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1.

General Information
General Safety

1-1

Lubrication & Seal Points

1-23

Model Identification

1-3

Cable & Harness Routing

1-25

Specifications

1-4

Emission Control Systems

1-45

Torque Valves

1-17

Tools

1-21

Emission Control Information Labels


(U.S.A. Only)

1-48

General Safety
Carbon Monoxide
If the engine must be funning 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 an enclosed area.

Gasoline
Work in a well ventilated area. Keep cigarettes, flames or
sparks away from the work area or where gasoline is

stored.

Gasoline is extremely flammable and is explosive


under certain conditions. KEEP OUT OF REACH

OF CHILDREN.
Hot Components

Used Engine/Transmission Oil

Used engine oil (or transmission oil in twc-enokeel


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. KEEP OUT OF REACH OF
CHILDREN.
Brake Dust
Brake dust may contain asbestos. Never use an air hose or
dry brush to clean brake assemblies. Use an OSHAapproved vacuum cleaner or alternate method approved
by OSHA. designed to minimize the hazard caused by
airborne asbestos fibers.

Inhaled asbestos fibers have been found to cause


respiratory disease and cancer.
Brake Fluid
CAUTION

Engine and exhaust system parts become very hot


and remain hot for some time after the engine is
run. Wear insulated gloves or wait until the engine
and exhaust system have cooled before handling
these parts.

Spilling fluid on painted. plastic or rubber parts will


damage them. Place a claan shop towel over
these parts whenever the system is serviced.
KEEP OUT OF REACH OF CHILDREN.

1-1

..

General Information
Coolant
Under some conditions, the ethylene glycol in engine
coolant is combustible and its flame is not visible. If the
ethylene glycol does ignite, you will not see any flame, but
you can be burned.

Avoid spilling engine coolant on the exhaust


system or engine parts. They may be hot enough
to cause the coolant to ignite and burn without a
visible flame.
Coolant (ethylene glycol) can cause some skin
irritation and is poisonous if swallowed. KEEP
OU]" OF REACH OF CHILDREN.
Do not remove the radiator cap when the engine is
hot. The coolant is under pressure and could scald
you.
Keep hands and clothing away from the cooling
fan, as it starts automatically.
If coolant contacts your skin, wash the affected areas
immediately with soap and water. If it contacts your eyes,
flush them thoroughly with fresh water and get immediate
medical attention. If it is swallowed, the victim must be
forced to vomit then rinse mouth and throat with fresh
water before obtaining medical attention. Because of
these dangers, always store coolant in a safe place, away
from the reach of children.

1-2

Battery Hydrogen Gas & Electrolyte

The battery gives off explosive gases;

keep
sparks, flames and cigarettes away. Provide
adequate ventilation when charging.
The battery contains sulfuric acid (electrolyte).
Contact with skin or eyes may cause severe
burns. Wear protective clothing and a face shild.
- 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.
Electrolyte is poisonous.
- I f swallowed, drink large quantities of water or
milk and follow with milk of magnesia or
vegetable oil and call a physician. KEEP OUT
OF REACH OF CHILDREN.

General Information

Model Identification
'91 (Standard model) Shown:

(1) VEHICLE IDENTIFICATION NUMBER


The Vehicle Identification Number (VIN) is located on the
Safety Certification Label on the left side of the steering
head.

f/
(2) ENGINE SERIAL NUMBER
The engine serial number is stamped on the rear of the
lower crankcase behind the oil pan.

(3) FRAME SERIAL NUMBER


The frame serial number is stamped on the right side of the
the steering head.

,,~

\,

---

~"~~
(4) CARBURETOR IDENTIFICATION NUMBER
The carburetor identification number is stamped on each
carburetor body on the intake side.

(5) COLOR LABEL


The color label is attached to the frame under the seat.

1-3

General Information

Specifications
Unit: mm (in)

General
Specifications

Item

Dimensions

1-4

Overall length
Overall width ('91-'93)
(After '93)
{'91-'94)
Overall height
(After '94)
Wheelbase
Seat height
Footpeq height
Ground clearance
Dry weight
ABS/TCS or LBS-ABS/TCS model
with saddlebag
('91-'94)
49 state type
California type
Canada type
(After '94)
49 state type
California type
Canada type
Standard model with saddlebag
('91-'94)
49 state type
California type
Canada type
(After '94)
49 state type
California type
Canada type
Curb weight
ABS/TCS or LBS-ABS/TCS model
with saddlebag
('91-'94)
49 state type
California type
Canada type
(After '94)
49 state type
California type
Canada type
Standard model with saddlebag
('91-'94)
49 state type
California type
Canada type
(After '94)
49 state type
California type
Canada type

2,285 (90.0)
835 (32.9) [Saddlebag end]
935 (36.8) [Rear view mirror end]
1,395 (54.9)
1,405 (55,3)
1,555 (61.2)
800 (31.5)

-145 (5.7l

297
298
293
298
299
297

kg
kg
kg
kg
kg
kg

(655
(657
(646
(657
(659
(655

Ib)
Ib)
lb)
Ib)
Ib)
Ib)

284
285
283
288
289
287

kg
kg
kg
kg
kg
kg

(626Ib}
(628 lb}
(624 lb)
(635 Ib)
(637 Ib)
(633 Ib)

326
327
322
327
328
326

kg
kg
kg
kg
kg
kg

(719 Ib)
(721 Ib)
(710 Ib)
(721 Ib)
(723Ib}
(719 Ib}

313
314
312
317
318
316

kg
kg
kg
kg
kg
kg

(690 Ib)
(692 Ib)
(688Ib)
(699Ib)
(701Ib)
(697 Ib)

General Information
Unit: mm (in)

Specifications

Item
Frame

Frame type
Front suspension
Front wheel travel
Rear suspension
Rear wheel travel
Front tire size
{Standard model and '92-'95 ABS/
TCS model}
(After '95 LBS-ABSn-CS model)
Rear tire size
(Standard model and '92-'95 ABS/
TCS model)
(After '95 LBS-ABSn-CS model)
Tire brand FR/RR
{Standard model and '92-'95 ABS/
TCS model}
(After '95 LBS-ABSn-CS model)
Front brake
Rear brake
Caster angle
Trail length
Fuel tank capacity
Fuel tank reserve capacity

Engine

110/80 V18 (Bridgestone, Dunlop)


110/80 V18-V240 (Metzeler)
120/70 ZR18
160/70 V17 (Bridqestone, Dunlop!
160/70 VB17-V240 (Metzeler)
160/70 ZR17
G547/G548 (Bridgestone)
D103F/D103 (Dunlop)
ME33 LASER/MES5A METRONIC (Metzelerl
BT-S4F/BT-54R (Bridgestone)
D202F/D202 (Dunlop)
Hydraulic double disc
Hydraulic single disc
21'30'
101 (4.0)
28 liters (7.40 US gal, 6.161mp gal)
73.0 x 64.8 (2.87 x 2.55)
1,085 em' (66.2 cu in)
10.0 : 1
Belt and gear driven DOHC

Bore and stroke


Displacement
Compression ratio
Valve train

Intake valve opens at 1 mm lift


Intake valve closes at 1 mm lift
Exhaust valve opens at 1 mm lift
Exhaust valve closes at 1 mm lift
Lubrication system
Oil pump type
Cooling system
Air filtration
Crankshaft type
Engine dry weight

Double cradle
Telescopic fork
150 (5.9)
Swingram
120 (4.7)

('91-'93)
('94)
(After '94)

'91-'93 :
Standard California and
U.S.A. ABSn-CS type
After '93 : California type

'91-'93 :
Standard 49 state and
Canada type
After '93 : 49 state and
Canada type

-5' BTDC {SO ATDCI


35 ABDC
40 BBDC
-5" ATDC (5 BTDC)

8' BTDC
37" ABDC
33 BBDC
2" ATDC

Forced pressure and wet sump


Trochoid
Liquid cooled
Paper Filter
Unit type, 3 main journals
93.0 kg (205 lb) : U.S.A. type and ABS/TCS Canada type
92.0 kg (203 Ib) : Standard Canada type
93.0 kg (205 Ib) : All types
93.0 kg (205 lbl : U.S.A. type
92.0 kg (203 Ib) : Canada type
1-90'-4-270-3-90
4 cylinders, 90'V
0-2-270"-1

Firing order
Cylinder arrangement
Cylinder number
Left

Front

1-5

General Information
-

Unit" mm (in)

General (cont'd)
Item

Specifications

Carburetor

Carburetor type
Throttle bore

Constant velocity 4 carburetors


34.5 (1.36)

Drive train

Clutch system
Clutch operation system
Transmission
Primary reduction
Secondary reduction
Third reduction
Final reduction
Gear ratio 1st
Gear ratio 2nd
Gear ratio 3rd
Gear ratio 4th
Gear ratio 5th
Gear ratio 6th
Gear ratio reverse
Gearshift pattern

Multi-plate. wet
Hydraulic operating
5 speeds
1.8292 (75/41)

Electrical

1-6

Ignition system
Starting system
Charging system
Regulator/rectifier type
Lighting system
AC regulator type

--2.8333
2.2666
1.5000
1.1428
0.9166
0.7586

(34/12)
(34/15)
(27/18)
(24/21)
(22/24)
(22/29)

---

Left foot operated return system 1- N -2-3-4-5


Digitalized full transistor ignition
Electric starter motor
Triple phase output alternator
Field controlltriple phase full-wave rectification
Battery
--

General Information
Unit: mm (in)
r-'

Lubrication
Item

Standard

Engine oil capacity at draining


at disassembly
at oil filter change
Recommended engine oil

3.6 liters (3.80 US qt, 3.17 Imp qt)


4.3 liters (4.54 US qt. 3.78 Imp qt)
3.7 liters (3.91 US qt. 3.26 Imp qt)
Use Honda GN4 a-stroke oil or equivalent motor oil certified to meet API
service classification SF or SG.
Viscosity: SAE 10W-40

OIL VISCOSITIES

,,
-"

-~

.4U

, ........ ,

--

---

Other viscosities shown in the chart may


be used when the average temperature in
your riding area is within the indicated
range.

,20

Service Limit

,
""'~

0 1 0 2 0 3 0 ~',

392-490 kP, (4.0--5.0 kg/em', 57


-71 psi) at 5,000 rpm (80'C/ 176'F}
0.15 (0.006)
0.15--0.22 (0.006--0.009)
0.02--0.09 (0,0008--0.0035)

Oil pressure at oil pressure switch


Oil pump rotor tip clearance
body clearance (2)
end clearance @

cD

---

--

0~~1I I,~

t
"

i
Fuel System
Carburetor identification number
('91-'93)
(Standard 49 state type}
(Standard California and
U.S.A. ABSjTCS type)
(Canada type)
(Standard 49 state type)
(After '93)
(49 state ABSjTCS or 49
state LBS-ABSjTCS type}
(California type}
(Canada type)
('91-'93}
Main jet
(49 state and Canada type)
(California type)
(After '93)
(Standard 49 state and
Canada type)
(49 state ABSjTCS or49
state LBS-ABSjTCS and
California type}
(All U.S.A. types}
Slow jet
(Canada type}
Pilot screw initial opening
Pilot screw high altitude adjustment
Pilot screw final opening
Float level
Carburetor vacuum difference
Base carburetor (For carburetor synchronization)
Idle speed
(All U.S.A. types)
(Canada type)
Throttle grip free play
Pulse secondary air injection (PAIR) control valve
vacuum pressure

r-'

VD BDA
VD BEA
VD B1A
VD BDA
VD BJA
VD BEA
VD B1A
:j;1: 128
:j;1: 125
:j;1: 128
:j;1:

125

"38

. .0
See page 5-12
See page 5-1 6
See page 5-12
7.0 (0.28)
Within 40 mmHg (1.6 inHg)
NO.4 carburetor
1 ,200 100 rpm
1 ,OOO 100 rpm
2-6 (0.08-0.24)
360 mmHg (14.2 inHg)

1-7

General Information
Unit: mm (in)
r-'

Cylinder Head

Standard

Item

1,373 1.96 kPa (14.0 2.0 kg/cm 2 ,


199 28 psil/400 rnln-' (rpm)

Cylinder compression
Cylinder compression difference
Valve clearance IN

EX
Cylinder head warpage
Cam lobe height CD
IN
IN (Standard California and U.S.A. ABS/TCS or
U.S.A. LBS-ABS/TCStype)

EX
EX{Standard California and U.S.A. ABS/TCS or
U.S.A. LBS-ABS/TCS type}
Camshaft runout
Camshaft oil clearance A
B
B

!If

Service Limit

0.13---0.19 (0.005---Q.007)
0.22---0.28 (0.009--0.011)

0.1010.0041
36.480--36.640 (1.4362-1.4425)
35.680-35.840 (1 .4047-1 .4110)

36.450 (1.4350)
35.650 (1.4035)

35.970--36.130 (1.4161-1.4224)
35.770-35.930 (1.4083-1.4146)

35.940 (1.4150)
35.740(1.4071)

0.020--0.062 (0.0008-0.0024)
0.050--0.092 (0.0020--0.0036)

0.05 (0.002)
0.100 (0.0039)
0.130 (0.0051)

AA

t
Camshaft journal O. D. A
B

Camshaft holder 1.0.

A
B

Valve stem 0.0. IN

EX
Valve guide 1.0. IN

EX
Stem-to guide clearance IN

EX
Valve guide projection above cylinder head IN (h)
EX {hI

24.959-24.980 (0.9826-0.9835)
24.929-24.950 (0.9815---Q.9823)
25.000--25.021 (0.9843-0.9851)
25.000--25.021 (0.9843---0.9851)
4.475--4.490 (0.1762---O. 1768)
4.465--4.480 (0.1758-0.1764)
4.500--4.512 (0.1772---0.1776)
4.500--4.512 (0.1772---0.1776)
0.010--0.037 (0.0004-0.0015)
0.020--0.047 (0.0008-0.0019)
15.3-15.5 (0.60--0.61)
15.3-15.5 (0.60--0.61)

24.950 (0.9823)
24.920(0.9811)

4.465
4.455
4.562
4.612

1.0 (0.04)
1.0 (0.04)
41.72 (1.643)
41.72 (1.643)

1.5 (0.06)
1.5 (0.06)
39.6 (15.59)
39.6 (15.59)

25.978-25.993 (1.0228-1.0233)
26.010--26.026 (1.0240--1.0246)

25.968 (1.0224)
26.040 11.0252)

(0.1758)
(0.1754)
(0.1796)
(0.1816)

Before guide installation:


1 . Chill the valve guide in the freezer
section of a refrigerator for about an
hour.
2. Heat the cylinder head to 100
-150C (212-300F)
'Valve seat width IN

EX
Valve spring free length IN

EX
Inner IN
Inner EX
Outer IN
Outer EX
Rocker arm 1.0. IN

EX
Rocker arm shaft 0.0. IN

EX
Rocker arm-to-rocker arm shaft clearance
Valve lifter 0.0.
Valve lifter bore 1.0.
Hydraulic tappet adjuster assist spring free length
Hydraulic tappet adjuster compression stroke with kerosene

1-8

General Information
Unit: mm (in)
-

Cylinder/Piston

Item

Standard

73.000--73.015 (2.8740--2.8746)

Cylinder I. D.
Cylinder out of round
Cylinder taper
Cylinder warpage
Piston mark direction
Piston O.D. (D)
Piston O. D. measurement point (H)
Piston pin hole I.D. (d)

--<

Service Limit

73.10 (2.878)
0.10 (0.004)
0.10 (0.004)
0.10 (0.004)

----

~IN"

--

mark facing toward the intake side

72.970--72.990 (2.8728-2.8736)
19 (0.75)
18.002-18.008 (0.7087-0. 7090)

72.850 (2.8681)

-18.020 (0.7094)

r-

TIu
\\

Cylinder-to-piston clearance
Piston pin O. D.
Piston-to-piston pin clearance
Connecting red-to-piston pin clearance
Top ring-to-ring groove clearance
Second ring-to-ring groove clearance
Top ring end gap
Second ring end gap
Oil ring (side rail) end gap
Top ring mark
Second ring mark

r- Crankshaft
Connecting rod small end 1.0.
Connecting rod big end side clearance
radial clearance
Crankshaft runout

0.010--0.045 (0.0004-0.0018)
17.994-18.000 (0.7084-0.7087)
0.002-0.014 (0.0001-0.0006)
0.016-0.040 (0.0006-0.0016)
0.025--0.060 (0.0010--0.0024)
0.015--0.050 (0.0006-0.0020)
0.15--0.30 (0.006-0.012)
0.30--0.45 (0.012-o.018)
0.20--0.70 (0.008-0.028)
~W

mark facing up
mark facing up

-17.98 (0.708)

--

--

0.10 (0.004)
0.10 (0.004)
0.5 (0.02)
0.7 (0.03)
1.0 (0.04)

--

~RN"

--

18.016-18.034 (0.7093-0.7100)
0.10--0.30 (0.004-0.012)

18.050 (0.7106)
0.40 (0.016)
0.05 (0.002)

0-

I-

Crankpin oil clearance


Crankpin bearing selection
Main journal oil clearance
Main journal bearing selection

0.030--0.052 (0.0012-0.0020)
See page 11-6
0.026-0.048 (0.0010-0.0019)
See page 1 1-6

0.080 (0.0031)
0.065 (0.0026}

Kickstarter
Kickstarter pinion gear 1.0.
Kickstarter spindle O. D.
Kickstarter idle gear 1.0.
Countershaft 0.0. at kickstarter idle gear
Klckstarter idle gear bushing 0.0.
I. O.

1-9

General Information
Unit: mm (in)
-

Transmission
Item

Standard

Transmission gear 1.0. M4,M5

31.000--31.025 (1.2204-1.2215)
31.000--31.025 (1.2204-1.2215)
30.950--30.975 (1.2185-1.2195)
30.950--30.975 (1.2185-1.2195)
28.000--28.021 (1.1024-1.1032)
0.02~.075 (0.0010--0.0030)
0.02~.075 (0.0010--0.0030)
27.967-27.980 (1.1011-1.1016)

C2, C3
Transmission gear bushing 0.0. M4,M5

C2, C3
Transmission gear bushing 1.0. M4
Gear-to-bushing clearance at M4, M5 gear
at C2, C3 gear
Mainshaft 0.0. at M4 gear bushing

servlce Limit

31.040 {1.2220l
31.040 {1.2220)
30.930 {1.2177J
30.930 i1.2177l
28.031 (1.1036)

27.960 (1 .1008l

M'

e:

=C

q
-

R
Shift fork shaft 0.0. at F shift fork
at C shift fork
at R shift fork

0.020--0.054 iO.000B-O.0021)
5.93-6.00 (0.233-0.236)
5.93-6.00 (0.233-0.236)
5.93-6.00 (0.233-0.236)
14.000--14.021 (0.5512-0.5520)
14.000--14.021 (0.5512-0.5520)
14.000--14.021 (0.5512-0.5520)
13.973-13.984 (0.5501-0.5506)
13.973-13.984 (0.5501-0.5506)
13.973-13.984 (0.5501-0.5506)

Primary Damper Shaft


Primary damper spring free length

95.4 (3.76)

93.0 (3.66)

Gear bushing-to-shaft clearance at M4 gear


Shift fork claw thickness F

C
R

Shift fork 1.0. F

1-10

5.9 (0.23)
5.9 {0.23)
5.9 (0.23)
14.03 (0.552)
14.03 (0.552)
14.03 (0.552)
13.965 (0.5498)
13.965 (0.54.98)
13.965 (0.5498l

General Information
Unit: mm (in)

r-- Clutch System

Standard

Item

-Clutch lever free play


Recommended clutch fluid
DOT 4 brake fluid
14.00(}-1 4.043 (0.5512---0.5529)
Clutch master cylinder I.D.
,13.957-13.984 (0.5495--0.5506)
Clutch master piston O. D.
-Clutch outer I. D.
34.975-34.991 (1.3770--1.3776)
Clutch outer guide O. D.
27.989-28.006 (1.1019-1.1026)
I. D.
Primary damper shaft O.D. at clutch outer guide
27.974-27.987 (1.1013-1.1018)
-Oil pump drive sprocket I.D.
-Clutch center B 1.0.
-One way clutch inner O.D.
-Clutch spring free height
43.0 (1.70)
Clutch spring free length
Clutch disc/plate thickness (Total of 10 discs and 9 plates) 54.72-55.72 (2. 154-2.194)
Centrifugal clutch drum I. O.
-bushing O.D.
-Centrifugal clutch center guide 1.0.
-O.D.
-Centrifugal clutch center guide collar height
Centrifugal clutch spring free length
-Clutch lining thickness
-Crankshaft 0.0. at clutch center

--

--

Service Limit
i

--14.06 (0.553)
13.94 (0.549)

-34.965 (1.3766)
28.016 (1.1030)

--

----40.0 (1.57)
54.2 (2.13)

------

----

r- Cooling System
Coolant capacity (Radiator and engine)
(Reserve tank)
Standard model
ABS/TCS or lBS-ABS/TCS model
Radiator cap relief pressure
Thermostat begins to open
Thermostat fully open
Thermostat valve lift

2.5 liters (2.6 US qt. 2.2 Imp qtl


0.5 liter (0.5 US qt, 0.41mp qt)
0.9 liter (1.0 US qt. 0.8 Imp qt)
108-137 kPa (1.1-1.4 kg/cm 2,
'6-20 psi)
80-84"C (176-183F}
95"C (203F)
8.0 (0.32) minimum

Drive Train
Recommended final drive oil
Hypoid gear oil SAE #80
150 ern' (5.1 US oa. 5.3 Imp oz)
Final drive gear oil capacity at disassembly
130 ern' (4,4 US OZ, 4.6 Imp oz)
at draining
0.05---0.15 (0.002---0.006)
Final drive gear backlash
Final drive gear backlash difference between measurements
: 0.30-0.60 (0.012---0.024)
Ring gear-to-stop pin clearance (A)
Stop pin shim
See page 12-10
Ring gear spacer
See page 12-10
Pinion spacer
See page 12-11
Final drive gear assembly preload
2-4 kg-cm (1,7-3,5 in-Ib)
Output gear backlash
Output gear I. D.
Output gear bushing 0.0.
1.0.
Output drive shaft 0.0.
Output gear damper spring free length
Output shaft adjustment shim
Countershaft drive shaft adjustment shim

r-'

10.3 (0.01)

1-11

General Information
Unit: mm (in)
-

Wheels/Tires
Standard

Item

---

Minimum tire tread depth (FR)


(RR)
Cold tire pressure Up to 90 kg (200 lb) load {FR)
(RR}

Up to maximum weight capacity (FR)


(RR)
Front and rear axle runout
Front and rear wheel rim runout (Radial)
(Axial)
Front wheel hub-to-rim distance
Front wheel hub standard surface
Rear wheel hub-to-rim distance
Rear wheel hub standard surface
Wheel balance weight (Front)
(Rear)
Drive chain slack
Drive chain size link (DID)
(RK)
Wheel sensor air gap (Front)
ABSfTCS model
LBS-ABSfTCS model
(Rear)
-

Service Limit

250
290
250
290

1.5 (0.06)
2.0 (0.08)

kPa
kPa
kPa
kPa

(2.50
(2.90
(2.50
(2.90

kg/cm 2,
kg/cm 2,
kg/cm 2,
kg/cm 2,

36
42
36
42

psi)
psi)
psi)
psi)

--

---

--0.2 (0.01)
2.0 (0.08)
2.0 (0.08)

---

-----

--

---------

60 g (2.1 ozl max.


60 g (2.1 ozj max.

------

0.4- 1.2 (0.016--0.047)


0.4-0.5 (0.016--0.020)
0.7-1.2 (O.028-Q.047)

--

Front Suspension
Front spring free length

Fork spring free length A


B
Fork spring direction
Fork tube runout
Recommended fork oil
Fork oil level
Fork oil level (R)

(L}

Fork oil capacity


Fork oil capacity {R}

415.6 (16.36)
474.2 (18.67)
483.1 (19.02)

Standard model
ABSfTCS model
LBS-ABSiTCS model

Tightly wound coil end facing down


0.2 (0.008)
Pro Honda Suspension Fluid SS-7
Standard
ABS/TCS
LBS-ABS/TCS
Standard
ABS/TCS
LBS-ABSfTCS

190
177
140
187
174
136

model
model
model
model
model
model

Standard model
ABS/TCS model
LBS-ABS/TCS model

(L}

Standard model
ABS/TCS Model
LBS-ABS/TCS model

Fork air pressure


Steering bearing preload

1-12

407.3 (16.04)
464.7 (18.30)
473.4 (1B.64)

(7.5)
(7.0)
(5.5)
(7.4)
(6.9)
(5.4)

385 2.5 em" (13.02


13.51 0.09 Imp oz)
372.0 2.5 em" (12.58
13.05 0.09 Imp ozl
533.0 2.5 cmv (18.02
18.71 0.09 Imp oz)
435.0 2.5 em- (14.71
15.27 0.09 Imp oz)
418.0 2.5 em' (14.14
14.67 0.091mp oz}
486.0 2.5 ern' (16.43
17.06 0.09 Imp oz)
1.5-2.0 kg (3.3-4.4 lb)

0.08 US oz.

0.08 US ca;

0.08 US oz,

0.08 US oz.

0.08 US oz.

0.08 US oz.

General Information
Unit: mm (in)
r-- Rear Suspension

Item

Standard

Shock absorber spring free length


Standard model
ABSfTCS or LBS-ABS/TCS
Shock absorber spring free length (R)

ILl
Damper gas pressure
Damper compressed gas
Damper rod compressed force at 10 mm compressed
Damper drilling point
Shock absorber spring installed length (Standard)
(Adjustable range)
Shock absorber spring adjuster standard position
Shock absorber spring direction
Recommended shock absorber oil
Shock absorber oil capacity
air pressure

256.5 (10.10)
258.9 (10.19)

-----

-------

----

Service Limit

251.4 (9.90)
253.7 (9.99)
--

-------

-------

Brakes - - - - - - - - - - - - - - - - , - - - - - - - - - - - - - , - - - - - - - ,
Front brake
Brake fluid
Brake lever free play
Brake pad wear indicator

Brake disc thickness


Brake disc runout
Master cylinder I.D. Standard and ABS/TCS model
LBS-ABS/TCS model
Master piston 0.0. Standard and ABS/TCS model
LBS-ABS/TCS model
Caliper cylinder I.D. Standard and ABSfTCS model
LBS-ABS/TCS model R. (Upper)
(Center)
(Lower)
L. (upper)
(Center)
(Lower)
Caliper piston 0.0. Standard and ABS/TCS model
LBS-ABS/TCS model R. (Upper)
(Center)
(Lower)
L. (Upper)
(Center)
(Lower)
Brake drum I.D.
Brake lining thickness

DOT 4
To the groove

4.8-5.2 (0.19-0.20)
14.000-14.043 (0.5512-0.5529)
12.700-12.743 (0.5000-0.5017)
13.957-13.984 (0.5495-0.5506)
12.657-12.684 (0.4983-0.4994)
27.000-27.050 (1.0630-1.0650)
27.000-27.050 (1.0630-1.0650)
22.650-22.700 (0.8917-0.8937)
25.400-25.450 (1.0000-1.0020)
25.400-25.450 (1.0000-1.0020)
25.400-25.450 (1.0000-1.0020)
22.650-22.700 (0.8917-0.8937)
26.918-26.968 (1.0598-1.0617)
26.935-26.968 (1.0604-1.0617)
22.585-22.618 (0.8892-0.8905)
25.335-25.368 (O.9974-0.9987)
25.335-25.368 (O.9974-0.9987)
25.335-25.368 (0.9974-0.9987)
22.585-22.618 (0.8892-o.8905)

CD

4.0 (0.16)
0.30 (0.012)
14.06 (0.554)
12.76 (0.502)
13.95 (0.549)
12.65 (0.498)
27.06 (1.065)
27.06 (1.065)
22.71 (0.894)
25.46 (1.002)
25.46 (1.002)
25.46 (1.002)
22.71 (0.894)
26.91 (1.059)
26.91 {1.059}
22.56 (O.888}
25.31 (O.996}
25.31 (O.996}
25.31 (O.996}
22.56 (O.888)

1-13

General Information
Unit: mm (in)
r- Brakes (cant'dl

Standard

Item
Rear brake
Brake fluid
Brake pedal height
Brake pedal free play
Brake pad wear indicator

DOT 4

To the groove (f:

Brake disc thickness Standard and ABS/TCS model


LBS-ABSrrCS model
Brake disc runout
Master cylinder 1.0. Standard and ABSrrCS model
LBS-ABS/TCS model
Master piston 0.0.
Standard and ABS!TCS model
LBS-ABSrrCS model
Caliper cylinder 1.0. Standard and ABSrrCS model
LBS-ABSJTCS model (Front)
(Center)
(Rear}
Caliper piston 0.0.
Standard and ABS/TCS model
LBS-ABSJTCS model (Front)
(Center)
(Rear}
Brake drum 1.0.
Brake lining thickness
Secondary master cylinder 1.0. (LBS-ABS/TCS model)
master piston 0.0. (LBS-ABSJTCS model)

Battery/Charging System

7.3-7.7 {O.29-0.30}
7.3-7.7 (0.29--0.30)
12.700-12.743
17.460-17.503
12.657-12.684
17.417-17.444
27.000-27.050
22.650-22.700
27.000-27.050
22.650-22.700
26.918-26.968
22.585-22.618
26.935-26.968
22.585-22.618

(0.5000-0.5017l
(0.6874-0.6891)
(0.4983-0.4994)
(0.6857-0.6868)
(1.0630-1.0650}
(0.8917--0.8937)
(1.0630-1.0650)
(0.8917-0.8937)
(1.0598-1.0617)
(0.8892--o.8905}
(1.0604-1.0617)
(0.8892-0.8905)

14.000-14.043 (0.5512--0.5529)
13.957-13.984 (0.5495-0.5506)

6.0 (0.24)
6.5 {0.26)
0.30 (0.012}
12.76 (0.502)
17.515 (0.6895)
12.65 (0.498)
17.405 (O.6852}
27.06 (1.065)
22.71 (0.894)
27.06 {1.065)
22.71 (0.894}
26.91 (1.059)
22.56 (0.888)
26.91 (l.059)
22.56 (0.888)

14.06 (0.554)
13.95 (0.549)

-------------r---------------,--------,

Alternator charging coil resistance (at 20'C/68"F}


Rotor coil (field coil) resistance {at 20C/68"F)
Regulator/rectifier regulated voltage ('91-'95)
(After '95}
Battery capacity
Specified current leakage ('91-'95)
(After '95)
Battery specific gravity {Fully charged)
(Needs charging)
Battery charging rate (Normal)
(Quick)
Battery voltage (Fully charged at 20OC/68"F)
(Needs charging at 20T/68F)
AC regulator regulated voltage (With analogue type)
(With digital type)
Brush length (After '95)
Slip ring 0.0. (After '95)

1-14

Service Limit

0-1.0 n ('91-'95}
0.22-0.26 n (After '95)
0-4.0 n ('91-'95)
2.6-3.2 n (After '95)
12.6-15.0 V at 5,000 rpm
14.2-14.8 V at 5,000 rpm
12 V-12 AH
(Maintenance free battery: YTX14-BS)
3 mA max.
2 mA max.

1.4Ax5h
6Ax1h
13.1 V
Below 12.3 V

13.7 (Q.54}
14.4 (0.57}

4.7 (O.19)
12(0.5)

General Information
-

Ignition System
Item
Spark plug
(Standard NGK)
(Standard NIPPONDENSO)
(For cold climate/below 5"C/41"F NGK)
(For cold climate/below 5"C/41 'F NIPPONDENSO)
(For extended high speed riding NGK)
(For extended high speed riding NIPPONDENSO)
Spark plug gap
Ignition timing "'F'. mark
Advance starts
stops
Full advance
Alternator exciter coil resistance {At 20'C/68'F}
Ignition coil resistance (Primary; at 20'C/68F)
(Secondary with plug cap)
(Secondary without plug cap)
Ignition pulse generator resistance (At 20"C/68'F)

Standard
CR8EH 9
U24FER9

--CR9EH 9
U27FER9
0.8-0.9 (0.031-0.035)
12~ BTDC at 1,000 rpm
2,000 rpm
5,000 rpm
2T BTDC at 5,000 rpm

-2.16-3.19 Q
22.5-27.5 kQ
13.5-16.5 kQ
405-495 Q

Service Limit

----i--

----------

---

1-15

General Information
Unit: mm (in)

lights/Meters/Switches
Item
Main fuse
Alternator fuse
Fuse ('91-95)
(After '95)

Standard
30A

Standard model
LBS-ABSfTCS model

ABS fuse (ABSfTCS model)


(LBS-ABSfTCS model)
Headlight (high/low beam) Standard and ABSfTCS model
LBS-ABSfTCS model
Tail/brake light
License light
Position light
Front turn signal/running light
Front turn signal light
Rear turn signal light
Instrument light
Oil pressure indicator
Standard model
ABSfTCS or LBS-ABSfTCS model
Tail/brake light indicator
Side stand indicator
Standard model
ABSfTCS or LBS-ABSfTCS model
Low fuel indicator
Standard model
ABSfTCS or lBS-ABSfTCS model
Coolant temperature indicator
Oil temperature indicator
High beam indicator
Standard model
ABSfTCS or LBS-ABSfTCS model
Turn signal indicator
Standard model
ABSfTCS or lBS-ABSfTCS model
Neutral indicator
Standard model
ABSfTCS or LBS-ABSfTCS model
TCS activation light (ABSfTCS or LBS-ABSfTCS model)
TCS OFF indicator (ABSfTCS or LBS-ABSfTCS model)
TCS indicator light (ABSfTCS or LBS-ABSfTCS model)
ABS indicator light (ABSfTCS or lBS-ABSfTCS model)
Reverse indicator
Overdrive indicator
Oil temperature sensor resistance
Fuel unit resistance (At full level)
(At empty)
Fuel pump flow capacity (min./minute)
Thermo sensor resistance (50'C/122F)
(80'C/176F)
(120C/248'F)
Fan motor switch Starts to close (ON)
Fully open (OFF)

55A
10Ax 6, 20Ax 1
5A {Accessory}, 10A x 6, 20A x 1
5A (Accessory), lOA x 5, 15A x 2
10Ax3, 20Ax 1
10Ax1,30Ax2
l2V45/45W x 2
12V 60/55W
12V32/3cp x 2

12V32/3cp x 2
12V32cp x 2
12V1.7W x 4
12V3.4W
12V3W
12V3.4W
12V1.7W
12V3.4W
12V3W

12V3.4W
12V3W
12V3.4 x 2
12V3W x 2
12V3.4W
12V1.7W
12V3W x 2
12V3W
LED x 1
LED x 2

10

90

n
n

130-180 n
45-60 n
10-20 n
98-102C (208-216F)
93-9TC (199-20TF)

Starting System
Starter driven gear 0.0.
Starter clutch outer I.D.
Starter motor brush length

1-16

57.749-57.768 (2.2736-2.2743)
74.414-74.440 (2.9297-2.9307)
12.0-13.0 (0.47--0.51)

Service limit

General Information

Torque Values
-

Standard

Torque

Fastener Type

5 (0.5, 3.5)
10 (1.0,7.2)
22 (2.2, 16)
35 (3.5, 25)
55 (5.5, 40)

5 mm bolt and nut


6 mm bolt and nut
8 mm bolt and nut
10 mm bolt and nut
12 mm bolt and nut

Torque

Fastener Type

Nom (kg-m, ft-Ib)

Nom (kg-m, tt-lb]

5 mm screw
6 mm screw
6 mm flange bolt (8 mm head)
6 mm flange bolt (10 mm head) and nut
8 mm flange bolt and nut
10 mm flange bolt and nut

410.4, 3)
9 (0.9, 7)
9 (0.9,7)
12 (1.2, 9)
27 (2.7, 20)
40 (4.0, 29)

Torque specifications listed below are for important fasteners.


Others should be tightened to standard torque values listed above.
Notes:

1.
2.
3.
4.
5.

Apply locking agent to the threads.


Apply oil to the threads and flange surface.
Apply sealant to the threads.
Stake.
Apply clean engine oil to the a-ring.

Engine
Item
Lubrication:
Oil pump driven sprocket bolt
Oil pressure switch
Oil filter
Oil drain bolt
Oil cooler bolt ("91-'95}
Oil filter boss
Oil pan bolt
Timing belt/cylinder head:
Timing belt tensioner bolt
Timing bait idle pulley bolt
Timing belt driven pulley bolt
Timing belt drive pulley bolt
Cylinder head bolt
Camshaft holder bolt
Cylinder head cover bolt
Spark plug
Vacuum joint
Reduction bolt
Clutch/gearshift linkage:
Clutch lock nut
Shift drum center bolt
Shift return spring pin bolt
Slave cylinder bleed valve
Gearshift arm bolt
Crankcaselcrankshaft/transmission :
Connecting rod cap nut
Crankcase bolt 6 mm

Bmm
10 mm
Pulse generator rotor bolt
Neutral switch
32 mm cap
Alternator:
Alternator terminal nut (After '95)
Alternator shaft nut
Alternator drive gear bolt

Q'ty

1
1
1
1
1
1
14
1
1
2
1
12
24
8

4
4
1
1
1
1
1
1
8
6
7
6

1
1
1
1
1
B

Thread

era.

(mm)

6
PT 1/8

20
12
20
20
6

10
12
8

12
10
6
6

10
5

12
22
8
8
8
6

B
6

B
10

12
10

32
6

14
6

Torque
Nom (kg-m, ft-Ib)
15(1.5,11)
12 (1.2, 9)
10 (1.0,7)
38 (3.8, 27)
65 (6.5, 47)
18 (1.8, 20)
12 (1.2, 9)
46 (4.6, 33)
46 (4.6, 33)
27 (2.7, 20)
65 (6.5, 47)
58 (5.8, 42)
12 (1.2, 9)
120.2,9)
11 (1.1,8)
4 (0.4, 2.9)
38 (3.8, 27)

Remarks

Note 1
Note 3
Note 5

Note 1

Note 1

Note 2

110(11.0,80)
23 (2.3, 17)
23 (2.3, 17)
9 (0.9, 6.5)
12 (1.2, 9)
36 (3.6, 26)
12 (1.2, 9)
23 (2.3, 17)
52 (5.2, 38)
100 (10.0,72)
12 (1.2, 9)
12 (1.2, 9)
8 (O.B, 5.8)
58 (5.B, 42)
16(1.6,12)

Note 2
Note 2
Note 2
Note 2
Note 5

Note 1
Note 1

1-17

General Information
r-'

Frame
Item

Frame/body panels:
Center stand pivot bolt
Side stand pivot bolt
Side stand pivot lock nut
Rotary switch attaching bolt
Footpeg holder 8 mm
10 mm
Grab rail
Grab rail center plate bolt
Saddle bag stay bolt 6 mm
8 mm
Center stand grip bolt
Engine guard mounting bolt
Windshield screw

Q'ty

6
4

2
2
2
3
5
1

Upper fairing bracket bolt


Exhaust system:
Exhaust pipe joint nut
Muffler band bolt
Exhaust pipe band bolt
Muffler mounting bolt
Exhaust pipe protector bolt
Fuel system:
Fuel tank mounting bolt
Fuel pump mounting nut
Carburetor connecting screw
Air cleaner housing cover screw
Fuel valve mounting screw
Cooling system:
Fan motor switch
Thermostat case
Water hose band screw
Engine mount:
Engine mounting bolt 10 mm
12 mm
Engine mounting bracket bolt 8 mm
10 mm
Sub frame bolt
Engine mounting collar lock nut ('91-'95)
(After '95)
Engine mounting collar adjusting nut (lower)
(After '95)
Gearshift pedal pivot bolt

1-18

1
1
1
1
2

Torque

dia. (mm)

Nem tka-m. ft-Ib)

8
10
10
6
8
10
8
8
6
8
6
8
5
8

27 (2.7, 20)
10 (1.0, 7)
27 (2.7, 20)
10 (1.0,7)
27 (2.7, 20)
35 (3.5, 25)
27 (2.7, 20)
35 (3.5, 25)
10 (1.0,7)

8
8
8
6

1
2
12

Thread

6
2
8
2
1
2
10

6
6
6
5
5
16
6

36 13.6, 25)
10 (1.0,7)
27 (2.7, 20)
0.6 (0.06, 0.43)
27 (2.7. 20)
170.7,12)
22 (2.2, 16)
22 (2.2, 16)
27 (2.7, 20)
12 (1.2, 9)
12 (1.2. 9)
10 (1.0, 7)
8 (0.8, 5.8)
0.9 (0.09, 0.65)
0.9 {0.09, 0.65)
12 (1.2, 9)
10 (1.0, 7)
1.2 (0.12, 0.9)

5
1
2

10
12
8
10
10
18
18

55
65
35
40
40
21
28

1
1

18
8

10 (1.0. 7)
27 (2.7, 20)

1
8
4

Remarks

(5.5,
(6.5,
(3.5,
(4.0,
(4.0.
(2.1,
(2.8.

40)
47)
25)
29)
29)
15)
20)

Note 2

Note 1

General Information

Frame
Item
Front suspension:
Handlebar lower cover bolt
Handlebar upper holder bolt
Handlebar weight screw
Ignition switch mounting bolt
Throttle housing screw
Front fender attaching socket bolt
Standard and LBS-ABSfTCS model
ABSfTCS model
Front fender plate bolt (LBS-ABSfTCS model)
Steering bearing adjustment nut
Steering stem nut
Upper fork pinch bolt
Lower fork pinch bolt
Fork cap
Standard and ABS/TCS model
LBS-ABS/TCS model
Fork socket bolt
Fork damper lock nut
Anti-drive case bolt
Front axle bolt
Front axle pinch bolt
Front pulser ring bolt (ABS/TCS or LBS-ABS/TCS model)
Rear suspension:
Shock absorber upper mounting bolt
Shock absorber lower mounting bolt
Swingarm right pivot bolt
Swinqarrn left pivot bolt
Standard and ABSfTCS model
LBS-ABSfTCS model
Swingarm left pivot bolt lock nut
Rear axle nut
Rear axle pinch bolt
Rear wheel damper plate bolt
Rear pulser ring bolt (ABS/TCS or LBS-ABS/TCS model)
Brake/clutch system:
Front wheel speed sensor bracket bolt (LBS-ABS/
TCS model)
Rear caliper stopper pin bolt
Pad pin plug
Pad pin
Caliper assembly bolt (LBS-ABSfTCS model)
Front caliper pin bolt (caliper side)
(bracket side)
Rear caliper pin bolt
(caliper side)
Standard and ABS/TCS model
LBS-ABSfTCS model
(bracket side)
Standard and ABS/TCS model
LBS-ABSfTCS model
Caliper bleed valve
Standard and ABS/TCS model
LBS-ABS/TCS model

Thread
dia. (mm)

Nrn (kg-m, ft-Ib)

5
8
6
8
5

4.3 (0.43, 3.1)


27 (2.7, 20)
9 (0.9, 6.5)
25 (2.5, 1S)
4.2 (0.42, 3.0)

6
8
8
26

8
10
5
14
8
5

12(1.2.9}
22 (2.2, 16)
22 (2.2, 16)
28 (2.8, 20)
105 (10.5, 76)
23 (2.3, 17)
50 (5.0, 36)
20 (2.0, 14)
23 (2.3, 17)
20 (2.0, 14)
23 (2.3, 17)
4 (0.4, 2.9)
90 (9.0, 65)
22 (2.2, 16)
8 (D.B, 5.B)

1
1
1

10
8
30

50 (5.0, 36)
23 (2.3, 17)
105 (10.5, 76)

1
1
1
1
1
5
6

30
30
30
18
8
6
5

18 (1.8, 13)
22 (2.2, 16)
105 (10.5, 76)
110 (11.0, SO)
27 (2.7,20)
20 (2.0, 14)
8 {O.8, 5.B}

1
1
3
3
9
2
2

6
18
10
10
8
8
8

12 (1.2, 9)
70 P.O, 51)
2.5 (D.25, 1.8)
18 (1.8.13)
33 (3.3. 24)
23 (2.3. 17)
13
9}

1
1
1
1

12
12
8
8

3
6

Q'ty

4
4

2
2
2
2
2
2
1
1
2
4

2
2
2
1
4

1
4

Torque

24
8
10

n.s.

28
28
13
23

(2.8,
(2.8,
(1.3,
(2.3,

20)
20)
17)
17)

Remarks

Note 1

Front side bolts


Note 2

Note 1
Note 1

Note 2

Note 1
Note 1
Note 1
Note 1
Note 1

5.5 (D.55, 4.0)


5.5 (D.55, 4.0)

1-19

General Information
r-r- Frame tccnt'dl
Item
Brake/clutch system tccnt'dj:
Right front caliper mounting bolt (Standard and
ABSrrCS model)
Left front caliper pivot bolt (Standard and ABS/
TCS model); upper
lower
Right front caliper pivot bolt (LBS-ABSrrCS
model); upper
lower
Left front caliper pivot bolt (LBS-ABSrrCS model)
Brake disc bolt
Rear master cylinder push rod lock nut
Secondary master cylinder mounting bolt
(LBS-ABSrrCS model)
Secondary master cylinder push rod lock nuts
(lBS-ABSJTCS model)
Secondary master cylinder link plate bolt
(LBS-ABSjTCS model)
Delay valve mounting bolt (LBS-ABSJTCS model)
Brake lever adjuster rod bolt
Master cylinder holder bolt
Master cylinder reservoir cap screw
Clutch lever pivot nut
Clutch lever pivot bolt
Clutch switch mounting screw
Brake lever pivot nut
Front brake lever pivot bolt
Front brake switch mounting screw
Brake hose oil bolt
Standard model
ABSJTCS model
LBS-ABSrrCS model
Clutch hose oil bolt
Brake pipe joint nut (LBS-ABSrrCS model)
Brake hose clamp screw {at fork tube;
Standard model}
Final drive:
Final gear case mounting nut
Final gear case oil filler cap
Pinion bearing retainer
Pinion joint nut
Retainer lock washer bolt
Final gear case bolt 8 mm
10 mm
Final gear case drain bolt
Dust guard plate bolt
Electrical system:
Ignition coil mounting bolt
Meter mounting bolt

1-20

Q'ty

Thread
dia. (mm)

Nm (kg-m, ft-Ib)

27 (2.7, 20)

1
1

8
6

27 (2.7, 20)
12 (1.2, 9)

1
1
2
18
1

8
6
8
8
8

30 (3.0, 22)
12(1.2,9)
30 (3.0, 22)
43 (4.3, 31)
18 (1.8, 13)

12(1.2,9)

18 (1.8, 13)

2
2
1

8
6
5
6

30 (3.0, 22)
12 (1.2, 9)
4 (0.4, 29)
12(1.2,9)
1.5 (Q.15, 1,1)
6 (0,6, 4,3)
1 (0.1,0.7)
1.2 (0.12, 0.9)
6 (0.6, 4.3)
1 (0.1, 0.7)
1,2 (0,12, 0.9)
35 (3.5, 25}
35 (3.5, 25}
35 (3.5, 25)
35 (3.5, 25)
17 (1,7, 12)

1
1
1
1
1
1
5
9
18
2

,.
1

1
1
1
6
2
1
1

6
6

6
6

10
10
10
10

Torque

4,3 (Q,43, 3.1)

10
30
70
16
6
8
10
6

65 {6.5, 43}
12(1.2,9)
150 {15.0, 108}
110(11.0,80}
10 (1.0, 7}
26 (2.6, 19)
63 (6.3, 46)
20 (2.0,14)
10 (1.0, 7)

6
6

9 (0,9, 6.5)
9 (0.9, 6.5)

,.

Remarks

Note 1

Note 1

Note 1

Note 1

General Information

Tools
Tool Number

Description

07HAA-PJ70100

Oil filter wrench


Oil pressure gauge
Oil pressure gauge
attachement
Float level gauge
Pilot screw wrench
Bearing remover set
- Remover handle
- Bearing remover, 17 mm
- Remover weight
Driver
Attachment, 37 x 40 mm
Pilot, 20 mm
Valve guide driver, 4.5mm
Valve spring compressor
Valve spring compressor
attachment
Tappet hole protector
Valve guide reamer, 4.5 mm
Compression gauge
attachment
Valve seat cutter, 24.5 mm
{45 EX)
Valve seat cutter, 29 mm
(45'IN)
Flat cutter, 25 mm (32" EX)
Flat cutter, 28 mm (32"IN)
Interior cutter, 30 mm
(60 IN, EX)
Cutter holder, 4.5 mm
Snap ring pliers
Clutch center holder
Clutch holder collar
Lock nut wrench, 30 x 32 mm
Extension bar
Attachment, 28 x 30 mm
Pilot 12 mm
Ball race & bearing driver
attachment
Attachment, 42 x 47 mm
Pilot, 25 mm
Attachment, 62 x 68 mm
Pilot, 30 mm
Pilot, 28 mm

Alternate Tool

07506"':30000~:J
07501-4220100
07401-0010000
07KMA-MS60101

07936-3710001
07936-3710100
07936-3710600
07741-0010201
07749-0010000

Equivalent commercially
available in U.S.A.

Ref.
Section(sl
4
4

4
Pilot screw wrench
(U.S.A. only)
! Not available in U.S.A.

07746-0010200
07746-0040500
07HMD-ML00100
07757-0010000

Tool Number

07959-KM30101
07HMG-MR70001
07HMH-ML0010l

07LMA-MT8010A or
07MMA-MT3010A

Remover weight

07936-3710200

Valve guide driver, 4.5mm

07HMD-ML0010l

or Equivalent (see page 8-9)


Valve guide reamer, 4.5mm
Equivalent commercially
available in U.S.A.

07JMJ-KY20100
07780-0010100

07HMH-ML0010A

5
5
8, 10
8, 10
8, 10
8,10,14
8,9,10,
12,13,14
8, 14
8, 10

8
8
8
8
8
8
8

Equivalent commercially
available in U.S.A.

07780-0010300
07780-001200007780-0012100-

8
8
8

07780-0014000
07781-0010600
07914-3230001
07JMB-MN50300

8
8
9, 15

07LMB-MT30100
07716-0020400, Equivalent commercially
07716-0020500....1 available in U.S.A.
07946-1870100
07746-0040200
07945-3330300
07746-0010300
07746-0040600
07746-0010500
07746-0040700
07746-0041100

07HGB-0010l0B
07MPB-764021A

Holder plate
Clutch center collar "B"

,,

s
s
s
s
s
s
10

10,12,13

10
10, 12

10
10

1-21

General Information
r-'

Cont'd
Description

Tool Number

Pinion retainer wrench


Shaft puller
Pinion holder attachmemt
attachment
Oil seal remover
Oil seal driver attachment
Bearing race remover
Oil seal driver
Attachment. 52 x 55 mm
Pilot, 35 mm
Driver, 40 mm I.D.
Attachment, 25 mm I.D.
Bearing insert attachment
Yoke joint compressor
attachment
Yoke joint compressor base
Fork seal driver attachment
Standard and ABS;TCS model
LBS-ABS/leS model
Fork seal driver body
Steering stem socket
Steering stem driver
Ball race remover set
- Driver attachment
- Driver handle
Bearing race remover
Shock absorber compressor
Shock absorber compressor
attachment

07910 MA10100
07931-ME40000
07924-ME40000
07924-9690102
07948-4630100
07948-5800101
07946-3710500
07965-MC70100
07746-0010400
07746-0040800
07746-0030100
07746-0030200
07931-4630300

Pivot bearing outer remover


Lock nut wrench
Digital multi meter
(U.S A. only)
Analogue tester (SANWA)

07936-4150000
07908-4690003

07LMF-MT30110,
07LMF-MT30120-l

Alternate Tool

Tool Number

Ref.
Section(s)

12
12
12
12
12
12
12
12

07931-ME4010A

Shaft puller

12, 13

12
12
12
12
12
12
13

Not available in U.S.A.


,

07947-KF00100
07947-KA40200
07947-KA50100
07916-3710100
07946-MBOOOOO
07953-MJ10000
07953-MJ10l00
07953-MJ 10200
07946-3710100
07GME-0010000

Race remover attachment


(U S.A. only)

13
13
13
13
13
13
13

07953-MJ 1OOOB

"

07959-MB 10000

,
KS-HBA-08-469

Lock nut wrench

KS-AHM-32-003 ~ Equivalent commerciallv


available

In

,.,.,.

17,18.20,

21

USA

SP-15D

17,18,20,

TH-5H

17,18,20,

21
Analogue tester (KOWA)

1-22

21

General Information

Lubrication & Seal Points


-

Engine
Location
Upper and lower crankcase mating surface

Material

Remarks

Uquid sealant

Do not apply sealant near


the rain journal bearings.
Do not apply sealant to the
switch thread head as shown.

Oil pressure switch thread

3-4 mm
(0.12-0.16 in)
Semi-circular portion of the cylinder head
Valve stem (valve guide sliding surface)
Crankshaft main journal bearings
Connecting rod bearings
Crankshaft thrust surfaces
Crankshaft thrust bearings
Camshaft journals, cam lobes and thrust surfaces
Camshaft driven gear
Cam reduction gear shaft spline
Valve lifter
Piston pin
Primary drive gear
Clutch outer guide
Transmission gearshift fork grooves
Alternator driven gears

Molybdenum disulfide oil (a mixture of engine oil and molybdenum disulfide grease in a 1
1
ratio)

Connecting rod bearing cap nuts


Piston
Connecting rod small end bearing
Transmission gears
Shift forks
Oil filter a-ring
Oil strainer packing
Clutch lifter rod
Litter rod guide
Shift fork shaft
10 mm crankcase bolts
8 mm crankcase bolts
Pulse generator rotor bolt
Cylinder head bolts
a-rings
Other sliding surfaces

Engine oil

Oil seal lips

Multipurpose grease

Clutch slave cylinder piston seal

DOT 4 brake fluid

Timing belt idle pulley bolt threads


Shift drum set plate bolt threads
Oil pump driven sprocket bolt threads
Primary damper shaft bearing set plate bolt threads
Alternator drive gear bolt threads
Timing belt tensioner spring hook bolt threads
Water pump mounting bolt threads
Cam reduction holder bolt threads
Clutch cover base bolt threads
Alternator shaft nut threads

Locking agent

1-23

General Information
r-

Frame
Material

Location
Center stand pivot
Side stand pivot
Rear brake pedal pivot
Gearshift pedal pivot
Throttle grip pipe flange
Steering head bearings
Steering head bearing dust seal lips
Front caliper pivot collars

Multipurpose grease

Driveshaft and driveshaft joint splines

Molybdenum disulfide grease

Driveshaft
Driveshaft
Driveshaft
Driveshaft
Driveshaft

Molybdenum disulfide
paste

CD
yoke joint cotters <Il
yoke joint thrust washer @
yoke joint oil seal lip
groove @

I'"

._-

~A

-, r
I.

"

Rear shock absorber upper mounting collar (inside and


outside surfaces)
Rear wheel thrust washer
Final driven flange splines
Final driven flange O-ring
Handlebar grip rubbers

Honda Bond A or equivalent

Steering bearing adjustment nut threads

Engine oil

Thermo sensor threads

Sealant

Fork
Fork oil seal lip

Fork fluid

Brake/clutch master cylinder pistons/piston cups


Caliper pistons/piston seals
Brake/clutch reservoir

DOT 4 brake fluid

Silicone grease
Insides of the caliper boots
Brake pad pin stopper rings (LBS-ABS/TCS model)
Front master cylinder push rod ends (LBS-ABS/TCS model)
Front master cylinder piston end (Standard and
ABS/TCS model)
Rear master cylinder push rod upper end and boot
groove
Handlebar weight screw threads
Front fork socket bolt threads
Cooling fan nut threads
Caliper pin bolt threads
Secondary master cylinder push rod lock nut threads
(LBS-ABS/TCS model)
Anti-dive case bolt threads

1-24

Apply to the area as shown.

@I-m

1+.....1Jl..... +
+

Remarks

Locking agent

Pack the groove with the


grease

General Information

Cable & Harness Routing


Standard Model

(1) CLOCK WIRE

(2) LEFT TURN SIGNAL


WIRE CONNECTOR

_,;rC'~~~~~~~1~~~il{3)

(7) RIGHT TURN SIGNAL


WIRE CONNECTOR

(6) BANK ANGLE SENSOR

SPEEDOMETER CABLE

I,

(5) FRONT BRAKE HOSE

-,I

(4) HEADLIGHT CONNECTORS

1-25

General Information
Standard Model

(2) CLUTCH HOSE


(3) BRAKE HOSE

(6) JOINT BOOTS _ _---'-+:~


('91-'94 only)

" 1~
(5) WIRE
(7) LEFT HANDLEBAR SWITCH
WIRE HARNESS

B~NDS ~

(8) RIGHT HANDLEBAR SWITCH


WIRE HARNESS

. \\ i
',

'

\~

,x,

(10) IGNITION COIL 3P CONNECTOR

1-26

General Information
Standard Model
(1) HIGH BEAM HEADLIGHT
RELAY

(2) BANK ANGLE SENSOR


RELAY

(3) LOW BEAM


HEADLIGHT RELAY

'l

~f
./ 'If '

/.4
.,,, /

(5) FUEL CUT-OFF RELAY

(6) CHOKE CABLE

(10) INDICATOR LIGHT


CH ECKER

>:

---==--J>!;;;~

(9) IGNITION
CONTROL
MODULE - -~7 (---',
(ICM)
(8) HARNESS CLIPS

(7) THROTILE CABLES

1-27

General Information
(3) THROTTLE STOP SCREW CABLE

Standard Model

(2) FUEL FILTER


(5) RADIATOR
OVERFLOW TUBE

(1) REAR BRAKE LIGHT SWITCH

2P CONNECTOR

----

~~~~,

~
(9) TURN SIGNAL RELAY

WIRE 4P CONNECTOR

(12) FUEL TANK TRAY


DRAIN TUBE

'91-'95:

n i)

(6) THERMO
SENSOR

(7) SPARK PLUG WIRES

(8) WIRE BAND

(10) IGNITION PULSE GENERATOR

(13) FUEL FILL CAP


BREATHER TUBE

FAN MOTOR 2P CONNECTOR

(14) FUEL UNIT


2P CONNECTOR
(15) REGULATOR/RECTIFIER
(16) FRAME
GROUND
(17) FUSE
CASE

(25)
SPARK PLUG
WIRES
,

(24) STARTER MOTOR


CABLE

{22} SIDE STAND


SWITCH WIRE

(23) ENGINE GROUND


CABLE

1-28

,,

' / (20j

\ ALTERNATOR
WIRE

(21) CARBURETOR
DRAIN TUBE

{18) BATTERY
{19} STARTER RELAY
SWITCH

General Information
Standard Model
After '95:

(2} FUEL TANK TRAY


DRAIN TUBE

(3) FUEL FILL CAP


BREATHER TUBE

(6) FRAME
GROUND

(4) FUEL UNIT 2P CONNECTOR


(1} FAN MOTOR 2P
CONNECTOR
(5) BATTERY

---~--

(7)

ACCESSORY
(ACC) FUSE

(17) SPARK
WIRES
(16)

1-29

General Information

ABS/TCS Model

(2) LOW BEAM HEADLIGHT RELAY

(1) CLOCK WIRE

rr>

//

'

(3) FUEL CUT-OFF RELAY

\
"

,/

\\

(14) BANK ANGLE


(4) INDICATOR LIGHT

SENSOR RELAY

CHECKER

--;r---- LoS8
(13) HIGH BEAM

HEADLIGHT
RELAY

,I

1'1
1'1"1

G5I ~11f" ~,#,(

"

,!~
"

',',y

(12) RIGHT TURN SIGNAL


WIRE CONNECTOR

(11) BANK ANGLE


SENSOR

(6) TCS/IGNITION
CONTROL
MODULE
(ICM)

Iir=
III{--,

",

,
,
,
,
,
,

"~-=I
11'--

,,',--

11,----"~I
"~

(7) SPEEDOMETER CABLE

',~
'I

(8) HEADLIGHT CONNECTORS


(10) FRONT WHEEL SENSOR WIRE
{9} FRONT BRAKE HOSE

1-30

(5) LEFT TURN SIGNAL


WIRE CONNECTOR

General Information

ABS/TCS Model

(2) CLUTCH HOSE


(3) BRAKE HOSE

(6) JOINT BOOT


('91-'94 only)

1~

(5) WIRE B;NDS


(7) LEFT HANDLEBAR SWITCH
WIRE HARNESS

(8) RIGHT HANDLEBAR SWITCH


WIRE HARNESS

(10) IGNITION COIL 3P CONNECTOR

1-31

General Information

ABsrrcs

(2} FRONT MODULATOR SOLENOID 4P CONNECTOR

Model
(1} FRONT WHEEL SENSOR
3P CONNECTOR

(3) LOW BEAM HEADLIGHT RELAY

(4) FRONT MODULATOR PUMP


MOTOR/GROUND 2P
CONNECTOR
f)rJ;l?>~'//

(5) HIGH BEAM HEADLIGHT


RELAY
(6) BANK ANGLE SENSOR

<;

.~~
(10) FRONT BRAKE HOSES

(7} BANK ANGLE SENSOR

(9) FRONT WHEEL SENSOR

(13} ABS MAIN RELAY


(12) REAR PUMP
MOTOR RELAY
(11) FRONT PUMP
MOTOR RELAY

=-~

7':------ ) \

,0 C::]\?\\
IV'"~ \,~'~'V

(14) CHOKE CABLE

'J! ((

'/ ( i
/:

I,

(B} FRONT
MODULATOR

I
\

\(\

'\J

, \ '0 Alt;&:~'0

0t-""--",,,,,"

(19) INDICATOR
LIGHT CHECKER

\.
--------

(18) FUEL CUT-OFF RELAY

(16) ABS CONTROL UNIT (ECU)


(17) INDICATOR CONTROL UNIT

1-32

General Information

ABS/TCS Model

(4) FUEL
FILTER
(3) REAR MODULATOR PUMP MOTOR!
GROUND 2P CONNECTOR

(5) THROTILE STOP SCREW CABLE


(6) IGNITION PULSE GENERATOR
WIRE 4P CONNECTOR

(2) REAR BRAKE LIGHT


SWITCH 2P CONNECTOR
(1) REAR MODULATOR

"-

-------

---

<

(7) HARNESS
CLIPS

(B) RADIATOR OVERFLOW TUBE


(13) REAR WHEEL
SENSOR

(11) REAR MODULATOR SOLENOID


3P CONNECTOR

(12) REAR BRAKE HOSES

(10) TURN SIGNAL RELAY

(9) REAR WHEEL SENSOR


3P CONNECTOR

1-33

General Information

ABS/TCS Model

(3) TCS ON/OFF SWITCH WIRE


(2) ABS/TCS INDICATOR
LIGHT SWITCH WIRE

(4) FUEL TANK TRAY


DRAIN TUBE
(5) FUEL FILL CAP
BREATHER TUBE

(1) FAN MOTOR 2P CONNECTOR

(6) FUEL UNIT


(7) REGULATOR/
2P CONNECTOR
RECTIFIER

(9) FUSE
CASE

;>
---(

0?1~'&_'~~ "

(19) SPARK PLUG


WIRES
(18) STARTER MOTOR
CABLE

(16) SIDE STAND


SWITCH WIRE

(17) ENGINE GROUND


CABLE

\/1
.

WIRE
(14) CARBURETOR
DRAIN TUBE

(15) CLAMPS:
('91-'95 only)

1-34

(13) ALTERNATOR

~,'llOl

ABS FUSE
CASE

(11)BATIERY
(12) STARTER RELAY
SWITCH

General Information

LBS-ABSfTCS Model

(2) LOW BEAM HEADLIGHT RELAY

,~

(1) CLOCK WIRE

(16) BANK ANGLE


SENSOR RELAY
r:

\ \,

(3) FUEL CUT-OFF RELAY

(4) INDICATOR LIGHT


CHECKER

---;;"-,

---rr~--

,/
(5) LEFT TURN SIGNAL
WIRE CONNECTOR

(14) RIGHT TURN SIGNAL


WIRE CONNECTOR

(6) TCS/IGNITION CONTROL


MODULE(ICM)

Ic\~

(13) BANK ANGLE


SENSOR

{12) FRONT MODULATOR

4"'~'\
I:' '~c-:>i

,
,
,
,
,
,

, ' 'r(" \ I "


I-: ' 0_:_~j/:J/

(11) LEVER BRAKE HOSE


(Front Modulator-toFront Calipers)

FRONT WHEEL SPEED


SENSOR WIRE

I,

----;J
I

(10) PEDAL BRAKE HOSE


{Front Modulator-toDelay Valve)

i (-)J

(8) SPEEDOMETER CABLE

~
(9) SERVO-BRAKE HOSE
(Secondary Master
Cylinder-to-PCV)

1-35

General Information

lBS-ABSITCS Model

(3) LEVER BRAKE HOSE


(Front Master Cylinderto-Front Modulator)

(2) CLUTCH HOSE

(1) CHOKE CABLE

(4) THROTTLE CABLES

~-

(5) WIRE BANDS


(6) LEFT HANDLEBAR SWITCH
WIRE HARNESS

(7) RIGHT HANDLEBAR SWITCH


WIRE HARNESS

(8) IGNITiON COIL

(9) IGNITION COIL 3P CONNECTOR

1-36

General Information

lBS-ABsrrcs Model

(2) PEDAL BRAKE HOSE


(Front Modulator-toDelay Valve)

(t) LEVER BRAKE HOSE

(Front Master Cylinder-toFront Modulator)

(3) FRONT WHEEL SPEED SENSOR


3P (Black) CONNECTOR
(4} LOW BEAM HEADLIGHT
RELAY

(10} LEVER BRAKE HOSE


(Front Modutator-toFront Calipers}

(5} MODULATOR CRANK


ANGLE SENSOR 3P
(Blue} CONNECTOR

(6) FRONT MODULATOR

/
~
J\\~
\

___====--==.=--=

.
I

Ii / (

-=O~~=~-~;=~~DAL BRAKE HOSE

/ /

(Rear Master Cylinder-toFront Modulator)

(13) BANK ANGLE SENSOR

(7) MODULATOR CONTROL MOTOR


2P (Black) CONNECTOR

/! )

(8} SERVO-BRAKE HOSE


(Secondary Master Cylinder
-to-PCV)

(14) BANK ANGLE SENSOR RELAY


(19) REFERENCE NUMBERS; align with the number
on the modulator head

(12) RIGHT TURN SIGNAL


WIRE

(15} HIGH BEAM


HEADLIGHT RELAY

(11) MOTOR DRIVER

(18} View of front modulator


from the right side:

(20} PINS
(21} STOPPERS

(17} 4P (Blue)
CONNECTOR

(16) 4P (Black}
CONNECTOR

(22} REFERENCE NUMBERS;


Two kinds of numbers are stamped
on each hose joint - refer to the
second line from the top for
the front modulator.

1-37

General Information

LBS-ABSfTCS Model
(1) SERVO-BRAKE HOSE
(Secondary Master Cylinder-to-PCV)

(2) PEDAL BRAKE HOSE


(Front Modulator-to-Delay Valve)

(3} DELAY VALVE


(4) LEVER BRAKE HOSE
(Front Modulator-to-Right Caliper)

(7) SECONDARY MASTER


CYLINDER

(5) FRONT WHEEL SPEED


SENSOR WIRE

,
,

(6) PEDAL BRAKE HOSE


(Delay Valve-to-Right Caliper}
(8) DELAY VALVE
{9} SERVO-BRAKE HOSE
(Secondary Master Cylinderto-PCV}

{10) SECONDARY MASTER CYLINDER

/
(11) LEVER BRAKE HOSE
(Front Modulator-toLeft Caliper)

--------t'--1!;isltili

(12) PEDAL BRAKE HOSE


{Delay Valve-toLeft Caliper)

1-38

General Information

LBS-ABS/TCS Model

L?~~

(1) REAR MODULATOR CONTROL


MOTOR RELAY

(8) CHOKE CABLE

'r

10-:(

(2) FRONT MODULATOR CONTROL


MOTOR RELAY

, //JJ
P

(7) THROTTLE CABLES

(3) INDICATOR LIGHT

CHECKER

(4) FUEL CUT-OFF RELAY

(S) INDICATOR CONTROL

UNIT

, .',

(6) ABS CONTROL UNIT (ECU)

(10) FUEL TANK TRAY

(14) FRAME

(11) FUEL FILL CAP BREATHER TUBE

DRAIN TUBE
(9) FAN MOTOR 2P

GROUND
(12) FUEL UNIT 2P CONNECTOR

CONNECTOR

(13) BATTERY

(15) ACCESSORY
(ACC) FUSE

<~)~"

1/)

(24) SPARK PLUG


WIRES

~)~~> --("'>

( 16)
ACCESSORY (ACC)
\ , 1 - ' TERMINALS
(Allowable power
and current
capacity: 60W/SA)

(20) STARTER RELAY


SWITCH

(21) ALTERNATOR CABLE


(20) SIDE STAND SWITCH

(18) ABS FUSE BOX

1-39

General Information

lBS-ABS/TCS Model
(3) MODULATOR CRANK ANGLE SENSOR
3P (White) CONNECTOR

(4) THROlTLE STOP SCREW CABLE


(5) PULSE GENERATOR WIRE
4P (White) CONNECTOR

(2) TURN SIGNAL RELAY


(1) MODULATOR CONTROL MOTOR
2P (Black) CONNECTOR

---------

'--

///-)-------'~.

, .
-_/

(10) REAR WHEEL SPEED


SENSOR

(8) REAR WHEEL SPEED SENSOR 3P (Yellow)


CONNECTOR
(9} REAR BRAKE LIGHT SWITCH
2P CONNECTOR
{14} SERVO-BRAKE PIPE
(Secondary Master Cylinder-to-PCV)

(11) SERVO-BRAKE PIPE


(PCV-to-Rear Modulator)

(13) PEDAL BRAKE PIPE


(Rear Master Cylinder-to-Front Modulator)
(12) FUEL FILTER

---~

./

(18) REAR MODULATOR


(17) REAR WHEEL SPEED SENSOR WIRE

1-40

(15) RADIATOR OVERFLOW


TUBE
(16)

Pcv (Proportional

Control Valve)

General Information

lBS-ABSITCS Model
(2) SERVO-BRAKE HOSE
(Rear Modulator-ta-Rear Caliper)

./

,/;---=0.

,/1

iii'

'1'

HOSE

(4) PEDAL BRAKE


I
(Rear Master Cylinder-ta-Rear Modulator)
(5) PEDAL BRAKE HOSE

(8) View of rear modulator


from the right side:

iRear Modulator-to-Hear Caliper)

(7) REFERENCE NUMBERS; align with the number


on the modulator head
(14) Route between the master cylinder
and reservoir hose

1- A
(9)

STOPPER
(10) JOINT
NECK
(11) REFERENCE NUMBERS;
Two kinds of the numbers are
stamped on each hose jointrefer to the upper line for the

rear modulator

{16} WHITE PAINT (3 places): Servo-brake line only

1-41

General Information
All Models

(1) HARNESS CLIPS

(2) MAIN WIRE HARNESS

1-42

General Information
Emission Control Systems'

Model'

49 state

PAIR control valves

California

PAIR control valves


EVAP purge control valve
EVAP CAV control valve
EVAP canister

Standard

ABS/TCS

LBS ABS
(TCS

94 ......95

49 state
91 ......

California

92 ......95

'96"-

Canada

Canada
(3) TO CARBURETOR
AIR CHAMBER

U.S.A. Only
(2) No. 15 TUBE

(4) AIR INJECTION PIPES


(No. 16)

(1) No. 10 TUBE

(12) AIR INJECTION PIPES


(No. 16)
(11) NO.4 TUBE
('91-'93: Standard
California and U.S.A.
ABS/TCS type only
After '93: California
type only)
{10} CLAMP:
('91-'95 only)

(9) FUEL TANK TRAY


DRAIN TUBE

(B) CARBURETOR
DRAIN TUBE

(7) EVAPORATIVE
EMISSION (EVAP)
CANISTER
('91-'93: Standard
California and U.S.A.
ABS/TCS type only
After '93: California
type only)

(13)No.15TUBE
(14) PULSE SECONDARY
AIR INJECTION {PAIR}
CONTROL VALVE
(FRONT)

(16) No. 10 TUBE

~=~~~:';~=~--r-(15)PULSE

'n-"r+Ff<

SECONDARY
AIR INJECTION (PAIR)
CONTROL VALVE
(REAR)

1-43

General Information

'91-'93:
Standard California Type and U.S.A. ABS/TCS Type
After '93:
California Type
(1) EVAPORATIVE EMISSION
(EVAP) PURGE CONTROL
VALVE

II

{3} No.4 TUBE

111'-

')I\----L.I\;J .'~TUBE\,fL1--.t::::-1,~1
/

(4) EVAPORATIVE EMISSION


CARBURETOR AIR VENT
(EVAP CAV) CONTROL
VALVE

~'\jiiC_-(5)

No.7 TUBE

(10) No.5 TUBE

(9) No. 6

TUBE,--J\lh~~~
III

il~~-+i+-(6) NO.5 TUBE

\
J---i-J----!--(7) NO.6 TUBE
(8) No.4 TUBE

(13) NO.6 TUBE


(12) NO.7 TUBE
(11) EVAP CAV CONTROL
VALVE

(14) EVAP PURGE CONTROL


VALVE

(15) No.5 TUBE

(20) No. 10TUBE~

(19) No.4 TUBE

(16) No. 15 TUBE


(18) NO.5 TUBE
(17) No. 11 TUBE

1-44

General Information

Emission Control Systems


The U.S. Environmental Protection Agency and California Air Resources Board (CARB) require manufacturers to certify
that their motorcycles comply with applicable exhaust emissions standards during their useful life, when operated and
maintained according to the instructions provided. and that motorcycles built after January 1, 1983 comply with applicable noise emission standards for one year or 6,000 km (3,730 miles) after the time of sale to the ultimate purchaser,
when operated and maintained according to the instructions provided. Compliance with the terms of the Distributor's
Warranties for Honda Motorcycle Emission Control Systems is necessary in order to keep the emissions system warranty
in effect.

Source of Emissions
The combustion process produces carbon monoxide and hydrocarbons. Control of hydrocarbons is very important because, under certain conditions, they react to form photochemical smog when subjected to sunlight. Carbon monoxide
does not react in the same way, but it is toxic.
Honda Motor Co., Ltd. utilizes lean carburetor settings as well as other systems, to reduce carbon monoxide and hydrocarbons.

Crankcase Emission Control System


The crankcase emission control system routes crankcase emissions through the air cleaner and into the combustion chamber.

'91 :

After '91:
(1) AIR CLEANER

(4) CRANKCASE
BREATHER
SEPARATOR

(4) CRANKCASE
BREATHER
SEPARATOR

~~~~~[]J

~ARBURETOR

<:

11---(31

CRANKCASE

... BLOW-BY GAS


FRESH AIR

I'J /

(3) CRANKCASE

... BLOW-BY GAS


<? FRESH AIR

1-45

General Information
Exhaust Emission Control System (Secondary Air Supply System) [U.S.A. only]
The exhaust emission control system consists of a secondary air supply system which introduces filtered air into the exhaust gases in the exhaust port. Fresh air is drawn into the exhaust port whenever there is a negative pressure pulse in
the exhaust system. This charge of fresh air promotes burning of the unburned exhaust gases and changes a considerable
amount of hydrocarbons and carbon monoxide into relatively harmless carbon dioxide and water vapor.
The pulse secondary air injection check valves prevents reverse air flow through the system. The pulse secondary air injection control valve reacts to high intake manifold vacuum and will cut off the supply of fresh air during engine deceleration, thereby preventing afterburn in the exhaust system.
No adjustments to the secondary air supply system should be made, although periodic inspection of the components is
recommended.

(1) AIR CLEANER

(2) PULSE SECONDARY AIR


INJECTION (PAIR)
CONTROL VALVE
(B) CARBURETOR

(7) EXHAUST PORT

(6) INTAKE MANIFOLD

fr-~2====ZF;!) {3 ) PULSE

SECONDARY
AIR INJECTION
(4) TO
(PAIR) CHECK
EXHAUST
VALVE
PORT

151
~,...

1-46

FRESH AIR

General Information
Evaporative Emission Control System
{'91-'93: Standard California Type and U.S.A. ABS/TCS Typel
(After '93: California Typel
This vehicle complies with the California Air Resources Board requirements for evaporative emission regulations.
Fuel vapor from the fuel tank and carburetors is routed into the evaporative emission canister where it is absorbed and
stored while the engine is stopped. When the engine is running and the evaporative emission purge control diaphragm
valve is open, fuel vapor in the evaporative emission canister is drawn into the engine through the carburetor. At the
same time, the evaporative emission carburetor air vent control valve is open and air is drawn into the carburetor through
the valve.

