HOW TO USE THIS MANUAL CONTENTS manual gascrtt tte serven procedures for the SERAL NFORMATION cre anny Ne Brean ring the tr schockod Sections 1 ad 4p othe whole metry, Section 9 arate ‘Seaton 9: Pron 20 cosesbe bar's of the m szcrangrobetten. z cuacninedeacn | EB u youn nraten, caves | odienasing t's tocton tna sutzecuert | Be ‘howe gn cena eens & ati win wis meter, wae Tacha! Femnrasin | 1 amr awn ae metre, ea Te 2 ~ CLUTGHSTARTER CLU T you dom know the source of Fa rouble, go m sicten ez | & | GEARSHIFT LINKAGE el u = a a ALTERNATOR ETE honed Guson we tame word amy | | = 5 Tesrges an cite’ sworraton troughou. fia mana ot pccal cr aati mam You sbou al he Seana rece (CRANKSHAFT/PISTONIGYLINDER ‘ex ot a overt Say tomato iw aly a toms | -——— ——<— nous 9 _ FRONT WHEELISUSPENSION/STEERING 1 Sauy Menno = preceded sla 8 on Sar tree boa! wo DANSER, OP 3 = —— = © HYDRAULIC BRAKE Rete faceted BATTERVICHARGING sysrem EE) Oe ye ont oko Pons 5 <= 2 poem eee |S five \2 ee \4 aded ty a THOME] seve! Tee purpona chm masage sia | ME Sain ures rags me shoe, her papery ee emcee TROUBLESHOOTING | 22] INDEX Date of ecco sanuary, 2007SYMBOLS ‘The symbols used throughout this manual sheer specie service procedures. f supplementary information Is required parang Wo ‘hase symbols, t wuld be explained speciicaly in the text without the use of the symbols. r - —] | | | | sg Fpiace he part(s) wth new ane (s) before assert. Use recommended engine ol, unless otherwise specified. Use molyticnum all solution (mture of the engina oll and malydenum grease in 2 ratio of 1:1), Use molybdenum diguiide grease (containing more than 37% molyodenum disulide, NLGI #2 oF ‘equaiert). Example: Molykote® BR-2 plus manutactured by Dow Gorring US.A. (Muli-purpose M2 manufactured by Mitsubishi Of, Japan | | eee) |e mutt: purpose grease (Linum tases mul purpose grease NLG! #2 or easton) Use motydenum dleuiée paste (conlaning more than 40% mahedanum ciutide, NLGI #2 or | | ‘equivalent. | Example: Molykote® G-n Paste manufactured ty Dow Corning USA. | Honda Moly 60 (U.S.A. ony) | Focol ASP manufactured by Focal Limited, UK. FRocol Paste manutactured by Surica Lubricant, Japan Use silicone grease. ‘Apply locking agent. Use a middle strength locking agent unless otherwise speciied. Apply sealant | Use DOT 4 brake fluid. Usa the recemmersed brake fluid unless ethenwica spectied. =arh o de | Daten oneenr1. GENERAL INFORMATION ‘SERVICE RULES - MODEL IDENTIFICATION: GENERAL SPECIFICATIONS -~ LUBRICATION SYSTEM SPECIFICATIONS FUEL SYSTEM (PGM-Fl) ‘SPECIFICATIONS - wT COOLING SYSTEM SPECIFICATIONS «1-7 CYLINDER HEAD/VALVES SPECIFICATIONS-. 18 CLUTCH/STARTER CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS... 18 CRANKCASE/TRANSMISSION SPECIFICATIONS 1-9 CRANKSHAFT/PISTON/CYLINDER ‘SPECIFICATIONS. 19 FRONT WHEEL/SUSPENSION/STEERING ‘SPECIFICATIONS. -10 REAR WHEEL/SUSPENSION SPECIFICATIONS -- nee 1210 HYDRAULIC BRAKE SPECIFICATIONS: 1-11 BATTERY/CHARGING SYSTEM ‘SPECIFICATIONS IGNITION SYSTEM SPECIFICATIONS ~-- 1-11 ELECTRIC STARTER SPECIFICATIONS LIGHTS/METERS/SWITCHES SPECIFICATIONS ~- STANDARD TORQUE VALUES--- ENGINE & FRAME TORQUE VALUES. LUBRICATION & SEAL POINTS -.- CABLE & HARNESS ROUTING EMISSION CONTROL SYSTEMS 1-36 1-1GENERAL INFORMATION SERVICE RULES 1 Use genuine Honda or Honda-recommended parts and lubricants or their equivalents, Parts that don't meet Honda's design specifications may cause damage to the motorcycle. 2. Use the special tools designed for this product to avoid damage and incorrect assembly. 3. Use only metric tools when servicing the motorcycle. Metric bolts, nuts and scraws are not interchengeable with English fasteners. 4, Install new gaskets, O-rings, cotter pins, and lock plates when reassembling. 5. When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque diagonally in incremental steps unless a particular sequence is specified. 6. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly. 7. After reassembly, check all parts for proper installation and operation, 8, Route all electrical wires as shown in the Cable and Harness Routing (page 1-21). ABBREVIATION ‘Throughout this manual, the following abbreviations are used to identify the respective parts or systems. Full term PDiagnostic Trouble Co cM Engine Control Module = Eng sensor [Electrically Erasable Programmable Read Only Memory | Exhaust Gas Control Valve Gas Control Valve Potentio Pressure switch Honda Diagnostic System Honda Electronic Steering Damper ———— cv ile Air Control Valve = “IAT sensor intake Air Tempersture senso is MAP sensor | Manifold Absolute Pressure sonsor injection mimed Fuel injaction = SCS connector Sarvieo Chock Short connector TP sensor Throiti Position sonsor VS sensor Vehicle Speed sensorGENERAL INFORMATION MODEL IDENTIFICATION SEY KC SERIAL NUMBERS ‘The Vehicle Identification Number (VIN) is stamped on the right side of the steering head. ‘The engine serial number is stamped on the upper side of the crankease as shown. TaGENERAL INFORMATION ‘The throttle body identifica the throttle body as shown, n number ‘on the right side of TFAROTTLE BODY IDENTIFICATION NUMBER LABELS The Safety Certification Label is located on left side of the frame. ‘The color labels attached as shown. When ordering color-coded parts, always specify the designated color code, The Emizcion Control Information Lebel is located on the rear fener B as shown,GENERAL INFORMATION GENERAL SPECIFICATIONS TEM é ‘SPECIFICATIONS DIMENSIONS | Overall length ae 210mm (79.1 in) |, Overall with 685 mm (270 in) Overall height 41,105 mm (43.8 in) Wheslbase 1,370 mm (533 in) | Seat height 820 mm (32.3 in} | Footpeg height 389 mm (15.3 in) Ground clearance 135 mm (5.3 in) Curb weight Except California type | 186 kg (410 Ibs) California type 187 ka (412 Ibs) | Maximum weight Except Canada type | 168 kg (366 Ibs) _ capa Canada type 170 ka (375 Ibs) | FRAME Frame type Diamond Front suspension Telescopic fork | Front axle travel 110 mm (4.3 in) Rear suspension ‘Swingarm Rear axle travel 129 mm (5.1 in} Front tire size 12070217 MIC (58W) Rear tire size 180/552R17 MIC (73W) | Front tire brand Bridgestone BTOISF RADIAL E Dunlop Qualifier PTS Rear tire brand Bridgestone BTOISR RADIAL E | Dunlop Qualifier PTG | Front brake Hydraulic double disc Rear brake Hydraulic single disc Caster angle 23°58" Trail length 98 mm (3.9 in} | Fuel tank capacity : 18,0 liter (4.76 US gal, 3.96 Imp gal) ENGINE Cylinder arrangement Geylinders in-line, inclined 38° from ver: Bore and stroke Displacement tical | 670 x 42.5 mm (2.64 x 1.67 in) 599 cm? (96.5 cu-in) Clutch operation system Transmission Primary reduction Final reduction Gear ratio Gearshift pattern Compression ratio 12.2:1 Valve train Chain driven, DOHC | Intake