SERVIGINGINFORWATION 94 SERVICING INFORMATION CONTENTS TROUBLESHOOTING. FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION ENGINE... RADIATOR (COOLING SYSTEM). cnassis. BRAKES. ELECTRICAL BATTERY . = s WIRING HARNESS, CABLE AND HOSE ROUTING. WIRING HARNESS ROUTING.. CABLE ROUTING... FUEL SYSTEM HOSE ROUTING. ‘COOLING SYSTEM HOSE ROUTING. OIL HOSE ROUTING FRONT BRAKE HOSE ROUTING. REAR BRAKE HOSE ROUTING. THROTTLE BODY INSTALLATION. FUEL TANK INSTALLATION. BRAKE PEDAL INSTALLATION. FRONT SIDE REFLEX REFLECTOR INSTALLATION (For E28). BRAKE LIGHT/TAILLIGHT INSTALLATION (For others). BRAKE LIGHT/TAILLIGHT INSTALLATION (For E-28). DRIVE CHAIN ROLLER INSTALLATION... SPECIAL TOOLS. TIGHTENING TORQUE. ENGINE vv FI SYSTEM AND INTAKE AIR SYSTEM. COOLING SYSTEM. chassis. TIGHTENING TORQUE CHART... SERVICE DATA. a2 o2 a4 910 910 912 913 ona 9.15 O45 oe 919 920 921 922 923 924 9.25 9.26 927 928 9.29 930 oat 934 934 9.5 935 9.36 937 93892_SEAVICNG INFORMATION TROUBLESHOOTING FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION Drone, | PETEETE™] pevecrED FALURE CONDITION | ___OHECKFOR Sa en Fi Ga Rename ESHER a ga tc ovmom ater rcohng a iAP_ [ea pare ae |sensor input signal. |CKP sensor, lead wire/coupler TRE srac—| Tso TT TGP aso RT TEST rege [erect ew sv & enor otage < 44 Iroerane ator ang, C12 [pote end 7 Sar geo orion psa A a Se aR ae Mic or yun aroun pores Sons wage bean Good mPa cee open L fave horad pounders cot en ll roto tanesien eu sv < soworvotage 48 Inoner ane tow ange, C14 [roto ene 7 a ge GT aT SpE aS SATS “| bers Ne or gund ceutonn poten Soaring ower an speed | TP err rc ope L rau herad yountervoC cat own EST aia] SS STOTT OT ]EST BRO HOTTEST ones panecion oss nr = srr age < 48 Ineor ano soo ane 15 (porn 7 Seen tap gir Ran epoood ET saa Ra oN io re pound cel open i Sar Wag var Ran poi [ ECT vrs Seo TTS TR] SORT RA ROUT SON AT WOES ‘own meses cat favs serorotage 48 Inaterthenbe aor arg, C2 [ron nace 7 Sonn loos iar Tan spate AT aaa Sa oR | be round creat open . Sons ing over Fareed | ona toa OTS ke pondSERVICNGINFORUATION 93 sii igonmarion 93 Orono, | ECTED cerecreorauuneconomion | eneox Fon Serco Th seo age Haas He BO ESWC [ovat or ar moe ter. |eomcten tion switch is turned ON, cas lo3V = sensor votage < 4.6 In other than the above valu, C23, (21651) is incicated ia ‘Sensor vollago i higher han spocified [TO sensor crcull shared To value. VCC or ground ercut open Presi [Sensor voltage is lower than speciid [TO sensor circuit open or L value. shorted to ground or VCC circuit lopen Tgnion sig: [CRP sensor (pidcup ool) signals pr [Ignition ool, winnglovapler oor nal ‘Suced, fut signal from ignition col's nection, power supply fom the tae) Interrupted S times or mare continu- {battery ously In his case, he code C24 ross | (P0351) is incicated (Gear post | Goar positon signal volage shouldbe [GP switch, wihg/coupler con 631 [tion signal higher than the following for 3 seconds |nection, earshit cam, etc land more, \Goar position switch voltage > 0.9.V 0705 lower than the above value, C31 (P0705) is incicates, Fuclijector_[CKP sensor (pickup coll Sigal ls pro- [Fuel myector, wing @upler Con - ‘duced, bu fuel injector signal is inter- | nection, power suppy tothe ‘upted 8 times or mare continuously. In injector this case, the code C32 (P0201) is 0201 indicates (Cai [Fuel pump — Fue! pump relay signal snot pat [Fuel pump relay. TeadwreToour 0230 |relay EOM. ler connection (G50 |Gooiing fan [Cooling fan relay signal enol input [Cooling fan relay Tead wireTcou- P0800 ——|retay ECM. ler connection4 SERVICING MFORWATION ENGINE ‘Complaint ‘Symptom and possible causes Fomedy Engine will not start | Compression too low Joris hard to start. | 1. Valve clearance out of adjustment Adjust. 2. Worn valve guides or poor seating of valves | Repair or replace, 3. Mistiming valves Adjust. 4. Excessively worn piston rings Replace. 5. Worn-down cylinder bore Replace, 6. Too slowly starter motor cranks See electrical section. 7. Poor seating of spark plug Retighten. 8, Broken, cracked or damaged piston Replace. Plug not sparking 1. Fouled spark plug ean 2. Wet spark plug Clean and ay. 43. Detective ignition coi Replace. 4. Detective CKP sensor Fopiace. 5. Detective ECM Foplace. 6. Open-circuited wiring connections pai or replace, No fuel reaching the intake manifold 1. Clogged tut fiter or fuel hose (Clean o place, 2. Detective tue! pump Replace, 3. Detective tuo pressure regulator Replace. 4, Doloctive fu! injector Replace, 5. Detective fuel pump relay Replace. 6. Detective ECM Replace 7. Open-cicuited wiring connections [Check and repa Incorrect tueair mixture 1. TP sensor out of adjustment Adjust. 2. Detective tual pump opiace. 43. Detective fuel pressure regulator Replace. 4. Detective TP sensor Roplace. 5. Defective CKP sensor Replace. 6. Defective IAP sensor Roplace. 