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HYOSUNG 2010 ST7, Service Manual

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HYOSUNG 2010 ST7 Service Manual Download Page 55

ENGINE  3-8

Remove the frame down tube.
Support the engine using an engine jack.
Remove the engine mounting nuts, bolts and engine
mounting lock nuts with the special tool.

Remove the frame down tube.
Support the engine using an engine jack.
Remove the engine mounting nuts, bolts and engine
mounting lock nuts with the special tool.

Remove the engine from the frame.

Remove the engine pulley.

①

②

NOTE

If it is difficult to remove the engine pulley, loosen
the rear axle bolt, belt adjusters 

①

① ②

②

to provide

additional belt slack. (Refer to page 2-15)

CAUTION

Remove the throttle body when removing or
installing the engine necessarily.
When removing the throttle body, loosen the
intake pipe mounting bolts at the same time.

Engine mounting socket wrench (M20)

: 09940H30010

Summary of Contents for 2010 ST7

Page 1: ...Servicemanual ST7 GV700C 2010 Holtvej 8 10 H ruphav 6470 Sydals Telefon 45 73 15 11 00 Fax 45 73 15 11 01 E mail info scanmi dk www scanmi dk CVR 27 73 31 07...

Page 2: ...and service This manual will help you know the vehicle better so that you can assure your customers of your optimum and quick service This manual has been prepared on the basis of the latest specifica...

Page 3: ...sections is listed on the previous page as GROUP INDEX select the section where you are looking for 3 Holding the manual as shown at the right will allow you to find the first page of the section eas...

Page 4: ...in voltage range Measure in resistance range Measure in current range Measure in diode test range Measure in continuity test range Use special tool Use engine coolant Torque control required Data bes...

Page 5: ...NOTE Difference between photographs and actual motorcycles depends on the markets...

Page 6: ...ear Position Switch I IAP Sensor Intake Air Pressure Sensor IAPS IAT Sensor Intake Air Temperature Sensor IATS IG Ignition ISC Solenoid Idle Speed Control Solenoid L LCD Liquid Crystal Display LED Lig...

Page 7: ...r GY Green with Yellow tracer GrB Gray with Black tracer GrR Gray with Red tracer GrW Gray with White tracer OB Orange with Black tracer OL Orange with Blue tracer OG Orange with Green tracer OR Orang...

Page 8: ...MATION LABELS 1 1 GENERAL PRECAUTIONS 1 1 SERIAL NUMBER LOCATION 1 3 FUEL OIL AND ENGINE COOLANT RECOMMENDATIONS 1 4 BREAK IN PROCEDURES 1 6 CYLINDER CLASSIFICATION 1 6 EXTERIOR ILLUSTRATION 1 7 SPECI...

Page 9: ...articular service operation ask a more experienced mechanic for advice WARNING CAUTION NOTE Please read this manual and follow its instructions carefully To emphasize special information the symbol an...

Page 10: ...removing the battery disconnect the battery lead wire first and then the battery lead wire When reconnecting the battery connect the battery lead wire first and then the battery lead wire Finally cove...

Page 11: ...e frame serial number or V I N Vehicle Identification Number is stamped on the right side of the steering head tube The engine serial number is stamped on the left downside of the crankcase assembly T...

Page 12: ...20W50 15W40 15W50 10W40 10W50 10W30 5W30 FRONT FORK OIL Use fork oil TELLUS 32 WARNING Don t mix the unrecommended oil It could damage the engine When refilling the oil tank don t allow the dust to ge...

Page 13: ...rature in your area does not go down to freezing point Hyosung recommends the use of HYOSUNG COOLANT anti freeze engine coolant If this is not available use an equivalent which is compatible with an a...

Page 14: ...EDURES During manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts to BREAK IN before s...

Page 15: ...1 7 GENERAL INFORMATION EXTERIOR ILLUSTRATION Unit mm...

Page 16: ...m 3 21 in 65 0 mm 2 56 in 678 2 41 4 in3 Electric fuel injection Electric starter Wet sump Type Number of cylinder Bore Stroke Piston displacement Fuel system Starter system Lubrication system Wet mul...

Page 17: ...0 rpm CR8E 12V 12Ah MF Main 30 A ECU 15 A 12 V H4 60 55 W 1 12 V W5 W 1 12 V RY10 W 4 LED type 12 V W5 W 1 Ignition type Ignition timing Spark plug Battery Head lamp Position lamp Turn signal lamp Bra...

Page 18: ...UNTING BOLTS 2 7 AIR CLEANER 2 7 ENGINE IDLE SPEED 2 9 THROTTLE CABLE PLAY 2 9 FUEL HOSE 2 10 CLUTCH 2 10 ENGINE OIL 2 12 ENGINE OIL FILTER 2 14 DRIVE BELT 2 15 BRAKE SYSTEM 2 17 STEERING 2 22 FRONT F...

Page 19: ...nspect Tighten Inspect Inspect Inspect Inspect Inspect Inspect Inspect Tighten Inspect every 1 000km Replace every 4 years Replace every 2 years CHASSIS 2 15 2 17 2 17 2 17 2 23 2 22 2 22 2 22 2 23 PE...

Page 20: ...e Passenger footrests pivot Side stand pivot and spring hook Footrests pivot Speedo sensor Front brake lever holder Throttle cable Rear brake pedal pivot O Motor oil G Grease NOTE Before lubricating e...

Page 21: ...ator cover and radiator Refer to page 2 5 Remove the right air cleaner box Remove the seat and fuel tank Refer to page 5 2 Remove the spark plugs Refer to page 2 5 Remove the cylinder head cover and R...

Page 22: ...which is not the tappet shim selection chart please follow instructions of example in the below For example the intake clearance is 0 4 and the shim is 170 1 70 mm select 195 1 95 mm of the shim whic...

Page 23: ...pect Interval Clean Initial 1 000 km and Every 6 000 km thereafter Replace Every 12 000 km Disconnect the spark plug caps Remove the spark plugs Remove the front seat and fuel tank Refer to page 5 2 C...

Page 24: ...st the gap ELECTRODE Check to see the worn or burnt condition of the elec trodes If it is extremly worn or burnt replace the spark plug with a new one And also replace the spark plug if it has a broke...

Page 25: ...ged with dust intake resis tance will be increased with a resultant decrease in power output and an increase in fuel consumption Check and clean the air cleaner element in the fol lowing manner Remove...

Page 26: ...riodic maintenance interval The air cleaner oil drain plug is located beneath the air cleaner case CAUTION Inspect the air cleaner element for tears A torn element must be replaced If driving under du...

Page 27: ...the adjuster Check free play again Cover the protection Connect an engine tachometer to the high ten sion cord Start the engine and inspect the engine idle speed between specified range 1 400 1 600 rp...

Page 28: ...adjuster Uncover the rubber boot Loosen the lock nut counter clockwise Turn the clutch lever adjuster in or out to acquire the specified play After end of adjustment tighten the lock nut clock wise f...

Page 29: ...the position is delivered from the factory on position GEARSHIFT LINK ROD When the footrests in position exchange the gearshift link rod for appropriate riding position Position Install the gearshift...

Page 30: ...oil should be changed while the engine is warm Oil filter replacement at the above intervals should be together with the engine oil change Keep the motorcycle upright Place an oil pan below the engine...

Page 31: ...the Lower line mark L in the inspection window Never fill the engine oil above the Upper line mark F Engine oil level being most suitable about 1 mm under the Upper line mark F of the engine oil lens...

Page 32: ...ine oil replacement procedure CAUTION Before installing the oil filter cap apply engine oil lightly to the new O ring CAUTION When install the oil filter necessarily HYOSUNG character and 16510HN910 p...

Page 33: ...usting the drive belt tighten the rear axle to the specified torque Tighten both belt adjuster lock nuts securely ADJUSTMENT OF DRIVE BELT SLACK Loosen the rear axle Loosen the lock nuts Loosen or tig...

Page 34: ...ty BEND CAPACITY OF DRIVE BELT Back least 204 mm 8 04 in Inner least 102 mm 4 02 in WARNING Be careful not to touch the muffler when it is hot a hot muffler can burn you CAUTION The drive belt for thi...

