CONTENTS MAINTENANCE. LUBRICATION SYSTEM 2 |_ FUEL SYSTEM (PGM-FI) & | COOLING SYSTEM w Le 5 2 |_ENGINE REMOVAL/INSTALLATION a © | CYLINDER HEAD/VALVES a Z| CYLINDERIPISTON 2 | CLUTCHIGEARSHIFT LINKAGE 2 a ALTERNATORISTARTER CLUTCH Ea REAR WHEEL/SUSPENSION HYDRAULIC BRAKE = "ANTFLOCK BRAKE SYSTEM (ABS) BATTERYICHARGING SYSTEM [IGNITION SYSTEM ELECTRIC STARTER | LIGHTS/METERS/SWITCHES ELECTRICAL ~ WIRING DIAGRAMS TROUBLESHOOTING =1. GENERAL INFORMATION SERVICE RULES MODEL IDENTIFICATION ~ GENERAL SPECIFICATIONS LUBRICATION SYSTEM SPECIFICATIONS FUEL SYSTEM (PGM-Fl) ‘SPECIFICATIONS COOLING SYSTEM SPECIFICATIONS CYLINDER HEAD/VALVES SPECIFICATIONS - CYLINDERIPISTON SPECIFICATIONS CLUTCHIGEARSHIFT LINKAGE SPECIFICATIONS ALTERNATORISTARTER CLUTCH ‘SPECIFICATIONS CRANKCASE/CRANKSHAFT/ TRANSMISSION/BALANCER SPECIFICATIONS FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS 4-10 REAR WHEEL/SUSPENSION SPECIFICATIONS----~ 1-40 HYDRAULIC BRAKE SPECIFICATIONS~1-10 BATTERY/CHARGING SYSTEM ‘SPECIFICATIONS: 141 IGNITION SYSTEM SPECIFICATIONS ~~~ 1-14 ELECTRIC STARTER SPECIFICATION 1-14 LIGHTS/METERS/SWITCHES SPECIFICATIONS: TORQUE VALUES 112 LUBRICATION & SEAL POINTS 116 CABLE & HARNESS ROUTING 118 EMISSION CONTROL SYSTEMS ~ 4-47GENERAL INFORMATION SERVICE RULES 1. Use Honda Genuine or Honda-recommencied parts and lubricants or their equivalents, Parts that do not meet Honda's design specifications may cause damage to the motorcycle. Use the special tools designed for this producto avoid damage and incorrect assembly. Use only metric tools when servicing the motorcycle. Metric bolts, nuts and screws are not interchangeable with English fasteners. Insta new gaskets, O-rings, cotter pins, and lock plates when reassembiing, When tightening bolts or nuts, begin with the larger clameter or inner bolt first. Then tighten to the specified torque diagonally in incremental steps unless a particular sequence is specified Clean pars in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly. ‘After reassembly, check al pers for proper installation and operation. Route all electrical wires as shown in the Cable and Hamess Routing (page 1-18). Do nat bend or twist control cables. Damaged control cables wil not operate smoothly and may stick or bind ABBREVIATION Throughout this manvel, the following abbreviations are used to identify the respective parts or systems. Ful arm —__| Antitock Brake System Crankshaft Poston sensor Data Link Connector ‘Diego Trouble Cod Eig Cond Weta — Ege Cooler Toe ePanFS FOr octal Erasable Programmable Read Only Meme Evaporaiee Eriscor Honda Dsghosti System le A Control Vane Vehicle Speed sensorGENERAL INFORMATION MODEL IDENTIFICATION CBR250RA shown: SERIAL NUMBERS ‘The Vehicle Identification Number (VIN) [1] is stamped on the right side of the steering head. ‘The ongne serialnumber [1] stampod on the lover let sce of theGENERAL INFORMATION ‘The throtle body identification number [1] is stamped on the lower left side of the thrattie body. i LABELS ‘The Safety Certification Label [1] I located on loft side of the frame. ‘The color label [1] is attached on the frame under the passenger seat. When ordering color-coded parts, always spectty te designated color code. ‘The Emission Contr information Label is attached on the rear fender. + USA/Canada type [1] + Canada type only [2] 1-4GENERAL INFORMATION GENERAL SPECIFICATIONS FRAME ENGINE | FUEL DELIVERY SYSTEM DRIVE TRAIN rn TE ‘Overall Tengtn Overall width Overall height Wheelbase Seat height Footpeg height Ground clearance Curb weight Maximum weight capacity Frame type eS Front suspension Front axle travel Rear suspension Rear axle travel Tire size Tite brand Front brake Rear brake Caster angle Trail length Fuel tank capacity Cylinder arrangement Bore and stroke Displacement Compression ratio Valve train Intake valve opens. closes Exhaustvalve opens closes Lubrication system il pump type Cooling system Airfitetion Engine dry weight Type Trrottle bore Clutch system Clutch operation system Transmission Primary reduction Final reduction Gear ratio Gearshift pattern cBR250R CBR250RA, CBR250R CBR250RA Front Rear Front Rear at 1.0 mm (0.04 in) lit at 1.0 mm (0.04 in) lft at 1.0 mm (0.04 in) lft at 4.0 mm (0.04 in) it tet 2nd 8rd ath sth ath SPECIFICATION 2,086 mim (60.1 in) 720 mm (28.3 in) 4,425 mm (44.3 in) 41,370 mm (63.9 in) 780 mm (30.7 in) 328 mm (12.9 in) 445 mm (67 in) 162 kg (657 Ibs) 166 kg (366 Ibs) 217 kg (478 Ibs) 219 kg (483 Ibs) “Twin-spar Telescopic fork 118 mm (4.8 in) ‘Swingarm. 404 mm (4.1 in) 110/70-47MUC 548 +140/70-17MIC 66S RX-O1FD (IRC) RX-OIRZ (IRC) Hydraulic single disc Hydraulic single disc 25° 30) 98.6 mm (3.88 in} 13,0 ters (3.43 US gal, 2.86 Imp gal) Single cylinder inclined 20° from vertical 76.0 x 85.0 mm (2.99 x 2.47 in) 2496 om? (16.2 cu-in) 40.731 Chain driven DOHC with rocker arm 20° TDC. 35° ABDC 40° BBDC or TD Forced pressure and wet sump Trochoid Liquid cooled Viscous paper fiter 35:4 kg (78.0 Ibs) PGM-FI 38 mm (1.5 in) Malt-plate, wet Cable operating Constant mesh, 6 speeds 2.808 (73/26) 2.714 (38/14) 3.399 (40/12) 2.197 (36117) 41871 (33/21) 4.304 (30/23) 1.115 (29/26) 0.962 (28/27) Left foot operated return system 1-N-2-3-4-5-6 1-5GENERAL INFORMATION ITEM ELECTRICAL Tonition system Starting system Charging system Regulatovrectiner Lighting system_ __'SPECIFICATION Computer controlled digital transistorized with electric advance Electric starter motor Triple phase output alternator ‘SCR shorted, triple phase fullwave rectification BatteryGENERAL INFORMATION LUBRICATION SYSTEM SPECIFICATIONS Unit: mm (in) TEM STANDARD SERVICE LIMIT Engine oll eapectty ‘At draining “a tters (11S US af, 1.2 Imp qi) Sree Aoi fiter change 1.Slters (16 US at 1.3 imp qi) - ‘Atdisassembly 1.8 liters (7.9 US qt, 1.6 Imp qi) = Recommended engine ch 2 ro Honda GNA 4-stioke oil (U.S.A and Canada) or equivalent motor of [API service classification: SG or Higher = “JASO T 903 standard: MA. __| Viscosity: SAE TOW30 ‘Oirpump rotor Tipdearance (0.15 (0.006) 0.20 0.008) Body dearance (0,180.22 (01008 =0,008) 0:35,(0.014) ‘Side clearance 0.02- 0.09 (0.001- 0.004) 0.10 (0.004) FUEL SYSTEM (PGM-Fl) SPECIFICATIONS ces = Tem 2 = ‘SPECIFICATION (Tihioie body Wienteation number r= Con INE os] Engine idle speed 7/400 + 100 rpm : “Throtte grip treeplay im (1116 = 14 in) "Fe! injector resistance (20°C/68°F) 1-130 Fuel pressure at idle a daar ~ 284 KPa (8.0 kgliom?, 43 psi) Fuel pump flow (at *2V) 5 {692 Gat" @.34 US 02, 2.44 Imp 02) minimurn/i0 seconds UR control solenoid valve resistance (20°CI66°F) =i “24-260 EVAP purge control solenoid valve resistance (20°C/65°F) e 30-340 COOLING SYSTEM SPECIFICATIONS IE cee a SS = ‘SPECIFICATION Coolant capacty Radiaior and engine 40 ers (1.16 US gt, 087 Imp a) At draining O.7alitar (0.83 US qt, 0.70 Imp at) Reserve tank 0.25 liter (0.26 US qt, 0.22 Imp at) oe Radiator cap relief pressure E 2.6 KPa (0,951.25 kgticm, 13.5 ~ 17.8 psi) “Thermostat "| Begin to open ‘81 ~ 84°C (178 ~ 183°F) Fully open ee oreo me Valve lift 1 ~a.5 mm (0.18 in) minima Recommended anliresze Pio Honda HP Coolant or an equivalent high qually ethylene — alycol antifreeze containing siicate-ree corrosion inhibitors ‘Standard coolant concentration =< z “11 (mixture with istiled water)GENERAL INFORMATION CYLINDER HEAD/VALVES SPECIFICATIONS ITEM _ Cylinder compression at 480 rpm. eens 2 & Valve, valve Valve stem OD. IN Valve guide height | IN/EX [Valve seat width IN/EX Valve spring Free length Inner ~ Rocker arm, ‘Arm 1.D. IN/EX Camshaft ‘Cam lobe height IN x Oil clearence — (Gyiinder head warpage 0,005 — 0.042 (0.0002 4.204 KPa (182 188 pai) 0:16 = 0.03 (0.006 + 0.001) 0.27 £003 (0.011 = 0.001) 4.470 — 4 495 (0.1760 ~ 0.1770) 4.460 4.485 0. 4500 = 4.512 (0.1772 0.1776) 34.58 (1.361) 40.37 (1.589) 9,987 (0.3926 ~ 0.3932) 0.018 0.049 (0.0005 - 0.0017) 30.931 - 31.171 (1.2178 — 1.2272) 12236) ) CYLINDER/PISTON SPECIFICATIONS rem Cylinder 1D. ‘Outofround Taper __| "Wearpage Piston,piion | Piston OD. at 11 mm (Oa) om pin. plson_ettom ing Piston pin hole [D._ Pision pin OD. 3 “Pistonto-iston pin clearance — Piionrngend Top ep Second Osi raip Piston rngtoving |Top groove seerance |” Second Cylindsto-ision clearance Connecting rod small end 1D. Connecting roe-o-psion pin clsarancs [17002 = 17-008 (0.6684 ‘STANDARD "76000= 76.010 (2.9924 = 9925) 75.980 ~ 75.980 (2.9905 - 2.9913) 0.20=0.70 (0,008 - 0.028) 0.040 = 0.080 (0.0016 - 0.0082 “0.015 = 0.050 (0.0006 - 0.0020) 0.020 = 0.050 (0.0008 = 0.0020) 47,016 — 17.034 (0.6699 - 0.6706) 0.616 = 0.040 (0,0006 - 0.0016) — CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS TEMES eae ‘Cush fever teoplay ~Cluien “Spring fee length Dise thickness Plate warpage Clutch outer guide 1D. Mainshaft 0.0. at cuich outer guide 4.2 STANDARD 70-20 = 13/16) 41.5 (1.63) 2:30~2.50 (0087 70,000 = 20.024 (0.78 49,967 = 19.960 (0.7861 7882) = 0.7865) = 10,075 (03087-03043) 0-40 (0.004) Unit: mm Cin) 446 (0.176) 4.45 (0.175) 4.540 (0.1787) (0.07 (0.008) : 0.08 (0,003) 4.50 (0.059) 32.85 (1.203) 38.35 (1.510) 70.10 (0.396) 9.75 (0.384) 10.10 (0.004) TT BOTT (T2170) ~ 30.819 (1.2133) 0.10 (0.004) 0.05 0.002) Unit: mm (in) VICE LIMIT 76.04 (2.984) 0.070 (0.0004) (0.010 (0.0004) 0.05 (0.002) 75.89 (2.988) 47.080 (0.6705) 16.980 (0.6685) 0.08 (0.003) 0.40 (0.016) 028) 1-40 (0.043) 0.40 (0.004) 0.09 (0.004) 0.09 (0.004) 17.06 (0872) 37.5 (1.48) 2.27 (0.089) 030.01) 20.04 (0.789) 19.947GENERAL INFORMATION ALTERNATORISTARTER CLUTCH SPECIFICATIONS eis = Unit mm in) zs TEM STANDARD SERVICE LIMIT |" Starter anven gear TB: BANOO 34073 (7.8386 - 73503) 34.033 (1.3399) OD. z 51.705 — 51.78 (2.0356 - 2.0364) 57.605 (2.0948) CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER SPECIFICATIONS : fara Unit: mm (n) TEM ‘STANDARD SERVICE LIMIT Crankshaft | Runout eae = 0.03 (0.001) Connecting rod big end radialGlearance | 0.008 — 0,076 (0,0002- 0.0006) 0.05 (0.002) “Connecting rod big end sie clearance — 0.05 ~ 0.50 (0,002 - 0.020) 0.85 (0.033) Main journal oft clearance (0.018 - 0.045 (0.0007 ~ 0.0018) 0.978 (0.0030) Main journal 0. 33.985 ~ 34,000 (1.3380 ~ 1.3386) 33.975 (1.3876) ‘ain journal Beating ares 1. 38.000 - 38.098 (7.4961 ~ 7.4968) 38.036 (1.4975) Transmission | Gear |. 23,000 = 23.021 (0.9055 - 0.9083) 23.07 (0.006) 3.020 23,041 (0.9063 - 0.9071) 23,09 (0.908) 25.000 — 25.021 (0.9843 — 0.9851) 25.04 (0.986) 28,000 = 28.021 (7.1024 1.1082) 28.04 (1.104) Bushing O-D- 22.959 - 22.980 (0.9039 = 0.9047) 22:51 (0.902) 22.984 ~ 23,005 (0.9040 = 0.9087) 22.47 (0.885) 24,959 ~ 24,980 (0.9820 ~ 0.9835) 24.90 (0,980) 27.959 — 27.980 (1.1007 1.1016) 27.95 (1.100) ieee 0.020 — 0.062 (0.0008 - 0.0024) 0.10 (0.004) 0.015 ~ 0.057 (0.0006 - 0.0022) 0.100.008) Bushing LD. MB, C1 20,000 = 20,021 (0.7874 = 0.7882) 20.08 (0.780) 2,000 ~ 22.024 (0.8681 = 0.8670) 22.07 (0.888) income 25,000 — 25.021 (0.9843 — 0.9851) 25.04 (0.986) Mainshatt/ atMS bushing 19.959 — 19.980 (0.7858 - 0.7866) 49.91 (0.784) countershaftO.D. at Ci bushing 19.959 = 19,980 (0.7858 - 0.7868) 19.91 (0.784) atG2bushing | 21.959 21.980 (0.8645 — 0.8653) 24.94 (0.863) at G3 bushing | 24.959 ~ 24 980 (0.9626 — 0.9635) 24.90 (0.980). Bushinge-shatt ys, c1,c2,C2 | 0,020—-0.082 (0.0008 - 0.0024) 0.10 (0.004) Shift fork Shit fork shaft O.. es 11.957 — 11.968 (04707 = 0.4712) 41.95 (0.470) shit fork Shit for 1. = ~ | 12.000 12.018 (0.4724 - 0.4731) 72,05 (0.474) shaft | Shift ork claw thigkness 4.98 — 5.00 (0.194 — 0.197) 4.82 (0.190) Shitéum | Shitdumoo. — Leftsde 13,066 ~ 13.984 (015496 — 0.5506) 73,94 (0.549) Shik comm Jouenal il afierade 14,000 14.027 (0.8512 - 0.5622) 14.06 (0.554) 7 Shittdumo-shit Blea i ‘rum journal Left side 0.016 ~ 0.061 (0.0006 - 0.0024) 0.08 (0.003) slearance 1-9GENERAL INFORMATION FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS Wheel rim runout | Wheel balancer weight aa Fork ‘Spring free length Pipe runout STANDARD Pa (2,00 ken, 29 psi) 200 KPa (2.00 Kalle, 29 psi) “| a37.8 664) Recommended fork aid | Fluid capacity ‘Sleeting head bearing preoad_ REAR WHEEL/SUSPENSION SP! Minimum tire thread depth Cold tire pressure Radial ‘Axial ‘Sizelink [Sisk fS EM Front | Specified brake fd = arpage es Master cylinder 1D. | CBRA5OR __caR250R4 ‘Master piston 0.D. 3R250R, ____|-CBRZs0RA (Caliper cyinder'.D.(CBR250R) CalpercyinderD. | Calipor GyinderA (CBR250RA) | Caliper cylinder B Caliper piston 0.0. (CBR250R) Caliperiston 0.0. | Caliper piston A ef pision B Rear Brake pad w Brake disc thickness. | [Caliper piston O: Brake pedal hel Pro Honda Suspension Fluid S 15063) _ 331 22.5 cn" (11.2 £0.08 US 07, 11.7 + 0.09 Imp oz) L157 = 24.5N(1.6-25kgf, 35-551) | ECIFICATIONS rANDAR! 20 KPa (2.00 Khem 29 psi) 225 KPa (2 DIDS20VF-108LE RKS20KLO-108LE 20 | DoT SerD0T 3-47 (017-01 47,000 17,043 (0.4331 = 42,700 — 12.743 (0.5000 = 12.857 - 12.68 25.400 ~ 25.450 (7.0000 “72.585 = 20.518 (0.8602 =0.5 (1.0508 = 7.0817) 38.18 - 38.23 (1.503 — 1.505) 36,096 28.148 (1.4900 — 1.5 55-8 (TON) aliem! 33s) STANDARD “40,957 = 10.964 (0.4314 - 0.4924) (0.4963 -0.4994) Unit: mm (in) iT SERVICE LI 1.5 (0.06), 0210.01) 2,0 (0.08) 2.00.08) 6Ogmex. (0:20 (0.008) “Unit: mm (in) SERVICE LIMIT 2.0 (0.08) 02 (001) 2.0 (0.108) 2.00.08) 609 mex | Unit: mm (in) ICE LIMIT | jo gtoove (35 @14) 03(0001) 47.055 (0.4963) 42.7585 (0.5022) 40.945 (0.4309) 412.645 (0.4978) — ‘8) 017) Ta groove 4.0 (0:16) 0:3 (0.01) z 141085 (05533) 43.948 (0.5490) — 36.28 (1.506) 38.00 (1.500)ITEM Battery Type. ‘Capacity ‘Current leakage Vottage (20°C/ 68°F) Needs Charging current ‘Riternator | Capacity Charging col resistanes (20-Ci6s°F) GENERAL INFORMATION BATTERY/CHARGING SYSTEM SPECIFICATIONS SPECIFICATION YDXTL-BS 12V-6 Ah 0.34 mA max 730-182 Below 123 CAB 70h SNth 0138 kW, 000 em o1=190 IGNITION SYSTEM SPECIFICATIONS ITEM Spark plug ‘Spark plug gap ~ Ignition coil peak voltage (CKP sensor peak voltage Tonitfon timing °F" mark) _SPECIFICAT ‘SIMRBAQ (NGK) {0.80 =0.90 mm (0.031 - 0.036 in} 100V minimum 0.7V minimum 40°BTDC atidle ELECTRIC STARTER SPECIFICATION x Tem Siarfer motor brush length TEM Bulbs Headlight Poston ight ‘Brakertal ight Tum signal ignt Tur signal indicator High beam indicator Neutal indicator MIL ‘ABS indicator (CBR250RA) Fuse Main fuse ‘Sub fuse (CBR250R (CBR250RA LIGHTS/METERS/SWITCHES SPECIFICATIONS ‘SPECIFICATION 12.V- 60155 W 12V-5Wx2 42V-2165W T2V-21Wx4 12V-5W LeD eo LED. 2V-17W LED ze LED 30A HOAx5 BOAx2, 10Ax6 3 Unit: mm (in) STANDARD ‘SERVICE LIMIT 118 - 12.3(0.46-0.48) 65 (0.26) 1-11GENERAL INFORMATION TORQUE VALUES STANDARD TORQUE VALUES z TORQUE _ FASTENER TYPE Nm (kgm, Ibe) bolt and nut 52 (0.5, 38) 6 mm bolt and nut 10 (1.0, 7) {Incudes SH flange bot) 8 mmbolt and nut 2222, 18) 40mm bolt and nut 24 (35,25), 42mm bolt and nut 54(55, 40) ENGINE & FRAME TORQUE VALUES + Torque specifications listed below are for important fasteners. + Others should be tightened to standard torque values listed above FRAME/BODY PANELSIEXHAUST SYSTEM THREAD TORQUE FASTENER TYPE ecatre “Simm screw 42 (04, 3.1) 6 mmscrow 9.0(0.9, 66) ‘6 mm flange bolt (8 mm head, large flange) and nut 12.(1.2.9) 8 mm flange bolt and nut 27 (28, 20) 410mm flange bolt and nut 39 (4.0, 29) TORQUE Tem prt oe elena a REMARKS Rearview mirror mounting socket bolt 4 o 52 (05,38) Feta | Front turn signal light mounting nut 2 10 24 (24, 15) Headlight mounting serow 6 5 4.40.08) Front side reflector stay mounting nut 2 6 4500211) | Uut Brakettal ight mounting sre 4 5 4.1(01,08) Side reflector mounting nut 4 6 15(0211) | Unt Reflector mounting nit 1 5 4502.41) | Urut Muffler band bolt 1 3 225(@3,17) Exhaust pipe joint nt 2 8 18.1.8, 13) Exhaust pipe stud bot zd bE Be = _| see page 222 MAINTENANCE THREAD TORQUE [ TEM aren eany Re REMARKS ‘Spark plug Te 10 16 (1.6, 12) a. Crankshaft hole cap 1 30 80(08.59) Apply enginecilto the treacs Oil rain bot 1 2 24 (24,18) Throttle cable A adjuster lock nut (rip side) 1 7 38 (04,28) Throttle cable A adjuster lock nut (throttle ody see) 1 6 003,22) Air cleaner cover screw 10 5 4.4 (01,08) Drive chain adjuster lock nut 2 8 21 (24, 16) Sicostand pivot bolt 1 10 10(1.0.7) Sidestand pivet lock nut ase -90(34.22) | nut FUEL SYSTEM (PGW-Fi) sy | THREAD TORQUE Trem Ses are Te ayant me) _ REMARKS ~O: sensor 1 25 (2.5, 18) = Insulator band screw z 42(04,31) | Seepage 5-49 Tarot cabo stay serew 2 34 (03,25) Camper stay screw 1 34 (0.3.25) IACV setting plate tore screw z 2.4 (02,1.) ‘Sensor uni ore sere 3 34 (03,25) Fuel injector joint mounting belt 2 541 (05.38) ECT sensor 1 25 (26, 18) Fuol pump seting plato rut 6 12(12,9) Seepage 5-42 Throte cable Ajoin nut (grip side) =| 46(02,1.1) Throtte cable B joint nut (rip side) 1 4§(02,4.1) Throtle cable B (throttle body side) 4 30 (03.2.2) Bank angle sensor mounting ut 2 40(1.0.7) 4.12GENERAL INFORMATION COOLING SYSTEM iTem Water pump impeller Water hose band screw Fan motor shroud mounting bott Fan molor screw Cooling fan nut ENGINE REMOVALJINSTALLATION rem Front engine mounting nut Front engine hanger plate bolt Rear engine mounting nut Drive sprocket fixing plate bolt CYLINDER HEADIVALVES Tem Gylinder head cover bolt ‘Camshaft holder mounting bolt (Cylinder head mounting nut PAIR check valve cover bolt Cam chain tonsioner liter plug CYLINDERIPISTON “TEM Cynder stud Bot fi CLUTCHIGEARSHIFT LINKAGE = TEM ‘Gluten center lock nut Primary drive gear lock nut ‘Shift drum stopper arm bolt ‘Shift drum stopper plate bolt Clutch liter plate bolt Gearshift spindle return spring pin ALTERNATORISTARTER CLUTCH rem lutch socket bolt Siai Flywheel bolt ‘Stator mounting socket bolt ‘CKP sensor mounting socket bolt THREAD DIA. (men) 7 THREAD DIA. (mm) 70 10 10 THREAD DIA. (mm) 6 6 0 THREAD DIA. (mm) 10 "THREAD |_DIA. (mm) 6 6 THREAD DIA. (mm) 8 2 TORQUE Nem (kgm, bf-) 40(1.0, 7) 85 (09,63) 2.8 (0.3, 2.1) 1.4 (0-1, 0.8) TORQUE _Nim (kgm, Ibf) 45 (4.6, 33) 45 (4.6, 33) 45 (4.8, 33) 40(1.0, 7) TORQUE Nem (kgm, br) 40(1.0, 7) 12 (12,9) 51 (62, 38) 52 (05,38) 42 (04,31) TORQUE Nem (kgm, Ib) TORQUE Nem (kgm, IbF-A) 108 (11.0, 80) 108 (11.0, 80) 40(1.0,7) 10 (1.0, 7) 12(1.2, 9) 30 (3-1, 22) TORQUE Nem (kgf, tb) 30 (3-1, 22) 128 (13.0, 94) 10(1.0, 7), 10 (1.0, 7) REMARKS See page 6-10 Apply locking agent to the threads, REMARKS REMARKS Apply engine oiltothe threads ‘and seating surtace. Apply engine olltothe threads ‘and seating surface. REMARKS ‘See page S86 REMARKS Lock nut: replace with a new fone and stake. Apply engine olltothe threads and seating surface, Apply engine oiltothe threads ‘and seating surface. Apply locking agent to the threads. Apply lacking agent to the threads. Apply lacking agent to the threads. REMARKS ‘Apply locking agent to the threads. Apply engine oil tothe threads ‘and seating surface. ‘Apply locking agent to the threads. Coating width: 6.5 + 1.0 mm (0.28 = 0.04 in) from tip 1-13GENERAL INFORMATION ‘CRANKCASEICRANKSHAFT/TRANSMISSIONIBALANCER. | THREAD Tem [aT | oan fom) ‘Cam chaln tensioner pvat bolt 7 é Balancer shat nut 1 4 FRONT WHEELSUSPENSIONISTEERING ace | ary | THREAD j rem eral arte) Handlebar pinch bolt 2 8 Handlebar switch housing screw 4 5 Front axle nut 1 12 Front axle pinch bolt 1 8 Front pulser ring mounting bolt 3 5 (CBR250RA) Front brake disc bolt 6 6 Fork bot 2 3 Fork socket bot 2 8 Steering stem nut 1 4 Steering stem adjusting nut 1 26 |Top bridge pinch boit 2 8 Bottom bridge pinch bolt 2 10 Front brake hose slay bolt 4 6 Brake hose mounting bolt (CBR2SORA) | 1 8 Clutch lever pivot bolt 1 6 Clutch lever pivot nut z iat 6 REAR WHEELISUSPENSION = ay THREAD | cs Tew ory linear od ees ‘8 Driven sprocket nut 6 10 Rear pulser ring mounting bolt 4 5 | (cBR250RA) Reser brake disc bolt 4 8 | Shock absorber mounting nut 2 10 Shock aera nut 1 10 Shock ink nut 2 10 Swingarm pivot rut 1 14 Rear brake hose guide mounting screw | 1 5 1-14 TORQUE 44 (45,92) threads. Coating width: 6.54 1.0mm | (0.28 = 0.04 in) from tip | Apply engine olto the threads ‘and seating surface. TORQUE 59 (6.0, 44) 22 (22, 16) 7.0 (07,52) 20 (2.0, 15) 22.22, 16) 20 (2.0, 15) 103 (10.5, 76) 2222, 16) 32(8.3, 24) 121.2, 9) 10(1.0,7) 1.0 (0.1,0.7) TORQUE ‘Nim (kam, bf) 88 (9.0, 65) 75(76, 55) 70(07.52) 42 (43,31) 36 7.27) 75(7.6.58), 757.6, 58) 88 8.0, 65) 430-1, 1.0) REMARKS U-nut ALOC bolt; replace with anew ‘ALOC bolt; replace with anew Apply locking agent to the threads. Apply engine ol to the threads. See page 13-33 ‘Apply locking agent to the threads. ‘Apply molybdenum disulfide ‘grease tothe sliding surface. REMARKS. Una Usnut ‘ALOCbot replace with anew ALOC bot replace witha now U-nut U-nut Umut Usnut ALOC screw; replace with aGENERAL INFORMATION HYDRAULIC BRAKE mem ary ~ Brake hose oil bolt (CBR250R) Brake hose oil bolt (CBR250RA) Brake caliper bleed valve (CBR250R) Brake caliper bleed valve (CBR250RA) Front master cylinder reservoir cover screw Front master cylinder holder bolt Front brake light switch screw Brake lever pivot bolt Brake lever pivot nut Front brake caliper mounting bott 2 Front brake caliper bracket pin 7 Front brake caliper pin 1 Front brake pad hanger pin 1 Pad pin plug (CBR250R) 1 Rear reservoir cover screw Rear master cylinder mounting bolt 2 Rear master cylinder push rod lock nut 1 Rear master cylinder hose joint screw 1 Rear reservoir mounting bolt fl Rear brake pad hanger pin 1 Rear brake caliper pin 1 Main stop holder mounting socket bolt | 4 Main step cap bolt 2 Passenger step holder mounting socket 4 bolt ANTI-LOCK BRAKE SYSTEM (ABS) (CBR250RA) Tew ary (Brake pipe ont nat 44 PCV mounting bot 2 Delay valve mounting bok A IGNITION SYSTEM Tem ary | ining oe cap + ELECTRIC STARTER Tew ary Ngative brush sorew aa Starter motor assembly bolt 2 LIGHTSIMETERSISWITCHES ITEM ee tan Rear turn signal ight mounting nut 2 Igntion switen mounting bolt 2 Combination meter mounting sew 3 Neutral swtcn 4 THREAD ORQUE DIA, (mm) Nem (kgm, IDFR) REMAN) es 34 (35, 28) 40 34 (35,26) 8 54 (08,40) 8 54 (06,40) 4 1902.11) | 6 4212.9) 4 42(0.1.09) 6 10 (01,07) | Apply 0.10.9 (0.004 oz) Slicone grease to the slicing surface. 