7. Detective ECM Replace. 8, Defective ECT sensor Replace. 8. Detective IAT sensor | Replace,SERVINGINFOMMATION 95 icin nisormarion ois Complaint ‘Symptom and possible causes Remedy Engine idles poorly. | 1. Valve cearance out of adustment Aas 2. Poor seating of valves Replace or repar 3, Detective valve guides Replace. 44. Worn down camshatts Replace. 5. Too wide sparkplug gap Adjust or replace, 6. Detective ignition collplog cap Replace, 7. Detective CKP sensor Replace, 8. Dolective ECM Roplace. 8. Defective TP sensor Replace, 10. Detective fuel pump Roplace. 11, Damaged or racked vacuum hose Replace, Engine stalls often, |Incorrect fuel/air mixture 1. Defective IAP sensor or crcut Fopair or replace 2, Clogged tue ter ‘Clean or replace 3. Detective fue! pump Replace, 4, Detective tue pressure regulator Replace, 5. Delective ECT sensor Replace. 6. Defective thermostat Replace, 7. Dolectve AT sensor Replace. 8. Damaged or eracked vacuum nose Replace, Fuel injector improperly operating 1. Detective fuel injectors Replace, 2. No injection signal rom ECM Fepairorropace. 3. Open or short cteuited wiring connection Repair or replace 4, Detective battery or low battery votage place ot recharge. Control cicult or sensor improperly operating 1. Detective ECM Replace, 2. Detective tue pressure raguator Replace, 3. Detective TP sensor Replace. 4. Detective IAT sensor place. 5, Dotectve CKP sensor place, 6. Detective ECT sensor place. 7, Detective fuel pump relay Replace. Engine internal parts improperly operating 1. Fouled sparkplug clean 2. Detective CKP sensor or ECM Replace. 3. Clogged tue! nose (Ciean 4, Out of adustment tappet clearance AdjustH4_SERVICING MFORUATION ‘Complaint ‘Symptom and possible causes Remedy Noisy engine ‘Excessive valve chatter 1. Too large tappet clearance Adjust. 2. Weakened or broken valve springs Replace. 3. Worn tappet or cam surface Replace, 4. Worn and burnt eamshalt journal Replace Noise seems to come from piston 1. Worn down piston or cylinder Replace. 2. Carbon combustion chamber fouled with carbon |Ciean, 3. Wom piston pins or piston pin bore Replace. 4, Win piston rings or ring grooves Replace, Noise seems to come from timing chal 1. Stretohed chain Roplace, 2. Ween sprockets Replace, 3. Tension adjuster not working Repair or replace. Noise seems to come from clutch 1. Worn splines of countershatt or hub Replace. 2. Worn oath f luch patos eopiace. 3, Distortod clutch plates, driven and drive Replace. 4. Worn clutch release bearing Replace '5, Weakened clutch damper place the primary riven gear Noise seems to come from erankahatt 1. Rattng bearings due to wear Replace. 2. Worn and burnt big-end bearings Replace. ‘3. Worn and burt journal bearings Roplace. Noise seems to come from balancer 1. Worn and burnt journal bearings Replace, Noise seems to come from transmission 1 Worn or rubbing gears Replace, 2. Worn spines Replace. 3. Worn or rubbing primary gears Replace, 4. Worn bearings Replace. Noise seems to come from water pump 1. Too much play on pum shaft bearing Replace, 2. Worn or damaged impeller shat Replace 3. Worn or damaged mechanical seal Replace 4. Contact between pump case and impeller Replace.SERVCNGINFORNATION 67 _stfvcnciitoniarion 7 Symptom and possible causes Remedy [Engine runs poorly | Defective engine internalelectical parts In high speed range. 1. Weakened valve springs Replace, 2. Worn camshatis Replace. 3. Valve ting out of adjustment Adjust 4, Too narrow spark plug gap Adjust 5. lgiton not advanced sufficiently due to poorly | Raplace ECM, working timing advance circuit 6. Detective ignition cai place, 7, Detective CKP sensor Replace. 8. Detective ECM Replace. 8. Clogged air cleaner element Cean, 10. Clogged tue! hose, resulting in inadequate fuel |iean and prime. supply to injector 11, Detective tue! pump Replace. 12, Detective TP sensor Replace, Detective airflow system 1. Clogged air cleaner element place. 2 Sucking arom tote bedy joint pair or replace, 3. Detective ECM Feplace. Detective control circuit or sensor 1. Low ful pressure Repair or replace 2. Dolectve TP eansor Replace, 3, Detective IAT sensor Replace, 4. Detective CKP sensor eplace, 5, Detective GP sensor Replace. 6. Detective IAP sensor Replace. 7. Detective ECM Replace, TP sensor out adjustment Replace.