valve opens. at mm(0.04in) litt | 21° BTOC closes at 1mm (0.04 in) litt | 44° ABDC Exhaust, opens at 1mm/(0.04in) lift | 40° BBDC valve closes at 1mm (0.04in) lift | 5° ATDC Lubrication system Forced pressure and wet sump Oil pump type Trochoid | Cooling system, Liquid cooled Ai filteation Paper element Engine dry weight 57 kg (126 Ibs) Firing order 1-2-4-3 _ 7 FUELDELIVERY Type PGM-FI see SYSTFM Throttle bore 40 men (1.6 in) DRIVE TRAIN Clutch system Multi-plate, wet tat 2nd 3rd 4th 8th eth Cable operating Constant mesh, 6-speeds 2.11 (76136), 2.625 (42/16) 2.750 (33/12) 2.000 (32/16) | 1.867 (30118) 11.444 (26/18) 1.304 (30128) 1.208 (29/28) Left foot operated return system, 1eN-2-3-4-5-6GENERAL INFORMATION TEM ELECTRICAL Ignition system ; | Computercontrolled digital ransistor- | ized with electric advance | Starting system | Electric starter motor Charging system Triple phase output alternator Regulatorirectfier FET shorteditriple phase, full wave recti- fication ___|_ Lighting system Battery uae 1-6GENERAL INFORMATION LUBRICATION SYSTEM SPECIFICATIONS Unit: mm (in) STANDARD ‘SERVICE LIMIT | (2.9 US qt, 2.4 Imp ail 1 1 Imp atl I Imp at) [ [ |" Engine olf capacity i ‘After disassembly Rocommended engine oi |” Pro Honds GN44-stroke oil (U.S.A. and | Canada) or equivalent motor oil | API service classification: SG or Higher JASO T 903 standard: MA Viscosity: SAE 10W-30 ‘Oil proaaure at EOP awiteh }B05 KPa (6.1 kgtiem?, 73 pai) = é ee at 6,000 rpmv/(80°C/176"F) ‘Oil pump [Tip clearance (0.16 (0.006) 20 (0.008) 0.15 ~0.21 (0,006 - 0.008) 0.35,(0.074) 004) 0.17 (0.007) Side clearance 14 = 0.09 (0.00: FUEL SYSTEM (PGM-Fl) SPECIFICATIONS a T ‘SPECIFICATIONS Throttle body identifica: | Except California typa = a tion number ["califoniatye Tale speed 100 = 100 rpm ] Throttle grip Feoplay 2=4mm (1716 36a) TAT sensor resistance (at 20°CI6F] 1-4 ECT sensor resistance (et 20°C/68°F) ZS=2.6 Fuel injoctor resistance | Primary injector W130 lat 20°C 768°F) Socondary injector 1730 [PAIR control solenoid valve resistance (at 20°Ci6a°F) waa qj (CMP sensor peak voltage (at 20°C/68"F) a ‘O7V minimum Pee ‘CKP sensor peak voitage [at 20°Ci68"F) ae ‘0.7 V minimum “Fuel pressure at idle HT Wa (3.5 kato’, 50 pal) Fuol pump flow (at 12V] 167 em"15.6 US 02, 5.9 Imp o2) minimunvi0 seconds COOLING SYSTEM SPECIFICATIONS a TEM ‘SPECIFICATIONS Coslant capacity |_Radiator and engine 3.76 Iter (3.33 US at, 2.77 Imp at) Reserve tank ‘0.30 itr (0:32 US qt 0.26 imp qi) 2 Radiator cap relief pressure 708 = 137 kPa (1-1 = 1.4 kgiVem’, 16 - 20 pai) ‘Thermostat Bagin to open 80 = 84°C (176 | Fully open 95°C [20°F] | iE Valve lif ‘Sim (03) minimum | Rocommanded antifreez Pro Honda HP Coolant or an equivalent high quality thy ‘ene glycol antifreeze containing silicata free corrosion i ‘Standard coolant cone: 17GENERAL INFORMATION CYLINDER HEAD/VALVES SPECIFICATIONS [een Tew Cylinder compression STANDARD 1,226 KPa (72.5 kgficm®, 178psi) Unit: mm (in) ‘SERVICE LIMIT - | 350 pm Valve clearance Ww 0.20 = 0.03 (0.008 = 0.001) SL EX (0.28 = 0.03 (0.011 = 0.001) a Camshatl | CamTobe height TIN cast = Laat) 3634 (7437) | io (Ex }35:34= 35.58 (1.391 1.401) "35.32 (1381) [Ranout— 10.05 (0.002) | Valve titer Valve lifter O. W 25,878 - 25,893 (1.0228 - 1.0233) 25.87 (1.022) | fe: 3 8855) 22.87 (0.885) Valve lifer bore 10. 26.010 - 26.026 {1.0240 — 1.0246) 26.04 1.025) | saeeere e: 22.510 - 22.526 (0.8862 - 0.8868) 22.54 (0.887) | Valve, valve 0.1873) 3.966 (0.1567) “| Valve stem O10. guide | 73.985 ~ 3.980 (0.1861 - 0.7587) 3.955 (0.1557) | | Valve guide 10. 4.000 = 4.012 (0.1575 - 0.1580) 4.04 (0.159) _ Stem-to-guide clearance | IN | 0.010 0.037 10,0004 - 0.0016) 0.076 (0.0030), Ex [0.020 - 0.047 (0.0008 - 0.0019) 0.085 (0.0033) | Valve guide projection IN “171 - 174 (0.67 - 0.69) = ra above cylinder head ex 158 16.1 (0.62- 0.63) = Vaive seat width INEX | 0.90 7,10 (0.035 -0.0 15 (008) ‘Valve spring IN Inner 36.17 (1.424) 38.1 17.38) free length’ ___| Outer —|40.38 (7.590) 39.2 (7.54) ex am -40-80.1.608) 38.6 (156) = [70.10 (0:0047 Cylinder head warpage CLUTCH/STARTER CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS a Unit: mm tin) Es L ‘STANDARD ‘SERVICE LIM 1020138 = 13716) 467 (1.88) wea (Ta) 292-308 (0115-0121) 26 (0:10) = 0:30 (0.072) Cluteh outer guide 24.993 = 25,008 (0.9840 0.9844) 25.013 (0.9848) i ‘34.996 - 36,008 (13778-13781) "34.986 (1.3774), Primary driven gear 1.0. [1.000 — 41.076 (1.6142 — 1.6148) 1,026 (1.6152) r 25.000 - 25.021 (0.9843 - 0.9851) 25.031 (0.9855) [34.950 - 34.975 (1.3760 - 1.3770) 34.940 (1.3756) Oil pump drive sprocket I.D. 5.0. 35.145 (1.3789 - 1.3837) 35.155 (1.3841) Mainshaft 0.0. at clutch outer guide 24 980 = 24.990 (0.9835 - 0.9639) 24.960 (0.9827) Mainshaft 0.0. at oil pump drive sprocket guide 24.980 - 24.990 (0.9896 - 0.9839) 24.960 (0.9827) [Starter driven gear boss O.. [48557 = 48.67311,7975 ~ 1.7961) 5.642 (1.7969) |GENERAL INFORMATION CRANKCASE/TRANSMISSION SPECIFICATIONS Unit: mm {in} [ ‘STANDARD SERVICE LIMIT | Fe a TEE 7203 (0.474) | 33(0.23)_ | ~1196 (0.470) Transmission T 28.04 (1.104) 24.04 (0.946) '3i1000= 31.025 (1.2206 - 1.2215) 31.06 (1.222) Gear busing OD. 21.959 = 27360 (1.1007 = 1.1016) 2794 1.100) (rez 30.965 = 30.980 (12187-12797) | 30.86 1.216) ‘H.80 — 30.97 (ZI = 7.2798) (suas (1278) Gearte-bushing 0.020 = 0.062 (0.0008 - 0.0024) 0.10 (0.004), clearance (0.004) 0.11 (0.004) (070 (0.0008 - 0.0028) 0.026 — 0.075 (0.0010 — 0.0030) | Gear bushing |., M5 (24.985 - 25.006 (0.9837 - 0.9845) _ 25.016 (0.9849) ea [rez ‘[ 27985 — 28.006 (1.1078 — 7.1026) EI} Mainshati 0.0. | at Ws 980 (0.9830 - 0.9835) 24.96 (0.983) | |“ Countarshaft OD. | at C2 ~ 21967 = 27980 (1.1011 — 1.1016) [72796 (1.101) Bushing to shaft | Mb (0.005 ~ 0.039 (0.0002 0.0015) 0.08 (0.002) clearance ez (0.005 ~ 0.039 (0.0002 0.0015) 0.08 0.002) CRANKSHAFT/PISTON/CYLINDER SPECIFICATIONS Unit: mm (in) [ TEM ‘STANDARD [SERVICE LIMIT | Crankshaft | Connecting rod side clearance 10.15 - 0.30 (0.006 - 0.012) 0.36 (0.014) ‘rankpin bearing oil clearance (0.028 - 0.062 (0.0071 - 0.0020) 0.06 (0.002). [Cain journal bearing oll clearance | 0.020 0.038 0.0008 = 0.0018) [0.08 (0.002) Runout : 0.05 (0.002) Fiaion piston | Piston OD. atSmm(Ozinifrom |” g5ag5 ep.es (2.6068 2.6972) 06.90 (2.698) Piston pin bore, 76.030 16044105917 - 0.5023) | 7807 (0.583) | Piston pin 0.0. ——|14'994 = 15.000 (0.5803 - 0.5806) [14.98 (0.590) iston-to-piston pin clearance (0.03 - 0:6 (0.001 = 0.002) 0.09 (0.004 [0.10 =0.20 {0.004 - 0.008) 0.4 (0.02) (0.21 = 0.31 (0.00 05 (0.02) | (olde Fal) 02-0.7 (0.01 -0.03) 10 10.04) [Top | 0.030 - 0.080 (0.0012 “0.1070.008)_—| saroove clearance [Second (0.115 ~ 0.150 (0.0048 - 0.0059) ‘0.08 (0.003) Cylinder 1D. {62000 - 62015 (2.6378 — 2.6388) (6710 (2.642) Out of round = 0.10 (0.008) Taper 0:10 (0.004) | [Warpage fora aa 0.100.008) ‘Gylindarto-piston clearance {0.975 ~0.050 (610008 - 0.0020) 0.100.008) ‘Connecting rod small end 1.0. zs i 15.05 (0.58 Connecting rod: fo-piston pin clearance 0.07 (0.003) (0.03 - 0.05 (0.001 ~' 1-9GENERAL INFORMATION FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS read depth ‘ Unit: me (in) Tem ie SERVICE LIMIT 1510.06) [250 KPa (2.50 kgller®, 36 psi) ["Coldtirepres- | Driver only 3 sure Driver a (2.50 kafiem?, 36 : ‘Axle runout = [227007 Wheel rim Radial rte = 2010.08) [Axial 2.0 (0.08) ‘Wheel balance weight si 60 g (2.102) | Fark Spring free length | 238.5 (8.38) ~Pipe runout : 20 (0.008), Recomme Pro Honda Suspension Fluid SS-A7 a (ow) Fluid fever 93187 = ‘Steering head bear Fluid capacity Pre-load adjusior initial sotting abound damping adjuster intial setting ‘Compression damping adjuster ini- 813 25 cm 1400.08 US oz, 145 = 0.09 Imp o2) ® turns from minimum — 212 turns out from full hard 2 turns out from full hard —[ e777 N= 18 ah REAR WHEEL/SUSPENSION SPECIFICATIONS (Minimum tre tread depi TEM mm (in) ‘umir 2.0 (0.08) J ‘Wheel balance weight Cold tire pres- Driver only 280 Ka (250 Kegtem®, a2 1 sure [Driver and passenger 290 kPa (2.80 kgfom®, 42 psi) = ‘Axle runout roe 0210.01) Wheel rim Radial = 2.0 (0.08) runout Axial : 2.00.08), [60g (2.1 oa) |" Drive chain ‘Sizeflink DID i AB Bees FSiack 30-40 (1.2 = 1.6) ‘Shock ‘Spring pre-load adjuster standard |p oiion absorber position | Rebound damping adjuster initial setting ‘Compression damping adjuster Ini- tial setting 2-1/2 turns out from full hard, 22 clicks out from full hard 1-10GENERAL INFORMATION HYDRAULIC BRAKE SPECIFICATIONS Unit: mm (in) TEM : [SERVICE LMT Front ‘Specified brake fuid DoTs z = Brake disc thickness 43-45 (0.17-0.18) a 3510.14) Brake disc runout t : 030 (0.727 Master evlinder LD, [yao =17503 0.6874 = 0.6891 TTHSTS (0.5006) | Mast paloma iar rena csr] —— Caliper cylinder I.D. A 32.080 - 32.130 (1.2630 - 1.2650) B 30.280 - 30.330 1.1941) 30.340 (1.1945) Caliper piston O.D_ A 31.967 - 32.000 1.2698) 31.957 (1.2581) | oC 30.167 = 30.200 (1.1877 - 1.1690) 30.157 (1.1873) Rear [pore 7 48-521079-020) an7o78) | Brake dise aren 0.30 0.072) Master cylinder LD, 74,000 14,049 (0.8512 - 055; 74.055 (0.5533) _ Master piston O.D. = 113.987 = 13.984 (0.5495 - 0.5506) | 13.945 (0.5480) Caliper eylinder 1. (7.1902 = 1.1921) '30:290'(7.1925) — Caliper piston 0.0. 195 (1.1843 - 1.1856) 30.140 (1.1866) BATTERY/CHARGING SYSTEM SPECIFICATIONS [ TEM ‘SPECIFICATIONS Battery Capaci Current leakage Voltage (20°C/6@°F) | Fully 0a ‘Nees Below 124V charging 7 | ! ap Adi erro eee ‘Alternator Capacity 0.342 KWI5,000 rom, ff Charging coil resistance (20°C168"F) 01-102 : IGNITION SYSTEM SPECIFICATIONS Trem T ‘SPECIFICATIONS cee ‘Spark plug (ridiurn) NGK TMRSC-SHES | DENSO. Spark plug gap CCKP sensor peak voltage oe imum, Tgnition timing ("F°mark) 78° BTDC at ile 2 ELECTRIC STARTER SPECIFICATIONS : : Unit: mm (in) eas a = ‘STANDARD ‘SERVICE LIMIT Starter motor brush length zs 72.010.47), 6.5 (0.26) j 1-11GENERAL INFORMATION LIGHTS/METERS/SWITCHES SPECIFICATIONS [ TEM ‘SPECIFICATIONS [Bulbs] Headiight Hi T2V-55W | | {fae eee 12-55, (Position ight TED | | Brekefaillicense ant CED [Front turn signaliposition Tight T2V= 238 Wx? | Rear turn signal light 12V=21 Wx? Instrument light [Tum signal indicator High beam indicator | Neutral indicator MIL | HESD indicator a | Engine oil pressure indicator zn jis Engine coolant temperature indicator 7 i “Fuse Main fuse pea E ss} ‘Sub fuse = ra TAX 4, 20Ax3 | [TYachometer peak voltage 105 V ini ECT sensorresistance [80°C [176°F1 120°C (248°F) 0.6-0.7k2 1-12GENERAL INFORMATION STANDARD TORQUE VALUES ‘TORQUE ‘TORQUE [PASTENER TYPE | yg ORIEL | FASTENER TYPE spa [smmrporand a 32005 38) | Smmscew yw azeaan 6 mm bolt and nut 10 (1.0, 7) ‘6mm screw | 9.0 (1.0, 6.6) Simm bolt and nut 2212216) | Smmfange bolt (8mm head, large fangs) | 1212.91 tom bot and nut 346,25) | 8mmflange bolt endnut, 2728.20 tammboltand nut | __6416.6, 40) 10 mm flange bolt and nut | 39 (40, 29), ENGINE & FRAME TORQUE VALUES * Torque specftons listed below ara for important fgtonere 5 thers should be tightened to standard torque vlues std above ENGINE MAINTENANCE ec in THREAD | TORQUE creda | Tew LST iA (mm) | Nom tkgfm, tot Re Span piG z ‘0 ett. i) Timing hole cap | 1 45 18(18,13) Apply. grease to the wee Ot ter carrie 1 20 26(27.19) | Appyalto the | | threde and Oring drain bot 1 2 | 018,22) il filter boss: 1 2 | - See page 4-18 Apply locking agent isa __ lesa | LUBRICATION SYSTEM ~ | THREAD TORQUE T ITEM QTY BIA (mm) Nm ligt, tt) REMARKS Oil pump assembly bolt 7 6 12 (72, 9) CT bolt | ll pump driven sprocket bolt al eace 15 (15, 11) ‘Apply locking agent | tothe threads | | oi cooler bot fist 20 59(60,48) | Apply olltothe ares Oil pipe A mounting bolt | 2] 8 12(12,9) | Apply locking agent to the threads FUEL SYSTEM (PGM-Fi) THREAD] —ToRavE Tew Oy | ora tmm) | nmiigim, bk) | REMARKS eT ear ee wean Tatar vl Sing Ho pa] ¢ oeeee JACV setting plate torx screw [ee 4 2.1 (0.2, 1.5) | Koon eran noun Be Li 3 pi cOouNG SYSTEM | | oF THREAD TORQUE | al | TEM cm DIA. (mm) N-m (kgf-m, Ibf-ft) pene ‘Water pump assembly bolt ry 6 12 (1.2, 9) CT bolt Treat nadie covert 1 H uaa | crear ENGINE REMOVALANSTALLATION oe THREAD | TORQUE | Mi iTeM _ [ERE DIA. (mm) Nem (kgf-m, Ibf-ft) Ri inks is SER — ean 1-13GENERAL INFORMATION CYLINDER HEAD/VALVES ‘THREAD TORQUE] r= ory a. | tum kgm, tbe) | __ REMARKS Cylinder head Bok 0 47 (6.8, 35), Apply oil to the | | threes and seating surface Camshaft holder bolt 20 6 12(12,9) Apply oil tothe | threads and seating surface Cylinder hed cover bot af | mato |_ PAIR check valve cover bolt 4 6 | 12(12,9) | Apply locking agent tothe threads Cam sprocket bolt | 4 7 | 20120, 15) ‘Apply locking agent | to the threads CMP sensor rotor bolt | 2 6 12(12,9) Apply locking agent | | tothe threads ‘Cam chain tensioner A pivot bolt 1 6 12 (12,9) Apply locking agent to the threads Cam chain tensioner 8 pivot bolt 1 10 | 20120, 15) Apply locking agent | tothe threads Cam chain guide A bolt 1 6 | r2t12,9) 8 (1 Insulator mounting bolt (CLUTCH/STARTER CLUTCH/GEARSHIFT LINKAGE rem | [Cluteh center Tock nut Apply oil to the — threads and seating surface, stake Cie sring bot ee raze) Shift drum center bolt 1 8 23 (2.3, 17) Apply locking agent Shit rum stopper am pvt bt 1 aeat raqua.s) | ppt ovng open | to the threads Gearshift spindle stopper pin 1 8 22 (2.2, 16) Starter clutch mounting bolt 1 70 | 83 (8.5, 61) Apply oil to the Soce ALTERNATOR sy Tigao] —Toraue | rem ory | cta'tmm) | nmr brn) | REMARKS ‘Stator mounting bolt 4 6 121.2, 8) Peel at Tm | mst | Aono ne was