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Honda TRX500FE FourTrax Foreman 4x4 ES, Service Manual

The Honda TRX500FE FourTrax Foreman 4x4 ES Service Manual is essential for any ATV owner. Easily download the manual for free from our website to quickly access vital information on maintenance, repairs, and troubleshooting. Ensure your vehicle is always in top shape with this comprehensive guide.

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Summary of Contents for TRX500FE FourTrax Foreman 4x4 ES

Page 1: ......

Page 2: ...y you can decide whether or not you should perfoon a given task AWARNING Failure to property follow instructions and precautions can cause you to be seriously hurt or killed Follow the procedures and...

Page 3: ...tion according to the malfunction or symptom In case of an engine trouble refer to PGM FI section troubleshooting first Your safety and the safety of others is very important To help you make informed...

Page 4: ...um disulfide grease containing more than 3 molybdenum disulfide NLGI 2 or equivalent Example Molykote BR 2 plus manufactured by Dow Coming U S A Multi purpose M 2 manufactured by Milsubishi Oil Ja pa...

Page 5: ...UTC H GEARSHIFT LINKAGE o WF A L T E R N A T O R S T A R T E R C L U T C H Z f Cl CRANKCASE TRANSMISSION CRANKSHAFT BALANCER Z w ENGINE REMOVAUINSTALLATION FRONT WHEEUSUSPENSION STEERING II REAR WHEEU...

Page 6: ...MEMO...

Page 7: ...SERVICE RULES 1 2 MODEL IDENTIFICATION 1 3 SPECIFICATIONS 1 6 TORQUE VALUES 1 13 1 GENERAL INFORMATION LUBRICATION SEAL POINTS 1 19 CABLE HARNESS ROUTING 1 23 EMISSION CONTROL SYSTEMS 144 1 1...

Page 8: ...ess Routing page 1 23 9 Do not bend or twist control cables Damaged control cables will not operates smoothly and may slid or bind 10 Do not tow your ATV behind a car or other vehicle ABBREVIATION Thr...

Page 9: ...Steering EPS FPE 4WDfElectric shift program ESP fElectric Power Steering EPS Be sure to refer to the procedure that pertains to the appropriate version of the TRX500 SERIAL NUMBERS The Vehicle Ideo f...

Page 10: ...the throttle body LABELS The certification label 1 U S A type or safety certification label 2 Canada type is attached on the left front frame down pipe The color label 11 is attached on the left front...

Page 11: ...The vehicle emission control information label 11 is attached on the left front frame pipe GENERAL INFORMATION U S A and Canada type 111 Canada type only 1 5...

Page 12: ...M FElFPE SPECIFICATIONS 2 127 mm 83 7 in 1 205 mm 47 4 in 1 197 mm 47 1 in 1 281 mm 50A in 915 mm 36 0 in 925 mm 36 4 in 881 mm 34 7 in 365 mm 14 4 in 355 mm 14 0 in 194 mm 7 6 in U S A 284 kg 626 Ibs...

Page 13: ...40 56 Cf104 41 F Fuel injector resistance 20 C 6 oS F l ________ IGNITION SYSTEM SPECIFICATIONS Electric starter motor Electric starter motor and emergency recoil slater Triple phase output alternato...

Page 14: ...stroke oil U S A and Canada or Honda 4 stroke oil Canada only or equivalent motor oil API service classification SG or higher except oils labeled as energy conserving on the circular API service label...

Page 15: ...e 0 020 0 047 0 0008 0 0019 0 10 0 004 CLUTCH GEARSHIFT LINKAGE SPECIFICATIONS Centrifugal clutch UOII mm in ITEM STANDARD SERVICE LIMIT 1Drum 1 0 150 0 150 2 5 906 5 913 150 4 5 9c 2 _ _ Weight linin...

Page 16: ...3 f I at M5 16 976 16 987 0 6683 0 6688 t16 93 0 667 I Countershaft 0 0 I at C4 24 959 24 980 0 9826 0 9835 24 93 0 981 erse idle shaft 0 0 12 966 12 984 0 5105 0 5112 12 94 0 S09 Bushlng to shaft M3...

Page 17: ...e Oil capacity After draining 200 em 6 8 US oz 7 0 Imp ozl A ft e disassembly_ 2 5 v0 icm3 8 S US 02 8 8 Imp ozl Recommended oil Honda shaft drive oil or equivalent Gear backlash Backlash d iff e c e...

Page 18: ...OiiA x 1 0 h __ 0 416 kWfS OOO rpm 0 1 1 00 _ LIGHTS METERS SWITCHES SPECIFICATIONS ITEM SPECIFICATIONS Bulbs t Headlight high low beam 12 V 30 30 W x2 l Assist headlight 12V 45W BrakeJtaitlighl LEO...

Page 19: ...o 8 8 32 _ 3 3 24 2 8 23 2 3 17 2 6 J 22 2 2 16 band bolt 3 2 0 0 2 1 5 screw front side 1 2 0 0 2 1 5 screw rear side 1 3 2 0 33 2 4 stud bolt 2 8 6 0 0 6 4 4 See page 2 15 MAINTENANCE ITEM a TV THRE...

Page 20: ...EAD Q TORQUE _ _ _ _ _ _ _ DIA mm N m k m bHt 5 2 7 0 3 2 0 I Cooling fan nul REMARKS 1 Apply locking agenllo the threads Fan motor bolt Fan motor stay bolt CYLINDER HEADNALVE ITEM Cylinder head nul _...

Page 21: ...hreads 8 THREAD DIA mm 8 12 27 2 8 2 0 ii Ao p ply locking agent to the threads TORQUE REMARKS N m kgf m Ibf ft 37 3 8 27 Apply locking agent to the threads 108 11 0 80 Apply engine oil to the threads...

Page 22: ...to the specified torque and further tighten until its grooves align with the cotter pin 1 6 c bolt replace with a new one AlOe bolt replace with a new one Lock nut replace with a newone I Lock nut rep...

Page 23: ...astle nut tighle Rear brake arm pinch bolt nut B 20 2 0 15 Rear wheel hub nut 2 20 137 14 0 101 the specified torque and further tighten until its grooves align with the colter pin hole Rear brake pan...

Page 24: ...ver pivot bolt Rear brake lever pivot nut 1 18 2 a TV THREAD DIA mm 5 THREAD DIA mm 4 6 __ _ 6 I TORQUE N m kgf m IbHt 47 4 8 35 25 2 5 18 98 10 0 72 52 5 3 38 47 4 8 35 39 4 0 29 32 3 3 24 47 4 8 35...

Page 25: ...in hOle _____ E ff iiC plale boss ouler surtace Change clutch disc lining whole surface st Change clutch lock nut threads and Sealing s u rt a ce __f Centrifugal clutch drum sprag clutch contacting su...

Page 26: ...ling width 6 5 1 mm W 0026 0 04 in Coating width 6 5 1 mm 0 26 0 04 in __ Coating width 5 8 mm 0 20 0 31 in Coating width 6 5 2 mm 0 26 O 08 Coaling width 6 5 1 mm 0 26 O 04 Coating width 6 5 1 mm 0 2...

Page 27: ...Front final haft o ter ace I Inion J I all i Front I j Ig loz Ig 10 3 4 0 1 140 Rear I gear ca e 0 eal lip for II haft I Rear fina gear case oil seal I r rlng g ear 3 I I i i jde Rear final gea Left a...

Page 28: ...GENERAL INFORMATION Honda Handgrip Ce me nt U S A only or equivalent Engine 1 22 nullhreads t J...

Page 29: ...t BAND THROTTLE CABLE REAR pARKING BRAKE CABLE FRONT BRAKE HOSE A REVERSE SELECTOR CABLE HANDLEBAR SWITCH WIRE FRONT SUB WIRE r HARNESS REAR BRAKE LIGHT SWITCH Lever side II 1 REVERSE o IGNITION SWITC...

Page 30: ...WITCH WIRE REAR BRAKE LIGHT SWITCH WIRE lever side 1 24 Front t FUEL TANK BREATHER HOSE IGNITION SWITCH B3 Ol I GRAY TAPE HANDLEBAR SWITCH WIRE To front brake light switch Front t FRONT BRAKE INHIBITO...

Page 31: ...T WIRE FAN MOTOR 2P Natural CONNECTOR SIPHON HOSE 4WD SElECT SWITCH WIRE FMfFPM HANDLEBAR SWITCH 10P Green CONNECTOR FElFPE HANDLEBAR SWITCH 14P Green CONNECTOR HANDLEBAR SWITCH WIRE Front ACCESSORY S...

Page 32: ...CKET 2P Black CONNECTOR Reverse side of radiator 4WD SELECT SWITCH WIRE 1 26 FAN MOTOR FAN MOTOR BREATHER HOSE I 3P Black CONNECTOR FAN MOTOR 2P Natural CONNECTOR 45 _ Right PAINT _ MARK WATER HOSE Ra...

Page 33: ...FRONT BRAKE PIPE FRONT FINAL GEAR CASE BREATHER HOSE 4WD SELECT SWITCH o 0 o FRONT FINAL GEAR CASE BREATHER HOSE GENERAL INFORMATION 4WD SELECT SWITCH WIRE FRONT BRAKE HOSE B 4WD SELECT WIRE 1 27...

Page 34: ...GENERAL INFORMATION Inside of front fender FRONT FENDER LID HEADLIGHT HOUSING H LI WIRE GROOVE GROOVE HEJ DL IG n WIRE SOCKET SOCKET WIRE 1 28...

Page 35: ...RAL INFORMATION FUEL VAPOR RETURN HOSE FRONT BRAKE HOSE A J S i FUELLEVEL SENSOR I 1 2P Red CONNECTOR FUEL OVERFLOW HOSE FCOot 3 8 mm 0 1 0 3 in 3 Bmm O 1 0 3in PAINT MARK Align paint mark with arrow...

Page 36: ...GENERAL INFORMATION FRONT BRAKE HOSE B STOPPER RIGHT FRONT BRAKE CALIPER FRONT BRAKE HOSE B STOPPER LEFT FRONT BRAKE CALIPER 1 30...

Page 37: ...ENERAL INFORMATION FUEL VAPOR RETURN HOSE FUEL HOSE SUB fUEL TANK FUEL PUMP L __ __ L PAINT MARK FRONT FINAL GEAR CASE BREATHER HOSE fAN MOTOR BREATHER HOSE Pink THROTTLE CABLE Eer SENSOR IGNITION COI...

Page 38: ...ray CONNECTOR I EPS MOTOR All models FPMIFPE shown 1 32 SHIFT CONTROL MOTOR WIRE FPE only EPS UNIT TORQUE SENSOR WIRE FRONT FINAL GEAR CASE BREATHER HOSE FAN MOTOR BREATHER HOSE Pink EPS SUB WIRE EPS...

Page 39: ...TION WATER HOSE WATER HOSE Up SHIFT CONTROL MOTOR WIRE FE only Up SHIFT CONTROL MOTOR 2P Black CONNECTOR FE only SHIFT CONTROL MOTOR WIRE FE only FRONT FINAL GEAR CASE BREATHER HOSE SHIFT CONTROL MOTO...

Page 40: ...OR WIRE FPE ooly _ Up FUEL HOSE WATER BREATHER HOSE EPS ECU 21 P Gray CONNECTOR EPS ECU 2P Gray CONNECTOR FUEL FEED HOSE 1 34 SHIFT MOTOR 2P Black CONNECTOR FPE only TORQUE SENSOR WIRE Mo rOR 2P EPS E...

Page 41: ...ATION FUEL VAPOR RETURN HOSE FUEL TANK FUEL JOINT 10mm 0 0 0 4 in rrn I D FUEL HOSE To be butted to the J Q T fuel joint 0 3 mm 0 0 1 in PAINT MARK FUEL VAPOR RETURN HOSE M e j OD I 1 SUB FUEL TANK FU...

Page 42: ...TOR REAR BRAKE PANEL BREATHER HOSE REAR FINAL GEAR CASE BREATHER HOSE INTAKE AIR DUCT IACV 4P Bllao j CONNECT OR FRONT FINAL GEAR CASE BREATHER HOSE FAN MOTOR BREATHER HOSE Pink FAN MOTOR BREATHER HOS...

Page 43: ...TOR BlaCk red WATER HOSE Thermostat la radiator Right Front AIR CLEANER HOUSING CONNECTING TUBe BAND Up t Right THROTTLE BODY BANDS GENERAL INFORMATION SPARK PLUG WIRE AIR CLEANER HOUSING CONNECTING T...

Page 44: ...R pA RKING BRAKE CABLE WIRE HARNESS REVERSE SELECTOR CABLE Righi STARTER MOTOR CABLE REAR FINAL GEAR CASE BREATHER HOSE BATIERY NEGATIVE HCABlE Up SIPHON HOSE BATIERY NEGATIVE H CABLE l i E r MAIN WIR...

Page 45: ...E only CLAMP VS SENSOR 3P SENSORNS SENSOR Black CONNECTOR f ll f ijCJ l J SHIFT ANGLE SENSOR 3P Gray CONNECTOR FElFPE only Up BATTERY NEGATIVE CABLE STARTER MOTOR CABLE GEAR POSITION SWITCH WIRE REAR...

Page 46: ...THER HOSE REAR BRAKE UGHT SWITCH WIRE PEDAL REAR BRAKE CABLE Spring installation direction FRAME 1 40 BRI KE PEDAL LEVER REAR PARKING BRAKE CABLE PEDAL REAR BRAKE CABLE BREATHER HOSE REAR BRAKE UGHT S...

Page 47: ...FENDER SUB WIRE HARNESS GENERAL INFORMATION SATTERY NEGATIVE CABLE BATTERY CONNECTOR Canada type Ole Red REAR FENDER SUB WIRE HARNESS lOP Gray CONNECTOR RADIATOR RESERVE TANK BREATHER HOSE CONDENSER...

Page 48: ...AKEfTAllLlGHT 3P Black CONNECTOR PCI ECM 33P Gray RELAY SWITCH CONNECTOR PCI vEC M P Bla CONNECTOR L li1 HN_ PCM ECM 33P Black CONNECTOR PUMP RELAY 8P Gray CONNECTOR POWER RELAY 8P Gray CONNECTOR Cana...

Page 49: ...GENERAL INFORMATION BRAKElTAllLiGHT WIRE CUP Right BRAKE TAllUGHT WIRE TOOL BOX LID 1 43...

Page 50: ...HAUST EMISSION CONTROL SYSTEM The exhaust emission control system is composed of the PGM FI system and no adjustments should be made The exhaust emission control system is separate from the crankcase...

Page 51: ...rts of the exhaust or intake system with parts other then those specified by the manufacturer FUEL PERMEATION EMISSION CONTROL SYSTEM This ATV complies with the Fuel Permeation Emission Control regula...

Page 52: ...MEMO...

Page 53: ...BOOY PANEL LOCATIONS 2 3 SEAT 2 4 SlOE COVER 2 4 FUEL TANK SIDE COVER 2 S FUEL TANK COVER 2 S MUDGUARD 2 6 ENGINE GUARD 2 7 FRONT GRILLE 2 7 FRONT FENDER CARRIER 2 8 REAR FENDER COVER 2 9 TOOL BOX LI...

Page 54: ...haust system Always mspecllhe exhaust system for leaks after installation TORQUE VALUES ITEM Muffler cover bolt Exhaust pipe cover band boll Muffler cover band screw front side Muffler cover band scre...

Page 55: ...ENDER COVER page 2 9 3 REAR FENDER CARRIER page 2 11 11 TOOL BOX LID page 2 10 4 MUDGUARD page 2 6 12 SIDE COVER page 2 4 5 MUDGUARD BRACKET page 2 13 13 METER COVER page 22 11 6 ENGINE GUARD page 2 7...

Page 56: ...and hooking the center prongs 5 to the seal retainers 6J of the frame Push the seal forward and align the mounting bosses 7 with the rubber mounts 8 then press down to lock it SIDE COVER Remove the se...

Page 57: ...r 3J release the three tabs 4 by sliding the cover rearward Installation is in the reverse order of removal 11 FUEL TANK COVER Remove the fuel tank side covers page 2 5 Remove the following six trim c...

Page 58: ...ng and installing the mudguard Remove the side cover page 2 4 Remove the following nine trim clips 11 socket bolt rear side 2J four flange bolts 3 and footpeg 4 Right mudguard only water pump breather...

Page 59: ...elease the two hooks 3 of the engine guard 4 from the frame and then remove the engine guard Installation is in the reverse order of removal FRONT GRILLE Remove the engine guard page 2 7 Remove the fo...

Page 60: ...page 2 5 Remove the front grille page 2 7 Remove the following accessory socket 2P Black connector 1 J headlight 3P Black connector 2 release from the side air guide plate and disconnect it ten trim...

Page 61: ...Canada type only Installation is in the reverse order of removal For headlight removal installation see LlghtsJmeterslSwitches section page 22 5 REAR FENDER COVER Remove the seat page 2 4 Be careful n...