6 59 (08.44) 8 30 (3.1.22) | ALOC bolt replace with anew 8 43(13,10) Apply locking agent to the threads 8 22(22,16) __Aoply locking agent to the throace 10 48 (1.6, 19) 40 24 (02. 18) 4 1.5(02, 1.4) 6 12(42.9) 8 A717, 13) 4 15(02\11) Apply locking agent tothe threads 6 10(40,7) ‘o 4701.7.13) 2 27 (28, 20) 8 27 (28, 20) 8 41 (1.4.8) 3 27 (28,20) THREAD TORQUE | DIA. (wm) | Nmi(gtm, ibe) | __ REMARKS 10 14 (14.10) Apply brake fui othe threads. 40 (1.0.7) 40(1.0.7) TORQUE “DIA (mm) Nm (kgm, en) | —_REMARKS ‘4 30(06.44) | Anplyengine oto the tyeeds THREAD TORQUE DIA. (mm) Nem (kgm, nem) REMARKS 3 37 (04,27) 5 | 490836) THREAD TORQUE DIA. (mm) __ Nm (kgm, Ib) eS 40 2 (fats 8 24(24,18) | One-way bolt replace with a new one 5 44(04,08) 10 1212.9)GENERAL INFORMATION LUBRICATION & SEAL POINTS ENGINE = LOCATION REMARKS Left crankcase mating surface ‘See page 12-25 12078, 1215 or equivalent) | Alternator/CKP sensor wire grommet sealing surface Scoee Liquid sealant (Three bond | Cylinder head semi-circular cut-out 5211C, SS KE45, 12078, | 1218 or equivalent) Engine oil (il pump rotor entre surface il pump shaft outer surface Water pump shaft outer surface Cam chain whole surface Cylinder inner surface Piston pin hole inner surface, ring groove and sliding surface Piston ring entire surface Clutch dise entre surface Gearshift spindle shaft outer surface Starter one-way clutch sprag Starter driven gear sliding surface Each ol seal lips Each bearing rotating area Each gear teeth Each O-ring pod vi a set % Mul-purpose grease Each ol seal lips (clutch lifer arm, gearshift spindle, [pases countershaft, water pump) Molybdenum oll solution (a | Valve stem sliding surface mixture of 1/2 engine oll and | Camshaft lobes and journal 112 melyodenum disulfide Rocker arm shaft outer surface ‘rease) Rocker arm inner surface, roller surface and slipper surface Piston pin outer surface Clutch outer guide inner surface Gutch iter arm sliding surface Starter reduction gear inner surface Starter reduction gear shaft outer surface Crankshaft main journal bearing siding surface Connecting rod big end slicing surface Connecting rod small end inner surface Left crankshaft needle bearing rotating surface Balancer driven gear and sub gear siding surface ‘Shift fork inner surface and guide pin Shift fork shat outer surface Shift crum journal outer surface and grooves M5, C1, C2, C3 goar bushing entire surace | M6, G4 gear bushing outer surface Ja. seem /Ceosking agent Mainsheft Bearing setting plate bot reads | Coating wares = LOmm = | (0250.04 in) from tip 1-16GENERAL INFORMATION Urea based mult-purpose ‘grease with extreme pressure (example: Kyodo Yushi, Shell stamina EP2 or equivalent) Mull-purpose grease Silicone grease DOTS or DOT 4 brake Mid LOCATION Steering head bearing inner race and outer race rolling surface Steering head bearing dust seal lips Fale outer surface ‘Swingarm pivot needle bearing rotating area ‘Swingarm pivot bolt outer surfaco Shock linkage needle bearing rotating area Passenger seat catch hook sliding area Main step pivot pin siding surface Sidestand pivot sliding surface Gearshift tie ro sliding surface Gearshift pedal pivot sliding surface Throttle pipe flange cable groove Right handlebar switch housing sliding area Brake pedal pivot siding area Each dust seal ips Each O-ring Brake pad hanger pin O-ring Brake calipor and bracket pins sliding surface Brake caliper dust seal whole surface Brake lever contacting area (master piston) Rear master cylinder push rod contacting area (master cylinder piston and boot) Brake master piston siding area Rear master cylinder hose joint O-ring Brake caliper piston sliding area and piston seal REMARKS 3.05.0 g (0.11~—0.18 02) (04 g (0.01 02) minimum 0.10 g (0.004 oz) 0.40 g (0.004 o2) (Cable lubricant Fork fluid Honda Bond A or equivalent _ Brake pad retainer mating surface Throttle cable casing inside Fork bolt O-ring Fork ol seal ips Lefthandlebar and throlle pipe outer surface ( ‘contacting area) Air cleaner connecting boot matching surface 1-17GENERAL INFORMATION CABLE & HARNESS ROUTING (CBR250R: COMBINATION METER 20P CONNECTOR FRONT BRAKE HOSE JUNCTION RIGHT HANDLEBAR | 12? CONNECTOR SWITCH WIRE FRONT BRAKE LIGHT SWITCH WIRE THROTTLE CABLES LEFT HANDLEBAR SWITCH WIRE ‘TURN SIGNAL POSITION RELAY {9P (BLACK) CONNECTOR FRONT SUB HARNESS 9 (BLACK) CONNECTOR BANK ANGLE SENSOR 3P CONNECTOR || FRONT BRAKE HOSE 1-18‘CBR250RA: RIGHT HANDLEBAR SWITCH WIRE re FRONT BRAKE LIGHT SWITCH WIRE THROTTLE CABLES FRONT SUB HARNESS: 9 (BLACK) CONNECTOR BANK ANGLE SENSOR 3P CONNECTOR, FRONT BRAKE HOSE JUNCTION 12P CONNECTOR GENERAL INFORMATION COMBINATION METER, 20P CONNECTOR | BRS CLUTCH SWITCH WIRE ‘CLUTCH CABLE ! LEFT HANDLEBAR ©) SWITCH WIRE ee IN | Ire scualiros hn retny ae — ah | | FRONT BRAKE HOSES FRONT WHEEL SPEED SENSOR WIRE 1-19GENERAL INFORMATION FRONT SUB HARNESS. POSITION LIGHT WIRE ‘9P (BLACK) CONNECTOR FRONT SUB HARNESS, POSITION LIGHT WIRE HEADLIGHT 3P CONNECTOR LEFT TURN SIGNAL LIGHT RIGHT TURN SIGNAL LIGHT WIRE CONNECTORS WIRE CONNECTORSGENERAL INFORMATION FRONT SUB HARNESS. FRONT SUS HARNESS: TURN SIGNAL LIGHT WIRE | = ~ TURN SieNaL Licht WIRE FRONT SUB HARNESS. 1-21GENERAL INFORMATION ‘CBR250R: FRONT BRAKE HOSE THROTTLE CABLES THROTTLE CABLES 1-22‘CBR250RA: GENERAL INFORMATION FRONT BRAKE HOSE THROTTLE CABLES aN <\ aN \\ i FRONT BRAKE HOSE vi \ \ : \ \ FRONT WHEEL ‘SPEED SENSOR WIRE FRONT BRAKE HOSES. FRONT WHEEL SPEED SENSOR WIRE 1-23GENERAL INFORMATION (CBRZ50R: MAIN WIRE HARNESS. CLUTCH CABLE CLUTCH SWITCH WIRE {S_ LEFTHANDLEBAR 77 SNITCHWIRE TURN SIGNAL POSITION RELAY 9 (BLACK) CONNECTOR FUEL PUMP RELAY FAN CONTROL RELAY MAIN WIRE HARNESS FRONT BRAKE HOSEGENERAL INFORMATION ‘CBR250RA: MAIN WIRE HARNESS LEFT HANDLEBAR SWITCH WIRE CLUTCH CABLE CLUTCH SWITCH WIRE MAIN WIRE HARNESS ‘TURN SIGNAL POSITION RELAY FAN CONTROL RELAY 9P (BLACK) CONNECTOR ROE Pae7 NN 7 FRONT WHEEL /, SPEED SENSOR WIRE ee FRONT WHEEL ‘SPEED SENSOR WIRE 1-25GENERAL INFORMATION ‘THROTTLE CABLES LEFT HANDLEBAR SWITCH WIRE IGNITION SWITCH WIRE FUEL TANK DRAIN HOSE EVAP PURGE CONTROL SOLENOID VALVE One cat 2P CONNECTOR if yp K JZ. we DAZX RIGHT HANDLEBAR SBP\ swarcriwne at CLUTCH CABLE SIPHON HOSE AIR INLET HOSE WATER HOSE ELT (THER HOSE. ECM 39P (BLACK) CONNECTOR Ga ose VACUUM HOSE ECT SENSOR SP CONNECTOR CANISTER to-EVAP PURGE CONTROL, SOLENOID VALVE HOSE 1-26GENERAL INFORMATION ——— RAL INFORMATION. (CBR250R: LEFT HANDLEBAR SWITCH 9P (BLACK) CONNECTOR IGNITION swiTcH SP CONNECTOR RIGHT HANDLEBAR SWITCH 9P (GROWN) CONNECTOR © SENSOR 1P CONNECTOR LEFT HANDLEBAR SWITCH 2P (BLACK) CONNECTOR PAIR CONTROL SOLENOID VALVE 2P (BLACK) CONNECTOR MAIN WIRE HARNESS FUEL TANK DRAIN HOSE 2 SENSOR Wi 0: SENSOR WIRE FAN MOTOR 2P (BLACK) CONNECTOR HORN CONNECTORS: 1-27GENERAL INFORMATION ‘CBR250RA: LEFT HANDLEBAR SWITCH 9P (BLACK) CONNECTOR IGNITION SWITCH SEOONNECTOR RIGHT HANDLEBAR SWITCH 9P (GROWN) CONNECTOR (02 SENSOR LEFT HANDLEBAR SWITCH 1P CONNECTOR 2P (BLACK) CONNECTOR PAIR CONTROL SOLENOID VALVE 2P (BLACK) CONNECTOR, FUEL TANK DRAIN HOSE MAIN WIRE HARNESS: FAN MOTOR. (Os SENSOR WIRE 2P (BLACK) CONNECTOR FRONT WHEEL SPEED Se HORN CONNECTORS FRONT WHEEL SPEED SENSOR 2 (BLUE) CONNECTOR 1-28GENERAL INFORMATION (CBRZ50R: EVAP PURGE CONTROL SOLENOID VALVE 2P CONNECTOR BATTERY NEGATIVE (-) CABLE IAGV 4P (BLACK) CONNECTOR. ECM 33P (BLACK) CONNECTOR y : REAR BRAKE LIGHT SWITCH WIRE SIPHON HOSE CLUTCH CABLE 1-29GENERAL INFORMATION (CBR250RA: FRONT BRAKE PIPE A FRONT BRAKE PIPE SIPHON HOSE FRONT BRAKE PIPE B. Scan weer EVAP PURGE CONTROL SOLENOID VALVE 2P (ORANGE) CONNECTOR: SP CONNECTOR ant _—— IACV 4P (BLACK) CONNECTOR 4 ge = WAY SNA BATTERY NEGATIVE (-) CABLE SIPHON HOSE REAR BRAKE LIGHT ‘SWITCH WIRE CLUTCH CABLE FRONT BRAKE PIPE C ECM 33P (BLACK) CONNECTOR (ABS MODULATOR to DELAY VALVE} FRONT BRAKE PIPE B (ABS MODULATOR to FRONT BRAKE CALIPER) FRONT BRAKE PIPE A, (ABS MODULATOR to FRONT MASTER CYLINDER) 1-30GENERAL INFORMATION ‘CBR250R: BATTERY NEGATIVE (-) CABLE FUSE BOX STARTER RELAY SWITCH BATTERY POSITIVE (+) CABLE REGULATORIRECTIFIER '5P CONNECTOR MAIN WIRE HARNESS GROUND TERMINALS 1-31GENERAL INFORMATION ‘CBR250RA: ABS FUSE BOX BATTERY NEGATIVE (-) CABLE ‘ABS 1P CONNECTOR BATTERY POSITIVE (+) CABLE REGULATORIRECTIFIER 5P CONNECTOR ABS SERVICE CHECK 3P CONNECTOR ‘GROUND TERMINALS [STARTER RELAY SWITCH MAIN WIRE HARNESS 1-32GENERAL INFORMATION (CRANKCASE BREATHER HOSE AIR CLEANER HOUSING DRAIN HOSE VS) OZ ete My) 2 SIDESTAND SWITCH WIRE NEUTRAL SWITCH WIRE RESERVE TANK OVERFLOW HOSE EVAP CANISTER DRAIN HOSE FUEL TANK DRAIN HOSE 1-33GENERAL INFORMATION (CBRZ50R: CLUTCH CABLE LEFT HANDLEBAR SWITCH - IGNITION COIL PRIMARY WIRE 9P (BLACK) CONNECTOR LEFT HANDLEBAR SWITCH 2P (BLACK) CONNECTOR IGNITION SwiTCH SP CONNECTOR FUEL TANK DRAIN HOSE FUEL PUMP 5P CONNECTOR MAIN WIRE HARNESS ¢ EVAP PURGE CONTROL SOLENOID VALVE PAIR CONTROL SOLENOID VALVE 2 (BLACK) CONNECTOR EIR FUEL INJECTOR 2P (GRAY) CONNECTOR 1-34GENERAL INFORMATION ‘CBR250RA: CLUTCH CABLE LEFT HANDLEBAR SWITCH IGNITION COIL PRIMARY WIRE ‘9P (BLACK) CONNECTOR / LEFT HANDLEBAR SWITCH 2P (BLACK) CONNECTOR IGNITION SWITCH aP CONNECTOR RIGHT HANDLEBAR SWITCH 9P (BROWN) CONNECTOR FUEL TANK DRAIN HOSE FUEL POMP 5P CONNECTOR SPARK PLUG WIRE MAIN WIRE HARNESS EVAP PURGE CONTROL SOLENOID VALVE 2P CONNECTOR FUEL INJECTOR 2P (GRAY) CONNECTOR PAIR CONTROL SOLENOID VALVE 2P (BLACK) CONNECTOR 1-35GENERAL INFORMATION FUEL PUMP HOSE B. FUEL FEED HOSE FN oe 5P CONNECTOR 1-36GENERAL INFORMATION (CBR250R: FUEL FEED HOSE INSIDE BOOT CONNECTORS: “ALTERNATOR 3P CONNECTOR = CKP SENSOR/NEUTRAL SWITCH 6P CONNECTOR. VS SENSOR 3P CONNECTOR = SIDESTAND SWITCH 3 (GREEN) CONNECTOR FUEL INJECTOR 2P (GRAY) CONNECTOR IACV 4P (BLACK) CONNECTOR, | SENSOR UNIT | 5P CONNECTOR ECT SENSOR SP CONNECTOR STARTER MOTOR CABLE GROUND CABLE FUELTANKDRAN |(" 7 | Vs SENSOR WIRE HOSE (CRANKCASE BREATHER HOSE 1-37GENERAL INFORMATION CBR250RA; FUEL FEED HOSE FUEL INJECTOR INSIDE BOOT CONNECTORS: Bo eee o NET aE = ALTERNATOR 3? CONNECTOR — CKP SENSORINEUTRAL SWITCH 6P CONNECTOR: lacy ~VS SENSOR $P CONNECTOR 4P (BLACK) CONNECTOR = SIDESTAND SWITCH 3P (GREEN) CONNECTOR SIDESTAND SWITCH 3P (GREEN) Ea ontnn 5P CONNECTOR, iH e I ; s) FUEL TANK DRAIN Hose oD eo Ne a ECT SENSOR 3P CONNECTOR \\|| “| starter motor CARE AK ¥ [\ GROUND CABLE CRANKCASE BREATHER HOSE 1-38GENERAL INFORMATION IACV 4P (BLACK) CONNECTOR PAIR CONTROL SOLENOID VALVE EVAP PURGE CONTROL SOLENOID VALVE 2P (BLACK) CONNECTOR 2P CONNECTOR ‘THROTTLE CABLES SECONDARY AIR SUPPLY HOSE FUEL INJECTOR 2P (GRAY) CONNECTOR: FUEL FEED HOSE 1-39GENERAL INFORMATION EVAP CANISTER DRAIN HOSE SIDESTAND SWITCH WIRE AIR CLEANER HOUSING DRAIN HOSE. FUEL TANK DRAIN HOSE SIPHON HOSE RESERVE TANK OVERFLOW HOSE 1-40GENERAL INFORMATION FUEL TANK BREATHER HOSE VACUUM HOSE PAIR CONTROL SOLENOID VALVE AIR INLET HOSE SECONDARY AIR, SUPPLY HOSES EVAP PURGE CONTROL SOLENOID VALVE CANISTER to-EVAP PURGE CONTROL ‘SOLENOID VALVE HOSE, AIR CLEANER HOUSING. EVAP CANISTER DRAIN HOSE AIR CLEANER DRAIN PLUG EVAP CANISTER DRAIN HOSE (CRANKCASE BREATHER HOSE 1-41GENERAL INFORMATION CBR250RA: REAR WHEEL SPEED SENSOR WIRE REAR BRAKE PIPE B (0 REAR MASTER CYLINDER) FRONT BRAKE PIPE B (io FRONT BRAKE CALIPER) ‘ABS MODULATOR 25P GONNEGTOR FRONT BRAKE PIPE C (i DELAY VALVE) REAR WHEEL SPEED SENSOR WIRE EAR BRAKE PIPE C. ((o REAR CALIPER) REAR BRAKE PIPE A. (o PCV) 1-42GENERAL INFORMATION (CBR250RA: FRONT BRAKE PIPE D DELAY VALVE FRONT BRAKE PIPE C FRONT BRAKE PIPE A FRONT BRAKE PIPE C FRONT BRAKE PIPE B. FRONT BRAKE PIPED 1-43GENERAL INFORMATION ‘CBR250R: INSIDE BOOT CONNECTORS: =DLC —BRAKE/TAIL LIGHT 2P CONNECTOR “REAR TURN SIGNAL LIGHT CONNECTORS “LICENSE LIGHT CONNECTORS, BATTERY NEGATIVE (-) CABLE MAIN WIRE HARNESS FUSE BOX BATTERY POSITIVE (+) CABLE 1-44GENERAL INFORMATION ‘CBR250RA: INSIDE BOOT CONNECTORS: =DLC —BRAE/TAIL LIGHT 2P CONNECTOR “REAR TURN SIGNAL LIGHT CONNECTORS: “LICENSE LIGHT CONNECTORS: p~ ABS FUSE BOX C MAIN WIRE HARNESS FUSE BOX BATTERY NEGATIVE (-) CABLE BATTERY POSITIVE (+) CABLE ABS SERVICE CHECK 3P CONNECTOR: 1-45GENERAL INFORMATION ‘CBR250R: REAR BRAKE LIGHT _ SWITCH WIRE REAR BRAKE HOSE CBR250RA: REAR BRAKE LIGHT SWITCH WIRE REAR WHEEL SPEED SENSOR WIRE 1-46GENERAL INFORMATION EMISSION CONTROL SYSTEMS EXHAUST EMISSION REQUIREMENT ‘The U.S. Environmental Protection Agency (EPA), Califomia Air Resources Board (CARB) and Transport Canada require ‘manufacturers to certity that their motorcycles compiy with applicable exhaust emissions standards during their useful life, when ‘operated and maintained according tothe instructions provided. NOISE EMISSION REQUIREMENT ‘The EPA also requires that motoreyeles built after January 1, 1983 comply with applicable noise emission standards for one year or £3,730 miles (6,000 km) efter the time of sale to the ultimate purchaser, when operated and maintained according to the instructions provided. WARRANTY COMPLIANCE ‘Compliance with the terms of the Distributors Limited Warranty for Honda Motoreycle Emission Control Systems is necessary in Corder to keep the emissions system warranty in effect. SOURCE OF EMISSIONS ‘The combustion process produces carbon monaxide (CO), oxides of nitrogen (NOx) and hydrocarbons (HC). Fuel evaporation produces hydrocarson emissions, The control of hydrocarbons and oxides of nitrogen 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 tis tox Honda Motor Co., Ltd utlizes various systems (page 1-48) to reduce carbon monoxide, oxides of nitrogen and hydrocarbons. CRANKCASE EMISSION CONTROL SYSTEM “The engine is equipped with 2 closed crankcase system to prevent discharging crankcase emissions into the atmosphere, Biow-by gas is returned to the combustion chamber through the air cleaner housing ané throttle body. AIR CLEANER HOUSING THROTTLE BODY ®) sro ow ® the manufecturers TOOL: néeciver® Save chain tol set{8] OTH MH MRO103 or ornare tsa ony) Locate the orimped pin ends of the master link [1] from the outside of the drive chain, and remove the link with the drive chain tool set 2) TooL: ak Drive chain toolset orumesrtoi0sor | {ge O7HMH-MRIOTOC (edu (USA. only) Cant | Remove the drive chain. Include the master Remove the excess drive chain links from a new drive link when you count chain with the drive chain tool set. the chive chain lings, STANDARD LINKS: 108 LINKS REPLACEMENT CHAIN DID: DIDS20VF RK: RKS20KLO 3-21MAINTENANCE ‘Naver reuse the olf Insert @ new master link [1] with new O-rings [2] from ‘ve chain, master the inside of the drive chain, and install a new plate [3] fink, mastorink and O-rings with the identification mark facing the plate and O-rings. outside. ‘Assemble and set the drive chain toolset [1] TOOL: Drive chain too! set O7HMH-MR10103 or O7HMH-MR1010C. (U.S.A. only) Make sure that the master lnk pins [1] are installed property ‘Measure the master link pin length projected trom the plate STANDARD LENGTH: ‘Approx. 1.1 mm (0.04 in) a Stake the master link pin. Make sure that the pins are staked properly by measuring the diameter of the staked area using a slide Bh caliper {1} DIAMETER OF THE STAKED AREA: DID: 5.50 ~ 5.80 mm (0.217 —0.228 in) RK: 5.25 5.65 mm (0.207 0.222 in) D>, GN 3-22MAINTENANCE “Alive chain wth a Afier staking, check the staked area of the master link ‘must not be used. If there is any cracking, replace the master link, O-rings clip-type master link for cracks [4]. ond plate, 6000 No.Gooo © © 3G © © @ @&) | - P~|\ eff | eee i BRAKE FLUID NOTICE Shled Maid can damage peinted, plese or rubber pans, Pace 2 rag over these pars whenever tho Systems soniced NoTE Do rol mix diferent types of fui, 28 they ae rot compat wih each ofr + Be" hot allow foreign material to enter the sys vihen fling the reservoir «itn he hs love Tom, cheok the broke pads for wear (page 228), «+ Rigm fad lovel may be due to wear of the brake pate I the brke pads are wor an caper pistons So pushod out, te account ora fw ld level If the broke pace ar not wom ana fu lave fs ow heck the entre syetom for ea (page 2-25). FRONT BRAKE sea area fete eet eo | level and check the front brake fluid level through the va iO) si glass It the level is near the "LOWER' level line [1], fil the | recommended brake fui | Remove the following = Scrows [2] = Reservoir cover [3] = Set pate 14) ’ = Diaphragm [5] (as) Fill the reservoir with DOT 3 or DOT 4 brake fluid from a 5 sealed container to the casting ledge [1] Install the diaphragm, sot plate and reservoir cover. Install and tighten the cover screws to the specified torque. TORQUE!1.5 Nim (0.2 kgfim, 1.1 IbFft)MAINTENANCE REAR BRAKE. Support the motorcycle on a level surface, and check (— the rear brake fuid level. Check the brake fuid level If the level is near the "LOWER" level line [1], fll the recommended brake fuid Remove the bolt [1] and reservoir (2), Remove the cover screws [3], reservoir cover [4], set plate [5] and ciaphcagm [6] ‘Add the reservoir with DOT 3 or DOT 4 brake flu from ‘a sealed container to the "UPPER® level line [7] Install the diaphragm, set plate and reservoir cover. Install and tighten the cover screws to the speciied B torque. TORQUE: 1.5 Nim (0.2 kgm, 4.1 IbF) Install the reservoir and bolt Tighten the bolt securely. BRAKE PADS WEAR FRONT BRAKE PADS Check the brake pads for wear. trate pads aso set botom of wea mk grooves [1 | fom evon dS Fr brake pad replacement | = CBR2SOR (page 18-16) | = CBR250RA (page 15-18) | | | i REAR BRAKE PADS ‘Check the brake pads for wear. a ‘Aways replace the Replace the brake pads if either pad is wom to the brake pads as @ set_bottom of wear limit grooves [1] teonsure ven 8° Fo brake pad replacement (page 15-19). mn 3-24MAINTENANCE BRAKE SYSTEM caR250RA: INSPECTION This model Is equipped with 2 Combined Brake system heck the front and rear brake operation as folows: Support the motoreycle securely and raise the front whee! [1 off the ground. Apply the brake podel (2). ‘Make sure the front wheel does not turn while the brake pedal is applied a Firmly apply the brake lever or pedal, and check that no air has entered the system. Ifthe lever or pedal feels soft or spongy when operated, bleed the air from the system, For brake air bleeding = CBR25OR (page 15-8) = CBR250RA (page 15-12) Inspect the brake hose [1] and fitings for deterioration, cracks and signs of leakage. Tighten any loose fitings Replace hoses and fitings as required, BRAKE PEDAL HEIGHT ADJUSTMENT Loosen the Jock nut [1] and turn the push rod (2) until the correct pedal height is obtained (page 15-28) STANDARD LENGTH: 66.5~ 68.5 mm (2.62 ~2.70 in) After adjustment, tighten the lock nut securely. 