1. GENERAL INFORMATION SERVICE RULES MODEL IDENTIFICATION. GENERAL SPECIFICATIONS. - LUBRICATION SYSTEM SPECIFICATIONS - 1-6 FUEL SYSTEM (Programmed Fuel Injection) ‘SPECIFICATIONS. 16 COOLING SYSTEM SPECIFICATIONS 16 CYLINDER HEAD/VALVES ‘SPECIFICATIONS. CLUTCH/STARTER CLUTCH/ GEARSHIFT LINKAGE SPECIFICATIONS-.--. 1-7 CRANKCASE/TRANSMISSION SPECIFICATIONS. 18 CRANKSHAFT/PISTON/CYLINDER SPECIFICATIONS. 1-8 FRONT WHEEL/SUSPENSION/ STEERING SPECIFICATIONS. . 19 REAR WHEEL/SUSPENSION ‘SPECIFICATIONS. HYDRAULIC BRAKE SPECIFICATIONS... BATTERY/CHARGING SYSTEM. ‘SPECIFICATIONS. IGNITION SYSTEM SPECIFICATIONS ELECTRIC STARTER SPECIFICATIONS LIGHTS /METERS/SWITCHES SPECIFICATIONS... STANDARD TORQUE VALUES ENGINE & FRAME TORQUE VALUES LUBRICATION & SEAL POINTS... CABLE & HARNESS ROUTING EMISSION CONTROL SYSTEMS... EMISSION CONTROL INFORMATION LABELS (U.S.A. only) 1-39 1-1se SERVICE RULES Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that don't meet Honda's design specifications may cause damage to the motarzycle, Use the special tools designed for this product to avoid damage and incorrect assembly, Use only metric tools when servicing the motorcycle. Metric bolts, nuts and scrows are not interchangeable with English fasteners. Install new gaskets, O-rings, cotter pins, and lock plates when reassembling, When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque diagonally in incremental steps uniess a particular sequence is specified. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly, After reassembly, check all parts for proper installation and operation Route all electrical wires as shown in the Cable and Harness Routing (page 1-22). MODEL IDENTIFICATIONGENERAL INFORMATION ‘The frame serial number is stamped on the right side of the steering head, FRAME SERIAL NUMBER The engine serial number is stamped on the lower side of the lower crankease. ENGINE SERIAL NUMBER The throttle body identification number is stamped on the intake side of the throttle body as shown. ‘THROTTLE BODY IDENTIFICATION NUMBER The color label is attached. as shown. When ordering color-coded | ————— GOLA LABEL parts, always specify the designated color code. | ‘COLOR LABELGENERAL INFORMATION ‘The Vehicle Ident ‘main frame on the Safety Certification Labels. tion Number (VIN) is located on left side of the et carpe [sca GENERAL SPECIFICATIONS = a EMSRS ara _—SPECIFICATIONS fai DIMENSIONS | Overall fengeh 2,080 mm (79.9 in Overall width 695 mm (274 in} Overall height 41,115 mm (43.9 in) | Wheelbase 4,390 mm (54.7 in) | Seat height | 820 mm (22.3 in) | Footneg height | 395 mm (15.6 in) | Ground clearance | 130. mm (5.1 in} Dry weight 49 states, Canada type: | 169 kg (373 ibs! | California type: 169 kg (373 Ibs) Curb weight 49 states, Canada type: 199 kg (438 Ibs} California type: 202 kg (445 Ibs) Maximum weight capacity 49 states, California type: 166 kg (366 Ibs) |___ Canada type: 170 kg (375 Ibs} FRAME Frame type Diamond a Front suspension Telescopic fork Front axle travel 102.7 mm (4.04 in) Rear suspension ‘Swingarm Rear axle travel 430 mm (5.12 in) Front tire size 3 120/702R17 MIC (58W) Rear tire size 380/55ZR17 MIC (73W) | Front tire brand, BTOTZF RADIAL G (Bridgestone) D208FK (Dunlop) Pilot SPORT E (Michelin) | Rear tire brand BTO12R RADIAL L (Bridgestone) 208K (Dunlop) Pilot SPORT E (Michelin) Front brake Hydraulic double disc Rear brake Hydraulic single dise Caster angle 2a Trail length 95 mm (3.7 in) L | Fuettankeapacity 18.0 liter (4.76 US gal, 3.96 Imp gal) JGENERAL INFORMATION —.ENERAL INFORMATION TEM | SPECIFICATIONS ENGINE Cylinder arrangement 4 cylinders in-line, inclined 38° from _ a Bore and stroke 610 X 42.5 min (266 X 167 in Displacement 509 cm" (28.5 cus) Compression ratio 20:1 ‘eve fain | Chain driven, Done Intake valve opens at 1mm (0.04 in) lift | 22° BTDC Sloses at imm(00kin) it 42° ABDC Exhaustvelve opens at mm(@o4inllit._ 40" BBD Siesesatimmidorinyin SS ATDC | Lubrication syst Forced pressure and wet sump Oitpumo ype | Trocrow Cooling system | Liquid cooled | Activin Paper semen | Engine dry weight 834g (1985 bo) Firing order 124-3 FUEL DELIVERY | Type ii PGM-FI (Programmed Fuel Injection) |_ system Throtle bore farm (16m) DRIVE TRAIN | Clutch system: | Multi-plate, wet é Clutch operation system Cable operating eran Constant mesh, 6 speeds Patnaryriuetion aan aor) al reduction | ama uane) | Goat ratio, Ist 2.509 22") and 1997 G6) rd isn ear) | th 4409 G22) | Sth 1.260 (29/23) ain ‘bee as) | Gearshift pattern Left foot operated return system, | TiN-2-3-4-8-6 [ELECTRICAL —Htaniton spate Computer contalled distal vansisorzed Starting system Charging system Regulator/rectifier Lighting system | Battery with electric advance Electric starter motor Triple phase output alternator SCR shorteditriple phase, full wave rectif cation 1-5GENERAL INFORMATION LUBRICATION SYSTEM SPECIFICATIONS ITEM = Unit: mm (in) ‘STANDARD Aor draining Engine oil capacity ‘ter oil filter change “SERVICE LIMIT 2B iter 2.7 US qt, 2.3 imp ath S 9 liter (3.1 US gt, 2.6 Imp at) = [Ater disassembly 3.5 liter (3.7 US qt, 3.1 Imp at) = Recommended engine oil Oil pressure at oll pressure switch [Oirpump Body clearance Side clearance Viscosity: SAE 10W-40 {ats ot tras OUR (0.04 = 0.09 (0.002 - 0.004) Pro Honda GNé or HP4 (without malyo- = denum additives) 4-stroke oll (U.S.A, & Canada) or Honda 4-stroke oil (Canada only) or an equivalent motorcycle oi! API service classification SG or Higher except oils labeled as energy consering ‘onthe circular API service label JASOT 903 standard: MA a0 KPa (6.5 kgi/om", 78 psi) at] a [0:20 (0-008) 0.35 (0.074) 0.17 (0.007) | FUEL SYSTEM (Programmed Fuel Injection) SPECIFICATIONS [eee ne. Ss meeITEMe "SPECIFICATIONS “Throttle body 49 states, Canada type: | Gassc | identification number __| “California type: 60636, | Storter valve vacuum difference Zomm Hi e (Base throttle vaive for synchronization No.3 idiespeed 7/300 = 100 Am ‘Throttle grip free play Z=amm (16— W8ia) Intake air emperature sensor resietance (at 20°C63"F] Ee 14k Engine coolant tomperature sensor resistance 23-25 K2 |_(ar20°ci6erF) % my § |" Fuel injection resistance | Secondary injector ee 05-459 (at 20°C J68"F) Primary injector 105-1450 PAIR control solonoid valve resistance (at 20°C/63°F] 20-240 [Cam pulse generator peak voltage (at 20°C/68°F) —07'V minimum ignition pulse gonerator peak voltage (at 20°C/68°F) | 0.7 V minimum F Manifold absolute pressure at ie 750-250 mm Hg Fuel pressure at idle 5 Fuel pump flow (at 12¥) __T89 em" (6.4 US 02, 6.7 Imp 07) minimum/i0 seconds | COOLING SYSTEM SPECIFICATIONS 343 KPa (3.5 kaffom?, 50 psi) TEM Radiator and engine Reserve tank Coolant capacity ‘SPECIFICATIONS 32iiter (3.4 US qt 2.8 imp qi 0.30 liter(0.32 US qr, 0.26 Imp atl | Radiator cap relief pressure Thermosiet Begin to open” __| Valve iit Recommended antifreeze Standard coolant concentration 108 137 kPa (1.1 ~ 1.4 kaflem®, 16 20 psi) 20 (76-183°F) 70.3) rhinimum at 90°C [194°F) seal ida HP Coolant or an equivalent high quality ethylene glycol antifteeze containing corrosion protection inhibitors TET mixture of antifreeze and sof water 1-6GENERAL INFORMATION CYLINDER HEAD/VALVES SPECIFICATIONS Unit: mm (io) ae “Trem ‘STANDARD SERVICE Liar Cylinder compression T7226 KPa (125 katlom?, 178pai) oe | at 350 ror - Valve clearance iM 0.20 = 0.03 (0.008 = 0.007) EX (0.28 = 0.03 [0.011 = 0.001) deans | Camshat | Cam lobe height iN 36:36 - 36.60 (1.431 - 1.447) 363017) | | 35.36 — 35.58 (1391 - 1.401) 6.32 (13011) | Funout = 0.05 (0.002) — | Oil clearance 0.020 = 0.062 (0.0008 = 0.0024) 0.100.008) Wawa titer Valve iter OD. 25 876 - 25.993 (1.0228 - 10233) 25.97 (1.022) | Valve liter bore LD. 26.010 = 26.026 (1.0240 ~ 1.0246) 26.08 (1.026) Valve, | Valve stem OD. iw 3.975 ~ 3.990 (0.1565 - 0.1571) 3 567) valve guide xX 3.965 - 3.960 (0.1561 - 0.1567) 3.955 (0.1557) Valve guide 1D- INEK | 4.000 4.012 (0.1675 -0.15 4.04 (0.159) Stom-to-guide clearance [IN 0.075 (0.0030), [EX | 0.020 0.047 (0.0008 - 0.0078) 0.085 (0.0033), Valve guide projection Wi = 17a (0.67 - 0.65) = | above cylinder head 733= 136 (052-058) = Valve seat head iN (0.90 = 1.10 (0.035 - 0.043) 15 (0.06) (0.90 = 1-10 (0.035 - 0.043) 15 (0.06) ‘Valve spring | IN 36.17 (1.424) 35.1 (1.38) freelength | 39°76.(1.565) 38.8 0.53) [ex inner | 35:34 (1.397) 34.4 (135) | ‘Outer | 39.05 (1537) az 38.1 (150) ‘Cylinder head warpage = O7070.0087 Tem Cluteh Taver free play CLUTCH/STARTER CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS Clutch Unit: mm (in) STANDARD. ‘SERVICE LIM 70=20 (3/8 13/76) ae Spring free lengih 65.5 (1.83) [asa ci7ey Dise thickness 282 - 3.08 (0:115- 0.121) ("26 (0.10) Plate warpage as 0.30 (0.012) 1D: )cluteh outer guide a 24,993 ~ 26,003 (0.8840 0.9844) — 36.004 ~ 95,012 (1.9781 - 1.3784) 24,993 — 25,003 (0.9840 —0.9844) 34.996 - 35,004 (1377 41.008 = 41.016 (1.6145. 3781) i a8 34,996 (1.3777) 25.015 (0.9888) [34.986 (1.3774) | ~ 41.026 (1.6152) “41,000 = 47.008 (1.6142 — 1.6145) (aor (iets) Oil pump drive sprocket 25.000 25.021 (0.9843 - 0.9851) {25.037 10.9855) guide 34.950 - 34.975 (1.3760 - 1.3770) [34.940 (1.3756) 35.025 — 35.145 (1.3789 — 1.3837) [38.155 sai) 24.980 ~ 24.900 (0.9835 0.9839) | 24.960 (0.9627) 24 $80 — 74.990 (0.9835 - 0.9839) 24960 (0.9827) Starter driven gear boss O.D, 45.657 — 45.673 (1.7975 - 1.7981) “45.842 (1.7969)GENERAL INFORMATION CRANKCASE/TRANSMISSION SPECIFICATIONS T STANDARD [8a 12.000 — 12.018 (0.4724 - 0.4731) 12.03 (0.474) - 593 - 60010293 -0738) 3910.23) (0.4707 — 0.4712) [11.85 (0.4707 = 1082) 76.04 (1104) 24.000 - 24.021 (0.9449 - 0.9457) ~ | 26.04 (7.025) 1000 = 31.095 (1.2005 =1.2215) S1patiz2a1 27.959 = 27.980 (1.1007 — 1.1016) 27.98 (1.100) [730.985 30.980 (i287 121871 ——~a0.94 (1278) 30.950 - 30.975 (1.2185 — 30.93 (1.218) 0.020 0.062 (0.0008 - 0.0024) Unit: mm (in) ~ Shift fork 1D. Claw thickness ‘Shift fork shaft 0. Transmission | Gear 1D. Gear busing O. Gearto-bushing clearance 3.070 (0.0008 - 0.0028) .075 (0.0010 — 0.0030) — 0.11 (0.008) Gear bushing ID. 24.985 - 25.006 (0.9837 - 0.9845) 5.016 (0.9849) _| 28,006 (1.1018 = 7.1026) | 28,021 (1.10321, Mainshatt OD, 24,967 ~ 24.980 (0.9830 - 0.9825) 24.96 (0.983), Countershaft O.D, Bushing to shaft clearance 21967-27980 (1.071 ~ 1.1076) 2796 1.301) 0.006 — 6.039 (0:0002 0. [0.06 (0.00; 0610-002) CRANKSHAFT/PISTON/CYLINDER SPECIFICATIONS Unit: mm tin) = TEM STANDARD “[ SERVICE Lina" Crankshat Connecting rad side clearance 0.16 0:30 (0,008 - 0.072) 0.35 (0.014) Crankpin bearing oil clearance | 0.028 0.052 (0.0011 - 0.0020) | 0.08 (0.002) Main journal bearing oll clearanée | 0,020 0.038 (0.0008 0.0075) 0.05 (0.002) 1 [Runout a Ss {0.05 10.002), Fiston. pision | Piston O.D. at 10 0.4) from botiom | 65.965 - 66.986 (2.6368- 2.6372) [68.90 (2.634) rings "Piston pin bore ID. ¥6.002 - 16.008 (0.6300 - 0.6302) 16.02 (0.631) ston pin 0.0. 15.994 ~ 16.000 (0.6297 — 0.6299) | 15.98 (0.628) Fiston-to-piston pin clearance 10,002 0.014 (0.0001 - 0.00081, 0.04 (0.002) Piston ring end 0.10 ~0.20 (0.004 - 0.008) 0.4 0.02) ep 0.27 0.37 (0.008 = 0.012) 0510.02) 02-07 (0.01 -0.03) 10 (0.08) (side rail Piston ringto-ring [Top 0.030 0.060 10.00T2- 0.0028) | 0.10 (0.008) groove clearance | “Second 0.015 — 0.050 10.0006 0.0020) 0.08 (0.003) [Cynder [1p 67000 - 67015 (2.6378 - 2.6384) | 6710 (2.642) | ‘Out of round ss Bi Se 0.10 (0.004) Taper = —8510"0.0087 Werpage an 0:10 (0.004) Cylinder io-piston clearance ce 0.016 = 0.050 (0.0006 = 0.0022) [0.10-0.004y Connecting rod smali end .D, s 16.010 - 16.036 (0.6303 - 0.6313) 16.050 (0.6319) Connecting rod-to-piston pin clearance 0.010 ~ 0.040 (6.0004 6.0016) | 0.070 6.0028)GENERAL INFORMATION FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS Unit mm fin) EM z ‘STANDARD SERVICE LIMIT ‘Minimum tire read depth 3 “15 (0.06) Cold tre pres- 250 KPa 2-50 Kafiom®, 36 pat a= re 250-kPa (2.50 kgfler, 36 psi “Aale runout Ei ozo ‘Wheel rim Radial a = 2.010.08), runout Ata a aE pe oe = 2.0(0.08), Wheel Balance weight = 60 g (2.102) max Fork Spring free 758.8 170.75) 253.6 (3.98) [Tube runout (6.20 (0.008) Recommended fork Hud Pro Hon [eras Fluid Tevel 1106.3) oa Fluid capacity Z B31 = 25m" (18.020.08 US oz, 187 = a 0.08 imp 02) co. ~Pre-Toad adjuster intial setting “14 mm (0.6 in) (ith groove from top) ma tay] Rebound adjuster intial setting | 2-1/2 turns out from full hard a Compression adjustar initial Zturns out from fullhard 2 setting ‘Swearing head bearing pre-load 98-15 Nem (10-15 kati e REAR WHEEL/SUSPENSION SPECIFICATIONS ie Unit: mm {in} i TEM “aa ‘STANDARD SERVICE LIMIT ‘Minimum ive wead dapth =a = 2.0 (0.08) Coidtire [Driver only 290 KPa (2:90 kaffem®, 2 pal) Es pressure |" Driverand passenger 730 kPa (2.90 kofiom?, 42 psi) = ‘Axle runout 2 ‘O20 Wheel rim [Radial Beer = 2.0 10.08) runout ‘Axial 3 = 2,010.08) Wheel balance weight = | 60g ans s (2.102 max Drive chain | Sizemink DID DIDS2SHV-12078 = Re RKE2SROZi-12OLIFZ—— Slack 25— 35 (1 7-318) z = Shock Spring pre-Toadl adjuster standard position | Postion 3 cm mn absorber [Rebound damping adjuster intial setting | 1-9/4 turns out from ull = ‘Compression damping adjuster initial setting 2iurns out from full hardGENERAL INFORMATION HYDRAULIC BRAKE SPECIFICATIONS Unit: men (in) c TEM s ‘STANDARD SERVICE LIMIT | Front” | Specified brake fluid Honda DOTA Brake Fluid Ee Brake disc thickness 4.4~ 4.6 (0.17 - 0.18) [35 (0.74) Brake dise runout E a [930 coorar Master eylindor 1. 17503 (016874 = 0.6891) 17515 (0.6696) Master piston 0.0. 17367 (0.6619 = 0.6837) [17308 (0.6575) | Caliper cylinder LD, 2.080 (7.2610 ~ 1.2630) ‘32.092 (1.2635) 1321) 30.292 (7.1926) Caliper piston OD. 31.940.(1.2574) | “30.074 (7.1840) Rear ~~ | Specified brake fluid Honda DOT4 Brake Fluid = Brake pedal height 75 (3.0) Brake disk thickness £010.16) 48-52 (0:19 =020) Broke dise runout 0:30 (0.072) “Master cylinder .0 15.870 = 15.913 10.6248 — 06265) 75.925 (0.6270) Master pision 0. 15.827 ~ 16.854 (0.6231 = 0.6242) 18.815 (0.6226) Caliper cylinder 1.0. ‘38.180 - 38.230 (1.5031 - 1.5051) 38.24 (1.506) L [Caliper piston 0.0. | "38.098 = 3.148 (1.4999 = 15018) 38.09 11.500) BATTERY/CHARGING SYSTEM SPECIFICATIONS iz 5 ENEMAS 5 oa PI S| = ee as SPECIFICATIONS = ra Battery Capacity 12V-8.6 Ah Current leakage [aie 2 Dinan Seka OE | | Voltage Fully ovarged | ‘i 130-132 (20°C/68°F) Needs ~~ Below 12.4V_ ai charging pute ai Charging current [Normal OSAB=10h ‘Quick I SATA $s | Atternator [Capacity 0.383 kWS,000 rpm | Charging coil resistance (20°CEB°F) 01-100 c IGNITION SYSTEM SPECIFICATIONS c Tem SPECIFICATIONS =] ‘Spark plug (iridium) IMRSC-SHE (NGK) “a ‘Spark plug gap 0.80 — 0.90 mm (0.031 - 0.035 in} Ignition coil peak voltage 100 V minimum: a [Ignition pulse generator peak voltage 3 0.7 Viminimum [Fanition timing CF*mark) ETT RE EET OC ac ress ELECTRIC STARTER SPECIFICATIONS ___Unit: mm tin) ae TEM 2 ‘STANDARD SERVICE LiMiT_ | [Starter motor brush fength [12.0=13010.47-051) 65 (0.26) 1-10GENERAL INFORMATION LIGHTS/METERS/SWITCHES SPECIFICATIONS re ‘SPECIFICATIONS Bulbs Headlight i eS : 72V— 55 W a Lo aa 12V=55 W | Position ight T 12-5 W fail ight ~ TED 5 “Turn signal light 2 TaV=71 We x | instrument light fe LED | “Turn signal indicator I to High beam indicator iz, sl ‘Neutral indicator Saas PGM-Fl warning indicator TED Fuse Main fuse 308 PGM-FI uso ; Sat SENET OAS a Sub fuse TAK 4, 2007 ‘Tachometer peak voltage ECT sensor resistance BO°C (176 F} [20°C ase —] 70.5 Viminimum 8k atiGENERAL INFORMATION STANDARD TORQUE VALUES TORQUE] TORQUE 2 A EES [Nm tkaf-m, thf) FASTENER NEG (kgf-m, tbe) ‘5mm hex bolt and nut 49105, 36) | Smmscrew 3.9 (0.4, 2.9) & mm hex belt and nut 8.8(10,7) 6mm screw 8.8.(0.9, 65) 8 mm hex bolt and nut 2212.2, 16) 6mm flange bolt 9.8 (10,7) | 10mm hex bolt and nut 34135, 25), (mm head, smal flange} | 12mm hex bolt and nut 5415.5, 40), mm fienge bolt 12112,9) | | mm head, large flange) | | | mm fiange bolt 12(12.9) (10 mm head) and nut 8 mm fiange bolt and nut | 281227,20) zi 10 mm flange bolt and nut 39 (4.0, 29), ENGINE & FRAME TORQUE VALUES + Torque specifications listed below are for important fasteners. + Others should be tightened to standard torque valves listed above. Note 1. Apply sealant to the threads. 2. Apply a locking agent to the threads. 3. Stake 4 Apply ollto the threads and flange surface. 5. Usnut 8. ALOC boltscrew: replace with a new one. 7. Apply grease to the threads. 8 Apply molybdenum disulfide oil o the threads and seating surface 8. CTrbolt ENGINE MAINTENANCE zi Ten | THREAD ‘TORQUE Sal 2 TEM GTY | DIA.tmmm) | _ Nim thom, sete) | REMARKS Spark plug : 7 70 76 (16, 12) | Timing hole cap 1 8 18 (18,13) Note 7 Engine oil fter cartridge 1 20 26 (27 20) NOTE 4 Engine ol drain bolt SeleGa 12 | _29(30,22) ESA LUBLICATION 4 THREAD [TORQUE J TEN ad ST | bia tm) | nm tka, toesty_| REMARKS Oil pump assembly flange bolt 7 6 7 (08, 5.8) NOTES |_ Gil fiter boss (stud side) 1 20° 18 (18, 13) NOTE 2 FUEL SYSTEM (Programmed Fuel Injection) a ~ | THREAD TORQUE — ] gu! TY | DIA. (mm)_|_Nem (kgm, thee) | REMARKS ECT Engine Coolant Temperature) sensor 7 12 "23 (2.3, 17) Throttle body insulator band screw 2 5 Seo page 1-15 Startor valve lock nut 4 10 118 (0.18, 1.3) Starter valve synchronizetion plate screw 4 EB 0.8 (0.08, 0.7) Fuel pipe mounting bolt 3 6 9.8(10,7) Fast idle wax unit link plate serow 1 3 0.8 (0.08, 0.7) Fast idle wax unit mounting screw 2 6 4.9 (0.5, 36) Secondary injector bracket mounting bolt [ei 5s | s4i0ss.4 | 1-12GENERAL INFORMATION ‘COOLING SYSTEM a) ae a ee TORQUE rem : any | um (kgton. tbe) | REMARKS ‘Water pump assembly flange bolt 2 12 (1.2, 9) ‘NOTES Thermostat housing eover flange bolt 2 13013,10) | NOTES ENGINE MOUNTING 2a ‘THREAD ‘TORQUE ee QTY DIA. (mm) _|_ Nim ikgfm, tots) REMARKS Drive sprocket special bok Pca 10 54 (55, 40) CYLINDER HeAD/VatvEs THREAD TORQUE TE : OTY | pia (mm)_| Nim ikgtm, ib REMAINS, Cylinder head mounting bolt | 9 47 (48, 35) | "NOTES Camshat holder bolt 20 8 120129) | NOTES Gylindor heed sealing bolt 3 te wae) | Note Cylinder head eover bot ‘ $ 38110.) Breather plate bolt 3 8 130139) | NoTEZ9 PAIR reed valve cover bot ‘ 8 waa | Notes Cam sprocket bot ‘ ; noo, — | Nore2 em pulae generator rotor bolt 2 5 12012,8) | NOTE? Cam chain tensioner iter mounting socket bolt 2 8 oto, Cam chain tensioner A pivot bat i 8 asian | Nove2 Cam chain tensioner B pivot bot 1 0 2020.) | Nore Cam chain gulde belt 1 8 12 (12.8) Gylnder block sockt bolt 1 to iatiz8|__| nove2 CLUTCH/GEARSHIFT LINKAGE vy] THREAD TORQUE eM ony, DIA. (mm) Nem (kgf-m, Ibf-ft) ae | Ta eater OSE mak 1 22 127118088) | NOTES, 4 Cluteh spring Bott 5 ° 1212.9) Oil pump driven sprocket bolt 1 8 tsas'm — | Nove2 | Shit crum conter socket bot 1 8 | ais | Norez | Shit drum stopper arm pivot bolt ' 8 12(12,8) | Coreen aa ol ptar aes naz | E| ALTERNATOR/STARTER CLUTCH sy] THREAD TORQUE Ee ny: DIA. (mm) Nem (kgf-m, Ibf-ft) pea “Alternator stator socket bolt t 6 12 (1.2, 9) ee Fiyaee! bolt 1 0 wsitas7 | Norex Stator wire clamp bott 1os|) see atta | Notes 4o | CRANKCASE/TRANSMISSION (es THREAD TORQUE | es oy, DIA. (mm) Nem (kgf-m, Ibf-ft) eee ‘Mainshaft bearing set plate flange bolt = “e¥ere 12(1.2, 9) NOTEZ Gearshift drum becring set bolt 2 6 wags) | Note? Lower eranksove sealing alt 2 20 28128, 20) Crankcaee Bm bolt ra ° 2112.8) Simm bolt c 8 25 (26, 18) 8 mm bolt (main ournel bot) 0 8 18118, 101+ 120° | S00 page we tomm bott 1 im 29140,29) | | 1-13GENERAL INFORMATION (CRANKSHAFT/PISTON/CYLINDER Eats ee irew TORQUE] ory um ugtim, bey | REMARKS [Connecting rod bearing cap bolt —e T4114, 10) +90" | NOTES IGNITION system TEM ow Nem tage, tt)_| _ REMARKS Starter clutch outer special bolt 7 NOTEe—| ELECTRIC STARTER trem ory “nem iatcinty_|_ REMARKS ~Startar motor terminal nut 7 fans se LIGHTS /METERS/SWITCHES Trem ary Num iigraeetmy | REMARKS | Oil pressure switch T 12 (1.2, 9) NOTE T Oil pressure ewitoh wite terminal screw 1 Neutea switch 1 1-14GENERAL INFORMATION Insulator clamp (Throttle body side): Insulator clamp (Cylinder head side! Exhaust pipe stud bolt: 12+ 1mm (050.04 in) | > <_ eS) Y 10. = 1mm (0.4 » 0.04 in) 455 = 0.5 mm (1.79 + 0.06 in) pe 1-15GENERAL INFORMATION FRAME FRAME BODY PANELS/EXHAUST SYSTEM 1" | THREAD TORQUE T ee TY | DIA. fmm) | Nem tkgém, tbe | REMARKS Tower cowl-to-middle cowl pan screw z 5 75 (0.15, 11) | i Middle cow-to-upper cowl pen screw 4 5 1500151) | Windscreen setting screw 6 5 0'5 (0.05, 0.4) Seat ral upper mounting flange nut 2 wo =| 54155, 40) Seat ral lower mounting flange bolt 2 wo | 445,33) Seat rail brace socket bolt ens Peps 26 (27,20) Seat ral assembly flange nut ea en 30(3.1,22) Exhaust pipe joint flange nut 8 1 12(12,9) Muffler band flange bolt 2 a 2323,17) Passenger footpeg bracket socket bolt 4 e | 2827.20) ace FUEL SYSTEM iz ie ot - ‘THREAD “TORQUE ITEM, OTY | pia. tmm)_| nem tkgtm, thet) | REMARKS Fuel filler cap socket Be sj 4 18 (0.18, ] Fuel feed hose banjo bolt (fuel tank side) 1 12 22 (22,16), Fuel hose sealing nut (throttle body side} 1 2 22 (22, 16) Fuol pump mounting nut 6 6 12(12,9) | | | | | | | 0: sensor (California type only) 1 2 25(26,19) | COOLING sysTEM THREAD TOROUE eM omy DIA. (mm) N-m {kgf-m, Ibf-ft) | PEMA: Cooling fan nut T 3 29 (03,22) NOTE Fan motor nut 3 5 49 (05,36) [Bra Mttarahfnuelrounting bok 3 8 | 7awa'sa, ea ENGINE MOUNTING THREAD TORQUE ues OTY | piaimm)_| nm tkgtm, tet) | REMARKS Front engine hanger bol (eft sido) T 2 54155, 40) Front engine hanger nut (right side} 1 2 54(55, 40) Front engine hanger pinch bolt 2 10 27 (2.7,20) Rear engine hanger adjusting boit 1 20 9.8(10,7) See page & ear engine hanger lock nut 1 20 54 (55, 40) 10 Rear engine hanger nut 1 2 59 (6.0, 43), Lower engine hanger pinch bolt 2 8 27 (27,20) __Lower engine hanger nut aa ls ee 1-16GENERAL INFORMATION FRONT WHEEL/SUSPENSHON/STEERING ae Tenv ] THREAD TORQUE rem Ty | ciate | wmigim nem | REMARKS | Handlebar weight mounting screw [Zz 5 98 (10,7) “NOTES | Front brake aise bot 2 6 20120,14 | NOTES Front axle bolt 1 14 59 (6.0, 43) | | Front axle holder pinch bolt 4 8 22 2.2, 16) | | Fork socket bolt 2. 