Untitled

20 21
HONDA
SERVICE M ANUAL
CRF3 0 0 L / LA
CRF3 0 0 LR /LRA
1. GENERAL INFORM ATION
A Few Words Abou t Saf et y 1-2 SPECIAL TOOL LIST .. 1-21
How To Use Th i s Manual 1-3 CABLE & HARNESS ROUTING ... .. 1-22
MODEL IDENTIFICATION 1-5 EMISSION CONTROL SYSTEMS 1-65
SPECIFICATIONS 1-8 MAINTENANCE SCHEDULE ......... 1-68
TORQUE VALUE ... -1-16
61K1T0O
1-1
i
GENERAL INFORMATION
A Few Wor d s Ab ou t Saf et y
Ser vi ce In f or m at i on
The service and repair inform at ion cont ained in t his m anual is int ended for use by qualified, professional t echnicians .
At t em pt ing service or repairs wit hout t he proper t raining , t ools , and equipm ent could cause injury t o you or ot hers . It could also
dam age t he vehicle or creat e an unsafe condit ion .
This m anual describes t he proper m et hods and procedures for perform ing servi ce , m aint enance and repairs. Som e procedures
require t he use of specially designed t ools and dedicat ed equipm ent . Any person who int ends to use a replacem ent part, service
procedure or a t ool t hat is not recom m ended by Honda , m ust det erm ine t he risks t o t heir personal safet y and t he safe operat ion of
t he vehicle .
If you need t o replace a part, use genuine Honda part s wit h t he correct part num ber or an equivalent part. We st rongly recom m end
t hat you do not use replacem ent part s of inferior qualit y.
For You r Cu st om er ’s Saf et y
Proper service and m aint enance are essent ial t o t he cust om er’s safet y and t he reliabilit y of t he vehicle . Any error or oversight while
servicing a vehicle can result in fault y operat ion , dam age t o t he vehicle , or inj ury t o ot hers .
AWARNING
Im proper servi ce or repai rs can creat e an un

safe condit ion t hat can cause your cust om er
t o be seri ously hurt or killed .
Follow t he procedures and precaut i ons in t his

m anual and ot her servi ce m at erials carefully .
For You r Saf et y
Because t his m anual is int ended for t he professional service t echnician , we do not provide warnings about m any basic shop safet y
pract ices ( e.g. , Hot part s -wear gloves ). If you have not received shop safet y t raining or do not feel confident about your knowledge
of safe servicing pract ice, we recom m ended t hat you do not at t em pt t o perform t he procedures described in t his m anual .
Som e of t he m ost im port ant general service safet y precaut ions are given below . However, we cannot warn you of every
conceivable hazard t hat can arise in perform ing service and repair procedures. Only you can decide whet her or not you should
perform a given task .
AWARNING
Fai lure t o properly follow inst ruct ions and

precaut i ons can cause you t o be seri ously
hurt or killed .
Follow t he procedures and precaut i ons in t his

m anual carefully
Im p or t an t Saf et y Pr ecau t i on s
Make sure you have a clear underst anding of all basic shop safet y pract ices and t hat you are wearing appropriat e clot hing and
using safet y equipm ent . When perform ing any service t ask , be especially careful of t he following:
.
Read all of t he inst ruct ions before you begin , and m ake sure you have t he t ools , t he replacem ent or repair part s, and t he skills
required t o perform t he t asks safely and com plet ely.
.
Prot ect your eyes by using proper safet y glasses, goggles or face shields any t im e you ham m er , drill , grind , pry or work around
pressurized air or liquids,and springs or ot her st ored - energy com ponent s. If t here i s any doubt ,put on eye prot ect ion .
Use ot her prot ect ive wear when necessary, for exam ple gloves or safet y shoes . Handling hot or sharp part s can cause severe
burns or cut s . Before you grab som et hing t hat looks like it can hurt you , st op and put on gloves.
Prot ect yourself and ot hers whenever you have t he vehicle up in t he air . Any t im e you lift t he vehicle , eit her wit h a hoist or a j ack ,
m ake sure t hat it is always securely support ed. Use j ack st ands .
Make sure t he engine i s off before you begin any servicing procedures , unless t he inst ruct ion t ells you t o do ot herwise. This wi ll
help elim inat e several pot ent ial hazards:
Carbon m onoxide poisoning from engine exhaust . Be sure t here is adequat e vent ilat ion whenever you run t he engine .
Burns from hot part s or coolant. Let t he engine and exhaust syst em cool before working in t hose areas.
Inj ury from m oving part s. If t he inst ruct ion t ells you t o run t he engine, be sure your hands , fingers and clot hing are out of t he way .
Gasoline vapors and hydrogen gases from bat t eries are explosive . To reduce t he possibilit y of a fire or explosion ,be careful when
working around gasoline or bat t eries.
Use only a nonflam m able solvent , not gasoline , t o clean part s.
Never drain or st ore gasoline in an open cont ainer .
Keep all cigaret t es, sparks and flam es away from t he bat t ery and all fuel-relat ed part s.
1-2
GENERAL INFORMATION i
How To Use Th i s Man u al
Thi s m anual is " Spec ( Speci fi c ) " Servi ce Manual . The servi ce and repai r inform at ion for t his m odel is descri bed in t his
m anual as speci fi c inform at ion . Refer t o " Basic " Servi ce Manual for basic /com m on servi ce inform at ion and
inst ruct ions.
Follow t he Mai nt enance Schedule recom m endat i ons t o ensure t hat t he vehi cle is in peak operat i ng condit ion .
Perform i ng t he first scheduled m ai nt enance is very im port ant. It com pensat es for t he init ial wear t hat occurs during t he
break - in period .
Find t he sect ion you want on t his page , t hen t urn t o t he t able of cont ent s on t he first page of t he sect ion .
Your safet y, and t he safet y of ot hers , is very im port ant. To help you m ake inform ed deci si ons we have provi ded
safet y m essages and ot her inform at ion t hroughout t his m anual . Of course , it is not pract ical or possi ble t o warn you
about all t he hazards associ at ed wit h servicing t his vehi cle .
You m ust use your own good j udgem ent .
You will find im port ant safet y inform at ion in a vari et y of form s including :
Safet y Labels - on t he vehi cle
Safet y Messages preceded by a safet y alert sym bol A and one of t hree signal words, DANGER , WARNING ,
or CAUTION . These signal words m ean :
ADANGER You WILL be KILLED or SERIOUSLY HURT if you don’t follow inst ruct ions.
AWARNING You CAN be KILLED or SERIOUSLY HURT if you don’t follow inst ruct ions.
A CAUTION You CAN be HURT if you don’t follow inst ruct ions.
Inst ruct ions - how t o servi ce t his vehi cle correct ly and safely .
As you read t his m anual , you will find inform at ion t hat is preceded by a NOTICE sym bol . The purpose of t his m essage
is t o help prevent dam age t o your vehi cle , ot her propert y, or t he envi ronm ent.
ALL INFORMATION , ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS

PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF
APPROVAL FOR PRINTING. Honda Mot or Co. , Lt d. RESERVES THE RIGHT TO MAKE CHANGES AT ANY
TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATSOEVER . NO PART OF THIS
PUBLICATION MAY BE REPRODUCED WITHOUT WRITTEN PERMISSION . THIS MANUAL IS WRITTEN FOR
PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTENANCE ON Honda MOTORCYCLES .
MOTOR SCOOTERS OR ATVS .
Honda Mot or Co., Lt d.

SERVICE PUBLICATION OFFICE
Dat e of Issue : January, 2021
1-3
i GENERAL INFORMATION
SYMBOLS
The sym bols used t hroughout t his m anual show speci fi c servi ce procedures. If supplem ent ary inform at ion is requi red
pert aining t o t hese sym bols, it would be explai ned speci fi cally in t he t ext wit hout t he use of t he sym bols .
INSTRUCTION SYMBOL
Rem oval or Di sassem bly procedure. Inst allat ion or Assem bly procedure.
Di sconnect t he connect or . Connect t he connect or .
Order of inst allat ion / assem bly wit h a point of

Order of rem oval / di sassem bly wit h a point of not e .
1 1 not e .
Ti ght en speci fi ed t orque . Replace wit h a new one before assem bly .
New
Check t he part for an inspect ion . Measure t he part for an inspect ion .
Turn ignit ion swit ch t o OFF . Turn ignit ion swit ch t o ON .
St art t he engi ne . Measure a resi st ance or check cont inuit y .

3)
A
Measure a volt age . Measure an am pere .
Ref er t o " Basic " Servi ce Manual for t he i nst ruc

Use t he Honda special t ool . m "
t ion .
SP t ool Basic
LUBRICATION AND SEAL SYMBOL
Apply m olybdenum oil solut ion (m ixt ure of an

Use t he recom m end engi ne oil . engi ne oil and m olybdenum grease in a rat ion of
Oi l Mo Oi l 1 : 1 ) .
Apply a speci fi ed grease . Use a m ult i - purpose

Apply a liquid sealant .
grease unless ot herwi se speci fi ed.
Grease Seal
Apply a locking agent . Use a m edium st rengt h

Use DOT 4 brake fluid .
one unless ot herwi se speci fi ed . BF
Lock
Use a speci fi ed fork oil or suspensi on fluid .

k roF
1-4
i
GENERAL INFORMATION
M ODEL IDENTIFICATION
Model nam e : CRF300LR / LRA / L /LA
DESTINATION CODES
Throughout t his m anual , t he followi ng codes are used t o ident ify individual t ypes for each region .
DESTINATION CODE REGION

AC USA 50 st at e ( m eet California )
CM Canada
TYPES and MODELS
Dest i nat i on Ant i - lock Brak e EVAP

Type Model LED headli ght
code Syst em cani st er
| O
CRF300LR
|
Rally
CRF300LRA IIITO
CM
||
CRF300L |
|
St andard O
AC
CRF300LA !
CM 00
1-5
Rally t ype
VEHICLE IDENTIFICATION NUMBER ENGINE SERIAL NUMBER
1983
1-6
i
GENERAL INFORMATION
St andard t ype
VEHICLE IDENTIFICATION NUMBER ENGINE SERIAL NUMBER
1-7
i
GENERAL INFORMATION
SPECIFICATIONS
GENERAL SPECIFICATIONS
Rally t ype
ITEM SPECIFICATIONS
DIMENSIONS Overall lengt h 2,230 m m (87.8 in )
Overall widt h 920 m m ( 36.2 in )
Overall height 1,415 m m (55.7 in )
Wheelbase 1,455 m m (57.3 in )
Seat height 8 8 5 m m ( 34.8 in )
Foot peg hei ght 369 m m ( 14.5 in )
Ground clearance 275 m m ( 10.8 in )
Curb wei ght LR 150 kg ( 331 lbs )
LRA 152 kg ( 335 lbs )
Maxi m um wei ght AC t ype 148 kg ( 326 lbs )
capaci t y CM t ype 145 kg ( 320 lbs )
FRAME Fram e t ype Sem i-double cradle t ype
Front suspension Telescopi c fork
Front axle t ravel 234 m m ( 9.2 in )
Rear suspension Pro - link
Rear axle t ravel 260 m m ( 10.2 in )
Front t ire si ze 80 / 100-21M / C 51P
Rear t ire si ze 120 / 80-18M / C 62P
Front t ire brand GP -21F ( IRC)
Rear t ire brand GP - 22R ( IRC)
Front brak e Hydrauli c disc brak e
Rear brake Hydrauli c disc brak e
Cast er angle 27 30 ’
Trail lengt h 109 m m ( 4.3 in )
Fuel t ank capaci t y 12.8 lit er ( 3.38 US gal, 2.82 Im p gal)
Fuel t ank reserve capaci t y 2.3 lit er ( 0.61 US gal , 0.51 Im p gal )
ENGINE Cyli nder arrangem ent Si ngle cyli nder 250 inclined from vert i cal
Bore and st roke 76.0 x 63.0 m m ( 3.00 x 2.50 in )
Di splacem ent 286 cm ( 17.5 cu - in )
Com pressi on rat io 10.7 : 1
Valve t rain Chai n driven , DOHC
Int ak e valve opens 12 BTDC at 1.0 m m ( 0.04 in ) lift
closes 3 1 ABDC at 1.0 m m ( 0.04 in ) lift
Exhaust valve opens 40 BBDC at 1.0 m m ( 0.04 in ) lift
closes ATDC at 1.0 m m ( 0.04 in ) lift
Lubri cat i on syst em Forced pressure and wet sum p
Oil pum p t ype Trochoi d
Cooli ng syst em Li qui d cooled
Ai r filt rat ion Vi scous paper filt er
Engi ne dry wei ght 35.9 kg ( 79.1 lbs )
Em ission cont rol AC t ype Crank case em ission cont rol syst em
syst em Secondary air supply syst em
Three -way cat alyt ic convert er
Evaporat i ve em ission cont rol syst em
CM t ype Crank case em ission cont rol syst em
Secondary air supply syst em
FUEL SYSTEM Type PGM -FI
Throt t le bore 38 m m ( 1.5 in )
1-8
ITEM SPECIFICATIONS
DRIVE TRAIN Clut ch syst em Mult i - plat e , wet
Clut ch operat ion syst em Cable operat i ng
Transm i ssi on 6 speed
Pri m ary reduct ion 2.8 07 (73/ 26 )
Fi nal reduct ion 2.857 ( 40/ 14 )
Gear rat io 1 st 3.538 ( 46/ 13 )
2nd 2.250 ( 36/ 16 )
3rd 1.650 ( 33/ 20 )
4t h 1.346 ( 35/ 26 )
5t h 1.115 ( 29/ 26 )
6t h 0.925 ( 25/ 27 )
Gearshi ft pat t ern Left foot operat ed ret urn syst em
1 - N - 2-3 -4-5-6
ELECTRICAL Ignit ion syst em Full t ransist orized
St art ing syst em Elect ri c st art er m ot or
Chargi ng syst em Tri ple phase out put alt ernat or
Regulat or / rect i fi er FET short ed , t riple phase full -wave
rect ificat ion
Light ing syst em Bat t ery
1-9
i
GENERAL INFORMATION
St andard t ype
ITEM SPECIFICATIONS
DIMENSIONS Overall lengt h 2,230 m m ( 8 7.8 in )
Overall widt h 8 20 m m ( 32.3 in )
Overall height 1,200 m m ( 47.2 in )
Wheelbase 1,455 m m ( 57.3 in )
Seat height 880 m m ( 34.6 in )
Foot peg height 365 m m ( 14.4 in )
Ground clearance 28 5 m m ( 11.2 in )
Curb wei ght L 139 kg ( 306 lbs )
LA 141kg ( 311 lbs )
Maxi m um wei ght AC t ype 148 kg ( 326 lbs )
capaci t y CM t ype 145 kg ( 320 lbs )
FRAME Fram e t ype Sem i- double cradle t ype
Front suspensi on Telescopi c fork
Front axle t ravel 234 m m ( 9.2 in )
Rear suspensi on Pro - link
Rear axle t ravel 260 m m ( 10.2 in )
Front t ire size 80 / 100-21M / C 51P
Rear t ire si ze 120 / 80-18M / C 62P
Front t ire brand GP- 21F ( IRC)
Rear t ire brand GP -22R ( IRC )
Front brake Hydrauli c disc brake
Rear brake Hydrauli c disc brak e
Cast er angle 27 30 ’
Trai l lengt h 109 m m ( 4.3 in )
Fuel t ank capaci t y 7.8 lit er ( 2.06 US gal , 1.72 Im p gal)
Fuel t ank reserve capaci t y 2.0 lit er (0.53 US gal , 0.44 Im p gal)
ENGINE Cyli nder arrangem ent Si ngle cyli nder 250 inclined from vert i cal
Bore and st roke 76.0 x 63.0 m m ( 3.00 x 2.50 in )
Di splacem ent 28 6 cm ( 17.5 cu - in )
Com pressi on rat io 10.7: 1
Valve t rain Chai n driven , DOHC
Int ak e valve opens 12 BTDC at 1.0 m m ( 0.04 in ) lift
closes 31 ABDC at 1.0 m m ( 0.04 in ) lift
Exhaust valve opens 40 BBDC at 1.0 m m ( 0.04 in ) lift
closes ATDC at 1.0 m m ( 0.04 in ) lift
Lubri cat i on syst em Forced pressure and wet sum p
Oi l pum p t ype Trochoi d
Cooli ng syst em Liquid cooled
Ai r fi lt rat i on Vi scous paper filt er
Engi ne dry wei ght 35.9 kg ( 79.1 lbs )
Em ission cont rol AC t ype Crank case em ission cont rol syst em
syst em Secondary air supply syst em
Evaporat i ve em ission cont rol syst em
CM t ype Crank case em ission cont rol syst em
Secondary air supply syst em
FUEL SYSTEM Type PGM - FI
Throt t le bore 38 m m ( 1.5 in )
I
1-10
i
GENERAL INFORMATION
ITEM SPECIFICATIONS
DRIVE TRAIN Clut ch syst em Mult i -plat e , wet
Clut ch operat ion syst em Cable operat i ng
Transm i ssi on 6 speed
Pri m ary reduct ion 2.8 07 (73/ 26 )
Fi nal reduct ion 2.8 57 ( 40/ 14 )
Gear rat io 1 st 3.538 ( 46/ 13 )
2nd 2.250 ( 36/ 16 )
3rd 1.650 ( 33/ 20 )
4t h 1.346 ( 35/ 26 )
5t h 1.115 ( 29/ 26 )
6t h 0.925 ( 25/ 27 )
Gearshi ft pat t ern Lef t foot operat ed ret urn syst em
1 - N - 2-3 -4-5-6
ELECTRICAL Igni t i on syst em Full t ransi st ori zed
St art i ng syst em Elect ri c st art er m ot or
Chargi ng syst em Triple phase out put alt ernat or
Regulat or /rect i fi er FET short ed , t riple phase full-wave
rect ificat ion
Li ght i ng syst em Bat t ery
FUEL & ENGINE SPECIFICATIONS
FUEL SYSTEM
ITEM SPECIFICATIONS
Throt t le body ident ificat ion num ber GQ9UA
Idle speed 1,450 + 100 rpm
Throt t le grip freeplay 2 - 6 m m ( 0.1 0.2 in )
Fu el pressure at idle 288 300 k Pa (2.9 5 42 - 44 psi )
3.1k gf/ cm ,
Fu el pum p flow (at 12 V) 55.6 cm (1.88 US OZ , 1.96 Im p oz ) m inim um / 10 seconds
LUBRICATION SYSTEM
Unit : m m ( in )
ITEM STANDARD LIMIT
Engi ne oi l capacit y Af t er drai ni ng 1.4 lit er ( 1.5 US qt , 1.2 Im p qt )
Af t er draining / filt er change 1.5 lit er ( 1.6 US qt , 1.3 Im p qt )
Af t er di sassem bly 1.8 lit er ( 1.9 US qt , 1.6 Im p qt )
Recom m ended engi ne oil Pro Honda GN4 4 - st roke oil (U.S.A. &
Canada ) or equi valent m ot orcycle oil
API servi ce classificat ion : SJ or hi gher
JASO T903 st andard : MA
Vi scosi t y : SAE 10W- 30
Oi l pum p rot or Ti p clearance 0.15 ( 0.006 ) 0.20 ( 0.008 )
COOLING SYSTEM
ITEM SPECIFICATIONS
Coolant capaci t y Replacem ent 0.77 lit er (0.8 1US qt, 0.68 Im p qt )
Aft er di sassem bly 0.86 lit er (0.91US qt , 0.76 Im p qt )
Radi at or cap reli ef pressure 107.9 137.3 k Pa ( 1.1 1.4 k gf/ cm , 16 20 psi)
Therm ost at Begi n t o open 8 1 - 84 C ( 178 - 18 3 F )
Fully open 95 C
Valve lift 4.5 m m ( 0.2 in ) m inim um
Recom m ended ant i freeze Pro Honda HP Coolant or an equi valent high qualit y et hylene
glycol ant i freeze cont aining corrosi on prot ect ion inhibit ors
St andard coolant
1 : 1 m ixt ure wit h dist illed wat er
concent rat i on
1-11
i
GENERAL INFORMATION
CYLINDER HEAD /VALVE
Unit : m m ( in )
ITEM STANDARD LIMIT
Cyli nder com pressi on at 490 rpm 1,294 k Pa ( 132 k gf/cm ,188 psi )
Valve clearance IN 0.16 + 0.03 (0.006 + 0.001)
EX 0.27 + 0.03 ( 0.011 + 0.001)
Cam shaft Cam lobe height IN 30.6878 - - 30.8478 ( 1.208 18 - 1.21448 ) 30.6578 ( 1.20700 )
EX 30.879 - 31.039 ( 1.2157 - 1.2220 ) 30.8 49 ( 1.2145 )
Rock er arm , rock er arm Shaft O.D. IN /EX 9.972-9.98 7 ( 0.3926 -0.3932 )
shaft Arm I.D. IN /EX 10.000 - 10.015 ( 0.3937 -0.3943 ) 10.055 ( 0.3959 )
Valve ,valve gui de Valve stem O.D. IN -
4.475 -4.490 ( 0.1732 -0.1768 ) 4.465 ( 0.1758 )
EX 4.465 -4.48 0 ( 0.1758 - 0.1764 ) 4.455 ( 0.1754 )
Valve gui de I.D. IN /EX 4.500 4.512 (0.1772 -0.1776 ) 4.542 ( 0.178 8 )
Valve guide proj ect ion IN / EX
13.8 - 14.0 ( 0.54 -0
0.55
. )
above cyli nder head
Valve seat widt h IN / EX -
0.90 - 1.10 (0.035 -0.043 ) 1.5 ( 0.06 )
Valve spring free lengt h Inner 35.24 ( 1.38 7) 34.54 ( 1.360
Out er 39.85 (1.569) 39.05 ( 1.537 )
Cyli nder head warpage 0.10 ( 0.004 )
CYLINDER / PISTON
Unit : m m ( in )
ITEM STANDARD LIMIT
Cyli nder 1.D - 76.010 ( 2.9921 - 2.9926 )
76.000 - 76.1 ( 3.00 )
Warpage 0.10 ( 0.004 )
Pist on , Pist on pin Pist on O.D. at 11m m (0.4 in ) from 75.960 - 75.98 0 ( 2.9905 - 2.9913 )
bot t om of skirt 75.8 8 ( 2.98 7 )
Pi st on pin bore I.D. 17.002 - - 17.008 ( 0.6694 -0.6694 ) 17.02 ( 0.670 )

