CONTENTS

HOW TO USE TH~S MANUAL

This service manual describes the service procedures for the FSC600.

Follow the Maintenance Schedule (Section 3) recommendations to ensure

that the vehicle is in peak operating condition and emission levels are at the
proper levels.
GENERAL ~NFORMATmN

FRAME/BODY PANELS/IEXHAUS T
SYSTEM
..
lfl
Performing the first scheduled maintenance is very important. It
compensates for the initial wear that occurs during the break-in period .

Sections 1 and 3 apply to the whole motorcycle. Section 2 illustrates

MA~NTIENANCIE
-111
procedures for removal/installation of components that may be required to lUIBFUCATION SYSTEM
perform service described in the following sections. Sections 4 through 21
describe parts of the motorcycle, grouped according to location. fUIEl SYSTEM
(Prn rammed! Fue~ in" ectoicm)
Find the section you want on this page, then turn to the table of contents on
· the first page of the section.
2 COOUNG SVSTIEM
Most sections start with an assembly or system illustration, service
<(
information and troubleshooting for the section. The subsequent pages give
a:
..,.,.
detailed procedures .
IENrnNIE REMOVAlnNSl AllAlmN
w
>
If you do not know the source of the trouble, go to section 23
Troubleshooting.
a:c CVUNDIER HEAD/VAlVES
t:l
Your safety, and th e safety of others, is very important. To help you make 2 CVUNDER/l?~STON
informed decisions we have provided safety messages and other infor- ~
mation throughout this manual. Of course, it is not practical or possible w IDR~VIE PUllEV /DRIVEN PUllEV I
to warn you about all the hazards associated with servicing this veh icle. 2 CLUTCH
You must use your own good judgement. (.!1
You will find important safety information in a variety of forms inclL,1ding : 2
• Safety Labels - on the vehicle w flNAl REDUCT~ON
• Safety Messages - preceded by a safety alert symbol .&. and one of
three signal words, DANGER, WARNING, or CAUTION .
These signal words mean: · AlTERNATOR/STARTER CLUTCH
You WILL be KILLED or SERIOUSLY HURT if
[! •
!!..!'!!D!•Jq&19;_ you don't follow instructions. CRANKCASE/CRA NKSHAFTI
BALANCER
You CAN be KILLED or SERIOUSLY HURT if
f"WM?W11N$JI you don't follow instructions. FRONT WHEEl/SUSPEN SmN/
STEERING
Piflft.\lia[•h'i ;ou C~N be HURT if you don't follow
- · - - - - ••• , ... instructions. ~
• Instructions - how to service this vehicle correctly and safely. (/) IRIEAR WHEIEl/SUSPENS ION
Cf.)
<(
::c BRAKIE SYSTEM
As you read this manual, you will find information that is preceded by a u
I NOTICE I symbol. The purpose of this message is to help prevent damage to
your vehicle, other property, or the environment. ANT~-lOCK IBIRAKE SYSTEM (ABS)

IBATIE RY /CHARGING SYSTEM

-B
~
mNITION SYSTEM
u
"
...,,
{J
w
d
w
IELECTR~C STARTER

UGHlS/METERS/SW~TCHES

W~R~NG D~AGRAMS

TROUBLESHOOT ING

Date of Issue: October 2007

 SYMBOLS
The. symbols used throughout this manual show specific service procedures. If supplementa ry information
is required
pertaining to these symbols, it will be explained specifically in the text without the use of the symbols.

~~
"'ijllll
Replace the part(s} with new one(s} before assembly.

~ Use the recommende d engine oil, unless otherwise specified .

·~ Use molybdenum oil solution (mi:Kture of the engine oil and molybdenum grease in a ratio of 1:1 }.

-~ Use multi -purpose grease (lithium based multi-purpos e grease NLGI #2 or equivalent).

Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or

~
equivalent}.
Example: Molykote® BR-2 plus manufacture d by Dow Corning U.S.A.
Multi-purpos e M -2 manufacture d by Mitsubishi Oil , Japan

Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or
equivalent}.
·~ Example: Molykote® G-n Paste manufacture d by Dow Corning U.S.A.
Honda Moly 60 (U.S.A. only}
Rocol ASP manufacture d by Rocol Limited, U.K.
.. Rocol Paste manufacture d by Sumico Lubricant, Japan

~ Use silicone grease.

cw Apply a locking agent . Use a medium strength locking agent unless otherwise specified.

.11mru Apply sealant.

I
..
Use DOT 4 brake fluid. Use the recommende d brake fluid unless otherwise specified.

• .
Use fork or suspension fluid.
 1. GENERAL INFORMATION
SERVICE RULES
MODEL IDENTIFICATION
SPECIFICATIONS
TORQUE VALUES
1-1
1-2
1-3
1-11
LUBRICATION & SEAL POINTS
CABLE & HARNESS ROUTING
EMISSION CONTROL SYSTEMS
EMISSION CONTROL INFORMATION
1-17
1-20
1-34
..
LABELS 1-37
TOOLS 1-15

SERVICE RULES
1. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Honda's
design specifications may cause damage to the motorcycle.
2. Use the special tools designed for this product to avoid damage and incorrect assembly.
3. Use only metric tools when servicing the motorcycle. Metric bolts, nuts and screws are not interchangeable with English
fasteners.
4. Install new gaskets, 0-rings, cotter pins, and lock plates when reassembling.
5. When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque diag-
onally in incremental steps unless a particular sequence is specified.
6. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly.
7. After reassembly, check all parts for proper installation and operation.
8. Route all electrical wires as shown on pages 1-20 through 1-33, Cable and Harness Routing .

1-1
GENERAL INFORMATION

MODEL IDENTIFICATION

VEHICLE IDENTIFICATION NUMBER (VIN)

The Vehicle Identification Number (VIN) is located on the

front air duct cover.

FRAME SERIAL NUMBER ENGINE SERIAL NUMBER

(1) The frame serial number is stamped on the right side (2) The engine serial number is stamped on the left
of the frame. crankcase.

THROTILE BODY IDENTIFICATION NUMBER

COLOR LABEL

(3) The throttle body identification number is stamped (4) The color label is attached as shown. When ordering
on the intake side of the throttle body as shown. color-coded parts, always specify the designated
color code.

1-2
 GENERAL INFORMATION

SPECIFICATIONS
- GENERAL
ITEM SPECIFICATIONS

DIMENSIONS Overall length 2,275 mm (89.6 in)

Overall width 770 mm (30.3 in)
Overall height 1,430 mm (56.3 in)
Wheelbase 1,595 mm (62.8 in)
Seat height '02 - '07: 755 mm (29.7 in)
After '07: 740 mm (29.1 in)
Ground clearance 140 mm (5.5 in)
Dry weight '02 - '04: STD TYPE 220 kg (485 lbs)
'03, '04: ABS TYPE 228 kg (502 lbs)
After '04: STD TYPE 227 kg (501 lbs)
ABS TYPE 232 kg (511 lbs)
Curb weight '02 - '04: STD TYPE 239 kg (527 lbs)
'03, '04: ABS TYPE 246 kg (542 lbs)
After '04: STD TYPE 245 kg (540 lbs)
ABS TYPE 250 kg (551 lbs)
Maximum weight capacity
'02 - '04, After '04 (U.S.A. type) 166 kg (366 lbs)
After '04 (Canada type) 170 kg (375 lbs)
Gross weight '02 - '04: STD TYPE 404 kg (891 lbs)
'03, '04: ABS TYPE 412 kg (908 lbs)
After '04 (U.S.A. type): STD TYPE 411 kg (906 lbs)
ABS TYPE 416 kg (917 lbs)
'05 - '07 (Canada type) : STD TYPE 415 kg (915 lbs)
After '04 (Canada type): ABS TYPE 420 kg (926 lbs)
FRAME Frame type Back bone
Front suspension Telescop ic fork
Front wheel travel 120 mm (4.7 in)
Front axle travel 106 mm (4.2 in)
Rear suspension Unit swing
Rear axle travel 115 mm (4.5 in)
Front tire size 120/80-14M/C 58S
Rear tire size 150/70-13M/C 64S
Tire brand
Bridgestone Front: HOOP B03 I Rear: HOOP B02
IRC Front: SS530F I Rear: SS530R
Front brake Hydraulic single disc brake with 3 pots caliper
Rear brake Hydraulic single disc brake with 2 pots caliper
Caster angle 28°30'
Trail length 105 mm (4.1 in)
Fuel tank capacity 16.0 liter (4.22 US gal, 3.52 Imp gal)

1-3
GENERAL INFORMATION

GENERAL (C on t'd)
ITEM SPECIFICATIONS
ENGINE Bore and stroke 72.0 x 71.5 mm (2.83 x 2.81 in)
Displacement 582 cm 3 (35.5 cu -in)
Compression ratio 10.2 : 1
Valve train Chain drive and DOHC
Intake valve opens 5° BTDC (At 1 mm lift)
closes 39° ABDC (At 1 mm lift)
Exhaust valve opens 35° BBDC (At 1 mm lift)
closes - 5° ATDC (At 1 mm lift)
Lubrication system Forced pressure and wet sump
Oil pump type Trochoid
Cooling system Liquid cooled
Air filtration Paper element
Engine dry weight 77.0 kg (169.7 lbs)
CARBURETION Type PGM-FI (Programmed Fuel Injection)
Throttle bore 32 mm (1.3 in)
DR/VE TRAIN Clutch system Dry, automatic centrifugal clutch
Primary reduction V-belt
V-belt ratio 2.100 - 0.850
Final reduction 6.016
ELECTRICAL Ignition system Full transistor digital ignition
Starting system Electric starter motor
Charging system Triple phase output alternator
Regulator/rectifier SCR shorted/triple phase, full wave rectification
Lighting system Battery

1-4
 GENERAL INFORMATION
Unit: mm (in)
- LUBRICATION SYSTEM
ITEM STANDARD SERVICE LIMIT

Engine oil capacity At draining 2.0 liter (2.1 US qt, 1.8 Imp qt) --
At disassembly 2.6 liter (2.7 US qt, 2.3 Imp qt) --
At oil filter change 2.2 liter (2.3 US qt, 1.9 Imp qt) --
Recommended engine oil Pro Honda GN4 4-stroke oil (U.S.A. and Canada)
or eq uivalent motor oil.
API service classification : SG or Higher.
JASO T903 standard : MA
Viscosity: SAE 10W-30
Oil pressure at oil pressure switch 530 kPa (5.4 kgf/cm 2 , 77 psi) at --
5,500 min- 1 (rpm) (80 °C/176 °F)
Oil pump rotor Tip clearance 0.15 (0.006) 0.20 (0.008)
Body clearance 0.12 - 0.22 (0.005 - 0.009) 0.35 (0.014)
Side clearance 0.02 - 0.09 (0.001 - 0.004) 0.12 (0 .005)

- FUEL SYSTEM (Programmed Fuel Injection)

ITEM SPECIFICATIONS

Throttle body identification number '02 - '07: GQ80B

After '07: G080D
No.1 and No.2 cylinders vacuum difference 20 mm Hg
Base throttle valve for synchronization No.1
Idle speed 1,300 ± 100 min- 1 (rpm)
Throttle grip free play 2 - 6 mm (1/16 - 1/4 in)
Intake air temperature sensor resistance (at 40°C/88°F) 1. 136 kQ ± 30 %
Engine coolant temperature sensor resistance (at 20°C/68°F) 2-3 kQ
Fuel injector resistance (at 20°C/68°F) 11.1-12.3 Q
PAIR solenoid valve resistance (at 20°C/68°F) 19 - 25 Q
CMP sensor peak voltage (at 20°C/68°F) 0.7 V minimum
CKP sensor peak voltage (at 20°C/68°F) 0.7 V minimum
Manifold absolute pressure at idle 64.8 kPa (0.66 kgf/cm 2, 9.4 psi)
Fuel pressure at idle 294 kPa (3 .0 kgf/cm 2, 43 psi)
Fuel pump flow (at 12 V) Minimum 60 cm 3 (2.0 US oz, 2.1 Imp oz) for 10 seconds

- COOLING SYSTEM
ITEM SPECIFICATIONS

·Coolant capacity Radiator and engine 2.2 liter (2.3 US qt, 1.9 Imp qt)
Reserve tank 0.8 liter (0.8 US qt, 0.7 Imp qt)
Radiator cap relief pressure 108-137 kPa (1.1-1.4 kgf/cm 2, 16 - 20 psi)
Thermostat Begin to open 80 - 84 °C (176 - 183 °F)
Fully open 95 °C (203 °F)
Valve lift 8 mm (0.3 in) minimum
Recommended antifreeze Pro Honda HP Coolant or an equivalent high quality ethylene
glycol antifreeze containing silicate-free corrosion inhibitors
Standard coolant concentration 50% mixture with soft water

1-5
GENERAL INFORMATION

Unit: mm (in)
- CYLINDER HEAD/VALVES
ITEM STANDARD SERVICE LIMIT
Cylinder compression 1,373 kPa (14.0 kgf/cm 2
, 199 psi) -
at 250 min -1 (rpm)
Cylinder head warpage - 0.05 (0.002)
Valve, Valve clearance IN 0.16 ± 0.03 (0.006 ± 0.001) -
valve gu ide
EX 0.22 ± 0.03 (0.009 ± 0.001) -
Valve stem O.D. IN 4.475 - 4.490 (0.1762 - 0.1768) 4.465 (0.1758)
EX 4.465 - 4.480 (0.1758 - 0.1764) 4.455 (0.1754)
Valve guide l.D. IN 4.500 - 4.512 (0.1772 - 0.1776) 4.540 (0.1787)
EX 4.500 - 4.512 (0.1772 - 0.1776) 4.540 (0.1787)
Stem-to-guide clearance IN 0.010 - 0.037 (0.0004 - 0.0015) -
EX 0.020 - 0.047 (0.0008 - 0.0019) -
Valve guide projection above IN 15.3 - 15.5 (0.60 - 0.61) -
cylinder head EX 15.3 - 15.5 (0.60 - 0.61) -
Valve seat width IN/EX 0.90 - 1.10 (0.035 - 0.043) 1.5 (0.06)
Valve spring free length IN/EX 40.19 (1.582) 38.2 (1.50)
Valve lifter Valve lifter O.D. IN/EX 25.978 - 25.993 ( 1.0228 - 1.0233) 25.97 (1.022)
Valve lifter bore l.D. IN/EX 26.010 - 26.026 (1.0240 - 1.0246) 26.04 ( 1.025)
Camshaft Cam lobe height IN 35.120 - 35 .200 ( 1.3827 - 1.3858) 34.82 ( 1.371)
EX 35.180 - 35.260 ( 1.3850 - 1.3882) 34.88 (1.373)
Runout - 0.05 (0.002)
Oil clearance 0.030 - 0.072 (0.012 - 0.0028) 0.10 (0.004)

Unit: mm (in)
- CYLINDER/PISTON
ITEM STANDARD SERVICE LIMIT
Cylinder l.D. 72.000 - 72.015 (2.8346 - 2.8352) 72.10 (2.839)
Out of round - 0.10 (0.004)
Taper - 0.10 (0.004)
Warpage - 0.10 (0.004)
Piston, piston Piston mark direction "IN" mark facing toward the intake side -
rings Piston O.D. 71.97 - 71.99 (2.833 - 2.834) 71.90 (2.831)
Piston O.D. measurement point 18 mm (0.7 in) from bottom of skirt -
Piston pin bore l.D. 17.002 - 17.008 (0.6694 - 0.6696) 17.04 (0.671)
Piston pin O.D. 16.994 - 17.000 (0.6691 - 0.6693) 16.96 (0.668)
Piston-to-piston pin clearance 0.002 - 0.014 (0.0001 - 0.0006) 0.02 (0 .001)
Piston ring -to-ring Top 0.030 - 0.065 (0.0012 - 0.0026) 0.08 (0 .003)
groove clearance
Second 0.015 - 0.050 (0.0006 - 0.0020) 0.065 (0.0026)
Piston ring end gap Top 0.15 - 0.30 (0.006 - 0.012) 0.50 (0.020)
Second 0.30 - 0.45 (0.012 - 0.018) 0.65 (0.026)
Oil (side rail) 0.20 - 0.70 (0 .008 - 0.028) 1.00 (0.040)
Cylinder-to-piston clearance 0.010 - 0.045 (0.0004 - 0.0018) 0.10 (0.004)
Connecting rod small end l.D. 17.016 - 17.034 (0.6699 - 0.6706) 17.06 (0.672)
Connecting rod-to-piston pin clearance 0.016 - 0.040 (0.0006 - 0.0016) 0.06 (0.002)

1-6
 GENERAL INFORM ATION
Unit: mm (in)
- DRIVE PULLEY /CLUTCH/DFJIVEN PULLEY
STANDARD SERVICE LIMIT
ITEM
Clutch outer l.D . 160.0 - 160.2 (6.30 - 6.31) 160.5 (6.32)
Clutch
Lining thickness 4.0 (0.16) 1.0 (0.04)
28.0(1.10) 27.0 (1.06)
Drive belt width

Movable drive face

8
Bushing l.D.
Boss O.D.
38.024 - 38.057 ( 1.4970 - 1.4983)
37.995 - 38.031 (1.4959 - 1.4973)
38.10 (1.50)
37.95 ( 1.494)

Weight roller O.D. 27.92 - 28.08 (1.099 - 1.106) 27.5 (1.08)

Face spring free length 107.7 (4.24) 102.7 (4.04)

Driven pulley
Driven face O.D. 47.965 - 47.985 (1.8883 - 1.8892) 47.94 (1.887)

Movable driven face l.D. 48.000 - 48.025 (1.8898 - 1.8907) 48.06 ( 1.892)

- FINAL REDUCT ION

ITEM SPECIFICATIONS

Final reduction oil capacity [ At draining 0.32 liter (0.34 US qt, 0.28 Imp qt)

I At disassemb ly 0.35 liter (0.37 US qt, 0.31 Imp qt)

Recommen ded final reduction oil Pro Honda GN4 4-stroke oil (U.S.A. and Canada) or equivalent
motor oil.
API service classificatio n : SG or Higher.
JASO T903 standard : MA
Viscosity: SAE 10W-30

Unit: mm (in)
- ALTERNATOR/STARTER CLUTCH
ITEM STANDARD SERVICE LIMIT

Boss O.D. 57.749 - 57.768 (2.2736 - 2.2743) 57.70 (2.272)

Starter driven gear
Bushing l.D. 29.046 - 29.062 (1.1435 - 1.1442) 29.10 (1.146)
74.412 - 74.442 (2.9296 - 2.9308) . 74.49 (2.933)
Starter clutch outer l.D.

Unit: mm (in)
- CRANKC ASE/CRA NKSHAF T /BALANC ER
ITEM STANDARD SERVICE LIMIT

0.15 - 0.30 (0.006 - 0.012) 0.40 (0.016)

Crankshaft Side clearance
0.028 - 0.052 (0.0011 - 0.0020) 0.07 (0.003)
Crank pin oil clearance
0.025 - 0.041 (0.0010 - 0.0016) 0.07 (0.003)
Main bearing oil clearance

1-7
GENERAL INFORMA TION

- FRONT WHEEL/SUSPENSION/STEERING Unit: mm {in)

ITEM STANDARD SERVICE LIMIT
Minimum tire tread depth - 1.5 (0.06)
Cold tire pressure Up to 90 kg (200 lb) load 200 kPa (2.00 kgf/cm 2, 29 psi) -
Up to maximum weight capacity 200 kPa (2.00 kgf/cm 2 , 29 psi) -
Axle runout - 0.20 (0.008)
Wheel rim runout Radial - 2.0 (0.08)
Axial - 2.0 (0.08)
Wheel balance weight - 60 g (2.1 oz)
Fork Spring free length 331.4 (13.05) 325 (12.8)
Tube runout - 0.20 (0.008)
Recommende d fork fluid Pro Honda Suspension Fluid SS-8 -
Fluid level 97 (3.8) -
Fluid capacity 302 ± 2.5 cm 3 (10.2 ± 0.08 US oz, -
10.6 ± 0.09 Imp oz)
Steering head bearing pre-load 13 - 17 N (1.3 - 1.7 kgf, 2.9 - 3.7 lbf) -

- REAR WHEEL/SUSPENSION Unit: mm {in)

ITEM STANDARD SERVICE LIMIT
Minimum tire tread depth - 2.0 (0.08)
Cold tire pressure Up to 90 kg (200 lb) load 225 kPa (2 .25 kgf/cm 2, 33 psi) -
Up to maximum weight capacity 250 kPa (2.50 kgf/cm 2, 36 psi) -
Wheel rim runout Radial - 2.0 (0.08)
Axial - 2.0 (0.08)
Wheel balance weight - 60 g (2.1 oz)
Right swingarm pivot O.D. 35.012 - 35.028 { 1.3784 - 1.3791) 34.70 (1.366)

1-8
 GENERAL INFORMATION
Unit: mm (in)
- BRAKE SYSTEM
ITEM STANDARD SERVICE LIMIT

Front Specified brake fluid DOT 4 -

Brake disc thickness '02 - '06 standard type 4.8 - 5.2 (0.19 - 0.20) 4.0 (0.16)
After '02 ABS type/ 5.8 - 6.2 (0.22 - 0.24) 5.0 (0.20)
After '06 standard type
Brake disc runout - 0.30 (0.012)
Master cylinder l.D. 11.000 - 11.043 (0.4331 - 0.4348) 11.055 (0.4352)
Master piston O.D. 10.957 - 10.984 (0.4314 - 0.4324) 10.945 (0.4309)
Caliper cylinder l.D. Upper 27.000 - 27.050 ( 1.0630 - 1.0650) 27.060 ( 1.0654)
Middle 22.650 - 22.700 (0.8917 - 0.8937) 22 .710 (0 .8941)
Lower 27.000 - 27.050 (1.0630 - 1.0650) 27.060 ( 1.0654)
Caliper piston O.D . Upper 26.935 - 26.968 (1.0604 - 1.0617) 26.910 ( 1.0594)
Middle 22.585 - 22.618 (0.8892 - 0.8905) 22.560 (0.8882)
Lower 26.935 - 26.968 (1.0604 - 1.0617) 26.910 (1.0594)
Rear Specified brake fluid DOT 4 -
Brake disc thickness 6.3 - 6.7 (0.25 - 0.26) 5.5 (0.22)
Brake disc runout - 0.30 (0.012)
Master cylinder l.D. 12.700 - 12.743 (0.5000 - 0.5017) 12.755 (0.5022)
Master piston 0.D. 12.657 - 12.684 (0.4983 - 0.4994) 12.645 (0.4978)
Caliper cylinder l.D. 27.000 - 27.050 ( 1.0630 - 1.0650) 27.060 ( 1.0654)
Caliper piston O.D. 26.935 - 26.968 (1.0604 - 1.0617) 26.910 (1.0594)
Parking Caliper cylinder l.D. 20.00 - 20.05 (0.787 - 0.789) 20.060 (0.790)
Caliper piston O.D. 19.935 - 19.968 (0.7848 - 0.7861) 19.927 (0.7845)

- BATTERY/CHARGING SYSTEM
ITEM SPECIFICATIONS

Battery Capacity 12 V - 11 (10) Ah

Current leakage 1.1 mA max.
Voltage (20°C/68°F) Fully charged 13.0 - 13.2 v
Needs charging Below 12.3 V
Charging current Normal 1.1 A/5 - 10 h
Quick 5.5 A/0.5 h
Alternator Capacity 441 W/5,000 min-1 (rpm)
Charging coil resistance (20°C/68°F) 0.1 - 0.5 Q

1-9
GENERAL INFORMATION

- IGNITION SYSTEM
ITEM SPECIFICATIONS
Spark plug NGK CR8EH-9
DENSO U24FER9
Spark plug gap 0.80 - 0.90 mm (0.031 - 0.035 in)
Ignition coil peak voltage 100 V minimum
CKP sensor peak voltage 0.7 V minimum
Ignition timing ("F" mark) 12° BTDC at idle

- Unit: mm (in)
ELECTRIC STARTER
ITEM STANDARD SERVICE LIMIT
Starter motor brush length 12.5 (0.49) 8.5 (0.33)

..- LIGHTS/METERS /SWITCHES

ITEM SPECIFICATIONS
Bulbs Headl ight 12 v - 55 w x 2
Brake/tail light 12 v - 21 /5 w x 2
Front turn signal/position light 12V-21Wx2
Rear turn signal 12 v - 21 w x 2
License light 12 V- 5 W
Instrument light LED
Turn signal indicator LED
High beam indicator LED
Parking indicator LED
Oil pressure indicator LED
PGM-FI warning indicator LED
Temp warning indicator LED
V-Matic indicator LED
ABS warning indicator (ABS TYPE) LED
Luggage box instrument light 12 V - 3.4 W
Fuse Main fuse Main A: 30 A, Main B: 30 A
Sub fuse (ABS TYPE) 30A x 2, 15 Ax 2, 10 Ax 5
Sub fuse (STD TYPE) 15Ax2,10Ax4
Thermosensor resistance at 80°C/176°F 2.1 - 2.6 kQ
at 120°C/248°F 0.65 - 0.73 kQ

1-10
 GENERAL INFORMA TION

TORQUE VALUES
TORQUE TORQUE
FASTENER TYPE FASTENER TYPE
N•m (kgf•m, lbfoft) N•m (kgf•m, lbfoft)

5 (0.5, 3.6) 5 mm screw 4 (0.4, 2.9)

5 mm bolt and nut
10 (1.0, 7) 6 mm screw 9 (0.9, 6.5)
6 mm bolt and nut (include small flange
6 mm flange bolt (10 mm head) and nut 12 (1.2, 9)
bolt)
22 (2 .2, 16) 8 mm flange bolt and nut 26 (2.7, 20)
8 mm bolt and nut
34 (3.5, 25) 10 mm flange bolt and nut 39 (4.0, 29)
10 mm bolt and nut
12 mm bolt and nut 54 (5.5, 40)

• Torque specifications listed below are for important fasteners.

• Others should be tightened to standard torque values listed above.

NOTES: 1. Apply oil to the threads and seating surface.

2. Apply a locking agent to the threads.
3. CT bolt.
4. UBS bolt.
5. Torx bolt.
6. Apply sealant to the threads.
7. ALOC bolt: replace with a new one.
8. U-nut.
9. One-way bolt.

~
ENGINE
THREAD TORQUE REMARKS
ITEM QTY
DIA. (mm) N•m (kgf•m, lbfoft)

MAINTENANCE:
Timing hole cap 1 14 10 (1.0, 7) NOTE 1
Balancer shaft hole cap 1 14 10 (1.0, 7) NOTE 1
Oil strainer screen cap 1 36 15 (1.5, 11) NOTE 1
Oil frlter cartridge 1 20 26 (2.7, 20) NOTE 1
Transmission oil check bolt 1 8 13 (1.3, 9)
Transmission oil drain bolt 1 8 13 (1.3, 9)
Spark plug 2 10 16 (1.6, 12)
LUBRICATION SYSTEM:
Oil pump screw 1 4 3 (0.3, 2.2)
Oil pump drive sprocket bolt 1 10 49 (5.0, 36) NOTE 1
Oil pump driven sprocket bolt 1 6 15 (1.5, 11) NOTE 2
Oil cooler bolt 1 20 64 (6.5, 47) NOTE 1
FUEL SYSTEM:
Fuel rail mounting bolt 2 6 10 ( 1.0, 7)
Fast idle wax unit mounting screw 2 4 4 (0.4, 2.9)
COOLING SYSTEM:
Water pump cover bolt 2 6 13 (1.3, 9) NOTE 3
CYLINDER HEAD/VALVES:
Reed valve cover bolt 2 6 13 (1.3, 9) NOTE 3
Breather separator bolt 3 6 13 (1.3, 9) NOTE 2, 3
Cylinder head sealing bolt 2 18 32 (3.3, 24) NOTE 2
Cylinder head 9 mm bolt 6 9 44 (4.5, 33) NOTE 1
Camshaft holder bolt 12 6 12 (1.2, 9) NOTE 1
Cylinder head cover bolt 4 6 10 (1.0, 7)
Cam sprocket bolt 4 7 20 (2.0, 14) NOTE 2
Cam chain tensioner pivot bolt 1 6 12 (1.2, 9)

1-11
GENERAL INFORM ATION

- ENGINE (C on t'd)

ITEM QTY THREAD TORQUE

DIA.(mm) REMARKS
N•m (kgf•m, lbf.ft)
DRIVE PULLEY /CLUTCH/D RIVEN PULLEY:
Drive plate bolt 6 8 26 (2.7, 20)
Element cover screw 1 4 1 (0.1, 0.7)
Left rear cover special bolt 4 6 10 (1.0, 7)
Drive face bolt 1 12 103 (10.5, 76) NOTE 1, 4
Driven pulley nut 1 16 54 (5.5, 40)
FINAL REDUCTION:
Transmissi on cover socket bolt 2 8 25 (2.5, 18)
Transmissi on cove flange bolt 5 8 25 (2.5, 18)
ALTERNATOR/STARTER CLUTCH:
Starter clutch socket bolt 6 8 29 (3.0, 22) NOTE 2
CKP sensor socket bolt 2 6 12 (1.2, 9)
Flywheel bolt 1 12 103 (10.5, 76) NOTE 1, 4
Stator socket bolt 3 6 12 (1.2, 9)
CRANKCASE/CRANKSHAFT /BALANCER:
Right crankcase socket bolt (10 mm) 1 10 34 (3.5, 25) NOTE 2
Right crankcase sealing bolt (18 mm) 1 18 44 (4.5, 33) NOTE 2
Left crankcase socket bolt 1 8 23 (2.3, 17) NOTE 2
Connecting rod bearing cap nut 4 9 42 (4.3, 31) NOTE 1
LIGHTS, METERS, SWITCHES:
Oil pressure switch 1 PT 1/8 12 (1.2, 9) NOTE 6
ECT!Therm osensor 1 12 23 (2.3, 17)

Insulator band: Exhaust pipe stud bolt:

I
i
- ~ · ~ · _J_ · ~ - ~ - 36 ± 0.5 mm (1.42 ± 0.02 in)

1-12
 GENERAL INFORMATION

FRAME
THREAD TORQUE
ITEM QTY REMARKS
DIA.(mm) N•m (kgf•m, lbf.ft)

FRAME BODY PANELS/EXHAUST SYSTEM:

Rear frame bolt 4 8 26 (2.7, 20)
Rear spoiler bolt 4 8 26 (2.7, 20)
Exhaust pipe band bolt 2 8 21 (2.1, 15)
Exhaust pipe joint nut.
Tightening procedure:
3 2

Right
..__ Left
___..
1 4

Exhaust pipe mounting bolt 1 8 22 (2.2, 16)

Muffler protector bolt 3 5 4 (0.4, 2.9)
Muffler tail cover mounting bolt 4 5 4 (0.4, 2.9)
Windscreen garnish set screw 2 5 2 (0.2, 1.4)
Windscreen set screw 6 5 1 (0.1, 0.7)
FUEL SYSTEM:
Fuel pump banjo bolt (Fuel tank side) 1 12 22 (2.2, 16)
Fuel hose sealing nut (Throttle body side) 1 12 22 (2.2, 16)
Fuel pump mounting nut 7 6 12 ( 1.2, 9)
Tightening procedure:
6

2
..-- Front 1

Fuel tank mounting nut 1 8 21 (2.1, 15)

Fuel tank mounting bolt 2 6 12(1.2,9)
02 sensor (After '07) 1 18 44 (4.5, 33)
COOLING SYSTEM:
Cooling fan nut 1 5 3 (0.3, 2.2) NOTE 2
Fan motor mounting bolt 3 5 5 (0.5, 3.6)
Radiator shroud mounting bolt 3 6 9 (0.9, 6.5)
Radiator reserve tank mounting bolt 2 6 10 ( 1.0, 7)
ENGINE MOUNTING:
Engine mounting nut 3 10 39 (4.0, 29)
FRONT WHEEL/SUSPENSION/STEERING:
Handle post pinch bolt (upper) 12 128 (13.0, 94)
Handle post pinch bolt (lower) 10 69 (7.0, 51)
Steering stem nut 26 74 (7.5, 54)
Steering top thread 26 13 (1.3, 9)
Steering stem pinch bolt 4 10 69 (7.0, 51)
Front axle bolt 1 14 59 (6.0, 43)
Front fork axle holder bolt 2 8 22 (2.2, 16)
Front fork cap 2 36 23 (2.3, 17)
Front fork socket bolt 2 10 29 (3.0, 22) NOTE 2
Front brake disc bolt 6 8 42 (4.3, 31) NOTE 7
Handlebar lower holder nut 2 10 39 (4.0, 29)

1-13
GENERAL INFORMATION

- FRAME (C on t'd)
THREAD TORQUE
ITEM QTY REMARKS
DIA.(mm) N•m (kgf•m, lbf.tt)
REAR WHEEL/SUSPENSION:
Rear brake disc bolt 4 8 42 (4.3, 31) NOTE 7
Rear axle nut 1 18 138 (14.1, 102) NOTE 8
Rear shock absorber upper mounting bolt 2 8 22 (2.2, 16)
Rear shock absorber lower mounting bolt 2 10 39 (4.0, 29)
Final shaft holder bolt 2 10 49 (5.0, 36)
Right swingarm torx bolt 3 10 34 (3.5, 25) NOTE 5
Swingarm case bolt (center swingarm) 4 10 37 (3.8, 27) NOTE 2
Right swingarm pivot mounting bolt 5 8 24 (2.4, 17)
Swingarm flange mounting bolt 6 8 25 (2.5, 18)
BRAKE SYSTEM:
Master cylinder reservoir cover screw 4 4 2 (0.2, 1.4)
Master cylinder holder bolt 4 6 12 (1.2, 9)
Brake lever pivot bolt 2 6 1 (0.1, 0.7)
Brake lever pivot nut 2 6 6 (0.6, 4.3)
Front brake light switch screw 1 4 1 (0.1, 0.7)
Rear brake light/limit switch screw 2 4 1 (0.1, 0.7)
Brake caliper mounting bolt 4 8 30 (3.1, 22) NOTE 7
Front brake caliper body B bolt 3 8 32 (3.3, 24) NOTE 7
Brake caliper bleed valve 3 8 6 (0.6, 4.3)
Brake pad pin 2 10 18 (1.8, 13)
Rear caliper pad pin plug 1 10 3 (0.3, 2.2)
Front caliper main pin bolt 1 8 22 (2.2, 16) NOTE 2
Front caliper sub pin bolt 1 8 12 (1.2, 9) NOTE 2
Rear caliper main pin bolt 1 12 28 (2.9, 21) NOTE 2
Rear caliper sub pin bolt 1 8 12 (1.2, 9) NOTE 2
Parking brake caliper mounting bolt 1 8 30 (3.1, 22) NOTE 2
Parking brake caliper pin bolt 1 8 23 (2.3, 17)
Brake hose oil bolt 7 10 34 (3.5, 25)
Brake pipe nut 4 10 14 (1.4, 10) NOTE 1
ANTI-LOCK BRAKE SYSTEM (ABS)
Front pulser ring bolt 3 5 8 (0.8, 5.8) NOTE 5, 7
Rear pulser ring bolt 3 5 8 (0.8, 5.8) NOTE 5, 7
Brake pipe nut 5 10 14 (1.4, 10)
LIGHTS/METERS/SWITCHES:
Ignition switch mounting bolt 2 8 26 (2.7, 20) NOTE 9
OTHERS:
Sidestand pivot bolt 1 10 10 (1.0, 7)
Sidestand pivot nut 1 10 29 (3.0, 22)
Sidestand switch mounting bolt 1 6 10 (1.0, 7)

1-14
 GENERAL INFORMA TION

TOOLS
NOTES: 1. Equivalent commercially available.
2. Alternative tool.
3. Newly provided tool.
4. Newly designed tool.
5. U.S.A. only

DESCRIPTION . _TOOL NUMBER REMARKS REF. SEC.

07406-00400 02 NOTE 5: 07406-004000B or 5

Fuel pressure gauge
07 406-004000A
07506-30000 00 NOTE 1 4
Oil pressure gauge
07510-4220100 NOTE 1 4
Oil pressure gauge attachment
07631-0010000 NOTE 1 11
Universal bearing puller
07702-0020001 14
Adjustable pin spanner
07725-00300 00 NOTE 5: 07AMB-MCTA100 10
Universal holder
07725-00400 00 NOTE 1 12
Flywheel holder
07733-0020001 NOTE 5: 07933-3950000 12
Flywheel puller
Remover weight 07741-0010201 NOTE 5: 07936-371020A or 11, 13, 14, 15
07936-3710200
07946-1870100 10
Attachment, 28 x 30 mm
Attachment, 32 x 35 mm 07746-0010100 10, 11
Attachment, 42 x 47 mm 07746-0010300 13, 14, 15
07746-0010400 11 , 14
Attachment, 52 x 55 mm
07746-0010500 11
Attachment, 62 x 68 mm
Attachment, 40 x 42 mm 07746-0010900 14
07746-0030300 14
Attachment, 30 mm
Pilot, 17 mm 07746-00404 00 10
07746-0040500 11, 13, 14, 15
Pilot, 20 mm
Pilot, 25 mm 077 46-0040600 10, 11
07746-0040700 11
Pilot, 30 mm
07746-0040800 15
Pilot, 35 mm
Pilot, 22 mm 07746-0041000 11
Bearing remover shaft 07746-0050100 14
Bearing remover head, 20 mm 07746-005060 0 14
Driver 07749-0010000 10, 11, 13, 14, 15
Tensioner holder 07AMG -001A100 NOTE 5 8
Valve spring compressor 07757-0010000 8
Valve seat cutter NOTE 1
Seat cutter, 24.5 mm 07780-0010100 8
Seat cutter, 29 mm 07780-0010300 8
Flat cutter, 30 mm 07780-0012200 8
Flat cutter, 27 mm 07780-0013300 8
Interior cutter, 30 mm 07780-0014000 8
Interior cutter, 26 mm 07780-0014500 8
Cutter holder, 4.5 mm 07781-0010600 8
07914-SA50001 16
Snap ring pliers
07916-KM 10000 14
Lock nut wrench
07936-3710100 11, 13, 15
Remover handle
07936-3710400 15
Bearing remover
07936-3710600 11, 13
Bearing remover, 20 mm
07936-ZV10100 NOTE 5: 07936-ZV1A 100 11
Bearing remover, 25 mm
07946-1870100 11
Attachment, 28 x 30 mm
Bearing driver attachment 07947-6340400 11
Slider weight 07947-KA50100 14
07947-KF00100 14
Fork seal driver attachment, 41 mm
Oil seal driver attachment 07948-SC20200 10
07953-4250002 NOTE 5: 07953-MJ 10008 14
Ball race remover
07953-MJ 10200 10
Driver handle
Piston ring slider 07954-28300 00 9
07958-2500001 9
Piston base
07959-KM30101 8
Valve spring compressor attachment
07965-VM002 00 11
Assembly shaft
07HAA-PJ70100 3, 4
Oil filter wrench
07HGJ -0020100 5, 18,20
Peak voltage adaptor
MTP07-0286 NOTE 5 5, 18, 20
lgnitionMate peak voltage tester

1-15
GENERAL INFORMA TION

DESCRIPTION TOOL NUMBER REMARKS REF. SEC.

Bearing driver attachment, 78 x 90 07GAD-SD40101 15
Needle bearing remover 07HMC-MR70100 Not available in U.S.A. 10
Valve guide driver 4.5 mm 07HMD-ML00101 8
Tappet hole protector 07HMG-MR7 0002 Not available in U.S.A. 8
Valve guide reamer, 4.508 mm 07HMH-ML00101 NOTE 5: 07HMH-ML0010B 8
Bearing remover shaft 07 JAC-PH80200 14
Pilot, 32 x 50 mm 07MAD-PR90200 11
Compression gauge attachment 07RMJ-MY50 100 NOTE 1 8
Adjustable bearing remover 07YAC-0010101 14
Assembly collar 07YM F-KPB0100 11
Christie battery charger MC1012/2 NOTE 5 17
Battery tester BM-210-AH or NOTE 5 17
BM-210
ECU test harness 07YMZ-0010100 NOTE 5: 07WMZ-MBGAOOO 5
Clutch outer puller 07ZMC-MCT0100 NOTE 5: 07ZMC-MCTA 100 10
Driver attachment, 110 x 140 mm 07ZMD-MCT0100 NOTE 5: 07ZMD-MCTA 100 15
Clutch spring compressor 07ZME-MCT0100 NOTE 5: 07ZME-MCTA 100 10
Clutch outer assembly tool 07ZMF-MCT0100 10
Crank assembly guide 07ZMG-MCT0100 NOTE 5: 07ZMG-MCTA 100 13
Slide hammer 3/8 x 16 Commerciall y available in U.S.A. 10, 14
Adjustable bearing puller 25-40 mm 07736-A01000B or NOTE 5 10, 14
07736-A01 OOOA
Assembly collar 07ZMF-MCTA 100 NOTE 5 10
Threaded shaft 22 x 1.5 x 240 07931-ME4010B NOTE 5 10
Special nut 07931-H B3020A NOTE 5 10
ECM test harness 32P 070MZ-0010201 5
SCS connector 070PZ-ZY30100 5
02 sensor wrench 07LAA-PT50101 5

1-16
 GENERAL INFORMATION

LUBRICATION & SEAL POINTS

ENGINE
LOCATION MATERIAL REMARKS

Crankcase mating surface Liquid sealant

(Three Bond 1207B or
equivalent)

Right crankcase cover mating surface Liquid sealant

(Three Bond 1207B or
equivalent)

Transmission cover mating surface Liquid sealant

(Three Bond 1215 or
equivalent)

Cylinder head mating surface Liquid sealant

Applied portion (Three Bond 1211 or
Shell KE45T or
equivalent)

Oil pressure switch threads Liquid sealant

(Three Bond 1207B or
Do not apply sealant to the thread equivalent)
head 3- 4 mm (0.1 - 0.2 in)

1-17
GENERAL INFORMATION

- ENGINE (C on t'd)
LOCATION MATERIAL REMARKS
Swingarm center bolt threads Locking agent Three Bond 2415, 1323B or
Right crankcase 10 mm socket bolt threads LOCTITE DL-200, DL-648 or equivalent
Right crankcase 18 mm sealing bolt threads
Left crankcase 8 mm socket bolt threads
Cylinder head 18 mm sealing bolt threads
Breather separator bolt threads
Cam sprocket bolt threads
Oil pump driven sprocket bolt threads
Starter clutch bolt threads
Driven pulley 040 bearing area and 2 mm width groove Molybdenum disulfide
paste
Main bearing thrust surface and sliding surface Molybdenum disulfide
grease
Connecting rod bearing sliding surface Molybdenum disulfide
Piston pin sliding area oil (a mixture of 50%
Crankshaft thrust surface engine oil and 50%
Crankshaft 029 surface of the starter driven gear area molybdenum disulfide
Balancer shaft sub-gear sliding area grease)
Camshaft bearing surface, cam surface and thrust surface
Valve stem sliding area
Valve lifter outer sliding area
Water pump sliding area and thrust surface Do not apply to the mechanical seal
sliding surface
Starter reduction gear and idle gear shaft sliding surface
Driven face boss inner surface Lithium based grease Filling 23 - 28 g : Do not apply to the
Movable driven face cam groove (Shell ALVANIA R3, driven pully surface.
Nippon Oil POWERNOC WB3, Filling 7 - 9 g : Do not apply to the
Idemitsu Kosan AUTOLEX B driven pully surface
or equivalent)
Final gear shaft 022 bearing area Multi-purpose grease
Final gear shaft dust seal lips
Each oil seal lip
Balancer shaft hole cap threads Engine oil
Timing hole cap threads
Oil strainer screen cap threads
Cylinder wall surface
Cylinder head bolt threads and seating surface
Camshaft holder bolt threads and seating surface
Connecting rod bolt/nut threads and seating surfaces
Piston sliding area
Piston ring sliding area
Cam chain whole surface
Oil pump drive sprocket bolt threads and seating surface
Oil pump drive chain whole surface
Oil filter cartridge threads and mating surface
Oil cooler bolt threads and seating surface
Drive face bolt threads
Transmission gear teeth and shaft
Starter clutch sliding lock surface
Flywheel bolt threads and seating surface
Each 0 -ring
Each bearing rotating area

1-18
 GENERAL INFOR MATIO N

FRAME REMARKS
LOCATION MATERI AL

Silicone grease Apply 0.1 g

Brake lever pivot
Apply 0.1 g
Brake lever-to- master piston contacti ng area
Apply 0.4 g min.
Caliper pin boot inside
Apply 0.4 g min.
Caliper dust seals
Apply 0.4 g min.
Parking brake caliper push rod sliding surface
Apply 0.4 g min.
Parking brake caliper shaft sliding surface
Apply 0.4 g min .
Parking brake caliper boot lip
Filling 0.1 cm 3
Throttle cable A and B inside
Urea based water Filling 3 - 5 g
Steering head bearing rolling surface
Steering head dust seal lips resistan t grease with
extreme pressure agent
(exampl e: EXCELITE
EP2 manufac tured
by KYODO YUSHI,
Japan) , or equivale nt.

Sidestan d pivot shaft Multi-pu rpose grease

Centerst and bracket outer sliding surface
Seat catch hook
Each dust seal lip
Brake pipe joint nut threads Engine oil

Brake master cylinder inner surface DOT 4 brake fluid

Brake master pistons and cups
Caliper piston outer surfaces
Caliper piston seals
Fork oil seal lips Pro Honda Suspens ion
Fluid SS-8
Honda bond A, Applied area 80% min.
Handle grip rubber inside
Air cleaner connect ing tube-to- housing mating area Honda Hand Grip
Cement (U.S.A. only)
or equivale nt

Fork socket bolt threads Locking agent

Caliper pin bolt threads

1-19
 GENERAL INFORM ATION

CABLE & HARNESS ROUT ING

STD TYPE:

THROTTLE CABLES

~--- LEFT HANDLEB AR

- "'"'"'"~ SWITCH WIRE

AFTER '02 (ABS TYPE):

CONNECTORS:
- IGNITION SWITCH 3P
- LEFT HANDLEB AR SWITCH 9P
- LEFT HANDLEB AR SWITCH 6P
- RIGHT HANDLEB AR SWITCH 9P (RED)
- BANK ANGLE SENSOR 3P (BLACK)
- HEADLIG HT/POSIT ION LIGHT/
TURN SIGNAL LIGHT 9P (BROWN)
FRONT WHEEL
FRONT WHEEL SPEED SENSOR
SPEED SENSOR WIRE 2P (ORANGE)
CONNECTOR

FRONT LEFT
FRONT RIGHT
TURN SIGNAL WIRE
TURN SIGNAL WIRE

/~

1-20
 GENERAL INFORMATION

STD TYPE:

FRONT BRAKE HOSE

AFTER '02 (ABS TYPE):

THROTILE CABLES

BRAKE
PIPES ~~~;ii~~

AFTER '02 (ABS TYPE):

FRONT WHEEL
SPEED SENSOR WIRE

1-21
GENERAL INFORMATI ON
STD TYPE:

LEFT HANDLEBAR
SWITCH WIRE

REAR BRAKE LIGHT

SWITCH/LIMIT
SWITCH WIRES

FUEL TANK SEPARATOR

BREATHER HOSE

IGNITION COIL
PRIMARY WIRE

SPARK PLUG WIRES

AFTER '02 (ABS TYPE):

PARKING BRAKE
CABLE

1-22
 GENERAL INFORMA TION

STD TYPE:

PAIR CONTROL VALVE

HOSES CRANKCASE
MAIN WIRE HARNESS BREATHER HOSE

I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
THROTILE CABLES I
I
I
I
FUEL RETURN HOSE I
I
I
I
I

VEHICLE SPEED SENSOR/

REAR WHEEL SPEED SENSOR WIRE

1-23
GENERAL INFORMATION
'02 - '07:

IAT SENSOR
MAP .SENSOR

FUEL TANK SEPARATOR

BREATHER HOSE

1-24
 GENERAL INFORMATION
AFTER '07:

CRANKCASE
BREATHER HOSE
MAP SENSOR

02SENSOR
4P (GRAY)
CONNECTOR

ALTERNATOR
WIRE
FUEL OVERFLOW
HOSE

FUEL TANK SEPATATOR

BREATHER HOSE

1-25
GENERAL INFORMATION
STD TYPE:

GROUND CABLES
MAIN FUSE BOX

I
I
I
I
I
I
I
I
I
I

I
I
I
I
I
I
I
I
SIDESTAND SWITCH WIRE I
I
I
I
I
OIL PRESSURE SWITCH WIRE I
I
I

AIR CLEANER CHAMBER

BREATHER HOSE

AFTER '02 (ABS TYPE):

r- -- - - - - - - - -- - -- - ---- - ---- ---- --- - - ---L-- - - - --- - - - -- _ l _ --- -- ____ ,

I I
L.---------------------------------------------------------------J
VEHICLE SPEED SENSOR/
REAR WHEEL SPEED SENSOR WIRE

1-26
 GENERAL INFORMATION
'02 - '07 STD TYPE:
FUEL CUT-OFF RELAY

ECM SERVICE
CONNECTOR

'03 - '07 ABS TYPE:

1-27
GENERAL INFORMATION
AFTER '07:

ENGINE STOP RELAY

MAIN FUSE BOX

FUSE BOX

ECM 32P (LIGHT GRAY)

CONNECTOR

VEHICLE SPEED SENSOR

REAR WHEEL SPEED SENSOR

(ABS TYPE)
STARTER RELAY SWITCH/
MAIN FUSE A
VEHICLE SPEED SENSOR
3P (STD TYPE)/6P (ABS TYPE)
CONNECTOR

PARKING BRAKE CABLE

1-28
 GENERAL INFORMATION
'02 - '07:
LUGGAGE BOX LIGHT SWITCH

REAR COMBINATION/
LICENSE PLATE LIGHT WIRE

AFTER '07: SEAT LOCK CABLE

LUGGAGE BOX LIGHT SWITCH

LUGGAGE BOX LIGHT WIRE

ABS SERVICE CHECK CONNECTOR

~ REAR COMBINATION/
(ABS TYPE ONLY) LICENSE PLATE LIGHT WIRE

1-29
GENERAL INFORMAT~IO:!,!N.:..__ __

AFTER '07:

SEAT LO CK CABLES

GUIDE )
~ite tape area

PARKING BRAK E CABLE

REAR BRAKE PIPE/HOSE

02 SENSOR WIRE

1-30
 GENERAL INFORMATION

No.5 TUBE (EVAP purge control

solenoid valve-to-throttle body)

EVAP PURGE CONTROL

SOLENOID VALVE

No.4 TUBE (Canister-to-EVAP purge

control solenoid valve)
EVAP CANISTER

1-31
GENERAL INFORMATION

No.5 TUBE(EVAP purge control

solenoid valve-to-throttle body)

THROTILE BODY PURGE TUBES

No.4 TUBE (Canister-to-EVAP purge

'02- '07:
control solenoid valve)

1-32
 GENERAL INFORMATION
AFTER '07:

HOSE CLAMPS

No.4 TUBE (Canister-to-EVAP purge

control solenoid valve)

No.1 TUBE (Fuel tank-to-canister)

1-33
GENERAL INFORMATION

EMISSION CONTROL SYSTEMS

SOURCE OF EMISSIONS
The combustion process produces carbon monoxide, hydrocarbons and oxides of nitrogen. Control of hydrocarbons and
oxides of nitrogen is very important because, under certain conditions, they react to form photochemical smog when subject-
ed to sunlight. Carbon monoxide does not react in the same way, but it is toxic.

Honda Motor Co., Ltd. Uses PGM-FI, oxidation catalist, and a PAIR system to reduce carbon monoxide, hydrocarbons, and
oxides of nitrogen.

CRANKCASE EMISSION CONTROL SYSTEM

The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere.
Blow-by gas is returned to the combustion chamber through the air cleaner and carburetor.

AIR CLEANER HOUSING

~ FRESHAIR

• BLOW-BY GAS

1-34
 GENERAL INFORMATION

EXHAUST EMISSION CONTROL SYSTEM

OXIDATIO N CATALYST
in the exhaust gas to carbon dioxide and water
The oxidation catalyst (QC) converts hydrocarb ons and carbon monoxide
vapor.

EXHAUST EMISSIO N CONTROL SYSTEM

a PGM-FI system, and an oxidation catalytic con-
The exhaust emission control system includes a secondar y air supply system,
verter.

n of the compone nts is recomme nded.

No adjustme nt to these systems should be made although periodic inspectio

PULSE SECONDARY AIR SUPPLY SYSTEM

system which introduce s filtered air into the
The exhaust emission control system also employs a secondar y air supply
is drawn into the exhaust port by the function of the Pulse Secondar y Air Injection
exhaust gases in the exhaust port. Fresh air
(PAIR) control valve.
and changes a considera ble amount of hydrocar-
This charge of fresh air promotes burning of the unburned exhaust gases
harmless carbon dioxide and water vapor.
bons and carbon monoxide into relatively

control valve is controlled by the PGM-FI unit,

The reed valve prevents reverse air flow through the system. The PAIR solenoid
closed according the running condition (ECT/IAT/TP/MAP sensor and engine revolu-
and the fresh air passage is opened and
tion).

periodic inspectio n of the compone nts is rec-

No adjustme nts to the secondar y air supply system should be made, although
ommende d.

PGM-FI SYSTEM
PGM-FI SYSTEM
s: Air Intake, Engine Control, Fuel Control,
The PGM-FI system uses sequentia l multiport fuel injection. It has four subsystem
and Exhaust Control.
much air is going into the engine. It then controls
The Engine Control Module (ECM) uses various sensors to determin e how
how much fuel to inject under all operating condition s.

AIR CLEANER HOUSING

~ FRESHAI R

.. EXHAUST GAS

1-35
 GENERAL INFORM ATION

EVAPORATIVE EMISSI ON CONTROL SYSTE M

This model complies with California Air Resources Board evaporati ve emission
requireme nts.

Fuel vapor from the fuel tank is routed into the evaporati ve emission (EVAP)
canister where it is adsorbed and stored while
the engine is stopped. When the engine is running and the EVAP purge control
valve is open, fuel vapor in the EVAP canis-
ter is drawn into the engine through the throttle body.

FRESH AIR

FUEL VAPOR

I
THROTTLE
EVAP CANISTER BODY

~-- EVAP PURGE CONTROL

SOLENOID VALVE

NOISE EMISSI ON CONTROL SYSTE M

TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: U.S Federal
Law or Canadian Provincia l Law may prohib-
it the following acts or the causing thereof: (1) The removal or rendering inoperativ
e by any person, other than for purposes
of maintena nce, repair or replacem ent, of any device or element of design
incorpora ted into any new vehicle for the purpose
of noise control prior to its sale or delivery to the ultimate purchase r or while
it is in use; (2) the use of the vehicle after such
device or element of design has been removed or rendered inoperativ e by
any person.

AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE

ACTS LISTED BELOW:
1. Removal of, or puncturin g of the muffler, baffles, header pipes or any other
compone nt which conducts exhaust gases.
2. Removal of, or puncturin g of any part of the intake system.
3. Lack of proper maintena nce.
4. Replacing any moving parts of the vehicle, or parts of the exhaust or intake
system, with parts other then those specified
by the manufact urer.

1-36
 GENERAL INFORMATION

EMISSIO N CONTROL INFORMA TION

LABELS
An Emission Control Information Label is located on
the right side of the luggage box as shown .

It gives base tune-up specifications.