10 34 (3.5, 25) NOTE 2 | Fork bolt 2 2 2323, 17) Fork top bridge pinch bolt 2 8 23 (23, 17) | Handlebar pinch bot 2 8 2323, Fork bottom bridge pinch bolt 2 8 27 (27,20) Stearing stem adjusting nut i 26 4960.36) | Stooring stem adjusting lock nut 1 26 tance Steering stom nut 1 | | sea4105,76 REAR WHEEL/SUSPENSION THREAD TORQUE — tna EM Op, DIA. (mam) Nom (kam, tbftt)_ | REMARKS ‘Rear brake disc bolt * 4 8 T 42 (4.3, 31) NOTE 6 Final driven sprocket nut 8 0 64165,47) | NOTES Rear axle nut 1 2 13(115,83) | NOTES Rear shock absorber upper mounting nut. 1 10 44 (4.5, 33) | NOTES Rear shock absorber lower mounting nut 1 10 44145, | NOTES Shock linkto-frame pvot nut 1 10 441653) | NOTES Shock arm-to-shook ink nut 1 10 4415.33) | NOTES Shock arm-to-swingarm nut 1 10 44us.33) | Notes Rear shock absorber bracket mounting bolt ale on 46 (45, 23) Drive chan alder flange bolt 3 6 88109,65) | NoTE2 Swingarm pivot pinch bolt 2 8 27 (2.720) Swingarm pivot ut 1 18 93 95,69) a I HYDRAULIC BRAKE 7 | THREAD ‘TORQUE L ud OY (DIA tmm) | Nim tkgfm, toes) | REMARKS Front master cylinder reservoir cap screw. 2 4 15 (0.15, 1.1) Fa Front brake lever pivot bolt ae 6 1.0 (0.1, 0.7) Front brake lever pivot nut 1 6 59 (08,43) Front brake light switch screw 1 4 10 (0.1, 0.) |. Front master eyinder holder bot 2 6 1234, 9) Front brake caliper assembly torx bolt 8 8 230231) | noTe2 Front brake caliper mounting bolt 4 8 30(31,29 | NOTES Rear master evlinder push rod joint nut 1 8 1818, 13) Rear master cylinder reservoir cap screw 2 1 15(035, 11) Rear master cylinder mounting bolt 2 6 8.8 (0.9, 6.5) | Rear brake reservoir mounting bolt 1 6 12112, 9 Rear brake reservoir hose joint screw 1 4 15101511) | Notez Rear brake caliper mounting bolt 1 8 23 (2.3, 17) | Rear brake caliper slide pin bolt 1 2 21 (238,20) Front brake caer pad pin 2 40 18.18, 13) Rear brake caliper pad pin 1 0 18118, 13) Brake hose oll bolt 5 10 24 (85, 251 Front brake hose clamp bott 2 6 12112, 9) Front brake hose 2-way joint bolt 3 6 1222, 9) Brake caliper bleed valve dieser 59106, 4.3) 1-17GENERAL INFORMATION Tot hari Tene uRexs— —roroue TEM DIA.(mm)_|_Nim (kgm, thf) | REMARKS STRAT $ Steno Sole ees ey Se Sea clas eee ? cee a THREAD TORQUE : ra oe | ans | ie stand pivot bolt 7 10 9.8 (1.0, 7) See are emer ae See a peo ne lees Bans | noes eer alee taza | Nore |_ Driver footpeg cap bolt 1-18Gi ENERAL INFORMATION LUBRICATION & SEAL POINTS ENGINE [ LOCATION — Crankease mating surface | Oil pan mating surface Right crankcase cover mating surface Alternator cover mating surface | ll pressure switch threads Do not apply sealant to the [7 thread head'3 - 4mm (0.10.2 in) [MATERIAL | Liquid seatant (Three Bond 12078 or equivalent) Liquid sealant (Three Bond 12078 or | equivatent) REMARKS]GENERAL INFORMATION LOCATION Era Cylinder head semi-circular cut-out [APPLIED PORTION Piston pin sliding surface Connecting rod bearing surface Connecting rod small end inner surface Crankshaft thrust surface Camshaft lobesyjournals and thrust surface Valve stem (valve guide sliding surface) Valve lifter outer sliding surface Water pump shaft spline and thrust washer sliding sur. face Clutch outer/primary driven gear sliding surface Clutch outer guide sliding surface il pump gear and collar sliding surface 1M3/é, C5, C6 shifter gear (shift fork grooves) Starter reduction gear sliding surface Statter reduction gear shatt sliding surface | | Main journal bearing surface | | MATERIAL ~ Sealant Molybdenum disulfide of {a mixture of 1/2 engine cil and 1/2 molybdenum disulfide grease REMARKS Piston and piston ring sliding area Oil strainer packing Clutch dise surface Starter one-way clutch sliding surface Connecting rod bolt threads and seating surface Flywheel bolt threads and seating surface Cylinder head special bolt (after removing anti-rust oll additive) Clutch center lock nut threads and seating surface Oil filter cartridge threads and O-ring Camshaft holder bolt threads and seating surface Each gear teeth and rotating surface Each bearing Each O-ring Other rotating area and sliding surface Timing hole cap threads Each oil seal lips Engine oil Multi-purpose Lower crankcase sealing bolt threads Cylinder head cover breather joint threads Cylinder head sealing bolt threads Cam pulse generator rotor bolt threads Oil pump driven sprocket bolt threads Oil cooler center bolt thread (stud side} Shift drum bearing set plate bolt threads Mainshaft bearing set plate bolt threads Cam sprocket bolt throads Cylinder head cover breather plate bolt threads | Shift drum center bolt threads Cam chain tensioner pivot A bolt threads Cam chain tensioner pivot B bolt threads Spindle plate tightening bolt threads Spindle set plate tightening bolt threads Upper crankcase sealing bolt threads | Locking agent Coating width: 6.5 + 1mm Coating width: 6.5 = 1mm Coating width: 6.5 = 1 mm Coating width: 6.5.2 1 mm Coating width: 6.5 = 1 mm Coating width: 6.5 = 1 mm Coating width: 6.5 = 1mm. Coating width: 6.5 + 1 mm. Coating width: 6.5 «11mm Coating width: 6.5 = 1mm. Coating width: 6.5 = 11mm. 1-20GENERAL INFORMATION ——_WH_ ______SENERAL INFORMATION FRAME LOCATION Seat catch hook sliding area Front whee! dust seal lips, Final driven flange-to-rear wheel hub mating surface and O-ring Rear whee! dust seal lips Rear whee! side collar inner surface Throttle grip pipe flange Clutch lever pivot bolt sliding area Rear brake pedal pivot sliding area Gearshift pedal link tie-rad ball joints Gearshift pedal pivot Driver footpeg sliding area Pillion footpeg sliding area Side stand pivot Center stand pivot arena — Multr-purpose grease REMARKS ‘Steering head bearing sliding surface Steering head dust seal lips Urea based multi-purpose grease with extreme pres- sure (example: EXCE- LIGHT EP2 manufactured by KYODO YUsHT, Japan), Shell stamina EP2 for equivalent ‘Swingarm pivot bearings Swingarm pivot dust seal ips Shock a'm and shock lnk needle bearings Shock arm and shock lnk dust sea ips Shock absorber needle bearings Shock absorber dust seal ips Multi-purpase grease | (Shell Alvania EP2 or equivalent) Throitle cable A, B outer inside Clutch cable outer inside Clutch cable outer inside ‘Cable Tubricant Handlebar grip rubber inside | ‘Sieering bearing adjustment nut threads Honda bond A or Handa hand Grip Cement (USA. only) [Engine oil Front brake leverto-master piston contacting area Front brake lever pivot Rear master brake master piston-to-push rod contacting area Brake caliper dust seals Rear brake caliper boot inside Rear brake caliper pin boot inside Silicone grease Brake masier piston and cups Brake caliper piston and piston seals Honda DOT 4 brake fi Fork cap O-ring Fork dust seal and oil seal lips Pro Honda Suspension Fluid $8-8 jervoir hose joint screw threads Front brake caliper assembly bolt threads Rear brake caliper pin bolt threads Locking agant 1-91GENERAL INFORMATION CABLE & HARNESS ROUTING RIGHT HANDLEBAR cucu caBLE THROTTLE CABLES ‘SWITCH WIRE, i LEFT HANDLEBAR SWITCH WIRE FRONT SUB-HARNESS 42-12? (BLUE) CONNECTOR FRONT SUB-HARNESS 12 (GRAY) CONNECTOR COMBINATION METER BANK ANGLE SENSOR MULTI-CONNECTOR ‘3P (BLACK) CONNECTOR > \ ©/ ihre TunN signatze {UGH BLUE) CONNECTOR \ Leer TUAW sIGwAL 2b (ORANGE CONNECTOR FRONT SUB-HARNESS 12P (GRAY) CONNECTOR FRONT SUB-HARNESS 12P (BLUE) CONNECTOR ayGENERAL INFORMATION eee LEFT HANDLEBAR SWITCH WIRE IGNITION SWITCH WIRE FRONT SUB-HARNESS 12P (BLUE) CONNECTOR FRONT SUB-HARNESS 12P (GRAY) CONNECTOR 1-23GENERAL INFORMATION CLUTCH CABLE RIGHT HANDLEBAR, ‘SWITCH WIRE HORN WIRE 1-24GENERAL INFORMATION IGNITION SWITCH WIRE CLUTCH CABLE THROTTLE CABLES LEFT HANDLEBAR, SWITCH WIRE SS ae NY RIGHT HANDLEBAR SWITCH WIRE FAN CONTHOL RELAY ENGINE STOP RELAY FUEL TANK FUEL HOSE AIR VENT HOSE FUEL TANK OVER FLOW Hose FUEL HOSE FUEL PUMP UNIT WIRE 1-25GENERAL INFORMATION ECM 32P (LIGHT GRAY} CONNECTOR ECM 32P (BLACK) CONNECTOR IAT SENSOR No.4 SECONDARY INJECTION CON- IGNITION switcH 4P (NATURAL) CONNECTOR, No.3 SECONDARY INJECTION CON- No.2 SECONDARY INJECTION CONNECTOR LEFT HANDLEBAR SWITCH 12P (GRAY) CONNECTOR No.1 SECONDARY INJECTION CONNECTOR 1-26GENERAL INFORMATION laT SENSOR No3. PRIMARY INJEC- ‘TOR CONNECTOR MAP SENSOR, No.2 PRIMARY INJEC- TOR CONNECTOR No.1 PRIMARY MAP SENSOR, INJECTOR, ‘VACUUM HOSE CONNECTOR INSIDE BodT CONNECTORS: CAM PULSE GENERATOR 2P (NATURAL) FUEL PUMP UNIT 3P BLACK) venice A SIDE STAND SWITCH 2P (GREEN) SPINATURALICONNECTOR FAST IDLE WAX UNIT WATER HOSES 1-27GENERAL INFORMATION CRANKCASE BREATHER HOSE PAIR CONTROL SOLENOID VALVE RIGHT HANDLEBAR SWITCH SP (BLACK) CONNECTOR PAIR CONTROL, SOLENOID VALVE 2 (BLACK) CONNECTOR SIPHON HOSE AIR BLEED HOSE IGNITION CONTROL SUB-HARNESS 6P (BLACK) CONNECTOR Ay a | i IGNITION PULSE GENERATOR 2° (RED) CONNECTOR, INSIDE BOOT CONNECTORS: ~ CAM PULSE GENERATOR 2P (NATURAL) STARTER MOTOR CABLE FUEL PUMP UNIT 3P (BLACK) ~ SIDE STAND SWITCH 2P (GREEN) 1-28GENERAL INFORMATION INSIDE 8007 CONNECTORS: ~ CAM PULSE GENERATOR 2P (NATURAL) = FUEL PUMP UNIT 3P (BLACK) = SIDE STAND SWITCH 2P (GREEN) FAN MOTOR 2P (BLACK) CONNECTOR ‘TP SENSOR 3P (BLACK) CONNECTOR MAIN WIRE HARNESS FUSE BOX FAN MOTOR WIRE CAM PULSE GENERATOR NEUTRAL SWITCH WIRE REGULATORIRECTIFIER 3P (NATURAL) CONNECTOR e DESTAND EWITcH WIRE RADIATOR RESERVE TANK OVER FLOW HOSE FON TANICOVER FUELTANK AIR FLOW HOSE VENT HOSE 1-29GENERAL INFORMATION PAIR CONTROL SOLENOID VALVE 2P (BLACK) CONNECTOR BRAKE LIGHT SWITCH RIGHT HANDLEBAR SWITCH 2? (BLACK) CONNECTOR SP (BLACK) CONNECTOR REAR BRAKE HOSE CLUTCH CABLE OIL PRESSURE SWITCH WIRE 1-30GENERAL INFORMATION —_2W SEERA INFORMATION PGIV-FI FUSE (20) HOLDER SEAT LOCK CABLE BATTERY POSITIVE (+) CABLE BRAKEVTAIL LIGHT 3P (NATURAL) CONNECTOR DATA LINK CONNECTOR INSIDE BOOT CONNECTORS: STARTER RELAY SWITCH) ~ RIGHT REAR TURN SIGNAL LIGHT 2° (LIGHT BLUE) = LEFT REAR TURN SIGNAL LIGHT 2° (ORANGE) MAIN WIRE HARNESS 1-31GENERAL INFORMATION REAR BRAKE RESERVOIR HOSE BRAKE LIGHT SWITCH 2P (BLACK) CONNECTOR REAR BRAKE HOSE CALIFORNIA TYPE: 1-32GENERAL INFORMATION IAT SENSOR No3. PRIMARY INJEC- TOR CONNECTOR, MAP SENSOR, No.2 PRIMARY INJEC- TOR CONNECTOR No.1 PRIMARY MAP SENSOR INJECTOR VACUUM HOSE CONNECTOR EVAP PURGE CONTROL SOLENOID VALVE HOSES INSIDE BOOT CONNECTORS: ~ CAM PULSE GENERATOR 2P (NATURAL} = FUEL PUMP UNIT 3P (BLACK) VEHICLE SPEED SENSOR ~ SIDE STAND SWITCH 2P (GREEN) 3P (NATURAL) CONNECTOR FAST IDLE WAX UNIT WATER HOSES IGNITION PULSE GENERATOR 2P (RED) CONNECTOR: 1-33GENERAL INFORMATION INSIDE BOOT CONNECTORS: FAN MOTOR 2P (BLACK) ~ CAM PULSE GENERATOR 2P (NATURAL) CONNECTOR ~ FUEL PUMP UNIT 3? |BLACK) EVAP PURGE CONTRGISIOE STAND SWITCH 2P (GREEN) ‘TP SENSOR 3P (BLACK) CONNECTOR SOLENOID VALVE FUSE BOX — FAN MOTOR WIRE ‘CAM PULSE GENERATOR NEUTRAL SWITCH WIRE REGULATOR/RECTIFIER SP (NATURAL) CONNECTOR SIDE STAND SWITCH WIRE 02SENSOR 4P (NATURAL) CONNECTOR FUEL TANK OVER, FLOW HOSE RADIATOR RESERVE TANK ‘OVER FLOW HOSE EVAP PURGE CONTROL SOLENOID VALVE HOSES. 1-34GENERAL INFORMATION EVAP PURGE CONTROL ‘SOLENOID VALVE FUEL TANK AIR VENT HOSE EVAP PURGE : ~ CONTROL SOLENOID » - VALVE HOSES: oo uu evap purge control \ Oa ‘SOLENOID VALVE \ FUEL TANK AIR VENT HOSE EVAP PURGE CONTROL SOLENOID | VALVE HOSESGENERAL INFORMATION EMISSION CONTROL SYSTEMS The U.S. Environmental Protection Agency, California Air Resources Board (CARB) and Transport Canada require manu- facturers to certify that their motorcycles comply with applicable exhaust emissions standards during their useful lite. When operated and maintained according to the instructions provided, and that motorcycles built after January 1, 1983 comply with applicable noise emission standards for one year or 6,000 km (3,730 miles) after the time of sale to the ult mate purchaser, when operated and maintained according to the instructions provided. Compliance with the terms of the Distributor's Limited Warranty for Honda Motorcycle Emission Control Systems is necessary in order to keep the emis. sions system warranty in effect, SOURCE OF EMISSIONS The combustion process produces carbon monoxide and hydrocarbons. Control of hydrocarbons is very important because, under certain conditions, they react to form photochemical smog when subject to sunlight. Carbon monoxide does not react in the same way, but itis toxic, Honda Motor Co., Ltd. utilizes lean injection settings as well as other systems, to reduce carbon monoxide and hydrocar- bons. CRANKCASE EMISSION CONTROL SYSTEM ‘The engine is equipped with a closed crankcase system to prevent diecharging crankcase emissions into the atmosphere, Blow-by gas is returned to the combustion chamber through the air cleaner and throttle body. AIR CLEANER HOUSING THROTTLE BODY FRESH AIR, BLOW-BY GAS 1-36GENERAL INFORMATION EXHAUST EMISSION CONTROL SYSTEM (SECONDARY AIR SUPPLY SYSTEM) ‘The exhaust emission control system is composed of a lean fuel injection setting, and no adjustments should be made except idle speed adjustment with the throttle stop screw. The exhaust emission control system is separate trom the crank case emission control system. ‘The exhaust emission control system consists of a secondary air supply system which introduces filtered air into the {haus gases inthe exhaust port. Fresh aris drawn into the exhaust port by the function ofthe PAIR (Pulse Secondary Air Injection} eontral valve. ‘This charge of fresh air promotes burning of the unburned exhaust gases and changes a considerable amount of hydrocar- bons and carbon monoxide into relatively harmless carbon dioxide and water vapor. ‘The reed valve prevents reverse air flow through the system. The PAIR control valve is operated by the solenoid valve, The solenoid valve is controlled by the PGM-Fl unit, and the fresh air passage is openedclosed according to running conditions, (ECTIAT/TP/MAP sensor and engine revolution) No adjustments to the secondary air supply system should be made, although periodic inspection of the components is recommended, AIR CLEANER HOUSING PAIR CHECK VALVE ‘THROTTLE 8ODY PAIR CONTROL SOLENOID VALVE EXHAUST PORT <== FRESH AIR u ] ExHausT cas California type only: The California type is equipped with two three-way warm-up catalytic converters, a three-way catalytic converter, and heated oxygen sensor. The three-way catalytic converters are in the exhaust system. Through chemical reactions, they convert HC, CO, and NOx in the engine's exhaust to carbon dioxide (C02), dinitrogen (N2), and water vapor. No adjustment to these systems should be made although periodic inspection of the components is recommended, 1-37GENERAL INFORMATION EVAPORATIVE EMISSION CONTROL SYSTEM (CALIFORNIA TYPE ONLY) This model complies with CARB evaporative emission requirements. Fuel vopor from the fuel tank is routed into the evaporative emission (EVAP) canister where is it absorbed and stored while the engine is stopped. When the engine is running and the evaporative emission (EVAP) purge control solenoid valve is open, fuel vapor in the EVAP canister is drawn into the engine through the throttle body, FUEL TANK THROTTLE BODY EVAP PURGE CONTROL SOLENOID VALVE <= FRESH AIR = FUEL VAPOR NOISE EMISSION CONTROL SYSTEM TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: U.S. Fedoral law prohibits, or Canadian provincial law Prohibits the following acts or the causing there of: (1) The removal ar rending inoperative by any person, other than for the purposes of maintenance, repair or replacement, of any device or element of design incorporated into any vehicle for the purpose of noise control prior to its sale or delivery to the ultimate customer or while itis in use; or (2) the use of any vehicle after such device or element of design has been removed or rendered inoperative by any person. AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW: 1. Removal of, or puncturing of the muffler, baffles header pipes or any other component which conducts exhaust gases, 2. Removal of, or puncturing of any part of the intake system 3. Lack of proper maintenance. 4. Replacing any moving parts of the vehicle, or parts of the exhaust or intake system, with parts other then those spect fied by the manufacturer. 1-38EMISSION CONTROL INFORMATION LABELS (U.S.A. only) ‘An Emission Control Information Label is located on the as shown. ‘The fuel tank must be opened to read it. Refer to page 6-61 fuel tank opening. VACUUM HOSE ROUTING DIAGRAM LABEL (CALI- FORNIA TYPE ONLY) ‘The Vacuum Hose Routing Diagram Label is on the sir cleaner housing cover as shown, The fuel tank must be opened to read it, Refer to page 6-61 for fuel tank opening. GENERAL INF‘ ORMATION EMISSION CONTROL INFORM: Vacuum Hose Routing rare tripe Ereporie oniy———7 Frortotvehicle 7 ences, EVAP Canis yap Pussies” oor) IN LABEL Diagram Bun Solent2. TECHNICAL FEATURE ABSOLUTE PRES: SUPPLY SYSTEM DUAL SEQUENTIAL FUEL INJECTION “22 SYSTEM (PGM-DSFI) UNIT PROLINK SUSPENSION.TECHNICAL FEATURE ABSOLUTE PRESSURE FUEL SUPPLY SYSTEM The fuel delivery system consists of the following components: fuel tank, fuel strainer, fuel pump, fuel filter, internal pres: sure regulator, fuel delivery hoses, fuel rails and injectors, This system is equipped with the absolute fuel pressure. There is no external fuel retum hose or vacuum pressure regula: tor with this system, The fuel pressure in the fuel delivery system is regulated by the internal pressure regulator and always kept absolute; 343 kPa (3.5 kgf/cm’, 50 ps. ‘Tho internal pressure regulator returns the fuel by opening @ valve when the fuel pressure increases more than 343 kPa (3.5 kgflem?, 50 psi) ‘This system optimizes injection volume by the ECM control. {Felon} [—Fuet rait [Secondary foal injectors] [Fast dotvery hose: (Fast iter [Pressure regarator Fuel rail PRESSURE FUEL FILTER REGULATOR ff SPRING VALVE FUEL RETURN f Hose 7 —_ F | ren une Y ae UII AP Fram | L, fuel pure — FUEL Rawenta STRAINER Less ten OE - SEIT s totem’, cops) SF lpa as ttn, 80 pa) 2-2TECHNICAL FEATURE DUAL SEQUENTIAL FUEL INJECTION SYSTEM (PGM-DSFI) ‘The CBRGOORR is equipped with two injectors per cylinder. ‘The primary injector is built in the throttle body and the secondary injactor is built on the upper air cleaner case. Four primary injectors and four upper injectors are connected in series to the fuel delivery hose. ‘The ECM controls the injector operation and injection time, according to the signals from each sensor. ‘The primary injector operates at all engine speed, both the primary and secondary injector operate at high engine speeds (over 8,800 rpm) and throttle wide opened lover 50°). AIR CLEANER CASE SECONDARY INJECTOR THROTTLE BODY PRIMARY INJECTOR 2-3TECHNICAL FEATURE UNIT PROLINK SUSPENSION The CBRGOORR features the unit pro-link rear suspension which consists of the swingarm, shock link, shock arm, shock absorber and upper mounting bracket The rear suspension unit is connected to the frame at the swingarm pivot and link arm, eliminating an upper shock connec. tion to the frame, ‘The upper part of rear shock absorber is mounted on the upper maunting bracket through the swingarm, therefore the ‘whole rear shock absorber moves in response to rear wheel movement. REAR SHOCK ABSORBER UPPER MOUNTING BRACKET SWINGARM REAR WHEEL sHocK LINK SHOCK ARM3. FRAME/BODY PANELS/EXHAUST SYSTEM BODY PANEL LOCATIONS --- AIR DUCT COVERS - SERVICE INFORMATION UPPER COW! 3-9 ‘TROUBLESHOOTING --.. FUEL TANK COVER: SEAT: FRONT FENDER.-. PASSENGER SEAT-. REAR FENDER - 3-16 SIDE COVERS... SEAT RAIL. 3-18 REAR COWL-».-- MUFFLER - 3-20 LOWER COWLS.....- EXHAUST PIPE 3-24 MIDDLE COWLS -FRAME/BODY PANELS/EXHAUST SYSTEM BODY PANEL LOCATIONS WINDSCREEN FUEL TANK COVER PASSENGER SEAT UPPER COWL FRONT FENDER REAR FENDER REAR COWL 2 IDE COVER LOWER COWL MIDDLE COWL AIR DUCT JOINT ‘AIR DUCT COVER ainouct RESONATOR CHAMBER 3-2FRAME/BODY PANELS/EXHAUST SYSTEM SERVICE INFORMATION GENERAL + This section covers removal and installation of the body panels, exhaust system and seat rail + Serious burns may result if the exhaust system is not allowed to cool before components are removed or serviced, + Always replace the exhaust pipe gaskets with a now one after removing the exhaust pipe from the engine + When installing the exhaust system, loosely install all of the exhaust pipe fasteners. Always tighten the exhaust clamps first, then tighten the mounting fasteners. + Always inspect the exhaust system far leaks after installation. TORQUE VALUES Lower cow/-to-middle cowl pan screw 115 Nem (0.18 kgfim, 1.1 Ibf-A) Middle cow!