Honda ST1100 Pan European Service Catalog Manual

1.
General Information
General Safety
Model Identification
Specifications
1-1
1-3
1-4
Lubrication & Seal Points
Cable & Harness Routing
Emission Control Systems
1-23
1-25
1-45
..
Torque Valves 1-17 Emission Control Information Labels
(U.S.A. Only) 1-48
Tools 1-21
General Safety
Carbon Monoxide Used Engine/Transmission Oil
If the engine must be funning to do some work, make sure
the area is well ventilated. Never run the engine in an
enclosed area.
Used engine oil (or transmission oil in twc-enokeel
may cause skin cancer if repeatedly left in contact
with the skin for prolonged periods. Although this
The exhaust contains poisonous carbon monoxide is unlikely unless you handle used oil on a daily
gas that can cause loss of consciousness and may basis. it is still advisable to thoroughly wash your
lead to death. hands with soap and water as soon as possible
after handling used oil. KEEP OUT OF REACH OF
Run the engine in an open area or with an exhaust CHILDREN.
evacuation system in an enclosed area.
Brake Dust
Gasoline Brake dust may contain asbestos. Never use an air hose or
Work in a well ventilated area. Keep cigarettes, flames or dry brush to clean brake assemblies. Use an OSHA-
sparks away from the work area or where gasoline is approved vacuum cleaner or alternate method approved
stored. by OSHA. designed to minimize the hazard caused by
airborne asbestos fibers.
Gasoline is extremely flammable and is explosive

under certain conditions. KEEP OUT OF REACH Inhaled asbestos fibers have been found to cause
OF CHILDREN. respiratory disease and cancer.
Hot Components Brake Fluid
CAUTION
Engine and exhaust system parts become very hot Spilling fluid on painted. plastic or rubber parts will
and remain hot for some time after the engine is damage them. Place a claan shop towel over
run. Wear insulated gloves or wait until the engine these parts whenever the system is serviced.
and exhaust system have cooled before handling KEEP OUT OF REACH OF CHILDREN.
these parts.
1-1
General Information
Coolant Battery Hydrogen Gas & Electrolyte

Under some conditions, the ethylene glycol in engine
coolant is combustible and its flame is not visible. If the
ethylene glycol does ignite, you will not see any flame, but The battery gives off explosive gases; keep
you can be burned. sparks, flames and cigarettes away. Provide
adequate ventilation when charging.
The battery contains sulfuric acid (electrolyte).
Avoid spilling engine coolant on the exhaust Contact with skin or eyes may cause severe
system or engine parts. They may be hot enough burns. Wear protective clothing and a face shild.
to cause the coolant to ignite and burn without a - if electrolyte gets on your skin, flush with
visible flame. water.
Coolant (ethylene glycol) can cause some skin - if electrolyte gets in your eyes, flush with water
irritation and is poisonous if swallowed. KEEP for at least 15 minutes and call a physician.
OU]" OF REACH OF CHILDREN. Electrolyte is poisonous.
Do not remove the radiator cap when the engine is - I f swallowed, drink large quantities of water or
hot. The coolant is under pressure and could scald milk and follow with milk of magnesia or
you. vegetable oil and call a physician. KEEP OUT
Keep hands and clothing away from the cooling OF REACH OF CHILDREN.
fan, as it starts automatically.
If coolant contacts your skin, wash the affected areas

immediately with soap and water. If it contacts your eyes,
flush them thoroughly with fresh water and get immediate
medical attention. If it is swallowed, the victim must be
forced to vomit then rinse mouth and throat with fresh
water before obtaining medical attention. Because of
these dangers, always store coolant in a safe place, away
from the reach of children.
1-2
General Information
Model Identification
'91 (Standard model) Shown:
(1) VEHICLE IDENTIFICATION NUMBER

The Vehicle Identification Number (VIN) is located on the
Safety Certification Label on the left side of the steering
head.
c
f/
(2) ENGINE SERIAL NUMBER (3) FRAME SERIAL NUMBER
The engine serial number is stamped on the rear of the The frame serial number is stamped on the right side of the
lower crankcase behind the oil pan. the steering head.
,,~
\, ---
~"~~ \
(4) CARBURETOR IDENTIFICATION NUMBER (5) COLOR LABEL

The carburetor identification number is stamped on each The color label is attached to the frame under the seat.
carburetor body on the intake side.
1-3
General Information
Specifications
Unit: mm (in)
- General
Item Specifications
Dimensions Overall length 2,285 (90.0)
Overall width ('91-'93) 835 (32.9) [Saddlebag end]
(After '93) 935 (36.8) [Rear view mirror end]
Overall height {'91-'94) 1,395 (54.9)
(After '94) 1,405 (55,3)
Wheelbase 1,555 (61.2)
Seat height 800 (31.5)
Footpeq height --
Ground clearance 145 (5.7l
Dry weight
ABS/TCS or LBS-ABS/TCS model
with saddlebag
('91-'94) 49 state type 297 kg (655 Ib)
California type 298 kg (657 Ib)
Canada type 293 kg (646 lb)
(After '94) 49 state type 298 kg (657 Ib)
Canada type 297 kg (655 Ib)
Standard model with saddlebag
('91-'94) 49 state type 284 kg (626Ib}
California type 285 kg (628 lb}
Canada type 283 kg (624 lb)
Curb weight
ABS/TCS or LBS-ABS/TCS model
with saddlebag
('91-'94) 49 state type 326 kg (719 Ib)
California type 328 kg (723Ib}
Canada type 326 kg (719 Ib}
Standard model with saddlebag
('91-'94) 49 state type 313 kg (690 Ib)
Canada type 312 kg (688Ib)
(After '94) 49 state type 317 kg (699Ib)
California type 318 kg (701Ib)
1-4
General Information
Unit: mm (in)
Item Specifications
Frame Frame type Double cradle
Front suspension Telescopic fork
Front wheel travel 150 (5.9)
Rear suspension Swingram
Rear wheel travel 120 (4.7)
Front tire size
{Standard model and '92-'95 ABS/ 110/80 V18 (Bridgestone, Dunlop)
TCS model} 110/80 V18-V240 (Metzeler)
(After '95 LBS-ABSn-CS model) 120/70 ZR18
Rear tire size
(Standard model and '92-'95 ABS/ 160/70 V17 (Bridqestone, Dunlop!
TCS model) 160/70 VB17-V240 (Metzeler)
(After '95 LBS-ABSn-CS model) 160/70 ZR17
Tire brand FR/RR
{Standard model and '92-'95 ABS/ G547/G548 (Bridgestone)
TCS model} D103F/D103 (Dunlop)
ME33 LASER/MES5A METRONIC (Metzelerl
(After '95 LBS-ABSn-CS model) BT-S4F/BT-54R (Bridgestone)
D202F/D202 (Dunlop)
Front brake Hydraulic double disc
Rear brake Hydraulic single disc
Caster angle 21'30'
Trail length 101 (4.0)
Fuel tank capacity 28 liters (7.40 US gal, 6.161mp gal)
Fuel tank reserve capacity
Engine Bore and stroke 73.0 x 64.8 (2.87 x 2.55)

Displacement 1,085 em' (66.2 cu in)
Compression ratio 10.0 : 1
Valve train Belt and gear driven DOHC
'91-'93 : '91-'93 :
Standard California and Standard 49 state and
U.S.A. ABSn-CS type Canada type
After '93 : California type After '93 : 49 state and
Canada type
-5' BTDC {SO ATDCI 8' BTDC

Intake valve opens at 1 mm lift 0
35 ABDC 37" ABDC
Intake valve closes at 1 mm lift 0
40 BBDC 33° BBDC
Exhaust valve opens at 1 mm lift
-5" ATDC (5° BTDC) 2" ATDC
Exhaust valve closes at 1 mm lift
Lubrication system Forced pressure and wet sump
Oil pump type Trochoid
Cooling system Liquid cooled
Air filtration Paper Filter
Crankshaft type Unit type, 3 main journals
Engine dry weight ('91-'93) 93.0 kg (205 lb) : U.S.A. type and ABS/TCS Canada type
92.0 kg (203 Ib) : Standard Canada type
('94) 93.0 kg (205 Ib) : All types
(After '94) 93.0 kg (205 lbl : U.S.A. type
92.0 kg (203 Ib) : Canada type
Firing order 1-90'-4-270°-3-90 0-2-270"-1
Cylinder arrangement 4 cylinders, 90'V

Cylinder number
Left
~ Front
1-5
General Information
Unit" mm (in)
- General (cont'd)
Item Specifications
Carburetor Carburetor type Constant velocity 4 carburetors
Throttle bore 34.5 (1.36)
Drive train Clutch system Multi-plate. wet

Clutch operation system Hydraulic operating
Transmission 5 speeds
Primary reduction 1.8292 (75/41)
Secondary reduction --
Third reduction --
Final reduction 2.8333 (34/12)
Gear ratio 1st 2.2666 (34/15)
Gear ratio 2nd 1.5000 (27/18)
Gear ratio 3rd 1.1428 (24/21)
Gear ratio 4th 0.9166 (22/24)
Gear ratio 5th 0.7586 (22/29)
Gear ratio 6th --
Gear ratio reverse --
Gearshift pattern Left foot operated return system 1- N -2-3-4-5
Electrical Ignition system Digitalized full transistor ignition

Starting system Electric starter motor
Charging system Triple phase output alternator
Regulator/rectifier type Field controlltriple phase full-wave rectification
Lighting system Battery
AC regulator type --
1-6
General Information
Unit: mm (in)
r-' Lubrication
Item Standard Service Limit
Engine oil capacity at draining 3.6 liters (3.80 US qt, 3.17 Imp qt) --
at disassembly 4.3 liters (4.54 US qt. 3.78 Imp qt) --
at oil filter change 3.7 liters (3.91 US qt. 3.26 Imp qt) --
Recommended engine oil Use Honda GN4 a-stroke oil or equiva-
lent motor oil certified to meet API
OIL VISCOSITIES service classification SF or SG.
Viscosity: SAE 10W-40
Other viscosities shown in the chart may

be used when the average temperature in
your riding area is within the indicated
,, I range.
,20 .4U , ........ ,
""'~
,
-" -~ 0 1 0 2 0 3 0 ~',
Oil pressure at oil pressure switch 392-490 kP, (4.0--5.0 kg/em', 57

-71 psi) at 5,000 rpm (80'C/ 176'F}
Oil pump rotor tip clearance cD 0.15 (0.006) --
body clearance (2) 0.15--0.22 (0.006--0.009) --
end clearance @ 0.02--0.09 (0,0008--0.0035) --
®
0~~1-
I I,~ t " !
,
i
r-' Fuel System
Carburetor identification number
('91-'93) (Standard 49 state type} VD BDA
(Standard California and VD BEA
U.S.A. ABSjTCS type)
(Canada type) VD B1A
(After '93) (Standard 49 state type) VD BDA
(49 state ABSjTCS or 49 VD BJA
state LBS-ABSjTCS type}
(California type} VD BEA
(Canada type) VD B1A
Main jet ('91-'93} (49 state and Canada type) :j;1: 128
(California type) :j;1: 125
(After '93) (Standard 49 state and :j;1: 128
Canada type)
(49 state ABSjTCS or49 :j;1: 125
state LBS-ABSjTCS and
California type}
Slow jet (All U.S.A. types} "38
(Canada type} . .0
Pilot screw initial opening See page 5-12
Pilot screw high altitude adjustment See page 5-1 6
Pilot screw final opening See page 5-12
Float level 7.0 (0.28)
Carburetor vacuum difference Within 40 mmHg (1.6 inHg)
Base carburetor (For carburetor synchronization) NO.4 carburetor
Idle speed (All U.S.A. types) 1 ,200± 100 rpm
(Canada type) 1 ,OOO± 100 rpm
Throttle grip free play 2-6 (0.08-0.24)
Pulse secondary air injection (PAIR) control valve 360 mmHg (14.2 inHg)
vacuum pressure
1-7
General Information
Unit: mm (in)
r-' Cylinder Head
Cylinder compression 1,373 ± 1.96 kPa (14.0 ± 2.0 kg/cm 2 ,
199 ± 28 psil/400 rnln-' (rpm)
Cylinder compression difference
Valve clearance IN 0.13---0.19 (0.005---Q.007)
EX 0.22---0.28 (0.009--0.011)
Cylinder head warpage 0.1010.0041
Cam lobe height CD
IN 36.480--36.640 (1.4362-1.4425) 36.450 (1.4350)
IN (Standard California and U.S.A. ABS/TCS or 35.680-35.840 (1 .4047-1 .4110) 35.650 (1.4035)
U.S.A. LBS-ABS/TCStype)
EX 35.970--36.130 (1.4161-1.4224) 35.940 (1.4150)
EX{Standard California and U.S.A. ABS/TCS or 35.770-35.930 (1.4083-1.4146) 35.740(1.4071)
U.S.A. LBS-ABS/TCS type}
Camshaft runout 0.05 (0.002)
Camshaft oil clearance A 0.020--0.062 (0.0008-0.0024) 0.100 (0.0039)
B 0.050--0.092 (0.0020--0.0036) 0.130 (0.0051)
B
!If AA
t
Camshaft journal O. D. A 24.959-24.980 (0.9826-0.9835) 24.950 (0.9823)
B 24.929-24.950 (0.9815---Q.9823) 24.920(0.9811)
Camshaft holder 1.0. A 25.000--25.021 (0.9843-0.9851)
B 25.000--25.021 (0.9843---0.9851)
Valve stem 0.0. IN 4.475--4.490 (0.1762---O. 1768) 4.465 (0.1758)
EX 4.465--4.480 (0.1758-0.1764) 4.455 (0.1754)
Valve guide 1.0. IN 4.500--4.512 (0.1772---0.1776) 4.562 (0.1796)
EX 4.500--4.512 (0.1772---0.1776) 4.612 (0.1816)
Stem-to guide clearance IN 0.010--0.037 (0.0004-0.0015)
EX 0.020--0.047 (0.0008-0.0019)
Valve guide projection above cylinder head IN (h) 15.3-15.5 (0.60--0.61)
EX {hI 15.3-15.5 (0.60--0.61)
Before guide installation:
1 . Chill the valve guide in the freezer
section of a refrigerator for about an
hour.
2. Heat the cylinder head to 100
-150°C (212-300°F)
'Valve seat width IN 1.0 (0.04) 1.5 (0.06)

EX 1.0 (0.04) 1.5 (0.06)
Valve spring free length IN 41.72 (1.643) 39.6 (15.59)
EX 41.72 (1.643) 39.6 (15.59)
Inner IN
Inner EX
Outer IN
Outer EX
Rocker arm 1.0. IN
EX
Rocker arm shaft 0.0. IN
EX
Rocker arm-to-rocker arm shaft clearance
Valve lifter 0.0. 25.978-25.993 (1.0228-1.0233) 25.968 (1.0224)
Valve lifter bore 1.0. 26.010--26.026 (1.0240--1.0246) 26.040 11.0252)
Hydraulic tappet adjuster assist spring free length
Hydraulic tappet adjuster compression stroke with kerosene
1-8
General Information
Unit: mm (in)
- Cylinder/Piston
Cylinder I. D. 73.000--73.015 (2.8740--2.8746) 73.10 (2.878)
Cylinder out of round -- 0.10 (0.004)
Cylinder taper -- 0.10 (0.004)
Cylinder warpage -- 0.10 (0.004)
Piston mark direction ~IN" mark facing toward the intake side --
Piston O.D. (D) 72.970--72.990 (2.8728-2.8736) 72.850 (2.8681)
Piston O. D. measurement point (H) 19 (0.75) --
Piston pin hole I.D. (d) 18.002-18.008 (0.7087-0. 7090) 18.020 (0.7094)
--< d r-
TIu \\ H
!
0 f
Cylinder-to-piston clearance 0.010--0.045 (0.0004-0.0018) --
Piston pin O. D. 17.994-18.000 (0.7084-0.7087) 17.98 (0.708)
Piston-to-piston pin clearance 0.002-0.014 (0.0001-0.0006) --
Connecting red-to-piston pin clearance 0.016-0.040 (0.0006-0.0016) --
Top ring-to-ring groove clearance 0.025--0.060 (0.0010--0.0024) 0.10 (0.004)
Second ring-to-ring groove clearance 0.015--0.050 (0.0006-0.0020) 0.10 (0.004)
Top ring end gap 0.15--0.30 (0.006-0.012) 0.5 (0.02)
Second ring end gap 0.30--0.45 (0.012-o.018) 0.7 (0.03)
Oil ring (side rail) end gap 0.20--0.70 (0.008-0.028) 1.0 (0.04)
Top ring mark ~W mark facing up --
Second ring mark ~RN" mark facing up --
r- Crankshaft
Connecting rod small end 1.0. 18.016-18.034 (0.7093-0.7100) 18.050 (0.7106)
Connecting rod big end side clearance 0.10--0.30 (0.004-0.012) 0.40 (0.016)
radial clearance
Crankshaft runout 0.05 (0.002)
0-
I-
Crankpin oil clearance 0.030--0.052 (0.0012-0.0020) 0.080 (0.0031)

Crankpin bearing selection See page 11-6
Main journal oil clearance 0.026-0.048 (0.0010-0.0019) 0.065 (0.0026}
Main journal bearing selection See page 1 1-6
- Kickstarter
Kickstarter pinion gear 1.0.
Kickstarter spindle O. D.
Kickstarter idle gear 1.0.
Countershaft 0.0. at kickstarter idle gear
Klckstarter idle gear bushing 0.0.
I. O.
1-9
General Information
Unit: mm (in)
- Transmission
Item Standard servlce Limit
Transmission gear 1.0. M4,M5 31.000--31.025 (1.2204-1.2215) 31.040 {1.2220l
C2, C3 31.000--31.025 (1.2204-1.2215) 31.040 {1.2220)
Transmission gear bushing 0.0. M4,M5 30.950--30.975 (1.2185-1.2195) 30.930 {1.2177J
C2, C3 30.950--30.975 (1.2185-1.2195) 30.930 i1.2177l
Transmission gear bushing 1.0. M4 28.000--28.021 (1.1024-1.1032) 28.031 (1.1036)
Gear-to-bushing clearance at M4, M5 gear 0.02~.075 (0.0010--0.0030) -
at C2, C3 gear 0.02~.075 (0.0010--0.0030) -
Mainshaft 0.0. at M4 gear bushing 27.967-27.980 (1.1011-1.1016) 27.960 (1 .1008l
M'
e: =C q
Gear bushing-to-shaft clearance at M4 gear 0.020--0.054 iO.000B-O.0021) -
Shift fork claw thickness F 5.93-6.00 (0.233-0.236) 5.9 (0.23)
C 5.93-6.00 (0.233-0.236) 5.9 {0.23)
R 5.93-6.00 (0.233-0.236) 5.9 (0.23)
Shift fork 1.0. F 14.000--14.021 (0.5512-0.5520) 14.03 (0.552)
C 14.000--14.021 (0.5512-0.5520) 14.03 (0.552)
R 14.000--14.021 (0.5512-0.5520) 14.03 (0.552)
Shift fork shaft 0.0. at F shift fork 13.973-13.984 (0.5501-0.5506) 13.965 (0.5498)
at C shift fork 13.973-13.984 (0.5501-0.5506) 13.965 (0.54.98)
at R shift fork 13.973-13.984 (0.5501-0.5506) 13.965 (0.5498l
Primary Damper Shaft

Primary damper spring free length 95.4 (3.76) 93.0 (3.66)
1-10
General Information
Unit: mm (in)
r-- Clutch System
Clutch lever free play -- i

--
Recommended clutch fluid DOT 4 brake fluid --
Clutch master cylinder I.D. 14.00(}-1 4.043 (0.5512---0.5529) 14.06 (0.553)
Clutch master piston O. D. ,13.957-13.984 (0.5495--0.5506) 13.94 (0.549)
Clutch outer I. D. -- --
Clutch outer guide O. D. 34.975-34.991 (1.3770--1.3776) 34.965 (1.3766)
I. D. 27.989-28.006 (1.1019-1.1026) 28.016 (1.1030)
Primary damper shaft O.D. at clutch outer guide 27.974-27.987 (1.1013-1.1018) --
Oil pump drive sprocket I.D. -- --
Clutch center B 1.0. -- --
One way clutch inner O.D. -- --
Clutch spring free height -- --
Clutch spring free length 43.0 (1.70) 40.0 (1.57)
Clutch disc/plate thickness (Total of 10 discs and 9 plates) 54.72-55.72 (2. 154-2.194) 54.2 (2.13)
Centrifugal clutch drum I. O. -- --
bushing O.D. -- --
Centrifugal clutch center guide 1.0. -- --
O.D. -- --
Centrifugal clutch center guide collar height -- --
Centrifugal clutch spring free length -- --
Clutch lining thickness -- --
Crankshaft 0.0. at clutch center -- --
r- Cooling System
Coolant capacity (Radiator and engine) 2.5 liters (2.6 US qt. 2.2 Imp qtl
(Reserve tank) Standard model 0.5 liter (0.5 US qt, 0.41mp qt)
ABS/TCS or lBS-ABS/TCS model 0.9 liter (1.0 US qt. 0.8 Imp qt)
Radiator cap relief pressure 108-137 kPa (1.1-1.4 kg/cm 2,
'6-20 psi)
Thermostat begins to open 80-84"C (176-183°F}
Thermostat fully open 95"C (203°F)
Thermostat valve lift 8.0 (0.32) minimum
r-' Drive Train

Recommended final drive oil
Final drive gear oil capacity at disassembly
Hypoid gear oil SAE #80
150 ern' (5.1 US oa. 5.3 Imp oz)
1-
at draining 130 ern' (4,4 US OZ, 4.6 Imp oz)
Final drive gear backlash 0.05---0.15 (0.002---0.006) 0.3 (0.01)
Final drive gear backlash difference between measurements
Ring gear-to-stop pin clearance (A) : 0.30-0.60 (0.012---0.024)
Stop pin shim See page 12-10
Ring gear spacer See page 12-10
Pinion spacer See page 12-11
Final drive gear assembly preload 2-4 kg-cm (1,7-3,5 in-Ib)
Output gear backlash
Output gear I. D.
Output gear bushing 0.0.
1.0.
Output drive shaft 0.0.
Output gear damper spring free length
Output shaft adjustment shim
Countershaft drive shaft adjustment shim
1-11
General Information
Unit: mm (in)
- Wheels/Tires
Minimum tire tread depth (FR) -- 1.5 (0.06)
(RR) -- 2.0 (0.08)
Cold tire pressure Up to 90 kg (200 lb) load {FR) 250 kPa (2.50 kg/cm 2, 36 psi) --
(RR} 290 kPa (2.90 kg/cm 2, 42 psi) --
Up to maximum weight capacity (FR) 250 kPa (2.50 kg/cm 2, 36 psi) --

(RR) 290 kPa (2.90 kg/cm 2, 42 psi) --
Front and rear axle runout -- 0.2 (0.01)
Front and rear wheel rim runout (Radial) -- 2.0 (0.08)
(Axial) -- 2.0 (0.08)
Front wheel hub-to-rim distance -- --
Front wheel hub standard surface -- --
Rear wheel hub-to-rim distance -- --
Rear wheel hub standard surface -- --
Wheel balance weight (Front) -- 60 g (2.1 ozl max.
(Rear) -- 60 g (2.1 ozj max.
Drive chain slack -- --
Drive chain size link (DID) -- --
(RK) -- --
Wheel sensor air gap (Front) ABSfTCS model 0.4- 1.2 (0.016--0.047) --
LBS-ABSfTCS model 0.4-0.5 (0.016--0.020) --
(Rear) 0.7-1.2 (O.028-Q.047) --
- Front Suspension
Front spring free length Standard model 415.6 (16.36) 407.3 (16.04)
ABSfTCS model 474.2 (18.67) 464.7 (18.30)
LBS-ABSiTCS model 483.1 (19.02) 473.4 (1B.64)
Fork spring free length A
B
Fork spring direction Tightly wound coil end facing down
Fork tube runout 0.2 (0.008)
Recommended fork oil Pro Honda Suspension Fluid SS-7
Fork oil level
Fork oil level (R) Standard model 190 (7.5)
ABS/TCS model 177 (7.0)
LBS-ABS/TCS model 140 (5.5)
(L} Standard model 187 (7.4)
ABS/TCS model 174 (6.9)
LBS-ABSfTCS model 136 (5.4)
Fork oil capacity
Fork oil capacity {R} Standard model 385 ± 2.5 em" (13.02 ± 0.08 US oz.
13.51 ± 0.09 Imp oz)
ABS/TCS model 372.0 ± 2.5 em" (12.58 ± 0.08 US ca;
13.05 ± 0.09 Imp ozl
LBS-ABS/TCS model 533.0 ± 2.5 cmv (18.02 ± 0.08 US oz,
18.71 ± 0.09 Imp oz)
(L} Standard model I 435.0 ± 2.5 em- (14.71 ± 0.08 US oz.
15.27 ± 0.09 Imp oz)
ABS/TCS Model 418.0 ± 2.5 em' (14.14 ± 0.08 US oz.
14.67 ± 0.091mp oz}
LBS-ABS/TCS model 486.0 ± 2.5 ern' (16.43 ± 0.08 US oz.
17.06 ± 0.09 Imp oz)
Fork air pressure
Steering bearing preload 1.5-2.0 kg (3.3-4.4 lb)
1-12
General Information
Unit: mm (in)
r-- Rear Suspension
Shock absorber spring free length Standard model 256.5 (10.10) 251.4 (9.90)
ABSfTCS or LBS-ABS/TCS 258.9 (10.19) 253.7 (9.99)
Shock absorber spring free length (R) -- --
ILl -- --
Damper gas pressure -- --
Damper compressed gas -- --
Damper rod compressed force at 10 mm compressed -- --
Damper drilling point -- --
Shock absorber spring installed length (Standard) -- --
(Adjustable range) -- --
Shock absorber spring adjuster standard position -- --
Shock absorber spring direction -- --
Recommended shock absorber oil -- --
Shock absorber oil capacity -- --
air pressure -- --
- Brakes - - - - - - - - - - - - - - - - , - - - - - - - - - - - - - , - - - - - - - ,
Front brake
Brake fluid DOT 4
Brake lever free play
Brake pad wear indicator To the groove CD
Brake disc thickness 4.8-5.2 (0.19-0.20) 4.0 (0.16)

Brake disc runout 0.30 (0.012)
Master cylinder I.D. Standard and ABS/TCS model 14.000-14.043 (0.5512-0.5529) 14.06 (0.554)
LBS-ABS/TCS model 12.700-12.743 (0.5000-0.5017) 12.76 (0.502)
Master piston 0.0. Standard and ABS/TCS model 13.957-13.984 (0.5495-0.5506) 13.95 (0.549)
LBS-ABS/TCS model 12.657-12.684 (0.4983-0.4994) 12.65 (0.498)
Caliper cylinder I.D. Standard and ABSfTCS model 27.000-27.050 (1.0630-1.0650) 27.06 (1.065)
LBS-ABS/TCS model R. (Upper) 27.000-27.050 (1.0630-1.0650) 27.06 (1.065)
(Center) 22.650-22.700 (0.8917-0.8937) 22.71 (0.894)
(Lower) 25.400-25.450 (1.0000-1.0020) 25.46 (1.002)
L. (upper) 25.400-25.450 (1.0000-1.0020) 25.46 (1.002)
(Center) 25.400-25.450 (1.0000-1.0020) 25.46 (1.002)
(Lower) 22.650-22.700 (0.8917-0.8937) 22.71 (0.894)
Caliper piston 0.0. Standard and ABS/TCS model 26.918-26.968 (1.0598-1.0617) 26.91 (1.059)
LBS-ABS/TCS model R. (Upper) 26.935-26.968 (1.0604-1.0617) 26.91 {1.059}
(Center) 22.585-22.618 (0.8892-0.8905) 22.56 (O.888}
(Lower) 25.335-25.368 (O.9974-0.9987) 25.31 (O.996}
L. (Upper) 25.335-25.368 (O.9974-0.9987) 25.31 (O.996}
(Center) 25.335-25.368 (0.9974-0.9987) 25.31 (O.996}
(Lower) 22.585-22.618 (0.8892-o.8905) 22.56 (O.888)
Brake drum I.D.
Brake lining thickness
1-13
General Information
Unit: mm (in)
r- Brakes (cant'dl
Rear brake
Brake fluid DOT 4
Brake pedal height
Brake pedal free play
Brake pad wear indicator
To the groove (f:
-
Brake disc thickness Standard and ABS/TCS model 7.3-7.7 {O.29-0.30} 6.0 (0.24)
LBS-ABSrrCS model 7.3-7.7 (0.29--0.30) 6.5 {0.26)
Brake disc runout 0.30 (0.012}
Master cylinder 1.0. Standard and ABSrrCS model 12.700-12.743 (0.5000-0.5017l 12.76 (0.502)
LBS-ABS/TCS model 17.460-17.503 (0.6874-0.6891) 17.515 (0.6895)
Master piston 0.0. Standard and ABS!TCS model 12.657-12.684 (0.4983-0.4994) 12.65 (0.498)
LBS-ABSrrCS model 17.417-17.444 (0.6857-0.6868) 17.405 (O.6852}
Caliper cylinder 1.0. Standard and ABSrrCS model 27.000-27.050 (1.0630-1.0650} 27.06 (1.065)
LBS-ABSJTCS model (Front) 22.650-22.700 (0.8917--0.8937) 22.71 (0.894)
(Center) 27.000-27.050 (1.0630-1.0650) 27.06 {1.065)
(Rear} 22.650-22.700 (0.8917-0.8937) 22.71 (0.894}
Caliper piston 0.0. Standard and ABS/TCS model 26.918-26.968 (1.0598-1.0617) 26.91 (1.059)
LBS-ABSJTCS model (Front) 22.585-22.618 (0.8892--o.8905} 22.56 (0.888)
(Center) 26.935-26.968 (1.0604-1.0617) 26.91 (l.059)
(Rear} 22.585-22.618 (0.8892-0.8905) 22.56 (0.888)
Brake drum 1.0.
Brake lining thickness
Secondary master cylinder 1.0. (LBS-ABS/TCS model) 14.000-14.043 (0.5512--0.5529) 14.06 (0.554)
master piston 0.0. (LBS-ABSJTCS model) 13.957-13.984 (0.5495-0.5506) 13.95 (0.549)
- Battery/Charging System -------------r---------------,--------,

Alternator charging coil resistance (at 20'C/68"F} 0-1.0 n ('91-'95}
0.22-0.26 n (After '95)
Rotor coil (field coil) resistance {at 20°C/68"F) 0-4.0 n ('91-'95)
2.6-3.2 n (After '95)
Regulator/rectifier regulated voltage ('91-'95) 12.6-15.0 V at 5,000 rpm
(After '95} 14.2-14.8 V at 5,000 rpm
Battery capacity 12 V-12 AH
(Maintenance free battery: YTX14-BS)
Specified current leakage ('91-'95) 3 mA max.
(After '95) 2 mA max.
Battery specific gravity {Fully charged)
(Needs charging)
Battery charging rate (Normal) 1.4Ax5h
(Quick) 6Ax1h
Battery voltage (Fully charged at 20OC/68"F) 13.1 V
(Needs charging at 20T/68·F) Below 12.3 V
AC regulator regulated voltage (With analogue type)
(With digital type)
Brush length (After '95) 13.7 (Q.54} 4.7 (O.19)
Slip ring 0.0. (After '95) 14.4 (0.57} 12(0.5)
1-14
General Information
- Ignition System
Spark plug
(Standard NGK) CR8EH 9 --
(Standard NIPPONDENSO) U24FER9 --
(For cold climate/below 5"C/41"F NGK) -- --
(For cold climate/below 5"C/41 'F NIPPONDENSO) -- --
(For extended high speed riding NGK) CR9EH 9 i--
(For extended high speed riding NIPPONDENSO) U27FER9 --
Spark plug gap 0.8-0.9 (0.031-0.035) --
Ignition timing "'F'. mark 12~ BTDC at 1,000 rpm --
Advance starts 2,000 rpm --
stops 5,000 rpm --
Full advance 2T BTDC at 5,000 rpm --
Alternator exciter coil resistance {At 20'C/68'F} -- --
Ignition coil resistance (Primary; at 20'C/68°F) 2.16-3.19 Q --
(Secondary with plug cap) 22.5-27.5 kQ --
(Secondary without plug cap) 13.5-16.5 kQ --
Ignition pulse generator resistance (At 20"C/68'F) 405-495 Q --
1-15
General Information
Unit: mm (in)
- lights/Meters/Switches
Item Standard Service limit
Main fuse 30A
Alternator fuse 55A
Fuse ('91-95) 10Ax 6, 20Ax 1
(After '95) Standard model 5A {Accessory}, 10A x 6, 20A x 1
LBS-ABSfTCS model 5A (Accessory), lOA x 5, 15A x 2
ABS fuse (ABSfTCS model) 10Ax3, 20Ax 1
(LBS-ABSfTCS model) 10Ax1,30Ax2
Headlight (high/low beam) Standard and ABSfTCS model l2V45/45W x 2
LBS-ABSfTCS model 12V 60/55W
Tail/brake light 12V32/3cp x 2
License light
Position light
Front turn signal/running light 12V32/3cp x 2
Front turn signal light
Rear turn signal light 12V32cp x 2
Instrument light 12V1.7W x 4
Oil pressure indicator Standard model 12V3.4W
ABSfTCS or LBS-ABSfTCS model 12V3W
Tail/brake light indicator
Side stand indicator Standard model 12V3.4W
ABSfTCS or LBS-ABSfTCS model 12V1.7W
Low fuel indicator Standard model 12V3.4W
ABSfTCS or lBS-ABSfTCS model 12V3W
Coolant temperature indicator
Oil temperature indicator
High beam indicator Standard model 12V3.4W
ABSfTCS or LBS-ABSfTCS model 12V3W
Turn signal indicator Standard model 12V3.4 x 2
ABSfTCS or lBS-ABSfTCS model 12V3W x 2
Neutral indicator Standard model 12V3.4W
ABSfTCS or LBS-ABSfTCS model 12V1.7W
TCS activation light (ABSfTCS or LBS-ABSfTCS model) 12V3W x 2
TCS OFF indicator (ABSfTCS or LBS-ABSfTCS model) 12V3W
TCS indicator light (ABSfTCS or LBS-ABSfTCS model) LED x 1
ABS indicator light (ABSfTCS or lBS-ABSfTCS model) LED x 2
Reverse indicator
Overdrive indicator
Oil temperature sensor resistance
Fuel unit resistance (At full level) 10 n
(At empty) 90 n
Fuel pump flow capacity (min./minute)
Thermo sensor resistance (50'C/122°F) 130-180 n
(80'C/176°F) 45-60 n
(120°C/248'F) 10-20 n
Fan motor switch Starts to close (ON) 98-102°C (208-216°F)
Fully open (OFF) 93-9TC (199-20TF)
- Starting System
Starter driven gear 0.0. 57.749-57.768 (2.2736-2.2743)
Starter clutch outer I.D. 74.414-74.440 (2.9297-2.9307)
Starter motor brush length 12.0-13.0 (0.47--0.51)
1-16
General Information
Torque Values
- Standard
Torque Torque
Fastener Type Fastener Type
Nom (kg-m, ft-Ib) Nom (kg-m, tt-lb]
5 mm bolt and nut 5 (0.5, 3.5) 5 mm screw 410.4, 3)
6 mm bolt and nut 10 (1.0,7.2) 6 mm screw 9 (0.9, 7)
8 mm bolt and nut 22 (2.2, 16) 6 mm flange bolt (8 mm head) 9 (0.9,7)
10 mm bolt and nut 35 (3.5, 25) 6 mm flange bolt (10 mm head) and nut 12 (1.2, 9)
12 mm bolt and nut 55 (5.5, 40) 8 mm flange bolt and nut 27 (2.7, 20)
10 mm flange bolt and nut 40 (4.0, 29)
Torque specifications listed below are for important fasteners.

Others should be tightened to standard torque values listed above.
Notes: 1. Apply locking agent to the threads.

2. Apply oil to the threads and flange surface.
3. Apply sealant to the threads.
4. Stake.
5. Apply clean engine oil to the a-ring.
- Engine
Thread Torque
Item Q'ty Remarks
era. (mm) Nom (kg-m, ft-Ib)
Lubrication:
Oil pump driven sprocket bolt 1 6 15(1.5,11) Note 1
Oil pressure switch 1 PT 1/8 12 (1.2, 9) Note 3
Oil filter 1 20 10 (1.0,7) Note 5
Oil drain bolt 1 12 38 (3.8, 27)
Oil cooler bolt ("91-'95} 1 20 65 (6.5, 47)
Oil filter boss 1 20 18 (1.8, 20) Note 1
Oil pan bolt 14 6 12 (1.2, 9)
Timing belt/cylinder head:
Timing belt tensioner bolt 1 10 46 (4.6, 33)
Timing bait idle pulley bolt 1 12 46 (4.6, 33) Note 1
Timing belt driven pulley bolt 2 8 27 (2.7, 20)
Timing belt drive pulley bolt 1 12 65 (6.5, 47)
Cylinder head bolt 12 10 58 (5.8, 42) Note 2
Camshaft holder bolt 24 6 12 (1.2, 9)
Cylinder head cover bolt 8 6 120.2,9)
Spark plug 4 10 11 (1.1,8)
Vacuum joint 4 5 4 (0.4, 2.9)
Reduction bolt 1 12 38 (3.8, 27)
Clutch/gearshift linkage:
Clutch lock nut 1 22 110(11.0,80)
Shift drum center bolt 1 8 23 (2.3, 17)
Shift return spring pin bolt 1 8 23 (2.3, 17)
Slave cylinder bleed valve 1 8 9 (0.9, 6.5)
Gearshift arm bolt 1 6 12 (1.2, 9)
Crankcaselcrankshaft/transmission :
Connecting rod cap nut 8 B 36 (3.6, 26) Note 2
Crankcase bolt 6 mm 6 6 12 (1.2, 9)
Bmm 7 B 23 (2.3, 17) Note 2
10 mm 6 10 52 (5.2, 38) Note 2
Pulse generator rotor bolt 1 12 100 (10.0,72) Note 2
Neutral switch 1 10 12 (1.2, 9)
32 mm cap 1 32 12 (1.2, 9) Note 5
Alternator:
Alternator terminal nut (After '95) 1 6 8 (O.B, 5.8)
Alternator shaft nut 1 14 58 (5.B, 42) Note 1
Alternator drive gear bolt B 6 16(1.6,12) Note 1
1-17
General Information
r-' Frame
Thread Torque
Item Q'ty Remarks
dia. (mm) Nem tka-m. ft-Ib)
Frame/body panels:
Center stand pivot bolt 1 8 27 (2.7, 20)
Side stand pivot bolt 1 10 10 (1.0, 7)
Side stand pivot lock nut ! 1 10 27 (2.7, 20)
Rotary switch attaching bolt 1 6 10 (1.0,7)
Footpeg holder 8 mm 2 8 27 (2.7, 20)
10 mm 4 10 35 (3.5, 25)
Grab rail 6 8 27 (2.7, 20)
Grab rail center plate bolt 4 8 35 (3.5, 25)
Saddle bag stay bolt 6 mm 2 6 10 (1.0,7)
8 mm 2 8 36 13.6, 25)
Center stand grip bolt 2 6 10 (1.0,7)
Engine guard mounting bolt 3 8 27 (2.7, 20)
Windshield screw 5 5 0.6 (0.06, 0.43)
Upper fairing bracket bolt 1 8 27 (2.7. 20)
Exhaust system:
Exhaust pipe joint nut 8 7 170.7,12)
Muffler band bolt 4 8 22 (2.2, 16)
Exhaust pipe band bolt 1 8 22 (2.2, 16)
Muffler mounting bolt 2 8 27 (2.7, 20)
Exhaust pipe protector bolt 12 6 12 (1.2, 9)
Fuel system:
Fuel tank mounting bolt 4 6 12 (1.2. 9)
Fuel pump mounting nut ! 6 6 10 (1.0, 7)
Carburetor connecting screw 2 6 8 (0.8, 5.8)
Air cleaner housing cover screw 8 5 0.9 (0.09, 0.65)
Fuel valve mounting screw 2 5 0.9 {0.09, 0.65)
Cooling system:
Fan motor switch 1 16 12 (1.2, 9)
Thermostat case 2 6 10 (1.0, 7)
Water hose band screw 10 - 1.2 (0.12, 0.9)
Engine mount:
Engine mounting bolt 10 mm 4 10 55 (5.5, 40) Note 2
12 mm 1 12 65 (6.5, 47)
Engine mounting bracket bolt 8 mm 8 8 35 (3.5, 25)
10 mm 4 10 40 (4.0, 29)
Sub frame bolt 5 10 40 (4.0. 29)
Engine mounting collar lock nut ('91-'95) 1 18 21 (2.1, 15)
(After '95) 2 18 28 (2.8. 20)
Engine mounting collar adjusting nut (lower)
(After '95) 1 18 10 (1.0. 7)
Gearshift pedal pivot bolt 1 8 27 (2.7, 20) Note 1
1-18
General Information
r Frame
Thread Torque
Item Q'ty Remarks
dia. (mm) Nrn (kg-m, ft-Ib)
Front suspension:
Handlebar lower cover bolt 4 5 4.3 (0.43, 3.1)
Handlebar upper holder bolt 4 8 27 (2.7, 20)
Handlebar weight screw 2 6 9 (0.9, 6.5) Note 1
Ignition switch mounting bolt 2 8 25 (2.5, 1S)
Throttle housing screw 2 5 4.2 (0.42, 3.0)
Front fender attaching socket bolt
Standard and LBS-ABSfTCS model 2 6 12(1.2.9}
ABSfTCS model 2 8 22 (2.2, 16)
Front fender plate bolt (LBS-ABSfTCS model) 2 8 22 (2.2, 16) Front side bolts
Steering bearing adjustment nut 1 26 28 (2.8, 20) Note 2
Steering stem nut 1 24 105 (10.5, 76)
Upper fork pinch bolt 2 8 23 (2.3, 17)
Lower fork pinch bolt 4 10 50 (5.0, 36)
Fork cap Standard and ABS/TCS model 2 - 20 (2.0, 14)
LBS-ABS/TCS model 2 - 23 (2.3, 17)
Fork socket bolt 2 8 20 (2.0, 14) Note 1
Fork damper lock nut 1 10 23 (2.3, 17)
Anti-drive case bolt 4 5 4 (0.4, 2.9) Note 1
Front axle bolt 1 14 90 (9.0, 65)
Front axle pinch bolt 4 8 22 (2.2, 16)
Front pulser ring bolt (ABS/TCS or LBS-ABS/TCS model) 6 5 8 (D.B, 5.B)
Rear suspension:
Shock absorber upper mounting bolt 1 10 50 (5.0, 36) Note 2
Shock absorber lower mounting bolt 1 8 23 (2.3, 17)
Swingarm right pivot bolt 1 30 105 (10.5, 76)
Swinqarrn left pivot bolt
Standard and ABSfTCS model 1 30 18 (1.8, 13)
LBS-ABSfTCS model 1 30 22 (2.2, 16)
Swingarm left pivot bolt lock nut 1 30 105 (10.5, 76)
Rear axle nut 1 18 110 (11.0, SO)
Rear axle pinch bolt 1 8 27 (2.7,20)
Rear wheel damper plate bolt 5 6 20 (2.0, 14)
Rear pulser ring bolt (ABS/TCS or LBS-ABS/TCS model) 6 5 8 {O.8, 5.B}
Brake/clutch system:
Front wheel speed sensor bracket bolt (LBS-ABS/
TCS model) 1 6 12 (1.2, 9)
Rear caliper stopper pin bolt 1 18 70 P.O, 51)
Pad pin plug 3 10 2.5 (D.25, 1.8)
Pad pin 3 10 18 (1.8.13)
Caliper assembly bolt (LBS-ABSfTCS model) 9 8 33 (3.3. 24)
Front caliper pin bolt (caliper side) 2 8 23 (2.3. 17) Note 1
(bracket side) 2 8 ! 13 n.s. 9} Note 1
Rear caliper pin bolt
(caliper side) Standard and ABS/TCS model 1 12 28 (2.8, 20) Note 1
LBS-ABSfTCS model 1 12 28 (2.8, 20)
(bracket side) Standard and ABS/TCS model 1 8 13 (1.3, 17) Note 1
LBS-ABSfTCS model 1 8 23 (2.3, 17) Note 1
Caliper bleed valve
Standard and ABS/TCS model 3 - 5.5 (D.55, 4.0)
LBS-ABS/TCS model 6 - 5.5 (D.55, 4.0)
1-19
General Information
r-r- Frame tccnt'dl

Thread Torque
Item Q'ty Remarks
dia. (mm) Nm (kg-m, ft-Ib)
Brake/clutch system tccnt'dj:
Right front caliper mounting bolt (Standard and
ABSrrCS model) 2 8 27 (2.7, 20)
Left front caliper pivot bolt (Standard and ABS/
TCS model); upper 1 8 27 (2.7, 20)
lower 1 6 12 (1.2, 9)
Right front caliper pivot bolt (LBS-ABSrrCS
model); upper 1 8 30 (3.0, 22)
lower 1 6 12(1.2,9)
Left front caliper pivot bolt (LBS-ABSrrCS model) 2 8 30 (3.0, 22)
Brake disc bolt 18 8 43 (4.3, 31)
Rear master cylinder push rod lock nut 1 8 18 (1.8, 13)
Secondary master cylinder mounting bolt
(LBS-ABSrrCS model) 2 6 12(1.2,9)
Secondary master cylinder push rod lock nuts
(lBS-ABSJTCS model) 2 8 18 (1.8, 13) Note 1
Secondary master cylinder link plate bolt
(LBS-ABSjTCS model) 2 8 30 (3.0, 22)
Delay valve mounting bolt (LBS-ABSJTCS model) 2 6 12 (1.2, 9)
Brake lever adjuster rod bolt 1 5 4 (0.4, 29) Note 1
Master cylinder holder bolt
Master cylinder reservoir cap screw
•• 6
•
12(1.2,9)
1.5 (Q.15, 1,1)
Clutch lever pivot nut 1 6 6 (0,6, 4,3)
Clutch lever pivot bolt 1 6 1 (0.1,0.7)
Clutch switch mounting screw
Brake lever pivot nut
1
1
•
6
1.2 (0.12, 0.9)
6 (0.6, 4.3)
Front brake lever pivot bolt 1 6 1 (0.1, 0.7)
Front brake switch mounting screw
Brake hose oil bolt Standard model 5
1
•
10
1,2 (0,12, 0.9)
35 (3.5, 25}
ABSJTCS model 9 10 35 (3.5, 25}
LBS-ABSrrCS model 18 10 35 (3.5, 25)
Clutch hose oil bolt
Brake pipe joint nut (LBS-ABSrrCS model) ,.
2 10
-
35 (3.5, 25)
17 (1,7, 12)
Brake hose clamp screw {at fork tube;
Standard model} 1 5 4,3 (Q,43, 3.1)
Final drive:
Final gear case mounting nut
Final gear case oil filler cap
•
1
10
30
65 {6.5, 43}
12(1.2,9)
Pinion bearing retainer 1 70 150 {15.0, 108}
Pinion joint nut 1 16 110(11.0,80} Note 1
Retainer lock washer bolt 1 6 10 (1.0, 7}
Final gear case bolt 8 mm 6 8 26 (2.6, 19)
10 mm
Final gear case drain bolt
2
1
1
,.
10
6
63 (6.3, 46)
20 (2.0,14)
10 (1.0, 7)
Note 1
Dust guard plate bolt

Electrical system:
Ignition coil mounting bolt
Meter mounting bolt
•
3
6
6
9 (0,9, 6.5)
9 (0.9, 6.5)
1-20
General Information
Tools
Ref.
Description Tool Number Alternate Tool Tool Number
Section(sl
Oil filter wrench 07HAA-PJ70100 4
,
Oil pressure gauge 07506"':30000~:J Equivalent commercially 4
Oil pressure gauge available in U.S.A.
attachement 07501-4220100 4
Float level gauge 07401-0010000 5
Pilot screw wrench 07KMA-MS60101 Pilot screw wrench 07LMA-MT8010A or 5
(U.S.A. only) 07MMA-MT3010A
Bearing remover set
- Remover handle
, 07936-3710001
07936-3710100
! Not available in U.S.A. 8, 10
8, 10
- Bearing remover, 17 mm 07936-3710600 8, 10
- Remover weight 07741-0010201 Remover weight 07936-3710200 8,10,14
Driver 07749-0010000 8,9,10,
12,13,14
Attachment, 37 x 40 mm 07746-0010200 8, 14
Pilot, 20 mm 07746-0040500 8, 10
Valve guide driver, 4.5mm 07HMD-ML00100 Valve guide driver, 4.5mm 07HMD-ML0010l 8
Valve spring compressor 07757-0010000 8
Valve spring compressor
attachment 07959-KM30101 8
Tappet hole protector 07HMG-MR70001 or Equivalent (see page 8-9) 8
Valve guide reamer, 4.5 mm I 07HMH-ML0010l Valve guide reamer, 4.5mm 07HMH-ML0010A 8
Compression gauge Equivalent commercially
attachment 07JMJ-KY20100 available in U.S.A. 8
Valve seat cutter, 24.5 mm
{45° EX) 07780-0010100 Equivalent commercially 8
Valve seat cutter, 29 mm available in U.S.A.
(45'IN) 07780-0010300 8
Flat cutter, 25 mm (32" EX) 07780-0012000- 8
Flat cutter, 28 mm (32"IN) 07780-0012100- 8
Interior cutter, 30 mm
(60° IN, EX) 07780-0014000 8
Cutter holder, 4.5 mm 07781-0010600 8
Snap ring pliers 07914-3230001 9, 15
Clutch center holder 07JMB-MN50300 Holder plate 07HGB-0010l0B s
Clutch center collar "B" 07MPB-764021A
Clutch holder collar 07LMB-MT30100 s
Lock nut wrench, 30 x 32 mm 07716-0020400, Equivalent commercially s
Extension bar 07716-0020500....1 available in U.S.A. ,, s
Attachment, 28 x 30 mm 07946-1870100 s
Pilot 12 mm 07746-0040200 s
Ball race & bearing driver
attachment 07945-3330300 10
Attachment, 42 x 47 mm 07746-0010300 , 10,12,13
Pilot, 25 mm 07746-0040600 10
Attachment, 62 x 68 mm 07746-0010500 10, 12
Pilot, 30 mm 07746-0040700 10
Pilot, 28 mm 07746-0041100 10
1-21
General Information
r-' Cont'd
I Ref.
Description Tool Number Alternate Tool Tool Number
Section(s)
Pinion retainer wrench 07910 MA10100 12
Shaft puller 07931-ME40000 Shaft puller 07931-ME4010A 12
Pinion holder attachmemt 07924-ME40000 12
attachment 07924-9690102 12
Oil seal remover 07948-4630100 12
Oil seal driver attachment 07948-5800101 12
Bearing race remover 07946-3710500 12
Oil seal driver 07965-MC70100 12
Attachment. 52 x 55 mm 07746-0010400 12, 13
Pilot, 35 mm 07746-0040800 12
Driver, 40 mm I.D. 07746-0030100 12
Attachment, 25 mm I.D. 07746-0030200 12
Bearing insert attachment 07931-4630300 12
Yoke joint compressor
attachment 07LMF-MT30110, Not available in U.S.A. 12
Yoke joint compressor base 07LMF-MT30120-l 12
Fork seal driver attachment , 13
Standard and ABS;TCS model 07947-KF00100
LBS-ABS/leS model 07947-KA40200
Fork seal driver body 07947-KA50100 13
Steering stem socket 07916-3710100 13
Steering stem driver 07946-MBOOOOO Race remover attachment 07953-MJ 1OOOB 13
Ball race remover set 07953-MJ10000 (U S.A. only) 13
- Driver attachment 07953-MJ10l00 13
- Driver handle 07953-MJ 10200 13
Bearing race remover 07946-3710100 13
Shock absorber compressor 07GME-0010000 , "
,.,.,.
Shock absorber compressor I
attachment 07959-MB 10000
Pivot bearing outer remover 07936-4150000
, I
Lock nut wrench 07908-4690003 Lock nut wrench KS-HBA-08-469
Digital multi meter KS-AHM-32-003 ~ Equivalent commerciallv 17,18.20,
(U.S A. only) available In USA 21
Analogue tester (SANWA) SP-15D 17,18,20,
21
Analogue tester (KOWA) TH-5H 17,18,20,
I 21
1-22
General Information
Lubrication & Seal Points

- Engine
Location Material Remarks
Upper and lower crankcase mating surface Uquid sealant Do not apply sealant near
the rain journal bearings.
Oil pressure switch thread Do not apply sealant to the
switch thread head as shown.
~
~ I
3-4 mm
(0.12-0.16 in)
Semi-circular portion of the cylinder head

Valve stem (valve guide sliding surface) Molybdenum disulfide oil (a mix-
Crankshaft main journal bearings ture of engine oil and molybde-
Connecting rod bearings num disulfide grease in a 1 1
Crankshaft thrust surfaces ratio)
Crankshaft thrust bearings
Camshaft journals, cam lobes and thrust surfaces
Camshaft driven gear
Cam reduction gear shaft spline
Valve lifter
Piston pin
Primary drive gear
Clutch outer guide
Transmission gearshift fork grooves
Alternator driven gears
Connecting rod bearing cap nuts Engine oil
Piston
Connecting rod small end bearing
Transmission gears
Shift forks
Oil filter a-ring
Oil strainer packing
Clutch lifter rod
Litter rod guide
Shift fork shaft
10 mm crankcase bolts
8 mm crankcase bolts
Pulse generator rotor bolt
Cylinder head bolts
a-rings
Other sliding surfaces
Oil seal lips Multipurpose grease
Clutch slave cylinder piston seal DOT 4 brake fluid
Timing belt idle pulley bolt threads Locking agent
Shift drum set plate bolt threads
Oil pump driven sprocket bolt threads
Primary damper shaft bearing set plate bolt threads
Alternator drive gear bolt threads
Timing belt tensioner spring hook bolt threads
Water pump mounting bolt threads
Cam reduction holder bolt threads
Clutch cover base bolt threads
Alternator shaft nut threads
1-23
General Information
r- Frame
Location Material Remarks
Center stand pivot Multipurpose grease
Side stand pivot
Rear brake pedal pivot
Gearshift pedal pivot
Throttle grip pipe flange
Steering head bearings
Steering head bearing dust seal lips
Front caliper pivot collars
Driveshaft and driveshaft joint splines Molybdenum disulfide grease
Driveshaft CD Molybdenum disulfide - Apply to the area as shown.
Driveshaft yoke joint cotters <Il paste -
Driveshaft yoke joint thrust washer @ -
Driveshaft yoke joint oil seal lip ® -
Driveshaft groove @ - Pack the groove with the

grease
1+.....1Jl..... +
+ @I-m
I'" ~ ~
I ._-
~A "
r I.
-, r
0
®
\
Rear shock absorber upper mounting collar (inside and
outside surfaces)
Rear wheel thrust washer
Final driven flange splines
Final driven flange O-ring
Handlebar grip rubbers Honda Bond A or equivalent
Steering bearing adjustment nut threads Engine oil
Thermo sensor threads Sealant
Fork Fork fluid
Fork oil seal lip
Brake/clutch master cylinder pistons/piston cups DOT 4 brake fluid
Caliper pistons/piston seals
Brake/clutch reservoir
Insides of the caliper boots Silicone grease
Brake pad pin stopper rings (LBS-ABS/TCS model)
Front master cylinder push rod ends (LBS-ABS/TCS model)
Front master cylinder piston end (Standard and
ABS/TCS model)
Rear master cylinder push rod upper end and boot
groove
Handlebar weight screw threads Locking agent
Front fork socket bolt threads
Cooling fan nut threads
Caliper pin bolt threads
Secondary master cylinder push rod lock nut threads
(LBS-ABS/TCS model)
Anti-dive case bolt threads
1-24
General Information

Standard Model
(1) CLOCK WIRE
(2) LEFT TURN SIGNAL

WIRE CONNECTOR
t
_,;rC'~~~~~~~1~~~il{3)
(7) RIGHT TURN SIGNAL
WIRE CONNECTOR
SPEEDOMETER CABLE
(6) BANK ANGLE SENSOR
I,
(5) FRONT BRAKE HOSE
\ I
-,I
(4) HEADLIGHT CONNECTORS
1-25
General Information
Standard Model
(2) CLUTCH HOSE
(3) BRAKE HOSE
(6) JOINT BOOTS _ _---'-+:~

('91-'94 only)
" 1~
(5) WIRE B~NDS ~
(7) LEFT HANDLEBAR SWITCH (8) RIGHT HANDLEBAR SWITCH
WIRE HARNESS WIRE HARNESS
. \\ i
', \ '
\~
,x,
, ,
(10) IGNITION COIL 3P CONNECTOR
1-26
General Information
Standard Model
(1) HIGH BEAM HEADLIGHT

RELAY

RELAY
(3) LOW BEAM

HEADLIGHT RELAY
'l
~f
~
./ 'If '
/
/.4
.,,, /
(5) FUEL CUT-OFF RELAY
(6) CHOKE CABLE
(10) INDICATOR LIGHT

CH ECKER ---==--J>!;;;~
»>:
(9) IGNITION
CONTROL
MODULE - -~7 (---',
(ICM)
(8) HARNESS CLIPS (7) THROTILE CABLES
1-27
General Information
Standard Model (3) THROTTLE STOP SCREW CABLE
(2) FUEL FILTER

