATIONS Engine dry weight 41 kg 90 4 lbs Engine oil capacity After draining 1 2 liter 1 3 US qt 1 1 lmp qt After oil filter change 1 4 liter 1 5 US qt 1 2 lmp qt After disassembly 1 7 liter 1 8 US qt 1...

Page 208: ...ant page 7 7 Remove the two bolts and brake hose protector Remove the two caliper mounting bolts and rear brake caliper Remove the two bolts and brake hose clamps Disconnect the ignition coil wire con...

Page 209: ...T sensor 3P gray connector and injector 2P black connector Release the wire band from the wire band stay Disconnect the sensor unit 5P black connector and IACV 4P connector Release the wire band from...

Page 210: ...bolt and cable clamp Remove the bolt and hose clamp Loosen the band screw and disconnect the upper water hose Loosen the band screw and disconnect the lower water hose Place a floor jack or other adju...

Page 211: ...the engine Remove the distance collar and engine mounting bushings Remove the frame pivot nut bolt and engine hanger bracket Remove the swing rod pivot nuts washer lower bolts and the swing rod The ja...

Page 212: ...r damage Also check that the bearing outer race fits tightly in hanger bracket B Check the bushings in the engine hanger bracket A and swing rod for wear deterioration or damage BEARING REPLACEMENT Re...

Page 213: ...page 1 19 TOOLS Driver 07749 0010000 Attachment 24 x 26 mm 07746 0010700 Pilot 20 mm 07746 0040500 ATTACHMENT PILOT DRIVER BEARING SWING ROD ENGINE HANGER BRACKET A INNER COLLAR DUST SEALS NEEDLE BEA...

Page 214: ...ecified torque Install the swing rod into the frame Install the upper bolt nut lower bolt washer nut and tighten the nuts to the specified torque Install the engine hanger bracket to the frame and loo...

Page 215: ...Install the shock absorbers page 16 12 Retract the centerstand and set the rear wheel on the ground to seat the pivots Tighten the engine pivot nut Tighten the frame pivot nut Install the remaining p...

Page 216: ...MEMO...

Page 217: ...6 CYLINDER HEAD COVER REMOVAL 9 6 CAMSHAFT ROCKER ARM REMOVAL 9 7 CYLINDER HEAD REMOVAL 9 11 CYLINDER HEAD DISASSEMBLY 9 12 VALVE GUIDE REPLACEMENT 9 14 VALVE SEAT INSPECTION REFACING 9 15 CYLINDER HE...

Page 218: ...CYLINDER HEAD VALVES 9 2 CYLINDER HEAD VALVES COMPONENT LOCATION 16 N m 1 6 kgf m 12 lbf ft 38 N m 3 9 kgf m 28 lbf ft 10 N m 1 0 kgf m 7 lbf ft 22 N m 2 2 kgf m 16 lbf ft...

Page 219: ...8 0 5118 0 5125 13 10 0 516 Shaft O D IN EX 12 966 12 984 0 5105 0 5112 12 91 0 508 Arm to shaft clear ance IN EX 0 016 0 052 0 0006 0 0020 0 08 0 003 Side spring free length 17 1 0 67 15 5 0 61 Valve...

Page 220: ...r 4 5 mm 07HMH ML00101 Valve guide driver 4 3 mm 07HMD ML00101 Cutter holder 4 5 mm 07781 0010600 Seat cutter 27 5 mm 45 IN 07780 0010200 Seat cutter 24 mm 45 EX 07780 0010600 Flat cutter 29 mm 32 IN...

Page 221: ...timing Broken valve spring Uneven valve seating Valve stuck open Cylinder head Leaking or damaged head gasket Warped or cracked cylinder head Loose spark plug Cylinder piston problem page 10 3 Compres...

Page 222: ...oper valve adjustment valve leakage worn piston ring or cylinder High compression can be caused by carbon deposits in the combustion chamber or on the piston head CYLINDER HEAD COVER REMOVAL Remove th...

Page 223: ...he index line on the cam sprocket must be flush with the cylinder head surface as shown Make sure the piston is at TDC Top Dead Center of the compression stroke by moving the rocker arms If the exhaus...

Page 224: ...e to the cam chain to prevent it from falling into the crankcase CAMSHAFT ROCKER ARM REMOVAL Shift the rocker arms to the spring side and remove the shims Do not allow the shims to fall into the crank...

Page 225: ...r damage Turn the bearing outer race with your finger The bearing should turn smoothly and quietly Also check that the bearing inner race fits tightly on the camshaft Check the cam lobes for scoring s...

Page 226: ...s Measure the O D of each shaft at the rocker arm sliding areas and record it Measure the I D of each rocker arm and record it Subtract each rocker arm shaft O D from the corre sponding rocker arm I D...

Page 227: ...11 Remove the main wire harness wire band CKP sen sor wire band ignition coil wire band and spark plug wire band from the clamp stay Remove the two bolts and clamp stay Disconnect the water hose Remo...

Page 228: ...D Be careful not to damage the valve seat and gasket surfaces Remove the carbon deposits from the combustion chamber Check the spark plug hole and valve areas for cracks Check the cylinder head for wa...

Page 229: ...m O D from the correspond ing guide I D to obtain the stem to guide clearance If the stem to guide clearance exceeds the service limit determine if a new guide with standard dimensions would bring the...

Page 230: ...g supply stores to be sure the cylinder head is heated to the proper tem perature Using a torch to heat the cylinder head may cause warpage Support the cylinder head and drive the valve guides out of...

Page 231: ...against the valve seat several times without rotating the valve to check for proper valve seat contact The valve cannot be ground If the valve face is burned or badly worn or if it contacts the seat...

Page 232: ...owered using a 32 flat cutter If the contact area is too low on the valve the seat must be raised using a 60 interior cutter Reface the seat with a 45 cutter whenever a valve guide is replaced Use a 4...

Page 233: ...Change the angle of the lapping tool frequently to prevent uneven seat wear Do not allow lapping compound to enter the guides After lapping wash any residual compound off the cylinder head and valve...

Page 234: ...lve stem sliding surface with molyb denum oil solution Insert the valve into the guide while turning it slowly to avoid damaging to the stem seal Install the valve spring with the tightly wound coils...

Page 235: ...ers firmly Install the cylinder head page 9 19 CYLINDER HEAD INSTALLATION Be careful not to damage the mating surfaces Clean the mating surfaces of the cylinder head and cylinder thoroughly Blow out t...

Page 236: ...nstall the two bolts and clamp stay Install the main wire harness wire band CKP sensor wire band ignition coil wire band and spark plug wire band to the stay Install the following spark plug page 4 7...

Page 237: ...the rocker arm shafts to the cylinder head Apply molybdenum oil solution to the camshaft bearing and cam lobes Install the camshaft with the cam lobe facing the cylinder side while pressing down on t...

Page 238: ...h in the crankcase cover Apply engine oil to the cam chain and sprocket teeth Install the cam sprocket onto the cam chain so that the index line on the cam sprocket is flush with the cylinder head sur...

Page 239: ...ace of the cylinder head when the T mark on the flywheel is aligned with the index notch in the right crankcase cover Apply engine oil to the threads of the timing hole cap Coat a new O ring with engi...

Page 240: ...head Install the head cover and the cover bolts with the special washers by aligning each bolt tip with the bolt hole in the cylinder head Tighten the cylinder head cover bolts to the speci fied torq...

Page 241: ...10 1 10 10 CYLINDER PISTON COMPONENT LOCATION 10 2 SERVICE INFORMATION 10 3 TROUBLESHOOTING 10 3 CYLINDER PISTON REMOVAL 10 4 CYLINDER PISTON INSPECTION 10 5 PISTON CYLINDER INSTALLATION 10 7...

Page 242: ...CYLINDER PISTON 10 2 CYLINDER PISTON COMPONENT LOCATION...

Page 243: ...9 5 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 gallery or oil straine...

Page 244: ...nd water hose clamp bolt cylinder gasket two dowel pins Clean off any gasket material from the cylinder mat ing surface PISTON REMOVAL Place a clean shop towel over the crankcase to pre vent the pisto...

Page 245: ...X and Y axis Take the maximum reading to determine the cylinder wear Calculate the taper and out of round at three levels in the X and Y axes Take the maximum reading to determine both measurements T...