stator ire damp bl four! ac ‘waza | Sten CRANKCASE/TRANSMISSION T THREAD TORQUE a QTY DIA. (mm)__ Nem (kgf-m, FR) REMAKE): | | | WMainshaft bearing set plate Bort 3 6 12 (12,3) ‘Apply locking agent Wiech Shift drum bearing set bolt saat 6 | 12 (1.2, 9) Apply locking agent Pettit ceantats stm vx w | 6 aa2s) enn ba f | 8 | acua | Emmbetinainjounatton | wo | 8 | astisinstar | Seepage 1217 Repeat cnew | 1omm bo 1 | wo | seen : 1-14GENERAL INFORMATION ‘CRANKSHAFT /PISTON/CYLINDER | THREAD [TORQUE aa : ee TY [DIA (mm)_|_ Nem (kgf-m, IF) SeMANeS /Crankpin Bearing cap balk new) @ 7 20 (2.0, 15] + 90° | Apply ollto the threads and seating | surface | Crankpin bearing cap bolt (retightening) 8 7 14114, 10)+90° | Apply oil to the | threads and seating surface Oil jet pipe mounting bolt 2 6 | 12(12,9) Apply locking agent fee et zt saat to the threads ELECTRIC STARTER THREAD TORQUE ] oes OY DIA. (mm) __ Nem (kgf, tof RPMS Starter motor terminal 6 101407) 5 LUGHTS/METERS/SWITCHES j | THREAD TORQUE rem LO | ra ton _| rm tage, tet) | __ REMARKS EOP switch 7 Prive | wite.8) ‘Rpply sealant to the threads EOP switch wire terminal bolt 1 4 2.0 (0.2.15) Neutral switch 1 10 1212,9) = 1-15GENERAL INFORMATION FRAME FRAME/BODY PANELS/EXHAUST SYSTEM THREAD TORQUE Te QTY DIA. (mm) _|_Nem (kgm, ttf) Tower cowFto-middle cow! screw a 3 75 (02, 11) | Seat rait mounting nut 2 ‘0 54(65,40) | Seat reil mounting bolt 2 10 44 (45, 32) | Seatrasesonty box 2 3 sgn 22) | Matfer band bolt 1 8 1707,13) Exhaust pipe joint nut 8 7 | 12029) | Front fender mounting screw 6 6 | rains) | | Rearview mirror mounting bor. 4 6 101052) Exhaust pipe mounting bolt 1 2 1717.13) Main step bracket mounting bolt 4 8 37 (38, 27) Passenger step bracket mounting bolt 4 8 26 (2.719) Exhaust pipe stud 8 8 : See page 3-26 Position light mounting screw 2 5 18 (02,13) | Rear fender bracket mounting bolt 4 6 12 (12,9) Air duct mounting bolt 4 6 12(12,9) ALOC bolt replace with a new one MAINTENANCE THREAD TORQUE DIA. (mm)___Nem (kgf, Ibff) ene ‘Aircleaner 5 2 (04,3. a FUEL SYSTEM (PGM-Fi) THREAD TORQUE a re [07 | inten) | temigtm ines | REMARKS Fuel pump mounting nut 3 6 12(12,9) ae EGCV pulley nut 1 6 5010537) | Bank angle sensor mounting screw 2 4 15(02, 141) Fuel tank mounting bolt 2 8 30 (3.1, 22), Ar funnelower housing mounting screw 6 5 42(04,31) IAT sensor mounting screw 2 5 11 (0.1, 08) MAP sensor mounting screw 1 5 1110.1, 08) ECM setting plate screw 2 4 a7ioozos) | COOLING SYSTEM THREAD TORQUE] a OTF | DIA. tmm)_| Nm (kfm. Nt) nea Fan motor nut 3 3 ~ a3 (05, 36) Fan motor shroud mounting bol 3 6 2.4(08,62) if ENGINE REMOVAL/INSTALLATION an THREAD | TORQUE — OY DIA. (mm)_|_ Nem (kgf, tot) Front angine Ranger Bott z 12 "4 (5.5, 40) Upper engine hanger adjusting bot 1 20 011.0, 7) | Upper engine hanger lock nut 7 20 54 (6.5, 40) Upper engine hanger nut 1 2 59 (6.0, 44) | Lower engine hanger adjusting bolt 1 20 1010, 7) Lower engine hanger lock nut 1 20 54 (5.5, 40) Lower engine hanger nut 1 2 59 (60, 44) te 1-16GENERAL INFORMATION FRONT WHEEL/SUSPENSION/STEERING ay] THREAD: TORQUE ail COTY DIA. (mm)__Nem (kgm. tot) fens | Handlebar welght mounting arew z 6 98110,7) | ALOCscrewsreplace | | | ith anew one Front brake disc bolt aa a: 20(2.0,15) | ALOC screw; replace: ‘vith a now one Front axle bolt 1 14 59 (60,48) Front axle holder bolt 4 8 22 (2.216) Fork socket bolt 2 10 34 (35,25) Fork damper rod lock nut 2 | 20(20,15) Fork bolt 2 44 34 (35, 25 Handlebar pinch bott |e 2 27 (28, 20) Top bridge pinch bolt {; 2 8 22 (2.2, 16) Bottom bridge pinch bolt 2 8 27 (28, 20) Steering stem adjusting nut 1 26 : ‘Soe page 14-41 Steering stem adjusting lock nut 1 26 : Soe page 14:41 Steering stem nut 1 24 | 103 (10.5, 76) Compression adjuster plug bolt 2 14 17 (43,13) | Stoering damper mounting bolt | 4 6 10(10,7) Second arm nut L2 6 1202.9) | un REAR WHEEL/SUSPENSION ay) THREAD TORQUE Lda oTy pa. (mm) Nem (kgf-m, Ibf-ft) Libtiaaaies ear brake aise bole feet leaaee #23 51) ALOU ole enlace | witha new one Driven sprocket nut | 6 0 64(65,47) | Usnut | Rear adi nut || 2 315,83) Umut | Rear shock absorber mounting nut 2 70 44(45,32) | Usnut | Shock arm to swingarm nut 1 10 46(45,32) | Umut Drive chain case bolt 3 6 12(3.2,9) Drive chain sider bolt 3 6 9.0(03,66) ALOC bok; replace | with a new one ‘Swingarm pivot adjusting bolt 1 so | 12012,8) | Apply ailtothe threads Swingarm pivot lock nut 1 20 64165, 47) | Swingarm pivot nut 1 8 93 (95, 69) Shock ink nut : 2 10 44(45,32) | U-nut 1-17GENERAL INFORMATION HYDRAULIC BRAKE THREAD TORQUE | na 27 pian) | Nam (kgm, tot Mente Front master cylinder reserve tank stopper | : 1 7 plate scrov 1 4 12(0.1,03) Front brake lever pivot bolt Ja 6 =| 1010307) | Apply siteone grease to the slid- | ing surface Fron te er et nat 1 | eppaan | Front brake light switch serew 1 4 | 1200108) | | | Front brake caliper assembly torx bolt 8 8 | 2212.2, 18) Apply locking agent tothe threads | Front brake caliper mounting bolt | 4 0 40 (4.6, 33) ALOC bolt; replace withanewone | Front brake reserve tank stay bolt 1 6 van29 | Rear master cylinder push rod lock nut 1 8 18 (1.8, 13) | Rear master cylinder reserve tank cap screw | 2 4 15(02, 1.1) Rear master cylinder mounting bolt 2 6 40(10,7) Rear brake reserve tank mounting bolt 1 6 1242,9) Rear brake hose joint screw 1 4 18(02,11) | Apply locking agent | tothe threads Front brake caliper pad pin 2 0 15115, 1) | Fear brake caliper ped pin 1 10 18 (18, 13) Brake hose ol bolt los 10 3435, 25) Front brake hose clamp bolt 1 6 9.0 (0.9, 66) Front brake hose clamp nut (ie 6 worwo.7) | Front brake hose 3-way joint bolt 1 6 10 (10,7) Front brake caliper bleed valve 2 a 8.0(08, 53) for be ue bandvanet | a_| soosed) LIGHTS/METERS/SWITCHES THREAD TORQUE Leal QTY | DIA. (mm) | Nem (kgf, bff) ee Combination mater screw > 3 70(0:1,07)f lantion toh mounting bolt 2 8 | 2412418) | Replace with anew Headlight mounting screw | sz 5 18 (02,13) Sidestand switen mounting bolt 1 6 10110, 7) ALOC bolt replace ‘with a new one Right handlebar switch housing screw 2 4 0.9 (0.09, 0.7) Mirtor stay mounting bolt 6 6 12 (12,9) ALOC bolt replace - fecal with @ new one OTHERS sy | THREAD TORQUE Tem GY |_DIA. (mm) ___ Nm (kgm, IF) Sidestand pivot bolt 1-18GENERAL INFORMATION LUBRICATION & SEAL POINTS ENGINE f MATERIAL ~Locarion — REMARKS | Tiquid sealant (Three Crankease mating surface ‘See page 12-16 | Band 12078 or equiva. il pan mating surface See page 5-7 lem) Fight crankcase cover mating surface See page 10-28 Alternator cover mating surface | See page 11-6 EOP switch threads | | Alternator cover wire grommet | Right crankcase cover wire grommet | Cylinder heed semi-circular cutout See pog0.004 ‘Molybdenum dlaulfide | Main journal bearing sliding surface