(5) RADIATOR
(1) REAR BRAKE LIGHT SWITCH
OVERFLOW TUBE
2P CONNECTOR
----
~~~~,
~ \ (6) THERMO
SENSOR
(7) SPARK PLUG WIRES

(8) WIRE BAND
(10) IGNITION PULSE GENERATOR
WIRE 4P CONNECTOR (9) TURN SIGNAL RELAY
(12) FUEL TANK TRAY

'91-'95: (13) FUEL FILL CAP
DRAIN TUBE
BREATHER TUBE
n i) FAN MOTOR 2P CONNECTOR
(14) FUEL UNIT
2P CONNECTOR
(15) REGULATOR/RECTIFIER
(16) FRAME
GROUND
(17) FUSE
CASE
(25)
SPARK PLUG
WIRES
,
,
,,
' / (20j
(24) STARTER MOTOR {22} SIDE STAND
CABLE \ ALTERNATOR
SWITCH WIRE {18) BATTERY
WIRE
(23) ENGINE GROUND
CABLE {19} STARTER RELAY
(21) CARBURETOR
DRAIN TUBE SWITCH
1-28
General Information
Standard Model
After '95:
(3) FUEL FILL CAP

BREATHER TUBE (6) FRAME
(2} FUEL TANK TRAY
GROUND
DRAIN TUBE
(4) FUEL UNIT 2P CONNECTOR
(1} FAN MOTOR 2P
CONNECTOR
(5) BATTERY
---~--
(7)
ACCESSORY
(ACC) FUSE
(17) SPARK
WIRES
(16)
1-29
General Information
ABS/TCS Model
(2) LOW BEAM HEADLIGHT RELAY
(1) CLOCK WIRE rr>

I '
// \ (3) FUEL CUT-OFF RELAY
"
,/ \\
(14) BANK ANGLE
SENSOR RELAY (4) INDICATOR LIGHT
CHECKER
--;r---- LoS8
(13) HIGH BEAM

HEADLIGHT
RELAY ,I
1'1
1'1"1
G5I ~11f" ~,#,(
"
,!~
t
"
',',y
WIRE CONNECTOR
/ 1
WIRE CONNECTOR
(6) TCS/IGNITION
(11) BANK ANGLE CONTROL
SENSOR I
I
Iir=
III{--,
MODULE
(ICM)
", "~-=I
,
, ,,',--
11'--
,
,
,
"~I
11,-----
"~
(7) SPEEDOMETER CABLE
, ',~
-
'I

(10) FRONT WHEEL SENSOR WIRE
{9} FRONT BRAKE HOSE
1-30
General Information
ABS/TCS Model
(2) CLUTCH HOSE
(3) BRAKE HOSE
(6) JOINT BOOT

('91-'94 only)
c 1~
(5) WIRE B;NDS ~
(7) LEFT HANDLEBAR SWITCH (8) RIGHT HANDLEBAR SWITCH
WIRE HARNESS WIRE HARNESS
1-31
General Information
ABsrrcs Model (2} FRONT MODULATOR SOLENOID 4P CONNECTOR
(1} FRONT WHEEL SENSOR (3) LOW BEAM HEADLIGHT RELAY

3P CONNECTOR
(4) FRONT MODULATOR PUMP

MOTOR/GROUND 2P
CONNECTOR
f)rJ;l?>~'//
(5) HIGH BEAM HEADLIGHT

RELAY
<;
.~~
(10) FRONT BRAKE HOSES
(7} BANK ANGLE SENSOR
(B} FRONT
(9) FRONT WHEEL SENSOR
MODULATOR
(13} ABS MAIN RELAY ~ =-~

7':------ ) \
(12) REAR PUMP
MOTOR RELAY
,0 C::]\?\\
'J! ((
IV'"~ \,~'~'V
(14) CHOKE CABLE
'/ ( i
/: I, I
I
\
\(\
'\J
(11) FRONT PUMP
, \ '0 Alt;&:~'0
MOTOR RELAY
0t-""--",,,,,"
(19) INDICATOR
LIGHT CHECKER
\.
--------
(16) ABS CONTROL UNIT (ECU)
(17) INDICATOR CONTROL UNIT
1-32
General Information
ABS/TCS Model
(4) FUEL (5) THROTILE STOP SCREW CABLE

FILTER
(3) REAR MODULATOR PUMP MOTOR! (6) IGNITION PULSE GENERATOR
GROUND 2P CONNECTOR WIRE 4P CONNECTOR
(2) REAR BRAKE LIGHT

SWITCH 2P CONNECTOR
(1) REAR MODULATOR
"-
-------
--- <
(7) HARNESS
CLIPS
(B) RADIATOR OVER-

FLOW TUBE
(13) REAR WHEEL (11) REAR MODULATOR SOLENOID
SENSOR 3P CONNECTOR (9) REAR WHEEL SENSOR
3P CONNECTOR
(12) REAR BRAKE HOSES (10) TURN SIGNAL RELAY
1-33
General Information
ABS/TCS Model
(3) TCS ON/OFF SWITCH WIRE
(2) ABS/TCS INDICATOR (4) FUEL TANK TRAY

DRAIN TUBE
LIGHT SWITCH WIRE
(1) FAN MOTOR 2P CONNECTOR (5) FUEL FILL CAP

BREATHER TUBE
(6) FUEL UNIT (7) REGULATOR/

2P CONNECTOR RECTIFIER
(9) FUSE
CASE
;>
---(
0?1~'&_'~~ "
(19) SPARK PLUG
WIRES
(18) STARTER MOTOR

CABLE
(16) SIDE STAND
SWITCH WIRE
\/1 . (13) ALTERNATOR
WIRE
~,'llOl ABS FUSE
CASE
(11)BATIERY
(17) ENGINE GROUND (14) CARBURETOR (12) STARTER RELAY

CABLE DRAIN TUBE SWITCH
(15) CLAMPS:
('91-'95 only)
1-34
General Information
LBS-ABSfTCS Model
,~
(1) CLOCK WIRE

/
.
\ \, (3) FUEL CUT-OFF RELAY
(4) INDICATOR LIGHT

(16) BANK ANGLE ---;;"-, CHECKER
SENSOR RELAY
r: ---rr~--
,/
WIRE CONNECTOR
WIRE CONNECTOR (6) TCS/IGNITION CONTROL
MODULE(ICM)
Ic\~
FRONT WHEEL SPEED
(13) BANK ANGLE
SENSOR WIRE
SENSOR
,
,
4"'~'\
, ' 'r(" \ I "
, I-: ' 0_:_~j/:J/
{12) FRONT MODULATOR
,
,
,
I:' '~c-:>i
,
I
I, i (-)J (8) SPEEDOMETER CABLE
----;J
~
(11) LEVER BRAKE HOSE
(Front Modulator-to- I
Front Calipers)
(10) PEDAL BRAKE HOSE (9) SERVO-BRAKE HOSE

{Front Modulator-to- (Secondary Master
Delay Valve) Cylinder-to-PCV)
1-35
General Information
lBS-ABSITCS Model

(Front Master Cylinder-
to-Front Modulator)
(2) CLUTCH HOSE
(1) CHOKE CABLE (4) THROTTLE CABLES
~-
(5) WIRE BANDS

(6) LEFT HANDLEBAR SWITCH
WIRE HARNESS (7) RIGHT HANDLEBAR SWITCH
WIRE HARNESS (8) IGNITiON COIL
1-36
General Information
lBS-ABsrrcs Model (2) PEDAL BRAKE HOSE

(Front Modulator-to- (3) FRONT WHEEL SPEED SENSOR
Delay Valve) 3P (Black) CONNECTOR
(t) LEVER BRAKE HOSE
(Front Master Cylinder-to-
Front Modulator) (4} LOW BEAM HEADLIGHT
RELAY
(10} LEVER BRAKE HOSE

(Front Modutator-to- (5} MODULATOR CRANK
Front Calipers} ANGLE SENSOR 3P
(Blue} CONNECTOR
(6) FRONT MODULATOR
I
\/
J\\~
~
. . . Ii / (
~ ___====--==.=--= I /! ) (7) MODULATOR CONTROL MOTOR
A -=O~~=~-~;=~~DAL BRAKE HOSE / /

2P (Black) CONNECTOR
(8} SERVO-BRAKE HOSE

(Rear Master Cylinder-to-
(Secondary Master Cylinder
Front Modulator)
-to-PCV)
(13) BANK ANGLE SENSOR (14) BANK ANGLE SENSOR RELAY
(12) RIGHT TURN SIGNAL (19) REFERENCE NUMBERS; align with the number
WIRE on the modulator head
(15} HIGH BEAM
HEADLIGHT RELAY
(11) MOTOR DRIVER
(18} View of front modulator

from the right side:
(20} PINS
(21} STOPPERS
(22} REFERENCE NUMBERS;

Two kinds of numbers are stamped
(17} 4P (Blue) (16) 4P (Black}
on each hose joint - refer to the
CONNECTOR CONNECTOR
second line from the top for
the front modulator.
1-37
General Information
LBS-ABSfTCS Model
(1) SERVO-BRAKE HOSE
(Secondary Master Cylinder-to-PCV)
(2) PEDAL BRAKE HOSE

(Front Modulator-to-Delay Valve)
(3} DELAY VALVE

(Front Modulator-to-Right Caliper)
(7) SECONDARY MASTER (5) FRONT WHEEL SPEED

CYLINDER ,i SENSOR WIRE
,
I

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

(Secondary Master Cylinder-
to-PCV}
{10) SECONDARY MASTER CYLINDER
/
(Front Modulator-to- --------t'--1!;islt¥ili
Left Caliper)

{Delay Valve-to-
Left Caliper)
1-38
General Information
LBS-ABS/TCS Model
(1) REAR MODULATOR CONTROL
L?~~ (8) CHOKE CABLE
MOTOR RELAY
I ~ 'r
10-:(
(2) FRONT MODULATOR CONTROL , //JJ
P
MOTOR RELAY
(7) THROTTLE CABLES
(3) INDICATOR LIGHT

CHECKER
(S) INDICATOR CONTROL

UNIT
, .',
(6) ABS CONTROL UNIT (ECU)
(10) FUEL TANK TRAY (11) FUEL FILL CAP BREATHER TUBE (14) FRAME
DRAIN TUBE GROUND
(9) FAN MOTOR 2P (12) FUEL UNIT 2P CONNECTOR
CONNECTOR
(13) BATTERY
(15) ACCESSORY
(ACC) FUSE
( 16)
<~)~" ACCESSORY (ACC)

\ , 1 - ' TERMINALS
1/)
~)~~> --("'>
(24) SPARK PLUG (Allowable power
WIRES and current
capacity: 60W/SA)
/ (20) STARTER RELAY
SWITCH
(18) ABS FUSE BOX
(21) ALTERNATOR CABLE
(20) SIDE STAND SWITCH
1-39
General Information
lBS-ABS/TCS Model
(3) MODULATOR CRANK ANGLE SENSOR (4) THROlTLE STOP SCREW CABLE
3P (White) CONNECTOR
(5) PULSE GENERATOR WIRE
(2) TURN SIGNAL RELAY 4P (White) CONNECTOR
(1) MODULATOR CONTROL MOTOR

2P (Black) CONNECTOR
---------
///-)-------'~.
'--
, .
-_/
(8) REAR WHEEL SPEED SENSOR 3P (Yellow)

CONNECTOR
(10) REAR WHEEL SPEED (9} REAR BRAKE LIGHT SWITCH
SENSOR 2P CONNECTOR {14} SERVO-BRAKE PIPE
(Secondary Master Cylinder-to-PCV)
(13) PEDAL BRAKE PIPE
(11) SERVO-BRAKE PIPE (Rear Master Cylinder-to-Front Modulator)
(PCV-to-Rear Modulator)
(12) FUEL FILTER
---~
./
(15) RADIATOR OVERFLOW
TUBE
(18) REAR MODULATOR
(16) Pcv (Proportional Control Valve)
(17) REAR WHEEL SPEED SENSOR WIRE
1-40
General Information
lBS-ABSITCS Model
(2) SERVO-BRAKE HOSE

(Rear Modulator-ta-Rear Caliper)
./ ,/1
iii'
,/;---=0.
°'1'

I
(Rear Master Cylinder-ta-Rear Modulator)

(8) View of rear modulator
iRear Modulator-to-Hear Caliper)
from the right side:
(7) REFERENCE NUMBERS; align with the number

on the modulator head 1- A
(9)
(14) Route between the master cylinder
STOPPER
and reservoir hose
(10) JOINT
NECK
(11) REFERENCE NUMBERS;

Two kinds of the numbers are
stamped on each hose joint-
refer to the upper line for the
rear modulator
{16} WHITE PAINT (3 places): Servo-brake line only
1-41
General Information
All Models
(1) HARNESS CLIPS
(2) MAIN WIRE HARNESS
1-42
General Information
Emission Control Systems' Model'

LBS ABS
49 state PAIR control valves Standard ABS/TCS (TCS
California PAIR control valves 49 state ·94 ......·95
EVAP purge control valve ·91 ...... '96"-
California
EVAP CAV control valve ·92 ......·95
EVAP canister Canada
Canada
U.S.A. Only (3) TO CARBURETOR (4) AIR INJECTION PIPES

AIR CHAMBER (No. 16)
(2) No. 15 TUBE
t
(1) No. 10 TUBE
(12) AIR INJECTION PIPES

(No. 16)
(11) NO.4 TUBE

('91-'93: Standard
(7) EVAPORATIVE
California and U.S.A.
EMISSION (EVAP)
ABS/TCS type only
CANISTER
After '93: California
('91-'93: Standard
type only)
California and U.S.A.
(B) CARBURETOR ABS/TCS type only
{10} CLAMP: (9) FUEL TANK TRAY DRAIN TUBE After '93: California
('91-'95 only) DRAIN TUBE
type only)
(13)No.15TUBE
(14) PULSE SECONDARY

AIR INJECTION {PAIR}
CONTROL VALVE
(FRONT)
(16) No. 10 TUBE
~=~~~:';~=~--r-(15)PULSE SECONDARY
'n-"r+Ff< AIR INJECTION (PAIR)
CONTROL VALVE
(REAR)
1-43
General Information
'91-'93:
Standard California Type and U.S.A. ABS/TCS Type
After '93:
California Type
(1) EVAPORATIVE EMISSION

(EVAP) PURGE CONTROL
VALVE {3} No.4 TUBE
II 111'- (4) EVAPORATIVE EMISSION
')I\----L.I\;J .'~TUBE\,fL1--.t::::-1,~1
/ CARBURETOR AIR VENT
(EVAP CAV) CONTROL
VALVE
~'\jiiC_-(5) No.7 TUBE
(10) No.5 TUBE
TUBE,--J\lh~~~
il~~-+i+-(6) NO.5 TUBE
(9) No. 6
III
\
J---i-J----!--(7) NO.6 TUBE
(8) No.4 TUBE
(13) NO.6 TUBE
(12) NO.7 TUBE
(11) EVAP CAV CONTROL

VALVE
(14) EVAP PURGE CONTROL

VALVE
(15) No.5 TUBE

(20) No. 10TUBE~
(19) No.4 TUBE
(16) No. 15 TUBE
(18) NO.5 TUBE

(17) No. 11 TUBE
1-44
General Information
Emission Control Systems

The U.S. Environmental Protection Agency and California Air Resources Board (CARB) require manufacturers to certify
that their motorcycles comply with applicable exhaust emissions standards during their useful life, when operated and
maintained according to the instructions provided. and that motorcycles built after January 1, 1983 comply with appli-
cable noise emission standards for one year or 6,000 km (3,730 miles) after the time of sale to the ultimate purchaser,
when operated and maintained according to the instructions provided. Compliance with the terms of the Distributor's
Warranties for Honda Motorcycle Emission Control Systems is necessary in order to keep the emissions system warranty
in effect.
Source of Emissions
The combustion process produces carbon monoxide and hydrocarbons. Control of hydrocarbons is very important be-
cause, under certain conditions, they react to form photochemical smog when subjected to sunlight. Carbon monoxide
does not react in the same way, but it is toxic.
Honda Motor Co., Ltd. utilizes lean carburetor settings as well as other systems, to reduce carbon monoxide and hydro-
carbons.
Crankcase Emission Control System
The crankcase emission control system routes crankcase emissions through the air cleaner and into the combustion cham-
ber.
'91 : After '91:
(1) AIR CLEANER
(4) CRANKCASE
BREATHER
(4) CRANKCASE
BREATHER
SEPARATOR
~ ~ARBURETOR
<: I'J /
SEPARATOR ~~~~~[]J
- 11---(31
CRANKCASE (3) CRANKCASE
... BLOW-BY GAS ... BLOW-BY GAS

<? FRESH AIR
FRESH AIR
1-45
General Information
Exhaust Emission Control System (Secondary Air Supply System) [U.S.A. only]
The exhaust emission control system consists of a secondary air supply system which introduces filtered air into the ex-
haust gases in the exhaust port. Fresh air is drawn into the exhaust port whenever there is a negative pressure pulse in
the exhaust system. This charge of fresh air promotes burning of the unburned exhaust gases and changes a considerable
amount of hydrocarbons and carbon monoxide into relatively harmless carbon dioxide and water vapor.
The pulse secondary air injection check valves prevents reverse air flow through the system. The pulse secondary air in-
jection control valve reacts to high intake manifold vacuum and will cut off the supply of fresh air during engine decelera-
tion, thereby preventing afterburn in the exhaust system.
No adjustments to the secondary air supply system should be made, although periodic inspection of the components is
recommended.
(1) AIR CLEANER
(2) PULSE SECONDARY AIR

INJECTION (PAIR)
CONTROL VALVE
(B) CARBURETOR
(7) EXHAUST PORT
(6) INTAKE MANIFOLD
1fr-~2====ZF;!) {3 ) PULSE SECONDARY

AIR INJECTION
(PAIR) CHECK
(4) TO
EXHAUST
VALVE PORT
151
~,... FRESH AIR
1-46
General Information
Evaporative Emission Control System

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

(EVAP) PURGE CONTROL (3) FUEL TANK
VALVE
(1) CARBURETOR
/
(5) EVAPORATIVE
(4) DRAIN
EMISSION (EVAP)
CANISTER

, CARBURETOR AIR VENT (EVAP CAV)
,
, CONTROL VALVE
t (ENGINE RUNNING)
(9) TO OPEN AIR (8)

~ FRESH AIR
... FUEL VAPOR
(7) EVAP CAV CONTROL VALVE

(ENGINE STOPPED)
Noise Emission Control System
TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: Federal law prohibits the following acts or the cau-
sing thereof: (1) The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or
replacement, of any device or element of design incorporated into any new vehicle for the purposes of noise control
prior to its sale or delivery to the ultimate purchaser or while it is in use; or (2) the use of the vehicle after such device or
element of design has been removed or rendered inoperative by any person,
AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW:
1. Removal of, or puncturing 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 than those
specified by the manufacturer.
1-47
General Information
Emission Control Information

Labels (U.S.A. Only)
(1) UPDATE LABEL
An Emission Control Information Label is located on the
right side of the frame as shown. The seat must be re-
moved to read it. it gives basic tune-up specifications.
Vehicle Emission Control Information Update

Label
After making a high altitude carburetor adjustment, attach
an update label on the left side of the frame as shown.
Instructions for obtaining the update label are given in {2} EMISSION CONTROL
Service Letter No. 132. INFORMATION LABEL
When readjusting the carburetors back to the low altitude (3) VACUUM HOSE ROUTING
specifications, be sure to remove this update label. DIAGRAM LABEL
Vacuum Hose Routing Diagram Label

('91-'93: Standard California type and U.S.A.
ABS/TCS type)
(After '93: California type)
The Vacuum Hose Routing Diagram Label is on the rear
fender as shown. The seat must be removed to read it.
'91-'93: After '93:
VACUUM HOSE ROUTING DIAGRAM

ENGINE FAMILY
EVAPORATIVE FAMILY
CALIFORNIA VEHICLE
EIlP ,mE
C611iOL iILIE~;~~~~~k~j~
1-48
Symbols
The symbols used throughout this manual show specific service procedures. If supplementary information is required pertain-
...
ing to these symbols, it would be explained specifically in the text without the use of the symbols .
Replace the partts] with new onets) before assembly.

~
Is :;O=ooLI Use special tool
IOP~OOLI Use optional tool. Use the same procedure you use to order parts.
C
10 (1.0, 7.2)
Torque specification. 10 N·m (1.0 kg-m, 7.2 ft-lb)
-:71 Use recommended engine oil, unless otherwise specified.
-, Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1 1) .
..~ Use multi-purpose grease (Lithium based multi-purpose grease NLGI #2 or equivalent)
Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
~
equivalent)
Example: Molykote® BR-2 plus manufactured by Dow Corning, U.S.A.
Multi-purpose M-2 manufactured by Mitsubishi Oil Japan
Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or
equivalent)
~ Example: Molykote® G-n Paste manufactured by Dow Corning, U.S.A.

Honda Moly 60 (U.S.A. only)
Rocol ASP manufactured by Rocol Limited. U.K.
Rocol Paste manufactured by Sumico Lubricant, Japan
~ Use silicone grease
Om Apply a locking agent. Use a middle strength locking agent unless otherwise specified.
"I~ Apply sealant
I Use brake fluid, DOT 3 or DOT 4. Use the recommended brake fluid, unless otherwise specified.
- Use Fork or Suspension Fluid.

2. Frame/Body Panels/Exhaust System
Service Information
Seat
Side Cover
Saddlebag
2-1
2-2
2·2
2-2
Fairing Pocket
Windshield
Instrument Panel
Middle Fairing Inner Cover
2-6
2-6
2-7
2-7
..
Seat cowling 2-3 Middle Fairing 2-8
Saddle Bag Stay 2-3 Rearview Mirror 2·8
Rear Fender 2-4 Upper Fairing 2-9
Lower fairing 2-4 Front Fender (LBS-ABS/TCS model) 2-11
Pivot Cover 2-5 Fuel Tank 2-12
Maintenance Cover 2-5 Muffler 2-13
Top Shelter 2-5 Exhaust Pipe 2-18
Service Information
Gasoline is extremely flammable and explosive under certain conditions.

Serious burns may result if the exhaust system is not allowed to cool before components are removed or
serviced.
Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can cause
a fire or explosion.
This section covers removal and installation of the frame body panels, fuel tank and exhaust system.
Frame body panel installation is in the reverse order of removal, unless noted otherwise.
When removing the covers be careful not to damage any tabs or grooves on the covers.
2-1
Frame/Body Panels/Exhaust System
Seat (2) HOLE (3) TAB
~:A _
Unlock the seat with the ignition key. (1) TAB
Push the front of the seat and remove the seat by pulling
it rearward. I (4) SEAT
Install the seat by aligning the four tabs and one hole as
h=" ",,>,,::2"
,,;:;:::>,,;;
shown, and lock it by pushing it down securely.
.
/
Side Cover (1) BOSS (2) GROMMET
(3) CENTER
Remove the seat.
STAND GRIP
Remove the attaching screw and trim clip, and release the
three bosses from the grommets, being careful not to
damage the tab. Remove the side cover.
NOTE
On the left side cover, pull the center stand grip out-
ward when removing the cover.
\
~. ~\\-k~
(7) TRIM' (4) TAB
CLIP
(6) SCREW
(5) SIDE COVER
Saddlebag
(1) SADDLEBAG
Unlock the saddlebag lock lever with the ignition key.
Release the saddlebag hook by pulling the lock lever.
\
Slide the saddle bag rearward and raise it slightly to remove
it.
(3) LOCK LEVER

(2) HOOK
2-2
Seat Cowling
Remove the left and right side covers and saddle bags.
Remove the four socket head caps.

Remove the four socket bolts, two 8 mm bolts and the left
and right grab rails.
Remove the two 6 mm bolts, ground terminal {After '95)
and collars, disconnect the tail/brake light connector, and
remove the seat cowling.
Torque:
Grab rail bolts: 27 N·m ( 2.7 kg-m, 20 ft-Ib)
(8) SEAT I
COWLl~~/
(5) GRAB
RAil
(6) CONNECTOR
(7) GROUND
TERMINAL
(After '95)
Saddlebag Stay (1) 8 mm BOLTS (2) CENTER PLATE
~~
Remove the seat cowling.
Remove the four 8 mm bolts and the grab rail center plate.
Remove the two 6 mm bolts, one 8 mm bolt and the saddle-
bag stay. (7) 8 mm NUT
Torque:
Center plate 8 mm bolt: 35 N'm (3.5 kg-m, 25 ft-lb}
Saddlebag stay 6 mm bolt: 10 Nrm (1.0 kg-m, 7 ft-Ib)
8 mm bolt: 35 N'm (3.5 kg-m, 25 ft-Ib)
'-';';l
'\131;~~
\
(4) 8mm BOLT

(6) SADDLEBAG STAY
(5) 6 mm BOLT
2-3
Rear Fender
Remove the battery (page 17-7).
Remove the left and right saddlebag stays (page 2-3).
Remove the four socket bolts, rear fender B and the saddle-
bag stay stopper.
Remove the starter motor cable from the starter relay
switch, and remove the starter relay switch from the rear (2} REAR FENDER A
fender A.
Remove the three bolts and the battery holder.
Remove the fuse case (s}. (3) REAR FENDER B
Remove the two bolts and the center stand grip.
Remove the two mounting bolts and rear fender A.
Torque:
Center stand grip bolt: 10 Nom (1.0 kg-m. 7 ft-Ib)
(1) FUSE CASE --~£7'f?-
(9) ABS FUSE CASE

{ABS/TCS or LBS-
ABS/TCS MODEL) ---A~-~
(6) BAITERY HOLDER
(7) STARTER RELAY SWITCH
Lower Fairing
Remove the nine socket bolts and the lower fairing.
/
(2) SOCKET BOLT
2-4
Pivot Cover
Remove the side cover (page 2-2).
Remove the three socket bolts and the pivot cover.
{2l PIVOT COVER
Maintenance Cover (1) MAINTENANCE COVER
Remove the two screws.

Release the four tabs by sliding the maintenance cover
rearward and remove the cover.
(2) TABS
(3) SCREWS
Top Shelter (11 TOP SHELTER 4 (2l SCREWS
Remove the left and right side covers (page 2-2).
Remove the two screws, two bolts and the top shelter.
\~. \,
(3) BOLTS
2-5
Fairing Pocket (2) SCREWS
Remove the maintenance cover (page 2-5).

Remove the top shelter (page 2-5).
Remove the six screws and the fairing pocket.
(3) SCREW
(4) SCREW
ABS/TCS or LBS-ABSfTCS model:

Remove the maintenance cover (page 2-5). i (1) FAIRING POCKET
Remove the top shelter (page 2-5).
Remove the six screws. (5) SCREWS

Disconnect the two connectors and left fairing pocket. (2) SCREW
NOTE
The TCS OFF indicator turns on when the TCS switch
connector is disconnected and then reconnected with
the ignition switch ON. The TCS can be reactivated
by pushing the TCS switch.
(4) SCREW
(3) CONNECTORS
Windshield (1) W'NDSH~:'E~L~D~====l

Remove the five screws and the windshield.
'91-'95:
~J.~
Remove the two screws and trim clip attaching the
windshield garnish.
Release the four tabs and remove the windshield garnish
from the upper fairing.
,
(2) TABS
J
(3) TRIM CLIP
(4) GARNISH
2-6
After '95: ~-- \___________:111 WINDSHIELD
(7) SCREW ~II --@)®~

Oi
/
(6) PLASTIC
WASHER
(5) SElTlNG
RUBBER
(2) TABS
(4) GARNISH
\
(3) TRIM CLIP
Instrument Panel (1) SCREWS
Remove the windshield and garnish (page 2-6).
Remove the four screws and the inner screen.
(2) INNER SCREEN
Remove the left and right fairing pockets (page 2-6). (1) INSTRUMENT PANEl
(2) SET WASHER
Disconnect the clock connectors under the instruments. (3) SET
SCREW
~/,
NOTE
• Adjust the clock after installing the instrument panel. ?
Remove the set screw, set washer and the headlight

adjuster knob.
Remove the headlight adjuster cable from the instrument
panel by removing the plastic nut, rubber washer and
washer.
Remove the two screws, release the four tabs and remove
the instrument panel from the upper fairing. (4) ADJUSTER
KNOB
(7) WASHER
(5) NUT
{S) ADJUSTER CABLE
(6) RUBBER
WASHER
2-7
Middle Fairing Inner Cover (1) MIDDLE FAIRING INNER COVER

<:
Disconnect the speedometer cable from the front wheel by
removing the cable set screw.
Remove the two trim clips from the middle fairing by

pulling them out.
Remove the six screws and the middle fairing inner-cover.
(4) TRIM CLIP
Middle Fairing ABS/TCS model shown:

(1) SOCKET BOLT
Remove the following:
- middle fairing inner cover (page 2-7)
-left and right fairing pockets (page 2-6)
-lower fairing (page 2-4).
Remove the socket bolt, three screws. trim clip, three

bolts and the middle fairing
NOTE
At installation, align the boss of the middle fairing with
the hole of the upper fairing properly.
(5) SCREWS
(4) MIDDLE FAIRING
(2) CLIP
Rearview Mirror
Remove the rearview mirror case by carefully releasing the
three bosses from the clips of the upper fairing.
Disconnect the front turn signal connector.
Remove the trim clip and the mirror cover inside spacer.
Remove the two bolts and the rearvtew mirror.
(3) CONNECTOR
(4) MIRROR
(5) MIRROR CASE
2-8
Upper Fairing
Removal/Installation 121
151
131
161
181
Requisite Service
Left and right rear view mirrors (page 2-8). • Middle fairing inner cover (page 2-7).
Instrument panel (page 2-7).
Procedure O'tv Remarks
Removal Order Installation is in the reverse order of removal.

111 Air duct 1
121 Headlight connector 2 ,
131 Position light connector
141 Trim clip
1
2
I
151 Screw , 4
161 Socket bolt 2
171 Bolt/collar 4/2
181 Upper fairing 1 At installation, align the holes in the headlight with the
mounting bosses of the fairing stay.
2-9
Diassembly/ Assembly
(4) (7)
(t)
,
/
,
,
,
,
,
, (4)
,
,
,
(2)
Requisite Service
. Upper fairing removal/installation (page 2-9).
Procedure a:ty Remarks

Disassembly Order Assembly is in the reverse order of disassembly.
(1 ) Socket bolt/nut 2/2
(2) Bolt 2
(3) Headlight 1
(4) Bolt/nut 1/1
(5) Upper fairing 2
(6) Screw 2
(7) Air duct 1
2-10
Front Fender (LBS·ABS/TCS model)

Brake pipe
(2)_=_
===---:!
n I
i-
'_~ __ ,.j I.
Tabs
Studs
(4)
-~IIII' / , , '
Setting bosses
NOTE
I • On the standard and ABSfTCS model, refer to page 13-6 "Front wheel removal/installation".
Procedure Q'ty Remarks

(1) Socket bolt 2
(2) Flange bolt/washer 2/2
(3) Upper fender 1 When installing, align the cutouts with the tabs on the
fender side covers.
(4) Lower fender 1 When installing, insert the fender end between the brake
pipe and fender plate, and align the holes in the lower
fenderwith the bolt hole studs and setting bosses on the
fender plate.
2-11
FuelTank
(2) (8) '4

....._ - ( 7 )
I
I
12 (1.2. 9)
Gasoline is extremely flammable and is explosive under certain conditions.
Requisite Service
• Air cleaner housing removal/installation (page 5-10)
,,
111 Fuel tank breather tube Remove from the fuel fill cap and clamp.
(2) Fuel line
(3)
(4)
Fuel
Fuel
pump connector
level sensor connector ,,
3
(51 Fuel fill cap

(61 Fuel tank tray 1
171 Fuel tank mounting bolt 4
(8)
(9)
Fuel
Fuel
tank
tank heat protector ,
1
2-12
Muffler
Right Muffler: Standard Model
-- 11 )
C 22 (2.2, 16)
141
C 27 (2.7, 20)
131 15)
16)
C 35 (3.5, 25)
-(2)
17)---\il·
C 27 (2.7, 20)
• Do not service the exhaust system while it is hot.
Requisite Service
• Right pivot cover removal/installation (page 2-5)

111 Muffler band 2 Loosen the band bolts.
,,
12) Muffler mounting bolt 1
13) Right footpeg holder bolt 6 mm
14) 8 mm
15)
16) Right footpeg holder
10 mm 2
1 . Remove with the master cylinder and rear brake light
switch installed.
.
171 Right muffler
,, Support with a piece of string.
181 Gasket
2-13
(9)
-.
Do not service the exhaust system while it is hot.
Requisite Service
• Right pivot cover removal/installation (page 2-5)

(1) Harness band 1 Loosen the band.
(2) Connector 3
(3) Muffler band 2 Loosen the band bolts.
(4} Muffler mounting bolt 1
(5} I Right footpeg holder bolt 6 mm 1
(6} 8 mm 1
(7) 10 mm 2
(8) Right footpeg holder 1 . Remove with the master cylinder and rear brake light
switch installed.
Support with a piece of string.
(9) Right muffler 1
(10) Gasket 1
2-14
Right Muffler: LBS-ABS/TCS Model

(1)
.'~~ tt;~-~ 022 (2.2, 16)

- ,7 ;~ ,/ "'10../
--,.- ',', ' ,
tII(S)
'-
,
cc-. ic~:::;~('" LBS-ABS/TCS model only
I· (5) 027 (2.7, 20)
<:~~
-,"
(7)
(3)
@
~ (2) ""'r
(8)
0 2 7 (2.7, 20) (6) 0 35 (3.5, 25)
Requisite Service
• Right pivot cover removal/installation (page 2-5).

(2) Modulator mounting bolt 3
(3) Muffler mounting bolt 1
(4) Right step holder bolt 6 mm 1
(5) 8mm 1
(6) 10 mm 2
(7) Right step holder 1 , . Remove with the master cylinder and rear brake light
. switch installed.
Support with a piece of string .
(8) Right muffler 1
(S) Gasket 1
2-15
Left Muffler: '91-'95
C
(11 .,
(9)
12)
(4)
(5) 22 (2.2, 16)
C~,
27 (2.7, 20)
(6)
35 (3.5, 25) 17)
(8)
Requisite Service
Left pivot cover removal/installation (page 2-5)

Battery removal/installation (page 17-12)

111 Muffler band 2 loosen the band bolts.
(2) Battery holder bolt 2
(4) Left footpeg holder bolt 6 mm 1
(5) 8 mm 1
(6) 10 mm 2
(7) left footpeg holder 1 Support with a piece of string.
(8) left muffler , 1
19) Gasket i 1
2-16
Left Muffler: After '95 i4) (11) erJ

(2)
o
27 (2,7, 20)
(8)
o /----------
35 (3.5, 25)
(9) (10)
Requisite Service
Left pivot cover removal/installation (page 2-5).

Battery removal/installation (page 17-12).

,
(1) Alternator fuse cover 1
(2)
, !
Bolt/fuse base plate , 2/1
[3) Battery holder bolt 2
[4)
,
Muffler band , 2 Loosen the band bolts.
!
[5) Muffler mounting bolt 1
[6) Left step holder bolt 6 mm 1
[7) 8mm 1
!
[8) 10 mm 2 ,
,
[9) Left step holder 1
(10) Left muffler 1
(11 ) Gasket 1
2-17
Exhaust Pipe
Right Exhaust Pipe
f!I
110)
.2, g)
18)
17 (1.7,12)
22 (2.2, 16)
(11)
f!I 161 191
• Do not service the exhaust system while it is hot.
Requisite Service
• Right middle fairing removal/installation (page 2-8) AB$/TC$ or LB$-ABS/TCS Model:

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

111 Lower engine mounting nut 1
12) Bolt 2
131 Right engine guard 1
141 Bolt 4
151 Protector gasket 5
161 Right exhaust pipe protector 1
17) Exhaust pipe band 1 Loosen the band bolt.
18) Exhaust pipe joint nut 4
191 Right exhaust pipe 1
1101
(' ,)
Exhaust pipe gasket
Exhaust chamber gasket
2
1
2-18
left Exhaust Pipe
151
C
(7)
1121 I~ ~111
17 (1.7,12)
(61 IBI (1)~ C
(21
141 E): 22 (2.2,16) C 55 (5.5, 40) 27 (2.7, 20)
Requisite Service
Left middle fairing removal/installation (page 2-8)

Right exhaust muffler removal/installation (page 2-14)

11) Bolt 2
(21 Left engine guard 1
13) Bolt 4 I
141 Protector gasket 5
15) Left exhaust pipe protector 1
171 Exhaust pipe joint nut Installation (page 2-20)
IBI
191
1101
(11):
8 mm mounting bolt/washer
Left exhaust pipe/,chamber
Exhaust pipe gasket
Muffler gasket
I
'B
2
2
(12}1 Mounting collar I 1
2-19
Exhaust Pipe Installation
1. Make sure that the mounting collar is installed in

position. Loosely install the left exhaust pipe/
chamber to the frame with the 8 mm mounting bolt
and washer.
2. Make sure that the exhaust pipe gaskets are

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

pipe/chamber.
4. Make sure that the exhaust pipe gaskets are

installed in position. Insert the right exhaust pipe
flanges into the cylinder head and loosely install the
joint nuts.
5. Tighten each pair of the joint nuts in 3 steps as

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

to the specified torque.
6. Tighten the exhaust pipe band.
Torque: 22 N'm (2.2 kg-m, 16 tt·lb)
7. Tighten the 8 mm mounting bolt.
(1) JOINT NUT
(2) RIGHT EXHAUST PIPE
~§SJt(JJ-/,~;;--
(6) LEFT EXHAUST PIPE/CHAMBER -! (3) MOUNTING
COLLAR
2-20
Symbols
...

~
C
10 (1.0, 7.2)
~
equivalent)
MUlti-purpose M-2 manufactured by Mitsubishi Oil Japan
equivalent)

"I~ Apply sealant

3. Maintenance
Service Information 3-1 Carburetor Synchronization 3-9
Service Access Guide 3-2 Engine Idle Speed 3-11
Maintenance Schedule 3-4 Radiator Coolant 3-11
Air Cleaner
Spark Plugs
3-6
3-6
Timing Belt
Brake Fluid
3-12
3-12
III
Valve Clearance 3-6 Brake System ILBS-ABSrrCS model) 3-13
Engine Oil 3-8 Headlight Aim 3-14
Service Information
Rafer to Common Service Manual for service procedures on items not included in this manual.
Refer to specifications (Section 1) for maintenance service data.
3-1
Maintenance
Service Access Guide

The following shows the locations of the parts that must be removed for the maintenance items listed below, Refer to
the Common Service Manual for items not included in this manual.
Refer to section 2 (frame/body panels/exhaust system), for the parts that must be removed for service.
For example: AIR CLEANER (Contamination, clogging, replacement) - Maintenance part (service items)
• Top shelter - The parts that must be removed for service.
ABS/TCS model shown:
(4) SPARK PLUG
(Wear, damage, color: page 3-6)
(5) THROTILE GRIP (Operation, free play)

(3) THROTILE STOP CONTROL KNOB
(6) BRAKE MASTER CYLINDER
(Idle speed adjustment: page 3-10)
(Level chek, fluid replacement
[LBS-ABS/TCS: page 15-2])
(2) FUEL LINE (Damage. leakage)
• Top shelter (7) HEADLIGHT ADJUSTING KNOB
(Aim' page 3-14)
(1) BRAKE RESERVOIR
(Level check: page 3-10, fluid replacement (B) BRAKE LEVER
[LBS-ABS/TCS: page 15-2]) (Air in system)
(9) STEERING HEAD

BEARING (Damage)
(11) TIRE (Wear,

damage, pressure)
(24) FINAL DRIVE
(Oil level check)
(12) WHEEL (Damage, runout,
corrosion)
(23) SUSPENSION
(Loose, wear, damage) (13) BRAKE HOSE (Leakage,
degradation, damage)
• Middle fairing inner cover.
(22) BRAKE HOSE (Leakage,
degradation, damage)
• Side cover (14) EVAP PURGE CONTROL VALVE and
EVAP CAV CONTROL VALVE
(Damage, faulty hose: page 5-17)
(21) RESERVE TANK
[Standard model]
(Coolant level: page 3-11) (15) OIL FILLER CAP
(Oil adding, replacement: page 3-9)
(20) BRAKE LIGHT SWITCH (Operation)

(16) OIL LEVEL INSPECTION WINDOW
(Level check: page 3-8)
(19) BRAKE PEDAL (Air bubbles in system)
(17) RESERVE TANK [ABS;TCS model]
(18) FUEL FILTER (Clogging) (Coolant level: page 3-11)
• Top shelter
--
3-2
Maintenance
ABS/TCS model shown
(7) AIR CLEANER

(6) PAIR CONTROL VALVE (Contamination, clogging, replacement: page 3-6)
(Damage, faulty hose: page 5-17)
(B) SYNCHRONIZATION ADJUSTING SCREW
(Synchronization: page 3-9)
(5} CARBURETOR CHOKE (Operation)
(9) BRAKE HOSE

(4) CLUTCH MASTER CYLINDER (Leakage, degradation,
(Level check, fluid replacement) damage)
(3) CLUTCH LEVER

(10) BRAKE CALIPER
(Air in system)
(Pad wear)
• Left saddle bag
(2) HEADLIGHT
ADJUSTING SCREW
(Aim: page 3-14)
(1) SUSPENSION
(Loose, wear, damage)
(19) TIMING HOLE COVER (Ignition timing)

• Lower fairing
(1 B) TIMING BELT (Cracks, damage,

(11) TIRE (Wear,
contamination: page 3- 12)
damage, pressure)
(17) RADIATOR HOSE

(12) WHEEL (Damage,
(Leakage, degradation, damage)
runout. corrosion)
(16) OIL DRAIN BOLT

(Oil replacement: page 3-B) (13) SIDE STAND (Operation)
(15) VALVE CLEARANCE (page 3-6)
(14) OIL FILTER

(Replacement: page 3-8)
3-3
Maintenance
Maintenance Schedule
'91-'94
Perform the PRE-RIDE INSPECTION in the Owner's Manual at each scheduled maintenance period.
I: Inspect and clean, adjust, lubricate, or replace if necessary.
R: Replace C: Clean l: lubricate A: Adjust
The following items require some mechanical knowledge. Certain items (particularly those marked > and U) may require
more technical information and tools. Consult an authorized Honda dealer.
~y ...•
Whichever Odometer Reading (Note 1)
comes
first xl,OOOmi 0.6 4 8 12 16 20 24
Refer to
x 100 km 10 i 64 128 192 256 320 ·384
page
Item Note Months 6 12 , 18 24 30 36
• Fuel line I I I Note 5
• Throttle Operation I I I I Note 5
• Carburetor Choke I I I Note 5
Air Cleaner Note 2 R R 36
,
Spark Plugs I R I R I R 3 6
,
"E • Valve Clearance I I 3-6
•
"-c• Engine Oil R R R R 38
.'"
•
~
c
·•
Engine Oil Filter
Carburetor Synchronization
Engine Idle Speed
R
I
I I
R
I
I I
R
I
I I
R
I
I
3-8
3-9
3-11
0
"Es Radiator Coolant Note 3 I I R 3-11

ur
·
•
Cooling System
Secondary Air Supply System Note 6
I
I
I
I
1
I
Note 5
Note 5
· Evaporative Emission Control System Note 4 I I Note 5
· Timing Belt I Every 60,000 mt (96,000 km}

REvery 90,000 mi (144,000 krn]
3-12
Final Drive Oil I I R Note 5

Brake Fluid Note 3 I I R I I R Note 5.3-12
,
Brake Pads Wear I I I I I I Note 5
"
E
• ' Brake System I I I I Note 5,3 13
"-•c •
..
Brake light Switch I I I Note 5
·
~
• Headlight Aim I I I 3-14

a: Clutch System I I
c I Note 5
0 ,
Clutch Fluid Note 3 I I R I I R Note 5
"E
sn
Side Stand I I I Note 5
•c, • , Suspension I I I Note 5
0
,
z
· Nuts, Bolts, Fasteners
Wheels/Tires
I • I I
I
I
I
Note 5
I" I Note 5
I.. Steering Head Bearings I I 1 I Note 5
• Should be serviced by your authorized Honda dealer, unless the owner has proper tools and service data and is mechanically
qualified.
*" In the interest of safety, we recommend these items be serviced only by your authorized Honda dealer.
Notes: 1. At higher odometer readings, repeat at the frequency interval established here.
2. Service more frequently when riding in unusually wet or dusty areas.
3. Replace every 2 years, or at indicated odometer interval, whichever comes first. Replacement requires mecha-
nical skill.
4. '91-'93: Standard California type and U S.A. ABS/TCS type.
'94: California type.
5. Refer to Common Service Manual.
6. All U.S.A. types.
3-4
Maintenance
After '94
Perlorm the PRE-RIDE INSPECTION in the Owner's Manual at each scheduled maintenance period.
I: Inspect and clean, adjust, lubricate, or replace if necessary.
R: Replace C: Clean L: Lubricate A: Adjust
The following items require some mechanical knowledge. Certain items (particularly those marked * and "*) may require
more technical information and tools. Consult an authorized Honda dealer.
~y ..•
Whichever Odometer Reading (Note 1)
comes
first x 1,000 mi 0.6 I 4 8 12 16 20 24
Refer to
x 100 km 10 64 128 192 256 320 I 384
page
Item ; Note Months 6 12 18 I 24 30 36
• Fuel Line I I I Note 5
• Throttle Operation I I I I Note 5
• Carburetor Choke I I I Note 5
Air Cleaner Note 2 , R R 36
; Spark Plugs I R I R I R 3-6
•E • Valve Clearance I 3-6
• ,
"-o• Engine Oil R R
R
R
R
R
R
3-8
~ Engine Oil Filter R 3-8
.s ,
•
'"c ·• Carburetor Synchronization
Engine Idle Speed
I
I I
I
I I
I
I I
I
I
3-9
3-11
0
I,
"eE Radiator Coolant Note 3
,
I I R 3-11
w
·• Cooling System
Secondary Air Supply System Note 6
I
I
I
I
I
I
Note 5
Note 5
· , Evaporative Emission Control System Note 4 I I Note 5
· Timing Belt I Every 60,000 mi (96,000 km)

REvery 90,000 mi (144,000 km]
3-12
Final Drive Oil I I R Note 5

Brake Fluid Note 3 I I R I I R Note 5,3-12
•E Brake Pads Wear I I I I I I Note 5
• Brake System I I I , I Note 5,3-13
"-•o· Brake Light Switch I I I Note 5
-.• ·
~
Headlight Aim I I I 3-14
'" c
0
Clutch System I I I Note 5
Clutch Fluid Note 3 I I R I I R : Note 5
"•
E Side Stand I I I Note 5
•c,
0
z
·• Suspension , I I I Note 5
.. Nuts, Bolts, Fasteners

WheelslTires
I I
I
I
I
I
I
Note 5
Note 5
.. Steering Head Bearings I I I I I Note 5
* Should be serviced by your authorized Honda dealer, unless the owner has propertoofs and service data and is mechanically
qualified .
.. In the interest of safety, we recommend these items be serviced only by your authorized Honda dealer.
Notes: 1. At higher odometer readings, repeat at the frequency interval established here.
2. Service more frequently when riding in unusually wet or dusty areas.
3. Replace every 2 years. or at indicated odometer interval, whichever comes first. Replacement requires mecha-
nical skill.
4. California type.
5. Refer to Common Service Manual.
6. All U.S.A. types.
3-5
Maintenance
Air Cleaner
(1) AIR CLEANER
Remove the top shelter (page 2-5). HOUSING COVERT5='~
Remove the eight screws and the air cleaner housing

cover. (2) SCREW--- """=7'
Remove the air cleaner and discard it.
Install a new air cleaner and the removed parts in the (3) AIR CLEANER
reverse order of removal.
Torque:Housing cover screw:
0.9 N.m (0.09 kg-m, 0.65 ft-Ib)
Spark Plugs
Disconnect the spark plug caps and clean any dirt from
around the spark plug bases.
Remove the spark plugs.
Visually inspect the spark plug electrodes for wear. The

center electrode should have square edges and the side
electrode should have a constant thickness. Discard the
spark plug if there is apparent wear or if the insulator is
cracked or chipped.
For recommended spark plug, see page 1-15.
Measure the spark plug gaps using a wire-type feeler (1) SIDE
ELECTRODE
gauge.
1
Spark plug gap: 0.8-0.9 mm (0.031-0.035 in)
0.B-0.9 mm
(0.031-0.035 in) i
If necessary, adjust the gap by carefully bending the side
electrode.
Install the spark plugs.

T
__U-__
Torque: 11 N-m (1.1 kg-m, 8 ft-lb]
Connect the spark plug caps and install the maintenance

cover (page 2-5).
Valve Clearance (1) TIMING HOLE COVER
Inspection
NOTE
Inspect and adjust valve clearance while the engine is
cold (below 35'C/95°F)
Remove the cylinder head covers (page 8-2).
Remove the timing hole cover.
3-6
Maintenance
Turn the crankshaft clockwise and align the T1 mark on

(1) INDEX MARK
the timing belt drive pulley guide plate with the timing
belt cover Index mark.
Make sure the No.1 piston is at Top Dead Center (TDC)

on the compression stroke and the RIGHT camshaft index
lines align with the top of the cylinder head and face (2) T1 MARK
OUT as shown.
If the No. 1 piston is not at TDC on the compression

stroke, turn the crankshaft clockwise one full turn and
realign the T1 mark with the index mark.
Measure the No. 1 cylinder valve clearances for the

intake and exhaust valves by inserting a feeler gauge
between the cam lobes and the valve lifters.
Valva clearance:
IN: 0.13-0.19 mm (0.005-0.007 in)
EX: 0.22-0.28 mm (0.009-0.11 in)
Record the clearance for each valve for reference, if shim

selection is needed.
(1) INDEX LINE {FACING OUT)
Turn the crankshaft clockwise 1/4 turn to align the T4
mark with the index mark. The LEFT camshaft index lines
should align with the top of the cylinder head and face
IN.
Measure and record the No.4 cylinder valve clearances.

mark. The RIGHT camshaft index lines should align with
the top of the cylinder head and face IN.

mark. The LEFT camshaft index lines should align with
the top of the cylinder head and face OUT.
(1) FEELER GAUGE
Shim Selection
If the valve clearance is not correct:

Remove the camshaft (page 8-4), valve lifter and shim
(page 8-8).
NOTE
Be careful not to allow the shims to fall into the
crankcase. The shim may occasionally stick to the
valve lifter.
Mark the positions of all valve lifters and shims to
ensure correct reassembly.
Remove the shim with tweezers or a magnet.
Clean the valve lifter with compressed air.
3-7
Maintenance
Clean the shim with a clean shop towel.

Measure the shim thickness with a micrometer and record (1) SHIM
it.
NOTE
Sixty-five different shims are available in thickness
,
o
intervals of 0.025 mm. The thinnest is 1.200 mm

and the thickest is 2. BOO mm.
To select' the shim needed to bring the valve clearance

within the specification, use the following formula:
a=b-c+d
a: new shim thickness
b: recorded valve clearance
c: specified valve clearance
d: old shim thickness
Example
b: recorded valve clearance = 0.18 rnm
c: specified valve clearance = 0.16 mm
d: old shim thickness = 1.850 mm
a=0.18-0.16+ 1.850
a = 1.B70
New shim thickness = 1.875 mm
NOTE
If the required thickness of the new shim is more than
2.800 mm, the valve seat is probably heavily
carboned. Reface the seat, recheck valve clearance
and reselect the shim.
Engine Oil
Engine Oil and Filter Change
CAUTION
Used engine oil may cause skin cancer if repeatedly
left in contact with the skin for prolonged periods.
Although this is unlikely unless you handle used
oil on a daily basis, it is still advisable to thoroughly
wash your hands with soap and water as soon as '
possible after handling used oil.
NOTE
Change the engine oil with the engine warm and the '91-'95 shown:
motorcycle on its center stand to assure complete
and rapid draining. (1) OIL FILTER
Remove the lower fairing (page 2-4).
Remove the oil filler cap and oil drain bolt. and drain the
engine oil.
Remove the oil filter with the special tool and let the re-
maining oil drain out. Discard the oil filter.
Is ';""OOL I
Oil filter wrench 07HAA-PJ70100
3-8
Maintenance
Apply a thin coat of engine oil to the O-ring on the new

oil filter.
Install the oil filter and tighten it with an oil filter wrench.
Torque: 10 N"m (1.0 kg-m. 7 tt-tb]
Check that the sealing washer on the drain bolt is in good

condition. Install the drain bolt and tighten it.
(1) O-RING
Torque: 38 Nom (3.8 kg-m. 27 ft-Ib)
Fill the crankcase with the recommended engine oil (page

1-7).
Install the oil filler cap.
Start the engine and let it idle for a few minutes.

Stop the engine. After a few minutes, check the oil level
inspection window, ......~--/
The oil level should be between the upper and lower level
marks. »: (1) OIL LEVEL INSPECTION
WINDOW
(2) UPPER
rJ.:J!;;~1 LEVEL
ll),.<;;;;l.iI=L I3 J LOWER
LEVEL
If required, remove the filler cap, and add the specified

oil up to the upper level mark. Do not overfill.
(1) OIL FILLER

CAP
Carburetor Synchronization
NOTE
(1) No.3 CYLINDER VACUUM TUBE
Refer to section 2 of Common Service Manual for
carburetor synchronization procedure.
Synchronize the carburetor with the engine at normal
operating temperature. the transmission in neutral and
the motorcycle supported upright.
Remove the left and right fairing pockets (page 2-6).
Disconnect the NO.3 cylinder vacuum tube from the auto

fuel valve, apply vacuum to the auto fuel valve and pinch
the tube with a clamp.
Connect the vacuum gauge adaptor to the No.3 cylinder
vacuum tube.
3-9
Maintenance
(All U.S.A. types)
U.S.A.TYPE (1) 3-WAY JOINT
Disconnect the NO.2 and 4 cylinder vacuum tubes at the
3-way joint, and connect the vacuum gauge adaptors.
{Canada type}
Remove the vacuum tube caps from the No. 2 and 4
cylinder vacuum tubes and install the vacuum gauge
adaptor tubes.
'91-'93:
(Standard California type and U.S.A. ABS/TCS type) (1) EVAP CAY
After '93: CONTROL VALVE
. ' r«).
~
(California type)
Disconnect the No. 1 cylinder vacuum tube from the
EVAP CAY control valve apply vacuum to the EVAP CAY
control valve and pinch the tube with a clamp.
" -
:-\ ' , _ I "" 'cL
• •
_~ I '---~
Connect the vacuum gauge adaptor to the No.1 cylinder , "I
vacuum tube. fO ,~-./iJl

L~;~Wlli , II
• I.
(2) No.1 CYLINDER VACUUM TUBE
'91-'93:
(Standard 49 state and Canada type)
After '93:
(49 state and Canada type} (1) No.1 CYLINDER VACUUM TUBE
Remove the vacuum joint tube cap from the No.1 cylinder
vacuum tube and install the vacuum gauge adaptor tube. .>:
~::Q\'
\. \
" "'~
~~
~~. ". a
~----
-
,--~',
---
®
-
-
=--
-f ~
-
(2) PLUG
NOTE I, 1(1) SYNCHRONIZATION ADJUSTING SCREW

I· The base carburetor is the NO.4 carburetor. ~~---
-
" \ ' \ ' \ \ \ '\ '\
, ,
Adjust the carburetor synchronization by turning the
synchronization adjusting screw.
<,
(2) RIGHT SIDE (3) LEFT SIDE
3-10
Maintenance
Engine Idle Speed (1) THROTILE STOP CONTROL KNOB
NOTE
Inspect and adjust idle speed after all other engine
adjustments are within specifications.
Engine must be warm for accurate adjustment. Ten
minutes of stop-end-go riding is sufficient.
Warm up the engine, shift the transmission into neutral

and place the motorcycle on its center stand.
Open the top shelter lid with the ignition key.
Adjust the idle speed by turning the throttle stop control ./ (2) TOP SHELTER LID
knob.
Idle speed:1.200 ± 100 rpm

1,000 ± 100 rpm (Canada typel STANDARD MODEl: (3) RUBBER PROTECTOR
/!)~
(1) RESERVE TANK
Radiator Coolant
Check the coolant level in the reserve tank while the
engine is at normal operating temperature. iJ,4cc;/ ~!lJl ~
The level should be between the UPPER and LOWER level /(!:»)-'- , / -' ' /
/~-Aq:.~h
lines. / / ~/' :0;-\__
/ ./-
<\
~
(2) UPPER LEVEL LINE (4) LOWER LEVEL LINE
ABS/TCS MODEL:
(2) RESERVE TANK
i (1) UPPER LEVEL L1~4~~~.

/ /. ' - --=-----=-------=---.-----=--
(Standard Model)
If the level is low, remove the right side cover (page 2-2),
remove the filler cap and add the recommended coolant to
the UPPER level line.
NOTE
I· Do not remove the rubber protector.
For coolant draining/refilling, see section 6.
(1) RESERVE TANK
3-11
Maintenance
(ABS/TCS or LBS-ABS/TCS model)

If the level is low, remove the right maintenance cover (1) RESERVE TANK
/
(page 2-5), remove the filler cap and add the recommended
coolant the UPPER level line.
For coolant draining/refilling, see section 6.
Timing Belt
(1) TIMING BELT
Remove the reduction holder covers (page 8-2).
Remove the timing hole cover (page 3-5).
Check the timing belt for cracking, damage or contamin-

ation with oil and/or coolant while turning the crankshaft
clockwise.
If the belt is cracked or damaged, replace it with a new

one (page 8-12).
If the belt is contaminated with oil and/or coolant, remove
the timing belt cover (page 8-3). Clean the timing belt
housing and pulleys thoroughly, then replace the belt with
a new one.
Brake Fluid (1) UPPER LEVEL
NOTE
For front brake fluid level checking and fluid
replacement, refer to the Common Service Manual.
For fluid replacement on the LBS-ABS/TCS model,
see page 15-2.
(2) LOWER LEVEL
Rear Brake Fluid Level
Remove the right saddlebag (page 2-2).
Check the fluid level by viewing from the rear as shown.

The level should be between the UPPER and LOWER level
lines.
3-12
Maintenance
Brake System (lBS-ABS/TCS model) (1) SECONDARY

MASTER
NOTE CYLINDER
The LBS-ABS{TCS brake pedal operation should be
inspected as described below.
The lever brake line of the LBS-ABS/TCS model
should be inspected in the same manner as the lever
brake line of the standard model and the ABS/TCS
model.
Place the motorcycle on its center stand and shift the

transmission into neutral.
Push the secondary master cylinder by pressing the left (2) BRAKE PEDAL
front caliper. ,
The rear wheel should not be able to rotate when the
secondary master cylinder is pushed forward.
Also check the smooth operation of the brake linkage.
The rear wheel should not be able to rotate when the brake
pedal is pressed.
Raise the front wheel off the ground by supporting the

engine.
The front wheel should not be able to rotate when the

brake pedal is pressed.
(1) BRAKE
PEDAL
t
(2) FRONT WHEEL
3-13
Maintenance
Headlight Aim
An improperly adjusted headlight may blind

on-coming drivers, or it may fail to light the road
for a safe distance.
Place the motorcycle on a level surface.
Horizontal:
Insert a screwdriver into the hole in the middle fairing inner
cover, and turn the adjusting screw to adjust the headlight
beam.
Vertical:
Adjust the headlight beam to suit riding conditions by
~
turning the headlight adjusting knob.
~
~ \\,
,
\ \\
I II
,
!
,
:~\\\~
I, I ~(
1 ~j ,
11
(1) ADJUSTING KNOB
3-14
Symbols
...

~
C
10 (1.0, 7.2)
~
equivalent)
equivalent)

"I~ Apply sealant

4. Lubrication System
Service Information 4-' Oil Cooler Removal/Installation 4-4
Troubleshooting 4-' Oil Pump Removal/Installation 4-6
lubrication System Diagram 4-2 Oil Pump Disassembly/Assembly 4-8
Service Information III

;' If the engine must be running to do some work, make sure the area is well ventilated. Never run the engine in
an enclosed area. The exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness
and may lead to death. Run the engine in an open area or with an exhaust evacuation system in an enclosed area.
Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although
this is unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with
soap and water as soon as possible after handling used oil.
When removing and installing the oil pump use care not to allow dust or dirt to enter the engine.
If any portion of the oil pump is worn beyond the specified service limits, replace the oil pump as an assembly.
After the oil pump has been installed, check that there are no oil leaks and that oil pressure is correct.
For oil pressure check, refer to section 4 of the Common Service Manual; for the switch location, see page 21-2 of this
manual.
For oil pressure light inspection, refer to section 25 of the Common Service Manual.
Troubleshooting
Oil level low Low oil pressure
Oil consumption. Pressure relief valve stuck open.
External oil leak. Clogged oil filter screen.
Worn piston ring or incorrect piston ring installation. Oil pump worn or damaged.
Worn valve guide or seal. Internal oil leak.
Incorrect oil being used.
Oil contamination (White appearance) Low oil level
Coolant mixing with oil.
-Faulty head gasket. No oil pressure
-Water leak in crankcase Oil level too low
Oil pump drive chain or drive/driven sprocket broken.
High oil pressure
Pressure relief valve stuck closed.
Plugged oil filter, gallery, or metering orifice.
Incorrect oil being used.
4-1
Lubrication System
Lubrication System Diagram (1) CAMSHAFT HOLDER
'91-'95
~!~iE~!~~~-- (2) CAMSHAFT
131 ORIFICE.-;-_ _-.ll~

(GASKET)
b!;;;l[f~- (5) PISTON
(4) OIL PRESSURE SWITCH

11---- (6) CONNECTING ROD
(3) ORIFICE
'\, ~. :'
(GASKET) (7) CRANKSHAFT
(10) OIL GALLERY
(8) ORIFiCE
(13) OIL PUMP
1 (12) OIL FILTER
(19) COUNTERSHAFT
(15) RELIEF VALVE

\
(14) CLUTCH HOUSING
_ =0
{20} MAINSHAFT
t:
(18)PRIMARY DAMPER SHAFT
(17) CLUTCH
4-2
Lubrication System
After '95 (1) CAMSHAFT HOLDER
~!~~!~!~I~~-- (2) CAMSHAFT
(3) ORIFICE
(GASKET} --_.~
~~~~_-- (5) PISTON
r..- - - (6) CONNECTING ROD

(3) ::I::~:RESSURE S\WITCH
(GASKET) (7} CRANKSHAFT
,,,
,,
I
(10) OIL GALLERY
(S) ORIFICE
(12) OIL PUMP
(9) ALTERNATOR (11} OIL FILTER
(15) OIL STRAINER
(18) COUNTERS HAFT
(14) RELIEF VALVE
-
t
(19) MAINSHAFT
i
(17) PRIMARY DAMPER SHAFT
(c
(16) CLUTCH
4-3
. System
Lubrication 1/InstaIIation
Oil Cooler Remova
til(8)
til
(2)
(4)
(3)
(5)
C 65 (6.5, 47)
" ite Service

Requrst
. Engln~
. °dlil draining
. remova l/installation
fairing . p
(age2 8).
Left mid e Q'ty
Procedure Remarks
Installation is in thehr(~7HAA PJ70100) .

Removal Order verse order a f removal.
(1)
(2)
(3)
(4)
Oil filter
a-ring
Water hose
Oil cooler bolt
(5) Oil cooler
I
I !~91-'95
1 Use 01'I filter wrenc
onlv
(6) a-ring 1
(7) , Oil orifice 1 Install with the 01 I hole end facing IN as shown.
(8) a-ring 1
4-4
Lubrication System
MEMO
4-5
Lubrication System
Oil Pump Removal/Installation
0 1 2 (1.2, 9)
qI 111
131 (21
(17)038 (3.8, 27)
\ J5).IiI
tIIP ~
qI
151 tIIP
191
.-... 181
(8) liS
1101
141
18)
(11 )
171
015{1.5,11)
(6)
(13) (14) (15) (16)"71

1121
4-6
Lubrication System
NOTE
• The oil pump drive and driven sprockets, and clutch outer guide, can be removed without removing the oil pan.
Requisite Service
Engine oil draining

Exhaust pipe removal/Installation (page 2- 1B)
Clutch disassembly/assembly (page 9-6)

(I) Oil pan bolt ,4
(2)
13)
Oil pan
Gasket ,,
1
,,,
14) Oil strainer
(5) Oil strainer packing
(6) Oil pump driven sprocket bolt
(7) Oil pump driven sprocket Install with the IN mark facing IN.
18) Oil pipe/pump mounting bolt 5
(9) Oil pipe 1
lID) a-ring 2
(11) Oil pump/a-ring 1/1 Disassembly/assembly (page 4-B)
(12)
('3)
Oil pump drive chain
Oil pump drive sprocket ,,
1
('4)
('5)
Washer
Thrust bearing ,,
(' 6) Clutch outer guide
{17} Oil drain bolt/washer 1/1
4-7
Lubrication System
Oil Pump Disassembly/Assembly

____________ Ia)
{b]
~ Io)
Ill)
qt
(10) (7)
(4)
111
113) 18) (9)
(12)
(6)
Punch mark
NOTE
The oil pump must be replaced as an assembly.
• Before assembling the oil pump, clean all parts thoroughly with clean engine oil.
Requisite Service
• Oi pump removal/installation (page 4-6)

111 Bolt 3
121 Oil pump cover 1
131 Scavenging pump outer rotor 1 Install with the punch mark facing the cover.
141 Scavenging pump inner rotor 1
15) Drive pin 1
(6) Scavenging pump body 1
(7) Oil seal 1
(8) Dowel pin 2
(9) Outer rotor 1
1101 Inner rotor 1
1111 Ojl pump shaft 1
1121 Drive pin 1
113) Washer 1
lal Snap ring 1
Ib) Washer 1
101 Relief valve spring 1
Id) Relief valve piston 1
4-8
Symbols
...

~
C
10 (1.0, 7.2)
~
equivalent)
equivalent)

"I~ Apply sealant

5. Fuel System
Service Information 5-1 Air Cleaner Housing Removal/Installation 5-10
Troubleshooting 5-2 Pilot Screw Adjustment 5-12
Carburetor Removal/Installation 5-3 High Altitude Adjustment (U.S.A. only) 5-16
Carburetor Separation/Combination 5-4 Emission Control System (U.S.A. onrvl 5-17
Carburetor Disassembly/Assembly 5-8 Carburetor Draining 5-18
Service Information
Bending or twisting the control cables will impair smooth operation and could cause the cable to stick or bind,
resulting in loss of vehicle control.
Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can
cause a fire or explosion.
CAUTION
Be sure to remove the diaphragms before cleaning air and fuel passages with compressed air. The diaphragms
might be damaged.
Refer to section 2 for fuel tank removal and installation.

Refer to section 21 for fuel pump inspection, removal and installation.
When disassembling fuel system parts, note the locations of the O-rings. Replace them with new ones on reassembly.
Before disassembling the carburetors, place an approved gasoline container under the carburetor drain tube, then loosen
the drain bolt and drain the carburetor (page 5-18).
After removing the carburetors, wrap the intake port of the engine with a shop towel or cover it with piece of tape to prevent
any foreign material from dropping into the engine.
U.S.A. only:
All hoses used in the secondary air supply system {All U.S.A. types} and evaporative emission control systems {"91-
'93: Standard California type and U.S.A. ABS/TCS type/After '93: California type are numbered for identification.
When connecting one of these hoses, compare the hose number with the Vacuum Hose Routing Diagram Label, page
1-35, and carburetor tubes. page 5-6.
NOTE
If the vehicle is to be stored for more than one month, drain the float bowls (page 5 18). Fuel left in the float bowls
may cause clogged jets resulting in hard starting or poor dnveability.
5-1
Fuel System
Troubleshooting
Engine won't start Rich mixture
Too much fuel getting to the engine Starting enrichment valve open
-Air cleaner clogged Float valve faulty
-Flooded carburetor Float level too high
Intake air leak Air jets clogged
Fuel contaminated/deteriorated Air cleaner contaminated
-jets clogged Flooded carburetor
Vacuum piston faulty
Starting enrichment circuit clogged
No fuel to carburetor
Engine stalls, hard to start, rough idling
-Fuel filter clogged
Fuel line restricted
-Fuel line clogged
Ignition malfunction
-Fuel level misadjusted
-Fuel tank breather tube clogged Fuel mixture too lean/rich
Fuel contaminated/deteriorated
-Fuel pump malfunction
-Auto fuel valve malfunction -jets clogged
Intake air leak
Lean mixture Idle speed misadjusted
Fuel jets clogged Float level misadjusted
Float valve faulty Fuel tank breather tube clogged
Float level too low Fuel pump malfunction
Fuel line restricted Pilot screw misadjusted
Carburetor air vent tube clogged Starting enrichment circuit clogged
Intake air leak Auto fuel valve malfunction
Fuel pump malfunction EVAP CAV control valve faulty
Auto fuel valve malfunction Hoses of the emission control system faulty
Vacuum piston faulty EVAP purge control valve faulty
Throttle valve faulty
Afterlire when engine braking is used
Lean mixture in slow circuit
Air cut-off valve malfunction
Secondary air supply system faulty
Hoses of emission control system faulty
Afterlire or misfiring during acceleration

Ignition system malfunction
• Fuel mixture too lean
Poor performance (driv8ability) and poor fuel economy

Fuel system clogged
Ignition system malfunction
Faulty EVAP CAV control valve
Damaged/misconnected emission control system hoses
5-2
Fuel System
Carburetor Removal/Installation
141 17)
131
lD~Tl:1--_121
1'1
191 18)
151
Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can
cause a fire or explosion.
Requisite Service
Fairing pocket removal/installation (page 2-6)

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

111
12)
Choke cable
Fuel tube ,,
1
13)
141
Throttle stop screw cable
NO.6 tube , Remove from the fuel tank tray.
Disconnect from the 3-way joint.
('91-'93: Standard California type and U.S.A. ASS/
TCS type/After '93 : California type)
15) Connecting tube band screw 4 Loosen the screws.
161
171
Throttle cable
No. 15 tube ,,
2
Disconnect from the carburetor
181 No.4 tube Disconnect from the EVAP purge control valve.
("91-'93: Standard California type and U.S.A. ASS/
TCS type/After '93 California type)
191 Carburetor drain tube 1
I'D) Carburetor assembly 1
5-3
Fuel System
Carburetor Separation/Combination
(2)
(4)
1'81
l
0' 8 (0.8, 5.8)
1111
\ 191
11 )
(81
;; til : Cotter pins. O-rings. lock plate
. , : O-rings
5-4
Fuel System
Requisite Service
Carburetor removal/installation (page 5-3)

EVAP purge control valve and tube removal/installation
('91-'93 : Standard California type and U.S.A. ABS;TCS type/After '93 : California type: page 5-17)
111
Disassembly Order
Carburetor drain tube/joint assembly ,
12) Screw 4
(3) Lock plate 2
14) Air duct holder 1
15) Screw/lock plate 8/4
IB) Air chamber/duct assembly 1
(7) Dowel pin 8
IB)
19)
Air vent tube/joint assembly
Fuel tube/joint assembly ,
2
(10) Carburetor joint bracket 1 Remove the four screws.

111)
112)
Carburetor connecting screw
Starting enrichment valve link ,,
2
Remove the cotter pins, washers and collars.
(13) Throttle link Remove the cotter pins and washers.
(14) Starting enrichment valve arm shaft/spring 2/2 Loosen the starting enrichment valve arm screw.
(15) Starting enrichment valve arm 2
(1B) Thrust spring 2
117) Synchronization spring 3
11 B) Sub air cleaner tube/joint 2
119) Air joint pipe/O-ring 2/4
120) Fuel joint pipe/O-ring 2/4
Reassembly Order
120) Fuel joint pipe/O-ring 2/4
119) Air joint pipe/O-ring 2/4
I' 8)Sub air cleaner tube/joint 2
I' 5)Starting enrichment valve arm 2
114) Starting enrichment valve rod/spring 2/2 Do not tighten the starting enrichment valve arm screw.
111) Carburetor connecting screw 2 Do not tighten the screws.
110) Carburetor joint bracket 1 Do not tighten the screws.
I' 3)Throttle link 1 Install with the washers and new cotter pins.
(12) Starting enrichment valve link
IB) Air chamber/duct assembly ,
1 Install with the collars, washers and new cotter pins.
Align the air duct flanges with the carburetor grooves.
After installing, tighten the carburetor connecting screws and
joint bracket screws. Then starting enrichment valve arm
15) Screw/lock plate 8/4 screws.
117) Synchronization spring 3
(1B)
19)
Thrust spring
Fuel tube/joint assembly ,
2
(8) Air vent tube/joint assembly 2

(7) Dowel pin 8
(4) Air duct holder 1
13) Lock plate 2
12) Screw 4
111 Carburetor drain tube/joint assembly
5-5
Fuel System
Carburetor Tube Routing ('91-'93: Standard California type and U.S.A. ABSrrCS type)
(After '93 : California type)
(1) No.6 TUBE
(2) EVAPORATIVE EMISSION (EVAP)

PURGE CONTROL VALVE
(3) No.5 TUBE

{5} NO.5 TUBE
(4) No. 11 TUBE
(7) EVAP PURGE

(6) No.5 TUBE CONTROL VALVE
(6) No. 11 TUBE
(9) No.2 CARBURETOR
(14) No.1 CARBURETOR
(13) No.6 TUBE 1---(10) No.5 TUBE

5-6
Fuel System
MEMO
5-7
Fuel System
Carburetor D'isassemblv/Assembly
Canada type (32)
151
(34)
1311
(31
~
1141 ~
1131~
(21 )
1201
{1 O} - - - - - - - - - - -
5-8
Fuel System
NOTE
The vacuum chamber and float chamber can be serviced with the carburetors assembled .
• The pilot screws are factory pre-set and should not be removed unless the carburetors are overhauled.
Requisite Service
• Carburetor separation/combination (page 5-4)

Disassembly Order ! Assembly is in the reverse order of disassembly .
. Vacuum chamber
(11 Screw 4
(2) Vacuum chamber cover 1
(3) Compression spring I 1
(4) Diaphragm/piston 1
15) Needle holder 1
(6) Spring 1
(7) Jet needle 1
(8) Washer (Canada type only) 1
Float chamber
(9) Screw 4
{10) Float chamber 1
(11 ) O-ring 1
(12) Float-pin 1
( l3) Float 1
(14) Float valve 1
(15) Float valve seat 1
( l6) Sealing washer 1
(17)' Main jet 1
(18)1 Needle jet holder 1
(19) Slow jet 1 .
,
Air cut-off valve
(20) Screw I 2
(21 ) Air cut-off valve cover 1
122) Diaphragm 1
123) Spring 1
(24) O-ring 1
Pilot screw
(25) Pilot screw 1
(26) O-ring 1
(27) Washer 1
(28) Spring 1
! Starting enrichment (SEl valve
(29): Nut/washer I 1/1 No.1, No.4 carburetor only
(30)' SE valve lever 1 No.4 carburetor only (Plain washer for No. 1 carburetor)
~=t
(311 CoHar
(32) Spring No.1, No.4, carburetor only
(33) SE valve shaft
(34) SE valve nut 1
(35) SE valve spring 1
(36) SE valve 1
5-9
Fuel System
Air Cleaner Housing Removal/Installation
0: 0.9 (0.09, 0.65)

(11
(2)
~
,}-----c, (3)
4)
~
(5)
u,...-__ 17)
61-_-- 18 )
(10) (9)
(13)
f!1
/.-_--1 6)
5-10
Fuel System
Requisite Service
• Top shelter removal/installation (page 2-5)

(' )
(2)
Air cleaner housing cover screw
Air cleaner housing cover ,
8
(3) a-rings 2 Do not remove the a-rings from the air cleaner housing
,,
cover unless necessary.
(4) Air cleaner
(5) Air cleaner gasket Do not remve the gasket from the air cleaner housing
unless necessary.
(6)
(7)
Sub air cleaner tube
Sub air cleaner cover ,
2
(6) Sub air cleaner 1

(9) Air cleaner housing screw 6
(10)
(11)
Auto fuel valve mounting screw
Breather tube ,,
2
(12)
(13)
Air cleaner housing
a-ring ,
5-11
Fuel System
Pilot Screw Adjustment Standard California Type and U.S.A. ABSITCS Type
'I I I
(11 NO. 1----.:1 . ~ (2) NO 3
Idle Drop Procedure CARBUR/ETETOORR~,.{' '-n-,~
For pilot screw access, see pages 5-13, 14 and 15. ~~ e , ,;.
.. I CARBU-
RETOR
Adjust the pilot screws as follows: W" .\> "'"T
NOTE (5) PILOT SCREW ~'" .~ -..·1
;-. .
Make sure the carburetor synchronization is within WRENCH I,,':', <'~"~.k:.,i.
specification before pilot screw adjustment. )''-:;;''~I'-<.."","
The pilot screws are factory pre-set and no adjust-
ment is necessary unless the pilot screws are replaced.
Use a tachometer with graduations of 50 rpm or
smaller that will accurately indicate a 50 rpm change.
A pilot screw wrench is necessary to turn the pilot
/
(4) NO.2 CARBURETOR --'
'<. /"
(3) NO.4 CARBURETOR ;,'I~

r
-""' _Y"
~
screws. (All U.S.A. types)
ISToOL)
Pilot screw wrench 07KMA-MS60101or
Standard 49 S"',e and Canada Tvpe "
07LMA-MT8010A or (1) NO.1 W.. ~ (2} NO.3
07MMA-MT3010A
(U.S.A. only) ~~;~~~~W-'" ~~;~t I
/
~" " P " \j
Insert the pilot screw wrench from the direction
', '(',;lYC-'(
· "'.
'C,\c'C:":----=,",-)~/'
shown to turn each pilot screw. Use a flashlight to I -'" '-'-'-
help locate the pilot screw. .1'1"
1. Turn each pilot screw clockwise until it seats lightly and

(5) ~~~~~~REW1" I,'~~~:~~ ;~:~::',~_
~.~-
back it out to the specification given.
This is an initial setting prior to the final pilot screw
adjustment.
Initial opening:
2-1/4 turns out (Standard 49 state typel
(4) NO.2 CARBURETOR
1 '"''-'''
'/c"=5)~~:o
T''--{
A \
,
~:JR:)
- -~
1,,]1 (3) NO.4 CARBURETOR

,'N.I
2-5/8 turns out (Standard California type and U.S.A.

ABSi TCS typel
All U.S.A. Types
1· 7/8 turns out (Canada type)
CAUTION
Damage to the pilot screw seat will occur if the
pilot screw is tightened against the seat.
2 Warm up the engine to operating temperature.