3-25MAINTENANCE BRAKE LIGHT SWITCH The rant brake light Adjust the brake light switch [1] so that the brake light ‘snitch doos not comes on just prior to the brake actually being require adjustment. engage. Ifthe light falls to come on, adjust the switch so that the light comes on at the proper time. NOTE: Hold the switch body and turn the adjuster [2]. Do not ‘um the switch body. HEADLIGHT AIM ‘Support the motorcycle in an upright position ‘Adjust he hesaight Adjust the headlight aim vertically by turning the vertical ‘aim as speciied by beam adjusting screw [1 aloud 6 cocniae reaten moves the beer up and ‘s#0"S. counterclockwise rotation moves the beam down. ‘Adjust the headlight aim horizontally by turning the hotizontal beam adjusting screw [1], ‘A clockwise rotation moves the beam toward the right and counterclockwise rotation moves the beam toward the left CLUTCH SYSTEM ‘Measure the clutch lever freeplay at the end of the clutch lever, 1020 mm (3/8 = 13/16in) | | FREEPLAY:10 ~ 20 mm (3/8 — 13/16 in) | 3-26MAINTENANCE Tho adlustor may be damaged itis positioned to0 for ut, faving minimal those ‘engagement ‘Minor adjustment is made with the upper adjuster atthe clutch lever, Loosen the lock nut [1] and turn the adjuster (2. It the adjuster is threaded out near its limit and the correct freeplay cannot be obtained, turn the adjuster al the way in and back out one turn Tighten the lock nut while holding the adjuster. Recheck the clutch lever freeplay. Major agjustment is made with the lower adjusting nut [Jat the clutch liter lever. Loosen the lock nut [2] and turn the adjusting nut to adjust the freeplay. Tighten the lock nut while holding the adjusting nut If proper freeplay cannot be obtained, or the clutch slips iring test ride, disassemble and inspect the clutch (page 10-12). SIDESTAND INSPECTION ‘Support the motorcycle using a safety stand or hoist. Check the sidestand spring [1] for damage or loss of tension, ‘Check the sidestand [2] assembly for freedom of | movement and lubricaie the sidestand pivot if necessary, Check the sidestand ignition cut-off system: = Sit astride the motorcycle and raise the sidestand. = Start the engine with the transmission in neutral, then, with the clutch lever fully squeezed, shift the transmission into ger. ‘Move the sidestand full down, = The engine should stop as the sidestand is lowered. It there is @ problem with the system, check the sidestand switch (page 20-17). i 3-27MAINTENANCE REMOVAL/INSTALLATION ‘Support the motorcycle upright on a level surface. Remove the sidestand switch (page 20-18), Remove the sidestand spring (1) Remove the sidestand pivot lock nut [2], bolt [3] and sidastand (4). ‘Apply grease to the sidestand pivot siding surface Install the sidestand and sidestand pivot bolt Tighten the sidestand pivot bolt fo the specified torque. TORQUE: 10 Nm (1.0 kgtm, 7 IDF) Install and tighten the sidestand pivot lock nut to the specified torque while holding the pivot bol. TORQUE: 30 N-m (3.0 kgf'm, 22 Ibf-ft) Install the sidestend spring, Install the sidestand switch (page 20-18). SUSPENSION FRONT SUSPENSION INSPECTION Check the action of the forks by operating the front brake and compressing the front suspension several times. Check the entire assembly for signs of leaks, damage or loose fasteners, Loose, wom or Replace damaged components which cannot be demaged repaired, suspension parts Totten all nuts and bolts. Impoirmotoroycie Tt stabilty nd control. For fork service (page 13-20), REAR SUSPENSION INSPECTION Check the action of the rear shock absorber by ‘compressing the rear end several times. Check the entire shock absorber assembly for leaks, damage or loose fasteners. Loose, wom or Replace damaged components which cannot be ‘damaged repaired. suspension Paris Tighten all nuts and bolts, impair motoroyete “tabity end contre!. For shock absorber service (page 14-13). 3-28MAINTENANCE ‘Support the ratarcycle using a safety stand or hoist, raice the rear wheel off the ground. Check for wor swingarm bushings by grabbing the rear wheel and attempting to move the wheel side to side, Replace the bushings if any looseness to noted. For swingarm service (page 14-17). NUTS, BOLTS, FASTENERS Check that all chassis nuts, screws and bolts are tightened to their correct torque values (page 1-12), Check that all coter pins, safety clips, hose clamps and cable stays are in place and properly secured. WHEELS/TIRES Support the motorcycle using a safely stand or hoist, raise the front whee! off the ground. Hold the font fork leg and move the front. wheel sideways with force to see if the wheel bearings are For front wheel service (page 19-14), ‘Support the motorcycle using a safety stand or hoist, (= ‘alse the rear wheel off the ground. Hold the swingarm and move the rear wheel sideways wih force to see ifthe wheel and driven flange bearings are worn. For rear wheel service (page 14-6)MAINTENANCE Check the tie pressure witha tre pressure gauge when [— the tres are cold ‘Tie pressure KPa feglen psy |D¥er only | | Driver ang ____|passenger Tire size MiG 548 | MIC 668 | Tie brand IRE RXOTFD | RX-OIRZ_ Check the ties for cuts, embedded nails, or other | damage. | Check the front and rear wheels for trueness. Measure the tread depth atthe center ofthe tes. Replace the tires when the tread depth reaches the following limits MINIMUM TIRE TREAD DEPTH Front: 1.5 mm (0.06 in) Rear: 2.0 mm (0.08 in) STEERING HEAD BEARINGS eae ae ins = Check for steering stem bearings by grabbing the fork legs and attempting to move the front fork forward to backward Ifthe handlebar moves unevenly, binds, or has vertical movement, inspect the steering head bearings (page 13-29) 3-304. LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM SERVICE INFORMATION TROUBLESHOOTING- he “43 ENGINE OIL STRAINER SCREEN: OIL PUMP «~~ PRESSURE RELIEF VALVE ~~LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM CAMSHAFT ROCKER ARM OIL FILTER, (CRANKSHAFT oI Pume PRESSURE RELIEF VALVE MAINSHAFT COUNTERSHAFT 4-2LUBRICATION SYSTEM SERVICE INFORMATION GENERAL Used engine oll may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely unless you handle used cil on a dally basis, itis still advisable to thoroughly wash your hands with soap and waler as soon as possible after handiing used ol. “The oil pump can be serviced with the engine installed in the frame ‘The service procedures in this section must be performed with the engine oll drained. When removing and instaling the oll pump, use care not to allow dust or dirt to enter the engine, If any portion ofthe oll 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, For engine oil level check (page 3-13) For engine oil change (page 3-14) For engine ol filer change (page 3-15) SPECIFICATIONS Unit: mm Gin) Tem STANDARD SERVICE LIMIT Engine of'capacly ‘| Atdraining “Alters (1.5 US at, 1.2 Imp al) 5 Atoilfter change 1 Silters (1.6 US at, 1.3 Imp qi) =| At disassembly Slits (1.9 US at, 1.6 Imp at) Recommended engine of Pro Honda GN4 4-stroke olf (U.S.A. and Canada) or equivalent motor oil API service classification: SG or Higher s 4JASO T 903 standard: MA Viscosity: SAE 10W-30 ‘Oil pump rater ~ | Tip clearance (0.45 (0.006) 2 (0:20 (0.008) Body clearance 10.15 ~ 0.22 (0.006 - 0.008) (0.35 (0.014) ‘Side clearank [0.02 =0.09 (0.001 - 0.004) 0.10 (0.004) TROUBLESHOOTING Engine oil level too low, high oll consumption + Oilconsumption + External ol leaks + Worn valve guide or stem seal + Worn piston rings + Improperiy installed piston rings + Wor cylinder Engine oil contamination + Oilnot changed often enough + Worn valve guide or stem seal + Worn piston rings + Improperly installed piston rings + Worn cylinder il emulsification * Faulty cylinder head gasket + Leaky coolant passage + nity of waler + Faulty water pump mechanical seal 4-3LUBRICATION SYSTEM ENGINE OIL STRAINER SCREEN REMOVALJINSTALLATION Remove the right crankcase cover (page 10-6). Be carefulnot to Pull the oll strainer screen [1] out of the crankcase. ‘Gamagethe ash the. ol ssiner secon thoroughly in viner SCIEN. onflammable or high flash point solvent until all Acoumulted ct hes Been removed Bow ity with compressed arto clean complete. fl Before isang the stains, t shoud be examined Glos fo damage, and mako su the selng rubber fa gos condo. instal he ol string screen wih the thin e666 ecg Sy srRANER SOREEN ee OIL STRAINER SCREEN DIRECTION ] Insta the ght crankcase cover (page 10-1) | | re Ser CRANKCASE REMOVAL/DISASSEMBLY Remove the right crankcase cover (page 10-6). Remove the oll pump driven gear [1] Remove the oil pump mounting bolts [1] and oil pump assembly bolt [2). Remove the oll pump cover assembly [3] 4-4LUBRICATION SYSTEM Remove the inner rotor assembly from the oll pump cover [1] while holding oll pump sha 2) 8 2 4 Remove the oll pump shaft and lock pin [3] from the | inner rotor (4) Remove the outer totor [5] and washer [6] Remove the dowel pins [1] from the oll pump body (2). Remove the oil pump body [1] and dowel pins (2. Remove the O-ring [3] from the oll pump body, INSPECTION Cll PUMP DRIVEN GEARIOIL PUMP SHAFTILOCK Check te ol pump crven gear {1 teeth, ell pump shaft [2] and lock pin [3] for wear or damage, replace them if |] a necessary, yLUBRICATION SYSTEM any parton of the pump is wom ‘beyond the specified service tint, replace the of pump as en ‘assembly, ‘OL PUMP NoTE: Measure each clearance at several points and use the largest reading to compare the service limit, Temporarily install the outer rotor, inner rotor and oil -— pump shaft into the oll pump cover. TIP CLEARANCE: Measure the tip clearance. ‘SERVICE LIMIT: 0.20 mm (0.008 in) Measure the body clearance, ‘SERVICE LIMIT: 0.35 mm (0.014 in) | | Bs Re pan ha nescence Measure the side clearance using a straight edge and fesler gauge SERVICE LIMIT: 0.10 mm (0.004 in)LUBRICATION SYSTEM ASSEMBLY lL PUMP BODY OIL PUMP COVER inner RoroR LOCK PIN ‘lL PUMP SHAFT outerroron WASHER OIL PUMP DRIVEN GEAR lL PUMP ASSEMBLY BOLT lL PUMP MOUNTING BOLTS. ‘Apply engine oil tothe inner rotor [1] and outer rotor [2] [= a = contre surface. 7h Q Ae ay ‘Apply engine oil to the oll pump shat [3] outer surface. Install the outer rotor and washer (4) into the oil pump cover [5 Install the lock pin [6] nto the oll pump shaft, then install the inner rotor while aligning its groove with the lock pin. Install the inner rotor assembly into the oll pump cover Install the dowel pins [4] to the oil pump cover [2 Install the oll pump body [3] to the oil pump cover.LUBRICATION SYSTEM Install and tighten the oll pump assembly bolt [1] securely. INSTALLATION Install the dowel pins [1] Apply engine oll to 2 new O-ring (2) Install the O-ring to the oll pump assembly [3]. Install the oil pump assembly wile aligning its stot with ‘cam chain guide end. Install and tighten the oll pump mounting bolts [1] securely. Install the oil pump driven gear [1] while aligning the flals of the oil pump driven gear and oil pump shaft Install the right crankcase cover (page 10-10), 4-8LUBRICATION SYSTEM PRESSURE RELIEF VALVE REMOVAL/INSTALLATION Remove the oll pump (page 4-4). Remove the oil pressure relief valve [1] and O-rings (2) Apply engine oll to new O-rings. Install the O-rings to the oll pressure relief valve ‘grooves. Install the oll pressure relief valve into the right crankcase with the pision side facing outside. Install the oll pump (page 4-8). PRESSURE RELIEF VALVE INSPECTION Check the operation of the pressure relief valve by lr pushing on the piston [1]. 1 VI Disassemble the pressure relief valve by removing the ssnap ring [2 Remove the washer, pring [2 and piston 3 ) Check hepato or weer, eng or damage, | Cineck te spring or fatigue or damage ‘Assemble the pressure relief valve in the reverse order of disassembly. NoTE: + Install the snap ring with the chamfered edges facing the thrust load side. e + Make sure the snap ring Is seated in the groove. | 4-9COMPONENT LOCATION - SERVICE INFORMATION PGM-FI SYMPTOM TROUBLESHOOTING: PGM-FI SYSTEM LOCATION PGM-FI SYSTEM DIAGRAM PGM-FI CONNECTOR LOCATIONS PGN-FI TROUBLESHOOTING INFORMATION: DTC INDEX SENSOR UNIT POWER LINE INSPECTION - : DTC TROUBLESHOOTING MIL CIRCUIT TROUBLESHOOTING~-~-~--5-32 FUEL LINE INSPECTION 5, FUEL SYSTEM (PGM-Fl) FUEL TANK « 5-39 FUEL PUMP UNIT- 5-39 FUEL PUMP RELA’ 5.42 AIR CLEANER HOUSING ~ 543 THROTTLE BODY «=~» 5.46 FUEL INJECTOR 5-51 lacy 5-53 ECT SENSOR ~ 554 BANK ANGLE SENSOR 5.55 ECM: oe 556, Q2 SENSO! 5-57 SECONDARY AIR SUPPLY SYSTEM 5-58 EVAP PURGE CONTROL SOLENOID VALVE! CANISTER 5-61FUEL SYSTEM (PGM-Fl) COMPONENT LOCATION 5-2FUEL SYSTEM (PGM: SERVICE INFORMATION GENERAL + Work in a well venilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can cause a fre or explosion. + Before disconnecting the fuel feed hose, relieve fuel pressure from the system by disconnecting the quick connect fiting from the system (page 5-33). + Bending or twisting the control cables will impair smooth operation and could cause the cables to stick or bind, resulting in loss of vehicle control + Dornot enep the throttle valve from full open to full close after the throttle cable has been removed. It may cause incorrect idle ‘operation + Seal the intake ports with tape or a clean cloth to keep dirt and debris from entering the engine after the throttle body has been removed. + Do not damage the thrattle body. It may cause incorrect throttle valve operation. {Prevent dit and debris from entering the throttle bore and air passages after the throttle body has been removed. Clean them Using compressed air tnecessary. + Dornot loosen or tighten the white painted nut and seraw of the throtle body. Loosening or tightening them can cause throttle valve and idle contro failure. + The parts ofthe thrattle body not shown in this manual should not be disassembled + A faulty PGNFI system Is often related to poorly connected or corroded connectors. Check those connections before proceeding « When disstsombling the PGM-FI system parts, nota the location of the O-rings. Replace them with new ones upon reassembly. + Use a digital tester for PGM FI system inspection. + For fuel level sensor inspection (page 20-19). SPECIFICATIONS SE ee ce ara ene ‘SPECIFICATION 5 Tirole body Kentifcaton number ai Goa Engine dle speed fre 4400 1007p = Throtle grip freeplay s 2=6 mm (176 ~ 114 in) Fue injector resisiance (20°C168°F) Fuel pressure al ile Fuel pump fow (at 12V)_ a 71-730 294 Pa (8.0 kato’, 43 psy {8.2 on"@.34 US 02, 2.44 Imp 02) minimum/10 seconds AIR contol solenoic valve resistance (20°C/68"F) 24-280 | EVAP purge contr! solenoid valve resistance (20°C/68°C) ss TORQUE VALUES ECT sensor 25 Nm (25 kgf, 18 bth) Fuel pump setting plate nut 42Nm(1.2kgtm, gibt) See page 5.42 Fuel injector joint mounting bot 5.1 Nem (05 kgtm, 3.8 bt) ©2sensor 25Nm (25 kgtm, 18 bf) ‘Sensor unit torx screw 34 Nim (0. kgfm, 25 lbtt) IACV setting plato torx serow 2.41 Nem (0.2 kgf, 15 bt) Throtle cable stay screw 34 Nim (0.3 kgm, 25 bt) Ciamper stay screw 3.4 Nim (0.3 kgém, 25 Ibi) Insulator band screw 42Nm (04 kghm, 3:1 Ibi) See page 5-49 Air cleaner cover screw 4.4 Nm (0.4 kgf, 0.8 Ibt) Throtte cable A adjuster look nut (thotle body side) 3.0.Nm (0.3 kgf, 22 IbF A) ‘Throttle cable 8 (thre body side) 3.0.Nim (0.3 kgf, 22 Ibtt) PAIR check valve cover bolt 52N«m (0.5 kof, 3:8 bE) Bank angle sensor mounting nut 40 Nm (1.0 kgtim, 7 bth)FUEL SYSTEM (PGM-Fl) TOOLS | Fuel pressure gauge, 0-100 psi) (07406-0040004 ‘0r 07406-0040008 (U.S.A. only) Hose attachment, 6 mm/9 mr O7ZAJ-S5A0130 (Not available in U.S.A.) ‘SCS Service connector o70P2-2¥30100 | Adaptor, male OTAAJ-S6MAZ00 (U.S.A, only) | (Not available in U.S.A.) |) Alfachment joint, 6 mm/9 mm Hose atiachment, 9 mm/9 mm JB ‘Pressure gauge manifold O7ZAJ-SSA0111 G ei (ot available in USA) IDS pocket tes O7ZAJ-SEAN180 (Not available in U.S.A.) | oe O7ZAJ-RDJA110 Pressure manifold hose | O7AMAJ-HW3A100 (U.S.A. only) ‘Adapior, female O7AAJ-S6MA400 (U.S.A, only) 5-4FUEL SYSTEM (PGM-Fl) PGM-FI SYMPTOM TROUBLESHOOTING When the motorcycle has one of these symptoms, check the DTC or ML blinking refer to the DTC index (page 6-14) and begin the ‘appropriate troubleshooting procedure. If there are no DTCIMIL blinking stored in the ECM memory, do the diagnostic procedure for the sympiom, in sequence listed below, until you find cause. ‘Symptom Engine canks but won't star (No DTC and MIL blinking) Engine cranks but wont start (No fuel pump operation sound ‘when turing the ignition ON) | Engine stalls, hard to start rough idling ‘Afterbuen whan engine Braking is used extrng oF misting Guring acceleration Poor performance (driveability) | ‘and poor fuel economy Idle speed is below specifications or fastidle 10 low (No DTC and MIL blinking) Idle speed is above specifications or fast idle too high (No DTC and MIL blinking) MIL stays ON but no DTCs set, ‘or MIL never comes ON al MIL stays ON at ail (No DTC set) Diagnosis procedure Ingpect the IACY (page 5-53) Inspect the fuel supply system (page 6-33). Inspect the ignition system (page 18-6). "7. EGM poweriground circuits malfunction (page 5-56), 2. Inspect the uel supply system (page 5-33). 1. Inspect the engine ile speed (page 3-16). 2. Inspect the IAC (page 553). 3. Inspect the fuel supply system (page 5-39). 4. Inspect the battery charging system (page 17-7) 5. Inspect th ystem (page 18-6). 1. Inspect the PAIR system (page 5-58) 2 system (page 16-6). Inspect he fuel supply system (page 5-9). 2, Inspect the sir cleaner element (page 3-7). 3. Inspedt the ignition system (page 18-6) Taspect the engine idle speed (page 3-16) Inspeet the IACV (page 5-53). Inspect the ignition system (page 18-8) Inspect the engine idle speed (page 3-16) Inspect the throttle operation and freeplay (page 3-6). Inspect the JACV (page 5-53). Inspect the ignition system (page 18-6). inspect the ML circuit (page 5-32) “1, Inspect the DLC circuit (page 5-22). 