VACUUM HOSE ROUTING DIAGRAM

LABEL ro2-'04)
The Vacuum Hose Routing Diagram Label is located on
top of the cover under the seat.

~~~
VACUUM HOSE ROUTING - - - - -
DIAGRAM LABEL

VACUUM HOSE ROUTING DIAGRAM

ENGINE FAMILY - 3HNXCO. 58AKA
f!.VAPORATIVE FAMILY - 3HNXE0019UZG
CALIFORNIA VEHICLE

TO
OPEN AIR

1-37
 FRAME/BODY PANELS/EXHAUST SYSTEM

BODY PANEL LOCATIONS

(14}

(16)

(1) Seat (page 2-3) (9) Rear Body Cover (page 2-7} (17) Front Cover (page 2-14)
(2) Floor Mat (page 2-4} ( 10} Rear Fender (page 2-10} (18} Handlebar Cover (page 2-14)
(3) Floor Skirt (page 2-4) (11} Luggage Box (page 2-10) (19} Meter Panel (page 2-15}
(4) Spark Plug Maintenance Lid (page 2-5) (12} Passenger Footpeg (page 2-12) (20) Front Airduct Cover (page 2-21)
(5) Seat Under Cover (page 2-5) (13} Windshield Garnish (page 2-12) (21) Inner Cover/Floor Upper Cover
(6) Rear Spoiler (page 2-6) (14} Windshield (page 2-13) (page 2-15)
(7) Rear Under Cover (page 2-6} (15} Front Meter Visor (page 2-13) (22) Floorstep (page 2-20}
(8) Side Body Cover (page 2-7) ( 16} Fn;mt Lower Cover (page 2-20} (23} Under Cover (page 2-21}

2-0
 2. FRAME/BODY PANELS/EXHAUST SYSTEM
BODY PANEL LOCATIONS 2-0 LUGGAGE BOX 2-10
BODY PANEL REMOVAL CHART 2-1 PASSENGER FOOTPEG 2-12
SERVICE INFORMATION 2-2 WINDSHIELD 2-12
TROUBLESHOOTING 2-2 FRONT COVER 2-14 lfl
TRIM CLIP 2-3 HANDLEBAR COVER 2-14
SEAT 2-3 METER PANEL 2-15
FLOOR MAT 2-4 INNER COVER/FLOOR UPPER COVER 2-15
FLOOR SKIRT 2-4 FLOORSTEP 2-20
SPARK PLUG MAINTENANCE LID 2-5 FRONT LOWER COVER 2-20
SEAT UNDER COVER 2-5 UNDER COVER 2-21
FRONT FENDER 2-6 FRONT AIRDUCT COVER 2-21
REAR SPOILER 2-6 MUFFLER ('02 - '07) 2-22
BODY COVER 2-6 MUFFLER/EXHAUST PIPE (After '07) 2-24
REAR FENDER 2-10

BODY PANEL REMOVAL CHART

This chart shows the removal order of various frame and body panels.

(8) Side Body (2) Floor Mat (13) Windshield

Cover Garnish

(14) Windshield
(3) Floor Skirt
(12) Passenger (5) Seat Under (15) Front Meter
Foot peg Cover Visor
(23) Under Cover
(18) Handlebar ( 16) Front Lower
Cover cover

(7) Rear Under (6) Rear Spoiler (19) Meter Panel ( 17) Front Cover
Cover

(20) Front Airduct

(9) Rear Body cover
Cover

(10) Rear Fender (11) Luggage Box (4) Spark Plug (1) Seat
Maintenance
Lid

(22) Floorstep

(21) Inner Cover/floor upper cover

2-1
FRAME/BODY PANELS/EXHAUST SYSTEM

SERVICE INFORMATION
GENERAL
• This section covers removal and installation of the body panels and exhaust system.
• Always replace the exhaust pipe gaskets after removing the exhaust pipe from the engine.
• When installing the exhaust system, loosely install all of the exhaust pipe fasteners. Always tighten the exhaust clamp first
then tighten the mounting fasteners. If you tighten the mounting fasteners first, the exhaust pipe may not seat
properly.
• Always inspect the exhaust system for leaks after installation.

TORQUE VALUES
Rear frame bolt 26 N•m (2.7 kgf•m, 20 lbf•ft)
Rear spoiler bolt 26 N•m (2.7 kgf•m, 20 lbf•ft)
Exhaust pipe band bolt 21 N•m (2.1 kgf•m, 15 lbf•ft)
Exhaust pipe mounting bolt 22 N•m (2.2 kgf•m, 16 lbf•ft)

Exhaust pipe joint nut tightening procedure:

3 2

Right
..__ Left
--..

1 4

Muffler protector bolt 4 N•m (0.4 kgf•m, 2.9 lbf•ft)

Muffler tail cover mounting bolt 4 N•m (0.4 kgf•m, 2.9 lbf•ft)
Windscreen garnish set screw 2 N•m (0.2 kgf•m, 1.4 lbf•ft)
Windscreen set screw 1 N•m (0.1 kgf•m, 0.7 lbf•ft)

TROUBLESHOOTING
Excessive exhaust noise
• Broken exhaust system
• Exhaust gas leaks

Poor performance
• Deformed exhaust system
• Exhaust gas leak
• Clogged muffler

2-2
 FRAME/BODY PANELS/EXHAUST SYSTEM

TRIM CLIP
CENTER PIN TRIM CLIP
REMOVAL
Release by pushing the center pin.
Remove the trim clip.

INSTALLATION
Raise the center pin by spreading apart the pin ends
and then push the pin back.

~
CENTER PIN
Install the trim clip.
Lock by pushing the center pin flush.

..~
TRIM CLIP

TRIM CLIP CENTER PIN

SEAT
REMOVAL
Unlock the seat with the ignition key.
Open the seat.

Remove the B-clips, collars, set pin and seat

damper unit.

Remove the nuts and the seat.

INSTALLATION
Apply grease to the seat catches.

To lock the seat, Installation is in the reverse order of removal.

push the front
and rear seat lock After installation, check the seat installation by mov-
securely. ing the seat.

NUTS

2-3
FRAME/BODY PANELS/EXHAU ST SYSTEM

FLOOR MAT
REMOVAL
FLOOR MAT
Release the bosses on the reverse side of the mat and
remove the floor mat.

INSTALLA Tl ON
Align the bosses on the reverse side of the mat and
install the floor mat securely.

BOSSES

FLOOR SKIRT
REMOVAL
Remove the floor mat (see above).

Remove the tapping screws and special bolts.

Be careful not to Release the front end tab on the floor skirt from the
damage the tab groove on the floorstep, then remove the floor skirt.
on the floor skirt.

INSTALLATION
When installing, Installation is in the reverse order of removal.
make sure the tab
on the floor skirt TAB
is attached to the
step floor.

SCREW ~
~/ ~
';I
SPECIAL BOLT ~SCREW

2-4
 FRAME/BODY PANELS/EXHAUST SYSTEM

SPARK PLUG MAINTENANCE LID

REMOVAL/INSTALLA Tl ON SCREWS

Open the seat (page 2-3).

Remove the screws.

Release the tabs on the maintenance lid from the
groove on the floorstep.
Remove the spark plug maintenance lid.

Installation is in the reverse order of removal.

SPARK PLUG
MAINTENANCE LID

SEAT UNDER COVER

REMOVAL/INSTALLATI ON SEAT UNDER COVER
SPECIAL SCREWS
Remove the side body cover front side set screws
(page 2-7).

Remove the seat under cover special screws and

remove the seat under cover.

Installation is in the reverse order of removal.

2-5
FRAME/BODY PANELS/EXHAU ST SYSTEM

FRONT FENDER BOLTS

REMOVAL/INST ALLATION
Remove the two bolts from the rear side of the front
fender.

· · Remove the nuts and both reflex reflectors.

Remove the two bolts, washers, both reflector stays

and front fender.

Installation is in the reverse order of removal.

DISASSEMBLY I ASSEMBLY
(AFTER '02 ABS TYPE/
AFTER '06 STD TYPE)
Remove the front fender bracket from the front fend-
er.

Remove the four collars from the front fender.

Install the four collars to the front fender.

Install the front fender bracket into the guides of the

front fender inside.
FENDER BRACKET (AFTER '02 ABS TYPE)

REAR SPOILER REAR SPOILER

REMOVAL/INSTALLATl ON
Unlock the seat with the ignition key.
Open the seat.

Remove the bolts and rear spoiler.

Installation is in the reverse order of removal.

TORQUE: 26 N•m (2. 7 kgf•m, 20 lbf.ft)

BODY COVER
REAR UNDER COVER REMOVAL
Remove the set screws and remove the rear
under cover.

2-6
 FRAME/BODY PANELS/EXHAUST SYSTEM

SIDE BODY COVER REMOVAL SIDE BODY COVER SEAT LOCK CABLE

Open the seat (page 2-3).

Remove the rear under cover (page 2-6).

Be careful not to Remove the tapping screw, set screws and side
damage the tabs body cover.
on the rear body
cover and bosses Disconnect the seat lock cable from the key cylinder
on the side body (left side only).
covers.

SET SCREWS

SIDE BODY COVER

REAR BODY COVER REMOVAL SCREWS REAR BODY COVER

~
Remove the rear spoiler (page 2-6) .
Remove the side body covers (see above).

Remove the bolts and tapping screws.

Disconnect the rear combination light and license

plate light 6P connector.

Remove the rear body cover.

6P CONNECTOR

2-7
FRAME/BODY PANELS/EXHAUST SYSTEM

REAR BODY COVER

REAR BODY COVER
DISASSEMBLYI ASSEMBLY
Remove the screws, then remove the rear combina-
tion light unit from the rear body cover.

Assembly is in the reverse order of disassembly.

REAR COMBINATION
LIGHT UNIT

During installa- REAR BODY COVER INSTALLATION

tion, be careful REAR BODY COVER
not to damage Connect the rear combination light and license plate
the wire harness. light 6P connector.
Route the wire
harness and
Install the rear body cover then tighten the bolts and
cables correctly
. (page 7-20).
screws.

Install the side body covers (page 2-9).

Install the rear under cover (page 2-9).
Install the rear spoiler (page 2-6).

6P CONNECTOR

2-8
 FRAME/BODY PANELS /EXHAU ST SYSTEM

SIDE BODY COVER INSTALLATION SIDE BODY COVER SEAT LOCK CABLE

Connect the seat lock cable to the key cylinder (left

side only).

Be careful not to Align the grooves on the side body cover with the
damage the tabs tabs on the rear body cover.
on the rear body Align the bosses on the side body cover with the
cover and bosses . grommet on the .frame and .passenger footpeg,. then
on the side body install the side body cover.
covers.
Install and tighten the set screws and tapping screws.

Install the rear under cover (see below). SET SCREWS

SIDE BODY COVER

REAR UNDER COVER INSTALLATION

Install the rear under cover and tighten the set screws
securely.
REAR UNDER COVER

SET SCREWS

2-9
FRAME/B ODY PANELS/E XHAUST SYSTEM

REAR FENDER
BOLTS
REMOVAL
Remove the body cover (page 2-6).
Remove the luggage box mat (page 2-11 ).

Remove the bolts and rear fender.

Installation is in the reverse order of removal.

REAR FENDER

LUGGA GE BOX
SEAT LOCK CABLES

REAR FRAME
REMOVAL/INSTALLATION
Remove the body cover (page 2-6).

Disconnect the seat lock cables and trunk light switch

wire connector from the seat catch.
Remove the bolts and rear frame.

Installation is in the reverse order of removal.

TORQUE: 26 N•m (2. 7 kgf•m, 20 lbMtl

TRUNK LIGHT WIRE

2-10
 FRAME/BODY PANELS/EXHAU ST SYSTEM

UPPER LUGGAGE BOX

REMOVAL/INSTALLATION
Remove the rear frame (page 2-10). 2P CONNECTOR
SCREWS
Disconnect the luggage box light 2P connector.
Remove the screws and upper luggage box.

Installation is in the reverse order of removal.

Route the luggage box light wire correctly (page 1-20).

\

UPPER LUGGAGE BOX

LOWER LUGGAGE BOX LUGGAGE BOX MAT

REMOVAL/INSTALLATION
Remove the upper luggage box (see above).
BATTERY BOX
.Remove the bolts and battery box from the frame. COVER
Remove the bolt and battery box cover.
Remove the luggage box mat.
Remove the luggage box bolts.
Remove the tab on the luggage box from the hook on
the battery box.
Remove the lower luggage box.

During installa- Installation is in the reverse order of removal.

tion, be careful
not to damage
the wire harness.

BATTERY BOX

2-11
FRAME/BODY PANELS/EXHAUST SYSTEM

SEAT CATCH SEAT CATCH

DISASSEMBLY I ASSEMBLY
Remove the nuts and collars.
Remove the seat catch and seat catch stay from the
lower luggage box.

Assembly is in the reverse order of disassembly.

PASSENGER FOOTPEG
REMOVAL/INSTALLATION
Remove the passenger footpeg socket bolts.
Release the grommet on the passenger footpeg from
the boss on the side body cover and remove the pas-
senger footpeg.

Installation is in the reverse order of removal.

PASSENGER FOOTPEG

SET SCREWS WINDSHIELD GARNISH

WINDSHIELD
WINDSHIELD GARNISH
REMOVAL/INSTALLATION
Remove the screws and set screws.
Remove the windshield garnish.

WINDSHIELD GARNISH RUBBER

Remove the rubber from the windshield garnish.
Remove the screws and garnish duct from the wind-
shield garnish.

Installation is in the reverse order of removal.

TORQUE:
Windscreen garnish set screw:
2 N•m (0.2 kgf•m, 1.4 lbf.ft)

2-12
 FRAME/BODY PANELS/EXHAUST SYSTEM

WINDSHIELD WINDSHIELD

REMOVAL
Remove the windshield garnish (page 2-12). PLASTIC WASHERS
SET SCREWS
TIGHTEN:
Remove the set screws and plastic washers.
Be careful not to
scra tch or
damage the
windshield
surface.
Remove the windshield.

INSTALLATION
Install the windshield aligning the holes on the wind -
shield with the setting nuts.
Install the plastic washers and set screws.
[!!]
Tighten the set screws securely as shown. . ~ ,.
©
TORQUE: 1 N•m (0.1 kgf•m, 0.7 lbf.ft)
~ "© ©
SET SCREWS "

SETTING NUTS

FRONT METER VISOR SCREWS

REMOVAL/INSTALLATION
Remove the windshield (see above).

Remove the trim clips, screws and front meter visor.

Installation is in the reverse order of removal.

2-13
FRAME/B ODY PANELS/E XHAUST SYSTEM

FRONT COVER
SOCKET BOLTS
REMOVA L/INSTALLATl ON
Remove the windshield {page 2-12).
Remove the front lower cover {page 2-20).
Remove the bolts, socket bolts and set screws.
Release the tabs on the front cover from the inner
cover, floorstep and floor skirt.
Remove the front cover.
Disconnect the headlight/fro nt turn signal unit 9P
brown connector.

During installa- Installation is in the reverse order of removal.

tion, be careful
not to damage After installation, make sure the tabs on the front
the tabs on the
cover are attached on to the inner cover, floorstep and
floor skirt.

FRONT COVER

HANDLEBAR COVER UPPER HANDLEBAR

COVER
REMOVA L/INSTALLA Tl ON
Remove the screws, socket bolts, right lower handle-
bar cover and left lower handlebar cover.
Remove the screws, bolts and upper handlebar cover.

During installa- Installation is in the reverse order of removal.

tion, be careful
not to damage When installing, align the tabs on the right and left
the wire harness.
lower handlebar cover with the tabs on the upper han-
dlebar cover.

LEFT LOWER RIGHT LOWER

HANDLEBAR COVER HANDLEBAR COVER

2-14
 FRAME/BODY PANELS/EXHAUST SYSTEM

METER PANEL
REMOVAL/INSTALLA Tl ON
METER PANEL
Remove the windshield (page 2-12).

Disconnect the speedometer 16P and 12P connectors.

Remove the screws and meter panel.

Installation is in the reverse order of removal.

SPEEDOMETER CONNECTORS

INNER COVER/FLOOR UPPER COVER

REMOVAL
Remove the front cover (page 2-14). SPECIAL SCREWS
Remove the meter panel (see above).
Remove the floorstep (page 2-20).

Pull up the parking brake lever.

Remove the parking brake lever boot from the

inner cover.
Remove the special screws.
Release the hook on the inner cover from the grom-
met on the frame.
Remove the inner cover and floor upper cover
as an assembly.

2-15
FRAME/BODY PANELS/EXHAUST SYSTEM

DISASSEMBLY I ASSEMBLY ('02 - '06)

FLOOR UPPER COVER
Remove the screws and separate the inner cover and
floor upper cover.

INNER COVER

LEFT INNER POCKET

Remove the screws. LEFT INNER POCKET
Be careful not to Remove the left inner pocket lock lever from the inner
damage the inner pocket groove.
pocket groove and Remove the left inner pocket from the inner cover.
lock lever.
RIGHT INNER POCKET
Release the tab on the right inner pocket from the
upper inner cover.
Remove the right inner pocket from the inner cover.

Assembly is in the reverse order of disassembly.

LOCK LEVER

RIGHT INNER POCKET

2-16
 FRAME/BODY PANELS/E XHAUST SYSTEM

DISASSEMBLY I ASSEMBLY (AFTER '06) FLOOR UPPER COVER

Remove the screws and separate the inner cover and

floor upper cover.

INNER COVER

LEFT INNER POCKET

Remove the screws then remove the left inner pocket SCREWS
from the inner cover.
LEFT INNER POCKET

2-17
FRAME/BODY PANELS/EXHAUST SYSTEM

Remove the pocket lid spring from the left inner pock-
et lid and inner cover.

RETAINER
Remove the screw, retainer and then remove the left
inner pocket lid.

Remove the screws and left outer pocket lid cover.

Remove the screw, knob, pocket lid hook and return

spring from the left inner pocket lid.

Assembly is in the reverse order of disassembly.

SCREW
INNER POCKET
LID

RIGHT INNER POCKET

Open the right pocket lid cover and remove the screw.
Release the tab on the right inner pocket from the
inner cover.
Remove the right inner pocket from the inner cover.

POCKET LID COVER

SCREW

2-18
 FRAME/BODY PANELS/EXHAUST SYSTEM

Remove the pocket lid spring from the right inner ·· -

pocket lid and right inner pocket.
INNER POCKET LID
Separate the right inner pocket lid and right inner
pocket. OUTER POCKET
LID COVER
Remove the screws and the right outer pocket lid
cover and right inner pocket lid.

Remove the screw, knob, pocket lid hook and return

spring from the right inner pocket lid.

Assembly is in the reverse order of disassembly.

INNER POCKET

INSTALLATION
Pull up the parking brake lever.
During installa- Install the inner cover through the hole with the park-
tion, be careful ing brake lever and align the hook on the inner cover SPECIAL SCREWS
not to damage to the grommet on the frame.
the wire harness
and the hoses. After installation, check the parking brake lever opera-
tion (page 3-19).

Installation is in the reverse order of removal.

2-19
FRAME/BODY PANELS/EXHAUST SYSTEM

FLOORSTEP
REMOVAL/INSTALLATION
Remove the seat (page 2-3).
Remove the maintenance lid (page 2-5) .
Remove the floor skirt (page 2-4).
Remove the passenger footpeg (page 2-12).

Remove the screws and washer bolts.

Remove the floorstep.

During installa- Installation is in the reverse order of removal.

tion, be careful
not to damage
the wire harness.

FLOORSTEP

FRONT LOWER COVER

REMOVAL/INSTALLATION
Remove the screws and trim clips.
Remove the front lower cover.

Installation is in the reverse order of removal.

l
SCREWS FRONT LOWER COVER

2-20
 FRAME/BODY PANELS/EXHAU ST SYSTEM

UNDER COVER
REMOVAL/INST ALLATION
Remove the floor skirt (page 2-4).
TRIM CLIPS
Remove the bolts, trim clips and under cover from the
lower frame.
Remove the fuel overflow hose from the hole on the
under cover.
Remove the fuel tank separator breather hose from
the hook on the under cover.

Installation is in the reverse order of removal.

FRONT AIRDUCT COVER

REMOVAL/INSTALLATl ON
Remove the front cover. (page 2-14).

Remove the bolt and screws.

Separate and remove the right/left airduct covers.

Installation is in the reverse order of removal.

SCREWS BOLT

2-21
FRAME/BODY PANELS/EX HAUST SYSTEM

MUFFLER ('02 - '07)

REMOVAL GASKETS

Remove the right floor skirt (page 2-4).

Remove the exhaust pipe joint nuts.

Loosen the exhaust pipe band bolt.
Remove the muffler mount bolts, washer, nut and
muffler from the exhaust pipe.
Remove the exhaust pipe mount bolt and exhaust
pipe.
Remove the bolts and exhaust pipe protector.
Remove the gaskets.

x
BOLTS EXHAUST PIPE
PROTECTOR

MUFFLER DISASSEMBLY I ASSEMBLY

Remove the socket bolts and tail cover.
Remove the socket bolts and muffler protector.
Remove the bolts and muffler protector stay.

Assembly is in the reverse order of disassembly.

TORQUE:
Muffler protector bolt:
4 N•m (0.4 kgf•m, 2.9 lbf.ft)
Muffler tail cover mounting bolt:
4 N•m (0.4 kgf•m, 2.9 lbf.ft)

MUFFLER
PROTECTOR
PROTECTOR STAY

2-22
 FRAME/BODY PANELS/EXHAUST SYSTEM

INSTALLATION
Replace the gaskets with new ones. ~
~,.. GASKETS
Install the exhaust pipe protector and tighten
the bolts. -=-
Install the exhaust pipe and muffler then loosely tight-
ening all fasteners.

Tighten the joint nuts in the sequence shown.

Tightening procedure:

3 2

x
Left
Right
.._ ...__..

1 4
BOLTS EXHAUST PIPE
PROTECTOR

Tighten the mount bolts, nut and band bolts.

TORQUE:
Exhaust pipe band bolt 21 N•m (2.1 kgf•m, 15 lbf.ft)

After installation, inspect the exhaust system for

leaks.

2-23
FRAME/BODY PANELS/EXHAUST SYSTEM

MUFFLER/EXHAU ST PIPE {After '07)

MUFFLER REMOVAL
Remove the right side body cover (page 2-6).

Disconnect the 02 sensor 4P (Gray) connector and

release the wire from the guide.

Loosen the muffler band bolts.

Remove the muffler mounting bolt, washer and nut,
then remove the muffler from the exhaust pipe.
Remove the muffler gasket.

MUFFLER DISASSEMBLY I ASSEMBLY

TAIL COVER
Remove the socket bolts and tail cover.
Remove the socket bolts and muffler protector.
Remove the bolts and muffler protector stay.

Assembly is in the reverse order of disassembly.

TORQUE:
Muffler protector bolt:
4 N•m (0.4 kgf•m, 2.9 lbfoft)
Muffler tail cover mounting bolt:
4 N•m (0.4 kgf•m, 2.9 lbfoft)

• Refer to procedure for the 02 sensor removal/instal-

lation (page 5-110).

MUFFLER
PROTECTOR

2-24
 FRAME/BODY PANELS/EXHAUST SYSTEM

EXHAUST PIPE REMOVAL

Remove the exhaust pipe joint nuts, exhaust pipe
mounting bolt and exhaust pipe.
Remove the gaskets from the exhaust port.

Remove the bolts and exhaust pipe protector.

PROTECTOR

BOLTS

/
MOUNTING BOLT
JOINT NUTS

EXHAUST PIPE

EXHAUST PIPE INSTALLATION

Replace the exhaust pipe gaskets with new ones.
Install the exhaust pipe protector and tighten the
bolts.
Install the exhaust pipe, then loosely tighten the
exhaust pipe joint nuts.
Install the exhaust pipe mounting bolt.

Install the exhaust pipe joint nuts and tighten them in

the sequence as shown.

TORQUE: 12 N•m (1.2 kgf•m, 9 lbf.ft)

Tightening procedure:
PROTECTOR
3 2

Right
.._. _.
Left

1 4 BOLTS /

Tighten the exhaust pipe mounting bolt to the speci- MOUNTING BOLT
fied torque.
EXHAUST PIPE
TORQUE: 22 N•m (2.2 kgf•m, 16 lbf.ft)

2-25
FRAME/BODY PANELS/EXHAUST SYSTEM

MUFFLER INSTALLATION
Replace the muffler gasket with a new one.
Install the muffler, mounting bolt, washer and nut,
then loosely tighten the nut.

Tighten the muffler band bolts to the specified torque.

TORQUE: 21 N•m (2.1 kgf•m, 15 lbf.tt)

Hold the muffler mounting bolt and tighten the nut.

Connect the 02 sensor 4P (Gray) connector and set

the wire into the guide.

Install the right side body cover (page 2-9).

After installation, inspect the exhaust system for

leaks.

2-26
 3. MAINTENANCE
SERVICE INFORMATION 3-1 EVAPORATIVE EMISSION CONTROL
MAINTENANCE SCHEDULE 3-3 SYSTEM 3-16
FUEL LINE 3-4 FINAL DRIVE OIL 3-16

•
THROTTLE OPERATION 3-4 BRAKE FLUID 3-17
AIR CLEANER 3-5 BRAKE PAD WEAR 3-18
CRANKCASE BREATHER 3-5 BRAKE SYSTEM 3-18
SPARK PLUG 3-5 BRAKE LOCK OPERATION 3-19
VAL VE CLEARANCE 3-7 HEADLIGHT AIM 3-20
ENGINE OIL 3-11 SIDESTAND 3-20
ENGINE OIL FILTER 3-12 SUSPENSION 3-20
ENGINE IDLE SPEED 3-13 NUTS, BOLTS, FASTENERS 3-21
RADIATOR COOLANT 3-14 WHEELS/TIRES 3-21
COOLING SYSTEM 3-14 STEERING HEAD BEARINGS 3-22
SECONDARY AIR SUPPLY SYSTEM 3-15

SERVICE INFORMATION
GENERAL

• Place the scooter on level ground before starting any work.

• Gasoline is extremely flammable and is explosive under certain conditions. Work in a well ventilated area. Smoking or
allowing flames or sparks in the work area or where the gasoline is stored can cause a fire or explosion.
• If the engine must be running to do some work, make sure the area is well ventilated. Never run the engine in an enclosed
area .
• The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and may lead to death. Run
the engine in an open area or with an exhaust evacuation system in an enclosed area.

3-1
MAINTENANCE

SPECIFICATIONS

ITEM SPECIFICATIONS
Throttle grip free play 2 - 6 mm (1/16 - 1/4 in)
Spark plug NGK CR8EH-9
DENSO U24FER9
Spark plug gap 0.80 - 0.90 mm (0.031 - 0.035 in)
Valve clearance IN 0.16 ± 0.03 (0.006 ± 0.001)
EX 0.22 ± 0.03 (0.009 ± 0.001)
Engine oil capacity At draining 2.0 liter (2.1 US qt, 1.8 Imp qt)
At draining/oil filter change 2.2 liter (2 .3 US qt, 1.9 Imp qt)
Recommended engine oil Pro Honda GN4 4-stroke oil (U.S.A. and Canada) or equivalent
motor oil.
API service classification: SG or Higher
JASO T903 standard: MA
Viscosity: SAE 10W-30
Engine idle speed 1,300 ± 100 min·1 (rpm)
Final reduction oil capacity (At draining) 0.32 liter (0.34 US qt, 0.28 Imp qt)
Recommended final reduction oil Pro Honda GN4 4-stroke oil (U.S.A. and Canada) or equivalent
motor oil.
API service classification: SG or Higher
JASO T903 standard: MA
Viscosity: SAE 10W-30
Recommended brake fluid DOT 4
Parking brake lever stroke 3 - 6 notch
Tire size Front 120/80-14M/C 58S
Rear 150/70-13M/C 64S
Tire brand Bridgestone Front HOOP B03
Rear HOOP B02
IRC Front SS530F
Rear SS530R
Tire air pressure Up to 90 kg (200 lb) Front 200 kPa (2.00 kgf/cm 2 , 29 psi)
load Rear 225 kPa (2.25 kgf/cm 2 , 33 psi)
Up to maximum Front 200 kPa (2.00 kgf/cm 2 , 29 psi)
weight capacity Rear 250 kPa (2.50 kgf/cm 2 , 36 psi)
Minimum tire tread depth Front 1.5 mm (0.06 in)
Rear 2.0 mm (0.08 in)

TORQUE VALUES
Timing hole cap 10 N•m (1.0 kgf•m, 7 lbf•ft) Apply oil to the threads and seating surface.
Balancer shaft hole cap 10 N•m (1.0 kgf•m, 7 lbf•ft) Apply oil to the threads and seating surface.
Oil strainer screen cap 15 N•m ( 1.5 kgf•m , 11 lbf•ft) Apply oil to the threads and seating surface.
Oil filter cartridge 26 N•m (2.7 kgf•m, 20 lbf•ft) Apply oil to the threads and seating surface.
Transm ission oil check bolt 13 N•m ( 1.3 kgf•m , 9 I bf•ft)
Transmission oil drain bolt 13 N•m ( 1.3 kgf•m, 9 lbf•ft)
Spark plug 16 N•m (1.6 kgf•m, 12 lbf•ft)

TOOLS
Oil filter wrench 07HAA-PJ70100

3-2
 MAINTENANCE
MAINTENANCE SCHEDULE
Perform the Pre-ride inspection in the Owner's Manual at each scheduled maintenance period.
I: inspect and Clean, Adjust, Lubricate or Replace if necessary. C: Clean. R: Replace. A: Adjust. L: Lubricate.
The following items require some mechanical knowledge. Certain items (particularly those marked * and ** ) may require
more technical information and tools. Consult your Honda dealer.

WHICHEVER c:) ODOMETER READING (NOTE 1)

COMES
FIRST x1,ooo mi 0.6 4 8 12 16 20 24 REFER

s D
NOTE x100 km 10 64 128 192 256 320 384
TO PAGE

* FUEL LINE I I I 3-4

* THROTILE OPERATION I I I 3-4
AIR CLEANER NOTE 2 R R 3-5
CJ)
CRANKCASE BREATHER NOTE 3 c c c c c c 3-5
~ SPARK PLUG R R R 3-5
LU
t:: * VALVE CLEARANCE I 3-7
0 ENGINE OIL '02 - '05 R R R R 3-11
LU
~
_J
AFTER '05 INITIAL = 600 mi (1,000 km) or 1 month : R
LU REGULAR =Every 8,000 mi (12,800 km)
a:
or 12 months: R
z ENGINE OIL FILTER R R R R 3-12
Q
CJ)
CJ)
* ENGINE OIL STRAINER SCREEN c c c 3-11
~ * ENGINE IDLE SPEED I I I I I I I 3-13
LU
RADIATOR COOLANT NOTE 5 I I R 3-14
* COOLING SYSTEM I I I 3-14
* SECONDARY AIR SUPPLY SYSTEM I I I 3-15
* EVAPORATIVE EMISSION CONTROL SYSTEM I I 3-16
* DRIVE BELT NOTE 4 I R 10-7
CJ) * BELT CASE AIR CLEANER c c c 10-4
~
LU * FINAL DRIVE OIL NOTE 6 3-16
t::
BRAKE FLUID NOTE 5 I I R I I R 3-17
0
LU BRAKE PADS WEAR I I I I I I 3-17
~
_J BRAKE SYSTEM I I I I 3-18
LU
a: * BRAKE LOCK OPERATION I I I I I I I 3-19
z * HEADLIGHT AIM I I I 3-19
0
** CLUTCH SHOES WEAR I I I I I I 10-15
U5
~ SIDESTAND
~
I I I 3-20
LU * SUSPENSION
I
I I I 3-20
z * NUTS, BOLTS, FASTENERS I I I I 3-21
0
z ** WHEELSfflRES I I I 3-21
** STEERING HEAD BEARINGS I I I I 3-22

* Should be serviced by your Honda dealer, unless you have the proper tools and service data and are mechanically quali-
fied. Refer to the official Honda service manual (page 210) .
* * In the interest of safety, we recommend these items be serviced only by your Honda dealer.

NOTES: 1. At higher odometer readings, repeat at the frequency interval established here.
2. Service more frequently if the scooter is ridden in unusually wet or dusty areas.
3. Service more frequently if the scooter is ridden often at full throttle or in the rain.
4. Inspect every 12,000 mi (19,200 km) after replacement.
5. Replace every 2 years, or at indicated odometer interval , whichever comes first. Replacement requires mechani-
cal skill. Refer to the official Honda service manual.
6. Replace every 2 years. Replacement requires mechanical skill.

3-3
MAINTENANCE

FUEL LINE
Remove the floorstep (page 2-20).

Check the fuel lines for deterioration, damage or leak-

age. Replace the fuel lines if necessary.

THROTTLE OPERATION 2 - 6 mm (1/16 - 1/4 in)

Check for smooth throttle grip full opening and auto-

matic full closing in all steering positions.
Check the throttle cables and replace them if they are
deteriorated, kinked or damaged.
Lubricate the throttle cables if throttle operation is not
smooth.

Measure the free play at the throttle grip flange.

FREE PLAY: 2 - 6 mm (1/16 - 1/4 in)

A WARNING
Reusing a damaged or abnormally bent or kinked
throttle cable can prevent proper throttle slide
operation and may lead to a loss of throttle control
while riding.

Throttle grip free play can be adjusted at either end of

the throttle cable.

Minor adjustment are made with the upper adjuster.

Adjust the free play by loosening the lock nut and
turning the adjuster.

Major adjustments are made with the lower adjuster. LOCK NUT

Remove the seat under cover (page 2-5).

Adjust the free play by loosening the lock nut and turn-
ing the adjuster.
\
After adjustment, tighten the lock nut.
Recheck the throttle operation.
Replace any damaged parts, if necessary.

3-4
 MAINTENANCE

AIR CLEANER SCREWS

~
Remove the right side body cover (page 2-6).

Remove the 02 sensor wire from the air cleaner hous-

ing cover (After '07).
~-
Remove the screws and air cleaner housing cover.
Remove the screws and air cleaner element.
~

AIR CLEANER HOUSING COVER

Remove and discard the air cleaner element in accor-

SCREW
dance with the maintenance schedule (page 3-3).
Also replace the air cleaner element any time it is
excessively dirty or damaged.

Install the removed parts in the reverse order of

removal.

AIR CLEANER ELEMENT

CRANKCASE BREATHER
• Service more frequently when ridden in rain, at full
throttle, or after the scooter is washed or over-
turned. Service if the deposits level can be seen in
the transparent section of the breather hose.

The air cleaner chamber drain hose is lower the left

swingarm.

Remove the air cleaner chamber drain hose plug from

the hose end and drain deposits into a suitable con-
tainer, then install the air cleaner chamber drain hose
plug.

SPARK PLUG SCREWS

REMOVAL
Remove the clips and spark plug maintenance lid.

SPARK PLUG
MAINTENANCE LID

3-5
MAINTENANCE

Clean around the Disconnect the spark plug caps and clean around the
spark plug bases
SPARK PLUG CAPS
spark plug bases.
with compressed
air before
removing, and be
sure that no
debris is allowed
to enter the
combustion cham-
ber.

Remove the spark plug using a equipped spark plug

SPARK PLUG
wrench or an equivalent tool.

Inspect or replace as described in the

maintenance schedule .

INSPECTION CENTER ELECTRODE

Check the insulator for cracks or damage, and the

electrodes for wear, fouling or discoloration.
Replace the plug if necessary.
If the electrode are contaminated with carbon
deposits, clean the electrodes using spark
plug cleaner.

Replace the spark plug if necessary.

Always use specified spark plugs on this motorcycle.

Always use
specified spark SPECIFIED SPARK PLUG: INSULATOR SIDE ELECTRODE
plugs on this NGK: CR8EH-9
motorcycle. DENSO: U24FER9

Measure the spark plug gap between the center and

side electrodes with the feeler gauge.
If necessary, adjust the gap by bending the side elec-
trode carefully.

SPARK PLUG GAP:

0.80 - 0.90 mm (0.031 - 0.035 in)

3-6
 MAINTENANCE

Install the spark plug in the cylinder head and hand SPARK PLUG SPARK PLUG CAP
tighten, then torque to the specificatio n.

TORQUE: 16 N•m (1.6 kgf•m, 12 lbf.ft)

Install the spark plug cap.

Install the removed parts in the reverse order of

removal.

VAL VE CLEARANCE BOLT SEALING WASHER

Inspect and adjust INSPECTION

the valve
clearance while Remove the cylinder head cover (page 8-4).
the engine is cold
(below 35 .C/95"FJ. Remove the cam chain tensioner lifter sealing bolt and
sealing washer.

Turn the cam chain tensioner lifter shaft fully and STOPPER TOOL
secure it using the mechanic's tensioner stopper tool
(page 8-7).

Remove the timing hole cap and 0-ring. 0-RING

Remove the balancer shaft hole cap and 0-ring .

TIMING HOLE CAP

3-7
 MAINTENANCE

Turn the crank shaft countercloc kwise and align the

"T" mark on the flywheel with the index mark on the
right crankcase cover.

The timing marks on the cam sprockets must be flush

\INDEX MARK

with the cylinder head surface as shown.

TIMING MARKS

Record the Measure the valve clearances for the #1 or #2 cylinder

clearance for each on the compressio n stroke by inserting the feeler
valve for gauge between the valve lifter and the cam lobe.
reference if valve
clearance adjust-
ment is required.
VAL VE CLEARANCE:
IN: 0.16 : 0.03 mm (0.006 : 0.001 in)
EX: 0.22 : 0.03 mm (0.009 : 0.001 in)

Turn the crank shaft counterclockwise a full turn (360°)

and align the "T" mark on the flywheel with the index
mark on the right crankcase cover.

\
INDEX MARK

3-8
 MAINTENANCE

Record the Check the valve clearance of the other cylinder using
clearance for each a feeler gauge.
valve for
reference if valve IN: 0.16 ::t 0.03 mm (0.006 ::t 0.001 in)
clearance adjust-
EX: 0.22 ::t 0.03 mm (0.009 ::t 0.001in)
ment is required.

ADJUSTMENT VALVE LIFTER

Remove the camshaft (page 8-6).

Remove the valve lifters and shims.

• The shims may stick to the inside of the valve lifter.

Do not allow the shims to fall into the crankcase.
• Mark all valve lifters and shims to ensure correct
reassembly in their original locations.
The valve lifter can be easily removed with a valve
lapping tool or magnet.
• The shims can be easily removed with tweezers or
a magnet.

Clean the valve shim contact area in the valve lifter VALVE LIFTER
with compressed air.

Sixty-nine different Measure the shim thickness and record it. SHIM

\
shim thicknesses
are available from Calculate the new shim thickness using the equation
1.200 mm to below.
2.900mm in
A= (8-C) + D __ _
intervals of 0.025 .~

mm.
A: New shim thickness
B: Recorded valve clearance
C: Specified valve clearance
D: Old shim thickness

3-9
MAINTENANCE

• Make sure the correct shim is selected by measur-

ing it with a micromete r.
• Reface the valve.seat if carbon deposits result in a
clearance of over 2.900 mm.

eeee
1.80 mm 1.825 mm 1.85 mm 1.875 mm

Install th e shims Install the newly selected shim on the valve retainer.
and valve lifters in Apply molybdenu m disulfide oil to the valve lifters.
their original loca- Install the valve lifters into the valve lifter holes.
tions.
Install the camshaft (page 8-23).

Rotate the camshafts by rotating the crankshaft clock-

wise several times.
Recheck the valve clearance.

Remove the cam chain tensioner stopper tool.

Install the new sealing washer and cam chain ten-

sioner lifter sealing bolt. BOLT ~~ SEALING WASHER
Tighten the bolt. .._....
Install the removed parts in the reverse order
of removal.

3-10
 MAINTENANCE

ENGINE OIL
OIL LEVEL INSPECTION

A CAUTION
Used engine oil may cause skin cancer if repeated-
ly left in contact with the skin for prolonged peri-
ods. Although this is unlikely unless you handle
used oil on a daily basis, it is still advisable to thor-
oughly wash your hands with soap and water as
soon as possible after handling used oil.

Start the engine and let it idle for 2 - 3 minutes.

Turn off the engine and support the scooter on a level
surface.
Remove the oil filler cap/dipstick and wipe the oil from
the dipstick with a clean cloth.

Insert the dipstick into the oil filler hole without screw- ,.._._
ing it in.

-- UPPER LEVEL LINE

-
~ LOWER LEVEL LINE
'----'

If the oil level is below or near the lower level line on

the dipstick, add the recommended engine oil until
OIL VISCOSITIES
the oil level is to the upper level line.

Other viscosities RECOMMENDED ENGINE OIL:

shown in the Pro Honda GN4 4-stroke oil (U.S.A. and Canada) or
chart may be used equivalent motor oil.
when the average API service classification: SG or Higher.
temperature in JASO T903 standard: MA
your riding area is Viscosity: SAE 10W-30
within the indicat-
ed range . Reinstall the filler cap/dipstick. -30 -20 -10 0 10 20 30 40 so·c
-20 0 20 40 60 80 100 120°F

See below for engine oil change.

ENGINE OIL & STRAINER SCREEN

Change the Warm up the engine.
engine oil with
the engine warm Stop the engine and remove the oil filler cap/dipstick.
and the scooter
on level ground to Remove the oil strainer cap, 0-ring, setting spring and
assure complete
strainer screen.
draining.

SETIING SPRING

3-11
MAINTENANCE

Clean the oil strainer screen.

STRAINER SCREEN
A CAUTIO N
Used engine oil may cause skin cancer if repeatedly
left in contact with the skin for prolonged periods.
Although this is unlikely unless you handle used oil
on a daily basis, it is still advisable to thoroughly
wash your hands with soap and water as soon as
possible after handling used oil.

After draining the oil completely, install the strainer

screen and setting spring into the engine.

Apply clean engine oil to the strainer cap threads, flange

surface and a new 0-ring.
Install and tighten the strainer cap with a new 0-ring.

TORQUE: 15 N•m (1.5 kgf•m, 11 lbf.ft)

STRAINER CAP

Fill the crankcase with the recommended engine oil.

OIL CAPACITY:
2.0 liter (2.1 US qt, 1.8 Imp qt)
at draining
2.2 liter (2.3 US qt, 1.9 Imp qt)
at oil filter change

Install the oil filler cap/dipstick.

Check the engine oil level (page 3-11 ).
Make sure there are no oil leaks.

ENGINE OIL FILTER

REPLACEMENT
Drain the engine oil (page 3-11).

Remove and discard the oil filter cartridge using the spe-
cial tool.

TOOL:
Oil filter wrench 07HAA-PJ70100

3-12
 MAINTENANCE
Apply clean engine oil to the new oil filter cartridge
threads, flange surface and a new 0-ring.
S~ 0 -RING

Install the new oil filter cartridge and tighten it to the

specified torque.

TOOL:
Oil filter wrench 07HAA-PJ70100

TORQUE: 26 N•m (2.7 kgf•m, 20 lbf.ft)

Refill the engine oil (page 3-12).

ENGINE IDLE SPEED

• Inspect and adjust the idle speed after all other
engine maintenance items have been performed
and are within specification.
• The engine must be warm for accurate idle speed
inspection and adjustment.

Warm up the engine.

Place the scooter on its centerstand.

Unlock the seat with the ignition key.

Open the seat.

Turn the throttle stop screw as required to obtain the

specified idle speed .

IDLE SPEED: 1,300 ~ 100 min- 1 (rpm)

3-13
MAINTENANCE

RADIATOR COOLANT
Place the scooter on its centerstand.

Remove the screw and right inner pocket.

Check the coolant level in the reserve tank with the

engine running at normal operating temperature.
The level should be between the "UPPER" and
"LOWER" level lines with the scooter upright on a
level surface.
If the level is low, remove the reserve tank cap and fill
the tank to the "UPPER" level line with 1:1 mixture of
distilled water and antifreeze (coolant mixture prepa-
ration: page 6-4).

I NOTICE I
Using coolant with silicate inhibitors may cause pre-
mature wear of water pump seals or blockage of radi- LOWER LEVEL LINE
ator passages. Using tap water may cause engine
damage.

Check to see if there are any coolant leaks when the

coolant level decrease very rapidly.
If reserve tank becomes completely empty, there is a
possibility of air getting into the cooling system.
Be sure to remove all air from the cooling system
(page 6-5).

Reinstall the filler cap.

COOLING SYSTEM
Remove the floorstep (page 2-20).

Check for any coolant leakage from the water pump,

radiator hoses and hose joints.
Check the radiator hoses for cracks or deterioration
and replace if necessary.
Check that all hose clamps are tight.

3-14
 MAINTENANCE

Remove the front lower cover (page 2-20).

Check the radiator air passages for clogs or damage.

Straighten any bent fins, and remove insects, mud or
other obstructions with compressed air or low
water pressure.
Replace the radiator if the air flow is restricted over
more than 20% of the radiating surface.

SECONDARY AIR SUPPLY SYSTEM

PAIR CONTROL SOLENOID VALVE
• This model is equipped with a built-in secondary air
supply system. The pulse secondary air supply sys-
tem is located on the cylinder head cover.
• The secondary air supply system introduces filtered
air into exhaust gases in the exhaust port. The sec-
ondary air is drawn into the exhaust port whenever
there is negative pressure pulse in the exhaust sys-
tem. This charged secondary air promotes burning
of the unburned exhaust gases and changes a con-
siderable amount of hydrocarbons and carbon
monoxide into relatively harmless carbon dioxide
and water.

Remove the air cleaner housing (page 5-89).

If the hoses show Check the PAIR (pulse secondary air injection) hoses
any signs of heat between the PAIR control solenoid valve and cylinder
damage, inspect head cover for deterioration, damage or loose con-
the PAIR check nections. Make sure the hoses are not cracked.
valve in the PAIR
reed valve cover
for damage. PAIR CHECK VALVE

~ FRESHAIR

~ EXAUSTGAS

Check the air suction hose between the air cleaner

housing and PAIR control solenoid valve for deterio-
ration, damage or loose connections.
Make sure the hoses are not kinked, pinched
or cracked.

3-15
MAINTENANCE

EVAPORATIVE EMISSION CONTROL SOLENOID VALVE TO

~ THROTTLE BODY TUBE
SYSTEM
~
Check the evaporative emission (EVAP) canister for
cracks or damage.

Check the tubes between the fuel tank, EVAP canister,

EVAP purge control valve ·and throttle body for deteri-
oration, damage or loose connections, Also check that
the tubes are not kinked or pinched.

Refer to the Vacuum Hose Routing Diagram Label and

Cable & Harness Routing (page 1-37) for tube connec-
tions and routing. EVAP PURGE CONTROL SOLENOID VALVE

CANISTER TO
SOLENOID VALVE
EVAP CANISTER TUBE

FINAL DRIVE OIL

LEVEL CHECK
Place the scooter on its centerstand.

Start the engine and let it idle for a few minutes.

Remove the final drive oil filler/check bolt and check
whether the oil flows out from the filler/check bolt hole.
If the level is low (no oil flows out), add the recom-
mended oil as described below.

Pour the recommended oil through the oil filler bolt

hole until it reaches the lower edge of the oil filler bolt
hole.

RECOMMENDED FINAL REDUCTION OIL:

Pro Honda GN4 4-stroke oil (U.S.A. and Canada) or
equivalent motor oil.
API service classification: SG or Higher.
JASO T903 standard: MA
Viscosity: SAE 1OW-30

Install the final drive oil filler/check bolt with a new

sealing washer and tighten it.

TORQUE: 13 N•m (1.3 kgf•m, 9 lbf.ft)

3-16
 MAINTENANCE

OIL CHANGE

Remove the left rear cover (page 10-3).

Remove the final drive oil drain bolt and the final drive
oil filler bolt. Slowly turn the rear wheel and drain the oil.
After draining the oil completely, install the oil drain bolt
with a new sealing washer and tighten it.

Fill the transmission case with the recommended oil up

to correct level (page 3-16).

OIL CAPACITY: 0.32 liter (0.34 US qt, 0.28 Imp qt)

OIL DRAIN BOLT
at draining

BRAKE FLUID
NOTICE
• Do not mix different types of fluid, as they are not
compatible with each other.
• Do not allow foreign material to enter the system
when filling the reservoir.
• Avoid spilling fluid on painted, plastic or rubber parts.
Place a rag over these parts whenever the system is
serviced.
When the fluid level is low, check the brake pads for
wear (see below). A low fluid level may be due to wear
of the brake pads. If the brake pads are worn, the caliper
piston is pushed out, and this accounts for a low reser-
voir level. If the brake pads are not worn and the fluid
level is low, check the entire system for leaks (see next
page).

FRONT BRAKE

Turn the handlebar so the reservoir is level and check the

front brake fluid reservoir level.
If the level is near the lower level line, check brake pad
wear (see below).

/ LOWER LEVEL

REAR BRAKE

Place the scooter on a level surface and support it in an

upright position.
Check the rear brake fluid reservoir level.
If the level is near the lower level line, check brake pad
wear (see next page).

LOWER LEVEL

3-17
MAINTENANCE

BRAKE PAD WEAR

FRONT BRAKE PADS
Check the brake pads for wear.
Replace the brake pads if either pad is worn to the
bottom of the wear limit groove.

Refer to page 16-9 for brake pad replacement.

WEAR INDICATOR

REAR BRAKE PADS

Check the brake pads for wear.
Replace the brake pads if either pad is worn to the
bottom of the wear limit groove.

Refer to page 16-11 for brake pad replacement.

WEAR INDICATOR

BRAKE SYSTEM
INSPECTION
This model is equipped with Combined Brake System.
Check the rear brake operation as follows:

Place the scooter on its centerstand.

Jack-up the scooter to raise the front wheel off the
ground.

I NOTICE
REAR BRAKE LEVER
Do not use the oil filter as a jack point.

Operate the rear brake lever.

Make sure the front wheel does not turn while the rear
brake lever is operated.

3-18
 MAINTENANCE

Firmly apply the brake lever and check that no air has
entered the system.
If the lever feels soft or spongy when operated, bleed
the air from the system.

Inspect the brake hose and fittings for deterioration,

cracks and signs of leakage.
Tighten any loose fittings.
Replace hoses .and fittinQs as required.

BRAKE LOCK OPERATION

INSPECTION
Release the parking brake pulling the lever this side
and move the parking brake lever downward.

Pull up the parking brake lever slowly and check the

parking brake lever stroke.

PARKING BRAKE LEVER STROKE: 3 - 6 notches

If out of specification, adjust the parking brake lever

(see below).

ADJUSTMENT
Place the scooter on its centerstand.
Release the parking brake lever lock.
Pull up the parking brake lever until 1 notch.

Loosen the lock nut.

Turn the adjust bolt until you feel resistance when
turn the rear wheel by your hand .
Hold the adjust bolt and tighten the lock nut.

Release the parking brake lever lock.

Make sure the rear wheel turns smoothly.
ADJUST BOLT

Pull the parking brake lever slowly and check the lever
stroke.

STAND ARD: 3 - 6 notches

ALL STROKE: 9 notches

If the lever stroke is out of specification, adjust again.

3-19
MAINTENANCE

HEADLIGHT AIM HORIZONTALLY ADJUSTING BOLT

Place the scooter on a level surface .

Adjust the headlight beam vertically by turning the

Adjust the vertical beam adjuster.
headlight beam as A clockwise rotation moves the beam down and coun-
specified by local terclockwise rotation moves the beam up.
laws and
regulations . Adjust the headlight beam horizontally by turning the
horizontal beam adjuster.
A clockwise rotation moves the beam toward the right
side of the rider.
VERTICALLY ADJUSTING SCREW

SIDESTAND
Support the scooter on a level surface.

Check the sidestand spring for fatigue or damage.

Check the sidestand assembly for smooth movement
and lubricate the sidestand pivot if necessary.

Check the sidestand ignition cut-off system:

- Start the engine.
- Fully lower the sidestand while running the engine.
- The engine should stop as the sidestand
is lowered.
SIDESTAND
If there is a problem with the system, check the side-
stand switch (page 21-20).

SUSPENSION
FRONT SUSPENSION INSPECTION
Check the action of the forks by certain operating the
front brakes and compressing the front suspension
several times.
Check the entire assembly for signs of leaks, damage
or loose fasteners.
Replace damaged components which cannot
be repaired.
Tighten all nuts and bolts.

Refer to section 14 for fork service.

REAR SUSPENSION INSPECTION

Support the scooter and raise the rear wheel off the
ground.

Hold the swingarm and move the rear wheel sideways

with force to see if the wheel bearings are worn.

Check for worn swingarm bearings by grabbing the

rear swingarm and attempting to move the swingarm
side to side.
Replace the bearings if any looseness is noted.

3-20
 MAINTENANCE

Check the action of the shock absorber by compress-

ing it several times.
Check the entire shock absorber assembly for signs of
leaks, damage or loose fasteners.
Replace damaged components which cannot
be repaired.
Tighten all nuts and bolts.

Refer to section 15 for_shock absorber service.

NUTS, BOLTS, FASTENERS

Check that all chassis nuts and bolts are tightened to
their correct torque values (page 1-11).
Check that all safety clips, hose clamps and cable
stays are in place and properly secured.

WHEELS/TIRES
Tire pressure should be checked when the tires are
cold.

RECOMMENDED TIRE PRESSURE AND TIRE SIZE:

--------
Tire pressure Up to 90 kg
kPa (kgf/cm 2, (200 lb)
psi) load
FRONT

200 (2.00, 29)

REAR

225 (2.25, 33)

Up ~o
maximum
weight 200 (2.00, 29) 250 (2.50, 36)
capacity
120/80-14M/C 150/70-13M/C
Tire size
(58S) (64S)

Bridgestone HOOP 803 HOOP 802

Tire brand
IRC SS530F SS530R

Check the tires for cuts, embedded nails, or

other damage.
Check the front and rear wheels for trueness (refer to
section 14 and 15).

Measure the tread depth at the center of the tires.

Replace the tires when the tread depth reaches the fol-
lowing limits.

MINIMUM TREAD DEPTH:

FRONT: 1.5 mm (0.06 in)
REAR: 2.0 mm (0.08 in)

3-21
MAINTENANCE

STEERING HEAD BEARINGS

Check that the control cables do not interfere with
handlebar rotation.

Support the scooter and raise the front wheel off the
ground.
Check that the handlebar moves freely from side to
side.
If the handlebar moves unevenly, binds, or has verti-
cal movement, inspect the steering head bearings
(section 14).

3-22
MEMO
LUBRICATION SYSTEM

LUBRICATION SYSTEM DIAGRAM

CAMSHAFT

STATOR

'

CRANKSHAFT

OIL PRESSURE SWITCH

OIL FILTER CARTRIDGE

OIL PUMP

RELIEF VALVE

OIL STRAINER SCREEN

4-0
 4. LUBRICATION SYSTEM
SERVICE INFORMATION 4-1 OIL PRESSURE RELIEF VALVE 4-4
TROUBLESHOOTING 4-2 OIL PUMP 4-5
OIL PRESSURE CHECK 4-3 OIL COOLER 4-9

SERVICE INFORMATION
GENERAL
ID
A CAUTION
• If the engine must be running to do some work, make sure the area is well ventilated. Never run the engine in an
enclosed area. The exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness and may
lead to death. Run the engine in an open area or with an exhaust evacuation system in enclosed area.
Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this
is unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap
and water as soon as possible after handling used oil.

• The engine must be removed from the frame before servicing the oil pressure relief valve. However, the oil pump service
may be done with the engine installed in the frame.
• When removing and installing the oil pump, use care not to allow dust or dirt to enter the engine.
• If any portion of the oil pump is worn beyond the specified service limits, replace the oil pump as an assembly.
• After the engine has been installed, check that there are no oil leaks and that oil pressure is correct.
• For oil pressure indicator inspection, refer to section 21 of this manual.

SPECIFICATIONS
Unit: mm (in)

ITEM STANDARD SERVICE LIMIT

Engine oil capacity At draining 2.0 liter (2.1 US qt, 1.8 Imp qt) --
At disassembly 2.6 liter (2.7 US qt, 2.3 Imp qt) --
At oil filter change 2.2 liter (2.3 US qt, 1.9 Imp qt) --
Recommended engine oil Pro Honda GN4 4-stroke oil (U.S.A. and
Canada) or equivalent motor oil.
API service classification : SG or Higher --
JASO T903 standard : MA
Viscosity : SAE 10W-30
Oil pressure at oil pressure switch 530 kPa (5.4 kgf/cm 2, 77 psi) at
5,500 min- 1 (rpm) (80 °C/176 °F)
--
Oil pump rotor Tip clearance 0.15 (0.006) 0.20 (0.008)
Body clearance 0.12 - 0.22 (0.005 - 0.009) 0.35 (0.014)
Side clearance 0.02 - 0.09 (0.001 - 0.004) o_ 12 (0.005)

4-1
LUBRICATION SYSTEM

TORQUE VALUES
Oil pump screw 3 N•m (0.3 kgf•m, 2.2 lbMt)
Oil pump drive sprocket bolt 49 N•m (5.0 kgf•m, 36 lbMt) Apply oil to the threads and seating surface .
Oil pump driven sprocket bolt 15 N•m (1 .5 kgf•m, 11 lbMt) Apply a locking agent to the threads.
Oil cooler bolt 64 N•m (6.5 kgf•m, 47 lbMt) Apply oil to the threads and seating surface.
Oil pressure switch 12 N•m (1.2 kgf•m, 9 lbMt) Apply sealant to the threads.
Oil strainer screen cap 15 N•m (1.5 kgf•m , 11 lbMt) Apply oil to the threads and seating surface.
Oil filter cartridge 26 N•m (2.7 kgf•m, 20 lbMt) Apply oil to the threads and seating surface.

TOOLS
Oil filter wrench 07HAA-PJ70100
Oil pressure gauge 07506-3000000-r-- Commercially available in U.S.A.
Oil pressure gauge attachment 07510-4220100 _J

TROUBLESHOOTING
Oil level low High oil pressure
• Oil consumption • Pressure relief valve stuck closed
• External oil leak • Plugged oil filter, gallery, or metering orifice
• Worn piston ring or incorrect piston ring installation • Incorrect oil being used
• Worn valve guide or seal
Seized engine
Oil contamination (White appearance) • No or low oil pressure
• From coolant m ixing with oil • Clogged oil orifice/passage
- Faulty water pump mechanical seal • Internal oil leak
- Faulty head gasket • Non-recommended oil used
- Water leak in crankcase
Oil contamination
No oil pressure • Deteriorated oil
• Oil level too low • Faulty oil filter
• Oil pump drive chain or drive sprocket broken • Worn piston ring (White appearance with water or moisture)
• Oil pump damaged (pump shaft) - Damaged water pump mechanical seal
• Internal oil leak - Damaged head gasket
- Oil relief not frequent enough
Low oil pressure
• Pressure relief valve stuck open Oil pressure warning indicator does not work
• Clogged oil filter and strainer screen • Faulty oil pressure switch
• Oil pump worn or damaged • Short circuit in the indicator wire
• Internal oil leak • Low or no oil pressure
• Incorrect oil being used
• Oil level too low

4-2
 LUBRICATION SYSTEM

OIL PRESSURE CHECK

If the engine is cold, the pressure reading will be
abnormally high. Warm up the engine to normal oper-
ating temperature before starting this test.

Warm up the engine.

Stop the engine.

Remove the screw cover and screw.

Disconnect the oil pressure switch cord.

Remove the oil pressure switch.

Connect the oil pressure gauge attachment and gauge
to the pressure switch hole.

TOOLS:
Oil pressure gauge 07506-3000000
(Commercially
available in U.S.A.)
Oil pressure gauge attachment 07510-4220100
(Commercially
available in U.S.A.)

Check the oil level and add the recommended oil if

necessary (page 3-11 ).

Start the engine and check the oil pressure at 5,500

min -1 (rpm).

OIL PRESSURE: 530 kPa (5.4 kgf/cm 2 , 77 psi) at

5,500 min- 1 (rpm) (80 °C/176 °F)
Do not apply sealant to the thread
head 3- 4 mm (0.1 - 0.2 in)
Stop the engine and remove the oil pressure gauge
attachment and gauge from the pressure switch hole.
I I
Apply sealant to the oil pressure switch threads as
shown and tighten it to the specified torque.

TORQUE: 12 N•m (1.2 kgf•m, 9 lbf.ft)

Route the oil pres- Connect the oil pressure switch cord and tighten the
sure switch cord screw.
correctly (page 7-
26). Start the engine.
Check the oil pressure indicator goes out after one or
two seconds. If the oil pressure indicator stay on, stop
the engine immediately and determine the cause
(page 21-17).

4-3
LUBRICATION SYSTEM

OIL PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE

REMOVAL
Separate the crankcase {page 13-2).

Remove the pressure relief valve and 0-ring from the

left crankcase.

0-RING

INSPECTION SNAP RING

• Be careful not to loose the disassembled parts.

Check the operation of the pressure relief valve by

pushing on the piston.
The snap ring is Remove the pressure valve snap ring and disassem-
under spring pres- ble the pressure relief valve.
sure. Use care
when removing it Check the piston for wear, sticking or damage.
and wear eye and
Check the valve spring and piston for wear or dam-
face protection.
age.
Check the relief valve for clogging or damage.

Clean the remaining parts and assemble the relief

valve in the reverse order of disassembly.

INSTALLATION
Apply oil to a new 0-ring and install in the pressure
relief valve groove, and install the relief valve to the
left crankcase.

4-4
 LUBRICATION SYSTEM

OIL PUMP
REMOVAL
Remove the right crankcase cover (page 12-2).

When removing Remove the bolt and washer.

and installing the .Remove the oil pump driven sprocket and drive chain.
oil pump, use
care not to allow
dust or dirt to
enter the engine.

Remove the bolts and oil pump from the right

crankcase.

Remove the dowel pin from the right crankcase.

DISASSEMBLY OIL PUMP COVER SCREW

Remove the screw and oil pump cover.

4-5
LUBRICATION SYSTEM

Remove the drive pin, washer, oil pump shaft, oil INNER ROTOR OUTER ROTOR
pump outer rotor and inner rotor.

OIL PUMP SHAFT

I
DRIVE PIN WASHER

INSPECTION
Measure at Temporarily install the oil pump shaft.
several points and Install the outer and inner rotors into the oil pump ·
use the largest body.
reading to
compare the
Measure the tip clearance.
service limit.

SERVICE LIMIT: 0.20 mm (0.008 in)

Measure the pump body clearance.

SERVICE LIMIT: 0.35 mm (0.014 in)

Measure the side clearance with the straight edge and

feeler gauge.

SERVICE LIMIT: 0.12 mm (0.005 in)

4-6
 LUBRICATION SYSTEM

ASSEMBLY
Dip all parts in clean engine oil.

DRIVE PIN

OIL PUMP BODY

OIL PUMP SHAFT

OIL PUMP COVER

Install the outer rotor into the oil pump body.

INNER ROTOR OUTER ROTOR
Install the inner rotor with the slot side facing the
pump cover.
Install the oil pump shaft and drive pin by aligning the
slots in the inner rotor.
Place the washer into the inner rotor groove.
OIL PUMP SHAFT

--~7!1 1. I

DRIVE PIN WASHER

Install the oil pump cover onto the oil pump body.
OIL PUMP COVER SCREW
Install and tighten the oil pump cover screw to the
specified torque.

TORQUE: 3 N•m (0.3 kgf•m, 2.2 lbf.ft)

4-7
LUBRICATION SYSTEM

INSTALLATION
Install the dowel pin to the right crankcase cover.

Install the oil pump while rotating the pump shaft to

seat the lug into the groove in the water pump shaft.

Align the bolt holes in the oil pump and right

crankcase.
Install and tighten the mounting bolts securely.

Install the oil pump driven sprocket and drive chain

with the "OUT" mark facing out and aligning the flat
surfaces of the sprocket and pump shaft.

Apply a locking agent to the oil pump driven sprocket

bolt threads.
Install and tighten the driven sprocket bolt to the spec-
ified torque.

TORQUE: 15 N•m (1.5 kgf•m, 11 lbf.ft)

Install the right crankcase cover (page 12-3).

After installation, fill the crankcase with recommend -

ed engine oil and check that there are no oil leaks.

4-8
 LUBRICATION SYSTEM

OIL COOLER
REMOVAL
Drain the engine oil and remove the oil filter cartridge
(page 3-11, 12).
Drain the coolant from the system (page 6-5).

Loosen the hose bands and disconnect the oil cooler

water hoses from the cooler.

WATER HOSES

Remove the oil cooler mounting bolt, lock washer and

oil cooler. LOCK WASHER OIL COOLER

Remove the 0-ring.

INSPECTION
Check the oil cooler for damage.

4-9
LUBRICATION SYSTEM

INSTALLATION WATER HOSES

OIL COOLER BOLT

64 N•m (6.5 kgf•m, 47 lbfoft)

OIL FILTER CARTRIDGE ~ 0-RING

26 N•m (2.7 kgf•m, 20 lbfoft)

Coat a new 0-ring with engine oil and install it into the
oil cooler groove.

Install the oil cooler aligning its guide groove with the
lug on the crankcase.

Apply oil to the oil cooler mounting bolt threads and "O" MARK
seating surface.
Install the lock Install the lock washer and oil cooler bolt.
washer with its
concave side
("0" mark) facing
the oil cooler

4-10
 LUBRICATION SYSTEM

Tighten the oil cooler mounting bolt to the specified

LOCK WASHER
torque.

TORQUE: 64 N•m (6.5 kgf•m, 47 lbf.ft)

Connect the oil cooler water hoses and tighten the

hose bands securely.

Install the oil filter cartridge and fill the crankcase with
the recommended engine oil (page 3-11).
Fill the cooling system and bleed the air (page 6-5).

4-11
FUEL SYSTEM (Programmed Fuel Injection)

21 N•m (2.1 kgf•m,

15 lbMt)

12 N•m (1.2 kgf•m, 9 lbf.ft)

5-0
 5. FUEL SYSTEM (Programmed Fuel Injection)
SERVICE INFORMATIO N 5-1 THROTTLE BODY/INTAK E MANIFOLD 5-92
TROUBLESHOOTING 5-3 INJECTOR 5-100
SYSTEM LOCATION ('02 - '07) 5-4 PRESSURE REGULATOR 5-102
SYSTEM DIAGRAM ('02 - '07) 5-5 FAST IDLE WAX UNIT 5-103
SYSTEM LOCATION (After '07) 5-6 AIR SCREW SYNCHRONIZ ATION 5-103
SYSTEM DIAGRAM (After '07) 5-7 MAP SENSOR 5-104

-
PGM-FI {PROGRAMMED FUEL IAT SENSOR 5-105
INJECTION) SYSTEM ('02 - '07) 5-8
ECT SENSOR 5-106
PGM-FI (PROGRAMMED FUEL
INJECTION) SYSTEM (After '07) CMP SENSOR 5-106
5-12
PGM-FI SELF-DIAGNOSIS MALFUNCTION TP SENSOR ('02 - '07) 5-107
INDICATOR LAMP (MIL) TP SENSOR (After '07) 5-109
FAILURE CODES ('02 - '07) 5-16
02 SENSOR (After '07) 5-110
MIL CODE INDEX (After '07) 5-44
BANK ANGLE SENSOR 5-112
MIL TROUBLESHOOTING (After '07) 5-46
ENGINE STOP RELAY 5-113
OTC CODE INDEX (After '07) 5-60
ECM (ENGINE CONTROL MODULE)
OTC TROUBLESHOOTING (After '07) 5-63 ('02 - '07) 5-114
FUEL LINE INSPECTION 5-79 ECM (ENGINE CONTROL MODULE)
FUEL PUMP {After '07) 5-115
5-82
FUEL CUT-OFF RELAY PAIR SOLENOID VALVE 5-116
5-84
FUEL TANK EVAPORATIVE EMISSION CONTROL
5-84
SYSTEM 5-117
AIR CLEANER HOUSING 5-89

SERVICE INFORMA TION

GENERAL
• This section covers service of the fuel system.
• These services can be done with the engine installed in the frame.
• Be sure to relieve the fuel pressure with the engine off.
• Bending or twisting the control cables will impair smooth operation and could cause the cables to stick or bind, resulting
in loss of vehicle control.
• Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can
cause a fire or explosion.

5-1
FUEL SYSTEM (Programmed Fuel Injection)

• Do not apply commercially available carburetor cleaners to the inside of the throttle bore, which is coated
with molybdenum.
• Do not snap the throttle valve from fully open to fully close after the throttle cable has been removed; it may cause incor-
rect idle operation.
• Seal the cylinder head intake ports with tape or a clean cloth to keep dirt and debris from entering the intake ports after the
throttle body has been removed.
• Do not apply excessive force to the fuel rail on the throttle body while removing or installing the throttle body.
• Do not damage the throttle body. It may cause incorrect throttle and idle valve synchronization.
• Prevent dirt and debris from entering the throttle bore, fuel hose and return hose. Clean them using compressed air.
• The throttle body is factory pre-set. Do not disassemble in a way other than shown in this manual.
• Do not loosen or tighten the white painted bolts and screws of the throttle body. Loosening or tightening them can cause
throttle and idle valve synchronization failure.
• Do not push the fuel pump base under the fuel tank when the fuel tank is stored.
• Always replace the packing when the fuel pump is removed.
• The programmed fuel injection system is equipped with the Self-Diagnostic System described on page 5-8, 12. If the mal-
function indicator lamp (MIL) blinks, follow the Self-Diagnostic Procedures to remedy the problem.
• When checking the PGM-FI, always follow the steps in the troubleshooting procedure (page 5-16, 44, 60).
The PGM -FI system is provided with fail-safe function to secure a minimum running capability even when there is trouble
in the system. When any abnormality is detected by the self-diagnosis function, running capability is secured by making
use of the numerical values of a situation preset in advance in the simulated program map. It must be remembered, how-
ever, that when any abnormality is detected in four injectors and/or the Crankshaft Position (CKP) and Camshaft Position
(CMP) sensor the fail safe function stops the engine to avoid engine damage.
• For PGM-FI system location, see page 5-4 ('02 - '07), page 5-6 (After '07).
• A faulty PGM -FI system is often related to poorly connected or corroded connectors. Check those connections
before proceeding.
• For fuel unit inspection, see section 21.
• The vehicle speed sensor sends digital pulse signals to the ECM (PGM -FI unit) for computation . For vehicle speed sensor
inspection, see section 21.
• When disassembling the programmed fuel injection parts, note the location of the 0-rings. Replace them with new ones
upon reassembly.
• Before disconnecting the fuel hoses, release the fuel pressure by loosening the fuel tube banjo bolt at the fuel tank.
• Always replace the sealing washers when the fuel hose banjo bolt is removed or loosened.
• Use a digital tester for PGM-FI system inspection.

SPECIFICATIONS

ITEM SPECIFICATIONS

Throttle body identification number '02 - '07: G080B

After '07: G080D
No.1 and No.2 cylinders vacuum difference 20 mm Hg
Base throttle valve for synchronization No.1
Idle speed 1,300 ± 100 min -1 (rpm)
Throttle grip free play 2 - 6 mm (1/16 - 1/4 in)
Intake air temperature sensor resistance (at 40°C/88°F) 1. 136 kQ ± 30 %
Engine coolant temperature sensor resistance (at 20°C/68°F) 2-3 kQ
Fuel injector resistance (at 20°C/68°F) 11.1 - 12.3 Q
PAIR solenoid valve resistance (at 20°C/68°F) 19 - 25 Q
CMP sensor peak voltage (at 20°C/68°F) 0.7 V minimum
CKP sensor peak voltage (at 20°C/68°F) 0.7 V minimum
Manifold absolute pressure at idle 64.8 kPa (0.66 kgf/cm 2, 9.4 psi)
Fuel pressure at idle 294 kPa (3.0 kgf/cm 2, 43 psi)
Fuel pump flow (at 12 V) Minimum 60 cm 3 (2.0 US oz, 2.1 Imp oz) for 10 seconds

5-2
 FUEL SYSTEM {Programmed Fuel Injection)

TORQUE VALUES
Fuel rail mounting bolt 10 N•m (1.0 kgf•m, 7 lbf•ft)
Fast idle wax unit mounting screw 4 N•m (0.4 kgf•m, 2.9 lbf•ft)
Fuel pump banjo bolt (Fuel tank side) 22 N•m (2.2 kgf•m, 16 lbf•ft)
Fuel tube sealing nut (Throttle body side) 22 N•m (2.2 kgf•m, 16 lbf•ft)
Fuel pump mounting nut 12 N•m (1.2 kgf•m, 9 lbf•ft) See page 5-83 for tightening sequence.
Fuel tank mounting nut 21 N•m (2.1 kgf•m, 15 lbf•ft)
Fuel tank mounting bolt 12 N•m (1.2 kgf•m, 9 lbf•ft)
02 sensor (After '07) 44 N•m (4.5 kgf•m, 33 lbf•ft)

TOOLS
Fuel pressure gauge 07406-0040002 or 07406-0040008 or 07406-004000A (U.S.A. only)
lgnitionMate peak voltage tester or
Peak voltage adaptor MTP07-0286 (U.S.A. only) or 07HGJ-0020100 (not available in U.S.A.) with
commercially available digital multimeter (impedance 10 MQ /DCV minimum)
ECU test harness 07YMZ-0010100 (two required) or 07WMZ-MBGAOOO (U.S.A. only)
ECM test harness 32P 070MZ-0010201
02 sensor wrench 07 LAA-PT50101
SCS connector 070PZ-ZY30100

TROUBLESHOOTING
Engine won't start Backfiring or misfiring during acceleration
• Intake air leak • Ignition system malfunction
• Fuel contaminated/de teriorated
• Pinched or clogged fuel hose Poor performance (driveability) and poor fuel economy
• Faulty fuel pump • Pinched or clogged fuel hose
• Clogged fuel filter • Faulty pressure regulator
• Clogged fuel injector filter
• Sticking fuel injector needle
• Faulty fuel pump operating system

Engine stall, hard to start, rough idling

• Intake air leak
• Fuel contaminated/de teriorated
• Pinched or clogged fuel hose
• Idle speed misadjusted
• Starter valve synchronization misadjusted

5-3
FUEL SYSTEM (Programmed Fuel Injection)

SYSTEM LOCATION ('02 - '07)

STD TYPE :

PAIR SOLENOID VALVE

CKP SENSOR AFTER '02 (ABS TYPE): SHOWN

FULL NAME ABBREVIATIONS

Manifold absolute pressure sensor MAP sensor

Throttle position sensor TP sensor
Intake air temperature sensor IAT sensor
Engine coolant temperature sensor ECT sensor
Camshaft position sensor CMP sensor
Crankshaft position sensor CKP sensor
Engine control module ECM

5-4
 FUEL SYSTEM (Programmed Fuel Injection)

SYSTEM DIAGRAM ('02 - '07)

(3 1)

(2)

:2
u
I.LI

(28)
(26) 0

(1) Engine stop relay (17) Injector

(2) Main fuse B (30A) (18) CMP sensor
(3) Engine stop switch (19) PAIR check valve
(4) Sub-fuse (15A) (20) ECT sensor
(5) Ignition switch (21) CKP sensor
(6) Main fuse A (30A) (22) Water temperatur e LCD
(7) Bank angle sensor (23) Fuel cut-off relay
(8) Sub-fuse (10A) (24) Fuel pump
(9) EVAP canister (25) Vehicle speed sensor
(10) Battery (26) Sidestand switch
( 11) Pressure regulator (27) Malfunctio n indicator lamp (MIL)
(12) IAT sensor (28) Immobilize r indicator
(13) Spark plug (29) Service check connector
(14) PAIR solenoid valve (30) Tachomete r
(15) TP sensor (31) Main relay
(16) MAP sensor (32) EVAP purge control solenoid valve

5-5
FUEL SYSTEM (Programmed Fuel Injection)

SYSTEM LOCATION (After '07)

PAIR SOLENOID VALVE

IGNITION SWITCH

No.1 INJECTOR

Oz SENSOR

FULL NAME ABBREVIATIONS

Manifold absolute pressure sensor MAP sensor

Throttle position sensor TP sensor

Intake air temperatur e sensor IAT sensor

Engine coolant temperatur e sensor ECT sensor

Camshaft position sensor CMP sensor
Crankshaft position sensor CKP sensor

Engine control module ECM

Data link connector DLC

5-6
 FUEL SYSTEM {Programmed Fuel Injection)

SYSTEM DIAGRAM (After '07)

Main Relay
AN Fuse 1OA Bl/Br

Bl/W

Bl/W

Bl/Bu
FANC A-23

Br/Bl
FLR A-20
GIP ..
Fuel Cut-off
Relay
ECM
Bl/W
IMOV B-29
Bl/W
IGP B-15

No.1 INJECTOR
P/Bu ~ 12 Bl/W
INJ1L A-11

PIY
INJ2L A-12

Y/Bu
IGPLS1 A-17
IGNITION
COIL

SPARK
PLUG ~
PAIR SOLENOID VALVE
O/BI Bl/W
EX-Al A-22

PURGE CONTROL SOLENOID VALVE

Bl/W
PCSV A-25

0 VEHICLE
SPEED
SENSOR
11

P/G
VSP B-25
W/Bu MIL
WARN B-9

A (Black) connector 8 (light Gray) connector

ECM 32P connector (ECM side of male terminals)

5-7
FUEL SYSTEM (Programmed Fuel Injection)

PGM-FI (PROGRAMMED FUEL MALFUNCTION INDICATOR LAMP (MIL)

INJECTION) SYSTEM ('02 - '07)

SELF-DIAGNOSTIC PROCEDURES
Place the scooter on its centerstand.
Start the engine and let it idle.

If the engine will not start, turn the starter motor for
more than 10 seconds and check that the MIL blinks.
If the malfunction indicator lamp (MIL) does not light
or blink, the system has no self-diagnosis memory
data.
If the MIL blinks, note how many times the MIL blinks,
and determine the cause of the problem (page 5-16
through 5-43).

If you wish to read the PGM-FI self-diagnosis memo-

ry data, perform the following:

Turn the ignition switch to "OFF':

Remove the left side body cover (page 2-6). SERVICE CHECK CONNECTOR

Short the PGM-FI system service check connector ter-

minals using a jumper wire.

~
JUMPER WIRE

Turn the ignition switch to "ON" and the engine stop

switch to "RUN':

5-8
 FUEL SYSTEM (Program med Fuel Injection}

Even if the PGM- If the ECM has no self diagnosis memory data, the
FI has memory MALFUNCTION INDICATOR LAMP (MIL)
MIL will illuminate when you turn the ignition switch
data, the MIL to "ON':
does not blink
when the engine
If the ECM has self diagnosis memory data, the MIL
running .
will start blinking when you turn the ignition switch to
"ON':

Note how many times the MIL blinks, and determine

the cause of the problem (page 5-16 through 5-43).

SELF-DIAGNOSIS RESET PROCEDURE SERVICE CHECK CONNECTOR

1. Turn the engine stop switch to "RUN" and the igni-
tion switch to "OFF':
2. Short the service check connector of the PGM-FI
system using a jumper wire.
3. Turn the ignition switch to "ON':
4. Remove the jumper wire from the service check
connector.

~
5. The MIL lights for about 5 seconds.
While the indicator is lit, short the service check con-
nector again with the jumper wire.
Self diagnosis memory data is erased if the MIL
turns off and then starts blinking. JUMPER WIRE

• The service check connector must be jumped while

the indicator is lit. If not, the MIL will not start blink- MALFUNCTION INDICATOR LAMP (MIL)
ing.
• Note that the self diagnosis memory data cannot be
erased if you turn off the ignition switch before the
MIL starts blinking.

If the MIL blinks 20 times, the data has not been

erased, so try again.

5-9
FUEL SYSTEM (Programmed Fuel Injection)

PEAK VOLTAGE INSPECTION

PROCEDURE
• Use this procedure for the CKP sensor and CMP
sensor inspection.
• Check all system connections before inspection. If
the system is disconnected, incorrect peak voltage
might be measured.
• Check cylinder compression and check that all spark
plugs are installed correctly.
• Use the recommended digital multimeter or a com-
mercially available digital multimeter with an
impedance of 10 MQ/DCV minimum.
• The display value differs depending upon the inter-
nal impedance of the multimeter.
• Disconnect the fuel pump/fuel unit connector
before checking the peak voltage. DIGITAL MULTIMETER

Remove the floorstep. (page 2-20)

Disconnect the fuel pump/fuel unit 4P connector.
·// \\
-. .~
-~ I
;
Connect the peak voltage adaptor to the
digital multimeter. :.... ' r.

TOOLS:
lgnitionMate peak voltage tester or
Peak voltage adaptor MTP07-0286 (U.S.A. only) or
07 HGJ-0020100
(not available in U.S.A.) PEAK VOLTAGE ADAPTOR
With commercially available digital multimeter
(impedance 10 MQ/DCV minimum)
22P(BLACK)CO NNECTOR
TEST HARNESS CONNECTIO N
Remove the left side body cover (page 2-6).

Remove the ECM from the stay.

Disconnect the 22P (Black) and 22P (Light gray) con-
nectors from the ECM.

ECM

Connect the ECU test harnesses between the main

wire harness and the ECM.

TOOL:
ECU test harness 07VMZ-0010100
(two required) or
07WMZ-MBGAOOO
(U.S.A. only)

5-10
 FUEL SYSTEM (Programmed Fuel Injection)

TEST HARNESS TERMIN AL LAYOUT VIEW FROM WIRE HARNESS SIDE:

The ECM connector terminals are numbered as

shown in the illustration . A11 81 811
A1

A: 22P (BLACK) CONNECTOR

B: 22P (LIGHT GRAY) CONNECTOR

The test harness terminals are the same layout as for FOR 22P (BLACK) CONNECTOR
the ECM connector terminals as shown.
