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Ab 2010 TNK
Ab 2010 TNK
Service Information
The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attempting
service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also damage the
vehicle or create an unsafe condition.
This manual describes the proper methods and procedures for performing service, maintenance and repairs. Some procedures
require the use of specially designed tools and dedicated equipment. Any person who intends to use a replacement part, service
procedure or a tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of
the vehicle.
If you need to replace a part, use genuine Honda parts with the correct part number or an equivalent part. We strongly recommend
that you do not use replacement parts of inferior quality.
For Your Customer’s Safety
Proper set-up and pre-delivery are essential to the customer’s safety and the reliability of the vehicle. Any error or oversight while
servicing a vehicle can result in faulty operation, damage to the vehicle, or injury to others.
Tonngokhong BikerVietNam
Some of the most important general service safety precautions are given below. However, we cannot warn you of every
conceivable hazard that can arise in performing set-up and pre-delivery procedures. Only you can decide whether or not you should
perform a given task.
0-1
How to use this manual
How To Use This Manual
This manual describes the service procedures for the ANC110.
Sections 1 and 4 apply to the whole scooter. Section 3 illustrates procedures for removal/installation of components that may be
required to perform service described in the following sections.
Section 5 through 20 describe parts of the scooter, grouped according to location.
If you are not familiar with this scooter, read Technical Feature in Section 2.
Follow the Maintenance Schedule recommendations to ensure that the vehicle is in peak operating condition.
Performing the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the break-in
period.
Find the section you want on this page, then turn to the table of contents on the first page of the section.
Most sections start with an assembly or system illustration, service information and troubleshooting for the section. The subsequent
pages give detailed procedure.
If you don't know the source of the trouble, go to Troubleshooting section.
Your safety, and the safety of others, is very important. To help you make informed decisions we have provided safety messag-
es and other information throughout this manual. Of course, it is not practical or possible to warn you about all the hazards as-
sociated with servicing this vehicle.
You must use your own good judgement.
You will find important safety information in a variety of forms including:
• Safety Labels – on the vehicle
• Safety Messages – preceded by a safety alert symbol and one of three signal words, DANGER, WARNING, or CAUTION.
These signal words mean:
You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions.
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• Instructions – how to service this vehicle correctly and safely.
As you read this manual, you will find information that is preceded by a symbol. The purpose of this message is to help
prevent damage to your vehicle, other property, or the environment.
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 Mo-
tor Co., Ltd. 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 PER-
MISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTENANCE
ON Honda MOTORCYCLES, MOTOR SCOOTERS OR ATVS.
0-2
How to use this manual
SYMBOLS
The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to
these symbols, it would be explained specifically in the text without the use of the symbols.
Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1:1).
Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NOGI #2 or
equivalent).
Example:
• Molykote® BR-2 plus manufactured by Dow Corning U.S.A.
• Multi-purpose M-2 manufactured by Mitsubishi Oil, Japan
Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NOGI #2 or
equivalent).
Example:
• Molykote® G-n Paste manufactured by Dow Corning U.S.A.
• Honda Moly 60 (U.S.A. only)
• Rocol ASP manufactured by Rocol Limited, U.K.
• Rocol Paste manufactured by Sumico Lubricant, Japan
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Use silicone grease.
Apply a locking agent. Use a medium strength locking agent unless otherwise specified.
Apply sealant.
Use DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified.
0-3
CONTENTS
GENERAL INFORMATION 1
TECHNICAL FEATURES 2
FRAME/BODY PANELS/EXHAUST SYSTEM 3
MAINTENANCE 4
LUBRICATION SYSTEM 5
FUEL SYSTEM (Programmed Fuel Injection) 6
ENGINE AND DRIVE TRAIN
COOLING SYSTEM 7
ENGINE REMOVAL/INSTALLATION 8
CYLINDER HEAD/VALVES 9
CYLINDER/PISTON 10
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH 11
FINAL REDUCTION 12
CRANKCASE/CRANKSHAFT 13
FRONT WHEEL/SUSPENSION/STEERING 14
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CHASSIS
REAR WHEEL/SUSPENSION 15
BRAKE SYSTEM 16
BATTERY/CHARGING SYSTEM/ALTERNATOR 17
ELECTRICAL
IGNITION SYSTEM 18
ELECTRIC STARTER SYSTEM 19
LIGHTS/METERS/SWITCHES 20
WIRING DIAGRAM 21
TROUBLESHOOTING 22
ANC110AVC-A ADDENDUM 23
INDEX
MEMO
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GENERAL INFORMATION
CONNECTORS:
· SPEEDOMETER SUB HARNESS 9P
CONNECTOR
· SPEEDOMETER SUB HARNESS 4P
CONNECTOR
· IGNITION SWITCH 2P CONNECTOR
OVERFLOW HOSE
FUEL TRAY
DRAIN HOSE
THROTTLE CABLE
1-21
GENERAL INFORMATION
STARTER ALTERNATOR/CKP
RADIATOR
MOTOR SENSOR WIRE
SIPHON HOSE
WIRE SIDESTAND
RADIATOR SIPHON HOSE SWITCH WIRE
Cut off the extra part:
MAIN WIRE HARNESS
ENGINE SUB HARNESS
1-22
GENERAL INFORMATION
90°
SENSOR UNIT 5P (BLACK)
CONNECTOR
THROTTLE CABLE
GROUND
TERMINALS
FUEL FEED
HOSE
CRANKCASE
BREATHER
GROUND HOSE
CABLE
INJECTOR 2P
(BLACK)
RADIATOR
CONNECTOR
STARTER MOTOR SIPHON HOSE
WIRE MAIN WIRE HARNESS
UPPER STARTER
MOTOR WIRE
ENGINE SUB
HARNESS
ENGINE SUB
HARNESS
ECT SENSOR 2P
CONNECTOR
O2 SENSOR 1P (BLACK)
CONNECTOR
1-23
GENERAL INFORMATION
STARTER
MOTOR WIRE
SPARK
PLUG
WIRE
ALTERNATOR/CKP
SENSOR WIRE
O2 SENSOR WIRE
1-24
GENERAL INFORMATION
THROTTLE CABLE
RADIATOR SIPHON HOSE
FUEL TRAY
DRAIN HOSE
RADIATOR
OVERFLOW
HOSE
UPPER UPPER
FUEL FEED
HOSE REAR BRAKE
30° – 40°
SIDESTAND CABLE
SWITCH WIRE
RESISTORS
IGNITION COIL
CRANKCASE BREATHER HOSE
1-25
GENERAL INFORMATION
RESISTOR WIRE
1-26
GENERAL INFORMATION
UPPER
THROTTLE CABLE
90°
STARTER MOTOR
GROUND CABLE INJECTOR WIRE
CRANKCASE
BREATHER HOSE
WATER HOSE
SPARK PLUG WIRE
WATER HOSE
1-27
GENERAL INFORMATION
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HEADLIGHT WIRE
HEADLIGHT 6P CONNECTOR
1-28
GENERAL INFORMATION
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1-29
GENERAL INFORMATION
EMISSION CONTROL SYSTEMS
SOURCE OF EMISSIONS
The combustion process produces carbon monoxide (CO), oxides of nitrogen (NOx) and hydrocarbons (HC). Control of carbon
monoxide, oxides of nitrogen and hydrocarbons is very important because, under certain conditions, they react to form
photochemical smog when subject to sunlight. Carbon monoxide does not react in the same way, but it is toxic.
Honda Motor Co., Ltd. utilizes various systems (page 1-31), to reduce carbon monoxide, oxides of nitrogen and hydrocarbons.
CRANKCASE EMISSION CONTROL SYSTEM
The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere. Blow-by
gas is returned to the combustion chamber through the air cleaner and throttle body.
THROTTLE BODY
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FRESH AIR
BLOW-BY GAS
1-30
GENERAL INFORMATION
THREE-WAY CATALYTIC CONVERTER
This scooter is equipped with a three-way catalytic converter.
The three-way catalytic converter is in the exhaust system. Through chemical reactions, they convert HC, CO and NOx in the
engine’s exhaust to carbon dioxide (CO2), nitrogen (N2) and water vapor.
No adjustment to these systems should be made although periodic inspection of the components is recommended.
NOISE EMISSION CONTROL SYSTEM
TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: Local law may prohibit the following acts or the causing
thereof: (1) The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or replacement, of
any device or element of design incorporated into any vehicle for the purpose of noise control prior to its sale or delivery to the
ultimate customer or while it is in use; (2) the use of the vehicle after such device or element of design has been removed or
rendered inoperative by any person.
AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW:
1. Removal of, or puncturing of the muffler, baffles, header pipes or any other component which conducts exhaust gases.
2. Removal of, or puncturing of any part of the intake system.
3. Lack of proper maintenance.
4. Replacing any moving parts of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the
manufacturer.
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1-31
MEMO
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1. GENERAL INFORMATION
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COOLING SYSTEM SPECIFICATIONS ·······1-5
CYLINDER HEAD/VALVES
ELECTRIC STARTER SYSTEM
SPECIFICATION ···········································1-8
SPECIFICATIONS ·········································1-6
LIGHTS/METERS/SWITCHES
CYLINDER/PISTON SPECIFICATIONS ·······1-6 SPECIFICATION ···········································1-8
1-1
GENERAL INFORMATION
SERVICE RULES
GENERAL INFORMATION
1. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Honda's design
specifications may cause damage to the scooter.
2. Use the special tools designed for this product to avoid damage and incorrect assembly.
3. Use only metric tools when servicing the scooter. Metric bolts, nuts and screws are not interchangeable with English fasteners.
4. Install new gaskets, O-rings, cotter pins, and lock plates when reassembling.
5. When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque diagonally in
incremental steps unless a particular sequence is specified.
6. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly.
7. After reassembly, check all parts for proper installation and operation.
8. Route all electrical wires as shown in the Cable and Harness Routing (page 1-14).
ABBREVIATION
Throughout this manual, the following abbreviations are used to identify the respective parts or systems.
Abbrev. term Full term
CKP sensor Crankshaft Position sensor
DLC Data Link Connector
ECM Engine Control Module
ECT sensor Engine Coolant Temperature sensor
IAT sensor Intake Air Temperature sensor
MAP sensor Manifold Absolute Pressure sensor
MIL Malfunction Indicator Lamp
PGM-FI Programmed Fuel Injection
SCS connector Service Check Short connector
TP sensor Throttle Position sensor
IACV Idle Air Control Valve
DESTINATION CODE
Throughout this manual, the following codes are used to identify individual types for each region.
TH
MODEL IDENTIFICATION
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DESTINATION CODE
Thailand
REGION
1-2
GENERAL INFORMATION
The frame serial number is stamped on the seat stay as shown.
FRAME SERIAL NUMBER
The engine serial number is stamped on the lower left side of the
crankcase.
The throttle body identification number is stamped on the lower side of the
throttle body.
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1-3
GENERAL INFORMATION
GENERAL SPECIFICATIONS
ITEM SPECIFICATIONS
DIMENSIONS Overall length 1,894 mm (74.6 in)
Overall width 680 mm (26.8 in)
Overall height 1,119 mm (44.1 in)
Wheelbase 1,273 mm (50.1 in)
Seat height 767 mm (30.2 in)
Footpeg height 258 mm (10.2 in)
Ground clearance 134.6 mm (5.3 in)
Curb weight (Spoke wheel type) 107.2 kg (236.3 lbs)
(Cast wheel-CBS type) 107.1 kg (236.1 lbs)
FRAME Frame type Under bone type
Front suspension Telescopic fork
Front axle travel 81.0 mm (3.19 in)
Rear suspension Unit swing
Rear axle travel 80.0 mm (3.3 in)
Front tire size 80/90 - 14M/C40P
Rear tire size 90/90 - 14M/C46P
Tire brand Front/Rear NR73TZ/NR73T (IRC)
V338F/V338R (VEE RUBBER)
Front brake Hydraulic disc brake
Rear brake Mechanical leading trailing
Caster angle 26°40’
Trail length 80.0 mm (3.15 in)
Fuel tank capacity 4.5 liter (1.19 US gal, 0.99 lmp gal)
ENGINE Bore and stroke 50.0 x 55.0 mm (1.97 x 2.17 in)
Displacement 108.0 cm3 (6.59 cu-in)
Compression ratio 11.0 : 1
Valve train 2 valve, single chain driven SOHC
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Intake valve
Exhaust valve
opens
closes
opens
closes
at 1 mm (0.04 in) lift
at 1 mm (0.04 in) lift
at 1 mm (0.04 in) lift
at 1 mm (0.04 in) lift
5° BTDC
30° ABDC
30° BBDC
0° ATDC
Lubrication system Forced pressure and wet sump
Oil pump type Trochoid
Cooling system Liquid cooled
Air filtration Paper filter
Engine dry weight 27.3 kg (60.2 lbs)
FUEL DELIV- Type PGM-FI (Programmed Fuel Injection)
ERY SYSTEM Throttle bore 22 mm (0.9 in) or equivalent
DRIVE TRAIN Clutch system Dry, automatic centrifugal clutch
Drive belt ratio 2.53 : 1 - 0.85 : 1
Final reduction 10.624 (51/18 x 45/12)
ELECTRICAL Ignition system Full transistorized
Starting system Kickstarter with electric starter motor
Charging system Single phase output alternator
Regulator/rectifier SCR opened/single phase, half wave rectifi-
cation
Lighting system Alternator
1-4
GENERAL INFORMATION
LUBRICATION SYSTEM SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Engine oil capacity After draining 0.7 liter (0.7 US qt, 0.6 lmp qt) –
After disassembly 0.8 liter (0.8 US qt, 0.7 lmp qt) –
Recommended engine oil API classification: SE, SF or SG
(except oils labeled as energy conserving
on the circular API service label) –
Viscosity: SAE 10W-30
JASO T 903 standard: MB
Oil pump rotor Tip clearance 0.15 (0.006) 0.20 (0.008)
Body clearance 0.15 – 0.21 (0.006 – 0.008) 0.35 (0.014)
Side clearance 0.05 – 0.10 (0.002 – 0.004) 0.12 (0.005)
1-5
GENERAL INFORMATION
CYLINDER HEAD/VALVES SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Cylinder compression 941 kPa (9.6 kgf/cm2, 137 psi) at 550
–
min-1 (rpm)
Cylinder head warpage – 0.05 (0.002)
Rocker Rocker arm I.D. IN/EX 10.000 – 10.015 (0.3937 – 0.3943) 10.04 (0.395)
arm Rocker arm shaft O.D. IN/EX 9.972 – 9.987 (0.3926 – 0.3932) 9.91 (0.390)
Arm to shaft clearance IN/EX 0.013 – 0.043 (0.0005 – 0.0017) 0.08 (0.003)
Camshaft Cam lobe height IN 32.525 – 32.765 (1.2805 – 1.2900) 32.50 (1.280)
EX 32.227 – 32.467 (1.2688 – 1.2782) 32.20 (1.268)
Valve, Valve clearance IN 0.14 ± 0.02 (0.006 ± 0.001) –
valve EX 0.20 ± 0.02 (0.008 ± 0.001) –
guide Valve stem O.D. IN 4.975 – 4.990 (0.1959 – 0.1965) 4.90 (0.193)
EX 4.955 – 4.970 (0.1951 – 0.1957) 4.90 (0.193)
Valve guide I.D. IN/EX 5.000 – 5.012 (0.1969 – 0.1973) 5.03 (0.198)
Stem-to-guide clearance IN 0.010 – 0.037 (0.0004 – 0.0015) 0.08 (0.003)
EX 0.030 – 0.057 (0.0012 – 0.0022) 0.10 (0.004)
Valve guide projection above IN/EX 9.1 – 9.3 (0.36 – 0.37) –
cylinder head
Valve seat width IN/EX 1.0 (0.04) 1.5 (0.06)
Valve spring free length Inner IN/EX 31.53 (1.241) 30.66 (1.207)
Outer IN/EX 38.33 (1.509) 37.04 (1.458)
CYLINDER/PISTON SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Cylinder I.D. 50.000 – 50.010 (1.9685 – 1.9689) 50.10 (1.972)
Out-of-round – 0.05 (0.002)
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Piston, piston
rings, piston
Taper
Warpage
Piston O.D.
Piston O.D. measurement point
–
–
49.975 – 49.995 (1.9675 – 1.9683)
6.0 (0.24) from bottom of skirt
0.05 (0.002)
0.05 (0.002)
49.95 (1.967)
–
pin Piston pin bore I.D. 13.002 – 13.008 (0.5119 – 0.5121) 13.04 (0.513)
Piston pin O.D. 12.994 – 13.000 (0.5116 – 0.5118) 12.96 (0.510)
Piston-to-piston pin clearance 0.002 – 0.014 (0.0001 – 0.0006) 0.02 (0.001)
Piston ring-to-ring Top 0.015 – 0.045 (0.0006 – 0.0018) 0.08 (0.003)
groove clearance Second 0.015 – 0.045 (0.0006 – 0.0018) 0.08 (0.003)
Piston ring end gap Top 0.10 – 0.25 (0.004 – 0.0020) 0.45 (0.018)
Second 0.10 – 0.25 (0.004 – 0.0020) 0.45 (0.018)
Oil (side rail) 0.20 – 0.70 (0.008 – 0.028) –
Cylinder-to-piston clearance 0.005 – 0.035 (0.0002 – 0.0014) 0.09 (0.004)
Connecting rod small end I.D. 13.010 – 13.028 (0.5122 – 0.5129) 13.05 (0.514)
Connecting rod-to-piston pin clearance 0.010 – 0.034 (0.0004 – 0.0013) 0.05 (0.002)
1-6
GENERAL INFORMATION
FINAL REDUCTION SPECIFICATIONS
Unit: mm (in)
ITEM SPECIFICATIONS
Final reduction oil capacity After draining 0.10 liter (0.11 US qt, 0.09 lmp qt)
After disassembly 0.12 liter (0.13 US qt, 0.11 lmp qt)
Recommended final reduction oil API classification: SE, SF or SG
(except oils labeled as energy conserving on the circular API
service label)
Viscosity: SAE 10W-30
JASO T 903 standard: MB
CRANKCASE/CRANKSHAFT SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Crankshaft Connecting rod side clearance 0.10 – 0.35 (0.004 – 0.014) 0.55 (0.022)
Connecting rod radial clearance 0.004 – 0.016 (00002 – 0.0006) 0.05 (0.002)
Runout – 0.10 (0.004)
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Wheel rim runout Radial – 2.0 (0.08)
Axial – 2.0 (0.08)
Wheel hub-to-rim distance (Spoke wheel type) 0 ± 1.0 (0 ± 0.04) –
Fork Spring free length 307.0 (12.09) 301.0 (11.85)
Pipe runout – 0.2 (0.01)
Recommended fluid Fork fluid –
Fluid level 86.5 (3.41) –
Fluid capacity 62.5 ± 1.5 cm3
–
(2.11 ± 0.05 US oz, 2.20 ± 0.05 Imp oz)
1-7
GENERAL INFORMATION
BRAKE SYSTEM SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Brake lever freeplay 10 – 20 (0.4 – 0.8) –
Brake drum I.D. 130.0 (5.12) 131.0 (5.16)
Specified brake fluid DOT 3 or 4 –
Brake disc Thickness 3.3 – 3.7 (0.13 – 0.15) 3.0 (0.12)
Warpage – 0.10 (0.004)
Master cylinder Cylinder I.D. 12.700 – 12.743 (0.5000 – 0.5017) 12.755 (0.5022)
Piston O.D. 12.657 – 12.684 (0.4983 – 0.4994) 12.645 (0.4978)
Caliper Cylinder I.D. 25.400 – 25.450 (1.0000 – 1.0020) 25.460 (1.0024)
Piston O.D. 25.318 – 25.368 (0.9968 – 0.9987) 25.31 (0.996)
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ITEM SPECIFICATIONS
Spark plug CPR7EA – 9 (NGK), U22EPR9 (ND)
Spark plug gap 0.8 – 0.9 mm (0.03 – 0.04 in)
Ignition coil peak voltage 100 V minimum
CKP sensor peak voltage 0.7 V minimum
Ignition timing 10° BTDC at idle speed
LIGHTS/METERS/SWITCHES SPECIFICATION
ITEM SPECIFICATIONS
Bulbs Headlight 12 V – 25/25 W x 2
Tail light 12 V – 5 W
Brake light LED
Front turn signal light 12 V – 10 W x 2
Rear turn signal light 12 V – 10 W x 2
Instrument light 12 V – 1.7 W x 2
PGM-FI malfunction indicator lamp 12 V – 1.7 W
(MIL)
High beam indicator 12 V – 1.7 W
Turn signal indicator 12 V – 3 W x 2
Coolant temperature warning indi- LED
cator
Fuse Main fuse 15 A x 1
Sub fuse 10 A x 1
Resistor resistance (20°C/68°F) 9.5 – 10.5 ǡ
1-8
GENERAL INFORMATION
STANDARD TORQUE VALUES
TORQUE TORQUE
FASTENER TYPE FASTENER TYPE
N·m (kgf·m, lbf·ft) N·m (kgf·m, lbf·ft)
5 mm hex bolt and nut 5.2 (0.5, 3.8) 5 mm screw 4.2 (0.4, 3.1)
6 mm hex bolt and nut 10 (1.0, 7) 6 mm screw 9.0 (0.9, 6.6)
(Include SH flange bolt) 6 mm flange bolt 12 (1.2, 9)
8 mm hex bolt and nut 22 (2.2, 16) (Include NSHF) and nut
10 mm hex bolt and nut 34 (3.5, 25) 8 mm flange bolt and nut 27 (2.8, 20)
12 mm hex bolt and nut 54 (5.5, 40) 10 mm flange bolt and nut 39 (4.0, 29)
MAINTENANCE
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Spark plug 1 10 16 (1.6, 12)
Valve adjusting screw lock nut 2 5 10 (1.0, 7) Apply oil to the threads and
seating surface
Engine oil drain bolt 1 12 24 (2.4, 18)
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Engine oil strainer screen cap
Final reduction oil check bolt
Final reduction oil drain bolt
Air cleaner housing cover screw
1
1
1
4
30
8
8
5
20 (2.0, 15)
13 (1.3, 10)
13 (1.3, 10)
1.1 (0.1, 0.8)
Equalizer connecting cable lock nut 1 8 6.4 (0.7, 4.7)
(CBS type only)
LUBRICATION SYSTEM
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Oil pump plate screw 1 4 3 (0.3, 2.2)
Oil pump mounting bolt 2 6 10 (1.0, 7)
COOLING SYSTEM
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Cooling fan mounting bolt 3 6 8 (0.8, 5.9)
Radiator drain bolt 1 10 1 (0.1, 0.7)
Thermostat mounting bolt 2 6 9 (0.9, 6.6)
Water pump impeller 1 6 10 (1.0, 7)
1-9
GENERAL INFORMATION
ENGINE REMOVAL/INSTALLATION
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Engine hanger link pivot nut 1 10 69 (7.0, 51)
(Frame side)
CYLINDER HEAD/VALVES
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Cylinder head cover special bolt 2 6 12 (1.2, 9)
Cylinder head nut 4 7 18 (1.8, 13) Apply oil to the threads and
seating surface.