(2) EVAPORATIVE EMISSION


(EVAP) PURGE CONTROL
VALVE

(3) FUEL TANK

(1) CARBURETOR

(4) DRAIN

(5) EVAPORATIVE
EMISSION (EVAP)
CANISTER
(6) EVAPORATIVE EMISSION
CARBURETOR AIR VENT (EVAP CAV)
CONTROL VALVE
(ENGINE RUNNING)

,
,

,
t
(9) TO OPEN AIR

(8)
~

FRESH AIR
... FUEL VAPOR

(7) EVAP CAV CONTROL VALVE


(ENGINE STOPPED)

Noise Emission Control System


TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or
replacement, of any device or element of design incorporated into any new vehicle for the purposes of noise control
prior to its sale or delivery to the ultimate purchaser or while it is in use; or (2) the use of the vehicle after such device or
element of design has been removed or rendered inoperative by any person,

AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW:
1.
2.
3.
4.

Removal of, or puncturing the muffler, baffles, header pipes or any other component which conducts exhaust gases.
Removal of, or puncturing of any part of the intake system.
Lack of proper maintenance.
Replacing any moving parts of the vehicle, or parts of the exhaust or intake system, with parts other than those
specified by the manufacturer.

1-47

General Information

Emission Control Information


Labels (U.S.A. Only)
(1) UPDATE LABEL

An Emission Control Information Label is located on the


right side of the frame as shown. The seat must be removed to read it. it gives basic tune-up specifications.

Vehicle Emission Control Information Update


Label
After making a high altitude carburetor adjustment, attach
an update label on the left side of the frame as shown.
Instructions for obtaining the update label are given in
Service Letter No. 132.

{2} EMISSION CONTROL

INFORMATION LABEL
(3) VACUUM HOSE ROUTING

When readjusting the carburetors back to the low altitude


specifications, be sure to remove this update label.

DIAGRAM LABEL

Vacuum Hose Routing Diagram Label


('91-'93: Standard California type and U.S.A.

ABS/TCS type)
(After '93: California type)
The Vacuum Hose Routing Diagram Label is on the rear
fender as shown. The seat must be removed to read it.

'91-'93:

After '93:
VACUUM HOSE ROUTING DIAGRAM
ENGINE FAMILY
EVAPORATIVE FAMILY
CALIFORNIA VEHICLE
EIlP ,mE

C611iOL

1-48

iILIE~;~~~~~k~j~

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

...

Replace the partts] with new onets) before assembly.

Is :;O=ooLI

Use special tool

IOP~OOLI

Use optional tool. Use the same procedure you use to order parts.

Torque specification.

10 Nm (1.0 kg-m, 7.2 ft-lb)

10 (1.0, 7.2)

-:71

-,
..~

Use recommended engine oil, unless otherwise specified.

Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1

Use multi-purpose grease (Lithium based multi-purpose grease NLGI #2 or equivalent)

Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote BR-2 plus manufactured by Dow Corning, U.S.A.
Multi-purpose M-2 manufactured by Mitsubishi Oil Japan

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

Use silicone grease

Om

Apply a locking agent. Use a middle strength locking agent unless otherwise specified.

"I~

Apply sealant

Use brake fluid, DOT 3 or DOT 4. Use the recommended brake fluid, unless otherwise specified.

Use Fork or Suspension Fluid.

1) .

2. Frame/Body Panels/Exhaust System


Service Information

Seat
Side Cover

Saddlebag
Seat cowling
Saddle Bag Stay

Rear Fender
Lower fairing

Pivot Cover
Maintenance Cover
Top Shelter

2-1
2-2
22
2-2

Instrument Panel

2-6
2-6
2-7

Middle Fairing Inner Cover

2-7

2-3
2-3
2-4
2-4

Middle Fairing

2-8
28

2-5
2-5
2-5

Fuel Tank

Fairing Pocket
Windshield

Rearview Mirror
Upper Fairing
Front Fender (LBS-ABS/TCS model)

Muffler

Exhaust Pipe

2-9
2-11
2-12
2-13
2-18

Service Information
Gasoline is extremely flammable and explosive under certain conditions.
Serious burns may result if the exhaust system is not allowed to cool before components are removed or
serviced.
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.
This section covers removal and installation of the frame body panels, fuel tank and exhaust system.
Frame body panel installation is in the reverse order of removal, unless noted otherwise.
When removing the covers be careful not to damage any tabs or grooves on the covers.

2-1

..

Frame/Body Panels/Exhaust System

Seat
Unlock the seat with the ignition key.
Push the front of the seat and remove the seat by pulling
it rearward.

(2) HOLE
(1) TAB
I

h="

Install the seat by aligning the four tabs and one hole as
shown, and lock it by pushing it down securely.

(3) TAB

~:A _

,,;:;:::>,,;;

(4) SEAT

",,>,,::2"

.
/

Side Cover

(2) GROMMET

(1) BOSS

(3) CENTER

Remove the seat.

STAND GRIP

Remove the attaching screw and trim clip, and release the
three bosses from the grommets, being careful not to
damage the tab. Remove the side cover.

NOTE
On the left side cover, pull the center stand grip outward when removing the cover.

~. ~\\-k~

(7) TRIM'

(4) TAB

CLIP

(6) SCREW

(5) SIDE COVER

Saddlebag
(1) SADDLEBAG

Unlock the saddlebag lock lever with the ignition key.


Release the saddlebag hook by pulling the lock lever.
Slide the saddle bag rearward and raise it slightly to remove
it.

\
(3) LOCK LEVER
(2) HOOK

2-2

Frame/Body Panels/Exhaust System

Seat Cowling
Remove the left and right side covers and saddle bags.
Remove the four socket head caps.
Remove the four socket bolts, two 8 mm bolts and the left
and right grab rails.
Remove the two 6 mm bolts, ground terminal {After '95)
and collars, disconnect the tail/brake light connector, and
remove the seat cowling.
Torque:
Grab rail bolts: 27 Nm ( 2.7 kg-m, 20 ft-Ib)
(8) SEAT

COWLl~~/
(5) GRAB
RAil

(6) CONNECTOR

(7) GROUND
TERMINAL
(After '95)

Saddlebag Stay
Remove the seat cowling.
Remove the four 8 mm bolts and the grab rail center plate.
Remove the two 6 mm bolts, one 8 mm bolt and the saddlebag stay.

(2) CENTER PLATE

(1) 8 mm BOLTS

~~

(7) 8 mm NUT

Torque:
Center plate 8 mm bolt: 35 N'm (3.5 kg-m, 25 ft-lb}
Saddlebag stay 6 mm bolt: 10 Nrm (1.0 kg-m, 7 ft-Ib)
8 mm bolt: 35 N'm (3.5 kg-m, 25 ft-Ib)
'-';';l

'\131;~~
\

(6) SADDLEBAG STAY

(4) 8mm BOLT

(5) 6 mm BOLT

2-3

Frame/Body Panels/Exhaust System

Rear Fender
Remove the battery (page 17-7).
Remove the left and right saddlebag stays (page 2-3).
Remove the four socket bolts, rear fender B and the saddlebag stay stopper.
Remove the starter motor cable from the starter relay
switch, and remove the starter relay switch from the rear
fender A.
Remove the three bolts and the battery holder.
Remove the fuse case (s}.
Remove the two bolts and the center stand grip.
Remove the two mounting bolts and rear fender A.

(2} REAR FENDER A

(3) REAR FENDER B

Torque:
Center stand grip bolt: 10 Nom (1.0 kg-m. 7 ft-Ib)

(1) FUSE CASE --~7'f?-

(9) ABS FUSE CASE


{ABS/TCS or LBSABS/TCS MODEL) ---A~-~

(6) BAITERY HOLDER

(7) STARTER RELAY SWITCH

Lower Fairing
Remove the nine socket bolts and the lower fairing.

(2) SOCKET BOLT

2-4

Frame/Body Panels/Exhaust System

Pivot Cover
Remove the side cover (page 2-2).
Remove the three socket bolts and the pivot cover.

{2l PIVOT COVER

Maintenance Cover

(1) MAINTENANCE COVER

Remove the two screws.


Release the four tabs by sliding the maintenance cover
rearward and remove the cover.

(2) TABS
(3) SCREWS

Top Shelter

(11 TOP SHELTER

(2l SCREWS

\,

\~
.

Remove the left and right side covers (page 2-2).


Remove the two screws, two bolts and the top shelter.

(3) BOLTS

2-5

Frame/Body Panels/Exhaust System

Fairing Pocket

(2) SCREWS

Remove the maintenance cover (page 2-5).


Remove the top shelter (page 2-5).
Remove the six screws and the fairing pocket.

(3) SCREW

(4) SCREW

ABS/TCS or LBS-ABSfTCS model:


Remove the maintenance cover (page 2-5).
Remove the top shelter (page 2-5).

Remove the six screws.


Disconnect the two connectors and left fairing pocket.

(1) FAIRING POCKET

(5) SCREWS
(2) SCREW

NOTE
The TCS OFF indicator turns on when the TCS switch
connector is disconnected and then reconnected with
the ignition switch ON. The TCS can be reactivated
by pushing the TCS switch.
(4) SCREW

(3) CONNECTORS

Windshield
Remove the five screws and the windshield.
Remove the two screws and trim clip attaching the
windshield garnish.
Release the four tabs and remove the windshield garnish
from the upper fairing.

(1)

W'NDSH~:'E~L~D~====l

'91-'95:

~J.~
,

(2) TABS

(3) TRIM CLIP

(4) GARNISH

2-6

Frame/Body Panels/Exhaust System


After '95:

~-- \___________:111 WINDSHIELD

~II --@)~

(7) SCREW

(6) PLASTIC

WASHER

Oi

(2) TABS

(5) SElTlNG

RUBBER

(3) TRIM CLIP

(4) GARNISH

Instrument Panel

(1) SCREWS

Remove the windshield and garnish (page 2-6).


Remove the four screws and the inner screen.

(2) INNER SCREEN

Remove the left and right fairing pockets (page 2-6).

(1) INSTRUMENT PANEl

(2) SET WASHER


(3) SET

Disconnect the clock connectors under the instruments.

SCREW
~/,

NOTE

Adjust the clock after installing the instrument panel.

Remove the set screw, set washer and the headlight


adjuster knob.
Remove the headlight adjuster cable from the instrument
panel by removing the plastic nut, rubber washer and
washer.
Remove the two screws, release the four tabs and remove
the instrument panel from the upper fairing.

(4) ADJUSTER

KNOB
(7) WASHER

{S) ADJUSTER CABLE

(5) NUT

(6) RUBBER
WASHER

2-7

Frame/Body Panels/Exhaust System

Middle Fairing Inner Cover

(1) MIDDLE FAIRING INNER COVER

<:

Disconnect the speedometer cable from the front wheel by


removing the cable set screw.
Remove the two trim clips from the middle fairing by
pulling them out.
Remove the six screws and the middle fairing inner-cover.

(4) TRIM CLIP


(3) SPEEDOMETER CABLE

Middle Fairing

ABS/TCS model shown:


(1) SOCKET BOLT

Remove the following:


- middle fairing inner cover (page 2-7)
-left and right fairing pockets (page 2-6)
-lower fairing (page 2-4).
Remove the socket bolt, three screws. trim clip, three
bolts and the middle fairing
NOTE
At installation, align the boss of the middle fairing with
the hole of the upper fairing properly.
(5) SCREWS

(4) MIDDLE FAIRING

(2) CLIP

Rearview Mirror
Remove the rearview mirror case by carefully releasing the
three bosses from the clips of the upper fairing.
Disconnect the front turn signal connector.
Remove the trim clip and the mirror cover inside spacer.
Remove the two bolts and the rearvtew mirror.

(3) CONNECTOR
(4) MIRROR
(5) MIRROR CASE

2-8

Frame/Body Panels/Exhaust System

Upper Fairing
Removal/Installation

121

151

131

161
181

Requisite Service
Middle fairing inner cover (page 2-7).

Left and right rear view mirrors (page 2-8).


Instrument panel (page 2-7).

Procedure

Remarks

O'tv

Installation is in the reverse order of removal.

Removal Order

111 Air duct


121 Headlight connector
131 Position light connector
141 Trim clip
151 Screw
161 Socket bolt
171 Bolt/collar
181 Upper fairing

1
2
1
2
4
2
4/2
1

I
At installation, align the holes in the headlight with the
mounting bosses of the fairing stay.

2-9

Frame/Body Panels/Exhaust System


Diassembly/ Assembly
(4)

(7)

(t)

/
,
,
,
,
,
,
,
,
,
,

(4)

(2)

Requisite Service
. Upper fairing removal/installation (page 2-9).

Procedure
(1 )

(2)
(3)

(4)
(5)
(6)
(7)

Disassembly Order
Socket bolt/nut
Bolt
Headlight
Bolt/nut
Upper fairing
Screw
Air duct

2-10

a:ty

Remarks
Assembly is in the reverse order of disassembly.

2/2
2
1
1/1

2
2
1

Frame/Body Panels/Exhaust System

Front Fender (LBSABS/TCS model)


Brake pipe

(2)_=_

===---:!

'_~

i__ ,.j

I.

Tabs
Studs

(4)

-~IIII' / , , '
Setting bosses

NOTE

I On the standard and ABSfTCS model, refer to page 13-6 "Front wheel removal/installation".

Procedure

(3)

Removal Order
Socket bolt
Flange bolt/washer
Upper fender

(4)

Lower fender

(1)

(2)

Q'ty

Remarks
Installation is in the reverse order of removal.

2
2/2
1
1

When installing, align the cutouts with the tabs on the


fender side covers.
When installing, insert the fender end between the brake
pipe and fender plate, and align the holes in the lower
fenderwith the bolt hole studs and setting bosses on the
fender plate.

2-11

Frame/Body Panels/Exhaust System

FuelTank

'4

....._ - ( 7 )

(2)

(8)

12 (1.2. 9)

Gasoline is extremely flammable and is explosive under certain conditions.

Requisite Service

Air cleaner housing removal/installation (page 5-10)


Procedure
Removal Order

111 Fuel tank breather tube


(2)
(3)
(4)

(51
(61
171
(8)

(9)

Fuel
Fuel
Fuel
Fuel
Fuel
Fuel
Fuel
Fuel

2-12

line
pump connector
level sensor connector
fill cap
tank tray
tank mounting bolt
tank
tank heat protector

Q'ty

,,
,,

1
4

,
1

Remarks
Installation is in the reverse order of removal.
Remove from the fuel fill cap and clamp.

Frame/Body Panels/Exhaust System

Muffler
Right Muffler: Standard Model

--

11 )

22 (2.2, 16)

141

131

15)

16)

35 (3.5, 25)

-(2)

17)---\il

27 (2.7, 20)

27 (2.7, 20)

Do not service the exhaust system while it is hot.

Requisite Service

Right pivot cover removal/installation (page 2-5)


Q'ty

Procedure

111
12)
13)
14)
15)
16)
171
181

Removal Order
Muffler band
Muffler mounting bolt
Right footpeg holder bolt 6 mm

8 mm
10 mm

,,

Remarks
Installation is in the reverse order of removal.
Loosen the band bolts.

Right footpeg holder

Right muffler
Gasket

,,

.
.

Remove with the master cylinder and rear brake light


switch installed.
Support with a piece of string.

2-13

Frame/Body Panels/Exhaust System

-.

(9)

Do not service the exhaust system while it is hot.

Requisite Service
Right pivot cover removal/installation (page 2-5)

Procedure

(1)

(2)
(3)
(4}
(5}
(6}
(7)

(8)

Removal Order
Harness band
Connector
Muffler band
Muffler mounting bolt
Right footpeg holder bolt 6 mm
8 mm
10 mm
Right footpeg holder

(9) Right muffler


(10) Gasket

2-14

Q'ty

Remarks

Installation is in the reverse order of removal.


Loosen the band.

3
2

Loosen the band bolts.

1
1
1
2

1
1

Remove with the master cylinder and rear brake light


switch installed.
Support with a piece of string.

Frame/Body Panels/Exhaust System

Right Muffler: LBS-ABS/TCS Model

(1)

.'~~ tt;~-~

- ,7 ;~ ,/
--,.- ',', ' ,
,

022 (2.2, 16)

"'10../

'-

tII(S)

cc-. ic~:::;~('"

LBS-ABS/TCS model only


(5)

<:~~

-,"

(7)

(3)
(8)

0 2 7 (2.7, 20)

027 (2.7, 20)

(2)

""'r
(6)

35 (3.5, 25)

Requisite Service
Right pivot cover removal/installation (page 2-5).
Procedure

Q'ty

(4)

Removal Order
Muffler band
Modulator mounting bolt
Muffler mounting bolt
Right step holder bolt 6 mm

(5)

8mm

1
1
1

10 mm

(1)
(2)
(3)

(6)

Remarks
Installation is in the reverse order of removal.
Loosen the band bolts.

2
3

(7)

Right step holder

(8)

Right muffler
Gasket

1
1

.
(S)

Remove with the master cylinder and rear brake light


switch installed.
Support with a piece of string .

2-15

Frame/Body Panels/Exhaust System

.,

Left Muffler: '91-'95

12)

(9)

(11

(5)

(4)

22 (2.2, 16)

C~,
27 (2.7, 20)

(6)

17)

35 (3.5, 25)

(8)

Requisite Service
Left pivot cover removal/installation (page 2-5)
Battery removal/installation (page 17-12)
Q'ty

Procedure

111
(2)
(3)
(4)

(5)
(6)
(7)
(8)

19)

Removal Order
Muffler band
Battery holder bolt
Muffler mounting bolt
Left footpeg holder bolt 6 mm
8 mm
10 mm
left footpeg holder
left muffler
Gasket

2-16

2
2

Remarks
Installation is in the reverse order of removal.
loosen the band bolts.

1
1
1
2

1
1
1

Support with a piece of string.

Frame/Body Panels/Exhaust System

Left Muffler: After '95 i4)

(11)

erJ

(2)

27 (2,7, 20)

(8)

o /----------

(9)

(10)

35 (3.5, 25)

Requisite Service
Left pivot cover removal/installation (page 2-5).
Battery removal/installation (page 17-12).
Procedure
(1)
(2)
[3)

[4)
[5)

[6)
[7)
[8)
[9)

(10)
(11 )

,
,
!

Removal Order
Alternator fuse cover
Bolt/fuse base plate
Battery holder bolt
Muffler band
Muffler mounting bolt
Left step holder bolt 6 mm
8mm
10 mm
Left step holder
Left muffler
Gasket

Q'ty

,
!

,
,
!

Remarks
Installation is in the reverse order of removal.

1
2/1
2
2
1
1
1
2
1
1
1

Loosen the band bolts.

,
,

2-17

Frame/Body Panels/Exhaust System

Exhaust Pipe
Right Exhaust Pipe

f!I
110)
.2, g)

18)

17 (1.7,12)

22 (2.2, 16)

(11)

f!I

161

191

Do not service the exhaust system while it is hot.

Requisite Service
Right middle fairing removal/installation (page 2-8)

Procedure

AB$/TC$ or LB$-ABS/TCS Model:


Radiator reserve tank removal/installation (page 6-9)
Q'ty

Installation is in the reverse order of removal.

Removal Order

111 Lower engine mounting nut


12) Bolt

131
141
151
161
17)
18)

191
1101
('

Right engine guard


Bolt
Protector gasket
Right exhaust pipe protector
Exhaust pipe band
Exhaust pipe joint nut
Right exhaust pipe
Exhaust pipe gasket
Exhaust chamber gasket

2-18

Remarks

1
2

4
5

1
1

4
1
2

Loosen the band bolt.

Frame/Body Panels/Exhaust System


left Exhaust Pipe

o
151

(7)

1121
17 (1.7,12)

(61

141

E): 22 (2.2,16)

IBI

I~
(1)~

55 (5.5, 40)

~111
C
(21

27 (2.7, 20)

Requisite Service
Left middle fairing removal/installation (page 2-8)
Right exhaust muffler removal/installation (page 2-14)
Procedure

11)
(21
13)
141
15)
(6)

171

IBI
191
1101
(11):
(12}1

Removal Order
Bolt
Left engine guard
Bolt
Protector gasket
Left exhaust pipe protector
Muffler band
Exhaust pipe joint nut
8 mm mounting bolt/washer
Left exhaust pipe/,chamber
Exhaust pipe gasket
Muffler gasket
Mounting collar

O'tv

Remarks
Installation is in the reverse order of removal.

2
1
4
5
1
4

'B

Loosen the band bolts.


Installation (page 2-20)

2
2
1

2-19

Frame/Body Panels/Exhaust System


Exhaust Pipe Installation
1. Make sure that the mounting collar is installed in
position. Loosely install the left exhaust pipe/
chamber to the frame with the 8 mm mounting bolt
and washer.

2. Make sure that the exhaust pipe gaskets are


installed in position, insert the left exhaust pipe
flanges into the cylinder head and loosely install the
joint nuts.

3. Insert the right exhaust pipe into the left eshaust


pipe/chamber.

4. Make sure that the exhaust pipe gaskets are


installed in position. Insert the right exhaust pipe
flanges into the cylinder head and loosely install the
joint nuts.

5. Tighten each pair of the joint nuts in 3 steps as


follows:
A. Temporarily tighten either nut to 10 Nvrn (1.0
kg-m, g ft-Ib).
B. Tighten the other nut to the specified torque.
Torque: 17 N'm (1.7 kg-m, 12 tt.lbl

C. Tighten the nut temporarily tightened in step A


to the specified torque.

6. Tighten the exhaust pipe band.


Torque: 22 N'm (2.2 kg-m, 16 ttlb)

7. Tighten the 8 mm mounting bolt.


(1) JOINT NUT

(2) RIGHT EXHAUST PIPE

~SJt(JJ-/,~;;--

-!

(3) MOUNTING
COLLAR

(6) LEFT EXHAUST PIPE/CHAMBER

2-20

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

...

Replace the partts] with new onets) before assembly.

Is :;O=ooLI

Use special tool

IOP~OOLI

Use optional tool. Use the same procedure you use to order parts.

Torque specification.

10 Nm (1.0 kg-m, 7.2 ft-lb)

10 (1.0, 7.2)

-:71

-,
..~

Use recommended engine oil, unless otherwise specified.

Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1

Use multi-purpose grease (Lithium based multi-purpose grease NLGI #2 or equivalent)

Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote BR-2 plus manufactured by Dow Corning, U.S.A.
MUlti-purpose M-2 manufactured by Mitsubishi Oil Japan

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

Use silicone grease

Om

Apply a locking agent. Use a middle strength locking agent unless otherwise specified.

"I~

Apply sealant

Use brake fluid, DOT 3 or DOT 4. Use the recommended brake fluid, unless otherwise specified.

Use Fork or Suspension Fluid.

1) .

3. Maintenance
3-9

Service Information

3-1

Carburetor Synchronization

Service Access Guide

3-2

Engine Idle Speed

3-11

Maintenance Schedule

3-4

Radiator Coolant

3-11

Air Cleaner

Timing Belt

3-12

Spark Plugs

3-6
3-6

Brake Fluid

3-12

Valve Clearance

3-6

Brake System ILBS-ABSrrCS model)

3-13

Engine Oil

3-8

Headlight Aim

3-14

Service Information
Rafer to Common Service Manual for service procedures on items not included in this manual.
Refer to specifications (Section 1) for maintenance service data.

3-1

III

Maintenance

Service Access Guide


The following shows the locations of the parts that must be removed for the maintenance items listed below, Refer to
the Common Service Manual for items not included in this manual.
Refer to section 2 (frame/body panels/exhaust system), for the parts that must be removed for service.
For example: AIR CLEANER (Contamination, clogging, replacement) - Maintenance part (service items)
Top shelter - The parts that must be removed for service.
ABS/TCS model shown:

(4) SPARK PLUG


(Wear, damage, color: page 3-6)
(5) THROTILE GRIP (Operation, free play)

(3) THROTILE STOP CONTROL KNOB


(Idle speed adjustment: page 3-10)
(2) FUEL LINE (Damage. leakage)
Top shelter
(1) BRAKE RESERVOIR
(Level check: page 3-10, fluid replacement
[LBS-ABS/TCS: page 15-2])

(6) BRAKE MASTER CYLINDER


(Level chek, fluid replacement
[LBS-ABS/TCS: page 15-2])
(7) HEADLIGHT ADJUSTING KNOB
(Aim' page 3-14)
(B) BRAKE LEVER
(Air in system)
(9) STEERING HEAD
BEARING (Damage)

(24) FINAL DRIVE


(Oil level check)
(23) SUSPENSION
(Loose, wear, damage)
(22) BRAKE HOSE (Leakage,
degradation, damage)
Side cover
(21) RESERVE TANK
[Standard model]
(Coolant level: page 3-11)
(20) BRAKE LIGHT SWITCH (Operation)
(19) BRAKE PEDAL (Air bubbles in system)
(18) FUEL FILTER (Clogging)
Top shelter
--

3-2

(11) TIRE (Wear,


damage, pressure)
(12) WHEEL (Damage, runout,
corrosion)
(13) BRAKE HOSE (Leakage,
degradation, damage)
Middle fairing inner cover.
(14) EVAP PURGE CONTROL VALVE and
EVAP CAV CONTROL VALVE
(Damage, faulty hose: page 5-17)
(15) OIL FILLER CAP
(Oil adding, replacement: page 3-9)
(16) OIL LEVEL INSPECTION WINDOW
(Level check: page 3-8)
(17) RESERVE TANK [ABS;TCS model]
(Coolant level: page 3-11)

Maintenance
ABS/TCS model shown

(6) PAIR CONTROL VALVE


(Damage, faulty hose: page 5-17)

(7) AIR CLEANER


(Contamination, clogging, replacement: page 3-6)
(B) SYNCHRONIZATION ADJUSTING SCREW
(Synchronization: page 3-9)

(5} CARBURETOR CHOKE (Operation)

(4) CLUTCH MASTER CYLINDER


(Level check, fluid replacement)

(3) CLUTCH LEVER


(Air in system)

(9) BRAKE HOSE


(Leakage, degradation,
damage)

(10) BRAKE CALIPER


(Pad wear)
Left saddle bag

(2) HEADLIGHT
ADJUSTING SCREW
(Aim: page 3-14)

(1) SUSPENSION
(Loose, wear, damage)

(19) TIMING HOLE COVER (Ignition timing)


Lower fairing

(1 B) TIMING BELT (Cracks, damage,


contamination: page 3- 12)

(17) RADIATOR HOSE


(Leakage, degradation, damage)

(16) OIL DRAIN BOLT


(Oil replacement: page 3-B)

(11) TIRE (Wear,


damage, pressure)

(12) WHEEL (Damage,


runout. corrosion)

(13) SIDE STAND (Operation)

(15) VALVE CLEARANCE (page 3-6)

(14) OIL FILTER


(Replacement: page 3-8)

3-3

Maintenance

Maintenance Schedule
'91-'94
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.
R: Replace C: Clean l: lubricate A: Adjust
The following items require some mechanical knowledge. Certain items (particularly those marked > and U) may require
more technical information and tools. Consult an authorized Honda dealer.

~y

...

Whichever
comes
first
Note

Fuel line
Throttle Operation

xl,OOOmi 0.6
x 100 km

Item

Odometer Reading (Note 1)

10

Months

.'"

c
0

"Es

ur

..
~

a:

c
0

sn

c,
0

I"
I..

Note 5

36

3 6
3-6
38

Engine Oil Filter

R
I

Carburetor Synchronization

Engine Idle Speed

Note 6

Evaporative Emission Control System

Note 4

3-11

3-11

Note 5

Note 5

Note 5

Cooling System
Secondary Air Supply System

Timing Belt

I Every 60,000 mt (96,000 km}


REvery 90,000 mi (144,000 krn]

3-12

Note 5

Note 5.3-12

I
Note 3

3-8
3-9

Note 3

Note 5

Note 5,3 13

Brake light Switch

Note 5

Headlight Aim

3-14

Clutch System

Note 3

, Suspension
Nuts, Bolts, Fasteners

Wheels/Tires
Steering Head Bearings

I
I

Side Stand

Clutch Fluid

"E

Engine Oil

' Brake System

Note 5

Brake Pads Wear

"-c

Note 5

Valve Clearance

Brake Fluid

"

Final Drive Oil

R
I

Radiator Coolant

Note 2

Spark Plugs

"

"-c

12
16
20 24
8
Refer to
128 192 256 320 384
page
12 , 18
24 30 36

Carburetor Choke
Air Cleaner

4
64
6

Note 5

Note 5

Note 5

Note 5

Note 5

Note 5

Note 5

Should be serviced by your authorized Honda dealer, unless the owner has proper tools and service data and is mechanically
qualified.
*" In the interest of safety, we recommend these items be serviced only by your authorized Honda dealer.
Notes: 1. At higher odometer readings, repeat at the frequency interval established here.
2. Service more frequently when riding in unusually wet or dusty areas.
3. Replace every 2 years, or at indicated odometer interval, whichever comes first. Replacement requires mechanical skill.
4. '91-'93: Standard California type and U S.A. ABS/TCS type.
'94: California type.
5. Refer to Common Service Manual.
6. All U.S.A. types.

3-4

Maintenance
After '94
Perlorm the PRE-RIDE INSPECTION in the Owner's Manual at each scheduled maintenance period.
I: Inspect and clean, adjust, lubricate, or replace if necessary.
R: Replace C: Clean L: Lubricate A: Adjust
The following items require some mechanical knowledge. Certain items (particularly those marked * and "*) may require
more technical information and tools. Consult an authorized Honda dealer.

~y

Fuel Line

"eE

64
6

10

Months

Carburetor Choke
I

Note 5

Note 5

Note 5

R
R

36
3-6

3-6
3-8

R
R

Engine Oil

Engine Oil Filter

Carburetor Synchronization
Engine Idle Speed

, Evaporative Emission Control System

I
I,

Note 3

Cooling System
Secondary Air Supply System

Note 6

I
I

3-8
3-9

3-11

3-11

Note 5

Note 5

Note 5

Note 4

Timing Belt

Brake Fluid

3-12

I Every 60,000 mi (96,000 km)


REvery 90,000 mi (144,000 km]

Final Drive Oil

I
I

Note 2

Valve Clearance

Radiator Coolant

; Spark Plugs

'"c

Note

12
16 20 24
8
Refer to
128 192 256 320 I 384
page
12
18 I 24
30 36

0.6 I 4

x 1,000 mi

Throttle Operation
Air Cleaner

"-o
.s

Odometer Reading (Note 1)

x 100 km

Item

..

Whichever
comes
first

I
Note 3

Brake Pads Wear

Note 5

Note 5,3-12

Note 5

Note 5,3-13

Brake Light Switch

Note 5

Headlight Aim

3-14

Clutch System

Note 5

"
E

Clutch Fluid

Brake System

"-o

-.
'"
~

c,
0

Note 3

Side Stand

..

..

Suspension

Nuts, Bolts, Fasteners

WheelslTires
Steering Head Bearings

: Note 5

Note 5

Note 5

Note 5

Note 5

Note 5

Should be serviced by your authorized Honda dealer, unless the owner has propertoofs and service data and is mechanically
qualified .
.. In the interest of safety, we recommend these items be serviced only by your authorized Honda dealer.
Notes: 1. At higher odometer readings, repeat at the frequency interval established here.
2. Service more frequently when riding in unusually wet or dusty areas.
3. Replace every 2 years. or at indicated odometer interval, whichever comes first. Replacement requires mechanical skill.
4. California type.
5. Refer to Common Service Manual.
6. All U.S.A. types.

3-5

Maintenance

Air Cleaner
Remove the top shelter (page 2-5).
Remove the eight screws and the air cleaner housing
cover.
Remove the air cleaner and discard it.
Install a new air cleaner and the removed parts in the
reverse order of removal.
Torque:Housing cover screw:
0.9 N.m (0.09 kg-m, 0.65 ft-Ib)

(1) AIR CLEANER


HOUSING COVERT5='~

"""=7'

(2) SCREW--(3) AIR CLEANER

Spark Plugs
Remove the maintenance cover (page 2-5).
Disconnect the spark plug caps and clean any dirt from
around the spark plug bases.
Remove the spark plugs.
Visually inspect the spark plug electrodes for wear. The
center electrode should have square edges and the side
electrode should have a constant thickness. Discard the
spark plug if there is apparent wear or if the insulator is
cracked or chipped.
For recommended spark plug, see page 1-15.
Measure the spark plug gaps using a wire-type feeler
gauge.
Spark plug gap: 0.8-0.9 mm (0.031-0.035 in)

0.B-0.9 mm
(0.031-0.035 in)

(1) SIDE
ELECTRODE

1
i

If necessary, adjust the gap by carefully bending the side


electrode.
Install the spark plugs.
T

Torque: 11 N-m (1.1 kg-m, 8 ft-lb]

__U-__

Connect the spark plug caps and install the maintenance


cover (page 2-5).

Valve Clearance
Inspection
NOTE
Inspect and adjust valve clearance while the engine is
cold (below 35'C/95F)
Remove the cylinder head covers (page 8-2).
Remove the timing hole cover.

3-6

(1) TIMING HOLE COVER

Maintenance
Turn the crankshaft clockwise and align the T1 mark on
the timing belt drive pulley guide plate with the timing
belt cover Index mark.

Make sure the No.1 piston is at Top Dead Center (TDC)


on the compression stroke and the RIGHT camshaft index
lines align with the top of the cylinder head and face
OUT as shown.

(1) INDEX MARK

(2) T1 MARK

If the No. 1 piston is not at TDC on the compression


stroke, turn the crankshaft clockwise one full turn and
realign the T1 mark with the index mark.
Measure the No. 1 cylinder valve clearances for the
intake and exhaust valves by inserting a feeler gauge
between the cam lobes and the valve lifters.
Valva clearance:
IN: 0.13-0.19 mm (0.005-0.007 in)
EX: 0.22-0.28 mm (0.009-0.11 in)
Record the clearance for each valve for reference, if shim
selection is needed.
(1) INDEX LINE {FACING OUT)

Turn the crankshaft clockwise 1/4 turn to align the T4


mark with the index mark. The LEFT camshaft index lines
should align with the top of the cylinder head and face
IN.
Measure and record the No.4 cylinder valve clearances.
Turn the crankshaft clockwise 3/4 turn to align the T1
mark. The RIGHT camshaft index lines should align with
the top of the cylinder head and face IN.
Measure and record the No.3 cylinder valve clearances.
Turn the crankshaft clockwise 1/4 turn to align the T4
mark. The LEFT camshaft index lines should align with
the top of the cylinder head and face OUT.
Measure and record the No.2 cylinder valve clearances.

(1) FEELER GAUGE

Shim Selection
If the valve clearance is not correct:
Remove the camshaft (page 8-4), valve lifter and shim
(page 8-8).
NOTE
Be careful not to allow the shims to fall into the
crankcase. The shim may occasionally stick to the
valve lifter.
Mark the positions of all valve lifters and shims to
ensure correct reassembly.
Remove the shim with tweezers or a magnet.
Clean the valve lifter with compressed air.

3-7

Maintenance
Clean the shim with a clean shop towel.
Measure the shim thickness with a micrometer and record
it.

(1) SHIM

NOTE

Sixty-five different shims are available in thickness


intervals of 0.025 mm. The thinnest is 1.200 mm
and the thickest is 2. BOO mm.
To select' the shim needed to bring the valve clearance
within the specification, use the following formula:
a=b-c+d
a: new shim thickness
b: recorded valve clearance
c: specified valve clearance
d: old shim thickness
Example
b: recorded valve clearance = 0.18 rnm
c: specified valve clearance = 0.16 mm
d: old shim thickness = 1.850 mm
a=0.18-0.16+ 1.850
a = 1.B70
New shim thickness = 1.875 mm
NOTE
If the required thickness of the new shim is more than
2.800 mm, the valve seat is probably heavily
carboned. Reface the seat, recheck valve clearance
and reselect the shim.

Engine Oil
Engine Oil and Filter Change
CAUTION
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.

NOTE
Change the engine oil with the engine warm and the
motorcycle on its center stand to assure complete
and rapid draining.
Remove the lower fairing (page 2-4).
Remove the oil filler cap and oil drain bolt. and drain the
engine oil.
Remove the oil filter with the special tool and let the remaining oil drain out. Discard the oil filter.

Is ';""OOL I
Oil filter wrench

3-8

07HAA-PJ70100

'91-'95 shown:
(1) OIL FILTER

Maintenance
Apply a thin coat of engine oil to the O-ring on the new
oil filter.
Install the oil filter and tighten it with an oil filter wrench.
Torque: 10 N"m (1.0 kg-m. 7 tt-tb]
Check that the sealing washer on the drain bolt is in good
condition. Install the drain bolt and tighten it.
Torque: 38 Nom (3.8 kg-m. 27 ft-Ib)

(1) O-RING

Fill the crankcase with the recommended engine oil (page


1-7).
Install the oil filler cap.

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


Stop the engine. After a few minutes, check the oil level
inspection window,
The oil level should be between the upper and lower level
marks.

......~--/

(1) OIL LEVEL INSPECTION


WINDOW

(2) UPPER
rJ.:J!;;~1 LEVEL

ll),.<;;;;l.iI=L I3 J LOWER
LEVEL

If required, remove the filler cap, and add the specified


oil up to the upper level mark. Do not overfill.

(1) OIL FILLER

CAP

Carburetor Synchronization
NOTE
Refer to section 2 of Common Service Manual for
carburetor synchronization procedure.
Synchronize the carburetor with the engine at normal
operating temperature. the transmission in neutral and
the motorcycle supported upright.

(1) No.3 CYLINDER VACUUM TUBE

Remove the left and right fairing pockets (page 2-6).


Disconnect the NO.3 cylinder vacuum tube from the auto
fuel valve, apply vacuum to the auto fuel valve and pinch
the tube with a clamp.
Connect the vacuum gauge adaptor to the No.3 cylinder
vacuum tube.

3-9

Maintenance
(All U.S.A. types)
Disconnect the NO.2 and 4 cylinder vacuum tubes at the
3-way joint, and connect the vacuum gauge adaptors.

U.S.A.TYPE

(1) 3-WAY JOINT

{Canada type}
Remove the vacuum tube caps from the No. 2 and 4
cylinder vacuum tubes and install the vacuum gauge
adaptor tubes.

'91-'93:
(Standard California type and U.S.A. ABS/TCS type)
After '93:
(California type)
Disconnect the No. 1 cylinder vacuum tube from the
EVAP CAY control valve apply vacuum to the EVAP CAY
control valve and pinch the tube with a clamp.

(1) EVAP CAY


CONTROL VALVE

. '

~
"

r).

:-\ ' , _
_~

Connect the vacuum gauge adaptor to the No.1 cylinder


vacuum tube.

fO

"" 'cL

'---~

I
,

"I

,~-./iJl

L~;~Wlli
,

II

I.

(2) No.1 CYLINDER VACUUM TUBE

'91-'93:
(Standard 49 state and Canada type)
After '93:
(49 state and Canada type}
Remove the vacuum joint tube cap from the No.1 cylinder
vacuum tube and install the vacuum gauge adaptor tube.

(1) No.1 CYLINDER VACUUM TUBE

.>:

~::Q\'
\.

~~.

" "'~
~~

". a

,--~',

~----

---

-f
~

=--

(2) PLUG

NOTE

The base carburetor is the NO.4 carburetor.

I,

1(1) SYNCHRONIZATION ADJUSTING SCREW

~~---

" \ ' \ ' \ \ \ '\ '\

, ,

Adjust the carburetor synchronization by turning the


synchronization adjusting screw.

<,

(2) RIGHT SIDE

3-10

(3) LEFT SIDE

Maintenance

Engine Idle Speed

(1) THROTILE STOP CONTROL KNOB

NOTE
Inspect and adjust idle speed after all other engine
adjustments are within specifications.
Engine must be warm for accurate adjustment. Ten
minutes of stop-end-go riding is sufficient.
Warm up the engine, shift the transmission into neutral
and place the motorcycle on its center stand.
Open the top shelter lid with the ignition key.
Adjust the idle speed by turning the throttle stop control
knob.
Idle speed:1.200 100 rpm
1,000 100 rpm (Canada typel

./

STANDARD MODEl:
(1) RESERVE TANK

(2) TOP SHELTER LID

(3) RUBBER PROTECTOR

/!)~
~!lJl ~

Radiator Coolant
Check the coolant level in the reserve tank while the
engine is at normal operating temperature.
The level should be between the UPPER and LOWER level
lines.

iJ,4cc;/

/(!:)-'-

, / -' ' /

/ / ~/' :0;-\__

<\

./-

(2) UPPER LEVEL LINE

ABS/TCS MODEL:

i (1) UPPER LEVEL

/~-Aq:.~h
~

(4) LOWER LEVEL LINE

(2) RESERVE TANK

L1~4~~~.
/ /.

' - --=-----=-------=---.-----=--

(Standard Model)
If the level is low, remove the right side cover (page 2-2),
remove the filler cap and add the recommended coolant to
the UPPER level line.
NOTE

Do not remove the rubber protector.

For coolant draining/refilling, see section 6.

(1) RESERVE TANK

3-11

Maintenance
(ABS/TCS or LBS-ABS/TCS model)
If the level is low, remove the right maintenance cover
(page 2-5), remove the filler cap and add the recommended
coolant the UPPER level line.
For coolant draining/refilling, see section 6.

(1) RESERVE TANK


/

Timing Belt
(1) TIMING BELT
Remove the reduction holder covers (page 8-2).
Remove the timing hole cover (page 3-5).
Check the timing belt for cracking, damage or contamination with oil and/or coolant while turning the crankshaft
clockwise.
If the belt is cracked or damaged, replace it with a new
one (page 8-12).
If the belt is contaminated with oil and/or coolant, remove
the timing belt cover (page 8-3). Clean the timing belt
housing and pulleys thoroughly, then replace the belt with
a new one.

Brake Fluid

(1) UPPER LEVEL

NOTE
For front brake fluid level checking and fluid
replacement, refer to the Common Service Manual.
For fluid replacement on the LBS-ABS/TCS model,
see page 15-2.
(2) LOWER LEVEL

Rear Brake Fluid Level


Remove the right saddlebag (page 2-2).
Check the fluid level by viewing from the rear as shown.
The level should be between the UPPER and LOWER level
lines.

3-12

Maintenance

Brake System (lBS-ABS/TCS model)


NOTE
The LBS-ABS{TCS brake pedal operation should be
inspected as described below.
The lever brake line of the LBS-ABS/TCS model
should be inspected in the same manner as the lever
brake line of the standard model and the ABS/TCS
model.

(1) SECONDARY
MASTER
CYLINDER

Place the motorcycle on its center stand and shift the


transmission into neutral.
Push the secondary master cylinder by pressing the left
front caliper.
The rear wheel should not be able to rotate when the
secondary master cylinder is pushed forward.

(2) BRAKE PEDAL

Also check the smooth operation of the brake linkage.


The rear wheel should not be able to rotate when the brake
pedal is pressed.

Raise the front wheel off the ground by supporting the


engine.
The front wheel should not be able to rotate when the
brake pedal is pressed.

(1) BRAKE
PEDAL

(2) FRONT WHEEL

3-13

Maintenance

Headlight Aim
An improperly adjusted headlight may blind
on-coming drivers, or it may fail to light the road
for a safe distance.
Place the motorcycle on a level surface.
Horizontal:
Insert a screwdriver into the hole in the middle fairing inner
cover, and turn the adjusting screw to adjust the headlight
beam.
Vertical:
Adjust the headlight beam to suit riding conditions by
turning the headlight adjusting knob.
~

11

~ \\,
\\
I II
,

:~\\\~
I,

~j

(1) ADJUSTING KNOB

3-14

~(

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

...

Replace the partts] with new onets) before assembly.

Is :;O=ooLI

Use special tool

IOP~OOLI

Use optional tool. Use the same procedure you use to order parts.

Torque specification.

10 Nm (1.0 kg-m, 7.2 ft-lb)

10 (1.0, 7.2)

-:71

-,
..~

Use recommended engine oil, unless otherwise specified.

Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1

Use multi-purpose grease (Lithium based multi-purpose grease NLGI #2 or equivalent)

Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote BR-2 plus manufactured by Dow Corning, U.S.A.
Multi-purpose M-2 manufactured by Mitsubishi Oil Japan

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

Use silicone grease

Om

Apply a locking agent. Use a middle strength locking agent unless otherwise specified.

"I~

Apply sealant

Use brake fluid, DOT 3 or DOT 4. Use the recommended brake fluid, unless otherwise specified.

Use Fork or Suspension Fluid.

1) .

4. Lubrication System
Service Information

4-'

Oil Cooler Removal/Installation

4-4

Troubleshooting

4-'

Oil Pump Removal/Installation

4-6

lubrication System Diagram

4-2

Oil Pump Disassembly/Assembly

4-8

III

Service Information
;'

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 an 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.
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 oil pump has been installed, check that there are no oil leaks and that oil pressure is correct.
For oil pressure check, refer to section 4 of the Common Service Manual; for the switch location, see page 21-2 of this
manual.
For oil pressure light inspection, refer to section 25 of the Common Service Manual.

Troubleshooting
Oil level low
Oil consumption.
External oil leak.
Worn piston ring or incorrect piston ring installation.
Worn valve guide or seal.
Oil contamination (White appearance)
Coolant mixing with oil.
-Faulty head gasket.
-Water leak in crankcase

Low oil pressure


Pressure relief valve stuck open.
Clogged oil filter screen.
Oil pump worn or damaged.
Internal oil leak.
Incorrect oil being used.
Low oil level
No oil pressure
Oil level too low
Oil pump drive chain or drive/driven sprocket broken.

High oil pressure


Pressure relief valve stuck closed.
Plugged oil filter, gallery, or metering orifice.
Incorrect oil being used.

4-1

Lubrication System

Lubrication System Diagram

(1) CAMSHAFT HOLDER

'91-'95

~!~iE~!~~~--

(2) CAMSHAFT

131 ORIFICE.-;-_ _-.ll~


(GASKET)

b!;;;l[f~-

11---- (6) CONNECTING ROD

(4) OIL PRESSURE SWITCH


(3) ORIFICE
(GASKET)

(5) PISTON

'\,

~.

:'
(7) CRANKSHAFT

(10) OIL GALLERY

(8) ORIFiCE

(13) OIL PUMP

(12) OIL FILTER

(19) COUNTERSHAFT

(14) CLUTCH HOUSING


(15) RELIEF VALVE

_ =0

{20} MAINSHAFT

t:

(18)PRIMARY DAMPER SHAFT


(17) CLUTCH

4-2

Lubrication System
(1) CAMSHAFT HOLDER

After '95

~!~~!~!~I~~--

(2) CAMSHAFT

(3) ORIFICE
(GASKET} --_.~

~~~~_-(3)

::I::~:RESSURE

(5) PISTON

r..- - - (6) CONNECTING ROD


S\WITCH
(7} CRANKSHAFT

(GASKET)

,,,
,,

I
(10) OIL GALLERY

(S) ORIFICE
(12) OIL PUMP
(9) ALTERNATOR

(11} OIL FILTER


(15) OIL STRAINER

(18) COUNTERS HAFT

(14) RELIEF VALVE

(19) MAINSHAFT

(17) PRIMARY DAMPER SHAFT


(c

(16) CLUTCH

4-3

System

Lubrication

Oil Cooler Remova

1/InstaIIation

til
(8)

til

(2)

(4)

(5)

(3)

65 (6.5, 47)

" ite Service


Requrst

. Engln~
.

p
dlil draining
fairing
. remova l/installation
.
(age2
8).

Left mid

Q'ty

Procedure
Removal Order
Oil filter
(2)
a-ring
(3)
Water hose
(4)
Oil cooler bolt
(5) Oil cooler
(6)
a-ring
(7) , Oil orifice
(8)
a-ring

(1)

4-4

Remarks

I
I

verse order a f removal.


Installation is in thehr(~7HAA PJ70100) .
Use 01'I filter wrenc

!~91-'95
1

1
1
1

onlv

Install with the

01 I

hole end facing IN as shown.

Lubrication System

MEMO

4-5

Lubrication System

Oil Pump Removal/Installation


0 1 2 (1.2, 9)

qI
131

(17)038 (3.8, 27)

(21

\
tIIP

qI
191
.-...

181

liS
1101

141
18)
(11 )

171
015{1.5,11)
(6)

(13)

1121

4-6

J5).IiI
~

tIIP

151

(8)

111

(14)

(15)

(16)"71

Lubrication System
NOTE

The oil pump drive and driven sprockets, and clutch outer guide, can be removed without removing the oil pan.

Requisite Service
Engine oil draining
Exhaust pipe removal/Installation (page 2- 1B)
Clutch disassembly/assembly (page 9-6)
Procedure

(I)
(2)

13)
14)
(5)
(6)
(7)

18)
(9)

lID)
(11)
(12)

('3)
('4)
('5)
(' 6)

{17}

Removal Order
Oil pan bolt
Oil pan
Gasket
Oil strainer
Oil strainer packing
Oil pump driven sprocket bolt
Oil pump driven sprocket
Oil pipe/pump mounting bolt
Oil pipe
a-ring
Oil pump/a-ring
Oil pump drive chain
Oil pump drive sprocket
Washer
Thrust bearing
Clutch outer guide
Oil drain bolt/washer

Q'ty

Remarks
Installation is in the reverse order of removal.

,4
1

,,
,,,

Install with the IN mark facing IN.

1
2

1/1
1

,,
,,

Disassembly/assembly (page 4-B)

1/1

4-7

Lubrication System

Oil Pump Disassembly/Assembly


____________ Ia)

{b]

Io)

Ill)

qt
(10)

(7)
(4)

111

113)

18)

(9)
(12)
(6)

Punch mark

NOTE

The oil pump must be replaced as an assembly.


Before assembling the oil pump, clean all parts thoroughly with clean engine oil.

Requisite Service
Oi pump removal/installation (page 4-6)
Procedure

111
121
131
141
15)
(6)
(7)

(8)
(9)

1101
1111
1121
113)

lal
Ib)

101
Id)

Disassembly Order
Bolt
Oil pump cover
Scavenging pump outer rotor
Scavenging pump inner rotor
Drive pin
Scavenging pump body
Oil seal
Dowel pin
Outer rotor
Inner rotor
Ojl pump shaft
Drive pin
Washer
Snap ring
Washer
Relief valve spring
Relief valve piston

4-8

O'tv

Remarks
Assembly is in the reverse order of disassembly.

3
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1

Install with the punch mark facing the cover.

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

...

Replace the partts] with new onets) before assembly.

Is :;O=ooLI

Use special tool

IOP~OOLI

Use optional tool. Use the same procedure you use to order parts.

Torque specification.

10 Nm (1.0 kg-m, 7.2 ft-lb)

10 (1.0, 7.2)

-:71

-,
..~

Use recommended engine oil, unless otherwise specified.

Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1

Use multi-purpose grease (Lithium based multi-purpose grease NLGI #2 or equivalent)

Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote BR-2 plus manufactured by Dow Corning, U.S.A.
Multi-purpose M-2 manufactured by Mitsubishi Oil Japan

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

Use silicone grease

Om

Apply a locking agent. Use a middle strength locking agent unless otherwise specified.

"I~

Apply sealant

Use brake fluid, DOT 3 or DOT 4. Use the recommended brake fluid, unless otherwise specified.

Use Fork or Suspension Fluid.

1) .

5. Fuel System
Service Information

5-1

Air Cleaner Housing Removal/Installation 5-10

Troubleshooting

5-2

Pilot Screw Adjustment

Carburetor Removal/Installation

5-3

High Altitude Adjustment (U.S.A. only) 5-16

Carburetor Separation/Combination

5-4

Emission Control System (U.S.A.

Carburetor Disassembly/Assembly

5-8

Carburetor Draining

5-12

onrvl 5-17
5-18

Service Information
Bending or twisting the control cables will impair smooth operation and could cause the cable to stick or bind,
resulting in loss of vehicle control.
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 gasoline is stored can
cause a fire or explosion.
CAUTION
Be sure to remove the diaphragms before cleaning air and fuel passages with compressed air. The diaphragms
might be damaged.
Refer to section 2 for fuel tank removal and installation.
Refer to section 21 for fuel pump inspection, removal and installation.
When disassembling fuel system parts, note the locations of the O-rings. Replace them with new ones on reassembly.
Before disassembling the carburetors, place an approved gasoline container under the carburetor drain tube, then loosen
the drain bolt and drain the carburetor (page 5-18).
After removing the carburetors, wrap the intake port of the engine with a shop towel or cover it with piece of tape to prevent
any foreign material from dropping into the engine.
U.S.A. only:
All hoses used in the secondary air supply system {All U.S.A. types} and evaporative emission control systems {"91'93: Standard California type and U.S.A. ABS/TCS type/After '93: California type are numbered for identification.
When connecting one of these hoses, compare the hose number with the Vacuum Hose Routing Diagram Label, page
1-35, and carburetor tubes. page 5-6.

NOTE
If the vehicle is to be stored for more than one month, drain the float bowls (page 5 18). Fuel left in the float bowls
may cause clogged jets resulting in hard starting or poor dnveability.

5-1

Fuel System

Troubleshooting
Engine won't start
Too much fuel getting to the engine
-Air cleaner clogged
-Flooded carburetor
Intake air leak
Fuel contaminated/deteriorated
-jets clogged
Starting enrichment circuit clogged
No fuel to carburetor
-Fuel filter clogged
-Fuel line clogged
-Fuel level misadjusted
-Fuel tank breather tube clogged
-Fuel pump malfunction
-Auto fuel valve malfunction
Lean mixture
Fuel jets clogged
Float valve faulty
Float level too low
Fuel line restricted
Carburetor air vent tube clogged
Intake air leak
Fuel pump malfunction
Auto fuel valve malfunction
Vacuum piston faulty
Throttle valve faulty

Rich mixture
Starting enrichment valve open
Float valve faulty
Float level too high
Air jets clogged
Air cleaner contaminated
Flooded carburetor
Vacuum piston faulty
Engine stalls, hard to start, rough idling
Fuel line restricted
Ignition malfunction
Fuel mixture too lean/rich
Fuel contaminated/deteriorated
-jets clogged
Intake air leak
Idle speed misadjusted
Float level misadjusted
Fuel tank breather tube clogged
Fuel pump malfunction
Pilot screw misadjusted
Starting enrichment circuit clogged
Auto fuel valve malfunction
EVAP CAV control valve faulty
Hoses of the emission control system faulty
EVAP purge control valve faulty
Afterlire when engine braking is used
Lean mixture in slow circuit
Air cut-off valve malfunction
Secondary air supply system faulty
Hoses of emission control system faulty
Afterlire or misfiring during acceleration
Ignition system malfunction
Fuel mixture too lean
Poor performance (driv8ability) and poor fuel economy
Fuel system clogged
Ignition system malfunction
Faulty EVAP CAV control valve
Damaged/misconnected emission control system hoses

5-2

Fuel System

Carburetor Removal/Installation
131

17)

141

lD~Tl:1--_121

1'1

191

18)

151

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 gasoline is stored can
cause a fire or explosion.

Requisite Service
Fairing pocket removal/installation (page 2-6)
Air cleaner housing removal/installation (page 5-10)
Procedure

111
12)
13)
141

Removal Order
Choke cable
Fuel tube
Throttle stop screw cable
NO.6 tube

15)
161
171
181

Connecting tube band screw


Throttle cable
No. 15 tube
No.4 tube

191 Carburetor drain tube


I'D) Carburetor assembly

O'tv

,,

Remarks
Installation is in the reverse order of removal.

4
2

,,

Remove from the fuel tank tray.


Disconnect from the 3-way joint.
('91-'93: Standard California type and U.S.A. ASS/
TCS type/After '93 : California type)
Loosen the screws.
Disconnect from the carburetor
Disconnect from the EVAP purge control valve.
("91-'93: Standard California type and U.S.A. ASS/
TCS type/After '93 California type)

1
1

5-3

Fuel System

Carburetor Separation/Combination
(2)

(4)

1'81

l
0'

8 (0.8, 5.8)

1111

191

11 )

;;

(81

til :

Cotter pins. O-rings. lock plate

. , : O-rings

5-4

Fuel System
Requisite Service
Carburetor removal/installation (page 5-3)
EVAP purge control valve and tube removal/installation
('91-'93 : Standard California type and U.S.A. ABS;TCS type/After '93 : California type: page 5-17)

Procedure

111
12)
(3)
14)
15)
IB)
(7)
IB)
19)
(10)
111)
112)
(13)
(14)
(15)
(1B)
117)
11 B)
119)
120)

Disassembly Order
Carburetor drain tube/joint assembly
Screw
Lock plate
Air duct holder
Screw/lock plate
Air chamber/duct assembly
Dowel pin
Air vent tube/joint assembly
Fuel tube/joint assembly
Carburetor joint bracket
Carburetor connecting screw
Starting enrichment valve link
Throttle link
Starting enrichment valve arm shaft/spring
Starting enrichment valve arm
Thrust spring
Synchronization spring
Sub air cleaner tube/joint
Air joint pipe/O-ring
Fuel joint pipe/O-ring

Reassembly Order
Fuel joint pipe/O-ring
Air joint pipe/O-ring
Sub air cleaner tube/joint
Starting enrichment valve arm
Starting enrichment valve rod/spring
Carburetor connecting screw
Carburetor joint bracket
Throttle link
(12) Starting enrichment valve link
IB) Air chamber/duct assembly

120)
119)
I' 8)
I' 5)
114)
111)
110)
I' 3)

15)
117)
(1B)
19)
(8)
(7)
(4)
13)
12)
111

Screw/lock plate
Synchronization spring
Thrust spring
Fuel tube/joint assembly
Air vent tube/joint assembly
Dowel pin
Air duct holder
Lock plate
Screw
Carburetor drain tube/joint assembly

Q'ty

Remarks

,
4
2
1
8/4
1
8
2

,
,,

1
2

2/2
2
2
3
2
2/4
2/4
2/4
2/4
2
2
2/2
2
1
1
1

8/4
3
2

Remove the four screws.


Remove the cotter pins, washers and collars.
Remove the cotter pins and washers.
Loosen the starting enrichment valve arm screw.

Do not tighten the starting enrichment valve arm screw.


Do not tighten the screws.
Do not tighten the screws.
Install with the washers and new cotter pins.
Install with the collars, washers and new cotter pins.
Align the air duct flanges with the carburetor grooves.
After installing, tighten the carburetor connecting screws and
joint bracket screws. Then starting enrichment valve arm
screws.

2
8
1
2
4

5-5

Fuel System
Carburetor Tube Routing ('91-'93: Standard California type and U.S.A. ABSrrCS type)
(After '93 : California type)

(1) No.6 TUBE

(2) EVAPORATIVE EMISSION (EVAP)


PURGE CONTROL VALVE

(3) No.5 TUBE

{5} NO.5 TUBE

(4) No. 11 TUBE

(6) No.5 TUBE

(7) EVAP PURGE


CONTROL VALVE
(6) No. 11 TUBE

(9) No.2 CARBURETOR


(14) No.1 CARBURETOR

(13) No.6 TUBE

1---(10) No.5 TUBE

(11) No.4 CARBURETOR


(12) No.3 CARBURETOR

5-6

Fuel System

MEMO

5-7

Fuel System

Carburetor D'isassemblv/Assembly
Canada type

(32)

151

(34)

1311
(31

~
1141

1131~

(21 )

1201
{1 O} - - - - - - - - - - -

5-8

Fuel System
NOTE
The vacuum chamber and float chamber can be serviced with the carburetors assembled .
The pilot screws are factory pre-set and should not be removed unless the carburetors are overhauled.

Requisite Service

Carburetor separation/combination (page 5-4)


Q'ty

Procedure

(11
(2)
(3)
(4)
15)
(6)
(7)

(8)

Disassembly Order
. Vacuum chamber
Screw
Vacuum chamber cover
Compression spring
Diaphragm/piston
Needle holder
Spring
Jet needle
Washer (Canada type only)

{10)
(11 )
(12)
( l3)
(14)
(15)
( l6)
(17)'
(18)1
(19)

Float chamber
Screw
Float chamber
O-ring
Float-pin
Float
Float valve
Float valve seat
Sealing washer
Main jet
Needle jet holder
Slow jet

(20)
(21 )
122)
123)
(24)

Air cut-off valve


Screw
Air cut-off valve cover
Diaphragm
Spring
O-ring

(25)
(26)
(27)
(28)

Pilot screw
Pilot screw
O-ring
Washer
Spring

(9)

! Starting enrichment (SEl valve


(29): Nut/washer
(30)' SE valve lever
(311 CoHar
(32) Spring
(33) SE valve shaft
(34) SE valve nut
(35) SE valve spring
(36) SE valve

Remarks
! Assembly is in the reverse order of disassembly .

4
I

1
1
1

1
1
1
1
4

1
1
1
1
1

1
1
1
1
1

1
1

1
1
1
1
1
1

I 1/1
1

~=t

No.1, No.4 carburetor only


No.4 carburetor only (Plain washer for No. 1 carburetor)
No.1, No.4, carburetor only

1
1
1

5-9

Fuel System

Air Cleaner Housing Removal/Installation

0:

0.9 (0.09, 0.65)

(11

(2)

,}-----c, (3)

4)

~
(5)

u,...-__ 17)

61-_-- 18 )

(10)

(9)

(13)

f!1
/.-_--1 6)

5-10

Fuel System
Requisite Service

Top shelter removal/installation (page 2-5)


Procedure

(' )
(2)
(3)

Removal Order
Air cleaner housing cover screw
Air cleaner housing cover
a-rings

(4)
(5)

Air cleaner
Air cleaner gasket

(6)
(7)
(6)

Sub air cleaner tube


Sub air cleaner cover
Sub air cleaner
Air cleaner housing screw
Auto fuel valve mounting screw
Breather tube
Air cleaner housing
a-ring

(9)

(10)
(11)

(12)
(13)

Q'ty

Remarks
Installation is in the reverse order of removal.

,,
,

Do not remove the a-rings from the air cleaner housing


cover unless necessary.
Do not remve the gasket from the air cleaner housing
unless necessary.

1
6
2

,,
,

5-11

Fuel System

Pilot Screw Adjustment


Idle Drop Procedure
For pilot screw access, see pages 5-13, 14 and 15.

Standard California Type and U.S.A. ABSITCS Type


'I

W" .\>

Adjust the pilot screws as follows:


NOTE
Make sure the carburetor synchronization is within
specification before pilot screw adjustment.
The pilot screws are factory pre-set and no adjustment is necessary unless the pilot screws are replaced.
Use a tachometer with graduations of 50 rpm or
smaller that will accurately indicate a 50 rpm change.
A pilot screw wrench is necessary to turn the pilot
screws. (All U.S.A. types)
ISToOL)

Pilot screw wrench

07KMA-MS60101or
07LMA-MT8010A or
07MMA-MT3010A
(U.S.A. only)
Insert the pilot screw wrench from the direction
shown to turn each pilot screw. Use a flashlight to
help locate the pilot screw.
1. Turn each pilot screw clockwise until it seats lightly and
back it out to the specification given.
This is an initial setting prior to the final pilot screw
adjustment.
Initial opening:
2-1/4 turns out (Standard 49 state typel
2-5/8 turns out (Standard California type and U.S.A.
ABSi TCS typel
1 7/8 turns out (Canada type)

I I

(11 NO. 1----.:1 .


CARBUR/ETETOORR~,.{' '-n-,~
~~

(5) PILOT SCREW

WRENCH

~ (2) NO 3

, ,;.
..

CARBURETOR

"'"T

~'" .~ -..1
)''-:;;''~I'-<.."","
;-.
.
I,,':', <'~"~.k:.,i.

'<. /"

-""'

(4) NO.2 CARBURETOR --'

_Y"

(3) NO.4 CARBURETOR ;,'I~

Standard 49 S"',e and Canada Tvpe "


(1) NO.1

W..

(2} NO.3

~~;~~~~W-'"
~~;~t
~" " P "

\j
/
'C,\c'C:":----=,",-)~/'
~~~~~~REW1" I,'~~~:~~ ;~:~::',~_

', '(',;lYC-'(
I -'" '-'-'-

"'.
1

.1'1"

(5)

~.~-

'"''-'''
,
-~
'/c"=5)~~:o
~:JR:)

T''--{

(4) NO.2 CARBURETOR

A \

1,,]1 (3) NO.4 CARBURETOR

,'N.I

All U.S.A. Types

CAUTION
Damage to the pilot screw seat will occur if the
pilot screw is tightened against the seat.
2 Warm up the engine to operating temperature.
Stop-and-go riding for 10 minutes is sufficient.
3. Attach the tachometer according to the tachometer
manufacturer's instructions.
4. Adjust the idle speed with the throttle stop control
knob.

(1) PILOT
SCREW

Idle speed: 1,200 100 rpm


1,000 100 rpm (Canada type)

5. Turn each pilot screw 1/2 turn out from the initial
setting.
6. If the engine speed increases by 50 rpm or more, turn
each pilot screw out by successive 1/2 turn increments
until engine speed does not increase.
7. Adjust the idle speed with the throttle stop control
k.nob.
8. Tum the No.1 carburetor pilot screw in until the engine
speed drops 50 rpm.
9. Turn the No.1 carburetor pilot screw out 7/8 turn
from the position obtained in step 8.
10. Adjust the idle speed with the throttle stop control
knob.
11. Perform steps 8, 9 and 10 for the No.2, 3 and 4
carburetor pilot screws.

5-12

Canada Type

(1) PILOT
SCREW

Fuel System
Pilot Screw Access
No. 1 Carburetor
Remove the right side Maintenance Cover. Remove the
plastic timing belt cover on the front of the cylinder
head. Using a 12-inch or longer #1 screwdriver and a
flashlight to guide you, push the rubber carburetor heat
insulator away from the carburetor body.
Insert the Pilot Screw Wrench into the pilot screw hole
by using the lug on the carburetor body as a guide.
Align the socket with the pilot screw head by turning the
wrench slowly while pushing it lightly onto the pilot
screw head.
Return the carburetor heat insulator to its
position after making the adjustment.

Pilot screw wrench

(2) LUG

(1) PILOT SCREW

original

07LMA-MTB010A or
07MMA-MT3010A

(3) PILOT SCREW WRENCH

No. 2 Carburetor
Insert the Pilot Screw Wrench from the rear upper side
of the cylinder head between the frame and the fairing
as shown.

Align the socket of the wrench to engage with the pilot


screw head in the same manner as for No. 1 carburetor.