FOR 22P (LIGHT GRAY) CONNECTOR

J 12 13 1 4 15 16 11 1e 19 20 2 1 22 I 12 13 14 15 16 171819202 1~

5-11
 FUEL SYST EM (Programmed Fuel Injection)

PGM-FI (PROGRAMMED FUEL INJEC-

TION) SYSTEM (After '07)
SELF-DIAGNOSTIC PROCEDURE
Suppo rt the scoote r with its centers tand.
Start the engine and let it idle.

If the engine will not start, turn the starter motor for
more than 10 second s and check that the MIL blinks.

If the malfun ction indicat or lamp (MIL) does not light

or blink, the system has no self-dia gnosis memo ry MALFU NCTIO N INDICATOR LAMP (MIL)
data.
If the MIL blinks, note how many times the MIL blinks
or read the Diagno sis Troubl e Code (OTC) with the LEFT MAINT ENANC E LID
Honda Diagno sis System (HOS) pocket tester, and
determ ine the cause of the proble m (MIL: page 5-44,
OTC: page 5-60).

If you wish to read the PGM-FI self-dia gnosis memo

-
ry data, perform the followi ng:

OTC (WITH THE HOS POCKET TESTER)

Turn the ignition switch to "OFF':
Open the seat and then remove the left mainte nance
lid.

Remov e the connec tor cover from the DLC.

Conne ct the Honda Diagno sis System (HOS) pocket
tester to the DLC.
Turn the ignition switch to "ON" and engine stop
switch to" 0 ':
Check the Diagno stic Troubl e Code (OTC) and note it.
Also, check the freeze data.

Refer to the OTC code index (page 5-60) and begin the
approp riate trouble shootin g proced ure.

MIL CODE (WITH OUT THE HOS POCKET TESTER)

Turn the ignition switch to "OFF':

Open the seat and then remove the left mainte nance
lid.
Remov e the connec tor cover from the DLC.
Short the DLC termin al using the special tool.

TOOL:
SCS connec tor 070PZ-ZV30100

5-12
 FUEL SYSTEM (Programmed Fuel Injection)

Turn the ignition switch to "ON" and engine stop

switch to " O ':

If the ECM has no self diagnosis memory data, the

MIL will illuminate when you turn the ignition switch
to "ON" and engine stop switch to 0 ':/1

If the ECM has self diagnosis memory data, the MIL

will start blinking when you turn the ignition switch to
"ON" and engine stop switch to 0 ':
/1

Note how many times the MIL blinks, and determine

the cause of the problem (page 5-44).
MALFUNCTIO N INDICATOR LAMP (MIU

SELF-DIAGNOSIS RESET PROCEDURE

Reset the self-diagnosi s memory data in either of 2
ways;

WITH THE HOS POCKET TESTER

Use the Honda Diagnosis System (HOS) pocket tester
to clear the ECM memory.

WITHOUT THE HOS POCKET TESTER

1. Turn the ignition switch to "OFF':
Open the seat and then remove the left mainte-
nance lid.
Remove the connector cover from the DLC.
2. Short the DLC terminals using the special tool.

TOOL:
SCS connector 070PZ-ZY301 00

3. Turn the ignition switch to "ON" and engine stop

switch to O ':
/1

4. Disconnect the SCS connector from the DLC.

5. The MIL lights about 5 seconds.

While the indicator lights, short the DLC terminals
again with the SCS connector.
Self-diagnosi s memory data is erased, if the MIL
turns off and starts blinking.

• The DLC must be jumped while the indicator is lit. If

not, the MIL will not start blinking.
• Note that the self diagnosis memory data cannot be
erased if you turn off the ignition switch before the
MIL starts blinking.
• If the MIL blinks 20 times, the data has not been
erased, perform the procedure again.
MALFUNCTIO N INDICATOR LAMP (MIU

5-13
FUEL SYSTEM (Programmed Fuel Injection)

PEAK VOLT AGE INSPECTION

PROCEDURE
• Use this procedure for the CKP sensor and CMP
sensor inspection.
• Check all system connections before inspection. If
the system is disconnected, incorrect peak voltage
might be measured.
• Check cylinder compression and check that all spark
plugs are installed correctly.
• Use the recommended digital multimeter or a com-
mercially available digital multimeter with an
impedance of 10 MQ/DCV minimum.
• The display value differs depending upon the inter-
nal impedance of the multimeter.
• Disconnect the fuel pump/fuel unit connector
before checking the peak voltage. DIGITAL MULTIMETER

Remove the floorstep. (page 2-20)

Disconnect the fuel pump/fuel unit 4P connector.
I
Connect the peak voltage adaptor to the
digital multimeter.

TOOLS:
lgnitionMate peak voltage tester or
Peak voltage adaptor MTP07-0286 (U.S.A. only) or
07HGJ-0020100
(not available in U.S.A.) PEAK VOLTAGE ADAPTOR
With commercially available digital multimeter
(impedance 10 MQ/DCV minimum)

TEST HARNESS CONNECTIO N

Remove the left side body cover (page 2-6).

Disconnect the 32P (Black) and 32P (Light gray) con-

nectors from the ECM.

Connect the ECM test harnesses between the main ECM TEST HARNESS ECM
wire harness and the ECM.

TOOL:
ECM test harness 32P 070MZ-0010201
(two required)

5-14
 ammed Fuel Injection)
FUEL SY ST EM (Progr

IN AL LAYOUT B: ECM 32P (Li ght gra

y)
TEST HARNESS TE RM CONNEC TO R
ere d as
r ter mi na ls are nu mb
Th e ECM con ne cto
n. A1
sho wn in thi s illu str atio

DDDODDDDDDDDDD
DDDDDDDDDDDDDD

A17

A: ECM 32P (Black)

CONNECTOR
7 A32 817
832

For 32P (Li ght gra y)

lay ou t as
s ter min als are sam e CONNECTOR
The ECM tes t har nes sho wn .

=1. "'" " " "'

r ter min als as
for the ECM con ne cto

1 1213 1415 16!

!1 2 3 4 5 6 7 8 9101
00
00 000 000 00> 000 000
00 00 00 00 00 00 00 00
00 00 00 00 00 00 00 00
00 00 00 00 00 00 00

For 32P (Black)

CONNECTOR

5-15
 FUEL SYSTEM (Progr
ammed Fuel Injectio
n)
PGM-FI SELF-DIAGN
OSIS M A LF U N C TI O N
FAILURE CODES ('02 INDICATOR LAMP (M
- '07) IL)
• Th e PGM-FI MI L de
no tes the fai lur e cod
is eq uiv ale nt to 10 blin es (the nu mb er of blin
ks. For exa mp le, a 1.3 ks fro m 0 to 33). Wh
blin ks. Fo llow cod e sec on d illu mi na tio n en the ind ica tor ligh
12 on page 5-32. and two blin ks (0.5 sec ts for 1.3 sec on ds it
• Wh en mo re tha n on ond x 2) of the ind ica
e fail ure occ urs , the tor eq ua ls 12
ple, if the ind ica tor blin MI L sh ow s the blin ks
ks once, the n two tim in the ord er of low est
es, tw o fai lur es ha ve nu mb er to hig he st nu
occ urr ed. Fo llow cod mb er. For exa m-
es 1 and 2 on pag e 5-1
8, 20.
Nu mb er of PGM-FI
MI L blin ks Causes Sy mp tom s
(Fail-safe con ten ts) Refer to
• Open cir cui t at the pa ge
po we r inp ut wir e of
the ECM • En gin e do es no t sta
.Fa ulty ba nk an gle sen
sor
rt

• Open cir cui t in ba nk

an gle sen sor
related cir cui t
Fa ulty en gin e sto p rel
ay
.
• Open cir cui t in en gin
Fa ulty en gin e sto p sw
e sto p rel ay rel ate d
itch
wir es
0 0 • Open cir cui t in en gin
e sto p sw itch
related wir es --
No blin ks • Fa ulty ign itio n sw itch
• Fa ulty ECM
. Blo wn PGM-FI fus e (20
A)
.
• Open cir cui t in en gin
Blo wn sub -fu se (10 A)
e sto p sw itch gro un d
(St art er/ ign itio n)
• Open or sho rt cir cui
0 . Fa ulty ECM
t in MI L wir e
• En gin e op era tes no
rm all y
No blin ks
--
• Sh ort cir cui t in ser
a
. . . Fa ulty ECM
vic e check con ne cto
r • En gin e op era tes no
rm all y
' '' • Sh ort cir cui t in ser
Sta y lit vic e check con ne cto
r wir e
--
. Loose or poor contacts on MAP sensor
1 a
. .
' ''
con ne cto r
• Open or sho rt cir cui
t in MA P sen sor wir e
• En gin e ope rat es no
rm all y
(si mu lat e usi ng nu me
ric al
Bli nks • Fa ulty MA P sen sor val ues ; 64.8 kPa /486 5-18

2 .a. . Loose or poor connection of the MAP mm Hg )

' '' vac uu m tub e sen sor • Eng ine op era tes no
rm all y
Bli nks • Fa ulty MA P sen sor (si mu lat e usi ng nu me
ric al
.a. . Loose or poor contact on ECT sen val ues ; 64.8 kPa /486
mm Hg )
5-20
7
• Open or sho rt cir cui sor . Hard sta rt at a low tem
' ''
Bli nks . Faulty ECT sensor t in ECT sensor wire (si mu lat e usi ng nu me
pe rat ure

. Loose or poor contact on TP sensor val ues ; 90°C/194°F)

ric al 5-22

8 a
. . con ne cto r . Po or en gin e res pon se
wh en
' '' • Open or sho rt cir cui op era tin g the thr ott le
Bli nks . Fa ulty TP sen sor
t in TP sen sor wir e
(si mu lat e usi ng nu me
qu ick ly
ric al 5-24
.a. . Loose or poor contact on IAT sen val ues ; thr ott le op en
s 0°)
9
• Open or sho rt cir cui sor . En gin e ope rat es no rm
' ''
Bli nks . Faulty IAT sensor t in IAT sensor wire (si mu lat e usi ng nu me
all y
ric al
val ues ; 35°C/95°F) 5-28

5-16
 FUEL SYSTEM (Programmed Fuel Injection)

Number of PGM-FI Symptoms Refer to

malfunction Causes (Fail-safe contents) page
indicator blinks
. Loose or poor contact on vehicle speed . Engine operates normally
sensor connector
11 a
4 .
; ''
. Open or short circuit in vehicle speed sensor 5-30

Blinks . connector
Faulty vehicle speed sensor
. Loose or poor contact on No.1 injector . Engine does not start
12 a
4 .
; '' . connector
Open or short circuit in No.1 injector wire
. Faulty No.1 injector
5-32

Blinks
. Loose or poor contact on No.2 injector . Engine does not start
13 40•
'' . connector
Open or short circuit in No.2 injector wire
5-35
;

Blinks . Faulty No.2 injector

. Loose or poor contact on CMP sensor . Engine does not start
18 a
4 .
;

Blinks
'' . Open or short circuit in CMP sensor
. Faulty CMP sensor
5-38

4a. . Loose or poor contact on CKP sensor . Engine does not start
19 '' . Open or short circuit in CKP sensor 5-40
;

Blinks . Faulty CKP sensor

4a. . Faulty E -PROM in ECM . operates normally
. Engine
2

33 ; '' Does not hold the self- 5-42

Blinks diagnosis data

5-17
FUEL SYSTEM (Programmed Fuel Injection)

PGM-FI Mlt 1 BLINK (MAP SENSOR)

Turn the ignition switch to "OFF':

Disconnect the MAP sensor 3P connector.

Check for loose or poor contact on the MAP
sensor connector.

Does not blink

Connect the MAP sensor connector. • Loose or poor contact on the MAP
Place the scooter on its main stand. sensor connector.
Start the engine and check that the MIL blinks.

1 blink
Turn the ignition switch to "OFF':

Out of range
Disconnect the MAP sensor 3P connector. • Open or short circuit in Yellow/Red wire.
Turn the ignition switch to "ON': • Loose or poor contact on the ECM connectors.
Measure the voltage at the wire harness
side connector.

Connection: Yellow/Red( +) - Ground(-)

Standard: 4. 75 - 5.25 V

Voltage exists
Out of range
• Open or short circuit in Green/Orang e wire.
• Loose or poor contact on the ECM connectors.

Connection: Yellow/Red (+) - Green/Orang e(-)

Standard: 4.75 - 5.25 V

Voltage exists

5-18
 FUEL SYSTEM (Programmed Fuel Injection)

Out of range
Measure the voltage between the terminals on • Open or short circuit in Light green/Yellow wire.
• Loose or poor contact on the ECM connectors.
the wire harness side.

Connection:
Light green/Yellow (+) - Green/Orang e (-)
Standard: 4.75 - 5.25 V

Voltage exists

Turn the ignition switch to "OFF':

Connect the MAP sensor 3P connector.

Disconnect the ECM connectors.

Connect the test harness to ECM connectors.
Turn the ignition switch to "ON':

Out of range
Measure the voltage at the test harness termi- • Faulty MAP sensor.
nals (page 5-11 ).

Connection: B7 (+) - A22 (-)

Standard: 2.7 - 3.1 V (760 mm Hg/1,013 kPa)
Voltage exists
• Replace the ECM with a new one, and inspect it
again.

5-19
FUEL SYSTE M (Programmed Fuel Injection)

PGM-FI MIL 2 BLINKS (MAP SENSOR)

Turn the ignition switch to "OFF':

Out of range
Disconne ct the vacuum tube from the • Check tube installatio n .
MAP sensor.
Connect the vacuum gauge between the throttle
body and the MAP sensor using a 3-way joint.
Start the engine and measure the manifold
absolute pressure at idle speed.

Standard: 150 - 250 mm Hg

Disconne ct the vacuum gauge and connect the

tube to the MAP sensor.

Disconne ct the ECM connecto rs.

Connect the test harness to the ECM connecto r.

5-20
 FUEL SYSTEM (Programmed Fuel Injection)

Out of range
Turn the ignition switch to "ON': • Faulty MAP sensor.
Measure the voltage at the test harness termi -
nals (page 5-11 ).

Connection: 87 (+) - A22 (-)

Standard: 2.7 - 3.1 V (760 mm Hg/1,013 kPa)

Voltage exists
Out of range
Start the engine. • Faulty MAP sensor.
Measure the voltage at the test harness termi -
nals (page 5-11 ).

Connection: 87 (+) - A22 (-)

Standard: 2. 7 V maximum
Voltage exists
• Replace the ECM with a new one, and inspect
it again.

5-21
FUEL SYSTEM (Programmed Fuel Injection}

PGM-FI MIL 7 BLINKS (ECT SENSOR}

Turn the ignition switch to "OFF':

Disconnect the ECT sensor 3P connector.

Check for loose or poor contact on the ECT
sensor connector.

No blinks
Connect the ECT sensor connector. • Loose or poor contact on the ECT
Place the scooter on its main stand. sensor connector.
Turn the ignition switch to "ON':

Check that the MIL blinks.

7 blinks
Abnormal
Turn the ignition switch to "OFF': • Faulty ECT sensor.
Disconnect the ECT sensor connector.
Measure the resistance at the ECT
sensor terminals. =====~

Connection: Pink/White (+) - Green/Orange (-)

(sensor side terminals)
Standard: 2.3 - 2.6 kQ (20°C/68°F)

Normal

5-22
 FUEL SYSTEM (Programmed Fuel Injection)

Out of range
Turn the ignition switch to "ON': • Open or short circuit in Pink and Pink/White wire.
Measure the voltage between the ECT sensor • Loose or poor contacts on the ECM connector.
connector terminal on the wire harness side and
ground.

Connection: Pink/White (+) - Ground (-)

Standard: 4.75 - 5.25 V

Voltage exists
Out of range
Measure the voltage at the ECT sensor connec- • Open or short circuit in Green/Orange wire .
tor on the wire harness side. • Loose or poor contacts on the ECM connector.

Connection: Pink/White (+) - Green/Orange (-)

Standard: 4.75 - 5.25 V
Voltage exists
• Replace the ECM with a new one, and inspect it
again.

5-23
FUEL SYSTEM (Programmed Fuel Injection)

PGM-FI MIL 8 BLINKS (TP SENSOR)

Turn the ignition switch to "OFF':

Disconnect the TP sensor 3P connector.

Check for loose or poor contact on the TP
sensor connector.

Does not blink

Connect the TP sensor connector. • Loose or poor contact on the TP sensor connector.
Place the scooter on its main stand.
Start the engine and check that the MIL blinks.

8 blinks
Turn the ignition switch to "OFF':

Out of range
Disconnect the TP sensor 3P connector. • Open or short circuit in the Yellow/Red wire.
Turn the ignition switch to "ON': • Loose or poor contact on the ECM connector.
Measure the voltage between the wire harness
side connector terminal and ground.

Connection: Yellow/Red( +) - Ground(-)

Standard: 4.75 - 5.25 V

Voltage exists

5-24
 FUEL SYSTEM (Programmed Fuel Injection)

Out of range
Measure the voltage at the TP sensor terminals • Open or short circuit in Green/Orange wire.
of the wire harness side. • Loose or poor contact on the ECM connectors.

Connection: Yellow/Red (+) - Green/Orange (-)

Standard: 4.75 - 5.25 V

Voltage exists

Turn the ignition switch to "OFF':

Disconnect the ECM 22P connectors.

Continuity
• Short circuit in Red/Yellow wire .

Connection: Red/Yellow(+) - Ground(-)

Standard: No continuity

No continuity

5-25
FUEL SYSTEM (Programmed Fuel Injection)

Connect the test harness to the ECM

connectors.

No continuity
Check for continuity between the test harness • Open or short circuit in Red/Yellow wire.
terminal and the TP sensor connector terminal.

Connection: Red/Yellow - 89
Standard: Continuity

Continuity

Connect the TP sensor 3P connector.

Normal
Turn the ignition switch ON. • Replace the ECM with a new one, and inspect it
Measure the voltage at the test again.
harness terminals.

Connection: 89 (+) - A22 (-)

Standard: *0.4 - 0.6 V (throttle fully closed)
*4.2 - 4.8 V (throttle fully open)
Out of range
• Faulty TP sensor.

5-26
 FUEL SYSTEM (Programmed Fuel Injection}

A voltage marked * refers to the value when the voltage reading at the TP sensor 3P connector (page 5-24) shows 5 V.
When the reading shows other than 5 V, derive a voltage at the test harness as follows:

In the case of a voltage of 4.75 Vat the TP sensor 3P connector:

0.4 x 4.75/5.0 = 0.38 v

0.6 x 4.75/5.0 = 0.57 v
Thus, the solution is "0.38 - 0.57 V" with the throttle fully closed.
To determine the throttle fully open range in the above equations, replace 0.4 and 0.6 with 4.2 and 4.8, respectively.

5-27
FUEL SYSTEM (Programmed Fuel Injection)

PGM-FI MIL 9 BLINKS (IAT SENSOR)

Turn the ignition switch OFF.

Disconnect the IAT sensor 2P connector.

Check for loose or poor contact on the IAT
sensor connector.

No blinks
Connect the IAT sensor 2P connector. • Loose or poor contact on the IAT sensor connector.
Place the scooter on its main stand.
Turn the ignition switch ON.
Check that the MIL blinks.

Turn the ignition switch OFF.

Abnormal
Disconnect the IAT sensor 2P connector. • Faulty IAT sensor.
Measure the resistance at the IAT sensor (at 20
- 30 °C/68 - 86 °F).

Standard: 1 - 4 kQ

Normal
Turn the ignition switch ON.

5-28
 FUEL SYSTEM (Programmed Fuel Injection)

Out of range
Measure the voltage between the terminals on • Open or short circuit in Gray/Blue wire.
the wire harness side. • Loose or poor contact on the ECM connectors.
l! c:::::Jll

-
Connection:
Gray/Blue (+) - Ground (-)
Standard: 4.75 - 5.25 V

Voltage exists
Out of range
Measure the voltage between the terminals on • Open or short circuit in Green/Orange wire.
the wire harness side. • Loose or poor contact on the ECM connectors.

Connection:
Gray/Blue(+) - Green/Orange( -)
Standard: 4. 75 - 5.25 V
Voltage exists
• Replace the ECM with a new one, and inspect it
again.

5-29
FUEL SYSTEM (Programmed Fuel Injection)

PGM-FI MIL 11 BLINKS (VEHICLE SPEED SENSOR)

Turn the ignition switch to "OFF':

Disconnect the vehicle speed sensor (3P: '02,

6P: AFTER '02 ABS TYPE) connector.
Check for loose or poor contact on the vehicle
speed sensor connector.

/
No blinks
Connect the vehicle speed sensor (3P: '02, • Loose or poor contact on the vehicle speed sensor
6P: AFTER '02 ABS TYPE) connector. connector.
Place the scooter on its main stand.
Start the engine and keep the engine revs more
than 5,000 min-1 (rpm) for 20 seconds or more.
Check that the MIL blinks.

11 blinks

Turn the ignition switch to "OFF':

Out of range
Disconnect the vehicle speed sensor (3P: '02, • Open or short circuit in Black/Brown wire of the
6P: AFTER '02 ABS TYPE) connector. engine sub-harness or main wire harness.
Turn the ignition switch to "ON ':
Measure the voltage at the wire harness side
connector.

Connection: Black/Brown (+) - Green/Black (-)

Standard: 12 V

Voltage exists

5-30
 FUEL SYSTE M (Programmed Fuel Injection)

Disconne ct the ECM connecto rs.

Connect the test harness to the wire
harness connecto rs.

Abnorma l
Place the scooter on its main stand and lift the • Open or short circuit in Pink/Gree n wire of the
engine sub-harne ss or main wire harness.
rear wheel off the ground.
Measure the voltage at the test harness termi-
nals with the ignition switch turned to "ON"
while slowly turning the rear wheel by hand.

Connection: Pink/Green (+) - Ground (-)

Standard: Repeat 0 to 5V
Normal
• Replace the ECM with a new one, and inspect it
again.

5-31
 FUEL SYSTE M (Programmed Fuel Injection)

PGM-FI MIL 12 BLINKS (No.1 INJECTOR)

Turn the ignition switch to "OFF':

Disconne ct the No.1 injector 2P connector .

Check for loose or poor contact on the No.1
injector 2P connecto r.

Does not blink

Connect the No.1 injector 2P connector . • Loose or poor contact on the No.1
Place the scooter on its main stand. injector connector .
Turn the ignition switch to "ON':
Check that the MIL blinks.

Abnorma l
Turn the ignition switch to "OFF': • Faulty No.1 injector.
Disconne ct the No.1 injector 2P connecto r and
measure the resistance of the No.1 injector.

Connection:
Black/Wh ite (+) - Pink/Blu e(-)
Standard: 11.1 - 12.3 Q (20°C/68°F)

Normal

5-32
 FUEL SYSTEM (Programmed Fuel Injection)

Check for continui ty between the No.1 injector Continu ity

• Faulty No.1 injector.
and ground .

Connection:
Black/W hite (+) - Ground (-)
Standard: No continuity

No continui ty
Turn the ignition switch to "ON': Out of range
• Open or short circuit in Black/W hite wire.
Measure the voltage between the No.1 injector
connect or on the wire harness side and ground.
ll c=ill

© 0

Connection:
Black/W hite(+) - Ground (-)
Standard: Battery voltage

Voltage exists
Turn the ignition switch to "OFF':
Connect the No.1 injector connecto r.

5-33
FUEL SYSTE M {Programmed Fuel Injection)

Disconne ct the ECM connecto rs.

Connect the test harness to the wire harness
connecto rs.

Out of range
Measure the resistance at the test • Open circuit in Black/Wh ite and/or Pink/Blue wire.
harness terminals .
.-------- --! Q f------,

8
Connection: A13 (-) - 82 (+)
Standard: 9 - 15 Q (20°C/68°Fl

Normal
Continuit y
Check for continuity between the test harness • Short circuit in Pink/Blue wire.
terminal and ground .

Connection: A 13 - Ground
Standard: No continuity
No continuity
• Replace the ECM with a new one, and inspect
it again.

5-34
 FUEL SYSTEM (Programmed Fuel Injection)

PGM-FI MIL 13 BLINKS (No.2 INJECTOR)

Turn the ignition switch to "OFF':

Disconnect the No.2 injector 2P connector.

Check for loose or poor contact on the No.2
injector 2P connector.

Does not blink

Connect the No.2 injector 2P connector. • Loose or poor contact on the No.2
Place the scooter on its main stand. injector connector.
Turn the ignition switch to "ON':
Check that the MIL blinks.

13 blinks
Abnormal
Turn the ignition switch to "OFF': • Faulty No.2 injector.
Disconnect the No.2 injector 2P connector and
measure the resistance of the No.2 injector.

Connection:
Black/White (+) - Pink/Yellow (-)
Standard: 11.1 - 12.3 Q (20°C/68°F)

Normal

5-35
FUEL SYSTEM (Programmed Fuel Injection)

Continuity
Check for continuity between the No.2 injector • Faulty No.2 injector.
and ground.

Connection:
Black/White (+) - Ground (-)
Standard: No continuity

No continuity
Out of range
Turn the ignition switch to "ON': • Open or short circuit in Black/White wire.
Measure the voltage between the No.2 injector
connector on the wire harness side and ground.
ll c::::::::J l

Connection:
Black/White (+) - Ground(-)
Standard: Battery voltage

Voltage exists

Turn the ignition switch to "OFF':

Connect the No.2 injector connector.

5-36
 FUEL SYSTEM (Programmed Fuel Injection)

Disconnect the ECM connectors .

Connect the test harness to the wire
harness connectors .

Out of range
Measure the resistance at the test Open circuit in Black/White and/or
harness terminals. Pink/Yellow wire.

8 ~--__,QI-----..,

Connection: A2 (-) - 82 (+)

Standard: 9 - 15 Q (20°C/68°F)

Normal
Continuity
Check for continuity between the test harness • Short circuit in Pink/Yellow wire.
terminal and ground.

Connection: A2 - Ground
Standard: No continuity

No continuity
• Replace the ECM with a new one, and inspect
it again.

5-37
FUEL SYSTEM (Programmed Fuel Injection)

PGM-FI MIL 18 BLINKS (CMP SENSOR)

Turn the ignition switch to "OFF':

Disconne ct the CMP sensor 2P connecto r.

Check for loose or poor contact on the CMP sen-
sor 2P connector .

Does not blink

Connect the CMP sensor 2P connector . • Loose or poor contact on the CMP sensor 2P con-
nector.
Place the scooter on its main stand.
Turn the starter motor for more than 10 seconds
and then check that the MIL blinks.

18 blinks

Turn the ignition switch to "OFF" and the engine

stop switch to "OFF':
Disconne ct the CMP sensor 2P connecto r.

Continuit y
Check the continuity between the CMP sensor • Faulty CMP sensor.
connecto r terminal and ground.

Connection: White/Ye llow - Ground

Standard: No continuity

No continuity

5-38
 FUEL SYSTEM (Programmed Fuel Injection)

Out of range
Crank the engine with the starter motor and • Faulty CMP sensor.
measure the CMP sensor peak voltage at the
CMP sensor 2P connector.

Connection: Gray (+) - White/Yello w(-)

Standard: 0.7 V minimum (20°C/68°F)

Normal
Connect the CMP sensor 2P connector.
Disconnect the ECM connectors.
Connect the test harness to ECM connectors.

Out of range
Crank the engine with the starter motor and • Open circuit in White/Yellow and/or Gray wire.
measure the CMP sensor peak voltage at the
test harness terminals.

, 2 3 .. 5 6 ._ 7 . 8 9 1011

._12 13 , .. ; u 6_Jt_ 1_a-1!_2 Q_21A_

Connection: 811 (+) - Ground(-)

Standard: 0. 7 V minimum (20°C/68°F)

Normal
• Replace the ECM with a new one, and inspect
it again .

5-39
FUEL SYSTEM {Programmed Fuel Injection)

PGM-FI MIL 19 BLINKS {CKP SENSOR)

Turn the ignition switch to "OFF':

Disconnect the CKP sensor 2P connector.

Check for loose or poor contact on the CKP sen-
sor 2P connector.

Does not blink

Connect the CKP sensor 2P connector. • Loose or poor contact on the CKP sensor 2P con-
Place the scooter on its main stand. nector.
Turn the starter motor for more than 10 seconds
and then check that the MIL blinks.

19 blinks

Turn the ignition switch to "OFF" and the engine

stop switch to "OFF':
Disconnect the CKP sensor 2P connector.

Abnormal
Check the continuity between the CKP sensor • Faulty CKP sensor.
connector terminal and ground.

Connection: White/Yellow - Ground

Standard: No continuity

No continuity

5-40
 FUEL SYSTEM (Programmed Fuel Injection)

Out of range
Crank the engine with the starter motor and • Faulty CKP sensor.
measure the CKP sensor peak voltage at the
CKP sensor 2P connector.

Connection: Yellow(+) - White/Yel low(-)

Standard: 0.7 V minimum (20°C/68°F)

Normal

Connect the CKP sensor 2P connector.

Disconnect the ECM connectors .
Connect the test harness to ECM connectors .

Out of range
Crank the engine with the starter motor and Open circuit in White/Yello w wire.
measure the CKP sensor peak voltage at the test • Open circuit in Yellow wire.
harness terminals.
1 2 3 .cs s 1 as io11

L1213141516171819 202122

Connection: 822 (+) - Ground (-)

Standard: 0.7 V minimum (20°C/68°F)

Normal
• Replace the ECM with a new one, and inspect it
again.

5-41
FUEL SYSTE M {Programmed Fuel Injection)

PGM-FI MIL 33 BLINKS {E -PROM)

2

Turn the ignition switch to "OFF':

Disconn ect the ECM connect ors.

Check for loose or poor contact on the
ECM connect ors.

33 blinks
Reset the self-diag nosis memory data (page 5-9).
Connect the ECM connecto rs.
Turn the ignition switch to "ON" and check that the
Short the service check connect or with a jumper
MIL blinks.
wire (page 5-8).
Turn the ignition switch to "ON" and check that 33 blinks
the MIL blinks.
• Replace the ECM.
Does not blink 33 times
Blinks
Remove the jumper wire from the service check
connecto r.

• No problem .
Turn the ignition switch to "ON" and check that
the MIL blinks.

33 blinks

5-42
 FUEL SYSTEM (Programmed Fuel Injection)

,,
Turn the ignition switch to "OFF':

Short the service check connector with a jumper -- • No problem.

wire (page 5-8).
Turn the ignition switch to "ON" and check that
the MIL blinks.

33 blinks Does not blink

33 blimes
Reset the self-diagnosis memory data -- • No problem.
(page 5-9).
Turn the ignition switch to "ON" and check that
the MIL blinks.
33 blinks
-- • Replace the ECM.

5-43
FUEL SYSTEM (Programmed Fuel Injection)

MIL CODE INDEX {After '07)

• The PGM-FI MIL denotes the failure codes (the number of blinks from 0 to 33). When the indicator lights for 1.3 seconds, it
is equivalent to 10 blinks. For example, a 1.3 second illumination and two blinks (0.5 second x 2) of the indicator equals 12
blinks. Follow the "MIL 12 BLINKS" troubleshoot ing (page 5-55).
• When more than one failure occurs, the MIL shows the blinks in the order of lowest number to highest number. For exam-
ple, if the indicator blinks once, then two times, two failures have occurred. Follow the "MIL 1 BLINK" troubleshoot ing (page
5-46) and "MIL 2 BLINKS" troubleshoot ing (page 5-47) .
Refer
MIL Function Failure Causes Symptoms
to

•Faulty ECM • Engine does not start 5-115

No blinks ECM malfunction
No blinks ECM power/ • Open circuit at the power input wire • Engine does not start
ground circuit • Faulty bank angle sensor
malfunction • Open circuit in bank angle sensor
related circuit
• Faulty engine stop relay
• Open circuit in engine stop relay
related wires
• Faulty engine stop switch 5-115
• Open circuit in engine stop switch
related wires
• Open circuit in engine stop switch
ground
• Blown main fuse B (30 A)
• Blown sub-fuse (15 A) (Starter,
Ignition, Fuel pump)
No blinks ECM output line • ECM output voltage line (Yellow/red • Engine does not start -
malfunction wire) short circuit
No blinks MIL circuit • Open or short circuit in MIL wire • Engine operates normally -
malfunction ·Faulty ECM
Stay lit Datalink circuit • Short circuit in DLC • Engine operates normally
• Short circuit in DLC wire -
malfunction
•Faulty ECM
1 blink MAP sensor circuit • Loose or poor contacts on MAP • Engine operates normally
malfunction sensor connector (simulate using numerical
• Open or short circuit in MAP sensor values; 64.8 kPa/ 486 mmHg) 5-46
wire
• Faulty MAP sensor
2 blinks MAP sensor • Loose or poor connection of the • Engine operates normally
MAP sensor vacuum hose (simulate using numerical 5-47
performance
problem • Faulty MAP sensor values; 64.8 kPa/486 mmHg)
7 blinks ECT sensor circuit • Loose o r poor contact on ECT sensor • Hard start at a low
malfunction • Open or short circuit in ECT sensor temperature (simulate using 5-48
wire numerical values; 90°C/ 194°F)
• Faulty ECT sensor
8 blinks TP sensor circuit • Loose or poor contact on TP sensor • Poor engine response and
malfunction connector performance when operating
throttle quickly the throttle quickly 5-50
• Open or short circuit in TP sensor (simulate using numerical
wire values; throttle opens 0°)
• Faulty TP sensor
9 blinks IAT sensor circuit • Loose or poor contact on IAT sensor • Engine operates normally
malfunction connector (simulate using numerical
• Open or short circuit in IAT sensor values; 35°C/95°F) 5-52
wire
• Faulty IAT sensor

5-44
 FUEL SYSTEM (Programmed Fuel Injection)

MIL Function Failure Causes Symptoms Refer

to
11 blinks Vehicle speed • Loose or poor contact on vehicle • Engine operates normally
sensor circuit speed sensor connector
malfunctio n • Open or short circuit in vehicle
5-53
speed sensor wire
• Faulty vehicle speed sensor
12 blinks No. 1 injector • Loose or poor contact on No. 1 • Engine does not start
circuit malfunctio n injector connector
• Open or short circuit in No. 1 injector
5-55
wire
• Faulty No. 1 injector
13 blinks No. 2 injector • Loose or poor contact on No. 2 • Engine does not start
circuit malfunctio n injector connector
• Open or short circuit in No. 2 injector
5-55, 56
wire
• Faulty No. 2 injector
18 blinks CMP sensor no • Loose or poor contact on CMP • Engine operates normally
signal sensor connector
• Open or short circuit in CMP sensor
5-56
wire
• Faulty CMP sensor
19 blinks CKP sensor no • Loose or poor contact on CKP • Engine operates normally
signal sensor connector
• Open or short circuit in CKP sensor 5-57
wire
• Faulty CKP sensor
21 blinks 02 sensor circuit • Loose or poor contact on 02 sensor • Engine operates normally
malfunctio n connector
• Short circuit in 02 sensor wire 5-58
• Faulty 02 sensor
23 blinks 02 sensor heater • Loose or poor contact on 02 sensor • Engine operates normally
malfunctio n connector
• Open or short circuit in 02 sensor 5-59
heater wire
• Faulty 02 sensor

5-45
FUEL SYSTEM (Progra mmed Fuel Injectio n)

MIL TROU BLES HOOT ING (AFTER '07)

MIL 1 BLINK (MAP SENSOR)
• Before starting the inspectio n, check for loose or
poor contact on the MAP sensor connecto r and
recheck the MIL blinking.

1. MAP Sensor System Inspectio n

Turn the ignition switch to "OFF':
Connect the ECM test harness to the ECM connec-
tors (page 5-14) .
Turn the ignition switch to "ON" and engine stop
switch to " 0 ':
Measure the voltage at the test harness terminals .
CONNECTION: 812 (+) - 826 (-)
Is the voltage within 2. 7 - 3. 1 V ?
YES - • Intermitte nt failure.
• Loose or poor contact on the ECM con- 00000000 00000000
nectors. 00000000 00000000

NO - • About 5 V. 1 17 )8 JQ 20 21222324 25 26 27 28 293031 32 1

GO TO STEP 2.
• About 0 V.
GO TO STEP 3.

2. MAP Sensor Output/G round Line Inspectio n MAP SENSOR 3P CONNECTOR

Turn the ignition switch to "OFF':
Disconne ct the MAP sensor 3P connecto r.
II 11
Turn the ignition switch to "ON" and engine stop cm

switch to " O ':

Measure the voltage at the wire harness side.
@@
CONNECTION: Light green/ye llow(+) -
Green/or ange(-)

Is the voltage within 4. 75 - 5.25 V?

YES Faulty MAP sensor.
NO • Open circuit in Light green/ye llow wire.
• Open circuit in Green/ora nge wire.

3. MAP Sensor Input Voltage Inspectio n MAP SENSOR 3P CONNECTOR

Turn the ignition switch to "OFF':
Disconne ct the MAP sensor 3P connecto r.
II I/
Turn the ignition switch to "ON" and engine stop cm

switch to " O ·:
Measure the voltage at the wire harness side.
CONNECTION: Yellow/re d(+) - Ground( -)
Is the voltage within 4. 75 - 5.25 V?
YES GO TO STEP 4.
NO - GO TO STEP 5.

5-46
 FUEL SYSTEM (Program med Fuel Injection)

4. MAP Sensor Output Line Short Circuit Inspection

MAP SENSOR 3P CONNECTOR
Turn the ignition switch to "OFF':
Disconnect the ECM test harness and ECM 32P con-
nectors disconnected .
Check for continuity between the MAP sensor 3P
connector terminal of the wire harness side and
ground.
CONNECTION: Light green/yellow - Ground
Is there continuity?
YES Short circuit in Light green/yellow wire.
NO Faulty MAP sensor.

5. MAP Sensor Power Input Line Open Circuit

Inspection
Turn the ignition switch to "OFF':
Disconnect the ECM 32P connectors.
Check for continuity at the Yellow/red wire between DDDDDDDDDDDDDD
the MAP sensor 3P connector and ECM 32P (Light DDDDDDDDDDDDDD
gray) connector terminal of the wire harness side.
832 A32
CONNECTION: Yellow/red - 818 (Yellow/red) A17

Is there continuity?
YES Replace the ECM with a new one, and
recheck.
NO Open circuit in Yellow/red wire.

MIL 2 BLINKS (MAP SENSOR)

• Before starting the inspection, check for loose or
poor contact on the MAP sensor connector and
recheck the MIL blinking.

1. MAP Sensor Hose Inspection

Turn the ignition switch to "OFF':
Check for connection and installation of the MAP
sensor vacuum hose.

Is the MAP sensor vacuum hose connection cor-

rect?
YES GO TO STEP 2.
NO - Correct the hose connection or installa-
tion.

2. MAP Sensor System Inspection

Connect the ECM test harness to the ECM connec-
tors (page 5-14).
Turn the ignition switch to "ON" and engine stop
switch to " 0 ':
Measure the voltage at the test harness terminals.
CONNECTION: 812 (+) - 826 (-)
Is the voltage within 2. 7 - 3. 1 V ?
YES GO TO STEP 3.
NO - Faulty MAP sensor.

5-47
FUEL SYSTEM (Program med Fuel Injection)

3. MAP Sensor System Inspection At Idle

Start the engine.
Measure the voltage at the test harness terminals.
CONNECTION: 812 (+) - 826 (-) 00000000000 00000
00000000000 00000
Is the voltage less than 2. 7 V?
1 1718 191021222324252627282 93031321

YES Replace the ECM with a new one, and

recheck.
NO Faulty MAP sensor.

MIL 7 BLINKS (ECT SENSOR)

• Before starting the inspection, check for loose or
poor contact on the ECT sensor 3P connector and
recheck the MIL blinking.

1. ECT Sensor System Inspection

Turn the ignition switch to "OFF':
Connect the ECM test harness to the ECM 32P con-
nectors (page 5-14).
Turn the ignition switch to "ON" and engine stop
switch to " 0 ':
Measure the voltage at the test harness terminals.
CONNECTION: 827 (+) - 826 (-)
Is the voltage within 2.7 - 3.1 V (20 °C/68°FJ?
YES - • Intermittent failure.
• Loose or poor contact on the ECM con-
nector.
NO - GO TO STEP 2.

2. ECT Sensor Output Voltage Inspection ECT SENSOR 3P CONNECTOR

Turn the ignition switch to "OFF':
Disconnect the ECT sensor 3P connector.
Turn the ignition switch to "ON" and engine stop
switch to " 0 ':
Measure the voltage at the test ECT sensor 3P con-
nector of the wire harness side.
CONNECTION: Pink/white (+) - Green/orang e (-)
Is the voltage within 4. 75 - 5.25 V?
YES GO TO STEP 3.
NO - GO TO STEP 4.

5-48
 FUEL SYSTEM (Programmed Fuel Injection)

3. ECT Sensor Resistance Inspection

Turn the ignition switch to "OFF':
Measure the resistance at the ECT sensor terminals.
CONNECTION: Pink/white - Green/orang e
Is the resistance within 2.3 -2.6 kQ (20°C/68°F)?
YES Replace the ECM with a new one, and
recheck.
NO Faulty ECT sensor.

4. ECT Sensor Output/Grou nd Line Open Circuit

Inspection
Turn the ignition switch to "OFF':
Disconnect the ECM test harness and the ECM 32P
00000000000000
connector disconnected .
00000000000000
Check for continuity at the Pink/white and
Green/orange wires between the ECT sensor 3P
A32 A17
connector and ECM 32P (Light gray) connector ter-
minals of the wire harness side.
CONNECTION: Pink/white - 827 (Pink/white)
Green/orange - 826 (Green/orange)
Is there continuity?
YES GO TO STEP 5.
NO - • Open circuit in Pink/white wire.
• Open circuit in Green/orange wire.

5. ECT Sensor Input Line Short Circuit Inspection

Check for continuity between the ECT sensor 3P
connector of the wire harness side and ground.
CONNECTION: Pink/white - Ground
Is there continuity?
YES Short circuit in Pink/white wire.
NO Replace the ECM with a new one, and
recheck.

5-49
FUEL SYSTEM {Programmed Fuel Injection)

MIL 8 BLINKS (TP SENSOR)

• Before starting the inspection, check for loose or
poor contact on the TP sensor connector and
recheck the MIL blinking.

1. TP Sensor System Inspection

Turn the ignition switch to "OFF':
Connect the ECM test harness to the ECM 32P con-
nectors (page 5-14).
Turn the ignition switch to "ON" and engine stop
switch to " 0 ':
Measure the voltage at the test harness terminals.
CONNECTION: 830 (+) - 826 (-)

STANDARD: *0.4 - 0.6 V (throttle fully closed)

*4.2 - 4.8 V (throttle fully opened)

NOTE:
• A voltage marked * refers to the value of the ECM
output voltage (STEP 2) when the voltage reading 00000000000 00000
00000000000 00000
shows 5 V.
l \118 192021222324252627282 93031321
When the ECM output voltage reading shows
other than 5 V, calculate the TP sensor output
voltage at the test harness as follows:
In the case of the ECM output voltage is 4.75 V:
0.4 x 4.75/5.0 = 0.38 v
0.6 x 4.75/5.0 = 0.57 v
Thus, the solution is "0.38 - 0.57 V" with the throt-
tle fully closed.
Replace 0.4 and 0.6 with 4.2 and 4.8 respectively,
in the above equations to determine the throttle
fully opened range.

Is the voltage at the standard value?

YES - • Intermittent failure.
• Loose or poor contact on the ECM con-
nector.
NO - GO TO STEP 2.

2. TP Sensor Input Voltage Inspection TP SENSOR 3P CONNECTOR

Turn the ignition switch to "OFF':
Disconnect the TP sensor 3P connector. !ID

Turn the ignition switch to "ON" and engine stop

switch to " 0 ':
Measure the voltage at the wire harness side.
®
@C

CONNECTION: Yellow/red (+) - Green/orang e (-)

Is the voltage within 4. 75 - 5.25 V?
YES GO TO STEP 4.
NO - GO TO STEP 3.

5-50
 FUEL SYSTEM (Programmed Fuel Injection)

3. ECM Output Voltage Inspection

Turn the ignition switch to "ON" and engine stop
switch to " 0 ':
Measure the voltage at the test harness terminals.
CONNECTION: 818 (+) - 826 (-) 0000000000000 000
0000000000000 000
Is the voltage within 4. 75 - 5.25 V? ill18 19202122232425262J28293031 32J

YES • Open circuit in Yellow/red wire.

• Open circuit in Green/orange wire.
NO Replace the ECM with a new one, and
recheck. e

4. TP Sensor Output Line Inspection

Turn the ignition switch to "OFF':
Disconnect the ECM test harness and the ECM 32P
connectors disconnected.
Check for continuity between the TP sensor 3P con- DDDDDDDDDDDDDD
DDDDDDDDDDDDDD
nector and ECM 32P (Light gray) connector terminal
of the wire harness side.
817 A32 A17
CONNECTION: Red/yellow - 830 (Red/yellow)
Is there continuity?
YES GO TO STEP 5.
NO - Open circuit in Red/yellow wire.

5. TP Sensor Output Line Short Circuit Inspection

TP SENSOR 3P CONNECTOR
Turn the ignition switch to "OFF': 11 1 111
Check for continuity between the TP sensor 3P con- CID

nector terminal of the wire harness side and

ground.
CONNECTION: Red/yellow - Ground
Is there continuity?
YES Short circuit in Red/yellow wire.
NO Faulty TP sensor.

5-51
FUEL SYSTEM (Programmed Fuel Injection)

MIL 9 BLINKS (IAT SENSOR)

• Before starting the inspection, check for loose or
poor contact on the IAT sensor connector and
recheck the MIL blinking.

1. IAT Sensor System Inspection

Turn the ignition switch to "OFF':
Connect the ECM test harness to the ECM connec-
tors (page 5-14).
Turn the ignition switch to "ON" and engine stop
switch to " 0 ·:
Measure the voltage at the test harness terminals.
CONNECTION: 88 (+) - 826 (-)
Is the voltage within 2.7 - 3.1 V (20 °C/68°F)?
YES - • Intermittent failure.
• Loose or poor contact on the ECM con-
nectors.
NO - GO TO STEP 2. 0000000000000000
0000000000000000
1 11181910111113141516271819303131 1

2. IAT Sensor Output Voltage Inspection

Turn the ignition switch to "OFF':
Disconnect the IAT sensor 2P connector.
Turn the ignition switch to "ON" and engine stop
switch to " 0 ':
Measure the voltage at the wire harness side.
CONNECTION: Gray/blue(+) - Green/orange(-)
Is the voltage within 4. 75 - 5.25 V?
YES GO TO STEP 3.
NO - GO TO STEP 4.

3. IAT Sensor Resistance Inspection

Turn the ignition switch to "OFF':
Measure the resistance at the IAT sensor terminals
(at 20 - 30°C/68 - 86°F).

@@
Is the resistance within 1 - 4 kQ (20 - 30 °C/68 -
86°F)?
YES Replace the ECM with a new one and
recheck.
NO Faulty IAT sensor.

IAT SENSOR

5-52
 FUEL SYSTEM (Program med Fuel Injection )

4. IAT Sensor Output/Gro und Line Open Circuit

Inspection
Turn the ignition switch to "OFF': ! 1 2 3 4 s 6 7 a 91011121 3 141516 !

Check for continuity at the Gray/blue and 000000000 0000000

Green/oran ge wires between the IAT sensor 2P 000000000 0000000
connector terminals of the wire harness side and l!718 19102122232425262 l28293031 321

test harness terminals.

CONNECTION: Gray/blue - BB
Green/orange - 826
Is there continuity?
YES GO TO STEP 5.
NO • Open circuit in Gray/blue wire.
• Open circuit in Green/oran ge wire.

5. IAT Sensor Output Line Short Circuit Inspection

IAT SENSOR 2P CONNECTOR
Disconnect the ECM test harness and the 32P con-
nector disconnect ed.
[Cg]
Check for continuity between the IAT sensor 2P con-
nector terminal of the wire harness side and
ground.
@
@@

CONNECTION: Gray /blue - Ground

Is there continuity?
YES Short circuit in Gray/blue wire.
NO - Replace the ECM with a new one, and
recheck.

MIL 11 BLINKS (VEHICLE SPEED SEN-

SOR)

• Before starting the inspection, check for loose or

poor contact on the vehicle speed sensor connector
and recheck the MIL blinking.

1. Vehicle Speed Sensor Pulse Inspection

Turn the ignition switch to "OFF':
Connect the ECM test harness to the ECM connec-
tors (page 5-14).
Support the scooter with its centerstan d and lift the
rear wheel off the ground.
Measure the voltage at the test harness terminals
with the ignition switch to "ON" and engine stop
switch to "0" while slowly turning the rear wheel
by hand.
CONNECTION: 825 (+) - A4 (-)
STANDARD: Repeat 0 to 5 V
Is the voltage at the standard value?
YES - • Intermitten t failure.
• Loose or poor contact on the ECM con-
nectors.
NO - GO TO STEP 2. 8 ...._____ ---I v ______, If)

5-53
FUEL SYSTEM {Programmed Fuel Injection}

2. Combination Meter Inspection

Check for operation of speedomet er.

Does the speedome ter operate normally?

YES - Open or short circuit in Pink/green wire
between the ECM and vehicle speed sen-
sor.
NO GO TO STEP 3.

3. Vehicle Speed Sensor Input Voltage Inspection

Turn the ignition switch to "OFF':
Disconnect the vehicle speed sensor 3P connector.
Turn the ignition switch to "ON" and engine stop
switch to " 0 ':
Measure the voltage at the wire harness side.
CONNECTION: Black/brow n(+) - Green/bla ck(-)
Does the battery voltage exist?
YES GO TO STEP 4.
NO • Open circuit in Black/brow n wire.
• Open circuit in Green/blac k wire.

4. Vehicle Speed Sensor Signal Line Short Circuit

Inspection
Turn the ignition switch to "OFF': !1 2 3 4 5 6 7 8 910 11 121Jl4151 6! ii 2 3 4 5 6 7 8 9 10111213 141 5161
Check for continuity between the test harness ter-
000000000 0000000
minal and ground. 000000000 0000000
CONNECTION: 825 - Ground 11118 19201112132425262 728193031321

Is there continuity?
YES Short circuit in Pink/green wire.
NO Inspect the vehicle speed sensor (page 21-
8).

5-54
 FUEL SYSTEM (Program med Fuel Injection )

MIL 12 BLINKS (N0.1 INJECTOR)

A11
POWER INPUT
• Before starting the inspection, check for loose or (Pink/blue)
LINE (Black/whit e)
poor contact on the injector connector and recheck
the MIL blinking.

MIL INJEC- POWER SIGNAL SIGNL

TOR INPUT LINE LINE ATECM
12 No. 1 Black/white Pink/blue A11
13 No. 2 Black/white Pink/yellow A12
A12
(Pink/yellow )

1. Injector Circuit Resistance Inspection

Turn the ignition switch to "OFF':
Connect the ECM test harness to the ECM connec-
tors (page 5-14).
Measure the resistance at the test harness termi-
nals.
CONNECTION: POWER INPUT LINE (815) - SIG-
NAL AT ECM
Is the resistance within 11.1- 12.3 Q (20 °C/68°FJ?
YES GO TO STEP 4.
NO - GO TO STEP 2.

2. lnjecto~ Resistance Inspection

Disconnect the No.1 injector 2P (Black) connector
and measure the resistance at the No.1 injector ter-
minals.

Is the resistance within 11.1 - 12.3 Q (20 °C/68°FJ?

YES GO TO STEP 3.
NO - Faulty injector.

3. Injector Input Voltage Inspection

Turn the ignition switch to "ON" and engine stop
switch to " O ':
Measure the voltage between the No. 1 injector 2P
(Black) connector terminal of the wire harness side
and ground.
CONNECTION: POWER INPUT LINE(+) - Ground(-)
Does the battery voltage exist?
YES Open circuit in SIGNAL LINE wire.
NO - Open circuit in POWER INPUT LINE wire.

5-55
FUEL SYSTEM (Program med Fuel Injection)

4. Injector Signal Line Short Circuit Inspection

Check for continuity between the test harness ter-
minal and ground.
0000000000 000000
CONNECTION: SIGNAL AT ECM - Ground 0000000000 000000
11718 19201112 13 14151627181930 3131 1
Is there continuity?
YES • Short circuit in SIGNAL LINE wire.
• Faulty injector.
NO Replace the ECM with a new one, and
recheck.

MIL 13 BLINKS (N0.2 INJECTOR)

See page 5-55.

MIL 18 BLINKS (CMP SENSOR)

• Before starting the inspection, check for loose or
poor contact on the CMP sensor connector and
recheck the MIL blinking.

1. CMP Sensor Peak Voltage Inspection at ECM

Turn the ignition switch to "OFF':
Connect the ECM test harness to the ECM connec-
tors.
Turn the ignition switch to "ON" and engine stop
switch to " O ':
Crank the engine with the starter motor, and mea-
sure the CMP sensor peak voltage at the test har-
ness terminals.
CONNECTION: 810 (+) - A31 (-)
Is the voltage more than 0.7 V (20 °C/68°F)?
YES - • Intermittent failure.
• Loose or poor contact on the ECM con-
nectors.
NO - GO TO STEP 2.

2. CMP Sensor Peak Voltage Inspection

CMP SENSOR
Turn the ignition switch to "OFF':
Disconnect the CMP sensor 2P connector.
Turn the ignition switch to "ON" and engine stop
switch to " 0 ':
Crank the engine with the starter motor, and mea-
sure the CMP sensor peak voltage at the CMP sen-
sor terminals.
CONNECTION: Gray(+) -White/yello w(-)
Is the voltage mote than 0.7 V (20 °C/68°F}?
YES Open or short circuit in White/yellow wire
or Gray wire.
NO Faulty CMP sensor.

5-56
 FUEL SYSTEM {Programmed Fuel Injection)

MIL 19 BLINKS {CKP SENSOR)

• Before starting the inspection, check for loose or
poor contact on the CKP sensor connector and
recheck the MIL blinking.

1. CKP Sensor Peak Voltage Inspection at ECM

Turn the ignition switch to "OFF':
Connect the ECM test harness to the ECM connec-
tors (page 5-14).
Turn the ignition switch to "ON" and engine stop
switch to " 0 ':
Crank the engine with the starter motor, and mea-
sure the CKP sensor peak voltage at the test harness
terminals.
CONNECTION: 811 (+) - A31 (-)
Is the voltage more than 0. 7 V (20 °C/68 °FJ?
YES - • Intermitten t failure.
• Loose or poor contact on the ECM con-
nectors.
NO - GO TO STEP 2.

2. CKP Sensor Peak Voltage Inspection

CKP SENSOR 2P (Red) CONNECTOR
Turn the ignition switch to "OFF':
Disconnect the CKP sensor 2P (Red) connector.
Turn the ignition switch to "ON" and engine stop
switch to " 0 ':
Crank the engine with the starter motor, and mea-
sure the CKP sensor peak voltage at the CKP sensor
2P (Red) connector terminals of the sensor side.
CONNECTION: Yellow(+) - White/yell ow(-)
Is the voltage more than 0.7 V (20 °C/68°FJ?
YES Open or short circuit in Yellow or
White/yello w wire.
NO Faulty CKP sensor.

5-57
FUEL SYSTEM (Programmed Fuel Injection)

MIL 21 BLINKS (02 SENSOR)

• Before starting the inspection, check for loose or
poor contact on the 02 sensor connector and
recheck the MIL blinking.

1. 02 Sensor Open Circuit Inspection

Turn the ignition switch to " OFF':
Connect the ECM test harness to the ECM connec-
tors (page 5-14).
Disconnect the 02 sensor 4P (Gray) connector.
Check for continuity between the 02 sensor 4P
(Gray) connector terminals of the wire harness side
DD
and test harness terminals.
CONNECTION: Black/red - B13
Green/orange - B26

Is there continuity?
YES GO TO STEP 2.
NO - • Open circuit in Black/red wire.
• Open circuit in Green/oran ge wire.

2. 02 Sensor Short Circuit Inspection

Disconnect the ECM test harness and the ECM 32P
connector disconnect ed.
Check for continuity between the 02 sensor 4P
(Gray) connector terminal of the wire harness side
and ground.
CONNECTION: Black/red - Ground
Is there continuity?
YES Short circuit in Black/red wire.
NO - GO TO STEP 3.

3. 02 Sensor Inspection
Replace the 02 sensor with a new one (page 5- 110).
Reset the ECM (page 5-13).
Turn the ignition switch to " ON" and engine stop
switch to " O ':
Start and warm the engine up to coolant tempera-
ture is 80°C (176°F).
Test ride the scooter, then stop the engine .
Perform the self-diagno stic procedure (page 5-12)
and check that the MIL blinks.

Is the MIL 21 blinks?

YES Replace the ECM with a new one, and
recheck.
NO Faulty original 02 sensor.

5-58
 FUEL SYSTEM (Programmed Fuel Injection)

MIL 23 BLINKS (02 SENSOR HEATER)

• Before starting the inspection, check for loose or
poor contact on the 02 sensor connector and
recheck the MIL blinking.

1. 02 Sensor Heater Resistance Inspection

Turn the ignition switch to "OFF':
Disconnect the 02 sensor 4P (Gray) connector and
measure the resistance at the sensor side connec-
tor.
CONNECTION: White - White
Is the resistance within 10 - 40 Q (20 °C/68°FJ?
YES GO TO STEP 2.
NO - Faulty 02 sensor.

2. 02 Sensor Heater Open circuit Inspection

Connect the ECM test harness to the ECM connec-
tors (page 5-14).
Connect the 02 sensor 4P (Gray) connector.
Measure the resistance at the test harness termi -
nals.
CONNECTION: A6 - B15
Is the resistance within 10 - 40 Q (20 °C/68 °FJ?
YES GO TO STEP 3.
NO - • Open circuit in Black/white wire
• Open circuit in White wire

3. 02 Sensor Heater Short Circuit Inspection 1

Disconnect the ECM test harness and ECM 32P con- B16 Bl A16 Al
nectors disconnect ed.
Disconnect the 02 sensor 4P (Gray) connector.
Check for continuity between the ECM 32P (Black) DDDDDDDD DDDDDD
connector terminal of the wire harness side and DDDDDDDDDDDDDD
ground.
B32 817 A32 A17 ..
CONNECTION: A6 (White) - Ground
Is there continuity?
YES Short circuit in White wire.
NO - GO TO STEP 4.

4. 02 Sensor Heater Short Circuit Inspection 2

Check for continuity between the 02 sensor 4P
(Gray) connector terminal of the sensor side and
ground.
CONNECTION: White - Ground
Is there continuity?
YES Faulty 02 sensor.
NO - Replace the ECM with a new one, and
recheck.

02 SENSOR 4P (Gray) CONNECTOR

5-59
FUEL SYSTEM (Programmed Fuel Injection)

OTC CODE INDEX (After '07)

as hyphen-
• The Diagnostic Trouble Codes (OTC) are based upon Malfunction Indicator Lamp (MIL) codes and are displayed
to an MIL code and indicate the Function Failure . The digit after the
ated numbers. The digits before the hyphen are equal
symptom. For example, in the case of the TP sensor, the ECM stores two levels of information, a func-
hyphen details the
tion failure and a detail of the symptom:
(08 - 1) = TP sensor voltage - lower than the specified value
or
(08 - 2) = TP sensor voltage - higher than the specified value.
• The MAP, ECT, TP and IAT sensor can be mean diagnosis according to the sensor output voltage value.
to the standard
If the failure occurs, the ECM determines the failure function, the output voltage is high or low compared
voltage, then read out the OTC to the HOS pocket tester.
For example:
5 V, then the OTC
- If the input voltage line (A) on the MAP sensor is opened, the ECM detects the output voltage is about
1-2 (MAP sensor circuit high voltage) will be read out.
the OTC 8-1 (TP
- If the input voltage line (B) on the TP sensor is opened, the ECM detects the output voltage is 0 V, then
sensor circuit low voltage) will be read out.

5V
5V
MAP SENSOR 5V TP SENSOR

(A)

OUTPUT VOLTAGE

5V 5V

ECT SENSOR IAT SENSOR

OUTPUT VOLTAGE OUTPUT VOLTAGE

5-60
 FUEL SYSTEM (Programmed Fuel Injection)

OTC Function Failure Causes Symptoms Refer

to
- ECM malfunction •Faulty ECM • Engine does not start
• 5-115
MIL does not blink
- ECM power input • Open circuit at the power input wire • Engine does not start
circuit malfunction of the ECM • MIL does not blink
• Faulty bank angle sensor
..... • Open circuit in bank angle sensor
related circuit
• Faulty engine stop relay
• Open circuit in engine stop relay
related wires -
• Faulty engine stop switch
• Open circuit in engine stop switch
related wires
• Faulty ignition switch
• Blown main fuse B (30 A)
• Blown sub-fuse (15 A) (Starter,
Ignition, Fuel pump)
- ECM output line • ECM output voltage line (Yellow/red • Engine does not start
malfunction wire) short circuit -
- MIL circuit • Open or short circuit in MIL wire • Engine operates normally
malfunction •Faulty ECM • MIL does not blink -
- Datalink circuit • Short circuit in DLC • Engine operates normally
malfunction • Short circuit in DLC wire • MIL stays lit -
·Faulty ECM
1-1 MAP sensor circuit • Open or short circuit in MAP sensor • Engine operates normally
low voltage wire (simulate using numerical 5-63
• Faulty MAP sensor values; 64.8 kPa/486 mmHg)
1-2 MAP sensor circuit • Loose or poor contact on MAP sensor • Engine operates normally
high voltage connector (simulate using numerical
• Open circuit in MAP sensor wire values; 64.8 kPa/486 mmHg) 5-64
• Faulty MAP sensor
2-1 MAP sensor • Loose or poor connection of the MAP • Engine operates normally
performance sensor vacuum hose (simulate using numerical 5-65
problem • Faulty MAP sensor values; 64.8 kPa/486 mmHg)
7-1 ECT sensor circuit • Short circuit in ECT sensor wire • Hard start at a low
low voltage • Faulty ECT sensor temperature (simulate using 5-66
numerical values; 90°C/194°F)
7-2 ECT sensor circuit • Loose or poor contact on ECT sensor • Hard start at a low
high voltage • Open circuit in ECT sensor wire temperature (simulate using 5-67
• Faulty ECT sensor numerical values; 90°C/194°F)
8-1 TP sensor circuit • Loose or poor contact on TP sensor • Poor engine response and
low voltage connector performance when operating
• Open or short circuit in TP sensor the throttle quickly 5-68
wire (simulate using numerical
• Faulty TP sensor values; throttle opens 0°)
8-2 TP sensor circuit • Open circuit in TP sensor wire • Poor engine response and
high voltage • Faulty TP sensor performance when operating
the throttle quickly 5-69
(simulate using numerical
values; throttle opens 0°)
9-1 IAT sensor circuit • Short circuit in IAT sensor wire • Engine operates normally
low voltage • Faulty IAT sensor (simulate using numerical 5-70
values; 35°C/95°F)
9-2 IAT sensor circuit • Loose or poor contact on IAT sensor • Engine operates normally
high voltage • Open circuit in IAT sensor wire (simulate using numerical 5-71
• Faulty IAT sensor values; 35°C/95°F)

5-61
FUEL SYSTEM {Programmed Fuel Injection)

Refer
OTC Function Failure Causes Symptoms
to

11-1 Vehicle speed • Loose or poor contact on vehicle • Engine operates normally
sensor no signal speed sensor connector
(circuit • Open or short circuit in vehicle 5-72
malfunction) speed sensor connector
• Faulty vehicle speed sensor
12-1 No. 1 injector • Loose or poor contact on No. 1 • Engine does not start
circuit malfunction injector connector
• Open or short circuit in No. 1 injector 5-73
wire
• Fau!ty No. 1 injector
13-1 No. 2 injector • Loose or poor contact on No. 2 • Engine does not start
circuit malfunction injector connector
• Open or short circuit in No. 2 injector 5-73, 74
wire
• Faulty No. 2 injector
18-1 CMP sensor no • Loose or poor contact on CMP • Engine does not start
signal sensor connector
• Open or short circuit in CMP sensor 5-74
wire
• Faulty CMP sensor
19-1 CKP sensor no • Loose or poor contact on CKP • Engine does not start
signal sensor connector
• Open or short circuit in CKP sensor 5-75
wire
• Faulty CKP sensor
21 -1 02 sensor circuit • Loose or poor contact on 02 sensor • Engine operates normally
malfunction connector 5-76
• Short circuit in 02 sensor wire
• Faulty 02 sensor
23-1 02 sensor heater • Loose or poor contact on 02 sensor • Engine operates normally
malfunction connector
• Open or short circuit in 02 sensor 5-77
heater wire
• Faulty 02 sensor
33-2 EEPROM in ECM ·Faulty ECM • Engine operates normally
malfunction • Does not hold the self 5-78
diagnosis data

5-62
 FUEL SYSTEM (Programm ed Fuel Injection)

OTC TROUBLESHOOTING (After '07)

OTC 1-1 (MAP SENSOR LOW VOLT-
AGE)

1. MAP Sensor System Inspection

Turn the ignition switch to "ON" and engine stop
switch to " O ':
Check the MAP sensor with the HOS pocket tester.

Is about 0 V or below indicated?

YES GO TO STEP 2.
NO - Intermittent failure.

2. MAP Sensor Input Voltage Inspection MAP SENSOR 3P CONNECTOR

Turn the ignition switch to "OFF':

Disconnect the MAP sensor 3P connector.
Turn the ignition switch to "ON" and engine stop
switch to " 0 ':
Measure the voltage at the wire harness side.
®@

CONNECTION: Yellow/red (+) - Green/orang e H

Is the voltage within 4. 75 - 5.25 V?
YES GO TO STEP 4.
NO - GO TO STEP 3.

3. MAP Sensor Input Line Inspection

Turn the ignition switch to "OFF':
Disconnect the ECM 32P connectors.
Check for continuity at the Yellow/Red wire between
the MAP sensor 3P connector and ECM 32P (Light DDDDDDDDDDDDDD
gray) connector terminal of the wire harness side. DDDDDDDDDDDDDD
CONNECTION: Yellow/red - 818 (Yellow/red)
832 A32 A17
Is there continuity?
YES Replace the ECM with a new one, and
recheck.
NO Open circuit in Yellow/red wire.

4. MAP Sensor Output Line Short Circuit lnspectio

MAP SENSOR 3P CONNECTOR
Turn the ignition switch to "OFF':
Check for continuity between the MAP sensor 3P
connector terminal of the wire harness side and
ground.
CONNECTION: Light green/yellow - Ground
Is there continuity?
YES Short circuit in Light green/yellow wire .
NO - GO TO STEP 5.

5-63
FUEL SYSTEM (Programmed Fuel Injection)

5. MAP Sensor Inspection

Replace the MAP sensor with a new one (page 5-
105).
Reset the ECM (page 5-13).

Turn the ignition switch to "ON" and engine stop

switch to " 0 ':
Check the MAP sensor with the HOS pocket tester.

Is the OTC 1-1 indicated?

YES Replace the ECM with a new one, and
recheck.
NO Faulty original MAP sensor.

OTC 1-2 (MAP SENSOR HIGH VOLT-

AGE)
• Before starting the inspection, check for loose or
poor contact on the MAP sensor connector and
recheck the OTC.

1. MAP Sensor System Inspection 1

Turn the ignition switch to "ON" and engine stop
switch to " 0 ':
Check the MAP sensor with the HOS pocket tester.

Is about 5 V indicated?
YES GO TO STEP 2.
NO - • Intermittent failure .
• Loose or poor contact on the MAP sen-
sor connector.

2. MAP Sensor System Inspection 2

Turn the ignition switch to "OFF':
Disconnect the MAP sensor 3P connector.
Connect the MAP sensor terminals at the wire har-
ness side with a jumper wire.
CONNECTION: Light green/Yellow - Green/orange
Turn the ignition switch to "ON" and engine stop
switch to " 0 ':
Check the MAP sensor with the HOS pocket tester.

Is about 0 V indicated?
YES Faulty MAP sensor.
NO - GO TO STEP 3.

5-64
 FUEL SYSTEM (Program med Fuel Injection )

3. MAP Sensor Input/Grou nd Line Inspection

Turn the ignition switch to "OFF':
Remove the jumper wire.
Turn the ignition switch to "ON" and engine stop
switch to " 0 ':
Measure the voltage at the wire harness side.
CONNECTION: Yellow/red (+) - Green/ora nge(-)
Is the voltage within 4. 75 - 5.25 V?
YES GO TO STEP 4.
NO - Open circuit in Green/oran ge wire.

MAP SENSOR 3P CONNECTOR

4. MAP Sensor Output Line Open Circuit Inspection

Turn the ignition switch to "OFF':
Disconnect the ECM 32P connectors .
Check for continuity at the Light green/yello w wire
00000000000000
between the MAP sensor 3P connector and ECM 00000000000000
32P (Light gray) connector terminal of the wire har-
ness side.
832 817 A32 A17
CONNECTION: Light Green/yell ow - 812 (Light
green/yello w)
Is there continuity?
YES Replace the ECM with a new one, and
recheck.
NO Open circuit in Light green/yello w wire.

OTC 2-1 (MAP SENSOR )

• Before starting the inspection, check for loose or

poor contact on the MAP sensor connector and
recheck the DTC.

1. MAP Sensor System Inspection

Turn the ignition switch to "ON" and engine stop
switch to " O ':
Start the engine and let it idle, check the HDS pock-
et tester.

Is the DTC 2-1 indicated?

YES GO TO STEP 2.
NO - Intermitten t failure.

2. Manifold Absolute Pressure Test

Turn the ignition switch to "OFF':
Check for connection and installation of the MAP
sensor vacuum hose.

Is the MAP sensor vacuum hose connection cor-

rect?
YES GO TO STEP 3.
NO - Correct the hose installation .

5-65
FUEL SYSTEM (Programmed Fuel Injection)

3. MAP Sensor System Inspection

Replace the MAP sensor with a new one (page 5-
105).

Turn the ignition switch to "ON" and engine stop

switch to " 0 ·:
Start the engine and let it idle, check the HOS pock-
et tester. _

Is the DTC 2-1 indicated?

YES Replace the ECM with a new one, and
recheck.
NO Faulty original MAP sensor.

OTC 7-1 (ECT SENSOR LOW VOLTAGE)

1. ECT Sensor System Inspection
Turn the ignition switch to "ON" and engine stop
switch to " 0 ·:
Check the ECT sensor with the HOS pocket tester.

Is about O V indicated?
YES GO TO STEP 2.
NO - Intermittent failure.

2. ECT Sensor Inspection

Turn the ignition switch to "OFF':
Disconnect the ECT sensor 3P connector.
Turn the ignition switch to "ON" and engine stop
switch to " O ·:
/
Check the ECT sensor with the HOS pocket tester.
., , . . _-~- , //
Is about 0 V indicated?
YES
NO -
GO TO STEP 3.
Faulty ECT sensor.

><Ir
ECT SENSOR 3P CONNECTOR

3. ECT Sensor Output Line Short Circuit Inspection

Turn the ignition switch to "OFF':
Disconnect the ECM 32P connectors.
Check for continuity between the ECT sensor 3P
connector terminal of the wire harness side and
ground.
CONNECTION: Pink/white - Ground
Is there continuity?
YES Short circuit in Pink/White wire.
NO - Replace the ECM with a new one, and
recheck.

5-66
 FUEL SYSTEM (Programmed Fuel Injection)

OTC 7-2 (ECT SENSOR HIGH VOLTAGE)

• Before starting the inspection, check for loose or
poor contact on the ECT sensor connector and
recheck the DTC.

1. ECT Sensor System Inspection

Turn the ignition switch to "ON" and engine stop
switch to " O ':
Check the ECT sensor with the HDS pocket tester.

Is about 5 V indicated?
YES GO TO STEP 2.

NO • Intermittent failure.
• Loose or poor contact on the ECT sensor
connector.

2. ECT Sensor Inspection

Turn the ignition switch to "OFF':
Disconnect the ECT sensor 3P connector.
Connect the ECT sensor terminals at the wire har-
ness side with a jumper wire.
CONNECTION: Pink/White - Green/orange
Turn the ignition switch to "ON" and engine stop
switch to " 0 ':
Check the ECT sensor with the HDS pocket tester.

Is about 0 V indicated?
YES Faulty ECT sensor.
NO - GO TO STEP 3.

3. ECT Sensor Output Line Inspection

Turn the ignition switch to "OFF':
Remove the jumper wire.
Disconnect the ECM 32P connectors.
Check for continuity at the Pink/white and
Green/orange wires between the ECT sensor 3P
connector and ECM 32P (Light gray) connector ter-
minals of the wire harness side.
DDDDDDDDDDDDDD
DDDDDDDDDDDDDD
CONNECTION: Pink/white - 827 (Pink/white)
Green/orange - 826 (Green/orange)
A32 Al 7

Is there continuity?
YES Replace the ECM with a new one, and
recheck.
NO • Open circuit in Pink/white wire.
• Open circuit in Green/orange wire.

5-67
FUEL SYSTEM (Programmed Fuel Injection)

OTC 8-1 (TP SENSOR LOW VOLTAGE)

• Before starting the inspection, check for loose or
poor contact on the TP sensor connector and
recheck the OTC.

1. TP Sensor System Inspection

Turn the ignition switch to "ON" and engine stop
switch to " 0 ':
Check the TP sensor with the HOS pocket tester
when the throttle fully closed.

Is 0 V indicated?
YES GO TO STEP 2.
NO - • Intermittent failure.
• Loose or poor contact on the TP sensor TP SENSOR 3P CONNECTOR
connector.

2. TP Sensor Input Voltage Inspection

Turn the ignition switch to "OFF':
Disconnect the TP sensor 3P connector.
Turn the ignition switch to "ON" and engine stop
switch to " 0 ':
Measure the voltage at the wire harness side.
CONNECTION: Yellow/red (+) - Green/orange (-)
Is the voltage within 4. 75 - 5.25 V?
YES GO TO STEP 4.
NO - GO TO STEP 3.

3. TP Sensor Circuit Inspection

Turn the ignition switch to "OFF':
Disconnect the ECM 32P connectors.
Check for continuity at the Yellow/Red wire between
the TP sensor 3P connector and ECM 32P (Light
gray) connector terminal of the wire harness side.
CONNECTION: Yellow/red - 818 (Yellow/red)
Is there continuity?
YES Replace the ECM with a new one, and
recheck.
NO Open circuit in Yellow/red wire.

4. TP Sensor Output Line Open Circuit Inspection

Turn the ignition switch to "OFF': Al

Disconnect the ECM 32P connectors.

Check for continuity at the Red/yellow wire between
DDDDDDDDDDDDDD
the TP sensor 3P connector and ECM 32P (Light DDDDDDDDDDDDDD
gray) connector terminal of the wire harness side.
CONNECTION: Red/yellow - 830 (Red/yellow) A32 A17

Is there continuity?
YES GO TO STEP 5.
NO - Open circuit in Red/yellow wire.

5-68
 FUEL SYSTEM (Programmed Fuel Injection)

5. TP Sensor Output Line Short Circuit Inspection

TP SENSOR 3P CONNECTOR
Disconnect the TP sensor 3P connector.
Check for continuity between the TP sensor 3P con-
nector terminal of the wire harness side and
ground.
CONNECTION: Red/yellow - Ground
Is there continuity?
YES Short circuit in Red/yellow wire.
NO - GO TO STEP 6.

6. TP Sensor Inspection
Replace the TP sensor with a new one.

Reset the ECM (page 5-13).

Turn the ignition switch to "ON" and engine stop

switch to " O ':
Check the TP sensor with the HDS pocket tester.

Is the DTC 8-1 indicated?

YES Replace the ECM with a new one, and
recheck.
NO Faulty original TP sensor.

OTC 8-2 (TP SENSOR HIGH VOLTAGE)

1. TP Sensor System Inspection
Turn the ignition switch to "ON" and engine stop
switch to " 0 ':
Check the TP sensor with the HDS pocket tester
when the throttle fully closed.

Is about 5 Vindicated?
YES GO TO STEP 2.
NO - • Intermittent failure.
• Loose or poor contact on the TP sensor
connector.

2. TP Sensor Resistance Inspection

G!O R/Y

~~
Turn the ignition switch to "OFF':
Disconnect the TP sensor 3P connector.
Measure the resistance at the TP sensor terminals.
00
CONNECTION: Red/yellow - Green/orange
Is the resistance within 0.5 - 1.5 kQ (20 °C/68°FJ?
YES GO TO STEP 3.
NO - Faulty TP sensor.

TP SENSOR

5-69
FUEL SYSTEM (Programmed Fuel Injection)

3. TP Sensor Input Voltage Inspection TP SENSOR 3P CONNECTOR

Turn the ignition switch to "ON" and engine stop
switch to " 0 ':
Measure the voltage at the wire harness side.
CONNECTION: Yellow/red (+) - Green/orange (-)
Is the voltage within 4. 75 - 5.25 V?
YES Replace the ECM with a new one, and
recheck.
NO Open circuit in Green/orange wire.

OTC 9-1 (IAT SENSOR LOW VOLTAGE)

1. IAT Sensor System Inspection
Turn the ignition switch to "ON" and engine stop
switch to " 0 ':
Check the IAT sensor with the HOS pocket tester.

Is about 0 V indicated?
YES GO TO STEP 2.
NO - • Intermittent failure.
• Loose or poor contact on the IAT sensor
connector.

2. IAT Sensor Inspection

Turn the ignition switch to "OFF':
Disconnect the IAT sensor 2P connector.
Turn the ignition switch to "ON" and engine stop
switch to " 0 ':
Check the IAT sensor with the HOS pocket tester.

Is about 0 V indicated?
YES GO TO STEP 3.
NO Faulty IAT sensor.

3. IAT Sensor Output Line Short Circuit Inspection IAT SENSOR 2P CONNECTOR
Turn the ignition switch to "OFF': [gJJ
Disconnect the ECM 32P connectors. Im

Check for continuity between the IAT sensor 2P con-

nector terminal of the wire harness side and
ground.
CONNECTION: Gray/blue - Ground
Is there continuity?
YES Short circuit in Gray/blue wire .
NO - Replace the ECM with a new one, and
recheck.

5-70
 FUEL SYSTEM (Programmed Fuel Injection)

OTC 9-2 (IAT SENSOR HIGH VOLTAGE)

• Before starting the inspection, check for loose or
poor contact on the IAT sensor connector and
recheck the OTC.

1. IAT Sensor System Inspection

Turn the ignition switch to "ON" and engine stop
switch to " O ': · -
Check the IAT sensor with the HOS pocket tester.

Is about 5 V indicated?
YES GO TO STEP 2.
NO - • Intermitten t failure.
• Loose or poor contact on the IAT sensor
connector.

2. IAT Sensor Inspection

Turn the ignition switch to "OFF':
Disconnect the IAT sensor 2P connector.
Connect the IAT sensor terminals at the wire har-
ness side with a jumper wire.
CONNECTION: Gray/blue - Green/oran ge
Turn the ignition switch to "ON" and engine stop
switch to " O ':
Check the IAT sensor with the HOS pocket tester.

Is about 0 V indicated? JUMPER WIRE

YES Faulty IAT sensor.

NO - GO TO STEP 3.

3. IAT Sensor Output Line Inspection

Turn the ignition switch to "OFF':
Disconnect the jumper wire.
Disconnect the ECM 32P connectors .
Check for continuity at the Gray/blue and
Green/oran ge wire between the IAT sensor 2P con-
nector and ECM 32P (Light gray) connector termi-
nals of the wire harness side. DDDDDDDDDDDDDD
DDDDDDDDDDDDDD
CONNECTION: Gray/blue - 88 (Gray/blue )
Green/orange - 826 (Green/orange)
A32 A17
Is there continuity?
YES Replace the ECM with a new one, and
recheck.
NO • Open circuit in Gray/blue wire.
• Open circuit in Green/oran ge wire.

5-71
FUEL SYSTEM (Programmed Fuel Injection)

OTC 11-1 (VEHICLE SPEED SENSOR)

• Before starting the inspection, check for loose or
poor contact on the vehicle speed sensor connec-
tor and recheck the OTC.

1. Vehicle Speed Sensor System Inspection

Support the scooter with its centerstand and lift the
rear wheel off the ground.
Check the vehicle speed sensor with the HOS pock-
et tester at 10 km/h.

Is 10 km/h indicated?

YES - • Intermittent failure.

• Loose or poor contact on the vehicle
speed sensor connector.
NO - GO TO STEP 2.

2. Combination Meter Inspection

Check for operation of speedometer.

Does the speedometer operate normally 7

YES - Open or short circuit in Pink/green wire

~
between the ECM and vehicle speed sen-
sor.

SPE~ETER~
NO - GO TO STEP 3.

3. Vehicle Speed Sensor Input Voltage Inspection

Turn the ignition switch to "OFF':
Disconnect the vehicle speed sensor 3P connector.
Turn the ignition switch to "ON" and engine stop
switch to " O ':
Measure the voltage at the wire harness side.
CONNECTION: Black/brown(+) - Green/Black(-)
Does the battery voltage exist7
YES GO TO STEP 4.
NO - • Open circuit in Black/brown wire.
• Open circuit in Green/black wire.

4. Vehicle Speed Sensor Signal Line Short Circuit

Inspection
Turn the ignition switch to "OFF':
Disconnect the ECM 32P connectors.
Check for continuity between the ECM 32P (Light 00000000000000
gray) connector terminal of the wire harness side 00000000000000
and ground.
CONNECTION: B25 (Pink/green) - Ground A32 A17

Is there continuity?
YES Short circuit in the Pink/green wire.
NO - Inspect vehicle speed sensor (page 21-9) .

5-72
 FUEL SYSTEM (Programmed Fuel Injection)

OTC 12-1 (N0.1 INJECTOR)

POWER INPUT LINE
• Before starting the inspectio n, check for loose or A 11