Page 62: ...er cover page 2 9 Remove the following brakellaillighl 3P Black connector 1 release from the holder plate 2 and disconnect it wire clip 31 brakeltaillight wire 4 from the wire guides 1001 box lid 5 fr...

Page 63: ...wire harnesses 5 by releasing the wire clips 6 rear fender sub wire harness lOP gray connector 7 2 1 junction connectors 8 brakeflaillighl 3P Black connector 9 main fuse connector 10J starter relay s...

Page 64: ...ing bolls 4J four 10 mm bolls 151 Remove the four bolts 6 and collars 7 two trim clips 8 and separate the rear fender 9 and carrier 10 Remove the two screws 11 and muffler protector 12 Remove the four...

Page 65: ...the frame Remove the mudguard page 2 6 Remove the following 6 mm bolt 1 6 mm boll 12 securing lever rear brake cable rear fender stay 13 four B mm bolts and nuts 4 mudguard bracket 5 and step bracket...

Page 66: ...STALLATION Install a new exhaust pipe gasket and muffler gasket Install the following by loosely lightening all the fasteners muffler onto the stays mounting bolt exhaust pipe into the muffler and ont...

Page 67: ...ied torque end 1 facing out TORQUE 6 0 N m 0 6 kgf m 4 4 IbHt After tightening the stud bolts check that the length from the bolt head to the cylinder head surface is within specification DISASSEMBLY...

Page 68: ...MEMO...

Page 69: ...ING SYSTEM 3 16 DRIVE TRAIN BOOTS 3 17 REAR FINAL GEAR CASE OIL AND DIFFERENTIAL OIL 3 17 3 MAINTENANCE 2WD 4WD SELECT SYSTEM 3 19 BRAKE FLUID 3 20 BRAKE SHOES WEAR 3 21 BRAKE PADS WEAR 3 21 BRAKE LIG...

Page 70: ...h arm cover bolt Front master cylinder reservoir cap screw Tie rod lock nut knuckle side Tie rod lock nut steering arm side TOOLS Adjusting screwdriver 07GMA KTB0110 3 2 a TV THREAD DIA mm 1 14 2 6 2...

Page 71: ...O IL AND DIFFERENTIAL Oil __ 2WD 4WD SELECT SY BRAKE FLUID STEM BRAKE SHOES WEAR BRAKE PADS WEAR BRAKE LIGHT SWITCH BRAKE SYSTEM REVERSE LOCK SYS GUARDS CLUTCH SYSTEM SUSPENSION SPARK ARRESTER TEM NO...

Page 72: ...ge 16 11 If the throttle lever still does not return properly replace the throttle cable With the engine idling turn the handlebar all the way to the right and left to ensure that the idle speed does...

Page 73: ...ion and install the throttle body cover page 7 13 AIR CLEANER NOTE If the vehicle is used in dusty areas sand or snow more frequent inspections are required Remove the seat page 2 4 Release the four r...

Page 74: ...horoughly and allow the element and filter to dry Apply approximately 20 9 0 7 oz of Pro Honda Foam Filler Oil 11 or equivalent oil from the inside of the element Place the element into a plastic bag...

Page 75: ...housing and tighten the band screw 4 MAINTENANCE Install the air cleaner cover 1 with the arrow 2 facing IlIII I I forward by aligning the stepped area 3 with the element Secure the cover with the fo...

Page 76: ...g if necessary RECOMMENDED SPARK PLUG BKR5E 11 NGK K16PR U11 DENSO Clean the spark plug center electrode 2 and side electrode 3 with a wire type brush or special plug cleaner 12J 13J 1J Check the spar...

Page 77: ...ge 7 22 right mudguard page 2 6 Remove the following rubber plug lJ from the heat guard plate intake valve adjusting hole cap 121 Release the cables 3 wire harness and hoses 4 oul of the heat guard pl...

Page 78: ...the one way decompressor system from functlOfllflg whICh would cause an in valve clearance measurement W hen checking the clearance slide the feeler gauge from the center toward the outside 3 10 Check...

Page 79: ...m 1 0 kgf m 7 lbHt Coat a new a ring 31 with engine oil and Install It into the crankcase cover groove Install the crankshaft hole cap 11 and tighten the three bolts 2 Install the removed parts in th...

Page 80: ...oil filler cap dipstick into the engine without screwing it in The engine contains a sufficient amount of oil if the oil level is between the upper level 21 and lower level 3 marks on the dipstick If...

Page 81: ...glfllter change 3 3 liters 3 5 US qt 2 9 Imp qt after disassembly Install the filler cap dipstick Check the oil level page 3 12 Resel the 011 change indicator after changing the engine oil as follows...

Page 82: ...e oil and install them into each groove in the filter cover 2J and front crankcase cover Installmg the oil Install the selling spring onto the lugs and a new oil filler filter backwards will with the...

Page 83: ...er freeplay page 3 4 intake air leak engine top end problem page 10 6 IACVoperation page 7 26 RADIATOR COOLANT Check the coolant level of the reserve tank 11with the engine running at normal operating...

Page 84: ...eleasing the two tabs Check for any coolant leakage from the water pump 1 water hoses 21 and hose joints Check the water hoses for cracks or deterioration and replace if necessary Check that aU hose c...

Page 85: ...el surface Remove the oil check bolt 11 and check that the oil flows out of the check bolt hole Check for leaks if there is no oil flow Remove the oil filler cap 2 and pour the oil slowly through the...

Page 86: ...5 Imp oz after disassembly Inslal1 the skid plate with new three bolts and tighten the bolts to the specified torque L ____ __ L _ TORQUE 32 N m 3 3 kgf m 24 IbHt DIFFERENTIAL OIL LEVEL CHECK Place t...

Page 87: ...two tabs 3 Shift the select lever to the 2WD position Be sure the clutch arm 4 position is between the 2WD marks 5 Temporarily loosen the adjusting nut 6J by turning it counterclockwise Tum the adjust...

Page 88: ...s are worn and the caliper pistons are pushed Qui this accounts for a low reservoir level If the brake pads are nol worn and the fluid level is low check the entire system for leaks page 3 22 Tum the...

Page 89: ...t brake is applied See Brake System section for brake pad replacement page 18 8 BRAKE LIGHT SWITCH NOTE The front brake light switch cannot be adjusted If the front brake light switch actuation and br...

Page 90: ...cracks damage or signs of leakage Tighten any loose fittings Replace hoses pipes and fittings as required REAR BRAKE Check the brake cable brake lever and brake pedal for loose connections excessive...

Page 91: ...and lever for loose connections excessive play or other damage Replace or repair if necessary Release the dust cover 1 Measure the lever freeplay at the lever end near the cable FREEPLAY 2 4 mm 0 1 0...

Page 92: ...rd as required CLUTCH SYSTEM 3 24 Remove Ihe left side cover page 2 4 Loosen the lock nut 11 and turn the adjusting screw 2 one fuiliurn clockwise Slowly turn Ihe adjusting screw counterclockwise unti...

Page 93: ...gine several times Stop the engine and allow the exhaust system to cool Install the boll and lighten it securely NUTS BOLTS FASTENERS Check thai all chassis nuts and bolts are tightened to Iheir corre...

Page 94: ...ARING Make sure the cables do not interfere with the rot8tfO l of the handlebar Raise the front wheels off the ground and support the vehicle securely Check that the handlebar moves freely from side t...

Page 95: ...ding the ball joints 3J 3 After adjusting each lie rod rotate both ball joints in the l r 1 same direction along the lie rod axis unlil they stop against the ball joint stud 2 Using a 22 mm wrench hol...

Page 96: ...MEMO...

Page 97: ...GRAM 4 3 MIL CIRCUIT INSPECTION 4 29 SERVICE INFORMATION 4 4 FUEL PUMP RELAY 4 29 SYMPTOM TROUBLESHOOTING 4 5 SENSOR UNIT MAPITP SENSOR 4 30 PGM FI CONNECTOR LOCATION 4 7 ECT SENSOR 4 32 PGM FI TROUBL...

Page 98: ...AINFUSE 30 A FElFPE MAIN FUSE 30 A FElFPE MAIN FUSE 2 30 A IGN FUSE 10 A FUEL PUMP RELAY IAT SENSOR 4 2 SENSOR UNIT MAP SENSOR TP SENSOR FUEL INJECTOR VS SENSOR MIL Eer SENSOR AiNKAN L SENSOR UIHIJ LT...

Page 99: ...f I t t I c ______ 1 B E SENSOR j 1 J I II CoM PLUG 919 o I _ F oc l 7 b r OLe SCSSERVlCECOOoHf CTOII AI C M COO JNG floH OTOfI WO _ l ll c_ o PCMIECM C l C 3 11 8 1 12 n U loglll bIufI o 0 _ G Go Go...

Page 100: ...or tightening them can cause throttle body malfunction Tighten the yellow painted screws of the throttle body to the specified torque A faulty PGM FI system is often related 0 poorty connected or cor...

Page 101: ...ngine stalls hard to start rough idling 1 Check the spark plug page 3 8 2 Check the air cleaner page 3 5 3 Check the Idle speed page 3 15 4 Check the IACV page 7 26 5 Insped the fuel supply system fue...

Page 102: ...11 fuel pump page 7 13 6 Inspect the ignition system I ___ _ p age 5 5 c f Idle speed is above 1 Checktheidle speed page 3 15 IACVSluck opened specifications or fast idle too 2 Check the throttle ope...

Page 103: ...ender carrier page 2 8 m A m f 0 BANK ANGLE SENSOR 3P Black CONNECTOR NOTE 1 NOTE 2 Remove the throttle body cover page 7 13 SENSOR UNIT 5P Black CONNECTOR NOTE 2 PGM FI SYSTEM FUEL INJECTOR 2P Gray C...

Page 104: ...PGM FI SYSTEM IAT SENSOR 2P Black CONNECTOR NOTE 1 Remove the left fuel tank side cover page 2 5 4 8 EeT SENSOR 2P Black CONNECTOR NOTE 1...

Page 105: ...NOTE 1 Remove the seat page 2 4 OLe NOTE 1 NOTE 2 Remove the rear fender cover page 2 9 B33 B23 PCM ECM 33P Gray CONNECTOR NOTE 2 PGM FI SYSTEM A33 A23 PCMlECM 33P Black CONNECTOR NOTE 2 4 9...

Page 106: ...s maintained by pre programed value in the simulated program map When any abnormality is detected in the fuel injector and crankshaft position CKP sensor the fail safe function slops the engine to pro...

Page 107: ...e MIL will start to blink as its DTC It is possible to readout the MIL blink pattern as the current OTC In case the PCM ECM does not detect any problem at present but has a problem stored in its memor...

Page 108: ...070PZ ZY30100 Connection Brown red Green 3 Tum Ihe ignition switch ON and engine stop switch 0 4 Remove Ihe special tool from the OLe 5 The MIL will light for approximately 5 seconds While Ihe MIL lig...

Page 109: ...sensor or its circuit malfunction r IAT sensor circuit high vottage more t h a n 4 9V3 V 9 2 9 loose or poor contact of the tAT sensor connector IAT sensor or its circuit rnatfuncllOn V7 S sensor no s...

Page 110: ...75 5 25 V YES GO TO STEP 4 111 NO GO TO STEP 3 3 MAP Sensor Input line Open Circuit Inspection Tum the ignition switch OFF I Disconnect the PCMlECM 33P Gray connector 11 1 Check for continuity betwee...

Page 111: ...Loose or poor contact of the sensor unit SP Black connector 2 MAP Sensor Inspection Turn the ignition switch OFF Disconnect the sensor unit SP Black connector 1 Connect Ihe wire harness side sensor u...

Page 112: ...Eer sensor with the HDS pocket tester Is about 0 V Indfcated YES GO TO STEP 2 NO Intermittent failure 2 Eel Sensor Inspection Tum the ignition switch OFF Disconnect the ECT sensor 2P Black connector...

Page 113: ...minals with a jumper wire 2 Connection Black blue Green red Turn the ignition switch ON and engine slop switch 0 Check the Eer sensor with the HDS pocket tester Is about 0 V indicated YES Faulty ECT s...

Page 114: ...of the sensor unit SP Black connector NO Faulty sensor unit TP sensor 3 TP Sensor Input Voltage Inspection Tum the ignition switch OFF Disconnect the sensor unit 5P Black connector 1J Tum the ignition...

Page 115: ...und Connection Blue black Ground Is there continuity YES Short circuil in the Bluelblack wire NO GO TO STEP 7 7 TP Sensor Inspection Replace the sensor unit with a known good one page 4 30 Erase the O...

Page 116: ...F J YES GO TO STEP 5 NO GO TO STEP 4 4 TP Sensor Ground Line Open Circuit Inspection Disconnect the sensor unit 5P Black connector 1 Check for continuity between the wire harness side sensor unit 5P B...

Page 117: ...the tAT sensor 2P Black connector Disconneci lhe PCMlECM 33P Gray connector 1 Measure the resistance between the wire harness side PCMfECM 33P Gray connector terminals Connection 82 826 TOOL Test prob...

Page 118: ...ide tAT sensor 2P Black connector terminals with a jumper wire 2 Connection Gray Green red Tum the ignition switch ON and engine SlOP switch 0 Check the tAT sensor with the HDS pocket tester Is about...

Page 119: ...6 12 4 a 20 e 68 F Is the resistance within 11 6 12 4 n 20 C 6BG F YES GO TO STEP 3 NO Fau ty fuel injector 3 Fuel Injector Input Voltage Inspection PGM FI SYSTEM 111 Q Turn the ignition switch ON and...

Page 120: ...he DIG 1 Recheck DIG Erase the DIG page 4 12 Start the engine and recheck the DIG with the HDS pocket lester Is the Dre 29 1 indicated YES GO TO STEP 2 NO Intermittent failure Loose or poor contact of...

Page 121: ...Resistance Inspection at PCM ECM Connector Measure the resistance between the wire harness side PCM ECM 33P Gray connector 1 lerminals Connection 819 829 B30 831 TOOL Test probe 07ZAJ RDJA110 Standard...

Page 122: ...witch ON and engine stop switch 0 Measure the voltage between the wire harness side bank angle sensor 3P Black connector terminals Connection Brownlwhite Green red Is the voltage within 4 75 5 25 V YE...

Page 123: ...ition switch ON and engine slop switch 0 Check the bank angle sensor with the HOS pocket tester Is Dre 54 1 indicated YES Replace the PCMIECM with a known good one page 4 34 and recheck NO Faulty orig...

Page 124: ...white bank angle sensor 3P Black connector 2 and PCM ECM 33P Gray connector terminals 2 Connection B2 Green red B3 Brown white TOOL Test probe 07ZAJ ROJA110 Brownlwhite B3 aIIB Are there continuities...

Page 125: ...few seconds comes on and it check as foUows Turn the ignition switch OFF Disconnect the PCM ECM 33P Gray connector 1 Check for continuity between the wire harness side PCM ECM 33P Gray connector and...

Page 126: ...3 1 Always clean around the throttle body before the sensor unit removal to prevent dirt and debris from entering the air passage Remove the following throttle body cover page 7 13 left side cover pag...

Page 127: ...n disconnect the jumper wire from the EeT sensor 2P Black connector within 10 seconds while the MIL is blinking reset receiving pattern Green red 121 7 When the reset procedure is complete the MIL bli...

Page 128: ...ated Heat Ihe coolant 1 1 mixture with an electric heating gloves and element adequate eye protection Keep ammable materials away from me burner Suspend the ECT sensor in heated coolant and check the...

Page 129: ...idle speed is normal page 3 15 Remove the bank angle sensor 1 with the bank angle sensor 3P Black connector is connected page 4 33 Do not disconnect the bank angle sensor 3P Black connector during in...

Page 130: ...tage with HOS pocket lester Standard 0 7 1 3 V If you repeat this test first turn the ignition switch OFF then tum the ignition switch ON and engine stop switch 0 REMOVALIINSTALLATION Remove the rear...

Page 131: ...y voltage exist YES GO TO STEP 2 PGM FI SYSTEM 81 NO Open circuit In the Black red wire ______ _ ________ 1 between the fuse box and PCM ECM Open circuil in the Black wire between the ignition switch...

Page 132: ...ack connector 1 J Tum the ignition switch ON and engine Slop switch 0 Measure the voltage between the wire hamess side PCM ECM 33P Black connector terminal and ground Connection A4 Ground H TOOL Test...

Page 133: ...ION 5 2 SYSTEM DIAGRAM 5 2 SERVICE INFORMATION 5 3 TROUBLESHOOTING 5 4 IGNITION SYSTEM INSPECTION 5 5 5 IGNITION SYSTEM IGNITION COIL 5 7 IGNITION TIMING 5 8 CONDENSER Canada Iype 5 8 RECTIFIER Canada...