Pi st on pin O.D. 16.994 - 17.000 ( 0.6691 -0.6693 ) 16.98 ( 0.669 )
Pi st on rings Pist on ring end gap | 0.28 - 0.38 ( 0.011 0.015 ) 0.48 ( 0.019 )
Second 0.40 -0.55 (0.016 -0.022 ) 0.65 (0.026 )
Oi l
0.20 0.70 ( 0.008 0.028 ) 0.9 ( 0.04 )
( si de rail )
Pi st on ring - t o - ring Top 0.040 - 0.080 (0.0016 - 0.0031)
groove clearance Second 0.015 -0.050 ( 0.0006 -0.0020 )
Connect i ng rod sm all end I.D. 17.016 - - 17.034 ( 0.6699 -0.6706 ) 17.044 (0.6710 )
CLUTCH/ GEARSHIFT LINKAGE
Unit : m m ( in )
ITEM STANDARD LIMIT
Clut ch lever freeplay 10 -20 ( 0.4 -0.8 )
Clut ch Di sc t hi ckness 2.92 -3.08 (0.115 -0 .121) 2.70 ( 0.106 )
Plat e warpage 0.15
Clut ch spring free lengt h 35.79 ( 1.409 ) 34.79 ( 1.370 )
Clut ch out er guide I.D. 19.978 - 19.992 ( 0.78 65 -0.78 71)
Mai nshaft O.D. at clut ch out er gui de 19.966 - 19.98 0 ( 0.78 61 0.78 66 )
ALTERNATOR /STARTER CLUTCH
Unit : m m ( in )
ITEM STANDARD LIMIT
St art er driven gear O.D. 51.705 - 51.718 ( 2.0356 - 2.0361
)
1-12
i
GENERAL INFORMATION
CRANKCASE / CRANKSHAFT/BALANCER
Unit : m m ( in )
ITEM STANDARD LIMIT
Connect i ng rod Si de clearance 0.05 -0.50 ( 0.002 -0.020 ) 0.60 ( 0.024 )
Radi al clearance -0.012 ( -0.0005 ) 0.05 (0.002 )
Crankshaft Runout Ri ght 0.03 ( 0.001)
Lef t 0.02 ( 0.001 )
Main j ournal oil clearance 0.018 -0.045 ( 0.0007 -0.0018 ) 0.05 ( 0.002 )
TRANSMISSION
Unit : m m ( in )
ITEM STANDARD LIMIT
Transm i ssi on Gear I.D. M5 , M6 23.000 - 23.021 ( 0.9055 - - 0.9063 )
C1 23.020 - 23.041 ( 0.9063 - 0.9071)
C2 25.000 - 25.021 (0.9843 -0.98 51 )
C3 , C4 28 .000 - 28 .021 ( 1.1024 - 1.1032 )
Gear bushing O.D. M5 , M6 22.959 - 22.980 ( 0.9039 0.9047 )
C1 22.98 4 - 23.005 ( 0.9049 - 0.9057)
C2 24.959 - 24.980 ( 0.9826 -0.98 35 )
C3, C4 27.959 27.98 0 ( 1.1007 1.1016 )
M5 ,9 C1 - 20.021 ( 0.78 74 -0.78
20.000 - - 82 )
Gear bushing I.D.
C2 22.000 - 22.021 (0.8 661 -0.8 670 )
C3 25.000 - 25.021( 0.9843 -0.98 51)
Mai nshaft O.D. at M5 bushing 19.959 - 19.98 0 ( 0.78 58 -0.78 66 )
Count ershaft O.D. at C1bushing 19.959 - 19.98 0 (0.7858 -0.78 66 )
at C2 bushing -
21.959 21.98 0 ( 0.8645 0.8854 )
at C3 bushing 24.959 - 24.980 ( 0.9826 -0.98 35 )
Shi ft fork , Fork I.D. 12.000 12.018 ( 0.4724 0.4731)
shi ft fork Fork shaft O.D. 11.957 11.968 ( 0.4707 -0.4712 )
shaft Fork claw t hi ckness -
4.93 - 5.00 ( 0.194 -0.197 ) 4.8 3 ( 0.190 )
Shi ft drum Shi ft drum O.D. Lef t si de -
13.966 - 13.984 (0.5498 -0.5506 )
Shift drum j ournal I.D. Left si de 14.000 14.027 (0.5512 - 0.5522 )
FRAME & CHASSIS SPECIFICATIONS
FRONT WHEEL/ SUSPENSIONISTEERING
Unit : m m ( in )
ITEM STANDARD LIMIT
Cold t ire Up t o 90 kg ( 200 lbs ) load 150 k Pa ( 1.5 k gf / cm ,22 psi )
pressure Up to m axim um 150 k Pa ( 1.5 k gf / cm ,22 psi ) -
wei ght capaci t y
Axle runout 0.2 ( 0.01)
Wheel rim Radi al 2.0 ( 0.08 )
runout Axi al 2.0 ( 0.08 )
Fork ( Right ) Spri ng free lengt h Rally t ype 544.9 ( 21.45 ) 534.0 ( 21.02 )
St andard t ype 536.1 ( 21.11) 525.4 ( 20.68 )
Recom m ended fluid Fork Fluid (viscosit y : 10W )
Fluid level Rally t ype 182 ( 7.2 )
St andard t ype 171 ( 6.7 )
Fluid capacit y Rally t ype 626 + 2.5 cm
( 21.2 + 0.08 US oz , 22.0 + 0.08 Im p )
St andard t ype 638 + 2.5 cm
( 21.6 + 0.08 US oz ,22.5 + 0.08 Im p )
Fork ( Left) Recom m ended fluid Fork Fluid ( viscosit y : 10W )
Flui d level 54 ( 2.1)
Flui d capaci t y 696 + 2.5 cm
( 23.5 + 0.08 US oz , 24.5 + 0.08 Im p )
1-13
REAR WHEEL / SUSPENSION
Unit : m m ( in )
ITEM STANDARD LIMIT
Cold t ire pressure Up to 90 k g ( 200 lbs ) load 150 k Pa ( 1.5 kgf / cm ,22 psi )
Up to m axim um wei ght capaci t y 175 k Pa ( 1.5 kgf/ cm ,22 psi )
Axle runout 0.2 ( 0.01)
Wheel rim runout Radi al 2.0 ( 0.08 )
Axi al 2.0 ( 0.08 )
Dri ve chain slack 50 -55 ( 2.0 - 2.2 ) 57 ( 2.2 )
Dri ve chain size /link DID 520VF- 106LE
HYDRAULIC BRAKE
Unit : m m ( in )
ITEM STANDARD LIMIT
Front Speci fi ed brak e fluid DOT 3 or 4 brake fluid
Brak e disc t hi ckness 3.5 +0.2 ( 0.14 + 0.01) 3.0 ( 0.12 )
Brak e disc warpage 10.30 ( 0.012 )
Mast er cylinder I.D. 12.700 12.743 (0.5000 - 0.5017 )
Mast er pist on O.D. 12.657 - 12.684 ( 0.4983 -0.4994 )
Cali per cyli nder I.D. 27.000 - 27.050 ( 1.0630 - 1.0650 )
26.918 --
Cali per pist on O.D. 26.968 ( 1.0598 1.0617)
Rear Speci fi ed brak e fluid DOT 3 or 4 brake fluid
Brak e di sc t hi ckness 4.5 + 0.2 ( 0.18 + 0.01) 4.0 ( 0.16 )
Brak e disc warpage 0.30 ( 0.012 )
Mast er cyli nder I.D. 12.700 12.743 ( 0.5000 - 0.5017)
Mast er pist on O.D. 12.657 12.684 (0.4983 -0.4994 )
Cali per cyli nder I.D. 27.000 - 27.050 ( 1.0630 1.0650 )
Cali per pist on O.D. 26.918 - 26.968 ( 1.0598 - 1.0617)
ELECTRICAL SYSTEM SPECIFICATIONS
PGM - FI SYSTEM
ITEM SPECIFICATIONS
Fuel inj ect or resi st ance 11 13 12
PAIR cont rol solenoi d valve resi st ance ( 20 C /68 F ) 24 28 12
EVAP purge cont rol solenoid AC t ype only 30-34
valve resi st ance ( 20 C/ 68 F)
ABS SYSTEM
Unit : m m ( in )
ITEM SPECIFICATIONS
Ai r gap Front 0.8 1.4 ( 0.03 0.06 )
Rear 0.7 - 1.3 (0.03 -0.05 )
IGNITION SYSTEM
ITEM SPECIFICATIONS
Spark plug SIMR8 A9 ( NGK )
Spark plug gap 0.8 0.9 m m ( 0.03 -0.04 in )
Ignit ion coil peak volt age 100 V m inim um
CKP sensor peak volt age 0.7 V m inim um
Ignit ion t im ing ( " F "m ark ) 10 BTDC at idle speed
1-14
i
GENERAL INFORMATION
BATTERYICHARGING SYSTEM
ITEM SPECIFICATIONS
Bat t ery Type YTZ8 V
Capaci t y 12 V - 7 Ah ( 10 HR )
Volt age Fully charged 12.8 V m inim um
Needs chargi ng Below 12.4 V
Norm al - 10 h
0.7 A / 5 -
Chargi ng
current Qu i ck 3.5 A / 1 h
Current leak age 0.105 m A m axim um
Alt ernat or Capaci t y 0.34 kW /5,000 rpm
Chargi ng coil resist ance - 1.022
0.1 -
( 20 C /68 F )
LIGHTS /METERS / SWITCHES
ITEM SPECIFICATIONS
Bulbs Headli ght St andard t ype 12 V - 55/ 60 W
Brak e / t aillight 12 V - 21/ 5 W
Front posit ion / turn signal light 12 V - 5/ 21 W
Rear t urn signal light 12 V - 21 W
Fuse Mai n fuse 30 A
Su b fuse St andard t ype 10 Ax 5
Rally t ype 10 A X6
ABS fuse ABS t ype only 10 A, 30A x 2
1-15
i
GENERAL INFORMATION
TORQUE VALUE
Each fast ener should be t ight ened t o t he st andard t orque value except t he fast eners speci fi ed t orque value .
Q TY: Quant i t y , DIA: Thread di am et er [ m m ] , TRQ: Ti ght eni ng t orque [ N.m ( kgf m , lbf.ft )]
STANDARD TIGHTENING TORQUE
FASTENER TYPE TRQ FASTENER TYPE TRQ

5 m m hex bolt and nut 5.2 ( 0.5 , 3.8 ) 5 m m screw 4.2 (0.4 7, 3.1)
6 m m hex bolt and nut 10 ( 1.0 , 7 ) 6 m m screw 9.0 (0.9 ,5 6.6 )
8 m m hex bolt and nut 22 (2.2 , 16 ) 6 m m flange bolt 12 ( 1.2 , 9 )
10 m m hex bolt and nut 34 ( 3.5 , 25 ) 8 m m flange bolt and nut 27 (2.8 , 20 )
12 m m hex bolt and nut 54 5.5 , 40 ) 10 m m flange bolt and nut 39 ( 4.0 ,29 )
FUEL PUMP UNIT

ITEM Q’TY DIA TRO REMARKS
Fuel pum p set t ing plat e nut 4 6 12 ( 1.2 , 9 ) 2-4
FUEL TANK
ITEM Q’TY DIA TRQ REMARKS

Fu el filler cap bolt (Rally t ype only ) 3 4 1.8 ( 0.2 , 1.3 )
AIR CLEANER

Ai r cleaner cover screw 4 5 1.2 ( 0.1 , 0.9 )
Ai r cleaner housing m ount ing bolt 1 6 7.0 (0.7 , 5 )
Air cleaner connect i ng hose band screw 1 4 1.5 (0.2 , 1.1)
THROTTLE BODY
Throt t le cable A lock nut (t hrot t le body side ) 1 6 3.0 ( 0.3 , 2.2 )
Throt t le cable B lock nut (t hrot t le body side) 1 6 3.0 ( 0.3 , 2.2 )
Sensor unit t orx screw 3 5 3.4 ( 0.3 , 2.5 )
IACV set t ing plat e t orx screw 2 4 2.1 ( 0.2 , 1.5 )
Throt t le cable holder screw 2 5 3.4 ( 0.3 , 2.5 )
Inj ect or j oint m ount ing bolt 2 5 5.1 ( 0.5 , 3.8 )
SECONDARY AIR SUPPLY SYSTEM

PAIR check valve cover bolt 2 5 5.2 ( 0.5 , 3.8 )
LUBRICATION SYSTEM

Oil drain bolt 1 12 24 ( 2.4 , 18 )
COOLING SYSTEM

Cooli ng fan nut 1 3 1.0 ( 0.1 3, 0.7) Apply locking agent.
Fan m ot or screw 3 4 2.7 ( 0.3 , 2.0 )
Wat er pum p i m peller 1 7 10 ( 1.0 , 7)
CYLINDER HEAD
Crank shaft hole cap 1 30 8.0 (0.8 , 5.9 ) Apply engi ne oil.
Ti m i ng hole cap 1 14 6.0 ( 0.6 , 4.4 ) Apply engi ne oi l .
Cyli nder head cover bolt 2 6 10 ( 1.0 , 7)
Cam chain t ensi oner lift er plug 1 6 4.2 ( 0.4 , 3.1 )
Cam shaft holder m ount ing bolt 8 6 12 ( 1.2 , 9 ) Apply engi ne oil .
Cyli nder head m ount i ng nut 4 10 45 (4.6 , 33 ) Apply engi ne oil .
Cyli nder head sealing bolt 2 12 15 ( 1.5 , 11)
1-16
i
GENERAL INFORMATION
CYLINDER / PISTON
Cyli nder st ud bolt 4 10 2-29
CLUTCH/ GEARSHIFT LINKAGE

Clut ch cent er lock nut 1 16 108 ( 11.0, 80 ) Lock nut; replace with a new
one and st ake. Apply engi ne
oil .
Clut ch lift er plat e bolt 3 6 12 ( 1.2 , 9 )
Pri m ary dri ve gear lock nut 1 16 108 ( 11.0 , 80 ) Apply engi ne oil .
6 *
Shi ft drum st opper arm bolt 1 10 ( 1.0 , 7 ) Apply locking agent.*
Shift drum st opper plat e bolt 1 6 10 ( 1.0 , 7 ) Apply locking agent.*

St art er clut ch socket bolt 6 8 30 ( 3.1, 22 ) Apply locking agent .
Flywheel bolt 1 12 128 ( 13.1, 94 ) Apply engi ne oil .
CKP sensor m ount ing sock et bolt 2 6 10 ( 1.0 3, 7 ) Apply locking agent . *
St at or m ount ing socket bolt 3 6 10 ( 1.0 , 7 )
CRANKCASE / TRANSMISSION /BALANCER

Cam chain t ensi oner pivot bolt 1 6 10 ( 1.0 , 7 ) Apply locking agent . *
Balancer shaft nut 1 14 69 (7.0 , 51 ) Apply engine oil.
ENGINE UNIT
Engi ne hanger plat e bolt 4 8 27 (2.8 , 20 )
Engi ne hanger nut Front upper 1 10 55 ( 5.6 , 41 )
Front lower 1 10 55 ( 5.6 , 41)
Rear upper 1 10 45 ( 4.6 , 33 )
Rear lower 1 10 45 ( 4.6 , 33 )
Dri ve sprock et fixing plat e bolt 2 6 10 ( 1.0 , 7 )
BODY PANELS

Wi nd screen screw ( Rally t ype only ) 3 5 0.75 (0.1, 0.6 )
Hook bolt 4 8 21 ( 2.1 9, 15 )
Brak e lever pivot bolt 1 6 1.0 (0.1, 0.7 )
Brake lever pivot nut 1 6 5.9 ( 0.6 , 4.4 )
NNW
Bat t ery box bolt 3 6 7.0 ( 0.7 , 5.2 )
Rearvi ew m irror lock nut 2 10 20 ( 2.0 , 15 ) Left -hand t hreads
Rearvi ew m irror adapt or bolt 2 10 20 ( 2.0 , 15 )
SIDESTAND
Si dest and pivot bolt 1 10 10 ( 1.0 , 7 )
Si dest and pivot nut 1 10 30 ( 3.1, 22 ) Self lock nut
Si dest and swit ch bolt 1 6 10 ( 1.0 , 7 ) Pre -coat ed (ALOC ) bolt , re
place wit h a new one.
1-17
EXHAUST PIPE/ MUFFLER

Exhaust pipe st ud bolt 2 8 > 3-24
Exhaust pipe j oint nut 2 8 18 ( 1.8 , 13 )
Muffler m ount i ng bolt 2 8 32 ( 3.3 , 24 )
Muffler band bolt 1 8 23 ( 2.3 , 17)
Exhaust pipe prot ect or bolt 2 6 12 ( 1.2 , 9 )
( St andard t ype only )
FRONT WHEEL
Front axle bolt 1 14 69 ( 7.0 , 51)
ON
Front axle holder bolt 2 8 22 ( 2.2 , 16 )
Front brake disc bolt 6 20 ( 2.0 , 15 ) Pre - coat ed ( ALOC) bolt , re
place wit h a new one .
Front spoke 36 BC 3.2 3.7 ( 0.4 , 2.7)
FORK

Top bri dge pinch bolt 4 8 29 ( 3.0 , 21)
Bot t om bri dge pinch bolt 4 8 29 ( 3.0 , 21 )
Fork cent er bolt 1
ONNI 8 20 ( 2.0 , 15 ) Apply locking agent .
Fork rod nut 2 10 20 ( 2.0 , 15 )
Fork cap 2 50 35 ( 3.6 , 26 )
Fork prot ect or bolt 6 6 7.0 (0.7 , 5.2 ) Pre - coat ed ( ALOC) bolt , r e
HANDLEBAR

Lef t handlebar swit ch screw 2 5 2.5 ( 0.3 , 1.8 )
Ri ght handlebar swit ch screw 2 5 2.5 ( 0.3 , 1.8 )
STEERING STEM
St eeri ng stem nut 1 24 103 ( 10.5 , 76 )
St eeri ng st em adj ust ing nut 1 26 3-33
Front brake hose gui de bolt 2 6 10 ( 1.0 , 7)
Front brak e hose clam p bolt 2 6 10 ( 1.0 , 7 )
REAR WHEEL

Rear axle nut 1 16 88 ( 9.0 , 65 ) Self lock nut
ANO
Dri ven sprocket nut 8 32 ( 3.3 , 24 ) Self lock nut
Dri ve chain adj ust er lock nut 8 27 (2.8 >, 20 ) UBS nut
Rear brake disc bolt 8 42 ( 4.3 , 31 ) Pre - coat ed ( ALOC) bolt , re
Rear spoke 32 BC 3.2 3.7 ( 0.4 , 2.7)
1-18
REAR SUSPENSION

Shock absorber upper nut 1 10 44 ( 4.5 5, 32 ) Self lock nut
Shock absorber lower nut 1 10 44 ( 4.5 , 32 ) Self lock nut
Shock link bolt ( Fram e side ) 1 10 44 ( 4.5 , 32 ) Self lock nut
Shock link nut ( Shock arm side ) 1 10 44 ( 4.5 , 32 ) Self lock nut
Shock arm -t o - swingarm nut 1 12 74 (7.5 , 55 ) Self lock nut
Apply engi ne oil .
Swi ngarm pivot nut 1 14 88 ( 9.0 , 65 ) Self lock nut
Drive chain slider bolt 4 5 4.2 ( 0.4 , 3.1 ) Pre -coat ed ( ALOC) bolt , re
Dri ve chain slider side bolt 1 5 4.2 ( 0.4 , 3.1) Pre - coat ed ( ALOC) bolt , re
Dri ve chain guide bolt 2 6 10 ( 1.0 , 7) Pre - coat ed ( ALOC ) bolt , re
O place wit h a new one .
Dri ve chain sli der gui de nut 2 6 2.5 (0.3, 1.8 ) Self lock nut
2 O
5
Rear brak e hose guidem ount i ng screw 1.2 (0.1, 0.9 )
FRONT BRAKE

Front brak e hose oil bolt 2 10 34 ( 3.5 , 25 )
Frontm ast er cylinder holder bolt 2. 6 9.8 ( 1.0 , 7.2 )
Front m ast er cyli nder reservoi r cover screw 2 4 1.5 ( 0.2 , 1.1)
Front brake light swit ch screw 1 4 1.2 ( 0.1, 0.9 )
Front brak e caliper m ount i ng bolt 2 8 30 ( 3.1, 22 ) Pre - coat ed ( ALOC) bolt , re
place wit h a new one.
Front brak e cali per bleed valve 1 8 5.4 (0.6 , 4.0 )
Front brak e cali per t orque nut 1 8 22 ( 2.2 , 16 ) Apply locking agent .
Front brake cali per pin bolt 1 8 17 ( 1.7 , 13 )
Front brak e pad hanger pin 1 10 17 ( 1.7 , 13 )
REAR BRAKE

Rear brake hose oil bolt 2 10 34 ( 3.5 , 25 )
Rear m ast er cyli nder bolt 2 6 14 ( 1.4 , 10 ) Pre - coat ed (ALOC) bolt , re
place with a new one .
Rear m ast er cyli nder reservoi r cover screw 2 4 1.5 (0.2 , 1.1)
Rear m ast er cyli nder push rod nut 1 8 17 ( 1.7 , 13 )
Rear brake cali per nut 1 8 22 ( 2.2 , 16 ) Apply locking agent .
Rear brak e caliper pin bolt 1 8 12 ( 1.2 , 9 ) Apply locking agent .
Rear brake pad hanger pin 1 10 17 ( 1.7 , 13 )
Rear brake cali per bleed valve 1 8 5.4 ( 0.6 , 4.0 )
PGM - FI SYSTEM

ECT sensor 1 12 25 ( 2.5 , 18 )
O2 sensor 1 12 25 ( 2.5 , 18 )
Bank angle sensor nut 2 6 9.0 ( 0.9 , 6.6 )
IGNITION SYSTEM

Spark plug 1 10 16 ( 1.6 , 12 )
ELECTRICAL STARTER
Negat i ve brush screw 1 5 3.7 (0.4 , 2.7)
St art er m ot or assem bly bolt 2 5 4.9 ( 0.5 , 3.6 )
Gear posit ion swit ch 1 6 10 ( 1.0 , 7 )
1-19
i
GENERAL INFORMATION
ABS
Brak e pipe j oint nut 4 10 14 ( 1.4 , 10 )
LIGHTING SYSTEM
A NNWA
Headli ght unit m ount ing bolt ( Rally t ype ) 4 6 8.5 (0.9 ,6.3 )
Headli ght unit m ount ing screw ( Rally t ype ) 3 5 1.2 ( 0.1,5 0.9 )
Brake /t aillight m ount i ng bolt 2 6 4.5 ( 0.5 , 3.3 )
Turn signal light screw ( Rally t ype ) 2 6 2.5 (0.3 , 1.8 )
Turn signal light screw ( St andard t ype ) 4 6 2.5 (0.3 , 1.8 )
Turn signal light lens screw 4. 4 1.5 (0.2 , 1.1)
COMBINATION METER
Met er screw 4 5 1.0 ( 0.1, 0.7)
ELECTRICAL COMPONENT

Igni t i on swit ch bolt 2 8 24 ( 2.4 , 18 ) One-way bolt , replace wit h a
new one .
OTHERS
Throt t le cable A lock nut ( grip si de ) 1 10 1.5 ( 0.2 , 1.1)
Throt t le cable A lock nut (adj ust nut ) 1 7 3.8 ( 0.4 , 2.8 )
Throt t le cable B lock nut ( grip si de ) 1 12 1.5 ( 0.2 , 1.1)
Brake / t aillight cover m ount i ng screw 2 5 4.5 ( 0.5 , 3.3 )
Headli ght unit plat e screw ( St andard t ype) 2 5 1.5 ( 0.2 , 1.1)
Rear reflect or nut 1 5 1.7 ( 0.2 , 1.3 ) Self lock nut
Si de reflect or nut 2 6 1.7 ( 0.2 , 1.3 ) Self lock nut
Li cense light m ount i ng screw 2 4 . 2.0 ( 0.2 , 1.5 )
Clut ch lever pivot bolt 1 6 1.0 ( 0.1 3, 0.7 )
Clut ch lever pivot nut 1 6 5.9 ( 0.6 3, 4.4 )
Gearshi ft spindle ret urn spring pin 1 8 30 ( 3.1, 22 ) Apply locking agent.
.
* : Apply locking agent t o t he t hreads as shown .
6.5 + 1.0 m m 2.0 + 1.0 m m
Lock Apply this area .