Page 246: ...Insert each piston ring into the bottom of the cylin der squarely using the piston Measure the ring end gap Measure the piston pin hole I D Take the maximum reading to determine I D Measure the piston...

Page 247: ...tall the piston rings into the piston ring grooves with the marks facing up Do not confuse the top and second rings To install the oil ring install the spacer first then install the side rails Stagger...

Page 248: ...areful not to damage the mating surfaces Clean the mating surfaces of the cylinder and crank case thoroughly Blow out the oil passage in the cylinder with com pressed air Install the dowel pins and a...

Page 249: ...stall the O2 sensor wire clamp and tighten the bolt Install the PAIR check valve page 6 79 oil pressure switch wire clamp and tighten the two bolts Install the cylinder head page 9 19 PAIR CHECK VALVE...

Page 250: ...MEMO...

Page 251: ...11 1 11 11 DRIVE AND DRIVEN PULLEYS CLUTCH COMPONENT LOCATION 11 2 SERVICE INFORMATION 11 3 TROUBLESHOOTING 11 4 LEFT CRANKCASE COVER 11 5 DRIVE BELT 11 7 DRIVE PULLEY 11 8 CLUTCH DRIVEN PULLEY 11 11...

Page 252: ...DRIVE AND DRIVEN PULLEYS CLUTCH 11 2 DRIVE AND DRIVEN PULLEYS CLUTCH COMPONENT LOCATION 74 N m 7 5 kgf m 55 lbf ft 83 N m 8 5 kgf m 61 lbf ft...

Page 253: ...1 1809 1 1823 29 98 1 180 Weight roller O D 22 92 23 08 0 902 0 909 22 5 0 89 Clutch Clutch outer I D 135 0 135 2 5 31 5 32 135 5 5 33 Lining thickness 4 0 0 16 1 0 0 04 Driven pulley Face spring fre...

Page 254: ...reeps 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 Bearing remover set 25 mm 07936 ZV...

Page 255: ...CTION Turn the bearing with your finger The bearing collar should turn smoothly and qui etly Also check that the bearing outer race fits tightly in the left crankcase cover DRIVESHAFT BEARING REPLACE...

Page 256: ...wo dowel pins into the left crankcase Be careful not to damage the rubber seal Install the left crankcase cover onto the left crank case by aligning the holes with the dowel pins Install the left cran...

Page 257: ...lley width by compressing the driven face spring while turning the movable driven face clockwise and install the drive belt into the driven pulley Take care not to get grease of the driven face inner...

Page 258: ...ve the drive belt from the crankshaft Remove the movable drive face assembly while holding the back of the ramp plate Remove the drive face boss from the movable drive face assembly Remove the ramp pl...

Page 259: ...Measure the face bushing I D Measure the boss O D INSTALLATION Avoid getting grease or oil on the drive belt and drive pulley faces in order to prevent belt slip page Do not apply grease to the movabl...

Page 260: ...ive belt onto the drive face boss Clean any oil and grease from the drive pulley face Install the drive pulley face Apply engine oil to the threads and seating surface of the drive pulley face bolt In...

Page 261: ...emove the drive belt from the driven pulley CLUTCH OUTER SHOE LINING INSPECTION Check the clutch outer for wear or damage Measure the clutch outer I D DISASSEMBLY CLUTCH DRIVEN PULLEY Set the clutch s...

Page 262: ...cial tool Loosen the clutch spring compressor gradually and remove the following clutch assembly spring seat spring collar B driven face spring spring collar A driven pulley assembly CLUTCH Remove the...

Page 263: ...13 three rubber dampers DRIVEN PULLEY Remove the following seal collar guide pins and rollers movable driven face two O rings two oil seals RUBBER DAMPERS DRIVE PLATE SEAL COLLAR MOVABLE DRIVEN FACE G...

Page 264: ...n until it is fully seated using the special tool Install the snap ring to the groove in the driven face securely Apply 5 7 g of grease Shell ALVANIA R3 or SHIN NIHON POWERNOC WB3 or IDEMITSU AUTOREX...

Page 265: ...free length DRIVEN FACE Check the driven face for scratches scoring or dam age Measure the driven face boss O D MOVABLE DRIVEN FACE Check the movable driven face for scratches scor ing or damage Chec...

Page 266: ...ity degreasing agent DRIVEN PULLEY Apply grease to new oil seal lips and outer surfaces and install them into the movable driven face Coat new O rings with engine oil and install them into grooves in...

Page 267: ...R3 or SHIN NIHON POWERNOC WB3 or IDEMITSU AUTOREX B or equivalent to the guide grooves Install the seal collar onto the driven pulley Clean any oil and grease from the pulley face CLUTCH Install the r...

Page 268: ...ulley and clutch Install the clutch driven pulley nut Hold the spring compressor in a vice and tighten the clutch driven pulley nut using the special tool to the specified torque Remove the clutch dri...

Page 269: ...o the bearing collar grooves Apply molybdenum disulfide paste SUMICO MOLY PASTE 300 or 500 or equivalent to the bearing col lar groove Install the bearing collar onto the driveshaft Install the clutch...

Page 270: ...MEMO...

Page 271: ...12 1 12 12 FINAL REDUCTION COMPONENT LOCATION 12 2 SERVICE INFORMATION 12 3 TROUBLESHOOTING 12 5 FINAL REDUCTION DISASSEMBLY INSPECTION 12 6 BEARING REPLACEMENT 12 8 FINAL REDUCTION ASSEMBLY 12 11...

Page 272: ...FINAL REDUCTION 12 2 FINAL REDUCTION COMPONENT LOCATION 24 N m 2 4 kgf m 18 lbf ft ABS type only 10 N m 1 0 kgf m 7 lbf ft...

Page 273: ...ter 0 30 US qt 0 25 lmp qt After disassembly 0 30 liter 0 32 US qt 0 26 lmp qt Recommended final drive oil Honda 4 stroke motorcycle oil or an equivalent API service classification SG or higher except...

Page 274: ...m 07746 0010800 Attachment 42 x 47 mm 07746 0010300 Attachment 48 2 x 51 5 mm 07946 3290000 Attachment 52 x 55 mm 07746 0010400 Pilot 14 mm 07746 0041200 Pilot 15 mm 07746 0040300 Pilot 20 mm 07746 00...

Page 275: ...aged final reduction Seized final reduction Faulty drive pulley and driven pulley clutch page 11 4 Abnormal noise Worn seized or chipped gears Worn or damaged final reduction bearing Oil leak Oil leve...

Page 276: ...ar wheel speed sensor page 18 25 Drain the final drive oil page 4 17 Remove the following from the left crankcase seven bolts final reduction case two dowel pins thrust washer right side counter gear...

Page 277: ...all bear ings in the final reduction case Turn the inner race of each bearing with your finger The bearing should turn smoothly and quietly Check the countershaft needle bearing in the final reduction...

Page 278: ...ion case Disassemble the final reduction page 12 6 BEARING DRIVESHAFT COUNTERSHAFT COUNTER GEAR DRIVESHAFT FINAL GEAR SHAFT FINAL GEAR SHAFT FINAL GEAR SHAFT BEARING 6204 20 x 47 x 4 COUNTERSHAFT FINA...

Page 279: ...ring Bearing remover head 14 mm 07WMC KFG0100 Bearing remover shaft 07936 KC10100 Remover weight 07741 0010201 Final gear shaft bearing Bearing remover 20 mm 07936 3710600 Bearing remover handle 07936...

Page 280: ...uction case surface is 3 0 3 5 mm 0 12 0 14 in Install the side collar into the dust seal TOOLS Driveshaft bearing Bearing remover head 15 mm 07936 KC10200 Bearing remover shaft 07936 KC10100 Remover...

Page 281: ...ll the oil seal until it is flush with the crankcase using the same tools Apply engine oil to the counter gear teeth and shaft sliding surfaces Apply engine oil to the final gear teeth and shaft journ...

Page 282: ...kcase Install and tighten the seven bolts in a crisscross pattern in 2 or 3 steps to the specified torque Fill the final reduction case with the recommended oil page 4 17 Install the following rear wh...

Page 283: ...13 1 13 13 ALTERNATOR STARTER CLUTCH COMPONENT LOCATION 13 2 SERVICE INFORMATION 13 3 TROUBLESHOOTING 13 3 RIGHT CRANKCASE COVER 13 4 STATOR CKP SENSOR 13 8 FLYWHEEL STARTER CLUTCH 13 9...