Page 134: ...DIAGRAM eM BuIY OfW G G Y BUR 81M SPARK PLUG r CONDENSER I I I G R I BI Black BuBtue G Green R Red W While y Yellow _ _ _ Canada type R l From regu i BIIW 0 ENGINE STOP ______1 1 SWITCH I I _ _ 1 1 I...

Page 135: ...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 spark plug Th...

Page 136: ...f the PCM ECM Black connector or loose or poorly connected PCM ECM Black connector 9 Faulty CKP sensor Measure the peak voltage 10 Faulty PCMfECM in case when above No 1 through 9 are normal Initial v...

Page 137: ...6 U S A only or Peak voltage adaptor 07HGJ 0020100 not available in U S A with commercially available digital multimeter impedance 10 MO DeV minimum IGNITION COIL PRIMARY PEAK VOLTAGE NOTE Check all s...

Page 138: ...llow the checks described in the troubleshooting chart page 5 4 CKP SENSOR PEAK VOLTAGE NOTE Check that the cylinder compression is normal and the spark plug is installed correctly in the cylinder hea...

Page 139: ...one measured at the alternator connector is normal the Blue yellow or Greenlwhile wire has an open or short circuit or loose connection If both peak voltages are abnormal follow the checks described i...

Page 140: ...e engine let it idle and check Ihe ignilion timing The ignition liming is correct if the F mark 2 on the flywheel aligns with Ihe index nolch 3 on the rear crankcase cover at idle Coat a new O ring 1...

Page 141: ...in the Red or Green wires rectifier and or related circuits page 5 10 If there is voltage check the condenser as following 1 Disconnect the battery negative cable page 21 8 and connect the condenser...

Page 142: ...mounting bolt 3 and rectifier 4 Install the rectifier by aligning its boss with the hole of the frame Install the removed parts in the reverse order of removal INSPECTION Remove the rectifier 1 page...

Page 143: ...COMPONENT LOCATION 6 2 SYSTEM DIAGRAM 6 2 SERVICE INFORMATION 6 3 TROUBLESHOOTING 6 4 6 ELECTRIC STARTER STARTER MOTOR 6 6 STARTER RELAY SWITCH 6 8 OIOOE 6 10 6 1...

Page 144: ...Green 1 Lg Light green R Red W While Y Yellow 6 2 STARTER SWITCH R FRONT BRAKE INHIBITOR SWITCH IGN T ON SWITCH ofl n 8 BATTERY L iC d p i RlBI RlBI I R FM FPM MAIN FUSE 30A j IGNITION FElfPE MAIN FUS...

Page 145: ...troubleshooting page 6 4 A weak battery may be unable to tum Ihe starter molor quickly enough or supply adequate ignition current Refor to each section for the foUowing components information Starter...

Page 146: ...otor Inspection Turn the ignition switch OFF Apply battery voltage to the slarter motor directly Do not use a thin wire because a large amount of current flows Does the starter motor turn YES _ loose...

Page 147: ...Low battery voltage Poorly connected battery cables Poorly connected starter molor cable Poorly connected ground cable Faulty starter motor Starter motor turns but engine does not turn Starter motor i...

Page 148: ...rom the starter motor Coat a new D ring with engine oil and install it into the starter motor groove Apply molybdenum oil solution to the starter motor shaft splines 3 Install the removed parts in the...

Page 149: ...ator bars of Ihe armature 2 for discoloration Clean any metal debris from between commutator bars NOTE Do not use emery or sand paper on the commutator Check for continuity between pairs of commutator...

Page 150: ...for continuity between the positive and negative brushes There should be no continuity Remove the brushes from the brush holder page 6 6 Measure the brush length SERVICE LIMIT 6 5 mm 0 26 in STARTER...

Page 151: ...should be battery voltage only when the starter switch is pushed CONTINUITY INSPECTION Remove the starter relay switch 1 page 6 9 Connect the fully charged 12 V 2 battery to the starter relay switch 2...

Page 152: ...s Remove the fuse box cover and the diode 2 from the fuse box Installation is In the reverse order of removal INSPECTION Remove the diode 1 page 6 10 Check for continuity between the diode terminals W...

Page 153: ...EM COMPONENTS 7 2 FUEL TANK 7 18 SERVICE INFORMATION 7 3 AIR CLEANER HOUSING 7 19 FUEL LINE TROUBLESHOOTING 7 5 THROTTLE BODY 7 20 FUEL LINE INSPECTION 7 6 IACV 7 24 SUB FUEL TANK FUEL PUMP 7 13 FUEL...

Page 154: ...FUEL SYSTEM SYSTEM COMPONENTS 3 4 N m 0 3 kgf m 2 SlbHt 34 N m 2 SlbHt 1 8 N m 0 2 kgf m 1 3IbHt 7 2...

Page 155: ...wn in this manual Do not loosen or tighten the white painted screws and nut of the throttle body Loosening or lightening them can cause throttle body malfunction Tighten the yellow painted screws of t...

Page 156: ...A OnIY _ 1c N O B able in U S A Hose attachment 6 mm 9 mm Attachment joint 6 m m gCC m mo 07ZAJ S5A0130 07ZAJ S5A0150 Not available in U S A Not available in U S A Pressure manifoM d h o S Adapter ma...

Page 157: ...re blown IGN fuse lOA faulty fuel pump relay page 4 29 and its circuits open circuit in the engine stop switch line of the PCM ECM page 4 36 open circuit in the power ground lines of Ihe PCM ECM page...

Page 158: ...11 off the sub fuel lank fuel pump assembly and disconnect the fuel pump 2P Black connector 2 4 Start the engine and let it idle until the it stalls 5 Turn Ihe ignition switch OFF 6 Disconnect the bat...

Page 159: ...e the retainer and connector damper from the pipe end NOTE Absorb the remaining fuel in the fuel feed hose from Howing out with a shop towel Be careful not to damage the hose or other parts Use the sp...

Page 160: ...l 1001 to the retainer tabs and push and release them from the locking pawls W 5J Fuel connector remover 070MF HP50200 Pull the connector off then remove the relainer and connector damper from the pip...

Page 161: ...2 Set a new connector damper 11 to the pipe end as shown Then press the quick connect fitting 121 onlo the pipe until both locking pawls 3 lock with a CLlCK NOTE Align the retainer groove with the con...

Page 162: ...of engine oil on the injector joint Align III g 21 3 Make sure the connection is secure and that the locking pawls 1 are firmly locked into place check visually and by pulling the connector 2 4 Make...

Page 163: ...6 mm 9 mm 01ZAJ 5SA0130 5J Attachment JOint 6 mml9 mm 07ZAJ S5A0150 U S A TOOLS Fuel pressure gauge 100 psi 01406 0040008 Pressure manifold hose 01AMJ HW3A100 Adapter female 07AAJ SSMA400 Adapter mal...

Page 164: ...Black connector Temporarily connect the battery negative cable to the battery page 21 8 Turn the ignition switch ON and engine stop SWitch O Measure the amount of fuel flow NOTE The fuel pump operates...

Page 165: ...on switch OFF Pull the rubber boot 11 off the sub fuel tank fuel pump assembly and disconnect the fuel pump 2P Black connector 2 Turn the ignition switch ON and engine SlOp switch 0 measure the voltag...

Page 166: ...Connect the fuel hose 4J and fuel vapor return hose 5 to the sub fuel tanklfuel pump assembly Remove the hose clip from the fuel hose Connect the quick connect fitting to the sub fuel lank fuel pump...

Page 167: ...f the fuel pump case 21 with clean gasoline 131 Visually inspect the fuel pump filter 1 for dirt debris or FA any clogging and replace it if necessary ype Fuel pump filter replacement Type A page 7 15...

Page 168: ...Do not blow compressed air directly into the feed pipe or suction port 2 3 1 Install a new fuel pump fitter 1 to the fuel pump unit 1 1 whife aligning the holes for the suction port 2 Hold the bottom...

Page 169: ...fuel pump damage the fuel unit 2 while aligning the holes for the suction port and pump umt holder three locking tabs with the grooves and fuel pump unit Make sure the fuel pump unit holder 1 securel...

Page 170: ...new O ring 11 and install it to It It the suction port 2 of the fuel pump unit holder IIIIi i 3 1 fIIIiiII iSitI Install a new fuel pump fiUer 3J to the fuel pump unit holder while aligning the sucti...

Page 171: ...PRING WASHERS COVER PLATE FUEL PUMP UNIT Type 8 BOLTS _ Ir SPRING WASHERS COVER PLATE FUEL PUMP UNIT FUEL PUMP UNIT c HOLDER e O RING c 1t D RING FUEL PUMP FILTER FUEL SYSTEM 0 O RING 1IIiiiiII FUEL P...

Page 172: ...1 with the chamfered edges r Be careful nol to drop the fuel pump unit facing up Install the spring washers 2J onto the fuel pump assembly bolls 3J as shown Instalilhe fuel pump assembly bolts Tighte...

Page 173: ...uel leak FUEL STRAINER SCREEN CLEANING Remove the fuel tank page 7 20 Drain the gasoline InlO an approved fuel container Remove the two mountmg bolts 1 and the fuel joinl12 from the fuel tank FUEL SYS...

Page 174: ...llowing rear final gear case breather hose 1 J rear brake panel breather hose 21 front final gear case breather hose 3 fan molor breather hose 4J Loosen the connecting lube band screw 51 Remove the tr...

Page 175: ...TTLE BODY NOTE If the sensor unit is removed from the throttle body the TP sensor reset procedure must be performed after installing the throttle body page 4 31 REMOVAL FUEL SYSTEM 111 161 151 41 21 1...

Page 176: ...this 1 7 24 manual Do not snap the throttle valve from full open to full close after the throttle cable has been removed It may cause incorrect Idle operation Do not damage the throttle body It may ca...

Page 177: ...TE Install the wire harness clamp stay and fuel feed hose damp slay by aligning each stay hole with the pin of the throttle body INSTALLATION Install the insulator 1 J onto the cylinder head by aligni...

Page 178: ...tor 2P Gray connector 121 and sensor unit 5P Black connector 3 Install the air cleaner housing page 7 22 Adjust the throttle lever freeplay page 3 4 Connect the quick connect fitting to the fuel injec...

Page 179: ...an the throllle body to prevent dirt and debris from entering the IACV passage Turn the Ignition switch OFF Disconnect the IACV 4P Black connector 11 Remove the two torx screws T20 2 relalner plate 31...

Page 180: ...njector 1 operating sounds with a sounding rod or stethoscope 2J REMOVAL Clean around Ihe fuel injector base with compressed alf and be sure Ihal no debris is allowed to enter the oombusllOn chamber R...

Page 181: ...Ahgn the boss 1 J of the injector jOint with the injector terminals 21 as shown Bec8refulnollo Install the fuel injector assembly lllnlO the throttle damage the seal body nng Install and tighten the f...

Page 182: ...FUEL SYSTEM 7 30...

Page 183: ...FLOW PATTERN S 2 SERVICE INFORMATION 8 3 TROUBLESHOOTING 8 4 SYSTEM TESTlNG 8 5 COOLANT REPLACEMENT 8 6 8 COOLING SYSTEM THERMOSTAT 8 8 RADIATOR COOLING FAN 8 9 RADIATOR RESERVE TANK 8 11 WATER PUMp 8...

Page 184: ...COOLING SYSTEM SYSTEM FLOW PATTERN RESERVE TANK RADIATOR J THERMOSTAT WATER PUMP 8 2...

Page 185: ...void spilling coolant on painted surfaces After servicing the system check for leaks with a cooling system tester For cooling fan motor inspection refer to Ughts MetersfSwitches section page 22 15 SPE...

Page 186: ...749 0010000 Bearing remover 15 mm Q7936 KC10500 U S A only Passage blocked in radiator hoses or water jacket Air in system Faulty cooling fan motor Faulty water pump Engine temperature too low Thermos...

Page 187: ...5 1 080 078 SO 1 086 1 084 55 I 1 095 1 093 10 SO 1008 15 20 25 30 3S 59l 68 77 1008 1007 1 00 i 017 016 015 6 1 4 01 02 02 03 04 054 062 069 1 026 1 025 1 024 1 2 1 034 1 033 1 031 1 9 1 043 1 042 04...

Page 188: ...or replace components if the system will nol hold the specified pressure for alleast 6 seconds Remove the tester and install the radiator cap Install the lid in the reverse order of removal COOLANT R...

Page 189: ...install the drain bolt with a new sealing washer securely Remove the two bolts 1 and reserve tank 2 then open the tank cap 3 to drain the tank Disconnecllhe siphon hose 4 to remove the tank Rinse the...

Page 190: ...ang the Remove Ihe two bolts 1 and ignition coil stay assembly assembly from the 12 wires 8 8 Remove the two bolts 1 and thermostat cover 21 Remove the thermostat 1 from the housing Make sure the rubb...

Page 191: ...e valve opens al a temperature other than those specified RADIATOR COOLING FAN RADIATOR REMOVAUINSTALLATION NOTE Take care not to damage the radiator servicing the radialor Remove the front fenderlcar...

Page 192: ...radiator assembly 5 release the mounting bosses 6 from the grommets Installation is in the reverse order of removal Fill and bleed the cooling system page 8 6 COOLING FAN REMOVAU INSTALLATION Remove...

Page 193: ...ank Disconnect the siphon hose 4 to remove the tank Connect the siphon hose and install the reserve tank with the two bolts Fill the reserve tank to the upper level line 5J and install the tank cap In...

Page 194: ...the impeller 1 through the pump shaft 21 using a screwdriver or equivalent Remove the mating ring and cup gasket of the mechanical seal from the impeller Remove the following pump shaft thrust washer...

Page 195: ...impeller 3 with the gasket facing the impeller until it is fully seated Do not gel oil on the Apply molybdenum oil solution to the thrust washer 1 mechanical seal and the journal 2 of a new pump shaf...

Page 196: ...the cover groove 2 1J 111 Install the pump cover 1 and the five bolts 2 with a new sealing washer 3J in position as shown triangular 2 mark 41 Tighten the bolts in a crisscross pattern in several ste...

Page 197: ...LUBRICATION SYSTEM DIAGRAM 9 2 SERVICE INFORMATION 9 3 TROUBLESHOOTING 9 3 9 LUBRICATION SYSTEM OIL PUMP 9 4 RELIEF VALVE 9 6 9 1...

Page 198: ...TION SYSTEM LUBRICATION SYSTEM DIAGRAM CYLINDER HEAD COVER CENTRIFUGAL CLUTCH CRANKSHAFT OIL FILTER RELIEF VALVE FRONT C INK CA E COVER OIL 9 2 OIL ST tAlNIER SCREEN FLYWHEEL ___ STATOR REAR CRANKCASE...

Page 199: ...STANDARD Unit mm in SERVICE LIMIT Engine oil capacity After draining 2 9 liters 3 1 US qt 2 6 Imp qt After draining filter change 3 0 liters 3 2 US ql 2 6 Imp ql After disassembly 1 3 3 liters 3 5 US...

Page 200: ...emove the three bolts PI and oil pump 12 DlSASSEMBLY INSPECTION Remove the boll 1 and rotor side plale 21 Measure the rotor lip clearance SERVICE LIMIT 0 20 mm 0 008 in Measure the pump body clearance...

Page 201: ...drive pin 4 into the pump shaft 5 and install the shaft into the inner rotor and pump body by aligning the drive pin with the inner rotor groove Install the rotor side plate 11 and bolt 12 Tighten th...

Page 202: ...ove the snap ring 1 washer 121 spring 3J and relief valve 4 from the valve body 5 Check the relief valve and spring for wear or damage Replace the relief valve assembly if necessary ASSEMBLY Install t...

Page 203: ...AD COVER REMOVAU DISASSEMBLY 10 7 CYLINDER HEAD REMOVAL 10 9 CYLINDER HEAD DISASSEMBLY 10 10 VALVE GUIOE REPLACEMENT 10 12 VALVE SEAT INSPECTIONI REFACING 10 13 CYLINOER HEAO ASSEMBLY 10 14 CYLINDER H...

Page 204: ...CYLINDER HEADNALVE SYSTEM COMPONENTS 48 N m 4 9 kgf m 351bHt 10 2 12N m 1 2 9Ibf ft 22 N m 2 2 kgl m 161bl HI Q A 48 N m 4 9 kgf m 35 IbHt 54 N m 5 5 kgf m 40 IbHt 32 N m 3 3 kgf m 24 IbNt...

Page 205: ...CYLINDER HEADNALVE or I J ____ 12 N m 12 kgf m 9lbHt 10 3...

Page 206: ...0004 0 0015 t EX 0 030 0 057 0 0012 0 0022 Valve guide projection IN EX 14 8 15 0 0 58 0 59 above cylinder head Valve seat width I IN EX 1 2 0 05 Valve spring Free length Inner 42 94 1 691 Outer 43 63...

Page 207: ...33 mm 32 EX Interior cutter 37 5 mm 60 IN 07780 0012900 07780 0014100 or equivalent commercially available in I U SA r 1nter ior cutter 34 mm 60 EX 07780 0014700 or equivalent commercially available...