Do not apply this area .
The bolt shown is t ypical.
1-2 0
i
GENERAL INFORMATION
SPECIAL TOOL LIST
TOOL No./ TOOL NAME U.S.A. TOOL No./ U.S.A. TOOL NAME
Fu el & Engi ne
07406-0040004 Fuel pressure gauge 07406-004000B
070MJ-K260100 Fuel pressure gauge at t achm ent 07 AMJ-K26A100 (Use Wit h : 07AMJ-HW1A100 , 07AAJ
SOMA200 , 07406-004000C )
07OMF- KVS0300 Fu el pum p case rem over
07OMZ -0010300 SCS connect or 070MZ - 001A300
07HMF- KR10101 Oi l seal dri ver 30 x 36 m m
07709-0010001 Ti m i ng cap wrench
070MG - 0010100 Cam chain t ensi oner lift er st opper 07 AMG-001A100 or 07AMG-MFJA100
07757-0010000 Valve spring com pressor
07959 - KM30101 Valve spring com pressor at t achm ent
07HMH -ML00101 Valve gui de ream er , 4.5 m m 07HMH -M LOO10B
07HMD -ML00101 Valve gui de dri ver , 4.3 m m
07743-0020000 Valve gui de dri ver 07742-0010100
07724-0050002 Clut ch cent er holder equi valent com m ercially available in U.S.A.
07724-0010200 Gear holder , M1.5 st rap wrench equi valent com m ercially avai lable in U.S.A.
07PAF - 0010620 Pi lot collar , 16 m m U.S.A.Use com m ercially avai lable t ool
07746-0050200 Beari ng rem over head , 10 m m U.S.A. Use com m erci ally avai lable t ool
07725-0040001 Flywheel holder equi valent com m erci ally available in U.S.A.
07733-0020001 Flywheel puller 07933-2160000

07724-0010100 Gear holder ,M2.5 U.S.A. use 07724-001A100
070MF-KYJO100 Met al inst aller set U.S.A. use 07OMF-KYJA100
Fram e & Chassi s
07746-0050500 Rem over head , 17 m m
07746-0050100 Beari ng rem over shaft equi valent com m ercially avai lable in U.S.A.
07746-0010100 At t achm ent , 32 x 35 m m
07746-0040400 Pi lot 17 m m
07749-0010000 Dri ver
07KMD -KZ30100 Fork seal dri ver, 45.2 m m 07KMD- KZ3010A
07NMD - KZ30101 Fork seal dri ver at t achm ent 07NMD -KZ3010A
07916-3710101 St eeri ng stem socket 07702-0020001
07948 -4630100 Ball race rem over 07953 -M J1000B
07GMD -KS40100 Ball race rem over 36 x L340
07946-4300101 Dri ver , 28 m m I.D. 07946 -MB0000D and 07946 -KA6000A
07746-0010300 At t achm ent, 42 x 47 m m
07914 - SA50001 Snap ring pliers 07914 -SA50001
Elect ri cal Syst em
07HGJ-0020100 Peak volt age adapt er com m erci ally available digit alm ult i m et er
( i m pedance 10M )
1-2 1
CABLE & HARNESS ROUTING
Rally t ype:
ABS :
5.5 - 6.5 m m
FRONT BRAKE HOSE
FRONT WHEEL SPEED

SENSOR WIRE
CLUTCH CABLE FRONT BRAKE HOSE

DE
THROTTLE
CABLE
RIGHT HANDLEBAR
LEFT HANDLEBAR SWITCH WIRE
SWITCH WIRE
1-2 2
i
GENERAL INFORMATION
Except ABS:
5.5 - 6.5 m m
IGNITION
SWITCH WIRE
CLUTCH CABLE FRONT

BRAKE HOSE
THROTTLE
CABLE
RIGHT HANDLEBAR
LEFT HANDLEBAR SWITCH WIRE
SWITCH WIRE
1-2 3
i
ABS : COMBINATION METER

28P CONNECTOR
REAR ABS CANCEL

SWITCH WIRE
REAR ABS CANCEL SWITCH

2P CONNECTOR
Except ABS :
COMBINATION METER
28P CONNECTOR
1-2 4
TO
LEFT FRONT TURN

RIGHT FRONT TURN SIGNAL LIGHT WIRE
SIGNAL LIGHT WIRE
HEADLIGHT 4P
CONNECTOR
RIGHT FRONT TURN SIGNAL LEFT FRONT TURN SIGNAL
LIGHT 2P CONNECTORS LIGHT 2P CONNECTORS
HEADLIGHT WIRE
COMBINATION
METER WIRE
TE
FRONT SUB
HARNESS
1-2 5
ABS :
FRONT WHEEL SPEED

BE SENSOR WIRE
Align FRONT BRAKE HOSE
FRONT WHEEL SPEED

SENSOR WIRE
Align
FRONT BRAKE HOSE
1-2 6
Except ABS
Align FRONT BRAKE HOSE
FRONT BRAKE HOSE
Align
1-2 7
(i ) GENERAL INFORMATION
ABS :
2 mm
3 m m m inim um
10
FRONT WHEEL SPEED

SENSOR WIRE
5 m m m inim um
20 - 24 FRONT WHEEL SPEED

Parallel SENSOR WIRE
45
FRONT BRAKE HOSE

FRONT BRAKE HOSE
FRONT BRAKE HOSE
THROTTLE
CABLE
CLUTCH CABLE
RIGHT HANDLEBAR
SWITCH WIRE
IGNITION
FRONT BRAKE HOSE SWITCH WIRE
LEFT HANDLEBAR
SWITCH WIRE
1-2 8
i
GENERAL INFORMATION
Except ABS :
2 mm
3 m m m inim um
THROTTLE
5 m m m inim um CABLE
20 - 24
Parallel
FRONT BRAKE HOSE
THROTTLE
CABLE
CLUTCH CABLE
RIGHT HANDLEBAR
SWITCH WIRE
IGNITION
SWITCH WIRE
LEFT HANDLEBAR
SWITCH WIRE
1-2 9
i
GENERAL INFORMATION
ABS :
FRONT BRAKE HOSE

Cont act
10
ABS :
FRONT BRAKE HOSE
FRONT WHEEL SPEED

SENSOR WIRE
RIGHT HANDLEBAR
SWITCH WIRE
ABS :
FRONT BRAKE HOSE
THROTTLE
CABLE
FRONT WHEEL SPEED

SENSOR WIRE
1-3 0
i
GENERAL INFORMATION
FRONT BRAKE HOSE (ABS )

IGNITION
SWITCH WIRE
Cont act
OG
ED
LEFT HANDLEBAR
SWITCH WIRE
CLUTCH CABLE
FRONT SUB HARNESS

12P CONNECTOR
FRONT SUB HARNESS

4P CONNECTOR
HT
FRONT SUB HARNESS

12P CONNECTOR
FRONT SUB
HARNESS
1-3 1
i
GENERAL INFORMATION
ABS : LEFT HANDLEBAR

SWITCH WIRE
RESERVE TANK
OVERFLOW HOSE
IGNITION
SWITCH WIRE
ECM 33P
LIGHT
CONNECTOR
HANDLEBAR
SWITCH 14P
CONNECTOR
6
IGNITION SWITCH 3P
RADIATOR CONNECTOR
SIPHON HOSE
Cont act
BANK ANGLE SENSOR

2P CONNECTOR
REGULATOR RECTIFIER
5P CONNECTOR
1-3 2
ABS :
RESERVE TANK
OVERFLOW HOSE
DI
WATER HOSE CLUTCH CABLE
IGNITION RADIATOR PAIR HOSE

SWITCH WIRE SIPHON HOSE
ECM WIRE
HORN WIRE
ABS MODULATOR WIRE

IGNITION COIL
WIRE CONNECTOR
( St raight t ype )
LEFT HANDLEBAR
SWITCH WIRE
IGNITION COIL
WIRE CONNECTOR
( L t ype)
1-3 3
.
25 25
SPARK PLUG
WIRE
1-3 4
24
RESERVE TANK )
OVERFLOW HOSE
IGNITION
SWITCH WIRE
WIRE HARNESS
LEFT HANDLEBAR
SWITCH WIRE
RADIATOR
SIPHON HOSE PAIR HOSE
1-3 5
THROTTLE
CABLE
RESERVE TANK
OVERFLOW HOSE
IF
RIGHT HANDLEBAR
SWITCH WIRE RIGHT HANDLEBAR
WIRE HARNESS SWITCH 10P
CONNECTOR
1-3 6
FAN MOTOR 2P
CONNECTOR
FRONT WHEEL SPEED

SENSOR 2P
CONNECTOR
PAIR CONTROL
SOLENOID VALVE 2P
CONNECTOR
Paint m ark Paint m ark

O2 SENSOR 2P CONNECTOR
1-3 7
i
GENERAL INFORMATION
Align
60 - 120
Right
Align
Front
Align
Left
60 - 120
60 - 100
Right
Front
Right -30 Front

Mark and
cover t op
Front
1-3 8
i
GENERAL INFORMATION
SENSOR UNIT 5P
CONNECTOR
FUEL TANK -to - EVAP

CANISTER HOSE ( EVAP )
O2 SENSOR WIRE
ECT SENSOR 3P
CONNECTOR
12 m m
7 mm
1-3 9
RESERVE TANK CLUTCH THROTTLE

EVAP :
CABLE CABLE
OVERFLOW HOSE
FUEL PUMP
UNIT 5P
CONNECTOR
FUEL FEED
HOSE
FUEL EVAP SOLENOID VALVE -t o

INJECTOR 2P CYLINDER HEAD HOSE
CONNECTOR
DRAIN HOSE
FUEL TANK -to - EVAP

IACV 4P
CANISTER HOSE
CONNECTOR
CLUTCH THROTTLE
Except EVAP: RESERVE TANK
CABLE
OVERFLOW HOSE CABLE
FUEL PUMP
UNIT 5P FUEL FEED
CONNECTOR HOSE
FUEL
INJECTOR 2P
CONNECTOR
DRAIN HOSE
FUEL TANK IACV 4P

BREATHER HOSE CONNECTOR
1-40
i
GENERAL INFORMATION
FUEL PUMP
UNIT 5P
CONNECTOR
Es
FUEL FEED
HOSE
Apply
engine oil
13 m m
1-41
ALTERNATOR WIRE GEAR POSITION

SWITCH WIRE
ALTERNATOR WIRE
llo
GEAR POSITION SWITCH

8P CONNECTOR
GEAR POSITION
SWITCH WIRE
SIDESTAND
SWITCH WIRE
oc
GEAR POSITION
SWITCH WIRE
DRAIN HOSE
EVAP CANISTER
DRAIN HOSE
SIDESTAND
SWITCH WIRE
1-42
REAR WHEEL
ALTERNATOR WIRE REAR WHEEL SPEED WIRE HARNESS
SPEED SENSOR 2P
SENSOR WIRE CONNECTOR
TURN SIGNAL LIGHT
RELAY WIRE
SIDESTAND
SWITCH 2P
CONNECTOR
SIDESTAND REAR WHEEL

SWITCH WIRE SPEED SENSOR 2P
CONNECTOR
WIRE HARNESS
TURN SIGNAL
LIGHT RELAY
CONNECTOR
SIDESTAND
SWITCH WIRE STARTER
RELAY 4P
CONNECTOR
BATTERY BATTERY
NEGATIVE (- ) SIDESTAND POSITIVE ( + )
CABLE SWITCH 2P CABLE
CONNECTOR
1-43
i
GENERAL INFORMATION
RESERVE TANK
EVAP:
OVERFLOW HOSE
WIRE HARNESS
EVAP CANISTER EVAP CANISTER

BREATHER HOSE BREATHER HOSE
OK
EVAP PURGE CONTROL GEAR POSITION SWITCH

SOLENOID VALVE 2P
8P CONNECTOR
CONNECTOR
Paint m ark
SENSOR UNIT 5P
CONNECTOR
EVAP CANISTER
DRAIN HOSE
1-44
i
GENERAL INFORMATION
Except EVAP :
AIR HOSE
RESERVE TANK
OVERFLOW HOSE
ST

8P CONNECTOR
SENSOR UNIT 5P
CONNECTOR
FUEL TANK DRAIN HOSE

BREATHER HOSE
FUEL TANK
BREATHER HOSE
FUEL TANK
BREATHER HOSE
1-45
VS SENSOR WIRE
WIRE
GROUND WIRE
HARNESS
VS SENSOR 3P
CONNECTOR
STARTER MOTOR CABLE
RESERVE TANK
OVERFLOW HOSE
i n
G
CRANKCASE
BREATHER
HOSE
1-46
ABS :
PAIR HOSE
AIR HOSE
Except EVAP
CRANKCASE
BREATHER
HOSE
FUEL TANK
BREATHER HOSE
REAR BRAKE
PIPE
REAR WHEEL SPEED

SENSOR WIRE
DRAIN HOSE
c
FUEL TANK
BREATHER HOSE
( except EVAP ) RESERVE TANK
OVERFLOW HOSE
EVAP CANISTER
DRAIN HOSE (EVAP)
1-47
Except ABS :
PAIR HOSE
AIR HOSE
Except EVAP
CRANKCASE
BREATHER
HOSE
FUEL TANK
BREATHER HOSE
SPRE
DRAIN HOSE
FUEL TANK
BREATHER HOSE
(except EVAP)
RESERVE TANK
OVERFLOW HOSE
EVAP CANISTER
DRAIN HOSE ( EVAP )
1-48
i
GENERAL INFORMATION
FUSE BOX
OPTION 2P
CONNECTOR HAZARD
DIODE
OPTION 4P
CONNECTOR
ABS FUSE BOX DLC OP

( ABS only ) CONNECTOR
RIGHT REAR TURN SIGNAL BRAKE / TAIL

LIGHT CONNECTORS LIGHT 3P
CONNECTOR
LEFT REAR TURN SIGNAL

LIGHT CONNECTORS
LICENCE
LIGHT WIRE
of
LICENCE
LICENSE LIGHT
LIGHT WIRE
2P
CONNECTOR
1-49
ABS :
REAR WHEEL SPEED

SENSOR WIRE
REAR BRAKE HOSE
Cont act
Except ABS:
REAR BRAKE HOSE
Cont act
1-50
St andard t ype:
Refer t o t he rally t ype except for t he st andard t ype illust rat ions
FRONT WHEEL SPEED
SENSOR WIRE
ABS :
FRONT BRAKE HOSE FRONT BRAKE HOSE

WIRE
HARNESS
Uu d LEFT FRONT
FRONT WHEEL SPEED TURN SIGNAL
SENSOR WIRE LIGHT WIRE
THROTTLE
CABLE
CLUTCH CABLE
LEFT HANDLEBAR RIGHT HANDLEBAR

SWITCH WIRE SWITCH WIRE
1-51
i
GENERAL INFORMATION
Except ABS :
WIRE
HARNESS
FRONT BRAKE HOSE
Sew
LEFT FRONT
TURN SIGNAL
LIGHT WIRE
THROTTLE
CABLE
CLUTCH CABLE
LEFT HANDLEBAR RIGHT HANDLEBAR

SWITCH WIRE SWITCH WIRE
1-52
LEFT FRONT TURN

SIGNAL LIGHT 3P
CONNECTOR RIGHT FRONT
TURN SIGNAL
RIGHT FRONT TURN LIGHT WIRE
SIGNAL LIGHT 3P
CONNECTOR
FRONT WHEEL SPEED

SENSOR WIRE
LEFT FRONT
TURN SIGNAL
LIGHT WIRE
REAR ABS CANCEL SWITCH
2P CONNECTOR
RIGHT HANDLEBAR LIGHT
SWITCH 10P HANDLEBAR
CONNECTOR SWITCH 14P
CONNECTOR
HEADLIGHT
RELAY WIRE
THROTTLE
CABLE
1
RIGHT FRONT LEFT FRONT HEADLIGHT FRONT WHEEL SPEED
TURN SIGNAL TURN SIGNAL COMBINATION 3P SENSOR WIRE
LIGHT 3P LIGHT 3P METER 28P CONNECTOR
CONNECTOR CONNECTOR CONNECTOR
FRONT BRAKE HOSE
1-53
FRONT WHEEL SPEED

SENSOR WIRE
FRONT BRAKE HOSE Cont act
CLUTCH CABLE
FRONT BRAKE HOSE
THROTTLE CABLE
FRONT WHEEL SPEED
SENSOR WIRE
1-54
WIRE HARNESS
ABS MODULATOR WIRE
FRONT
BRAKE
HOSE ( ABS )
01
15 m m m axim um
WIRE HARNESS
1-55
BANK ANGLE SENSOR

2P ( Black ) CONNECTOR
RESERVE TANK
OVERFLOW HOSE
ABS :
RADIATOR
SIPHON HOSE
Cont act
REGULATOR RECTIFIER
5P ( Black ) CONNECTOR
1-56
i
GENERAL INFORMATION
ECM 33P
CONNECTOR
RESERVE TANK RADIATOR

SIPHON HOSE
OVERFLOW HOSE
ag u k
RADIATOR
SIPHON HOSE
THROTTLE CABLE
ECM WIRE
HORN WIRE ge
CLUTCH CABLE
IGNITION COIL
WIRE CONNECTOR
89
(St raight t ype)
ABS MODULATOR WIRE
IGNITION COIL
WIRE CONNECTOR
( L t ype)
1-57
i
GENERAL INFORMATION
RESERVE TANK
OVERFLOW HOSE
WIRE HARNESS
PAIR HOSE
RADIATOR
SIPHON HOSE
1-58
EVAP :
RESERVE TANK THROTTLE

OVERFLOW HOSE CLUTCH EVAP SOLENOID VALVE -t o
CABLE
CABLE CYLINDER HEAD HOSE
FUEL PUMP
UNIT 5P
CONNECTOR
FUEL FEED
HOSE
FUEL
INJECTOR 2P
CONNECTOR
eik
FUEL TANK - to - EVAP

CANISTER HOSE IACV 4P
CONNECTOR
1-59
Except EVAP:
THROTTLE
RESERVE TANK CLUTCH CABLE
OVERFLOW HOSE CABLE
FUEL PUMP
UNIT 5P
CONNECTOR
FUEL FEED
HOSE
FUEL
INJECTOR 2P
CONNECTOR
IACV 4P
FUEL TANK
CONNECTOR
BREATHER HOSE
1-60
EVAP : RESERVE TANK

OVERFLOW HOSE
WIRE HARNESS
EVAP CANISTER
BREATHER HOSE
EVAP CANISTER
BREATHER HOSE
EVAP CANISTER
BREATHER HOSE
EVAP PURGE CONTROL

SOLENOID VALVE 2P
CONNECTOR

8P CONNECTOR
SENSOR UNIT 5P
CONNECTOR
EVAP CANISTER
DRAIN HOSE
1-61
i
GENERAL INFORMATION
Except EVAP:
ed
UT
AIR HOSE

8P CONNECTOR
SENSOR UNIT 5P FUEL TANK

CONNECTOR BREATHER HOSE
RESERVE TANK
OVERFLOW HOSE
CRANKCASE
BREATHER
HOSE
RESERVE TANK
OVERFLOW HOSE
AIR HOSE
FUEL TANK
BREATHER HOSE
FUEL TANK
BREATHER HOSE
1-62
i
GENERAL INFORMATION
EVAP :
PAIR HOSE
LOAD
ar CRANKCASE
BREATHER
D HOSE
SIDESTAND
SWITCH WIRE
ALTERNATOR
WIRE
110 m m
REAR BRAKE
PIPE
REAR WHEEL SPEED

SENSOR WIRE EVAP CANISTER RESERVE TANK
DRAIN HOSE OVERFLOW HOSE
1-63
Except EVAP : PAIR HOSE
CRANKCASE
BREATHER
SIDESTAND HOSE
SWITCH WIRE
ALTERNATOR
WIRE
110 m m
FUEL TANK RESERVE TANK

BREATHER HOSE OVERFLOW HOSE
1-64
i
i
GENERAL INFORMATION
EM ISSION CONTROL SYSTEM S
EXHAUST EMISSION REQUIREMENT
The U.S. Envi ronm ent al Prot ect i on Agency ( EPA) , Cali forni a Ai r Resources Board ( CARB ) and Envi ronm ent and
Cli m at e Change Canada ( ECCC) requi re m anufact urers t o cert ify t hat t heir m ot orcycles com ply wit h appli cable
exhaust em i ssi ons st andards during t heir useful life , when operat ed and m aint ained accordi ng t o t he inst ruct ions
provi ded .
NOISE EMISSION REQUIREMENT
The EPA also requi res t hat vehi cles built aft er January 1 , 1983 com ply wit h appli cable noi se em ission st andards for
one year or 3,730 m iles ( 6,000 km ) aft er t he t im e of sale t o t he ult im at e purchaser , when operat ed and m aint ained
accordi ng t o t he inst ruct ions provided .
WARRANTY COMPLIANCE
Com pli ance wit h t he t erm s of t he Dist ribut or’s Lim it ed Warrant y for Honda Mot orcycle Em i ssi on Cont rol Syst em s is
necessary in order t o k eep t he em i ssi ons syst em warrant y in effect.
SOURCE OF EMISSIONS
The com bust ion process produces carbon m onoxi de ( CO) , oxi des of nit rogen ( NOx ) and hydrocarbons (HC ).
The cont rol of hydrocarbons and oxi des of nit rogen is very im port ant because , under cert ain condit ions , t hey react t o
form phot ochem i cal sm og when subj ect t o sunlight . Carbon m onoxi de does not react in t he sam e way, but it is t oxic .
Uncont rolled fuel evaporat i on also releases hydrocarbons t o t he at m osphere.
Honda Mot or Co. , Lt d. ut ilizes vari ous syst em t o reduce carbon m onoxi de , oxi des of nit rogen and hydrocarbons.
CRANKCASE EMISSION CONTROL SYSTEM
The engi ne is equi pped wit h a closed crank case syst em t o prevent di schargi ng crank case em i ssi ons int o t he
at m osphere .
Blow - by gas is ret urned t o t he com bust ion cham ber t hrough t he air cleaner and t hrot t le body .
AIR CLEANER HOUSING
THROTTLE BODY
CRANKCASE
BREATHER HOSE
Fresh Air
Blow - by gas
1-65
EXHAUST EMISSION CONTROL SYSTEM
The exhaust em i ssi on cont rol syst em is com posed of a t hree - way cat alyt ic convert er and PGM - FI syst em .
THREE -WAY CATALYTIC CONVERTER
Thi s vehi cle is equi pped wit h a t hree -way cat alyt ic convert er. The t hree -way cat alyt ic convert er is in t he exhaust
syst em . Through chem ical react i ons, it convert HC , CO and NOx in t he engi ne’s exhaust t o carbon di oxi de ( CO2 ) ,
dinit rogen ( N2 ) , and wat er vapor .
No adj ust m ent t o t hese syst em s should be m ade alt hough peri odi c inspect ion of t he com ponent s is recom m ended .
The pulse secondary air supply syst em i nt roduces filt ered air int o t he exhaust gases in t he exhaust port . Fresh air is
drawn int o t he exhaust port by t he funct ion of t he PAIR cont rol valve .
Thi s charge of fresh air prom ot es burning of t he unburned exhaust gases and changes a consi derable am ount of
hydrocarbons and carbon m onoxi de int o relat i vely harm less carbon di oxi de and wat er vapor.
The reed valve prevent s reverse air flow t hrough t he syst em . The PAIR cont rol valve is operat ed by t he solenoi d
valve . The solenoi d valve is cont rolled by t he PGM - FI unit , and t he fresh air passage is opened / closed accordi ng t o
running condit ion (ECT/IAT/ TP /MAP sensor and engi ne revolut ion ).
No adj ust m ent s t o t he secondary air supply syst em should be m ade , alt hough peri odi c inspect ion of t he com ponent s
is recom m ended .
PAIR CONTROL AIR CLEANER HOUSING