oil (a mixture of 1/2 Piston pin sliding surface engine oll and 12 CCrankpin bearing siding surface molybdenum disufide | Connecting rod small end inner surface grease) Crankshaft thrust surface Camshaft lobes and journals Valve stem (valve guide sliding surface) | Valve lifter sliding surface Gil pump drive sprocket guide sliding surface Water pump shaft and thrust washer sliding surface | Clutch outer sliding surface Clutch outer guide sliding surface (M3/4, C5, CE shifter gear [shift fork grooves) Starter reduction gear sliding surface Starter idle gear shaft sliding surface Cylinder head bolt threads and seating surface Piston and piston ring sliding surface Clutch dise surface Starter one-way clutch sliding surface Crankpin bearing cap bolt threads and seating surface Flywheel bolt threads and seating surface Clutch center lock nut threads and seating surface il filter cartridge threads and O-ring Oil cooler bolt threads and sealing washer seating surface Camshaft holder bolt threads and seating surface | Each gear teeth and rotating surface | Each bearing Each O-ring Each seal ring Other rotating ares and sliding surface Starter clutch mounting bolt threads and seating surface ing hole cap threads Each oil seal lips Mul rp | Tosking agent CMP sensor rotor bolt threads | || Oil pump driven sprocket bolt threads | Coating width: 6.5: 1mm || Shift arum bearing set plate bolt hreads Coating width: 6.5: 1 mm Mainshaft bearing set plate bolt threads Coating width: 65+ 1mm. ‘Cam sprocket bolt threads Coating width: 65+ 1mm. Shift drum center bolt threads Coating width: 6.5 1mm Cam chain tensioner A pivot bolt threads Coating width: 6.52 1mm Cam chain tensioner B pivot bolt threads Coating width: 6.5 = 1mm Shift drum stopper arm pivot bolt threads Coating width: il pump drive chain guide mounting bolt threads Coating width: | Shift spindle setting plate bolt threads | Coating wiath: jet pipe mounting bolt threads | Coating wicth: il level plate bolt threads | Coating width: | || Oil pipe A/B mounting bolt threads | Coating width: || PAIR check valve cover bolt threads | ae Oil filter boss threads (crankcase side) Coating width:GENERAL INFORMATION FRAME MATERIAL aan LOCATION REMARKS Multrpurpose grease | Passengar seat catth hook sliding area Front wheel dust seal lips Foor wee! dt seal ine ‘Throttle pipe sliding surface Clutch lever pivot bolt sliding surface | Rear brake pedal pivot sliding surface Gearshift padal link tie rod ball joints Gearshift peda pot sting surface | Sidestand pivot sliding surface ‘Axle surface Swingarm pivot bol surface Urea based multi-pur” Steering head bearing sliding surface 3-89 ose grease with Steering heed dust seal lips 3-59 extreme pressure Steering stem adjusting nut threads 01-039 | [example: EXCELITE EP2 manufactured by KYODO YUSHI, Japan) or equivalent _ ‘Multi-purpose grease | Swingarm pivot bearings (Shell Aivania EP2 or | Swingarm pivot dust seal lips equivalent) ‘Shock lnk needle bearings | Shock link dust seal lips Shock absorber needle bearing | Shock absorber dust seal ips ble lubricant Throttle cable inside e Clutch cable inside ie EGCV control cable inside Honda bond A or Pr Handlebar grip rubber inner surface Honda hand grip cement U.S.A. only) 7 /Engine oit Swingarm pivot adjusting bolt threads Each O-ring e |" Sleane arease 7 Front brake push roc-to-master piston contact surface Front brake push rod tip Front brake lever pivot bo sliding surface 01g Rear brake master piston-to-push rod contacting area 01g Rear brake caliper pin sliding surface 04g Rear brake caliper pad pin O-ring [DOT brake fia Brake master piston and cups Brake caliper piston and piston seals Fork fluid Fork O-ring Fork dust seal and oil seal lips Locking agent 1-20 Front brake caliper assembly torx bolt threads Cooling fan nut threadsGENERAL INFORMATION CABLE & HARNESS ROUTING COMBINATION METER 20P (Black) CONNECTOR 0 ( ee) Le = ci 5 § li POSITION UGHT WIRE BANK ANGLE ‘SENSOR WIRE BANK ANGLE SENSOR POSITION LIGHT 2P (Black) 3? (Black) CONNECTOR ‘CONNECTOR HEADLIGHT 2P (Natural) CONNECTOR HEADLIGHT 2° (Natural) CONNECTOR 1-21GENERAL INFORMATION THROTTLE CABLES: CLUTCH CABLE FRONT BRAKE LIGHT ‘SWITCH WIRE LEFT HANDLEBAR, ‘SWITCH WIRE HEADLIGHTIBANK ANGLE SENSOR wine LEFT HANDLEBAR SWITCH WIRE 1-22GENERAL INFORMATION CLUTCH CABLE LEFTHANDLEBAR, ‘SWITCH WIRE FRONT BRAKE HOSE HEADLIGHT/BANK ANGLE SENSOR WIRE 1-23GENERAL INFORMATION THROTTLE CABLES CLUTCH CABLE MAINWIRE HARNESSGENERAL INFORMATION BANK ANGLE SENSOR 43 (Black) CONNECTOR HEADLIGHT 2P (Natural) CONNECTOR LEFTHANDLEBAR SWITCH 12 (Gray) CONNECTOR POSITION LIGHT 2° IGNITION SWITCH 2° (Black) CONNECTOR (Brown) CONNECTOR RIGHT HANDLEBAR SWITCH IEADLIGHT 2. CLUTCH CABLE tural) CONNECTOR 8 (Gray) CONNECTOR (Natural) CONNECTO? 1-25GENERAL INFORMATION IAT SENSOR 2P (Gray) CONNECTOR EM ECM 339P (Gray) CONNECTOR Me KYO REGULATOR/RECTIFIER MAIN WIRE HARNESS IAT SENSOR 2P (Gray) CONNECTOR nah cane ee S ~e a ©, a} RIGHT HANDLEBAR , SWITCH WIRE 1-26GENERAL INFORMATION ALTERNATOR 3P (Natural) SIDESTAND SWITCH 2P ‘CONNECTOR (Groen) CONNECTOR CMP SENSOR 2P (Black) CONNECTOR ES SNY/ restuatonmecrinien iL [ I 2P (Natural) CONNECTOR oe FAN MOTEA 2P (Black) < CONNECTOR ‘ CLUTCH CABLE 1-27GENERAL INFORMATION FUEL TANK DRAIN HOSE hisen FUEL PUMP 2P (Brown) CONNECTOR FUEL HOSE a FUEL TANK BREATHER HOSE {California type: to EVAP canister) FUEL LEVEL SENSOR 2P (Black) CONNECTOR KNOCK SENSOR ‘3P (Black) CONNECTOR SROUND COB STARTER MOTOR CABLE SIDESTAND SWITCH WIRE COOLANT OVER FLOW HOSE FUEL TANK DRAIN HOSE FUEL TANK BREATHER HOSE COOLANT OVER FLOW HOSE Lower COWL 1-28GENERAL INFORMATION MAP SENSOR 3° (Black) CONNECTOR CKP SENSOR 2 (Black) CONNECTOR IACV 4P (Black) ‘CONNECTOR ECT SENSOR 3P (Gray) CONNECTOR KNOCK SENSOR 3P (Black) CONNECTOR ||. PAINT MARKS VS SENSOR 3? (Black) CONNECTOR PAINT MARK KNOCK SENSOR 1-29GENERAL INFORMATION PAIR CONTROL SOLENOID HESD 2P (Brown) CONNECTOR YVALVE 2? (Black) CONNECTOR PAIR CONTROL SOLENOID VALVE IGNITION SUB HARNESS THROTTLE CABLES 6P (Black) CONNECTOR TP SENSOR 3P (Black) CONNECTOR DIRECT IGNITION COIL \acv4e(aidee CONNECTOR —_DIRECTIGNITiON cow. 2 (Whit) CONNECTOR ACV 4P (Black) CONNECTOR ‘TP SENSOR aP (Black) CONNECTOR No. 4 PRIMARY INJECTOR 2P (Gray) CONNECTOR No. 1 PRIMARY INJECTOR 2P (Gray) CONNECTOR No. 3 PRIMARY INJECTOR 2P (Gray) CONNECTOR KNOCK SENSOR 3P No. 2 PRIMARY INJECTOR (Black) CONNECTOR 2P (Gray) CONNECTOR 1-30GENERAL INFORMATION EGCV 6P (Natural) CONNECTOR FUSE/RELAY BOX STARTER RELAY SWITCH REAR BRAKE LIGHT SWITCH 2P (Black) CONNECTOR REAR BRAKE LIGHT SWITCH WIRE 1-31GENERAL INFORMATION REAR BRAKE LIGHT SWITCH WIRE EGCV CONTROL CABLES 1-32GENERAL INFORMATION LEFT TURN SIGNAL LIGHT WIRE RIGHT TURN SIGNAL LIGHT WIRE, BRAKE/TAILILICENSE LIGHT WIRE LEFT TURNSIGNAL LIGHT WIRE RIGHTTURN SIGNAL, LIGHT WiRE BRAKE/TAILLICENSE —] 7X _—_——L.