-to-upper cow! pan screw 115 Nem (0.15 kgf-m, 1.1 Ib) Windscreen setting screw 0.5 Nem (0.08 kaf-m, 0.4 lof ft) Front brake hose clamp bolt 12 Nem {1.2 kafem, 9 Ib6t) Front brake hose 3-way joint bolt 12. Nem (1.2 kgt-m, 8 lof) Rear brake reservoir mounting bolt 12.Nem (22 kgfem, 9 lb-ft} Seat rail upper mounting flange nut 54 N.m (5.5 kgfim, 40 Ibf-t) Seat rail lower mounting flange bolt 44 Nem (4.5 kgm, 33 Ibf-t) Seat rail brace socket bolt 26 Nim (2.7 kgfim, 20 Ibt-) Seat rail essembly flange nut 30 Nem (3.1 kgfsm, 22 Ibf-t) Exhaust pipe joint flange nut 42. Nem (1.2 kgt-m, 9 lot) Muffler band flange bolt 23 Num (2.3 kgm, 17 Ibttt) Passenger footpeg bracket socket bolt 26 N.m (2.7 kgf, 20 Ibfft) 2 sensor {California type only) 25 Nom (2.6 kgf-m, 18 IDF) TROUBLESHOOTING Excessive exhaust noise + Broken exhaust system + Exhaust gas leak Poor performance + Deformed exhaust system + Exhaust gas leak + Clogged muffler 3-3FRAME/BODY PANELS/EXHAUST SYSTEM SEAT REMOVAL Remove the two seat mounting bolts and collars. Remove the seat by pulling it backward. INSTALLATION Install the seat hooks under the fuel tank rear bracket. Install the collars and seat mounting bolts. PASSENGER SEAT REMOVAL/INSTALLATION Unhook the passenger seat lock using the ignition ke Remove the patsengor soot by pulling it forward Install the passenger seat in the reverse order of removal SIDE COVERS Be caret not REMOVAL/INSTALLATION Remove the seat (page 3-2). Remove the side cover by carefully releasing the omage tab and bosses from the grommets and slide it forward, 100%. Install the side cover in the reverse order of removal, COLLAR GROMMETS: 3-4FRAME/BODY PANELS/EXHAUST SYSTEM REAR COWL REMOVAL Remove the following: Se = Seat (page 3-4) [~ us = Passenger Seat (page 3-4) REAR COWL ~ Side covers (page 3-4) Remove the four bolts, Disconnect the stoprtail light connector. Carefully pull both out sides of the rear cowl, then remove it backward, Re ‘STOP/TAIL LIGHT CONNECTOR INSTALLATION PASSENGER SEAT SEAT a REAR COWL SIDE COVER 3-5FRAME/BODY PANELS/EXHAUST SYSTEM ‘ake sure that the Install the rear cow! over the seat rail being careful | — not to damage the wire harness. Connect the stop/tail light connector. Install the removed parts in the reverse order of removal, STOP/TAIL LIGHT CONNECTOR LOWER COWLS (ui not 0 REMOVAL/INSTALLATION °° Remove the five trim clips and bolt from the bottom [— of the lower cowls. Remove the lower cowi-to-middle cowl pan screws, ‘anGove: Remove the lower cowl mounting bolts and then LOWER cowL remove the lower cowls by sliding them backward, Install the lower cow! by aligning the tabs of the lower cow! with the grooves of the middle cowl. Install and tighten the lower cowl-to-middle cow! | pan screws to the specified torque. TORQUE: 1.5 Nem (0.15 kgfim, 1.1 Ibtt) Install the lower cowl mounting bolts Install the five trim clips and bolt from the bottom of the lowor cowis. TAY Noo ott Tha 3-6FRAME/BODY PANELS/EXHAUST SYSTEM ‘ype Remove the seven trim clips and bolt from the bot ‘tom af the lower cowis. Remove the lower cavl-to-middle cow pan screws. Remove the lower cowl mounting bolts and then remove the lower cowls by sliding them backward. | Install the lower cowl by aligning the tabs of the | lower cow! with the grooves of the middle cow. Install and tighten the lower cowl-to-middle cow! pan screws to the specified torque ‘TORQUE: 1.5 N-m (0.15 kgf-m, 1.1 Ibf-ft), | LOWER COWL Install the lower cow! mounting bolts. Install the seven trim clips and bolt from the bottom of the lower cowls. MOUNTING BOLT PAN SCREW. BoiT TAB TRIM CLIP MIDDLE COWLS: REMOVAL Remove the lower cowls (page 26). Remove the middle cowl-to-upper cowl pan serews | and trim clip, Unlock the lock bolt by turning it counterclockwise ‘and remove the middle cowl.FRAME/BODY PANELS/EXHAUST SYSTEM INSTALLATION Except California type: RIGHT MIDDLE COWL 15 Nem 10.15 kgm, 1.1 Ib) LEFT MIDDLE COWL MOUNTING BOLT RIGHT LOWER COWL ! TRIM CLP 1.8 Nem (0.15 kgfim, 1.1 Ibe) LEFT LOVER COWL California type: RIGHT MIDDLE COWL 115 Nem (0.15 kaf-m, 1.1 bff) LEFT MIDDLE CowL RIGHT LOWER COWL ! / TRIM cup 15 Nem (0.18 kgm, 1.1 Ib EAD SBBT LOWEN COM.FRAME/BODY PANELS/EXHAUST SYSTEM Install the middle cow! and lock the lock bolt by turning it clockwise. Tighten the upper cowl-to-middle cowl pan screws: to the specified torque. ‘TORQUE: 1.5 Nim (0.15 kgt-m, 1.1 IbF-t) Install the trim clip. Install the lower cowls (page 3-6). AIR DUCT COVERS Be carefut otto damage the tats ‘20 grooves REMOVAL/INSTALLATION Remove the upper cowl-to-middle cow! pan screw [ {and the two trim clips. Release the groove of the air duet cover from the pin of the upper cowl and unhook the tabs of the uct cover from the fuel tank cover, then ramove the air duct cover. Install the air duct cover of the reverse order of removal. UPPER COWL windscreen in oder to remove the ‘ypper cow REMOVAL Remove the following: = Lower cowls (page 3-6) — Middle cowis (page 3-7) = Air duct covers (page 3-9) Remove the screws, plastic and rubber washers, then remove the windscreen. Remove the two trim clips and resonator chambers from the radiator. DUCT COVER PIN TRIM CLIP eo Lock BOLT PAN SCREW. RUBBER WASHER PLASTIC WASHER TRIM CLIPFRAME/BODY PANELS/EXHAUST SYSTEM Remove the rearview mirror mounting socket bolts and rearview mirrors. Disconnect the fro! bination meter mul Release the uppar cowl off the rearview mirror bolt hole studs and bosses of the upper cowl from the meter stay grommets, then remove the upper cow! assembly. sub-harness connectors, com: connector, REARVIEW MIROR SOCKET BOLTS UPPER COWL ASSEMBLY MULTI-CONNECTOR ‘SUB-HARNESS CONNECTORS 3-10FRAME/BODY PANELS/EXHAUST SYSTEM Remove the relays and rubber from the left air duct joint. Remove the air duct joints from the air cleaner housing. DISASSEMBLY/ASSEMBLY Remove the trim clips, air ducts and set plate from [~ the upper cow. Remove the resonator chamber from the alr duct. RIGHT AIR DUCT JOINT RELAYS RUBBER LEFT AIR DUCT JOINT ~ rine cup Al DUCTFRAME/BODY PANELS/EXHAUST SYSTEM Ree beet Pos Con Screws FRONT am our OVER yy Remove the screws and front air duct covers from the upper cowl. Remove the nuts and setting plates, then remove | the front turn signal units. TURN SIGNAL UNIT [ ‘Assembly is in the reverse order of disassembly. INSTALLATION sn {0.08 kati, 0.4 Ib ‘Ginpsoneen 0.5 Nem (0.05 kat-m, 0.4 IbF ft) REARVIEW MIRROR RESONATOR CHAMBER FRONT AIR DUCT COVERFRAME/BODY PANELS/EXHAUST SYSTEM Install the air duct joints into the air cleaner hous- ing, Install the rubber and relays onto the left air duct joint. Connect the front sub-harness connectors, combi- nation meter mult-conneetor. Install the upper cowl, aligning the basses with the grommets on the meter stay. RIGHT AIR DUCT JOINT RELAYS LEFT AIR DUCT JOINT | UPPER COWL ASSEMBLY | GROMMETS MULTI-CONNECTOR BOSSES ‘SUB-HARNESS CONNECTORS 3-13FRAME/BODY PANELS/EXHAUST SYSTEM. Align the rearview mirror bolt hole studs of uppar ‘cow! with the rearview mirror stay. Install the rearview mirror and tighten the socket bolts securely. SOCKET BOLTS REARVIEW MIROR Install the trim clips and resonator chambers onto, the radiator. Install the windscreon, then install the rubber and plastic washers and screws. ‘Tighten the screws to the specified torque. TORQUE: 0.5 Nim (0.08 kgf-m, 0.4 Ibf-ft) Install the following: = Air duct covers (page 3-9) = Middle cawis (page 3-7) = Lower cowls (page 3-6) __ RUBBER WasHER PLASTIC WASHER | 3-14FRAME/BODY PANELS/EXHAUST SYSTEM FUEL TANK COVER REMOVAL/INSTALLATION Remove the following: ~ Seat (page 3-8) ~ Side covers (page 3-4) SOCKET BOLT — Air duct covers (page 3-9) Remove the six socket bolts, washers and fuel tank | FUEL TANK COVER Install the fuel tank cover in the reverse order of removal. WASHER FRONT FENDER REMOVAL/INSTALLATION Remove the fork protectors (page 14-19} Remove the front brake hose 3-way joint bolt, hose clamp bolt and reflectors. HOSE CLAMP BOLT 3-15FRAME/BODY PANELS/EXHAUST SYSTEM. Remove the socket bolts and front fender from the forks. Nore: Pull the front fender up, above the sliders and then pull it for ward between the fark tubes, FRONT FENDER Install the front fender in the reverse order of removal, TORQUE: Front brake hose clamp bolt: 12 Nem (1.2 kgm, 9 IDE) Front brake hose 3-way joint bolt: 12 Nim (12 kgf-m, 9 If ft) Install the fork protectors (page 14-26). REAR FENDER REMOVAL | CAT) Remove the following: ~ Rear cowl (page 35) ~ Battery (page 17-5) Muffler (page 3-20) Lift and support the fuel tank (page 6-61). Remove the bolts and passenger seat joint, Remove the four bolts and seat lack cable stay. Disconnect the seat lock cable from the cable stay. SEAT LOCK CABLE 3-16FRAME/BODY PANELS/EXHAUST SYSTEM Remove the bolts/nuts and seat bracket, NOTE: After removing the seat bracket, be careful the angle of the fuel tank ple SEAT BRACKET, Remove the screw from the rear fender. Remove the trim clip, Unhook the rear fender A from the seat rail brace, then remove the rear fender A by pulling up and REAR FENDER A. back. TRIM CLIP; yi Remove the seat lock cable guide. | / caBLe GUIDE 3-17FRAME/BODY PANELS/EXHAUST SYSTEM INSTALLATION Instellation isin the reverse order of removal X REAR FENDER A ‘SEAT BRACKET CABLE GUIDE SEAT RAIL REMOVAL Remove the following: ‘Muffler ipage 3-20) = ear fender (page 3-16) = Fuel tank (page 6-61) = Battery tay (page 17-7) Loosen the four seat rail brace socket bolts Remove the seat rail upper mounting beltsinuts and lower mounting bolts/collars/nuts, then remove the seat rail 3-18FRAME/BODY PANELS/EXHAUST SYSTEM. DISASSEMBLY/ASSEMBLY Remove the four seat rail brace socket bolts and. seat rail brace, ‘SOCKET BOLTS Remove the seat rail assembly flange boltsinuts and separate the seat rails. elie SEAT RAIL Replace the seat Assemble the seat rail by installing the seat rail rallasan assembly, assembly flange boltinut and seat rail brace socket bolts temporaiy. INSTALLATION SEAT RAILS SEAT RAIL BRACE 44 Nom (6.5 kgf.m, 33 Ibf tt) 54Num {6.5 kaf-m, 40 bith 30 Nim (3.1 kgtim, 22 loth) REFLECTOR 26 Nem (2.7 kgf.mn, 20 IbE-) 26 Nim (2.7 kgfim, 20 IbEI) PASSENGER FOOTPEG BRACKET 3-19FRAME/BODY PANELS/EXHAUST SYSTEM. Install the seat rail to the frame. Install the upper mounting boltsinuts and lower ‘mounting bolts/eollars/nuts, Tighten the bolts and nuts to the specified torque, TORQUE: Upper mounting flange nut: 54 Nem (5.5 kgfom, 40 It) Lower mounting flange bolt: 44 Nim [455 kaf-m, 36 Ibt-t) Tighten the four seat rail brace socket bolts and seat seat rail assembly flange nuts to the specified By torque. TORQUE: Seat rail brace socket bolt: 26 Nem (2.7 kgf-m, 20 Ibt-Fe Seat rail assembly flange nut: 30 Nem (3.1 kaf-m, 22 Ibtft) Install the Following: ~ Battery tray (page 17-7) = Fuel tank (page 6-61) = Rear fender ipage 3-18) Muffler (page 3-22) MUFFLER REMOVAL Famove the following: — Lower eowls (page 3-6) = Rear cow! (page 3-5) Remove the two bolts, washer and muffler quard Remove the bolt and rear brake reservoir tank. RESERVOIR TANK BOLT. 3-20FRAME/BODY PANELS/EXHAUST SYSTEM Remove the socket bolts and right footpeg bracket. CSarormatype shown Play RENT TOOTPESI BRACKET Disconnect the turn signal light and license light connectors. Remove the four bolts and rear fendor 8. why PELCONNECTORS ppp REAR FENDER B J cosen the muffler ban! ange bots = — one ent sang Calitomia ype stone Jal fo Remove the muffler mounting holt and washer. Remove the muffler clamp bolt and nut Remove the muffler fram the exhaust pipe. MUFFLER MOUNTING BOLT>W. /ASHER & 3-21FRAME/BODY PANELS/EXHAUST SYSTEM INSTALLATION REAR FENDER 8 on 12.Nemn (1.2 kgm, 9 Ib.) —e MUFFLER Install a new gasket onto the exhaust pipe, Install the mufier to the exhaust pipe. Tighten the muffler mounting boltwasher and mut fler clamp boli. CLAMP BOLT/NUT 1 MUFFLER ER. 3-22FRAME/BODY PANELS/EXHAUST SYSTEM Tgton the muffler band flange bos tothe spect colton gestae) TORQUE: 23 N-m (2.3 kgf-m, 17 bff) Install the rear fender B and four bolts. Connect the tum signal light and license light cor neetors Instsll the right footpeg bracket and tighten the WEaqomisnosaewn | socket bolts to the specified torque. Se RIGHT FOOTPEG| BRACKET TORQUE: 37 Nem (3.8 kgf-m, 28 IbF-Ft} Install the rear brake reservoir tank and tighten the bolt to the specified torave. TORQUE: 12 Nem (1.2 kgt-m, 9 bff) ae RESERVOIR TANK BOLT 3-23FRAME/BODY PANELS/EXHAUST SYSTEM Install the muffler guard, washer and two bolts Install the following Rear cow! (page 3-5) = Lower cowls [page 3-8) EXHAUST PIPE REMOVAL Remove the following: = Lower cowls (page 3-6) = Middle cowis (page 3-7) Cattomia spe only: Disconnect the Oe sensor 4P {Natural) connectors. Loosen the muffler band flange bolts. 3-24FRAME/BODY PANELS/EXHAUST SYSTEM Remove the radiator lower mounting boltinut, then move the radiator forward. Remove the exhaust pipe joint nuts, Remove the boltsinuttwashers and exhaust pipe. Remove the exhaust pipe gaskets, 3-25FRAME/BODY PANELS/EXHAUST SYSTEM INSTALLATION Except California type: D oaseer EXHAUST PIPE a California type: Com SX ak G2 kat, embry > SENSOR, 25 Nem [2.6 kgf-m, 19 IbFtth EXHAUST PIPE 3-26FRAME/BODY PANELS/EXHAUST SYSTEM 12 Install a now exhaust pipe gaskets onto the exhaust 3 c Ports of the cylinder head. Install a new gasket onto the exhaust pipe and install the exhaust pipe into the muffler. Temporarily install the exhaust pine joint nuts, and mounting bolts/nut/washers. 1. Tighten the oxhaust pipe joint nuts to the speci fied torque, TORQUE: 12 Nom (1.2 kgm, 9 Ibf-f) 3-27FRAME/BODY PANELS/EXHAUST SYSTEM. 2, Tighten the exhaust pipe mounting bolts/nut - securely. BOLT/NUT. 3. Tighten the muffler band flange bolts to the specified torque. TORQUE: 23 Nom (2.3 kgf-m, 17 Ibf-ft) Install the radiator lower mounting boltinut and tighten the nut Route the O2 sensor wire into the frame, Connect the Or sensor 4P (Natural) connectors. Install the following: ~ Upper cows! (page 3-12) Middle cowls (page 3-8) ~ Lower cowis (page 3-6) 3-28FRAME/BODY PANELS/EXHAUST SYSTEM. — | 4P (NATURAL) CONNECTOR4. MAINTENANCE SERVICE INFORMATION - MAINTENANCE SCHEDULE FUEL LINE. THROTTLE OPERATION. AIR CLEANER. ‘SPARK PLUG ---- VALVE CLEARANCE an ENGINE OIL/OIL FILTER -- 415 ENGINE IDLE SPEED a8 RADIATOR COOLANT-» 418 COOLING SYSTEM. 419 SECONDARY AIR SUPPLY SYSTEM..-- 4-19 EVAPORATIVE EMISSION CONTROL SYSTEM (CALIFORNIA TYPE ONLY) 4-20 DRIVE CHAIN. 421 BRAKE FLUID oh 25 BRAKE PAD WEAR... 426 BRAKE SYSTEM. seve 26 BRAKE LIGHT SWITCH. 427 HEADLIGHT AIM 4-28 CLUTCH SYSTEM... 28 SIDE STAND + 29 SUSPENSION -. 4-29 NUTS, BOLTS, FASTENERS.----0-vresnued-33 WHEELS/TIRES STEERING HEAD BEARINGS -MAINTENANCE SERVICE INFORMATION GENERAL + Place the motoreycle on a level graund before starting any work. + The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and may lead to death, Run the engine in an open area or with an exhaust evacuation system in and enclosed area, ‘SPECIFICATIONS Trem Throttle grip fea play “Spark plug Spark plug Gap) Valve MRSC 3 [0.80 — 0.90 mm (0.031 0.035 0.20 0.03 mm (0.008 + 0.001 in) dleerence - 0:28 = 0.03 mm 0.011 = 0.007 In - Engine oit After draining P25 iter 12.7 US Gt, 23 Imp atl J | cataaty [Panera titer diige ———|-25 herta't us dts oat ——= Recommended engine oi ie Honda GN¢ or HPs (without molybdenum adiivea © stroke oil U.S.A. & Canada) or Honda «stroke oil {Canada only}, or an equivalent motorayele oil | API service classification: SG oF higher excopt oils labeled as energy consering on the circular API service labol JASO 7:80 standard: MA _| Viscosity: SAE 1oW-40 1,300. 100 rpm idle speed ‘Drive chain Sizejiink | stack commended brake flu Cluteh lever tree play — Tire size Honda DOT 4 brake fd “10= 20 mn (38 ~ 19776 in] ‘ZR 17 MIC [5BW) i - 180/65 ZR 17 IC I7SW) Tire brand Bridgestone Front ITOT2F RAGIAL G 1 Dunlop — - ~ Michi — ~ Tire air baron | 250 kPa (2.50 kaffom®, 36 pall — pressure - 290 kPa (2.90 kaffem’, 42 psi) - Driver and 0.kPa (2.50 katiom®, 36 psi) passenger (2.90 kgffem?, 42 psi) [Minimo He W258 doth 15 mm (0.08in TORQUE VALUES Spark plug 16 Num (1.6 kgf, 12 IbFA) Timing hole eap 18 N.m (1.8 kgm, 13 bf) Apply grease to the threads, Cylinder head cover bolt 8.8 Nem (1.0 kgf-m, 7 lbs) Engine oil drain bolt 29 Nim @.0 kgf-m, 22 Ibf ft} Engine oil filter cartridge 26 N-m (2.7 kgf-m, 20 bff} Apply clean engine oll tothe O-ring Rear axle nut 113 Nem (11.5 kgm, 83 bff} Usnut Drive sprocket special bolt 54 Nim (5.5 kghm, 40 IbF-t) Final driven sprocket nut GEN (6S kafm, 47 Ibe) Usnut Rear master cylinder push rod joint nut 18 N-m (1.8 kgf-m, 13 Ibf-t) 4-2MAINTENANCE TOOLS Oil fter wranch Drive chain toolset O7HAA-PJ70101 | ofA Toto 4-3MAINTENANCE MAINTENANCE SCHEDULE Perform the Pre-ride inspection in the Owner's Manual at each scheduled maintenance period. l:Inspect and Clean, Adjust, Lubricate or Replace if necessary. C: Clean. R: Replece. A: Adjust. L: Lubricate. The following items require some mechanical knowledge. Certain items (particularly those marked * and **} may require more technical information and tools. Consult their authorized Honde dealer FREQUENCY WHICHEVER |) REFER TO COMES FIRST |? ODOMETER READING (NOTE 1) PAGE XTo00mi[O6 | 4 | B | 12 | 16 | x xT000 Km 3 19.2|256|320 — —T 1 T T a5 = THROTTLE OPERATION oT i 1 Tp ss = TAIR CLEANER = 7 Tp #6 ‘SPARK PLUG _ 7 a7 =e = EVERY 25,780 km (16,000 mi) | EVERY 51,500 km (32,000 mi}, = VALVE CLEARANCE ENGINE OIL. ENGINE OIL FILTER I ENGINE IDLE SPEED I RADIATOR COOLANT ~_NOTES = [COOLING SYSTEM — = SECONDARY AIR SUPPLY SYSTEM | * EVAPORATIVE EMISSION CONTROL | —NOTEZ | SYSTEM DRIVE CHAIN — BRAKE FLUID RTT TPR as BRAKE PAD WEAR T 1) #96 BRAKE SYSTEM = if #8 = BRAKE LIGHT SWITCH i427 (CETREADLIGHT aim 1 #78 CLUTCH SYSTEM - ee] SIDE STAND 28 + /SUSPENSION T £28 = INUTS, BOLTS, FASTENERS 233 * WHEELS/TIRES 433 == STEERING HEAD BEARINGS aa 36 Should be serviced by an authorized Honda dealer, unless the owner has proper tools and service data and is mechanically qualified ** In the interest of safety, we recommended those items be serviced only by an authorized Honda dealer Notes: ‘Athigher odometer reading, repeat at the frequency interval established here. 2. Service more frequency if the motorcycle is ridden in unusually wet or dusty areas. 