Cylinder head bolt 2 6 12 (1.2, 9) Apply oil to the threads and
seating surface.
Cam sprocket bolt 2 5 8 (0.8, 5.9) Apply oil to the threads and
seating surface.
Cam chain tensioner lifter screw 1 6 4 (0.4, 3.0)
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Left crankcase cover plate screw 5 4 3 (0.3, 2.2)
Drive pulley face nut 1 14 108 (11.0, 80) Apply oil to the threads and
seating surface.
Clutch/driven pulley nut 1 28 54 (5.5, 40)
Clutch outer nut 1 12 49 (5.0, 36)
FRONT WHEEL/SUSPENSION/STEERING
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
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Front axle nut
Front brake disc socket bolt
36
12
8
BC 3.2
59 (6.0, 44)
42 (4.3, 31)
1-10
GENERAL INFORMATION
BRAKE SYSTEM
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Rear brake arm bolt 1 6 10 (1.0, 7) ALOC bolt: replace with a
new one
Brake caliper bleed valve 1 8 5.4 (0.6, 4.4)
Brake master cylinder reservoir cap screw 2 4 1.5 (0.2, 1.1)
Brake pad pin 1 10 18 (1.8, 13)
Front brake lever pivot bolt 1 6 1 (0.1, 0.7)
(Standard type only)
Front brake lever pivot screw 1 6 1 (0.1, 0.7)
(CBS type only)
Front brake lever pivot nut 1 6 6 (0.6, 4.4)
Front brake light switch screw 1 4 1 (0.1, 0.7)
Brake hose oil bolt 2 10 34 (3.5, 25)
Rear brake lever pivot screw (CBS type 1 5 4.2 (0.4, 3.1)
only)
Rear brake lever pivot nut (CBS type only) 1 5 5.2 (0.5, 3.8) U-nut
Equalizer rod pivot screw (CBS type only) 1 5 4.2 (0.4, 3.1)
Equalizer rod pivot nut 1 5 5.2 (0.5, 3.8) U-nut
(CBS type only)
Rear brake lever bracket cover screws 2 5 4.2 (0.4, 3.1)
(CBS type only)
Rear brake lever bracket cover special 1 5 4.2 (0.4, 3.1)
screw (CBS type only)
Brake caliper mounting bolt 2 8 30.4 (3.1, 22) ALOC bolt: replace with
new ones
Brake caliper torque pin 1 8 22(2.2, 16)
Brake caliper pin 1 8 18 (1.8, 13)
BATTERY/CHARGING SYSTEM/ALTERNATOR
Tonngokhong BikerVietNam
ITEM
Stator mounting socket bolt
Q'TY
3
THREAD
DIA. (mm)
6
TORQUE
N·m (kgf·m, lbf·ft)
10 (1.0, 7)
REMARKS
OTHERS
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Muffler protector mounting bolt 2 6 10 (1.0, 7)
Brake shoe anchor pin nut 1 8
(When using the stake nut) 20 (2.0, 15)
(When using the normal nut) 18 (1.8, 13)
Sidestand pivot nut 1 10 29 (3.0, 21)
Sidestand pivot bolt 1 10 10 (1.0, 0.7)
1-11
GENERAL INFORMATION
LUBRICATION & SEAL POINTS
ENGINE
MATERIAL LOCATION REMARKS
Liquid sealant (recommend- Right crankcase mating surface See page 13-10
ed: Three Bond 1207B or
Three Bond 1215 or equiva-
lent)
Liquid sealant (recommend- Cylinder head mating surface (semicircular area) See page 9-8
ed: Three Bond 5211C or
SHINETSU-SILICONE
KE45T or Three Bond 1215
or equivalent)
Locking agent (recommend- Driveshaft bearing set plate bolt threads See page 12-13
ed: Three Bond 2415 or
1322N or LOCKTITE 200 or
equivalent)
Molybdenum disulfide oil (a Camshaft cam lobes
mixture of 1/2 engine oil and
1/2 molybdenum disulfide
grease)
Molybdenum disulfide paste Kickstarter spindle sliding surface 0.1 – 0.3 g
Kickstarter driven gear shaft 0.2 – 0.3 g
Kickstarter driven gear friction spring sliding area
Grease (Shell ALVANIA R3 Driven face inner surface 7.0 – 8.0 g
or IDEMITSU AUTOREX B Movable driven face cam groove 1.5 – 2.0 g
or equivalent) Starter pinion gear shaft (both end) 0.1 – 0.3 g
Driven face ball bearing and needle bearing
Bearing area of final shaft
Engine oil (Without molybde- Oil pump drive gear teeth
Tonngokhong BikerVietNam
num additives) Oil pump rotor whole surface
Oil pump shaft and pump cover sliding area
Oil pump driven gear teeth
Rocker arm shaft sliding surface
Rocker arm roller sliding area
Camshaft decompressor rotating surface 0.5 – 1.0 cc
Camshaft bearing
Cam sprocket teeth
Cam chain whole surface
Timing sprocket teeth
Piston and cylinder sliding surfaces
Piston ring whole surface and ring grooves
Piston pin outer surface
Connecting rod small end inner surface
Crankshaft bearings Fill up 2 cc minimum
Connecting rod big end bearing Fill up 3 cc minimum
Valve stem (valve guide sliding area)
Valve stem seal inner surface
Bearing area of drive and counter shaft
Drive, counter and final gear teeth
Water pump shaft sliding area
Water pump chain whole surface
Water pump driven gear teeth
Ball/needle bearing sliding area
Each O-ring whole surface
Oil seal lips and outer surfaces
Degrease Right crankshaft tapered area
Drive/driven pulley face and drive belt
Left crankcase cover bearing bushing inner surface
1-12
GENERAL INFORMATION
FRAME
MATERIAL LOCATION REMARKS
Multi-purpose grease with Steering bearing race Spread each 3 g minimum
extreme pressure (recom- Steering stem dust seal lip Spread each 3 g minimum
mended: EXCELIGHT EP2
manufactured by KYODO
YUSHI, japan. or Shell AL-
VANIA EP2 or equivalent)
Grease (Shell BEARING Speedometer gear box inside
GREASE HD or equivalent)
Multi-purpose grease Front/rear wheel dust seal lip
Front wheel axle sliding surface
Front wheel distance collar whole surface
Speedometer gear box seal lip
Throttle cable-to-throttle drum sliding area Apply 0.1 - 0.2 g
Rear brake cam and shaft Spread each 0.2 - 0.3 g
Rear brake anchor pin shaft Spread 0.2 - 0.3 g
Rear brake dust seal lip
Rear brake lever pivot screw sliding surface
Equalizer rod pivot screw sliding surface (CBS type only)
Seat catch contact area Apply 2.2 g minimum
Fuel lid lock pin contact area Apply 2.2 g minimum
Centerstand pivot area
Sidestand pivot area
Silicone grease Rear brake cable cap boot inside
Front brake lever-to-master piston contacting area Spread each 0.1 g
Front brake lever pivot sliding area
Brake caliper pin sliding area Spread 0.4 g minimum
Brake caliper pad pin O-ring whole surface.
Brake caliper dust seal whole surface
Tonngokhong BikerVietNam Brake equalizer cable cap boot inside (CBS type only)
Speedometer cable
Throttle cable boot inside Fill up 0.1 g
Throttle cable inside Fill up 0.2 g minimum
Brake fluid Master cylinder inside and sliding area
(DOT 3 or DOT 4) Brake caliper piston seal whole surface
Brake caliper piston whole surface
Master cylinder piston cup
Fork fluid Fork dust seal and oil seal lips
Fork spring seat O-ring whole surface
Adhesive (Honda bond A or Handlebar grip rubber inside
equivalent) Air cleaner connecting hose-to-housing mating area
1-13
GENERAL INFORMATION
CABLE & HARNESS ROUTING
STANDARD TYPE
DIMMER SWITCH 3P CONNECTOR
Tonngokhong BikerVietNam
FRONT BRAKE HOSE
SPEEDOMETER CABLE
SPEEDOMETER
SUB HARNESS
REAR BRAKE
DLC (DATA LINK CONNECTOR) CABLE
STARTER RELAY
SEAT LOCK CABLE
BATTERY POSITIVE
BATTERY NEGATIVE (+) CABLE
(–) CABLE
LIGHTING
CUT RELAY
1-14
GENERAL INFORMATION
CBS TYPE
DIMMER SWITCH 3P CONNECTOR
Tonngokhong BikerVietNam
FRONT BRAKE HOSE
THROTTLE CABLE
SPEEDOMETER CABLE
SPEEDOMETER
SUB HARNESS
THROTTLE
CABLE
SPEEDOMETER CABLE
SEAT LOCK CABLE
STARTER RELAY
1-15
GENERAL INFORMATION
STANDARD TYPE
BATTERY POSITIVE
(+) CABLE
SEAT LOCK CABLE
CONNECTORS:
· SPEEDOMETER SUB HARNESS
9P CONNECTOR
Tonngokhong BikerVietNam
· SPEEDOMETER SUB HARNESS
4P CONNECTOR
· IGNITION SWITCH 2P
SEAT LOCK
FUEL PUMP WIRE CABLE
SPEEDOMETER
CABLE
SPEEDOMETER CABLE
1-16
GENERAL INFORMATION
CBS TYPE
THROTTLE CABLE
MAIN FUSE 15A
SUB FUSE 10A
FUEL LID OPENER CABLE
BATTERY POSITIVE
(+) CABLE
SEAT LOCK CABLE
CONNECTORS:
· SPEEDOMETER SUB HARNESS
Tonngokhong BikerVietNam
9P CONNECTOR
· SPEEDOMETER SUB HARNESS
4P CONNECTOR
· IGNITION SWITCH 2P
SEAT LOCK
FUEL PUMP WIRE CABLE
MAIN WIRE HARNESS
CONNECTORS:
· STARTER MOTOR 2P
CONNECTOR
· SIDESTAND SWITCH 3P (GREEN)
CONNECTOR
SPEEDOMETER
CABLE
SPEEDOMETER CABLE
1-17
GENERAL INFORMATION
STANDARD TYPE
BATTERY NEGATIVE
(–) CABLE
REGULATOR/
SPEEDOMETER SPEEDOMETER
RECTIFIER
CABLE SUB HARNESS
SPEEDOMETER
STARTER RELAY CABLE
REAR
BRAKE REGULATOR/
CABLE RECTIFIER
FRONT BRAKE
HOSE THROTTLE
THROTTLE STARTER CABLE
CABLE RELAY
WIRE REAR BRAKE
CABLE
FRONT BRAKE
HORN WIRE
THROTTLE CABLE
OVERFLOW HOSE
1-18
GENERAL INFORMATION
CBS TYPE
BATTERY NEGATIVE
(–) CABLE
REGULATOR/
SPEEDOMETER SPEEDOMETER RECTIFIER
CABLE SUB HARNESS
SPEEDOMETER
STARTER RELAY CABLE
REAR BRAKE
CABLE REGULATOR/
RECTIFIER
FRONT BRAKE
HOSE
STARTER THROTTLE
THROTTLE CABLE RELAY CABLE
WIRE REAR BRAKE
CABLE
FRONT BRAKE
Tonngokhong BikerVietNam
HOSE
HORN WIRE
THROTTLE CABLE
OVERFLOW HOSE
1-19
GENERAL INFORMATION
FUEL LID
OPENER CABLE
Tonngokhong BikerVietNam
HORN WIRE
SEAT
LOCK
CABLE
SPEEDOMETER
CABLE
RADIATOR SIPHON
HOSE CONNECTORS:
· STARTER MOTOR 2P CONNECTOR
· SIDESTAND SWITCH 3P (GREEN) CONNECTOR
FUEL PUMP WIRE · ALTERNATOR 3P CONNECTOR
1-20
2. TECHNICAL FEATURES
Tonngokhong BikerVietNam
2-1
TECHNICAL FEATURES
PGM-FI (Programmed Fuel Injection) SYSTEM
TECHNICAL FEATURES
SYSTEM COMPONENTS
This model utilizes PGM-FI (Programmed Fuel Injection) system, instead of conventional carburetor system. This system consists
of the following: Injector, throttle body, ECM, fuel pump, sensor unit (MAP/TP/IAT sensors), CKP sensor, ECT sensor, O2 sensor
and IACV.
INJECTOR
Electromagnetic valve
to discharge fuel
Tonngokhong BikerVietNam
THROTTLE BODY
It controls the volume of
intake air by opening/
closing the throttle valve.
ECM
ECM regulates amount of fuel discharged by
CKP SENSOR O2 SENSOR
injector. It also controls PGM-FI electrical
It measures the crankshaft It measures the amount of system such as IACV and ignition system,
rotation speed. oxygen in exhaust gas. according to collected signals from each
sensor.
ECT SENSOR FUEL PUMP
It measures the engine It delivers fuel from fuel tank
coolant temperature. to injector by applying
constant pressure.
PGM-FI Programmed Fuel Injection IAT SENSOR Intake Air Temperature Sensor
MAP SENSOR Manifold Absolute Pressure Sensor CKP SENSOR Crankshaft Position Sensor
TP SENSOR Throttle Position Sensor IACV Idle Air Control Valve
ECT SENSOR Engine Coolant Temperature Sensor ECM Engine Control Module
2-2
TECHNICAL FEATURES
PGM-FI SYSTEM DIAGRAM
R/W Bl
IGNITION
SWITCH
BATTERY
W REGULATOR/ R/Bl Bl
RECTIFIER
G
Bu/Y 12 PCP Bl
W/Y 23 PCM
CKP
SENSOR PRC 7 W/Bl
ALTERNATOR
IGP 1 Bl
SENSOR UNIT
TP
Tonngokhong BikerVietNam
SENSOR
(9)
IAT
W/Bu 14 TA
IGPLS 11 G/R Bl
Bl (12)
INJECTOR
SENSOR
IGNITION
P/W 24 TW COIL
(7)
ECT
SENSOR G/O G/O 4 SG ECM SPARK Bl
PLUG
(21) Bl Bl
O2 Bl/O 3 O2
SENSOR MIL
FRONT REAR
FI WARN 22 Bu/Y Bl BRAKE BRAKE
LIGHT LIGHT
SWITCH SWITCH
From starter relay Y/G 33 S/RELAY TW WARNING
INIDICATOR G/Y G/Y
To sidestand switch G/W 25 SSTAND
TW WARN 18 Lg/R Bl
DLC
SCS Bl Bl
CONNECTOR G/Y
O/W 30 K-LINE IACV1A 21 Lg/R
G 9 PG1
STSW 29 Y/G
1 11
Bl : Black Br : Brown
12 22 Y : Yellow O : Orange
( ) : Number of MIL blinks Bu : Blue Lg : Light green
23 33
G : Green P : Pink
: The engine does not start if there is mulfunction ECM 33P CONNECTOR R : Red Gr Gray
ECM side of the male terminals W : White
2-3
TECHNICAL FEATURES
OUTLINE
The Programmed Fuel Injection (PGM-FI) system injects the required amount of fuel calculated by computer, using sensor to
collect information, such as revolution of the engine, suction pressure in the intake manifold, throttle opening and temperature.
While the engine takes fuel from the nozzle using suction force when carburetor is used, the PGM-FI system injects pressurized
fuel into the intake port by force from an injector (solenoid nozzle).
The construction of the PGM-FI can be divided in 2 major systems, the “fuel supply system” and the “electronic control system”.
The electronic control system consists of the detector section to send information from sensors to the Engine Control Module
(ECM) and the control section that processes information in the ECM before sending fuel injection commands to the fuel supply
system.
The fuel supply system consists of the fuel pump for forced delivery of fuel, the pressure regulator (integrated in the fuel pump) that
maintains the fuel pressure constant and the injector that injects fuel according to the signal sent from the ECM.
SENSOR UNIT
Tonngokhong BikerVietNam
IAT SENSOR
MIL CONTROL
INJECTOR
FUEL PUMP
DLC
CKP SENSOR
MIL
ECT SENSOR
ECM
O2 SENSOR
BATTERY VOLTAGE
2-4
TECHNICAL FEATURES
SENSORS
There are two kinds of sensor output: One translates changes of the electrical resistance into changes of voltage, the other
produces its own voltage or current.
OUTPUT VOLTAGE SENT TO ECM
• As shown on the diagram below, two resistors divide the source voltage when connected to the source in series.
5V
2.5 V A= 1 kΩ
2.5 V
B= 1kΩ
When resistor A and B have same resistance value, source voltage would be divided equally. When one of them has larger
resistance value than the other, it would receive larger share of the load.
ECT sensor and IAT sensor utilize this principle.
ECM receives changes of physical information (changes of temperature, pressure etc.) as variable voltage by reading it at both
ends of resistor B (Resistor A: fixed resistor/Resistor B: variable resistor that reacts to physical changes).
For example, when source voltage is 5 V, resistance value of resistor A is 1.5 kΩ, resistance value of resistor B is 2.5 kΩ, the
voltage measured at point C would be 3.125 V as shown below. If the value of resistor B is 0.1 k Ω, the voltage measured at
point C would be 0.3125 V.
Tonngokhong BikerVietNam
e.g.: ECT (engine coolant temperature) SENSOR
WHEN ENGINE COOLANT TEMPERATURE IS 20°C: WHEN ENGINE COOLANT TEMPERATURE IS 113 – 116°C:
ECM ECM
5V 5V
ECT SENSOR ECT SENSOR
A= 1.5 kΩ A= 1.5 kΩ
CPU CPU
B= 2.5 kΩ C= 3.125 V B= 0.1 kΩ C= 0.3125V
2-5
TECHNICAL FEATURES
TP SENSOR
• TP sensor detects the opening degree of throttle valve.
• TP sensor consists of a variable resistor (volume) located on the same axis with throttle valve and a contact point (brush) that
moves above the variable resistor in accordance with the throttle valve.
• TP sensor detects the changes of brush angle synchronized with throttle valve movement by converting them into variable
resistance values. The input voltage from ECM becomes regulated by this varying resistance value and comes back into ECM.
• Output voltage sent back to ECM is low when throttle opening is small. The voltage becomes higher as throttle opening
becomes larger.
• Depending on output voltage, ECM controls the following:
– determines basic discharge duration and cuts off fuel supply on deceleration (with CKP sensor)
– increases the amount of fuel injected on acceleration
ECM
SENSOR UNIT
5V
TP SENSOR
OUTPUT
VOLTAGE
4.13 – 4.76 V
0.29 – 0.71 V
CONTACT POINT (BRUSH)
FULL FULL
CLOSE OPEN
(IDLE)
2-6
TECHNICAL FEATURES
MAP SENSOR
• MAP sensor detects the changes of vacuum pressure inside the intake manifold.
• MAP sensor consists of the following: a pressure sensing device (silicone diaphragm) that varies its resistance value when
pressure is applied, and an amplifier that boosts tiny changes of voltage.
• MAP sensor outputs the changes of vacuum pressure by converting them into changes of resistance value and amplifies them.
ECM receives the output signal from the sensor as variable voltages.
• Output voltage into ECM is low when intake manifold vacuum pressure is low. The voltage becomes higher as vacuum pressure
becomes greater.
• Depending on output voltage, ECM determines basic discharge duration with CKP sensor.
SENSOR UNIT
ECM
5V
MAP SENSOR 5V
OUTPUT
VOLTAGE
MAP SENSOR
Tonngokhong BikerVietNam
OUTPUT VOLTAGE
PRESSURE SENSING DEVICE
(SILICONE DIAPHRAGM)
3.41 V
0.5 V
13 kPa 120 kPa AMPLIFIER
2-7
TECHNICAL FEATURES
IAT SENSOR
• IAT sensor detects temperature of incoming air into engine.
• IAT sensor consists of a thermistor that varies its resistance value according to changes of temperature.