Page 284: ...ALTERNATOR STARTER CLUTCH 13 2 ALTERNATOR STARTER CLUTCH COMPONENT LOCATION 103 N m 10 5 kgf m 76 lbf ft...

Page 285: ...BLESHOOTING Engine does not turn Faulty starter one way clutch Damage starter reduction gear ITEM STANDARD SERVICE LIMIT Starter driven gear Boss O D 45 660 45 673 1 7976 1 7981 45 615 1 6778 Bushing...

Page 286: ...e 7 7 Disconnect the alternator 3P connector and CKP sensor 2P red connector Remove the wire band from the stay Release the alternator CKP sensor wire from the wire guide and remove them out of the fr...

Page 287: ...twelve bolts in a crisscross pattern in 2 or 3 steps then remove the bolts and right crank case cover Remove the following two dowel pins gasket water joint and O ring oil joint and O ring INSTALLATIO...

Page 288: ...l during installation Install the right crankcase cover by aligning the oil pump shaft groove with the water pump shaft tab Install and tighten the ten bolts in a crisscross pat tern in 2 or 3 steps C...

Page 289: ...and install the wire band onto the stay Connect the alternator 3P and CKP sensor 2P red connector Install the following exhaust pipe muffler page 3 15 under cover page 3 9 floor side cover page 3 8 l...

Page 290: ...ur bolts and stator two bolts and CKP sensor wire grommet INSTALLATION Install the stator and tighten the four bolts Install the CKP sensor and tighten the two bolts Set the wire grommet into the righ...

Page 291: ...lt Remove the flywheel bolt and washer Screw the flywheel bolt in until its threads are not visible then install a special tool Slide off the flywheel from the crankcase using the flywheel puller Remo...

Page 292: ...should be able to turn the driven gear clock wise smoothly but the gear should not turn coun terclockwise Remove the starter driven gear from the starter clutch on the flywheel while turning it clock...

Page 293: ...O D Check the starter clutch outer and sprag clutch for abnormal wear or damage Measure the starter clutch outer I D ASSEMBLY Apply engine oil to the sprag clutch outer surface Install the sprag clutc...

Page 294: ...ter driven gear inner surface Apply engine oil to the starter driven gear boss outer surface and gear teeth Install the starter driven gear into the starter clutch on the flywheel while turning it clo...

Page 295: ...el bolt threads and seating surface Install the washer and nut Hold the flywheel with the special tool and tighten the bolt to the specified torque Clean the starter driven gear guide bolt threads App...

Page 296: ...MEMO...

Page 297: ...CASE CRANKSHAFT COMPONENT LOCATION 14 2 SERVICE INFORMATION 14 3 TROUBLESHOOTING 14 4 CRANKCASE SEPARATION 14 5 CRANKSHAFT CONNECTING ROD 14 6 CRANKPIN BEARING 14 8 MAIN JOURNAL BEARING 14 10 CRANKCAS...

Page 298: ...CRANKCASE CRANKSHAFT 14 2 CRANKCASE CRANKSHAFT COMPONENT LOCATION 33 N m 3 4 kgf m 24 lbf ft 12 N m 1 2 kgf m 9 lbf ft...

Page 299: ...and assembling the crankcase halves Clean all disassembled parts with clean solvent and dry them using compressed air before inspection Prior to assembling the crankcase halves apply sealant to their...

Page 300: ...S TROUBLESHOOTING Abnormal noise Worn crankshaft bearing Worn connecting rod big end bearing Worn connecting rod small end Driver 40 x 42 7 mm 07965 VM00100 Driver base 48 4 x 56 mm 07946 KM90600 Meta...

Page 301: ...ove the cam chain tensioner pivot bolt and tensioner slider from the crankcase Loosen the crankcase bolts in a crisscross pattern in 2 or 3 steps and remove them Place the crankcase with the left cran...

Page 302: ...LEARANCE INSPECTION Remove the crankshaft connecting rod page 14 5 Before removing the connecting rod check the big end side clearance Measure the side clearance by inserting the feeler gauge between...

Page 303: ...ing the tab with the groove Apply molybdenum disulfide oil to the thrust sur face of the bearings Install the connecting rod and cap on the crankshaft by aligning the I D code on the rod and cap Face...

Page 304: ...g the oil hole Carefully install the connecting rod and bearing cap on the crankpin Do not rotate the crankshaft during inspection Apply engine oil to the threads and seating surfaces of the bearing c...

Page 305: ...fter selecting new bearings recheck the clearance with a plastigauge Incorrect clearance can cause severe engine damage CONNECTING ROD I D CODE NUMBER CRANKPIN O D CODE LETTER CONNECTING ROD I D CODE...

Page 306: ...rankshaft journals Measure and record the crankshaft main journal O D Calculate the main journal oil clearance If the clearance exceeds the service limit select the bearing BEARING SELECTION Set a spe...

Page 307: ...nly is replaced Main bearings only are replaced Carefully refer to the following instructions and tables for main bearing selection Record the bearing support I D code letter Letters A or B on each cr...

Page 308: ...G SUPPORT I D 45 000 45 006 mm 1 7717 1 7719 in D Green C Brown B Black 45 006 45 012 mm 1 7719 1 7721 in C Brown B Black A Blue 45 012 45 024 mm 1 7721 1 7726 in B Black A Blue A Blue 45 024 45 036 m...

Page 309: ...rankcase main journal Align the mating line of the bearings with the index mark on the crankcase as shown Set the hydraulic press BEARING THICKNESS O S E Blue Blue Thick O S F Black Black O S G Brown...

Page 310: ...correct clearance can cause severe engine damage Install the crankshaft page 14 14 CRANKCASE ASSEMBLY Clean the insides and mating surface of the crank cases Check for cracks or other damage Dress any...

Page 311: ...main journal bearing inserts and install the crankshaft connecting rod into the left crankcase Install the reed valve of the left crankcase as shown Install the water joint pin and new O ring Install...

Page 312: ...t Three Bond 1207B or equivalent to the right crankcase mating surface Install the right crankcase over the left crankcase Install the crankcase bolts and tighten them in a crisscross pattern in 2 or...

Page 313: ...orque Apply engine oil to the timing sprocket teeth cam chain and oil pump chain then install the cam chain and oil pump chain onto the timing sprocket Install the removed parts in the reverse order o...

Page 314: ...MEMO...

Page 315: ...15 1 15 15 FRONT WHEEL SUSPENSION STEERING COMPONENT LOCATION 15 2 SERVICE INFORMATION 15 3 TROUBLESHOOTING 15 5 FRONT WHEEL 15 6 FORK 15 12 HANDLEBAR 15 20 STEERING STEM 15 27...

Page 316: ...ERING 15 2 FRONT WHEEL SUSPENSION STEERING COMPONENT LOCATION 98 N m 10 0 kgf m 72 lbf ft 128 N m 13 1 kgf m 94 lbf ft 12 N m 1 2 kgf m 9 lbf ft 36 N m 3 7 kgf m 27 lbf ft 49 N m 5 0 kgf m 36 lbf ft 3...

Page 317: ...on page 22 18 SPECIFICATIONS Unit mm in TORQUE VALUES ITEM STANDARD SERVICE LIMIT Minimum tire tread depth 1 5 0 06 Cold tire pressure Driver only 200 kPa 2 00 kgf cm2 28 psi Driver and passenger 200...

Page 318: ...9 0010000 Attachment 42 x 47 mm 07746 0010300 Attachment 52 x 55 mm 07746 0010400 Pilot 15 mm 07746 0040300 Fork seal driver weight 07747 0010100 Fork seal driver attachment 37 2 mm I D 07747 0010600...

Page 319: ...gine mounting bushings page 8 4 Front wheel wobbles Bent rim Worn or damaged wheel bearings Axle fastener not tightened properly Unbalanced tire and wheel Faulty tire Wheel turns hard Faulty wheel bea...

Page 320: ...axle holder socket bolts washers and axle holder Remove the right and left side collars from the wheel hub INSPECTION AXLE Set the axle in V blocks Turn the axle and measure the runout using a dial i...