(1) PILOT SCREW WRENCH

(1) PILOT SCREW HOLE

~~~(3) LUG

(2) SOCKET

5-13

Fuel System
No.3 Carburetor
Insert the pilot screw wrench from the lower side of the
auto fuel valve between the frame and the fuel filter as
shown.
Align the socket of the wrench to engage with the pilot
screw head in the same manner as for No. 1 carburetor.

(1) PILOT SCREW

)~~

(2) FRONT

:?'H--f--131 LUG

(6) FUEL
FILTER (5) FRAME TUBE

No.4 Caburetor (Standard 49 state and Canada type)


Insert the pilot screw wrench from the front upper side
of the cylinder head through the middle fairing hole as
shown.

(1) PILOT SCREW WRENCH

Align the socket of the wrench to engage with the pilot


screw head in the same manner as for No.1 carburetor.

(1) SOCKET

- ." :'[",--=-.

(2) PILOT SCREW

No.4 Carburetor (Standard California type and U.S.A.


ABS/TCS type)
Move the tube marked #4 down, out of the way as
shown.

\
(1) #4 TUBE

5-14

Fuel System
Position the socket end of the wrench against the lug on
the carburetor.

(1) SOCKET

(2) FLEXIBLE PORTION OF


PILOT SCREW WRENCH

(4) PILOT SCREW HOLE


(31 LUG

Push the tool against the lug to bend the flexible portion
of the tool under the throttle bell crank as shown.

(1) THROTILE
BELL CRANK

Align the socket of the wrench to engage with the pilot


screw head in the smae manner as for No.1 carburetor.

{2) PILOT
SCREW
WRENCH

Use a flashlight to verify that the socket seats on the


pilot screw.

NOTE
Do not operate the throttle when the Special Tool is
on the pilot screw.

{3) BEND TOOL UNDER BELL CRANK

After making the adjustment, return the #4 tube to its


original position.

5-15

Fuel System

High Altitude Adjustment


(U.S.A. only)
When the vehicle is to be operated continuously above
2,000 m (6,500 feet] . the carburetor must be readjusted
as described below to improve driveability and decrease
exhaust emissions.

Standard 49 State and Canada Type

(1) NO, 1

,r-"...-[

CARBU---1_C

l+i~2il;~~~

RETOR

(2) NO.3
CARBURETOR

For pilot screw access, see pages 5- 13, 14 and 15.


Warm up the engine to operating temperature. Stop and
go riding for 10 minutes is sufficient.
Turn each pilot screw clockwise 1/2 turn with a pilot
screw wrench.

(4) NO.

NOTE

Standard California Type and U.S.A. ABS/TCS Type

~ pilot screw wrench is necessary to turn the pilot


I
screws.

(1) NO

1'~
~

CARBURETOR

Is~()~1

07KMA-MS60101 or
07LMA-MT8010A or
07MMA-MT3010A
(U.S.A. only)
Insert the pilot screw wrench from the direction
shown for each pilot screw. Use a flashlight to help
locate the pilot screw.

""

rx-r121 NO.3

~--1tB:! . ,-- --:~~'


I .,";'j-::~:>'>_.0:~~?::~h,1

Pilot screw wrench

(51 PILOT SCREW


WRENCH

(L ")''.::,:1
I.

".y.>.'

~,,;~-,<'-J'~
~,=zJ/_ =->:(\~ r

{4} NO.2 CARBURETOR

(3) NO.4 CARBURETOR


Adjust the idle speed to the specified rpm with the throttle stop control knob.
Idle speed: 1.200

j-

CARBURETOR

~I~-_

I.,:

100 rpm

NOTE
These adjustments must be made at high altitude to
ensure proper high altitude operation.
---!
Attach the Vehicle Emission Control Information Update
label on the left side of the frame as shown. See Service
Letter No. 132 for information on obtaining the label.
NOTE

Do not attach the label to any part that can be easily I


removed from the vehicle.

Operation at an altitude lower than 1,500 m


(5.000 feet) with the carburetors adjusted for high
altitudes may cause the engine to idle roughly and
stall.
When the vehicle is to be operated continuously below
1,500 m {5,000 feet}, turn each pilot screw counterclockwise 1/2 turn to its original position and adjust the
idle speed to the specified rpm. Remove the Vehicle
Emission Control Update Label.
Be sure to do these adjustments at low altitude with the
engine at normal operating temperature.

5-16

(1) PILOT SCREW

(1) UPDATE

LABEL

Fuel System

Emission Control System


(U.S.A. only)

(2) No. 10 VACUUM


(1) AIR

SUC~TlaN
PORT

Secondary Air Supply System

, I
U

Remove the fairing pocket (page 2-6)

'

Ix

NOTE
The pulse secondary air injection (PAIR) control valve
and the pulse secondary air injection (PAIR) check
valve are combined in one assembly.

rfTUBE

,,'

..

r.E09

, ( 3 ) PAIR
:
CONTROL

L-

/~{;..,:c~=~.
l
VALVE

:", . "'J~I
[!Ot'y! ,<,
i~

Disconnect the No 10 vacuum tube (routed from the


PAIR control valve) from the 3-way joint.
Plug the 3-way joint and connect the vacuum pump to
the No. 10 vacuum tube.

'

Remove the air cleaner housing cover and put your finger
on the air suction port of the air chamber.
Perform the secondary air supply system inspection (refer
to section 7 of the Common Service Manual).

(1) NO.15TUBE

Specified vacuum: 360 mmHg (14,2 inHg)


Pulse Secondary Air Injection (PAIR) Control
Valve Removal/Installation
Remove the carburetor (page 5-3).
Remove the heat insulator rubber.
Remove the bolts, disconnect the No. 16 (air injection)
hoses, No. 10 tubes and No.1 5 (air suction) tubes from
the PAIR control valves, and remove the PAIR control valves.
Install the PAIR control valve in the reverse order of
removal.

\
"

(2) NO.1 0 TUBE

(3) No. 16 (AlA INJECTION) HOSE

Evaporative Emission (EVAP) Purge Control


Valve and Tube Removal/Installation
1'91-'93 : Standard California type and U.S.A.

",,,",

ABS/TCS type}

(1) N} 11 TUBE

(After '93 : California type)


Remove the carburetor (page 5-3).
Remove the No.5 and No. 11 tubes, 3-way joints and
the EVA? purge control valve from the carburetor.
Install the EVAP purge control valve in the reverse order
of removal.
NOTE

For EVA? purge control valve tube routing, see page


5-6.

~'~:}~;,~7r:;!:'~',~:~",~
'''''''' ' ",,,,, I, '"",. 1J
' :~i?l;f$~ , V;."",,'

(J;
~'", ,"
f? "~,-", '",""':'

U . 1i~/

,~

(4) 3-WAY JOINT

<,

(2)EVAP
PURGE
(3} No.5 TUBE CONTROL
VALVE

5-17

Fuel System

Carburetor Draining

~2

CARBURETOR:
(2) ACCESS HOLE

Remove the maintenance covers (page 2-5}.


Remove the access covers from the fairing pockets.
Place a suitable container under the carburetor drain hose.

(3)

14 in.
SCREWDRIVER

--

(1} FRONT

Drain the ;: 2 carburetor by placing a long (minimum 14


in} flat blade screwdriver through the access hole, between
the carburetor synchronization linkage and the carburetorto-manifold boot. The screwdriver must be angled down.
toward the front of the motorcycle.
An adjustable flashlight will help locate the drain screw.
Drain the ::I' 4 carburetor by placing a long screwdriver
through the maintenance opening, above the cylinder
head, to the rear of the head cover bolt, between the
carburetor synchronization linkage and the carburetor-tomanifold boot. The screwdriver fits in a notch in the upper
fairing. The screwdriver must be angled down, foward
the rear of the motorcycle.

~4

CARBURETOR:

:"""-.

...

(2) 14 in. SCREWDRIVER ".

----

(1) FRONT

Loosen the screws until the fuel is drained, and tighten


the screws.
Repeat this procedure on the right side of the motorcycle
for the ~ 1 (tront] and ~ 3 (rear) carburetors.

5-18

(4) BOLT. FRONT HEAD COVER

(3) NOTCH

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

...

Replace the partts] with new onets) before assembly.

Is :;O=ooLI

Use special tool

IOP~OOLI

Use optional tool. Use the same procedure you use to order parts.

Torque specification.

10 Nm (1.0 kg-m, 7.2 ft-lb)

10 (1.0, 7.2)

-:71

-,
..~

Use recommended engine oil, unless otherwise specified.

Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1

Use multi-purpose grease (Lithium based multi-purpose grease NLGI #2 or equivalent)

Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote BR-2 plus manufactured by Dow Corning, U.S.A.
Multi-purpose M-2 manufactured by Mitsubishi Oil Japan

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

Use silicone grease

Om

Apply a locking agent. Use a middle strength locking agent unless otherwise specified.

"I~

Apply sealant

Use brake fluid, DOT 3 or DOT 4. Use the recommended brake fluid, unless otherwise specified.

Use Fork or Suspension Fluid.

1) .

6. Cooling System
Service Information

6-1

Radiator Disassembly/Assembly

6-6

Troubleshooting

6-1

Water Pump Removal/Installation

6-7

System Flow Pattern

6-2

Radiator Reserve Tank Removal!

Coolant Draining

6-4

Installation

6-8

Radiator Removal/Installation

6-5

Thermostat Removal/Installation

6-10

Service Information
Wait until the engine is cool before slowly removing the radiator cap. Removing the cap while the engine is hot
and the coolant is under pressure may causa serious scalding.

Radiator coolant is toxic. Keep it away from eyes. mouth, skin and clothes.
-If any coolant gets in your eyes. rinse them with water and consult a doctor immediately.
-If any coolant is swallowed, induce vomiting. gargle and consult a physician immediately.
-If any coolant gets on your skin or clothes. rinse thoroughly with plenty of water.
KEEP OUT OF REACH OF CHILDREN.
Add coolant at the reserve tank. Do not remove the radiator cap except to refill or drain the system.
All cooling system service can be made 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 25 of the Common Service Manual for fan motor switch and thermo sensor inspections.

Troubleshooting
Engine temperature too high
Faulty radiator cap.
Insufficient coolant.
Passages blocked in radiator, hoses, oil cooler, or water jacket.
Air in system.
Faulty water pump.
Thermostat stuck closed.
Faulty cooling fan motor.
Faulty cooling fan motor switch.

Engine temperature too low


Faulty temperature gauge or gauge sensor.
Thermostat stuck open.
Faulty cooling fan motor switch.
Faulty cooling fan motor swith.

Coolant leaks
Faulty pump mechanical seal.
Deteriorated O-rings.
Faulty radiator cap.
Damaged or deteriorated cylinder head gasket.
Loose hose connection or clamp.
Damaged or deteriorated hoses.

6-1

Cooling System

System Flow Pattern


'91-'95

(5) RESERVE TANK


ABS/TeS model shown:

(3) RADIATDR
OVERFLOW TUBE
(2) THERMOSTAT
(1) RADIATOR CAP
(4) BYPASS TUBE

(8) RADIATOR

(7) WATER PUMP

6-2

(6) OIL COOLER

Lubrication System
After '95

(3) RADIATOR
OVERFLOW TUBE
(5) RESERVE TANK
LBS-ABSjTCS model shown:

(2) THERMOSTAT
(1) RADIATOR CAP
(4) BYPASS TUBE

(7) RADIATOR

(6) WATER PUMP

6-3

Cooling System

Coolant Draining

(1) RADIATOR CAP

Wait until the engine is cool before servicing the


cooling system. Removing the radiator cap while
the engine is hot and the coolant is under pressure
may cause serious scalding.

NOTE
For coolant replacement, refer to section 5 of the
Common Service Manual.
Remove the left and right middle fairings (page 2-8).
Remove the radiator cap.
Remove the radiator drain plug and gasket, and drain the
coolant from the radiator.

Remove the drain bolts and sealing washers from the left
and right cylinders, and drain the coolant from the engine.

(1) DRAIN BOLT

Remove the reserve tank mounting bolts (page 6-8).


Place a suitable container under the radiator overflow tube
joint of the reserve tank, disconnect the overflow tube from
the tank, and drain the coolant from the tank.
Install the drain plug with a gasket.
Install the drain bolts with new sealing washers.
Install the reserve tank (page 6-8).

STANDARD MODEL:

ABS!TCS or lBS-ABSI
TCS MODEL:

. ~ R~DIATIR DVERFLDW TUBE

.. ~

~.\
~"t!J~>:-~1
.. ~

6-4

---_/1

(2) RESERVE TANK

Cooling System

Radiator Removal/Installation

151

111

.2 (0.12, 0.9)

141

"

~;o,~--131

Requisite Service
Upper fairing removal/installation (page 2-9)
Coolant draining {page 6-4}
Coolant refill (Section 5 of the Common Service Manual)
Procedure

111
121
131
141
151

Removal Order
Radiator hose
Fan motor switch connector
Horn
Radiator mounting bolt/collar
Radiator

Q'ty

,,

Remarks
Installation is in the reverse order of removal.

2
1
1

2/2
1

At installation, align the pin of the radiator with the


mounting grommet of the frame properly.

6-5

Cooling System

Radiator Disassembly/Assembly
(1) '91-'95 shown

ew
(51

181

(41

(101------!~-

et

c:

(91
12 (1.2, 9)

(31

Requisite Service
Radiator removal/installation (page 6-5)
Q'ty

Procedure
( 11
(21
(31
(41
(51
(61
(71
(81
(91
(101

Disassembly Order
Radiator grille
Fan motor switch wire connector
Shroud mounting bolt/ground wire
Shroud
Fan mounting nut
Cooling fan
Fan motor mounting nut
Fan motor
Fan motor switch
O-ring

6-6

Remarks
Assembly is in the reverse order of disassembly,

I,
I

1
1
3/1
1
1
1
3
1
1
1

Cooling System

Water Pump Removal/Installation

After '91:

iIiIliI
(3)

,.,
(6)

'91-'95 only:

Requisite Service
Timing belt idle pulley removal/installation (page 8-10)
Procedure

(11
(2)
(3)
(4)

(5)
(6)

Removal Order
Oil cooler water hose/breather hose
Timing belt tensloner spring hook bolt
Bolt
Water pump
I Dowel pin
'I O-ring

my

Remarks
Installation is in the reverse order of removal.

1/1
1
7

,
Be careful not to damage the reduction holder gasket.

2
2

6-7

Cooling System

Radiator Reserve Tank Removal/Installation


Standard Model

P) --f+--f-~'ir'

-'IV"

~ "'~ --...v ~~~~\

~(j

(2)~_ _

(3)

(4)

Requisite Service

Right side cover removal/installation (page 2-2)


Procedure

{11
(2)
(3)
(4)

Removal Order
Rear brake reservoir mounting bolt
Reserve tank mounting bolt/clamp
Radiator overflow tube
Reserve tank

6-8

O"ty

,
,,

2/1

Remarks
Installation is in the reverse order of removal.

Cooling System

ABS/TCS or LBS-ABS/TCS Model

I I '-

Requisite Service
Right middle fairing removal/installation (page 2-8).
Q'ty

Procedure

(' I
(21
(31
141

Removal Order
Reseve tank mounting bolt
Radiator overflow tube
Breather tube
Reserve tank

,,

Remarks
Installation is in the reverse order of removal.

6-9

Cooling System

Thermostat Removal/Installation
161

~10 (1.0, 7)

..... 18)
111

121

.2 (0.12, 0.9}

110)

1.2 (0.12, 0.9)

191

13)

"'14)

{11}

~151

Requisite Service
Upper fairing removal/installation (page 2-9)
Coolant draining (page 6-4)
Coolant refill (Section 5 of the Common Service Manual)
Procedure

Removal Order
Mounting bolt
Radiator overflow tube
Bypass tube
Thermo sensor
Thermo sensor wire connector
Radiator hose
Water hose
Thermostat case bolt
Thermostat case
Thermostat
(11 ) O-ring

111
12)
13)
14)
15)
16)
17)
18)
19)
110)

6-10

a'ty

Remarks
Installation is in the reverse order of removal.

1
1
1
1
1
1
2
2
1
1
1

Apply sealant to threads when installing.

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

...

Replace the partts] with new onets) before assembly.

Is :;O=ooLI

Use special tool

IOP~OOLI

Use optional tool. Use the same procedure you use to order parts.

Torque specification.

10 Nm (1.0 kg-m, 7.2 ft-lb)

10 (1.0, 7.2)

-:71

-,
..~

Use recommended engine oil, unless otherwise specified.

Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1

Use multi-purpose grease (Lithium based multi-purpose grease NLGI #2 or equivalent)

Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote BR-2 plus manufactured by Dow Corning, U.S.A.
Multi-purpose M-2 manufactured by Mitsubishi Oil Japan

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

Use silicone grease

Om

Apply a locking agent. Use a middle strength locking agent unless otherwise specified.

"I~

Apply sealant

Use brake fluid, DOT 3 or DOT 4. Use the recommended brake fluid, unless otherwise specified.

Use Fork or Suspension Fluid.

1) .

7. Engine Removal Installation


Service Information

7-1

Engine Removal/Installation

7-2

Service Information

A floor jack or other adjustable support is required to support and maneuver the engine.

CAUTION
Do not support the engine using the oil filter.
The following components can be serviced with the engine installed in the frame.
- Oil pump (Section 4)

-Carburetor (Section 5)
-

Oil cooler (Section 5)


Water pump (Section 6)
Cylinder head (Section 8)
Timing belt (Section 8)
Clutch (Section 9)
Gearshift linkage (Section 10)
Alternator (Section 17)
Ignition pulse generator (Section 18)

- Starter motor (Section 20)


The following components require engine removal for service.
- Transmission (Section 10)
- Primary damper shaft (Section 10)
- Crankshaft (Section 11)
- Connecting rod (Section 11)
- Piston (Section 11)
- Primary drive gear (Section 11)
- Starter clutch

7-1

Engine Removal/Installation

Engine Removal/Installation
'91-'95
(1 1 )

131

(16)

111

40 (4.0, 29)

(19)

35 (3.5, 25)

0 4 0 (4.0, 29)

65 (6.5, 47)

1151
1151

--rr----=~~~

40 (4.0, 29)

~~o

35 (3.5, 25)

141
(14)

(20)

(13)

1171

(18)

(16)

171

40 (4.0, 29)

7-2

.,

55 (5.5, 40)

Engine Removal/Installation
Requisite Service
Muffler removal/installation (page 2- 13)
Exhaust pipe removal/installation (page 2-1 B)
Carburetor removal/installation (page 5-3)
Radiator removal/installation (page 6-5)
Procedure

Q'ty

11}
12}
13}
14}
15}
16}
17}
18}
19}
110}
111}
112}
113}
114}
115}

Removal Order
Engine ground cable
Starter motor cable
Gearshift pedal tie rod bolt
Spark plug cap
Altemator wire connector
Heat guard plate
Front head cover
Ignition pulse generator wire connector
Carburetor heat insulator rubber
Water outlet hose
Water bypass hose
Auto fuel valve vacuum tube
Clutch slave cylinder
Breather hose
Engine mounting bracket

1
1
1
4
2
1
2
1
1
2
1
1
1
1
4

116}
117}
118}
(19)
120}

Sub frame bolt


10 mm engine mounting bolt/adjusting collar
Sub frame
12 mm engine mounting bolt/collar
Engine assembly

Remarks
Installation is in the reverse order of removal.

44/1
1
1/2
1

Loosen the lock nuts and remove the bolt by turning it.

Disconnect from the cylinder heads.


Disconnect from the water pipe.
Disconnect from the No.3 cylinder intake manifold.
Remove the three mounting bolts.
Remove from air cleaner housing.
Remove the two 8 mm bolts and 10 mm bolt per each
bracket.
Tigntening procedure (page 7-6)

Tightening procedure (page 7-6)

Move the engine assembly out of the frame to the left.


CAUTION
Carefully align the mounting points with the jack to
prevent damage to the mounting bolt threads, wire
harnesses and cables.

7-3

Engine Removal/Installation
After '95

Ii) 55 (5.5,40)

(11)

(12)

(10}

(17)

(4)

(1 )

(16)

Ii) 40 (4.0, 29)

(19)

Ii)
I

27 (2.7, 20)

Ii)

65 (6.5, 47)

40 (4.0, 29}

(15}it!-_--;:
(5)

A~~

(14}

(17)

{18)
{16)

Ii)
40 {4.0, 29)

7-4

Ii)
55 (5.5, 40)

Engine Removal/Installation
Requisite Service
Muffler removal/installation (page 2-13).
Exhaust pipe removal/installation (page 2-1S).
Carburetor removal/installation (page 5-3).
Radiator removal/installation (page 6-5).
Procedure
Removal Order
Engine ground cable
(2) Starter motor cable
(3)
Alternator cable/connector
(4) Gearshift pedal tie rod bolt
(5) Spark plug cap
(6) Hear guard plate
(7)
Front head cover
(B)
Ignition pulse generator wire connector
(9) Carburetor heat insulator rubber
(10) Water outlet hose
(1 1) i Water bypass hose
(12) Auto fuel valve vacuum tube
(13) Clutch slave cylinder
(14} Breather hose
(15} Engine mounting bracket
,

Q'ty

Installation is in the reverse order of removal.

(1)

(16)
(17)

us:
(19)
(20)

Sub frame bolt


'0 mm engine mounting bolt/adjusting collar
Sub frame
12 mm engine mounting bolt/adjusting collar
Engine assembly

Remarks

1
1
1
1

Loosen the lock nuts and remove the bolt by turning it.

4
1

2
1
1

,
1

1
1
1

Disconnect from the cylinder heads.


Disconnect form the water pipe.
Disconnect from the No.3 cylinder intake manifold.
Remove the three mounting bolts.
Remove from air cleaner housing.
Remove the two S mm bolts and '0 mm bolt per each
bracket.
Tightening procedure (page 7-6)

4;'t Tightening procedure {page 7-6}

1:,J
1

Move the engine assembly out of the frame to the left.


, CAUTION
Carefully align the mounting points with the jack to
prevent damage to the mounting bolt threads. wire
harnesses and cables.

7-5

Engine Removal/Installation
Engine Mounting Bolt Tightening Procedure
(1) ADJUSTING
COLLAR

Apply oil to the 10 mm engine mounting bolt threads and


seating surfaces.
Loosely install all engine mounting bolts, nut, sub frame
bolts, nuts, and engine mounting brackets.

.-

~-

Tighten the sub frame bolts in the sequence below.

L-o--

(j)-~-@-@-@

CD

Torque: 40 Nom (4.0 kg-m, 29 ft-Ib)


Tighten the 10 mm engine mounting bolts

and (J).

Torque: 55 Nom (5.5 kg-m, 40 ftlb)

(2} ADJUSTING
COLLAR
(After '95)

Lengthen the adjusting collar on the 10 mm engine


mounting bolt @ until the collar contacts with the engine
and frame by turning the adjusting nut of the collar.

.:

After '95:
Lengthen the lower adjusting collar on the 12 mm engine
mounting bolt@untilthecollarcontactswiththeengine
and frame by turning the adjusting nut of the collar.
Tighten the adjusting nut of the lower adjusting collar.
Torque: 10 Nom (1.0 kg-m, 7 ft-Ib)
Tighten the lO mm engine mounting bolts

and

~'.

Torque: 55 Nom (5.5 kg-m, 40 ft-Ib)


Tighten the 12 mm engine mounting bolt @ and nut@.

'91

95 Shown:
(1) ADJUSTING COLLAR

TOfque: 65 Nom (6.5 kgm, 47 ftlb)


Tighten the adjusting collar lock nut.
(6) ENGINE

Torque: '91-'95: 21 Nom (2.1 kg-m, 15 ft-Ib)


After '95: 28 Nom (2.8 kg-m, 20 ft-Ib)

~
~

7-6

(2) FRAME

~
-,

Tighten the engine mounting brackets @, 1), @ and @.


Torque: 10 mm bolt: 40 Nom (4.0 kg-m, 29 ft-Ibl
8 mm bolt: 35 Nom (3.5 kg-m, 25 tt-lbl

(5) ADJUSTING
BOLT

'\

(4) LOCK
NUT

(3) ADJUSTING
NUT

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

...

Replace the partts] with new onets) before assembly.

Is :;O=ooLI

Use special tool

IOP~OOLI

Use optional tool. Use the same procedure you use to order parts.

Torque specification.

10 Nm (1.0 kg-m, 7.2 ft-lb)

10 (1.0, 7.2)

-:71

-,
..~

Use recommended engine oil, unless otherwise specified.

Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1

Use multi-purpose grease (Lithium based multi-purpose grease NLGI #2 or equivalent)

Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote BR-2 plus manufactured by Dow Corning, U.S.A.
Multi-purpose M-2 manufactured by Mitsubishi Oil Japan

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

Use silicone grease

Om

Apply a locking agent. Use a middle strength locking agent unless otherwise specified.

"I~

Apply sealant

Use brake fluid, DOT 3 or DOT 4. Use the recommended brake fluid, unless otherwise specified.

Use Fork or Suspension Fluid.

1) .

8. Cylinder Head
Service Information

8-1

Cylinder Head Removal/Installation

8-4

Troubleshooting

8-1

Cylinder Head Disassembly/Assembly

8-8

Cylinder Head Cover Removal/


Installation

8-2

Timing Belt Pulley Removal/


Installation

8-10

Timing Belt Cover Removal!


Installation

8-3

Service Information
Camshaft lubricating oil is fed through oil passages in the cylinder head. Clean the oil passages before assembling the
cylinder head.
Clean all disassembled parts with clean solvent and dry them by blowing them off compressed air before inspection.
When disassembling, mark and store the disassembled parts to ensure that they are reinstalled in their proper locations.
Take care not to damage the cylinder walls and pistons.
~
If valve seat cutting is required. a commercially available cutting set is recommended.

-=-

Troubleshooting
Engine top-end problems usually affect engine performance. These can be diagnosed by a compression or leak down
test, or by tracing noises to the top-end with a sounding rod or stethoscope.
If performance is poor at low speeds, check for white smoke in the crankcase breather tube. If the tube is smokey,
check for a seized piston ring.
Compression too low, hard starting or poor performance
at low speed
Valves
-e-Incorrect valve clearance
- Burned or bent valves
-Incorrect valve timing
- Broken valve spring
- Uneven valve seating
- Sticking valve
Cylinder head
- Leaking or damaged head gasket
- Warped or cracked cylinder head

Excessive noise
Incorrect valve clearance
Sticking or broken valve spring
Damaged or worn camshaft
Loose or damaged timing belt
Weak or damaged belt tensioner
Damaged timing belt pulleys
Rough idle
Low cylinder compression

Compression too high, overheating or knocking


Excessive carbon build-up in cylinder head or combustion
chamber
Excessive smoke
Worn valve stem or valve guide
Damaged stem seal

8-1

Cylinder Head

Cylinder Head Cover Removal/Installation

~'6lm!

181~

19)--

E/''''----151

~16)
171

11)

141~\ ,\\>--..I~

12)

~
Requisite Service
Upper fairing removal/installation (page 2-9)
Procedure

111
12)
13)
14)
151
161
171
181
191

Removal Order
Bolt
Front head cover
Bolt/collar
Reduction holder cover
Spark plug cap
Cylinder head cover bolt
Washer
Cylinder head cover
Gasket

8-2

a'ty

Remarks
Installation is in the reverse order of removal.

2
1

3/3
1

2
4
4
1
1

Install with the uUp u mark facing up.


The right head cover has the oil filler cap.

Cylinder Head

Timing Belt Cover Removal/Installation

III

12}

Requisite Service
Radiator removal/installation (page 6-5)
Reduction holder cover removal/installation (page 8-2)
Clutch cover removal/installation (page 9-6)
Procedure
(1)
(2)

Removal Order
Bolt
Timing belt cover

Q'ty

Remarks
Installation is in the reverse order of removal.

8-3

Cylinder Head

Cylinder Head Removal/Installation

if): 12 (1.2, 9)

(2)

11 }

if):71
58 (5.8, 42)
(e)

(b)

6 x 40 mm

"""~~_J

(3)

(k)

L:W
(h)

(i!

~
(g)

~
(f)

(,)

8-4

,/

Cylinder Head
NOTE

The camshaft can be removed with the timing belt driven pulley installed and without removing the carburetors and
exhaust pipe. The timing belt driven pulley, carburetors and exhaust pipe must be removed to remove the cylinder
head.
Before removing the right cylinder camshaft, align the index line on the driven pulley with the index mark on the
reduction holder. Before removing the left cylinder camshaft, align the punch mark on the driven pulley with the index
mark on the reduction holder.
For camshaft installation, see page 8-6.

Requisite Service
Cylinder head cover removal/installation (page 8-2)
Timing belt driven pulley removal/installation (page 8-10)
Carburetor removal/installation (page 5-3)
Exhaust pipe removal/installation (page 2-18)
Procedure

(11

Removal Order
Camshaft holder bolt

5 x 40 mm
5 x 45 mm

(21 Camshaft holder


(31 Dowel pin
(41 Camshaft

(,I
[b}

101
(dl
(el
(fl

(91
(hi
(i)

01

Ikl

Air injection pipe (u S.A only)


Cylinder head bolt
Washer
Cylinder head
Cylinder head gasket
Dowel pin
Cam reduction holder gasket
Bolt
Cam reduction holder
Gasket
Cam reduction gear shaft

Q'ty

4
8

Remarks
Installation is in the reverse order of removal.
Install in the positions shown on page 8-4

Installation (page 8-6)


At installation, apply molybdenum disulfide oil to the
bearing and lobe surfaces (see page 8-5)

6
6

,,
,

3
1

,, .
.

III

Cam reduction gear

The shaft for the right cylinder has a single bearing and
the one for the left cylinder has a double bearing.
Align the wide tooth with the wide groove (punch mark)
of the reduction gear.

8-5

Cylinder Head
Camshaft Installation

(1) CAMSHAFT IDENTIFICATION MARKS

Lubricate the camshaft journals. cam lobes and driven


gears with a mixture of engine oil and molybdenum
disulfide grease in a 1: 1 ratio.
NOTE
Each camshaft has the identification marks shown
below.
Right intake camshaft: RH IN
- Right exhaust camshaft: RH EX
- Left intake camshaft: LH IN
- Left exhaust camshaft: LH EX

Remove the two bolts and timing hole cover.

Right cylinder head:


Tum the crankshaft clockwise and align the T1 Mark on
the drive pulley guide plate with the Index Mark on the
timing cover.

(1) TIMING HOLE COVER

(1) INDEX MARK

(2) T1 MARK

Make sure that the Index Line on the driven pulley aligns with
the Index Mark on the reduction holder. If not, turn the
crankshaft clockwise one full turn and realign the T1 Mark
with the Index Mark.

(1) INDEX MARK

(2) INDEX LINE

8-6

Cylinder Head
Install the intake and exhaust camshafts so that the Index
Lineson the end of the shafts are facing outward and that
they align with the top of the cylinder head as shown.

(1) INDEX LINES

Install the dowel pins and camshaft holders.


NOTE

II

I'

Each camshaft holder has the identification marks


shown below.
- Right intake camshaft holder- R I
- Right exhaust camshaft holder: R E
_ Left intake camshaft holder: L I
- Left exhaust camshaft holder: L E
Install camshaft holder B with its tab facing out as
shown.

Left cylinder head:


Turn the crankshaft clockwise and align the T4 Mark on the
drive pulley guide plate with the Index Mark on the timing
belt cover.

(4) CAMSHAFT J--....


HOLDER A
(3) CAMSHAFT
HOLDER B

./

"--< _

---'-'t-(2) TAB

(1) INDEX MARK

NOTE
If the right camshaft has been removed. install it first,
then turn the crankshaft clockwise 1-1/4 turns (450
degrees) and align the T4 Mark with Index Mark.

(2) T4 MARK

Make sure that the Punch Mark on the driven pulley aligns
with the Index Mark on the reduction holder. If not, turn the
crankshaft clockwise one full turn and realign the T4 Mark
with the Index Mark.

(1) INDEX MARK

Install the intake and exhaust camshafts, and camshaft


holders in the same manner as the right camshaft
installation.

(2) PUNCH MARK

8-7

Cylinder Head

Cylinder Head Disassembly/Assembly

~121
131~
1,~oocI141

~
~"f:)

.~V

151
161

A_

...

191~(fjji)
~
~~
I,~ooq 1101--===-~ ~
181

111

171---/1

/)

8-8

Cylinder Head
NOTE
The valve lifter and valve adjusting shim can be removed with the cylinder head installed. Refer topage 3-5 for the shim
replacement.
Mark all parts during disassembly so they can be placed back in their original position.

Requisite Service

Cylinder head removal/installation (page 8-4)


Procedure

Remarks

Q'ty

111

Disassembly Order
Carburetor insulator

12)

Valve lifter

13) Valve adjusting shim


(4) Valve spring cotter

8
16

16) Valve spring retainer


(6) Valve spring
(7) Valve
18) Valve stem seal
(9) Valve spring seat
110) Valve guide

8
8
8
8
8
8

Assembly is in the reverse order of disassembly.


Install with the ~CARB" mark facing to the carburetor and
align the grooves with the lugs on the cylinder head.
NOTE:
, Remove using a handlapping tool. Do not damage the
cylinder head bucket sliding surface.
Use valve spring compressor (07757-0010000) with
valve spring compressor attachment (07959-KM301 01)
and tappet hole protector (07HMG-MR70001 ) Not
Available iii U.S.A., to make equivalent tool, see below.
Install with the narrow pitch end facing down.

Use valve guide driver (07HMD-ML00100 or 07HMDMLOO101).

mm mm
I

TOP VIEW

'; ;--- --,~

/ /

,,'
I,

r: . .

I]

\\

-..'

'~~~

,\

\\
. \\

II

'r

,Ii

/,..1

\ .:::-

25 mm 0.0.

[when compressed)

Tappet hole protector; an equivalent tool can be made from


a plastic 35 mm film container using the measurements
shown above.

8-9

Cylinder Head

Timing Belt Pulley Removal/Installation

46 (4.6, 33)

(4)

(2)

----------------------~

C
46 (4.6, 33)

(1 1)

8-10

(8)

(101

(6)

27 (2.7, 20)
;

(9)

65 (6 5, 47)

Cylinder Head
NOTE

Perform the timing belt service while the engine is cold.

Requisite Service
Timing belt cover removal/installation (page 8-3)
Spark plug removal/installation
Procedure

Q'ty

Remarks

Removal Order
Drive pulley bolt/washer

2/2

Installation is in the reverse order of removal.


Hold the drive pulley bolt when loosening and tightening the
driven pulley bolt.

(51
(61
(71
(81

Driven pulley guide


Timing belt
Driven pulley/woodruff key
Timing belt tensioner bolt/washer
Tensioner roller/spring
Idle pulley bolt/pulley
Drive pulley bolt/washer

1
1
2/2
1/1
1/1
1/1
1/1

(91

Guide plate A

(10) Drive pulley


(11) Guide plate B

1
1

(11
(21
(31
(4)

Removal/installation (page 8-12)

Hold the crankshaft by placing the transmission in 5th gear


and applying the rear brake when loosening and tightening
the drive pulley bolt.
Install with the groove aligned with the woodruff key on the
crankshaft.
Install the guide plates with the flat side toward the drive
pulley.

8-11

Cylinder Head

Timing Belt Removal/Installation

(1) GUIDE
(2) WASHER

NOTE

Perform this service while the engine is cold.


For easy servicing, remove the spark plugs.

CAUTION

Be careful not to contaminate the timing belt with


oilete.
Do not bend the timing belt excessively.
Removal
Hold the crankshaft and remove the left driven pulley bolt,
washer and guide.

( 3) BOLT

Loosen the timing belt tensioner bolt 1/4-1/2 turn.


Release the tensioner by turning the crankshaft
counterclockwise while holding the right driven pulley,
and temporarily tightening the tensioner bolt.

Tum the crankshaft clockwise and align the T1 Mark on


the drive pulley guide plate with the Index Mark on the
crankcase.

(1) INDEX MARK

(3) PUNCH MARK

CAUTION
When align the T1 Mark with the Index Mark, be
sure that the Punch Mark on the drive pulley guide
plate aligns with the Projection on the crankcase,
too.
Remove the timing belt from the pulleys.

CAUTION
Do not turn the camshafts after removing the
timing belt or you may damage the valves and
piston domes.
Installation

NOTE
When the camshafts are removed, install the camshaft I
first (page 8-6). then install the timing belt.
Before installing the timing belt, move the tenaioner
pulley to the fully released position and temporarily
tighten the teC"'='CoC"CeC'CbCoCIt,.

8-12

Cylinder Head
Align the T1 Mark on the drive pulley guide plate with the
Index Mark on the crankcase.
CAUTION
When align the T1 Mark with the Index Mark, be
sure that the Punch Mark on the drive pulley guide
plate aligns with the Projection on the crankcase,
too.
Align the Index Lines on the driven pulley with the Index
Marks of the reduction holders.
NOTE
When the Index Line is aligned with the Index Mark:
-on right cylinder head, the Index lines on the
camshaft end are facing outward and align with the
top of the cylinder head.
-on left cylinder, the Punch Marks on the camshaft
end are facing outward and align with the top of the
cylinder head.
Install the timing belt on the drive pulley, next on the left
driven pulley, then on the right driven pulley.

(2) INDEX MARK


(5) INDEX MARK

~
~

(3) INDEX LINE

..

(4) INDEX LINE


(1) INDEX LINES

-'",

1-'././,

/Q-o

, ,-

-', "~

,i

(6) PUNCH MARKS

(7) INDEX MARK


(9) PUNCH
MARK

(8) Tl MARK

(10) PROJECTION

Install the left driven pulley guide, washer and bolt, and
tighten the bolt while holding the crankshaft.
Torque: 27 Nom (2.7 kg-m, 20 ft-Ib)
Loosen the timing belt tensioner bolt to apply the tension
to the belt. Then turn the crankshaft 2 to 4 full turns to
stabilize the belt run, and tighten the bolt.
Torque: 46 Nom (4,6 kg-m, 33 ft-lb)
When installing a new belt, apply initial tension to the belt
as follows:

8-13

Cylinder Head
Loosen the tensioner bolt.
Turn the crankshaft clockwise 2 to 4 full turns, and align the
T1 Mark with the Index Mark. (The Index Lines on the driven
pulleys must align with the Index Marks.)
CAUTION
When align the T1 Mark with the Index Marit, be
sure that the Punch Mark on the drive pulley guide
plate aligns with the Projection on the crankcase,
too,
Then turn the crankshaft ckockwise 3 teeth further and
tighten the tensioner bolt.

Torque: 46 Nom (4.6 kg-m, 33 ft-Ib)

8-14

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

...

Replace the partts] with new onets) before assembly.

Is :;O=ooLI

Use special tool

IOP~OOLI

Use optional tool. Use the same procedure you use to order parts.

Torque specification.

10 Nm (1.0 kg-m, 7.2 ft-lb)

10 (1.0, 7.2)

-:71

-,
..~

Use recommended engine oil, unless otherwise specified.

Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1

Use multi-purpose grease (Lithium based multi-purpose grease NLGI #2 or equivalent)

Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote BR-2 plus manufactured by Dow Corning, U.S.A.
Multi-purpose M-2 manufactured by Mitsubishi Oil Japan

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

Use silicone grease

Om

Apply a locking agent. Use a middle strength locking agent unless otherwise specified.

"I~

Apply sealant

Use brake fluid, DOT 3 or DOT 4. Use the recommended brake fluid, unless otherwise specified.

Use Fork or Suspension Fluid.

1) .

9. Clutch
Service Information

9-1

Troubleshooting

9-1

Clutch Master Cylinder Disassembly/


Assembly

Clutch Slave Cylinder Removal/


Installation

9-4

Clutch Disassembly/Assembly

9-6

9-2

Service Information
DOT 4 brake fluid is used for the hydraulic clutch and is referred to as clutch fluid in this section. Do not use other
types of fluid as they are not compatible.
Engine oil viscosity and level and the use of oil additives have an effect on dutch disengagement. Oil additives of any
kind are specifically not recommended. When the clutch does not disengage or the vehicle creeps with clutch disengaged, inspect the engine oil for proper level and the presence of additives before servicinq the clutch system.
Clutch maintenance can be done with the engine in the frame.

Troubleshooting
Clutch lever soft or spongy
Air in hydraulic system
Low fluid level
Leaking hydraulic system

Clutch lever too hard


Sticking master piston
Sticking slave cylinder piston
Clogged hydraulic system

Clutch slips
Sticking hydraulic system
Worn discs
Weak clutch springs
Hydraulic system clogged
Oil additive used

Clutch operation feels rough


Rough clutch outer slots
Sticking master piston
Sticking slave cylinder piston

Clutch will not disengage or motorcycle creeps with


clutch disengaged
Warped plate
Loose clutch lock nut
Oil level too high, improper oil viscosity or oil additive

"..d
Air in hydraulic system
low fluid level
leaking or sticking hydraulic system

9-1

Clutch

Clutch Master Cylinder Disassembly/Assembly

X: IB)

1.5 (0.15, 1.1)

19)

\
)10)

-1--'/

15)

X:

12 (1.2, 9)

f!~J!-----(6)

Boot:
'91-'94

(19)

(2)

X:
35 (3.5, 25)

(12)

X:

1 {0.1, 0.7)

(1)
(7)

1.2 (0.12, 0.9)

X:

(17)

(11 )

ISTOO~I

6 (0.6, 4.3)
(14)

(13)

9-2

Clutch
CAUTION
Avoid spilling hydraulic clutch fluid on painted. plastic. or rubber parts. Place a rag over these parts whenever the
system is serviced.
When removing the oil bolt. cover the end of the clutch hose to prevent contamination. Do not allow the foreign
material to enter the system.
Handle the master piston. spring, primary cup and secondary cup as a set.
Do not allow the lips of the master cylinder cups to tum inside out and be certain the snap ring is firmly seated
in the groove.
NOTE

Use only DOT 4 brake fluid from a sealed container.

Requisite Service

Clutch fluid draining


Procedure

(II
(21
(31
(41
(51
(61
(71
(81
(91
(101

(' 11
(12)
('31
('41
(151
('61
('71
('81
('91
(201
(211

Removal
Clutch switch wire
Oil bolt
Sealing washer
Clutch hose
Master cylinder holder bolt
Master cylinder holder
Clutch switch
Reservoir cap screw
Reservoir cap
Set plate/diaphragm
Clutch lever pivot nut
Clutch lever pivot screw
Clutch lever
Push rod end piece
Push rod
Boot
Snap ring
Washer
Master piston
Primary cup
Spring

Q'ty

,
,,
,,

Remarks
Installation is in the reverse order of removal.

2
2

Remove the master cylinder assembly from the handlebar.

2
I

1/'
I
I

,,
,,
,,
1

Use snap ring pliers (07914-3230001).

I
I

9-3

Clutch

Clutch Slave Cylinder Removal/Installation


15)

(4)

(7)

131
12)

CAUTION
Avoid spilling hydraulic clutch fluid on painted. plastic. or rubber parts. Place a rag over these parts whenever the
system is serviced.
When removing the oil bolt. cover the end of the clutch hose to prevent contamination. Do not allow the foreign
material to enter the system.
NOTE
Use only DOT 4 brake fluid from a sealed container.

Requisite Service
lower fairing removal/installation (page 2-4)
Clutch fluid draining
Procedure
Removal Order
Oil bolt
Sealing washer
Clutch hose
Mounting bolt
151 Slave cylinder assembly
161 Gasket
17) Dowel pin
(8) Slave cylinder piston
(' )
(2)
(3)
(4)

191 Piston seal


110) Spring
(11) Oil seal

9-4

Q'ty

,
,

Remarks
Installation is in the reverse order of removal.

2
3

1
1
2

1
1
1

If piston removal is difficult, wrap the slave cylinder with a


shop towel and apply compressed air to the fluid inlet to
remove the piston.

Clutch

MEMO

9-5

Clutch

Clutch Disassembly/Assembly

14)

/(12)

'A"'J'"\

(131

Clutch
NOTE

It is not necessary to disconnect the clutch hydraulic system for clutch disassembly/assembly.

Requisite Service
Engine oil draining
Clutch slave cylinder removal/installation (page 9-4)
Right exhaust pipe removal/installation (page 2-18)
Q'ty

Procedure

111
(21
(31
(41
(51
(61

(71
(81
(91
(101
(111
(121
(131

Disassembly Order
Clutch cover bolt
Clutch cover
Gasket
Dowel pin
Litter rod
utter plate bolt

9
1
1
2
1
5

Lifter plate
Lifter rod guide
Clutch spring
Lock nut
Lock washer
Clutch assembly
- pressure plate

1
1
5
1
1
1
1

Assembly is in the reverse order of disassembly.

(141 - clutch disc


(151 -clutch plate
(161 -judder spring '91 only:
(171
(18)
(191
(201

-spring seat '91 only:


- clutch center
-Washer
Clutch outer

Remarks

10
9
1

1
1
1
1

NOTE:
, After tightening the belts, check that the lifter rod guide
rotates smoothly.
Remove from the lifter plate.
Removal/installation (page 9-8)
Install with the "OUr wark facing out.
At installation, align the ~ ... ~ marks on the pressure plate
and clutch center as shown.

At installation, install with the convex side facing to the


pressure plate as shown.

At installation, install with the chamfered side facing out.


Installation (page 9-8)

9-7

Clutch
Clutch Lock Nut Removal/Installation
Removal
Unstake the clutch lock nut with a drill or grinder. Using
the special tools, place a collar in each of the slots marked
with a "5 on the tool.
Install the clutch center holder by aligning the collars in
the slots so they fit over the bosses in the clutch center.
Using a 17 mm wrench, tighten the collar nuts in position.
Secure the holder to the clutch center using the clutch
spring bolts.
Hold the clutch center with the clutch center holder and
remove the lock nut.

(1) LOCK NUT_I


WRENCH

>""1

(4)

<""~

Nd~~

HOLDER-:c~~~~~

COLLAR

(3) CLUTCH CENTER


HOLDER

07JMB-MN50300 or
07HGB-001010B
(U.S.A. only)
Clutch holder collar (3 pieces) 07LMB-MT30100 or
07MPB-764021A
Clutch center collars "B"
(U .S.A. only)
Lock nut wrench, 30 x 32 mm 07710-0020400 l
07716-0020500 l
Extension bar
Equivalent commercially
available in U.S.A.
Clutch center holder

Installation
Hold the clutch center with the clutch center holder as
described above.

07JMB-MN50300 or
07HGB-001010B
(U.S.A. only)
07LMB-MT301oo or
Clutch holder collar (3 pieces)
07MPB-764021A
Clutch center collars "B"
(U.S.A. only)
Lock nut wrench, 30 x 32 mm 07716-0020400 l
07716-0020500 l
Extension bar
Equivalent commercially
available in U.S.A.
Install a new lock nut and tighten it.
Clutch center holder

Torque: 110 Nem (11.0 kg-m, BOft-lb)


Stake the lock nut.
Clutch Outer Installation
Install the clutch outer onto the primary damper shaft and
mesh it with the primary drive sub gear.
Turn the clutch outer counterclockwise while pushing
inward as shown to align the primary drive sub gear teeth
with the primary drive gear teeth. The clutch hub will move
inward when the gear teeth align.

(1) CLUTCH OUTER

9-8

(2) EXTENSION BAR

Clutch
Turn the oil pump driven sprocket with a screwdriver as
shown while pushing the clutch outer in until you feel a click.
At this time. the holes in the clutch outer are aligned with
the pins on the oil pump drive sprocket. Push in the clutch
outer further to insert the pins into the holes.

9-9

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

...

Replace the partts] with new onets) before assembly.

Is :;O=ooLI

Use special tool

IOP~OOLI

Use optional tool. Use the same procedure you use to order parts.

Torque specification.

10 Nm (1.0 kg-m, 7.2 ft-lb)

10 (1.0, 7.2)

-:71

-,
..~

Use recommended engine oil, unless otherwise specified.

Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1

Use multi-purpose grease (Lithium based multi-purpose grease NLGI #2 or equivalent)

Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote BR-2 plus manufactured by Dow Corning, U.S.A.
Multi-purpose M-2 manufactured by Mitsubishi Oil Japan

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

Use silicone grease

Om

Apply a locking agent. Use a middle strength locking agent unless otherwise specified.

"I~

Apply sealant

Use brake fluid, DOT 3 or DOT 4. Use the recommended brake fluid, unless otherwise specified.

Use Fork or Suspension Fluid.

1) .

10. Gearshift Linkage/Transmission


Service Information

10-1

Troubleshooting

10-1

Gearshift Linkage Removal/


Installaton

10-2

Primary Damper Shaft Disassembly/


Assembly

10-5

Transmission Removal/Installation

10-6

Transmission Disassembly/Assembly

10-8

Transmission Unit/Primary Damper

Shaft Removal/Installation

10-4

Service Information
The gearshift linkage can be serviced with the engine installed in the frame.
The transmission can be removed as a unit without separating the crankcases.

Troubleshooting
Hard to shift
Improper clutch operation

Incorrect engine oil weight


Bent shift forks
Bent shift fork shaft
Bent shift fork claw
Damaged shift drum cam groove
Bent gearshift spindle
Transmission jumps out of gear
Worn gear dogs or slots
Broken shift drum stopper arm
Worn or bent shift forks
Broken shift linkage return spring

10-1

Gearshift LinkagelTransmission

Gearshift Linkage Removal/Installation

(6)

(12)
(17)

(16)

(14)

r<f:r-----{B)

(10)

(2)

17)

(1)

12{1.2,9)

jet
(4)

10-2

23 (2.3,17)

Gearshift Linkage/Transmission
Requisite Service

Swingarm removal/installation (page 14-8)


Procedure

(11
(21

Removal Order
Gearshift arm bolt
Gearshift arm

Q'ty

Installation is in the reverse order of removal.


1

(10)
(11)

1
1
1
4
1

(12)
(13)
(14)
(15)
(16)
(17)

Dowel pin
Stopper arm bolt
Collar
Return spring
Stopper arm
Washer

1
1
1
1
1
1

(5)
(5)

(7)
(8)
(9)

After '91: Align the wide groove on the gearshift arm


with the wide tooth on the gearshift spindle.

Bolt
Gearshift linkage cover
Gasket
Dowel pin
Gearshift spindle assembly
Shift drum center bolt
Shift drum center plate
Dowel pin
Shift drum center

(3)
(4)

Remarks

1
1

2
Pull out the spindle while pushing the shift pawl in.

Align the groove in the shift drum center with the


dowel pin.

10-3

Gearshift Linkage/Transmission

Transmission Unit/Primary Damper Shaft Removal/Installation

141

NOTE
The transmission can be removed from the engine as an unit.
The transmission unit can be removed with the clutch installed.
The clutch and oil pump drive sprocket must be removed to remove the primary damper shaft.

Requisite Service
Engine removal/installation (page 7-2)
Clutch disassembly/assembly (page 9-6)

ow

Procedure

(I)
(2)
(3)
(4)

1'1

Removal Order
Transmission unit mounting bolt
Transmission unit
Gasket
Dowel pin
Primary damper shaft

10-4

,,
8

,
2

Remarks
Installation is in the reverse order of removal.

Gearshift LinkagelTransmission

Primary Damper Shaft Disassembly/Assembly


(4)

(2)

L-o
t

(8)

(5)

(6)

(1)

(1)-----~

Requisite Service
Primary damper shaft removal/installation (page 10-4)
Procedure

, I Disassembly Order
(1) , Primary spring cotter

O'tv

Remarks
Assembly is in the reverse order of disassembly.
Set the damper shaft assembly in a hydraulic press
with the washer {3l supported. Compress the spring
approx. 5 mm (0.2 inl, slide the retainer (2) up and
remove the cotters as shown.
CAUTION
Do not compress the spring more than 7 mm
(0.28 in).

(2)
(3)
(4)

(51
(61
(71
(8)
(9)

Primary spring retainer


Washer
Primary damper spring
Spring stopper washer
Washer
Damper cam
Primary damper lifter
Primary shaft

,,
1

,
,,

I Install with the small coil end facing away from the
pimary damper lifter as shown.

10-5

Gearshift LinkagelTransmission

Transmission Removal/Installation

121

141

191

,
,

151

11.o-~_171

131

161

181
o

111

10-6

Gearshift Linkage/Transmission
Requisite Service
Gearshift linkage removal/instaliation (page 10-2)
Transmission unit removal/installlation (page 10-4)
Procedure
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)

Disassembly Order
Transmission case cover bolt
Transmission case
Dowel pin
Shift fork shaft
Aear shift fork
Center shift fork
Gearshift drum
Front shift fork
Mainshaft/countershaft assembly

Q'ty

Remarks
Assembly is in the reverse order of disassembly.

2
1
1

1
1

,,

Install with the "A" mark facing down (forward).


Install with the "C" mark facing down (forward),
Install with the "F" mark facing down (forward).

10-7

Gearshift Linkage/Transmission

Transmission Disassembly/Assembly
After '91

Mainshaft

: SHIFTER GEAR
GROOVE
: GEAR SLIDING
SURFACE

24T
(9)

(9)

(2)

(11 )

(4)

16)

16/21T

(4)

18)

(8)
(5)

NOTE

Always install the thrust washers and snap rings with the chamfered (rolled) edge facing away from the thrust load.
After installing a snap ring, slightly open the ring and rotate it in its groove to be sure it is fully seated.
Do not use worn snap rings which could easily spin in the groove. They may be too loose to properly seat in the
groove. Align the gap in the snap ring with the groove in the spline.
Align all oil holes in the bushings with the shaft oil holes.

Requisite Service
Transmission removal/installation (page 10-61
Procedure
0)
(2)
(3)
(4)
(5)
(6)
(7)
(B)
(9)
(10)
(11)

Disassembly Order
Washer
M5 gear (29T)
M5 gear bushing
Spline washer
Snap ring
M2IM3 gear (18121
Snap ring
Spline washer
M4 gear (24T)
M4 gear bushing
Mainshaft/M1 gear (15n

10-8

Remarks

Q'ty

I Assembly is in the reverse order of disassembly.

1
1
1
1

,,
1

~ I

Align the gap with the groove in the spline.

Gearshift Linkage/Transmission

Countershaft

22T
(16)

: SHIFTER GEAR
GROOVE
(' 5)

: GEAR SLIDING
SURFACE

(10)

(16\) ('3) ('2)

T
+

(17)

+
(3)

(5)
(15)

(7)

(3)
(4)
(5)
(6)
(7)
(6)
(9) I
(10)
(11 )
('2)

(13)
(14)
(15)
(16)
(17)

22T

(14)

Procedure
(I)
(2)

(6)

Disassembly Order
Washer
Cl gear (34T)
Cl gear needle bearing
Washer
C4 gear (22T)
Snap ring
Spline washer
C3 gear (24n
C3 gear bushing
Lock washer
Spline washer
C2 gear (27T)
C2 gear bushing
Spline washer
Snap ring
C5 gear (22T)
Countershah

, O'ty

Remarks
Assembly is in the reverse order of disassembly.

1
1
1
1

,,
,,

!
i

1
1
1
1
1
1
1
1

10-9

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

...

Replace the partts] with new onets) before assembly.

Is :;O=ooLI

Use special tool

IOP~OOLI

Use optional tool. Use the same procedure you use to order parts.

Torque specification.

10 Nm (1.0 kg-m, 7.2 ft-lb)

10 (1.0, 7.2)

-:71

-,
..~

Use recommended engine oil, unless otherwise specified.

Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1

Use multi-purpose grease (Lithium based multi-purpose grease NLGI #2 or equivalent)

Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote BR-2 plus manufactured by Dow Corning, U.S.A.
Multi-purpose M-2 manufactured by Mitsubishi Oil Japan

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

Use silicone grease

Om

Apply a locking agent. Use a middle strength locking agent unless otherwise specified.

"I~

Apply sealant

Use brake fluid, DOT 3 or DOT 4. Use the recommended brake fluid, unless otherwise specified.

Use Fork or Suspension Fluid.

1) .

11. Crankcase/Piston/Crankshaft
Service Information

11 -1

Troubleshooting

11-1

Crankcase Separation/Assembly

11-2

Crankshaft/Connecting Rod
Removal/Installation

11-4

Piston Removal/Installation

11-8

Primary Drive Gear/Starter Clutch


Removal/Installation

11-10

Service Information
CAUTION
Improper installation of bearing inserts may block the oil holes, causing insufficient lubrication and eventual
engine seizure.

Remove the engine and separate the crankcases to inspect the crankshaft, connecting rod and starter clutch.
Mark and store the connecting rod and crankshaft bearing inserts so they can be installed in their original locations for
reassembly.
Prior to assembling the crankcase halves, apply a sealant to their mating surfaces. Wipe off excess sealant thoroughly.
Mark and store the disassembled parts to ensure that they are reinstalled in their original locations.

Troubleshooting

III

Excessive noise
Worn connecting rod bearings
Bent connecting rod
Worn crankshaft main journal bearing

11-1

Crankcase/Piston/Crankshaft

Crankcase Separation/Assembly

(12)

'91-'95

-:71
52 (5 2, 38)

161

~171

12 (1.2, 9)

1,1--__ (5)

1131

I~/
...-/'

13 1 _

~---121
I

191

o
11-2

23 (2.3, 17)

4-

1~

lll

Crankcase/Piston/Crankshaft
CAUTION
Improper installation of bearing inserts may block the oil holes causing insufficient lubrication and eventual
engine seizure.
NOTE

Mark all parts during disassembly so they can be replaced in their original position.
All bearing inserts are select fitted and are identified by color code. Select replacement bearings from the selection
tables (pages 11-6 and 11-7).

Requisite Service
Engine removal/installation (page 7-2)
Cylinder head removal/installation (page 8-2)
Oil cooler removal/installation (page 4-4)
Alternator removal/installation (page 17-18)
Starter motor removal/installation {page 20-B}
Procedure

(2)
(3)
(4)
(5)

(6)
(7)
(B)
(9)

(10)
(11)
(12)
(13)
(14)

Separation Order
Bolt
Water cover/pipe
O-ring
Bolt/cooler hose guard
Clutch cover base"
Gasket
Dowel pin
Upper crankcase bolt 6 mm
Bmm
Lower crankcase bolt 6 mm/stay
B mm
10 mm/washer
Dowel pin
Crankshaft main journal bearing

i O'rv

Water pump removal/installation (page 6-7)


Transmission/primary damper shaft removal/installation
(page 10-4)
Timing pulley removal/installation (page 8-10)
Ignition pulse generator (page 18-9)
Remarks
Assembly is in the reverse order of disassembly.

I
,

3
1

1
7/1
1
1
2
2
1
4/1

6
6/6

3
3

Hose guard: '91-'95 only

Washer: '91-'95 only


Selection (page 11-6). See CAUTION above.

11-3

Crankcase/Piston/Crankshaft

Crankshaft/Connecting Rod Removal/Installation

36 (3.6, 26)
(1)

(2)
(4)

(5)

(6)

(7J

(4)

(3)

11-4

Crankcase/Piston/Crankshaft
CAUTION
Improper installation of bearing inserts may block the oil holes causing insufficient lubrication and eventual
engine seizure.

NOTE
Mark all parts during disassembly so they can be replaced in their original position.
All bearing inserts are select fitted and are identified by color code. Select replacement bearings from the selection
~_ _
tables (pages 11-6 and 11-7).

Requisite Service
Crankcase separation/assembly (page 11-2)
Procedure
(I)
(2)
(3)

(4)
(5)

(6)
(7)

Removal Order
Connecting rod bearing cap nut
Connecting rod bearing cap
Connecting rod/piston assembly
Connecting rod bearing
Crankshaft
Crankshaft thrust bearing

I Crankshaft journal bearing

O'ty

Remarks
Installation is in the reverse order of removal.

4
4
B

;' Piston removal/installation (page 11-8)


Selection (page 11-6). See CAUTION above.

1
2

At installation, align the tab with the groove in the


case.
Selection (page 11-6). See CAUTION above.

11-5

Crankcase/Piston/Crankshaft
Main Journal Bearing Selection
Record the crankcase 1.0. code letters on the front side of
the upper crankcase.
NOTE
Letter A, B or C is the code for the main jounal 1.0.
The numerals 1, 2 and 3 stand for the crankshaft
main journals, as viewed from the front.

(1) MAIN JOURNAL 1.0. CODE

Record the main journal 0.0. code numbers on the crank


weights.
NOTE

Number 1, 2 or 3 is the code for the main journal 0.0.

, ,
2

(1) MAIN JOURNAL 0.0. CODE

Cross reference the case and journal codes to determine


the replacement bearing color code.

~'

(1) COLOR CODE

I.D.code 43.000-

Main journal
0.0. code

43.006- 43.01243.006 mm 43.012 mm 43.018 mm


i (1.6929- (1.6931- I (1.69331.6931 in) 1.6933 in) 1.6936 in)

39.994--40.000 mm
(1.5746-1.5748 in)

Yellow

Green

Brown

39.988-39.994 mm
(1.5743-1.5746 in)

Green

Brown

Black

3 39.982-39.988
(1.5741-1.5743 in)

Brown

Black

Blue

See section 14 of the Common Service Manual for crankshaft main bearing oil clearance inspection.

Connecting Rod Bearing Selection


Record the connecting rod 1.0. code number on the connecting
<ad.
NOTE

Number 1, 2 or 3 is the code for the connecting rod


to. code.

11-6

(1) CONNECTING ROD 1.0. CODE

Crankcase/Piston/Crankshaft
Record the crankpin 0.0. code letters on the crank weights.
NOTE
[

le-tt-e-'~A-.~B-o-'-C--c;,--cthe code for the

crank pin 0.0.

(1l CRANK PIN 0.0. CODE

Cross reference the connecting rod and crankpin codes to


determine the replacement bearing color code.

~
I.D. code

Crank pin
O.D. code

(1) COLOR CODE

43.000- 43.006- 43.01243.006 mm 43.012 mm 43.018 mm


(1.6929- {1.6931- (1.69331.6931 in) 1.6933 inl 1.6936 inl

A 39.994-40.000 mm
(1.5746-1.5748 in)

Yellow

Green

Brown

B 39.988-39.994 mm
(1.5743-1.5746 in)

Green

Brown

Black

C 39.982-39.988
(1.5741-1.5743 in)

Brown

81ack

Blue

See section 14 of the Common Service Manual for


connecting rod bearing oil clearance inspection.

11-7

Crankcase/Piston/Crankshaft

Piston Removal/Installation

(4)

(5)

Left cylinder piston


"IN" mark

171

Oil hole

(21

(11

/~

Right cylinder piston

"IN" mark

Oil hole

11-8

<<::

Crankcase/Piston/Crankshaft
Requisite Service
Connecting rod removal/installation (page 11-4)
Procedure

Q'ty

. I Removal Order
Piston pin clip
Piston pin
Piston

Piston top ring


Piston second ring
(6: I Side rail
(7) Spacer

1
1

0)
(2)
(3)

(4)

(5)

Remarks
Installation is in the reverse order of removal.

1
1

Install the left cylinder piston so that the ~IW mark


is facing the same direction as the oil hole in the
connecting rod as shown.
N
Install the right cylinder piston so that the NIN mark
is facing the opposite direction as the oil hole in the
connecting rod as shown.
Install with the marking facing up.
Stagger position of ring end gaps as shown.

2-

1-

11-9

Crankcase/Piston/Crankshaft

Primary Drive Gear/Starter Clutch Removal/Installation


{9}

(12}

(111

iIiIII

16(1.6,12)
(10}

{BI

\J/

~ ..
t?

t?

~~~~~

{5}

(13)
{1}

{21
{3}

i\)~

{7}

{6}

"'I

After '91:

o
{.}

11-10

..,

Crankcase/Piston/Crankshaft
NOTE
The starter idle gear can be removed without removing the crankshaft.

Requisite Service

Crankshaft removal/installation (page 11-4)


Q'ty

Procedure
(' )
(2)
(3)

(41
(51
(6)
(7)

(6)
(9)
(10)
(11 )
(12)
(13)
(,)
(b)

(el
(d} !

Removal Order
Collar
O.ring
Stopper circlip
Primary drive gear
Starter clutch assembly
- Starter driven gear
- Needle bearing
- Snap ring
- Starter clutch
- Bolt
- Alternator drive gear
- Starter clutch outer
Washer
Bolt/washer
Starter idle gear shaft
Starter idle gear
Oil separate plate After '91

Remarks
Installation is in the reverse order of removal.

,,
,
,
1

Install with the "our mark facing out.


At installation. align the wide groove in the starter
clutch outer with the wide tooth on the crankshaft.

1
1
1

8
1
1
1

,,
1

Install in position shown at assembly.

11-11

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

...

Replace the partts] with new onets) before assembly.

Is :;O=ooLI

Use special tool

IOP~OOLI

Use optional tool. Use the same procedure you use to order parts.

Torque specification.

10 Nm (1.0 kg-m, 7.2 ft-lb)

10 (1.0, 7.2)

-:71

-,
..~

Use recommended engine oil, unless otherwise specified.

Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1

Use multi-purpose grease (Lithium based multi-purpose grease NLGI #2 or equivalent)

Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote BR-2 plus manufactured by Dow Corning, U.S.A.
Multi-purpose M-2 manufactured by Mitsubishi Oil Japan

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

Use silicone grease

Om

Apply a locking agent. Use a middle strength locking agent unless otherwise specified.

"I~

Apply sealant

Use brake fluid, DOT 3 or DOT 4. Use the recommended brake fluid, unless otherwise specified.

Use Fork or Suspension Fluid.

1) .

12. Final Drive


Service Information

12-1

Final Gear Case Removal/Installation 12-3

Troubleshooting

12-1

Final Gear Case Disassembly

12-4

Driveshaft Disassembly/Assembly

12-2

Final Gear Case Assembly

12-6

Service Information
Replace all oil seals and O-rings whenever the final drive gear assembly is disassembled.
Check the tooth contact pattern and gear backlash when the bearing, gear set and/or gear case is replaced.
(Section 15 of the Common Service Manual)

Troubleshooting
Excessive noise in final drive
Worn or damaged ring gear and driven flange
Damaged driven flange or wheel hub
Worn or damaged pinion gear and/or pinion joint splines
Excessive backlash between pinion and ring gears.
Low oil level
Excessive rear wheel backlash
Worn driveshaft splines
Excessive backlash between ring gear and pinion gear
Worn driven flange and ring gear splines
Excessive play in final drive case bearings
Worn driveshah and or pinion joint splines
Oil leaks at final gear case
Clogged breather hole
Oil level too high
Faulty oil seans)

12-1

Final Drive

Driveshaft Disassembly/Assembly

Attachment

(')

(2)

(4)

Base

Requisite Service
Swingarm removal/installation (page 14-8)
O'ty

Procedure

I
(11
(2)
(3)
(4)

(5)
(6)
(7)

Disassembly Order
Snap ring
Spring stopper
Driveshaft spring
Universal joint cotter

Support the driveshaft with the yoke joint compressor


base (07LMF-MT30120), compress the spring with
the yoke joint compressor attachment (07LMF-MT
30110) using the hydraulic press and remove the
cotters as shown.

,,
1

Thrust washer
Damper case

,,

14.8 x 2.4 mm O-ring


19 x 1.9 mm O-ring
Case stopper ring
(11 ) Oil seal
('2) Oil seat guide
(8)
(9)
(10)

12-2

,
1

I Universal joint

('3) Damper cam


('4) Damper spring

Remarks
Assembly is in the reverse order of disassembly.

1
1

,,

Fill the case with 30 cc (1.0 US OZ, 1.1 Imp oz) of


Hypoid gear oil (SAE #80) after installation.

I
Remove from the damper case.
If necessary, remove using the bearing race remover
{07946-371 0500).
Install using the driver (07749----001 CXXlO) and attachment,
52 x 55 mm (07746-0010400).

Final Drive

Final Gear Case Removal/Installation


ABS/TCS model shown:

r;;;;;;,.

til

ABS{TCS or LBSABS{TCS model:

110}

23 (2.3, 17)

151
65 (6.5, 43)

17}

19}

NOTE

ABS/TCS or LBS-ABS/TCS model: After installing the rear wheel, perform the wheel sensor air gap inspection
(page 16-A-51 or 16-B-34).

Requisite Service
Rear wheel removal/installation (page 14-2)
Final gear oil draining
Procedure
(1)
(2)
(3)
(4)
(5)

Removal Order
Wheel sensor mounting bolt
Wheel sensor
Sensor shim
Shock absorber lower mounting bolt
Final gear case mounting nut

(6)

Final gear case assembly

(7)

Driveshaft joint

(8) Oil seal


(9) Driveshaft cap
(10) a-ring

Q'ty
2
1

Remarks
Instllation is in the reverse order of removal.
ABS/TCS or LBS-ABS/TCS model
Remove from wire clamp.

11}
1
4

Support the final gear case and remove the nuts.


At installation, loosely install the nuts, install the rear wheel
completely (page 14-2), then tighten the nuts.
At installation, apply molybdenum disulfide grease to the
driveshaft joint splines and remove the grease from the one
spline groove to allow air to escape from the joint.
Install into the final gear case being careful not to damage
the oil seal lip.
Remove from the driveshaft joint.
Remove from the driveshaft cap.

12-3

Final Drive

Final Gear Case Disassembly


ABS/TCS model shown:

(6)

(4)
(5)

(26)

(27)
(9)
(3)

(25)

(2)

120}
(19)

(23)
(22)

Is TOOL)
(18)

( 1)
(8)

( 17)
{16}

(14)

Is~ooLI

12-4

(7)

(12)
(11)
(10)

Final Drive

----

Always wear insulated gloves when handling a heated gear case to prevent burning your handso

CAUTION

Do-n-o-.-u-s-.-.-o-,cCh-.o--:h-.-atthe
e
final gear case; it may cause warpingo

NOT"E=--

Keep dust and dirt out of the gear case.


Be careful not to damage the case and cover mating surfaces.
Refer to section 15 of the Common Service Manual for the backlash inspection and the gear tooth contact pattern
check. See page 1-11 for the backlash specification.

Requisite Service

Final gear case removal (page 12-3l


Procedure

(I I
(2)
13)
14)
15)
(6)
(7)

(8)
(9)

(10)
(11)
(12)
113)
(14)
115)
116)
(17)
(18)
(19)
(20)
(21 )
(22)

123)
124
125)
126)
127)
128)

Disassembly Order
Distance collar
Standard model
Bolt
ASS/TeS or LBS-ABS/TCS model
Dust guard plate
8 mm gear cover bolt
10 mm gear case cover bolt
Gear case cover
Ring gear

Wave washer
Oil seal
Ring gear bearing
Ring gear shim
O-ring guide
O-ring
Pinion joint nut
Pinion joint
Bolt
Pinion retainer lock washer
Pinion retainer
O-ring
Oil seal
Pinion gear assembly
Pinion bearing/inner race
Pinion gear shim
Final gear case bearing
Oil seal
Breather cap
Ring gear stop pin
Stop pin shim

)1

Remarks

Oty .

1
1
3
1
6
2

I
I

NOTE
If the ring gear stays in the cover, press the ring
gear out of the cover.

,,
1
1

Pry out the bearing from the ring gear.

I
I
I
I
I

Remove by tapping from the opposite side.


Remove from the guide.
Removal (page 12-8)

1
1
1
1

I
1/2

Removal (page 12-8)


Remove from the pinion retainer.
Removal (page 12-9)
Remove from the shaft with the bearing puller.

I
2

Removal (page 12-9)

I
I
I
I

12-5

Final Drive

Final Gear Case Assembly


ABS/TCS model shown:

Iilii

26 (2.6, 19)
(241

63 (6.3, 46)
(25)

.m:iiIt
~

(3)

~[STOOLI

(2)

(201

(23)

"'=....

010

(4)

(1.0,7)

(271

~
fiijii"

I S ;COOL I
-Aoo

(6)

SO'
(7)

(10)

(14)

(28)

.,

(26)

(5)

-[s ~oLI (221

(16)
(17)

(101

0 1 0 fl.0,7)

(15)

CUa
0

110(11.0.80)

12-6

(11 )

Is ;;;OL I
0150 (15.0,108)

(21 )

.....
(18)

Final Drive
NOTE
Keep dust and dirt out of the gear case.
Be careful not to damage the case and cover mating surfaces.
Refer to section 15 of the Common Service Manual for the backlash inspection, the gear tooth contact pattern check
and the ring gear-to-stop pin clearance check.
If the gear set, pinion gear bearing, ring gear bearing, gear case bearing and/or gear case are replaced, install a
1.50 mm pinion gear shim and a 2.00 mm ring gear shim.
The ring gear and pinion gear must be replaced as a set.

Requisite Service

Final gear case installation (page 12-3)


O'ty

Procedure

(I)
(2)
(31
(41

Disassembly Order
Stop pin shim
Ring gear stop pin
Breather cap
Oil seal

1
1
1
1

(51

Final case bearing

(61
(7)

Pinion gear shim


Pinion bearing/outer race

(6)

I Pinion gear assembly

1
112

Oil seal

(12)

O-ring
Pinion retainer
Pinion retainer lock washer

1
1
1

(13)
(14)
(15)
(16)
117)
(18)
(19)

Bolt
Pinion joint
Pinion joint nut
Ring gear shim
Ring gear bearing
O-ring
O-ring guide

1
1
1
1
1
1
1

(20)
121)
122)
123)

Oil seal
Ring gear
Wave washer
Gear case cover

1
1
1
1

(24)
(25)
(26).
(27) I

10 mm gear case cover bolt


8 mm gear case cover bolt
Dust guard plate
Bolt
Standard model
ABS/TCS or LBS-ABS/TCS model
Distance collar

2
6

(9)

Remarks
Selection (page 12-10)
Clean the breather hole and install.
Use the driver (07749--OO10CXXl) and attachment. 52
x 55 mm (07746-0010400).
Use the driver (07749--0010000), attachment, 62 x
I 68 mm (07746--0010500) and pilot, 35 mm (07746. 00408001.
Selection (page 12-10)
Drive onto the pinion gear, using the driver, 40 mm
I.D. (07746-0030100) and attachment, 25mm 1.0.
(07746-0030200).
Drive into the gear case until enough threads are
visible to engage the pinion retainer, using the bearing
race insert attaccnment (07931-4630300).
Install into the pinion retainer, using the driver (077490010000) and attachment, 52 x 55 mm (07746-

(010400).
(10)
(11)

(28)

Install onto the pinion retainer.


, Installation (page 12-8).
NOTE
There are two types (A or B) of lock washers .

Installation (page 12-8)


Selection (page 12-11)
Installation (page 12-9)
Install onto the O-ring guide.
Drive in the ring gear, using the driver (07749001<XXXl) and attachment 42 x 47 mm (07746-00103C0).

Clean the mating surfaces of the case and cover


thoroughly, and apply liquid sealant to them.

1
1
3

[Install with the polished side toward the final gear case.

12-7

Final Drive
Pinion Joint Nut Removal/Installation

(1) PINION JOINT HOLDER

Removal
Install the pinion joint holder and remove the pinion joint
nut.

Pinion joint holder


Pinion joint holder attachment

07924-M E40000
07924-9690102

rf ::::,:/ ;~;
~'

Installation
Install the pinion joint and pinion joint nut.
Install the pinion joint holder and tighten the pinion joint nut.

(2) PINION JOINT HOLDER


ATTACHMENT

(1) PINION JOINT HOLDER


/

r{,

~~",\

Torque: 110 N'm (11.0 kg-m, 80 ft-Ib)


[s -;=001.1

Pinion joint holder


Pinion joint holder attachment

;,J";9',~C',"

07924-ME40000
07924-9690102

(2) PINION JOINT HOLDER


ATTACHMENT

Pinion Retainer Removal/Installation

(1) RETAINER WRENCH

Removal
Remove the pinion retainer with the pinion retainer wrench.

Is-;=001.1
Pinion retainer wrench

07910-MA10100

Installation
Coat the O-ring on the pinion retainer with grease or gear
oil. Screw the pinion retainer in, pressing the pinion bearing
in place, then tighten it with the pinion retainer wrench.
Torque: 150 N'm (15.0 kg-m. 108 ftlbJ
(S ';'"001.1
Pinion retainer w:'8f1ch

12-8

07910-MA10100

(1) RETAINER WRENCH

Final Drive
Pinion Gear Assembly Removal

~g,~~"",;(') SHAFT PULLER

Pull the pinion gear off with the pinion puller.