2) Inspect the MIL circuit (page 5-32). ~ Also check for + No fuel to fuel injector = Clogged fuel filter = Pinched or clogged fuel feed hose ~ Faulty fuel pump = Faulty fuel pump circuits + Intake air leak * Contaminatedideteriorated fuel _Faully fuel injector + Open circult in the power input ‘andlor ground wire of the ECM + Blown main fuse (30 A) + Blown sub fuse (10 A) + Restricted fuel feed hose + Contaminatedideteriorated fuel + Intake air leak + Faulty MAP sensor + Restricted fuel tank breather hose Faully pressure regulator (fuel pump) + Faulty fuel injector + Faulty MAP sens = Intake air leak + Engine top-end problem * Aircleaner element conditionFUEL SYSTEM (PGM-FI) PGM-FI SYSTEM LOCATION IGNITION swiTcH FUEL PUMP FUEL INJECTOR PAIR CONTROL SOLENOID VALVE ©:SENSOR ECT SENSOR SENSOR UNIT =MAP SENSOR = IAT SENSOR TP SENSOR SIDESTAND SWITCH CKP SENSOR 5-6FUEL SYSTEM (PGM-Fl) PGM-FI SYSTEM DIAGRAM © C= nerwer ora anes ‘ee a eer faooooooooo Bias ‘ioe TR Tremere aise |oooooo00008- gen low feeckmieces 2 pepooooooooes)# reps p= sete oe Soa feodrene ECU 99° CONNECTOR CI id trasFUEL SYSTEM (PGM-FI) PGM-FI CONNECTOR LOCATIONS NOTE 4: Remove the upper cowl (page 2-9) POTS BANK ANGLE SENSOR 3P CONNECTOR 7 WoTE A) NOTE 2: Remove the left middle cowl (page 2-7). #5 ©: SENSOR 1P CONNECTOR ‘2 wore) 5-8FUEL SYSTEM (PGM-Fl) NOTE 1; Remove the right side cover (page 2-16) « 8 2 é 8 § 2 a = & NOTE 2: Remove the rear under cover (page 2-13). @ 5-9FUEL SYSTEM (PGM-Fl) NOTE 1: Lift and suppor the fuel tank (page 3-5). FUEL INJECTOR 2P (GRAY) CONNECTOR (Nore 1) IAG 4° (BLACK) CONNECTOR (NOTE 1) PCTS sensor UNrT 5° conNecToR EGT SENSOR 3P CONNECTOR (9, (NOTE 1) ¢ o 5-10FUEL SYSTEM (PGM-Fl) PGM-FI TROUBLESHOOTING INFORMATION GENERAL TROUBLESHOOTING Intormittent Failure ‘The term “intermittent failure” means a system may have had a failure, but it checks OK now. Ifthe MIL. does not come on, check for poor contact or loose pins at all connectors related to the circuit that of the troubleshooting. ifthe MIL was on, but then went out, the orginal problem may be intermittent. Opens and Shorts, “Opens” and "Shorts" are common electical terms. An open is a break in a wire or at a connection. A short is an accidental ‘connection of a wire to ground of to another wie. In simple electronics, this usually means something will not work at al. With CMs this can something mean something work, but nol the way its supposed to. H the MIL has come on Refer to DTC READOUT (page §-13). If the MIL did not stay on Ifthe MIL did not stay on, but there is a driveability problem, do the SYMPTOM TROUBLESHOOTING (page 5-5). SYSTEM DESCRIPTION SELF-DIAGNOSIS SYSTEM “The PGM-FI system is equipped with the self-dlagnostic system. When any abnormality occurs in the system, the ECM turns on the MIL and stores @ DTC in ts erasable memory. FAIL-SAFE FUNCTION “The PGM-FI system is provided with a fail-safe function to secure a minimum running capability even when there is trouble in the system. When any abnormality is detected by the self-diagnosis function, running capability s maintained by pre-programed value in the simulated program map. When any abnormality is detected in the fuel injector, the fail-safe function stops the engine to protect it from damage, prc + The DTCis composed of a main code and a sub code and it is displayed as a hyphenated number when retrieved from the ECM the HDS pocket tester. ‘The cigits in front of the hyphen are the main code, they indicate the component of function failure. “The digits behind the hyphen ate the sub code, they detail the specific symptom of the component or function failure. For example, in the case of the TP sensor ~ DTC 08 — 1 = (TP sensor voltage) — (lower than the specified value) — DTC 08 ~ 2= (TP sensor voltage) — (higher than the specified value) + The MAP, ECT, TP and IAT sensor diagnosis will be made according to the voltage output of the affected sensor Ifa failure occurs, the ECM detemines the Function Failure, compares the sensor voltage output to the standard value, and then outputs the corresponding DTC to the HDS pocket tester. For example: =F the input voltage line (A) on the MAP sensor is opened, the ECM detects the output voltage is about § V, then the DTC 1-2 (MAP sensor eircut high voltage) will be cisplayed, = Ifthe input voltage line (B) on the TP sensor is opened, the ECM detects the output voltage is 0 V, then the DTC 8-1 (TP ‘sensor crcult low voltage) will be displayed. sv Se TP SENSOR MAP SENSOR 5v (OUTPUT VOLTAGE ‘OUTPUT VOLTAGE BV 5v ECT SENSOR IAT SENSOR OUTPUT VOLTAGE, ‘OUTPUT VOLTAGE 5-11FUEL SYSTEM (PGM. MIL Blink Pattern + Ifthe HDS pooket tester isnot available, DTC can be read from the ECM memory by the MIL [1] blink pattern. + The number of MIL blinks is the equivalent the main code of the OTC (the sub code cannot be displayed by the MIL). + The MIL wil blink the current DTC. in case the ECM detects the problem at present. when the ignition switch ON and engine stop switch "0" or idling with the sidestand down. The MIL will siay ON when the engine sspeod is over 1,900 rpm or withthe sidestand up. + The MIL has two types of blinks, a long blink and short blink. The long blinking lasts for 1.3 seconds, the short blinking lasts for 0.3 seconds. (One long blink is the equivalent of ton short blinks, For example, when {wo long blinks are followed by five short binks, the MIL is 25 (two long blinks = 20 biinks, plus five short blinks), + When the ECM stores more than ane DTC, the MIL will indicate them by blinking In the ordor from the lowest number to highest number. l MIL Check. ‘When the ignition switch is tumed ON and engine stop switch “othe MIL will stay on fora few seconds, then go off. Ifthe MIL does. ot come on, troubleshoot the MIL crcult (page 5-32) CURRENT DTCIFREEZE DTC The DTC Is indicated in two ways according to the failure status, + In case the ECM detects the problem at present, the MIL will come on and the MIL wil start to blink as its OTG when the sidestand is lowered. Its possible to readout the MIL blink pattern as the current DTC. + Incase the ECM does not detect any problem at present but has a problem stored in its memory, the MIL will not ight and blink, Ifit is necessary to retrieve the past problem, readout the freeze DTC by following the DTC readout procedure (page 5-13). ) HDS POCKET TESTER INFORMATION + The HDS pocket tester can readout the DTC, freeze data, current data and other ECM condition, How to connect the HDS pocket tester Turn the ignition switch OFF. Remove the rear under cover (page 2-13) Remove the dummy connector [1] from the DLC [2] Connect the HDS pocket tester to the DLC. TOOL: HDS pocket tester 7Ds3557.0112.01 (S.A. only) Turn the ignition switch ON and engine stop switch "" check the DTC and freeze data, NOTE: Freeze data indicates the engine conditions when the first maifunction was [tf detected. Fe ECM reset ‘The HDS pocket tester can raset the ECM data Including the DTC, freeze data and some learning memory ‘After the ECM reset, follow the idle leam procedure from ECM inttialization (page 6-50). 5-12FUEL SYSTEM (PGM-Fl) DTC READOUT ‘Start the engine and check the MIL. Note When the ignition switch is turned ON and engine stop switch *c", the Mil. vill stay on fora few seconds, then go oft. If the MIL stays on or blinks, connect the HDS pocket tester to the DLC (page 5-12) Read the DTC, freaze data and follow the troubleshooting index (page 5-14). ‘To read the DTC with the MIL blinking, refer to the following procedure. Reading DTC with the MIL ‘Tum the ignition switch OFF. Remove the rear under cover (page 2-13). Remove the dummy connector [i] from the DLC [2]. ‘Short the DLC terminals using a special tool | TOOL: ‘SCS Service connector o70P2-2Y30100 Conneetion: Blue— Green “Turn the ignition switch ON and engine stop switch "0", read, note the ML blinks and refer to the DTC index (page 5-14), Note Ifthe ECM has any DTC in its memory, the MIL will start blinking a ERASING DTC Connect the HDS pocket tester to the DLC (page 5-12). Erase the DTC with the HDS pocket tester while the engine is stopped. To erase the DTC without HDS pocket tester, refer to the following procedure, How to erase the DTC with SCS Service connector 4. Tum the igntion switch OFF. 2. Remove the dummy connector from the DLC [1] ‘Short the DLC terminals using a special tool TOOL: SCS Service connector [2] 070PZ-ZY30100 Connection: Blue ~ Green ‘3, Tur the ignition switch ON and engine stop swite! 4, Remove the special tool from the DLC. 5. The MIL will ight for approximately 5 soconds. While the MIL lights, short the DLC terminals again with a epecial tool. The sel-diagnostic memory is erased ifthe MIL goes off and stars blinking. NOTE: + The DLC must be jumped while the MIL lights. If not, the MIL will not start blinking, + Note that the self-diagnostic memory cannot be erased ifthe ignition switch is tumed OFF before the ML starts blinking a 5-13FUEL SYSTEM (PGM. CIRCUIT INSPECTION INSPECTION AT ECM CONNECTOR + Always clean around and keep any foreign material away from the ECM 39P (Black) connector before disconnecting i. + A fauity PGN-FI system ie often related to poorly connected or corroded terminals, Check all elated connections before proceeding. + In testing at ECM 33P (Black) connector (wire hamess side) terminal always use the test probe [1]. Insert the test probe into the connector terminal, then attach the digital multimeter probe to the test probe. TOOL: Tost probe: O7ZAJ-RDJAT1IO !) DTC INDEX ~ pre (Ma Function Failure _ blinks) IMAP sensor arcull low voltage (less than 0.19.V)_ 441(1) + MAP sensor or its circuit malfunction ‘MAP sensor circult high voltage (more than 9.84 V) 4-2(1)_| + Loose or poor contact of the sensor unit connector + MAP sensor ors circuit maffunction ECT sensor circu low voltage (less than 0.07 V) 7-1 (7) | + ECT sensor or its circuit malfunction. | ECT sensor circult high voltage (more than 4.92 V) 7-2(7) | + Loose or poor contact of the ECT sensor connector + ECT sensor or its circut malfunction “TP sensor circuit low voltage (less than 0.21 V) 8-1 (@) | + Loose or paor contact of the sensor unit connector +_ TP sensor or ls circuit malfunction TP sensor circuit high voltage (more than 4.92 V) + TP sensor or its circuit malfunction TAT sonsor ccult low voltage (less than 0.07 V) IAT sensor or its circuit malfunction XT sensor crcut high voltage (more than 492 V) 9-2(@) + Loose or poor contact of the sensor unit connector + IAT sensor ots circuit matfunction Fuel injector circuit maifunction 124 (12) | + Loose or poor contact ofthe fuel injector connector | | + Fuel injector or its circuit malfunction t ‘©; sensor malfunction + Loose of poor coniact af the O2 sensor connector + O:sonsor or is ctcuit malfunction TACV circuit maifunction + Loose or poor contact of the ACV connector + TACV or is circuit malfunction EEPROM malfunction ar Bank angle sensor circuit low voltage (less than 0.31 V) ‘+ Bank angle sensor or is circuit malfunction 4264) | * Leake or poor contact of the bank angle sensor + Bank angle sensor or Its circuit malfunction ‘Bank angle sensor ciruithigh vollage (more than 453V) ‘Symptom/Fall-safe function Engine operates normally re-program value: 698 mmHg! 930 hPa Engine operates normally re-program value: 698 mmHa! 930 hPa > Hard start ata low temperature re-program value: 80°C/176'F Cod tums on Hard start at a low temperature re-program value: 80°C!176"F Cooling fan turns on oor engine acceleration re-program value: 0° re-program vaiue: 0° Engine operates normally re-program value: 35°C/95°F Engine operates normally re-program value: 35°C/95°F Engine does not star Fuelinjoctor, fuel pump and ignition coll shut down Engine operates normally Engine stalls, hard fo star, rough idling Engine operates normaly == Engine operates normally Engine stop function dose not operate Engine operates normally Engine stop function dose not operate Refer to 516 520 | 5.21 5.22 523 524 526 527 528 5.29FUEL SYSTEM (PGM-FI) SENSOR UNIT POWER LINE INSPECTION BEFORE DTC TROUBLESHOOTING NOTE: + When the DTC displays 1-1, 1-2, 6-1, 82, 9-4 and 9- 2, check the folowing before DTC troubleshooting + Before staring the inspection, check for loose or oor contact on the Sensor unit SP connector and ECM 33? (Black) connector. 4. Sensor Unit Power Input Voltage Inspection Tum the ignition switch OFF. Disconnect the sensor unit SP connector [1] Turn the igntton switch ON and engine stop switch Measure the voltage at the wire side. Connection: Yollowired (+) ~ Greeniwhite (-) Standard: | 4.75-525V Is the voltage within 4.75 ~ 5.25 V? YES — Tum the ignition switch OFF. Connect the sensor unit 5P connector and start the DTC troubleshooting (page 5-16). NO -GOTOSTEP2 2, Sensor Unit Input Voltage Line Short Circuit Inspection ‘Tum the ignition switch OFF. ail CChack for continuity between the sensor unit 5P | ‘connector [1] of the wire side and ground. | Connection: Yellowired - Ground {s there continuity? YES. ~ Shortcicutin Yetowre wire NO -GOTOSTEPS a a] 3. Sensor Unit Power Line Open Circuit Inspection Disconnect the ECM 33P (Black) connector [i]. 7 Check for continuities at the Yellowlred and Green/ a ‘white wires between the sensor unit SP connector [Bj and ECM 33P (Black) connector. Connection: Yellowired ~ Yellow/red Green/white ~ Greeniwhite vIR TOOL: Test probe O7ZAJ-RDJAN10 Is there continuity? YES — Replace the ECM with a known good one, ‘and recheck. NO = + Open circuit in Yelowired wire {2 + Open circuit in GreenMwite wire a 15FUEL SYSTEM (PGM-Fl) DTC TROUBLESHOOTING 5-16 DTC 1-1 (MAP SENSOR LOW VOLTAGE) 1. MAP Sensor System Inspection ‘Turn the ignition switch ON and engine stop switch co Check the MAP sensor with the HOS pocket tester. Is about 0 Vindicated? YES - GOTOSTEP2 NO = Intermittent faiure 2, Sensor Unit Power Line Inspection Check the sensor unit power line inspection (page 5-15), Is the sensor unit power line normal? YES - GOTOSTEP 3. NO — Replace or repair the abnormal citcult 3. MAP Sensor Output Voltage Inspection ‘Turn the ignition switch OFF. Disconnect the sensor unit §P connector [1]. ‘Tum the ignition switch ON and engine stop switch ‘Measure the voltage at the sensor unit SP connector of the wire side Connection: Light groon/yellow (+) ~ Greeniwhite (-) ‘Standard: 4,75 — 5.25 V Is the voltage within 4,75 ~ 5.25 V? YES - GOTOSTEPS. No -GOTOSTEP4, 4, MAP Sensor Output Line Short Circuit Inspection ‘Turn the ignition switch OFF. Check for continuity between the sensor unit SP Connector [1] of the wire side and ground. Connection: Light green/yellow - ground Is there continuity? YES — Short circuit in Light greeniyellow wire No -GOTOSTEPS.FUEL SYSTEM (PGM. a EE ‘6. MAP Sensor Inspection Replace the sensor unit with 2 known good one (page 5-46), Erase the DTC's (page 5-19), ‘Tum the ignition switch OFF. Connect the sensor unit SP connector. ‘Turn the ignition switch ON and engine stop switch Bh Check the MAP sensor with the HDS pocket tester. Is DTC 1-1 indicated? YES ~ Replace the ECM with a known good one, ‘and recheck. NO ~ Faulty original sensor unit (MAP sensor) DTC 1-2 (MAP SENSOR HIGH VOLTAGE) 4. MAP Sensor System Inspection 4 ‘urn the ignition switch ON and engine stop switch (Check the MAP sensor with the HDS pocket tester Is about § Vindicated? YES — GO TOSTEP 2 NO = = Intermittent failure + Loose of poor contact on the sensor Unit SP connector 2, Sensor Unit Power Line Inspection Check the sensor unit power line inspection (page 5:18) Is the sensor unit power line normal? YES - GOTOSTEP 3, NO = Replace or repair the abnormal circuit 3, MAP Sensor System Inspection 2 ‘Turn the ignition switch OFF. al Disconnect the sensor unit SP connector [1] Connect the sensor unit SP connector terminals at the wice side witha jumper wire 2) Connection: Light greentyellow ~ Greeniwhite | ‘Tum the ignition switch ON and engine stop switch Me Check the MAP sensor with the HDS pocket tester Is about 0 V indicated? | YES. — Faully sensor unit (MAP sensor) tt | No -GOTOSTEP4. 5-17FUEL SYSTEM (PGM-FI) ‘4, MAP Sensor Output Line Open Circuit Inspection ‘Turn the ignition switch OFF. Remove the jumper wire Disconnect the ECM 33P (Biack) connector [1]. Check the continuity between the ECM 33P (Black) onnector and sensor unit SP connactor [2] of the wire side. Connection: Light greenlyellow ~ Light greenlyellow TOOL: Test probe O7ZAJ-RDJAM10 Is thore continuity? a YES — Replace the ECM with a known good one, and recheck. NO — Open circuit in Light green/yelion wire DTC 7-1 (ECT SENSOR LOW VOLTAGE) 4. ECT Sensor System Inspection Te eign switch ON and engine sop sich ies Check the ECT sensor wth the HDS pocket testr. {s about 0 V indicated? YES - GOTO STEP2 NO = Intermittent faiure 2, ECT Sensor inspection Tur te ignition switch OFF. Disconnect the ECT sensor 3P connector the ignition switeh ON and engine stop switch (Check the ECT sensor with the HDS pocket tester. Is about 0 Vindicated? YES - GOTO STEP4. No -GOTOSTEPS 3, ECT Sensor Resistance Inspection Tum the ignition switch OFF. Masur the resistance at the ECT sensor [1] terminals, Standard: 2.3 ~2.6 kA (20°C/68"F) | Is the resistance within 2.3 2.6 kQ (20°C/68"F)? | YES — Replace the ECM with a known good one, ‘and recheck NO — Faulty ECT sensor 5-184, ECT Sensor Short Circuit Inspection. Tun the jgnition switch OFF. Check for continuity between the ECT sensor 3P Connector [1] of the wire side and ground. Connection: Yellow/blue ~ Ground Is there continuity? YES. — Short circuit in Yellow/blue wire NO — Replace the ECM with a known good one, and recheck. DTC 7-2 (ECT SENSOR HIGH VOLTAGE) Nore: Before starting the inspection, check for loose or poor ‘contact on the ECT sensor 3P connector and recheck the DTC, 1. ECT Sensor System Inspection ‘Tum the ignition switch ON and engine stop switch "d Check the ECT sensor with the HDS pocket tester. Is about 5 V indicated? YES - GOTO STEP2, NO ~ + Intermittent fature + Loose or poor contact on the ECT sensor 3P connector 2, ECT Sensor Inspection Turn the ignition switch OFF. Disconnect the ECT sensor 3P connector [1] Connect the ECT sensor SP connector terminals at the wire side with a jumper wire [2] Connection: Yellow/blue ~ Greeniwhito ‘Tum the ignition switch ON and engine stop switch ‘a Check the ECT sensor with the HDS pocket tester. Is about 0 Vindicated? YES. - Inspect the ECT sensor (page 20-12). NO -GOTOSTEP3 FUEL SYSTEM (PGM-FI) a 5-19FUEL SYSTEM (PGM-Fl) 3, ECT Sensor Open Circuit inspection “Turn the ignition switch OFF, Remove the jumper wire. Disconnect the ECM 33P (Biack) connector [1]. (Q) ‘Check the continuities between the ECM 33P. (Black) connector and ECT sensor 3P connector (2) S15) of the wire side. Connection: Yellow/blue ~ Yellowiblue Groon/white ~ Green!white en Ye! ieee orzassoai0 Q)- Is there continuity? YES — Replace the ECM with a known good one, =e and recheck NO ~ + Open circuit in Yollow/blue wire + Open circu in Greeniwhite wire DTC 8-1 (TP SENSOR LOW VOLTAGE) NOTE Before starting the inspection, check for loose or poor Contact on the sensor unit 5° connector and recheck the DTC. 4. TP Sensor System Inspection Turn the ignition switch ON and engine stop switch i Check the TP sensor with the HDS pocket testor when the throttle fully closed. Is about 0 V indicated? YES — + Intermittent failure * Loose or poor contact on the sensor unit 5P connector NO -GOTOSTEP 2, 2. Sensor Unit Power Line Inspection ‘Check the sensor unit power line inspection (page 5-15), Is the sensor unit power line normal? YES -GOTOSTEP3. NO = Replace or repair the abnormal circu. 3. TP Sonsor Output Line Short Circuit inspection Turn the ignition switch OFF. Disconnect the sensor unit SP connector [1] Check for continuity between the sensor unit SP connector of the wire side and ground. Connection: Yellow ~ Ground Is there continuity? YES ~ Short cicuitin Yellow wire NO -GOTOSTEP 4. | 5-20FUEL SYSTEM (PGM-FI) ‘4, TP Sensor Output Line Open Circuit inspection Disconneet the ECM 33° (Black) connector [1]. (Check for continuity between the ECM 33P (Black) Connector and sensor unit SP connector [2] of the | Wire side, | Connection: Yellow - Yellow | TOOL: | Test probe O7ZAJ-RDJAN10 Is there continuity? YES -GOTOSTEPS. NO — Open circuit in Yellow wire 5, TP Sensor Inspection Replace the sensor unit with 2 known good one (page 6-48) Connect the sensor unit SP and ECM 39P (Black) connectors. Erase the DTC's (page 5-13). the ignition switch ON and engine stop switch (Check the TP sensor with the HDS pocket tester. Is DTC 8-1 indicated? YES — Replace the ECM with a known good one, and recheck. NO = Faulty original sensor unit (TP sensor) DTC 8-2 (TP SENSOR HIGH VOLTAGE) 4. TP Sensor System Inspection Tun the ignition switch ON and engine stop switch Check the TP sensor with the HDS pocket tester Is about § V indicated? YES -GOTOSTEPS. NO -GOTOSTEP2 2. TP Sensor Inspection Check that the TP sensor voltage increases Continuously when moving the throttle from fully ‘closed to fully opened using the data list menu of the HDS pocket tester Js the voltage increase continuously? YES - Intermittent failure NO — Replace the TP sensor (sensor unit) with a known good one, and recheck 5-21FUEL SYSTEM (PGM-FI) 5-22 3. TP Sensor Resistance Inspection ‘Turn the ignition switch OFF. Disconnect the ECM 33P (Black) connector [1]. Measure the resistance at the ECM 33P (Black) connector of the wire side. Connection: Yellow — Greeniwhito Standard: 0.29 0.71 0 (20°C/68°F) Is the resistance within 0.29- 0.71.0? YES - GO TOSTEP 4. NO — Faulty sensor unit (TP sensor) 4, TP Sensor Power Input Voltage Inspection Connect the ECM 33P (Black) connector. Disconnect the sensor unit SP connector [1] ‘Turn the ignition switch ON and engine stop switch Measure the voltage at the sensor unit SP connector | of the wire side, Connection: Yellowired (+) - Green/white (-) Standard: 4.75-525V Is the voltage within 4.75~ 5.25 V? YES — Replace the ECM with a known good one, ‘and recheck. NO — + Qpen circuit in Greeniwhite wire * Open circuit in Yellowred wire DTC 9-1 (IAT SENSOR LOW VOLTAGE) 4. IAT Sensor System Inspection Tum the ignition switch ON and engine stop switch va CGheck the IAT sensor with the HDS pocket tester | about 0 Vinclcated? YES - GOTOSTEP2 NO — Intermitent falure 2. IAT Sensor inspection Turn the ignition switch OFF. Disconnect the sensor unit SP connector. Turn the ianiton switch ON and engine stop sich o Check the IAT sensor withthe HDS pocket tester. Is about 0 V indicated? YES - GOTOSTEPS. NO ~ Fauity sensor unit (AT sensor) tt3. IAT Sensor Voltage Input Line Short Circuit Inspection ‘Check for continuity between the sensor unit 5P ‘connector [1] of the wire side and ground. Connection: Gray/blue~ Ground Is there continuity? YES — Short circult in Graylblue wire NO = Replace the ECM with a known good one, and recheck. DTC 9-2 (IAT SENSOR HIGH VOLTAGE) NoTE Before starting the inspection, check for loose or poor ‘contact on the sensor unit SP connector and recheck the DTC. 4. IAT Sensor Systom Inspection ‘Tur the ignition switch ON and engine stop switch o Check the IAT sensor with the HDS pocket tester. Is about 5 Vindicated? YES - GOTOSTEP2 NO = + Intermittent felure + Loose or poor contact on the sensor Unit SP connector 2, Sonsor Unit Power Line Inspection Check the sensor unit power line inspection (page 5-18), Is the sensor unit power line normal? YES -GOTOSTEPS NO = Replace or repair the abnormal circu. 