SOLENOID VALVE
1 0
ruhy
21
PAIR CHECK
VALVE
THROTTLE BODY
EXHAUST PORT
Fresh air
Exhaust gas
1-66
EVAPORATIVE EMISSION CONTROL SYSTEM
Fuel vapor from t he fuel t ank is rout ed int o t he EVAP cani st er where is it absorbed and st ored whi le t he engi ne is
st opped . When t he engi ne is running and t he EVAP purge cont rol solenoi d valve is open , fuel vapor in t he EVAP
cani st er is drawn int o t he engi ne .
FUEL TANK
EVAP CANISTER
Fuel Vapor
EVAP PURGE CONTROL SOLENOID VALVE Fresh Air
FUEL PERMEATION EMISSION CONTROL SYSTEM
Thi s m ot orcycle com pli es wit h t he Fuel Perm eat i on Em i ssi on Cont rol regulat i ons of t he U.S. Envi ronm ent al Prot ect i on
Agency ( EPA), t he Cali forni a Ai r Resources Board ( CARB ) , and Envi ronm ent and Cli m at e Change Canada ( ECCC) .
The fuel t ank , fuel hoses , and fuel vapor charge hoses used on t his m ot orcycle i ncorporat e fuel perm eat i on cont rol
t echnologi es . Tam peri ng wit h t he fuel t ank , f u el hoses , or fuel vapor charge hoses t o reduce or defeat t he
effect i veness of t he fuel perm eat i on t echnologi es is prohibit ed by federal regulat i ons .
NOISE EMISSION CONTROL SYSTEM
TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED : U.S. Federal law prohibit s law m ay prohibit
t he followi ng act s or t he causing t here of: ( 1 ) The rem oval or renderi ng i noperat i ve by any person , ot her t han for
purposes of m ai nt enance , repai r or replacem ent, of any devi ce or elem ent of desi gn i ncorporat ed int o any vehi cle for
t he purpose of noi se cont rol prior t o it s sale or deli very t o t he ult im at e cust om er or whi le it is in use ; ( 2 ) t he use of t he
vehi cle aft er such devi ce or elem ent of desi gn has been rem oved or rendered i noperat i ve by any person .
AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW :
1. Rem oval of , or punct uring of t he m uffler, baffles , header pipes or any ot her com ponent which conduct s exhaust
gases .
2. Rem oval of , or punct uring of any part of t he int ake syst em .
3. Lack of proper m aint enance .
4. Replaci ng any m oving part s of t he vehi cle , or part s of t he exhaust or int ake syst em , wit h part s ot her t han t hose
speci fi ed by t he m anufact urer.
1-67
i
GENERAL INFORMATION
M AINTENANCE SCHEDULE
Perform t he Pre- ride inspect ion in t he Owner’s Manual at each scheduled m ai nt enance period .
> I : Inspect and Clean , Adj ust, Lubri cat e or Replace if necessary . C: Clean . R : Replace . A : Adj ust . L: Lubri cat e.
The followi ng it em s requi re som e m echani cal k nowledge . Cert ai n it em s (part i cularly t m arked * and ** ) m ay requi re
m ore t echni cal inform at ion and t ools . Consult a dealer .
Refer t o " Basi c " Servi ce Manual for each m ai nt enance inst ruct ion except t he inst ruct ions descri bed in t his
m anual .
Basic
FREQUENCY FREQUENCY (NOTE 1 ) REFER

REGULAR
NOTE X1,000 m i 0.6 4 8 12 16 20 24 TO
REPLACE
ITEMS X1,000 km 1.0 6.4 12.8 19.2 25.6 32.0 38.4 PAGE
* I I I 2-2
FUEL LINE
* THROTTLE OPERATION | 1
ITEMS NOTE2 R R 2-7
AIR CLEANER
CRANKCASE BREATHER NOTE3
SPARK PLUG EVERY 16000 m i ( 25600 km ) I ,
RELATED 4-28
EVERY 32000 m i ( 51200 km ) R
VALVE CLEARANCE I 2-22
ENGINE OIL R. R R R 1 year 2-15
ENGINE OIL FILTER R R 2-15
EMISSION *
ENGINE IDLE SPEED I I
RADIATOR COOLANT NOTE7 1 1 I 3 years 2-17
* . |
COOLING SYSTEM
*
SECONDARY AIR SUPPLY
1
SYSTEM
* EVAPORATIVE EMISSION NOTE4
CONTROL SYSTEM
DRIVE CHAIN NOTE5 Every 600 m i ( 1000 km ) I, L
ITEMS I |
DRIVE CHAIN SLIDER | | I |
BRAKE FLUID NOTEZ I 1 | | 2 years 3-37
BRAKE PADS WEAR 1 1
RELATED
BRAKE SYSTEM I
BRAKE LIGHT SWITCH 1 1 1
HEADLIGHT AIM 1 1 4-57
CLUTCH SYSTEM 1 .
EMISSION
SIDESTAND .
*
SUSPENSION | I 1
*
SPARK ARRESTER NOTE6
*
NUTS , BOLTS , NOTE5
- I I 1
NON FASTENERS
** WHEELS/ TIRES NOTE5 | | | T I
** STEERING HEAD
1 1 1
BEARINGS
* Should be servi ced by a dealer , unless t he owner has proper t ools and servi ce dat a and is m echani cally qualified .
** In t he int erest of safet y, we recom m end t hese it em s be servi ced only by a dealer .
NOTES :
1. At hi gher odom et er readi ngs , repeat at t he frequency int erval est abli shed here.
2. Servi ce m ore frequent ly when riding in unusually wet or dust y areas .
3. Servi ce m ore frequent ly when riding in rain or at full t hrot t le .
4. 50 STATE ( m eet s California )
5. Servi ce m ore frequent ly when riding OFF -ROAD .
6. USA only .
7. Replacem ent requi res m echani cal skill .
1-68
2 . FUEL & ENGINE
FUEL LINE ------ ...... 2-2 CYLINDER HEAD 2-22
FUEL PUMP UNIT 2-4 CYLINDER /PISTON 2-29
FUEL TANK 2-6 CLUTCHIGEARSHIFT LINKAGE ......... 2-30
AIR CLEANER 2-7 ALTERNATOR /STARTER CLUTCH ..... 2-33
THROTTLE BODY ... 2-8 CRANKCASE / CRANKSHAFTI

BALANCER ...... 2-35
SECONDARY AIR SUPPLY SYSTEM --- 2-12
TRANSMISSION 2-39
LUBRICATION SYSTEM .2-14
ENGINE UNIT 2-40
COOLING SYSTEM 2-17
2 -1
leshomme
FUEL & ENGINE
FUEL LINE
Thi s vehi cle uses resin for t he part s of m at erials in t he fuel

hose . Do not bend or t wist t he fuel hose .
Fuel t ank lift ing 2-6
1Fuel pum p 5P connect or
Let t he engi ne idle unt il it st ops.
Bat t ery negat i ve ( - ) cable 4-51

101
To
1
Do not use t ools in rem oval . If t he connect or does not
m ove , alt ernat ely pull and push t he connect or unt il it
1 com es off easi ly .
Check t he fuel quick connect fit t ing for dirt, and clean if
necessary .
.
Place a shop t owel over t he quick connect fit t ing.
1Push t he ret ai ner t ab forward .
2 Press down t he ret ai ner and di sconnect t he connect or
from t he fuel j oint .
Check t he ret ai ner condit ion and replace t he fuel hose if
necessary .
To prevent dam age and keep forei gn m at t er out , cover t he
2 di sconnect ed connect or and pipe end wit h a plast ic bag .
Press t he connect or ont o t he fuel j oint unt il t he ret ai ner
locks wit h a "CLICK" . If it is hard t o connect, put a sm all
am ount of engi ne oil on t he pipe end .
Mak e sure t he connect i on is secure ; check vi sually and by
pulling t he connect or .
Aft er inst alling t he rem oved part s, t urn t he ignit ion swit ch
ON . ( Do not st art t he engi ne . )
The fuel pum p will run for about 2 seconds , and fuel
pressure will ri se. Repeat 2 or 3 t im es , and check t hat
t here is no leak age in t he fuel supply syst em .
2-2
FUEL & ENGINE
FUEL SUPPLY TEST
If t he fuel in t ank is sufficient but such sym pt om as poor en

gi ne perform ance, lack of fuel, or engi ne st art failure exist ,
perform t he following .
Perform t he fuel pressure t est . 2-3
.
If t he fuel pressure is wit hin specificat ion , perform t he fuel
flow inspect ion . 2-3
Perform t he fuel flow inspect ion in t he speci fi ed fuel quan
t it y . 2-3
FUEL PRESSURE TEST
Qui ck connect fit t ing ( fuel pum p si de ) 2-2

[A ]
BBC At t ach t he fuel pressure gauge and at t achm ent.

[ A ] Fuel pressure gauge : 07406-0040004
[ B] Fuel pressure gauge at t achm ent: 070MJ - K260100
Tem porari ly connect t he negat i ve cable t o t he bat t ery and
[ B] fuel pum p 5P connect or .
St art t he engi ne and let it idle , and read t he fuel pressure .
St andard : 28 8 -300 k Pa
If t he fuel pressure is hi gher t han specified , replace t he fuel
pum p unit . 2-4
t o INJECTOR If t he fuel pressure is lower t han specified , inspect t he
( fuel feed hose ) followi ng
- Fuel line leaking
- Any errat ic swing or vibrat ion of t he gauge needle in t he
pressure gauge readi ng .
If t he needle is swing or vibrat ion , replace t he fuel f i l
t er . 2-5
If t he needle is st able , replace t he fuel pum p unit . 2
4
from FUEL PUMP
FUEL FLOW INSPECTION
Qui ck connect fit t ing ( inj ect or si de ) 2-2

from FUEL PUMP Place t he end of t he hose int o an approved gasoli ne con
t ainer . Wi pe off spilled out gasoli ne .
.
The fuel pum p operat es for 2 seconds . Repeat 5 t im es t o
m eet t he t ot al m easuri ng t im e .
St andard : 55.6 cm m i ni m um / 10 seconds
If fuel flow is less t han speci fi ed, inspect t he followi ng:
- Clogged fuel hose
- Fuel pum p unit
1 Place t he vehi cle on t he level ground wit h it s sidest and .
Adj ust t he fuel in t he t ank so t hat t he fuel gauge
M
segm ent is posi t i oned t he speci fi ed range [ A ], and inspect
1 t he fuel flow .
F
- If t he fuel flow is above specificat ion, check for ot her m al
funct ioning part s.
- If t he fuel flow is under specificat ion , replace t he fuel f i l
[ A] t er . 2-5
E
2-3
FUEL & ENGINE
FUEL PUM P UNIT
12 N m
5
2
New
Oil
Qui ck connect fit t ing ( fuel pum p si de ) 2-2

Fuel t ank 2-6
.
1Loosen t he nut s in a cri sscross pat t ern in several st eps .
Carefully rem ove t he fuel pum p unit from t he fuel t ank t o prevent dam agi ng t he fuel level sensor .
1Inst all a new out er packing ont o t he fuel pum p unit groove by aligning it s t ab wit h t he boss .
2 Inst all t he fuel pum p int o t he fuel t ank by ali gni ng t he t ri angle m arks of t he set t ing plat e and t he fuel t ank .
3 Set t he set t ing plat e ont o t he fuel pum p by aligning it s hole wit h t he boss .
4 ) Ti ght en t he fuel pum p set t ing plat e nut s in t he speci fi ed sequence as shown .
5 Mak e sure t hat t he out er packing t ab can be seen in t he set t ing plat e hole .
.
Fuel pum p m alfunct ion and inspect ion
m
Basic
2-4
FUEL & ENGINE
FUEL FILTER
G G. Y 2
1
Liberty
Y
New Oil
New Y
G
New
co
New Oil
New Oil
New
G
3
Y BI Y
R G
Fuel clog or excessi vely dam aged

If t he fuel filt er is clogged , replace it wit h a new one .
To prevent dirt and debris from ent ering t he fuel pum p unit , always clean it before di sassem bly .
Clean t he fuel pum p unit and fuel pum p filt er wit h clean gasoli ne . Never use com m erci ally avai lable
carburet or cleaners .
. 1Fuel pum p m ot or wi res ( Y and Gwi re )
2 Release t he hooks from t he st oppers by slight ly spreadi ng t he hooks .

Fuel pum p case rem over : 070MF- KVS0300
Before inst alling t he fuel pum p filt er, check t he fuel pum p unit for dirt. If necessary , clean t he fuel pum p unit
wit h com pressed air . Do not blow int o t he fuel pum p unit .
If t he R or Bl wi re connect or is di sconnect ed , replace t he fuel level sensor wit h a new one .
1Mak e sure t he " CLICK " and inst all t he four t abs securely when t he fuel pum p unit is assem bled .
2 Connect t he fuel pum p m ot or wi res t o t he speci fi ed angle .
3 Rout e t he fuel pum p m ot or wi res and fuel level sensor wi res t o t he guide and t erm inals properly .
2-5
FUEL & ENGINE
FUEL TANK
Rally t ype shown :
Rally t ype only
Fuel t ank shroud 3-13

. Qui ck connect fit t ing ( fuel pum p si de )
2-2
A pressure release can be heard when openi ng t he fuel

Rally t ype only :
filler cap , but t his is not block age of t he passage. If check
ing for clog in t he passage of t he fuel t ank si de is neces
New sary , apply air pressure t o t he breat her hose end wit h t he
fuel filler cap opened .
If rem ove t he fuel filler cap , replace t he breat her seal wit h
a new one .
1.8 N.m
2-6
FUEL & ENGINE
AIR CLEANER
1
1.5 Nim
G 1.2 N.m
7.0 N m
TE
1Di scard t he air cleaner elem ent in accordance wit h t he m ai nt enance schedule . 1-68
Replace t he elem ent any t im e it is excessi vely dirt y or dam aged .
Fuel t ank 2-6
Rear fender B 3-17
2 -7
FUEL & ENGINE
THROTTLE BODY
3.0 N m
3.0 N.m
Ai r cleaner 2-7
O
Inj ect or 2-11
TP sensor reset procedure 2-10
Throt t le body cleani ng and inspect ion

Basic
2-8
FUEL & ENGINE
5 3.4 N.m
2.1 N.m
New
New
2
3.4 N.m
The t hrot t le body is fact ory pre- set . Do not di sassem ble in a way ot her t han shown in t his m anual .
. Do not loosen or t ight en t he whi t e paint ed fast eners . Looseni ng or t ight ening it can cause t hrot t le body m alfunct ion .
.
Do not hold t he t hrot t le drum when inst alling t he sensor unit .
Sensor uni t
Throt t le body 2-8
1Inst all t he sensor unit t o t he t hrot t le body by aligning t he clip of t he sensor unit and boss of t he t hrot t le
valve .
Perform t he TP sensor reset procedure. 2-10
IACV
. Fuel t ank 2-6
2 Inst all t he IACV by aligning it s slide valve slot wit h t he pin in t he t hrot t le body .
3 Inst all t he set plat e by aligning it s slot wit h t he IACV t ab .
2-9
FUEL & ENGINE
TP SENSOR RESET PROCEDURE
Mak e sure t hat DTC is not st ored in ECM . If t he DTC is

[A] st ored in ECM , TP sensor reset m ode won’t st art by
following t he procedure below .
Seat 3-5
SOU Connect or cover from t he DLC ( A ).
Connect t he special t ool t o t he DLC .
SCS connect or : 070MZ- 0010300
ECT sensor 3P connect or [ B ] .

[ B]
Short t he ECT sensor t erm inals wit h j um per wi re .
Connect i on : G / W - Y/ Bu
Y/ Bu G /W
Turn t he ignit ion swit ch ON t hen di sconnect t he j um per

wi re from t he ECT sensor 3P connect or wit hin 10 seconds
whi le t he MIL is blinking ( reset recei vi ng pat t ern ).
[ B]
Check if t he MIL blinks .
Aft er di sconnect i on of t he j um per wi re, t he MIL should st art
blinking . ( reset com plet ed pat t ern )
| If t he j um per wi re is connect ed for m ore t han 10 seconds ,
t he MIL will st ay ON ( unsuccessful pat t ern ). Try again from
wit hin 10 sec . t he first st ep .
Check t he engi ne idle speed .
Reset procedure and MIL blinking pat t ern
wit hin 10 sec . | 0.3 sec .
0.3 sec .
0.1 sec .
1.3 sec .
M L
Reset receiving Reset com plet ed
2 -10
FUEL & ENGINE
INJECTOR
5.1 N.m
New Oil
New Oil
Qui ck connect fit t ing ( inj ect or si de ) 2-2
2 -11
FUEL & ENGINE
Radi at or wit h it s hoses connect ed 2-18
PAIR cont rol solenoi d valve inspect ion

m
Basic
5.2 N.m
Radi at or wit h it s hoses connect ed and cooli ng fan 2-18
PAIR check valve inspect ion

Basic
2 -12
FUEL & ENGINE
EVAP SYSTEM ( AC t yp e )
CA
CO
2 -13
FUEL & ENGINE
LUBRICATION SYSTEM
SYSTEM DIAGRAM
OIL STRAINER
SCREEN
OIL PUMP
0)0 O S
nu
ULTY
aD
ENGINE OIL LEVEL CHECK
Place t he vehi cle on t he level ground wit h it s sidest and .

Let it idle for 3 5 m inut es .
UPPER 3
OEF Wai t for 2-3 m inut es .
NO
Support t he m ot orcycle in an upright posit ion on a level
surface .
If t he level is below t he lower level line , rem ove t he oil filler
cap and fill t he crank case wit h t he recom m ended engi ne
LOWER oil up t o t he upper level line .
Check t hat t he O- ring on t he filler cap is in good condit ion ,
replace it if necessary.
RECOMMENDED ENGINE OIL:
Oil Pro Honda GN4 4 - st rok e oi l ( U.S.A. & Canada ) or
equi valent m ot orcycle oi l
API servi ce classi fi cat i on : SJ or hi gher
JASO T903 st andard : MA
Vi scosi t y : SAE 10W- 30
2 -14
FUEL & ENGINE
ENGINE OIL CHANGE
Drain oil com plet ely .

Q
New Fill t he crank case wit h t he recom m ended engi ne oil .
ENGINE OIL CAPACITY :

Oil 1.4 li t er aft er drai ni ng
On 1.5 li t er aft er oi l fi lt er change
1.8 li t er aft er di sassem bly
24 N.m
ENGINE OIL FILTER CHANGE
JUTSIDE
1Inst all t he oil filt er wit h t he " OUT- SIDE " m ark facing out .
Inst alling t he oil filt er backwards will result in severe engi ne dam age .
Engi ne oil filt er inspect ion

m
Basic
2 -15
FUEL & ENGINE
ENGINE OIL STRAINER SCREEN / OIL PUMP
AAN
New Oil
New Oi l
9)
3 0 50
Oil
Oil
Ri ght crank case cover 2-30
Oi l pum p inspect ion

Basic
2 -16
FUEL & ENGINE
COOLING SYSTEM
SYSTEM DIAGRAM
When t he engine is cold : When t he engine is hot :
COOLANT REPLACEMENT
Coolant drai n
Cooli ng syst em t est ing and inspect ion

Basic
New
C Fuel t ank shroud 3-13
Radi at or cap
. Coolant from t he
syst em
Si phon hose from t he filler neck

Coolant from t he reserve t ank
2 -17
FUEL & ENGINE
Ai r bleedi ng / Addi ng
Fill t he syst em wit h t he coolant t hrough t he filler openi ng t o

t he filler neck .
RECOMMENDED ANTIFREEZE:
Pro Honda HP Coolant or an equi valent hi gh quali t y
et hylene glycol ant i freeze cont ai ni ng corrosi on pro
t ect i on i nhi bi t ors
St art t he engi ne and let it idle for 2-3 m inut es .
Snap t he t hrot t le t hree or four t im es t o bleed air from t he
syst em .
St op t he engi ne and add coolant up t o t he filler neck .
Rei nst all t he radiat or cap .
Radi at or reserve t ank cap .
If t he coolant level is below or near t he lower level , add t he

UPPER recom m ended coolant t o t he upper level line .
LOMMER
AL
RADIATOR /COOLING FAN
Coolant 2-17
2 -18
FUEL & ENGINE
Lock 1.0 N.m
2.7 N m
RADIATOR RESERVE TANK
Left fuel t ank shroud 3-13
2 -19
FUEL & ENGINE
WATER PUMP / THERMOSTAT W

/ ATER PIPE
10 N.m
Oil
New Oil
New
New Grease
New SP tool
New
Right crank case cover 2-30
Press a new m echani cal seal using t he hydrauli c press and speci al t ool .
Oi l seal dri ver 30 x 36 m m : 07HMF- KR10101
Coolant 2-17
Therm ost at inspect ion

Basic
2-20
FUEL & ENGINE
New
-TOITDA New
Coolant 2-17
2 -2 1
FUEL & ENGINE
CYLINDER HEAD
VALVE CLEARANCE
INSPECTION
Inspect while t he engi ne is cold ( below 35 C) .

6.0 N m Aft er t he valve clearance inspect ion , check t he engi ne idle
New Oil Oil
speed .
Cyli nder head cover 2-24
Ti m i ng hole cap / O - ring, crankshaft hole cap / O- ring
Ti m i ng cap wrench : 07709-0010001
SP tool
New Oil
SP
SE t ool
Oil 8.0 N.m
Rot at e t he crankshaft count erclock wi se and align t he " T "

m ark on t he flywheel wit h t he i ndex not ch on t he left crank
case cover .
The index lines on t he cam sprocket s m ust be flush wit h

t he cyli nder head surface.
Mak e sure t he pist on is at TDC ( Top Dead Cent er ) on t he
com pressi on st roke .
ma
EX
Valve clearance (Insert a feeler gauge bet ween t he rock er

arm and shim ) .
IN : 0.16 + 0.03 m m , EX : 0.27 + 0.03 m m
2-22
FUEL & ENGINE
ADJUSTMENT
Adj ust whi le t he engi ne is cold ( below 35 C ) .

.
Mo Oil Do not allow t he shim s t o fall int o t he crankcase .
New
Mark all shim s t o ensure correct reassem bly in t heir
original locat ions .
The shim s can be easi ly rem oved wit h t weezers or
m agnet
Bolt , sealing washer and rock er arm shaft
Sli de t he rock er arm .
. Shi m s
Clean t he valve shim cont act area wit h com pressed air .
15 N.m
Shim t hi ckness and record it .
eD
Calculat e t he new shim t hi ckness using t he equat i on

below .
A = ( B - C) + D
A: New shim t hi ckness
B : Recorded valve clearance
C: Speci fi ed valve clearance
180 182 185 188 D : Old shim t hi ckness
Fift y - seven different t hi ckness shim s are avai lable from t he
1.80 m m 1.825 m m 1.85 m m 1.875 m m t hinnest 1.500 m m shim t o t he t hickest 2.900 m m shim in
int ervals of 0.025 m m .
Mak e sure of t he correct shim t hi ckness by m easuring t he
shim by m i crom et er .
Reface t he valve seat if carbon deposi t result in a
calculat ed di m ensi on of over 2.900 m m .
Newly select ed shim on t he valve spring ret ai ner.
Rem oved part s
Rot at e t he cam shaft s by rot at ing t he crankshaft
count erclock wi se several t im es .
Recheck t he valve clearance 2-22
2-23
FUEL & ENGINE
CYLINDER HEAD COVER
10 N.m
UP
Seal Seal
New
SI
Radi at or wit h it s hoses connect ed and cooli ng fan 2-18
1Apply sealant ( Three bond 5211C or 1207B or 1215 or Shin - Et su Si li cone KE45 or equi valent ) t o t he cyl
inder head cover gasket sem icircular corner .
CAMSHAFT/ ROCKER ARM

4.2 N.m Set t he pist on t o t he TDC ( Top Dead Cent er ) on t he
R
com pressi on st roke 2-22
Inst all t he speci al t ool int o t he t ensi oner body and t urn t he
t ool clockwi se unt il it st ops. Hold t he t ensi oner lift er by
pushing t he t ool whi le aligning t he t abs of t he t ool wit h t he
grooves of t he t ensi oner lift er .
Cam chai n t ensi oner li ft er st opper : 070MG- 0010100
New Oil
2-24
FUEL & ENGINE
" EX" Oil 12 N m
" IN "
.D
" EX " 10
OC O
" IN "
" IN "
Mo Oil
Brendan
" EX "
" EX"
Mo Oil
Oil Mo Oil
mo Mo Oil
New
WA
15 N m
000
Inst all each cam shaft , rock er arm , cam shaft holder and cam chain gui de B t o t he correct posit ion wit h t he
ident ificat ion m ark .
. Cam shaft
inspect ion
m Cam shaft oil clearance inspect ion
Basic
2-25
FUEL & ENGINE
1 Oil 45 N.m
Oil
1)
New
1 Oil
SO
co
o
loco
o
oelC
ed
ne lo
Throt t le body 2-8

Cam shaft 2-24
Therm ost at 2-20
1Loosen t he cyli nder head nut s in a cri sscross pat t ern in t wo or t hree st eps.
1Inst all t he cam chain gui de while aligning it s pins wit h t he grooves on t he cyli nder head and it s end wit h
t he groove on t he left crankcase .
2-26
FUEL & ENGINE
38331332
$
)
O New
00 000
) ) )
1 O
2
OO
O
OO OO
Lot e
3 9 DI
41
Mo Oil
Mo Oil
1Rem ove t he valve cot t ers .