Stop-and-go riding for 10 minutes is sufficient.
3. Attach the tachometer according to the tachometer
manufacturer's instructions.
4. Adjust the idle speed with the throttle stop control
knob.
Idle speed: 1,200 ± 100 rpm

(1) PILOT
SCREW
o
1,000 ± 100 rpm (Canada type)
5. Turn each pilot screw 1/2 turn out from the initial
setting. Canada Type
6. If the engine speed increases by 50 rpm or more, turn
each pilot screw out by successive 1/2 turn increments
until engine speed does not increase.
k.nob.
8. Tum the No.1 carburetor pilot screw in until the engine
speed drops 50 rpm.
9. Turn the No.1 carburetor pilot screw out 7/8 turn
from the position obtained in step 8.
knob. (1) PILOT
11. Perform steps 8, 9 and 10 for the No.2, 3 and 4 SCREW
carburetor pilot screws.
5-12
Fuel System
Pilot Screw Access
No. 1 Carburetor
Remove the right side Maintenance Cover. Remove the
plastic timing belt cover on the front of the cylinder
head. Using a 12-inch or longer #1 screwdriver and a
flashlight to guide you, push the rubber carburetor heat
insulator away from the carburetor body.
(2) LUG
Insert the Pilot Screw Wrench into the pilot screw hole
by using the lug on the carburetor body as a guide.
Align the socket with the pilot screw head by turning the
wrench slowly while pushing it lightly onto the pilot (1) PILOT SCREW
screw head.
Return the carburetor heat insulator to its original

position after making the adjustment.
Pilot screw wrench 07LMA-MTB010A or

07MMA-MT3010A
(3) PILOT SCREW WRENCH
No. 2 Carburetor (1) PILOT SCREW WRENCH

Insert the Pilot Screw Wrench from the rear upper side
of the cylinder head between the frame and the fairing
as shown.
Align the socket of the wrench to engage with the pilot (1) PILOT SCREW HOLE
screw head in the same manner as for No. 1 carburetor.
~~~-
(3) LUG (2) SOCKET
5-13
Fuel System
No.3 Carburetor (1) PILOT SCREW

Insert the pilot screw wrench from the lower side of the
auto fuel valve between the frame and the fuel filter as
shown.
Align the socket of the wrench to engage with the pilot ~

(2) FRONT
screw head in the same manner as for No. 1 carburetor.
)~~
:?'H--f--131 LUG
(6) FUEL
FILTER (5) FRAME TUBE
No.4 Caburetor (Standard 49 state and Canada type)

Insert the pilot screw wrench from the front upper side
of the cylinder head through the middle fairing hole as
shown.
(1) PILOT SCREW WRENCH
Align the socket of the wrench to engage with the pilot (1) SOCKET
screw head in the same manner as for No.1 carburetor.
- ." :'[",--=-.
(2) PILOT SCREW
No.4 Carburetor (Standard California type and U.S.A.

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

shown.
\
(1) #4 TUBE
5-14
Fuel System
Position the socket end of the wrench against the lug on (1) SOCKET (2) FLEXIBLE PORTION OF
the carburetor. PILOT SCREW WRENCH
(4) PILOT SCREW HOLE

(31 LUG
Push the tool against the lug to bend the flexible portion (1) THROTILE
of the tool under the throttle bell crank as shown. BELL CRANK
Align the socket of the wrench to engage with the pilot

{2) PILOT
screw head in the smae manner as for No.1 carburetor.
SCREW
WRENCH
Use a flashlight to verify that the socket seats on the
pilot screw.
NOTE
• Do not operate the throttle when the Special Tool is
on the pilot screw.
{3) BEND TOOL UNDER BELL CRANK
After making the adjustment, return the #4 tube to its
original position.
5-15
Fuel System
~
Standard 49 State and Canada Type
High Altitude Adjustment
(U.S.A. only) (1) NO, 1
CARBU---1_C
RETOR
r
l+i~2il;~~~
,r-"...-[
(2) NO.3
CARBU-
RETOR
When the vehicle is to be operated continuously above
2,000 m (6,500 feet] . the carburetor must be readjusted
as described below to improve driveability and decrease
exhaust emissions.
For pilot screw access, see pages 5- 13, 14 and 15.
Warm up the engine to operating temperature. Stop and

go riding for 10 minutes is sufficient.
Turn each pilot screw clockwise 1/2 turn with a pilot (4) NO.
screw wrench.
NOTE Standard California Type and U.S.A. ABS/TCS Type

~ pilot screw wrench is necessary to turn the pilot (1) NO 1'~ ~
I screws. CARBU- ~ "" rx-r121 NO.3
RETOR ~--1tB:! . ,-- --:~~' CARBU-
Is~()~1 ~I~-_ RETOR
Pilot screw wrench 07KMA-MS60101 or
I .,";'j-::~:>'>_.0:~~?::~h,1
07LMA-MT8010A or (51 PILOT SCREW (L ")''.::,:1
07MMA-MT3010A WRENCH I. ".y.>.'
(U.S.A. only)
Insert the pilot screw wrench from the direction
~,,;~-,<'-J'~
shown for each pilot screw. Use a flashlight to help ~,=zJ/_ =->:(\~ r
locate the pilot screw. {4} NO.2 CARBURETOR ) A
(3) NO.4 CARBURETOR I.,:
Adjust the idle speed to the specified rpm with the throt-
tle stop control knob.
Idle speed: 1.200 j- 100 rpm
NOTE
These adjustments must be made at high altitude to
ensure proper high altitude operation. ---!
Attach the Vehicle Emission Control Information Update

label on the left side of the frame as shown. See Service
Letter No. 132 for information on obtaining the label.
NOTE
I· Do not attach the label to any part that can be easily I
removed from the vehicle. (1) PILOT SCREW
Operation at an altitude lower than 1,500 m

(5.000 feet) with the carburetors adjusted for high (1) UPDATE
LABEL
altitudes may cause the engine to idle roughly and
stall.
When the vehicle is to be operated continuously below

1,500 m {5,000 feet}, turn each pilot screw counter-
clockwise 1/2 turn to its original position and adjust the
idle speed to the specified rpm. Remove the Vehicle
Emission Control Update Label.
Be sure to do these adjustments at low altitude with the
engine at normal operating temperature.
5-16
Fuel System
Emission Control System (2) No. 10 VACUUM

(U.S.A. only) (1) AIR SUC~TlaN
PORT rfTUBE
Secondary Air Supply System , I '
, U r.E09
Ix , ( 3 ) PAIR
NOTE
i I ,,' \ .. L-
: CONTROL
/~{;..,:c~=~.
The pulse secondary air injection (PAIR) control valve
and the pulse secondary air injection (PAIR) check l VALVE
valve are combined in one assembly. :", . "'J~I '
Remove the fairing pocket (page 2-6) [!Ot'y! ,<, i
i~ ,
Disconnect the No 10 vacuum tube (routed from the
PAIR control valve) from the 3-way joint.
Plug the 3-way joint and connect the vacuum pump to
the No. 10 vacuum tube.
Remove the air cleaner housing cover and put your finger
on the air suction port of the air chamber.
Perform the secondary air supply system inspection (refer (1) NO.15TUBE
to section 7 of the Common Service Manual).
Specified vacuum: 360 mmHg (14,2 inHg)
Pulse Secondary Air Injection (PAIR) Control

Valve Removal/Installation
Remove the carburetor (page 5-3).

Remove the heat insulator rubber.
Remove the bolts, disconnect the No. 16 (air injection)

hoses, No. 10 tubes and No.1 5 (air suction) tubes from
the PAIR control valves, and remove the PAIR control val-
ves.
\
"
Install the PAIR control valve in the reverse order of

removal.
(2) NO.1 0 TUBE
\
(3) No. 16 (AlA INJECTION) HOSE
Evaporative Emission (EVAP) Purge Control

Valve and Tube Removal/Installation
1'91-'93 : Standard California type and U.S.A.
",,,", (1) N} 11 TUBE
ABS/TCS type}
(After '93 : California type)
Remove the carburetor (page 5-3). ~'~:}~;,~7r:;!:'~',~:~",~

'''''''' ' ",,,,, I, '"",. 1J
~'", ,"
Remove the No.5 and No. 11 tubes, 3-way joints and
the EVA? purge control valve from the carburetor.
' :~i?l;f$~ ,¥ V;."",,'
f? "~,-", '",""':'
(J; U . 1i~/
Install the EVAP purge control valve in the reverse order
of removal.
,~ <,
(2)EVAP
NOTE / \ PURGE
For EVA? purge control valve tube routing, see page (4) 3-WAY JOINT (3} No.5 TUBE CONTROL
5-6. VALVE
5-17
Fuel System
Carburetor Draining ~2 CARBURETOR:

(2) ACCESS HOLE
Remove the maintenance covers (page 2-5}.
(3)
14 in.
--
Remove the access covers from the fairing pockets. SCREWDRIVER
/
Place a suitable container under the carburetor drain hose.

(1} FRONT
Drain the ±;: 2 carburetor by placing a long (minimum 14
in} flat blade screwdriver through the access hole, between
the carburetor synchronization linkage and the carburetor-
to-manifold boot. The screwdriver must be angled down.
toward the front of the motorcycle.
An adjustable flashlight will help locate the drain screw.
Drain the ::I' 4 carburetor by placing a long screwdriver ~4 CARBURETOR: (3) NOTCH
through the maintenance opening, above the cylinder :"""-. ~ ...
head, to the rear of the head cover bolt, between the ~
(2) 14 in. SCREWDRIVER ".
carburetor synchronization linkage and the carburetor-to-
manifold boot. The screwdriver fits in a notch in the upper
----
fairing. The screwdriver must be angled down, foward
the rear of the motorcycle.
(1) FRONT
Loosen the screws until the fuel is drained, and tighten
the screws.
Repeat this procedure on the right side of the motorcycle

for the ~ 1 (tront] and ~ 3 (rear) carburetors. (4) BOLT. FRONT HEAD COVER
5-18
Symbols
...

~
C
10 (1.0, 7.2)
~
equivalent)
equivalent)

"I~ Apply sealant

6. Cooling System
Service Information 6-1 Radiator Disassembly/Assembly 6-6
Troubleshooting 6-1 Water Pump Removal/Installation 6-7
System Flow Pattern 6-2 Radiator Reserve Tank Removal!
Installation 6-8
Coolant Draining 6-4
Thermostat Removal/Installation 6-10
Radiator Removal/Installation 6-5
Service Information
Wait until the engine is cool before slowly removing the radiator cap. Removing the cap while the engine is hot
and the coolant is under pressure may causa serious scalding.
Radiator coolant is toxic. Keep it away from eyes. mouth, skin and clothes.
-If any coolant gets in your eyes. rinse them with water and consult a doctor immediately.
-If any coolant is swallowed, induce vomiting. gargle and consult a physician immediately.
-If any coolant gets on your skin or clothes. rinse thoroughly with plenty of water.
KEEP OUT OF REACH OF CHILDREN.
Add coolant at the reserve tank. Do not remove the radiator cap except to refill or drain the system.
All cooling system service can be made with the engine in the frame.
Avoid spilling coolant on painted surfaces.
After servicing the system, check for leaks with a cooling system tester.
Refer to section 25 of the Common Service Manual for fan motor switch and thermo sensor inspections.
Troubleshooting
Engine temperature too high
Faulty radiator cap.
Insufficient coolant.
Passages blocked in radiator, hoses, oil cooler, or water jacket.
Air in system.
Faulty water pump.
Thermostat stuck closed.
Faulty cooling fan motor.
Faulty cooling fan motor switch.
Engine temperature too low

Faulty temperature gauge or gauge sensor.
Thermostat stuck open.
Faulty cooling fan motor switch.
Faulty cooling fan motor swith.
Coolant leaks
Faulty pump mechanical seal.
Deteriorated O-rings.
Faulty radiator cap.
Damaged or deteriorated cylinder head gasket.
Loose hose connection or clamp.
Damaged or deteriorated hoses.
6-1
Cooling System
System Flow Pattern

'91-'95
(5) RESERVE TANK

(3) RADIATDR ABS/TeS model shown:
OVERFLOW TUBE
(2) THERMOSTAT
(1) RADIATOR CAP

(4) BYPASS TUBE
(8) RADIATOR
(7) WATER PUMP (6) OIL COOLER
6-2
I
Lubrication System
After '95
(3) RADIATOR
OVERFLOW TUBE
(5) RESERVE TANK
LBS-ABSjTCS model shown:
(2) THERMOSTAT
(1) RADIATOR CAP
(4) BYPASS TUBE
(7) RADIATOR
(6) WATER PUMP
6-3
Cooling System
Coolant Draining (1) RADIATOR CAP
Wait until the engine is cool before servicing the

cooling system. Removing the radiator cap while
the engine is hot and the coolant is under pressure
may cause serious scalding.
NOTE
For coolant replacement, refer to section 5 of the
Common Service Manual.
Remove the left and right middle fairings (page 2-8).

Remove the radiator cap.
Remove the radiator drain plug and gasket, and drain the
coolant from the radiator.
Remove the drain bolts and sealing washers from the left
and right cylinders, and drain the coolant from the engine.
(1) DRAIN BOLT
Remove the reserve tank mounting bolts (page 6-8). STANDARD MODEL: ABS!TCS or lBS-ABSI
TCS MODEL:
Place a suitable container under the radiator overflow tube
. ~ R~DIATIR DVERFLDW TUBE
joint of the reserve tank, disconnect the overflow tube from
the tank, and drain the coolant from the tank.
, .. ~ ,
~.\
Install the drain plug with a gasket.
Install the drain bolts with new sealing washers.
Install the reserve tank (page 6-8).
~"t!J~>:-~1
.. ~ ---_/1
(2) RESERVE TANK
6-4
Cooling System
Radiator Removal/Installation
151
111
o
.2 (0.12, 0.9)
141
" ~;o,~--131
Requisite Service
Upper fairing removal/installation (page 2-9)

Coolant draining {page 6-4}
Coolant refill (Section 5 of the Common Service Manual)
Procedure Q'ty ,, Remarks

111 Radiator hose 2
121 Fan motor switch connector 1
131 Horn 1
141 Radiator mounting bolt/collar 2/2
151 Radiator 1 At installation, align the pin of the radiator with the
mounting grommet of the frame properly.
6-5
Cooling System
Radiator Disassembly/Assembly
(1) '91-'95 shown
ew (51
181
(41
(101------!~-
et
c: (91
12 (1.2, 9)
(31
Requisite Service
• Radiator removal/installation (page 6-5)
Procedure Q'ty ! Remarks

Disassembly Order Assembly is in the reverse order of disassembly,
( 11 Radiator grille 1
(21 Fan motor switch wire connector 1
(31 Shroud mounting bolt/ground wire 3/1
(41 Shroud 1
(51 Fan mounting nut
I 1
(61 Cooling fan 1
(71
(81
Fan motor mounting nut
Fan motor
I, 3
1
(91 Fan motor switch 1
(101 O-ring 1
I
6-6
Cooling System
Water Pump Removal/Installation
After '91:
o
iIiIliI
(3)
,., (6)
'91-'95 only:
Requisite Service
• Timing belt idle pulley removal/installation (page 8-10)
Procedure my Remarks

(11 Oil cooler water hose/breather hose 1/1
(2) Timing belt tensloner spring hook bolt 1 ,
(3) Bolt 7
(4) Water pump 1 Be careful not to damage the reduction holder gasket.
(5) I Dowel pin 2
(6) 'I O-ring 2
6-7
Cooling System
Radiator Reserve Tank Removal/Installation

Standard Model
P) --f+--f-~'ir'
~
-'IV" ~ "'~ --...v ~~~~\
~(j
(2)~_ _
(3)
(4)
Requisite Service
• Right side cover removal/installation (page 2-2)
Procedure O"ty Remarks
{11
Removal Order
Rear brake reservoir mounting bolt , Installation is in the reverse order of removal.
,,
(2) Reserve tank mounting bolt/clamp 2/1
(3) Radiator overflow tube
(4) Reserve tank
6-8
Cooling System
ABS/TCS or LBS-ABS/TCS Model
I I '-
Requisite Service
• Right middle fairing removal/installation (page 2-8).

Removal Order ! Installation is in the reverse order of removal.
(' I
(21
Reseve tank mounting bolt
Radiator overflow tube ,,
2
(31
141
Breather tube
Reserve tank ,
6-9
Cooling System
Thermostat Removal/Installation
161 ~10 (1.0, 7)

..... 18)
111
121
.2 (0.12, 0.9}
110)
191 1.2 (0.12, 0.9)

"'14) {11}
13)
~151 ~
Requisite Service

Coolant draining (page 6-4)
Coolant refill (Section 5 of the Common Service Manual)
Procedure a'ty Remarks

111 Mounting bolt 1
12) Radiator overflow tube 1
13) Bypass tube 1
14) Thermo sensor 1 Apply sealant to threads when installing.
15) Thermo sensor wire connector 1
16) Radiator hose 1
17) Water hose 2
18) Thermostat case bolt 2
19) Thermostat case 1
110) Thermostat 1
(11 ) O-ring 1
6-10
Symbols
...

~
C
10 (1.0, 7.2)
~
equivalent)
equivalent)

"I~ Apply sealant

7. Engine Removal Installation
Service Information 7-1 Engine Removal/Installation 7-2
Service Information
• A floor jack or other adjustable support is required to support and maneuver the engine.
CAUTION
Do not support the engine using the oil filter.
The following components can be serviced with the engine installed in the frame.
- Oil pump (Section 4)
-Carburetor (Section 5)
- Oil cooler (Section 5)
- Water pump (Section 6)
- Cylinder head (Section 8)
- Timing belt (Section 8)
- Clutch (Section 9)
- Gearshift linkage (Section 10)
- Alternator (Section 17)
- Ignition pulse generator (Section 18)
- Starter motor (Section 20)
The following components require engine removal for service.
- Transmission (Section 10)
- Primary damper shaft (Section 10)
- Crankshaft (Section 11)
- Connecting rod (Section 11)
- Piston (Section 11)
- Primary drive gear (Section 11)
- Starter clutch
7-1
Engine Removal/Installation
'91-'95
(1 1 )
131
(16)
C 40 (4.0, 29) 111
(19)
35 (3.5, 25)
0 4 0 (4.0, 29) o
65 (6.5, 47)
1151 --rr----=~~~
1151
o
40 (4.0, 29)
~~o
35 (3.5, 25)
141
(14)
(20)
(13)
(18) 1171
e
171
(16)
o
40 (4.0, 29)
.,
55 (5.5, 40)
7-2
Requisite Service
Muffler removal/installation (page 2- 13)

Exhaust pipe removal/installation (page 2-1 B)
Radiator removal/installation (page 6-5)

11} Engine ground cable 1
12} Starter motor cable 1
13} Gearshift pedal tie rod bolt 1 Loosen the lock nuts and remove the bolt by turning it.
14} Spark plug cap 4
15} Altemator wire connector 2
16} Heat guard plate 1
17} Front head cover 2
18} Ignition pulse generator wire connector 1
19} Carburetor heat insulator rubber 1
110} Water outlet hose 2 Disconnect from the cylinder heads.
111} Water bypass hose 1 Disconnect from the water pipe.
112} Auto fuel valve vacuum tube 1 Disconnect from the No.3 cylinder intake manifold.
113} Clutch slave cylinder 1 Remove the three mounting bolts.
114} Breather hose 1 Remove from air cleaner housing.
115} Engine mounting bracket 4
· Remove the two 8 mm bolts and 10 mm bolt per each
bracket.
116} Sub frame bolt 4-

· Tigntening procedure (page 7-6)
117} 10 mm engine mounting bolt/adjusting collar 4/1 Tightening procedure (page 7-6)
118} Sub frame 1
(19) 12 mm engine mounting bolt/collar 1/2
120} Engine assembly 1 Move the engine assembly out of the frame to the left.
CAUTION
· Carefully align the mounting points with the jack to
prevent damage to the mounting bolt threads, wire
harnesses and cables.
7-3
After '95
Ii) 55 (5.5,40) (11) (10} (12)
(17)
(4)
(1 )
(16)
Ii) 40 (4.0, 29) (19)
Ii)
27 (2.7, 20)
I Ii) 65 (6.5, 47)
40 (4.0, 29}
(15}it!-_--;:€
(5)
A~~
(14}
(17)
{18)
{16) Ii)
Ii) 55 (5.5, 40)
40 {4.0, 29)
7-4
Requisite Service
Muffler removal/installation (page 2-13).

Exhaust pipe removal/installation (page 2-1S).
Carburetor removal/installation (page 5-3).
Radiator removal/installation (page 6-5).

(1) Engine ground cable 1
(2) Starter motor cable 1
(3) Alternator cable/connector 1
(4) Gearshift pedal tie rod bolt 1 Loosen the lock nuts and remove the bolt by turning it.
(5) Spark plug cap 4
(6) Hear guard plate 1
(7) Front head cover 2
(B) Ignition pulse generator wire connector 1
(9) Carburetor heat insulator rubber
(10) Water outlet hose
,
,
1
Disconnect from the cylinder heads.
(1 1) i Water bypass hose 1 Disconnect form the water pipe.
(12) Auto fuel valve vacuum tube 1 Disconnect from the No.3 cylinder intake manifold.
(13) Clutch slave cylinder 1 Remove the three mounting bolts.
(14} Breather hose 1 Remove from air cleaner housing.
(15} Engine mounting bracket
,
4 · Remove the two S mm bolts and '0 mm bolt per each
bracket.
(16) Sub frame bolt

· Tightening procedure (page 7-6)
(17) '0 mm engine mounting bolt/adjusting collar 4;'t Tightening procedure {page 7-6}
us: Sub frame
(19) 12 mm engine mounting bolt/adjusting collar 1:,J
(20) Engine assembly 1 Move the engine assembly out of the frame to the left.
, CAUTION
· Carefully align the mounting points with the jack to

prevent damage to the mounting bolt threads. wire
harnesses and cables.
7-5
Engine Mounting Bolt Tightening Procedure

(1) ADJUSTING
Apply oil to the 10 mm engine mounting bolt threads and COLLAR
seating surfaces. \
Loosely install all engine mounting bolts, nut, sub frame \
bolts, nuts, and engine mounting brackets.
.-
Tighten the sub frame bolts in the sequence below. ~- @
L-o--
(j)-~-@-@-@
CD
Torque: 40 Nom (4.0 kg-m, 29 ft-Ib)
Tighten the 10 mm engine mounting bolts ® and (J).

- ®
(2} ADJUSTING
Torque: 55 Nom (5.5 kg-m, 40 ft·lb)
® COLLAR
(After '95)
.:
Lengthen the adjusting collar on the 10 mm engine @
mounting bolt @ until the collar contacts with the engine
and frame by turning the adjusting nut of the collar.
After '95:
Lengthen the lower adjusting collar on the 12 mm engine
mounting bolt@untilthecollarcontactswiththeengine
and frame by turning the adjusting nut of the collar.
Tighten the adjusting nut of the lower adjusting collar.
Tighten the lO mm engine mounting bolts ® and ~'.

® ®
'91 ·95 Shown:
Tighten the 12 mm engine mounting bolt @ and nut@. (1) ADJUSTING COLLAR
TOfque: 65 Nom (6.5 kg·m, 47 ft·lb)

~
Tighten the adjusting collar lock nut.
(6) ENGINE ~ (2) FRAME
~
Torque: '91-'95: 21 Nom (2.1 kg-m, 15 ft-Ib)
After '95: 28 Nom (2.8 kg-m, 20 ft-Ib) -, '\ /
Tighten the engine mounting brackets @, 1), @ and @.

(5) ADJUSTING
r
(4) LOCK (3) ADJUSTING
Torque: 10 mm bolt: 40 Nom (4.0 kg-m, 29 ft-Ibl BOLT NUT NUT
8 mm bolt: 35 Nom (3.5 kg-m, 25 tt-lbl
7-6
Symbols
...

~
C
10 (1.0, 7.2)
~
equivalent)
equivalent)

"I~ Apply sealant

8. Cylinder Head
Service Information 8-1 Cylinder Head Removal/Installation 8-4
Troubleshooting 8-1 Cylinder Head Disassembly/Assembly 8-8
Cylinder Head Cover Removal/ Timing Belt Pulley Removal/
Installation 8-2 Installation 8-10
Timing Belt Cover Removal!
Installation 8-3
Service Information
Camshaft lubricating oil is fed through oil passages in the cylinder head. Clean the oil passages before assembling the
cylinder head.
Clean all disassembled parts with clean solvent and dry them by blowing them off compressed air before inspection.
-=-
When disassembling, mark and store the disassembled parts to ensure that they are reinstalled in their proper locations.
Take care not to damage the cylinder walls and pistons.
If valve seat cutting is required. a commercially available cutting set is recommended.
~
Troubleshooting
Engine top-end problems usually affect engine performance. These can be diagnosed by a compression or leak down
test, or by tracing noises to the top-end with a sounding rod or stethoscope.
If performance is poor at low speeds, check for white smoke in the crankcase breather tube. If the tube is smokey,
check for a seized piston ring.
Compression too low, hard starting or poor performance Excessive noise

at low speed Incorrect valve clearance
Valves Sticking or broken valve spring
-e-Incorrect valve clearance Damaged or worn camshaft
- Burned or bent valves Loose or damaged timing belt
-Incorrect valve timing Weak or damaged belt tensioner
- Broken valve spring Damaged timing belt pulleys
- Uneven valve seating
- Sticking valve Rough idle
Cylinder head Low cylinder compression
- Leaking or damaged head gasket
- Warped or cracked cylinder head
Compression too high, overheating or knocking

Excessive carbon build-up in cylinder head or combustion
chamber
Excessive smoke
Worn valve stem or valve guide
• Damaged stem seal
8-1
Cylinder Head
Cylinder Head Cover Removal/Installation
~'6lm!
181~
19)-- _
E/''''----151
~16)
171
11)
141~\ ,\\>--..I~ 12)
Requisite Service
• Upper fairing removal/installation (page 2-9)

111 Bolt 2
12) Front head cover 1
13) Bolt/collar 3/3
14) Reduction holder cover 1
151 Spark plug cap 2
161 Cylinder head cover bolt 4
171 Washer 4 Install with the uUp u mark facing up.
181 Cylinder head cover 1 The right head cover has the oil filler cap.
191 Gasket 1
8-2
Cylinder Head
Timing Belt Cover Removal/Installation
III
12}
Requisite Service
Radiator removal/installation (page 6-5)

Reduction holder cover removal/installation (page 8-2)
Clutch cover removal/installation (page 9-6)

(1)
(2)
Bolt
Timing belt cover ,
4
8-3
Cylinder Head
Cylinder Head Removal/Installation

if): 12 (1.2, 9) (2)
11 }
if):71
58 (5.8, 42)
(b) (e)
6 x 40 mm """~~_J
(3)
(k)
L:W
(h)
/
f
,/
(i!
~
(g)
(f)
(,)
8-4
Cylinder Head
NOTE
The camshaft can be removed with the timing belt driven pulley installed and without removing the carburetors and
exhaust pipe. The timing belt driven pulley, carburetors and exhaust pipe must be removed to remove the cylinder
head.
Before removing the right cylinder camshaft, align the index line on the driven pulley with the index mark on the
reduction holder. Before removing the left cylinder camshaft, align the punch mark on the driven pulley with the index
mark on the reduction holder.
For camshaft installation, see page 8-6.
Requisite Service
Cylinder head cover removal/installation (page 8-2)

Timing belt driven pulley removal/installation (page 8-10)
Exhaust pipe removal/installation (page 2-18)

(11 Camshaft holder bolt 5 x 40 mm 4 Install in the positions shown on page 8-4
5 x 45 mm 8
(21 Camshaft holder
(31 Dowel pin
(41 Camshaft 8 Installation (page 8-6)
At installation, apply molybdenum disulfide oil to the
bearing and lobe surfaces (see page 8-5)
(,I Air injection pipe (u S.A only) 2
[b} Cylinder head bolt 6
101
(dl
Washer
Cylinder head ,,
6
(el Cylinder head gasket

(fl
(91
Dowel pin
Cam reduction holder gasket ,
2
(hi Bolt 3
,, .
(i) Cam reduction holder 1
01 Gasket
Ikl Cam reduction gear shaft The shaft for the right cylinder has a single bearing and
the one for the left cylinder has a double bearing.
. Align the wide tooth with the wide groove (punch mark)
of the reduction gear.
III Cam reduction gear f
8-5
Cylinder Head
Camshaft Installation (1) CAMSHAFT IDENTIFICATION MARKS
Lubricate the camshaft journals. cam lobes and driven

gears with a mixture of engine oil and molybdenum
disulfide grease in a 1: 1 ratio.
NOTE
Each camshaft has the identification marks shown
below.
Right intake camshaft: RH IN
- Right exhaust camshaft: RH EX
- Left intake camshaft: LH IN
- Left exhaust camshaft: LH EX
Remove the two bolts and timing hole cover. (1) TIMING HOLE COVER
Right cylinder head:

(1) INDEX MARK
Tum the crankshaft clockwise and align the T1 Mark on
the drive pulley guide plate with the Index Mark on the
timing cover.
(2) T1 MARK
Make sure that the Index Line on the driven pulley aligns with (1) INDEX MARK
the Index Mark on the reduction holder. If not, turn the
crankshaft clockwise one full turn and realign the T1 Mark
with the Index Mark.
(2) INDEX LINE
8-6
Cylinder Head
Install the intake and exhaust camshafts so that the Index

Lineson the end of the shafts are facing outward and that
they align with the top of the cylinder head as shown.
(1) INDEX LINES
Install the dowel pins and camshaft holders.
NOTE
Each camshaft holder has the identification marks
shown below.
- Right intake camshaft holder- R I
- Right exhaust camshaft holder: R E
_ Left intake camshaft holder: L I
II - Left exhaust camshaft holder: L E
I' Install camshaft holder B with its tab facing out as
(4) CAMSHAFT J--.... ./
shown.
HOLDER A "--< _
(3) CAMSHAFT ---'-'t-(2) TAB
HOLDER B
Left cylinder head:

(1) INDEX MARK
Turn the crankshaft clockwise and align the T4 Mark on the
drive pulley guide plate with the Index Mark on the timing
belt cover.
NOTE
If the right camshaft has been removed. install it first,
then turn the crankshaft clockwise 1-1/4 turns (450
degrees) and align the T4 Mark with Index Mark.
(2) T4 MARK
Make sure that the Punch Mark on the driven pulley aligns
(1) INDEX MARK
with the Index Mark on the reduction holder. If not, turn the
crankshaft clockwise one full turn and realign the T4 Mark
with the Index Mark.
Install the intake and exhaust camshafts, and camshaft

holders in the same manner as the right camshaft
installation.
(2) PUNCH MARK
8-7
Cylinder Head
Cylinder Head Disassembly/Assembly
~121
131~ A_
1,~oocI141 ~
~"f:)
151 .~V
161 ... Q
191~(fjj§i)
181 ~ ~~
I,~ooq 1101--===-~ ~
~
~
111
171---/1
/)
8-8
Cylinder Head
NOTE
The valve lifter and valve adjusting shim can be removed with the cylinder head installed. Refer topage 3-5 for the shim
replacement.
Mark all parts during disassembly so they can be placed back in their original position.
Requisite Service
• Cylinder head removal/installation (page 8-4)

111 Carburetor insulator 2 Install with the ~CARB" mark facing to the carburetor and
align the grooves with the lugs on the cylinder head.
12) Valve lifter 8 NOTE:
, Remove using a handlapping tool. Do not damage the
cylinder head bucket sliding surface.
13) Valve adjusting shim 8
(4) Valve spring cotter 16 Use valve spring compressor (07757-0010000) with
valve spring compressor attachment (07959-KM301 01)
and tappet hole protector (07HMG-MR70001 ) Not
Available iii U.S.A., to make equivalent tool, see below.
16) Valve spring retainer 8
(6) Valve spring 8 Install with the narrow pitch end facing down.
(7) Valve 8
18) Valve stem seal 8
(9) Valve spring seat 8
110) Valve guide 8 Use valve guide driver (07HMD-ML00100 or 07HMD-
MLOO101).
5 5
mm mm
I TOP VIEW
D
'; ;--- --·,~ ·
/ / . . ,\
,,' . \\
I, . \\
r: . .
I]
.
.
II
'r
\\-..'
,Ii
/,..1
'~~~ \ .:::-
25 mm 0.0. •
[when compressed)
Tappet hole protector; an equivalent tool can be made from

a plastic 35 mm film container using the measurements
shown above.
8-9
Cylinder Head
Timing Belt Pulley Removal/Installation
n
C •
46 (4.6, 33)
(4)
(2)
----------------------~
C ;
27 (2.7, 20)
(8)
(6) (101
C 46 (4.6, 33)
C 65 (6 5, 47)
(9)
(1 1)
8-10
Cylinder Head
NOTE
I· Perform the timing belt service while the engine is cold.
Requisite Service
Timing belt cover removal/installation (page 8-3)

Spark plug removal/installation

(11 Drive pulley bolt/washer 2/2 Hold the drive pulley bolt when loosening and tightening the
driven pulley bolt.
(21 Driven pulley guide 1
(31 Timing belt 1 Removal/installation (page 8-12)
(4) Driven pulley/woodruff key 2/2
(51 Timing belt tensioner bolt/washer 1/1
(61 Tensioner roller/spring 1/1
(71 Idle pulley bolt/pulley 1/1
(81 Drive pulley bolt/washer 1/1 Hold the crankshaft by placing the transmission in 5th gear
and applying the rear brake when loosening and tightening
the drive pulley bolt.
(91 Guide plate A 1 Install with the groove aligned with the woodruff key on the
crankshaft.
(10) Drive pulley 1
(11) Guide plate B 1 Install the guide plates with the flat side toward the drive
I pulley.
8-11
Cylinder Head
Timing Belt Removal/Installation

(1) GUIDE
NOTE (2) WASHER
/
Perform this service while the engine is cold.
For easy servicing, remove the spark plugs.
CAUTION
I
Be careful not to contaminate the timing belt with
oilete.
Do not bend the timing belt excessively.
Removal ( 3) BOLT
Hold the crankshaft and remove the left driven pulley bolt,
washer and guide.
Loosen the timing belt tensioner bolt 1/4-1/2 turn.

Release the tensioner by turning the crankshaft
counterclockwise while holding the right driven pulley,
and temporarily tightening the tensioner bolt.
Tum the crankshaft clockwise and align the T1 Mark on

(1) INDEX MARK
the drive pulley guide plate with the Index Mark on the
(3) PUNCH MARK
crankcase.
CAUTION
When align the T1 Mark with the Index Mark, be
sure that the Punch Mark on the drive pulley guide
plate aligns with the Projection on the crankcase,
too.
Remove the timing belt from the pulleys.
CAUTION
Do not turn the camshafts after removing the
timing belt or you may damage the valves and
piston domes.
Installation
NOTE
When the camshafts are removed, install the camshaft I
first (page 8-6). then install the timing belt.
Before installing the timing belt, move the tenaioner
pulley to the fully released position and temporarily
tighten the teC"'='CoC"CeC'CbCoCIt,. _
8-12
Cylinder Head
Align the T1 Mark on the drive pulley guide plate with the
Index Mark on the crankcase.
CAUTION
When align the T1 Mark with the Index Mark, be
too.
Align the Index Lines on the driven pulley with the Index
Marks of the reduction holders.
NOTE
When the Index Line is aligned with the Index Mark:
-on right cylinder head, the Index lines on the
camshaft end are facing outward and align with the
top of the cylinder head.
-on left cylinder, the Punch Marks on the camshaft
end are facing outward and align with the top of the
cylinder head.
Install the timing belt on the drive pulley, next on the left
driven pulley, then on the right driven pulley.
(2) INDEX MARK

(5) INDEX MARK
~
(3) INDEX LINE ~ /Q-o
.. -'", , ,-
(4) INDEX LINE 1-'././-
, -', "~ ~
,i
(1) INDEX LINES
(6) PUNCH MARKS
(7) INDEX MARK
(9) PUNCH
MARK
(8) Tl MARK (10) PROJECTION
Install the left driven pulley guide, washer and bolt, and
tighten the bolt while holding the crankshaft.
Loosen the timing belt tensioner bolt to apply the tension

to the belt. Then turn the crankshaft 2 to 4 full turns to
stabilize the belt run, and tighten the bolt.
Torque: 46 Nom (4,6 kg-m, 33 ft-lb)
When installing a new belt, apply initial tension to the belt

as follows:
8-13
Cylinder Head
Loosen the tensioner bolt.

Turn the crankshaft clockwise 2 to 4 full turns, and align the
T1 Mark with the Index Mark. (The Index Lines on the driven
pulleys must align with the Index Marks.)
CAUTION
When align the T1 Mark with the Index Marit, be
too,
Then turn the crankshaft ckockwise 3 teeth further and

tighten the tensioner bolt.
8-14
Symbols
...

~
C
10 (1.0, 7.2)
~
equivalent)
equivalent)

"I~ Apply sealant

9. Clutch
Service Information 9-1 Clutch Slave Cylinder Removal/
Troubleshooting 9-1 Installation 9-4
Clutch Master Cylinder Disassembly/

Clutch Disassembly/Assembly 9-6
Assembly 9-2
Service Information
DOT 4 brake fluid is used for the hydraulic clutch and is referred to as clutch fluid in this section. Do not use other
types of fluid as they are not compatible.
Engine oil viscosity and level and the use of oil additives have an effect on dutch disengagement. Oil additives of any
kind are specifically not recommended. When the clutch does not disengage or the vehicle creeps with clutch disen-
gaged, inspect the engine oil for proper level and the presence of additives before servicinq the clutch system.
Clutch maintenance can be done with the engine in the frame.
Troubleshooting
Clutch lever soft or spongy Clutch lever too hard
Air in hydraulic system Sticking master piston
Low fluid level Sticking slave cylinder piston
Leaking hydraulic system Clogged hydraulic system
Clutch slips Clutch operation feels rough

Sticking hydraulic system Rough clutch outer slots
Worn discs Sticking master piston
Weak clutch springs Sticking slave cylinder piston
Hydraulic system clogged
Oil additive used
Clutch will not disengage or motorcycle creeps with

clutch disengaged
Warped plate
Loose clutch lock nut
Oil level too high, improper oil viscosity or oil additive
"..d
Air in hydraulic system
low fluid level
leaking or sticking hydraulic system
9-1
Clutch
Clutch Master Cylinder Disassembly/Assembly

€X: IB)
1.5 (0.15, 1.1)
19)
\
)10)
-1--'/ 15)
€X:
12 (1.2, 9)
o f!~J!-----(6)
Boot:
'91-'94
(19)
(2)
€X:
35 (3.5, 25)
(12)
€X:
1 {0.1, 0.7)
(1)
(7)
(11 ) (17)
1.2 (0.12, 0.9)
€X: 6 (0.6, 4.3)
ISTOO~I
(14)
(13)
9-2
Clutch
CAUTION
Avoid spilling hydraulic clutch fluid on painted. plastic. or rubber parts. Place a rag over these parts whenever the
system is serviced.
When removing the oil bolt. cover the end of the clutch hose to prevent contamination. Do not allow the foreign
material to enter the system.
Handle the master piston. spring, primary cup and secondary cup as a set.
Do not allow the lips of the master cylinder cups to tum inside out and be certain the snap ring is firmly seated
in the groove.
NOTE
I· Use only DOT 4 brake fluid from a sealed container.
Requisite Service
• Clutch fluid draining
Removal Installation is in the reverse order of removal.

(II
(21
Clutch switch wire
Oil bolt
2
,
(31
(41
Sealing washer
Clutch hose
2
,,
(51
(61
Master cylinder holder bolt
Master cylinder holder ,, Remove the master cylinder assembly from the handlebar.
(71 Clutch switch
(81 Reservoir cap screw 2
(91 Reservoir cap I
(101 Set plate/diaphragm 1/'
(' 11 Clutch lever pivot nut I
(12) Clutch lever pivot screw I
('31
('41
Clutch lever
Push rod end piece ,,
1
(151
('61
Push rod
Boot ,,
('71
('81
Snap ring
Washer ,, Use snap ring pliers (07914-3230001).
('91 Master piston

(201 Primary cup I
(211 Spring I
9-3
Clutch
Clutch Slave Cylinder Removal/Installation

15)
(4)
(7)
131
12)
CAUTION
Avoid spilling hydraulic clutch fluid on painted. plastic. or rubber parts. Place a rag over these parts whenever the
system is serviced.
When removing the oil bolt. cover the end of the clutch hose to prevent contamination. Do not allow the foreign
material to enter the system.
NOTE
• Use only DOT 4 brake fluid from a sealed container.
Requisite Service
lower fairing removal/installation (page 2-4)

Clutch fluid draining
(' )
Removal Order
Oil bolt , Installation is in the reverse order of removal.
(2)
(3)
Sealing washer
Clutch hose
2
,
(4) Mounting bolt 3
151 Slave cylinder assembly 1
161 Gasket 1
17) Dowel pin 2
(8) Slave cylinder piston 1 If piston removal is difficult, wrap the slave cylinder with a
shop towel and apply compressed air to the fluid inlet to
remove the piston.
191 Piston seal 1
110) Spring 1
(11) Oil seal 1
9-4
Clutch
MEMO
9-5
Clutch
Clutch Disassembly/Assembly
14)
/(12)
'A"'J'"\ (131
Clutch
NOTE
1· It is not necessary to disconnect the clutch hydraulic system for clutch disassembly/assembly.
Requisite Service
Engine oil draining

Clutch slave cylinder removal/installation (page 9-4)
Right exhaust pipe removal/installation (page 2-18)

111 Clutch cover bolt 9
(21 Clutch cover 1
(31 Gasket 1
(41 Dowel pin 2
(51 Litter rod 1
(61 utter plate bolt 5 NOTE:
, After tightening the belts, check that the lifter rod guide
rotates smoothly.
(71 Lifter plate 1
(81 Lifter rod guide 1 Remove from the lifter plate.
(91 Clutch spring 5
(101 Lock nut 1 Removal/installation (page 9-8)
(111 Lock washer 1 Install with the "OUr wark facing out.
(121 Clutch assembly 1
(131 - pressure plate 1 At installation, align the ~ ... ~ marks on the pressure plate
and clutch center as shown.
(141 - clutch disc 10
(151 -clutch plate 9
(161 -judder spring '91 only: 1 At installation, install with the convex side facing to the
pressure plate as shown.
(171 -spring seat '91 only: I 1
(18) - clutch center 1
(191 -Washer 1 At installation, install with the chamfered side facing out.
(201 Clutch outer 1 Installation (page 9-8)
9-7
Clutch
Clutch Lock Nut Removal/Installation

(1) LOCK NUT_I
Removal WRENCH
Unstake the clutch lock nut with a drill or grinder. Using
the special tools, place a collar in each of the slots marked >""1 Nd~~
with a "5 on the tool.
<""~
N
(4)
Install the clutch center holder by aligning the collars in
the slots so they fit over the bosses in the clutch center. HOLDER-:c~~~~~
COLLAR
Using a 17 mm wrench, tighten the collar nuts in position.
Secure the holder to the clutch center using the clutch
spring bolts.
Hold the clutch center with the clutch center holder and ,
remove the lock nut. (3) CLUTCH CENTER (2) EXTENSION BAR
HOLDER
Clutch center holder 07JMB-MN50300 or

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

07HGB-001010B
(U.S.A. only)
Clutch holder collar (3 pieces) 07LMB-MT301oo or
Clutch center collars "B" 07MPB-764021A
(U.S.A. only)
Lock nut wrench, 30 x 32 mm 07716-0020400 l
Extension bar 07716-0020500 l
Equivalent commercially
available in U.S.A.
Install a new lock nut and tighten it.
Torque: 110 Nem (11.0 kg-m, BOft-lb)
Stake the lock nut.
Clutch Outer Installation
Install the clutch outer onto the primary damper shaft and
mesh it with the primary drive sub gear.
Turn the clutch outer counterclockwise while pushing
inward as shown to align the primary drive sub gear teeth
with the primary drive gear teeth. The clutch hub will move
inward when the gear teeth align.
(1) CLUTCH OUTER
9-8
Clutch
Turn the oil pump driven sprocket with a screwdriver as

shown while pushing the clutch outer in until you feel a click.
At this time. the holes in the clutch outer are aligned with
the pins on the oil pump drive sprocket. Push in the clutch
outer further to insert the pins into the holes.
9-9
Symbols
...

~
C
10 (1.0, 7.2)
~
equivalent)
equivalent)

"I~ Apply sealant

10. Gearshift Linkage/Transmission
Service Information 10-1 Primary Damper Shaft Disassembly/
Assembly 10-5
Troubleshooting 10-1
Transmission Removal/Installation 10-6
Gearshift Linkage Removal/
Installaton 10-2 Transmission Disassembly/Assembly 10-8
Transmission Unit/Primary Damper
Shaft Removal/Installation 10-4
Service Information
The gearshift linkage can be serviced with the engine installed in the frame.
The transmission can be removed as a unit without separating the crankcases.
Troubleshooting
Hard to shift
• Improper clutch operation
• Incorrect engine oil weight
Bent shift forks
Bent shift fork shaft
• Bent shift fork claw
• Damaged shift drum cam groove
• Bent gearshift spindle
Transmission jumps out of gear

Worn gear dogs or slots
• Broken shift drum stopper arm
• Worn or bent shift forks
• Broken shift linkage return spring
10-1
Gearshift LinkagelTransmission
Gearshift Linkage Removal/Installation
(6)
(12)
(17)
(16)
(14)
r<f:r-----{B)
(10)
o
23 (2.3,17)
(2) (1) 17)
I
o
12{1.2,9)
jet
(4)
10-2
Gearshift Linkage/Transmission
Requisite Service
• Swingarm removal/installation (page 14-8)

(11 Gearshift arm bolt 1
(21 Gearshift arm 1 After '91: Align the wide groove on the gearshift arm
with the wide tooth on the gearshift spindle.
(3) Bolt 7
(4) Gearshift linkage cover 1
(5) Gasket 1
(5) Dowel pin 2
(7) Gearshift spindle assembly 1 Pull out the spindle while pushing the shift pawl in.
(8) Shift drum center bolt 1
(9) Shift drum center plate 1
(10) Dowel pin 4
(11) Shift drum center 1 Align the groove in the shift drum center with the
dowel pin.
(12) Dowel pin 1
(13) Stopper arm bolt 1
(14) Collar 1
(15) Return spring 1
(16) Stopper arm 1
(17) Washer 1
10-3
Transmission Unit/Primary Damper Shaft Removal/Installation
141
NOTE
The transmission can be removed from the engine as an unit.
The transmission unit can be removed with the clutch installed.
The clutch and oil pump drive sprocket must be removed to remove the primary damper shaft.
Requisite Service
Engine removal/installation (page 7-2)

Clutch disassembly/assembly (page 9-6)
Procedure ow Remarks
(I)
(2)
Transmission unit mounting bolt
Transmission unit I
,,
8
(3) Gasket
(4)
1'1
Dowel pin
Primary damper shaft ,
2
10-4
Primary Damper Shaft Disassembly/Assembly

(2) (4)
~
L-o t
(8)
(1)
(6)
(5)
(1)-----~
Requisite Service
• Primary damper shaft removal/installation (page 10-4)

I
, I Disassembly Order Assembly is in the reverse order of disassembly.
(1) , Primary spring cotter 2 Set the damper shaft assembly in a hydraulic press
with the washer {3l supported. Compress the spring
approx. 5 mm (0.2 inl, slide the retainer (2) up and
remove the cotters as shown.
CAUTION
. Do not compress the spring more than 7 mm
(0.28 in).
(2)
(3)
Primary spring retainer
Washer ,,
1
Primary damper spring

I Install with the small coil end facing away from the
(4)
,
pimary damper lifter as shown.
(51
(61
Spring stopper washer
Washer ,
2
(71
(8)
Damper cam
Primary damper lifter ,,
1
(9) Primary shaft I
10-5
Transmission Removal/Installation
121
,
141
, 191
,
151
,
11.o-~_171
131
161
181
o
111
10-6
Requisite Service
Gearshift linkage removal/instaliation (page 10-2)

Transmission unit removal/installlation (page 10-4)

(1)
(2)
Transmission case cover bolt
Transmission case ,
7
(3) Dowel pin 2

(4) Shift fork shaft 1
(5) Aear shift fork 1 Install with the "A" mark facing down (forward).
(6) Center shift fork 1 Install with the "C" mark facing down (forward),
(7)
(8)
Gearshift drum
Front shift fork ,,
1
Install with the "F" mark facing down (forward).
(9) Mainshaft/countershaft assembly
10-7
Transmission Disassembly/Assembly
Mainshaft After '91 : SHIFTER GEAR
GROOVE
: GEAR SLIDING
SURFACE
24T
(9)
(2) (9)
(11 )
(4)
t
16)
16/21T 18)
(8)
(4)
(5)
NOTE
• Always install the thrust washers and snap rings with the chamfered (rolled) edge facing away from the thrust load.
• After installing a snap ring, slightly open the ring and rotate it in its groove to be sure it is fully seated.
• Do not use worn snap rings which could easily spin in the groove. They may be too loose to properly seat in the
groove. Align the gap in the snap ring with the groove in the spline.
• Align all oil holes in the bushings with the shaft oil holes.
Requisite Service
• Transmission removal/installation (page 10-61
0)
Disassembly Order
Washer
I
, I Assembly is in the reverse order of disassembly.
(2) M5 gear (29T) 1

(3) M5 gear bushing 1
(4) Spline washer 1
(5) Snap ring 1
(6) M2IM3 gear (18121 n 1
(7)
(B)
Snap ring
Spline washer ,,
1 Align the gap with the groove in the spline.
(9) M4 gear (24T)

(10) M4 gear bushing
(11) Mainshaft/M1 gear (15n I ~ I
10-8
Countershaft 22T : SHIFTER GEAR

GROOVE
(16)
(' 5)
: GEAR SLIDING
SURFACE
(10)
(16\) ('3) ('2) T

(17) +
+
(3)
(5)
(7) (6) 22T
(15)
(14)
Procedure , O'ty Remarks

(I) Washer 1
(2) Cl gear (34T) 1
(3) Cl gear needle bearing 1
(4)
(5)
Washer
C4 gear (22T)
1
,,
,,
(6) Snap ring !
(7) Spline washer
,
i
(6) C3 gear (24n
(9) I C3 gear bushing i
(10) Lock washer 1
(11 ) Spline washer 1
('2) C2 gear (27T) 1
(13) C2 gear bushing 1
(14) Spline washer 1
(15) Snap ring 1
(16) C5 gear (22T) 1
(17) Countershah 1
10-9
Symbols
...

~
C
10 (1.0, 7.2)
~
equivalent)
equivalent)

"I~ Apply sealant

11. Crankcase/Piston/Crankshaft
Service Information 11 -1 Piston Removal/Installation 11-8
Troubleshooting 11-1 Primary Drive Gear/Starter Clutch
11-2 Removal/Installation 11-10
Crankcase Separation/Assembly
Crankshaft/Connecting Rod
Removal/Installation 11-4
Service Information
CAUTION
Improper installation of bearing inserts may block the oil holes, causing insufficient lubrication and eventual
engine seizure.
• Remove the engine and separate the crankcases to inspect the crankshaft, connecting rod and starter clutch.
Mark and store the connecting rod and crankshaft bearing inserts so they can be installed in their original locations for
reassembly.
Prior to assembling the crankcase halves, apply a sealant to their mating surfaces. Wipe off excess sealant thoroughly.
• Mark and store the disassembled parts to ensure that they are reinstalled in their original locations.
Troubleshooting
III
Excessive noise
Worn connecting rod bearings
Bent connecting rod
Worn crankshaft main journal bearing
11-1
Crankcase/Piston/Crankshaft
Crankcase Separation/Assembly
(12) -:71
'91-'95 0 52 (5 2, 38)
-
161
~171
12 (1.2, 9)
1,1--__ (5)
•
1131
Q I
I~/
...-/' 13 1 _
~---121
191 I
o 23 (2.3, 17) I
4-
1~ lll
11-2
CAUTION
Improper installation of bearing inserts may block the oil holes causing insufficient lubrication and eventual
engine seizure.
NOTE
I· Mark all parts during disassembly so they can be replaced in their original position.
• All bearing inserts are select fitted and are identified by color code. Select replacement bearings from the selection
tables (pages 11-6 and 11-7).
Requisite Service
Engine removal/installation (page 7-2) • Water pump removal/installation (page 6-7)

• Cylinder head removal/installation (page 8-2) • Transmission/primary damper shaft removal/installation
• Oil cooler removal/installation (page 4-4) (page 10-4)
• Alternator removal/installation (page 17-18) Timing pulley removal/installation (page 8-10)
• Starter motor removal/installation {page 20-B} Ignition pulse generator (page 18-9)
Procedure i O'rv Remarks

Separation Order Assembly is in the reverse order of disassembly.
••
(2)
Bolt
Water cover/pipe I
3
1
(3) O-ring , 1
(4) Bolt/cooler hose guard 7/1 Hose guard: '91-'95 only
(5) Clutch cover base" 1
(6) Gasket 1
(7) Dowel pin 2
(B) Upper crankcase bolt 6 mm 2
(9) Bmm 1
(10) Lower crankcase bolt 6 mm/stay 4/1
(11) B mm 6
(12) 10 mm/washer 6/6 Washer: '91-'95 only
(13) Dowel pin 3
(14) Crankshaft main journal bearing I 3 Selection (page 11-6). See CAUTION above.
11-3
Crankshaft/Connecting Rod Removal/Installation
C 36 (3.6, 26)
(1)
(2)
(4)
(5)
(6) (7J
(4)
(3) ,
11-4
CAUTION
Improper installation of bearing inserts may block the oil holes causing insufficient lubrication and eventual
engine seizure.
NOTE
Mark all parts during disassembly so they can be replaced in their original position.
All bearing inserts are select fitted and are identified by color code. Select replacement bearings from the selection
tables (pages 11-6 and 11-7). ~_ _
Requisite Service
• Crankcase separation/assembly (page 11-2)
,
Procedure i O'ty Remarks
(I) Connecting rod bearing cap nut B
(2) Connecting rod bearing cap 4
(3) Connecting rod/piston assembly 4 ;' Piston removal/installation (page 11-8)
(4) Connecting rod bearing B Selection (page 11-6). See CAUTION above.
(5) Crankshaft 1
(6) Crankshaft thrust bearing 2 At installation, align the tab with the groove in the
I Crankshaft journal bearing case.
(7) ! 3 Selection (page 11-6). See CAUTION above.
11-5
Main Journal Bearing Selection
Record the crankcase 1.0. code letters on the front side of

the upper crankcase.
NOTE
• Letter A, B or C is the code for the main jounal 1.0.
• The numerals 1, 2 and 3 stand for the crankshaft
main journals, as viewed from the front.
(1) MAIN JOURNAL 1.0. CODE
Record the main journal 0.0. code numbers on the crank

weights.
NOTE
• Number 1, 2 or 3 is the code for the main journal 0.0. •• ••
, ,
2 1 2
(1) MAIN JOURNAL 0.0. CODE
Cross reference the case and journal codes to determine

the replacement bearing color code. (1) COLOR CODE
~'
B C
I.D.code 43.000- 43.006- 43.012-
43.006 mm 43.012 mm 43.018 mm
Main journal i (1.6929- (1.6931- I (1.6933-
0.0. code 1.6931 in) 1.6933 in) 1.6936 in)
, 39.994--40.000 mm Yellow Green Brown
(1.5746-1.5748 in)
2 39.988-39.994 mm Green Brown Black
(1.5743-1.5746 in)
3 39.982-39.988 Brown Black Blue
(1.5741-1.5743 in)
See section 14 of the Common Service Manual for crank-

shaft main bearing oil clearance inspection. (1) CONNECTING ROD 1.0. CODE
Connecting Rod Bearing Selection
Record the connecting rod 1.0. code number on the connecting

<ad.
NOTE
• Number 1, 2 or 3 is the code for the connecting rod
to. code.
11-6
Record the crankpin 0.0. code letters on the crank weights.
NOTE
[ le-tt-e-'~A-.~B-o-'-C--c;,--cthe code for the crank pin 0.0.
(1l CRANK PIN 0.0. CODE
Cross reference the connecting rod and crankpin codes to (1) COLOR CODE
determine the replacement bearing color code.
~
1 2 3
I.D. code
43.000- 43.006- 43.012-
43.006 mm 43.012 mm 43.018 mm
Crank pin
(1.6929- {1.6931- (1.6933-
O.D. code
1.6931 in) 1.6933 inl 1.6936 inl
A 39.994-40.000 mm Yellow Green Brown
(1.5746-1.5748 in)
B 39.988-39.994 mm Green Brown Black
(1.5743-1.5746 in)
C 39.982-39.988 Brown 81ack Blue
(1.5741-1.5743 in)
See section 14 of the Common Service Manual for
connecting rod bearing oil clearance inspection.
11-7
Piston Removal/Installation
(4)
(5) \ Left cylinder piston
"IN" mark
171
Oil hole
(21
/~
(11
~
Right cylinder piston
"IN" mark
<<:«:
Oil hole
11-8
Requisite Service
• Connecting rod removal/installation (page 11-4)

. I Removal Order Installation is in the reverse order of removal.
0) Piston pin clip 2
(2) Piston pin 1
(3) Piston 1 Install the left cylinder piston so that the ~IW mark
is facing the same direction as the oil hole in the
connecting rod as shown.
N
Install the right cylinder piston so that the NIN mark
is facing the opposite direction as the oil hole in the
connecting rod as shown.
(4) Piston top ring 1 Install with the marking facing up.
(5) Piston second ring 1 Stagger position of ring end gaps as shown.
(6: I Side rail 2-
(7) Spacer 1-
11-9
Primary Drive Gear/Starter Clutch Removal/Installation

{BI
{9}
\J/
(111
o (12}
iIiIII
C 16(1.6,12)
(10}
~ .. t? t?
~~~~~ {5}
~ (13)
{1}
7i\)~
{3}
{21
..,
{7} "'I
{6} After '91:
o
{.}
11-10
NOTE
• The starter idle gear can be removed without removing the crankshaft.
Requisite Service
• Crankshaft removal/installation (page 11-4)

(' ) Collar 1
(2)
(3)
O.ring
Stopper circlip ,,
1
(41
(51
Primary drive gear
Starter clutch assembly , Install with the "our mark facing out.
At installation. align the wide groove in the starter
(6) - Starter driven gear , clutch outer with the wide tooth on the crankshaft.
(7) - Needle bearing 1

(6) - Snap ring 1
(9) - Starter clutch 1
(10) - Bolt 8
(11 ) - Alternator drive gear 1
(12) - Starter clutch outer 1
(13) Washer 1
(,)
(b)
Bolt/washer
Starter idle gear shaft ,,
1
(el Starter idle gear

(d} ! Oil separate plate After '91 I 1 Install in position shown at assembly.
11-11
Symbols
...

~
C
10 (1.0, 7.2)
~
equivalent)
equivalent)

"I~ Apply sealant

12. Final Drive
Service Information 12-1 Final Gear Case Removal/Installation 12-3
Troubleshooting 12-1 Final Gear Case Disassembly 12-4
Driveshaft Disassembly/Assembly 12-2 Final Gear Case Assembly 12-6
Service Information
Replace all oil seals and O-rings whenever the final drive gear assembly is disassembled.
Check the tooth contact pattern and gear backlash when the bearing, gear set and/or gear case is replaced.
(Section 15 of the Common Service Manual)
Troubleshooting
Excessive noise in final drive
• Worn or damaged ring gear and driven flange
Damaged driven flange or wheel hub
Worn or damaged pinion gear and/or pinion joint splines
• Excessive backlash between pinion and ring gears.
• Low oil level
Excessive rear wheel backlash

• Worn driveshaft splines
• Excessive backlash between ring gear and pinion gear
Worn driven flange and ring gear splines
Excessive play in final drive case bearings
Worn driveshah and or pinion joint splines
Oil leaks at final gear case

Clogged breather hole
Oil level too high
Faulty oil seans)
12-1
Final Drive
Driveshaft Disassembly/Assembly
Attachment
(')
(2)
(4) Base
Requisite Service
Procedure O'ty Remarks

I Disassembly Order
, Assembly is in the reverse order of disassembly.
(11 Snap ring
(2)
(3)
Spring stopper
Driveshaft spring I ,
1
(4) Universal joint cotter 2 Support the driveshaft with the yoke joint compressor
base (07LMF-MT30120), compress the spring with
the yoke joint compressor attachment (07LMF-MT
30110) using the hydraulic press and remove the
I Universal joint cotters as shown.
(5)
(6) Thrust washer ,,
1
(7) Damper case Fill the case with 30 cc (1.0 US OZ, 1.1 Imp oz) of
(8) 14.8 x 2.4 mm O-ring ,, Hypoid gear oil (SAE #80) after installation.
(9)
(10)
19 x 1.9 mm O-ring
Case stopper ring 1
I
(11 ) Oil seal 1 Remove from the damper case.
('2) Oil seat guide 1 If necessary, remove using the bearing race remover
{07946-371 0500).
Install using the driver (07749----001 CXXlO) and attachment,
('3) Damper cam

; ,, 52 x 55 mm (07746-0010400).
('4) Damper spring I
12-2
Final Drive
Final Gear Case Removal/Installation

ABS{TCS or LBS-
• r;;;;;;,. til ABS{TCS model:
110}
23 (2.3, 17)
151
C 65 (6.5, 43)
17} 19}
NOTE
• ABS/TCS or LBS-ABS/TCS model: After installing the rear wheel, perform the wheel sensor air gap inspection
(page 16-A-51 or 16-B-34).
Requisite Service
Rear wheel removal/installation (page 14-2)
Final gear oil draining

Removal Order Instllation is in the reverse order of removal.
(1) Wheel sensor mounting bolt 2 ABS/TCS or LBS-ABS/TCS model
(2) Wheel sensor 1 Remove from wire clamp.
(3) Sensor shim 11}
(4) Shock absorber lower mounting bolt 1
(5) I Final gear case mounting nut 4 Support the final gear case and remove the nuts.
At installation, loosely install the nuts, install the rear wheel
completely (page 14-2), then tighten the nuts.
(6) Final gear case assembly At installation, apply molybdenum disulfide grease to the
driveshaft joint splines and remove the grease from the one
spline groove to allow air to escape from the joint.
(7) Driveshaft joint Install into the final gear case being careful not to damage
the oil seal lip.
(8) Oil seal Remove from the driveshaft joint.
(9) Driveshaft cap
(10) a-ring Remove from the driveshaft cap.
12-3
Final Drive
Final Gear Case Disassembly

(6)
(4)
(5)
(26)
(27)
(9)
(25) (3)
120} (2)
(19)
(23)
(22)
Is TOOL)
(18)
( 1)
(8)
( 17)
{16} (7)
(12)
(11)
(14)
Is~ooLI (10)
12-4
Final Drive
-----
C·
•
CAUTION
Always wear insulated gloves when handling a heated gear case to prevent burning your handso
Do-n-o-.-u-s-.-.-o-,cCh-.o--:h-.-atthe
e final gear case; it may cause warpingo
NOT"E=-- _
Keep dust and dirt out of the gear case.
Be careful not to damage the case and cover mating surfaces.
Refer to section 15 of the Common Service Manual for the backlash inspection and the gear tooth contact pattern
check. See page 1-11 for the backlash specification.
Requisite Service
• Final gear case removal (page 12-3l
Procedure O°ty . Remarks

Disassembly Order
(I I Distance collar 1
(2) Bolt Standard model 1
ASS/TeS or LBS-ABS/TCS model 3
13) Dust guard plate 1
14) 8 mm gear cover bolt 6
15) 10 mm gear case cover bolt 2
(6) Gear case cover I
(7) Ring gear I NOTE
• If the ring gear stays in the cover, press the ring
,,
gear out of the cover.
(8) Wave washer
(9) Oil seal
(10) Ring gear bearing 1 Pry out the bearing from the ring gear.
(11) Ring gear shim 1
(12) O-ring guide I Remove by tapping from the opposite side.
113) O-ring I Remove from the guide.
(14) Pinion joint nut I Removal (page 12-8)
115) Pinion joint I
116) Bolt I
(17) Pinion retainer lock washer 1
,
(18) Pinion retainer 1 Removal (page 12-8)
(19) O-ring 1 Remove from the pinion retainer.
(20) Oil seal 1
(21 ) Pinion gear assembly I Removal (page 12-9)
(22) Pinion bearing/inner race 1/2 Remove from the shaft with the bearing puller.
123) Pinion gear shim I
124 )1Final gear case bearing 2 Removal (page 12-9)
125) Oil seal I
126) Breather cap I
127) Ring gear stop pin I
128) Stop pin shim I
12-5
Final Drive
Final Gear Case Assembly

o
Iilii
0 26 (2.6, 19)
o 63 (6.3, 46)
(241
(25)
• .m:iiIt
(3)
~
(23) (201
(2)
~[STOOLI
"'=....
(4) 010 (1.0,7)
(271
I S ;COOL I
~ -Aoo
SO'
(6)
• fiijii" (7)
(10)
(14)
(28)
., (5)
-[s ~oLI (221

(26)
(16)
(17)
(101
0 1 0 fl.0,7)
.....
(21 ) (18)
(11 )
~
(15)
Is ;;;OL I
0150 (15.0,108)
CUa
0 110(11.0.80)
12-6
Final Drive
NOTE
• Keep dust and dirt out of the gear case.
• Be careful not to damage the case and cover mating surfaces.
• Refer to section 15 of the Common Service Manual for the backlash inspection, the gear tooth contact pattern check
and the ring gear-to-stop pin clearance check.
• If the gear set, pinion gear bearing, ring gear bearing, gear case bearing and/or gear case are replaced, install a
1.50 mm pinion gear shim and a 2.00 mm ring gear shim.
• The ring gear and pinion gear must be replaced as a set.
Requisite Service
• Final gear case installation (page 12-3)

Disassembly Order
(I) Stop pin shim 1 Selection (page 12-10)
(2) Ring gear stop pin 1
(31 Breather cap 1 Clean the breather hole and install.
(41 Oil seal 1 Use the driver (07749--OO10CXXl) and attachment. 52
x 55 mm (07746-0010400).
(51 Final case bearing 2 Use the driver (07749--0010000), attachment, 62 x
I 68 mm (07746--0010500) and pilot, 35 mm (07746-
. 00408001.
(61 Pinion gear shim , 1 Selection (page 12-10)
(7) Pinion bearing/outer race 112 Drive onto the pinion gear, using the driver, 40 mm
I.D. (07746-0030100) and attachment, 25mm 1.0.
(6)
I Pinion gear assembly 1
(07746-0030200).
Drive into the gear case until enough threads are
visible to engage the pinion retainer, using the bearing
race insert attaccnment (07931-4630300).
(9) Oil seal 1 Install into the pinion retainer, using the driver (07749-
0010000) and attachment, 52 x 55 mm (07746-
(010400).
(10) O-ring 1 Install onto the pinion retainer.
(11) Pinion retainer 1 , Installation (page 12-8).
(12) Pinion retainer lock washer 1 NOTE
• There are two types (A or B) of lock washers .
(13) Bolt 1
(14) Pinion joint 1
(15) Pinion joint nut 1 Installation (page 12-8)
(16) Ring gear shim 1 Selection (page 12-11)
117) Ring gear bearing 1 Installation (page 12-9)
(18) O-ring 1 Install onto the O-ring guide.
(19) O-ring guide 1 Drive in the ring gear, using the driver (07749-
001<XXXl) and attachment 42 x 47 mm (07746-00103C0).
(20) Oil seal 1
121) Ring gear 1
122) Wave washer 1
123) Gear case cover 1 Clean the mating surfaces of the case and cover
thoroughly, and apply liquid sealant to them.
(24) 10 mm gear case cover bolt 2
(25) 8 mm gear case cover bolt 6
(26). Dust guard plate 1
(27) I Bolt Standard model 1
ABS/TCS or LBS-ABS/TCS model 3
(28) Distance collar 1 [Install with the polished side toward the final gear case.
12-7
Final Drive
Pinion Joint Nut Removal/Installation (1) PINION JOINT HOLDER
Removal
Install the pinion joint holder and remove the pinion joint
nut.
Pinion joint holder 07924-M E40000

Pinion joint holder attachment 07924-9690102
rf ::::,:/ ;~; ;,J";9',~C',"
~' (2) PINION JOINT HOLDER

ATTACHMENT
Installation
Install the pinion joint and pinion joint nut. (1) PINION JOINT HOLDER
Install the pinion joint holder and tighten the pinion joint nut. /
r{,
Torque: 110 N'm (11.0 kg-m, 80 ft-Ib)
~~",\
[s -;=001.1
Pinion joint holder 07924-ME40000
(2) PINION JOINT HOLDER

ATTACHMENT
Pinion Retainer Removal/Installation (1) RETAINER WRENCH
Removal
Remove the pinion retainer with the pinion retainer wrench.
Is-;=001.1
Pinion retainer wrench 07910-MA10100
Installation
Coat the O-ring on the pinion retainer with grease or gear (1) RETAINER WRENCH
oil. Screw the pinion retainer in, pressing the pinion bearing
in place, then tighten it with the pinion retainer wrench.
Torque: 150 N'm (15.0 kg-m. 108 ft·lbJ
(S ';'"001.1
Pinion retainer w:'8f1ch 07910-MA10100
12-8
Final Drive
Pinion Gear Assembly Removal

~g,~~"",;(') SHAFT PULLER
Pull the pinion gear off with the pinion puller.
[s ;"ooLI (2) PINION

Shaft puller 07931-ME40000 or JOINT
07931-ME4010A /HOLDER
(U.S.A. only)
Pinion joint holder 07924-ME40000
131 PINION ~" A,
JOINT :::1J
HOLDER ~~~~
AITACHMENT @ ~
Final Gear Case Bearing Removal
Heat the gear case to approximately 80'C (' 76"F)

,
Always wear insulated gloves when handling the
gear case after it has been heated.
I
CAUTION
• Do not use. a torch to heat the gear case. or it may]

cause warping.
(1) GEAR CASE BEARING
Install the oil seal remover into the gear case bearing. (1) OIL SEAL REMOVER
is ~oLI
Oil seal remover 07948-4630100
Turn the gear case over and drive the gear case bearing out.
Ring Gear Bearing Installation

(1) OIL SEAL DRIVER
If the ring gear assembly was loose against the cover:
Install the original shim onto the ring gear.
NOTE
• If the gear set, pinion bearing, ring gear bearing, gear
case bearing and/or gear case are replaced, install a
2.00 mm thick shim (standard).
Place a new ring gear bearing on the ring gear and drive it
on with the oil seal driver.
[s ;"OOL I
(2) BEARING
Oil seal driver 07965-MC70100
12-9
Final Drive
If the ring gear stayed in the cover: (2) AITACHMENT

Press the ring gear bearing into the case cover. (1) DRIVER
[s -;=-oo~l
Driver 07749-0010000
Oil seal driver attachment 07948-8800101
Install the original shim onto the ring gear.
NOTE
• If the gear set. pinion bearing, ring gear bearing, gear
case bearing and/or gear case are replaced, install a
2.00 mm thick shim (standard).
Support the bearing inner race with the oil seal driver
attachment, and press the ring gear into the bearing with a
suitable tool.
Is Too~1
Oil seal driver 07965-MC70100
/.'1i!:==
(1) OIL SEAL DRIVER
Stop Pin Shim Selection
Measure the ring gear-to-stop pin clearance (Section 5 of

the Common Service Manual).
Clearance: 0.30-0.60 mm (0.012-0.024 in)
Install a stop pin shim to obtain the correct clearance.
Shim thickness: A: 0.10 mm

A: 0.15 mm
(3) STOP PIN
(3) STOP PIN (2l SHIM

Ring Gear Shim Selection
Check the tooth contact pattern (Section 5 of the Common

Service Manual).
If the pattern is not correct, remove and change the pinion

gear shim.
The pattern will shift about 1.5-2.0 mm (0.06-0.08 in)
when the thickness of the shim is changed by 0.1 mm
(0.004 in)
NOTE
Thirteen shims (A-M) are available in thickness
intervals of 0.03 mm. The thinnest is 1.32 mm and
the thickest is 1.68 mm.
• The standard shim (G) thickness is 1.50 mm. (2) RING GEAR SHIM
12-10
Final Drive
Pinion Gear Shim Selection
Check the gear backlash (Section 5 of the Common Service

Manual).
Backlash: 0.05-0.15 mm (0.002-0.006 in)
If the backlash is not within the specifications, remove and

change the ring gear shim.
The backlash is changed by about 0.06-0.07 mm (0.002-
0.003 in) when the thickness of the shim is changed by
0.10 mm (0.004 in).
NOTE
I • Seventeen shims (A-O) are available in thickness

intervals of 0.03 mm. The thinnest is 1.82 mm and
the thickest is 2.30 mm.
! The standard shim (G) thickness is 2.00 mm.
12-11
Symbols
...

~
C
10 (1.0, 7.2)
~
equivalent)
equivalent)

"I~ Apply sealant

13. Front Wheel/Suspension/Steering
Service Information 13-1 Fork Removal/Installation 13-11
Troubleshooting 13-1 Left Fork Disassembly 13-14
Handlebar Cover Removal/Installation 13-2 Left Fork Assembly 13-18
Handlebar Removal/Installation 13-4 Right Fork Disassembly 13-22
Anti-dive Case Disassembly/Assembly 13-5 Right Fork Assembly 13-26
Front Wheel Removal/Installation 13-6 Steering Stem Removal/
Installation 13-30
Front Wheel Disassembly/Assembly 13-10
Service Information
-'---------------
• Riding on damaged rims impairs safe operation of the vehicle.
When servicing the front wheel, support the motorcycle securely with a jack or other support under the engine.
Tubeless tire removal, repair, and remounting procedures are covered in the section 16 of the Common Service
Manual. When remounting the tire, note the normal rotating direction.
Refer to the section 15 for brake system information.
Refer to the section 21 for light, meter and switch information.
Troubleshooting
Hard steering Soft suspension
Steering head bearing adjustment nut too tight
Faulty steering head bearings
• Damaged steering head bearings
• Weak fork springs
Low fluid level in fork
Faulty anti-dive system
III
• Low tire pressure
Faulty tire
Hard suspension
Steers to one side or does not track straight • Incorrect fluid viscosity
• Bent fork • Bent fork tubes
• Bent front axle: wheel installed incorrectly • Clogged fluid passage
• faulty steering head bearings
Bent frame Front suspension noise
Worn wheel bearings Low fluid level in fork
• Worn swingarm pivot bearings • Loose fork fasteners
• Lack of grease in speedometer gearbox
Front wheel wobbling
Bent rim
Worn front wheel bearings
• Faulty tire
Wheel turns hard

• Brake misadjusted
• Faulty wheel bearings
faulty speedometer gear
13-1
Front Wheel/Suspension/Steering
Handlebar Cover Removal/Installation

'91-'94
Holes (310
4.3 (0.43, 3.1)
(41--~~;$'
T'b
Procedure O'tv I Remarks

-
(1)
(2)
Screws
Handlebar upper cover ,
2
At installation, align the pins with the holes in the lower
cover and insert the tab into the latch securely.
(3) Bolt 4
(4) Handlebar lower cover 2
13-2
After '94
(5)
(2)
/<vp /~~
(1)
1:----(6)
(4)

(11 Trim clip 4
(2) Screw 4
(3) Handlebar rear cover 1
(4) Screw 1
(5) Handlebar front cover 1
(6) Handlebar cover stay 1
13-3
Handlebar Removal/Installation
(15)
(1)
•
(3)
(16) • ~
(9)
(5)
-(7)
C
4.2 (0.42, 3.0)
C
12(1.2,9)
(13)
C 27 (2.7, 20)
(14)
Requisite Service
• Handlebar cover removal/installation (page 13-2)

I Disassembly Order Assembly is in the reverse order of disassembly.
(1) Clutch switch wire 2
(2) Clutch master cylinder holder 1
(3) I Clutch master cylinder 1 CAUTION
• Keep master cylinder upright, to prevent air
from entering the system.
(4) Left handlebar switch 1
(5) Choke cable 1 Disconnect from the choke lever flange.
(6) Front brake light switch wire 2
(7) Brake master cylinder holder 1
(8) i Brake master cylinder 1 CAUTION
Keep master cylinder upright, to prevent air
from entering the system.
(9) I Right handlebar switch 1
(10) Wire band 2
(11) Handlebar weight screw 2
(12) Handlebar weight 2
(13) Handlebar upper holder bolt 4
(14) Handlebar upper holder 2
(15:) Throttle grip
Ii
1
(16) Throttle cable 2 I Disconnect from the throttle grip flange.
(17) Handlebar 1
13-4
Anti-dive Case Disassembly/Assembly
(9)
(7)
(8)
(6)
(3)
(2)
(11
o
1IIIIiI (5)
C 4 (0.4. 2.9)
The anti-dive case is under spring pressure. Use care when removing the case to keep it from becoming a
projectile.
Requisite Service
Left fork oil draining (Standard and ABS/TCS model)
• Right fork oil draining (LBS-ABS/TCS model)

- - -
,
Disassembly Order
I' ) Stop ring ,, Assembly is in the reverse order of disassembly.
12)
13)
Pivot collar
Bushing ,
,
14) Rubber boot
15)
16)
Socket bolt
Case cover
4
,,
,,,
17) O-ring
18) Piston seal
19) Oil seal
(10)
(11)
Anti-dive piston
Spring ,
13-5
Front Wheel Removal/Installation

Standard and ABS/TCS Model
Wheel sensor
~(101 \
(121
(5) C 90 (9.0, 65)
(61~ (11 )
€:X: 22 (2.2,16)
(141 (91
(151
(13) (BI
13-6
..- • A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated
disc with a high quality braka degreasing agent.
Brake dust may contain asbestos. Inhaled asbestos fibers have been found to cause respiratory disease and cancer.
· Never use an air hose or dry brush to clean brake assembly. Use an OSHA-approved vacuum cleaner or an alternate
method epprovedbv OSHA, designed to minimize the hazard caused by airborne asbestos fibers.
CAUTION
· After installing the front wheel. apply the front brake and check the brake operation. I
NOTE
• Do not depress the brake lever when the caliper is removed, or it will be difficult to refit the disc between the brake
pads.
l
Requisite Service
• Raise the wheel off the ground by placing a jack or other support under the engine .

111 Wheel sensor wire grommet (ABSjTCS 2 Remove the left grommet first.
model only)
(21 Bolt 2
(31 Front brake hose stay 2 Remove from the front forks.
(41 Socket bolt 2
(51 Front fender 1
(61 Front fender plate 1
(71 Right front brake caliper mounting bolt 2 CAUTION
ABSiTCS model only: Be careful not to damage the tip
of the wheel sensor.
Do not heng the caliper from the brake hose. Air
, I may enter the brake system.
(81 Speedometer cable set screw 1
(91
(101
Speedometer cable
Front axle bolt ,
1
(11) Front axle pinch bolt 4 Loosen the bolts.

(12) Front axle 1
(131 Front wheel assembly 1
(141 Right side collar 1
(15) Speedometer gear box 1
13-7
LBS-ABS/TCS Model
14)
0 1 2 (1.2, 9)
0 3 0 (3.0, 22)
_~ (1)
12)
(7) ~"..I
0 9 0 (9.0, 65) ....... __ '
(9)
li
(8)
\,
022 (2.2, 16)
(11)
(6)
(5)
(12)
13-8
A contaminated brake disc or pad reduces stopping power, discard contaminated pads and clean contaminated disc
with a high quality degreasing agent.
Inhaled asbestos fibers have been found to cause respiratory disease and cancer. Never use an air hose or dry brush
to clean brake assemblies.
CAUTION
I. After installing the front wheel. operate the brake lever and pedal and check the brake operation {page 3·13).
NOTE
Do not depress the brake lever or pedal when the front caliper is removed, or it will be difficult to refit the disc
between the brake pads.
Requisite Service
Raise the wheel off the ground by placing a jack or other support under the engine.
Frant fender removal/installation (page 2-11).