3. Replace every 2 years, or at indicated odometer interval, whichever comes first. Replacement requires mechenicel skill 4, California type only. 4-4MAINTENANCE FUEL LINE Route tho wires ang hamess prop ey (page 1221 Be age the hamess pada Remove the fuel tank cover page 3-15). Remove the fuel tank mounting bolts, Lift the front end of fuel tank and release the fuel hose from the clamp. Support the fuel tank using @ suitable support as shown, Check the fuel lines for deterioration, damage or Ieakage. Replace the fuel line if necessary, Check the fuel pipes and fuel line joint for damage or leakage. Replace them if necessary. Check the fuel pump mounting area for leakage. Replace the fuel pump packing if necessary. Check the upper/lower injectors for damage or leak- age. Replace them if necessary. Remove a suitable support, then lower the fuel tank Install and tighten the fuel tank mounting bolts securely. Install the fuel tank cover (page 3-15}, a5MAINTENANCE THROTTLE OPERATION Check for smooth throttle grip full opening and automatic full closing in all steering positions, Check the throttle cables and replace them if they. are deteriorated, kinked or damaged. Lubricate the throttle cables, if throttle operation is not smooth, Measure the free play at the throttle grip flange. FREE PLAY: 2-4 mm (1/16~1/8 in} Throttle grip free play can be adjusted at either end of the throttle cable. Minor adjustment is made with the upper adjuster. ‘Adjust the free play by loosening the lock nut and turning the adjuster. Major adjustment is made with the lower adjuster. Romove the air cleaner housing (page 664) Adjust the free play by loosening the lock nut and turning the adjuster. ‘After adjustment, tighten the lock nut securely. Recheck the throttle operstion, Replace any damaged parts, if necessary. AIR CLEANER Remove the following: ~ Fuel tank cover (page 3-15) = ECM (page 6-94) Remove the air cleaner housing cover sorews.MAINTENANCE IAT SENSOR CONNECTOR: ull up the air cleaner housing cover and disconnect the IAT sensor connector, Remove the three screws, Remove and discard the air cleaner element in accordance with the maintenance schedule (page 4- 4). Also replace the air cleaner element any time it is excessively dirty or damage. Install the removed parts removal n the reverse order of SPARK PLUG REMOVAL Be cavolutnet to Remove the following: fin — Lower cowls (page 3-6) = Middie cowl (page 3-7) Remove the two trim clips and resonator chambers from the radiator. Remove the radiator lower mounting bolt, nut and washer. BOLTINUTWASHERMAINTENANCE Remove the wire band, WIRE BAND. Remove tho radiator upper mounting bolt and washer and horn mounting stay. Release the radiator grommet fram the frame boss: by moving the radiator to the left sido, then move J RADIATOR the radiator downward. ” roam Disconnect the direct ignition coil connectors, (Gban sround the Remove the direct ignition coils from the spark plug boses plugs. wth compressed rg. abe sere thot no dobre en Remove the spark plug using 8 equipped spark plug ‘wrench or an equivalent. Inspect or replace as described in the maintenance schedule (page 4-4),MAINTENANCE This metoreyl Spt log quypod wth id nter elo trod. aptoce the tammared. Always use spect fied spark plugs 09 ve menoreyele Te prevent domag: ing the nau con fer electrode, use a te type footer gauge to check the ‘snark plas om Do not ads the the gap is out of specication, replace witha new Bo not over tighren the plug INSPECTION Check the following and replace if necessary [rec- ‘ommended spark plug: page 4-2) Insulator for damage + Electrodes for wear + Burning condition, coloration If the electrodes are contaminated with accumu- lated objects or dirt, replace the spark plug. Replace the plug if the center electrode is rounded ‘as shown in the illustration. SPECIFIED SPARK PLUG: IMR9C-SHE [NGK} Check the gap between the center and side elec: trodes with a wire type feeler gauge. Make sure that the 6 1.0 mm (0.04 in} plug gauge does not insert between the gap. It the gauge can be inserted into the gap, replace the plug with anew one, Reinstall the spark plug in the cylinder head and hand tighten, then torque to specification, TORQUE: 16 Nem (1.6 kgf-m, 12 lb-ft fusing the new plug, install as follows: Install and hand tighten the new spark plug, then tighten it about 1/2 turn after the sealing washer contacts the seat of the plug hole. INSULATOR WIRE TYPE FEELER GAUGE, CENTER ELECTRODE SIDE ELECTRODE ROUNDED ELECTRODE ‘SPARK PLUG WRENCH,MAINTENANCE Install the direct ignition coils, Connect the direct ignition coil connectors. DIRECT IGNITION COILS. Install the radistor by aligning the grommet and frame boss. ic Install the horn mounting stay, wesher and radiator upper mounting bolt. Install the wire band. Install the radiator lawer mounting bolt, washer and put Tighten the nut securely. BOLT/NUTWWASHER A.1fMAINTENANCE Trstall the trim clips and resonator chambers onto the radian ial TRIM CLP Install the following: ~ Middle cowls jpage 3-8) = Lower cowls {page 36) VALVE CLEARANCE INSPECTION Remove the cylinder head covar jpage 9-6), Remove the timing hole eap and O-ring. Turn the crankshaft clockwise, align the "T* mark on the ignition pulse generator rotor with the index ‘mark on the right crankcase cover.MAINTENANCE The timing marks (IN" and "EX") on the cam sprockets must be flush with the eylinder head sur- face and facing outward as shown, {f the timing marks on the cam sprockets are facing Inward, turn the crankshaft clockwise one full turn (360°) and realign the timing marks with the cylin der head surface so they are facing outward. Insert the feeler gauge between the valve lifter an SE = Com tobe, eT Baus? Between the valve Iter and A Tae VALVES Aoconthe low Check the vaive clearance forthe No.1 and No.3 cyl: NOt INTAKE VALVES snce foreaen ave inder intake valves using a feeler gauge oecerenee VALVE CLEARANCE: justnont IN: 0.20-+ 0.03 mm (0,008 + 0.001 in) quired Turn the crankshaft clockwise 1/2 turn (180%), align the index line on the ignition pulse generator rotor s0 that itis facing up as shown. fcord the clear Cheek the valve clearance for the No.2 and No cy ance for ea0n ake Inder exhaust valves using a feoler gauge. shiv seecicns? VALVE CLEARANCE: Suusimens = EX: 0.28 £ 0.08 mm (0.011 + 0.001 in) ‘oauted NO.4 EXHAUST VALVES NO.2 EXHAUST VALVES 4-12MAINTENANCE “Turn the crankshaft clockwise 1/2 turn (180°), align the *T* mark on the ignition pulse generator rotor with the index mark on the right crankease cover. Record te clea Check the valve clearance for the No.2 and No.4 cyl- ance for each vatve Inder intake valves using feeler gauge. {or reference m shin scieotoniy VALVE CLEARANCE: ‘astment ie IN: 0.20-4 0.03 mm (0.008-+ 0.001 in) requiced Turn the crankshaft clockwise 1/2 tum (180°), align’ the index line on the ignition pulse generator rotor 0 that its facing up as shown, Fecors sve clear Check the valve clearance for the No.1 and No.3 cyl ance foreach valve inder exhaust valves using a feeler gauge. for relerence shim seiecton# VALVE CLEARANCE: chustment is EX: 0.28 + 0.03 mm (0.011 + 0.001 requires, NO.3 EXHAUST VALVES NO.1 EXHAUST VALVES. 13MAINTENANCE ADJUSTMENT Remove the camshafts (page 9-8), Remove the valve lifters and shims, + Shim may stick to the inside of the vaive lifter Do not allow the shims to fall into the crankcase. + Mark all valve lifters and shims to ensure correct reassembly in their ariginal locations. + The valve lifter can be easily removed with @ valve lapping tool or magnet. + The shims can be easily removed with a twee- if zers or magnet. Clean the valve shim contact area in the valve lifter with compressed air. Measure the shim thickness and record it. Calculate the new shim thickness using the equa- SHIM tion below. A=(8-C)+D A: New shim thickness B: Recorded valve clearance C: Specified valve clearance D: Old shim thickness + Make sure of the correct shim thickness by mes: suring the shim by micrometer. + Reface the valve seat if carbon deposit result in a calculated dimension of over 2.900 mm. QGOO0O 189mm 825mm 185mm 1.875 mm 4-14MAINTENANCE Install shims Install the nawly selected shim on the valve spring and valve liters in retainer. ther orgiai'ocs- Apply molybdenum disulfide oll to the valve lifters. ‘ions Install the valve lifters into the valve lifter holes, Install the camshafts (page 9-26). Rotate the camshafts by rotating the crankshaft clockwise cevaral times, Rochock the valve clearance. Check thot the O- Apply grease the timing hole cap threads, sing isn good cor Tightan the timing hole eap to the specified torque. sen eee? TORQUE: 18 Nem (1.8 kgf-m, 13 Ib ft) Install the removed parts in the reverse order of removal. ENGINE OIL/OIL FILTER OIL LEVEL INSPECTION Start the engine and lot it idle for 3-5 minutes. Stop the engine and walt 2-3 minutes, Hold the motorcycle in an upright position. ‘Check the ol level through the inspection window. IF the level is below the lower level line, remove the oil filer cap and fill he crankease with the recarn- mended oil up to the upper level line as following procedures. 4-15MAINTENANCE Remove the ail filer cap, OILFILLER CAP, Fill the recommended engine oll up to the upper level line. Other wscosives RECOMMENDED ENGINE OIL: town the chart Pro Honda GNA or HP4 (without molybdenum ‘may be used when additives) the average tery 4-stroke oil (U.S.A, & Canada] or Honda 4-stroke perature your oil (Canada only), oF an equivalent motorcycle oil ‘ding areas wribio API service classification: SG or higher except oils the ntcared emge. labeled as energy consering on the circular APL service label JASO T 903 standard: MA Viscosity: SAE 10W—40 Ean ee | ESE Lal Reinstall the oil filler cap. ENGINE OIL & FILTER CHANGE Change the engine Start the engine and let it idle for 3-5 minutes. ‘7 wth ahe warm Stop the engine and wait 2 ~ 3 minute and the motoieyofe Hold the motoreycle in an upright position. ‘1 level groune 19 ‘assure complete airing. Remove the oil filler cap, Remove the lower cowls (page 2-6), Remove the drain bolt and sealing washer, drain the oll completely, OIL DRAIN BOLT/SEALING WASHER 4-16MAINTENANCE Remove the radiator reserve tank (page 7-17). Remove and discard the oil filter cartridge using the special tool. O7HAA-PJ70101 oF O7HAA-PS70100 (USA. only) Check that the sealing washer on the drain bolt is in. =r" ‘good condition, and replace if necessary. : Install and tighten the drain bolt. TORQUE: 23 N.m (3.0 kgt-m, 22 Ibt-ft) j Apply clean engine oil to the new oil filter O-ring, Install the new oil iter and tighten it to the specified torque. TOOL: Oil filter wrench O7HAA-PJ7O101 TORQUE: 26 Nem (2.7 kgfim, 20 tb ft) Install the radiator reserve tank (page 7-12), 4-17MAINTENANCE Fill the crankcase with recommended engine oil OILFILLER CAP. ‘lL capacity: 2.6 liter (2.7 US qt, 2.3 Imp at) after draining 2.9iter (3.1 US at, 2.6 Imp qt) after oll filter change Check that the O-ring on the oil filler cap is in good condition, and replace it if necessary. Install the oil filer cap, Start the engine and fot it idle for 3-5 minutes, Stop the engine and wait 2-3 minutes and recheck the oil level Make sure there are no oil leaks. Install the lower cowls (page 3-6. ENGINE IDLE SPEED + Inspect and adjust the idle speed after all other Be engine maintenance items have been performed and are within specification. + The engine must be warm for accurate idle speed inspection and adjustment. Warm the engine for about 10 minutes. THROTTLE STOP SCREW the specified idle speed, IDLE SPEED: 1,300: 100 pm RADIATOR COOLANT Check the coolant level of the reserve tank with the engine running at normal operating temperature, The level should be between the “UPPER™ and “LOWER” level lines. I necessary, add recommended coolant. RECOMMENDED ANTIFREEZE: Pro Honda HP Coolant or an equivalent high qu ity ethylene glycol antifreeze containing corrosion protection in Remove the following: = Lower cowls [page 3-6) = Middle cowis (page 3-7) Remove the reserve tank filler cap and fill to the “UPPER' lovel lino with 1:1 mixture of distilled water and antifreeze. Reinstall the filer cap. Install the following: = Middle cowls {page 3-8) ~ Lower cowls (page 3-6) 4-18MAINTENANCE COOLING SYSTEM Romove the following: ~ Lower cowis (page 3-6) = Middle cowis (page 3-7) Check the radiator air passages for clogging or dam: age. Straighten bent fins, and remove insects, mud or ‘other obstructions with compressed air or low water pressure. Roplace the radiator if the air flow is restricted over more than 20% of the radiating surface, | Inspect the radiator hoses for cracks or deteriora tion, and replaco thom i necessary. Check the tightness of al hose clamps and fasten- SECONDARY AIR SUPPLY SYSTEM “3 show any signs of heat ciamoge, nspect the PAIR raed + This model is equipped builtin secondary air (— supply system. The pulse secondary ait supply ] system is located on the cylinder head cover, Pall REEDINALVE + The secondary air supply system introduces fil- tered air into exhaust gases in the exhaust port. The secondary air is drawn into the exhaust port | whenever there is negative pressure pulse in the exhaust system. This charged secondary air pro- motes burning of the unburned exhaust gases and changes a considerable amount of hydrocar- bons and carbon monoxide into relatively harn less carbon dioxide and water. Remove the air cleaner housing (page 6-64) Check the PAIR (pulse secondary air injection) host between the PAIR control solenoid valve and eylin- | der head cover for deterioration, damage ar loose | connections. Make sure that the hoses are not cracked. EXHAUST PORT 4.19MAINTENANCE Check the air suction hose between the air cleaner housing and PAIR control solenoid valve for deterio ration, damage or loose connections. Make sure that the hoses are not kinked, pinched or cracked. EVAPORATIVE EMISSION CONTROL SYSTEM (CALIFORNIA TYPE ONLY) Check the hoses between the fuel tank, EVAP canis- ter, EVAP purge control solenoid valve far deteriora tion, damage or loose connectors, Check the EVAP canister for cracks or other damage. Refer to the Vacuum Hose Routing Diagram Lebel {page 1-39} and Cable & Harness Houting (page 7 33] for hose connections, REMOVAL/INSTALLATION Disconnect the EVAP purge control solenoid valve hose and fuel tank air vent hose. Remove the four bolts and EVAP canister. Install the EVAP canister in the reverse order of removal. PAIR CONTROL VALVE ‘SOLENOID VALVE SOLENOID VALVE HOSE BOLTS Le AIR SUCTION HOSE EVAP CANISTER SOLENOID VALVE HOSE AIR VENT HOSE 4-20MAINTENANCE DRIVE CHAIN res running DRIVE CHAIN SLACK INSPECTION Turn the ignition switch OFF, place the motoreyele on its side stand and shift the transmission into neu: tral Check the slack in the drive chain lower run midway between the sprockets, CHAIN SLACK: 25 ~ 35 mm (1 ~ 1.9/8 in) NOTICE | Excessive chain slack, 50 mm (2.0 in) or more, may damage the frame. Lubrieste the drive chain with #80 - 90 gear oil or chain lubricant designed specifically for use with ting chains. Wipe off the excess oil or chain lub cant ADJUSTMENT Loosen the rear axle nut Turn both adjusting bolts until the correct drive chain slack is obtained. ‘Make sure the index marks on both adjusting plates are aligned with the end of the swingarm Tighten the rear axie nut to the specified torque TORQUE: 113 Nom (11.5 kgfm, 83 Ibf-ft) Recheck the driv Lubricate the drive chain with #80 ~ 90 gear oil or drive chain lubricant designed specifically for use with O-ring chains. Wipe off the excess ail or chain lubricant. Check the drive chain wear indicator label attached on the left drive chain adjusting plate. If the swingarm index mark reaches red zone of the indicator label, replace the drive chain with a new fone (page 4-23), win slack and free wheel rata- | | twotcarom Tape CLEANING AND LUBRICATION Cae te oan wih non lammable oF Nigh Mesh Tio FLAMMABLE OR HIGH Be sure the chain has dried completely before lubri- |FLASH POINT SOLVENT coving Insp the drive chain for possible darnage or wes. | Roplace any chain tat has damaged rolers, oss {fitting links, or otherwise appears unserviceable. | CLEAN Instaling new enain on badly worn sprockets will Cause the new chain tower quick. Inspect and repiace sprocket ae necosseryMAINTENANCE Lubricate the drive chain with #80 ~ 90 gear oil or Grive chain lubricant designed specifically for use | LUBRICATE with O-ring chains, Wipe off the excess oil or chain lubricant a" | #80-90 GeaRiL OR DRIVE CHAIN LUBRICANT SPROCKET INSPECTION Inspect the drive and driven sprocket teeth for wear (—— ‘or damage, replace if necessary Never use a new drive chain on worn sprockets. Both chain and sprockets must be in good condi tion, or the new replacement chain will wear rap. idly. Cheek the attaching bolts and nuts on the drive and driven sprockets. ifany are loose, torque them, TORQUE Drive sprocket special bolt:54 Nm (5.5 kg-m, 40 Ibf-ft) Final driven sprocket nut: 64.N-m (6.5 kgf-m, 47 Ibf-ft) 4-22When using the the manufacturer's Include the master fink when you oun the dive chain inks, REPLACEMENT This motorcycle uses a drive chain with a staked master link Loosen the drive chain (page 421) Assemble the special tool as shown, TooL: Drive chain tool set 07HMH-MR10103 oF O7HMH-MRI010C (US.A. only) Locate the crimped pin ends of the master link from the outside of the chain, and remove the link with, ‘tho drive chain tool set Tool: Drive chain tool set O7HMH-MR10103 or O7HMH-MRTO10C (US.A. only) Remove the drive chain, Remove the excess drive chain links from the new drive chain with the drive chain tool set, STANDARD LINKS: 112 LINKS REPLACEMENT CHAIN DID: DIDS2SHV-1202B RK: RKS25ROZI-120LJ-FZ MAINTENANCE DRIVE CHAIN TOOL SET MASTER LINK DRIVE CHAIN TOOL SETMAINTENANCE ~ Never reuse the old drive chain, master link, ‘master link plate and O-rings. | ‘Assemble the new master link, O-rings and plate. ‘Assemble and set the drive chain tool set. Toot: Drive chain too! set 07HMH-MR10103 or O7HMH-MR1010C. (U.S.A. only) Make sure that the master link pins are installed -————— 7 properly. MASTER LINK PINS Measure the master link pin length projected from the plate ¥ STANDARD LENGTH: DID: 1.15 ~ 1.55 mm (0.045 ~ 0.061 in} | RK: 12-14 mm (0.05 ~ 0.06 in) Stake the master link pins. Make sure that the pins are staked properly by mea- [— - SLIDE CALIPER suring the diameter of the staked area using a slide | caliper. DIAMETER OF THE STAKED AREA. DID: 5.50 - 5.80 mm (0.217- 0.228 in) RK: 5.30 - 5.70 mm (0.208 ~ 0.224 in) 4-24MAINTENANCE oF 09 us0d, ‘After staking, check the staked area of the master link for cracks. If there is any cracking, replace the master link, O- rings and plate. BRAKE FLUID NOTICE Spilled fluid can damage painted, plastic or rubber arts. Place a rag over these parts whenever the system is serviced, + Do not mix different types of fluid, as they are not compatible with ach other. + Do not allow foreign material to enter the system. when filling the reservoir. When the fluid level is low, chack the brake pads for wear (page 4-26). A low fluid level may be due to wear of the breke pads. If the brake pads are worn, the caliper piston is pushed out, and this accounts for a low reservoir level. I the brake pads are not worn and the fluid level is low, check entire system, for leaks (page 4-26). FRONT BRAKE Turn the handlebar so that the reservoir is level and check the front brake fluid level If the level is near the lower level line, check the brake pad wear (page 4-26) REAR BRAKE Remove the rear cowl (page 3-5), Place the motorcycle on a level surface, end support it an upright position, ‘Chock the rear brake fluid level If the level is near the lower level line, check the brake pad wear (page 4-26) LOWER LEVEL LINE fa No Goon 4-25MAINTENANCE BRAKE PAD WEAR FRONT BRAKE PADS Check the brake pads for we Replace the brake pads if bottom of wear limit groove ier pad is worn to the Rofer to page 16-9 for brake pad replacement. REAR BRAKE PADS Cheek the brake pads for Replace the brake pads if either pad is worn to the | bottom of wear limit gro: Refer to page 16-11 for brake pad replacement, BRAKE SYSTEM INSPECTION Firmly apply the brake lever or pedal, and check that no air has entered the system. Ifthe levar or pedal feels soft or spongy when oper: ated, bleed the air from the system (page 16-7). Inspect the brake hose and fittings for deterioration, and signs of leah Tighten any loose fittings. Replace hoses and fittings as required, Refer to page 16:6 for brake bleeding procedures. 4-26MAINTENANCE BRAKE LEVER ADJUSTMENT hie slow The distance between the top of the brake lever and the grip can be adjusted by turning the adjuster. numaro BRAKE PEDAL HEIGHT ADJUSTMENT Loosen the lock nut and turn the push rod until the correct pedal height is obtained, Prustnoe Make sure the push rod threads can be seen [— through the pedal joint hole. | After adjustment, tighten the lock nut to the speci fied torque. TORQUE: 18 N-m (1.8 kgf-m, 13 Ibf ft) BRAKE LIGHT SWITCH fronttvake Adjust the brake light switch so that the brake light Y=") comes on just prior to the brake actually being engaged. Ifthe light fails to come on, adjust the switch so that the light comes on at the proper time. Hold the switch body and turn the adjuster. Do not turn the switch body,MAINTENANCE HEADLIGHT AIM Place the motorcycle on a level surface, Ads the headight Adjust the headlight aim vertically by turning the simas specited by vertical bearn adjusting screw, focaliaws and gar A clockwise rotation moves the beam up and coun- lations. torelockwise rotation moves the beam down Adjust the headlight aim horizontally by turning the -————— | horizontal beam adjusting screw. eft Mescight: A clockwise rotation moves the beam toward the fight and counterclockwise rotation moves the beam toward the loft side of the rider. Headiigm A clockwise rotation moves the beam toward the left and counterclockwise rotation moves the beam toward the right side of the rider. Pot HORIZONTAL BEAM ADJUSTING SCREWS | CLUTCH SYSTEM Measure the clutch lover free play at the end of the clutch lever. 10-20 mm (3/8 — 13/16 in) FREE PLAY: 10-20 mm (3/8 - 13/16 in} The adaster may Minor adjustment is made using the upper adjuster at the clutch lever, csitorad too far Loosen the lock nut and turn the adiuster fara n° Wang adjuster fs threaded out near its limit and the vee encase correct free play cannot be “obtained, turn the "6°! adjuster all the way in and back out one turn, Tighten the lock nut while holding the adjuster and make @ major adjustment as described as follow. 