• IAT sensor detects changes of intake air temperature by converting them into the changes of thermistor's resistance values.
ECM receives the output signal from the sensor as variable voltages.
• Output voltage into ECM is high when intake air temperature is low. The voltage becomes lower as temperature increases.
• Depending on output voltage, ECM corrects discharge duration corresponding with intake air temperature.
SENSOR UNIT
ECM
5V
IAT SENSOR
OUTPUT
VOLTAGE
IAT SENSOR
Tonngokhong BikerVietNam
OUTPUT
VOLTAGE
THERMISTOR
4.63 V
0.47 V
INTAKE AIR
-20°C 100°C TEMPERATURE
2-8
TECHNICAL FEATURES
ECT SENSOR
• ECT sensor detects engine coolant temperature.
• ECT sensor consists of a thermistor that varies its resistance value according to changes of temperature.
• ECT sensor detects the changes of engine coolant temperature by converting them into the changes of thermistor's resistance
values. ECM receives the output signal from the sensor as variable voltages.
• Output voltage into ECM is high when engine coolant temperature is low. The voltage becomes lower as temperature increases.
• Depending on output voltage, ECM corrects discharge duration corresponding with engine coolant temperature.
ECM
5V
ECT SENSOR
OUTPUT
VOLTAGE
ECT SENSOR
Tonngokhong BikerVietNam
OUTPUT
VOLTAGE
4.54V THERMISTOR
0.43V
ENGINE
-
-20°C 100°C COOLANT
TEMPERATURE
2-9
TECHNICAL FEATURES
O2 SENSOR
• O2 sensor detects the amount of oxygen in exhaust gas.
• O2 sensor consists of a cylindrical-shaped, white gold-coated zirconia device. The inside of the device is exposed to
atmosphere, whereas its outside is exposed to exhaust gas.
Zirconia device: produces electromotive force by difference of oxygen concentration between atmosphere and exhaust gas
when temperature is higher than certain value.
• O2 sensor detects changes of oxygen concentration in exhaust gas by measuring the electromotive force. ECM receives the
values as voltages.
• The output voltage of O2 sensor is about 0 V when the difference of oxygen concentration between the atmosphere and the
exhaust gas is very small (when air/fuel ratio is lean), whereas about 1 V when the difference is very big (when air/fuel ratio is
rich).
• Depending on output voltage, ECM corrects discharge duration corresponding with oxygen concentration in exhaust gas.
ECM
O2 SENSOR
OUTPUT
VOLTAGE
O2 SENSOR
WHITE GOLD-COATED
GENERAL IDEA OF O2 SENSOR OUTPUT CHARACTERISTICS: POLE
2-10
TECHNICAL FEATURES
CKP SENSOR
GENERAL DESCRIPTION
• CKP sensor detects engine revs and crankshaft angle.
• CKP sensor consists of the reluctors on the flywheel (9 projections) and the pickup in CKP sensor with built-in permanent
magnet and coil.
• When reluctors on the flywheel cross CKP sensor as the crankshaft rotates, changes of magnetic flux in the pickup coil occur.
CKP sensor detects the changes by converting them into pulse voltages and sends the pulse into ECM (9 pulses per 1
crankshaft rotation).
• Depending on output voltage, ECM controls the following:
– determines timing of fuel discharge
– determines basic discharge duration (with TP sensor and MAP sensor)
– cuts off fuel supply on deceleration (with TP sensor)
– determines ignition timing
RELUCTOR
PICKUP
ECM (WITH BUILT-IN PERMANENT
FLYWHEEL MAGNET AND COIL)
OUTPUT
VOLTAGE
OUTPUT
CKP SENSOR VOLTAGE
Tonngokhong BikerVietNam
RELUCTOR
CKP SENSOR
CKP SENSOR
OUTPUT
VOLTAGE
2-11
TECHNICAL FEATURES
SELF DIAGNOSIS FUNCTION
MIL
(Malfunction Indicator Lamp)
Tonngokhong BikerVietNam
• ECM stores a failure code when problem is detected. Once recorded, the code remains in erasable memory until the clearing
procedure is performed.
• PGM-FI system is provided with a fail-safe function that maintains a minimum running capability by using a programmed value in
the simulated map even when there is problem in the system.
When any abnormality is detected in injector and/or crankshaft position (CKP) sensor, the fail-safe function stops the engine to
protect it from serious damage.
• The time of blinks represents each failure code (0 – 29). The MIL uses two kinds of blink duration, long blink lasts 1.3 second,
whereas the short blink lasts 0.3 second.
ON
IGNITION
SWITCH OFF
ON
NO
PROBLEM
DETECTED OFF
0.5 sec.
0.3 sec. 0.4 sec. 1.3 sec. 0.3 sec.
3.0 sec.
ON
PROBLEM
DETECTED
OFF
2-12
TECHNICAL FEATURES
FUEL SUPPLY SYSTEM
GENERAL DESCRIPTION
• Fuel pump is located inside the fuel tank.
• Fuel pump draws in the fuel via fuel filter and delivers it to the injector.
The pressure regulator (integrated in the fuel pump) maintains fuel pressure in constant at 294 kPa (3.0 kgf/cm2, 43 psi).
• This system uses resin for the part of materials in the fuel feed hose. Do not bend or twist the fuel feed hose.
FUEL TANK
FUEL PUMP
INJECTOR
Tonngokhong BikerVietNam
FUEL FILTER
FUEL FEED HOSE
2-13
TECHNICAL FEATURES
FUEL PUMP CONSTRUCTION
Fuel pump assembly consists of armature coil, pump section, residual pressure check valve, suction port and discharge port.
The pump section consists of armature coil-driven impeller and pump chamber composed of pump casing and pump cover.
FUEL PUMP OPERATION
• When the motor turns, fin grooves located on impeller circumference produce pressure difference due to hydro-friction force,
fuel is drawn into the pump, then delivered out of the pump.
• The drawn fuel via the filter circulates inside the motor and passes the residual pressure check valve, then becomes delivered
through the discharge port.
• When engine is turned OFF and fuel pump is not operating, the check valve maintains residual fuel pressure to ease engine
restarting.
• Fuel pressure regulator maintains fuel pressure in constant by the regulator valve that opens when fuel pressure in discharge
circuit (between the pump and injector) becomes higher than certain.
DISCHARGE PORT
To INJECTOR
FIN GROOVES
delivery suction
FIN GROOVES
IMPELLER CASING
ARMATURE COIL
CASING
IMPELLER
FILTER
2-14
TECHNICAL FEATURES
INJECTOR
GENERAL DESCRIPTION
• Fuel injector is a solenoid valve that consists of needle valve/plunger,
solenoid coil, solenoid spring and filter.
• Constantly pressurized fuel (294 kPa (3.0 kgf/cm2, 43 psi)) is supplied to
the injector. It sprays the proper amount of fuel through idle to maximum PLUNGER
engine revs. (NEEDLE VALVE) FILTER
• The injector is either fully closed or fully open with fixed stroke. The
amount of fuel injected is dependent on how long the injector is kept
open.
• The ignition switch supplies constant power for the injector. When ECM
starts up the drive transistor, current flows through the solenoid coil and
injector opens.
OPERATION
1. The fuel pressurized by the fuel pump is blocked at the injector nozzle that consists of plunger/needle valve and valve seat.
2. When ECM turns the drive transistor ON, current flows through the solenoid coil in the injector. The electromagnetized coil pulls
up the plunger/needle valve while compressing the solenoid spring.
3. Nozzle opens as the plunger/needle valve lifts up. The fuel blocked at the injector nozzle passes the filter and then sprays into
the intake manifold.
BATTERY
FILTER VOLTAGE
FUEL PUMP
ECM
PLUNGER/
NEEDLE VALVE
VALVE
INJECTOR NOZZLE SEAT
4. When ECM turns the drive transistor OFF, current no longer flows through the solenoid coil in the injector.
The solenoid spring closes the nozzle and injecting stops in result.
BATTERY
VOLTAGE
FUEL PUMP
SOLENOID
COIL
ECM
PLUNGER/
NEEDLE VALVE
VALVE
INJECTOR NOZZLE SEAT
2-15
TECHNICAL FEATURES
IDLE AIR CONTROL VALVE (IACV)
IACV consists of ECM, step motor, slide valve and bypass circuit.
IACV regulates the amount of air flow through the throttle valve by operating the slide valve in accordance with the input signal from
ECM in order to maintain specified engine idle speed at 1,700 ± 100 min-1 (rpm).
THROTTLE VALVE
BYPASS CIRCUIT IACV
SLIDE
VALVE
STEP
MOTOR
Tonngokhong BikerVietNam
WHEN IGNITION SWITCH IS TURNED ON:
SLIDE SLIDE
VALVE VALVE
STEP
MOTOR
When ignition switch is turned ON, ECM turns the step motor and it pulls the slide valve toward itself. While detecting engine
coolant temperature, ECM drives the motor in order to slide the valve back to proper position where necessary amount of incoming
air for starting the engine can be obtained.
DURING WARM UP:
When the engine is still cold, ECM controls the slide valve position in order to increase the amount of incoming air. As a result,
engine idle speed is maintained at 1,900 ± 100 min-1 (rpm)
As the engine gets warmed up, slide valve returns toward its original position. ECM decreases the amount of incoming air by
controlling the position of the slide valve in order to obtain specified engine idle speed at 1,700 ± 100 min-1 (rpm).
SLIDE
SLIDE
VALVE
VALVE
STEP
MOTOR
2-16
TECHNICAL FEATURES
POWER SUPPLY CIRCUIT
GENERAL DESCRIPTION
This scooter adopts a power supply circuit that utilizes the output from the alternator as power supply required when starting the
engine, even when the battery is discharged.
When starting the engine with normal battery, it can supply enough voltage required for lighting system such as turn signal or each
indicator, as well as the electric starter system, ignition system and fuel system.
When the ECM detects low battery voltage, the output voltage generated from alternator is supplied exclusively for ignition system
and fuel system operation when starting the engine, whereas the power supply for the charging/lighting system are shut off.
- HEADLIGHT
LIGHTING CUT RELAY - BRAKE/TAIL LIGHT
SUB FUSE 10 A
MAIN FUSE 15 A
ECM BATTERY
REGULATOR/
RECTIFIER
INJECTOR
ALTERNATOR
FUEL PUMP
IGNITION COIL/
SPARK PLUG
STARTER RELAY
STARTER MOTOR
2-17
TECHNICAL FEATURES
OPERATION
When the battery is adequately charged:
• When the ignition switch is turned ON, the ECM detects the battery voltage.
If the battery voltage is normal, ECM turns ON the lighting cut relay (page 2-20) and the battery voltage is supplied to electric
parts.
The battery voltage is supplied for ignition system and fuel system via regulator/rectifier internal circuit (B – A) and ignition
switch.
The headlight does not turn ON as it relies on the alternator output voltage.
- PGM-FI SYSTEM
- ELECTRIC STARTER
IGNITION SWITCH
A B C
REGULATOR/ BATTERY
RECTIFIER
• When the engine is started, the output voltage from alternator is supplied for electric devices as well as the ignition system and
fuel system via the regulator/rectifier.
The voltage generated by the alternator is also utilized for charging the battery.
- PGM-FI SYSTEM
- ELECTRIC STARTER
IGNITION SWITCH
A B C
REGULATOR/ BATTERY
RECTIFIER
2-18
TECHNICAL FEATURES
When the battery is discharged:
• When the ECM detects the low battery voltage, ECM leaves the lighting cut relay OFF (page 2-20), in result, the power supply
for electrical devices, such as turn signal relay, remains OFF. The voltage generated by the alternator is exclusively supplied for
ignition and fuel system via regulator/rectifier and ignition switch when the kickstarter is operated.
- PGM-FI SYSTEM
- ELECTRIC STARTER
IGNITION SWITCH
A B C
REGULATOR/ BATTERY
RECTIFIER
Tonngokhong BikerVietNam
• When the engine is started, the ECM turns ON the lighting cut relay. In result, the voltage generated by alternator is also
supplied for charging and operating other electrical devices.
- PGM-FI SYSTEM
- ELECTRIC STARTER
IGNITION SWITCH
A B C
REGULATOR/ BATTERY
RECTIFIER
2-19
TECHNICAL FEATURES
LIGHTING CUT RELAY
Lighting cut relay turns ON/OFF the power supply for lighting devices, such
as turn signal relay. LIGHTING CUT RELAY
When the ignition switch is turned ON, the ECM detects the battery voltage.
The coil inside the lighting cut relay becomes electromagnetized when the
ECM grounds the power, in result, the lighting cut relay turns ON.
CPU CPU
ECM ECM
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ELECTRIC PARTS ELECTRIC PARTS
2-20
3. FRAME/BODY PANELS/EXHAUST SYSTEM
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MAIN PIPE UPPER COVER··························3-5
3-1
FRAME/BODY PANELS/EXHAUST SYSTEM
BODY PANEL LOCATIONS
FRAME/BODY PANELS/EXHAUST SYSTEM
(7)
(23) (6)
(22) (8) (10)
(12)
(2) (13)
(1)
(5)
(3)
(11)
(4)
(24) (15)
(9) (18)
(21) (20)
(19) (14) (16) (17)
(1) Front fender (page 3-4) (9) Maintenance lid (page 3-9) (17) Rear fender/rear inner fender
(page 3-15)
(2) Front top cover (page 3-4) (10) Seat (page 3-10) (18) Front side cover (page 3-15)
(3) Main pipe upper cover (page 3-5) (11) Body garnish (page 3-10) (19) Main pipe side cover (page 3-16)
(4) Side garnish (page 3-5) (12) Luggage box (page 3-11) (20) Front lower cover (page 3-17)
Tonngokhong BikerVietNam
(5) Front inner cover (page 3-6)
(6) Front cover (page 3-6)
(7) Front handlebar cover (page 3-8)
(8) Rear handlebar cover (page 3-8)
(13) Rear center cover (page 3-11)
(14) Pillion step bracket (page 3-11)
(15) Fuel lid/center cover (page 3-18)
(16) Body cover (page 3-14)
(21) Under cover (page 3-17)
(22) Rearview mirror (page 3-8)
(23) Grab rail (page 3-12)
(24) Radiator cover (page 3-12)
(15) Fuel lid/center cover (4) Side garnish (22) Rearview mirror
(13) Rear center cover (14) Pillion step bracket (7) Front handlebar cover
(16) Body cover (18) Front side cover (8) Rear handlebar cover
(19) Main pipe side cover (21) Under cover (11) Body garnish
3-2
FRAME/BODY PANELS/EXHAUST SYSTEM
SERVICE INFORMATION
GENERAL
• This section covers removal and installation of the body panels and exhaust system.
• Always replace the exhaust pipe gasket after removing the exhaust pipe from the engine.
• When installing the exhaust system, loosely install all of the exhaust pipe fasteners. Always tighten the exhaust joint first, then
tighten the mounting fasteners. If you tighten the mounting fasteners first, the exhaust pipe may not seat properly.
• Always inspect the exhaust system for leaks after installation.
TORQUE VALUES
Pillion step bracket socket bolt 2.65 N·m (2.7 kgf·m, 20 lbf·ft)
Muffler mounting bolt 2.65 N·m (2.7 kgf·m, 20 lbf·ft)
TROUBLESHOOTING
Excessive exhaust noise
• Broken exhaust system
• Exhaust gas leak
Poor performance
• Deformed exhaust system
• Exhaust gas leak
• Clogged muffler
Tonngokhong BikerVietNam
3-3
FRAME/BODY PANELS/EXHAUST SYSTEM
FRONT FENDER
REMOVAL/INSTALLATION
Release the speedometer cable guide from the hole on
the front fender.
Remove the four bolts and front fender. FRONT FENDER
Installation is in the reverse order of removal.
SPEEDOMETER
CABLE GUIDE
BOLTS
HOOKS
TABS
3-4
FRAME/BODY PANELS/EXHAUST SYSTEM
MAIN PIPE UPPER COVER
REMOVAL/INSTALLATION
Unlock the fuel lid with fuel lid opener.
Open the fuel lid.
Remove the four tapping screws and a screw.
Be careful not to Slightly slide the main pipe upper cover backward and
damage the hooks release the hooks and tabs from the slots, then remove
and tabs. it.
Installation is in the reverse order of removal.
TABS
HOOKS
TAPPING SCREWS
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SIDE GARNISH
REMOVAL/INSTALLATION
Remove the screw/washer.
Release the hook on the upper side, slide the side HOOK
garnish backward and remove it.
Installation is in the reverse order of removal.
SCREW/
WASHER
SIDE GARNISH
3-5
FRAME/BODY PANELS/EXHAUST SYSTEM
FRONT INNER COVER
REMOVAL/INSTALLATION
Remove the main pipe upper cover (page 3-5).
FRONT INNER COVER
Remove the screws/washers.
Be careful not to Slightly slide the front inner cover upward and unhook
damage the hooks the hooks from the slots, then remove the front inner
and slots. cover.
Installation is in the reverse order of removal.
SCREWS/
HOOKS
WASHERS
FRONT COVER
REMOVAL/INSTALLATION
Remove the following:
– Front top cover (page 3-4)
– Side garnish (page 3-5)
– Front inner cover (page 3-6)
Disconnect the headlight 6P connector.
Remove the two bolts and four screws.
Be careful not to Release the hooks on the front side cover from the slots
damage the hooks, on the front cover.
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slots and the boss. Release the boss from the grommet, then remove the
front cover.
Installation is in the reverse order of removal.
GROMMET
HOOKS
SCREWS
6P CONNECTOR
BOLTS
FRONT COVER
BOSS
3-6
FRAME/BODY PANELS/EXHAUST SYSTEM
DISASSEMBLY/ASSEMBLY
Remove the following:
– Four screws/washers
– Two screws SCREWS/
– Headlight unit FRONT COVER WASHERS
SCREWS
HEADLIGHT UNIT
– Screw
– Front grill
LEFT FRONT COVER
Be careful not to Separate the right and left front covers by releasing the
damage the tabs. tabs. RIGHT FRONT COVER
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Assembly is in the reverse order of disassembly.
SCREW
FRONT GRILL
TABS
3-7
FRAME/BODY PANELS/EXHAUST SYSTEM
FRONT HANDLEBAR COVER
REMOVAL/INSTALLATION
Loosen the lock nuts and remove the rearview mirrors
by turning them counterclockwise. REARVIEW MIRRORS
LOCK NUTS
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REAR HANDLEBAR COVER
REMOVAL/INSTALLATION
Remove the following: WIRE GUIDES
– Front handlebar cover (page 3-8)
– Front inner cover (page 3-6)
Disconnect the following connectors:
– Headlight unit 6P connector
– Speedometer 9P connector
– Speedometer 4P connector
Release the speedometer sub harness from the wire
guides.
CONNECTORS
3-8
FRAME/BODY PANELS/EXHAUST SYSTEM
Disconnect the following:
CBS type shown:
– Rear brake light switch wire connectors REAR HANDLEBAR
– Front brake light switch wire connectors COVER
– Speedometer cable BRAKE LIGHT
SWITCH WIRE
Remove the three screws and rear handlebar cover. CONNECTORS
Route the wire Installation is in the reverse order of removal.
harness properly
(page 1-14).
SPEEDOMETER CABLE
SCREWS
MAINTENANCE LID
REMOVAL/INSTALLATION
Tonngokhong BikerVietNam
Be careful not to
damage the hook
Remove the screw and special screw.
Slightly slide the maintenance lid backward and release
the hook and the tabs.
HOOK SPECIAL SCREW
and tabs. Remove the maintenance lid.
Installation is in the reverse order of removal. TABS
SCREW
MAINTENANCE LID
3-9
FRAME/BODY PANELS/EXHAUST SYSTEM
SEAT
REMOVAL/INSTALLATION
Unlock the seat with seat opener.
Open the seat. SEAT
NUTS
BODY GARNISH
REMOVAL/INSTALLATION
Remove the screw/washer.
SCREW/
Be careful not to Release the hooks on the body garnish by pulling it WASHER
damage the hooks. backward and remove it.
Installation is in the reverse order of removal.
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BODY GARNISH
HOOKS
3-10
FRAME/BODY PANELS/EXHAUST SYSTEM
LUGGAGE BOX
REMOVAL/INSTALLATION
Remove the grab rail (page 3-12).
BOLTS/WASHERS
Remove the four bolts/washers and luggage box.
Installation is in the reverse order of removal.
LUGGAGE
BOX
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damage the tabs cover backward. COVER
and hook. Slightly slide the rear center cover forward and release
the hook, then remove the rear center cover.
Installation is in the reverse order of removal.
TABS
HOOK
BOLTS
3-11
FRAME/BODY PANELS/EXHAUST SYSTEM
RADIATOR COVER
REMOVAL/INSTALLATION
Remove the pillion step bracket (page 3-11).
Release the wire boss from the radiator cover.
Be careful not to Remove the three bolts and radiator cover. WIRE BOSS
damage the radiator
surface.
Route the wire Installation is in the reverse order of removal.
harness properly
(page 1-14).
BOLTS
RADIATOR COVER
GRAB RAIL
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REMOVAL/INSTALLATION
Unlock the seat with the ignition key.
Open the seat. BOLTS GRAB RAIL
3-12
FRAME/BODY PANELS/EXHAUST SYSTEM
FUEL LID/SEAT OPENER
REMOVAL/INSTALLATION
Remove the front cover (page 3-6).