Page 208: ...ck open Cylinder head leaking or damaged cylmder head gasket Warped or cracked cylinder head loose spark plug Cylinder piston problem page 11 3 Compression too high Excessive carbon build up on piston...

Page 209: ...no leakage althe gauge connection Low compression can be caused by blown cylinder head gasket improper valve adjustment valve leakage wom piston ring or cylinder High compression can be caused by car...

Page 210: ...inder head cover 3 Marle the push rods push rods 1J so they can b gasket 2 placed back In their two dowel pins 3 original locations DISASSEMBLY Remove the two rocker arm shaft retaining bolls 1 and se...

Page 211: ...ker arm to shaft clearance SERVICE LIMIT 0 08 mm 0 003 in PUSH ROD Check the push rods for wear or damage If the push rod is worn or damaged check the cam follower and camshaft page 10 20 CYLINDER HEA...

Page 212: ...he mating surfaces Remove the gasket 1 and two dowel pins 2 CYLINDER HEAD DISASSEMBLY Remove the cylinder head page 10 9 To prevent loss of Remove the valve spring colters using the valve spring enslO...

Page 213: ...ight iillIII edge and feeler gauge across the stud holes SERVICE LIMIT 0 10 mm 0 004 In VALVE SPRING Check the valve springs for fatigue or damage Measure the valve spring free length SERVICE LIMITS I...

Page 214: ...replace the valve VALVE GUIDE REPLACEMENT Be sure to wear heaV gloves 10 allOid bums when handling the healed cylinder head Using a lorch 10 heat the cylinder head may cause warpage 10 12 Mark new val...

Page 215: ...alve seat face be ground If the The valve seat contact should be wilhin the specified valve face is burned seat width 1 and even all around the circumference or badly worn or if it contacts the seat u...

Page 216: ...cutting the seat apply lapping compound to the valve face and lap the valve using a hand lapping tool 1 with a light pressure NOTE Excessive lapping pressure may deform or damage the seat Change the a...

Page 217: ...DNALVE Lubricate the valve 1 stem sliding surface with 111 molybdenum oil solution Insert the valve into the guide while turning it slowly to avoid damaging the stem seal Install the inner and ouler v...

Page 218: ...eful not to leI Apply engine oil to the threads and seating surface of 1 0 lhenu sand the cap nuts lJ and flange nuts 21 and inslalilhe washers faNinlO the washers 3 and nuts Ctankcase Tighten the nut...

Page 219: ...hanger bolts and nut 10 the specified torque TORQUE 10 rnm nut 54 N m 5 5 kgf m 40 IbHt 8 mm bolt 32 N m 3 3 kgf m 24 IbHt Install the following cylinder head cover page 10 17 throttle body page 7 25...

Page 220: ...setting plates IlIon the cylinder head cover as shown Install the intake rocker arm lJ and exhaust rocker arm 12 properly and Insert the rocker arm shafts NOTE Intake rocker arm has IN mark 1 31 and...

Page 221: ...h rods onto the gasket grooves 31 as shown Apply engine oil to the rocker arm followers and adjusting screw lips and install the cylinder head cover 11 I g Make sure there is no clearance al the matin...

Page 222: ...ove the following cylinder page 11 4 primary drive gear page 12 13 Malt the followers Remove Ihe cam followers 1 Jfrom the crankcase so they can be plaaxi back in their anginal iocallOfls 10 20 Push i...

Page 223: ...EADNALVE Check the cam lobe surfaces 1 for scoring scratches 13 1 1 1 or evidence of insufficient lubrication Check the cam sprocket teeth 2 for wear or damage Turn the outer race of the bearing 3 wit...

Page 224: ...the exhaust cam lobe CAM CHAIN TENSIONER Check Ihe slipper surface 1 of Ihe tensioner for wear or damage Check Ihe tensioner lifter operation The tensioner lifter shaft should not go into the body wh...

Page 225: ...haft to align the r mark IJ on the with a shop lowe or flywheel with the index mark 2 on the crankcase coyer 6qufllolent 0 protect it from damage CYLINDER HEADNALVE 2 I 1 L Lubricate the camshaft bear...

Page 226: ...ply locking agent to the threads of the setting plate IIIIIIIIIIIIIIIIIIIIIIII bolt 1 Install the bearing selling plate 2J onto the crankcase and tighten the bolt securely Apply locking agent to the t...

Page 227: ...Remove the pin from the tensioner lifter Make sure that the camshaft pin and index mark M line up when the r mark on the flywheel is aligned with the index mark on the crankcase cover Apply engine oi...

Page 228: ...MEMO...

Page 229: ...SYSTEM COMPONENTS 11 2 SERVICE INFORMATION 11 3 TROUBLESHOOTING 11 3 11 CYLINDER PISTON CYLINDER PISTON REMOVAL 11 4 CYLINDER PISTON INSTALLATION 11 8 11 1...

Page 230: ...CYLINDER PISTON SYSTEM COMPONENTS 11 2 I I I I 1 0...

Page 231: ...ond 0 30 0 45 0 012 0 016 O S 0 02 I Piston ring to ring Oil side rail I 0 20 0 70 0 008 0 026 0 9 0 04 Top 0 030 O OSO 0 0012 0 0024 0 09 0 004 groove clearance Second 0 030 O OSO 0 0012 0 0024 0 09...

Page 232: ...off as il could damage the mating surface Remove the gasket 1 Jand the two dowel pins 2 PISTON REMOVAL Place a clean shop towel over the crankcase to prevent the piston pin clip from falling into the...

Page 233: ...IMIT 0 10 mm 0 004 In Calculate the cylinder taper and out of round at three levels in an X and Y axis Take the maximum reading to determine the taper and out of round SERVICE LIMIT Taper 0 10 mm 0 00...

Page 234: ...VICE LIMIT Top Second 0 09 mm 0 004 In Insert each piston ring 111 into the bottom of the cylinder 1 1 squarely using the piston Measure the ring end gap M SERVICE LIMITS Top 0 5 mm 0 02 in Second 0 6...

Page 235: ...piston pin 0 0 at three points SERVICE LIMIT 18 96 mm 0 746 In Calculate the piston to piston pin clearance SERVICE LIMIT 0 08 mm 0 003 in Measure the connecting rod small end 1 0 SERVICE LIMIT 19 07...

Page 236: ...rom the cylinder mating surface of the crankcase Adjust the height if necessary CYLINDER PISTON INSTALLATION PISTON RING INSTALLATION 11 8 Carefully install the piston rings into the piston ring groov...

Page 237: ...he piston pin hole CYLINDER PISTON NOTE Make sure that the piston pin clips 1J are seated r securely Do nol align the piston pin clip end gap 12 with the piston cutout 13 CYLINDER INSTALLATION Clean t...

Page 238: ...CYLINDERfPISTON 11 10 Make sure thai the cylinder touches the crankcase evenly Install the two bolts 1 Inslall the cylinder head page 10 16...

Page 239: ...KAGE SYSTEM COMPONENTS 12 2 CENTRIFUGAL CLUTCH 12 8 SERVICE INFORMATION 12 3 CHANGE CLUTCH 12 13 TROUBLESHOOTlNG 12 5 GEARSHIFT LINKAGE 12 19 FRONT CRANKCASE COVER FRONT CRANKCASE COVER REMOVAL 12 6 I...

Page 240: ...TCH GEARSHIFT LINKAGE SYSTEM COMPONENTS FElFPE models shown 118 N m 12 0 kgf m 87 Ibf ft 108 N m 11 0 kgf m __ 801bHt 12 2 16 N m 1 6 kgf m 121bHt 7 r 12 N m 1 2 kgf m 9Ibf ft j 22 N m 2 2 kgf m 16Ibf...

Page 241: ...assages in the front crankcase cover Clean the oil passages before installing the crankcase cover The FEiFPE models are equipped with the electric shift program ESP ESP service page 23 30 SPECIFICATIO...

Page 242: ...O 3 5 X C OC Oi Cmm 1 07749 0010000 07933 HA80000 t _ _ or 07933 HB3000A U S A only Bearing remover shaft 1S mm Bearing remover head 15 mm Bearing remover 15 mm 07936 KC10100 07936 KC10200 07936 KC 10...

Page 243: ...lates Loose clutch lock nul Faulty clutch lifter Improper oil viscosity or oil level Hard to shift Incorrect clutch adjustment page 3 24 Worn or damaged gearshift linkage components Faulty clutch lift...

Page 244: ...peller shaft page 19 12 FElFPE models only shift control molor and reduction gears page 23 30 Disconnect the waler hoses 1 from the front crankcase cover Remove the following fifteen bolls lJ front cr...

Page 245: ...bearing squarely with the sealed side facing down until it is fully sealed I _ r TOOLS 11 Driver 2J Attachment 32 x 35 mm 3J Pilot 15 mm CLUTCH LIFTER 07749 0010000 07746 0010100 07746 040300 Check lh...

Page 246: ...TOOL Clutch holder 07ZMB HN20001 07ZMB HN20101 07ZMB HN20200 07ZMB HN2A101 Remove the lock nut and washer PI Remove the centrifugal clutch assembly 111 using the special tool TOOL 2 Puller 35 1 0 mm...

Page 247: ...or irregular movement Remove the sprag clutch 1 from the clutch drum CLUTCH GEARSHIFT LINKAGE 11 Check the sprag clutch contacting surface 1 for c abnormal wear or damage DRIVE PLATE Check the sprag...

Page 248: ...the clutch spring 121 Remove the following outer plate 3 clutch spring inner plate 4J Measure the clutch spring height SERVICE LIMIT 2 84 mm 0 112 In WEIGHT SPRING Check the weight springs 11 for wea...

Page 249: ...LATE CLUTCH DRUM INNER PLATE E CUPS SPRAG CLUTCH Install with the Install the clutch weights 1 and springs 2 onto the spring s open ends drive plate as shown t facing In InSlall the inner plate 1 with...

Page 250: ...he sprag dutch O U T S D E 1 and the sprag dutch contacting surface of the clutch drum Install the sprag dutch into the clutch drum with the OUT SIDE mark facing up Apply engine oil 10 the sprag clutc...

Page 251: ...holder 07ZMB HN20001 07ZMB HN20101 07ZMB HN20200 07ZMB HN2A101 TORQUE 118 N m 12 0 kgf m 87 Ibf h Stake the lock nut into the crankshaft groove Install the front crankcase cover page 12 23 CHANGE CLU...

Page 252: ...the four clutch spring bolts 2 TOOL Clutch center holder U S A TOOLS Holder plate Holder collar A 07JMB MN50302 07HGB 001010B or 07HGB 001010A with 07HGB 001020B or 07HGB 001020A Hold the clutch cente...

Page 253: ...Tum the inner race of the lifter bearing 111 with your F The bearing should tum smoothly and quietly_ Replace if necessary Check the tifter cam plate 21 lifter plate 3 and oollar 4 for deformation or...

Page 254: ...diSCS and plates as Check the plate warpage on a surface plate using a a sel feeler gauge 12 16 SERVICE LIMIT 0 20 mm 0 008 in CLUTCH CENTER Check the clutch center and pressure plate for nicks Inden...

Page 255: ...drive gear 1 0 SERVICE LIMIT 29 05 mm 1 144 in MAINSHAFT AND CRANKSHAFT Measure the mainshaft 0 0 at the clutch outer gUIde SERVICE LIMIT 21 93 mm 0 863 in Measure the crankshaft 0 0 at the primary dn...

Page 256: ...outside clutch center 4J clutch dISC tabs mto the Shallow slots 3 In the dutch outer 12 18 Install the washer 1 Jto the malnshaft Apply engine oil 10 the threads and seating surface of a new lock nul...

Page 257: ...f m 10 IbHt Apply engine 01110 the lifter bearing 11 and install the lifter collar 21 and bearing Install the following FEJFPE models gearshift linkage page 12 22 FMfFPM models liftarlever page 12 22...

Page 258: ...asher 5 To service the gearshift spindles 16J remove the rear crankcase cover page 12 22 0011 1 guide plate 2 gearshift plaia 1J FM FPM models only washer from the gearshift spindle gearshift cam 2 wh...

Page 259: ...ighten the bolt to the specified torque TORQUE 12 N m 1 2 kgf m 9lbHt Hold the stopper arm 1 with a screwdriver 2 and install the gearshift cam 3 by aligning the pin hole 4 with the dowel pin 5 FM FPM...

Page 260: ...ing 16 to the gearshift arm and plate Install the lifter lever 7 by aligning the wide groove with the wide tooth of the splines Install the rear crankcase cover page 13 9 All models Inslallthe centrif...

Page 261: ...the adjusting plate CLUTCH GEARSHIFT LINKAGE Install a new output shaft oil seal 1 into the front crankcase cover FElFPE models only Install a new gearshift spindle oil seal 12 into the front crankcas...

Page 262: ...bolts 3 and lighten them in a crisscross pattern in several sleps Connecllhe water hoses lJ to the crankcase cover Inslallthe following FElFPE models only reduction gears and shift control motor page...

Page 263: ...13 ALTERNATORISTARTER CLUTCH SYSTEM COMPONENTS 13 2 RECOIL STARTER Canada type 13 6 SERVICE INFORMATION 13 4 ALTERNATOR STATOR 13 6 TROUBLESHOOTlNG 13 5 FLYWHEEUSTARTER CLUTCH 13 11 13 1...

Page 264: ...ALTERNATOR STARTER CLUTCH SYSTEM COMPONENTS U S A type FElFPE models shown 108 N m 11 0 kgf m 80 IbfftJ 13 2...

Page 265: ...ALTERNATORISTARTER CLUTCH Canada type FElFPE models shown t08N m 11 0 13 3...

Page 266: ...er section page 6 6 SPECIFICATIONS ITEM STANDARD Starter driven gear boss 0 0 51 705 51 718 2 0356 2 0361 I D _ _ _ 31 946 31 962 1 2577 1 2583 Crankshaft 0 0 at starter driven gear 31 884 31 900 1 25...

Page 267: ...26 mm 07746 0010700 Driver 07749 0010000 Bearing remover 10 mm 07936 GEOAOOO U S A only Starter motor turns but engine does not turn Faulty starter clutch Damaged starter reduction gear andlor driven...

Page 268: ...J and housing 3J and secure the pulley with a vise pliers or equivalent 1001 to prevent Ihe pulley from rewinding fUming the pulley 6 112 tums counterclockwise and hold it Untie Ihe slarter rope and r...

Page 269: ...ly rear crankcase cover 2 aflracted to the flywheel be careful during removal two dowel pins 1 oil joint pipe and O ring 2 countershaft thrust washer 3J reverse stopper shaft thrust washer 4 output sh...

Page 270: ...lts 4J and CKP sensor bolts and lighten them to the specified torque TORQUE CKP sensor bolt 6 0 N m 0 6 kgf m 4 4IbHt 4J E J OUTPUT SHAFT BEAR NG REPLACEMENT Turn the inner race of the bearing 11 with...

Page 271: ...stall the two dowel pins 1 and oil joint pipe 12 Coat a new O ring 3 with engine oil and install it onlo the oil joint pipe Install the thrust washers 4J onto the countershaft and reverse stopper shaf...

Page 272: ...lith SHe 100 EXXON Coal a new O ring 12 with engine oil and install it onto the pulley bolt nanga Apply engine oil to the threads and sealing surface of the pulley boll 3 Install the driven pulley 4 w...

Page 273: ...Hold the flywheel using the special 1001111 and remove the flywheel bolt 121 and collar 3J TOOL Flywheel holder 07725 0040001 ALTERNATOR STARTER CLUTCH Hold the f1 heel 1 Jand remove it from the crank...

Page 274: ...he flywheel with the special tool 11 and remove 11 the starter clutch bolts T40 2 TOOL Flywheel holder 07725 0040001 Remove the starter clutch assembly from the flywheel 121 INSPECTION Check the start...

Page 275: ...clutch 1J with engine oil and install it into the clutch outer 2J with the flange facing the flywheel side Inslalithe starter clutch onto the flywheel Apply locking agent to the threads of the starter...

Page 276: ...apered portions of the crankshaft and flywheel Apply engine oil to the starter driven gear boss inner surface Instalilhe flywheel ttl aligning the key way with the key on the crankshaft u S A type App...

Page 277: ...secure it with the bolt Hold the driven pulley using the special tool and tighten the bolt TOOL 3 Recoil pulley holder 07SMB HM70100 TORQUE 108 N m 11 0 kgf m 80 IbHt loosen the pulley bolt Remove the...

Page 278: ...ts loosely in the cover Remove the bearing using the special tools TOOLS Bearing remover shaft 10 mm Bearing remover head 10 mm Remover weight U S A TOOLS Bearing remover 10 mm Remover weight Apply en...