[s ;"ooLI

Shaft puller

Pinion joint holder


Pinion joint holder attachment

(2) PINION
JOINT
/HOLDER

07931-ME40000 or
07931-ME4010A
(U.S.A. only)
07924-ME40000
07924-9690102

~"

131 PINION
JOINT
HOLDER
AITACHMENT

A,

:::1J
~~~~

Final Gear Case Bearing Removal


Heat the gear case to approximately 80'C (' 76"F)

Always wear insulated gloves when handling the


gear case after it has been heated.

CAUTION

Do not use. a torch to heat the gear case. or it may]


cause warping.
(1) GEAR CASE BEARING

Install the oil seal remover into the gear case bearing.

(1) OIL SEAL REMOVER

is ~oLI
Oil seal remover

07948-4630100

Turn the gear case over and drive the gear case bearing out.

Ring Gear Bearing Installation


If the ring gear assembly was loose against the cover:
Install the original shim onto the ring gear.

(1) OIL SEAL DRIVER

NOTE

If the gear set, pinion bearing, ring gear bearing, gear


case bearing and/or gear case are replaced, install a
2.00 mm thick shim (standard).

Place a new ring gear bearing on the ring gear and drive it
on with the oil seal driver.
[s ;"OOL I

Oil seal driver

07965-MC70100

(2) BEARING

12-9

Final Drive
If the ring gear stayed in the cover:
Press the ring gear bearing into the case cover.

(2) AITACHMENT

(1) DRIVER

[s -;=-oo~l
Driver
Oil seal driver attachment

07749-0010000
07948-8800101

Install the original shim onto the ring gear.


NOTE

If the gear set. pinion bearing, ring gear bearing, gear


case bearing and/or gear case are replaced, install a
2.00 mm thick shim (standard).

Support the bearing inner race with the oil seal driver
attachment, and press the ring gear into the bearing with a
suitable tool.

Is Too~1
Oil seal driver

07965-MC70100

/.'1i!:==
(1) OIL SEAL DRIVER

Stop Pin Shim Selection


Measure the ring gear-to-stop pin clearance (Section 5 of
the Common Service Manual).

Clearance: 0.30-0.60 mm (0.012-0.024 in)


Install a stop pin shim to obtain the correct clearance.
Shim thickness:

A: 0.10 mm
A: 0.15 mm
(3) STOP PIN
(3) STOP PIN

(2l SHIM

Ring Gear Shim Selection


Check the tooth contact pattern (Section 5 of the Common
Service Manual).
If the pattern is not correct, remove and change the pinion
gear shim.
The pattern will shift about 1.5-2.0 mm (0.06-0.08 in)
when the thickness of the shim is changed by 0.1 mm
(0.004 in)
NOTE
Thirteen shims (A-M) are available in thickness
intervals of 0.03 mm. The thinnest is 1.32 mm and
the thickest is 1.68 mm.
The standard shim (G) thickness is 1.50 mm.

12-10

(2) RING GEAR SHIM

Final Drive
Pinion Gear Shim Selection
Check the gear backlash (Section 5 of the Common Service
Manual).
Backlash: 0.05-0.15 mm (0.002-0.006 in)
If the backlash is not within the specifications, remove and
change the ring gear shim.
The backlash is changed by about 0.06-0.07 mm (0.0020.003 in) when the thickness of the shim is changed by
0.10 mm (0.004 in).

NOTE

I Seventeen shims (A-O) are available in thickness


intervals of 0.03 mm. The thinnest is 1.82 mm and
the thickest is 2.30 mm.
!
The standard shim (G) thickness is 2.00 mm.

12-11

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

...

Replace the partts] with new onets) before assembly.

Is :;O=ooLI

Use special tool

IOP~OOLI

Use optional tool. Use the same procedure you use to order parts.

Torque specification.

10 Nm (1.0 kg-m, 7.2 ft-lb)

10 (1.0, 7.2)

-:71

-,
..~

Use recommended engine oil, unless otherwise specified.

Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1

Use multi-purpose grease (Lithium based multi-purpose grease NLGI #2 or equivalent)

Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote BR-2 plus manufactured by Dow Corning, U.S.A.
Multi-purpose M-2 manufactured by Mitsubishi Oil Japan

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

Use silicone grease

Om

Apply a locking agent. Use a middle strength locking agent unless otherwise specified.

"I~

Apply sealant

Use brake fluid, DOT 3 or DOT 4. Use the recommended brake fluid, unless otherwise specified.

Use Fork or Suspension Fluid.

1) .

13. Front Wheel/Suspension/Steering


Service Information

13-1

Fork Removal/Installation

13-11

Troubleshooting

13-1

Left Fork Disassembly

13-14

Handlebar Cover Removal/Installation 13-2

Left Fork Assembly

13-18

Handlebar Removal/Installation

Right Fork Disassembly

13-22

Anti-dive Case Disassembly/Assembly 13-5

Right Fork Assembly

13-26

Front Wheel Removal/Installation

Steering Stem Removal/


Installation

13-30

13-4

13-6

Front Wheel Disassembly/Assembly 13-10

Service Information

-'-------------- Riding on damaged rims impairs safe operation of the vehicle.

When servicing the front wheel, support the motorcycle securely with a jack or other support under the engine.
Tubeless tire removal, repair, and remounting procedures are covered in the section 16 of the Common Service
Manual. When remounting the tire, note the normal rotating direction.
Refer to the section 15 for brake system information.
Refer to the section 21 for light, meter and switch information.

Troubleshooting
Hard steering
Steering head bearing adjustment nut too tight
Faulty steering head bearings
Damaged steering head bearings
Low tire pressure
Faulty tire
Steers to one side or does not track straight
Bent fork
Bent front axle: wheel installed incorrectly
faulty steering head bearings
Bent frame
Worn wheel bearings
Worn swingarm pivot bearings

Soft suspension
Weak fork springs
Low fluid level in fork
Faulty anti-dive system

III

Hard suspension
Incorrect fluid viscosity
Bent fork tubes
Clogged fluid passage
Front suspension noise
Low fluid level in fork
Loose fork fasteners
Lack of grease in speedometer gearbox

Front wheel wobbling


Bent rim
Worn front wheel bearings
Faulty tire
Wheel turns hard
Brake misadjusted
Faulty wheel bearings
faulty speedometer gear

13-1

Front Wheel/Suspension/Steering

Handlebar Cover Removal/Installation

'91-'94

(31

Holes

4.3 (0.43, 3.1)

(41--~~;$'

T'b

Procedure

O'tv

Remarks
-

(1)
(2)
(3)

(4)

Removal Order
Screws
Handlebar upper cover
Bolt
Handlebar lower cover

13-2

Installation is in the reverse order of removal.

At installation, align the pins with the holes in the lower


cover and insert the tab into the latch securely.

Front Wheel/Suspension/Steering

After '94

(5)

(2)

/~~

/<vp

(1)

1:----(6)
(4)

Procedure

(11
(2)
(3)

(4)
(5)
(6)

Removal Order
Trim clip
Screw
Handlebar rear cover
Screw
Handlebar front cover
Handlebar cover stay

Q'ty

Remarks
Installation is in the reverse order of removal.

4
4
1
1
1

13-3

Front Wheel/Suspension/Steering

Handlebar Removal/Installation
(15)

(1)

(3)

(16)

(9)

(5)

-(7)

C
4.2 (0.42, 3.0)

12(1.2,9)
(13)

27 (2.7, 20)

(14)

Requisite Service

Handlebar cover removal/installation (page 13-2)


Procedure

I Disassembly Order
(1) Clutch switch wire
(2) Clutch master cylinder holder
(3) I Clutch master cylinder

(4)
(5)
(6)
(7)
(8) i

Left handlebar switch


Choke cable
Front brake light switch wire
Brake master cylinder holder
Brake master cylinder

(9) I
(10)
(11)
(12)
(13)
(14)

Right handlebar switch


Wire band
Handlebar weight screw
Handlebar weight
Handlebar upper holder bolt
Handlebar upper holder

(15:) Throttle grip


(16) Throttle cable
(17) Handlebar
Ii

13-4

Q'ty

Remarks
Assembly is in the reverse order of disassembly.

2
1
1

CAUTION
Keep master cylinder upright, to prevent air
from entering the system.

1
2
1
1

Disconnect from the choke lever flange.

CAUTION
Keep master cylinder upright, to prevent air
from entering the system.

1
2
2

2
4

2
1
2
1

I Disconnect from the throttle grip flange.

Front Wheel/Suspension/Steering

Anti-dive Case Disassembly/Assembly

(9)
(8)

(7)
(6)

(3)
(2)

(11

o
1IIIIiI (5)

4 (0.4. 2.9)

The anti-dive case is under spring pressure. Use care when removing the case to keep it from becoming a
projectile.

Requisite Service
Left fork oil draining (Standard and ABS/TCS model)
Right fork oil draining (LBS-ABS/TCS model)
Procedure
-

Disassembly Order

I' ) Stop ring


12)
13)
14)
15)
16)
17)
18)
19)
(10)
(11)

Pivot collar
Bushing
Rubber boot
Socket bolt
Case cover
O-ring
Piston seal
Oil seal
Anti-dive piston
Spring

O'tv
-

,,
,

Remarks
,

Assembly is in the reverse order of disassembly.

,,
,,,
,
4

13-5

Front Wheel/Suspension/Steering

Front Wheel Removal/Installation


Standard and ABS/TCS Model
ABS/TCS model shown:

Wheel sensor

~(101
C

(5)

(121

90 (9.0, 65)

(61~

(11 )

:X:

22 (2.2,16)

(141

(91

(151
(13)

13-6

(BI

Front Wheel/Suspension/Steering

..

A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated
disc with a high quality braka degreasing agent.
Brake dust may contain asbestos. Inhaled asbestos fibers have been found to cause respiratory disease and cancer.
Never use an air hose or dry brush to clean brake assembly. Use an OSHA-approved vacuum cleaner or an alternate
method epprovedbv OSHA, designed to minimize the hazard caused by airborne asbestos fibers.

CAUTION

After installing the front wheel. apply the front brake and check the brake operation.

NOTE

Do not depress the brake lever when the caliper is removed, or it will be difficult to refit the disc between the brake
pads.

Requisite Service

Raise the wheel off the ground by placing a jack or other support under the engine .

O'tv

Procedure
111
(21
(31
(41
(51
(61
(71

Removal Order
Wheel sensor wire grommet (ABSjTCS
model only)
Bolt
Front brake hose stay
Socket bolt
Front fender
Front fender plate
Right front brake caliper mounting bolt

,
(81
(91
(101
(11)
(12)
(131
(141
(15)

2
2
2
2

Installation is in the reverse order of removal.


Remove the left grommet first.

Remove from the front forks.

1
1
2

I
Speedometer cable set screw
Speedometer cable
Front axle bolt
Front axle pinch bolt
Front axle
Front wheel assembly
Right side collar
Speedometer gear box

Remarks

CAUTION
ABSiTCS model only: Be careful not to damage the tip
of the wheel sensor.
Do not heng the caliper from the brake hose. Air
may enter the brake system.

1
1

,
4

Loosen the bolts.

1
1
1
1

13-7

Front Wheel/Suspension/Steering

LBS-ABS/TCS Model
14)

0 1 2 (1.2, 9)

0 3 0 (3.0, 22)
_~

(1)

12)

(7)

~"..I

0 9 0 (9.0, 65) ....... __

'
(9)

li

\,

(8)

022 (2.2, 16)

(11)

(6)
(5)

(12)

13-8

Front Wheel/Suspension/Steering

A contaminated brake disc or pad reduces stopping power, discard contaminated pads and clean contaminated disc
with a high quality degreasing agent.
Inhaled asbestos fibers have been found to cause respiratory disease and cancer. Never use an air hose or dry brush
to clean brake assemblies.

CAUTION

I. After installing the front wheel. operate the brake lever and pedal and check the brake operation {page 313).
NOTE
Do not depress the brake lever or pedal when the front caliper is removed, or it will be difficult to refit the disc
between the brake pads.

Requisite Service
Raise the wheel off the ground by placing a jack or other support under the engine.
Frant fender removal/installation (page 2-11).
Procedure
Removal Order
Sensor bracket bolt

Wheel sensor assembly

(3)

Right front brake caliper mounting bolt

(4)

Front brake caliper/pivot collar


Speedometer cable setting screw
Speedometer cable
Front axle bolt
Front axle pinch bolt
Front axle
Front wheel assembly
Right side collar
Speedometer gear box

(1)

(2)

(5)

(6)
(7)
(8)

(9)
(10)

nn
{12}

Remarks

Q'ty

1/1
1
1
1

Installation is in the reverse order of removal.


CAUTION
Be careful not to damage the tip of the wheel sensor.
NOTE
When tightening, perform the air gap inspection
(page 16-8-34).
NOTE
At installation, route the sensor wire properly (page
1-25). and align the hole in the bracket with the pin of
the upper caliper mounting bolt.
CAUTION
Do not hang the caliper from the brake hose/pipe.

Only loosen these bolts.

1
1
1
1

13-9

Front Wheel/Suspension/Steering

Front Wheel Disassembly/Assembly


151

151

fit

B (0.8, 5 8)

....

IBI

(21

III

NOTE
The left brake disc has "L" mark and the right brake disc has' "R" mark. Install them on the correct sides.

- Always replace wheel bearings as a set.


I

For wheel bearing replacement, refer to the section 1 of the Common Service Manual.

Requisite Service
-

Front wheel removal/installation (page 13-6)


Procedure

111
121
131
141
151
151

III

Q'ty

Disassembly Order
Dust seal
Speedometer gear retainer
Brake disc bolt
Brake disc
Gasket
Torx bolt (T25) (ABS;TCS or LBS-ABS/TCS
model)
Pulsar ring (ABS;TCS or LBS-ABSjTCS
model)

IBI Left wheel bearing (6004UU)

Assembly is in the reverse order of disassembly.

2
1
12
2

At installaion, align the tabs with the slots in the wheel hub
Install the disc with the" L mark on the left side, and the
disc with the .. R mark on the right side.

12
5
1

191 Distance collar


1101 Right wheel bearing (6004UU)

1
1
1

(1 1) Front tire

13-10

Remarks

Install the pulser ring with the concave portion of bolt hole
facing out.
CAUTION
Be careful not to deform, distort. or damage the pulser
ring.

At installation, drive a new right wheel bearing in the hub first,


then drive a new left bearing in.

Front Wheel/Suspension/Steering

Fork Removal/Installation

Standard and ABS/TCS Model

/
4.3 (0.43, 3.1)

23 (2.3, 17)
(51

//

\
(61

'---J"'" -

(I I

c_"'"- .

~.,.'-

.-.,.-.-".-.-.-:0-

-/

~~\

~\
/

(II

~
P
j~\

"

(2)

27 (2.7, 20)

12 (1.2, 9)

NOTE~_ _

When the fork is to be disassembled, loosen the fork bolt but do not remove it.

I . After assembling the fork, tighten the fork cap temporarily before tightening the upper fork pinch bolt.

Requisite Service
Handlebar cover removal/installation (page 13-2)
Front wheel removal/installation (page 13-6)
Procedure

(I )
(2)

Removal Order
Left brake caliper pivot bolt (upper)/collar
Left brake caliper pivot bolt (lower)

Q'ty

Remarks
Installation is in the reverse order of removal.

III
I

CAUTION

(31
(41
(51

Brake hose clamp (Standard model)


Lower fork pinch bolt
Upper fork pinch bolt

(61

Fork asssembly

Do not hang the brake caliper from the brake


hose.
Right fork only.
loosen the bolts.
loosen the bolt
NOTE
Be careful not to let the fork drop when loosening
the bolt.
At installation, align the end of the fork tube with the
upper surface of the top bridge.

13-11

Front Wheel/Suspension/Steering
LBS-ABS/TCS Model
(6) E:t 22 (2.2, 16)

/
E:t 12 (1.2. 9)
(51
, ,0

~'~~

(11

Short
I
(21

(4)

""'--'(J

30 (3.0, 22)

E:t12 (1.2, 9)
(31

E:t 30 (3.0, 22)

/
Tube end

(10)

(8)

E:t 50 (5.0, 36)

13-12

Front Wheel/Suspension/Steering
CAUTION
When performing this service, provide the calipers with a support (sl. Do not hang the calipers from the brake hose
and pipe.
NOTE
When the fork is to be disassembled, loosen the fork cap but do not remove it yet.
After assembling the fork, tighten the fork cap which is temporarily tightened before tightening the upper fork pinch
bolt.

Requisite Service
Handlebar cover removal/installation (page 13-2).
Front wheel removal/installation (page 13-6).
Procedure
(1)
(2)
(3)
(4)
(5)
(6)

(7)
(8)
(9)

Removal Order
Oil pipe and wire stay fixing bolt
Delay valve mounting bolt
Left brake caliper pivot bolt (lowen/couar
Secondary master cylinder link plate bolt
{lower; slider-to-link born/cottar
Secondary master cylinder mounting bolt
Fender plate mounting bolt
Front fender plate
Lower fork pinch bolt
Upper fork pinch bolt

Q'ty

Remarks
Installation is in the reverse order of removal.

1
2
1(1
1(1

Secure the upper bolt with the fender plate.


Secure the upper bolt with the fender plate.

2
2
1
4

Only loosen.
Only loosen.
NOTE
Be careful not to let the fork drop when loosening the
bolt.
At installation, align the end of the fork tube with the upper
surface of the top bridge.

.
(10)

Fork assembly

13-13

Front Wheel/Suspension/Steering

Left Fork Disassembly


Standard and ABS/TCS Model

(151

116)
1181
(191

/
/

~(21

/
(3)

(41

(5)

(21)
(61

13-14

(91

(81

Front Wheel/Suspension/Steering

DIIII__
The fork cap is under spring pressure. Use care when removing it.

Requisite Service
Fork removal (page 13-11)
Procedure
I--~------''-''-'
Disassembly Order
(1)
Fork tube protector

Remarks

Q'ty

NOTE

(2)
(3)
(4)
(5)
(6)

(7)
(8)
(9)
(10)
(11)

(12)
(13)
(14)

Fork cap/O-ring
Spring collar
Spring seat
Fork spring
Socket bolt/washer
Fork piston assembly
Stopper ring
Oil lock valve
Oil lock valve spring
Spring seat
Stopper ring
Rebound spring
Piston rings

Do not remove unless necessary.

1/1
1

1
1

Drain the fork fluid after removing the spring.

1/1

1
1

Remove from the fork piston.

1
1
1
1
2

NOTE
Do not remove the piston rings unless they are to
be replaced.

(15)
(16)

(17)
(18)
(19)

Dust seal
Stopper ring

Fork tube
Oil seal
Back-up ring
(20~ i Slider bushing
(21) I Fork tube bushing

CAUTION
Be careful not to damage the fork tube sliding
surface.
1

1
1
1
1

I NOTE

Do not remove bushing unless it is to be replaced.

13-15

Front Wheel/Suspension/Steering

LBS-ABS/TCS Model

(5)~

'-----l

(14)

12)
1'1

Lock nut

13-16

Front Wheel/Suspension/Steering
Requisite Service
Fork removal (page 13-12).
Procedure

Q'ty

Remarks

1/1

Remove the cap form the fork tube, then remove it from
the fork damper rod while holding the lock nut as shown.
Remove the stopper while compressing the fork spring as
shown.

11 }

Disassembly Order
Fork cap/O-ring

12}

Spring seat stopper

13}

18}
19}

Spring seat
Fork spring
Socket bolt/washer
Fork damper
Oil lock piece
Dust seal
Stopper ring

1
1
1/1
1
1
1
1

(10)
(11)
(12)
(13)
(14)

Fork tube
Oil seal
Back-up ring
Slider bushing
Fork tube bushing

I'}
15}
16}
17}

1
1
1
1
1

CAUTION
Be careful not to damage the fork tube sliding surface .

NOTE
Do not remove the bushing unless it is to be replaced .

13-17

Front Wheel/Suspension/Steering

Left Fork Assembly


Standard and ABS/TCS Model

~~
S'"
(14)

(15)

if) 20 (2.0,14)

(20)

(19(

(1 B)

(111

/
..

\ -

17)
18)
(9)

(11

if) 20 (2.0, 14)


n

13-18

Uii

(21 J

Front Wheel/Suspension/Steering
Q'ty

Procedure
(I)
(2)
(3)
(4)
(5)
(6)
(7)
(B)
(9)
(10)
(11 )
(12)
(13)
(14)

Assembly Order
Fork tube bushing
Fork tube
Piston rings
Rebound spring
Stopper ring
Spring seat
Oil lock valve spring
Oil lock valve
Stopper ring
Fork piston assembly
Socket bolt/washer
Slider bushing
Back-up ring
Oil seal

(15)

Stopper ring

(16)

Dust seal

,
,

(' 7)

Fork spring

(18) Spring seat


(19) Spring collar
(20)! Fork cap/O-ring

(21 ) Fork tube protector

Remarks

1
1
2

Install onto the fork piston

1
1
1
1
1
1
1

11'
;

,
1

,,
11'

NOTE
Wrap vinyl tape around the fork tube top end to
avoid damaging the oil seal lip during installation.
Drive the slider bushing and oil seal into the slider
using the fork seal driver body (07947-KA501 DO}
and attachment (07947-KFOOl 00).
CAUTION
Be careful not to damage the fork tube sliding
surface.
Pour in the fork fluid to the specified level with the fork
fully compressed before installing the fork spring.
Wipe fluid off the spring thoroughly using a clean lint
free cloth and install with the tightly wound coil end
facing down.

Screw in the bolt, but do not tighten yet.


CAUTION
Be careful not to cross-thread the fork cap.
Align the lug with the groove in the fork slider.
NOTE
For easy installation, immerse in hot water (5060C/122-140F).

After completing fork assembly, refer to fork installation procedures (page 13-11}.

13-19

Front Wheel/Suspension/Steering

lBS-ABS/TCS Model

I,;;ocl"

(B)~
0 2 3 (2.3,17)

,
/

,/
,/

//
,!

/
''

'------~!
(4)

(' )
(3)

(13)

mm (O.41
>-c--~ 10.5
minimum

in)

~=

13-20

=~::~~~;=:::t~
lock nut

0 2 0 (2.0, 14)

Front Wheel/Suspension/Steering

Procedure

111
121
131
141
151
161
171
181

Assembly Order
Fork tube bushing
Fork tube
Oil lock piece
Fork damper
Socket bolt/washer
Slider bushing
Back-up ring
Oil seal

191

Q'ty

1
1
1
1
1/1
1
1
1

Stopper ring
,
(10) : Dust seal

{ll}

Fork spring

(12)

Spring seat
Spring seat stopper

1
1

(13)

Remarks

Install onto the end of the fork damper.

NOTE
Wrap vinyl tape around the fork tube top end to avoid
damaging the oil seal lip during installation.
Drive the slider bushing and oil seal into the slider using
the fork seal driver body (07947-KA50100) and attachment (07947-KA40200l.
CAUTION
Be careful not to damage the fork tube sliding surface.
Pour in the fork fluid to the specified level before installing
the fork spring.
Wipe fluid off the spring thoroughly using a clean lintfree cloth and install with the tightly wound coil eod
facing
down.
,

Install the stopper between the spring seat and lock nut
while compressing the fork spring as shown.
NOTE
Before installing the stopper, measure the distance
between the lock nut and the top of the damper rod, it
should be at least 10.5 mm (0.41 mm)
Instatl the fork cap onto the damper rod and tighten the
lock nut as shown, then screw it into the fork tube, but do
not tighten yet.
CAUTION
Be careful not to cross-thread the fork cap.

(14)

Fork cap/a-ring

1/1

After completing fork assembly, refer to fork installation procedure (page 13-13).

13-21

Front Wheel/Suspension/Steering

Right Fork Disassembly


Standard and ABS/TCS Model
(12)

(13)
(15)

(2)

~ ~7

(16)~~

(17)~~
~~

(14)~ ~

(1)

/1

~\

(5)

(6)

(7)

(9)

(8)

(18)

(11)

(4)

=
(2)

13-22

Front Wheel/Suspension/Steering
Requisite Service

Fork removal (page t 3-11)


Procedure

O'ty

(1)

I Fork
Disassembly Order
tube protector

(2)

I Fork cap

(3)
(4)

a-ring
Spring seat stopper

(5)
(5)
(7)
(8)
(9)
(10)

Spring seat
Spring collar
Spring seat
Fork. spring
Socket bolt/washer
Fork damper
(11) Oil lock piece
(12) Dust seal
(13) Stopper ring

(14)
(15)

(16)
(17)
(18)

Fork tube
Oil seal
Back-up ring
Slider bushing
Fork tube bushing

Remarks
NOTE
Do not remove unless necessary.
Remove the fork cap from the fork tube, then remove it
from the fork damper rod while holding the lock nut as
shown.

1
1

Remove the stopper while compressing the fork spring


as shown.

1
1
1
1
1/1
1
1
1
1

1
1
1
1
1

CAUTION
Be careful not to damage the fork tube sliding
surface.

I NOTE

Do not remove the bushing unless it is to be replaced.

13-23

Front Wheel/Suspension/Steering

LBS-ABS/TCS Model
(14)

(15)

(17)
(18)
(19)
(20)

(1)

(21)

(16}

(2(

(22}
(8)
(5)

13-24

(7)

Front Wheel/Suspension/Steering

The fork cap is under spring pressure. Use care when removing it.

Requisite Service
Fork removal (page 13-12).

Q'ty

Procedure
Disassembl Order
Fork cap/a-ring
Spring collar
Spring seat
I'} Fork spring
15} Socket bolt/washer
16} Fork piston assembly
17} Stopper ring
18} Oil lock valve
19} Oil lock valve spring
(10) Spring seat
(1 1} Stopper ring
(12} Rebound spring
(13} Piston ring
11}
12}
13}

(14)

Dust seal

1/1
1
1
1
1/1
1
1
1
1
1
1
1
2

(15) i Snap ring

1
1

Fork tube
(17) Oil seal
(18) Back-up ring (upper)
(19) Packing
(20) Back-up ring (lower)
(21 ) Slider bushing
(22) Fork tube bushing

1
1
1
1
1
1
1

(16)

Remarks

Drain the fork fluid after removing the spring.

Remove from the fork piston.

i
NOTE
Do not remove the piston rings unless they are to be
replaced.

CAUTION
Be careful not to damage the fork tube sliding surface.

NOTE
Do not remove bushing unless it is to be replaced.

13-25

St a nda rd an dABS /TCS Model

_
8'"
(10)

tf!:tt. 20 (2.0,
~(18)

(15)

s-.

$I

R':::"

(19)

es

(14)

(13)

(12)

(11)

~ 23 (2.3,17)

~ (15)
(16)

10.5 mm (0 .4 1 in) minimum

UP

13-26

14)

(lB)~

Lock nut

Front Wheel/Suspension/Steering

t(11
(2)

(3)
(4)
(5)
(5)
(7)
(8)

a'ty

Procedure
Assembly Order
Fork tube bushing
Fork tube
Oil lock piece
Fork damper
Socket bolt/washer
Slider bushing
Back-up ring
Oil seal

1
1
1
1
1;1
1
1
1

(9)

(10)

Stopper ring

Dust seal

1
1

(11 ) Fork spring

(12)

(13)
(14)
(15)

Spring seat
Spring collar
Spring seat
Lock nut

(16) Spring seat stopper

( 17) O-ring
(18) Fork cap

(19)

Remarks

Fork pipe protector

1
1
1
1
1

1
1;1

Install onto the end of the fork damper.

NOTE
Wrap vinyl tape around the fork tube top end to
avoid damaging the oil seal lip during installation.
Drive the slider bushing and oil seal into the slider
using the fork seal driver body (07947-KA501 00)
and attachment (07947-KFOO100).
CAUTION
Be careful not to damage the fork tube sliding
surface,
Pour in the fork fluid to the specified level with the fork
fully compressed before installing the fork spring.
Wipe fluid off the spring thoroughly using a clean lint
free cloth and install with the tightly wound coil end
facing down.

I Install in the direction shown in the illustration-with the


fully threaded end up.
I Install the stopper between the spring seat and lock
nut while compressing the fork spring as shown.
NOTE
Before installing the stopper, measure the distance
between the lock nut and the top of the damper
rod. It should be at least 10.5 mm (0.41 in)
Install the fork cap onto the damper rod and tighten
the lock nut as shown, then screw it into the fork
tube, but do not tighten yet.
CAUTION
Be careful not to cross-thread the fork cap.
Align the lug with the groove in the fork slider.
NOTE
For easy installation, immerse in hot water (50aOC/1 22 -140F).

After completing fork assembly, refer to fork installation procedures (page 13-11).

13-27

Front Wheel/Suspension/Steering

LBS-ABS/TCS Model

..

(15)

UP

(18)

1,';""ooLI . ,

,t::rl====
1
. . 1141-----+i~O~~\~ ~~~
1
I

(1S}

IIii;'ijiIII

(,3)~'j

(17}

I I

(22)

~\
(20)

/$/

20 (2.0, 14)

1ta

13-28

111

181

121)

Front Wheel/Suspension/Steering
Procedure
Assembly Order
11 } Fork tube bushing
12} fork tube
13} Piston ring
14} Rebound spring
15} Stopper ring
16} Spring seat
17} Oil lock valve spring
IS} Oil lock valve
19} Stopper ring
(10) Fork piston assembly
(11) Socket bolt/washer
(12) Slider bushing
(13) Back-up ring (lower}
(14) Packing
(15) Back-up ring {upper)
(16) Oil seal

Q'ty

Remarks

1
1

2
1
1
1
1
1
1
1
1/1
1
1
1
1
1

(17)

Snap ring

(18)

Dust seal

(19)

Fork spring

{20}
{21}
(22)

Spring seat
Spring collar
Fork cap/O-ring

1
1
1/1

Install onto the fork piston.

Install with the flat side facing down.


Install with the groove side facing down.
Install with the camfered side facing down.
NOTE
Wrap vinyl type around the fork tube top end to avid
damaging the oil seal lip during installation.
Drive the slider bushing and oil seal into the slider using
the fork seal driver body (07947-KA50100} and attachment
(07947-KA40200).

CAUTION
Be careful not to damage the fork tube sliding surface.
Pour in the fork fluid to the specified level before
installing the fork spring.
Wipe fluid off the spring thoroughly using a clean lint
free cloth and install with the tightly wound coil end
facing down.

Screw in the cap, but do not tighten yet.

I CAUTION

I Be careful not to cross-thread the fork cap bolt.

After completing fork assembly, refer to fork installation procedures (page 13-13l.

13-29

Front Wheel/Suspension/Steering

Steering Stem Removal/Installation

e1I

151

161

171

28 (2.8, 20)

,,

-,

(4)

-,

,,
,,
131

13-30

Front Wheel/Suspension/Steering
NOTE
The steering head bearings and races should always replaced as a set .
When loosening and tightening the steering stem nut, temporarily install the fork legs.

Requisite Service

Handlebar removal/installation (page 13-4)


Fork removal/installation (page 13-11}

my

Procedure
(I)
(2)
(3)

Removal Order
Steering stem nut
Washer
Ignition switch wire

(4)
(5)
(6)
(7)
(8)
(9)
('D)
(11)
(' 2)
(' 3)
(14)
(15)

Fork top bridge


Lock nut
Lock washer
Steering bearing adjustment nut
Dust seal
Steering stem
Upper bearing inner race
Upper bearing
Lower bearing
Lower bearing inner race
Dust seal
Upper bearing outer race

(16)

Lower bearing outer race

Remarks
Installation is in the reverse order of removal.

1
1

,,
,,
,
I

route the wire porperly (page 1-25).

,,
,

,,
,
,

i
I Disconnect at the connector holder. At installation,

Install using the steering stem driver (07946-MBOOOOO).


Remove using the race remover attachment (07953MJ 1ODDS}. Install using the driver{07749-001 0000)
and attachment, 42 x 47 mm (07746-0010300).
Remove using the race bearing remover (079463710500). Install with the driver (07749-oo1ClCXlO)
and attachment, 52 x 55 mm (07746--0010400).

13-31

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

...

Replace the partts] with new onets) before assembly.

Is :;O=ooLI

Use special tool

IOP~OOLI

Use optional tool. Use the same procedure you use to order parts.

Torque specification.

10 Nm (1.0 kg-m, 7.2 ft-lb)

10 (1.0, 7.2)

-:71

-,
..~

Use recommended engine oil, unless otherwise specified.

Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1

Use multi-purpose grease (Lithium based multi-purpose grease NLGI #2 or equivalent)

Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote BR-2 plus manufactured by Dow Corning, U.S.A.
Multi-purpose M-2 manufactured by Mitsubishi Oil Japan

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

Use silicone grease

Om

Apply a locking agent. Use a middle strength locking agent unless otherwise specified.

"I~

Apply sealant

Use brake fluid, DOT 3 or DOT 4. Use the recommended brake fluid, unless otherwise specified.

Use Fork or Suspension Fluid.

1) .

14. Rear Wheel/Suspension


Service Information

14-1

Troubleshooting

14-1

Rear Wheel Removal/Installation

14-2

Rear Wheel Disassembly/Assembly

14-4

Shock Absorber Removal/

Installation

14-6

Shock Absorber Disassembly/


Assembly
Swingarm Removal/Installation

14-7
14-8

Service Information

-~--:-:----:---c---=~ Riding on damaged rims impairs safe operation of the vehiC_'.c.

Tubeless tire removal, repair, and remounting procedures are covered in the section 16 of the Common Service
Manual. When remounting the tire, note the normal rotating direction indicated by the arrow.
Refer to the section 15 for brake system information.
Use only genuine Honda replacement bolts and nuts for all suspension pivot and mounting points.

Troubleshooting
Rear wheel wobbling
Bent rim

Worn rear wheel bearing(s)


Faulty tire
Unbalanced tire and wheel
Low tire pressure
Faulty swingarm pivot bearing(s)

Wheel turns hard


Faulty wheel bearing(s)
Brake drag (section 15)
Bent rear axle

Hard suspension
Damaged shock absorber mount bushing
Incorrect suspension adjustment
Bent damper rod
Damaged swingarm pivot bearing(s)
Lack of lubrication in swing arm pivot bearings or
suspension pivot points

III

Soft suspension
Weak shock absorber spring
Oil leakage from damper unit
Incorrect suspension adjustment

14-1

Rear Wheel/Suspension

Rear Wheel Removal/Installation


ABS/TCS model shown:

151

70 (7.0, 5 1)

111

I
II,
"",

Wheel sensor

12)
,

0110 (11.0, 80)

14)

131
27 (2.7, 20)

i1l~LS0,,!f}~- Pulser ring

Driven flange
Dust guard plate

Ring gear

161

Handle of pliers

14-2

Rear Wheel/Suspension

~
. A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated
disc with a high quality brake degreasing agent.
NOTE

.
0
0

ABS/TCS or LBS-ABS/TCS model: Do not remove the wheel sensor to remove and install the rear wheel.
Do not depress the brake pedal when the caliper is removed, or it will be difficult refit the disc between the brake pad.
Support the removed caliper with a piece of wire so that it does not hang from the brake hose. Do not twist the brake
hose.
Apply multipurpose NLGI NO.2 grease (molybdenum disulfide additive) to the driven flange and the ring gear
engagement splines.

Requisite Service
0

Place the motorcycle on its center stand.


Procedure

Removal Order
caliper stopper pin bolt
axle nut
axle pinch bolt
axle
caliper assembly
wheel assembly

,
,

Q'ty

01 Rear
121 Rear
131 Rear
141 Rear
151 , Rear
151 i Rear

1
1
1
1
1
1

171 , Side collar

Remarks
Loosen the bolt.

from the brake disc.


! Remove
Separate the driven flange of the

wheel from the ring


gear of the final drive gear by prying the driven flange
with the handle of the pliers through the slot in the dust
guard plate as shown.
CAUTION
0
ABS/TCS or LBS-ABS/TCS model: Be careful not to
damge the pulser ring and wheel sensor.

1 4-3

Rear Wheel/Suspension

Rear Wheel Disassembly/Assembly


ABS/TCS model shown:

~
/

(3 g/0.11 oz to each surface}

J >I

//

//

...

l ir e;;
/ ://r ~,
l{~~ . '

"f'~;;
)/)\, <:

'

'\'v~

(1) 8 (0_8, 5.8)

~~

20 (2.0, 14)

111

(51
(15)

(81

(21

.,

_ fiiiiiiH

(21
(51

191
(111

(41

(101

43 (4.3,31)

"

~
171
( 13)
(12)

Arrow([)
Arrow4;'

00

@ ---~
Arrow

14-4

//

Rear Wheel/Suspension
NOTE
Replace the rear wheel damper rubbers as a set.
Replace the wheel bearings as a set.
For wheel bearing replacement, refer to the section 1 of the Common Service Manual.
ABS(TCS or LBS-ABS(TCS model: When the pulser ring is replaced, perform the wheel sensor air gap inspection
{page 16-A-51 or 16-B-34} after installing the rear wheel.

Requisite Service
Rear wheel removal/installation {page 14-2}.
Procedure
(1 )
(2)

Disassembly Order
Torx bolt (T25) (ABS(TCS or LBS-ABS(TCS
model)
Pulser ring (ABS(TCS or LBS-ABS(TCS model)

G'ty

Remarks
Assembly is in the reverse order of disassembly.

Install the pulser ring with the concave of bolt hole facing
out.
CAUTION
Be careful not to deform, distort, or damage the pulser
ring.
At assembly, apply 3 g {D.1 1 oz} of molybdenum disulfide
paste to the driven flange mating surface of the hub, to
the inside diameter of the driven flange and to the
splines of the driven flange as shown.

(3)

Final driven flange

(4)

Thrust washer
O-ring
Socket bolt
Damper holder plate

1
1
5
1

(14)

Rear wheel damper rubber


Dust seal
Socket bolt
Rear brake disc
Right wheel bearing {dual, 20x47x20.6 mm)
Distance collar
Left wheel bearing (6204UU)

5
1
6
1
1
1
1

(15)

Rear tire

(5)
(6)
(7)

(8)
(9)

(10)
(11)
(12)
(13)

Remove the plate by turning it counterclockwise and


aligning the arrow on the plate with the errowO on the
wheel as shown.
Install the plate, aligning the arrow with the arrow Ct:, and
turn it clockwise until the arrow aligns with the arrow iI;
as shown.
Install with the "OUTSIDE" mark facing out.

Install with the "OUTSIDE" mark facing out.

I
I

At installation, drive a new left wheel bearing in the hub


first, then drive a new right bearing in.

14-5

Rear Wheel/Suspension

Shock Absorber Removal/Installation

/
~121
~ 23 (2.3,17)
NOTE

Use a floor jack or other adjustable support under the final drive to relieve stress for ease of left shock absorber lower
mounting bolt removal/installation.
Note the position of the spring preload adjuster for future reference. Adjust the spring preload adjuster to the softest
position for disassembly. Return the adjuster to the position noted before disassembly.

Requisite Service
Place the motorcycle on its center stand
Right side cover (page 2-2)

(1)
(2)
(3)

Removal Order
Upper mounting bolt
Lower mounting bolt
Shock absorber assembly

14-6

I Disassembly/assembly (page 14-7)

Rear Wheel/Suspension

Shock Absorber Disassembly/Assembly


~
(4)

(2)

NOTE

Adjust the spring preload adjuster to the softest position before disassembly.

---'----

Requisite Service

Shock absorber removal/installation (page 14-6)


a'ty

Procedure
(1)

Disassembly Order
Stopper ring

Upper spring seat


Spring
Upper mount collar

1
1
1

,
(2)
(3)
(4)

Remarks
Assembly is in the reverse order of disassembly.
Compress the shock absorber spring using the spring
I compressor (07GME-0010000) and attachment
(07959-MB10000) and remove the stopper ring.
Install with the tightly wound coil end facing up.

14-7

Rear Wheel/Suspension

Swingarm Removal/Installation
LBS-ABS/TCS model shown:

0:

:'.TOOLI
105 (10.5, 76)
13)

18)

I')

e;:,. Standard
~

0:

model"
18 (1.8,13)
ABS/TCS or
LBS-ABS/TCS model:

22 (2.2, 16)

I' )

\ v/

(6)

"UP" mark

14-8

Rear Wheel/Suspension
NOTE
,.
,

Replace the pivot bearings and outer races as a set,

Requisite Service

Final gear case removal/installation (page 12-3)


Procedure
I I Removal Order
(1) Wheel sensor wire (ABS/TCS or
LBS-ABSITCS model only
(2) Rear brake hose clamp bolt
(3) Left pivot lock nut
14) Left pivot bolt
151 Right pivot bolt
161 Swingarm
17) Pivot bearing
18) Driveshaft assembly
19) Rubber boot

O'ty

Remarks
Installation is in the reverse order of removal.
Remove the wire harness from the swingarm.

2
1
1
1
1
2
1
1

19)
181
17)
151
161

Installation Order
Rubber boot
Driveshaft assembly
Pivot bearing
Right pivot bolt
Swingarm

1
1
1
1
1

14)

Left pivot bolt

13)

Left pivot lock nut

12)
111

Rear brake hose clamp bolt


Wheel sensor wire harness

4
1

Remove the rear brake hose clamp from the swinqarm.


Use the swingarm lock nut wrench (07908-4690003).

,
Pivot bearing outer race replacement (page 14-10)
Disassembly/Assembly (page 12-2)

Install with the "UP" mark facing up.


Install into the swingarm

Install in the frame and on the right pivot bolt while


engaging the driveshaft joint with the countershaft.
After installing the pivot bolts, fit the rubber boot tab
into the transmission case groove properly.
Tighten the nut with the swingarm lock nut wrench (0
7908-4690003 orKS-HBA-08-469, U.S.A. only)
while holding the left pivot bolt.
Install the clamp onto the swingarm.
Install the wire harness onto the swingarm.

14-9

Rear Wheel/Suspension
Pivot Bearing Outer Race Replacement
Punch or drill a 13 mm (1/2 in) hole into each grease retain-

(1) BEARING OUTER


REMOVER

e,Remove the attachment from the bearing remover. Slide the


shaft through the hole and install the attachment onto the
shaft.
Install the sliding weight and remove the outer race with the
grease retainer.
Repeat for the other side.

Pivot bearing outer remover


Sliding weight

07936-4150000
07741-0010201

(3) ATTACHMENT

(2) SLIDING WEIGHT

Install new bearing outer races into the swingarm pivot.

"-------"

Driver
Attachment, 37 x 40 mm

07749-0010000
07746-0010200

(1) DRIVER

' '_"
(~

'"
.---/

~-:-:~_

,,~

1'"",;;/,'0"',
_--_-~""':>,J./~-

-_,,/'

\i , \
----;

14-10

"

(2) ATTACHMENT,
37 x 40 mm

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

...

Replace the partts] with new onets) before assembly.

Is :;O=ooLI

Use special tool

IOP~OOLI

Use optional tool. Use the same procedure you use to order parts.

Torque specification.

10 Nm (1.0 kg-m, 7.2 ft-lb)

10 (1.0, 7.2)

-:71

-,
..~

Use recommended engine oil, unless otherwise specified.

Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1

Use multi-purpose grease (Lithium based multi-purpose grease NLGI #2 or equivalent)

Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote BR-2 plus manufactured by Dow Corning, U.S.A.
Multi-purpose M-2 manufactured by Mitsubishi Oil Japan

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

Use silicone grease

Om

Apply a locking agent. Use a middle strength locking agent unless otherwise specified.

"I~

Apply sealant

Use brake fluid, DOT 3 or DOT 4. Use the recommended brake fluid, unless otherwise specified.

Use Fork or Suspension Fluid.

1) .

15. Brake System


Service Information
Troubleshooting

15-'
15-1

Brake Fluid Filling/Bleeding (LBS-ABS/


TCS modell
15-2

Brake Pad Replacement

15-8

Front Master Cylinder Disassemblyj


Assembly

15-10

Front Brake Caliper Disassembly!


Assembly

15-12

Rear Master Cylinder Disassembly!


Assembly

15-16

Rear Brake Caliper Disassembly!


Assembly

15-20

Rear Brake Pedal Removal!


Installation

15-24

Secondary Master Cylinder Disassemblyj


Assembly ILBS-ABS/TCS modell
15-26

Delay Valve Removal/Installation


ILBS-ABS/TCS modell

15-28

Proportional Control Valve Removal!


Installation ILBS-ABS/TCS model)

15-29

Service Information
A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated
disc with a high quality brake degreasing agent.
Brake dust may contain asbestos. inhaled asbestos fibers have been found to cause respiratory disease and cancer.
Never use an air hose or dry brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner or alternate
method approved by OSHA. designed to minimize the hazard of airborne asbestos fibers.
Spilled brake fluid will severely damage instrument lenses and painted surfaces. It is also harmful to some rubber
parts. Be very careful whenever you remove the reservoir cap; make sure the front reservoir is horizontal first.
Never allow contaminants (dirt, water, etc.) to get into an open reservoir.
Once the hydraulic system has been opened, or if the brakes feel spongy, the system must be bled.
The brake fluid air bleeding procedure on the ABS/TCS ('92-95) model must be performed in the same manner as in
the ordinal air bleeding procedure. Note that replacement and bleeding air from the brake fluid in the modulator is
not necessary, as it is sealed in the modulator. On the LBS-ABSfTCS model (After '95), refer to page 15-2.
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 motorcycle.

~
~

Troubleshooting
Brake lever/pedal soft or spongy
Air in the hydraulic system
Leaking hydraulic system
Contaminated brake pad/disc
Worn caliper piston seal
Worn master cylinder piston cups
Worn brake pad/disc
Contaminated caliper
Caliper not sliding properly
Low brake fluid level
Clogged fluid passage
Warped/deformed brake disc
Sticking/worn caliper piston
Sticking/worn master cylinder piston
Contaminated master cylinder
Bent brake lever/pedal

Brake lever/pedal hard


Clogged/restricted brake system
Sticking/worn caliper piston
Caliper not sliding properly
Clogged/restricted fluid passage
Worn caliper piston seal
Sticking/worn master cylinder piston
Bent brake lever/pedal
Brake drag
Contaminated brake pad/disc
Misaligned wheel
Badly worn brake pad/disc
Warped/deformed brake disc
Caliper not sliding properly
Clogged/restricted fluid passage
Sticking/worn caliper piston

15-1

Brake System

Brake Fluid Filling/Bleeding


(LBS-ABS/TCS model)
A contaminated brake disc or pad reduces stopping
power. Discard contaminated pads and clean a
contaminated disc with a high quality brake
degreasing agent.
CAUTION
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.

(1) SCREWS

NOTE
On the LBS-ABSiTCS model, note that there is no brake
fluid in the modulator (except in the modulator head),
because the modulator is the motor-driven hydraulic
pressure type. Therefore, brake fluid replacement and
bleeding air from the modulator body is not necessary.
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.

Lever Brake Line


FLUID FEEDING
Support the motorcycle on its center stand.
Turn the handlebar to the left until the reservoir is level before
removing the reservoir cap.
Remove the reservoir cap, set plate and diaphragm.
Connect a commercially available brake bleeder {example,
Mityvac PIN 6826) to the outer bleed valve (upper side of the
each front caliper).

Fill the reservoir with DOT 4 brake fluid from a sealed


container.

CAUTION
Use only DOT 4 brake fluid from a sealed container.
Do not mix different types of fluid. They are not
compatible.
Operate the brake lever several times to bleed air from the
master cylinder.

15-2

(2) CAP

(1) LEFT

(2) RIGHT

Brake System
1. Pump the brake bleeder and loosen the bleed valve.
Add brake fluid when the fluid level in the reservoir is low.

(1) Until sufficient amount of fluid


flows out.

NOTE
Check the fluid level often while bleeding the brake to
prevent air from being pumped into the system.
Repeat the above procedure until sufficient amount of the
fluid flows out from the bleed valve.
Close the bleed valve.

NOTE
It is not a problem if the fluid flowing out from the bleed
valve contains air bubbles because the lines will be bled
in later steps.
If air is entering the bleeder from around the bleed valve
threads, seal the threads with teflon tape.
2. Perform step 1 for the other side bleed valve.
Next, periorm the air bleeding from the system (page 15-4).

(2) BLEEDER

If a commercial brake bleeder is not available, use the


following procedure:
Connect a transparent bleed hosetothe bleed valve and place
the other end ofthe hose in a container.
1. Pump the brake lever several (5-10) times quickly, then
squeeze the brake lever all the way and loosen the bleed
valve 1/4 turn. Wait several seconds and close the bleed
valve.
NOTE

It is not a problem if the fluid flowing out from the bleed


valve contains air bubbles because the lines will be bled
in later steps.
Do not release the brake lever until the bleed valve has
been closed.

(1)

Release the brake lever slowly and wait several seconds


after it reaches the end of its travel.
Repeat steps 1-2 until sufficient amount of the fluid flows out
from the bleed valve.
2. Perform step 1 for the other side bleed valve.
Next, periorm the air bleeding from the system (page 15-4).

15-3

Brake System
AIR BLEEDING
1. Connect a transparent bleed hose to the bleed valve.
Pump the brake lever several (5-10) times quickly. then
squeeze the brake lever all the way and loosen the bleed
valve 1/4 turn. Wait several seconds and close the bleed
valve.

-@"

~/

NOTE
Do not release the brake lever until the bleed valve has
been closed.
Release the brake lever slowly and wait several seconds
after it reaches the end of its travel.

/~/ ...../1,"I,
(1) LEVER

Repeat above procedure until air bubbles do not appear in


the transparent hose.

2. Perform step 1 for the other side bleed valve.


Make sure the bleed valves are closed and operate the brake
lever. If it still feels spongy, bleed the system again.

air bubbles
disappear
~
,

--

I
I

After bleeding air completely. tighten the bleed valves to the


specified torque.

~ntil
-

I
I

:;-:{j'
Ii! -,",',~; {"f)/1'

"

"'"

'I f
v

'.,'

(1) SCREWS

Torque: 5.5 Nm (0.55 kg-m. 4.0 ft-Ib)


Fill the reservoir to the casting ledge with DOT 4 brake fluid
from a sealed container.
Install the diaphragm, set plate and reservoir cap and tighten
the cap screws.
Torque: 1.5 Nm (0.15 kg-m. 1.1 ft-Ib)
Check the front brake operation (page 3-13).
(2) CAP

15-4

,1,.0"

---

Brake System

Pedal Brake Line


NOTE
Refer to the Technical Features (Section 23) for
additional informaition pertaining to the pedal brake
line.
Before performing this service, have at least 500 cc (16.9
US OZ, 14.1 Imp oz) of brake fluid.
Insert fluid and bleed air from the pedal brake line in the
following sequence:
1. Left front caliper lower side bleed valve
(from the rear brake pedal master cylinder-front
modulator--elelay valve line)
2. Right front caliper lower side bleed valve
(from the rear brake pedal master cylinder-front
modulator--elelay valve line)
3. Rear caliper front side bleed valve
(from the rear brako pedal master cylinder-rear
modulator line)
4. Rear caliper rear side bleed valve
(from the secondary master cyJinder-PCV-rear
modulator line)

FLUID FEEDING
Support the motorcycle on its center stand.
Remove the right side cover (page 2-2}.

Remove the reservoir cap.


Fill the reservoir with DOT 4 brake fluid from a sealed
container.
CAUTION
Use only DOT 4 brake fluid from a sealed container.
Do not mix different types of fluid. They are not
compatible.

~(1)CAP
--'<',

~"",

~ ~7~~----

(2) RESERVOIR

Operate the brake pedal several times until brake fluid level in
the reservoir goes down.

."'-: ,- "E:3'

w~

(1) FILLING

(2) PEDAL

15-5

Brake System
NOTE

Check the fluid level often while bleeding the brake to


prevent air from being pumped into the system.
1. Connect a commercially available brake bleeder
(example, Mityvac PIN 6826) to the left front caliper lower
side bleed valve.
Pump the brake bleeder and loosen the bleed valve.
Add brake fluid when the fluid level in the reservoir is low.
Repeat the above procedure until sufficient amount of the
fluid flows out from the bleed valve.
Close the bleed valve.
NOTE

It is not a problem if the fluid flowing out from the bleed


valve contains air bubbles because the lines will be bled
in later steps.
If air is entering the bleeder from around the bleed valve
threads, seal the threads with teflon tape.
2. Repeat step 1 for each valve in the sequence as follows:
the right front caliper lower-side bleed valve
the rear caliper front-side bleed valve
the rear caliper rear-side bleed valve
Next, perform the air bleeding from the system (page 15-7).

If a commercial brake bleeder is not available, use the


following procedure:
1. Connect a transparent bleed hose to the left front caliper
lower-side bleed valve.
Pump the brake pedal several (5-10) times quickly, then
depress the brake pedal all the way and loosen the bleed
valve 1/4 turn. Wait several seconds and close the bleed
valve.
NOTE

It is not a problem if the fluid flowing out from the bleed


valve contains air bubbles because the lines will be bled
later, steps.
Do not release the brake pedal until the bleed valve has
been closed.
Release the brake pedal slowly and wait several seconds
after it reaches the end of its travel.
Repeat the above procedure until sufficient amount of the
fluid flows out from the bleed valve.
2. Repeat step 1 for each valve in the sequence as follows:
the right front caliper lower-side bleed valve
the rear caliper front-side bleed valve
the rear caliper rear-side bleed valve
Next, perform the air bleeding from the system (page 15-7).

15-6

@~~mc__~_

f~~
{SJ:'' '.
~~

Brake System
AIR BLEEDING
1. Connect a transparent bleed hose to the left front caliper
lower-side bleed valve.

CD

Pump the brake pedal several (5-10) times quickly, then


depress the brake pedal all the way and loosen the bleed
valve 1/4 turn. Wait several seconds and close the bleed
valve.
NOTE
Do not release the brake pedal until the bleed valve has
been closed.
Release the brake pedal slowly and wait several seconds
after it reaches the end of its travel.
Repeat above procedure until air bubbles do not appear in
the transparent hose.
After the air bubbles cease to appear in the fluid, repeat air
bleeding procedure about 2-3 times.
NOTE
Note that you may feel strong resistance on the brake
pedal during pumping to bleed air from the right front
caliper. This symptom is caused by the delay valve
function. Be sure to depress the brake pedal fully to the
bottom.

(l!;J
...

~C)j.
/~':J

(2) BRAKE PEDAL

2. Repeat step 1 for each valve in the sequence as follows:


the right front caliper lower-side bleed valve
the rear caliper front-side bleed valve
the rear caliper rear-side bleed valve
Make sure the bleed valves are closed and operate the brake
pedal. If it still feels spongy. bleed the system again.
After bleeding air completely, tighten the bleed valves to the
specified torque.
Torque: 5.5

ra-m (0.55 kg-roo 4.0 ft-Ib)

Fill the reservoir to the upper level line with DOT 4 brake fluid
from a sealed container.
Install the diaphragm, set plate and reservoir cap.
Check the pedal line brake operation (page 3-13).

15-7

Brake System

Brake Pad Replacement


Standard and ABS/TCS Model

LBS-ABS/TCS Model

Front

Front

(4) Pad spring

r.
,i"

(3)

\i-

..""l

:~\
..

..\.\\

(1) " - - ; ;__

2.5 (0.25, 1.8)

\~
,

I',

(2)

E): 18 (1.8,13)

",',

/>

-';',

(3)

" "

1
C

2.5 (0.25, 1.8)

(4) Pad spring

Rear

Rear

(2)

E): 18 (1.8,13)

E): 18 (1.8, 13}

...-

Stopper ring

mO

(1 )

Stopper ring

(2)

(11

2.5 (0.25, 1.8)

(31
18 (1.8,13)

91
I

:' I
1,1

r-

_~

(4} Pad spring

15-8

(5) Tabs

Brake System

A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc
with a high quality brake degreasing agent.
Brake dust may contain asbestos. Inhaled asbestos fibers have been found to cause respiratory disease and cancer.
After replacement, operate the brake lever or pedal to seat the caliper pistons against the pads and check the brake
operation [For front brake pad of the LBS-ABS/TCS model, operate the lever and pedal (page 3-13) 1.
Never use an air hose or dry brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner or alternate method
approved by OSHA, designed to minimize the hazard of airborne asbestos fibers.
NOTE
The brake pads can be replaced without disconnecting the hydraulic system.
Replace the brake pads as a set.
Apply a thin coat of grease onto the pad pin and pad pin plug threads to prevent rust.
Standard and ABS/TCS model:
Procedure
111
121
13}

Removal Order
Pad pin plug
Pad pin

Remarks

D'tv

Installation is in the reverse order of removal.


1
1
2

P,d

NOTE
Push the pistons all the way in to provide clearance for
the new pads.
Before installing the pads, make sure that the pad
spring is positioned properly as shown.

LB5-ABS/TCS model'
Procedure
11}
12}
13}

Removal Order
Pad pin plug
Pad pin

P,d

Q'ty

Remarks
Installation is in the reverse order of removal.

1
1
2

NOTE
Push the piston all the way in to provide clearance for
the new pads.
On the rear pad, be careful not to scratch the rear wheel
hub.
When installing the inside pad, insert between the tabs
(retainers) of the pad spring and caliper body.

15-9

Brake System

Front Master Cylinder Disassembly/Assembly

012

(10)

(1.2, 9)

(5)

o
et

(6)_~-;--t:~

35 (3.5, 25)
(2)

(3)

(12)

: Lever pivot

1 (0.1,0.7)

~MIIl---Boot:

e:w

(7)

'91-94

(I)

1 .2 to. 12, 0.9)

(14)

0 4 (0.4, 2.9)
(11 )

if) 6 (0.6, 4.3)

------....,

1'3)
(19)

Standard and ABSjTCS model:

{20)

-4'

15-10

lBS-ABS/TCS model:

Brake System

Check the brake system by applying the lever brake after air bleeding.

CAUTION
Avoid spilling fluid on painted, plastic. or rubber parts. Place a rag over these parts whenever the system is serviced.
When removing the oil bolt, COverthe end of the brake hose to prevent contamination. Do not allow foreign material to
enter the system.
Do not allow the lips of the master cylinder piston cups to be turned inside out and be certain the snap ring is firmly
seated in the groove.

NOTE
Use only DOT 4 brake fluid from a sealed container.
After assembly, align the index mark on the adjuster with the arrow mark on the joint pin.

Requisite Service
Handlever cover removal/installation (page 13-2}
Front brake fluid draining/air bleeding (Standard and ABSJTCS model: section 17 in Common Service Manual)
Lever brake line fluil draining/air bleeding (LBS-ABS,rrCS model: page 15-2)

Procedure

G'ty

Disassembly Order

(1)
(2)
(3)

(4)
(5)
(6)

(7)
(8)
(9)

(10)
(11)
(12)
(13)
{14}
(15)
(16)
(17)

(18)
{19}
{20)
(21)
(22)
(23)
(24)
(25)

Brake switch wires


Oil bolt
Sealing washer
Brake hose
Master cylinder holder bolt
Master cylinder holder
Brake switch
Reservoir cap screw
Reservoir cap
Set plate/diaphragm
Brake lever pivot nut
Brake lever pivot bolt
Brake lever assembly
Socket bolt
Adjuster arm
Brake lever spring
Adjuster rod
Adjuster
Joint pin
Boot
Push rod
Snap ring
Master piston
Primary cup
Sprinq

Remarks
Assembly is in the reverse order of disassembly.
At assembly, check the brake system by applying the brake
after bleeding air from the system.

2
1
2
1
2
1
1
2
1
1/1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1

Remove the master cylinder assembly from the handlebar.

At installation, apply silicone grease.

LBS-ABSJTCS model
Use snap ring pliers (07914-3230001),
On the LBS-ABS,rrCS model, it is installed onto the piston.

15-11

Brake System

Front Brake Caliper Disassembly/Assembly


ABS/TCS model:

Right side:

If) 35 (3.5, 25)

(1)

'<\~
-------\

(5)
(9)

027 (2.7, 20l

Wheel sensor

ew

0 2 3 (2.3, 17)
(14)
(17)

05.5 (0.55, 4.0l

(11 )

(15)

110}

02.5 (0.25, 1.8l


(10)

(13)

...-'iiSiII

15-12

Brake System

A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc
with a high quality brake degreasing agent.
Brake dust may contain asbestos. Inhaled asbestos fibers have been found to cause respiratory disease and cancer.
Check the brake system by applying the brake after air bleeding.
Never use an air hose or dry brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner or alternate method
approved by OSHA, designed to minimize the hazard of airborne asbestos fibers.
CAUTION
Spilled brake fluid will damage painted, plastic. or rubber parts.
NOTE

Do not remove the bleed valve unless it is replaced.

Requisite Service

Front brake fluid draining/air bleeding (section 17 in Common Service Manual)

Procedure

Q'tv

Disassembly Order

(' )

(2)
(3)
(4)
(5)

Brake oil bolt


Sealing washer
Brake hose

P,d

(8)
(9)

Caliper mounting bolt


Brake caliper assembly
Wheel sensor wire clamp bolt
Wheel sensor mounting bolt
Wheel sensor

(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)

Pad spring
Caliper bracket
Pad retainer
Caliper pin bolt boot
Caliper pin bolt
Caliper piston
Dust seal
Piston seal

(6)

Remarks
Assembly is in the reverse order of disassembly.
At assembly, check the brake system by applying the brake
after bleeding air from the system.

,
,
,,
,
,, .
,
2

2
2

Removal/installation (page 15-8)


Install the bolt with longer threads at the upper side.

CAUTION
Be careful not to damage the wheel sensor.
Install as shown.

2
2
2

Do not remove unless necessary.

;T .

CAUTION
Be careful not to damage the piston sliding surface.

15-13

Brake System

LBS-ABS/TCS Model

Right side:

left side:

(5)

30 (3.0, 22)

0 3 0 (3.0, 22)
~/7----c ~i'/(
/-.
--~ -'U'
{;
r- " / ; '
0/ ':.0. el
.'-.j,c,,,-~~
.z
0

./
/

",
I Q

'~',

:''.,,,

c 'I"~

I'
, C

(,i y.

nrr

I'IC" j 'I';_?'-'. ~~~~

"\ o"\\J

.",:0'\

:::;\0' 'I',.,
...-umtt,
,

-:

{51

0 3 0 (3.0, 22)
{6J

{7J

iV

{81

,'(::

..

33 (3.3, 24)

;<"/>"

(10)

13 (1 .3_,9_J_-Hc'ii

(11)

RIGHT:

LEFT:

2.5 (0.25, 1.8)

..-'iiSiIi
Stopper
ring

{9J

{41
, ~-J- __ ~

(11)

15-14

1 8 (1 8 , 13 )

Brake System

A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc
with a high quality brake degreasing agent.
Brake dust may contain asbestos. Inhaled asbestos fibers have been found to cause respiratory disease and cancer.
Check the brake system by applying the lever and pedal brake after air bleeding (page 3-13).
Never use an air hose or dry brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner or alternate method
approved by OSHA, designed to minimize the hazard of airborne asbestos fibers.
CAUTION
Spilled brake fluid will damage painted, plastic, or rubber parts.
NOTE
Do not remove the bleed valve unless it is replaced.
Reinstall the removed pistons and seals in the original position securely.
After installing the right caliper, check the wheel speed sensor air gap (page 16-B-34).

Requisite Service

Lever and pedal brake lines fluid draining/air bleeding (page 15-2)
Procedure
(1)

(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)

Disassembly Order
Brake oil bolt
Sealing washer
Brake hose
Pad
Caliper mounting bolt

Brake caliper assembly


Caliper bracket
Pad retainer
Pad spring
Assembly bolt/caliper body
(11) Caliper piston
(12) Dust seal
(13) Piston seal

no:

Q'ty

Remarks
Assembly is in the reverse order of disassembly.

2
4

2
2
2
1
1
1
1
3/1
3

Removal/installation {page 15-8}


On the left side, install the bolt with longer threads at the
lower side.

Install as shown.

;I .

CAUTION
Be careful not to damage the piston sliding surface.

15-15

Brake System

Rear Master Cylinder Disassembly/Assembly


Standard and ABS/TCS Model
Standard model shown:

E:t

(ZIe/

35 (3.5, 25)

(4)

(1)----.,

----

>

(3)

(,OI------:t:::jrilJ

(10)

(7)
.-

IS"

131

(6)

(8)---(51

fit

191

(181
1161

IABS/TCSM"';-d-el:1
I
I

I
I

I
I

I
I

I
I
I
I
I

I
I
I
I
I

I
I

I
I

.....

"
(12)

(17)

.J

@--------j(11)

E:t

/LJ
1141

(15)

I s ';"OO~ I

15-16

(13)

18(1.8, 13)

Brake System

Check the brake system by applying the brake after bleeding air from the system.

CAUTION
Avoid spilling fluid on painted, plastic, or rubber parts. Place a rag over these parts whenever the system is
serviced.
When removing the oil bolt, cover the end of the brake hose to prevent contamination. Do not allow foreign material to
enter the system.
Do not allow the lips of the master cylinder piston cups to be turned inside out and be certain the snap ring is firmly
seated in the groove.
NOTE
Use only DOT 4 brake fluid from a sealed container.
Loosen and tighten the oil bolt and master cylinder mounting bolts with the step holder installed.
The master piston, piston cups and spring must be replaced as a set.

Requisite Service

Rear brake fluid draining/air bleeding (section 17 in Common Service Manual)


Right step holder removal/installation (page 2-13)

my

Procedure
(1)
(2)
(3)
(41
(5)
(6)
(7)
(8)
(91
(10)
(111
(12)
(13)
(14)
(15)
(16)
(17)
(18) I

Disassembly Order
Oil bolt
Sealing washer
Brake hose
Mounting bolt
Reservoir hose joint screw
Reservoir hose joint
O-ring
Cotter pin
Joint pin
Master cylinder assembly
Lock nut
Spring pin
Push rod joint
Boot
Snap ring
Push rod
Master piston/piston cup
Spring

Remarks
Assembly is in the reverse order of disassembly.

1
2
1
2
1
1
1
1
1
1
1
1
1
1
1
1

1;2

Loosen the nut.

Use snap ring pliers (07914-3230001).

15-17

Brake System

c:

LBS-ABS/TCS Model

35 (3 5, 25)

121

161
131t!1
,,~

14I

1151~

11 I

(19}

(1O}

027

(2. 7, 20)

(11)

35 (3.5, 25)

(18}

i.~

(12)

(11) ..... 3513 5,25)

; : " " , zo:

(22)

-'I' i

rl~

162 m m

1 lJ

15-18

J?J

1201' LI__i-

I
18(1.8,13}

Brake System

Check the brake system by applying the brake after air bleeding (page 313).
CAUTION
Avoid spilling fluid on painted. plastic, or rubber parts. Place a rag over these parts whenever the system serviced.
When removing the oil bolt, cover the end of the brake hose to prevent contamination. Do not allow foreign material to
enter the system.
Do not allow the lips of the cups to be turned inside out and be certain the snap ring is firmly seated in the groove.
NOTE
The master piston, piston cups and spring must be replaced as a set.
Use only DOT 4 brake fluid from a sealed container.

Requisite Service
Pedal brake line fluid draining/air bleeding (page 15-2).
Right pivot cover removal/installation (page 2-5).
Procedure
Disassembly Order

111
121
13}
14}
{5}
16}
(7)

(8)
19}

(10)
(11)
{12}
{13)
(14)
(15)
(16)
(17)
{1S}
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)

Brake light switch 2P (Black) connector


Oil bolt
Sealing washer
Brake hose
Reservoir bolt
Master cylinder reservoir
Modulator mounting bolt
Muffler mounting bolt
Right step holder bolt 6 mm
8mm
10mm
Right step holder
Hose joint screw
Reservoir hose joint
O-ring
Cotter pin
Joint pin
Mounting bolt
Master cylinder assembly
Boot
Snap ring
Push rod
Master piston/cup
Spring
Lock nut
Spring pin
Push rod joint

Remarks

Q'tv

Assembly is in the reverse order of disassembly.


Before removing the step holder, loosen the master
cylinder mounting bolts.
1
1
3
2
1
1
3
1
1
1
2
1
1
1
1
1
1

1
1
1
1
1
1/2
1
1
1
1

Use snapring pliers (07914-3230001).

Loosen the nut.

15-19

Brake System

Rear Brake Caliper Disassembly/Assembly

Standard and ABS/TCS Model

90 (9.0, 65)
(7)

\\!/I---~~

(91

(I)

35 (3.5, 25)

.,

,,

(2)

(3)

(5):---~.elJ

70 (7.0, 51)

(8)--~.J

ew

0 2 8 (2.8, 20)
(14)

f!!J

18(1.8,13)

(6)

27 (2.7, 20)

5 .5 (0 .55, 4.0)

(15).

2.5 (0.25, 1.8)

.--'iSitI
(131

(121

(131

~
(10)

(4)

(14)

0 1 3 (1.3, 9)

15-20

iI!ili

(11)

Brake System

A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent.
Check the brake system by applying the brake after air bleeding.
Brake dust may contain asbestos. Inhaled asbestos fibers have been found to cause respiratory disease and cancer.
Never use an air hose or dry brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner or alternate
method approved by OSHA, designed to minimize the hazard of airborne asbestos fibers.
CAUTION

Spilled brake fluid will damage painted, plastic, or rubber parts.

NOTE
Do not remove the bleed valve unless it is replaced.

Requisite Service

Rear brake fluid draining/air bleeding {section 17 in Common Service Manual)


Q'ty

Procedure

(I)
(2)
(3)
(4)
(5)

(6)
(7)
(8)
(9)

(10)
(11)
(12)
(13)
(14)
(15)

(16)
(17)

Disassembly Order
Brake oil bolt
Sealing washer
Brake hose
Pad
Caliper stopper pin bolt
Rear axle pinch bolt
Rear axle nut
Rear axle
Brake caliper assembly
Pad spring
Caliper bracket
Pad retainer
Caliper pin bolt boot
Caliper pin bolt
Caliper piston
Dust seat
Piston seal

Remarks
Assembly is in the reverse order of disassembly.

1
2

1
2

Removal/installation (page 15-8)

1
1
1
1

loosen the bolt.

, After removing the caliper assembly, temporarily install


the rear axle and axle nut.

1
1
2
2
2
2
2

Do not remove unless necessary.


CAUTION
Be careful not to damage the piston sliding surface.

15-21

Brake System

lBS-ABSfTCS model

(8)

(6)

0 2 7 (2 7, 20)

5 (0 25

2.

1.B)

28

(2.8. 20)

~,."'~~"'~
'. t"~/"

(12)

"~'"~
/

".

5.5 )0.55, 4.0)

(13)

. (2)'.
/!!: .,'10:>.
.
"I
,,

\------------------------------.

(4)?-~--'-'.;
(14)

UP

(16)

~.

Same 0.0.

15-22

I
t1t
(15)

(11)
(14)

c:

23 (2 3. 17)

"

'U1!ti

(10)

Brake System

Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent.
Check the brake system by applying the pedal brake after air bleeding (page 3-131.
CAUTION

Spilled brake fluid will damage painted, plastic, or rubber parts.

NOTE

Do not remove the bleed valve unless it is replaced.

Requisite Service

Pedal brake line fluid draining/air bleeding {page 15-2)


Procedure

II)
)2)
)3)
14)
15)
16)
17)
18)
19)

Disassembly Order
Brake oil bolt
Sealing washer
Brake hose
Pad
Caliper stopper pin bolt
Rear axle pinch bolt
Rear axle nut
Rear axle
Brake caliper assembly

(10}
(11}
(12)
(13)
(14)
(15)
(16}

Caliper bracket
Pad retainer
Pad spring
Assembly bolt I caliper body
Caliper piston
Dust seal
Pistson seal

Q'tv

Remarks
Assembly is in the reverse order of disassembly.

2
4
2
2

Removal I installation {page 15-8}

1
1
1
1

Loosen the bolt.

After removing the caliper assembiy, temporarily install the


rear axle and axle nut.

1
1

1
3/1
3
3~
3~

Install as shown.

CAUTION
Be careful not to damage the piston sliding surface.

15-23

Brake System

Rear Brake Pedal Removal/Installation


(1)

(8)

(7)

~~---13)
16)

.,
12)

(4)

Requisite Service
Right step holder removal/installation {page 2-13)
Q'ty

Procedure

Remarks
Installation is in the reverse order of removal.

Removal Order

11)
12)
13)
14)
15)
16)
(7)
(8)

(9)

Rear brake light switch spring


Cotter pin
Joint pin
Brake pedal return spring
Snap ring
Washer
Dust seal
Brake pedal
i Dust seal

15-24

1
1
1
1
1
1
1
1
1

Brake System

MEMO

15-25

Brake System

Secondary Master Cylinder Disassembly I Assembly (LBS-ABS/TCS model)

til

(2)

if) 35 (3.5. 25)


(1 )

(9)

Rubber

.u> til

(4)

{10)

0~~~--(3)

(1)

0 3 5 {3.5, 25}
(7)

0 3 0 (3.0. 22)

~~
(3)

.1(161

""~'"
'if

0 ' 8 (1.8, 13)

(19)

tw:I

(15}

@
(21)

.~

if)1B{1.8,13}
(20)

c:w

(13)'

(17)

(14)

15-26

.I

Brake System

Check the brake system by applying the brake after air bleeding (page 3-13J.
CAUTION
Avoid spilling fluid on painted. plastic. or rubber parts. Place a rag over these parts whenever the system is serviced.
When removing the oil bolt, cover the end of the brake hose to prevent contamination. Do not allow foreign material to
enter the system.
Do not allow the lips of the cups to be turned inside out and be certain the snap rings is firmly seated in the groove.
NOTE
The master piston, piston cups and spring must be replaced as a set.
Use only DOT 4 brake fluid from a sealed container.

Requisite Service
Pedal brake line fluid draining/air bleeding (page 15-2)
Front fender removal/installation (page 2- 11)
Procedure

111
12}
13}

14}
15}
15}
17}

IB}
19}
(10)
(11)
(12)
(13}
(14)
(15)
(16)
(17)

{18}
(19)
(20)
(21)

Disassembly Order
Oil bolt
Sealing washer
Brake hose
Oil pipe stay bolt
Link plate bolt
Link plate
Upper caliper pivot bolt
Master cylinder mounting bolt
Secondary master cylinder & link arm assembly
Cotter pin
Joint pin
Link arm
Boot
Snap ring
Push rod
Master piston
Primary cup
Spring
Lock nut
Push rod nut
Push rod joint

Remarks

Q'ty

Assembly is in the reverse order of disassembly.


2

4
2
1
2
2
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1

Install the bolt with longer threads at the upper side.

Use snap ring pliers (07914-3230001).

Loosen the nut.

15-27

Brake System

Delay Valve Removal/Installation (LBS-ABS/TCS model)

C:

17 (1.7,12)

{3)

Check the brake system by applying the pedal brake after air bleeding (page 3-13).
CAUTION
Avoid spilling fluid on painted, plastic, or rubber parts. Place a rag over these parts whenever the system is serviced.
When removing the oil bolt or pipe, cover the end of the brake hose and pipe to prevent contamination. Do not allow
foreign material to enter the system.
Requisite Service
Pedal brake nne fluid drainmq/air bleeding (page 15-2)
Front fender removal/installation (page 2-11)
Procedure
(1)

{2)
{3)
{4)

{51
{51

Removal Order
Oil bolt
Sealing washer
Oil pipe joint nut
Wire stay & hose joint bolt
Mounting bolt
Delay valve

15-28

Q'ty

Remarks
Installation is in the reverse order of removal.

2
4

1
1

2
1

Install the bolt with longer threads at the upper side"

Brake System

Proportional Control Valve Removal/Installation (LBSABS/TCS modell


"
---------------;r~. Ii) :
i'~- 5?', (j<~-

I \,

-:

\ \,

~~~~~~~~~~?~~~.;.~:=~~

cj
/

II
/1
I

i/

,'''

{21

{ll

{31

17 (1.7,12)

Check the brake system by applying the pedal brake after air bleeding (page 3-13).
CAUTION
Avoid spilling fluid on painted, plastic, or rubber parts. Place a rag over these parts whenever the system is serviced.
When disconnecting the oil pipe, cover the end of the oil pipe to prevent contamination. Do not allow foreign material
to enter the system.

Requisite Service
Pedal brake nne fluid draining/air bleeding (page 15-2)
Right side cover removal/installation (page 2-2)
Procedure
{11
{21
{31

Removal Order
Oil pipe joint nut
Mounting bolt
Proportional control valve

my
2
2
1

Remarks
Installation is in the reverse order of removal.
Be careful not to deform the oil pipe.

15-29

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

...

Replace the partts] with new onets) before assembly.

Is :;O=ooLI

Use special tool

IOP~OOLI

Use optional tool. Use the same procedure you use to order parts.

Torque specification.

10 Nm (1.0 kg-m, 7.2 ft-lb)

10 (1.0, 7.2)

-:71

-,
..~

Use recommended engine oil, unless otherwise specified.

Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1

Use multi-purpose grease (Lithium based multi-purpose grease NLGI #2 or equivalent)

Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote BR-2 plus manufactured by Dow Corning, U.S.A.
Multi-purpose M-2 manufactured by Mitsubishi Oil Japan

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

Use silicone grease

Om

Apply a locking agent. Use a middle strength locking agent unless otherwise specified.

"I~

Apply sealant

Use brake fluid, DOT 3 or DOT 4. Use the recommended brake fluid, unless otherwise specified.

Use Fork or Suspension Fluid.

1) .

16-A. ABS ('92 - '95)


Service Information

16-A-1

Troubleshooting

16-A-5

System location

16-A-2

Wheel Sensor Air Gap Inspection

16-A-51

System Wiring Connections/Locations

16-A-3

Front Modulator Removal/Installation

16-A-52

Circuit Diagram

16-A-4

Rear Modulator Removal/Installation

16-A-54

Service Information
CAUTION
Use a fully charged battery for troubleshooting. Do not diagnose the ABS with a charger connected to the battery.
On removal and installation of the wheels and wheel sensors, be careful not to damage the wheel sensors and'
pulser rings.

NOTE
Check the following before performing any ASS troubleshooting.
- Pre-start self-diagnosis of ABS
- ABS indicator light
If an abnormality is found during the above checks, perform the ASS troubleshooting following the Symptom-toSystem Chart (page 16-A-8). The ASS is normal if no trouble is found. Go to the checks on the other basic systems (e.q.,
brake system).
Troubles not resulting from a faulty ASS, i.e. brake disc squeak, unevenly worn brake pad, etc., cannot be recognized by
the ASS diagnosis system. (See the Common Service Manual.)
Record the symptom ofthe problem and the problem code in MEMO before troubleshooting.
When the ASS is faulty, the ASS indicator light blinks or it comes on. The ASS does not function at this time; take care
during the test ride.
Do not disassemble the modulator assembly. If it is faulty, replace it as an assembly.
After replacing the modulator, bleed air from the brake fluid according to the standard air bleeding procedure. Note that
replacement and bleeding air from the brake fluid is not possible, as it is sealed in the modulator.
When the rear wheel sensor or rear pulsar ring is replaced, perform the air gap inspection (page 16-A-51).
The ASS indicator light might blink in the following cases. If the indicator light blinks, clear the problem code and
perform the pre-start self-diagnosis of the ASS (page 16-A-5). The ASS is normal if the ASS indicator light goes oft.
- The motorcycle has continuously run on the bumpy road.
- The ASS control unit (ECU) was disrupted by extremely powerful radio wave (Electromagnetic Interference).
- After riding {i.e. after the pre-start self-diagnosis), the engine was kept running and the rear wheel turning (for more
than 30 seconds) with the motorcycle on the center stand.
The ASS indicator light might blink in the following cases. If the indicator light blinks, service the faulty parts, clear the
problem code, and perform the pre-start self-diagnosis of the ASS (page 16-A-5). The ASS is normal if the ASS indicator
light goes off.
- Incorrect tire pressure
- Tires not recommended for the motorcycle were installed.
- Deformation of the wheel
After troubleshooting, clear the problem code and perform the pre-start self-diagnosis again to be sure that the ASS
indicator light is operating normally.

16-A-1

l'1:li.

u:.

ABS ('92 '95)

System Location

(6) INDICATOR CONTROL UNIT


(7) ASS INDICATOR LIGHT 2
(5) IGNITION SWITCH

(4) AB5/TCS INDICATOR LIGHT SWITCH

(8) ASS INDICATOR LIGHT 1


(9) ASS CONTROL UNIT{ECU)
(10) PUMP MOTOR

(3) BATTERY

(11) LIMIT SWITCH

(2) ASS FUSE CASE


(l) REAR WHEEL

SENSOR

(12) SOLENOID VALVE


( 13)

FRONT PUMP MOTOR RELAY


(14)

REAR PUMP MOTOR RELAY


(15) ASS MAIN RELAY

(20)

REAR PUlSER RING

(19) REAR MODULATOR


(18) FRONT MODULATOR

(16l FRONT PULSER RING

(17) FRONT WHEEL SENSOR

16-A-2

System Wiring Connections/Locations

,~; ABS/TCS INDICATOR

CD REAR LIMIT SWITCH

-R. side cover (page 2-2)

. Refer to section 2, (frame/body


panels/exhaust system), for the parts
that must be removed for sevice.

For example:

LIGHT SWITCH
-Top shelter
(page 2-5)

:); ASS INl

-Inner

MJ
,

(~)

ABS/TCS INDICATOR
LIGHT SWITCH
e-Maintenance part

S(

(page 2-

ABS FUSE CASE


-L. side cover (page

___-~_2-21

-Top shelter' The parts

that must be removed for


service.

ASS MAIN (lOA)

FRONT SOLENOID (1 GAl


REAR SOLENOID (lOA)

PUMP MOTOR (20A)

@GROUND TERMINAL
-R. side cover (page 2-2)

/
,j]) FRONT PUMP
-Upper fairing
(page 2-9)

t4J REAR

PUMP MOTOR
-R. side cover (page 2-2)

Bl

BLACK

Y YELLOW
Bll BLUE
G GREEN
R RED
W WHn:E

Br
0
Lb
Lg
P

__---L_, r:_ _---'

,~-_

BROWN
ORANGE

UGHTBLUE
UGHTGREEN

PINK
Or GRAY

PI iW, o~
W

IP

BI

'l} REAR SOLENOID VALVE


-R. side cover (page 2-2)

(~) ~
J2: REAR WHEEL SENSOR
-R. side cover (page 2-2)

{~,

FRDr

-uoo
(page

llCATOR LIGHT 2
Teen
7}

ABS ('92-'95)

'S: INDICATOR CONTROL UNIT

:1::

ASS INDICATOR LIGHT 1


-Inner screen

-L. fairing pocket


(page 2-6)

(page 2-7)

I~I

(~)

L~B1

Y;Gr

GfSI

o: INDICATOR (WHITE)
-Inner screen (page 2-7)

@FRONT PUMP MOTOR RELAY


-Upper fairing (page 2-9)

s,

,-,
B7y

Rlsr %u
t]) REAR PUMP MOTOR RELAY

-Upper fairing (page 2-9)

r-r-r

B~p B~L9
R/ R/
Sr Su

@lABS MAIN RELAY


-Upper fairing (page 2-9)

@ECU {BLACK}
-Upper fairing (page 2-9)

{~GROUND

(f" ECU

(WHITE)
-Upper fairing (page 2-9}

TERMINAL

-Upper fairing
(page 2~-..:9..:)_ _-,-

~ [~)

IT WHEEL SENSOR
er fairing
2-9)

INDICATOR (BLACK)
-Inner screen (page 2-7)

~
:J.: FRONT SOLENOID VALVE
-Upper fairing
(page 2-9}

-,

($I$J

@FRONT LIMIT SWITCH


-Upper fairing
(page 2-9)

16-A-3

ABS ('92-'95)

Circuit Diagram
PUMP MOTOR RELAY
(FRONT) (REAR)

ABS

MAIN~~~rm~

ASS FUSE

BOX
1 2 3

1:
2:
3:
4:

~TTIT%:rr=rr%:

RELAY

!1::
sea:;
;::(:J,,
m"

c,il..5'<i5
.--.-"-"

~~~.ii
0>"-

a1Cl:c3O::

III

a: III c::

Ci

"(,'J

:::0 ~ :::0

m"m

1QA
2QA
10A
lOA

REAR SOLENOID
PUMP MOTOR
FRONT SOLENOID
ASS MAIN

a:E'2. !!?

""

BlfGr~
BI/Gr_
O!G_
P/BI..-04

BI/G----4

BlfGoooo4

alBI_
PN/Bu/P_
Br/Lg_
Bu/Lg_

BrlY_

Bu/Gr ...

ASS CONTRe

G/_
Gr/R-

I~
l

(:J

PUMPMOTOR

>
m

I""

iiim~
,@,
~

sss
os:li:

c..

Q tD

~~~~

e,

E!:

9~

l~ ~C

FRONT MODU LAT OR

16-A-4

iiic..~

LIMIT
SWITCH

CONNECT(
. - 81

o-w

SOLENOID

VALVE

REAR MODULATO R

61

BLACIt

YELLOW

; S,
0

BROWN
ORANGE

MAIN FUSE 30A

Su ~(Lb' LIGHT6LUE
G ~REEN

Lg LIGHT GREEN

RED

PIN It

WHITE

cr

GRAY

(!)

BATTERY

4P

STARTER{" SYSTEM

_-----I

---+I "

=====+:t-_

==

----LJ$'p
-w
'I
==eRJJ[R..l:J ,GN'T'ON

1
t"

R/BI1lfR/BIt.:..J SWITCH

;>--R/Br-

G/SI I'ND'CATOR
~Gr/.~"==l~;;~~~;~~~!~~~~~~~~~~;;:~BI
L...-R/BI~BI/B,

Bl/Br

CONTROL
UNIT

2P_BI

I l - - L g / O . - - - - - ...... TCS

4P-BI

2P-R

:0
l UNIT {ECU)

:J [

~g::I~
ABS INDICATOR

4P-W

2P-BI

~lIGHT 2

"':l
:J L G: IBu
~G/O
9P-W

ABS INDICATOR
LIGHT 1

~G/Gr

~BI/O
>-Bu/G

~G/O
~BI/P

~G,/YJ..-E3-1
INDICATOR LIGHT
SWITCH

WHEEL SENSOR

ABS 1'92-'95}

Troubleshooting
Before Beginning Troubleshooting:
Summary of ABS pre-start self-diagnosis system
The ASS pre-start self-diagnosis system diagnoses the electrical system as well as the hydraulic system operation in the
modulator. When there is any abnormality, the problem and the problem part can be detected by outputting the problem
code.
After starting the engine, the ASS pre-start self-diagnosis system operates the pump motor and solenoid valve inside the
modulator, checks the limit switch ON/OFF condition with the ECU and detects whether the hydraulic operation is normal.
Then, the diagnosis system enters the stand-by phase for receiving the signal from the wheel sensor, and it completes the
pre-start self-diagnosis when the wheel sensor signal is input in the ECU at approximately 10 km/h (6 mile/h) or more of
the vehicle speed.
If the ASS is normal, the ASS indicator light goes off just after starting the engine and the motorcycle is in motion indicating
that the dignosis is completed.
If a problem is detected, the ASS indicator light blinks or comes on and stays on to notify the rider of the problem.The
self-diagnosis is also made while the motorcycle is running, and the indicator light blinks when a problem is detected.
When the indicator light blinks, the cause of the problem can be identified by retrieving the problem code following the
specified retrieval procedure. (page 16-A-6)

PRE-START SELF-DIAGNOSIS WHEN NORMAL

~F~::Jr---------------

IGNITION SWITCH

ENGINE RUN:~~~

m- m
mu----

n----

START

o
VEHICLE SPEED

o km/h (6mile/h) or above

ON -----------.-------------

PUMP MOTOR

OFF ---------'
O~~

SOLENOID VALVE

-nnumummnmm-muJU1JlL-

~~F-~

ABS INDICATOR
LIGHT 1, 2

L
L
Pre-start self-diagnosis completes

Pre-start self-diagnosis procedure (Everyday check-up)


1.
2.
3.
4.
5.