$8 SERVICING WFORWATION Complaint ‘Symptom and possible causes Remedy Engine lacks power, Detective engine intornaelectrical parts 1, Loss of tappet clearance 2. Weakened valve springs 3, Valve timing out of adjustment 44. Worn paton rings or cylinder 5. Poor seating of valves 6. Fouled spark plug 7. Incoroct spark plug 8. Clogged tut injector 9. TP sensor out of adjustment 10. Clogged air cleaner element 11. Sucking ai trom that valve or vacuum hose 12, Too much engine oil 18, Detective fuel pump or ECM 14, Defective CKP sensor and ignition col Detective control circuit or sensor Low ful pressure Delectiva TP sensor Detective IAT sensor Detective GKP sensor Detective GP sensor Detective IAP sensor Detective ECM TP sensor out of adjustment Aaiust Replace. dust piace Repair. Clean or replace Adjust or replace place, |Adjust. Replace, Retighten or replace. Drain out excess ol. Replace. Replace, Repair or replace Fopiace Replace. Fopace Replace. Replace, Replace, |djustSERVCNGINFORMATION 99) icc nrorarion sg ‘Complaint Symptom and possible causes Ramedy Engine overheats Detective engine internal parts 1. Heavy carbon deposit on piston crowns 2. Not enough oilin the engine 3, Detective ol pump of clogged ol circuit 4 Sucking air rom intake pipe 5. Use incorrect engine oi 6. Detective cooing system Lean fuel/air mixture 1. Shor-cicuited IAP sensorload wire 2. Shor-cicuied IAT sensorlead wire ‘3. Sucking arom intake pipe joint 4, Detective fue injector Detective ECT sensor Other factors 1. Ignition timing is too advanced due to detective timing advance systom (ECT sensor, GP sensor, (CKP sensor and ECR, 2. Drive chain too tight. ean Add oi Replace or clan, Retighten or repace. Change, ‘See radiator seaton, Repair or replace Ropair ot replace Replace. Adjust Dirty or heavy exhaust smoke 1. Too much engine olin the engine ‘Check wih inspection window, drain ou exces i 2. Worn piston ings or eylinser Repace, 3. Worn valve guides Replace, 4, Scored or scuffed cylinder wall Replace. 5. Worn valos stems Roplace. 6. Detective stem seal Replace. 7. Worn ol ring ida rails Replace. [Slipping clutch | 1. Weakened clutch springs Replace. 2. Worn or aistorted pressure pate Replace 3. Distortod clutch plates or pressure plate Replace, [Dragging clutch | 1. Some cutch spring weakened while others [Replace ~~} are no L 2, Distorted pressure plates of clutch plates Replace, Fransmission wil | 1. Broken gearshiftcam Replace. not shit. 2, Distorted gearshit foxks Replace, 3. Wiorn gearshit paw Replace. Transmission will | 1. Broken return spring on shit shaft place not shit back. | 2. Rubbing orsicly shit shat Ropair or replace 8. Distortod or worn gearshit forks Replace, Transmission jumps | 1. Worn shiting gears on driveshaft or Replace. lout of gear. countershatt 2, Distorted or wom gearshit forks Replace. 3, Weakened stopper spring on gearshift stopper | Replace. 4 Worn goarshit cam plate Replace. 5. Gear dogidag hole worn FoplaceSERVICING INFORMATION RADIATOR (COOLING SYSTEM) Compraint “Symptom and possible causes Remedy Engine overhoais | 7. Net enough engine coolant Ral coolant. 2, Radiator core clogged with ato scale iean 3, Faulty cooing fan Repair or repace. 4. Defective cooing fan olay or open or short | Repaioreplace. created 5. Detective Eom Replace 6. Delectve ECT sansor Replace 7. Giogged water passage ‘Giean 8. Air rapped in the cooing crc Bleed ai 8. Detective water pump Repace 10, Use inconset coolant Repiace 1, Detecve thermostat Repiace Engine overcools | 1. Delectve ECT sensor epiace 2. Exemely cold weather Puton the radator cover. 3. Detective thermastat Repco 4 Detective cooing fan clay, or open: or short: |Repaior replace. crcuted 5. Delectve ECM place. CHASSIS Complaint ‘Symptom and possible caus T Remedy Handling istoo | 7. improper rontwhes! agement "agus heavy orstit. | 2. incuteionty treated Lubiate 2. Low aie pressure in ont res Adjust. 4, Tie rod ands tending to soize Replace 5. Linkage connections tending to seize Repair or replace Steering wobbles. | 1. Unequal infiatoa tes Rogue. 2 Loose ron whee! hub nuts Tighen 3. Damaged or wom font whee! hub bearings | Replace 4, Worn or loose te rod ends Replace or ghten 5. Detective or incoroct ont es Replace. 6. Damaged oc wom wishbone arms and related |Repace. bearings 7, Distorted font wheels Replace 8. Loose chassis nus and bots Highton, [Seering pula to). Unequally inflated tres Regulate one sie, 2 Improper font whee alignment Adjust | 3. wom ton wae! hub bearings Repace 4 Distorted tame or wishbone Repair 0 oplace 5. Detective shock absorber Repiace [Shocks fet inthe | 1. High te prossure Regulate steering. 2. Wom stocring linkage connections Replace. | 8. Loose suspension systom bts TightenSEAVICNG INFORMATION _ 911 ico nrorarion tt [_Compraint ‘Symptom and possible causes Remedy Fires rapidly or | 7. Wor or loose front wheel hub bearings Replace, Juneventy wear. | 2 Improper front whee! alignment Adjust Steering too noisy. | 1. Loose nuts and bots Tighten | 2. Damaged or worn tront wheel hub bearings | Replace, 3. Insufciony lubricated Lubricate Front suspension | 1. Weakened spring of shock absorber Replace, too sort. 2. Leakage olor gas of shock absorber Roplace. 23. Improperty set ont spring pre-oad adusters | Adjust. 