HOOK
Remove the tapping screw and fuel lid/seat opener
lower cover by releasing its hook.
Tonngokhong BikerVietNam
– Ball
– Spring OPENER CABLES
SPECIAL
SCREWS
WASHER
SWITCH KNOB
LEVERS
SWITCH HOUSING
LEVER PIVOT SHAFT
3-13
FRAME/BODY PANELS/EXHAUST SYSTEM
BODY COVER
REMOVAL/INSTALLATION
Remove the following:
– Pillion step brackets (page 3-11).
– Fuel lid/center cover (page 3-18).
– Rear center cover (page 3-11).
– Two tapping screws from the lower side
– Two screws/washers from the upper side
Be careful not to Disconnect the rear combination light 6P connector.
damage the boss, Release the hooks and tabs from the slots and boss
tabs and hooks. from the grommet, then remove the body cover
backward.
Installation is in the reverse order of removal.
TABS SCREWS/WASHERS
BODY COVER
6P CONNECTOR
HOOKS
BOSS
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TAPPING SCREWS
DISASSEMBLY/ASSEMBLY
Remove the following:
REAR UNDER
SCREWS
– Body garnish (page 3-10) COVER
– Two screws
– Rear under cover REAR
– Right/left body covers COMBINATION
– Rear combination light unit LIGHT UNIT
Assembly is in the reverse order of disassembly.
BODY COVERS
3-14
FRAME/BODY PANELS/EXHAUST SYSTEM
REAR FENDER/REAR INNER FENDER
REMOVAL/INSTALLATION
Remove the following:
– Body cover (page 3-14)
– Three bolts/washers
– Rear fender
– Rear inner fender
Installation is in the reverse order of removal.
BOLTS/WASHERS
HOOK
TABS
FRONT SIDE COVER
3-15
FRAME/BODY PANELS/EXHAUST SYSTEM
MAIN PIPE SIDE COVER
REMOVAL/INSTALLATION
Remove the following:
– Fuel lid/center cover (page 3-18)
– Front lower cover (page 3-17)
– Pillion step bracket (page 3-11)
– Maintenance lid (right side only) (page 3-9)
Remove the screw, two bolts and two special bolts.
Be careful not to Slightly spread the body cover and release its holes
damage the hooks from the frame bosses.
and slots. Slightly slide the main pipe side cover backward and
release the lower hooks from the slots.
Release the slot from the front hook on the body cover
and remove the main pipe side cover.
Installation is in the reverse order of removal.
SLOT
SPECIAL BOLTS
SCREW
HOOKS
DISASSEMBLY/ASSEMBLY
Remove the following: Left side shown:
– Five screws (Left side:)
FLOOR STEP
– Four screws (Right side:)
– Floor step SCREWS
– Glove box GLOVE
BOX
Assembly is in the reverse order of disassembly.
3-16
FRAME/BODY PANELS/EXHAUST SYSTEM
FRONT LOWER COVER
REMOVAL/INSTALLATION
Remove the front side covers (page 3-15).
Be careful not to Remove the six screws.
damage the slots Release the lower tabs from the slots of under cover
and tabs. Remove the front lower cover.
Installation is in the reverse order of removal.
TABS
SCREWS
FRONT LOWER COVER
UNDER COVER
REMOVAL/INSTALLATION
Support the scooter with its centerstand.
Remove the following:
– Front lower cover (page 3-17)
Tonngokhong BikerVietNam
– Four special bolts
– Four bolts
Disconnect the radiator overflow hose and fuel tray
drain hose from the under cover.
Be careful not to Slightly spread the main pipe side covers.
damage the main Release the slots from the hooks on the main pipe side
pipe side covers covers by pulling the under cover forward and remove
and under cover. it.
Installation is in the reverse order of removal.
SPECIAL BOLTS
HOOKS
OVERFLOW
HOSE
SLOTS
BOLTS
FUEL TRAY
DRAIN HOSE
UNDER COVER
3-17
FRAME/BODY PANELS/EXHAUST SYSTEM
FUEL LID/CENTER COVER
REMOVAL/INSTALLATION
Remove the following:
– Main pipe upper cover (page 3-5).
– Luggage box (page 3-11).
Release the fuel lid cable from the cable holder and
disconnect the cable from the opener.
Remove the four screws.
Be careful not to Release the hooks and tabs by pulling the fuel lid/center
damage the hooks cover upward and remove it.
and tabs.
Installation is in the reverse order of removal.
SCREWS TABS
CABLE HOLDER
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FUEL LID CABLE
HOOKS
FUEL LID OPENER
DISASSEMBLY/ASSEMBLY
Remove the following:
FUEL LID FUEL LID TRAY
– Five screws
– Fuel lid
– Fuel lid tray
– Center cover
Assembly is in the reverse order of disassembly.
SCREWS
CENTER COVER
3-18
FRAME/BODY PANELS/EXHAUST SYSTEM
EXHAUST PIPE/MUFFLER
REMOVAL
Remove the exhaust pipe joint nuts.
Remove the muffler mounting bolts, collar, exhaust
pipe/muffler and the gasket.
INSTALLATION
Replace the exhaust gasket with a new one.
Align the exhaust pipe flange with the stud bolts and
install the joint nuts, but do not tighten yet.
Install the muffler mounting bolts and collar, but do not
tighten yet.
Tighten the exhaust pipe joint nuts.
Tighten the muffler mounting bolts to the specified
torque.
TORQUE: 26.5 N·m (2.7 kgf·m, 20 lbf·ft)
After installation, make sure the exhaust system does
not leak.
JOINT NUTS
COLLAR
MOUNTING BOLTS
EXHAUST PIPE/MUFFLER 26.5 N·m (2.7 kgf·m, 20 lbf·ft)
3-19
MEMO
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4. MAINTENANCE
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SPARK PLUG················································4-7
VALVE CLEARANCE····································4-9
HEADLIGHT AIM ········································4-20
DRIVE BELT················································4-14
4-1
MAINTENANCE
SERVICE INFORMATION
MAINTENANCE
GENERAL
• Gasoline is extremely flammable and is explosive under certain conditions. Work in a well ventilated area. Smoking or allowing
flames or sparks in the work area or where the gasoline is stored can cause a fire or explosion.
• If the engine must be running to do some work, make sure the area is well ventilated. Never run the engine in an enclosed area.
The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and may lead to death. Run the
engine in an open area or with an exhaust evacuation system in enclosed area.
• Place the scooter on a level ground before starting any work.
SPECIFICATIONS
ITEM SPECIFICATIONS
Throttle grip freeplay 2 – 6 mm (0.1 – 0.2 in)
Spark plug Standard CPR7EA-9 (NGK) U22EPR9 (ND)
Spark plug gap 0.8 – 0.9 mm (0.03 – 0.04 in)
Valve clearance IN 0.14 ± 0.02 mm (0.006 ± 0.001 in)
EX 0.20 ± 0.02 mm (0.008 ± 0.001 in)
Recommended engine oil API classification: SE, SF or SG
(except oils labeled as energy conserving on the circular API
service label)
Viscosity: SAE 10W-30
JASO T 903 standard: MB
Engine oil capacity After draining 0.7 liter (0.7 US qt, 0.6 Imp qt)
After disassembly 0.8 liter (0.8 US qt, 0.7 Imp qt)
Engine idle speed 1,700 ± 100 min-1 (rpm)
Drive belt width Service limit: 18.0 mm (0.71 in)
Recommended final reduction oil API classification: SE, SF or SG
(except oils labeled as energy conserving on the circular API
service label)
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Final reduction oil
capacity
After draining
After disassembly
Viscosity: SAE 10W-30
JASO T 903 standard: MB
0.10 liter (0.11 US qt, 0.09 Imp qt)
0.12 liter (0.13 US qt, 0.11 Imp qt)
Rear brake lever freeplay 10 – 20 mm (0.4 – 0.8 in)
Clutch lining thickness Service limit: 2.0 mm (0.08 in)
Cold tire pressure Driver only Front 200 kPa (2.00 kgf/cm2, 29 psi)
Rear 225 kPa (2.25 kgf/cm2, 33 psi)
Driver and passenger Front 200 kPa (2.00 kgf/cm2, 29 psi)
Rear 225 kPa (2.25 kgf/cm2, 33 psi)
Tire size Front 80/90 – 14M/C40P
Rear 80/90 – 14M/C46P
Tire brand IRC Front NR73TZ
Rear NR73T
VEE RUBBER Front V338F
Rear V338R
Minimum tire tread depth Front To the indicator
Rear To the indicator
4-2
MAINTENANCE
TORQUE VALUES
Spark plug 16 N·m (1.6 kgf·m, 12 lbf·ft)
Valve adjusting screw lock nut 10 N·m (1.0 kgf·m, 7 lbf·ft) Apply engine oil to the threads and seating
surface.
Engine oil drain bolt 24 N·m (2.4 kgf·m, 18 lbf·ft)
Engine oil strainer screen cap 20 N·m (2.0 kgf·m, 15 lbf·ft)
Final reduction oil check bolt 13 N·m (1.3 kgf·m, 10 lbf·ft)
Final reduction oil drain bolt 13 N·m (1.3 kgf·m, 10 lbf·ft)
Air cleaner housing cover screw 1.1 N·m (0.1 kgf·m, 0.8 lbf·ft)
Equalizer connecting cable lock nut 6.4 N·m (0.7 kgf·m, 4.7 lbf·ft)
(CBS type only)
Headlight aim adjusting bolts 0.6 N·m (0.1 kgf·m, 0.4 lbf·ft)
Spoke 3.7 N·m (0.4 kgf·m, 2.7 lbf·ft)
TOOLS
Valve adjusting wrench Spoke wrench, 5.8 x 6.1 mm
07708-0030400 07701-0020300
Tonngokhong BikerVietNam
4-3
MAINTENANCE
MAINTENANCE SCHEDULE
Perform the Pre-ride inspection in the Owner’s Manual at each scheduled maintenance period.
I: Inspect and Clean, Adjust, Lubricate or Replace if necessary. C: Clean. R: Replace. A: Adjust. L: Lubricate.
The following items require some mechanical knowledge. Certain items (particularly those marked * and **) may require more
technical information and tools. Consult an authorized Honda dealer.
FREQUENCY WHICHEVER ODOMETER READING (NOTE 1)
COMES FIRST
REFER TO
X1,000 km 1 4 8 12
PAGE
X1,000 mi 0.6 2.5 5 7.5
ITEMS Months 6 12 18
* FUEL LINE I I I 4-5
* THROTTLE OPERATION I I I 4-5
AIR CLEANER NOTE2 EVERY 16,000 km (10,000 mi) R 4-6
CRANKCASE BREATHER NOTE4 C C C 4-7
SPARK PLUG I R I 4-7
* VALVE CLEARANCE I I I I 4-9
ENGINE OIL R R 4-10
* ENGINE OIL STRAINER SCREEN C 4-12
* ENGINE IDLE SPEED I I I I 4-12
RADIATOR COOLANT NOTE3 I 4-13
* COOLING SYSTEM I 4-13
* DRIVE BELT EVERY 8,000 km (5,000 mi) I,
4-14
EVERY 24,000 km (15,000 mi) R
* FINAL DRIVE OIL NOTE3 4-14
BRAKE FLUID NOTE3 I I I 4-15
BRAKE SHOES/PADS WEAR I I I 4-15
BRAKE SYSTEM I I I I 4-16
* BRAKE LIGHT SWITCH I I I 4-19
*
*
**
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BRAKE LOCK OPERATION
HEADLIGHT AIM
CLUTCH SHOES WEAR
SIDESTAND
I I
I
I
I
I
I
I
I
I
I
4-20
4-20
4-21
4-21
* SUSPENSION I I I 4-21
* NUTS, BOLTS, FASTENERS I I 4-22
** WHEELS/TIRES I I I I 4-22
** STEERING HEAD BEARINGS I I 4-24
* SHOULD BE SERVICED BY AN AUTHORIZED Honda DEALER, UNLESS THE OWNER HAS PROPER TOOLS AND SER-
VICE DATA AND IS MECHANICALLY QUALIFIED.
** IN THE INTEREST OF SAFETY, WE RECOMMEND THESE ITEMS BE SERVICED ONLY BY AN AUTHORIZED Honda
DEALER.
Honda recommends that an authorized Honda dealer should road test your scooter after each periodic maintenance is carried out.
NOTES:
1. At higher odometer readings, repeat at the frequency interval established here.
2. Service at every 16,000 km (10,000 mi) or more frequently when riding in unusually wet or dusty areas (cleaning is prohibited).
3. Replace every 2 years. Replacement requires mechanical skill.
4. Service more frequently when riding in rain or at full throttle.
4-4
MAINTENANCE
FUEL LINE
Remove the left main pipe side cover (page 3-16).
Check the fuel hose for deterioration, damage or
leakage.
Also, check the fuel hose fittings for leakage.
Replace the fuel hose if necessary.
Install the left main pipe side cover (page 3-16).
THROTTLE OPERATION
• Reusing a damaged or abnormally bent or kinked
throttle cable can prevent proper throttle slide
operation and may lead to a loss of throttle control
while riding.
Check for any deterioration or damage to the throttle
cable. Check the throttle grip for smooth operation.
Check that the throttle opens and automatically closes
in all steering positions.
If the throttle grip does not return properly, lubricate the
throttle cable.
For cable lubrication, disconnect the throttle cable at
Tonngokhong BikerVietNam
their pivot points and apply commercially available
cable lubricant or light weight oil.
If the throttle grip still does not return properly, replace
the throttle cable.
With the engine idling, turn the handlebar all the way to
the right and left to ensure that the idle speed does not
change. If idle speed increases, check the throttle grip
freeplay and throttle cable routing.
4-5
MAINTENANCE
Measure the throttle grip freeplay at the throttle grip
flange.
LOCK NUT
AIR CLEANER
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• The viscous paper element cannot be cleaned
because the element contains a dust adhesive.
SCREWS
• If the scooter is used in unusually wet or dusty
areas, more frequent inspections are required.
Remove the screws and air cleaner housing cover from
the left side.
Remove and discard the air cleaner element in
accordance with the maintenance schedule (page 4-4).
Replace the element any time if it is excessively dirty or
damaged.
Install the removed parts in the reverse order of
removal.
TORQUE: COVER ELEMENT
Air cleaner housing cover screw:
1.1 N·m (0.1 kgf·m, 0.8 lbf·ft)
4-6
MAINTENANCE
CRANKCASE BREATHER
• Service more frequently when ridden in rain, at full
throttle, or after the scooter is washed or overturned.
Service if the deposit level can be seen in the
transparent section of the drain plug.
Remove the crankcase breather drain plug from the air
cleaner and drain deposits into a suitable container.
Install the crankcase breather drain plug.
DRAIN PLUG
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SPARK PLUG
BREATHER HOSE
4-7
MAINTENANCE
Remove the spark plug.
SPARK PLUG
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Always use the specified spark plug on this scooter.
SPECIFIED SPARK PLUG:
Standard: CPR7EA-9 (NGK), U22EPR9 (ND)
Measure the spark plug gap between the center and
side electrodes with a feeler gauge of a wire type.
If necessary, adjust the gap by bending the side
electrode carefully.
SPARK PLUG GAP: 0.8 – 0.9 mm (0.03 – 0.04 in) 0.8 – 0.9 mm
(0.03 – 0.04 in)
Do not overtighten Install and hand tighten the spark plug to the cylinder
the spark plug. head, then tighten the spark plug to the specified SPARK PLUG
torque.
TORQUE: 16 N·m (1.6 kgf·m, 12 lbf·ft)
4-8
MAINTENANCE
Connect the spark plug cap.
Install the maintenance lid (page 3-9).
VALVE CLEARANCE
INSPECTION
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through the exhaust stroke to TDC.
Rotate the crankshaft one full turn by operating the
kickstarter slowly and match up the "T" mark again.
"T" MARK
NOTCH
VALVE CLEARANCE:
IN: 0.14 ± 0.02 mm (0.006 ± 0.001 in)
EX: 0.20 ± 0.02 mm (0.008 ± 0.001 in)
4-9
MAINTENANCE
If the valve clearance is incorrect, loosen the valve
VALVE ADJUSTING WRENCH
adjusting screw lock nut and adjust the valve clearance
by turning the adjusting screw until there is a slight drag
on the feeler gauge.
Apply engine oil to the valve adjusting screw lock nut
threads and seating surface.
Hold the adjusting screw and tighten the lock nut.
TOOL:
Valve adjusting wrench 07708-0030400
ENGINE OIL
OIL LEVEL CHECK
Support the scooter with its centerstand on a level
surface. FILLER CAP/DIPSTICK
Start the engine and let it idle for 3 - 5 minutes.
Stop the engine and wait for 2 - 3 minutes.
Remove the oil filler cap/dipstick and wipe off the oil
from the dipstick with a clean cloth.
UPPER
Insert the oil filler cap/dipstick without screwing it in,
remove it and check the oil level.
The level should be between the "UPPER" and LOWER
"LOWER" level lines of the oil filler cap/dipstick.
Tonngokhong BikerVietNam
Other viscosities If the oil level is below or near the lower level line on the
shown in the chart dipstick, add the recommended oil to the upper level.
may be used when
the average RECOMMENDED ENGINE OIL:
temperature in your API classification: SE, SF or SG
riding area is within (except oils labeled as energy conserving on the
the indicated range. circular API service label)
Viscosity: SAE 10W-30
JASO T 903 standard: MB
FILLER CAP/DIPSTICK
4-10
MAINTENANCE
OIL CHANGE
• Change the engine oil with the engine warm and the
scooter on level ground to assure complete draining.
Support the scooter with its centerstand.
Start the engine, warm it up and stop it.
Remove the oil filler cap/dipstick.
FILLER CAP/DIPSTICK
Place an oil drain pan under the engine to collect the oil,
then remove the oil drain bolt and sealing washer.
Slowly apply kickstarter and drain the engine oil.
After draining the oil completely, install the new sealing
washer and oil drain bolt.
Tighten the drain bolt to the specified torque.
TORQUE: 24 N·m (2.4 kgf·m, 18 lbf·ft)
Fill the crankcase with the recommended engine oil.
ENGINE OIL CAPACITY:
0.7 liter (0.7 US qt, 0.6 lmp qt) after draining
0.8 liter (0.8 US qt, 0.7 lmp qt) after disassembly
WASHER/DRAIN BOLT
Tonngokhong BikerVietNam
RECOMMENDED ENGINE OIL:
API classification: SE, SF or SG
(except oils labeled as energy conserving on the
circular API service label)
Viscosity: SAE 10W-30
JASO T 903 standard: MB
Check the oil level (page 4-10).
Make sure that there are no oil leaks.
4-11
MAINTENANCE
ENGINE OIL STRAINER SCREEN
Drain the engine oil (page 4-11).
OIL STRAINER SCREEN OIL STRAINER
Remove the oil strainer screen cap, O-ring, spring and SCREEN CAP
oil strainer screen.
Wash the strainer screen thoroughly in non-flammable
or high flash point cleaning solvent until all accumulated
dirt has been removed.
Blow dry it with compressed air to clean completely.
Before installing the strainer screen, it should be
examined closely for damage and make sure the O-RING
sealing rubber is in good condition.
Make sure the O-ring is in good condition and replace it
if necessary.
SPRING
Install the oil strainer screen and spring with the strainer
sealing rubber toward the crankcase.
Coat the O-ring with engine oil and install the oil strainer
screen cap.
Tighten the oil strainer screen cap to the specified
torque.
TORQUE: 20 N·m (2.0 kgf·m, 15 lbf·ft)
Fill the crankcase with recommended engine oil and
check the engine oil level (page 4-10).
Make sure that there are no oil leaks.
Tonngokhong BikerVietNam
maintenance items have been performed and are
within specifications.
• Before checking the idle speed, inspect following
items.
– No MIL blinking
– Spark plug condition (page 4-7)
– Air cleaner condition (page 4-6)
• The engine must be warm for accurate idle speed
inspection.
• This system eliminates the need for manual idle
speed adjustment.
• Use a tachometer with graduations of 50 min-1 (rpm)
or smaller that will accurately indicate a 50 min-1
(rpm) change.
Support the scooter with its centerstand.
Warm up the engine about ten minutes.
Connect the tachometer and check the idle speed.
ENGINE IDLE SPEED: 1,700 ± 100 min-1 (rpm)
If the idle speed is out of the specification, check the
following:
• Throttle operation and throttle grip freeplay (page 4-
5).
• Intake air leak or engine top-end problem (page 9-
6).
• IACV operation (page 6-38).
4-12
MAINTENANCE
RADIATOR COOLANT
Support the scooter with its centerstand. RESERVE TANK CAP
UPPER
Check the coolant level of the reserve tank with the LEVEL
engine running at normal operating temperature.
The level should be between the "UPPER" and
"LOWER" level lines with the scooter upright on a level
surface.
COOLING SYSTEM
Tonngokhong BikerVietNam
Remove the following:
– Body cover (page 3-14)
– Luggage box (page 3-11)
WATER HOSES
WATER
PIPE
WATER HOSE WATER PUMP
4-13
MAINTENANCE
DRIVE BELT
Remove the left crankcase cover (page 11-13).
Check the drive belt for cracks, separation or abnormal
or excessive wear and replace it if necessary (page 11-
13).
DRIVE BELT
Using the suitable two flat plates, measure the drive belt
width as shown. DRIVE BELT
DRIVE BELT
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FINAL DRIVE OIL
OIL LEVEL CHECK
Make sure that the final reduction case has no oil leaks.