Page 279: ...ISSION CRANKSHAFT BALANCER SYSTEM COMPONENTS 14 2 TRANSMISSION 14 8 SERVICE INFORMATION 14 3 CRANKSHAFT BALANCER 14 15 TROUBLESHOOTING 14 6 CRANKCASE BEARING 14 18 CRANKCASE SEPARATION 14 7 CRANKCASE...

Page 280: ...CRANKCASEITRANSMISSION CRANKSHAFT BALANCER SYSTEM COMPONENTS 14 2...

Page 281: ...1 0 7868 19 94 0 785 C2 27 984 28 005 1 1017 1 1026 27 94 1 100 C1 C4 CR 27 979 28 000 1 1015 1 1024 27 93 1 100 M3 0 020 0 062 0 0008 0 0024 0 10 0 004t _ 1 M5 0 016 0 055 0 0006 0 0022 0 10 f Q4 C2...

Page 282: ...07936 3710200 Attachment 32 x 35 mm 07746 0010100 IU S A ______ U S A o n y Attachment 37 x 40 mm Attachment 42 x 47 mm Attachment 62 x 68 mm 07746 0010200 07746 0010300 07746 0010500 Attachment 72 x...

Page 283: ...0B U S A only 07936 3710100 Bearing remover 17 mrn 07936 3710300 Bearing remover head 15 mm 07936 KC10200 Bearing remover 20 mm 07936 3710600 J I BeaMng mo shaft 15 mm TQ7936 KC10100 Beanng o e m o eO...

Page 284: ...Worn balancer bearing Improper balancer installation Transmission Jumps out of gear Worn gear dogs or dog holes Worn shift drum guide groove Worn shift fork guide pin Worn gear shifter groove Worn sh...

Page 285: ...assembly 11 output shaft drive gear 2J driven gear 3J and output shaft 4 two front crankcase bolts 1 Loosenthe fifteen rear crankcase bolls 1 crankcase bolts in a cnssClOSS pattem in several steps Do...

Page 286: ...tely Before installing the strainer the screen mesh should be examined closely for damage Install the strainer and plate with the wedge facing the crankcase TRANSMISSION DISASSEMBLY Separate the crank...

Page 287: ...bnormal wear or r 1 c 31 c I c I damage Check the gear dogs 21 dog slots 3 and teeth for abnormal wear or damage Measure the 1 0 of each gear SERVICE LIMITS M3 25 05 mm 0 986 in M5 20 05 mm 0 789 in C...

Page 288: ...e SERVICE LIMIT 0 10 mm 0 004 in OUTPUT SHAFT GEAR Check the output shaft drive gear 1 driven gear 2 teeth and each gear output shaft 3 splines for abnormal wear or damage SHIFT FORK SHAFT Check the s...

Page 289: ...ring with the chamfered rolled edge facing away from the thruslload Install the snap ring 111 so its ends aligns With the grooves in the splines Make sure the snap ring is fully seated in the shaft g...

Page 290: ...T WASHER M5 GEAR 33T M2IMR GEAR 18T SPECIAL WASHER MAINSHAFT M5 BUSHING r THRUST WASHER M3 GEAR 23T SNAP RING M4 GEAR 28T SPLINE WASHER M4 GEAR 28T M3 GEAR 23T 78 Gear and bushing sliding surfaces SPL...

Page 291: ...SHE R C3 GEAR 37T 11 CR GEAR 48T C2 GEAR 43T CRANKCASEITRANSMISSION CRANKSHAFT BALANCER CR GEAR 48T C1 GEAR SST C 1 GEAR SST C4 GEAR 33T SPLINE COLLAR C4 GEAR 33T l C3 GEAR 37T C5 28T Gear and bushing...

Page 292: ...on the crank weights so Ihalthey do not interfere with the mainshaft 1 Inslall the mainshaft counlershafl 2 and washer 3 assemblies as a set into the rear crankcase Apply molybdenum oil solution to th...

Page 293: ...CRANKSHAFT BALANCER REMOVAL Separate the crankcase halves page 14 7 Remove the transmission page 14 8 Be careful not to Remove the crankshaft 1 and balancer 2J from the damage the feaf crankcase using...

Page 294: ...eeler gauge SERVICE LIMIT 0 8 mm 0 03 in Measure Ihe radial clearance at the connecting rod big end in an X and Y directions SERVICE LIMIT 0 05 mm 0 002 in INSTALLAT ON Apply engine oil to a new rear...

Page 295: ...pecial tools onto the crankshaft and crankshaft and crankshaft bearing balan r do not fall out of he TOOLS crankcase when 1 Assembly collar installing the 2J Puller shaft and nut speclalloo s 07965 VM...

Page 296: ...NT Remove the balancer bearing 11 and counlershaft 14 18 bearing 21 with the special tools TOOLS Countershaft bearing 3J Remover handle 4 Bearing remover 20 mm 5 Remover weight Balancer bearing Remove...

Page 297: ...20 mm Output shaft bearing 1 Driver 21 Attachment 42 47 mm 3 Pilot 22 mm Shift drum bearing 1 Driver 2 Attachment 42 x 47 mm 3 Pilot 35 mm 07749 0010000 07GAD SD40101 07746 0040900 07749 0010000 0774...

Page 298: ...A TOOLS Bearing remover 15 mm Remover weight 07936 KC10500 07936 3710200 or 07936 371020A Drive the countershaft bearing 6 and balancer bearing 7 out of the rear crankcase Apply engine oil to new bea...

Page 299: ...pply liquid sealant TB1215 or equivalent to the J mating surface shadowed area of the front crankcase I as shown 1 Install the thcee dowel pin 111to the ceac ccankc e I Make sure all the parts are ins...

Page 300: ...drive and driven gears 2 Apply engine oil to the journal surfaces of the reverse stopper shaft 13 Install the reverse stopper shaft assembly into the crankcase as shown Install the following fl heel...

Page 301: ...15 ENGINE REMOVAUINSTALLATION SYSTEM COMPONENTS 15 2 ENGINE REMOVAL 15 4 SERVICE INFORMATION 15 3 ENGINE INSTALLATION 15 9 15 1...

Page 302: ...ENGINE REMOVAUINSTALLATION SYSTEM COMPONENTS FE model shown 44 N m 4 5 kgf m 32Ibf ft 44 N m 4 5 kgf m 32 IbHt 54 N m 55 kgfm 40 Ibf tt 32 N m 3 3 kgf m 24 Ibf ft 1 15 2...

Page 303: ...kg 113 3Ibs Canada 52_ 5 kg 115 7 Ibs U S A 523kg 11S 3 Ibs Canada 53 4 kg 117 7Ibs Engine oil capacity After draining 2 ghlers 3 1 US qt 2 6 Imp ql After draining filter change 3 0 liters 3 2 US qt...

Page 304: ...nly Remove the pinch bolt 1 and the gearshift pedal 12 Disconnect the following VS sensor 3P Black connector 1 FElFPE only shift angle sensor 3P Gray connector 21 sub wire harness from the clamp 3 wir...

Page 305: ...le selector cable 3 from the cable holder 14 of the engine spark plug cap 11 bolts 2J and ignition ooillbrackel 3 water hose 4 water hose 1 shift control motor connector 2 FElFPE only ENGINE REMOVAUIN...

Page 306: ...g 61 joint pin final gear case mounting nuts 11 and bolts 12 two bolts 31 and mounting bracket 4 Move the gear case assembly 11 forward for maximum clearance between the propener shaft joint and engin...

Page 307: ...of the gear case assembly Pull the propeller shaft 4 to force the stopper ring 5 past the groove in the pinion joint to remove the propeller shaft Remove the stopper ring from the propeller shaft Remo...

Page 308: ...e frame and engine 15 8 Remove the following from each engine lower mount engine hanger nut 1 and bolt 2 spacer 3 mounting rubbers 4 Move the engine forward and disconnect the output shaft 1 from the...

Page 309: ...ON 2 1 3 3 Hold the engine securely and be careful not to damage the frame and engine P Place the engine in the frame from the left side and 7 ____iiiiiiii support it with suitable wooden blocks Coat...

Page 310: ...d seal them tighten the fasteners to the specified torque in order as follows left and right lower engine hanger nuts TORQUE 54 N m 5 5 kgf m 40 Ibf ft engine side upper engine hanger bolts TORQUE 32...

Page 311: ...d end 5 Engage the shaft joint over the output shaft and move the gear case assembly rearward Align the rear mounting bolt holes in the gear case 1 and frame then install the mounting bolt 2 from the...

Page 312: ...properly Install the retaining plate 8 onto Ihe cable with the concave side facing the cable holder to secure the cable Inslalilhe water hose 1 Connect the shift control molor connector 2 FElFPE only...

Page 313: ...e sensor 3P Gray connector 2 VS sensor 3P Black connector 3 FMlFPM only Install the gearshift pedal 1 so thai the bottom surface of the pedal joint 21 is parallel with the frame pipe 3 FM FPM models I...

Page 314: ...MEMO...

Page 315: ...NUCKLE 16 16 SERVICE INFORMATION 16 4 SUSPENSION ARM 16 23 TROUBLESHOOTING 16 7 FRONT SHOCK ABSORBER 16 26 HANDLEBAR 16 8 STEERING SHAFT FM FE models 16 27 THROTTLE HOUSING 16 11 STEERING SHAFT EPS UN...

Page 316: ...del shown 54 N m 55 kgf m __ 401bHt 108 N m kgf m 80 Ibf ftl 78 N m 8 0 kgf m 58lbHt 16 2 39 N m 4 0 kgf m 291bHt 39 N m 4 0 kgf m 29Ibf ft 1 i 34 N m 3 5 kgl m 251bHt 11 Nm 1 1 kgf m BlbHt 29 N m 3 0...

Page 317: ...0 N m 6 1 kgf m 44 IbHt 108 N m 11 0 kg m 80 Ibf ft 78 N m B Okgf m 58lbf tt 1 I FRONT WHEEUSUSPENSIONISTEERING 39 N m kgf m 29 IbHt 39 N m 4 0 291bHt 64 N m 6 5 kgf m 47Ibf ft 22 N m 2 2 kgfrn 161bHt...

Page 318: ...tion page 18 2 For each sWitch inspection see LightslMeterslSwitches section handlebar switch page 22 11 front brake sWitch page 22 12 rear brake light sWitch page 22 13 FPMfFPE model only Perform the...

Page 319: ...er mounting bolt 2 I 32 3 3 24 _ _ _ _ 8 __ 0 r 64 6 5 47 _ _ 2 16 78 8 0 58 Castle nut tighten to the specified torque and further lighten until its grooves align with Ihe cotter pin _ hOIe 8 8 331 A...

Page 320: ...0900 Attachment 20 mm I O OP ilo t 2 m O m m 07746 0020400 07746 0040500 Pilot 22 rnm I cOriver 07746 0041000 07749 0010000 r Phljlo t 30mm 07746 0040700 I Attachment 28 x 30 m m I 07946 1870100 rFork...

Page 321: ...Incorrect wheel alignment Unequal Ure pressure Ben tle rod suspension arm or frame Worn or damaged knuckle bearing or wheel hub beanng Weak shock absorber Front wheel wobbling Benl rim Worn or damage...

Page 322: ...rs 3 meter cover stay 4J Remove the two screws 1J throttle housing holder 2 and throttle housing 13 Disconnect the connectors 4 Keep the mas ar Remove Ihe two bolls 151 master cylinder holder 6 and cy...

Page 323: ...ten the front bolls first then tighten the rear botts Apply Honda Bond A or Pro Honda Handgrip Cement r 1 a J U S A onty to the inside surface of each handlebar I grip 1J and to the ctean surfaces of...

Page 324: ...RQUE 4 2 N m 0 4 kgf m 3 1Ibf ft Instalilhe brake lever bracket 1 and holder 2 with the punch mark 3 facing up Tighten the upper screw first then tighten the lower screw to the specified torque TORQUE...

Page 325: ...specified torque TORQUE 32 N m 3 3 kgf m 24 Ibfoft Secure the wires with the two wire bands 3 Connect the 21P connector 4 to the combination meter Install the meter cover 1 and tighten the screw 12 I...

Page 326: ...ottle lever pivot in the housing and to the throttle cable end Connect the cable 2 to the throttle arm 3 Insert the throttle lever 4 with the plastic washer 5 into the housing Install the throttle arm...

Page 327: ...hanger or equivalent to remove the tire from the rim If a tire changer is not available rim protectors and tire irons may be used Adjust the bottom rim supports 1 to the proper rim size Align the flat...

Page 328: ...oe 2 is still engaged turn the wheel as far as it will go between strokes as you break the bead around Ihe rim Remove Ihe breaker arm assembly and flip Ihe wheel over Inslall the breaker arm assembly...

Page 329: ...e repair to dry Drying lime will vary with air temperature Refer to the tire repair kit manufacturer s recommendations Inflate the tire and test the seal by dabbing a small amount of cement around the...

Page 330: ...nflate the tire to seat the lire bead Deflate the tire Wail 1 hour and inflate the lire to the specified pressure RECOMMENDED TIRE PRESSURE Front Standard 30 kPa 0 30 kgflcm2 4 4 psi With cargo 30 kPa...

Page 331: ...ul 2 wheel hub 3 three socket bolts 1J splash guard 2 coller pin 1 J from the lie rod ball joint stud ball jOint nul 2 by holding the joint stud nat surfaces 3 tie rod 4 cotter pins 1 Loosen the ball...

Page 332: ...turning the pressure boll penetf1ltmg type lubricant 0 loosen the bal pnt 16 18 To prevenllhe tool from dropping tie the strap 1 on a neighboring solid part such as the suspension arm tie rod etc bef...

Page 333: ...r cracks Inspect the ball jOint boot 4 for tears or other damage by moving the ball joint stud It should move freely and smoothly BRAKE DISC REPLACEMENT Remove the four disc bolts 1 and brake disc 21...

Page 334: ...tachment 52 x 55 mm 51 Pilot 30 mm 07749 0010000 07746 0010400 07746 040700 Inslall the snap ring into the knuckle groove with the chamfered side facing in Apply grease to the lips of new inner dust s...

Page 335: ...07946 1870100 Set the knuckle 1 and special tools with 8 mark 2 side of the removerlinstaller facing to the ball joint 3 in the vise as shown Press the ball joint into the knuckle until it is fully se...

Page 336: ...nstall new cotter pins 4 Inslall the tie rod 1 Jinto the knuckle with a new joint nul 2i Tighten the nut to the specified torque by holding the joinl stud flat surfaces 3 TORQUE 54 N m 5 5 kgf m 40 Ib...

Page 337: ...ke caliper 1 with new mounting bolls 2 and lighten them to Ihe specified torque TORQUE 30 N m 3 1 kgf m 22 Ibf ft Install the outboard guard 3 and lighten the bolts 4 Install the hose clamps 1 with ne...

Page 338: ...pivot bushings 1 for wear or damage Ir I1i 1 foi l Inspect the ball joint boot 2 on the upper arm 3J for I 16 24 lears or other damage by moving the ball joint stud 4 It should move freely and smoothl...

Page 339: ...to the upper arm until it is fully seated TOOLS 4 Ball joint remover installer 07WMF HN00100 5 Attachment 20 mm I D 07746 0020400 I NOTICE I If you feel strong resistance when lowering the press stop...

Page 340: ...nuts 3 and loosely lighten them Install the knuckle and wheel hub page 16 22 Install the front wheel page 16 13 Place the vehicle on level ground and tighten the lower arm pivot nuts to the specified...

Page 341: ...ecified torque TORQUE 39 N m 4 0 kgf m 29 IbHt STEERING SHAFT FM FE models REMOVAL Remove the following mudguards page 2 6 front fender carrier page 2 8 front wheels page 16 13 meier cover stay page 1...

Page 342: ...per guide IS master cylinder two nuts and washers 6 reservoir upright handlebar assembly 7 from the steering shaft brake hose 1 from the clamp 2 connector clip 31 cables 4J and wires 5J from the lower...

Page 343: ...SHAFT Check the steering shaft for distortion or damage STEERING SHAFT BEARING Turn the mner race of the sleermg shaft bearing with your finger The bearing should turn smoothly and quietly Also check...

Page 344: ...ked side facing up TOOLS 1 Driver 2 AHachment 42 x 47 mm 3 Pilot 22 mm 07949 3710001 07746 0010300 07746 0041000 Make sure lhe snap Install the snap ring into the groove properly with the nng Is firml...

Page 345: ...nstall the tie rods 5 into the steering arm Install new joint nuts 61 and tighten them to the specified torque by holding the joint stud flat surfaces TORQUE 54 N m 5 5 kgf m 40 Ibf ft Install new col...

Page 346: ...djusting nut 4 cable retaining plate 5 2WD 4WD selector cable 6 remove from the cable holder 7 and joint pin 8 cable spring 9J jOint pin Release the wire clip 1 Remove the following connectors from th...