4, Improperly set damping force adjusters Adjust. Front suspension | 1. Worn upper or lower wishbone arms and Tighten to0 sti. related bearings 2. Bent shock absorber rod Replace 3 Improperly set front spring pre-road adjusters | Adjust. 4. Improperly set damping force adjusters Adjust Front wheels wob- | 1. Distorted font wheel ims Replace. bie. 2. Damage or worn front wheel hub bearings | Rplace, 3. Detective or incorrect font tres Replace, 4, Loose tront whee! hub nuts Tighten 5. Damaged or worn wishbone arms and elated | Replace, bearings 6. Front shock absorber leaks Replace, ie | 7. Loose chassis nuts and halts Tighten, [Suspension too | 1. Loose suspension system bolts Tighten. noiy. 2. Wom wishbone arms and elated bearings | Replace. ’3_ Worn swingarm and suspension bearings Replace, [Rear suspension | 1. Weakened spring of shock absorber Repiace t00 sort. 2. Leakage aor gas of shock absorber Replace. 3. Improperly set rear spring preload adjuster | Adust, 4. Improperly set damping force adjuster Adjust Rear suspension | 1. Bond shock absorber rod Replace, too suit. 2. Bont swingarm pivot shat Replace, 3, Wom swingarm and rear suspension bearings | Replace. 4. Improperty set rear spring pre-load adjuster | Adust. 5, Improperly set damping force adjuster Adjust. | 6. Improper chain adjustment Adjust. [Rear wheels wob- | 1. Distorted ear wheel rms Ropiace bie. 2. Damage or worn roar axel housing bearings | Replace. 3. Detective or incorrect rear ures Replace. 4. Loose rear who! hub nut Tighten 5. Distorted rear axle Replace, 6. Loosen rear axle housing mounting bolts Tighten, 7. Improper rear brake adjustment ‘Adjust. 8. Damaged or wom rear swingarm and related | Replace, bearings 8, Rear shock absorber leaks ol Replace 10. Loose rear swingarm nut Tighten,(412 SERVING INFORMATION BRAKES Complaint | Symplom and possible causes Remedy neufficlent brake | 1 Leakage of brake lid trom hydraulic system [Repair or replace power 2 Worn pads Replace. 3. Oil adhesion of engaging surtace of pads/shoe _|Clean ese and pads 4 Worn disc Replace, 5. Alrinhyaraue system Bleed ai 6. Not enough brake fui in tho reservoir Roplonish. 7. improper parking brake adjustment Agust 1. Carbon adhesion on pad surface Repair surface wih sandpaper. 2, Tited pad Correct pad fting or replace. 2. Loosen front wheel axe or tear wheol axle | Tighten to specified torque. 4. Wor pads Roplace. Excessive brake ever stroke 5. Foreign material in brake uid 6. Clogged return port of master cylinder 1. Ari hydraulic system 2. Insuificient brake Hud 3. improper quality of brake Hid Leakage of brake sia 1. Insutfientghtening of connection joints 2. Cracked hose 3. Worn piston andior cup Replace brake thi. Disassemble anc clean master eyinder. Blood al Replonishthid te specifies evel bleed air Replace wih covect tid righten to species torque opiace. Replace piston andor cup. Brake drags 1. Rusty part 2, Inaufcient brake lever or brake pedal Pivot lubrication 3. Improper parking brake adjustment [Clean and lbrieat. Lubvcate, Aust.SERVICING INFORMATION 912 a_i mrornaion tg ELECTRICAL Complaint Symptom and possible causes Remedy [No sparking or poor | 7. Defoctive ignition cols Replace, sparking 2. Detective spark plugs Replace. 3. Detective CKP sensor Replace, 4, Detective ECM Replace. 5. Dotectve TO sensor place, 6. Open circuited wiring connections ‘Check and repr. [Spark plug soon | 1. Mixture too rich Inspect Fl systom become fouled with | 2. lang speed set too high Adust ile air cron, ‘carbon, 3. Incorect gasoline ‘Change 4. Ditty ar cleaner element Replace. 5. Too cold spark pugs Replace with ho: ype plug [Spark plug Become | 1. Worn piston rings Replace. fouted too soon. | 2. Worn piston or cylinder Replace, 3, Excessive clearance of valve stems in valve | Replace. guides | 4, Worn stem oil seal Replace. [Spark plug elec- | 1. Too hot spark plugs Replace with cod type trodes overheat or lugs. burn 2, Ovorheated the engine Tune up. 4. Loose spark plugs Retighten. _| 4. To0 lean mieture Inspoct Fl ey2tem. [Generator dees not | 1. Open-or shor-crcuted lead wire, or loose lead | Fepair or replace or charge. connettions retighten, 2, Short circuited, rounded or open ganerator coll | Replace. 3. Short-cteuited o punctured reguatorrectiior —_| Replace 1. Lead wires tend to get shorted or open-crcuted | Repair or tighten, [charge, but charg | or loosely connected at terminals ing rate is below the | 2. Grounded or open-cieuited generator col | Replace. specification. 3. Detective raguatorrectfier Replace, 4, Detective cell piates inthe battery Replace the battory [Generator over 1. Internal short-cut in te battery oplace the bar, Jeharges 2. Damaged or dotectve requatoriractiier Replace, 3, Poorly grounded regulatorrectiior ‘Clean and tighten ground connection, [Unstable charging | 1. Load wire insulation frayed due to viration, | Repair or replace resulting in inormitent short-reuting. 