poor contact on the injector connect ors and
recheck the OTC.

MIL INJEC- POWER SIGNAL SIGNL

TOR INPUT LINE LINE ATECM
12 No. 1 Black/wh ite Pink/blu e A11
13 No. 2 Black/wh ite Pink/yel low A12
B32 Bl7

1. Injector System Inspection

Reset the ECM (page 5-13).

Turn the ignition switch to "ON" and check the No.1

injector with the HOS pocket tester.

Is the OTC 12-1 indicated?

YES GO TO STEP 2.
NO - • Intermitt ent failure .
• Loose or poor contact on the injector
connecto r.

2. Injector Circuit Resistance Inspection

Turn the ignition switch to "OFF':
Disconn ect the ECM 32P connecto rs.
Measure the resistance at the wire harness side.
CONNECTION: POWER INPUT LINE (815) - SIG-
DDDDDDDDDDDDD DODD DDDDDDDDD
NAL AT ECM DDDDDDDDDDDDD DODD DDDDDDDDD
Is the resistance within 11.1 - 12.3 Q (20 °C/68°FJ?
YES GO TO STEP 5. B32 B17 A32 Al7

NO GO TO STEP 3. '------ ------; Q 1---~

3. Injector Resistance Inspection

Disconn ect the No.1 injector 2P (Black) connect or
and measure the resistanc e of the No.1 injector ter-
minals.

Is the resistance within 11.1 - 12.3 Q (20 °C/68°F)?

YES GO TO STEP 4.
NO - Faulty injector.

5-73
FUEL SYSTEM (Programmed Fuel Injection)

4. Injector Input Voltage Inspection

Turn the ignition switch to "ON" and engine stop
switch to " O ':
Measure the voltage between the No.1 injector 2P
(Black) connector terminal of the wire harness side
and ground.
CONNECTION: POWER INPUT LINE (+) - Ground (-)
Does the battery voltage exist?
YES Open circuit in SIGNAL LINE wire.
NO - Open circuit in POWER INPUT LINE wire.

5. Injector Signal Line Short Circuit Inspection

Check for continuity between the ECM 32P (Black)
connector terminal of the wire harness side and
ground.
CONNECTION: SIGNAL AT ECM - Ground DDDDDDDDDDDDDD
DDDDDDDDDDDDDD
Is there continuity?
YES • Short circuit in SIGNAL LINE wire. B32 817

• Faulty injector.
NO Replace the ECM with a new one, and'
recheck.

OTC 13-1 (N0.2 INJECTOR)

See page 5-73

OTC 18-1 (CMP SENSOR)

• Before starting the inspection, check for loose or
poor contact on the CMP sensor connector and
recheck the OTC.
CMP SENSOR
1. CMP Sensor Peak Voltage Inspection
Turn the ignition switch to "OFF':
Disconnect the CMP sensor 2P connector.
Turn the ignition switch to "ON" and engine stop cm
switch to " O ':
Crank the engine with the starter motor, and mea -
sure the CMP sensor peak voltage at the CMP sen -
((y)
sor terminals.
CONNECTION: Gray(+) - White/yell ow(-)
Is the voltage more than 0.7 V (20 °C/68 °F)?
YES GO TO STEP 2.
NO - Faulty CMP sensor.

5-74
 FUEL SYSTEM (Programmed Fuel Injection)

. 2 . .CMP .Sensor Circuit Inspection

Turn the ignition switch to "OFF':
Disconnect the ECM 32P connectors.
Check for continuity at the Grey and White/Yellow
wire between the CMP sensor 2P connector and
ECM 32P connector terminals of the wire harness
side.
CONNECTION: Gray - 810 (Gray)
White/yellow-A 31 (White/yellow)
Is there continuity?
YES Short circuit in Gray wire.
NO - • Open circuit in Gray wire.
• Open circuit in White/yellow wire.

OTC 19-1 (CKP SENSOR)

• Before starting the inspection, check for loose or
poor contact on the CKP sensor connector and
recheck the OTC.

1. CKP Sensor Peak Voltage Inspection

Turn the ignition switch to "OFF':
Disconnect the CKP sensor 2P (Red) connector.
Turn the ignition switch to "ON" and engine stop
switch to " 0 ':
Crank the engine with the starter motor, and mea-
sure the CKP sensor peak voltage at the CKP sensor
2P (Red) connector of the sensor side.
CONNECTION: Yellow (+) - White/yellow (-)
Is the voltage more than 0.7 V (20°C/68 °F)? CKP SENSOR 2P (Red) CONNECTOR

YES GO TO STEP 2.
NO - Faulty CKP sensor. IID

®
cc

2. CKP Sensor Circuit Inspection

Turn the ignition switch to "OFF':
Disconnect the ECM 32P connectors.
Check for continuity at the Yellow and White/yellow
wire between the CKP sensor 2P (Red) connector
and ECM 32P connector terminals of the wire har-
ness side.
CONNECTION:Yellow - 811 (Yellow)
White/Yellow - A31 (White/yellow)
Is there continuity?
YES Short circuit in Yellow wire.
NO - • Open circuit in Yellow wire.
• Open circuit in White/yellow wire.

5-75
FUEL SYSTEM (Programmed Fuel Injection)

OTC 21-1 (02 SENSOR)

• Before starting the inspection, check for loose or
poor contact on the 02 sensor connector and
recheck the OTC.

1. 02 Sensor Open Circuit Inspection

Turn the ignition switch to "OFF':
Disconnect the 02 sensor 4P (Gray) connector and
ECM connectors.
Check for continuity between the 02 sensor 4P
(Gray) connector and ECM 32P (Light gray) connec-
tor terminals of the wire harness side.
CONNECTION: Black/red - B13 (Black/red)
Green/orange - Bi6 (Green/orange)

Is there continuity?
YES GO TO STEP 2.
• Open circuit in Black/red wire .
DDDDDDDDDDDDDD
NO - DDDDDDDDDDDDDD
• Open circuit in Green/orange wire.

A32 A17

2. 02 Sensor System Short Circuit Inspection

Disconnect the ECM connectors.
Check for continuity between the ECM 32P (Light
gray) connector terminal of the wire harness side
and ground. DD DDDDDDDDDDD DDDDDDDDDDDDDD
DD DDDDDDDDDDD DDDDDDDDDDDDDD
CONNECTION: B13 (Black/red) - Ground
B32 817 A32 A17
Is there continuity?
YES Short circuit in Black/red wire.
NO - GO TO STEP 3.

3. 02 Sensor Inspection
Replace the 02 sensor with a new one (page 5-110).

Reset the ECM (page 5-13).

Turn the ignition switch to "ON" and engine stop

switch to " 0 ':
Start and warm the engine up to coolant tempera-
ture is 80°C (176°F), then let it idle .
Test ride the scooter and recheck the 02 sensor with
the HOS pocket tester.

Is the OTC 21-1 indicated?

YES Replace the ECM with a new one, and
recheck.
NO Faulty original 02 sensor.

5-76
 FUEL SYSTEM (Programmed Fuel Injection)

OTC 23-1 (02 SENSOR HEATER)

• Before starting the inspection, check for loose or
poor contact on .the 02 sensor 4P (Gray) connec-
tor and recheck the OTC.

1. 02 Sensor System Inspection

Res_et the ECIV) (page 5-13).

Start the engine and check the 02 sensor heater

with the HOS pocket tester.

Is the DTC 23-1 indicated?

YES GO TO STEP 2.
NO - • Intermittent failure.
• Loose or poor contact on the 02 sensor
4P (Gray) connector.

2. 02 Sensor Heater Resistance Inspection

Turn the ignition switch to "OFF':

Disconnect the 02 sensor 4P (Gray) connector and

measure the resistance at the sensor side connec-
tor.
CONNECTION: White - White
Is the resistance within 10 - 40 Q (20 °C/68°FJ?
YES GO TO STEP 3.
NO - Faulty 02 sensor.

3. 02 Sensor Heater Open circuit Inspection

Connect the 02 sensor 4P (Gray) connector.
Disconnect the ECM 32P connectors.
Measure the resistance at the wire harness side.
CONNECTION: 815 (Black/white) - A6 (white) DDDDDDDDDDDDD DDDDDDDDD DODD
DDDDDDDDDDDDD DDDDDDDDD ODDO
Is the resistance within 10 - 40 Q (207 C/687 FJ?
YES GO TO STEP 4. 832 817 A32 A17
NO - • Open circuit in Black/white wire .
• Open circuit in White wire. ~------; Q J-----~

4. 02 Sensor Heater Short Circuit Inspection 1

Disconnect the 02 sensor 4P (Gray) connector.
Check for continuity between the ECM 32P (Black)
connector terminal of the wire harness side and
ground.
DDDDDDDDDDDDDD
CONNECTION: A6 (White) - Ground DDDDDDDDDDDDDD

Is there continuity?
832 817
YES Short circuit in White wire.
NO - GO TO STEP 5.

5-77
FUEL SYSTEM (Programmed Fuel Injection)

5. 02 Sensor Heater Short Circuit Inspection 2

Check for continuity between the 02 sensor 4P
(Gray) connector terminal of the sensor side and
ground.
CONNECTION: White - Ground
Is there continuity?
YES Faulty 02 sensor.
NO - Replace the ECM with a new one, and
recheck.

02 SENSOR 4P (Gray) CONNECTOR

OTC 33-2 (EEPROM)

1. Recheck OTC
Reset the ECM (page 5-13).

Turn the ignition switch ON and engine stop switch

"O':
Recheck the ECM EEPROM.

Is the DTC 33-2 indicated?

YES Replace the ECM with a new one, and
recheck.
NO Intermittent failure.

5-78
 FUEL SYSTEM (Programmed Fuel Injection)

FUEL LINE INSPECTION

FUEL PRESSURE INSPECTION

I NOTICE I
• Before disconnectin g the fuel hoses, relieve the fuel
pressure by loosening the service check bolt at the
fuel tank.
• Always replace the sealing washer when the service
check bolt is removed or loosened.

Remove the battery box cover (page 18-4). NEGATIVE TERMINAL BATTERY

Disconnect the battery negative cable from the

battery terminal.

Remove the floorstep (page 2-20).

Disconnect and plug the pressure regulator vacuum

hose.

VACUUM HOSE

Cover the service check bolt with a rag or shop towel.

SERVICE CHECK BOLT
Slowly loosen the service check bolt and drain the
remaining fuel into an approved gasoline container.

Remove the service check bolt and sealing washer.

Attach the fuel pressure gauge. SERVICE CHECK BOLT

TOOL:
Fuel pressure gauge 07 406-0040002 or
07 406-0040008 or
07 406-004000A
(U.S.A. only)

5-79
FUEL SYSTEM {Programmed Fuel Injection)

Connect the battery negative cable. FUEL PRESSURE GAUGE

Start the engine.
Read the fuel pressure at idle speed.

IDLE SPEED: 1,300 :t 100 rpm

STANDARD: 294 kPa (3.0 kgf/cm 2 , 43 psi)

If the fuel pressure is higher than specified, inspect

the following:
- Pinched or clogged fuel return hose
- Pressure regulator
- Fuel pump (page 5-82)

If the fuel pressure is lower than specified , inspect a

following:
- Fuel line leaking
- Clogged fuel filter SERVICE CHECK BOLT
- Pressure regulator
- Fuel pump (page 5-82)

Always replace After inspection , remove the fuel pressure gauge and
the sealing wash- reinstall and tighten the service check bolt with a new
er when the ser- sealing washer.
vice check bolt is
removed or loos-
ened.

Connect the pressure regulator vacuum hose.

Install the removed parts in the reverse order of

removal.

VACUUM HOSE

FUEL FLOW INSPECTION

Remove the left side body cover (page 2-6).
Remove the floorstep (page 2-20).

Remove the fuel cut-off relay.

5-80
 FUEL SYSTEM (Programmed Fuel Injection)

Jump the Brown and Black/White wire terminals of

the wire harness side using a jumper wire.

• When the fuel return hose is disconnected, gasoline

FUEL RETURN HOSE
may spill out from the hose. Place a approved gaso-
line container under the hose and drain the gaso-
line. HOSE
Wipe off any spilled out gasoline. JOINT

Disconnect the fuel return hose at the fuel tank and

plug the return hose joint.

Turn the ignition switch to "ON" for 10 seconds.

Measure the amount of fuel flow.

Amount of fuel flow:

Minimum 60 cm 3 (2.0 US oz, 2.1 Imp oz)/
10 seconds

If the fuel flow is less than specified, inspect

the following:
- Pinched or clogged fuel hose and fuel return hose
- Clogged fuel filter
- Pressure regulator
- Fuel pump (page 5-82)

After inspection, connect the fuel return hose.

FUEL RETURN HOSE
Start the engine and check for leaks.

5-81
FUEL SYSTEM (Programmed Fuel Injection)

FUEL PUMP
INSPECTION
Turn the ignition switch to "ON" and confirm that the
fuel pump operates for a few seconds.
If the fuel pump does not operate, inspect as follows:

Remove the floorstep (page 2-20).

Disconnect the fuel pump/fuel unit 4P connector.

Turn the ignition switch to "ON" and measure the

voltage between the terminals.

Connection: Brown (+) - Green/Pink (-) 4P CONNECTOR

There should be battery voltage for a few seconds.

IIIl

If there is battery voltage, replace the fuel pump.

If there is no battery voltage, inspect the following:
- Main fuse 30A
®
0 0

- Sub fuse 15A

- Fuel cut-off relay (page 5-84)
- Engine stop relay (page 5-113)
- Bank angle sensor (page 5-112)
- ECM (page 5-114, 115)

REMOVAL

NOTICE I
Before disconnecting the fuel hose, relieve the fuel
pressure by loosening the service check bolt at the
fuel tank.
• Always replace the sealing washer when the service
check bolt is removed or loosened.

Remove the fuel tank (page 5-84).

Remove the fuel pump mounting nuts.

Remove the fuel pump assembly and packing.

5-82
 FUEL SYSTEM (Programmed Fuel Injection)

FUEL FILTER REPLACEMENT FUEL FILTER

Disconnect the fuel hoses from the fuel filter.

Remove the screw and fuel filter.

Note the direction Install the fuel filter in the reverse order of removal.
of the fuel filte r.

INSTALLATION
Always replace Place a new packing onto the fuel pump base.
s ~ PACKING

th e packing with a
new one. Install the fuel pump being careful not to damage the
fuel pump wires.

'*

Install and tighten the fuel pump mounting nuts in the NUTS
sequence as shown .
4
TORQUE: 12 N•m (1.2 kgf•m, 9 lbf.ft)
@
@ 2
~Front

1 @
@} 0

0
~WoJo
@
@
3

7
5
FUEL PUMP

5-83
FUEL SYSTEM {Programmed Fuel Injection)

FUEL CUT-OFF RELAY FUEL CUT-OFF RELAY

I ~
INSPECTION
Remove the left side body cover (page 2-6).

Remove the fuel cut-off relay.

Connect the ohmmeter to the fuel cut-off relay

connector terminals. FUEL CUT-OFF RELAY BATIERY

CONNECTION: Black/White - Brown

Connect the 12-V battery to the following fuel cut-off

relay connector terminals.

CONNECTION: Brown/Black - Black/White

There should be continuity only when the 12-V battery

is connected.
If there is no continuity when the 12-V battery is con-
nected, replace the fuel cut-off relay.

FUEL TANK
REMOVAL
Relieve the fuel pressure (page 5-79).

Remove the bolts and lower frame.

Disconnect the fuel pump/fuel unit 4P connector.

I
BOLTS

5-84
~------------~---------

FUEL SYSTEM (Programmed Fuel Injection)

Disconnect the fuel return hose from the pressure reg- FUEL RETURN HOSE
ulator.

Remove the sealing nut and sealing washers, then SEALING WASHERS SEALING NUT
disconnect the fuel hose.

~~

Remove the fuel tank upper mounting nut.

Remove the fuel tank mounting bolts and the fuel

tank.

5-85
FUEL SYSTEM (Programmed Fuel Injection)

Remove the banjo bolt and sealing washers, then dis-

connect the fuel hose from the fuel pump. r BANJOBOLT

SEALING
WASHERS

Remove the fuel return hose and heat guard rubber.

Refer to page 5-82 for fuel pump removal.

INSTALLATION 22 N•m (2.2 kgf•m,

16 lbfoft)

~
~

FUEL TANK

LOWER FRAME

5-86
 FUEL SYSTEM (Programmed Fuel Injection)

Install the heat guard rubber and connect the fuel

return hose.

While aligning the stopper on the fuel hose banjo with

the the fuel pump, connect the fuel hose banjo to the r BANJOBOLT
fuel rail with new sealing washers.

Install and tighten the fuel hose banjo bolt to the ®

specified torque. SEALING _____,, :J
WASHERS u----

~
TORQUE: 22 N•m (2.2 kgf•m, 16 lbMt) /

<®aft:::: ALIGN

Install the fuel tank on the frame.

Tighten the mounting bolts.

Tighten the upper mounting nut.

5-87
FUEL SYSTEM (Programmed Fuel Injection)

With the painted side of the fuel hose banjo facing up,
~~ SEALING WASHERS
align the banjo to the stopper on the fuel rail stay, and
lll!ijlll
connect the fuel hose banjo to the fuel rail with new
sealing washers.
Install and tighten the sealing nut to the specified
torque.

TORQUE: 22 N•m (2.2 kgf•m, 16 lbMt)

Connect the fuel return hose to the pressure regulator.

FUEL RETURN HOSE

Connect the fuel pump/fuel unit 4P connector.

Install the lower frame and tighten the bolts.

Install the removed parts in the reverse order of

removal.

BOLTS
I
5-88
 FUEL SYSTEM (Programmed Fuel Injection)

AIR CLEANER HOUSING

REMOVAL
Remove the luggage box (page 2-10) .

Loosen the air cleaner housing-to-air cleaner chamber

connecting hose band screw.
Disconnect the connecting hose from the air cleaner
chamber.

Remove the bolts and air cleaner housing from the

frame.

Remove the air cleaner chamber stay bolt.

Disconnect the IAT sensor connector from the air

cleaner chamber cover.
Remove the screws and air cleaner chamber cover.

5-89
FUEL SYSTEM (Programmed Fuel Injection)

Remove the screws and air funnel, then remove the

air cleaner chamber from the throttle body.

Disconnect the crankcase breather hose and PAIR con- PAIR CONTROL VALVE HOSE
trol valve hose from the air cleaner chamber.
Remove the luggage box light wire from the clamps.

Remove the seal ring.

INSTALLATION
Check that the air cleaner chamber seal ring is in good
condition, and replace if necessary.

Connect the PAIR control valve hose and crankcase PAIR CONTROL VALVE HOSE
breather hose.
Install the luggage box light wire to the clamps.

5-90
 FUEL SYSTEM (Programmed Fuel Injection)

Install the air cleaner chamber to the throttle body.

Install the air funnel and tighten the screws.

Install the air cleaner chamber cover to the air

cleaner chamber.
Install and tighten the screws.
Connect the IAT sensor connector.

Tighten the air cleaner housing stay bolts.

Install the air cleaner housing to the frame.

Install and tighten the bolts securely.

5-91
FUEL SYSTEM (Programmed Fuel Injection}

Connect the air cleaner housing-to-air cleaner cham-

ber connecting hose.
Tighten the connecting hose band screw.

Install the luggage box (page 2-10).

THROTTLE BODY/INTAKE MANIFOLD

REMOVAL
• Before disconnecting the fuel hose, relieve the fuel
pressure by loosening the service check bolt (page
5-79).
• Always replace the sealing washer when the service
check bolt is removed or loosened.

Drain the coolant from the cooling system (page 6-4).

Remove the seat under cover (page 2-5).

Remove the air cleaner housing (page 5-89).
Remove the seat hinge stay (page 7-2).

Relieve the fuel pressure (page 5-79).

Loosen the lock nut and turn the throttle cable

adjuster to increase the freeplay.
Disconnect the throttle cable ends from the throttle
drum.

Disconnect the ECT sensor connector.

Loosen the insulator band screws and remove the

throttle body from the insulator.

5-92
 FUEL SYSTEM (Programmed Fuel Injection)

Disconnect the fast idle wax unit water hoses from the
wax unit.
Remove the throttle body.

Disconnect the injector connectors from the injectors.

Disconnect the fuel return hose from the pressure reg-

ulator.

Remove the sealing nut and sealing washers, then

disconnect the fuel hose.

5-93
FUEL SYSTEM (Programmed Fuel Injection)

Remove the bolts and intake manifold from the cylin-

der head.
Disconnect the No.5 tube from the 3-way joint.

Remove the 0-rings from the intake manifold.

Seal the cylinder head intake ports with tape or a

clean cloth to keep dirt and debris from entering the
intake ports after the intake manifold has
been removed.

Loosen the insulator band screws and remove the

insulators from the intake manifold.

5-94
 FUEL SYSTEM (Programmed Fuel Injection)

I NOTICE
• Do not damage the throttle body, this may cause incorrect throttle and idle valve synchronizat ion.
• The throttle body is factory pre-set, do not disassemble it in a way other than shown in this manual.
• Do not loosen or tighten the white painted bolts and screws on the throttle body. Loosening or tighten-
ing them can cause throttle and idle valve synchronizat ion failure.

THROTTLE BODY VACUUM tUBE ROUTING

PRESSURE REGULATOR
VACUUM TUBE

THROTTLE BODY
PURGE TUBE

MAP SENSOR
VACUUM TUBE

N0.5 TUBE

5-95
FUEL SYSTEM (Programmed Fuel Injection)

THROTTLE BODY TOP VIEW:

I I

4 N•m (0.4 kgf•m, 2.9 lbMt)

THROTTLE BODY LEFT SIDE VIEW: THROTTLE BODY RIGHT SIDE VIEW:

4 N•m (0.4 kgf•m, 2.9 lbfeft)

5-96
 FUEL SYSTEM (Programmed Fuel Injection)

INSTALLATION
Install the insulators with their grooves aligning with
the throttle body tabs.

Tighten the throttle body side insulator band so that

the insulator band distance is 9 - 12 mm (0 .4 - 0.5 in).
9 - 12 mm
(0.4 - 0.5 in)

Install new 0-rings into the intake manifold grooves.

Install the intake manifold to the cylinder head.

Install and tighten the bolts securely.
Install the No. 5 tube to the 3-way joint.

5-97
FUEL SYSTEM (Programmed Fuel Injection)

With the painted side of the fuel hose banjo facing up,
align the banjo to the stopper on the fuel rail stay, and
connect the fuel hose banjo to the fuel rail with new
sealing washers.
Install and tighten the sealing nut to the specified
torque.

TORQUE: 22 N•m (2.2 kgf•m, 16 lbf.ft)

Connect the fuel return hose to the pressure regulator.

Connect the injector connectors.

Connect the water hoses to the fast idle wax unit.

5-98
 FUEL SYSTEM (Programmed Fuel Injection)

Install the throttle body to the insulators.

Tighten the throttle body side insulator band so that

the insulator band distance is 9 - 12 mm (0.4- 0.5 in).
9- 12 mm
(0.4 - 0.5 in)

Connect the ECT sensor connector.

Connect the throttle cable ends to the throttle drum.

Install the removed parts in the reverse order

of removal.

Adjust the throttle grip free play (page 3-4).

5-99
FUEL SYSTEM (Programmed Fuel Injection)

INJECTOR
INSPECTION
Start the engine and let it idle.
Confirm proper injector operation with a sounding
rod or stethoscope.

If the injector does not operate properly, replace it.

REMOVAL BOLTS

Remove the intake manifold (page 5-92).

Disconnect the vacuum hose from the

pressure regulator.
Remove the bolts and fuel rail/injectors
as an assembly.

Remove the injector mounting clips and injectors

INJECTORS
from the fuel rail.

CLIPS

Remove the 0-rings and cushion tube.

CUSHION TUBE

5-100
 FUEL SYSTEM (Programmed Fuel Injection)

INSTALLATION 0-RING (Black) -~ CUSHION TUBE

~~
lll!ijjilllll
Replace the 0- Install new 0-rings to the injector.
rings and cushion - Black 0-ring: fuel rail side
tube with new - Orange 0-ring: throttle body side
ones as a set.
Install a new cushion tube.

Align the lug on Install the fuel injectors into the fuel rail, being careful INJECTOR
the injector with not to damage the 0-ring.
the cut-out on the
fuel rail.

Install the injector mounting clips.

CLIPS

Install the fuel rail/injector assembly onto the throttle FUEL RAIL
body, being careful not to damage the 0-rings.

0-RINGS

5-101
FUEL SYSTEM (Programmed Fuel Injection)

Install and tighten the fuel rail mounting bolts.

BOLTS
Connect the vacuum hose to the pressure regulator.

Install the intake manifold (page 5-97).

VACUUM HOSE

PRESSURE REGULATOR VACUUM HOSE LOCK NUT

REMOVAL/INSTALLATI ON

I NOTICE I
Do not apply excessive force to the fuel rail.

Remove the intake manifold (page 5-92).

Disconnect the vacuum hose from the

pressure regulator.
Holding the fuel rail, loosen the pressure regulator
lock nut, then remove the pressure regulator.

Install a new 0-ring into the pressure regulator body.

Install the pressure regulator onto the fuel rail.

0-RING

Check that the pressure regulator angle is as shown.

VACUUM HOSE LOCK NUT
Hold the fuel rail and tighten the pressure regulator
lock nut.

Connect the vacuum hose to the pressure regulator.

5-102
 FUEL SYSTEM (Programmed Fuel Injection)

FAST IDLE WAX UNIT WAX UNIT ASSEMBLY

oo not disassem- REMOVAL/INSTALLATION

ble the fast idle
wax unit. Remove the throttle body (page 5-92).

Remove the screws and fast idle wax unit assembly.

Replace the 0- Remove the 0-ring from the wax unit.

ring with a
new one. Installation is in the reverse order of removal.

TORQUE: 4 N•m (0.4 kgf•m, 2.9 lbf.ft)

AIR SCREW SYNCHRONIZATION

• Synchronize the air screw with the engine at the
normal operating temperature.
• Use a tachometer with graduations of 50 rpm or
smaller that will accurately indicate 50 rpm change.

Remove the seat under cover (page 2-5).

Disconnect the No.1 or No.2 vacuum hose from the

intake manifold.
Connect the suitable hose to the disconnected
vacuum joint.
Connect the vacuum gauges to the vacuum hoses.
Connect the tachometer.
Start the engine and let it idle until the radiator cool-
ing fan starts.

1. Check the difference in vacuum between each cylin-

der.

VACUUM DIFFERENCE: 20 mm Hg

5-103
FUEL SYSTEM (Programmed Fuel Injection}

2. Adjust the vacuum difference within specified value

by turning the air screw on the higher vacuum pres-
sure side cylinder counterclockwise.
If the air screw is turned counterclockwise 1-1/2
turns or more, turn the other cylinder air screw
clockwise 1/2 turn, then repeat step 1.

3. Disconnect the vacuum gauges and hose from the

hose joint.
Connect the vacuum hose to the intake manifold.

Install the seat under cover (page 2-5).

Start the engine and let it idle.

4. Turn the throttle stop screw as required to obtain

the specified idle speed.

IDLE SPEED: 1,300 ~ 100 rpm

MAP SENSOR
OUTPUT VOLTAGE INSPECTION (VI

Connect the test harness to the ECM; 3.5

- '02 - '07: page 5-10
- After '07: page 5-14 3.1
3.0
Measure the voltage at the test harness terminals.
2.7

CONNECTION: 2.5 2.5

'02 - '07: 87 (+) - A22 (-)
After '07: 812 (+) - 826 (-)
STANDARD: 2.7 - 3.1 V 2.1
2.0

The MAP sensor output voltage (above) is measured

under the standard atmosphere (1 atm = 1,013 hPa). 1.5
The MAP sensor output voltage is affected by the dis-
tance above sea level, because the output voltage is
changed by atmosphere. 1.0
Check the sea level measurement and be sure that the
measured voltage falls within the specified value.
0.5

0 500 1,000 1,500 2,000 :m

(1,650) (3,300) (4,950) (6,600) (feet)

5-104
 FUEL SYSTEM (Programmed Fuel Injection)

MAP SENSOR REMOVAL/

INSTALLATION
Remove the luggage box (page 2-10).

Disconnect the MAP sensor 3P connector.

Disconnect the vacuum hose from the MAP sensor.

Remove the screw and MAP sensor from the frame.

Installation is in the reverse order of removal.

IAT SENSOR
REMOVAL/INSTALLATION
Remove the seat under cover (page 2-5).

Disconnect the IAT sensor connector.

CONNECTOR

Remove the screws and IAT sensor from the air clean-
SCREWS
er chamber cover.

Installation is in the reverse order of removal.

5-105
FUEL SYSTEM (Programmed Fuel Injection)

ECT SENSOR
Replace the ECT REMOVAL/INSTALLATION
sensor while the
engine is cold. Drain the coolant from the system (page 6-5).
Remove the seat under cover (page 2-5).

Disconnect the ECT sensor connector from the sensor.

Remove the ECT sensor and sealing washer.

Always replace a Install the ECT sensor with a new sealing washer.
sealing washer Tighten the ECT sensor.
with a new one.
Connect the ECT sensor connector.

Fill the cooling system with the recommended

coolant (page 6-5).

CMP SENSOR
REMOVAL/INSTALLATION
Remove the floorstep (page 2-20) .

Disconnect the CMP sensor 2P (Black) connector.

Remove the bolt and CMP sensor from the cylinder

head.

BOLT CMP SENSOR

5-106
 FUEL SYSTEM (Programmed Fuel Injection)

Install a new 0-ring onto the CMP sensor.

Install the CMP sensor into the cylinder head.

Install and tighten the mounting bolt.

Routing the CMP sensor wire properly, connect the 2P

(Black) connector.

Install the removed parts in the reverse order of

removal.

2P BLACK CONNECTOR ~
TP SENSOR ('02 - '07)
ECM
INSPECTION
Remove the left side body cover (page 2-6).

Disconnect the ECM 22P (Black) and 22P

(Light gray) connectors.
Check the connectors for loose or corroded terminals.
Connect the ECU test harness between the ECM and
main wire harness.

TOOL:
ECU test harness 07YMZ-0010100
(two required) or
07WMZ-MBGAOOO
(U.S.A. only)

1. INPUT VOLTAGE INSPECTION

Turn the ignition switch to "ON" and measure and
record the input voltage at the test harness terminals
using a digital multimeter.

CONNECTION:
B2 (+) - A22 (-)
Standard: 4.5 - 5.5 V

If the measurement is out of specification, check the

following:
- Loose connection on the ECM connectors
- Open circuit in wire harness

5-107
FUEL SYSTEM (Programmed Fuel Injection)

2. OUTPUT VOLTAGE INSPECTION WITH THROTTLE

FULLY OPEN
Turn the ignition switch to "ON" and measure and
record the output voltage at the test
harness terminals.

CONNECTION:
89 (+) - A22 (-)
MEASURING CONDITION:
At throttle fully open

3. OUTPUT VOLTAGE INSPECTION WITH THROTTLE

FULLY CLOSED
Turn the ignition switch to "ON" and measure and
record the output voltage with the throttle fully
closed .

CONNECTION:
89 (+) - A22 (-)
MEASURING CONDITION:
At throttle fully closed

4. CALCULATE RESULT COMPARISON

Compare the measurement of the result with the
following calculation.

With the throttle fully open:

Measured input voltage (step 1) x 0.824 =Vo
The sensor is normal if the measurement output volt-
age measured in step 2 is within 10% of Vo .

With the throttle fully closed:

Meas~red input voltage (step 1) x 0.1 =Ve
The sensor is normal if the throttle closed output volt-
age measured in step 3 is within 10% of Ve.

Using an analog meter, check that the needle of the 3P CONNECTOR

voltmeter swings slowly when the throttle is opened
gradually.

CONTINUITY INSPECTION
Remove the seat under cover (page 2-5).

Disconnect the ECM 22P (Light gray) connector and

the TP sensor 3P connector.
Check for continuity between the ECM and TP sensor.

If there is no continuity, check for an open or short cir-

cuit in the wire harness.
22P (LIGHT GRAY) CONNECTOR

5-108
 FUEL SYSTEM (Programmed Fuel Injection)

TP SENSOR (After '07) ECM TEST HARNESS ECM

INSPECTION
Remove the left side body cover (page 2-6).

Disconnect the ECM 32P (Black) and 32P (Light gray)

connectors.
Check the connector for loose or corroded terminals.
Connect the ECM test harness between the ECM and
main wire harness.

TOOL:
ECM test harness 070MZ-0010201
(two required)

1. INPUT VOLT AGE INSPECTION

Turn the ignition switch to "ON" and measure and
record the input voltage at the test harness terminals ! 1 1 3 4 5 6 7 e 910 11 1113 141s 16I

using a digital multimeter. 0000000000000000

0000000000000000
CONNECTION: 818 (+) - 826 (-) 117 18 19102111131415161J18193031311

STANDARD: 4. 75 - 5.25 V

If the measurement is out of specification, check the

following : 8
- Loose connection of the ECM multi-connector.
- Open circuit in wire harness.

2. OUTPUT VOLT AGE INSPECTION WITH THE

THROTTLE FULLY OPENED
Turn the ignition switch to "ON" and measure and
record the output voltage at the test harness termi-
nals.

CONNECTION: 830 (+) - 826 (-)

MEASURING CONDITION:
At throttle fully opened

3. OUTPUT VOLTAGE INSPECTION WITH THE

THROTTLE FULLY CLOSED
Turn the ignition switch to " ON" and measure and
record the output voltage with the throttle fully
closed.

CONNECTION: 830 (+) - 826 (-)

OOODDDDODDODDDOO
MEASURING CONDITION: OOOODDDDDOODDOOO
At throttle fully closed l pt8t92021222324252627282930313Zi

5-109
FUEL SYSTEM (Programmed Fuel Injection)

4. CALCULATE RESULT COMPARISON

Compare the measurement to the result of the follow-
ing calculation.

With the throttle fully opened:

Measured input voltage (step 1) x 0.824 =Vo

The sensor is normal if the measurement output volt-

age measured in step 2 is within 10% of Vo.

With the throttle fully closed:

Measured input voltage· (step 1) x 0.1 = Ve
The sensor is normal if the throttle closed output volt-
age measured in step 3 is within 10% of Ve.

Using an analog meter, check that the needle of the

voltmeter swings slowly when the throttle is opened
gradually.

02 SENSOR (After '07) 4P(GRAY)CONNECTOR

~
REMOVAL
• Handle the 02 sensor with care.
• Do not get grease, oil or other materials in the 02
sensor air hole, or it may be damaged.
• Do not service the 02 sensor while it is hot.

Remove the right side body cover (page 2-6).

Remove the muffler protector (page 2-22).

Disconnect the 02 sensor 4P (Gray) connector.

Release the wire from the guide.

Remove the 02 sensor using the special tool.

02 SENSOR WRENCH
TOOL:
02 sensor wrench 07LAA-PT50101

• Be careful not to damage the sensor wire.

• Do not use an impact wrench while removing the 02
sensor, or it may be damaged.

5-110
 FUEL SYSTEM (Programmed Fuel Injection)

INSTALLATION 02SENSOR

Install a new sealing washer to the 02 sensor.

Using the special tool, install and tighten the 02 sen-

02 SENSOR WRENCH
sor to the specified torque.

TOOL:
02 sensor wrench 07LAA-PT50101

• Be careful not to damage the sensor wire.

• Do not use an impact wrench while installing the 02
sensor, or it may be damaged.

TORQUE: 44 N.m (4.5 kgf .m, 33 lbf .ft)

Route the 0 2 sen- Connect the 02 sensor 4P (Gray) connector and set
sor wire properly the wire into the guide.
(page 7-20).
Install the muffler protector (page 2-22).
Install the right side body cover (page 2-9).

5-111
FUEL SYSTEM (Programmed Fuel Injection)

BANK ANGLE SENSOR BANK ANGLE SENSOR

/
INSPECTION
Support the motorcycle on a level surface.
Remove the front cover (page 2-14).

Turn the ignition switch to "ON" and measure the

voltage between the following terminals of the bank
angle sensor connector with the connector connect-
ed.

TERMINAL STANDARD
White (+) - Green (-) Battery voltage
Red/White (+) - Green (-) 0-1V WASHERS

Turn the ignition switch to "OFF':

Do not disconnect Remove the screws, washers and bank angle sensor.
the bank angle
sensor connector
during inspection.

BANK ANGLE SENSOR

Place the bank angle sensor horizontal as shown, and

60° BANK ANGLE POSITION
turn the ignition switch to "ON" with the engine stop
switch to "RUN': ~ ·
The bank angle sensor is normal if the engine stop
relay clicks and power supply is closed.

Incline the bank angle sensor approximately 60

~~NORMAL (approximately) 60° c.
degrees to the left or right with the ignition switch POSITION ~
turned to "ON':
The bank angle sensor is normal if the engine stop
relay clicks and power supply is open.
:\ 60°
If you repeat this test, first turn the ignition switch to (approximately)
"OFF'; then turn the ignition switch to "ON':

REMOVAL/INSTALLATION BANK ANGLE SENSOR

Remove the front cover (page 2-14).

/
Disconnect the bank angle sensor 9P (Black) connec-
tor.

~
CONNECTOR

5-112
 FUEL SYSTEM (Programmed Fuel Injection)

Remove the two screws, washers and bank angle

sensor.

BANK ANGLE SENSOR

Installation is in the reverse order of removal.

• Install the bank angle sensor with its "UP" mark fac-
ing up.

ENGINE STOP RELAY ENGINE STOP RELAY

INSPECTION
Remove the left side body cover (page 2-6).

Remove the engine stop relay.

Connect the ohmmeter to the engine stop relay

connector terminals. ENGINE STOP RELAY BATTERY

CONNECTION: Black/White - Black

1
Connect the 12-V battery to the following engine stop
relay connector terminals.

CONNECTION: Black/Orange - Black

There should be continuity only when the 12-V battery

is connected.
If there is no continuity when the 12-V battery is con-
nected, replace the engine stop relay.

5-113
FUEL SYSTEM (Programmed Fuel Injection)

ECM (ENGINE CONTROL MODULE) 22P(BLACK)CONNECTOR

('02 - '07)
REMOVAL/INST ALLA Tl ON
Remove the left side body cover (page 2-6) .

Disconnect the ECM 22P (Black) and 22P (Light gray)

connectors.
Remove the ECM from the frame.

ECM

POWER/GROUND LINE INSPECTION

Connect the test harness between the main wire har-
ness and ECM (page 5-10).

TOOL: , , 2 3 . 5 6 7 8 9 10 11 !

ECU test harness 07VMZ-0010100

(two required) or
07WMZ-MBGAOOO
[==:]
) ·~· •_} ·~· _,

1 12 13 14 1 61 617 18 1 92~
-,..I -' ·_1 ._ / ·J _ :

(U.S.A. only)

GROUND LINE
Check for continuity between the ECM test harness
connector A10 terminal and ground, between the A21
terminal and ground , and between the A 11 terminal
and ground .
There should be continuity at all times.
If there is no continuity, check for an open circuit in the
Green/Pink wires or Green wire.

POWER INPUT LINE

Turn the ignition switch to "ON" with the engine stop
switch in the "RUN" position. ! 1 2 3• S 6 7 LLIO]IJ
Measure the voltage between the ECM test harness

~==
connector B2 terminal (+) and ground .
I - ' _I ~ _I } _ _l _, ._' _I

There should be battery voltage.

L12 13 14 15 16 17 18 19 20 21 22
If there is no voltage, check for an open circuit in the
Black/White wire between the ECM and engine stop
relay.
If the wire is OK, check the engine stop relay (page 5-
113).

5-114
 FUEL SYSTEM (Programmed Fuel Injection)

ECM (ENGINE CONTROL MODULE)

(After '07)
REMOVAL/INSTALLATION
Remove the left side body cover (page 2-6).

Disconnect the ECM 32P (Black) and 32P (Light gray)

connectors.
Remove the ECM from the frame .

Installation is in the reverse order of removal.

POWER/GROUND LINE INSPECTION

ENGINE DOES NOT START (MIL DOES NOT BLINK)

1. ECM Power Input Voltage Inspection

• Before starting the inspection, check for loose or
poor contact on the ECM 32P connectors and
recheck.

Connect the test harness to the ECM 32P connec-

tors (page 5-14).

Turn the ignition switch to "ON" and engine stop

switch to " 0 ':
Measure the voltage at the test harness terminal
and ground.
CONNECTION: 815 (+) - Ground (-)
Does the battery voltage exist?
YES GO TO STEP 2.
NO - GO TO STEP 3.

2. ECM Ground Line Inspection

Turn the ignition switch to "OFF':
Check for continuity between the test harness ter-
minals and ground.
CONNECTION: A4 - Ground
A18 - Ground
A19 - Ground ! 1 2 3 . 5 6 1 8 g1 0 11 1213141$16 !

A32 - Ground 0000000000000000

ooooooooooococcc
Is there continuity? l 17 10 19 20 21 22 23 24 zs zp1 2p930 31 32 I

YES Replace the ECM with a new one, and

recheck.
NO • Open circuit in Green/pink (A4) wire.
• Open circuit in Green/pink (A 18) wire.
• Open circuit in Green/pink (A 19) wire .
• Open circuit in Green (A32) wire .

5-115
FUEL SYSTEM {Programmed Fuel Injection)

3. Engine Stop Relay Inspection 1

Turn the ignition switch to "OFF':
Remove the engine stop relay.
Turn the ignition switch to "ON" and engine stop
switch to " O ':
Measure the voltage at the engine stop relay con-
nector terminals.
CONNECTION: Black(+) - Black/Orange(-)
Does the battery voltage exist?
YES GO TO STEP 4.
NO - • Open circuit in Black wire.
• Open circuit in Black/orange wire.
• Faulty engine stop switch (page 21-12).
Open circuit in Red/orange wire
between the en~ine stop switch and
bank angle sensor.
• Inspect the bank angle sensor (page 5-
112).

4. Engine Stop Relay Inspection 2

Turn the ignition switch to "OFF':
Jump the engine stop relay connector terminals.
CONNECTION: Black - Black/white
Turn the ignition switch to "ON':
Measure the voltage at the ECM connector terminal
and ground.
RELAY CONNECTOR
CONNECTION: B15 (+) - Ground (-)
Does the battery voltage exist?
YES Inspect the engine stop relay (page 5-113).
NO - Open circuit in power input line
(Black/white or Black) between the battery
and ECM.

PAIR SOLENOID VALVE

REMOVAL/INST ALLATION
Remove the floorstep (page 2-20).

Disconnect the PAIR solenoid valve 2P connector.

Disconnect the PAIR air suction hoses.

Remove the bolt and PAIR solenoid valve.

Installation is in the reverse order of removal.

5-116
 FUEL SYSTEM (Programmed Fuel Injection)

INSPECTION
Remove the PAIR solenoid valve.
(B)
Check that air flows (A) to (8), only when the 12-V bat-
tery is connected to the PAIR solenoid valve terminals.
(A)

Check the resistance between the terminals of the

PAIR solenoid valve.

STANDARD: 20 - 24 Q (20 °C/68°F)

leg I
If the resistance is out of specification, replace the
PAIR solenoid valve.

PAIR SOLENOID VALVE

EVAPORATIVE EMISSION CONTROL

SYSTEM
NOTE:
• Refer to the Vacuum Hose Routing Diagram and
Cable & Harness Routing (page 1-36) for the tube
connections and routing.

EVAPORATIVE EMISSION (EVAP)

CANISTER REMOVAL/INSTALLA TION

Remove the floor mats and the floor skirts (page 2-4).
N0.1 TUBE EVAP CANISTER
Disconnect the No. 1 and No. 4 tube from the EVAP
canister.
Remove the four bolts and EVAP canister from the
bracket.

Install the EVAP canister in the reverse order of

removal.

5-117
FUEL SYSTEM (Programmed Fuel Injection)

EVAP PURGE CONTROL SOLENOID

VALVE
REMOVAL/INSTALLATION

Disconnect the No.4 and No.5 tubes from the EVAP

purge control solenoid valve.
Remove the nuts and solenoid valve from the stay.
Disconnect the 2P connector from the solenoid valve.

Install the solenoid valve in the reverse order of

removal.

INSPECTION

Remove the solenoid valve.

Check air flow from tube fitting (A) (input port) to tube
fitting (B) (output port).
Air should not flow out.

Connect the 12-V battery to the solenoid valve con-

nector.

CONNECTION:
Battery (+) - Black/White terminal
Battery(-) - Yellow/Black terminal

Air should flow when the battery is connected.

5-118
MEMO
COOLING SYSTEM

SYSTEM FLOW PATTERN

OIL COOLER WATER HOSE

AIR BLEED HOSE

THERMOSTAT

6-0
 6. COOLING SYSTEM
SYSTEM FLOW PATTERN 6-0 THERMOSTAT 6-6
SERVICE INFORMATION 6-1 WATER PUMP 6-8
TROUBLESHOOTING 6-2 RADIATOR 6-11
SYSTEM TESTING 6-3 RADIATOR RESERVE TANK 6-15
COOLANT REPLACEMENT 6-4 FAN MOTOR RELAY 6-16

SERVICE INFORMATION
GENERAL

A WARNING
a ·.
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 cool down before removing the radiator cap.

I NOTICE
Use Coolant with silicate inhibitors may cause premature wear of water pump seals or blockage of radiator passages. Using
tap water may cause engine damage.

• This section covers service of the cooling system.

• These services can be done with the engine installed in the frame.
• Add coolant at the reserve tank. Do not remove the radiator cap except to refill or drain the system.
• All cooling system services can be done with the engine in the frame.
• Avoid spilling coolant on painted surfaces.
• After servicing the system, check for leaks with a cooling system tester.
• Refer to section 5 for engine coolant temperature (ECT) sensor inspection .
• Refer to section 21 for coolant temperature indicator, ECT/thermosensor inspection.

SPECIFICATIONS

ITEM SPECIFICATIONS

Coolant capacity Radiator and engine 2.2 liter (2.3 US qt, 1.9 Imp qt)
Reserve tank 0.8 liter (0.8 US qt, 0.7 Imp qt)
Radiator cap relief pressure 108 - 137 kPa (1.1 - 1.4kgf/cm 2, 16 - 20 psi)
Thermostat Begin to open 80 - 84 ·c (176 - 183 °F)
Fully open 95 °C (203 °F)
Valve lift 8 mm (0.3 in) minimum
Recommended antifreeze Pro Honda HP Coolant or an equivalent high quality ethylene
glycol antifreeze containing silicate-free corrosion inhibitors
Standard coolant concentration 50% mixture with soft water

6-1
COOLING SYSTEM

TORQUE VALUES
Water pump cover bolt 13 N•m (1.3 kgf•m, 9 lbfoft) CT bolt
Cooling fan nut 3 N•m (0.3 kgf•m, 2.2 lbfoft) Apply a locking agent to the threads.
Fan motor bolt 5 N•m (0.5 kgf•m, 3.6 lbfoft)
Radiator shroud mounting bolt 9 N•m (0.9 kgf•m, 6.5 lbfoft)
Radiator reserve tank mounting bolt 10 N•m (1 .0 kgf•m, 7 lbfoft)

TROUBLESHOOTING
Engine temperature too high Coolant leak
• Faulty radiator cap • Faulty water pump mechanical seal
• Faulty temperature gauge or thermosensor • Deteriorated 0-rings
• Air in system • Faulty radiator cap
• Thermostat stuck closed • Damaged or deteriorated cylinder head gasket
• Insufficient coolant • Loose hose connection or clamp
• Passages blocked in radiator, hoses or water jacket • Damaged or deteriorated hoses
• Faulty cooling fan motor
• Faulty fan motor switch
• Faulty water pump

Engine temperature too low

• Faulty temperature gauge or thermosensor
• Thermostat stuck open
• Faulty fan motor switch

6-2
 COOLING SYSTEM

SYSTEM TESTING
COOLANT (HYDROMETER TEST}
Remove the right inner pocket (page 3-14).

Remove the bolt and pull out the radiator cap (filler
neck) to the lid opening.

Remove the radiator cap.

I
Test the coolant gravity using a hydrometer (see
below for "Coolant gravity chart").
For maximum corrosion protection, a 50% solution of
eth.y lene glycol and distilled water is recommended
(page 6-4).
Look for contamination and replace the coolant
if necessary.

COOLANT GRAVITY CHART

1
~ Coolant temperature ·c (°F)
0 5 10 15 20 25 30 35 40 45 50
Coolant ratio% ~ (32) (41) (50) (59) (68) (77) (86) (95) (104) (113) (122)
5 1.009 1.009 1.008 1.008 1.007 1.006 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 1.031 1.029 1.027 1.025 1.023 1.021 1.019
25 1.045 1.044 1.043 1.042 1.040 1.038 1.036 1.034 1.031 1.028 1.025
30 1.053 1.052 1.051 1.047 1.046 1.045 1.043 1.041 1.038 1.035 1.032
35 1.063 1.062 1.060 1.058 1.056 1.054 1.052 1.049 1.046 1.043 1.040
40 1.072 1.070 1.068 1.066 1.064 1.062 1.059 1.056 1.053 1.050 1.047
45 1.080 1.078 1.076 1.074 1.072 1.069 1.066 1.063 1.060 1.057 1.054
50 1.086 1.084 1.082 1.080 1.077 1.074 1.071 1.068 1.065 1.062 1.059
55 1.095 1.093 1.091 1.088 1.085 1.082 1.079 1.076 1.073 1.070 1.067
60 1.100 1.098 1.095 1.092 1.089 1.086 1.083 1.080 1.077 1.074 1.071

6-3
COOLING SYSTEM

RADIATOR CAP/SYSTEM PRESSURE RADIATOR CAP CAP TESTER

INSPECTION
Remove the radiator cap (page 6-3).

Befo re ins ta lling Pressure test the radiator cap.

the cap in the Replace the radiator cap if it does not hold pressure,
tester, wet the or if relief pressure is too high o r too low.
sealing surface. It must hold the specified pressure for at least
6 seconds.

RADIATOR CAP RELIEF PRESSURE:

108 - 137 kPa (1.1 - 1.4 kgf/cm 2 , 16 - 20 psi)

Excessive Pressurize the radiator, engine and hoses, and check

pressure can CAP TESTER
for leaks.
damage the
cooling system
components. Do I NOTICE
not exceed 103
Excessive pressure can damage the cooling system
kPa (1.05kgf/cm 2 ,
components. Do not exceed 137 kPa (1.4 kgf/cm 2,
15 psi).
20psi)

Repair or replace components if the system will not

hold the specified pressure for at least 6 seconds.

COOLANT REPLACEMENT
AHTIFREEZE
PREPARATION
SOLUTION

I NOTICE I
(ETHYLENE
Using coolant with silicate corrosion inhibitors may GLYCOL BASE LOW MINERAL OR
cause premature wear of water pump seals or block- SOLUTION) DISTILLED WATER
ae of radiator passage. Using tap water may cause
engine damage.

NOTE:
•The effectiveness of coolant decreases with the
COOLANT
accumulation of rust or if there is a change in the
m ixing proportion during usage. Therefore, for best
performance change the coolant regularly as speci-
fied in the maintenance schedule.
Mix only distilled, low mineral water with the
recommended antifreeze .

RECOMMENDED ANTIFREEZE:
Pro Honda HP Coolant or an equivalent high quality
ethylene grycol antifreeze containing silicate-free
corrosion inhibitors

RECOMMENDED MIXTURE:
1:1 (Distilled water and recommended antifreeze)

6-4
 COOLING SYSTEM

When filling the REPLACEMENT I AIR BLEEDING

system or reserve
tank with coolant
Remove the following:
(checking the
coolant level),
- right inner pooket (page 3-14)
place the scooter - radiator cap
in a vertical posi- Remove the drain bolt and drain the coolant from the
tion on a flat, system with the sidestand applied.
level surface.

Remove the reserve tank cap and drain the coolant

from the reserve tank.

Reinstall the drain bolt with the new sealing washer

securely.

Place the scooter on its centerstand on a flat, level

surface.
Fill the reserve tank to the upper level line.

/
Fill the system with the recommended coolant
through the filler opening up to the filler neck.

I
6-5
COOLING SYSTEM

Bleed air from the system as follow:

1. Start the engine and let it idle for 2 - 3 minutes.
2. Snap the throttle three to four times to bleed air
from the system.
3. Stop the engine and add coolant to the proper level
if necessary. Reinstall the radiator cap.
4. Check the level of coolant in the reserve tank and fill
to the upper level if it is low.

THERMOSTAT
REMOVAL
Remove the left body cover (page 2-6).
Drain the coolant (page 6-5).

Remove the bolt and thermostat housing stay from

the frame.

Remove the bolts, housing stay and thermostat

housing cover.

Remove the 0-ring from the housing cover.

Remove the thermostat.

6-6
 COOLING SYSTEM

INSPECTION THERMOSTAT

Keep flammable
Visually inspect the thermostat for damage.

Heat the water with an electric heating element to

~
materials away operating temperature for 5 minutes.
from the electric Suspend the thermostat in heated water to check its
heating element.
operation.
Do not let the
thermostat or
thermometer
touch the pan, or
you will get false
readings.

Replace the thermostat if the valve stays open at

room temperature, or if it responds at temperatures
other than those specified.

THERMOSTAT BEGIN TO OPEN:

80 - 84 °C (176 - 183 °F)
VALVE LIFT:
8 mm (0.3 in) minimum at 85 °C (185 °F)

THERMOSTAT

INSTALLATl ON
Install the thermostat into the housing with its air
bleed hole facing up and aligning its ribs with the
grooves in the housing.

Install a new 0-ring into the housing cover groove.

6-7
COOLING SYSTEM

Install the housing cover and housing stay to the

housing.
Tighten the bolts securely.

Install the housing stay to the frame.

Tighten the bolt securely.

Fill the system with recommended coolant and bleed

the air (page 6-5).
Install the left body cover (page 2-9).

WATER PUMP
MECHANICAL SEAL INSPECTION
Inspect the telltale hole for sign of coolant leakage.
If there is leakage, the mechanical seal is defective,
and it should be replaced (see before).

REMOVAL
Drain the coolant (page 6-5).

Loosen the hose bands and disconnect the water

hoses and bypass hose from the water pump.

6-8
 COOLING SYSTEM

Remove the bolts and water pump cover.

Remove the 0-ring from the water pump body.

Remove the water pump body from the crankcase.

INSTALLATION

S"
~
SEALING WASHER

6-9
COOLING SYSTEM

Apply engine oil to a new 0-ring and install it onto the

stepped portion of the water pump.

Install the water pump into the crankcase while align-

ing the water pump shaft groove with oil pump
shaft end .

Align the mounting bolt holes in the water pump and

crankcase and make sure the water pump is securely
installed.

Install a new 0-ring into the groove in the water pump

body.

Install the water pump cover and tighten the bolts to

the specified torque.

TORQUE: 13 N•m (1.3 kgf•m, 9 lbf.ft)

Connect the water hoses and bypass hose, then tight-

en the hose bands.

Fill the system with recommended coolant and bleed

the air (page 6-5).

6-10
 COOLING SYSTEM

RADIATOR
REMOVAL
Drain the coolant (page 6-5).
Remove the floor skirts (page 2-4).
Remove the front cover (page 2-14).
Remove the front airduct cover (page 2-21 ).
Disconnect the fan .motor 2P black connector.

Loosen the hose band and disconnect the radiator

lower hose from the radiator.

Loosen the hose band and disconnect the radiator

upper hose from the radiator.

Be careful not to Remove the bolts and radiator from the frame.
damage the
radiator core .

6-11
COOLING SYSTEM

Loosen the hose band and disconnect the radiator

upper hose from the radiator.

DISASSEMBLV
Remove the bolts, clamp and fan motor/shroud
assembly.

Remove the nut and cooling fan .

Remove the bolts and fan motor from the shroud.

6-12
 COOLING SYSTEM

ASSEMBLY

9 N•m (0.9 kgf•m, 6.5 lbMt)

111~ -'.I

FAN SHROUD

Install the fan motor to the shroud.

Tighten the bolts to the specified torque.

TORQUE: 5 N•m (0.5 kgf•m, 3.6 lbf.ft)

Install the cooling fan onto the fan motor shaft by

aligning the flat surface.
Apply a locking agent to the cooling fan nut threads.
Tighten the nut to the specified torque.

TORQUE: 3 N•m (0.3 kgf•m, 2.2 lbf.ft)

6-13
COOLING SYSTEM

Install the fan motor/shroud assembly to the radiator.

Route the fan motor wire properly.
Install and tighten the bolts and clamp to the specified
torque.

TORQUE: 9 N•m (0.9 kgf•m, 6.5 lbf.ft)

INSTALLATION
Connect the upper hose to the radiator.
Tighten the hose band securely.

Install the radiator to the frame.

Tighten the bolts securely.

Connect the upper hose to the radiator.

Tighten the hose band securely.

6-14
 COOLING SYSTEM

Connect the lower hose to the radiator.

Tighten the hose band securely.

Connect the fan motor 2P black connector.

Route the wire harness and hoses correctly

(page 1-20).

Fill the system with recommended coolant and bleed

the air (page 6-5).
Install the floor skirt (page 2-4).
Install the front airduct cover (page 2-21 ).
Install the front cover (page 2-14).

RADIATOR RESERVE TANK

REMOVAL
Remove the front cover (page 2-14).
RESERVE TANK SIPHON TUBE
Remove the bolts and radiator reserve tank from the
frame.

Open the reserve tank cap and drain the coolant from
the reserve tank.

Disconnect the siphon tube.

INSTALLATl ON
Installation is in the reverse order of removal.

TORQUE: 10 N•m (1.0 kgf•m, 7 lbf.ft)

Pour the recommended coolant to the upper level line

with the centerstand applied.
BOLTS
Install the front cover (page 2-14).

6-15
COOLING SYSTEM

FAN MOTOR RELAV

INSPECTION
Remove the front cover (page 2-14).

Remove the fan motor relay.

Connect the ohmmeter to the fan motor relay connec-

tor terminals. FAN MOTOR RELAY BATTERY

CONNECTION: Green - Black

Connect the 12-V battery to the following fan motor

relay connector terminals.

CONNECTION: Black/Blue - Blue

There should be continuity only when the 12-V battery

is connected.
If there is no continuity when the 12-V battery is con-
nected, replace the fan motor relay.

6-16
MEMO
ENGINE REMOVAL/INSTALLATION

39 N•m (4 ·0 kgf•m, 29 lbMt)

39 :~f•m, 29 !bf.ft)

30 N•m (3.1 kgf•m, 22 !bf.ft)

7-0
 7. ENGINE REMOVAL/INSTALLATION
SERVICE INFORMATION 7-1 MAIN STAND 7-6
ENGINE REMOVAL 7-2 ENGINE INSTALLATION 7-6

SERVICE INFORMATION
GENERAL
• Support the scooter on its main stand during engine removal and installation, .
• Support the frame using a jack or other adjustable support to ease in the removal of the hanger bolt.
• The following components can be serviced with the engine installed in the frame.
- Oil pump (Section 4)
- Injector (Section 5)

--
- Water pump (Section 6)
- Cylinder head (Section 8)
- Drive and driven pulleys/clutch (Section 10)
- Final reduction (Section 11)
- Alternator/starter clutch (Section 12)
• The following components require engine removal for service.
- Cylinder/piston (Section 9)
- Crankshaft/crankcase/balancer (Section 13)

SPECIFICATIONS

ITEM SPECIFICATIONS
Engine dry weight 76.8 kg (169.3 lbs)
Engine oil capacity At draining 2.0 liter (2.1 US qt, 1.8 Imp qt)
At disassembly 2.6 liter (2.7 US qt, 2.3 Imp qt)
At oil filter change 2.2 liter (2.3 US qt, 1.9 Imp qt)

TORQUE VALUES
Engine mounting nut 39 N•m (4.0 kgf•m, 29 lbf•ft)
Rear shock absorber lower mounting bolt 39 N•m (4.0 kgf•m, 29 lbf•ft)
Rear brake caliper mounting bolt 30 N•m (3.1 kgf•m, 22 lbf•ft) ALOC bolt: replace with a new one.
Parking brake caliper mounting bolt 30 N•m (3.1 kgf•m, 22 lbf•ft) Apply a locking agent to the threads.
Fuel tube sealing nut 22 N•m (2.2 kgf•m, 16 lbf•ft)

7-1
ENGINE REMOVAL/INSTALLATION

ENGINE REMOVAL
Remove the following:
- Luggage box (page 2-10)
- Floorstep (page 2-20)
- Muffler and exhaust pipe (page 2-22, 24)
- Air cleaner housing/air cleaner chamber (page 5-89)
- Starter motor (page 20-4)

Drain the coolant from the system (page 6-5).

Release the fuel pressure (page 5-38)

Support the scooter on its main stand.

Loosen the hose band and disconnect the water hose

from the hose joint.

Remove the spark plug caps.

Disconnect the PAIR control valve hose from the
cylinder head.

Disconnect the MAP sensor connector and vacuum

hose from the sensor.
Remove the bolts, nut and seat hinge stay from the
frame.

Disconnect the alternator 3P white connector, CKP

sensor 2P red connector and TP
sensor connector.

7-2
 ENGINE REMOVAL/INSTALLATION

Disconnect the ECT sensor connector and injector

connectors.

Disconnect the fuel return hose from the fuel pipe. FUEL RETURN HOSE BREATHER HOSE
Remove the sealing nut and sealing washers then dis-
connect the fuel hose.
Disconnect the crankcase breather hose from the
cylinder head cover.

FUEL HOSE SEALING NUT

Disconnect the rear wheel speed sensor/speed sensor

3P (STD TYPE)/6P (AFTER '02 ABS TYPE) connector,
sidestand switch 2P green connector and CMP sensor
2P black connector.
Remove the screw and disconnect the oil pressure
switch wire.

Loosen the throttle cables free play with the adjusting

nut.
Disconnect the throttle cable ends from the throttle
drum.

7-3
ENGINE REMOVAL/INSTALLATION

Disconnect the air tube A from the 3-way joint.

Remove the bolts and rear brake hose/parking brake

wire clamps.

Remove the bolt and rear brake hose clamp.

Remove the bolts and rear brake caliper.
Remove the bolts and parking brake caliper.

Place a floor jack or other adjustable support under

the frame.

I NOTICE
Do not use the oil filter as a jack point.

Remove the rear cushion lower mount bolts.

7-4
 ENGINE REMOVAL/INSTALLATION

Remove the engine mount nuts.

Pull out the engine mount bolts and collars then

remove the engine from the frame.

After removing the engine, be careful not to catch

your hand or finger between the swingarm and
crankcase.

7-5
ENGINE REMOVAL/INSTALLATION

MAIN STAND BOLTS SPRING

REMOVAL/INSTALLATION
Remove the bolts and return spring.
Remove the main stand from the frame.

Installation is in the reverse order of removal.

BOLTS

ENGINE INSTALLATION
I NOTICE I
As installing the engine, be careful not to catch your
hand or finger between the swingarm and crankcase.

Remove the engine mount dust covers. ENGINE MOUNT RUBBER

Check the engine mount rubbers for damage and
replace if necessary.
If you replace the mount rubber, refer to following
illustration and be careful not to choose the wrong
type mount rubber.
DUST
COVER
'02: Install the engine to the frame by aligning the tab of
the engine and paint of engine mount rubber. TAB

After '02: Set the engine mount rubber to the engine mount so MOUNT RUBBER A:
that there will be certainly a difference of 0° - 10°
between both center lines as shown.

Install the engine mount rubber into the engine

mount with a hydraulic press so that the outer surface
of the outer pipe align the outer surface of the engine
mount. 0 - 10°

OUTER PIPE

7-6
 ----------~E~N~G3111NEREM OVAL/INSTALLATION
'02:

ENGINE MOUNT RUBBER

',
',
ENGINE
MOUNT
RUBBER
TAB

STOPPER

After '02:
MOUNT RUBB ER B!TUBE/COLLAR

7-7
ENGINE REMOVAL/INSTALLATION

Set the engine to the frame and install the engine

mount bolt.

Make sure there Tighten the engine mount nut to the specified torque.
is no opening
between the TORQUE: 39 N•m (4.0 kgf•m, 29 lbf.ft)
upperend of tabs
and stoppers of
the front engine
mounts.

Install and tighten the rear cushion lower mount bolts

to the specified torque.

TORQUE: 39 N•m (4.0 kgf•m, 29 lbf.ft)

Install the rear caliper.

Install and tighten the new rear caliper mount bolts to
the specified torque.

TORQUE: 30 N•m (3.1 kgf•m, 22 lbf.ft)

Apply a locking agent to the parking brake caliper bolt

threads.
Install and tighten the parking brake caliper mount
bolts to the specified torque.

TORQUE: 30 N•m (3.1 kgf•m, 22 lbf.ft)

Install the rear brake hose clamp and tighten the

bolts.

7-8
 ENGINE REMOVAL/INSTALLATION

Route the tubes, Install the rear brake hose/parking brake wire clamps
cables and wire and tighten the bolts.
harness correctly
(page 1-20).

Connect air tube A to the 3-way joint.

Connect the throttle cables to the throttle drum.

Adjust the throttle grip free play (page 3-4).

Connect the oil pressure switch wire to the oil

pressure switch.
Tighten the screw and install the dust cover.
Connect the rear wheel speed sensor/speed sensor 3P
(STD TYPE)/6P (AFTER '02 ABS TYPE) connector, side-
stand switch 2P green connector and CMP sensor 2P
black connector.

7-9
ENGINE REMOVAL/INSTALLATION

Connect the fuel return hose to the fuel rail.

While aligning the fuel hose banjo to the stopper on
the fuel rail stay, connect the fuel hose banjo to the
fuel rail with new sealing washers.
Install and tighten the sealing nut to the specified
torque.

TORQUE: 22 N•m (2.2 kgf•m, 16 lbf.tt)

Connect the crankcase breather hose to the cylinder

head cover.
Connect the No. 5 tube to the 3-way joint.

Connect the ECT sensor connector and injector con-

INJECTOR
nectors.
CONNECTORS

Connect the alternator 3P white connector, CKP sen-

sor 2P red connector and
TP sensor connector.

Install the seat hinge stay to the frame .

Tighten the nuts.
Connect the MAP sensor connector and vacuum hose
to the sensor.

7-10
 ENGINE REMOVAL/INSTALLATION

Install the spark plug caps.

Connect the PAIR control valve hose to the cylinder
head.

Connect the water hose to the hose joint.

Tighten the hose band.

Install the following:

- Starter motor (page 20-10)
- Air cleaner housing/air cleaner chamber (page 5-90)
- Muffler and exhaust pipe (page 2-23, 25)
- Floorstep (page 2-20)
- Luggage box (page 2-10)

Fill the cooling system with recommended coolant

and bleed the air (page 6-4).

7-11
CYLINDER HEAD/VALVES

10 N•m (10
. kgf•m 7 lb Mt)
I

44 N•m (4 ·5 kgf•m, 33 lbfeft)

 8. CYLINDER HEAD/V ALVES
SERVICE INFORMATION 8-1 VALVE GUIDE REPLACEMENT 8-16
TROUBLESHOOTING 8-3 VALVE SEAT INSPECTION/REFACING 8-17
CYLINDER COMPRESSION TEST 8-4 CYLINDER HEAD ASSEMBLY 8-20
CYLINDER HEAD COVER REMOVAL 8-4 CYLINDER HEAD INSTALLATION 8-22
CYLINDER HEAD COVER DISASSEMBL
. . . .. . .- -... . .
_ .. - - .
~
V 8-5 CAMSHAFT INSTALLATION 8-23
CAMSHAFT REMOVAL 8-6 CYLINDER HEAD COVER ASSEMBLY 8-26
CYLINDER HEAD REMOVAL 8-11 CYLINDER HEAD COVER
CYLINDER HEAD DISASSEMBLY INSTALLATION 8-28
8-12
CYLINDER HEAD INSPECTION CAM CHAIN TENSIONER LIFTER 8-29
8-13

SERVICE INFORMATI ON
GENERAL
• This section covers service of the cyl1nder head, valves and camshafts. These services can be done with the engine
installed in the frame.
• When disassembling, mark and store the disassembled parts to ensure that they are reinstalled in their original locations.
• Clean all disassembled parts with cleaning solvent and dry them by blowing them off with compressed air
before inspection.
• Be careful not to damage the mating surfaces when removing the cylinder head cover and cylinder head. Do not strike
the cylinder head too hard during removal.

SPECIFICATION S
Unit: mm (in)

ITEM STANDARD SERVICE LIMIT

Cylinder compression 1,373 kPa (14.0 kgf/cm 2, 199 psi) -
at 250 min- 1 (rpm)
Cylinder head warpage - 0.05 (0.002)
Valve, Valve clearance IN 0.16 ± 0.03 (0.006 ± 0.001) -
valve guide
EX 0.22 ± 0.03 (0.009 ± 0.001) -
Valve stem O.D. IN 4.475 - 4.490 (0.1762 - 0.1768) 4.465 (0.1758)
EX 4.465 - 4.480 (0.1758 - 0.1764) 4.455 (0.1754)
Valve guide l.D. IN 4.500 - 4.512 (0.1772 - 0.1776) 4.540 (0.1787)
EX 4.500 - 4.512 (0.1772 - 0.1776) 4.540 (0.1787)
Stem-to-guide clearance IN 0.010 - 0.037 (0.0004 - 0.0015) -
EX 0.020 - 0.047 (0.0008 - 0.0019) -
Valve guide projection above IN 15.3 - 15.5 (0.60 - 0.61) -
cylinder head
EX 15.3 - 15.5 (0.60 - 0.61) -
Valve seat width IN/EX 0.90 - 1.10 (0.035 - 0.043) 1.5 (0.06)
Valve spring free length IN/EX 40.19 (1.582) 38.2 (1.50)
Valve lifter Valve lifter O.D. IN/EX 25.978 - 25.993 (1.0228 - 1.0233) 25.97 ( 1.022)
Valve lifter bore l.D. IN/EX 26.010 - 26.026 (1.0240 - 1.0246) 26.04 (1.025)
Camshaft Cam lobe height IN 35.120- 35.200 (1.3827 - 1.3858) 34.82 ( 1.371)
EX 35.180 - 35.260 (1.3850- 1.3882) 34.88 ( 1.373)
Runout - 0.05 (0.002)
Oil clearance 0.030 - 0.072 (0.012 - 0.0028) 0.10 (0.004)

8-1
CYLINDER HEAD/VALVES

TORQUE VALUES
Reed valve cover bolt 13 N•m (1.3 kgf•m, 9 lbf•ft) CT bolt
Breather separator bolt 13 N•m (1.3 kgf•m, 9 lbf•ft) Apply a locking agent to the threads
CT bolt
Cylinder head sealing bolt 32 N•m (3.3 kgf•m, 24 lbf•ft) Apply a locking agent to the threads
Cylinder head 9 mm bolt 44 N•m (4.5 kgf•m, 33 lbf•ft) Apply oil to the threads and seating surface
Camshaft holder bolt 12 N•m (1.2 kgf•m, 9 lbf•ft) Apply oil to the threads and seating surface
Cylinder head cover bolt 10 N•m (1.0 kgf•m, 7 lbf•ft)
Cam sprocket bolt 20 N•m (2.0 kgf•m, 14 lbf•ft) Apply a locking agent to the threads
Cam chain tensioner pivot bolt 12 N•m (1.2 kgf•m, 9 lbfeft)

Exhaust pipe stud bolt:

36 ± 0.5 mm (1.42 ± 0.02 in)

TOOLS
Tensioner holder 07AMG-001A100 (U.S.A. only)
Valve spring compressor 07757-0010000
Valve seat cutter
- Seat cutter, 24.5 mm 07780-0010100 or equivalent commercially available in U.S.A.
- Seat cutter, 29 mm 07780-0010300
- Flat cutter, 30 mm 07780-0012200
- Flat cutter, 27 mm 07780-0013300
- Interior cutter, 30 mm 07780-0014000
- Interior cutter, 26 mm 07780-0014500
- Cutter holder, 4.5 mm 07781-0010600
Valve spring compressor attachment 07959-KM30101
Valve guide driver 4.5 mm 07HMD-ML00101
Tappet hole protector 07HMG-MR70002 not available in U.S.A.
Valve guide reamer, 4.508 mm 07HMH-ML00101 or 07HMH-ML00108 (U.S.A. only)
Compression gauge attachment 07RMJ-MY50100 commercially available in U.S.A.

8-2
 CYLINDER HEAD/VALVES

TROUBLESHOOTING
• Engine top-end problems usually affect engine performance. These problem can be diagnosed by a compression test or by
tracing engine noises to the top-end with a sounding rod stethoscope.
• If the performance is poor at low speeds, check for white smoke in the crankcase breather tube. If the tube is smoky, check
for a seized piston ring (Section 9).

Compression too low, hard starting or poor performance at Excessive noise

low speed • .Cylinder,head:
• Valves: - Incorrect valve adjustment
- Incorrect valve adjustment - Sticking valve or broken valve spring
- Burned or bent valve - Damaged or worn camshaft
- Incorrect valve timing - Loose or worn cam chain
- Broken valve spring - Worn or damaged cam chain tensioner
- Uneven valve seating - Worn cam sprocket teeth
• Cylinder head: • Worn cylinder, piston or piston rings (Section 9)
- Leaking or damaged cylinder head gasket
- Warped or cracked cylinder head Rough idle
• Faulty cylinder, piston or piston rings (Section 9) • Low cylinder compression

Compression too high or overheating

Excessive carbon build-up on piston head or combustion
chamber.

Excessive smoke
• Cylinder head:
- Worn valve stem or valve guide
- Damaged stem seal
• Worn cylinder, piston or piston rings (Section 9)

8-3
CYLINDER HEAD/VALVES

CYLINDER COMPRESSION TEST SPARK PLUG

Warm up the engine to normal

operating temperature.
Stop the engine and remove all the spark plug caps
and remove the number one spark plug (page 3-5) .
Disconnect the fuel pump 4P black connector
(page 5-82 ).

Install a compression gauge into the spark plug hole.

TOOL:
Compression gauge attachment 07RMJ-MY50100
(Commercially
available in U.S.A.)

To avoid Open the throttle all the way and crank the engine COMPRESSION GAUGE
discharging the with the starter motor until the gauge reading stops
battery, do not rising.
operate the The maximum reading is usually reached within
starter motor for
4 - 7 seconds.
more than seven
seconds.
Compression pressure:
1,373 kPa (14.0 kgf/cm 2 , 199 psi) at 250 min- 1 (rpm)

Low compression can be caused by:

- Blown cylinder head gasket
- Improper valve adjustment
- Valve leakage
- Worn piston ring or cylinder

High compression can be caused by:

- Carbon deposits in combustion chamber or on
piston head

CYLINDER HEAD COVER REMOVAL

Remove the floorstep (page 2-20).

Remove the spark plug caps.

Disconnect the crankcase breather hose from the
cyl inder head cover.

Remove the bolts and cylinder head cover.

8-4
 CYLINDER HEAD/VALVES

Remove the dowel pins and 0-rings.

CYLINDER HEAD COVER PACKING

DISASSE~BL V
Remove the cylinder head cover packing.

Remove the bolts and breather separator. BOLTS

Remove the separator gasket. GASKET

8-5
CYLINDER HEAD/VALVES

Remove the bolts and PAIR reed valve cover from the
cylinder head cover.

Remove the PAIR check valves from the cylinder

head cover.
Check the PAIR check valves for wear or damage,
replace if necessary.

Remove the PAIR check valve port plates from the

cylinder head cover.

CAMSHAFT REMOVAL
Remove the cylinder head cover (page 8-4).

Avoid damaging the CMP sensor while removing the

camshafts. Remove the bolt, 0-ring and CMP sensor
from the cylinder head.

CMP SENSOR

8-6
 CYLINDER HEAD/VALVES

Remove the timing hole cap and 0-ring. 0-RING

Remove the balancer shaft hole cap and 0-ring.

TIMING HOLE CAP

Turn the crankshaft counterclockwise, align the "T"

mark on the flywheel with the index mark on the right
crankcase cover.
Make sure the No.1 piston is at TDC (Top Dead Center)
on the compression stroke.

\\
INDEX MARK

Remove the cam chain tensioner lifter sealing bolt and BOLT SEALING WASHER
sealing washer.

Turn the tensioner lifter shaft full in (clockwise) and

secure it using the stopper tool or tensioner holder.

TOOL:
Tensioner holder 07AMG-001A100
(U.S.A. only)

This tool can easily be made from a thin (1 mm thick-

ness) piece of steel.

15 mm 19 mm

3 mm

15mm

4.5 mm

MATERIAL THICKNESS: 1.0 mm

8-7
CYLINDER HEAD/VA LVES

If you plan to replace the camshaft and/or cam sprock-

et, loosen the cam sprocket bolts as follow: CAM SPROCKET BOLTS

• It is not necessary to remove the cam sprocket from

the camshaft except when replacing the camshaft
and/or cam sprocket.

Be careful not to - Remove the cam sprocket bolts from intake and
drop the cam exhaust camshafts.
sprocket bolts into
the crankcase.

- Turn the crankshaft one full turn (360°), remove the

CAM SPROCKET BOLTS
other cam sprocket bolts from the camshafts.

- Remove the bolts and cam chain guide B.

BOLTS
- Remove the cam sprocket from the camshaft.

Suspend the cam Loosen and remove the camshaft holder bolts in a
chain with a piece crisscross pattern in several steps, then remove the BOLTS
of wire to prevent camshaft holders and camshafts.
the chain from
falling into the
crankcase.

8-8
 CYLINDER HEAD/VALVES

Remove the valve lifters and shims. VALVE LIFTER

• Be careful not to damage the valve lifter bore.

• The shims may stick to the inside of the valve lifters.
Do not allow the shims to fall into the crankcase.
• Mark all valve lifters and shims to ensure correct
reassembly in their original locations.
• The valve lifter can be easily removed with a valve
lapping tool or magnet.
• The shims can be easily removed with tweezers or
a magnet.

INSPECTION
CAMSHAFT HOLDER
Inspect the bearing surface of each camshaft holder
for scoring, scratches, or evidence of
insufficient lubrication.

CAMSHAFT RUNOUT
Support both ends of the camshaft with V-blocks and
check the camshaft runout with a dial gauge.

SERVICE LIMIT: 0.05 mm (0.002 in)

CAM LOBE HEIGHT

Using a micrometer, measure each cam lobe height.

SERVICE LIMITS:
IN: 34.82 mm (1.371 in)
EX: 34.88 mm (1.373 in)

8-9
CYLINDER HEAD/VALVES

CAMSHAFT OIL CLEARANCE

Wipe any oil from the journals of the camshaft, cylin-
der head and camshaft holders.
Lay a strip of plastigauge lengthwise on top of each
camshaft journal.

Install the camshaft holders and tighten the bolts in a

crisscross pattern in two to three steps.

TORQUE: 12 N•m (1.2 kgf•m, 9 lbf.ft)

Remove the camshaft holders and measure the width

of each plastigauge.
The widest thickness determines the oil clearance.

SERVICE LIMIT: 0.10 mm (0.004 in)

When the service limits are exceeded, replace the

camshaft and recheck the oil clearance.
Replace the cylinder head and camshaft holders as a
set if the clearance still exceeds the service limit.

CAM CHAIN GUIDE B

Inspect the cam chain slipper surface of the cam chain
guide for wear or damage.

8-10
 CYLINDER HEAD/VALVES

CYLINDER HEAD REMOVAL BOLTS GASKET

Remove the camshaft (page 8-6).

Remove the bolts and cam chain tensioner lifter

and gasket.

Remove the two 6 mm bolts.

Loosen the 9 mm Remove the six 9 mm bolts and washers.
bolts in a criss- Remove the cylinder head.
cross pattern in
two or
three steps.

Remove the dowel pins and cylinder head gasket.

Remove the flywheel (page 12-5).

Remove the cam chain guide.

Remove the socket bolt and chain guide.

Remove the cam chain from the crankshaft.

8-11
CYLINDER HEAD/VALVES

CYLINDER HEAD DISASSEMBLY

Remove the bolts and water joint.

Remove the spark plugs from the cylinder head.

Install the tappet hole protector into the valve

lifter bore.

TOOL:
Tappet hole protector 07HMG-MR70002
(Not available in U.S.A.)

An equivalent tool can easily be made from a 35-mm

plastic film container as shown.

5 mm 5mm
TOP VIEW

25 mm l.D.
(when compressed)

To prevent loss of Remove the valve spring cotters using the special
tension, do not VALVE SPRING COMPRESSOR
tools as shown.
compress the
valve spring more
than necessary to
TOOLS: I
Valve spring compressor 07757-0010000
remove
the cotters.
Valve spring compressor attachment
07959-KM30101

8-12
 CYLINDER HEAD/VALVES

Mark all parts dur- Remove the following:

ing disassembly - Spring retainer
so they can be - Valve spring
placed back - Valve
in their
- Stem seal
original position.
- Valve spring seat

CYLINDER HEAD INSPECTION COMBUSTION CHAMBERS

CYLINDER HEAD
Avoid damaging Remove the carbon deposits from the
the mating and combustion chambers.
valve seat sur- Check the spark plug hole and valve areas for cracks.
faces.

Check the cylinder head for warpage with a straight

