2003-2006 aeons). 2003-2006 simeeo3 ae SNeHOW TO USE THIS MANUAL This sevice manuel descrtes the sevice procedues for the CaREcon Fellow tha Malntanance Schedule (Seaton 4) recommendations to ‘nature hae venice in peat operating canton Poorming te Ws seneciled maikesranco is vary emporant omental ort sia wor tat secre ring the Brake parce Sections 1 and $ apey tothe whole motoyela. Seton 9 Muster procesires fr remevatnstalaten of componants that ay bo fected {5 partrm seniceceserzedin ho fetowngseclons Secon § troupn 2" desea parts ef the motarele, geuped azeaing locaton, Find ne secon you want cn ths page, hen urn othe ete of eonants ‘nto ret page othe sectan Most sections start wah en assembly oF system lissraton, service Inloration and woutlosioing er tho sen. The subeequon pages (a datas procera. It you ate not tase with thie metoreyle read Teenie! Fetes it Seton 2 H'you dont know she source of tne touble, go 1 secton 22 Trotleshooting, ‘our sic, andthe salty of ane, very inant To hep you ‘mace iiormod decisions we have prided slaty messages and (tar tormaaon froughau tis Marval OF couse, I not praca or psstis to warm ou about lho hazards associa Wi sorving is vo. “You ust us yur own good judgemont. You wl fed Important eae Intomaton Ina varity ot forms Inet + Seley Labets~ onthe vile + Suey Mossagos ~ procaoa by a sat aon syed ana tne of Ce0o shal wars, DANGER, WARNING, oF CAUTION, “hoco signal wores maar “eu MLL bo KLLED or SERIOUSLY EEE ioe. cent ister. You CAN be KILLED or SERIOUSLY KURT CRT oscar erctone. PRETTY 22 o88,88 10 9 ot sow + lnrctone how te cervice hi veil correcta aay CONTENTS GENERAL INFORMATION El [TECHNICAL FEATURES Hi FRAME/BODY PANELS/EXHAUST SYSTEM. MAINTENANCE Ei ENGINE AND DRIVE TRAIN LUBRICATION SYSTEM | 5] FUEL SYSTEM rogrammed Fuel Injection) COOLING SYSTEM ENGINE REMOVALJINSTALLATION Ei CYLINDER HEAD/VALVES - HH CLUTCH/STARTER CLUTCH? GEARSHIFT LINKAGE ALTERNATOR ai CRANKCASE/TRANSMISSION Ea CRANKSHAFT/PISTONICYLINDER Ea FRONT WHEELISUSPENSION STEERING REAR WHEEL/SUSPENSION | 15 HYDRAULIC BRAKE | 16 BATTERY/CHARGING SYSTEM Ed IGNITION SYSTEM Eo ‘As you roa ths al, youl id ihtematon tate preceded by Ronee! rit. The purosa of tis messaga is i help grove damage to your ote, fer pepeny, oe arvrear, ELECTRICAL || cxassis ELECTRIC STARTER Eo LIGHTS/METERS/SWITCHES EI WIRING DIAGRAMS El TROUBLESHOOTING | 22] INDEX EISYMBOLS ‘The symbols used throughout this manual show speci service procedures. It supplementary information is required pertaining to these symbols, i would be expained specifically in the text without the use ofthe symbols s Replace the part(s) wth new ones) before assembly. ms) Use recommended engine oil unless otherwise spected. A Use molyedenum cl solution (misture of the engine ot and molysdenum grease ina rato of 1: 1) } aj | USO multipurpose groase (Lithium based mut-purpese grease NLGI #2 or equivalnt) ] Use molybdenum, disuifide grease (containing more than 3% molybdenum disulfide, NLGI #2 or | equivalent Be — | xample: Motykote® BA-2 plus manufactured by Dew Corning US.A | ‘Multipurpose M-2 manufactured by Mitsubishi Oil, Japan Use molybdenum disuifide paste (containing more than 40% molybdenum disulfide, NLGI #2 or equivalent), Example: Molykote® G-n Paste manufactured by Dow Corning U.S.A. ACEH Honda Moly 60 (U.S.A. only) Focol ASP manufactured by loco! Limited, U.K. ocol Paste manufactured by Sumico Lubricant, Japan Use silicone grease. Apply a locking agent, Use a middle strength locking agent unless otherwise specified Apply sealant Use DOT 4 brake fluid. Use the recommended brake fluid unless otherwise spectiog. nl Use Fork or Suspension Fluid.1. GENERAL INFORMATION SERVICE RULES “1-2 MODEL IDENTIFICATION 1-2 GENERAL SPECIFICATIONS-~ 15 LUBRICATION SYSTEM SPECIFICATIONS - 1-7 FUEL SYSTEM (Programmed Fuel Injection) SPECIFICATIONS: 17 COOLING SYSTEM SPECIFICATIONS +--+ 1-7 CYLINDER HEAD/VALVES ‘SPECIFICATIONS: CLUTCH/STARTER CLUTCH/ GEARSHIFT LINKAGE SPECIFICATIONS---- 1-8 CRANKCASE/TRANSMISSION SPECIFICATIONS: CRANKSHAFT/PISTON/CYLINDER SPECIFICATIONS. FRONT WHEEL/SUSPENSION/STEERING = 1-10 ‘SPECIFICATIONS: REAR WHEEL/SUSPENSION SPECIFICATIONS: HYDRAULIC BRAKE SPECIFICATIONS --+--1-11 BATTERY/CHARGING SYSTEM SPECIFICATIONS: IGNITION SYSTEM SPECIFICATIONS -~» ELECTRIC STARTER SPECIFICATIONS -~-1-11 LIGHTS/METERS/SWITCHES ‘SPECIFICATIONS: STANDARD TORQUE VALUES ENGINE & FRAME TORQUE VALUES LUBRICATION & SEAL POINTS CABLE & HARNESS ROUTING ('03, '04)--.1-23 CABLE & HARNESS ROUTING (AFTER '04) EMISSION CONTROL SYSTEMS « EMISSION CONTROL INFORMATION LABELS (U.S.A. only) 1-1GENERAL INFORMATION SERVICE RULES 1L Use genuine Honda or Honda-recommended parts and lubricants or thelr equivalents. Parts that don't meet Honda's design specifications may cause damage to the motorcycle. Use the special tools designed for this product to avoid damage and incorrect assembly. Use only metric tools when servicing the motorcycle, Metric bolts, nuts and screws are not interchangeable with English fasteners. Install new gaskets, O-rings, cotter pins, and lock plates when reassembling, ‘When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque diagonally in incremental steps unless a particular sequence is specified. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly. After reassembly, check all parts for proper installation and operation. Route all electrical wires as shown in the Cable and Harness Routing (page 1-23, 1-38). MODEL IDENTIFICATION "03, 04:GENERAL INFORMATION AFTER ‘04: The engine serial number is stamped on the lower side of the lower. ————— crankcase.GENERAL INFORMATION ‘The throttle body identification numbor is stamped on the of the throttle body as shown. ‘The color label is attached as shown. When ordering color-coded parts, |S. oa agg always specify the designated color code. e Identification Nu IN) {s located on left side of the | — Zea ei pENTIFGATION NUMBER IV) The Vehicle Ider ao oe aa a" 0" It Side oF HOT VeviCLe IDENTIFICATION NUMBER (VIN) YYGENERAL INFORMATION GENERAL SPECIFICATIONS | Front brake Pilot SPORT E (Michelin) Hydraulic double dise TEM T ‘SPECIFICATIONS | DIMENSIONS | ~OverallTangth 103, 04) 2,030 mim (78.9 in) (atier‘08) | 2,025 mm (78.7 in) | ‘Overall width ('03, 04) 895 mm (27.4 in) | stter‘04) | 690 mm (271 in) | Overall height 1,115 mm (43.9 in) Wheelbase 1,380 mm (54.7 in) Seat height 820 mm (32.3 in} Footpeg height 395 mn (18.6 in} Ground clearance 130 mm (6.1 in} | Dry weight 49 states, Canada type: (03, 04) | 169 kg (373 bs) (After '04) 164 kg (362 Ibs) California type: (03, ‘04) 169 kg (373 Ibs) | (ater ’04) | 166 kg (386 Ibs) | Curb weight | a9 states, Canada type ('03, 04) | 199.kg (439 Ibs) (tter‘04) | 194 kg (828 Ibs) California type: {'03, 04) | 202 kg (445 tbs) (After '04) 196 kg (432 Ibs) Maximum weight capacity | | aBstates, California type: | 186 kg (268 ibs) | Canada type: 170 kg (375 Ibs) FRAME Frame type Diamond Front suspension Telescopic fork Front axle travel ('03, 04) | 102.7 men (4.04 i} (After '04) 110 mm (4.3 in) Rear suspension Swingarm Rear axle travel 130 mm (5.12i0) Front tire size ‘120/70ZR17 MIC (S8W}, Rear ire size 1BO/SSZA17 MIC (73WW1 Front tice brand ((03, 08) BTOI2F RADIAL G (Bridgestone) (03,08) | D208°K (Duntop) (Aiter‘04) | D218FK (Dunlop) | Pilot SPORT E (Michelin) Rear tire brand ((03, 08) BTOT2R RADIAL L (Bridgestone) ((03, 08) 208K (Dunlop) (after‘0a) 028K (Dunlop) Rear brake Hydraulic single dise Caster angle |e ‘Trail length | 95 mm (37 in) Le Fuel tank capacity, 18.0 liter (4.76 US gal, 3.96 Imp gal) ENGINE Cylinder arrangement 4 cylinders incline, inclined 38° from Bore and stroke Displacement Compression ratio Valve train Intake valve opens closes Exhaustvalve opens closes Lubrication system Oil pump type Cooling system Air filtration Engine dry weight Firing order at mm (0.04 in) lift att mim (0.04 in) lift at 1 mmm (0.04 in) lift att mim (0.04 in} lift (703, "04) (alter '04) vantical 820 X 42.5 mm (2.64 X 1.67 in) 599 cm? (36.5 cuin) 12.0:1 Chain driven, DOHC 22° BDC 43° ABDC 40° B8DC 5° TOC Forced pressure and wet sump Trochoid Liquid coated Paper element 58.3 kg (128.5 Ibs) 58.7 kg (129-4 Ibs) 122-463GENERAL INFORMATION TEM ‘SPECIFICATIONS FUEL DELIVERY | Type PGN-FT Programmed Fuel Injection SYSTEM Throttle bore 40 mm (1.8 in) DRIVE TRAIN Clutch system Malti-plate, wat ) ELECTRICAL | Clutch operation system Transmission Primary reduction Final reduction Goar ratio Gearshift pattern Tanition system Starting system Charging system Regulator/rectifier "03, After 03 Canads type: After '03 49 states, California type: Lighting system st 2nd 3rd 4th 5th th Cable operating Constant mesh, 6-speeds 2.111 (76736) 2.688 (43/16) 2.666 (32/12), 1.937 (31/16) 1.811 (29/18) 1.408 (31/22) 4.260 (29/23) 41.166 (28/24) Lett foot operated return system, 1-N-2-3-4-5-6 ‘Computer controlled digital tansistorized with electric advance Electric starter motor Triple phase output alternator SCR shorteditriple phase, full wave rectifi- cation FET shorteditriple phase, full wave rectifi- cation BatteryGENERAL INFORMATION LUBRICATION SYSTEM SPECIFICATIONS - _ Unit: mm (in) TEN ‘STANDARD [SERVICE Lina | Engine oll capacity | Aitor draining 26 ter 2.7 US gt 23 Imp gil | = After ol fiter change ~ [28 iter (8.1 US gt 26 Imp qt] = | [After disassembly 35 iter (3.7 US qt, 3.1 Imp at) = Recommended engine oil ~ Pro Honda GN4 or HP4 (without molyb- denum additives) 4-stroke oil U.S.A. & Canada) or Honda 4-stroke oil (Canada | only) or an equivalent motorcyele oll API service classification SG or Higher excepi oils labeled as energy conserv- | ing on the circular AP! service label ASO T 903 standard: MA Viscosity: SAE 10W-40 Oil pressure at EOP (Engine oil pressure) switch 540 kPa (5.5 koficm’, 78 pall at = 6,000 rpmilg0rC/176°F) Oil pump ip clearance 10.15 (0.006) CHOCO] Body clearance (0.15 0.21 (0,006 — 0.008) 0.36 (0.074) ~Side clearance ‘0104 - 0.08 (0.020.004) 0.17 (0.007) FUEL SYSTEM (Programmed Fuel Injection) SPECIFICATIONS TEM "SPECIFICATIONS ‘Throtile body 49 states, =| a Identification num- | Canada type: = ber California type: ~ [Cine Tae ar control valve vacuumn afarence | [Base thot vaive for synchronization 1 Hated t | Throttle grip free play 2-4 mm (1/16 - 316 in) Trike petty naar reaiaaea AO CRET] Teak |" Engine eootan trnperature sone elsance aa=20kn {at 20°C/68°F) Ful iesior fale] “Secondary ‘tance (at 20°C /68°F) injector After 04 Primary injec- "03, "047 105-1450 tor | After 04 10-142 | [PAIR control solenoid valve resistance (at 20°Cres'F) 20-24 Chi (Gormshat postion] senses peat votoge a7 minima | tatzorce ‘CKP (Crankshaft position) sensor peak voltage 0.7 V minimum (at 20°C/68°F) ano bela prossur aa 10-2 | {Rust press orale SHG KPa (38 kg, SOs | (Fuel pump flow (at T2V) TSS emi” 16.4 US 02, 6.7 Imp oz] minimum/id seconds COOLING SYSTEM SPECIFICATIONS re rcs Coslaricapeciy —[_Ranlaor and angie aaier es Us qr 20impa) Reserve tank 0.3 10.32 US qt, 0.26 Imp qt) Radiator cap relief pressure Toe = 137 KPa (1.1 ~ 14 katicm?, 16 - 20 pall Taoeat Eee 30 84°C (78188 7) | rao SmTO al iam 9-0 FF] Recommended antifreeze Pro Honda HP Coolant or an equivalent high quality ethylene glyco! antifreeze containing corrosion (Standard cootant concentrationGENERAL INFORMATION CYLINDER HEAD/VALVES SPECIFICATIONS ‘Unit: mm (in) TEM STANDARD ‘SERVICE LIMIT | Cylinder compression 7226 Wa (IZ kgtlem®, 17BRRT = 8 350 rpm Valve clearance iN 0.20 £0.03 (0.008 + 0.0017 = _ ex (0.28 = 0.03 (0.011 = 0.001) tT =, Camana ‘Cam Tobe height IN 36.36 - 36.60 (1.451 - 1.447) E54 7A3T) | [EX] 5.34 36.58 (1.391 L401) ¥ 1 Funeut = | Oil clearance 10.020 - 0.062 (0.0008 - 0.0024) 10.10 (0.004) | Valve iter Valve lifer OD. 25,578 - 25.593 (1.0228 - 10233] (2597 (L022) | (Wale tiie bore 10. | 26.010 ~ 26.026 {1.0240 - 1.0248) [28.04 (4.025) | Valve, | Valve stem 0.0. Liv 3.975 ~3.990 (0.1565 — 0.1571) 3.365 (0.1561) valve guide (TEX [3.965 — 3.980 [0.1561 — 0.1867) 1 Valve gutde 6: INEX | 4.000 — 4.012 (0.1575 — 0.1580) 4.04 (0.153) |" Stem-to-guide clearance [IN | 0.010 - 0.037 (0.0004 [70.075 (0.0030) L EX 0.020 0.047 (0.0008 - 0.0018) | 0.086 (0.0033) Valve guide projection [IN ¥71 = 174 (0.67 0.65) t = | |_above cylinder head Bx 13,3 = 13.6 (0.82 0.54) = Valve seat head 0.80110 (0.038 - 0.043) 75 10.06) BX 0.90 = 1.10 (0.035 = 0.043) 1.6 (0.06) Valve spring IN — Inner 36.17 (1.424) 35.1 (1.38) free length ‘Outer 39.76 (1.565) 38.8(1.53) EX inner [35.34 (7.391) [344 (1.35) ‘Outer "39.05 (1.537) 38.1 (7.50) [Cylinder head warpage = 0.10 (0.004) CLUTCH/STARTER CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS Unit: mm in) Cc eM ‘STANDARD SERVICE LIMIT [elute fever free play 10-20 (8 13716) | = | [Chute [Spring Wee length | 45.5 (1.83), LA a | Disc thicknoss: [z92- 3.08 (0716 O21) | [Piate warpage = 630 (0.02) | |" cluteh outer guide A [o5. 