2, Internally shorted generator Ropiace, 3. Defective roguatorrecttior Replace, [Starter buttons not | 1. Run down battery Repair or replace ettective 2. Detective switen contacts Replace, 3, Brushes not seating properly on stater moter | Repair or replace commutator 4, Detective starter relay pace 5. Defocive main tuse Replace.8:14 SERVICNG INFORNATION BATTERY ‘Complaint ‘Symptom and possible causes Remedy 1 Cracked battery case place the battery white powdery sub- | 2. Battery hasbeen let in a run-down condition fr | Replace the battery. stance or spots on | longtime. surface of cell plates Battery runs down | 1 Trouble nthe charging system icky 2. Coll plates nave lost much of thelr active material as a result of overcharging Internal short-circuit inthe battery ‘oo low battery votage “Too ols battery [Gheak he genereior, regu atorrectiir andcrcut ‘connections and make nec- essary adustments to ‘obtain spected cnarging ‘operation. Replace the battery and correct the chargng sys Replace the battery Recharge the batery tly. Replace tho battery Battery “sulfation” | 1. Incorrect charging rate (When not in use batteries should be checked at least once @ month to avoid sultation ) 2. The batiery was left unused in a cold climate for to tom Replace the battery place the battery ibadly lai [Battery discharged | 1. Dirty container top and sides, too polarity 2, Old battery Ciean, Replace the batterySERVING NFORUATON 9.15 WIRING HARNESS, CABLE AND HOSE ROUTING WIRING HARNESS ROUTINGvg naaSERVING NFORUATON 917 ‘corm (s5et" ren”) 201m 20 aH.SERVING INFORMATION CABLE ROUTING \ easel aE \ Sater cae Pasa the toto and catch cabs trough downside of the high-tension cord (Pass tho savior cable hough rearward ofthe parking brake cable. Pass the starter cable between the frame and Pass the starter eablo trough upside of the wiring harness. ? | wing harness. 7 | siphon hose. Pass the starter cable fwough upside ofthe wir], [Pass the starter cable through upside of he fuel ing harness. hose. “g|[Pass the clutch cabo through downside ofthe | | Pass the thot and dutch cables tough lever upside ofthe breather hose. 1 [Clamp the starter cable and iefthandie switch |... [Pass te cute cable trough forwardof he {throtte body and inside ofthe ignition co.SERVICNGINFORUATION 919 FUEL SYSTEM HOSE ROUTING [DFoatnose [B[Fostpam 2 | Fuel retire hose (Fuel pressure regulator Fuel Pose [Fuel teed hose [2 [Fuel vapor ren hose:20_SeRVICING INFORMATION COOLING SYSTEM HOSE ROUTING Bsnmiossiatm 99 m4) BT end of eclap shows ace. - a vaing \\\ ogee Geto > S aaa eae, avnacvnie) @ wen ton 1 Fag SR ae rT RT TTT at un tis hose staighty down, (@ [lla radiator hose D|clamp [Radiator cover [Siphon hose (@ | Radiator Reservoir tank overow hose (® | Outet radiator hose fator pumo i | Water pump crven gearSERVICING NFORUATION 9.21 OIL HOSE ROUTING Total the ol tank custion tothe both addos of a 1 |iesa ® Breather hose DO eve! gauge [Breather hose [21 return tank (@)[O1 hase (A) (@)[ 04 tank @ [Or hose (@)[Breather Rose [Matching mark (5)[O1 tank over-tow hose(922_SEAVICING INFORMATION FRONT BRAKE HOSE ROUTING g AS “Atar the brake hose union has Conlaced the [The brack paint fs forward 5 under surtace of master cylinder, ghton the tion bot "Alor the under surlac of brake pipe joint has -2| contacted the end face of hose braket ol frame, lighten the pipe joint mounting bot. 1g {Alter the brake hose union has contacted the stopper tighten the union bot F3[Clamp the brake hose fii. | Stopper Fit the brake hose with brake hose sleave Shape *correcty fited inside clamp.SERVICNG NFORUATION 9.23 REAR BRAKE HOSE ROUTING [Face the white mark on the reservoir hose othe outdo [Brake hose 72] Ft the reservar hose tothe union all the way tothe end (2 Parking brake cab 3] Clamp the reservoihose fmiy [Guide 74 [Pass the brake hose between the face ofthe swingarm and tame. | [Gude rsa the brake hose along swingarm upper ace witout Slack ard | |g i guides in order of & and. S| eves un brake hose through guide. (@| Stopper After the brake hose union has cantacied the stopper, tighten the = fete | Rear cape -a[ ithe bra hose wit brake hose dave shapo coveaiv ed [racer inside clamp, elemen:24_SEAVICING INFORMATION THROTTLE BODY INSTALLATION — I 4 i os Deki sem - Aa Face te clamp ends left se. (@ [Foe teed nose Naz Pass the Tvl vapor return hose through if ide | fintake pipe ? |ot the wiring hamess. Install the fuel feed hose No.2 with the white | | Throttle body “S| paint sido tothe fuel oump. [[IAT sensor (@Airceanor 2) Fuel vapor return hose [IAP sensor [3)|Fuetteed hose No.1 (| Fuel pumpSERVING NFORUATON 925 FUEL TANK INSTALLATION Fuel vapor return hose (| Fue ank breather ose (Foal vane [@)[ Fuel tank cap @ [Fuel vave cushion [Fuel tank cushion (@ [Fuel pressure regulator [Fuel tank