Valve spri ng com pressor : 07757-0010000
Valve spri ng com pressor at t achm ent: 07959 - KM30101
2 Ream t he valve gui de t o rem ove any carbon build up before m easuri ng t he gui de . Insert t he ream er from
t he com bust ion cham ber si de of t he cyli nder head and always rot at e t he ream er clockwi se .
Valve gui de ream er , 4.5 m m : 07HMH - ML00101
3 Support t he cyli nder head and drive t he valve gui des out of t he cyli nder head from t he com bust ion
cham ber si de .
Valve gui de dri ver , 4.3 m m : 07HMD -ML00101
1Dri ve new valve gui des int o t he cyli nder head t o t he speci fi ed height from t he cyli nder head .
INTAKE /EXHAUST VALVE GUIDE PROJECTION : 13.8 14.0 m m
Valve gui de dri ver : 07743-0020000
Valve and valve spring inspect ion
Valve gui de inspect ion
Basic
Valve seat inspect ion
2 -2 7
O
FUEL & ENGINE
CAM CHAIN TENSIONER
Inst all t he speci al t ool int o t he t ensi oner body and t urn t he
t ool clock wi se unt il it st ops . Hold t he t ensi oner lift er by
New Oil Oil m ore t han 0.5 cm 3
pushing t he t ool whi le aligning t he t abs of t he t ool wit h t he
grooves of t he t ensi oner lift er .
Cam chai n t ensi oner li ft er st opper : 070MG- 0010100
4.2 N m New
Check t he cam chain t ensi oner lift er operat i on :
- The t ensi oner shaft should not go int o t he body when it
is pushed .
- When it is t urned clock wi se wit h t he t ensi oner st opper ,
t he t ensi oner shaft should be pulled int o t he body . The
shaft should prot rude from t he body as soon as t he t en
si oner st opper is released .
2-28
FUEL & ENGINE
CYLINDER /PISTON
Oil
1
E
New
000
New UZD
)
10 0
1
Mo Oil
3
N
2
Oil
New
Mo Oil
142 + 1 m m
Cyli nder head 2-22

Cam chain t ensi oner 2-28
.
1Spread each pist on ring and rem ove it by lift ing up at a point opposi t e t he gap .
1Carefully inst all t he pist on rings int o t he pist on ring grooves wit h t he m arkings facing up .
2 Inst all t he pist on wit h t he IN m ark facing t he int ake si de .
3 Do not align t he pist on pin clip end gap wit h t he pist on cut - out.
Pi st on and pist on rings inspect ion
m .
Basic Cyli nder inspect ion
2-29
FUEL & ENGINE
CLUTCH / GEARSHIFT LINKAGE
New
12 N.m
(
102 1
1
Oil
1
Mo Oil
Oum waarden
New Oil 108 N.m 10 N.m
Lock DO
3100
Oil
8 .b New
|
Oil 108 N.m
Lock 10 N.m
New
Gearshi ft pedal 3-16

Wat er pipe 2-20
.
Brak e pedal 3-10
1Loosen t he clut ch cent er lock nut .
Clut ch cent er holder : 07724-0050002
2 Hold t he flywheel and loosen t he prim ary dri ve gear lock nut .
Gear holder , M1.5 : 07724-0010200
1The m ainshaft and clut ch out er gui de has ID color paint m ark .
When t he clut ch out er assem bly is replaced , be sure t o select i ng sam e color codes of t he m ainshaft and
clut ch out er gui de .
2-3 0
FUEL & ENGINE
New Oil
0.5-1.0 m m
New Oil
ih
SPt ool [ A ] EV
SPt ool [ B]
Mo Oil
| 6.5-7.5 m m
New Grease
49.0 - 50.0 m m
CLUTCH LIFTER ARM NEEDLE BEARING:

[ A] Pi lot collar , 16 m m : 07PAF-0010620 [ B ] Beari ng rem over head , 10 m m : 07746-0050200
2 -3 1
FUEL & ENGINE
01 7 OUTSIDE
[A ] [ B] [C]
[A]
Oil [ C]
Oi l [ B ]
Oi l [ A]
Clut ch inspect ion
Basic
2-3 2
FUEL & ENGINE
Thi s servi ce can be perform ed wit h t he engi ne inst alled in t he fram e .
Mo Oil
ho
Mo Oil
New
Mo Oil
1
det
wc
( EET
rest
( ECCO (
Mo Oil ( CECCO
Lock 30 N m
Oil
cert @ CELET
CC @
CALCETTO
Oil CETTE Cart
20 0 0 0
1 2
128 N.m
Oil
Under cowl 3-7

Dri ve sprocket cover 3-16
1Hold t he flywheel wit h t he speci al t ool for t he bolt rem oval.
Flywheel holder : 07725-0040001
2 Flywheel
Flywheel puller : 07733-0020001
1Clean any oil and grease from crankshaft and flywheel cont act area .
2-3 3
FUEL & ENGINE
10 N m
Lock 10 N.m
El
Clicca
3)23
Seal
Coat ing widt h :

Lock 6.5+ 1 m m from t he tip
Apply liquid sealant ( Three bond 1207B , 1215 or equi valent ) t o t he sem icircular area .
2-3 4
FUEL & ENGINE
CRANKCASE / CRANKSHAFT / BALANCER
so v u
Crea -
CC
C-
C
1.
LC
Lo
00
OCEL
recaH
CE FECTE
oc
0 -0 0
AKU
CO
RETICEHLE
FRE
GEET
WO
EUTE 10 CRU
Clerc
lit e
CAUTIO EC
101
Engi ne 2-40
Cyli nder / pist on 2-29
.
Clut ch / gearshift linkage 72-30
Alt ernat or / st art er clut ch 2-33
Oi l pum p 2-16
VS sensor 4-61
Gear posit ion swit ch 4-33
. St art er m ot or 4-32
1Insert t he gear holder bet ween t he balancer dri ve gear and balancer driven gear assem bly .
Gear holder , M2.5 : 07724-0010100
Rem ove t he crank case bolt s in a cri sscross pat t ern in 2-3 st eps .
Place t he crank case wit h t he right crank case facing down and separat e .
2-3 5
FUEL & ENGINE
CRANKSHAFT RUNOUT INSPECTION
Set t he crankshaft on V- blocks and m easure t he runout u s

ing a dial indicat or .
Li m i t : ( L) 0.02 m m / ( R) 0.03 m m
51 m m 75.5 m m
MAIN JOURNAL BEARING SELECTION
Record t he beari ng support I.D. code let t er [ 1] .

[ 1]
Let t ers A, B or C on each crank case is t he code for t he
crank case m ain j ournal beari ng support I.D.
BEARING SUPPORT MAIN JOURNAL O.D.

I.D. CODE BEARING SUPPORT I.D. 33.985 34.000 m m
33.975 - 33.985 m m
(Crank case replaced ) (Crankshaft replaced )
C ( Brown ) B ( Black )
A 38.000 38.006 m m
1.996 - 1.999 m m 1.999 2.002 m m
B B ( Black ) A ( Blue )
38.006 - 38 .012 m m
1.999 2.002 m m 2.002 - 2.005 m m
A ( Blue ) O.S. G ( Pink )
38 .012 - 38 .018 m m
2.002 - 2.005 m m 2.005 - 2.008 m m
10 O.S. G ( Pink ) O.S. F ( Yellow )
38 .018 - 38.024 m m
2.005 - 2.008 m m 2.008 - 2.011 m m
O.S. F (Yellow ) O.S. E (Green )
38.024 38.030 m m
2.008 - 2.011 m m 2.011 - 2.014 m m
O.S. E (Green ) O.S.D (Red )
- 38.030 - 38.036 m m
2.011 2.014 m m 2.014 2.017 m m
2-3 6
o
FUEL & ENGINE
IDENTIFICATION COLOR
BEARING THICKNESS :
O.S.D (Red ) : Thi ck
O.S. E ( Green ) :
O.S. F (Yellow ):
O.S. G ( Pi nk ) : Mi ddle
A ( Blue ) :
1
B (Black )
C ( Brown ): Thi n
Aft er select i ng new beari ngs , recheck t he clearance . In
correct clearance can cause severe engi ne dam age .
2 -3 7
FUEL & ENGINE
Lock 10 N.m OUTSIDE
CREATE
C Lock
G
R Mo Oil
Oil 69 N.m
COC
3 [ A] Til
Mo Oil
,
Mo Oil
L Mo Oil
secan
New 4
[A]
[ B]
Mo Oil ZZ
1 ZZ ZZ
R
Mo Oil
New Grease
609 BEL
00 New Grease
Mo Oil
Mo Oil
2
0.5 1.0 m m
ol e
Each bearing Seal

Oil rot at ing area
1Set t he beari ngs and speci al t ools assem bly on inside of t he crank case , fit t ing t he bearing edge in t he
crank case m ain j ournal . Ali gn t he m at ing line of t he beari ngs wit h t he index m ark on t he crank case as shown .
Met al i nst aller set : 070MF -KYJO100
2 Apply sealant ( Three bond 1207B , 1215 or equi valent ) t o t he left crank case m at ing surface except t he oil
passage area .
3 Inst all t he balancer dri ve and driven gear wit h it s " OUT" m ark [ A ] facing out . Ali gn t he punch m arks [ B] of
t he balancer dri ve and driven gear .
4 Each shift fork has an ident ificat ion m ark .
Crankshaft inspect ion
Basic Connect i ng rod inspect ion
Shift fork / shift drum / drum j ournal inspect ion
2-3 8
FUEL & ENGINE
TRANSM ISSION
MAINSHAFT
Oil
Mo Oil
Oil
O
Oil
New Oil
p ool oo
Mo Oil
006 New
DO
Oil
Transm i ssi on inspect ion

m
Basic
COUNTERSHAFT
Oil Mo Oil
Mo Oil
Oil
Oil
Oil
00
oooo
C0 0 0 f 0
New
QOCC
O
Oil
OO
MoOii Mo Oil
Oil
Tv
B
Transm i ssi on inspect ion

m
Basic
2-3 9
FUEL & ENGINE
ENGINE UNIT
Rally t ype
55 N m
15 N.m
55 N m
27 N.m
an ))
45 N.m s 10 N m
[6 ]
[5]
OOD [3]
[2 ]
[ 1]
[ 4]
Radi at or 2-18
Throt t le body 2-8
Exhaust pi pe/m uffler 3-24
.
Brak e pedal 3-10
EVAP syst em ( AC t ype ) 2-13
1Loosely inst all all t he engi ne fast ener of [ 1] t o [6 ], t hen t ight en t hem wit h t he speci fi ed t orque in order of
[ 1] t o [ 6 ] .
2-40
FUEL & ENGINE
St andard t ype
55 N.m
45 N m
55 N.m
27 N.m
45 N m
10 N.m
[6 ]
[5]
[3]
[2 ]
[ 1]
[4]
Radi at or 2-18
Throt t le body 2-8
Exhaust pi pe /m uffler 3-24
.
Brak e pedal 3-10
1Loosely inst all all t he engi ne fast ener of [ 1 ] t o [ 6 ] , t hen t ight en t hem wit h t he speci fi ed t orque in order of
[ 1] t o [ 6 ] .
2 -41
MEMO
3 . FRAM E & CHASSIS
BODY PANELS ...... 3-2 STEERING STEM .. 3-32
SIDESTAND 3-23 REAR WHEEL 3-34
EXHAUST PIPE/ MUFFLER ...... -3-24 REAR SUSPENSION .. 3-36
FRONT WHEEL...... 3-26 FRONT BRAKE . 3-37
FORK 3-28 REAR BRAKE UBO ...

- 3-40
HANDLEBAR 3-31
3 -1
FRAME & CHASSIS
BODY PANELS
Rally t ype
[ 4]
[ 3]
[6 ] [5]
[ 1]
[2]
]
7
[
[ 15]
8
[
]
[9]
[ 10 ]
[ 11] [ 12 ] [ 13 ] [ 14 ]
[ 18 ]
[ 17]
[ 16 ]
[ 19]
[20 ]
[26 ]
[ 21] [ 24 ] [ 25 ]
[ 22 ]
[23 ]
[ 1] Front fender 3-4 [ 10 ] Heel guard 3-18 [ 19 ] Reserve t ank cover 3-12
[2] Turn signal light st ay 3-6 [ 11] Brak e pedal 3-10 [ 20 ] Gearshi ft pedal 3-16
[ 3] Wi ndscreen 3-5 [ 12 ] Fuel t ank shroud 3-13 [ 21] Dri ve sprocket cover 3-16
[ 4] Rearvi ew m irror 3-4 [ 13 ] Front under cowl 3-7 [ 22 ] Bat t ery box 3-22
[ 5] Seat 3-5 [ 14 ] Front under guard 3-7 [ 23 ] Pillion st ep 3-10
[ 6 ] Rear fender 3-8 [ 15 ] Radi at or guard 3-20 [ 24 ] Mud guard 3-18
[ 7] Num ber plat e bracket 3-9 [ 16 ] Helm et holder 3-19 [ 25 ] Chai n case 3-19
[ 8 ] Muffler guard 3-20 [ 17] Tool box 3-21 [ 26 ] Rear fender B3 -17
[ 9 ] Si de cover 3-8 [ 18 ] Knuckle guard 3-11
3 -2
FRAME & CHASSIS
St andard t ype
[3]
[4]
[5 ]
[2]
[ 1]
[6]
[ 7]
[8] [9 ]
[ 10 ] [ 11] [ 12 ]
[ 14]
[ 13 ]
[ 15]
[ 16]
[ 22 ]
[ 17]
[ 20 ] [21]
[ 18 ] [ 19 ]
[ 1] Front fender 3-4 [ 10 ] Brak e pedal 3-10 [ 19 ] Pillion st ep 3-10

[ 2 ] Front vi sor 3-6 [ 11] Fuel t ank shroud 3-13 [ 20 ] Mud guard 3-18
[ 3 ] Rearvi ew m irror 3-4 [ 12 ] Radi at or guard 3-20 [ 21] Chai n case 3-19
[ 4 ] Seat 3-5 [ 13 ] Helm et holder 3-19 [ 22 ] Rear fender B 3-17
[ 5 ] Rear fender 3-8 [ 14 ] Tool box 3-21
[ 6 ] Num ber plat e bracket >3-9 [ 15 ] Reserve t ank cover 3-12
[ 7] Muffler guard 3-20 [ 16 ] Gearshi ft pedal 3-16
[ 8 ] Si de cover 3-8 [ 17] Dri ve sprocket cover 3-16
[ 9 ] Heel guard 3-18 [ 18 ] Bat t ery box 3-22
3 -3
FRAME & CHASSIS
FRONT FENDER
REARVIEW MIRROR
20 N m
20 N.m
Rally t ype left side only
3 -4
FRAME & CHASSIS
SEAT
mo
21 N.m
WINDSCREEN ( Ral l y t yp e )
MW
0.75 N m
3 -5
FRAME & CHASSIS
TURN SIGNAL LIGHT STAY
Front t urn signal light 4-52
FRONT VISOR ( St an d ar d t yp e)
AJ
3 -6
FRAME & CHASSIS
FRONT UNDER GUARD ( Ral l y t yp e )
see
REAR UNDER COWL ( Ral l y t yp e )
AND
Front under guard 3-7
3 -7
FRAME & CHASSIS
REAR FENDER
21 N.m
Seat 3-5
SIDE COVER
Seat 3-5
3 -8
FRAME & CHASSIS
NUMBER PLATE BRACKET
.
Rear fender 3-8
3 -9
FRAME & CHASSIS
PILLION STEP
e
Grease
New
Si de cover 3-8
BRAKE PEDAL
New
New
New
Grease
3 -10
FRAME & CHASSIS
KNUCKLE GUARD ( Ral l y t yp e on l y ) / BRAKE LEVER
1.0 N m
Grease
5.9 N.m
Rearvi ew m irror 3-4
3 -11
FRAME & CHASSIS
RESERVE TANK COVER
Rally t ype
lI
St andard t ype
3 -12
FRAME & CHASSIS
FUEL TANK SHROUD
Rally t ype ri ght
AM
Seat 3-5
3 -13
FRAME & CHASSIS
Rally t ype left
Seat 3-5
3 -14
FRAME & CHASSIS
St andard t ype
Seat 3-5
3 -15
FRAME & CHASSIS
DRIVE SPROCKET COVER
GEARSHIFT PEDAL
3 -16
FRAME & CHASSIS
REAR FENDER B
Rear fender 3-8

Num ber plat e bracket 3-9
Muffler 3-24
Helm et holder 3-19
3 -17
FRAME & CHASSIS
HEEL GUARD
MUD GUARD
3 -18
FRAME & CHASSIS
HELMET HOLDER
New
CHAIN CASE
ROC
3 -19
FRAME & CHASSIS
RADIATOR GUARD
JI
MUFFLER GUARD
Si de cover 3-8
3 -20
FRAME & CHASSIS
TOOL BOX
Rear fender 3-8

Si de cover 3-8
3 -2 1
FRAME & CHASSIS
BATTERY BOX
El
SO
7.0 N m
Bat t ery 4-51
3 -22
FRAME & CHASSIS
SIDESTAND
Grease
New 10 N.m
30 N.m
10 N.m
3 -23
FRAME & CHASSIS
EXHAUST PIPE/ M UFFLER
Rally t ype
32 N.m
IS
2
23 N - m

Si de cover 3-8
Muffler guard 3-20
21.5 - 22.5 m m
-.- .
New
18 N.m
3 -24
FRAME & CHASSIS
St andard t ype
32 N.m ---
IS
23 N m
12 N m

Si de cover 3-8
Muffler guard 3-20
21.5 - 22.5 m m
EET
lor
New
18 N.m
3 -25
FRAME & CHASSIS
FRONT WHEEL
22 N m
69 Nm
Wheel inspect ion

Basic
3 -26
FRAME & CHASSIS
New Grease
[ B]
New 20 N m
[A]
o
New Grease
B
1
SPt ool A 1 mm
51.5 m m
[A] [ B]
11
A = 51.5 m m - m easured B / 2
Inst all t he beari ng rem over head int o t he bearing . From t he opposi t e side , inst all t he bearing rem over shaft
and drive out t he beari ng from t he wheel hub .
Rem over head , 17 m m : 07746-0050500
Beari ng rem over shaft : 07746-0050100
Dri ve in a new left beari ng [ A] squarely wit h it s sealed side facing out side unt il it is fully seat ed .
Inst all t he di st ance collar .
Dri ve in a new right beari ng [ B] squarely wit h it s sealed si de facing out si de unt il it is fully seat ed on t he di s
t ance collar .
At t achm ent , 32 x 35 m m : 07746-0010100
Pi lot 17 m m : 07746-0040400
Dri ver : 07749-0010000
Wheel di sassem bly and inspect ion
m
Basic
3 -27
FRAME & CHASSIS
FORK
29 N.m
e noce r
29 N.m
New 7 N.m
DO
New
New 7 N.m
Front wheel 3-26
1Inst all t he front fork so t hat t he end of t he out er pipe is ali gned wit h t he t op bri dge upper surface.
3 -28
FRAME & CHASSIS
RIGHT SIDE:
1 N 4 [ B]
2
I
[ A]
35 N.m 20 N m
New DDDD
2
k roF
1 QC
k roF
New
RECE
New
1Dri ve in t he oil seal int o t he out er t ube using t he speci al t ool .

Fork seal dri ver , 45.2 m m : 07KMD - KZ30100
Fork seal dri ver at t achm ent: 07NMD -KZ30101
2 Pour t he speci fi ed am ount of recom m ended fork fluid int o t he fork pipe .
k roF RECOMMENDED FORK FLUID : Fork Flui d ( vi scosi t y : 10W)
FORK FLUID CAPACITY: 1-13
Com press t he fork leg fully and m easure t he fluid level from t he t op of t he out er t ube .
FORK FLUID LEVEL: + 1-13
3 Inst all t he fork spring wit h it s t ight ly wound coil side facing up .
4 Hold t he fully seat ed fork rod nut [ A ] and t ight en t he fork cap [ B] .
Fork di sassem bly and inspect ion

Basic
3 -29
FRAME & CHASSIS
LEFT SIDE :
1 2 3 [ B]
]
A
[
35 N m 20 N.m
)
8
k roF
(
New k roF k roF
New
oo doo d
OU (
New k roF
New
Lock 20 N m
1Dri ve in t he oil seal int o t he out er t ube using t he speci al t ool .