Turn the ignition switch ON.


Be sure that the ABS indicator lights 1 and 2 come ON.
Start the engine.
Ride the motorcycle and raise the vehicle speed to approximately 10 km/h (pre-start self-diagnosis completes).
The ASS is normal if both the ASS indicator lights 1 and 2 go off.

Tee

I[

,
A

iii s

110lL

II

ASS INDICATOR LIGHT 1

ASS INDICATOR LIGHT 2

16-A-5

ASS 1'92-'95)
ABS/TCS INDICATOR LIGHT SWITCH

Retrieval of/Clearing Problem Code


NOTE
The ASS indicator light indicates the problem code by
its number of blinks {see the next page).
The problem code is not cleared when the ignition
switch is turned OFF during output of the problem

-,

code. However, output cannot be restarted by turning the ignition switch ON. Restart the output following the problem code retrieval procedure.

After retrieving the problem code, be sure to record it


in MEMO, etc. Clear the problem code after trouble-

shooting.

res

ON/OFF SWITCH

Retrieval:
1. Turn the ignition switch OFF.
2. Turn the ignition switch ON while pressing the ASS/
res indicator light switch. The ASS indicator light 1
and 2 should come ON.
3. Hold the ABS/TCS indicator light switch pressed (for
approximately 5 seconds). The ABS indicator light 1
and 2 should go OFF.
4. Release the ABS/TCS indicator light switch immdiately
(within 1 second) after the ABS indicator light go OFF.
~> Output of the problem code starts and the ABS indicator light 1 blinks. (The ASS indicator light 2 is OFF
this time.)

Clearing:
5. Press the ASS/TCS indicator light switch during
output of the problem code (while the ASS indicator
lignt is blinking).
=? The Problem code is cleared and the ASS indicator
light 1 and 2 comes ON and stay ON.

Turn ignition switch ON


while pressing
indicator light switch.

I~

ABS INDICATOR LIGHT 2

ABS INDICATOR LIGHT 1

Release indicator light switch immediately


(within 1 eec.I
after ASS indicator lights go OFF.

Problem code
clearing signal

,,

ABS/TCS
INDICATOR
LIGHT SWITCH
IGNITION SWITCH

:~~::sej
ON

==J-----+----------ON---+OFF

OFF

Blinking

ON

ASS INDICATOR
LIGHT 1

OFF

ASS INDICATOR
LIGHT 2

ON
OFF

16-A-6

---.JrL

L.-

:::::::::J

,,
,

i
=.=:o+--+-+-+-H--+--+--+i-.------.J

Release of modulator internal


pressure (Solenoid valve
!-!
operation sound}
Problem code L .J
start signal
Latest
problem
code

Previous time
problem code

ABS ("92-'95)
Problem code indication pattern
Example:
When the problem code is stored;
Latest problem
Problem code start signal

code

~pmbl",m code:
ASS indicator light 1 ON------------------

r--

Previous time
problem code

Latest problem code

Problem code:

Problem code:

r--.r--z:-~'r--~r---

Pattern repeated

ASS indicator light 1 OFF

-----=-1

/>--t-tt---

Release ASS(TCS indicator light switch.

,"0 .

0.3 sec.

~--0.2 sec.

When the problem code not stored;


Problem code start signal
No output of code
ASS indicator light 1 ON __.. ----- ----------

OPe
ASS indicator light 1 OFF

.>

ttern repeated

~ 3 sec.

Release ASS(TCS indicator light switch.

NOTE

The ECU can store up to two problem codes. The latest problem code is output first, then the previous one is output,
When the two problem codes are output, diagnose on the latest problem code (i.e. code output first).
After troubleshooting, perform the pre-start self-diagnosis again to be sure that there is no problem in the ASS indicator
lights and the problem code is cleared.
See page 16-A-46 for the problems that are not represented with the problem codes.
Check the following before performing ASS troubleshooting:
- Pre-start self-diagnosis of ASS
- ASS indicator light
If an abnormality is found during the above checks, perform the ASS toubleshooting following the Symptom-toSystem Chart (see the following page). The ASS is normal if no trouble is found. Go on to the check the other basic
systems (e.g., brake system).

16-A-7

ABS ('92 '95)


Symptom-ta-System Chart
Affected

Problem
Fuse

Modulator

-c
0

sr
0

Item

"'3

-c

0
c,

ro 3
0
0

,
~

-c

"

"'0,

-c

J>

,"'0

-c

,-e

0
0

0;

-n

-n

, ,o , , , ,

" " "


{1)

Faulty front hydraulic


pressure circuit system

Faulty rear hydraulic


pressure circuit system

Faulty front hydraulic


control system

Faulty rear hydraulic


control system

Faulty front wheel speed


sensor system

$:

sensor system

Faulty ASS main relay

$:

Faulty power circuit

0:

Faulty control unit (ECU)

Problems not recognized


by control unit (ECU)

,-n

0
0

-n

" "

<e-

".

0 0

16-A-9

0 0

16-A-16

0 0

16-A-23

0 0

0 0

16-A-30

0 0

16-A-37

0 0

16-A-4{)

0 01

16-A-43

0
,

0
0

0 0
,

,
,

c,

0
0

, , , ,

"3 , , ,

"'

,n0;

-n

e,
o0 J>
, ro a
3' 0,

,Q. s n
" 3 -m". , ,Q.
0
.c, -c:o ". ,

Faulty rear wheel speed

<

0
0

..

s-c

". "'3 ,
,
"o 0; ,
s

"z

,<1

.- ,e. ,s
;;
0

-u

"-

ro

J>

,-

-c

:;;

16-A-45

16-A-45

0 0 0 0 0

16-A-46

NOTE
Check the following before periorming ASS troubleshooting.
- Pre-start self-diagnosis of ASS (page 16-A-5)
- ABS indicator light (page 16-A-5)
If an abnormality is found during the above checks, perform the ABS troubleshooting following the Symptom-toSystem Chart. The ABS is normal if no trouble is found. If no trouble is found, continue on to the other basic system
checks (e.g .. brake system).
After troubleshooting, clear the problem code (page 16-A-6} and perform the pre-start self-diagnosis again (page
16-A-6) to be sure that the ABS indicator light is operating properly.

16-A-8

ABS ('92-'95)

Flowcharts
NOTE

Turn the ignition switch OFF unless otherwise specified.


When the control unit {ECU) or modulator is detected to be faulty, recheck the wire harnesses and connectors
connections closely before replacing the control unit or modulator.
After troubleshooting, perform the pre-start self-diagnosis again and be sure that the ASS indicator light is normal.
The encircled numbers in the text and connector diagrams indicate the connectors (see page 16-A-3).

Problem code 1: Faulty front hydraulic pressure circuit system


After starting the engine (before riding the
motorcycle), check the ASS indicator light.

Light stays on.


Light blinks.

There are two types of modulator pre-start


self-diagnosis sounds; one is the intermittent
clattering sound of the solenoid valve operation sound, and the other is the continuous
beep of the pump motor operation sound.

Restart the engine and check for the pre-start


self-diagnosis sound (Le.. motor sound)from the
front and rear modulators right after the engine
starts.

Is there a motor sound in the front and


rear modulators?

Normal
(Temporary problem: Fine foreign matter in the
modulator or the ECU has been disrupted by an
extremely powerful radio wave.)
NOTE

Motor sound in b oth


modulators.
(Go to page 16-A-12)

No
I
No motor sound in either
modulator
I

I
No motor sound in
the front modulator

IL

.. (Go to the following page.)

ASS FUSE CASE


Turn the ignition switch OFF.

Check the pump motor fuse in the ASS fuse I


I
I case.

Is the fuse normal?

Burned out.

Normal
Disconnect the pump motor relay connectors Q) I

I and @.

(Continue to the following page)

16-A-9

ABS 1'92-'95)
View from terminal side.

(From the previous page: Disconnect the pump


motor relay connecrors rs: and @'.)

t!f~

Check for voltage between the pump motor relay


connector C) and :];. terminals and the body
ground respectively.

No battery

<

voltage

Does battery voltage register?

Repair open in the RED or RED/BLUE harnesses between the battery and pump motor relay.

Battery voltage
Check the harnesses and connectors for secure
connection (page 16-A-3).
(From the previous page: No motor sound in the
front modulator)

Turn the ignition switch OFF.

Interchange the front ,"d rear pump motor


relays with each other.

: Start the engine. Check whether the front and

I rear pump motor sounds interchanged with each


other.

Did the pump motor sounds interchange? \


(No motor sound in the rear pump motor?) /

Interchanged.
Faulty pump motor relay

Did not interchange.

Turn the ignition switch OFF.


View from terminal side
Disconnect the pump motor relay connector
and the BLACK connector [C' of the ECU.

~8)

(jJ;

I I
-

Check for continuity between the pump motor


relay connector
terminal and the BLACK connector @ terminal of the ECU.

co

j
(Continue to the following page)

16-A-10

I I

->

BLUE/LIGHT GREEN
BLUE/LIGHT GREEN

ABS ('92-'95)
(From the previous pagel

I
Is there continuity?

No continuity

Repair open in the BLUE/LIGHT GREEN harness between the pump motor relay and ECU.

Continuity

View from terminal side


I '/

Disconnect the pump motor connector@.

cE

,:/y"

EB

Check for continuity between the pump motor


,nd pump motor
connector <1$ terminal.

I'--~

<

BROW N/YELLOW

relay connector @ terminal

Is there continuity?

;*i~~",t"'J~

\'1'
'I 1,/;1 If;.

No continuity

Continuity

BRQWN/yELLOW

1--------"

Repair open in the BROWN/YElLOW harness


between the pump motor relay and pump
motor.

Install the pump motor relay connector ,~, pump


motor connector@andthe BLACK connector it

of the ECU.

! Start the engine and check the front pump motor

, relay for a clicking sound at the relay contact

I point.

<

Is there a clicking sound in the relay?

Sound

Faulty modulator

No sound

Faulty ECU

16-A-11

ABS 1'92-'951
(From page 16-A-9: Motor sound in both modulators]

Front motor
sound does not
stop.

j
(Go to page

16-A-14.)

I
j

I Turn the ignition switch OFF.

j
Interchange the front

end rear pump motor

relays with each other.

j
Interchanged.

Start the engine. Did the front and rear motor \


sounds interchange with each other?

Faulty pump motor relay

Did not interchange.


Check the modulator limit switch connector @
for secure connection.

<

Poor connection

Is it connected securely?

Connect securely and recheck.

Secure connection

Turn the ignition switch OFF.

Disconnect the limit switch connector @'.

View from terminal side

I
I

GRAY/RED

Start the engine. Check for continuity between


the switch side terminals of the limit switch
connector @ during pump motor rotation (see
page 16-9).

GREEN/PINK

No continuity

Is there continuity during pump motor rotation?

Repair open in the limit switch side GRAY/RED


or GREEN/PINK harness.
Faulty modulator

Continuity

Clear the problem code.

(Continue to the following page)

16-A-12

ABS ('92-'951
(From the previous page)

j
Turn the ignition switch OFF.

View from terminal side

Connect the main harness side terminals of the


limit switch connector @ with a piece of jumper

wire.

WIRE

Perform the pre-start selt-diaqnosis and retrieve


the problem code.

<

Problem code "3"


Problem code 1
M

Check the harnesses and connectors for secure


connection (page 16-A-3l.

Is the problem code "3"?


H

Turn the ignition switch OFF.

View from terminal side

I Disconnect the WHITE connector @ofthe ECU. I

I@

GRAY/R~EEN/PINK

While connecting the main harness side terminate of the limit switch ccnnectcr -J with a
jumper wire, check for continuity between the
WHITE connector eft' terminals cif the ECU.

<

No continuity
Is there continuity?

Continuity

Repair open in GRAY/RED or GREEN/PINK


harness between the ECU and modulator (limit
switch) .

Faulty ECU

16-A-13

ABS ('92-'95)
(From page 16-A-12: Front motor sound does
not stop.)

Turn the ignition switch OFF.

Interchange the front


relays with each other.

,nd

rear pump motor

Interchanged.

Start the engine. Did the front and rear motor \


sounds interchange with each other?

Faulty motor relay

Did not interchange.


View from terminal side
Turn the ignition switch OFF.

I
BLUE/LIGHT

_BROWN/YELLOW

GREEN

Disconnect the pump motor relay connector ,])


and BLACK connector @ of the ECU.

Check for continuity between the pump motor


relay connector ~ terminals and body ground

respectively.

<

Continuity

Is there continuity?
No continuity

Faulty ECU

16-A-14

Repair short in the BLUE/LIGHT GREEN or


BROWN/YELLOW harness between the pump
motor relay and EeU.

ABS ('92 '95)


(From page 16-A-12: Motor sound is normal

Turn the ignition switch OFF.

Interchange the front and rear pump motor


relays with each other.

Perform the pre-start self-diagnosis and retrieve


the problem code.

<

Problem code '2-Is the problem code

Faulty front pump motor relay

~2"?

Problem code

~ 1"

View from terminal side


Turn the ignition switch OFF.

Disconnect the pump motor relay connector


and WHITE connector@ofthe ECU.

':E'

Check for continuity between the pump motor


relay connector and WH ITE connector :g of
the ECU.

<

No continuity
Repair open in the BROWN!YELLOW harness
between the pump motor relay and ECU.

Is there continuity?
Continuity

View from terminal side

rs':

Disconnect the front and rear modulator pump


motor connectors -T$ and ifq,.

~~OWN/YELLOW

Check for continuity between the pump motor


relay connector .:::: and body ground.

<

Continuity
Is there continuity?
No continuity

Repair short in the BROWN!YELLOW harness


between the pump motor relay and ECU

Faulty ECU

16-A-15

ABS ('92-'95)
Problem code 2: Faulty rear hydraulic pressure circuit system

After starting the engine {before riding the


motorcycle}. check the ASS indicator light.

<Does the ASS

light stays on.


Norna! (Temporary problem: Fine foreign matter in the modulator or the ECU has been
disrupted by an extremely powerful radio wave.)

indicator light blink or stay on?


light blinks.

NOTE
There are two types of the modulator prestart self-diagnosis sounds; one is the intermittent clattering sound of the solenoid valve
operation sound, and the other is the continuous beep of the pump motor operation
sound.

Restart the engine and check for the pre-start


self-diagnosis sound (i.e., motor sound) from the
front and rear modulators right after the engine

starts.

15 there a motor sound in the front and rear


modulators?

Motor sound in both


modulators.

(Go to page 16-A-19.)

No

No motor sound in either


modulator.

No motor sound in the


rear modulator.

-----------~ (Go to the following page.)

I
Turn the ignition switch OFF.

ASS FUSE CASE

O~

10=

Check the pump motor fuse in the ASS fuse I


I
I case.

-'

PUMP MOTOR FUSE (20A)

Is the fuse normal?


(=====~;;;;~~~~~i':=====:::;~--"""'."':'...':~:-_-'
Replace the fuse and recheck.
Burned out.

Normal

D i sc ~ ~ n e ct the pump motor relay connectors ,j~:

and ~!Jl;.

(Continue to the following page)

16-A-16

I
I

ABS ('92-'95)
View from terminal side

(From the previous page: Disconnect the pump

motor relay connectors

and

Eq

@l,)

RED/BL~

Check for voltage between the pump motor relay


connector and terminals and the body
ground respectively.

No battery voltage

Does battery voltage register?

Battery voltage

Repair open in the RED or RED/BLUE harnesses between the battery and pump motor relay.

Check the harnesses and connectors for secure


connection (page 16-A-31.
(From the previous page: No motor sound in the
rear modulator.)

I
Turn the ignition switch OFF.

Interchange tho front


relays with each other.

'nd

rear pump

motor

IStart the engine. Check whether the front and


Irear pump motor sounds interchanged with each
other.

Did the pump motor sounds interchange? (No \


motor sound in the front pump motor?)
/

Interchanged.
Faulty pump motor relay

Did not interchange.

Turn the ignition switch OFF.


View from terminal side
Disconnect the pump motor relay connector .;
and the BLACK connector @ of the ECU.

Check for continuity between the pump motor


relay connector terminal and the BLACK connector @ terminal of the ECU.

~E8

QJ;

BLUE/~E/PINK

{Continue to the following paqel

16-A-17

ABS ('92-'95)
(From the previous page)

No continuity

Is there coutinuity?

Repair open in the BLUE/LIGHT GREEN harness between the pump motor relay and ECU.

Continuity

Disconnect the pump motor connector @.

@c,. --';______

side

_~_

connector terminal.

B ROWN/L1GHT GREEN

I
No continuity

Continuity

Install the pump motor relay connector . pump


motor connector ano the BLACK connector (jJ)

ee

of the ECU.

j
Start the engine and check the front pump motor
relay for a clicking sound at the relay contact

point.

Sound
Is there a clicking sound in the relay?
No Sound

Faulty ECU

16-A-18

BROWN/LIGHT GREEN

Repair open in the BROWN/LIGHT GREEN


harness between the pump motor relay and
pump motor.

Is there continuity?

<

."'?~~
,,_ ""

" ' - -__ ,7----"

9~'@f~~T

Check for continuity between the pump motor


relay connector ':ID terminal and pump motor

<::::S~~;'!!!Jlf0~"-

Vie w from terminal

Faulty modulator

ABS {'92-'951
(From page 16-A- 16. Motor sound in both modulators. )

I
Rear motor sounds for
approximately
5
seconds, then it stops. (Normally, it should sound for
approximately
3
seconds.)

Rear motor sound does


not stop.

Motor sound is normal.


(It stops within 3 seconds.)

I
(Go to page 16-A-21).

(Go to page 16-A-22).

I
Turn the ignition switch OFF.

j
: Interchange the front eod rear pump motor
with each other.

i relays

Interchanged.

Start the engine. Did the front and rear motor \

Faulty punp motor relay

sounds interchange with each other?

Did not interchange

ICheck the modulator limit switch connector CD


for secure connection.

<

Poor connection

Is it connected securely?

Connect securely and recheck.

Secure connection
View from terminal side

Turn the ignition switch OFF.

I
I

Disconnect the limit switch connector

CD.

GRA Y/ORANGE

No continuity
(Is there continuity during pump motor rotation?
Continuity

Clear the problem code.

GREEN/BROWN

Start the engine. Check for continuity between


the switch side terminals of the limit switch
connector ,:]j during pump motor rotation {see
page 16-16)

Repair open in the limit switch side GRAY/


ORANGE or GREEN/BROWN harness.
Faulty modulator

(Continue to the following page)

16-A-19

ABS 1'92-'951
(From the previous page)

Turn the ignition switch OFF.

I
View from terminal side

CD
Connect the main harness side terminals of the
limit switch connector CD with a piece of jumper
wire.

Perform the pre-start self-diagnosis and retrieve

the problem code.

Problem code

~4"

Is the problem code "4";'

Check the harness and connector for secure


connection {page 16-A-3).

Problem code "T

Turn the ignition switch OFF.

I Disconnect the WHITE connector@ofthe ECU.

View from terminal side

G RAY/ORANGE GREEN/BROWN

While connecting the main harness side terminals of the limit switch connector CD with a
jumper wire, check for continuity between the
WHITE connector@terminalsofthe ECU.

<

JUMPER WIRE

l@J
No continuity

Is there continuity?
Continuity

Faulty ECU

16-A-20

Repair open in the GRAY/ORANGE or GREEN/


BROWN harness between the ECU and modulator (limit switch) .

ABS ('92 '95)


(From page 16-A-19: Rear motor sound does not
stop.)

Turn the ignition switch OFF.

Interchange the front


relays with each other.

,nd rear

pump motor

( Start the engine. Did the front and rear motor


sounds interchange with each other?
/

Interchanged.
Faulty motor relay

Did not interchange.

View from terminal side

Turn the ignition switch OFF.

B
Disconnect the pump motor relay connector
and BLACK connector 'CD: of ECU.

Check for continuity between the pump motor


relay connector :E. terminals and body ground
respectively.

<

Continuity

Is there continuity?
No continuity

Repair short in the BLUE/PINK or BROWN/


LIGHT GREEN harness between the pump
motor relay and ECU .

Faulty ECU

16-A-21

ABS ('92-'95)
(From page 16-A-19: Motor sound is normal.)

Turn the ignition switch OFF.

Interchange the front and rear pump motor


relays with each other.

Perform the pre-start self-diagnosis and retrieve


the problem code.

<

Is the problem code" 1 N?

Problem code" 1"


) c - - - - - - - _ . . . Faulty rear pump motor relay

Problem code "2"


View from terminal side
Turn the ignition switch OFF.

{g,

~t]

Disconnect the pump motor relay connector l~

and WHITE connector @ of the ECU.

BROWN/LIGHT GREEN

BROWN/LIGHT G R L @ - - J

Check for continuity between the pump motor


relay connector (~) and WHITE connector @ of

the ECU.

<

No continuity
Is there continuity?

Repair open in the BROWN/LIGHT GREEN


harness between the pump motor relay and
ECU.

Continuity

View from terminal side

Disconnect the front and rear modulator pump


motor connectors@ and >2q,.

Check for continuity between the pump motor


relay connectcr rg: and body ground.

<

I
Is there continuity?
No continuity

Faulty ECU

16-A-22

Continuity
Repair short in the BROWN/LIGHT GREEN
harness between the pump motor relay and
ECU.

ABS ('92-'95)
Problem code 3: Faulty front hydraulic control system
Turn the ignition switch ON {but do not start the
enginel and check the ASS indicator light 1 and

2.

Light blinks.

Does the ASS indicator light blink or come


on and stay on?

Retrieve the problem code and record it. Clear

- I the problem code.

Light stays on.


Turn the ignition switch OFF.

Start the engine. Check the ASS indicator light


before riding the motorcycle.

Perform the pre-start self-diagnosis (including


riding the motorcycle) and check the ASS indicator light.

Light stays

<Does the ASS indicator light blink or stay on?

00.

Light blinks.

1<
1

Turn the ignition switch OFF.

Does the ASS indicator light blink or go off?

Light goes
OFF.

Light blinks
(Appears repeatedly).

J Retrieve the problem code again and clear the

problem code.

! Check the solenoid fuse in the ASS fuse case. I


Is the fuse normal?

I
Check the harness and connector for secure
connection (page 16-A-3 I
(Go to page 16-A-2B.)

<

Burned out.

Replace the fuse and recheck.

Normal

ABS FUSE CASE


FRONT SOLENOID ____
FUSE

! Start the engine. Check the ABS main relay for a


! clicking sound at the relay contact point immediately after starting the engine.

<

Is there a clicking sound in the relay?

Turn the ignition switch OFF.

Sound

(Go to page 16-A-25.)

[nc:=:J
Lj

0
1

No sound
(Continue the following page)

16-A-23

ABS 1'92-'95)
HEADLIGHT RELAY

(From the previous page)

j
Disconnect the ASS main relay connector@land
connect the headlight relay instead.

Restart the engine. Check the ASS indicator


light 1 and 2 before riding the motorcycle.

Ught stays on.

< Does the ASS indicator light blink or stay on?

Faulty ASS main relay

Light blinks.
View from terminal side

,---1E

Disconnect the ASS main relay connector @


from the headlight relay.

RED/BROWN

Turn the ignition switch ON.

Check for voltage between the ASS main relay


connector@)terminal and body ground.

<

No battery voltage

Does battery voltage register?

Battery voltage

Turn the ignition switch OFF.

Repair open in the RED/BROWN harness


between the ABS main relay and ABS main
fuse.

I
View from terminal side

(iJ)

Connect the ASS main relay connector rin to the

~BLUE/GRAY

ASS main relay and disconnect the BLACK connector @ of the ECU.

Turn the ignition switch ON.

Check for voltage between the BLACK connectcrqe terminal of the ECU and body ground.

<

Does battery voltage register?

Battery vclteqe

Faulty ECU

16-A-24

No battery voltage

Repair open in the BLUE/GRAY harness


between the ABS main relay and ECU.

ABS ('92-'95)
(From page 16-A-23: Operation sound in the
ASS main relay.)

View from terminal side

tom

Turn the ignition switch OFF.

Disconnect the ASS main relay connector@and


solenoid valve connector @.

WH'TE/P~'TE/P'NK

Check for continuity between the ASS main


relay connector@)terminal and the main harness

side terminal of the solenoid valve connectorqc.

No continuity

Is there continuity?
Continuity

Repair open in the WHITE/PINK harness


between the ASS main relay and modulator
(solenoid valve).
@

View from terminal side

OJ.GREEN

Check for continuity between the ASS main


relay connector @) terminal and body ground.

rIl

No continuity

Is there continuity?
Continuity

Open harness between the ASS main relay and


modulator ground terminal@, or poor groundmq ,

Install the ASS main relay connector @ and


solenoid valve connector@.

I
Retrieve the problem code. Check whether the
valve operation sound (i.e., clattering sound] can
be heard for approximately 3 seconds before the
problem code appears.

Operation sound

Is there the operation sound?

Go to page 16-A-27

No operation sound

Turn the ignition switch OFF.

(Continue to the following page)

16-A-25

ABS ('92-'95)
{From the previous page}

View from terminal side

J]"_,_F::;:=:;==j_,",,

rE

Disconnect the solenoid valve connector :[4 and


BLACK connector .:It of the ECU,

ORANGE! GREEN

Check for continuity between the main harness


side terminal of the solenoid valve connector @
and BLACK connector @ terminal of the ECU.

<

I
No continuity

Is there continuity?

ORANGE/GREEN

-----1@1
Repair open in the ORANGE/GREEN harness
between the modulator (solenoid valve) connector and ECU.

Continuity

View from terminal side

Turn the ignition switch ON.

BLAC

Check for voltage betwen the BLACK connector

,g. terminals of the ECU and body ground respectively.

Does battery voltage register?

No battery voltage

Battery voltage

Repair open in the BLACK/GRAY or RED harness between the ECU and battery.
View from terminal side

WHITE/PINK
! Connect the valve side terminals of the solenoid
valve connector ':11; to the battery terminals.
I ORANGE/GREEN: Positive (+)
WHITE/PINK: Negative(-)

ORANCllCREEN ,j,

(J

When connecting, is there the valve operation sound (i.e., clattering sound)?
/

Operation sound

Faulty ECU

OJ

m
W

BAITERY

ND operation sound

Repair open in the ORANGE/GREEN or


WHITE/PINK harness of the valve solenoid.
Faulty modulator

CAUTION
Connect to the battery terminals securely.
Be sure not to connect to the battery terminals for more than 5 seconds continuously.

16-A-26

ABS 1'92-'951
(From page 16-A-25: Valve operation sound.)

View from terminal side

flrr=Tli

After checking the operation sound, turn the


ignition switch OFF ,nd disconnect the limit
switch connector @.

~N/PINK

GRAYl@J
Check for continuity between the switch side
terminals of the limit switch connector@.

Is there continuity?

Continuity
Faulty modulator

No continuity

View from terminal side

I Disconnect the WHITE connector 01:' of the ECU.

GRAY/RED~

Check for continuity between the main harness


side terminal of the limit switch oonnector qp and
body ground.

Is there continuity?
No continuity

Continuity

Repair short in the GRAY/RED harness


between the ECU and limit switch connector.

Faulty ECU

16-A-27

ABS ('92-'95)
(From page 16-A-23: ASS indicator light stays
on.)

j
Start the motorcycle. Raise the vehicle speed to
10 km/h (6 mile/h) and check the ABS indicator
light. (After checking, the motorcycle can be
parked.)

The ABS indicator light

1 and 2 blink as the

The ASS indicator light


, and 2 go off once as

motorcycle starts to
move.

the motorcycle starts to


move, then they blink.

I
Turn the ignition switch OFF.

Go to page 16-A-29

I
View from terminal side

E8

Disconnect the solenoid valve connector (j]) and


BLACK connector @ of the ECU.

PINK/BLACK
Check for continuity between the main harness
side terminal of the solenoid valve connector @
and BLACK connector 'J!) terminal of the ECU.

<

No continuity

Is there continuity?

Continuity

PINK/BLACK

Q _ _I

Repair open in the PINK/BLACK harness


between the solenoid connector and ECU.
View from terminal side

With the BLACK connector of the ECU disconnected, check for continuity between the main
harness side terminal of the solenoid valve connector@and body ground.

<

PINK/BLACK

Continuity

Is there continuity?
No continuity

Connect the BLACK connector (jJ) of the ECU.

Disconnect the limit switch connector@.

(Continue to the following page)

16-A-28

Repair short in the PINK/BLACK harness


between the solenoid connector and ECU.

ABS ('92

'95)

(From the previous page)

View from terminal side


:[j

Check for continuity between the switch side


terminals of the limit switch connector @,

GRAY/RED
Connect the valve side terminals of the solenoid
valve connector 8 to the battery terminals, and
check for continuity between the switch side
terminals of the limit switch connector @.
Connect the PINK/BLACK (Inlet valve side)

WH
G REENjPINK

n
@ORANG

ITE/PIN~

"

PIL/SLAC K

.J,
E/GREEN

!J

8
BATTERY

harness to the terminal first, then connect the


C AUTION

ORANGE/GREEN (Outlet valve side) harness


immediately.

Does continuity stop within 1 second after.


connecting the ORANGE/GREEN harness?

Connect to the battery terminals securely.


Be sure not to connect to the battery terminals for more than 5 seconds continuously.
Continuity stops.

Faulty modulator

Continuity
Faulty ECU

(From page 16-A-28: The ASS indicator light 1


and 2 go off as the motorcycle starts to move.
then they blink.)

Retrieve the problem code.

Is the problem code

"3~?

No problem code

Check the harness and connector for secure


connection (page 16-A-3) .

Faulty ECU

16-A-29

ABS ('92-'95)
Problem code 4: Faluty rear hydraulic control system
Turn the ignition switch ON {but do not start the
engine} and check the ASS indicator light 1 and

2.

Light blinks. I Retrieve the problem code and record it. Clear
the problem code.

Does the ASS indicator light blink or come on


and stay on?

Light stays on.


Turn the ignition switch OFF.

Start the engine. Check the ASS indicator light I


before riding the motorcycle.
1

<

Perform the pre-start self-diagnosis (including


riding the motorcycle) and check the ASS indicator light.

Light stays
on.

Does the ASS indicator light blink or stay on?


Light blinks.

0085 the ASS indicator light blink or go off?

1<

Turn the ignition switch OFF_

Light go
OFF.

Light blinks
(Appears repeatedly}.

Retrieve the problem code again and clear the


problem code.

I
Turn the ignition switch OFF.

.
I Check the solenoid fuse in the ASS fuse case.
Is the fuse normal?

Normal
Start the engine. Check the ASS main relay for a
clicking sound at the relay contact point immediately after starting the engine.

In there a clicking sound in the relay?


No sound
(Continue to the following page)

16-A-30

\
Check the harness and connector for secure
connection (page 16-A-3).
(Go to page 16-A-35).

Burned out.

Sound

ABS ('92-'951
HEADLIGHT RELAY

(From the previous page}

l
Disconnect the ASS main relay connector
and connect the headlight relay instead.

(I~

Restart the engine. Check the ASS indicator


light before riding the motorcycle.

Light stays on.

<Does the ASS indicator light 1 and 2 stay on?

Faulty ABS main relay

Light blinks.
View from terminal side
Disconnect the ASS main relay connector
from the headlight relay.

Turn the ignition switch ON.

Check for voltage between the ASS main relay


connector@)terminal and body ground.

<

No battery voltage

Does battery voltage register?

Battery voltage

Turn the ignition switch OFF.

Repair open in the RED/BROWN harness


between the ASS main relay and ABS main
fuse.
View from terminal side

Tr

Connect the ASS main relay connector .J]; to the


ASS main relay and disconnect the BLACK connector @ofthe ECU.

Turn the ignition switch ON.

~GRAY
@)

Check for voltage between the BLACK connector {fl terminal of the ECU and body ground.

Does battery voltage register?


Battery voltage

No battery voltage

Repair open in the BLUE/GRAY harness


between the ABS main relay and ECU.

Faulty ECU

16-A-31

ABS ('92-'95)
(From page 16-A-30: Operation sound in the
ASS main relay.)

View from terminal side

I
Turn the ignition switch OFF.

B3cw

Disconnect the ASS main relay connector@)and

WHITE/PINK

solenoid valve connector @.

Check for continuity between the ASS main


relay connectorca terminal and the main harness
side terminal of the solenoid valve connector@.

<

WHITE/PINK

No continuty

Is there continuity?
Continuity

Repair open in the WHITE/PINK harness


between the ASS main relay and modulator
(solenoid valve).
View from terminal side

i>ril
~-

Check for continuity between the ASS main


relay connector@terminal and body ground.

<

ITJ.GREEN

No continuity

Is there continuity?

Continuity

Open harness between the ASS main relay and


modulator ground terminal @, or poor grounding.

Install the ASS main relay connector @ and


solenoid valve connector @.

Retrieve the problem code. Check whether the


valve operation sound (i.e. clattering sound) can
be heard for approximately 3 seconds before the
! problem code appears.

<

Operation sound

Is there the operation sound?


No operation sound.

Turn the ignition switch OFF.

(Continue to the following pagel

16-A-32

Go to page 16-A-34.

ABS {'92-'951
{From the previous page}
View from terminal side

Disconnect the solenoid valve connector @ and


BLACK connector (iJ) of the ECU.

ORAN
Check for continuity between the main harness
side terminal of the solenoid valve connector @
and BLACK connector @ of the ECU.

No continuity

Is there continuity?

Repair open in the ORANGE/BLACK harness


between the modulator (solenoid valve) connector and ECU.

Continuity

View from terminal side

lID
Turn the ignition switch ON .

I
B

Check for voltage between the BLACK connector (jJ) terminals of the ECU and body ground
respectively.

<

Does battery voltage register?

BLACK/GREEN

No battery voltage

Battery voltage

Repair open in the BLACK/GREEN or RED


harness between the ECU and battery.
View from terminal side

Connect the valve side terminals of the solenoid


valve connector @ to the battery terminals.
ORANGE/BLACK: Positive (+)
WHITE/PINK: Negative (-)

ORANGE/ WHITE/PINK
BLA,\;K
;!,

CJ

BATTERY

<

When connecting, is there valve operation \


sound (Le. clattering sound)?
I
Operation sound

Faulty ECU

No operation sound

Repair open in the ORANGE/BLACK or WHITE/


PINK harness of the valve solenoid.
Faulty modulator

CAUTION
Connect to the battery terminals securely.
Be sure not to connect to the battery terminals for more than 5 seconds continuously.

16-A-33

ABS ('92-'95)
(From page 16-A-32: Valve operation sound.)

View from terminal side

1TIL

After checking the operation sound, turn the


ignition switch OFF and disconnect the limit
switch connector CD.

I ~N~BROWN

GRAY/ORA~
Check for continuity between the switch side
terminals of the limit switch connector CD.

Is there continuity?

Continuity

Faulty modulator

No continuity

View from terminal side


Disconnect the WHITE connector@afthaECU. I

-GRAY/ORANGE
Check for continuity between the main harness
side terminal of the limit switch connector CD and
body ground.

Is there continuity?

No continuity

Faulty ECU

16-A-34

Continuity

Repair short in the GRAY/ORANGE harness

between the ECU and limit switch connector.

ABS ('92-'95)
(From page 16-A-30: ASS indicator light stays
on.]

j
Start the motorcycle. Raise the vehicle speed to
10 km/h (6 mile/h) and check the ASS indicator
light. (After checking, the motorcycle can be
parked.)

I
The ASS indicator light
1 and 2 go off once as

The ASS indicator light


1 and 2 blink as the

motorcycle
move.

start

to

the motorcycle starts to


move, then they blink.

Turn the ignition switch OFF.

Disconnect the solenoid valve connector


BLACK connector @ of the ECU.

View from terminal side

-tt

and

1];

PINK/i H1TE
Check for continuity between the main harness
side terminal of the solenoid valve ccnnectorqt
and BLACK cormector Jr of the ECU.

(Go to page 16-A-36.)

Is there continuity?

No continuity

Continuity

~
PINK/WHITE

. Repair open in the PINK/WHITE harness of the


solenoid connector and ECU.
View from terminal side

With the BLACK connector of the ECU disconnected, check for continuity between the main
harness side terminal of the solenoid valve connector {to and body ground.

Is there continuity]
No continuity

Q~PINK/WHITE

Continuity

Repair short in the PINK/WHITE harness


between the solenoid connector and ECU.

Connect the BLACK connector '[0 of the ECU.

Disconnect the limit switch connector CD.

(Continue to the following page)

16-A-35

ABS ('92-'95)
(From the previous page)

View from terminal side

CD

Check for continuity between the switch side


terminals of the limit switch connector CD.

GRAY/ORANGE
GREEN

ORANGE/BLACK

l@JROWN

Connect the valve side terminals of the solenoid

.II

II

WHITEI

/p INK

valve connector @ to the battery, and check for


continuity between the switch side terminals of
the limit switch connector <D.
,
Connect the PINK/WHITE (Inlet valve side)

PINK/
W HIT E

ri,

BATTERY

harness to the battery first, then connect the


ORANGE/BLACK (Outlet valve side) harness
immediately.

CAU TION
,
Connect to

the battery terminals securely.

B e sure not to connect to the battery termin als for more than 5 seconds continuously.

Continuity stops.

Does continuity stop within 1 second after


connecting the ORANGE/BLACK harness?

Faulty modulator

Continuity

Faulty ECU

(From page 16-A-35: The ASS indicator light 1

and 2 go off as the motorcycle starts to move,


then they blink.)

<

Retrieve the problem code.

Is the problem code

16-A-36

No problem code

~4"?

Problem code

Faulty ECU

~4 y

Check the harness and connector for secure


connection (page 16-A-3).

ABS 1'92-'95)
Problem code 5: Faulty front wheel speed sensor system
CAUTION
When removing/installing the wheel sensor and wheel. take care not to damage the tip of the sensor.
NOTE
Check the tire size and air pressure and check the tire for deformation before troubleshooting.
The ASS indicator light might come on while riding under the following conditions. Turn the ignition switch OFF and
periorm the pre-start self-diagnosis. The ASS is normal if the warning light goes off. However, the problem code is
stored in the ECU. Ask the rider for the riding conditions in detail when he brings his motorcycle to your dealership for
inspection.
The motorcycle has continuously run on bumpy road.
After riding on the roadlatter 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 center stand.
Periorm the inspection of the wheel sensor.
Check the area around the wheel sensor as
well

Place the motorcycle on its center stand eod


measure the air gap between the pulser ring
and wheel sensor.
Standard: 0.8 ::/- 0.4 mm (0.031 0.016 in)

<

Is the air gap correct?

Incorrect

Correct
Defomed and/or
Is the pulser ring defonned or damaged (e.q. ~ damaged
chipped teeth, etc.] ?

Check each part for deformation and looseness


and correct accordingly. Recheck the air gap.

Replace the pulser ring and recheck.

Not deformed and


damaded
there iron DC other magnetic deposits">,
between
the pulser ring and wheel sensor?
"

Deposits

. Remove the deposits and recheck.

NOTE

No deposits

Check the wheel sensor tip for damage. If it is


damaged, replace with a new one and recheck the air gap.
Are the pulsar ring, wheel sensor, and caliper
bracket loosely installed?

Loosely installed.

Correct deformation. Install securely and recheck.

Securely installed.

(Contiue to the following page)

16-A-37

ABS ('92-'951
(From the previous page)

Check the wheel sensor signal in the ECU.

NOTE

Turn the front wheel with the problem code


cleared. (Do not operate the ignition switch
after clearing the problem code.)

Retrieve the problem code and record it. Clear


the problem code.

res

Turn the front wheel [Vehicle speed: approximately 4 km/h (2.5 mile/h) or above, t.e.as fast
as when the wheel rs turned with all your

INDICATOR LIGHT

strength by hand.]

TIVE)

Check the ASS indicator light.

ABS INDICATOR LIGHT

I
ABS

l~

Light blinks. (Sensor


signal is input in the
ECU.)

Does the light blink or stay on?


Light stays on.

Check the harness and connector for secure


connection (page 16-A-3).

Perform the pre-start self-diagnosis (including


riding the motorcycle), then check the
indieter light.

res

<
,
,

Does the light stay on or go off?


Does not go off.

>

Turn the ignition switch OFF.

Light goes off.

Repair open in the BLUE/GREEN harness


between the wheel sensor and ABS ECU.
Faulty ABS ECU

I
View from terminal side

I
Disconnect the wheel sensor connector @.

I
Turn the ignition switch ON.

I
Check for voltage between the main harness side
terminals of the wheel sensor connector @.

<

Does battery voltage register?

IBattery voltage

(Continue to the following page)

16-A-38

GREEN/ORANGE

BLA CK/PIN~

No battery voltage

Repair open in the BLACK/PINK or GREEN/


ORANGE harness between the wheel sensor
and ABS ECU.
Faulty ABS ECU

ABS ('92 '95)


(From the previous pagel

Turn the ignition switch OFF.

I
View from terminal side

I Disconnect the WHITE connector@ofthe ECU.

~EEN~
@

Check for continuity between the WH ITE connectar @ terminal of the ECU and the main
harness side terminal of the wheel sensor connector@.

Is there continuity?
Continuity

BLUE/

WLJE/GREEN

No continuity

Repair open in the BLUE/GREEN harness


between the wheel sensor and ASS ECU.

. Faulty wheel sensor

16-A-39

ABS ('92-'951
Problem code 6: Faulty rear wheel speed sensor system
CAUTON
When removing/installing the wheel sensor and wheel, take care not to damage the tip of the sensor.
NOTE
Check the tire size and air pressure and check the tire for deformation before troubleshooting.
The ASS indicator light might come on while riding under the following conditions. Turn the ignition switch OFF and
perform the pre-start self-diagnosis. The ABS is normal if the warning light goes off. However, the problem code is
stored in the ECU. Ask the rider for the riding conditions in detail when he brings his motorcycle to your dealership for
inspection. (Was the motorcycle has continuously run on bumpy road?)
When the rear wheel sensor or rear pulser ring is replaced, perform the air gap inspection (page 16-A-51).

Perform the inspection of the wheel sensor.


Check the area around the wheel sensor as
well.

\
Place the motorcycle on its center stand ood
measure the air gap between the pulser ring
and wheel sensor.
Standard: 0.8 ~g1 mm
(0.031 ;- g:86~ in)

<

Incorrect

Is the air gap correct?


Correct

Check each part for deformation and looseness and correct accordingly. Recheck the air
gap.

Deformed and/or
Is the pulser ring deformed or damaged (e.g.
chipped teeth, etc.I?

\damaged

Replace the pulser ring and recheck.

Not deformed
and damaged

I, there iron DC other magnetic deposits \


between the pulser ring and wheel sensor? /

Deposits
Remove the deposits and recheck.

NOTE

No deposits

Check the wheel sensor tip for damage. If it is


damaged, replace with a new one and recheck the air gap.

<

Are the pulser ring, wheel sensor, and caliper \


bracket loosely installed?
Securely installed.

(Continue to the following page)

16-A-40

Loosely installed.

Correct deformation. Install securely and recheck.

ABS 1'92-'951
(From the previous page)

NOTE

Check the wheel sensor signal in the ECU.

Turn the rear wheel with the problem code


cleared. (Do not operate the ignition switch
after clearing the problem code.)

j
Retrieve the problem code and record it. Clear
the problem code.

res INDl CATOR LIGHT

Check the ASS indicator light.

TIVEj

Does the light blink or stay on?

81

ABS

I
Light blinks.

<

ABS INDICATOR LIGHT

Turn the rear wheel [Vehicle speed: approximately 4 km/h (2.5 mile/h) or above, i.e. as fast
as when the wheel is turned with ,II your
strength by hand.]

(Sensor

signal is input in the


ECU.)

light stays on.

Check the harness and connector for secure


connection (page 16-A-3}.

Perform the pre-start self-diagnosis (including


riding the motorcycle), then check the
indi-

res

cator light.

<

Light goes off.

Does the light stay on or go off?


Does not go off.
Turn the ignition switch OFF.

View from terminal side

Disconnect the wheel sensor connector @'.

;DlJ

I
Turn the ignition switch ON.

BLA CK/ORANGE

Does battery voltage register?


Battery voltage

GREEN/GRAY

l@

Check for voltage between the main harness side


terminals of the wheel sensor connector @.

<

Repair open in the BLUE/GREEN harness


between the wheel sensor and ABS ECU.
Faulty ABS ECU

No battery voltage

Repair open in the BLACK/ORANGE or


GREEN/GRAY harness between the wheel
sensor and ABS ECU.
Faulty ABS ECU

(Continue to the following page)

16-A-41

ABS 1'92-'951
(From the previous page}

J
Turn the ignition switch OFF.

View from terminal side

I Disconnect the WHITE connector (I~ of the ECU.

Check for continuity between the WH ITE connector (@ terminal of the ECU and the main
harness side terminal of the wheel sensor con-

nector

<

J:$
BLUE/ BROW~UE/BROWN

::[~:.

Is there continuity?
continuity

. Faulty wheel sensor

16-A-42

No continuity

Repair open in the BLUE/BROWN harness


between the wheel sensor and ASS ECU.

ABS 1'92-'95)
Problem code 7: Faulty ABS main relay system
Disconnect the ASS main relay connector @ .

Perform the pre-start self-diagnosis and retrieve


the problem code.

Problem code "3

Problem code "7" - - - - - - - - - -__ (Go to the following page.)

HEADLIGHT RELAY

Clear the problem code.

Connect the headlight relay to the ABS main


relay connector @.

Perform the pre-start self- diagnosis and check


the ABS indicator light.

Does the light blink or go off?

Light goes off.

. Faulty ABS main relay

Light blinks.

Connect the ABS main relay to the ABS main


relay connector :j9' _ (Return to the original
condition. )

Disconnect the BLACK connector 'fDof the ECU. I

Turn the ignition switch ON and check the ASS


main relay for the operation sound (i.e.clattering sound).

I
Is there a clattering sound?
No clattering sound

Clattering sound

Repair short in the BLUE/GRAY harness


between the ABS main relay and ECU.

Faulty ECU

16-A-43

ABS ('92-'95)
{From the previous page: problem code

~r}

Clear the problem code.

modulator

Perform the pre-start self- diagnosis and retrieve


the
problem code.
I

I
I

Disconnect

the

front

and

rear

I solenoid connectors @ and @.

I
Problem code

I
Problem code "3"

~7"

IL

Turn the ignition switch OFF.

. Repair short in the WHITE/PINK harness


between the ASS main relay and solenoid.
View from terminal side

I
8 FRONT:

I Disconnect the BLACK connector 11) of the ECU. I

Check for continuity between the harness side


terminals of the solenoid connectors @or@ and
the body ground respectively.

Is there continuity?
No continuity

Faulty ECU

16-A-44

Tv REAR:

PINK/~E/BLACK

"ifF O@"""' @ @
Continuity

Repair short in the ORANGE/BLACK and PINK/


WHITE, or ORANGE/GREEN and PINK/BLACK
harnesses between the ECU and solenoid .

ABS 1'92-'951
Problem code 8: Faulty power circuit
NOTE
Before starting the troubleshooting, check to see whether the idle speed.conforms to the specified speed. If the idle
speed is below specification, adjust idle speed.
Ask the rider about the following when the motorcycle is brought in for inspection.
- Ask whether the motorcycle has been run with electrical accessories.
- Ask whether the motorcycle has been left for a long time with the ignition switch in the ON position. This problem
code will light up to indicate battery discharge.

Check the battery for charging condition.

Low or no battery

voltage

Is it normal?

Check the charging system/alternator (see section 17).

Normal

Check the harness and connector for secure


connection (page 16-A-3).

Problem code 9: Faulty ECU


NOTE
The ASS indicator light blinks or comes on and stays on when the ECU has been disrupted by an extremely powerful
radio wave (Electromagnetic Interference). This is just a temporary symptom. Clear the problem code and the ECU
will operate normally unless the symptom recurs.
Perform the pre start self diagnosis and retrieve
the problem code, then clear the code. Repeat
this procedure several times.

Does not appear

Does the problem code "9" appear repeatedIy?


/

repeatedly.
,>-_-,-====

Temporary problem (Electromagnetic interference)

Appears repeatedly.
Faulty ECU

16-A-45

ABS ('92-'95)
Trouble not represented by a problem code
Abnormal sound from the modulator
(Difference in sound level is twice or more between the front and rear modulators during the pre-start
self-diagnosis.) :
Connect the pump motor terminal to the battery securely. Avoid loose terminal connections and do not allow the
battery terminals to contact the frame and other parts.
The modulator motor becomes very hot when it is turned ON repeatedly to check for the motor sound. Take care
not to burn your hands. etc.

CAUTION
Do not turn the motor continuously for more than 30 seconds. If you have to turn the motor repeatedly to check
for the sound. be sure to stop the motor within 30 seconds and wait at least one minute before starting it again.
Otherwise. the motor can be damaged.
NOTE
There are two types of the modulator sounds; the solenoid valve clattering sound and the pump motor beep sound.
Front modulator:
Remove the instrument panel (page 2-7). Check
the modulator for interference with the upper
fairing and/or other parts.

Not
interfering.

Is it interfering?
Interfering.

jRemove the upper fairing


(page 2-9). Are there loose Normal
modulator mounting bolt DC
\damaged mounting rubber?

ILoose bolt or

. damaged rubber

Tighten the mounting bolt


securely. or replace the mounting rubber.
Remove the upper fairing (page 2-9). Are the
upper fairing stay and modulator mounting
stay deformed 7
Normal
Reinstall the modulator if it was removed.

Retrieve the problem code (page 16-A-6)


release the modulator fluid pressure.)

(Continue to following page)

16-A-46

{To

Deformed.

Repair the upper fairing stay


or modulator mounting stay.

ABS ('92-'95)
(From the previous page)

)
I

Turn the ignition switch OFF.

Remove the right side cover (to compare the


modulator sound between the front and rear
modulators).

FRONT MO DULATOR

\/f:,

"

.,!!

Disconnect the pump motor connectors (@ and

REAR MODULATOR

r~>

'1~ ~~!

N from the front and rear modulators.

','7(

Connect the front and rear pump motor termi-

nals to the battery respectively, and compare the


sound (motor sound) between the front and rear
modulators.

()

BAn ERY
12 V

~,

BATIERY
12V

l
-.-L

Sound changes and


Does the sound change within 3 seconds after
connecting the pump motor terminal to the

drops at the front


and rear modulators.

battery, and does the sound level drop?


Front modulator sound
does not change {regular)

Faulty front modulator

Normal: Recheck the front modulator for


proper mounting (page 16-A-46)
(Improper mounting may cause unnecessary vibrational noise.)

NOTE
After checking the motor sound. connect
the front and rear pump motor connectors,
retrieve the problem code and erase it (page
16-A-6) .

16-A-47

ABS ('92-'95)
Rear modulator:
Remove the right side cover (page 2-2). Check

tho modulator for interference with tho right


footpeg holder and/or other parts.

Is it interfering?

Not

Remove the right footpeg hold - \

intertering.

er (page 16-A-54). Are there


loose modulator mounting bott

Interiering.

or damaged mounting rubber?

Normal

Loose bolt or
damaged rubber

. Tighten

tho mounting bolt


securely, or replace the mounting rubber.

Remove the right footpeg holder (page 16A-54).


I, tho modulator mounting stay
deformed?

Deformed.

Reinstall the right footpeg holder.

Retrieve the problem code (page 16-A-6)


release the modulator fluid pressure)

(To

Turn the ignition switch OFF.

Remove the instrument panel (to compare the


motor sound between the front and rear moduletors) .

Disconnect the pump motor connectors (@ and


from the front and rear modulators.

,~)

j
(Continue to the touowtnc page)

16-A-48

Repair the modulator mounting

stay.

1Normal
!

I
!

ABS ('92-'95)
(From the previous page)

REAR MODULATOR

FRONT MODULATOR

Connect the front and rear pump motor terminals to the battery respectively, and check the
motor sound between the front and rear modulators.

Does the sound change within 3 seconds


after connecting the terminals to the battery,
and does the sound level drop?

Sound changes and


drops at the front
and rear modulators.

Rear modulator sound


does not change (regular).
Faulty rear modulator

Normal: Recheck the rear modulator for proper


mounting (page 16-A-48).
(Improper mounting may cause unnecessary vibrational noise.)

NOTE
After checking the motor sound, connect
the front and rear pump motor connectors,
retrieve the problem code and erase it (page
16-A-6) .

16-A-49

ABS ('92

'95)

- Faulty ABS indicator light


When the pre-start self-diagnosis sound (motor sound) from the modulator can be heard after starting the engine, and
where the ASS operates normally while riding:
Before pre-start self-diagnosis (Ignition switch ON)

-,
,.
tn

U>

,c,
a
0

"

'"
5
0

<is.
~

"

0
~

ASS indicator light 2

ASS indicator light 2

ON

Blink

OFF

Normal

A. B. F. E

-.

~ ~

D. G.I. K

D. G.!. K

-n

While riding

"" -. -.
-. ~ -.
ON

,.

Blink

tn

OFF

U>

S
c,

o
a ,
~

"

<is.
~

"

D. E. F. G. I

-n
-n

A. C.I

Normal

When there is no motor sound in the modulator after starting the engine and the indicator light is faulty (i.e. pre-start
self-diagnosis does not start):
-

- Before riding (with the engine started and the motorcycle par'r<ed)

r.
,.
~

Blink

OFF

H.I. J. M

U>

,c,

o
" ,_.

Q
<is.

~
~

0
-n
-n

ASS indicator light 2

ON

-.

While riding

,.
~

-.

K. L

ASS indicator light 2

ON
I. J. M

Blink

OFF

K. L

U>

,c,
0
,_.
~

~
~

0
-n
-n

A: Faulty indicator control unit


B : Poor connection of the indicator control unit connector
(4P)
C: Poor connection of the indicator control unit connector ~) (2P)
D: Faulty ABS indicator light LED 1, poor connection of the connector Ct
E: Faulty ASS indicator light LED 2, poor connection of the connectorco
F . Poor connection of the ASS indicator light connector@
G: Poor connection of the ASS indicator light connetor X
H: Faulty indicator light switch, poor connection of the connector (I)
I : Faulty ASS ECU
J : Faulty TCS/ignition control module (ICM), Open or short in the LIGHT GREEN/ORANGE harness between the TCS/
ICM and ASS ECU
K: Poor connection of the ASS ECU connector ::u.:
ASS INDICATOR
ASS INDICATOR
l : Burned ASS main fuse (lOA)
M: Improper battery charge {See section 17 .}

LIGHT

16-A-50

>.

jHT 2

ABS 1'92-'951

Wheel Sensor Air Gap Inspection


(Rear wheel only)

(21 REAR WHEEL SENSOR


(1) REAR PULSER RING

Place the motorcycle on its center stand.


Measure the air gap between the wheel sensor and pulsar
ring using a feeler gauge. It must be within the specification.

Standard: 0.8 ~g:~ mm (O.031g:~ in)

If not within specification, perform the shim adjustment

16-A-51

ABS ('92-'95)

Front Modulator Removal/Installation

<

(1)

c:

35 (3.5, 25)
(3)

(2)
,
)6)

(4)

~\-1 ~
,
,
\

"
"

c:
16-A-52

(3)

35 (3. 5, 25)

ABS ('92-'95)

Check the brake system by applying the brake after the bleeding air from the system.
CAUTION
Avoid spilling fluid on painted, plastic, or rubber parts. Place a rag over these parts whenever the system is
serviced.
When removing the oil bolt, cover the end of the brake hose to prevent contamination. Do not allow foreign ma-

terial to enter the system.


When removing and installing the modulator, take care not to drop or strike the modulator.
NOTE
After replacement of the moduator, bleed the brake system according to the standard air bleeding procedure.
Note that replacement and bleeding air from the brake fluid in the modulator is not possible, as it is sealed in the
modulator.
Use only DOT 4 brake fluid from a sealed container.

Requisite Service
Front brake fluid draining/air bleeding
Upper fairing removal/installation {page 2-9}.
Procedure
Removal Order
(1 ( Conector
(21 Ground terminal bolt
(31 Oil bolt
(41 Sealing washer
(51 Modulator mounting bolt/collar
(61 Washer
(71 Modulator

Q'ty

Remarks
Installation in the reverse order of removal.

3
1
2
4
3/3
3
1

CAUTION
, Do not disassemble the modulator.

16-A-53

ABS ('92-'9 5)

Rear Modulator Removal/Installation


151 ~

III

31

12 1

121

121

151 ~

191

'~

- - ' > l l0)

0, 35 (3. 5,25)

181

(12)

16-A-54

27 f2.7, 20)

111}

ABS ('92-'95)

Check the brake system by applying the brake after the bleeding air from the system.

CAUTION
Avoid spilling fluid on painted, plastic, or rubber parts. Place a rag over these parts whenever the system is

serviced.
When removing the oil bolt, cover the end of the brake hose to prevent contamination. Do not allow foreign ma-

terial to enter the system.


When removing and installing the modulator, take care not to drop or strike the modulator.

NOTE

After replacement of the moduator, bleed the brake system according to the standard air bleeding procedure.
Note that replacement and bleeding air from the brake fluid in the modulator is not possible, as it is sealed in the
modulator.

Use only DOT 4 brake fluid from a sealed container.

Requisite Service
Rear brake fluid draining/air bleeding
Right pivot cover removal/installation (page 2-5)
Procedure

11)
12)
13)
14)
15)
161
171
181
191
1101

Q'ty

Removal Order
Harness band
Connector
Ground terminal bolt
Oil bolt
Sealing washer
Reservoir bolt
Muffler mounting bolt
Right footpeg holder bolt 6 mm

8 mm

10 mm
(11 ) Modulator mounting bolt/collar
[121 Washer
(13) Modulator

Remarks
Installation is in the reverse order of removal.

1
4
1
2
4
1
1

1
1
2
3/3
3
1

CAUTION
Do not disassemble the modulator .

16-A-55

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

...

Replace the partts] with new onets) before assembly.

Is :;O=ooLI

Use special tool

IOP~OOLI

Use optional tool. Use the same procedure you use to order parts.

Torque specification.

10 Nm (1.0 kg-m, 7.2 ft-lb)

10 (1.0, 7.2)

-:71

-,
..~

Use recommended engine oil, unless otherwise specified.

Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1

Use multi-purpose grease (Lithium based multi-purpose grease NLGI #2 or equivalent)

Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote BR-2 plus manufactured by Dow Corning, U.S.A.
Multi-purpose M-2 manufactured by Mitsubishi Oil Japan

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

Use silicone grease

Om

Apply a locking agent. Use a middle strength locking agent unless otherwise specified.

"I~

Apply sealant

Use brake fluid, DOT 3 or DOT 4. Use the recommended brake fluid, unless otherwise specified.

Use Fork or Suspension Fluid.

1) .

16-B. ABS (After '95)


Service Information

168-1

Troubleshooting

16-8-5

System Location

16-6-2

Wheel Speed Sensor Air Gap Inspection

16-B-34

System Wiring Connections/Locations

16-6-3

Front Modulator Removal/Installation

16-B-36

Circuit Diagram

16-6-4

Rear Modulator Removal/Installation

16-B-38

Service Information
CAUTION
Use a fully charged battery for troubleshooting. Do not diagnose the ABS with a charger connected to the battery.
On removal and installation of the wheels and wheel speed sensors, be careful not to damage the wheel speed sensors
and pulser rings.
NOTE

Check the following before performing any ASS troubleshooting.


- Pre-start self-diagnosis of ASS
- ASS indicator light
If an abnormality is found during the above checks, perform the ASS troubleshooting following the Symptom-toSystem Chart (page 16-B-8). The ASS is normal if no trouble is found. Go to the checks on the other systems {e.g., LBS
or basic brake system}.
Troubles not resulting from a faulty ASS, l.e. brake disc squeak, unevenly worn brake pad, etc., cannot be recognized by
the ABS diagnosis system. (See the Common Service Manual.)
Record the symptom of the problem and the problem code in MEMO before troubleshooting.
When the ASS is faulty, the ABS indicator light blinks or it comes on. The ASS does not function at this time; take care
during the test ride.
Do not disassembly the modulator assembly. If 'It is faulty, replace it an assembly.
Refer to page 15-2 for brake fluid filling and bleeding. Note that there is no brake fluid in the modulator (except in the
modulator head), because the modulator is the motor-driven hydraulic pressure type. Therefore, brake fluid
replacement and bleeding air from the modulator body is not necessary.
When the wheel is removed, perform the air gap inspection (page 16-B-51).
The ASS indicator light might blink in the following cases. If the indicator light blinks, clear the problem code and
perform the pre-start self-diagnosis ofthe ABS (page 16-5). The ABS is normal if the ABS indicator light goes off.
- The motorcycle has continuously run on the bumpy road.
- The ABS control unit (ECU) was disrupted by extremely powerful radio were (Electromagnetic Interference).
- After riding Ii.e. after the pre-start self-diagnosis), the engine was kept running and the rear wheel turning (for more
than 30 seconds} with the motorcycle on the center stand.
The ASS indicator light might blink in the following cases. If the indicator light blinks, service the faulty parts, clear the
problem code, and perform the pre-start self-diagnosis of the ABS (page 16-S-5}. The ASS is normal if the ABS indicator
light goes off.
- Incorrect tire pressure
- Tires not recommended for the motorcycle were instailed.
- Deformation ofthe wheel
After troubleshooting, clear the problem code and perform the pre-start self-diagnosis again to be sure that the ASS
indicator light is operating normally.

16-8-1

ABS (After '95)

System Location

(7) ASS INDICATOR LIGHT 2


(5) INDICATOR CONTROL UNIT
(8) ASS INDICATOR LIGHT 1

(5) IGNITION SWITCH


(12) MODULATOR CONTROL
MOTOR

(4) ABS,TCS INDICATOR LIGHT SWITCH

(9) ASS CONTROL UNIT


(ECU)

(3) BATIERY
(2) ASS FUSE CASE
(1) REAR WHEEL

SENSOR

(13) CRANK ANGLE SENSOR

(10) FRONT MODULATOR CONTROL


MOTOR RELAY

(19) REAR PULSER RING


(18) REAR MODULATOR
(11) REAR MODULATOR CONTROL
MOTOR RELAY

(17) MOTOR DRIVER


(16) FRONT MODULATOR

(14) FRONT PULSER RING


(15) FRONT WHEEL SPEED SENSOR

16-B-2

System Wiring Connections/Locations


Refer to section 2, for the parts that must be removed for service.
For example: ::1) CRANK ANGLE SENSOR -e-Maintenance part
-R. side cover (page 2-2) <- The parts that must be removed for service
(~) INDICATOR CONTROL

Ci:

ct' ABS/TCS
REAR MODULATOR
CRANK ANGLE SENSOR
-R. side cover (page 2-2)

INDICATOR
LIGHT SWITCH

-Tap shelter

UNIT
-L. fairing pocket
(page 2-6)

(page 2-5)
BI/Sr GISI

GriBu LgiBI

~~
"i

ASS MAIN (30A)

?oS

FRONT MODULATOR

CONTROL MOTOR

!SJ

(lOA)

REAR MODULATOR

CONTROL MOTOR
(10A)
ASS FUSE CASE
-L. side cover (page 2-2)

,ec..
",.

"

BLACK
YELLOW
BLUE
GREEN
RED
WHITE

Br ..
0

,C,'"

BROWN
ORANGE
LIGHT BLUE
LIGHT GREEN
PINK

G,--

GRAY

/
G

e.v

BI/G

SliR

:f~ REAR WHEEL SPEED SENSOR

@ REAR MODULATOR CONTROL MOTOR


-R. side cover (page 2-2)

-R. side cover


(page 2-2)

Cftj

MOTOR DRIVE
(4P Blue)
-Upper fairing
(page 2-9)

ABS IAfter '95)

~'ASS

INDICATOR
LIGHT 1
-Inner screen
(page 2-7)

@INDICATOR (Black)
-Inner screen
(page 2-7)

ASS

INDICATOR
LIGHT 2

-tnner screen
(page 2-7)

J)

INDICATOR (White)
-Inner screen (page 2-7)
~

LgiBI

Lg..'B1rx

G/81 ViG,

v:(;, GI81

(;..0

WiO

W.ID

GiO

G'iSe

fl.: 0

RiO

Gr:'Bu

(]~,

FRONT MODULATOR CONTROL


MOTOR RELAY -Upper fairing
(page 2-9)

Y.'O

RiG

RiBr

Br'Y

::E' REAR

MODULATOR CONTROL
MOTOR RELAY -Upper fairing
(page 2-9)

ViO

W:'Bu

RiB,

V..W

,:[~~

(fj) FRONT WHEEL SPEED SENSOR


-Upper fairing (page 2-9}

.>

~
-

~2!

FRONT MODULATOR CRANK ANGLE


SENSOR -Upper fairing (page 2-9)

(LZ' ECU (Black)


-Upper fairing (page 2-9)

{,1' ECU (White)


-Upper fairing (page 2-9)

==

R ,j', MOTOR DRIVER (12P)


-Upper fairing
(page 2-9)

'W

BIlG

BliR

@, MOTOR DRIVER
(4P Black)
-Upper fairing
(page 2-9)

H' FRONT

MODULATOR CONTROL MOTOR


-Upper fairing (page 2-9)

16-B-3

ABS IAfter '95)

Circuit Diagram

MODULATOR

CONTROL MOTOR RHAY


(FRONT)

(REAR)

~~~

ASSFUSE

,OX
3 ,

lOA ASS MAIN

2 30A FRONT MODULATOR CONTROL


3 30A REAR MODULATOR CONTROL r

~~~~ ~~~~

,--~--""---------,
12P-BI

~RiBr

~RJBr

I-R/Br-

f--Grlal---+

\I---O/G--"
r1--- Lg/O--"
1---- G'/'I--<>

1--- R/'I'----;

f-- BuIGr---+

MOTOR DRIVER

f--BuIG--"

1--- Bu/Lg,--"
1--- '"/p---

I---R/'"'---+
I
ABSCONT

CONNECTOR: 4P

BI
0- Bu

...L

2P-BI

2P-BI~

r-

CONTROL
MOTOR
CONNECTOR

BI

O-W
REAR MODULATOR

FRONT MODULATOR
CRANK ANGLE

SENSOR

16-B-4

Be

BI
y
G

R
W

BLACK
YELLOW
BLUE

GREEN

RED

WHITE

MOTOR

Be.
Ge
Lb
L9 .

BROWN
ORANGE
LIGHT BLUE
LIGHT GREEN

PINK

MAIN FUSE 30A

~Ie

GRAY

WTOR

STARTER
SYSTEM

{f

<O---..

.JI

Ell

0:

);

BATIERY

4'
II
"

$3PW
'I

I~

-==:;R~R'~
RIBlllrRlBIU

IGNITION
SWITCH

4P-BI

>--Gr!BB:=J~~~~~~;;i~~~~~~~~~~~~~j~~1
,
;--,
lOA

GISI

L-R/al~BI/Br

BllSr

INDICATOR

CONTROL UNIT

2P-BI

4P-BI
.

IOLUNIT(ECUI

2P-R

[ ] )[

LglBI----+N+.,

GIBI~

lOS
~

coa, .......fDi+,

ASS INDICATOR
LIGHT 2

GlO~

ABS INDICATOR

>-GlG e-lf-H H ------- - - I---lf--4- - ---------------.

>-B"!B:~~~
~BI/O

>-aufG
G10 1

r-

~BI/P

2P-BI

,,"""GelY"'--fl~
~C-GIR:::1

16P

_____

~G/BI---,

J 1,
I ~
G

,V

---'>--G/BI----+---G!B'--/-~,
ABSfTCS INDICATOR LIGHT

SWITCH

.'WHEEL SPEED SENSOR

LIGHT1

ABS (After '95)

Troubleshooting
Before Beginning Troubleshooting
Summary of ABS pre-start self-diagnosis system
The ASS pre-start self-diagnosis system diagnoses the electrical system as well as the operating status of the modulator.
When there is any abnormality, the problem and the problem part can be detected by outputting the problem code.

When the vehiclespeed is approximately 10 km/h (6 mile/h) or more, thewheel speed sensor signal is inputto the ASS control
unit (ECU), then the ASS pre-start self-diagnosis system operates the control motor inside the modulator, checks the crank
angle condition with ASS control unit (ECU) and thereby it detects whether the modulator operation is normal, and it
completes the pre-start self-diagnosis.
When the ASS is normal, the ASS indicator light goes off just after starting up indicating that the diagnosis is completed.
If a problem is detected, the ASS indicator light blinks or comes on and stays on to notify the rider of the problem. The selfdiagnosis is also made while the motorcycle is running, and the indicator light blinks when a problem is detected.
When the indicator light blinks, the cause of the problem can be identified by retrieving the problem code following the
specified retrieval procedure. {page 16-S-6}

PRE-START SELF-DIAGNOSIS WHEN NORMAL

O~~ =.J

IGNITION SWITCH

O~~

CONTROL MOTOR RELAY

ENGINE RUNNING
STOP

VEHICLE SPEED

ON
CONTROL MOTOR

=:J

-------------------r= START
__ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

nn__m__ mmm n

~ 10

km h (6 mile/h) or above

nnmm_m_1 1 -

OFF
ASS INDICATOR

ON::J
OFF

LIGHT 1 and 2

Pre-start self-diagnosis completes

Pre-start self-diagnosis procedure (Everyday check-up)


1. Turn the ignition switch ON.
2. Be sure that the ABS indicator lights 1 and 2 come ON.
3. Start the engine.
4. Ride the motorcycle and raise the vehicle speed to approximately 10 km/h (pre-start self-diagsosis completes).
5. The ABS is normal if both the ASS indicator light 1 and 2 go OFF.

~[

ASS

ASS INDICATOR LIGHT 1

I~

-"----~
ABS INDICATOR LIGHT 2

16-8-5

ABS IAfter '95)


ASS/Tes INDICATOR LIGHT SWITCH

Retrieval of/Clearing Problem Code


NOTE
The ASS indicator light indicates the problem code
by its number of blinks (see the next page).
The problem code is not cleared when the ignition
switch is turned OFF during output of the problem
code. However, output cannot be restarted by
turning the ignition switch ON. Restart the output
following the problem code retrieval procedure.
After retrieving the problem code, be sure to record it
in MEMO, etc. Clear the problem code after
troubleshoot! ng.

Retrieval:
1. Turn the ignition switch OFF.
2. Turn the ignition switch ON while pressing the ASS/
TCS indicator light switch. The ASS indicator light 1
and 2 should come ON. (The ASS indicator light 2 is
OFF this ttrne.)
3. Hold the ASS/TCS indicator light switch pressed (for
approximately 5 seconds). The ASS indicator light 1
should go OFF.
4. Release the ASS/TCS indicator light switch
immediately (within 1 second) after the ASS indicator
light go OFF.
~. Output of the problem code starts and the ASS
indicator light 1 blinks.
Clearing:
5. Press the ABS/TCS indicator light switch during output
of the problem code (while the ASS indicator light is
blinking).
<::. The Problem code is cleared and the ASS indicator
light 1 and 2 comes ON and stay ON.

Turn ignition switch ON


while pressing
indicator light switch.
ASS'TCS
INDICATOR
LIGHT SWITCH
IGNITION SWITCH

ASS INDICATOR
LIGHT 2

\
TCS ON/OFF SWITCH

Release indicator light switch immediately


(within 1 sec)
after ASS indicator lights go OFF.

Problem code
Clearing signal

:~!

ON

rL

::::::Ji-i- - - - - + - - - - - - - - - ON--->OFF

Blinking

ON

OFF

i;
~~F ==nL..----------+---+--+-+---+-f---i--+_
,!

--'

Problem code
start signal
Latest
problem
code

16-8-6

ASS INDICATOR LIGHT 2

ASS INDICATOR LIGHT 1

~i
:~~::se =J~'-+-------+-L
OFF

ASS INDICATOR
LIGHT 1

:
!

:
:

,!

Previous time
problem code

ABS (Afte' '951


Problem code indication pattern
Example:
When the problem code is stored;
Latest problem
Problem code start signal

code
'"

ABS indicator light 1 ON, __

n m __ n

__

ProbleZm code:

Previous time
problem code

Latest problem code

Problem code:

Problem code:
2

mm~~r----'~-~~-~'-~ -

(>
ABS indicator light 1 OFF

Pattern repeated

-----.,1

/1---1*--

Release ABSjTCS indicator light switch.

3 sec.

- ' * - - 0 . 3 sec
-1-1---0.2 sec.

When the problem code not stored;


Problem code start signal

No output of code

ABS indicator light 1 ON_ --- ---- ----------- c'-

(>
ASS indicator light 1 OFF

/'

I--- 3

p attern repeated

sec.

Release ABSjTCS indicator light switch.

NOTE
The ECU can store up to two problem codes. The latest problem code is output first, then the previous one is output.
When the two problem codes are output, diagnose on the latest problem code (i.e. code output first).
After troubleshooting, perform the pre-start self-diagnosis again to be sure that there is no problem in the ABS indicator
lights and the problem code is cleared.
See page 16-B-33 for the problems that are not represented with the problem codes.
Check the following before performing ABS troubleshooting:
- Pre-start self-diagnosis of ABS
- ASS indicator light
If an abnormality is found during the above checks, perform the ABS troubleshooting following the Symptom-toSystem Chart (see the following paqe). The ABS is normal if no trouble is found. Go on to the check the other basic
systems (e.g., LBS or basic brake system).

16-B-7

ABS (After '95)

Symptom-to System Chart


Problem

Affected

Fuse

Item

Modulator

"
CD

<n

cQ.

3
a

!-:;;--=+=cr::1 ~

"

Faulty front modulator


crank angle sensor system

o o
o o

faulty front modulator


control motor system
Faulty rear modulator
control motor system

~.

00

16-8-15

00

16-8-19

00

16-8-23

00

16-B-26

000

16-8-29

00

16-8-31

Faulty power circuit

Problems not recognized


by ASS control unit (ECU)

c
o

16-8-12

Faulty rear wheel


speed sensor system

00

"

00

o o
o o

(ECU)

c
n

16-8-9

Faulty front wheel


speed sensor system

Faulty ASS control unit

cO

00

Faulty rear modulator


crank angle sensor system

0000016-8-33

NOTE
Check the following before performing ASS troubleshooting.
- Pre-start self-diagnosis of ASS (page 16-B-5)
- ASS indicator light (page 16-8-5)
If an abnormality is found during the above checks, perform the ABS troubleshooting following the Symptom-toSystem Chart. The ABS is normal if no trouble is found. If no trouble is found, continue on to the other system checks
(e.g., LBS or basic brake system).
After troubleshooting, clear the problem code (page 16-B-6) and perform the pre-start self-diagnosis again (page16B-5) to be sure that the ABS indicator light is operation properly.

16-8-8

ABS IAfter '95)

Flowcharts
CAUTION

Use a fully charged battery. Do not diagnose with a charger connected to the battery.
NOTE
Turn the ignition switch OFF unless otherwise specified.
When the ASS control unit (ECUl. motor driver or modulator is detected to be faulty, recheck the wire harnesses and
connectors connections closely before replacing the control unit, motor driver or modulator.
After troubleshooting, perform the pre-start self-diagnosis again and be sure that the ASS indicator light is normal.
The encircled numbers in the texts and connector diagrams indicate the connectors (see page 16-8-3). All connectors
diagrams in the text are view from the terminal side.

Problem code 1: Faulty front modulator crank angle sensor system

Turn the ignition switch ON (but do not start the


engine) and check the ABS indicator light.

Light stays
on_. . 1. Retrieve the problem code and record it. Clear the
")__-"_
_'--_
problem code.
/
2. Perform the pre-start self-diagnosis (including riding motorcycle I and check the ASS indicator light.