Gb |Fuetretuen hose 5) it o Fuel tank iower cover Fuel hose:(825 SEAVIONG INFORMATION BRAKE PEDAL INSTALLATION eam Loom eee) Sater pin [a] Rear brake switch sping (2 [Brake pedal pivot bot (@)| Brake pedal spring (3)[Rear brake switch (6 [Brake podal‘SERVING NFORUATION 927 FRONT SIDE REFLEX REFLECTOR INSTALLATION (For E-28)$28 _SERVICNG INFORMATION BRAKE LIGHT/TAILLIGHT INSTALLATION (For others) \4 Metin ostatm. «sion Daswmesigin, em) —e- Dsnmosegtn, asi em l ale igh Tami zSERVICING INFORMATION 929 BRAKE LIGHT/TAILLIGHT INSTALLATION (For E-28) a Gung, Devin osrgtm «sion Baswmesigtm, 4h y / / er o 7 D Brake Tanita (Get efector (2) [ Brake ightTalight cover (a) | Retox eiector bracket490_sEAVICNG NFORMATION DRIVE CHAIN ROLLER INSTALLATION Blaine tate 225m)SERVICING NFORUATION 931 SPECIAL TOOLS | L <> br | ‘e Cc oeeo-20%01 oe esonosice _|assooonans _—_lessanatiog Srapring les |Snapring prs _|impertarverset_| Yer eatpers ry g—) = ossonze20t soo. 2ons Memes’ iteromeer’ ——|oweaoost loss. 2ss0 [cs~i00mm __[fr'asmm ___leyindergnage rod levine grog et {tune Sy ose 20607 seco 2104 Dirgnuce” ——fosnzoror_—osaozoses__—fowsoo.2oms (nea ae vicomm —__[tagnetentna __|etmese gouge |The sept guage [ieee oven 2230 oreo 000 ooo 22302 eels potted Ponignoge pret a a, oorwsoet1 acstoszer2 [Untesat camp onotrsraio ——fowsistoreo—_fasorssoxa [Crankshaft installer | wrench attachment ‘Adaptor Oi seal remover(832_SEAVICING INFORMATION ale ¢ 3 OS omseusie —orszasty —_loworezuser__lonorezran osors.recte_[tamgresin_[Stnonirpege |Sttrenre age |r forhgh prs earn atest espe at i sae) — y = Sy iN etotv'o | SS eerste ent-see0 osresoers ——fosresesio —ossteseow> ——lovoreausz_ | ave gute ramer |Srcupeerae_|venwtner” __(stasnent [eer haa [mn \ } Ok emse-20 osresssso __astestoio ——_|owsiessoo ewe ne guvmaner [Vane quae |tavegaelaialeossiestt [incu pump fesuieaye the | enesects loecmerteetlreuces teers loss20-13120 ‘09020-53740 \o0922-20711 Crankcase ‘cluten sieeve nub | 0021-20210 \o0s21-20240 ve chan cutting Say emmorsena fommame, jem, yea G % Go| J foment Sta Ete oe SnSERVING NFORUATON 9.33 \ S ove30-73120 essaoaoros _lossaosorar_ _fassaoarsat -—[asasosss20—_—(Stanarsuque Sizing hammer __[Rotorremover__[Rotorremover__|Rotor older __ ime sechet e ae LH \ ee) \ ag e an | QD osssorsiro _loosaoeara0 csesosnz20 —_losouosato Startertorque [ede section _[oss4o-4n211 | runtgrssuregeuge |e finite nlgor | swe owe stant [wrench se NS overcast Bearing instar lossoe-s1010 \sos '20565-01010-007 [cO-ROM ver. 7{:34_SEAVIING INFORMATION TIGHTENING TORQUE ENGINE TER Nim kot To [Gyindor head cover bot 14 14 1000 Spark plug 1 1 80 [Cyinder nead bot (M0) ca a7, 180 (M6) 10 10) 70. [Cylinder bor 10 10) 70 [Camshaft journal older bot 10 10) 70 [Balancer driven gear nut 50 50. 36.0 Primary drive gear nat 140) 140 1015 [Generator rotor rut 120 120 a7 [Clutch sleove hub nut 0 90 35.0 [Gearshift iever bot 10 10) 7.0 [Gearshift arm stopper a 32. 230 Starter eutch bot 70 10) 70) [Gearsni cam driven goarbok 31 31 228 [Gam chain tension adjuster mounting Bot 10 10 70 [Gam chain tensioner mounting bot 70 10 [Gam chain tension spring holder bot 20 30 [Engine of drain plug (on the crankcase) 18 18 [Enaine of drain bot (on the ol tank) 12 12 (Crankcase bolt 11 1 [Gear position switch bolt 65 065 47, [Oi hose mounting bolt 10 70 [Starter motor mounting bot 10 70 | FTDC plug 23 165 [Generator cover cap 15 310 [Engine mounting bolt 55. 400 [Engine mounting bracket Bolt 26 26 790) Exhaust pipe nut 23 28 165) Mutter connection Bok 2 23 765 Mufier mounting bot 23 23. 165) Engine sprocket bolt 10 10 7.0 Intake pipe mounting bot 3 09) 65FI SYSTEM AND INTAKE AIR SYSTEM Tew Tm rm oat [KP sensor mounting bait 65 0.65 47, [IAT sensor mounting serew 1a 0.18 13 Fuel devery pipe mounting serow 35. 0.35 25. Fuel pump mounting bolt a 08 65: [TP sensor mounting screw 35 0.35 25 COOLING SYSTEM Tre wm gem ee [Water pump cover screw 10, 10 70 Water pump cover bolt 10 10 70) [Engine coolant dain plug 35 055 40 JECT sensor 12 12 a5 [Thermostat Gover bal 10 10) 70895 SEAVIONG FORMATION CHASSIS Trew em katem bn andisbar imp bait 26 26 190 Handlebar holder nut 0. 60 35 Steering shaft holder bot 23 23 165 Steering shaft ower nut 120 120 a7 Stesring arm pate bot 29 29 210 [Steering knuckle end nul (Upper & Lower) 23 23 165 Tie rod end nut 23 23) 165 Tie rod look-nut 29 29) 210 Front shock absorber mouring rut (Upper & Lower) 60 60. 435 [Wishbone arm pivot nut 65 65: 470 Wheel nub nut. (Front) 65 65: 470 (ear) 12 121 ars Wheat sat nut Front & Fear) 66 6s 475 Brake hose union bolt 23 23 165 Brake disc bot (Fron & Rear) 23 23 165 Brake ai Deeder valve 6 05. 45 Brake caliper mounting bok (Front & Fear) 26 26 790 Brake mastr cyinder mounting bot (Front & Rear) 10 10. 79) Front brake lever pivot Bot 5 06 45. Front brake over pivot bot lodnut 6 08 45: Front brave calper noise pn 16 18. 