--- = UGHT WIRE 1-33GENERAL INFORMATION CALIFORNIA TYPE: NOTE: Face the paint marks upward. FUEL TANGREATHER Ose {to fuel tank EVAP PURGE CONTROL SOLENOID VALVE i d CANISTER-TO-PURGE CONTROL SOLENOID VALVE HOSE PAINT MARK EVAP CANISTER DRAIN HOSE cLamP 1-34GENERAL INFORMATION CALIFORNIA TYPE: VACUUM HOSES SS Y, FUEL TANK BREATHER HOSE (to EVAP canister) EVAP PURGE CONTROL SOLENOID VALVE EVAP PURGE CONTROL SOLENOID VALVE 2P (Black) CONNECTOR EVAP CANISTER DRAIN HOSE EVAP CANISTER, 1-35GENERAL INFORMATION EMISSION CONTROL SYSTEMS EXHAUST EMISSION REQUIREMENT The U.S. Environmental Protection Agency (EPA), California Air Resources Board (CARB) and Transport Canada 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. NOISE EMISSION REQUIREMENT ‘The EPA also requires that motorcycles built after January 1, 1983 comply with applicable noise emission standards for ‘one year or 3,730 miles (6,000 km) after the time of sale to the ultimate purchaser, when operated and maintained according to the instructions provided WARRANTY COMPLIANCE Compliance with the terms of the Distributor's Limited Warranty 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 (CO), oxides of nitrogen (NOx) and hydrocarbons (HC). Control of carbon monoxide, oxides of nitrogen and hydracarbons is very important becauso, under certain conditions, they react to form photochemical smog when subject to sunlight. Carbon monoxide does not react in the same way, but itis toxic. Honda Motor Co., Ltd. utilizes various systems to reduce carbon monoxide and hydrocarbons. CRANKCASE EMISSION CONTROL SYSTEM ‘The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere Blow-by gas is returned to the combustion chamber through the air cleaner housing and throttle body. AIR CLEANER HOUSING ‘THROTTLE BODY << Fresh ala = 5L0w-8y cas 1-36GENERAL INFORMATION EXHAUST EMISSION CONTROL SYSTEM. Tne exhaust emission control system is composed of a pulse secondary air supply system, an oxidation catalytic converter ‘and PGM-FI system, SECONDARY AIR SUPPLY SYSTEM ‘The pulse secondary air supply system introduces filtered air into the exhaust gases in the exhaust port. Fresh air is drawn into the exhaust port by the function of the PAIR control valve, ‘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 reed valve prevents reverse air flow through the system. The PAIR control valve is operated by the solenoid valve. The solenoid valve is controlled by the PGM-FI unit, and the fresh air passage is opened/ciosed according to running conditions (ECTIATITPIMAP sensar and angine revolution). No adjustments to the secondary air supply system should be made, although periodic inspection of the components is ee = AR CLEANER HOUSING f ( J f kgf t Be TiRgTTi BooY pain cONTHOL VALVE pan cna valve a extaust roRt | h <= resin ee exaust Gas iene OXIDATION CATALYTIC CONVERTER, This motorcycle is equipped with an oxidation catalytic converter. ‘The oxidation catalytic converter is in the exhaust system. Through chemical reactions, it converts HC and CO in the engine's exhaust to carbon dioxide (CO2) and water vapor. 1-37GENERAL INFORMATION EVAPORATIVE EMISSION CONTROL SYSTEM (CALIFORNIA TYPE) This model complies with California Air Resources Board (CARB) evaporative emission requirement. Fuel vapor from the fuel tank is routed into the evaporative emission (EVAP) canister where it is absorbed and stored while the engine is stopped. When the engine is running and the evaporative emission (EVAP) purge control solenoid valve Is open, fuel vapor in the EVAP canister is drawn into the engine through the throttle body. FUEL TANK EvappunGe CONTROL Sitenomuawe mesh an TwRorTte 800 Gem F021 2008 NOISE EMISSION CONTROL SYSTEM ‘TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: U.S. Federal law prohibits, or Canadian provincial law ‘may prohibit the following acts or the causing there of: (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 vehicle for the purpose of noise control prior to its sale or delivery to the ultimate customer or while itis in use; (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 ANE TIIC ACTS LISTED BELOW: 1. Removal of, or puncturing of the muffler, baffles, header pipes or any other component which conducts exhaust gases. 2. Removal of, or puncturing of any part of the intake system. 3. Lack of proper maintenance. 4. Replacing any moving parts of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the manufacturer. 1-382. TECHNICAL FEATURES WA GV ceseerseseet ainsi ssssectbsensacotee DP KNOCK SENSOR rstrenetreee Da 2-1TECHNICAL FEATURES IACV SUMMARY This motorcycle adopts an electronic Idle Air Control system for the inline-four engine, this system is composed the IACV and distribution hoses on the throttle body. The IACV consists of a step motor and a slide valve to control the amount of air bypassed around the closed throttle valve. With the ignition switch on, the amount of inlet air is determined from informa- tion detected by the ECT sensor. During engine start up or while maintaining idle (throttle valve closed), the amount of inlet air is corrected by various sensors’ information. This system eliminates the need for manual idle speed adjustment and air screw adjustment for throttle body synchroniza- tion, DISTRIBUTION HOSES ——> Idle airflowTECHNICAL FEATURES OPERATION The ECM controls the IACV during engine idling, also the ECM stops controlling the IACV operation and closes the valve when the ECM detects the following conditions: * Throttle valve open + Neutral switch OFF (in gear) and clutch switch OFF (release clutch lever) During engine idling, from ignition switch ON to warming up, the ECM controls the IACV step motor as follows: With the ignition switch ON ‘When the ignition switch is turned ON, the IACV activates initial func- tion, idle ~ open - idle position. There will be a step motor operating | STEP MOTOR sound. Engine start ~ warming up | This optimizes the bypass opening with the throttle vaive closed, end the correct amount of inlet air passes through, allowing proper engine U start up, After the engine has started, the ECM controls the IACV slide valve - position and adjusts the amount of inlet air in response to the engine coolant temperature. temperature, it operates the step motor to move the slide valve to the | STEP MOTO! VALVE 2-3TECHNICAL FEATURES KNOCK SENSOR SUMMARY Under certain conditions the mixture in the perimeter of the combustion chamber can self-ignite due to the expansion of the combusting gas ignited by the spark plug. At this point there are two flame-fronts colliding within the combustion