24,993 — 75 003 (0.5840 - 03847) [25.013 (0.9808) (03, '04: Without ID mark) "35.004 ~ 35.012 (1.3781 - 1.3784) 34,994 (1.3777) |" Guteh cuter guides 24,993 — 25.003 (0.9840 ~ 0.9644) 25,073 (0.9848) _| (With 1D mark) 34.986 (1.3774) Primary driven goar LD. 1.008 41.016 (1.6145 - 1.6148) 49.026 (1.6162) (03, "04 41.000 — 41.008 (1.6142 ~ 1.6145) 47.08 (1.6749) (Primary dfiven gear LD. (After a) |" a1000= 47.016 (16142 — 1.6148) 1026 (1.6162) Oil pump drive sprocket 1. 25,000 - 26.021 (0.9843 - 0.8851) 125.031 (0.3855) guide oo. 34,950 -24.97511 | 34.940,(1.3756) (Oil pump drive sprocket LD. [36.158 (1.3861) | Wainshaft 0.0. st eiutch outer guide 24980 - 24.990 (0.9835 - 0.9839) | 24: 960 (0.98271 Mainshaft 0.0. atoll pump drive sprocket guide | 24880 - 24 980 (0.9835 — 0.9839) [24.960 (0.9827) Starier driven gear boss O.D. [48.657 = 45.673 (1.7975 — 17981) 5.642 (1.7969) 1-8GENERAL INFORMATION CRANKCASE/TRANSMISSION SPECIFICATIONS Unit: mm {in} c ITEM ‘STANDARD [SERVICE Lint | ‘Shiftfork [1D 72.000 — T2018 (0.4724 — 47ST 42.03 (0.474) Claw thickness 5.93 — 6.00 (0.233 — 0.236) 5.3 (0.23) ] earrorcaaron T1957 = 1.968 (0.4707 - 0.4712] 1.95 (0.470) Transmission | Gear 1D. 28,000 ~ 28.023 (1.1024 1.1032] 26,08 (1.104) | 24,000 = 24.021 (0.9449 — 0.9457) [26.04 (7.025), 31,000 31.025 (1.2205 - 1.2215) | su0a (i272) | Gear busing OD, 21.969 = 27.980 (1.1007 = 1.1016) [2794 (1.100) 30.94 (218) Gearto-bushing 30.950 - 30.975 (7.2185 - 1.2195) 10.020 ~ 0.062 (0.0008 - 0.0024) (1.218) 0.10 (0.008) (caso [ooo —| clearance 10.025 = 0.075 (0,010 = 0.0030). 0.11 (0.004) | Gear bushing LD. 24,985 - 25,006 (0.9837 - 0.9845) 25.016 (0.9845) | 27.985 ~ 28.00611.1018 = 1.1026) 28.021 (1.1032) | “Mainshait OD. 24,967 ~ 24.980 (0.9830 - 0.9835) 24.96 (0.983). [[Countershaft OD 21.967 ~ 27.980 (1.1011 ~ 7.1016) 2798 (1.101) Bushing to shaft 10.005 — 0.039 (0.0002 - 0.0015) (0.002) L clearance 10.005 — 0.039 (0.0002 - 0.0015) 0.06 (0.002) CRANKSHAFT/PISTON/CYLINDER SPECIFICATIONS TEM t STANDARD SERVICE Lt Crankshaft | Connecting rod side clearance | 0415 0:30 (0.008 - 0.012) [[Crankpin bearing oll clearance (0.028 = 0.082 (0.0071 ~ 0.0020) Main journal bearing oi clearance | 0.020 0,038 0.0008 0.0018) (0.002) Runout ,05 (0.002) Pision piston (Piston O10. at 1010.4) tam botiom | 65.965 66,905 (216364 = 2.6372) 86.80 (2.634) rings Piston pin bore LO. 76.002 = 16.008 (0.6300 0.6902) 16.02 (0.631) | Piston pin O.D. ~ | 18.884 = 16.000 (0.6297 - 0.6298) 15.98 (0.629) | |Piston-to-piston pin clearance 10.002 - 0.074 (0.0001 - 0.0006) 9.04 (0:002) Pistonring end |Top {0:19 0.20 0.004 - 0.908), 0.4 (0.02) ‘sap Second | 021-031 (0,008 -0.012) 05 (0.02) | Oi | 02=0.7 0.01 - 0.03) 10 0.04) (side rain | Piston ring-t0-ring [ 0,40 0.00) ‘groove clearance — [2.016 = 0.050 (0.0006 - 0.0020) [70.06 (0.003) Cylinder LD. e000 67.005 (2.6378 - 2.6384) S710 (2.642) | [Out oFreund = 0.100.004) | (taper [ (100.008) | [Warpage I 9.100.004) Gylinderto-piston clearance | 8.018 = 0050 (0.0006 ~0.0029), 0.100.004) | Connecting rod small end .0. 16.010 — 16.034 (0.6303 — 0.6313] [716.050 (0.63757) Connecting rodto:piston pin clearance 0.010 ~ 0.040 (0.0004 - 0.0016) [0470 (0.0028),GENERAL INFORMATION FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS Unit: mm (in) f TEM T STANDARD ———|-SERVICE LIMIT ‘Minima tire oad depih = 115 (0:06) Coli tirepres- |_Driver only 250 KPa (2S0KaVEM?, 36 pal i = sure Driver and passenger 250 kPa (2.50 kafem’, 36 psi = [Axia runout = TROT) Wheel rim Radial t = 2010.08) runout [Axial 1 = 2.0 (0.08) ‘Wheel balance weight = 60g (2 102) For Spring Tree Tength "03, "04 75018 (10:19) [253.6 (098) | (After 04 273.0 (10.75) 2675 (10.53) |_Tube runout _ = 10.20 (0.008) Recommended Pro Honda Suspension Fuld S55 = | fork fluld ‘fier ro Honda Suspension Fluid SS-55 | Fiuid level "03,04 | 110(4.3) = 1 ‘Alier’04 [120 18.7) = | Fluid capacity "03,08 B21 = 25 em’ (180 50.08 US 07, 187= = | 0.09 Imp 02) | | After"0a [362 2.5 om (12.2: 0.08 US oz, 12.7= = _ L 10.09 imp o2) Preload adjuster 703,04 “14 mm (0.6 in) (ath groove from top) | | | initial sexing ‘ier’04 |S turns from minimum Rebound damping adjuster initia | 2-1/2 turne out from full hard setting \ Compression "03,708 Ziurns out from ful hard damping adjuster |~After"04 | 2-1/2 turns out from Tull hard 1 | initia seting | Siearing head bearing pre-locd |_08,"04 17-2 NTT= 2K = After "0 18-24 N (15-24 kal) REAR WHEEL/SUSPENSION SPECIFICATIONS Units mn (in) [ STANDARD ~ [SERVICE LIM | CWinimum tre wend a = [2.0 (0.08) Cold ire pres |_Dri [200°KPa [2.90 kgtfem®, 42 psi) 1 = | sure [Driver and passenger 20-KPa [2.60 kgfiem 42 psi) I = (Taxte ronout I = azo /Wheet im [Radial = 2010.08) | | runout Axial = 2.0 (0.08) Whos anes wate = oo | (202) max. | [Drive chain | Sizlfink oD (DiDesHV-TI2VE = | | RK [CRKS2GROZI-TTALIFZ —— | (since = 25-350 THe) e Shock | “Spring pre-load [03,04 Position 3 - = | absorber adjuster standard | After’04 | Position = | | pon - | Rebound dan ya turn out From Tall hard | | legeduserinin | 9-12 turns out from full hard | setting | daring adister | Ar‘0e [Paks ou rom Ri herd = | | itil seving 1-10GENERAL INFORMATION HYDRAULIC BRAKE SPECIFICATIONS ~ Unit: mam (in) rem STANDARD [SERVICE LIMIT | Front specified brake fuid Honda DOTS Brake Fluld = } Brake dise thickness 44-45 (0.17 -0.18) [asia Brake dise runout i = 0.30 (0.012) [Master eylindor.0.— [17460 = 17503 0.6874 - 0.6851) [72616 (0.6896) | Master piston 0. 17321 = 17367 (0.6819 - 0.6837) [17309 (0.6815) | Caliper "03," [A] 32.030 32080 (1.2610 = 1.26301 32.082 (1.2635) | evlinder LO. 8 9o.290= 30.250 (1 202— 1921) 30.282.