Fork seal dri ver , 45.2 m m : 07KMD - KZ30100
Fork seal dri ver at t achm ent: 07NMD -KZ30101
-
2 Pour t he speci fi ed am ount of recom m ended fork fluid int o t he fork pipe .
kroF RECOMMENDED FORK FLUID : Fork Flui d ( vi scosi t y : 10W )
FORK FLUID CAPACITY : 1-13
Com press t he fork leg fully and m easure t he fluid level from t he t op of t he out er t ube .
FORK FLUID LEVEL: 1-13
3 Hold t he fully seat ed fork rod nut [ A ] and t ight en t he fork cap [ B] .
Fork di sassem bly and inspect ion

Basic
3 -3 0
FRAME & CHASSIS
HANDLEBAR
New
2.5 N m
2.5 N m
Rearvi ew m irror 3-4

Front brake m ast er cyli nder 3-37
.
1Ali gn t he upper surface of t he lower handlebar holder wit h t he punch m ark on t he handlebar . Ti ght en t he
forward bolt s first , t hen t he rear bolt s .
3 -3 1
FRAME & CHASSIS
STEERING STEM
TOP BRIDGE
10 N m
ed
11
103 N.m
10 N.m
Handlebar 3-31
. Left fuel t ank shroud 3-13
3 -3 2
FRAME & CHASSIS
BOTTOM BRIDGE
Oil 1
Grease
Grease SPtool
[ B]
Col 6 [A]
Grease 3.0 5.0 g
a
Grease SPt ool
[ C]
Grease 3.0 - 5.0 g
e
Grease SP t ool
[ D]
Mult i -purpose ext rem e pressure

Grease grease NLGI # 2 ( EXCELITE EP2
m anufact ured by KYODO YUSHI
CO. , LTD. or equivalent )
Fork 3-28
Top bri dge 3-32
STEERING STEM :
[ A ] St eeri ng st em sock et : 07916-3710101
. STEERINGSTEM BEARING:
[ B] / [ C] Ball race rem over : 07948 -4630100 , Ball race rem over 36 x L340 : 07GMD- KS40100
STEERING STEM BEARING :
[ D] Dri ver , 28 m m I.D .: 07946-4300101
. STEERING STEM :
[ A ] St eeri ng st em sock et : 07916-3710101

1Inst all t he adj ust ing nut . Hold t he st eeri ng st em and t ight en t he adj ust ing nut t o t he init ial t orque .
TORQUE: 29.5 N m
2. Turn t he st eering st em lock -t o - lock fi ve t im es t o seat t he beari ng . Com plet ely loosen t he adj ust ing nut , and
t hen t ight en t he adj ust ing nut t o t he speci fi ed t orque .
TORQUE: 4.9 N.m
St eeri ng di sassem bly / assem bly and inspect ion
Basic
3 -3 3
FRAME & CHASSIS
REAR WHEEL
88 N.m
27 N.m
Front
Wheel inspect ion
Basic
( 1 Inst all t he swingarm plat e in t he direct ion as shown .
3 -3 4
FRAME & CHASSIS
New 42 N.m
New Grease
0 1- 0 0
20 0 6
[ B]
]
A
[
New Grease New 32 N m
SPt ool
[ B] [A] A + 1 mm
63.2 m m
A = 63.2 m m - m easured B / 2
REAR WHEEL
Inst all t he beari ng rem over head int o t he beari ng . From t he opposi t e si de , inst all t he beari ng rem over shaft
and dri ve out t he beari ng from t he wheel hub .
Rem over head , 17 m m : 07746-0050500
Beari ng rem over shaft : 07746-0050100
Dri ve in a new right beari ng [ A] squarely wit h it s sealed si de faci ng out si de unt il it is fully seat ed .
Inst all t he di st ance collar .
Dri ve in a new left beari ng [ B] squarely wit h it s sealed side facing out si de unt il it is fully seat ed on t he di st ance
collar.
At t achm ent, 42 x 47 m m : 07746-0010300
Pi lot 17 m m : 07746-0040400
Dri ver : 07749-0010000
Wheel di sassem bly and inspect ion
Basic
3 -3 5
FRAME & CHASSIS
REAR SUSPENSION
44 N.m
11 - 11.5 m m
88 N.m
32.0 -
32.5 m m
44 N.m Y
27.0 -
27.5 m m
7.0 - 7.5 m m
44 N.m
MelekeLI
5.8 - 6.2 m m
Grease
o
Grease
Grease ----
5.8 - 6.2 m m 1.2 N.m

44 N.m
C.
5.8 - 6.2 m m Grease
8.3 - 8.7 m m 4.2 N m

74 N.m
0.3 -0.7 m m
4.2 N.m
www
Lock 10 N.m
)
10 N.m
5.8 - 6.2 m m

Si de cover 3-8
Dri ve chain case 3-19
Rear wheel 3-34
3 -3 6
FRAME & CHASSIS
BRAKES
BRAKE FLUID REPLACEMENT
1.5 N.m 1.5 N m
Set line
Set line
From a sealed cont ai ner , add brake fluid t o t he set line on t he resevoi r.
RECOMMENDED BRAKE FLUID : DOT 3 or 4 brak e flui d
FRONT BRAKE
BRAKE MASTER CYLINDER
9.8 N.m
34 N.m
New 1
UP
3 -3 7
FRAME & CHASSIS
1.5 N m
000000
1.2 N.m
Rearvi ew m i rror 3-4

Knuckle guard ( rally t ype ) / brake lever 3-11
1Inst all t he holder wit h t he " UP " m ark facing up . Ali gn t he edge of t he m ast er cyli nder wit h t he punch m ark .
Rem ove t he snap ring .

Snap ri ng pli ers : 07914 -SA50001
Mast er cyli nder inspect ion
Basic
3 -3 8
FRAME & CHASSIS
BRAKE CALIPER
BRAKE PAD REPLACEMENT
17 Nim
10
Silicone
New Grease grease
New 30 N.m
34 N.m
New
3 -3 9
FRAME & CHASSIS
Silicone
Lock 22 N.m
Grease grease
Silicone
New Grease grease
5.4 N.m
C
10
00
Silicone
Grease grease
BF
17 Nom
BF
New
Brak e cali per inspect ion

Basic
3 -40
FRAME & CHASSIS
REAR BRAKE
BRAKE MASTER CYLINDER
34 N.m
New
New
FONU
14 N.m
New
10
New
1.5 N.m
s 17 N.m
BF
Silicone
Grease grease
Rem ove t he snap ring .

Snap ri ng pli ers : 07914 - SA50001
Mast er cyli nder inspect ion
m
Basic
3 -41
FRAME & CHASSIS
BRAKE CALIPER
BRAKE PAD REPLACEMENT
Silicone
New Grease grease
Align
17 N.m
34 Nim
New New
New
Rear wheel 3-34
3 -42
FRAME & CHASSIS
Silicone Silicone
22 N.m 5.4 N.m
Lock Grease grease New Grease grease
12 N.m
OOO O
Silicone BF
Grease grease
BF
New
Brak e cali per inspect ion

m
Basic
3 -43
MEMO
4. ELECTRICAL SYSTEM
PGM - FI SYSTEM ....... 4-2

BATTERYICHARGING SYSTEM ......... 4-50
IGNITION SYSTEM ---- 4-27 LIGHTING SYSTEM 4-52
ELECTRICAL STARTER ....-4-30 COMBINATION METER .... 4-59
ABS ...III
. . III ..- 4-34
ELECTRICAL COMPONENT 4-63
4-1
12V
ELECTRICAL SYSTEM
PGM - FI SYSTEM
Refer t o " Basi c Shop m anual " for t he following inform at ion .
- PGM - FI t echnical feat ure and each sensor funct ion .
Basic
- Sym pt om t roubleshoot i ng for t he PGM - FI syst em .
- MCS (Mot orcycle Com m uni cat i on Syst em ) inform at ion .
If t he MCS or GST is not used , perform all of t he inspect ion on t he correspondi ng m ain code ( digit s in front
of hyphen ) of t he DTC .
DTC INDEX
DTC Funct i on Fai lure Sym pt om /Fai l -safe funct i on Page

P0107 MAP sensor m alfunct ion Engi ne operat es norm ally 4-5
( 1-1) MAP sensor low volt age
P0108 MAP sensor m alfunct ion Engi ne operat es norm ally 4-6
( 1-2 ) MAP sensor high volt age
P0117 ECT sensor m alfunct ion Hard st art at a low t em perat ure 4-7
( 7-1 ) ECT sensor low volt age
P0118 ECT sensor m alfunct ion Hard st art at a low t em perat ure 4-8
( 7-2 ) ECT sensor high volt age
P0122 TP sensor m alfunct ion Poor engi ne accelerat i on 4-9
( 8-1 ) TP sensor low volt age
PO123 TP sensor m alfunct ion Poor engi ne accelerat i on 4-10
( 8-2 ) TP sensor high volt age
P0112 IAT sensor m alfunct ion Engi ne operat es norm ally 4-11
( 9-1) IAT sensor low volt age
P0113 IAT sensorm alfunct i on Engi ne operat es norm ally 4-12
( 9-2 ) IAT sensor high volt age
P0500 VS sensor m alfunct ion Engi ne operat es norm ally 4-13
( 11-1)
P0201 Inj ect or m alfunct ion Engi ne does not st art 4-14
( 12-1) Inj ect or, fuel pum p and ignit ion coil shut down
P0131 O2 sensor m alfunct ion Engi ne operat es norm ally 4-15
( 21-1) O2 sensor low volt age
PO132 O2 sensor m alfunct ion Engi ne operat es norm ally 4-16
( 21-2 ) O2 sensor high volt age
P0135 O2 sensor heat er m alfunct ion Engi ne operat es norm ally 4-17
( 23-1)
P0511 IACV m alfunct ion Engi ne st alls , hard t o st art, rough idling 4-18
( 29-1)
ECM EEPROM m alfunct ion Engi ne st alls , hard t o st art , rough idling
P062F Does not hold t he self di agnosi s dat a 4-19
( 33-2 ) Does not erase t he self di agnosi s dat a wit h
SCS connect or
.
P1000 Bank angle sensor m alfunct ion Engi ne operat es norm ally 4-20
( 54-1) Bank angle sensor low volt age Engi ne st op funct ion does not operat e
P1001 Bank angle sensor m alfunct ion Engi ne operat es norm ally
. 4-21
( 54-2 ) Bank angle sensor high volt age Engi ne st op funct ion does not operat e
EVAP purge cont rol solenoid valve Engi ne operat es norm ally
m alfunct ion
P0443 Loose or poor cont act of t he EVAP purge
4-22
( 88-1 ) cont rol solenoi d valve connect or
EVAP purge cont rol solenoi d valve or it s
circuit m alfunct ion
P0412 PAIR cont rol solenoid valve m alfunct ion Engi ne operat es norm ally 4-23
( 89-1)
P0351 Ignit ion coil prim ary circuit m alfunct ion Engi ne does not st art
4-24
( 91-1) Ignit ion coil or it s circuit m alfunct ion Inj ect or and ignit ion coil shut down
4-2
12 V
ELECTRICAL SYSTEM
PGM - FI SYSTEM LOCATION
ENGINE STOP SWITCH

COMBINATION METER
FUEL PUMP UNIT
IGNITION SWITCH
FUEL INJECTOR
IACV
IGNITION COIL
FUSE BOX
PAIR CONTROL
DLC
SOLENOID VALVE
ECM
BANK ANGLE
SENSOR
SENSOR UNIT:
- MAP SENSOR
- IAT SENSOR
- TP SENSOR
ECT SENSOR
EVAP PURGE CONTROL

SOLENOID VALVE
VS SENSOR
O2 SENSOR
CKP SENSOR BATTERY
4-3
12 V
ELECTRICAL SYSTEM
PGM - FI SYSTEM DIAGRAM
IGN RELAY
R R /W B1/Bu
FI FUSE ( 10A) 000
Br
BI/ O
R FAN FUSE ( 10A) R
ALTERNATOR
IGNITION SWITCH START SWI
R BIR RELAY 10A BI/ Y
CKP SENSOR R
P BV/Bu
MAIN FUSE Rally type
BI ( 30A ) BI/Bu
BI lllll
WIY
EVAP PURGE CONTROL
EVAP type only SOLENOID VALVE
+
BATTERY BI /Bu
G Bu / Y P Y / BI
13 IMOV PCS 33
Lg / R G /R G/ R
29 NLSW Standard type
W
DIODE FFP 8 Br FUEL PUMP UNIT
GEAR BI/Bu
POSITION CLUTCH IGP 1
SWITCH SWITCH COMBINATION METER
| (N ) BINY
G /O G /O G /O W /Bu
25 SSTAND FI-IND 18 B1/ Bu
MIL
BINY
SIDESTAND SWITCH TACHO 23 Rally type
ECM
Buly 12 PCP
G G G /BI ENGINE
2 LG BI BIR STOP
G SWITCH
BI/Bu P BI
BANK ANGLE BI/ O R
SENSOR R / Bu VS SENSOR
26 BA BI
VSP 17 FAN CONTROL
RELAY
BUG
FANC 19 000
MAP SENSOR Lg /BI 27 PB BV/ Bu
PW INJECTOR
INJ 16
Bu G
TP SENSOR 5 THL BVBU SPARK PLUG
G /R
Gr /Bu IGPLS 11
11
14 TA IGNITION COIL BI/ W BI
IAT SENSOR
O /G BI/ Bu
SENSOR UNIT EX -AI 28 t u llell FAN MOTOR
Y/Bu 24 TW PAIR CONTROL
ECT SENSOR SOLENOID VALVE BI/Bu
K- LINE 30 Y
G /W 4 Bu / BI
SG SCS 15
Y /R 6 VCC Bu / G
IACV1A 21 DLC
Gr BI BIW Bu /BI
3 02 IACV1B 32
IACV2A 20 Br/ w
W W W /BI Br /BI
Hl l l l l 22 O2HT IACV2B 31
G G
02 SENSOR 9 PG1 PG2 10 IACV
BV/Bu BVBu Br : Brown

BI : Black
Y : Yellow
1 11 Bu : Blue
G : Green
R : Red
W : White
12 22 : Orange
Lg : Light green
23 33 Gr : Gray
P : Pink
ECM 33P ( BLACK ) CONNECTOR ( ECM SIDE)
4-4
12 V
ELECTRICAL SYSTEM
DTC TROUBLESHOOTING
P0107 ( MAP SENSOR LOW VOLTAGE)
MAP Sensor Di agram
1 Sensor unit 5P ( Black ) connect or 2 2 ECM 33P ( Black ) connect or

(
G /W Y/ R GM
YIR Lg/ BI
Lg / BI
5V
VCC
YIR 5 V
Sensor unit PB ECM
Lg/ BI
( MAP sensor )
SG
G /W
1. MAP Sensor Syst em Inspect i on
Check t he MAP sensor volt age wit h MCS . No Int erm it t ent failure
Is t he volt age about O V indicat ed ? Loose or poor cont act at t he connect or
Yes y
2. Sensor uni t Power Input Volt age Inspect i on
V
1 o ( 1
No Open or short circuit in Y / R wi re

Connect i on : Y/ R ( + ) - G / W ( - )
If t here is no open or short circuit , replace t he ECM
Is t he volt age wit hin 4.75 -5.25 V ? wit h a new one 4-25 , and recheck .
Yes V
3. MAP Sensor Out put Volt age Inspect i on
V
1
Connect i on : Lg /BI ( + ) - G / W ( - ) Yes Replace t he sensor unit ( MAP sensor ) wit h a new
Is t he volt age wit hin 3.80 -5.25 V? one 2-8 , and recheck .
No V
4. MAP Sensor Out put Li ne Inspect i on
Check for a short circuit in Lg / Bl wi re .

If t here is no short circuit , replace t he ECM wit h a
new one 4-25 , and recheck .
4-5
12 V
ELECTRICAL SYSTEM
PO108 ( MAP SENSOR HIGH VOLTAGE )
MAP Sensor Di agram
Sensor unit 5P ( Black ) connect or 2 ECM 33P ( Black ) connect or
1 G /W 1 YIR G /W
1
1 Y/ R Lg/ BI 1
Lg / BI
5 V
VCC
Y/ R 5V
Sensor unit PB
Lg / BI ECM
(MAP sensor )
SG
G /W
1. MAP Sensor Syst em Inspect i on
Check t he MAP sensor volt age wit h MCS . No Int erm it t ent failure
.
Is t he volt age about 5 V indicat ed ? Loose or poor cont act at t he connect or
Yes
2. MAP Sensor Inspect i on
Inst all a j um per wi re bet ween t he t erm inals .

Connect i on : Lg / BI - G / W Yes Replace t he sensor unit ( MAP sensor ) wit h a new
Check t he MAP sensor volt age wit h MCS . one 2-8 , and recheck .
Is t he volt age about V indicat ed ?
No
3. MAP Sensor Out put Li ne Inspect i on
Check for an open circuit in Lg / BI and G / W wire .

If t here is no open circuit , replace t he ECM wit h a
4-6
12 V
ELECTRICAL SYSTEM
P0117 ( ECT SENSOR LOW VOLTAGE )
ECT Sensor Di agram
1ECT sensor 3P (Gray ) connect or 2 ECM 33P ( Black ) connect or
G /W
1
1
. Y/ Bu G /W
Y/ Bu
-
5 V
TW
Y/ Bu
ECT sensor ECM

SG
G /W
1. ECT Sensor Syst em Inspect i on
Check t he ECT sensor volt age wit h MCS . No Int erm it t ent failure
.
Yes
2. ECT Sensor Inspect i on
1 - >
Check t he ECT sensor volt age wit h MCS . No Replace t he ECT sensor wit h a new one 4-25 ,
Is t he volt age about O V indicat ed ? and recheck .
Yes
3. ECT Sensor Out put Li ne Inspect i on
Check for a short circuit in Y/ Bu wi re .

If t here is no short circuit , replace t he ECM wit h a
4-7
12V
ELECTRICAL SYSTEM
P0118 ( ECT SENSOR HIGH VOLTAGE)
ECT Sensor Di agram
D ECT sensor 3P ( Gray ) connect or 2 ECM 33P ( Black ) connect or
G /W
1 1
1 1
Y/ Bu G /W 1
1
Y/ Bu
5 V
TW
Y/ Bu
ECT sensor ECM

SG
G/
1. ECT Sensor Syst em Inspect i on
Check t he ECT sensor volt age wit h MCS . No Int erm it t ent failure
. .
Yes
2. ECT Sensor Inspect i on
1.

Connect i on : Y / Bu - G / W Yes Replace t he ECT sensor wit h a new one 4-25 ,
Check t he ECT sensor volt age wit h MCS . and recheck .
Is t he volt age about V indicat ed ?
No
3. ECT Sensor Out put Li ne Inspect i on
Check for an open circuit in Y/ Bu and G / W wire .

4-8
12 V
ELECTRICAL SYSTEM
P0122 ( TP SENSOR LOW VOLTAGE)
TP Sensor Di agram
1 Sensor unit 5P ( Black ) connect or 2 ECM 33P ( Black ) connect or
Y/ R Y G/
I
G /W 1
1 YIR
-
5V
VCC
Y/ R
Sensor unit
THL ECM
( TP sensor ) Y
SG
G /W
1. TP Sensor Syst em Inspect i on
Check t he TP sensor volt age wit h MCS . No Int erm it t ent failure
Is t he volt age about V indicat ed ? Loose or poor cont act at t he connect or
Yes
2. Sensor uni t Power Input Volt age Inspect i on
1S
-> => ( 1
No Open or short circuit in Y/ R wi re

Connect i on : Y / R ( + ) - G / W ( - )
If t here is no open or short circuit, replace t he ECM
Is t he volt age wit hin 4.75 -5.25 V?
wit h a new one 4-25 , and recheck .
Yes V
3. TP Sensor Out put Li ne Inspect i on

. Yes
Check for an open or short circuit in Y wi re .
Fault y Y wi re
Is t here open or short circuit ?
No v
4. TP Sensor Inspect i on
Replace t he sensor unit ( TP sensor ) wit h a new

one 2-8
Erase t he DTC .
Check t he TP sensor wit h MCS .
If DTC 8-1 is indicat ed , replace t he ECM wit h a
4-9
12 V
ELECTRICAL SYSTEM
PO123 ( TP SENSOR HIGH VOLTAGE )
TP Sensor Di agram
1 Sensor unit 5P ( Black ) connect or 2 ECM 33P ( Black ) connect or
YIR G /W
1
1
G /W 1
1 Y/ R
5V
VCC
YIR
Sensor unit THL
Y ECM
(TP sensor ) W
SG
G /W
1. TP Sensor Syst em Inspect i on
Check t he TP sensor volt age wit h MCS .

Operat e t he t hrot t le from fully closed t o fully
Check t he TP sensor volt age wit h MCS when t he No opened .
t hrot t le fully closed . A If t he volt age is not i ncrease cont i nuously , replace
Is t he volt age about 5 V indicat ed ?
t he sensor unit ( TP sensor ) wit h a new one 2-8 ,
and recheck .
Yes v
2. TP Sensor Ground Li ne Inspect i on
Check for an open circuit in G / W wi re . Yes

Fault y GW wi re
Is t here open circuit ?
No v
3. TP Sensor Inspect i on
Replace t he sensor unit ( TP sensor ) wit h a new

one 2-8
Erase t he DTC.
Check t he TP sensor wit h MCS .
4-10
12 V
ELECTRICAL SYSTEM
P0112 ( IAT SENSOR LOW VOLTAGE)
IAT Sensor Di agram
1Sensor unit 5P ( Black ) connect or 2 ECM 33P ( Black ) connect or
GMW
Gr/ Bu GM
Gr / Bu
5 V
TA
Gr /Bu
Sensor unit
( IAT sensor ) ECM
SG
G /W
1. IAT Sensor Syst em Inspect i on
Check t he IAT sensor volt age wit h MCS . No Int erm it t ent failure
Is t he volt age about V indicat ed ? Loose or poor cont act at t he connect or
Yes V
2. IAT Sensor Inspect i on
1 >
Check t he IAT sensor volt age wit h MCS . No Replace t he sensor unit ( IAT sensor ) wit h a new
. Is t he volt age about O V indicat ed ? one 2-8 , and recheck .
Yes y
3. IAT Sensor Out put Li ne Inspect i on
Check for a short circuit in Gr / Bu wi re .

If t here is no short circuit, replace t he ECM wit h a
4-11
12V
ELECTRICAL SYSTEM
P0113 ( IAT SENSOR HIGH VOLTAGE)
IAT Sensor Di agram
1 2 ECM 33P ( Black ) connect or

Sensor unit 5P ( Black ) connect or
GW
Gr/ Bu G /W
Gr / Bu
5V
TA
Gr /Bu
Sensor unit
ECM
(IAT sensor )
SG
G /W
1. IAT Sensor Syst em Inspect i on
Check t he IAT sensor volt age wit h MCS . No Int erm it t ent failure
Yes V
2. IAT sensor Inspect i on
a(15

Connect i on : Gr/ Bu - G / W Yes Replace t he sensor unit ( IAT sensor ) wit h a new
Check t he IAT sensor volt age wit h MCS . one 2-8 , and recheck .
Is t he volt age about O V indicat ed ?
No v
3. IAT Sensor Volt age Input Li ne Inspect i on
Check for an open circuit in Gr / Bu and G / W wire .