Page 347: ...her 5 sleering arm 6 Suppor1the hose clamp bolt 1 handlebar securely wire band 2 while keeping the cables 3 and wires 4 from the upper guide 5 master cylinder two nuts and washers 6 reservoir upright...

Page 348: ...the EPS unit Remove the following securely and steering shaft 3 maneuver it auto shaft bushing 41 the frame to the left mounting nuts and bolts 2 side being careful EPS unit 51 nor to damage lhe shaf...

Page 349: ...each shaft 11 of the EPS unit for wear or damage STEERING SHAFT BEARING Turn the inner race of the steering shaft bearing with your finger The bearing should turn smoothly and quietly Also check that...

Page 350: ...100 1 41 1 51__ 1 6 1 cf __ 11I 3 Drive a new bearing into the frame with the marked side facing up TOOLS 1J Driver 21 Attachment 42 x 47 mm 3 Pilot 20 mm 01949 3710001 07746 0010300 07746 0040500 Mak...

Page 351: ...the bearing Install the mounting bolts 2 from the right side and Ihe nuts 3 but do not lighten them yet Apply molybdenum disulfide grease to the splines Inslall the steering arm 1 with Ihe marked side...

Page 352: ...olt 5 Install the steering shaft holder 1 with the guide 2 facing down while routing the wires and cables into the guide Install the two holder bolts 3 Install the brake hose 4 into the clamp 5 Instal...

Page 353: ...Tighten the nuls Install the wires 3 and cables 4 into the guide 151 Secure the wires to the guide with the wire band 61 Install the hose clamp 71 with a new clamp bolt 8J and lighten it to the speci...

Page 354: ...cable Adjust the 2WQ 4WD selector cable page 3 19 InstaU the following meier cover stay page 16 9 front wheels page 16 13 front fender carrier page 2 8 mudguard page 2 6 Referto Service Perform the t...

Page 355: ...ll the right hand threads nul and unmarked ball joint on the flat wrench holding area for loe adjustment side 2 of the lie rod and the lefl hand threads nut and L marked 3 ball joint on the opposite s...

Page 356: ...rod toward the knuckle 3 Install new joint nuts 4 and lighten them to the specified torque by holding the joint stud flat surfaces 15J TORQUE 54 N m 5 5 kgf m 40 IbHt Install new cotter pins 6 Instal...

Page 357: ...17 REAR WHEEUSUSPENSION SYSTEM COMPONENTS 17 2 SERVICE INFORMATION 17 3 TROUBLESHOOTING 17 5 REAR WHEEL 17 6 REAR SHOCK ABSORBER 17 6 SWINGARM 17 8 17 1...

Page 358: ...REAR WHEEUSUSPENSION SYSTEM COMPONENTS 39 N m 4 0 kgf m 29Ibf ft 64 N m 6 5 kgf m 47 IbUt 39 N m 4 0 kgf m 29Ibf ft 118 N m 12 0 kgf m 87Ibf ft 17 2...

Page 359: ...driving mechanism service see Rear Driving Mechanism section page 20 2 SPECIFICATIONS ITEM r STANDARD E standard 30 kPa 0 30 kgf cm2 4 4 psi 30 kPa O 30 kgf cm1 4 4 psi With cargo TORQUE VALUES ITEM Q...

Page 360: ...SPENSION TOOLS Attachment 24 x 26 mm 07746 0010700 Pilot 25 mm 07746 0040600 Driver 07949 3710001 17 4 Pilol 12 mm 07746 0040200 Driver 07749 0010000 B Pilot 20 mm 07746 0040500 Attachment 28 30 mm 07...

Page 361: ...ed swingarm pivot bearing Rear suspension noise Faulty rear shock absorber Loose rear suspension fasteners Worn rear suspension pivot bearings or bushings Steering is heavy Steering shaft nut or holde...

Page 362: ...rchange Install the rear wheel with the tire valve facing out and the left and right the arrow mark 2 facing in the normal rotating wheels direction Install the wheel nuts with the tapered side facing...

Page 363: ...ry Remove the lower pivot collar 3 REAR WHEEL SUSPENSION Check the lower pivot bushing 1 and collar 2 for wear or damage INSTALLATION Inslall new dust seals 1 into the lower pivot with the flat side f...

Page 364: ...gf m 29 Ibf tt Lower 39 N m 4 0 kgf m 29 IbHt Ins18llll le skid plate page 3 18 SWINGARM REMOVAL Remove the mudguards page 2 6 Remove the final gear assembly page 20 9 Remove the following breather ho...

Page 365: ...bearing Press the needle bearing into the right pivot until the wilhthemarked depth from the Quter surface is 7 0 7 5 mm 0 28 side facing up 0 30 in TOOLS 1 Driver 2 Attachment 24 x 26 mm 3 Pilot 20...

Page 366: ...universal joint guard 2 with new bolts 3 and tighten them to the specified torque TORQUE 10 N m 1 0 kgf m 7 IbHt l 1 mm 4 places Right side Left side f 21 11 111 Insert the bolts from Install the swi...

Page 367: ...NENTS 18 2 BRAKE PAD DISC 18 8 SERVICE INFORMATION 18 4 FRONT MASTER CYLINDER 18 10 TROUBLESHOOTlNG 18 6 FRONT BRAKE CALlPER 18 12 BRAKE FLUID REPLACEMENT AIR REAR BRAKE DRUM SHOES 18 16 BLEEDING 18 7...

Page 368: ...SYSTEM SYSTEM COMPONENTS 12 N m 1 2 kgf m 9lbHt 2 0 N m 0 2 kgf m 1 5IbHt I 34 N m 3 5 kgf m 251bHt v 2 4 N m 0 2 kgf m 1 8 IbHt 17 N m 1 7 kgf m 13 IbHt 34 N m 3 5 kgf m 251bHt 30 N m 3 1 kgf m 221bH...

Page 369: ...BRAKE SYSTEM 20 N m 2 0 kgf m 1SlbHt 137 N m 14 0 101 Ibf ft 18 3...

Page 370: ...reservoir cap make sure the front reservoir is horizontal first A contaminated brake disc pad drum or shoe reduces stopping power Discard contaminated pads or shoes and clean a contaminated disc or d...

Page 371: ..._ O 2 4 0 2 1 8 6 1 0 0 1 0 7 __ 6 5 9 0 6 4 4 4 1 2 0 1 0 9 Apply locking agent to O TY 3 2 2 4 4 1 1 1 REMARKS the threads 2 4 6 12 1 2 9 I 8 30 3T22 ALOe boil replace with a newone 2 8 22 2 2 16 A...

Page 372: ...Slicking worn master cylinder piston Bent brake lever Brake lever hard Clogged restricted brake system Slicking wom caliper piston Slickinglwom master cylinder piston Caliper nol sliding properly Bent...

Page 373: ...the other side bleed valve BRAKE FLUID FILLING BLEEDING Close each brake caliper bleed valve Fill the master cylinder reservoir with DOT 4 brake fluid from a sealed container Connect a commercially a...

Page 374: ...ghten the bleed valve to the specified torque TORQUE 5 4 N m 0 6 kgf m 4 0 IbHt Perform air bleeding for the other side bleed valve After bleeding air operate the front brake lever If it still feels s...

Page 375: ...ins 3 to the specified torque TORQUE 17 N m 1 7 kgf m 13 IbHt Install the pad pin plugs and tighten them to the specified torque TORQUE 2 4 N m 0 2 kgf m 1 8 IbHt Squeeze the front brake lever to seat...

Page 376: ...7 Remove the dust cover 1 and disconnect the connectors 21 from the switches Disconnect the brake hose by emoving the oil boll 3 and sealing washers 14 Remove the two bolts 5 holder 61 and master cyli...

Page 377: ...5 mm 0 5490 in INSTALLATION Instalilhe brake master cylinder 1 and holder 2 with __ _ the UP mark facing up Tighten the upper bolt f3J first then lighten the lower bolt 4 to the speCified torque TORQU...

Page 378: ...J loosen the slide pin 3 Remove Ihe brake pads page 18 8 Remove the following caliper brackel11 loosen the slide pin spring washer 2 pad spring 3 slide pin 4 by releasing the boot rib from the pin gro...

Page 379: ...der and piston for scoring scratches or damage Measure the caliper cylinder 1 0 SERVICE LIMIT 32 090 mm 1 2634 in Measure the caliper piston 0 0 SERVICE LIMIT 31 94 mm 1 257 in ASSEMBLY iiSioI 1m CALI...

Page 380: ...o the caliper body with the open side toward the brake pad Cover the piston with the boot carefully then push the piston and sel the outside boot rib into the boot groove in the piston to seallhe pist...

Page 381: ...es in the slide and bracket pins properly f B a k e t InslaUthe brake pads page 18 9 SideJ 2 Tighten the slide pin 1 10 the specified torque TORQUE 22 N m 2 2 kgfm 16Ibf ft Rest the brake hose joint o...

Page 382: ...M REMOVAL 18 16 Remove the right rear wheel page 17 6 Remove the following coUerpin 1 hub nut 2 wheel hub 3 six bolts 111 drum cover 2J dust seal 3 Q ring lJ brake drum 2 INSPECTION Measure the brake...

Page 383: ...s 4 brake panel drain bolt 5J and washer 61 nut and bolt lJ brake arm 2 wear indicator 3 return spring 4 brake cam 5 felt seal dust seat ASSEMBLY Apply grease to the lips of a new dust seal 1 and inst...

Page 384: ...1 into the cable holders on the brake panel upper holder for lever brake cable and lower holder for pedal brake cable InslaUthe cable springs 2 onto the cables and the jOint pins 3 Inlo the brake arm...

Page 385: ...h 3 4 9 of grease 2J Install the dust seal into the drum cover so thai it is flush with the cover surface TOOL 2J Driver 3J Attachment 72 x 75 mm 4J Oil seal driver 07749 0010000 07746 0010600 070MF M...

Page 386: ...MOVAL 18 20 Remove the right mudguard page 2 6 Disconnect the pedal brake cable from the brake arm page 18 17 Remove the following switch spring 1 return spring 2 brake cable 3 from the cable holder 4...

Page 387: ...1 and cable holder 3 Install the return spring 41 and switch spring 51 in the direction as shown Connect the brake cable to the brake arm page 18 18 Adjust the brake pedal freeplay page 3 22 Install t...

Page 388: ...MEMO...

Page 389: ...CE INFORMATION 19 3 FRONT FINAL GEAR DISASSEMBLYI INSPECTION 19 22 TROUBLESHOOTlNG 19 6 GEAR CASE BEARING FRONT DRIVE SHAFT 19 7 REPLACEMENT 19 30 FRONT FINAL DRIVE REMOVAL 19 12 FRONT FINAL GEAR ASSE...

Page 390: ...FRONT DRIVING MECHANISM SYSTEM COMPONENTS 19 2 1 44 N m 4 5 kgf m 32 Ibf ft 44 N m 4 5 kgf m 321bHt 10 N m kgf m 7Ibf ft...

Page 391: ...e shaft parts SPECIFICATIONS Front final drive ITEM Oil capacity After draining After disassembly Recommended oil I Gear backlash Backlash diffe e n c e Slip torque c Unit mm in STANDARD SERVICE LIMIT...

Page 392: ...r 070MF HPSA100 U S A only Attachment 22 x 24 mm 07746 0010800 Remover weight 07741 0010201 or 07936 371 020A or 07936 3710200 1 U S A only Attachment 30 mm 1 0 07746 0030300 P i 2 m mo r P i O I 5 m...

Page 393: ...07936 37101 00 Remover head 12 mm 07936 1660110 Remover shaft 15 mm 07936 KCl 01 00 h B e a ri ng c re m o e r S m m Altachment 45 x50 mm 07936 KC10500 U SA only 07946 6920100 Remover shaft 12 mm 0793...

Page 394: ...ntaminating gear oil Chipped or damaged gears Improper tooth contact between ring gear and pinion gear Gear noises while coasting Chipped or damaged gears Abnormal noises when turning Worn or damaged...

Page 395: ...heck the drive shaft joints 2 for excessive play or noise by moving the joints in a CIrcular direction If the outboard joint seems to be worn or damaged the drive shaft must be replaced NOTE To replac...

Page 396: ...12 snap ring 1 bearing 2 inboard boot 3J boot band A 4 Replace these Check the following for wear or damage components as an bearing cage 1 19 8 assembly race 2 steel balls 3 inboard joint 4 Remove t...

Page 397: ...AFT BOOT BAND tI j INBOARD BOOT OUTBOARD BOOT BANDA It 1Ip OUTBOARD BOOT ____ BAND The outboard boot 1 is larger than the inboard boot 2 Do not interchange them 2 11 Nole the installation direction of...

Page 398: ...g 1 with the small 0 0 facing the _ drive shatto Install the snap ring 21 with the chamfered side facing the bearing Pack the inboard joint 111 with 40 60 9 of specified grease SPECIFIED GREASE NKG205...

Page 399: ...wn the band end and secure it with the lock labs 3J Tap the lock tabs with a plastic hammer INSTALLATION Install a new stopper ring 1 into the groove In the inboard joint spline B6 careful not 10 Inst...

Page 400: ...e following from the final gear case breather hose 1 select switch connector 2J disconnect it and remove its wire from the guide 3 and clamp 4 cover boll 1 clutch arm cover 2 by releasing the two tabs...

Page 401: ...n the gear case to avoid scratch or damage the lie rod end 2 Puilihe shaft joint 1 oul of the output shaft 2 of Ihe engine Remove the boot band 3 and release the propeller shaft boot 4 off the pinion...

Page 402: ...r ring gear bearing and or clutch components may be damaged or faulty They must be checked after disassembly replace them if necessary Operate the change over mechanism while turning the pinion joint...

Page 403: ...stall the boot bands into the each boot groove Install the jOint spring 31 into the propeller shaft securely Apply 5 8 9 of molybdenum disulfide grease to the propeller shaft joint splines Set the sha...

Page 404: ...sleeve 5 clutch sleeve O ring 6 dowel pins 7 Check the splines of the pinion joint 8 dutch sleeve and pinion gear shaft gl for wear or damage Check the needle bearing 10J in the pinion gear shaft for...

Page 405: ...fork craws for wear or damage Check the arm shaft and stopper plale for deformation or damage Check the each spring for fatigue or damage PINION JOINT BALL BEARING REPLACEMENT Remove the snap ring 1 a...

Page 406: ...IIIIIIIIIIIIIIIIII with the chamfered edge facing the bearing Pack the seal lips of a new oil seal 2 with grease Install the oil seal so thaI its rubber area flush wilh the housing end Hold the bearin...

Page 407: ...M 10 N m 1 0 kgf m LOCK qJ SHAFT 7lbHt SPRING COLLAR O RING urn Coat a new O ring 1 with grease and install it into the urn clutch arm shaft groove Apply grease to the clutch arm shaft outer surface I...

Page 408: ...come off the coI af during assembly Install the shift fork 1J and align the groove with the end of the lock spring 2 While hOldmg the Instalilhe stopper plate 1 by aligning the flat surfaces IIIIIIIII...

Page 409: ...e fork bolt to the specified torque TORQUE 10 N m 1 0 kgf m 7Ibf ft Turn the clutch arm shaft 1 and set the ends of the clutch spring 2J onto the housing groove 3 and the reverse side of the stopper p...

Page 410: ...e 19 16 BACKLASH INSPECTION Sel the final gear case into a jig or vise with soft jaws Remove the oil filler cap Cover the clutch Hold the pinion gear 1 Jwith the special 10015 housing mating s Jrface...

Page 411: ...If the backlash is too small replace the ring gear left side shim with a thicker one The backlash is changed by about 0 06 mm 0 002 in when the thickness of the shim is changed by 0 10 mm 0 004 in NO...

Page 412: ...case cover with your finger The bearings should tUfn smoothly and quietly Also check that the bearing outer race fits tightly in the case or cover GEAR TOOTH CONTACT PATTERN CHECK Apply thin coal of...

Page 413: ...e is transferred 10 the approxImate center of each tooth but slightly to the heel side and to the flank side If the patterns are not correct remove and change the pinion shim with one of an alternate...

Page 414: ...LIMIT 12 N m 1 2 kgf m 9lbHt L _____ _____J If the slip torque is out of specification disassemble the differential and perform Ihe components inspection page 19 27 since Ihe differential may be faull...

Page 415: ...discoloration Measure the depth of the ring gear from the mating surface as shown SERVICE LIMIT 6 55 mm 0 258 In DIFFERENTIAL HOUSING FACE CAM CAM FOLLOWER If the djfferential Check the sliding surfa...

Page 416: ...ying a load of 1 47 kN 150 kgf to the face cam boss using a hydraulic press SERVICE LIMIT 3 3 mm 0 13 in If the height is less than the limit replace the differential as an assembly SIDE CONE SPRING C...

Page 417: ...nut Threaded adaptor 07HMC MM8011A 07931 ME4010B 07931 HB3020A 070MF HP5A100 Pull the pinion assembly 151 out from the gear case PINION BALL BEARING AND SHIM REPLACEMENT Protect the shaft Pull the bea...