(1.1928) | Altar 0a [32.080 = 32.1301(1.2630- 1.2650) [32.140 (1.2654) (-B—Sine0= soso (tieer=teell ——|- soso noes Caliper piston | "03,708 [A [731340 (72574) —| on. eso = 30.074 (1.1840) | Aier"0a | | [TB |-30.167= 30.2001 187711880) | Fear ‘Specified brake fluid | Honda DOTS Brake Flui i Brake pedal height (75 30) - t = [Brake disk thickness 485.2 10;19=0.20) 1 | ise runout = (ora) Master eylinder |. 75.870= 16.515 (0.6248 - 0.6265) 26 (0.6270) _| Master piston 01 15.627 ~ 16.854 (0.6231 ~ 0.6242) [18.815 (0.6226) Calipareylindar| = 38,280 (1.5031 = 15051) | 38.24 (1.506) Caliper piston 0.D. 148 (1.4998 = 1.5018) | 38,091.50) BATTERY/CHARGING SYSTEM SPECIFICATIONS Trew ‘SPECIFICATIONS Bate [Capacity “2V- 86 Ah Current leakage 2.0 mA mex, Yoliage Fully charged 73.0 18.2V | (20°Ci6a"F) Needs - Below 123 charging | Charaing Normal OSS i0h current ‘Quick 45 A7Th |" Aliemator—— [Capacity ‘0335 KW/5,000 rpm =| Charging coil resistance (20°C/63°F) 01-100 IGNITION SYSTEM SPECIFICATIONS TEM SPECIFICATIONS Spark plug Wriiamy IMRSC-SHE INGKY 1 IMRSC-SHES (NGK =i (Spark plug gap t 0 = 0.90 mm (0.031 - 0.038 in) [Canition coil peak voltage 00 V minimum ‘CKP (Crankshaft position) sensor peak voltage O.7V minimum Tonition timing (mark) [703,04 at ELECTRIC STARTER SPECIFICATIONS _ Unit: man (in) TEM — STANDARD [SERVICE Linarr ‘Starter motor brush Tength - 12.0=18.0 1047-051) [65 (0.26) 1-11GENERAL INFORMATION LIGHTS/METERS/SWITCHES SPECIFICATIONS TEM. T ‘SPECIFICATIONS: Bulbs] Headlight Ti — T2V = 55 W. Lo 1 TaV— 55 W. Position tight | 72v-5W. (CBrakefail light TED Front turn signal/position light TaV= 23/8 WE Rear turn signal ight 12V=23WX2 License light - 72-5 W. instrument ight LED “Turn signal indicator 1 TED. High beam indicator LED) ‘Neutral indicator LED. | PGM-Fl warning indicator TED. Fuse Main fuse 30 A PGWEFI fuse 2A Sub fuse “WARS, 20KXZ “Tashometer peak voltage 70.5 V minimum [ECT sensor resistance [Bore T176FT 21=2.6 0 | 20°C (248 °F) | Ge5-0.73k0 1-12GENERAL INFORMATION STANDARD TORQUE VALUES ‘TORQUE TORQUE FASTENERTYPE | yon igh tt FASTENER TYPE fan etn bt) ‘Sim hex bolt and nut | 4510536) | Smmscrew 33 (0.4, 29) mmhorboland nat e087 | smmecew ates, 6s) Som ox bolton nat 2202.10) | Smmnfange bot | Seto 40 mm hex bolt and nut | 3435.25) (8 mm head, small lange) | Tammnexbokendmt —— | 46540) | Smmfonge bt 12112,9) {emm ned, ge lange) Sam fange bok 22a) fromm toe) and ut fim flange blond ut 28 2.220 toTmm ange boltand nut $9 (40,28) ENGINE & FRAME TORQUE VALUES + Toys specail Int btaw op for mpeiane fantanara + Gitar shouldbe iganed to sondard torque values feted above wore 1. Apply sealant the thread 2 Apatyatocking agent the threads x Site 4. Aoplyoilto the threads and flange surface 5 Oe &. ALDC botserverplce wih new one tf Awwoune oko ieale &: Apply rabcerum delRGe oto th threads and seating surface 8 crbat ENGINE MAINTENANCE fi | THRERO | —roRave rem OTY DIA (mm) | thom (gti, tbetty | REMARKS ‘Spark plug 4 10 ‘16 (1.6, 12) | Timing hoe cap : s faut) | Novey | Engin of ha carve : 2 aeiaz) | Noes |_Engine oil drain bolt 1 12 29 (3.0, 22) Lusuicsrion ta CO 7 ~] TORQUE” a eH ony we [nema | OT Ra RSD Tiree 7 Tata eal Noes — Oi hterboes (ud siéeh : atta.) | NoTe2 FUEL SYSTEM (Programmed Fut Injection) [ery | THREAD TORQUE = = OT | ata. tm | nvm thgtm, tory | REMARKS | er tegineCaotnYapararey sensor 7 e wes Throne body insletor bend scrow 2 | 3 seepage vis IAC Ide arcana valve loc nut ‘ ° 13040. 12) IAG lide conto vale syachvonzaion ple | 3 es (03,02) coer foal mounting bot 3 6 28 110,7) URE fle arcontol thermal valve ink pateserew | 2 ea es. 02 IAG tle ar conta hormal valve mounting 2 é 0108.38) Secondary injactor bracket mounting belt los s | saiossa) |GENERAL INFORMATION GENERAL Eee TOOLING SYSTEM [ T THREAD ‘TORQUE eM {OT | practmm) | nn (ugem, tty | REMARKS | Water pump assembly flange bolt 2 6 12 (7.2, 9) NOTES: Thotmostat housing cover flange bolt 2 6 13113, 10) NOTES ENGINE MOUNTING : THREAD TORQUE itgeM tl ore DIA, (mm) Nem (lgf-m, Ioffe) Renin: (Dive sprocket spectal Bolt Top) BAIS 5, 40) (CYLINDER HEAD/VALVES i | THREAD ‘TORQUE —] | a on |_DIA. (mm) N-m (kgfm, Ibfft)_ aan Cylinder head mounting Bok i 3 47(46,35) | NOTES Camshaft holder bolt 2 8 4212.9) Note 4 Gylinder head seating bolt 3 4 3818, 13) NoTE2 Cylinder head eover bolt 4 6 9.6 (10,7) | Breather plate bolt 3 6 13(13,9) NOTE 2,9 PAIR reed valve cover bolt a 6 3313.9) NOTES Cam sprocket bolt 4 7 20(20,14) | NOTE2 CMP (Camshaft postion) senso 2 6 121129) NOTE 2 Cam chain tensioner lifter mounting socket bott | 2 6 98 (10,7) Gam chain tensioner A pivot bolt \ 4 6 9810.7) note2 Gam chain tonsionar 8 pivot bolt 1 10 20 (20,14) NOTE 2 Cam chain guide A bolt 1 \ 6 12 (1.2, 9) Cylinder block socket bolt 1 | 0 32112.) NOTE 2 CCLUTCH/GEARSHIFT LINKAGE THREAD TORQUE L _ Tren TY | DIA. mm) | nem (gt.m, tbe) | REMARKS |} cluteh center tock nut 1 2 127 (13.0, 34) NOTES, & | clutch spring bolt 5 6 12(12,8) Gil pump driven sprocket bolt 1 6 15005, 1 NoTE2 Shift drum canter socket bolt \ 4 8 23 (23,17) NOTE 2 Shift drum stopper arm pivot bolt 1 6 12112,9) Gearshift spindle return spring pin 1 8 22 (2.2, 16) ALTERNATOR/STARTER CLUTCH —] THREAD | TORQUE | i | CEN TY | DIA. (rm) | Nem thm, trey | REMARKS ‘Alternator stator socket Bolt a 6 > wus | ] Fiynheo! bolt 1 10 =| —1031105,75) | NOTES ‘Stator wire clamp bolt po 6 | ta tna, 10 NOTE CCRANKCASE/TRANSMISSION Cc ‘THREAD “TORQUE 7) [ Tem) QTY DIA) | Nem (kgm, bese) | REMARKS Mainsha®t boaring cat plate bolt 3 3 12 (12, 3 NOTEZ Gearshift drum bearing set bolt 2 6 12112.) NOTE 2 Lover crankcase sealing bolt 2 20 228,20) | Crankease @mm bot ‘0 6 1212, 9) | 8 mm bolt 6 | 3 25125, 18) | 8 mm bolt (main journal bolt) 0 8 16(15, 10)4720° | See page | 27 0mm bolt, 1 10 | 9180,29) 1-14CRANKSHAFT/PISTON/CYLINDER GENERAL INFORMATION GENERAL INFORMATION i iret THREAD] ——ToRQUE Cx DIA, (mm) | Nem (kgm, ibe) | REMARKS Connecting rod bearing cap BOW cana or 0 NOTE IGNITION sysTEM sy) THREAD TORQUE iZ rei ary | gia tm |W tigtm,ineny | REMARKS Siartarelutch etter spacial bolt 0 7a (05, 84) | NOTES —— ELECTRIC STARTER THREAD TORQUE 7 i QTV ciatimm) | Nem teat. bry _|_ REMARKS (CSiaer rotor termina nut 7 6 12(12,9) LighTs/meTERs/swiTcHES ; TORQUE a ary | fen fkgtm, tase) | REMARKS | EOP (Engine