edge and feeler gauge.

SERVICE LIMIT: 0.05 mm (0.002 in)

CAM CHAIN TENSIONER/ CAM CHAIN TENSIONER

CAM CHAIN GUIDE
Inspect the cam chain tensioner for excessive wear or
damage. Replace if necessary.

8-13
CYLINDER HEAD/VA LVES

Inspect the cam chain guide for excessive wear or

damage. Replace if necessary. CAM CHAIN GUIDE

VAL VE SPRING
Measure the free length of the valve springs.

SERVICE LIMIT: 38.2 mm (1.50 in)

Replace the springs if they are shorter than the service

limit.

VALVE LIFTER
Inspect each valve lifter for scratches or
abnormal wear.
Measure each valve lifter O.D .

SERVICE LIMIT: 25.97 mm (1.022 in)

VALVE LIFTER BORE

Inspect each valve lifter bore for scratches
or abnormal wear.
Measure each valve lifter bore l.D.

SERVICE LIMIT: 26.04 mm (1.025 in)

8-14
 CYLINDER HEAD/VALVES

VALVE/VALVE GUIDE
Inspect each valve for bends, burns, or abnormal
stem wear.
Check valve movement in the guide. Measure and
record each valve stem O.D.

SERVICE LIMITS:
IN: 4.465 mm (0.1758 in)
EX: 4.455 mm (0.1754 in)

Ream the guides to remove any carbon deposits

before checking clearances.
Insert the reamer from the combustion chamber side
of the head and always rotate the reamer clockwise.

TOOL:
Valve guide reamer, 4.508 mm 07HMH-ML00101 or
07HMH-ML0010B
(U.S.A. only)

Measure and record each valve guide l.D.

SERVICE LIMITS:
IN: 4.540 mm (0.1787 in)
EX: 4.540 mm (0.1787 in)

Subtract each valve stem O.D. from the porrespond-

ing guide l.D. to obtain the stem-to-guide clearance.

STANDARDS:
IN: 0.010 - 0.037 mm (0.0004- 0.0015 in)
EX: 0.020 - 0.047 mm (0.0008 - 0.0019 in)

Reface the valve If the stem-to-guide clearance is out of standard,

seats whenever determine if a new guide with standard dimensions
the valve guides would bring the clearance within tolerance. If so,
are replaced replace any guides as necessary and ream to fit.
(page 8-77).
If the stem-to-guide clearance is out of standard with
the new guides, replace the valves and guides.

8-15
CYLINDER HEAD/VALV ES

VALVE GUIDE REPLACEMENT

Chill the valve guides in a freezer for about an hour.

Be sure to wear Heat the cylinder head to 130°C-140°C (275°F-290°F)

heavy gloves to with a hot plate or oven. Do not heat the cylinder head
avoid burns when beyond 150°C (300°F). Use temperature indicator
handing the heat- sticks, available from welding supply stores, to be
ed cylinder head.
sure the cylinder head is heated to the
proper temperature.

Using a torch to Support the cylinder head and drive the valve guides
heat the cylinder out of the cylinder head from the combustion cham-
head may cause ber side.
warpage.
TOOL:
Valve guide driver 4.5 mm 07HMD-ML00101

Drive new guides in the cylinder head from the

camshaft side while the cylinder head is still heated.

TOOL:
Valve guide driver 4.5 mm 07HMD-ML00101

VALVE GUIDE PROJECTION ABOVE CYLINDER HEAD:

VALVE GUIDE
IN/EX: 15.3 -15.5 mm (0.60 - 0.61 in)

Let the cylinder head cool to room temperature.

Ream the new valve guides.

Insert the reamer from the combustion chamber side
of the head and always rotate the reamer clockwise.

TOOL:
Valve guide reamer, 4.508 mm 07HMH-ML00101 or
07HMH-ML0010 B
(U.S.A. only)

Use cutting oil on the reamer during this operation.

Clean the cylinder head thoroughly to remove any

metal particles after reaming and reface the valve seat
(page 8-17).

8-16
 CYLINDER HEAD/VALVES

VALVE SEAT INSPECTION/REFACING

INSPECTION
Clean all intake and exhaust valves thoroughly to
remove any carbon deposits.

Apply a light coat of Prussian Blue to each yalv.e face L

Tap the valve against the valve seat several times
using a hand-lapping tool, without rotating the valve,
to make a clear pattern.

The valve cannot Remove the valve and inspect the valve seat face.
be ground. If the The valve seat contact should be within the specified
valve face is width and even all around the circumference.
burned or badly
worn or if it con-
STANDARD: 0.90-1.10 mm (0.035- 0.043 in)
tacts the seat
SERVICE LIMIT: 1.5 mm (0.06 in)
unevenly, replace
the valve.
If the valve seat width is not within specification,
reface the valve seat (page 8-18).

SEAT WIDTH

Inspect the valve seat face for:

• Uneven seat width:
- Bent or collapsed valve stem;
Replace the valve and reface the valve seat
• Damaged face:
- Replace the valve and reface the valve seat

I
DAMAGED FACE
I
UNEVEN SEAT WIDTH

• Contact area (too low or too high):

- Reface the valve seat

TOO LOW TOO HIGH

8-17
CYLINDER HEAD/VALVES

VALVE SEAT REFACING

• Follow the refacing manufacturer's

V\
operating instructions.
• Be careful not to grind the seat more I 45°
than necessary. '\ /

j~ \ )~o
I
I
32°
"""

If the contact area is too high on the valve, the seat

must be lowered using a 32° flat cutter. CONTACT TOO HIGH OLD SEAT WIDTH

If the contact area is too low on the valve, the seat

must be raised using a 60° interior cutter.
Refinish the seat to specifications, using a 45°
finish cutter.
~~2°
CONTACT TOO LOW OLD SEAT WIDTH

T -~160°
Using a 45° seat cutter, remove any roughness or
irregularities from the seat.

TOOLS:
Valve seat cutter, 29 mm (45° IN) 07780-0010300
Valve seat cutter, 24.5 mm (45° EX) 07780-0010100
Valve seat cutter holder, 4.5 mm 07781-0010600
or equivalent commercially available in U.S.A.

Using a 32° flat cutter, remove 1/4 of the existing valve

seat material.

TOOLS: OLD SEAT WIDTH

Valve seat cutter, 30 mm (32° IN) 07780-0012200
Valve seat cutter, 27 mm (32° EX) 07780-0013300
Valve seat cutter holder, 4.5 mm 07781-0010600
or equivalent commercially available in U.S.A.

32°

8-18
 CYLINDER HEAD/VALVES

Using a 60° interior cutter, remove 1/4 of the existing

valve seat material. ·

TOOLS:
Valve seat cutter, 30 mm (60° IN) 07780-0012200
Valve seat cutter, 26 mm (60° EX) 07780-0013300
Valve seat cutter holder, 4.5 mm 07781-0010600
or equivalent commercially available in U.S.A.

Using a 45° seat cutter, cut the seat to the proper

width.

VALVE SEAT WIDTH: 1.0 mm (0.004in)

Make sure that all pitting and irregularities

are removed.

Excessive lapping After cutting the seat, apply lapping compound to the
pressure may valve face, and lap the valve using light pressure.
deform or dam- Change the angle of lapping tool frequently to prevent
age the seat. uneven seat wear.
Do not allow lap-
ping compound to
After lapping, wash any residual compound off the
enter the guides.
cylinder head and valve. Recheck the seat contact.

8-19
CYLINDER HEAD/VALVES

CYLINDER HEAD ASSEMBLY

8 g

iA ~SHIM
if VALVE LIFTER

,A~ CODERS
~ RETAINER

~ VALVE SPRING

~ ~ "sTEM SEAL
~ SPRING SEAT

VALVE GUIDE

EXHAUST VALVE

Clean the cylinder head assembly with solvent and

blow out all oil passages with compressed air.

Install the valve spring seats.

Install the new stem seals. SPRING SEAT

Lubricate the valve stems with molybdenum disulfide

oil and insert the valve into the valve guide.

To avoid damage to the stem seal, turn the valve

slowly when inserting.

·1
RETAINER
\
STEM SEAL VALVE

Install the tappet hole protector into the valve

lifter bore.

TOOL:
Tappet hole protector 07HMG-MR70002
(Not available in U.S.A.)

8-20
 CYLINDER HEAD/VALVES

Install the valve springs with the tightly wound coils

facing the combustion chamber.
Install the valve spring retainer.

Install the valve cotters using the special tools as VALVE SP'RING COMPRESSOR
shown.

I NOTICE
I
To prevent loss of tension, do not compress the valve
spring more than necessary to remove the cotters.

TOOLS:
Valve spring compressor 07757-0010000
Valve spring compressor attachment
07959-KM30101

Tap the valve stems gently with two plastic hammers

as shown to seat the cotters firmly.

Install the water joint and tighten the bolts.

8-21
CYLINDER HEAD/VALVES

CYLINDER HEAD INSTALLATI ON

Install the cam chain to the crankshaft.

Install the cam chain tensioner and tighten the socket

bolt to the specified torque.

TORQUE: 12 N•m (1.2 kgf•m, 9 lbf.ft)

Install the cam chain guide.

Install the flywheel (page 12-9).

Install the dowel pins and a new cylinder head gasket

as shown.

Install the cylinder head.

Apply engine oil to the cylinder head 9 x 155 mm bolt

threads and seating surface.
Tighten the bolts in a crisscross pattern in two to
three steps to the specified torque.

TORQUE:
9 mm bolt: 44 N•m (4.5 kgf•m, 33 lbf.ft)

Install the cam chain tensioner lifter onto the cylinder

BOLTS GASKET
head with a new gasket.
Install and tighten the mounting bolts.

8-22
 CYLINDER HEAD/VALVES

CAMSHAFT INSTALLATION VALVE LIFTER

Apply molybdenum disulfide oil to the outer surface

of each valve lifter.

Install the shims and valve lifters into the valve

lifter bores.

If the sprockets are removed, install the following: INTAKE CAM EXHAUST CAM
SPROCKET SPROCKET
Install the intake cam sprocket with the timing mark
(IN) facing inward and the No.1 cam lobes facing in as
shown .
Install the exhaust cam sprocket with the timing mark
(EX) facing inward and the No.1 cam lobes facing in
as shown.

TIMING MARKS

Clean the cam sprocket bolts and apply a locking

agent to the bolt threads.
Install the cam sprocket bolts.

Turn the crankshaft counterclockwise, align the "T"

mark on the flywheel with the index mark on the right
crankcase cover.

~
INDEX MARK

8-23
CYLINDER HEAD/VALVES

Apply molybdenum disulfide oil to the camshaft jour-

nals of the camshaft holder.

Apply molybdenum disulfide oil to the camshaft jour-

nals of the cylinder head.

Install the cam chain over the cam sprockets and then
INTAKE CAMSHAFT EXHAUST CAMSHAFT
install the intake and exhaust camshafts.

• Install each camshafts to the correct locations. Note

the identification marks.
"IN": Intake camshaft
"EX": Exhaust camshaft
• Make sure the timing marks on the cam sprockets
are facing inward and flush with the cylinder head
upper surface as shown.

TIMING MARKS

Install the intake and exhaust camshaft holders onto

"IN" MARK
the camshafts.

• Install each camshaft holders to the correct loca-

tions. Note the identification marks .
" IN": Intake camshaft holder
"EXH": Exhaust camshaft holder

Apply engine oil to the camshaft holder bolt threads

and seating surface.
Install and tighten the holder bolts in a crisscross pat-
ter in two to three steps to the specified torque.

TORQUE: 12 N•m (1 .2 kgf•m, 9 lbf.ft) BOLTS "EXH" MARK

8-24
 CYLINDER HEAD/VALVES

Install the cam chain guide B, and tighten the bolts. BOLTS

In case the cam sprockets were removed, apply lock- CAM SPROCKET BOLTS
ing agent to the cam sprocket bolt threads.
Install and tighten the cam sprocket bolts to the
specified torque.

TORQUE: 20 N•m (2.0 kgf•m, 14 lbf.ft)

Turn the crankshaft clockwise one full turn (360°) and CAM SPROCKET BOLTS
tighten the other cam sprocket bolts.

Remove the stopper tool from the cam chain tension- STOPPER TOOL
er lifter.

8-25
CYLINDER HEAD/VALV ES

Install a new sealing washer and tighten the

sealing bolt. -~ SEALING WASHER
........
Recheck the valve timing.

Apply oil to the new 0-ring, and install it onto the

CMP sensor.
Install the CMP sensor into the cylinder head.

CMP SENSOR

Install and tighten the mounting bolt.

.., ..._
........
0-RING

CYLINDER HEAD COVER ASSEMB LY

Install the PAIR check valve port plates into the cylin-
der head cover.

8-26
 CYLINDER HEAD/VALVES

Install the PAIR check valves into the cylinder

head covers.

Install the reed valve cover to the cylinder head cover

and tighten the bolts to the specified torque.

TORQUE: 13 N•m (1.3 kgf•m, 9 lbfoft)

Install a new gasket to the cylinder head cover.

~-. GASKET '
llllliijjllll

Install the crankcase breather separator to the cylin-

der head cover.

Apply a locking agent to the crankcase breather sepa-

rator mounting bolt threads.
Install and tighten the bolts to the specified torque.

TORQUE: 13 N•m (1.3 kgf•m, 9 lbfoft)

8-27
CYLINDER HEAD/VALV ES

CYLINDER HEAD COVER PACKING

INSTALLATION
Install the cylinder head packing into the groove of the
cylinder head cover.

Apply sealant to the cylinder head semi-circular

cutouts as shown.

Install the dowel pins and 0-rings.

Install the cylinder head cover onto the cylinder head

and tighten the cylinder head cover bolts to the spec-
ified torque.

TORQUE: 10 N•m (1.0 kgf•m, 7 lbf.ft)

8-28
 CYLINDER HEAD/VALV ES

Connect the crankcase breather hose from the cylin-

der head cover.
Install the spark plug cap.

Install the floorstep (page 2-20).

CAM CHAIN TENSIONER LIFTER

REMOVAL
Remove the cam chain tensioner sealing bolt and
sealing washer.

Turn the tensioner shaft fully in (clockwise) and secure

it using the stopper tool or tensioner holder to pre-
vent damaging the cam chain.

TOOL:
Tensioner holder 07AMG-001A100
{U.S.A. only)

See page 8-7 for detail of the tool.

Remove the bolts and cam chain tensioner lifter. BOLTS GASKET
Remove the gasket.

8-29
CYLINDER HEAD/VA LVES

INSTALLATION
Install the new gasket onto the cam chain
tensioner lifter.

CAM CHAIN TENSIONER LIFTER

Install the cam chain tensioner lifter into the

cylinder head. BOLTS GASKET
Install and tighten the mounting bolts.

Remove the stopper tool.

STOPPER TOOL

Install a new sealing washer and tighten the sealing

bolt. ~~ SEALING WASHER
illliiijlll

8-30
MEMO
CYLINDER/PISTON

9-0
 9. CYLINDER/PISTON
SERVICE INFORMATION 9-1 CYLINDER/PISTON REMOVAL 9-3
TROUBLESHOOTING 9-2 CYLINDER/PISTON INSTALLATION 9-6

SERVICE INFORMATION
GENERAL
• This section covers maintenance of the cylinder and piston. These services can be done with the engine installed in the
frame.
• Take care not to damage the cylinder wall and piston.
• Be careful not to damage the mating surfaces by using a screwdriver when disassembling the cylinder.
• Clean all disassembled parts with clean solvent and dry them using compressed air before inspection.
• When disassembling, mark and store the disassembled parts to ensure that they are reinstalled in their original locations.
Camshaft lubricating oil is fed through the oil passage in the cylinder. Clean the oil passage before installing the cylinder.

SPECIFICATIONS Unit: mm (in)

ITEM STANDARD SERVICE LIMIT

Cylinder l.D. 72.000 - 72 .015 (2.8346 - 2.8352) 72.10 (2.839)

Out of round - 0.10 (0.004)
Taper - 0.10 (0.004)
Warpage - 0.10 (0.004)
Piston, piston Piston mark direction "IN" mark facing toward the intake side -
rings Piston O.D. 71.97 - 71.99 (2 .833 - 2.834) 71.90 (2.831)
Piston 0.0. measurement point 18 mm (0.7 in) from bottom of skirt -
Piston pin bore l.D. 17.002 - 17.008 (0.6694 - 0.6696) 17.04 (0.671)
Piston pin 0.D. 16.994 - 17.000 (0.6691 - 0.6693) 16.96 (0.668)
Piston-to-piston pin clearance 0.002 - 0.014 (0.0001 - 0.0006) 0.02 (0.001)
Piston ring-to-ring Top 0.030 - 0.065 (0.0012 - 0.0026) 0.08 (0.003)
groove clearance Second 0.015 - 0.050 (0.0006 - 0.0020) 0.065 (0.0026)
Piston ring end gap Top 0.15 - 0.30 (0.006 - 0.012) 0.50 (0.020)
Second 0.30 - 0.45 (0.012 - 0.018) 0.65 (0.026)
Oil (side rail) 0.20 - 0.70 (0.008 - 0.028) 1.00 (0.040)
Cylinder-to-piston clearance 0.010 - 0.045 (0.0004 - 0.0018) 0.10 (0.004)
Connecting rod small end l.D. 17.016 - 17.034 (0.6699 - 0.6706) 17.06 (0.672)
Connecting rod-to-piston pin clearance 0.016 - 0.040 (0.0006 - 0.0016) 0.06 (0.002)

TOOLS
Piston ring slider 07954-2830000 (two required)
Piston base 07958-2500001 (two required)

9-1
CYLINDER/PISTON

TROUBLESHOOTING
Compression to low, hard starting or poor performance at Excessive smoke
low speed • Worn cylinder, piston or piston ring
• Leaking cylinder head gasket • Improper installation of piston rings
• Worn, stuck or broken piston ring • Scored or scratched piston or cylinder wall
• Worn or damaged cylinder and piston • Cylinder head/valve problem (Section 8)
• Bent connecting rod
Abnormal noise
Compression to high, overheating or knocking • Worn piston pin or piston pin hole
• Excessive carbon build-up on piston head or on • Worn connecting rod small end
combustion chamber • Worn cylinder, piston or piston rings
• Excessive carbon build-up

9-2
 CYLINDER/PISTON

CYLINDER/PISTON REMOVAL
Remove the cylinder head (page 8-11).

Remove the bolts and water joint from the cylinder.

Do not strike the Remove the cam chain guide and cylinder.
cylinder too hard
and do not
damage the
mating surface
with a
screwdriver.

Remove the dowel pins and gasket.

Place clean shop towels in the crankcase to keep the

piston pin clips, or other parts, from falling into the PISTON
crankcase.

Remove the piston pin clips with pliers.

Remove the piston pin out of the piston.
Remove the piston.

PISTON PIN CLIP

9-3
CYLINDER/PISTON

Do not damage Spread each piston ring and remove it by lifting up at PISTON RING
the piston ring by a point opposite the gap.
spreading the
ends too far.
/

Clean carbon deposits from the ring grooves with a PISTON PISTON RING
ring that will be discarded. Never use a wire brush; it
will scratch the groove.

INSPECTION
PISTON RING
Inspect the piston rings for movement by rotating the
rings. The rings should be able to move in their
grooves without catching.

Push the ring until the outer surface of the piston ring
is nearly flush with the piston and measure the ring-
to-groove clearance.

SERVICE LIMITS: Top: 0.08 mm (0.003 in)

Second: 0.065 mm (0.0026 in)

Insert each piston ring into the bottom of the cylinder

squarely using the piston.
Measure the ring end gap.

SERVICE LIMITS: Top: 0.50 mm (0.020 in)

Second: 0.65 mm (0.026 in)
Oil (side rail): 1.00 mm (0.040 in)

9-4
 CYLINDER/PISTON

PISTON/PISTON PIN
Measure the piston O.D. at the point 10 mm (0.4 in)
from the bottom and 90° to the piston pin hole.

SERVICE LIMIT: 71.90 mm (2.831 in)

Calculate the cylinder-to-piston clearance (cylinder

l.D.: page 9-6).

SERVICE LIMIT: 0.10 mm (0.004 in)

Measure the piston pin hole. Take the maximum read-

PISTON
ing to determine the l.D.

SERVICE LIMIT: 17.04 mm (0.671 in)

Measure the piston pin O.D. at piston and connecting

rod sliding areas.

SERVICE LIMIT: 16.96 mm (0.668 in)

Calculate the piston -to-piston pin clearance.

SERVICE LIMIT: 0.02 mm (0.001 in)

Measure the connecting rod small end l.D ..

SERVICE LIMIT: 17 .06 mm (0.672 in)

Calculate the connecting rod-to-piston pin clearance.

SERVICE LIMIT: 0.06 mm (0.002 in)

CYLINDER
Check the cylinder for warpage with a straight edge
and feeler gauge in the directions shown.

SERVICE LIMIT: 0.10 mm (0.004 in)

9-5
CYLINDER/PISTON

Check the cylinder wall for wear or damage.

Measure and record the cylinder l.D. at three levels in
an X and Y axis. Take the maximum reading to deter-
mine the cylinder wear.

SERVICE LIMIT: 72.10 mm (2.839 in)

Calculate the piston-to cylinder clearance. MIDDLE i.

•~.---+---:
Take a maxlm.um "reading to determine the clearance.
...-
Refer to page 9-5 for measurement of the piston O.D. /

BOTIOM , _...../

SERVICE LIMIT: 0.10 mm (0.004 in)

Calculate the taper and out-of-round at three levels in

an X and Y axis. Take the maximum reading to
determine them .
PISTON RING
SERVICE LIMITS: Taper: 0.10 mm (0.004 in)

CYLINDER/PISTON INSTALLATION
Out-of-round: 0.10 mm (0.004 in)
/
PISTON RING INSTALLATION
Be careful not to Carefully install the piston rings into the piston ring
damage the grooves with the markings facing up.
piston and rings
• Do not confuse the top and second rings.
• To install the oil ring, install the spacer first, then
install the side rails.

Stagger the piston ring end gaps 120° degrees apart

from each other.
Stagger the side rail end gaps as shown.

TOP RING

SECOND
RING

or more SPACER

PISTON

9-6
 CYLINDER/PISTON

CYLINDER/PISTON INSTALLATION
Clean any gasket material from the cylinder mating
surfaces of the crankcase and oil passage.

Place a clean shop towel over the crankcase to pre- PISTON PIN "IN" MARK PISTON
vent the clip from falling into the crankcase.

Apply molybdenum disulfide oil to the piston pin.

Apply engine oil to the connecting rod small end and
piston pin hole.

Install the piston with the "IN" mark facing the

intake side.
Install the piston pin and new pin clip.

• Make sure that the piston pin clips are seated.

• Do not align the piston pin clip end gap with the pis-
ton cut-out. PISTON PIN CLIP

Install the dowel pins and a new gasket.

Apply engine oil to the cylinder wall, piston and pis-

ton ring outer surfaces.

Be careful not to Pass the cam chain through the cylinder and install
damage the the cylinder over the piston using the special tools.
piston rings and
cylinder walls. TOOLS:
Piston ring slider 07954-2830000
Piston base 07958-2500001

9-7
CYLINDER/PISTON

Install the cam chain guide by aligning its tab with the
groove on the cylinder.

CAM CHAIN GUIDE

Install a new 0-ring into the water joint groove.

Install the water joint to the cylinder.

Tighten the bolts.

Make sure that the cylinder touches the

crankcase evenly.

Install the cylinder head (page 8-22).

9-8
MEMO
 ---------- -

DRIVE PULLEY /DRIVEN PULLEY /CLUTCH

STD TYPE:

/®
103 N•m (10.5 kgf•m,
76 lbfoft)

40 lbfoft)

AFTER '02 (ABS TYPE):

10 N•m (1.0 kgf•m, 7 lbfoft)

10-0
 10. DRIVE PULLEY /DRIVEN PULLEY /CLUTCH
SERVICE INFORMATION 10-1 DRIVE PULLEY 10-6
TROUBLESHOOTING 10-2 CLUTCH/DRIVEN PULLEY 10-10
LEFT REAR COVER 10-3

SERVICE INFORMATION
GENERAL
• This section covers maintenance of the drive pulley, driven pulley and clutch.
• These services can be done with the engine installed in the frame.
• To prevent belt slippage, avoid getting grease and oil on the V-belt and pulley drive faces.
• Do not apply grease to the movable drive face and weight rollers.

SPECIFICATIONS
Unit: mm (in)

ITEM STANDARD SERVICE LIMIT

Clutch Clutch outer l.D. 160.0 - 160.2 (6.30 - 6.31) 160.5 (6.32)

Lining thickness . 4.0 (0.16) 1.0 (0.04)

Drive belt width 28.0 (1.10) 27.0 ( 1.06)

Movable drive face

8
Bushing l.D.
Boss O.D.
38.024 - 38.057 ( 1.4970 - 1.4983)
37.995 - 38.031 (1.4959 - 1.4973)
38.10 (1.50)
37.95 (1.494)
Weight roller 0.D. 27.92 - 28.08 ( 1.099 - 1.106) 27.5 (1.08)
Driven pulley Face spring free length 107.7 (4.24) 102.7 (4.04)
Driven face O.D. 47.965 - 47.985 (1.8883 - 1.8892) 47.94 (1.887)
Movable driven face l.D. 48.000 - 48.025 (1.8898 - 1.8907) 48.06 ( 1.892)

TORQUE VALUES . }-.:~

Drive plate bolt 26 N•m (2.7 kgf•m, 20 lbf•ft)

Element cover screw 1 N•m (0.1 kgf•m, 0.7 lbf•ft)
Left rear cover special bolt 10 N•m (1.0 kgf•m, 7 lbf•ft)
Drive face bolt 103 N•m (10.5 kgf•m, 76 lbf•ft) UBS bolt.
Apply oil to the threads and seating surface.
Driven pulley nut 54 N•m (5.5 kgf•m, 40 lbf•ft)

10-1
DRIVE PULLEY /DRIVEN PULLEY /CLUTCH

TOOLS
Universal holder 07725-0030000 or 07AMB-MCTA100 (U.S.A. only)
Attachment, 28 x 30 mm 07946-1870100
Attachment, 32 x 35 mm 07746-0010100
Pilot, 17 mm 077 46-0040400
Pilot, 25 mm 077 46-0040600
Driver 07749-0010000
Oil seal driver attachment 07948-SC20200
Driver handle 07953-MJ 10200
Needle bearing remover 07HMC-MR70100 not available in U.S.A.
Clutch outer puller 07ZMC-MCT0100 or 07ZMC-MCTA 100 (U.S.A. only)
Clutch spring compressor 07ZME-MCT0100 or 07ZME-MCTA 100 (U.S.A. only)
Clutch outer assembly tool 07ZMF-MCT0100
Assembly collar 07ZMF-MCTA 100 (U.S.A. only)
Threaded shaft 22 x 1.5 x 240 mm 07931-ME4010B (U.S.A. only)
Special nut 07931-H B3020A (U.S.A. only)
Adjustable bearing puller 25 - 40 mm 07736-A01 OOOB or 07736-A01000A and commercially available slide hammer

TROUBLESHOOTING
Engine starts but scooter won't move Poor performance at high speed or lack of power
• Worn drive belt • Worn drive belt
• Damaged ramp plate • Weak driven face spring
• Worn or damaged clutch shoe • Worn weight rollers
• Broken driven face spring • Contaminated pulley faces

Engine stalls or scooter creeps

• Broken clutch shoe spring

10-2
 DRIVE PULLEY /DRIVEN PULLEY /CLUTCH

LEFT REAR COVER BOLTS

REMOVAL
Remove the left passenger footpeg (page 2-12).

Remove the bolts and the left front cover.

Remove the special bolts and the left rear cover. BOLTS

LEFT REAR COVER

Remove the speed sensor wire and guide from the

left cover.
Remove the bolts and left cover.

LEFT COVER

Remove the seal rubber from the left cover.

10-3
DRIVE PULLEY /DRIVEN PULLEY /CLUTCH

BELT CASE AIR CLEANER BELT CASE AIR CLEANER COVER SCREW

Remove the screw.

Remove the belt case air cleaner cover with its tab
located in the hole on the left front cover.

Check the air cleaner element.

Remove the element from the base and wash it in
cleaning solvent if necessary.
Dry the element thoroughly, then install it on
the base.

Install the air cleaner cover with its tab in the hole on
the left front cover.
Tighten the screw to the specified torque.

TORQUE: 1 N•m (0.1 kgf•m, 0.7 lbf.ft)

DRIVESHAFT BEARING REPLACEMENT

INDUSTRIAL DRYER
Heat the left cover around the driveshaft bearing with
industrial dryer.
Remove the driveshaft bearing from the left cover.

BEARING

Install the new driveshaft bearing into the left cover

OIL SEAL DRIVER
using a special tool.

TOOL:
Oil seal driver attachment 07948-SC20200

I
,~
' ~~~
I
I

BEARING

10-4
 DRIVE PULLEY /DRIVEN PULLEY /CLUTCH

INSTALLATION

Check the seal rubber and replace it if it is deteriorat-

ed or damaged.
Clean the gasket groove in the left cover.

Install the left cover onto the crankcase by aligning

the dowel pins with the holes.
Tighten the left cover bolts.
Route the speed sensor wire and install the wire guide
on the left cover as shown.

LEFT COVER

Install the left rear cover to the left cover.

BOLTS
Tighten the special bolts to the specified torque.

TORQUE: 10 N•m (1.0 kgf•m, 7 lbf.ft)

LEFT REAR COVER

Install the left front cover and tighten the

BOLTS
bolts.

Install the left passenger footpeg (page 2-12).

10-5
DRIVE PULLEY /DRIVEN PULLEY /CLUTCH

DRIVE PULLEY
REMOVAL
Remove the left rear cover (page 10-3).

Hold the drive pulley face with the special tool and
loosen the drive pulley face bolt.

TOOL:
Universal holder 07725-0030000

U.S.A. only
Pulley holder 07AMB-MCTA100

Remove the nut, washer and drive pulley face.

Remove the drive belt from the crankshaft.

Remove the movable drive face assembly while hold-

ing the back of the face (ramp plate).

DISASSEMBLV RAMP PLATE

Remove the ramp plate, slide pieces and

weight rollers.

SLIDE PIECES

10-6
 DRIVE PULLEY /DRIVEN PULLEY /CLUTCH

Remove the drive face boss from the movable

drive face.

INSPECTION COG

DRIVE BELT
Check the drive belt for cracks, separation or abnor- -.. .
mal or excessive wear.

·., ·.,

Attach the suitable plates as shown. DRIVE BELT

Measure the drive belt width.

SERVICE LIMIT: 27.0 mm (1.06 in)

Remove the clutch/driven pulley, then replace the

drive belt if necessary.

PLATES

WEIGHT ROLLER
Check each roller for wear or damage.
Measure the weight roller 0.0.

SERVICE LIMIT: 27 .5 mm ( 1.08 in)

10-7
DRIVE PULLEY /DRIVEN PULLEY /CLUTCH

MOVABLE DRIVE FACE

Check the drive face boss for wear or damage.
Measure the boss O.D ..

SERVICE LIMIT: 37 .95 mm (1.494 in)

Measure the face bushing l.D ..

SERVICE LIMIT: 38.10 mm (1.50 in)

ASSEMBLY
Clean any oil or grease from the pulley faces and
weight rollers.
RAMP PLATE

MOVABLE DRIVE FACE

~ SLIDE PIECE

WEIGHT ROLLER

Install the drive face boss into the movable drive face.

10-8
 DRIVE PULLEY /DRIVEN PULLEY /CLUTCH

Install the weight rollers in the movable drive face. RAMP PLATE

Install the slide pieces in the ramp plate.

Install the ramp plate in the movable drive face.

SLIDE PIECES . WEIGHT ROLLERS

INSTALLATION
Clean any oil or grease from the pulley faces and the
drive belt.

Install the movable drive face assembly on the crank-

shaft while holding the ramp plate.

Install the drive belt onto the drive face boss.

Install the drive pulley face and washer.

Apply oil to the drive pulley face nut threads and seat-
ing surface and install the nut. ·

Hold the drive face with the special tool and tighten
the bolt to the specified torque.

TOOL:
Universal holder 07725-0030000

U.S.A. only
NUT/WASHER
Pulley holder 07AMB-MCTA100

TORQUE: 103 N•m (10.5 kgf•m, 76 lbMt)

Install the left cover (page 10-5).

10-9
DRIVE PULLEY /DRIVEN PULLEY /CLUTCH

CLUTCH/DRIVEN PULLEY UNIVERSAL HOLDER

REMOVAL
Remove the left cover (page 10-3).

Place the univer- Hold the clutch outer with the special tool as shown.
sal holder in the
holes on the back TOOL:
(Inside) of the Universal holder 07725-0030000 or
clutch outer.
07AMB-MCTA100
(U.S.A. only)

Remove the nut, washer and clutch/driven

pulley assembly.
Remove the drive belt from the driven pulley.

DRIVE BELT CLUTCH/DRIVEN PULLEY

Remove the snap ring from the driveshaft.

Remove the clutch outer from the driveshaft using a

special tool.

TOOL:
Clutch outer puller 07ZMC-MCT0100 or
07ZMC-MCTA100 (U.S.A. only)

10-10
 DRIVE PULLEY /DRIVEN PULLEY /CLUTCH

DISASSEMBLY 0-RINGS

CLUTCH/DRIVEN PULLEY DISASSEMBLV

Remove the 0-rings from the driven face grooves.

Set the clutch spring compressor onto the driven pul- CLUTCH SPRING COMPRESSOR
ley/clutch assembly.

TOOL:
/
Clutch spring compressor 07ZME-MCT0100 or
07ZME-MCTA100
(U.S.A. only)

SPRING

Hold the clutch spring compressor in a vise.

Compress the driven face spring.

Remove the snap ring from the driven face groove.

Remove the spring compressor and disassemble DRIVEN PULLEY/CLUTCH

the following:
- Spring seat
- Driven face spring
- Spring collar
- Driven pulley/clutch assembly

10-11
DRIVE PULLEY /DRIVEN PULLEY /CLUTCH

CLUTCH DISASSEMBLY
Remove the bolts and clutch from the drive pulley.

Remove the E-clips and clutch side plate.

SIDE PLATE

Remove the clutch shoes and shoe springs from the

CLUTCH SHOE DRIVE PLATE
drive plate.

Remove the damper rubbers from the clutch shoes.

DAMPER RUBBER

10-12
 DRIVE PULLEY /DRIVEN PULLEY /CLUTCH

Remove the clutch shoes and shoe springs. CLUTCH SHOE

DRIVEN PULLEY DISASSEMBLV

Remove the seal collar.

Remove the guide roller pins, guide rollers and the

movable driven face.

Remove the 0-rings and oil seals from the movable OIL SEALS
driven face.

10-13
DRIVE PULLEY /DRIVEN PULLEY /CLUTCH

DRIVEN FACE BEARING REPLACEMENT

DRIVER HANDLE
Remove the driven face needle bearing using the
special tools.

TOOLS:
Driver handle 07953-MJ 10200
Needle bearing remover 07HMC-MR7010 0
(Not available in U.S.A.)
U.S.A. only
Adjustable bearing 07736-A010008 or
puller 25 - 40 mm 07736-A01 OOOA and
commercially available
slide hammer

Remove the snap ring, then remove the ball bearing.

TOOLS:
Driver 077 49-0010000
Attachment, 28 x 30 mm 07946-1870100
Pilot, 17 mm 077 46-0040400

Apply grease to a new ball bearing.

Install the ball bearing into the driven face with the
marked side facing up.

TOOL:
Driver 07749-0010000
Attachment, 32 x 35 mm 077 46-0010100
Pilot, 17 mm 077 46-0040400

,S~
~
~
-~
BEARING

Install the snap ring to the groove in the driven

face.

10-14
 DRIVE PULLEY /DRIVEN PULLEY /CLUTCH

Fill 23 - 28 g of grease to the driven face

inner surface.

Apply grease to a new needle bearing.

Press the needle bearing into the driven face with the
-
DRIVER/ATIACHMENT/PILOT

marked side facing up.

TOOL:
Driver 077 49-0010000
Attachment, 32 x 35 mm 077 46-0010100
Pilot, 25 mm 077 46-0040600

INSPECTION
CLUTCH OUTER
Check the clutch outer for wear or damage.
Measure the clutch outer 1.0.

SERVICE LIMIT: 160.5 mm (6.32 in) •

-.•
'
\
fp

. .
,.

·'~. "<~· __________.·~·

.
.
·
e I
.l

CLUTCH SHOE LINING

Check the clutch shoe for wear or damage.
Measure the thickness of each shoe.

SERVICE LIMIT: 1.0 mm (0.04 in)

10-15
DRIVE PULLEY /DRIVEN PULLEY /CLUTCH

DRIVEN FACE SPRING

Measure the driven face spring free length.

SERVICE LIMIT: 102.7 mm (4.04 in)

DRIVEN FACE
Check the driven face for scratches, scoring or
damage.
Measure the driven face boss O.D.

SERVICE LIMIT: 47.94 mm (1.887 in)

MOVABLE DRIVEN FACE

Check the movable driven face for scratches, scoring
or damage.
Check the guide grooves for stepped wear or damage.
Measure the movable driven face l.D.

SERVICE LIMIT: 48.06 mm (1.892 in)

10-16
- ----------------------------- ------ -

DRIVE PULLEY /DRIVEN PULLEY /CLUTCH

ASSEMBLY
SHOE SPRING
Clean any oil and grease from the pulley faces and
clutch outer. SIDE PLATE

OIL SEAL

GUIDE ROLLER

DRIVEN PULLEY ASSEMBL V OIL SEALS

Clean any oil from the drive belt sliding surfaces on
the driven face.

Apply grease to new oil seal lips and install them into
the movable driven face.
Coat new 0-rings with grease and install them into
the movable driven face grooves.

Install the movable driven face onto the driven face. GUIDE ROLLER PIN/GUIDE ROLLER
Install the guide rollers and guide roller pins.
Fill 7 - 9 g of grease in each guide groove.

MOVABLE DRIVEN FACE

10-17
DRIVE PULLEY /DRIVEN PULLEY /CLUTCH

Install the seal collar.

CLUTCH ASSEMBLY
CLUTCH SHOE
Assemble the clutch shoes and shoe springs.

Install the damper rubbers into the clutch shoes.

Install the clutch shoes and shoe springs onto the

CLUTCH SHOE DRIVE PLATE
drive plate.

10-18
 DRIVE PULLEY /DRIVEN PULLEY /CLUTCH

Install the clutch side plate and secure it with SIDE PLATE
the E-clips.

Install the clutch to the driven pulley and tighten the

bolts to the specified torque.

TORQUE: 26 N•m (2.7 kgf•m, 20 lbf.ft)

CLUTCH/DRIVE N PULLEY ASSEMBL V DRIVEN PULLEY/CLUTCH

Assemble the following:
- Driven pulley/clutch assembly
- Spring collar SPRING COLLAR
- Driven face spring
- Spring seat
I

Set the clutch spring compressor over the clutch/dri- CLUTCH SPRING COMPRESSOR
ven pulley assembly and hold the spring compressor
in a vice.

TOOL:
Clutch spring compressor 07ZME-MCT010 0 or
07ZME-MCTA10 0
(U.S.A. only)

Install the drive belt into the driven pulley.

Squeeze and hold the drive belt in your hand as
shown.

10-19
DRIVE PULLEY /DRIVEN PULLEY /CLUTCH

Compress the driven face spring.

Install the snap ring.

Remove the spring compressor from the clutch/driven

pulley assembly.

Apply grease to the 0-rings and install them on the

driven face grooves.
_:-;-=.;- 0-RINGS
-~

INSTALLATION
Install the clutch outer using a special tool.

TOOL:
Clutch outer assembly tool 07ZMF-MCT0100
U.S.A. only
Assembly collar 07ZMF-MCTA 100
Threaded shaft 22 x 1.5 x 240 mm 07931-ME4010B
Special nut 07931-HB3020A

Install the snap ring to the drive shaft.

10-20
 DRIVE PULLEY /DRIVEN PULLEY /CLUTCH

Hold the clutch outer with the special tool as shown. UNIVERSAL HOLDER

TOOL:
Universal holder 07725-0030000 or
07AMB-MCTA10 0
(U.S.A. only)

Install the clutch/driven pulley assembly and drive

belt to the drive shaft.

Install the washer and nut. WASHE~/NUT

Tighten the nut to the specified torque. '
TORQUE: 54 N•m (5.5 kgf•m, 40 lbf.ft)

Install the drive pulley (page 10-9).

Install the rear wheel (page 15-12).

10-21
FINAL REDUCTION

11-0
 11. FINAL REDUCTION
SERVICE INFORMATION 11-1 FINAL REDUCTION INSPECTION 11-4
TROUBLESHOOTING 11-2 BEARING REPLACEMENT 11-5
FINAL REDUCTION DISASSEMBLY 11-3 FINAL REDUCTION ASSEMBLY 11-8

SERVICE INFORMATION
GENERAL
• This section covers maintenance of the final reduction.
• These services can be done with the engine installed in the frame.
• When installing the drive shaft, be sure to use the special tool; position the special tool against the bearing inner race and
pull the drive shaft into the bearing .
• Refer to page 3-16 for final drive oil inspection and change.

SPECIFICATIONS

ITEM SPECIFICATIONS

Final reduction oil capacity I At draining 0.32 liter (0.34 US qt, 0.28 Imp qt)
I At disassembly 0.35 liter (0.37 US qt, 0.31 Imp qt)
Recommended final reduction oil Pro Honda GN4 4-stroke oil (U.S.A. and Canada) or
equivalent motor oil.
API service classification: SG or Higher.
JASO T903 standard: MA
1111
Viscosity: SAE 10W-30

TORQUE VALUES
Transmission cover bolt 25 N•m (2.5 kgf•m, 18 lbf•ft)

TOOLS
Remover weight 07741-0010201 or 07936-371020A or 07936-3710200 (U .S.A. only)
Attachment, 32 x 35 mm 07746-0010100
Attachment, 52 x 55 mm 07746-0010400
Attachment, 62 x 68 mm 07746-0010500
Pilot, 20 mm 07746-0040500
Pilot, 25 mm 077 46-0040600
Pilot, 30 mm 077 46-0040700
Pilot, 22 mm 07746-0041000
Driver 07749-0010000
Remover handle 07936-3710100
Bearing remover, 20 mm 07936-3710600
Bearing remover, 25 mm 07936-ZV10100 or 07936-ZV1A 100 (U.S.A. only)
Attachment, 28 x 30 mm 07946-1870100
Bearing driver attachment 0794 7-6340400
Pilot, 32 x 50 mm 07 MAD-PR90200
Un iversal bearing puller 07631-0010000 commercially available in U.S.A.
Remover handle 07936-3710100
Assembly shaft 07965-VM00200
Assembly collar 07YMF-KPB0100

11-1
FINAL REDUCTION

TROUBLESHOOTING
Engine starts but scooter won't move Oil leak
• Damaged transmission • Oil level too high
• Seized transmission • Worn or damaged oil seal
• Faulty drive and driven pulleys/clutch (Section 10) • Cracked crankcase

Abnormal noise
• Worn, seized or chipped gears
• Worn or damaged transmission bearing

11-2
 FINAL REDUCTION

FINAL REDUCTION DISASSEMBLV

TRANSMISSION DISASSEMBLV
Drain the final drive oil (page 3-16).
Remove the clutch/driven pulley assembly
(page 10-10).
Remove the rear wheel (page 15-4).

Remove the bolts and transmission cover.

Remove the dowel pins.

Remove the final gear shaft, countershaft and

thrust washers.

DRIVE SHAFT REMOVAL

Be careful not to Press the driveshaft out of the transmission cover.
damage the
transmission Check the drive shaft for wear or damage.
cover mating
surface.

11-3
FINAL REDUCTION

Remove the driveshaft oil seal, snap ring and bearing

from the transmission cover.

If the bearing is left on the driveshaft, remove it with

DRIVES HAFT BEARING
the special tool.

TOOL:
Universal bearing puller 07631-0010000
(Commercially
available in
U.S.A.)

UNIVERSAL BEARING PULLER

FINAL REDUCTION INSPECTION

Check the oil seal and bearings in the left swingarm
for wear or damage.

Check the bearings in the transmission cover for wear

or damage.

11-4
 FINAL REDUCTION

Check the countershaft, countershaft gear and final

FINAL GEAR SHAFT
gear shaft for wear or damage.

COUNTERSHAFT GEAR COUNTERSHAFT

BEARING REPLACEMENT

0-RING
COUNTERSHAFT BEARING

COUNTERSHAFT

OIL SEAL FINAL GEAR SHAFT BEARING

LEFT CRANKCASE
Be careful not to Remove the final gear shaft oil seal, snap ring and
damage the bearing.
left crankcase
mating surface.

11-5
FINAL REDUCTION

Remove the driveshaft bearing using the special tools.

TOOLS:
Remover weight 07741-0010201 or
07936-371020A or
07936-3710200
(U.S.A. only)
Remover handle 07936-3710100
Bearing remover, 17 mm 07936-3710600

Remove the countershaft bearing using the special

tools.

TOOLS:
Remover weight 07741-0010201 or
07936-371020A or
07936-3710200
(U.S.A. only)
Remover handle 07936-3710100
Bearing remover, 17 mm 07936-3710600

Apply engine oil to the needle rollers of a new

countershaft bearing.
Press the countershaft bearing into the left swingarm
using the special tools.

TOOLS:
Driver 07749-0010000
Attachment, 28 x 30 mm 07946-1870100
Pilot, 22 mm 077 46-0041000

Apply engine oil to the new bearings cavities.

Drive new bearings into the left swingarm.

Final gear shaft bearing:

TOOLS:
Driveshaft bearing:
Driver 07749-0010000
Attachment, 52 x 55 mm 077 46-0010400
Pilot, 20 mm 077 46-0040500

11-6
 FINAL REDUCTION

Final gear shaft bearing:

Driver 07749-0010000
Bearing driver attachment 07947-6340400
Pilot, 32 x 50 mm 07MAD-PR90200

Apply oil to a new final gear shaft oil seal lip and
outer surface.
Install the final gear shaft oil seal.

TOOLS:
Driver 07749-0010000
Attachment, 62 x 68 mm 077 46-0010500

..,.
TRANSMISSION COVER REMOVER SHAFT ASSEMBLY
~

Be careful not to Remove the final gear shaft bearing using the
damage the trans- special tools.
mission cover
mating TOOLS:
surface.
Remover weight 07741-0010201
Bearing remover, 25 mm 07936-ZV10100

U.S.A. only
Remover weight 07936-371020A or
07936-3710200
Bearing remover, 25 mm 07936-ZV1A100

Remove the countershaft bearing using the - - """'···

BEARING REMOVER
special tools.

TOOLS:
Remover weight 077 41-0010201
Bearing remover handle 07936-3710100
Bearing remover, 20 mm 07936-3710600

11-7
FINAL REDUCTION

Apply engine oil to the needle rollers of a new

countershaft bearing.
Press the countershaft bearing into the transmission
cover using the special tools.

TOOLS:
Driver 077 49-0010000
Attachment, 32 x 35 mm 07946-0010100
Pilot, 22 mm 077 46-0041000

Apply engine oil to the new bearing cavities.

Drive a new driveshaft bearing into the transmission
cover using the special tools.

TOOLS:
Driver 077 49-0010000
Attachment, 62 x 68 mm 07746-0010500
· Pilot, 30 mm 07746-0040700

Apply engine oil to new bearing cavities.

Drive new final gear shaft bearing into the transmis-
sion cover using the special tools. "~

TOOLS:
Driver 07749-0010000
Attachment, 62 x 68 mm 077 46-0010500
Pilot, 25 mm 077 46-0040600

FINAL REDUCTION ASSEMB LY DRIVES HAFT ASSEMBLY COLLAR

DRIVESHAFT INSTALLATI ON
Install the driveshaft into the transmission cover.
Position the assembly collar against the driveshaft
bearing inner race.
Thread the assembly shaft onto the driveshaft.
Hold the assembly shaft and draw the driveshaft into
the bearing inner race by turning the nut.

TOOLS:
Assembly shaft 07965-VM00200
Assembly collar ASSEMBLY SHAFT
07VMF-KPB0100

11-8
 FINAL REDUCTION

Using the special tools, install the driveshaft oil seal

until it is flush with the transmission cover surface.
-~ SNAPRING ASSEMBLY COLLAR
llllijjlll

TOOLS:
Assembly shaft 07965-VM00200
Assembly collar 07YMF-KPB0100

Apply oil to a new driveshaft oil seal lip and

outer surface.

Install the new snap ring. I

. .~· /M
llllijjlll . fll

OIL SEAL ASSEMBLY SHAFT

TRANSMISSION ASSEMBLY PLASTIC WASHER

Assemble the countershaft thrust washers as

shown in the following illustration.

STEEL WASHERS

Install the new snap ring and new oil seal.

Install the thrust washer on the left swingarm side of

the countershaft.

Install the countershaft and final gear shaft into the

left swingarm.
Install the thrust washers onto the countershaft.

11-9
FINAL REDUCTION

Clean the mating surfaces of the left swingarm and

transmission cover.
Apply sealant to the transmission cover mating sur-
face as shown.

Install the dowel pins.

Install the transmission cover and tighten the bolts in

a crisscross pattern in 2 - 3 steps.

Tighten the socket bolts to the specified torque.

TORQUE: 25 N•m (2.5 kgf•m, 18 lbf.ft)

Fill the transmission case with the recommended oil

(page 3-16).
Install the clutch/driven pulley assembly (page 10-20).
Install the rear wheel (page 15-12).

11-10
MEMO
AL TERNA TOR/ST ARTER CLUTCH

34 N•m (3.5 kgf•m, 25 lbMt)

12-0
 12. ALTERNATOR/STARTER CLUTCH
SERVICE INFORMATION 12-1 FLYWHEEL/STARTER CLUTCH/
CKP SENSOR 12-5
TROUBLESHOOT ING 12-1
ALTERNATOR STATOR 12-2

SERVICE INFORMATI ON
GENERAL
• This section covers maintenance of the starter reduction gear, alternator, cranksahft position (CKP) sensor, flywheel and
starter clutch.
• These services can be done with the engine installed in the frame .
• Refer to section 18 for alternator inspection, and to section 19 for CKP sensor inspection.

SPECIFICATIONS Unit: mm (in)

ITEM STANDARD SERVICE LIMIT

Starter driven gear Boss 0.D. 57.749 - 57.768 (2.2736 - 2.2743) 57.70 (2.272)
Bushing l.D. 29.046- 29.062 (1.1435- 1.1442) 29.10 (1.146)

Starter clutch outer l.D. 74.412 - 74.442 (2.9296 - 2.9308) 74.49 (2 .933)

TORQUE VALUES
Starter clutch socket bolt 29 N•m (3.0 kgf•m , 22 !bf.ft) Apply a locking agent to the threads.
CKP sensor socket bolt 12 N•m (1.2 kgf•m, 9 lbf•ft)
Flywheel bolt 103 N•m (10.5 kgf•m , 76 lbf•ft) UBS bolt.
Apply oil to the threads and seating surface.
Stator socket bolt 12 N•m (1.2 kgf•m, 9 lbf•ft)
Right swingarm torx bolt 34 N•m (3.5 kgf•m, 25 lbf•ft) Torx bolt.

TOOLS
Flywheel holder 07725-0040000 commercially available in U.S.A.
Flywheel puller 07733-0020001 or 07933-3950000 (U.S.A. only)

TROUBLESHOOTING
Starter motor turns, but engine does not turn
• Faulty starter clutch
• Damaged starter reduction gear

12-1
ALTERNATOR/STARTER CLUTCH

ALTERNATOR STATOR ALTERNATOR CONNECTOR

RIGHT CRANKCASE COVER REMOVAL

Drain the engine oil (page 3-11).

Disconnect the alternator 3P white connector and CKP

sensor 2P red connector, and free the wires from the
clamps.

Remove the rear brake hose/parking brake

wire clamps (page 7-4).

Remove the bolt and driveshaft holder cover.

Remove the torx bolts and right swingarm.

Remove the bolts and right crankcase cover.

12-2
 ALTERNA TOR/ST ARTER CLUTCH

Remove the dowel pins and 0-ring.

STATOR REMOVAL/INST ALLATION

REMOVAL
Remove the bolts and stator wire holder.
Remove the stator mount bolts, grommet and the sta-
tor from the left crankcase cover.

INSTALLATION
Install the stator and tighten the stator mount bolts to
the specified torque.

TORQUE: 12 N•m (1.2 kgf•m, 9 lbf.ft)

Apply sealant to the grommet seating surface and

install it to the cover groove properly.

Install the stator wire holder and tighten the bolts to

the specified torque.

TORQUE: 12 N•m (1.2 kgf•m, 9 lbf.ft)

RIGHT CRANKCASE COVER

INSTALLATION
Clean the mating surfaces of the right crankcase
and cover.
Apply sealant to the right crankcase cover mating sur-
face as shown.

12-3
ALTERNA TOR/ST ARTER CLUTCH

Install the dowel pins and 0-ring.

Install the right crankcase cover and tighten the bolts

in a crisscross pattern in 2 or 3 steps.

Install the right swingarm and tighten the torx bolts to

the specified torque.

TORQUE: 34 N•m (3.5 kgf•m, 25 lbf.ft)

Install the driveshaft holder cover.

Tighten the bolt.

Install the rear brake hose/parking brake wire clamps

(page 7-9).

12-4
 ALTERNATOR/ST ARTER CLUTCH

Route and clamp the alternator and CKP sensor wires ALTERNATOR CONNECTOR
properly (page 1-24). I
:0

Connect the alternator 3P white connector and CKP

sensor 2P red connector.

Fill the crankcase with the recommended engine oil

(page 3-11).

../\
,Y
CKP SENSOR CONNECTOR

FLYWHEEL/STARTER CLUTCH/
CKP SENSOR
REMOVAL
Remove the right crankcase cover (page 12-2).

Pull the reduction gear shaft out and remove the

reduction gear.
Pull the idle gear shaft out and remove the idle gear.

Hold the flywheel with the special tool and loosen the
flywheel nut.

TOOL:
Flywheel holder 07725-0040000
(Commercially
available in
U.S.A.)

When the CKP sensor rotor is ready to be removed,

loosen the CKP sensor rotor bolt.

Remove the flywheel nut and washer.

Remove the flywheel/starter driven gear assembly

using the special tool.

TOOL:
Flywheel puller 07733-0020001 or
07933-3950000
(U.S.A. only)

12-5
ALTERNATOR/S T ARTER CLUTCH

Remove the woodruff key and starter driven gear

from the crankshaft.

CKP SENSOR REMOVAL/INSTALLATION

Remove the socket bolts and CKP sensor from the
right crankcase.

Installation is in the reverse order of removal.

CKP SENSOR

L
TORQUE: 12 N•m (1.2 kgf•m, 9 lbf.ft)

4:!
/
BOLTS

DISASSEMBLY
Check the operation of the sprag clutch by turning the
driven gear.
You should be able to turn the driven gear clockwise
smoothly, but the gear should not turn counterclock-
wise.

Remove the starter driven gear by turning the

driven gear.

Hold the flywheel with the special tool and remove

the starter clutch outer bolts. BOLTS

TOOL:
Flywheel holder 07725-0040000
(Commercially
available in
U.S.A.)

12-6
 ALTERNATOR/ST ARTER CLUTCH

Remove the starter clutch outer and sprag clutch from FLYWHEEL
the flywheel.

STARTER CLUTCH OUTER/

SPRAG CLUTCH

INSPECTION DRIVEN GEAR

Check the starter driven gear teeth for wear

or damage.

Measure the starter driven gear boss O.D.

SERVICE LIMIT: 57.70 mm (2.272 in)

Measure the starter driven gear bushing l.D.

SERVICE LIMIT: 29.10 mm (1.146 in)

Check the starter clutch outer and sprag clutch for

abnormal wear or damage.

Measure the starter clutch outer l.D.

SERVICE LIMIT: 74.49 mm (2.933 in)

Check the starter reduction gear teeth, shaft and jour- IDLE GEAR
nal for wear or damage.
Check the starter idle gear teeth, shaft and journal for
wear or damage. /

REDUCTION GEAR
,____/
SHAFTS

12-7
ALTERNATOR/STARTER CLUTCH

ASSEMBLY

~
, SPRAG CLUTCH
~~

~'°um BOLTS
29 N•m (3.0 kgf•m, 22 lbfeft)

Apply oil to the sprag clutch outer surfaces.

SPRAG CLUTCH
Install the sprag clutch into the starter clutch outer
as shown.
~

STARTER CLUTCH OUTER

Install the starter clutch assembly on the flywheel.

FLYWHEEL

STARTER CLUTCH OUTER/

SPRAG CLUTCH

12-8
 ALTERNATOR/STARTER CLUTCH

Align the bolt holes on the starter clutch outer .

and flywheel.
C4u BOLTS

Apply locking agent to the starter clutch bolt threads

and install them.

Hold the flywheel with the special tool and tighten the
starter clutch outer bolts to the specified torque.

TOOL: .. ·
Flywheel holder 07725-0040000
(Commercially
available in
U.S.A.)

TORQUE: 29 N•m (3.0 kgf•m, 22 lbMt)

Apply molybdenum oil solution to the starter driven

gear bushing .
Install the starter driven gear by turning the driven
gear clockwise.

INSTALLATION
Clean any oil from the tapered portion of
the crankshaft.

Install the. woodruff key in the crankshaft key groove.

Clean any oil from the tapered portion of the

flywheel l.D ..

Install the flywheel onto the crankshaft, aligning the

key way with the woodruff key.

Apply oil to the washer and flywheel nut threads and

seating surface.
Install the washer and flywheel nut to the crankshaft.

Hold the flywheel with the special tool and tighten the
flywheel nut to the specified torque.

TOOL:
Flywheel holder 07725-0040000
(Commercially
available in U.S.A.)

TORQUE: 103 N•m (10.5 kgf•m, 76 lbMt)

12-9
ALTERNATO R/ST ARTER CLUTCH

Apply oil to the starter reduction gear, starter idle gear

and shafts.
Install the starter reduction gear, starter idle gear and
shafts to the right crankcase as assembly.

Install the right crankcase cover (page 12-3).

12-10
MEMO
CRANKCAS E/CRANKSH AFT/BALANCER

'02:

13-0
13. CRANKCASE/CRANKSHAFT/BALANCER
SERVICE INFORMATIO N 13-1 CRANKSHAF T/CONNECTI NG ROD 13-4

TROUBLESHOOTING 13-1 BALANCER SHAFT 13-9

CRANKCASE SEPARATION 13-2 CRANKCASE ASSEMBLY 13-12

SERVICE INFORMA TION

GENERAL
• This section covers the crankcase separation to service the crankshaft and balancer.
The following components must be removed before separating the crankcase.
- Oil pump (section 4)
- Water pump (section 6)
- Engine (section 7)
- Cylinder head (section 8)
- Cylinder, piston (section 9)
- Left swingarm (section 10)
- Flywheel, starter clutch (section 12)
- Starter motor (section 19)
• Be careful not to damage the crankcase mating surfaces when separating and assembling the crankcase halves.

SPECIFICATIONS Unit: mm (in)

ITEM STANDARD SERVICE LIMIT

Crankshaft Side clearance 0.15 - 0.30 (0.006 - 0.012) 0.40 (0.016)

Crank pin oil clearance 0.028 - 0.052 (0.0011 - 0.0020) 0.07 (0.003)

Main bearing oil clearance 0.025 - 0.041 (0.0010 - 0.0016) 0.07 (0.003) DI
TORQUE VALUES
Right crankcase sealing bolt (10 mm) 34 N•m (3.5 kgf•m, 25 lbf•ft) Apply a locking agent to the threads.
(18 mm) 44 N•m (4.5 kgf•m, 33 lbf•ft) Apply a locking agent to the threads.
Left crankcase sealing bolt 23 N•m (2.3 kgf•m, 17 lbf•ft) Apply a locking agent to the threads.
Connecting rod bearing cap nut 42 N•m (4.3 kgf•m, 31 lbf•ft) Apply oil to the threads and seating surface.

TOOLS
Remover weight 07741-0010201 or 07936-371020A or 07936-3710200 (U.S.A. only)
Attachment, 42 x 47 mm 07746-0010300
Pilot, 20 mm 07746-0040500
Driver 07749-0010000
Remover handle 07936-3710100
Bearing remover, 20 mm 07936-3710600
Crank assembly guide 07ZMG-MCT010 0 or 07ZMG-MCTA 100 (U.S.A. only)

TROUBLESHOOTING
Abnormal engine noise
• Worn connecting to small end
• Worn or damaged connecting rod big end bearing
. • Worn or damaged crankshaft bearings

13-1
CRANKC ASE/CR ANKSHA FT/BALAN CER

CRANKCASE SEPAR ATION

Remove the engine and main stand (section 7).
Remove the parts required for crankcase separation
(page 13-1).

Remove the bolts and engine under guard.

Loosen the bolts Remove the bolts from the right crankcase.
in a crisscross
pattern in
several steps.

Loosen the bolts Remove the bolts from the left crankcase.
in a crisscross BOLTS

~-
pattern in
several steps.

Install the special tool to the crankshaft.

TOOL:
Crank assembly guide 07ZMG-MC T0100 or
07ZMG-MC TA 100
(U.S.A. only)

~CRANK ASSEMBLY GUIDE

13-2
 CRANKCAS E/CRANKSH AFT /BALANCER

Place the crankcase assembly with the left side down

and separate the right crankcase from the left
crankcase.

• Separate the right crankcase from the left

crankcase while prying at the points as shown.
• Separate the right crankcase from the left
crankcase while tapping them at several locations
with a soft hammer.

Remove the dowel pins and 0-rings.

Clean the sealant from the left and right crankcase
mating surfaces.

Remove the balancer shafts from the left crankcase. BALANCER SHAFTS

Remove the crankshaft/conn ecting rod from the CRANKSHAFT/

left crankcase. CONNECTING ROD
~

13-3'
CRANKCA SE/CRAN KSHAFT /BALANCE R

Remove the oil seal from the left crankcase.

OIL SEAL

CRANKSHAFT /CONNE CTING ROD FEELER GAUGE

DISASSEM BLY
Inspect the connecting rod big end side clearance
before removing the connecting rod.
Measure the side clearance by inserting the feeler
gauge between the crankshaft and connecting rod big
end as shown.

STANDARD: 0.40 mm (0.016 in)

Tap the side of Remove the connecting rod bearing cap nuts, bearing
the cap lightly if cap and connecting rod.
the bearing cap is
hard to remove.

Mark the bearing caps, bearings and connecting rod

BEARINGS
as you remove them to indicate the correct cylinder
and position on the crank pins for reassembly.

Connecting rod small end inspection (page 9-5).

13-4
 CRANKCASE/CRANKSHAFT /BALANCER

Inspect the timing sprocket teeth and balancer drive BALANCER DRIVE GEAR
gear teeth for wear or damage.
Replace if necessary.

CONNECTIN G ROD BEARING

INSPECTION
Inspect the bearing inserts for unusual wear, damage
or peeling and replace if necessary.

CRANK PIN OIL CLEARANCE PLASTIGAUGE

Do not rotate the Clean off any oil from the connecting rod bearing
crankshaft during inserts and crank pin.
inspection. Put a strip of plastigauge on each crank pin, avoiding
the oil hole.

Apply oil engine to the connecting rod bearing cap NUTS

nut threads and seating surface.

~
Install the connecting rod bearing and bearing cap to
the original location.
Install and tighten the connecting rod bearing cap
nuts in a crisscross pattern in several steps.

TORQUE: 42 N•m (4.3 kgf•m, 31 lbf.ft)

13-5
CRANKCASE/CRANKSHAFT /BALANCER

Remove the connecting rod bearing cap nuts, bearing

cap and bearing.
Measure the compressed plastigauge at its widest
point on each crank pin to determine the oil clearance.

SERVICE LIMIT: 0.07 mm (0.003 in)

If the clearance exceeds the service limit, select the

correct replacement bearings as follows.

CONNECTIN G ROD BEARING

SELECTION
Determine the connecting rod l.D. number.
The code will be either a number 1 or 2 located on the
rod in the area shown.

Determine the corresponding crank pin O.D. code (or

measure the crank pin O.D.). The code will be either a CRANK PIN O.D. CODE
letter A or B on the crank weight.

Cross reference the crank pin and connecting rod

codes to determine the replacement bearing color.

Unit: mm (in)

~
Crank pin A B
O.D. code
42.982 - 42.990 42.974 - 42.981
Connecting rod
l.D. number

46.000 - 46.007
\ (1.6922 - 1.6925) (1.6919 - 1.6922)

c B
1
(1.8110 - 1.8113) (Yellow) (Green)
46.008 - 46.016 B A
2
(1.8113 - 1.8116) (Green) (Brown)

BEARING INSERT THICKNESS:

A (Brown): 1.500 - 1.504 mm (0.0591 - 0.0592 in)
B (Green): 1.496 - 1.499 mm (0.0589 - 0.0590 in)
C (Yellow): 1.492 - 1.495 mm (0.0587 - 0.0589 in)

13-6
 CRANKCASE/CRANKSHAFT /BALANCER

CRANKSHAFT /CRANKCASE MAIN JOURNAL O.D. CODE NUMBER ·

SELECTION
Crankcase and crankshaft are select fitted.

Record the main journal O.D. code number (1 or 2).

Record the main journal bearing l.D. code

(A or Nothing).

If the crankcase and/or crankshaft are replaced, select

them with the following fitting table.

The "O" mark in the table indicates that mating is l.D. CODE
possible in the crossed codes.

I\ Main journal
O.D. code

Main journal \
1 2

bearing l.D. code

A 0 0
Nothing 0

-----------
MAIN BEARING INSPECTION
Inspect the bearing inserts for unusual wear, damage
or peeling and replace the crankcase if necessary.

MAIN BEARING OIL CLEARANCE JOURNALS

Clean off any oil from the main bearing inserts and
crankshaft journals.

13-7
CRANKCASE/CRANKSHAFT /BALANCER

Measure and record the crankshaft main journal O.D ..

Measure and record the main bearing l.D ..

Calculate the oil clearance by subtracting the journal

O.D. from bearing l.D ..

STANDARD: 0.025- 0.041 mm (0.0010- 0.0016 mm)

SERVICE LIMIT: 0.07 mm (0.003 in)

Replace the crankcase if the service limit is exceeded.

Select the replacement crankcase (page 13-7).

Be sure that ASSEMBLY

each part is
installed in its
Clean off any oil from the main bearing inserts and
original position.
connecting rod bearing cap.
Apply molybdenum disulfide oil to the bearings.
Install the main bearing to the connecting rod and
bearing cap aligning the tab on the bearing with the
groove on the connecting rod and bearing cap.

BEARINGS

Install the connecting rods with its oil holes facing

intake side as shown.

INTAKE SIDE . . .

13-8
 CRANKCASE/CRANKSHAFT/BALANCER

Align the l.D. Install the bearing caps on the crank pin. BEARINGS
code on the bear-
ing cap and
connecting rod.

Apply oil to the connecting rod bearing cap bolt/nut -"7M

threads and flange surface. · ii
Install and tighten the connecting rod bearing cap
nuts to the specified torque in several steps.

TORQUE: 42 N•m (4.3 kgf•m, 31 lbf.ft)

BALANCER SHAFT SNAP RING

BALANCER SHAFT SUB-GEAR

REMOVAL
Remove the snap ring.

Remove the balancer shaft sub-gear and springs.

SUB-GEAR

;:y
SPRINGS

13-9
CRANKCASE/CRANKSHAFT /BALANCER

BALANCER SHAFT SUB-GEAR

INSTALLATION
Apply molybdenum disulfide oil to the balancer shaft
gear-to-balancer shaft sub-gear sliding surface.

BALANCER SHAFT GEAR SUB-GEAR

Install the springs into the balancer shaft gear.

ALIGN BALANCER SHAFT GEAR
Assemble the balancer shaft gear and sub-gear
as shown.

SPRINGS SUB-GEAR

Install the washer and snap ring.

SNAP RING

BALANCER SHAFT BEARING

REPLACEMENT
Remove the crankshaft and balancer shaft
(page 13-3).

Turn the inner race of each bearing with your finger.

The bearings should turn smoothly and quietly. Also
check that the bearing outer race fits tightly in the
crankcase.

Replace the bearings if the races does not turn

smoothly and quietly, or if they fit loosely in
the crankcase.

13-10
 CRANKCASE/CRANKSHAFT/BALANCER

Remove the balancer shaft bearings from the right

crankcase. BALANCER SHAFT BEARINGS

Remove the balancer shaft bearings from the left

crankcase using the special tools.

TOOLS:
Remover weight 07741-0010201 or
07936-371020A or
07936-3710200
(U.S.A. only)
Remover handie 07936-3710100
Bearing remover, 20 mm 07936-3710600

Install the new bearings to the right crankcase using

the special tools.

TOOLS:
Driver 077 49-010000
Attachment, 42 x 47 mm 077 46-0010300
Pilot, 20 mm 077 46-0040500

Install the new bearings to the left crankcase using the

special tools.

TOOLS:
Driver 077 49-010000
Attachment, 42 x 47 mm 077 46-0010300
Pilot, 20 mm 077 46-0040500

13-11
CRANKCASE/CR ANKSHAFT /BALANCER

CRANKCASE ASSEMBLY TO CYLINDER

Install the crankshaft/connecting rod to the left

crankcase with the "!)." mark on the crankshaft facing
t
the cylinder side.

"!)."MARK

Turn the balancer shaft sub-gear clockwise and align

6 mm SOCKET BOLT
the teeth on the sub-gear and balancer shaft gear.
Install the suitable 6 mm socket bolt into the bolt
holes on the gears, then tighten the bolt temporally.

SUB-GEAR

Install the balancer shaft A to align the "O" mark with

CRANKSHAFT
the punch mark on the crankshaft. TO CYLINDER
Install the balancer shaft B to align the index line with
the index line on the crankshaft.

BALANCER SHAFT B BALANCER SHAFT A

Clean the right and left crankcase mating surface thor-

DOWEL PINS
oughly, being careful not to damage them.

Install the dowel pins and 0 -rings.

13-12
 CRANKCASE/CRANKSHAFT /BALANCER

Apply a light but through coating of sealant to all

crankcase mating surfaces except the oil
passage area.

Install the special tool to the crankshaft. CRANKSHAFT

TOOL:
Crank assembly guide 07ZMG-MCT0100 or
07ZMG-MCTA 100
(U.S.A. only)

~CRANK ASSEMBLY GUIDE

Install the right crankcase over the left crankcase.

Remove the special tool.

Install the right crankcase bolts and tighten them in a

crisscross pattern in 2 - 3 steps.
Remove the 6 mm socket bolts.

13-13
CRANKCASE/CRANKSH AFT /BALANCER

Install the left crankcase bolts and tighten them in a

crisscross pattern in 2 - 3 steps.

Make sure that the crankshaft turns smoothly.

Apply oil to a new crankshaft oil seal lip and

outer surface.
Install the crankshaft oil seal until it is flush with the
crankcase surface.

Install the engine under guard and tighten the

bolts.

Install the removed parts in the reverse order

of removal.

13-14
MEMO
FRONT WHEEL/SUSPENSION/STEERING

STD TYPE:

22 N•m (2.2 kgf•m,

16 lbMt)

AFTER '02 (ABS TYPE):

59 N•m (6.0 kgf•m, 43 lbMt)

14-0
14. FRONT WHEEL/SUSPENSION/STEERING
SERVICE INFORMATIO N 14-1 FORK 14-8

TROUBLESHOOTING 14-2 STEERING HANDLE 14-18

FRONT WHEEL 14-3 STEERING STEM 14-26

SERVICE INFORMA TION

GENERAL
• A contaminated brake disc or pad reduces stopping power. Discard contaminated parts and clean a contaminated disc
with a high quality brake degreasing agent.
• This section covers the front wheel, fork, handlebar, and steering.
• A jack or other support is required to support the vehicle.
• Do not twist or bend the brake hose and pipe when servicing.
• Use genuine Honda replacement bolts and nuts for all suspension pivots and mounting points.
• Refer to section 16 for brake system information.

SPECIFICATIONS Unit: mm (in)

ITEM STANDARD SERVICE LIMIT

Minimum tire tread depth - 1.5 (0.06)

Cold tire pressure Up to 90 kg (200 lb) load 200 kPa (2.00 kgf/cm 2
, 29 psi) -
Up to maximum weight capacity 200 kPa (2.00 kgf/cm 2
, 29 psi) -
Axle runout - 0.20 (0.008)

Wheel rim runout Radial - 2.0 (0.08)

Axial - 2.0 (0.08)

Wheel balance weight

Fork Spring free length
Tube runout
331.4 ( 13.05)
-

-
60 g (2.1 oz) max.
325 (12.8)
0.20 (0.008)
m
Recommended fork fluid Pro Honda Suspension Fluid SS-8 -
Fluid level 97 (3.8) -
Fluid capacity 302 ± 2.5 ± 0.08 US oz,
cm 3 ( 10.2 -
10.6 ± 0.09 Imp oz)
Steering head bearing pre-load 13 - 17 N (1.3 - 1.7 kgf, 2.9 - 3.7 lbf) -

TORQUE VALUES
Handle post pinch bolt (upper) 128 N•m (13.0 kgf•m, 94 lbMt)
Handle past pinch bolt (lower) 69 N•m (7.0 kgf•m, 51 lbMt)
Steering stem nut 74 N•m (7.5 kgf•m, 54 lbMt) See page 14-30
Steering top thread 13 N•m (1.3 kgf•m, 9 lbMt)
Steering stem pinch bolt 69 N•m (7.0 kgf•m, 51 lbMt)
Front axle bolt 59 N•m (6.0 kgf•m , 43 lbMt)
Front fork axle holder bolt 22 N•m (2.2 kgf•m, 16 lbMt)
Front fork cap 23 N•m (2.3 kgf•m, 17 lbMt)
Front fork socket bolt 29 N•m (3.0 kgf•m, 22 lbMt) Apply a locking agent to the threads.
Front brake disc bolt 42 N•m (4.3 kgf•m, 31 lbMt) ALOC bolt: replace with a new one.
Handlebar lower holder nut 39 N•m (4.0 kgf•m, 29 lbMt)

14-1
 FRONT WHEEL/S USPENSIO N/STEERI NG

TOOLS
Adjustable pin spanner 07702-0020001
Remover weight 07741-0010201 or 07936-371020A or 07936-3710200 (U.S.A. only)
Attachment, 42 x 47 mm 077 46-0010300
Attachment, 52 x 55 mm 07746-0010400
Attachment, 40 x 42 mm 077 46-0010900
Attachment, 30 mm 077 46-0030300
Pilot, 20 mm 077 46-0040500
Bearing remover shaft 07746-0050100
Bearing remover head, 20 mm 077 46-0050600
Driver 07749-0010000
Lock nut wrench 07916-KM 10000
Slider weight 07947-KA50100
Fork seal driver attachment, 41 mm 0794 7-KF00100
Ball race remover 07953-4250002 or 07953-MJ 1000B (U.S.A. only)
Bearing remover shaft 07 JAC-PH80200 not available in U.S.A.
Adjustable bearing remover 07YAC-0010101 not available in U.S.A.
Slide hammer 3/8 x 16 commercially available in U.S.A.
Adjustable bearing puller 25 - 40 mm 07736-A01000B

TROUBLESHOOTING
Hard steering Wheel turns hard
Steering stem top thread too tight • Faulty front wheel bearings
Worn or damaged steering bearings • Bent front axle
Worn or damaged steering bearing races • Brake drug (section 16)
Bent steering stem
Insufficient tire pressure Soft suspension
Faulty front tire • Weak fork spring
• Insufficient fluid in fork
Steers to one side or does not track straight • Deteriorated fork fluid
• Damaged or loose steering bearings • Incorrect fork fluid weight
• Bent fork • Low tire pressure
• Bent front axle: wheel installed incorrectly
• Bent frame Hard suspension
• Faulty front tire • Bent fork tube
• Worn or damaged front wheel bearings • Too much fluid in fork
• Worn or damaged engine mounting bushings (section 7) • Incorrect fork fluid weight
• Clogged fork fluid passage
Front wheel wobbling • High tire pressure
• Bent rim
• Worn or damaged front wheel bearings Front suspension noise
• Faulty front tire • Worn slider or fork tube bushing
• Loose front axle fasteners • Insufficient fluid in fork
• Loose fork fasteners

14-2
 FRONT WHEEL/SUSPENSION/STEERING

FRONT WHEEL
REMOVAL
Loosen the right and left front axle holder bolts.

Loosen the front axle bolt.

Support the scooter using a hoist or equivalent and

raise the front wheel off the ground.

Remove the front axle bolt.

Do not operate Pull the front axle out and remove the front wheel.
the front and rear
brake lever after
removing the
front wheel.

Remove the right and left side collar from the

wheel hub.

14-3
FRONT WHEEL/S USPENSIO N/STEERI NG

INSPECTION
AXLE
Place the axle in V-blocks and measure the runout.
Actual runout is 1/2 the total indicator reading.

SERVICE LIMIT: 0.20 mm (0.008 in)

WHEEL
Check the rim runout by placing the wheel in a
turning stand.
Spin the wheel slowly and read the runout using a
dial indicator.
Actual runout is 1/2 the total indicator reading.

SERVICE LIMITS: Radial: 2.0 mm (0.08 in)

Axial: 2.0 mm (0.08 in)

WHEEL BEARING
Turn the inner race of each bearing with your finger.
The bearings should turn smoothly and quietly. Also
check that the bearing outer race fits tightly in
the hub.

Replace the Remove and discard the bearings if the races do not
w heel bearings turn smoothly, quietly, or if they fit loosely in the hub.
in pairs.

DISASSEMBLY
Remove the brake disc bolts and brake disc.

Check the brake disc for wear or damage, replace if

necessary.
AFTER '02 (A BS Remove the pulser ring bolts and pulser ring.
TYPE):
Check the pulser ring for clacks or damage, replace if
necessary.

14-4
 FRONT WHEEL/SUSPENSION/STEERING

Remove the dust seals.

Replace the Install the bearing remover head into the bearing.
wheel bearings From the opposite side, install the bearing remover
in pairs. shaft and drive the bearing out of the wheel hub.
Do not reuse Remove the distance collar and drive out the
old bearings.
other bearing .

TOOLS:
Bearing remover shaft 077 46-0050100
Bearing remover head, 20 mm 077 46-0050600

ASSEMBLY
STD TYPE: AFTER '02 (ABS TYPE):

.... ~ s ~ ,,.---~

0
-=:eTimli
fl - ~
lllilliijjlll -
DUST SEAL LEFT BEARING

RIGHT BEARING

/ .
~

BRAKE DISC BOLT

s~
PULSER RING BOLT
42 N•m (4.3 kgf•m, 31 lbf•ft) 8 N•m (0.8 kgf•m, 5.8 lbf•ft)

14-5
FRONT WHEEL/SUSPENSION/STEERING

Pack the new bearing cavities with grease.

Drive the new left bearing squarely with the sealed
side facing up until it is fully seated.

TOOLS:
Driver 077 49-0010000
Attachment, 40 x 42 mm 077 46-0010900
Pilot, 20 mm 077 46-0040500

Install the distance collar.

Drive a new right bearing squarely with the sealed

side facing up until it is fully seated.

TOOLS:
Driver 07749-0010000
Attachment, 40 x 42 mm 07746-0010900
Pilot, 20 mm 077 46-0040500

Apply grease to the new dust seal lips.

Install the dust seals into the wheel hub until there are
flush with the wheel hubs.

Install the brake disc onto the wheel hub with the
marked side facing out.
Install new disc bolts and tighten them to the
specified torque.

TORQUE: 42 N•m (4.3 kgf•m, 31 lbfoft)

A FTER '02 (ABS Install the pulser ring onto the wheel hub.
TYPE): Install the new pulser ring bolts and tighten them to
the specified torque.

TORQUE: 8 N•m (0.8 kgf•m, 5.8 lbfoft)

14-6
 FRONT WHEEL/SUSPENSION/STEERING

INSTALLATION
Install the side collars into the wheel hub.

Be careful not to Install the front wheel between the fork leg while
damage the inserting the disc between the pads.
brake pads. Install the front axle from the right side.

Hold the axle and tighten the axle bolt to the

specified torque.

TORQUE: 59 N•m (6.0 kgf•m, 43 lbf.ft)

Tighten the left axle holder bolt to the

specified torque.

TORQUE: 22 N•m (2.2 kgf•m, 16 lbf.ft)

With the front brake applied, pump the fork up and

down several times to seat the axle and check
brake operation.

Check the brake operation by applying the brake lever.

14-7
FRONT WHEEL/SUSPENSION/STEERING

Tighten the right axle holder bolt to the

specified torque.

TORQUE: 22 N•m (2.2 kgf•m, 16 lbf.ft)

FORK BOLTS/WASHERS/STAYS
"'
II
11

REMOVAL
Remove the following:
- Front wheel (page 14-3)
- Nuts and both reflectors
- Front side two bolts, washers and reflector stays
- Rear side two bolts and front fender

Remove the bolt and brake hose clamp.

Support the brake Remove the mount bolts and front brake caliper from
caliper so that it the fork leg.
does not hang
from the
brake hose.
Do not twist the
brake hose.

Remove the upper fork pinch bolt.

FORK CAP UPPER PINCH BOLT
When the fork is ready to be disassembled, loosen the
fork cap, but do not remove it.
Loosen the lower fork pinch bolt and remove the fork
tube from the steering stem.

14-8
 FRONT WHEEL/SUSPENSION/STEERING

DISASSEMBLY FORK CAP

Remove the fork cap and 0-ring from the fork tube.
/
The fork cap is under spring pressure. Use care when
removing it and wear eye and face protection.

\.
a°-RING

Remove the spring spacer from the fork tube.

SPACER

Remove the spring seat from the fork tube.

SPRING SEAT

Remove the fork spring from the fork tube.

14-9
FRONT WHEEL/SUSPENSION/STEERING

Pour the fork oil from the fork leg by pumping the fork
8 - 10 times.

Do not over Hold the axle holder in a vise with a piece of wood or
tighten the soft jaws to avoid damage.
fork slider.
Loosen and remove the fork socket bolt and sealing
washer from the bottom case.

If the fork piston turns with the socket bolt, temporar-

ily install the fork spring, spring seat, spring spacer
and fork cap.

Do not remove Remove the fork piston and rebound spring.

FORK PISTON
the fork piston
ring, unless it is
necessary to
replace with a
new one.

Remove the dust seal from the bottom case.

DUST SEAL

14-10
 FRONT WHEEL/SUSPENSION/STEERING

Do n.ot s_cratch . Remove the stopper ring from the groove on STOPPER RING
the fork tube the bottom case.
sliding surface.

Check that the fork tube moves smoothly in the bot-

tom case. If does not, check the fork tube for bending
or damage, and bushings for wear or damage.

Using quick successive motions, pull the fork tube out

of the bottom case.

Remove the oil lock piece from the bottom case.

OIL LOCK PIECE

BOTIOM CASE

Remove the oil seal, back-up ring and slider bushing

OIL SEAL SLIDER BUSHING
from the fork tube.

I
BACK-UP RING

14-11
FRONT WHEEL/SUSPENSION/STEERING

Do not remove Carefully remove the fork tube bushing by prying the
the fark tube slot with a screwdriver until the bushing can be pulled
bushing unless it off by hand.
is necessary to
replace it with a
new one.

INSPECTION
FORK SPRING
Measure the fork spring free length.

SERVICE LIMIT: 325 mm (12.8 in)

FORK TUBE/BOTIOM CASE

FORK TUBE
Check the fork tube and bottom case for score marks
and excessive or abnormal wear.

Replace the component if necessary. I

·\....

Set the fork tube in V-blocks and measure the fork

tube runout with a dial indicator reading.

SERVICE LIMIT: 0.20 mm (0.008 in)

14-12
 FRONT WHEEL/SUSPENSION/STEERING

FORK PISTON FORK PISTON