(1) Sensor bracket bolt 1 CAUTION
· Be careful not to damage the tip of the wheel sensor.
NOTE
· When tightening, perform the air gap inspection
(page 16-8-34).
(2) Wheel sensor assembly 1 NOTE
, · At installation, route the sensor wire properly (page
1-25). and align the hole in the bracket with the pin of
the upper caliper mounting bolt.
(3) Right front brake caliper mounting bolt 2 CAUTION
(4) Front brake caliper/pivot collar 1/1

· Do not hang the caliper from the brake hose/pipe.
(5) Speedometer cable setting screw 1

(6) Speedometer cable 1
(7) Front axle bolt 1
(8) Front axle pinch bolt 4 Only loosen these bolts.
(9) Front axle 1
(10) Front wheel assembly 1
nn Right side collar 1
{12} Speedometer gear box 1
13-9
Front Wheel Disassembly/Assembly

151
151 fit
B (0.8, 5 8)
....
IBI III
(21
NOTE
• The left brake disc has "L" mark and the right brake disc has' "R" mark. Install them on the correct sides.
- Always replace wheel bearings as a set.
- For wheel bearing replacement, refer to the section 1 of the Common Service Manual.
I
Requisite Service
- Front wheel removal/installation (page 13-6)

111 Dust seal 2
121 Speedometer gear retainer 1 At installaion, align the tabs with the slots in the wheel hub
131 Brake disc bolt 12
141 Brake disc 2 Install the disc with the" L· mark on the left side, and the
disc with the .. R· mark on the right side.
151 Gasket 12
151 Torx bolt (T25) (ABS;TCS or LBS-ABS/TCS 5
model) I
III Pulsar ring (ABS;TCS or LBS-ABSjTCS 1 Install the pulser ring with the concave portion of bolt hole
model) facing out.
CAUTION
Be careful not to deform, distort. or damage the pulser
ring.
IBI Left wheel bearing (6004UU) 1
191 Distance collar 1
1101 Right wheel bearing (6004UU) 1 At installation, drive a new right wheel bearing in the hub first,
then drive a new left bearing in.
(1 1) Front tire 1
13-10
Fork Removal/Installation
/
C 23 (2.3, 17)
C 4.3 (0.43, 3.1) //

(51
I \
,
! (61
(I I
C 27 (2.7, 20)
'---J"'" -
c_"'"- . (II
~
~.,.'-
.-.,.-.-".-.-.-:0- -/
~~\
~\
/
P
j~\
NOTE~_ _
" (2) C 12 (1.2, 9)
• When the fork is to be disassembled, loosen the fork bolt but do not remove it.
I . After assembling the fork, tighten the fork cap temporarily before tightening the upper fork pinch bolt.
Requisite Service
Handlebar cover removal/installation (page 13-2)
Front wheel removal/installation (page 13-6)

(I ) Left brake caliper pivot bolt (upper)/collar III
(2) Left brake caliper pivot bolt (lower) I CAUTION
• Do not hang the brake caliper from the brake
hose.
(31 Brake hose clamp (Standard model) 1 Right fork only.
(41 Lower fork pinch bolt 4 loosen the bolts.
(51 Upper fork pinch bolt 2 loosen the bolt
NOTE
• Be careful not to let the fork drop when loosening
the bolt.
(61 Fork asssembly I At installation, align the end of the fork tube with the
upper surface of the top bridge.
13-11
LBS-ABS/TCS Model
(6) E:t 22 (2.2, 16)
/
E:t 12 (1.2. 9)
(51
, ,0
~'~~
I
(11 Short
I
(4)
(21 I ""'--'(J C 30 (3.0, 22)

E:t12 (1.2, 9)
(31
E:t 30 (3.0, 22)
/
Tube end
(10)
(8)
E:t 50 (5.0, 36)
13-12
CAUTION
When performing this service, provide the calipers with a support (sl. Do not hang the calipers from the brake hose
and pipe.
NOTE
When the fork is to be disassembled, loosen the fork cap but do not remove it yet.
After assembling the fork, tighten the fork cap which is temporarily tightened before tightening the upper fork pinch
bolt.
Requisite Service
Handlebar cover removal/installation (page 13-2).

Front wheel removal/installation (page 13-6).

(1) Oil pipe and wire stay fixing bolt 1
(2) Delay valve mounting bolt 2 Secure the upper bolt with the fender plate.
(3) Left brake caliper pivot bolt (lowen/couar 1(1
(4) Secondary master cylinder link plate bolt 1(1 Secure the upper bolt with the fender plate.
{lower; slider-to-link born/cottar
(5) Secondary master cylinder mounting bolt 2
(6) Fender plate mounting bolt 2
(7) Front fender plate 1
(8) Lower fork pinch bolt 4 Only loosen.
(9) Upper fork pinch bolt 2 Only loosen.
.
NOTE
Be careful not to let the fork drop when loosening the
bolt.
(10) Fork assembly 1 At installation, align the end of the fork tube with the upper
surface of the top bridge.
13-13
Left Fork Disassembly

(151
116)
1181
(191
/
~(21
/
/ / (3)
/
(41
(5)
(21) (91
(61 (81
13-14
DIIII__
• The fork cap is under spring pressure. Use care when removing it.
Requisite Service
• Fork removal (page 13-11)

I--~------''-''-'
Disassembly Order
(1) Fork tube protector NOTE
• Do not remove unless necessary.
(2) Fork cap/O-ring 1/1
(3) Spring collar 1
(4) Spring seat 1
(5) Fork spring 1 Drain the fork fluid after removing the spring.
(6) Socket bolt/washer 1/1
(7) Fork piston assembly 1
(8) Stopper ring 1 Remove from the fork piston.
(9) Oil lock valve 1
(10) Oil lock valve spring 1
(11) Spring seat 1
(12) Stopper ring 1
(13) Rebound spring 1
(14) Piston rings 2 NOTE
Do not remove the piston rings unless they are to
be replaced.
(15) Dust seal
(16) Stopper ring CAUTION
Be careful not to damage the fork tube sliding
surface.
(17) Fork tube 1
(18) Oil seal 1
(19) Back-up ring 1
(20~ i Slider bushing 1
(21) I Fork tube bushing 1 I NOTE
• Do not remove bushing unless it is to be replaced.
13-15
LBS-ABS/TCS Model
(5)~
'-----l (14)
12)
1'1
Lock nut
13-16
Requisite Service
• Fork removal (page 13-12).

Disassembly Order
11 } Fork cap/O-ring i 1/1 Remove the cap form the fork tube, then remove it from
the fork damper rod while holding the lock nut as shown.
12} Spring seat stopper 1 Remove the stopper while compressing the fork spring as
shown.
13} Spring seat 1
I'} Fork spring 1
15} Socket bolt/washer 1/1
16} Fork damper i 1
17} Oil lock piece 1
18} Dust seal 1
19} Stopper ring 1 CAUTION
. Be careful not to damage the fork tube sliding surface .
(10) Fork tube 1
(11) Oil seal 1
(12) Back-up ring 1
(13) Slider bushing 1
(14) Fork tube bushing 1
.
NOTE
Do not remove the bushing unless it is to be replaced .
13-17
Left Fork Assembly

~~
S'"
(14) (15)
if) 20 (2.0,14)
(20)
(19(
(1 B)
(111
/
\ - .. (11
(9)
18)
17)
if) 20 (2.0, 14)

n •
Uii (21 J
13-18

Assembly Order
(I) Fork tube bushing 1
(2) Fork tube 1
(3) Piston rings 2 Install onto the fork piston
(4) Rebound spring 1
(5) Stopper ring 1
(6) Spring seat 1
(7) Oil lock valve spring 1
(B) Oil lock valve 1
(9) Stopper ring 1
(11 ) Socket bolt/washer 11'
(12)
(13)
Slider bushing
Back-up ring
;
,
1
(14) Oil seal 1 NOTE

· Wrap vinyl tape around the fork tube top end to
avoid damaging the oil seal lip during installation.
• Drive the slider bushing and oil seal into the slider
using the fork seal driver body (07947-KA501 DO}
(15) Stopper ring

, and attachment (07947-KFOOl 00).
CAUTION
• Be careful not to damage the fork tube sliding
(16) Dust seal , surface.
Pour in the fork fluid to the specified level with the fork
fully compressed before installing the fork spring.
(' 7) Fork spring 1 Wipe fluid off the spring thoroughly using a clean lint
free cloth and install with the tightly wound coil end
(18) Spring seat ,, facing down.
(19) Spring collar

(20)! Fork cap/O-ring 11' Screw in the bolt, but do not tighten yet.
CAUTION
(21 ) Fork tube protector , • Be careful not to cross-thread the fork cap.
Align the lug with the groove in the fork slider.
NOTE
· For easy installation, immerse in hot water (50-
60·C/122-140·F).
After completing fork assembly, refer to fork installation procedures (page 13-11}.
13-19
lBS-ABS/TCS Model
I,;;ocl"
(B)~
0 2 3 (2.3,17)
,
/
!
,/
,/
//
/
/
/
/
,!
'------~!
''
(' ) (4)
(3)
=~::~~~;=:::t~
(13)
>-c--~ 10.5 mm (O.41
minimum
in)
~=
~ lock nut
0 2 0 (2.0, 14)
13-20

Assembly Order
111 Fork tube bushing 1
121 Fork tube 1
131 Oil lock piece 1 Install onto the end of the fork damper.
141 Fork damper 1
151 Socket bolt/washer 1/1
161 Slider bushing 1
171 Back-up ring 1
181 Oil seal 1 NOTE
· Wrap vinyl tape around the fork tube top end to avoid
damaging the oil seal lip during installation.
· Drive the slider bushing and oil seal into the slider using
the fork seal driver body (07947-KA50100) and attach-
ment (07947-KA40200l.
191 Stopper ring 1 CAUTION
,
(10) : Dust seal 1
· Be careful not to damage the fork tube sliding surface.
Pour in the fork fluid to the specified level before installing
the fork spring.
{ll} Fork spring 1 Wipe fluid off the spring thoroughly using a clean lint-
free cloth and install with the tightly wound coil eod
, facing down.
(12) Spring seat 1
(13) Spring seat stopper 1 Install the stopper between the spring seat and lock nut
while compressing the fork spring as shown.
NOTE
· Before installing the stopper, measure the distance
between the lock nut and the top of the damper rod, it
should be at least 10.5 mm (0.41 mm)
(14) Fork cap/a-ring 1/1 Instatl the fork cap onto the damper rod and tighten the
lock nut as shown, then screw it into the fork tube, but do
not tighten yet.
CAUTION
· Be careful not to cross-thread the fork cap.
After completing fork assembly, refer to fork installation procedure (page 13-13).
13-21
Right Fork Disassembly

(12)
(13)
(2)
(15) ~ ~7
(16)~~
(17)~~
~~
,
(1)
(14)~ ~ /1
~\ (6)
(5)
(7)
(9)
(8)
(18) (11)
(4)
=
(2)
13-22
Requisite Service
• Fork removal (page t 3-11)
I
(1)
I Fork
Disassembly Order
tube protector 1 NOTE
(2)
I Fork cap 1
· Do not remove unless necessary.
Remove the fork cap from the fork tube, then remove it
from the fork damper rod while holding the lock nut as
shown.
(3) a-ring 1
(4) Spring seat stopper 1 Remove the stopper while compressing the fork spring
as shown.
(5) Spring seat 1
(5) Spring collar 1
(7) Spring seat 1
(8) Fork. spring 1
(10) Fork damper 1
(11) Oil lock piece 1
(12) Dust seal 1
(13) Stopper ring 1 CAUTION
· Be careful not to damage the fork tube sliding
surface.
(14) Fork tube 1 !
(15) Oil seal 1
(16) Back-up ring 1
(18) Fork tube bushing 1 I NOTE
• Do not remove the bushing unless it is to be replaced.
13-23
LBS-ABS/TCS Model
(14)
(15)
(17)
(18)
(19)
(20) (1)
(21)
(16}
(2(
(22}
(8)
(5)
(7)
13-24
The fork cap is under spring pressure. Use care when removing it.
Requisite Service
• Fork removal (page 13-12).

Disassembl Order
11} Fork cap/a-ring 1/1
12} Spring collar 1
13} Spring seat 1
I'} Fork spring 1 Drain the fork fluid after removing the spring.
15} Socket bolt/washer 1/1
16} Fork piston assembly 1
17} Stopper ring 1 Remove from the fork piston.
18} Oil lock valve , 1
19} Oil lock valve spring 1
(10) Spring seat 1
(1 1} Stopper ring 1
i
(12} Rebound spring 1
(13} Piston ring 2 NOTE
· Do not remove the piston rings unless they are to be
replaced.
(14) Dust seal 1
(15) i Snap ring 1 CAUTION
(16) Fork tube 1

· Be careful not to damage the fork tube sliding surface.
(17) Oil seal 1

(18) Back-up ring (upper) 1
(19) Packing 1
(20) Back-up ring (lower) 1
(21 ) Slider bushing 1
(22) Fork tube bushing 1 NOTE
· Do not remove bushing unless it is to be replaced.
13-25
9
St a nda rd an dABS /TCS Model _
8'"
(10)
tf!:tt. 20 (2.0, 14)
~(18)
(15)
~
I
s-. $I
(19)
es
R':::" (14)
(13)
(12)
(11)
~ 23 (2.3,17)
~ (15) Lock nut
(16)
10.5 mm (0 .4 1 in) minimum (lB)~
UP
13-26

t- -
Assembly Order
(11 Fork tube bushing 1
(2) Fork tube I 1
(3) Oil lock piece 1 Install onto the end of the fork damper.
(4) Fork damper 1
(5) Socket bolt/washer 1;1
(7) Back-up ring 1
(8) Oil seal 1 NOTE
,
· Wrap vinyl tape around the fork tube top end to
avoid damaging the oil seal lip during installation.
I • Drive the slider bushing and oil seal into the slider
using the fork seal driver body (07947-KA501 00)
and attachment (07947-KFOO100).
(9) Stopper ring 1 CAUTION
• Be careful not to damage the fork tube sliding
surface,
(10) Dust seal 1 Pour in the fork fluid to the specified level with the fork
fully compressed before installing the fork spring.
(11 ) Fork spring 1 Wipe fluid off the spring thoroughly using a clean lint
facing down.
(12) Spring seat 1
(13) Spring collar 1
(14) Spring seat 1
(15) Lock nut 1 I Install in the direction shown in the illustration-with the
I fully threaded end up.
(16) Spring seat stopper 1 I Install the stopper between the spring seat and lock
nut while compressing the fork spring as shown.
NOTE
• Before installing the stopper, measure the distance
between the lock nut and the top of the damper
rod. It should be at least 10.5 mm (0.41 in)
( 17) O-ring 1
(18) Fork cap 1;1 Install the fork cap onto the damper rod and tighten
the lock nut as shown, then screw it into the fork
tube, but do not tighten yet.
CAUTION
• Be careful not to cross-thread the fork cap.
(19) Fork pipe protector 1 Align the lug with the groove in the fork slider.
NOTE
· For easy installation, immerse in hot water (50-
aO°C/1 22 -140°F).
After completing fork assembly, refer to fork installation procedures (page 13-11).
13-27
LBS-ABS/TCS Model
(15)
\ UP
D
..
1,';""ooLI . ,
(1S} IIii;'ijiIII
(17}
(18)
,t::rl==== I )
. . 1141-----+i~O~~\~ ~~~
1 0 \
1
(,3)~'j
I I
(22)
~\ 121)
(20)
C
/$/
20 (2.0, 14)
111 181
1ta
13-28

Assembly Order
11 } Fork tube bushing 1
12} fork tube 1
13} Piston ring 2 Install onto the fork piston.
14} Rebound spring 1
15} Stopper ring 1
16} Spring seat 1
17} Oil lock valve spring 1
IS} Oil lock valve 1
19} Stopper ring 1
(13) Back-up ring (lower} 1 Install with the flat side facing down.
(14) Packing 1 Install with the groove side facing down.
(15) Back-up ring {upper) 1 Install with the camfered side facing down.
(16) Oil seal 1 NOTE
• Wrap vinyl type around the fork tube top end to avid
damaging the oil seal lip during installation.
• Drive the slider bushing and oil seal into the slider using
the fork seal driver body (07947-KA50100} and attachment
(07947-KA40200).
(17) Snap ring 1 CAUTION
• Be careful not to damage the fork tube sliding surface.
(18) Dust seal 1 Pour in the fork fluid to the specified level before
installing the fork spring.
(19) Fork spring 1 Wipe fluid off the spring thoroughly using a clean lint
facing down.
{20} Spring seat 1
{21} Spring collar 1
(22) Fork cap/O-ring 1/1 Screw in the cap, but do not tighten yet.
I CAUTION
i I • Be careful not to cross-thread the fork cap bolt.
After completing fork assembly, refer to fork installation procedures (page 13-13l.
13-29
Steering Stem Removal/Installation
e1I
161
151
0 171
28 (2.8, 20)
,
-,
,, (4)
-,
,,
,,
131
13-30
NOTE
The steering head bearings and races should always replaced as a set .
• When loosening and tightening the steering stem nut, temporarily install the fork legs.
Requisite Service
• Handlebar removal/installation (page 13-4)

• Fork removal/installation (page 13-11}
(I) Steering stem nut 1
(2) Washer 1 i
(3) Ignition switch wire 1 I Disconnect at the connector holder. At installation,
(4) Fork top bridge ,, route the wire porperly (page 1-25).
(5)
(6)
Lock nut
Lock washer
,,
(7)
(8)
Steering bearing adjustment nut
Dust seal ,
,,
(9) Steering stem
('D)
(11)
Upper bearing inner race
Upper bearing I ,
,,
(' 2) Lower bearing
(' 3)
(14)
Lower bearing inner race
Dust seal
,, Install using the steering stem driver (07946-MBOOOOO).
(15) Upper bearing outer race Remove using the race remover attachment (07953-
MJ 1ODDS}. Install using the driver{07749-001 0000)
(16) Lower bearing outer race

i , and attachment, 42 x 47 mm (07746-0010300).
Remove using the race bearing remover (07946-
3710500). Install with the driver (07749-oo1ClCXlO)
and attachment, 52 x 55 mm (07746--0010400).
13-31
Symbols
...

~
C
10 (1.0, 7.2)
~
equivalent)
equivalent)

"I~ Apply sealant

14. Rear Wheel/Suspension
Service Information 14-1 Shock Absorber Removal/
Installation 14-6
Shock Absorber Disassembly/
Rear Wheel Removal/Installation 14-2 Assembly 14-7
Rear Wheel Disassembly/Assembly 14-4 Swingarm Removal/Installation 14-8
Service Information
-~--:-:----:---c---=-
~ Riding on damaged rims impairs safe operation of the vehiC_'.c. _
Tubeless tire removal, repair, and remounting procedures are covered in the section 16 of the Common Service
Manual. When remounting the tire, note the normal rotating direction indicated by the arrow.
Refer to the section 15 for brake system information.
Use only genuine Honda replacement bolts and nuts for all suspension pivot and mounting points.
Troubleshooting
Rear wheel wobbling Hard suspension
Bent rim Damaged shock absorber mount bushing
• Worn rear wheel bearing(s) • Incorrect suspension adjustment
• Faulty tire Bent damper rod
• Unbalanced tire and wheel Damaged swingarm pivot bearing(s)
• Low tire pressure Lack of lubrication in swing arm pivot bearings or
Faulty swingarm pivot bearing(s) suspension pivot points
Wheel turns hard

• Faulty wheel bearing(s)
Brake drag (section 15)
III
Bent rear axle
Soft suspension
Weak shock absorber spring
Oil leakage from damper unit
Incorrect suspension adjustment
14-1
Rear Wheel/Suspension
Rear Wheel Removal/Installation

151
0 70 (7.0, 5 1)
111 ,
I
II, Wheel sensor
"",
12)
, 0 0110 (11.0, 80)
14)
o 131
27 (2.7, 20)
i1l~LS0,,!f}~- Pulser ring
Driven flange
Dust guard plate Ring gear
161
Handle of pliers
14-2
~
. A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated
disc with a high quality brake degreasing agent.
NOTE
. ABS/TCS or LBS-ABS/TCS model: Do not remove the wheel sensor to remove and install the rear wheel.
0
Do not depress the brake pedal when the caliper is removed, or it will be difficult refit the disc between the brake pad.
0
Support the removed caliper with a piece of wire so that it does not hang from the brake hose. Do not twist the brake
hose.
0
Apply multipurpose NLGI NO.2 grease (molybdenum disulfide additive) to the driven flange and the ring gear
engagement splines.
Requisite Service
0
Place the motorcycle on its center stand.
,
Procedure , Q'ty Remarks
Removal Order
01 Rear caliper stopper pin bolt 1 Loosen the bolt.
121 Rear axle nut 1
131 Rear axle pinch bolt 1
141 Rear axle 1
151 , Rear caliper assembly 1
151 i Rear wheel assembly 1
! Remove from the brake disc.
Separate the driven flange of the wheel from the ring
gear of the final drive gear by prying the driven flange
with the handle of the pliers through the slot in the dust
guard plate as shown.
CAUTION
0 ABS/TCS or LBS-ABS/TCS model: Be careful not to
damge the pulser ring and wheel sensor.
171 , Side collar 1
1 4-3
Rear Wheel Disassembly/Assembly

~ (3 g/0.11 oz to each surface}
/ J >I
//
( //
l ir e;;
/ ://r ~,
l{~~ . '
...
"f'~;;
'
'\'v~
)/)\, <:
(1) 8 (0_8, 5.8)
~~
C 20 (2.0, 14)
(51 111
(15)
(81
(21
(21
(51 .,
_ fiiiiiiH C (101
43 (4.3,31)
~
(41
191
(111
"
171
( 13)
(12)
Arrow([)
Arrow4;'
00
@ ---~
Arrow
\ //
14-4
NOTE
Replace the rear wheel damper rubbers as a set.
Replace the wheel bearings as a set.
For wheel bearing replacement, refer to the section 1 of the Common Service Manual.
ABS(TCS or LBS-ABS(TCS model: When the pulser ring is replaced, perform the wheel sensor air gap inspection
{page 16-A-51 or 16-B-34} after installing the rear wheel.
Requisite Service
• Rear wheel removal/installation {page 14-2}.
Procedure G'ty Remarks

(1 ) Torx bolt (T25) (ABS(TCS or LBS-ABS(TCS 6
model)
(2) Pulser ring (ABS(TCS or LBS-ABS(TCS model) 1 Install the pulser ring with the concave of bolt hole facing
out.
CAUTION
. Be careful not to deform, distort, or damage the pulser
ring.
(3) Final driven flange 1 At assembly, apply 3 g {D.1 1 oz} of molybdenum disulfide
paste to the driven flange mating surface of the hub, to
the inside diameter of the driven flange and to the
splines of the driven flange as shown.
(4) Thrust washer 1
(5) O-ring 1
(6) Socket bolt 5
(7) Damper holder plate 1 Remove the plate by turning it counterclockwise and
aligning the arrow on the plate with the errowO on the
wheel as shown.
Install the plate, aligning the arrow with the arrow Ct:, and
turn it clockwise until the arrow aligns with the arrow iI;
as shown.
(8) Rear wheel damper rubber 5 Install with the "OUTSIDE" mark facing out.
(9) Dust seal 1
(10) Socket bolt 6
(11) Rear brake disc 1 Install with the "OUTSIDE" mark facing out.
(12) Right wheel bearing {dual, 20x47x20.6 mm) 1 I
I
(13) Distance collar 1
(14) Left wheel bearing (6204UU) 1 At installation, drive a new left wheel bearing in the hub
first, then drive a new right bearing in.
(15) Rear tire 1
14-5
Shock Absorber Removal/Installation
/
~121
~ 23 (2.3,17)
NOTE
I Use a floor jack or other adjustable support under the final drive to relieve stress for ease of left shock absorber lower
mounting bolt removal/installation.
Note the position of the spring preload adjuster for future reference. Adjust the spring preload adjuster to the softest
position for disassembly. Return the adjuster to the position noted before disassembly.
Requisite Service
Place the motorcycle on its center stand
Right side cover (page 2-2)
Removal Order
(1) Upper mounting bolt 1
(2)
(3)
Lower mounting bolt
Shock absorber assembly ~ I Disassembly/assembly (page 14-7)
14-6
Shock Absorber Disassembly/Assembly

~
(4)
(2)
NOTE
• Adjust the spring preload adjuster to the softest position before disassembly.
---'----
Requisite Service
• Shock absorber removal/installation (page 14-6)

(1) Stopper ring 1 Compress the shock absorber spring using the spring
, I compressor (07GME-0010000) and attachment
(07959-MB10000) and remove the stopper ring.
(2) Upper spring seat 1
(3) Spring 1 Install with the tightly wound coil end facing up.
(4) Upper mount collar I 1
14-7
Swingarm Removal/Installation
LBS-ABS/TCS model shown:
:'.TOOLI
0: 105 (10.5, 76)
13)
18)
I')
e;:,. Standard
model"
~ 18 (1.8,13)
ABS/TCS or
LBS-ABS/TCS model:
0: 22 (2.2, 16)
I' )
\ v/
(6)
"UP" mark
14-8
NOTE
,.
, Replace the pivot bearings and outer races as a set,
Requisite Service
• Final gear case removal/installation (page 12-3)
I I Removal Order Installation is in the reverse order of removal.

(1) Wheel sensor wire (ABS/TCS or 1 Remove the wire harness from the swingarm.
ILBS-ABSITCS model only
(2) Rear brake hose clamp bolt
I 2 Remove the rear brake hose clamp from the swinqarm.
(3) Left pivot lock nut 1 Use the swingarm lock nut wrench (07908-4690003).
14) Left pivot bolt 1
151 Right pivot bolt 1
161 Swingarm 1 ,
17) Pivot bearing 2 Pivot bearing outer race replacement (page 14-10)
18) Driveshaft assembly 1 Disassembly/Assembly (page 12-2)
19) Rubber boot 1
Installation Order
19) Rubber boot 1 Install with the "UP" mark facing up.
181 Driveshaft assembly 1 Install into the swingarm
17) Pivot bearing 1
151 Right pivot bolt 1
161 Swingarm 1 Install in the frame and on the right pivot bolt while
engaging the driveshaft joint with the countershaft.
14) Left pivot bolt 1 After installing the pivot bolts, fit the rubber boot tab
into the transmission case groove properly.
13) Left pivot lock nut 1 Tighten the nut with the swingarm lock nut wrench (0
7908-4690003 orKS-HBA-08-469, U.S.A. only)
while holding the left pivot bolt.
12) Rear brake hose clamp bolt 4 Install the clamp onto the swingarm.
111 Wheel sensor wire harness 1 Install the wire harness onto the swingarm.
14-9
Pivot Bearing Outer Race Replacement

(1) BEARING OUTER
REMOVER
Punch or drill a 13 mm (1/2 in) hole into each grease retain-
e,-
Remove the attachment from the bearing remover. Slide the
shaft through the hole and install the attachment onto the
shaft.
Install the sliding weight and remove the outer race with the
grease retainer.
Repeat for the other side.
Pivot bearing outer remover 07936-4150000

Sliding weight 07741-0010201 (2) SLIDING WEIGHT (3) ATTACHMENT
Install new bearing outer races into the swingarm pivot.
"--------
" .---/
'"
,,~
Driver 07749-0010000 (1) DRIVER ~-:-:~_ 1'"",;;/,'0"',

Attachment, 37 x 40 mm 07746-0010200 ' '_" _--_-~""':>,J./~- -_,,/'
(~
\i , \
"
----; (2) ATTACHMENT,

37 x 40 mm
14-10
Symbols
...

~
C
10 (1.0, 7.2)
~
equivalent)
equivalent)

"I~ Apply sealant

15. Brake System
Service Information 15-' Rear Brake Caliper Disassembly!
Assembly 15-20
Brake Fluid Filling/Bleeding (LBS-ABS/
Rear Brake Pedal Removal!
Installation 15-24
TCS modell 15-2
Secondary Master Cylinder Disassemblyj
Brake Pad Replacement 15-8
Assembly ILBS-ABS/TCS modell 15-26
Front Master Cylinder Disassemblyj
Delay Valve Removal/Installation
Assembly 15-10
ILBS-ABS/TCS modell 15-28
Front Brake Caliper Disassembly!
Proportional Control Valve Removal!
Assembly 15-12
Installation ILBS-ABS/TCS model) 15-29
Rear Master Cylinder Disassembly!
Assembly 15-16
Service Information
A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated
disc with a high quality brake degreasing agent.
Brake dust may contain asbestos. inhaled asbestos fibers have been found to cause respiratory disease and cancer.
Never use an air hose or dry brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner or alternate
method approved by OSHA. designed to minimize the hazard of airborne asbestos fibers.
Spilled brake fluid will severely damage instrument lenses and painted surfaces. It is also harmful to some rubber
parts. Be very careful whenever you remove the reservoir cap; make sure the front reservoir is horizontal first.
Never allow contaminants (dirt, water, etc.) to get into an open reservoir.
Once the hydraulic system has been opened, or if the brakes feel spongy, the system must be bled.
The brake fluid air bleeding procedure on the ABS/TCS ('92-95) model must be performed in the same manner as in
the ordinal air bleeding procedure. Note that replacement and bleeding air from the brake fluid in the modulator is ~
not necessary, as it is sealed in the modulator. On the LBS-ABSfTCS model (After '95), refer to page 15-2. ~
Always use fresh DOT 4 brake fluid from a sealed container when servicing the system. Do not mix different types of
fluid as they may not be compatible.
Always check brake operation before riding the motorcycle.
Troubleshooting
Brake lever/pedal soft or spongy Brake lever/pedal hard
Air in the hydraulic system Clogged/restricted brake system
Leaking hydraulic system Sticking/worn caliper piston
Contaminated brake pad/disc Caliper not sliding properly
Worn caliper piston seal Clogged/restricted fluid passage
Worn master cylinder piston cups Worn caliper piston seal
Worn brake pad/disc Sticking/worn master cylinder piston
Contaminated caliper Bent brake lever/pedal
Caliper not sliding properly
Low brake fluid level Brake drag
Clogged fluid passage Contaminated brake pad/disc
Warped/deformed brake disc Misaligned wheel
Sticking/worn caliper piston Badly worn brake pad/disc
Sticking/worn master cylinder piston Warped/deformed brake disc
Contaminated master cylinder Caliper not sliding properly
Bent brake lever/pedal Clogged/restricted fluid passage
Sticking/worn caliper piston
15-1
Brake System
Brake Fluid Filling/Bleeding

(LBS-ABS/TCS model)
A contaminated brake disc or pad reduces stopping

power. Discard contaminated pads and clean a
contaminated disc with a high quality brake
degreasing agent.
CAUTION
Do not allow foreign material to enter the system when
filling the reservoir.
Avoid spilling fluid on painted, plastic or rubber parts.
Place a rag over these parts whenever the system is
serviced. (1) SCREWS
NOTE
On the LBS-ABSiTCS model, note that there is no brake
fluid in the modulator (except in the modulator head),
because the modulator is the motor-driven hydraulic
pressure type. Therefore, brake fluid replacement and
bleeding air from the modulator body is not necessary.
Once the hydraulic system has been opened, or if the
brake feels spongy, the system must be bled.
When using a commercially available brake bleeder,
follow the manufacturer's operating instructions.
(2) CAP
Lever Brake Line (1) LEFT (2) RIGHT
FLUID FEEDING
Support the motorcycle on its center stand.
Turn the handlebar to the left until the reservoir is level before
removing the reservoir cap.
Remove the reservoir cap, set plate and diaphragm.
Connect a commercially available brake bleeder {example,

Mityvac PIN 6826) to the outer bleed valve (upper side of the
each front caliper).
Fill the reservoir with DOT 4 brake fluid from a sealed

container.
CAUTION
Use only DOT 4 brake fluid from a sealed container.
Do not mix different types of fluid. They are not
compatible.
Operate the brake lever several times to bleed air from the
master cylinder.
15-2
Brake System
1. Pump the brake bleeder and loosen the bleed valve.

Add brake fluid when the fluid level in the reservoir is low.
(1) Until sufficient amount of fluid
flows out.
NOTE
Check the fluid level often while bleeding the brake to
prevent air from being pumped into the system.
Repeat the above procedure until sufficient amount of the

fluid flows out from the bleed valve.
Close the bleed valve.
NOTE
It is not a problem if the fluid flowing out from the bleed

valve contains air bubbles because the lines will be bled
in later steps.
If air is entering the bleeder from around the bleed valve
threads, seal the threads with teflon tape.
2. Perform step 1 for the other side bleed valve.
Next, periorm the air bleeding from the system (page 15-4).
(2) BLEEDER
If a commercial brake bleeder is not available, use the

following procedure:
Connect a transparent bleed hosetothe bleed valve and place
the other end ofthe hose in a container.
1. Pump the brake lever several (5-10) times quickly, then
squeeze the brake lever all the way and loosen the bleed
valve 1/4 turn. Wait several seconds and close the bleed
valve.
NOTE

in later steps.
Do not release the brake lever until the bleed valve has
been closed. (1)
Release the brake lever slowly and wait several seconds

after it reaches the end of its travel.
Repeat steps 1-2 until sufficient amount of the fluid flows out
from the bleed valve.
2. Perform step 1 for the other side bleed valve.
Next, periorm the air bleeding from the system (page 15-4).
15-3
Brake System
AIR BLEEDING
1. Connect a transparent bleed hose to the bleed valve.
Pump the brake lever several (5-10) times quickly. then

squeeze the brake lever all the way and loosen the bleed
-@"
~/
valve.
NOTE
Do not release the brake lever until the bleed valve has
been closed.
/~/ ...../1,"I,
~ntil
Release the brake lever slowly and wait several seconds
after it reaches the end of its travel. (1) LEVER air bubbles
disappear
Repeat above procedure until air bubbles do not appear in -- ~ ,
the transparent hose. ~ :;-:{j'
2. Perform step 1 for the other side bleed valve. "
Ii! -,",',~; {"f)/1'
"'" '.,' ,1,.0"
- 'I f ---
Make sure the bleed valves are closed and operate the brake
lever. If it still feels spongy, bleed the system again.
2
I
I
I
I
I
-
v
0 1
After bleeding air completely. tighten the bleed valves to the

(1) SCREWS
specified torque.
Torque: 5.5 Nm (0.55 kg-m. 4.0 ft-Ib)
Fill the reservoir to the casting ledge with DOT 4 brake fluid
from a sealed container.
Install the diaphragm, set plate and reservoir cap and tighten
the cap screws.
Torque: 1.5 Nm (0.15 kg-m. 1.1 ft-Ib)
Check the front brake operation (page 3-13).

(2) CAP
15-4
Brake System
Pedal Brake Line

NOTE
Refer to the Technical Features (Section 23) for
additional informaition pertaining to the pedal brake
line.
Before performing this service, have at least 500 cc (16.9
US OZ, 14.1 Imp oz) of brake fluid.
Insert fluid and bleed air from the pedal brake line in the
following sequence:
1. Left front caliper lower side bleed valve
(from the rear brake pedal master cylinder-front
modulator--elelay valve line)
2. Right front caliper lower side bleed valve
(from the rear brake pedal master cylinder-front
modulator--elelay valve line)
3. Rear caliper front side bleed valve
(from the rear brako pedal master cylinder-rear
modulator line)
4. Rear caliper rear side bleed valve
(from the secondary master cyJinder-PCV-rear
modulator line)
FLUID FEEDING
Support the motorcycle on its center stand.
Remove the right side cover (page 2-2}. ~(1)CAP
Remove the reservoir cap. --'<', ~
Fill the reservoir with DOT 4 brake fluid from a sealed ."'-: ,- "E:3'
container. ~"",
CAUTION
Do not mix different types of fluid. They are not
~ ~-
7~~----
compatible.
(2) RESERVOIR w~
Operate the brake pedal several times until brake fluid level in (1) FILLING
the reservoir goes down.
(2) PEDAL
15-5
Brake System
NOTE
Check the fluid level often while bleeding the brake to
prevent air from being pumped into the system.
1. Connect a commercially available brake bleeder

(example, Mityvac PIN 6826) to the left front caliper lower
side bleed valve.
Pump the brake bleeder and loosen the bleed valve.

Add brake fluid when the fluid level in the reservoir is low.
Close the bleed valve.
NOTE

in later steps.
If air is entering the bleeder from around the bleed valve
threads, seal the threads with teflon tape.
2. Repeat step 1 for each valve in the sequence as follows:

• the right front caliper lower-side bleed valve
• the rear caliper front-side bleed valve
• the rear caliper rear-side bleed valve
Next, perform the air bleeding from the system (page 15-7).
If a commercial brake bleeder is not available, use the

following procedure:
1. Connect a transparent bleed hose to the left front caliper
lower-side bleed valve.
Pump the brake pedal several (5-10) times quickly, then

depress the brake pedal all the way and loosen the bleed
valve.
NOTE
valve contains air bubbles because the lines will be bled @~~mc__~_
f~~
later, steps.
Do not release the brake pedal until the bleed valve has
been closed.
Release the brake pedal slowly and wait several seconds {SJ:'' '.
after it reaches the end of its travel. ~~

Next, perform the air bleeding from the system (page 15-7).
15-6
Brake System
AIR BLEEDING
1. Connect a transparent bleed hose to the left front caliper CD
lower-side bleed valve.
Pump the brake pedal several (5-10) times quickly, then

depress the brake pedal all the way and loosen the bleed
valve.
NOTE
Do not release the brake pedal until the bleed valve has
been closed.
Release the brake pedal slowly and wait several seconds

after it reaches the end of its travel.
Repeat above procedure until air bubbles do not appear in

the transparent hose.
After the air bubbles cease to appear in the fluid, repeat air
bleeding procedure about 2-3 times.
NOTE
Note that you may feel strong resistance on the brake
pedal during pumping to bleed air from the right front
caliper. This symptom is caused by the delay valve
(l!;J
... ~C)j.
function. Be sure to depress the brake pedal fully to the /~':J
bottom. (2) BRAKE PEDAL

Make sure the bleed valves are closed and operate the brake
pedal. If it still feels spongy. bleed the system again.
After bleeding air completely, tighten the bleed valves to the

specified torque.
Torque: 5.5 ra-m (0.55 kg-roo 4.0 ft-Ib)

Fill the reservoir to the upper level line with DOT 4 brake fluid
from a sealed container.
Install the diaphragm, set plate and reservoir cap.
Check the pedal line brake operation (page 3-13).
15-7
Brake System
Brake Pad Replacement

Standard and ABS/TCS Model LBS-ABS/TCS Model
Front Front (4) Pad spring
(3)
r.
,i" .
\i- )
C ..""l :~\
(1) " - - ; ;__
..\.\\
I
.. \ I
\~
2.5 (0.25, 1.8)
, ",',
I', -';', />

(2) , ) (3)
E): 18 (1.8,13) •
•
" "
1
(11
C 2.5 (0.25, 1.8)

(2)
Stopper ring
E): 18 (1.8, 13}
Rear
(4) Pad spring
Rear
...- Stopper ring
(31
(1 )
C 2.5 (0.25, 1.8)

mO 18 (1.8,13)
(2)
E): 18 (1.8,13)
L I
91
:' I r-
(5) Tabs
1,1 I _~
(4} Pad spring
15-8
Brake System
A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc
with a high quality brake degreasing agent.
After replacement, operate the brake lever or pedal to seat the caliper pistons against the pads and check the brake
operation [For front brake pad of the LBS-ABS/TCS model, operate the lever and pedal (page 3-13) 1.
Never use an air hose or dry brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner or alternate method
approved by OSHA, designed to minimize the hazard of airborne asbestos fibers.
NOTE
The brake pads can be replaced without disconnecting the hydraulic system.
Replace the brake pads as a set.
Apply a thin coat of grease onto the pad pin and pad pin plug threads to prevent rust.
Standard and ABS/TCS model:
Procedure D'tv Remarks

111 Pad pin plug 1
121 Pad pin 1
13} P,d 2 NOTE
· Push the pistons all the way in to provide clearance for
the new pads.
· Before installing the pads, make sure that the pad
spring is positioned properly as shown.
LB5-ABS/TCS model'

11} Pad pin plug 1
12} Pad pin 1
13} P,d 2 NOTE
· Push the piston all the way in to provide clearance for
the new pads.
· On the rear pad, be careful not to scratch the rear wheel
hub.
· When installing the inside pad, insert between the tabs
(retainers) of the pad spring and caliper body.
15-9
Brake System
Front Master Cylinder Disassembly/Assembly

012 (5)
(1.2, 9)
(10)
o 35 (3.5, 25)
(2)
et
(6)_~-;--t:~
(3)
(12)
~ : Lever pivot 0
1 (0.1,0.7)
~MIIl---Boot: '91-·94
~ ~ (7) (I)
e:w (14)
o
1 .2 to. 12, 0.9)
0 4 (0.4, 2.9)
(11 )
if) 6 (0.6, 4.3)

1'3)
------....,
(19)
{20)
Standard and ABSjTCS model:
-4' lBS-ABS/TCS model:
15-10
Brake System
Check the brake system by applying the lever brake after air bleeding.
CAUTION
Avoid spilling fluid on painted, plastic. or rubber parts. Place a rag over these parts whenever the system is serviced.
When removing the oil bolt, COverthe end of the brake hose to prevent contamination. Do not allow foreign material to
enter the system.
Do not allow the lips of the master cylinder piston cups to be turned inside out and be certain the snap ring is firmly
seated in the groove.
NOTE
• After assembly, align the index mark on the adjuster with the arrow mark on the joint pin.
Requisite Service
Handlever cover removal/installation (page 13-2}

Front brake fluid draining/air bleeding (Standard and ABSJTCS model: section 17 in Common Service Manual)
Lever brake line fluil draining/air bleeding (LBS-ABS,rrCS model: page 15-2)
Procedure G'ty Remarks

At assembly, check the brake system by applying the brake
after bleeding air from the system.
(1) Brake switch wires 2
(2) Oil bolt 1
(3) Sealing washer 2
(4) Brake hose 1
(5) Master cylinder holder bolt 2
(6) Master cylinder holder 1 Remove the master cylinder assembly from the handlebar.
(7) Brake switch 1
(8) Reservoir cap screw 2
(9) Reservoir cap 1
(10) Set plate/diaphragm 1/1
(11) Brake lever pivot nut 1
(12) Brake lever pivot bolt 1
(13) Brake lever assembly 1
{14} Socket bolt 1
(15) Adjuster arm 1
(16) Brake lever spring 1
(17) Adjuster rod 1 At installation, apply silicone grease.
(18) Adjuster 1
{19} Joint pin 1
{20) Boot 1
(21) Push rod 1 LBS-ABSJTCS model
(22) Snap ring 1 Use snap ring pliers (07914-3230001),
(23) Master piston 1
(24) Primary cup 1 On the LBS-ABS,rrCS model, it is installed onto the piston.
(25) Sprinq 1
15-11
Brake System
Front Brake Caliper Disassembly/Assembly

ABS/TCS model:
Right side:
If) 35 (3.5, 25) /

(1)
'<\~
-------\
(5)
027 (2.7, 20l (9)
Wheel sensor
ew
0 2 3 (2.3, 17)
(14)
(17) 05.5 (0.55, 4.0l
(11 )
(15)
110}
• (10)
02.5 (0.25, 1.8l
(13)
...-'iiSiII
15-12
Brake System
Check the brake system by applying the brake after air bleeding.
CAUTION
• Spilled brake fluid will damage painted, plastic. or rubber parts.
NOTE
• Do not remove the bleed valve unless it is replaced.
Requisite Service
• Front brake fluid draining/air bleeding (section 17 in Common Service Manual)
Procedure Q'tv Remarks

At assembly, check the brake system by applying the brake
(' ) Brake oil bolt , after bleeding air from the system.
(2)
(3)
Sealing washer
Brake hose
2
,
(4) P,d 2 Removal/installation (page 15-8)
,,
(5) Caliper mounting bolt 2 Install the bolt with longer threads at the upper side.
(6) Brake caliper assembly
m Wheel sensor wire clamp bolt
(8) Wheel sensor mounting bolt 2
,
,, .
(9) Wheel sensor CAUTION
Be careful not to damage the wheel sensor.
(10) Pad spring Install as shown.
(11)
(12)
Caliper bracket
Pad retainer ,
(13) Caliper pin bolt boot 2
(14) Caliper pin bolt 2 Do not remove unless necessary.
(15) Caliper piston 2
(16)
(17)
Dust seal
Piston seal ;T .CAUTION
Be careful not to damage the piston sliding surface.
15-13
Brake System
LBS-ABS/TCS Model
Right side:
(5) left side: C 30 (3.0, 22)
0 3 0 (3.0, 22)
~/7-----
./
0 °c ~i'/(
'U'
0
/-. --~ --
{;
r- " / ; '
0/ ':.0. el
/ C
", .'-.j,c,,,-~~
I Q
I
.z
'~',
:''.,,, (,i y.
c 'I"~ nrr
I'
, C I'IC" j 'I';_?'-'. ~~~~
I
"\ o"\\J .",:0'\ i ~
:::;\0' 'I',.,
...-umtt,
,
-:
{51
0 3 0 (3.0, 22)
{6J
{7J
{81
;<"/>"
iV
,'(:: ..
~
C 33 (3.3, 24)
(10)
C 13 (1 .3_,9_J_-Hc'ii
I
(11)
C 2.5 (0.25, 1.8)
LEFT: RIGHT:
I
..-'iiSiIi
Stopper
J
ring
{9J 0 1 8 (1 8 , 13 )
{41
, ~-J- __ ~
(11)
15-14
Brake System
Check the brake system by applying the lever and pedal brake after air bleeding (page 3-13).
CAUTION
• Spilled brake fluid will damage painted, plastic, or rubber parts.
NOTE
Do not remove the bleed valve unless it is replaced.
Reinstall the removed pistons and seals in the original position securely.
After installing the right caliper, check the wheel speed sensor air gap (page 16-B-34).
Requisite Service
• Lever and pedal brake lines fluid draining/air bleeding (page 15-2)

(1) Brake oil bolt 2
(3) Brake hose 2
(4) Pad 2 Removal/installation {page 15-8}
(5) Caliper mounting bolt 2 On the left side, install the bolt with longer threads at the
lower side.
(6) Brake caliper assembly 1
(7) Caliper bracket 1
(8) Pad retainer 1
(9) Pad spring 1 Install as shown.
no: Assembly bolt/caliper body 3/1
(12) Dust seal
(13) Piston seal ;I . CAUTION
Be careful not to damage the piston sliding surface.
15-15
Brake System
Rear Master Cylinder Disassembly/Assembly

Standard model shown:
E:t 35 (3.5, 25)

(ZIe/ (4)
(1)----.,
----
»>
(3)
(,OI------:t:::jril£J (10)
(7)
131
.- (6)
IS"
(8)----
(51
fit 191
(181
1161
IABS/TCSM"';-d-el:1
I
I
I
I
I
I
I
I
I
I
I
I
I
I
"
(12)
I
I I
I I
I I
I I
I I
I I (17)
I I
i
..... I
.J
@--------j(11)
@ E:t 18(1.8, 13)
g
1141
/LJ (15)
(13)
I s ';"OO~ I
15-16
Brake System
• Check the brake system by applying the brake after bleeding air from the system.
CAUTION
• Avoid spilling fluid on painted, plastic, or rubber parts. Place a rag over these parts whenever the system is
serviced.
• When removing the oil bolt, cover the end of the brake hose to prevent contamination. Do not allow foreign material to
enter the system.
Do not allow the lips of the master cylinder piston cups to be turned inside out and be certain the snap ring is firmly
seated in the groove.
NOTE
• Loosen and tighten the oil bolt and master cylinder mounting bolts with the step holder installed.
• The master piston, piston cups and spring must be replaced as a set.
Requisite Service
• Rear brake fluid draining/air bleeding (section 17 in Common Service Manual)
• Right step holder removal/installation (page 2-13)
(1) Oil bolt 1
(3) Brake hose 1
(41 Mounting bolt 2
(5) Reservoir hose joint screw 1
(6) Reservoir hose joint 1
(7) O-ring 1
(8) Cotter pin 1
(91 Joint pin 1
(10) Master cylinder assembly 1
(111 Lock nut 1 Loosen the nut.
(12) Spring pin 1
(13) Push rod joint 1
(14) Boot 1
(15) Snap ring 1 Use snap ring pliers (07914-3230001).
(16) Push rod 1
(17)
(18) I
Master piston/piston cup
Spring I
1;2 I
15-17
Brake System
LBS-ABS/TCS Model
c:
121
35 (3 5, 25)
161
131t!1
,,~ 14I
1151~
11 I
(19}
(1O}
027 (2. 7, 20)
(11)
o
35 (3.5, 25)
(18}
@
(12)
i.~
~
(11) ..... 3513 5,25)
; : " " , zo:
(22)
-'I' i
rl·~·
162 m m ~
1 l§J J?J
1201·' LI_·_i- I
18(1.8,13}
15-18
Brake System
Check the brake system by applying the brake after air bleeding (page 3·13).
CAUTION
Avoid spilling fluid on painted. plastic, or rubber parts. Place a rag over these parts whenever the system serviced.
When removing the oil bolt, cover the end of the brake hose to prevent contamination. Do not allow foreign material to
enter the system.
Do not allow the lips of the cups to be turned inside out and be certain the snap ring is firmly seated in the groove.
NOTE
The master piston, piston cups and spring must be replaced as a set.
Requisite Service
Pedal brake line fluid draining/air bleeding (page 15-2).

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

Before removing the step holder, loosen the master
cylinder mounting bolts.
111 Brake light switch 2P (Black) connector 1
121 Oil bolt 1
13} Sealing washer 3
14} Brake hose 2
{5} Reservoir bolt 1
16} Master cylinder reservoir 1
19} Right step holder bolt 6 mm 1
(10) 8mm 1
(11) 10mm 2
{12} Right step holder 1
{13) Hose joint screw 1
(14) Reservoir hose joint 1
(15) O-ring 1
(16) Cotter pin 1
(17) Joint pin 1
{1S} Mounting bolt 1
(19) Master cylinder assembly 1
(20) Boot 1
(21) Snap ring 1 Use snapring pliers (07914-3230001).
(22) Push rod 1
(23) Master piston/cup 1/2
(24) Spring 1
(25) Lock nut 1 Loosen the nut.
(26) Spring pin 1
15-19
Brake System
Rear Brake Caliper Disassembly/Assembly

o 90 (9.0, 65)
(7)
(91
\\!/I---~~ (I)
35 (3.5, 25)
., (5):---~.elJ
,,
, (2) f!!J
(3)
0 70 (7.0, 51)
(8)--~.J
ew o (6)
27 (2.7, 20)
0 2 8 (2.8, 20)
(14) 0 18(1.8,13) 0 5 .5 (0 .55, 4.0)
2.5 (0.25, 1.8)
(15).
/ .--'iSitI
(131
(121
(131
~
(10)
(4) (11)
(14)
0 1 3 (1.3, 9)
n
iI!ili
15-20
Brake System
A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a conta-
minated disc with a high quality brake degreasing agent.
Check the brake system by applying the brake after air bleeding.
Brake dust may contain asbestos. Inhaled asbestos fibers have been found to cause respiratory disease and can-
cer.
Never use an air hose or dry brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner or alternate
method approved by OSHA, designed to minimize the hazard of airborne asbestos fibers.
CAUTION
NOTE
Requisite Service
• Rear brake fluid draining/air bleeding {section 17 in Common Service Manual)

(I) Brake oil bolt 1
(3) Brake hose 1
(4) Pad 2 Removal/installation (page 15-8)
(5) Caliper stopper pin bolt 1
(6) Rear axle pinch bolt 1 loosen the bolt.
(7) Rear axle nut 1
(8) Rear axle 1
(9) Brake caliper assembly 1 , After removing the caliper assembly, temporarily install
i the rear axle and axle nut.
(10) Pad spring 1
(11) Caliper bracket I 1
(12) Pad retainer 1
(13) Caliper pin bolt boot 2
(14) Caliper pin bolt 2 Do not remove unless necessary.
(16) Dust seat 2 CAUTION
(17) Piston seal 2 • Be careful not to damage the piston sliding surface.
15-21
Brake System
lBS-ABSfTCS model
(8)
o 5 (0 25 1.B)
(6)
0 2 7 (2 7, 20)
2. . ~ 0 28
(2.8. 20) 0 5.5 )0.55, 4.0)
~,."'~~"'~
(12) '. t"~/" ". • (13)
"~'"~ . (2)'.
/!!: .,'10:>.
/
,,
. "I
\------------------------------.
(4)?-~--'-'.;
.
(14)
UP
I
Same 0.0. -
(16)
~.
I
(15)
t1t
(14)
c: 23 (2 3. 17)
(11)
I
(10)
"
'U1!ti
15-22
Brake System
Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent.
Check the brake system by applying the pedal brake after air bleeding (page 3-131.
CAUTION
NOTE
Requisite Service
• Pedal brake line fluid draining/air bleeding {page 15-2)

II) Brake oil bolt 2
)2) Sealing washer 4
)3) Brake hose 2
14) Pad 2 Removal I installation {page 15-8}
15) Caliper stopper pin bolt 1
16) Rear axle pinch bolt 1 Loosen the bolt.
17) Rear axle nut 1
18) Rear axle 1
19) Brake caliper assembly 1 After removing the caliper assembiy, temporarily install the
rear axle and axle nut.
(10} Caliper bracket 1
(11} Pad retainer 1
(12) Pad spring 1 Install as shown.
(13) Assembly bolt I caliper body 3/1
(15) Dust seal 3~ CAUTION
(16} Pistson seal 3~ . Be careful not to damage the piston sliding surface.
15-23
Brake System
Rear Brake Pedal Removal/Installation
(1)
(8)
(7)
~~---13)
16)
.,
12)
(4)
Requisite Service
• Right step holder removal/installation {page 2-13)

11) Rear brake light switch spring 1
12) Cotter pin 1
13) Joint pin 1
14) Brake pedal return spring 1
15) Snap ring 1
16) Washer 1
(7) Dust seal 1
(8) Brake pedal 1
(9) i Dust seal I 1 I
15-24
Brake System
MEMO
15-25
Brake System
Secondary Master Cylinder Disassembly I Assembly (LBS-ABS/TCS model)
til (2)
if) 35 (3.5. 25)
(1 )
(9)
Rubber
.u> til {10)

(4)
0~~~--(3)
n
~
(1)
0 3 5 {3.5, 25}
(7)
0 3 0 (3.0. 22) ~~
(3)
.1(161
0 ' 8 (1.8, 13)

(19) ~ (15}
""~'"
_ 'if
n ,
tw:I
@
(21) .~ I
if)1B{1.8,13}
(20)
c:w (13)' (17)
(14)
.I
15-26
Brake System
Check the brake system by applying the brake after air bleeding (page 3-13J.
CAUTION
Avoid spilling fluid on painted. plastic. or rubber parts. Place a rag over these parts whenever the system is serviced.
enter the system.
Do not allow the lips of the cups to be turned inside out and be certain the snap rings is firmly seated in the groove.
NOTE
The master piston, piston cups and spring must be replaced as a set.
Requisite Service
Pedal brake line fluid draining/air bleeding (page 15-2)

Front fender removal/installation (page 2- 11)

111 Oil bolt 2
12} Sealing washer 4
13} Brake hose 2
14} Oil pipe stay bolt 1
15} Link plate bolt 2
15} Link plate 2
17} Upper caliper pivot bolt 1
IB} Master cylinder mounting bolt 2 Install the bolt with longer threads at the upper side.
19} Secondary master cylinder & link arm assembly 1
(10) Cotter pin 1
(11) Joint pin 1
(12) Link arm 1
(13} Boot 1
(14) Snap ring 1 Use snap ring pliers (07914-3230001).
(15) Push rod 1
(16) Master piston 1
(17) Primary cup 1
{18} Spring 1
(19) Lock nut 1 Loosen the nut.
(20) Push rod nut 1
15-27
Brake System
Delay Valve Removal/Installation (LBS-ABS/TCS model)

C: 17 (1.7,12)
{3)
Check the brake system by applying the pedal brake after air bleeding (page 3-13).
CAUTION
Avoid spilling fluid on painted, plastic, or rubber parts. Place a rag over these parts whenever the system is serviced.
When removing the oil bolt or pipe, cover the end of the brake hose and pipe to prevent contamination. Do not allow
foreign material to enter the system.
Requisite Service
Pedal brake nne fluid drainmq/air bleeding (page 15-2)

Front fender removal/installation (page 2-11)

(1) Oil bolt 2
{2) Sealing washer 4
{3) Oil pipe joint nut 1
{4) Wire stay & hose joint bolt 1
{51 Mounting bolt 2 Install the bolt with longer threads at the upper side"
{51 Delay valve 1
15-28
Brake System
Proportional Control Valve Removal/Installation (LBS·ABS/TCS modell
" ~-
---------------;r- ~. Ii) :
i'~- 5?', (j<- I \,
\ \, -:
~~~~~~~~~~?~~~.;.~:=~~
cj
/
i/
/
II I ,'''
/1 /
{21
{ll
C 17 (1.7,12) {31
Check the brake system by applying the pedal brake after air bleeding (page 3-13).
CAUTION
Avoid spilling fluid on painted, plastic, or rubber parts. Place a rag over these parts whenever the system is serviced.
When disconnecting the oil pipe, cover the end of the oil pipe to prevent contamination. Do not allow foreign material
to enter the system.
Requisite Service
Pedal brake nne fluid draining/air bleeding (page 15-2)

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

{11 Oil pipe joint nut 2 Be careful not to deform the oil pipe.
{21 Mounting bolt 2
{31 Proportional control valve 1
15-29
Symbols
...

~
C
10 (1.0, 7.2)
~
equivalent)
equivalent)

"I~ Apply sealant

16-A. ABS ('92 - '95)
Service Information 16-A-1 Troubleshooting 16-A-5
System location 16-A-2 Wheel Sensor Air Gap Inspection 16-A-51
System Wiring Connections/Locations 16-A-3 Front Modulator Removal/Installation 16-A-52
Circuit Diagram 16-A-4 Rear Modulator Removal/Installation 16-A-54
Service Information
CAUTION
Use a fully charged battery for troubleshooting. Do not diagnose the ABS with a charger connected to the battery.
On removal and installation of the wheels and wheel sensors, be careful not to damage the wheel sensors and'
pulser rings.
NOTE
Check the following before performing any ASS troubleshooting.
- Pre-start self-diagnosis of ABS
- ABS indicator light
If an abnormality is found during the above checks, perform the ASS troubleshooting following the Symptom-to-
System Chart (page 16-A-8). The ASS is normal if no trouble is found. Go to the checks on the other basic systems (e.q.,
brake system).
Troubles not resulting from a faulty ASS, i.e. brake disc squeak, unevenly worn brake pad, etc., cannot be recognized by
the ASS diagnosis system. (See the Common Service Manual.)
Record the symptom ofthe problem and the problem code in MEMO before troubleshooting.
When the ASS is faulty, the ASS indicator light blinks or it comes on. The ASS does not function at this time; take care
during the test ride.
Do not disassemble the modulator assembly. If it is faulty, replace it as an assembly.
After replacing the modulator, bleed air from the brake fluid according to the standard air bleeding procedure. Note that
replacement and bleeding air from the brake fluid is not possible, as it is sealed in the modulator.
When the rear wheel sensor or rear pulsar ring is replaced, perform the air gap inspection (page 16-A-51).
The ASS indicator light might blink in the following cases. If the indicator light blinks, clear the problem code and l'1:li.
perform the pre-start self-diagnosis of the ASS (page 16-A-5). The ASS is normal if the ASS indicator light goes oft.
- The motorcycle has continuously run on the bumpy road.
u:.
- The ASS control unit (ECU) was disrupted by extremely powerful radio wave (Electromagnetic Interference).
- After riding {i.e. after the pre-start self-diagnosis), the engine was kept running and the rear wheel turning (for more
than 30 seconds) with the motorcycle on the center stand.
The ASS indicator light might blink in the following cases. If the indicator light blinks, service the faulty parts, clear the
problem code, and perform the pre-start self-diagnosis of the ASS (page 16-A-5). The ASS is normal if the ASS indicator
light goes off.
- Incorrect tire pressure
- Tires not recommended for the motorcycle were installed.
- Deformation of the wheel
After troubleshooting, clear the problem code and perform the pre-start self-diagnosis again to be sure that the ASS
indicator light is operating normally.
16-A-1
ABS ('92 '95)
System Location
(7) ASS INDICATOR LIGHT 2

(5) IGNITION SWITCH
(9) ASS CONTROL UNIT{ECU)

(4) AB5/TCS INDICATOR LIGHT SWITCH
(10) PUMP MOTOR

(3) BATTERY
(11) LIMIT SWITCH
(2) ASS FUSE CASE
(l) REAR WHEEL

SENSOR
(12) SOLENOID VALVE

( 13)
FRONT PUMP MOTOR RELAY
(14)
REAR PUMP MOTOR RELAY
(15) ASS MAIN RELAY
(20)
REAR PUlSER RING
(19) REAR MODULATOR

(18) FRONT MODULATOR
(16l FRONT PULSER RING
16-A-2
System Wiring Connections/Locations ,~; ABS/TCS INDICATOR
LIGHT SWITCH :); ASS INl
CD REAR LIMIT SWITCH -Top shelter -Inner S(
-R. side cover (page 2-2) (page 2-5) (page 2-
. Refer to section 2, (frame/body
panels/exhaust system), for the parts
that must be removed for sevice.
MJ
For example: (~)
ABS/TCS INDICATOR ,
LIGHT SWITCH ABS FUSE CASE
e-Maintenance part -L. side cover (page
-Top shelter' The parts
___-~_2-21
that must be removed for
service.
ASS MAIN (lOA)

FRONT SOLENOID (1 GAl
REAR SOLENOID (lOA)
PUMP MOTOR (20A)
@GROUND TERMINAL
-R. side cover (page 2-2)
/
,j]) FRONT PUMP
-Upper fairing
t4J REAR PUMP MOTOR (page 2-9)
-R. side cover (page 2-2)
~ __---L_, r:_ _---' ,~-_
Bl BLACK Br BROWN
Y YELLOW 0 ORANGE
(~) ~
Bll BLUE Lb UGHTBLUE
G GREEN Lg UGHTGREEN PI iW, o~
W IP BI
R RED P PINK
W WHn:E Or GRAY {~, FRDr
'l} REAR SOLENOID VALVE J2: REAR WHEEL SENSOR
-R. side cover (page 2-2) -R. side cover (page 2-2) -uoo
(page
ABS ('92-'95)
'S: INDICATOR CONTROL UNIT

llCATOR LIGHT 2 :1:: ASS INDICATOR LIGHT 1 -L. fairing pocket
Teen -Inner screen (page 2-6)
7} (page 2-7)
~ I~I (~) INDICATOR (BLACK)

-Inner screen (page 2-7)
X L~B1
Y;Gr GfSI
o: INDICATOR (WHITE)
@FRONT PUMP MOTOR RELAY
s,
-Upper fairing (page 2-9)
,-,
B7y
Rlsr %u
t]) REAR PUMP MOTOR RELAY

r-r-r
B~p B~L9
R/ R/
Sr Su
@lABS MAIN RELAY

@ECU {BLACK}
{~GROUND
TERMINAL (f" ECU (WHITE)
-Upper fairing (page 2-9}
-Upper fairing
(page 2~-..:9..:)_ _-,- -,
~ [~) ~ ($I$J
IT WHEEL SENSOR @FRONT LIMIT SWITCH
er fairing :J.:¢ FRONT SOLENOID VALVE -Upper fairing
2-9) -Upper fairing (page 2-9)
(page 2-9}
16-A-3
ABS ('92-'95)
Circuit Diagram
PUMP MOTOR RELAY ASS FUSE
(FRONT) (REAR) BOX
MAIN~~~rm~
1 2 3 4 1: 1QA REAR SOLENOID
ABS 2: 2QA PUMP MOTOR
RELAY ~TTIT%:rr=rr%: 3: 10A FRONT SOLENOID
4: lOA ASS MAIN
!1:: sea:;
;::(:J,, c,il..5'<i5
.--.-"-" ~~~.ii
0>"-
m" a1Cl:c3O:: III a: III c:: Ci "(,'J - ~

:::0 ~ :::0 a:E'2. !!?
m"m
""
BlfGr~
BI/Gr_
O!G_
P/BI..-04
BI/G----4
I
BlfGoooo4
alBI_
PN/-
Bu/P_
Br/Lg_
Bu/Lg_
BrlY_
Bu/Gr ...
ASS CONTRe
G/_
Gr/R-
I~
iiic..~ Q tD
>
iiim~
,@,
e,
~~~~
I""
~ N
m
sss
l(:J
os:li:
c..
9~
E!:
l~ ~C
LIMIT CONNECT(
PUMP- SWITCH . - 81
MOTOR o-w
SOLENOID
VALVE REAR MODULATO R
FRONT MODU LAT OR
16-A-4
61 BLACIt ; S, BROWN
Y YELLOW 0 ORANGE
Su ~(Lb' LIGHT6LUE MAIN FUSE 30A
G ~REEN Lg LIGHT GREEN
R RED P PIN It
W WHITE cr GRAY
o 4P
(!)
BATTERY
e
I
STARTER{" -
SYSTEM _-----I
---+I "
=====+:t-_ ----LJ$'p-w
== 'I
1
t"
==eRJJ[R..l:J ,GN'T'ON
R/BI1lfR/BIt.:..J SWITCH
;>--R/Br-
G/SI I'ND'CATOR
~Gr/.~"==l~;;~~~;~~~!~~~~~~~~~~;;:~BI
L...-R/BI~BI/B, Bl/Br
p
CONTROL
UNIT
2P_BI
I l - - L g / O . - - - - - ...... TCS 4P-BI
2P-R
:0 :J [ ~g::I~
l UNIT {ECU) 4P-W ABS INDICATOR
2P-BI ~lIGHT 2
"':l
~G/O
:J L G: IBu
9P-W
ABS INDICATOR
LIGHT 1
~G/Gr
~BI/O
>-Bu/G
~G/O
~BI/P
~G,/YJ..-E3-1
INDICATOR LIGHT
SWITCH
WHEEL SENSOR
ABS 1'92-'95}
Troubleshooting
Before Beginning Troubleshooting:
Summary of ABS pre-start self-diagnosis system

The ASS pre-start self-diagnosis system diagnoses the electrical system as well as the hydraulic system operation in the
modulator. When there is any abnormality, the problem and the problem part can be detected by outputting the problem
code.
After starting the engine, the ASS pre-start self-diagnosis system operates the pump motor and solenoid valve inside the
modulator, checks the limit switch ON/OFF condition with the ECU and detects whether the hydraulic operation is normal.
Then, the diagnosis system enters the stand-by phase for receiving the signal from the wheel sensor, and it completes the
pre-start self-diagnosis when the wheel sensor signal is input in the ECU at approximately 10 km/h (6 mile/h) or more of
the vehicle speed.
If the ASS is normal, the ASS indicator light goes off just after starting the engine and the motorcycle is in motion indicating
that the dignosis is completed.
If a problem is detected, the ASS indicator light blinks or comes on and stays on to notify the rider of the problem.The
self-diagnosis is also made while the motorcycle is running, and the indicator light blinks when a problem is detected.
When the indicator light blinks, the cause of the problem can be identified by retrieving the problem code following the
specified retrieval procedure. (page 16-A-6)
PRE-START SELF-DIAGNOSIS WHEN NORMAL
IGNITION SWITCH ~F~::Jr---------------
ENGINE RUN:~~~ r
r
m- m n----
mu---- START
o o km/h (6mile/h) or above

VEHICLE SPEED
ON -----------.-------------
PUMP MOTOR
OFF ---------'
SOLENOID VALVE O~~ -nnumummnmm-muJU1JlL- L
ABS INDICATOR
LIGHT 1, 2
~~F-~ L
Pre-start self-diagnosis completes
Pre-start self-diagnosis procedure (Everyday check-up)

1. Turn the ignition switch ON.
2. Be sure that the ABS indicator lights 1 and 2 come ON.
3. Start the engine.
4. Ride the motorcycle and raise the vehicle speed to approximately 10 km/h (pre-start self-diagnosis completes).
5. The ASS is normal if both the ASS indicator lights 1 and 2 go off.
,
Tee I[ A iii s 110lL
II
ASS INDICATOR LIGHT 1 ASS INDICATOR LIGHT 2
16-A-5
ASS 1'92-'95)
Retrieval of/Clearing Problem Code ABS/TCS INDICATOR LIGHT SWITCH
NOTE
The ASS indicator light indicates the problem code by
its number of blinks {see the next page).
The problem code is not cleared when the ignition
switch is turned OFF during output of the problem
code. However, output cannot be restarted by turn- -,
ing the ignition switch ON. Restart the output follow-
ing the problem code retrieval procedure.
After retrieving the problem code, be sure to record it
in MEMO, etc. Clear the problem code after trouble-
shooting.
res
\
ON/OFF SWITCH
\
Retrieval:
1. Turn the ignition switch OFF.
2. Turn the ignition switch ON while pressing the ASS/
res indicator light switch. The ASS indicator light 1
and 2 should come ON.
3. Hold the ABS/TCS indicator light switch pressed (for
approximately 5 seconds). The ABS indicator light 1
and 2 should go OFF.
4. Release the ABS/TCS indicator light switch immdiately
(within 1 second) after the ABS indicator light go OFF.
s I~
~> Output of the problem code starts and the ABS indica-
tor light 1 blinks. (The ASS indicator light 2 is OFF
\
this time.)
Clearing:
5. Press the ASS/TCS indicator light switch during
ABS INDICATOR LIGHT 1
\
output of the problem code (while the ASS indicator

lignt is blinking).
=? The Problem code is cleared and the ASS indicator
light 1 and 2 comes ON and stay ON.
Turn ignition switch ON Release indicator light switch immediately

while pressing (within 1 eec.I Problem code
indicator light switch. after ASS indicator lights go OFF. clearing signal
~ ~
,,
ABS/TCS
INDICATOR
LIGHT SWITCH :~~::sej L.- ---.JrL
IGNITION SWITCH
ON
OFF
==J-----+----------- ON---+OFF
Blinking
ASS INDICATOR ON
LIGHT 1 OFF ,,
ASS INDICATOR
ON :::::::::J I ,
LIGHT 2 OFF =.=:o+--+-+-+-H--+--+--+-
i-.------.J
Release of modulator internal
i
pressure (Solenoid valve
operation sound}
!-!
Problem code L .J
start signal Latest
problem
code
L
Previous time
problem code
16-A-6
ABS ("92-'95)
Problem code indication pattern
Example:
• When the problem code is stored;
Latest problem Previous time Latest problem code

t problem code
Problem code start signal code
~pmbl",m code: •
Problem code:
6
t
Problem code:
2
ASS indicator light 1 ON-------·---·-----·--- r-- r--.r--z:-~'r--~r---
o Pattern repeated
-----=-1
/>--t-tt---
ASS indicator light 1 OFF
3 ,"0 .
Release ASS(TCS indicator light switch. 0.3 sec.
~--0.2 sec.
When the problem code not stored;
Problem code start signal

No output of code
ASS indicator light 1 ON __.. ----- ----------
OPe ttern repeated
.>
Release ASS(TCS indicator light switch.
~ 3 sec.
NOTE
The ECU can store up to two problem codes. The latest problem code is output first, then the previous one is output,
When the two problem codes are output, diagnose on the latest problem code (i.e. code output first).
After troubleshooting, perform the pre-start self-diagnosis again to be sure that there is no problem in the ASS indicator
lights and the problem code is cleared.
See page 16-A-46 for the problems that are not represented with the problem codes.
Check the following before performing ASS troubleshooting:
- Pre-start self-diagnosis of ASS
- ASS indicator light
If an abnormality is found during the above checks, perform the ASS toubleshooting following the Symptom-to-
System Chart (see the following page). The ASS is normal if no trouble is found. Go on to the check the other basic
systems (e.g., brake system).
16-A-7
ABS ('92 '95)
Symptom-ta-System Chart
Problem Affected
Fuse Modulator
-c
-c
,-
.- ••,e. ,s
0
:;; -u o0 J> e,
,• ro •a
0
,"'0 -
-c 3 0 C J> ~ 0 ~
,-e 0 ~
3 ro •"- "' •
"'0, 3 ". "'3 ,•• ~ 3' •0, •
• ,Q. s n
0 -c 0 3 ;;
sr J> 0 -c 0
0
•s S·
c, ,n0;
0
3 Item
ro 3
"'3 -c 0 3 ,<1 "•z
e ,••
"o 0; •,
~
0
~
0
" •3 -m". •,• ,•Q.