Support the scooter with its centerstand. SEALING WASHER
Remove the oil check bolt.
Check whether the oil flows out from the check bolt
hole.
If the level is low (oil does not flow out), add the
recommended oil as described below.
RECOMMENDED FINAL REDUCTION OIL:
API classification: SE, SF or SG
(except oils labeled as energy conserving on the
circular API service label)
Viscosity: SAE 10W-30 CHECK BOLT LOWER LEVEL
JASO T 903 standard: MB
Install the oil check bolt with a new sealing washer and
tighten it to the specified torque.
TORQUE: 13 N·m (1.3 kgf·m, 10 lbf·ft)
4-14
MAINTENANCE
OIL CHANGE
Place an oil drain pan under the final reduction case to
SEALING WASHER
collect the oil, then remove the oil check bolt, oil drain
bolt and sealing washers.
Slowly turn the rear wheel and drain the oil.
After draining the oil completely, install the oil drain bolt
with a new sealing washer and tighten the drain bolt to
the specified torque.
TORQUE: 13 N·m (1.3 kgf·m, 10 lbf·ft)
Fill the final reduction case with recommended oil up to
the correct level (page 4-14).
FINAL REDUCTION OIL CAPACITY:
0.10 liter (0.11 US qt, 0.09 lmp qt) after draining DRAIN BOLT CHECK BOLT
0.12 liter (0.13 US qt, 0.11 lmp qt) after disassem-
bly
Install the oil check bolt with a new sealing washer and
tighten it to the specified torque.
TORQUE: 13 N·m (1.3 kgf·m, 10 lbf·ft)
BRAKE FLUID
• Spilling fluid can damage painted, plastic or rubber
parts. Place a rag over these parts whenever the
system is serviced.
• Do not mix different types of fluid, as they are not
compatible with each other.
Tonngokhong BikerVietNam
• Do not allow foreign material to enter the system
when filling the reservoir.
• When the fluid level is low, check the brake pads for
wear (page 4-15). A low fluid level may be due to
wear of the brake pads.
If the brake pads are worn, the caliper piston is
pushed out, and this accounts for a low reservoir
level. If the brake pads are not worn and the fluid
level is low, check entire system for leaks (page 4- "LOWER" LEVEL MARK
16).
Support the scooter with its centerstand.
Turn the handlebar to the left so the reservoir is level
and check the front brake reservoir fluid level through
the sight glass.
If the level is near the lower level mark, check the brake
pads for wear (page 4-15).
LIMIT GROOVES
4-15
MAINTENANCE
REAR DRUM BRAKE SHOES
Check the wear indicator position when the brake lever
WEAR
is applied.
INDICATOR
If the indicator aligns with the " " mark, inspect the
brake drum (page 16-7).
Replace the brake shoes if the drum I.D. is within
service limit.
BRAKE SYSTEM
FRONT DISC BRAKE
Firmly apply the brake lever and check that no air has
entered the system.
If the lever feels soft or spongy when operated, bleed
the air from the system.
For air bleeding procedures (page 16-8).
Tonngokhong BikerVietNam
Remove the front handlebar cover (page 3-8).
Inspect the brake hose and fittings for deterioration,
cracks, or signs of leakage.
Tighten any loose fittings.
Replace the hose and fittings as required.
Install the front handlebar cover (page 3-8).
BRAKE
HOSE
4-16
MAINTENANCE
REAR DRUM BRAKE
Check the brake cable and brake lever for loose
connections, excessive play or other damage.
Replace or repair if necessary.
10 – 20 mm (0.4 – 0.8 in)
Measure the rear brake lever freeplay at the end of the
lever.
FREEPLAY: 10 – 20 mm (0.4 – 0.8 in)
Make sure the cut- Adjust the rear brake lever freeplay by turning the rear
out of the adjusting brake arm adjusting nut.
nut is seated on the
joint pin.
ADJUSTING NUT
4-17
MAINTENANCE
Lift the front wheel off the ground and rotate it by hand.
Make sure that the front wheel rotates smoothly.
Lift the front wheel off the ground and apply the rear
brake lever.
Make sure that the front wheel does not rotate while the
rear brake lever is applied.
If it is abnormal, inspect as follows:
Tonngokhong BikerVietNam
Remove the front handlebar cover (page 3-8).
Measure the distance between the edge surface of the
knocker and the edge surface of the master cylinder 0 – 0.1 mm (0 – 0.004 in)
LOCK NUT
body with the feeler gauge.
STANDARD: 0 – 0.1 mm (0 – 0.004 in)
If the distance exceeds the standard, adjust the ADJUSTER
connecting cable.
Loosen the lock nut and turn the adjuster until the
distance between the edge surfaces is within standard. KNOCKER
INSPECTION
POINT
Check that there is no gap between the knocker pin and ADJUSTER
the end of the slot of the knocker joint. LOCK NUT
If there is any gap, loosen the lock nut and turn the
adjuster until there is no gap between the knocker pin
and the end of the slot of the knocker joint.
After the adjustment, hold the adjuster and tighten the
lock nut to the specified torque.
TORQUE: 6.4 N·m (0.7 kgf·m, 4.7 lbf·ft)
After tightening the lock nut, check that there is no gap KNOCKER PIN
between the knocker pin and the end of the slot of the
knocker joint.
Apply rear brake lever several times and check that the KNOCKER JOINT
distance between the edges has not been changed
after applying the brake.
4-18
MAINTENANCE
Recheck the distance between the edge surface of the
knocker and the edge surface of the master cylinder
body is within standard. 0 – 0.1 mm (0 – 0.004 in)
LOCK NUT
STANDARD: 0 – 0.1 mm (0 – 0.004 in)
Recheck the combined brake system.
If the combined brake system adjustment is normal, but ADJUSTER
the front wheel rotates abnormally, check for other
malfunction parts.
Install the front handlebar cover (page 3-8). KNOCKER
INSPECTION
POINT
Tonngokhong BikerVietNam
4-19
MAINTENANCE
BRAKE LOCK OPERATION
STANDARD TYPE
BRAKE LEVER
CBS TYPE
Squeeze the rear brake lever and set the lock lever by
pulling it up.
Check that the rear wheel is locked completely.
Tonngokhong BikerVietNam
BRAKE LEVER
HEADLIGHT AIM
• Adjust the headlight beam as specified by local laws
and regulations.
ADJUSTING GEAR
Place the scooter on a level ground.
Adjust the headlight beam vertically by turning the
headlight aim adjusting gear using the screwdriver.
A clockwise rotation moves the beam down and
counterclockwise rotation moves the beam up.
4-20
MAINTENANCE
CLUTCH SHOES WEAR
Remove the clutch assembly (page 11-19).
Check the clutch shoes for abnormal wear.
Measure the thickness of each shoe.
SERVICE LIMIT: 2.0 mm (0.08 in)
Replace the clutch shoes if they are less than the
service limit (page 11-20).
Install the clutch assembly (page 11-22).
CLUTCH SHOE
SIDESTAND
Support the scooter with its centerstand.
Check the sidestand spring for damage or loss of
tension.
Check the sidestand assembly for freedom of
movement and lubricate the sidestand pivot if
necessary.
Check the sidestand ignition cut-off system:
1. Retract the sidestand.
2. Start the engine.
3. Move the sidestand full down.
4. The engine should stop as the sidestand is lowered.
SUSPENSION
FRONT
Loose, worn or Check the action of the forks by operating the front
damaged brake and compressing the front suspension several
suspension parts times.
impair scooter Check the entire assembly for signs of leaks, damage
stability and control. or loose fasteners.
Replace damaged components which cannot be
repaired.
Tighten all nuts and bolts.
For fork service (page 14-11).
4-21
MAINTENANCE
REAR
Check the action of the shock absorber by compressing
it several times.
Check the entire shock absorbers assembly for signs of
leaks, damage or loose fasteners.
Replace damaged components which cannot be
repaired.
Tighten all nuts and bolts.
For rear shock absorber service (page 15-8).
Tonngokhong BikerVietNam
NUTS, BOLTS, FASTENERS
Check that all chassis nuts and bolts are tightened to
their correct torque values (page 1-9).
Check that all cotter pins, safety clips, hose clamps and
cable stays are in place and properly secured.
WHEELS/TIRES
Support the scooter with its centerstand.
Making sure that the fork is not allowed to move, raise
the front wheel and check for play.
Check for worn front wheel bearings by grabbing the
front wheel and attempting to move the wheel side to
side.
Replace the front wheel bearings if any looseness is
noted.
Turn the wheel and check that it rotates smoothly with
no unusual noises.
If any abnormal conditions are suspected, inspect the
front wheel bearings (page 14-10).
4-22
MAINTENANCE
Support the scooter securely and raise the rear wheel.
Check for worn final gear shaft bearings by grabbing
the rear wheel and attempting to move the wheel side
to side.
Replace the final gear shaft bearings if any looseness is
noted.
Turn the wheel and check that it rotates smoothly with
no unusual noises.
If any abnormal conditions are suspected, check the
final reduction (page 12-8).
PRESSURE GAUGE
Tonngokhong BikerVietNam
Tighten any loose spokes.
TOOL:
Spoke wrench, 5.8 x 6.1 mm 07701-0020300
SPOKE WRENCH
4-23
MAINTENANCE
STEERING HEAD BEARINGS
• Check that the control cables do not interfere with
handlebar rotation.
Support the scooter with its centerstand and raise the
front wheel off the ground.
Check that the handlebar moves freely from side-to-
side. If the handlebar moves unevenly or binds, inspect
the steering head bearings (page 14-21).
Tonngokhong BikerVietNam
4-24
5. LUBRICATION SYSTEM
Tonngokhong BikerVietNam
5-1
LUBRICATION SYSTEM
LUBRICATION SYSTEM DIAGRAM
LUBRICATION SYSTEM
CAMSHAFT
PISTON
Tonngokhong BikerVietNam
CRANKSHAFT
OIL PUMP
5-2
LUBRICATION SYSTEM
SERVICE INFORMATION
GENERAL
Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely
unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and water as soon as
possible after handling used oil.
• The oil pump can be serviced with the engine installed in the frame.
• The service procedures in this section must be performed with the engine oil drained.
• When removing and installing the oil pump, use care not to allow dust or dirt to enter the engine.
• If any portion of the oil pump is worn beyond the specified service limits, replace the oil pump as an assembly.
• After the oil pump has been installed, check that there are no oil leaks.
SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Engine oil capacity After draining 0.7 liter (0.7 US qt, 0.6 lmp qt) –
After disassembly 0.8 liter (0.8 US qt, 0.7 lmp qt) –
Recommended engine oil API classification: SE, SF or SG
(except oils labeled as energy conserving
on the circular API service label) –
Viscosity: SAE 10W-30
JASO T 903 standard: MB
Oil pump rotor Tip clearance 0.15 (0.006) 0.20 (0.008)
Body clearance 0.15 – 0.21 (0.006 – 0.008) 0.35 (0.014)
Side clearance 0.05 – 0.10 (0.002 – 0.004) 0.12 (0.005)
Tonngokhong BikerVietNam
TORQUE VALUES
Oil pump plate screw 3 N·m (0.3 kgf·m, 2.2 lbf·ft)
Oil pump mounting bolt 10 N·m (1.0 kgf·m, 7 lbf·ft)
TROUBLESHOOTING
Engine oil level too low
• Oil consumption
• External oil leak
• Worn piston rings or incorrect piston ring installation (page 10-10)
• Worn cylinder (page 10-6)
• Worn valve guide or seal (page 9-24)
Oil contamination
• Oil not changed often enough
• Faulty cylinder head gasket
• Worn piston rings (page 10-10)
5-3
LUBRICATION SYSTEM
OIL PUMP
REMOVAL
• When removing the oil pump, do not allow dust or
BOLTS
dirt to enter the engine.
Remove the stator base/water pump (page 7-13).
Remove the oil pump mounting bolts and oil pump.
OIL PUMP
INSTALLATION
Install the oil pump to the crankcase by aligning the
dowel pins and holes. Align
Tonngokhong BikerVietNam
Install and tighten the oil pump mounting bolts to the
OIL PUMP
BOLTS
specified torque.
5-4
LUBRICATION SYSTEM
DISASSEMBLY/ASSEMBLY
Remove the following:
– Dowel pins
– Oil pump plate screw
– Pump plate
– Outer rotor
– Inner rotor
Apply engine oil to Assembly is in the reverse order of disassembly.
the inner rotor and
outer rotor.
TORQUE: Oil pump plate screw
3 N·m (0.3 kgf·m, 2.2 lbf·ft)
OUTER ROTOR
PUMP BODY
INNER ROTOR
INSPECTION
TIP CLEARANCE
• Measure at several points and use the largest
TIP CLEARANCE:
reading to compare the service limit.
Temporarily install the outer rotor and inner rotor to
pump body and oil pump shaft into the oil pump inner
rotor.
Measure the clearance between the outer rotor and the
inner rotor with a feeler gauge.
SERVICE LIMIT: 0.20 mm (0.008 in)
5-5
LUBRICATION SYSTEM
BODY CLEARANCE
Measure the clearance between the oil pump body and
BODY CLEARANCE:
the outer rotor with a feeler gauge.
SIDE CLEARANCE
Measure the side clearance using a straight edge and a SIDE CLEARANCE:
feeler gauge.
Tonngokhong BikerVietNam
5-6
6. FUEL SYSTEM (Programmed Fuel Injection)
Tonngokhong BikerVietNam
PGM-FI TROUBLESHOOTING
INFORMATION············································6-10
ECM ·····························································6-42
INJECTOR···················································6-44
6-1
FUEL SYSTEM (Programmed Fuel Injection)
COMPONENT LOCATION
FUEL SYSTEM (Programmed Fuel Injection)
Tonngokhong BikerVietNam
6-2
FUEL SYSTEM (Programmed Fuel Injection)
SERVICE INFORMATION
GENERAL
• Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can cause a
fire or explosion.
• Before disconnecting the fuel feed hose, relieve fuel pressure from the system by disconnecting the quick connect fitting at the
fuel pump (page 6-25).
• Bending or twisting the control cables will impair smooth operation and could cause the cables to stick or bind, resu-lting in loss
of vehicle control.
• Use an electric heating element to heat the coolant for the ECT sensor inspection, keep flammable materials away from the
electric heating element. Wear protective clothing, insulated gloves and eye protection.
• Do not apply commercially available carburetor cleaners to the inside of the throttle bore.
• Do not snap the throttle valve from full open to full close after the throttle cable has been removed. It may cause incor-rect idle
operation.
• Seal the intake port with tape or a clean cloth to keep dirt and debris from entering the engine after the throt-tle body has been
removed.
• Do not damage the throttle body. It may cause incorrect throttle valve operation.
• Prevent dirt and debris from entering the throttle bore and air passages after the throttle body has been removed. Clean them
using com-pressed air if necessary.
• The throttle body is factory pre-set. Do not disassemble in a way other than shown in this manual.
• Do not loosen or tighten the white painted nut and screw of the throttle body. Loosening or tightening them can cause throttle
valve and idle control failure.
• The parts of the throttle body not shown in this manual should not be disassembled.
• Always replace the packing when the fuel pump is removed.
• A faulty PGM-FI system is often related to poorly connected or corroded connectors. Check those connections before
proceeding.
• The PGM-FI system is equipped with the Self-Diagnostic System described (page 6-10). If the MIL blinks, follow the Self-
Diagnostic Procedures to remedy the problem.
• When checking the PGM-FI, always follow the steps in the troubleshooting flow chart.
• The PGM-FI system is provided with fail-safe function to secure a minimum running capability even when there is any trouble in
the system. When any abnormality is detected by the self-diagnosis function, running capability is secured by making use of the
numerical values of a situation preset in the simulated program map.
Tonngokhong BikerVietNam
It must be remembered, however, that when any abnormality is detected in injector, the fail-safe function stops the engine to
protect it from damage.
• For PGM-FI system location (page 6-6).
• When disassembling the fuel system parts, note the location of the O-rings. Replace them with new ones upon reassembly.
• Use a digital tester for PGM-FI system inspection.
• For fuel level sensor inspection (page 20-11).
SPECIFICATIONS
ITEM SPECIFICATIONS
Throttle body identification number GQR8A
Engine idle speed 1,700 ± 100 min-1 (rpm)
Throttle grip freeplay 2 – 6 mm (0.1 – 0.2 in)
ECT sensor resistance (40°C/104°F) 1.0 – 1.3 kǡ
(100°C/212°F) 0.1 – 0.2 kǡ
Fuel injector resistance (20°C/68°F) 9 – 12 ǡ
Fuel pressure at idle 294 kPa (3.0 kgf/cm2, 43 psi)
Fuel pump flow (at 12 V) 120 cm3 (4.1 US oz, 4.2 Imp oz) minimum/10 seconds
TORQUE VALUES
ECT sensor 17.7 N·m (1.8 kgf·m, 13 lbf·ft)
IACV torx screw 2.1 N·m (0.2 kgf·m, 1.5 lbf·ft)
Sensor unit torx screw 3.4 N·m (0.3 kgf·m, 2.5 lbf·ft)
Throttle cable stay mounting screw 3.4 N·m (0.3 kgf·m, 2.5 lbf·ft)
O2 sensor 25 N·m (2.5 kgf·m, 18 lbf·ft)
6-3
FUEL SYSTEM (Programmed Fuel Injection)
TOOLS
Fuel pressure gauge Pressure gauge manifold Hose attachment, 9 mm/9 mm
07406-0040004 07ZAJ-S5A0111 07ZAJ-S5A0120
SCS connector
070PZ-ZY30100
Tonngokhong BikerVietNam
6-4
FUEL SYSTEM (Programmed Fuel Injection)
PGM-FI SYMPTOM TROUBLESHOOTING
When the scooter has one of these symptoms, check the MIL blinking, refer to the MIL code index (page 6-14) and begin the
appropriate troubleshooting procedure. If there are no MIL blinking stored in the ECM memory, do the diagnostic procedure for the
symptom, in sequence listed below, until you find cause.
Symptom Diagnosis procedure Also check for
Engine cranks but won’t start 1. Crank the engine for more than • No fuel to injector
(No MIL blinking) ten seconds and check the MIL – Clogged fuel filter
(page 6-10) and execute the trou- – Clogged fuel filler cap breather hole
bleshooting according to the MIL. – Pinched or clogged fuel feed hose
2. Inspect the fuel supply system – Faulty fuel pump
(page 6-25). – Faulty fuel pump circuits
• Intake air leak
• Contaminated/deteriorated fuel
• Faulty fuel injector
• IACV stuck
• Faulty ignition system
Engine cranks but won’t start 1. ECM power/ground circuits mal- • Open circuit in the power input and/or ground
(No fuel pump operation function (page 6-43). wire of the ECM
sound when turning the igni- 2. Inspect the fuel supply system • Blown main fuse (15 A)
tion ON) (page 6-25).
Engine stalls, hard to start, 1. Check the idle speed (page 4-12). • Restricted fuel feed hose
rough idling 2. Check the IACV (page 6-38). • Clogged fuel filler cap breather hole
3. Inspect the fuel supply system • Contaminated/deteriorated fuel
(page 6-25). • Intake air leak
4. Inspect the battery charging sys- • Restricted fuel tank cap breather
tem (page 17-12). • Faulty ignition system
Backfiring or misfiring during Check the ignition system (page 18-
acceleration 5).
Poor performance (driveabili- Inspect the fuel supply system (page • Pinched or clogged fuel feed hose
ty) and poor fuel economy 6-25). • Faulty pressure regulator (fuel pump)
• Faulty injector
Tonngokhong BikerVietNam
Idle speed is below specifica-
tions (No MIL blinking)
Idle speed is above specifica-
1.
2.
1.
Check the idle speed (page 4-12).
Check the IACV (page 6-38).
Check the idle speed (page 4-12).
•
•
•
•
Faulty ignition system
Faulty fuel supply system
Faulty ignition system
Faulty ignition system
tions (No MIL blinking) 2. Check the throttle operation and • Intake air leak
freeplay (page 4-5). • Engine top-end problem
3. Check the IACV (page 6-38). • Air cleaner condition
MIL stays ON or MIL never Inspect the MIL circuit (page 6-24).
comes ON at all (Engine oper-
ates normally)
MIL stays ON Inspect the DLC circuit.