4-12
12 V
ELECTRICAL SYSTEM
P0500 ( VS SENSOR)
Rally t ype : Wi nd screen 3-5

St andard t ype : Front vi sor 3-6
VS Sensor Di agram
1 VS sensor 3P ( Blue ) connect or 2 Com binat ion m et er 28P ( Gray ) connect or 3 ECM 33P ( Black ) connect or
I BI / R G/ BI BI / R BI
BI RODOGRODOS
G/ BI
Com binat ion

m et er
BI VSP
VS sensor G/ BI ECM
BI / R
1. VS Sensor Syst em Inspect i on
Check t he VS sensor wit h MCS . No Int erm it t ent failure

Is t he DTC 11-1 indicat ed ? A Loose or poor cont act at t he connect or
Yes V
2. VS Sensor Input Volt age Inspect i on
( - > 1
1
Connect i on : BI / R ( + ) - G/ BI ( - ) NO >
Fault y BI / R or G/ Bl wi re
Does t he bat t ery volt age exist ?
Yes y
3. VS Sensor Si gnal Li ne Inspect i on
Check for an open or short circuit in Bl wi re . Yes

Fault y Bl wi re
No V
4. VS Sensor Inspect i on
Replace t he VS sensor wit h a new one . 4-61

Erase t he DTC’s .
Test - ride t he vehi cle and check t he VS sensor wit h
MCS .
If DTC 11-1 is indicat ed , replace t he com binat ion
m et er wit h a new one 4-59, and recheck .
Test - ride t he vehi cle and check t he VS sensor wit h
MCS .
4-13
12 V
ELECTRICAL SYSTEM
P0201 ( INJECTOR)
Inj ect or Di agram
1 Inj ect or 2P connect or 1Inj ect or 2P ( Gray ) connect or

( Inject or side ) (Wire side ) 2 ECM 33P ( Black ) connect or
P /W
1
1 1
. B PW BI / Bu
From Bat t ery
BI / Bu
Inject or ECM
INJ
P /W
1. Fuel Inj ect or Syst em Inspect i on
Check t he fuel inj ect or wit h MCS . No Int erm it t ent failure
Is t he DTC 12-1 is indicat ed ? Loose or poor cont act at t he connect or
Yes
2. Fuel Inj ect or Input Volt age Inspect i on
V
1> => 1
Connect i on : BI / Bu ( + ) - Ground ( - ) No
Open circuit in BI / Bu wi re
Does t he bat t ery volt age exi st ?
Yes y
3. Fuel Inj ect or Si gnal Li ne Inspect i on
Check for an open or short circuit in P / W wi re . Yes

Fault y P / W wi re
No 7
4. Fuel Inj ect or Resi st ance i nspect i on
Connect i on : A - B No
A Fault y fuel inj ect or
Is t he resi st ance wit hin 11 13 2 (( 20 C
C ))??
Yes y
Replace t he ECM wit h a new one 4-25 , and re

check .
4-14
12 V
ELECTRICAL SYSTEM
P0131 ( O2 SENSOR LOW VOLTAGE)
O2 Sensor Di agram
1 O2 sensor 4P ( Black ) connect or 2 ECM 33P ( Black ) connect or

G W BI W I BI/ W
1
1 1
1
02 ECM
O2 sensor
BI BI / W
SG
Gr G /W
1. O2 Sensor Syst em Inspect i on
Test - ride t he vehi cle and check t he O2 sensor wit h

No Int erm it t ent failure
MCS .
Loose or poor cont act at t he connect or
Is t he DTC 21-1 indicat ed ?
Yes V
2. O2 Sensor Ci rcui t Inspect i on
Check for a short circuit in BI / W wi re . Yes

Fault y BI/ W wi re .
Are t here short circuit ?
No
3. Fuel Supply Test ( Fuel Pressure Test )
Check t hat t here is any errat ic swing or vibrat ion of

t he gauge needle in t he pressure gauge readi ng .
Perform t he fuel pressure t est . 2-3 No - If t he needle is swing or vibrat ion , replace t he
Is t he fuel pressure wit hin specificat ion ? A fuel filt er. 2-5
- If t he needle is st able , replace t he fuel pum p
unit . 2-4
Yes y
4. Fuel Supply Test ( Fuel Flow Test )
Adj ust t he fuel in t he t ank unt il t he fuel gauge seg

m ent is posi t i oned t he speci fi ed range , and i n No
Replace t he fuel filt er . 2-5
spect t he fuel flow . 2-3
Is t he fuel flow wit hin specificat ion ?
Yes V
5. O2 Sensor Inspect i on
Replace t he O2 sensor wit h a new one . 4-26

. Erase t he DTC’s .
.
MCS .
4-15
12 V
ELECTRICAL SYSTEM
PO132 ( O2 SENSOR HIGH VOLTAGE)
O2 Sensor Di agram
1 O2 sensor 4P ( Black ) connect or (2 ECM 33P ( Black ) connect or

1 G /W BI / W BI/ W
1
1
IG / W
ECM
O2 sensor 02
BI BI/ W
SG
Gr G /W
1. O2 Sensor Syst em Inspect i on
Test - ride t he vehi cle and check t he O2 sensor wit h No Int erm it t ent failure
MCS .
A Loose or poor cont act at t he connect or
Yes
2. O2 Sensor Ci rcui t Inspect i on
Check for open circuit in BI / W and G / W wi res . Yes

. Fault y BI / W or G / W wi re .
Are t here open circuit ?
No
3. O2 Sensor Inspect i on
Replace t he O2 sensor wit h a new one . 4-26

MCS .
4-16
12V
ELECTRICAL SYSTEM
PO135 ( O2 SENSOR HEATER)
O2 Sensor Heat er Di agram

1 O2 sensor 4P ( Black ) connect or 1
O2 sensor 4P ( Black ) connect or
( O2 sensor side ) ( Wire side ) Q 2 ECM 33P ( Black ) connect or
I
. A
. W W BI/ Bu W/ BI
W/ BI
From Bat t ery
W BI / Bu I
W W /BI O2HT
O2 sensor ECM
1. O2 Sensor Heat er Syst em Inspect i on
Erase t he DTC’s , and check t he O2 sensor heat er . Int erm it t ent failure
No
wit h MCS .
Is t he DTC 23-1 indicat ed ? Loose or poor cont act at t he connect or
Yes y
2. O2 Sensor Heat er Input Volt age Inspect i on
1 = -> O 1
Connect i on : Bl / Bu ( + ) - Ground ( - ) No
Fault y BI/ Bu wi re
Yes V
3. O2 Sensor Heat er Si gnal Li ne Inspect i on
Check for an open or short circuit in W / BI wi re . Yes

. Fault y W/ BI wi re
No v
3. O2 Sensor Heat er Resi st ance Inspect i on
1 1
Connect i on : W W No
Fault y O2 sensor
Is t he resi st ance wit hin 13 19 12 ( 20 C) ?
Yes y
Replace t he ECM wit h a new one 4-25 , and

recheck .
4-17
12V
ELECTRICAL SYSTEM
P0511 ( ACV )
IACV Di agram
1 IACV 4P connect or IACV 4P ( Black ) connect or

( IACV side ) (Wire side ) 2 ECM 33P ( Black ) connect or
Br / w Br /BI Bu / w Br / W
ABCD Gol e
COORDODUORODOS
Bu / W Bu / BI
Bu / BI Br / BI
Bu / w IACV1A
Bu / BI IACV1B ECM
IACV
Br / w IACV2A
Br / BI IACV2B
1. IACV Syst em Inspect i on
Check t he IACV wit h MCS . No Int erm it t ent failure

Is t he DTC 29-1 is indicat ed ? A Loose or poor cont act at t he connect or
Yes V
2. IACV Ci rcui t Inspect i on
Check for an open or short circuit in Bu / W , Br / W , Yes

Br / Bl and Bu / Bl wi res . O Fault y Bu / W , Br / W ,5 Br / Bl or Bu / BI wi re
No v
3. IACV Resi st ance Inspect i on
1 1
Connect i on : A - D , B - C No
. A Fault y IACV
Is t he resi st ancewit hin 110 - 150 12 ( 25 C) ?
?
Yes V
4. IACV Short Ci rcui t Inspect i on
Connect i on : A , B , C - D Yes
Fault y IACV
Is t here cont inuit y ?
No v

check .
4-18
12 V
ELECTRICAL SYSTEM
P062F ( EEPROM )
1. EEPROM Syst em Inspect i on
Check t he EEPROM wit h MCS . Int erm it t ent failure

Is t he DTC 33-2 is indicat ed ? NO Loose or poor cont act at t he connect or
Yes

check .
4-19
12 V
ELECTRICAL SYSTEM
P1000 ( BANK ANGLE SENSOR LOW VOLTAGE )
Bank Angle Sensor Di agram
1 Bank angle sensor 2P ( Black )

connect or 2 ECM 33P ( Black ) connect or
.
1 R / Bu
1
1
R/ Bu BI / Bu CONTRODS
From Bat t ery
BI/ Bu
Bank angle sensor ECM

BA
R/ Bu
1. Bank Angle Sensor Syst em Inspect i on
Check t he bank angle sensor volt age wit h MCS . No Int erm it t ent failure
Yes
2. Bank Angle Sensor Power Input Volt age Inspect i on
D -
1 1
A Fault y BI / Bu wi re
Yes y
3. Bank Angle Sensor Out put Li ne Inspect i on
Check for an open or short circuit in R/ Bu wi re . Yes

Fault y R / Bu wi re
No v
4. Bank Angle Sensor Inspect i on
Replace t he bank angle sensor wit h a new one .

4-26
Check t he bank angle sensor wit h MCS .
4-20
12 V
ELECTRICAL SYSTEM
P1001 ( BANK ANGLE SENSOR HIGH VOLTAGE)
.
Bank angle sensor ( Connect or is connect ed . ) 4-26
Bank Angle Sensor Di agram
1 Bank angle sensor 2P ( Black )

connect or 2 ECM 33P ( Black ) connect or
R/ Bu
R/ Bu BI/ Bu
From Bat t ery
BI/ Bu
Bank angle sensor ECM

BA
R / Bu
1. Bank Angle Sensor Syst em Inspect i on
Check t he bank angle sensor volt age wit h MCS .

Yes Replace t he ECM wit h a new one 4-25 , and
Incline t he bank angle sensor .
recheck .
Is t he volt age decrease ?
No V
Replace t he bank angle sensor it h a new one

4-26 , and recheck .
4-2 1
12 V
ELECTRICAL SYSTEM
P0443 ( EVAP PURGE CONTROL SOLENOID VALVE )
EVAP Purge Cont rol Solenoi d Valve Di agram
1EVAP purge cont rol solenoid valve 1 EVAP purge cont rol solenoid valve
2P connect or (Valve side ) 2P ( Black ) connect or (Wire side ) 2 ECM 33P ( Black ) connect or
Y/ BI
" COLORIOU
A B BI / Bu Y/ BI
1
From Bat t ery
BI/ Bu
EVAP purge cont rol
solenoid valve ECM
PCS
Y/ BI
1. EVAP Purge Cont rol Solenoi d Valve Syst em Inspect i on
Check t he EVAP purge cont rol solenoi d valve wit h No Int erm it t ent failure
MCS .
Loose or poor cont act at t he connect or
Yes 7
2. EVAP Purge Cont rol Solenoi d Valve Input Volt age Inspect i on
V
15>> 1
. - No
Connect i on : BI / Bu ( + ) - Ground ( - ) , Fault y BI/ Bu wi re
Yes v
3. EVAP Purge Cont rol Solenoi d Valve Si gnal Li ne Inspect i on
Check for an open or short circuit in Y/ Bl wi re . Yes

Fault y Y / BI wi re
No
4. EVAP Purge Cont rol Solenoi d Valve Resi st ance i nspect i on
( 1 1
Is t he resi st ance wit hin 30-34 2 ( 20 C ) ? Fault y EVAP purge cont rol solenoi d valve
Yes V

check .
4-22
12 V
ELECTRICAL SYSTEM
P0412 ( PAIR CONTROL SOLENOID VALVE)
PAIR Cont rol Solenoi d Valve Di agram
1 PAIR cont rol solenoid valve 1PAIR cont rol solenoid valve 2P
2P connect or (Valve side ) ( Black ) connect or (Wire side ) 2 ECM 33P ( Black ) connect or
1
1 O /G
1 1
1
1
A B O/ G BI / Bu
L
From Bat t ery
BV/ Bu Y
PAIR cont rol

ECM
solenoid valve
EX-AI
O/ G
1. PAIR Cont rol Solenoi d Valve Syst em Inspect i on
Check t he PAIR Cont rol Solenoi d Valve wit h MCS . No Int erm it t ent failure
Yes
2. PAIR Cont rol Solenoi d Valve Input Volt age Inspect i on
1>> . ID
A Fault y BI/ Bu wi re
Yes
3. PAIR Cont rol Solenoi d Valve Si gnal Li ne Inspect i on
Check for an open or short circuit in O/ G wi re . Yes

Fault y O/ G wi re
No
4. PAIR Cont rol Solenoi d Valve Resi st ance Inspect i on
Is t he resi st ance wit hin 24 - 28 2 ( 20 C) ? Fault y PAIR Cont rol Solenoi d Valve
Yes y
.
Replace t he ECM wit h a new one 4-25 , and r e
check .
4-23
12V
ELECTRICAL SYSTEM
P0351 ( IGNITION COIL PRIMARY CIRCUIT)
Igni t i on Coi l Pri m ary Ci rcui t Di agram
2 ECM 33P ( Black ) connect or
G/ R
1Ignit ion coil wire connect or
From Bat t ery
ECM
IGNITION BI/ Bu
COIL G/ R IGPLS
1. Igni t i on Coi l Pri m ary Ci rcui t Syst em Inspect i on
Check t he Ignit ion coil wit h MCS . No . Int erm it t ent failure
Yes
2. Igni t i on Coi l Pri m ary Ci rcui t Input Volt age Inspect i on
V
1 1
Connect i on : BI / Bu ( + ) - Ground ( - ) No .
, Fault y BI / Bu wi re
Yes y
3. Igni t i on Coi l Pri m ary Ci rcui t Si gnal Li ne Inspect i on
Check for an open or short circuit in G/ R wi re Yes

Fault y G/ R wi re
No V
4. Igni t i on Coi l Inspect i on
Replace t he ignit ion coil wit h a new one

Test - ride t he vehi cle and check t he ignit ion coil
wit h MCS .
4-24
12 V
ELECTRICAL SYSTEM
ECM
VA
ECM power circuit and ground circuit inspect ion

m
Basic
ECT SENSOR
25 N.m
m uc
.
New
Ri ght fuel t ank shroud 3-13
ECT sensor inspect ion

Basic
4-25
12 V
ELECTRICAL SYSTEM
O2 SENSOR
25 N m 1.
Exhaust pipe 3-24

1Rem ove t he O2 sensor .
Flare nut sock et: FRXM17 ( Snap on ) or equi valent
BANK ANGLE SENSOR
9 N.m
Bank angle sensor inspect ion

Basic
4-26
12 V
ELECTRICAL SYSTEM
IGNITION SYSTEM
IGNITION SYSTEM LOCATION
IGNITION SWITCH
IGNITION COIL BATTERY
FUSE BOX
ECM
MAIN FUSE
SPARK PLUG CKP SENSOR (30 A)
IGNITION SYSTEM DIAGRAM
MAIN FUSE FI FUSE

30 A 10 A
R R ao
R /W
00 e dL
BI / R R
START IGNITION SIDESTAND
BATTERY
SW /RELAY SWITCH SWITCH
10 A G
BINY BI/ O
CLUTCH
ENGINE
Br G/ O SWITCH
STOP BINY BANK
SWITCH G/ O
La ANGLE
SENSORI
IGN RELAY G/ O G/ R
BI / Bu G/ R
G/ R R/ Bu
BI / Bu Lg/ R
IGNITION GEAR
COIL POSITION
ECM SWITCH
SPARK PLUG (N)
O Bu / Y G
of
www
SENSOR
4-2 7
12 V
ELECTRICAL SYSTEM
SPARK PLUG REPLACEMENT
16 N.m
O
Radi at or wit h it s hoses connect ed and cooling fan 2-18
Spark plug inspect ion

Basic
4-28
12 V
ELECTRICAL SYSTEM
INSPECTION
IGNITION COIL PRIMARY PEAK VOLTAGE
Refer t o " Basi c Shop Manual " for t he det ail inform at ion of
1
Basic ignit ion coil prim ary peak volt age inspect ion .
Fuel t ank 2-6
1 Connect a known - good spark plug t o t he spark plug cap

and ground it t o t he cyli nder head bolt as done in a spark
t est .
2 Wit h t he ignit ion coil prim ary wi res connect ed , connect
t he peak volt age adapt or probes t o t he ignit ion coil
prim ary t erm inal and ground .
CONNECTION : G/ R ( +) - -
Ground (- )
Check t he init ial volt age at t his t im e .

STANDARD VOLTAGE: Bat t ery volt age
. Shift t he t ransm ission int o neut ral .
Crank t he engi ne wit h t he st art er and m easure t he

ignit ion coil prim ary peak volt age .
PEAK VOLTAGE: 100 V m i ni m um
IGNITION TIMING
.
Warm up t he engi ne norm al operat i ng t em perat ure.
Ti m i ng hole cap 2-22
Connect t he t im ing light t o t he spark plug wi re .

F
St art t he engi ne and let it idle
* IDLE SPEED : 1,450 + 100 rpm
The ignit ion t im ing is correct if t he " F " m ark on t he

flywheel aligns wit h t he index not ch on t he left crank case
cover .
4-29
12V
ELECTRICAL SYSTEM
ELECTRICAL STARTER
ELECTRICAL STARTER SYSTEM LOCATION
IGNITION SWITCH ENGINE STOP SWITCH

STARTER SWITCH
BATTERY
FUSE BOX
CLUTCH . 10 A
SWITCH
STARTER
RELAY
SWITCH
MAIN FUSE
( 30A )
STARTER GEAR
MOTOR POSITION
SWITCH SIDE STAND
SWITCH
ELECTRICAL STARTER SYSTEM DIAGRAM
BI BI R BI / R
BI MAIN FUSE
30 A START SWI
RELAY
IGNITION
SWITCH 10 A
BATTERY
Y/ R BINY
STARTER STARTER
MOTOR M RELAY
SWITCH STARTER
SWITCH
ENGINE STOP
SWITCH
G/ R
BI / O
Lg/ R G/ R G/ R - G/ O
CLUTCH
SWITCH
W
DIODE
Lg
GEAR SIDESTAND
G
SWITCH
POSITION
SWITCH
(N)
NEUTRAL INDICATOR
4-3 0
12 V
ELECTRICAL SYSTEM
ELECTRICAL STARTER TROUBLESHOOTING

STARTER MOTOR DOES NOT TURN
Left si de cover 3-8
Loose or poor cont act s of relat ed t erm i nal/ connect or

Bat t ery condit ion
Burned fuse
Connect or Di agram
1St art er relay 4P ( Red ) connect or
G/ R Y/ R
1. St art er Relay Coi l Input Ci rcui t Inspect i on
V
1
Inspect t he following .
Connect i on : Y/ R ( + ) - Ground ( - ) - Ignit ion swit ch
No
Push and hold t he st art er swit ch . A - St art er swit ch
Does t he bat t ery volt age exist ? - Engi ne st op swit ch
- St art er relay coil input circuit relat ed circuit
Yes V
2. St art er Relay Coi l Ground Ci rcui t Inspect i on
1 1
.
Connect i on : G/ R - Ground Inspect t he followi ng.
Squeeze t he clut ch lever or t ransm ission in neut ral - Di ode
posit ion . No - Clut ch swit ch
. Squeeze t he clut ch lever and ret ract t he sidest and A - Neut ral swit ch
or shift t he t ransm ission in neut ral posit ion . - Si dest and swit ch
Is t here cont inuit y ? - St art er relay coil ground circuit relat ed circuit
Yes V
3. St art er Relay Inspect i on
Replace t he st art er relay wit h a new one , and re Yes Fault y original st art er relay
check .
Does t he st art er m ot or t urn ?
No v
Check for a short or open circuit in st art er m ot or

cable .
If t here is no fault y circuit , replace t he St art er m o
t or wit h a new one , and recheck .
4-3 1
12 V
ELECTRICAL SYSTEM
STARTER MOTOR
New Oil
Exhaust pipe 3-24

O
Cam chain t ensi oner 2-28
4.9 N.m
New New
O2 0
New Oil
L0 0 0
Oil New
LV
3.7 N.m
4-3 2
12 V
ELECTRICAL SYSTEM
10 N.m
New Oil
Engi ne oil 2-15

Gear shift pedal 3-16
1Set t he t ransm ission t o neut ral and align t he swit ch longer pin wit h t he paint m ark .
4-3 3
12 V
ELECTRICAL SYSTEM
ABS
Refer t o " Basi c Shop m anual" for t he followi ng inform at ion .

Basic - ABS t echnical feat ure and each
funct ion .
- Troubleshoot i ng for t he ABS .
- MCS (Mot orcycle Com m uni cat i on Syst em ) inform at ion .
DTC INDEX
Det ect i on
DTC Funct i on Fai lure Sym pt om / Fai l -safe funct i on Page
*A *B
ABS indicat or m alfunct ion ABS indicat or never com e
4-38
ABS m odulat or volt age input line ON at all
- Indicat or relat ed wi res ABS indicat or st ays ON

Com bi nat i on m et er 4-38
ABS m odulat or
ABS MAIN fuse ( 10 A)
Front wheel speed sensor circuit inspect ion St ops ABS operat i on 4-40
1-1 O
Wheel speed sensor or relat ed wi res
Front wheel speed sensor m alfunct ion St ops ABS operat i on
1-2 Wheel speed sensor , pulser ring or relat ed 4-40
wi res
Elect rom agnet i c i nt erference
.
1-3 Rear wheel speed sensor circuit m alfunct ion St ops ABS operat i on 4-41
O
Wheel speed sensor or relat ed wi res
.
Rear wheel speed sensor m alfunct ion St ops ABS operat i on
1-4 Wheel speed sensor , pulser ring or relat ed 4-41
wi res
Elect rom agnet i c i nt erference
2-1 Front pulser ring O St ops ABS operat ion 4-40
Pulser ring or relat ed wi res
Rear pulser ring St ops ABS operat i on
2-3 O 4-41
Pulser ring or relat ed wi res
3-1 Solenoi d valve m alfunct ion (ABS m odulat or ) St ops ABS operat i on
3-2
o 4-42
3-3
3-4
.
4-1 Front wheel lock O St ops ABS operat i on
Riding condit ion 4-40
Front wheel lock (Wheeli e )
4-2 O
Ri di ng condit ion
Rear wheel lock St ops ABS operat i on
4-3 O 4-41
Ri di ng condit ion
Pum p m ot or lock St ops ABS operat i on
Pum p m ot or ( ABS m odulat or ) or relat ed
5-1 4-43
wi res
MR+ B fuse ( 30 A)
Pum p m ot or st uck off St ops ABS operat i on
5-2 Pum p m ot or ( ABS m odulat or ) or relat ed O O 4-43
wi res
MR+ B fuse ( 30 A)
Pum p m ot or st uck on St ops ABS operat i on
5-3 Pum p m ot or ( ABS m odulat or ) or relat ed O 4-43
wi res
MR+ B fuse ( 30 A)
Power supply relay m alfunct ion St ops ABS operat i on
5-4 Power supply relay ( ABS m odulat or ) or O O 4-44
relat ed wi res
FSR+ B fuse ( 30 A)
4-3 4
12 V
ELECTRICAL SYSTEM
Det ect i on
DTC Funct i on Fai lure
*A *B Sym pt om / Fai l -safe funct i on Page
Power circuit under volt age St ops ABS operat i on
6-1 Input foot age ( t oo low ) O O 4-45
ABS MAIN fuse ( 10 A)
Power circuit over volt age St ops ABS operat ion
6-2 O O 4-45
Input volt age ( t oo high )
Ti re m alfunct i on St ops ABS operat ion
7-1 Ti re si ze
4-46
Incorrect sprocket gear rat io ( Sprock et s not
recom m ended for t he vehi cle are inst alled.)
ABS cont rol unit St ops ABS operat i on
8-1 ABS cont rol unit m alfunct ion ( ABS 4-46
m odulat or )
8-2 Rear ABS off indicat or Rear ABS off m ode funct ion
O O 4-47
Rear ABS off i ndi cat or or relat ed wire does not work
* A: Pre - st art self - diagnosis
* B : Ordi nary self - diagnosis : di agnoses whi le t he vehi cle is running ( aft er pre - st art self -diagnosis )
4-3 5
12 V
ELECTRICAL SYSTEM
How To Erase t he DTC Wi t hout MCS
Connect t he DLC.
(ABS)
Squeeze t he brake lever .
The ABS indicat or should com e on 2 seconds and go off .