Page 321: ...g the wheel WHEEL BALANCE Mount the tire with the arrow mark facing in the direction of rotation For optimum balance the tire balance mark light mass point a paint dot on the side wall must be located...

Page 322: ...heel will no longer stop in the same position when it is spun Do not add more than 70 g 2 5 oz to the wheel DISASSEMBLY Remove the following three torx bolts pulser ring Do not reuse the socket bolts...

Page 323: ...c side squarely with the sealed side facing up until it is fully seated Install the distance collar Drive in a new right side bearing squarely with the sealed side facing up until it is fully seated T...

Page 324: ...hub with the marked side facing out Install new socket bolts and tighten them in a criss cross pattern in several steps ABS type only Install the front pulser ring on the left wheel hub Install and t...

Page 325: ...pads Install the front wheel between the fork legs while inserting the brake disc between the pads in caliper Install the front axle from the right side Hold the axle and tighten the axle nut to the s...

Page 326: ...usted If it is not within specification check each installa tion part for deformation looseness and damage FORK REMOVAL Support the brake caliper so it does not hang from the brake hose Do not twist t...

Page 327: ...remove the stopper ring Do not compress the fork spring more than nec essary Take care not to allow the spring seat to pop out when removing the fork leg from a hydraulic press Remove the spring seat...

Page 328: ...ng unless it is neces sary to replace with a new one fork piston rebound spring Do not scratch the fork pipe sliding surface dust seal stopper ring Using quick successive motion pull the fork pipe out...

Page 329: ...SPRING Measure the fork spring free length FORK PIPE BOTTOM CASE PISTON Check the fork pipe and bottom case for score marks and excessive or abnormal wear Replace any damaged component if necessary O...

Page 330: ...nd guide bushings Replace the bushing if there is excessive scoring or scratching or if the teflon is worn so that the copper surface appears on more than 3 4 of the entire sur face Check the back up...

Page 331: ...up ring onto the fork pipe Apply fork fluid to the new oil seal lips Install the oil seal onto the fork pipe with its marked side facing up Remove the burrs from the bushing mating sur face being care...

Page 332: ...new sealing washer into the fork piston Tighten the fork socket bolt to the specified torque Drive the oil seal until the stopper ring groove is vis ible using a special tools FORK PISTON REBOUND SPRI...

Page 333: ...ork pipe Pull the fork pipe up and install the fork spring with the tightly wound coil side facing down Coat a new O ring with fork fluid and install it into the spring seat groove Set the fork assemb...

Page 334: ...stall the brake caliper with new mounting bolts and tighten the bolts to the specified torque Install the following front fender page 3 8 front wheel page 15 10 HANDLEBAR REMOVAL Remove the following...

Page 335: ...w left handlebar weight handlebar grip Disconnect the front brake light switch connectors REAR BRAKE LIGHT SWITCH CONNECTORS INHIBITOR SWITCH CONNECTORS Keep the rear mas ter cylinder upright to preve...

Page 336: ...ttle housing Remove the following from the cable guides throttle cables front brake hose rear brake hose combination meter handlebar switch wire Keep the front mas ter cylinder upright to prevent air...

Page 337: ...stall the grip Rotate the grip for even application of the adhesive Clean the sliding surfaces of the throttle pipe and handlebar Apply 0 1 0 2 g of grease to the throttle pipe flange groove and slidi...

Page 338: ...r bolt Install a new lower handlebar bolt Tighten the upper lower handlebar bolts to the specified torque Route the cables and hose properly page 1 19 Set the following into the cable guides combinati...

Page 339: ...rake light switch connectors Clean the inside surface of the left handlebar grip and the outside surface of the handlebar Apply Honda Bond A or equivalent to the inside sur face of the handlebar grip...

Page 340: ...the specified torque Connect the rear brake light switch and inhibitor switch connectors Set the turn signal relay to the handlebar Secure the combination meter handlebar switch wire to the wire band...

Page 341: ...clamps Hold the steering stem adjusting nut using the pin spanner then loosen the steering stem lock nut using the socket wrench Remove the steering stem lock nut Hold the steering stem and loosen th...

Page 342: ...move the lower outer race using the special tools UPPER INNER RACE UPPER BEARING DUST SEAL LOWER BEARING STEERING STEM TOOLS Adjustable bearing remover 07YAC 0010102 Bearing remover shaft 07JAC PH8020...

Page 343: ...install it onto the steering stem Drive in a new lower outer race into the steering head pipe using the special tools Drive in a new upper outer race into the steering head pipe using the special too...

Page 344: ...e stem Apply grease to new upper dust seal lip and upper inner race Insert the steering stem into the steering head pipe and install the following while holding the stem upper steering bearing upper i...

Page 345: ...ger tighten it all the way Turn the inner race counterclockwise 45 1 8 from above finger tightened position Install the lock nut Tighten the lock nut while holding the steering stem adjusting nut Mak...

Page 346: ...l the brake hose clamps and tighten the bolts Install the following handlebar page 15 23 fork page 15 20 front inner cover page 3 10 rear handlebar cover page 3 14 front handlebar cover page 3 14 fron...

Page 347: ...16 1 16 16 REAR WHEEL SUSPENSION COMPONENT LOCATION 16 2 SERVICE INFORMATION 16 3 TROUBLESHOOTING 16 4 REAR WHEEL SWINGARM 16 5 REAR SHOCK ABSORBER 16 12...

Page 348: ...REAR WHEEL SUSPENSION 16 2 REAR WHEEL SUSPENSION COMPONENT LOCATION 49 N m 5 0 kgf m 36 lbf ft 118 N m 12 0 kgf m 87 lbf ft 30 N m 3 1 kgf m 22 lbf ft...

Page 349: ...stem service page 17 4 SPECIFICATIONS Unit mm in TORQUE VALUES TOOLS ITEM STANDARD SERVICE LIMIT Minimum tire tread depth 2 0 0 08 Cold tire pressure Driver only 225 kPa 2 25 kgf cm2 33 psi Driver and...

Page 350: ...inal gear shaft bearing Insufficient tire pressure Soft suspension Low tire pressure Oil leakage from damper unit Weak rear shock absorber spring Stiff suspension High tire pressure Bent damper rod Wo...

Page 351: ...follow ing two bolts brake hose protector bolt and brake hose clamp two caliper mounting bolts rear brake caliper right side shock absorber lower mounting bolt and secure the shock absorber with a pie...

Page 352: ...ck the wheel rim runout using dial indicators Actual runout is 1 2 the total indicator readings WHEEL BALANCE Refer to page 15 7 for wheel balance Do not add balance weight more than 70 g 2 5 oz to th...

Page 353: ...Do not reuse the socket bolts six socket bolts brake disc SWINGARM BEARING INSPECTION REPLACEMENT Remove the dust seals from the both sides of the swingarm Remove the snap ring ABS type only Do not r...

Page 354: ...s loosely Drive the bearing out of the swingarm Drive in a new bearing into the swingarm squarely until it is fully seated using the special tools Install the snap ring into the swingarm groove secure...

Page 355: ...and tighten them in a criss cross pattern in several steps Install the pulser ring onto the wheel hub Install and tighten new torx bolts to the specified torque 42 N m 4 3 kgf m 31 lbf ft 8 N m 0 8 kg...

Page 356: ...final gear shaft Install the inside outside collars into the swingarm Install the swingarm and tighten the swingarm mounting bolts to the specified torque Install the rear axle nut and temporarily tig...

Page 357: ...e specified torque Install the exhaust pipe muffler page 3 15 ABS type only Measure the clearance air gap between the sensor and pulser ring at several points by turning the wheel slowly It must be wi...

Page 358: ...k or adjustable support to relieve stress from the shock absorber Remove the upper lower mounting bolts and shock absorber Installation is in the reverse order of removal INSPECTION Check the upper jo...

Page 359: ...NFORMATION 17 4 TROUBLESHOOTING 17 6 BRAKE FLUID REPLACEMENT AIR BLEEDING 17 7 BRAKE PAD DISC 17 13 FRONT MASTER CYLINDER 17 16 REAR MASTER CYLINDER 17 21 DELAY VALVE STD TYPE 17 25 DELAY VALVE ABS TY...