3, IAT Sensor Inspection ‘Tum the ignition switch OFF. Disconnect the sensor unit SP connector [1] Connect the IAT sensor terminals at the wire side with a jumper wire (2). Connection: Graylblue ~ Green/white ‘Tur the lgnition switch ON and engine slop switch Cheek the IAT sensor with the HDS pocket tester. Is about 0 V indicated? YES. — Faulty sensor unit (IAT sensor) No -GOTOSTEP4. FUEL SYSTEM (PGM-Fl) creu} enw cS ti 5-23FUEL SYSTEM (PGM-F) 4. IAT Sensor Voltage Input Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the ECM 33P (Black) connector [1]. (Check for continuity between the ECM 33P (Black) Connector and sensor unit SP connector [2] of the wire side. Connection: Gray/blue— Gray/blue TOOL: Test probe OTZAJ-RDJAN10 Is there continuity? YES — Replace the ECM with a known good one, and recheck. NO = Open circuit in Grayibiue wire DTC 12-1 (FUEL INJECTOR) NoTE: Before starting the inspection, check for loose or poor contact on the fuel injector connector and recheck the Dre. 41. Fuel injector System Inspection Erase the DTC's (page 5-13). the ignition switch ON and engine stop switch ‘Siart the engine and check the fuel injector with the HDS pocket tester. Is the DTC 12-1 indicated? YES -GOTOSTEP2 NO = = Intermittent failure + Loose or poor contact on the fuel Injector 2P (Gray) connector 2. Fuel injector Input Voltage Inspection. Turn the ignition switch OFF. Disconnect the fuel injector 2 (Gray) connector [1]. ‘Turn the ignition switch ON and engine stop switch Measure the voltage between the fuel injector 2P (Gray) connector of the wire side and ground Gonnection: Black/blue (+) ~ Ground (-) Standard: Battery voltage Does the standard voltage exist? YES - GOTOSTEPS. NO = Open or shor circuit in Black/blue wire 5-24FUEL SYSTEM (PGM-Fl) 3. Fuol injector Signal Line Short Circuit Inspection Turn the ignition switch OFF. Check for continuity between the fuel injector 2 (Gray) connector [1] of wire side and ground. Connection: Pinklwhite — Ground Is thore continuity? YES. ~ Shor circult in Pink/white wire No -GOTOSTEP4 ‘Standard: 8 ~ 16 © (20°C/68°F) ‘5. Fuel injector Signal Line Open Circuit inspection Disconnect the ECM 33P (Black) connector [1]. Check the continuity between the ECM 23P (Black) Connector and fuel injector 2P (Gray) connector 2] of the wire side. Connection: Pinkiwhite - Pink/white TooL: 4 Tost probe O7ZAJ-RDJAI10 aia Is there continuity? ee ~Q—_ YES — Replace the ECM with a known good one, and recheck. NO ~ Open circuit in Pink/white wire 5-25FUEL SYSTEM (PGM-FI) DTC 21-1 (02 SENSOR) NOTICE + Do not get grease, ol! or other materials in the Or sensor air hole. + Do not reuse O: sensor cord, ifthe O: sensor cap is disconnected, replace the Oz sensor cord with @ new NOTE Before starting the inspection, check for loose or poor ‘contact on the O: sensor 1P connector or O2 sensor cap ‘and recheck the DTC. 4. O2 Sensor System Inspection Tum the ignition switch ON and engine stop switch ee Start the engine and warm up the engine up to ‘coolant temperature is 80°C (176°F), Testride the motoreycle and check the O: sensor with the HDS pocket tester. Is the DTC 21-1 indicated? YES - GOTO STEP2 NO = Intermittent failure 2, 02 Sensor Short Circuit Inspection Turn the ignition switch OFF. Disconnect the O: sensor 1P connector [1] Check for continuity between the Oz sensor 1P Connector of the wire side and ground. Connection: Black/white ~ Ground Is there continuity? YES. — Short circuit in Blackiwhite wire No -GOTOSTEPS, 3, 02 Sensor Open Circuit Inspection Disconnect the ECM 34P (Black) connector [1]. Check the continuity between the ECM 33P (Black) connecter and Oz sensor 1P connector [2] of the wire side, Connection: Black/white ~ Black/whito TOOL: Test probe O7ZAJ-RDJA110 Is there continuity? YES - GOTOSTEP4 NO — Open circuit in Blackiwhite wire 5-26FUEL SYSTEM (PGM-Fl) ee ‘4. 02 Sensor Inspection Replace the O: sensor and O: sensor cord with a known good one (page 5-57). Erase the DTC's (page 5-13). Connect the O2 sensor 1P connector and ECM 33P (Black) connector. ‘Tur the ignition switch ON and engine stop switch Start the engine and warm up the engine up to ‘coolant temperature is 80°C (176°C). Test-rde the motorcycle and recheck the O2 sensor with the HDS pocket tester. Is the DTC 21-1 indicated? YES — Replace the EGM with a known good one, and recheck. NO — Faulty orginal O: sensor and/or O: sensor cord DTC 29-1 (IACV) NoTE Before starting the inspection, check for loose or poor ‘contact on the ACV 4P (Black) connector and recheck the DTC. 4, Recheck DTC Erase the DTC's (page 5-19). “Turn the ignition switch ON and engine stop switch te Check the IACV with the HDS pocket tester: Is the DTC 29-1 indicated? YES - GO TOSTEP2 NO =» Intermittent failure + Loose or poor contact on the |ACV 4 (lack) connector 2. IAGV Short Circuit Inspection ‘Turn the ignition switch OFF, Disconnect the IACV 4P (Black) connector [1]. Check fr continues betveen the ACY 4P (Black) | i omoctrcfthe we aide and grou p_ ehh Connection: lulvhite Ground Brownivfite= Ground pu] en | Brownback Ground | Bluollack~ Ground ©) ta tore contnuty? YES — + Shot otc In Blewhite or Brown! ss tio wee + Shor cul in Brownback or Biv! Bockwee oa NO - GOTOSTEP 3, 5-27FUEL SYSTEM (PGM-Fl) 3. IACV Open Circuit Inspection Disconnect the ECM 33P (Black) connector [1]. Check the continuities between the ECM 33. (Black) connector and IACV 4P (Black) connector [2] ofthe wire side, Connection: Brown/white — Browniwhite Blue/white ~ Blue/white Brown/black ~ Browniblack Bluefblack ~ Blue/black Too! Tost probe OTZAJ-RDJAT10 Is there continuity? YES - GOTOSTEP 4. NO + Open circuit in BlueMhite or Browns white wire + Open circuit in Brownlblack or Blue/ black wire IAC Resistance Inspection Measure the resistance at the IACV 4P (Black) connector [1] atthe motor side. Connection: Blue/white ~ Blue/black Brown/white ~ Brown/black Standard: 110-1500 (25°C/77°F) Is the resistance within 110 — 150 0 (25°C/77°F)? YES — Replace the ECM with a good one, and recheck, No — Faulty ACV DTC 33-2 (EEPROM) 4. Recheck DTC Erase the DTC's (page 5-13). Turn the ignition switch ON and engine stop switch Recheck the ECM EEPROM. Is the DTC 33-2 indicated? YES — Replace the ECM with a known good one, and recheck NO = Intermittent failure tH Busi Bu Briw ti | 5-28DTC 54-1 (BANK ANGLE SENSOR LOW VOLTAGE) 4. Recheck DTC Erase the DTC's (page 5-13). ‘Tum the ignition switch ON and engine stop switch ‘Check the bank angle sensor with the HDS pocket tester |s the DTC 84-1 indicated? YES -GOTOSTEP 2 NO — Intermittent failure 2. Bank Angle Sensor Power Input Voltage Inspection. ‘Tur the ignition switch OFF. Disconnect the bank angle sensor 3P connector [1] the ignition switch ON and engine stop switch | Measure the voltage at the bank angle sensor Connector of the wire sida, Connection: Yellowired (+) ~ Greeniwhite (-) Standard: 4.75 -5.25V Is the voltage within 4.75 ~ 6.25 V? YES - GOTO STEP 4 NO -GOTOSTEP3. 3. Bank Angle Sensor Input Voltage Line Short Circuit Inspection Turn the ignition switch OFF. Check the continuity between the bank angle sensor 3P connector [1] of the wire side and ground, Connection: Yellowired ~ Ground Is there continuity? | YES — Short circuit in Yellow/ted wire NO — Replace the ECM with a known good one, and recheck 4. Bank Angle Sensor Output Line Short Circuit Inspection Turn the ignition switch OFF. Disconnect the ECM 33P (Black) connector. Check the continuity between the bank angle sensor | 3P connector [1] of the wire side and ground, | Connection: Red/blue~ Ground | Is there continuity? YES ~ Short circuit in Redolue wire NO -GOTOSTEPS. 'UEL SYSTEM (PGM-Fl) a fe rol te) 5-29FUEL SYSTEM (PGM. ‘5. Bank Angle Sensor Inspection. Replace the bank angle sensor with a known good tone (page 5-55) Erase the DTC's (page 6-13). Connect the bank angle sensor 3P connector. ‘Turn the ignition switch ON and engine stop switch ‘o ‘Chack the bank angle sensor with the HDS pocket tester. Is DTC 54-2 indicated? YES ~ Replace the ECM with a known good one, and recheck. NO — Faulty orginal bank angle sensor DTC 54.2 (BANK ANGLE SENSOR HIGH VOLTAGE) NOTE Before starting the inspection, check for loose or poor contact on the bank angle sensor 3P connector and recheck the DTC. 4. Recheck DTC Erase the DTC's (page 5-13). Turn the ignition switch ON and engine stop switch a eck the bank angle sener withthe HDS pocket ester. Is the DTC 54-2 indicated? YES -GOTOSTEP2 NO = = Intermittent failure + Loose or poor contact on the bank angle sensor 3P connector 2. Bank Angle Sensor Power Input Voltage Inspection Tum the ignition switch OFF. Disconnect the bank angle sensor 3P connector [1]. Measure the voltage at the bank angle sensor 3P. ‘connector ofthe wire side, Connection: Yellowired (+) ~ Greeniwhite (-) Standard: 4.75-5.25V Is the voltage within 4.75 - 5.25 V? YES - GOTO STEP 4. NO -GOTOSTEPS. {Ln he gon sch ON and enghe sop ste | 5-30FUEL SYSTEM (PGM-FI) 3. Bank Angle Sonsor Input Voltage Line Open Circuit inspection ‘Tum the ignition switch OFF, Disconnect the ECM 33P (Black) connector [1]. Check the continuities between the ECM 33P (Black) connector and bank angle sensor 3P Connector [2] of the wire side Connection: Yellowired - Yellowired Green!white - Green/white TOOL: Test probe O7ZAJ-RDJAA10 Are there continuities? YES — Replace the ECM with a known good one, and recheck. San SAN OEON NO = + Open citcuit in Yellowred wire + Open circut in Graentwhite wire 4, Bank Angle Sensor Output Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the ECM 33P (Black) connector [1]. Check the continuity between the ECM 33P (Black) Connector and bank angle sensor 3P connector [2] of the wire side, Connection: Rediblue ~ Red/blue TOOL: Test probe O7ZAJ-RDJAT10 1s there continuity? YES ~ Inspect the bank angle sensor (page 5-55) NO = Open circuit in Red/blue wire 5-31FUEL SYSTEM (PGM-Fl) MIL CIRCUIT TROUBLESHOOTING NoTE: Before starting the inspection, check the combination ‘meter power input line (page 20-6). With The Ignition Switch ON, The MIL. Does Not Come On Ifthe engine can be started but the MIL does not come fon when the ignition switch Is turned ON and engine slop switch "0", check as follows: (Check for the combination meter function Turn the ignition switch OFF. Remove the right side cover (page 2-16). Disconnect the ECM 93P (Black) connector [1] Ground the White/blue wice terminal ofthe wire hamess side ECM 33P (Black) connector [1] with a jumper wire. | CONNECTION: Whitelblue - Ground TOOL: Test probe O7ZAJ-RDIAI1O ‘Turn the ignition switch ON and engine stop switen the MIL should come on. = Ifthe MIL comes on, replace the ECM with a known {good one and recheck the MIL indication, = the MIL. does not come on, check for open circuit in the Whitefblue wire between the MIL and ECM | 39P (Black) connector. I ifthe wire is OK, replace the combination meter With The Ignition Switch ON, The MIL Does Not Go Off Within A Few Seconds (Engine starts) Turn the ignition switch OFF. Remove the right side cover (page 2-16) Disconnect the ECM 33P (Black) connector 1} ‘Turn the ignition swteh ON and engine stop switch °C the MIL should come on = If the MIL come on, check for short circuit in the Whitefblue wire between the combination meter and j ECM, Ifthe White/olue wire is OK, replace the ECM with a known good one and recheck = Ifthe MIL turns off, check the following 5-32FUEL SYSTEM (PGM-FI) ‘Check the continuity between the ECM 93P (Black) ———— ‘ail connector [1] of the wire side and ground. Mn CONNECTION: Blue ~ Ground STANDARD: No continuity TOOL: Test probe O7ZAJ-RDIA10 IT there is continuity, check for short circuit in the Blue Wire hetween the DLC and ECM. If there is no continuity, replace the ECM with a known {good one and recheck, FUEL LINE INSPECTION FUEL PRESSURE RELIEVING Nore Before disconnecting fuel feed hose, relieve pressure from the system as follows. 4. Tum the ignition switch OFF. 2, Liftand support the fuel tank (page 3-5). 3, Disconnect the fuel pump SP connector [1 Tum the ignition switch ON and engine stop switch 4, Start the engine, and let tale until the engine stals 5, Tum the ignition switch OFF. 6, Disconnect the battery negative (~) cable (page 17-6) QUICK CONNECT FITTING REMOVAL NoTE: Do not bend or twist fuel feed hose. FUEL PUMP SIDE 1. Relieve the fuel pressure (page 5-33) ig 2. Check the fual quick connect fiting [1] for dirt, and | ‘lean it necessary. | Place a shop towel [2] over the quick connect fitting. | 5-33FUEL SYSTEM (PGM-Fl) 3. Pull and release the joint rubber [1] from the retainer. 4, Hold the connector with one hand and squeeze the retainer tabs [2] with the other hand to release them ‘rom the locking pawis (3) Pull the connector off and remove the retainer. NoTE: + Absoro the remaining fuel inthe fuel feed hose from flowing out with a shop towel + Be careful not to damage the hose or other parts. + Do not use tools. + Ifthe connector does not move, keep the retainer tabs pressed down, and alternately pull and push the connector until it comes off easily 5. To prevent damage and keep foreign matter out, covar the disconnected connector and pipe end with the plastic bags [tl FUEL INJECTOR SIDE 4. Relieve the fuel pressure (page 5-33) (Check the fuel quick connect fiting [1] for dirt, and clean necessary lace a shop towel over the quick connect fiting 2, Pl aera he Jantar tabs tom he gfe ialenmnesa yh op (rd end oyiars ta | tie tbe Bl wih he cbr tad olan om | from the locking paws [3]. PM ted ll eo racer NOTE *+ Absorb the remaining {ve inthe fuel feed hose from flowing out with a shop towel. + Be careful not to damage the hose or other parts. + Donot use tools. + Ifthe connector does not move, keep the ret tabs pressed down, and altemately pull and pusl the connector untl it comes off easly 5-344. To provent damage and keep foreign matter out, cover the disconnected connector and pipe end with | the plastic bags [1] QUICK CONNECT FITTING INSTALLATION Nore: + Always replace the retainer and joint rubber of the uick connect fiting when the fuel feed hose is disconnected, * Replace the retainar and joint rubber with the same ‘manufacturer's item that was removed, + Do not bent or twist fuel feed hose, FUEL PUMP SIDE 4. Insert a new retainer [1] into the connector (2. Nore: + Align new retainer locking pawis with the connector grooves. 2, Set a new joint rubber [1] as shown, ‘Then press the quick connect fiting onto the pipe Lunt both retainer pawis [2] lock with a "CLICK" NOTE * Align the quick connect iting with the pipe. + Ifitis hard to connect, put a small amount of engine ‘il on the pipe end. FUEL SYSTEM (PGM-Fl) m ® 5-35FUEL SYSTEM (PGM-F1) ‘3. Make sure the connection is secure and that the ‘pais are fmly locked into place; check visually and by puling the connector [1] 4, Make sure the joint rubber [2] Is in place (between the retainer tabs), ‘5. Increase the fuel pressure and check that there is no | leakage in fuel supply system (page 6-37). FUEL INJECTOR SIDE 1. Insert @ new retainer [1] nto the connector (2) NoTE + Align new retainer lacking pals with the connector ‘grooves. 2, Set a new joint rubber [1] as shown. ‘Then press the quick connect fing onto the pipe Until both retainer paws [2] lock with a "CLICK. NoTE: * Align the quick connect fiting with the fuel injector | joint Ititis hard to connect, put a small amount of engine cll on the fuel injector joint 3, Make sure the connection is secure and that the») paws are firmly locked into place; check visually and. by pulling the connector [1]. ‘4, Make sure the joint rubber [2] Is in place (between the retainer tabs). 5, Increase the fuel pressure and check that there is no leakage in fuel supply system (page 5-37) 5-36FUEL SYSTEM (PGM-Fl) FUEL PRESSURE NORMALIZATION 41. Connect the fuel pump 5P connector [1] Connect the battery negative (-) cable (page 17-6). 2, Tum the ignition switch ON and engine stop switch NOTE + Do not start the engine. The fuel pump wil run for about 2 seconds, and fuel pressure wil ise. leakage in the fuel supply system. “Turn the ignition switch OFF. Remove the sultable support and close the fuel tank (page 3-5). FUEL PRESSURE TEST Relieve the fuel pressure and disconnect the quick connect fiting from the fuel pump (page 5-33). | ‘Attach the fuel pressure gauge, attachments and io manifold | TOOLS: | Fuol prossure gauge, 0-100 psi [1] 07406-0040004 Pressure gauge manifold [2] O7ZAJ-S5A0111 | Hose attachment, | 9 mm/9 mm [3] 07ZAs-8500120 Hose attachment, mm/s mm [4] 07ZA5-85A0130 Attachment joint, 6 mm/9 mm [5] 072As-85A0150, TOOLS, U.S.A. only: a Fuel pressure gauge, 0-100 psi 07406-0040008 Pressure manifold hose O7AMJ-HW3A100 Adaptor, male "8" O7AAJ-S6MAZ00 Adaptor, female" O7AAJ-S6MA400 ‘Temporarily connect the battery negative (-) cable and {uel pump 5P connector. “Turn the ignition switch ON and engine stop switch "0 ‘Siar the engine and let it idle, | Read the fuel pressure. | ‘STANDARD: 294 kPa (3.0 kgf/cm? 43 ps!) | Iv the fuel pressure is extremely higher than specified, replace the fuel pump assembly If the fuel pressure is extremely lower than specified, ingpect the folowing: Fuel line leaking = Pinched or clogged fuel feed hose or fuel tank breather hose Fuel pump unit (page 5-39) Clogged fue! fiter After inspection, relieve the fuel pressure (page 5-33). Remove the fuel pressure gauge, attachment and ‘manifold from the fuel pump. Connect the quick connect iting (page 5-36). 5-37FUEL SYSTEM (PGM-Fl) FUEL FLOW INSPECTION Relieve the fuel pressure and disconnect the quick ‘connect fiting (page 5-33). Wine off piled Connect the special tool to the fuel pump jit gasoline. ToQL; Hose attachment, Smmi9 mm [1] O7ZAJ-S5A0130 NOTE: | Meke sure the fuel pressure gauge Is installed when using U.S.A. tools TOOLS, U.S.A. only: Fuel pressure gauge, ‘0-100 psi 07406-0040008 Prossure manifold hose O7AMJ-HW3A100 ‘Adaptor, female "B” O7AAJ-S6MA400 Place the end of the hose into en approved gasoline container. ‘Temporatly connect the battery negative (-) cable and fuel pump SP connector. Turn the ignition switch ON and engine stop switch "2" Measure the amount of fuel flow. NOTE: + The fuel pump operates for 2 seconds. Repeat 5 times s0 that the total measuring time, + Retum fuel fo the fuel tank when the first fuel is flowed ‘Amount of fuel flow: 69.2 cm (2.34 US 02, 2.44 Imp 02) minimum/10 seconds at 12V If fuel flow is less than specified, Inspect the following: Fue! pump unit (page 5-39) = Clogged tus! fiter Connect the quick connect fiting (page 5-35). 