oll pressure) Sh 7 T2123} NOTE, —— Ep Ean al pare eh tn | screw 1 4 2.002, 14) | | Neutral switen 1 10 12(12,9) 1-15GENERAL INFORMATION Insulator clamp (Throttle body side): 1241 mm (0.5 +0.04 in) > ot Insulator clamp (Cylinder head sidel: 10 £1 mm (0.4 = 0.04 in) | Exhaust pipe stud bolt: 45,5 £ 0.5 mm (1.79 £0.04 in) ee 1-16GENERAL INFORMATION FRAME FRAME BODY PANELS/EXHAUST SYSTEM ] THREAD TORQUE | nevianks eM 07 | cham | mgm, tmy | REMARKS | Tower cowi-to-miidale cowl pan serew | 2 5 15 (015,11) | || Middle cowl-to-upper cowl pan screw 6 5 45 (0.15, 1.1) Windsereen setting serew 6 5 0.5 (0.05, 0.4) Seat rel upper mounting flange nut 2 10 54 (5.5, 40) ‘Seat rail lower mounting flange bolt 2 10 44 (45,33) ‘Seat rail brace socket bolt | 4 8 26(2.7.20) Seat rll assembly flange nut (03, 08) 2 8 30 (3.1, 22) | | Seat ral assembly flange bolt (atter'0a | 2 8 30 (8.1, 22) Exhaust pipe joint flange nut a | 7 12(12,9) Front fender mounting bolt (after‘0a) | 6 6 202.9) | Rear view mirror mounting socket bolt 4 6 69(02.5.) ‘Muffler band flange bolt (03,08) 2 8 232.3, 17), (after‘oa) | 4 a 48118, 13) Exhaust pipe mounting bolt (After‘oa) | 1 8 23i23,17) | Passenger footneg bracket socket bolt 4 8 26 (2.7, 20) MAINTENANCE ~ THREAD rem Ory | ia. mm) (Air cleanor element mounting serew CT 5 FUEL SYSTEM ~ THREAD | ee [ew | onimm Nem (haf-m, tbtft) | REMARKS Fuel filer eap socket bale 3 a 7.8 0.18, 1.) Fuel feed hose benjo bolt (fuel tank ) 1 | 2 2212.2, 16) side) Fuel hose sealing nut (throttle body 1 2 2212.2, 16) | | side) | Fuel pump mounting nut 6 6 1211.2.) | 02 sensor (California type) (03, ‘04) 2 | 2 44 (45,33) (After'0g) 1 2 44 (45, 33) Bank angle sensor mounting screw | 2 4 15 (0.18, 14) | Fuel tank mounting bolt | 2 8 29 (3.0, 22) Air funnelir cleaner housing mounting serew 6 5 4.2 (0.83, 3.1) |_ Fue! hose joint bolt 2 6 9810, 7) COOLING sysTEM cn ] | THREAD TORQUE = L ue — SY piA(mm)_| Nem tkgm, tof) | REMARKS Cooling fan nut , . 2.9 (0:3, 2.2) NOTE? Fan motor nut 3 8 4.9 (05, 3.6) Fan motor shroud mounting bolt 3 6 7810. 4-17GENERAL INFORMATION ENGINE MOUNTING THREAD [ rem on | eee REMARKS | Front engine hanger bolt (left side) 1 2 | Front engine hanger nut (ight side) 1 2 5416.5, 40) Front engine hanger pinch bolt 2 10 27 (2.7, 20) Rear engine hanger adjusting bolt 1 20 38(10,71 | Seepage s- | Rear engine hanger lock aut 1 20 54 (6.5, 40) 10 | Reer engine hanger nut 1 12 5916.0, 43) Lawer engine hanger pinch bot 2 8 272.720) Lower engine hanger nut 1 |e | ste, 43) FRONT WHEEL/SUSPENSION/STEERING Ten) THREAB TORQUE _ a LOTY | pia tmm) | nm tkghm, Ibttt) | REMARKS Hanalobar weight mounting serew | sy 88lt0.7) | NOTES Front brake aise bolt |p 6 | 2012014 | NOTES Front axle bolt fod 4 | 59 (6.0, 43) Front ax holder pinch bolt 4 a | 22216) Fork socket bolt 2 10 | 34 (3.5, 25) NOTE2 Fork bolt ('03, “04) 2 | 42 | 232.3, 17) | (After ‘04) 2 46 34 (3.5, 25) Fork damper lock nut tater‘oe) | 2 1 25 (2.6, 19) Fark top bridge pinch bolt 2 8 23123. 17) Handlebar pinch bolt (3,08) | 2 8 23123, 17 (ater'oay | 2 8 27 (2.220) Fork bortom bridge pinch bolt 2 8 271(27,20) Stoering stem adjusting nut 1 26 2 Steoring stem adjusting lock nut 1 2% - 1 See peas Stooring stem nut 1 24 | t03(105,76) — Compression adjuster _ tarer'oy | 2 | | 808,19) REAR WHEEL/SUSPENSION THREAD TORQUE Wie) _| an DIA.(mm) __N-m (kgf-m, Ibfft) HEMMARKE: Rear brake disc bolt 4 8 42 (4.3, 37) | NOTES Final driven sprocket nut 8 10 64(65,47) | NOTES eer axe nut 1 2 ng(mts,83) | NOTES Rear shock absorber upper mounting nut 1 0 aa(as,33) | NOTES Rear shock absorber lower mounting nut 1 10 aa(as.a3) | NOTES Shock lnkto-rame pivot nt i 10 44 (45,33) | NOTES ‘Shock arm-to-shock link nut 1 10 4d (4.5, 33) NOTE 5 Shock orm-o-swingarm nut 1 m0 | aalas.sa) | NOTES Rear shock absorber bracket bolt vos,o4) | 4 0 24145,99) Drive chain guard bolt 3 6 228) | Dive ehain sider bolt 3 5 | a8(0%65) NOTE? Swingarm pivot pinch bolt a a | 2712720) _ Swingarm pivot nut joa 18 | __—93 (9.5, 69) 1-18HYDRAULIC BRAKE GENERAL INFORMATION THREAD TORQUE 7 TEM: OY | ia. tmm) | nm (gem, test) | REMARKS Front master cylindor reservoir cap screw z 4 75 (0.15, 14) | Front brake lever pivot bolt 1 8 40(0.1,07) | Front brake lever pivot nut 1 5 59105 43) Front brake light switch screw 1 4 10104,07) | Front master eylindar holder bol 2 8 12 (1.2, 9) Front brake caliper assembly torx bolt a @ 23(2.3,17) NoTe2 Front brake caliper mounting bolt (03,04) 4 a 303.1, 22) NOTE 6 (Ater'oa) | 4 10 45 (4.8, 39) NOTE 6 Rear master cylinder push rod joint nut 1 e 18 (18, 13) Rear master eylindar reservoir cap screw 2 4 15(0.15,11) Rear master cylinder mounting bolt 2 6 £8109, 68) Rear brake reservoir mounting bolt 1 6 12 (12,9) Rear brake reservoir hose joint seraw 1 4 15 (018,11) | NoTE2 Rear brake caliper mounting bolt J) 8 2312.3, 17) NOTES Rear brake caliper slide pin bolt 1 2 2728, 20) NOTE 2 Front brake caliper pad pin (03,00) 2 10 18(18,13) (aker‘oa) | 2 10 16(16, 12) Rear brake caliper pad pin 1 10 18(18, 13) Brake hose oll bolt 5 10 24 (3, 25) Front brake hose clamp bolt (03,04) 2 6 12 (12,9) | (After ‘04) | 1 6 8.8 (0.9, 6.5) Front brake hose left clamp nut (after‘oa) | 8 98 (10,7) | Front brake hose Sway joint bok ——_('03, 04) 1 6 12 (12,9) (after‘oay | 6 9.8 110,7) Brake caliper bleed valve 3 a 5.9(0.6,43) |_Front brake caliper bleed valve (afer'oay | 2 a 78 (0.8, 58) LUGHTS/METERS/SWITCHES To THREAD TORQUE a [OT | bia. (mm) Nem (kgfom, Ibf-ft) REMARHS ‘Combination meiar mounting screw ; 3 5 0:9 (0.1, 0.7) Side stand switch bolt \ 4 8 9.8(10,7) Notes Ignition switch mounting bolt 2 a 25:(25, 18) |_Rider fooineg bracket socket bolt La 8 37 (3.8, 28) OTHERS i THREAD TORQUE aren OTY | bia.