(Engine operates normally
and No MIL code set)
6-5
FUEL SYSTEM (Programmed Fuel Injection)
PGM-FI SYSTEM LOCATION
SENSOR UNIT (MAP/ INJECTOR IGNITION
IAT/TP SENSORS) SWITCH
DLC
REGULATOR/
RECTIFIER
ECT SENSOR
Tonngokhong BikerVietNam
CKP SENSOR
O2 SENSOR
FUEL PUMP
ECM
MIL
6-6
FUEL SYSTEM (Programmed Fuel Injection)
PGM-FI SYSTEM DIAGRAM
MAIN FUSE LIGHTING SUB FUSE
15A CUT RELAY 10A
R R/W R/W R/Y Bl/Br
R/W Bl
IGNITION
SWITCH
BATTERY
W REGULATOR/ R/Bl Bl
RECTIFIER
G
Bu/Y 12 PCP Bl
W/Y 23 PCM
CKP
SENSOR PRC 7 W/Bl
ALTERNATOR
IGP 1 Bl
SENSOR UNIT
TP
Tonngokhong BikerVietNam
SENSOR
(9)
IAT
W/Bu 14 TA
IGPLS 11 G/R Bl
Bl (12)
INJECTOR
SENSOR
IGNITION
P/W 24 TW COIL
(7)
ECT
SENSOR G/O G/O 4 SG ECM SPARK Bl
PLUG
(21) Bl Bl
O2 Bl/O 3 O2
SENSOR MIL
FRONT REAR
FI WARN 22 Bu/Y Bl BRAKE BRAKE
LIGHT LIGHT
SWITCH SWITCH
From starter relay Y/G 33 S/RELAY TW WARNING
INIDICATOR G/Y G/Y
To sidestand switch G/W 25 SSTAND
TW WARN 18 Lg/R Bl
DLC
SCS Bl Bl
CONNECTOR G/Y
O/W 30 K-LINE IACV1A 21 Lg/R
G 9 PG1
STSW 29 Y/G
1 11
Bl : Black Br : Brown
12 22 Y : Yellow O : Orange
( ) : Number of MIL blinks Bu : Blue Lg : Light green
23 33
G : Green P : Pink
: The engine does not start if there is mulfunction ECM 33P CONNECTOR R : Red Gr Gray
ECM side of the male terminals W : White
6-7
FUEL SYSTEM (Programmed Fuel Injection)
CONNECTOR LOCATION
NOTE 1: Remove the front top cover (page 3-4).
NOTE 2: Remove the right main pipe side cover (page 3-16).
Tonngokhong BikerVietNam
NOTE 3:
Remove the following:
– Maintenance lid (page 3-9)
– Radiator cover (page 3-12)
6-8
FUEL SYSTEM (Programmed Fuel Injection)
NOTE 4: Remove the luggage box (page 3-11).
Tonngokhong BikerVietNam
6-9
FUEL SYSTEM (Programmed Fuel Injection)
PGM-FI TROUBLESHOOTING INFORMATION
SYSTEM DESCRIPTION
SELF-DIAGNOSIS SYSTEM
The PGM-FI system is equipped with the self-diagnostic system. When any
abnormality occurs in the system, the ECM turns on the MIL (Malfunction
Indicator Lamp) and stores a failure code in its erasable memory.
CURRENT FAILURE CODE/STORED FAILURE CODE
The failure code is indicated in two ways according to the failure status.
• In case the ECM detects the problem at present, the MIL will start
blinking as its failure code. It is possible to read out the MIL blink pattern
as the current failure code.
• In case the ECM does not detect any problem at present but has a
problem stored in its memory, the MIL will not blink. If it is necessary to
retrieve the past problem, read out the stored failure code by following
the failure code readout procedure (page 6-11). MIL (Malfunction
MIL BLINK PATTERN Indicator Lamp)
• Failure code can be read by the MIL blink pattern.
• In case the ECM does not detect any problem at present, when the ignition switch is turned "ON", the MIL will stay on for a few
seconds, then go off.
• In case the ECM detects the problem at present, when the ignition switch is turned "ON", the MIL will stay on for a few seconds
and go off, then the MIL blinks as its failure code.
• The MIL has two types of blinks, a long blink and short blink. The long blinking lasts for 1.3 seconds, the short blinking lasts for
0.3 seconds. One long blink is the equivalent to ten short blinks. For example, when two long blinks are followed by five short
blinks, the MIL is 25 (two long blinks = 20 blinks, plus five short blinks).
• The MIL will start blinking when the ignition switch is "ON" or engine revs are below 2,200 min-1 (rpm). In any other conditions,
the MIL will illuminate and stay on.
Tonngokhong BikerVietNam
ON
IGNITION
SWITCH
OFF
ON
MIL
(No problem at present)
OFF
0.5 sec.
0.3 sec. 0.4 sec. 3.0 sec. 1.3 sec. 0.3 sec.
MIL
ON
(Detect the problem at
present)
OFF
6-10
FUEL SYSTEM (Programmed Fuel Injection)
FAILURE CODE READOUT
CURRENT FAILURE CODE
Support the scooter with its centerstand and check the MIL.
• When the ignition switch is turned "ON", the MIL will stay on for a few
seconds, then go off.
If the MIL stays on or blinks, note how many times the MIL blinks and
determine the cause of the problem.
If the MIL does not blink, the system is normal at present. If you wish to read
the stored failure code, perform the following:
MIL (Malfunction
Indicator Lamp)
If the ECM has no stored failure code, the MIL will illuminate, when you turn the ignition switch "ON".
SCS CONNECTOR
If the ECM has stored failure code, the MIL will illuminate 0.3 seconds and go off, then start blinking as its failure code when you
turn the ignition switch "ON".
Note how many times the MIL blinks, and determine the cause of the problem.
ON
IGNITION
and SWITCH OFF
ON
MIL
(No stored failure code)
OFF
ON
MIL
(Stored failure code)
OFF
6-11
FUEL SYSTEM (Programmed Fuel Injection)
ERASING STORED FAILURE CODE
• The stored failure code can not be erased by simply disconnecting the battery negative cable.
1. Turn the ignition switch "OFF".
CONNECTOR
2. Remove the front top cover (page 3-4). COVER
3. Remove the DLC from the connector cover and short the DLC terminals
using the special tool.
TOOL:
SCS connector 070PZ-ZY30100
CONNECTION: Blue – Green
4. Turn the ignition switch "ON".
2 – 3 sec.
0.3 sec.
within 5 sec.
MIL
STORED
ON FAILURE CODE
IS ERASED.
OFF
IGNITION
FAILURE PATTERN RESET RECEIVING SUCCESSFUL
SWITCH
PATTERN PATTERN
ON
OFF
OFF
6-12
FUEL SYSTEM (Programmed Fuel Injection)
GENERAL TROUBLESHOOTING
INTERMITTENT FAILURE
The term "intermittent failure" means a system may have had a failure, but it checks OK now. If the MIL does not come on, check
for poor contact or loose pins at all connectors related to the circuit. If the MIL was on, but then went out, the original problem may
be intermittent.
OPENS AND SHORTS
"Opens" and "Shorts" are common electrical terms. An open is a break in a wire or at a connection. A short is an accidental
connection of a wire to ground or to another wire. In simple electronics, this usually means something will not work at all. With
ECMs this can sometimes mean something works, but not the way it’s supposed to.
If the Engine has problem, and MIL comes on
Refer to FAILURE CODE READOUT (page 6-11).
If the Engine has problem, but MIL does not stay on or blink
Do the SYMPTOM TROUBLESHOOTING (page 6-5).
CIRCUIT INSPECTION
INSPECTION AT ECM AND SENSOR UNIT CONNECTOR
• Always clean around and keep any foreign material away from the
connector before disconnecting it.
• A faulty PGM-FI system is often related to poorly connected or corroded
connections. Check those connections before proceeding.
• When testing at connector (wire harness side) terminal, always use the
test prove. Insert the test prove into the connector terminal, then connect
the digital multimeter probe to the test probe.
TOOL:
Test probe 07ZAJ-RDJA110
6-13
FUEL SYSTEM (Programmed Fuel Injection)
MIL CODE INDEX
Refer
MIL Function Failure Symptom/Fail-safe function
to
MAP sensor malfunction • Engine operates normally
1 • Loose or poor contact of the MAP sensor connector • Pre-program value: 481 mmHg/641 hPa 6-15
• MAP sensor or its circuit malfunction
ECT sensor malfunction • Hard start at a low temperature
7 • Loose or poor contact of the ECT sensor connector • Pre-program value: 83°C/181°F 6-16
• ECT sensor or its circuit malfunction
TP sensor malfunction • Poor engine acceleration
8 • Loose or poor contact of the TP sensor connector • Pre-program value: 0° 6-17
• TP sensor or its circuit malfunction
IAT sensor malfunction • Engine operates normally
9 • Loose or poor contact of the IAT sensor connector • Pre-program value: 35°C/95°F 6-19
• IAT sensor or its circuit malfunction
Injector malfunction • Engine does not start
12 • Loose or poor contact of the injector connector • Injector, fuel pump and ignition coil shut 6-20
• Injector or its circuit malfunction down
O2 sensor malfunction • Engine operates normally
21 • Loose or poor contact of the O2 sensor connector 6-21
• O2 sensor or its circuit malfunction
IACV malfunction • Engine stalls, hard to start, rough idling
29 • Loose or poor contact of the IACV connector 6-22
• IACV or its circuit malfunction
Tonngokhong BikerVietNam
6-14
FUEL SYSTEM (Programmed Fuel Injection)
MIL TROUBLESHOOTING
MIL 1 BLINK (MAP SENSOR)
• Before starting the inspection, check for loose or
poor contact on the sensor unit 5P (Black) connector
and ECM 33P (Black) connector and recheck the
MIL blinking.
1. Sensor Unit Power Input Voltage Inspection
Turn the ignition switch "OFF".
SENSOR UNIT 5P (Black) CONNECTOR
Disconnect the sensor unit 5P (Black) connector.
(Wire side/female terminals)
Turn the ignition switch "ON".
Measure the voltage at the wire side.
CONNECTION:
Yellow/orange (+) – Green/orange (–)
STANDARD: 4.75 – 5.25 V
Yellow/orange Green/orange
Is the voltage within 4.75 – 5.25 V?
YES – GO TO STEP 3.
NO – GO TO STEP 2.
Tonngokhong BikerVietNam
TOOL:
Test probe
CONNECTION
07ZAJ-RDJA110
STANDARD
Yellow/orange Green/
orange
Yellow/orange – Yellow/orange
Continuity
Green/orange – Green/orange
Are the above inspections normal?
ECM 33P (Black) CONNECTOR
YES – Replace the ECM with a known good one, (Wire side/female terminals)
and recheck.
NO – • Open circuit in Yellow/orange wire
• Open circuit in Green/orange wire
3. MAP Sensor Input Voltage Inspection
Turn the ignition switch "ON".
Measure the voltage at the sensor unit 5P (Black) SENSOR UNIT 5P (Black) CONNECTOR
connector of the wire side. (Wire side/female terminals)
CONNECTION:
Yellow/red (+) – Ground (–)
STANDARD: 4.75 – 5.25 V
Is the voltage within 4.75 – 5.25 V?
YES – Replace the sensor unit with a new one
and recheck (faulty MAP sensor) Yellow/red
NO – GO TO STEP 4.
6-15
FUEL SYSTEM (Programmed Fuel Injection)
4. MAP Sensor Output Line Circuit Inspection
Turn the ignition switch "OFF".
Disconnect the ECM 33P (Black) connector. SENSOR UNIT 5P (Black) CONNECTOR
(Wire side/female terminal)
Check the continuity between the ECM 33P
connector and sensor unit 5P (Black) connector of
the wire side.
Check for continuity between sensor unit 5P
Yellow/red
connector and ground.
TOOL:
Test probe 07ZAJ-RDJA110
CONNECTION STANDARD
Yellow/red – Yellow/red Continuity
Yellow/red – Ground No Continuity
ECM 33P (Black) CONNECTOR
Are the above inspections normal? (Wire side/female terminals)
YES – Replace the ECM with a known good one,
and recheck
NO – • Open circuit in Yellow/red wire
• Short circuit in Yellow/red wire
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ECT SENSOR 2P (Black) CONNECTOR
Disconnect the ECT sensor 2P (Black) connector.
(Wire side/female terminal)
Turn the ignition switch "ON".
Measure the voltage at the ECT sensor 2P
connector of the wire side and ground.
CONNECTION: Pink/white (+) –Green/orange (–)
STANDARD: 4.75 – 5.25 V
Green/orange Pink/white
Is the voltage within 4.75 – 5.25 V?
YES – Inspect the ECT sensor (page 6-46), and if
the sensor is normal, replace the ECM with
a known good one, and recheck.
NO – GO TO STEP 2.
6-16
FUEL SYSTEM (Programmed Fuel Injection)
2. ECT Sensor Circuit Inspection
Turn the ignition switch "OFF". ECT SENSOR 2P (Black) CONNECTOR
Disconnect the ECM 33P (Black) connector.
(Wire side/female terminals)
Check the continuities between the ECM 33P
connector and ECT sensor 2P (Black) connector of
the wire side.
Pink/white
Check for continuity between ECT sensor 2P
connector and ground.
TOOL:
Test probe 07ZAJ-RDJA110
CONNECTION STANDARD
Pink/white – Pink/white Green/
Continuity
Green/orange – Green/orange orange ECM 33P (Black) CONNECTOR
Pink/white – Ground No Continuity (Wire side/female terminals)
Are the above inspections normal?
YES – Replace the ECM with a known good one,
and recheck.
NO – • Open circuit in Pink/white wire
• Open circuit in Green/orange wire
• Short circuit in Pink/white wire
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1. Sensor Unit Power Input Voltage Inspection
Turn the ignition switch "OFF".
SENSOR UNIT 5P (Black) CONNECTOR
Disconnect the sensor unit 5P (Black) connector.
(Wire side/female terminals)
Turn the ignition switch "ON".
Measure the voltage at the wire side.
CONNECTION:
Yellow/orange (+) – Green/orange (–)
STANDARD: 4.75 – 5.25 V
Yellow/orange Green/orange
If the voltage within 4.75 – 5.25 V?
YES – GO TO STEP 3.
NO – GO TO STEP 2.
6-17
FUEL SYSTEM (Programmed Fuel Injection)
3. TP Sensor Inspection
Turn the ignition switch "OFF".
Continuity Resistance inspection (with
Check for continuity between the following terminals inspection: throttle operation):
of the sensor side.
CONNECTION: C–D C D B C
STANDARD: Continuity
Check that the resistance between the following
terminals changes in accordance with the throttle
operation.
CONNECTION: B–C
Are the above inspections normal?
YES – GO TO STEP 4. SENSOR UNIT 5P CONNECTOR (Sensor
side/male terminal)
NO – Replace the sensor unit with a new one,
and recheck. (Faulty TP sensor)
4. TP Sensor Signal Line Circuit Inspection
Disconnect the ECM 33P (Black) connector.
ECM 33P (Black) CONNECTOR
Check for continuity between the sensor unit 5P
(Wire side/female terminals)
(Black) connector of the wire side and ECM 33P
connector of the wire harness side.
Check for continuity between the sensor unit 5P
(Black) connector and ground.
TOOL:
Test probe 07ZAJ-RDJA110
White/red
CONNECTION STANDARD
White/red – White/red Continuity
White/red – Ground No Continuity
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Are the above inspections normal?
YES – Replace the ECM with a known good one,
and recheck.
SENSOR UNIT 5P (Black) CONNECTOR
(Wire side/female terminals)
6-18
FUEL SYSTEM (Programmed Fuel Injection)
MIL 9 BLINKS (IAT SENSOR)
• Before starting the inspection, check for loose or
poor contact on the sensor unit 5P (Black) connector
and ECM 33P (Black) connector and recheck the
MIL blinking.
1. IAT Sensor Input Voltage Inspection
Turn the ignition switch "OFF".
SENSOR UNIT 5P (Black) CONNECTOR
Disconnect the sensor unit 5P (Black) connector.
(Wire side/female terminals)
Turn the ignition switch "ON".
Measure the voltage at the wire side.
CONNECTION: White/blue (+) – Green/orange (–)
STANDARD: 4.75 – 5.25 V
White/blue Green/orange
If the voltage within 4.75 – 5.25 V?
YES – GO TO STEP 3.
NO – GO TO STEP 2.
Tonngokhong BikerVietNam
TOOL:
Test probe 07ZAJ-RDJA110
CONNECTION STANDARD
White/blue – White/blue
Continuity
Green/orange – Green/orange ECM 33P (Black) CONNECTOR
White/blue – Ground No Continuity (Wire side/female terminals)
6-19
FUEL SYSTEM (Programmed Fuel Injection)
MIL 12 BLINKS (INJECTOR)
• Before starting the inspection, check for loose or
poor contact on the injector 2P (Black) connector
and ECM 33P (Black) connector and recheck the
MIL blinking.
1. Injector Input Voltage Inspection
Turn the ignition switch "OFF".
Disconnect the injector 2P (Black) connector. INJECTOR 2P (Black) CONNECTOR
(Wire side/female terminal)
Turn the ignition switch "ON".
Measure the voltage between the injector 2P
connector of the wire side and ground.
CONNECTION: Black (+) – Ground (–) Black
STANDARD: Above (Battery voltage – 1.1) V
Does the standard voltage exist?
YES – GO TO STEP 2.
NO – Open or short circuit in Black wire
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NO – Faulty injector
CONNECTION STANDARD
Pink/blue – Pink/blue Continuity
Pink/blue – Ground No Continuity ECM 33P (Black) CONNECTOR
Are the above inspections normal? (Wire side/female terminals)
6-20
FUEL SYSTEM (Programmed Fuel Injection)
MIL 21 BLINKS (O2 SENSOR)
• Before starting the inspection, check for loose or
poor contact on the O2 sensor 1P (Black) connector
and ECM 33P (Black) connector and recheck the
MIL blinking.
1. O2 Sensor Short Circuit Inspection
Turn the ignition switch "OFF".
O2 SENSOR CAP
Disconnect the ECM 33P (Black) connector and O2
sensor cap.
Check the continuity between the O2 sensor cap
terminal and ground.
CONNECTION: O2 sensor cap terminal – Ground
TERMINAL
Is there continuity?
YES – • Short circuit in Black/orange wire.
• Short circuit in O2 sensor Black/orange
wire
NO – GO TO STEP 2.
Tonngokhong BikerVietNam
Is there continuity?
YES – GO TO STEP 3.
NO – • Open circuit in Black/orange wire.
• Open circuit in O2 sensor Black/orange
Black/orange
wire
3. O2 Sensor Inspection
Replace the O2 sensor with a known good one
(page 6-47).
Erase the self diagnosis memory data from the ECM
(page 6-12).
Start the engine and warm it up.
Test-ride the scooter and recheck the MIL blinking.
Does the MIL blink 21 times?
YES – Replace the ECM with a known good one,
and recheck.
NO – Faulty original O2 sensor
6-21
FUEL SYSTEM (Programmed Fuel Injection)
MIL 29 BLINKS (IACV)
• Before starting the inspection, check for loose or
poor contact on the IACV 4P (Black) connector and
ECM 33P (Black) connector and recheck the MIL
blinking.
1. IACV Short Circuit Inspection
Turn the ignition switch "OFF".
IACV 4P (Black) CONNECTOR
Disconnect the IACV 4P (Black) connector. (Wire side/female terminals)
Check the connector for loose contacts or corroded
terminals. Light green/red Gray/red
Check for continuities between the IACV 4P
connector of the wire harness side and ground.
Brown/ Black/
Connection: Light green/red – Ground
red red
Brown/red – Ground
Gray/red – Ground
Black/red – Ground
STANDARD: No continuity
Are there continuities?
YES – • Short circuit in Light green/red or
Brown/red wire
• Short circuit in Gray/red or Black/red
wire
NO – GO TO STEP 2.
2. IACV Circuit Continuity Inspection
Disconnect the ECM 33P (Black) connector.
IACV 4P (Black) CONNECTOR
Check the continuity between the IACV 4P (Black)
connector terminals and ECM 33P connector (Wire side/female terminals)
Tonngokhong BikerVietNam
terminals of the wire harness side.
Connection: Light green/red – Light green/red
Brown/red – Brown/red
Gray/red – Gray/red
Light green/red
Black/red – Black/red
STANDARD: Continuity
Brown/red
TOOL:
Test probe 07ZAJ-RDJA110
Are there continuity?
YES – GO TO STEP 3.
NO – • Open circuit in Light green/red or
Brown/red wire
Black/red
• Open circuit in Gray/red or Black/red
wire
Gray/red
6-22
FUEL SYSTEM (Programmed Fuel Injection)
3. IACV Resistance Inspection
Measure the resistance at the IACV 4P connector
terminals. IACV 4P CONNECTOR
Connection: A – D (IACV side of male terminals)
B–C
STANDARD: 110 – 150 ǡ (20 °C/68 °F)
Tonngokhong BikerVietNam
6-23
FUEL SYSTEM (Programmed Fuel Injection)
MIL CIRCUIT INSPECTION
WHEN THE IGNITION SWITCH IS
TURNED ON, THE MIL DOES NOT
COME ON
Turn the ignition switch "OFF".
ECM 33P (Black)
Remove the right main pipe side cover (page 3-16). CONNECTOR
Disconnect the ECM 33P (Black) connector.
Ground the ECM 33P connector terminal of the wire
harness side connector with a jumper wire.
CONNECTION: No.22 (Blue/yellow) – Ground
No.22 (Blue/yellow)
TOOL:
Test probe 07ZAJ-RDJA110
Turn the ignition switch "ON", the MIL should come on.
• If the MIL comes on, replace the ECM with a known
good one, and recheck.
• If the MIL does not come on, check for open circuit
in the Blue/yellow wire between the speedometer
and ECM.
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ECM
Remove the right main pipe side cover (page 3-16).
Disconnect the ECM 33P (Black) connector.
Turn the ignition switch "ON", the MIL should turn off.
• If the MIL comes on, check for short circuit in the
Blue/yellow wire between the speedometer and
ECM.
• If the MIL turns off, check the following.
TOOL:
Test probe 07ZAJ-RDJA110
No.15
• If there is continuity, check for short circuit in the (Brown)
Brown wire between the DLC and ECM.
• If there is no continuity, replace the ECM with a
known good one, and recheck.
6-24
FUEL SYSTEM (Programmed Fuel Injection)
FUEL LINE INSPECTION
FUEL PRESSURE RELIEVING/QUICK
CONNECT FITTING REMOVAL
• Before disconnecting fuel feed hose, relieve
pressure from the system by following the
procedures below.
