Honda SH300I 2006 Скачать руководство пользователя страница 244

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CYLINDER/PISTON

10-4

CYLINDER/PISTON REMOVAL

CYLINDER REMOVAL

Remove the cylinder head (page 9-11).

Remove the two bolts, oil pressure switch wire
clamp and PAIR check valve (page 6-79).

Remove the bolt and O

sensor wire clamp

Release the water hose from the clamp.

Remove the following:

–

two bolts and water hose clamp

–

bolt

–

cylinder

–

gasket

–

two dowel pins

Clean off any gasket material from the cylinder mat-
ing surface.

PISTON REMOVAL

Place a clean shop towel over the crankcase to pre-
vent the piston pin clip from falling into the crank-
case.

Remove the piston pin clips with pliers.
Push the piston pin out of the piston and connecting
rod, and remove the piston.

PAIR CHECK VALVE

BOLTS

CLAMP

BOLT/CLAMP

CYLINDER

BOLT

BOLTS/CLAMP

WATER HOSE

GASKET

DOWEL PINS

PISTON

PISTON PIN CLIP/PISTON PIN

Содержание SH300I 2006

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 54: ...MEMO...

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

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

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

Страница 58: ...MEMO...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 122: ...t start turn the starter motor for more than 10 seconds and check that the MIL blinks When the ignition switch is turned ON the MIL will stay on for a few seconds then go off If the MIL stays on or bl...

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

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

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

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

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

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

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

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

Страница 131: ...sensor unit with a new one and recheck Faulty TP sensor 3 TP Sensor Resistance Inspection Turn the ignition switch OFF Disconnect the sensor unit 5P Black connector Measure the resistance at the senso...

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

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

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

Страница 135: ...IAT sensor with the HDS pocket tester Is about 0 V indicated YES Replace the sensor unit with a new one and recheck Faulty IAT sensor NO GO TO STEP 3 3 IAT Sensor Output Line Open Circuit Inspection...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 165: ...eir correct position If you cannot assemble them easily the clip may be misaligned Do not attempt to force them together and make sure that the clip is aligned Perform the TP sensor reset procedure pa...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 216: ...MEMO...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 243: ...9 5 Abnormal noise Worn piston pin or piston pin hole Worn connecting rod small end Worn cylinder piston or piston rings Piston ring sticking scuffing bearing damage Clogged oil gallery or oil straine...

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

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

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

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

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

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

Страница 250: ...MEMO...

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

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

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

Страница 254: ...reeps Broken clutch shoe spring Poor performance at high speed or lack of power Worn drive belt Weak driven face spring Worn weight rollers Contaminated pulley faces Bearing remover set 25 mm 07936 ZV...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 270: ...MEMO...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 296: ...MEMO...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 314: ...MEMO...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 366: ...iper upper bleed valve Operate the brake bleeder and loosen the upper bleed valve If an automatic refill system is not used add brake fluid when the fluid level in the reservoir is low Check the fluid...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 394: ...MEMO...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 422: ...MEMO...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 440: ...MEMO...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 456: ...MEMO...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 484: ...MEMO...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 509: ...MEMO...

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

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

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