(mm)_| nem tkatm, these) | REMARKS ‘Sie stand pivat Fock nut i 0 29180, 22) | | Side stond bracket socket bolt 2 10 39 (4.0, 29) vores | Fider footpeg bolt | 32 10 4a (45, 39) NOTES Fier footpeg cap bolt | 2 6 11001,8), as Fs :)GENERAL INFORMATION LUBRICATION & SEAL POINTS ENGINE LOCATION MATERIAL REMARKS: Crankease mating surface Cit pan mating surface Right crankcase cover mating surface Co) Alternator cover mating surface 0 EOP (Engine oil pressure) switch threads 10 not apply sealant tothe = fhtead hebd’S "4 mm {04-02 tn) ap Tiquid sealant (Three Bond 12078 or equivalent) oGENERAL INFORMATION TOCATION MATERIAL REMARKS Cylinder head semiF-circular cut-out ‘Sealant [APPLIED PORTION © Main journal bearing surface | Molybdenum disulfide off Piston pin sliding surface {a mixture of 1/2 engine ‘Connecting rod bearing surface | oiland 1/2 malyadenum Connacting rod small end inner surface | aisulfide grease] Crankshaft thrust surface ‘Camshaft lobes/journals and thrust surface | Valve stem (valve quide sliding surface) Valve lifter outer sliding surface Water pump shaft spline and thrust washer sliding sur- face Clutch outer/primary driven gear sliding surface CClutch outer guide sliding surface il pump gear and collar sliding surface M3/4, C6, CB shifter gear (shift fork grooves) Starter reduction gear sliding surface Starter reduction gear shaft sliding surface Piston and piston ring sliding area, Engine ail il strainer packing Clutch dise surface Starter one-way clutch sliding surface Connacting rod bolt threads and seating surface Flywheel bolt threads and seating surface Cylinder head special bolt (after removing anti-ust oil additive) Clutch center lock nut threads and seating surface Gil filter cartridge threads and O-ring ‘Camshaft holder bolt threads and seating surface Each gear teeth and rotating surface Each bearing Each O-ring Other rotating area and sliding surface Timing hole cap threads | Multi-purpose grease Each oll seal igs Upper crankcase sealing bolt threads Locking agent Lower crankcase sealing bolt threads Cylinder head cover breather joint threads Cylinder head sealing bolt threads | CMP (Camshaft position) sensor rotor bolt threads, il pump driven sprocket bolt threads Oil cooler center bolt thread (stud side) | Shift drum bearing set plate bolt threads Mainshaft bearing set plate bolt threads Cam sprocket bolt threads Cylinder head cover breather plete bolt threads Shift drum conter bolt thresds | Cam chain tensioner pivot A bolt threads | Cam chain tensioner pivot B bolt threads Spindle plate tightening bolt threads Spindle set plate tightening bolt threads | Coating width: 6.5: 1 mm Coating width: 6.5 + 1 mm Coating width: 6.5 +1 mm Coating width: 65 +1 mm Coating width: 65 +1: mm Coating width: 6.5 = 1 mm Coating width: 65 1 mm Costing width: 6.5 = 1 mm Coating width: 6.5 =1 mm Coating width: 6.51 mm Coating width:6.5=1mm | 1-21GENERAL INFORMATION FRAME C LOCATION ‘Seat catch hook sliding area Front wheel dust seal lips Final driven flange-to-rear wheel hub mating surface and O-ring Rear wheel dust seal lips Rear wheel sido collar inner surface ‘Throttle grip pipe flange Rear brake pedal pivot sliding area Gearshift pedal link tie-rod ball joints Gearshift pedal pivot Rider footpeg sliding area Passenger footpeg sliding area Side stand pivot Center stand pivot Steering head bearing sliding surface Steering head dust seal lips MATERIAL ‘Multi-purpose grease Urea based multi-purpose grease with extreme pres- sure (example: EXCELITE EP2 manufactured by KYODO YUSHI, Japan), Shall stamina EP2 or equivalent REMARKS: ‘Swingarm pivat bearings ‘Swingarm pivot dust seal lips ‘Shock arm and shock link needle bearings ‘Shook arm and shock link dust seal lips ‘Shock absorber needle bearings, Shock absorber dust seal lips ‘Multi-purpose grease (Sholl Alvania EP2 or equivalent) Throttle cable A, 8 outer inside Clutch cable outer inside Clutch cable outer inside Handlebar grip rubber inside ‘Steering bearing adjustment nut threads Cable lubricant Honda bond A or Honda hand Grip Cement (U.S.A. ‘only! Engine of Front brake laverto-master piston contacting area Front brake lever pivot Rear brake master piston-to-push rod contacting ar Breke caliper dust seals Rear brake caliper boot inside Rear brake caliper pin boot inside | Rear brake caliper pad pin O-ring Silicone grease Brake master piston and cups Brake caliper piston and piston seals Honda DOT @ brake fluid | Fork cap O-ring Fork dust seal and oll seal lips jear brake reservoir hose joint screw threads: Front brake caliper assembly bolt threads Roar brake caliper slide pin bolt threads 1-22 Pro Handa Suspension Fluid 8-8 (03, ‘04) Pro Honda Suspension Fluid $S-55 (After 04) Locking agentGENERAL INFORMATION CABLE & HARNESS ROUTING (03, ‘04) RIGHTHANDLEBAR, cron caste THROTTLE CABLES: SL WRE LEFTHANDLEBAR Src ie senmow siren ne A> 5 é a | | __-Tnowr susanness TAONT BRAKE HOSE ‘Bequlus conaeeson 1 = J Onin ? S FRONT SUB-HARNESS TEP era CONNECTOR COMBNATONNETER SANK ANGLE SENSOR MULTI-CONNECTOR 3P (BLACK) CONNECTOR RIGHT TURN SIGNAL 2° (LIGHT BLUE) CONNECTOR HEADLIGHT RELAY LEFT TURN SIGNAL 2P (ORANGE) CONNECTOR HEADLIGHT SOCKET FRONT SUS-HARNESS 12? (GRAY CONNECTOR FRONT SUB-HARNESS 12P (BLUE) CONNECTOR 1-23GENERAL INFORMATION "03, ‘04; CLUTCH CABLE LEFTHANDLEBAR ‘SWITCH WIRE, FRONT SUB-HARNESS 12P (BLUE) CONNECTOR FRONT SUB-HARNESS 12? (GRAY) CONNECTOR 1-24GENERAL INFORMATIONGENERAL INFORMATION “03, 08: IGNITION SWITCH WIRE CLUTCH CABLE THROTTLE CABLES LEFTHANDLEBAR SWITCH WIRE. RIGHT HANDLEBAR, SWITCH WIRE ENGINE STOP RELAY FUEL TANK BREATHER HOSE THEE Hae: FUEL PUMP UNIT WIRE 1-26GENERAL INFORMATION hw ee VATION ECM 32? (LIGHT GRAY} CONNECTOR ECM 32P (BLACK) CONNECTOR IAT SENSOR, No.4 SECONDARY INJECTOR CONNECTOR IGNITION SWITCH 4P (NATURAL) CONNECTOR No.3 SECONDARY INJECTOR CONNECTOR No.2 SECONDARY INJECTOR CONNECTOR LEFT HANDLEBAR SWITCH 12 (GRAY) CONNECTOR No.1 SECONDARY INJECTOR CONNECTOR 1-27GENERAL INFORMATION “03,08: IAT SENSOR, No3. PRIMARY INJECTOR CONNECTOR MAP SENSOR No.2 PRIMARY INJECTOR CONNECTOR No.1 PRIMARY MAP SENSOR INJECTOR VACUUM HOSE CONNECTOR ECT SENSOR JAC IDLE AIR CONTROL) VS (VEHICLE SPEED) SENSOR 3P THERMAL VALVE WATER (NATURAL) CONNECTOR HOSES INSIDE 800T CONNECTORS: = CMP (CAMSHAFT POSITION) SENSOR 2P (NATURAL) = FUEL PUMP UNIT 3P (BLACK) = SIDE STAND SWITCH 2P (GREEN) 1-28GENERAL INFORMATION “03, ‘04: KKCASE BREATHER HOSE PAIRLCONTROL CRAN ‘ ER HO SOLENOID VALVE RIGHT HANDLEBAR SWITCH 9P (BLACK) CONNECTOR N HOSES. PAIR CONTROL PAIR AIR SUCTION SOLENOID VALVE 2P (BLACK) CONNECTOR SIPHON HOSE AIR BLEED HOSE IGNITION CONTROL SUB-HARNESS 6? (BLACK) CONNECTOR CKP {CRANKSHAFT