5-38FUEL SYSTEM (PGM-Fl) FUEL TANK REMOVAL/INSTALLATION Relieve the fuel pressure and disconnect the quick (— ‘connect fiting (page 5-33) Release the fue! feed hose [1] from the hose guide (2) Release the clamp [3] from the setting plate. Remove the bolts [4], collar [5], washers [6], mounting | rubbers [7] and fuel tank (8) | NOTE Place the suitable support under the front side of the removed fuel tank to avoid damage the fuel fiter. } io} ia) Route the hose and Install the fuel tank in the reverse order of removal | "0807 40° Connect the quick conned tng (page 5-38) FUEL PUMP UNIT INSPECTION ‘Tum the ignition switch ON and engine stop switch “" ‘and confirm that the fuel pump operates for 2 seconds. Ifthe fuel pump does not operate, inspect as follows: ‘Turn the ignition switch OFF. Lift and support the fuel tank (page 3-6. Disconnect the fuel pump 5P connector [1] 5-39FUEL SYSTEM (PGM-Fl) “Tum the ignition switch ON and engine stop switen °c Measure the voltage at the fuel pump SP connector [1] terminals of the wire side CONNECTION: Brownired (+) — Groen (-) STANDARD: Battery voltage ‘There should be standard voltage for a few seconds. If there is standard voltage, replace the fuel pump unit. It there is no standard voltage, inspect the following: Main fuse 30 A Sub fuse 10.4 Ignition switch Engine stop switch Fuel pump relay (page 5-42) (Open circuit in Brownired or Green wire ECM (page 5-56) REMOVAL NOTE Do not disassemble the fuel pump. ‘Clean around the fuel pump. Remove the fuel tank (page 5-39). Disconnect the flowing — Fuol pump hose A [1] = Fuel pump hose 8 [2] Remove the fue ite [3] from the setting plate NoTE: Prevent the remaining fue! in the fuel pump hoses and {ul filter from the flowing out with a shop towel Loosen the fuel pump setting plate nuts [1] in a ‘crisscross pattern in 2 oF 9 sleps and remove the nuts. 5-40FUEL SYSTEM (PGM-FI) 9 caratu'notto Remove the setting plate [1], fuel pump unit [2] and damage the fue! packing [3 level sensor foat INSPECTION ‘Check the fuel pump unit for wear or damage, replace it if necessary, INSTALLATION “Atways replace the Install a new packing [1] onto the fuel pup unit [2 packing with a now ‘one. Be careful not to get dit and debris botwoen tho ue pump unt anc packing, Be careful otto. Install the fuel pump unit into th fuel tank. damage the fuel level sensor float Install the fuel pump selting plate [1] onto the fuel pump Unit [2] by aligning the slots of the setting plate and tabs cof the fue! purnp unit 5-41FUEL SYSTEM (PGM-FI) Install and tighten the fuel pump setting plate nuts to the ig specified sequence as shown. TORQUE:12 Nom (1.2 kgfm, 9 IbFt) Route the pump Install the fuel fit {1] to the setting plate with the r——— unit wire properly flange side facing forward. H (202 $18). Connect the following = Fuel pump hose A [2] = Fuel pump hose B (3) NOTE: Install the hoses aligning Its paint mark with bosses of filter. Install the fuel tank (page 5-20). FUEL PUMP RELAY INSPECTION Remove the left middle cow (page 2-7) Remove the fuel pump relay [1] Connect @ ohmmeter to the fuel pump relay [1] [ry terminats. Connect a 12 V battery to the fuel pump relay terminals as shown. ‘There should be continuity only when 12 V battery is connected, If there 1s no continuity only when the 12 V battery is connected, replace the fuel pump relay, 5-42FUEL SYSTEM (PGM-FI) AIR CLEANER HOUSING REMOVAL/INSTALLATION Remove the fuel tank (page 5-38). Rotate the side cover out ofthe way to allow access, Disconnect the vacuum hose [1] from the hose joint [2 Disconnect the EVAP purge control solenoid valve 2° connector [3] Disconnect the secondary air supply hose [1] and PAIR contol solenoid valve 2P (Black) connector [2 Disconnect the crankcase breather hose [1] Loosen the conneeting hose band screw [1] 5-43FUEL SYSTEM (PGM-Fl) Remove the bolts [1] and air cleaner housing, Disconnect the air cleaner housing drain hose [2} Route the hose and Installation isin the reverse order of removal wre prose 80° Nore ‘After installing the air cleaner housing, make sure the tir cleaner housing drain hose is not kinked or pinched, 5-44FUEL SYSTEM (PGM-Fl) ee DISASSEMBLY/ASSEMBLY Remove the PAIR control solenoid valve (page 5-59). Remove the screw [1] and PAIR control solenoid valve stay (2) Remove the Air cleaner cover screws [3] and element holder lia (4), Remove the alr cleaner element (5) Loosen the band screw (6) Remove the resonator [7] by releasing its tab [6] from the air cleaner cover [9] sit Disconnect the canister-to-EVAP purge control solenoid valve hose [10] from the canister [11]. Remove the screw [12], EVAP purge control solenoid valve [13] and stay [14] Remove the canister from the air cleaner cover tabs, Remove the following: Air cleaner cover screws Air cleanor cover Packings [15] Element holder (16) Air cleaner case [17] ‘Assemble is in the reverse order of disassembly, NOTE Make sure the packings are in good condition, replace them wit new one if necessary. TORQUE: ‘lr cleaner cover screw: 4.1 Nem (0-4 kgfem, 0.8 Ibttt) 5-45FUEL SYSTEM (PGM-Fl) THROTTLE BODY REMOVAL, Relieve the fuel pressure and disconnect the quick jp ‘connect fiting from the fuel injector side (page 5-34). Remove the air cleaner housing (page 5-43). Disconnect the sensor unit SP connector [1]. Disconnect the ICV 4P (Black) connector [1] end fuel injector 2P (Gray) connector [2 Release the clamp [3] from the clamper stay. Loosen the throttle cable A adjuster lock nut [1] and adjusting nut [2] than disconnect the throtte cable A (3) | from the throttle drum and cable stay. Loosen the throttle cable B [4] then disconnect the throtle cable B [5] from the throttle drum and cable sizy, Loosen the insulator band screws [1] and remove the throttle body assembly (2). 5-46FUEL SYSTEM (PGM-Fl) DISASSEMBLY NOTICE + Do not remave the sensor unit unfess iti replaced. AAT Oe | + The throtle body/sensor unit is factory pre-set. Do ¥ Bh not disassemble in a way other than shown in this: ‘manuel. + Do nol snap the throttle valve from full open (o full ‘lose affer the throitle cable has been removed. It may cause incorrect idle operation. + Do not damage the tnvottie body. It may cause incorrect throttle valve operation + Do not loasen or tighten the white painted nut and screw [i] of the throttle body. Loosening or lightening it can cause throtle valve and idle control failure, + Always elean around the throtie body before each sensor removal to prevent dit and debris from entering the air passage. NOTE: = For fuel injector removal (page 6-51). = ForlAGV removal (page 5-53). Remove the throttle body insuiator [2} Remove the sensor unit torx serawes [1], sensor unit [2] [> ‘and O-ring (3) ‘Cleaning the sir Clean the air passage of the throttle body using passages and compressed air. sensor hole wili a Check the air passage for clogs. ‘lece of wie will damage the tote boxy. 5-47Install the throttle body insulator {1} to the throttle body by aligning the tab of the throttie body with the groove of, the throttle body insulator. NOTE: + Install the throttle body insulator with "Ys" mark [2] facing cylinder head. + Align the insulator band hole with the insulator boss. INSTALLATION Correctly position the rubber blanket against the back of the cylinder head, Install the throttle body assembly [1] to the cylinder head by aligning the tab of the cylinder head with the ‘groove of the tattle body insulator. Tighten the insulator band screws to the specified torque. TORQUE: 4.2 Nim (0.4 kgfim, 3.4 Ibft) Aer tightening the insulator band screws, check that the width between the band ends clearance is within specification. Connect the throttle cables [1] to the throttie drum and throttle cable stay. Tighten the throttle cable 8 [2] to the specified torque. TORQUE: 3.0 Nim (0.3 kgf-m, 2.2 IbF4t) Tighten the throttle cable A adjuster jock nut {3] to the specified torque. TORQUE: 3.0 Nim (0.3 kgfm, 2.2 Ibt) ‘Adjust the throttle grip freeplay (page 3-6) FUEL SYSTEM (PGM-F | Align (2) Omm (0.0in) aoe 5-49FUEL SYSTEM (PGM. “Raulethewres Connect the IAGV 4P (Black) connector [1] and fuel ‘propery injector 2P (Gray) connector 2} (age 18). Install the clamp [3] to the clamp stay. Connect the sensor unit SP connector [1]. NoTE If the sensor unt is removed, reset the throttle valve fully closed postion (page 5-50), Install the air cleaner housing (page 5-43), Route the hose and ire property (rage 1-18) Connect the quick connect fiting to the fuel injector side (page 5-36), THROTTLE VALVE FULLY CLOSED POSITION RESET PROCEDURE NoTE If the sensor unit is removed, reset the throttle valve fully closed position as folowing, 4. Erase the DTC's (page 5-13), 2, Turn the ignition switch OFF. 3, Remove the dummy connector. 4, Short the DLC [1] using a special tool TOOL: SCS Service connector [2] _070PZ-2¥30100 5, Disconnect the ECT sensor 3P connector [1] Short the ECT sensor 3P connector terminals of the wire harness side with a jumper wire [2] Connection: Yellow/blue - Greeniwhite 6. Turn the ignition switch ON and engine stop switch "CY the ML wil then start blinking. Disconnect the jumper wire while the is MIL blinking. (within 10 seconds).FUEL SYSTEM (PGM-Fl) 7. Aller disconnection of the jumper wi will stat shor blinking the MIL [1] 8 Check ifthe MIL blinks. Ifthe MIL begins shor binking (0.3 seconds), the throttle vale fully closed postion is reset (| ee 0.1 see. MILON i 1.2 800, n MIL OFF a RESET RECEIVING PATTERN ‘SUCCESSFUL PATTERN Ifthe MIL stays li, the throttle valve fully closed position is not reset, repeat the reset procedure from step 1 9, Tum the ignition switch OFF. 40.Connect the ECT sensor 3P connector (1) FUEL INJECTOR REMOVAL Relieve the fuel pressure and disconnect the quick ‘connect iting from the fuel injector side (page 6-34) Disconnect the fuel injector 2P (Gray) connector [1] Remove the bolts [2] and fuel injector assembly [3] from the throttle body. 5-51FUEL SYSTEM (PGM-F) Be careful not to damage the seat ng. Remove the fuel injector joint [1], O-ing [2), cushion [, Fing [3] and seal ing [4] from the fuel injector {5} 8 Check the removed parts for wear or damage and replace them if necessary (4) INSTALLATION alas ‘Apply engine oll to @ new O-ing [1] end a new seal rng a rn Rear er ee ee eee ce e Intal the Oving tothe uel noc. g Instal the fuel injector [1] into the fuel Injector joint [2 7 being careful not to damage the O-ring. F NOTE: ‘Align the fuel injector body withthe fuel injector joint tab [alas shown, | Install the fuel injector assembly [1] to the throtte body. Install and tighten the fuel injector joint mounting bolts [BJ alternately to the specified torque. ‘TORQUE: 5.1 Nem (0.5 kgFim, 3.8 IbF*t) Connect the fuel injector 2P (Gray) connector [3] while aligning its groove with the tab of the fuel injector joint, Connect the quick connect fiting o the fuel injector side | (page 5-35) 5-52FUEL SYSTEM (PGM-FI) IACV REMOVAL/INSPECTION Lift and support the fuel tank (page 3-5). ‘The IACV Is installed on the throttle body and is ‘operated by the step motor. When the ignition switch is tuned ON and engine stop switch "c’, the IAC ‘operates for a few seconds. Check the step motor operating (beep) sound with the ignition switch tured ON and engine slop switch "0". Disconnect the |ACV 4P (Black) connector [1] Remove the IACV setting plate tore serews [1] and setting plate (21 Remove the IACV [3] and O-ring [4] Check the |ACV [1] for wear or damage. The IACV operation can be checked visually as follows: 4, Connect the |AGV 4P (Black) connector (2). 2, Tum ignition switch ON and engine stop switch cheek the IACV operation. Disconnect the IACV 4P (Black) connector. INSTALLATION Turn the slide velve [1] clockwise until lightly seated on Iacv.FUEL SYSTEM (PGM-Fl) Install a new O-ring [1] to the IACV (2) Install the IACV by aligning its groove with the slide | vvaive housing pin, | Install the setting plate [1] while aligning its cut-out with the tab on the IACV. Install and tighten the IACV setting plate torx screws [2] to the specified torque. TORQUE:2.1 Nim (0.2 kgm, 1.5 bff) Connect the IACV 4P (Black) connector [3 Remove the sutable support and close the fuel tank (age 35) ECT SENSOR REMOVALIINSTALLATION Drain the coolant (page 6-7). Remove the ECT Disconnect the ECT sensor 3P connector [1]. ‘sensor while the ensor unde ie Remove the ECT sensor [2] and sealing washer [3] Install a new sealing washer [1] onto the ECT sensor [2] and install them. Tighten the ECT sensor to the specified torque. TORQUE: 25 N-m (2.6 kgf'm, 18 Ibf-t) ‘Always replace a ‘sealing washer with 5-54Connect the ECT sensor 3P connector [1], Fil the cooling system with recommended coolant (age 6-4). BANK ANGLE SENSOR Instat the bank angle sensor vith ts "UP" mark 1} acing up, REMOVAL/INSTALLATION Remove the upper cova (page 2-0) Remove the bank angle sensor mounting nuts {1}, collars [2] and bank angle sensor [3 Install the bank angle sensor, collars and mounting -— ruts, Tighten the bank angle sensor mounting nuts to the | ‘specified torque. | TORQUE: 10 Nom (1.0 kgm, 7 Ibf-ft) Install the upper cow (page 2-9) SYSTEM INSPECTION Connect the HDS pocket tester (page 5-12) Remove the bank angle sensor (page 5-55). Connect the bank angle sensor 3P connector. Pace the bank angle sensor is horizontal as shown, Turn the ignition switch ON and engine stop switch * Read the voltage with the HDS pocket tester. STANDARD: 3.6-4.4V | Incline the bank angle sensor 60 = 5° to the left or ight | With keeping the ignition switch ON, Read the voltage with HDS pocket tester STANDARD: 0.7~1.3V |FUEL SYSTEM (PGM. ECM 5-56 REMOVAL/INSTALLATION Remove the right side cover (page 2-16). ‘Tum the ignition switch OFF. Disconnect the ECM 33P (Black) connector [1 Remove the rubber holder [2] and ECM [3]. Remove the ECM from the rubber holder. Install the ECM to the rubber holder install them to the frame. ‘Connect the ECM 33P (Black) connector. Insiall the right side cover (page 2-16), ECM POWER/GROUND LINE INSPECTION NOTE: Bofore starting the inspection, check for loose or poor contact on the ECM 33P (Black) connecior and recheck the MIL blinking. ENGINE DOES NOT START (MIL does not blink) 4. ECM Power input Voltage Inspection Remove the right side cover (page 2-16). Disconnect the ECM 33P (Black) connector [1]. ‘Turn the ignition switch ON and engine stop switch [> ‘or Measure the voltage at the ECM 33P (Black) connector [1] of the wire side and ground, Connection: Blacklblue (+) ~ Ground (-) Standard: Battery voltage TOOL: Test probe OTZAJ-RDJAN10 Does the standard voltage exist? YES -GOTOSTEP2 NO — + Open or short circuit in Blaclbive wire + Faulty ignition switch + Blown main fuse 30 A + Blown sub fuse 10 A (IGP, PUMP, FI SOLENOID) + Faulty engine stop switchFUEL SYSTEM (PGM. Tum the ignition switch OFF. Check the continuities between the ECM 33°. (Black) connector [1] of the wire side and ground. Connection: Green/black — Ground Green ~ Ground Green ~ Ground | TOOL: Test probe O7ZAJ-RDJA110 1s there continuity? | | YES — Replace the ECM with a known good one, and recheck. | NO — + Open circuit in Green/black wire = + Open cicuit in Green wires O2 SENSOR NOTICE * Do not get greese, oil or other meterials in the O: sensor air hale + The Os sensor may be damaged if dropped. Replace itwith 2 new one, if dropped. NOTE: + Handle the Os sensor with care, * Donat service the O: sensor while itis hot REMOVAL Remove the left middie cow (page 2-7) Disconnect the O2 sensor 1P connector [1] Disconnect the O: sensor cap [1] Remove the Os sensor [2]. NOTICE Do not use an impact wrench while removing or Installing the Ox sensor, or may be damaged,FUEL SYSTEM (PGM-Fl) INSTALLATION Install and hand tighten a new O2 sensor [1] onto the cylinder head. Tighton the O: sensor to the specified torque. TORQUE:25 N-m (2.5 kgm, 18 Ibft) Connect the O: sensor cap [1 Lworice | + Take care dt to tt the Oz sensor cap when connecting the cap to the Oz sensor. + Donot tum the Oo sensor cap, after connecting it. Connect the O2 sensor 1P connector {1} Install the left middle cow! (page 2-7). SECONDARY AIR SUPPLY SYSTEM SYSTEM INSPECTION Start the engine and warm it up to coolant temperature is 80°C (176°F). Stop the engine, Disassemble the air cleaner housing (page 5-45) Check that the secondary sir intake port [1] of the ‘element holder is clean and free of carbon deposits. ‘Gheck the PAIR check valve ifthe port is carbon fouled (page 5-60), 5-58FUEL SYSTEM (PGM-Fl) Start the engine and open the throttle slightly to be certain that air is sucked in through the air supply hose. Ifthe air is not drawn in, check the alr supply hoses [1] for clogs and PAIR control solenoid valve [2] (page 5-59), <= FRESHAR <— EXHAUST GAS PAIR CONTROL SOLENOID VALVE REMOVALJINSTALLATION Lift and suppor the fuel tank (page 3-5), Disconnect the PAIR control solenoid valve 2P (Black) connector [1 Disconnect the air supply hoses [2] from the PAIR control solencid valve (3). Remove the bolts [4], collars [5] and PAIR. control solenoid valve from the stay, Installation is in the reverse order of removal INSPECTION Remove the PAIR control solenoid valve (page 5-59). ‘Check that air does not flow (A) to (8) when the 12 V | battery is connected to the PAIR control solenoid vaive terminals. Air should flow (A) to (B) when there is no voltage applied to the PAIR control solenoid valve terminals.FUEL SYSTEM (PGM. Measure the resistance between the connector —— terminals STANDARD: 2428 (20°C/68°F) I it is out of the standard, replace the PAIR control solenoid valve, PAIR CHECK VALVE INSPECTION The PAIR check Remove the middle cows (page 2-7). ‘valve can be sonido canbe Remove the bolts [1] and PAIR check valve cover [2 ‘engine installed in the tame, Remove the PAIR check valve [1] and batfie plate [2] {rom the cylinder head cover. Check the reed [1] for damage or fatigue. Replace if necessary. Replace the PAIR check valve if the rubber seat [2] is cracked, deteriorated or damaged, or if there is clearance between the reed and seat Install the PAIR check valve in the reverse order of removal TORQUE: PAIR check valve cover bolt: '5.2.Nem (0.5 kgFm, 3.8 IbFt) fm 5-60FUEL SYSTEM (PGM-Fl) EVAP PURGE CONTROL SOLENOID VALVE/CANISTER out the hoses and wie propery (page 1-18). Route the hoses ‘and wire proporly (pag0 1-18). REMOVAL/INSTALLATION EVAP PURGE CONTROL SOLENOID VALVE Lift and suppor the fuel tank (page 3-5). Disconnect the following, = EVAP purge control solenoid valve 2P connector [1] Vacuum hose [2] ~ Canister-to-EVAP purge control solenoid valve hose 8) Remove the screw [4], sty [5] and EVAP purge control solenoid vaiva (6 Installation is in the reverse order of removal CANISTER Remove the air cleaner housing (page 5-43) Disconnect the following from the EVAP canister = Fuel tank breather hose [1] — Ganister-io-EVAP purge control solenoid valve hose: gy = Airinlet hose (3) ~ EVAP canister drain hose [4] Remove the canister [5] from the air cleaner cover tabs. Installation is in the reverse order of removal INSPECTION Remove the EVAP purge control solenoid vaive (page 561) (Check that air should flow (A) to (B), only when @ 12 V battery is connected to the EVAP purge. contol solenoid valve terminalFUEL SYSTEM (PGM-Fl) 5-62 ‘Measure the resistance at the EVAP purge control solenoid valve [1] terminals, STANDARD 30-34 0 (20°C/68"F) Ifthe resistance is out specification, replace the EVAP purge control solenoid valve. a t L@ ee‘SYSTEM FLOW PATTERN: SERVICE INFORMATION. TROUBLESHOOTING: SYSTEM TESTING-~--~ COOLANT REPLACEMENT THERMOSTAT 6. COOLING SYSTEM RADIATORICOOLING FAN:« WATER PUMP RADIATOR RESERVE TANK: FAN CONTROL RELAY WATER PIPECOOLING SYSTEM SYSTEM FLOW PATTERN WATER HOSE RADIATOR SIPHON HOSE WATER PUMP WATER HOSE WATER PIPE THERMOSTAT RESERVE TANK 6-2COOLING SYSTEM SO OLING SYSTEM SERVICE INFORMATION GENERAL Removing the radiator cap while the engine is hot can allow the coolant to spray out, seriously scalding you. Avveays lel the engine and radiator coo! [NOTICE | ‘down before removing the radiator cap, Using coolant with siicate inhibtors may cause premature wear of water pump seals or blockage of radiator passages. Using tap water may cause engine damage. + Add cooling system at the reserve tank, Do not remove the radia + All cooling system services can be done with + Avoid spiling coolant on painted surfaces, + After servicing the system, check for leaks with a cooling system tester. + For ECT sensor inspection (page 20-13) + For ECT sensor removallinsiallation (page 5-54) SPECIFICATIONS Z ie 4.40 Tiers (1.16 US qt, 0.97 Imp tor cap except to refil or drain the system, the engine installed in the frame. SPECIFICATION. 0 10.79 liter (0.83 US qt, 0.70 imp at) (0.25 lter (0.26 US at, 0.22 Imp ai) ~93.2= 122.6 kPa (0.95 ~ 1.25 kgflen?, 13 ~ 17 8 psi) _ TEM oot Coolant capacity Radiator and engine At draining Reserve tank Radiator cap relief pressure “Thermostat Begin fo open Fully open, Valve tit Recommended antifreeze ‘Standard coolant concentration TORQUE VALUES Water pump impeller Cooiing fan nut Fan motor screw Fan motor shroud mounting bolt Water hose band screw TOOLS Bearing remover set, 12mm 07836-1660101 (Not available in U.S.A.) Bi - 84°C (178 - 163°F) 95°C (203°) 5mm (0.18 in) minimum "| Pro Honda HP Coolant or an equivalent high quality ethylene glycol antifreeze containing silicate-free corrosion inhibitors ___1:4 (inixture with distiled water) 40 Nem (1.0 kgm, 7 bf) 4.4 Nim (0.1 kgm, 0.8 Ibét) 28 Nm (0.3 ktm, 2.1 bt) 8.5Nm (0.8 kofm, 6.3 br) Remover weight 07741-0010201, 0 07936-371020A (U.S.A, only) ‘Apply locking agent to the threads. See page 6-10 | Diver —— 07749.0010000COOLING SYSTEM |" Aitachment, 28 «30mm Pilot, 2mm Oil seal driver, 30% 36 mm 07946-1870100 o7746-0040200 OTHMF-KR10101 | @Qy) ~ Bearing remover. 