Page 35: ...WEAR The extend of brake pad wear can be checked by observing the grooved limit on the pad When the wear exceeds the grooved limit replace the pads with new ones Rear Brake WARNING The brake system of...

Page 36: ...rake pad spring Remove the brake pads To reassemble reverse the above sequence Front Brake Rear Brake CAUTION Do not operate the brake lever or pedal while dis mounting the pads NOTE After replacing t...

Page 37: ...alve and insert the other end of the hose into a receptacle Specification and Classification DOT 4 Close the air bleeder valve and disconnect the transparent hose Fill the reservoir with new brake flu...

Page 38: ...ake system Squeeze and release the brake lever several times in rapid succession and sqeeze the lever fully with out releasing it Loosen the bleeder valve by turn ing it a quarter of a turn so that th...

Page 39: ...beneath the front brake lever Loosen the switch fitting screws and adjust the timing by moving the switch body forward or backward REAR BRAKE LAMP SWITCH Adjust the rear brake lamp switch so that the...

Page 40: ...ad and pull forward If play is found perform steering stem nut adjustment as described in page 8 33 of this manual FRONT FORK Inspect the front forks for oil leakage scoring or scratch es on the outer...

Page 41: ...ghtened to their specified torque Refer to page 9 19 COLD INFLATION TIRE PRESSURE Front Rear SOLO RIDING KPa 200 225 2 00 2 25 30 0 33 0 225 250 2 25 2 50 33 0 36 0 kgf cm2 psi DUAL RIDING KPa kgf cm2...

Page 42: ...ater other than dis tilled water can corrode and clog the alu minum radiator The 50 50 mixture of distilled water and ethy lene glycol anti freeze will provide the optimum corrosion protection and exc...

Page 43: ...ssemble the right frame head cover remove the two mounting bolts Bleed the air from the engine coolant circuit as fol lowing procedure Engine coolant capacity Reserve tank side Radiator side Engine si...

Page 44: ...t the above procedure until no air bleed from the radiator cap inlet Close the radiator cap securely After warming up and cooling down the engine sev eral times add the engine coolant up to the F Full...

Page 45: ...on pressure readings are nearly 12 kg even when they measure more than 12 kgf COMPRESSION TEST PROCEDURE COMPRESSION PRESSURE The compression pressure reading of a cylinder is a good indicator of its...

Page 46: ...ine speed to 3 000 rpm with the engine tachometer and read the oil pressure gauge Tighten the engine oil check plug to the specified torque LOW OIL PRESSURE Clogged oil filter Oil leakage from the oil...

Page 47: ...ion of assembly location on each removed part so that each will be restored to the original position during reassembly Wash clean and dry the removed parts before inspecting and measuring Oil the rota...

Page 48: ...emove the seat Refer to page 8 1 Remove the fuel tank Refer to page 5 2 Remove the frame cover Refer to page 8 2 Disconnect the battery lead wire Drain engine oil Refer to page 2 12 Drain engine coola...

Page 49: ...case and cap case bolt COOLING FAN After removing the two mounting bolts remove the right frame head cover Remove the four radiator cover mounting bolts Remove the radiator cover With the bolt removed...

Page 50: ...ng fan motor lead wire coupler Remove the radiator Disconnect the cooling fan thermo switch lead wire coupler Disconnect the radiator inlet hose Remove the radiator mounting bolts Disconnect the radia...

Page 51: ...f clutch lever Disconnect the clutch cable end out of clutch release arm SENSORS Remove the all sensor couplers Refer to chapter 4 and 5 Disconnect the fuel injector hoses THROTTLE BODY Remove the thr...

Page 52: ...k plug caps remove the spark plug Front Cylinder Rear Cylinder EXHAUST PIPE AND MUFFLER With the exhaust pipe bolts exhaust pipe connect ing bolts and muffler mounting bolts removed remove the exhaust...

Page 53: ...move the starter motor lead wire ENGINE 3 6 Remove the engine ground lead wire Disconnect the two magneto coupler Disconnect the neutral switch terminal Disconnect the side stand switch lead wire coup...

Page 54: ...ulley cover Disconnect the front crankcase breather hose and rear crankcase breather hose Remove the gearshift arm Flatten the lock washer Remove the engine pulley nut and washer NOTE When loosening t...

Page 55: ...and engine mounting lock nuts with the special tool Remove the engine from the frame Remove the engine pulley NOTE If it is difficult to remove the engine pulley loosen the rear axle bolt belt adjust...

Page 56: ...nting nut 45 70 N m 4 5 7 0 kgf m Engine mounting lock nut M20 35 50 N m 3 5 5 0 kgf m Frame down tube mounting bolt 22 35 N m 2 2 3 5 kgf m CAUTION Set the part of engine mounting bolt align center l...

Page 57: ...lock washer securely Install the gearshift arm and adjust the gearshift lever height Refer to page 2 10 After remounting the engine the following adjustments are necessary Engine pulley nut 130 160 N...

Page 58: ...emove the starter motor Remove the gear position switch Remove the contacts and springs CAUTION Identify the position of each removed part Organize the parts in their respective groups so that they ca...

Page 59: ...Remove the cylinder head cover Front Cylinder NOTE Thermostat inspection and servicing Refer to page 6 9 CAUTION Align the index mark on the magneto rotor with the index mark on the magneto cover as t...

Page 60: ...emove the cam chain guide NO 2 Remove the camshaft housing Remove the camshaft IN EX Rear Cylinder NOTE Mark an identification of assembly location on each removed parts so that each will be restored...

Page 61: ...er head bolts Remove the chain guide NO 1 and cylinder head Loosen the cylinder head base bolt NOTE When loosening the cylinder head bolts loosen each bolt little by little diagonally CAUTION Draw out...

Page 62: ...from the other side Remove the two cylinder base nuts and cylinder CAUTION The tappet and shim should be lined so that each will be restored to the original posi tion during reassembly CAUTION If tap...

Page 63: ...ankcase Remove the piston pin circlips with long nose pliers Remove the piston pin by using the special tool Remove the rear cylinder head and cylinder with the same manner of the front cylinder head...

Page 64: ...NETO ROTOR With the magneto rotor held immovable using the special tool loosen the rotor nut Remove the magneto rotor by using the special tool Remove the key Remove the starter driven gear Remove the...

Page 65: ...OVER Remove the clutch release arm Remove the clutch cover bolts Remove the clutch cover Remove the cam chain tensioner NOTE When remove or inspect the clutch drive and driven plate remove only the cl...

Page 66: ...ove the disk pressure Remove the clutch drive plates NO 1 and driven plates Remove the spring washer and spring washer seat Remove the clutch drive plate NO 2 Flatten the lock washer With the clutch s...

Page 67: ...PRIMARY DRIVE GEAR With the crankshaft held immovable using special tool remove the primary drive gear nut Remove the water pump drive gear and primary drive gear Conrod holder 09910 20115 CAUTION Th...

Page 68: ...il pump GEARSHIFT SHAFT Draw out the gearshift shaft Remove the gearshift cam stopper Loosen the gearshift cam plate bolt Remove the gearshift cam stopper plate Remove the crankcase securing bolts rig...

Page 69: ...cial tool Remove the mission oil pipe mounting bolt Crankcase separator 09920 13120 CAUTION When separating the crankcase necessarily remove it after installed the special tool Crankcase separator on...

Page 70: ...and measure runout If the service limit is exceeded or abnormal condi tion exists replace the valve CYLINDER HEAD DISTORTION Decarbonate in combustion chamber Check the gasket surface of the cylinder...

Page 71: ...it of cam wear is specified for both intake and exhaust cams in terms of cam height which is to be measured with a micrometer Replace camshafts if found it worn down to the limit CAMSHAFT JOURNAL WEAR...

Page 72: ...tem by rigging up the dial gauge as shown If the clearance is measured exceeds the limit specified below then deter mine whether the valve or the guide should be replaced to reduce the clearance to wi...

Page 73: ...on Inner Outer Standard 4 2 4 8 kgf 9 3 10 6 lbs at length 29 9 mm 1 18 in 17 0 19 6 kgf 37 5 43 2 lbs at length 33 4 mm 1 32 in Standard 81 500 81 515 mm 3 2087 3 2093 in Service limit 81 575 mm 3 21...