Does the ABS indicator light blink or come on


'\ and stay on?

I Light blinks

Light goes

Turn the ignition switch OFF.

'------

--"O"-FF

Does the ASS indicator light blink or go off?

Turn the ignition switch ON and check for the prestart self-diagnosis sound (Le. click sound) from the
front modulator.

fight blinks

---,------

~---~--

Is there a sound in the front modulator?

(Continue to the following page)


\

/1
(Go to page 16-B-11)

1. Disconnect the front modulator crank angle sensor


connector:@ with the ignition switch OFF.
2. Measure the output voltage between the main
wire harness side terminals of the sensor connector)]' with the ignition switch ON.
Standard: 4.5-5.5 V

(Continue to the following page)

,,

Click
sound

NormallTemporary problem)
- Fine foreign matter in the modulator or the ECU
has been disrupted by an extremely powerful radio
wave.
- Check the harness and connector for secure connection (page 15-B-3)

View from terminal side

j~
Green. Brown

Black Blue

'------@-J

16-8-9

ABS (After '95)


(From the previous page: Measure the
output voltage at the ':lit connector)

__L

Out of specification ~

Is the voltage normal?


- - - - -

Normal

f~;

_ _ _L

~CmJ

1. Disconnect the White connectnrqf of the ECU


with the ignition switch OFF.
2. Check for continuity between the ECU connector
JJ' terminal and the main harness side terminal of
the crank angle sensor connectorqe.

ve;w;ught Green

l
I

"

No continuity
/>_:C:C'::::,"::,"='-_.~~

15 there continuity?

Continuity

Repair open in the Yellow/Light Green harness


between the modulator tanq!e sensor connector)
and ASS control unit (ECU)

Check for continuity between the ECU connector


:t~ terminal and body ground.

~'"0W
_ Liqht Green
--'--'--'--'----.~~
Continuity

Is there continuity?

Yellow Light Green

- - - -

(,

Repair open in the Black/Blue or Green/Brown


harness between the modulator (angle sensor
connector) and ABS control unit (ECUj
Faulty ASS control unit (ECU)

-------'

~""ity

Repair short in the Yellow/Light Green harness


between the modulator langle sensor connector)
and ABS control unit (ECUl

Faulty front modulator

(From the previous page: Light blinks]

I
1. Retrieve the problem code and record it.
Clear the problem code.
2. Interchange the front and rear modulator with each
other (page 16-B-36 and 16-B-38).
3. Perform the pre-start self-diagnosis (including riding motorcycle) and retrieve the problem code.

Problem code "2"


Is the problem code "2" )

Problem code "1"

Faulty ABS control unit (ECUI

16-B-10

..

Faulty front modulator assembly

ABS (After '951


(From page 16-6-9: Click sound)

1. Disconnect the front modulator control motor


relay connector 10 and connect the headlight relay

HEADLIGHT RELAY

instead with the ignition switch OFF.


2. Turn the ignition switch ON and check the ABS

IL indicator light.

-'

--,

Does the ABS indicator light blink or come on


and stay on?

Light stays on

Faulty front modulator control motor relay

Light blinks

1. Disconnect the front and rear modulator control

Yellow

motor relay connector C!t/;ID and EeU White


connector ,jJI with the ignition switch OFF.
2. Check for continuity between the connector :$)
terminal and body ground.

Continuity

Is there continuity?

No continuity

Faulty ABS control unit (ECUl

16-8-11

ABS (After '95)


Problem code 2: Faulty rear modulator crank angle sensor system

Turn the ignition switch ON (but do not start the


engine) and check the ABS indic8ctoc'cclig""htC.

Light stays on

Does the ASS indicator light blink or come on

and slay on?


Light blinks
Turn the ignition switch OFF.

Light goes

~
.

<,

OFF

Does the ABS indicator light blink or go off? - - ;

Turn the engine stop switch OFF to deaden a fuel


pump sound.
2. Turn the ignition switch ON and check for the
pre-start self-diagnosis sound (i.e. click sound)
from the modulator.

Light blinks

(Continue to the following page)

Click
sound

Is there a sound in the rear modulator?

,
Normal (Temporary problem)

Fine foreign matter in the modulator or the ECU has


been disrupted by an extremely powerful radio wave.
Check the harness and connector for secure connection (page 16-8-3)

No sound
(Go to page 16-8-14)

1. Disconnect the front modulator crank angle sensor


connector j) with the ignition switch OFF.
2. Measure the output voltage between the main
wire harness side terminals of the sensor connector :l' with the ignition switch ON.
Standard: 4.5-S.SV

Is the voltage normal?

Normal

(Continue to the following page)

16-8-12

View from terminal side

Brown Green

Black 'Gray

~
Out of specification

Repair open in the Black/Gray or Brown/Green


harness between the modulator (angle sensor connectar) and ABS control unit (ECU)
Faulty ABS control unit (ECU)

ABS (After '95)


(From the previous page: Normal)

~~

1. Disconnect the White connector 'U' of the ECU


with the ignition switch OFF.

2. Check for continuity between the ECU connector


:jJ: terminal and the main harness side terminal of
the crank angle sensor connector

- ~ No continuity
_/

...

Continuity

-----

No continuity

Repair open in the Blue/Brown harness


between the modulator (connector angle
sensor) and ASS control unit (ECUl

--------.

.
>
Continuity

Is there continuity?

Blue Brown

Is there continuity?

Blue Brown

CD.

Repair short in the Blue/Brown harness


between the modulator (angle sensor
connecter} and ASS control unit (ECUl

Faulty rear modulator

(From the previous page: Light blinks)

..
1. Retrieve the problem code and record it.
Clear the problem code.
2. Interchange the front and rear modulator with each
other (page 16-B-36and 16-B-38).
3. Perform the pre-start self-diagnosis (including rid
ing motorcycle) and retrieve the problem code.

"
Is the problem code "1" ?

Problem code "1"


Faulty rear modulator assembly

Problem code "2"

Faulty ASS control unit (ECU)

16-8-13

ABS (After '95)


(From page 16-8-12: Click sound)

Disconnect the rear modulator control motor relay


connector i~) and connect the headlight relay instead with the ignition switch OFF.
2. Turn the ignition switch ON and check the ASS indicator light.
,

rF.01;...-~-HEADLIGHTRELAY

"-----~

.r.,
Does the ASS indicator light blink or come
on and stay on?

Ugh< blinks

ig ht stays on

.-===.-c-'C'--_

Faulty rear modulator control motor relay

11~co nnect -'h-e--:fc-o-O-,-,-o-d~ce-,-r mod ulator control

motor relay connector @i:~) and ECU White connector


with the ignition switch OFF.
2. Check for continuity between the connector C!ij
terminal and body ground.

Yellow

,n,

-'-------Is there continuity?

No continuity

Faulty ASS control unit (ECU)

16-8-14

Continuity

Repair short in the Yellow/Orange harness


between the front/rear modulator control
motor relay and ASS control unit (ECU).

ABS (After '95)


Problem code 3: Faulty front modulator control motor system
Turn the ignition switch ON (but do not start the
engine) and check the ASS indicator light.

I
Light blinks

Does the ASS indicator light blink or come on


and stay on?

Retrieve the latest problem code and record it.


Clear the problem code.

Light stays on

Other

___--'

,code

Is the problem code "3"?

Problem code "3"

1. Retrieve the problem code and record it.


Clear the problem code.
2. Peform the pre-start self-diagnosis (including
riding motorcycle} and check the ASS indicator
light.

__i

In

the I

ASS FUSE CASE

Burned out

-)>--=--

Replace the fuse and recheck.

Normal

1. Install the fuse in the fuse case.


2. Disconnect the front modulator control motor relay
connector CID and connect the headlight relay
instead.
3. Perform the pre-start self-diagnosis (including
riding motorcycle) and check the ASS indicator
light.

flS;~'----~ HEADliGHT RELAY

------,----~

<

Front modulator control motor fuse

I.:~

Is the fuse normal?

Normal (Temporary problem}


- Fine foreign matter in the modulator or the
ECU has been disrupted by an extremely powerful radio wave.
- Check the harness and connector for secure
connection (page 16-8-3)

l~: :~

ASS tue case with the ignition switch OFF.

Light goes off

L,g" bliok,

--C-h-'-'-k-'-h,-',-o-o-'-m-O-d-,-',-'-or control motor fuse

Diagnose on the latest problem code

G s the ASS Indicator light blink or go off?


[

Faulty ASS control unit (ECU)

Light goes off


Doesthe ASS indicator light blink or go off?

Faulty front modulator control motor relay

Light blinks

(Continue to the following page)

16-8-15

ABS IAfter '951


(From the previous page: Light blinks)

..
1. Disconnect the front modulator control motor relay
connector (8) with the ignition switch OFF.
2. Check for voltage between the relay connector (~)
terminal and body ground.

No voltage
Does battery voltage register?

Repair open in the Red or Red/Green harness


between the front modulator control motor relay
and battery.

Vo"ogo

1.- DC,~-o-O-O-ed-C,"Co-m-o-,-o-'-dnver Blue

connecto~

2 Check for continuity between the relay con~~~tor I


(It and motor driver connector 'JV terminals. ~

...

---

No continuity

Is there continuity?
Continuity

Repair open in the Brown/yellow harness


between the front modulator control motor relay
and motor driver.

--

Check for voltage between the relay connector@


terminal and body ground with the ignition
switch ON.

Rod

Does battery voltage register?

Voltage

1. Disconnect the White connector ,11, of the ECU


with the ignition switch OFF.
2. Check for continuity between the ECU connector
and relay connector (8) terminals.

No voltage

~ c~

,n

Repair open in the Red/Brown harness


between the fuse case and front modulator
control motor relay.

Yellow Orange

4:----J

No continuity

Is there continuity?

)-~

Continuity

(Continue to the following pagel

16-B-16

Yellow/Oranqe

Repair open in the Yellow/Orange harness


between the ABS control unit (ECU) and front
modulator control motor relay.

ASS (After '95)


(From the previous page: Continuity)

1. Disconnect the front modulator control motor


connector@ofthefrontmodulator.
2. Check for continuity between the motor connector
@and motor driver connector C]. terminals.

----'------

'--------~----).-----==~
No continuity

Is there continuity?

Continuity

n~:,

GJG,eec

Check for continuity between the control motor


connector ,j5 and body ground.

IS

Repair open in the Black/Red or Black/Green


harness between the front modulator
(control motor) and motor driver.

,
the~e continui~

~--

~r-"""""~'"'---"
Continuity

No continuity

RedY,~,ow
II

Repair short in the Black/Green harness


between the front modulator (control motor)
and motor driver.

Orange iRed i

'~,'1.2:: ?reen

Orange. Green

Yell\w

/Gray,pra

nge

:J[

I I
,

1. Disconnect the Black connector .:)} of the ECU


and motor driver 12P connector '.
2. Check for continuity between the ECU connectors
@/@'and connector@terminalsinthesame

harness colors.

- - --------"

/
Light Green

Gray.'

Orange

Orange

I
Light Green

Orange

~
e
Gravvellcw

<

=">P

GraYi'(ellow

,
No continuity

Is there continuity?

Repair open in the harness between the


ASS control unit (ECUj and motor driver.

Continuity

(Continuity to the following pagel

16-B-17

ABS (After '951


(From the previous page: Continuity)
,r~

J---c-------;c _

I Check for continuity between the motor driver


connector@f:lI'terminalsand body ground.

Green/Black

No continuity
Is there continuity?

Repair open in the Green or Green/Black


harness between the motor driver and

body ground.

Continuity

1. Replace the motor driver with a new one.

2. Connect the@,Qt',,'!t'and,:n'connectors.
3. Perform the pre-start self-diagnosis (including
riding motorcycle) and check the ASS indicator
light.

__J

~--="""'c::-=~--1~~
Light goes off

-c.

Does the ASS indicator light blink or go off?

11.
i

Faulty motor driver

Ught blinks

Retrieve the problem code and record it.


Clear the problem code.
, 2. Interchange the front and rear modulator with
each other (page 16-8-36 and 16-8-38).
3. Perform the pre-start self-diagnosis (including riding motorcycle) and retrieve the problem code.

_ _ "3"?
_ _ _ _ _
Is the problem code
_

TCObl,m

cod, "3"

"Faulty A8S control unit (ECU)

16-8-18

~>-problem code "4" ...


h-

Faulty front modulator assembly

ABS (After '951


Problem code 4: Faulty rear modulator control motor system

! Turn the ignition switch ON (but do not start the

engine) and check the ASS indicator light.

Light blinks

Does the ASS indicator light blink or come on


and stay on?
Continuity

Retrieve the latest problem code and


record it. Clear the problem code.

Other
Code

Is the problem code "4"?


Problem code "4"

1. Retrieve the problem code and record it.

Clear the problem code.

Faulty ASS control unit (ECU)

2. Perform the pre-start self-diagnosis (including riding motorcycle) and check the ASS indicator light.

Diagnose on the latest problem code


Light goes off

Does the ASS indicator light blink or go off?

Normal (Temporary problem)


Fine foreign matter in the modulator or the
ECU has been disrupted by an extremely
powerful radio wave.
Check the harness and connector for secure
connection (page 16-8-3)

Light blinks

ASS FUSE CASE

11--1

Check the rear modulator control motor fuse in the


ASS fuse case with the ignition switch OFF.

L"i,~i'---

-~'-------

Rear modulator control motor fuse

Burned out

Is the fuse normal?

Normal

1. Install the fuse in the fuse case.


2. Disconnect the rear modulator control motor relay
connectcr rg.eno connect the headlight relay
instead.
3. Perform the pre-start self-diagnosis (including riding motorcycle) and check the ASS indicator light.

Does the ABS indicator light blink or go off?

~ghtblinks

>

~t"'rj;;:--.:o,. HEADLIGHT RELAY

Light goes off


Faulty rear modulator control motor relay

(Continue to the following page)

16-B-19

ABS (After '95)


(From the previous page: Light blinks)

1. Disconneet the rear modulator control motor relay,


connector with the ignition switch OFF.
~

Blue

2. Check for voltage between the relay connector


terminal and body ground.

Does battery voltage re9ist:;-=--=>-

No voltage
---.

Repair open in the Red or White/Blue harness


between the rear modulator control motor
relay and battery.

- - ~ Volt,g,

I',
I

Disconnect the motor driver 4P Black connector 'f~.1


2. Check for continuity between the relay connector I
(1) and motor driver connector j]) terminals.

tE

E@

Yellow/White

Yellow/White

--I(Q))-----"

,---I

No continuity

Repair open in the veuowrwtute harness


between the rear modulator control motor
relay and motor driver.

Is there continuity?
Continuity

Check for voltage between the relay connector

<ID

terminal and body ground with the ignition switch


ON.

Red Brown

I-t~tj

J
Does battery voltage register?

>-

No vOCC'''c9,'=--_--<..

Repair open in the Red/Brown harness


between the fuse case and rear modulator

control motor relay.

Voltage

____t _

~ ~~
veuow/Oranoe

_
L
c=_

Is there continuity?

Continuity

J
(Continue to the following page)

16-8-20

Yellow 'Orange

4Q}----J

No continuity

--

Repair open in the Yellow/Orange harness


between the ABS control unit (feU) and rear
modulator control motor relay.

ABS (After '95)


(From the previous page: Continuity)

1. Disconnect the rear modulator control motor


connectcrqb ofthe rear modulator.
2. Check for continuity between the motor connector
~ and motor driver connector ~ terminals.

,
No continuity

Repair open in the Black/Red or Black/Green


harness between the rear modulator (control
motor) and motor driver.

Continuity

,
I

Check for continuity between the control motor


connector OJt and body ground.

Continuity

Repair short in the Black/Green harness


between the rear modulator {control motor}
and motor driver.

Is there continuity?
No continuity

Blue/

Blue/Green

Red/Blue

1. Disconnect the Black connector @ of the ECU


and motor driver 12P connector @.
2. Check for continuity between the ECU connectors
@mandconnector@terminalsinthesame
harness colors.

Red/

Light Green

'\

n:,

Blue

I I I

, I

I
Bluei

Bluei
Light Green

Gray

""
'>"

/
Blue/

Bluei
Green

Gray

Blue/Pink

No continuity

Is there continuity?

,
I

Repair open in the harness between the ASS


control unit (ECU} and motor driver.

Continuity

(Continue to the following pagel

16-B-21

ABS IAfter '95)


(From the previous page: Continuity)

Check for continuity between the motor driver


connector T~'!t~, terminals and body ground.

Green/Black

,
No continuity

Repair open in the Green or Green/Black harness


between the motor driver and body ground.

,
I

<

0r-~~~"''-C--.
Light goes off

Does the ASS indicator light blink or go off

Faulty motor driver

~bl;"k'
,-------

- -

1. Retrieve the problem code and record it.

Clear the problem code.


2. Interchange the front and rear modulator with
each other (page 16-8-36 and 16-8-38).
3. Perform the pre-start self-diagnosis (including
riding rnctorcvcte) and retrieve the problem code.
L_

,I

Is the problem code "4"7


Problem code "4"

Faulty ASS control unit (ECUj

16-8-22

~rOblem code "3" . .

Faulty rear modulator assembly

ABS (Afte' '951


Problem code 5: Faulty front wheel speed sensor system

CAUTION
When removing/installing the wheel speed sensor and wheel. take care not to damage the sensor and pulser
ring.

NOTE
Check the tire size and air pressure and check the tire for deformation before troubleshooting.
The ASS indicator light might come on while riding under the following conditions. Turn the ignition switch OFF and
perform the pre-start self-diagnosis. The ABS is normal if the indicator light goes off. However, the problem code is
stored in the ECU. Ask the rider for the riding conditions in detail when the brings his motorcycle to your dealership for
inspection.
- The motorcycle has conttnouslv run on bumpy road.
-After riding on the road (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 center stand.

Perform the inspection of the wheel speed sensor,


Check the area around the wheel speed sensor as well.

Place the motorcycle on its center stand and measure the air gap between the pulser ring and wheel
speed sensor (page 16-8-34).
Standard: 0.4-0.5 mm (0.016-0.020 in)

<

-----c-------='
-----,
Incorrect

Is the air gap correct?


Correct

Deformed andl
or damaged

Is there iron or other magnetic deposits between the pulser ring and wheel speed sensor?

,
,
I

Check each part for deformation and


looseness and correct accordingly.
Recheck the air gap.

Replace the purser ring and recheck.

Deposits

Remove the deposits and recheck.

No deposits

Are the purser ring and sensor bracket loosely


installed?

Loosely installed
Correct deformation. Install securely
and recheck.

Securely installed

(Continue to the following page)

NOTE
r-:-check the wheel speed sensor tip for damage. If it is damaged, replace with a new
,
one and recheck the air gap.

16-8-23

ABS IAfter '95)


(From the previous pagel

1. Retrieve the problem code and record it.


Clear the problem code.
2. With the ignition switch in the ON position
(do not operate the ignition switch after clearing
the problem code), turn the front wheel (Vehicle
speed: approximately 4 km/h [2.5 mile/h] or above)
and check the ASS indicator light.

Light blinks (Sensor


signal is input in the
ECU)

Dose the ASS indicator light blink or stay on?

Normal (Temporary problem)

- The ECU has been disrupted by an extremely powerful radio wave.


- Check the harness and connector for secure
connection at the wheel speed sensor
system (page 23-117).

Light stays on

1. Disconnect the front wheel speed sensor connector@withtheignition switch OFF.


2. Check for voltage between the main harness side
terminals of the sensor connector
@.
===C
_

Black/Pink

Green-Oranqe

L-w---J
No voltage
Repair open in the Black/Pink or Green/
Orange harness between the wheel speed
sensor and ABS control unit (ECU).

Does battery voltage register?


Voltage

:::j'

1. Disconnect the White connector@'oftheECU


with the ignition switch OFF.
2. Check for continuity between the ECU OJ. connector
and sensor connector terminals.

<

--

_i__
IS the_,_e_"O_"_'_!"_"_!_"_'_'

Continuity

(Continue to the following page)

16-8-24

No continuity
--./

Repair open in the Blue/Green harness


between the ABS control unit (ECU) and
wheel speed sensor.

ABS {After '95)


(From the previous pagel

,
!

!,. with each other.

res INDICATOR

2. Connect the ECU connector 1l


, 3. Perform the pre-start self-diagnosis (including riding motorcycle), then check the TCS indicator light.

Does the

Light goes off

res indicator light stay on or go off?

ASS INDICATOR LIGHT

~~I AB=M[~

Interchange the front and rear wheel speed sensor

LIGHT

Faulty ASS control unit (ECU)

Does not go off

Retrieve the problem code and record it. Clear the


I problem code.

~~rOblem

Is the problem code "5"?

~/

code "5"
..

Faulty ASS control unit (ECU)

Problem code "6"

Faulty front wheel speed sensor

16-8-25

ABS (After '95)


Problem code 6: Faulty rear wheel speed sensor system

CAUTION
When removing/installing the wheel speed sensor and wheel. take care not to damage the sensor and pulser ring.
NOTE

Check the tire size and air pressure and check the tire for deformation before troubleshooting.
The ASS indicator light might come on while riding under the following conditions. Turn the ignition switch OFF and
perform the pre-start self-diagnosis. The ASS is normal if the indicator light goes off. However, the problem code is
stored in the ECU. Ask the rider for the riding conditions in detail when he brings his motorcycle to your dealership for
inspection (Was the motorcycle continuously run on bumpy road?}.

Perform the inspection of the wheel speed sensor.


Check the area around the wheel speed sensor as well.

t'----_

Place the motorcycle on its center stand and measure the air gap between the pulser ring and wheel
speed sensor (page 16-B-34).
Standard: 0.8 ~:t mm (0.031 ~:8J~ in)

Incorrect

Is the air gap correct?

Check each part for deformation and


looseness and correct accordingly_
Recheck the air gap.

Correct

Is the pulser ring deformed or damaged


(e.g. chipped teeth, etc.j?

Deformed and!
or damaged
-----.

Replace the pulser ring and recheck.

- -

Not deformed and


damaged
Is there iron or other magnetic deposits between the pulsar ring and wheel speed sensor?

---.

Deposits

Remove the deposits and recheck.

No deposits

--.

Loosely installed
Are the pulser ring and sensor loosely installed?

,
!

Correct deformation. Install securely


and recheck.

Securely installed

(Continue to the following page)

NOTE

Check the wheel speed sensor tip for damage. If it is damaged, replace with a new
one and recheck the air gap.

16-B-26

ABS (After '95)


(From the previous page)

1, Retrieve the problem code and record it.


Clear the problem code.
2. With the ignition switch in the ON position
(do not operate the ignition switch after clearing
the problem code), turn the rear wheel (Vehicle
speed: approximately 4 km/h 12.5 mile/h] or above)
and check the ASS indicator light.

Light blinks
(Sensor signal is
input in the EeU)

Dose the ABS indicator light blink or stay on?

Normal (Temporary problem)


- The EeU has been disrupted by an extremely
powerful radio wave.
- Check. the harness and connector for Secure
connection at the wheel speed sensor system
(page 16-B-3).

Light stays on

~--J

11. Disconnect ~he. rear w~eel speed sensor connector


I .. '1a: with the Ignition SWitch OFF.

2. Check for voltage between the main harness side


terminals of the sensor connectcr djr
_

__

Black Orange

~voltage

Does battery voltage register?


Voltage

--+-- ::J

1. Disconnect the White connecter f~ of the ECU


with the ignition switch OFF.
2. Check for continuity between the ECU
connector and sensor connector @terminals.

--

Green Gray

LwJ

Repair open in the Black/Orange Of Green/Gray


harness between the wheel speed sensor and
ABS control unit (ECU}.

Cnf~
BI"e~Bcown

at'

-----,----- ----)
.
Is there continuity?

NocontinuH;'~Y
_ _
-..

Repair open in the Blue/Brown harness between


the ABS control unit (ECUj and wheel speed sensor.

I Continuity

(Continue to the following pagel

16-8-27

ABS (After '95)


{From the previous page}

res INDICATOR

1. Interchange the front and rear wheel speed sensor


with each other.
2. Connect the ECU connectcr fj;
Perform the pre-start self-diagnosis (including rid- i
ing motorcycle), then check the
indicator light. I

res

Does the TeS indicator light stay on or go off?

Retrieve the problem code and record it. Clear the

problem code.

Problem code "6"

Problem code "5"

Faulty rear wheel speed sensor

16-8-28

ASS INDICATOR LIGHT

ABb~

Light goes off


- ~ - - - - - . Faulty ASS control unit (ECU)

Does not go off

Is the problem code "S"?

LIGHT

ABS (After '951


Problem code 7: Faulty power circuit
NOTE
Before starting the troubleshooting, check to see whether the idle speed conforms to the specified speed. If the idle
speed is below specification, adjust idle speed.
Ask the rider about the following when the motorcycle is brought in for inspection.
- Ask whether the motorcycle has been run with electrical accessories.
- Ask whether the motorcycle has been left for a long time with the ignition switch in the ON position. This problem
code will light up to indicate battery discharge.

Check the battery for charging condition.

Low or no battery
voltage

Is it normal?

Check the charging system/alternator


(section 17).

Normal

1. Retrieve the problem code and record it.

Clear the problem code.


2. Perform the pre-start self-diagnosis (including riding motorcycle) and check the ASS indicator light.

/' Does the ASS indicator light stay on. (The


\
Light blinks
pre-start self-diagnosis is not completed at appro- )',C'-"-''-C''--C'\\\~Ximately 10 km/h [6 mile/h] or more of the vehicle
speed) or go off and blink?
i
/

~ (Go to the following page)

---~/

Light goes off ---------~


Normal (Temporary problem)
Check the harness and connector for secure
connection (page 16-8-3 and section 17).

Light stays on

I
I

Disconnect the ECU connecrors nz- and Yl with


the ignition switch OFF.
2. Measure the voltage between the ECU connector
'izlH terminals with the ignition switch ON.
Standard: 11 V-18 V

j~G~
I
"',00'
Black

0j)

Red Brown

Red/Brown

0j)1--_ _

___t

(~

Abnormal
(Less than 11 Vor
More than 18 V)

Is it normal?

Check the charging system/alternator


(page section 17).

Normal{11V-18VJ

Faulty ASS control unit (ECU)

16-8-29

ABS (After '95)


( From the previous page; Light blinks)

1. Retrieve the problem code. Verify the problem


code "7" and clear the problem code.
2. Replace the battery with a new fully charged

battery (paqe 17-12).


3. Perform the pre-start self-diagnosis (including
riding motorcycle) and check the ASS indicator
light.

__

:oc"-=::C"-=__~~.,

Light blinks

Does ASS indicator light blink or go off?


__________
Light goes off

Faulty battery

16-B-30

Check the harness and connector for secure


connection (page 16-8-3 and section 17).

ABS (After '951


Problem code 8: Faulty ASS control unit (ECU)
NOTE

The ASS indicator light blinks or comes on and stays on when the ECU has been disrupted by an extremely powerful
radio wave (Electromagnetic interference}, This is just a temporary symptom. Clear the problem code and the ECU is
normal unless the symptom recurs. Ask the ride whether he used a radio apparatus or a security unit of a radio system
when he brings his motorcycle to your dealership for inspection.

Turn the ignition switch ON (but do not start the


engine) and check the ABS indicator light.

<

Light blinks
Does the ABS indicator light blink or come on ~~_~~
a stay on?
/

-j....

1Retrieve the problem code and record it.

J------

I Clear the problem code.

Light stays on

Is the problem code "8"7

i Problem

code "8"

Faulty ASS control unit (ECU)

Diagnose on the latest problem code


Perform the pre-start self-diagnosis (including riding
motorcycle) and check the ASS indicator light.

Light goes off

Does the ASS indicator light blink or go off?

..

Light blinks

Light Green Orange

1. Perform the pre-start self-diagnosis (include riding motorcycle) and retrieve the
problem code.
2. Repeat above procedure several times.

Blue Light Green


Does not appear
repeatedly

-)l

Does the problem code "8" appear repeatedly?


Blue/Green

,
1. Disconnect the motor driver 12P connector :,16',
and ECU Black connector ,tt with the ignition
switch OFF.
2. Check for continuity between the motor driver
W' connector terminals and body ground.

<

Is there continuity?

Faulty ASS control unit


Faulty front or rear modulator if the
problem code "8" appears repeatedly
after the ABS control unit is replaced
with a new one

Temporary problem
(Electromagnetic interference)

~
/

Appears repeatedly

Repair short in the harness between the


ASS control unit (ECUJ and motor driver

No continuity

(Continue to the following page)

16-8-31

ABS (After '95)


(From the previous page)

'--------

,--

1. Connect the ECU connectors ,j't.


2. Replace the motor driver with a new one.
3. Retrieve the problem code and record It.
Clear the problem code.
4. Perform the pre-start self-diagnosis (including
riding motorcycle) and check the ASS indicator
light.

-- ,

r-Does the ASS indicator light blink or go off?

-,

I Light blinks

Faulty ASS control unit (ECU)

16-8-32

~Ight goes off

- - - ------. Faulty motor driver

ABS (After '95)


Trouble not represented by a problem code: Fautty ASS indicator light

When the clicking sound in the modulator control motor relay can be heard after turning the ignition switch ON, and where
the ASS operates normally while riding:
-

Before pre-start self-diagnosis (Ignition switch ON)

- While riding

I~

ASS indicator light 2

,. 0

co z

ON

Blink

OFF

Normal

A.S.f.E

,.ro

'"

"'f.-l-,---------+,--------+,---------1
o
c,
(i"

0
Z

o co
_.

:3'
"

, H-----'--+-------''------I----'---i

D.G.I.J

D.G.I.J

- "
to
,

D. E. F. G.I

0
~
-n

ASS indicator light 2

ON

Blink

OFF

-, -,
-, -, -,
-,
I

A.C.I

Normal

When there is no clicking sound in the modulator control motor relay after turning the ignition switch ON and the indicator
light is faulty Ii.e. pre-start self-diagnosis does not start).
-

Before riding (with the engine started and the


motorcycle parked)

- While riding

r,

ABS indicator light 2

,. 0
'" Z
en

ON

Blink

OFF

H. I. L

-,
A:
S:
C:
0:
E:
F:
G:
H:
I:

,.
rn

'"_.

0
Z

ABS indicator light 2

ON

Blink

OFF

I.L

<,

J.K

0
c,

o ro

0,

'"

J. K

""
0
-n
-n

Faulty indicator control unit


Poor connection of the indicator control unit connector ':JJ (4P)
Poor connection of the indicator control unit connector
(2P)
Faulty ASS indicator light LED 1, poor connection of the connector '6'
Faulty ASS indicator light LED 2, poor connection of the connector os
Poor connection of the ASS indicator light connector :8:'
Poor connection of the ABS indicator light connectorz.
Faulty indicator light switch, poor connection of the connectorct
Faulty ASS ECU
J: Poor connection of the ASS ECU connector ::11'
ASS INDICATOR
K: Burned ASS main fuse (lOA)
L: Improper battery charge (See section 17.)
LIGHT 1

~L

ASS INDICATOR
LIGHT 2

ABS~I'e?l

16-B-33

ABS (After '95)

Wheel Speed Sensor Air Gap


Inspection

(1) FRONT WHEEL SPEED


SENSOR

Front

,'>,

Raise the front wheel off the ground.


Measure the air gap between the wheel speed sensor
and pulser ring all the way around while rotating the front
wheel by hand. It must be within the specification.

(3) BRACKET BOLT

Standard: 0.4-0.5 mm (0.016-0.020 in)


Adjust by following procedure:
Turn the front wheel so one of the poles of the pulser ring
and sensor face each other.
Insert a feeler gauge 0.5 mm between the sensor and
pole, then hold the sensor lightly against the pole.
Tighten the sensor bracket bolt.
Torque: 12 Nm(1.2 kg-m. 9 ft-Ib)

Take off feeler gauge from the gap.


Rotate the front wheel one full turn to make sure that the
pulser ring does not interfere with the sensor.
If not still within specification, remove the sensor
mounting bolts and perform the shim adjustment.
Adjust the air gap again.

Rear

(2) PULSER RING

(2) SENSOR
(1) FEELER
GAUGE
O.5mm

/
~

(4) PULSER RING

(1) REAR WHEEL SPEED SENSOR

(2) f1ULSER RING

Place the motorcycle on its center stand.


Measure the air gap between the wheel speed sensor
and pulser ring all the way around while rotating the rear
wheel by hand. It must be within the specification.
Standard: 0.8 ~:t mm (0.031 K~l,:inl
If not within specification, remove the sensor mounting
bolts and perform the shim adjustment.
Rotate the rear wheel one full turn to make sure that the
pulser ring does not interfere with the sensor.

16-B-34

(3) SHIM

ABS (After '95)

MEMO

16-B-35

AB5 (After '95)

Front Modulator Removal/Installation

(4) 3P Blue

if) 35 (3.5, 25)


(61

(81

(31

(5) 2P Black

(2(

(10)

(1)

16-B-36

ABS (Afte, '95)

Check the brake system applying the lever and pedal brake after the air bleeding (page 3-13).
CAUTION

Avoid spilling fluid on a painted, plastic. or rubber parts. Place a rag over these parts whenever system is serviced.
When removing the oil bolts, cover the end of the brake hose to prevent contamination. Do not allow foreign material

to enter the system.


When removing and installing the modulator and motor driver, take care not to drop or strike the modulator.
NOTE
Note that there is no brake fluid in the modulator (except in the modulator head}, because the modulator is the motordriven hydraulic pressure type. Therefore, brake fluid replacement and bleeding air from the modulator body is not
necessary.
Use only DOT 4 brake fluid from a sealed container.

Requisite Service
Lever and pedal brake line fluid draining/air bleeding (page 15-2)
Upper fairing removal/installation (page 2-9)

Procedure
(1)
{21
(31

(')
(5)
(6)

{71
{81

Removal Order
Motor driver connector
Motor driver mounting bolt
Motor driver
Modulator crank angle sensor connector
Modulator control motor connector
Oil bolt
Sealing washer
Brake hose

(9)
Modulator mounting bolt
(10) Front modulator

Remarks

O'tv

Installation is in the reverse order of removal.

3
2
2
1
1

,
,
8

3
1

NOTE
The reference nu-mbers are stamped on each brake hose
end and the modulator head. When installing, align each
numbers (page 1-37)

CAUTION
Do not disassemble the modulator.

16-B-37

(After '95 J

ABS
Rear
Modulator Remova 1/lnstaliatlOn

~
(3)~

35 (3.5, 25)
15)
17)

(1) 3P White
(2) 2P Black

16)

16-B-38

ABS (After '951

Check the brake system by applying the pedal brake after the air bleeding (page 3-13).
CAUTION
Avoid spilling fluid on painted, plastic, or rubber parts. Place a rag over these parts whenever system is serviced.

When removing the oil bolt, cover the end of the brake hose to prevent contamination. Do not allow foreign material to
enter the system.
When removing and installing the modulator, take care not to drop or strike the modulator.
NOTE
Note that there is no brake fluid in the modulator (except in the modulator head), because the modulator is the motordriven hydraulic pressure type. Therefore, brake fluid replacement and bleeding air from the modulator body is not
necessary.
Use only DOT 4 brake fluid from a sealed container.

Requisite Service
Pedal brake line fluid draining/air bleeding (page 15-2)
Right side cover removal/installation (page 2-2)

Procedure
(1)

(2)
(3)

(4)
(5)

Removal Order
Modulator crank angle sensor connector
Modulator control motor connector
Oil bolt
Sealing washer
Brake hose

Q'ty
1
1
4

Remarks
Installation is in the reverse order of removal.
Remove the sensor wire from the clamp and clip.

8
4

.NOTE
The reference numbers are stamped on each brake hose
end and the modulator head. When installing, align each
numbers (page 1-41),

(6)
(7)

Modulator mounting bolt


Rear modulator

CAUTION
Do not disassemble the modulator.

16-8-39

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

...

Replace the partts] with new onets) before assembly.

Is :;O=ooLI

Use special tool

IOP~OOLI

Use optional tool. Use the same procedure you use to order parts.

Torque specification.

10 Nm (1.0 kg-m, 7.2 ft-lb)

10 (1.0, 7.2)

-:71

-,
..~

Use recommended engine oil, unless otherwise specified.

Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1

Use multi-purpose grease (Lithium based multi-purpose grease NLGI #2 or equivalent)

Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote BR-2 plus manufactured by Dow Corning, U.S.A.
Multi-purpose M-2 manufactured by Mitsubishi Oil Japan

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

Use silicone grease

Om

Apply a locking agent. Use a middle strength locking agent unless otherwise specified.

"I~

Apply sealant

Use brake fluid, DOT 3 or DOT 4. Use the recommended brake fluid, unless otherwise specified.

Use Fork or Suspension Fluid.

1) .

17. Charging System/Alternator


1 7-1

Battery Removal/Installation

System Location

17-2

Stator Coil Removal/Installation

Troubleshooting

17-4

Alternator Removal/Installation

Service Information

17-12

('91-'95) 17-13

(After '95) 17-14

Charging System Inspection ('91-'95) 17-6


(After-'951 17-9

Alternator Disassembly/Assembly

Regulator/Rectifier ('91'95)

17-7

Alternator Shaft Removal/Installation 17-18

Alternator Inspection ('91-'95)


(After '95)

17-8
17-10

Alternator Shaft Disassembly/


Assembly

(After '95) 17-16


17-20

Service Information
The battery gives off explosive gases; keep sparks. flames, and cigarettes away_ Provide adequate ventilation
when charging or using the battery in an enclosed space.
The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear
protective 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. If swallowed, drink large quantities of water or milk and follow with milk of magnesia or vegetable oil and call a physician.
KEEP OUT OF REACH OF CHILDREN.
-------

Always turn off the ignition switch before disconnecting any electrical component.

I.

CAUTION

So~e electrical components may be damaged if terminals or connectors are connected or disconnected while
the ignition switch is ON and current is present.
For extended storage, remove the battery. give it a full charge. and store it in a cool, dry place.
For battery remaining in a stored motorcycle, disconnect the negative battery cable from the battery terminal.

NOTE
The maintenance free battery must be replaced when it reaches the end of its service life.

~~~~------

CAUTION
The battery caps should not be removed. Attempting to remove the sealing caps from the cells may damage the
battery.

Battery can be damaged if overcharged or undercharged, or if left to discharge for long periods.These same conditions
contribute to shortening the "lite span" of the battery. Even under normal use, the performance of a battery deteriorates
after 2-3 years.
Battery voltage may recover after battery charging, but under heavy load. battery voltage will drop quickly and
eventually die out. For this reason, the charging system is often suspected to be the problem. Battery overcharge often
results from problems in the battery itself, which may appear to be an overcharge symptom. If one of the battery cells is
shorted and battery voltage does not increase, the regulator/rectifier supplies excess voltage to the battery. Under
these conditions, the electrolyte level goes down quickly.
Before troubleshooting the charging system, check for proper use and maintenance of the battery. Check if the battery
is frequently under heavy load, such as having the headlight and taillight ON for long periods of time without riding the
motorcycle.
The battery will self-discharge when the motorcycle is not in use. For this reason, charge the battery every two weeks
to prevent sulfation from forming.
Filling a new battery with electrolyte will produce some voltage, but in order to achieve its maximum performance,
always charge the battery. Also, the battery life is lengthened when it is initial-charged.
When checking the charging system, always follow the steps in the troubleshooting flow chart (page 17-4).
For battery testing/charging, refer to section 22 of the Common Service Manual.
For charging system location. see page 17-2.

17-1

Charging System/Alternator

System Location
'91-'95
Standard model shown:
(1) IGNITION

SWITCH
(2) REGULATOR
RECTIFIER

(3) BATIERY

(5) ALTERNATOR
(4) MAIN FUSE
30A

(6) FUSE lOA

----- - -

{1} IGNITION
SWITCH

BI~R/BI~
,

(4) MAIN FUSE


30A

(3) BATTERY
lZV lZA

8
(Z) REGULATOR

RECTIFIER

(5) ALTERNATOR

17-2

Charging System/Alternator
After '95
LBS-ABS/TCS model shown:

--~l
(1) IGNITION SWITCH

/tarjl ,

(2) BATTERY

(6) ALTERNATOR

(5) MAIN FUSE 30A

(4) ALTERNATOR FUSE 55A

(4)

ALTERNATOR
FUSE 55A

(6) ALTERNATOR

~-,--.----~

,
(5)

~,

~
~

.i

'0"-

"

00

'n

"

f-SY

~
~

(2) BATTERY

MAIN
FUSE
30A

~ j
0

"

"
-m-

(3) FUSE lOA


---W-BI~RlBI

.Q: "

RECTIFIER

(1) IGNITION

SWITCH

L-

_ ri)

:.=:J

,/,,--0

R--- --Red

BI Black

17-3

Charging System/Alternator

Troubleshooting
'91-'95
Battery Overcharging
Faulty regulator/rectifier
Battery Undercharging
NOTE
In order to obtain accurate test readings when checking the charging system, the battery must be fully charged and
in good condition. See Common Service Manual section 22 for checking the battery condition.

Measure the battery current leakage


(Leak test) (page 17-6)

Incorrect

Check the regulator/rectifier unit inspection


(page 17-7, 17-8)

Incorrect

L:

Correct

Inspect the regulated voltage (page 17-6)

Correct

Shorted wire harness


Faulty ignition switch
Faulty regulator/rectifier

Correct

Not Charging

~-----:--L

:="""':-:c__

Check the voltages of the regulator/rectifier battery, __Abnormal


charging line and ground line (page 17-6)
r

Open circuit in wire harness


Poorly connected connectors

Normal
Check the alternator (charging and field coils)
resistance at the regulator/rectifier connector
(page 17-7}

Abnormal

1-

Check the charging and field coils at alternator


(page 17-7)
Abnormal

Poorly connected alternator


connector

Normal

1_ _

,--~.-.

Abnormal

17-4

Normal

Faulty alternator

Faulty regulator/rectifier

Charging System/Alternator

After '95
Inspect the following before diagnosis the system.
- discharged battery
- loose or corroded terminals of the connectors
NOTE

In order to obtain accurate test readings when charging system, the battery must be fully charged and in good condition.
See Common Service Manual section 22 for checking the battery condition.

Measure the battery current

a~pere leakage

Incorrect
!'-_'-='-::C'

---.1

Check the alternator (regulator/rectifier)


(page 17-10)

I {Leak test} (page 17-9)

---

I
Correct

Incorrect

Correct

_t,--------',

llnspect the regulated voltage (page 17-9)

14.2-14.8 V

Lessthan 14.2 V

Abnormal

Normal

Abnormal
If--'-=='-='-_

Open circuit in wire harness


Loose connections
Burned out alternator fuse {55 A)

Normal

L'~~~~
Disassemble the alternator
and inspect the
following:
stator coil (page 17-11)
rotor coil (page 17-11)
brush length (page 17-11)
regulator/rectifier (page 17-10)

Open circuit in wire harness


Loose connections
Faulty ignition switch

; Check the voltage of the battery charging line


(page 26-152)
I

Faulty regulator/rectifier

Faulty battery

Check the voltage of the regulator/


rectifier input line (page 17-10)

=:J- More than 14.8 V

Shorted wire harness


Faulty ignition switch

Abnormal

Faulty rotor coil


Faulty stator coil
Worn brush
Faulty regulator/rectifier

17-5

Charging System/Alternator

Charging System Inspection ('91-'95)

(1) BATTERY GROUND CABLE

Current Leakage Test

(2) BATTERY
NEGATIVE
TERMINAL

Turn off the ignition switch, and disconnect the ground H


cable from the battery.
Connect the ammeter (+) probe to the ground cable and the
ammeter (-) probe to the battery (-) terminal.
With the ignition switch off, check for current leakage.

NOTE

I.

When measuring current using a tester, set it to a


high range, and then bring the range down to an
appropriate level. Current flow larger than the range
selected may blowout the fuse in the tester.
While measuring current, do not turn the ignition on.
A sudden surge of current may blowout the fuse in
the tester.
---------

Specified Current Leakage: 3 mA max.


If current leakage exceeds the specified value, a short circuit
is likely.
Locate the short by disconnecting connections one by one
and measuring the current.

Regulated Voltage/Ampere Inspection


NOTE
Before performing this test be sure that the battery is
fully charged and that the voltage between its terminals
is greater than 12.6 V.
Remove the left side cover (page 2-2).
Start the engine and warm it up to operating temperature,
then turn the ignition switch OFF.

-,-----

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 01 consciousness and lead
to death.

Connect a voltmeter between the battery terminals.

17-6

Charging SystemlAlternator
Disconnect the starter relay switch connector and remove
the main fuse.
Reconnect the connector secoretv.
Connect the ammeter as shown.

~n
~l
~ ~

(11 MAIN FUSE

"

CAUTION
0

(2) CONNECTOR

Be careful not to short any tester probes.


Although the current could be measured when the
ammeter is connected between the battery positive !
terminal and the positive cable, a sudden surge of
current to the startBr motor could damage the ammeter.
Always turn the ignition off when conducting the
test. Disconnecting the ammeter or wires when current
IS flOWing may damage the ammeter.

NOTE
Before making this test. all the lights and the other
electrical equipment should be OFF.
Use fully charged battery to make this test for correct
measurement.

."

'~~

Ir: +eo

liLt'!! e

~,~f~

(3) STARTER RELAY SWITCH

(1) BATIERY POSITIVE(+)


TERMINAL

Start the engine and increase the engine speed gradually.


Regulated Voltage: 12.6-15.0 V/5,OOO rpm
Charging Current: 0-1.0 A/5.000 rpm

~~~~--~~--(~2~1

:B1ATIERY NEGATIVE(-)

TERMINAL

Regulator/Rectifier ('91-'95)

.-------

(1) CONNECTOR

Wire Harness Inspection


Remove the left side cover (page 2-2).
Disconnect the regulator/rectifier 6P connector and check
the connector for loose or corroded terminals.
Measure the following between the connectors of the wire
harness side.
Terminals

Specification

Battery charging
line

Red/White (+)
and ground

Battery voltage
should register.

Charging coil line

Yellow and Yellow 0-1.0n.


(20"C/68 F)

Field coil line

White and
Black

Item

0-4_0n.

1120'C/68'FI

17-7

Charging System/Alternator
Unit Inspection

Unit' kg

Provided the circuits on the wire harness side are normal and
there are no loose connections at the connector, inspect the
regulator!rectifier unit by measuring the resistance between
the terminals.
NOTE

You'll get false readings ifthe probes touch your fingers.


Use the specified multlrneters. Using other equipment
may not allow you to obtain the correct results.
This is due to the characteristic of semiconductors,
which have different resistance values depending on
the applied voltage.

Specified Multimeter :
-SP-15D
-TH-5H

\ + Probe
"

Red/
White

~lWhite

<,

- Probe

.veuow 1 Yellow 2 Yellow 31,


.
co

co

ca

co

Yellow 1

7.5

<,

co

ca

co

~low2

7.5

<,

oo

co

7.5

co

co

<,

cc

60

28

28

28

<,

Yellow

White

(SANWA Analogue type)


(KOWA Analogue type)

Select the following range:

SANWA; kO
KOWA; Xl00

'-

(2) BLACK

._\

White

(1)YELLOW~

An old battery stored in the multimeter could cause inaccurate readings. Check the battery if the multi meter
resistance is incorrect.

(3) WHITE

(4) YELLOW

~"'

Replace the regulator/rectifier unit if the resistance value


between the terminals is abnormal.
(6) REDIWHITE

Alternator Inspection ('91-'95)


NOTE

It is not necessary to remove the stator coil to make


this test.

Remove the left side cover (page 2-2) and disconnect the
alternator 3P (Red) and 2p (Black) connectors.
Measure the resistance between the yellow wire terminals
and check for no continuity between each terminal and
ground.

Yellow terminal-Yellow terminal: 0-1.00


Yellow terminal-White terminal: No continuity
Yellow terminal-Red/white terminal: No continuity
Measure the resistance between the white and black terminals
and check for continuity between the 2P connector terminals.

Standard: 0-4.00 (20'C/68" Fl


Replace the stator if the resistance is out of specification or
if there is continuity between any terminal and ground.

17-8

(5) YELLOW

(1) 3P CONNECTOR

---,

,4

!~

~__

..u=:.
__ -"S:y

::-.::~ -1~ I'

/.~_!,n,
,
c
I'",
-

V.------

I,

(2) 2P CONNECTOR

-'p

'

, _'

Charging System/Alternator

Charging System Inspection (After '951

(1) BATTERY GROUND CABLE

Current Leakage Test


(2) BATTERY

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


Turn off the ignition switch, and disconnect the ground (-)
cable from the battery.

NEGATIVE
TERMINAL

Connect the ammeter {+} probe to the ground cable and the
ammeter (-) probe to the battery (-) terminal.

With the ignition switch off, check for current leakage.


NOTE
When measuring current using a tester, set it to a
high range, and then bring the range down to an
appropriate level. Current flow larger than the rang],
selected may blowout the fuse in the tester.
While measuring current, do not turn the ignition on.
A sudden surge of current may blowout the fuse in
the tester.
Specified Current Leakage: 2 mA max.
If current leakage exceeds the specified value, a short circuit
is likely.
Locate the short by disconnecting connections one by one
and measuring the current.

Regulated Voltage Inspection


NOTE

i.

Before performing this test, be sure that the battery is


fully charged and that voltage between its terminals
~ greaterthan 12.6 V.

Start the engine and warm it up to operating temperature,


then turn the ignition switch OFF.

H 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 monOXideJ
'
gas that may cause loss of consciousness and lead
to
_ _ death.
cc"'---__
_
_

---------

CAUTION

i Be car~ul not to short any tester probes.


Connect a voltmeter between the battery terminals.
Turn the headlight ON (High beam) and start the engine.
Gradually increase the engine speed and check that the
voltage is regulated.
Regulated Voltage: 14.2-14.8 V/5,OOO mln-' (rpml

17-9

Charging System/Alternator
Wire Harness Inspection

(1) WHITE CONNECTOR


(Input line)

::==J
I-~
drL

Disconnect the battery negative (-) cable.

i/""

I.'~

Disconnect the battery negative cable from the


battery to prevent sparking when disconnecting the
alternator cable.

- -

V,:1

$>,

Ij~ooo<~-_-:'-:'~~~j;:;0/-

'-

r~

Disconnect the alternator cable and White connector from


the alternator.

(2) ALTERNATOR CABLE


(Charging line)

Connect the battery negative (-) cable onto the battery.


Measure the voltage between each wire (wire harness side)
and ground as indicated on the chart.
Disconnect the battery negative (-) cable to avoid sparki ng
which would otherwise occur when connecting each wire
to the alternator.

ITEM

TERMINALS

Battery charging line

SPECIFICATION

Alternator cable

BalTery voltage

terminal ITI and

ground H

Alternator Inspection (After '95)

should register.

BalTery voltage

White connector

Battery voltage should

input line

terminal (+1 and


ground I-I

ignition switch ON,

register with the

(1) E (ground)

Disassemble the alternator (page 17-16)

Rectifier

P,

"'-e

'"

Before inspecting, the rectifier must be separated from the


regulator.
NOTE

The diodes are designed to allow current to pass in


one direction while blocking it in the opposite
direction. Since the alternator rectifier is made up of
eight diodes, each diode must be tested for continuity
in both directions that has diode checking capability;
a total of 16 checks.
Check for continuity in each direction between
- Band P (P" Pl, P3, P4) terminals.
- E (ground) and P (P" P" P3, P,) terminals.
All diodes should have continuity in only one direction.
If any of the diodes fails, replace the rectifier assembly.
(Diodes are not available separatefv.)

17-10

Charging System/Alternator
Stator

(1) TERMINALS

Check the resistance between each pair of terminals. There


should be minimal resistance.

Standard: 0.22 - 0.26 n (20C/68F)


Check for continuity between each terminal and the coil
core. There should be no continuity.

Rotor Coil
Check the slip rings for stepped wear.
Measure the 0.0. of each slip ring.

Service limit: 12 mm (0.5 in)

Measure the resistance between the slip rings.

Standard: 2.6 - 3.2 n (20C/68Fl


Check for continuity between the slip ring and the
rotor or rotor shaft. There should be no continuity.

Brushes
Measure each brush length.

Service limit: 4.7 mm (0.19 in)

(l) BRUSHES

17-11

Charging System/Alternator

Battery Removal/Installation
{11

(4)

(3)

~(2)

Requisite Service

Left side cover removal/installation (page 2-2)


With the ignition switch "OFF", disconnect the negative (-) cable first, then the positive (+} cable.

f-(1)
(2)
(3)
14)

Procedure

Removal Order
Battery negative (-) cable
Battery holder nut
Battery positive (+) cable
Battery

17-12

Q'ty

Remarks
Installation is in the reverse order of removal.

1
1
1
1

,
After removing, open the battery holder.

Charging SystemlAlternator

Stator Coil Removal/Installation ('91-'95)

(5)

{11

(4)

------~

(3)

(2)

~l~-~
{7)=!t"7J

{6)~-~ ~

Requisite Service

Swingarm removal/installation (page 14-8)


Procedure

(1)

(2)
(3)
[4)
(5)
(6)
[7)

Removal Order
Lock nut
Gearshift pedal connecting rod
Tube holder
Gearshift pedal
Alternator connector
Stator assembly
O-ring

Q'ty

Installation is in the reverse order of removal.


It is not necessary to remove, just loosen.

2
1
1
1

Remarks

After installation, route the tubes correctly (page 1-25).

2
1
1

17-13

Charging System/Alternator

Alternator Removal/Installation (After '95)


View from rear:

~1t:=~{41

Alternator base

Secure with a Bmm bolt

~T
i

Mounting bosses

Alternator base

(6)

-,

Alternator shaft assembly

17-14

...

Charging System/Alternator

servicing, disconnect the batlery negative cable from the batlery to prevent sparking when disconnecting the
alternator cable.

Requisite Service
Left pivot cover removal/installation (page 2-5}

FueI tan k remova Vinstallation (page 2-12)


Swingarm removal/installation (page 14-8)
Procedure

Q'ty

Installation is in the reverse order of removal.

Removal Order

11) 2P {White} connector


(2) Terminal nut
(3)

(4)

Remarks

1
1

, Alternator cable

After tightening the terminal nut, install the terminal cap to


the terminal flange securely.

Mounting bolt

(5)

Alternator

(6)

O-ring

NOTE
Before removing the alternator, turn the alternator
clockwise and temporarily secure the alternator base
with a 8 mm bolt as shown.
If the alternator base is not secured, it will cause the
alternator shaft to come out with the alternator. If this
occurs, oil pan removal will be necessary when
reinstalling (page 17-18}.
Pry the mounting bosses of the alternator using a
screwdriver.
Disassembly/assembly (page 17-16)

17-15

Charging System/Alternator

Alternator Disassembly/Assembly (After '95)

(10)

cu )

---------

1131qJ.

141
------------

(5)

..,

{3j

151

(9)

17(

12(

17-16

Charging SystemlAlternator
Requisite Service

Alternator removal/installation (page 17-14)


Procedure

11 }
12}
131
141
151
161
171
18}
19}
(10)
(11)
(12)

(13)

(14),
(15}i
(16}
(H}

Disassembly or der
End cover screw
Nutfterminal insulator
Rear end cover
Terminal screw (pan-head)
Terminal screw (flange)
Regulator
Brush assembly/holder insulator
Terminal screw (flange)
Rectifier
Housing nut
Rear housing
Rotor

Oil seal
Retainer screw
Bearing retainer
Front bearing (6202)/washer
Spacer ring/rear bearing (6002}

, Q'ty

Remarks
Assembly is in the reverse order of disassembly.

3
1/1
1
2
3
1
1/1
4
1
2
1
1

1
4
1
1/1
1/1

,
,

Before installing, clean the slip rings thoroughly.


NOTE:
Usea hydraulic press. Do not strike the slip ring ofthe
rotor shaft.

17-17

Charging System/Alternator

Alternator Shaft Removal/Installation


'91-'95

131et,

.{J/~Y

(t I

5 8 (5.8, 42)

121

6 mm bolt

Requisite Service
Engine removal/installation (page 7-2)
Oil pan removal/installation (page 4-6)
Stator coil removal/installation {page 17-13)
Procedure

Q'ty

(t)

Removal Order
Alternator shaft bolt

121

Alternator shaft assembly

(31

O-ring

17-18

Remarks
Installation is in the reverse order of removal.
NOTE
Before removing, insert a 6 mm bolt in the holes in the
alternator shaft driven gears for easy alternator shaft
assembly installation. After installing, do not forget to
remove the bolt.
NOTE
Before installing, apply molybdenum disulfide grease to the
alternator shaft driven gears. Disassembly/assembly {page
17-20}

Charging System/Alternator
After '95

et'l
121

I' 1

6mm bolt

Requisite Service
Oil pan removal/installation (page 4-6)
Alternator removal/installation {page 17-14}
Procedure

Q'ty

Remarks

i Installation is in the reverse order of removal.

Removal Order

.NOTE
Before removing, insert a 6 mm bolt into the holes in

I' 1 Alternator shaft assembly

(2) la-ring

the alternator shaft driven gears for easy alternator


shaft assembly installation. After installing, do not
forget to remove the 6 mm bolt.
NOTE
Before installing, apply molybdenum oil solution to
the alternator shaft driven gears.
Disassembly/assembly (page 17-21)

17-19

Charging System/Alternator

Alternator Shaft Disassemlby/Assembly


'91-'95
110}
19}

IS}

IS}

141

131

15}

17}

Requisite Service
. Alternator shaft removal/installation (page 17-18).
Procedure

11 }
12}
13}
14}
15}

Disassemlby Order
Alternator shaft nut
Washer
Bearing
Shaft collar
Cone washer

Remarks

Q'ty

Assembly is in the reverse order of disassembly.

1
1

1
1
1

Install the washer with the tapered side facing to the


shaft nut.

Alternator shaft driven gear


IS}
17} Damper spring
IS} , Spring seat
Flywheel

19:}1
110}
Alternator shaft assembly

17-20

5
12
1
1

Charging System/Alternator
After '95

(9(

~I
I
I
I

(51
(41

(31

(11)

Requisite Service

Alternator shaft removal/i nstauatron (page 17-19)


Procedure

Q'ty

Disassembly Order
(1) , Alternator shaft nut
(2(

(31
141
151
161
171
181
(91

Washer
Bearing (6003)
Shaft collar
Cone washer

Alternator shaft driven gear


Damper spring
Spring seat
Flywheel
(10) Bolt
(11) Retainer plate
(12) Alternator base
(13) Bearing (20 x 47 x 10.5)

Remarks
Assembly is in the reverse order of disassembly.

1
1
1
1
1

Install the washer with the tapered side facing to the shaft
nut.

4
8
1

3
1

1
1

17-21

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

...

Replace the partts] with new onets) before assembly.

Is :;O=ooLI

Use special tool

IOP~OOLI

Use optional tool. Use the same procedure you use to order parts.

Torque specification.

10 Nm (1.0 kg-m, 7.2 ft-lb)

10 (1.0, 7.2)

-:71

-,
..~

Use recommended engine oil, unless otherwise specified.

Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1

Use multi-purpose grease (Lithium based multi-purpose grease NLGI #2 or equivalent)

Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote BR-2 plus manufactured by Dow Corning, U.S.A.
Multi-purpose M-2 manufactured by Mitsubishi Oil Japan

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

Use silicone grease

Om

Apply a locking agent. Use a middle strength locking agent unless otherwise specified.

"I~

Apply sealant

Use brake fluid, DOT 3 or DOT 4. Use the recommended brake fluid, unless otherwise specified.

Use Fork or Suspension Fluid.

1) .

18. Ignition System


Service Information

18-1

Ignition Coil

18-8

System Location

18-2

Ignition Pulse Generator Inspection

18-9

Troubleshooting

18-4

18-10

Ignition System Inspection

18-6

Ignition Pulse Generator Removal!


Installation
Ignition Timing

18-11

Service Information

When checking the ignition system, always follow the steps in the troubleshooting flow chart (page 18-4).
The digital transistorized ignition system uses an electrically controlled ignition timing system. No adjustments can be
made to the ignition timing.
A rough diagnosis can be made by identifying the cylinder whose spark timing is incorrect.
The ignition control module (leM) may be damaged if dropped. Also, if the connector is disconnected when current is
flowing, the excessive voltage may damage the unit. Always turn off the ignition switch bercre servicing.
A faulty ignition system is often related to poorly connected connectors. 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 plugs.
Use spark plugs of the correct heat range. Using spark plugs with an incorrect heat range can damage the engine.
Refer to section 2 of the Common Service Manual.
For neutral switch inspection, refer to section 25 of the Common Service Manual; for switch location, see page 18-2 or
18-3 of this manual (System Location).
For the ignition switch and engine stop switch inspection, check for continuity on the continuity chart of the Wiring
Diagram (section 22). Refer to page 21-4 for side stand switch inspection.

18-1

Ignition System

System Location

(4) BANK ANGLE


SENSOR RELAY

Standard Model

(5) BANK ANGLE

(3) SIDE STAND


INDICATOR LIGHT

SENSOR

(2) IGNITION SWITCH

(1) No. 2,4 IGNITION


COIL

(6) ENGINE STOP


SWITCH

y;"

(7) No.1,3 IGNITION


COil

/\

(8) IGNITION PULSE

GENERATOR

(13) IGNITION

CONTROL
MODULE
{ICM}

(12) NEUTRAL
SWITCH

{11} SIDE STAND


SWITCH
(10) MAIN
FUSE

30A
(9) BATIERY

(4) BANK ANGLE

SENSOR RELAY
(5) BANK ANGLE

SENSOR

S~TCH

(1) No. 2,4

-0

IGNITION COIL

/>-J

{71 No. 1 ,3-~


IGNITION I
COIL
-r-r

W I G RIW

-;[

(6) ENGINE STOP

(13) ICM

RjW
W/Y

...L

,--'--

lOA

L--BI'-----I
..."..,

R _

R/BI

(10) MAIN (2) IGNITION

FUSE
30A

_L'----

-=-

(9) BATTERY

SWITCH

FUSE

lOA

(11)SIDESTAND
SWITCH

(12) NEUTRAL
SWITCH

TO TACHOMETER
TO STARTER
CIRCUIT

18-2

Ignition System
ABS/TCS model shown:

ABS/TCS or LBS-ABS/TCS Model


(4) BANK ANGLE SENSOR RELAY

(3) SIDE STAND

INDICATOR LIGHT

(5) BANK ANGLE SENSOR

(2} IGNITION SWITCH

~-~

(1) TCS/ignition
control module
(lCM)
C~\

(6) ENGINE STOP SWITCH

(7) No.1, 3 IGNITION


COIL

(8) IGNITION PULSE

GENERATOR

'---~

(13) No. 2,4


IGNITION COIL

(12) NEUTRAL
SWITCH
(11) SIDE STAND
SWITCH

(10) MAIN
FUSE
30A

(9) BATTERY

(4) BANK ANGLE

SENSOR RELAY (6) ENGINE STOP


(5) BANK ANGLE

SENSOR

(1) TCS/ICM

BI/Y

W/Y

'-

L--BI----.J
R _

R/BI

(lOJ MAIN (2) IGNITION


FUSE
SWITCH
30A

_BI/BR

FUSE (3) SIDESTANDlQI'10A


INDIATOR
LIGHT

--=-

(9) BATTERY

LG

~~o

-~,

(11)SIDESTAND
(12) NEUTRAL
SWITCH
SWITCH
TO TACHOMETER
(8) IGNITION PULSE
TO STARTER
GENERATOR
CIRCUIT

18-3

Ignition System

Troubleshooting
No spark at all plugs (Faulty input system)
If there is no spark at all plugs, the problem could be at the input of the ignition system (ignition pulse generator. power input circuit of the ignition control module (ICM), neutral switch, side stand switch or ICM).
Check for loose or poorly connected ICM con-I
nector.
I

Poorly connected connector


Abnormal

Normal

Check for loose or poorly connected ignition coil


3P mini connector.

Poorly connected connector


Abnormal

~ Normal
I Check for battery voltage between the power
input line (Black/White: standard model, Black/
'Yellow: ABSTCS model) and ground (Green) at
the 'CM connector with the engine stop switch
at RUN (except ABSTCS model) and the ignition
, switch ON (page 1B-6).

Abnormal

Faulty ignition switch


Faulty engine stop switch (except A8STCS
model) For the engine stop switch inspection of
ABS' TCS model, see page 18-1.
Open circuit in wire harness
Loose or poor contact of related circuit connectors
Faulty bank angle sensor relay
Faulty bank angle sensor

I Normal

j
Measure the ignition pulse generator resistance I
at the lCM connector (page 18-6).

Check the ignition pulse generator (page 18 7). I


Abnormal
Normal

Normal

Check the neutral switch for continuity at the I


ICM connector (page 18-6).

Faulty ignition pulse


generator
Open circuit between the ICM and ignition pulse
generator
Loose or poor contact of the ignition pulse generater connector

i Check the neutral switch.


Abnormal
Normal

Normal

Check the side stand switch at the ICM connect-j


or (page 18-6).

!Normal
Faulty ICM

Abnormal

Abnormal
Faulty neutral
switch

Open circuit between the leM and neutral


switch
Loose or poor contact of the neutral switch
connectors

Check the side stand switch (page 21 4).


Abnormal
Normal

Abnormal
Faulty side stand
switch

Open circuit between the ICM and side stand


switch
Loose or poor contact of the side stand switch
connector

18-4

Ignition System
No spark at either ignition group
If there is no spark at either group, the problem is suspected in the primary coil side of the ignition system (ignition
coil, or ignition control module (ICM) and ignition coil circuit).

..I

Switch the ignition coil primary terminal con! nection between the faulty pair and good pair.
Try spark test again

"No Spark"
condition
remains with
faulty pair

No Spark" condition
shifts to other pair
U

Measure resistance of the ignition primary coil


'
at ICM connector (page 18-6).
_~"-_ _~
~

Faulty Ignition coli


" Faulty spark plug
wire

~.
.. "

I,

Remove the faulty pair ignition coil and check

I the ignition coil resistance (page 18-7).

Abnormal

Normal

Poor or loose contact of ignition coil 3P mini


connector
Open circuit between the 1CM and ignition coil

Faulty ICM
No spark at one plug (Trouble in secondary coil side)
" Faulty spark plug is most likely.
Replace (suspected bad spark plug) with known I
good spark plug and conduct spark test.
i

-.." Original spark plug no good.


Normal

Abnormal
Put the spark plug wire on and measure resistance
of ignition secondary coil (page 18-7).

Normal

Conduct spark test on good ignition coil.


Normal

Abnormal
Remove the spark plug wire, and measure the
_"
resistance of the ignition secondary coil (page f - Abnormal
18-7) .

Faulty ignition coil

Normal

Poor contact of spark plug wire


Faulty spark plug wire
Side stand switch does not function at all.
Side Stand Indicator:
I Check the side stand indicator for function.

Normal

___" Faulty side stand switch


Open circuit in Green/White or Green wire

Abnormal

ISide Stand Switch:

Normal

Check the side stand switch for continuity.

-.." Loose or poor contact of related connectors


Open or short circuit in wire harness
Burnt indicator bulb

Abnormal
Faulty side stand switch

18-5

Ignition System

Ignition System Inspection

STANDARD MODEL:
(1) ICM

NOTE
Check the system components and lines step-by-step
according to the troubleshootinq chart on pages 1B-4
and 18-5.

Standard model:
Remove the left fairing pocket (page 2-6).
Remove the ignition control module (ICM} from the stay,
disconnect the ICM connector and check it for loose or
corroded terminals.

ABS/TCS or LBS-ABSITCS model:


Remove the middle fairing inner cover (page 2-7).
Disconnect the TCS/ignition control module (ICM) 16P connector and check it for loose or corroded terminals.

ASS/TCS or LBS-ABS/TCS MODEL:


(1) TCS/ICM

Measure the data between the connector terminals using


the following chart.

Item

Terminals

Standards (20"C/6B"F)

Battery voltage input line

Black/white [ABS/TCS or LBS-ABS/TCS


model: Black/Yellow] (+) and Ground (-)
with the engine stop switch RUN (Standard
model) and the ignition switch ON.

Battery voltage should register

Ignition pulse generator line

Yellow and White/yellow

405-495 Q

Ignition primary
coil line

No. , ,3

Yellow/blue and Black/white

No. 2,4

Blue/yellow and Black/white

2.16-3.19

Neutral switch line

Light green and Ground

Continuity in neutral
No continuity in any gear

Side stand switch line

Green/white and Ground

Continuity with the stand up


No continuity with the stand down

Ground line

Green and Ground

Continuity

Tachometer line

18-6

Yellow/green and Green wire connector of


( the harness side at the instruments

Continuity

Ignition System

Ignition Coil

(1) 3P CONNECTOR

Inspection
Remove the upper fairing (page 2-9).
Disconnect the ignition primary coil 3P connector (white)
and measure the primary coil resistance between each ignition
coil.
Primary coil resistance:
Standard: 2.16-3.19Q (20'C/6So F)

Disconnect the spark plug caps from the plugs and measure
the secondary coil resistance with the spark plug caps in
place,

(1lIGNITION COIL

OJl\-~

Standard: 22.5-27.5kQ (20'C/6S" F)

(OJ

;,=

(iiiiiii

If the resistance is out of the range, remove the spark plug


caps and measure the resistance between the secondary
coil terminals

Standard: 13.5-16.5kQ (20C/6S" F)

(2) IGNITION COIL

.~t:r
iiiiiii

f
I

(1) SPARK PLUG WIRES

18-7

Ignition System

Ignition Pulse Generator Inspection

STANDARD MODEL:

NOTE
It is not necessary to remove the ignition pulse generator to make this inspection.
Standard model:
Remove the right side cover (page 2-2).
ABS/TCS or LBS-ABS/TCS model:
Remove the top shelter (page 2-5).

w
@
~---

~~~~~~

-~~~cccc~_D
(G';"'-------------::;)~~q
:----J

-;:-------r--

(1) IGNITION PULSE GENERATOR 4P CONNECTOR


Disconnect the ignition pulse generator 4P connector and
measure the resistance between the White/Yeliow and
Yellow wires.
ABS/TCS or LBS-ABS/TCS MODEL:

Standard: 405-4950. (20e/68F)


Refer to page 18-9 for ignition pulse generator replacement.

18-8

Ignition System

Ignition Pulse Generator Removal/Installation


\ \

ABS/TCS model shown:

"

(11
0'12 (1.2, 9)

.,('G1l!
(61

(31

(~,

Clamp
0'12 (1.2, 9)

(21

Requisite Service

Fuel tank Removal/Installation (page 2-12).


Procedure

111
(21

Removal Order
Oil pressure switch terminal
Neutral switch connector

(3}

Waterproof connector (4P)

my

Installation is in the reverse order of removal.

1
1

(6}

2
2

(7}

(81

At installation, insert the neutral switch wire into the


clamp as shown.

14} Bolt
151 Gasket
Dowel pin
Bolt
Ignition pulse generator

Remarks

18-9

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

...

Replace the partts] with new onets) before assembly.

Is :;O=ooLI

Use special tool

IOP~OOLI

Use optional tool. Use the same procedure you use to order parts.

Torque specification.

10 Nm (1.0 kg-m, 7.2 ft-lb)

10 (1.0, 7.2)

-:71

-,
..~

Use recommended engine oil, unless otherwise specified.

Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1

Use multi-purpose grease (Lithium based multi-purpose grease NLGI #2 or equivalent)

Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote BR-2 plus manufactured by Dow Corning, U.S.A.
Multi-purpose M-2 manufactured by Mitsubishi Oil Japan

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

Use silicone grease

Om

Apply a locking agent. Use a middle strength locking agent unless otherwise specified.

"I~

Apply sealant

Use brake fluid, DOT 3 or DOT 4. Use the recommended brake fluid, unless otherwise specified.

Use Fork or Suspension Fluid.

1) .

19. les
Service Information

19-1

Circuit Diagram

19-4

System location

19-2

Troubleshooting

19-5

System Wiring Connections/Locations 19-3

Service Information
CAUTION
Use the fully charged battery for troubleshooting. Do not diagnose the TeS with a charger connected to the
battery .
On removal and installation of the wheel sensors/wheels. be careful not to damage the wheel sensors and pulser
rings.
NOTE

Check the following before performing any TCS troubleshooting.


- Pre-start self-diagnosis of
- Check on all lights and indicators of
If an abnormality is found during the above checks, perform the TCS troubleshooting following the Symptom-toSystem Chart (page 19-6). The TCS is normal if no trouble is found. Go on to the check the other basic systems (e.
g. fuel system, ignition system, etc.).
Record the symptom of the problem and the problem code in MEMO before troubleshooting.
When the TCS is faulty, the TCS indicator light blinks or it comes on. The TCS does not function this time; take care
during the test ride.
The TCS OFF indicator turns on when the TCS ON/OFF switch connector is disconnected and then reconnected with i
the ignition switch ON. The TCS can be recovered this time by pushing the TCS ON/OFF switch. Take care when
removing the left side pocket.
When the rear wheel sensor or rear purser ring is replaced, perform the air gap inspection (16-51).
The TCS indicator light might blink in the following cases. If the indicator light blinks, turn the ignition switch OFF and
perform the pre-start self-diagnosis (page 19-5}. The TCS is normal if the TCS indicator light goes off.
The lCS/ignition control module was disrupted due to an extremely powerful radio wave (Electromagnetic Interference).
After riding (i.e. after the pre-start self- diagnosis), either front or rear wheel was stopped and the other wheel was
turned (for more than 10 seconds) with the engine kept running.
Example:' Only the rear wheel was turned with the motorcycle set on the main stand.
o
Only the front wheel was turned for inspection of the meter.
When, after the test ride (i.e. after pre-start self- cnaancstsj.the motorcycle is set on the center stand with the engine
running and the throttle is opened quickly with the gear engaged (rear wheel idles), the ignition timing is retarded
because of the difference in wheel speed between the front and rear wheels, which might cause afterfire and afterburn .. ~
The TCS indicator light might blink under the following conditions. Turn the ignition switch OFF to return to the normal ~
condition and perform the pre-start self-diagnosis (page 19-5) of the TCS. The TCS is normal if the TCS indicator goes
off:
Improper tire air pressure
Tire not recommended for the motorcycle is installed.
Deformation of the wheel

res

res

19-1

TCS

System Location
ASS/les model shown:

(6)

res INDICATOR

LIGHT
(7)

(4)

res ON/OFF

res

ACTIVATION LIGHTS

SWITCH

(8)

res

OFF INDICATOR

(3) ASS/leS INDICATOR LIGHT SWITCH

(2) BATTERY
(1) FUSE CASE

(9) leS/IGNITION CONTROL


MODULE
(10) BANK ANGLE SENSOR RELAY

1~""'~~~~~~\\.,L-(11) BANK ANGLE SENSOR


(12) FRONT WHEEL SENSOR
-------- -

(19)

REAR
WHEEL SENSOR

(17)
IGNITION
PULSE GENERATOR

(1S) REAR PULSER RING

(16) NEUTRAL SWITCH

(13) FRONT PULSER RING

(15) SIDE STAND SWITCH

(14) IGNITION COILS

19-2

System Wiring Connections/Locations


(2)

'J:: REAR WHEEL SENSOR

. Refer to section2, (frame/body panels

lexhaust system), for the parts that

-R. side coler (page 2-2)

res

ON/OFF SWITCH
-Top shelter
(page 2-5)

must be removed for service

For

example::~

res SWITCH<-Maintenance part


-Top shelter-s-The parts

_---_

that must be removed


for service.

INDICATOR FUSE
("METER TAIL POSIT1QW)

IGNITION FUSE
nGN ACG STARTER")
FUSE CASE
-L. side cover
(page 2-2)

~~~'"~~C
------------------------

--------

..
G
R

GREEN

RE.

0 ORANGE
Lb UGHTBLUE
L. UGHTGREEN
P PINK

WHITE

G. GRAY

0' BLACK
Y YELLOW

BLUE

O.