0
•
n
0
c,
• ••,
3
0
,•
0
"
0
,•
0 0;
s-
-c
•
~
..
<
0
0-
•
0
.c•, •• -c:o ". , •

~
~
0
~
0
~
~ ~ -n ~ -n ~ ~ ~ ,-n ~ -n ~ -n ~
• ".
, ,• , ••,
"3 •, ,• ••,
<e-
, ,•o , ••, , ••,
"• "• "• 0 0
"• " •
0
Faulty front hydraulic

{1) pressure circuit system 0 0 0 0 0 0 16-A-9
Faulty rear hydraulic

$ pressure circuit system 0 0 0 0 0 0 16-A-16
Faulty front hydraulic

W control system 0 0 0 0 0 0 16-A-23
Faulty rear hydraulic

0 control system 0 0 0 0 0 0 16-A-30
Faulty front wheel speed

W sensor system , 0 0 0 0 16-A-37
Faulty rear wheel speed ,

$: sensor system 0 0 0 0 16-A-4{)
0 Faulty ASS main relay , 0 0 01 16-A-43
$: Faulty power circuit 0 0 16-A-45
,
0: Faulty control unit (ECU) 0 16-A-45
Problems not recognized

~ by control unit (ECU) 0 , I 0 0 0 0 0 16-A-46
NOTE
Check the following before periorming ASS troubleshooting.
- Pre-start self-diagnosis of ASS (page 16-A-5)
- ABS indicator light (page 16-A-5)
If an abnormality is found during the above checks, perform the ABS troubleshooting following the Symptom-to-
System Chart. The ABS is normal if no trouble is found. If no trouble is found, continue on to the other basic system
checks (e.g .. brake system).
After troubleshooting, clear the problem code (page 16-A-6} and perform the pre-start self-diagnosis again (page
16-A-6) to be sure that the ABS indicator light is operating properly.
16-A-8
ABS ('92-'95)
Flowcharts
NOTE
Turn the ignition switch OFF unless otherwise specified.
When the control unit {ECU) or modulator is detected to be faulty, recheck the wire harnesses and connectors
connections closely before replacing the control unit or modulator.
After troubleshooting, perform the pre-start self-diagnosis again and be sure that the ASS indicator light is normal.
The encircled numbers in the text and connector diagrams indicate the connectors (see page 16-A-3).
Problem code 1: Faulty front hydraulic pressure circuit system
After starting the engine (before riding the

motorcycle), check the ASS indicator light.
Light stays on.

Normal
(Temporary problem: Fine foreign matter in the
Light blinks.
modulator or the ECU has been disrupted by an
extremely powerful radio wave.)
NOTE
There are two types of modulator pre-start
Restart the engine and check for the pre-start self-diagnosis sounds; one is the intermittent
self-diagnosis sound (Le.. motor sound)from the clattering sound of the solenoid valve opera-
front and rear modulators right after the engine tion sound, and the other is the continuous
starts. beep of the pump motor operation sound.
Motor sound in b oth

Is there a motor sound in the front and modulators.
(Go to page 16-A-12)
rear modulators? /
No
I I
No motor sound in either No motor sound in
modulator the front modulator
I IL .. (Go to the following page.)
ASS FUSE CASE

I Turn the ignition switch OFF. I
Check the pump motor fuse in the ASS fuse I

I case. I
Burned out.
Is the fuse normal?
Normal
Disconnect the pump motor relay connectors Q) I

I and @.
(Continue to the following page)
16-A-9
ABS 1'92-'95)
View from terminal side.
(From the previous page: Disconnect the pump
®t!f~
motor relay connecrors rs: and @'.)
Check for voltage between the pump motor relay
~
connector C§) and :];. terminals and the body
ground respectively.
No battery
voltage
< Does battery voltage register? Repair open in the RED or RED/BLUE harnes-
ses between the battery and pump motor relay.
Battery voltage
Check the harnesses and connectors for secure

connection (page 16-A-3).
(From the previous page: No motor sound in the

front modulator)
Turn the ignition switch OFF.
Interchange the front ,"d rear pump motor

relays with each other.
: Start the engine. Check whether the front and

I rear pump motor sounds interchanged with each
other.
Did the pump motor sounds interchange? \ Interchanged.

• Faulty pump motor relay
(No motor sound in the rear pump motor?) /
Did not interchange.
I Turn the ignition switch OFF.
View from terminal side

(jJ;
Disconnect the pump motor relay connector ~8)
and the BLACK connector [C' of the ECU.
I I I
I I
-
Check for continuity between the pump motor
relay connector co
terminal and the BLACK con- ->
BLUE/LIGHT GREEN
nector @ terminal of the ECU.
BLUE/LIGHT GREEN
j
16-A-10
ABS ('92-'95)
(From the previous pagel

I No continuity
Is there continuity? Repair open in the BLUE/LIGHT GREEN har-
Continuity ness between the pump motor relay and ECU.
I '/
I Disconnect the pump motor connector@.
cE· ;*i~~",t"'J~
'I 1,/;1 If;.
\'1'
,:/y"
EB
I

relay connector @ terminal ,nd pump motor BROW N/YELLOW
connector <1$ terminal.
BRQWN/yELLOW
< Is there continuity?

No continuity
I'--~
®n 1--------"
Repair open in the BROWN/YElLOW harness
between the pump motor relay and pump
Continuity
motor.
Install the pump motor relay connector ,~, pump

motor connector@andthe BLACK connector it
of the ECU.
! Start the engine and check the front pump motor

, relay for a clicking sound at the relay contact
I point.
Sound
< Is there a clicking sound in the relay? • Faulty modulator
No sound
• Faulty ECU
16-A-11
ABS 1'92-'951
(From page 16-A-9: Motor sound in both modu-

lators]
Front motor
sound does not
stop.
j
(Go to page
16-A-14.)
I
j
j
Interchange the front
end rear pump motor I
j
Start the engine. Did the front and rear motor \ Interchanged.
sounds interchange with each other? /
Check the modulator limit switch connector @

for secure connection.
Poor connection
< Is it connected securely? • Connect securely and recheck.
Secure connection

~
I
I Disconnect the limit switch connector @'. I
I GRAY/RED GREEN/PINK
Start the engine. Check for continuity between
the switch side terminals of the limit switch
connector @ during pump motor rotation (see
page 16-9). W
No continuity
Is there continuity during pump motor rotation? Repair open in the limit switch side GRAY/RED
or GREEN/PINK harness.
Continuity Faulty modulator
I Clear the problem code. I
I
16-A-12
ABS ('92-'951
(From the previous page)
j
I Turn the ignition switch OFF. I View from terminal side
Connect the main harness side terminals of the

limit switch connector @ with a piece of jumper
wire.
WIRE
Perform the pre-start selt-diaqnosis and retrieve
the problem code.
Problem code "3"

< Is the problem code "3"? Check the harnesses and connectors for secure
connection (page 16-A-3l.
Problem code 1 M H
I Disconnect the WHITE connector @ofthe ECU. I I@
While connecting the main harness side termi- GRAY/R~EEN/PINK

nate of the limit switch ccnnectcr -J» with a
jumper wire, check for continuity between the
WHITE connector eft' terminals cif the ECU.
No continuity
Continuity
Repair open in GRAY/RED or GREEN/PINK
harness between the ECU and modulator (limit
switch) .
• Faulty ECU
16-A-13
ABS ('92-'95)
(From page 16-A-12: Front motor sound does

not stop.)
I
Turn the ignition switch OFF. I
Interchange the front ,nd rear pump motor

• Faulty motor relay
BLUE/LIGHT _BROWN/YELLOW
Disconnect the pump motor relay connector ,]) GREEN
and BLACK connector @ of the ECU.
n
relay connector ~ terminals and body ground
respectively.
Continuity
< Is there continuity? Repair short in the BLUE/LIGHT GREEN or
BROWN/YELLOW harness between the pump
No continuity
motor relay and EeU.
• Faulty ECU
16-A-14
ABS ('92 '95)
(From page 16-A-12: Motor sound is normal
Interchange the front and rear pump motor

Perform the pre-start self-diagnosis and retrieve

the problem code.
Problem code '·2--

< Is the problem code ~2"?
Problem code ~ 1"

Faulty front pump motor relay
I Turn the ignition switch OFF. I @
Disconnect the pump motor relay connector ':E'

and WHITE connector@ofthe ECU.

relay connector ® and WH ITE connector :g of
the ECU.
No continuity
< Is there continuity? Repair open in the BROWN!YELLOW harness
between the pump motor relay and ECU.
Continuity
Disconnect the front and rear modulator pump rs':
~~OWN/YELLOW
motor connectors -T$ and ifq,.
~
relay connector .:§::: and body ground.
Continuity
< Is there continuity? Repair short in the BROWN!YELLOW harness
No continuity between the pump motor relay and ECU
• Faulty ECU
16-A-15
ABS ('92-'95)
Problem code 2: Faulty rear hydraulic pressure circuit system
After starting the engine {before riding the

motorcycle}. check the ASS indicator light.
light stays on.

<Does the ASS indicator light blink or stay on? Norna! (Temporary problem: Fine foreign mat-
light blinks. ter in the modulator or the ECU has been
disrupted by an extremely powerful radio wave.)
NOTE
Restart the engine and check for the pre-start There are two types of the modulator pre-
self-diagnosis sound (i.e., motor sound) from the start self-diagnosis sounds; one is the inter-
front and rear modulators right after the engine mittent clattering sound of the solenoid valve
starts. operation sound, and the other is the continu-
ous beep of the pump motor operation
sound.
Motor sound in both

15 there a motor sound in the front and rear modulators.
(Go to page 16-A-19.)
modulators? /
No
I I
No motor sound in either No motor sound in the
modulator. rear modulator.
I -----------~ (Go to the following page.)
I
ASS FUSE CASE
O~
Check the pump motor fuse in the ASS fuse I
10=·
-'
PUMP MOTOR FUSE (20A)
I case. I , ,
(=====~;;;;~~~~~i':=====:::;~--"""'."':'...':~:-_-'
Burned out.
Is the fuse normal? Replace the fuse and recheck.
Normal
I
D i sc ~ ~ n e ct the pump motor relay connectors ,j~: I
and ~!Jl;. I
16-A-16
ABS ('92-'95)

(From the previous page: Disconnect the pump
motor relay connectors ® and @l,)
®Eq®
RED/BL~
o
Check for voltage between the pump motor relay
connector ® and ® terminals and the body
ground respectively.
No battery voltage
( Does battery voltage register? Repair open in the RED or RED/BLUE harnes-
Battery voltage ses between the battery and pump motor relay.
Check the harnesses and connectors for secure

connection (page 16-A-31.
(From the previous page: No motor sound in the

rear modulator.)
I
Interchange tho front 'nd rear pump motor

IStart the engine. Check whether the front and

Irear pump motor sounds interchanged with each
other.
Did the pump motor sounds interchange? (No \ Interchanged.

motor sound in the front pump motor?) /
, Turn the ignition switch OFF.

Disconnect the pump motor relay connector .;£
~E8
QJ;
and the BLACK connector @ of the ECU.

relay connector ® terminal and the BLACK con- BLUE/~E/PINK
nector @ terminal of the ECU.
I
{Continue to the following paqel
16-A-17
ABS ('92-'95)
j No continuity
Is there coutinuity? Repair open in the BLUE/LIGHT GREEN har-
Continuity ness between the pump motor relay and ECU.
Disconnect the pump motor connector @. Vie w from terminal <::::S~~;'!!!Jlf0~"-

I I side @c,. --';______
_~_
."'?~~
" ' - -__ ,7----" ,,_ ""

relay connector ':ID terminal and pump motor
®9~'@f~~T
connector ® terminal. B ROWN/L1GHT GREEN BROWN/LIGHT GREEN
I ~ I
No continuity
( Is there continuity? Repair open in the BROWN/LIGHT GREEN
Continuity harness between the pump motor relay and
pump motor.
Install the pump motor relay connector ®. pump

ee
motor connector ano the BLACK connector (jJ)
of the ECU.
j
Start the engine and check the front pump motor
relay for a clicking sound at the relay contact
point.
Sound
< Is there a clicking sound in the relay? • Faulty modulator
No Sound
• Faulty ECU
16-A-18
ABS {'92-'951
(From page 16-A- 16. Motor sound in both modu-

lators. )
I I
Rear motor sounds for Rear motor sound does Motor sound is normal.
approximately 5 sec- not stop. (It stops within 3 sec-
onds, then it stops. (Nor- onds.)
mally, it should sound for I
approximately 3 sec- (Go to page 16-A-21). (Go to page 16-A-22).
onds.)
I

j
: Interchange the front eod rear pump motor
i relays with each other.
I
• Faulty punp motor relay
Did not interchange
ICheck the modulator limit switch connector CD

for secure connection.
I Poor connection
< Is it connected securely?
Secure connection
Connect securely and recheck.
I
I
Disconnect the limit switch connector
I
CD. I
~
GRA Y/ORANGE GREEN/BROWN
W
Start the engine. Check for continuity between
the switch side terminals of the limit switch
connector ,:]j during pump motor rotation {see
page 16-16)
No continuity
(Is there continuity during pump motor rotation? • Repair open in the limit switch side GRAY/
ORANGE or GREEN/BROWN harness.
Continuity
Faulty modulator
Clear the problem code. I

I
16-A-19
ABS 1'92-'951
I
CD
Connect the main harness side terminals of the
limit switch connector CD with a piece of jumper
wire.

the problem code.
~ JUMPER WIRE
Problem code ~4"

( Is the problem code "4";' Check the harness and connector for secure
connection {page 16-A-3).
Problem code "T
I Turn the ignition switch OFF. 1 View from terminal side
©I
I Disconnect the WHITE connector@ofthe ECU. I
While connecting the main harness side termi- G RAY/ORANGE GREEN/BROWN

nals of the limit switch connector CD with a
jumper wire, check for continuity between the
WHITE connector@terminalsofthe ECU. l@J
No continuity
< Is there continuity? Repair open in the GRAY/ORANGE or GREEN/
BROWN harness between the ECU and modu-
Continuity
lator (limit switch) .
• Faulty ECU
16-A-20
ABS ('92 '95)
(From page 16-A-19: Rear motor sound does not

stop.)
I
Interchange the front ,nd rear pump motor

( Start the engine. Did the front and rear motor Interchanged.
Faulty motor relay
B
Disconnect the pump motor relay connector ®
and BLACK connector 'CD: of ECU.

relay connector :E. terminals and body ground
respectively.
Continuity
< Is there continuity? Repair short in the BLUE/PINK or BROWN/
LIGHT GREEN harness between the pump
No continuity
motor relay and ECU .
• Faulty ECU
16-A-21
ABS ('92-'95)
(From page 16-A-19: Motor sound is normal.)
Interchange the front and rear pump motor


the problem code.
Problem code" 1"

< Is the problem code" 1 N?
Problem code "2"

) c - - - - - - - _ . . . Faulty rear pump motor relay

{g,
Disconnect the pump motor relay connector l~

and WHITE connector @ of the ECU. ~t±] BROWN/LIGHT GREEN
BROWN/LIGHT G R L @ - - J
relay connector (~) and WHITE connector @ of
the ECU.
No continuity
< Is there continuity? Repair open in the BROWN/LIGHT GREEN
harness between the pump motor relay and
Continuity
ECU.
Disconnect the front and rear modulator pump

motor connectors@ and >2q,.

relay connectcr rg: and body ground.
I Continuity
< Is there continuity? Repair short in the BROWN/LIGHT GREEN
harness between the pump motor relay and
No continuity
ECU.
• Faulty ECU
16-A-22
ABS ('92-'95)
Problem code 3: Faulty front hydraulic control system
Turn the ignition switch ON {but do not start the

enginel and check the ASS indicator light 1 and
2.
Does the ASS indicator light blink or come Light blinks. Retrieve the problem code and record it. Clear
on and stay on? - I the problem code.
Light stays on.

Start the engine. Check the ASS indicator light
before riding the motorcycle. 1
Perform the pre-start self-diagnosis (including

riding the motorcycle) and check the ASS indica-
Light stays tor light.
<Does the ASS indicator light blink or stay on? 00.
Light blinks. Light goes

OFF.
1< Does the ASS indicator light blink or go off?
Light blinks
1
Turn the ignition switch OFF. 1
(Appears repeatedly).
IJ Retrieve the problem code again and clear the

problem code.
y Turn the ignition switch OFF. 1
.
I
Check the harness and connector for secure
connection (page 16-A-3 I
! Check the solenoid fuse in the ASS fuse case. I (Go to page 16-A-2B.)
j
Burned out. .
< Is the fuse normal?
Normal
Replace the fuse and recheck.
ABS FUSE CASE
! Start the engine. Check the ABS main relay for a

! clicking sound at the relay contact point immedi-
FRONT SOLENOID ____
FUSE
[nc:=:J
Lj
i ately after starting the engine.
0
1 I
1 1
Sound
< Is there a clicking sound in the relay? (Go to page 16-A-25.)
No sound
(Continue the following page)
16-A-23
ABS 1'92-'95)
(From the previous page) HEADLIGHT RELAY
j
Disconnect the ASS main relay connector@land
connect the headlight relay instead.
Restart the engine. Check the ASS indicator

light 1 and 2 before riding the motorcycle.
Ught stays on.

< Does the ASS indicator light blink or stay on? Faulty ASS main relay
Light blinks.
,---1E
Disconnect the ASS main relay connector @
from the headlight relay.
RED/BROWN
~
Turn the ignition switch ON. I
Check for voltage between the ASS main relay

connector@)terminal and body ground.
No battery voltage
< Does battery voltage register? Repair open in the RED/BROWN harness
Battery voltage between the ABS main relay and ABS main
fuse.

Connect the ASS main relay connector rin to the (iJ)
~BLUE/GRAY
ASS main relay and disconnect the BLACK con-
nector @ of the ECU.
~
Check for voltage between the BLACK con-

nectcrqe terminal of the ECU and body ground.
No battery voltage
< Does battery voltage register? Repair open in the BLUE/GRAY harness
j Battery vclteqe between the ABS main relay and ECU.
Faulty ECU
16-A-24
ABS ('92-'95)
(From page 16-A-23: Operation sound in the

ASS main relay.)
I View from terminal side
tom
Disconnect the ASS main relay connector@and

solenoid valve connector @. WH'TE/P~'TE/P'NK
Check for continuity between the ASS main

relay connector@)terminal and the main harness
side terminal of the solenoid valve connectorqc.
No continuity
( Is there continuity? Repair open in the WHITE/PINK harness
Continuity between the ASS main relay and modulator
(solenoid valve).
@ rIl View from terminal side
Check for continuity between the ASS main OJ.GREEN
~
relay connector @) terminal and body ground.
No continuity
( Is there continuity? Open harness between the ASS main relay and
modulator ground terminal@, or poor ground-
Continuity
mq ,
Install the ASS main relay connector @ and

solenoid valve connector@.
I
Retrieve the problem code. Check whether the
valve operation sound (i.e., clattering sound] can
be heard for approximately 3 seconds before the
problem code appears.
Operation sound
( Is there the operation sound? Go to page 16-A-27
No operation sound
16-A-25
ABS ('92-'95)
{From the previous page}
J]"_,_F::;:=:;==j_,",,
Disconnect the solenoid valve connector :[4 and
BLACK connector .:It of the ECU,
rE
ORANGE! GREEN ORANGE/GREEN
Check for continuity between the main harness

side terminal of the solenoid valve connector @
and BLACK connector @ terminal of the ECU.
I -----1@1
No continuity
< Is there continuity? Repair open in the ORANGE/GREEN harness
between the modulator (solenoid valve) con-
Continuity
nector and ECU.
I Turn the ignition switch ON. I

BLAC
Check for voltage betwen the BLACK connector

,g. terminals of the ECU and body ground respec-
tively.
No battery voltage
Does battery voltage register? Repair open in the BLACK/GRAY or RED har-
Battery voltage ness between the ECU and battery.
! Connect the valve side terminals of the solenoid

WHITE/PINK
ORANCllCREEN ,j,
OJ m
W
valve connector ':11; to the battery terminals.
I ORANGE/GREEN: Positive (+)
i WHITE/PINK: Negative(-)
(±J 8
BAITERY
When connecting, is there the valve opera- ND operation sound

Repair open in the ORANGE/GREEN or
tion sound (i.e., clattering sound)? / WHITE/PINK harness of the valve solenoid.
Operation sound Faulty modulator
• Faulty ECU CAUTION

Connect to the battery terminals securely.
Be sure not to connect to the battery termi-
nals for more than 5 seconds continuously.
16-A-26
ABS 1'92-'951
(From page 16-A-25: Valve operation sound.)

j View from terminal side
After checking the operation sound, turn the

ignition switch OFF ,nd disconnect the limit flrr=Tli
~N/PINK
switch connector @.
Check for continuity between the switch side

GRAYl@J
terminals of the limit switch connector@.
Continuity
( Is there continuity? Faulty modulator
No continuity
I Disconnect the WHITE connector 01:' of the ECU.
GRAY/RED~
side terminal of the limit switch oonnector qp and
body ground.
n
Continuity
( Is there continuity? Repair short in the GRAY/RED harness
between the ECU and limit switch connector.
No continuity
• Faulty ECU
16-A-27
ABS ('92-'95)
(From page 16-A-23: ASS indicator light stays

on.)
j
Start the motorcycle. Raise the vehicle speed to
10 km/h (6 mile/h) and check the ABS indicator
light. (After checking, the motorcycle can be
parked.)
I
I I
The ABS indicator light The ASS indicator light
1 and 2 blink as the , and 2 go off once as
motorcycle starts to the motorcycle starts to
move. move, then they blink.
I I Go to page 16-A-29
I
Disconnect the solenoid valve connector (j]) and

BLACK connector @ of the ECU.
E8
PINK/BLACK
PINK/BLACK
and BLACK connector 'J!) terminal of the ECU.
I
® Q _ _I
No continuity
Continuity
Repair open in the PINK/BLACK harness
between the solenoid connector and ECU.
With the BLACK connector of the ECU discon-

nected, check for continuity between the main
harness side terminal of the solenoid valve con- PINK/BLACK
nector@and body ground.
Continuity
No continuity
Repair short in the PINK/BLACK harness
I Connect the BLACK connector (jJ) of the ECU. I
I Disconnect the limit switch connector@. I
16-A-28
ABS ('92 '95)

:[j
~
terminals of the limit switch connector @, @
WH ITE/PIN~
GRAY/RED G REENjPINK PIL/SLAC K
Connect the valve side terminals of the solenoid "
valve connector 8 to the battery terminals, and
check for continuity between the switch side
terminals of the limit switch connector @.
. Connect the PINK/BLACK (Inlet valve side)
@ORANG
n
E/GREEN !±J
BATTERY
8
.J,
harness to the terminal first, then connect the

ORANGE/GREEN (Outlet valve side) harness C AUTION
immediately. Connect to the battery terminals securely.
Does continuity stop within 1 second after. Continuity stops.

Faulty modulator
connecting the ORANGE/GREEN harness?
Continuity
• Faulty ECU
(From page 16-A-28: The ASS indicator light 1

and 2 go off as the motorcycle starts to move.
then they blink.)
Retrieve the problem code.
No problem code
Is the problem code "3~? Check the harness and connector for secure
connection (page 16-A-3) .
• Faulty ECU
16-A-29
ABS ('92-'95)
Problem code 4: Faluty rear hydraulic control system
Turn the ignition switch ON {but do not start the

engine} and check the ASS indicator light 1 and
2.
Does the ASS indicator light blink or come on Light blinks. I Retrieve the problem code and record it. Clear
and stay on? the problem code.
Light stays on.
1 Turn the ignition switch OFF. 1

Start the engine. Check the ASS indicator light I
before riding the motorcycle. 1

riding the motorcycle) and check the ASS indica-
Light stays tor light.
on.
< Does the ASS indicator light blink or stay on?
Light blinks. Light go
OFF.
1< 0085 the ASS indicator light blink or go off?
Light blinks
Turn the ignition switch OFF_ 1 (Appears repeatedly}.
Retrieve the problem code again and clear the

problem code.
I
Turn the ignition switch OFF. 1
.
\
I Check the solenoid fuse in the ASS fuse case. I

(Go to page 16-A-35).
Burned out.
Is the fuse normal?
Normal
Start the engine. Check the ASS main relay for a

clicking sound at the relay contact point immedi-
ately after starting the engine.
Sound
In there a clicking sound in the relay?
No sound
16-A-30
ABS ('92-'951
(From the previous page} HEADLIGHT RELAY
l
Disconnect the ASS main relay connector (I~
and connect the headlight relay instead.
Restart the engine. Check the ASS indicator

light before riding the motorcycle.
Light stays on.

<Does the ASS indicator light 1 and 2 stay on? Faulty ABS main relay
Light blinks.
Disconnect the ASS main relay connector @

from the headlight relay.
Check for voltage between the ASS main relay

connector@)terminal and body ground.
No battery voltage
< Does battery voltage register? Repair open in the RED/BROWN harness
between the ASS main relay and ABS main
Battery voltage
fuse.
I Turn the ignition switch OFF. View from terminal side

I
Tr
~GRAY
Connect the ASS main relay connector .J]; to the
ASS main relay and disconnect the BLACK con-
nector @ofthe ECU.
I Turn the ignition switch ON. I

@)
nector {fl terminal of the ECU and body ground.
No battery voltage
( Does battery voltage register? Repair open in the BLUE/GRAY harness
Battery voltage between the ABS main relay and ECU.
• Faulty ECU
16-A-31
ABS ('92-'95)
(From page 16-A-30: Operation sound in the

ASS main relay.) View from terminal side
B3cw
Disconnect the ASS main relay connector@)and WHITE/PINK WHITE/PINK

solenoid valve connector @.

%
relay connectorca terminal and the main harness
side terminal of the solenoid valve connector@.
No continuty
Continuity
Repair open in the WHITE/PINK harness
between the ASS main relay and modulator
(solenoid valve).

relay connector@terminal and body ground.
·i>ril
~- ITJ.GREEN
No continuity
~
Continuity
Open harness between the ASS main relay and
modulator ground terminal @, or poor ground-
ing.
Install the ASS main relay connector @ and

solenoid valve connector @.
Retrieve the problem code. Check whether the

valve operation sound (i.e. clattering sound) can
be heard for approximately 3 seconds before the
! problem code appears.
Operation sound
< Is there the operation sound? Go to page 16-A-34.
No operation sound.
(Continue to the following pagel
16-A-32
ABS {'92-'951
Disconnect the solenoid valve connector @ and

@
BLACK connector (iJ) of the ECU.
ORAN
and BLACK connector @ of the ECU.
No continuity
( Is there continuity? Repair open in the ORANGE/BLACK harness
between the modulator (solenoid valve) con-
Continuity
nector and ECU.

lID
I
. Turn the ignition switch ON . I
B
nector (jJ) terminals of the ECU and body ground
respectively.
BLACK/GREEN
No battery voltage
< Does battery voltage register? Repair open in the BLACK/GREEN or RED
harness between the ECU and battery.
Battery voltage
Connect the valve side terminals of the solenoid

valve connector @ to the battery terminals.
ORANGE/BLACK: Positive (+)
~
ORANGE/ WHITE/PINK
BLA,\;K ;!,
WHITE/PINK: Negative (-)
C±J 8
BATTERY
< When connecting, is there valve operation \ No operation sound

Repair open in the ORANGE/BLACK or WHITE/
sound (Le. clattering sound)? I
PINK harness of the valve solenoid.
Operation sound Faulty modulator
• Faulty ECU CAUTION

16-A-33
ABS ('92-'95)
(From page 16-A-32: Valve operation sound.) View from terminal side
I
After checking the operation sound, turn the
ignition switch OFF and disconnect the limit 1TIL
I ~N~BROWN
switch connector CD.
GRAY/ORA~
terminals of the limit switch connector CD.
Continuity
( Is there continuity? Faulty modulator
No continuity
Disconnect the WHITE connector@afthaECU. I
-GRAY/ORANGE
side terminal of the limit switch connector CD and
body ground.
Continuity
( Is there continuity? Repair short in the GRAY/ORANGE harness
between the ECU and limit switch connector.
No continuity
• Faulty ECU
16-A-34
ABS ('92-'95)
(From page 16-A-30: ASS indicator light stays

on.]
j
Start the motorcycle. Raise the vehicle speed to
10 km/h (6 mile/h) and check the ASS indicator
light. (After checking, the motorcycle can be
parked.)
I
I I
The ASS indicator light The ASS indicator light
1 and 2 blink as the 1 and 2 go off once as
motorcycle start to the motorcycle starts to
move. move, then they blink.
I • (Go to page 16-A-36.)
j
I Turn the ignition switch OFF. View from terminal side
~
Disconnect the solenoid valve connector -tt and 1];
BLACK connector @ of the ECU.
PINK/i H1TE PINK/WHITE

side terminal of the solenoid valve ccnnectorqt
and BLACK cormector Jr of the ECU.
No continuity
( Is there continuity? . Repair open in the PINK/WHITE harness of the
solenoid connector and ECU.
Continuity
With the BLACK connector of the ECU discon-

nected, check for continuity between the main
harness side terminal of the solenoid valve con- Q~PINK/WHITE
nector {to and body ground.
Continuity
Is there continuity] Repair short in the PINK/WHITE harness
No continuity
Connect the BLACK connector '[0 of the ECU.
Disconnect the limit switch connector CD.
I
16-A-35
ABS ('92-'95)

J
CD @
Check for continuity between the switch side =
~
terminals of the limit switch connector CD.
II .II PINK/
W HIT E
GRAY/ORANGE ORANGE/BLACK
V WHITEI
Connect the valve side terminals of the solenoid

GREEN
l@JROWN
/p INK
valve connector @ to the battery, and check for
continuity between the switch side terminals of
Q ri,
the limit switch connector <D.
,
® 8
Connect the PINK/WHITE (Inlet valve side) BATTERY
harness to the battery first, then connect the
ORANGE/BLACK (Outlet valve side) harness
immediately.
CAU TION
,
B e sure not to connect to the battery termi-
n als for more than 5 seconds continuously.
Does continuity stop within 1 second after Continuity stops.

• Faulty modulator
connecting the ORANGE/BLACK harness?
Continuity
• Faulty ECU
(From page 16-A-35: The ASS indicator light 1

and 2 go off as the motorcycle starts to move,
then they blink.)
I Retrieve the problem code. I
No problem code
< Is the problem code ~4"? Check the harness and connector for secure
Problem code ~4 y
• Faulty ECU
16-A-36
ABS 1'92-'95)
Problem code 5: Faulty front wheel speed sensor system
CAUTION
• When removing/installing the wheel sensor and wheel. take care not to damage the tip of the sensor.
NOTE
Check the tire size and air pressure and check the tire for deformation before troubleshooting.
The ASS indicator light might come on while riding under the following conditions. Turn the ignition switch OFF and
periorm the pre-start self-diagnosis. The ASS is normal if the warning light goes off. However, the problem code is
stored in the ECU. Ask the rider for the riding conditions in detail when he brings his motorcycle to your dealership for
inspection.
The motorcycle has continuously run on bumpy road.
After riding on the roadlatter the pre-start self diagnosis), the engine was kept running and the rear wheel turning (for
more than 30 seconds) with the motorcycle placed on the center stand.
Periorm the inspection of the wheel sensor.

Check the area around the wheel sensor as
well
j
Place the motorcycle on its center stand eod
measure the air gap between the pulser ring
and wheel sensor.
Standard: 0.8 ::/- 0.4 mm (0.031 ± 0.016 in)
Incorrect
< Is the air gap correct? Check each part for deformation and looseness
and correct accordingly. Recheck the air gap.
Correct
Defomed and/or
Is the pulser ring defonned or damaged (e.q. ~ damaged
• Replace the pulser ring and recheck.
chipped teeth, etc.] ?
Not deformed and
damaded
there iron DC other magnetic deposits">, Deposits

. Remove the deposits and recheck.
between
" the pulser ring and wheel sensor?
No deposits NOTE
Check the wheel sensor tip for damage. If it is
damaged, replace with a new one and re-
check the air gap.
Are the pulsar ring, wheel sensor, and caliper Loosely installed.
Correct deformation. Install securely and re-
bracket loosely installed?
check.
Securely installed.
(Contiue to the following page)
16-A-37
ABS ('92-'951
I
Check the wheel sensor signal in the ECU.
NOTE
j Turn the front wheel with the problem code

cleared. (Do not operate the ignition switch
Retrieve the problem code and record it. Clear after clearing the problem code.)
the problem code.
Turn the front wheel [Vehicle speed: approxi-

res INDICATOR LIGHT ABS INDICATOR LIGHT
mately 4 km/h (2.5 mile/h) or above, t.e.as fast

as when the wheel rs turned with all your
strength by hand.]
\ I
TIVE) ABS
l~
I Check the ASS indicator light. I
Light blinks. (Sensor

signal is input in the
ECU.)
Does the light blink or stay on? Check the harness and connector for secure
Light stays on. connection (page 16-A-3).

riding the motorcycle), then check the res
in-
dieter light.
Light goes off.

< Does the light stay on or go off?
Does not go off.
> Repair open in the BLUE/GREEN harness
between the wheel sensor and ABS ECU.
Faulty ABS ECU
,
, Turn the ignition switch OFF. I
I Disconnect the wheel sensor connector @. I
I
Turn the ignition switch ON.
GREEN/ORANGE
I BLA CK/PIN~
Check for voltage between the main harness side
terminals of the wheel sensor connector @.
No battery voltage
< Does battery voltage register?
IBattery voltage
Repair open in the BLACK/PINK or GREEN/
ORANGE harness between the wheel sensor
and ABS ECU.
Faulty ABS ECU
I
16-A-38
ABS ('92 '95)
I
I
~EEN~
I Disconnect the WHITE connector@ofthe ECU. )
@
Check for continuity between the WH ITE con- BLUE/

nectar @ terminal of the ECU and the main WLJE/GREEN
harness side terminal of the wheel sensor con-
nector@.
No continuity
( Is there continuity? Repair open in the BLUE/GREEN harness
between the wheel sensor and ASS ECU.
Continuity
. Faulty wheel sensor
16-A-39
ABS ('92-'951
Problem code 6: Faulty rear wheel speed sensor system
CAUTON
• When removing/installing the wheel sensor and wheel, take care not to damage the tip of the sensor.
NOTE
perform the pre-start self-diagnosis. The ABS is normal if the warning light goes off. However, the problem code is
inspection. (Was the motorcycle has continuously run on bumpy road?)
When the rear wheel sensor or rear pulser ring is replaced, perform the air gap inspection (page 16-A-51).
Perform the inspection of the wheel sensor.

Check the area around the wheel sensor as
well.
\
Place the motorcycle on its center stand ood
measure the air gap between the pulser ring
and wheel sensor.
Standard: 0.8 ~g1 mm
(0.031 ;- g:86~ in)
j
Incorrect
< Is the air gap correct? Check each part for deformation and loose-
ness and correct accordingly. Recheck the air
Correct
gap.
Deformed and/or
Is the pulser ring deformed or damaged (e.g. \damaged
• Replace the pulser ring and recheck.
chipped teeth, etc.I? /
Not deformed
and damaged
I, there iron DC other magnetic deposits \ Deposits

• Remove the deposits and recheck.
between the pulser ring and wheel sensor? /
No deposits NOTE
Check the wheel sensor tip for damage. If it is
damaged, replace with a new one and re-
check the air gap.
< Are the pulser ring, wheel sensor, and caliper \

bracket loosely installed?
Loosely installed.
Correct deformation. Install securely and re-
check.
Securely installed.
16-A-40
ABS 1'92-'951
I
Check the wheel sensor signal in the ECU.
NOTE
Turn the rear wheel with the problem code
j cleared. (Do not operate the ignition switch
Retrieve the problem code and record it. Clear after clearing the problem code.)
the problem code.
res INDl CATOR LIGHT ABS INDICATOR LIGHT

Turn the rear wheel [Vehicle speed: approxi-
mately 4 km/h (2.5 mile/h) or above, i.e. as fast \ I
as when the wheel is turned with ,II your
strength by hand.] TIVEj 81 ABS
Check the ASS indicator light. I

Light blinks. (Sensor
ECU.)
< Does the light blink or stay on? Check the harness and connector for secure
connection (page 16-A-3}.
light stays on.

riding the motorcycle), then check the res
indi-
cator light.
Light goes off.

< Does the light stay on or go off? Repair open in the BLUE/GREEN harness
between the wheel sensor and ABS ECU.
Does not go off.
Faulty ABS ECU
Disconnect the wheel sensor connector @'. I
I
I
Turn the ignition switch ON. I BLA CK/ORANGE
;DlJ GREEN/GRAY

terminals of the wheel sensor connector @.
l@
No battery voltage
< Does battery voltage register? Repair open in the BLACK/ORANGE or
GREEN/GRAY harness between the wheel
Battery voltage
sensor and ABS ECU.
Faulty ABS ECU
16-A-41
ABS 1'92-'951
(From the previous page}
J
I Disconnect the WHITE connector (I~ of the ECU. J:$
BLUE/ BROW~UE/BROWN
Check for continuity between the WH ITE con-
nector (@ terminal of the ECU and the main
harness side terminal of the wheel sensor con-
nector ::[~:.
No continuity
< Is there continuity? Repair open in the BLUE/BROWN harness
between the wheel sensor and ASS ECU.
continuity
. Faulty wheel sensor
16-A-42
ABS 1'92-'95)
Problem code 7: Faulty ABS main relay system
Disconnect the ASS main relay connector @ .

the problem code.
Problem code "3

N
Problem code "7" - - - - - - - - - -__ (Go to the following page.)
I
HEADLIGHT RELAY
i Clear the problem code. I
Connect the headlight relay to the ABS main

relay connector @.
Perform the pre-start self- diagnosis and check

the ABS indicator light.
Light goes off.

( Does the light blink or go off? . Faulty ABS main relay
Light blinks.
Connect the ABS main relay to the ABS main

relay connector :j9' _ (Return to the original
condition. )
Disconnect the BLACK connector 'fDof the ECU. I
Turn the ignition switch ON and check the ASS

main relay for the operation sound (i.e.clatter-
ing sound).
I
Clattering sound
Is there a clattering sound? Repair short in the BLUE/GRAY harness
between the ABS main relay and ECU.
No clattering sound
• Faulty ECU
16-A-43
ABS ('92-'95)
{From the previous page: problem code ~r}
I
f
Clear the problem code. I
Disconnect the front and rear modulator I

I solenoid connectors @ and @.
Perform the pre-start self- diagnosis and retrieve I

I the problem code. I
I I
Problem code ~7" Problem code "3"
I
IL
I
. Repair short in the WHITE/PINK harness
between the ASS main relay and solenoid.
8 FRONT: Tv REAR:
I Disconnect the BLACK connector 11) of the ECU. I

~ PINK/~E/BLACK
Check for continuity between the harness side
terminals of the solenoid connectors @or@ and
the body ground respectively.
"ifF O@"""' @ @
Continuity
Is there continuity? Repair short in the ORANGE/BLACK and PINK/
WHITE, or ORANGE/GREEN and PINK/BLACK
No continuity
harnesses between the ECU and solenoid .
• Faulty ECU
16-A-44
ABS 1'92-'951
Problem code 8: Faulty power circuit
NOTE
Before starting the troubleshooting, check to see whether the idle speed.conforms to the specified speed. If the idle
speed is below specification, adjust idle speed.
Ask the rider about the following when the motorcycle is brought in for inspection.
- Ask whether the motorcycle has been run with electrical accessories.
- Ask whether the motorcycle has been left for a long time with the ignition switch in the ON position. This problem
code will light up to indicate battery discharge.
Check the battery for charging condition.
Low or no battery
voltage
Is it normal? Check the charging system/alternator (see sec-
tion 17).
Normal

Problem code 9: Faulty ECU
NOTE
The ASS indicator light blinks or comes on and stays on when the ECU has been disrupted by an extremely powerful
radio wave (Electromagnetic Interference). This is just a temporary symptom. Clear the problem code and the ECU
will operate normally unless the symptom recurs.
Perform the pre start self diagnosis and retrieve

the problem code, then clear the code. Repeat
this procedure several times.
Does not appear

Does the problem code "9" appear repeated- ,>-_-,-====
repeatedly. _ Temporary problem (Electromagnetic interfer-
Iy? /
ence)
Appears repeatedly.
Faulty ECU
16-A-45
ABS ('92-'95)
Trouble not represented by a problem code
Abnormal sound from the modulator

(Difference in sound level is twice or more between the front and rear modulators during the pre-start
self-diagnosis.) :
Connect the pump motor terminal to the battery securely. Avoid loose terminal connections and do not allow the
battery terminals to contact the frame and other parts.
The modulator motor becomes very hot when it is turned ON repeatedly to check for the motor sound. Take care
not to burn your hands. etc.
CAUTION
Do not turn the motor continuously for more than 30 seconds. If you have to turn the motor repeatedly to check
for the sound. be sure to stop the motor within 30 seconds and wait at least one minute before starting it again.
Otherwise. the motor can be damaged.
NOTE
• There are two types of the modulator sounds; the solenoid valve clattering sound and the pump motor beep sound.
Front modulator:
Remove the instrument panel (page 2-7). Check

the modulator for interference with the upper
fairing and/or other parts.
Not jRemove the upper fairing

interfering. (page 2-9). Are there loose Normal
c Is it interfering?
modulator mounting bolt DC
Interfering. \damaged mounting rubber?
ILoose bolt or
. damaged rubber
I
Tighten the mounting bolt
securely. or replace the mount-
ing rubber.
Remove the upper fairing (page 2-9). Are the Deformed.
upper fairing stay and modulator mounting Repair the upper fairing stay
stay deformed 7 or modulator mounting stay.
Normal
Reinstall the modulator if it was removed.
Retrieve the problem code (page 16-A-6) {To

release the modulator fluid pressure.)
I
(Continue to following page)
16-A-46
ABS ('92-'95)
)
Remove the right side cover (to compare the

modulator sound between the front and rear REAR MODULATOR
modulators). FRONT MO DULATOR
r-
"\/f:, ~>
Disconnect the pump motor connectors (@ and .,!!
®N from the front and rear modulators.
'1~ ~~!
','7(
Connect the front and rear pump motor termi-

nals to the battery respectively, and compare the
sound (motor sound) between the front and rear
modulators.
1
(±) 8
~
~,
~
8
l
BAn ERY BATIERY
12 V 12V -.-L
Sound changes and
drops at the front
Does the sound change within 3 seconds after
and rear modulators.
connecting the pump motor terminal to the • Normal: Recheck the front modulator for
battery, and does the sound level drop? proper mounting (page 16-A-46)
Front modulator sound (Improper mounting may cause unnec-
does not change {regular) essary vibrational noise.)
• Faulty front modulator

NOTE
After checking the motor sound. connect
the front and rear pump motor connectors,
retrieve the problem code and erase it (page
16-A-6) .
16-A-47
ABS ('92-'95)
Rear modulator:
Remove the right side cover (page 2-2). Check

tho modulator for interference with tho right
footpeg holder and/or other parts.
Not Remove the right footpeg hold - \

intertering. er (page 16-A-54). Are there Normal
Is it interfering?
loose modulator mounting bott
Interiering. or damaged mounting rubber? I
Loose bolt or
damaged rubber
. Tighten tho mounting bolt

securely, or replace the mount-
ing rubber.
Remove the right footpeg holder (page 16- Deformed.
A-54). I, tho modulator mounting stay . Repair the modulator mounting
deformed? stay.
1Normal
! Reinstall the right footpeg holder.
Retrieve the problem code (page 16-A-6)

release the modulator fluid pressure)
(To I
! Turn the ignition switch OFF. !
Remove the instrument panel (to compare the

motor sound between the front and rear module-
tors) .
Disconnect the pump motor connectors (@ and

,~)from the front and rear modulators.
j
(Continue to the touowtnc page)
16-A-48
ABS ('92-'95)
REAR MODULATOR
FRONT MODULATOR
Connect the front and rear pump motor termi-

nals to the battery respectively, and check the
motor sound between the front and rear modula-
tors.
Sound changes and

drops at the front
Does the sound change within 3 seconds
and rear modulators.
after connecting the terminals to the battery, • Normal: Recheck the rear modulator for proper
and does the sound level drop? mounting (page 16-A-48).
Rear modulator sound (Improper mounting may cause unnec-
does not change (regular). essary vibrational noise.)
• Faulty rear modulator NOTE

After checking the motor sound, connect
the front and rear pump motor connectors,
retrieve the problem code and erase it (page
16-A-6) .
16-A-49
ABS ('92 '95)
- Faulty ABS indicator light
When the pre-start self-diagnosis sound (motor sound) from the modulator can be heard after starting the engine, and
where the ASS operates normally while riding:
- Before pre-start self-diagnosis (Ignition switch ON) - While riding
-, ASS indicator light 2 ASS indicator light 2
,. 0
z
ON
Normal
Blink
A
OFF
A. B. F. E "" -. -.
,. 0
z
ON Blink OFF
-.
tn
-. ~ -.
tn
U>
,c, U>
S·
~ ~
c,
o·
'" •a ,
0 ~
•a
~ 5
0
~
0
" "
<is. <is.
~
~
~
"
~ 0 " 0
~ D. G.I. K D. G.!. K D. E. F. G. I ~
-n A. C.I Normal
-n -n
When there is no motor sound in the modulator after starting the engine and the indicator light is faulty (i.e. pre-start
self-diagnosis does not start):
- Before riding (with the engine started and the motorcycle par'r<ed) - While riding
r. ON
ASS indicator light 2
Blink OFF ~ ON
ASS indicator light 2
Blink OFF
,.
~
0
z H.I. J. M I I ,.
~
0
z
I. J. M I I
-.
U> U>
,c, ,c,
•" ,_. • ,_.
o· ~ 0 ~
I I ~
I H I
Q 0
-.
Q 0
-
<is. -
~
~
~ ~
~ ~
0 0
~
-n K. L I ~
-n K. L I
-n -n
A: Faulty indicator control unit

B : Poor connection of the indicator control unit connector (4P) (»
C: Poor connection of the indicator control unit connector ~) (2P)
D: Faulty ABS indicator light LED 1, poor connection of the connector Ct
E: Faulty ASS indicator light LED 2, poor connection of the connectorco
F . Poor connection of the ASS indicator light connector@
G: Poor connection of the ASS indicator light connetor X
H: Faulty indicator light switch, poor connection of the connector (I)
I : Faulty ASS ECU
J : Faulty TCS/ignition control module (ICM), Open or short in the LIGHT GREEN/ORANGE harness between the TCS/
ICM and ASS ECU
K: Poor connection of the ASS ECU connector ::u.:
ASS INDICATOR
l : Burned ASS main fuse (lOA)
M: Improper battery charge {See section 17 .}
ASS INDICATOR
LIGHT >. jHT 2
16-A-50
ABS 1'92-'951
Wheel Sensor Air Gap Inspection

(1) REAR PULSER RING
(21 REAR WHEEL SENSOR 1
(Rear wheel only)
Place the motorcycle on its center stand.
Measure the air gap between the wheel sensor and pulsar
ring using a feeler gauge. It must be within the specifica-
tion.
Standard: 0.8 ~g:~ mm (O.031·g:~ in)
If not within specification, perform the shim adjustment
16-A-51
ABS ('92-'95)
Front Modulator Removal/Installation
<
(1)
c: 35 (3.5, 25)
(3) ,
(2)
)6)
U ~\-1 ~
\ "
(4)
, , , "
I
c: (3)
35 (3. 5, 25)
16-A-52
ABS ('92-'95)
Check the brake system by applying the brake after the bleeding air from the system.
CAUTION
Avoid spilling fluid on painted, plastic, or rubber parts. Place a rag over these parts whenever the system is
serviced.
When removing the oil bolt, cover the end of the brake hose to prevent contamination. Do not allow foreign ma-
terial to enter the system.
When removing and installing the modulator, take care not to drop or strike the modulator.
NOTE
After replacement of the moduator, bleed the brake system according to the standard air bleeding procedure. I
Note that replacement and bleeding air from the brake fluid in the modulator is not possible, as it is sealed in the
modulator.
Requisite Service
Front brake fluid draining/air bleeding
Upper fairing removal/installation {page 2-9}.

Removal Order Installation in the reverse order of removal.
(1 ( Conector 3
(21 Ground terminal bolt 1
(31 Oil bolt 2
(41 Sealing washer 4
(51 Modulator mounting bolt/collar 3/3
(61 Washer 3
(71 Modulator 1 CAUTION
, Do not disassemble the modulator.
16-A-53
ABS ('92-'9 5)
Rear Modulator Removal/Installation

151 ~
III 31
~ 121
12 1 121 -
151 ~
191
C 27 f2.7, 20)
'~ _ _ - - ' > l l0)
181 0, 35 (3. 5,25)
(12) 111}
16-A-54
ABS ('92-'95)
Check the brake system by applying the brake after the bleeding air from the system.
CAUTION
Avoid spilling fluid on painted, plastic, or rubber parts. Place a rag over these parts whenever the system is
serviced.
When removing the oil bolt, cover the end of the brake hose to prevent contamination. Do not allow foreign ma-
terial to enter the system.
NOTE
After replacement of the moduator, bleed the brake system according to the standard air bleeding procedure.
Note that replacement and bleeding air from the brake fluid in the modulator is not possible, as it is sealed in the
modulator.
Requisite Service
Rear brake fluid draining/air bleeding

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

11) Harness band 1
12) Connector 4
13) Ground terminal bolt 1
14) Oil bolt 2
15) Sealing washer 4
161 Reservoir bolt 1
171 Muffler mounting bolt 1
181 Right footpeg holder bolt 6 mm 1
191 8 mm 1
1101 10 mm 2
(11 ) Modulator mounting bolt/collar 3/3
[121 Washer 3
(13) Modulator 1 CAUTION
. Do not disassemble the modulator .
16-A-55
Symbols
...

~
C
10 (1.0, 7.2)
~
equivalent)
equivalent)

"I~ Apply sealant

16-B. ABS (After '95)
Service Information 16·8-1 Troubleshooting 16-8-5
System Location 16-6-2 Wheel Speed Sensor Air Gap Inspection 16-B-34
System Wiring Connections/Locations 16-6-3 Front Modulator Removal/Installation 16-B-36
Circuit Diagram 16-6-4 Rear Modulator Removal/Installation 16-B-38
Service Information
CAUTION
Use a fully charged battery for troubleshooting. Do not diagnose the ABS with a charger connected to the battery.
On removal and installation of the wheels and wheel speed sensors, be careful not to damage the wheel speed sensors
and pulser rings.
NOTE
Check the following before performing any ASS troubleshooting.
- Pre-start self-diagnosis of ASS
If an abnormality is found during the above checks, perform the ASS troubleshooting following the Symptom-to-
System Chart (page 16-B-8). The ASS is normal if no trouble is found. Go to the checks on the other systems {e.g., LBS
or basic brake system}.
Troubles not resulting from a faulty ASS, l.e. brake disc squeak, unevenly worn brake pad, etc., cannot be recognized by
the ABS diagnosis system. (See the Common Service Manual.)
Record the symptom of the problem and the problem code in MEMO before troubleshooting.
When the ASS is faulty, the ABS indicator light blinks or it comes on. The ASS does not function at this time; take care
Do not disassembly the modulator assembly. If 'It is faulty, replace it an assembly.
Refer to page 15-2 for brake fluid filling and bleeding. Note that there is no brake fluid in the modulator (except in the
modulator head), because the modulator is the motor-driven hydraulic pressure type. Therefore, brake fluid
replacement and bleeding air from the modulator body is not necessary.
When the wheel is removed, perform the air gap inspection (page 16-B-51).
The ASS indicator light might blink in the following cases. If the indicator light blinks, clear the problem code and
perform the pre-start self-diagnosis ofthe ABS (page 16-5). The ABS is normal if the ABS indicator light goes off.
- The motorcycle has continuously run on the bumpy road.
- The ABS control unit (ECU) was disrupted by extremely powerful radio were (Electromagnetic Interference).
- After riding Ii.e. after the pre-start self-diagnosis), the engine was kept running and the rear wheel turning (for more
than 30 seconds} with the motorcycle on the center stand.
The ASS indicator light might blink in the following cases. If the indicator light blinks, service the faulty parts, clear the
problem code, and perform the pre-start self-diagnosis of the ABS (page 16-S-5}. The ASS is normal if the ABS indicator
light goes off.
- Incorrect tire pressure
- Tires not recommended for the motorcycle were instailed.
- Deformation ofthe wheel
After troubleshooting, clear the problem code and perform the pre-start self-diagnosis again to be sure that the ASS
indicator light is operating normally.
16-8-1
ABS (After '95)
System Location

(5) IGNITION SWITCH
(12) MODULATOR CONTROL

(4) ABS,TCS INDICATOR LIGHT SWITCH MOTOR
(9) ASS CONTROL UNIT

(3) BATIERY (ECU)
(2) ASS FUSE CASE
(1) REAR WHEEL

SENSOR
(13) CRANK ANGLE SENSOR
(10) FRONT MODULATOR CONTROL

MOTOR RELAY
(19) REAR PULSER RING
(18) REAR MODULATOR

(11) REAR MODULATOR CONTROL
(17) MOTOR DRIVER
MOTOR RELAY
(16) FRONT MODULATOR
(14) FRONT PULSER RING

(15) FRONT WHEEL SPEED SENSOR
16-B-2
System Wiring Connections/Locations
Refer to section 2, for the parts that must be removed for service.
For example: ::1) CRANK ANGLE SENSOR -e-Maintenance part
-R. side cover (page 2-2) <- The parts that must be removed for service
(~) INDICATOR CONTROL

UNIT
ct' ABS/TCS
INDICATOR
Ci: REAR MODULATOR LIGHT SWITCH -L. fairing pocket
CRANK ANGLE SENSOR (page 2-6)
-Tap shelter
-R. side cover (page 2-2) (page 2-5)
BI/Sr GISI
GriBu LgiBI E
~~
"i
ASS MAIN (30A)
FRONT MODULATOR
CONTROL MOTOR ?oS
(lOA)
REAR MODULATOR
!SJ
CONTROL MOTOR
(10A)
ASS FUSE CASE
-L. side cover (page 2-2)
,ec..
",. BLACK
YELLOW
BLUE
Br ..
0
BROWN
ORANGE
,C,'"
LIGHT BLUE
G GREEN LIGHT GREEN
RED
"
W WHITE G,--
PINK
GRAY
/
G e.v
BI/G SliR
:f~ REAR WHEEL SPEED SENSOR
@ REAR MODULATOR CONTROL MOTOR -R. side cover Cftj MOTOR DRIVE
-R. side cover (page 2-2) (page 2-2) (4P Blue)
-Upper fairing
(page 2-9)
ABS IAfter '95)
@INDICATOR (Black)
~'ASS INDICATOR ® ASS INDICATOR
LIGHT 1 LIGHT 2
-Inner screen J) INDICATOR (White)
(page 2-7) -Inner screen (page 2-7)
-Inner screen -tnner screen ~
(page 2-7) (page 2-7)

Lg..'B1rx LgiBI (;..0 WiO W.ID GiO
G/81 ViG, v:(;, GI81 G'iSe fl.: 0 RiO Gr:'Bu
=
(]~, FRONT MODULATOR CONTROL
MOTOR RELAY -Upper fairing
(page 2-9)
Y.'O RiG
RiBr Br'Y
::E' REAR MODULATOR CONTROL

MOTOR RELAY -Upper fairing
(page 2-9)
ViO W:'Bu
RiB, V..W
,:[~~ FRONT MODULATOR CRANK ANGLE

SENSOR -Upper fairing (page 2-9)
~ (fj) FRONT WHEEL SPEED SENSOR

.>» -Upper fairing (page 2-9}
~
-
~2!
I
f
(LZ' ECU (Black)

{,1' ECU (White)

==
c 'W
BIlG BliR
R ,j§', MOTOR DRIVER (12P) @, MOTOR DRIVER H' FRONT MODULATOR CONTROL MOTOR
-Upper fairing (4P Black) -Upper fairing (page 2-9)
(page 2-9) -Upper fairing
(page 2-9)
16-B-3
ABS IAfter '95)
Circuit Diagram MODULATOR

CONTROL MOTOR RHAY
ASSFUSE
(FRONT) (REAR) ,OX
~~~
3 ,
1 lOA ASS MAIN
2 30A FRONT MODULATOR CONTROL
3 30A REAR MODULATOR CONTROL r
~~~~ ~~~~
~RiBr
,--~--""---------,
12P-BI
~RJBr
I-R/Br-
f--Grlal---+
\I---O/G--"
r1--- Lg/O--"
1---- G'/'I--<>
1--- R/'I'----;
MOTOR DRIVER
f-- BuIGr---+
f--BuIG--"
1--- Bu/Lg,--"
1--- '"/p---¢
I---R/'"'---+
I
CONNECTOR: 4P ABSCONT
• BI
0- Bu
...L
2P-BI r- 2P-BI~
CONTROL
MOTOR
CONNECTOR
• BI
O-W
FRONT MODULATOR REAR MODULATOR
CRANK ANGLE
SENSOR
16-B-4
Be
BI
y
BLACK
YELLOW
Be.
0
BROWN
ORANGE
Ge
BLUE Lb LIGHT BLUE MAIN FUSE 30A
G GREEN L9 . LIGHT GREEN
/
~Ie 0:
R RED P PINK
W WHITE GRAY
MOTOR 0
Ell e );
WTOR L BATIERY
STARTER {f <O---.. .JI II

4'
SYSTEM -
"
$3PW
'I
I~
t
-==:;R~R'~
RIBlllrRlBIU
IGNITION
SWITCH
4P-BI
>--Gr!BB:=J~~~~~~;;i~~~~~~~~~~~~~j~~1
;--,
L-R/al~BI/Br
,
lOA GISI
BllSr INDICATOR
CONTROL UNIT
2P-BI
4P-BI
2P-R
LglBI----+N+.,
. [ ] )[ GIBI~
IOLUNIT(ECUI lOS
ASS INDICATOR
~ LIGHT 2
coa, .......fDi+,
GlO~
ABS INDICATOR
LIGHT1
>-GlG e-lf-H H ------- - - I---lf--4- - ---------------.

>-B"!B:~~~
~BI/O
>-aufG
r- G10 1
~BI/P
2P-BI
,,"""GelY"'--fl~
~C-GIR:::1
~ J 1,° m
a
I ~
16P
_____
~G/BI---, -
---'>--G/BI----+---G!B'--/-~,
G
ABSfTCS INDICATOR LIGHT

,V .'-
SWITCH WHEEL SPEED SENSOR
ABS (After '95)
Troubleshooting
Before Beginning Troubleshooting
Summary of ABS pre-start self-diagnosis system

The ASS pre-start self-diagnosis system diagnoses the electrical system as well as the operating status of the modulator.
When there is any abnormality, the problem and the problem part can be detected by outputting the problem code.
When the vehiclespeed is approximately 10 km/h (6 mile/h) or more, thewheel speed sensor signal is inputto the ASS control
unit (ECU), then the ASS pre-start self-diagnosis system operates the control motor inside the modulator, checks the crank
angle condition with ASS control unit (ECU) and thereby it detects whether the modulator operation is normal, and it
completes the pre-start self-diagnosis.
When the ASS is normal, the ASS indicator light goes off just after starting up indicating that the diagnosis is completed.
If a problem is detected, the ASS indicator light blinks or comes on and stays on to notify the rider of the problem. The self-
diagnosis is also made while the motorcycle is running, and the indicator light blinks when a problem is detected.
When the indicator light blinks, the cause of the problem can be identified by retrieving the problem code following the
specified retrieval procedure. {page 16-S-6}
PRE-START SELF-DIAGNOSIS WHEN NORMAL
IGNITION SWITCH O~~ =.J

CONTROL MOTOR RELAY O~~ =:J
ENGINE RUNNING
STOP
-------------------r= START
__ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ 10 km h (6 mile/h) or above
VEHICLE SPEED 0
ON nn__m__ mmm n nnmm_m_1 1 -

CONTROL MOTOR
OFF
ASS INDICATOR
LIGHT 1 and 2
ON::J
OFF L
Pre-start self-diagnosis completes
Pre-start self-diagnosis procedure (Everyday check-up)

2. Be sure that the ABS indicator lights 1 and 2 come ON.
3. Start the engine.
4. Ride the motorcycle and raise the vehicle speed to approximately 10 km/h (pre-start self-diagsosis completes).
5. The ABS is normal if both the ASS indicator light 1 and 2 go OFF.
~[ ASS I~
7
ASS INDICATOR LIGHT 1
-"----~
16-8-5
ABS IAfter '95)
Retrieval of/Clearing Problem Code ASS/Tes INDICATOR LIGHT SWITCH
NOTE
The ASS indicator light indicates the problem code
by its number of blinks (see the next page).
The problem code is not cleared when the ignition
switch is turned OFF during output of the problem
code. However, output cannot be restarted by
turning the ignition switch ON. Restart the output
following the problem code retrieval procedure.
After retrieving the problem code, be sure to record it ,
in MEMO, etc. Clear the problem code after \
troubleshoot! ng.
TCS ON/OFF SWITCH
Retrieval:
1. Turn the ignition switch OFF.
2. Turn the ignition switch ON while pressing the ASS/
TCS indicator light switch. The ASS indicator light 1
and 2 should come ON. (The ASS indicator light 2 is
OFF this ttrne.)
3. Hold the ASS/TCS indicator light switch pressed (for
approximately 5 seconds). The ASS indicator light 1
should go OFF.
4. Release the ASS/TCS indicator light switch
immediately (within 1 second) after the ASS indicator
light go OFF.
~. Output of the problem code starts and the ASS
indicator light 1 blinks.
Clearing:
5. Press the ABS/TCS indicator light switch during output
of the problem code (while the ASS indicator light is ASS INDICATOR LIGHT 1 ASS INDICATOR LIGHT 2
blinking).
<::. The Problem code is cleared and the ASS indicator
light 1 and 2 comes ON and stay ON.
Turn ignition switch ON Release indicator light switch immediately

while pressing (within 1 sec) Problem code
:
indicator light switch.
: ~i
after ASS indicator lights go OFF. Clearing signal
:~!
ASS'TCS
INDICATOR
LIGHT SWITCH
:~~::se =J~'-+-------+-L rL
IGNITION SWITCH
ON ::::::Ji-i- - - - - + - - - - - - - - - -
OFF ON--->OFF
Blinking
ASS INDICATOR ON
LIGHT 1 OFF
ASS INDICATOR
LIGHT 2
i;
~~F ==nL..----------+---+--+-+---+-f---i--+_ : :
!
!
~
:
i
,!
,!
Problem code
start signal
--'
Latest :
,
!
~
problem Previous time

code problem code
16-8-6
ABS (Afte' '951
Problem code indication pattern
Example:
• When the problem code is stored;
Latest problem Previous time Latest problem code

t problem code
t
'"
code
ProbleZm code: •
Problem code:
6
Problem code:
2
ABS indicator light 1 ON, __ n m __ n __ mm~~r----'~-~~-~'-~ -
(> Pattern repeated
ABS indicator light 1 OFF -----.,1
/1---1*--
Release ABSjTCS indicator light switch.
3 sec.
- ' * - - 0 . 3 sec
-1-1---0.2 sec.
When the problem code not stored;

No output of code
ABS indicator light 1 ON_ --- ---- ----------- c'- \
(> p attern repeated
Release ABSjTCS indicator light switch.

/' I--- 3 sec.
NOTE
The ECU can store up to two problem codes. The latest problem code is output first, then the previous one is output.
When the two problem codes are output, diagnose on the latest problem code (i.e. code output first).
After troubleshooting, perform the pre-start self-diagnosis again to be sure that there is no problem in the ABS indicator
lights and the problem code is cleared.
See page 16-B-33 for the problems that are not represented with the problem codes.
Check the following before performing ABS troubleshooting:
- Pre-start self-diagnosis of ABS
System Chart (see the following paqe). The ABS is normal if no trouble is found. Go on to the check the other basic
systems (e.g., LBS or basic brake system).
16-B-7
ABS (After '95)
Symptom-to System Chart
Problem Affected
Fuse Modulator
Item "CD
<n
3 o
•o 3
~
• m cO·
a cQ. c
s o c
n "
o
~.
"
!-:;;--=+=cr::1 ~
Faulty front modulator

crank angle sensor system o 0 00 16-8-9
Faulty rear modulator

crank angle sensor system o o 00 16-8-12
faulty front modulator

control motor system o o o 00 16-8-15

control motor system o o o 00 16-8-19
Faulty front wheel

speed sensor system o o 00 16-8-23
Faulty rear wheel

speed sensor system o o 00 16-B-26
Faulty power circuit

000 16-8-29
Faulty ASS control unit

(ECU) 00 o 00 16-8-31
Problems not recognized

by ASS control unit (ECU) o 0000016-8-33
NOTE
Check the following before performing ASS troubleshooting.
- Pre-start self-diagnosis of ASS (page 16-B-5)
- ASS indicator light (page 16-8-5)
System Chart. The ABS is normal if no trouble is found. If no trouble is found, continue on to the other system checks
(e.g., LBS or basic brake system).
After troubleshooting, clear the problem code (page 16-B-6) and perform the pre-start self-diagnosis again (page16-
B-5) to be sure that the ABS indicator light is operation properly.
16-8-8
ABS IAfter '95)
Flowcharts
CAUTION
Use a fully charged battery. Do not diagnose with a charger connected to the battery.
NOTE
When the ASS control unit (ECUl. motor driver or modulator is detected to be faulty, recheck the wire harnesses and
connectors connections closely before replacing the control unit, motor driver or modulator.
After troubleshooting, perform the pre-start self-diagnosis again and be sure that the ASS indicator light is normal.
The encircled numbers in the texts and connector diagrams indicate the connectors (see page 16-8-3). All connectors
diagrams in the text are view from the terminal side.
Problem code 1: Faulty front modulator crank angle sensor system
Turn the ignition switch ON (but do not start the

engine) and check the ABS indicator light.
( Does the ABS indicator light blink or come on Light stays

")__-"_ _'--_ on_. . 1. Retrieve the problem code and record it. Clear the
problem code.
,
'\ and stay on? / 2. Perform the pre-start self-diagnosis (including rid-
I Light blinks ing motorcycle I and check the ASS indicator light.
Turn the ignition switch OFF. I Light goes

'------ , --"O"-FF
( Does the ASS indicator light blink or go off?
Turn the ignition switch ON and check for the pre-

start self-diagnosis sound (Le. click sound) from the fight blinks
front modulator.
---,------
~---~--
,,
Click
/1
\ sound
Is there a sound in the front modulator?
NormallTemporary problem)
- Fine foreign matter in the modulator or the ECU
(Go to page 16-B-11) has been disrupted by an extremely powerful radio
wave.
1. Disconnect the front modulator crank angle sensor - Check the harness and connector for secure con-
connector:@ with the ignition switch OFF. nection (page 15-B-3)
2. Measure the output voltage between the main
wire harness side terminals of the sensor connec-
tor)]' with the ignition switch ON.
Standard: 4.5-5.5 V
, View from terminal side
j~
Green. Brown Black Blue

'------@-J
16-8-9
ABS (After '95)
(From the previous page: Measure the

output voltage at the ':lit connector)
__L Out of specification ~ • Repair open in the Black/Blue or Green/Brown

( Is the voltage normal?
- - - - -
)
harness between the modulator (angle sensor
connector) and ABS control unit (ECUj
Faulty ASS control unit (ECU)
Normal
I f~;
_ _ _L
~CmJ
1. Disconnect the White connectnrqf of the ECU
with the ignition switch OFF.
2. Check for continuity between the ECU connector
JJ' terminal and the main harness side terminal of
the crank angle sensor connectorqe. ve;w;ught Green Yellow Light Green
~
- - - -
"
No continuity
/>_:C:C'::::,"::,"='-_.~~ . Repair open in the Yellow/Light Green harness
(, 15 there continuity?
between the modulator tanq!e sensor connector)
l and ASS control unit (ECU)
, Continuity
I Check for continuity between the ECU connector

:t~ terminal and body ground.
~'"0W
r
_ Liqht Green
Is there continuity?
-------'
»--'--'--'--'----.~~
Continuity
. Repair short in the Yellow/Light Green harness
between the modulator langle sensor connector)
~""ity
and ABS control unit (ECUl
• Faulty front modulator
(From the previous page: Light blinks]
1. Retrieve the problem code and record it.

Clear the problem code.
2. Interchange the front and rear modulator with each
other (page 16-B-36 and 16-B-38).
3. Perform the pre-start self-diagnosis (including rid-
ing motorcycle) and retrieve the problem code.
Problem code "2"

Is the problem code "2" ) .. • Faulty front modulator assembly
,
Problem code "1"
Faulty ABS control unit (ECUI
16-B-10
ABS (After '951
(From page 16-6-9: Click sound)
1. Disconnect the front modulator control motor

relay connector 10 and connect the headlight relay HEADLIGHT RELAY
instead with the ignition switch OFF.
2. Turn the ignition switch ON and check the ABS
IL indicator light. -'
--,
Does the ABS indicator light blink or come on
and stay on?
Light stays on
Faulty front modulator control motor relay
Light blinks
1. Disconnect the front and rear modulator control

motor relay connector C!t/;ID and EeU White Yellow
connector ,jJI with the ignition switch OFF.
2. Check for continuity between the connector :$)
terminal and body ground.
c Continuity
,
, No continuity
• Faulty ABS control unit (ECUl
16-8-11
ABS (After '95)
Problem code 2: Faulty rear modulator crank angle sensor system

engine) and check the ABS indic8ctoc'cclig""htC.
l
_
Does the ASS indicator light blink or come on Light stays on

and slay on?
Light blinks
Turn the ignition switch OFF. Light goes
,
, OFF
<,Does the ABS indicator light blink or go off? - - ;
~
. Turn the engine stop switch OFF to deaden a fuel ~
pump sound.
2. Turn the ignition switch ON and check for the
~ Light blinks
pre-start self-diagnosis sound (i.e. click sound)

from the modulator.
, Click
sound
,
Is there a sound in the rear modulator? Normal (Temporary problem)
Fine foreign matter in the modulator or the ECU has
been disrupted by an extremely powerful radio wave.
No sound Check the harness and connector for secure connec-
tion (page 16-8-3)
(Go to page 16-8-14)

1. Disconnect the front modulator crank angle sensor I
~
connector j) with the ignition switch OFF.
2. Measure the output voltage between the main
wire harness side terminals of the sensor connec-
tor :l' with the ignition switch ON. Brown Green Black 'Gray
Standard: 4.5-S.SV ~
Out of specification
Is the voltage normal? Repair open in the Black/Gray or Brown/Green
harness between the modulator (angle sensor con-
nectar) and ABS control unit (ECU)
, Normal

Faulty ABS control unit (ECU)
16-8-12
ABS (After '95)
(From the previous page: Normal)
t
1. Disconnect the White connector 'U' of the ECU
:jJ: terminal and the main harness side terminal of
the crank angle sensor connector CD.
~~ Blue Brown Blue Brown
~
- ~ No continuity
Is there continuity? _/ ... • Repair open in the Blue/Brown harness
between the modulator (connector angle
,
sensor) and ASS control unit (ECUl
Continuity
-----
--------.
> • .
Continuity
~ Repair short in the Blue/Brown harness
between the modulator (angle sensor
connecter} and ASS control unit (ECUl
,
No continuity
(From the previous page: Light blinks)
..
2. Interchange the front and rear modulator with each
other (page 16-B-36and 16-B-38).
3. Perform the pre-start self-diagnosis (including rid·
" Problem code "1"

Is the problem code "1" ? • Faulty rear modulator assembly
,
/
,
Problem code "2"
16-8-13
ABS (After '95)
(From page 16-8-12: Click sound)
_ , Disconnect the rear modulator control motor relay

.
connector i~) and connect the headlight relay in- rF.01;...-~-HEADLIGHTRELAY

1 stead with the ignition switch OFF.
2. Turn the ignition switch ON and check the ASS in-
dicator light.
"-----~
I
.r.,
Does the ASS indicator light blink or come
on and stay on?
~ Ugh< blinks
r
_
ig ht stays on
.-===.-c-'C'--_• • Faulty rear modulator control motor relay
11~co nnect -'h-e--:fc-o-O-,-,-o-d~ce-,-r mod ulator control

motor relay connector @i:~) and ECU White conne-
Yellow
ctor ,n,
2. Check for continuity between the connector C!ij
-'--------
c Is there continuity?
No continuity
Continuity
•• Repair short in the Yellow/Orange harness
between the front/rear modulator control
motor relay and ASS control unit (ECU).
,
• Faulty ASS control unit (ECU)
16-8-14
ABS (After '95)
Problem code 3: Faulty front modulator control motor system

engine) and check the ASS indicator light.
I
Does the ASS indicator light blink or come on Light blinks Retrieve the latest problem code and record it.
and stay on? Clear the problem code.
Light stays on
Other
___--' ,code
Is the problem code "3"?
1. Retrieve the problem code and record it. Problem code "3"
2. Peform the pre-start self-diagnosis (including
riding motorcycle} and check the ASS indicator
light.
, J
__i
G s the ASS Indicator light blink or go off? ~
Light goes off
Diagnose on the latest problem code
Normal (Temporary problem}

- Fine foreign matter in the modulator or the
ECU has been disrupted by an extremely power-
[ L,g" bliok,
ful radio wave.
- Check the harness and connector for secure
connection (page 16-8-3)
--C-h-'-'-k-'-h,-',-o-o-'-m-O-d-,-',-'-or control motor fuse In the I ASS FUSE CASE
l~: :~
ASS tue case with the ignition switch OFF.
Front modulator control motor fuse
, I.:~
c _
Is the fuse normal?
-)>--=--
Burned out
Replace the fuse and recheck.
, Normal
1. Install the fuse in the fuse case.