Page 74: ...damaged replace it with a new one CAM CHAIN AND CAM CHAIN GUIDE Check the cam chain for wear damage and kinked or bind ing links If any defects are found replace it with a new one Check the cam chain...

Page 75: ...ter measure the piston pin outside diameter at three position both the ends and the center If any of the measurements is founds less than the ser vice limit replace the pin Piston pin hole bore Servic...

Page 76: ...007 in 0 150 mm 0 006 in Piston ring groove clearance 1st 2nd PISTON RING TO GROOVE CLEARANCE INSPECTION Remove carbon deposit both from the piston ring and its groove Fit the piston ring into the gro...

Page 77: ...conrod small end inside diameter both in vertical and horizontal directions If any of the measurements exceeds the service limit replace the conrod 20 006 20 014 mm 0 7876 0 7880 in Standard Service...

Page 78: ...CTION With the right and left crank journals supported with V block turn the crankshaft slowly At this time measure the crankshaft end runout using a dial gauge If the runout exceeds the service limit...

Page 79: ...eplace the defective parts DISASSEMBLY With the magneto rotor held immovable remove the starter clutch bolts REASSEMBLY Apply a small quantity of THREAD LOCK 1324 to the starter clutch bolts and tight...

Page 80: ...bush using the special tool OIL JET REMOVAL Remove the oil jet from the right crankcase half Remove the oil jet from the left crankcase half Bearing remover 20 35 mm 09923 74510 NOTE If it is difficul...

Page 81: ...Fit the new O ring to each oil jets Install the oil jet to the oil hole of crankcase Apply engine oil to the O ring CLUTCH COVER OIL FILTER REPLACEMENT Refer to page 2 14 DISASSEMBLY Remove the circl...

Page 82: ...O 1 NO 2 Clutch drive plate thickness CLUTCH DRIVE PLATES Measure the thickness and claw width of the clutch drive plates using vernier calipers If a clutch drive plate is not within the service limit...

Page 83: ...h decide whether it can be reused or if it should be replaced Smooth engagement and disengagement of the clutch depends on the condition of this bearing PRIMARY DRIVEN GEAR Inspect the primary driven...

Page 84: ...n important role in the smoothness and positiveness of shifting action If the clearance checked is noted to exceed the limit specified replace the fork or its gear or both Service limit 0 50 mm 0 020...

Page 85: ...circlips and spacers 1 0mm 1 2mm 1 5mm CAUTION Never reuse a circlip After a circlip has been removed from a shaft it should be discarded and a new circlip must be installed When installing a new cir...

Page 86: ...tation while the bearings are in the crankcase Replace the bearing in the following procedure if there is anything unusual DISASSEMBLY RIGHT CRANKCASE BEARING Remove the bearing retainer bolt and Remo...

Page 87: ...EMBLY RIGHT CRANKCASE BEARING Drive in the bearings and Bearing installer 09913 76010 CAUTION The removed bearing should be replaced with a new one Oil seal remover 09913 50121 Bearing remover 17 mm 0...

Page 88: ...r the follow ing points must be observed in the reassembly opera tion GV7 Bearing installer 09913 70122 Bearing installer 09913 76010 SUPER GREASE A CAUTION Make sure to coat the rotating and sliding...

Page 89: ...smission Install the gearshift cam and gearshift fork shaft GEARSHIFT CAM AND GEARSHIFT FORKS Install the gearshift fork NO 1 NO 2 and NO 3 Install the dowel pins Before assembling the crankcase apply...

Page 90: ...et BOND 1215 enter into the oil hole or bearing Crankcase bolt M6 11 N m 1 1 kgf m Crankcase bolt M8 26 N m 2 6 kgf m BOND 1215 NOTE Tightening the crankcase bolts tighten each bolt little by little d...

Page 91: ...driveshaft spacer Install the oil seal retainer GEARSHIFT CAM STOPPER Apply a small quantity THREAD LOCK 1324 to the gearshift cam plate bolt Install the gearshift cam stopper plate and gearshift cam...

Page 92: ...oil pump driven gear and install the circlip CAUTION When installing the oil pump to the crankcase turn the pump gear and check that rotation is smooth by the hand CAUTION After the cam driven gear c...

Page 93: ...so that the mark on the gear align the key groove as shown in figure With the crankshaft held immovable using special tool install the water pump drive gear and primary drive gear nut CAUTION Pay att...

Page 94: ...rely Install the clutch sleeve hub nut and tighten it to the specified torque using the special tool Install the clutch drive plate NO 2 Install the spring washer seat and spring washer onto the clutc...

Page 95: ...gs and clutch spring mounting bolts Hold the primary drive gear nut and tighten the clutch spring mounting bolts in a crisscross pattern CLUTCH COVER Install the two dowel pins and new gasket Apply en...

Page 96: ...notch mark align matching mark of the crankcase as shown in the right figure THREAD LOCK 1324 STATOR Apply a small quantity of THREAD LOCK 1324 to the threaded parts of screws THREAD LOCK 1324 STARTE...

Page 97: ...arter clutch on the crankshaft Apply a small quantity of THREAD LOCK 1324 to the threaded parts of crankshaft Tighten the magneto rotor bolt to the specified torque STARTER IDLE GEAR AND MOTOR Install...

Page 98: ...he piston ring in order of oil ring 2nd ring and 1st ring at the front cylinder PISTON Apply the MOLY PASTE to the piston pin When installing the piston turn the mark on the piston head to exhaust sid...

Page 99: ...ket on the crankcase Apply the engine oil to the conrod small end piston and the piston rings Coat the cylinder wall with oil Install the cylinder and tighten the cylinder base nuts This cylinder is d...

Page 100: ...he tappet fitted it should be replaced if it doesn t turn smoothly by the hand CAUTION The tappet and shim should be installed at the original position when removed If otherwise it is difficult to adj...

Page 101: ...cylinder head install first the exhaust camshaft following the intake camshaft The rear cylinder head install first the intake as the cam chain tensioner adjuster exist exhaust side CAUTION When adjus...

Page 102: ...w of exhaust camshaft sprocket should be in a vertical position to the plane of cylinder head when exhaust camshaft sprocket was geared into cam chain The 1R arrow of intake camshaft sprocket should b...

Page 103: ...16 Link 1 Link Rotated Direction Exhaust Intake Exhaust Intake 1 Link 16 Link CAUTION The cam chain is installed to the all of three sprocket Be sure to lie the crankshaft until the two holder and ca...

Page 104: ...il the han dle is turned to the end Fix the adjuster into the cylinder block Get out the pushrod for the front to turn the lock shaft handle in counter clockwise Lock shaft handle CAUTION The camshaft...

Page 105: ...s within standard after mea sured the valve clearance begin the next operation If it is out of stanadard adjust the valve clearance within standard limit after disassembled the camshaft and replaced t...

Page 106: ...ead and cylinder SUPER GREASE A GEAR POSITION SWITCH Install the spring and contact Apply SUPER GREASE A to the O ring and install the gear position switch THERMOSTAT Install the thermostat case along...

Page 107: ...or 0113 IAT SENSOR CIRCUIT MALFUNCTION 4 31 0117 or 0118 WT SENSOR CIRCUIT MALFUNCTION 4 33 0122 or 0123 TP SENSOR CIRCUIT MALFUNCTION 4 35 0201 or 0202 FUEL INJECTOR CIRCUIT MALFUNCTION 4 38 0230 or...

Page 108: ...sure to hold the coupler body and do not pull the lead wires Inspect each terminal on the connector coupler for looseness or bending Inspect each terminal for corrosion and contamina tion The termina...

Page 109: ...tor for bend and female con nector for excessive opening Also check the coupler for locking looseness corrosion dust etc FUSE When a fuse blows always investigate the cause to correct it and then repl...

Page 110: ...mpo nents of the EI system instantly when reverse power is applied Removing any battery terminal of a running engine is strictly prohibited The moment such removal is made damaging counter electromoti...

Page 111: ...te measurements may not be obtained and personal injury may result USING TESTERS Use well charged batteries in the tester Be sure to set the tester to the correct testing range USING THE TESTER Incorr...

Page 112: ...DIAGRAM ECU IAT Sensor TP Sensor IAP Sensor ISCSolenoid AIR AIR CLEANER THROTTLE BODY FUEL TANK FUEL FUEL PUMP FUEL INJECTOR INTAKE PIPE CYLINDER EXHAUST PIPE O2 Sensor Electrical signal flow Air flo...