BROWN

t.':: FRQN
-Upp
(page

TCS

F SWITCH

::j', ABS/TCS INDICATOR LIGHT SWITCH


-Top shelter (page 2-5)

($) INDICATOR (BLACK)

-Inner screen (page 2-7)

:~:

INDICATOR (WHITE)
-trmer screen (page 2-7)

=
G/O
G~

ts u

V\jo
RJ
0

Vj

Ala G!B

(1) reS/IGNITION CONTROL

MODULE (leM) (16P)


-Upper fairing (page 2-9)

(8: reS/IGNITION CONTROL


MODULE (leM) (4P)
-Upper fairing (page 2-9)

(~)

BANK ANGLE SENSOR


-Upper fairing (page 2-9)

<C!]) BANK ANGLE SENSOR RELAY

-Upper fairing (page 2-9)

yv

61 B

AIw 61

(~l
dJ FRONT WHEEL SENSOR
-Upper fairing
(page 2-9)

19-3

TCS

Circuit Diagram
B,

81

BLACK

YELLOW ,0

BROWN
ORANGE

GREEN

REO

Lb LIGHT BLUE
Lg LIGHT GREEN
P PINK

WHITE

Gr GRAY

~BLUE

SIDE STAND SW
NEUTRAL SW

IGNITION PULSE GENERATOR

SWITCH

....... - - - . ,

.... - -

{:lllJ~I~~~~~G;':,.
y-

* 6-::=====+.

rBl-r--- g
res

reS/IGNITION CONTROL MODULE

-Z

-Z

-n

-n

G,IY
WI

"o

-i

-i

IGNITION

r-

"o
m

Q
~

o
e

"

"

-Z

-Z

2P- 81

rB r-'i{~~'::::Y====l:H
INDICATOR LIGHT
SWITCH

01y.

-i

-i

Bul G
BIIO

Bul 8'

-n

"
o
m

Q
~
n

e-

TRACTION
CONTROL

f-

o
e

"

-i

ASS CONTROL UNIT

19-4

REAR WHEEL

SENSOR

Q
~

FRONT WHEEL
SENSOR

"
o
m

res ACTIVATION L1G HT

res OFF INDICATOR

//~

: ~ ~fl

~~CS INDICATOR LIGHT

D5 0 fe. ~ a:l{.9 ~
~~ iii): ~;: ~

TACHO

METER

~R~AITERP

Q.
II:

~W/O
~R/O

t- Su/Y

lOA

I-Y/Bu
~BIIY

~LglO_

IGNITION SWITCH

lrl-I-F~B~~

R/W-=t..a

BANK ANGLE
SENSOR RELAY

3P-G

-+-----t=;~:::1J1::=~~
rRIW~/~
BANK ANGLE

9~-R

-Y/G<-+....,H--..1
,.....-+-BIIW-BIIY-

SENSOR

_BIIW:===r~BIIW~

-BIIY

-BIIY-h::::U

ENGINE STOP
SWITCH

~G,--t-----~

~Ii 2,4 ~B"/Y_


BIIWIGNITION COIL

_L.

.L.

TCS

Troubleshooting
Before Beginning Troubleshooting:

Summary of TCS pre-start self-diagnosis system


The TCS pre-start self-diagnosis system diagnoses inside the TCS/ignition control module (leM) and the electrical circuit
of the wheel sensors.
When the ignition switch is turned ON, the TCS starts the pre-start self-diagnosis to check inside the TCS/ICM for condition. Then it g08S to the stand-by mode for the wheel sensor signal. After starting the motorcycle, the pre-start self-diagnosis completes when the wheel sensor signal is transmitted to the TCSjlCM with the front/rear wheel rotating at the speed
of approximately 10 km/h (6 mile/h) or above.
If the TCS is normal, the indicator light goes off after the motorcycle starts notifying the rider that the pre-start self-diagnosis
is completed. When a problem is detected, the indicator light blinks or stays ON to notify the rider. The self-diagnosis is made
while the motorcycle is moving, too, and the indicator light blinks when a problem is detected. (The TCS OFF indicator
comes ON simultaneously.) The probable cause of the trouble can be detected from the lighting condition of the TCS
indicator light, indicator, etc. (see the following page).

(1) IGNITION SWITCH


(2) VEHICLE SPEED
(3) TCS INDICATOR LIGHT
(4) TCS OFF INDICATOR
(5) TCS ACTIVATION LIGHT

ON
OFF

o
ON
OFF

ON
OFF
ON
OFF

_ _ _ _ _ _/

.J
.J

10 km/h (6 mile/h) or above

I"

=:J------

; Pre start self diagnosis

I completes.

.JC'

Approx, 2 seconds
(Check for blown out bulb)

Pre-start self-diagnosis procedure (Pre-start check-up)


1. Turn the ignition switch ON.
2. Be sure that the TCS OFF indicator and TCS activation light turn ON for approximately 2 seconds and then go OFF,
and be sure that the TCS indicator light stays ON.
3. Start the engine and ride the motorcycle until the engine speed reaches approximately 10 km/h (6 mile/h).
4. The TCS is normal if the TCS indicator light goes OFF.

(2) TCS ACTIVATION LIGHT


(1) TCS OFF INDICATOR

TCSACTIVE

NOTE
Check the following before performing TCS troubleshooting:
- Pre-start self-diagnosis of TCS
- Check all lights and indicators of TCS
If an abnormality is found during the above checks, perform the TCS troubleshooting following the Symptom-toSystem Chart (see the following page). The TCS is normal if no trouble is found. Go on to the check the other basic:
systems (e.g., fuel system, ignition system).
I

19-5

TCS
Symptom-to-System Chart
Affected
Fuse

-0

Symptom

c,

o
0

."

--< - l>
tn

;:i: Ul

0
~o

'"a:
0

_z

;:i:

U)

0_
~-<

-"
~- ~~
~O
O~

3~

3~

Wheel
sensor
system

0"

-n
<3

0
-= ;::j:

3-<
~U>

0-~

"
0

0'

"0
0

0
0

'"
Lights and indicator of leS (except les indicator light) do
not go off 2 seconds after the ignition switch is ON.

after the ignition switch is ON or while riding.

r c s does not turn on or off by pushing the

rcs

ON/OFF switch.
When leS indicator light blinks while riding, it does not
go off by operating the indicator light switch.

-< Reference

"

U>

c,

-n
5

c,

o
0

0
0

g.

page

<

"'. "
Q
~
~

(J (J

leS indicator light blinks and leS OFF indicator turns on

"

o-<

U>

leS indicator light does not go off after the motorcycle


starts to move.

-<

U>

Lights and indicator of leS do not turn on when the


ignition switch is ON.

Indicator system

t:::::'

e-

"

(J (J (J

19-7

(J (J (J

19-10

(J

19-11

'0

(J

C)

r'.
,~

(J

19-13

(J

19-15

19-17

"
'J
(J

NOTE
Check the following before performing TCS troubleshooting.
- Pre-start self-diagnosis of TCS (page 19-5)
- Check all lights and indicators of TCS (page 19-5)
If an abnormality is found during the above checks, perform the TCS troubleshooting following the Symptom-toSystem Chart. The TCS is normal if no trouble is found. Go on to the check the other basic systems (e.g. fuel system,
ignition system, etc.}.
After troubleshooting, perform the pre-start self-diagnosis again (page 19-5) to be sure that the indicator lights of the
TCS are operating properly.

Tes
TCS OFF
INDICATOR

ABS/TCS INDICATOR
LIGHT SWITCH

ACTIVATION
LIGHT

TC.

0 ..

ABB~

\
TCS ON/OFF SWITCH

19-6

TCS
Flowcharts
NOTE
Turn the ignition switch OFF unless otherwise specified.
When the reS/ignition control module oeM) is found to be faulty, recheck the connectors before replacing the res;
ICM.
Atter troubleshooting, perform the pre-start self-diagnosis again and be sure that the indicator light of the
are
normal.
The encircled numbers in the text and connector diagrams indicate the connectors (see page 19-3).

res

Lights and indicators of the leS do not turn on when the ignition switch is ON.
NOTE

res

TeS

Tes

The indicator lights of the


must turn on when the ignition switch is ON. The
activation light and
OFF
indicator should go off approximately 2 seconds after the ignition switch is ON, while the
indicator light should not
go off unless the motorcycle starts to move.

TCS OFF INDICATOR

..

//------f-=
~

TCS ACTIVATION LIGHT

~= - - -, - '
TCSACTIVa

T""

A ....

/:=- -=:_-~
-

ICheck the indicator lights other than of TCS (e.


is.. neutral, fuel, and oil pressure switch indicator

res

~~:---:..~

"

TCS INDICATOR LIGHT

lights)

Lights go off.

( Do the indicator lights come on or go off?

Turn the ignition switch OFF.

lights come on.


Turn the ignition switch OFF.

I Check the indicator fuse ("METER TAll POSITIOW).

Check the ignition fuse ("IGN ACG STARTER")

<

Is it normal?

Burned out.

Normal

<

Are they connected securely?

Is it normal?
JNormal

Burned out.

Repair open in the BLACK/BROWN harness


between the indicator fuse and meter.

I~heck the 16P connector Cl) and 4P connector


(:' of the TCS/ICM for secure connection.

<

Replace the fuse and recheck.

-'

Poor connection

Replace the fuse and recheck.


Connect securely and recheck.

Secure connection

I Disconnect the 4P connector CS)of the TCS/ICM.I

I
(Continue to the following page)

-',r(

r :-='1
L

INDIC':-'TOR FUSE
"METER TAIL POSITION)

I11_
LI ~

IGNITION FUSE
r'IGN ACG STARTER")

~~
FUSE CASE

19-7

TCS
(From the previous page)

View from terminal side

GREffi

Check for continuity between the GREEN terminal of the TCS/ICM 4P ccnnectcr rg and body
ground.

<

No continuity

Is there continuity?

Repair open in the GREEN harness between the


TCS/ICM and body ground, or poor grounding.

Continuity
Disconnect the 16P connector <7) and 4P con-

nector

(~)

View from terminal side

of the TCS/ICM.

'L'

Turn the ignition switch ON.

8LACK/YEL
I

Check for voltage between the BLACK/yELLQW


terminal of the TCS/ICM 16P connector (j) and
the GREEN terminal of the 4P connector @

No battery voltage

Does battery voltage register?

Battery voltage

leM

Turn the ignition switch OFF.

I
TCS activation light and
OFF indicator do not
come on (See page 19-

Repair open in the BLACK harness between the


ignition fuse and bank angle sensor relay.

View from terminal side

.~

TCS indicator light does


not come on (See page
19-7).

7)
I

Repair open in the BLACK/YELLOW harness


between the bank angle sensor relay and leS/

o (To the following page.)


__

Install the 4P connector '::': of the TCM/ICM.

YELLOW/GRAY

1-

j
Connect the WHITE/ORANGE terminal (TCS
OFF indicator) and the YELLOW/GRAY terminal
(TCS activation light} of the TCS/ICM 16 P connector (lJ to the body to ground.

WHITE/ORANGE

Turn the ignition switch ON and check the TCS


OFF indicator or TCS activation light.

I
Does the light come on or go off?
Light comes on.

Faulty TCS/ICM

19-8

.L
Light goes off.

Replace the burned out bulb.


Repair open in the WHITE/ORANGE or YELLOW/GRAY harness between the TCS/ICM and
meter .

TCS
(From the previous page)

I Connect the 4P connector :]; of the TCSjICM. I

I
Disconnect the BLACK/BROWN connector
the TCS indicator light.

C1; of

I
Turn the ignition switch ON.

I
! Check for voltage between the BLACK/BROWN
connector@ofthereS indicator light and body

i
i ground.

No battery voltage

<

Repair open in the BLACK/BROWN harness


between the indicator fuse and meter.

Does battery voltage register?

Battery voltage

Turn the ignition switch OFF.

7' View from term inal side

,~

Disconnect the RED/ORANGE connector @ of


the TeS indicator light.

I I I I
I I I

I
Check for continuity between the RED/ORANGE

terminal

of the

RED/O

res

indicator light and the


. RED/ORANGE terminal of the TCS/ICM 16P
(4)

iconnector Ct,.

Is there continuity?

No continuity

Repair open in the RED/ORANGE harness


between the TCS/ICM and meter.

Continuity

Connect the TCS/ICM 16P connector ,j)and connect the BLACK/BROWN and WHITE/ORANGE
connectors of the TCS indicator light.
Replace the LED of the TCS indicator light.
Turn the ignition switch ON and check the TCS
indicator light.
Does the light come on?

Light comes on.

..

TCS INDICATOR LIGHT LED


Faulty TCS indicator tight LED

Light goes off.


Faulty TCS/ICM

19-9

TCS
Indicator lights of the TCS (except TCS indicator light) do not go off 2 seconds after the ignition switch is ON.
NOTE

res

res

res

The indicator lights of the


must come on when the ignition switch is ON. The
activation light and
OFF
indicator should go off approximately 2 seconds after the ignition switch is ON, while the
indicator light should not
go off unless the motorcycle starts to move.

res

Turn the ignition switch OFF.

Disconnect the 16P connector


nector (~, of the TCS/ICM

mand

4P con-

Turn the ignition switch ON and check the


activation light and res OFF indicator.

res

Do the lights come on or go off?

Lights come on

Lights go off.

Faulty TCS/ICM
TCS OFF INDICATOR

TCS ACTIVATION LIGHT

TCS ACTIVE

19-10

1 Tce

I~

Repair short in the YELLOW/GRAY harness


(TeS activation light) or WHITE/ORANGE harness (TeS OFF indicator) between the res/
leM and meter .

TCS
TCS indicator light does not go off after the motorcycle starts to move.
NOTE
If the

res

is normal, the wheel sensor system self checks and the

res indicator light goes off after the motorcycle starts

to move.

res

Turn the ignition switch OFF.

INDICATOR LIGHT

Check the l6P connector (]) and 4P connector


.]) of the TCS/ICM for secure connection.

Are they connected securely]

Poor connection

Secure connection

i
Disconnect the 4P connector () of theTCS/ICM,1

j
Check for continuity between the GREEN terminal of the TCS/ICM 4P connector (f{;: and body
ground

j
<

Is there continuity?

No continuity

Continuity

Repair open in the GREEN harness between the


TCSjlCM and body ground, or poor grounding

Check the wheel sensor connectors ({D for front

,nd 0: for rear) for secure connection.

<

Are they connected securely?

Poor connection

Connect securely and recheck.

Secure connection

Disconnect the ,6P connector ct, of the TCS/


leM and the wheel sensor connectors (,n, for
front and .'L for rear).

Check for continuity between the 16P connector

(-t terminals of the TCS/ICM and the main harness side terminal of the wheel sensor cormectors eft: for front and CD for rear)

(Continue to th

following page)

View from terminal side


'J)

ill)FRONT,

BLUE/GREE~EEN

L-@-J

~ cfb
'J) REAR:

BLUE/BROWN

BLUE/BROWN

C@--J

19-11

TCS
(From the previous page)

<

No continuity

Is there continuity?

Continuity

Repair open in the BLUE/GREEN or BLUE!


BROWN harness between the TCSjlCM and
wheel sensor connectors.

Inspect the wheel sensor and the area around the


wheel sensor as instructed under Problem code
5 or 6 of the ASS troubleshooting (page "91'95: 16-A-37 or 16-A-40jAfter '95; 16-8-23
or 16-8-26).

<

I, the wheel

,~n,o, no,m,I'

>

Abnormal

Repair short in the RED/ORANGE harness


between the TCS/ICM and meter.

Faulty TCSjlCM

19-12

TCS
TCS indicator light blinks and TCS OFF indicator comes on after the ignition switch is turned ON or while
riding.
NOTE

I . res indicator light should go off after the motorcycle starts to move.
Turn the ignition switch OFF.

res OFF IND ICATOR


TC.

D"

C[, of the TCSjlCM for secure connection.

Are they connected securely?

Poor connection

Secure connection

Disconnect the 4P connector

LIGHT

/~~

Check the l6P connector CJ) and 4P connector

res INDICATOR

TC.

-"T'"''

TC.

Connect securely and recheck.

V iew from terminal side

of the TCS/ICM.

Check for continuity between the GREEN terminal of the TCS/ICM 4P connector ::E' and body

, ground.

Is there continuity?

No continuity

Continuity

Repair open in the GREEN harness between the


TCSjlCM and body ground, or poor grounding.

Check the wheel sensor connectors ( @) for front


and CD for rear) for secure connection.

<

Are they connected securely?

Poor connection

Connect securely and recheck.

I Secure connection

l
Disconnect the 16P connector CD of the TCS/
ICM and the wheel sensor connectors (CI9' for
front and (j) for rear).

(Continue to the following page)

19-13

TCS
(From the previous page)

I
Check for continuity between the l6P connector
terminal of the TCS/I~M and the main
harness side terminals of the wheel sensor con-

.t:

nector

(rLO

View from terminal side

CD

:[ilFRONT"

BLUE/GREE~REEN

for front and ~(: for rear).

%
~~
(t

BLUE/B~ROWN

~T

:T REAR:

I I I I

q:tJ

BLACK/O RANG@ BLACK/IORANGE

Is there continuity?

No continuity

No continuity

Repair open in the BLUE/GREEN, BLUE/


BROWN,
or
BLACK/ORANGE
harness
between the TCS/ICM and wheel sensor connectors.

Inspect the wheel sensor and the area around the


wheel sensor as instructed under Problem code
5 or 6 of the ASS troubleshooting (page '91'95: 16-A-37 or 16-A-40/After '95: 16-8-23
or 16-8-26).

Is the wheel sensor normal?

INormal

j
Faulty TCSIICM

19-14

Abnormal

Service as instructed in the ASS


shooting and recheck.

trouble-

TCS
TCS does not turn ON or OFF by operating the TCS ON/OFF switch.
NOTE
The

res

should automatically turn ON when the ignition switch is ON. The TCS can then be turned ON/OFF by

operating the TCS ON/OFF switch.


Turn the ignition switch OFF.

j
Check the res ON/OFF switch connector ':tJ for
secure connection.

<

Poor connection

Is it connected securely?

\
Connect securely and recheck.

Secure connection

Discormest the

View from terminal side

res ON/OFF switch connector

(2).

Check for continuity between the switch side


connector (2) terminals.
Push:No continuity
Release: Continuity

Abnormal

Is it normal?

Faulty TCS ON/OFF switch

Normal
Check the 16P connector U) and 4P connector
':a:, of the TCS/ICM for secure connection.

Poor connection
Are they connected securely?
c===~;:tI~~~~*~~~~~:===>-~~~"":"'~"-_
Connect securely and recheck.
Secure connection

Disconnect the 4P connector @oftheTCS/ICM.


Check for continuity between the GREEN termi

nal of the TCSjlCM 4P connector

ca:, and body -

ground.

Is there continuity?
Continuity

No continuity

Repair open in the GREEN harness between the


TCS/ICM and body ground. or poor grounding.
View from terminal side

(Continue to the following page)

..

GREEN

n
19-15

TCS
(From the previous page)

View from terminal side

j
Disconnect the 16P connector

nector

res

ill

and 4P con-

of the TCSjICM, and disconnect the


ON/OFF switch connector C?).
()

Check for continuity between the TCS/ICM 4P


connector (~) terminal end main harness side
connector (2:: terminal of the TCS ON/OFF switch, and between the TCS/ICM , 6P connector
([; terminal and harness side connector ct, terminal of the TCS ON/OFF switch.

iJ)

-,
ORANGE

jYElLOW

<

No continuity

Is there continuity?

Continuity

Repair open in the GREEN harness or ORANGE


/YELLOW harness between the TCS/ICM and
TCS ON/OFF switch connector.
View from terminal side

With the TeS ON/OFF switch connector

disconnected, check for continuity between the


16P connector (7) terminal and 4P connector ':ID
of the TCS/ICM.

tj)

~tB
ORANGE/YELL~EEN

<

Is there continuity
No continuity

Faulty TCS/ICM

19-16

Continuity

Repair short in the ORANGE/YELLOW harness


between the TCS/ICM and TCS ON/OFF switch.

TCS
TCS indicator light blinks while riding and does not go off by operating ABS/TCS indicator light switch.
NOTE

res

res

When the TCS is faulty and the


indicator light blinks and TCS OFF indicator light comes on, the
indicator light
can be turned off by operating the ABS!TCS indicator light switch. (However. the TCS OFF indicator cannot be turned
off.)
TCS INDICATOR LIGHT

Turn the ignition switch OFF.

I
Check the ABS!TCS indicator light switch connector (J) for secure connection.

-- -

~=U=:4 ~".
=--

->
(

Is it connected securely?

- - -

--

Poor connection
--------

Secure connection

Connect securely and recheck.


View from terminal side

Disconnect the ABS!TCS indicator light switch

connector (J).

I
Check for continuity between the switch side
connector Q) terminals of the indicator light

switch.
Push: No continuity
Release: continuity

Is it normal?

Abnormal

Faulty ABS/TCS indicator light switch

Normal

Check the 16P connector (f; and 4P connector


(8~' of the TCS/ICM for secure connection.

Are they connected securely?

Poor connection

I Secure connection

: Disconnect the 4P connector

wtE

View from terminal side

ca; of the reS/ICM.

Check for continuity between the GREEN terminal of the rCS/ICM 4P connector :Je and body
: ground.
~

Is there continuity?
Continuity

Connect securely and recheck.

No continuity

Repair open in the GREEN harness between the


TCS/ICM and body ground, or poor grounding.

(Continue to the following page)

19-17

TCS
(From the previous page)

View from terminal side

m~

CD and 4P connector ,]::; of the TCS/ICM, and disconnect the


ABS/leS indicator light switch connector c:~_\
Disconnect the l6P connector

GR~EN

Check for continuity between the 4P connector

Cit terminal of the TCS/ICM and the main harness side connector :,3) terminal of the ABS/leS
indicator light switch, ,nd between the 16P
connector oj) terminal of the TCS/ICM and the
main harness side connector CJ" terminal of the
ASS/leS indicator light switch.

.tp

(])

GRAY/yELLQW
I

<

Is there continuity?

No continuity

Continuity

Disconnect the WHITE_ connector of the ABS I


TCS/ICM (page 16-3-n_t,).
:
,

I
With the ABS/leS indicator light switch connector C~: disconnected, check for continuity
between the 16P connector CD terminal and 4P
connector ;~!L terminal of the TCSjICM.

<

Is there continuity?
No continuity

Install the 4P connector :~; of the TCS/ICM and i


the WHITE connector (page 16-3-(C~') ofthe ABS
ECU. (Do not yet install the ABS/TCS indicator
light switch connector ':1.:' and 16P connector CD
of the TCSjICM.)

Turn the igntion switch ON.

(Continue to the following page)

19-18

GRAY/YELLOW

Repair open in the GREEN harness or GRAY/


YELLOW harness between the TCS/ICM and
ABS;TCS indicator light switch connector.
View from terminal side

~tp
GR AY/YELLQW

Continuity

GREEN

Repair short in the GRAY!yELLOW harness


between the TCS/ICM and ABS;TCS indicator
light switch.

TCS
(From the previous page)
View from terminal side

(~
GRAY/YELJ

Check for voltage between the main harness side

EN

connector (j:: terminals of the ABS!TCS indicator


light switch.

Is there approximately 5V?

No

. Faulty ASS ECU

Yes

Faulty TCS/ICM

19-19

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

...

Replace the partts] with new onets) before assembly.

Is :;O=ooLI

Use special tool

IOP~OOLI

Use optional tool. Use the same procedure you use to order parts.

Torque specification.

10 Nm (1.0 kg-m, 7.2 ft-lb)

10 (1.0, 7.2)

-:71

-,
..~

Use recommended engine oil, unless otherwise specified.

Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1

Use multi-purpose grease (Lithium based multi-purpose grease NLGI #2 or equivalent)

Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote BR-2 plus manufactured by Dow Corning, U.S.A.
Multi-purpose M-2 manufactured by Mitsubishi Oil Japan

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

Use silicone grease

Om

Apply a locking agent. Use a middle strength locking agent unless otherwise specified.

"I~

Apply sealant

Use brake fluid, DOT 3 or DOT 4. Use the recommended brake fluid, unless otherwise specified.

Use Fork or Suspension Fluid.

1) .

20. Electric Starter


Service Information

20-1

Starter Motor Removal/Installation

System Location

20-2

Starter Motor Disassembly/Assembly 20-7

Troubleshooting

20-4

20-6

Service Information

~tion

switch OFF before servicing the starter motor. The motor could suddenly start. causing

serious injury.

A weak battery may be unable to turn the starter motor quickly enough, or supply adequate ignition current.
If the current is kept flowing through the starter motor to turn it while the engine is not cranking over, the starter motor
may be damaged.
For the following component inspections, refer to the following pages; for the parts locations, see page 20-2 of this
manual (System Location).

Clutch switch diode

Section 24 of the Common Service Manual.

Starter motor

Section 24 of the Common Service Manual.


-

Clutch switch

Section 25 of the Common Service Manual.

Neutral switch

Section 25 of the Common Service Manual.

Ignition switch

Check for continuity on the continuity chart of the Wiring Diagram, section 22.

Side stand switch

See page 21-4.

20-1

Electric Starter

System Location

(3) BANK ANGLE


SENSOR RELAY

Standard Model

(4) BANK ANGLE SENSOR

(2) NEUTRAL LIGHT

(13) ENGINE STOP SWITCH

(1) SIDE STAND

(5) STARTER SWITCH

INDICATOR LIGHT IYIfit,~'2

112)IGNITION--,If7~~+~~~~~~~~-;--:--;;
:j

(6) NEUTRAL SWITCH

SWITCH

- -

(10) STARTER MOTOR

---(9) SIDE STAND SWITCH


(7) BATIERY
(8) STARTER RELAY SWITCH

'91-'9 4

I---

--':-

SENSOR RELAY

(4) BANK

ANGLE
SENSOR

--

(5) STARTER SWITCH

VIR

G/R
R

MOTOR

1M

(7) BATIERY

TO REGULATOR/RECTIFIER

(3) BANK ANGLE

~O)STARTER

R/W

BIIY

(12) IGNITION SWITCH

FUSE lOA

co R/BI

BI

-'

I
-'-

GIW
Lo'11) CLUTCH SWifCH
FUSE lOA
(1) SIDE STAND

r;;

BIIBr ~

_____ -

~lg/R

32

INDICATOR LIGHT
(2) NEUTRAL
LIGHT

01000

Lg

(6) NEUTRAL
SWITCH

20-2

~
.......

YIBI
)

G/R

-J
L

G;;)
(9) SIDE STAND
SWITCH

Electric Starter

ABS/TCS 0' lBS-ABS/TCS Model

ABS/TCS model shown"

(2) SIDE STAND INDICATOR LIGHT

111 NEUTRAL

L1GHTJ~~. _~
~\,

1121 IGNITION
__
SWITCH -~y.d.

(11) CLUTCH
SWITCH

:::

~:::::~~:~:::~:RE~Y

:-V:',

(13) ENGINE STOP SWITCH


STARTER SWITCH

;:::=lJ2,.--(5)

(6) NEUTRAL SWITCH

(9) SIDE STAND

SWITCH
(8) STARTER RELAY SWITCH

After -94

, - - - - - - , (1 0) STARTER
MOTOR

(7) BATTERY

MAIN FUSE 30A

---e-

Y-+--t-J

(8) STARTER RELAY SWITCH

(12) IGNITION SWITCH


FUSE lOA
~R/BI

G/R

IL-_-T~-G/R

BI

Y/R

G/R

(5) STARTER

t-BIIl

BIBI

R/W-

SWITCH

2Y-6-

CLUTCH
DIODE

sl/w

L9

BI/Y

R:+=~=t1 (13)
~

(4) BANK
ANGLE
SENSOR

( 1 1) CLUTCH
SWITCH

G/W

ENGINE STOP
SWITCH
(6) NEUTRAL
SWITCH

(3) BANK ANGLE


SENSOR RELAY

20-3

Electric Starter

Troubleshooting
Starter motor will not tum
Check for a blown out main or sub fuses before servicing.
Make sure the battery is fully charged and in good condition.

Check for loose or poorly connected battery


L terminals, and open or shorted battery cable.

Abnormal

Normal
Check for loose or poorly connected starter relay
switch terminals and 4P connector.

Abnormal

Normal

Check for loose or poorly connected starter motor


cable, and open cable.
I

Abnormal

Poorly connected motor cable


Open circuit in starter motor cable

Normal
Turn the ignition switch ON and the engine stop
switch to "RUN" position. Push the starter switch
and check for a "click" sound from the starter
relay switch.

Connect the starter motor terminal to the battery


positive terminal directly. (Because a large amount
of current flows, do not use thin wires).

Clicks

St~rter
motor
turns

No click

Turn the ignition switch OFF. Disconnect starter


relay switch connector, and check the relay coil
ground wire lines as below for continuity:
1 . Green/Red terminal-clutch switch diodeneutral switch line (with transmission in neutral
and c1uch lever released.)
2. Green/Red terminal-clutch switch-side stand
switch line (in any gear except neutral, with the
clutch lever pulled in and the side stand up.)

No continuity

Starte1r motor
does not turn

Faulty starter motor

loose or disconnected starter motor cable


Faulty starter relay switch

Faulty neutral switch


Faulty clutch switch diode
Faulty clutch switch
Faulty side stand switch
Loose or poor contact of connector
Open circuit in wire harness

Continuity

Connect the starter relay switch connector. Turn


the ignition switch ON. With the starter switch
pushed, measure the starter relay voltage at the
starter switch connector (between Yellow/Red
(+) and ground (-)).

No voltage

Battery Voltage Measured

l Check the starter relay switch operation. ~


Abnormal

20-4

..

Normal

Faulty ignition switch


Faulty starter switch
Faulty bank angle sensor
Faulty bank angle sensor relay
Faulty engine stop switch (After '94)
Blown out main or sub fuses
loose or poor contact of connector
Open circuit in wire harness
loose or poor contact of the starter relay
switch co nn ecto r

Electric Starter
The starter motor turns when the transmission is in neutral, but does not turn with the transmission in any position
except neutral, with the side stand up and the clutch lever pulled in.

Check the side stand indicator operation with


the ignition switch ON.

Abnormal

Normal

LCheck the clutch switch operation.

Abnormal

Faulty side stand switch


Burnt bulb
Open circuit in wire harness

Faulty clutch switch

Faulty side stand switch

Open circuit in wire harness


Loose or poor contact of connector

Normal
Check the side stand switch (page 21 4).

Abnormal

Normal

Starter motor turns slowly


Low specific gravity in battery (or dead battery)
Poorly connected battery terminal cable
Poorly connected starter motor cable
Faulty starter motor
Poorly connected battery ground cable
Starter motor turns. but engine does not turn
Starter motor is running backwards
- Case assembled improperly
- Terminals connected improperly
Faulty starter clutch
Damaged or faulty starter pinion
Damaged reduction gears
Starter relay switch "clicks". but engine does not turn over
Crankshaft does not turn due to engine problems
Excessive reduction gear friction

20-5

Electric Starter

Starter Motor Removal/Installation

(7)

(B)qJ-,

. ""0)~---=:='(2)
(4)
(5)

Requisite Service
Middle fairing removal/installation (page 2-8)
With the ignition switch "OFF", remove the negative cable at the battery before servicing the starter motor.
Procedure

(11
(21
(3)

(4)
(5)
(6)

(71

(BI

Removal Order
Heat guard mounting nut
Starter motor mounting bolt
Starter motor heat guard
Starter motor terminal cover
Terminal nut
Starter motor cable
Starter motor assembly
O-ring

20-6

O'ty

Remarks
-

Installation is in the reverse order of removal.

1
2

1
1
1
1
1
1

Electric Starter

Starter Motor Disassembly/Assembly


('0)

(3)f1I
(6)

I' )

..'"

cs
III

"

"
/

~~

~\

<

(2)

I
I

l/

")~(

(6)

(8)

(4)

(9)

Requisite Service

Starter motor removal/installation (page 20-6)


Procedure

Disassembly Order
Starter motor cover bolt
(2)
Front cover
(3)
Packing
(4)
Insulator washer
(5)
Shim
(6) Rear Cover
(7) Packing
(8)
Shim
(9) Armature
(10) Brush holder

I Q'ty

(1)

,,
,
,,
,,

Remarks
Assembly is in the reverse order of disassembly.

Note the location and number of the shims.

Note the location and number of the shims.

20-7

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

...

Replace the partts] with new onets) before assembly.

Is :;O=ooLI

Use special tool

IOP~OOLI

Use optional tool. Use the same procedure you use to order parts.

Torque specification.

10 Nm (1.0 kg-m, 7.2 ft-lb)

10 (1.0, 7.2)

-:71

-,
..~

Use recommended engine oil, unless otherwise specified.

Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1

Use multi-purpose grease (Lithium based multi-purpose grease NLGI #2 or equivalent)

Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote BR-2 plus manufactured by Dow Corning, U.S.A.
Multi-purpose M-2 manufactured by Mitsubishi Oil Japan

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

Use silicone grease

Om

Apply a locking agent. Use a middle strength locking agent unless otherwise specified.

"I~

Apply sealant

Use brake fluid, DOT 3 or DOT 4. Use the recommended brake fluid, unless otherwise specified.

Use Fork or Suspension Fluid.

1) .

21. Lights/Meters/Switches
Service Information

21-1

Bank Angle Sensor

21-5

System Location

21-2

Fuel Cut-off Relay

21-5

Headlight

21-3

Fuel Pump Inspection

21-6

Front Turn Signal

21-3

Fuel light Test Circuit Inspection

Rear Turn Signal and BrakejTaillight

21-3

Fuel Pump Removal/Installation

21-6
21-7

Position Light

21-4

Indicator Bulb Replacement

21-4

Combination Meter Removal/


Installation

21-8

Side Stand Switch

21-4

Combination Meter Disassembly/


Assembly

21-10

Service Information

~en

headlight bulb becomes very hot while the headlight is ON, and remain hot for a while after it is turned
OFF. Be sure to let it cool down before servicing .
Use an electric heating element to heat the water/coolant mixture for the fan motor switch inspection. Keep all
flammable materials away from the electric heating element. Wear protective clothing, insulated gloves and eye,
protection.

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 its 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 motorcycle.
For the following component locations, see page 21-2 of this manual {System Location}; for inspections, refer to the
applicable pages.
Component
Clutch switch
-

Inspection method

Remarks

j Section 25 of the Common Service Manual

Front brake light switch

Section 25 of the Common Service Manual

Horn

Section 25 of the Common Service Manual

Handlebar switches
Ignition switch

Check for continuity on the continuity chart of Switch connectors are located behind the
the Wiring Diagram, section 22.
instruments (page 1-25}.

Neutral switch

Section 25 of the Common Service Manual

--

IrORQUE: 12 Nom (1.2 kq-m, 9 ft-lb]


! Apply

Section 25 of the Common Service Manual

Oil pressure
switch/indicator
light

Oil pressure check: Section 4 of the Comman Service Manual.


Oil pressure switch torque: 12 Nom (1.2
kg-m, 9 ft-Ib)

,
Fan motor switch

Seetin 25 of the Common Service Manual

Rear brake light switch

Section 25 of the Common Service Manual

Turn signal lights

sealant to the threads.

i Section 25 of the Common Service Manual

21-1

Lights/Meters/Switches

System Location
Standard model shown:
(2) BANK ANGLE SENSOR

(3) FRONT BRAKE LIGHT SWITCH


(4) ENGINE STOP SWITCH

(1) IGNITION SWITCH


(5) STARTER SWITCH
(16) DIMMER SWITCH
(6) THERMO SENSOR
(15) TURN SIGNAL
SWITCH

(7) OIL PRESSURE SWITCH


(8) REAR BRAKE LIGHT SWITCH

(14) CLUTCH SWITCH

(13) HORN SWITCH c:;;;<,~,D:~~


p

'-----

I, I,

(12) FAN MOTOR SWITCH

(11) NEUTRAL SWITCH


(10) SIDE STAND SWITCH
(9) BATIERY

21-2

Lights/Meters/Switches

Headlight

(1) CONNECTOR
(2) "TOP" MARK

(3) BULB
(4) RETAINER

Bulb Replacement
Remove the middle fair"mg inner cover (page 2-7).
Disconnect the connector and remove the dust cover.
Remove the bulb by removing the bulb retainer.
Install a new headlight bulb.
CAUT"'O,,N

If you touch the bulb with your bare hands, clean it !


with a cloth moistened with alcohol to prevent early

failu.~'e:.~

(5) DUST COVER

NOTE

121 BULB rm~cc-~

Install the dust cover with its 'TOP" mark facing up.

Front Tum Signal

(1) BULB
SOCKET

Bulb Replacement
Remove the rear view mirror (page 2-8).
Remove the bulb socket by turning it counterclockwise.
Remove the bulb by turning it counterclockwise while pushing
in the bulb.

J,

';::

NOTE

Check that the rubber seal is in good condition and

replace it if

neCeCeC,,~a~,"y~.

.
------

Installation is in the reverse order of removal.


Install the rear view mirror (page 2-8).

(1) END SHIELDS

Rear Turn Signal and Brake/


Taillight
Bulb Replacement

'I,
,

Remove the seat (page 2-2)_


Fold the rear end shields as shown.

"

I,"

Remove the bulb socket by turning it counterclockwise.


Remove the bulb by turning it counterclockwise while
pushing in the bulb.

(n BULB ..----,;:-

y/

NOTE

Check that the rubber seal is in good condition and


replace it if necessary.

'-----'--

...J

Installation is in the reverse order of removal.


Install the seat (page 2-2).

21-3

Lights/Meters/Switches

Indicator Bulb Replacement

(11 BULB

Remove the instrument panel (page 2-7).


Remove the bulb socket and bulb.
Install a new bulb and install the removed parts in the
reverse order of removal.

(2) BULB SOCKET

Side Stand Switch

(1) 3P CONNECTOR

(2) SIDE STAND

Inspection
Remove the left side cover (page 2-2).
Disconnect the side stand 3P connector (green) and check
for continuity between each terminal as shown below.
There should be countinuity between the C-C) positions on
the continuity chart.
Green/
White
Side stand down
Side stand up

Yellow/
Black

Green

(4) DOWN

.rv

Replace the side stand switch if Continuity is not as shown in


the chart above.

Replacement
Remove the pivot cover (page 2-5).
Diconnect the 3P connector (green} and release the wire
from the clamp.
Remove the bolt and side stand switch.
Install the side stand switch aligning the stop pin on the
frame with the cut out of the switch and the pin on the
switch with the hole in the side stand
Secure the side stand switch with the bolt.
Torque: 10 Nom (1.0 kg-m , 7 ft-Ibl
Install removed parts in the reverse order of removal.

21-4

ifi;/

"<,

t?g!

(3IALlGN
(4) BOLT CUT OUT

Lights/Meters/Switches

Bank Angle Sensor

(1) BANK ANGLE SENSOR

Inspection
Remove the upper fairing (page 2-9).
Turn the ignition switch "ON" and measure voltage between
the following terminals of the bank angle sensor with the
3P connector (green) connected.
Terminals

Standard voltage

Red/White (+) and Green (-)

I-

White (+) and Green H

0-3.0V
10.0-14.0V

Remove the screws and bank angle sensor.


Turn the ignition switch "OFF".
Place the bank angle sensor horizontal with the connector
connected and turn the ignition switch "ON'".
The bank angle sensor is normal if the bank angle sensor
relay clicks and the power supply line is closed.
Position the bank angle sensor at approximately 50 degrees
to the left or right with the ignition switch ~ON".
The bank angle sensor is normal if the bank angle sensor
relay clicks and the power supply line is open.

(2l3P CONNECTOR

(2) 50' BANK ANGLE


POSITION

50~

(1) NORMAL
POSITION

(approximately]

0'

~-

NOTE
If you repeat this test, first turn the ignition switch
"OFF~, then back to "ON" before you try the test
again
Installation is in the reverse order of removal.

(eoorcxunetefvl

ABS;TCS MODEl:

STANDARD MODEl:

y/1
! /") '~\\L
t t s.

Fuel Cut-off Relay

//(;,

".. . . .':c. -

Gasoline is extremely flammable and is explosive


under certain conditions. Work in a well ventilated
area.
Do not smoke or allow flames or sparks in your
work area or where gasoline is stored.

, ,

:'

- - - -

Remove the instrument panel (page 2-7).


Check the sub fuse (10A:IGN, STARTER, ACG)_
Check the relay 4P connector (white) for looseness and
corrosion.
Disconnect the relay connector and test the wires to the
main harness side.
1tem

~-/:,

"I
I

7;0~~~i~1 :
;

I"

... I

'il

I,

i-----i-

{ll FUEL CUT-OFF RELAY

1I

Standard

f
Between
the BI/W (+) and body ground Battery voltage
(-) with the ignition switch "ON".

'should register

Bu/Y wire between the pump relay and


fuel pump.

Continuity

Br/R wire between the fuel pump relay


and fuel pump.

Continuity

Green wire and body ground

Continuity

(2) 4P CONNECTOR

21-5

Lights/Meters/Switches

Fuel Pump Inspection

(1) FUEL CUT-OFF RELAY

Turn the ignition switch "OFF".


Remove the instrument panel (page 2-7).
Remove the seat (page 2-2).
Disconnect the fuel outlet tube at the fuel filter.

c0

Gasoline is extremely flammable and is explosive


under certain conditions. Work in a well ventilated
area.
Do not smoke or allow flames or sparks in the your
work area or where gasoline is stored.
Short the Black and Brown/Red wire terminals with a
jumper wire.
Turn the ignition switch "ONU and.1.et fuel flow into a graduated beaker for 5 seconds, then mm the ignition switch
"OFF" .
Multiply the amount in the beaker by 12 to determine the
fuel pump flow capacity per minute.
Fuel pump flow minimum capacity:
640cc (0.676
0.563 Imp qtl!minute

u.s.ei.

(2) GRADUATED BEAKER

Fuel Light Test Circuit Inspection


Turn the ignition switch "ON".
The fuel indicator light should come on for few seconds, then
go off.
If it does not come on, check the fuel sensor circuit.

If there is no problem with the circuit, remove the upper


fairing (page 2-9) and disconnect the indicator light check
unit connector.
Measure the voltage between the Black/Brown and Green/
Black wires of the connector at the wire harness side.
Battery voltage should be measured.
If battery voltage is measured, replace the check unit.
If battery voltage is not measured, check the wire harness for
an open, short circuit or loose connection.

21-6

(1) INDICATOR LIGHT CHECK UNIT

.:

;~,' ;\"U_~'
I I ,

Lights/Meters/Switches

Fuel Pump Removal/Installation


(1)---------

(5)--------i~A

-...

'

"~"

Gasoline is extremely flammable and is explosive under certain conditions. Refuel in a well-ventilated area with
the engine stopped. Do not smoke or allow flames or sparks in your work area or where gasoline is stored .
Keep away from flames or sparks. Wipe up spilled gasoline at once.

Requisite Service

Seat removal/installation (page 2-2l


Procedure

Q'ty

Remarks
-

Removal Order
(1) Fuel outlet tube
(2) Fuel pump/level sensor connector
(3) I Fuel pump mounting nut
(4)
Fuel inlet tube
(5)
Fuel pump assembly
(6) Base packing

Installation is in the reverse order of removal.


1

3
6
1
1
1

21-7

Lights/Meters/Switches

Combination Meter Removal/Installation


Standard Model

Cl\"",::.::::::::::;;-__~_~~
9 (D.9,

6.5)

(5)

, ,,
(4)

Requisite Service

Instrument panel removal/installation {page 2-7}


Procedure

Q'ty

Remarks
-

Removal Order
(' ) Meter mounting bolt
(2)
Collar
(3) Speedometer cable
(4)1 Meter connector
15) , Meter assembly

21-8

Installation is in the reverse order of removal.

3
3

,
3

lights/Meters/Switches

ABS/TCS Model

141

~'~-------=111

9 (0 "9 ,

6.51

(21

131
(31
Requisite Service
Instrument panel removal/installation (page 2-7)
Procedure

(1)
(2)
(3)
(4)

Removal Order
Meter mounting bolt
Speedometer cable
Meter connector
Meter assembly

O'tv

Remarks
Installation is in the reverse order of removal.

3
1
5
1

21-9

Lights/Meters/Switches

Combination Meter Disassembly/Assembly


Standard Model
(91
(61

(31

(17)

Requisite Service
Combination meter removal/installation (page 21-8)
Procedure
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11);
(12)
(13)
(14)
(15)
(16)
(17)1
(18)1

Disassembly Order
Nut/washer
Screw
Meter visor
Reset knob
Screw/Band
Indicator housing
Screw
Cover
Indicator lens
Terminal screw
Fuel gauge
Temperature gauge
Screw
Speedometer gear box
O-ring
Speedometer
Screw
Tachometer

21-10

Q'W

Remarks
Assembly is in the reverse order of disassembly.

2/2
5
1
1

3/3
1

2
1
1

6
1

1
4
1
1

1
2
1

Lights/Meters/Switches
ABS/TCS Model

(11)

(13)

(3)

(19)

(4)

11\

(6)

___-12}

(5)

18}

Requisite Service
Combination meter removal/installation (page 21-9)

Procedure

(11
(2)
(3)

(4)
(5)
(6)

171
18)
(9)
(10)
( 11)
(12)
( 13).
( 14)
(15)
(16)
(17)
(18)
(19)
(20)
(21 )
(22)
(23)

Disassembly Order
Nut/washer
Screw
Meter visor
Reset knob
Screw
Lens/case
Harness band
Screw/band
Screw
Cover
Indicator housing
Screw
Cover
Indicator lens
Terminal screw
Fuel gauge
Temperature gauge
Screw
Speedometer gear box
O-ring
Speedometer
Screw
Tachometer

O'tv

Remarks
Assembly is in the reverse order of disassembly.

2/2
5
1
1

4
1/1
1
2/2
2
1
1
2
1
1
6

1
1

4
1
1
1
2
1

21-11

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

...

Replace the partts] with new onets) before assembly.

Is :;O=ooLI

Use special tool

IOP~OOLI

Use optional tool. Use the same procedure you use to order parts.

Torque specification.

10 Nm (1.0 kg-m, 7.2 ft-lb)

10 (1.0, 7.2)

-:71

-,
..~

Use recommended engine oil, unless otherwise specified.

Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1

Use multi-purpose grease (Lithium based multi-purpose grease NLGI #2 or equivalent)

Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote BR-2 plus manufactured by Dow Corning, U.S.A.
Multi-purpose M-2 manufactured by Mitsubishi Oil Japan

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

Use silicone grease

Om

Apply a locking agent. Use a middle strength locking agent unless otherwise specified.

"I~

Apply sealant

Use brake fluid, DOT 3 or DOT 4. Use the recommended brake fluid, unless otherwise specified.

Use Fork or Suspension Fluid.

1) .

22. Wiring Diagram

(Standard Model) ('91-'94)


1

TAClOIETER

LEFT TURN SIGNAL ItOCATOR

5 ~L

PRESSURE

2 FUELINDICATOR

3 HIGH BEAM rfolllCATOR


4 rUTRAL IroCATOR

7 RIGHT T\"qN SIGI

SIDE STAND INC

COOLANT TEMPERATURE GAUGE

FUEL GAUGE

SPEEDOMETER

IADlJGHT RElAY

(L.o)

~~:/;BI===~~l
4PR

HEAlX.JGHT RElAY (Hi)

~;t

~~~::'/BI;::==mn

CLUTCH DIODE

~!~r

4PW

RIGHT FRONT TURN SIGNAL

IADl.lGHTS

1~2Y45/45W12

12Y32/3CP

a./II
WIBl

IIIV

ViR

Ill/Ii
will

Ill/R

Brill
rlBI
BI

o
Br

G/R
II/Ill
Br/R
ill",

.
FUSE BOX

A lOA

(NEUTRAL_OIL_ TEMPeTACHO-

~~R~;~SOR

HORN)

B lOA (FRONT POSITION METER LIGHTTAIL)

ill ~

c:r-

TURN SIGNAL RELAY

C 20A (HEADLIGHT)

o lOA (IGNITION. STARTER. ALTERNATOR)


E IDA (TI.llN SIGNAL' FRONT.
F IDA (CLOCK)
G lOA
CLUTCH SWITCH

0- '-0
\..

PR

PL

Lo

-0
( )--0- k)

DIMMER SWITCH

.J

}--Q

(FAN MOTOR)

11JRN SIGNAL.DIMMERHORN SWITCH

TURN SIGNAL SWITCH

REAR BRAKE)

Lo
IN)

Hi

HORN SWITCH

Hi

~BAT3
FREE
PUSH

STARTER SWITCH

ENGlE STOP SWITCH

IG

BAT2

BAT!

0- -0

PUSH

BAH

0-1-

FREE

OFF
RUN

ST

0- -0

JGI<T

:ATOR
Il HJlCATOR

IGNmON CONTROL
MODULE

ENGINE STOP
SENSOR RELA V

.~

ENSOR

~iii

III

I/W
I/G

1/11

.a
riG

~:::r:::r:J OGHT REAR TURN ~GN'L

.b

I/Br

12V32C'

!D]
'T"!D]

,W

,II

12Y3213CP Xl

'I~I

o ~EUTRAL J
r

IG"TKlN
PULSE GENERATOR

.:,~.~~~ ~>->~

SWITCH

'=

II lD

~:::::::c:::l:') LEFTREAR TURN %NAL


III

SlOE STAND SWITCH

>

'CPRE~S_~~

ilJrJ

~II/W

IGNITION COILS

---1......

o~:; ~ ~
REGULAToojRECTIFIER

-=-

12Y32CP

f
BI
Y
Bu ....

ALTERNATOR

BRAKE 'NC TAILLIGHTS

G
R
W

BLACK

Br

BROWN

YELLOW

ORANGE

BLUE
GREEN

Lb

1-&.

LIGHT B1LUE
LIGHT GREEN

REO
WHITE

P
Gr

GRAY

PINK

IGNITION SWITCH

FAN
ON

IG

BAT!

0- -0- -0

OFF
LOCK

0030Z- MT3 -6700

22-1

Wirig Diagram

(Standard Model) ('95)


5 OIL PRESSURE LIGHT
6 SlOE STAND INDICATOR
7 RIGHT TURN SIGNAL NllCATOR

METER LIGHTS

THERMO!
r- :

IAOlJtiHT RELAY (La)

~G'-==--"
" R

Will

HEADLIGHT RELAY (H' )

m'~G:;:==+i:tl
"W

Ill/il

W/P

"6<

CD!~t
RIGHT FRONT TURN SIGNAL

HEADLIGHTS

IZV3213CP

Ill/II
Will

~~/II
~W/II

~O/W
rr---t:g~~rGi:==I=t===-..:::;-ttt-tn~~;;dEE_"I_-+~:::l=0

Lm FRONT TU
RN SIGNAL

O/W

11V3213CP

A IDA (

mtlIM
~~~

lli+ :',
-,.CI<

'i

"!/.

TURN SIGNAL. DIMMER HORN SWITCH

22-2

B lOA
C IDA

FUSE BOX

IGNITKlN SWITCH

NEUTRAL. OIL. TEM


(FRONT POSITION. MP. TACHO HORN)

(HEADLIGHT)

ETERLIGHT' TAIL)

D IDA
E lOA
F IDA

(CLOCK) AL' FRONT. REAR BRAKE)

G IDA

(FAN MOTOR)

(IGNITION. START
(TURN SIGN
ER. ALTERNATOR)

IGNITION CONTROL

MODULE

~~~Y/FiJ

FiJ/Y

ENGINE STOP
SENSOR RLAY

81/W
G

BI~

1m
~iii

iD

~::::t=r:) RIGHT REAR TURN ~GNAL


12Yl2CP

!D]
-.. .,. . . "'t-!D]
12V3213CPX2

BRAKE AND TAILLIGHTS

~:::::c::=()
ill

f
IGNITION COILS

ALTERNATOR

LEFTREAR TURN

12Y32CP

BI
Y

BLACK

Br

BROWN

YELLOW

au

BLUE
GREEN

Lb

ORANGE
LIGHT BLUE

I..g

LIGHT GREEN

RED
WHITE

PINK
GRAY

G
R
W

Gr

IGNITION SWITCH

FAN
ON

IG

BAT!

V-r-v- -0

OFF

LOCK

0030Z-MAJ-AOOO

~NAL

(Standard Model) (After '95)

LEFT TURN SIGNAL INDICATOR


FUEL INDICATOR

5
6

OIL PRESSURE INDICATOR

HIGH BEAM INDICATOR

RIGHT TURN SIGNAL INDICATOR

NEUTRAL INDICATOR

METER LIGHTS

SIDE STAND INDICATOR

12V 3.4 W x 7

OA,"OM':::(~~f?
~_c
:~.., m30H~TS'Wi -~
=:

...J:~av-

-:

COOLANT TEMPERATURE GAUGE

oo

--

l;liiii

11l=I&:o8I/Br
!t"oG/B1

I---

1 t1

~
(
FUELGAUGE(~~

SPEEDOMETER

HEADLIGHT RELAY (LOW)

HEADLIGHT RELAY

ID~~~,~~~~il

(HIGH)~;~I~~~~rn
I!ill.FJU/~~

BI

CLOCK 12 V 1.7 W

3P~

(M/~

b~
3P G' b/W_
G

~~

~~

~_

~m ~t

-'aJ

HEADLIGHT

~r.?

~~

Lb-

iL
1f
a.=::;l>-: :n rr=!-J
m

t-UI~

(MINI

",CLUTCH:t
cO ~iii~ lf1:"ll~l!l~JII
D a:: 0011 >OIODE
C' !!'
>iii"'';;00" o_iii -' '>' -' ,
rn

co

If

HER'
ssns

CD

'E

::::l

~ co

CJ

nI

ml

.:5

CJ

f i3

J2UvR~~'2'rL

12V45/45WX~2 G

~ , r<

Ii~ 119'~~~~1

~~~ ~~

RIGHT FRONT

U~I
W/BI

ENGINE STOPSTARTER
LIGHTING SWITCH

L..-

b... d'M~i,

~i~r

Lb

il
I

lIflflfiT ~
J! 'I" ~ ~
e HUl'~.lii

Br/W

rn

';;,~

[Ilill

I~~-'~:=
...

-~

BI/Y BIIW

BU/B-,H1~~~~~'!:R:~~~~m:n#FW~rt-ttittP
~I+f+-"""
W/~::
= G~

YIR

G/Y
Y/G

WIG

Lgo
V/B

Bu/R Br/B
Gr/BI LbG/BI I/Br
o G-

BI

GIR

GIW BI/B,
R BrlW
Br/R

"~ t1J ~ - ~
111
~~ I~j ~~! }; "'~~ I~~~~'~~~Ii
It

~M~

lJ.t:4t~t!P~~
:rt]
SIGNAL'DIMM~'
1

CLUTCH SWITCH

161 11'6 l i a.'

cD

TURN
HORN SWITCH

m o

a:l

r-. 10 k)
W

DIMMER SWITCH
PR

Pl

(NI

HI

A
B
C
D
E
F
G
H

10 A
10 A
20 A
10 A
10 A
10A
10 A
5A

ON

10ro

OFF

LOCK

FAN

IG

r
I

t~~~Wlo~:
"'~'"

BAn

BAT

BAT

OP, OP2

lO 1010101-0

~IN"~
0 ~~G'L

TURN SIGNAL
RELAY

NEUTRAL, OIL, TEMp, TACHO HORN


POSITION, METER LIGHT, TAIL,
HEADLIGHT
IGNITION, STARTER,ALTERNATOR
TURN SIGNAL, BRAKE
CLOCK
FAN MOTOR
ACCESSORY

PUSH

'").

k)

SWITCH

IGNITION SWITCH

HO BATJ

~ .c:I~G~N~'T~'O~N

_H ABCDE FG
FUSE BOX

<,
FREE

:.i

HORN SWITCH

LO

a:

~t

It t1

ACCESSORY

TURN SIGNAL SWITCH

GI
(

Wirig Diagram

ENGINE STOP
SWITCH

IGNITION
CONTROL
MODULE
FAN MOTOR
SWITCH
BANK ANGLE
SENSOR

:'~/----"
,
BIlF'b~OR

LAMP
CHECK
UNIT

REAR
BRAKE
LIGHT
~
SWITCH
,
,PIMINI)

RMO
ISOR FUEL UNIT

'

a;~

~2P
"'81

C>&:

~~INI)m
ii5"'~
a:

Q5mCij

~~a

~liIMINI)

0<3

miD
82P
'ifIX'NI)

~~
",,,,

~~

iii iii

BANK
ANGLE
SENSOR
RELAY

?;J;ii5~
a:

Ol

VI

Lb.............-{ RIGHT REAR TURN SIGNAL


G~12V32CP

r~

~ BRAKE AND TAILLIGHT

IiBu

GIY~.12V 32/3CP x 2

~...t~t-~~

0........-(""'\ LEFT REAR TURN SIGNAL

G-L......l..J 12V 32CP

~>-~.5'

--,
>

4P
W

>-~

C>

0. ~

~'E~~'"
4P

MI

~~~
mm

CUT RELAY~~INI)

--' FUEL

~~

3P

~2P
I' .,

>-alOl

NEUTRAL
SWITCH

CD

SIDE STAND SWITCH

IGNITION
PULSE
GENERATOR

OIL PRESSURESWITCH

~#13' Y/Bu
~BI/W

~~r,o;
IGNITION COILS

ALTERNATOR

.,

BLACK

YELLOW

Sr

BROWN

ORANGE

Bu BLUE

Lb LIGHT BLUE
Lg LIGHT GREEN

GREEN

REO

WHITE

Gr GRAY

PINK

0030Z-MAJ-A200

22-3

Wiring Diagram

(ABS/TCS Model) ('92 '94)


'1
2
3
4
5
B
7

LEFTTURN SIGNALINDIATOR
FUELINDICATOR

HIGH BEAM INDICATOR


NEUTRALINDICATOR
OIL PRESSURE LIGHT

res OFFINDICATOR
9 res ACTIVATION
'10 res INDICATOR
'1'1 ABSINDICATOR 1
'12 ASSINDICATOR 2
B

SIDESTAND INDICATOR
RIGHTTURN SIGNALINDICATOR

FRONTBRAKELIGHTSWITCH

12'

STARTE,.,NGINE STOP
~ ~'GHTING

SWITCH

ASSles WAI

COOLANTTEMPERATURE GAUGE

FUELGAUGE

SPEEDOMETER'

lEFT FRONTT(Th;URN
SIGNAL

,,>J----"-

,"J~~~l
~~~~~~~~F

res SWITCH

\ j

r 2P~~~ II

3P
W

~~~

Cla Cl~

1J.

oru O

o~WG
12V32/3CP

O/W

3P

"~

Cl~c.:J

ASSCONTROL UNIT

IMlNllb

'U

TURN SIGNALRELAY

FRONT

rosrnox

A~H~.~~~~~:ci~~IL

IDA

NEUTRALOILT

15A

HEADLIGHT LOW

15A

HEADLIGHT

IDA
IDA
IDA
IDA

IGNITION5TARTERALTERNATOR

E
F
G

22-4

HIGH

TURN SIGNALFRONTREARBRAKE
CLOCK

FANMOTOR

~ ~

R SWITCH

H
I

ST BAT2 GND HL

ABS MAIN

lOA

'J

FRONTSOLENC'IO

lOA
20A

lOA

B2

REAR SOLENOID

PUMP

MOTOR

TCS/IGNITION
CONTROL MODULE

THERMOSTATCSWITCH
- -

~iii.~ 9" ~~t~T'sr;c'~~H)lil


U~~ m
~

l
/

WARNING LIGHTSWITCH

ENGINESTOP SENSOR

FAN MOTOR

FUEL UNIT

FRONTPUMP MOTORRELAY

REARPUMP

rm;~RELAY

r."..

ENGINESTOP

CHECKER

SOLENOID RELAY

II

FUEL INDICATOR

oa~

2P
ar

SENSCR RELAY

~~
iiic:ll.:/

iii-

ii5C'~

STARTERRELAYSWITCH

~iiiiii~

FUSE(MAIN)

ii5iii

~~"a (MINII
2P

iii

3P
"'MI

IMIMI

H'~11
'iT
w
~5

(5<3
'I" ."."

--I:H+-++tt-+tt+-O/y_--~+--~+--#t---+t--irt---tlrt---rt-Httttffit' I
BlIW

G,/8u

RIGHT REAR TURN SIGNAL

lililil;iliillj~~ij~~~i~~i~~~i~iI~~~~~~r[:::g~m'J:1 g~y1
BlIV

LylBI

VIR

Y/G,

Irrt=t;======..=~

BI/B,

VlG

Y/BI

-Br/BI

Bu/R

6~

lZV32CP

~iDLiGHTS

l,

G,/BI

GIBI
G,/Y L

13CflIZ

G/Y G

Br

gU)1ZV3ZCf'
Br

Br

-l-HI-+---1I-+- W/G;- - + + - + t+I- t--t- --t- .........


I
=i::;;F--1---l-l--GIW

G~RTURN SIGNAL

Lg/O

GIA

BI

BI!Bu

lZV32CP

a,/R
Bl/OSr/LIl

,/0

G/B,

Bu/G
W/P

GIG,
Bu/Br

PIW

O/BI

j
0' PRESSURE

e:

>-

~~~
INDICATOR

~!!,
"

~"?;

DOWN

~ ~'ij.B
LJ

1 A t"
.t

;~

IGNITION
PULSEGENfRATC/fl

~~~ ~~
.,,~:IT.2P

'lJ

1m

SIDE STAND SWITCH

I~

ur e

SWITC~ ~ ~EUTRAl
fl SWlTcJ~~~

>-C'

~
REARMODULATOR

as >->->-

PEGUlATOR RECTIFIER

8~3P

EiIt;,1l:f-rllR

~ ~~ 1~",,",
--r-----to.'olV
--L.r-------JD"BlfW

IGNITIONCOILS

...........
...........
.........
G ...........
R ...........
W ..........
BI

BLACK

YELLOW

'0

BLUE
GREEN

lb
19

RED

.........
..........

WHITE

G,

.......... GRAY

"

. ....... BROWN

. ........ ORANGE
.......... LIGHT BLUE
LIGHT GREEN
PINK

0030Z-MY3-6900

(ABS/Tes Model) ('95)

ENGINESTOPSWI

res OfF INDICATOR


res ACTIVATION
.,0 res INDICATOR
B
9

LEFTTURN SIGNALINDIATOR

2
3
4

HIGHBEAMINDICATOR

OIL PRESSURE LIGHT

SIDESTANDINDICATOR

RIGHTTURN"SIGNALINDICATOR

fUEL INDICATOR

....

NEUTRAL INDICATOR

.,2

.12V

3WX8

IG BI
OFF

RUN

ASSINDICATOR 1
ASSINDICATOR 2

1.7WX2

TACHOMETER

lCS
COOLANTTEMPERATURE GAUGE

FUELGAUGE

i
-

B~~~l_

---<

~U/RIR

LEFT FRONTTURN SIGNAL

2P

~~OO~IW====lffi1m_F~T1F~~

12V32/3CP

~~~ a~

'il ~~
t~Se9~

3P ~~Cl

FRONT WHEEL SENSORtj

-~ClUTCHSWITCH

(MINI~
TURNSIGNALPASSINGDIMMER
HORNSWITCH

FUSEBOX

IGNITION SWITCH

I~

RDN
L

f--O

PASSINGSWITCH

PR

PL

0- :::0
0--0- FO
~
0

BAT4 HI

"U

TURN SIGNALRELAY L -

FRONT MODULATOR

TURN SIGNALSWITCH

ABSCONTI

IGNlTION SWITCH

<,
ON
OFF
LOCK

FAN

IG

BAll

0::::::0:: -0

lOA

fRONT POSITIONM EW
NEUTRALOILTACHQT

15A
15A

HEADLIGHT

lOA
lOA

IGNITION S1ARTERAL T

C
D
E
F
G

lOA
lOA

LOW

HEADLIGHT HIGH

TURN SIGNAL FRONT RI


ClOCK
FAN MOTOR

nTCH

Wirig Diagram

STARTER SWITCH

<,

ST BAT1 GND

0- l-o

fREE
PUSH

H
I

HL

J
K

0- --0

RLIGHTTAIL
[MPHQRN

fERNATOR

EAR BRAKE

ASS MAIN

FRONT SOlENOID

.2

REAR SOLENOID

PUMP MOTOR

CONTROL MODULE

THERMOSTATC SWITCH

/~-s

FAN MOTOR

FUELUNIT

~
_

iil~

ENGINESTOP SENSOR

FUELINDICATOR
CHECKER
REARBRAKE
2P

~ B1

U
~~

9~
.-

LlGerrHT
SWITCH

1lI~~ "

SE;NSOR
RELAY

iiiii5

BI

STARTER RELAY SWITCH

>:

ii5~~

~l~n

ENGINE STOP

"'::"'

~~~

~~

ROL UNIT

lOA
20A
lOA

reS/IGNITION

iSWlTCH

lOA

;;;iiiiii~

FUSE(MAIN)

~l~

~5

~5

OIY----t+--tt---ftt---H--++---+l~-__1__l_.u.IUJ.UUJ I
BIIW
RIO
WIO

. .~1It: jlr~~~
./Bu

RIGHTREARTURN SIGNAL

BIIY VIR
19fBI

V/Gr

1r*=ti======"=~J1fiD~

BIISr

V/G

V/81

-8r/81

L,

Bu/R

Gr/BI

"':"'~~~V

G.IY Lb""
IY
B. G

glEn.

af~r

g~
B~

WIG

GIW

G d D R TURNSIGNAL

Lola
G/R
R

12V32CP

BllBu
ertR

BI/O

r/lll

GISr

ButG rIO

WIP
G/Gr
BulBr

,~,

1 ~~I~'
,:L
o,,"'~"'_~ 0,), ill I~
IGMITION
fEUTRAl SWITCJ
PULSE GENERATOR

mit o->

BI

~r

~ BI~
~~BI

m
o ....

CIt::!

oM

REAR MODULATOR

REGULATQRRECTIFIER

~~ l~m. ",.
IGNITION COILS

~~~ ~~
-,,~)'.I:lP

BI ......... BLACK
Y

YELLOW

Br

....... BROWN
ORANGE

Bu ......... BLUE

lb

........ LIGHT GREEN


PINK

........ GRAY

........ GREEN

RED

Lg
P

WHITE

Gr

LIGHT BLUE

0030Z-MAJ -A 100

22-5

Wirig Diagram

(LBS-ABS/TCS Model) (After '95)


ENG

8 TCS OFF INDICATOR


9 res ACTIVATION LIGHT
10

TCS ACTIVATION LIGHT

11

TCS INDICATOR LIGHT

12
13

ASS INDICATOR LIGHT

~
~
'

1,
2
3

COOLANT TEMPERATURE G AUGE

FUEL GAUGE

SPEEDOMETER

HEADLIGHT RELAY (lOW)

~BI~I
Wffl~~=:=;il
W~':

HEADLIGHT RELAY (HIGH)

B'ffl~Ettt

W
~':I

BU/B11=

HEADLIGHT

~'i.'lflfmll-.:..::=::~~~~-JjlllLIII
w~,

LEFT FRONT TURN

SIGNAL~

12V 32/3CP

3P Gr

m $O
0
g
om

~;;

m' "..,.,.

(Q~

ASS CONTROL UNIT

mlfllo",
..

FRONTWHE
SPEED SENS'6-R

~
~

TURN SIGN

D1MMER.HO~L~PSASSING.
WITCH

~.
CLUTCH
SWITCH

MOTOR DRIVER

ACCESSORY

A lOA
B15A
C 1SA
D lOA
E lOA
F lOA
G lOA
H 5 A

POSITION, METER 1I

HEADLIGHT LOW
HEADLIGHT HIGH

GHT, TAIL, NEUTRAL

,OIL, TEMp' TACHO, HORN

IGNITION, STARTER
TURN SIGNAL
. ALTERNATOR

CLOCK

' BRAKE

FANMOTOR
ACCESSORY

FRONT MODULATOR

n:s-----=22-6

;tNE STOP
ITCH

LIGHTING SWITCH

<,

'"

TLGN[

HL

"
TCS/
IGNITION CONTROL MODULE

30A

ASS MAIN

30 A

FRONT CONTROL MOTOR

tOA

REAR CONTROL MOTOR

IR

FRONT
MODULATOR

CONTROL
MOTOR RELAY

I MODULATOR
rROL

0!JLAY

~~~

FAN MOTOR
SWITCH

REAR BRAKE
LIGHT

"~x?~ "om"
,

I'

.:

I~

"'"'7I Q
!I::t~""

LAMP CHECK

BANK ANGLE

>"'~ W' i,,tf ~!-~,r~'

ASS
FUSE BOX

~ ~~~<~

iiiiD

~W'M''''
~~

~i~

MAIN FUSE 30 A

iDiD

~I"""
~t3

"
~;Jj\i3::::::I:::tt--i+-f++-1-'
II
r

',IW

ill!lliliiiB.f

tJSWITCH

ffl

0;;:-

BI:

W'G

o..,........-,r' LEFT REAR TURN


G~12V32CP

GW

"'"
"'G'
'''0
BIIG

~
G~

O~

ae
G

SIDE STAND SWITCH

REAR WHEEL
SPEED SENSOR

~
REAR MODULATOR

IGNITION SWITCH

<,

,., 'G

BAT!

~~i ~~~

ON

0"
LOCK

ALTERNATOR

0030Z-MAJ-A300

SIGNAL

23. Technical Features


LBS {Linked Brake System} [After '95] 23-17

ASS (Anti-lock Brake System)

['92-'95]

23-1

[After '95]

23-10

TCS (Traction Control System)

[After '91]

23-23

ABS (Anti-lock Brake System) ['92-'95]


Summary
The Anti-lock Brake System (ASS) is designed to help prevent wheel lock up during hard braking or braking on loose or
slippery surfaces. ASS momentarily reduces the brake caliper fluid pressure when the wheels are about to lock. When the
system senses that the tendency for wheel lock is reduced, brake caliper fluid pressure is restored. ABS repeats this cycle
as required for secure brake performance with minimum possibility of wheel lock.

23-1

Technical Features
The braking effectiveness and balance of the motorcycle can be significantly affected by the way the front and rear brakes
are applied. This ABS system is characterized by high deceleration and follow-up performance thanks to its quick response
to a variety of road surface conditions. It is also characterized by its compact size, which is achieved by collective
arrangement of the hydraulic control components in the modulator.

CD ASS

INDICATOR LIGHT 2

:J) ASS

INDICATOR LIGHT 1

C~) ABS/TCS INDICATOR

LIGHT SWITCH
:~

TABS MAIN RELAY

REAR WHEEL
SENSOR

:Q;. REAR PUMP MOTOR


RELAY

4\;;-"c1i) FRONT PUMP MOTOR


RELAY
(~)

<.

<:>

ASS CONTROL UNIT


(ECU}

ct FRONT WHEEL

\ __ -'.L~-..J

SENSOR

(t, REAR PULSER


RING
3) REAR
MODULATOR

'::5) FRONT
MODULATOR
~)

FRONT PULSER
RING

rJ) ASS indicator lights


Blinks of stays ON when a problem occurred in the ASS.
,~) Pulser ring
Rotates together with the wheel and detects the wheel speed using the wheel sensor.
:]; Wheel sensor
Inputs the pulse signal, generated proportionally to the rotating speed of the pulser ring, in the control unit.
::1 ASS control unit (ECU)
Controls ASS by monitoring the input signal of each sensor and switch.
::~: Modulator
Adjusts the caliper fluid pressure.
Cfi; Pump motor relay
Controls the modulator motor power source based on a signal from the control unit (ECU}.
Ct ABS main relay
When the control unit detects abnormality, power to the solenoid valve is shut off by the ASS main relay as it receives
the signal from the control unit.
(~) ASS/TCS indicator light switch
A common switch for the ASS and TCS. When the ABS indicator lights 1 and 2 blink, the ABS indicator light 1 can be
dimmed and the indicator light 2 can be turned OFF in order not to interfere with the rider's v'sion.The ASS/TCS indicator
light switch is also used to output the problem code.

23-2

Technical Features
System Construction
Modulator:
The modulator controls and supplies the brake fluid that is essential for the ABS operation. The motorcycle is equipped with
separate and independent front and rear modulators.
The modulators are sealed type containing the brake fluid and constituent parts, and are maintenance free. Additionally. they
have no reservoir pipe and are light-weight and compact. These features make the modulators well suited for motorcycles.
The modulator consists of the following parts;
Expander piston:

Operates in accordance with the change in the piston fluid pressure and adjusts the caliper fluid
pressure.
Back-up piston: Pushes the expander piston up when fault occurs.
Limit switch: Detects the pressure in the system by detecting the back-up piston position.
Pump motor: Drives the pump to generate puressre in the system.
Inlet valve/Outlet valve: Adjusts the puressure in the system.
(5) EXPANDER

(6) CALIPER

PISTON

Front modulator shown:

(7} BACK-UP

(2) LIMIT SWITCH

PISTON
(8) LIMIT SWITCH

(4) MASTER

CYLINDER
(12) CUT-OFF

VALVE

WlI

1/

(3) SOLENOID VALVE

(9)
PUMP MOTOR

(11) OUTLET VALVE

(INLET VALVE/OUTLET VALVE)

Wheel sensor/pulser ring:


The wheel sensor is the contactless sensor that detects front and rear wheel speed. Consisting of a permanent magnet and
Hall element, the sensor is connected to the ASS control unit. When the projection on the outer circumference of the pulser
ring that is rotating with the front/rear wheel passes across the wheel sensor, a pulse signal is generated at the sensor. The
control unit detects the wheel speed as it receives the pulse signal, because the frequency of the signal increases proportionally to the wheel speed.
(1) HALL ELEMENT
(9) WHEEL SENSOR

(3)
----OUTPUT

l.'::::=== (4)
POWER

(5) PULSER RING


(6)
SIGNAL

---

(7) at HIGH SPEED

,-----,
,
,
''
,,
:'
:,
'
,
:'
:,
'
,
'

;'
I

! ii
1

: _1

I,-----

(8) at LOW SPEED

,-----

! !
i !

i
i

___J

(10) PULSER RING

23-3

Technical Features
ASS control unit (ECU):
The ASS control unit consists of two systems that monitors each other:the main CPU and the sub CPU. The control unit
is designed to activate the solenoid valve and pump motor only when the calculation results of both systems agree with each
other.

ABS CONTROL UNIT

FRONT WHEEL SENSOR

REAR WHEEL SENSOR

ASS/TeS INDICATOR
LIGHT SWITCH

FRONT LIMIT SWITCH

REAR LIMIT SWITCH

FRONT SOLENOID VALVE


MAIN
CPU

REAR SOLENOID VALVE

t t

SUB
CPU

.1

ASS MAIN RELAY


FR. PUMP
MOTOR RELAV

RR. PUMP
MOTOR RELAY

FR.PUMPI
MOTOR

RR. PUMP
MOTOR

ABS INDICATOR LIGHT

The control unit detects the wheel speed as it receives the signal from each wheel sensor. When the unit senses that the
wheel are about to lock, it controls the caliper fluid pressure by activating the solenoid valve of each modulator.
The control unit also includes a change-over function to the regular system that monitors the system condition by receiving
signals from the limit switch, pump motor etc. It stops theABS function and switches back to the regular brake system when
the control unit detects an abnormality in the ASS.

Indicator lights

!r___.....~.J''~'~.~"~o!:=--~

~~
<r

{11 CUT-OFF
VALVE

{2) BACK-UP
PISTON

il Ii 'V

{3{L1MIT
SWITCH

./

r__~

,
,

Rear wheel
sensor

(4) PUMP
Front wheel
senSOr

(5) INLET VALVE

MOTOR

(6) OUTLET VALVE

Pump motor control


The ABS control unit monitors the pressure accumulation by receiving a signal from the limit switch. When the pressure
drops, the back-up piston moves forward and the limit switch turns OFF to operate the pump. When the pressure rises to
a given level. the limit switch turns ON to stop the pump. (The pump is operated continuously while the ABS is active.]

23-4

Technical Features
Self-diagnosis function
When the engine starts, the ASS control unit evaluates the hydraulic circuit condition by activating the pump motors and
solenoid valves and receiving the signal from the limit switch, The ASS indicator light blinks when an abnormality is detected
in the circuit. When the circuit is normal, the ASS indicator light stays ON indicating that the control unit is in the stand-by
mode for the wheel sensor signal. The wheel sensors send signals to the ECU after the motorcycle starts to move (approximately 10km/h or above}. The ASS indicator light goes off when the ECU receives signals from the wheel sensor and the
wheel sensor system is found to be normal.
The ASS control unit monitors the main function while the motorcycle is moving, too.
When it detects a problem with the system, it blinks the ASS indicator light and stops the system immediately. When the
control unit detects a problem while the ASS is active, it stops the system and blinks the ASS indicator light, notifying the
rider of the problem and that the system is diactivated.
Change-over function to the regular system
When the ASS contol unit detects a problem in the system by the self-diagnosis function, the control unit activates the ASS
main relay and shuts off the ground circuits of the front and rear solenoid valves to stop the solenoid valve. The ASS stops
its function when the system is faulty and switches to the regular brake system.
Problem code storage function
The problems can be memorized and stored in the control unit (up to two codes), and can be retrieved and indicated by the
number of blinks of the ASS indicator light (page 16-A-6).

23-5

Technical Features
ABS main relay:
The secondary side contact points of the ASS main relay is the normal open type, where the electric current does not
normally flow. When the current flows to the primary side relay coil, the contact points close forming the ground circuit of
the solenoid valve.

1---(1} ASS

CONTROL
UNIT (ECU)

(2)

1)~~~?E:R~:::::t===-REARSOLENOID VALVE
=~(3)
FRONT SOLENOID VALVE

IVI,---------(4) ASS MAIN RELAY

ABS/TCS indicator light switch:


When a problem occurs with the ASS and ASS indicator lights 1 and 2 blink, ASS indicator light 1 can be dimmed and
the indicator light 2 can be turned OFF by pressing the ASSjTCS indicator light switch.
Dimming and turning off these indicator lights keeps them from interiering with the rider's vision.
Another function of the ASS/TCS indicator light switch is to retrieve the problem codes that are stored in he control unit
according to the problem code storage function explained in the previous page. The problem codes are indicated by the
number of times the ASS indicator light blinks. When two problem codes are stored, the latest problem code is output
first.

{3)ASS/TCS INDICATOR
LIGHT SWITCH

(2) ASS INDICATOR


LIGHT 2

(1} ASS INDICATOR

LIGHT 1

~~
I
TCa

1$1

\\\

(4} TCS ON/OFF SWITCH

23-6

Technical Features
ASS Operation
Regular brake system operation:
Brake fluid pressure is accumulated fully in the system. When the pressure drops, the pump motor operates to accumulate
pressure. The expander piston and back-up piston are supported by this brake fluid pessure. The cut-off valve is pushed by
the expander piston as it opens at this time and the master cylinder and caliper are interconnected with a passage. The fluid
pressure in the master cylinder is transmitted to the caliper by way of the cut-off valve; allowing the brake to operate.
As the outlet valve closes, the high pressure of the brake fluid is maintained in the chamber and the expander piston is not
affected by the operation of the regular brake system.
This condition is the same as when the ASS is in the stand-by mode.

(2) EXPANDER PISTON


(3) BACK-UP PISTON

(1) CUT-OFF VALVE

14)
/ " LIMIT SWITCH

""'------j10

(5) PUMP MOTOR

p
IB) RESERVOIR/

(7) OUTLET VALVE

(6) INLET VALVE

23-7

Technical Features
When ABS is working:
Pressure DECREASE
When the control unit detects that the wheels are about to lock, the control unit sends signals to activate the pump motor
and to open the outlet valve, while closing the inlet valve. The brake fluid in chamber B flows through the outlet valve into
the reservoir side and pushes the expander piston back. Then, the cut-off valve, supported by the expander piston, is closed
by the spring force shutting the passage between the master cylinder and caliper. Simultaneously, as the expander piston
moves backward, the volume of chamber A increases and, the caliper fluid pressure is reduced.
Pressure HOLD
When both the outlet valve and inlet alve are closed, the brake fluid pressure in chamber A is maintained.
The caliper fluid pressure can then be maintained at a given level.
Pressure INCREASE
When the pressure is increasing, the outlet valve closes and the inlet valve opens; this allows the brake fluid from the pump
to flow through the inlet valve to chamber B. The brake fluid then pushes the expander piston forward and fluid flows to the
caliper.
The ABS control unit controls the brake fluid pressure and prevents a wheel from locking by performing the sequential
operations of the above "Pressure Decrese", "Pressure Hold" and "Pressure Increase" in accordance with the wheel rotation.
When the control unit senses that the possibility of wheel lock has passed, it closes the outlet valve and opens the inlet valve
to move the expander piston to the forward-most position. This in turn opens the cut-off valve and the passage between the
master cylinder and caliper to restore regular brake operation (page 23-7).
Pressure DECREASE
(2} CHAMBER B

Pressure HOLD

Pressure INCREASE

(3) PUMP
MOTOR

(1) CHAMBER A

(4) INLET VALVE


(5) OUTLET VALVE
(5} RESERVOIR

Fluid Pressure Control


Operation

Caliper fluid
pressure

Inlet valve

Outlet valve

Electric signal

Pressure relief
passage

Electic signal

Pressure relief
passage

Decrease

ON

Closes

ON

Open

To maintain
braking force

Hold

ON

Closes

OFF

Closes

To apply
braking force

Increase

OFF

Opens

OFF

Closes

To release braking
force

23-8

Technical Features
When trouble occurs:
When the fluid pressure in the chambr (page 23-7) cannot be maintained for some reason, the back-up piston is pushed
forward by the mechanical back-up spring force, which in turn pushes the expander piston up and the cut-off valve opens
fully. Fluid pressure in the master cylinder can then be transmitted by way of the cut-off valve to the caliper. Regular brake
operation can then be maintained.
As the back-up piston spring is preloaded enough to with stand the maximum brake pressure from the master cylinder the
expander piston cannot move backward during regular brake operation.

(2) EXPANDER PISTON


(3) BACK-UP PISTON

(1) CUT-OFF VALVE


~(4) LIMIT SWITCH

~O
(5) BACK-UP SPRING

fn~_

{6) PUMP MOTOR

(9) RESERVOIR /

(8) OUTLET VALVE

(7) INLET VALVE

23-9

Technical Features

ABS (Anti-lock Brake System) [After '951


Summary
The ASS is designed to help prevent wheel lock up during hard braking or braking on loose or slippery surfaces. ASS
momentarily reduces the brake caliper fluid pressure when the wheels are about to lock. When the system senses that the
tendency for wheel lock is reduced, brake caliper fluid pressure is restored. ASS repeats this cycle as required for secure
brake performance with rnlrurnurn possibrlrtv of wheel lock.
The conventional ASS is composed of the modulator with controlled hydraulic pressure circuit consisting of the pump and
inlet/outlet solenoid valves. The system indirectly controls brake fluid pressure that regulates the fluid pressure inside the
controlled hydraulic circuit by actuating the solenoid valves.
In this ASS, brake fluid pressure is directly controlled by motor's regulating of the rotational angle of piston-crank mechanism, which in turn controls the brake fluid. Therefore, in comparison with conventional systems, the modulator size. number
of parts required, and weight are all substantially reduced. In addition, the fluid pressure can be regulated continuously,
unlike the conventional ASS which has staqed control. This ASS embodies such a high accuracy control system in a more
simplified system.

MASTER CYLINDER

EXPANDER

CALIPER

PISTON'

- - rr=/irnY\i
\~'

I~

'~~J
1

BACK-UP
PISTON

MASTER
CYLINDER

CONTROL PISTON

LlJ~"

LIMIT SWITCH
-/

~~~~FF~ 'Ii'I:::WtclU~~

CRANK ANGLE
SENSOR

I 'UJ...):J
""':1""''''''

BACK-UP SPRING

CUT -OFF VALVE

WLrcli.l1i--'=i'i~i&or"-

~=='I PUMP

OUTLET VALVE

CONTROL MOTOR

INLET VALVE

CONVENTIONAL ABS

23-10

MOTOR

NEW ABS

Technical Features

CD ABS

indicator lights
Blinks or stays ON when a problem occurrs in the ABS.
(z; Pulser ring
Rotates together with the wheel and detects the wheel speed using the wheel speed sensor.
:j:: Wheel speed sensor
Inputs the pulse signal, generated proportionally to the rotating speed of the purser ring, in the ASS control unit (ECU).
:'1: ABS control unit (ECU)
Controls ABS by monitoring the input signals of each sensor.
:~) Motor driver
Receives control signal from the ASS control unit (ECU} and delivers high-amperage electrical power output to the
modulator's motor for quick changes in operation.
(E' Modulator
Adjusts the caliper fluid pressure.
(f) Modulator control motor relays (front and rear}
When the ASS control unit (ECU) detects abnormality, power to the motor driver is shut off by the control motor relays as
it receives the final from the ASS control unit (ECU).
@ ASSrrCS indicator light switch
A common switch for the ASS and TCS. When ASS indicator lights 1 and 2 blink, ASS indicator light 1 can be dimmed and
indicator light 2 can be turned OFF in order not to interfere with the rider's vision. The ASSfTCS indicator light switch is
also used to output the problem code.