4-28SIDE STAND SUSPENSION MAINTENANCE Major adjustment is performed at the clutch lifter Loosen the lock nut and turn the adjusting nut to adjust the free play. Tighten the lock nut while holding the adjusting nut. Hf proper free play cannot be obtained, or the clutch slips during test ride, disassemble and inspect the clutch (page 10-7). Support the motoreycle on a level surface. Check the side stand spring for damage or loss of tension, Check the side stand assembly for freedom of movement and lubricate the side stand pivot if nee: essary Check the side stand ignition cut-off system: =e ~ Sit astride the motoreycle and raise the side stand, ~ Start the engine with the transmission in neutr then shift the transmission into gear, with the clutch lever squeezed. Move the side stand full down. — The engine should stop as the side stand is low. red there is 3 problem with the system, check the side stand switch (page 20-22) FRONT SUSPENSION INSPECTION Chock the action of the forks by operating the front brakes and compressing the front suspension sev. eral times, Check the entire assembly for signs of leaks, dam. age or loose fasteners Replace damaged components which cannot be repaired, Tighten all nuts and bolts. Rofer to page 14-18 for fork service, 4-29MAINTENANCE Check for warn steering stem bearings by grabbing the front fork leg and attempting to move the front fork side to side. Replace the bearings if any looseness is noted. FRONT SUSPENSION ADJUSTMENT ‘SPRING PRE-LOAD ADJUSTER Spring pre-load can be adjusted by turning the adjuster. ‘TURN CLOCKWISE: Increase the spring preload ‘TURN COUNTERCLOCKWISE: Decrease the spring pre-load PRE-LOAD ADJUSTER ADJUSTABLE RANGE. 6-21 mm (0.2- 0.8 in) from top of fork bolt PRE-LOAD ADJUSTER STANDARD POSITION: 114 mm (0.6 in): 4th groove from top of fork bolt PRE-LOAD ADJUSTER, 4TH GROOVE COMPRESSION AND REBOUND DAMPING ADJUSTERS NOTICE Do not turn the adjusters more than the given posi- tions or the adjusters may be damaged. + Alldamping adjustments are referenced from the full hard position, + Be sure that the rebound and compression adjusters are firmly looated ina detent, end not between positions. both The compression and rebound damping can be me mem: adjusted by turning the adjusters, DIRECTION H: Increase the damping force DIRECTION S: Decrease the damping force COMPRESSION ADJUSTER 4-30MAINTENANCE Tum the compression adjuster clockwise until it stops {full hard position), then turn the adjuster counterclockwise. COMPRESSION ADJUSTER STANDARD POSITION: 2 turns out from full hard Turn the rebound adjuster clockwise until it stops (full hard position), then turn the adjuster counter clockwise. REBOUND ADJUSTER STANDARD POSITION: 2~1/2 tums out from full hard REAR SUSPENSION INSPECTION Support the motorcycle securely and raise the rear wheel off the ground, Check for worn swingarm bearings by grabbing the rear end of the swingarm and attempting to move the swingarm side to side, Replace the bearings if any are looseness is noted. Check the action of the shack absorber by com- Zz Pressing it several times. Check the entire shock absorber assembly for signs of leaks, damage or loose fasteners. Replace damaged components which cannot be repaired, Tighten all nuts and bolts. Refer to page 15-18 for shock absorber service. 4-31MAINTENANCE REAR SUSPENSION ADJUSTMENT COMPRESSION AND REBOUND DAMPING ADJUSTERS. NOTICE Do not turn the adjusters more than the given posi tions or the adjusters may be damaged. + All damping adjustments are referenced from the full hard position ‘The compression and rebound damping can be adjusted by turning the adjusters, DIRECTION H: Increase the damping force DIRECTION S: Decrease the damping force Turn the compression adjuster clockwise until it stops (full hard position|, then turn the adjuster counterclockwise. COMPRESSION ADJUSTER STANDARD POSITION: 7 clicks out from full hard Turn the rebound adjuster clockwise until it stops (ull hard position), then turn the adjuster counter- clockwise, REBOUND ADJUSTER STANDARD POSITION: 1/=3/4 turns out from full hard 4-32MAINTENANCE NUTS, BOLTS, FASTENERS Check that all chassis nuts and bolts are tightened to their correct torque values (page 1-12). Check that all safety clips, hose clamps and cable slays are in place and properly secured. WHEELS/TIRES Support the motoreyele securely and raise the front whol off the ground, Hold the front fork leg and move the front wheel sideways with force to see if the wheel bearings ate Refer to page 14-12 for front wheel service, ‘Support the motorcycle securely and raise the rear wheel off the ground. Hold the swingarm and move the rear wheol side- ways with force to see if the wheel bearings are Rofer to page 18.8 for rear wheel service 4-33MAINTENANCE Tire pressure should be checked when the tires are: COLD. RECOMMENDED TIRE PRESSURE AND TIRE SIZE: FRONT REAR Tire pressure KPa 7 eee 250 (250,36) | 29012.90, 42 | Tire size eno a caw) Bridgeston | STO12F Tire |e RADIALG | RADIAL bland Dunfop D208FK Da08k lin Pilot SPORT E Pilot SPORTE Check the tires for cuts, embedded nails, or other [ie damage Check the front wheel (page 14-12) and rear wheel (page 15-8) for truoness, Measure the tread depth at the center of the tres Replace the tires when the tread depth reaches the following limits. MINIMUM TREAD DEPTH FRONT: 1.5 mm (0.06 in} REAR: 2.0 mm (0.08 in) STEERING HEAD BEARINGS Check that the control cables de not interfere with handlebar rotation, Support the motorcycle securely and raise the front wheel off the ground, Check that the handlebar moves freely from side to side. if the handlebar moves unevenly, binds, or has ver- tical movernent, inspect the steering head bearings (page 14-27) 4-345. LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM -........ 5-2 OIL STRAINER/PRESSURE RELIEF VALVE..5-6 SERVICE INFORMATION -. we 53 OIL PUMP. 5B TROUBLE SHOOTING OIL COOLER... OIL PRESSURE INSPECTION. 5-1LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM. aan cam —o PISTONS ? on Jer CRANK SHAFT OIL COOLER, OIL FILTER CARTRIDGE OIL PUMP OlL PRESSURE RELIEF VALVE * OIL STRAINER 5-2LUBRICATION SYSTEM SERVICE INFORMATION GENERAL ACAUTION 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 oil on a daily basis, its still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oi + The oil pump can be serviced with the engine installed in the frame. + The service procedures in this section must be porfarmed with the engine oil drained. + When removing and installing the oil pump, use care not to allow dust or dirt to enter the engine, + Ifany portion of the oi! pump is worn beyond the specified service limits, replace the oil pump 2s an assembly. + After the oil pump has been installed, check that there are no oil leaks and that oil pressure fs correct, SPECIFICATIONS Units mm tin) ~ “TEM - = ‘STANDARD ‘SERVICE LIMIT | Engine oll capacity Aller draining [2.6 tter @.7 US at. 23 imp ad — After oll filter change | 2.9 liter G.T US qt 2.6 Imp qd | Biter disossembly 3.5 liter (3.7 US at 3.1 Imp at) = Recommended engine oil Pro Handa GNé or HP4 (with out | | molybdenum additives) &stroke oil | (U.S.A. & Canada) or Honda &stroke | oil (Canada only), equivalent motorcy- cle oil | | API service classification SG, or higher exceptoils labeled as energy consering on the circular API service label | ASO T 803 standard: MA Viscosity: SAE 10W ~ 40 540 KPa (5.5 kafiom®, 78 pall at = 6,000 rprn/is0:C/176°F} Oirpump ~]-fbstearence 0750.08) 0.200.008) Body clearanes {0.48 0.21 (0.008 - 0.008) 0.35 (0.014) l Side clearan 0.04 ~ 0.08 (0.002 - 0.008) 0.77 (0.007) TORQUE VALUES Gil pressure switch 12. Num (1.2 kgm, 9 IbF} Apply sealant to the threads Oil pressure switch wire terminal screw 2.0 N.m (0.2 kgm, 1.4 Ibe th iil pump assombly flange bolt 78 Nom (0.8 kgm, 5.8 Ibfft) CT bolt Engine oil filter cartridge 26 N:m (2.7 kgfim, 20 Ib-t) Apply clean engine oil to the O-ring Engine oil drain bolt 29 Nm .0 kgf, 22 Ibt-) Oil pump driven sprocket boit 15 Nm (15 kghm, 11 Ibfft) Apply a locking agent to the threadsLUBRICATION SYSTEM ——— TOOLS Oil pressure gauge set | Oil pressure gauge attachment (07506-3000001 07408-00300, cr equivalent commercially avail or equivalent commercially avail able in USA, able in USA, TROUBLE SHOOTING Oil level too low * Oil consumption + External oil leak + Worn piston rings + Improperly installed piston rings + Worn eylinders + Worn valve stom seals + Worn valve guide Low oil pressure + Oil level low + Clogged ol strainer + Internal oil leak + Incorrect oil being used No oil pressure + Oil level too low + Oil prossure reliaf valve stuck open + Broken oil pump drive chain + Broken oil pump drive or driven sprocket + Damaged ail pump. + Internal oil leak igh oil pressure Oil pressure relief valve stuck closed + Clogged ail filter, cil cooler gallery or metering orifice + Incorrect oil being used Oil contamination * Dil or filter not changed aften enough + Worn piston rings il emulsification * Blown oylinder head gasket + Leaky coolant passage + Entry of waterLUBRICATION SYSTEM OIL PRESSURE INSPECTION If the of pressure trokcator sot remains on a 00 seconds enact the incloator system before checking the oll pressure Romove the lower cawls (page 3-6) Remove the screw and disconnect the oil pressure switeh wire, Remove the oil pressure switeh while holding the switch base. Install the oil pressure gauge attachment to the switch base. Connect the oil pressure gauge to the oil pressure gauge attachment TooLs: Oil pressure gauge set 07506-3000001 or equivalent commercially avail- able in USA. 07406-0030000 or equivalent commercially avail- able in USA, Check the oil lavel {page 4-15). Warm the engine to normal operating temperature {approximately 80°C/178°F) and inerease the engine speed to 6,000 min” (rpm) and read the oil pressure. Oil pressure gauge attach- ment OIL PRESSURE: 540 kPa (5.5 kigf/em*, 78 psi) at 6,000 spm/ (80°C/176"F) Stop the engine and remove the tools. Apply a sealant to the oil pressure switch threads as shown. Install and tighten the oil prossure switch to the specified torque while holding the switch base, TORQUE: 12 Nem (1.2 kgf-m, 9 IDE) Connact the oil pressure switch wire terminal to the switch and tighten the screw to the specified torque, TORQUE: 2.0 Nim (0.2 kgm, 1.4 IDF.) Install the dust cover. Install the lower cowls (page 3-6) ‘OIL PAESSURE SWITCH Do not apply sealant to the thread head] 3-4 mm (0.1 ~0.2 in} Ese OIL PRESSURE SWITCHLUBRICATION SYSTEM OIL STRAINER/PRESSURE RELIEF VALVE REMOVAL Drain the engine oil (page 4-16) Remove the exhaust pipe (page 3-24), Remove the oil pan flange bolts, stay and oil pan, Remove the pressure relief valve and O-ring, Remove the oll strainer and oil seal Clean the oil strainer sereen, INSPECTION Check the operation of the pressure relief valve by pushing on the piston, Disassemble the relief valve by removing the snap ring. Inspect the piston for wear, unsmooth movement or damage Inspect the spring for fatigue or damage. Assemble the relief valve in the reverse order of dis. assembly. RELIEF VALVE BODY SPRING PISTON - a" O WASHER f SNAP RING 5-6LUBRICATION SYSTEM INSTALLATION Ani GLSEA. ap Install the oil strainer into the crankcase while align s Apply oil to a now O-ring and install it onto the relief valve. Install the relief valve into the crankcase. Clean the oil pan mating surface thoroughly. Do not apply more Apply sealant (Three Bond 12078 or an equivalent) sealant thaneces to the mating surface. Install the oil pan onto the lawer crankcase. Install the oil pan flange bolts and stay. Tighten the bolts in a crisscross pattern in two or three steps. : Install the exhoust pipe (page 3-261 or Elle crankone wath the recommended ol ago aaa a6) ‘After installation, check that there are no oil Jeaks. 5-7LUBRICATION SYSTEM OIL PUMP REMOVAL Drain the engine oil (page 4-16) Remove the right crankcase cover (page 10-5} Remove the bolt, washer and oll pump driven sprocket Remove the three flange bolts and oll pump assem- bly, OIL PUMP ASSE! MBLY DISASSEMBLY Remove the dowel pins Remove the ol pump assembly bolt and oil pump ASSEMBLY BOLT Olt PUMP PLATE plate DO\ WEL PINS body. . lL PUMP SHAFT Clean all disassembly parts thoroughly. WASHER DRIVE PIN, 5-8LUBRICATION SYSTEM INSPECTION Hf any portion of the Temporarily install the outer and inner rotors into ‘of pumps wom the oil pump body. TIP CLEARANCE: beyond he ‘Temporarily install the drive pin and oil pump shat. Measure the rotor tip clearance. SERVICE LIMIT: 0.20 mm (0,008 in) Measure the pump body clearance. SERVICE LIMIT: 0.35 mm (0.014 in) Measure the side clearance using a straight edge and feeler gauge SIDE CLEARANCE: SERVICE LIMIT: 0.17 mm (0.007 in) 5-9LUBRICATION SYSTEM ASSEMBLY Dip all parts in clean engine oil. OL PUMP BODY OUTER ROTOR INNER ROTOR OIL PUMP SHAFT WASHER, a lL PUMP PLATE DRIVE PIN. DOWEL PIN 28 Nom (0.8 kgf, 8.8 Ith Install the outer rator into the ail pump body with its punch mark facing the oil pump plate. Install the inner rotor into the outer rotor with its drive pin groove facing the oll pump plate. Install the oil pump shaft through the inner rotor and oil pump body, Install the drive pin into the hole in the oil pump shaft and align the drive pin with the groove in the inner rotor. Install the thrust washer. INNER ROTOR OUTER ROTOR OIL PUMP SHAFT DRIVE PIN. WASHER Install the dowel pins. Install the oil pump plate and tighten the assembly bolt to the specified torque, TORQUE: 7.8 Nom (0.8 kgf'm, 5.8 Ibfft) Check the oil pump operation by turning the pump shat. If necessary, reassemble the oil pump. ASSENIBLY BOLT OL PUMP PLATE DOWEL PINS 5-10LUBRICATION SYSTEM INSTALLATION Install the oil pump assembly onto the crankease while aligning the oil pump shaft lug with the water pump shaft groove by turing the oil pump shaft, Install and tighten the three flange bolts securely. Apply cil to the oil pump driven sprocket and drive chain Install the driven sprocket with its "OUT" mark fac- ing out “OUT MARK foe ee me Apply a locking agent to the oil pump driven sprocket bolt threads. Install and tighten the driven sprocket boltiwasher to the specified torque. TORQUE: 15 Nem (1.5 kgf-m, 1 Ib) Install the right erankease caver (page 10-24), After installation, fill the crankcase with the recom: ‘mended oil (page 4-16) and check that there is no oil leaks. Check the oil pressure (page 5-5). oN BOLTWASHER § eo”LUBRICATION SYSTEM OIL COOLER REMOVAL Drain the engine oil (page 4-16). Drain the coolant from the system (page 7-6) Remove the exhaust pipe (page 3-24 Loosen the hose clamp screws and disconnect the oil cooler water hoses from the oil cooler, Remove the four bolts, washers and cil cooler, Remove the O-ring fram the oil cooler. INSPECTION Check the oi! cooler for damage. INSTALLATION Ol COOLER, oe FB onneCoat @ new O-ring with engine oil and install it into the oll cooler groove, Install the oil cooler on the crankease. Install the four washers and bolts. Tighten the bolts securely. Connect the oil cooler water hoses into the cil cooler and tighten the hose clamp sorews securely. Install the exhaust pipe Ipage 3-26). Fill the crankcase with the recommended ofl (page 4-16) and check that there is no oil leaks. Fill the cooling system and bleed any air [page 7-6. 5-136. FUEL SYSTEM (Programmed Fuel Injection) COMPONENT LOCATION THROTTLE BODY ‘SERVICE INFORMATION PRIMARY INJECTOR. TROUBLESHOOTING FAST IDLE WAX UNIT -. SYSTEM LOCATION: ‘STARTER VALVE.-. SYSTEM DIAGRAM: STARTER VALVE SYNCHRONIZATION -... PGM-Fl SELF-DIAGNOSIS MAP SENSOR. INFORMATION IAT SENSOR +1ssvssessesve 6-89 MIL CODE INDEX-. ECT SENSOR «sss 6-89 MIL TROUBLESHOOTING: CAM PULSE GENERATOR. DTC CODE INDEX.-. 6-33 ‘TP SENSOR... DTC TROUBLESHOOTING. 6-37 BANK ANGLE SENSOR -~ FUEL LINE INSPECTION sone mees 6-56. ENGINE STOP RELAY... FUEL PUMP UNIT- 6-58 ENGINE CONTROL MODULE (ECM! FUEL CUT-OFF RELAY 6-60 PAIR CONTROL SOLENOID VALVE FUEL TANK... + 6-61 AIR CLEANER HOUSING 6-64 (California type only) - SECONDARY INJECTOR. “6-67 Oz SENSOR (California type only) -FUEL SYSTEM (Programmed Fuel Injection) COMPONENT LOCATION 22 Nom (2.2 Kofom, 16 fel} 6-2FUEL SYSTEM (Programmed Fuel Injection) SERVICE INFORMATION GENERAL + Be sure to relieve the fuel pressure while the engine is OFF. + Bending or twisting the control cables will impair smooth operation and could cause the cables to stick or bind, result- ing in loss of vehicle conttal. + Work in a wall ventilated aréa. Smoking or allowing flames or sparks in the work area or where gasoline is stored can cause a fire oF explosion. + Do not apply commercially available carburetor cleaners to the inside of the throttle bore, which is coated with molyb- denum, + Do not snap the throttle valve from full open to full close after the throttle cable has been removed. it may cause incor rect idle operation. + Seal the cylinder head intake ports with tape or a clean cloth to keep dirt and debris from entering the intake ports after the throttle body has been removed. + Do nat apply excessive farce to the fuel pipe on the throttle body while removing or installing the throttle body. Do not damage the throttle body. It may eause incorrect throttle and idle valve synchronization, Prevent dirt and debris from entering the throttie bore, fuel tube and return tube, clean them using compressed air. ‘The throttle body is factory pre-set. Do not disassembie in a way other than shown in this manual Do not push the fuel pump base under the fuel tank when the fuel tank is stored. + Always replace the packing when the fuel pump is removed. + The programmed fual injection (PGM-F) system is equipped with the Self-Diagnostic System described (page 6-8). If ‘the malfunction indicator lamp (MIL) blinks, follow the Self-Diagnostic Procedures to remedy the problem. + When checking the PGM-Fl, always follow the steps in the troubleshooting flow chart (page 6-15)Ipage 6-37). + The PGMFl system is provided with fail-safe function to secure a minimum running capability even when there is any trouble in the system. When any abnormality is detected by the self-diagnosis function, running capability is secured by using numerical values preset in advance in the program map. It must be remembered, however, that when any abnor- ality is detected in 8 injectors and/or the ignition and cam pulse generator, the fail safe function stops the engine to protactit from damage. + Refer to PGM-FI system location (page 6-6) + A faulty PGN-FI system is often related to poorly connected or corroded connectors. Check those connections before proceeding. + Refer to procedures for fuel level sensor inspection (page 20-18), + The vehicle speed sensor sends digital pulse signal to the ECM (PGN-FI unit) and computation. Refer to procedures for vehicle speed sensor inspection (page 20-13), + When disassembling the programmed fuel injection parts, note the location of the O-rings. Replace them with new ones ‘upon reassembly. + Before disconnecting the fuel hose, release the fuel pressure by loosening the fuel hose banjo bolt atthe fuel tank. + Always replace the sealing washers when the fuel hose banjo bolt is removed ar loosened. + Use a digital tester for PGM-FI system inspection. SPECIFICATIONS TEM — ‘SPECIFICATIONS ] Throttle body 29 states, Canada type! GOB _ identification number 60638 Starter valve vacuum di - — 20mm He ‘Base throttle valve for synchronization No.3 [Hate spec 7,300 = 1007 “Thro grip ree pla tin 18 TT |Ttake air temperature sensor resistance (ot 27°C786-F) eer Engine coolant temperature sensor resistance 7 23-26k2 Listzo'ciesey 4 a} Fuel injection resistance | Secondary injector 05-1450 (et20°C esr) Primary injector ——— 105-1450 — PAIR conirol solenoid valve resistance (at 20°Ci6@°F] 20-280 ——— OF V minimum [BS een TEA US 06.7 Imp o7] minimum/0 seconds “Cam pulse generator peak voltage {at 20°C/68"F) [Fuel pressure at idie Fuel pump flow tat YW) 6-3FUEL SYSTEM (Programmed Fuel Injection) TORQUE VALUES ECT (Engine Coolant Temperature) sensor 23 Nem (2.3 kgf, 17 lott) Throttle body insulator band screw See page 1-15 Starter valve synchronization plate screw 0,9 Nem (0.09 kofim, 0.7 Ibfft), Starter valve lock nut 18 Nem (0.18 kgm, 13 IDFA Fast idle wax unit link plate screw 0.8 Nom {0.09 kgfem, 0.7 Ife Fast idle wax unit mounting screw 4.9.Nem (0.5 kgf, 36 Ibttt) Fuel filler cap socket bolt 18 Nem (0.18 kgfim, 1.3 Ibe Secondary injector bracket mounting bot 5.4 Nem (0.55 kgf, 4 Ibf ft) Fuel rail mounting bolt 9.8Nom (1.0 kgf, 7 IDEA Fuel feed hose banjo bolt (fuel tank side) 22 Nem (2.2 kgm, 16 Ibflt Fuel hose sealing nut (throttle body side) 22 Nem (2.2 kgt-m, 16 Ibf-A) Fuel pump mounting nut 12 Nm (1.2 kgfim, 8 oF) On sensor (California type only] 25 Num (2.6 kom, 19 Ibftt) TOOLS | Fut pressure goune, 100 psi Peak voltage adaptor 07408-0080003 0746J-0020100 (not available in USA) (or 07406-004000A (U.S.A, only) with commercially available digital multimeter {impedance 10 M&/OCV minimum) ‘or 07406-0040002 | SCS service connector Ignition Mate peak voltage tester o70P2-2v30100 MTPO7-0286 (U.S.A, only} See page 1-16 for tightening sequence ECM test harness o7oMz-o010200 (two required! Vacuum gauge set O7LMJ-0010000TROUBLESHOOTING Engine won't start * Intake air leak + Fuel contaminated/deteriorsted + Pinched or clogged fuel hose + Faulty fuel pump unit + Clogged fuol fiterstrainer + Clogged fuel injector filter + Sticking fuel injector needle + Faulty fuel pump operating system Engine stalls, hard to start, rough idling + Intake air feake + Fuel contaminatedideterioratod + Pinched or clogged fuel hose + Idle speed misadjusted + Starter valve synchronization misadjustad Backfiring or misfiring during acceleration + Ignition system matfunction Poor performance (drive ability) and poor fuel economy + Pinched or clogged fuel hose + Faulty pressure regulator FUEL SYSTEM (Programmed Fuel Injection)FUEL SYSTEM (Programmed Fuel Injection) SYSTEM LOCATION IGNITION swiTcH PAIR CONTROL SOLENOID VALVE BANK ANGLE SENSOR ECM FUEL CUTOFF RELAY IAT SENSOR SECONDARY INJECTOR MAP SENSOR PRIMARY INJECTOR ENGINE STOP RELAY ‘CAM PULSE GENERATOR 7 TP SENSOR LL PURGE CONTROL SOLENOID VALVE (California type only) VEHICLE SPEED SENSOR |vSS) (0: SENSOR (California type only} FUEL PUMP. IGNITION PULSE GENERATOR ——_uuewaMe abate roses enor ‘ABBREVIATIONSFUEL SYSTEM (Programmed Fuel Injection) SYSTEM DIAGRAM é oe 8 8 Ap tal Le (1) Engine stop relay (991 ECT sensor (2) PGM-FI fuse (208) (20) Ignition pulse generator @)_—_ Engine stop switch (21) Oz sensor (California type only} a (22) Water temperature LCD (5) Ignition switch (23) Fuel cutoff relay (6) Main fuse A (308) (24) Fuel pump unit (7) Bank angle sensor (25) Fuel indicator (8) EVAP canister (California type} (26| Vehicle speed sensor (9) Batery (27) Speedometer (10) IAT sensor (28) Neutral switch IM) Direct ignition coilvspark plug (23) Clutch switch {12} PAIR control soleneid valve (30) Side stand switch (13) TP sensor (31) Malfunction indicator lamp (MiL) (14) MAP sensor (32) Data link connector (15) Primary injector (33) Tachometer (16) Secondary injector (34) EVAP purge control solenoid valve (17) Cam pulse generator {California type only) (18) PAIR check vaive 6-7FUEL SYSTEM (Programmed Fuel Injection) PGM-FI SELF-DIAGNOSIS INFORMATION SELF-DIAGNOSTIC PROCEDURE Place the motoreycle on its side stand. Start the engine and lot itil. NOTE Ifthe engine will not start, turn the starter motor for more than 10 seconds and check that the MIL blinks. I —— | MALFUNCTION INDICATOR LAMP (MIL) The Mil wilbink If the malfunction indicator lamp (MIL) does not only wth te side. light or blink, the system has no memory of prob: stand cow” 273 lem data, with the engine off (engine stp switen If the malfunction indieator blinks, note how many SUN) or angina times the MIL blinks or read the Diagnosis Trouble ‘o¥s a9 noiew Code {OTC) with the Honda Diagnosis System (HDS) 5.000;0m pany Pocket Tester, and determine the cause of the prob- otterconanien, ine lem (page 6-12, page 6-37). - MA wit umiate ‘2nd stay on. If you wish to read the PGM-FI memory for trouble data, perform the following: DTC (With the HDS Pocket Tester) Turn the ignition switeh OFF, Remove the seat (page 3-4) Connect the HDS Pocket Tester to the Date Link Connector (DLC. ‘Turn the ignition switch ON and engine stop switch “ae Chock the Diagnostic Trouble Code (DTC) and note it, Also check the freeze data, Refer to the DTC index page 6-33) and begin the appropriate troubleshooting procedure. Note: For specific operations, refer to the user's manual | oo that came with the HDS Pocket Tester. MIL CODE (Without the HDS Pocket Tester) Turn the ignition switch OFF, Remove the seat |page 3-4) ‘Short the Data Link Connector (DLC) terminals using the special tool TooL: SCS service connector o70Pz-z¥30100 DATA LINK CONNECTOR, Turn the ignition switch ON end engine stop switch “a SCS SERVICE CONNECTOR, 6-8Evan i the POMFL ‘nas memory aot, the MIL does not fink when the engine srunnig, FUEL SYSTEM (Programmed Fuel Injection) I the ECM has no self diagnosis memory data, the MIL will illuminate, when you turn the ignition switch ON. If the ECM has self diagnosis memory data, the MIL | will start blinking when you turn the ignition switch | ON. Note how many times the MIL blinks, and determine the cause of the problem (page 6-12). SELF-DIAGNOSIS RESET PROCEDURE Reset the self-diagnosis memory data in either of 2 ways; With the HDS. Use the HDS Pocket Tester to clear the ECU mem ory. See the HDS Pocket Tester user's manual for specific instruction. Without the HDS 1. Turn the engine stop switch * ()* and ignition switch OFF. 2. Short the Data Link Connector {OLC} terminals Using a special tool Took: ‘SCS service connector 3. Turn the ignition switch ON. 4, Remove the special tool from the Data Link Con- rector (OLC} o70Pz-2¥30100 ‘The MIL lights about 5 seconds. While the indica tor lights, short the Data Link Connector (DLC) again with the special tool. Self-diagnosis memory data is erased, ifthe ML. turns off and starts blinking, + The Data Link Connector {DLC} must be jumped while the indicator is lit. net, the MIL will not start blinking, + Note that the self diagnosis memory data cannot | be erased if you turn off the ignition switch before the MIL starts blinking. Ifthe MIL blinks 20 times, the data has not been erased, so try again. MALFUNCTION INDICATOR LAMP (MIL} DATA LINK CONNECTOR SCS SERVICE CONNECTOR 6-9FUEL SYSTEM (Programmed Fuel Injection) PEAK VOLTAGE INSPECTION PROCE- DURE * Use this procedure for the ignition pulse genera: tor and cam pulse generator inspection Check all system connections before inspection. I the system is disconnected, incorrect peak volt age might be measured. + Check cylinder compression and check that all spark plugs are installed correctly + Use the recommended digital multimeter or commercially available digital multimeter with an impedanee of 10 MQ/OCY minimum, + Ifthe Imrie diagnostic tester (model 625) is used, follow the manufacturer's instruction, + The display value differs depending upon the intornal impedance of the multimeter * Disconnect the fuel pump connector before checking the peak voltage. Lift and support the fuel tank (page 6-81) Disconnect the fuel pump unit 3P (Black) connector. ‘SP (BLACK) CONNECTOR © Connect the peak voltage adaptor to the digital mul: Toots: IgnitionMate peak voltage tester MTPO7-0286, (USA. only} or Poak voltage adaptor O7HGJ-0020100 (not available in USA) with commercially available digital multimeter (impedance 10 Ma2/DCV minimum) TEST HARNESS CONNECTION Remove the follawing: ~ Fuel tank cover (page 3-15) = ECM cover page 584) Disconnect the ECM 32P (Black) and 32P (Light gray) connectors from the ECM. 6-10FUEL SYSTEM (Programmed Fuel Injection) Connect the ECM test harnesses between the main | wire harness and the ECM, ECM TEST HARNESSES A TooLs: ECM test hamess o70mz-0010200 (two required) TEST HARNESS TERMINAL LAYOUT The ECM connector terminals ere numbered as a shown. VIEW FROM WIRE HARNESS SIDE: ‘A: 32P (BLACK) CONNECTOR The ECM test harness terminals are same layout ag for the ECM connector terminals as shown. FOR 32P (BLACK) CONNECTOR FOR 32P (LIGHT GRAY} CONNECTOR | 6-11FUEL SYSTEM (Programmed Fuel Inje: MIL CODE INDEX in) + The PGM-F1 MIL denotes the failure codes (the number of blinks fram 0 to 49). When the indicator lights for 1.3 seconds, it is equivalent to ten blinks, For example, s 1.3 second illumination and two blinks (0.5 second x 2} of the indicator ‘equals 12 blinks, Follow code 12 troubleshooting (page 6-24), + When more than one failure occurs, the MIL shows the blinks in the order of lowest number to highest number. For ‘exemple if the indicator blinks once, then two times, two failures have occurred. Follow cades 1 (page 6-15} and 2 (page 6-16) troubleshooting, speed sensor wire + Faulty vehicle speed sensor ML Function Failure Causes Symptoms | Peer No inks | ECM malfunction > Faulty ECW 7 * Engine doesnotsian | 6-94 No blinks ECM power? + Open circuit at tie power input» Engine does not start 638 ground circuits wiro of the ECM malfunction + Faulty bank angle sensor + Open cireuit in bank angle sen- sor related civoult + Faulty angine stop rolay + Open circuit in engine stop relay related wires | + Faulty engine stop switch + Open cireuit in engine stop switch related wires + Faulty ignition switeh + Blown PGM-FI fuse (20 A) | + Blown sub-fuse (10A) (Starter, _ - Bank angle senson | _ - ECM! ouiput line + ECM output voltage line [Vallow) > Engine does not start = malfunction | __ red wire) shor circuit | Faulty ECM > Engine operates nor oe “| function + Open or short circuit in MIL wire mally | Stays lit Data linkeireu | > Short circuit in data link connec: > Engine operates nor malfunction tor mally + Faulty Eom + Short circuit in data link connec: tor wire 1 Blink WAP sensor cir + Lease or poor contact on MAP Engine operates nor os cuit malfunetion sensor connector mally + Open or short circuit in MAP son- ser wire + Faulty MAP sensor _ | 2Blinks MAP Sensor par” | + Loose or poor connection ofthe > Engine operates nor are formence prob MAP sensor vacuum hose mally lem + Faulty MAP sensor reine CT sensor * Loose or poor contact on ECT + Hard start ata Tow tome 677 cuit malfunetion sensor perature (Simulate using + Open or short citcuit in ECT sen- Aumerieal values; 90°C) sorwira 98°F) I + Faulty ECT sensor _ . - BBlinks | TP sensor circuit | + Loose or poor contact on TP sen- | > Poor engine parfor= ae malfunction sor connector ‘mance response and + Open or short circuit in TP sen- when operating the | sor wire throttle quickly (Simu- | + Faulty TP sensor late using numerical val: | — - | _ues: Throwie opensor) | | SBlInks TAT sensor circuit | > Loose or poor contact an IAT ~ Engine operates nor oa malfunction sensor mally (Simulate using | + Open or short circuit in AT sen- numerical values; 26 "C) sor wire 77°) Faulty (AT sensor Blinks —Vericie speed Loose or poor contast an vehicle) > Engine operates nor- ea sensor circuit speed sensor connector mally ‘malfunction + Open or short circuit in vehicle 6-12FUEL SYSTEM (Programmed Fuel Injection) ML Funetion Failure Causes Symptoms "32 Blinks | No.1 Primary Loose oF poor contact on No.t * Engine does nat injector circuit Primary injector connector malfunction + Open or short circuit in No.1 Pri- mary injector wire + Faulty No.1 Primary injector | _ "Blinks No.2 Primary > Loose or poor contact on NZ + Engine does not start 525 Injector circuit Primary injector connector malfunction Open or short circuit in No.2 Pri | mary injector wire Faulty No.2 Primary injector No.2 Primary |» Loose or poor contact on No + Engine does not start 625 | injector circuit Primary injector connector malfunction (Open or short circuit in No.3 Pri- mary injector wire Faulty No.3 Primary injector Nod Primary Loose or poor contact on No.# + Engine does not start e258 Injector circuit Primary injector connector | malfunction Open or short circuit in No.4 Pri: mary injector wire | Faulty No.4 Primary injector TSBlinks | No.1 Secondary Loose or poor contact on No.1 + Engine does not start injector circuit malfunction’ /TTBiinks | No.2 Secondary injector circuit malfunction Secondary injector connector Open or shor circuit in No.1 Seo- ondary injector wire Faulty No.1 Secondary injector Loose or poor contact on No.2 Secondary injector connector ‘Open or shor circuitin No.2 Sec- ondary injector wire Faulty No.2 Secondary injector al Engine dos not start ine does not start | 78 Blink am pulse gen Toose or poor contact on eam om ator, no signal pulse generator | | Open or short circuit in eam | pulse generator jo Faulty cam pulse generator WS Blinks Ignition pulse Loose or poor contact on ignition generator, no sia- pulse generator pal Open or shor circuit in ignition pulse generator Faulty ignition pulse generator _ 27 Blinks: No.1 O2 sensor ‘Loose or poor contact on Ozsen- + Engine operates nor- 6-28 circuit maifune sor connector mally tion (California Short circuit in O» sensor type only} Faulty 0: sensor | ‘22Blinks | No.2 Gs sensor Loose or poor contact on Or sen- | * Engine operates nor- 629 circuit maltune- sor connector | mally tion (California Short circuit in Os sensor |_ type oniy! Faulty O: sensor 23 Blinks | No.1 Os sensor Loose or poar contact on Orsen- | > Engine oporates nor 650 heater matfunc- sor connector mally tion (California Open or short circuit in Oz sensor | type onlyi heater | Faulty Oz sensor arBinks | Ned Or sens ‘008e or poor contact on O: sen heater malfunce tion (California | type only) sor connector Open or shart circuit in O: sensor heater Faulty O: sensor mally 6-13Refer mi sppesan 33 Blinks z + Engine operates nor “| 632 iran | ret |. + Boot net hold the set {| Gignoseda | | 48Blinks | No.3 Secondary + Loose or poor contact on No.3 * Engine does not start 6-25 fescue Sncondar ijoter connecter mmatneion + Open ar shortcut in ies ee ondary Inlector wire _ Pauly No Sebordary injector 49 Blinks "No.4 Secondary | + Loose or poor contact on No. miosor aici Seeoncaty injector sonectes Oeiaen + Open shor cheutin Nes ec ondary injector wire |_+ Faulty No.4 Secondary inje 6-14FUEL SYSTEM (Programmed Fuel Injection) MIL TROUBLESHOOTING MIL 1 BLINK (MAP SENSOR) + Before starting the inspection, check for loose or poor contact on the MAP sensor connector and recheck the MIL blinking, 1. MAP Sensor Output Voltage Inspection Turn the ignition switch OFF. Connect the ECM test harness to ECM connec: tors (page 6-10). Turn the ignition switch ON and engine stop | == switch" C) (seneee: ] (Pezezseponeanen, jS8BSsODoOOONE Measure the voltage at the test harness termi- | Sinnammsmemnmnor nals. 1s the voltage within 2.7 -3.1V? YES — + Intermittent failure + Loose or poor contact on the ECM connectors NO - + AboutsV. GOTO STEP 2, Pe + About OV GOTO STEP 3. 2, MAP Sensor Output Line Inspection Turn the ignition switch OFF, Disconnect the MAP sensor 3P connector. Turn the ignition switch ON and engine stop switch * Q*. Measure the voltage at the wire harness side. Connection: Light green/yellow [+) ~ Green/ orange (-) Is the voltage within 4.75 - §.25V? YES. ~ Faulty MAP sensor NO - + Open circuit in Light greenyellow wire + Open circuit in Green/orange wire 3. MAP Sensor Input Voltage Inspection Measure the voltage at the wire harness side, Connection: Yellow/red (+) ~ Ground +} Is the voltage within 475 ~ 5.25V? YES - GOTO STEP 4 NO - GOTOSTEPS. 6-15FUEL SYSTEM (Programmed Fuel Injection) 4. MAP Sensor Output Line Short Circuit Inspec- tion Check for continuity between the MAP sensor aP [— connector terminal of the wire harness side and ground. Connection: Light green/yellow ~ Ground Is there continuity? YES ~ Short circuit in Light greenivellowiyel- low wire NO ~ Faulty MAP sensor 5. MAP Sensor Input Line Inspection Turn the ignition switch OFF. Disconnect the ECM 32P connectors Check for continuity at the Yellowired wire between the MAP sensor 3? connector terminal and the ECM 32P (Light gray) connector. Connection: B18 ~ Yellow/red Is there continuity? YES ~ Roplaco the ECM with @ known good fone, and recheck, NO = Open circuit in Yellowired wire MIL 2 BLINKS (MAP SENSOR) + Before starting the inspection, check for loose or oor contact on the MAP sensor connector and recheck the MIL blinking, 1. MAP Sensor Hose Inspection Tum the ignition switch OFF Cheek for connection and installation of the MAP sensor vacuum hose. Is the MAP sensor hose connection correct? Yes -GoTOSTEP 2, NO ~ Correct the hose connection or installation MAP SENSOR 3P CONNECTOR 6-16FUEL SYSTEM (Programmed Fuel Injection) 2. MAP Sensor Output Voltage Inspection Connect the ECM test harness to ECM connec- tors (page 6-10) Turn the ignition switch ON and engine stop | switch * | Measure the voltage at the test harness termi- nals. Connection: B15 (+) -B17 (+1 isthe voltage within 22-3.1 VP Yes - coTosTePs NO = Faulty WAP sensor | MAP Sensor Output Voltage Inspection At Idle Start the engine, Measure the voltage at the test harness termi- nals. Connection: B15 (+) -B17 (-) Standard: | 2.7 V maximum Is the voltage lass than 2.7 V? YES - Replace the ECM with @ known good tone, and recheck NO - Faulty MAP sensor MIL 7 BLINKS (ECT SENSOR) + Before starting the inspection, check for loose or poor cantact on the ECT sensar connector and recheck the MIL blinking. |. ECT Sensor Output Voltage Inspection Turn the ignition switch OFF. Connect ECM the test harness to ECM connec- tors {page 6-10) Turn the ignition switch ON and engine stop switch" Q* Measure the voltage at the ECM test harness ter- minals. Connection: B27 (+) -B17 +) Standard: 2.7 -3.1V (20°C/68°F) Is the voltage within 2.73.1 V? YES - + Intermittent failure | + Loose or poor contact on the ECM | connectors NO - GOTOSTEP2 Wy {v)—_le (Bessseaseasassas| 6-17FUEL SYSTEM (Programmed Fu Injection) 2. ECT Sensor Input Voltage Inspection ‘Turn the ignition switch OFF. Disconnect the ECT sensor 3P connector. Turn the ignition switch ON and engine stop switeh * Q* Measure the voltage at the wire harness side of ECT sensor connector. Connection: Pink (+) ~ Ground (-) Is the voltage within 4.75 - 5.25V? YES ~ Inspect the ECT sensor (page 20-16) No -~ GOTO STEP, 3. ECT Sensor Resistance Inspection Tum the ignition switch OFF. Disconnect the ECT sensor connector. Measure the resistance at the ECT sensor ter nals. Connection: ink (+) ~ Green/orange (-1 (sensor side terminals} Standard: 2.3~2.6 0 (20°C/68 *F] Is the resistance within 2.3 ~2.6 220 °C/68 F)? NO - Faulty ECT sensor. YES - GOTO STEP 4. 4. ECT Sensor Open Circuit Inspection Turn the ignition switch OFF. Check fer continuity at the Pink and Green/ orange wires between the ECT sensor 3° con- nectar terminal and the ECM 32P (Light gray} connector terminal Kk reen/orange Connection: 817 | B27 - Is there continuity? YES - GOTOSTEPS, NO = + Open circuit in Pink oF Pinkiwhite wire + Open circuit in Green/orange wire 5. ECT Sensor Output Line Short Circuit Inspection Check for continuity between the ECT sensor aP- Connector terminal of the wire harness side and ground. Connection: Pink - Ground Is there continuity? YES ~ Shor circuit in Pink wire NO - Replace the ECM with @ known good ‘one, and recheck. ECT SENSOR 3P CONNECTOR ECT SENSOR SP CONNECTOR ECT SENSOR, oF NNECTOR 6-18FUEL SYSTEM (Programmed Fuel Injection) MIL 8 BLINKS (TP SENSOR) + Before starting the inspection, check for loose or poor contact on the TP sensor connector and recheck the MIL blinking, 1. TP Sensor Output Voltage Inspection Turn the ignition switch OFF Connect the ECM test harness to ECM cannee- tors (page 6-10). Turn the ignition switch ON and engine stop oe einaheye a ee Measure the TP sensor output voltage at the test harness terminals. Connection: B14 (+) ~ B17 (-) Standard; *0.4~0.6 V (throttle fully closed) +42 - 48 V (throttle fully opened) NOTE: + A voltage marked * refers to the value of the ECM output voltage (STEP 1) when the volt- age reading shows 5 V. ‘When the ECM output voltage reading shows other than 5 V, derive the TP sensor output voltage at the test harness as follows: In the case of the ECM output voltage is 4.75, Vv: 0.4X 4755.0 -0.28V 0.8 X 4.75/5.0 = 0.87 V ‘Thus, the solution is “0.38 - 0.67 V" with the ‘throttle fully closed Replace 0.4 and 0.8 with 42 and 4.8 respec- tively, in the above equations to determine the throttle fully opened range, Is there standard voltage? YES — + Intermittent feilure + Loose or poor contact on the ECM connectors NO - GOTO STEP2 2. TP Sensor Input Voltage Inspection Turn the ignition switch OFF. Disconnect the TP sensor 3P connector. Turn the ignition switch ON and engine stop switch" Q)* Measure the voltage at the wire harness side. Connection: Yellow/red (+) - Green/orange {-) Is the voltage within 4.75 ~ 5.25 V? YES - GOTO STEP 4. No - GOTO STEPS 6-19FUEL SYSTEM (Programmed Fuel Injection) 6-20 3. ECM Output Voltage Inspection Turn the ignition switch OFF. Connect the ECM test harness to ECM connec- tors (page 6-10) Turn the ignition switch ON and engine stop switch = 2) Measure the voltage at the test harness termi: nals. Connection: B18 (+) -B17 (-) Is the voltage within 4.75 ~ 5.25? YES — + Open cirouit in Yellow/red + Open circuit in Greenvorange wire NO - Replace the ECM with a known good one, and recheck, 4. TP Sensor Output Line Inspection Check for continuity between the TP sensor 3P ‘connector terminal of the wire harness side and ECM 22P (Light gray) connector. Connection: Red/yellow - 814 Is there continuity? YES - GOTO STEPS. NO ~ Open circuit in Red/yellow wire 5. TP Sensor Output Line Short Circuit Inspection Turn the ignition switch OFF. Check for continuity between the TP sensor 3P Connector terminal of the wire harness side and ground. Connection: Red/yellow (+) - Ground {-) 1s there continuity? YES ~ Short circuit in Rediyellow wire NO ~ Faulty TP sensor =a ‘TP SENSOR 3P CONNECTORFUEL SYSTEM (Programmed Fuel Injection) MIL 9 BLINKS (IAT SENSOR) + Before starting the inspection, check for loose or poor contact on the IAT sensor connector and techeck the MIL blinking, 1, IAT Sensor Output Voltage Inspection Turn the ignition switeh OFF ——————— Connect the ECM test harness to ECM cone: tors (page 6-10) Turn the ignition switch ON and engine stop | SEES EEE o SSaaaaETSaETeal switch "7 scoseesescesoet| [gsseoesseccooesal Connection: B30 (+) -B17 (-) Standard: 2.7-3.1 V (20°C/68°F) Is the voltage within 2.7-3.1 V2 ves - @ @- Intermittent failure + Loose or poor contact on the ECM connectors NO - GOTOSTEP2, 2. IAT Sensor Input Voltage Inspection ‘Turn the ignition switeh OFF. = ——— Disconnect the IAT sensor 2P connector. | IAT SENSOR 2? CONNECTOR Turn the ignition switch ON and engine stop | ~ switch * * Measure the voltage at the wire harness side of IAT sensor connector. Connecti ray/blu Is the voltage within 4.75 ~5.25V? YES - GOTO STEPS. NO - GOTO STEPS, Green/orange 3. IAT Sensor Resistance Inspection Turn the ignition switch OFF, Disconnect the IAT sensor 2P connector. Measure the resistance at the IAT sensor termi- Standard: 1-4 KO (20-30 °C/68 ~ 86°F) |s the resistance within 1~ 4 k2? NO ~ Faulty IAT sensor YES - GOTOSTEP4. 