Page 113: ...various compensations These compensations are determined according to the signals from various sensors that detect the engine and driving conditions Intake Air Pressure Sensor IAP Sensor Intake air p...

Page 114: ...monitors the voltage signal for compensation of the fuel injection time volume A longer injection time is needed to adjust injec tion volume in the case of low voltage At high speed the injection time...

Page 115: ...AGNOSIS 4 8 EI SYSTEM PARTS LOCATION Speedometer Fuel pump relay Fuel injector NO 1 TP sensor IAT sensor Fuel injector NO 2 GP switch Pick up coil Ignition coil NO 1 3 3 6 6 2 2 7 7 8 8 9 9 1 1 4 4 5...

Page 116: ...4 9 EI SYSTEM DIAGNOSIS RO switch Ignition coil NO 2 IAP sensor WT sensor Oxygen sensor NO 1 Oxygen sensor NO 2 E EC CU U 1 14 4 1 11 1 1 13 3 1 10 0 1 12 2 1 15 5...

Page 117: ...t to ON position with the engine stopped or fail to go out after the engine start EI SYSTEM DIAGNOSIS 4 10 SELF DIAGNOSIS FUNCTION The self diagnosis function is incorporated in the ECU The function h...

Page 118: ...ode coupler at the wiring harness and the ignition switch is set to ON posi tion 3 Turn the special tool s switch ON position 4 Push the select switch in the normal mode for 5 seconds 5 The memorized...

Page 119: ...ICATION MODE FI CHECK LAMP INDICATION CAUTION Confirm the malfunction code after turn the ignition switch ON position and after starting the engine in twice The dealer mode coupler is located under th...

Page 120: ...Check the malfunction code to determine the malfunction part MALFUNCTION NO YES Malfunction code is blinked in chronological order FI CHECK LAMP INDICATION FI check lamp goes off KEY CAUTION Take spec...

Page 121: ...2 0 0 3 NO 1 O S heater Circuit High Voltage For NO 1 cylinder 0037 0 0 3 7 0 0 NO 2 O S heater Circuit Low Voltage For NO 2 cylinder 0038 0 0 3 8 0 0 NO 2 O S heater Circuit High Voltage For NO 2 cy...

Page 122: ...igh Voltage or Open 0122 0 1 2 2 0 1 2 2 0 1 2 TPS Circuit Low Voltage or Open 0123 0 1 2 3 0 1 2 3 0 1 TPS Circuit High Voltage 0131 0 1 3 1 0 1 3 1 0 1 3 NO 1 O S Circuit Low Voltage For NO 1 cylind...

Page 123: ...0 2 0 2 0 2 0 2 NO 2 Fuel injector Circuit Malfunction For NO 2 cylinder 0230 0 2 3 0 0 2 3 Fuel pump relay Circuit Low Voltage or Open 0232 0 2 3 2 0 2 3 2 0 Fuel pump relay Circuit High Voltage 033...

Page 124: ...0 4 4 4 0 4 4 4 PV Circuit Open California model only 0445 0 4 4 5 0 4 4 5 PV Circuit Shorted California model only 0505 0 5 0 5 0 5 ISC Error 0562 0 5 6 2 0 5 6 2 Battery Voltage Low 0563 0 5 6 3 0 5...

Page 125: ...OSIS 4 18 In the FI check lamp the malfunction code is blinked in chronological order In the LCD DISPLAY panel the malfunction code is indicated in chronological order LCD DISPLAY INDICATION FI CHECK...

Page 126: ...etimes ON Always OFF Good condition No code Malfunction code PROBLEM SYMPTOMS Difficult Starting Poor Driveability No cranking Hesitation on acceleration No initial combustion Back fire After fire No...

Page 127: ...F C Always Always Sometimes times day month Only once Under certain condition Urban Suburb Highway Mountainous Uphill Downhill Tarmacadam Gravel Other Cold Warming up phase Warmed up Always Other at s...

Page 128: ...layed on the LCD DISPLAY panel or displayed with blinks sig nal of the FI check lamp To check malfunction code read SELF DIAGNOSIS FUNCTION DEALER MODE Refer to page 4 11 18 carefully to have good und...

Page 129: ...position and turn ON position again If noEr then CLOCK LCD INDICATION is indicates the malfunction codes are cleared Disconnect the special tool from the dealer mode coupler B FI CHECK LAMP Repair th...

Page 130: ...ygen sensor lead wire coupler connection 0038 After engine running if oxygen sensor heater signal is hap pened the high short fault for 1 second by 10 times in 12 times test cycle the code 0038 is ind...

Page 131: ...n 0131 NO 1 O S Circuit NO 2 O S Circuit After engine running the oxygen sensor signal is inputted in ECU since then 300 sec In this case the sensor voltage should be the following 30 mV Sensor output...

Page 132: ...engine running if fuel pump relay signal is happened the high short fault for 1 second by 10 times in 20 times test cycle the code 0232 is indicated Pick up coil wiring and mechanical parts Pick up c...

Page 133: ...n to ECU 0562 Battery Voltage FI check lamp Circuit Malfunction GP or Clutch lever Switch Circuit Malfunction The battery voltage should be the following 9 V Battery voltage Without the above range fo...

Page 134: ...1 0132 0137 0138 LCD DISPLAY INDICATION FI CHECK LAMP INDICATION 0 0 3 1 0 0 3 1 0 0 3 2 0 0 3 0 0 3 7 0 0 0 0 3 8 0 0 0 1 3 1 0 1 3 1 0 1 3 0 1 3 2 0 1 3 2 0 1 0 1 3 7 0 1 3 7 0 1 3 8 0 1 3 8 DETECTE...

Page 135: ...pler open or shorted to the wiring harness Heater side If wire and connection are OK intermittent trouble or faulty ECU Recheck each terminal and wire harness for open circuit and poor connection Repl...

Page 136: ...s depending on weather conditions as well as altitude Take that into consideration when inspecting voltage Clogged vacuum passage between throttle body and IAP sensor Air being drawn from vacuum passa...

Page 137: ...or GR wire open or shorted to ground or poor or connection of ECU coupler If wire and connection are OK intermittent trouble or faulty ECU Recheck each terminal and wire harness for open circuit and...

Page 138: ...ose or poor contacts If OK then measure the IAT sensor resistance 4 Disconnect the IAT sensor coupler 5 Measure the resistance between the terminals and DETECTED CONDITION POSSIBLE CAUSE Refer to page...

Page 139: ...aulty ECU Recheck each terminal and wire harness for open circuit and poor connection Replace the IAT sensor with a new one Resistance Intake Air Temp IAT sensor resistance 44 642 5 14 958 5 5 734 5 2...

Page 140: ...6 8 for details 3 Disconnect the WT sensor coupler 4 Measure the resistance between the terminals and DETECTED CONDITION POSSIBLE CAUSE Refer to page 4 24 WT sensor circuit open or short WT sensor ma...

Page 141: ...ulty ECU Recheck each terminal and wire harness for open circuit and poor connection Replace the WT sensor with a new one Resistance To ECU Engine Coolant Temp WT sensor resistance Approx 48 140 Appro...

Page 142: ...OB GR Is the input voltage OK Tester knob indication Voltage 0122 or 0123 TP SENSOR CIRCUIT MALFUNCTION INSPECTION Step 1 1 Turn the ignition switch OFF position 2 Check the TP sensor coupler for loo...

Page 143: ...ith a new one Is the continuity OK Ground Tester knob indication Resistance Step 3 1 Connect the TP sensor coupler 2 Insert the needle pointed probes to the lead wire coupler 3 Turn the ignition switc...

Page 144: ...ground or poor or connection of ECU coupler If wire and connection are OK intermittent trouble or faulty ECU Recheck each terminal and wire harness for open circuit and poor connection If check result...

Page 145: ...he resistance between ter minals 5 If OK then check the continuity between injector terminals and ground DETECTED CONDITION POSSIBLE CAUSE Refer to page 4 25 Injector circuit open or short Injector ma...

Page 146: ...YR NO 1 RB NO 2 wire open or shorted to ground or poor NO 1 NO 2 connection of ECU coupler If wire and connection are OK intermittent trouble or faulty ECU Recheck each terminal and wire harness for o...