12.mm Remover handie 07936-168010A (USA. only) (07936-3710100 (U.S.A. only) 07965-416000A (U.S.A, only) TROUBLESHOOTING Engine temperature too high + Faulty tomperature gauge or ECT sensor + ‘Thermostat stuck closed Faulty radiator cap Insufficient coolant Passage blocked in radiator, hoses or water jacket Air in system Faulty cooling fan motor Faulty fan control relay Faulty water pump Engine temperature too 1ow + Faulty tamperature gauge or ECT senor + Thermostat stuck open + Faulty fan control relay Coolant leak * Faulty water pump mechanical seal Deteriorated O-ring Faulty radiator cap Damaged or deteriorated cylinder head gasket Loose hose connection or clamp Damaged or deteriorated hoses Damaged radiator 6-4 ‘Mechanical sealinstallorCOOLING SYSTEM SYSTEM TESTING The engine must be cool Before removing the | tadiator cap, of severe scalding may result COOLANT (HYDROMETER TEST) Remove the right middle cowl (page 2-7), Remove the screw [] and radiator cap [2] Test the coolant gravity using @ hydrometer [1] (see below for “COOLANT. GRAVITY CHART"). Look for contamination and replace the coolant ifnecessary. After checking the gravity instal the raciator cap and screw socurely Install the right middle cow! (page 2-7). COOLANT GRAVITY CHART nt temperature °C (F) 0 5 7 10 1 20 25 | 30 | 38 | 40 45 | 50 (32)_|_(4t)_|_(60)_(88) | (68) (77) (86) | (05) | (104) | (113) | (122) +008 [1.008 [1.008 [7.008 | 1.007 | 7.006, 7.005] 1.003 | 11001 0-999 0.907 1.018 [L017 | 4.017 [4.016 [4.018 | 7.014 | 1.013 1.011 4.000} 1.007 | 1008 81.027 1.028 | 1.025 1.024.022 4.020. 4.078 4.016 1014 1012] 034 [7.033 | 4.031 | 1.029) 1.027/-4.025 | 7.028 1021 | 1.018 1,043 1.042.040, 1.038 [7.038 | 1.034 4.031 1.028 | 1025 [4.052 (7.051 | 1.048 4.047 4.045 [4.045 oat 1038 (1.035 | To 62 | 7.060 | 1.058 | 7.056 | 1.056 | 1.052 | 1.048) 1.048 1.043 | 4.040 4.070 | 1.068 7.066 | 1.064 |7.062 [7.059 | 7.056 / 1.053 1.050’-1.047/ [1.078 [1.076 [7.074 | 4.072 | 7,069 | 4,066 | 7.085 /1.080[ 1.057 | 1.084 | 4.077 | 1.074 | 1.071 | 9.088 7.065 1.062 | 4.080 4.088 | 1.085 | 7.082 | 4.079 | 1.076 | 4.073 | 1.070 [1.067 4.002 | 1.089 | 1.086 "7.085 1.080. 7.077 | 1.074 07 Coolant ratio% 6-5COOLING SYSTEM RADIATOR CAP/SYSTEM PRESSURE INSPECTION 13.5 - 17.8 psi) Prossurize the radiator, engine and hoses using the tester [1], and check for leaks. NOTICE Excassive pressure can damage the cooling system ‘components, Do not exceed 122.6 KPa (1.25 kgi/em, 178 psi. Repair or replace components ifthe system will not hold the spacified pressure for atleast 6 seconds. Remove the tester. Install the radiator cap (page 6-5). COOLANT REPLACEMENT PREPARATION NOTE: “+The effectiveness of coolant [1] decreases with the accumulation of rust or if there is a change in the mixing proportion during usage. Therefore, for best performance change the coolant reguiarly as a pected in the maintenance schedule. 0 + Mix only distilled, iow mineral water [2] with the \ ) recommenced antifreeze [3] RECOMMENDED ANTIFREEZE: Pro Honda HP Coolant or an equivalent high quality ethylene glycol antifreeze containing silicate-free corrosion inhibitors ‘STANDARD GOOLANT CONCENTRATION: 4:1 (mixture with distilled wator) it 6-6= Wh fing the system or reserve ‘ank with coetant {checking caotent feve)) suppor the mmetorcyole on a level surface. COOLING SYSTEM REPLACEMENTIAIR BLEEDING Remove the following: = Under cow (page 2-11) = Radiator cap (page 6-5) Remove the drain bolt [1] and sealing washer [2] on the Water pump cover and drain the system coolant. Reinsall the drain bolt with @ new sealing washer. Install and tighten the drain bolt securely The engine must be cool before removing the radiator cap, of may result Disconnect the siphon hose [1] from the radiator and release it to the clamps [2] Drain the coolant from the reserve tank. Emply the coolant and rinse the inside of the reserve tank with water. | | a Install the siphon hose to the clamps and connect it to the radiator. NOTE: Route the hose properly (page 1-18) Fill the system with the recommended coolant through the filer opening up to filer neck (1) Bleed air from the system as folows: 41. Shift the transmission into neutral Slart the engine and let it idle for 2-3 minutes. 2. Snap the throttle 3 ~ 4 times to bleed air from the system, 3. Stop the engine and add the coolant up to the filer neck, 4, Inslall the radiator cap (page 6-5).COOLING SYSTEM Remove the reserve tank cap [f] and fill the reserve tank to the "UPPER" level line [2] Install the reserve tank cap, Install the under cow (page 2-11), THERMOSTAT REMOVALIJINSTALLATION Drain the coolant (page 6-7). Remove the bolts [1] and thermostat cover [2 Remove the thermostat [1] from the cylinder head, Installation is In the reverse order of removal NOTE + Install the thermostat with the bleed hole [2] facing up, + When installing the thermostat, align the tab of the seal ring [3] with the groove of the thermostat cover. Fill and bleed the cooling system (page 6-6). INSPECTION Visually ingpect the thermostat [1] for damage. ‘Check the seal ring [2] for damage.Wear insulated gloves and addoquate eye protection. Keep Tammable ‘materials away from the elecine heating elernent. Do not let the thermostat or thermometer touch the pan, oF you wil (8 folse reading, COOLING SYSTEM Heat the water with an electric heating element to Se operating temperature fr 5 minutes, Suspend the thermostat [1] in heated water to check its | operation. ‘THERMOSTAT BEGIN TO OPEN: 81 84°C (178 - 183°F) VALVE LIFT: | 4.5 mm (0.18 in) minimum at 95°C (203°F) | Replace the thermostat If the valve open at a temperatures other than those specified RADIATOR/COOLING FAN REMOVAL/INSTALLATION Drain the coolant (page 6-7) Remove the middle cowls (page 2-7). Disconnect the fan motor 2P (Black) connector [1] and remove It from the stay (2) Disconnect the siphon hose [1] from the radiator. ‘Loosen the water hose band screw and disconnect the mm ewer water hose [2] Loosen the water hose band screw and disconnect the upper water hose [1]COOLING SYSTEM Remove the radiator mounting bolt [1] and collar (2. ie boss by moving the radiator to the lft Be carefu'not to Unhook the rubber [1] from the radiator tabs (2), then ‘damage the remove the radiator assembly. reatator fs. Installation isin the reverse order of removal NOTE: Route the wire and hoses property (page 1-18) Tighten the hose band screw to the specified range. Fil the system with the recommended coolant (page 6-6). 6-10COOLING SYSTEM ——— COORG STEM DISASSEMBLY Remove the bolts [1] and fan motor assembly [2] from the radiator (3). 1 Inhook the fan motor wire [1] from the fan motor stay = aT, Loneck te fan moter wie [1 fom the fen motor sty Fy rT ] Remove the screws [3] and fan motor stay (4] from the fan motor (5). Remove the cooling fan nut [1] and cooling fan (2).COOLING SYSTEM ASSEMBLY RADIATOR 85 N-m (0.9 kgfm, 6.3 1bFt) COOLING FAN FAN MOTOR 2.8 Nem (0.3 kgfim, 21 bf) EeNMOTO SIA Install the cooling fan [1] onto the fan motor shaft by aligning the flat surfaces, Ama 2 Apply locking agent to the cooling fan nut [2] threads. Install and tighten the cooling fan nut to the specified torque. | TORQUE:1.1 N-m (0.4 kgf'm, 0.8 Ibfft) Install the fan motor stay [1] onto the fan motor [2 Install and tighten the screws (3} to the specified torque. TORQUE:2.8 N-m (0.3 kgf'm, 2.1 Ib ft) Hook the fan motor wire [4] to the fan motor stay wire guide (5) 6-12COOLING SYSTEM Install the fan motor assembly [1] onto the radiator (2) Inetall and tighten the bolts [3] fo the specified torque. TORQUE: 8.5 N-m (0.9 kgf'm, 6.3 IbFft) YQ WATER PUMP = MECHANICAL SEAL INSPECTION Check the inspection hole [1] of the water pump for signs of coolant leakage. ‘A small amount of coolant weeping from the inspection hole andlor residue is normal I there is continuous coolant leakage from the inspection hole while the engine is running, replace the mechanical seal (page 6-14). IF oil leaks through the Inspection hole, replace the oil seal (page 6-14) REMOVAL Drain the coolant (page 6-7) Remove the bolts [1], drain bolt [2), sealing washer [3], water pump cover [4] and O-ring (8. be Remove the right crankcase cover (page 10-6). Hold the water pump shaft and remove the impeller [1] and plain washer (2). Y@COOLING SYSTEM Remove the water pump shaft [1] from the right crankcase cover. Check the water pump shaft [1] for wear or damage, replace it necessary BEARING/MECHANICAL SEAL/OIL SEAL REPLACEMENT @ ean o1 960. aenanos 1S?COOLING SYSTEM Remove the water pump shaft bearings [1] using the special tools. TOOLS: = Remover weight [2] (07741-0010201, Bearing remover set, 12 mm [3] 07936-1660101 TOOLS, U.S.A. only: Bearing remover, 12mm. (07936-166010A, Remover handle (07936-3710100 Remover weight (07936-3710208, Remove the mechanical seal [1] and oil seal [2] from iy the right crankcase cover. Apply grease to anew ol seal [1] lips. Install the ll seal to the right crankcase cover 2s \ shown Drive ina new Drive in new bearings [1] into the right crankcase cover bering squarely _using the special tools, ‘i the marking ‘side facing up. TOOLS: Driver [2] 07749.0010000 Attachment, 28 x 30 mm [3] 07946-1870100 Pilot, 12 mm [4] (07746-0040200 Afierinstaling the bearing, lubricate it with engine ol. (vt)COOLING SYSTEM man using ha Press @ new mechanical seal [1] until itis fully seated to -— USA too, side “A*_ the right crankcase cover using the hydraulic press and ‘must face the special 001 TOOL: il seal driver, 30x36 mm [2] O7HMF-KR10101 TOOL, U.S.A. only: ‘Mechanical seal installer 07965-4150008 INSTALLATION ‘Apply engine oll to the water pump shaft {1] outer surface. Install the water pump shaft 0 the right crankcase Install the plain washer [1] and impeller [2] fo the water pump shaft. Hold the water pump shaft and tighten the water pump impeller [1] tothe specified torque. TORQUE: 10 N-m (1.0 kafim, 7 IbF) Install the right rankcase cover (page 10-10). 6-16RADIATOR RESERVE TANK Route the hoses properly (page 1-18). COOLING SYSTEM Install a new O-ring [1] 10 the water pump cover [ Install the water pump cover. Install and tighten the bot [1], drain bolt [2] and a new soaling washer [3} securely Fill the recommended coolant mixture to the filer neck and bleed the air (page 6-6), REMOVAL/INSTALLATION Remove the shock linkage (page 14-14). Drain the coolant from the reserve tank (page 6-7). Remove the bolts [1] and reserve tank [2]. Disconnect the overflow hose [] nd siphon hose [2] — from the reserve tank. Installation isin the reverse order of removal Fil the reserve tank with coolant (page 6-6).COOLING SYSTEM FAN CONTROL RELAY INSPECTION Remove the lat middle cow! (page 2-7) Remove the fan control relay [1] Connect 2 ohmmeter to the fan control relay [1] terminals Connect a 12 V battery to the fan control relay terminals as shown, There should be continuity only when 12 V battery is connected. If there is: no continuity only when the 12 V battery is ‘connected, replace the fan control relay. WATER PIPE 6-18 REMOVAL/INSTALLATION Drain the coolant (page 6-7) Remove the bolts [1] and water pipe (2) Remove the O-rings [1] from the water pipe Install new O-rings to the water pipe. Installation is in the reverse order of removal Fill the system with the recommended cootant (page 6.6) ia} Bur Bo Bik a |7. ENGINE REMOVAL/INSTALLATION COMPONENT LOCATION ~ ENGINE REMOVAL ~~ SERVICE INFORMATION ~~~ “7-3 ENGINE INSTALLATION: 7-1ENGINE REMOVAL/INSTALLATION COMPONENT LOCATION 45 Nem (4.6 kgtm, 93 t=) 45 Nom (4.6 kgf, 33 1b) 45 Nem (4.6 Kgtm, 33 tt) AO Nem (1.0 kgm, 7 bet) 7-2ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION GENERAL + Abhoit or equivalent is required to suppor the matorcycle when removing and installing the engine. + When removinginstaling the engine, tape the frame around the engine beforehand for frame protection When insalng the engine, be sure otignten the engine mounting fasteners tothe specifed toque inthe specfed sequence. If you mistake the torque or sequence, loosen all mounting fasteners, then lighten them again to ine spectied torque in te correct Eequence + The folowing components can be serviced with the engine installed inthe frame. = Oil pump (page +4), = Throtle body (page 6-46) = Camshaft (page 8-7) ~ Water pump (page 6-13) = Clutch (page 10-12) ~ Gearshift linkage (page 10-18) — Stator/CKP sensor (page 11-5) Flywheel (page 11-7) = Starter motor (page 19-6) + The folowing components require engine removal for service. — Cylinder headivalves (page 8-15) = Gylinderiston (page 8-8) = Crankshaft (page 12-8) — Transmission (page 12-14) — Balancer (page 12-19) SPECIFICATIONS TEM Z SPECIFICATION = Engine dry weight > __364 kg (78.0 Ibs) Engine of capaciy ‘training i ilars (75 US at 12 pa ‘Acoifiter change Sites (1.6 US qi, 1.3 Imp qt), ele | an Bees 1.8 iters (.9US at 1.6 Imp qb) Coolant capacity Radiator and Engine 0 ers (1.16 US gt, 0.97 Imp gi) ‘A raining 078i (0.89 US gl.0.70 imp at) Reserve lank 025 iter (0.26 US gt 0.22 imp at) 1 TORQUE VALUES Frontengine hanger plate bolt 45 N'm (4.8 kgf, $3 Ibt8) Frontengine mounting nut 45 N‘m (48 kgf. $3 bt 8) Rear engine mounting rut 45 Nem (4.8 kam, 39 br) Drive sprocket fixing plate bolt 10 Nem (1.0 kgfm, 7 Ibft)ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL Drain the engine oil (page 9-14). Drain the coolant (page 6-7) Remove the following: ~ Throttle body (page 5-48) = Exhaust pipe/muffier (page 2-18) = Drive sprocket cover (page 2-12) Remove the bolts [1] and clutch cable guide (2), then disconnect the clutch cable [3] from the clutch lier arm 4 Release the rubber cap [5] Remove the starter motor terminal nut [6] and starter ‘motor cable (7 Remove the starter motor mounting bolt [8] and ground cable (3) Disconnect the O: sensor cap [1]. Remove the pinch bolt [1] and gearshit arm (2) Loosen the rear axle nut [1], lock nuts [2} and adjusting ruts (3. Push the rear wheel forward as far as it will go to slacken the drive chain, 7-4ENGINE REMOVAL/INSTALLATION Remove the bolts [1], fixing plate [2] and drive sprocket 3) Loosen the water hose band screws [1] and disconnect the water hoses [2] Disconnect the spark plug cap [1]. The gonads Disconnect folowing stand comed coos Altemator 3P connector [1] ntneedtobe KB sonsorneial swith 6P connector [2] eee VS sensor 3P connector [3] ECT soneor 3 connector Release the VS sensor wire om te wie ues 6 Disconnect the cooling fan 2P (black) connector from the slay and move it away from the engine, 7-5ENGINE REMOVAL/INSTALLATION Thejackhelaht Support the engine using a jack or other adjustable ‘must be continually support to ease of engine hanger bolts removal. ‘dusted fo reieve dusted 0 rfV8 Remove the following: ‘oltremoval. — Front engine mounting bolts {1] and nuts (2) Front engine hanger plate bolts [3] = Front engine hanger plates (4) Remove the rear upper and lower engine mounting bos [1] and nuts [2] During engine Remove the engine from the frame. removal. hol the ‘engine securely and ‘be careful not fo damage the frame orengine. ENGINE INSTALLATION NoTE: + Note the direction ofthe engine hanger bolts + Place the jack or other adjustable support under the engine. + The Jack height must be continually adjusted to relieve tension for ease bolt installation * Carefully align the mounting points with the jack to prevent damage to engine, frame, water hose, wires. ‘and cables. + Loosely install all the engine mounting bolts and huts, then tighten the bolts and nuts to the specified ‘torque in the specified sequence. + Route the water hose, wires and cables property (page 1-18) During engine ace the engine inte rams, then loosely instal al the station ne. bots nts and font engine Ranger petes. sites, Tatton to both ont engine hanger pate bolts [1] to {besarte ing spaced treue, frame or engine. TORQUE: 45 N-m (4.6 kgf-m, 33 Ibf-ft) Tighten the front upper engine mounting nut [2] to the specified torque. TORQUE: 45 N-m (4.6 kgfm, 33 Ibft) Tighten the front lower engine mounting nut [3] to the: specified torque. TORQUE: 45 N-m (4.6 kgfm, 33 Ibf-t) 7-6ENGINE REMOVAL/INSTALLATION Tighten the rear upper engine mounting nuts [1] to the. speditied torque, TORQUE: 45 N-m (4.6 kgfm, 33 Ibf-t) Tighten the rear lower engine mounting nut [2] to the: specified torque. TORQUE: 45 N-m (4.6 kgfm, 33 Ibf-t) Install the VS sensor wire from the wire guides [1]. Connect the following: = Alternator 3P connector [2] — CKP sensorineutral switch 6P connector [3] = VS sensor 3P connecior [4] = ECT sensor 3P connector [5] Connect the spark plug cap (1), Connect the water hoses [1] and tighten the water hose, band screws [2] to the specified range (page 6-10). 7-7ENGINE REMOVAL/INSTALLATION Install the drive chain [1] over the drive sprocket [2]. Install the drive sprocket to the countershaft with the "147" mark [3] facing out Install the fixing plate [4 Rotate the fixing plate and align the hole in the plate With the bolt hole in the drive sprocket Install and tighten the drive sprocket fixing plate bolts [}to the specified torque. TORQUE: 10 N-m (1.0 kgf, 7 Ibf-ft) Install the gearshift arm [1] onto the gearshift spindle, while aligning its sit wth the punch mark Install and tighten the pinch bot [2] securely ‘Connect the O: sensor cap [1]. NOTICE * Take care not to tit the O> sensor cap when connecting the cap to the Ox sensor. + Do not turn the O: sensor cap, after connecting it Connect the cooling fan 2P (black) connector to the stay.Install the ground cable [1] and starter motor mounting bolt (2) Tighten the mounting bolt securely. Install the starter motor cable [3] and starter motor terminal nut (41 Tighten the terminal nut securely and repostion the rubber cap [5] properly on the starter motor terminal Connect the clutch cable [6] to the clutch lifter arm [7] Install clutch cable guide [8] and bolts [9]. Tighten the bots securely Install the folowing: ~ Drive sprocket cover (page 2-12) = Exhaust ppe/muer(psge 2-20) = Throtle body (page 5-48) = Fuel tank (page #39) Inspect the folowing = Driv chain slack (page 2-18) = Thotte grip treeplay (nage 3-8) — Clutch lever freeplay (page 3-26) Fil the engine withthe recommended engine ol (nage 313) Fil the recommended coolant mixture to the filer neck ‘and bleed the air (page 6:6). Check the exhaust system and cooling system for leaks. ENGINE REMOVAL/INSTALLATION a ae eo] Y ee8. CYLINDER HEAD/VALVES COMPONENT LOCATION --- CYLINDER HEAD COVER SERVICE INFORMATION-~-- CAMSHAFT-~~ TROUBLESHOOTING: ROCKER ARM -vrvsvsvvrvsereresenrsnenenes Ba CYLINDER COMPRESSION: CYLINDER HEAD ~~»CYLINDER HEADIVALVES COMPONENT LOCATION 4ONm (1.0 kgf, 7 tt) 12Nm (.2kofm, 91) 3 \ 42.Nm (04 kfm, 3.4 FR)CYLINDER HEADIVALVES SERVICE INFORMATION GENERAL + This section covers service of the cylinder head, valves, rocker arms and camshaft ‘The camshaft service can be done with the engine installed inthe frame. The cylinder head service requires engine removal + Be careful not to damage the mating surfaces when removing the cylinder head cover and cylinder head. Do not siike the ‘yinder head cover and cylinder head too hard during removal + When disassembling, mark and store the disassembled pers to ensure that they are reinstalled in their original locations. + Clean all disassembied perts with cleaning solvent and dry them by blowing them off with compressed air before inspection. + Camshaft and rocker aim lubricating oil is fed through oll passage in the cylinder head (stud bolt hole) and camshaft holder. Clean the ol passage before assembling them. SPECIFICATIONS Unit: mmm (in) TEM STANDARD SERVICE LIMIT Cylinder compression at 490 rpm 7.208 KPa (15.2 katie’, 188 psi) a Valve clearance TIN 10.16 # 0.08 (0.006 = 0.001) 5 =e x if 20.001) Valve, vale Valve siom OD. IN 495 (0.1760 — 0.1770) 4.46 (0.175) guide : 4.460 = 4485 (0.1756 = 0.1768) 4.45 (0.175) Valve guide 10. 