POSITION} SENSOR 2P (RED) CONNECTOR INSIDE BOOT CONNECTORS: = CMP (CAMSHAFT POSITION) SENSOR 2P {NATURAL} STARTER MOTOR CABLE ~ FUEL PUMP UNIT 3P (BLACK) = SIDE STAND SWITCH 2P (GREEN) 1-29GENERAL INFORMATION ‘03, "04; INSIDE BOOT CONNECTORS: = CMP (CAMSHAFT POSITION) SENSOR FAN MOTOR 2 2P (NATURAL) (BLACK) CONNECTOR — "FUEL PUMP UNIT 3P (BLACK) = SIDE STAND SWITCH 2° (GREEN) ‘TP SENSOR 3P (BLACK) CONNECTOR FUSE BOX FAN MOTOR WIRE CMP (CAMSHAFT. POSITION) SENSOR WIRE NEUTRAL SWITCH WIRE REGULATORRECTIFIER 3P (NATURAL] CONNECTOR SIDE STAND SWITCH WIRE RADIATOR RESERVE TANK OVER FLOW HOSE FUEL TANK BREATHER HOSE FUEL TANK DRAIN HOSE MAIN WIRE HARNESS 1-30GENERAL INFORMATION ‘03, "04: PAIR CONTROL SOLENOID \VALVE 2P (BLACK) CONNECTOR BRAKE LIGHT SWITCH RIGHT HANDLEBAR SWITCH 2P (BLACK) CONNECTOR ‘9P (BLACK) CONNECTOR REAR BRAKE HOSE CLUTCH CABLE SIPHON HOSE AIR BLEED HOSE CKP (CRANKSHAFT POSITION) SENSOR WIRE EOP (ENGINE OIL PRESSURE) SWITCH WIRE a REAR BRAKE LIGHT SWITCH WIRE 1-31GENERAL INFORMATION PGM-FI FUSE (208) HOLDER SEAT LOCK CABLE BATTERY POSITIVE (+) CABLE BRAKE/TAIL LIGHT 3P. (NATURAL) CONNECTOR DATA LINK CONNECTOR MAIN WIRE HARNESS: INSIDE 800 CONNECTORS: STARTER RELAY SWITCH RIGHT EAR TURN SIGNAL ict ze (LIGHT BLUE] UTEFT REAR TURN SIGNALLIGHT STARTER MOTOR CABLE 2F (ORANGE) = LICENSE LIGHT 2 (WHITE) 1-32GENERAL INFORMATION “0a: ‘03, REAR BRAKE RESERVOIR HOSE BRAKE LIGHT SWITCH 2P (BLACK) CONNECTOR REAR BRAKE HOSE 1-33GENERAL INFORMATION “03, (04 California Type: IAT SENSOR, No3. PRIMARY INJECTOR CONNECTOR MAP SENSOR No.2 PRIMARY INJECTOR CONNECTOR, MAP SENSOR No.1 PRIMARY INJECTOR ‘VACUUM CONNECTOR ECT SENSOR EVAP PURGE CONTROLSOLENOID VALVE HOSES INSIDE BOOT CONNECTORS: cM (CAMSHAFT POSITION, Vs (VEHICLE SPEED) IAC HOLE AIR CONTROL) See ATA SENSOR 2° (NATURAL) “THERMAL VALVE WATER “FUEL PUMP UNIT 2P (BLACK) CONNECTOR HOSES = SIDE STAND SWITCH 2P (GREEN) CKP (CRANKSHAFT POSITION) SENSOR 2P (RED) CONNECTOR 1-34GENERAL INFORMATION “03, 04 Califor INSIDE 800T CONNECTORS: ~CMP (CAMSHAFT POSITION) FAN MOTOR 2P (BLACK) ‘SENSOR 2P (NATURAL) CONNECTOR = FUEL PUMP UNIT 3P (BLACK) ol ey EVAPPUAGE CONTROL SIDE STAND SWITCH 2? (GREEN) SOLENOID VALVE ‘TP SENSOR 3P (BLACK) CONNECTOR FUSE 80x FAN MOTOR WIRE, MP (CAMSHAFT POSITION) SENSOR WIRE NEUTRAL SWITCH WIRE REGULATORIRECTIFIERSP (NATURAL) CONNECTOR SIDE STAND SWITCH WIRE (Oz SENSOR 4P (NATURAL) CONNECTOR, FUEL TANK DRAIN HOSE RADIATOR RESERVE TANK OVER FLOWHOSE evap PURGE CONTROL SOLENOID VALVE HOSES 1-35GENERAL INFORMATION "03, '04 California Tyt PAIR CONTROL SOLENOID VALVE 2P (BLACK) CONNECTOR BRAKE LIGHT SWITCH RIGHT HANDLEBAR SWITCH 2P (BLACK) CONNECTOR 9P (BLACK) CONNECTOR REAR BRAKE HOSE CLUTCH CABLE SIPHON HOSE AIR BLEED HOSE CKP (CRANKSHAFT POBITION: SENSOH WIE EOP (ENGINE OIL PRESSURE} SWITCH WIRE (2 SENSOR WIRE 1-36GENERAL INFORMATION “03, (04 California Type: EVAP PURGE CONTROL SOLENOID VALVE FUEL TANK BREATHER HOSE EVAPPURGE CONTROL ‘SOLENOID VALVE EVAP PURGE CONTROL, SOLENOID VALVE HOSES 1-37GENERAL INFORMATION CABLE & HARNESS ROUTING (AFTER '04) RIGHTHANDLEBAR cuuToH caste THROTTLE CABLES ‘SWITCH WIRE CH CAL \ ae ef LEFT HANDLEBAR: 5 i SvTcH WIRE Of mm ®) | senPhow swe une FRONT SUB-HARNESS = 112P (BLUE) CONNECTOR FRONT SUB-HARNESS 12° (GRAY) CONNECTOR Ds HORN WiRE FRONT BRAKE HOSE COMBINATION METER HEADLIGHT RELAY MULIE-CONNECTOR BANK ANGLE SENSOR 3P (BLACK) CONNECTOR LEFT TURN SIGNAL 2° (ORANGE) CONNECTOR RIGHT TURN SIGNAL 2P (LIGHT BLUE) CONNECTOR FRONT SUB-HARNESS FRONT SUB-HARNESS. Y2P (BLUE) CONNECTOR 12 (GRAY} CONNECTORGENERAL INFORMATION CLUTCH CABLE LEFT HANDLEBAR, SWITCH WIRE IGNITION SWITCH WIRE FRONT SUB-HARNESS 12P (BLUE) CONNECTOR FRONT SUB-HARNESS 12° (GRAY) CONNECTOR HORN WIRE 1-39GENERAL INFORMATION ‘After ‘04:GENERAL INFORMATION After ‘04: IGNITION SWITCH WIRE CLUTCH CABLE THROTTLE CABLES LEFT HANDLEBAR, ‘SWITCH WIRE s RIGHT HANDLEBAR FAN CONTROL RELAY SWITCH WIRE FAN MOTOR 2P (BLACK) CONNECTOR FUEL PUMP UNIT WIRE FUEL HOSE FUEL TANK BREATHER HOSE 1-41GENERAL INFORMATION After ‘04: ECM 32P (LIGHT GRAY) CONNECTOR ECM 92P (BLACK) No.d SECONDARY ‘CONNECTOR INJECTOR CONNECTOR IAT SENSOR IGNITION SWITCH 4P No.3 SECONDARY (NATURAL) CONNECTOR INJECTOR CONNECTOR No.2 SECONDARY INJECTOR CONNECTOR LEFT HANDLEBAR swiTcH 7 CONNECTOR LENSE No.1 SECONDARY INJECTOR CONNECTOR 1-42GENERAL INFORMATION After IAT SENSOR MAP SENSOR at No3, PRIMARY INJECTOR CONNECTOR jC) ff a | IY ) No.2 PRIMARY Ss INJECTOR CONNECTOR, 5 T FUEL PUMP UNIT ap (BLACK) NNECTOR No.1 PRIMARY H cor i INJECTOR | CONNECTOR | | MAP SENSOR 7 VACUUM HOSE ( ( D) Al S Sf No.4 PRIMARY INIECTOR CONNECTOR EcT SENSOF (eS iy S INSIDE Boor connectORS =VS (VEHICLE SPEED) SENSOR 3P (NATURAL) SALA = NEUTRAL SWITCH/EOP (ENGINE OIL PRESSURE) SWITCH re 3P (BLACK) CONNECTOR 1-43GENERAL INFORMATION ‘After ‘04: PAIR CONTROL, ‘SOLENOID VALVE CRANKCASE BREATHER HOSE SIPHON HOSE PAIR AIR SUCTION HOSES AIR BLEED HOSE CKP (CRANKSHAFT POSITION) SENSOR 2P {RED) CONNECTOR IGNITION CONTROL, SUB-HARNESS 6? (BLACK) CONNECTOR EOP (ENGINE OIL PRESSURE) SWITCH WIRE NEUTRAL SWITCH WIREGENERAL INFORMATION ‘After ‘04: INSIDE BOOT CONNECTORS: CMP [CAMSHAFT POSITION) ‘SENSOR 2P (NATURAL) TP SENSOR 3P (BLACK) CONNECTOR ST et op (GREEN) MAIN WIRE HARNESS: FAN MOTOR WiRE S37 ° BS ee POSITION) > : FUEL TANK Canada type: BREATHER HOSE FUEL TANK. REGULATORIRECTIFIER 3P DRAIN HOSE (NATURAL) CONNECTOR RADIATOR RESERVE TANK OVER FLOW HOSE 1-45GENERAL INFORMATION After ‘04: RIGHT HANDLEBAR SWITCH 9P (BLACK) CONNECTOR CLUTCH CABLE PAIR CONTROL, SOLENOID VALVE 2p (BLACK) REAR BRAKE LIGHT SWITCH CONNECTOR 2P (BLACK) CONNECTOR ‘AIR BLEED HOSE EOP (ENGINE OIL PRESSURE) ‘SWITCH WIRE REAR BRAKE HOSE KP (CRANKSHAFT POSITION) SIPHON HOSE SENSOR WIRE 1-46GENERAL INFORMATION After ‘04: BRAKE/TAIL LIGHT 3P (NATURAL) CONNECTOR PGIV-FI FUSE (204) HOLDER BATTERY POSITIVE (+) CABLE BATTERY NEGATIVE (-] CABLE INSIDE BOOT CONNECTORS: RIGHT REAR TURN SIGNAL UGHT 2P (LIGHT BLUE) LEFT REAR TURN SIGNAL LIGHT 2P (ORANGE) “LICENSE LIGHT 2P (WHITE) ‘STARTER RELAY SWITCH MAIN FUSE (308) MAIN WIRE HARNESS DATA LINK CONNECTOR BATTERY NEGATIVE (-) CABLE STARTER MOTOR CABLE 1-47GENERAL INFORMATION ‘After ‘04: REAR