Page 147: ...IBLE CAUSE Refer to page 4 25 Fuel pump relay circuit open or short Fuel pump relay malfunction ECU malfunction YES NO GW wire open or shorted to ground or poor connection of ECU coupler If wire and c...

Page 148: ...oreign materiel being attached on the pick up coil and rotor tip Pick up coil circuit open or short Pick up coil malfunction ECU malfunction Refer to page 4 25 INSPECTION 1 Remove the frame cover 2 Tu...

Page 149: ...r or connection of ECU coupler If wire and connection are OK intermittent trouble or faulty ECU Recheck each terminal and wire harness for open circuit and poor connection Loose or poor contacts on th...

Page 150: ...3 EI SYSTEM DIAGNOSIS 0351 0352 LCD DISPLAY INDICATION FI CHECK LAMP INDICATION 0 3 5 1 0 3 5 1 0 3 5 2 0 3 5 2 0351 or 0352 IGNITION COIL MALFUNCTION Refer to the IGNITION COIL for details See page 7...

Page 151: ...ION 0 4 4 4 0 4 4 4 0 4 4 5 0 4 4 5 5 If OK then check the continuity between each ter minal and ground Purge control valve resistance 19 22 at 20 68 Pick up coil continuity Purge control valve contin...

Page 152: ...connection of ECU coupler YL coupler open or shorted to the wiring harness If wire and connection are OK intermittent trouble or faulty ECU Recheck each terminal and wire harness for open circuit and...

Page 153: ...h ON DETECTED CONDITION POSSIBLE CAUSE Refer to page 4 26 ISC solenoid malfunction ISC solenoid s step is out of the specified range ECU malfunction LY G BBr or YL wire loose or poor contacts on the I...

Page 154: ...15 G9 B2 DETECTED CONDITION POSSIBLE CAUSE Battery voltage circuit open and short Battery malfunction ECU malfunction Refer to page 4 26 0562 or 0563 BATTERY VOLTAGE MALFUNCTION 0562 LCD DISPLAY INDIC...

Page 155: ...CTED CONDITION POSSIBLE CAUSE FI check lamp circuit open and short FI check lamp malfunction ECU malfunction Refer to page 4 26 0650 FI CHECK LAMP CIRCUIT MALFUNCTION 0650 LCD DISPLAY INDICATION FI CH...

Page 156: ...the GP switch and the clutch lever switch resistance 4 Park the motorcycle on a firm flat surface vertical ly 5 Disconnect the GP switch coupler and then check the continuity between L wire and groun...

Page 157: ...connection Replace the GP switch or Clutch lever switch with a new one Is OK ECU Coupler Gray Black Clutch lever switch continuity 0 GR Br 7 Measure the voltage between of the ECU and the LY wire of t...

Page 158: ...take air pressure IAP sensor is installed at the left side of the throttle body Refer to page 4 29 IAP SENSOR REMOVAL AND INSTALLATION Remove the fuel tank Remove the IAP sensor from the left side of...

Page 159: ...val RO SWITCH INSPECTION REMOVAL AND INSTALLA TION The roll over RO switch is located in the down side of the fuel tank mounting bolts Romove the front seat Remove the RO switch from the frame Install...

Page 160: ...FUEL PUMP RELAY INSPECTION 5 4 FUEL MESH FILTER INSPECTION AND CLEANING 5 5 FUEL GAUGE INSPECTION 5 5 THROTTLE BODY 5 6 REMOVAL 5 7 CLEANING 5 8 INSPECTION 5 8 INSTALLATION 5 8 CONTENTS 5 FUEL SYSTEM...

Page 161: ...5 1 FUEL SYSTEM AND THROTTLE BODY FUEL SYSTEM...

Page 162: ...gauge coupler Remove the fuel tank mounting bolts and take off the hooks Remove the fuel pump coupler Remove the fuel injector hose CAUTION After disconnecting the fuel injector hose insert a blind p...

Page 163: ...embly When installing the fuel pump assembly first tight en all the fuel pump assembly mounting bolts lightly in diagonal stages and then tighten them in the above tightening order WARNING Gasoline is...

Page 164: ...ing the special tool turn the igni tion switch to OFF position and release the fuel pressure slowly Gasoline is highly flammable and explosive Keep heat sparks and flame away If the fuel pressure is l...

Page 165: ...dge with a new one FUEL GAUGE INSPECTION Measure resistance between the terminals when float is at the position instead below If the resistance measured is out of the specifica tion replace the gauge...

Page 166: ...FUEL SYSTEM AND THROTTLE BODY 5 6 THROTTLE BODY...

Page 167: ...the air cleaner chamber Disconnect the throttle cables from their drum Dismount the throttle body assembly CAUTION Be careful not to damage the throttle cable bracket when dismounting or remounting t...

Page 168: ...anu facturer s instructions for proper use and clean ing of the throttle body components Do not apply throttle body cleaning chemicals to the rubber and plastic materials CAUTION Never operate the idl...

Page 169: ...ENGINE COOLANT 6 1 COOLING CIRCUIT 6 2 RADIATOR 6 2 COOLING FAN 6 5 COOLING FAN THERMO SWITCH 6 6 WATER TEMPERATURE SENSOR 6 8 THERMOSTAT 6 9 WATER PUMP 6 11 COOLING SYSTEM 6 CONTENTS...

Page 170: ...han 50 Refer to Right figure Do not use a radiator anti leak additive 50 Engine coolant including reserve tank capacity Anti freeze Water 0 8 0 8 WARNING You can be injured by scalding fluid or steam...

Page 171: ...emoving the two mounting bolts remove the right frame head cover Remove the radiator cap case bolt Remove the radiator cover by the four mounting bolts Disconnect the radiator outlet hose RESERVE TANK...

Page 172: ...t be removed Use of compressed air is recommended for this clean ing Remove the radiator by the mounting bolts Disconnect the cooling fan thermo switch lead wire coupler Disconnect the radiator inlet...

Page 173: ...Pour engine coolant Refer to page 2 25 Bleed air from the cooling circuit Refer to page 2 26 Fins bent down or dented can be repaired by straighten ing them with the blade of a small screwdriver INSP...

Page 174: ...e radiator Route the radiator hoses properly Pour engine coolant Refer to page 2 25 Bleed air from the cooling circuit Refer to page 2 26 Install the radiator cover INSTALLATION Install the cooling fa...

Page 175: ...he cooling fan thermo switch INSPECTION Check the thermo switch closing or opening tempera tures by testing it at the bench as shown in the figure Connect the thermo switch to a circuit tester and pla...

Page 176: ...Install the radiator cover INSTALLATION Install the cooling fan thermo switch in the reverse order of removal Pay attention to the following points Install a new O ring and apply engine coolant to the...

Page 177: ...all a new O ring and apply engine coolant to the O ring Tighten the WT sensor to the specified torque Resistance To ECU Engine Coolant Temp WT sensor resistance Approx 48 140 Approx 5 790 Approx 2 450...

Page 178: ...the photo graph Immerse the thermostat in the WATER contained in a beaker as shown in the illustration Note that the immersed thermostat is in suspension Heat the water by placing the beaker on a stov...

Page 179: ...n the reverse order of removal Pay attention to the following points Apply engine coolant to the rubber seal on the ther mostat Install the thermostat Install the thermostat case cap Pour engine coola...

Page 180: ...and clutch cover If engine oil is leaking visually inspect the oil seal and O ring If engine coolant is leak ing visually inspect the O ring WATER PUMP REMOVAL AND DISASSEM BLY Drain engine coolant Re...

Page 181: ...COOLING SYSTEM 6 12 Remove the water pump from the clutch cover Remove the O rings Remove the E ring from the impeller shaft Remove the impeller from the other side...

Page 182: ...the bearing if there is anything unusual BEARING CASE Visually inspect the bearing case for damage Replace the water pump body if necessary REASSEMBLY AND INSTAL LATION Install the water pump in the...

Page 183: ...our engine coolant Refer to page 2 25 Pour engine oil Refer to page 2 12 Install the impeller to the water pump body Apply SUPER GREASE A to the impeller shaft Fix the impeller shaft with the E ring F...