330 [Front brake caliper holder nut 23 23 165. From brake ppe nut 16 16. m5 Front brake pad mounting pin 18 18 130 ar brake masir cylinder rod ok nut 18 18. 130 Rear brake pedal pivot bot Ey 29) 210 [Rear brake pad mounting pin 18 18. 730) Rear brake caliper holder pin 18 18 730 ear brake caliper holder side pin 2 23. 165 Parking brake housing bot 28 28 205; Parking rake adjuster locknt 18 18) 130) Footrest mounting bolt 55 55. 200) Seat rail bot (Upper & Lower) 80 60) 435 Rear sprocket mounting bot 60 80) 235, Rear axie nut 2407 240 173s ear axe look nut 240 280 1735 ear axle housing sett 28 28 200 Swingarm pivot nut 95 35 a5 Roar shock absorber mounting rut (Upper & Lower) 60 60. 435 [Cushion lever nut 78 78: 565 [Cushion rod nut 78 78. 365 Drive chain contol mounting bol 3 34 225 Tht ever case Bot 3 05: 35. [Cluen lever hold mounting Bok 10 10 75.SERVICING NFOFUATION 937 sions nroruarion sar TIGHTENING TORQUE CHART For other nuts and bolts not sted in the procoding page, refer to this chart [BoltDiameter| Conventional or "a" marked bolt "7 marked bolt & (mm) Nem kgtim ist Wm kam bt 4 15 0.15 10) 23 023 15. (ea 3 03 20 45 0.85 30 6 35, 055 40 70 10 70) [aa 13 13 95: 2 23 165 10 23 29 210 50 50. 36.0 [eer a 45 225 35 85. 615 14 65 5 470) 135 135 975 amare! 105, 705 76.0 210 210 152.0 18 160) 16.0 1155 240 24.0 1735 o-am-{1) cme ex®338 SERVICING NFORUATION SERVICE DATA VALVE + GUIDE Unit: mm (in) re aa th 3 a (1.14) aE Ete a 9-08 : d= 83 ena = clearance a (0.0004 - 0.0015) = ory (8g aa ar ms eee mace] gB=E Ry i (0.2148 ~ 0.2154) — ares ae = ie a ma ie oes Saretareav aaa —T aoe : = aaa ea - : o Le ad on (ist) wm | ogee BP wee | — | gasehtaes, : EB aySERVING NFORUATION 999 CAMSHAFT + CYLINDER HEAD Unt: men in) Te ‘STANDARD cai am peight n 92.564 ~ 32.08 33264 L 23880 — 73696) fear 3945133401 151 G3t70-F3te) 5052) [Gamat journal oi earance 0.032 = 0.086 3.150 : bins (06049 - 8.0028) (03659) [Gamat journal note 22012-22095 ‘ Meee (6668 - 3.8971) = [Gama joursar OO 21.959 21.960 i wae (G'seas - 318659) aa iGamchan pin st pin = (Gyinder head distortion a 208 00) CYLINDER + PISTON + PISTON RING Unit: men) Tre ‘STANDARD uM Compression pressure ] 800 kPa - autSmates decomp. sctuatod) (a0 uglem 114 5) Piston to eyinder clearance 0.045 -0 055 3,29 (06048 ~0.0022) oat) yindar bore 95.500 95.515. Nols or (0.7599 - 3.7608) seratehes Fiion dam 95.4509 465 195,980 3039 — 39888) ci Moasue at 18mm {0 nj ram ihe skitena._| (7851) [Cynder cistorion ~ 905 bbe) Piston ring ree end gap [tet “aprox. 7.6 (0.30) 7 na [FR ‘Approx. 123 (0.48) [= Piston ring end oa 0.08 = 020 050 cues - (01608 ~ 680) Cox) os 0.08 =020 050 (01008 = 09) on Pision ing to groove clearance 9,180 aoe = es 07) 9150 2nd i (8386) Piston ring groove with 278-080 = = (0.0867 - 98815) B 90= 1.32 ~ (0.0842 08820) ‘061-089 id (00349-88827) = a 201-209 = (06751-5700)$40_SEAVING INFORMATION eM _ ‘STANDARD. tar Psion ving hckness 0.71076, = i (0.0280 ~ 0.0209) 4.08 1.10 is (0.0425 - 00433) i oat 07-073 es (0.0803 ~ 0.0311) Piston pin bore 72.002 - 19.008 73,030 (077484 ~ 077283) 07492) Picton pin OD. 18.994 19,000 18.980 (0:7478~ 0.7480) (ora72) CONROD + CRANKSHAFT Unit: mm Gin) TEM ‘STANDARD ‘unr [Conrad email end 1.0, 79.010- 19.018 19.040 (orr4ea = 0.7487) (a7496) [Conrad detection 30) ee 0.12) [Gonvod big end side clear 039-085, 19) (oo12— 0.026) 0.08) [Gonrod big end wicth 21.75 21,80 _ (oi863— 0.8583) [Crank web to web width 00.1 = (2441's 0.008) [Grarkshaft nour = 208, (@:963) OL PUMP eM ‘STANDARD. oT [Oi pressure (at 60°C, 140°F) TOKPa (0.1 kaor, 74 ps = 3.00 rin CLUTCH si: mm in) TEM ‘STANDARD. unr Civch cable pia 10-15 eee (08-08) = Drive plat ticknoss 307-323, ait Wo. No 2) (o'i20-0:127) 103) Driv plat claw width 13.85 — 13.95, 3.95 (No. &No. 2) (0545 — 0848), (528) Driven plate distortion T — 010 | (0.004) [Guich sering tee length 53.08 504 Gon, (ise)SERVING IMFORUATION ot Sic ion ott DRIVE TRAIN + DRIVE CHAIN Unit: mm (in) Sxeept ratio TEM ‘STANDARD uMIT Primary reduction ratio 2.851 (77/27) Sj Final reduction ratio 2571 (96/14) = [Gear ratios Low 2.076 (27/13) = 2nd 1.647 (28/17) = ‘3a 1.933 (28/21) = ath 1.085 (23/21) = Top 0.913 (21/28) = Shit fork to groove clearance 01-03 O58, (0.004 - 0.012) (0.020) Shit fork groove wiath Not Nod 48-49 al Nod (0.169 = 0.199) = Shit fork thickness: No.1, Nod 46-47 aa & Nos (0.181 = 0.185) [Drive chain Type Rk 5208MOZ105 = Links 96 =] 2o-pitch _ 3194 Tength (i287) Drive chain slack 45-55, _ (18-32) [Gearshift ever height ee _ THERMOSTAT + RADIATOR + FAN + COOLANT. TEN ‘STANDARDISPECIFICATION Wore Feemowat vave panna epee Tanase = heros va ZS mF) over a BO™C BNF) = ECT soncorroitance 30° 23, Approx 26K = BS Agpox a772 a es 0° aS popion 0279K2 = 0S Lo wes Aporon 018K 4 Fair cap ve open we Tos i9r apa jsure . (1.08 - 1.37 kgtiom?, 15.4 - 19.5 psi) ee cooing an oprangomporaure [OFFSON| Approx a6 00), = ON=OFF | Approx 8°6 109°F) =a Erg conan ipo Use an enieezecolant compatible with 3a pum adatr, mised with ted weer oni athe] — rato o 5050, Ege cola inlog resonve Appi 10m (13293 Usime a)942 SEAVIONG INFORMATION INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR ren ‘SPECIFICATION NOTE injector esstance 317 aat20°C 87) E Fue pump discharge amount open BB mH 8/28 USI o2) and more Fuel pressure regulator operating | Approx. 