BRAKE RESERVOIR HOSE REAR BRAKE LIGHT SWITCH 2P (BLACK) CONNECTOR BRAKE LIGHT SWITCH REAR BRAKE HOSE LICENSE LIGHT WIRE NNN RIGHT TURN SIGNAL WIRE LEFT TURN SIGNAL WIREGENERAL INFORMATION lT SENSOR MAP SENSOR VACUUM HOSE L\ Noa. PRIMARY MAP SENSOR INJECTOR CONNECTOR No.2 PRIMARY INJECTOR CONNECTOR, No.1 PRIMARY INJECTOR CONNECTOR ECT SENSOR EVAP PURGE CONTROL ‘SOLENOID VALVE WIRE No PRIMARY INJECTOR CONNECTOR INSIDE BOOT CONNECTORS: JAC IDLE AIR CONTROL) ~VS (VEHICLE SPEED) SENSOR 3P (NATURAL) SYA PURO i THERMAL VALVE WATER NEUTRAL SWITCH/EOP, HOSES {OP (ENGINE OIL Senmocsee PRESSURE) SWITCH 3P (BLACK) CKP (CRANKSHAFT POSITION} ‘SENSOR 2? (RED) CONNECTOR SS Ee 1-49GENERAL INFORMATION ‘After ‘04 California Type: (02 SENSOR 4P (NATURAL) RIGHT HANDLESAR SWITCH CONNECTOR ‘9P (BLACK) CONNECTOR CLUTCH CABLE PAIR CONTROL ‘SOLENOIDVALVE 2P (BLACK) CONNECTOR REAR BRAKE LIGHT SWITCH 2P (BLACK) CONNECTOR AIR BLEED HOSE EOP (ENGINE OIL PRESSURE) REAR BRAKE HOSE SWITCH WIRE (Or SENSOR WIRE SIPHON HOSE KP (CRANKSHAFT POSITION) SENSOR WIRE 1-50GENERAL INFORMATION ‘After 04 California Type: Fu: EVAP PURGE CONTROL JEL TANK SOLENOID VALVE BREATHER HOSE EVAP PURGE CONTROL, SOLENOID VALVE HOSES EVAP PURGE CONTROL SOLENOID VALVE EVAP PURGE CONTROL SOLENOID VALVE 2P (BLACK) CONNECTOR EVAP PURGE CONTROL SOLENOID VALVE HOSES FUEL TANK BREATHER HOSE EVAP CANISTER 1-51GENERAL INFORMATION EMISSION CONTROL SYSTEMS The U.S, Environmental Protection Agency, 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, and that motorcyoles built aftor January 1, 1983 comply with applicable noise emission standards for one year or 6,000 km {3,730 miles) after the time of sale to the ultimate purchaser, when operated! and maintained according to the instructions provided. Compliance with the terms of the Distributor's Limited Warranty for Honda Motorcycle Emission Control Systems is necessary in order to keep the emissions system warranty in effect. SOURCE OF EMISSIONS The combustion process produces carbon monoxide, oxides of nitrogen and hydrocarbons. Control of oxides of nitrogen ‘and hydrocarbons is very important because, under certain conditions, they react to form photochemical smog when subject to sunlight. Carbon monoxide does not react in the same way, but itis toxic. Honda Motor Co., Lid. utilizes lean injection settings as well as other systems, to reduce carbon monoxide, oxides of nitrogen and hydrocarbons, CRANKCASE EMISSION CONTROL SYSTEM ‘The engine is equipped with @ closed crankcase system to prevent discharging crankcase emissions into the atmosphere. Blow-by gas is returned to the combustion chamber through the air cleaner and throttle body. AIR CLEANER HOUSING ‘THROTTLE BODY <== FrEsHAIR <= blowsy Gas 1-52GENERAL INFORMATION EXHAUST EMISSION CONTROL SYSTEM ‘The exhaust amission control system is composed of 2 secondary air supply system, an oxidation catalytic converter or three-way catalytic converter and a lean fuel injection setting. No adjustments should be made exzept idle speed adjustment with the throttle stop screw. The exhaust emission control eystem is separate from the crank case emission control system, SECONDARY AIR SUPPLY SYSTEM ‘The pulse secondary air supply system introduces filtered air into the exhaust gases in the exhaust port. Fresh airis drawn into the oxhaust port by the function of the PAIR (Pulse Secondary Air Injection) 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 airflow through the system. The PAIR control valve is operated by the solenoid valve. The solenoid vaive is controlled by the PGM-FI unit, and the fresh air passage is openadiclosed eecording to running conditions (ECTIAT/TPIMAP sensor and engine revolution). No adjustments to the secondary air supply system should be made, although periodic inspection of the components is recommended. AIR CLEANER HOUSING PAIR CHECK VALVE THROTTLE BODY PAIR CONTROL SOLENOID VALVE EXHAUST PORT <= presnain EXHAUST GAS OXIDATION CATALYTIC CONVERTER ‘Tho 49-State and Canada types are 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 angine’s exhaust to carbon dioxide (COs) and water vapor. THREE-WAY CATALYTIC CONVERTER The California type is equipped with three-way warm-up catalytic converters, a three-way catalytic converter, and a heated oxygen sensor. The three-way catalytic converter is in the exhaust system. Through chemical reactions, it converts HC, CO, and NOxin the tengine’s exhaust to carbon dioxide (COs), dinitrogen [Ns], and water vapor. No adjustment to these systems should be made although periodic inspection of the components is recommended, 1-53GENERAL INFORMATION EVAPORATIVE EMISSION CONTROL SYSTEM (CALIFORNIA TYPE ONLY) “This model complies with CARB evaporative emission requirements. Fup vapor from the fuel tanks routed into the evaporative emission (EVAP) canister where is it absorbed and stored while the engine is stoppod. When the engine is running and the evaporative emission (EVAP) purge control solenoid valve is ‘open, fuel vapor In the EVAP canister is drawn into the engine through the throttle body. FUEL TANK. ‘THROTTLE BODY EVAPPURGE CONTROL ‘SOLENOID VALVE aa << FRESH AIR == FUEL VAPOR NOISE EMISSION CONTROL SYSTEM TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: U.S, Federal law prohibits, or Canadian provincial law prohibits the following acts or the causing there of: (1) The removal or rending inoperative by any person, other than for the purposes of maintenance, repait or replacement, of any device or element of design incorporated into’any vehicle for the purpose of noise control prior to its sale or delivery to the ultimate customer or while itis in Use; or (2) the use of any vehicle after such device or element of design has been removed or rendered inoperative by any person. AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW: Removal of, or puncturing of the muifier, baffles, header pipes or any other component which conducts exhaust gases. Removal of, or puncturing of any part of the intake system. Lack of proper maintenence. Replacing any moving parts of the vehicle, or parts of the exhaust or intake system, with parts other than those speci- fied by the manufacturer. 1-54