Page 418: ...t 12 mm Bearing remover 12 mm 2 I USlfIg a torch to heallhe gear may cause warpage Remover weight 07936 1660110 07936 1660120 or 07936 166010A U S A only with 07936 3710100 07741 0010201 or 07936 3710...

Page 419: ...access hole 2J Strike genlly near the end of the ring with a punch to bend the end upward Grasp the end of the ring with needle nose pliers and pull the stopper ring out through the access hole Remove...

Page 420: ...nd tool assembly into a freezer for al leasl 30 minutes Heat the gear case to ao c 176 F Remove Ihe bearing and tool assembly from the freezer and drive Ihe bearing into Ihe gear case using the specia...

Page 421: ...RING 30x56x 13 DIFFERENTIAL 4WO SELECT SWITCH BEARING 6006 12 N m 1 2kgf m 9lbHt SEALING WASHER fI PINION BALL SLEEVE 98 N m 10 0 kgf m 72lbftt FINAL CLUTCH HOUSING DOVVELPINS 25 N m 2 5 kgf m 181bOt...

Page 422: ...face cam into the differential housing out of he Install six cam followers A rib 1J and six followers B differential housing flat 2 into the specified grooves in the housing 3 by two and two as shown...

Page 423: ...ring gear side Inslalilhe ring gear 3 I Install new ring gear bolls 11 and screw them until the seating surfaces of all the bolts touches the housing but do not lighten them yet Temporarily install th...

Page 424: ...r only light lightening 19 36 Install the proper ring gear shims 1 onto the differential _ _ o assembly 21 o 1 lmDI Install the differential assembly into the gear case 131 4 Coat a new O ring 4 with...

Page 425: ...he front side boot 4 Make sure Ihe seal lip is not turned outside in Apply molybdenum disulfide grease to the front end of the propeller shaft Apply 5 8 9 of molybdenum disulfide grease to the splines...

Page 426: ...output shaft and move the gear case assembly rearward Align the rear mounting bolt holes in the gear case and frame then instalilhe mounting boll 1 from the right side and a new mounting nut 2 Install...

Page 427: ...utch arm with the joint pin 41 and adjusting nut 5 Set the groove in the cable grommet 6 onto the cover base end properly_ Install the retaining plate 7 onto the cable with the concave facing the cabl...

Page 428: ...MEMO...

Page 429: ...DISASSEMBLYI INSPECTION 20 12 SERVICE INFORMATION 20 3 GEAR CASE BEARING TROUBLESHOOTING 20 6 REPLACEMENT 20 17 REAR AXLE REMOVAL 20 7 REAR FINAL GEAR ASSEMBLY 20 19 REAR FINAL DRIVE REMOVAL 20 9 REAR...

Page 430: ...COMPONENTS 137 N m 14 0 kgl m 1011bHt 47 N m 4 8 kgf m 351bHt 39 N m 4 0 kgf m 291bHI 34 N m 3 5 kgf m 25Ibf ft 47 N m 4 8 kgf m 35 Ibf ft 20 2 j Ii I 0 I 32 N m 3 3 kgf m 24 IbUt 52 N m S 3 kgf m 381...

Page 431: ...D 75 cm 2 5 US oz 2 6 Imp oz 100 cm3 3 4 US oz 3 5 Imp oz Honda shaft drive oil or equivalent ___ j hi2YPOid gear oil SAE II 80 Gea l backlash 0 05 0 25 0 002 0 010 Backlash difference 0 4 0 02 0 2 0...

Page 432: ...371020A or 07936 3710200 U S A only Attachment 62 x 68 mm 07746 0010500 Attachment 42 x 47 mm 07746 0010300 Attachment 24 x 26 mrn 07746 0010700 I cA a ch m t 3 5 m m t O h pi1o o 15 m m Dp oOi 3 5 m...

Page 433: ...shaft and nul 07931 ME40000 Remover shaft 15 mm l R e m o OC v e Oih e aO d SfCm m 07936 KC10100 07936 KC10200 Bearing remover 15 mm 07936 KC10500 U S A only t Attachm e n t nD riv e Pinion puller bas...

Page 434: ...inion gear and propener shaft splines Worn or damaged bearing Worn pinion and ring gears Excessive backlash between pinion and ring gears 0 1 1level too low Wobble or vibration in vehicle Axle not tig...

Page 435: ...ingarm and remove the following on the brake shoe breather hose 1 linings adjusting nuts 2 joint pins 3 springs 41 brake cables 5J fOUf nuts 6 brake panel assembly 7 O ring 8 from the brake panel cott...

Page 436: ...race of the bearing 12 with your finger The bearings should tum smoothly and quietly Also check thai the bearing Quter race fits lightly in the housing or panel BEARING REPLACEMENT AXLE HOUSING 263 mm...

Page 437: ...3J Driver 4 Oil seal driver attachment 5 Pitot 28 mm 07749 0010000 07JAD PH80101 07746 0041100 Drive a new bearing with the sealed side facing up axle housing side using the same tools Install the sna...

Page 438: ...four nuts and bolts 4 attaching to the swingarm while supporting the gear case securely gear case axle housing assembly 5J joint spring lJ propeller shaft 2 universal joint 131 O rings 4 from the prop...

Page 439: ...J t andlor bearing may be damaged or faulty They must be checked after disassembly replace them jf necessary JOINT BOOT REPLACEMENT Bend up the lock tabs 1 and raise each band end 2 to loosen the boot...

Page 440: ...procedure once more Compare the difference of the three measurements SERVICE LIMIT 0 2 mm 0 01 in If the difference in measurements exceeds Ihe service limit it indicates thai the bearing is not insta...

Page 441: ...1 in the gear case and cover with your finger The bearings should turn smoothly and quietly Also check that the bearing outer race fits tightly in the case or cover Ring gear bearing replacement page...

Page 442: ...m 35 IbUt 8 mm bolt 25 N m 2 5 kgf m 18 IbUt Remove the oil filler cap Rotate the ring gear several times in both directions of rotation Check the gear tooth contact pattern through the oil filler ho...

Page 443: ...in G 2 18 mm 0 086 in H 2 24 mm 0 088 in t 2 30 mm 0 091 in Pinion shim replacement page 20 16 PINION GEAR REMOVAL Remove the oil seal 1 from the gear case REAR DRIVING MECHANISM Too Low 1 Drive side...

Page 444: ...from the gear case PINION BEARING AND SHIM REPLACEMENT 12J 13J Pull the bearing from the shaft with a commercially available bearing puller Remove the bearing and shim Install the shim 1 and bearing 2...

Page 445: ...the gear case and cover Drive new bearings into Ihe gear case and cover TOOLS Cover Side 1J Driver 07749 0010000 2 Attachment 62 x 68 mm 07746 0010500 3 Pilot 35 mm 07746 0040800 Case Side 1J Driver 0...

Page 446: ...ward Grasp the end of the ring with needle nose pliers and pull the stopper ring 01 11through the access hole Remove the oil filler cap Heat the gear case to about eo e 176 F and remove the needle bea...

Page 447: ...ly strike the driver once If you slrlke it more than once the stopper ring 5 may slip oul of the groove If this happens remove the stopper ring and bearing and install a new stopper ring Make sure the...

Page 448: ...ht 07749 0010000 07746 0010300 07747 0010100 InstaU a new lock nul I and tighten it to the specified II IIIIIIIIIIIIIIIIII torque 2 TOOL 2 Lock nut wrench 30 x 64 mm 01916 MB00002 Referto Service TORQ...

Page 449: ...lue heat the case cover to approximately 80 C 176 F and remove the stop pin by tapping the cover Install a stop pin shim 4 to obtain the correct clearance Stop pin shims A 0 10 mm 0 004 in B 0 15 mm 0...

Page 450: ...In a crisscross pattern in several steps TORQUE 10 mm bolt 47 N m 4 8 kgf m 35 IbHt 8 mm bolt 25 N m 2 5 kgf m 181bHI Make sure that the gear assembly rotales smoothly without binding REAR FINAL DRIVE...

Page 451: ...cting the propeller shaft 1 then install the four bolts 2 and new nuts 3 Temporarily tighten the nuts Connect the breather hose 4 to the gear case Tighten the four axle housing to swingarm nuts 3 to t...

Page 452: ...nes 11of the axle 2J Inslall the axle into the final gear case from right side until it is fully seated 121 Coat a new O ring 111 with grease and install it into the 20 24 groove in the left axle hous...

Page 453: ...our new nuts 1 and tighten them to the specified torque TORQUE 47 N m 4 8 kgf m 35 IbUt Install the brake cables 121 into the cable holders on the brake panel upper holder for lever brake cable and lo...

Page 454: ...MEMO...

Page 455: ...COMPONENT LOCATION 21 2 SYSTEM DIAGRAM 21 2 SERVICE INFORMATION 21 4 TROUBLESHOOTING 21 6 BATTERY 21 8 CHARGING SYSTEM INSPECTION 21 9 ALTERNATOR CHARGING COIL 21 10 REGULATOR RECTIFIER 21 10 POWER RE...

Page 456: ...SE BOX FMfFPM MAINFUSE 30 A FElFPE MAIN FUSE 1 30 A PO ERRELAY Canada type PCMIECM RECTIFIER SYSTEM DIAGRAM U S A type ALTERNATOR BATIERY I I Canada type FMfFPM MAIN FUSE 30A FElFPE MAIN FUSE 1 30A Rl...

Page 457: ...ER b r I r r I ALTERNATOR REGULATOR RECTIFIER BATTERY CHARGING SYSTEM POWER RELAY R W BI BIIR RlBI RlBI RlBI F F BIIR r O BI IGN FUSE lOA R al IGNITION SWITCH MlFPM MAIN FUSE 30A E FPE MAIN FUSE 1 30A...

Page 458: ...rcharge often results from problems in the battery itself which may appear to be an overcharging symptom If one of the battery cells is shorted and battery voltage does not increase the regulator rect...

Page 459: ...BATIERY CHARGING SYSTEM TOOLS M ot o o cy o c tehb t te a na tyz e Chh ist fu i batlery ch a g eCC Micro 404XL U S A only MC1012 2T U S A only 21 5...

Page 460: ...or Charging Coli Inspection Measure the alternator charging coil resistance page 21 10 Standard 0 1 1 0 n 20 CI68 F Is the alternator charging coli resistance within the standard value YES GO TO STEP...

Page 461: ...e Harness Inspection Perform the regulator rectifier wire harness inspection page 21 10 Are the measurements correct YES Faulty regulator rectifier NO Open circuit in related wire loose or poor contac...

Page 462: ...ative H cable VOLTAGE INSPECTION Remove the rear fender cover page 2 9 Measure the battery voltage using a commercially available digital multimeter VOLTAGE 20 C f6 8 F Fully charged 13 0 13 2 V Under...

Page 463: ...specified value a shorted circuit is likely Locate the short by disconnecting connections one by one and measuring the current CHARGING VOLTAGE INSPECTION NOTE Be sure the battery is in good conditio...

Page 464: ...the two mounting bolts 3 and regulatorl 6 rectifier 14 S 11 Disconnect the regulator reclifier 3P Gray 5 and Black 16 connectors Installation is in the reverse order of removal 13J 4J WIRE HARNESS IN...

Page 465: ...IRCUIT INSPECTION Olsconnect the power relay 8P Gray connector 1 r page 21 11 Redlblack Red Check the following al the wire harness side power relay 8P Gray connector Charging Line Battery side Measur...

Page 466: ...MEMO...

Page 467: ...4 HEADLIGHT 22 5 BRAKEfTAILLIGHT 22 6 COMBINATION METER 22 6 ACCESSORY SOCKET 22 10 IGNITION SWITCH 22 11 HANDLEBAR SWITCH 22 11 FRONT BRAKE SWITCH 22 12 REAR BRAKE LIGHT SWITCH 22 13 GEAR POSITION S...

Page 468: ...CATION HANDLEBAR SWITCH GEAR pmilTl N SWITCH 22 2 COMBINATION METER REAR BRAKE LIGHT SWITCH SIDE REAR LIGHT SWITCH PEDAL SIDE FRONT BRAKE LIGHT SWITCH FRONT BRAKE INHIBITOR SWITCH IGNITION SWITCH W JL...

Page 469: ...e SPECIFICATIONS Bulb M t i i I 8 JD 19 Ught green 0 Orange P Pink beam EPS indicator FPMlFPE Fuse Main fuse Sub fuse EP fuse FPM FPE TORQUE VALUES ITEM Combination meter mounting screw Gear position...

Page 470: ...e the bulb 3 from the assist headlight 4 Align the bulb tab 51 with housing groove 6 Install a new bulb and removed parts in the reverse order of removal 2 After installing the removed parts adjust th...

Page 471: ...headlight cover cap 1 headlight 3P connector from the bulb 2 three trim clips 3 two lapping screws 4 mounting bolt 5 headlight assembly 6 adjusting screw 1 washer 2 nut 3 spring 4 headlight unit 5 fro...

Page 472: ...ght Be careful not to Install a new brake taillight in the reverse order of damage the seal removal rubber COMBINATION METER REMOVAUINSTALLATION 22 6 Remove the assist headlight cover page 22 4 Remove...

Page 473: ...P connector 11 terminal and ground There should be continuity all times Connection Green Ground If there is no continuity check for an open circuit in the Green wire SERIAL COMMUNICATION LINE Gear pos...

Page 474: ...ntinuity between the PCM ECM 33P r Black connector 111 and combination meter 21P 1 1 22 8 connector 12 terminals TOOL Test probe 07ZAJ RDJA110 Connection Orange A2l Orange Is there continuity YES GO T...

Page 475: ...ng page 23 14 NO GO TO STEP 3 3 Speedometer Line Open Circuit Inspection Remove the left side cover page 2 4 Disconnect the VS sensor 3P Black connector 1 LIGHTS METERS SWITCHES Disconnect the combina...

Page 476: ...erminal 121 of the sockel and between the Green wire terminal and side wall terminal 3 There should be continuity If there is no continuity replace the accessory socket page 22 10 REPLACEMENT Remove t...

Page 477: ...tch 4P connector page 22 11 Remove the meter cover page 22 6 Release the ignition switch wire from the wire band wire dips and wire guides Remove the ignition switch lJ from the meter cover by pushing...

Page 478: ...INE STOP SWITCH 3 STARTER SWITCH 14 Color BU R Position BIIW Color Position FREE PUSH BlfIIV Y R w FRONT BRAKE SWITCH PECTION The mhlbltor sWItch WIre has gl1iY tape 1 22 12 INS NOTE The lower switch...

Page 479: ...AR BRAKE LIGHT SWITCH LEVER SWITCH INSPECTION Remove the dust cover 1 from the brake light switch Disconnect the rear brake lever switch connectors 2 and check for continuity between the switch termin...

Page 480: ...gear position as follows Gear position Connection Reverse Gray ground N e I I L I c 9 hl 9 fj n jf e d 9 o n d 1 1st White green ground 2nd White red ground 3rd Blue ground 4th Yellow ground 5th Light...

Page 481: ...Te 7 1 and or 7 2 indicated YES Perform the DTG 7 1 troubleshooting page 4 16 Perform the DTG 7 2 troubleshooting page 4 17 NO GO TO STEP 3 3 Ground Line Inspection Remove the rear fender cover Discon...

Page 482: ...ling fan 2P connector 1 from the frame and disconnect it With the jumper wire connected to the PCM ECM 5P connector check for continuity between the fan motor 2P connector 2 terminal and ground Connec...

Page 483: ...the LIGHTS METERS SWITCHES EPS ECU and combination meter FPMfFPE shown 13 FMlFE models If the 4WD indicator operation is abnormal check the Blue white wire between the 4WD select switch and combinati...

Page 484: ...areful not to Remove the three bolts 3 fuel level sensor 4 and 0 deform the noat ring 51 from the fuel tank 22 18 Install a new O ring 1 onto the fuel tank Install the fuel level sensor 2 into the fue...

Page 485: ...n switch OFF Remove the fuellevei sensor page 22 18 Connect the fuel level sensor 2P Red connector With the fuel level sensor float 1 at the top FULL position 2 turn the ignition switch ON and check t...

Page 486: ...l sensor page 22 18 Measure the fuel level sensor resistance with the float 1 at the lop FULL 2 and bollom RESERVE 3J positions Connection Green yellow Yellow white pF L O A T P O S IT I02iN R E S ISS...

Page 487: ...ICE INFORMATION 23 4 BEFORE TROUBLESHOOTING 23 5 SYMPTOM TROUBLESHOOTING 23 5 ESP CONNECTOR LOCATION 23 7 ESP TROUBLESHOOTING INFORMATION 23 10 ESP OTC INDEX 23 13 OTC TROUBLESHOOTING 23 14 VS SENSOR...

