HOW TO USE THIS MANUAL Ths saniee manual decaibes the service procedures for the CaRecoRR Flow the Maitenance Schade (Secon 4) reeommandations to nau that he vac poak Opera conion and the erision loves ave wien the stancards set by re US. Envrcnmertal Bretacios Agency (EPA arg Caltoma Ar Rosourcos Board (CARB) tnd Tanor Corea. Pertring the fist scheduled maintenarco is ory important. Conparastes fo te iil wear tal oecuts dung the breacin eros and 4 spay toe wre metre. Section 3 states pero serves deaeoea nthe flowing secuore. ‘youped ‘Sebson § fougr 20" sesembe pars of the moter sesarng 1 lation. Fira te section you want on ts pape, ten tum to the tbe of ‘Coren on the rt page ote aoeten est sections start wth an assert of system istration, sorvice ‘lormaton end: roubleshostng fr tho eecton, The sutseqvent ‘ages ge cetala procedure. tyou ae etait win hs metorcyl, read Technical Features in Fryou cont know the sours at tha trouble, go 10 section 22 ‘roxbleshoctng, ‘Yur salty and the elt of tr, every print To help You mele Infrmed dessions wo have. provided salty iran tnoughost fie anual Ot Curse tis not paces or possi to arn you abou al the ‘feuds sueccatea win sarveing na ven, “lu mustuxe your own goos usorent ‘eu nd inportat alt ineratin i a varity of forme + Safety Labels 1 Safety Messages ~p ne ot tee Signa Ton’ ‘Those signal words mar: PEO esses sen HURT # you dont fotow nsvuctons. OO ee HURT #you dont fotow navuctons. + Inston ~ how sare tis eile coecty and sale eho vehicle rid bya sat alr symbol Bs and TDRNGER, WARNING, or CAL You CAN be HURT if you dont flow CONTENTS [GENERAL INFORMATION TECHNICAL FEATURES | COOLING SYSTEM GLUTCH/STARTER C GEARSHIFT LINKAGE ENGINE AND DRIVE TRAIN CRANKSHAFT/PISTON/CYLINOER = Ey FRONT WHEEL/SUSPENSION/STEERING Ey CHASSIS. ELECTRIC STARTER ‘A you reed this manual, you wil fd information tat 6 oro ado by (MITRE symbol. The purpose o! his messages 10 Fp preverttamnage to your vee, ater property, & the Date of issue: January, 2007 LIGHTS/METERS/SWITCHES ELECTRICAL WIRING DIAGRAM ‘TROUBLESHOOTINGSYMBOLS ‘The symbols used throughout this manual show specific service procedures. It supplementary information is required pertaining to these symbols, it would be explained specifically n the text without the use of the symbols. 2 Replace the part(s) with new one (s) before assembly a” Use recommended engine ol, unless otherwise specified. 7A | Use molybdenum oll solution (mixture of the engine oil and molybdenum grease in a ratio of 1:1). “zy | Uso multipurpose grease (Litium based multi-purpose grease NLGI #2 or equivalent), Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or fauivalent). ARBH | Example: Molykote® BR-2 plus manufactured by Dow Corning USA. Mut-purpose M-2 manufactured by Mitsubishi Oi, Japan | Use molybdenum disuiide 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 (US.A. only) Rocol ASP manufactured by Rocol Limited, UK Rocol Pasta manufactured by Sumico Lubricant, Japan Use silicone grease, Apply sealant. Use DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specif. om ‘Apply locking agent. Use a middle strength locking agent unless otherwise specified sem Prox] Use Fork or Suspension Fluid. AdAspys1. GENERAL INFORMATION ‘SERVICE RULES - MODEL IDENTIFICATION: GENERAL SPECIFICATIONS -~ LUBRICATION SYSTEM SPECIFICATIONS FUEL SYSTEM (PGM-Fl) ‘SPECIFICATIONS - wT COOLING SYSTEM SPECIFICATIONS «1-7 CYLINDER HEAD/VALVES SPECIFICATIONS-. 18 CLUTCH/STARTER CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS... 18 CRANKCASE/TRANSMISSION SPECIFICATIONS 1-9 CRANKSHAFT/PISTON/CYLINDER ‘SPECIFICATIONS. 19 FRONT WHEEL/SUSPENSION/STEERING ‘SPECIFICATIONS. -10 REAR WHEEL/SUSPENSION SPECIFICATIONS -- nee 1210 HYDRAULIC BRAKE SPECIFICATIONS: 1-11 BATTERY/CHARGING SYSTEM ‘SPECIFICATIONS IGNITION SYSTEM SPECIFICATIONS ~-- 1-11 ELECTRIC STARTER SPECIFICATIONS LIGHTS/METERS/SWITCHES SPECIFICATIONS ~- STANDARD TORQUE VALUES--- ENGINE & FRAME TORQUE VALUES. LUBRICATION & SEAL POINTS -.- CABLE & HARNESS ROUTING EMISSION CONTROL SYSTEMS 1-36 1-1