Check the fork piston for score marks and excessive or

I
abnormal wear.

Check the rebound spring for fatigue or damage.

If the fork piston is removed, replace with a new one.

REBOUND SPRING

FORK TUBE BUSHING

Visually inspect the slider and fork tube bushings.
Replace the bushings if there is excessive scoring or
BUSHING
scratching, or if the teflon is worn so that the copper
surface appears on more 3/4 of the entire surface. BACK-UP RING

v
Check the back-up ring; replace it if there is any dis-
tortion at the point shown.

ASSEMBLY
CHECK POINTS
Before assembly, wash all parts with a high flash
point or non-flammable solvent and wipe them off
completely. COPPER SURFACES

. . DUST SEAL FORK PISTON

~J
STOPPER RING ~FORKCAP
-=-
~~ ....
....... OIL SEAL
- ~
,. -.:::s::::!3 n
~
~ ~~
.... .. 0-RING

BACK-UPR~ ~PACER
FORK TUBE BUSHING SPRING SEAT

FORK SPRING
BOTTOM CASE

~ u
~ SLIDER BUSHING flt
OIL LOCK PIECE

14-13
FRONT WHEEL/SUSPENSION/STEERING

Be careful not to Remove the burrs from the bushing mating surface,
damage the FORK TUBE BUSHING
being careful not to peel off the coating.
fork tube
bushing coating. Install a new fork tube bushing if the tube bushing has
Do not open been removed.
the fork tube
bushing more
than necessary.

Install the slider bushing and back-up ring to the

. . OILSEAL SLIDER BUSHING
fork tube.

I
Apply fork oil to the new oil seal lip.
Install the new oil seal to the fork tube with its mark-
ing side facing up.

BACK-UP RING

Install the oil lock piece onto the fork piston end.
OIL LOCK PIECE
Coat the fork tube bushing with the fork oil and install
the fork into the bottom case.

BOTTOM CASE

Install the rebound spring to the fork piston.

FORK TUBE FORK PISTON
Install the fork piston/rebound spring into the fork
tube.

REBOUND SPRING

14-14
 FRONT WHEEL/SUSPENSION/STEERING

Apply locking agent to the socket bolt threads. SOCKET BOLT

Install the socket bolt with a new sealing washer into
the fork piston.

~~
lllliiijlll SEALING WASHER

Do not over Hold the bottom case in a vise with a soft jaws or
tighten the shop towel.
fork slider.
Tighten the fork socket bolt to the specified torque.

TORQUE: 29 N•m (3.0 kgf•m, 22 lbf.ft)

If the fork piston turns with the socket bolt, temporar-

ily install the fork spring, spring seat, spring spacer
and fork cap.

Drive the new oil seal in the fork tube until the stop DUST SEAL
ring groove is visible, using the special tools.
STOPPER
TOOLS: RING
Slider weight 07947-KA50100
Fork seal driver attachment, 41 mm
07947-KF00100

SLIDER BUSHING

Install the stopper ring in the groove in the bottom STOPPER RING
case.

14-15
FRONT WHEEL/SUSPENSION/STEERING

Coat a dust seal lip with fork fluid and install it into the
. . DUSTSEAL
bottom case.

Pour the specified amount of recommended fork fluid

in the fo rk tube.

RECOMMENDED FLUID: Pro Honda Suspension

Fluid SS-8
FORK FLUID CAPACITY:
302 ~ 2.5 cm 3 (10.2 ~ 0.08 US oz, 10.6 ~ 0.09 Imp oz) SPECIFIED
LEVEL
Slowly pump the fork tube several times to remove
trapped air.
Compress the fork tube fully and measure the oil level
from the top of the fork tube.

OIL LEVEL: 97 mm (3.8 in)

Pull the fork tube up fully.

Install the fork spring with the tightly wound end
facing up.

..
FACING
UP

Install the spring seat.

SPRING SEAT

14-16
 FRONT WHEEL/SUSPENSION/STEERING

Install the spring spacer. SPACER

Tighten the fork

cap after installing
the fork tube in
Apply fork oil to a new 0-ring and install it on
the fork cap.
Install the fork cap in the fork tube.
~~
~ ....
...... 0-RING

the fork bridge.

INSTALLATION
Install the fork in the steering stem and align the
groove of the fork tube with the upper bolt hole in the
stem, then install the upper pinch bolt. FORK CAP UPPER PINCH BOLT
Align the index line on the fork tube with the upper
surface of the steering stem .

Tighten the steering stem lower pinch bolt to the

specified torque.

TORQUE: 69 N•m (7.0 kgf•m, 51 lbf.ft)

Tighten the fork cap to the specified torque.

TORQUE: 23 N•m (2.3 kgf•m, 17 lbf.ft)

Tighten the steering stem upper pinch bolt to the

specified torque.

TORQUE: 69 N•m (7.0 kgf•m, 51 lbf.ft)

Tighten the steering stem lower pinch bolt to the

specified torque.

TORQUE: 69 N•m (7 .0 kgf•m, 51 lbf.ft)

Install the brake caliper onto the fork leg with new
mount bolts.

TORQUE: 30 N•m (3.1 kgf•m, 2.2 lbf.ft)

Install the brake hose clamp on the fork leg with

the bolt.

14-17
FRONT WHEEL/SUSPENSION/STEERING

Install the following to fork leg:

BOLTS/WASHERS/STAYS
- Rear side two bolts and front fender ,.'
- Reflector stays, washers and front side two bolts II
II
I I
- Nuts and both reflectors f-...1

- Front wheel (page 14-7)

FRONT FENDER

STEERING HANDLE
REMOVAL
Remove the front cover (page 2-14).
Remove the handlebar cover (page 2-14).

Disconnect the ignition switch 3P connector.

Remove the right and left rearview mirrors.

REARVIEW MIR~

Disconnect the front brake light switch connectors.

14-18
 FRONT WHEEL/SUSPENSION/STEERING

Keep the master Remove the bolts, master cylinder holder and front MASTER CYLINDER
master cylinder.
cylinder upright to
prevent air from
entering the
I
hydraulic system.

Disconnect the rear brake light switch connectors and

limit switch connectors.

Keep the master Remove the bolts, master cylinder holder and rear
cylinder upright to master cylinder.
prevent air from
entering the
hydraulic system.

Remove the screws and left handlebar SWITCH HOUSING

switch housing.

SCREWS

14-19
FRONT WHEEL/SUSPENSION/STEERING

Hold the handlebar weight and remove the screw and

SCREW
the left handlebar weight.

HANDLEBAR WEIGHT

Remove the left handlebar grip from the

steering handle.
Remove the left handlebar switch housing end.

Hold the handlebar weight and remove the screw and

SCREW
the right handlebar weight.

Remove the screws and right handlebar

switch housing.

14-20
 FRONT WHEEL/SUSPENSION/STEERING

Remove the bolts and handlebar cover stay.

Remove the bolts and the upper holders.

Remove the handlebar.

Remove the throttle grip/right handlebar switch hous- SWITCH HOUSING THROTILE CABLES
ing from the handlebar.

Disconnect the throttle cables end from the

throttle grip.

t
THROTILE GRIP

Remove the handlebar post pinch bolt.

Remove the handlebar post from the steering stem .

BOLTS HANDLEBAR POST

Remove the nuts and handlebar lower holders from LOWER HOLDERS
the handlebar post.

INSTALLA Tl ON
• Route the cables and wires properly (page 1-20).

Install the handlebar lower holder to the handlebar

post.
riiJ
I

Install the handlebar temporarily (page 14-22).

Tighten the handlebar lower holder nuts to the speci-
fied torque.

TORQUE: 39 N•m (4.0 kgf•m, 29 lbf.ft) NUTS

14-21
FRONT WHEEL/SUSPENSION/STEERING

Install the handlebar post over the steering stem,

aligning the pin on the handlebar post with the ALIGN
groove on the stem.
Install the pinch bolt, aligning the bolt hole with the
groove in the stem.
Tighten the upper Tighten the handlebar post pinch bolt to the specified
bolt first, then torque.
thighten the lower
bolt. PINCH BOLT UPPER
TORQUE: 128 N•m (13.0 kgf•m, 94 lbf.ft)

PINCH BOLT LOWER

TORQUE: 69 N•m (7 .0 kgf•m, 51 lbf.ft)
BOLT HANDLEBAR POST

Install the handlebar to the handle post.

Install the upper holders with its punch marks

facing forward.
Align the punch mark on the handlebar with the cut
out on the upper holder.
Install the upper holder bolts.
Tighten the front bolts first, then tighten the rear
bolts.

Install the handlebar cover stay and tighten the bolts.

Apply grease to the throttle grip flange groove, throt-

SWITCH HOUSING
tle grip inner surface and throttle cable end.

Install the throttle grip to the right handlebar

switch housing.
Connect the throttle cables to the throttle grip.

Install the right handlebar switch housing/throttle grip

to the handlebar.

I
THROTTLE GRIP

Align the pin on the right handlebar switch housing

with the hole on the steering handle.

14-22
 FRONT WHEEL/SUSPENSION/STEERING

Install the screws and tighten the forward screw first, SWITCH HOUSING
then tighten the rear screw.
_/

Install the right handlebar weight to the

steering handle.
cw SCREW

Clean and apply a locking agent to the screw threads.

Install and tighten the screw.

HANDLEBAR WEIGHT

Install the left handlebar switch housing end onto the LEFT HANDLEBAR GRIP
steering handle.

Allow the adhe-

sive to drv for an
hour before using.
Apply Honda Bond A or, Honda Hand Grip Cement
(U.S.A. only)or equivalent to the inside surface of the
handlebar grip and to the clean surface of the steering
handle. Wait 3 - 5 minutes and install the grip.
Rotate the grip for even application of the adhesive.
I
SWITCH HOUSING END

Install the left handlebar weight to the

steering handle.
cw SCREW

Clean and apply a locking agent to the screw threads.

Install and tighten the screw.

14-23
FRONT WHEEL/SUSPENSION/STEERING

Align the pin on the left handlebar switch housing

with the hole on the steering handle.
Install the the left handlebar switch housing to the
steering handle by aligning it with the groove on the
left handlebar switch housing end.

Install the screws and tighten the forward screw first,

SWITCH HOUSING
then tighten the rear screw.

SCREWS

Install the rear master cylinder and holder with the

PUNCH MARK
"UP" mark facing up.
Align the end of the master cylinder with the punch
mark on the handlebar and tighten the upper bolt
first, then tighten the lower bolt to the specified
torque.

TORQUE: 12 N•m (1.2 kgf•m, 9 lbf.ft)

Connect the rear brake light switch connectors and

limit switch connectors.

14-24
 FRONT WHEEL/SUSPENSION/STEERING

Install the front master cylinder and holder with the MASTER CYLINDER
PUNCH MARK
"UP" mark facing up.
Align the end of the master cylinder with the punch
mark on the handlebar and tighten the upper bolt
I
first, then tighten the lower bolt to the specified
torque.

TORQUE: 12 N•m (1.2 kgf•m, 9 lbf.ft)

Connect the front brake light switch connector.

Install the right and left rearview mirrors.

Connect the ignition switch 3P connector.

Install the handlebar cover (page 2-14).

Install the front cover (page 2-14).

14-25
FRONT WHEEL/SUSPENSION/STEERING

STEERING STEM
REMOVAL
Remove the following:
- Front cover (page 2-14)
- Steering handle (page 14-18)
- Front airduct cover (page 2-21)
- Fork (page 14-8)

AFTER '02 (ABS Remove the bolt and brake hose/front wheel sensor
TYPE) : wire clamp from the steering stem.

Remove the handle post seal from the steering stem.

HANDLE POST SEAL

AFTER '02 (A BS Remove the front cover stay mount bolts and move
TYPE): the front cover stay assembly forward.

Hold the steering stem top thread using the pin span-
ner and remove the steering stem lock nut.

TOOLS:
Adjustable pin spanner 07702-0020001
Lock nut wrench 07916-KM10000

Remove the lock washer.

Loosen the steering stem top thread using the
pin spanner.

TOOL:
Adjustable pin spanner 07702-0020001

Hold the steering stem and remove the steering stem

top thread.

14-26
 FRONT WHEEL/SUSPENSION/STEERING

Remove the dust seal, upper inner race and

upper bearing.

Remove the steering stem and lower bearing. LOWER BEARING

STEERING STEM

BEARING REPLACEMENT
Always replace Remove the upper bearing outer race.
the bearings and
races as a set. TOOL:
Ball race remover 07953-4250002 or
07953-MJ 1OOOB
(U.S.A. only)

BALL RACE REMOVER

Remove the lower bearing outer race .

BEARING REMOVER
TOOLS:
Remover weight 07741-0010201 or
07936-371020A or
07936-3710200
(U.S.A. only)
Bearing remover shaft 07 JAC-PH80200
Adjustable bearing remover 07VAC-0010101

U.S.A. only
Slider hammer 3/8 x 16 commercially
available in U.S.A.
Adjustable bearing puller 25 - 40 mm
07736-A01 OOOB

14-27
FRONT WHEEL/SUSPENSION/STEERING

Drive a new lower bearing race into the steering

ATIACHMENT LOWER OUTER
head pipe.
RACE~~
lilljjjjjillll
TOOLS:
Driver 077 49-0010000
Attachment, 52 x 55 mm 07746-0010400

Drive a new upper bearing race into the steering

head pipe.

TOOLS:
Driver 07749-0010000
Attachment, 42 x 47 mm 07746-0010300

Install the steering stem lock nut onto the steering

LOWER INNER RACE
stem to prevent the threads from being damaged
when removing the lower bearing inner race from the
steering stem.

Remove the lower bearing inner race with a chisel or

equivalent tool, being careful not to damage the
steering stem.

Remove the dust seal.

Apply grease to a new lower bearing inner race using

a hydraulic press.

TOOL:
Attachment, 30 mm 077 46-0030300

14-28
 FRONT WHEEL/SUSPENSION/STEERING

INSTALLATION
-~
lllllijjjillll
LOCK NUT ............. ~HANDLE POST SEAL
74 N•m (7.5 kgf•m, 54 lbMt) ~ -

TOP THREAD ~:...----LOCK WASHER

13 N•m (1.3 kgf•m, 9 lbMt) ~ -~
rs lllllijjjillll

~~....._____ UPPER INNER RACE

s - ,,.---_
UPPER BEARING
~
---!l'ffiIJiDi

STEERING STEM

Apply urea based water resistant grease with extreme

LOWER BEARING
pressure agent (example:EXCELITE EP2 manufac-
tured by KYODO YUSHI, JAPAN), or equivalent to
each new bearing and inner race.
Install the lower bearing onto the stem.
Insert the steering stem into the steering head pipe.

Install the upper bearing and upper inner race.

14-29
FRONT WHEEL/SUSPENSION/STEERING

Install the steering top thread and tighten it to the

specified torque.

TOOL:
Adjustable pin spanner 07702-0020001

TORQUE: 13 N•m (1.3 kgf•m, 9 lbf.ft)

Turn the steering stem lock-to-lock several times to

seat the bearings. STEERING STEM

Temporarily loosen the steering stem top thread.

Install the fork (page 14-17).

Install the front wheel (page 14-7).

Tighten the steering top thread to the specified torque

with the front wheel grounded.

TOOL:
Adjustable pin spanner 07702-0020001

TORQUE: 13 N•m (1.3 kgf•m, 9 lbf.ft)

Install the lock washer aligning its tab in the groove on

the steering stem.

Install the steering stem lock nut.

Hold the steering stem top thread using the pin span-
ner and tighten the steering stem lock nut to the
specified torque.

TOOLS:
Adjustable pin spanner 07702-0020001
Lock nut wrench 07916-KM10000

TORQUE: 74 N•m (7.5 kgf•m, 54 lbf.ft)

Make sure that the steering stem moves smoothly

without play or binding.

A FTER '02 (A BS Install the front cover stay and mount bolts to the
TYPE): frame with tighten the bolts.

14-30
 FRONT WHEEL/SUSPENSION/STEERING

Install the handle post tube to the steering stem. HANDLE POST TUBE

Install the following:

- Fork (page 14-17)
- Front airduct cover (page 2-21)
- Steering handle (page 14-21)
- Front cover (page 2-14)

A FTER '02 (A BS Set the brake hose/wheel speed sensor wire clamp
TYPE): and tighten the bolt.

STEERING BEARING PRELOAD

Raise the front wheel off the ground.
Position the steering stem to the straight
ahead position.
Hook a spring scale to the fork tube.
Make sure that there is no cable or wire
harness interference.
Pull the spring scale keeping the scale at a right angle
to the steering stem .

Read the scale at the point where the steering stem

just starts to move. goo

STEERING BEARING PRELOAD:

13 - 17 N (1.3 - 1.7 kgf, 2.9 - 3.7 lbf)

If the readings do not fall within the limits, readjust

the steering top thread.

Install the removed parts in the reverse order

of removal.

14-31
REAR WHEEL/SUSPENSION

STD TYPE:

39 N•m (4.0 kgf•m,

29 lbMt)

30 N•m (3.1 kgf•m, 22 lbMt)

AFTER '02 (ABS TYPE):

15-0
 15. REAR WHEEL/SUSPENSION
SERVICE INFORMAT ION 15-2 REAR WHEEL/SW INGARM 15-4
TROUBLESHOOTING 15-3 REAR SHOCK ABSORBER 15-13

~ 39 N•m (4.0 kgf•m, 29 lbMt)

37 N•m (3.8 kgf•m, 27 lbMt)

15-1
 REAR WHEEL/SUSPEN SION

SERVICE INFORMATI ON
GENERAL

• A contaminated brake disc or pad reduces stopping power. Discard contaminated parts and clean a contaminated disc with
a high quality brake degreasing agent.
• Riding on damaged rims impairs safe operation of the vehicle.
• This section covers of the rear wheel and rea r suspension.
• A jack or other support is required to support the vehicle.
• Do not twist or bend the brake hose when servicing.
• Use genuine Honda replacement bolts and nuts for all suspension pivots and mounting points.
• Refer to section 16 for brake system information.

SPECIFICATIONS
Unit: mm (in)

ITEM STANDARD SERVICE LIMIT

Minimum tire tread depth -- 2.0 (0.08)
Cold tire pressure Up to 90 kg (200 lb) load 225 kPa (2.25 kgf/cm 2
, 33 psi) --
Up to maximum weight capacity 250 kPa (2.50 kgf/cm 2, 36 psi) - -
Wheel rim runout Radial - 2.0 (0.08)
Axial - 2.0 (0.08)
Wheel balance weight - 60 g (2.1 oz) max.
Right swingarm pivot O.D . 35.012 - 35.028 ( 1.3784 - 1.3791) 34.70 (1.366)

TORQUE VALUES
Rear brake disc bolt 42 N•m (4.3 kgf•m, 31 lbf•ft) ALOC bolt: replace with a new one.
Rear axle nut 138 N•m (14.1 kgf•m, 102 lbf•ft) U-nut.
Rear shock absorber upper mounting bolt 22 N•m (2.2 kgf•m, 16 lbf•ft)
Rear shock absorber lower mounting bolt 39 N•m (4.0 kgf•m , 29 lbf•ft)
Final shaft holder bolt 49 N•m (5.0 kgf•m, 36 lbf•ft)
Right swingarm torx bolt 34 N•m (3.5 kgf•m, 25 lbf•ft) Torx bolt.
Swingarm case bolt (center swingarm) 37 N•m (3 .8 kgf•m, 27 lbf•ft) Apply a locking agent to the threads.
Right swingarm pivot bolt 24 N•m (2 .4 kgf•m, 17 lbf•ft)
Left swingarm flange socket bolt 25 N•m (2.5 kgf•m, 18 lbf•ft)
Rear brake caliper mounting bolt 30 N•m (3.1 kgf•m, 22 lbf•ft) ALOC bolt: replace with a new one.
Parking brake caliper mounting bolt 30 N•m (3.1 kgf•m, 22 lbf•ft) Apply a locking agent to the threads.

TOOLS
Remover weight 07741 -0010201 or 07936-371020A or 07936-3710200 (U.S.A. only)
Attachment, 42 x 47 mm 07746-0010300
Pilot, 20 mm 077 46-0040500
Pilot, 35 mm 077 46-0040800
Driver 07749-0010000
Remover handle 07936-3710100
Bearing remover, 35 mm 07936-3710400
Bearing driver attachment, 78 x 90 07GAD-SD40101
Driver attachment, 110 x 140 mm 07ZMD-MCT0100 or 07ZMD-MCTA 100 (U.S.A. only)

15-2
 REAR WHEEL/S USPENSI ON

TROUBLESHOOTING
Rear wheel wobbling Hard suspension
• Bent rim • Bent damper rod
• Faulty tire • Worn or damaged engine mount bushings
• Axle nut and/or engine mount bolt not tightened properly • High tire pressure
• Loose or worn final gear shaft bearing
• Insufficient tire pressure Rear suspension noisy
· • Unbalanced tire and wheel Loose mounting fasteners
Faulty shock absorber
Soft suspension • Weak rear suspension mount bushings
• Weak rear shock absorber spring
• Oil leakage from damper unit

15-3
REAR WHEEL/SUSPEN SION

REAR WHEEL/SW INGARM

REMOVAL
Remove the muffler (page 2-22, 24).
Remove the parking brake caliper (page 16-30).
Remove the rear brake caliper (page 16-27).

Loosen the rear axle nut.

Support the scooter on its main stand.

Remove the bolts and brake hose/cable clamps from

the final shaft holder and right swingarm .
Remove the rear shock absorber lower mount bolt.
Remove the rear axle nut.

Remove the bolt and final shaft holder cover.

Remove the final shaft holder mount bolts and final

shaft holder.
Remove the right swingarm mount torx bolts and
right swingarm .

15-4
 REAR WHEEL/SUSPENSION

Remove the inner side collar.

Remove the rear wheel.

Remove the following:

- Drive pulley/driven pulley/clutch (section 10)
- Left rear shock absorber lower bolt (page 15-13)

Remove the left swingarm pivot collar.

Remove the left swingarm mount bolts and left

swingarm from the crankcase.

15-5
REAR WHEEL/SUSPENSION

Remove the bolts and center swingarm from the

left swingarm.

INSPECTION
WHEEL
Check the wheel rim runout using a dial indicator.
Actual runout is 1/2 the total indicator reading.

SERVICE LIMITS: Radial: 2.0 mm (0.08 in)

Axial: 2.0 mm (0.08 in)

RIGHT SWINGARM PIVOT

Check the right swingarm pivot for wear or damage.
Measure the pivot O.D ..

SERVICE LIMIT: 34. 70 mm ( 1.366 in)

DISASSEMBLY
WHEEL
Remove the brake disc bolts and rear brake disc.

Check the brake disc for wear or damage, replace if

necesary.

AFTER '02 (A BS Remove the bolts and pulser ring.

TYPE): Check the pulser ring for damage or cracks, replace if
necessary.

15-6
 REAR WHEEL/SUSPENSION

RIGHT SWINGARM PIVOT

Remove the socket bolts and right swingarm pivot
from the right crankcase cover.

Remove the dowel pins from the right

crankcase cover.

DOWEL PINS SOCKET BOLTS

FINAL SHAFT HOLDER BEARING

REPLACEMENT
Remove the outer side collar from the final
shaft holder.

Remove the outer side dust seal and inner side dust
seal from the final shaft holder.

Remove the snap ring.

Turn the inner race of the bearing with your finger.

The bearing should turn smoothly and quietly. Also
check that the bearing outer race fits tightly in the final
shaft holder.

Remove and discard the bearing if the race does not

turn smoothly and quietly, or if it fits loosely in the
final shaft holder.

Remove the bearing from the final shaft holder.

15-7
REAR WHEEL/SUS PENSION

Drive in a new bearing squarely until it is fully seated,

using the special tools.

TOOLS:
Driver 077 49-0010000
Attachment, 42 x 47 mm 07746-0010300
Pilot, 20 mm 077 46-0040500

BEARING

Install the snap ring to the groove of the final shaft

holder.

Apply grease to the new dust seal lips and install

them to the final shaft holder until they are flush with
the swingarm surfaces.

Check the bushing for wear or damage.

15-8
 REAR WHEEL/SUSPENSION

SWINGARM PIVOT BEARING

REPLACEMENT
RIGHT SWINGARM PIVOT BEARING
Remove the right swingarm pivot bearing using the
special tools.

TOOLS:
·RemoveF weighf- 07741-0010201 or
07936-371020A or
07936-3710200
(U.S.A. only)
Remover handle 07936-3710100
Bearing remover, 35 mm 07936-3710400

Drive in a new bearing squarely until it is fully seated,

using the special tools.

TOOLS:
Driver 07749-0010000
Attachment, 42 x 47 mm 077 46-0010300

LEFT SWINGARM PIVOT BEARING

Remove the snap rings from the left swingarm pivot
bearing and bearing flange

Remove the left swingarm pivot bearing flange using

the special tools.

TOOLS:
Driver 077 49-0010000
Bearing driver attachment, 78 x 90 07GAD-SD40101

15-9
REAR WHEEL/SUS PENSION

Heat the left swingarm around the left swingarm pivot

bearing with an industrial dryer.
Remove the pivot bearing from the left swingarm.

Assemble the new bearing and bearing flange using

DRIVER ~~ BEARING
the special tools.
lllli,_i

TOOLS:
Driver 077 49-0010000
Driver attachment, 07ZMD-MCT010 0 or
110 x 140 mm 07ZMD-MCTA 100
(U.S.A. only)

ATTACHMENT BEARING FLANGE

Drive in the bearing and bearing flange assembly

squarely until it is fully seated, using the special tools.

TOOLS:
Driver 07749-0010000
Driver attachment, 07ZMD-MCT010 0 or
110 x 140 mm 07ZMD-MCTA10 0
(U.S.A. only)

BEARING/FLANGE ASSEMBLY

Install the snap rings to the left swingarm pivot bear-

ing and bearing flange. Make sure the snap rings are
secure.

15-10
 REAR WHEEL/SUSPENSION

ASSEMBLY
WHEEL
A FTER '02 (A BS Install the pulser ring and new pulser ring bolts onto
TYPE): the wheel hub with tighten the bolts to the specified
torque.

TORQUE: 8 N•m (0.8 kgf•m, 5.8 lbf.ft)

Install the brake disc on the wheel hub with the

marked side facing out.

Install new brake disc bolts and tighten them to the

specified torque.

TORQUE: 42 N•m (4.3 kgf•m, 31 lbf.ft)

SWINGARM PIVOT
Install the dowel pins to the right crankcase cover.

Install the swingarm pivot aligning its holes with the

dowel pins

Tighten the socket bolts to the specified torque.

TORQUE: 24 N•m (2.4 kgf•m, 17 lbf.ft)

DOWEL PINS SOCKET BOLTS

INSTALLATION CENTER SWINGARM

Install the center swingarm to the left swingarm .

Apply a locking agent to the swingarm bolt threads .
Tighten the bolts to the specified torque.

TORQUE: 37 N•m (3.8 kgf•m, 27 lbf.ft)

Install the left swingarm to the crankcase.

Tighten the socket bolts to the specified torque.

TORQUE: 25 N•m (2.5 kgf•m, 18 lbf.ft)

15-11
REAR WHEEL/SUSPENSION

Install the left swingarm pivot collar.

Install the following:

- Drive pulley/driven pulley/clutch (section 10)
- Left rear shock absorber lower bolt (page 15-14)

Install the rear wheel onto the final gear shaft, align-
ing the spline.

Install the inner side collar.

Apply grease to the 3 mm groove in the final
gear shaft.

Install the right swingarm and tighten the torx bolts to

the specified torque.

TORQUE: 34 N•m (3.5 kgf•m, 25 lbf.ft)

Install the final shaft holder and tighten the bolts to

the specified torque.

TORQUE: 49 N•m (5.0 kgf•m, 36 lbf.ft)

15-12
 REAR WHEEL/SUSPENSION

Install the driveshaft holder cover.

Tighten the bolt.

Install and tighten the rear axle nut temporarily.

Install and tighten the rear shock absorber lower
mount bolt to the specified torque.

TORQUE: 39 N•m (4.0 kgf•m, 29 lbf.ft)

Install the brake hose/cable clamps to the final shaft

holder and tighten the bolts.

Release the main stand and support the scooter on its

sidestand.

Tighten the rear axle nut to the specified torque .

TORQUE: 138 N•m (14.1 kgf•m, 102 lbf.ft)

Install the parking brake caliper (page 16-35).

Install the rear brake caliper (page 16-30).
Install the muffler (page 2-23, 26).

REAR SHOCK ABSORBER

REMOVAL
Remove the luggage box (page 2-10).

Support the scooter on its centerstand.

Support the swingarm with a hoist or equivalent.

Remove the rear shock absorber lower mount bolt.

15-13
REAR WHEEL/SUS PENSION

Remove the rear shock absorber upper mount bolt

and shock absorber.

INSPECTION BUSHING

Check the damper unit for leakage or other damage.

Check the upper joint bushing for wear or damage.

Replace the shock absorber assembly if necessary.

I
DAMPER UNIT

INSTALLATl ON
Install the rear shock absorber. Tighten the upper
mount bolt to the specified torque.

TORQUE: 22 N•m (2.2 kgf•m, 16 lbf.ft)

Install and tighten the lower mount bolt to the

specified torque.

TORQUE: 39 N•m (4.0 kgf•m, 29 lbf.ft)

Install the luggage box {page 2-10).

15-14
MEMO
BRAKE SYSTEM

STD TYPE:
? k g f • m , 9 lbf.ftl

i\
34 N•m (3.5 kgf•m, 25 lbMt)

34 N•m (3.5 kgf•m, 25 lbMt)

AFTER '02 (ABS TYPE):

-~
30 N•m (3.1 kgf•m, 22 lbMt) -~

16-0
 16. BRAKE SYSTEM
SERVICE INFORMATIO N 16-2 REAR MASTER CYLINDER 16-17
TROUBLESHOOTING 16-3 DELAY VALVE 16-22
BRAKE FLUID REPLACEME NT/ 16-4 FRONT BRAKE CALIPER 16-23
AIR BLEEDING REAR BRAKE CALIPER 16-27
BRAKE PAD/DISC 16-9 16-30
PARKING BRAKE
FRONT MASTER CYLINDER 16-12

34 N•m (3.5 kgf•m, 25 lbfoft) ~7 12 N•m (1.2 kgf•m, 9 lbf.ft)

m .·:-_

30 N•m (3.1 kgf•m, 22 lbfoft)

30 N•m (3.1 kgf•m, 22 lbfoft)

16-1
BRAKE SYSTEM

SERVICE INFORMATI ON
GENERAL

A CAUTION
Frequent inhalation of brake pad dust, regardless of material composition could be hazardous to your health.
• Avoid breathing dust particles.
• Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner.

• A contaminated brake disc or pad reduces stopping power. Discard contaminated parts and clean a contaminated disc with
a high quality brake degreasing agent.
• Avoid spilling brake fluid on painted, plastic or rubber parts. Place a rag over these parts whenever the system is serviced.
• This section covers maintenance of the front and rear hydraulic brake system .
• Never allow contaminants (dirt, water, etc.) to get into an open reservoir.
• Once the hydraulic system has been opened, or if the brake feels spongy, the system must be bled.
• Always use fresh DOT 4 brake fluid from a sealed container when servicing the system. Do not mix different types of fluid
as they may not be compatible.
• Always check brake operation before riding the vehicle.

SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Front Specified brake fluid DOT 4 --
Brake disc thickness '02 - '06 standard type 4.8 - 5.2 (0.19 - 0.20) 4.0 (0.16)
After '02 ABS type/ 5.8 - 6.2 (0.22 - 0.24) 5.0 (0.20)
After '06 standard type
Brake disc runout -- 0.30 (0.012)
Master cylinder l.D. 11.000 - 11.043 (0.4331 - 0.4348) 11.055 (0.4352)
Master piston O.D. 10.957 - 10.984 (0.4314 - 0.4324) 10.945 (0.4309)
Caliper cylinder l.D. Upper 27.000 - 27.050 ( 1.0630 - 1.0650) 27.060 (1.0654)
Middle 22.650 - 22.700 (0.8917 - 0.8937) 22.710 (0.8941)
Lower 27.000 - 27.050 ( 1.0630 - 1.0650) 27.060 ( 1.0654)
Caliper piston O.D. Upper 26.935 - 26.968 (1.0604 - 1.0617) 26.910 (1.0594)
Middle 22.585 - 22.618 (0.8892 - 0.8905) 22.560 (0.8882)
Lower 26.935 - 26.968 (1.0604 - 1.0617) 26.910 (1.0594)
Rear Specified brake fluid DOT 4 --
Brake disc thickness 6.3 - 6.7 (0.25 - 0.26) 5.5 (0.22)
Brake disc runout -- 0.30 (0.012)
Master cylinder l.D. 12.700 - 12.743 (0.5000 - 0.5017) 12.755 (0.5022)
Master piston O.D. 12.657 - 12.684 (0.4983 - 0.4994) 12.645 (0.4978)
Caliper cylinder l.D. 27.000 - 27.050 ( 1.0630 - 1.0650) 27.060 ( 1.0654)
Caliper piston O.D. 26.935 - 26.968 (1.0604 - 1.0617) 26.910 (1.0594)
Parking Caliper cylinder l.D. 20.00 - 20.05 (0.787 - 0.789) 20.060 (0.790)
Caliper piston O.D. 19.935 - 19.968 (0.7848 - 0.7861) 19.927 (0.7845)

16-2
 BRAKE SYSTEM

TORQUE VALUES
Master cylinder reservoir cover screw 2 N•m (0.2 kgf•m, 1.4 lbMt)
Master cylinder holder bolt 12 N•m (1.2 kgf•m, 9 lbMt)
Brake lever pivot bolt 1 N•m (0.1 kgf•m, 0.7 lbMt)
Brake lever pivot nut 6 N•m (0.6 kgf•m, 4.3 lbMt)
Brake light switch screw 1 N•m (0.1 kgf•m, 0.7 lbMt)
Brake caliper mounting bolt 30 N•m (3.1 kgf•m, 22 lbMt) ALOC bolt: replace with a new one.
Front brake caliper body B bolt 32 N•m (3.3 kgf•m, 24 lbMt) ALOC bolt: replace with a new one.
Brake caliper bleed valve 6 N•m (0.6 kgf•m, 4.3 lbMt)
Brake pad pin 18 N•m (1.8 kgf•m, 13 lbMt)
Rear caliper pad pin plug 3 N•m (0.3 kgf•m, 2.2 lbMt)
Front caliper main pin bolt 22 N•m (2.2 kgf•m, 16 lbMt) Apply a locking agent to the threads.
Front caliper sub pin bolt 12 N•m (1.2 kgf•m, 9 lbMt) Apply a locking agent to the threads.
Rear caliper main pin bolt 28 N•m (2.9 kgf•m, 21 lbMt) Apply a locking agent to the threads.
Rear caliper sub pin bolt 12 N•m (1.2 kgf•m, 9 lbMt) Apply a locking agent to the threads.
Parking brake caliper mounting bolt 30 N•m (3.1 kgf•m, 22 lbMt) Apply a locking agent to the threads.
Parking brake caliper pin bolt 23 N•m (2.3 kgf•m, 17 lbMt)
Brake hose oil bolt 34 N•m (3.5 kgf•m, 25 lbMt)
Brake pipe nut 14 N•m (1.4 kgf•m, 10 lbMt) Apply oil to the threads and seating surface.

TOOLS
Snap ring pliers 07914-SA50001

TROUBLESHOOTING
Brake lever soft or spongy Brake lever hard
Air in the hydraulic system • Clogged/restricted brake system
Low brake fluid level • Sticking/worn caliper piston
Clogged fluid passage • Caliper not sliding properly
Contaminated brake disc/pad • Clogged/restricted fluid passage
Warped/deformed brake disc • Worn caliper piston seal
Worn brake disc/pad • Sticking/worn master cylinder piston
Sticking/worn master cylinder piston • Bent brake lever
Contaminated master cylinder
Contaminated caliper Brake drag
Caliper not sliding properly • Contaminated brake disc/pad
Leaking hydraulic system • Worn brake disc/pad
Worn caliper piston seal • Warped/deformed brake disc
Worn master cylinder piston cups • Caliper not sliding properly
Bent brake lever

16-3
BRAKE SYSTEM

BRAKE FLUID REPLACEMENT I SCREWS

AIR BLEEDING
NOTE:
• A contaminated brake disc or pad reduces stopping
power. Discard contaminated pads and clean a con-
taminated disc with a high quality brake
degreasing agent.
• Do not allow foreign material to enter the system
when filling the reservoir.
• Avoid spilling brake fluid on painted, plastic or rub- ,/
ber parts. Place a rag over these parts whenever the
system is serviced. PLATE -~
DIAPHRAGM

Once the hydraulic system has been opened, or if the

brake feels spongy, the system must be bled.
When using a commercially available brake bleeder,
follow the manufacturer's operating instructions.

BRAKE FLUID DRAINING

Make sure that the master cylinder is parallel to the
ground before removing the reservoir cover.

FRONT:
Remove the screws, reservoir cover, diaphragm plate
and diaphragm.

Connect a bleed hose to the upper bleed valve.

Loosen the upper bleed valve and pump the

brake lever.
Stop operating the brake when no more fluid flows
out of the upper bleed valve.

REAR (COMBINED):
SCREWS
Remove the screws, reservoir cover, diaphragm plate
and diaphragm.

PLATE- ._ DIAPHRAGM

16-4
 BRAKE SYSTEM

Connect a bleed hose to the front caliper lower LOWER BLEED VALVE
bleed valve.

Loosen the front caliper lower bleed valve and pump

the brake lever.
Stop operating the brake when no more fluid flows
out of the front caliper lower bleed valve.

Tighten the front caliper lower bleed valve.

REAR BRAKE LEVER

Connect a bleed hose to the rea r caliper bleed valve.

Following the caliper bleed valve procedure above,

drain the brake fluid from the rear caliper bleed valve.

BRAKE FLUID FILLING/AIR BLEEDING UPPER LEVEL

Do not mix differ- Fill the master cylinder with DOT 4 brake fluid to the
ent types of fluid upper level.
since they are
not compatible. Connect a commercially available brake bleeder to
the front caliper upper bleed valve.

Check the fluid level often while bleeding the brakes

to prevent air from being pumped into the system .
When using a brake bleeding tool, follow the manu -
facturer's operating instructions.

16-5
BRAKE SYSTEM

If air enters the Pump the brake bleeder and loosen the front caliper
bleeder from upper bleed valve. Add fluid when the fluid level in
around the bleed the master cylinder is low to prevent drawing air into
valve threads, seal
the system.
the threads with
Repeat the above procedures until no air bubbles
teflon tape.
appear in the plastic hose.

Close the front caliper upper bleed valve and operate

the front brake lever.
If it still spongy, bleed the system again.

If the brake bleeder is not available, perform the

following procedure.

Pump up the system pressure with the lever until

these are no air bubbles in the fluid flowing out of the
reservoir small hole and lever resistance is felt.

Do not release 1. Pump the brake lever several times, then squeeze
the brake lever the brake lever all the way and loosen the bleed
until the bleed valve 1/4 turn. Wait several seconds and close the
valve has bleed valve.
been closed. 2. Release the brake lever slowly until the bleed valve
has been closed.
3. Repeat steps 1 - 2 until there are no air bubbles in
the bleed hose.

After bleeding air completely, tighten the bleed valves

to the specified torque.

TORQUE: 6 N•m (0.6 kgf•m, 4.3 lbf.ft)

Fill the reservoir to the casting ledge with DOT 4 brake

SCREWS
fluid to the upper level.

Install the diaphragm, set plate and reservoir cover

and tighten the screws to the specified torque.

TORQUE: 2 N•m (0.2 kgf•m, 1.4 lbf.ft)

16-6
 BRAKE SYSTEM

REAR (COMBINED): UPPER LEVEL

FLUID FEEDING
Fill with fluid and bleed air from the rear brake lever
line in the sequence as follow:
1. Front caliper lower bleed valve
2. Rear caliper bleed valve

Fill the rear master cylinder with DOT 4 brake fluid to

the upper level.

Operate the rear brake lever several times to bleed air

from the master cylinder.

REAR BRAKE LEVER

(1) Connect a commercially available brake bleeder LOWER BLEED VALVE

to the front caliper lower bleed valve.

If air enters the 1. Pump the brake bleeder and loosen the front
bleeder from caliper lower bleed valve. Add fluid when the
around the bleed fluid level in the master cylinder is low to pre-
valve threads, seal vent drawing air into the system.
the threads w ith
2. Repeat the above procedures until a sufficient
teflon tape.
amount of the fluid flows out of the caliper
lower bleed valve.

It is not a problem if the fluid flowing out from the

lower bleed valve contains air bubbles because the
lines will be bled in later steps. BRAKE BLEEDER

(2) Connect a commercially available brake bleeder

to the rear caliper bleed valve.
Repeat step 1 and 2 for the rear caliper bleed
valve.

Next, bleed air from the system (page 16-5).

16-7
BRAKE SYSTEM

If the brake bleeder is not available, perform the

following procedure.

Do not release (1) Connect a bleed hose to the front caliper lower
the brake lever bleed valve.
until the bleed 1. Pump the rear brake lever several (5-10) times
valve has
quickly, then operate the rear brake lever all
been closed.
the way and loosen the front caliper lower
bleed valve and loosen the bleed valve 1/4
turn. Wait several seconds and close the bleed
valve.

REAR BRAKE LEVER

Release the rear brake lever slowly and wait

LOWER BLEED VALVE
several seconds after it reaches the end of its
travel.

2. Repeat the above procedures until a sufficient

amount of the fluid flows out of the caliper
lower bleed valve.

It is not a problem if the fluid flowing out from the

lower bleed valve contains air bubbles because the
lines will be bled in later steps.

(2) Connect a bleed hose to the rear caliper bleed

valve.
Repeat step 1 and 2 for rear caliper bleed valve.

Next, bleed air from the system (see below).

AIR BLEEDING

Connect a bleed ( 1) Connect a bleed hose to the rear caliper bleed

hose to the front valve.
caliper lower 1. Pump the rear brake lever several (5-10) times
bleed valve quickly, then operate the rear brake lever all
(AFTER '02 ABS
the way and loosen the front caliper lower
TYPE).
bleed valve and loosen the bleed valve 1/4
turn. Wait several seconds and close the bleed
valve.

REAR BRAKE LEVER

16-8
 BRAKE SYSTEM

Release the rear brake lever slowly and wait

several seconds after it reaches the end of its
travel.

2. Repeat the above procedures until air bubbles

do not appear in the transparent hose.

Connect a bleed (2) Connect a bleed hose to the front caliper lower
hose to tf:ie rear bleed valve.
Calip.er .bieed valve Repeat step 1 and 2 for the front caliper upper
(A FTER '02 ABS bleed valve.
TYPE).
Note that you may feel strong resistance on the rear
(combined) brake lever during pumping to bleed air
from the caliper. This symptom is caused by the delay
valve function. Be sure to push the rear brake lever
fully in at this point. UPPER LEVEL

Until air bubbles cease to appear in the fluid, repeat

the air bleeding procedure about 2 - 3 times at each
bleed valve.
Make sure the bleed valves are closed and operate the
brake lever. If it still feels spongy, bleed the
system again.

After bleeding the air completely, tighten the bleed

valves to the specified torque.

TORQUE: 6 N•m (0.6 kgf•m, 4.3 lbf.ft)

Fill the reservoir to the casting ledge with DOT 4 brake

fluid to the upper level.
SCREWS RESERVOIR COVER

~
Install the diaphragm, set plate and reservoir cover
and tighten the screws to the specified torque.

TORQUE: 2 N•m (0.2 kgf•m, 1.4 lbf.ft)

......_

~ '-
PLATE '-- DIAPHRAGM

BRAKE PAD/DISC
BRAKE PAD REPLACEMENT
FRONT:
Always replace To provide clearance for new pads, push the caliper
the brake pads pistons all the way in by pushing the caliper body
in pairs to inward.
ensure even
disc pressure.

16-9
BRAKE SYSTEM

Remove the pad pin plug and loosen the pad pin.

Remove the pad pin and the brake pads.

Make sure that the pad spring is installed in position.

Install new pads so that the their ends rest properly
on the pad retainer on the bracket.

Install the pad pin by pushing the pads against the

pad spring, aligning the pad pin holes in the pads and
caliper. ·

Tighten the pad pin to the specified torque.

TORQUE: 18 N•m (1.8 kgf•m, 13 lbf.ft)

Install the pad pin plug.

16-10
 BRAKE SYSTEM

REAR:
Always replace To provide clearance for new pads, push the caliper
the brake pads piston all the way in by pushing the caliper body
in pairs to inward.
ensure even
disc pressure.

Remove the pad pin plug and loosen the pad pin.

Remove the pad pin and brake pads.

Install new pads so that their ends rest properly on

the pad retainer on the bracket.

Install the pad pin by pushing the pads against the

pad spring, aligning the pad pin holes in the pads and
caliper.

Tighten the pad pin to the specified torque.

TORQUE: 18 N•m (1.8 kgf•m, 13 lbf.ft)

16-11
BRAKE SYSTEM

Install and tighten the pad pin plug to the

specified torque.

TORQUE: 3 N•m (0.3 kgf•m, 2.2 lbf.ft)

BRAKE DISC INSPECTION

Visually inspect the brake disc for damage or cracks.
Measure the brake disc thickness.

SERVICE LIMITS: Front ('02 - '06 standard type):

4.0 mm (0.16 in)
(After '02 ABS type/
After '06 standard type):
5.0 mm (0.20 in)
Rear: 5.5 mm (0.22 in)

Replace the brake disc if the smallest measurement is

less than the service limit.

Measure the brake disc runout.

SERVICE LIMIT: 0.30 mm (0.012 in)

FRONT MASTER CYLINDER

REMOVAL
When removing the brake hose bolt, cover the end of
the hose to prevent contamination. Secure the hose to
prevent fluid from leaking out.

Remove the handlebar cover (page 2-14).

Remove the rearview mirror (page 14-18).
Drain the front brake hydraulic system (page 16-4).

Disconnect the brake light switch connectors.

16-12
 BRAKE SYSTEM

Remove the brake hose oil bolt, sealing washers and

brake hose eyelet.

Remove the bolts from the master cylinder holder and

remove the master cylinder assembly.

DISASSEMBLV
Remove the brake lever pivot bolt and nut.
Remove the brake lever.

Remove the screw and brake light switch. SCREW

16-13
BRAKE SYSTEM

Remove the boot.

Remove the snap ring from the master cylinder body

SNAP RING PLIERS SNAP RING
using a special tool as shown.

TOOL:
Snap ring pliers 07914-SA50001

Remove the master piston and spring.

Clean the inside of the cylinder and reservoir with

brake fluid .

INSPECTION
Check the piston boot, primary cup and secondary
cup for fatigue or damage.
Check the master cylinder and piston for
abnormal scratches.

Measure the master cylinder l.D.

SERVICE LIMIT: 11.055 mm (0.4352 in)

Measure the master cylinder piston O.D.

SERVICE LIMIT: 10.945 mm (0.4309 in)

16-14
 BRAKE SYSTEM

ASSEMBLY
2 N•m (0.2 kgf•m, 1.4 lbMt)

1 N•m (0.1 kgf•m, 0.7 lbMt)

RESERVOIR COVER

MASTER CYLINDER

BRAKE LEVER

NOTE: SPRING
Keep the piston, spring, snap ring and boot as a set;
do not substitute individual parts. I
Coat all parts with clean brake fluid before assembly.
Dip the piston in brake fluid.
Install the spring to the piston.
When installing the cups, do not allow the lips to turn
inside out.
Install the piston assembly into the master cylinder.

Be certain the snap ring is firmly seated in the groove.

SNAP RING PLIERS SNAP RING
Install the snap ring using a special tool.

TOOL:
Snap ring pliers 07914-SA50001

16-15
BRAKE SYSTEM

Apply silicone grease to the inside of the boot.

Install the boot.

~BOOT
Install the brake light switch and tighten the screw to
SCREW
the specified torque.

TORQUE: 1 N•m (0.1 kgf•m, 0.7 lbf.ft)

Apply silicone grease to the master piston tip.

BRAKE LEVER
Install the brake lever.

Apply silicone grease to the brake lever pivot bolt

sliding surface.
Install and tighten the pivot bolt to the
specified torque.

TORQUE: 1 N•m (0.1 kgf•m, 0.7 lbf.ft)

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

TORQUE: 6 N•m (0.6 kgf•m, 4.3 lbf.ft) PIVOT BOLT/NUT

INSTALLATION PUNCH MARK

Place the master cylinder assembly on the handlebar.

Align the end of the master cylinder with the punch
mark on the handlebar.

Install the master cylinder holder with the "UP" mark

facing up.
Tighten the upper bolt first, then the lower bolt.

TORQUE: 12 N•m (1.2 kgf•m, 9 lbf.ft)

16-16
 BRAKE SYSTEM

Rest the brake hose eyelet against the stopper. SEALING WASHERS
Install the brake hose eyelet with the oil bolt and new
sealing washers.
Tighten the oil bolt to the specified torque.

TORQUE: 34 N•m (3.5 kgf•m, 25 lbf.ft)

Connect the brake light switch connectors.

Fill the reservoir to the upper level and bleed the

brake system (page 16-5).
Install the rearview mirror (page 14-25).
Install the handlebar cover (page 2-14).

REAR MASTER CYLINDER

REMOVAL
When removing the brake hose bolt, cover the end of
the hose to prevent contamination. Secure the hose to
prevent fluid from leaking out.

Remove the handlebar cover (page 2-14).

Remove the rearview mirror (page 14-18).
Drain the rear brake hydraulic system (page 16-4).

Disconnect the brake light switch connectors.

Disconnect the limit switch connectors.

Remove the brake hose oil bolt, sealing washers and SEALING WASHERS BOLT
brake hose eyelet.

/
16-17
BRAKE SYSTEM

Remove the bolts from the master cylinder holder and

remove the master cylinder assembly.

DISASSEMBLV
BRAKE LEVER

I
Remove the brake lever pivot bolt and nut.
Remove the brake lever.

/
PIVOT BOLT/NUT

Remove the screws and brake light/limit switch.

SCREWS

Remove the boot.

BOOT

16-18
 BRAKE SYSTEM

Remove the snap ring from the master cylinder body SNAP RING
using a special tool as shown.

TOOL:
Snap ring pliers 07914-SA50001

Remove the master piston, cup and spring.

Clean the inside of the cylinder and re~ervoir with

brake fluid.

INSPECTION
Check the piston boot, primary cup and secondary
cup for fatigue or damage.
Check the master cylinder and piston for
abnormal scratches.

Measure the master cylinder l.D.

SERVICE LIMIT: 12.755 mm (0.5022 mm)

Measure the master cylinder piston O.D.

SERVICE LIMIT: 12.645 mm (0.4978 in)

16-19
BRAKE SYSTEM

ASSEMBLY

RESERVOIR COVER

MASTER CYLINDER

BRAKE LEVER

NOTE: SPRING
Keep the piston, spring, snap ring and boot as a set;
do not substitute individual parts.
I
Coat all parts with clean brake fluid before assembly.
Dip the piston in brake fluid.
Install the spring and cup to the piston.
When installing the cups, do not allow the lips to turn
inside out.
Install the piston assembly into the master cylinder.
\,
o~I· • MASTER PISTON

Be certain the snap ring is firmly seated in the groove.

SNAP RING
Install the snap ring using a special tool.

TOOL:
Snap ring pliers 07914-SA50001

16-20
 BRAKE SYSTEM

Apply silicone grease to the inside of the boot.

Install the boot.

Install the brake light/limit switch and tighten the SCREWS

screws to the specified torque.

TORQUE: 1 N•m (0.1 kgf•m, 0. 7 lbMt)

Apply silicone grease to the master piston tip. BRAKE LEVER

Install the brake lever.

Apply silicone grease to the brake lever pivot bolt

sliding surface.
Install and tighten the pivot bolt to the
specified torque.

TORQUE: 1 N•m (0.1 kgf•m, 0. 7 lbMt)

Install and tighten the pivot nut to the

specified torque.

TORQUE: 6 N•m (0.6 kgf•m, 4.3 lbf.ft)

INSTALLATION MASTER CYLINDER PUNCH MARK

Place the master cylinder assembly on the handlebar.

Align the end of the master cylinder with the punch
mark on the handlebar.

Install the master cylinder holder with the "UP" mark

facing up.
Tighten the upper bolt first, then the lower bolt.

TORQUE: 12 N•m (1.2 kgf•m, 9 lbMt)

16-21
BRAKE SYSTEM

Rest the brake hose eyelet against the stopper.

Install the brake hose eyelet with the oil bolt and new SEALING WASHERS BOLT
sealing washers.

/
Tighten the oil bolt to the specified torque.

TORQUE: 34 N•m (3.5 kgf•m, 25 lbMt)

Connect the brake light switch connectors.

Connect the limit switch connectors.

Fill the reservoir to the upper level and bleed the

brake system (page 16-7).
Install the rearview mirror (page 14-25).
Install the handle cover (page 2-14).

DELAY VALVE
REMOVAL
When removing the brake hose bolt, cover the end of
the hose to prevent contamination. Secure the hose to
prevent fluid from leaking out.

Remove the front cover (page 2-14).

Remove the front airduct cover (page 2-21 ).
Drain the front brake hydraulic system (page 16-4).

Loosen the brake pipe nut and disconnect the brake

pipe from the brake hose eyelet.

Remove the brake hose oil bolts, sealing washers and

brake hose eyelets.

16-22
 BRAKE SYSTEM

Remove the bolts and delay valve.

INSTALLATION
Install the delay valve and tighten the bolts.

Install the brake hose eyelets and new

sealing washers.
Tighten the brake hose bolt to the specified torque
while resting hose eyelet against the stopper on the
delay valve.

TORQUE: 34 N•m (3.5 kgf•m, 25 lbf.tt)

Connect the brake pipe to the brake hose eyelet.

Tighten the brake pipe nut to the specified torque.

TORQUE: 14 N•m (1.4 kgf•m, 10 lbf.tt)

Fill the reservoir to the upper level and bleed the

brake system (page 16-5).
Install the front airduct cover (page 2-21 ).
Install the front cover (page 2-14).

FRONT BRAKE CALIPER

REMOVAL
Drain the front brake hydraulic system (page 16-4).
Remove the brake pad (page 16-9).

Remove the oil bolts, sealing washers and brake hose

from the brake caliper.

16-23
BRAKE SYSTEM

Remove the following:

- Bolts and front wheel speed sensor {AFTER '02 ABS
TYPE)
- Screw and front wheel speed sensor wire clamp
{AFTER '02 ABS TYPE)
- Mount bolts and front brake caliper

DISASSEMB LV CALIPER BODY PIN BOOTS

Do not remove Remove the caliper bracket from the caliper body.
the caliper and
bracket pins Remove the pin boot and retainer from the bracket.
unless replace-
ment.
Remove the pin boot and pad spring from the
caliper body.

Remove the bolts and caliper body B.

Do not use high Place a shop towel over the pistons.

pressure air or Position the caliper body with the pistons down and
bring the nozzle apply small squirts of air pressure to the fluid inlets to
too close to the
remove the pistons.
inlet.

16-24
 BRAKE SYSTEM

Be careful not Push the dust seals and piston seals in and lift DUST SEAL PISTON SEAL
to damage them out.
the piston
sliding surface . Clean the seal grooves, caliper pistons and caliper pis-
ton sliding surfaces with clean brake fluid.

INSPECTION
Check the caliper cylinder and pistons for scoring,
scratches or damage.

Measure the caliper cylinder l.D.

SERVICE LIMITS: Upper: 27.060 mm (1.0654 in)

Middle: 22.710 mm (0.8941 in)
Lower: 27.060 mm (1.0654 in)

Measure the caliper piston O.D.

SERVICE LIMITS: Upper: 26.910 mm (1.0594 in)

Middle: 22.560 mm (0.8882 in)
Lower: 26.910 mm (1.0594 in)

ASSEMBLY
STD TYPE: AFTER '02 (ABS TYPE):

BRACKET

~ PINBOOTS

CALIPER BODY

~PIN

I PISTON SEAL
PAD PIN PLUG

BRAKE PAD
DUST SEAL

16-25
BRAKE SYSTEM

Replace the dust seals and piston seals with

new ones.
Replace the caliper and bracket pin boots there it is
wear, deterioration or damage.
Apply silicone grease to the boots inner surfaces.
Be sure that each part is free from dust or dirt before
reassembly.

Coat new piston seals with clean brake fluid .

Coat new dust seals with silicone grease.
Install the piston seals and dust seals into the grooves
of the caliper body.
Coat the caliper pistons with clean brake fluid and
install them into the caliper cylinder with their closed
ends facing the pad.
I
Install the caliper body B.
Install and tighten new caliper body B bolts to the
specified torque.

TORQUE: 32 N•m (3.3 kgf•m, 24 lbf.ft)

Install the pad spring into the caliper body as shown.

CALIPER BODY
Apply silicone grease to the boot inner surface.
Install the boot to the caliper.

Apply silicone grease to the boot inner surface.

Install the boot to the caliper bracket.

Install the retainer to the caliper bracket.

Install the caliper bracket to the caliper.

BRACKET

INSTALLATl ON
Install the front caliper on the fork leg.
Install and tighten the new front caliper mount bolts
to the specified torque.

TORQUE: 30 N•m (3.1 kgf•m, 22 lbf.ft)

AFTER '02 (ABS Install the front wheel speed sensor, clamp and bolts
TYPE) : to the bracket and tighten the bolts.'
Install the clamp and screw to the brake caliper and
tighten the screw.

16-26
 BRAKE SYSTEM

Install the brake hose eyelet to the caliper body with

new sealing washers and oil bolts.
BRAKE HOSE~
Push the brake hose eyelet to the stopper on the
caliper, then tighten the oil bolts to the
specified torque.

TORQUE: 34 N•m (3.5 kgf•m, 25 lbf.ft)

__ lnsta.11 the brake pads (page 16-10).

Fill and bleed the hydraulic system (page 16-5).

--
REAR BRAKE CALIPER
REMOVAL
Remove the muffler (page 2-22, 24).
Drain the rear brake hydraulic system (page 16-4).

Remove the oil bolt, sealing washers and brake hose

from the brake caliper.

Remove the pad pin plug and loosen the pad pin.

Loosen the caliper bolt and caliper pin bolt.

Remove the mount bolts and rear brake caliper from

the final shaft holder.

Remove the rear brake pad (page 16-11).

DISASSEMBLY PIN BOOTS

Do not remove Remove the caliper bracket from the caliper body.
the caliper and
bracket pins Remove the pin boot and retainer from the bracket.
unless replace-
ment.
Remove the pin boot and pad spring from the caliper
body.

f
PAD SPRING
\
RETAINER

16-27
BRAKE SYSTEM

Place a shop towel over the pistons.

Position the caliper body with the pistons down and
apply small squirts of air pressure to the fluid inlets to
remove the pistons.

Push the dust seals and piston seals in and lift

DUST SEAL PISTON SEAL
them out.
Clean the seal grooves, caliper pistons and caliper pis-
ton sliding surfaces with clean brake fluid.

INSPECTION
Check the caliper cylinder and pistons for scoring,
scratches or damage.

Measure the caliper cylinder l.D.

SERVICE LIMIT: 27.060 mm (1.0654 in)

Measure the caliper piston O.D.

SERVICE LIMIT: 26.910 mm (1.0594 in)

16-28
 BRAKE SYSTEM

ASSEMBLY
CALIPER BODY

BRAKE PAD I
>
PAD PIN '
PAD PIN PLUG

Replace the dust seals and piston seals with

new ones.
Replace the caliper and bracket pin boots if there is
wear, deterioration or damage.
Apply silicone grease to the boots inner surfaces.
Be sure that each part is free from dust or dirt before
reassembly.

Coat new piston seals with clean brake fluid.

Coat new dust seals with silicone grease.
Install the piston seals and dust seals into the grooves
of the caliper body.
Coat the caliper pistons with clean brake fluid and
install them into the caliper cylinder with their closed
ends facing the pad.
I PISTON

Install the pad spring into the caliper body as shown. CALIPER BODY

Apply silicone grease to the boot inner surface.

·install the boot to the caliper.

Apply silicone grease to the boot inner surface.

Install the boot to the caliper bracket.

Install the retainer to the caliper bracket.

Install the caliper bracket to the caliper.

f
PAD SPRING BRACKET
\
RETAINER

16-29
BRAKE SYSTEM

INSTALLA Tl ON

Install the rear brake caliper to the final shaft holder.

Install and tighten the new rear caliper mounting bolts
to the specified torque.

TORQUE: 30 N•m (3.1 kgf•m, 22 lbf.ft)

Connect the brake hose to the brake caliper with new

sealing washers.

While tightening Install and tighten the brake hose oil bolt to the
the brake hose oil specified torque.
bolt, align the
brake hose end TORQUE: 34 N•m (3.5 kgf•m, 25 lbf.ft)
with thf3 stopper

Install the brake pads (page 16- 11).

Fill and bleed the hydraulic system (page 16-7).
Install the muffler (page 2-23, 26).

PARKING BRAKE
CALIPER REMOVAL/DISASSEMBLY
Remove the muffler (page 2-22, 24).

Remove the mount bolts and parking brake caliper

from the final shaft holder.
Disconnect the parking brake cable from the
brake arm.

Remove the pad pins and brake pads.

16-30
 BRAKE SYSTEM

Remove the caliper pin bolt. PIN BOOTS BRACKET

Remove the caliper bracket from the caliper body.
Remove the collar and pin boots.
Remove the pad spring.

COLLAR

Loosen the lock nut and parking brake arm.

BRAKE ARM LOCK NUT

Remove the master cylinder boot and parking

BRAKE SHAFT
brake shaft.

Remove the snap ring and washer.

Remove the push rod, washer and piston from the
caliper body.

PISTON PUSH ROD

16-31
BRAKE SYSTEM

Remove the dust seal and push rod from the caliper.

Clean the inside of the caliper and adjusting bolt

sliding surface.

Check the brake pads for wear.

PAD
Replace the brake pads if either pad is worn to the
bottom of the wear limit groove.

If necessary, replace the pads as a set.

LIMIT GROOVE

Check the caliper cylinder and pistons for scoring,

scratches or damage.

Measure the caliper cylinder l.D.

SERVICE LIMIT: 20.060 mm (0.790 in)

Measure the caliper piston O.D.

SERVICE LIMITS: 19.927 mm (0.7845 in)

Check the boot for deterioration or damage.

Check the threads of the adjust bolt and caliper body
for wear or damage.
Check the push rod for wear or damage.

CALIPER

16-32
 BRAKE SYSTEM

CALIPER ASSEMBLV /INSTALLATION

WASHER

SNAP RING CALIPER BODY

COLLAR

PIN BOOTS

PUSH ROD

~BOOT

~~LOCKNUT
/ /
BRAKEARM

BRAKE PADS ~ BRAKE SHAFT

Apply silicone grease to a new dust seal lips.

Install the dust seal into the caliper body groove.

Check the piston 0-ring.

0-RING
Replace if necessary.

16-33
BRAKE SYSTEM

Install the piston into the caliper body.

Apply silicone grease to the push rod rolling surface
and piston sliding surface.
Install the washer onto the push rod with its rounded PUSH ROD
side facing piston side.
Install the push rod and washer into the piston.
Install the washer with its rounded side facing
out side .
. rristall the snap ring info the push rod groove.

~PISTON
Apply .silicone grease to the parking brake shaft
rolling surface.
Screw the parking brake shaft to the push rod.

Apply silicone grease to the boot lips.

BOOT
Install the boot over the shaft and caliper, making sure
that the boot is seated in the groove in the shaft and
caliper properly.

Install the parking brake arm onto the shaft, aligning

BRAKE ARM

\ ,.
the punch marks.

16-34
 BRAKE SYSTEM

Temporarily install the parking brake adjusting bolt BRAKE ARM LOCK NUT
and lock nut.

Make sure that the pad spring is installed in position .

~ PINBOOTS BRACKET
Apply silicone grease to the boots inside.
Install the pin boot and pin bolt boot.

Install the caliper bracket to the caliper body.

Install the caliper pin bolt and tighten the bolt to the
specified torque.

TORQUE: 23 N•m (2.3 kgf•m, 17 lbf.ft)

,~,

COLLAR PAD SPRING

Install the pads in the caliper.

Align the pad pin bolt holes by depressing the pads
against the caliper, and tighten the pad pins.

Connect the parking brake cable to the brake arm .

Install the caliper to the final shaft holder so that the

disc is positioned between the pads, being careful not
to damage the pads.
Apply a locking agent to the parking brake caliper bolt
threads.
Install and tighte the parking brake caliper mounting
bolts to the specified torque.

TORQUE: 30 N•m (3.1 kgf•m, 22 lbf.ft)

Install the muffler (page 2-23, 26).

16-35
BRAKE SYSTEM

PARKING BRAKE LEVER LINK BOLT

Remove the inner cover (page 2-15).

Loosen the lock nut and disconnect the parking brake

cable from the parking brake lever link.
Disconnect the parking brake switch connectors.
Remove the bolts and the parking brake lever link.

Installation is in the reverse order of removal.

CONNECTOR

PARKING BRAKE CABLE PARKING BRAKE CABLE

Remove the inner cover (page 2-15).

Remove the right floor skirt (page 2-4).

Loosen the lock nut and disconnect the parking brake

cable from the parking brake lever link.

Disconnect the parking brake cable from the

parking brake.
Remove the spring.

Remove the parking brake cable from the clamp

(page 7-4).

Installation is in the reverse order of removal.

Route the parking brake cable correctly (page 1-28).

16-36
MEMO
ANTI-LOCK BRAKE SYSTEM (ABS)

REAR MASTER CYLINDER

REAR PULSER RING

R ~0-----RJBI A/Br
MAIN FUSE IGNITION ABS MAIN
RIG 30A SWITCH FUSE 10A

\
8 ffi RIG
ABS MOTOR
FUSE 30A

Bl
ABS FAIL
SAFE RELAY
FUSE 30A

A/Bl
COMBINATION
MITTR ABS WARNING
INDICATOR Bl/Br

D=
FRONT BRAKE

I
LIGHT SWITCH

·~·
WHEEL
SPEED
SENSOR
Bl

W
GN -----if'

'"'"' D="
Bl/Br Bl/Br .

WHEEL

~
SPEED
SENSOR W REAR BRAKE

:J
LIGHT SWITCH

""''"
CHECK
CONNECTOR ~"'"I Br/W 2P 0
GN

Bl/Br
-----if'
N
1 I I I
G G G G Br(W Qiu
I
I I I GI°
T Gr
T A/Bl
I
Bl
I
R
I
A/Br
I
I
I 25PWPC l
ABS ABS SERVICE DIAGNOSIS FRONT FRONT REAR REAR FRONT ABS ABS ABS IGNITION
MOTOR LOGIC CHECK WHEEL WHEEL WHEEL WHEEL /REAR WARNING FAIL MOTOR
GROUND GROUND CONNECTOR SPEED SPEED SPEED SPEED BRAKE INDICATOR SAFE
SENSOR SENSOR SENSOR SENSOR LIGHT RELAY
(+) H H (+) SWITCH

ABS MODULATOR

17-0
 ANTI-LOCK BRAKE SYSTEM (ABS)

SERVICE INFORMATION 17-1 FRONT PULSER RING 17-20

BEFORE STARTING REAR WHEEL SPEED SENSOR 17-20
TROUBLESHOOTING 17-2 17-22
REAR PULSER RING
TROUBLESHOOTING 17-7 17-22
ABS MODULATOR
FRONT WHEEL SPEED SENSOR 17-19

SERVICE INFORMATION
GENERAL
• This section covers service of the Anti-lock Brake System (ABS). For service of the conventional brake system, see page 16-4.
• When the ABS control unit detects a problem, it stops the ABS function and switches back to the conventional brake oper-
ation, and the ABS indicator blinks or stays on. Take care during the test ride.
• When the motorcycle is running and the front wheel leaves the ground for a long time (wheelies), the ABS control unit
detects difference of the front and rear wheel speeds and then the indicator blinks.
• Troubles not resulting from a faulty ABS (e.g. brake disc squeak, unevenly worn brake pad) cannot be recognized by the ABS
diagnosis system.
• Read "Before Starting Troubleshooting" carefully, inspect and troubleshoot the ABS sytem according to the Diagnostic
Troubleshooting Flow Chart. Observe each step of the procedures one by one. Write down the problem code and probable
faulty part before starting diagnosis and troubleshooting.
• After troubleshooting , erase the problem code and perform the pre-start self-diagnosis to be sure that the ABS indicator is
operating normally.
• Be careful not to damage the wheel speed sensor and pulser ring when removing and installing the wheel or speed sensor.
• The ABS control unit may be damaged if dropped. Also if a connector is disconnected when current is flowing, the exces-
sive voltage may damage the ECU. Always turn off the ignition switch before servicing.
• Do not disassemble the ABS modulator. Replace the modulator as an assembly when it is faulty.
• Refer to the ABS circuit diagram (page 17-0).
• The following color codes are used throughout this section.

Bu= Blue G =Green Lg = Light Green R =Red

Bl= Black Gr= Gray 0 =Orange W =White
Br= Brown Lb = Light Blue P =Pink Y =Yellow

TORQUE VALUES
Front wheel pulser ring mounting bolt 8 N•m (0.8 kgf•m, 5.1 lbf•ft) ALOC bolt; replace with a new one
Rear wheel pulser ring mounting bolt 8 N•m (0.8 kgf•m, 5.1 lbf•ft) ALOC bolt; replace with a new one
ABS modulator mounting bolt 12 N•m ( 1.2 kgf•m, 9 lbf•ft)
Brake pipe nut 14 N•m ( 1.4 kgf•m, 10 lbf•ft)

17-1
ANTI-LOCK BRAKE SYSTEM (ABS)

BEFORE STARTING TROUBLESHOOTI NG

• ABS (Anti-Lock Brake System) is equipped with the self-diagnostic system described.
• Before checking ABS, turn the ignition switch "ON" and check that the ABS indicator lights.
Then, start the engine and ride the scooter and raise the vehicie speed to approximately 10 km/h.
The ABS is normal, if the ABS indicator goes out.
• When checking the ABS, always follow the steps in the troubleshooting flow chart (page 17-7 thru 18).
• The ABS indicator light blinks in the following cases.
- Front or rear wheel turns when other wheel stops
- Noise pulse
- The ABS modulator operates for more than 30 seconds.
• When more than one failure occurs, the indicator shows the blinks in the order of lowest number to highest number (for
example: see below).
• The ABS indicator denotes the failure codes (the number of blinks from 11 to 81 ).

ABS INDICATOR
CODE:12 CODE:33
1.3 sec.
ON - - ------.

OFF - -

2 sec. 3.6 sec. 3.6 sec. 0.4 sec. 0.5 sec_""".____ 3.6 sec.

IGNITION 0.3 sec. 0.4 sec.

SWITCH "ON"

• After troubleshooting, reset the problem code (page 17-3).

SELF-DIAGNOSIS PROCEDURE
(After 1Okm/h running, ABS indicator
lights or blinks)
Turn the ignition switch "ON':
Be sure that the ABS indicator lights.
Start the engine and ride the scooter and raise the
vehicle speed to approximately 10km/h.

The ABS is normal, if the ABS indicator goes out.

If the ABS indicator does not go out, perform the fol- ~®®©~
lowing:
ABS INDICATOR~
1. Turn the ignition switch "OFF':

Remove the left side body cover (page 2-6).

Short the ABS service check 3P (Natural) connec-

tor terminals with a jumper wire.

TERMINALS: Brown/White - Green

SERVICE CHECK 3P (NATURAL) CONNECTOR

17-2
 ANTI-LOCK BRAKE SYSTEM (ABS)

2. Do not squeeze the brake lever.

Turn the ignition switch "ON':
Read and record the how many times indicator
blinks, and determine the cause of the problem
(page 17-6).

ABS INDICATOR~

3. Turn the ignition switch "OFF':

Remove a jumper wire from the ABS service check

3P (Natural) connector.

\
SERVICE CHECK 3P (NATURAL) CONNECTOR

SELF-DIAGNOSIS MEMORY RESET

PROCEDURE
1. Turn the ignition switch "OFF':

Remove the left side body cover (page 2-6).

Short the ABS service check 3P (Natural) connec-

tor terminals with a jumper wire.

TERMINALS: Brown/White - Green

2. Squeeze the brake lever and turn the ignition

switch "ON·:
\
SERVICE CHECK 3P (NATURAL) CONNECTOR

3. Release the brake lever when the ABS indicator

goes out.

4. Squeeze the brake lever when the ABS indicator

lights.

5. Release the brake lever when the ABS indicator

goes out.

17-3
ANTI-LOCK BRAKE SYSTEM (ABS)

6. Check the ABS indicator blinks 2 times.

If the ABS indicator does not blink 2 times, the

self-diagnostic memory has not been erased.

Repeat the memory reset procedure from step

one.

7. Turn the ignition switch "OFF':

Remove a jumper wire from the ABS service check

3P (Natural) connector.

SERVICE CHECK 3P (NATURAL) CONNECTOR

17-4
 ANTI-LOCK BRAKE SYSTEM (ABS)

DIAGNOSTIC TROUBLESHOOTING FLOW CHART

I NOTICE I
Be careful not to damage the wheel speed sensor and pulser ring when servicing.
• All connector diagrams in the flow charts are viewed from the terminal side.
• Perform inspections with the ignition switch turned to "OFF'; unless otherwise specified.
• Use a fully charged battery. Do not diagnose with a charger connected to the battery.
• When the ABS control unit or modulator is detected to be faulty, recheck the wire harness and connector connections close-
ly before replacing it.
• After troubleshooting, erase the problem code and perform the pre-start self-diagnosis to be sure that the ABS Indicator is
operating normally.
• The ABS indicator might blink in the following cases.
- Incorrect tire pressure.
- Tires not recommended for the motorcycle were installed (incorrect tire size).
• The ABS indicator might blink while riding under the following conditions. Erase the problem code and perform the pre-start
self-diagnosis. The ABS is normal if the indicator goes off. Ask the rider for the riding conditions in detail when the motor-
cycle is brought in for inspection.
- The motorcycle has continuously run bumpy roads .
- After riding (after the pre-start self-diagnosis), the engine was kept running and the rear wheel turning (for more than 30
seconds) with the motorcycle placed on the centerstand .

17-5
ANTI-LOCK BRAKE SYSTEM (ABS)

ABS INDICATOR FAILURE CODE

Number of ABS Refer to

indicator blinks Problem/Symptoms ( 1) (2) Cause
page
Does not light ABS indicator does not light 17-7
Stay lit ABS indicator stays lit 17-8
Blinks ABS indicator blinks 17-11
11 Front wheel speed sensor
•• • Open or short circuit in wheel speed sensor
wire.
17-12, 14

13 Rear wheel speed sensor

•• • Short circuit between the wheel speed sen-
sor wire terminals.
12 Front wheel speed sensor
• • When front or rear wheel speed is over
10 km/h, no pulse at other side speed sensor.
17-12, 14

• Short circuit between the wheel speed sen-

14 Rear wheel speed sensor
• sor wire terminals.
• Input noize pulse.
21 Front pulser ring
• • Pulser ring is damaged or cracked. 17-12, 14
23 Rear pulser ring
•
31
32
Solenoid valve
•• • Faulty ABS modulator. 17-16

33
34
37
38
41 Front wheel lock
• •The wheel lock while riding the scooter. 17-12, 14
43 Rear wheel lock
•
51 Motor lock
• • Faulty ABS modulator. 17-16
52 Motor stuck off
•
53 Motor stuck on
••
54 Fail safe relay
• • Faulty fail safe relay 17-17
61 Ignition voltage
•• • Ignition voltage is too low 17-18
62 Ignition voltage
• • Ignition voltage is too high
71 Tire size
• • lncorrectry tire size.
81 CPU
•• • Faulty ABS modulator.

(1) Prestart inspection: While the ignition switch "ON" to the motorcycle starts.
(2) Ordinary inspection : While the prestart inspection stops to the ignition switch "OFF':

17-6
 ANTI-LOCK BRAKE SYSTEM (ABS)

TROUBLESHOOTING
ABS INDICATOR DOES NOT LIGHT
ABS INDICATOR INPUT VOLTAGE INSPECTION ._DOES NOT~• Blown the combination meter fuse (10A).
Turn the ignition switch "ON" and check the LIGHT • Open circuit between the combination meter and
combination meter light comes. combination meter fuse (10A).

I
LIGHTS

ABS MODULATOR INSPECTION •

Turn the ignition switch "OFF" and disconnect
LIGHTS ---11•~ • Loose or poor contact on the ABS modulator
25P (Black) connector.
• Faulty ABS modulator.
the ABS modulator 25P (Black) connector.
Turn the ignition switch "ON" and check that the
ABS indicator lights.

DOES NOT LIGHT

'
ABS INDICATOR INPUT VOLTAGE LINE INSPEC-
TION
Disconnect the combination meter 28P (Black)
connector.
CONTINUITY ~ • Short circuit in Red/Black wire between the com -
bination meter 28P (Black) connector and ABS
modulator 25P (Black) connector.

Check for continuity between the Red/Black ter-

minal and Body ground at the combination
meter 28P (Black) connector wire harness side.

~
/

\ .
\ ,,._~'--~---­
STANDARD: No continuity

NO CONTINUITY

ABS INDICATOR GROUND LINE INSPECTION LIGHTS ____.. • Open circuit in Green wire between the combi-
Connect the combination meter 28P (Black) con- nation meter 28P (Black) connector and body
nector. Short the Green terminal and body ground .
ground at the combination meter 28P (Black)
connector using a jumper wire. DOES NOT
Turn the ignition switch "ON" and check that the LIGHT --.. • Faulty combination meter.
ABS indicator lights.

17-7
ANTI-LOCK BRAKE SYSTEM {ABS)

ABS INDICATOR STAYS LIT

SERVICE CHECK CONNECTOR SHORT CIRCUIT CONTINUITY__. • Short circuit in Brown/White wire between the
INSPECTION service check connector and ABS modulator 25P
Disconnect the ABS modulator 25P (Black) con- (Black) connector.
nector.
Check for continuity between the Brown/White
terminal and body ground at the ABS modula-
tor 25P (Black) connector wire harness side.

STANDARD: No continuity

NO CONTINUITY

SERVICE CHECK CONNECTOR OPEN CIRCUIT CONTINUITY__.. • Open circuit in Brown/White wire between the
INSPECTION service check 3P (Natural) connector and ABS
Short the service check 3P (Natural) connector modulator 25P (Black) connector.
Brown/White terminal and Green terminals • Open circuit in ground line.
using a jumper wire.
Check for continuity between the Brown/White
terminal and body ground at the ABS modula-
tor 25P (Black) connector wire harness side.

STANDARD: No continuity

NO CONTINUITY

FAIL SAFE RELAY FUSE (30A) INSPECTION BLOWN ---11..,_ · Replace the fail safe relay (30A) and inspect
Remove a jumper wire from the service check again.
3P (Natural) connector.
Check fail safe relay fuse (30A) on the fuse box
for a blown.

NORMAL

17-8
•
 ANTI-LOCK BRAKE SYSTEM (ABS)

FAIL SAFE RELAY LINE OPEN CIRCUIT INSPEC- NO VOLTAGE---.• Open circuit in Black wire between the fail safe
TION relay fuse (30A) and ABS modulator 25P (Black)
Disconnect the ABS modulator 25P (Black) con- connector.
nector.
Measure the voltage between the Black terminal
and --body ground at .the .ABS modulator 25P
(Black) connector wire harness side.

STANDARD: Battery voltage

BATTERY VOLTAGE

ABS MODULATOR INPUT VOLTAGE INSPEC- NO VOLTAGE_..• Open circuit in Red/Brown wire between the main
TION fuse box and ABS modulator 25P (Black) connec-
Turn the ignition switch "ON': tor.
Measure the voltage between the Red/Brown
terminal and body ground at the ABS modula-
tor 25P (Black) connector wire harness side.

STANDARD: Battery voltage

BATTERY VOLTAGE

COMBINATION METER INSPECTION DOES NOT_____.. • Faulty combination meter.

GO OUT
Short the Red/Black wire of the combination
meter 28P (Black) connector and body ground
using a jumper wire.
Check that the ABS indicator goes out.

GOES OUT

t
17-9
ANTI-LOCK BRAKE SYSTEM (ABS)

ABS MODULATOR INPUT VOLTAGE INSPEC- DOES NOT

GO OUT _____. • Faulty combination meter.
TION
Remove a jumper wire from the combination
meter 28P (Black) connector.
Short the Red/Black wire of the ABS modulator
25P (Black) connector and body ground using a
jumper wire.
Check that the ABS indicator goes out.