4500 = 4.512 (0.172- 0.1776) 4.540 (0.1787) ‘Stem-to-guide 0.005 ~ 0.042 (0.0002 ~ 0.0017) 0.07 (0.003) a eerance 0.015 ~ 0.052 (0.0006 - 0.0020) (0.08 (0.003) Valve guide height INEX ¥4.0(0.54 - 0.65) = Valve seat width = 1.10 (0.035 - 0.043) 1.50 (0.059) Valve spring | Free length | 34,58 (1.361) 32.85 (1.293) 40.37 (1589) 2 (35 (7.510) Rocker arm, " ~ 10.10 (0.398) rocker arm 8.75 (0.384) aa clearance eos) Camshait [Cam lobe height IN 30.981 31.171 (12176-12072) 30.911 (1.2170) iad ‘30.830 — 31.079 (1.2163 — 1.2206) 30.819 (7.2133) Oil clearance 10.020 — 0.062 (0.0008 - 0.0024) 0.10 (0.004) Cylinder head warpage ol a = (0.05 (0.002) TORQUE VALUES Cylinder head cover bolt 40N-m (1.0 kgtm, 7 bf) Camshaft holder mounting bot 2N'm(1.2 kgf. 9bFA) Apply engine ollto the threads and seating surface. Cam chain tensioner liter tug 42 Nem (0.4 kgm, 3.1 IF) Gylinder head mounting nut 51 Nm (6.2 kgfm, 36 bf) Apply engine ol tothe threads and seating surface.CYLINDER HEAD/VALVES TOOLS ‘Valve spring compressor Valve spring compressor attachment 07757-0010000, 07959-KM30101 @ Seat cutter, 27.5 mm (45° EX) 0780-0010200 ‘Seat eater, 33 mm SIN) 07760-0010800 ‘or equivalent commercially availablein | or equivalent commercially available in USA. USA “Flat cuter, 30 mm (32° IN} Inferior cutter, 30 mm 160" EX) 07780-0012200 (07780-0014000 ‘oF equivalent commercially available in USA. USA. |" Catterholder, 45mm —— Valve guide reamer, 45mm 07781-0010600 OTHMH-ML00101 | orequivalent commercially avaliable in | orequivalont commercially avaliable in Usa, a4 Valve quide driver, 43 mm O7HMD-MLo0101 Flat cutter, 27 mim (2° EX) 0780-00130 or equivalent commercially available in Us. ~~ interior cutter, 37-5 mam (60° IN) 0780-0014100, or equivalent commercially available in USA ner slope o70MG-0010160CYLINDER HEADIVALVES EE ‘Valve guide driver 07743-00200 (Not available in USA) TROUBLESHOOTING + Engine top-end problems usually affect engine performance. These problems can be diagnosed by a compression test, or by tracing top-end noise with a sounding rod or stethoscope. + Ifthe performance is poor at low speeds, check for white smoke in the crankcase breather hose. if the hose is smoky, check for seized piston rings. Compression too low, hard starting or poor performance al low speed + Valves: = Incorrect vaive adjustment = Burned or bent valve = Incorrect valve timing = Weak vaive spring = Uneven vaive seating = Valve stuck open + Cylinder head: = Leaking or damaged cylinder head gasket = Warped or cracked cylinder head = Loose spark plug + Faully cylinder, piston or piston rings (page 9-5). Compression too high, over-heating or knocking. * Excessive carbon build-up on piston head or combustion chamber Excessive smoke Worn valve stem or valve guide Damaged stem seal + Faulty cylinder, piston or piston rings (page 9-5). Excessive noise Incorrect valve adjustment Sticking valve or broken valve spring Worn or damaged camshaft Worn rocker arm andor shaft Worn rocker arm and valve stem end Worn cam sprocket teeth Worn and loose cam chain Worn or damaged cam chain tensioner Faulty cylinder, piston or piston rings (page 9-5) Rough idle + Low cylinder compression + Faulty fuel systemCYLINDER HEADIVALVES CYLINDER COMPRESSION To avoid Ascharging the Dattory, donot ‘operate the stator ‘metor for more than seconds. Warm the engine to normal operating temperature. ‘Stop the engine. Remove the spark plug (page 3-8), Insal the compression gauge [1 nto the spark plug ‘Turn the ignition switch ON and engine stop switc Shift the transmission into neutral pen the throttle all the way and crank the engine with the starter motor unil the gauge reading stops rising ‘STANDARD: 41,294 kPa (13.2 katicm?, 188 psi) at 490 rpm Low compression can be caused by: ~ Blown cylinder head gasket = Improper valve adjustment - Valve leakage = Wom piston ring or cylinder High compression can be caused by: = Carbon deposits in combustion chamber or on piston head CYLINDER HEAD COVER “The eyinder head covercan bo serviced with tho engin insta in the tame. REMOVAL, Remove the folowing: = Spark plug cap (page 3-8) = PAIR check valve (page 5-60) Remove the cylinder head caver bats [1], rubber seals [2], cylinder head cover [3] end packing [4 INSTALLATION Apoly sealant (Three bond 5211C, SS KE45, 12078, | 1216 or equivalent) to the cylinder head semi-circular cut outs 2s shown,CAMSHAFT The camshaft csn be serviced with the ‘engine stale in the fame. CYLINDER HEADIVALVES Install a new packing [1] nto the cylinder head cover [2] groove. instal the cylinder head cover onto the cylinder head. Check the rubber seals [1] are in good condition, f replace them if necessary. rubber seals to the cylinder head cover with | marks (2] facing up. | io} Install and tighten the cylinder head cover bolts [1] to the specified torque. TORQUE: 10 Nim (1.0 kgm, 7 IDF) Install the folowing = PAIR check valve (page 5-60) = Spark plug cap (page 3-10) REMOVAL Remove the cylinder head cover (page 8-6). Make sure the piston is at TDC (Top Dead Genter) on the compression stroke (page 3-11). Remove the cam chain tensioner liter plug [1] and O-ting 2)CYLINDER HEADIVALVES Be careful not to et ‘the cam chain guide bots fa nto th crankcase Be careful notto let ‘the cam camshaft oder bots fal into the crankcase Altech apiece of Wwiro fo the cam hain to prevent it ‘rom fling int the crankcase. Tum the cam chain tensioner lifter shaft fully in [ (clockwise) and secure it using a tensioner stopper [1] to prevent damaging the cam chain. | TOOL: Tensioner stopper 070MG-0010100 or O7AMG-0014100 (S.A. only) Remove the bolts [1] and cam chain guide B (2) Remove the bolts [1] and camshaft holders [2} NOTE: From autside to inside, loosen the bolts in a crisscross patter in several steps or the camshaft holder might break. Remove the camshafts [1] by removing the cam chain [2] from the cam sprockets. 2 8-8CYLINDER HEAD/VALVES Lift the rocker arms (1) Remove the shims (2. NoTE: + Do not allow the shims to fll into the crankcase. + Mark all shims fo ensure correct reassembly in their original locations. + The shims can be easily removed with a tweezers or a magnet. INSPECTION CAMSHAFT Check the cam lobe surfaces for scoring or evidence of insufficient lubricant. (Check the cam spracket teeth for wear or damage. Check the oll holes in the camshaft for clogging, ‘Measure the height of each cam lobe. SERVICE LIMITS: IN: 30.911 mm (1.2170 in) opel EX: 30.819 mm (1.2133 in) | CAMSHAFT HOLDERS ‘Check the camshaft joual surfaces of each camshaft holder for scoring, scratches or evidence of insufficient a lubrication Check the camshaft holder for installation ofthe dowel pine {1} Inspect the ol passages of the holders for clogging @ at ® z 2 la °F CAM CHAIN GUIDE B Inspect the cam chain slipper surface [1] of the cam chain guide B for wear or damage.CYLINDER HEAD/VALVES ‘CAMSHAFT OIL CLEARANCE, Do notrofate the Wipe any cil rom the journals of the camshaft, cylinder ‘camshaft when head and camshaft holders, using plostgauge. Lay a strip of plastigauge [7] lengthwise on top of each camshaft journal so seth dowel ral each camshat holder tothe coe! locaons ‘pins inthe camshaft with the identification marks [1]. fer algn be gh camshaft hdr halen pinder — 7 aa canat heldr = — "IN" mark: intake side mark exhaust sie Apply engine oil to the camshaft holder mounting bolt [1] threads and seating surface and install them, NOTICE Failure to tighten the camshaft holder in a crisscross pattern might cause a camshaft holder fo break Tighten all camshaft holder mounting bolts to the specified torque. TORQUE: 12 N-m (1.2 kgf'm, 9 bff) Nore: From inside to outside, tighten the bolts in a crisscross pattern in several steps. Remove the camshaft holders and measure the width of each plastigauge. ‘The widest thickness determines the oll clearance. ‘SERVICE LIMIT: 0.10 mm (0.004 in) When the service limits are exceeded, replace the ‘camshaft and recheck the oll clearance. Replace the cylinder head and camshaft holders as a set f the clearance sill exceeds the service limit, 8-100 careful not to {jam the cam hain and timing sprocket fn the crankshaft when rotating the crankshat careful not to fet ‘the shies fal into the crankcase. CYLINDER HEADIVALVES INSTALLATION Rotate the crankshaft counterclockwise, and align the ""T" mark [1] on the flywheel with the index notch [2] on the let crankcase cover. Install the shims [1] In their original locations on the valve retainer. Lower the rocker arms [2] Each camshaft has an identification mark (1) = “IN* mark: intake camshaft adh id} t 8-11CYLINDER HEAD/VALVES ‘Apply molybdenum oil solution to the camshaft lobes ye Al and journal surfaces. ‘Apaly engine oll the cam chain whole surface. Install the camshafts [1] into the cylinder head while installing eam chain [2] onto the cam sprockets. NOTE When installing the camshaft wth its lobes facing up and align the outside index lino ("IN" [3] and "EX" [4] marks) on the cam sprockets with the cylinder head top surface, fa] 4 0 sure tho cowel_ install each camstat holder 10 the conect locations ‘pinsin the camshaft with the identification marks [1] hot lon it Pe mar ight camshat olor finder — ts Mar ef camanat heler emai tae side Tse" mark exaust sido Apply engine oil to the camshaft holder mounting bolt [threads and seating surface and install them NOTICE Failure to tighten the camshaft holder in a crisscross pattern might cause a carnshaft holder to break Tighten all camshaft holder mounting bolts to the specified torque. TORQUE: 12 N-m (1.2 kgfm, 9 IbFft) NoTE: From inside to outside, tighten the bolts in a crisscross pattern in several stops. 8-12Bo careol roto let_ Install the eam chain guide B [1] and botts (2) 7 ee the bolts al into the Totten the cam chain guide bolts securely CYLINDER HEADIVALVES Remove the tensioner stopper [1] from the cam chain tensioner iter. Recheck the valve timing, ‘Apply engine oll to a new O-ring [1] and install it to the ‘cam chain tensioner liter. Install and tighten the cam chain tensioner lifter plug [2] to the specified torque. TORQUE: 4.2 Nim (0.4 kgf, 3.4 IDE) Install the cylinder head cover (page 8-6). 8-13CYLINDER HEADIVALVES ROCKER ARM NOTE: + The rocker arm can be serviced with the engine Installed inthe frame. + The intake and exhaust rocker arm service: procedures are the same. REMOVAL/INSTALLATION Remove the camshafts (page 8-7). Remove the bolt [1] and sealing washer [2) Remove the rocker arm shaft [1] using a 6 mm bolt [2] \while holding the rocker arm (3) Remove the rocker arm. ‘Apply molybdenum oll solution to the rocker arm inner surface, roller surface, slipper surface and rocker arm shaft outer surface. Install the rocker arm and rocker arm shat. NoTE: + The rocker arms are identified by the stamped marks: = "IN" mark: Intake rocker arm [4] "EX" mark: Exhaust rocker arm [5] 8-14CYLINDER HEAD/VALVES Install a new sealing washer [1] and bot (2) Install the camshafts (page 8-11). (ye) INSPECTION Check the sliding surface of each rocker arm and rocker frm shatt for wear or damage. ‘Check the oil hole for clog of each rocker arm. Mensur the rocket arm 0. ‘SERVICE LIMIT: 10.0 mm (0.398 in) oo ee y ya peece inne eesteeet ra | a Calculate the rocker arm-to-shaft clearance ‘SERVICE LIMIT: 0.10 mm (0.004 in) CYLINDER HEAD REMOVAL Remove the folowing: = Engine (page 7-4) = Camshaft (page 8-7) ‘Be careful not tole Remove the cylinder head bolts [1], nuts [2] and the cyinderfiead cylinder head (3) bots and nuts fore. into the crankease + Attach a piece of wire to the cam chain to prevent it from falling into the crankcase. * Do not strike the cylinder too hard and do not damage the mating surface with a screwdriver. Remove the folowing — Dowel pins [1] — Gasket [2] = Gam chain guide A 3]CYLINDER HEAD/VALVES To prevent loss of tension, do not ‘compress ihe valve ‘springs mere than ‘necessary 10 remove the cotors. Mark al parts ring disassembly s0 they can be Instated in ther nginal iocations. Use care not 0 scratch the ‘combustion chamter or head gasket surface. Be careful not to damage the gasket ‘urls 8-16 DISASSEMBLY Remove the following: — Spatk plug (page 2-8) = Oe sensor (page §-57) = Rocker arm (page 8-14) Remove the valve spring colters [1] using the special tools. TooLs: Valve spring compressor[2] 07757-00100 Valve spring compressor attachment [3] 07959-KM30101 Remove the following: = Spring retainer [1] ‘Outer valve spring [2] Inner valve spring [3] Valve [4] Stem seal [5] Spring seat [6] INSPECTION CYLINDER HEAD. Remove the carbon depasits from the combustion [— ‘chamber or exhaust port Cheek the spark plug hole and valve area for cracks, Replace the cylinder head if necessary. Check the eyinder head for warpage with a straight edge and feeler gauge. ‘SERVICE LIMIT: 0.05 mm (0.002 in)VALVE SPRING ‘Check the valve springs for fatigue or damage. Measure the free length of the inner valve spring [1] and ‘outer valve spring 2) ‘SERVICE LIMITS: Inner: 32.85 mm (1.293 in) ‘Outer: 38.35 mm (1.810 in) Replace the springs i they are shorter than the service limits, VALVE ‘Check that the valve moves smoothly in the guide. Inspect each valve for bending, burning, scratches or abnormal stem wear. Measure and racord each valve stom 0.0. ‘SERVICE LIMITS: IN: 4.48 mm (0.176 in) EX: 4.45 mm (0.175 in) VALVE GUIDE Ream the valve guide to remove any carbon build-up before measuring the guide I.D, NoTE: + Use cutting oil on the reamer during this operation + Take care not to tit or lean the reamer in the guide while reaming, Otherwise, the valves may be installed slanted, causing oil leakage from the stem ‘seal and improper valve seat contact. This may prevent valve seat refacing, + Insert the reamer from the combustion chamber side Cf the head and always rotate the reamer clockwise. TOOL: Valve guide reamer, 4.5 mm [1] O7HMH-MLO0101 (O7HMEH-MLOO10B (U.S.A only) CYLINDER HEAD/VALVES tt) a | 8-17CYLINDER HEAD/VALVES ‘Measure each valve guide ILD. and record it [SERVICE LIMIT: IN/EX: 4.540 mm (0.1787 in) Subtract each valve stem O.D. from the corresponding {ice |.D. to obtain the stem-to-guide clearance. SERVICE LIMITS: IN: 0.07 mm (0.003 in) EX: 0.08 mm (0.003 in) Ifthe stern-to-guide clearance exceeds the service limit determine if a new guide with standard dimensions ‘would bring the clearance within tolerance. Iso, replace any guides as necessary and ream to fit. If the stem-to-guide clearance exceeds the service limit with a new guide, also replace the valve. NOTE: Inspect and reface the valve seats whenever the valve {uides are replaced (page 8-20) CAM CHAIN GUIDE A Inspect the cam chain guide A [1] for excessive wear or damage, replace it if necessary. ny VALVE GUIDE REPLACEMENT NOTE: Refinish the valve seats whenever the valve guides are replaced to prevent uneven seating. Chill new valve guides in a freezer section of refrigerator for aboul an hour. Donot sea torch Heal the cylinder head to 190 ~ 140°C (266 ~ 264°F) {oheat the cyinder with a hot plate or oven. Do not heat the cylinder head head: may cause beyond 150°C (302°), Use temperature indicator ‘narping. sticks, available fom wolding supply stores, to be sure the cylinder head is heated to the proper temperature. To avoid bums, wear insulated gloves when handling the heated cylinder head. 8-18CYLINDER HEAD/VALVES ‘Support the cylinder head and drive out the valve guides from the combustion chamber side of the eylinder head. TooL: Valve guide driver, 4.3mm [1] _07HMD-ML00101 in While the cylinder head is stil heated, take new vale, —} ‘uides [1] from the freezer. ‘Adjust the valve guide driver to the valve guide height ‘and drive in the valve guide from the camshatt side. Toot ‘Valve guide driver [2] 07743-00200 | (Not available in USA) ‘SPECIFIED HEIGHT: INIEX: 13.8 = 14.0 mm (0.54 ~ 0.55 in) USA. only instalation: & ‘Mark the depth ofthe valve guide using a marker. Use the valve guide driver to correct the depth Let the cylinder head coo! to room temperature. Ream a new valve guides. TOOL: Valve guide reamer, 4.5 mm [1] | 07HMH-MiL00101 O7HMH-MLOO10B, (U.S.A. only) NOTE: + Use cultng oll on the reamer during this operation. + Take care not to tit or lean the reamer in the guide while reaming. Otherwise, the valves may be installed slanted, causing oll leakage from the stem seal and improper valve seat contact. This may prevent valve seat refacing + Insert the reamer from the combustion chamber side of the head and always rotate the reamer clockwise. Clean the cylinder head thoroughly o remove any metal particles after reaming and reface the valve seal (page 821), 8-19CYLINDER HEADIVALVES VALVE SEAT INSPECTION Clean the intake and exhaust valves thoroughly to remove carbon deposits. Apply thin coat of Prussian Blue to each valve face. ‘Tap the valve against the valve seat several times using a hand lapping tool [1] without rotating valve to make a clear pattern, Remove the valve and inspect the valve seat face. NOTE | ‘The valve cannot be ground. Ifthe valve face is burned or badly worn or ifit contacts the seat unevenly, replace the valve. Inspect the valve seat face for \ i + Damaged face 1]: = Replace the valve and reface the valve seat + Uneven seat width (2) - = Replace the valve and reface the valve seat + Contact area (too high [1] or too low [2] area}: = Reface the valve seat Inspect the width ofthe valve seat [1]. ‘The valve seat contact should be within the specified Width and even all around the circumference. STANDARD: _ 0.90— 4.10 mm (0.035 ~ 0.043 in) ‘SERVICE LIMIT: 1.50 mm (0.059 in) Ifthe vate seat with is not within specication, rface | the valve seat (page 8-21), 8-20CYLINDER HEADIVALVES VALVE SEAT REFACING NoTE * Follow the refacing manufacturer's operating 1 instructions. | Reface the valve seat whenever the valve guide has Snes : et : a a = If the contact area is too high [1] on the valve, the seat trust be owored using 8 32 Nat cuter. — OLD sear work If the contect area is too low [2] on the valve, the seat yO ‘must be raised using a 60° inner cutter. a = OLD SEAT S — a woth | Reface the valve Use a 45° cutter [1], remove any roughness {2} or seat wif a 45°. imegularties from the seat. cut when avaive guide is replace, TOOLS: Seat cutter, 27.5 mm (45° EX) _07780-0010200 Seat cutter, 33mm (45° IN) 07780-01080 Cutter holder, 4.5 mm 07781-0010600 or equivalent commercially available in U.S.A. Using 92° cutter, remove the top 1/4 of the existing valve seat material TooLs: Flat cutter, 27 mm (32° EX) __07780-0013300 Flat cutter, 30mm (32°IN) 07780-00220 Cutter holder, 4.5 mm 07781-0010600 or equivalent commercially available In U.S.A. 8-21MG WHUN DERI ADIN AI i gc i i a Using 60° cuter remove the botiom 1 of the sect) ————————J Remove the cutier and inspect the area you have just ‘OLD SEAT WIDTH removed, TOOLS: Interior cutter, 30 mm (60° EX) 0780-00140 Interior utter, 7.5 mm (60° IN) 07780-0014100 Cutter holder, 4.6 mm 07781-0010600 | ‘or equivalent commercially available inUS.A. | Using @ 45° cutter, cu the seal to proper with I Make sure that all pitting and iregularities are removed. | Refinish if necessary | STANDARD SEAT WIDTH: (0,90 - 1.10 mm (0.035 — 0.043 in) Afr cutting the seat, apply lapping compound to the valve face and lap the valve using light pressure. NOTE: + Excessive lapping pressure may deform or damage the seat, + Change the angle of tapping tool [1] frequently to prevent uneven seat wear. + Lapping compound can cause damage if it enters between the valve stem and guide. After lapping, wash any residual compound off the cyinder head and valve. Recheck the seat contact after lapping. 8-22CYLINDER HEAD/VALVES To avoid damage to ‘the soa, tum the valve slowly when Tnserting ASSEMBLY 5 COTTERS es hee ge ; Q\' IS 7B wiw€Vave ExIADETVALVE ie Clean the cylinder head assembly with solvent and blow through all cil passages with compressed air. Install the spring seats [1] and new valve stem seals (2). Ss | ‘Apply molybdenum oil solution to each valve stem sliding surface Inset the intake and exhaust valves (9 into the valve guides. a Ta ey Install the inner valve spring [1] and outer valve spring [2] with the tightly wound colls should face toward tne ‘combustion chamber [3] io}