Page 360: ...HYDRAULIC BRAKE COMPONENT LOCATION FRONT 34 N m 3 5 kgf m 25 lbf ft 30 N m 3 1 kgf m 22 lbf ft ABS type 12 N m 1 2 kgf m 9 lbf ft 34 N m 3 5 kgf m 25 lbf ft STD type 30 N m 3 1 kgf m 22 lbf ft 34 N m...

Page 361: ...17 3 REAR 12 N m 1 2 kgf m 9 lbf ft 30 N m 3 1 kgf m 22 lbf ft 34 N m 3 5 kgf m 25 lbf ft 34 N m 3 5 kgf m 25 lbf ft 14 N m 1 4 kgf m 10 lbf ft 14 N m 1 4 kgf m 10 lbf ft 34 N m 3 5 kgf m 25 lbf ft ST...

Page 362: ...te that there is no brake fluid in the ABS modulator except in the modulator head because the modulator is the motor driven hydraulic pressure type Therefore brake fluid replacement and bleeding air f...

Page 363: ...m 4 4 lbf ft Brake light switch screw 1 2 N m 0 1 kgf m 0 9 lbf ft Brake light inhibitor switch screw 1 2 N m 0 1 kgf m 0 9 lbf ft Master cylinder holder bolt 12 N m 1 2 kgf m 9 lbf ft Caliper mountin...

Page 364: ...med brake disc Sticking worn caliper piston Sticking worn master cylinder piston Bent brake lever Brake lever hard Clogged restricted hydraulic system Sticking worn caliper piston Caliper not sliding...

Page 365: ...ap Remove the screws reservoir cap diaphragm plate and diaphragm from the front master cylinder Connect a commercially available brake bleeder to the front brake caliper upper bleed valve Loosen the u...

Page 366: ...iper upper bleed valve Operate the brake bleeder and loosen the upper 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...

Page 367: ...e end of its travel 3 Repeat steps 1 and 2 until there are no air bub bles in the bleed hose After bleeding air completely tighten the front brake caliper upper bleed valve to the specified torque Fil...

Page 368: ...r from around the bleed valve threads seal the threads with teflon tape It is not a problem if the fluid flowing out of the bleed valve contains air bubbles because the lines will be bled in later ste...

Page 369: ...because the lines will be bled in later steps Connect a bleed hose to the rear caliper bleed valve Repeat step for rear caliper bleed valve Next perform the air bleeding from the system AIR BLEEDING C...

Page 370: ...sure the bleed valves are closed and operate the rear brake lever If it still feels spongy bleed the system again After the bleeding air completely tighten the bleed valves to the specified torque Fi...

Page 371: ...g is installed correctly Install new brake pads so that their ends are set in the pad retainer on the caliper bracket properly Apply silicone grease to the pad pin stopper ring outer surface Install t...

Page 372: ...e rear caliper pin and remove the rear caliper bolt Remove the brake pads Clean the inside of the caliper especially around the caliper piston Install new pads so that their ends are set in the pad re...

Page 373: ...fler page 3 15 BRAKE DISC INSPECTION Visually inspect the brake disc for damage or cracks Measure the brake disc thickness at several points Measure the brake disc warpage with a dial indica tor Check...

Page 374: ...17 7 Remove the oil bolt and sealing washers Disconnect the front brake light switch connectors Remove the bolts holder and front master cylinder DISASSEMBLY Remove the following pivot nut pivot bolt...

Page 375: ...an brake fluid INSPECTION Check the piston cups for wear deterioration or damage Check the spring for fatigue or damage Check the master cylinder and piston for scoring scratches or damage SCREW BRAKE...

Page 376: ...the spring and master piston into the master cylinder SERVICE LIMIT 11 055 mm 0 4352 in SERVICE LIMIT 10 945 mm 0 4309 in SNAP RING BOOT MASTER CYLINDER BRAKE LEVER SPRING PIVOT NUT PIVOT BOLT BRAKE...

Page 377: ...y and hole of the master cylinder Install and tighten the screw to the specified torque Apply 0 1 g of silicone grease to the contact sur faces of the brake lever piston tip and brake lever pivot bolt...

Page 378: ...the oil bolt and new sealing washers Tighten the brake hose oil bolt to the specified torque while setting the hose joint against the stop per on the master cylinder Fill brake fluid and bleed air the...

Page 379: ...il bolt and sealing washers Disconnect the inhibitor switch and rear brake light switch connectors Remove the bolts holder and rear master cylinder DISASSEMBLY Remove the following pivot nut pivot bol...

Page 380: ...brake fluid INSPECTION Check the piston cups for wear deterioration or damage Check the spring for fatigue or damage Check the master cylinder and piston for scoring scratches or damage BRAKE LIGHT I...

Page 381: ...and master piston into the master cylinder SERVICE LIMIT 12 755 mm 0 5022 in SERVICE LIMIT 12 645 mm 0 4987 in SNAP RING BOOT MASTER CYLINDER SPRING PIVOT NUT PIVOT BOLT BRAKE LIGHT INHIBITOR SWITCH S...

Page 382: ...witch and tighten the screws to the specified torque Apply 0 1 g of silicone grease to the contact sur faces of the brake lever piston tip and brake lever pivot bolt sliding surface Install the brake...

Page 383: ...ront upper cover page 3 9 front handlebar cover page 3 14 rear handlebar cover page 3 14 DELAY VALVE STD TYPE REMOVAL Remove the front upper cover page 3 9 Drain the brake fluid from the hydraulic sys...

Page 384: ...page 3 9 DELAY VALVE ABS TYPE REMOVAL Remove the following front upper cover page 3 9 front handlebar cover page 3 14 rear handlebar cover page 3 14 front inner cover page 3 10 Drain the brake fluid f...

Page 385: ...en the joint nut to the specified torque Fill brake fluid and bleed air the hydraulic system page 17 7 Install the following front inner cover page 3 10 rear handlebar cover page 3 14 front handlebar...

Page 386: ...aliper body Remove the following from the caliper bracket bracket pin boot pad retainer Remove the following from the caliper body caliper pin boot pad spring Place a shop towel over the pistons Posit...

Page 387: ...INSPECTION Check the caliper cylinder for scoring or other dam age Measure the caliper cylinder I D Check the caliper pistons for scratches scoring or other damage Measure the caliper piston O D DUST...

Page 388: ...d or damaged Install the pad spring onto the caliper body as shown Apply 0 4 g minimum of silicone grease to the cali per bracket pin boots and install them into the cali per body and bracket Install...

Page 389: ...oppers on the caliper body Install the brake pads page 17 13 Fill brake fluid and bleed air the hydraulic system page 17 7 ABS type only Set the front wheel speed sensor and tighten the bolts Set the...

Page 390: ...exhaust pipe muffler page 3 15 brake hose protector page 16 5 Drain the brake fluid from the rear combined brake line hydraulic system page 17 7 Disconnect the brake hose from the rear brake cali per...

Page 391: ...iston seal in and lift them out Clean the seal grooves caliper cylinder and piston with clean brake fluid INSPECTION Check the caliper cylinder for scoring scratches or damage Measure the caliper cyli...

Page 392: ...hard deteriorated or damaged Apply 0 4 g minimum of silicone grease to the cali per bracket pin boots and install them into the cali per body and bracket Install the caliper pin to the pin boot as sh...

Page 393: ...hose to the rear brake caliper with the oil bolt and new sealing washers Tighten the brake hose oil bolt to the specified torque while setting the hose joint against the stop per on the caliper body F...

Page 394: ...MEMO...

Page 395: ...ATION 18 2 ABS SYSTEM DIAGRAM 18 3 SERVICE INFORMATION 18 4 ABS CONNECTOR LOCATIONS 18 5 BEFORE STARTING TROUBLESHOOTING 18 7 ABS INDICATOR PROBLEM CODE INDEX 18 10 TROUBLESHOOTING 18 11 FRONT WHEEL S...

Page 396: ...BRAKE SYSTEM ABS SH300A AII AIII ABS SYSTEM LOCATION ABS MODULATOR REAR WHEEL SPEED SENSOR FRONT WHEEL SPEED SENSOR REAR BRAKE CALIPER REAR PULSER RING FRONT BRAKE CALIPER DELAY VALVE REAR BRAKE MAST...

Page 397: ...WARN IND 1 PUMP RELAY SOLENOIDS PUMP P R Bl Y Bl Br Bl R Bl R Y R R R A MOTOR B FAIL SAFE RLY 8 IGN POWER 4 STOP LAMP SW A REAR FRONT R G R BI MAIN FUSE 30A IGNITION SWICTH MAIN RELAY BATTERY 1 2 3 4...