Page 184: ...CATION OF ELECTRICAL COMPONENTS 7 1 IGNITION SYSTEM 7 4 CHARGING SYSTEM 7 8 STARTER SYSTEM AND SIDE STAND IGNITION INTERLOCK SYSTEM 7 10 SWITCHES 7 14 LAMP 7 15 BATTERY 7 17 ELECTRICAL SYSTEM 7 CONTEN...

Page 185: ...OF ELECTRICAL COMPONENTS Ignition coil NO 1 Turn signal relay Side stand relay Regulator Rectifier Main relay Fuel pump relay ISC solenoid Cooling fan motor Cooling fan thermo switch Magneto Pick up c...

Page 186: ...7 2 22 WT sensor 23 Thermostat Starter motor relay Cooling fan motor relay Head lamp relay 24 Rear brake lamp switch Fuel injector NO 2 Fuel injector NO 1 IAP sensor Oxygen sensor NO 1 21 Oxygen senso...

Page 187: ...7 3 ELECTRICAL SYSTEM 26 Ignition coil NO 2 25 RO switch 27 Front brake lamp switch 27 TP sensor 28 ECU fuse 15A 29 Main fuse 30A 30 ECU 30 Battery 28 IAT sensor 26 25 28 29 30 27...

Page 188: ...he following table If the resistance is not within the specified value replace the stator coil with a new one IGNITION SYSTEM IGNITION COIL NO 1 IGNITION COIL NO 2 ECU IGNITION SWITCH ENGINE STOP SWIT...

Page 189: ...connect the ignition coil plug cap lead wire couplers Shift the transmission into the neutral and then turn the ignition switch to the ON position Squeeze the clutch lever Press the starter switch and...

Page 190: ...ITION COIL PLUG CAP RESISTANCE 0 52 0 64 Terminal Terminal 6 4 7 8 Plug cap Terminal Secondary Primary SPARK PLUG CARBON DEPOSITS Check to see if there are carbon deposits on the spark plug If carbon...

Page 191: ...loss of performance CAUTION Before tightening the spark plug to the specified torque carefully turn the spark plug by finger into the threads of the cylinder head to prevent damage the aluminum thread...

Page 192: ...cket tester measure the DC voltage between the battery terminal and If the voltage is not within the specified value check the magneto no load performance and regulator rectifier 13 5 15 0 V at 5 000...

Page 193: ...0 7 0 4 0 7 0 4 0 7 0 5 1 2 Tester probe Tester probe Unit V Tester knob indication Diode test MAGNETO NO LOAD PERFOR MANCE Disconnect the three lead wires from the magneto terminal Start the engine a...

Page 194: ...e motorcycle from being started with side stand down The system is operated by an electric circuit provided between the battery and ignition coil The circuit consists of the neutral indicator light an...

Page 195: ...TTERY IGNITION COIL IGNITION SWITCH ON IGNITION SWITCH ON NEUTRAL INDICATOR LAMP NEUTRAL SWITCH ON DIODE NEUTRAL SWITCH OFF NEUTRAL INDICATOR LAMP DIODE SIDE STAND SWITCH SIDE STAND UP RIGHT POSITION...

Page 196: ...rmature shaft If there is no continuity between the segments or there is continuity between the segment and shaft replace the starter motor with a new one Segment STARTER MOTOR REMOVAL AND DISASSEMBLY...

Page 197: ...he housing with the line on the housing end SUPER GREASE A Apply SUPER GREASE A to the O ring and remount the starter motor STARTER MOTOR REASSEMBLY Reassemble the starter motor Pay attention to the f...

Page 198: ...witch assemblies with new ones R O BW BR ON OFF IGNITION SWITCH BBr BW ON OFF HORN SWITCH Br GR ON OFF CLUTCH LEVER SWITCH O WB ON OFF FRONT REAR BRAKE LAMP SWITCH O Y ON OFF PASS SWITCH OB YR PUSH OF...

Page 199: ...ICAL SYSTEM LAMP TURN SIGNAL LAMP HEAD LAMP BRAKE TAIL LAMP CAUTION If you touch the bulb with your bare hands clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bu...

Page 200: ...Using the pocket tester check the continuity between lead wires Blue color coupler and 3 pin coupler in the following illustration If the continuity measured incorrect replace the respective part CAU...

Page 201: ...er When they were stained clothes will come into being a hole or painting will take off Consult a doctor When the battery electrolyte was dropped to the surface of land wash it with a vast quantity of...

Page 202: ...that it does not fall Take precaution not to allow any fluid to spill Confirmation of pour Make sure that air bubbles are coming up each electrolyte container and keep this position for more than abou...

Page 203: ...OPERATION Using the pocket tester check the battery voltage If the voltage reading is less than the 12 0 V DC recharge the battery with a battery charger CAUTION Draw the empty receptacle out slowly...

Page 204: ...8 1 FRAME COVER 8 2 SEAT TAIL COVER SEAT TAIL COVER BRACE 8 5 FRONT WHEEL 8 7 FRONT BRAKE 8 11 HANDLEBAR 8 18 FRONT FORK 8 21 STEERING 8 29 REAR WHEEL 8 36 REAR BRAKE 8 41 REAR SHOCK ABSORBER 8 46 SW...

Page 205: ...front seat push down firmly until the seat latch snaps into the lock position REAR SEAT To remove the rear seat loosen the rear seat mounting bolt on the rear side of the rear seat To install the rear...

Page 206: ...CHASSIS 8 2 FRAME COVER FRAME HEAD COVER Loosen the two mounting bolts and disengage the right and left frame head cover from the frame Right...

Page 207: ...mounting bolts and remove the air cleaner cover FUEL TANK LOWER DECO RATION COVER Loosen the two mounting bolts and remove the fuel tank lower decoration cover SIDE COVER Unhook the three hook and rem...

Page 208: ...CHASSIS 8 4 Left PILLION RIDER PLATE Loosen the two mounting bolts from the inside of the seat tail cover Disengage the right and left pillion rider plate from the seat tail cover...

Page 209: ...ER BRACE Remove the front and rear seat Refer to page 8 1 Remove the rear shock absorber upper bolts from the inside of the frame right and left Install the rear shock absorber upper bolts with the fr...

Page 210: ...move the battery fuses and ECU Disconnect the rear turn signal lamp coupler and rear combination lamp coupler Remove the two bolts After loosening the two bolts remove the seat tail cover and seat tai...

Page 211: ...osen the front axle pinch bolt the right side of the motorcycle Loosen the front axle Raise the front wheel off the ground with a block or jack Remove the front wheel by removing the front axle CAUTIO...

Page 212: ...or loose wheel bearings and can be reduced by replacing the bearings If bearing replacement fails to reduce the runout replace the wheel Axle shaft runout Service limit 0 25 mm 0 01 in Wheel runout a...

Page 213: ...d remount the front wheel in the reverse order of removal and disassembly Pay attention to the following points SUPER GREASE A Install the wheel bearings as follows by using the special tools WHEEL BE...

Page 214: ...ASSIS 8 10 Tighten the front axle and front axle pinch bolt to the specified torque Install the front axle pinch bolt cap Front axle 50 80 N m 5 0 8 0 kgf m Front axle pinch bolt 15 25 N m 1 5 2 5 kgf...

Page 215: ...and Do not use a brake fluid kept in an open container or stored for long period of time To store brake fluid make sure to seal the container and keep it in a safe place to be out of reach of children...

Page 216: ...brake caliper by loosening the caliper mounting bolts Separate the caliper halves by loosening the caliper housing bolts CAUTION To prevent brake fluid from splashing on the parts nearby cover the par...

Page 217: ...ages If any abnormal condition is noted replace the caliper WARNING Place a rag over the pistons to prevent it from popping out and flying and keeping hand off the piston Be careful of brake fluid whi...

Page 218: ...ification and classification DOT 4 Tighten the caliper housing bolts to the specified torque CAUTION Wash the caliper components with fresh brake fluid before reassembly Do not wipe off brake fluid af...

Page 219: ...exceeds the service limit If measurement exceeds the service limit replace the brake disk Refer to page 8 8 Brake disk thickness Service limit 3 0 mm 0 12 in Brake disk runout Service limit 0 3 mm 0 0...