23-11

Technical Features

System Construction

FRONT MODULATOR
Pedal input route
WHEEL SPEED SENSOR

Torque reaction route

OJ

REAR WHEEL

REAR MODULATOR

WHEEL SPEED SENSOR

Motor Driven Modulator:


The modulator controls the brake fluid pressure that is essential for the ASS operation. The motorcycle is equipped with
separate and independent front and rear modulators. At the same time, in order to combine with the LBS (Linked Brake
System), a single modulator controls two routes for brake fluid pressure, as two routes for braking input are given respectively
to the front and rear wheels.
The modulator consists of the following parts;
- Control piston: Operates in accordance with the change of the crankshaft angle and adjusts the caliper fiuid pressure.
Because each modulator must provide simultaneous control over two separate systems, each features
two sets of control pistons.
- Crankshaft: Turns with the control motor to change the piston position.
- Back-up spring: Pushes the control pistons up (hold the cut-off valve open) by way of the crankshaft.
- Control motor: Drives the crankshaft and adjust the pressure in the system.
- Crank arigle sensor: Detects the crank angle.
- Cut-off valve {3-stages}: Cuts hydrau lie pressure to the brake caliper.

CONTROL MOTOR

3-STAGE CUT-OFF
VALVE

FILTER

Inlet
(from master cylinder)

Outlet
(to calipers)

.1r~tl\u;r,~LRiErD_U_C_T_'OIiN

~~111CONTROL
GEAR

CRANK ANGLE
SENSOR
CRANK ANGLE SENSOR

CRANKSHAFT

PISTON

~RANKSHAFT
\>~:;J_' ~/

,'"

CONTROL MOTOR
BACK-UP SPRING

23-12

BACK-UP SPRING

Technical Features
Wheel Speed Sensor/Pulser Ring:
The wheel speed sensor is the contactless sensor that detects front and rear wheel speed. Consisting of a permanent magnet
and Hall element, the sensor is connected to the ABS control unit. When the projection on the outer circumference of the
pulser ring that is rotating with the front/rear wheel passes across the wheel speed sensor, a pulsar signal is generated at the
sensor. The ABS control unit detects the wheel speed as it receives the pulse signal, because the frequency of the signal
increases proportionally to the wheel speed.

WHEEL SPEED SENSOR

HALL ELEMENT

PERMANENT
MAGNET

' - - - - - - OUTPUT

l!::::===~ POWER

PULSER RING
SIGNAL

, !
l,
-

::

i i

.._---_.i

,:

i': i,
,
.----_.:

eue"H RING

ABS Control Unit {ECU}/Motor Driver:


The dual-CPU configuration ensures instant recognition of computer-related malfunctions, since the parallel CPUs run
constant checks on each other whenever the ignition switch is ON. The ASS control unit (ECU) is designed to activate the
modulator control motor only when the calculation results of both systems agree with each other.

ASS CONTROL UNIT (ECU)

c----

[FRONT WHEEL SPEED SENS-oRJ--_


1

MAIN CPU

REAR WHEEL SPEED SENSOR

ASSfTCS INDICATOR
LIGHT SWITCH

FRONT CRANK ANGLE SENSOR

REAR CRANK ANGLE SENSOR

1--.
.--.

,------J

..

SUB-CPU

----

'-----.
1

MOTOR DRIVER

~--->.~~-----;- CONTROL MOTOR

ASS INDICATOR LIGHT

The ABS control unit (ECU) detects the wheel speed as it receives the signal from each wheel speed sensor. When the unit
senses that the wheel are about to lock, it controls the caliper fluid pressure by activating the control motor of each modulator.
The control unit also includes a change-over function to the standard LBS operation that monitors the system condition by
receiving signals from the wheel speed sensor, crank angle sensor, etc. It stops the ASS function and switches back to the
standard LBS operation when the control unit detects an abnormality in the ABS.

23-13

Technical Features
Modulator motor control
The ABS control unit monitors both front and rear wheel speed sensors and the modulator crank angle sensors that provide
precise readings of each modulator's crankshaft positioning (i.e., control piston position). The ASS control unit directs its
control signals to the motor driver that delivers high-amperage electrical power output to the control motors and operate the
system.
Self-diagnosis function
When the ignition switch is ON, the ASS control unit evaluates the control motor relays. The indicator light blinks when an
abnormality is detected in the system. When the system is normal, the ASS indicator light stays ON indicating that the ASS
control unit is in the stand-by mode for the wheel speed sensor and modulator crank angle sensor signals. The wheel speed
sensors send signals to the ASS control unit after the motorcycle starts to move (approximately 10 km/h or above), then the
ASS control unit evaluates the system condition by activating the modulator control motors and receiving the signal from the
crank angle sensors. The ABS indicator light goes off when the system is found to be normal.
The ASS control unit monitors the main function while the motorcycle is moving, whether the brakes are engaged or not.
When it detects a problem with the system, it blinks the ABS indicator light and stops the system immediately. When the
control unit detects a problem while the ASS is active, it stops the system and blinks the ASS indicator light, notifying the rider
of the problem and that the system is deactivated.
Change-over function to the standard (LBS) system
When the ASS control unit detects a problem in the system by the self-diagnosis function, the control unit stops the ABS
function. The back-up spring pushes the control piston automatically to open the cut-off valve and restore standard LBS
operation {page 23-16}.
Problem code storage function
The problems can be memorized and stored in the ASS control unit {up to two codes), and can be retrieved and indicated by
the number of blinks of the ASS indicator light (page 16-B-6).

23-14

Technical Features
ABS/Tes Indicator Light Switch:
When a problem occurs with the ASS and ASS indicator lights 1 and 2 blink, ASS indicator light 1 can be dimmed and the
indicator light 2 can be turned OFF by pressing the ABS/TCS indicator light switch.
Dimming and turning off these indicator lights keeps them from interfering with the rider's vision.
Another function of the ABS/TCS indicator light switch is to retrieve the problem codes that are stored in the ASS control unit
according to the problem code storage function explained above. The problem codes are indicated by the number of times the
ASS indicator light blinks. When two problem codes are stored, the last problem code is output first.

ABSTCS INDICATOR
LIGHT SWiTCH

BS

ASS INDICATOR
LIGHT 1

l[~
ASS INDICATOR
LIGHT 2

\ ..

TCS ON OFF SWITCH

3-Stage Cut-off Valve:


In conventional ASS configurations, a ball-type cut-off valve is used to cut hydraulic pressure to the brake calipers. in thls
ASS, an additional orifice valve is positioned directly behind the cut-off valve to realize three stages of valve operation.
tst stage
When the ASS is enabled, the control piston moves down to close both the cut-off valve and the orifice valve, cutting the
hydraulic line between the master cylinder and the brake caliper.
2nd stage
The control piston moves up slightly to open only the cut-off valve, leaving the orifice valve closed. This stage permits only a
small amount of hydraulic pressure to seep through the center of the orifice valve to the brake caliper.
3rd stage
The control piston returns to its uppermost position, opening both the cut-off valve and the orifice valve, and restoring the full
hydraulic pressure needed for standard lBS brake operation.

3-STAGE CUT-OFF
VALVE

ORIFICE VALVE

CUT-OFF VALVE
Open

(.o~- Open

CONTROL
PISTON

PISTON--l1t=":::ipill
Closed

23-15

Technical Features
ABS Operation
Pressure DECREASE
When the ABS control unit (ECU) detects any tendency towards wheel lock, it rapidly reduces hydraulic pressure to the brake
caliper by rotating the crankshaft to lower the control pistons, closing the 3-stage cut-off valves.
Pressure HOLD
Following a predetermined decompression interval, the crankshaft is rotated up slightly to move the control pistons into the
pressure HOLD position, which permits the slipping wheel to recover its rotational speed.
Pressure INCREASE
One the ABS control unit detects full wheel speed recovery, it rotates the crankshaft back into its highest position. This rapid
cycle of pressure DECREASE, HOLD, and INCREASE makes possible nearly instantaneous correction of changes in wheel
rotation while ensuring highly accurate control of hydraulic pressure to both independent sets of brake caliper pistons.

Pressure DECREASE

ASS OFF

Pressure INCREASE

CONTROL MOTOR
PISTON
From master
cylinder

To
caliper
CUT-OFF VALVE

BACK-UP SPRING

Caliper

Caliper

CRANKSHAFT

Automatic protection against system failure


During conventional braking operation, the modulator's control piston remains in its uppermost position to hold the cut-off
valve open. If any malfunction in the ASS is detected at this time, the system is turned off without affecting the control
piston's position, thus maintaining standard LBS operation. During ABS operation, if any malfunction-such as loss of the
modulator motor's power-is detected, the control piston back-up spring pushes the control piston into its upper most
position to open the cut-off valve and restore standard LBS operation.

23-16

Technical Features

lBS (linked Brake System) [After '951


Summary
The Linked Brake System (LBS} was designed to engage both front and rear brakes when either the front brake lever or rear
brake pedal is used.
Not merely a linked system that divides pedal braking force between the rear caliper and one of the front calipers, this system
features a set of a-piston calipers that are connected to two independent hydraulic systems. These combine to provide an
optimal balance offront and rear braking forces whenever either the brake lever and and/or the brake pedal is used. Featuring
no electronic control about the LBS, the completely hydraulic system's key component is a mechanical linkage that transmits
front caliper braking force to a secondary master cylinder mounted on the left fork slider.

Pedal input route

Front calipers (3-pistons)


Link mechanism
::~; Rear caliper (3-pistons)
f Delay valve
Slows front brake engagement to minimize its associated dive when performing minor speed corrections with only the
brake pedal.
:5: Secondary master cylinder
Transmits the rotational torque exerted on the front caliper to the rear brake caliper by way ofthe Proportional Control
Valve (PCV).
(6) Proportional control valve (PCV}
Regulates the rear caliper hydraulic pressure from the secondary master cylinder.

'Z

23-17

Technical Features

System Construction

LEVER BRAKE MASTER CYLINDER

--')

PROPORTIONAL CONTROL VALVE (PCV)

PEDAL BRAKE MASTER CYLINDER

REAR CAUPER

DELAY VALVE

FRONT CALIPERS

SECONDARY MASTER CYUNDER

3-Piston Caliper:
A set of three newly designed 3-piston calipers are controlled by two independent hydraulic systems.
The center piston of all three calipers are operated directly by the brake pedal.
The two outer pistons of the front calipers are controlled by the brake lever, and the two in the rear are controlled by the
servomechanism-actuated secondary master cylinder (page 23-17).
This arrangement delivers a broad, yet easily controlled range of braking force, depending on which either or both of the two
(lever and pedal) brake are engaged.

REAR:

FRONT:

CENTER PISTON
CENTER PISTON

OUTER PISTONS

23-18

OUTER PISTONS

Technical Features
Delay Valve:
The delay valve positioned between the pedal brake master cylinder and the center pistons of the front calipers, the delay
valve engages only the left front caliper at first, effectively reducing the initial front wheel braking force (Fig. A-B).
As pedal pressure gradually increases, the delay valve introduces pressure to the right front caliper, which increases to match
the pressure to the left front caliper at a predetermined level {Fig. C}. The resulting feel is of comfortably even deceleration that
begins at the rear, with little of the rapid forward dive that is usually brought on when the front brakes are suddenly applied.

PEDAL BRAKE
MASTER CYLINDER

L. FRONT
CALIPER

R. FRONT
CALIPER

REAR
CALIPER

DELAY VALVE

INLET {from pedal


master cylinder}
OUTLET 2 (to right
front caliper)

'T:,-::g~:

Outlet 1

.-

/,\

/
1'
,-""

Fig. A
B
C[:,-J:': Fig C
,j)- : Alternating Fig. Band C
:J:-':~): Fig

Outlet 2

___........-'.:t.
I

,-,

Inlet pressure

23-19

Technical Features
Link Mechanism/Secondary Master Cylinder:
The system's servomechanism uses the rotational torque exerted on the front caliper when they are engaged to actuate a
secondary master cylinder by way of its caliper mounting linkage.
This secondary master cylinder then applies a corresponding amount of pressure to the rear brake caliper.

SECONDARY MASTER CYLINDER

Torque reaction route

.r---;.:.:...:....-----,

REAR
CALIPER

LEFT FRONT
CALIPER

LINK MECHANISM

PCV

Proportional Control Valve (PCV):


The pev installed between the secondary master cylinder and the outer pistons of the rear caliper, regulates pressure in three
stages of operation.
Initially, the PCV's output pressure increases in direct proportion to the increasing input pressure originating from the
secondary master cylinder (Fig. Al.
As input pressure continues to increase, the cut piston activates, closing the valve and causing the output pressure to hold
(Fig. B).
A further increase in input pressure forces the decompression piston down, which expands a sub-chamber that draws
pressure off the output side of the pev (Fig. C)

Open

Outlet (to rear caliper)

Closed

Closed

Inlet (from secondary


master cylinder)

DECOMPRESSION PISTON

-(2" : Fig. A
'~2~-K: Fig. 8
,~>-:;t:

Inlet pressure

23-20

Fig. C

Technical Features

LBS Operation
When hand brake is applied:
On initial operation, the hand brake works like any conventional motorcycle front brake system. A squeeze on the brake lever
pressurizes the master cylinder which transmits its increased hydraulic pressure to the two outer pistons of the front calipers,
causing a corresponding braking force to be applied to the front wheel.
In response to the braking force applied by the front caliper onto the spinning brake rotor, the caliper is pulled in the direction
of wheel rotation, around its lower caliper pivot. This forward caliper motion also acts on the link arm which is connected to
the secondary master cylinder. This direct pressure on the secondary master cylinder is regulated by the PCV which then
transmits its hydraulic pressure to the outer pistons of the rear caliper.
Front Master Cylinder

___1-- _
Left Front Caliper

,
Right Front Caliper

(Mechanical Linkage)

Secondary Master Cylinder

PCV (Regulating pressure)

,
Rear Caliper (Outer pistons)

BRAKE
LEVER

PCV

23-21

Technical Features
When foot brake is applied:
When the brake pedal is pressed, hydraulic pressure from the rear master cylinder is routed through two lines. One connects
directly to the rear caliper and acts on the center piston. The other line runs to the center pistons of the front calipers by way
of the delay valve that slows front brake engagement to minimize its associated dive. As during hand brake operation,
hydraulic pressure from the secondary master cylinder passes through the PCV, and acts on the outer pistons of the rear
caliper. Because hydraulic pressure from the rear master cylinder is also being applied by the rear cali per's center piston, the
braking force applied to the rear wheel is greater than that applied when using the brake lever only.

Front Master Cylinder

Delay valve

(Center Piston) (Outer Pistons)


Rear Caliper

J
Left Front Caliper
(Mechani~al

RighI Front Caliper

Linkagel

J
Secondary Master Cylinder

PCV (Regulating pressure)

o
DELAY
VALVE

BRAKE PEDAL

l-l------------1

pev

The system offers the same braking feel as conventional brake systems, but adds a more progressive range of brake control
and enhanced balance of braking capability. Because the two systems are independent of each other, both the brake pedal
and the lever can be used in any combination without resulting in excessive braking force or other unusual responses.

23-22

Technical Features

TCS (Traction Control System) [After '91]


Summary
The Traction Control System (TCSj is designed to help prevent excessive rear wheel slippage during hard acceleration or
acceleation on loose or slippery surfaces. TCS helps maintain rear wheel traction by controlling the ignition timing when it
senses rear wheel slippage. The system alerts the rider that TCS is active by turning the TCS activation light on.

(1) TCS ACTIVATION LIGHT

------

~;:.,TIV
..I ' Tee] L
IA Bel
CFF
_

The TCS adjusts and controls the engine power by adjusting the ignition timing. This helps match the rear wheel torque to
the road surface traction condition.

100%

,,
,,
,,
,,
,,
,,
,,
,,
,,
,

o
Retarded
Normal
(1) IGNITION TIMING

23-23

Technical Features
The TCS/ignition control module (lCM) judges the rear tire traction conditions as it receives the signal from the front and
rear wheel sensors.
When the
is activated the TCS/ICM turns on the
activation light and controls engine power through changes in
ignition timing. The TCS automatically turns ON by turning the ignition switch ON, and can be turned OFF manually as
the rider wishes by pushing the TCS ON/OFF switch.
Note that the TCS cannot be turned OFF when it is active or while the motorcycle is moving.

rcs

rcs

CD TCS

ACTIVATION
LIGHT

Q) TCS WARNING LIGHT

$- TCS ON/OFF SWITCH

(n ABS/TCS

C?! TCS

OFF INDICATOR

I~'

TCS/IGNITION
CONTROL MODULE (fCM)

INDICATOR LIGHT

SWITCH

\ \\

~:: FRONT WHEEL

SENSOR
@o FRONT PULSER
RING

:~-

REAR WHEEL
SENSOR

@ REAR PULSER
RING

CD TCS

activation light
Turns ON when the TCS is active.
(~) TCS OFF indicator
Turns ON when the TCS is turned OFF using the TCS switch or when the TCS is not activated because of a problem
with the TCS.
~; TCS indicator light
Blinks when a problem occurs in the TCS. The light stays ON when the pre-start self-diagnosis is not passed.
'Al Pulser ring
Rotates together with the wheel and detects the wheel speed using the wheel sensor.
I~ Wheel sensor
Sends the pulse signal, generated proportional to the rotating speed of the pufser ring, to the TCS/ICM.
@TCS ON/OFF Switch
The TCS can be turned ON and OFF by pushing the TCS ON/OFF switch. The TCS OFF indicator comes ON when the
TCS ON/OFF switch is OFF.
(1) ABS/TCS indicator light switch
The indicator light switch is the common switch between the ASS and TCS.
When the TCS indicator light blinks, it can be turned OFF so it does not interfere with the rider's vision. (The
OFF
indicator stays ON).
~ TCS/ignition control module (ICM)
While receiving signals from the front and rear wheel sensors, the TCS/ICM judges the running condition and it outputs
a signal for appropriate ignition timing.

rcs

23-24

Technical Features
System Construction
TCS/ignition control module (ICM):
The TCS/ICM detects front and rear wheel speed by receiving signals from the wheel sensors. When
exceeds a given ratio of front-to-rear wheel speed, the TCS/ICM judges that the rear driving wheel is
it activates the TCS.
The TCS/ICM body is the ECU that is integrated with the spark unit. As the ignition CPU and the
communicate with each other and the ignition CPU monitors the traction control CPU, the engine
even if the TCS becomes inoperative due to a problem in the system.
When the TCS in inoperative, the TCS indicator light and TCS OFF indicator turn ON.

the rear wheel speed


beginning to slip and
traction control CPU
will operate normally

The TCS/ICM constantly monitors the input signal inside the TCS/ICM, and shuts off the TCS when it detects a problem with the system.
Simultaneously, the TCS/ICM turns ON or makes the TCS indicator light blink notifying the rider of the problem with the
system, and turning the TCS OFF indicator ON to notify the rider of the inoperative state of the TCS.

TCS/IGNITION
CONTROL MODULE
(ICMI

TCS ON/OFF SWITCH


ABS/TCS INDICATOR
LIGHT SWITCH

IGNITION COIL

I
I

IGNITION

CPU

TCS OFF INDICATOR

TCS INDICATOR LIGHT

t -+
I

FRONT WHEEL SENSOR

REAR WHEEL SENSOR

TRACTION
CONTROL

CPU

TeS ACTIVATION LIGHT

23-25

Technical Features
. Self-diagnosis function
The TCS/ICM starts self-diagnosis as the ignition switch is turned ON. It diagnoses the TCS/ICM itself and the wheel sensor power source. When it detects a problem, it stops TCS operation, makes the TCS indicator light blink and turns on the
TCS OFF indicator light to notify the rider of a fault in the TCS. When the TCS/ICM is found to be normal, it moves to the
stand-by mode for the wheel sensor signal and the TCS indicator light turns ON. (The TCS does not function when the
TCS indicator light is ON).
The wheel sensors send signals to the TCS/ICM after the motorcycle is in motion [approximately 1Okm/h(6 mile/h) or above] , and the TCS indictor light goes OFF after the wheel sensor signal is input and the wheel sensors are found to be as
normal.
If the TCS indicator light stays ON, there is an abnormality with the wheel sensors.

(1) TCS OFF INDICATOR

r.... ....-

~ ASS ECU

(2) TCS INDICATOR


LIGHT

I S'"'p''' I! ..'..-...-..-.. ~

......

Rear wheel
sensor

Front wheel
sensor

Wheel sensor/pulser ring:


The ASS and TCS share the same wheel sensor/pulser rings.
They transmit the vehicle speed signal to both the ASS control unit and the TCS/ICM. (See page 23-3)

23-26

Technical Features
ABS/TCS indicator light switch:
When a problem with the TCS occurrs, the TCS indicator light blinks and the TCS OFF indicator turns ON. The TCS indicator
light can be turned OFF by pressing the ABS/TCS indicator light switch. Turns off the indicator light prevents the light from
interfering with the rider's vision. The TCS OFF indicator does not go off but stays ON.

TCS ON/OFF switch:


The TCS can be turned ON and OFF by pushing the Tes ON/OFF switch. The TCS is activated when the switch is ON, the
TCS activation light turns ON, and when the TCS is active. When the TCS ON/OFF switch is OFF, the TCS cannot be
activated but the TCS OFF indicator comes ON. The TCS cannot be shut off when it is active or while riding.

(1}ABS/TCS INDICATOR LIGHT


SWITCH

(4) TCS ACTIVATION LIGHT


(5) TCS INDICATOR
LIGHT

(3) TCS OFF INDICATOR

TCS ACTIVE)

Tcs

(2) TCS ON/OFF SWITCH

23-27

Technical Features
TCS Operation
When TCS is active:
After receiving the signal from the front and rear wheel sensors, the TCS/ICM judges whether traction control is required
by detecting the rear wheel speed and comparing it to the front wheel speed (i.e vehicle speed). The engine will operate
normally when the TCS is not active. When the rear wheel speed exceeds a given ratio of the front-to-rear wheel speed,
the TCS/ICM judges that the rear wheel is slipping excessively and controls the engine power by determining the suitable
ignition timing. The TCS performs the above operations instantaneously to help prevent the skid from becoming excessive
and to hold it within a specified range .

. . ... .. ~ ABS ECU ~

Sparkplug

Rear wheel
sensor

,
!

Front wheel
sensor

When a problem occurs:


When the TCS/ICM detects a problem with the TCS, it makes the TCS indicator light blink, turns the TCS OFF indicator
ON, and immediately shuts off the
function. When the TCS/ICM detects a problem while the TCS is active, it returns
the engine slowly to regular ignition timing, then deactivates the TCS.

rcs

23-28

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

...

Replace the partts] with new onets) before assembly.

Is :;O=ooLI

Use special tool

IOP~OOLI

Use optional tool. Use the same procedure you use to order parts.

Torque specification.

10 Nm (1.0 kg-m, 7.2 ft-lb)

10 (1.0, 7.2)

-:71

-,
..~

Use recommended engine oil, unless otherwise specified.

Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1

Use multi-purpose grease (Lithium based multi-purpose grease NLGI #2 or equivalent)

Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote BR-2 plus manufactured by Dow Corning, U.S.A.
Multi-purpose M-2 manufactured by Mitsubishi Oil Japan

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

Use silicone grease

Om

Apply a locking agent. Use a middle strength locking agent unless otherwise specified.

"I~

Apply sealant

Use brake fluid, DOT 3 or DOT 4. Use the recommended brake fluid, unless otherwise specified.

Use Fork or Suspension Fluid.

1) .

24. Troubleshooting
Engine Does Not Start or is Hard

to Start

24-1

Engine Lacks Power

24-2

Poor Performance at Low and Idle


Speeds

24-3

Poor Performance at High Speed

24-4

Poor Handling

24-4

Engine Does Not Start or is Hard to Start


Possible Cause
'l . Check fuel flow to carburetor - - - Not Reaching Carburetor - - - - - - _ . . .
Reaching Carburetor

2. Perform a spark test - - - - - - - Weak or No Spark ---------~-..

Good Spark

Clogged fuel tube or fuel filter


Sticking float valve
Faulty fuel pump
Faulty fuel pump relay
Clogged fuel tank breather
Disconnected or faulty auto
fuel valve vacuum tube
Faulty spark plugs
Fouled spark plugs
Faulty ignition control module
Broken or shorted spark plug
wires
Broken or shorted ignition coil
Faulty ignition switch
Faulty ignition pulse generator
Faulty engine stop switch
Faulty bank angle sensor
Faulty bank angle sensor relay
Faulty side stand switch

Loose or disconnected ignition


system wires

3. Test cylinder compression - - - - - Low Compression - - - - - - - - - - . . .

Improper valve clearance


(shim too thick)
Improper valve and seat
contact
Valve stuck open
Worn cylinder and piston rings
Damaged cylinder head gasket
Seized valve
Improper valve timing

Compression Normal

4. Start by following normal starting procedure

Engine Starts But Stops - - - - - - - - . . .

Engine Does Not Fire

j
5. Remove and inspect spark plug - - Wet Plug ------------~.~.

Improper starting enrichment


valve operation
Carburetor incorrectly adjusted
Intake pipe leaking
Improper ignition timing (Faulty
ignition control module or
ignition pulse generator)
Fuel contaminated
Carburetor flooded
Starting enrichment valve opened
Throttle valve open
Air cleaner dirty

24-1

Troubleshooting

Engine Lacks Power


Possible Cause
1. Raise wheels off ground and ---Wheels Do Not Spin Freely ----~...
spin by hand

Wheel Spins Freely

Brake dragging
Worn or damaged wheel bearings
Wheel bearings need lubrication
Final gear bearing damaged

2. Check tire pressure -------Pressure L o w - - - - - - - - - - o - . Faulty tire valve


Pressure Normal

3. Accelerate rapidly from low to - - Engine Speed Does Not Change


second

_0

When Clutch Released

Engine Speed Reduced When


Clutch is Released

Clutch slipping
Worn clutch discs/plates
Warped clutch discs/plates
Weak clutch spring
Sticking clutch hydraulic system
Check for engine oil additive

4. Accelerate lightly - - - - - - - Engine Speed Does Not Increase----- Starting enrichment valve opened
Clogged air cleaner
Restricted fuel flow
Increases
Clogged muffler
Clogged fuel tank breather
Faulty fuel pump
Faulty fuel pump relay

'loe Speed

5. Check ignition timing ------Incorrect -----------~._. Faulty ignition control module


Faulty ignition pulse generator
Correct

6. Check valve clearance ------Incorrect -----------~._. Improper valve adjustment


Worn valve seat
Correct

7. Test cylinder compression - - - - T o o Low

------------0-.

Normal

Valve stuck open


Worn cylinder and piston rings
Leaking head gasket
Improper valve timing
Seized valve
Improper valve and seat contact

8. Check carburetor for clogging--- Clogged -----------~._. Carburetor not serviced


frequently enough
Not Clogged

9. Remove spark plug - - - - - - - Fouled or Discolored - - - - - - - _ _

Plugs not serviced frequently


enough
Spark plugs are incorrect heat range

Not Fouled or Discolored

0_.

Oil level too high

Oil level too low


Contaminated oil

10 Check oil level and condition'---Incorrect - - - - - - - - - -__


Correct

11. Remove cylinder hed cover


and inspect lubrication
Valve Train Lubricated
Property

j
24-2

Valve Train Not


Properly

Lubricated----~

Clogged oil passage


Clogged oil control orifice
Contaminated oil
Faulty oil pump

Troubleshooting
Possible Cause
12. Check for engine overheating - - - Overheating - - - - - - - - - - _ . . .
Not Overheating

j
13. Accelerate or run at high speed --Engine K n o c k s - - - - - - - - -
Engine Does Not Knock

Coolant level low


Fan motor not working
(Faulty fan motor switch)
Thermostat stuck closed
Excessive carbon build-up in
combustion chamber
Use of poor quality fuel
Clutch slipping
- Check for engine oil additive
Lean fuel mixture
Wrong type of fuel
Worn piston and cylinder
Wrong type of fuel
Excessive carbon build-up in
combustion chamber
Ignition timing too advanced
(Faulty ignition control module)
Lean fuel mixture

Poor Performance at Low and Idle Speeds


Possible Cause
1. Check ignition timing and valve - - Incorrect -----------~._. Improper valve clearance
clearance
Improper ignition timing
- Faulty ignition control module
Correct
- Faulty ignition pulse generator

2. Check carburetor pilot screw - - - Incorrect ------------~._See Fuel System Section


adjustment
Correct

3. Check for leaking intake pipe - - - Leaking -----------~._


Not Leaking
4. peJorm spark test - - - - - - - - Weak or Intermittent Spark

---~.-.

Good Spark

Loose insulator clamps


Damaged insulator

Faulty, carbon or wet fouled


spark plug
Faulty ignition control module
Faulty ignition coil
Broken or shorted spark plug
wires
Faulty engine stop switch
Faulty ignition pulse generator
Faulty ignition switch
Faulty bank angle sensor
Faulty bank angle sensor relay
Faulty side stand switch
Loose or disconnected ignition
system wires

24-3

Troubleshooting

Poor Performance at High Speed


Possible Cause

1. Check ignition timing and valve - - Incorrect - - - - - - - - - - -clearance

Improper valve clearance


Improper ignition timing
- Faulty ignition control module
- Faulty ignition pulse generator

Correct

2. Disconnect fuel tube at - - - - - - Fuel Flow Restricted - - - - - - - .


carburetor
Fuel Flows Freely

Clogged fuel line


Clogged fuel tank breather
Clogged fuel filter
Faulty fuel pump or relay
Fuel tank empty
Faulty auto fuel valve

3. Remove carburetor and check - - - Clogged - - - - - - - - - - - _ . Clean


for clogged jets
Not Clogged

4. Check valve timing - - - - - - - Incorrect - - - - - - - - - - - - . _ . Camshaft not installed properly


Cam reduction gear not
Correct
installed properly
Timing marks on the timing
belt pulleys not aligned

5. Check valve spring - - - - - - - - W e a k - - - - - - - - - - - - _ . Faulty spring


Not Weakened

Poor Handling-----. Check tire pressure


Possible Cause

1. If steering is heavy - - - - - - - - - - - - - - - - - - - - - - Steering head bearing adjustment


nut too tight
Damaged steering head bearings
Bent steering stem
2. If either wheel is wobbling -------------------~_
Excessive wheel bearing play
Bent rim
Improperly installed wheel hub
Swingann pivot bearing excessively
worn
Bent frame
Swingann pivot adjusting bolt
too tight
3. If the motorcycle pulls to one side - - - - - - - - - - - - - - - - _
Front and rear wheels not aligned
Bent fork
Bent swingarm
Bent front axle
Bent frame

24-4

ST1100P Addendum
How to Use This Manual

Contents

This addendum contains information for ST1100P.


Refer to ST11 OO/ST11 OOA SHOP MAN UAL (No.
61MY311) for service procedures and data not included
in this addendum.

Model Identification
Specification.........
Cable & Harness Routing
Emission Control Information Labels
Seat
Upper Seat Cowling
Seat Cowling
Saddlebag Stay/Amplifier Stay
Fairing Pocket
Instrument Panel
Rearview Mirror
Headlight Aim
Lights/Meters/Switches Location
Rear Turn Signal and BrakelTaillight
Voltmeter
Wiring Diagram

ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN


THIS PUBLICATION ARE BASED ON THE LATEST
PRODUCT INFORMATION AVAILABLE AT THE
TIME OF APPROVAL FOR PRINTING. Honda
Motor Co., Ltd. RESERVES THE RIGHT TO
MAKE CHANGES AT ANY TIME WITHOUT
NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT
WRITIEN PERMISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED
BASIC KNOWLEDGE OF MAINTENANCE ON
Honda MOTORCYCLES, MOTOR SCOOTERS
ORATVS.
Honda Motor Co., Ltd.
SERVICE PUBLICATION OFFICE

Date of Issue: October, 2003

Honda Motor Co., Ltd.

;
:

2
13
20
21
21
22
22
23
24
25
25
26
27
27
29

ST1100P Addendum

Modelldentification

(1) VEHICLE IDENTIFICATION NUMBER


The Vehicle Identification Number (VIN) is located on the
Safety Certification Label on the left side of the steering
head.

(2) ENGINE SERIAL NUMBER


The engine serial number is stamped on the rear of the
lower crankcase behind the oil pan.

(3) FRAME SERIAL NUMBER


The frame serial number is stamped on the right side of the
steering head.

(4) CARBURETOR IDENTIFICATION NUMBER


The carburetor identification number is stamped on each
carburetor body on the intake side.

(5) COLOR LABEL


The color label is attached to the frame under the seat.

ST1100P Addendum

Specifications
Unit: mm (in)

G enera
Specifications

Item
Dimensions

Overall length
Overall width
Overall height
Wheelbase
Seat height
Footpeg height
Ground clearance
Dry weight (with saddle bag)
Curb weight (with saddle bag)
Maximum weight capacity

2,285 (90.0)
835 (32.9)
1,405 (55.3)
1,555 (61.2)
800 (31.5)
309 (12.1)
145 (5.7)
297 kg (655 Ib)
326 kg (719 Ib)
175 kg (386 Ib)

Frame

Frame type
Front suspension
Front wheel travel
Rear suspension
Rear wheel travel
Front tire size
Rear tire size
Tire brand (Bridgestone)
Tire brand (Dunlop)
Tire brand (Metzeler)
Front brake
Rear brake
Caster angle
Trail length
Fuel tank capacity
Fuel tank reserve capacity

Double cradle
Telescopic fork
150 (5.9)
Swingarm
120 (4.7)
110/80-18M/C 58V
160/70-17M/C 73V
G547/G548

FR/RR
FR/RR
FR/RR

-~

-~

Hydraulic double disc


Hydraulic single disc
27 30'
101 (4.0)
28 liters (7.40 US gal, 6.16 Imp gal)
- ~

ST1100P Addendum
Unit: mm (in)

General cont'd
Item
Engine

Specifications

Bore and stroke


Displacement
Compression ratio
Valve train
Intake valve opens at 1 mm lift
Intake valve closes at 1 mm lift
Exhaust valve opens at 1 mm lift
Exhaust valve closes at 1 mm lift
Lubrication system
Oil pump type
Cooling system
Air filtration
Crankshaft type
Engine weight
Firing order
Cylinder arrangenment
Cylinder number

73.0 x 64.8 (2.87 x 2.55)


1,084 em' (66.1 cu in)
10.0 : 1
Belt and gear driven DOHC
_5 BTDC (5 ATDC)
35 ABDC
40 BBDC
_5 ATDC (5 BTDC)
Forced pressure and wet sump
Trochoid
Liquid cooled
Paper Filter
Unit type, 3 main journals
93.0 kg (205 Ib)
1 - 90 - 4 - 270
3 - 90 4 cylinders, 90
0

2 -

270 -

0V

Left

Front

Carburetor

Carburetor tvpe
Throttle bore

Constant velocity 4 carburetors


34.5 (1.36)

Drive train

Clutch system
Clutch operation system
Transmission
Primary reduction
Secondary reduction
Third reduction
Final reduction
Gear ratio 1st
Gear ratio 2nd
Gear ratio 3rd
Gear ratio 4th
Gear ratio 5th
Gear ratio 6th
Gear ratio reverse
Gearshift pattern

Multi-plate, wet
Hydraulic operating
5 speeds
1.829 (75/41 )

Electrical

Ignition system
Starting system
Charging system
Regulator/rectifier type
Lighting system
AC regulator type

2.833
2.266
1.500
1.142
0.916
0.758

(34/12)
(34/15)
(27/18)
(24/21)
(22/24)
(22/29)

Left foot operated return system 1-N-2-3-4-5


Digitalized full transistor ignition
Electric starter motor
Triple phase output alternator
Field control/triple phase full-wave rectification
Battery

ST1100P Addendum
Unit: mm (in)
-

Lubrication
Standard

Item

Service Limit

3.6 liters (3.80 US qt, 3.17 Imp qt)


4.3 liters (4.54 US qt. 3.78 Imp qt)
3.7 liters (3.91 US qt, 3.26 Imp qt)
Pro Honda GN4 or HP4 (without molybdenum additives) 4-stroke oil or equivalent motor oil
API service classification: SG or Higher
JASO T 903 standard: MA
Viscosity: SAE 10W-40

Engine oil capacity at draining


at disassembly
at oil filter change
Recommended engine oil

OIL VISCOSITIES

-1
I
I
1

-I

I
1

I
20

40

60

100'F

80

10

10

20

I
30

I
40'C

Oil pressure at oil pressure switch


Oil pump rotor tip clearance G)
body clearance W
end clearance G)

r-

392-490 kPa (4.0-5.0 kq/cm>, 57-71


psi) at 5,000 rpm (80CI176F)
0.15 (0.006)
0.15-0.22 (0.006-0.009)
0.02-0.09 (0.0008-0.0035)

Fuel System - - - - - - - - - - - - - - - - - - - , . - - - - - - - - - - - - - - - - . - - - - - - - - - ,

Carburetor identification number


Main jet
(High altitude)
(2,3)
(1,4)
(Front)
(Rear)
Slow jet
Jet needle clip position
Pilot screw intial opening
Pilot screw high altituge adjustment
Pilot screw final opening
Air screw intial opening
Air screw high altitude adjustment
Float level
Carburetor vacuum difference
Base carburetor (For carburetor synchronization)
Idle speed
Throttle grip free play
Accelertor pump clearance
Pulse secondary air injection (PAIR) control valve vacuum
pressure

Other viscosities shown in the chart may


be used when the average temperature
in your riding area is within the indicated
range.

VDBEA
#125

#38
See page 5-12 (2-5/8 turns out)
See page 5-16
See page 5-12

7.0 (0.28)
Within 40 mmHg (1.6 inHg)
No.4 carburetor
1,200 100 rpm
2-6 (0.08-0.24)
360 mmHg (14.2 inHg)

ST1100P Addendum
Unit: mm (in)
~

Cylinder Head
Standard

Item

Cylinder compression
Cylinder compression difference
Valve clearance IN
EX
Cylinder head warpage
Cam lobe height CD IN
EX
Camshaft runout
Camshaft oil clearance A
B

Camshaft journal O. D. A
B
Camshaft holder I. D. A
B
Valve stem O.D. IN
EX
Valve guide I. D. IN
EX
Stem-to guide clearance IN
EX
Valve guide projection above cylinder head IN (h)
EX (h)

Service Limit

1,373 196 kPa (14.0 2.0 kq/crn",


19928 psi)/400 rpm
0.13-0.19 (0.005-0.007)
0.22-0.28 (0.009-0.011)
35.680-35.840 (1.4047-1.4110)
35.770-35.930 (1.4083-1.4146)
0.020-0.062 (0.0008-0.0024)
0.050-0.092 (0.0020-0.0036)

0.10 (0.004) .35.650 (1.4035)


35.740 (1.4071)
0.05 (0.002)
0.100 (0.0039)
0.130 (0.0051)

24.959-24.980 (0.9826-0.9835)
24.929-24.950 (0.9815-0.9823)
25.000-25.021 (0.9843-0.9851)
25.000-25.021 (0.9843-0.9851)
4.475-4.490 (0.1762-0.1768)
4.465-4.480 (0.1758-0.1764)
4.500-4.512 (0.1772-0.1776)
4.500-4.512 (0.1772-0.1776)
0.010-0.037 (0.0004-0.0015)
0.020-0.047 (0.0008-0.001 9)
15.3-15.5 (0.60-0.61)
15.3-15.5 (0.60-0.61)

24.950 (0.9823)
24.920 (0.9811)

1.0 (0.04)
1.0 (0.04)
41 .72 (1 .643)
41 .72 (1 .643)

1.5 (0.06)
1.5 (0.06)
39.6 (15.59)
39.6 (15.59)

25.978-25.993 (1.0228-1.0233)
26.010-26.026 (1.0240-1.0246)

25.968 (1.0224)
26.040 (1.0252)

4.465
4.455
4.562
4.562

(0.1758)
(0.1754)
(0.1796)
(0.1796)

Before guide installation:


1. Chill the valve guide in the freezer
section of a refrigerator for about an
hour.
2. Heat the cylinder head to 100
-150C (212-300F)
. Valve seat width IN
EX
Valve spring free length IN
EX
Inner IN
Inner EX
Outer IN
Outer EX
Rocker arm I. D. IN
EX
Rocker arm shaft O. D. IN
EX
Rocker arm-to-rocker arm shaft clearance
Valve lifter O. D.
Valve lifter bore I. D.
Hydraulic tappet adjuster assist spring free length
Hydraulic tappet adjuster compression stroke with kerosene

ST1100P Addendum
Unit: mm (in)
po-

Cylinder/Piston
Item

Standard
73.00~73.015 (2.874~2.8746)

Cylinder I. D.
Cylinder out of round
Cylinder taper
Cylinder warpage
Piston mark direction
Piston O. D. (D)
Piston O.D. measurement point (H)
Piston pin hole I. D. (d)

Service Limit

73.10 (2.878)
0.10(0.004)
0.10(0.004)
0.10(0.004)

"IN" mark facing toward the intake side


72.97~72.990

(2.8728-2.8736)
19 (0.75)
18.002-18.008 (0.7087-0.7090)

72.850 (2.8681)
18.020 (0.7094)

-df4I

Cylinder-to-piston clearance
Piston pin O. D.
Piston-to-piston pin clearance
Connecting rod-to-piston pin clearance
Top ring-to-ring groove clearance
Second ring-to-ring groove clearance
Top ring end gap
Second ring end gap
Oil ring (side rail) end gap
Top ring mark
Second ring mark
Crankshaft
Connecting rod small end I. D.
Connecting rod big end side clearance
radial clearance
Crankshaft runout

Crankpin oil clearance


Crankpin bearing selection
Main journal oil clearance
Main journal bearing selection
Kickstarter
Kickstarter pinion gear I. D.
Kickstarter spindle O. D.
Kickstarter idle gear I. D.
Countershaft O. D. at kickstarter idle gear
Kickstarter idle gear bushing O. D.
I.D.

po-

0.010-0.045 (0.0004-0.0018)
17.994-18.000 (0.7084-0.7087)
0.002-0.014 (0.0001-0.0006)
0.016-0.040 (0.0006-0.0016)
0.025-0.060 (0.0010-0.0024)
0.015-0.050 (0.0006-0.0020)
0.15-0.30 (0.006-0.012)
0.30-0.45 (0.012-0.018)
0.20-0.70 (0.008-0.028)

17.98 (0.708)

0.10 (0.004)
0.10(0.004)
0.5 (0.02)
0.7 (0.03)
1.0 (0.04)

"R" mark facing up


"RN" mark facing up

18.016-18.034 (0.7093-0.7100)
0.10-0.30 (0.004-0.012)

18.050 (0.7106)
0.40 (0.016)

0.05 (0.002)

0.030-0.052 (0.0012-0.0020)
See page 11-6
0.026-0.048 (0.0010-0.0019)
See page 11-6

0.080 (0.0031)
0.065 (0.0026)

ST1100P Addendum
Unit: mm (in)
r-

Transmission
Standard

Item

31.000-31.025 (1.2204-1.2215)
31 .000-31 .025 (1 .2204-1 .2215)
30.950-30.975 (1.2185-1.2195)
30.950-30.975 (1.2185-1.2195)
28.000-28.021 (1.1024-1.1032)
0.025-0.075 (0.0010-0.0030)
0.025-0.075 (0.0010-0.0030)
27.967-27.980 (1.1011-1.1016)

Transmission gear I.D. M4, M5


C2, C3
Transmission gear bushing O. D. M4, M5
C2, C3
Transmission gear bushing I. D. M4
Gear-to-bushing clearance at M4, M5 gear
at C2, C3 gear
Mainshaft O. D. at M4 gear bushing

Service Limit

31.040
31.040
30.930
30.930
28.031

(1.2220)
(1.2220)
(1.2177)
(1 .2177)
(1.1036)

27.960 (1.1008)

M4

=f:

Gear bushing-to-shaft clearance at M4 gear


Shift fork claw thickness F
C
R
Shift fork I. D. F
C
R
Shift fork shaft O. D. at F shift fork
at C shift fork
at R shift fork

q
0.020-0.054 (0.0008-0.0021)
5.93-6.00 (0.233-0.236)
5.93-6.00 (0.233-0.236)
5.93-6.00 (0.233-0.236)
14.000-14.021 (0.5512-0.5520)
14.000-14.021 (0.5512-0.5520)
14.000-14.021 (0.5512-0.5520)
13.973-13.984 (0.5501-0.5506)
13.973-13.984 (0.5501-0.5506)
13.973-13.984 (0.5501-0.5506)

5.9 (0.23)
5.9 (0.23)
5.9 (0.23)
14.03 (0.552)
14.03 (0.552)
14.03 (0.552)
13.965 (0.5498)
13.965 (0.54,98)
13.965 (0.5498)

------------r--------------,..---------,
94.5 (3.72)

Primary Damper Shaft


Primary damper spring free length

96.9 (3.81)

ST1100P Addendum
Unit: mm (in)
-

Clutch System

Standard

Item
Clutch lever free play
Recommended clutch fluid
Clutch master cylinder I. D.
Clutch master piston O. D.
Clutch outer I. D.
Clutch outer guide O. D.
I. D.
Primary damper shaft O. D. at clutch outer guide
Oil pump drive sprocket I. D.
Clutch center B I. D.
One way clutch inner O. D.
Clutch spring free height
Clutch spring free length
Clutch disc/plate thickness (Total of 10 discs and 9 plates)
Centrifugal clutch drum I. D.
bushing O. D.
Centrifugal clutch center guide I. D.
O.D.
Centrifugal clutch center guide collar height
Centrifugal clutch spring free length
Clutch lining thickness
Crankshaft O. D. at clutch center
-

Cooling System
Coolant capacity (Radiator and engine)
(Reserve tank)
Radiator cap relief pressure
Thermostat begins to open
Thermostat fully open
Thermostat valve lift

.- Drive Train
Recommended final drive oil
Final drive gear oil capacity at disassembly
at draining
Final drive gear backlash
Final drive gear backlash difference between measurements
Ring gear-to-stop pin clearance (A)
Stop pin shim
Ring gear spacer
Pinion spacer
Final drive gear assembly preload
Output gear backlash
Output gear I. D.
Output gear bushing O. D.
I. D.
Output drive shaft O. D.
Output gear damper spring free length
Output shaft adjustment shim
Countershaft drive shaft adjustment shim

--

Service Limit

--

DOT 4 brake fluid

--

14.000-14.043 (0.5512-0.5529)
13.957-13.984 (0.5495-0.5506)

14.06 (0.553)
13.94 (0.549)

--

--

34.975-34.991 (1.3770-1.3776)
27.989-28.006 (1.1019-1.1026)
27 .974-27 .987 (1 . 101 3-1 . 101 8)

34.965 (1.3766)
28.016 (1.1030)

--

----

----

43.0 (1.70)
54.72-55.72 (2.154-2.194)

40.0 (1.57)
54.2 (2.13)

---------

---

--

--

--

----

---

2.5 liters (2.6 US qt, 2.2 Imp qt)


0.5 liter (0.5 US qt, 0.4 Imp qt)
108-137 kPa (1.1-1.4 kq/cm",
16-20 psi)
80-84C (176-183F)
95C (203F)
8.0 (0.32) mm

Hypoid gear oil SAE #80


150 ern" (5.1 US OZ, 5.3 Imp oz)
130 em" (4.4 US OZ, 4.6 Imp oz)

0.05-0.15 (0.002-0.006)
0.30--0.60 (0.012-0.024)
See page 12 -1 0
See page 12 - 10
See page 12 - 11
2-4 kg-cm (1 .7-3.5 in-Ib)

0.3 (0.01)

ST1100P Addendum
Unit: mm (in)

Wheels/Tires
Item
Minimum tire tread depth (FR)
(RR)
Cold tire pressure (FR)
(RR)
Front and rear axle runout
Front and rear wheel rim runout (Radial)
(Axial)
Front wheel hub-to-rim distance
Front wheel hub standard surface
Rear wheel hub-to-rim distance
Rear wheel hub standard surface
Wheel balance weight (Front)
(Rear)
Drive chain slack
Drive chain size link (DID)
(RK)

Front Suspension
Front spring free length
Fork spring free length A
B
Fork spring direction
Fork tube runout
Recommended fork oil
Fork oil level
Fork oil level (R)
(L)
Fork oil capacity
Fork oil capacity (R)
(L)
Fork air pressure
Steering bearing preload

Standard

Service Limit
1.5 (0.06)
2.0 (0.08)

250 kPa (2.50 kq/cms, 36 psi)


290 kPa (2.90 kq/crn>, 42 psi)
0.2 (0.01)
'2.0 (0.08)
2.0 (0.08)

60 9 (2.1 oz) max.


60 9 (2.1 oz) max.

474.2 (18.67)

464.7 (18.30)

Tightly wound coil end facing down


0.20 (0.008)
Pro Honda Suspension Fluid SS-8
177(7.0)
174 (6.9)
372.02.5 em- (12.580.08 US oz,
13.050.09 Imp oz)
418.02.5 em- (14.140.08 US oz,
14.670.09 Imp oz)
1.5-2.0 kg (3.3-4.4Ib)

ST1100P Addendum
Unit: mm (in)
r--

Rear S uspensron
Item

Standard

Shock absorber spring free length


Shock absorber spring free length (R)
(L)
Damper gas pressure
Damper compressed gas
Damper rod compressed force at 10 mm compressed
Damper drilling point
Shock absorber spring installed length (Standard)
(Adjustable range)
Shock absorber spring adjuster standard position
Shock absorber spring direction
Recommended shock absorber oil
Shock absorber oil capacity
air pressure

Service Limit
253.7 (9.99)

258.9 (10.19)

--

--

-------

----

---

--

---

---

--

----

--

---

--

B ra k es

Front brake fluid


Brake lever free play
Brake pad wear indicator

---

DOT 4

---

To the groove CD

WOO
4.8-5.2 (0.19-0.20)

brake disc thickness


brake disc runout
master cylinder 1.0.
master piston O. D.
caliper cylinder 1.0.
caliper cylinder I. D. (Upper)
(Lower)
caliper piston 0.0.
caliper piston O. D. (Upper)
(Lower)
brake drum 1.0.
brake lining thickness
Rear brake fluid
brake pedal height
,
brake pedal free play
brake pad wear indicator

-14.000-14.043 (0.5512-0.5529)
13.957-13.984 (0.5495-0.5506)
27.000-27.050 (1.0630-1.0650)

4.0 (0.16)
0.30 (0.012)
14.06 (0.554)
13.95 (0.549)
27.06 (1.065)

---

--

-26.918-26.968 (1.0598-1.0617)

26.91 (1.059)

---

----

DOT 4

----

---

--

----

To the groove (l)

-'

un,

r--,

r-"-

....J

brake disc thickness


brake disc runout
master cylinder 1.0.
master piston O. D.
caliper cylinder 1.0.
caliper piston 0.0.
brake drum 1.0.
brake lining thinckness

10

7.3-7.7 (0.29-0.30)

-12.700-12.743
12.657-12.684
27.000-27.050
26.918-26.968

---

(0.5000-0.5017)
(0.4983-0.4994))
(1.0630-1.0650)
(1.0598-1.0617)

6.0 (0.24)
0.30 (0.012)
12.76 (0.502)
12.65 (0.498)
27.06 (1.065)
26.91 (1.059)

---

ST1100P Addendum
Unit: mm (in)

Battery ICh argmg S ystem


Item

Standard

Stator coil resistance (at 20C/68F)


Rotor coil (field coil) resistance (at 20C/68F)
Regulator/rectifier regulated voltage
Battery capacity

0.22-0.26 Q
2.6-3.2 Q
14.2-14.8 V at 5,000 rpm
12 V-12 AH
(Maintenance free battery: YTX14-BS)

Specified current leakage


Battery specific gravity (Fully chaged)
(Needs charging)
Battery charging (Normal)
(Quick)
Battery voltage (Fully charged at 20C/68F)
(Needs charging at 20C/68F)
AC regulator regulated voltage (With analog type)
(With digital type)
Brush length
Slip ring 0.0.

----

Ignition System
Spark plug
(Standard NGK)
(Standard OENSO)
(For cold climate/below 5C/41F NGK)
(For cold climate/below 5C/41F OENSO)
(For extended high speed riding NGK)
(For extended high speed riding OENSO)
Spark plug gap
Ignition timing "F" m a rk
Advance starts
stops
Fully advance
Alternator exciter coil resistance (At 20C/68F)
Ignition coil resistance (Primary; at 20CI68F)
(Secondary with plug cap)
(Seconday without plug cap)
Ignition pulse generator resistance (At 20C/68F)

Service Limit

--

----

---

---

-------

13.7 (0.54)
14.4 (0.57)

4.7 (0.19)
12 (0.5)

1.4Ax5h
6Ax1h
13.1 V
Below 12.3 V

2 mA max.

r-

CR8EF 9
U24FER9

CR9EH 9
U27FER9
0.8-0.9 (0.031-0.035)
12 BTOC at 1,000 rpm
2,000 rpm
5,000 rpm
2]0 BTOC at 5,000 rpm
2.16-3.19 Q
22.5-27.5 kQ
13.5-16.5 kQ
405-495 Q

11

ST1100P Addendum
Lights/Meters/Switches - - - - - - - - - - - - - - r - - - - - - - - - - - - - - - - - , , - - - - - - - - ,
Service Limit
Standard
Item

Main fuse
Fuse
Headlight (high/low beam)
Tail/brake light
License light
Position light
Front turn signal/running light
Front turn signal light
Rear turn signal light
Instrument light
Oil pressure indicator
Tail/brake light indicator
Side stand indicator
Low fuel indicator
Coolant temperature indicator
Oil temperature indicator
High beam indicator
Turn signal indicator
Neutral indicator
Reverse indicator
Overdrive indicator
Oil temperature sensor resistance
Fuel unit resistance (At full level)
(At empty)
Fuel pump flow capacity (min./minute)
Thermo sensor resistance (50C/122F)
(80C/176F)
(120C/248F)
Fan motor switch Starts to close (ON)
Stops to open (OFF)
Starti ng System
Starter driven gear 0.0.
Starter clutch outer 1.0.
Starter motor brush length

30A
10AX6,20AX1
12V45/45W X 2
12V32/3CP X 2

--12V32/3CP X 2

-12V32CPX2
12V1.7WX4
12V3.4W

-12V3.4W
12V3.4W

--

-12V3.4W
12V3.4X2
12V3.4W

--

--10Q
90Q

-130-180Q
45-60Q
10-20Q
98-102C (208-216F)
93-9TC (199-20TF)

--

---

-----

----

--

------

--

--------------

'll!

r-

57.749-57.768 (2.2736-2.2743)
74.414-74.440 (2.9297-2.9307)
12.0-13.0 (0.47-0.51)

12

ST1100P Addendum

Cable & Harness Routing

(1) CLOCK WIRE

(2) VOLTMETER WIRE

(3) CONNECTORS
for Optional Equipment

(4) LEFT TURN SIGNAL


WIRE CONNECTOR

(8) RIGHT TURN SIGNAL


WIRE CONNECTOR

.~

(5) SPEEDOMETER CABLE

(6) HEADLIGHT CONNECTORS

13

ST1100P Addendum

(2) CLUTCH HOSE

(1) CHOKE CABLE

(5) LEFT HANDLEBAR SWITCH


WIRE HARNESS
(6) RIGHT HANDLEBAR SWITCH
WIRE HARNESS

(8) IGNITION COIL 3P CONNECTOR

14

ST1100P Addendum

(1) BANK ANGLE SENSOR


(2) SIREN SPEAKER
RELAY

(5) STROBE LAMP


RELAY

(6) AIMING CABLE

(7) LOW BEAM HEADLIGHT RELAY


(9) CHOKE CABLE

(11) HARNESS CLIPS

15

~T1100P

Addendum

HT HAZARD
(4) HEADLlGCONNECTOR
SWITCH

(3) SWITCH 6 CONNECTOR

(6) FUEL T A NK TRAY


DRAUN TUBE

(5) REAR FOG LAMP


SWITCH
CONNECTOR

FUEL FILL CAP


(7) BREATHER TUBE

19) SPARK PLUG


WIRES
(18) STARTER MOTOR
CABLE

ROUND
(17) ENGINE G
CABLE
(16) CARBURETOR
DRAIN TUBE

(14) ALTERNATOR
WIRE

(15) SIDE STAND


SWITCH

(13) STARTER RELAY


SWITCH

ST1100P Addendum
(3) THROTTLE STOP SCREW CABLE

(5) RADIATOR
OVERFLOW TUBE

(1) REAR BRAKE LIGHT SWITCH


2P CONNECTOR

(6) THERMOSENSOR

(11) IGNITION PULSE GENERATOR WIRE


4P CONNECTOR

(9) WIRE BAND

(8) CONNECTORS
for Optional Equipment

(10) TURN SIGNAL RELAY

(16) HEADLIGHT HAZARD


RELAY

(12) CONNECTORS
for Optional Equipment

(15) TURN SIGNAL HAZARD


RELAY

(13) HARNESS CLIP

(14) MAIN WIRE HARNESS

17

ST1100P Addendum

(3) TO CARBURETOR
AIR CHAMBER

(4) AIR INJECTION PIPES


(No. 16)

(5) FUEL FILL CAP


BREATHER TUBE

(1) No. 10 TUBE

(6) No.2 TUBE

(7) EVAPORATIVE
EMISSION (EVAP)
CANISTER

(10) CLAMP:

(9) FUEL TANK TRAY


DRAIN TUBE

(13)No.15TUBE
(14) PULSE SECONDARY
AIR INJECTION (PAIR)
CONTROL VALVE
(FRONT)

(16) No.1 0 TUBE

~1...L'2Z..:.-t1d~~~~rc~~~_-!_ (15)

18

PULSE SECON DARY


AIR INJECTION (PAIR)
CONTROL VALVE
(REAR)

ST1100P Addendum

(4) EVAPORATIVE EMISSION


CARBURETOR AIR VENT
(EVAP CAV) C'oNTROL
VALVE

(5) No.7 TUBE


(10) No. 5TUBE
'~_--i-+--;---(6)

No.5 TUBE

(9) No.6 TUBE

(7) No.6 TUBE


(8) No.4 TUBE

(13) No.6 TUBE


(12) No.7 TUBE
(11) EVAP CAV CONTROL
VALVE
(14) EVAP PURGE CONTROL
VALVE

(15) No.5 TUBE

(18) No.5 TUBE


(17) No. 11 TUBE

19

ST1100P Addendum

Emission Control Information


Labels
An Emission Control Information Label is located on the
rear fender near the frame cross-pipe as shown. The seat
must be removed to read it. It gives basic tune-up
specifications.

Vehicle Emission Control Information Update


Label
After making a high altitude carburetor adjustment, attach
an update label on the right side of the fuel tank as shown.
Instructions for obtaining the update label are given in
Service Letter No. 132.

(1) EMISSION CONTROL


INFORMATION LABEL

T--~U
(2) REAR FENDER
(3)

When readjusting the carburetors back to the low altitude


specifications, be sure to remove this update label.

Vacuum Hose Routing Diagram Label


The Vacuum Hose Routing Diagram Label is on the reverse
side of the right side cover as shown.

VACUUM HOSE ROUTING DIAGRAM


ENGINE FAMILY
EVAPORATIVE FAMILY
CALIFORNIA VEHICLE

20

=c================

ST1100P Addendum

Seat

(1)

Unlock the seat with the ignition key.


Remove the seat by pulling the rear of the seat upward.
Install the seat, aligning the hole with the setting boss as
shown, and lock it by pushing it down securely.

(4) BOSS

Upper Seat Cowling


Remove the seat.
Remove the four bolts and the rear cowling bracket.
Remove the two bolts and the upper seat cowling.

(2) BRACKET

(3) UPPER SEAT


COWLING

21

ST1100P Addendum

Seat Cowling
Remove the left and right side covers and saddle bags
(page 2-2). Remove the upper seat cowling (page 21).

(1) BOLTS/
COLLARS

Remove the two bolts and collars.


Slide the seat cowling rearward, then disconnect the tail!
brake light connector to remove it.

(2) SEAT

COWLING

Saddlebag StayI Amplifier Stay


(1) 8 mm NUTS

Remove the seat cowling.

(8) STAY/BOLTS

Remove the four 8 mm bolts, two nuts and the grab rail
center plate.
Remove the relays from the amplifier stay.
Remove the four 8 mm bolts, two washers and the
amplifier stay.
Remove the two 6 mm bolts and the saddlebag stay.
Torque:
Center plate 8 mm bolt: 35 Nm (3.5 kg-m, 25 ft-Ib)
Saddlebag stay 6 mm bolt: 10 Nm (1.0 kg-m, 7 ft-Ib)
8 mm bolt: 35 Nm (3.5 kg-m, 25 ft-Ib)

(7)

(6)

22

ST1100P Addendum

Fairing Pocket
Remove the maintenance cover (page 2-5).
Remove the top shelter (page 2-5),

RIGHT:

(1) TAPPING SCREW

(2) SCREWS

(4)

Remove the trim clip, five screws and the fairing pocket.
Left Side only:
Disconnect the connectors.

23

ST1100P Addendum

Instrument Panel
Remove the windshield and garnish (page 2-6).
Remove the four screws and the inner screen.

Remove the left and right fairing pockets (page 23).


Disconnect the clock and voltmeter connectors under the
instruments.

NOTE

Adjust the clock after installing the instrument panel.

(1) INNER SCREEN

Remove the two screws, release the tabs and remove the
instrument panel from the upper fairing.

(?) INSTRUMENT

(1) SCREWS

PANEL

(3) CLOCK
CONNECTORS

(4) VOLTMETER
CONNECTOR

24

ST1100P Addendum

Rearview Mirror
(1) STAY
Remove the rearview mirror case by carefully releasing
the three bosses from the clips of the upper fairing.
Disconnect the front turn signal connector.
Remove the two bolts, front strobe lamp stay and the
rearview mirror.

(2) CLIPS

=/
(3) CONNECTOR

(4) MIRROR

(5) MIRROR CASE

Headlight Aim

An improperly adjusted headlight may blind


on-coming drivers, or it may fail to light the road
for a safe distance.

Place the motorcycle on a level surface.


HOLE

Horizontal:
Insert a screwdriver into the hole in the middle fairing inner
cover, and turn the adjusting screw to adjust the headlight
beam.
Vertical:
Remove the right maintenance cover (page 2-5).
Remove the harness band securing the adjusting knob
(Adjusting knob is located under the right fairing pocket:
page 15).
pull out the adjusting knob, and turn the knob to adjust
the headlight beam.

(1) ADJUSTING KNOB

Ir'l"''''

The cylinder head cover becomes hot when running


the engine. Take care not to touch the cylinder
head cover during adjustment.

25

ST1100P Addendum

Light/Meters/Switches Location
(5) BANK ANGLE SENSOR

(4) IGNITION SWITCH

(22) HORN SWITCH

(18) THRMOSENSOR
(19) TURN SIGNAL
HAZARD SWITCH

(14) BATTERY
(16) SIDE STAND SWITCH

(17) NEUTRAL
SWITCH

26

ST1100P Addendum

Rear Turn Signal and Brake!


Taillight
Bulb Replacement

(1) BULB
SOCKET

Remove the seat cowling (page 22).


Remove the bulb socket by turning it counterclockwise.
Remove the bulb by turning it counterclockwise while
pushing in the hub.
NOTE

(2) BULB

Check that the rubber seal is in good condition and


replace it if necessary.

Installation is in the reverse order of removal.

Voltmeter
Bulb Replacement
Release the instrument panel off the upper fairing (page
24).
Remove the bulb socket and bulb.
Install a new bulb and install the removed parts in the
reverse order of removal.

(2) BULB SOCKET

Remova IIInstallation

(1) VOLTMETER

Remove the instrument panel (page 24).


Remove the two screws and the voltmeter.
[nstallation is in the reverse order of removal.

(2) SCREWS

27

ST1100P Addendum

MEMO

28

ST1100P Addendum

Wiring Diagram
METER LIGHT
12V 1 7Wx4

eerB
INDICATOR

~a

~m !fl~i~R:,_

TACHOMETER

1 LEFT!"" SlGNAt

~<D .,~ ~~ ~~ ~:

SW ITCH 1 2 3

l2V 3. 4Wx7

FRONT BRAKE
liGHT SW I TCH

0:5

SWITCH 4
f

to fO ro to
ro ro lo

10 0
10
1 0 -0
3

""g
ON

0~

OFF
COlOR

SWITCH 5

-,

BAT OUT

lo

ON ( )
OFF

BIBu

SWITCH 78
I

"" Ie;> R>


J

1. lOA (REAR FOG) VOLTMETER


2 lOA (STROBE)
3, lOA HAZARD
4 lOA (SllEN) SWITCH 5

COLOR PBI RY

Slo- -6 0

FUSE BOX

-0

COLOR BrBu BrW BIR BeW


----J

ENG INE STOP,STARTER SW ITCH

COLOR

COOLANT
TEMPRETURE
GUAGE

Lg W

Bu

GO OBI

G
REAR BRAKE liGHT
SWI TCH
FAN
MOTOR

FUEL GAUGE

~
1r~ENSOR

IGN I TION CONTROL


MODULE

_ _E

FUEL
lEVEL
SENSOR

SPEEDOMETER

FUEL INO ICATOR


CHECK UNIT

4f~

CLOCK

~BR~~~
~BI/Br===

Re><D<D

HEADLIGHT
HAZARD

~RElAY ~~C~~D

<D~;;'3PMINI3PQ
~~

BI

12V 1. 7W

__ I I

ca

cc

BANK ANGLE
SENSOR
RELAY

:~:P;
~
~;;, GlfTll ~

3P
R

I
ALTERNATOR FUSE
55A

Lg

HEADLI GHT RELAY


(lOW)

Br
Br

~BtR
l.!iB:F

BI~R

BI

STARTER RELAY
SWITCH

W/BI

o
Y

HEADl IGHT RELAY


(HI)

BU
G

BI/R
BulBI

RIGHT FRONT TURN SIGNAL


12V 32/3CP
Lb/W

cta:

:ITE

Lb

MINI3P
Gr

VOLTMETER

,G/BI
W
B1

,....

,"+-_ _L--_

Lb/W -

G ----<~~

Lb-

12V 1. 7W

--I

I~

=.J
I--'

IBI _ _-+-I'+-_

_::t-

MINI4P

j~1 --t-t+++----.J
-

Y/W
Bu
B1

@d:

Bu
I/Bu .....

L.....-

HEADLIGHT
12V 45/45Wx2

r
Br
R

G/R
G/WB1/BG/BI
Br/R
Bu/R

--=-

I~"X==-

r-I---J

IIII

-=

L- Lb

GhY

~ Lb

Ii

---J

G/Y-

~Br

~INI

fiP

0-

"":i

~~

ABCOE

TURN SIGNAL' 0 IMMER' HORN' SW ITCH

HO

BAT3

IGNITION SW ITCH

FREE
PUSH

~
ON I

10+0

FAN

lEFT REAR TURN SIGNAL


12V 21W

TURN SIGNAl
HAZARD SW ITCH

SWITCH 6
_____

Br/R -c::J iR{AR---~


G -c::J ~~O_G_~~M.!'J

~~S

FG

IG BAT!

KEY

ok>R5 KEY

ON

KEY OFF
OFF
t--t--+-I---l-----1
KEY OFF
LOCK
LOCK PIN

SIDE STAND SWITCH

IGNITION coSWITCH

FUSE BOX

SWITCH CONTINUITY
HORN SWI TCH

FUEL PUMP &


RESERVE SENSOR

CLUTCH SW ITCH

-G~

.~~~<D;,',~~;;;~~m !~:mu

l2V 21/5Wx2

___

MINI~~
0<3:5

BRAKE AND TAilliGHT

H-U~====:1

SIREN
RELAY

~~~

f- G C a ; D

BGr=~=Br

A, lOA (NEUTRAL ou- TEMP


B
TACHOMETER' HORN)
, lOA (POSITION' METER LIGHT' TAIL)

C, lOA (HEAOLI GHTl

D,
E,
F,
G,

lOA
lOA
lOA
lOA

(IGNITION' STARTER ALTERNATOR)


(TURN SIGNAL' BRAKE LIGHTl
(CLOCK)
(FAN MOTER)

ALTERNATOR

BI
Y
Bu
G
R
W
V

BLACK
YELLOW
BLUE
GREEN
RED
WHITE
VIOLET

Br BROWN
0
ORANGE
Lb LIGHT BLUE
Lg LIGHT GREEN
P PINK
Gr DRAY

0030l-MAJ-8300

29