Page 398: ...leshooting flow chart Observe each step of the procedures one by one Write down the problem code and proba ble faulty part before starting diagnosis and troubleshooting ABS control unit ECU can record...

Page 399: ...ATIONS NOTE 1 Remove the front upper cover page 3 9 NOTE 2 Remove the front inner cover page 3 10 ABS MODULATOR 25P CONNECTOR NOTE 1 Wire side of female terminal FRONT WHEEL SPEED SENSOR 2P CONNECTOR...

Page 400: ...NOTE 3 Remove the maintenance lid page 3 4 NOTE 4 Remove the luggage box page 3 5 Wire side of female terminal ABS SERVICE CHECK CONNECTOR NOTE 3 Wire side of female terminal Sensor side of male termi...

Page 401: ...hen the vehi cle speed goes to 10 km h 6 mph approximately If the ABS indicator blinks because problem is detected during the pre start self diagnosis See page 18 10 If the ABS indicator does not come...

Page 402: ...trol unit ECU can record only the first problem data detected while the ignition switch is turned ON until it is turned OFF even when there are multiple failures If the problem code is not stored the...

Page 403: ...zing the brake lever The ABS indicator should come on for 2 seconds and go off 3 Release the brake lever immediately after the ABS indicator is off The ABS indicator should come on 4 Squeeze the brake...

Page 404: ...y run bumpy roads The front wheel leaves the ground for a long time when riding wheelie Only either the front or rear wheel rotates The ABS operates continuously The ABS control unit has been disrupte...

Page 405: ...ABS INDICATOR DOES NOT COME ON when the ignition switch turned ON 1 Combination Meter Power ground Line Inspec tion Check the combination meter power and ground lines page 22 8 Are the wires normal Y...

Page 406: ...ow wire between the fuse box and ABS modula tor NO Intermittent failure Replace the ABS MAIN fuse 10 A with a new one and recheck 3 ABS Power Input Line Open Circuit Inspection Install the ABS MAIN fu...

Page 407: ...icator with the ignition switch turned ON Does the ABS indicator go off YES GO TO STEP 6 NO Faulty combination meter 6 Indicator Signal Line Open Circuit Inspection Turn the ignition switch OFF Remove...

Page 408: ...spection Inspect the area around the front wheel speed sensor Check that there is iron or other magnetic depos its between the pulser ring and wheel speed sen sor and the pulser ring slots for obstruc...

Page 409: ...of the wire harness side front wheel speed sensor 2P Orange connector Is there continuity YES GO TO STEP 6 NO Open circuit in wire between the ABS modulator and speed sensor 6 Failure Reproduction wi...

Page 410: ...the area around the rear wheel speed sensor Check that there is iron or other magnetic depos its between the pulser ring and wheel speed sen sor and the pulser ring slots for obstructions Check instal...

Page 411: ...ire harness side rear wheel speed sensor 6P con nector Is there continuity YES GO TO STEP 6 NO Open circuit in wire between the ABS modulator and speed sensor 6 Failure Reproduction with a New Speed S...

Page 412: ...use Inspection Check the ABS MOTOR fuse 30 A in the fuse box for blown Is the fuse blown YES GO TO STEP 2 NO GO TO STEP 3 2 Motor Power Input Line Short Circuit Inspection Disconnect the ABS modulator...

Page 413: ...reen wire between the ABS modulator and body ground Loose or poor contact on the connec tor 4 Failure Reproduction Turn the ignition switch OFF Connect the ABS modulator 25P connector Erase the proble...

Page 414: ...e between the ABS modula tor 25P connector from the wire harness side There should be battery voltage at all times Is there battery voltage YES GO TO STEP 4 NO Open circuit in Black wire and or Red wi...

Page 415: ...O Intermittent failure Replace the ABS MAIN fuse 10 A with a new one and recheck 3 ABS Power Input Line Open Circuit Inspection Install the ABS MAIN fuse Disconnect the ABS modulator 25P connector Mea...

Page 416: ...he scooter were installed incorrect tire size Deformation of the wheel or tire 1 Failure Reproduction If the above items are normal recheck the prob lem code indication Erase the problem code page 18...

Page 417: ...within specification The sensor air gap cannot be adjusted If it is not within specification check each installa tion part for deformation looseness and damage REMOVAL INSTALLATION Remove the front i...

Page 418: ...eel speed sensor Remove any deposits Check the sensor tip for deformation or damage e g chipped pulser ring teeth Replace the speed sensor if necessary Installation is in the reverse order of removal...

Page 419: ...ion looseness and damage REMOVAL INSTALLATION Remove the following Rear wheel page 16 5 Luggage box page 3 5 Disconnect the rear wheel speed sensor VS sensor 6P connector Remove the two mounting bolts...

Page 420: ...nsor tip for deformation or damage e g chipped pulser ring teeth Replace the speed sensor if necessary Installation is in the reverse order of removal Replace the sensor protector socket bolt with new...

Page 421: ...t nuts cover the end of the brake pipes to pre vent contamination Loosen the joint nuts and disconnect the five brake pipes Remove the three mounting bolts and ABS modula tor assembly so the assembly...

Page 422: ...MEMO...

Page 423: ...19 19 BATTERY CHARGING SYSTEM SYSTEM LOCATION 19 2 SYSTEM DIAGRAM 19 2 SERVICE INFORMATION 19 3 TROUBLESHOOTING 19 5 BATTERY 19 6 CHARGING SYSTEM INSPECTION 19 7 ALTERNATOR 19 8 REGULATOR RECTIFIER 1...

Page 424: ...ING SYSTEM 19 2 BATTERY CHARGING SYSTEM SYSTEM LOCATION SYSTEM DIAGRAM ALTERNATOR REGULATOR RECTIFIER BATTERY MAIN FUSE 30 A 3P MAIN FUSE 30A 3P BI BATTERY ALTERNATOR REGULATOR RECTIFIER YELLOW GREEN...

Page 425: ...egulator rectifier supplies excess voltage to the battery Under these conditions the electrolyte level goes down quickly Before troubleshooting the charging system check for proper use and maintenance...

Page 426: ...M SPECIFICATIONS Battery Capacity 12 V 11 10 Ah Current leakage 1 5 mA max Voltage 20 C 68 F Fully charged Above 12 8 V Needs charging Below 12 3 V Charging current Normal 1 1 A 5 10 h Quick 5 5 A 1 0...

Page 427: ...e and record the battery voltage using a digital multimeter page 19 7 Start the engine Measure the charging voltage Compare the measurement to result of the following calculation BV Battery Voltage CV...

Page 428: ...ove the battery Install the battery in the reverse order of removal After installing the battery coat the terminals with clean grease Install the maintenance lid page 3 4 VOLTAGE INSPECTION Remove the...

Page 429: ...the current CHARGING VOLTAGE INSPECTION Make sure the battery is in good condition before performing this test Remove the maintenance lid page 3 4 Warm up the engine to normal operating tempera ture...

Page 430: ...ifier 3P Black connec tor and check them for loose contact or corroded terminals Check the regulator rectifier 3P connector terminals wire harness side as follows Measure the voltage between the Red w...

Page 431: ...20 1 20 20 IGNITION SYSTEM SYSTEM LOCATION 20 2 SYSTEM DIAGRAM 20 2 SERVICE INFORMATION 20 3 TROUBLESHOOTING 20 4 IGNITION SYSTEM INSPECTION 20 5 IGNITION COIL 20 8 IGNITION TIMING 20 8...

Page 432: ...FUSE 30 A SUB FUSE 10 A ENGINE STOP RELAY BATTERY G W ECM Y Bu Bl W W G Y W Y Bl W 33P WPC R 2P CKP SENSOR ENGINE STOP RELAY R Bu Bl R G SWITCH ENGINE STOP 3P G BANK ANGLE SENSOR Bl FUSE 10A R Bl IGN...

Page 433: ...eck those connections before proceeding Make sure the battery is adequately charged Using the starter motor with a weak battery results in a slower engine cranking speed as well as no spark at the spa...

Page 434: ...5 An open circuit or loose connection in Yellow Blue wire between the ignition coil and ECM 6 Short circuit in the ignition primary coil 7 Faulty sidestand switch 8 Loose or poor connection or an open...