Page 220: ...re coupler Remove the union bolt Remove the two clamp bolts and take off the master cylinder Remove the two fitting screws and separate the cap and diaphragm Detach the dust seal boot and remove the c...

Page 221: ...master cylinder in the reverse order of removal and disassembly Pay attention to the following points WARNING Bleed air from the brake fluid circuit after assem bling master cylinder Refer to page 2...

Page 222: ...d wires and remove the master cylinder Refer to page 8 16 Remove the handlebar balancer and grip HANDLEBAR LEFT SIDE PARTS REMOVAL AND DISASSEMBLY Remove the left handlebar switches Remove the handleb...

Page 223: ...cylinder Refer to page 8 17 Tighten the handlebar clamp bolts to the specified torque REASSEMBLY AND REMOU NTING Perform the reassembly and remounting work in the reverse order of the removal and dis...

Page 224: ...20 Apply SUPER GREASE A to the throttle cables Install the throttle cable and returning cable to the throttle grip Throttle cable Returning cable SUPER GREASE A Throttle grip Throttle cable Rotated d...

Page 225: ...8 21 CHASSIS FRONT FORK...

Page 226: ...brake hose Remove the front fork after loosening the front fork upper and lower clamp bolts Remove the front fork cap bolt O ring and front fork inner spacer Invert the front fork and stroke it sever...

Page 227: ...With the damper rod held immovable remove the damper rod bolt Remove the damper rod and rebound spring from the inner tube Remove the dust seal and oil seal stopper ring Separate the inner tube from t...

Page 228: ...If the length is found shorter than the service limit replace the spring INNER AND OUTER TUBE Inspect the inner tube outer surface and outer tube slide metal face for scratches If any defects are foun...

Page 229: ...he outer tube Apply SUPER GREASE A to the lip of the oil seal and install it into the outer tube using the front fork oil seal installer CAUTION Wash and clean the front fork oil seal installer before...

Page 230: ...er ring and dust seal Dust seal Oil seal stopper ring Oil seal Oil seal retainer Slide metal THREAD LOCK 1324 FRONT FORK OIL With the inner tube in fully compressed position pour the specified amount...

Page 231: ...136 mm 5 4 in from end of outer tube When maximum com pressed without spring Front fork oil level Install the front fork to the motocycle Align the upper surface of the inner tube with the upper surfa...

Page 232: ...ION When installing the front fender install the front brake hose guide to left side of the front fender Front fork upper clamp bolt 22 35 N m 2 2 3 5 kgf m Front fork lower clamp bolt 22 35 N m 2 2 3...

Page 233: ...8 29 CHASSIS STEERING REMOVAL AND DISASSEM BLY Take off the front wheel Refer to page 8 7 Remove the front fender Refer to page 8 1 Take off the front fork Refer to page 8 22...

Page 234: ...gnal lamp assembly Remove the handlebars Refer to page 8 18 Remove the steering stem head nut Remove the steering stem upper bracket Remove the steering stem upper nut and steering stem nut using the...

Page 235: ...stem lower bracket Remove the upper and lower bearing CAUTION Hold the steering stem lower bracket by hand to prevent from falling CAUTION The removed bearing outer race must be replaced with a new on...

Page 236: ...removal and disassembly However operate the work taking care for the following points Press in the steering stem upper and lower bearing outer races using the special tool Apply SUPER GREASE A to the...

Page 237: ...lower bracket about five or six times to the right and left Loosen the steering stem nut of a turn Clamp wrench 09940 10122 Steering stem nut 80 100 N m 8 0 10 0 kgf m NOTE This adjustment will vary f...

Page 238: ...he front fork inner tube with the upper surface of the steering stem upper bracket Tighten the upper front fork clamp bolts to the specified torque Tighten the steering stem head nut to the speci fied...

Page 239: ...8 35 CHASSIS NOTE Hold the front fork legs move them back and forth and make sure that the steering is not loose...

Page 240: ...CHASSIS 8 36 REAR WHEEL REMOVAL AND DISASSEM BLY Raise the rear wheel off the ground with a jack or block After loosening the four mounting bolts remove the engine pulley cover...

Page 241: ...osening the four mounting bolts remove the drive belt cover Remove the rear axle Remove the rear wheel Loosen the lock nuts and drive belt adjusters right and left Disengage the drive belt from the re...

Page 242: ...using the special tool Remove the rear wheel shock absorber Remove the rear pulley from the rear pulley mounting drum Wheel bearing remover 09941 50111 CAUTION The removed bearing should be replaced w...

Page 243: ...e REAR WHEEL SHOCK ABSOR BER Inspect the rear wheel shock absorber for wear and damage Replace the rear wheel shock absorber if there is any thing unusual REAR PULLEY Inspect the pulley s teeth for we...

Page 244: ...CHASSIS 8 40 After installing the drive belt to the rear pulley adjust the drive belt by turning both belt adjusters Tighten both belt adjuster lock nuts securely Left Right...

Page 245: ...long period To store brake fluid make sure to seal the container and keep it in a safe place to be out of reach of chil dren When filling brake fluid take care not to allow water or dirt to enter the...

Page 246: ...ke fluid in a suitable receptacle Remove the brake caliper by loosening the caliper mounting bolts Remove the brake pad mounting bolt Remove the brake pad Refer to page 2 18 Remove the brake pad sprin...

Page 247: ...n or other damages If any abnormal condition is noted replace the caliper CAUTION Care not to cause scratch on the cylinder bore Do not reuse the piston seal and dust seal that have been removed WARNI...

Page 248: ...e fluid specification and classification DOT 4 CAUTION Wash the caliper components with fresh brake fluid before reassembly Do not wipe off brake fluid after washing the components When washing the co...

Page 249: ...8 45 CHASSIS Fill the system with brake fluid and bleed air Refer to page 2 19 20 Inspection after reassembly Refer to page 2 17 BRAKE DISK INSPECTION Refer to page 8 15...

Page 250: ...CHASSIS 8 46 REMOVAL Remove the rear shock absorbers by removing their bolts and nuts REAR SHOCK ABSORBER...

Page 251: ...he specified torque Rear shock absorber spring free length Service limit 200 0 mm 7 87 in Rear shock absorber spring pre load Standard 2 5 position SPRING PRE LOAD ADJUS TMENT Adjust the rear shock ab...

Page 252: ...CHASSIS 8 48 REMOVAL AND DISASSEM BLY Remove the rear wheel Refer to page 8 36 Remove the exhaust pipes and muffler Refer to page 3 5 SWINGARM...

Page 253: ...er and drive belt covers After loosening the rear shock absorber lower bolts disconnect the rear shock absorber from swingarm Remove the swingarm mounting lock nut Remove the swingarm pivot nut Remove...

Page 254: ...shaft exceeds the service limit replace it with a new one Swingarm pivot shaft runout Service limit 0 6 mm 0 024 in INSPECTION SWINGARM Inspect the swingarm for damage If any defects are found replace...

Page 255: ...the part of swingarm pivot shaft align center line by the hand temporarily and install the swingarm pivot shaft to the specified torque If otherwise it is damage to the thread of swingarm pivot shaft...

Page 256: ...SERVICING INFORMATION TROUBLESHOOTING 9 1 SPECIAL TOOLS 9 15 TIGHTENING TORQUE 9 18 SERVICE DATA 9 20 WIRE AND CABLE ROUTING 9 30 WIRING DIAGRAM 9 37 CONTENTS 9...

Page 257: ...icated Oxygen sensor lead wire coupler connection 0038 After engine running if oxygen sensor heater signal is hap pened the high short fault for 1 second by 10 times in 12 times test cycle the code 00...

Page 258: ...n 0131 NO 1 O S Circuit NO 2 O S Circuit After engine running the oxygen sensor signal is inputted in ECU since then 300 sec In this case the sensor voltage should be the following 30 mV Sensor output...

Page 259: ...engine running if fuel pump relay signal is happened the high short fault for 1 second by 10 times in 20 times test cycle the code 0232 is indicated Pick up coil wiring and mechanical parts Pick up c...

Page 260: ...n to ECU 0562 Battery Voltage FI check lamp Circuit Malfunction GP or Clutch lever Switch Circuit Malfunction The battery voltage should be the following 9 V Battery voltage Without the above range fo...