• This scooter uses resin for the part of materials in
the fuel feed hose. Do not bend or twist the fuel feed
hose.
1. Turn the ignition switch "OFF".
2. Remove the left main pipe side cover (page 3-16). 5P CONNECTOR
Disconnect the fuel pump 5P connector.
3. Turn the ignition switch "ON".
4. Start the engine and let it idle until the engine stalls.
5. Disconnect the battery negative (–) cable (page 17-
11).
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SHOP TOWEL
CLAMP
6-25
7. COOLING SYSTEM
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7-1
COOLING SYSTEM
SYSTEM FLOW PATTERN
COOLING SYSTEM
SIPHON HOSE
OVERFLOW HOSE
RADIATOR
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WHEN THE ENGINE IS HOT
THERMOSTAT WATER PUMP
RESERVETANK
WATER HOSE
SIPHON HOSE
OVERFLOW HOSE
RADIATOR
7-2
COOLING SYSTEM
COMPONENT LOCATION
10 N·m
(1.0 kgf·m, 7 lbf·ft)
Tonngokhong BikerVietNam
59 N·m (6.0 kgf·m, 44 lbf·ft)
7-3
COOLING SYSTEM
SERVICE INFORMATION
GENERAL
Removing the radiator cap while the engine is hot can allow the coolant to spray out, seriously scalding you.
Always let the engine and radiator cool down before removing the radiator cap.
• Use only Honda PRE-MIX COOLANT containing corrosion inhibitors, specifically recommended for aluminum engines when
adding or replacing the coolant.
Genuine Honda PRE-MIX COOLANT is excellent at preventing corrosion and overheating. The effects last for up to 2 years.
• The coolant should be inspected and replaced properly by following the maintenance schedule (page 4-4).
• Use any genuine Honda PRE-MIX COOLANT without diluting with water.
• DO NOT use non-ethylene glycol coolant, tap water, nor mineral water when adding or replacing the coolant.
Use of improper coolant may cause damage, such as corrosion in the engine, blockage of the cooling passage or the radiator
and premature wear of the water pump seal.
• Add coolant at the reserve tank. Do not remove the radiator cap except to refill or drain the system.
• All cooling system can be serviced with the engine in the frame.
• Avoid spilling coolant on painted surfaces.
• After servicing the system, check for leaks with a cooling system tester.
SPECIFICATIONS
ITEM SPECIFICATIONS
Coolant capacity Radiator and engine 0.49 liter (0.52 US qt, 0.43 lmp qt)
Reserve tank 0.24 liter (0.25 US qt, 0.21 lmp qt)
Radiator cap relief pressure 108 – 137 kPa (1.1 – 1.4 kgf/cm2, 16 – 20 psi)
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Thermostat Begin to open 74 – 78 °C (165 – 172 °F)
Fully open 100 °C (212 °F)
Valve lift 8 mm (0.3 in) minimum
Recommended coolant Honda PRE-MIX COOLANT
TORQUE VALUES
Radiator drain bolt 1 N·m (0.1 kgf·m, 0.7 lbf·ft)
Cooling fan mounting bolt 8 N·m (0.8 kgf·m, 5.9 lbf·ft)
Water pump impeller 10 N·m (1.0 kgf·m, 7 lbf·ft)
Thermostat mounting bolt 9 N·m (0.9 kgf·m, 6.6 lbf·ft)
Flywheel nut 59 N·m (6.0 kgf·m, 44 lbf·ft)
Stator mounting socket bolt 10 N·m (1.0 kgf·m, 7 lbf·ft)
7-4
COOLING SYSTEM
TOOLS
Driver Attachment, 24 x 26 mm Attachment, 28 x 30 mm
07749-0010000 07746-0010700 07946-1870100
Tonngokhong BikerVietNam
Remover weight
07741-0010201
7-5
COOLING SYSTEM
TROUBLESHOOTING
Engine temperature too high
• Thermostat stuck closed
• Faulty radiator cap
• Insufficient coolant
• Passage blocked in radiator, hoses or water jacket
• Air in system
• Faulty water pump
Engine temperature too low
• Thermostat stuck open
Coolant leak
• Deteriorated O-rings
• Faulty radiator cap
• Damaged or deteriorated cylinder head gasket
• Loose hose connection or clamp
• Damaged or deteriorated hoses
Tonngokhong BikerVietNam
7-6
COOLING SYSTEM
COOLANT SYSTEM TESTING
RADIATOR CAP/SYSTEM PRESSURE
INSPECTION
Remove the radiator cover (page 3-12).
RADIATOR CAP CLAMP
Pinch the siphon hose using a hose clamp.
Remove the radiator cap.
SIPHON HOSE
Wet the sealing surfaces of the cap, then install the cap
onto the tester. RADIATOR CAP TESTER
Tonngokhong BikerVietNam
Pressurize the radiator, engine and hoses using the
RADIATOR CAP
7-7
COOLING SYSTEM
COOLANT REPLACEMENT
REPLACEMENT/AIR BLEEDING
Remove the following:
RADIATOR CAP CLAMP
– Maintenance lid (page 3-9)
– Radiator cover (page 3-12)
Pinch the siphon hose using a hose clamp.
Remove the radiator cap.
SIPHON HOSE
Remove the radiator drain bolt, seal ring and drain the
SEAL RING
coolant from the radiator.
Remove the hose clamp from the siphon hose and
drain the coolant from the reserve tank.
Tonngokhong BikerVietNam
Remove the drain bolt with sealing washer from the
water pump cover and drain the coolant from the
DRAIN BOLT
SEALING WASHER
engine.
DRAIN BOLT
7-8
COOLING SYSTEM
Tonngokhong BikerVietNam
coolant level,
support the scooter Install the reserve tank cap.
with its centerstand
on a flat, level Install the following:
surface. – Radiator cover (page 3-12)
– Maintenance lid (page 3-9)
7-9
COOLING SYSTEM
RADIATOR
REMOVAL/INSTALLATION
Drain the coolant (page 7-8).
SIPHON HOSE
Disconnect the siphon hose and water hose from the
radiator.
WATER HOSE
Tonngokhong BikerVietNam
Remove the four radiator mounting bolts/washers,
radiator top cover and radiator.
RADIATOR TOP COVER BOLTS/
WASHERS
Installation is in the reverse order of removal.
Make sure that the Fill and bleed the cooling system (page 7-9).
hose clips are After installation, make sure the coolant does not leak.
installed in the
correct direction
(page 1-14).
RADIATOR
COOLING FAN
REMOVAL/INSTALLATION
Remove the radiator (page 7-10).
BOLTS
Remove the three bolts and cooling fan.
Installation is in the reverse order of removal.
TORQUE: COOLING FAN MOUNTING BOLT
8 N·m (0.8 kgf·m, 5.9 lbf·ft)
COOLING FAN
7-10
COOLING SYSTEM
RADIATOR RESERVE TANK
REMOVAL/INSTALLATION
Remove the right main pipe side cover (page 3-16).
HOSE CLAMP
Pinch the siphon hose using a hose clamp.
Disconnect the siphon hose from the radiator.
Remove the hose clamp and drain the coolant into the
approved pan.
SIPHON HOSE
THERMOSTAT
REMOVAL
Drain the coolant (page 7-8).
BOLTS
Disconnect the water hoses from the thermostat.
Remove the two bolts and thermostat.
Remove the O-ring. O-RING WATER
HOSES
THERMOSTAT
7-11
COOLING SYSTEM
INSTALLATION
Install a new O-ring into the groove of the thermostat.
THERMOSTAT
Install the thermostat to the water pump cover.
O-RING
Make sure that the Connect the water hoses to the thermostat.
hoses and clips are WATER
Fill and bleed the cooling system (page 7-9).
installed in the HOSES
correct direction After installation, make sure the coolant does not leak.
(page 1-14).
THERMOSTAT
Tonngokhong BikerVietNam
INSPECTION
Visually inspect the thermostat for damage.
Replace the thermostat if it stays open at room
temperature.
THERMOMETER
THERMOSTAT
7-12
COOLING SYSTEM
WATER PUMP
REMOVAL
• Water pump can be serviced with the engine
installed on the frame.
Drain the coolant (page 7-8).
WIRE GUIDE
Drain the engine oil (page 4-11).
Remove the following:
– Thermostat (page 7-11)
– Flywheel/alternator stator (page 17-7)
– Woodruff key (page 17-9)
Remove the bolts, wire guide and water pump cover.
Be careful not to Unhook the clip from the water pipe and slide the water CLIP
damage the water pipe to the stator base side.
pipe.
WATER PIPE
7-13
COOLING SYSTEM
Remove the following:
– Four bolts
– Water pump/stator base
– Oil pump driven gear
– Water pump drive gear/oil pump shaft
– Drive chain
– Water pump driven gear
– Two dowel pins
DOWEL PINS
DRIVE CHAIN
WATER PUMP
DRIVEN GEAR
WATER PUMP/
STATOR BASE
OIL PUMP
DRIVEN GEAR
7-14
COOLING SYSTEM
Remove the O-ring from the water pump/stator base.
O-RING
INSTALLATION
Apply engine oil to the water pump shaft.
Install a new O-ring into the water pump/stator base
groove.
O-RING
Tonngokhong BikerVietNam
Install the new O-rings into the grooves of the water
pipe.
Install the water pipe into the water pump/stator base.
O-RING WATER PIPE
DOWEL PINS
7-15
COOLING SYSTEM
Apply engine oil to the oil pump driven gear and oil
OIL PUMP DRIVEN GEAR Align (CUT-OUT)
pump shaft.
Set the oil pump driven gear to the drive gear of the
crankshaft as shown.
Install the water pump drive gear/oil pump shaft by
aligning the oil pump shaft cut-out with the oil pump cut- OIL PUMP
out, and the pin groove of the oil pump driven gear with SHAFT
the pin of the oil pump shaft.
Align (PIN/GROOVE)
DRIVE CHAIN
Tonngokhong BikerVietNam
Install the water pump/stator base to the right
crankcase by aligning the water pump drive gear shaft
with the journal on the stator base.
STATOR BASE
Align
Align the pin groove of the water pump driven gear with
the pin of the water pump shaft by rotating the water
pump impeller.
IMPELLER
7-16
COOLING SYSTEM
Install the woodruff key (page 17-9).
FLYWHEEL
Temporarily install the flywheel by aligning the key way
in the flywheel with the key on the crankshaft.
Make sure that the water pump impeller rotates by
rotating crankshaft.
After inspection, remove the flywheel.
IMPELLER
Slide the water pipe into the cylinder. WATER PIPE CLIP
Hook the clip to the water pipe groove.
Tonngokhong BikerVietNam
O-RING
7-17
COOLING SYSTEM
Install the water pump cover and the wire guide.
Install the drain bolt with a new sealing washer. WATER PUMP WIRE GUIDE
Install and tighten the bolts. COVER
BOLT/SEALING
BOLTS WASHER
INSPECTION
OIL PUMP DRIVEN GEAR
Check the oil pump driven gear teeth for wear or
damage. OIL PUMP DRIVEN GEAR
Tonngokhong BikerVietNam
WATER PUMP DRIVE GEAR
Check the water pump drive gear teeth for wear or
damage.
WATER PUMP
Check the water pump drive gear shaft and shaft hole DRIVE GEAR
of the stator base for wear or damage.
7-18
COOLING SYSTEM
WATER PUMP SHAFT
Check the water pump shaft and shaft hole of the right
WATER PUMP SHAFT
crankcase for wear or damage.
SHAFT HOLE
WATER PUMP
SHAFT BEARING
Tonngokhong BikerVietNam
MECHANICAL SEAL INSPECTION
Check the bleed hole of the water pump for signs of
coolant leakage.
If water leaks through the bleed hole, replace the
mechanical seal (page 7-20).
If oil leaks through the bleed hole, replace the oil seal
(page 7-20).
Make sure that there are no continuous coolant leakage
from the bleed hole while operating the engine.
BLEED HOLE
7-19
COOLING SYSTEM
MECHANICAL SEAL REPLACEMENT
Remove the following:
FLYWHEEL IMPELLER
– Cooling fan (page 7-10)
– Water pump cover (page 7-13)
Hold the flywheel with the special tool and loosen the
water pump impeller.
TOOL:
Universal holder 07725-0030000
Remove the water pump/stator base (page 7-13).
UNIVERSAL
HOLDER
Remove the water pump impeller.
IMPELLER
Tonngokhong BikerVietNam
Be sure to use the
hydraulic press.
Do not use the
hammer.
Remove the water pump shaft from the water pump/
stator base using a hydraulic press.
7-20
COOLING SYSTEM
Remove the shaft from the bearing using a hydraulic
press. BEARING
– If the bearing remains in the water pump/stator
base, remove the bearing using the special tools.
TOOLS:
Bearing remover head, 12mm 07936-1660110
Bearing remover shaft, 12mm 07936-1660120
Remover weight 07741-0010201
REMOVER
WEIGHT
REMOVER SHAFT
Tonngokhong BikerVietNam
MECHANICAL SEAL
7-21
COOLING SYSTEM
BEARING (6001)
MECHANICAL SEAL
IMPELLER
OIL SEAL
Tonngokhong BikerVietNam
The marked side of
Apply engine oil to a new water pump oil seal lips.
Drive a new water pump oil seal until it is flush with the
DRIVER
OIL SEAL
TOOLS:
Driver 07749-0010000
Mechanical seal driver 07945-4150400 ATTACHMENT
attachment
MECHANICAL SEAL
7-22
COOLING SYSTEM
Support the inner race of new bearing properly.
Drive the water pump shaft into the new bearing until BEARING
the distance between the bearing surface and the
extended line from the flange of the shaft is
25.9 – 26.1 mm (1.02 – 1.03 in) as shown, using a
hydraulic press.
WATER PUMP
SHAFT
BEARING
25.9 – 26.1 mm
(1.02 – 1.03 in)
WATER PUMP
SHAFT
Tonngokhong BikerVietNam
Drive the water pump shaft/bearing squarely until it is
fully seated on the water pump/stator base using a
hydraulic press.
INNER
DRIVER
TOOL:
Inner driver, 22 mm 07746-0020100
WATER
PUMP
SHAFT/
BEARING
7-23
COOLING SYSTEM
Install the following:
FLYWHEEL IMPELLER
– Water pump/stator base (page 7-15)
– Woodruff key (page 17-9)
– Flywheel/alternator stator (page 17-9)
Hold the flywheel with the special tool and tighten the
water pump impeller to the specified torque.
TOOL:
Universal holder 07725-0030000
Tonngokhong BikerVietNam
Apply engine oil to a new crankshaft oil seal lips.
DRIVER
The marked side of Drive a new crankshaft oil seal until it is flush with the
the oil seal is facing stator base.
the flywheel.
TOOLS:
Driver 07749-0010000 ATTACHMENT
Attachment, 28 x 30 mm 07946-1870100
Install the water pump/stator base (page 7-15).
OIL SEAL
7-24
8. ENGINE REMOVAL/INSTALLATION
Tonngokhong BikerVietNam
8-1
ENGINE REMOVAL/INSTALLATION
COMPONENT LOCATION
ENGINE REMOVAL/INSTALLATION
Tonngokhong BikerVietNam
8-2
ENGINE REMOVAL/INSTALLATION
SERVICE INFORMATION
GENERAL
• Support the frame using a hoist to ease engine mounting bolt removal.
• When removing/installing the engine, tape the frame around the engine beforehand for frame protection.
• The following components require engine removal for service.
– Crankcase/crankshaft
• The following components can be serviced with the engine installed in the frame.
– Drive pulley/driven pulley/clutch
– Final reduction
– Alternator/starter clutch
– Cylinder head/valves
– Cylinder/piston
– Water pump
– Throttle body
– Oil pump
SPECIFICATIONS
ITEM SPECIFICATIONS
Engine dry weight 27.3 kg (60.2 lbs)
Coolant capacity Radiator and engine 0.49 liter (0.52 US qt, 0.43 lmp qt)
Engine oil capacity After draining 0.7 liter (0.7 US qt, 0.6 lmp qt)
After disassembly 0.8 liter (0.8 US qt, 0.7 lmp qt)
TORQUE VALUE
Engine hanger link pivot nut (frame side) 69 N·m (7.0 kgf·m, 51 lbf·ft)
Tonngokhong BikerVietNam
8-3
ENGINE REMOVAL/INSTALLATION
ENGINE REMOVAL
Place the scooter on its centerstand.
BRAKE CABLE JOINT PIN
Remove the following:
– Body cover (page 3-14)
– Main pipe side covers (page 3-16)
– Under cover (page 3-17)
– Injector (page 6-44)
Remove the rear brake adjusting nut and joint pin from
the rear brake cable.
Pull out the brake cable from the cable holder.
CABLE CLAMP
Tonngokhong BikerVietNam
Loosen the band screw and disconnect the air duct
from the left crankcase cover. BAND SCREW
AIR DUCT
Remove the fuel hose clamp bolt and fuel hose clamp
FUEL HOSE CLAMP BOLT
from the cylinder head cover.
• This scooter uses resin for the part of materials in
the fuel feed hose. Do not bend or twist the fuel feed
hose.
8-4
ENGINE REMOVAL/INSTALLATION
Loosen the throttle cable lock nut and adjusting nut and
ADJUSTING CABLE GUIDE CLAMP
disconnect it from the throttle drum.
Release the throttle cable from the cable guide and NUT
clamp.
GROUND CABLE
Disconnect the following:
STARTER MOTOR ALTERNATOR 3P
Tonngokhong BikerVietNam
– Alternator/CKP sensor 3P connector
– Starter motor 2P connector
Release the following wires from the wire guide:
2P CONNECTOR CONNECTOR
WIRE GUIDE
8-5
ENGINE REMOVAL/INSTALLATION
Disconnect the spark plug cap from the spark plug.
Release the spark plug wire boss from the radiator SPARK PLUG CAP
cover.
WIRE BOSS
Pinch the siphon hose using a hose clamp and HOSE CLAMP HOSE GUIDE
disconnect the siphon hose from the radiator.
Plug the joint of the radiator.
Release the siphon hose from the hose guide.
SIPHON HOSE
To avoid damage to Support the frame in upright position.
the rear shock
Tonngokhong BikerVietNam
absorber mounting
bolt threads, the
engine height must
be adjusted
Remove the rear shock absorber upper mounting bolts.
NUT/BOLT
8-6
ENGINE REMOVAL/INSTALLATION
ENGINE INSTALLATION
Support the frame in upright position.
Hold the front wheel. STOPPER RUBBER
Insert the stopper rubber into the hole of the frame.
HOLE
Install the engine hanger linkage bolt from the left side
of the scooter.
Temporarily tighten the engine hanger linkage nut.
NUT/BOLT
Tonngokhong BikerVietNam
To ease installation
of the rear shock
absorber mounting
bolts, slightly lift the
Install and tighten the rear shock absorber upper
mounting bolts. NUT
Retract the Tighten the engine hanger linkage nut to the specified
centerstand before torque.
tightening the
engine hanger
TORQUE: 69 N·m (7.0 kgf·m, 51 lbf·ft)
linkage nut.
Remove the plug and connect the siphon hose to the HOSE CLAMP
radiator. HOSE GUIDE
Remove the clamp from the siphon hose.
Secure the siphon hose to the hose guide.
SIPHON HOSE
8-7
ENGINE REMOVAL/INSTALLATION
Route the wire Connect the spark plug cap to the spark plug.
harness properly Secure the wire boss to the radiator cover. SPARK PLUG CAP
(page 1-14)
WIRE BOSS
Route the wire Secure the following wire bosses to the frame:
harness properly
– Engine sub harness wire boss
(page 1-14)
– Alternator/CKP sensor wire boss
– Starter motor wire boss
Secure the following wires to the wire band:
– Engine sub harness wire
– Alternator/CKP sensor wire
– Starter motor wire
Tonngokhong BikerVietNam
– Engine sub harness wire
– Alternator/CKP sensor wire
– Starter motor wire
Connect the following:
2P CONNECTOR CONNECTOR
WIRE GUIDE
GROUND CABLE
8-8
ENGINE REMOVAL/INSTALLATION
Connect the throttle cable to the throttle drum.
CABLE GUIDE CLAMP
Secure the throttle cable to the cable guide and clamp.
Be sure that the Set the fuel hose clamp in position, then install and FUEL HOSE CLAMP
stopper of the tighten the bolt. BOLT
clamp is in the
• This scooter uses resin for the part of materials in
correct position.
the fuel feed hose. Do not bend or twist the fuel feed
hose.
STOPPER
Tonngokhong BikerVietNam
Set the connecting hose band in the specified angle as
shown.
Tighten the band screw so that the clearance between
the band ends is 11 – 13 mm (0.4 – 0.5 in).
AIR DUCT
Clearance:
11 – 13 mm (0.4 – 0.5 in)
30 – 40°
OUT
side
8-9
ENGINE REMOVAL/INSTALLATION
Set the cable clamp in position, then install and tighten
CABLE CLAMP BOLT
the cable clamp bolt.
CABLE CLAMP
Secure the rear brake cable with the cable holder.