~~~:""""~

GOES OUT

GROUND LINE OPEN CIRCUIT INSPECTION DggsO~~T-----. • Open circuit in Green wire between the ABS
Remove a jumper wire from the ABS modulator modulator 25P (Black) connector and body
25P (Black) connector. ground.
Short the Red/Black wire and Green wire of the
ABS m odulat or 25P (Black) connector using a

GOES OUT

+
• Faulty ABS modulator.

17-10
 ANTI-LOCK BRAKE SYSTEM (ABS)

ABS INDICATOR BLINKS

Check for service check 3P (Natural) connector

for connection.

I
NO CONNECTION

SERVICE CHECK CONNECTOR SHORT CIRCUIT CONTINU ITY-. • Short circuit in Brown/White wire between the
INSPECTION service check connector and ABS modulator 25P
Disconnect the ABS modulator 25P (Black) con- (Black) connector.
nector.
Check for continuity between the Brown/White
terminal and body ground at the ABS modula-
tor 25P (Black) connector wire harness side.

STANDARD: No continuity

NO CONTINUITY

+
• Faulty ABS modulator.

17-11
ANTI-LOCK BRAKE SYSTEM (ABS)

ABS INDICATOR 11, 12, 21 OR 41 BLINKS (FRONT WHEEL SPEED SENSOR AND
ABS MODULATOR)
• If the ABS indicator 41 blinks, check for brake drag before troubleshooting.

WHEEL PULSER AIR GAP INSPECTION ABNORMAL-. • Check each part of deformation and looseness
and correct accordingly.

NORMAL

WHEEL PULSER INSPECTION ABNORMAL_. • Remove any deposis and install properly or
Check for iron or other magnetic deposits replace any faulty parts.
between the pulser ring and wheel speed sen-
sor.
Check for loose pulser ring or wheel speed sen-
sor.
Check the pulser ring for deformation or dam-
age (e.g.,chipped teeth) and the wheel speed
sensor tip for damage.

NORMAL

•
WHEEL SPEED SENSOR LINE SHORT CIRCUIT
INSPECTION AT ABS MODULATOR
CONTINUITY ~ • Go to the WIRE HARNESS CONTINUITY
INSPECTION (page 17-13).
Disconnect the ABS modulator 25P (Black) con-
nector.
Measure for continuity between the ABS modu-
lator 25P (Black) connector wire harness side
terminals and body ground.
Connection: Pink /Black - Body ground
Green/Orange - Body ground
Standard: No continuity

NO CONTINUITY

17-12
•
 ANTI-LOCK BRAKE SYSTEM {ABS)

WHEEL SPEED SENSOR LINE SHORT CIRCUIT CONTINUITY~ • Faulty front wheel speed sensor.
INSPECTION AT SENSOR CONNECTOR
Check for continuity between the sensor side
terminals and body ground.
Connection: Black - Body ground
. _. . __ _____ __ ... .. __. .. .... ____W.b.i!~ _:J~~-~y _gr()un_d ... __

NO CONTINUITY

WIRE HARNESS CONTINUITY INSPECTION NO CONTINUITY-.. • Open circuit in wire between the ABS modula-
Disconnect the front wheel speed sensor 2P tor and front wheel speed sensor.
(Orange) connector and short the terminals of
the connector with a jumper wire.
Check for continuity between the ABS modula-
tor 25P (Black) connector wire side terminals.
Connection: Pink/Black - Green/Orange
Standard: Continuity

CONTINUITY

RECHECKING THE INDICATOR FUNCTION NOT BLINK---.. • Faulty original wheel speed sensor.
Replace the front wheel speed sensor with a
new one (page 17-19).
Connect the ABS modulator 25P (Black) connec-
tor.
Reset the self-diagnosis memory (page 17-3).
Test-ride the motorcycle and perform the self-
diagnosis and check the ABS indicator.

BLINK

+
• Faulty ABS modulator.

17-13
ANTI-LOCK BRAKE SYSTEM (ABS)

ABS INDICATOR 13, 14, 23 OR 43 BLINKS (REAR WHEEL SPEED SENSOR AND
ABS MODULATOR)
• If the ABS indicator 43 blinks, check for brake drag before troubleshooting.

WHEEL PULSER AIR GAP INSPECTION ABNORMAL~ • Check each part of deformation and looseness
Measure the air gap between the speed sensor and correct accordingly.
and pulser ring (page 17-20).
Standard air gap: 0.2 - 1.2 mm (0.008 - 0.050 in)

NORMAL

WHEEL PULSER INSPECTION•

Check for iron or other magnetic deposits
...__ABNORMAL~ • Remove any deposis and install properly or
replace any faulty parts.
between the pulser ring and wheel speed sen-
sor.
Check for loose pulser ring or wheel speed sen-
sor.
Check the pulser ring for deformation or dam-
age (e.g.,chipped teeth) and the wheel speed
sensor tip for damage.

I
NORMAL

•
WHEEL SPEED SENSOR LINE SHORT CIRCUIT
INSPECTION AT ABS MODULATOR
CONTINUITY__... • Go to the WIRE HARNESS CONTINUITY
INSPECTION (page 17-15).
Disconnect the ABS modulator 25P (Black) con-
nector.
Measure for continuity between the ABS modu-
lator 25P (Black) connector wire harness side
terminals and body ground.
Connection: Pink/White - Body ground
Green/Red - Body ground
Standard: No continuity

NO CONTINUITY

•
17-14
 ANTI-LOCK BRAKE SYSTEM (ABS)

WHEEL SPEED SENSOR LINE SHORT CIRCUIT NO CONTINUIT Y-.. • Faulty rear wheel speed sensor.
INSPECTION AT SENSOR CONNECTOR
Check for continuity between the sensor side
terminals and body ground
Connection: Black - Body ground
~hi~~ - Bo~y ~ound

CONTINUITY

•
WIRE HARNESS CONTINUITY INSPECTION
Disconnect the rear wheel speed sensor/vehic le
NO CONTINUIT Y--.. • Open circuit in wire between the ABS modula-
tor and front wheel speed sensor.
speed sensor 6P (Natural) connector and short
the terminals of the connector with a jumper
wire.
Check for continuity between the ABS modula-
tor 25P (Black) connector wire harness side ter-
minals.
Connection: Pink/White - Green/Red
Standard: Continuity

CONTINUITY

RECHECKING THE INDICATOR FUNCTION NOT BLINK-----... • Faulty original wheel speed sensor
Replace the rear wheel speed sensor and with a
new one (page 17-21 ).
Connect the ABS modulator 25P (Black) connec-
tor.
Reset the self-diagnosi s memory (page 17-3).
Test-ride the motorcycle and perform the self-
diagnosis and check the ABS indicator.

BLINK

• Faulty ABS modulator.•

17-15
 ANTI-LOCK BRAKE SYSTEM (ABS)

ABS INDICATOR 31, 32, 33, 34, 37 OR 38 BLINKS (SOLENOID VALVE)

Reset the self-diagnosis memory (page 17-3) and turn the ignition switch "ON': Check that the ABS indicator lights.
Operate the self-diagnosis system (page 17-2) and Check that the ABS indicator blinks 31, 32, 33, 34, 37 or 38 times.
If the ABS indicator blinks 31, 32, 33, 34, 37 or 38 times, replace the ABS modulator.

ABS INDICATOR 51, 52 OR 53 BLINKS (MOTOR)

ABS MOTOR FUSE (30A) INSPECTION ABNORMAL~ • Replace the ABS motor fuse (30A) and inspect
Check for a blown ABS motor fuse (30A) on the
again.
main fuse box.

NORMAL

ABS MOTOR LINE OPEN CIRCUIT INSPECTION

NO VOLTAGE----.. • Open circuit in Red wire between the ABS motor
Disconnect the ABS modulator 25P (Black) con-
fuse (30A) and ABS modulator 25P (Black) con-
nector.
nector.
Measure the voltage between the ABS modula-
tor 25P (Black) connector wire harness side and
body ground.

CONNECTION: Red (+) - Body ground (-)

STANDARD: Batterty voltage

BATTERY VOLTAGE

•
RECHECK THE INDICATOR FUNCTION
Reset the self-diagnosis memory (page 17-3).
Then test-ride with the vehicle speed 10km/h or
, _ 51, 52,0R ____.... Faulty ABS modulator.
53 BLINKS

more.
Operate the self-diagnosis system (page 17-2)
and check the ABS indicator blinks 51, 52 or 53
times.

I
NO BLINK

• ABS is normal. •
17-16
 ANTI-LOCK BRAKE SYSTEM (ABS)

ABS INDICATOR 54 BLINKS (FAIL SAFE RELAY)

FAIL SAFE RELAY FUSE (30A) INSPECTION ABNORMAL---..• Replace the fail safe relay fuse (30A) and inspect
Check for a blown fail safe relay fuse (30A) on again.
the main fuse box.

NORMAL

FAIL SAFE RELAY LINE OPEN CIRCUIT INSPEC- NO VOLTAGE__.. • Open circuit in Black wire between the fail safe
TION relay fuse (30A) and ABS modulator 25P (Black)
Disconnect the ABS modulator 25P (Black) con- connector.
nector.
Measure the voltage between the ABS modula-
tor 25P (Black) connector wire harness side and
body ground.

CONNECTION: Black(+) - Body ground(-)

STANDARD: Batterty voltage

BATTERY VOLTAGE

RECHECK THE INDICATOR FUNCTION 54 BLINKS~· Faulty ABS modulator.

Reset the self-diagnosis memory (page 17-3).
Then test-ride with the vehicle speed 10km/h or
more.
Operate the self-diagnosis system (page 17-2)
and check the ABS indicator blinks 54 times.

NO BLINK

t
• ABS is normal.

17-17
 ANTI-LOCK BRAKE SYSTEM (ABS)

ABS INDICATOR 61OR62 BLINKS (IGNITION VOLTAGE)

ABS MAIN FUSE INSPECTION

ABNORMAL____....• Replace the ABS main fuse (10A) and inspect it
Check for a blown ABS main fuse (10A) on the
main fuse box. again.

NORMAL

~
IGNITION VOLTAGE LINE INSPECTION
ABNORMAL __.... • Check the charging system (page 18-5).
Disconnect the the ABS modulator 25P (Black)
• Open circuit in Red/Brown wire.
connector.
Measure the voltage between the ABS modula-
tor 25P (Black) connector wire harness side and
body ground.
CONNECTION: Red/Brown(+) - Body ground(-)
STANDARD: 10 - 17V at all time

NORMAL

RECHECK THE INDICATOR FUNCTION 61

OR 62 ___.. • Faulty ABS modulator.
Reset the self-diagnosis memory (page 17-3). BLINKS
Then test-ride with the vehicle speed 10km/h or
more.
Operate the self-diagnosis system (page 17-2)
and check the ABS modulator.

NO BLINK

• ABS is normal. •
ABS INDICATOR 71 BLINKS (INCORRECT TIRE SIZE)
• Check that the all tires are the specified size pressure and are inflated to the proper specification.
• Reset the self-diagnosis memory (page 17-3). Then test-ride with the vehicle speed 10km/h or more.
Operate the self-diagnosis system (page 17-2) and Check that the ABS indicator blinks 71 times.
If the ABS indicator blinks 71 times, replace the ABS modulator.

ABS INDICATOR 81 BLINKS (CPU)

• Reset the self-diagnosis memory (page 17-3). Then test-ride with the vehicle speed 10km/h or more.
Operate the self-diagnosis system (page 17-2) and Check that the ABS indicator blinks 81 times.
If the ABS indicator blinks 81 times, replace the ABS modulator.

17-18
 ANTI-LOCK BRAKE SYSTEM (ABS)

FRONT WHEEL SPEED SENSO R

AIR GAP INSPECTION
Measure the clearance (air gap) between the sensor
and pulser ring at several points by turning the wheel
slowly.
It must be within specification.

STANDARD: 0.2 - 1.2 mm (0.008 - 0.050 in)

The sensor air gap cannot be adjusted.

If it is not within specification, check each installed PULSER RING SPEED SENSOR
part for deformation, looseness and damage.

REMOVA L/INSTALLA Tl ON
Remove the front cover (page 2-14).

Disconnect the front wheel speed sensor 2P (Orange)

connector.

Remove the front wheel speed sensor wire from the

wheel speed sensor clamps.

Remove the screw and clamp.

Remove the front wheel speed sensor wire from the
clamp.
Remove the bolts and front wheel speed sensor.

17-19
ANTI-LOCK BRAKE SYSTEM (ABS)

Check the front wheel speed sensor for damage or

cracks.

Replace the front wheel speed sensor if necessary

(see above).

Route the wire Installation is in the reverse order of removal.

harness proparly
(page 1-20). TORQUE: 15 N•m (1.5 kgf•m, 11 lbMt)

FRONT PULSER RING

REMOVAL/INSTALLA Tl ON
Remove the front wheel (page 14-3).

Remove the torx bolts and pulser ring.

Install the pulser ring and new torx bolts.

Tighten the torx bolts to the specified torque.

TORQUE: 8 N•m (0.8 kgf•m, 5.8 lbf.ft)

INSPECTION
Check the pulser ring for damage or cracks .
Replace the pulser ring if necessary (see above).

REAR WHEEL SPEED SENSOR

AIR GAP INSPECTION
Measure the clearance (air gap) between the sensor
and pulser ring at several points by turning the wheel
slowly.
It must be within specification .

STANDARD: 0.2-1.2 mm (0.008- 0.050 in)

If it is not within specification, check each installed

part for deformation, looseness and damage.

17-20
 ANTI-LOCK BRAKE SYSTEM (ABS)

REMOVAL /INSTALL ATION 3P:- STD TYPE/6P: AFTER '02 ABS

TYPE(NATUR AL)CONNEC TOR
Remove the following:
- Rear wheel (page 15-4)
- Left passenger footpeg (page 2-12)
- Left front cover (page 10-3)

Disconnect the speed sensor wire 3P (Natural) con-

nector.
AFTER '02 (ABS Disconnect the rear wheel speed sensor/speed sensor
TYPE): wires 6P (Natural) connector.
Remove the rear wheel speed sensor/speed sensor
wires clamp from the frame.

Remove the bolts and speed sensor cord clamp.

r

Remove the bolts and rear wheel speed sensor pro-

tector and speed sensor protector.

Remove the rear wheel speed sensor wire clamp from

the protector.

Disconnect the speed sensor 3P (Black) connector.

Remove the bolts and rear wheel speed sensor.
Check the rear wheel speed sensor for damage or
cracks.

Replace the rear wheel speed sensor if necessary (see

above).

Route the wire Installation is in the reverse order of removal.

harness proparly
(page 7-20). TORQUE: 15 N•m (1.5 kgf•m, 11 Ibf.ft)

17-21
ANTI-LOCK BRAKE SYSTEM (ABS)

REAR PULSER RING

REMOVAL/INSTALLATION
Remove the rear wheel (page 15-4).

Remove the torx bolts and pulser ring .

Install the pulser ring and new torx bolts.

Tighten the torx bolts to the specified torque.

TORQUE: 8 N•m (0.8 kgf•m, 5.8 lbMt)

INSPECTION
Check the pulser ring for damage or cracks.
Replase the pulser ring if necessary (see above) .

ABS MODULATOR
REMOVAL
Remove the front cover (page 2-14).
Drain the front brake hydraulic system (page 16-4).

Pull up the ABS modulator 25P (Black) connector lock

and disconnect the ABS modulator 25P (Black) con-
nector.

Remove the brake pipe nuts and disconnect the brake

pipes from the ABS modulator.

17-22
 ANTI-LOCK BRAKE SYSTEM (ABS)

Be care ful no t to Remove the ABS modulator mount bolts.

damage-the brake Remove the ABS modulator to the-front cover stay.
pipes.

INSTALLATION

I BRAKE PIPE

~~~
(TO REAR MASTER
CYLINDER)

' ' BOLTS/COLLARS/RUBBERS

ABS MODULATOR ~ ABS MODULATOR MOUNT BOLTS

25P(BLACK)CONNECTOR

Be careful not to Install the ABS modulator to the front cover stay
damage the brake aligning the hole on the ABS modulator with the
pipes. mount rubber on the front cover stay.

Install the ABS modulator mount bolts.

Tighten the ABS modulator mount bolts.

17-23
ANTI-LOCK BRAKE SYSTEM (ABS)

Install the brake pipes to the ABS modulator properly

and tighten the nuts to the specified torque.

TORQUE: 14 N•m (1.4 kgf•m, 10 lbMt)

Connect the ABS modulator 25P (Black) connector

and push down the ABS modulator 25P (Black) con-
nector lock.

Fill and bleed the hydraulic system (page 16-5).

Install the front cover (page 2-14).

17-24
MEMO
BATTERY /CHARGING SYSTEM

SYSTEM DIAGRAM
STD TYPE:

REGULATOR/RECTIFIER

AFTER '02 (ABS TYPE):

R .... RED

r--= FUSE (15 A)

R/Bl--0~ R
Y ... . YELLOW
G .... GREEN
Bl. ... BLACK

Y Y Y
I
Bl R
I lr
R G G
R

3P
3P~ ~6P MAIN FUSE (30 A)

y y y
Y Y Y Bl R R G G

REGULATOR/RECTIFIER
e
BATTERY

ALTERNATOR

18-0
 18. BAT TER Y/CH ARG ING SYS TEM
SYSTEM DIAGRAM 18-0 CHARGING SYSTEM INSPECTION 18-5

SERVICE INFORMAT ION 18-1 ALTERNATOR CHARGING COIL 18-6

TROUBLESHOOTING 18-3 REGULATOR/RECTIFIER 18-7

BATTERY 18-4

SERVICE INFORM ATION

GENERAL

A CAUTI ON
ventilation
• The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate
when charging.
protective
• The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear
clothing and a face shield.
- If electrolyte gets on your skin, flush with water.
- If electrolyte gets in your eyes, flush with water for at least 15 minutes and call a physician immediately.
• Electrolyte is poisonous.
immedi-
- If swallowed, drink large quantities of water or milk and call your local Poison Control Center or physician
ately, KEEP OUT OF REACH OF CHILDREN.

• Always turn off the ignition switch before disconnectin g any electrical component.
while the igni-
• Some electrical components may be damaged if terminals or connectors are connected or disconnected
tion switch is turned to "ON" and current is present.
• For extended storage, remove the battery, give it a full charge, and store it in a cool, dry place.
terminal.
• For a battery remaining in a stored motorcycle, disconnect the negative battery cable from the battery
• The maintenance free battery must be replaced when it reaches the end of its service life.
same condi-
• The battery can be damaged if overcharged or undercharge d, or if left to discharge for long period. These
Even under normal use, the performance of the battery dete-
tions contribute to shortening the "life span" of the battery.
riorates after 2 - 3 years.
quickly and even-
• Battery voltage may recover after battery charging, but under heavy load, the battery voltage will drop
often suspected as the problem. Battery overcharge often results
tually die out. For this reason, the charging system is
battery itself, which may appear to be an overcharging symptom. If one of the battery cells is short-
from problems in the
these con-
ed and battery voltage does not increase, the regulator/rec tifier supplies excess voltage to the battery. Under
ditions, the electrolyte level goes down quickly.
if the battery is
• Before troubleshoot ing the charging system, check for proper use and maintenance of the battery. Check
without riding
frequently under heavy load, such as having the headlight and taillight on for long periods of time
the vehicle.
ft!ll
• The battery self-discharg es when the vehicle is not in use, for this reason, charge the battery every 2
weeks to prevent U:.
sulfation from occurring.
• When checking the charging system, always follow the steps in the troubleshoot ing flow chart (page 18-3).
• For alternator service, refer to section 12.

18-1
 BATTERV /CHARGING SYSTEM

BATTERV CHARGING
• Turn power ON/OFF at the charger, not at the battery terminal.
• For battery charging , do not exceed the charging current and time specified on the
battery. Using excessive current or
extending the charging time may damage the battery.
• Quick charging should only be done in an emergency ; slow charging is preferred.

BATTERV TESTING
Refer to the instructions in the Operation Manual for the recommen ded battery tester for
details about battery testing. The rec-
ommended battery teste r puts a " load " on the battery so that the actual battery condition
can be measured.

Recommended battery tester Micro 404XL (U.S.A. only), BM-210 or equivalent

SPECIFICATIONS

ITEM SPECIFICATIONS
Battery Capacity 12 V - 11 (10) Ah
Current leakage 1.1 mA max
Voltage (20°C/68°F) Fully charged 13.0 - 13.2 v
Needs charging Below 12.3 V
Charging current Normal 1.1 A/5 - 10 h
Quick 5.5 A/0.5 h
A lternator Capacity 441 W/5,000 min-1 (rpm)
Charging coil resistance (20°C/68°F) 0.1 - 0.5 Q

TOOL
Christie battery charger MC1012/2 (U.S.A. only) or equivalent
Battery tester M icro 404XL (U.S.A. only), BM-210 or equivalent

18-2
 BATTERY /CHARGIN G SYSTEM

TROUBLESHOOTING
Battery is damaged or weak

Remove the battery (page 18-4). .....---- Incorrect --.. • Faulty battery.
Check the battery condition using the recom-
mended battery tester.

RECOMMENDED BATTERY TESTER:

Micro 404XL (U.S.A. only), BM-210 or equivalent

I
Correct

+
Install the battery (page 18-4). .....---- Incorrect Disconnect the regulator/rec tifier connectors and
Check the battery current leakage (leak test: page recheck the battery current leakage.
18-7).

SPECIFIED CURRENT LEAKAGE:

1.1 mA max.

I
Correct
•
Incorrect

L
Correct

Faulty reguttor/rect ifier.

• Shorted wire harness.

• Faulty ignition switch.

Check the alternator charging coil (page 18-6). Incorrect __.. • Faulty charging coil.

STANDARD: 0.1 - 0.5 Q (20°C/68°F)

Correct

+
Measure and record the battery voltage using a - - Correct _.... • Faulty battery.
digital multimeter (page 18-4).
Start the engine.
Measure the charging voltage (page 18-6).
Compare the measuremen ts to the results of the
following calculation.

Measured BV <Measured CV< 15.5 V

• BV=Battery Voltage
• CV=Charging Voltage

I
Incorrect

Perform the regulator/rec tifier wire Incorrect __.. • Open circuit in related wire.
harness inspection (page 18-7). • Loose or poor contacts of related terminal.
• Shorted wire harness.

Correct

• Faulty reguttor/rect ifier.

18-3
BATTERY /CHARGIN G SYSTEM

BATTERY
REMOVA L/INSTALLATl ON
Turn the ignition switch OFF.
Unlock and open the seat {page 2-3).

Remove the special bolt and battery box cover.

BATTERY BOX COVER

With the ignition switch to "OFF'; disconnect the neg-

ative {-) cable first, then remove the terminal cover BATTERY
and disconnect the positive {+) cable.

Installation is in the reverse order of removal.

NEGATIVE TERMINAL POSITIVE TERMINAL

VOLTAGE INSPECTION BATTERY

Remove the battery cover {see above).

Measure the battery voltage using a commercially IID

available digital multimeter.

VOLTAGE (20°C/68°F):
©
cc
Fully charged: 13.0 - 13.2 V
Under charged: Below 12.3 V

18-4
 BATTERY /CHARGIN G SYSTEM

BATTERY TESTING
Refer to the instructions that are appropriate to the
battery testing equipment available to you.

TOOL:
Battery tester Micro 404XL (USA only),
BM-210 or equivalent

BATTERY CHARGING (U.S.A. ONLY)

Refer to the instructions that are appropriate to the
battery charging equipment available to you.

TOOL:
Battery charger Christie battery charger
(MC1012/2) or equivalent

CHARGING SYSTEM INSPECTION BATTERY

Remove the battery cover (page 18-4).

CURRENT LEAKAGE TEST

Turn the ignition switch OFF, and disconnect the neg-
ative (-) cable from the battery.
Connect the ammeter (+) probe to the negative (-)
cable and the ammeter (-) probe to the
battery(-) terminal.
With the ignition switch OFF, check for
current leakage.

When measuring current using a tester, set it to a high

range, and then bring the range down to an appropri-
ate level. Current flow higher than the range selected
may blow out the fuse in the tester.
While measuring current, do not turn the ignition
switch ON. A sudden surge of current may blow out
the fuse in the tester.

SPECIFIED CURRENT LEAKAGE: 1.1 mA max.

If current leakage exceeds the specified value, a short-

ed circuit is likely.
Locate the short by disconnectin g connections one by
one and measuring the current.

18-5
BATTERY/CHARGING SYSTEM

CHARGING VOLTAGE INSPECTION BATTERY

Be sure that the battery is in good condition before
performing this test.

Do not disconnect Start the engine and warm it up to the operating

the battery or any temperatur e; stop the engine.
cable in the Connect the multimeter between the positive and
charging system
negative terminals of the battery.
without first
switching off the
ignition switch . To prevent a short, make absolutely certain which are
Failure to follow the positive and negative terminals or cable.
this precaution With the headlight on and turned to the high beam
can damage the position, restart the engine.
tester or electrical Measure the voltage on the multimeter when the
components . engine runs at 5,000 min·1 (rpm) .

STANDARD :
Measured BV < Measured CV < 15.5 V
• BV=Battery Voltage
• CV=Chargi ng Voltage

ALTERNATOR CHARGING COIL ALTERNATOR CONNECTOR

INSPECTION
Remove the right passenger footpeg (page 2-12).

Disconnect the alternator 3P white connector.

Measure the resistance between the Yellow wire ter-

minals of the alternator side connector. ALTERNATOR CONNECTOR

STAND ARD: 0.1 - 0.5 Q (20°C/68°F )

Check for continuity between each Yellow wire termi-

nal of the alternator side connector and ground.
There should be continuity.
co

Replace the alternator stator if resistance is out of

specificatio n, or if any wire has continuity to ground.

Refer to section 12 for alternator stator replacemen t.

18-6
 BATTERY /CHARGING SYSTEM

REGULATOR/RECTIFIER REGULATOR/RECTIFIER CONNECTOR

WIRE HARNESS INSPECTION

Remove the front cover (page 2-14).

Disconnect the regulator/rectifie r 6P connector.

Check the connector for loose contacts or corroded
terminals.

BATTERY LINE
Measure the voltage between the Red/White wire
terminal and ground.
There should be battery voltage at all times.

GROUND LINE REGULATOR/RECTIFIER CONNECTOR

Check the continuity between the Green wire terminal
and ground.
There should be continuity at all times.

CHARGING COIL LINE

Measure the resistance between the Yellow
wire terminals.

STANDARD: 0.1 - 0.5 Q (20°C/68°F)

Check for continuity between each Yellow wire termi-

nal and ground.
There should be no continuity.

REMOVAL/I NSTALLA Tl ON REGULATOR/RECTIFIER 6P CONNECTOR

Remove the front cover (page 2-14).

Disconnect the regulator/rectifie r 6P connector.

Disconnect the regulator/rectifie r 3P connector. 3P CONNECTOR

Remove the bolts, regulator/rectifie r and stay.

Installation is in the reverse order of removal.

BOLTS [___e1
18-7
IGNITION SYSTEM

SYSTEM DIAGRAM

AFTER '02 (ABS TYPE):

IGNITION
COIL
CMP SENSOR

CKP SENSOR

II l I I
IMAIN RELAY

R/BI R/W G R/Y

~..__.. Tofou•"

To Tachometer

I I~~~~E STOP
MAIN FUSE B 30 A

SIDESTAND SWITCH Bl~W I ~I ~I SUB FUSE 15 A IGNITION SWITCH R/G

UP G/W--frJl-G/W
G--t_]J--G ' j° ,......,,,, ,.,w, <:r- R

m\_
MAIN FUSE A 30 A
2P (Green)
DOWN ' - - - - - - 1.~
. To Engine Stop Switch

G/O TP SENSOR

~----Bl/W--.+---1--a

I
Y/Bu
y
I
~,.,....,
WI
Y/Bu Y/G R/Y Y/R y
IGNmON
COIL
G G/W Bl/W G/0 Gr
I
I W(Y W/Y y

j_j_
ECM (Engine Control Module)

Do Bo
CMPSENSOR CKP SENSOR
R: Red
G: Green
Y: Yellow
Gr: Gray
Bl: Black
Bu: Blue
0 : Orange
W: White

19-0
 19. IGNIT ION SYST EM
SYSTEM DIAGRAM 19-0 IGNITION SYSTEM INSPECTION 19-3

SERVICE INFORMATION 19-1 IGNITION COIL 19-6

TROUBLESHOOTING 19-2 IGNITION TIMING 19-6

SERVICE INFORMA TION

GENERAL
• Some electrical components may be damaged if terminals or connectors are connected or disconnected while the igni-
tion switch is ON and current is present.
• When servicing the ignition system, always follow the steps in the troubleshooting on page 19-2.
• This scooter's Ignition Control Module (ICM) is built into the Engine Control Module (ECM).
• The ignition timing does not normally need to be adjusted since the ECM is factory preset.
The ECM may be damaged if dropped. Also, if the connector is disconnected when current is flowing, the excessive volt-
age may damage the module. Always turn off the ignition switch before servicing.
• A faulty ignition system is often related to poor connections. Check those connections before proceeding . Make sure the
battery is adequately charged . Using the starter motor with a weak battery results in a slower engine cranking speed as
well as no spark at the spark plug.
• Use spark plugs of the correct heat range. Using a spark plug with an incorrect heat range can damage the engine.
• Refer to section 5 for Throttle Position (TP) sensor, Camshaft Position (CMP) sensor and ECM inspection.

SPECIFICATIONS

ITEM SPECIFICATIONS

Spark plug NGK CR8EH-9

DENSO U24FER9

Spark plug gap 0.80 - 0.90 mm (0.031 - 0.035 in)

Ignition coil peak voltage 100 V minimum

CKP sensor peak voltage 0.7 V minimum

Ignition timing ("F" mark) 12° BTDC at idle

TORQUE VALUES
Timing hole cap 10 N•m (1.0 kgf•m, 7 lbMt) Apply engine oil to the threads, seating surface
and 0-ring.

TOOL
lgnitionMate peak voltage tester
(U .S.A. only) or Peak voltage adaptor MTP07-0286 or 07HGJ-0020100 (not available in U.S.A.) with commercially
available digital multimeter (impedance 10 MQ/DCV minimum)
m

19-1
IGNITION SYSTEM

TROUBLESHOOTING
• Inspect the following before diagnosing the system.
- Faulty spark plug
- Loose spark plug cap or spark plug wire connection
- Water got into the spark plug cap (leaking the ignition coil secondary voltage)

No spark at spark plug

Unusual condition Probable cause (Check in numerical order)

Ignition coil No initial voltage with ignition and 1. Faulty engine stop switch.
primary engine stop switches turned to "ON': 2. An open circuit in Black/White wire between the ignition
voltage (other electrical componen ts coil and engine stop switch.
are normal.) 3. Loose primary terminal or an open circuit in primary
coil.
4. Faulty ECM (in the case when the initial voltage is nor-
mal while disconnect ing ECM connector.
Initial voltage is normal, but it drops 1. Incorrect peak voltage adaptor connection s.
down to 2 - 4 V while cranking 2. Undercharg ed battery.
the engine. 3. No voltage between the Black/White (+) and body
ground (-) at the ECM multi-conn ector or loosen ECM
connection .
4. An open circuit or loose connection in Green wire.
5. An open circuit or loose connection in Yellow/Blu e wire
between the ignition coils and ECM.
6. Short circuit in ignition primary coil.
7. Faulty sidestand switch.
8. An open circuit or loose connection in No.7 related cir-
cuit wires (Green/Wh ite and Green wires).
9. Faulty CKP sensor (measure the peak voltage).
10. Faulty ECM (in case when above No. 1 - 9 are normal).
Initial voltage is normal, but no peak 1. Faulty peak voltage adaptor connection s.
voltage while cranking the engine. 2. Faulty peak voltage adaptor.
3. Faulty ECM (in case when above No.1, 2 are normal).
Initial voltage is normal, but peak volt- 1. The multimete r impedance is too low; below 10
age is lower than standard value. MQ/DCV.
2. Cranking speed is too low (battery undercharg ed).
3. The sampling timing of the tester and measured pulse
were not synchroniz ed (system is normal if measured
voltage is over the standard voltage at least once).
4. Faulty ECM (in case when above No. 1 - 3 are normal).
Initial and peak voltage are normal, but 1. Faulty spark plug or leaking ignition coil secondary
does not spark. current ampere.
2. Faulty ignition coil.
CKP sensor Peak voltage is lower than 1. The multimeter impedance is too low; below
standard value. 10MQ/DCV.
2. Cranking speed is too low (battery undercharg ed).
3. The sampling timing of the tester and measured pulse
were not synchroniz ed (system is normal if measured
voltage is over the standard voltage at least once).
4. Faulty ECM (in case when above No. 1 - 3 are normal).
No peak voltage. 1. Faulty peak voltage adaptor.
2. Faulty CKP sensor.

19-2
 IGNITION SYSTEM

IGNITION SYSTEM INSPECTION DIGITAL MULTIMETER

If no spark jumps at the plug, check all connections for

loose or poor contact before measuring each
peak voltage.
Use the recommended digital multimeter or commer-
cially available digital multimeter with an impedance
of 10 MQ/DCV minimum .
The display value differs depending upon the-internal
impedance of the multimeter.
Connect the peak voltage adaptor to the
digital multimeter.
PEAK VOLTAGE ADAPTOR
TOOLS:
lgnitionMate peak voltage tester (U.S.A. only) or
Peak voltage adaptor MTP07-0286 or
07HGJ-0020100
(not available in U.S.A.)
with commercially available digital multimeter
(impedance 10 MQ/DCV minimum)

IGNITION COIL PRIMARY PEAK VOLTAGE KNOWN - GOOD SPARK PLUG

Remove the right lower skirt (page 2-4).

Remove the spark plug maintenance lid (page 2-5).

Check all system connections before inspection. If the

system is disconnected, incorrect peak voltage might
be measured.
Check cylinder compression and check that the spark
plug is installed correctly in the cylinder.
Disconnect the spark plug cap from the spark plug.

Connect a known-good spark plug to the spark plug

cap and ground the spark plug to the cylinder as done
in the spark test.

With the ignition coil primary wire connected, connect

the peak voltage adaptor to the ignition coil.

CONNECTION: Black/White(-) - Body ground(+)

Turn the ignition switch to "ON" and engine stop

switch "ON·:
Check for initial voltage at this time.
The battery voltage should be measured.
If the initial voltage cannot be measured, check the
power supply circuit (refer to the troubleshooting ,
page 19-2).

19-3
IGNITION SYSTEM

To prevent electric shock, avoid touching the spark

plug and tester probes . IGNITION COIL
Crank the engine with the starter motor and read the
ignition coil primary peak voltage.
CID

PEAK VOLTAGE: 100 V minimum

If the peak voltage is abnormal, check for an open cir-

©
@C

cuit or poor connection in the Black/White wires.

If no defects are found in the harness, refer to the
troubleshoot ing chart on page 19-2.

PEAK VOLTAGE ADAPTOR

CKP SENSOR PEAK VOLTAGE ('02 - '07)

ECM
Check cylinder compressions and check that the spark
plug is installed correctly.

Remove the right passenger footpeg (page 2-12).

Remove the left side body cover (page 2-6).

Disconnect the ECM 22P (Light gray) connector.

Connect the peak voltage adaptor probes to the connec-
tor terminals of the wire harness side.

TOOLS:
lgnitionMate peak voltage tester (U.S.A. only) or 22P (LIGHT GRAY) CONNECTOR
Peak voltage adaptor MTP07-0286 or
07HGJ-0020100
(not available in U.S.A.)
with commercially available digital multimeter PEAK VOLTAGE ADAPTOR
(impedance 10 MQ/DCV minimum)

CONNECTION: White/Yellow (+) - Ground (-)

Retract the sidestand.

Turn the ignition switch ON and engine stop switch
to RUN.
Avoid touching the tester probes to prevent electric
shock.
Crank the engine with the starter motor and read CKP
sensor peak voltage.
22P (LIGHT GRAY) CONNECTOR
PEAK VOLTAGE: 0.7 V minimum

If the peak voltage measured is abnormal, recheck the

following:
Disconnect the CKP sensor 2P red connector. L_
Connect the peak voltage adaptor to the terminals of the
CKP sensor side and recheck the peak voltage.
If the peak voltage at the ECM 22P (Light gray) connec-
tor is abnormal and peak voltage at the CKP sensor 2P
red connector is normal, check for poorly connected con-
nectors or a broken wire harness.
If the peak voltage is abnormal at both connectors, follow
the checks described in the troubleshooting on page 19-2.

19-4
 IGNITION SYSTEM

CKP SENSOR PEAK VOLTAGE (After '07)

• Check all system connections before inspection. If

the system is disconnected, incorrect peak voltage
might be measured.
• Check cylinder compressions and check that the
spark plug is installed correctly.

Remove the left side body cover (page 2-6) .

Remove the ECM from the stay.

Disconnect the 32P (Black) and 32P (Light gray) con-
nectors from the ECM.
Connect the peak voltage adaptor to the digital multi-
meter.

TOOLS:
lgnitionMate peak voltage tester (U.S.A. only) or
Peak voltage adaptor MTP07-0286 or
07HGJ-0020100
(not available in U.S.A.) 00000000000000
with commercially available digital multimeter 0000000000000
(impedance 10 MQ/DCV minimum)
A32 A17

Connect the peak voltage adaptor probes to the ECM

32P connector terminals of the wire harness side. e
CONNECTION: 811 (Yellow) (+) - A31 (White/yellow) (-)

Retract the sidestand.

Turn the ignition switch to "ON" and engine stop
switch to " 0 ':
Crank the engine with the starter motor, and measure CKP SENSOR 2P (Red) CONNECTOR
the CKP sensor peak voltage.

PEAK VOLTAGE: 0.7 V minimum

If the peak voltage measured at ECM connector is

abnormal, measure the peak voltage at the CKP sen-
sor connector.

Remove the right passenger footpeg (page 2-12).

Disconnect the CKP sensor 2P (Red) connector and

connect the peak voltage adaptor probes to the CKP
sensor side connector terminals ;

CONNECTION: Yellow(+) - White/yellow(- )

In the same manner as at the ECM connector, mea-

sure the peak voltage and compare it to the voltage
measured at the ECM connector.
If the peak voltage measured at the ECM is abnormal
and the one measured at the CKP sensor is normal,
check the 2P (Red) connector for loose connection and
the wire harness for an open circuit or loose connec-
tion.
If both peak voltage measured are abnormal, check
each item in the troubleshooting chart (page 19-2). If
all items are normal, the CKP sensor is faulty. Refer to
procedure for the CKP sensor replacement (page 12-
5) .

19-5
IGNITION SYSTEM

IGNITION COIL SPARK PLUG CAPS

REMOVAL/INSTALLATION
Remove the right lower skirt (page 2-4).
Remove the spark plug maintenan ce lid (page 2-5).

Disconnect the spark plug cap from the spark plug .

Disconnect the ignition coil primary connectors .

Remove the bolts and the ignition coil.

Installation is in the reverse order of removal.

Route the spark plug wire and ignition coil primary

connectors properly (page 1-20).

IGNITION TIMIN G
The ignition timing is factory preset and need only be
checked when an electrical system componen t
is replaced.

Warm up the engine to normal

operating temperatur e.
Stop the engine.

Remove the timing hole cap and 0-ring.

TIMING HOLE CAP

Attach the timing light to the spark plug wire.

TIMING LIGHT

19-6
 IGNITION SYSTEM

1
Start the engine and let it idle [1 ,300 min- (rpm)].

The timing is correct if the "F" mark on the flywheel

aligns with the index notch on the left crankcase cover
at 1,500 min- 1 (rpm).

If the ignition timing is incorrect, inspect the ECM and

CKP sensor.

\
INDEX NOTCH

Apply engine oil to the timing hole cap threads, seat-

ing surface and 0-ring.
Tighten the timing hole cap to the specified torque.

TORQUE: 10 N•m (1.0 kgf•m, 7 lbf.ft)

TIMING HOLE CAP

19-7
 ELECTRIC STARTER

SYSTEM DIAGRAM
STD TYPE:

ENGINE STOP SWITCH

LIMIT SWITCH STARTER RELAY SWITCH
(MAIN FUSE A)

AFTER '02 {ABS TYPE):

IGNITION
SWITCH
SIDESTAND SWITCH

STARTER RELAY SWITCH

STARTER EB 8 BANK ANGLE

SENSOR
MOTOR MAIN BATTERY
FUSE A
(30AJ

Bl Bl G

~
IGNITION
Y/R SWITCH
~ FUSE15A

l
~----G/W
R--0--- 0--R/BI~ Bl

~
E } : O P SWITCH
SIDESTAND
SWITCH I ~G/R--O~Bl/W
STARTER SWITCH LIMIT SWITCH I
Bl Bl/0 Bl/W
I I I
G
_L_
ENGINE STOP
RELAY
R: Red
W: White
Y: Yellow
G: Green
Bl: Black
0: Orange

20-0
 20. ELECTRIC STARTER
20-0 STARTER MOTOR 20-4
SYSTEM DIAGRAM
20-1 STARTER RELAY SWITCH 20-11
SERVICE INFORMA TION
TROUBLESHOOTING 20-2

SERVICE INFOR MATIO N

GENERAL
could suddenly start, causing
• Always turn the ignition switch to "OFF" before servicing the starter motor. The motor
serious injury.
• The starter motor can be serviced with the engine in the frame.
chart (page 20-2).
• When checking the starter system, always follow the steps in the troublesho oting flow
motor quickly enough, or supply adequate ignition current.
• A weak battery may be unable to turn the starter
flowing through the starter motor to turn it but the engine is not cranking over, the starter motor may
• If the current is kept
be damaged.
• See section 12 for starter clutch servicing.
• See section 21 for following componen ts:
- Ignition switch
- Starter switch
- Sidestand switch
- Limit switch

SPECIFICATIONS Unit: mm (in)

ITEM STANDARD SERVICE LIMIT

12.5 (0.49) 8.5 (0.33)

Starter motor brush length

20-1
 ELECTRIC STARTER

TROUBLESHOOTING
• Check for the followin g before troubles hooting:
- Blown main fuse (30 A) and sub fuse (10 A)
- Loose battery and starter motor cable
- Discharged battery
• The starter motor can turn with the followin g conditio ns:
- Ignition switch ON
- Engine stop switch in RUN
- Rear brake lever fully squeezed
- Sidestan d retracted
- Starter switch pushed

Starter motor will not turn

Check for loose or poorly connecte d battery ter- - Abnorm al -----.. • Poorly connecte d battery terminal s.
minals and opened or shorted battery cable.
• Open or short circuit in battery cable.

I
Normal

Check for loose or poorly connecte d starter relay

Abnorm al _____.. • Poorly connecte d terminal s.
switch terminal s.

Normal

Check for loose or poorly connecte d or broken Abnorm al -----.. • Poorly connecte d starter motor cable.
starter motor cable.
• Open circuit in starter motor cable.

Normal

t
With the ignition switch turned to "ON'; push the - Clicks ---.;-- Connect the starter motor terminal directly to the
starter switch and check for a click sound from the
battery positive terminal (Because a large amount
starter relay switch.
of current flows, do not use a thin wire).

No Jlicks I I
Starter motor turns. Starter motor
does not turn .

J •
• Faulty starter motor.

• Loose or disconne cted starter motor cable.

• Faulty starter relay switch.

(Go to followin g page)

20-2
 ELECTRIC STARTER

(From previous page)

Check the starter relay coil ground line (page 20- Abnormal _..•Faulty sidestand switch.
11 ). • Loose or poor contact of connector.
• Open or short circuit in wire harness.
I
Normal

Check the starter relay voltage (page 20-11). No voltage____. .• Faulty engine stop switch.
• Faulty limit switch.
• Faulty starter switch.
Battery voltage registers · • Loose or poor contact of connector.
• Open circuit in wire harness.

Check the starter relay operation (page 20-11). Abnormal ~ • Faulty starter relay.

20-3
 ELECTRIC STARTER

STARTER MOTO R MOTOR CABLE CAP NUT

REMOVA L
Remove the air cleaner housing/ai r cleaner chamber
(page 5-89).

Turn the ignition switch turned to "OFF':

Release the rubber cap and remove the terminal nut

to disconnect the starter motor cable.
Remove the bolts, ground cable and starter motor.

GROUND CABLE STARTER MOTOR

Remove the 0-ring from the groove on the starter

motor. 0-RING

DISASSE MBLY CASE BOLTS/SET PLATES/0-RINGS

Remove the starter motor case bolts, set plates
and 0-rings.
Remove the front cover.

FRONT COVER

Record the Remove the following:

location and - Lock washer
number of shims. - Insulator washer
- Shims
- Seal ring

SHIMS LOCK WASHER

20-4
 ELECTRIC STARTER

- Rear cover assembly

Record the - Shims SEAL RING

location and - Seal ring
number of shims. - Armature

wfj@
ARMATURE SHIMS

INSPECTION
Check the bushing in the rear cover for wear
or damage.

Check the oil seal and needle bearing in the front FRONT COVER OIL SEAL
cover for deterioration, wear or damage.

NEEDLE BEARING

20-5
ELECTRIC STARTER

Do not use emery Check the commutator bars of the armature

or sand paper on for discoloration . ARMATURE
the commutator

COMMUTATO R BAR

Check for continuity between pairs of

commutator bars.
There should be continuity.

Check for continuity between each commutator bar

and the armature shaft.
There should be no continuity.

Check for continuity between the insulated (+) brush

an cable terminal. CABLE TERMINAL (+)BRUSH
There should be continuity.

Check for continuity between the insulated (+) brush

and rear cover.
There should be no continuity.

REAR COVER

20-6
 ELECTRIC STARTER

REAR COVER DISASSEMBLV INSULATOR WASHERS

Remove the following:
- Nut
-Washer
- Insulator washers
- 0-ring

- Brush holder BRUSH REAR COVER

- Brush

Remove the brushes from the brush holder.

BRUSH HOLDER

Measure the brush length.

SERVICE LIMIT: 8.5 mm (0.33 in)

20-7
ELECTRIC STARTER

ASSEMBLY

INSULATOR WASHER
NUT
~ SEAL RING
,,e~1----S
~ WASHER

~INSULATOR WASHERS