2. Disconnect the front modulator control motor relay flS;~'----~ HEADliGHT RELAY
connector CID and connect the headlight relay
instead.
3. Perform the pre-start self-diagnosis (including
riding motorcycle) and check the ASS indicator
light.
------,--
---~ ,
< Doesthe ASS indicator light blink or go off?

Light goes off
Faulty front modulator control motor relay
, Light blinks
16-8-15
ABS IAfter '951
..
1. Disconnect the front modulator control motor relay
connector (8) with the ignition switch OFF.
2. Check for voltage between the relay connector (~)
No voltage
Does battery voltage register? Repair open in the Red or Red/Green harness
between the front modulator control motor relay
~ Vo"ogo and battery.
1.- °DC,~-o-O-O-ed-C,"Co-m-o-,-o-'-dnver Blue connecto~

2 Check for continuity between the relay con~~~tor I
(It and motor driver connector 'JV terminals. ~
...
Continuity
--
No continuity
--- Repair open in the Brown/yellow harness

between the front modulator control motor relay
and motor driver.
Check for voltage between the relay connector@

terminal and body ground with the ignition
switch ON.
Rod
Does battery voltage register?

) No voltage
• Repair open in the Red/Brown harness
between the fuse case and front modulator
control motor relay.
Voltage
,
~ c~
1. Disconnect the White connector ,11, of the ECU
,n and relay connector (8) terminals.
L -
Yellow Orange Yellow/Oranqe
4:»----J
, No continuity
Is there continuity? )- Repair open in the Yellow/Orange harness
-~ between the ABS control unit (ECU) and front
modulator control motor relay.
Continuity
16-B-16
ASS (After '95)
(From the previous page: Continuity)
t
1. Disconnect the front modulator control motor
connector@ofthefrontmodulator.
2. Check for continuity between the motor connector
@and motor driver connector C]. terminals.
~ - ----'------
'--------~----).-----==~
No continuity
Is there continuity? Repair open in the Black/Red or Black/Green
harness between the front modulator
Continuity (control motor) and motor driver.
n~:,
,
Check for continuity between the control motor
connector ,j5 and body ground. GJG,eec
~
C IS
,
the~e continui~
~--
~r-"""""~'"'---"
Continuity
Repair short in the Black/Green harness
between the front modulator (control motor)
and motor driver.
No continuity
RedY,~,ow
II
Orange iRed i
'~,'1.2:: ?reen Yell\w
Orange. Green
/Gray,pra
:J[
nge
I I
, ~
/ =-
">P
I
Light Green Gray.' Light Green
Orange Orange Orange
1. Disconnect the Black connector .:)} of the ECU
and motor driver 12P connector ®'.
~© e
2. Check for continuity between the ECU connectors
@/@'and connector@terminalsinthesame
harness colors.
- - --------"
Gravvellcw GraYi'(ellow
,
<
No continuity
Is there continuity? Repair open in the harness between the
ASS control unit (ECUj and motor driver.
Continuity
(Continuity to the following pagel
16-B-17
ABS (After '951
,r~
J---c-------;c _
I Check for continuity between the motor driver
connector@f:lI'terminalsand body ground.
J ~ Green/Black
~
Continuity
No continuity
Repair open in the Green or Green/Black
harness between the motor driver and
body ground.
1. Replace the motor driver with a new one.

2. Connect the@,Qt',,'!t'and,:n'connectors.
light. __J
~»--="""'c::-=~--1~~
Light goes off
-c. Does the ASS indicator light blink or go off? . Faulty motor driver
,
Ught blinks
11.
i
Retrieve the problem code and record it.
, 2. Interchange the front and rear modulator with
each other (page 16-8-36 and 16-8-38).
c TCObl,m _
_ _ "3"?
Is the problem code _ _ _ _ _
cod, "3"
~>-problem code "4" ...
h- Faulty front modulator assembly
"Faulty A8S control unit (ECU)
16-8-18
ABS (After '951
Problem code 4: Faulty rear modulator control motor system
! Turn the ignition switch ON (but do not start the

i engine) and check the ASS indicator light. ~
t
Does the ASS indicator light blink or come on Light blinks Retrieve the latest problem code and
,
and stay on? record it. Clear the problem code.
Continuity
C Is the problem code "4"?

Other
Code
Problem code "4"

ing motorcycle) and check the ASS indicator light.
, ,
Light goes off
Does the ASS indicator light blink or go off? Normal (Temporary problem)
Fine foreign matter in the modulator or the
Light blinks ECU has been disrupted by an extremely
powerful radio wave.
connection (page 16-8-3)
ASS FUSE CASE
Check the rear modulator control motor fuse in the 11--1

L"i,~i'---
ASS fuse case with the ignition switch OFF.
-~'-------
Rear modulator control motor fuse
Burned out
Is the fuse normal?
, Normal
1. Install the fuse in the fuse case.

2. Disconnect the rear modulator control motor relay ~t"'rj;;:--.:o,. HEADLIGHT RELAY
connectcr rg.eno connect the headlight relay
instead.
Light goes off

Does the ABS indicator light blink or go off?
~ghtblinks
> Faulty rear modulator control motor relay
,
16-B-19
ABS (After '95)
1. Disconneet the rear modulator control motor relay, Blue

connector ® with the ignition switch OFF. ~
2. Check for voltage between the relay connector ®
No voltage
Does battery voltage re9ist:;-=--=>- ---. Repair open in the Red or White/Blue harness
between the rear modulator control motor
- - ~ Volt,g, relay and battery.
I', Disconnect the motor driver 4P Black connector 'f~.1
tE E@
2. Check for continuity between the relay connector I
I (1) and motor driver connector j]) terminals.
Yellow/White Yellow/White
--I(Q))-----"
,---I
1
J No continuity
Is there continuity? Repair open in the veuowrwtute harness
between the rear modulator control motor
relay and motor driver.
Continuity
Check for voltage between the relay connector <ID
I-t~tj
terminal and body ground with the ignition switch
ON.
Red Brown
v
C J
Does battery voltage register? >- No vOCC'''c9,'=--_--<.. Repair open in the Red/Brown harness
between the fuse case and rear modulator
Voltage control motor relay.
____t _
~ ~~
veuow/Oranoe Yellow 'Orange
4Q}----J
_ L
c=_ Is there continuity?
J
Continuity
)
No continuity
-- Repair open in the Yellow/Orange harness

between the ABS control unit (feU) and rear
modulator control motor relay.
16-8-20
ABS (After '95)
1. Disconnect the rear modulator control motor

connectcrqb ofthe rear modulator.
2. Check for continuity between the motor connector
~ and motor driver connector ~ terminals.
, No continuity
Repair open in the Black/Red or Black/Green
harness between the rear modulator (control
i Continuity motor) and motor driver.
,I
Check for continuity between the control motor

connector OJt and body ground.
Continuity
Is there continuity? Repair short in the Black/Green harness
between the rear modulator {control motor}
No continuity and motor driver.
Blue/ Red/
Red/Blue Blue/Green
Light Green Blue
, / n§:, '\
I
1. Disconnect the Black connector @ of the ECU
and motor driver 12P connector @.
! I I I I , I
2. Check for continuity between the ECU connectors , / ~
I /
@mandconnector@terminalsinthesame
harness colors.
Bluei
/ Bluei
""
'>" Blue/
Bluei
Green
Light Green Gray Gray
I
Blue/Pink
,
No continuity
Repair open in the harness between the ASS
control unit (ECU} and motor driver.
, I Continuity
16-B-21
ABS IAfter '95)
~
~
-
I Check for continuity between the motor driver
connector T~'!t~, terminals and body ground.
Green/Black
~
, No continuity
Repair open in the Green or Green/Black harness
between the motor driver and body ground.
,I
< Does the ASS indicator light blink or go off 0r-~~~"''-C--.

Light goes off
Faulty motor driver
~bl;"k'
,------- - -
2. Interchange the front and rear modulator with
each other (page 16-8-36 and 16-8-38).
riding rnctorcvcte) and retrieve the problem code.
L- _
,I ~rOblem code "3" . .

( Is the problem code "4"7 Faulty rear modulator assembly
Problem code "4"
• Faulty ASS control unit (ECUj
16-8-22
ABS (Afte' '951
Problem code 5: Faulty front wheel speed sensor system
CAUTION
When removing/installing the wheel speed sensor and wheel. take care not to damage the sensor and pulser
ring.
NOTE
perform the pre-start self-diagnosis. The ABS is normal if the indicator light goes off. However, the problem code is
stored in the ECU. Ask the rider for the riding conditions in detail when the brings his motorcycle to your dealership for
inspection.
- The motorcycle has conttnouslv run on bumpy road.
-After riding on the road (after the pre-start self-diagnosis), the engine was kept running and the rear wheel turning (for
more than 30 seconds) with the motorcycle placed on the center stand.
Perform the inspection of the wheel speed sensor,

Check the area around the wheel speed sensor as well.
,
Place the motorcycle on its center stand and meas-
ure the air gap between the pulser ring and wheel
speed sensor (page 16-8-34).
Standard: 0.4-0.5 mm (0.016-0.020 in)
< -----c----»---='-------
Is the air gap correct?
,
Correct
Incorrect
Check each part for deformation and
looseness and correct accordingly.
Recheck the air gap.
Deformed andl
or damaged
• Replace the purser ring and recheck.
Is there iron or other magnetic deposits bet- Deposits

Remove the deposits and recheck.
ween the pulser ring and wheel speed sensor?
,I No deposits
Are the purser ring and sensor bracket loosely

Loosely installed
Correct deformation. Install securely
installed? and recheck.
, Securely installed
(Continue to the following page) NOTE
r-:-check the wheel speed sensor tip for dam-

I age. If it is damaged, replace with a new
, one and recheck the air gap.
16-8-23
ABS IAfter '95)

2. With the ignition switch in the ON position
(do not operate the ignition switch after clearing
the problem code), turn the front wheel (Vehicle
speed: approximately 4 km/h [2.5 mile/h] or above)
and check the ASS indicator light.
Light blinks (Sensor

ECU)
Dose the ASS indicator light blink or stay on? Normal (Temporary problem)
- The ECU has been disrupted by an extre-
Light stays on mely powerful radio wave.
- Check the harness and connector for secure
connection at the wheel speed sensor
system (page 23-117).
~
1. Disconnect the front wheel speed sensor connec-
tor@withtheignition switch OFF.
2. Check for voltage between the main harness side
terminals of the sensor connector @. Black/Pink Green-Oranqe
===C _
L-w---J
No voltage
Does battery voltage register? Repair open in the Black/Pink or Green/
Orange harness between the wheel speed
sensor and ABS control unit (ECU).
Voltage
1. Disconnect the White connector@'oftheECU

2. Check for continuity between the ECU OJ. connector
:::j'
and sensor connector ® terminals.
! --
_i__
< IS the_,_e_"O_"_'_!"_"_!_"_'_' --./
No continuity
Repair open in the Blue/Green harness
between the ABS control unit (ECU) and
wheel speed sensor.
, Continuity
16-8-24
ABS {After '95)
,!
res INDICATOR LIGHT ASS INDICATOR LIGHT
!,. with each other.
~~I AB=M[~
Interchange the front and rear wheel speed sensor
2. Connect the ECU connector 1l

, 3. Perform the pre-start self-diagnosis (including rid-
ing motorcycle), then check the TCS indicator light.
, Light goes off

Does the res indicator light stay on or go off? • Faulty ASS control unit (ECU)
Does not go off
Retrieve the problem code and record it. Clear the

I problem code.
~-
~rOblem code "5"
Is the problem code "5"? ~/ .. • Faulty ASS control unit (ECU)
~
Problem code "6"
• Faulty front wheel speed sensor
16-8-25
ABS (After '95)
Problem code 6: Faulty rear wheel speed sensor system
CAUTION
When removing/installing the wheel speed sensor and wheel. take care not to damage the sensor and pulser ring.
NOTE
perform the pre-start self-diagnosis. The ASS is normal if the indicator light goes off. However, the problem code is
inspection (Was the motorcycle continuously run on bumpy road?}.
Perform the inspection of the wheel speed sensor.

Check the area around the wheel speed sensor as well.
t'----_
Place the motorcycle on its center stand and meas-
ure the air gap between the pulser ring and wheel
speed sensor (page 16-B-34).
Standard: 0.8 ~:t mm (0.031 ~:8J~ in)
,
c Is the air gap correct?
Incorrect
Check each part for deformation and
looseness and correct accordingly_
, Correct
Is the pulser ring deformed or damaged )

Deformed and!
or damaged -----.
Recheck the air gap.
Replace the pulser ring and recheck.

(e.g. chipped teeth, etc.j?
- -
Not deformed and

damaged
Is there iron or other magnetic deposits bet-

ween the pulsar ring and wheel speed sensor?
---.
Deposits
Remove the deposits and recheck.
No deposits
Are the pulser ring and sensor loosely installed? --.

Loosely installed
Correct deformation. Install securely
and recheck.
,! Securely installed
(Continue to the following page) NOTE
Check the wheel speed sensor tip for dam-

age. If it is damaged, replace with a new
one and recheck the air gap.
16-B-26
ABS (After '95)
1, Retrieve the problem code and record it.

2. With the ignition switch in the ON position
(do not operate the ignition switch after clearing
the problem code), turn the rear wheel (Vehicle
speed: approximately 4 km/h 12.5 mile/h] or above)
and check the ASS indicator light.
Light blinks
(Sensor signal is
input in the EeU)
Dose the ABS indicator light blink or stay on? Normal (Temporary problem)
- The EeU has been disrupted by an extremely
Light stays on powerful radio wave.
- Check. the harness and connector for Secure
~--J
connection at the wheel speed sensor system
(page 16-B-3).
~
11. Disconnect ~he. rear w~eel speed sensor connector
I .. '1a: with the Ignition SWitch OFF.
2. Check for voltage between the main harness side
L terminals of the sensor connectcr djr _ Black Orange Green Gray
LwJ
L __
c Does battery voltage register?
Voltage
~voltage
-- Repair open in the Black/Orange Of Green/Gray

harness between the wheel speed sensor and
ABS control unit (ECU}.
--+-- ::J
1. Disconnect the White connecter f~ of the ECU
Cnf·~
2. Check for continuity between the ECU at'
connec-
BI"e~Bcown
tor and sensor connector @terminals.
I
NocontinuH;'~Y
c -----,----- ----)
Is there continuity? .
_ _•
-.. Repair open in the Blue/Brown harness between
the ABS control unit (ECUj and wheel speed sensor.
,I Continuity
16-8-27
ABS (After '95)

res INDICATOR LIGHT ASS INDICATOR LIGHT
1. Interchange the front and rear wheel speed sensor

with each other.
2. Connect the ECU connectcr fj;
Perform the pre-start self-diagnosis (including rid- i
ing motorcycle), then check the res indicator light. I
~
ABb~
Light goes off
Does the TeS indicator light stay on or go off? - ~ - - - - - - . • Faulty ASS control unit (ECU)
Does not go off
Retrieve the problem code and record it. Clear the

problem code.
! Problem code "6"

( Is the problem code "S"?
, Problem code "5"
• Faulty rear wheel speed sensor
16-8-28
ABS (After '951
Problem code 7: Faulty power circuit
NOTE
Before starting the troubleshooting, check to see whether the idle speed conforms to the specified speed. If the idle
speed is below specification, adjust idle speed.
Ask the rider about the following when the motorcycle is brought in for inspection.
- Ask whether the motorcycle has been run with electrical accessories.
- Ask whether the motorcycle has been left for a long time with the ignition switch in the ON position. This problem
code will light up to indicate battery discharge.
Check the battery for charging condition.
, Low or no battery
I Is it normal?
voltage
Check the charging system/alternator
(section 17).
Normal

/' Does the ASS indicator light stay on. (The \

/ Light blinks
pre-start self-diagnosis is not completed at appro- )',C'-"-''-C''--C'- ~ • (Go to the following page)
\\\~Ximately 10 km/h [6 mile/h] or more of the vehicle
speed) or go off and blink? i
---~/
I
Light stays on Light goes off ---------~
• • • Normal (Temporary problem)
I Check the harness and connector for secure
connection (page 16-8-3 and section 17).
I
J
j~G~
Disconnect the ECU connecrors nz- and Yl with
the ignition switch OFF.
2. Measure the voltage between the ECU connector
'izlH terminals with the ignition switch ON.
Standard: 11 V-18 V Black Red Brown Red/Brown
I "',00' 0j) I 0j)1--_ _
,
___t Abnormal
(Less than 11 Vor
(~
More than 18 V)
Is it normal? Check the charging system/alternator
(page section 17).
Normal{11V-18VJ
• Faulty ASS control unit (ECU)
16-8-29
ABS (After '95)
( From the previous page; Light blinks)
1. Retrieve the problem code. Verify the problem

code "7" and clear the problem code.
2. Replace the battery with a new fully charged
battery (paqe 17-12).
light.
Does ASS indicator light blink or go off?

__________
»__:oc"-=::C"-=__~~.,
Light blinks
connection (page 16-8-3 and section 17).
Light goes off
• Faulty battery
16-B-30
ABS (After '951
Problem code 8: Faulty ASS control unit (ECU)
NOTE
The ASS indicator light blinks or comes on and stays on when the ECU has been disrupted by an extremely powerful
radio wave (Electromagnetic interference}, This is just a temporary symptom. Clear the problem code and the ECU is
normal unless the symptom recurs. Ask the ride whether he used a radio apparatus or a security unit of a radio system
when he brings his motorcycle to your dealership for inspection.

engine) and check the ABS indicator light.
I
, 1Retrieve the problem code and record it.
< Does the ABS indicator light blink or come on ~~_~~
Light blinks -j....
a stay on?
Light stays on
/
J------
I Clear the problem code.
Is the problem code "8"7
,i Problem code "8"

Perform the pre-start self-diagnosis (including riding
motorcycle) and check the ASS indicator light.
, Light goes off

Does the ASS indicator light blink or go off? .. 1. Perform the pre-start self-diagnosis (in-
clude riding motorcycle) and retrieve the
Light blinks problem code.
2. Repeat above procedure several times.
Blue Light Green

Light Green Orange Does not appear
-)l repeatedly
Does the problem code "8" appear repeatedly?
Appears repeatedly
Blue/Green
, ~ Faulty ASS control unit

Faulty front or rear modulator if the
problem code "8" appears repeatedly
after the ABS control unit is replaced
with a new one
1. Disconnect the motor driver 12P connector :,16',
and ECU Black connector ,tt with the ignition
switch OFF.
2. Check for continuity between the motor driver
W' connector terminals and body ground. Temporary problem
, (Electromagnetic interference)
< Is there continuity? ~

/
Repair short in the harness between the
ASS control unit (ECUJ and motor driver
,
No continuity
16-8-31
ABS (After '95)
I
,-- '--------
1. Connect the ECU connectors ,j't.
2. Replace the motor driver with a new one.
3. Retrieve the problem code and record It.
-- ,
light.
r-Does the ASS indicator light blink or go off?

~
~Ight goes off
/ - - - ------. • Faulty motor driver
-,
,I Light blinks
16-8-32
ABS (After '95)
Trouble not represented by a problem code: Fautty ASS indicator light
When the clicking sound in the modulator control motor relay can be heard after turning the ignition switch ON, and where
the ASS operates normally while riding:
- Before pre-start self-diagnosis (Ignition switch ON) - While riding
I~
ASS indicator light 2 ASS indicator light 2
ON Blink OFF ON Blink OFF
,. 0
co z Normal A
"'f.-l-,---------+,--------+,---------1
A.S.f.E ,.ro
'"
0
Z -, -, I
o
c,
(i"
~
o
~
:3'
"
0
c
o· co
•
~
,
0
_.
- "
0
-, -, -,
-,
, H-----'--+-------''------I----'---i
to
~
~ 0
D.G.I.J D.G.I.J D. E. F. G.I ~ A.C.I Normal
~
-n
When there is no clicking sound in the modulator control motor relay after turning the ignition switch ON and the indicator
light is faulty Ii.e. pre-start self-diagnosis does not start).
- Before riding (with the engine started and the

motorcycle parked) - While riding
ON
ABS indicator light 2
Blink OFF
r, ON
ABS indicator light 2
Blink OFF
,. 0
H. I. L I I
,.
rn
0
Z I.L I I
'" Z
en
'"_.
0
~
c,
o· ro
• I H I
I I ~
0, ""
-, J. K
-
'"
~
-
~ 0
-n
-n <, J.K I
A: Faulty indicator control unit

S: Poor connection of the indicator control unit connector ':JJ (4P)
C: Poor connection of the indicator control unit connector c
(2P)
0: Faulty ASS indicator light LED 1, poor connection of the connector '6'
E: Faulty ASS indicator light LED 2, poor connection of the connector os
F: Poor connection of the ASS indicator light connector :8:'
G: Poor connection of the ABS indicator light connectorz.
H: Faulty indicator light switch, poor connection of the connectorct
I: Faulty ASS ECU
J: Poor connection of the ASS ECU connector ::11' ASS INDICATOR ASS INDICATOR
K: Burned ASS main fuse (lOA)
~
LIGHT 2
L: Improper battery charge (See section 17.) LIGHT 1
/
~L ABS~I'e?l
16-B-33
ABS (After '95)
Wheel Speed Sensor Air Gap (1) FRONT WHEEL SPEED (3) BRACKET BOLT
SENSOR
Inspection
Front , • ,'>,
~ ,
~ ~ j ,
Raise the front wheel off the ground.
Measure the air gap between the wheel speed sensor
and pulser ring all the way around while rotating the front
wheel by hand. It must be within the specification.
Standard: 0.4-0.5 mm (0.016-0.020 in)

(2) PULSER RING
Adjust by following procedure:
Turn the front wheel so one of the poles of the pulser ring
and sensor face each other. (2) SENSOR
Insert a feeler gauge 0.5 mm between the sensor and
pole, then hold the sensor lightly against the pole.
Tighten the sensor bracket bolt.
Torque: 12 N·m(1.2 kg-m. 9 ft-Ib)
Take off feeler gauge from the gap.

(1) FEELER
GAUGE
O.5mm
\
/
Rotate the front wheel one full turn to make sure that the
pulser ring does not interfere with the sensor.
If not still within specification, remove the sensor

mounting bolts and perform the shim adjustment.
Adjust the air gap again.
~ (4) PULSER RING
Rear
(1) REAR WHEEL SPEED SENSOR
Place the motorcycle on its center stand. (2) f1ULSER RING
Measure the air gap between the wheel speed sensor
and pulser ring all the way around while rotating the rear
wheel by hand. It must be within the specification.
Standard: 0.8 ±~:t mm (0.031 ±K~l,:inl
If not within specification, remove the sensor mounting

bolts and perform the shim adjustment.
Rotate the rear wheel one full turn to make sure that the
pulser ring does not interfere with the sensor.
(3) SHIM
16-B-34
ABS (After '95)
MEMO
16-B-35
AB5 (After '95)
Front Modulator Removal/Installation
(4) 3P Blue
if) 35 (3.5, 25)
(81
(61
(31
(5) 2P Black
(2(
(10)
(1)
16-B-36
ABS (Afte, '95)
Check the brake system applying the lever and pedal brake after the air bleeding (page 3-13).
CAUTION
Avoid spilling fluid on a painted, plastic. or rubber parts. Place a rag over these parts whenever system is serviced.
When removing the oil bolts, cover the end of the brake hose to prevent contamination. Do not allow foreign material
to enter the system.
When removing and installing the modulator and motor driver, take care not to drop or strike the modulator.
NOTE
Note that there is no brake fluid in the modulator (except in the modulator head}, because the modulator is the motor-
driven hydraulic pressure type. Therefore, brake fluid replacement and bleeding air from the modulator body is not
necessary.
Requisite Service
Lever and pedal brake line fluid draining/air bleeding (page 15-2)

(1) Motor driver connector 3
{21 Motor driver mounting bolt 2
(31 Motor driver 2
(') Modulator crank angle sensor connector 1
(5)
(6)
Modulator control motor connector
Oil bolt ,
1
{71 Sealing washer

,
8
{81 Brake hose
.
NOTE
The reference nu-mbers are stamped on each brake hose
end and the modulator head. When installing, align each
numbers (page 1-37)
(10) Front modulator 1 CAUTION
. Do not disassemble the modulator.
16-B-37
(After '95 J •
ABS
Rear Modulator Remova 1/lnstaliatlOn
~
(3)~ 35 (3.5, 25)
15)
17)
(1) 3P White
(2) 2P Black
16)
16-B-38
ABS (After '951
Check the brake system by applying the pedal brake after the air bleeding (page 3-13).
CAUTION
Avoid spilling fluid on painted, plastic, or rubber parts. Place a rag over these parts whenever system is serviced.
enter the system.
NOTE
Note that there is no brake fluid in the modulator (except in the modulator head), because the modulator is the motor-
driven hydraulic pressure type. Therefore, brake fluid replacement and bleeding air from the modulator body is not
necessary.
Requisite Service
Pedal brake line fluid draining/air bleeding (page 15-2)
Right side cover removal/installation (page 2-2)

(1) Modulator crank angle sensor connector 1 Remove the sensor wire from the clamp and clip.
(2) Modulator control motor connector 1
(3) Oil bolt 4
(5) Brake hose 4
.NOTE
The reference numbers are stamped on each brake hose
end and the modulator head. When installing, align each
numbers (page 1-41),
(7) Rear modulator 1
.
CAUTION
Do not disassemble the modulator.
16-8-39
Symbols
...

~
C
10 (1.0, 7.2)
~
equivalent)
equivalent)

"I~ Apply sealant

17. Charging System/Alternator
Service Information 1 7-1 Battery Removal/Installation 17-12
System Location 17-2 Stator Coil Removal/Installation
('91-'95) 17-13
Troubleshooting 17-4 Alternator Removal/Installation
Charging System Inspection ('91-'95) 17-6 (After '95) 17-14
(After-'951 17-9 Alternator Disassembly/Assembly
(After '95) 17-16
Regulator/Rectifier ('91·'95) 17-7 Alternator Shaft Removal/Installation 17-18
Alternator Inspection ('91-'95) 17-8 Alternator Shaft Disassembly/
(After '95) 17-10 Assembly 17-20
Service Information
The battery gives off explosive gases; keep sparks. flames, and cigarettes away_ Provide adequate ventilation
when charging or using the battery in an enclosed space.
• The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear
protective clothing and a face shield.
- If electrolyte gets on your skin. flush with water.
- If electrolyte gets in your eyes. flush with water for at least 15 minutes and call a physician immediately.
Electrolyte is poisonous. If swallowed, drink large quantities of water or milk and follow with milk of magne-
sia or vegetable oil and call a physician.
KEEP OUT OF REACH OF CHILDREN.
-------
• Always turn off the ignition switch before disconnecting any electrical component.
I.
CAUTION
So~e electrical components may be damaged if terminals or connectors are connected or disconnected while
the ignition switch is ON and current is present.
For extended storage, remove the battery. give it a full charge. and store it in a cool, dry place.
• For battery remaining in a stored motorcycle, disconnect the negative battery cable from the battery terminal.
NOTE
• The maintenance free battery must be replaced when it reaches the end of its service life.
~~~~------
CAUTION
The battery caps should not be removed. Attempting to remove the sealing caps from the cells may damage the
battery.
• Battery can be damaged if overcharged or undercharged, or if left to discharge for long periods.These same conditions
contribute to shortening the "lite span" of the battery. Even under normal use, the performance of a battery deteriorates
after 2-3 years.
Battery voltage may recover after battery charging, but under heavy load. battery voltage will drop quickly and
eventually die out. For this reason, the charging system is often suspected to be the problem. Battery overcharge often
results from problems in the battery itself, which may appear to be an overcharge symptom. If one of the battery cells is
shorted and battery voltage does not increase, the regulator/rectifier supplies excess voltage to the battery. Under
these conditions, the electrolyte level goes down quickly.
Before troubleshooting the charging system, check for proper use and maintenance of the battery. Check if the battery
is frequently under heavy load, such as having the headlight and taillight ON for long periods of time without riding the
motorcycle.
• The battery will self-discharge when the motorcycle is not in use. For this reason, charge the battery every two weeks
to prevent sulfation from forming.
• Filling a new battery with electrolyte will produce some voltage, but in order to achieve its maximum performance,
always charge the battery. Also, the battery life is lengthened when it is initial-charged.
• When checking the charging system, always follow the steps in the troubleshooting flow chart (page 17-4).
• For battery testing/charging, refer to section 22 of the Common Service Manual.
• For charging system location. see page 17-2.
17-1
Charging System/Alternator
System Location
'91-'95
(1) IGNITION
SWITCH
(2) REGULATOR
RECTIFIER
(3) BATIERY
(5) ALTERNATOR
(4) MAIN FUSE

----- - -
30A
{1} IGNITION
(6) FUSE lOA SWITCH
BI~R/BI~
, W R
(4) MAIN FUSE
30A
(3) BATTERY
8 lZV lZA
(Z) REGULATOR
RECTIFIER
G
(5) ALTERNATOR
1
17-2
After '95
LBS-ABS/TCS model shown:
--~l
(1) IGNITION SWITCH
/tarjl ,
(2) BATTERY
(6) ALTERNATOR
(5) MAIN FUSE 30A
(4) ALTERNATOR FUSE 55A
(4)
ALTERNATOR ~-,--.----~
(6) ALTERNATOR FUSE 55A
,
(5) (2) BATTERY
~,
MAIN
~ FUSE
30A
~
.i '0"- " ,
-00
'n
:.=:J
- m
c
~
c "
-m-
(3) FUSE lOA
" ~ j .Q: "---W-BI~RlBI ,/,,--0

f-SY ~ 0 (1) IGNITION
L-" SWITCH
_ ri) RECTIFIER
R--- --Red
BI ·····Black
17-3
Troubleshooting
'91-'95
Battery Overcharging
• Faulty regulator/rectifier
Battery Undercharging
NOTE
In order to obtain accurate test readings when checking the charging system, the battery must be fully charged and
in good condition. See Common Service Manual section 22 for checking the battery condition.
Measure the battery current leakage Incorrect Check the regulator/rectifier unit inspection
(Leak test) (page 17-6)
• (page 17-7, 17-8)
Incorrect Correct
I
Correct
Correct
L: Shorted wire harness
Faulty ignition switch
Faulty regulator/rectifier
Inspect the regulated voltage (page 17-6)
Not Charging
~-----:--L :="""':-:c__
Check the voltages of the regulator/rectifier battery, __Abnormal
charging line and ground line (page 17-6) r • Open circuit in wire harness
I • Poorly connected connectors
Normal
Check the alternator (charging and field coils)

Abnormal Check the charging and field coils at alternator
resistance at the regulator/rectifier connector • (page 17-7)
(page 17-7}
1-
Normal
Abnormal Normal
I
Poorly connected alternator
connector
1_ _ ,--~.-. Faulty alternator
Abnormal
17-4
After '95
Inspect the following before diagnosis the system.
- discharged battery
- loose or corroded terminals of the connectors
NOTE
In order to obtain accurate test readings when charging system, the battery must be fully charged and in good condition.
See Common Service Manual section 22 for checking the battery condition.
Measure the battery current a~pere leakage !'-_'-='-::C'

Incorrect ---.1 Check the alternator (regulator/rectifier)
I {Leak test} (page 17-9) (page 17-10)
1 ---
I
Correct
I Incorrect
I
Correct
,
_t,---
llnspect the regulated voltage (page 17-9) =:J- More than 14.8 V J
Shorted wire harness
14.2-14.8 V
------', Lessthan 14.2 V
Check the voltage of the regulator/

rectifier input line (page 17-10)
Abnormal
-
Faulty battery
Open circuit in wire harness
,
Loose connections
Normal Faulty ignition switch
- ,
; Check the voltage of the battery charging line If--'-=='-='-_

Abnormal
I
(page 26-152) J Open circuit in wire harness
Loose connections
Burned out alternator fuse {55 A)
_
Normal
Disassemble the alternatorL'~~~~ and inspect the

following:
Faulty rotor coil
stator coil (page 17-11) Abnormal
rotor coil (page 17-11) • Faulty stator coil
Worn brush
brush length (page 17-11)
regulator/rectifier (page 17-10)
17-5
Charging System Inspection ('91-'95) (1) BATTERY GROUND CABLE
Current Leakage Test

(2) BATTERY
Turn off the ignition switch, and disconnect the ground H NEGATIVE
cable from the battery. TERMINAL
Connect the ammeter (+) probe to the ground cable and the
ammeter (-) probe to the battery (-) terminal.
With the ignition switch off, check for current leakage.

e
NOTE
I. When measuring current using a tester, set it to a
high range, and then bring the range down to an
appropriate level. Current flow larger than the range
selected may blowout the fuse in the tester.
While measuring current, do not turn the ignition on.
A sudden surge of current may blowout the fuse in
the tester.
---------
Specified Current Leakage: 3 mA max.
If current leakage exceeds the specified value, a short circuit

is likely.
Locate the short by disconnecting connections one by one
and measuring the current.
Regulated Voltage/Ampere Inspection
NOTE
Before performing this test be sure that the battery is
fully charged and that the voltage between its terminals
is greater than 12.6 V.
Remove the left side cover (page 2-2).

Start the engine and warm it up to operating temperature,
-,-----
then turn the ignition switch OFF.
If the engine must be running to do some work,

make sure the area is well-ventilated. Never run the
engine in an enclosed area.
• The exhaust contains poisonous carbon monoxide
gas that may cause loss 01 consciousness and lead
to death.
Connect a voltmeter between the battery terminals.
17-6
Charging SystemlAlternator
Disconnect the starter relay switch connector and remove

(2) CONNECTOR ~
the main fuse.
~n ~l
Reconnect the connector secoretv.
Connect the ammeter as shown.

(11 MAIN FUSE
CAUTION ~ ~ " ." Ir: +eo
0
Be careful not to short any tester probes.
'~~
Although the current could be measured when the
liLt'!! e
0
ammeter is connected between the battery positive !
•
terminal and the positive cable, a sudden surge of
current to the startBr motor could damage the ammeter.
Always turn the ignition off when conducting the
~,~f~
,
test. Disconnecting the ammeter or wires when current (3) STARTER RELAY SWITCH
IS flOWing may damage the ammeter.
NOTE (1) BATIERY POSITIVE(+)

Before making this test. all the lights and the other TERMINAL
electrical equipment should be OFF.
Use fully charged battery to make this test for correct
measurement.
Start the engine and increase the engine speed gradually.
Regulated Voltage: 12.6-15.0 V/5,OOO rpm

Charging Current: 0-1.0 A/5.000 rpm
~~~~--~~--(~2~1 :B1ATIERY NEGATIVE(-)

TERMINAL
Regulator/Rectifier ('91-'95) .-------

,
(1) CONNECTOR
Wire Harness Inspection

Disconnect the regulator/rectifier 6P connector and check
the connector for loose or corroded terminals.
Measure the following between the connectors of the wire

harness side.
Item Terminals Specification

Battery charging Red/White (+) Battery voltage
line and ground should register.
Charging coil line Yellow and Yellow 0-1.0n.
(20"C/68° F)
Field coil line White and 0-4_0n.
Black 1120'C/68'FI
17-7
Unit Inspection Unit' kg

\ + Probe Red/
Provided the circuits on the wire harness side are normal and
- Probe " White
.veuow 1 Yellow 2 Yellow 31, White
there are no loose connections at the connector, inspect the .
regulator!rectifier unit by measuring the resistance between ~lWhite <, co co ca co
the terminals.
Yellow 1 7.5 <, co ca co
NOTE
~low2 7.5 = <, oo co
'-
• You'll get false readings ifthe probes touch your fingers.
• Use the specified multlrneters. Using other equipment
Yellow 3 7.5 co co , <, cc
may not allow you to obtain the correct results.
This is due to the characteristic of semiconductors,
White 60 28 28 28 <,
which have different resistance values depending on
the applied voltage.
Specified Multimeter :
-SP-15D (SANWA Analogue type)
-TH-5H (KOWA Analogue type) (2) BLACK
._\ (3) WHITE
• Select the following range: (1)YELLOW~ \
(4) YELLOW
SANWA; kO
KOWA; Xl00
• An old battery stored in the multimeter could cause in-
accurate readings. Check the battery if the multi meter ~"'
resistance is incorrect. =
Replace the regulator/rectifier unit if the resistance value
between the terminals is abnormal.
(6) REDIWHITE (5) YELLOW
Alternator Inspection ('91-'95) (1) 3P CONNECTOR

---,
NOTE
,4 !~ .
• It is not necessary to remove the stator coil to make
this test. ~__ ..u=:.
Remove the left side cover (page 2-2) and disconnect the __ -"S:y
alternator 3P (Red) and 2p (Black) connectors.
::-.::~ -1~ I'
Measure the resistance between the yellow wire terminals /.~_!,n,
c
- I'",
,
and check for no continuity between each terminal and I, '
ground. V.-----·- -'p , _'
Yellow terminal-Yellow terminal: 0-1.00 (2) 2P CONNECTOR

Yellow terminal-White terminal: No continuity
Yellow terminal-Red/white terminal: No continuity
Measure the resistance between the white and black terminals
and check for continuity between the 2P connector termi-
nals.
Standard: 0-4.00 (20'C/68" Fl
Replace the stator if the resistance is out of specification or

if there is continuity between any terminal and ground.
17-8
Charging System Inspection (After '951 (1) BATTERY GROUND CABLE
Current Leakage Test

(2) BATTERY
NEGATIVE
Turn off the ignition switch, and disconnect the ground (-) TERMINAL
cable from the battery.
Connect the ammeter {+} probe to the ground cable and the
ammeter (-) probe to the battery (-) terminal. 8
With the ignition switch off, check for current leakage.
NOTE
When measuring current using a tester, set it to a
high range, and then bring the range down to an
appropriate level. Current flow larger than the rang],
selected may blowout the fuse in the tester.
While measuring current, do not turn the ignition on.
A sudden surge of current may blowout the fuse in
the tester.
Specified Current Leakage: 2 mA max.
If current leakage exceeds the specified value, a short circuit

is likely.
Locate the short by disconnecting connections one by one
and measuring the current.
Regulated Voltage Inspection
NOTE
i.
Before performing this test, be sure that the battery is
!fully charged and that voltage between its terminals
~ greaterthan 12.6 V.
Start the engine and warm it up to operating temperature,

then turn the ignition switch OFF.
• H the engine must be running to do some work, make ---------

sure the area is well-ventilated. Never run the engine
in an enclosed area. ,
• The exhaust contains poisonous carbon monOXideJ
' gas that may cause loss of consciousness and lead
_ _ death.
to cc"'---__ _ _
CAUTION
i • Be car~ul not to short any tester probes.
Connect a voltmeter between the battery terminals.

Turn the headlight ON (High beam) and start the engine.
Gradually increase the engine speed and check that the
voltage is regulated.
Regulated Voltage: 14.2-14.8 V/5,OOO mln-' (rpml
17-9
L
Wire Harness Inspection (1) WHITE CONNECTOR
(Input line)
I-~
::==J
Disconnect the battery negative (-) cable.
i/"" - -
I.'~ V,:1
Disconnect the battery negative cable from the
battery to prevent sparking when disconnecting the I
drL I $>,
alternator cable. Ij~ooo<~-_-:'-:'~~~j;:;0/-
'-»
Disconnect the alternator cable and White connector from r~
the alternator. (2) ALTERNATOR CABLE
(Charging line)
Connect the battery negative (-) cable onto the battery.
Measure the voltage between each wire (wire harness side)

and ground as indicated on the chart.
-
Disconnect the battery negative (-) cable to avoid sparki ng ITEM TERMINALS SPECIFICATION
which would otherwise occur when connecting each wire Battery charging line Alternator cable BalTery voltage
to the alternator. terminal ITI and should register.
ground H
,
BalTery voltage White connector Battery voltage should
input line terminal (+1 and register with the
ground I-I ignition switch ON,
Alternator Inspection (After '95) (1) E (ground) B

Disassemble the alternator (page 17-16)
Rectifier P,
P '"
"'-e
Before inspecting, the rectifier must be separated from the
regulator.
NOTE
The diodes are designed to allow current to pass in
one direction while blocking it in the opposite
P
direction. Since the alternator rectifier is made up of
eight diodes, each diode must be tested for continuity
in both directions that has diode checking capability;
a total of 16 checks.
Check for continuity in each direction between

- Band P (P" Pl, P3, P4) terminals.
- E (ground) and P (P" P" P3, P,) terminals.
All diodes should have continuity in only one direction.
If any of the diodes fails, replace the rectifier assembly.

(Diodes are not available separatefv.)
17-10
Stator (1) TERMINALS
Check the resistance between each pair of terminals. There

should be minimal resistance.
Standard: 0.22 - 0.26 n (20°C/68°F)
Check for continuity between each terminal and the coil

core. There should be no continuity.
Rotor Coil
Check the slip rings for stepped wear.
Measure the 0.0. of each slip ring.
Service limit: 12 mm (0.5 in)
Measure the resistance between the slip rings.
Standard: 2.6 - 3.2 n (20°C/68°Fl
Check for continuity between the slip ring and the

rotor or rotor shaft. There should be no continuity.
Brushes
Measure each brush length.
Service limit: 4.7 mm (0.19 in)
(l) BRUSHES
17-11
Battery Removal/Installation
{11
(4)
(3)
~(2)
Requisite Service
• Left side cover removal/installation (page 2-2)

With the ignition switch "OFF", disconnect the negative (-) cable first, then the positive (+} cable.

f--
(1) Battery negative (-) cable 1 ,
(2) Battery holder nut 1 After removing, open the battery holder.
(3) Battery positive (+) cable 1
14) Battery 1
17-12
Stator Coil Removal/Installation ('91-'95)
(5)
{11
(4) ------~
\ / (2)
(3)
~l·········~-~ {7)=!t"7J {6)~-~ ~
Requisite Service

(1) Lock nut 2 It is not necessary to remove, just loosen.
(2) Gearshift pedal connecting rod 1 .
(3) Tube holder 1 After installation, route the tubes correctly (page 1-25).
[4) Gearshift pedal 1
(5) Alternator connector 2
(6) Stator assembly 1
[7) O-ring 1
17-13
Alternator Removal/Installation (After '95)

View from rear:
~1t:=~{41
Alternator base
Secure with a Bmm bolt
~T
i
c
~
, ...
Mounting bosses
Alternator base (6)
-,
Alternator shaft assembly
17-14
~ servicing, disconnect the batlery negative cable from the batlery to prevent sparking when disconnecting the
alternator cable.
Requisite Service
FueI tan k remova Vinstallation (page 2-12) Left pivot cover removal/installation (page 2-5}
Swingarm removal/installation (page 14-8)

11) 2P {White} connector 1
(2) Terminal nut 1 After tightening the terminal nut, install the terminal cap to
the terminal flange securely.
(3) , Alternator cable 1
(4) Mounting bolt 3
.
NOTE
Before removing the alternator, turn the alternator
clockwise and temporarily secure the alternator base
with a 8 mm bolt as shown.
If the alternator base is not secured, it will cause the
alternator shaft to come out with the alternator. If this
occurs, oil pan removal will be necessary when
, reinstalling (page 17-18}.
(5) Alternator 1 Pry the mounting bosses of the alternator using a
screwdriver.
Disassembly/assembly (page 17-16)
(6) O-ring i 1
17-15
Alternator Disassembly/Assembly (After '95)
(10)
cu ) 1131qJ. ~
--------- -
141
------------
(5)
1 .., {3j
151
(9)
17(
12(
17-16
Requisite Service
• Alternator removal/installation (page 17-14)
Procedure , Q'ty Remarks
Disassembly or der Assembly is in the reverse order of disassembly.

11 } End cover screw 3
12} Nutfterminal insulator 1/1
131 Rear end cover 1
141 Terminal screw (pan-head) 2
151 Terminal screw (flange) 3
161 Regulator 1 ,
,
171 Brush assembly/holder insulator 1/1
18} Terminal screw (flange) 4
19} Rectifier 1
(10) Housing nut 2
(11) Rear housing , 1 Before installing, clean the slip rings thoroughly.
(12) Rotor 1 NOTE:
. Usea hydraulic press. Do not strike the slip ring ofthe
rotor shaft.
(13) Oil seal 1
(14), Retainer screw 4
(15}i Bearing retainer 1
(16} Front bearing (6202)/washer 1/1 i
(H} Spacer ring/rear bearing (6002} 1/1 I
17-17
Alternator Shaft Removal/Installation

'91-'95
131et,
(t I
.{J/~§Y 0 5 8 (5.8, 42)
121
6 mm bolt
Requisite Service
Engine removal/installation (page 7-2)
Oil pan removal/installation (page 4-6)
Stator coil removal/installation {page 17-13)

(t) Alternator shaft bolt 4 NOTE
Before removing, insert a 6 mm bolt in the holes in the
alternator shaft driven gears for easy alternator shaft
assembly installation. After installing, do not forget to
remove the bolt.
121 Alternator shaft assembly t NOTE
Before installing, apply molybdenum disulfide grease to the
alternator shaft driven gears. Disassembly/assembly {page
17-20}
(31 O-ring t
17-18
After '95
et'l
121
I' 1
6mm bolt
Requisite Service
Oil pan removal/installation (page 4-6)

Alternator removal/installation {page 17-14}
Removal Order i Installation is in the reverse order of removal.

.NOTE
Before removing, insert a 6 mm bolt into the holes in
the alternator shaft driven gears for easy alternator
shaft assembly installation. After installing, do not
I' 1 Alternator shaft assembly , forget to remove the 6 mm bolt.

NOTE
. Before installing, apply molybdenum oil solution to
the alternator shaft driven gears.
(2) la-ring , Disassembly/assembly (page 17-21)
17-19
Alternator Shaft Disassemlby/Assembly

'91-'95
110}
19}
IS}
IS}
131 141 15}
17}
Requisite Service
. Alternator shaft removal/installation (page 17-18).
Disassemlby Order Assembly is in the reverse order of disassembly.

11 } Alternator shaft nut 1
12} Washer 1
13} Bearing 1
14} Shaft collar 1
15} Cone washer 1 Install the washer with the tapered side facing to the
shaft nut.
IS} Alternator shaft driven gear 1
17} Damper spring 5
IS} , Spring seat 12
Flywheel 1
19:}1
110} 1
Alternator shaft assembly
17-20
After '95 (9(
~I
(51 I
I
(41 I
(31
(11)
Requisite Service
• Alternator shaft removal/i nstauatron (page 17-19)
Procedure Q'ty I Remarks

(1) , Alternator shaft nut 1
(2( Washer 1
(31 Bearing (6003) 1
141 Shaft collar 1
151 Cone washer 1 Install the washer with the tapered side facing to the shaft
nut.
161 Alternator shaft driven gear 1
171 Damper spring 4
181 Spring seat 8
(91 Flywheel 1
(10) Bolt 3
(11) Retainer plate 1
(12) Alternator base 1
(13) Bearing (20 x 47 x 10.5) 1
17-21
Symbols
...

~
C
10 (1.0, 7.2)
~
equivalent)
equivalent)

"I~ Apply sealant

18. Ignition System
Service Information 18-1 Ignition Coil 18-8
System Location 18-2 Ignition Pulse Generator Inspection 18-9
Troubleshooting 18-4 Ignition Pulse Generator Removal! 18-10
18-6 Installation
Ignition System Inspection
Ignition Timing 18-11
Service Information
• When checking the ignition system, always follow the steps in the troubleshooting flow chart (page 18-4).
The digital transistorized ignition system uses an electrically controlled ignition timing system. No adjustments can be
made to the ignition timing.
• A rough diagnosis can be made by identifying the cylinder whose spark timing is incorrect.
• The ignition control module (leM) may be damaged if dropped. Also, if the connector is disconnected when current is
flowing, the excessive voltage may damage the unit. Always turn off the ignition switch bercre servicing.
A faulty ignition system is often related to poorly connected connectors. Check those connections before proceeding.
Make sure the battery is adequately charged. Using the starter motor with a weak battery results in a slower engine
cranking speed as well as no spark at the spark plugs.
• Use spark plugs of the correct heat range. Using spark plugs with an incorrect heat range can damage the engine.
Refer to section 2 of the Common Service Manual.
For neutral switch inspection, refer to section 25 of the Common Service Manual; for switch location, see page 18-2 or
18-3 of this manual (System Location).
For the ignition switch and engine stop switch inspection, check for continuity on the continuity chart of the Wiring
Diagram (section 22). Refer to page 21-4 for side stand switch inspection.
18-1
Ignition System
System Location (4) BANK ANGLE

Standard Model SENSOR RELAY
(5) BANK ANGLE

(3) SIDE STAND
INDICATOR LIGHT SENSOR
(2) IGNITION SWITCH (6) ENGINE STOP

SWITCH
(1) No. 2,4 IGNITION y;"
COIL
/\ (7) No.1,3 IGNITION
COil
(8) IGNITION PULSE

GENERATOR
(13) IGNITION
CONTROL
MODULE
{ICM}
(12) NEUTRAL
SWITCH
{11} SIDE STAND

SWITCH
(10) MAIN
FUSE
30A
(9) BATIERY
(4) BANK ANGLE
SENSOR RELAY
(6) ENGINE STOP
(5) BANK ANGLE
SENSOR I S~TCH
-0
/>-J
V
(1) No. 2,4
IGNITION COIL
{71 No. 1 ,3-~

IGNITION I (13) ICM
W I G RIW COIL -r-r
RjW
-;[ W/Y
...L lOA ,--'--
y
L--BI'-----I
...".., R _ R/BI
(10) MAIN (2) IGNITION FUSE
FUSE SWITCH lOA
30A
_L'----
(11)SIDESTAND
SWITCH
I (12) NEUTRAL
-=- (9) BATTERY
SWITCH
TO TACHO-
METER
TO STARTER
CIRCUIT
18-2
Ignition System
ABS/TCS or LBS-ABS/TCS Model ABS/TCS model shown:
(3) SIDE STAND (4) BANK ANGLE SENSOR RELAY

INDICATOR LIGHT
(2} IGNITION SWITCH (6) ENGINE STOP SWITCH

~-~
(7) No.1, 3 IGNITION
(1) TCS/ignition
COIL
control module
(lCM) C~\ - (8) IGNITION PULSE
'---~ GENERATOR
(13) No. 2,4

IGNITION COIL
(12) NEUTRAL
SWITCH
(11) SIDE STAND

SWITCH
(10) MAIN
FUSE (9) BATTERY
30A
(4) BANK ANGLE
SENSOR RELAY (6) ENGINE STOP
(5) BANK ANGLE
SENSOR
(1) TCS/ICM
BI/Y
W/Y
'-
L--BI----.J T
LG
R _ R/BI _BI/BR = -
~~o
(lOJ MAIN (2) IGNITION FUSE (3) SIDESTANDlQI'-
FUSE
-~,
SWITCH 10A INDIATOR
30A
LIGHT
(11)SIDESTAND
/ J
--=- (9) BATTERY SWITCH (12) NEUTRAL
TO TACHO- SWITCH
METER (8) IGNITION PULSE
TO STARTER GENERATOR
CIRCUIT
18-3
Ignition System
Troubleshooting
No spark at all plugs (Faulty input system)
If there is no spark at all plugs, the problem could be at the input of the ignition system (ignition pulse generator. pow-
er input circuit of the ignition control module (ICM), neutral switch, side stand switch or ICM).
Check for loose or poorly connected ICM con-I

• Poorly connected connector
nector. I Abnormal
1 Normal
Check for loose or poorly connected ignition coil

• Poorly connected connector
3P mini connector. Abnormal
~ Normal
I Check for battery voltage between the power
input line (Black/White: standard model, Black/
'Yellow: ABS·TCS model) and ground (Green) at
Abnormal
• Faulty ignition switch
Faulty engine stop switch (except A8S·TCS
the 'CM connector with the engine stop switch
at RUN (except ABS·TCS model) and the ignition model) For the engine stop switch inspection of
, switch ON (page 1B-6).
ABS' TCS model, see page 18-1.
I Normal
Loose or poor contact of related circuit con-
nectors
j Faulty bank angle sensor relay

Faulty bank angle sensor
Measure the ignition pulse generator resistance I Check the ignition pulse generator (page 18 7). I
at the lCM connector (page 18-6). Abnormal
Normal Abnormal
• Faulty ignition pulse

Normal generator
· Open circuit between the ICM and ignition pulse
generator
· Loose or poor contact of the ignition pulse gene-
rater connector
Check the neutral switch for continuity at the I
ICM connector (page 18-6).
i Check the neutral switch.
Abnormal
Normal Abnormal
• Faulty neutral
switch
Normal 1
· Open circuit between the leM and neutral
switch
· Loose or poor contact of the neutral switch
connectors
Check the side stand switch at the ICM connect-j
Check the side stand switch (page 21 4).
or (page 18-6).
i
i Abnormal
Normal Abnormal
!Normal
. Faulty ICM
• Faulty side stand
switch
Open circuit between the ICM and side stand

switch
Loose or poor contact of the side stand switch
connector
18-4
Ignition System
No spark at either ignition group

If there is no spark at either group, the problem is suspected in the primary coil side of the ignition system (ignition
coil, or ignition control module (ICM) and ignition coil circuit).
Switch the ignition coil primary terminal con-

! nection between the faulty pair and good pair.
..I Remove the faulty pair ignition coil and check
"No Spark" I the ignition coil resistance (page 18-7).
i Try spark test again
condition
UNo Spark" condition

shifts to other pair
remains with
faulty pair f Faulty Ignition coli
" Faulty spark plug
wire
Measure resistance of the ignition primary coil

'
I, ~.
.. " Poor or loose contact of ignition coil 3P mini
at ICM connector (page 18-6).
_~"-_ _~ ~ Abnormal connector
Open circuit between the 1CM and ignition coil
r Normal
Faulty ICM
No spark at one plug (Trouble in secondary coil side)

" Faulty spark plug is most likely.
Replace (suspected bad spark plug) with known I

-.." Original spark plug no good.
good spark plug and conduct spark test. i Normal
Abnormal
Put the spark plug wire on and measure resistance

~ Conduct spark test on good ignition coil.
of ignition secondary coil (page 18-7). Normal
Abnormal Normal
Remove the spark plug wire, and measure the

resistance of the ignition secondary coil (page f - - _" Faulty ignition coil
18-7) . Abnormal
~ Normal
Poor contact of spark plug wire
Faulty spark plug wire
Side stand switch does not function at all.
Side Stand Indicator: Normal

___" Faulty side stand switch
I Check the side stand indicator for function. Open circuit in Green/White or Green wire
Abnormal
ISide Stand Switch: Normal

-.." Loose or poor contact of related connectors
Check the side stand switch for continuity.
Open or short circuit in wire harness
Burnt indicator bulb
Abnormal
Faulty side stand switch
18-5
Ignition System
Ignition System Inspection STANDARD MODEL:

(1) ICM
NOTE
Check the system components and lines step-by-step
according to the troubleshootinq chart on pages 1B-4
and 18-5.
Standard model:
Remove the left fairing pocket (page 2-6).
Remove the ignition control module (ICM} from the stay,
disconnect the ICM connector and check it for loose or
corroded terminals.
ABS/TCS or LBS-ABSITCS model: ASS/TCS or LBS-ABS/TCS MODEL:

Remove the middle fairing inner cover (page 2-7).
Disconnect the TCS/ignition control module (ICM) 16P con-
(1) TCS/ICM
nector and check it for loose or corroded terminals.
Measure the data between the connector terminals using

the following chart.
Item Terminals Standards (20"C/6B"F)

Battery voltage input line Black/white [ABS/TCS or LBS-ABS/TCS Battery voltage should register
model: Black/Yellow] (+) and Ground (-)
with the engine stop switch RUN (Standard
model) and the ignition switch ON.
Ignition pulse generator line Yellow and White/yellow 405-495 Q
Ignition primary No. , ,3 Yellow/blue and Black/white

2.16-3.19 Q
coil line
No. 2,4 Blue/yellow and Black/white
Neutral switch line Light green and Ground Continuity in neutral

No continuity in any gear
Side stand switch line Green/white and Ground Continuity with the stand up
No continuity with the stand down
Ground line Green and Ground Continuity
Tachometer line Yellow/green and Green wire connector of Continuity

( the harness side at the instruments
I
18-6
Ignition System
Ignition Coil (1) 3P CONNECTOR
Inspection
Remove the upper fairing (page 2-9).

Disconnect the ignition primary coil 3P connector (white)
and measure the primary coil resistance between each ignition
coil.
Primary coil resistance:

Standard: 2.16-3.19Q (20'C/6So F)
Disconnect the spark plug caps from the plugs and measure (1lIGNITION COIL
OJl\-~
the secondary coil resistance with the spark plug caps in
place,
Standard: 22.5-27.5kQ (20'C/6S" F)
;,= (OJ (iiiiiii
,
0
If the resistance is out of the range, remove the spark plug

caps and measure the resistance between the secondary (2) IGNITION COIL
coil terminals .~t:r
Standard: 13.5-16.5kQ (20°C/6S" F) 0 iiiiiii
Q 0
(1) SPARK PLUG WIRES f

I I
18-7
Ignition System
Ignition Pulse Generator Inspection STANDARD MODEL:
NOTE
It is not necessary to remove the ignition pulse gene-
rator to make this inspection.
Standard model:
w
@
Remove the right side cover (page 2-2).
~--- ~~~~~~
-~~~cccc~_D (G';"'--
ABS/TCS or LBS-ABS/TCS model: ------------::;)~~q -;:-------r--
Remove the top shelter (page 2-5). :----J V ~
(1) IGNITION PULSE GENERATOR 4P CONNECTOR
Disconnect the ignition pulse generator 4P connector and
measure the resistance between the White/Yeliow and
Yellow wires.
ABS/TCS or LBS-ABS/TCS MODEL:
Standard: 405-4950. (20·e/68·F)
Refer to page 18-9 for ignition pulse generator replacement.
18-8
Ignition System
Ignition Pulse Generator Removal/Installation

ABS/TCS model shown: \ \ "
(11
0'12 (1.2, 9)
.,('G1l!
(61 (31
Clamp (~,
0'12 (1.2, 9)
(21
Requisite Service
• Fuel tank Removal/Installation (page 2-12).
111 Oil pressure switch terminal 1
(21 Neutral switch connector 1 At installation, insert the neutral switch wire into the
clamp as shown.
(3} Waterproof connector (4P) 1
14} Bolt 4
151 Gasket 1
(6} Dowel pin 2
(7} Bolt 2
(81 Ignition pulse generator 1
18-9
Symbols
...

~
C
10 (1.0, 7.2)
~
equivalent)
equivalent)

"I~ Apply sealant

19. les
Service Information 19-1 Circuit Diagram 19-4
System location 19-2 Troubleshooting 19-5
System Wiring Connections/Locations 19-3
Service Information
CAUTION
Use the fully charged battery for troubleshooting. Do not diagnose the TeS with a charger connected to the
battery .
On removal and installation of the wheel sensors/wheels. be careful not to damage the wheel sensors and pulser
rings.
NOTE
Check the following before performing any TCS troubleshooting.
res
- Pre-start self-diagnosis of
res
- Check on all lights and indicators of
If an abnormality is found during the above checks, perform the TCS troubleshooting following the Symptom-to-
System Chart (page 19-6). The TCS is normal if no trouble is found. Go on to the check the other basic systems (e.
g. fuel system, ignition system, etc.).
Record the symptom of the problem and the problem code in MEMO before troubleshooting.
When the TCS is faulty, the TCS indicator light blinks or it comes on. The TCS does not function this time; take care
The TCS OFF indicator turns on when the TCS ON/OFF switch connector is disconnected and then reconnected with i
the ignition switch ON. The TCS can be recovered this time by pushing the TCS ON/OFF switch. Take care when
removing the left side pocket.
When the rear wheel sensor or rear purser ring is replaced, perform the air gap inspection (16-51).
The TCS indicator light might blink in the following cases. If the indicator light blinks, turn the ignition switch OFF and
perform the pre-start self-diagnosis (page 19-5}. The TCS is normal if the TCS indicator light goes off.
The lCS/ignition control module was disrupted due to an extremely powerful radio wave (Electromagnetic Interfer-
ence).
After riding (i.e. after the pre-start self- diagnosis), either front or rear wheel was stopped and the other wheel was
turned (for more than 10 seconds) with the engine kept running.
Example:' Only the rear wheel was turned with the motorcycle set on the main stand.
o Only the front wheel was turned for inspection of the meter.
• When, after the test ride (i.e. after pre-start self- cnaancstsj.the motorcycle is set on the center stand with the engine
running and the throttle is opened quickly with the gear engaged (rear wheel idles), the ignition timing is retarded
because of the difference in wheel speed between the front and rear wheels, which might cause afterfire and afterburn .. ~
• The TCS indicator light might blink under the following conditions. Turn the ignition switch OFF to return to the normal ~
condition and perform the pre-start self-diagnosis (page 19-5) of the TCS. The TCS is normal if the TCS indicator goes
off:
Improper tire air pressure
Tire not recommended for the motorcycle is installed.
Deformation of the wheel
19-1
TCS
System Location
ASS/les model shown:
(6) res INDICATOR LIGHT

(7) res ACTIVATION LIGHTS
(4) res ON/OFF SWITCH

(8) res OFF INDICATOR
(3) ASS/leS INDICATOR LIGHT SWITCH
(2) BATTERY
(1) FUSE CASE (9) leS/IGNITION CONTROL

MODULE
(10) BANK ANGLE SENSOR RELAY
1~""'~~~~~~\\.,L-(11) BANK ANGLE SENSOR

-------- -
(19)
REAR (17)
WHEEL SENSOR IGNITION
PULSE GENERATOR
(16) NEUTRAL SWITCH (13) FRONT PULSER RING
(1S) REAR PULSER RING
(14) IGNITION COILS
19-2
System Wiring Connections/Locations
(2) res ON/OFF SWITCH
. Refer to section2, (frame/body panels 'J:: REAR WHEEL SENSOR -Top shelter
lexhaust system), for the parts that -R. side coler (page 2-2) (page 2-5)
must be removed for service
For example::~ res SWITCH<-Maintenance part