chamber. As a result, the pressure and temperature in the cylinder increase at a time different from normal-combustion conditions, ‘causing damage to the piston andior the combustion chamber. Such a phenomenon is called knocking Deteriorated or low-actane gasoline may cause the knocking more frequently, resulting in engine damage. To detect knocking, the knock sensor Is attached in the reer of No.3 cylinder block. Monitoring signals from the knock sen- sor, the ECM detects knocking, and prevents engine damage by regulating ignition timing, In this model, a non-resonating type knock sensor is employed. With the vollaye signals free of resonant characteristics {and the convergence period short, the responsiveness is superb, the knocking signals do not overlap in the high rpm zone, allowing detection of knocking. The non-resonating type knock sensor consists of the base, which is mounted on the cylinder block, the weight, and the piezoelectric element. The vibrations from the cylinder block are directly transmitted to the base. The weight applies the pressure occurring from its inertia force to the piezoelectric element. The pressure is converted to voltage by the piezoelectric element, and trans- mitted to the ECM. The ECM modifies the voltage signal waveform, separates knocking signals from engine noise signals, and detects knocking. WEIGHT PIEZO ELECTRIC ELEMENT T FROM CYLINDER (1) Conveeting motion of the engine to the weight (2) Pressure from the weight (3) Converted voltage signal by the piezo electric element When the ECM determines that the voltage signal is higher than the prescribed level {knock occurring), it retards the igni- tion timing. When the ECM determines that the voltage signal is lower than the prescribed level (no knocking) during the retarded ignition timing period, it gradually advances the ignition timing back to normal. ‘The ECM has self-diagnostic functions for the knock sensor circuit. It can detect a sensor output line short, f Integrated circuit (IC) within the ECM, and a connector coming off. lure of the 2-4TECHNICAL FEATURES IGNITION COILS Adjusted ignition timing signal ECM KNOCK IC ENGINE FILTER a ECM monitors engine condition through PGM-FI sensors (ECT ,MAP ,TP sensor etc...) (1) Regulate the input voltage signal wave (2) Noise signal pick up circuit (3) Knock signal pick up circuit (4) Detect the knock (6) Calculate proper ignition timing (6) Detect the fall safe (7) Input voltage line (for open circuit detection} (8) Open circuit detection line (9} Ourput voltage line 2-5MEMO.3. FRAME/BODY PANELS/EXHAUST SYSTEM BODY PANEL LOCATIONS SERVICE INFORMATION ---rese-eorenenenes 323 TROUBLESHOOTING - SEAT-» PASSENGER SEAT-» REAR COW! LOWER COWL -. UPPER INNER COWL/HEADLIGHT COVER: MIDDLE COWL-» FUEL TANK COVER/SIDE COVER: REARVIEW MIRROR WINDSCREEN -~- UPPER COWL/FRONT SPOILER -- AIR DUCT: FRONT FENDER --~ REAR FENDER A REAR FENDER B--.- REAR FENDER C: SEAT RAIL ~ MUFFLER - EXHAUST PIPE-- 3-1FRAME/BODY PANELS/EXHAUST SYSTEM BODY PANEL LOCATIONS REARVIEW MIRROR, WINDSCREEN aera PASSENGER SEAT REAR FENDER B FEAR FENDER C SIDE COVER LOWER COWL upren NNER cow, — MIDDLE COWL 3-2SERVICE INFORMATION GENERAL FRAME/BODY PANELS/EXHAUST SYSTEM ‘+ This section covers removal and installation of the body panels, exhaust system and seat rail + Serious burns may result if the exhaust system is not allowed to cool before components are removed or serviced. + Always replace the exhaust pipe gaskets with new ones after removing the exhaust pipe from the engine, * When installing the exhaust system, loosely install all of the exhaust pipe fasteners. Always tighten the exhaust clamps first, then tighten the mounting fasteners. ‘+ Always inspect the exhaust system for leaks after installation. TORQUE VALUES Lower cowl-to-middle cowl screw Rearview mirror mounting bolt Windscreen mounting screw Front brake hose clamp nut Front brake hose 3-way joint bolt Front fender mounting screw Seat rail mounting nut Seat rail mounting bolt Seat rail assembly bolt Exhaust pipe joint nut, Exhaust pipe mounting bolt Main step bracket mounting bolt Passenger step bracket mounting bolt Rear master cylinder mounting bolt Position light mounting screw Rear fender brackat mounting bolt Muffler band bolt Air duct mounting bolt TROUBLESHOOTING Excessive exhaust n + Broken exhaust system * Exhaust gas leak Poor performance * Deformed exhaust system + Exhaust ges leak * Clogged muffer 15 Nem (0.2 kgfim, 1.1 Ibfft) 20 Nem (0.7 kgfm, 6.2 Ibf-R) 0.48 Nom (0.05 kgf'm, 0.3 IDF) AONem (1.0 kgf, 7 IbF) 10.N-m (1.0 kgm, 7 bff) 12.Nem (1.2 kgfim, 9 IDF) 54 Nem (6.5 kgfim, 40 IbF-t) 44 Nem (4.5 kgf-m, 32 Ib) 30 Nem (3.1 kgf-m, 22 lb-ft) 32.Nem (1.2 kgm, 9 IDF) 17 Nem (1.7 kgfim, 13 IF) 37 Nem (3.8 kgf-m, 27 lbF-A) 26 Nem (2.7 kgf-m, 19 IbFft) 42.Nem (1.2 kgFem, 9 IbF-) 18 Nem (0.2 kgm, 1.3 IDF) 12.Nem (1.2 kgf-m, 9 IDF) 17 Nem (1.7 kgm, 13 IF) 12. Nem (1.2 kgf'm, 9 IbF-A) ALOC bolt; replace with a new oneFRAME/BODY PANELS/EXHAUST SYSTEM SEAT PASSENGER SEAT REMOVAL/INSTALLATION Remove the screws, washers and seat rearward, instal the seat by inserting the prong and aligning its holes with the seat ral Bosses. Tighten the screws securely. SCREWS/WASHERS REMOVAL/INSTALLATION Unhook the passenger seat lock using the ignition key. Remove the passenger seat by pulling it forward Install the passenger seat in the reverse order of removal and push down it to lock.FRAME/BODY PANELS/EXHAUST SYSTEM. REAR COWL REMOVAL/INSTALLATION Remove the following: aes ~ Seat (page 3-4) = Passenger seat (page 3-4) Sheen Seren Remove the screws, special screws and rear cow! | q upward, Installation is in the reverse order of removal. 3-5FRAME/BODY PANELS/EXHAUST SYSTEM LOWER COWL REMOVAL/INSTALLATION Remove the lower cowi-to-middle cowl screws. Release the hoses from the lower cowl. Be caretulnotto Remove the lower cow! screw, collar and special damage the ats screws then remove the lower cowl downward. and grooves. Ccoltomia type Remove the lower cowl screw, collar, special screws and clamp then remove the lower cowl downward. he reverse order of removal. Inetallation * Align the middle cowl tabs with the lower cow! grooves. TORQUE: Lower cowl-to-middle cow! serew: 15 Nom (0.2 kgfim, 1.1 Ibfft) Route the hoses properly: Except California type (page 1-21) = California type (page 1-34) California type: ee [ LOWER COWL-TO-MIDDLE COWL SCREWS SPECIAL SCREW ‘SCREW RIGHT LOWER COWLFRAME/BODY PANELS/EXHAUST SYSTEM UPPER INNER COWL/HEADLIGHT COVER REMOVAL/INSTALLATION Remove the middle cow! (page 2-8). eee Remove the trim clips and upper inner cowl. ‘TRIM CLIPS: Remove the screw and headlight cover. SCREW Foute the wires Installation is in the reverse order of removal. propery (page 1211 | HEADLIGHT CovER —_UPPERINNER COWL | ae 3-7FRAME/BODY PANELS/EXHAUST SYSTEM MIDDLE COWL REMOVAL/INSTALLATION Be carsfulnot 0 Remove the screws, trim clips and middle cowl damage the 2%. Osconnect the turn signal light 3P connector. Route te wires Installation is in the reverse order of removal. propery meer” TORQUE: Pe ic, Lower cowl-to-middle cow! screw: Be careful not to Den tho wires SNem (0.2 kgm, 1.1 Ibftt) MIDDLE COWL TRIM CLIPS as 3P CONNECTOR DISASSEMBLY/ASSEMBLY MIDDLE COWL A, MIDDLE COVER B MIDDLE COWL B INNER COWLFRAME/BODY PANELS/EXHAUST SYSTEM FUEL TANK COVER/SIDE COVER REMOVAL/INSTALLATION Remove the following: Sera sal EUEL TANK covery — Middle cowls (page 3-8) | SIDE.COVER ASSEMBLY: = Upper inner cows (page 3-7) SCREWS! TRIM CLIPS GROMMETS Romove the screws, grommets, trim clips, collars ‘and fuel tank cover/side cover assembly. coLtars. DISASSEMBLY/ASSEMBLY FUEL TANK COVER RIGHT SIDE COVER LEFT SIDE COVERFRAME/BODY PANELS/EXHAUST SYSTEM REARVIEW MIRROR REMOVAL/INSTALLATION Remove the bolts and rearview mirror. REARVIEW MIRROR | Insta the rearviw mirror and tighten the bolts to | the epecied torque TORQUE: 20 Nim (0.7 kgm, 5.2 Ib) | Se x | WINDSCREEN REMOVAL/INSTALLATION Remove the rearview mirror (page 3-10) Remove the screws, plastic washers, rubber wash- ers, windscreen and nuts. installation isin the reverse order of removal PLASTIC WASHER Installation is in the reverse order of removal fees Torque: Windscreen mounting screw: — 0.45 Nem (0.05 kgf m, 0.3 Itt) 8 RUBBER WASHER 3-10FRAME/BODY PANELS/EXHAUST SYSTEM. UPPER COWL/FRONT SPOILER REMOVAL/INSTALLATION Remove the following: Ea = Middle cowis (page 3-8) = Headlight covers (page 3-7) = Upper inner cowis (page 3-7) = Windsereen (page 3-10) Disconnect the position light 2 (Black) connecter. Uy % TOR Remove the main wire harness 20P (Gray) connec: tor from the front spoiler. FRONT SPOILER Remove the screws and upper cowltront spoiler [— assembly. Installation is in the reverse order of removal. SCREW = | er | UPPER COWL/FRONT ‘SPOILER ASSEMBLYFRAME/BODY PANELS/EXHAUST SYSTEM DISASSEMBLY/ASSEMBLY Remove the screws and position light from the upper cow 20 czretulnot ta Remove the front spoiler from the upper cowl, er 8g0 te 35. sombly i TORQUE: Position light mounting screw: 1.8 Nem (0.2 kgf.m, 1.3 Ibftt) UPPER COWL | | in the reverse order of disassembly. POSITION LIGHT FRONT SPOILER AIR DUCT REMOVAL/INSTALLATION Famove tho combination meter (page 208). Remove the ct attachment and gil from the ar duct Siralghton the lock woshor tbe Boor weeps? Remove the bots, lock washes and ir ck 0 Install the air duct and new lock washers then tighten new bolts to the specified torque. TORQUE: 12 Nem (1.2 kgf-m, 9 IbFt) Bend the lock washer tabs up against the air duct ‘mounting bolts securely. | Install the grill and duct attachment securely. Install the combination meter (page 20-10). AIR DUCT GRILL DUCT ATTACHMENT 3-12FRAME/BODY PANELS/EXHAUST SYSTEM FRONT FENDER REMOVAL/INSTALLATION Remove the front brake hose 3.way joint bolt nd {> hose clamp nut. Remove the screws, grommets, collars, reflectors land front fender from the fork legs. * BOLT NUT NOTE FRONT FENDER, * Pull the front fender up and then pull it forward between the fork legs. ‘+ Be careful not to damage the fork legs. Installation is in the reverse order of removal ToRQUE: SS Front fender mounting serew: | Guz 12 Nem (1.2 kgf, 9 bf) | Front brake hose clamp nut: 10.N-m (1.0 kgm, 7 lott) Front brake hose 3-way joint bolt 40 Nem (1.0 kgm, 7 otf) REFLECTOR (COULAR ‘SCREWS/GROMMETS REAR FENDER A REMOVAL/INSTALLATION Remove the rear cowl (page 35). Disconnect the brakertail and turn signal light con- nectors, Remove the bolts, reflectors and rear fender A assembly rearward. Installation isin the reverse order of removal. | REFLECTORFRAME/BODY PANELS/EXHAUST SYSTEM. DISASSEMBLY/ASSEMBLY BRAKE/TAILLICENSE LIGHT HEAT GUARD CENTER PLATE REAR FENDER A REAR TURN SIGNAL LIGHT FENDER STAY REAR FENDER B REMOVAL Remove the following: Rear cow! (page 3-5) = Battery (page 17-6) = Fuel tank (page 6-50) = EGCV servamotor (page 6-80) = Starter relay switch (page 19-14) Remove the bolts, passenger seat hooks and pas- senger seat bracket. Remove the heat guard mounting screw. SceeW 3-14FRAME/BODY PANELS/EXHAUST SYSTEM Release the rear brake light switch 2P (Black) con- nector from the rear fender B. Release the wire harnesses from the rear fender B. Remove the trim clips, screw and rear fender B. INSTALLATION ‘Route the wires. Installation is in the reverse order of removal, properly (osge 1-21) SCREW TRIM CLIPS 3-15FRAME/BODY PANELS/EXHAUST SYSTEM REAR FENDER C REMOVAL/INSTALLATION Remove the special screws, rear fender C and brak hose guide from the swingarm. Install the brake hose guide by aligning its tab to the swingarm hole. Install the rear fender C and tighten the special screws securely, SEAT RAIL REMOVAL Remove the following: = Fuel tank (page 6-50) = Muffler (page 3-19) = Rear fonder A (page 3-13) = Rear fender B (page 3-14) Remove the bolts and left passenger step bracket. Sy LEFT PASSENGER STEP BRACKET Remove the bolts, nuts and seat rail eta RAIL ey eOLiaNOTs 3-16FRAME/BODY PANELS/EXHAUST SYSTEM DISASSEMBLY Remove the bolts. BOLTS Remove the bolts and rear fender bracket. ‘Separate the seat rail. REAR FENDER BRACKET = (f —BOLTS. Romove the dowel pin from the seat rail. DOWEL PINFRAME/BODY PANELS/EXHAUST SYSTEM ASSEMBLY 30 Nem (3.1 kgfimn, 22 bff) REAR FENDER BRACKET ide x 26 Nim (2.7 kgfim, 19 Ib 12.Nem (1.2 kgt'm, 9 IbF) 44 Nom (6.5 kofim, 92 IbF ft) Install the dowel pin onto the seat rail and assemble the seat rail Tighten the seat rail assembly bolts to the specified torque. on TORQUE: 30 N-m (3.1 kgf-m, 22 Ibfft) DOWEL PIN Install the rear fender bracket and bolts temporarily resnrentoomocr Y adus 3-18FRAME/BODY PANELS/EXHAUST SYSTEM INSTALLATION Install the seat rail, bolts and nuts. Tighten the bolts and nuts to the specified torque. ‘TORQUE: Seat rail mounting bolt: 44 Nem (4.5 kgf-m, 32 Ib] ‘Seat rail mounting nut: 54 Nem (5.5 kaf-m, 40 Ibf ft) SEAT RAIL BOLTSINUTS Tighten the rear fender bracket mounting bolts to the specified torque, TORQUE: 12 Nem (1.2 kgf-m, 9 Ibfft) Install the left passenger step bracket and tighten the bolts to the specified torque. TORQUE: 26 N-m (2.7 kgf-m, 19 Ibf-t) Install the following: ~ Rear fender 8 (page 3-15) = Rear fender A (page 3-13) = Muffler (page 3-22) ». = Fuel tank (page 6-50) é x LEFT PASSENGER STEP BRACKET MUFFLER REMOVAL Remove the following REAR BRAKE LIGHT SWITCH — Rear fender A (page 3-13) — Right passengor stop bracket (page 16-19) Unhook the rear brake light switch spring from the brake pedal. Remove the ar brake light switch, 3-19