Page 435: ...age adapter to the digital mul timeter or use the peak voltage tester IGNITION COIL PRIMARY PEAK VOLTAGE Check all system connections before this inspec tion Poor connected connectors can cause incor...

Page 436: ...ch OFF Disconnect the ECM 33P connector Connect the Imrie diagnostic tester or peak voltage adaptor probes to the ECM connector terminals Retract the sidestand Turn the ignition switch ON with the eng...

Page 437: ...f both peak voltages are abnormal check each item in the troubleshooting chart page 20 4 For CKP sensor replacement page 13 8 Install the removed parts in the reverse order of removal SIDESTAND SWITCH...

Page 438: ...gnition coil Installation is in the reverse order of removal IGNITION TIMING Start the engine and warm it up operating temperature Stop the engine and remove the timing hole cap from the right crankca...

Page 439: ...r at idle Increase the engine speed and make sure the F mark begins to move Apply engine oil to the timing hole cap threads and seating surface Coat a new O ring with engine oil and install it onto th...

Page 440: ...MEMO...

Page 441: ...21 1 21 21 ELECTRIC STARTER SYSTEM LOCATION 21 2 SYSTEM DIAGRAM 21 2 SERVICE INFORMATION 21 3 TROUBLESHOOTING 21 4 STARTER MOTOR 21 6 STARTER RELAY 21 14...

Page 442: ...Y MAIN FUSE 30 A ENGINE STOP RELAY STARTER SWITCH BANK ANGLE SENSOR SIDE STAND SWITCH BATTERY ENGINE STOP RELAY R Bu Bl R G SWITCH ENGINE STOP 3P G BANK ANGLE SENSOR 10A FUSE MAIN FUSE 30A RELAY START...

Page 443: ...e troubleshooting page 21 4 If the current is kept flowing through the starter motor to turn it while the engine is not cranking over the starter motor may be damaged For starter clutch servicing page...

Page 444: ...GO TO STEP 4 NO Inspect the starter motor page 21 9 4 Starter Relay Continuity Inspection Check the starter relay for continuity page 21 15 Is there continuity YES Loose or poorly connected starter mo...

Page 445: ...en wire and or Green wire between the starter relay and side stand switch Inspect the sidestand switch Starter motor turns engine slowly Low battery voltage Poorly connected battery cable Poorly conne...

Page 446: ...ut Disconnect the starter motor cable Remove the two mounting bolts ground cables Remove the starter motor from the crankcase Remove the O ring from the starter motor DISASSEMBLY INSPECTION Remove the...

Page 447: ...heck for continuity between starter motor cable terminal and positive brushes There should be continuity Check for continuity between positive brushes and rear cover There should be no continuity Chec...

Page 448: ...shes Remove the terminal nut Remove the washer insulator terminal stopper and O ring Remove the terminal bolt positive brushes and brush holder SCREW NEGATIVE BRUSHES NUT O RING INSULATOR WASHER TERMI...

Page 449: ...he armature with a new one if necessary Check for continuity between pairs of commutator bars There should be continuity Check for continuity between each individual com mutator bar and the armature s...

Page 450: ...the bushing of the rear cover for wear or damage ASSEMBLY DUST SEAL BALL bearing BUSHING REAR COVER MOTOR CASE BRUSH HOLDER REAR COVER BOLT NUT O RING WASHER INSULATOR FRONT COVER ARMATURE O RING O R...

Page 451: ...erminal stopper insulator and washer Install and tighten the terminal nut securely Install the negative brushes and tighten the screw to the specified torque BRUSH HOLDER POSITIVE BRUSHES TERMINAL BOL...

Page 452: ...starter motor case The coil may be damaged if the magnet pulls the armature against the case Install a new O ring to the starter motor case Install the starter motor case by aligning the starter moto...

Page 453: ...shaft Align the index marks on the front cover starter motor case and rear cover Install a new O rings to the bolts Install and tighten the bolts to the specified torque INSTALLATION Apply oil to a ne...

Page 454: ...LICK but starter motor does not turn inspect the starter relay page 21 15 If you do not hear the starter relay CLICK inspect the starter relay circuits page 21 14 CIRCUIT INSPECTION RELAY COIL POWER I...

Page 455: ...the negative cable from the starter relay Disconnect the starter relay 4P Red connector Remove the battery cable and starter motor cable from the starter relay Connect the fully charged 12 V battery...

Page 456: ...MEMO...

Page 457: ...IGHT 22 7 COMBINATION METER 22 8 SPEEDOMETER VS SENSOR 22 11 FUEL GAUGE FUEL LEVEL SENSOR 22 13 COOLANT TEMPERATURE GAUGE ECT SENSOR 22 14 OIL PRESSURE INDICATOR 22 15 IGNITION SWITCH 22 16 HANDLEBAR...

Page 458: ...el pump REAR BRAKE LIGHT INHIBITOR SWITCH COMBINATION METER ACCESSORY SOCKET TURN SIGNAL RELAY HORN SWITCH TURN SIGNAL SWITCH DIMMER SWITCH FRONT BRAKE LIGHT SWITCH IGNITION SWITCH ENGINE STOP SWITCH...

Page 459: ...otective clothing insulated gloves and eye protection Check the battery condition before performing any inspection that requires proper battery voltage A continuity test can be made with the switches...

Page 460: ...ace it with a new one Installation is in the reverse order of removal Align the bulb tab with the grooves properly When installing the dust cover align the wires with the cutout in the headlight housi...

Page 461: ...eplace it with a new one if necessary Installation is in the reverse order of removal POSITION LIGHT BULB Remove the front upper cover page 3 9 Pull the bulb socket out of the turn signal position lig...

Page 462: ...LB Remove the following two screws brake taillight lens While pushing the brake taillight bulb in turn it counterclockwise to remove it and replace it with a new one Make sure the lens gasket is insta...

Page 463: ...MOVAL INSTALLATION Remove the body cover page 3 6 Remove the six screws and rear turn signal brake taillight unit Installation is in the reverse order of removal LICENSE LIGHT BULB REPLACEMENT Remove...

Page 464: ...ll scale and then return to zero If the all needles does not move perform the power and ground line inspection of the combination meter page 22 8 POWER GROUND LINE INSPECTION POWER INPUT LINE Remove t...

Page 465: ...is no voltage check the following Open circuit in the Light green Black wire Blown CLOCK fuse 10 A Open circuit between the Red wire between the fuse box and battery REMOVAL INSTALLATION Remove the re...

Page 466: ...following harness clamp screw and meter harness four screws and meter lens eight screws and under case reflecting plate meter assembly Assembly is in the reverse order of disassembly METER ASSEMBLY M...

Page 467: ...owing Disconnect the VS sensor 3P connector page 22 12 Check for loose or poor contact of the VS sensor 3P connector Turn the ignition switch ON then measure the voltage at the VS sensor connector of...

Page 468: ...eplace the VS sensor with a new one and recheck REMOVAL INSTALLATION Remove the sensor protector page 18 25 Disconnect the VS sensor 3P connector Remove the bolt and VS sensor Remove the O ring and re...

Page 469: ...s if the system circuit is normal In that case check the fuel level sensor page 22 13 If the needle does not move check the following Gray Black wire between the fuel pump fuel level sensor and combin...

Page 470: ...ECT SENSOR INSPECTION Remove the ECT sensor page 6 74 Suspend the ECT sensor in a pan of coolant 1 1 mixture on an electric heating element and mea sure the resistance between the ECT sensor termi nal...

Page 471: ...or If the indicator comes on replace the oil pressure switch If the indicator does not come on check for loose an open circuit in the Blue Red wire If the wire is OK replace the combination meter page...

Page 472: ...age 3 10 Disconnect the ignition switch 2P connector Check for continuity between the switch side con nector terminals in each switch position Continuity should exist between the color coded wire term...

Page 473: ...e joint nut and disconnect the seat lock cable from the ignition switch Remove the ignition switch mounting bolts and ignition switch Install the ignition switch with new one way bolts Tighten the ign...

Page 474: ...ear handlebar cover page 3 14 Check for continuity between the switch terminals in each switch position Continuity should exist between the terminals of the corresponding color coded wire as follows C...