~~~
~ -=- 0-RING

SEAL RING REAR COVER

Install the brushes into the brush holder.

BRUSH REAR COVER
Install the brush holder assembly into the rear cover
by aligning the tab of the holder with the groove in
the rear cover.

BRUSH HOLDER

Install the following:

INSULATOR WASHERS
- New 0 -ring
- Insulator washers
- Washer
- Nut

20-8
 ELECTRIC STARTER

Hold the armature Install the armature in the rear cover. ARMATURE
coil shaft or the
armature might
be drawn out
by the
magnetic field.

MOTOR CASE

Install the shims to the armature coil in the correct SEAL RING
positions as recorded.

Install the seal ring on the motor case.

Apply grease to the armature shaft.

tp
w
ARMATURE SHIMS

Assemble the motor case and rear cover, aligning the ALIGN
tab on the brush holder with the groove on the motor
case.

REAR COVER ASSEMBLY

Install the shims, insulator washer and lock washer to INSULATOR WASHER
. . . . SEAL RING
the armature coil in the correct positions as recorded.
lllijjllll

SHIMS LOCK WASHER

20-9
ELECTRIC STARTER

Apply grease to the dust seal lip and needle bearing

FRONT COVER OIL SEAL
in the front cover.

-~ NEEDLE BEARING

Align the index lines on the front cover and motor

0-RING CASE BOLT
case.

Install the set plates and new 0-rings onto the motor
case bolts.
Install the motor case bolts and tighten them.

FRONT COVER SET PLATE

INSTALLATION STARTER MOTOR

Coat a new 0-ring with engine oil and install it into the
starter motor groove.

Install the starter motor into the crankcase.

Install the bolts with the ground cable terminal and

tighten them.

Connect the starter motor cable to the motor terminal

with the terminal nut and tighten it.

Install the air cleaner chamber/air cleaner housing

(page 5-90).

GROUND CABLE STARTER MOTOR

20-10
 ELECTRIC STARTER

STARTER RELAV SWITCH

INSPECTION
Remove the left side body cover (page 2-6).

Retracted the sidestand.

Turn the ignition switch to "ON" and engine stop
switch on.
Squeeze the rear brake lever fully and push the
starter switch.
The coil is normal if the starter relay switch clicks.
STARTER RELAY SWITCH
If you do not hear the switch click, inspect the relay
switch using the procedure below.
RELAY SWITCH CONNECTOR
GROUND LINE INSPECTION
Disconnect the starter relay switch 4P red connector.
Check for continuity between the Green/White wire
(ground line) terminal and ground.
0 Ci>

There should be no continuity with the sidestand low-

ered, and there should be continuity with the side-
stand retracted.

VOLTAGE INSPECTION
Connect the starter relay switch 4P red connector.
Turn the ignition switch to "ON" and engine stop
switch to RUN.

Measure the starter relay switch Yellow/Red connec-

tor (+) and ground.

If the battery voltage appears only when the rear

brake lever is squeezed fully and starter switch is
pushed, the circuit is normal.

STARTER RELAY SWITCH

CONTINUITY INSPECTION
Disconnect the starter relay switch 4P red connector
and cables.
Connect a fully charged 12 V battery positive wire to
the relay switch Yellow/Red wire terminal and nega-
tive wire to the Green/White wire terminal.

There should be continuity between the cable termi-

nals while the battery is connected, and no continuity
when the battery is disconnected.

· STARTER RELAY SWITCH

20-11
LIGHTS/METERS/SWITCHES

STD TYPE:
LEFT HANDLEBAR
SWITCH RIGHT HANDLEBAR SWITCH

FAN MOTOR
RELAY FRONT BRAKE
LIGHT SWITCH

ECT;THERMOSENSOR

OIL PRESSURE SWITCH

AFTER '02 (ABS TYPE):

21-0
 21. LIGHTS/METERS/SWITCHES
SERVICE INFORMATION 21-1 LUGGAGE BOX LIGHT SWITCH 21-13
TROUBLESHOOTING 21-3 TACHOMETER 21-14
BULB REPLACEMENT 21-5 V-MATIC INDICATOR 21-15
COMBINATION METER 21-7 COOLANT TEMPERATURE INDICATOR,
ECT/THERMOSENSOR 21-16
SPEEDOMETER/
VEHICLE SPEED SENSOR 21-8 OIL PRESSURE ·swlTCH 21-17
LIMIT SWITCH 21-10 FUEL UNIT 21-19
BRAKE LIGHT SWITCH 21-10 SIDESTAND SWITCH 21-20
IGNITION SWITCH 21-11 HORN 21-21
HANDLEBAR SWITCHES 21-12 LOW BEAM RELAY 21-22
PARKING SWITCH 21-13 TURN SIGNAL RELAY 21-22

SERVICE INFORMATI ON
GENERAL
• A halogen head light bulb becomes very hot while the head light is on, and remains hot for a while after it is turned off.
Be sure to let it cool down before servicing.

• Note the following when replacing the halogen headlight bulb.

- Wear clean gloves while replacing the bulb. Do not put finger prints on the headlight bulb, as they may create hot spots
on the bulb and cause it to fail.
- If you touch the bulb with your bare hands, clean it with a cloth moistened with alcohol to prevent early failure.
- Be sure to install the dust cover after replacing the bulb.
• Check the battery condition before performing any inspection that requires proper battery voltage.
• A continuity test can be made with the switches installed on the scooter.
• Route the wires and and cables properly after servicing each component (page 1-20).

fD

21-1
LIGHTS/METER S/SWITCHES

SPECIFICATIONS

ITEM SPECIFICATIONS
Bulbs Headlight 12 v - 55 w x 2
Brake/tail light 12 v - 21 /5 w x 2
Front turn signal/position light 12V-21Wx2
Rear turn signal 12V-21Wx2
License light 12 v- 5 w
Instrument light LED
Turn signal indicator LED
High beam indicator LED
Parking indicator LED
Oil pressure indicator LED
PGM-FI warning indicator LED
Temp warning indicator LED
V-Matic indicator LED
ABS warning indicator LED
Luggage box instrument light 12V-3.4W
Fuse Main fuse Main A: 30 A, Main B: 30 A
Sub fuse (ABS TYPE) 30 Ax 2, 15 Ax 2, 10 Ax 5
Sub fuse (STD TYPE) 15Ax2,10Ax4
Thermosensor resistance I at 80°C/176°F 2.1 - 2.6 kQ
I at 120°C/248°F 0.65 - 0.73 kQ

TORQUE VALUES
Oil pressure switch 12 N•m ( 1.2 kgf•m, 9 lbMt) Apply sealant to the threads.
(Do not apply to the sensor head.)
ECT/Thermo sensor 23 N•m (2.3 kgf•m, 17 lbfoft)
Ignition switch bolt 26 N•m (2.7 kgf•m, 20 !bf.ft) One-way bolt.

TOOL
lgnitionMate peak voltage tester
(U.S.A. only) or Peak voltage adaptor MTP07-0286 or 07HGJ -0020100 (not available in U.S.A.) with commercially
available digital multimeter (impedance 10 MQ/DCV minimum)

21-2
 LIGHTS/METER S/SWITCHES

TROUBLESHOOTING
SPEED SENSOR/SPEEDOMETER
The odometer/trip meter operates normally, but the speedometer does not operate
• Faulty speedometer

The speedometer operates normally, but the odometer/trip meter does not operate
• Faulty odometer/trip. meter . . .

The speedometer operation is abnormal

• Check for the following before diagnosing.
- Blown main or sub fuses
- Loose or corroded terminals or the connectors
- Discharged battery
Abnormal
Check for loose or poor contact of the speed 1-----------::..-~ • Loose or poor contact of related terminals.
sensor 3P (Natural) connector. • Open circuit in Black/Brown or Green/Black wires
With the ignition switch turned to "ON'; measure between the battery and speed sensor.
the voltage at the speed sensor connector.

I
Normal

Abnormal
Check for loose or poor contact on the combi- 1 - - - - - - - - - - • Loose or poor contact of related terminals.
nation meter multi-connectors. • Open circuit in Black/Brown or Green/Black wires
With the ignition switch turned to "ON'; mea- between the battery and speedometer.
sure the voltage at the bottom of the
speedometer terminals.

Normal

Abnormal
With the ignition switch turned to "OFF'; check for 1 - - - - - - - - - - • Open circuit or loose connection in Pink/Green
continuity of the Pink/Green wire between the ter- wire.
minals of the speed sensor and speedometer.

Normal

Abnormal
Support the scooter using a hoist or other sup- 1 - - - - - - - - - - • Faulty speed sensor.
port to raise the rear wheel off the ground. • Loose speed sensor mounting bolts.
Measure the output voltage (sensor signal) at
the speedometer with the ignition switch turned
to "ON" while slowly turning the rear wheel by
hand.

I
Normal

._____________ _________ _ •Faulty speed sensor.

21-3
LIGHTS/METERS/SWITCHES

V-MATIC INDICATOR
The V-Matic indicator functions normally, when the V-Matic indicator comes on for approx. Few seconds then it goes off when
the ignition switch is turned ON.

V-MATIC INDICATOR DOES NOT COME ON WHEN THE IGNITION SWITCH IS TURNED ON

• Check for a blown main fuse A (30 A), main fuse 8 (30 A) and sub-fuse (10 A).
• Check for a battery

Do not come on
Check that the coolant temperature indicator Check the power input line (black/brown wire)
lights come on with the ignition switch ON. and sensor ground line (green/black) at the com-
bination meter connector (page 21-8).

Normal
Abnormal Abnormal

+
• Open circuit in
black/brown wire or
green/black wire

,, • Faulty combination meter

Check the following systems.

- Speedometer/vehicle speed sensor (page 21-8)
- CKP sensor (page 19-4, 5).
- Combination meter (page 21-8).
- ECM (Engine Control Module) (page 5-114, 115).

21-4
 LIGHTS/METERS/SWITCHES

BULB REPLACEMENT HEADLIGHT BULBS

HEADLIGHT
NOTE:
A halogen head light bulb becomes very hot while the
head light is ON, and remains hot for a while after it is
turned OFF. Be sure to let it cool down before servic-
ing.

Remove the windshield garnish (page 2-12).

Disconnect the headlight 3P connector from the head-

light bulb and remove the dust cover.

Unhook the retainer and remove the bulb from the ARROW MARK DUST COVER BULB

\
headlight case.

Avoid touching Install a new bulb in the headlight case by aligning the
the halogen head- bulb tab with the case groove.
light bulb. Finger
prints can create Hook the retainer.
hot spots that
cause a bulb to
Install the dust cover properly on the headlight with
break.
the arrow mark facing up and connect the headlight
3P connector.

HEADLIGHT CONNECTOR RETAINER

FRONT TURN SIGNAL/PO SITION

Remove the windshield garnish (page 2-12).

Turn the bulb socket counterclockwis e to remove it.

Remove the bulb and replace it with a new one.

Installation is in the reverse order of removal.

SOCKET

21-5
LIGHTS/MET ERS/SWITC HES

REAR TURN SIGNAL, BRAKE/TAIL LIGHT

Unlock and open the seat.
Open the maintenance lid.

REAR TURN SIGNAL

Turn the bulb socket counterclockwis e to remove it. SOCKET
Remove the bulb and replace it with a new one.

Installation is in the reverse order of removal.

BRAKE/TAIL LIGHT
Turn the bulb socket counterclockwis e to remove it. SOCKET
Remove the bulb and replace it with a new one.

Installation is in the reverse order of removal.

LICENSE LIGHT LICENSE LIGHT COVER

Remove the screws.

Remove the license light cover and lens.

Remove the bulb and replace it with a new one.

Installation is in the reverse order of removal.

BULB

21-6
 LIGHTS/M ETERS/SW ITCHES

COMBINATION METER
DISASSEMBLY I ASSEMBLY
Remove the meter panel (page 2-15) .

Remove the screws and disassemble the

combination meter.

Assembly is in the reverse order of disassembly.

STD TYPE:

TURN SIGNAL INDICATOR

COVER

METER PANEL

AFTER '02 (ABS TYPE):

21-7
LIGHTS/METERS/SWITCHES

POWER/GROUND LINE INSPECTION

Disconnect the combination meter 16P and 12P
connectors.
Check the following at the wire harness side connec-
tor terminals of the combination meter.

Power input line

Measure the voltage between the Black/ Brown wire
terminal (+) and Ground (-).
There should be battery voltage with the ignition
switch ON.
If there is no voltage, check for open circuit in
Black/Brown wire.

Back-up voltage line

Measure the voltage between the Light green/Black
wire terminal (+) and Ground (-).
There should be battery voltage at all times.
If there is no voltage, check for open circuit in
Red/Green wire .

Sensor ground line

Measure the voltage between the Green/Black wire
terminal (+) and Ground (-).
There should be battery voltage at all times.
If there is no voltage, check for an open circuit in the
Green/Black wire.

SPEEDOMETER/VEHICLE SPEED SENSOR 16P CONNECTOR 12P CONNECTOR

SYSTEM INSPECTION
Disconnect the combination meter 16P and 12P con -
nectors and turn the ignition switch to "ON':
Measure the voltage between the Pink/Green (+) and
Green/Black (-) wire terminals of the wire harness
side connector.
Slowly turn the rear wheel by hand .
There should be 0 to 5 V pulse voltage.

- If pulse voltage appears, replace the combination

meter print circuit board.
- If pulse voltage does not appear, check for open or
short circuit in Pink/Green wire.
If the Pink/Green wire is OK, check the speed sensor
(see next page).

21-8
 LIGHTS/METERS/SWITCHES

SPEED SENSOR INSPECTION 3P (STD TYPE)/6P (AFTER '02

ABS TYPE) CONNECTOR
Remove the left side body cover (page 2-6).
Remove the front cover (page 2-14).

Disconnect the speed sensor 3P (STD TYPE)/6P

(AFTER '02 ABS TYPE) connector and check for loose
or poor contact on the connector.
Also check for loose or poor contact on the combina-
tion meter 16P and 12P connectors.

Connect the combination meter 16P and 12P connec- 3P (STD TYPE)/6P (AFTER '02
tors and speed sensor 3P (STD TYPE)/6P (AFTER '02 ABS TYPE) CONNECTOR
ABS TYPE) connector.

Turn the ignition switch to "ON" and measure the

voltage at the 3P connector with the connector con-
nected.

Connection: Black/Brown (+) - Green/Black (-)

Standard: Battery voltage

If there is no voltage, check for an open circuit in

Black/Brown and Green/Black wire and loose contact
of the wire harness connectors.

Support the scooter with a main stand and rear wheel 16P CONNECTOR
off the ground.

Measure the voltage at the sensor connector termi-

nals with the ignition switch to "ON" while slowly
turning the rear wheel by hand.

CONNECTION: Pink/Green( +) - Green/Black (-)

STANDARD: Repeat 0 to 5V

If the measuremen t is out of specification , replace the

speed sensor. #> ~ • ~
3P (STD TYPE)/6P (AFTER '02
ABS TYPE) CONNECTOR

REMOVAL/INSTALLATION
Remove the rear wheel (page 15-4).

Remove the speed sensor clump from the protector.

Remove the bolts and speed sensor wire protector.

21-9
LIGHTS /METER S/SWITC HES

Disconnect the connector from the speed sensor.

Remove the bolts and speed sensor.

Check that the 0-ring is in good condition, replace

if necessary.

Installation is in the reverse order of removal.

LIMIT SWITCH
Remove the handlebar cover (page 2-14).

Disconnect the limit switch connectors and check for

continuity between the switch terminals.

There should be continuity when the rear brake lever

is squeezed, and there should be no continuity when
the rear brake lever is released.

Install the handle cover (page 2-14).

BRAKE LIGHT SWITCH

FRONT
Disconnect the front brake light switch connectors
and check for continuity between the
switch terminals.

There should be continuity when the front brake lever

is squeezed, and there should be no continuity when
the front brake lever is released.

REAR
Remove the handlebar cover (page 2-14).

Disconnect the rear brake light switch connectors and

check for continuity between the switch terminals.

There should be continuity when the rear brake lever

is squeezed, and there should be no continuity when
the rear brake lever is released.

Install the handle cover (page 2-14).

21-10
 LIGHTS/METERS/SWITCHES

IGNITION SWITCH
INSPECTION
Remove the front cover (page 2-14).

Disconnect the ignition switch 3P connector and check

for continuity at the switch side connector terminals.
Continuity should exist between the color coded
wires as follows:

-----
ON
OFF
LOCK
MA BAT FAN IGN BAT1

CORD COLOR R Bu/0 R/BI

REMOVAL/INSTALLATION
Remove the steering handle (page 14-18).

Disconnect the ignition switch 3P connector.

Remove the bolts and ignition switch.

Installation is in the reverse order of removal using

new mounting bolts.

TORQUE: 26 N•m (2.7 kgf•m, 20 lbf.ft)

~~
llllliii" BOLTS

21-11
LIGHTS/METERS/SWITCHES

HANDLEBAR SWITCH ENGINE STOP SWITCH

INSPECTION
Remove the front cover (page 2-14).

RIGHT HANDLEBAR SWITCH

Disconnect the right handlebar switch 9P red connec-
tor and check for continuity at the switch side
connector terminals.
Continuity should exist between the color code wires
as follows:

------
STARTER SWITCH STARTER SWITCH
BAT9 HL ST1 ST2
FREE
PUSH
CORD COLOR Bl/R Bu/W G/R Y/R

------
ENGINE STOP SWITCH
KRLY KS
OFF
RUN
CORD COLOR Bl/0 R/0

LEFT HANDLEBAR SWITCH

Disconnect the left handlebar switch 6P red and 9P
black connectors and check for continuity at the switch
side connector terminals.
Continuity should exist between the color code wires
as follows:

------
HORN SWITCH
BAT7 HO
FREE
PUSH .._, .._,

CORD COLOR Bl/Br Lg

TURN SIGNAL SWITCH

W L R Po LPo RPo

N
L DIMMER SWITCH
PUSH
COLOR Gr 0 Lb Bu/Bl O/W Lb/W
DIMMER SWITCH
HI HL LO
Lo
(N)

Hi .._, .._,

CORD COLOR Bu Bu/W w HORN SWITCH TURN SIGNAL SWITCH

21-12
 LIGHTS/MET ERS/SWITC HES

PARKING SWITCH
FRONT
Remove the front cover {page 2-14).

Disconnect the parking switch connectors and check

for continuity between the switch terminals.

There should be continuity with the parking lever

pulled up, and there should be no continuity with the
front brake lever is pushed down.

-----
PARKING LEVER SWITCH

PARK
{N)

RUN
GND
~
PARK
~

CORD COLOR G W/BI

LUGGAGE BOX LIGHT SWITCH LUGGAGE BOX LIGHT SWITCH

INSPECTION
Remove the left and right side body cover {page 2-6).
Remove the rear body cover {page 2-7).

Disconnect the luggage box light switch connector

and check for continuity between the switch terminal.

There should be no continuity with the luggage box

light switch pushed, and there should be continuity
with the luggage box light switch is released.

REMOVAL/I NSTALLA Tl ON
Remove the left and right side body cover {page 2-6).
Remove the rear body cover {page 2-7).
Remove the rear frame {page 2-10).

Disconnect the luggage box light switch connector.

Remove the screw and luggage box light switch.

Apply locking agent to the luggage box light switch
screw threads.
Installation is in the reverse order of removal.

CONNECTOR LUGGAGE BOX LIGHT SWITCH

21-13
LIGHTS/METERS/SWITCHES

TACHOMETER
SYSTEM INSPECTION ('02 - '07)
Check the combinatio n meter power input line
(page 21-8).

Disconnect the combinatio n meter 16P and

12P connectors (page 21-8).
Connect the peak voltage adaptor to the tachomete r
Yellow/Gre en (+)termina l and Green (-).

TOOLS:
lgnitionMa te peak voltage tester {U.S.A. only) or PEAK VOLTAGE ADAPTOR
Peak voltage adaptor MTP07-028 6 or
07HGJ-0020100
(not available in U.S.A.)
with commercially available digital multimete r
(impedance 10 MQ/DCV minimum)

CONNECTION: Yellow/Gre en(+) and Green(-)

Start the engine and measure the tachomete r input

peak voltage.

PEAK VOLTAGE: 10.5 V minimum

If the value is normal, replace the combinatio n meter

printed circuit board (page 21-7).
If the measured value is below 10.5 V, replace
the ECM.

If the value is 0 V, check for continuity between the

combinatio n meter 16P and 12P connectors terminal
and the ECM multi-conn ector Yellow/Gre en terminals.
If there is no continuity, check the wire harness and
combinatio n meter sub-harnes s for an open circuit.
If there is continuity, replace the combinatio n meter
printed circuit board (page 21-7).

21-14
 LIGHTS/METERS/SWITCHES

SYSTEM INSPECTION (After '07)

• Check for loose or poor contact terminals at the IID

combinatio n meter 16P and 12P connectors .

• Check the combinatio n meter power input line
(page 21-8).
(j)
Disconnect the combinatio n meter 16P and 12P con-
nectors (page 21-8).

Connect the peak voltage adaptor probes to the

tachomete r Yellow/Gre en and Green wire terminals.

TOOLS: PEAK VOLTAGE ADAPTOR

lgnitionMate peak voltage tester (U.S.A. only) or
Peak voltage adaptor MTP07-0286 or
07HGJ-0020100
(not available in U.S.A.)
with commercially available digital multimeter
(impedance 10 MQ/DCV minimum)

CONNECTION: Yellow/gre en (+) - Green (-)

Start the engine and measure the tachomete r input

peak voltage.

PEAK VOLTAGE: 10.5 V minimum

If the peak voltage is normal, replace the combinatio n

meter assembly (page 21-7).
If the measured value is below 10.5 V, replace the
ECM.

If the value is 0 V, check for continuity between the

combinatio n meter 16P (Black) connector and the 00000000 DODOO 00000000000000
ECM 32P (Light gray) connector Yellow/gre en termi- 00000000 DODOO 00000000000000
nals.
B32 817 A:J2 A17
CONNECTION: Yellow/gre en - B-7 (Yellow/green)

If there is no continuity, check the wire harness

between the ECM and combinatio n meter for an open
circuit.
If there is continuity, replace the combinatio n meter
printed circuit board (page 21-7).

V-MAT IC INDICATOR
INSPECTION
The V-Matic indicator functions normally. If the V-
Matic indicator comes on for few seconds then goes
off when the ignition switch is turned to "ON':

If the indicator does not come on, check that the

coolant temperatur e indicator lights come on with the
ignition switch "ON':

INDICATOR LIGHT

21-15
LIGHTS/ METERS /SWITCH ES

If the coolant temperatur e indicator light does not

come on, check the power input line (Black/Brow n
wire) and sensor ground line (Green/Black) at the
combinatio n meter connector (page 21-8).

If the power input line and sensor ground line are

normal, check the following systems.
- Speedome ter/vehicle speed sensor (page 21-8).
- CKP sensor (page 19-4, 5).
- ECM (Engine Control Module) (page 5-114, 115).

INDICATOR SYSTEM RESET "MODE" BUTTON "RESET" BUTTON

If the V-Matic indicator light comes on, check and
replace the V-Matic system componen ts (section 10)
and then reset the V-Matic indicator system
as follows.

1. Push the "RESET" button and "MODE" button at

the same time then the ignition switch to "ON':
2. Hold the buttons for more than 5 seconds and then
check that the indicator light blinks.
3. Release the buttons, check that the indicator light
goes off.
INDICATOR LIGHT

COOL ANT TEMPERATURE INDICATOR,

ECT /THER MOSE NSOR
ECT /THERMOSENSOR INSPECTION
Remove the lower luggage box (page 2-10).
Drain the coolant (page 6-5).

Disconnec t the ECT/therm osensor connector and

remove the ECT/therm osensor from the
cylinder head.

Suspend the ECT/therm osensor in a pan of coolant

(50% mixture) on an electric heating element and
measure the resistance between the ECT/therm osen-
sor terminals and body as the coolant heats up.

Soak the ECT/therm osensor in coolant up to its

threads with at least 40 mm (1.57 in) from the bot-
tom of the pan to bottom of the sensor.
• Keep the temperatur e constant for 3 minutes before
testing. A sudden change of temperatur e will result
in an incorrect reading. Do not let the thermome ter
or the ECT/therm osensor touch the pan. @@

STANDARD: 2.1 - 2.6 kQ (80°C/176°F)

0.65 - 0.73 kQ (120°C/248°F)

ECT/THERMOSENSOR

21-16
 LIGHTS/METERS/SWITCHES

If the resistance is out of above range, replace the

ECT/thermosensor.

ECT/thermosensor TERMINAL

Apply sealant to the ECT/thermosensor threads. Do

not apply sealant to the sensor head.
Install the new sealing washer and ECT/thermosen-
sor.

TORQUE: 23 N•m (2.3 kgf•m, 17 lbf.ft)

Connect the ECT/thermosensor connector.

Fill and bleed the cooling system (page 6-5).

Install the lower luggage box (page 2-10).

OIL PRESSURE SWITCH OIL PRESSURE WARNING INDICATOR

INSPECTION
If the oil pressure warning indicator stays on with the
engine running, check the engine oil level
before inspection.

Make sure that the oil pressure warning indicator

come on with the ignition switch "ON':

21-17
LIGHTS/METERS/SWITCHES

If the indicator does not come on, inspect as follow:

Remove the dust cover.

Remove the screw and oil pressure switch terminal.

Short the oil pressure switch wire terminal with the

ground using a jumper wire.
The oil pressure warning indicator should come on
with the ignition switch is "ON':
If the light does not comes on, check the sub-fuse
(10A) and wires for a loose connection or an
open circuit.

Start the engine and make sure that the light goes out.
If the light does not go out, check the oil pressure
(page 4-3).
If the oil pressure is normal, replace the oil pressure
switch (see below).

REMOVAL/INSTALLA Tl ON
Remove the dust cover, terminal screw and
wire terminal.
Remove the oil pressure switch from the crankcase.

Apply sealant to the oil pressure switch threads Do not apply sealant to the thread
as shown. head 3 - 4 mm (0.1 - 0.2 in)

Install the oil pressure switch onto the crankcase, then

tighten it to the specified torque .

TORQUE: 12 N•m (1.2 kgf•m, 9 lbf.ft)

Connect the oil pressure switch terminal to the switch

and tighten the screw.

Install the dust cover.

21-18
 LIGHTS/METERS/SWITCHES

FUEL UNIT
SYSTEM INSPECTION
Turn the ignition switch is ON and make sure the fuel
level indicator comes ON.

If the fuel level indicator does not indicate properly,

preform the following:

Remove the floorstep (page 2-20).

Disconnect the fuel unit 4P connector.

Short the wire harness side connector Gray/Black and
Green/Black terminals with a jumper wire.
FUEL LEVEL INDICATOR
Turn the ignition switch ON and make sure the fuel
level indicator comes ON.

If the indicator comes ON, replace the fuel

pump assembly.
If the indicator still dose not come ON, check for open
or short circuit in the wire harness.

FLOAT LEVEL SENSOR INSPECTION

Remove the fuel pump/unit (page 5-82).
Measure the resistance between the A and B termi -
nals when the float is at upper and lower end position.
A"frB 0 0

UPPER END
Float Position Upper end Lower end
Resistance
20- 24 Q 93 - 97 Q
(20°C/68°F)

Move the fuel unit float up and down, and make sure
the resistance changes smoothly.
If the resistance is out of specification, or the float
does not move smoothly, replace the fuel pump/unit
with a new one.

21-19
LIGHTS/METERS/SWITCHES

SI DESTAND SWITCH 2P CONNECTOR

INSPECTION
Remove the left passenger footpeg (page 2-12).

Disconnect the sidestand switch 2P green connector.

Check for continuity at the switch side of the 2P
green connector.

There should be continuity with the sidestand retract-

ed.
There should be no continuity with the sidestand
applied.

REMOVAL 2P CONNECTOR

Remove the left passenger footpeg (page 2-12).

Disconnect the sidestand switch 2P green connector.

Remove the bolt and sidestand switch from the side- SIDESTAND SWITCH
stand pivot.

Install the sidestand switch aligning the switch pin

with the sidestand hole and the switch groove with
the bracket pin.

21-20
 LIGHTS/METERS/SWITCHES

Secure the sidestand switch with the bolt.

Route the side- Connect the sidestand switch 2P green connector. 2P CONNECTOR
stand switch wire
properly {page 1- Install the left passenger footpeg (page 2-12).
20).

HORN
INSPECTION
Remove the front cover (page 2-14).
Remove the front airduct cover (page 2-21 ).
Disconnect the horn connectors from the horn.

Connect a 12 V battery to the horn terminals.

The horn is normal if it sounds when the 12 V battery
is connected across the horn terminals.

REMOVAL/INSTALLATION CONNECTORS

Remove the front cover (page 2-14).

Remove the front airduct cover (page 2-21 ).
Disconnect the horn connectors from the horn.
Remove the bolt from the horn.

Installation is in the reverse order of removal.

Install the front airduct cover (page 2-21 ).
Install the front cover (page 2-14).

BOLT HORN

21-21
LIGHTS/METERS/SWITC HES

LOW BEAM RELAY

INSPECTION
Remove the front cover (page 2-14).

Remove the low beam relay.

Connect the ohmmeter to the low beam relay

connector terminals.

CONNECTION: White - Black/Red

Connect the 12-V battery to the following low beam

relay connector terminals. LOW BEAM RELAY BATTERY

CONNECTION: Green - Blue

There should be continuity only when the 12-V battery

is connected.
If there is no continuity when the 12-V battery is con-
nected, replace the low beam relay.

TURN SIGNAL RELAY 16P CONNECTOR 12P CONNECTOR

INSPECTION
Remove the front cover (page 2-14) .

Check for the following:

- Battery condition
- Burned bulbs
- Burned fuse
- Ignition switch and turn signal switch function
- Loose connectors

If the above items are all normal, check the following:

Disconnect the 16P and 12P connectors from the
combination meter.

Short the black/light green and gray terminals of the

combination meter connector with a jumper wire.
Start the engine and check the turn signal light by
turning the switch ON.

+
Light comes on +
Light does not come on

+
l • Broken wire harness

• Faulty turn signal relay (combination meter).

• Poor connection of the connector.

21-22
 22. WIRING DIAGRAMS
'02 - '07 STD TYPE:
ENGINE
RIGHT HANDLEBAR STOP STARTER SERVICE CHECK CONNECTOR , ------------------

OM><UOH~~1m11
ECM

w • ~ · r~~~NG e
SWITCH
1i ~ tt~ "'I'<~
~IT ~"

A- :O:l
Lr-t--J-F=tt=l=t!+=l==i~====-= i: ~~ EXHAUST AIR INJECT SOLENOID VALVE

11==t==l:J::===== ~~ =11:gi}Q CMP SENSOR

~~~ ~~~~ ~it1ttt-ttti-tt--+t-++~-+-W------JL= ::~INJECTOR PN ~ INJECTOR2

1

~~~~6R P - tt-t---f+------- FVY~

r:~ '"""'
a
~
~ ~ ~a ¥.:~i~==#=t-11+-4-+J==ff===fF$=tt===~~LG/Or.;: =:f.rih
,,.
-~:(QJJ "'"""'
=Jl--1' -~ '""''

1~- ~+--_L,,,,~
,--t+-----_::'-= g:g, :fi:[JJ ECT SENSOR

M;
I
L__-tt-r.====i==w"N:&,,", ~ CKP SENSOR

j
OIL PRESSURE SWITCH
~~~~[JEAR TURN SIGNAL LIGHT

~~
:a, ~1
G
Gf1 ~
BRAKE AND TAIWGHTS
12V21WISW'2
B~r ~

,il,, ~ UC.ENSELIGHT
12V5W

RIGHT FRONT
TURN SIGNAL LIGHT
& POSITION LIGHT
12V21W
C@l= 0
'-"Nl 1 g~
~~fz WAR TURN SIGNAL LIGHT
1

~"' "t'~~-
=f=====ff!#=#::;:t~~===~--
HEADLIGHT (HI)
12V55W ,, "' G -

.L ~ l !l ~~
~V ~-

~
,-----------1.Ul.Ll
Bu Bu

~ G•---_J
11 - i~tE r r-i II
HEADLIGHT (LO) ~~lgo~.9'
~ ~""~ ~m ~1<~" 1..

m
a.ii ;o.;:1;Hi]i
~ ; _ _ ___,

dtl~ ,~:·rn•
~~
12V55W

!·" il
~J>!IJ lib u.~. ~~~ ~ j ~~~GAGE

J
ENGINE FUEL MAIN LUGGAGE
LIGHT BOX LIGHT

m.~u.
LEFT FRONT STOP POMP RELAY HiMAFINO '
RELAY RELAY FUSE BOX J.4W SWITCH
TURN SIG NAL LIGHT ~ SWITCH
t!v~~~ONLIGHT ~ J..,
.• !I! I! (MAIN ACC ABS)

~"'" IW! IHll~·I ~I ~

VEHICLE
SPEED SENSOR

~~~E ~IX/icH
@
TURN SIGNAL •HORN SWITCH •PASSING oOIMMER FAN MOTOR
LIGHT
SWITCH
LEFT HANDLEBAR
BRAKE LIGHT SWITCH

A .• • HEADLIGHT
B ~~~~/~~~ BRAKE UGHT/fAIL
c .. . Bl BLACK Br BROWN
D FAN MOTOR Y YELLOW 0 ORANGE
E IGN/FUEL PUMP START Bu BLUE Lb LIGHTBLUE
G GREEN ~g ~ll~~T GREEN
F ~~~~~BACK UP LUGGAGE BOX LIGHT R RED
G W WHITE Gr GRAY

0030Z-MCT-6500

22-1
WIRING DIAGRAMS
'02 - '07 ABS TYPE:
ENGINE
RIGHT HANDLEBAR STOP STARTER SERVICE CHECK CONNECTOR ECM

""AArnOH~ki1m11
'8lr ' ' rn~~~NG GffJ
0
·
SWITCH
C!:!l''
ll ~!NJ

~ ~ t!._11 l"~!jo~
~ _J"

~~~~MEAR TURN SIGNAL LIGHT

~~
~~~~~-
WHEEL SPEED SENSOR (FRONn
~·~1
G
GIV
Bl:r
~ BRAKEANDTAILLIGKTS
12V21W/5Wx2

Bl';.~ LICENSE LIGHT

~12V5W

g~
RIGHTFRONT
~~~ ~EAR TURN SIGNAL LIGHT
TURN SIGNAL LIGHT 1
tfv~~~}ION LIGHT

"'"
~ ~H!il~m
r 'n II
m
mi"'

~~~~~ill
~
~
ENGIN E FUEL MAIN
~~~GAGE
LIGHT
LUGGAGE
BOX LIGHT

~ ~ii.:, :::t'.:,
.4W SWITCH
LEFT FRONT
TURN SIGNAL LIGHT ~ "'" 3
t!v~f~ION LIGHT 0~ ~-=::'._
/CLE
ED SENSOR

WHEEL SPEED SENSOR (REAR)

LEFT HANDLEBAR
BRAKE LIGHT SWITCH

Bl BLACK Br BROWN
Y YELLOW 0 ORANGE
ENGINE STOP PARKING LEVER Bu BLUE Lb LIGHTBLUE
SWITCH SWITCH G GREEN Lg LIGHT GREEN
R RED P PINK
W WHITE Gr GRAY

0030Z-MCT-9500

22-2
 WIRING DIAGRAMS
After '07 STD TYPE :

PURGE CONTROL
SOLENOID VALVE
(CALIFORNIA ONRYI

rr~-ttttt~=f:f#=F============ ~:=ffi:~: :[J:J z

PAIR SOLENOID VALVE

tt---lmff=1=1~=t~Ff==I================= ij~ =11:@0 CMP SENSOR

~ ,Tf ~:LP -1111t--tt----Ht~-+-t--t-+U--+--------~=[~:W:~ P~~ INJECTOR2

INJECTOR 1

BAN K ANGLE
~-----------,,:~ TPSENSOR

SENSOR

i.-;.0012~Y/
~ Bu _j ~=l--l==r=t~===========1~ £==11.U-J'
~e11w-11tt--++------Uj_L_l
~
~ ~ ;;(; IGNITION COIL

SPARK PLUG =:Pih MAP SENSOR

~""' Tr-1---H-+----------_J~= G/O -mn

---I..Z.IJ--1 G'~" IAT SENSOR

~ ~iDt!I

OIL PRESSURE SWITCH

G ~ RIGHTREAR
Lb ~ TURN SIGNAL LIGHT
12V21W

~'~}
: ~
eua,
BRVAKEffAILLIGHTS
12 21W/5Wx2
G

H~W.,SE LIGHT

LEFT REAR
i2uv~~0I GN AL LIGHT

II FUSE BOX

·~ rr~ b"
g""' M
A HEADLIGHT
,., rl "
HEADLIGHT ~ o, _ _ _
11
INI B HORN/METER/BRAKE LIGHT!TAILLIGHT

~~
(LO) _J

J n~~wcm~'
C TURN SIGNAL
12V55W w- - - _ _ J m"' D FAN MOTOR
3 0
E IGNITION/FUEL PU MP/START
MAIN FUSE BOX
LUGGAGE
~~Q,LIGHT~
F ACCESSORY SOCKET
~ ~~~KB BACK UP/LUGGAGE BOX LIGHT

ENGINE STOP RELAY

LUGGAGE BOX
VHEICLE LIGHT SWITCH
SPEED SENSOR

Bl BLACK II Br BROWN
y YELLOW 0 ORANGE
Bu BLUE Lb LIGHT BLUE
G GREE N Lg LIGHT GREEN
R RED p PINK
PARKING
SWITCH w WHITE Gr GRAY
COLO R COMB. GROUND/MARKING

STARTER MOTOR STARTER RELAY SWITCH

0030Z-MCT-L600

22-3
 I

WIRING DIAGRAMS
·1
After '07 ABS TYPE:
DLC

~.
"- ~~

:~m ~ ~ 02 SENSOR

~=======#=~~~~~~-j~~~~~~~~~~~tt~~===~====~ ~~~~oo~~ --Li..LJ--J G•/B' SOLENOIDVALVE

(CALIFORNIA ONRYI

11--11---tttttt-i=lP=Hit=t========== ~~::fbii:, :CJ:J PAIR SOLENOID VALVE

rr---tti~Pt==f==t=m=f=================-,J;fv =!Igj}Q CMP SENSOR

FUEL
FUEL PUMP
~-111tt--it----HtH--+-t----t-+U-+-------===t :~~ ','"'~
If~ INJECTOR21
INJECTOR

~-----------! :~
~:+-!02~ mu~
TPSENSOR

~01~sW1---t1r--tt---++-----llLI-:~-ll=:=f1~~~~~~ ~~~~~~ ~ ----Pih

IGNITION COIL
&~ mfg

SPARK PLUG l ==tLU---J' - MAP SENSOR

-rr--~---t--t-+----------__t:--GrG,,.,o --Li..LJ--J
~ IAT SENSOR

11---t-----------==c::::~if,,~ ECTSE NSOR

ABS
MODULATOR ~l~~lttttitlH--W
~Bl r---tH=f=~~$=========1==v:":dtw'"~ CKP SENSOR

% -----
,.,_
tN-

j OIL PRESSURE SWITCH

G ~ RIGHT REAR
LI> ~ TURN SIG NAL LI GHT
12V21W

~'~}
G
~,
~ BRAKE/TAILLIGHTS
12V21W/5Wx2
G

LICENSE LIGHT
12V5W
LEFT REAR
i2uv~~~IGNA L LIGHT
I

II FUSE BOX

~ #~·
HEADLIGHT~ G• -
A HEADLIGHT
(LO) ~ ~i::~~~~~~BRAKE LIGHT/TAILLIGHT
12V55W w- - - _ _ J

~
D FAN MOTOR
E IGNITION/FUEL PUMP/START

~ LUGGAGE
~~~LIGHT~
~~ MAIN FUSE BOX
F ABS MAIN
~G­
~0-
FUEL CUlOFF RELAY FUSE BOX ~ ;~~~~l~AsC:F~~~~~GAGE BOX LIGHT
I ABS MOTOR
J MAIN B
ENGINE STOP RELAY
LU GGAGE BOX
VHEICLE LIGHT SWITCH
SPEED SENSOR

Bl BLACK Br BROWN
y YELLOW 0 ORANGE
Bu BLUE Lb LIGHT BLUE
G GREEN Lg LIGHT GREEN
R RED p PINK
PARKING
SWITCH w WHITE Gr GRAY
COLOR COMB. GROUND/MARKING

COlOR G W/81
STARTER MOTOR STARTER RELAY SWITCH
0030Z-MCT-L700

22-4
 23. TROUBLESHOOTING
ENGINE DOES NOT START OR IS POOR PERFORMANCE AT
HARD TO START 23-1 HIGH SPEED 23-4
ENGINE LACKS POWER 23-2 POOR HANDLING 23-4
POOR PERFORMANCE AT LOW
AND IDLE SPEED 23-3

ENGINE DOES NOT START OR IS HARD TO START

Possible cause

1. Check for operation of the fuel p u m p - - - - - - Abnormal _ _ _ __,_ • Faulty fuel pump (Section 5)
I
Normal

t
2. Inspect the fuel flow - - - - - - - - - - - A b n o r m a l --------1- • Faulty pressure regulator
I (Section 5)
Normal

t
3. Inspect the fuel injector - - - - - - - - - - A b n o r m a l --------1- • See section 5
I
Normal

t
4. Perform a spark test - - - - - - - - - - - W e a k or no spark --t•- ·• Faulty spark plug
I Fouled spark plug
Good spark • Faulty ECM
• Broken or shorted spark plug wire
• Faulty ignition switch
• Faulty CKP sensor
• Faulty engine stop switch
• Loose or disconnected spark
plug wires

5. Test cylinder c o m p r e s s i o n - - - - - - - - - Low compression ----1•- • Valve stuck open

I • Worn cylinder and piston ring

i :~;~~ip~~l~!lve
Compression normal • Damaged cylinder head gasket

timing

6. Starting following normal procedure - - - - - - E n g i n e starts but --t•- • Improperpipechoke operation

I stops • Intake leaking
Engine does not start • Improper ignition timing (Faulty
ignition coil or CKP sensor)
• Fuel contaminated

l
7. Remove and inspect spark plug Wet p l u g - - - - - - - - • Choke closed
• Throttle valve open
• Clogged air cleaner

23-1
TROUBLESHOOTING

ENGINE LACKS POWER

Possible cause

1. Raise wheel off the ground and spin - - - Wheels do not spin ... • Brake dragging
by hand freely • Worn or damaged wheel bearing
I
Wheel spins freely

2.
t
Check tire pressure Pressure low • Faulty tire valve
I • Punctured tire
Pressure normal

3.
•
Accelerate lightly
I
Engine speed increase
Engine speed does
not increase
... •
•
•
Air cleaner dirty
Restricted fuel flow
Clogged muffler
• Pinched fuel tank breather

4. +
Check ignition timing Incorrect • Faulty ECM
I • Faulty CKP sensor
Correct

5.
+
Test cylinder compression Incorrect • Valve stuck open
I • Worn cylinder and piston rings
Normal • Leaking head gasket
• Improper valve timing

6.
•
Inspect fuel flow
I
Normal
Abnormal • Faulty pressure regulator (Section 5)

7.
t
Inspect the fuel injector Abnormal • See section 5
I
Normal

8.
t
Remove spark plugs Fouled or discolored ... • Faulty spark plug
!·

I
Not fouled or discolored

9.
+
Check oil level and condition Incorrect • Oil level too high
I • Oil level too low
Correct • Contaminated oil

t
10. Remove cylinder head cover and inspect - - - Valve train not lubri- ... • Clogged oil passage
lubrication cated properly • Clogged oil control orifice
I
Valve train lubricated properly

23-2
 TROUBLESHOOTINIG

Possible cause

'
11. Check for engine overheating -------Overheating - - - - - - - • Coolant level low
1

Not overheating
• Fan motor not working (faulty fan
motor relay)
• Thermostat stuck close
• Excessive carbon build-up in
combustion chamber
• Use of poor quality fuel
• Wrong type of fuel
• Drive and driven
pulleys/clutch slipping (Section 10)

12. Accelerate or run at high speed - - - - - - Engine knocks------..- • Worn piston and cylinder
• Wrong type of fuel
+
Engine does not knock
• Excessive carbon build-up in com-
bustion chamber
• Ignition timing to advanced (faulty
ECM)
• Lean fuel mixture

POOR PERFORMANCE AT LOW AND IDLE SPEED

Possible cause

1. Check ignition t i m i n g - - - - - - - - - - - Incorrect - - - - - - - - • Improper ignition timing

1

Correct

t
2. Check the starter valve synchronization - - - - Incorrect • See section 5
I
Correct

+
3. Inspect the fuel flow - - - - - - - - - - - Abnormal - - - - - - - - • Faulty pressure regulator (Section 5)
1
Normal

t
4. Inspect the fuel injector - - - - - - - - - A b n o r m a l - - - - - - - - • See section 5
1
Normal

t
5. Check for leaks in the intake pipe - - - - - - L e a k i n g - - - - - - - - - • Loose insulator clamp
I • Damaged insulator
Not leak

t
6. Perform spark test - - - - - - - - - - - W e a k or intermittent -----•~ • Faulty spark plug
spark • Faulty carbon or wet fouled spark

j
plug
• Faulty ECM
• Faulty ignition coil
• Faulty engine stop switch
• Faulty CKP sensor
Good spark • Faulty ignition switch
• Loose or disconnected spark
plug wires

23-3
TROUBLESHOOTING

POOR PERFORMANCE AT HIGH SPEED

Possible cause

1. Check ignition timing - - - - - - - - - - I n c o r r e c t • Faulty ECM

I
Correct

t
2. Inspect the fuel flow - - - - - - - - - - A b n o r m a l • Faulty pressure regulator (Section 5)

I
Normal

t
3. Inspect the fuel injector - - - - - - - - - A b n o r m a l - - - - - - - • See section 5
1

Normal

+
4. Check valve timing - - - - - - - - - - - I n c o r r e c t • Camshaft not installed properly
I
Correct

+
5. Check valve spring • Faulty valve spring
I
Not weak

POOR HANDLING
Possible cause

1. If steering is heavy - - - - - - - - - - - - - - - - - - - - - - - • Steering stem adjusting nut too tight

• Damaged steering head bearings

2. If either wheel is wobbling - - - - - - - - - - - - - - - - - - - • Excessive wheel bearing play

• Bent rim
• Improper installed wheel hub
• Swingarm pivot bearing
excessively worn
• Bent frame

3. If the motorcycle pulled to one s i d e - - - - - - - - - - - - - - - - - • Faulty shock absorber

• Front and rear wheel not aligned
• Bent fork
• Bent swingarm
• Bent axle

23-4
 INDEX

ABS MODULATOR 17-22 EMISSION CONTROL SYSTEMS 1-34

AIR CLEANER 3-5 EMISSION CONTROL INFORMATION LABELS 1-37
AIR CLEANER HOUSING 5-89 ENGINE DOES NOT START OR IS HARD TO START 23-1
AIR SCREW SYNCHRONIZATION 5-103 ENGINE IDLE SPEED 3-13
ALTERNATOR CHARGING COIL 18-6 ENGINE INSTALLATION 7-6
ALTERNATOR STATOR 12-2 ENGINE LACKS POWER 23-2
BALANCER SHAFT 13-9 ENGINE OIL 3-11
BANK ANGLE SENSOR 5-112 ENGINE OIL FILTER 3-12
BATTERY 18-4 ENGINE REMOVAL 7-2
BEARING REPLACEMENT 11-5 ENGINE STOP RELAY 5-113
BEFORE STARTING TROUBLESHOOTING 17-2 EVAPORATIVE EMISSION CONTROL SYSTEM
BODY COVER 2-6 (FUEL SYSTEM) 5-117
BODY PANEL LOCATIONS 2-0 (MAINTENANCE) 3-16
BODY PANEL REMOVAL CHART 2-1 FAN MOTOR RELAY 6-16
BRAKE FLUID 3-17 FAST IDLE WAX UNIT 5-103
BRAKE FLUID REPLACEMENT/AIR BLEEDING 16-4 FINAL DRIVE OIL 3-16
BRAKE LIGHT SWITCH 21-10 FINAL REDUCTION ASSEMBLY 11-8
BRAKE LOCK OPERATION 3-19 DISASSEMBLY 11-3
BRAKE PAD WEAR 3-18 INSPECTION 11-4
BRAKE PAD/DISC 16-9 FLOOR MAT 2-4
BRAKE SYSTEM 3-18 FLOOR SKIRT 2-4
BULB REPLACEMENT 21-5 FLOORSTEP 2-20
CABLE & HARNESS ROUTING 1-20 FLYWHEEL/STARTER CLUTCH/CKP SENSOR 12-5
CAM CHAIN TENSIONER LIFTER 8-29 FORK 14-8
CAMSHAFT INSTALLATION 8-23 FRONT AIRDUCT COVER 2-21
CAMSHAFT REMOVAL 8-6 FRONT BRAKE CALIPER 16-23
CHARGING SYSTEM INSPECTION 18-5 FRONT COVER 2-14
CLUTCH/DRIVEN PULLEY 10-10 FRONT FENDER 2-6
CMP SENSOR 5-106 FRONT LOWER COVER 2-20
COMBINATION METER 21-7 FRONT MASTER CYLINDER 16-12
COOLANT REPLACEMENT 6-4 FRONT PULSER RING 17-20
COOLANT TEMPERATURE INDICATOR, FRONT WHEEL 14-3
ECT/THERMOSENSOR 21 -16 FRONT WHEEL SPEED SENSOR 17-19
COOLING SYSTEM 3-14 FUEL CUT-OFF RELAY 5-84
CRANKCASE ASSEMBLY 13-12 FUEL LINE 3-4
. CRANKCASE BREATHER 3-5 FUEL LINE INSPECTION 5-79
CRANKCASE SEPARATION 13-2 FUEL PUMP 5-82
CRANKSHAFT/CONNECTING ROD 13-4 FUEL TANK 5-84
CYLINDER COMPRESSION TEST 8-4 FUEL UNIT 21-19
CYLINDER HEAD COVER ASSEMBLY 8-26 HANDLEBAR COVER 2-14
DISASSEMBLY 8-5 HANDLEBAR SWITCHES 21-12
INSTALLATION 8-28 HEADLIGHT AIM 3-20
REMOVAL 8-4 HORN 21-21
CYLINDER HEAD DISASSEMBLY 8-12 IAT SENSOR 5-105
INSPECTION 8-13 IGNITION COIL 19-6
ASSEMBLY 8-20 IGNITION SWITCH 21-11
INSTALLATION 8-22 IGNITION SYSTEM INSPECTION 19-3
REMOVAL 8-11 IGNITION TIMING 19-6
CYLINDER/PISTON INSTALLATION 9-6 INJECTOR 5-100
REMOVAL 9-3 INNER COVER/FLOOR UPPER COVER 2-15
DELAY VALVE 16-22 LEFT REAR COVER 10-3
DRIVE PULLEY 10-6 LIMIT SWITCH 21-10
OTC CODE INDEX (After '07) 5-60 LOW BEAM RELAY 21-22
OTC TROUBLESHOOTING (After '07) 5-63 LUBRICATION & SEAL POINTS 1-17
ECM (ENGINE CONTROL MODULE) LUGGAGE BOX 2-10
('02 - '07) 5-114 LUGGAGE BOX LIGHT SWITCH 21-13
(After '07) 5-115 MAIN STAND 7-6
ECT SENSOR 5-106 MAINTENANCE SCHEDULE 3-3
MAP SENSOR 5-104 (MAINTENANCE) 3-1
METER PANEL 2-15 (REAR WHEEL/SUSPENSION) 15-2
MIL CODE INDEX (After '07) 5-44 SERVICE RULES 1-1
MIL TROUBLESHOOTING (After '07) 5-46 SIDESTAND 3-20
MODEL IDENTIFICATION 1-2 SIDESTAND SWITCH 21-20
MUFFLER ('02 - '07) 2-22 SPARK PLUG 3-5
MUFFLER/EXHAUST PIPE (After '07) 2-24 SPARK PLUG MAINTENANCE LID 2-5
NUTS, BOLTS, FASTENERS 3-21 SPECIFICATIONS 1-3
02 SENSOR (After '07) 5-110 SPEEDOMETERNEHICLE SPEED SENSOR 21-8
OIL COOLER 4-9 STARTER MOTOR 20-4
OIL PRESSURE CHECK 4-3 STARTER RELAY SWITCH 20-11
OIL PRESSURE RELIEF VALVE 4-4 STEERING HANDLE 14-18
OIL PRESSURE SWITCH 21-17 STEERING HEAD BEARINGS 3-22
OIL PUMP 4-5 STEERING STEM 14-26
PAIR SOLENOID VALVE 5-116 SUSPENSION 3-20
PARKING BRAKE 16-30 SYSTEM DIAGRAM
PARKING SWITCH 21-13 (FUEL SYSTEM; '02 - '07) 5-5
PASSENGER FOOTPEG 2-12 (FUEL SYSTEM; After '07) 5-7
PGM-FI (PROGRAMMED FUEL INJECTION) SYSTEM (BATTERY/CHARGING SYSTEM) 18-0
('02 - '07) 5-8 (ELECTRIC STARTER) 20-0
(After '07) 5-12 (IGNITION SYSTEM) 19-0
PGM-FI SELF-DIAGNOSIS MALFUNCTION SYSTEM FLOW PATTERN 6-0
INDICATOR LAMP (MIL) FAILURE CODES ('02 - '07) 5-16 SYSTEM LOCATION
POOR HANDLING 23-4 (FUEL SYSTEM; '02 - '07) 5-4
POOR PERFORMANCE AT HIGH SPEED 23-4 (FUEL SYSTEM; After '07) 5-6
POOR PERFORMANCE AT LOW AND IDLE SPEED 23-3 SYSTEM TESTING 6-3
PRESSURE REGULATOR 5-102 TACHOMETER 21-14
RADIATOR 6-11 THERMOSTAT 6-6
RADIATOR COOLANT 3-14 THROTTLE BODY/INTAKE MANIFOLD 5-92
RADIATOR RESERVE TANK 6-15 THROTTLE OPERATION 3-4
REAR BRAKE CALIPER 16-27 TOOLS 1-15
REAR FENDER 2-10 TORQUE VALUES 1-11
REAR MASTER CYLINDER 16-17 TP SENSOR
REAR PULSER RING 17-22 ('02 - '07) 5-107
REAR SHOCK ABSORBER 15-13 (After '07) 5-109
REAR SPOILER 2-6 TRIM CLIP 2-3
REAR WHEEL/SWINGARM 15-4 TROUBLESHOOTING
REAR WHEEL SPEED SENSOR 17-20 (ALTERNATOR/STARTER CLUTCH) 12-1
REGULATOR/RECTIFIER 18-7 (ANTI-LOCK BRAKE SYSTEM (ABS)) 17-7
SEAT 2-3 (BATTERY/CHARGING SYSTEM) 18-3
SEAT UNDER COVER 2-5 (BRAKE SYSTEM) 16-3
SECONDARY AIR SUPPLY SYSTEM 3-15 (COOLING SYSTEM) 6-2
SERVICE INFORMATION (CRANKCASE/CRANKSHAFT/BALANCER) 13-1
(ALTERNATOR/STARTER CLUTCH) 12-1 (CYLINDER HEADNALVES) 8-3
(ANTI-LOCK BRAKE SYSTEM (ABS)) 17-1 (CYLINDER/PISTON) 9-2
(BATTERY/CHARGING SYSTEM) 18-1 (DRIVE PULLEY/DRIVEN PULLEY/CLUTCH) 10-2
(BRAKE SYSTEM) 16-2 (ELECTRIC STARTER) 20-2
(COOLING SYSTEM) 6-1 (FINAL REDUCTION) 11-2
(CRANKCASE/CRANKSHAFT/BALANCER) 13-1 (FRAME/BODY PANELS/EXHAUST SYSTEM) 2-2
(CYLINDER HEADNALVES) 8-1 (FRONT WHEEL/SUSPENSION/STEERING) 14-2
(CYLI N DER/PISTON) 9-1 (FUEL SYSTEM) 5-3
(DRIVE PULLEY/DRIVEN PULLEY/CLUTCH) 10-1 (IGNITION SYSTEM) 19-2
(ELECTRIC STARTER) 20-1 (LIGHTS/METERS/SWITCHES) 21-3
(ENGINE REMOVAL/INSTALLATION) 7-1 (LUBRICATION SYSTEM) 4-2
(FINAL REDUCTION) 11-1 (REAR WHEEL/SUSPENSION) 15-3
(FRAME/BODY PANELS/EXHAUST SYSTEM) 2-2 TURN SIGNAL RELAY 21-22
(FRONT WHEEL/SUSPENSION/STEERING) 14-1 UNDER COVER 2-21
(FUEL SYSTEM) 5-1 VALVE CLEARANCE 3-7
(IGNITION SYSTEM) 19-1 VALVE GUIDE REPLACEMENT 8-16
(LIGHTS/METERS/SWITCHES) 21-1 VALVE SEAT INSPECTION/REFACING 8-17
(LUBRICATION SYSTEM) 4-1 V-MATIC INDICATOR 21-15
WATER PUMP 6-8
WHEELS/TIRES 3-21
WINDSHIELD 2-12
WIRING DIAGRAMS
('02 - '07 STD TYPE) 22-1
('02 - '07 ABS TYPE) 22-2
(After '07 STD TYPE) 22-3
(After '07 ABS TYPE) 22-4