Page 261: ...reaching the intake manifold 1 Clogged fuel filter or fuel hose 2 Defective fuel pump 3 Defective fuel pressure regulator 4 Defective fuel injector 5 Defective fuel pump relay 6 Defective ECU 7 Open c...

Page 262: ...erating 1 Defective fuel injectors 2 No injection signal from ECU 3 Open or short circuited wiring connection 4 Defective battery or low battery voltage Control circuit or sensor improperly operating...

Page 263: ...clutch plates 3 Distorted clutch plates driven and drive 4 Worn clutch release bearing 5 Weakened clutch dampers Noise seems to come from crankshaft 1 Rattling bearings due to wear 2 Worn and burnt bi...

Page 264: ...or 10 Defective fuel pump 11 Defective TP sensor 12 Defective SAV solenoid 13 Clogged air cleaner element Defective air flow system 1 Clogged air cleaner element 2 Defective throttle valve 3 Sucking a...

Page 265: ...rbon deposit on piston crowns 2 Not enough oil in the engine 3 Defective oil pump or clogged oil circuit 4 Sucking air from intake pipes 5 Use incorrect engine oil 6 Defective cooling system Lean fuel...

Page 266: ...s 3 Weakened stopper spring on gearshift stopper Check with inspection win dow drain out excess oil Replace Replace Replace Replace Replace Replace Replace Replace Replace Replace Replace Replace Repl...

Page 267: ...lead connections 2 Short circuited grounded or open stator coil 3 Short circuited or punctured regulator rectifier 1 Lead wire insulation frayed due to vibration resulting in intermit tent shorting 2...

Page 268: ...ator regulator rectifier and circuit connec tions and make necessary adjustments to obtain speci fied charging operation Replace the battery and cor rect the charging system Replace the battery Rechar...

Page 269: ...eakened springs 2 Not enough fork oil 3 Wrong viscous fork oil 4 Improperly set front fork damping force adjuster Replace Refill Replace Adjust Front suspension too stiff 1 Fork oil too viscous 2 Too...

Page 270: ...ing 1 Carbon adhesion on pad surface 2 Tilted pad 3 Damaged wheel bearing 4 Loosen front wheel axle or rear wheel axle 5 Worn pads 6 Foreign material in brake fluid 7 Clogged return port of master cyl...

Page 271: ...r 09900 20605 Dial calipers Meassure width of conrod big end 09900 20606 Dial gauge Meassure oscillation of wheel with using magnetic stand 09900 20701 Magnetic stand With using dial gauge 09900 20806...

Page 272: ...in 09913 80112 Bearing installer Used to drive bearing in 09915 64511 Compression gauge Measure cylinder compression 09915 74511 Oil pressure gauge Measure oil pressure of 4 stroke engine Separate to...

Page 273: ...remove rotor 09940 10122 Clamp wrench A hook wrench to adjust the steering head of motorcycle 09940H30010 Engine mounting socket wrench M20 Used to install or remove engine mounting lock nut 09940H35...

Page 274: ...nting bolt Spark plug Cam chain tensioner bolt Cam chain tensioner adjuster bolt Clutch sleeve hub nut Primary drive gear nut Camshaft housing bolt Horn mounting bolt 1 1 1 4 0 8 1 2 0 8 1 3 0 8 1 2 1...

Page 275: ...bolt Front fork damper rod bolt Front fork upper clamp bolt Front fork cap bolt Front fork lower clamp bolt Footrest mounting bolt Frame down tube mounting bolt Handlebar clamp bolt Handlebar holder n...

Page 276: ...19 6 kgf 37 5 43 2 lbs at length 33 4 mm 1 32 in 1 2 1 7 0 047 0 067 IN EX IN EX IN EX IN EX IN EX IN EX IN EX IN EX IN EX IN EX Inner Outer Inner Outer 0 35 0 014 0 05 0 002 0 50 0 02 0 03 0 0012 36...

Page 277: ...ox 9 9 0 390 Approx 10 5 0 413 0 20 0 35 0 008 0 013 0 20 0 35 0 008 0 013 1 21 1 23 0 0476 0 0484 1 01 1 03 0 040 0 041 2 01 2 03 0 079 0 080 0 970 0 990 0 0382 0 0390 1 170 1 190 0 0461 0 0469 1st 2...

Page 278: ...ive plate thickness Drive plate claw width Driven plate distortion Clutch spring free length 2 62 0 103 3 12 0 123 15 1 0 595 15 1 0 595 0 1 0 004 51 2 008 CLUTCH 2 0 08 2 92 3 08 0 115 0 121 3 42 3 5...

Page 279: ...DRIVE BELT 2 46 32 13 1 78 32 18 1 38 29 21 1 13 27 24 0 96 25 26 Poly chain belt 26 1 02 11 0 43 1st 2nd 3rd 4th 5th Type Width Pitch NO 1 NO 2 NO 3 NO 1 NO 2 NO 3 0 10 0 30 0 004 0 012 Gear ratio Sh...

Page 280: ...le cable play 39 1 400 1 600 rpm 0 5 1 0 mm 0 02 0 04 in SPECIFICATION NOTE FUEL INJECTOR FUEL PUMP ITEM Fuel injector resistance Fuel injector voltage Fuel pressure of fuel pump 11 4 12 6 at 20 68 Ba...

Page 281: ...temperature is 40 120 40 248 230 430 940 ITEM STANDARD NOTE THERMOSTAT COOLING FAN COOLANT Valve opening Valve full open Valve closing 40 40 0 32 20 68 40 104 60 140 80 176 120 248 Reserve tank side...

Page 282: ...ging voltage Stator coil resistance Ignition coil resistance Spark plug Ignition timing Spark performance Ignition coil primary peak voltage Type Gap Hot type Standard type Cold type 12V H4 60 55 W 1...

Page 283: ...ch leg Rear wheel travel Swingarm pivot shaft runout Rear shock absorber pre load position Rear shock absorber spring length 321 12 6 0 6 0 024 200 0 7 87 ITEM STANDARD LIMIT SUSPENSION Unit mm in 130...

Page 284: ...3 0 17 14 280 14 320 0 5622 0 5638 12 700 12 743 0 5000 0 5017 14 230 14 260 0 5602 0 5614 12 657 12 684 0 4983 0 4994 25 4 1 00 25 4 1 00 DOT4 DOT4 120 80 16 60H 170 80 15 77H J16 MT2 75 J15 MT4 00...

Page 285: ...graded 91 octane or higher An unleaded gasoline is recommened API Over SL SAE 10W 40 3 000 3 200 3 400 ITEM SPECIFICATION FUEL OIL Change Filter change Overhaul TIRE PRESSURE COLD INFLATION TIRE PRESS...

Page 286: ...SERVICING INFORMATION 9 30 WIRE AND CABLE ROUTING...

Page 287: ...9 31 SERVICING INFORMATION...

Page 288: ...SERVICING INFORMATION 9 32...

Page 289: ...9 33 SERVICING INFORMATION...

Page 290: ...SERVICING INFORMATION 9 34...

Page 291: ...9 35 SERVICING INFORMATION...

Page 292: ...SERVICING INFORMATION 9 36...

Page 293: ...9 37 SERVICING INFORMATION WIRING DIAGRAM...

Page 294: ...SERVICING INFORMATION 9 38...

Page 295: ...0 2 15 2 20 2 20 1 35 1 40 1 45 1 50 1 55 1 60 1 65 1 70 1 75 1 80 1 85 1 90 1 95 2 00 2 05 2 10 2 15 2 20 1 40 1 45 1 50 1 55 1 60 1 65 1 70 1 75 1 80 1 85 1 90 1 95 2 00 2 05 2 10 2 15 2 20 1 45 1 5...

Page 296: ...90 1 95 1 75 1 80 1 85 1 90 1 95 2 00 1 80 1 85 1 90 1 95 2 00 2 05 1 85 1 90 1 95 2 00 2 05 2 10 1 60 1 65 1 70 1 75 1 80 1 85 1 90 1 95 2 00 2 05 2 10 2 15 1 65 1 70 1 75 1 80 1 85 1 90 1 95 2 00 2...

Page 297: ...Prepared by 1st Ed JAN 2010 Manual No 99000H99D10 Printed in Korea...

Page 298: ...S T Motors Co Ltd...

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