Page 488: ...P COMPONENT LOCATION FUSE BOX MAIN FUSE 1 30 A MAIN FUSE 2 30 A IGN FUSE 10 A SENSOR UNIT MAP SENSOR TP SENSOR BATTERY UPSHIFT SWITCH DOWNSHIFT SWITCH GEAR POSITION INDICATOR SHIFT CONTROL MOTOR VS SE...

Page 489: ...PROGRAM ESP FE FPE models IGNITION ION FUSE SWITCH lOA B ENGINE STOP SWITCH w B Il w _ l N Bl _______________________________ E l rrf 1 ONTROl Ei IW _II 5 1 8 11 A l Zl 11 12 B n 331 SI CONNECTOR J3f...

Page 490: ...a digital lester for ESP system inspection For ESP Troubleshooting The PCM controls the PGM Ft and ESP systems Therefore some detection items are shared by the PGM FI and ESP and they may affect the o...

Page 491: ...ecord a DTC Be sure to note and erase any stored OTC s when verifying the customer s complaint If the customer s complaint is duplicated during the test ride and the blinking gear position indicator d...

Page 492: ...PCM Connector Disconnect the PCM 33P Black connector 1 Check for continuity between the wire harness side PCM 33P Black connector terminals while pushing the gearshift sWitch TOOL Test probe 07ZAJ RDJ...

Page 493: ...els ESP CONNECTOR LOCATION NOTE 1 Remove the front fender carrier page 2 8 I D Switch side connector HANDLEBAR SWITCH 14P Green CONNECTOR NOTE 1 NOTE 2 Remove the right mudguard page 2 6 SHIFT CONTROL...

Page 494: ...E 2 Remove the left side cover page 24 NOTE 3 Remove the left mudguard page 2 6 D VS SENSOR 3P Black CONNECTOR NOTE 2 23 8 ENGINE SUB WIRE HARNESS 6P Black CONNECTOR NOTE 1 Switch side connector GEAR...

Page 495: ...cover page 2 9 B33 B23 PCM 33P Gray CONNECTOR NOTE 1 NOTE 2 Remove the seal page 2 4 DLC NOTE 2 ELECTRIC SHIFT PROGRAM ESP FE FPE models A33 A23 PCM 33P Black CONNECTOR NOTE 1 C3 C1 P9 C5 C4 PCM 5P B...

Page 496: ...rmation page 4 10 INDICATOR BUNKING PATIERN 11 R N I J 000 u U I J 1 1 il 101 I I WltE I The number of indicator blinks IS the equivalent of the main code of the OTC the sub code cannot be displayed b...

Page 497: ...roblem OTC s page 23 12 and test ride the vehicle to be sure that the problem s have been removed Connect the HOS pocket tester to the OLC page 23 11 Read the DTC stored data and follow the troublesho...

Page 498: ...e indicator tights short the OLC terminals again with the special tool The self diagnostic memory is erased if the malfunction indicator goes off and starts blinking NOTE 1 The OLC must be shorted whi...

Page 499: ...its circuil malfunction _cc Shift angle sensor response Control motor lock ESP does not work PCM activates the motor but the angle sensor voltage 22 1 22 does not change in middle position Control mo...

Page 500: ...ting the troubleshooting check for loose or poor contact of the following connectors and recheck the OTC page 23 14 VS sensor 3P Black engine sub wire harness 6P Black PCM 33P Black and Gray Make sure...

Page 501: ...e NO GO TO STEP 5 5 VS Sensor Inspection Turn the ignition switch OFF Replace the VS sensor with a new one page 23 27 Erase the DTC page 23 12 Test ride the vehicle and recheck the DTC Is the ore 11 1...

Page 502: ...voltage within 4 75 5 25 V YES GO TO STEP 4 NO Open circuit in Brown white or Green red wire If the wire is normal faulty PCM 4 Shift Angle Sensor Output Line Open short Circuit Inspection Turn the ig...

Page 503: ...easure the resistance at the shift angle sensor side connector 1 terminals Connection A C Standard 4 6 kO 20 e 68 F Connection A B Standard 2 3 kO 20 C 58 F Is the resistance within specification YES...

Page 504: ...page 2 4 Tum the tgnltion switch OFF Manually shift the transmission by rotating the gearshift spindle lJ with the emergency gear change tool 21 Can the gears be changed manually YES GO TO STEP 3 NO C...

Page 505: ...rn the ignition switch ON and engine stop switch 0 Check the shift angle sensor with the HDS pocket tester Is about Low voltage about 0 V or High voltage about 5 V indicated YES _ OV RefertoDTC21 1 pa...

Page 506: ...ery voltage YES GO TO STEP 2 NO Blown main fuse 2 30 A Open circuit in the Redlwhite or Red C4 wire 2 PCM Motor Power Ground Line Inspection Check for continuity between the wire harness side PCM 5P B...

Page 507: ...ctric Shift Failure Checking Connect the PCM SP Black and control moior 2P Black connectors Erase the DTG page 23 12 Turn the ignition switch OFF Turn the ignition switch ON and engine stop switch 0 R...

Page 508: ...the HDS data list menu Is the gear p YES ositfon status normal mitten failure Inter NO o GO TO STEP 2 Gear Position Switch Inspection on switch OFF Turn the igniti Disconnect the gear position switch...

Page 509: ...n or short circuit in the wire harness between Ihe peM and gear position switch 4 Recheck oTe Connect the PCM 33P Black connector Erase the OTC page 23 12 Turn the ignition switch OFF Turn the ignitio...

Page 510: ...tch Inspection at PCM Connector Connect he gear position switch BP Gray connector and disconnect the PCM 33P Black 1 connector 1 Check for continuity between the wire harness side nnector terminals an...

Page 511: ...ontinuity between the handlebar switch side 14P Green connector terminals while pushing the gearshift switch Connection With the upshift switch pushed White red White blue With the downshift switch pu...

Page 512: ...Green and PCM 33P Black connectors Erase the OlC page 23 12 Tum the ignition switch OFF Tum the ignition switch ON and engine stop switch O Check the shift operation and the Ole Is the ore 42 1 Indic...

Page 513: ...the VS sensor 3P Black connector Install the left side cover page 2 4 SHIFT ANGLE SENSOR INSPECTION Remove the left mudguard page 2 6 Disconnecllhe shift angle sensor 3P Gray connector 111 SENSOR RES...

Page 514: ...connector 11 Remove the two socket bolts 2 and shift angle sensor 131_ Remove the O ring 4J from the shift angle sensor Check the shift angle sensor for wear or damage INSTALLATION 111 Brownlwhite Gr...

Page 515: ...te Whitel Position red blue yellow Upshift pushed Free Downshift pushed INPUT VOLTAGE 1 2 Remove the handlebar switch 14P Green connector White red 1 from the frame and disconnect it page 23 29 Turn t...

Page 516: ...e 2 4 right mudguard page 2 6 right frontwtleet page 16 13 Disconnect the control motor 2P Black connector 1 Remove the three bolts 2J and Ihe control motor 3 REDUCTION GEARS Remove the three bolls 1J...

Page 517: ...s of the covers thoroughly being careful not to damage them Install the spindle gear 11 by aligning with the reference marks on the crankcase cover Apply 2 4 9 0 07 0 14 oz of specified grease to the...

Page 518: ...gear cover as shown Tighten the bolts Install the gear cover with the three bolts 3J after installing the control motor 23 32 Coat a new O ring 11 with engine oil and install it into the control moto...

Page 519: ...LOCATION 24 2 EPS TROUBLESHOOTING INFORMATION 24 9 EPS SYSTEM DIAGRAM 24 3 EPS DTC INDEX 24 16 SERVICE INFORMATION 24 4 DTC TROUBLESHOOTING 24 18 SYMPTOM TROUBLESHOOTING 24 4 EPS INDICATOR CIRCUIT EPS...

Page 520: ...models EPS COMPONENT LOCATION EPS FUSE BOX 40A FUSE BOX FPM MAINFUSE 30 A FPE MAIN FUSE 1 30 A IGN A PCMlECM VS SENSOR 24 2 EPS INDICATOR 4WD INDICATOR CKP SENSOR EPS UNIT Including EPS MOlor and Torq...

Page 521: ...Ughl green Lb L ghl blue 0 Orange P P nk R R W While VallO EPS i hcator bhnk Shon terminals lor readmg OTC 4 canada rypo i i rtlRECTIFIER R I I I t oo l t I A R e VSSENSOR _ _j 8111 1241 c L_ __w r w...

Page 522: ...nector is disconnected when current is flowing the excessive voltage may damage the EPS ECU Always turn off the ignition switch before disconnecting or connecting the connectors TOOLS SCS service conn...

Page 523: ...light cover page 22 4 COMBINATION METER 21P Black CONNECTOR NOTE 1 NOTE 2 Remove the right side cover page 2 4 Cl C7 I IX CB r X J C14 X X X IX IX CIS C21 EPS ECU 21P Gray CONNECTOR NOTE 2 EPS EeU 2P...

Page 524: ...over page 2 4 TORQUE SENSOR 3P Gray CONNECTOR NOTE 1 NOTE 2 Remove the right side cover page 2 4 Motoe de co ectoe n n EPS MOTOR 2P Gray CONNECTOR NOTE 1 FPM ENGINE SUB WIRE HARNESS 3P Black CONNECTOR...

Page 525: ...ELECTRIC POWER STEERING EPS FPM FPE models NOTE 1 Remove the left side cover page 2 4 I 1 n v s SENSOR 3P Black CONNECTOR NOTE 1 NOTE 2 Remove the seat page 2 4 OLe NOTE 2 24 7...

Page 526: ...ELECTRIC POWER STEERING EPS FPM FPE models NOTE 1 Remove the rear fender cover page 2 9 24 8 PCM ECM 33P Gray CONNECTOR NOTE 1 Mtt 8lifEg A12 A33 A23 PCMfECM 33P Black CONNECTOR NOTE 1 l...

Page 527: ...PS indicator comes on there are cases that the indicator stays on until the ignition switch is turned OFF and the indicator goes off automatically when the system returns to normal If a problem is con...

Page 528: ...ck the DTC and stored data DTC READOUT NOTE 121 If Ihe HoS pocket tester is not available oTC can be read from the EPS ECU memory by the EPS indicator blinking pattern page 24 10 After pettorn ling di...

Page 529: ...ec 04 1 3 sec _ I sec I OFF f 10 2 OTCI2 ERASING DTC NOTE 0 3 sec 0 4 sec 2 6 ec l OTC21 Pattern Repealed Perform this procedure using fully charged battery The EPS indicator will stay Iii and the EPS...

Page 530: ...or goes off after 4 seconds 4 seconds 121 9 Within 4 seconds after the EPS indicator 1 goes off lurn the handlebar 11I 2 in the straight ahead position and release it immediately Straight The EPS indi...

Page 531: ...page 24 10 3 Turn the ignition switch ON and engine slop switch 0 Tum the handlebar 1 straight ahead Initialize the torque sensor With the HOS while the engine is stopped Follow the Instructions on th...

Page 532: ...4 seconds I 4 seconds 21 9 Tum the handlebar I1J in the straight ahead position fully tum to r 21 straight ahead lime within 1 second and release it immediately after the Straight EPS indicator 2 goes...

Page 533: ...m is often related to poorly connected or corroded connections Check Ihose connections before proceeding Do not pull the wire harness while disconnecting the EPS ECU and PCMfECM connector In lesting a...

Page 534: ...gine speed signal control of the engine p m _ ____ _______ j 13 01 13 EPS EGU internal circuit Indicator ON Disables Initial ____ _ Lower FET stuck ON _____ te e i g_ assist immediately I 13 02 13 EPS...

Page 535: ...sensor Indicator ONfDisables Regular Reset 24 28 Temperature sensorl Torque sensor 23 05 23 Sensor Goil steering assist until the DTG Regular Latch 24 29 is erased Engine speed signal Indicator ONlDi...

Page 536: ...the connector DTC 11 01 EXCESSIVE CHANGE OF VEHICLE SPEED SIGNAL REGULAR DIAGNOSIS NOTE Before starting the troubleshooting check for loose or poor contact of the following connectors and recheck the...

Page 537: ...NITIAL DIAGNOSIS NOTE Before starting the troubleshooting check for loose or poor contact of the following connectors and recheck the DTC page 24 18 EPS ecu 21 P Gray EPS motor 2P Gray 1 EPS EeU Syste...

Page 538: ...nals Connection Black Red Is there continuity YES Short circUit in the EPS sub wire harness NO Recheck for loose or poor contact on the EPS EeU 2P Gray connector and EPS motor 2P Gray connector If the...

Page 539: ...rs and recheck the 4WD indicator page 24 18 4WD select switch EPS ECU 21 P Gray combination meter 21 P Black When this problem occurs there are some of problem of 2WDf4WD select system Question the cu...

Page 540: ...hat speed etc 1 EPS ECU System Inspection Erase the DIG page 24 11 Start the engine and check the EPS indicator Does the indicator come on YES GO TO STEP 2 NO Intermittent failure 2 4WD Indicator Insp...

Page 541: ...EPS ECU Internal circuit Motor current deflection Regular diagnosis EPS ECU internal circuit 1M2 I Regular diagnosis 33 iC 2 iEPS ECU internal circuit EEPR O M Regular diagnosis 35 01 EPS ECU interna...

Page 542: ...e on YES GO TO STEP 2 NO Intermittent failure 2 Motor Line Open Circuit Inspection Turn the ignition switch OFF Disconnect the EPS EGU 2P Gray connector Ill Check for continUIty between the wire harne...

Page 543: ...U stores the torque sensor neutral position The torque sensor must be initialized whenever the EP unit the EPS EeU etc is serviced page 24 13 Refer to torque sensor neutral position information for de...

Page 544: ...ECU 21P Gray connector 1 Measure the resistance between the wire harness side EPS ECU 21 P Gray connector terminals Connection C1 C2 TOOL Test probe C1 C3 C2 C3 07ZAJ RDJA110 Is the resistance less t...

Page 545: ...Ground Is there continuity YES Replace the EPS unit with a new one page 16 32 and recheck short circuit in the torque sensor coil NO Short circuit in the Yellow red wire Short circuit in the Whitelblu...

Page 546: ...loose or poor contact of the following connectors and recheck the OTe page 24 18 EPS ECU 21 P Gray torque sensor 3P Gray 1 EP ECU System Inspection 1 Erase the oTC page 24 11 2 Start the engine 3 Ful...

Page 547: ...1J C19 and PCM ECM 33P Black connector 2 Check for continuity between the wire harness side EPS ECU 21P Gray connector and PCMfECM 33P Black connector terminals Connection C19 EPS EeU A20 PCM ECM TOO...

Page 548: ...1 P Gray connector 1 Turn the ignition switch ON and engine slop switch 0 Measure the voltage between the wire harness side EPS ECU 21 P Gray connector terminal and ground Connection C7 Ground TOOL Te...

Page 549: ...cuit Inspection Turn the ignition switch OFF Disconnect the EPS ECU 2P Brown connector 1 Turn the ignition switch ON and engine stop switch 0 Measure the voltage between the wire harness side EPS ECU...

Page 550: ...on Turn the ignition switch OFF Disconnect the EPS ECU 21P Gray connector Turn the ignition switch ON and engine stop switch O Check the EPS indicator Does the Indicator come on YES Recheck for loose...

Page 551: ...OK YES GO TO STEP 2 NO Replace Ihe fuse and recheck If the fuse is blown check for short to ground in this fuse circuit 2 Recheck OTC Check the DTG page 24 10 Are there any DTCs YES Perform the troub...

Page 552: ...TOOL Test probe 07ZAJ ROJA110 Is there continuity YES Short circuit in the Brown red wire between the EPS ECU and DLC NO GO TO STEP 6 6 IG1 Line Open Circuit Inspection C5 21 111 C9 Yellow green 00 00...

Page 553: ...In good condition YES Recheck for loose or poor contact on the combination meter 21 P Black connector EPS ECU 21 P Gray connector and EPS ECU 2P Brown If they are OK replace the EPS EeU with a known...

Page 554: ...MEMO...

Page 555: ...25 WIRING DIAGRAMS FM model 25 2 FPM model 25 4 FE model 25 3 FPE model 25 5 25 1...

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Page 563: ...POWER STEERING EPS 24 16 ELECTRIC SHIFT PROGRAM ESP 23 13 PGM FI SYSTEM 4 13 DTC TROUBLESHOOTING ELECTRIC POWER STEERING EPS 24 16 INDEX ELECTRIC SHIFT PROGRAM ESP 23 14 PGM FI 4 14 ECT SENSOR 4 32 EM...

Page 564: ...S UNIT FPMJFPE models 16 32 STEERING SYSTEM 3 26 SUB FUEL TANK FUEL PUMp 7 13 SUSPENSION 3 25 SUSPENSION ARM 16 23 SWINGARM 17 8 SYMPTOM TROUBLESHOOTING ELECTRIC POWER STEERING EPS 24 4 ELECTRIC SHIFT...

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