294 KPa (2.94 kgm 1.81 as FISENSORS Tete SPECIFICATION NOTE EK sensor sistance 155-2528 ICKP sonsor peak voage SV and more When cranking IAP sensor input votago 45-55V IAP sensor output votage ‘oprox. 2.7 V at ila speed FTP sensor input volage —45-55v FTP sensor sistance Roprox. 45x Gosed | ‘Approx. 14K ‘Opened ‘Approx. 4.2K "TP sensor oui wotage Closed ‘ApGFOK.O.6V ‘Opened | __—Approx. 38 ECT sensorinpat wohage a-55V FECT sensor output voage o15=s85V [ECT eonsorosstance apron 2.8K 3 20°C 7) IAT sensor input votage 45-55V IAT sensor output vokage 0:15= 4.850 IAT sensor resistance ‘Approx 2.6K at 20°C (68°F) FTO sensor resistance 150 ~250K0 | FTO sensor vatage Normal 04-14 Leaning 37-44V oaths (GP anich votage 3 Vand more From 1st to Top Injector votage toy wotage Ignition coi primary peak vokago 50 V and more When cranking THROTTLE BODY TEM ‘SPECIFICATION Bare se Sm ID. No. 4560 ite rimin TI 7/800 = 100 rin Saal Ile air sew 7-5/8 turns back ~ rote cable play 3-5mm (0.18020 in)SERVICING NFORUATION 9.43 «sinc ncorarion it ELECTRICAL Unit am TEN ‘SPECIFICATION NOTE Spare pag Tye NGK: CRGES 07-08 cop (0.028 =890) Spar parornance Over 870.3) att aim ICKP sensor esstanca 155-2520 ICKP sensor peak votage 05 V and more Wher cranking ignition cot resistance naar aieisa Terminal = Secondary 815K Pi cap gnon cal primary peak vokage TS0V and more When cranking [Generator col resistance 01-150 [Generator Max. ouput ‘pprox 240 Wat 5 OOO rnin Generator nosoas votage finer engine oo) 50 V (AC) and more at 5000 rin | Starter motor burs length ‘Slandare 7.5036) Umit 35 (0.14) equated volage 35~ 150 Vat 000 min Starter ay resistance 3-60 [GP swic vetage {0.3 V and more (From Tato Toa) =I ead anatfeaion FDXTA-BS Capacity W2V 216K AHIOHA za Fuse ae Ignition 0A al Fan 10a Main 2OA WATTAGE Unie w eit ‘SPECIFICATION Feast Hi 20 io 20 Brake igh Taight Leo |Fuslinceator ight 34 Nua inccatr ight L 34 Engine coolant temp. F warning Incieator ig sa{.44_sEAVICING NFORUATION BRAKE + WHEEL Unit mm tin) Tem 'STANDARDISPECIFICATION uit Fear brake padal height 0-10 av (9-08) fs Brake calper ofinder bore 25.40 95.5 eae fet 9.0000 = 6020) = 33.9634 01 a (13370 = 1.5300) Brake caliper pision dam 25.918 - 25.368, = . O88) Aa 33.878 33.908 = (13838-15357) Brake Waid ype DoT = Brake disc thickness ae 28-32 25. (0110-0126) (6688) a 38-42 35, i (0.180 = 0.765) (6338) Brake aise rnout Fron & Fe 330 = | wate Master cylinder bore 12.700 - 12743 — dau 3000 = 08017) = ase 12.700 — 12.743 ee @'s000 = 08017) aster cyinder piston dam. 12.657 - 12.684 ‘erin Front | (0.4983 ~ 04094) _ = =e 12.657 - 12.684 ~ a (6809 ~ 0.4588) uring vagus Bamiish Foe-in (with 75K, 165s) O84 (02616) [Camber =30" [Castor a0 Wheel rim runout 20) a i 0) 20 om = 05 Wet vim size Front TOxS5AT = Rear 8x80AT = Fire sae Front ATO TRIO TET = Rear ATI» TORS oes = Hie pe Front ‘DUNLOP: KT38T = Rear ‘DUNLOP: KTSE5 = Fre wead depth a0 : eae = ero) 40 = = 6) Whee! axle runout | ear = 80, 024)[SERVECINGINFORMATION 94 TIRE PRESSURE COLD INFLATION ‘ifle PRESSURE ie ‘atone Pa FRONT é 04s 68 REAR 35 045 65 \VENIGLE LOAD CAPAGITY LIMIT 170g (289 by SUSPENSION TEM ‘STANDARDISPECIFICATION Tar Front shook absorber sping 245 = preset length (08) Front shock absorber damping | Rebound | 1-1/2 tums out om stifest positon = once ster Coneesson] 2-14 tums out rom sist postion = Fear shock absorber spring pre-set 299) engi cee 8) = Rear shock absorber damping | Rebound | _ 7 cick out rom siffest postion = force adjuster eo empress] clicks out rom stifest postion = GRRE | 34 tn out tom stttest postion Front wheal waver 24 = (00) Rear wheel waver T 277 a io) FUEL + OIL. eM ‘SPECIFICATION NOTE: Fost ype [Use only unleaded gasoline of af east 90 pump] octane (Rr2 + M12), Gasoline containing MTBE (Methy! Tertiary Buty Ethen, less than 10% ethanol, or tess than 5%] ©2893 methanol with appropriate cosolents. and coro: sion inhibitor is permissible, [Sasoine used shoud be graded 5 ocane OF one higher An unleaded gasoine is recommended, Fuel tank incding reserve 10.0 (2.622 US/imp ga Engine ol ype ‘SAE 10 W240, API SFISG or SHISU with JASO MA Engine al ca 1700.mi ; etn! ae (1.911 U8 at one : ang Engine side (04104 0Sin a) = 7300 mi — (Lani USimp a Obani sie ost Engine side (0.4104 USinp a 7 400 mi oo (152 USimp at = 40 a Engine side (0.41080Simp at bs