Ne Aft er t he ABS indicat or is off, release t he brake lever i m m e
diat ely .
SEL (18:88 7 8 9 10 11 12
KUUMIMITIVITIMIXadimer Aft er t he ABS indicat or is on , squeeze t he brake lever i m
TOTAL TRP AB
SET JAmite m edi at ely .
M SAVG 8
BB86 * GEAR Aft er t he ABS indicat or is off, release t he brake lever i m m e
19 9m1 kinph/h km /h alboKM diat ely .
- When code erasure is com plet e , t he ABS indicat or blinks
2 t im es and st ay on .
If t he ABS indicat or does not blink , t he dat a has not been
erased , so t ry again .
ABS LOCATION
COMBINATION METER
FUSE BOX
- 10 A IGNITION SWITCH
- 10 A
-
FRONT BRAKE
ABS FUSE BOX LIGHT SWITCH
- 30 A
- 30 A
DLC
BRAKE / TAIL
LIGHT
MAIN FUSE ( 30 A)
ABS MODULATOR
FRONT WHEEL SPEED SENSOR

BATTERY REAR BRAKE
LIGHT SWITCH
REAR WHEEL SPEED SENSOR
4-3 6
12 V
ELECTRICAL SYSTEM
ABS DIAGRAM
MAIN FUSE 30 A
R
FRONT BRAKE
LIGHT SWITCH
IGNITION
SWITCH BI BRAKE / TAIL
TAIL, STOP, HORN GNY LIGHT
10A
BI/ R BI G /Y G
BI BI
REAR BRAKE
LIGHT SWITCH
ABS MAIN G /Y
10A BLS 4 G
BI/ R BI
7 IG
BI BI Bu / R ABS
+ IND 13
MR+B INDICATOR
30 A
R R /BI BI/ W REAR ABS
BATTERY 9 MR + B MODE IND 3 OFF
INDICATOR
FSR+B
30 A COMBINATION METER
R R /W
18 FSR+B
Y
DIAG 5
SCS 14 Bu / BI
G
G BI BI/ G G /BI
12 MODE_ SW
REAR ABS DLC
CANCEL SWITCH
W Y G/ R
17 FVWS MOTOR_ GND 1
Bu / Y
8 FVWB
W Bu
W G /Y
FRONT WHEEL 15 RVWS GND 10
SPEED SENSOR Bu
6 RVWB
FRONT PULSER RING
REAR WHEEL ABS MODULATOR

SPEED SENSOR
oh
REAR PULSER RING

BI : Black
Bu : Blue
1 9 G : Green
23 45678 : Orange
R : Red
W : White
10 11 12 13 14 15 16 17 18 Y : Yellow
ABS MODULATOR 18P ( Black ) CONNECTOR (MODULATOR SIDE)
4-3 7
12 V
ELECTRICAL SYSTEM
DTC TROUBLESHOOTING
. Before st art ing t his t roubleshoot i ng , check t he burned fuse and init ial funct ion of t he com binat ion m et er.
Use a fully charged bat t ery. Do not di agnose wit h a charger connect ed t o t he bat t ery.
Perform inspect ion wit h t he ignit ion swit ch OFF , unless ot herwi se specified .
All connect or di agram s in t he t roubleshoot i ng are vi ewed from t he t erm inal si de .
When t he ABS m odulat or assem bly is det ect ed t o be fault y , recheck t he wi re harness and connect or connect i ons
closely before replaci ng it.
.
Aft er diagnost ic t roubleshoot i ng , erase t he DTC and t est - ride t he vehi cle t o check t hat t he ABS indicat or operat es
norm ally duri ng pre -st art self -diagnosis.
ABS i ndi cat or m alfunct i on
Rally t ype : Wi nd screen 3-5

ABS i ndi cat or does not com e ON (When t he i gni t i on swi t ch ON )
Com binat ion m et er 28P ( Gray ) connect or 2 ABS m odulat or 18P ( Black ) connect or
Bu / R Bu / R
From Bat t ery
IGN
COMBINATION ABS Bu / R IND ABS MODULATOR

METER
1. ABS Indi cat or Inspect i on
. Check t he Yes
ABS indicat or .
Fault y ABS m odulat or
Does not t he ABS indicat or com e on ?
No v
2. ABS i ndi cat or Li ne Inspect i on
Check for a short circuit in Bu / R wi re. No

A Fault y com binat ion m et er
Is t here short circuit ?
Yes y
.
Fault y Bu / R wi re
4-3 8
12 V
ELECTRICAL SYSTEM
ABS i ndi cat or st ays ON (Indi cat or does not go of f when t he m ot orcycle is runni ng , but DTC is not st ored )
1ABS m odulat or 18P ( Black ) connect or
BI
1
G/ R
Bu / BI Bu / R
From Bat t ery
DLC
e BI IG
Bu / BI
SCS
ABS MODULATOR
COMBINATION ABS Bu / R IND

G/ R www MOTOR GND
METER
1. Servi ce Check Li ne Inspect i on
Check for a short circuit in Bu / Bl wi re . Yes

Is t here short circuit ? Fault y Bu / Bl wi re
No V
2. ABS Indi cat or Li ne Inspect i on
( 1
Inst all a j um per wi re bet ween t he t erm inal and

ground . No Fault y Bu / R wi re
Jum per t erm inal : Bu / R . . If wi re is ok , fault y com binat ion m et er .
Does t he ABS indicat or go off ?
Yes
3. ABS Modulat or Ground Li ne Inspect i on
Check for an open circuit in G/ R wi re . Yes

Fault y G/ R wi re
Is t here open circuit ?
No
4. ABS Modulat or Power Li ne Inspect i on
Connect i on : Bl ( + ) - Ground ( - ) No .
Fault y Bl wi re
Yes y
4-3 9
12 V
ELECTRICAL SYSTEM
DTC 1-1, 1-2 , 2-1, 4-1 or 4-2
(Front wheel speed sensor ci rcui t / Front wheel speed sensor / Front pulser ri ng / Front wheel lock )
2 ABS m odulat or 18P ( Black ) connect or
1 Front wheel speed sensor
2P ( Black ) connect or 1 Buly
Bury WIY
WIY
FRONT WHEEL Bu Bu / Y FVWB

SPEED SENSOR W WIY FVWS ABS MODULATOR
Od
1. Ai r Gap Inspect i on
Measure t he air gap . No Check each part for deform at ion , looseness and
Is t he air gap correct ? correct accordi ngly . Recheck t he air gap .
Yes V
2. Wheel Speed Sensor and Pulser Ri ng Inspec

t i on
Check t he wheel speed sensor and pulser ring .

No Rem ove any deposi t s .
Are t he sensor and pulser ring in good condit ion
Inst all properly or replace fault y part.
and properly inst alled ?
Yes v
3. Speed Sensor Li ne Inspect i on 1
1 2

Jum per t erm inal : W / Y and Bu / Y No
A Fault y W / Y or Bu / wi re
Check for cont inuit y bet ween t he above wi res .
Yes
Check for a short circuit in Bu , Bu / Y , W and W / Y

Yes
wi re . Fault y Bu , Bu / Y , W or W / Y wi re
No v
5. Fai lure Reproduct i on
Replace t he speed sensor wit h a new one . 4-48

Erase t he DTC and t est - ride t he vehi cle above 30 No
Fault y original speed sensor
km / h , t hen recheck t he DTC .
Is t he DTC 1-1 , 1-2 , 2-1 , 4-1 or 4-2 indicat ed ?
Yes y
4-40
12 V
ELECTRICAL SYSTEM
DTC 1-3,1-4 , 2-3 or 4-3
( Rear wheel speed sensor ci rcui t / Rear wheel speed sensor / Rear pulser ri ng / Rear wheel lock )
1 Rear wheel speed sensor 2 ABS m odulat or 18P ( Black ) connect or
2P ( Black ) connect or
1
Bu
Bu W
Bu Bu RWWB
REAR WHEEL
W ABS MODULATOR
SPEED SENSOR RVWS
Od C
O E
1. Ai r Gap Inspect i on
Measure t he air gap . No Check each part for deform at ion , looseness and
Is t he air gap correct ? correct accordi ngly . Recheck t he air gap .
Yes V
2. Speed Sensor and Pulser Ri ng Inspect i on
Check t he speed sensor and pulser ring .

No Rem ove any deposi t s .
Are t he sensor and pulser ring in good condit ion Inst all properly or replace fault y part .
and properly inst alled ?
Yes
12

Jum per t erm inal : W and Bu No
A Fault y W or Bu wi re
Check for cont inuit y bet ween t he above wi res .
Yes y
Check for a short circuit in Bu and W wi re . Yes

Fault y Bu or W wi re
No
Replace t he speed sensor wit h a new one . + 4-48

- Fault y original speed sensor
Is t he DTC 1-3 , 1-4 , 2-3 or 4-3 indicat ed ?
Yes V
4-41
+
12 V
ELECTRICAL SYSTEM
DTC 3-1, 3-2 , 3-3 or 3-4
( Solenoi d Valve m alfunct i on )
From Bat t ery

ABS MODULATOR
SOLENOID
VALVE
Erase t he DTC and t est - ride t he vehi cle above 30

No
km / h , t hen recheck t he DTC. Int erm it t ent failure
. A
Is t he DTC 3-1 , 3-2 , 3-3 or 3-4 indicat ed ?
Yes V
4-42
12v
ELECTRICAL SYSTEM
DTC 5-1, 5-2 or 5-3
( Pum p Mot or Lock / Pum p m ot or st uck of f / Pum p m ot or st uck on )
R / BI
From Bat t ery
R/ BI MR+ B
MR+ B
IM
30 A ABS MODULATOR
PUMP
MOTOR
1. ABS Modulat or Power Li ne Inspect i on 1
D -> 0 -> 1
. - Ground }
No
Connect i on : R/ BI ( + ) -
Fault y R /BI wi re
Yes y
Check for a short circuit in R/ BI wi re . Yes

. Is t here short circuit ? Fault y R / BI wi re
No

km / h , t hen recheck t he DTC . Int erm it t ent failure
Is t he DTC 5-1 , 5-2 or 5-3 indicat ed ?
Yes y
4-43
12 V
ELECTRICAL SYSTEM
DTC 5-4
( Power Supply Relay m alfunct i on )
D ABS m odulat or 18P ( Black ) connect or
IR / W
From Bat t ery
- RAW FSR+ B
FSR+ B
ABS MODULATOR
20 A
V
D - > 1
Connect i on : R / W ( + ) - Ground No
A Fault y R / W wi re
Yes V
Check for a short circuit in R / W wi re . Yes

Fault y R / W wi re
No

No . Int erm it t ent failure
A
Yes y
4-44
12 V
ELECTRICAL SYSTEM
DTC 6-1 or 6-2
( Power Ci rcui t )
BI
I
1
1
1
1
1
From Bat t ery

ABS MODULATOR
BI IG
ABS MAIN
NM
10 A
V
ID -> - 1 ( D
Connect i on : BI ( + ) - Ground No
Fault y Bl wi re
Yes V
Check for a short circuit in Bl wi re . Yes

Fault y Bl wi re
No

No
Is t he DTC 6-1 or 6-2 indicat ed ?
Yes y
4-45
12 V
ELECTRICAL SYSTEM
DTC 7-1
( Ti re Si ze )
Check t he followi ng and correct t he fault y part.

Incorrect t ire pressure
Ti res not recom m ended for t he vehi cle were inst alled i ncorrect t ire size ) .
Sprock et s not recom m ended for t he vehi cle were inst alled i ncorrect sprocket gear rat io ) .
Deform at i on of t he wheel or t ire .

No
A
Yes y
DTC 8-1
( ABS Cont rol Uni t )

No
km / h , t hen recheck t he DTC . A
Int erm it t ent failure
Yes y
4-46
12 V
ELECTRICAL SYSTEM
DTC 8-2
( Rear ABS Of f Indi cat or )
1 Com binat ion m et er 28P ( Gray ) connect or 2 ABS m odulat or 18P ( Black ) connect or
1
BI / W BI/ W
From Bat t ery
IGN
COMBINATION ABS RR OFF BIM MODE IND ABS MODULATOR

METER
1. ABS Indi cat or Inspect i on
Check t he ABS indicat or . Yes

Does not t he ABS indicat or com e on ?
No V
2. ABS i ndi cat or Li ne Inspect i on
Check for a short circuit in BI/ W wi re. No

A Fault y com binat ion m et er
Yes y
Fault y BI/ W wi re
4-47
12 V
ELECTRICAL SYSTEM
WHEEL SPEED SENSOR
New
Front wheel >3-26
Wheel speed sensor inspect ion

m
Basic
New
Rear wheel 3-34

.
Left side cover 3-8
Wheel speed sensor inspect ion
Basic
4-48
12 V
ELECTRICAL SYSTEM
ABS MODULATOR
BF 14 N.m
Regulat or / rect ifier + 4-51

. Horn 4-64
1Pull up t he lock lever and di sconnect t he ABS m odulat or 18 P connect or .
4-49
12 V
ELECTRICAL SYSTEM
BATTERY/ CHARGING SYSTEM
BATTERY / CHARGING SYSTEM LOCATION
BATTERY
MAIN FUSE ( 30 A)
REGULATORI
RECTIFIER
ALTERNATOR
BATTERY /CHARGING SYSTEM DIAGRAM
MAIN FUSE
30 A
BI R /W
BATTERY
00
G Y Y Y
e l le iv
vl l l l l l
REGULATORI
ALTERNATOR
RECTIFIER
Bat t ery / charging syst em inform at ion , t roubleshoot i ng and inspect ion
m
Basic
4-50
12 V
ELECTRICAL SYSTEM
BATTERY

Left side cover 3-8
REGULATOR/ RECTIFIER
Radi at or reserve t ank 2-19
4-51
+
12 V
ELECTRICAL SYSTEM
LIGHTING SYSTEM
Rally t ype :
8.5 N m
OC
1.2 N m
4-52
12 V
ELECTRICAL SYSTEM
Rally t ype :
Wi ndscreen 3-5
Headli ght 4-52
St andard t ype:
2.5 N m
Front vi sor 3-6
4-53
12 V
ELECTRICAL SYSTEM
i s
2.5 N m
Rear fender 3-8
s 4.5 N m
Rear fender 3-8
4-54
12 V
ELECTRICAL SYSTEM
BULB REPLACEMENT
St andard t ype:
1.2 N m
Front vi sor 3-6
4-55
12 V
ELECTRICAL SYSTEM
Rear fender >3-8
1.5 N m
4-56
12 V
ELECTRICAL SYSTEM
HEADLIGHT AIM
Rally t ype
HORIZONTAL BEAM
VERTICAL BEAM
ADJUSTING SCREW
ADJUSTING SCREW
St andard bulb t ype
HORIZONTAL BEAM
ADJUSTING SCREW VERTICAL BEAM
ADJUSTING SCREW
4-57
12 V
ELECTRICAL SYSTEM
TURN SIGNAL LIGHT TROUBLESHOOTING
When all t urn signal light s blink fast er t han usual , replace t he t urn signal light relay wit h a known good one ,
and recheck .
ALL TURN SIGNAL LIGHTS DO NOT LIGHT
Loose or poor cont act s of relat ed t erm inal / connect or

Bat t ery condit ion
Burned fuse
1 Turn signal light relay 3P 2 Left handlebar swit ch 14P

( Black ) connect or connect or
Gr !
I
1
BI
1
1. Turn Si gnal Li ght Relay Input Volt age Inspect i on
V
( 1 1
Connect i on : BI ( + ) - G ( - ) No
A Fault y Bl or G wi re
Yes v
2. Turn Si gnal Li ght Relay Inspect i on
2
= 1 ( Wit h peak volt age adapt er )
Connect i on : Gr ( + ) - Ground ( - )
( Connect or connect ed )
No Replace t he t urn signal light relay wit h a new
Peak volt age adapt er : 07HGJ - 0020100 or com m er
one , and recheck .
cially avai lable digit al m ult im et er ( i m pedance 10M )
Bat t ery volt age - Measured volt age = 1.5 V m ax . ?
Yes V
Check for an open or short circuit in O or Lb wi re .

If t here is no fault y circuit , replace t he left handlebar
swit ch wit h a new one 3-31, and recheck .
4-58
12 V
ELECTRICAL SYSTEM
COM BINATION M ETER

r
ABS t ype only :
10
1.0 N.m
Rally t ype : Headli ght 4-52

4-59
12V
ELECTRICAL SYSTEM
CLOCK ADJUST
Push and hold bot h t he SEL but t on and SET but t on for
m ore t han 2 seconds .
The clock will be set in t he adj ust m ode wit h t he hour
10 :2 5 di splay flashing.
SEL
SET
10 :2 5
2 seconds
The t im e is advanced by one hour , each t im e t he but t on is

pushed .
The t im e advances fast when t he but t on is pushed and
held .
10 :2 5
SEL
SET
52 5
Push t he SET but t on .

The m inut e di splay will st art flashi ng.
5 :2 5
SEL
SET
5:2 5
.
The t im e advances by one m inut e , each t im e t he but t on is
pushed .
.
The t im e advances fast when t he but t on is pushed and
held
5 :2 5
SEL To end t he adj ust m ent, push t he SET but t on or t urn t he
ignit ion swi t ch t o OFF .
The di splay will st op flashing aut om at i cally and t he
SET adj ust m ent will be cancelled if t he but t on is not pushed for
about 30 seconds .
5 :4 5
4-60
12 V
ELECTRICAL SYSTEM
VS SENSOR
New Oil

VS sensor inspect ion
Basic
FUEL LEVEL SENSOR
BI
BI
R G
R
New
Fuel pum p unit 2-4
1Rout e t he fuel level sensor wi res t o t he gui de and t erm inals properly.
4-61
12 V
ELECTRICAL SYSTEM
FUEL METER TROUBLESHOOTING
FUEL GAUGE FAILURE INDICATION
Fuel pum p unit 2-4
Loose or poor cont act s of relat ed t erm i nal / connect or
FULL
Open circuit indicat ion Short circuit indicat ion
7 7 ) 7
-7- ]
1FUEL UNIT 5P CONNECTOR EMPTY
A B
1. Fuel Level Sensor Ci rcui t Inspect i on
Check t he Y, G wi re . No Fault y Y or G wi re
Is t here no open or short circuit ?
Yes y
2. Fuel Level Sensor Inspect i on
Connect i on : A - B
No Replace t he fuel level sensor wit h a new one 4
St andard : FULL 6 10 12, EMPTY 380 400 12 A 61, and recheck .
Does t he St andard resi st ance exi st ?
Yes y
Replace t he com binat ion m et er wit h a new one 4

59 , and recheck .
4-62
+
12V
ELECTRICAL SYSTEM
ELECTRICAL COM PONENT
IGNITION SWITCH
New 24 Nim
Top bri dge 3-32
IGNITION SWITCH INSPECTION
Rally t ype: St andard t ype :
1 Ignit ion swit ch 3P connect or 1 Ignit ion swit ch 3P connect or
R /W R /W
22 12
( 1
Check for cont inuit y at t he ignit ion swit ch 3P connect or of t he ignit ion swit ch side .
Connect i on : Red /whi t e ( + ) Pi nk ( - )

Red / whi t e ( - ) - Pi nk ( +)
It is norm al if t here is cont inuit y in one direct ion .

It is fault y of t he ignit ion swit ch if t here is cont inuit y in bot h direct ions .
4-63
12V
ELECTRICAL SYSTEM
SIDESTAND SWITCH
10 Nim
New
HORN
ECRO
OPE
4-64
INDE
A Few Words About Safet y 1-2 FUEL LINE 2-2

ABS 4-34 FUEL PUMP UNIT 2-4
AIR CLEANER 2-7 FUEL TANK 2-6
ALTERNATOR /STARTER CLUTCH 2-33 HANDLEBAR 3-31
BATTERY/ CHARGING SYSTEM 4-50 HORN ... - 4-64
BODY PANELS -3-2 How To Use This Manual 1-3
BRAKE FLUID REPLACEMENT 3-37 IGNITION SYSTEM 4-27
BULB REPLACEMENT 4-55 INJECTOR ..... 2-11
CABLE & HARNESS ROUTING 1-22 LIGHTING SYSTEM 4-52
CLUTCH/ GEARSHIFT LINKAGE 2-30 LUBRICATION SYSTEM 2-14
COMBINATION METER 4-59 MAINTENANCE SCHEDULE : 1-68
COOLANT REPLACEMENT 2-17 MODEL IDENTIFICATION 1-5
COOLING SYSTEM ... 2-17 PGM - FI SYSTEM : -4-2
CRANKCASE /CRANKSHAFT/ BALANCER 2-35 RADIATOR / COOLING FAN 2-18
CYLINDER HEAD 2-22 REAR BRAKE 3-40
CYLINDER/ PISTON 2-29 REAR SUSPENSION 3-36
ELECTRICAL COMPONENT 4-63 REAR WHEEL 3-34
ELECTRICAL STARTER 4-30 SECONDARY AIR SUPPLY SYSTEM 2-12
EMISSION CONTROL SYSTEMS 1-65 SIDESTAND ..... 3-23
ENGINE OIL CHANGE ..... 2-15 SPARK PLUG REPLACEMENT 4-28
ENGINE OIL FILTER CHANGE 2-15 SPECIAL TOOL LIST 1-21
ENGINE OIL LEVEL CHECK 2-14 SPECIFICATIONS: - 1-8
ENGINE OIL STRAINER SCREEN / OIL PUMP 2-16 STEERING STEM 3-32
ENGINE UNIT 2-40 THROTTLE BODY 2-8
EXHAUST PIPE /M UFFLER 3-24 TORQUE VALUE 1-16
FORK .... 3-28 TP SENSOR RESET PROCEDURE 2-10
FRONT BRAKE -3-37 TRANSMISSION : 2-39
FRONT WHEEL 3-26 VALVE CLEARANCE 2-22
FUEL LEVEL SENSOR 4-61 WATER PUMP/THERMOSTAT 2-20
HONDA
MSV 17671
61K1TOO
Honda Mot or Co. , Lt d. Tokyo , Japan - All Right s Reserved

PRINTED IN U.S.A.

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20 21

A Few Words Abou t Saf et y 1-2 SPECIAL TOOL LIST .. 1-21

MODEL IDENTIFICATION 1-5 EMISSION CONTROL SYSTEMS 1-65

SPECIFICATIONS 1-8 MAINTENANCE SCHEDULE ......... 1-68

TORQUE VALUE ... -1-16

A Few Wor d s Ab ou t Saf et y

For You r Cu st om er ’s Saf et y

Im proper servi ce or repai rs can creat e an un

Follow t he procedures and precaut i ons in t his

For You r Saf et y

Fai lure t o properly follow inst ruct ions and

Follow t he procedures and precaut i ons in t his

How To Use Th i s Man u al

ALL INFORMATION , ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS

Honda Mot or Co., Lt d.

Dat e of Issue : January, 2021

Order of inst allat ion / assem bly wit h a point of

Turn ignit ion swit ch t o OFF . Turn ignit ion swit ch t o ON .

St art t he engi ne . Measure a resi st ance or check cont inuit y .

Ref er t o " Basic " Servi ce Manual for t he i nst ruc

LUBRICATION AND SEAL SYMBOL

Apply m olybdenum oil solut ion (m ixt ure of an

Apply a speci fi ed grease . Use a m ult i - purpose

Apply a locking agent . Use a m edium st rengt h

Use a speci fi ed fork oil or suspensi on fluid .

Model nam e : CRF300LR / LRA / L /LA

DESTINATION CODE REGION

TYPES and MODELS

Dest i nat i on Ant i - lock Brak e EVAP

VEHICLE IDENTIFICATION NUMBER ENGINE SERIAL NUMBER

VEHICLE IDENTIFICATION NUMBER ENGINE SERIAL NUMBER

FUEL & ENGINE SPECIFICATIONS

CYLINDER HEAD /VALVE

Pi st on pin bore I.D. 17.002 - - 17.008 ( 0.6694 -0.6694 ) 17.02 ( 0.670 )

CLUTCH/ GEARSHIFT LINKAGE

ALTERNATOR /STARTER CLUTCH

FRAME & CHASSIS SPECIFICATIONS

FRONT WHEEL/ SUSPENSIONISTEERING

REAR WHEEL / SUSPENSION

ELECTRICAL SYSTEM SPECIFICATIONS

LIGHTS /METERS / SWITCHES

FASTENER TYPE TRQ FASTENER TYPE TRQ

FUEL PUMP UNIT

ITEM Q’TY DIA TRQ REMARKS

ITEM Q’TY DIA TRO REMARKS

SECONDARY AIR SUPPLY SYSTEM

ITEM Q’TY DIA TRQ REMARKS

ITEM Q’TY DIA TRQ REMARKS

ITEM Q’TY DIA TRQ REMARKS

CLUTCH/ GEARSHIFT LINKAGE

ALTERNATOR /STARTER CLUTCH

ITEM Q’TY DIA TRQ REMARKS

CRANKCASE / TRANSMISSION /BALANCER

ITEM Q’TY DIA TRO REMARKS

EXHAUST PIPE/ MUFFLER

ITEM Q’TY DIA TRQ REMARKS

ITEM Q’TY DIA TRQ REMARKS

ITEM Q’TY DIA TRQ REMARKS

ITEM Q’TY DIA TRQ REMARKS

ITEM Q’TY DIA TRQ REMARKS

ITEM Q’TY DIA TRQ REMARKS

ITEM Q’TY DIA TRQ REMARKS

ITEM Q’TY DIA TRQ REMARKS

ITEM Q’TY DIA TRO REMARKS