-Top shelter-s-The parts _---_
that must be removed
for service.
INDICATOR FUSE
("METER TAIL POSIT1QW)
IGNITION FUSE
nGN ACG STARTER")
FUSE CASE
-L. side cover
(page 2-2)
~~~'"~~C
-
------------------------
--------
,
..
0' BLACK
Y YELLOW
G
R
BLUE
GREEN
RE.
O. BROWN
0 ORANGE
Lb UGHTBLUE
L. UGHTGREEN
P PINK
W WHITE G. GRAY t.':: FRQN
-Upp
(page
TCS
F SWITCH
::j', ABS/TCS INDICATOR LIGHT SWITCH
-Top shelter (page 2-5)
($) INDICATOR (BLACK)

:~: INDICATOR (WHITE)

-trmer screen (page 2-7)
= =
G/O V\jo Vj %
G~
ts u
RJ
0 Ala G!B
(1) reS/IGNITION CONTROL

MODULE (leM) (16P)
(8: reS/IGNITION CONTROL

MODULE (leM) (4P)
(~)
m
BANK ANGLE SENSOR
<C!]) BANK ANGLE SENSOR RELAY

61 B yv
AIw 61
(~l
dJ FRONT WHEEL SENSOR
-Upper fairing
(page 2-9)
19-3
TCS
Circuit Diagram
81 BLACK B, BROWN
Y YELLOW ,0 ORANGE
~BLUE Lb LIGHT BLUE
reS/IGNITION CONTROL MODULE
G GREEN Lg LIGHT GREEN
R REO P PINK
-
W WHITE Gr GRAY
SIDE STAND SW ....... - - - . ,
NEUTRAL SW .... - -
{:lllJ~I~~~~~G;':,.
-Z -Z
-i -i
m m
~ ~
IGNITION PULSE GENERATOR -n -n
"o - "o
* 6-::=====+.
n
y-
m IGNITION r- m
Q
~ ~
rBl-r--- g Y
G,IY·
WI
o
e
n
e
res SWITCH " "
2P- 81
rB r-'i{~~'::::Y====l:H
INDICATOR LIGHT
SWITCH
-Z -Z
01y. -i -i
m m
~ ~
Bul G -n ~
BIIO·
Bul 8'
"
o
m e- TRACTION
CONTROL
f- "
o
m
Q Q
~ ~
n o
e e
-i
"
ASS CONTROL UNIT
FRONT WHEEL REAR WHEEL

SENSOR SENSOR
19-4
res ACTIVATION L1G HT
res OFF INDICATOR ~~CS INDICATOR LIGHT
//~
-
- TACHO
: ~ ~fl
D5 0 fe. ~ a:l{.9 ~
~~ iii): ~;: ~
Q.
II:
~R~AITERP
METER
~W/O
~R/O
t- Su/Y lOA
I-Y/Bu
~BIIY
~LglO_
IGNITION SWITCH
-
lrl-I-F§~§B~~ R/W-=t..a
- 3P-G
BANK ANGLE
SENSOR RELAY
-+-----t=;~:::1J1::=~~
r- RIW~/~
BANK ANGLE
9~-R SENSOR
-Y/G<-+....,H--..1
,.....-+-BIIW- _BIIW:===r~BIIW~
-BIIY- -BIIY -BIIY-h::::U
ENGINE STOP
SWITCH
-
~G,--t-----~
-
~Ii 2,4 ~B"/Y_

BIIW-
IGNITION COIL
_L.
- .L.
TCS
Troubleshooting
Before Beginning Troubleshooting:
Summary of TCS pre-start self-diagnosis system
The TCS pre-start self-diagnosis system diagnoses inside the TCS/ignition control module (leM) and the electrical circuit
of the wheel sensors.
When the ignition switch is turned ON, the TCS starts the pre-start self-diagnosis to check inside the TCS/ICM for condi-
tion. Then it g08S to the stand-by mode for the wheel sensor signal. After starting the motorcycle, the pre-start self-diag-
nosis completes when the wheel sensor signal is transmitted to the TCSjlCM with the front/rear wheel rotating at the speed
of approximately 10 km/h (6 mile/h) or above.
If the TCS is normal, the indicator light goes off after the motorcycle starts notifying the rider that the pre-start self-diagnosis
is completed. When a problem is detected, the indicator light blinks or stays ON to notify the rider. The self-diagnosis is made
while the motorcycle is moving, too, and the indicator light blinks when a problem is detected. (The TCS OFF indicator
comes ON simultaneously.) The probable cause of the trouble can be detected from the lighting condition of the TCS
indicator light, indicator, etc. (see the following page).
(1) IGNITION SWITCH

ON
OFF
_ _ _ _ _ _/ 10 km/h (6 mile/h) or above
(2) VEHICLE SPEED o
ON
(3) TCS INDICATOR LIGHT
OFF .J I" ; Pre start self diagnosis
ON
(4) TCS OFF INDICATOR
OFF .J I completes.
(5) TCS ACTIVATION LIGHT ON
OFF .JC' =:J------
Approx, 2 seconds
(Check for blown out bulb)
Pre-start self-diagnosis procedure (Pre-start check-up)

2. Be sure that the TCS OFF indicator and TCS activation light turn ON for approximately 2 seconds and then go OFF,
and be sure that the TCS indicator light stays ON.
3. Start the engine and ride the motorcycle until the engine speed reaches approximately 10 km/h (6 mile/h).
4. The TCS is normal if the TCS indicator light goes OFF.
(2) TCS ACTIVATION LIGHT
TCSACTIVE
NOTE
Check the following before performing TCS troubleshooting:
- Pre-start self-diagnosis of TCS
- Check all lights and indicators of TCS
System Chart (see the following page). The TCS is normal if no trouble is found. Go on to the check the other basic:
systems (e.g., fuel system, ignition system). I
19-5
TCS
Symptom-to-System Chart
Affected
Fuse
."
--< - l>
• tn
;:i: Ul
0
~o
_z
;:i:
0_
~-<
U)
Wheel
sensor
system
3-<
0"
~U>
t:::::'
0-~
Indicator system
-0 -" -n
"
0
-= ;::j: -< o-< -< Reference
"
Symptom c,
o·
0
~
'"a:
0
0
~- ~~
~O
O~
3~
0
3~
0
<3
0
~
0
~
o
-
"0
0
0'
0
"
U>
~
-n
U>
0
c,
U>
0
g.
<
page
Q 0
0 0 0
~ 0 5· 0
~
S
Q ~
"'. "
c,
- ~ o· Q 0
0
e-
'"
~
~
~
Q ~
~
"
Lights and indicator of leS do not turn on when the
ignition switch is ON.
(J (J 0 (J (J (J 19-7
Lights and indicator of leS (except les indicator light) do

not go off 2 seconds after the ignition switch is ON. 0 (J (J (J 19-10
leS indicator light does not go off after the motorcycle

starts to move. '0 (J C) (J 19-11
leS indicator light blinks and leS OFF indicator turns on r'.
after the ignition switch is ON or while riding. ,~ (J C 19-13
r c s does not turn on or off by pushing the rcs

ON/OFF switch. 'J
" (J 19-15
When leS indicator light blinks while riding, it does not n

go off by operating the indicator light switch.
(J U 19-17
NOTE
Check the following before performing TCS troubleshooting.
- Pre-start self-diagnosis of TCS (page 19-5)
- Check all lights and indicators of TCS (page 19-5)
System Chart. The TCS is normal if no trouble is found. Go on to the check the other basic systems (e.g. fuel system,
ignition system, etc.}.
After troubleshooting, perform the pre-start self-diagnosis again (page 19-5) to be sure that the indicator lights of the
TCS are operating properly.
Tes ABS/TCS INDICATOR

TCS OFF ACTIVATION LIGHT SWITCH
INDICATOR LIGHT
TC.
0 ..
ABB~
\
TCS ON/OFF SWITCH
19-6
TCS
Flowcharts
NOTE
When the reS/ignition control module oeM) is found to be faulty, recheck the connectors before replacing the res;
ICM.
Atter troubleshooting, perform the pre-start self-diagnosis again and be sure that the indicator light of the are res
normal.
The encircled numbers in the text and connector diagrams indicate the connectors (see page 19-3).
Lights and indicators of the leS do not turn on when the ignition switch is ON.
NOTE
The indicator lights of the res must turn on when the ignition switch is ON. The TeS
activation light and OFF Tes
indicator should go off approximately 2 seconds after the ignition switch is ON, while the res
indicator light should not
go off unless the motorcycle starts to move.
TCS OFF INDICATOR

L _ TCS ACTIVATION LIGHT
//------f-= -
~= - - -, - '
.. ~ TCSACTIVa· T"" A ....
ICheck the indicator lights other than of TCS (e. /:=- -=:_-~
-
/
-
" ~~:---:..~
is.. neutral, fuel, and oil pressure switch indicator TCS INDICATOR LIGHT
lights)
Lights go off.
( Do the indicator lights come on or go off? Turn the ignition switch OFF.
lights come on.
I Turn the ignition switch OFF. I Check the indicator fuse ("METER TAll POSI-
TIOW).
I
1 Check the ignition fuse ("IGN ACG STARTER") 1
< Is it normal?
JNormal Burned out.
Burned out.
< Is it normal?
,
Repair open in the BLACK/BROWN harness
between the indicator fuse and meter.
Normal
I~heck the 16P connector Cl) and 4P connector Replace the fuse and recheck.
•
(§:' of the TCS/ICM for secure connection.
Poor connection
-' Replace the fuse and recheck.
< Are they connected securely?

Secure connection
,
I Disconnect the 4P connector CS)of the TCS/ICM.I

I
I11_
LI ~
-',r(
r :-='1
L -
-
INDIC':-'TOR FUSE
"METER TAIL POSITION)
IGNITION FUSE
r'IGN ACG STARTER")
.
~~
FUSE CASE
19-7
TCS
(From the previous page) View from terminal side
I
Check for continuity between the GREEN termi- GRE€ffi
~
nal of the TCS/ICM 4P ccnnectcr rg and body
ground.
No continuity
,
< Is there continuity? Repair open in the GREEN harness between the
TCS/ICM and body ground, or poor grounding.
Continuity
Disconnect the 16P connector <7) and 4P con-

nector (~) of the TCS/ICM. View from terminal side
'L'
Check for voltage between the BLACK/yELLQW 8LACK/YEL

I
terminal of the TCS/ICM 16P connector (j) and
the GREEN terminal of the 4P connector @
, Does battery voltage register?

Battery voltage
No battery voltage
• Repair open in the BLACK/YELLOW harness
between the bank angle sensor relay and leS/
leM
Repair open in the BLACK harness between the
I Turn the ignition switch OFF. I ignition fuse and bank angle sensor relay.
I I View from terminal side
.~
TCS activation light and
TCS indicator light does
OFF indicator do not
not come on (See page
come on (See page 19-
19-7).
7)
I o (To the following page.)
L __
YELLOW/GRAY
I 1-
Install the 4P connector ':§:': of the TCM/ICM. I
j
Connect the WHITE/ORANGE terminal (TCS
OFF indicator) and the YELLOW/GRAY terminal
(TCS activation light} of the TCS/ICM 16 P con-
nector (lJ to the body to ground.
I WHITE/ORANGE
Turn the ignition switch ON and check the TCS
OFF indicator or TCS activation light.
.L
I Light goes off.
Does the light come on or go off? Replace the burned out bulb.
Repair open in the WHITE/ORANGE or YEL-
Light comes on.
LOW/GRAY harness between the TCS/ICM and
meter .
• Faulty TCS/ICM
19-8
TCS
I
I Connect the 4P connector :]; of the TCSjICM. I
I
Disconnect the BLACK/BROWN connector C1; of
the TCS indicator light.
I
I
! Check for voltage between the BLACK/BROWN
i connector@ofthereS indicator light and body
i ground.
No battery voltage
< Does battery voltage register? Repair open in the BLACK/BROWN harness
between the indicator fuse and meter.
Battery voltage

I 7' View from term inal side
,~
Disconnect the RED/ORANGE connector @ of

the TeS indicator light. I I I I
I I I I I
Check for continuity between the RED/ORANGE
terminal (4) of the res
indicator light and the RED/O
. RED/ORANGE terminal of the TCS/ICM 16P
iconnector Ct,. ,
I
No continuity
Is there continuity? Repair open in the RED/ORANGE harness
between the TCS/ICM and meter.
Continuity
Connect the TCS/ICM 16P connector ,j)and con-

nect the BLACK/BROWN and WHITE/ORANGE
connectors of the TCS indicator light.
Replace the LED of the TCS indicator light.
Turn the ignition switch ON and check the TCS

indicator light.
TCS INDICATOR LIGHT LED
Does the light come on?

Light comes on.
.. Faulty TCS indicator tight LED
Light goes off.
Faulty TCS/ICM
19-9
TCS
Indicator lights of the TCS (except TCS indicator light) do not go off 2 seconds after the ignition switch is ON.
NOTE
The indicator lights of theres must come on when the ignition switch is ON. The res activation light and res OFF
indicator should go off approximately 2 seconds after the ignition switch is ON, while the resindicator light should not
go off unless the motorcycle starts to move.
Disconnect the 16P connector mand 4P con-

nector (~, of the TCS/ICM
Turn the ignition switch ON and check the res

activation light and res OFF indicator.
Lights come on
Do the lights come on or go off? Repair short in the YELLOW/GRAY harness
Lights go off. (TeS activation light) or WHITE/ORANGE har-
ness (TeS OFF indicator) between the res/
leM and meter .
• Faulty TCS/ICM
TCS OFF INDICATOR TCS ACTIVATION LIGHT
TCS ACTIVE 1 Tce I~
19-10
TCS
TCS indicator light does not go off after the motorcycle starts to move.
NOTE
If the res is normal, the wheel sensor system self checks and the res indicator light goes off after the motorcycle starts
to move.
Turn the ignition switch OFF. res INDICATOR LIGHT
Check the l6P connector (]) and 4P connector

.]) of the TCS/ICM for secure connection.
Poor connection
Are they connected securely]
Secure connection
i
Disconnect the 4P connector (§) of theTCS/ICM,1
j
Check for continuity between the GREEN termi-
nal of the TCS/ICM 4P connector (f{;: and body
ground
j No continuity
< Is there continuity? Repair open in the GREEN harness between the
TCSjlCM and body ground, or poor grounding
Continuity
j
Check the wheel sensor connectors ({D for front
,nd 0:· for rear) for secure connection.
Poor connection
Secure connection
• Connect securely and recheck.
Disconnect the ,6P connector ct, of the TCS/ View from terminal side
leM and the wheel sensor connectors (,n, for 'J)
front and .'L for rear).
~ ill)FRONT,
Check for continuity between the 16P connector

(-t· terminals of the TCS/ICM and the main har-
BLUE/GREE~EEN
ness side terminal of the wheel sensor cormec-
tors eft: for front and CD for rear) L-@-J
~ cfb
(Continue to th following page) 'J) REAR:
BLUE/BROWN BLUE/BROWN
C@--J
19-11
TCS
j No continuity
< Is there continuity? Repair open in the BLUE/GREEN or BLUE!
1 Continuity
BROWN harness between the TCSjlCM and
wheel sensor connectors.
Inspect the wheel sensor and the area around the
wheel sensor as instructed under Problem code
5 or 6 of the ASS troubleshooting (page "91-
'95: 16-A-37 or 16-A-40jAfter '95; 16-8-23
or 16-8-26).
< I, the wheel ,~n,o, no,m,I' >

Abnormal
Repair short in the RED/ORANGE harness

between the TCS/ICM and meter.
• Faulty TCSjlCM
19-12
TCS
TCS indicator light blinks and TCS OFF indicator comes on after the ignition switch is turned ON or while
riding.
NOTE
I . res indicator light should go off after the motorcycle starts to move.

res INDICATOR LIGHT
res OFF IND ICATOR
Check the l6P connector CJ) and 4P connector

C[, of the TCSjlCM for secure connection.
/~~ TC.
D"
TC. -"T'"'' TC. L ~
Poor connection
c Are they connected securely? • Connect securely and recheck.
Secure connection
V iew from terminal side
Disconnect the 4P connector ® of the TCS/ICM.

nal of the TCS/ICM 4P connector ::E' and body
, ground.
No continuity
( Is there continuity? Repair open in the GREEN harness between the
Continuity TCSjlCM and body ground, or poor grounding.
Check the wheel sensor connectors ( @) for front

and CD for rear) for secure connection.
Poor connection
I Secure connection
• Connect securely and recheck.
l
Disconnect the 16P connector CD of the TCS/
ICM and the wheel sensor connectors (CI9' for
front and (j) for rear).
19-13
TCS

Check for continuity between the l6P conne- CD
ctor.t:terminal of the TCS/I~M and the main
~ :[ilFRONT"
harness side terminals of the wheel sensor con-
nector (rLO for front and ~(: for rear).
BLUE/GREE~REEN
%
(t
~~ BLUE/B~ROWN
~T
I I I I
:T REAR:
I I I I
BLACK/O RANG@ BLACK/IORANGE
q:tJ
I
No continuity
( Is there continuity? Repair open in the BLUE/GREEN, BLUE/
No continuity BROWN, or BLACK/ORANGE harness
between the TCS/ICM and wheel sensor con-
nectors.
Inspect the wheel sensor and the area around the

wheel sensor as instructed under Problem code
5 or 6 of the ASS troubleshooting (page '91-
'95: 16-A-37 or 16-A-40/After '95: 16-8-23
or 16-8-26).
Abnormal
( Is the wheel sensor normal? Service as instructed in the ASS trouble-
INormal shooting and recheck.
j
Faulty TCSIICM
19-14
TCS
TCS does not turn ON or OFF by operating the TCS ON/OFF switch.
NOTE
The res should automatically turn ON when the ignition switch is ON. The TCS can then be turned ON/OFF by
operating the TCS ON/OFF switch.

j
Check the res ON/OFF switch connector ':tJ for
secure connection.
I Poor connection
\
< Is it connected securely? Connect securely and recheck.
Secure connection
Discormest the res ON/OFF switch connector
(2).

connector (2) terminals.
Push:No continuity
Release: Continuity
Abnormal
Is it normal? • Faulty TCS ON/OFF switch
Normal
Check the 16P connector U) and 4P connector

':a:, of the TCS/ICM for secure connection.
c===~;:tI~~~~*~~~~~:===>-~~~"":"'~"-_·
Are they connected securely?
Poor connection
Secure connection
Disconnect the 4P connector @oftheTCS/ICM.
Check for continuity between the GREEN termi I

nal of the TCSjlCM 4P connector ca:, and body -
ground.
No continuity
Is there continuity? Repair open in the GREEN harness between the
TCS/ICM and body ground. or poor grounding.
Continuity
.. GREEN
19-15
TCS
(From the previous page) View from terminal side

j
Disconnect the 16P connector ill and 4P con-
nector of the TCSjICM, and disconnect the
(§)
res ON/OFF switch connector C?).
Check for continuity between the TCS/ICM 4P

connector (~) terminal end main harness side
connector (2:: terminal of the TCS ON/OFF swit- iJ)
ch, and between the TCS/ICM , 6P connector
([; terminal and harness side connector ct, termi-
nal of the TCS ON/OFF switch.
-,
ORANGE
jYElLOW
No continuity
< Is there continuity? Repair open in the GREEN harness or ORANGE
/YELLOW harness between the TCS/ICM and
Continuity
TCS ON/OFF switch connector.

® tj)
~tB
With the TeS ON/OFF switch connector
disconnected, check for continuity between the
16P connector (7) terminal and 4P connector ':ID
of the TCS/ICM.
ORANGE/YELL~EEN
Continuity
< Is there continuity Repair short in the ORANGE/YELLOW harness
between the TCS/ICM and TCS ON/OFF switch.
No continuity
• Faulty TCS/ICM
19-16
TCS
TCS indicator light blinks while riding and does not go off by operating ABS/TCS indicator light switch.
NOTE
When the TCS is faulty and the res
indicator light blinks and TCS OFF indicator light comes on, the res
indicator light
can be turned off by operating the ABS!TCS indicator light switch. (However. the TCS OFF indicator cannot be turned
off.)
TCS INDICATOR LIGHT

I Turn the ignition switch OFF. I -- - - - -
I
Check the ABS!TCS indicator light switch con- ~=U=:4 ~". A
nector (J) for secure connection. =--

--
->
( Is it connected securely? --------
Poor connection
Secure connection
Disconnect the ABS!TCS indicator light switch

connector (J).
I
connector Q) terminals of the indicator light
switch.
Push: No continuity
Release: continuity
Abnormal
( Is it normal? • Faulty ABS/TCS indicator light switch
Normal
Check the 16P connector (f; and 4P connector

(8~' of the TCS/ICM for secure connection.
Poor connection
( Are they connected securely? • Connect securely and recheck.
1
I Secure connection
wtE
: Disconnect the 4P connector ca; of the reS/ICM.
~
~ nal of the rCS/ICM 4P connector :Je and body
: ground.
No continuity
Is there continuity? Repair open in the GREEN harness between the
Continuity TCS/ICM and body ground, or poor grounding.
19-17
TCS

j
m~
Disconnect the l6P connector CD and 4P con-
nector ,]::; of the TCS/ICM, and disconnect the
ABS/leS indicator light switch connector c:~_\
GR~EN
Check for continuity between the 4P connector
Cit terminal of the TCS/ICM and the main har-
.tp
ness side connector :,3) terminal of the ABS/leS (])
indicator light switch, ,nd between the 16P
connector oj) terminal of the TCS/ICM and the
main harness side connector CJ" terminal of the
ASS/leS indicator light switch.
GRAY/yELLQW GRAY/YELLOW
I I
No continuity
< Is there continuity? Repair open in the GREEN harness or GRAY/
YELLOW harness between the TCS/ICM and
Continuity
ABS;TCS indicator light switch connector.

Disconnect the WHITE_ connector of the ABS I
X
~tp
TCS/ICM (page 16-3-n_t,). :
,
I
With the ABS/leS indicator light switch con-
nector C~: disconnected, check for continuity GR AY/YELLQW GREEN
between the 16P connector CD terminal and 4P
connector ;~!L terminal of the TCSjICM.
Continuity
< Is there continuity? Repair short in the GRAY!yELLOW harness
between the TCS/ICM and ABS;TCS indicator
No continuity
light switch.
Install the 4P connector :~; of the TCS/ICM and i

the WHITE connector (page 16-3-(C~') ofthe ABS
ECU. (Do not yet install the ABS/TCS indicator
light switch connector ':1.:' and 16P connector CD
of the TCSjICM.)
Turn the igntion switch ON.
I
19-18
TCS

(~
EN
GRAY/YEL®J
connector (j:: terminals of the ABS!TCS indicator
light switch.
No
Is there approximately 5V? . Faulty ASS ECU
jYes
Faulty TCS/ICM
19-19
Symbols
...

~
C
10 (1.0, 7.2)
~
equivalent)
equivalent)

"I~ Apply sealant

20. Electric Starter
Service Information 20-1 Starter Motor Removal/Installation 20-6
System Location 20-2 Starter Motor Disassembly/Assembly 20-7
Service Information
~tionserious injury.
switch OFF before servicing the starter motor. The motor could suddenly start. causing
• A weak battery may be unable to turn the starter motor quickly enough, or supply adequate ignition current.
• If the current is kept flowing through the starter motor to turn it while the engine is not cranking over, the starter motor
may be damaged.
• For the following component inspections, refer to the following pages; for the parts locations, see page 20-2 of this
manual (System Location).
Clutch switch diode Section 24 of the Common Service Manual.
Starter motor Section 24 of the Common Service Manual.

-
Clutch switch Section 25 of the Common Service Manual.

,
Neutral switch Section 25 of the Common Service Manual.
-
Ignition switch Check for continuity on the continuity chart of the Wiring Diagram, section 22.
-
Side stand switch See page 21-4.
20-1
Electric Starter
System Location (3) BANK ANGLE

SENSOR RELAY
Standard Model
(2) NEUTRAL LIGHT (13) ENGINE STOP SWITCH
(1) SIDE STAND (5) STARTER SWITCH
INDICATOR LIGHT IYIf£it,~'2
112)IGNITION--,If7~~+~~~~~~~~-;--:--;;
SWITCH :j (6) NEUTRAL SWITCH
- - -
(10) STARTER MOTOR

----

(7) BATIERY
'91-'9 4
k I--- r
~O)STARTER
M
MOTOR
(3) BANK ANGLE
,
SENSOR RELAY
(4) BANK
ANGLE
1M
(7) BATIERY
SENSOR
--':- -
--
-
l -'
TO REGULATOR/RECTIFIER
G/R
VIR -
(5) STARTER SWITCH
BIIY R/W
G
R (12) IGNITION SWITCH
FUSE lOA
co R/BI BI
I
GIW -'-
-
Lo'11) CLUTCH SWifCH r;»; YIBI
FUSE lOA BIIBr ~ )
G/R
~ l -J
(1) SIDE STAND _____ - ~lg/R
INDICATOR LIGHT 32 01000 L
(2) NEUTRAL
LIGHT
Lg
• G;;)
(6) NEUTRAL ~ (9) SIDE STAND
SWITCH
SWITCH .......
20-2
Electric Starter
ABS/TCS 0' lBS-ABS/TCS Model ABS/TCS model shown"

(2) SIDE STAND INDICATOR LIGHT
L1GHTJ~~. _~ ~:::::~~:~:::~:RE~Y
~\,
111 NEUTRAL :::
1121 IGNITION __
SWITCH -~y.d. :-V:', (13) ENGINE STOP SWITCH
;:::=lJ2,.--(5) STARTER SWITCH
(6) NEUTRAL SWITCH
(11) CLUTCH
/
SWITCH
(9) SIDE STAND

SWITCH
After -94
, - - - - - - , (1 0) STARTER
MOTOR
(7) BATTERY
M
MAIN FUSE 30A
BI
FUSE lOA
~R/BI
---e-
(12) IGNITION SWITCH
R
Y-+--t-J
Y/R
G/R
IL-_-T~-G/R
G/R
(5) STARTER ( 1 1) CLUTCH
t
t-BIIl SWITCH SWITCH
2Y-6-
CLUTCH
DIODE
BIBI
R/W- sl/w L9
G/W
BI/Y
R:+=~=t1 (13) ENGINE STOP
~ SWITCH
(6) NEUTRAL
G (4) BANK SWITCH
l ANGLE
SENSOR
(3) BANK ANGLE
SENSOR RELAY
20-3
Electric Starter
Troubleshooting
Starter motor will not tum
• Check for a blown out main or sub fuses before servicing.
• Make sure the battery is fully charged and in good condition.
Check for loose or poorly connected battery Abnormal

L terminals, and open or shorted battery cable.
Normal
Check for loose or poorly connected starter relay Abnormal

switch terminals and 4P connector.
I Normal
Check for loose or poorly connected starter motor Abnormal

cable, and open cable.
• Poorly connected motor cable
I • Open circuit in starter motor cable
Normal
Turn the ignition switch ON and the engine stop Connect the starter motor terminal to the battery
Clicks
switch to "RUN" position. Push the starter switch positive terminal directly. (Because a large amount
and check for a "click" sound from the starter of current flows, do not use thin wires).
relay switch.
St~rter Starte1r motor
motor does not turn
turns
I•
No click
•
I Faulty starter motor
loose or disconnected starter motor cable

• Faulty starter relay switch
Turn the ignition switch OFF. Disconnect starter

relay switch connector, and check the relay coil
ground wire lines as below for continuity:
1 . Green/Red terminal-clutch switch diode-
neutral switch line (with transmission in neutral No continuity
• Faulty neutral switch
and c1uch lever released.)
• Faulty clutch switch diode
2. Green/Red terminal-clutch switch-side stand
switch line (in any gear except neutral, with the ·· Faulty clutch switch
clutch lever pulled in and the side stand up.)
•
· Loose or poor contact of connector
Continuity
Connect the starter relay switch connector. Turn

the ignition switch ON. With the starter switch
pushed, measure the starter relay voltage at the
starter switch connector (between Yellow/Red
No voltage
..· Faulty ignition switch
Faulty starter switch
(+) and ground (-)). · Faulty bank angle sensor
· Faulty bank angle sensor relay
· Faulty engine stop switch (After '94)
Battery Voltage Measured · Blown out main or sub fuses

· loose or poor contact of connector
· Open circuit in wire harness
l Check the starter relay switch operation. ~ Normal

•• loose or poor contact of the starter relay
switch co nn ecto r
Abnormal
20-4
Electric Starter
The starter motor turns when the transmission is in neutral, but does not turn with the transmission in any position
except neutral, with the side stand up and the clutch lever pulled in.
Check the side stand indicator operation with Abnormal

• Faulty side stand switch
the ignition switch ON.
• Burnt bulb
• Open circuit in wire harness
Normal
Abnormal
LCheck the clutch switch operation. • Faulty clutch switch
Normal
Abnormal
Check the side stand switch (page 21 4). • Faulty side stand switch
Normal
• Open circuit in wire harness
• Loose or poor contact of connector
Starter motor turns slowly

• Low specific gravity in battery (or dead battery)
• Poorly connected battery terminal cable
• Poorly connected starter motor cable
• Faulty starter motor
• Poorly connected battery ground cable
Starter motor turns. but engine does not turn

Starter motor is running backwards
- Case assembled improperly
- Terminals connected improperly
• Faulty starter clutch
• Damaged or faulty starter pinion
• Damaged reduction gears
Starter relay switch "clicks". but engine does not turn over
Crankshaft does not turn due to engine problems
• Excessive reduction gear friction
20-5
Electric Starter
Starter Motor Removal/Installation
(7)
(B)qJ-,
. ""0)~---=:='(2)
(4)
(5)
Requisite Service
Middle fairing removal/installation (page 2-8)
• With the ignition switch "OFF", remove the negative cable at the battery before servicing the starter motor.

-
(11 Heat guard mounting nut 1
(21 Starter motor mounting bolt 2
(3) Starter motor heat guard 1
(4) Starter motor terminal cover 1
(5) Terminal nut 1
(6) Starter motor cable 1
(71 Starter motor assembly 1
(BI O-ring 1
20-6
Electric Starter
Starter Motor Disassembly/Assembly
('0)
(3)f1I
(6)
I' )
..'"
cs
III
~
"
"
~~
~\
/
r
»<
(2) I
")®~(
(6) (4)
I
l/ (8)
(9)
Requisite Service
• Starter motor removal/installation (page 20-6)
Procedure I Q'ty Remarks

(2)
(1)
Starter motor cover bolt
Front cover ,,
2
(3)
(4)
Packing
Insulator washer ,
(5) Shim
(6) Rear Cover
-
,, Note the location and number of the shims.
(7) Packing
(8) Shim
(9) Armature
-
,, Note the location and number of the shims.
(10) Brush holder I
20-7
Symbols
...

~
C
10 (1.0, 7.2)
~
equivalent)
equivalent)

"I~ Apply sealant

21. Lights/Meters/Switches
Service Information 21-1 Bank Angle Sensor 21-5
System Location 21-2 Fuel Cut-off Relay 21-5
Headlight 21-3 Fuel Pump Inspection 21-6
Front Turn Signal 21-3 Fuel light Test Circuit Inspection 21-6
Rear Turn Signal and BrakejTaillight 21-3 Fuel Pump Removal/Installation 21-7
Position Light 21-4 Combination Meter Removal/
Installation 21-8
Indicator Bulb Replacement 21-4
Combination Meter Disassembly/
Side Stand Switch 21-4
Assembly 21-10
Service Information
~en headlight bulb becomes very hot while the headlight is ON, and remain hot for a while after it is turned
OFF. Be sure to let it cool down before servicing .
• Use an electric heating element to heat the water/coolant mixture for the fan motor switch inspection. Keep all
flammable materials away from the electric heating element. Wear protective clothing, insulated gloves and eye,
protection. I
• Note the following when replacing the halogen headlight bulb.
- Wear clean gloves while replacing the bulb. Do not put finger prints on the headlight bulb, as they may create hot spots
on the bulb and cause it to fail.
- If you touch the bulb with your bare hands, clean it with a cloth moistened with alcohol to prevent its early failure.
- Be sure to install the dust cover after replacing the bulb.
Check the battery condition before performing any inspection that requires proper battery voltage.
A continuity test can be made with the switches installed on the motorcycle.
For the following component locations, see page 21-2 of this manual {System Location}; for inspections, refer to the
applicable pages.
Component Inspection method Remarks

Clutch switch j Section 25 of the Common Service Manual
- -
Front brake light switch Section 25 of the Common Service Manual
-
Horn Section 25 of the Common Service Manual

Handlebar switches Check for continuity on the continuity chart of Switch connectors are located behind the
Ignition switch the Wiring Diagram, section 22. instruments (page 1-25}.
- -
Neutral switch Section 25 of the Common Service Manual IrORQUE: 12 Nom (1.2 kq-m, 9 ft-lb]
! Apply sealant to the threads.
--
Oil pressure Section 25 of the Common Service Manual Oil pressure check: Section 4 of the Com-
switch/indicator man Service Manual.
light Oil pressure switch torque: 12 Nom (1.2
, kg-m, 9 ft-Ib)
Fan motor switch Seetin 25 of the Common Service Manual
Rear brake light switch Section 25 of the Common Service Manual I
Turn signal lights i Section 25 of the Common Service Manual
21-1
Lights/Meters/Switches
System Location
(2) BANK ANGLE SENSOR (3) FRONT BRAKE LIGHT SWITCH
(4) ENGINE STOP SWITCH

(1) IGNITION SWITCH
(5) STARTER SWITCH
(16) DIMMER SWITCH
(6) THERMO SENSOR
(15) TURN SIGNAL
SWITCH (7) OIL PRESSURE SWITCH
(8) REAR BRAKE LIGHT SWITCH

(14) CLUTCH SWITCH
(13) HORN SWITCH c:;;;<,~,D:~~

p
\ '-----
,
(12) FAN MOTOR SWITCH I, I,
(11) NEUTRAL SWITCH

(9) BATIERY
21-2
Headlight (1) CONNECTOR

(2) "TOP" MARK
(3) BULB
(4) RETAINER
Bulb Replacement
Remove the middle fair"mg inner cover (page 2-7).

Disconnect the connector and remove the dust cover.
Remove the bulb by removing the bulb retainer.
Install a new headlight bulb.
CAUT"'O,,N _
I If you touch the bulb with your bare hands, clean it !

with a cloth moistened with alcohol to prevent early
failu.~'e:.~ _ (5) DUST COVER
NOTE
• Install the dust cover with its 'TOP" mark facing up. 121 BULB rm~cc-~
Front Tum Signal (1) BULB

SOCKET
Bulb Replacement
Remove the rear view mirror (page 2-8).

Remove the bulb socket by turning it counterclockwise.
Remove the bulb by turning it counterclockwise while pushing
in the bulb.
J, .
NOTE ';:: ------
I· Check that the rubber seal is in good condition and

i replace it if neCeCeC,,~a~,"y~. _
Installation is in the reverse order of removal.

(1) END SHIELDS
Install the rear view mirror (page 2-8).
Rear Turn Signal and Brake/

Taillight
Bulb Replacement
'I,
Remove the seat (page 2-2)_ ,
Fold the rear end shields as shown. "
I,"
Remove the bulb socket by turning it counterclockwise. (n BULB ..----,;:-

Remove the bulb by turning it counterclockwise while y/
pushing in the bulb.
NOTE
• Check that the rubber seal is in good condition and
replace it if necessary.
'-----'-- ...J

Install the seat (page 2-2).
21-3
Indicator Bulb Replacement (11 BULB
Remove the instrument panel (page 2-7).

Remove the bulb socket and bulb.
Install a new bulb and install the removed parts in the
(2) BULB SOCKET
Side Stand Switch (1) 3P CONNECTOR (2) SIDE STAND
Inspection

Disconnect the side stand 3P connector (green) and check
for continuity between each terminal as shown below.
There should be countinuity between the C-C) positions on
the continuity chart.
Green/ Yellow/ Green

White I Black
Side stand down I 0 0 (4) DOWN

Side stand up .rv
Replace the side stand switch if Continuity is not as shown in
the chart above.
Replacement
Remove the pivot cover (page 2-5).

Diconnect the 3P connector (green} and release the wire
from the clamp.
Remove the bolt and side stand switch.
Install the side stand switch aligning the stop pin on the
frame with the cut out of the switch and the pin on the
switch with the hole in the side stand ifi;/
t?g!
Secure the side stand switch with the bolt. "<, (3IALlGN
Torque: 10 Nom (1.0 kg-m , 7 ft-Ibl (4) BOLT CUT OUT
Install removed parts in the reverse order of removal.
21-4
Bank Angle Sensor (1) BANK ANGLE SENSOR
Inspection
/
Remove the upper fairing (page 2-9).

Turn the ignition switch "ON" and measure voltage between
the following terminals of the bank angle sensor with the
3P connector (green) connected.
Terminals Standard voltage

Red/White (+) and Green (-) 0-3.0V
I-
White (+) and Green H 10.0-14.0V
(2l3P CONNECTOR
Remove the screws and bank angle sensor. (2) 50' BANK ANGLE
Turn the ignition switch "OFF". POSITION
Place the bank angle sensor horizontal with the connector
50~
connected and turn the ignition switch "ON'". (1) NORMAL
The bank angle sensor is normal if the bank angle sensor POSITION
relay clicks and the power supply line is closed. (approximately]
Position the bank angle sensor at approximately 50 degrees
0'
to the left or right with the ignition switch ~ON".
The bank angle sensor is normal if the bank angle sensor
~-
relay clicks and the power supply line is open.
NOTE
If you repeat this test, first turn the ignition switch
"OFF~, then back to "ON" before you try the test
(eoorcxunetefvl
again
Installation is in the reverse order of removal. STANDARD MODEl: ABS;TCS MODEl:
Fuel Cut-off Relay y/1 ! /") '~\\L

t t s. I
//(;, r
~-/:, "I
• Gasoline is extremely flammable and is explosive ".. . . .':c. - I I
7;0~~~i~1 :
under certain conditions. Work in a well ventilated , ,
area. :'
Do not smoke or allow flames or sparks in your
work area or where gasoline is stored.
- - - - ; I" 'il I, I

, ... I i i-----i-
Check the sub fuse (10A:IGN, STARTER, ACG)_
Check the relay 4P connector (white) for looseness and
corrosion.
{ll FUEL CUT-OFF RELAY
Disconnect the relay connector and test the wires to the
main harness side.
f -
Between
1tem
1-
I
the BI/W (+) and body ground Battery voltage
(-) with the ignition switch "ON".
Standard
'should register
Bu/Y wire between the pump relay and
fuel pump.
Continuity r I
Br/R wire between the fuel pump relay Continuity
and fuel pump.
Green wire and body ground Continuity (2) 4P CONNECTOR
21-5
Fuel Pump Inspection (1) FUEL CUT-OFF RELAY
Turn the ignition switch "OFF".

Remove the seat (page 2-2).
~ c0
Disconnect the fuel outlet tube at the fuel filter.
Gasoline is extremely flammable and is explosive

under certain conditions. Work in a well ventilated
area.
Do not smoke or allow flames or sparks in the your
work area or where gasoline is stored.
Short the Black and Brown/Red wire terminals with a
jumper wire.
Turn the ignition switch "ONU and.1.et fuel flow into a gra-
duated beaker for 5 seconds, then mm the ignition switch
"OFF" .
Multiply the amount in the beaker by 12 to determine the
fuel pump flow capacity per minute.
Fuel pump flow minimum capacity:

640cc (0.676 u.s.ei.
0.563 Imp qtl!minute
(2) GRADUATED BEAKER
Fuel Light Test Circuit Inspection

Turn the ignition switch "ON".
The fuel indicator light should come on for few seconds, then
go off.
If it does not come on, check the fuel sensor circuit.
If there is no problem with the circuit, remove the upper

(1) INDICATOR LIGHT CHECK UNIT
fairing (page 2-9) and disconnect the indicator light check
unit connector.
Measure the voltage between the Black/Brown and Green/
Black wires of the connector at the wire harness side.
Battery voltage should be measured.

.:«
;~,' ;\"U_~'
If battery voltage is measured, replace the check unit.
If battery voltage is not measured, check the wire harness for
an open, short circuit or loose connection.
I I ,
21-6
Fuel Pump Removal/Installation
(1)---------
(5)--------i~A
-... '
"£~"
• Gasoline is extremely flammable and is explosive under certain conditions. Refuel in a well-ventilated area with
the engine stopped. Do not smoke or allow flames or sparks in your work area or where gasoline is stored .
• Keep away from flames or sparks. Wipe up spilled gasoline at once.
Requisite Service
• Seat removal/installation (page 2-2l

-
(1) Fuel outlet tube 1
(2) Fuel pump/level sensor connector , 3
(3) I Fuel pump mounting nut 6
(4) Fuel inlet tube 1
(5) Fuel pump assembly 1
(6) Base packing
I
1
21-7
Combination Meter Removal/Installation

Standard Model Cl\"",::.::::::::::;;-__~_~~
9 (D.9,
6.5)
(5)
, ,,
(4)
Requisite Service
• Instrument panel removal/installation {page 2-7}

-
(' ) Meter mounting bolt 3
(2) Collar
(3) Speedometer cable ,
3
i
(4)1 Meter connector 3
15) , Meter assembly 1
21-8
lights/Meters/Switches
ABS/TCS Model
141
•
~'~-------=111
0 9 (0 "9 ,
6.51
(21
131
(31
Requisite Service
Instrument panel removal/installation (page 2-7)

(1) Meter mounting bolt 3
(2) Speedometer cable 1
(3) Meter connector 5
(4) Meter assembly 1
21-9
Combination Meter Disassembly/Assembly

Standard Model
(91
(61
(31
(17)
Requisite Service
Combination meter removal/installation (page 21-8)
Procedure Q'W Remarks

(1) Nut/washer 2/2
(2) Screw 5
(3) Meter visor 1
(4) Reset knob 1
(5) Screw/Band 3/3
(6) Indicator housing 1
(7) Screw 2
(8) Cover 1
(9) Indicator lens 1
(10) Terminal screw 6
(11); Fuel gauge 1
(12) Temperature gauge 1
(13) Screw 4
(15) O-ring 1
(16) Speedometer 1
(17)1 Screw 2
(18)1 Tachometer 1
21-10
ABS/TCS Model
(13) (11)
(3)
(19)
(4)
11\
___-12}
(6) (5)
18}
Requisite Service
• Combination meter removal/installation (page 21-9)

(11 Nut/washer 2/2
(2) Screw 5
(3) Meter visor 1
(4) Reset knob 1
(5) Screw 4
(6) Lens/case 1/1
171 Harness band 1
18) Screw/band 2/2
(9) Screw 2
(10) Cover 1
( 11) Indicator housing 1
(12) Screw 2
( 13). Cover 1
( 14) Indicator lens 1
(15) Terminal screw 6
(16) Fuel gauge 1
(17) Temperature gauge 1
(18) Screw 4
(20) O-ring 1
(21 ) Speedometer 1
(22) Screw 2
(23) Tachometer 1
21-11
Symbols
...

~
C
10 (1.0, 7.2)
~
equivalent)
equivalent)

"I~ Apply sealant

22. Wiring Diagram (Standard Model) ('91-'94)
1 LEFT TURN SIGNAL ItOCATOR 5 ~L PRESSURE
2 FUELINDICATOR 6 SIDE STAND INC
3 HIGH BEAM rfolllCATOR 7 RIGHT T\"qN SIGI
TAClOIETER 4 r£UTRAL IroCATOR
COOLANT TEMPERATURE GAUGE
FUEL GAUGE
SPEEDOMETER
I£ADlJGHT RElAY (L.o)
~~:/;BI===~~l
4PR
HEAlX.JGHT RElAY (Hi)
~~~::'/BI;::==mn ~;t CLUTCH DIODE
4PW ~!~r
RIGHT FRONT TURN SIGNAL
~
G
12Y32/3CP
a./II
WIBl IIIV
I£ADl.lGHTS
1~2Y45/45W12 G ViR
Y
Ill/Ii
will Ill/R
Brill
rlBI
BI
o
Br
G/R
II/Ill
Br/R
ill",
~~R~;~SOR ill ~
c:r-
.
FUSE BOX
A lOA (NEUTRAL_OIL_ TEMPeTACHO- HORN)

B lOA (FRONT POSITION· METER LIGHT·TAIL) TURN SIGNAL RELAY
C 20A (HEADLIGHT)
o lOA (IGNITION. STARTER. ALTERNATOR)
E IDA (TI.llN SIGNAL' FRONT. REAR BRAKE)
F IDA (CLOCK)
G lOA (FAN MOTOR)
CLUTCH SWITCH
11JRN SIGNAL.DIMMER·HORN SWITCH
TURN SIGNAL SWITCH DIMMER SWITCH HORN SWITCH ENGlE STOP SWITCH STARTER SWITCH
W R L P PR PL
Lo Hi ~BAT3 IG BAT2 ST BAT! BAH
R 0- '-0 ( -0 Lo FREE OFF FREE 0-1-
N ( )--0- k) IN) PUSH RUN 0- -0 PUSH 0- -0
L \.. .J ( }--Q •
Hi
JGI<T
:ATOR
Il HJlCATOR
IGNmON CONTROL
MODULE
ENGINE STOP
SENSOR RELA V
ENSOR
.~ ~iii
III
I/W
I/G
1/11
.a
riG
.b ~:::r:::r:J OGHT REAR TURN ~GN'L
I/Br
12V32C'
I
,W
,II
!D] 12Y3213CP Xl BRAKE 'NC TAILLIGHTS
'T"!D]
'I~I ~
---1......
o ~EUTRAL J
IG"TKlN
PULSE GENERATOR
r
'=
.:,~.~~~ ~>->-
SWITCH II lD ~
~ >
REGULAToojRECTIFIER
o~:; ~ ~
-=-
SlOE STAND SWITCH
III
f
~:::::::c:::l:') LEFTREAR TURN %NAL
12Y32CP
'CPRE~S_~~ ilJrJ
~II/W
IGNITION COILS
~ ALTERNATOR
BI
Y
BLACK
YELLOW
Br
0
BROWN
ORANGE
Bu .... BLUE Lb· LIGHT B1LUE
G GREEN 1-&. LIGHT GREEN
R REO P PINK
W WHITE Gr GRAY
IGNITION SWITCH
FAN IG BAT!
ON 0- -0- -0
OFF
LOCK
0030Z- MT3 -6700

22-1
Wirig Diagram
(Standard Model) ('95)

METER LIGHTS 5 OIL PRESSURE LIGHT
6 SlOE STAND INDICATOR
7 RIGHT TURN SIGNAL NllCATOR
THERMO!
r- :
I£AOlJtiHT RELAY (La)
~G'-==--"
~
" R Will
HEADLIGHT RELAY (H' )
m'~G:;:==+i:tl
W/P
"6<
"W Ill/il
CD!~t
RIGHT FRONT TURN SIGNAL
~
G
IZV3213CP
Ill/II
Will
HEADLIGHTS ~~/II
~W/II
rr---t:g~~rGi:==I=t===-..:::;-ttt-tn~~;;§dEE_"I_-+~:::l=-
~O/W 0
Lm FRONT TU O/W
RN SIGNAL
11V3213CP
FUSE BOX
A IDA ( IGNITKlN SWITCH
NEUTRAL. OIL. TEM
B lOA (FRONT POSITION. MP. TACHO· HORN)
C IDA (HEADLIGHT) ETERLIGHT' TAIL)
mtlIM
~~~
D IDA (IGNITION. START

E lOA
lli+ :', -,.CI< "!/.
'i
I
§! F IDA
(TURN SIGN ER. ALTERNATOR)
(CLOCK) AL' FRONT. REAR BRAKE)
G IDA (FAN MOTOR)
TURN SIGNAL. DIMMER • HORN SWITCH
22-2
IGNITION CONTROL
MODULE
ENGINE STOP
~~~Y/FiJ FiJ/Y
81/W
G
SENSOR R£LAY
BI~
1m
~iii
iD
~::::t=r:) RIGHT REAR TURN ~GNAL

12Yl2CP
!D]
12V3213CPX2 BRAKE AND TAILLIGHTS
-.. .,. . . "'t-!D]

~:::::c::=() LEFTREAR TURN ~NAL
ill
12Y32CP
f
BI BLACK Br BROWN
IGNITION COILS ALTERNATOR
Y YELLOW 0 ORANGE
au BLUE Lb LIGHT BLUE
G GREEN I..g LIGHT GREEN
R RED P PINK
W WHITE Gr GRAY
IGNITION SWITCH
FAN IG BAT!
ON V-r-v- -0
OFF
LOCK
0030Z-MAJ-AOOO
1 LEFT TURN SIGNAL INDICATOR 5 OIL PRESSURE INDICATOR
(Standard Model) (After '95) 2 FUEL INDICATOR 6 SIDE STAND INDICATOR
3 HIGH BEAM INDICATOR 7 RIGHT TURN SIGNAL INDICATOR
4 NEUTRAL INDICATOR
METER LIGHTS 12V 3.4 W x 7
OA,"OM':::(~~f?
=-
~_c
:~.., m30H~TS'Wi -~ oo -- -~ ';;,~
:
~~ ~~ ~_ ENGINE STOP·STARTER·
-: ...J:~av- l;liiii il -'aJ ~m ~t LIGHTING SWITCH
COOLANT TEMPERATURE GAUGE 11l=I&:o8I/Br I--- I I L..- ~ ~ , r< Q nI
1 t1 !t"oG/B1 - Ii~ 119'~~~~1
( ~
FUELGAUGE(~~
~~~ ~~
ml
a.=::;l>-: :n rr=!-J
HEADLIGHT RELAY (LOW) ID~~~,~~~~il
SPEEDOMETER
I~~-'~:=
...
CLOCK 12 V 1.7 W
Br/W
~i~r
(M/~
J! 'I" ~ ~
3P~
[Ilill
b... d'M~i,
BI e HUl'~.lii
lIflflfiT ~
(MINI
cO ~iii~ lf1:"ll~l!l~JII
£D a:: 0011 >OIODE C' !!'
",CLUTCH:t >-
0
iL
t-UI~
1f
~
m
co §CD
If HER'
ssns
(HIGH)~;~I~~~~rn
rn
HEADLIGHT RELAY b~
3P G' b/W_ iii"'';;00" o_iii -' '>' -' ,
I!ill.FJU/~~ G
Lb
G
Lb-
~r.?
~~ CJ
rn
~ co
::::l 'E
.:5 CJ
RIGHT FRONT
J2UvR~~'2'rL f i3
HEADLIGHT
~
12V45/45WX~2 G
U~I
W/BI
W
f BI/Y BIIW
BU/B-,H1~~~§~~'!:R:~~~~m:n#FW~rt-ttittP ~I+f+-"""
YIR WIG
W/~:: = G~ G/Y
Y/G
Lgo
V/B
Bu/R Br/B
Gr/BI Lb-
G/BI I/Br
o G-
BI GIR·
GIW BI/B,
R BrlW
Br/R
"~ t1J ~ - ~ ~ .c:-
CLUTCH SWITCH
111
1
TURN
161 11'6 l i a.'
lJ.t:4t~t!P~~ :rt]
SIGNAL'DIMM~'
It
~~ I~j ~~! }; "'~~ I~~~~'~~~Ii

~M~
cD
It t1
_H ABCDE FG
~ FUSE BOX
a:l
m o
~ a:
~t
~
:.i
II~G~N~'T~'O~N
~
t~~~Wlo~: ·
~IN"~
"'~'"
0 ~~G'L
r
I
-
HORN SWITCH ~ SWITCH TURN SIGNAL GI

RELAY
A 10 A NEUTRAL, OIL, TEMp, TACHO HORN (
ACCESSORY B 10 A POSITION, METER LIGHT, TAIL,
C 20 A HEADLIGHT
D 10 A IGNITION, STARTER,ALTERNATOR
E 10 A TURN SIGNAL, BRAKE
F 10A CLOCK
G 10 A FAN MOTOR
H 5A ACCESSORY
TURN SIGNAL SWITCH DIMMER SWITCH HORN SWITCH IGNITION SWITCH
r-. 10 k)
W R l P PR Pl <, HO BATJ
~ FAN IG BAn BAT BAT
OP, OP2
R LO FREE ON
lO 1010101-0
N '"). (NI PUSH 10ro OFF
l k) HI LOCK
Wirig Diagram
ENGINE STOP
SWITCH
IGNITION
CONTROL
MODULE
FAN MOTOR
SWITCH
BANK ANGLE
:'~/----"
, BIl®F'b~OR SENSOR
BANK
Q
: : 0 LAMP REAR
• - M CHECK BRAKE ANGLE
SENSOR
UNIT LIGHT
_ ~ RELAY
~
~~INI)m
RMO ' SWITCH
ISOR FUEL UNIT a;~ ,
~
~2P ,PIMINI)
"'81 R
C>&: Q5mCij ii5"'~

a: ?;J;ii5~
a:
~ ~~a Ol
iii iii miD

0<3 82P
~liIMINI) 'ifIX'NI)
~~
",,,, ~~
I
VI
Lb.............-{ RIGHT REAR TURN SIGNAL

G~12V32CP
r~
IiBu ~ BRAKE AND TAILLIGHT
GIY~.12V 32/3CP x 2
~...t~t-~~
0........-(""'\ LEFT REAR TURN SIGNAL

G-L......l..J 12V 32CP
-¥-,
~>-~.5'
> 4P
~'E~~'"
4P W
MI
~2P
W
O
>-~ C>
~~~
mm
I' ., SIDE STAND SWITCH
0. ~
CUT RELAY~~INI)
--' FUEL 3P
~~
>-alOl
CD m
NEUTRAL
SWITCH
IGNITION
PULSE
GENERATOR
OIL PRESSURESWITCH
~
~#13' Y/Bu
~BI/W
~~r,o; ALTERNATOR
., BLACK Sr BROWN
IGNITION COILS y YELLOW 0 ORANGE
Bu BLUE Lb LIGHT BLUE
G GREEN Lg LIGHT GREEN
R REO P PINK
- -
W WHITE Gr GRAY
0030Z-MAJ-A200
22-3
Wiring Diagram
(ABS/TCS Model) ('92 '94)

'1 LEFTTURN SIGNALINDIATOR B res OFFINDICATOR
2 FUELINDICATOR 9 res ACTIVATION
3 HIGH BEAM INDICATOR '10 res INDICATOR
4 NEUTRALINDICATOR '1'1 ABSINDICATOR 1
5 OIL PRESSURE LIGHT '12 ASSINDICATOR 2
B SIDESTAND INDICATOR
7 RIGHTTURN SIGNALINDICATOR
FRONTBRAKELIGHTSWITCH
12'
j
~ ~'GHTING
STARTE,.,NGINE STOP
SWITCH
ASS·les WAI
,"J~~~l
res SWITCH I
COOLANTTEMPERATURE GAUGE
\ j
~~~~~~~~F
r 2P~~~ II
FUELGAUGE
SPEEDOMETER' ,,>J----"- I
3P
W
~~~ y ~ ~
Cla Cl~
lEFT FRONTT(Th;URN
SIGNAL 1J.
oru O
o~WG
12V32/3CP O/W
"~
3P Cl~c.:J
ASSCONTROL UNIT
IMlNllb
·'U
TURN SIGNALRELAY
FRONT rosrnox
A IDA NEUTRAL·OIL·T A·~H~.~~~~~:ci~~IL
B 15A HEADLIGHT LOW
C 15A HEADLIGHT HIGH
D IDA IGNITION·5TARTER•ALTERNATOR
E IDA TURN SIGNAL·FRONTREARBRAKE
F IDA CLOCK
G IDA FANMOTOR
22-4
R SWITCH
ST BAT2 GND HL H lOA ABS MAIN
I lOA 'J FRONTSOLENC'IO
J 20A PUMP MOTOR
K lOA B2 REAR SOLENOID
TCS/IGNITION
CONTROL MODULE
THERMOSTATCSWITCH
~iii.~ 9" ~~t~T'sr;c'~~H)lil

- -
WARNING LIGHTSWITCH l
/
~ 0 FAN MOTOR
ENGINESTOP SENSOR
SOLENOID RELAY
U~~ m M FUEL INDICATOR

CHECKER
ENGINESTOP
SENSCR RELAY
~ ~
2P
II
FUEL UNIT IMIMI 3P
"'MI I
FRONTPUMP MOTORRELAY ar R G
STARTERRELAYSWITCH FUSE(MAIN)
oa~ ~~§ ii5C'~ ~iiiiii~

REARPUMP
iiic:ll.:/
\
rm;~RELAY
iii- ii5iii
~~"a (MINII
2P H'~11
'iT w
r.".. 'I" ."."

§iii
(5<3
R ~5
--I:H+-++tt-+tt+-O/y·_--~+--~+--#t---+t--irt---tlrt---rt-Httttffit' I
BlIW
G,/8u RIGHT REAR TURN SIGNAL

R
lililil;iliillj~~ij~~~i~~i~~~i~iI~~~~~~r[:::g~m'·J:1 g~y1
BlIV
LylBI
VIR 6~
Y/G, lZV32CP
BI/B,
Y/BI
-Br/BI
Bu/R
VlG
l,
Irrt=t;======..=~ ~iDLiGHTS
G,/BI
GIBI 13CflIZ
G,/Y L
G/Y G
e Br Br gU)1ZV3ZCf'
Br
o o 0
-l-HI-+---1I-+- W/G;- - + + - + t+I- t--t- --t- .........

=i::;;F--1---l-l--GIW
I G~RTURN SIGNAL
Lg/O
GIA
BI
BI!Bu lZV32CP
a,/R
Bl/OSr/LIl
G/B, ,/0
Bu/G
W/P
GIG,
Bu/Br
P
PIW
O/BI
~~~ ~!!,
j I
1 A t"
e: >-
~ ~'ij.B
LJ
.t
INDICATOR
W
~§"?;
ur e ;~ I~
~ '€lJ
DOWN
"
>-C'
SIDE STAND SWITCH
1m
~
~~~ ~~
.,,~:IT.2P
0' PRESSURE SWITC~ ~ ~EUTRAl

fl SWlTcJ~~~
IGNITION as >->->- PEGUlATOR RECTIFIER
0
REARMODULATOR
PULSEGENfRATC/fl 8~3P
EiIt;,1l:f-rllR
~ ~~ 1~",,"·,·
BI........... BLACK . ....... BROWN
y ........... YELLOW "
0 . ........ ORANGE
--r-----to.'olV '0.........
G ...........
BLUE·
GREEN
lb
19
.......... LIGHT BLUE
.........
--L.r-------JD"BlfW LIGHT GREEN
IGNITIONCOILS
R ........... RED P .......... PINK
W .......... WHITE G, .......... GRAY
0030Z-MY3-6900
(ABS/Tes Model) ('95)
.
2
LEFTTURN SIGNALINDIATOR
fUEL INDICATOR
B
9
res OfF INDICATOR
res ACTIVATION
ENGINESTOPSWI
IG BI
OFF
3 HIGHBEAMINDICATOR .,0 res INDICATOR
4 NEUTRAL INDICATOR .... ASSINDICATOR 1 RUN
5 OIL PRESSURE LIGHT .,2 ASSINDICATOR 2
B SIDESTANDINDICATOR
7 RIGHTTURN"SIGNALINDICATOR
.12V 3WX8 1.7WX2
TACHOMETER
lCS
COOLANTTEMPERATURE GAUGE
FUELGAUGE
i
-
n B~~~l_
W
---<
~U/R-
IR
~
1
LEFT FRONTTURN SIGNAL 2P
~~OO~IW====lffi1m_F~T1F~~
12V32/3CP
~~~ a~
'il ~~
FRONT WHEEL SENSORtj
t~Se9~
-~ClUTCHSWITCH TURNSIGNAL·PASSING·DIMMER
FUSEBOX IGNITION SWITCH
"U
~
3P ~~Cl
(MINI~
ABSCONTI
HORN·SWITCH
FRONT MODULATOR TURN SIGNALRELAY L - _
fRONT POSITION·M EW
TURN SIGNALSWITCH PASSINGSWITCH IGNlTION SWITCH A lOA NEUTRAL·OIL·TACHQ·T
I~ w R L P PR PL BAT4 HI <, FAN IG BAll

B 15A HEADLIGHT LOW
RD- f--O 0- :::0 ON 0::::::0:: -0 C 15A HEADLIGHT HIGH
N 0--0- FO OFF D lOA IGNITION· S1ARTER·AL T
~ E lOA TURN SIGNAL ·FRONT RI

L 0 LOCK
F lOA ClOCK
G lOA FAN MOTOR

Wirig Diagram
nTCH STARTER SWITCH
<, ST BAT1 GND HL H lOA ASS MAIN
I lOA • I FRONT SOlENOID

fREE 0- l-o
J 20A PUMP MOTOR
PUSH 0- --0 K lOA .2 REAR SOLENOID
reS/IGNITION
CONTROL MODULE
THERMOSTATC SWITCH
:/~-- I 0 FAN MOTOR ENGINESTOP SENSOR

Ls
M FUELINDICATOR
n
iil~ 9~ 1lI~~ "
CHECKER REARBRAKE ENGINE STOP
iSWlTCH FUELUNIT 2P LlGerrHT
SWITCH SE;NSOR
RELAY
~
~ B1 R "'::"' BI
U
~~
.-
~~~ ii5~~
>:
;;;iiiiii~
STARTER RELAY SWITCH FUSE(MAIN)
_
\
~~ iiiii5 ~
L ~l~n ~l~
~5 ~5
OIY----t+--tt---ftt---H--++---+l~-__1__l_.u.IUJ.UUJ I
BIIW
RIO
WIO
. .~1It: jlr~~~
./Bu RIGHTREARTURN SIGNAL
R
BIIY VIR
19fBI
V/Gr
1r*=ti======"=~J1fiD~
•
BIISr
V/G
V/81
-8r/81
Bu/R
Gr/BI
L,
"':"'~~~V g~
G.IY Lb""
IY
B. G
glEn.
a af~r B~
WIG
GIW G d D R TURNSIGNAL
Lola
G/R
R BllBu 12V32CP
ertR
BI/O
r/lll
GISr
ButG rIO
WIP
G/Gr
BulBr
,~, ~
1 ~~I~'
~~~ ~~
-,,~)'.I:lP
,£:L
ROL UNIT
m
~ BI~
•• ~~BI
o,,"'~"'_~ 0,), ill I~

o .... CIt::!
oM
REAR MODULATOR
IGMITION
PULSE GENERATOR
fEUTRAl SWITCJ mit »o-> REGULATQRRECTIFIER
~r
RLIGHT·TAIL
[MP·HQRN
BI
fERNATOR
EAR BRAKE
~~ l~·m. ",.
IGNITION COILS
BI .........•• BLACK
Y
G
R
W
YELLOW
Bu •........•. BLUE
.......•.• GREEN
RED
WHITE
Br
o
lb
Lg
P
Gr
...•..••.. BROWN
ORANGE
LIGHT BLUE
.....•..•. LIGHT GREEN
PINK
•........ GRAY
0030Z-MAJ -A 100
22-5
Wirig Diagram
(LBS-ABS/TCS Model) (After '95)

ENG
8 TCS OFF INDICATOR
9 res ACTIVATION LIGHT
~
10
11
TCS ACTIVATION LIGHT
TCS INDICATOR LIGHT

~
12 ASS INDICATOR LIGHT
13 '
1,
2
3
COOLANT TEMPERATURE G AUGE
FUEL GAUGE
SPEEDOMETER
HEADLIGHT RELAY (lOW) ~BI~I

Wffl~§~=:=;il
W~':
HEADLIGHT RELAY (HIGH) ~':I

W
B'ffl~Ettt
BU/B11=
HEADLIGHT ~'i.'lflfmll-.:..::=::~~~~-JjlllLIII
w~,
LEFT FRONT TURN SIGNAL~ 3P Gr

12V 32/3CP m $O
g 0
om
~;;
~ m' "..,.,.
(Q~ ~
ASS CONTROL UNIT
mlfllo",
.. ·
~
~
~.
FRONTWHE ACCESSORY
SPEED SENS'6-R a
A lOA POSITION, METER 1I
TURN SIGN HEADLIGHT LOW GHT, TAIL, NEUTRAL
D1MMER.HO~L~PSASSING.
WITCH
B15A HEADLIGHT HIGH ,OIL, TEMp' TACHO, HORN
CLUTCH C 1SA
SWITCH
D lOA IGNITION, STARTER
TURN SIGNAL . ALTERNATOR
E lOA
CLOCK ' BRAKE
~
F lOA
G lOA FANMOTOR
~
H 5 A ACCESSORY
MOTOR DRIVER
~
FRONT MODULATOR
n:s-----=-
22-6
;tNE STOP
ITCH LIGHTING SWITCH
<, TLGN[ HL
'"
•,
"
TCS/
IGNITION CONTROL MODULE
30A ASS MAIN FAN MOTOR REAR BRAKE

SWITCH LIGHT
30 A
tOA
FRONT CONTROL MOTOR
REAR CONTROL MOTOR
"~x?~ "om"
, .: ° I~
"'"'7I Q
!I::t~""
I'
LAMP CHECK BANK ANGLE
>"'~ W' i,··,tf ~!-~,r~'

FRONT ASS
IR MODULATOR FUSE BOX
CONTROL
I
MOTOR RELAY
I MODULATOR
rROL
3
MAIN FUSE 30 A
~ ~~~<~
iiiiD iDiD
0!JLAY
~W'M'''' ~I"""
~~£~ ~i£~ ~~ ~t3
"
~;Jj\i3::::::I:::tt--i+-f++-1-' II
~
',IW
ill!lliliiiB.f
°ffl
0;;:-
BI:
W'G
o..,........-,r' LEFT REAR TURN
G~12V32CP
SIGNAL
GW
"'"
"'G'
'''0
BIIG
~
~
O~§
ae
~
G
G~
SIDE STAND SWITCH REAR WHEEL
REAR MODULATOR
SPEED SENSOR
tJSWITCH IGNITION SWITCH

,., 'G
~
<, BAT! ~~i ~~~
ON
ALTERNATOR
0"
LOCK
0030Z-MAJ-A300
23. Technical Features
ASS (Anti-lock Brake System) LBS {Linked Brake System} [After '95] 23-17
['92-'95] 23-1
TCS (Traction Control System)
[After '95] 23-10 [After '91] 23-23
ABS (Anti-lock Brake System) ['92-'95]

Summary
The Anti-lock Brake System (ASS) is designed to help prevent wheel lock up during hard braking or braking on loose or
slippery surfaces. ASS momentarily reduces the brake caliper fluid pressure when the wheels are about to lock. When the
system senses that the tendency for wheel lock is reduced, brake caliper fluid pressure is restored. ABS repeats this cycle
as required for secure brake performance with minimum possibility of wheel lock.
23-1
Technical Features
The braking effectiveness and balance of the motorcycle can be significantly affected by the way the front and rear brakes
are applied. This ABS system is characterized by high deceleration and follow-up performance thanks to its quick response
to a variety of road surface conditions. It is also characterized by its compact size, which is achieved by collective
arrangement of the hydraulic control components in the modulator.
CD ASS INDICATOR LIGHT 2

:J) ASS INDICATOR LIGHT 1
C~) ABS/TCS INDICATOR

LIGHT SWITCH
TABS MAIN RELAY

:~ REAR WHEEL
SENSOR
:Q;. REAR PUMP MOTOR

RELAY
4\;;-"c1i) FRONT PUMP MOTOR
RELAY
(~) ASS CONTROL UNIT
(ECU}
\ __ -'.L~-..J ct FRONT WHEEL

<.
<:> SENSOR
(t, REAR PULSER

RING
·3) REAR '::5) FRONT
MODULATOR MODULATOR
~) FRONT PULSER
RING
rJ) ASS indicator lights

Blinks of stays ON when a problem occurred in the ASS.
,~) Pulser ring
Rotates together with the wheel and detects the wheel speed using the wheel sensor.
:]; Wheel sensor
Inputs the pulse signal, generated proportionally to the rotating speed of the pulser ring, in the control unit.
::1 ASS control unit (ECU)
Controls ASS by monitoring the input signal of each sensor and switch.
::~: Modulator
Adjusts the caliper fluid pressure.
Cfi; Pump motor relay
Controls the modulator motor power source based on a signal from the control unit (ECU}.
Ct ABS main relay
When the control unit detects abnormality, power to the solenoid valve is shut off by the ASS main relay as it receives
the signal from the control unit.
(~) ASS/TCS indicator light switch
A common switch for the ASS and TCS. When the ABS indicator lights 1 and 2 blink, the ABS indicator light 1 can be
dimmed and the indicator light 2 can be turned OFF in order not to interfere with the rider's v'sion.The ASS/TCS indicator
light switch is also used to output the problem code.
23-2
Technical Features
System Construction
Modulator:
The modulator controls and supplies the brake fluid that is essential for the ABS operation. The motorcycle is equipped with
separate and independent front and rear modulators.
The modulators are sealed type containing the brake fluid and constituent parts, and are maintenance free. Additionally. they
have no reservoir pipe and are light-weight and compact. These features make the modulators well suited for motorcycles.
The modulator consists of the following parts;

Expander piston: Operates in accordance with the change in the piston fluid pressure and adjusts the caliper fluid
pressure.
Back-up piston: Pushes the expander piston up when fault occurs.
Limit switch: Detects the pressure in the system by detecting the back-up piston position.
Pump motor: Drives the pump to generate puressre in the system.
Inlet valve/Outlet valve: Adjusts the puressure in the system.
(5) EXPANDER (6) CALIPER

Front modulator shown: PISTON
(2) LIMIT SWITCH (7} BACK-UP

PISTON
(8) LIMIT SWITCH

(4) MASTER
CYLINDER
(12) CUT-OFF
VALVE
WlI
(3) SOLENOID VALVE /

1- (9)
PUMP MOTOR
(INLET VALVE/OUTLET VALVE) (11) OUTLET VALVE
Wheel sensor/pulser ring:

The wheel sensor is the contactless sensor that detects front and rear wheel speed. Consisting of a permanent magnet and
Hall element, the sensor is connected to the ASS control unit. When the projection on the outer circumference of the pulser
ring that is rotating with the front/rear wheel passes across the wheel sensor, a pulse signal is generated at the sensor. The
control unit detects the wheel speed as it receives the pulse signal, because the frequency of the signal increases proportion-
ally to the wheel speed.
(1) HALL ELEMENT

(9) WHEEL SENSOR
(3)
----OUTPUT
l.'::::=== (4)
POWER
I
(5) PULSER RING (7) at HIGH SPEED
(6) I
,-----, ;'
(8) at LOW SPEED
,-----
SIGNAL , , ,
'' ,, I I I
:'
'
:,
, ! ii ! !
i
:' :,
, 1 i
- --- '
'
: _1 I,----- i ! ___J (10) PULSER RING
23-3
Technical Features
ASS control unit (ECU):

The ASS control unit consists of two systems that monitors each other:the main CPU and the sub CPU. The control unit
is designed to activate the solenoid valve and pump motor only when the calculation results of both systems agree with each
other.
ABS CONTROL UNIT
I FRONT WHEEL SENSOR

MAIN
FRONT SOLENOID VALVE
CPU
I REAR WHEEL SENSOR REAR SOLENOID VALVE
I
ASS/TeS INDICATOR
LIGHT SWITCH I t t ASS MAIN RELAY
I FRONT LIMIT SWITCH SUB·

CPU
, .1 FR. PUMP
MOTOR RELAV
H FR.PUMPI
MOTOR
RR. PUMP RR. PUMP

REAR LIMIT SWITCH MOTOR RELAY
I MOTOR
ABS INDICATOR LIGHT
The control unit detects the wheel speed as it receives the signal from each wheel sensor. When the unit senses that the
wheel are about to lock, it controls the caliper fluid pressure by activating the solenoid valve of each modulator.
The control unit also includes a change-over function to the regular system that monitors the system condition by receiving
signals from the limit switch, pump motor etc. It stops theABS function and switches back to the regular brake system when
the control unit detects an abnormality in the ASS.
{2) BACK-UP
PISTON
~~
I
Indicator lights
{3{L1MIT
<r il Ii 'V SWITCH
,
{11 CUT-OFF
VALVE
W ./
!r···_······················_·_························.....~.J''~'~.~"~o!:=--~
r························_·_··············~
,
,
Rear wheel
(4) PUMP
sensor
(5) INLET VALVE MOTOR
Front wheel
senSOr (6) OUTLET VALVE
Pump motor control
The ABS control unit monitors the pressure accumulation by receiving a signal from the limit switch. When the pressure
drops, the back-up piston moves forward and the limit switch turns OFF to operate the pump. When the pressure rises to
a given level. the limit switch turns ON to stop the pump. (The pump is operated continuously while the ABS is active.]
23-4
Technical Features
• Self-diagnosis function
When the engine starts, the ASS control unit evaluates the hydraulic circuit condition by activating the pump motors and
solenoid valves and receiving the signal from the limit switch, The ASS indicator light blinks when an abnormality is detected
in the circuit. When the circuit is normal, the ASS indicator light stays ON indicating that the control unit is in the stand-by
mode for the wheel sensor signal. The wheel sensors send signals to the ECU after the motorcycle starts to move (approxi-
mately 10km/h or above}. The ASS indicator light goes off when the ECU receives signals from the wheel sensor and the
wheel sensor system is found to be normal.
The ASS control unit monitors the main function while the motorcycle is moving, too.
When it detects a problem with the system, it blinks the ASS indicator light and stops the system immediately. When the
control unit detects a problem while the ASS is active, it stops the system and blinks the ASS indicator light, notifying the
rider of the problem and that the system is diactivated.
• Change-over function to the regular system

When the ASS contol unit detects a problem in the system by the self-diagnosis function, the control unit activates the ASS
main relay and shuts off the ground circuits of the front and rear solenoid valves to stop the solenoid valve. The ASS stops
its function when the system is faulty and switches to the regular brake system.
• Problem code storage function

The problems can be memorized and stored in the control unit (up to two codes), and can be retrieved and indicated by the
number of blinks of the ASS indicator light (page 16-A-6).
23-5
Technical Features
ABS main relay:

The secondary side contact points of the ASS main relay is the normal open type, where the electric current does not
normally flow. When the current flows to the primary side relay coil, the contact points close forming the ground circuit of
the solenoid valve.
1----
• (1} ASS CONTROL
UNIT (ECU)
(2)
1)~~~?E:R~:::::t===-REARSOLENOID VALVE
=~(3)
FRONT SOLENOID VALVE
IVI,---------(4) ASS MAIN RELAY
ABS/TCS indicator light switch:

When a problem occurs with the ASS and ASS indicator lights 1 and 2 blink, ASS indicator light 1 can be dimmed and
the indicator light 2 can be turned OFF by pressing the ASSjTCS indicator light switch.
Dimming and turning off these indicator lights keeps them from interiering with the rider's vision.
Another function of the ASS/TCS indicator light switch is to retrieve the problem codes that are stored in he control unit
according to the problem code storage function explained in the previous page. The problem codes are indicated by the
number of times the ASS indicator light blinks. When two problem codes are stored, the latest problem code is output
first.
{3)ASS/TCS INDICATOR
(2) ASS INDICATOR LIGHT SWITCH
(1} ASS INDICATOR
LIGHT 1 LIGHT 2 \
~~
I
TCa A 1$1 S
\\\
(4} TCS ON/OFF SWITCH
23-6
Technical Features
ASS Operation
Regular brake system operation:
Brake fluid pressure is accumulated fully in the system. When the pressure drops, the pump motor operates to accumulate
pressure. The expander piston and back-up piston are supported by this brake fluid pessure. The cut-off valve is pushed by
the expander piston as it opens at this time and the master cylinder and caliper are interconnected with a passage. The fluid
pressure in the master cylinder is transmitted to the caliper by way of the cut-off valve; allowing the brake to operate.
As the outlet valve closes, the high pressure of the brake fluid is maintained in the chamber and the expander piston is not
affected by the operation of the regular brake system.
This condition is the same as when the ASS is in the stand-by mode.
(2) EXPANDER PISTON

(3) BACK-UP PISTON
(1) CUT-OFF VALVE

14)
/ " LIMIT SWITCH
""'------j10
(5) PUMP MOTOR
p
IB) RESERVOIR/
(7) OUTLET VALVE (6) INLET VALVE
23-7
Technical Features
When ABS is working:

• Pressure DECREASE
When the control unit detects that the wheels are about to lock, the control unit sends signals to activate the pump motor
and to open the outlet valve, while closing the inlet valve. The brake fluid in chamber B flows through the outlet valve into
the reservoir side and pushes the expander piston back. Then, the cut-off valve, supported by the expander piston, is closed
by the spring force shutting the passage between the master cylinder and caliper. Simultaneously, as the expander piston
moves backward, the volume of chamber A increases and, the caliper fluid pressure is reduced.
• Pressure HOLD
When both the outlet valve and inlet alve are closed, the brake fluid pressure in chamber A is maintained.
The caliper fluid pressure can then be maintained at a given level.
• Pressure INCREASE
When the pressure is increasing, the outlet valve closes and the inlet valve opens; this allows the brake fluid from the pump
to flow through the inlet valve to chamber B. The brake fluid then pushes the expander piston forward and fluid flows to the
caliper.
The ABS control unit controls the brake fluid pressure and prevents a wheel from locking by performing the sequential
operations of the above "Pressure Decrese", "Pressure Hold" and "Pressure Increase" in accordance with the wheel rotation.
When the control unit senses that the possibility of wheel lock has passed, it closes the outlet valve and opens the inlet valve
to move the expander piston to the forward-most position. This in turn opens the cut-off valve and the passage between the
master cylinder and caliper to restore regular brake operation (page 23-7).
Pressure DECREASE Pressure HOLD Pressure INCREASE
(2} CHAMBER B (3) PUMP

MOTOR
(1) CHAMBER A
(4) INLET VALVE

(5) OUTLET VALVE
(5} RESERVOIR
• Fluid Pressure Control
Caliper fluid Inlet valve Outlet valve

Operation
pressure Pressure relief Pressure relief
Electric signal Electic signal
passage passage
To release braking Open
Decrease ON Closes ON
force
To maintain Closes
Hold ON Closes OFF
braking force
To apply Closes
Increase OFF Opens OFF
braking force
23-8
Technical Features
When trouble occurs:

When the fluid pressure in the chambr (page 23-7) cannot be maintained for some reason, the back-up piston is pushed
forward by the mechanical back-up spring force, which in turn pushes the expander piston up and the cut-off valve opens
fully. Fluid pressure in the master cylinder can then be transmitted by way of the cut-off valve to the caliper. Regular brake
operation can then be maintained.
As the back-up piston spring is preloaded enough to with stand the maximum brake pressure from the master cylinder the
expander piston cannot move backward during regular brake operation.
(2) EXPANDER PISTON

(3) BACK-UP PISTON
(1) CUT-OFF VALVE

~(4) LIMIT SWITCH
~O
(5) BACK-UP SPRING
p fn~_
(9) RESERVOIR / {6) PUMP MOTOR
(8) OUTLET VALVE (7) INLET VALVE
23-9
Technical Features
ABS (Anti-lock Brake System) [After '951

Summary
The ASS is designed to help prevent wheel lock up during hard braking or braking on loose or slippery surfaces. ASS
momentarily reduces the brake caliper fluid pressure when the wheels are about to lock. When the system senses that the
tendency for wheel lock is reduced, brake caliper fluid pressure is restored. ASS repeats this cycle as required for secure
brake performance with rnlrurnurn possibrlrtv of wheel lock.
The conventional ASS is composed of the modulator with controlled hydraulic pressure circuit consisting of the pump and
inlet/outlet solenoid valves. The system indirectly controls brake fluid pressure that regulates the fluid pressure inside the
controlled hydraulic circuit by actuating the solenoid valves.
In this ASS, brake fluid pressure is directly controlled by motor's regulating of the rotational angle of piston-crank mecha-
nism, which in turn controls the brake fluid. Therefore, in comparison with conventional systems, the modulator size. number
of parts required, and weight are all substantially reduced. In addition, the fluid pressure can be regulated continuously,
unlike the conventional ASS which has staqed control. This ASS embodies such a high accuracy control system in a more
simplified system.
MASTER CYLINDER
EXPANDER
!
CALIPER
PISTON'
- - rr=/irnY\i \~'
BACK-UP
PISTON
'~~J
1 CONTROL PISTON
I~
LlJ~"
CRANK ANGLE
MASTER LIMIT SWITCH SENSOR
CYLINDER -/
~~~~FF~ 'Ii'I:::WtclU~~
I 'UJ...):J
""':1""'''''' BACK-UP SPRING
CUT -OFF VALVE
r
WLrcli.l1i--'=i§'i~i&or"-
~=='I PUMP MOTOR
CONTROL MOTOR
OUTLET VALVE INLET VALVE
CONVENTIONAL ABS NEW ABS
23-10
Technical Features
CD ABS indicator lights