6-21FUEL SYSTEM (Programmed Fuel Injection) 4, IAT Sensor Open Circuit Inspection ‘Turn the ignition switch OFF. Check for continuity at the Gray/olue and Greeny orange wires between the IAT sensor 2P connec- tor terminal and the ECM 32P (Light gray) con- nectar. Are there continuity? YES - GOTO STEPS. NO + Open circuit in Grayjblue wire + Open circuit in Greenvorange wire 5. IAT Sensor Output Line Short Circuit Inspection Check for continuity botween the IAT sensor 2P connector terminal of the wire harness side and ground. Connection: Gray/blue - Ground Is there continuity? YES ~ Short circuit in Gray/blue wire NO Replace the ECM with a known good one and recheck. MIL 11 BLINKS (VEHICLE SPEED SEN- SOR) + Before starting the inspection, check for loose or oor contact on the vehicle speed sensor con- hector and recheck the MIL Blinking, 1. Vehicle Speed Sensor Pulse Inspection Turn the ignition switch OFF. Connect the ECM test harness to the ECM con- ectors ipage 6-10), Support the motoreycle securely and place the rear wheel off the ground Shift the transmission into gear, Measure the voltage at the test harness termi nals with the ignition switch ON and engine stop switch * C)* while slowly turning the rear wheel by han. Connection: B25 (+) ~ Ad (-) Standard: Repeat 0105 V 1s there standard voltage? YES — + Intermittent failure + Loose or poor contact on the ECM ‘connectors NO - GOTO STEP 2, noapeeeeaasg| sesesecsaanag v 6-22FUEL SYSTEM (Programmed Fuel Injection) 2. Combination Meter Inspection Check for operation of spsed meter, Does the speed meter operate normally? YES Open or short circuit in the Pink/green ‘SPEED METER NO - GOTO STEPS 3. Vehicle Speed Sensor Input Voltage Inspection ‘Tum the ignition switch OFF. -— - — Disconnect the vehicle speed sensor 3P connec- | VEHICLE SPEED SENSOR 3P CONNECTOR, tor. Turn the ignition switch ON and engine stop switch * Measure the voltage at the wire harness side. Connection: Black (+) ~ Green {-) |s there battery voltage? YES - GOTOSTEP 4. NO = + Open circuit in the Black or Black! brown wire + Open circuit in the Green or Green! black wire 4. Vehicle Speed Sensor Signal Line Short Circuit Inspection Turn the ignition switch OFF, Check for continuity between the test harness and the ground. wpOoaa Is there continuity? SES TET YES - Short circuit in the Pink oF Pinkigreen wire NO = Inspect the vehicle speed sensor (page 20-13) 6-23FUEL SYSTEM (Programmed Fuel Injection) 6-24 MI TOR) | jz a IL. 12 BLINKS (No.1 PRIMARY INJEC- No.1 Blackiwhite | Pinkiyellow ATT Primary No.2 |Blackwhite /Pinkiblue (A12 Primary JEC- | POWER | SIGNAL | SIGNAL TOR |INPUTLINE) LINE | ATECM ‘A 32P (BLACK) CONNECTOR [SBBBDsqp00c0: POWER INPUT LINE [Baooecssensenco4)] No.3 |BiackWwhite |Pinklgreen ATS Blackwhite | are Primary ‘No.1 Blackrwhite BT ‘Second: Biackiwhite [Pinklblve [82 1 Pinkigreen [83 [Pinkibtack [8a Injector Circuit Resistance Inspection Turn the ignition switch OFF. Connect the ECM test harness to the ECM con- nectors ‘page 6-10}. ‘Measure the resistance at the test harness termi: nals. Connection: POWER INPUT LINE - SIGNAL AT ECM 1s there continuity? YES - GOTO STEP 4, No - GOTO STEP 2, . Injector Resistance Inspection Disconnect the No.1 primary injector 2P connec- tor and measure the resistance of the No.1 pri- mary injector 2P connector terminals. Is the resistance within 11.1 - 12.3 0 (20°C/ ear? YES - GOTO STEP NO ~ Faulty injector TongRo) 8: 32P (LIGHT GRAY) CONNECTOR,FUEL SYSTEM (Programmed Fuel Injection) 3. Injector Input Voltage Inspection Tum the ignition switch ON and engine stop switch" Q) Measure the voltage between the No. 1 primary injector connector of the wire harness side and ground. NO.1 PRIMARY INJECTOR 2° CONNECTOR Connection: POWER INPUT LINE (+]~Ground (-) YES Open circuit in SIGNAL LINE wire NO - Open circuit in POWER INPUT LINE wire | | Is there battery voltage? | | l 4. Injector Signal Line Short Circuit Inspection Check for continuity between the test harness terminals and ground Connection: SIGNALATECM Ground | SEESLEGEEau larson? eae) (es YES. = Shortccutn sha SGNALLINE wie | NO. = Replace the ECM with # known good | one, and recheck | ® MIL 13 BLINKS (No.2 PRIMARY INJECTOR) (page 6-24) MIL 14 BLINKS (No.3 PRIMARY INJECTOR) (page 6-24) MIL 15 BLINKS (No.4 PRIMARY INJECTOR) (page 6-24) MIL 16. BLINKS (No.1 SECONDARY INJECTOR) (page 6-24) MIL 17. BLINKS (No.2 SECONDARY INJECTOR) (page 6-24) MIL 48 BLINKS: (No.3 SECONDARY INJECTOR) (page 6-24) MIL 49 BLINKS (No.4 SECONDARY INJECTOR) (page 6-24) 6-25FUEL SYSTEM (Programmed Fuel Injection) Mu 18 BLINKS (CAM PULSE GENERA- + Before starting the inspection, check for loose or oor contact on the eam pulse generator connec: tor and recheck the MIL blinking, 1. Cam Pulse Generator Peak Voltage Inspection at ECM Turn the ignition switch OFF. ne Connect the ECM test harnass to the ECM con- neetors (page 6-10), Turn the ignition switch ON and engine stop [Bessaasessccccc9)| || [Seoccessotossess switch" Q)*, Crank the engine with the sterter motor, and | (Sesssusussenose. measure the cam pulse generator peak voltage at the test harness terminals, Connection: B10 (+) ~ A31 (+) Is the voltage more than 0.7 V (20 °C/68 *F)? YES ~ + Intermittent tate + Unaae oF poor contact on the ECM connectors L NO - GOTO STEP 2 2. Cam Pulse Generator Peak Voltage Inspection Turn the ignition switeh OFF, Disconnect the cam pulse generator 2P connec- | CAM PULSE GENERATOR 2P CONNECTOR tor. Turn the ignition swit switch" Q" Crank the engine with the starter moter, and | measure the cam pulse generator peak voltage at the cam pulse generator 2P connector. h ON and engine stop Connection: Gray (+) ~ White/yellow (-) Is the voltage more than 0.7 V (20 °C/68 “FJ? YES - Open or short circuit in the Green/ orange wire or Gray wire NO - Faulty cam pulse generator 6-26FUEL SYSTEM (Programmed Fuel Injection) MIL 19 BLINKS (IGNITION PULSE GEN- ERATOR) + Before starting the inspection, check for loose or poor contact on the ignition pulse generator con- rector and recheck the MIL blinking. 1. Ignition Pulse Generator Peak Voltage Insp tion at ECM Turn the ignition switch OFF Connect the ECM test harness to the ECM con- nectors (page 6-10) Turn the ignition switch ON and engine stop switch" Q" Crank the engine with the starter motor, and measure the ignition pulse generator poak volt: age at the test harness terminals. Aan) Is the voltage more than 0.7 V (20 C/68 °F? ves Connection: B9 (+| ~ = + Intermittent failure + Loose or poor contact on the ECM. connectors NO - GOTO STEP? 2. Ignition Pulse Generator Peak Voltage Insp tion Turn the ignition switch OFF. Lift and support the fuel tank (page 6-61) Disconnect the ignition pulse generator 2P (Red) connector, Turn the ignition switch ON and engine stop switch " )* Crank the engine with the starter motor, and Measure the ignition pulse generator peak volt- age at the ignition pulse generator 2P (Rec) con- | nectar. Connection: Yellow (+) ~ Yellow/white |-) Is the voltage more than 0.7 V (20 °C/68 *F/? YES - Open or short circuit in the Yellow, Green/orange or Yellow/white wire NO ~ Faulty ignition pulse generator (gsssasassesssasa] [sscocospecoss566] (ssszessbeease=49) lossonnségocases IGNITION PULSE GENERATOR 2P (RED) CONNECTOR, 6-27FUEL SYSTEM (Programmed Fuel Injection) Mit 21 BLINKS (No.1 Oz SENSOR! California type only + Before starting the inspection, check for loose or oor contact on the O2 sensor connector and recheck the MIL blinking yMiLy GROUND | SIGNAL | SIGNAL | _ om Som ine” | Sine | Sth [Bese [onre 20 Groen? — Blagg — Be [sensor orange _lorange _| 22 - a ‘A: 32P (BLACK) CONNECTOR 1. 02 Sensor Output Voltage Inspection Turn the ignition switch OFF. Connect the ECM test harness to the ECM con- nectors page 6-10), Tum the ignition switch ON and engine stop switch * Q Warm the engine until the coolant temperature is 80°C 1176" ‘Check the voltage at the test harness terminal. | Connection: SIGNAL AT ECM (+) ~ B17 (-) Standard: 0.1-0.3V Is the voltage as specified? L YES — Check the fuel pressure (page 6-56). If the system is correct, GO TO STEP 4, NO -GOTOSTEP2 2. 2 Sensor Open Circuit Inspection ‘Turn the ignition switeh OFF Disconnect the O2 sensor 4P connector. Check the continuity between the test harness ‘connector terminals and the O: sensor 4P con- rector. Connection: SIGNAL LINE - SIGNAL AT ECM Js there continuity? YES - GOTO STEP, NO Open circuit in the SIGNAL wire ‘sosouoosososeeep| vy Sa See) [aoe 500 re00$505) 6-23FUEL SYSTEM (Programmed Fuel Injection) 3. Oz Sensor Short Circuit Inspection Connect the O: Sensor 4P connector. Check the continuity between the ECM connec- tar terminal and ground. —— ever Connection: SIGNAL AT ECM - Ground [Bsssscesccsseeg|| |[easssoqpeosoqoes) Is there continuity? [sssssscbesssensd]| |ezsosstesesensss| YES ~ Short circuit in the SIGNAL wire oes ° T . NO - GOTOSTEP4. A 4, 0: Sensor Inspection Replace the O2 sensor with a known good one {page 6-99). Foeset the ECM (page 6-8). | with" (ee is 60°C (176 °C). | Sooo Check the voltage at the test harness terminal Connection: SIGNAL AT ECM (+) ~ B17 +} Standard: 0.1-03V 1s the voltage as specified? YES - Faulty O: sensor NO ~ Check the fuel supply system (page 2-2) MIL 22 BLINKS (No.2 02 SENSOR): California type only (page 6-28) 6-29FUEL SYSTEM (Programmed Fuel Injection) MIL 23 BLINKS (No. 1 02 SENSOR HEATER): California type only + Before starting the inspection, check for loose or oor contact on the O: sensor connector and recheck the MIL blinking “MIL /O:Sensor) POWER | SIGNAL SIGNAL ) | INPUT | LINE | ATECM LINE 23 No.0: Black’ Wh Sensor white _ 24 [No.2 Black/White Ao [Sensor __|white _| jo 1. O: Sensor Heater Resistance Inspection ‘Turn the ignition switch OFF Disconnect the O: sensor connector and mea- sure the resistance at the sensor side connector white wire terminal and Green/orange terminal Connection: White - Green/orange 1s the resistance within 10 - 40 9 (20°C/68F)? YES - GOTOSTEP2, NO ~ Faulty Os sensor 2. Or Sensor Heater Open Connect the O: sensor connector. Measure the resistance at the test harness termi- nals, Connection: POWER INPUT LINE - SIGNAL AT ecm uit Inspection 1s the resistance within 10 ~ 40 2 (20°C/68'F)? YES - GOTO STEP, NO = + Open circuit in the Blackiwhite wire + Open circuit in the SIGNAL LINE wire A: 32P (BLACK) CONNECTOR POWER INPUT LINE =a ([paassssgesesos09 |[Ssesseesooeocce5| 6-30FUEL SYSTEM (Programmed Fuel Injection) ‘3. O» Sensor Heater Short Circuit Inspection 1 Discannect the O: sensor connector. Check for continuity between the SIGNAL LINE wire terminal at test harness and ground. Connection: SIGNAL AT ECM - Ground Is there continuity? VES Short circuit in the SIGNAL LINE wire NO - GOTO STEP 4 4, 02 Sensor Heater Short Circuit Inspection 2 Cheek for continuity between the O sensor con- nectar terminals and ground. Connection: White ~ Ground 1s there continuity? YES ~ Faulty 02 sensor NO ~ Roplace the ECM with 2 known good fone, and recheck, MIL 24 BLINKS (No.2 02 SENSOR): California type only. (page 6-30) -— [seasenopeessusea] 6-31FUEL SYSTEM (Programmed Fuel Injection) MIL 33 BLINKS (E?-PROM) 1. Recheck MIL Blinks 1 Reset the self-diagnosis memary deta (page 6-9) Turn the ignition switch ON and engine stop switch " Q) Check that the MIL blinks. Does the ML blink 33 times? YES = Replace the ECM with @ known good fone, and recheck, NO - GOTOSTEP2, 2, Recheck MIL Blinks 2 Turn the ignition switch OFF, Short the data link connector with the SCS service connector (070PZ-ZY30 100), Turn the ignition switch ON and engine stop switch" Q* Check thai the MIL binks. Does the MIL blink 33 times? YES -GOTOSTEPS, | NO = Intermittent failure | 3. Recheck MIL Blinks 3 Reset the self-diagnosis memory data (page 6-9), Turn the ignition switch ON and engine stop switeh" Q)* Check that the MIL blinks. Does the MIL Blink 33 times? YES - Replace the ECM with @ known good tone, and recheck. NO — Intermittent failure 6-32FUEL SYSTEM (Programmed Fuel Injection) DTC CODE INDEX + The Diagnostic Trouble Codes (OTC) are based upon Malfunction Indicator Lamp (MIL} codes and aro displayed as hyphenated numbers. The digits in front of the hyphen are equal to an MIL code and indicate the Funetion Failure. The digit behind the hyphen details the symptom, For example, in the case of the TP sensor, the ECM storas twa levels of information, a function failure and a detail of the symptom® (08 ~1) = TF sensor voltage ~ lower than the specified value (08 - 2) = TP sensor voltage — higher than the specified value. ‘The MAP, ECT, TP and IAT sensor diagnosises will be made according to the voltage output of the affected sensor. Ifa failure occurs, the ECM deterrmines the Function Failure, compares the sensor voltage output to the standard value, and then outputs the corresponding DTC to the HDS Pocket Testar For example: ~ If the input voltage fine (A) on the MAP sensor is opened, the ECM detects the output voltage is about 5 V, then the DTC 1-2 (MAP sensor circuit high voltage) will be displyaed, ~ 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 circuit low voltage! will be displyaed. MAP SENSOR sv TP SENSOR a OUTPUT VOLTAGE OUTPUT VOLTAGE 5v 5v ‘CT SENSOR IAT SENSOR OUTPUT VOLTAGE ‘OUTPUT VOLTAGE 6-33FUEL SYSTEM (Programmed Fuel Injection) pre t Function Failure Causes ‘Symptoms Refer EChmalfunction | + Faulty ECM > Engine does not siart 698 a - + MIL does not blink | ECM power input | > Open circuit at the power Input Engine dees not start eae circuit malfunc- tion wire of the ECM + Faulty bank angle sensor + Open circuit in bank angle sensor related circuit + Faulty engine stop relay + Open circuit in engine stop relay related wires + Faulty engine stop switch + Open circuit in engine stop switch related wires Faulty ignition switeh + Blown PGM-FI fuse {20 A) + Blown sub-fuse (10 A) (Starter, Bank angle sensor) MIL does not blink ECM output ine + ECM output voltage Tine (Wellow? Engine does not shart malfunction __|__red wire) short cireuit - “ MIL circuit mal + Faulty ECM + Engine operates nor function + Open or short circuit in MIL wire mally MIL does nat blink Data Tink eiveuit malfunction MAP sensor cir- cuit low voltage + Short circuit in data link connector + Faulty ECM + Short circuit in deta link connector + Open or shor circuit in MAP san- + Faulty MAP sensor Engine operates nor mally MIL stays it Engine operates nor- mally 1 MAP sensor ci= + Loose or poor contact on MAP + Engine operates nor 6-38 suit high voltage sensor connector mally, + Open circuit in MAP sensor wire + Faulty MAP sensor a MAP sensor par | Loose or poor connection ofthe > Engine operates nor- 539 formance prob- MAP sansor vacuum hose mally lem + Faulty MAP sensor a ECT sensor cir Shor circuit in ECT sensor wire + Hard start ata low tem- 6-40 cuitlow voltage | + Faulty ECT sensor perature (Simulate using fumerical values; 80°C) | 194 "F) mc ECT sensor ci | > Loose or paar contact on ECT san- > Herd atarata lowtems | 6-40 cuit high voltage sor perature (Simulate using + Open circuit in ECT sensor wire numerical values; 80°C) | | + Faulty ECT sensor - 49e"F1 - s7 TP sansor fcuk |= Loose or poor contact on TPsen > Poor ean pa 5a low voltage sor connector ‘ance and response + Open or short circuit in TP sensor when opereting the wire throttle quickty[Simu- | + Faulty TP sensor Iste using numerical val- ues: Throttle opens 0°) 32 ‘TPsensor circuit | + Open circultin TP sensor wire * Poor engine parfo eas high voltage + Faulty TP sensor mance end response when operating the throtte quickly (Sim late using numerical val | - tues; Throtle opens 0") FF IAT sensor circuit | ~+ Shor circuit (AT sensor wire 7 Engine operates nor low voltage + Faulty AT sensor mally (Simulate using fumerical values; 25 °C) 71°F) vs TAT sensor tet | > Loose or poor contact on AT 3en° > Engine operates nor | 645 nigh voltage sor mally (Simulate using + Open circuit in IAT sensor wire humeral values; 25°C) L - + Faulty AT sensor 77°F)FUEL SYSTEM (Programmed Fuel Injection) pre Function Failure Causes Symptoms TET) Vehicle speed + Loose or poor contact on vehicle |» Engine operates nor. eas sensor no signal speed sensor connector mally (circuit matfune- + Open or short circuit in vehicle tion) speed sensor connector | + Faulty vehicle speed sensor _ 127 No.1 Primary > Loose oF poor contact an No.1 + Engine dees not start &-€7 injector circuit mary injector connector matuncton + Opeh orahon creat nN. | mmory iecter wire | Faulty No.1 Primary injector TST Nad Primary * Loose or poor contact on No.zPr- | + Engine doos notatart > 6-49 injector eircuit ‘mary injector connector malfunction + Open or short circuit in No.2 Pri- mary injector wire | Faulty No.2 Primary injector Te No. Primary + Loose or poor contact on No3PH- | > Engine doas not start Injector circuit mary injector connector malfunetion * Open or shor circuit in No.3 Pri- mary injector wire Faulty No.3 Primary injector 1ST Not Primary * Loose or poor contact on No.# Pri- |» Engine doos not start oe injector circuit mary injector connector maifunetion + Open or short circuit in No.¢ Pri- | | mary injector wire ||. Feu Nect Primary injector | ye | No.1 Secondary * Loose or poor contact on No.T | > Engine does not tar ee | injector eircuit Secondary injector connector malfunction + Open or short circuit in No.1 Sec- ondary injector wire + Faulty No.1 Secondary injactor TA No.2 Secondary | + Loose or poorcontacton No.2 | + Enginedoesnotstat «648 | injector circuit Secondary injector connector malfunction + Open or shor circuit in No.2 See. ondary injector wire | + Faulty No.2 Secondary injector Te ‘Cam pulso ganar > Loose or poor contact on cam, + Engine doos nor start 550 ator no signal pulse generator + Open or shor circuit in cam pulse generator + Faulty cam pulse gener eT Ignition pulse * Loose or poor contact an ignition Engine does not start generator no sig pulse generator nal + Open or short circuit in ignition pulse generator |_1 Faulty ignition pulse generator 201 No.1 O2 sensor | + Loose or poor contact an O: sen- Engine operates nor- 652 circu maltune- sor connector maily tion (California + Shor circuit in O> sensor type only) + Faulty 0: sensor ZT No2 Orsensor | + Loose or poor eontactan Orsen- | > Engine operates nor 353 circuit maifune- sor connector mally tion (Callfernia + Shor ciccuit in Os sensor type only) __|_+ Faulty Or senor 231 No.1 Or sensor Loose or poor contact on O2 sen- + Engine operates nor- 6-54. heater malfune- sor connector mally tion (California + Open or short circuit in O2 sensor type ony) heater |_+ Faulty 02 sensor - et No2orsers07 * Loose or poor eontaet on Orsen- | * Engine operates nor os heater malfune- soreonnector mally tion {California + Open or short circuit in O2 sensor type only) neater LE _ | rat orseoneseFUEL SYSTEM (Programmed Fuel Injection) prc Function Failure Causes Symptoms a1 E-PROM in ECM Faulty ECM * Engine operates nor- | malfunction mally + Does not hold the selt: a _ 7 __Giagnosis data Bi No.3 Secondary + Loose or poor contact on No.3 Engine does not start 629 injector circuit Secondary injector connector malfunetion + Open or short circuit in No.3 Sec- ondary injector wire _ __|_+ Faulty’No.3 Secondary injector - “IT| No.t Secondary * Loose or poor contact an No.t + Engine does not start Injector circuit ‘Secondary injector connector | malfunction + Open or short circuit in No.d Sec- ondary injector wire + Faulty’No.4 Secondary injector 6-36FUEL SYSTEM (Programmed Fuel Injection) DTC TROUBLESHOOTING BiG 1-1 IMAP SENSOR LOW VOLT. 1, MAP Sensor System Inspection Turn the ignition switch ON and engine stop switch" Q)*. ‘Check the MAP sensor with the HDS, Is about 0 V or below indicated? YES - GOTO STEP 2. NO = + Intermittent failure + Loose or poor contact on the MAP sensor connector 2, MAP Sensor Input Voltage Inspection ‘Tum the ignition switch OFF, r Disconnect the MAP sensor 3P connector. Turn the ignition switch ON and engine stop switch" Q)* Measure the voltage at the wire harness side. Connection: Yellow/red (+) ~ Gre snforange (-) Js the voltage within 4.75 - 5.25V? YES - GOTO STEP 4 NO - GOTO STEPS 3, MAP Sensor Input Line Inspection Tuen the ignition switch OFF. Disconnect the ECM 32P connectors. Check for continuity at the Yellowired wire between the MAP sensor 3P connector terminal and the ECM 32? (Light gray) connector. Connection: B18 ~ Yellow/red | Is there continuity? YES. = Replace tho ECM with a known good | Snes vecheck NO ~ Opon circuit in Yellowlred wire 4. MAP Sonsor Output Line Short Circuit Inspec- tion Cheek for continuity between the MAP sensor 3P connector terminal of the wire harness side and ground. Connection: Light green/yellow - Ground Is there continuity? YES Short circuit in Light greeniyellow wire No - GOTO STEPS.FUEL SYSTEM (Programmed Fuel Injection) 5. MAP Sensor Inspection Roplace the MAP sensor with @ known good one (page 6-88) Reset the ECM (page 6-3). Turn the ignition switen ON and engine stop switch" Q". Check the MAP sensor with the HDS, Is DTC 1-1 indicated? YES = Replace the ECM with s known good one, and recheck NO ~ Foulty original MAP sensor DTC 1-2 (MAP SENSOR HIGH VOLT- AGE) + Before starting the inspection, chack for loose or poor contact on the MAP sensor connactor end recheck the DTC. 1. MAP Sensor System Inspection 1 Turn the ignition switch ON and engine stop switeh "+ Check the MAP sensor with the HDS. 