Page 475: ...INSPECTION Remove the front handlebar cover page 3 14 Disconnect the inhibitor switch connectors Check for continuity between the switch terminals There should be continuity with the brake lever squee...

Page 476: ...continuity when the brake lever is released SIDESTAND SWITCH INSPECTION Remove the right floor side cover page 3 8 Disconnect the sidestand switch 2P Black connec tor Check for continuity between the...

Page 477: ...the bolt and sidestand switch Install the sidestand switch by aligning its pin with the sidestand hole and switch groove with the bracket pin Install and tighten the bolt to the specified torque Inst...

Page 478: ...r ness side with a jumper wire Remove the rear fender A page 3 7 Disconnect the ECM 33P connector Turn the ignition switch ON Measure the voltage between the ECM connector of the wire harness side and...

Page 479: ...appear inspect the following Open circuit in Blue wire between the fuse box and fan motor relay switch line side Open circuit in Black wire between the fan motor relay and fan motor FUNCTION TEST Remo...

Page 480: ...he battery voltage does not appear inspect the open circuit in Red Black wire between the ignition switch and main relay coil line side If the battery voltage appears the main relay coil input voltage...

Page 481: ...s not appear inspect the following Open circuit in Red wire between the main fuse and main relay switch line side Open circuit in Red Yellow wire between the main relay and fuse box FUNCTION TEST Remo...

Page 482: ...nector to remove the turn sig nal relay Check the connector for loose contacts or corroded terminals Short the Black Brown and Gray wire terminals of the 3P connector with a jumper wire Turn the ignit...

Page 483: ...ON ACCESSORY SOCKET DOES NOT OPERATE Remove the front upper cover page 3 9 Disconnect the accessory socket 2P connector Turn the ignition switch ON and measure the volt age at the accessory socket 2P...

Page 484: ...MEMO...

Page 485: ...R SYSTEM HISS SYSTEM LOCATION 23 2 SYSTEM DIAGRAM 23 2 SERVICE INFORMATION 23 3 KEY REGISTRATION PROCEDURES 23 4 DIAGNOSTIC CODE INDICATION 23 7 TROUBLESHOOTING 23 9 IMMOBILIZER INDICATOR 23 12 IMMOBI...

Page 486: ...OP SWITCH ENGINE STOP RELAY BATTERY G G G ECM O Bu P G Bl Y R Y W Y Bl W 33P WPC R 2P CKP SENSOR ENGINE STOP RELAY R Bu Bl R G SWITCH ENGINE STOP 3P G BANK ANGLE SENSOR G MAIN RELAY Bl FUSE 10A R Bl 4...

Page 487: ...board in the car etc where the temperature will rise Do not leave the key in the water for a prolonged time such as by washing the clothes The ECM as well as the transponder keys must be replaced if a...

Page 488: ...all key except the original key inserted in the ignition switch are cancelled Registration of the lost key or spare key is cancelled The spare key must be registered again 6 Turn the ignition switch O...

Page 489: ...22 17 7 Turn the ignition switch ON with a first new key The indicator comes on for four seconds then it blinks four times repeatedly The first new key is registered in the ECM If there is any problem...

Page 490: ...keys in accordance with the shape of the original key or use the key number plate when all keys have been lost Replace the ECM with a new one 3 Turn the ignition switch ON with a first new key The imm...

Page 491: ...e immobilizer indicator remains on when the sys tem is normal The system is in the normal mode and the diagnostic code does not appear DIAGNOSTIC CODE When the system ECM enters the diagnostic mode fr...

Page 492: ...TERN SYMPTOM PROBLEM PROCEDURE Registration is overlapped The key is already regis tered properly Use a new key or cancelled key Code signals cannot send or receive Communication fails Follow the trou...

Page 493: ...ine Inspection Check the power input line Black Brown wire at the combination meter connector page 22 8 Is the voltage specified value YES Faulty combination meter NO Open circuit in Black Brown wire...

Page 494: ...indicator The indicator should come on for 2 seconds then go off Is there indicator go off YES Faulty first transponder key NO GO TO STEP 3 3 Diagnostic Code Inspection Perform the diagnostic code in...

Page 495: ...zer receiver connector page 23 13 Is there continuity NO Open circuit in Green Black wire YES GO TO STEP 3 3 Immobilizer Receiver Signal Line Inspection Check the signal lines Pink and Orange Blue bet...

Page 496: ...and combination meter connector of the wire har ness side If there is no continuity open circuit in White Red wire between the combination meter and ECM There should be continuity check the following...

Page 497: ...be continuity at all time SIGNAL LINE INSPECTION Measure the voltage between the Pink wire terminal of the wire harness side connector and body ground Turn the ignition switch ON There should be appro...

Page 498: ...ceiver Install new receiver and tighten the two screws Install the removed parts in the reverse order of removal REPLACEMENT PARTS FOR PROBLEM 4P CONNECTOR Wire side of female terminals O Bu 4P CONNEC...

Page 499: ...24 1 24 24 WIRING DIAGRAMS STD type 24 3 ABS type 24 4...

Page 500: ...WITCH FAN MOTOR RELAY RELAY MAIN R R Bl 2P R Bl R P Y R O Bu G Bl 4P Vcc RxDT GND TxCT IMMOBILIZER 12V11 10 A BATTERY MAIN FUSE 30A STARTER RELAY 4P R MOTOR STARTER R G Y W G R G Bl G G W G W HORN Lg...

Page 501: ...TARTER 3P Bl Br Gr G RELAY SIGNAL TURN Bl Bu Bl W Bl Bu Bl R R Bl G R Y BAT1 BAT2 IGNITION SWITCH FAN MOTOR RELAY RELAY MAIN R R Bl 2P R Bl R P Y R O Bu G Bl 4P Vcc RxDT GND TxCT IMMOBILIZER 12V11 10...

Page 502: ...25 1 25 25 TROUBLESHOOTING ENGINE DOES NOT START OR IS HARD TO START 25 2 ENGINE LACKS POWER 25 3 POOR PERFORMANCE AT LOW AND IDLE SPEED 25 5 POOR PERFORMANCE AT HIGH SPEED 25 6 POOR HANDLING 25 7...

Page 503: ...pection You should hear the pump hum when the ignition switch is turned ON Is the hum heard YES GO TO STEP 4 NO Broken fuel pump wire Faulty fuel pump 4 Cylinder Compression Inspection Test the cylind...

Page 504: ...re correct YES GO TO STEP 4 NO Faulty tire valve Punctured tire 4 Spark Plug Inspection Remove and inspect the spark plug Is spark plug in good condition YES GO TO STEP 5 NO Plug not serviced frequent...

Page 505: ...e overheating YES Coolant level too low Faulty cooling fan Thermostat stuck closed Excessive carbon build up in combustion chamber Use of poor quality fuel Lean fuel mixture NO GO TO STEP 10 10 Engine...

Page 506: ...here weak or intermittent spark YES GO TO STEP 4 NO Faulty spark plug Fouled spark plug Opened or shorted spark plug wire Faulty ignition coil Faulty CKP sensor Faulty ECM 4 Ignition Timing Inspection...

Page 507: ...t serviced frequently enough Incorrect spark plug heat range Incorrect spark plug gap Dirty air cleaner element 3 Fuel Flow Inspection Inspect the fuel flow page 6 48 Is the fuel flow within specifica...

Page 508: ...amaged steering head bearings Low tire pressure Either wheel is wobbling Excessive wheel bearing play Faulty tire Bent rim Excessively worn engine mounting bushings Bent frame The scooter pulls to one...

Page 509: ...MEMO...

Page 510: ...AD INSTALLATION 9 19 CYLINDER HEAD REMOVAL 9 11 CYLINDER HEAD VALVES SPECIFICATIONS 1 8 CYLINDER PISTON INSPECTION 10 5 CYLINDER PISTON REMOVAL 10 4 CYLINDER PISTON SPECIFICATIONS 1 8 D DELAY VALVE AB...

Page 511: ...RANKCASE CRANKSHAFT 14 3 CYLINDER HEAD VALVES 9 3 CYLINDER PISTON 10 3 DRIVE AND DRIVEN PULLEYS CLUTCH 11 3 ELECTRIC STARTER 21 3 ENGINE REMOVAL INSTALLATION 8 3 FINAL REDUCTION 12 3 FRAME BODY PANELS...

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