Blinks or stays ON when a problem occurrs in the ABS.
(z; Pulser ring
Rotates together with the wheel and detects the wheel speed using the wheel speed sensor.
:j:: Wheel speed sensor
Inputs the pulse signal, generated proportionally to the rotating speed of the purser ring, in the ASS control unit (ECU).
:'1: ABS control unit (ECU)
Controls ABS by monitoring the input signals of each sensor.
:~) Motor driver
Receives control signal from the ASS control unit (ECU} and delivers high-amperage electrical power output to the
modulator's motor for quick changes in operation.
(E' Modulator
Adjusts the caliper fluid pressure.
(f) Modulator control motor relays (front and rear}
When the ASS control unit (ECU) detects abnormality, power to the motor driver is shut off by the control motor relays as
it receives the final from the ASS control unit (ECU).
@ ASSrrCS indicator light switch
A common switch for the ASS and TCS. When ASS indicator lights 1 and 2 blink, ASS indicator light 1 can be dimmed and
indicator light 2 can be turned OFF in order not to interfere with the rider's vision. The ASSfTCS indicator light switch is
also used to output the problem code.
23-11
Technical Features
System Construction
FRONT MODULATOR
Pedal input route
WHEEL SPEED SENSOR
Torque reaction route
OJ
REAR WHEEL
REAR MODULATOR /
WHEEL SPEED SENSOR
Motor Driven Modulator:

The modulator controls the brake fluid pressure that is essential for the ASS operation. The motorcycle is equipped with
separate and independent front and rear modulators. At the same time, in order to combine with the LBS (Linked Brake
System), a single modulator controls two routes for brake fluid pressure, as two routes for braking input are given respectively
to the front and rear wheels.
The modulator consists of the following parts;

- Control piston: Operates in accordance with the change of the crankshaft angle and adjusts the caliper fiuid pressure.
Because each modulator must provide simultaneous control over two separate systems, each features
two sets of control pistons.
- Crankshaft: Turns with the control motor to change the piston position.
- Back-up spring: Pushes the control pistons up (hold the cut-off valve open) by way of the crankshaft.
- Control motor: Drives the crankshaft and adjust the pressure in the system.
- Crank arigle sensor: Detects the crank angle.
- Cut-off valve {3-stages}: Cuts hydrau lie pressure to the brake caliper.
3-STAGE CUT-OFF
VALVE Inlet
CONTROL MOTOR
FILTER Outlet (from master cylinder)
(to calipers) ~
~~111CONTROL PISTON
.1r~tl\u;r,~LRiErD_U_C_T_'OIiN GEAR ~RANKSHAFT

i \>~:;J_' ~/ ,'"
CRANK ANGLE
CRANK ANGLE SENSOR

SENSOR
CRANKSHAFT
\
CONTROL MOTOR
BACK-UP SPRING BACK-UP SPRING
23-12
Technical Features
Wheel Speed Sensor/Pulser Ring:

The wheel speed sensor is the contactless sensor that detects front and rear wheel speed. Consisting of a permanent magnet
and Hall element, the sensor is connected to the ABS control unit. When the projection on the outer circumference of the
pulser ring that is rotating with the front/rear wheel passes across the wheel speed sensor, a pulsar signal is generated at the
sensor. The ABS control unit detects the wheel speed as it receives the pulse signal, because the frequency of the signal
increases proportionally to the wheel speed.
HALL ELEMENT WHEEL SPEED SENSOR

PERMANENT
MAGNET
) ' - - - - - - OUTPUT
l!::::===~ POWER
I
PULSER RING
SIGNAL
, ! ::
,:
l, i i i': i,
-
.._---_.i \ .----_.:
, eue"H RING
ABS Control Unit {ECU}/Motor Driver:

The dual-CPU configuration ensures instant recognition of computer-related malfunctions, since the parallel CPUs run
constant checks on each other whenever the ignition switch is ON. The ASS control unit (ECU) is designed to activate the
modulator control motor only when the calculation results of both systems agree with each other.
ASS CONTROL UNIT (ECU)

c----
[FRONT WHEEL SPEED SENS-oRJ--_
1 REAR WHEEL SPEED SENSOR MAIN CPU
ASSfTCS INDICATOR I
LIGHT SWITCH
1 FRONT CRANK ANGLE SENSOR 1--. .. MOTOR DRIVER
~ ~--->.~~-----;- CONTROL MOTOR
,------J
1
SUB-CPU
REAR CRANK ANGLE SENSOR .--.
·1 ----
'-----.
••1 ASS INDICATOR LIGHT
The ABS control unit (ECU) detects the wheel speed as it receives the signal from each wheel speed sensor. When the unit
senses that the wheel are about to lock, it controls the caliper fluid pressure by activating the control motor of each modulator.
The control unit also includes a change-over function to the standard LBS operation that monitors the system condition by
receiving signals from the wheel speed sensor, crank angle sensor, etc. It stops the ASS function and switches back to the
standard LBS operation when the control unit detects an abnormality in the ABS.
23-13
Technical Features
• Modulator motor control

The ABS control unit monitors both front and rear wheel speed sensors and the modulator crank angle sensors that provide
precise readings of each modulator's crankshaft positioning (i.e., control piston position). The ASS control unit directs its
control signals to the motor driver that delivers high-amperage electrical power output to the control motors and operate the
system.
• Self-diagnosis function
When the ignition switch is ON, the ASS control unit evaluates the control motor relays. The indicator light blinks when an
abnormality is detected in the system. When the system is normal, the ASS indicator light stays ON indicating that the ASS
control unit is in the stand-by mode for the wheel speed sensor and modulator crank angle sensor signals. The wheel speed
sensors send signals to the ASS control unit after the motorcycle starts to move (approximately 10 km/h or above), then the
ASS control unit evaluates the system condition by activating the modulator control motors and receiving the signal from the
crank angle sensors. The ABS indicator light goes off when the system is found to be normal.
The ASS control unit monitors the main function while the motorcycle is moving, whether the brakes are engaged or not.
When it detects a problem with the system, it blinks the ABS indicator light and stops the system immediately. When the
control unit detects a problem while the ASS is active, it stops the system and blinks the ASS indicator light, notifying the rider
of the problem and that the system is deactivated.
• Change-over function to the standard (LBS) system

When the ASS control unit detects a problem in the system by the self-diagnosis function, the control unit stops the ABS
function. The back-up spring pushes the control piston automatically to open the cut-off valve and restore standard LBS
operation {page 23-16}.
• Problem code storage function

The problems can be memorized and stored in the ASS control unit {up to two codes), and can be retrieved and indicated by
the number of blinks of the ASS indicator light (page 16-B-6).
23-14
Technical Features
ABS/Tes Indicator Light Switch:

When a problem occurs with the ASS and ASS indicator lights 1 and 2 blink, ASS indicator light 1 can be dimmed and the
indicator light 2 can be turned OFF by pressing the ABS/TCS indicator light switch.
Dimming and turning off these indicator lights keeps them from interfering with the rider's vision.
Another function of the ABS/TCS indicator light switch is to retrieve the problem codes that are stored in the ASS control unit
according to the problem code storage function explained above. The problem codes are indicated by the number of times the
ASS indicator light blinks. When two problem codes are stored, the last problem code is output first.
ABSTCS INDICATOR
LIGHT SWiTCH
\
BS l[~
ASS INDICATOR ASS INDICATOR

LIGHT 1 LIGHT 2
\
\ ..
TCS ON OFF SWITCH
\
3-Stage Cut-off Valve:
In conventional ASS configurations, a ball-type cut-off valve is used to cut hydraulic pressure to the brake calipers. in thls
ASS, an additional orifice valve is positioned directly behind the cut-off valve to realize three stages of valve operation.
tst stage
When the ASS is enabled, the control piston moves down to close both the cut-off valve and the orifice valve, cutting the
hydraulic line between the master cylinder and the brake caliper.
• 2nd stage
The control piston moves up slightly to open only the cut-off valve, leaving the orifice valve closed. This stage permits only a
small amount of hydraulic pressure to seep through the center of the orifice valve to the brake caliper.
• 3rd stage
The control piston returns to its uppermost position, opening both the cut-off valve and the orifice valve, and restoring the full
hydraulic pressure needed for standard lBS brake operation.
3-STAGE CUT-OFF ORIFICE VALVE

VALVE
CUT-OFF VALVE
Open
(.o~- Open
CONTROL PISTON--l1t=":::ipill
PISTON
Closed
23-15
Technical Features
ABS Operation
• Pressure DECREASE
When the ABS control unit (ECU) detects any tendency towards wheel lock, it rapidly reduces hydraulic pressure to the brake
caliper by rotating the crankshaft to lower the control pistons, closing the 3-stage cut-off valves.
• Pressure HOLD
Following a predetermined decompression interval, the crankshaft is rotated up slightly to move the control pistons into the
pressure HOLD position, which permits the slipping wheel to recover its rotational speed.
Pressure INCREASE
One the ABS control unit detects full wheel speed recovery, it rotates the crankshaft back into its highest position. This rapid
cycle of pressure DECREASE, HOLD, and INCREASE makes possible nearly instantaneous correction of changes in wheel
rotation while ensuring highly accurate control of hydraulic pressure to both independent sets of brake caliper pistons.
ASS OFF Pressure DECREASE Pressure INCREASE
CONTROL MOTOR
PISTON
From master
cylinder
1 /
CUT-OFF VALVE
To
caliper
CRANKSHAFT
BACK-UP SPRING
t
Caliper •
Caliper
• Automatic protection against system failure

During conventional braking operation, the modulator's control piston remains in its uppermost position to hold the cut-off
valve open. If any malfunction in the ASS is detected at this time, the system is turned off without affecting the control
piston's position, thus maintaining standard LBS operation. During ABS operation, if any malfunction-such as loss of the
modulator motor's power-is detected, the control piston back-up spring pushes the control piston into its upper most
position to open the cut-off valve and restore standard LBS operation.
23-16
Technical Features
lBS (linked Brake System) [After '951

Summary
The Linked Brake System (LBS} was designed to engage both front and rear brakes when either the front brake lever or rear
brake pedal is used.
Not merely a linked system that divides pedal braking force between the rear caliper and one of the front calipers, this system
features a set of a-piston calipers that are connected to two independent hydraulic systems. These combine to provide an
optimal balance offront and rear braking forces whenever either the brake lever and and/or the brake pedal is used. Featuring
no electronic control about the LBS, the completely hydraulic system's key component is a mechanical linkage that transmits
front caliper braking force to a secondary master cylinder mounted on the left fork slider.
Pedal input route
Front calipers (3-pistons)

'Z Link mechanism
::~; Rear caliper (3-pistons)
f Delay valve
Slows front brake engagement to minimize its associated dive when performing minor speed corrections with only the
brake pedal.
:5: Secondary master cylinder
Transmits the rotational torque exerted on the front caliper to the rear brake caliper by way ofthe Proportional Control
Valve (PCV).
(6) Proportional control valve (PCV}
Regulates the rear caliper hydraulic pressure from the secondary master cylinder.
23-17
Technical Features
System Construction
LEVER BRAKE MASTER CYLINDER --') PROPORTIONAL CONTROL VALVE (PCV)
PEDAL BRAKE MASTER CYLINDER
REAR CAUPER
DELAY VALVE
SECONDARY MASTER CYUNDER

FRONT CALIPERS
3-Piston Caliper:
A set of three newly designed 3-piston calipers are controlled by two independent hydraulic systems.
The center piston of all three calipers are operated directly by the brake pedal.
The two outer pistons of the front calipers are controlled by the brake lever, and the two in the rear are controlled by the
servomechanism-actuated secondary master cylinder (page 23-17).
This arrangement delivers a broad, yet easily controlled range of braking force, depending on which either or both of the two
(lever and pedal) brake are engaged.
FRONT: REAR:
CENTER PISTON
CENTER PISTON
OUTER PISTONS OUTER PISTONS
23-18
Technical Features
Delay Valve:
The delay valve positioned between the pedal brake master cylinder and the center pistons of the front calipers, the delay
valve engages only the left front caliper at first, effectively reducing the initial front wheel braking force (Fig. A-B).
As pedal pressure gradually increases, the delay valve introduces pressure to the right front caliper, which increases to match
the pressure to the left front caliper at a predetermined level {Fig. C}. The resulting feel is of comfortably even deceleration that
begins at the rear, with little of the rapid forward dive that is usually brought on when the front brakes are suddenly applied.
PEDAL BRAKE
MASTER CYLINDER
R. FRONT L. FRONT REAR

CALIPER CALIPER CALIPER
DELAY VALVE
INLET {from pedal

master cylinder}
OUTLET 2 (to right

front caliper)
A B c
'T:,-::g~:Fig. A
:J:-':~): Fig B
Outlet 1 /
.- C[:,-J:': Fig C
,j)- : Alternating Fig. Band C
/
/,\
Outlet 2
1'
,-""
___........-'.:t.
I ,-,
Inlet pressure
23-19
Technical Features
Link Mechanism/Secondary Master Cylinder:

The system's servomechanism uses the rotational torque exerted on the front caliper when they are engaged to actuate a
secondary master cylinder by way of its caliper mounting linkage.
This secondary master cylinder then applies a corresponding amount of pressure to the rear brake caliper.
SECONDARY MASTER CYLINDER
Torque reaction route

.r---;.:.:...:....-----,
LEFT FRONT REAR

LINK MECHANISM CALIPER CALIPER
PCV
Proportional Control Valve (PCV):

The pev installed between the secondary master cylinder and the outer pistons of the rear caliper, regulates pressure in three
stages of operation.
Initially, the PCV's output pressure increases in direct proportion to the increasing input pressure originating from the
secondary master cylinder (Fig. Al.
As input pressure continues to increase, the cut piston activates, closing the valve and causing the output pressure to hold
(Fig. B).
A further increase in input pressure forces the decompression piston down, which expands a sub-chamber that draws
pressure off the output side of the pev (Fig. C)
Open Closed Closed
Outlet (to rear caliper) ~
Inlet (from secondary

master cylinder)
DECOMPRESSION PISTON A B C
-(2" : Fig. A
'~2~-K: Fig. 8
,~>-:;t: Fig. C
Inlet pressure
23-20
Technical Features
LBS Operation
When hand brake is applied:
On initial operation, the hand brake works like any conventional motorcycle front brake system. A squeeze on the brake lever
pressurizes the master cylinder which transmits its increased hydraulic pressure to the two outer pistons of the front calipers,
causing a corresponding braking force to be applied to the front wheel.
In response to the braking force applied by the front caliper onto the spinning brake rotor, the caliper is pulled in the direction
of wheel rotation, around its lower caliper pivot. This forward caliper motion also acts on the link arm which is connected to
the secondary master cylinder. This direct pressure on the secondary master cylinder is regulated by the PCV which then
transmits its hydraulic pressure to the outer pistons of the rear caliper.
Front Master Cylinder
___1-- _ [
,
Left Front Caliper
J Right Front Caliper
(Mechanical Linkage)
Secondary Master Cylinder
PCV (Regulating pressure)
,
Rear Caliper (Outer pistons)
BRAKE
LEVER
PCV
23-21
Technical Features
When foot brake is applied:

When the brake pedal is pressed, hydraulic pressure from the rear master cylinder is routed through two lines. One connects
directly to the rear caliper and acts on the center piston. The other line runs to the center pistons of the front calipers by way
of the delay valve that slows front brake engagement to minimize its associated dive. As during hand brake operation,
hydraulic pressure from the secondary master cylinder passes through the PCV, and acts on the outer pistons of the rear
caliper. Because hydraulic pressure from the rear master cylinder is also being applied by the rear cali per's center piston, the
braking force applied to the rear wheel is greater than that applied when using the brake lever only.
Front Master Cylinder
Delay valve
(Center Piston) (Outer Pistons)
Rear Caliper J
Left Front Caliper RighI Front Caliper
(Mechani~al Linkagel
,
J
Secondary Master Cylinder
PCV (Regulating pressure)
o
DELAY BRAKE PEDAL
VALVE l-l------------1
pev
The system offers the same braking feel as conventional brake systems, but adds a more progressive range of brake control
and enhanced balance of braking capability. Because the two systems are independent of each other, both the brake pedal
and the lever can be used in any combination without resulting in excessive braking force or other unusual responses.
23-22
Technical Features
TCS (Traction Control System) [After '91]

Summary
The Traction Control System (TCSj is designed to help prevent excessive rear wheel slippage during hard acceleration or
acceleation on loose or slippery surfaces. TCS helps maintain rear wheel traction by controlling the ignition timing when it
senses rear wheel slippage. The system alerts the rider that TCS is active by turning the TCS activation light on.
------
~;:.,TIV
CFF IA Bel
..I ' Tee] L _
The TCS adjusts and controls the engine power by adjusting the ignition timing. This helps match the rear wheel torque to
the road surface traction condition.
100%
,,
,,
N ,,
,,
,,
,,
,,
,,
,,
,
o
Retarded
Normal
(1) IGNITION TIMING
23-23
Technical Features
The TCS/ignition control module (lCM) judges the rear tire traction conditions as it receives the signal from the front and
rear wheel sensors.
When the rcs is activated the TCS/ICM turns on the rcs activation light and controls engine power through changes in
ignition timing. The TCS automatically turns ON by turning the ignition switch ON, and can be turned OFF manually as
the rider wishes by pushing the TCS ON/OFF switch.
Note that the TCS cannot be turned OFF when it is active or while the motorcycle is moving.
CD TCS ACTIVATION
LIGHT
C?! TCS OFF INDICATOR
Q) TCS WARNING LIGHT
$- TCS ON/OFF SWITCH I~' TCS/IGNITION

CONTROL MODULE (fCM)
(n ABS/TCS INDICATOR LIGHT

SWITCH
v
\ \\ ~:: FRONT WHEEL
SENSOR
@o FRONT PULSER
RING
:~- REAR WHEEL

SENSOR
@ REAR PULSER
RING
CD TCS activation light

Turns ON when the TCS is active.
(~) TCS OFF indicator
Turns ON when the TCS is turned OFF using the TCS switch or when the TCS is not activated because of a problem
with the TCS.
~; TCS indicator light
Blinks when a problem occurs in the TCS. The light stays ON when the pre-start self-diagnosis is not passed.
'Al Pulser ring
Rotates together with the wheel and detects the wheel speed using the wheel sensor.
I~ Wheel sensor
Sends the pulse signal, generated proportional to the rotating speed of the pufser ring, to the TCS/ICM.
@TCS ON/OFF Switch
The TCS can be turned ON and OFF by pushing the TCS ON/OFF switch. The TCS OFF indicator comes ON when the
TCS ON/OFF switch is OFF.
(1) ABS/TCS indicator light switch
The indicator light switch is the common switch between the ASS and TCS.
rcs
When the TCS indicator light blinks, it can be turned OFF so it does not interfere with the rider's vision. (The OFF
indicator stays ON).
~ TCS/ignition control module (ICM)
While receiving signals from the front and rear wheel sensors, the TCS/ICM judges the running condition and it outputs
a signal for appropriate ignition timing.
23-24
Technical Features
System Construction
TCS/ignition control module (ICM):

The TCS/ICM detects front and rear wheel speed by receiving signals from the wheel sensors. When the rear wheel speed
exceeds a given ratio of front-to-rear wheel speed, the TCS/ICM judges that the rear driving wheel is beginning to slip and
it activates the TCS.
The TCS/ICM body is the ECU that is integrated with the spark unit. As the ignition CPU and the traction control CPU
communicate with each other and the ignition CPU monitors the traction control CPU, the engine will operate normally
even if the TCS becomes inoperative due to a problem in the system.
When the TCS in inoperative, the TCS indicator light and TCS OFF indicator turn ON.
The TCS/ICM constantly monitors the input signal inside the TCS/ICM, and shuts off the TCS when it detects a prob-
lem with the system.
Simultaneously, the TCS/ICM turns ON or makes the TCS indicator light blink notifying the rider of the problem with the
system, and turning the TCS OFF indicator ON to notify the rider of the inoperative state of the TCS.
TCS/IGNITION
CONTROL MODULE
(ICMI
TCS ON/OFF SWITCH

I IGNITION COIL
I
ABS/TCS INDICATOR I IGNITION
I LIGHT SWITCH I CPU TCS OFF INDICATOR
! I
TCS INDICATOR LIGHT
t -+
I FRONT WHEEL SENSOR
TRACTION
CONTROL
i TeS ACTIVATION LIGHT I
I REAR WHEEL SENSOR CPU
I
23-25
Technical Features
. Self-diagnosis function
The TCS/ICM starts self-diagnosis as the ignition switch is turned ON. It diagnoses the TCS/ICM itself and the wheel sen-
sor power source. When it detects a problem, it stops TCS operation, makes the TCS indicator light blink and turns on the
TCS OFF indicator light to notify the rider of a fault in the TCS. When the TCS/ICM is found to be normal, it moves to the
stand-by mode for the wheel sensor signal and the TCS indicator light turns ON. (The TCS does not function when the
TCS indicator light is ON).
The wheel sensors send signals to the TCS/ICM after the motorcycle is in motion [approximately 1Okm/h(6 mile/h) or abo-
ve] , and the TCS indictor light goes OFF after the wheel sensor signal is input and the wheel sensors are found to be as
normal.
If the TCS indicator light stays ON, there is an abnormality with the wheel sensors.
(1) TCS OFF INDICATOR (2) TCS INDICATOR

LIGHT
r..·..··••··••·•··•·•··••··· · ·..·.·.- ··· · ~ ASS ECU f··

1
. ......
r
I S'"'p''' I····················! ..'..-...-..-.. ~
Rear wheel Front wheel

sensor sensor
Wheel sensor/pulser ring:

The ASS and TCS share the same wheel sensor/pulser rings.
They transmit the vehicle speed signal to both the ASS control unit and the TCS/ICM. (See page 23-3)
23-26
Technical Features
ABS/TCS indicator light switch:

When a problem with the TCS occurrs, the TCS indicator light blinks and the TCS OFF indicator turns ON. The TCS indicator
light can be turned OFF by pressing the ABS/TCS indicator light switch. Turns off the indicator light prevents the light from
interfering with the rider's vision. The TCS OFF indicator does not go off but stays ON.
TCS ON/OFF switch:

The TCS can be turned ON and OFF by pushing the Tes ON/OFF switch. The TCS is activated when the switch is ON, the
TCS activation light turns ON, and when the TCS is active. When the TCS ON/OFF switch is OFF, the TCS cannot be
activated but the TCS OFF indicator comes ON. The TCS cannot be shut off when it is active or while riding.
(1}ABS/TCS INDICATOR LIGHT

SWITCH
(5) TCS INDICATOR
\ LIGHT
TCS ACTIVE) Tcs ~
(2) TCS ON/OFF SWITCH
23-27
Technical Features
TCS Operation
When TCS is active:
After receiving the signal from the front and rear wheel sensors, the TCS/ICM judges whether traction control is required
by detecting the rear wheel speed and comparing it to the front wheel speed (i.e vehicle speed). The engine will operate
normally when the TCS is not active. When the rear wheel speed exceeds a given ratio of the front-to-rear wheel speed,
the TCS/ICM judges that the rear wheel is slipping excessively and controls the engine power by determining the suitable
ignition timing. The TCS performs the above operations instantaneously to help prevent the skid from becoming excessive
and to hold it within a specified range .
••••••••••••••••••••••••••••••••••••••••••••••••••••••. . ... .. ~ ABS ECU ~ ••

,
ISparkplug ~ ! ;
Rear wheel Front wheel

sensor sensor
When a problem occurs:

When the TCS/ICM detects a problem with the TCS, it makes the TCS indicator light blink, turns the TCS OFF indicator
ON, and immediately shuts off the rcs function. When the TCS/ICM detects a problem while the TCS is active, it returns
the engine slowly to regular ignition timing, then deactivates the TCS.
23-28
Symbols
...

~
C
10 (1.0, 7.2)
~
equivalent)
equivalent)

"I~ Apply sealant

24. Troubleshooting
Engine Does Not Start or is Hard Poor Performance at High Speed 24-4
to Start 24-1 24-4
Poor Handling
Engine Lacks Power 24-2
Poor Performance at Low and Idle
Speeds 24-3
Engine Does Not Start or is Hard to Start

Possible Cause
'l . Check fuel flow to carburetor - - - Not Reaching Carburetor - - - - - - _ . . . Clogged fuel tube or fuel filter
Sticking float valve
Reaching Carburetor Faulty fuel pump
• Faulty fuel pump relay
Clogged fuel tank breather
Disconnected or faulty auto
fuel valve vacuum tube
2. Perform a spark test - - - - - - - Weak or No Spark ---------~-.. Faulty spark plugs

• Fouled spark plugs
Good Spark • Faulty ignition control module
• Broken or shorted spark plug
wires
Broken or shorted ignition coil
Faulty ignition pulse generator
Faulty engine stop switch
Faulty bank angle sensor relay
• Loose or disconnected ignition

system wires
3. Test cylinder compression - - - - - Low Compression - - - - - - - - - - . . . Improper valve clearance

(shim too thick)
Compression Normal Improper valve and seat
contact
• Valve stuck open
Worn cylinder and piston rings
• Damaged cylinder head gasket
• Seized valve
• Improper valve timing
4. Start by following normal starting - Engine Starts But Stops - - - - - - - - . . . Improper starting enrichment
procedure valve operation
• Carburetor incorrectly adjusted
• Intake pipe leaking
Engine Does Not Fire Improper ignition timing (Faulty
ignition control module or
ignition pulse generator)
j Fuel contaminated
5. Remove and inspect spark plug - - Wet Plug ------------~.~. Carburetor flooded
• Starting enrichment valve opened
Throttle valve open
Air cleaner dirty
24-1
Troubleshooting
Engine Lacks Power

Possible Cause
1. Raise wheels off ground and ---Wheels Do Not Spin Freely ----~... Brake dragging
spin by hand • Worn or damaged wheel bearings
• Wheel bearings need lubrication
Wheel Spins Freely Final gear bearing damaged
I
2. Check tire pressure -------Pressure L o w - - - - - - - - - - o - . Faulty tire valve
Pressure Normal
I
3. Accelerate rapidly from low to - - Engine Speed Does Not Change
second When Clutch Released
_0 Clutch slipping
Worn clutch discs/plates
I Warped clutch discs/plates
Engine Speed Reduced When Weak clutch spring
Clutch is Released • Sticking clutch hydraulic system
I • Check for engine oil additive
4. Accelerate lightly - - - - - - - Engine Speed Does Not Increase-----· Starting enrichment valve opened
Clogged air cleaner
'loe Speed Increases
Restricted fuel flow
Clogged muffler
Clogged fuel tank breather
Faulty fuel pump
Faulty fuel pump relay
5. Check ignition timing ------Incorrect -----------~._. Faulty ignition control module

Correct
I
6. Check valve clearance ------Incorrect -----------~._. Improper valve adjustment
Worn valve seat
Correct
I
7. Test cylinder compression - - - - T o o Low ------------0-. Valve stuck open
• Worn cylinder and piston rings
Normal Leaking head gasket
Improper valve timing
j • Seized valve
Improper valve and seat contact
8. Check carburetor for clogging--- Clogged -----------~._. Carburetor not serviced

frequently enough
Not Clogged
I
9. Remove spark plug - - - - - - - Fouled or Discolored - - - - - - - _ _ Plugs not serviced frequently
enough
Not Fouled or Discolored Spark plugs are incorrect heat range
I
10 Check oil level and condition'---Incorrect - - - - - - - - - -__ 0_. Oil level too high
• Oil level too low
Correct • Contaminated oil
I Lubricated----~
11. Remove cylinder hed cover Valve Train Not •• Clogged oil passage
and inspect lubrication Properly Clogged oil control orifice
Contaminated oil
Valve Train Lubricated • Faulty oil pump
Property
j
24-2
Troubleshooting
Possible Cause
12. Check for engine overheating - - - Overheating - - - - - - - - - - _ . . . Coolant level low

Fan motor not working
Not Overheating (Faulty fan motor switch)
Thermostat stuck closed
Excessive carbon build-up in
combustion chamber
Use of poor quality fuel
Clutch slipping
- Check for engine oil additive
j
Lean fuel mixture
Wrong type of fuel
13. Accelerate or run at high speed --Engine K n o c k s - - - - - - - - -•• • Worn piston and cylinder
Wrong type of fuel
Engine Does Not Knock Excessive carbon build-up in
combustion chamber
Ignition timing too advanced
(Faulty ignition control module)
Lean fuel mixture
Poor Performance at Low and Idle Speeds

Possible Cause
1. Check ignition timing and valve - - Incorrect -----------~._. Improper valve clearance
clearance Improper ignition timing
- Faulty ignition control module
Correct - Faulty ignition pulse generator
I
2. Check carburetor pilot screw - - - Incorrect ------------~._See Fuel System Section
adjustment
Correct
I
3. Check for leaking intake pipe - - - Leaking -----------~._ Loose insulator clamps
Damaged insulator
Not Leaking
4. peJorm spark test - - - - - - - - Weak or Intermittent Spark ---~.-. Faulty, carbon or wet fouled
spark plug
Good Spark Faulty ignition control module
• Faulty ignition coil
Broken or shorted spark plug
wires
• Faulty engine stop switch
Faulty bank angle sensor relay
Loose or disconnected ignition
system wires
24-3
Troubleshooting
Poor Performance at High Speed

Possible Cause
1. Check ignition timing and valve - - Incorrect - - - - - - - - - - -••- Improper valve clearance
clearance Improper ignition timing
- Faulty ignition control module
Correct - Faulty ignition pulse generator
I
2. Disconnect fuel tube at - - - - - - Fuel Flow Restricted - - - - - - - . • Clogged fuel line
carburetor Clogged fuel tank breather
Clogged fuel filter
Fuel Flows Freely • Faulty fuel pump or relay
• Fuel tank empty
j • Faulty auto fuel valve
3. Remove carburetor and check - - - Clogged - - - - - - - - - - - _ . Clean

for clogged jets
Not Clogged
I
4. Check valve timing - - - - - - - Incorrect - - - - - - - - - - - - . _ . Camshaft not installed properly
• Cam reduction gear not
Correct installed properly
I
Timing marks on the timing
belt pulleys not aligned
5. Check valve spring - - - - - - - - W e a k - - - - - - - - - - - - _ . Faulty spring
Not Weakened
Poor Handling-----. Check tire pressure

Possible Cause
• • Steering head bearing adjustment

1. If steering is heavy - - - - - - - - - - - - - - - - - - - - - - -
nut too tight
• Damaged steering head bearings
• Bent steering stem
2. If either wheel is wobbling -------------------~_
• • Excessive wheel bearing play
• Bent rim
• Improperly installed wheel hub
• Swingann pivot bearing excessively
worn
• Bent frame
• Swingann pivot adjusting bolt
too tight
• • Front and rear wheels not aligned

3. If the motorcycle pulls to one side - - - - - - - - - - - - - - - - _
Bent fork
• Bent swingarm
• Bent front axle
• Bent frame
24-4
ST1100P Addendum
How to Use This Manual Contents
This addendum contains information for ST1100P. Model Identification .
Refer to ST11 OO/ST11 OOA SHOP MAN UAL (No. Specification......... 2
61MY311) for service procedures and data not included Cable & Harness Routing 13
in this addendum. Emission Control Information Labels 20
Seat ; 21
Upper Seat Cowling 21
ALL INFORMATION, ILLUSTRATIONS, DIREC-
Seat Cowling : 22
TIONS AND SPECIFICATIONS INCLUDED IN
Saddlebag Stay/Amplifier Stay 22
THIS PUBLICATION ARE BASED ON THE LATEST Fairing Pocket 23
PRODUCT INFORMATION AVAILABLE AT THE Instrument Panel 24
TIME OF APPROVAL FOR PRINTING. Honda Rearview Mirror 25
Motor Co., Ltd. RESERVES THE RIGHT TO Headlight Aim 25
MAKE CHANGES AT ANY TIME WITHOUT Lights/Meters/Switches Location 26
NOTICE AND WITHOUT INCURRING ANY OBLI- Rear Turn Signal and BrakelTaillight 27
GATION WHATEVER. NO PART OF THIS PUBLI- Voltmeter 27
CATION MAY BE REPRODUCED WITHOUT Wiring Diagram 29
WRITIEN PERMISSION. THIS MANUAL IS WRIT-
TEN FOR PERSONS WHO HAVE ACQUIRED
BASIC KNOWLEDGE OF MAINTENANCE ON
Honda MOTORCYCLES, MOTOR SCOOTERS
ORATVS.
Honda Motor Co., Ltd.

SERVICE PUBLICATION OFFICE
Date of Issue: October, 2003

© Honda Motor Co., Ltd.
ST1100P Addendum
Modelldentification
(1) VEHICLE IDENTIFICATION NUMBER

The Vehicle Identification Number (VIN) is located on the
Safety Certification Label on the left side of the steering
head.
(2) ENGINE SERIAL NUMBER (3) FRAME SERIAL NUMBER

The engine serial number is stamped on the rear of the The frame serial number is stamped on the right side of the
lower crankcase behind the oil pan. steering head.
(4) CARBURETOR IDENTIFICATION NUMBER (5) COLOR LABEL

The carburetor identification number is stamped on each The color label is attached to the frame under the seat.
carburetor body on the intake side.
1
ST1100P Addendum
Specifications
Unit: mm (in)
- G enera
Item Specifications
Dimensions Overall length 2,285 (90.0)
Overall width 835 (32.9)
Overall height 1,405 (55.3)
Wheelbase 1,555 (61.2)
Seat height 800 (31.5)
Footpeg height 309 (12.1)
Ground clearance 145 (5.7)
Dry weight (with saddle bag) 297 kg (655 Ib)
Curb weight (with saddle bag) 326 kg (719 Ib)
Maximum weight capacity 175 kg (386 Ib)
Frame Frame type Double cradle
Front suspension Telescopic fork
Front wheel travel 150 (5.9)
Rear suspension Swingarm
Rear wheel travel 120 (4.7)
Front tire size 110/80-18M/C 58V
Rear tire size 160/70-17M/C 73V
Tire brand (Bridgestone) FR/RR G547/G548
Tire brand (Dunlop) FR/RR -~
Tire brand (Metzeler) FR/RR -~
Front brake Hydraulic double disc

Rear brake Hydraulic single disc
Caster angle 27° 30'
Trail length 101 (4.0)
Fuel tank capacity 28 liters (7.40 US gal, 6.16 Imp gal)
Fuel tank reserve capacity - ~
2
ST1100P Addendum
Unit: mm (in)
- General cont'd
Item Specifications
Engine Bore and stroke 73.0 x 64.8 (2.87 x 2.55)
Displacement 1,084 em' (66.1 cu in)
Compression ratio 10.0 : 1
Valve train Belt and gear driven DOHC
Intake valve opens at 1 mm lift _5° BTDC (5° ATDC)
Intake valve closes at 1 mm lift 35° ABDC
Exhaust valve opens at 1 mm lift 40° BBDC
Exhaust valve closes at 1 mm lift _5° ATDC (5° BTDC)
Lubrication system Forced pressure and wet sump
Oil pump type Trochoid
Cooling system Liquid cooled
Air filtration Paper Filter
Crankshaft type Unit type, 3 main journals
Engine weight 93.0 kg (205 Ib)
Firing order 1 - 90° - 4 - 270
0
3 - 90° -
- 2 - 270° - 1
Cylinder arrangenment 4 cylinders, 90
0V
Cylinder number
Left
~ Front
Carburetor Carburetor tvpe Constant velocity 4 carburetors

Throttle bore 34.5 (1.36)
Drive train Clutch system Multi-plate, wet
Clutch operation system Hydraulic operating
Transmission 5 speeds
Primary reduction 1.829 (75/41 )
Secondary reduction
Third reduction
Final reduction 2.833 (34/12)
Gear ratio 1st 2.266 (34/15)
Gear ratio 2nd 1.500 (27/18)
Gear ratio 3rd 1.142 (24/21)
Gear ratio 4th 0.916 (22/24)
Gear ratio 5th 0.758 (22/29)
Gear ratio 6th
Gear ratio reverse
Gearshift pattern Left foot operated return system 1-N-2-3-4-5
Electrical Ignition system Digitalized full transistor ignition
Starting system Electric starter motor
Charging system Triple phase output alternator
Regulator/rectifier type Field control/triple phase full-wave rectification
Lighting system Battery
AC regulator type
3
ST1100P Addendum
Unit: mm (in)
- Lubrication
Engine oil capacity at draining 3.6 liters (3.80 US qt, 3.17 Imp qt)
at disassembly 4.3 liters (4.54 US qt. 3.78 Imp qt)
at oil filter change 3.7 liters (3.91 US qt, 3.26 Imp qt)
Recommended engine oil Pro Honda GN4 or HP4 (without molyb-
denum additives) 4-stroke oil or equiva-
lent motor oil
API service classification: SG or Higher
JASO T 903 standard: MA
Viscosity: SAE 10W-40
OIL VISCOSITIES
-1
I
I Other viscosities shown in the chart may
1 -I
I
be used when the average temperature
1 1 in your riding area is within the indicated
I
20 40 60 80 100'F
range.
I I I I I I
·10 0 10 20 30 40'C
Oil pressure at oil pressure switch 392-490 kPa (4.0-5.0 kq/cm>, 57-71
psi) at 5,000 rpm (80°CI176°F)
Oil pump rotor tip clearance G) 0.15 (0.006)
body clearance W 0.15-0.22 (0.006-0.009)
end clearance G) 0.02-0.09 (0.0008-0.0035)
r- Fuel System - - - - - - - - - - - - - - - - - - - , . - - - - - - - - - - - - - - - - . - - - - - - - - - ,
Carburetor identification number VDBEA
Main jet #125
(High altitude)
(2,3)
(1,4)
(Front)
(Rear)
Slow jet #38
Jet needle clip position
Pilot screw intial opening See page 5-12 (2-5/8 turns out)
Pilot screw high altituge adjustment See page 5-16
Pilot screw final opening See page 5-12
Air screw intial opening
Air screw high altitude adjustment
Float level 7.0 (0.28)
Carburetor vacuum difference Within 40 mmHg (1.6 inHg)
Base carburetor (For carburetor synchronization) No.4 carburetor
Idle speed 1,200± 100 rpm
Throttle grip free play 2-6 (0.08-0.24)
Accelertor pump clearance
Pulse secondary air injection (PAIR) control valve vacuum 360 mmHg (14.2 inHg)
pressure
4
ST1100P Addendum
Unit: mm (in)
~ Cylinder Head
Cylinder compression 1,373 ± 196 kPa (14.0 ± 2.0 kq/crn",
199±28 psi)/400 rpm
Cylinder compression difference
Valve clearance IN 0.13-0.19 (0.005-0.007)
EX 0.22-0.28 (0.009-0.011)
Cylinder head warpage 0.10· (0.004) .-
Cam lobe height CD IN 35.680-35.840 (1.4047-1.4110) 35.650 (1.4035)
EX 35.770-35.930 (1.4083-1.4146) 35.740 (1.4071)
Camshaft runout 0.05 (0.002)
Camshaft oil clearance A 0.020-0.062 (0.0008-0.0024) 0.100 (0.0039)
B 0.050-0.092 (0.0020-0.0036) 0.130 (0.0051)
Camshaft journal O. D. A 24.959-24.980 (0.9826-0.9835) 24.950 (0.9823)

B 24.929-24.950 (0.9815-0.9823) 24.920 (0.9811)
Camshaft holder I. D. A 25.000-25.021 (0.9843-0.9851)
B 25.000-25.021 (0.9843-0.9851)
Valve stem O.D. IN 4.475-4.490 (0.1762-0.1768) 4.465 (0.1758)
EX 4.465-4.480 (0.1758-0.1764) 4.455 (0.1754)
Valve guide I. D. IN 4.500-4.512 (0.1772-0.1776) 4.562 (0.1796)
EX 4.500-4.512 (0.1772-0.1776) 4.562 (0.1796)
Stem-to guide clearance IN 0.010-0.037 (0.0004-0.0015)
EX 0.020-0.047 (0.0008-0.001 9)
Valve guide projection above cylinder head IN (h) 15.3-15.5 (0.60-0.61)
EX (h) 15.3-15.5 (0.60-0.61)
Before guide installation:

1. Chill the valve guide in the freezer
section of a refrigerator for about an
hour.
2. Heat the cylinder head to 100
-150°C (212-300°F)
. Valve seat width IN 1.0 (0.04) 1.5 (0.06)

EX 1.0 (0.04) 1.5 (0.06)
Valve spring free length IN 41 .72 (1 .643) 39.6 (15.59)
EX 41 .72 (1 .643) 39.6 (15.59)
Inner IN
Inner EX
Outer IN
Outer EX
Rocker arm I. D. IN
EX
Rocker arm shaft O. D. IN
EX
Rocker arm-to-rocker arm shaft clearance
Valve lifter O. D. 25.978-25.993 (1.0228-1.0233) 25.968 (1.0224)
Valve lifter bore I. D. 26.010-26.026 (1.0240-1.0246) 26.040 (1.0252)
Hydraulic tappet adjuster assist spring free length
Hydraulic tappet adjuster compression stroke with kerosene
5
ST1100P Addendum
Unit: mm (in)
po- Cylinder/Piston
Cylinder I. D. 73.00~73.015 (2.874~2.8746) 73.10 (2.878)
Cylinder out of round 0.10(0.004)
Cylinder taper 0.10(0.004)
Cylinder warpage 0.10(0.004)
Piston mark direction "IN" mark facing toward the intake side
Piston O. D. (D) 72.97~72.990 (2.8728-2.8736) 72.850 (2.8681)
Piston O.D. measurement point (H) 19 (0.75)
Piston pin hole I. D. (d) 18.002-18.008 (0.7087-0.7090) 18.020 (0.7094)
-df4-
I
Cylinder-to-piston clearance 0.010-0.045 (0.0004-0.0018)

Piston pin O. D. 17.994-18.000 (0.7084-0.7087) 17.98 (0.708)
Piston-to-piston pin clearance 0.002-0.014 (0.0001-0.0006)
Connecting rod-to-piston pin clearance 0.016-0.040 (0.0006-0.0016)
Top ring-to-ring groove clearance 0.025-0.060 (0.0010-0.0024) 0.10 (0.004)
Second ring-to-ring groove clearance 0.015-0.050 (0.0006-0.0020) 0.10(0.004)
Top ring end gap 0.15-0.30 (0.006-0.012) 0.5 (0.02)
Second ring end gap 0.30-0.45 (0.012-0.018) 0.7 (0.03)
Oil ring (side rail) end gap 0.20-0.70 (0.008-0.028) 1.0 (0.04)
Top ring mark "R" mark facing up
Second ring mark "RN" mark facing up
Crankshaft
Connecting rod small end I. D. 18.016-18.034 (0.7093-0.7100) 18.050 (0.7106)
Connecting rod big end side clearance 0.10-0.30 (0.004-0.012) 0.40 (0.016)
radial clearance
Crankshaft runout 0.05 (0.002)
Crankpin oil clearance 0.030-0.052 (0.0012-0.0020) 0.080 (0.0031)

Crankpin bearing selection See page 11-6
Main journal oil clearance 0.026-0.048 (0.0010-0.0019) 0.065 (0.0026)
Main journal bearing selection See page 11-6
po- Kickstarter
Kickstarter pinion gear I. D.
Kickstarter spindle O. D.
Kickstarter idle gear I. D.
Countershaft O. D. at kickstarter idle gear
Kickstarter idle gear bushing O. D.
I.D.
6
ST1100P Addendum
Unit: mm (in)
r- Transmission
Transmission gear I.D. M4, M5 31.000-31.025 (1.2204-1.2215) 31.040 (1.2220)
C2, C3 31 .000-31 .025 (1 .2204-1 .2215) 31.040 (1.2220)
Transmission gear bushing O. D. M4, M5 30.950-30.975 (1.2185-1.2195) 30.930 (1.2177)
C2, C3 30.950-30.975 (1.2185-1.2195) 30.930 (1 .2177)
Transmission gear bushing I. D. M4 28.000-28.021 (1.1024-1.1032) 28.031 (1.1036)
Gear-to-bushing clearance at M4, M5 gear 0.025-0.075 (0.0010-0.0030) - .
at C2, C3 gear 0.025-0.075 (0.0010-0.0030) -
Mainshaft O. D. at M4 gear bushing 27.967-27.980 (1.1011-1.1016) 27.960 (1.1008)
M4
q
[
=f:
Gear bushing-to-shaft clearance at M4 gear 0.020-0.054 (0.0008-0.0021)
5.93-6.00 (0.233-0.236)
-
5.9 (0.23)
Shift fork claw thickness F
C 5.93-6.00 (0.233-0.236) 5.9 (0.23)
R 5.93-6.00 (0.233-0.236) 5.9 (0.23)
Shift fork I. D. F 14.000-14.021 (0.5512-0.5520) 14.03 (0.552)
C 14.000-14.021 (0.5512-0.5520) 14.03 (0.552)
R 14.000-14.021 (0.5512-0.5520) 14.03 (0.552)
Shift fork shaft O. D. at F shift fork 13.973-13.984 (0.5501-0.5506) 13.965 (0.5498)
at C shift fork 13.973-13.984 (0.5501-0.5506) 13.965 (0.54,98)
at R shift fork 13.973-13.984 (0.5501-0.5506) 13.965 (0.5498)
Primary Damper Shaft ------------r--------------,..---------,

94.5 (3.72)
Primary damper spring free length 96.9 (3.81)
7
ST1100P Addendum
Unit: mm (in)
- Clutch System
Clutch lever free play -- --
Recommended clutch fluid DOT 4 brake fluid --
Clutch master cylinder I. D. 14.000-14.043 (0.5512-0.5529) 14.06 (0.553)
Clutch master piston O. D. 13.957-13.984 (0.5495-0.5506) 13.94 (0.549)
Clutch outer I. D. -- --
Clutch outer guide O. D. 34.975-34.991 (1.3770-1.3776) 34.965 (1.3766)
I. D. 27.989-28.006 (1.1019-1.1026) 28.016 (1.1030)
Primary damper shaft O. D. at clutch outer guide 27 .974-27 .987 (1 . 101 3-1 . 101 8) --
Oil pump drive sprocket I. D. -- --
Clutch center B I. D. -- --
One way clutch inner O. D. -- --
Clutch spring free height -- --
Clutch spring free length 43.0 (1.70) 40.0 (1.57)
Clutch disc/plate thickness (Total of 10 discs and 9 plates) 54.72-55.72 (2.154-2.194) 54.2 (2.13)
Centrifugal clutch drum I. D. -- --
bushing O. D. -- --
Centrifugal clutch center guide I. D. -- --
O.D. -- --
Centrifugal clutch center guide collar height -- --
Centrifugal clutch spring free length -- --
Clutch lining thickness -- --
Crankshaft O. D. at clutch center -- --
- Cooling System
Coolant capacity (Radiator and engine) 2.5 liters (2.6 US qt, 2.2 Imp qt)
(Reserve tank) 0.5 liter (0.5 US qt, 0.4 Imp qt)
Radiator cap relief pressure 108-137 kPa (1.1-1.4 kq/cm",
16-20 psi)
Thermostat begins to open 80-84°C (176-183°F)
Thermostat fully open 95°C (203°F)
Thermostat valve lift 8.0 (0.32) mm
.- Drive Train
Recommended final drive oil Hypoid gear oil SAE #80
Final drive gear oil capacity at disassembly 150 ern" (5.1 US OZ, 5.3 Imp oz)
at draining 130 em" (4.4 US OZ, 4.6 Imp oz)
Final drive gear backlash 0.05-0.15 (0.002-0.006) 0.3 (0.01)
Final drive gear backlash difference between measurements
Ring gear-to-stop pin clearance (A) 0.30--0.60 (0.012-0.024)
Stop pin shim See page 12 -1 0
Ring gear spacer See page 12 - 10
Pinion spacer See page 12 - 11
Final drive gear assembly preload 2-4 kg-cm (1 .7-3.5 in-Ib)
Output gear backlash
Output gear I. D.
Output gear bushing O. D.
I. D.
Output drive shaft O. D.
Output gear damper spring free length
Output shaft adjustment shim
Countershaft drive shaft adjustment shim
8
ST1100P Addendum
Unit: mm (in)
- Wheels/Tires
Minimum tire tread depth (FR) 1.5 (0.06)
(RR) 2.0 (0.08)
Cold tire pressure (FR) 250 kPa (2.50 kq/cms, 36 psi)
(RR) 290 kPa (2.90 kq/crn>, 42 psi)
Front and rear axle runout 0.2 (0.01)
Front and rear wheel rim runout (Radial) '2.0 (0.08) •
(Axial) 2.0 (0.08)
Front wheel hub-to-rim distance
Front wheel hub standard surface
Rear wheel hub-to-rim distance
Rear wheel hub standard surface
Wheel balance weight (Front) 60 9 (2.1 oz) max.
(Rear) 60 9 (2.1 oz) max.
Drive chain slack
Drive chain size link (DID)
(RK)
- Front Suspension
Front spring free length 474.2 (18.67) 464.7 (18.30)
Fork spring free length A
B
Fork spring direction Tightly wound coil end facing down
Fork tube runout 0.20 (0.008)
Recommended fork oil Pro Honda Suspension Fluid SS-8
Fork oil level
Fork oil level (R) 177(7.0)
(L) 174 (6.9)
Fork oil capacity
Fork oil capacity (R) 372.0±2.5 em- (12.58±0.08 US oz,
13.05±0.09 Imp oz)
(L) 418.0±2.5 em- (14.14±0.08 US oz,
14.67±0.09 Imp oz)
Fork air pressure
Steering bearing preload 1.5-2.0 kg (3.3-4.4Ib)
9
ST1100P Addendum
Unit: mm (in)
r-- Rear S uspensron
Shock absorber spring free length 258.9 (10.19) 253.7 (9.99)
Shock absorber spring free length (R)
(L)
--
--
--
--
Damper gas pressure -- --
Damper compressed gas -- --
Damper rod compressed force at 10 mm compressed -- --
Damper drilling point -- --
Shock absorber spring installed length (Standard) -- --
(Adjustable range) -- --
Shock absorber spring adjuster standard position -- --
Shock absorber spring direction -- --
Recommended shock absorber oil -- --
Shock absorber oil capacity -- --
air pressure -- --
- B ra k es
Front brake fluid DOT 4 --
Brake lever free play -- --
Brake pad wear indicator -- To the groove CD
WOO
brake disc thickness 4.8-5.2 (0.19-0.20) 4.0 (0.16)
brake disc runout -- 0.30 (0.012)
master cylinder 1.0. 14.000-14.043 (0.5512-0.5529) 14.06 (0.554)
master piston O. D. 13.957-13.984 (0.5495-0.5506) 13.95 (0.549)
caliper cylinder 1.0. 27.000-27.050 (1.0630-1.0650) 27.06 (1.065)
caliper cylinder I. D. (Upper) -- --
(Lower) -- --
caliper piston 0.0. 26.918-26.968 (1.0598-1.0617) 26.91 (1.059)
caliper piston O. D. (Upper) -- --
(Lower) -- --
brake drum 1.0. -- --
brake lining thickness -- --
Rear brake fluid DOT 4 --
brake pedal height -- --
,
brake pedal free play -- --
brake pad wear indicator -- To the groove (l)
~
-' un,
r--, r--
- "-
~
....J
Y
brake disc thickness ® 7.3-7.7 (0.29-0.30) 6.0 (0.24)
brake disc runout -- 0.30 (0.012)
master cylinder 1.0. 12.700-12.743 (0.5000-0.5017) 12.76 (0.502)
master piston O. D. 12.657-12.684 (0.4983-0.4994)) 12.65 (0.498)
caliper cylinder 1.0. 27.000-27.050 (1.0630-1.0650) 27.06 (1.065)
caliper piston 0.0. 26.918-26.968 (1.0598-1.0617) 26.91 (1.059)
brake drum 1.0. -- --
brake lining thinckness -- --
10
ST1100P Addendum
Unit: mm (in)
Battery ICh argmg S ystem
Stator coil resistance (at 20°C/68°F) 0.22-0.26 Q --

Rotor coil (field coil) resistance (at 20°C/68°F) 2.6-3.2 Q --
Regulator/rectifier regulated voltage 14.2-14.8 V at 5,000 rpm --
Battery capacity 12 V-12 AH --
(Maintenance free battery: YTX14-BS) .
Specified current leakage -- 2 mA max.
Battery specific gravity (Fully chaged) -- --
(Needs charging) -- --
Battery charging (Normal) 1.4Ax5h --
(Quick) 6Ax1h --
Battery voltage (Fully charged at 20°C/68°F) 13.1 V --
(Needs charging at 20°C/68°F) Below 12.3 V --
AC regulator regulated voltage (With analog type) -- --
(With digital type) -- --
Brush length 13.7 (0.54) 4.7 (0.19)
Slip ring 0.0. 14.4 (0.57) 12 (0.5)
r- Ignition System
Spark plug
(Standard NGK) CR8EF 9
(Standard OENSO) U24FER9
(For cold climate/below 5°C/41°F NGK)
(For cold climate/below 5°C/41°F OENSO)
(For extended high speed riding NGK) CR9EH 9
(For extended high speed riding OENSO) U27FER9
Spark plug gap 0.8-0.9 (0.031-0.035)
Ignition timing "F" m a rk 12° BTOC at 1,000 rpm
Advance starts 2,000 rpm
stops 5,000 rpm
Fully advance 2]0 BTOC at 5,000 rpm
Alternator exciter coil resistance (At 20°C/68°F)
Ignition coil resistance (Primary; at 20°CI68°F) 2.16-3.19 Q
(Secondary with plug cap) 22.5-27.5 kQ
(Seconday without plug cap) 13.5-16.5 kQ
Ignition pulse generator resistance (At 20°C/68°F) 405-495 Q
11
ST1100P Addendum
- Lights/Meters/Switches - - - - - - - - - - - - - - r - - - - - - - - - - - - - - - - - , , - - - - - - - - ,
Main fuse 30A --
Fuse 10AX6,20AX1 --
Headlight (high/low beam) 12V45/45W X 2 --
Tail/brake light 12V32/3CP X 2 --
License light -- --
Position light -- --
Front turn signal/running light 12V32/3CP X 2 --
Front turn signal light -- --
Rear turn signal light 12V32CPX2 --
Instrument light 12V1.7WX4 --
Oil pressure indicator 12V3.4W --
Tail/brake light indicator -- --
Side stand indicator 12V3.4W --
Low fuel indicator 12V3.4W --
Coolant temperature indicator -- -- «
Oil temperature indicator -- --
High beam indicator 12V3.4W --
Turn signal indicator 12V3.4X2 --
Neutral indicator 12V3.4W --
Reverse indicator -- --
Overdrive indicator -- --
Oil temperature sensor resistance -- --
Fuel unit resistance (At full level) 10Q --
(At empty) 90Q --
Fuel pump flow capacity (min./minute) -- --
Thermo sensor resistance (50°C/122°F) 130-180Q --
(80°C/176°F) 45-60Q --
(120°C/248°F) 10-20Q --
Fan motor switch Starts to close (ON) 98-102°C (208-216°F) --
Stops to open (OFF) 93-9TC (199-20TF) -- 'll!
r- Starti ng System
Starter driven gear 0.0. 57.749-57.768 (2.2736-2.2743)
Starter clutch outer 1.0. 74.414-74.440 (2.9297-2.9307)
Starter motor brush length 12.0-13.0 (0.47-0.51)
12
ST1100P Addendum
(1) CLOCK WIRE (2) VOLTMETER WIRE
(3) CONNECTORS
for Optional Equipment

(8) RIGHT TURN SIGNAL WIRE CONNECTOR
.~
~
WIRE CONNECTOR
13
ST1100P Addendum
(2) CLUTCH HOSE
(1) CHOKE CABLE
(5) LEFT HANDLEBAR SWITCH

WIRE HARNESS
(6) RIGHT HANDLEBAR SWITCH

WIRE HARNESS
14
ST1100P Addendum
(2) SIREN SPEAKER

RELAY
·(5) STROBE LAMP

RELAY
(6) AIMING CABLE

(9) CHOKE CABLE
(11) HARNESS CLIPS
15
~T1100P Addendum
HT HAZARD
(4) HEADLlGCONNECTOR
SWITCH
(6) FUEL T A NK TRAY
DRAUN TUBE
(5) REAR FOG LAMP

(3) SWITCH 6 CONNECTOR
SWITCH
CONNECTOR
FUEL FILL CAP
(7) BREATHER TUBE
19) SPARK PLUG

( WIRES
(18) STARTER MOTOR (14) ALTERNATOR (13) STARTER RELAY

WIRE SWITCH
CABLE ROUND
(17) ENGINE G
CABLE
(15) SIDE STAND
(16) CARBURETOR SWITCH
DRAIN TUBE
ST1100P Addendum
(3) THROTTLE STOP SCREW CABLE
(1) REAR BRAKE LIGHT SWITCH (5) RADIATOR

2P CONNECTOR OVERFLOW TUBE
(6) THERMO-
SENSOR
(11) IGNITION PULSE GENERATOR WIRE

4P CONNECTOR (9) WIRE BAND (8) CONNECTORS
for Optional Equipment
(10) TURN SIGNAL RELAY
(12) CONNECTORS
(16) HEADLIGHT HAZARD for Optional Equipment
RELAY
(15) TURN SIGNAL HAZARD

RELAY
(13) HARNESS CLIP
(14) MAIN WIRE HARNESS
17
ST1100P Addendum
(3) TO CARBURETOR (4) AIR INJECTION PIPES

AIR CHAMBER (No. 16)
t (5) FUEL FILL CAP

(1) No. 10 TUBE BREATHER TUBE
(6) No.2 TUBE
(7) EVAPORATIVE
EMISSION (EVAP)
CANISTER
(10) CLAMP: (9) FUEL TANK TRAY

DRAIN TUBE
(13)No.15TUBE
(14) PULSE SECONDARY

AIR INJECTION (PAIR)
CONTROL VALVE
(FRONT)
(16) No.1 0 TUBE
~1...L'2Z..:.-t1d~~~~rc~~~_-!_ (15) PULSE SECON DARY

AIR INJECTION (PAIR)
CONTROL VALVE
(REAR)
18
ST1100P Addendum

CARBURETOR AIR VENT
(EVAP CAV) C'oNTROL •
VALVE
(5) No.7 TUBE
(10) No. 5TUBE

'~_--i-+--;---(6) No.5 TUBE
(9) No.6 TUBE
(7) No.6 TUBE
(8) No.4 TUBE
(13) No.6 TUBE
(12) No.7 TUBE
(11) EVAP CAV CONTROL

VALVE
(14) EVAP PURGE CONTROL

VALVE
(15) No.5 TUBE
(18) No.5 TUBE

(17) No. 11 TUBE
19
ST1100P Addendum
Emission Control Information (1) EMISSION CONTROL

INFORMATION LABEL
Labels
An Emission Control Information Label is located on the
rear fender near the frame cross-pipe as shown. The seat
must be removed to read it. It gives basic tune-up
specifications.
o
=
Vehicle Emission Control Information Update
Label
After making a high altitude carburetor adjustment, attach T--~U
an update label on the right side of the fuel tank as shown.
(2) REAR FENDER
Instructions for obtaining the update label are given in (3)
Service Letter No. 132.
When readjusting the carburetors back to the low altitude

specifications, be sure to remove this update label.
Vacuum Hose Routing Diagram Label

The Vacuum Hose Routing Diagram Label is on the reverse
side of the right side cover as shown.
VACUUM HOSE ROUTING DIAGRAM

ENGINE FAMILY \
EVAPORATIVE FAMILY =c================
CALIFORNIA VEHICLE
20
ST1100P Addendum
Seat (1)
Unlock the seat with the ignition key.

Remove the seat by pulling the rear of the seat upward.
Install the seat, aligning the hole with the setting boss as
shown, and lock it by pushing it down securely.
(4) BOSS
Upper Seat Cowling

Remove the seat.
(2) BRACKET
Remove the four bolts and the rear cowling bracket.
Remove the two bolts and the upper seat cowling.
(3) UPPER SEAT
COWLING
21
ST1100P Addendum
Seat Cowling
Remove the left and right side covers and saddle bags
(page 2-2). Remove the upper seat cowling (page 21). (1) BOLTS/
COLLARS
Remove the two bolts and collars.
Slide the seat cowling rearward, then disconnect the tail!
brake light connector to remove it.
(2) SEAT
COWLING
Saddlebag StayI Amplifier Stay

(1) 8 mm NUTS
Remove the seat cowling.
(8) STAY/BOLTS
Remove the four 8 mm bolts, two nuts and the grab rail
center plate.
Remove the relays from the amplifier stay.

Remove the four 8 mm bolts, two washers and the
amplifier stay.
Remove the two 6 mm bolts and the saddlebag stay.
Torque:
Center plate 8 mm bolt: 35 N·m (3.5 kg-m, 25 ft-Ib)
Saddlebag stay 6 mm bolt: 10 N·m (1.0 kg-m, 7 ft-Ib)
8 mm bolt: 35 N·m (3.5 kg-m, 25 ft-Ib)
(7)
(6)
22
ST1100P Addendum
Fairing Pocket RIGHT: (1) TAPPING SCREW

~ (2) SCREWS
Remove the top shelter (page 2-5), (4)
Remove the trim clip, five screws and the fairing pocket.
Left Side only:
Disconnect the connectors.
23
ST1100P Addendum
Instrument Panel
Remove the windshield and garnish (page 2-6).
Remove the four screws and the inner screen.
Remove the left and right fairing pockets (page 23).
Disconnect the clock and voltmeter connectors under the

instruments.
NOTE
I· Adjust the clock after installing the instrument panel. I (1) INNER SCREEN
Remove the two screws, release the tabs and remove the
instrument panel from the upper fairing.
(?) INSTRUMENT
(1) SCREWS PANEL
(3) CLOCK
CONNECTORS
(4) VOLTMETER
CONNECTOR
24
ST1100P Addendum
Rearview Mirror
(1) STAY
Remove the rearview mirror case by carefully releasing
(2) CLIPS
the three bosses from the clips of the upper fairing.
Disconnect the front turn signal connector.
Remove the two bolts, front strobe lamp stay and the
rearview mirror. =/
(3) CONNECTOR
(4) MIRROR
(5) MIRROR CASE
Headlight Aim
• An improperly adjusted headlight may blind

on-coming drivers, or it may fail to light the road
for a safe distance.
Place the motorcycle on a level surface.
Horizontal: HOLE
Insert a screwdriver into the hole in the middle fairing inner
cover, and turn the adjusting screw to adjust the headlight
beam.
Vertical:
Remove the right maintenance cover (page 2-5). (1) ADJUSTING KNOB
Remove the harness band securing the adjusting knob
(Adjusting knob is located under the right fairing pocket:
page 15).
pull out the adjusting knob, and turn the knob to adjust
the headlight beam.
Ir'l"'''' •
• The cylinder head cover becomes hot when running
the engine. Take care not to touch the cylinder
head cover during adjustment.
25
ST1100P Addendum
Light/Meters/Switches Location
(4) IGNITION SWITCH
(22) HORN SWITCH
(18) THRMO-
SENSOR
(14) BATTERY
(19) TURN SIGNAL
HAZARD SWITCH (16) SIDE STAND SWITCH
(17) NEUTRAL
SWITCH
26
ST1100P Addendum
Rear Turn Signal and Brake!

Taillight
Bulb Replacement (1) BULB
SOCKET
Remove the seat cowling (page 22).
Remove the bulb socket by turning it counterclockwise.

Remove the bulb by turning it counterclockwise while
pushing in the hub.
NOTE (2) BULB

• Check that the rubber seal is in good condition and
replace it if necessary.
Voltmeter
Bulb Replacement
Release the instrument panel off the upper fairing (page
24).
Remove the bulb socket and bulb.
Install a new bulb and install the removed parts in the
(2) BULB SOCKET
Remova IIInstallation (1) VOLTMETER

Remove the instrument panel (page 24).
Remove the two screws and the voltmeter.
[nstallation is in the reverse order of removal.
/
(2) SCREWS
27
ST1100P Addendum
MEMO
28
ST1100P Addendum
Wiring Diagram
- SW ITCH 1 • 2 • 3 SWITCH 4 SWITCH 5 SWITCH 7·8
METER LIGHT
12V 1 7Wx4
~ eerB
INDICATOR l2V 3. 4Wx7 -
~a b c d e f ""g h -, BAT OUT I
""• Ie;> R>

J k 1
1. lOA (REAR FOG) VOLTMETER
2 lOA (STROBE)
~m !fl~i~R:,_
I 1 LEFT!"" SlGNAt
-
3 10 0 to fO ro to ON 0~ ON ( ) lo 3, lOA HAZARD
4 lOA (SllEN) SWITCH 5
ro ro lo
n
OFF OFF
-
2 10 7
FUSE BOX
TACHOMETER
~
1 0 -0 COlOR 0 BIBu COLOR PBI RY Slo- -6 0 -0
~ 0 ~<D .,~ ~~ ~~ ~: 0:5 FRONT BRAKE ----J
COLOR BrBu BrW BIR BeW
liGHT SW I TCH ENG INE STOP,STARTER SW ITCH
COLOR Lg W Bu GO OBI G
COOLANT
TEMPRETURE
- REAR BRAKE liGHT
SWI TCH
GUAGE IGN I TION CONTROL
~
MODULE
FAN
MOTOR
FUEL GAUGE
_ _E
SPEEDOMETER
FUEL
lEVEL
SENSOR
FUEL INO ICATOR
o
CHECK UNIT
HEADLIGHT
1r~ENSOR
__ I I
ca cc ~
BANK ANGLE
SENSOR
I
4f~ HAZARD ~ RELAY

~RElAY ~~C~~D
CLOCK
~BR~~~
Re><D<D
:~:P; ~ 3P
<D~;;'3PMINI3PQ ~;;, GlfTll ~

R
~BI/Br=== I I
12V 1. 7W
BI ~~
W
ALTERNATOR FUSE
Lg 55A
HEADLI GHT RELAY
(lOW) Br
Br - BI~R
~BtR
W
BI
l.!iB:F W/BI
R
o
STARTER RELAY
SWITCH
Y
HEADl IGHT RELAY Bu
(HI) - - I/Bu .....
m
L.....- ,.... 0 --I
BU RIGHT FRONT TURN SIGNAL ,"+-_ _L--_ j~1 --t-t+++----.J
G
BI/R
12V 32/3CP
:ITE =.J
BulBI
cta: Lb/W
VOLTMETER
G
Lb
MINI3P
Gr
Lb/W -
G ----<~~
Lb-
_
I~
IBI _ _-+-I'+-_
- I--'
,G/BI Y/W 1
@d: B1
W
MINI4P
B1
Bu
_::t- I
12V 1. 7W
- 1
HEADLIGHT
12V 45/45Wx2
r
Br
R
G/R
G/W-
B1/B-
G/BI
I
Br/R
Bu/R --=-
I
r-I---J I~"X==- I
~Br
-=
L- Lb
GhY
~ Lb
G/Y-
---J
BGr=~=Br
f- G C a ; D
Ii
IIII 1 I o
~INI fiP
0-
• BRAKE AND TAilliGHT
H-U~====:1 l2V 21/5Wx2
SIREN ___ o ~
RELAY
-G~
MINI~~ lEFT REAR TURN SIGNAL
12V 21W
~~~ 0<3:5 "":i ~~ .~~~<D;,',~~;;;~~m !~:mu TURN SIGNAl

HAZARD SW ITCH
SWITCH 6
_____
Br/R -c::J iR{AR---~
G -c::J ~~O_G_~~M.!'J
~
FUEL PUMP &
RESERVE SENSOR
~ ABCOE FG ~~S
CLUTCH SW ITCH TURN SIGNAL' 0 IMMER' HORN' SW ITCH FUSE BOX IGNITION coSWITCH SIDE STAND SWITCH
SWITCH CONTINUITY
A, lOA (NEUTRAL· ou- TEMP
HORN SWI TCH IGNITION SW ITCH B • TACHOMETER' HORN)
, lOA (POSITION' METER LIGHT' TAIL)
~ HO BAT3 ~ FAN IG BAT! KEY C, lOA (HEAOLI GHTl BI BLACK Br BROWN
FREE ON I ok>R5 KEY ON D,
E,
lOA
lOA
(IGNITION' STARTER· ALTERNATOR)
(TURN SIGNAL' BRAKE LIGHTl
Y
Bu
YELLOW
BLUE
0 ORANGE
Lb LIGHT BLUE 0030l-MAJ-8300
PUSH 10+0 OFF KEY OFF
t--t--+-I---l-----1
KEY OFF
F,
G,
lOA
lOA
(CLOCK)
(FAN MOTER)
ALTERNATOR G
R
GREEN
RED
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29

Honda ST1100 Pan European Service Catalog Manual

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Honda ST1100 Pan European Service Catalog Manual

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1.

Gasoline is extremely flammable and is explosive

Hot Components Brake Fluid

Coolant Battery Hydrogen Gas & Electrolyte

If coolant contacts your skin, wash the affected areas

(1) VEHICLE IDENTIFICATION NUMBER

(4) CARBURETOR IDENTIFICATION NUMBER (5) COLOR LABEL

Engine Bore and stroke 73.0 x 64.8 (2.87 x 2.55)

-5' BTDC {SO ATDCI 8' BTDC

Cylinder arrangement 4 cylinders, 90'V

Drive train Clutch system Multi-plate. wet

Gear ratio reverse --

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

Electrical Ignition system Digitalized full transistor ignition

Other viscosities shown in the chart may

Oil pressure at oil pressure switch 392-490 kP, (4.0--5.0 kg/em', 57

'Valve seat width IN 1.0 (0.04) 1.5 (0.06)

Crankpin oil clearance 0.030--0.052 (0.0012-0.0020) 0.080 (0.0031)

Primary Damper Shaft

Clutch lever free play -- i

r-' Drive Train

Up to maximum weight capacity (FR) 250 kPa (2.50 kg/cm 2, 36 psi) --

Damper drilling point -- --

Shock absorber spring installed length (Standard) -- --

Brake disc thickness 4.8-5.2 (0.19-0.20) 4.0 (0.16)

- Battery/Charging System -------------r---------------,--------,

Torque specifications listed below are for important fasteners.

Notes: 1. Apply locking agent to the threads.

r-r- Frame tccnt'dl

Dust guard plate bolt

Lubrication & Seal Points

Semi-circular portion of the cylinder head

Driveshaft yoke joint thrust washer @ -

Driveshaft yoke joint oil seal lip ® -

Driveshaft groove @ - Pack the groove with the

Cable & Harness Routing

(1) CLOCK WIRE

(2) LEFT TURN SIGNAL

(5) FRONT BRAKE HOSE

(4) HEADLIGHT CONNECTORS

(2) CLUTCH HOSE

(3) BRAKE HOSE

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

(10) IGNITION COIL 3P CONNECTOR

(1) HIGH BEAM HEADLIGHT

(2) BANK ANGLE SENSOR

(3) LOW BEAM

(5) FUEL CUT-OFF RELAY

(6) CHOKE CABLE

(10) INDICATOR LIGHT

(8) HARNESS CLIPS (7) THROTILE CABLES

Standard Model (3) THROTTLE STOP SCREW CABLE

(2) FUEL FILTER

(7) SPARK PLUG WIRES

(12) FUEL TANK TRAY

(3) FUEL FILL CAP

(2) LOW BEAM HEADLIGHT RELAY

(1) CLOCK WIRE rr>

(13) HIGH BEAM

(8) HEADLIGHT CONNECTORS

{9} FRONT BRAKE HOSE

(2) CLUTCH HOSE

(3) BRAKE HOSE

(6) JOINT BOOT