's about 5 V indicated? YES - GOTO STEP2 NO + Intermittent failure + Loose or poor contact on the MAP sensor connector 2. MAP Sensor System Inspection 2 Turn the ignition switen OFF. cee “ | MAP SENSOR 3° CONNECTOR Disconnect the MAP sensor 3P connector. ‘ Connect the MAP sensor terminals at the wire harness side with a jumper wire Connection: Light green/yellow ~ Green/orange Turn the ignition switch ON and engine stop switch" (Q* Check the MAP sensor with the HDS. Is about 0 V indicated? YES ~ Faulty MAP sensor No -GOTOSTEP3 a JUMPER WIRE 3. MAP Sensor Input Voltage Inspection Turn the ignition switeh OFF. — Remove the jumper wire. MAP SENSOR 3P CONNECTOR Tur the ignition switch ON and engine ‘stop switeh Q) Measure the voltage st the wire harness side. Connection: Yellow/red (+) ~ Green/orange : 6-38FUEL SYSTEM (Programmed Fuel Injection) 4, MAP Sensor Output Line Open Circuit Inspec- tion Disconnect the ECM 32P connectors. Check for continuity at the Light green/yellow wire between the MAP sensor 3P connector ter minal and the ECM 32P (Light gray) connector. Connection: B15 - Light gr n/yellow Is there continuity? YES - Roplaco the ECM with a known good ‘one, and recheck NO - Open circuit in Light green/yellow wire DTC 2-1 (MAP SENSOR) + Boforo starting the inspection, check for loose or oor contact on the MAP sensor connector and recheck the DTC. 1, MAP Sensor System Inspection Turn the ignition switch ON and engine stop switch =" Start the engine and check the MAP sensor with ‘the HDS at idle speed, Js 1.8 Vindicated? YES ~ Intermittent failure NO - GOTO STEP2 2. Manifold Absolute Pressure Test ‘Turn the ignition switch OFF. ‘Check for connection and installation of the MAP. sensor vacuum hase, Js the MAP sensor vacuum hose connection cor- rect? YES - GOTO STEPS, NO ~ Correct the hose installation 3, MAP Sensor System Inspection Replace the MAP sensor with a known gaod one (page 6-83). Turn the ignition switch ON and engine stop switch") Start the engine and check the MAP sensor with the HDS at idle speed. Is 1.6 Vindicated? YES ~ Faulty original MAP sensor NO ~ Replace the ECM with @ known good one, and rechack. VACUUM HOSE 6-39FUEL SYSTEM (Programmed Fuel Injection) DTC 7-1 (ECT SENSOR LOW VOLT- AGE) 1. ECT Sensor System Inspection Turn the ignition switch ON and engine stop switch " Q)* Check the ECT sensor with the HOS. Js about 0 V indicated? YES - GOTO STEP 2, NO = + Intermittent failure + Loose or poor contact on the ECT sensor connector 2. ECT Sensor Inspection ‘Turn the ignition switch OFF jsconnect th ‘sensor 3P connector. ECT SENSOR ° “tne ECT SP eonnect 3P CONNECTOR , Turn the ignition switch ON and engine stop é switch *()" Check the ECT sensor with the HOS, Is about 0 V indicated? | extsevsoe 3. ECT Sensor Output Line Short Circuit Inspection Turn the ignition switch OFF. Check for continuity between the ECT sensor 3P connector terminal of the wire harness side and ground. Connection: Pink - Ground Is there continuity? YES - Short circuit in Pink wire NO = Replace the ECM with @ known good fone, and recheck, DTC 7-2 (ECT SENSOR HIGH VOLT- AGE) * Before starting the inspection, check for loose or oor contact on the ECT sensor connector and recheck the DTC. 1. ECT Sensor System Inspection Turn the ignition switch ON and engine stop switch * ()* Check the ECT sensor with the HDS, Is about § V indicated? YES -GOTOSTEP2 NO — = Intermittent failure + Loose or poor contact on the ECT sensor connector 6-402. ECT Sensor Inspection Turn the ignition switch OFF, Disconnect the ECT sonsor 3P connector. Connect the ECT sensor terminals with a jumper Connection: Pink - Green/orange Turn the ignition switch ON and engine stop switch * Q) Check the ECT sensor with the HDS. Is about 0 V indicated? YES. ~ inspect the ECT sensor (page 20-16) | No - GOTO STEP3. > JUMPER WIRE 3. ECT Sensor Output Line Inspection Turn the ignition switch OFF. Remove the jumper wire, | Discannect the ECM 32P connectors, | Check for continuity atthe Pink (ECM side: Pink’ | white) and Graen/orange wires between the ECT sensor 3P connector terminal and the ECM 32P (Light gray} connector. Connection: 827 ~ Pink B17 ~ Green/orange Are there continuity? YES ~ Replace the ECM with a known good fone, and recheck No - Open circuit in Pink or Pinkiwhite + Open circuit in Green/orange wireFUEL SYSTEM (Programmed Fuel Injection) DTC 8-1 (TP SENSOR LOW VOLTAGE) Before starting the inspection, check for loose or oor contact on the TP sensor connector and recheck the OTC. 1. TP Sensor System Inspection Turn the ignition switch ON and engine stop switch" Q)*. Check the TP sensor with the HDS when the throttle fully closed, Is about 0 V indicated? YES - + Intermittent failure + Loose or poor contact on the MAP sensor connector NO - GOTO STEP2 2. TP Sensor Input Voltage Inspection ‘Tum the ignition switch OFF. Disconnect the TP sensor 3P connector. "TP SENSOR 3P CONNECTOR Tur the ignition switch ON and engine stop switch * Measure the voltage at the wire harness side. Connection: Yellow/red (+) - Green/orange (-) Js the voltage within 4.75 ~ 5.25 V? YES - GOTOSTEP 4 NO - GOTO STEP 3. TP Sensor Circuit Inspection Disconnect the ECM 32P connectors. Check for continuity at the Yellow/ed wire between the TP sensor 3P connector terminal and the ECM 39P (Light gray) connector. Conneetion: B18 Yellow/red Is there continuity? YES - Replace the ECM with @ known good ‘one, and recheck NO ~ Open circuit in Yellow/red wire 6-42FUEL SYSTEM (Programmed Fuel Injection) 4. TP Sensor Output Line Open Circuit Inspection Check for continuity at the Rediyellow wire between the TP sensor 3P connector terminal and the ECM 32? (Light gray) connector. Connection: B14 - Red/yellow Is there continuity? Yes - GOTOSTEPS NO - Open circuit in Rediyellow wire 5. TP Sensor Output Line Short Circuit Inspection Disconnect the TP sensor 3P connector. Check for continuity between the TP sensor 3P connector terminal of the wire harness side and ground Connection: Red/yellow ~ Ground TP SENSOR 3P CONNECTOR, Is there continuity? YES - Short circuit in Red/yellow wire NO - GOTOSTEPS. 6. TP Sensor Inspection Roplace the TP sensor with known good one. Rosot the ECM (page 6-8) Turn the ignition switch ON and engine stop switch" Q)" Check the TP sensor with the HDS. 1s DTC 8-1 indicated? YES - Replace the ECM with a known good fone, and recheck NO = Faulty original TP sensor DTC 8-2 (TP SENSOR HIGH VOLTAGE) 1. TP Sensor System Inspection Turn the ignition switch ON and engine stop switeh" Q* Check the TP sensor with the HDS. Is about 5 V indicated? YES ~ GOTOSTEP2 NO ~ = Intermittent failure + Loose or poor contact on the TP sen- sor connector 6-43FUEL SYSTEM (Programmed Fuel Injection) 2. TP Sensor Resistance Inspection Turn the ignition switch OFF. Disconnect the TP sensor 3P connector. Measure the resistance at the TP sensor side, Connection: Red/yellow - Green/orange Is the resistance within 0.4 -0.6 0? YES - GOTOSTEPS No - Faulty TP sensor 3. TP Sensor Input Voltage Inspection Turn the ignition switch ON and engine stop switch" Q* Measure the voltage at the wire harness side. | ‘TP SENSOR 3° CONNECTOR Connection: Yellow/red (+] ~ Green/orange (-) Is the voltage within 4.75 — 5.25 V? YES - Replace the ECM with a known good ‘one, and recheck NO ~ Open circuit in Green/orange wires DTC 9-1 (IAT SENSOR LOW VOLTAGE) 1. IAT Sensor System Inspection Turn the ignition switch ON and engine stop switch " )* Check the IAT sensor with the HDS, Is about 0 V indicated? YES - GOTO STEP2 NO ~ + Intermittent failure + Loose er poor contact on the IAT Sensor connector 2. IAT Sensor Inspection Turn the ignition switch OFF a Disconnect the IA sensor 2 connector, IAT SENSOR 2P CONNECTOR Turn the ignition switch ON and engine stop switch * Check the IAT sensor with the HDS, Is about 0 V indicated? Yes - coro sTePs NO. ~ Faulty IAT sensor 6-44FUEL SYSTEM (Programmed Fuel Injection) 3. IAT Sensor Output Line Short Circuit Inspection comecter termine] fe wife hemess side and | /AT SENSOR 2F CONNECTOR round Connection: Gray/blue Ground le there continuity? YES Short circuit in Gray/blue wire NO - Replace the ECM with @ known good ‘one, and recheck DTC 9-2 (IAT SENSOR HIGH VOLTAGE} + Before starting the inspection, check for loose or poor contact on the IAT sensor connector and recheck the DTC. 1. IAT Sensor System Inspection Turn the ignition switch ON and engine stop switch" Q". Check the IAT sensor with the HOS, Is about 5 V indicated? YES - GOTO STEP2 NO = = Intermittent failure + Loose or poor contact on the IAT sensor connactor 2. IAT Sensor Inspection Turn the ignition switch OFF. | ‘arsewson ae conyecroa Disconnect the IAT sensor 2P connector. th fooke Connect the IAT sensor terminals with a jumper Connection: Gray/blue ~ Green/orange | Turn the ignition switch ON and engine stop switch * * Check the IAT sensor with the HDS. Is about 0 V indicated? YES - Faulty IAT sensor NO - GOTO STEP. 3. IAT Sensor Output Line Inspec Disconnect the ECM 32P connectors. Check for continuity at the Gray/blue and Greeny orange wire between the IAT sensor 2P connec- tor terminals and the ECM 32° (Light gray] con- nectar. Connection: 817 - Gray/blue 830 ~Green/orange Are there continuity? YES - Replace the ECM with @ known good fone, and recheck. Tisicoxstosanieo Seenee NO - + Open circuit in Gray/blue wire + Open circuit in Gresnjorange wireFUEL SYSTEM (Programmed Fuel Injection) DTC 11-1 (VEHICLE SPEED SENSOR) + Before starting the inspection, check for loose or oor contact on the vehicle speed sensor con nector and recheck the DTC. 1. Vehicle Speed Sensor System Inspection Support the motorcycle securely and place the tear wheel off the ground. Stert the engine and shift the transmission into gear. Check the vehicle speed sensor with the HDS at 10 kmh, Is 10 km/h indicated? YES + Intermittent failure + Loose or poor contact on the vehicle speed sensor connector NO ~ GOTO sTEP2 2. Combination Meter Inspection Check for operation of speed meter. Does the speed moter operate normally? YES = Open or short circuit in the Pink/green NO -GOTOSTEP3 9" a | oe we 3, Vehicle Speed Sensor Input Voltage Inspection Turn he ignition sch OF Turn the igi swith ON and engine stop | sch" Neosure the votage at the wie harness side Connection: lack e)- Green Js there battery voltage? YES - GOTOSTEP 4, NO - + Opon cist in he Black or Black | brown wire + Open circuit in the Green or Greeny black wia 6-464. Vehicle Speed Sensor Signal Line Short Inspection Turn the ignition switch OFF I Disconnect the ECM 32P connectors. Check for continuity between the ECM 32P Light gray) connector terminal and the ground, Connection: B25 - Ground Is there continuity? YES - Short circuit in the Pink or Pink/areen shy Ate NO - Inspect vehicle speed sensor (page 20. 13) DTC 12-1 (No.1 PRIMARY INJECTOR) * Before starting the inspection, check for loose or oor contact On the Primary injector connectors and recheck the OTC. DTC) INJEC: POWER | SIGNAL | SIGNAL Bi S2P (LIGHT GRAY) CONNECTOR TOR INPUTLINE| LINE | ATECM wee i pUT LINE T21 No.1 Blackiwhite Pinkiyellow [ATT Primary _ 13:1 [No.2 Glackiwhite Pinkiblue [AT a x Als | Peseenctennatos | os Primary | | Sree TST [No.4 Blacklwhite |Pinkiblack [A1a ah ar i Primary | ET /No.1 Blacklwhite |Pinldyellow [BT Sec ondary A: 32P (BLACK) CONNECTOR | Sec. ondary | 87 No.3 Blackiwhite /PinWarean B39 See: | ondary 49-1 (No.8 Blackiwhite (Pinkiblack 84 BlacKwhite Pinkbiue | 1. Injector System Inspection Roset the ECM (page 6.8) Start the engine and check the injector with the Hos. Js the DTC 12-1 indicated? YES - GOTOSTEP2 NO = = Intormittent failure + Loose or poor contact on the injector connector 6-47FUEL SYSTEM (Programmed Fuel Injection) Injector Circuit Resistance Inspection Turn the fanition switch OFF. Disconnect the ECM 32P connectors and mea sure the resistance of the ECM 32P connector terminals, Connection: POWER INPUT LINE - SIGNAL AT ECM |s there continuity? YES -GOTOSTEPS NO -GOTOSTEPS 3. Injector Resistance Inspection Disconnect the primary injector 2P connector ‘and measure the resistance of the primary injec: tor 2P connector terminals. Is the resistance within 10.5 - 14.5 2 (20°C/ 68°F)? YES - GOTO STEP 4, NO - Faulty injector 4. Injector Input Voltage Inspection Turn the ignition switch ON and engine stop switch "(0)" Measure the voltage between the primary injec tor connector of the wire harness side and ground. Connection: POWER INPUT LINE (+) ~ Ground (+1 Is there battery voltage? YES — Open circuit in SIGNAL LINE wire NO - Open circuit in POWER INPUT LINE wire 6-48FUEL SYSTEM (Programmed Fuel Injection) 5. Injector Signal Line Short Circuit Inspection Check for continuity between the ECM 32P con. Rector terminal and ground Connection: SIGNAL AT ECM - Ground continuity? Short circuitin the SIGNAL LINE wire + Faulty injector NO — Replace the ECM with a known good ‘one, and recheck DTC 13-1 (No.2 PRIMARY INJECTOR) (page 6-47) DTC 14-1 (No.3 PRIMARY INJECTOR) [page 6-47) DTC 15-1 (No.4 PRIMARY INJECTOR) page 6-47) DTC 16-1 (No.1 SECONDARY INJECTOR) {page 6-47) DTC 17-1 (No.2 SECONDARY INJECTOR} (page 6-47) DTC 48-1 (No.3 SECONDARY INJECTOR} (page 6-47) DTC 49-1 (No.4 SECONDARY INJECTOR) (page 6-47) 6-49FUEL SYSTEM (Programmed Fuel Injection) DTC 18-1 (CAM PULSE GENERATOR) + Before starting the inspection, check for loose or poor contact on the cam pulse generator connec: tor and recheck the DTC. 1, Cam Pulse Generator Peak Voltage Inspection, Turn the ignition switch OFF. (eam POSE GENERATOREEGONNESIEG Disconnect the cam pulse generator 2° connec- | CAM PULSE GENERATOR 2P CONNECTOR tor. Turn the ignition switch ON and engine stop switch") Crank the engine with the starter motor, and ‘measure the cam pulse generator peak voltage at the cam pulse generator 2P connector. Connection: Gray («| - White/yellow (+) 's the voltage more than 0.7 V (20 °C/68 F/? YES - GOTOSTEP2 NO - Faulty cam pulse generator 2. Cam Pulse Generator Circuit Inspection Turn the ignition switch OFF. — Disconnect the ECM 32P connectors, Check for continuity at the Grey and Green/ | ay a Ae 4 ‘orange wire between the cam pulse generator | ¢t—— 6 2P connector terminals and the ECM 32P con- rectors terminals. Connection: B10 - Gray A31 ~ Green/orange Is there continuity? YES ~ Short circuit in the Gray wire NO + Open circuit in the Greenforange wire + Open circuit in the Gray wire 50FUEL SYSTEM (Programmed Fuel Injection) DTC 19-1 (IGNITION PULSE GENERATOR) + Before starting the inspection, check for loose or oor contact on the ignition pulse generator con hector and recheck the DTC, 1. Ignition Pulse Generator Peak Voltage Inspec- ttion Turn the ignition switch OFF. Lift and support the fuel tank (page 6-61) Disconnect the ignition pulse generator 2P (Red) connector. Turn the ignition switch ON and engine stop switch "Q* Crank the engine with the starter motor, and measure the ignition pulse generator peak volt ‘age at the ignition pulse generator 2P (Red) con: rector. Connection: Yellow (+) ~ Yellow/white (-} 1s the voltage more than 0.7 V (20 °C/68 °F? YES - GOTO STEP 2 NO - Faulty ignition pulse generator 2. Ignition Pulse Generator Circuit Inspection ‘Turn the ignition switch OFF. Disconnect the ECM 32P connectors. Chock for continuity at the Yellow and Green! ‘orange wire between the ignition pulse genera- tor 2P (Red) connector terminals and the ECM connector terminals. Connection: 89 - Yellow A831 - Yellow/white 1s there continuity? YES - Short circuit in the Yellow wire NO = + Open circuit in the Yellow wire + Open circuit in the Green/orange wire "IGNITION PULSE GENERATOR 2 |RED) CONNECTOR 6-51FUEL SYSTEM (Programmed Fuel Injection) DTC 21-1 (No.1 O2 SENSOR): California type only + Before starting the inspection, check far loose or poor contact on the O: sensor connector and Facheok the DTC, DIC] O:SEN: | GROUND SIGNAL] SIGNAL | 5:97? (LIGHT GRAY! CONNECTOR SOR LINE LINE | ATECM 21 No.10; Green’ Blackired B13 ‘GROUND UNE Sensor orange Black? orange ‘A: 32P {BLACK} CONNECTOR 1, O:Sensor System Inspection 2 Turn the ignition switch ON and engine stop switeh " )*, Warm the engine until the coolant temperature is 80°C (176 Check the O: sensor with the HDS, Standard: 0.1-0.3V Is the voltage as specified? YES Check the fuel pressure (page 6-56), If the system is correct, GO TO STEP 4, NO - GOTOSTEP2, 2. 0: Sensor Open Circuit Inspection, Turn the ignition switen OFF. Disconnect the O: sensor 4P connector and the ECM connectors, Check the continuity between the ECM connec- tor terminals and the O: sensor éP connector. Connection: SIGNAL LINE ~ SIGNAL AT ECM |s there continuity? YES - GOTO STEP, NO = + Open circuit in the at SIGNAL LINE + Open circuit in the GROUND LINE wire 6-52FUEL SYSTEM (Programmed Fuel Injection) 3. 2 Sensor System Short Circuit Inspection Connect the O: sensor 4P connector and discon- ect the ECM connectors. Check the continuity between the ECM connec tor terminals end ground, Connection: SIGNAL AT ECM - Ground Is there continuity? YES ~ Short circuit in the SIGNAL LINE wire No - GOTO STEP«. 4. O: Sensor Inspection Roplace the O: sensor with a known good one. (page 6-99). Reset the ECM (page 6-9). Turn the ignition switch ON and engine stop switch" Q* Warm the engine until the coolant temperature is 80 °C (176 °C. Check the voltage at the test harness terminal, Connection: SIGNAL AT ECM (+) - B17 [-) Standard: 0.1-0.3V Is the voltage as specified? YES ~ Faulty Oz sensor NO = Check the fuel supply system (page 2-2) DTC 22-1 (No.2 O2 SENSOR): California type only (page 6-52) 6-53FUEL SYSTEM (Programmed Fuel Injection) DTC 23-1 (No.1 O2 SENSOR HEATER): California type only + Before starting the inspection, check for loose or poor contact on the Os sensor connector and recheck the DTC. _ - | eraeeresencumucerm | DTC Or Sensor] POWER | SIGNAL” SIGNAL 8: 22P (UIGHT GRAY CONNECTOR | wweuT | “LINE” | ATECM | poweR INPUT LINE jo.102 Black! White A Sensor white 261 /No2 0: — Black’ White 189 Sensor [white ‘A: 32P (BLACK) CONNECTOR | 1. 0: Sensor System Inspection Reset the ECM (page 6-3) Start the engine and check the Oz sensor heater with the HDS. Is the DTC 23-1 indicated? YES - GOTOSTEP2 NO - + Intermittent failure + Loose or poor contact on the O: sen- sor connector 2. O: Sensor Heater Resistance Inspection Turn the ignition switch OFF, r (2 SENSOR CONNECTOR Disconnect the Qs sensor connector and mea sure the resistance at the sensor side connector white and Green/orange wire terminals. Connection: White - White Is the resistance within 10 40 :2(20°C/68°F)? YES - GOTO STEPS, NO - Faulty 02 sensor 3, 2 Sensor Heater Open circuit Inspection Connect the O> sensor eannector. 7 Disconnect the ECM 32P connectors and mea sure the resistance at the ECM terminals. Connection: POWER INPUT LINE ~ SIGNAL Is the resistance within 10-40 © (20°C/68°F)? YES - GOTOSTEP 4 NO - + Open circuitin the Black/white wire + Open circuit in the SIGNAL LINE wire 6-54FUEL SYSTEM (Programmed Fuel Injection) 4, 0: Sensor Hester Short Circuit Inspection 1 Disconnect the O: sensor connector. Check for continuity between the SIGNAL LINE wire terminal at ECM 32P connectors and ground. Connection: SIGNAL AT ECM - Ground Is there continuity? YES ~ Short circuit in the SIGNAL LINE wire NO - GOTOSTEPS, 5. O2 Sensor Heater Short Circuit Inspection 2 Check for continuity between the O2 sensor heater connector terminal and ground, Connection: White - Ground 0: SENSOR CONNECTOR Is there continuity? YES ~ Faulty O2 sensor NO — Replace the ECM with a known good one, and recheck, DTC 24-1 (No.2 O2 SENSOR HEATER): California type only (page 6-54) DTC 33-1 (EPROM) 1. Recheck DTC. Roset the ECM (page 6-9) Turn the ignition switch ON and engine stop switch * Q)* Recheck the ECM EPROM Is the DTC 33-1 indicated? YES - Replace the ECM with a known good cone, and recheck, NO = Intermittent failure 6-55