Install the joint pin and adjusting nut. BRAKE CABLE JOINT PIN
Adjust the following:
– Throttle grip free play (page 4-5)
– Rear brake lever free play (page 4-17)
Install the following:
– Injector (page 6-45)
– Under cover (page 3-17)
– Main pipe side covers (page 3-16)
– Body cover (page 3-14)
Tonngokhong BikerVietNam
8-10
8. ENGINE REMOVAL/INSTALLATION
Tonngokhong BikerVietNam
8-1
ENGINE REMOVAL/INSTALLATION
COMPONENT LOCATION
ENGINE REMOVAL/INSTALLATION
Tonngokhong BikerVietNam
8-2
ENGINE REMOVAL/INSTALLATION
SERVICE INFORMATION
GENERAL
• Support the frame using a hoist to ease engine mounting bolt removal.
• When removing/installing the engine, tape the frame around the engine beforehand for frame protection.
• The following components require engine removal for service.
– Crankcase/crankshaft
• The following components can be serviced with the engine installed in the frame.
– Drive pulley/driven pulley/clutch
– Final reduction
– Alternator/starter clutch
– Cylinder head/valves
– Cylinder/piston
– Water pump
– Throttle body
– Oil pump
SPECIFICATIONS
ITEM SPECIFICATIONS
Engine dry weight 27.3 kg (60.2 lbs)
Coolant capacity Radiator and engine 0.49 liter (0.52 US qt, 0.43 lmp qt)
Engine oil capacity After draining 0.7 liter (0.7 US qt, 0.6 lmp qt)
After disassembly 0.8 liter (0.8 US qt, 0.7 lmp qt)
TORQUE VALUE
Engine hanger link pivot nut (frame side) 69 N·m (7.0 kgf·m, 51 lbf·ft)
Tonngokhong BikerVietNam
8-3
ENGINE REMOVAL/INSTALLATION
ENGINE REMOVAL
Place the scooter on its centerstand.
BRAKE CABLE JOINT PIN
Remove the following:
– Body cover (page 3-14)
– Main pipe side covers (page 3-16)
– Under cover (page 3-17)
– Injector (page 6-44)
Remove the rear brake adjusting nut and joint pin from
the rear brake cable.
Pull out the brake cable from the cable holder.
CABLE CLAMP
Tonngokhong BikerVietNam
Loosen the band screw and disconnect the air duct
from the left crankcase cover. BAND SCREW
AIR DUCT
Remove the fuel hose clamp bolt and fuel hose clamp
FUEL HOSE CLAMP BOLT
from the cylinder head cover.
• This scooter uses resin for the part of materials in
the fuel feed hose. Do not bend or twist the fuel feed
hose.
8-4
ENGINE REMOVAL/INSTALLATION
Loosen the throttle cable lock nut and adjusting nut and
ADJUSTING CABLE GUIDE CLAMP
disconnect it from the throttle drum.
Release the throttle cable from the cable guide and NUT
clamp.
GROUND CABLE
Disconnect the following:
STARTER MOTOR ALTERNATOR 3P
Tonngokhong BikerVietNam
– Alternator/CKP sensor 3P connector
– Starter motor 2P connector
Release the following wires from the wire guide:
2P CONNECTOR CONNECTOR
WIRE GUIDE
8-5
ENGINE REMOVAL/INSTALLATION
Disconnect the spark plug cap from the spark plug.
Release the spark plug wire boss from the radiator SPARK PLUG CAP
cover.
WIRE BOSS
Pinch the siphon hose using a hose clamp and HOSE CLAMP HOSE GUIDE
disconnect the siphon hose from the radiator.
Plug the joint of the radiator.
Release the siphon hose from the hose guide.
SIPHON HOSE
To avoid damage to Support the frame in upright position.
the rear shock
Tonngokhong BikerVietNam
absorber mounting
bolt threads, the
engine height must
be adjusted
Remove the rear shock absorber upper mounting bolts.
NUT/BOLT
8-6
ENGINE REMOVAL/INSTALLATION
ENGINE INSTALLATION
Support the frame in upright position.
Hold the front wheel. STOPPER RUBBER
Insert the stopper rubber into the hole of the frame.
HOLE
Install the engine hanger linkage bolt from the left side
of the scooter.
Temporarily tighten the engine hanger linkage nut.
NUT/BOLT
Tonngokhong BikerVietNam
To ease installation
of the rear shock
absorber mounting
bolts, slightly lift the
Install and tighten the rear shock absorber upper
mounting bolts. NUT
Retract the Tighten the engine hanger linkage nut to the specified
centerstand before torque.
tightening the
engine hanger
TORQUE: 69 N·m (7.0 kgf·m, 51 lbf·ft)
linkage nut.
Remove the plug and connect the siphon hose to the HOSE CLAMP
radiator. HOSE GUIDE
Remove the clamp from the siphon hose.
Secure the siphon hose to the hose guide.
SIPHON HOSE
8-7
ENGINE REMOVAL/INSTALLATION
Route the wire Connect the spark plug cap to the spark plug.
harness properly Secure the wire boss to the radiator cover. SPARK PLUG CAP
(page 1-14)
WIRE BOSS
Route the wire Secure the following wire bosses to the frame:
harness properly
– Engine sub harness wire boss
(page 1-14)
– Alternator/CKP sensor wire boss
– Starter motor wire boss
Secure the following wires to the wire band:
– Engine sub harness wire
– Alternator/CKP sensor wire
– Starter motor wire
Tonngokhong BikerVietNam
– Engine sub harness wire
– Alternator/CKP sensor wire
– Starter motor wire
Connect the following:
2P CONNECTOR CONNECTOR
WIRE GUIDE
GROUND CABLE
8-8
ENGINE REMOVAL/INSTALLATION
Connect the throttle cable to the throttle drum.
CABLE GUIDE CLAMP
Secure the throttle cable to the cable guide and clamp.
Be sure that the Set the fuel hose clamp in position, then install and FUEL HOSE CLAMP
stopper of the tighten the bolt. BOLT
clamp is in the
• This scooter uses resin for the part of materials in
correct position.
the fuel feed hose. Do not bend or twist the fuel feed
hose.
STOPPER
Tonngokhong BikerVietNam
Set the connecting hose band in the specified angle as
shown.
Tighten the band screw so that the clearance between
the band ends is 11 – 13 mm (0.4 – 0.5 in).
AIR DUCT
Clearance:
11 – 13 mm (0.4 – 0.5 in)
30 – 40°
OUT
side
8-9
ENGINE REMOVAL/INSTALLATION
Set the cable clamp in position, then install and tighten
CABLE CLAMP BOLT
the cable clamp bolt.
CABLE CLAMP
Secure the rear brake cable with the cable holder.
Install the joint pin and adjusting nut. BRAKE CABLE JOINT PIN
Adjust the following:
– Throttle grip free play (page 4-5)
– Rear brake lever free play (page 4-17)
Install the following:
– Injector (page 6-45)
– Under cover (page 3-17)
– Main pipe side covers (page 3-16)
– Body cover (page 3-14)
Tonngokhong BikerVietNam
8-10
10. CYLINDER/PISTON
TROUBLESHOOTING·································10-3
10
Tonngokhong BikerVietNam
10-1
CYLINDER/PISTON
COMPONENT LOCATION
CYLINDER/PISTON
Tonngokhong BikerVietNam
10-2
CYLINDER/PISTON
SERVICE INFORMATION
GENERAL
• This section covers maintenance of the cylinder and piston.
• The engine must be removed from the frame to service the cylinder and piston.
• Be careful not to damage mating surfaces when removing the cylinder. Do not tap the cylinder too hard during removal.
• Take care not to damage the cylinder wall and piston.
• Clean all disassembled parts with clean solvent and dry them using compressed air before inspection.
• When removing the piston, clean carbon and sludge from the top of the cylinder.
SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Cylinder I.D. 50.000 – 50.010 (1.9685 – 1.9689) 50.10 (1.972)
Out-of-round – 0.05 (0.002)
Taper – 0.05 (0.002)
Warpage – 0.05 (0.002)
Piston, piston Piston O.D. 49.975 – 49.995 (1.9675 – 1.9683) 49.95 (1.967)
rings, piston Piston O.D. measurement point 6.0 (0.24) from bottom of skirt –
pin Piston pin bore I.D. 13.002 – 13.008 (0.5119 – 0.5121) 13.04 (0.513)
Piston pin O.D. 12.994 – 13.000 (0.5116 – 0.5118) 12.96 (0.510)
Piston-to-piston pin clearance 0.002 – 0.014 (0.0001 – 0.0006) 0.02 (0.001)
Piston ring-to-ring Top 0.015 – 0.045 (0.0006 – 0.0018) 0.08 (0.003)
groove clearance Second 0.015 – 0.045 (0.0006 – 0.0018) 0.08 (0.003)
Piston ring end gap Top 0.10 – 0.25 (0.004 – 0.0020) 0.45 (0.018)
Second 0.10 – 0.25 (0.004 – 0.0020) 0.45 (0.018)
Oil (side rail) 0.20 – 0.70 (0.008 – 0.028) –
Cylinder-to-piston clearance 0.005 – 0.035 (0.0002 – 0.0014) 0.09 (0.004)
Connecting rod small end I.D. 13.010 – 13.028 (0.5122 – 0.5129) 13.05 (0.514)
Tonngokhong BikerVietNam
Connecting rod-to-piston pin clearance 0.010 – 0.034 (0.0004 – 0.0013) 0.05 (0.002)
TROUBLESHOOTING
Compression too low, hard starting or poor performance at low speed
• Worn, stuck or broken piston ring
• Worn or damaged cylinder and piston
• Bent connecting rod
• Cylinder head/valve problem (page 9-23)
Compression too high, overheating or knocking
• Excessive carbon build-up on piston head or on combustion chamber
Excessive smoke
• Worn cylinder, piston or piston ring
• Improper installation of piston rings
• Scored or scratched piston or cylinder wall
• Cylinder head/valve problem (page 9-23)
Abnormal noise
• Worn piston pin or piston pin hole
• Worn connecting rod small end
• Worn cylinder, piston or piston rings
Piston ring sticking/scuffing, bearing damage
• Clogged oil gallery or oil strainer screen
• Internal oil leak
• Not using recommended engine oil
10-3
CYLINDER/PISTON
CYLINDER
REMOVAL
Remove the cylinder head (page 9-14).
CLIP
Unhook the clips and slide the water pipe into the water
pump/stator base.
Tonngokhong BikerVietNam
Remove the gasket and dowel pins.
Clean off any gasket material from the cylinder mating
CYLINDER CAM CHAIN
GASKET
DOWEL PINS
Slide the water pipe out of the water pump/stator base.
WATER PIPE
Remove the O-rings from the water pipe.
O-RINGS
10-4
CYLINDER/PISTON
INSTALLATION
Install the dowel pins and a new gasket.
GASKET
DOWEL PINS
Install the new O-rings into the grooves of the water
pipe. WATER PIPE
O-RINGS
Tonngokhong BikerVietNam
Attach a piece of
Apply engine oil to the cylinder and piston sliding
surface.
Apply engine oil to the piston rings.
Route the cam chain through the cylinder.
PISTON RINGS
WATER PIPE
10-5
CYLINDER/PISTON
INSPECTION
Inspect the cylinder bore for wear or damage.
Measure the cylinder I.D. in the X and Y axis at three
levels. Y
Take the maximum reading to determine the cylinder
wear. TOP X
SERVICE LIMIT: 50.10 mm (1.972 in)
Calculate the taper and out-of-round at three levels in MIDDLE
the X and Y axis. Take the maximum reading to
determine both measurements.
BOTTOM
SERVICE LIMIT:
Taper: 0.05 mm (0.002 in)
Out of round: 0.05 mm (0.002 in)
The cylinder must be rebored and an oversize piston/
piston rings fitted if the service limits are exceeded.
The following oversize pistons/piston rings are
available:
0.25 mm (0.010 in)
0.50 mm (0.020 in)
0.75 mm (0.030 in)
1.00 mm (0.039 in)
The piston to cylinder clearance for the oversize piston
must be: 0.005 – 0.035 mm (0.0002 – 0.0014 in).
Tonngokhong BikerVietNam
SERVICE LIMIT: 0.05 mm (0.002 in)
10-6
CYLINDER/PISTON
STUD BOLT REPLACEMENT
Thread two nuts onto the stud and tighten them
together, and use wrench on them to turn the stud bolt
out.
Install new stud bolts A, B into the crankcase and STUD BOLT A
tighten them.
178.0 – 179.0 mm (7.01 – 7.05 in)
After crankcase stud bolt installation, check that the
length from the bolt head to the crankcase surface is
within specification.
SPECIFIED STUD BOLT A: 178.0 – 179.0 mm
LENGTH: (7.01 – 7.05 in)
STUD BOLT B: 183.0 – 184.0 mm
(7.20 – 7.24 in)
STUD BOLT B
183.0 – 184.0 mm (7.20 – 7.24 in)
Tonngokhong BikerVietNam
PISTON
REMOVAL
Be careful not to let Remove the cylinder (page 10-4).
the piston pin clips CLIP/PISTON PIN
Remove the piston pin clips with pliers.
fall into the opening
Push the piston pin out of the piston and connecting
of the crankcase.
rod, then remove the piston.
PISTON
10-7
CYLINDER/PISTON
Clean carbon deposits from the ring grooves with a ring
that will be discarded. PISTON RING
INSTALLATION
Apply engine oil to the rings and ring grooves.
Carefully install the piston rings into the piston ring
grooves with the markings facing up.
• Do not confuse the top and second rings.
• To install the oil ring, install the spacer first, then
install the side rails.
Stagger the piston ring end gaps 120 degrees apart
from each other.
Stagger the side rail end gaps as shown.
SECOND RING
120°
MARK 120°
120° TOP RING
SECOND RING
OIL RING
SPACER
SIDE RAILS
20 mm or
more
20 mm or
more
10-8
CYLINDER/PISTON
Apply engine oil to the connecting rod small end hole.
CONNECTING ROD
Apply engine oil to the piston pin.
"IN" MARK PISTON
Install the piston with the "IN" mark facing the intake PIN
side.
Install the piston pin.
Tonngokhong BikerVietNam
fall into the opening
of the crankcase.
• Make sure the piston pin clips are seated securely.
• Do not align the piston pin clip end gap with the
piston cut-out.
Install the cylinder (page 10-5).
CLIP
PISTON CUT-OUT
CLIP
10-9
CYLINDER/PISTON
INSPECTION
Inspect the piston rings for movement by rotating the
rings. The rings should be able to move in their grooves
without catching.
Push the ring until the outer surface of the piston ring is
nearly flush with the piston and measure the ring-to-
groove clearance.
SERVICE LIMIT:
Top/Second: 0.08 mm (0.003 in)
PISTON RING
Tonngokhong BikerVietNam
Check the piston outer surface for scratches or
damage.
Measure the piston pin hole. Take the maximum
reading to determine I.D.
SERVICE LIMIT: 13.04 mm (0.513 in)
Measure the piston pin O.D. at piston and connecting
rod sliding areas.
SERVICE LIMIT: 12.96 mm (0.510 in)
Calculate the piston-to-piston pin clearance.
SERVICE LIMIT: 0.02 mm (0.001 in)
10-10
CYLINDER/PISTON
Measure the connecting rod small end I.D.
SERVICE LIMIT: 13.05 mm (0.514 in)
Calculate the connecting rod-to-piston pin clearance.
SERVICE LIMIT: 0.05 mm (0.002 in)
Tonngokhong BikerVietNam
10-11
MEMO
Tonngokhong BikerVietNam
11. KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
Tonngokhong BikerVietNam
11-1
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
COMPONENT LOCATION
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
Tonngokhong BikerVietNam
11-2
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
SERVICE INFORMATION
GENERAL
• This section covers maintenance of the kickstarter, drive pulley, driven pulley and clutch.
• These services can be done with the engine installed in the frame.
• Avoid getting grease and oil on the drive belt and drive/driven pulley faces in order to prevent belt slippage.
• Do not apply grease to the weight rollers.
SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Drive belt width 19.0 (0.75) 18.0 (0.71)
Movable drive face Bushing I.D. 22.035 – 22.085 (0.8675 – 0.8695) 22.11 (0.871)
Boss O.D. 22.010 – 22.025 (0.8665 – 0.8671) 21.98 (0.865)
Weight roller O.D. 17.92 – 18.08 (0.706 – 0.712) 17.5 (0.69)
Clutch Lining thickness – 2.0 (0.08)
Clutch outer I.D. 125.0 – 125.2 (4.92 – 4.93) 125.5 (4.94)
Driven pulley Face spring free length 111.4 (4.39) 108.0 (4.25)
Driven face O.D. 33.965 – 33.985 (1.3372 – 1.3380) 33.94 (1.336)
Movable driven face I.D. 34.000 – 34.025 (1.3386 – 1.3396) 34.06 (1.341)
TORQUE VALUE
Left crankcase cover plate screw 3 N·m (0.3 kgf·m, 2.2 lbf·ft)
Drive pulley face nut 108 N·m (11.0 kgf·m, 80 lbf·ft) Apply engine oil to the threads and seating
surface
Clutch/driven pulley nut 54 N·m (5.5 kgf·m, 40 lbf·ft)
Clutch outer nut 49 N·m (5.0 kgf·m, 36 lbf·ft)
Tonngokhong BikerVietNam
11-3
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
TOOLS
Clutch center holder Socket wrench, 39 x 41 mm Clutch spring compressor
07724-0050002 07GMA-KS40100 07LME-GZ40201
Tonngokhong BikerVietNam
Attachment, 28 x 30 mm
07946-1870100
11-4
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
TROUBLESHOOTING
Engine starts but scooter won’t move
• Worn drive belt
• Damaged ramp plate
• Worn or damaged clutch shoe
• Broken driven face spring
Engine stalls or scooter creeps
• Broken clutch shoe spring
Poor performance at high speed or lack of power
• Worn drive belt
• Weak driven face spring
• Worn weight rollers
• Contaminated pulley faces
Tonngokhong BikerVietNam
11-5
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
LEFT CRANKCASE COVER
REMOVAL
Loosen the band screw and disconnect the air duct
from the left crankcase cover. AIR DUCT
BAND SCREW
REAR BRAKE
Tonngokhong BikerVietNam
Remove the two dowel pins and cover gasket from the
left crankcase.
CABLE CLAMP VENT HOLE COVER
GASKET
Clean the gasket mating surface.
DOWEL PINS
INSTALLATION
Clean any oil and grease from the bearing bushing on BUSHING
GASKET
the left crankcase cover.
Install the two dowel pins.
Install a new cover gasket.
DOWEL PINS
11-6
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
Install the left crankcase cover onto the left crankcase
BOLTS
by aligning the dowel pins with the holes.
Install the rear brake cable clamp, vent hole cover and
tighten the left crankcase cover bolts in a crisscross
pattern in two or three steps.
REAR BRAKE
CABLE CLAMP VENT HOLE COVER
BAND SCREW
Clearance:
30 – 40°
OUT
side
DISASSEMBLY
Raise the lock tabs of the left crankcase cover plate and COVER PLATE
remove the screws and plate.
LOCK TABS/SCREWS
11-7
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
Remove the kickstarter driven gear while turning the
KICKSTARTER DRIVEN GEAR
kickstarter spindle.
Remove the thrust washer.
THRUST WASHER
BOLT
Tonngokhong BikerVietNam
WASHER
11-8
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
Unhook the return spring from the pin on the crankcase
KICKSTARTER SPINDLE RETURN SPRING
cover.
Remove the kickstarter spindle and return spring.
PIN
COLLAR
ASSEMBLY
Tonngokhong BikerVietNam
BUSHING
COLLAR
KICKSTARTER SPINDLE
*1
3 N·m (0.3 kgf·m, 2.2 lbf·ft)
RETURN SPRING
DRIVEN GEAR
*2
COVER PLATE
FRICTION SPRING
THRUST WASHER
LEFT CRANKCASE COVER
SNAP RING
WASHER
11-9
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
Install the bushing and collar into the left crankcase
BUSHING
cover.
COLLAR
Tonngokhong BikerVietNam
cover while setting the return spring along the guide on
the crankcase cover.
Hold the kickstarter spindle in position.
SHORT END
KICKSTARTER SPINDLE
Keep holding the Install the washer onto the kickstarter spindle and set
SNAP RING
kickstarter spindle the snap ring to the kickstarter spindle groove.
until the snap ring is
installed in order to
prevent the spring
from coming off
from the guide.
WASHER
11-10
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
Hook the long end of the return spring to the pin on the LONG END PIN
crankcase cover.
When installing the Install the kickstarter pedal in its original position as MARK
kickstarter pedal to marked during removal and tighten the bolt. KICKSTARTER PEDAL
Tonngokhong BikerVietNam
the standard
position, see page
11-8.
BOLT
THRUST WASHER
11-11
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
Apply 0.2 – 0.3 g of molybdenum disulfide paste to the
driven gear shaft. DRIVEN GEAR FRICTION SPRING
Apply molybdenum disulfide paste to the friction spring
sliding area.
Depress the kickstarter pedal and hold it.
Install the driven gear while aligning the friction spring
hook with the groove in the crankcase cover, and return
the kickstarter spindle to engage the driven gear teeth
and spindle gear teeth before the wide tooth point.
WIDE TOOTH
Install the left crankcase cover plate and tighten the COVER PLATE
screws to the specified torque.
LOCK TABS/SCREWS
INSPECTION
Tonngokhong BikerVietNam
Inspect the following:
–
–
–
Spindle for wear or damage
Gear teeth for wear or damage
Return spring for weakness or damage
RETURN SPRING
COLLAR
– Collar for wear or damage
– Bushing for wear or damage
SPINDLE
BUSHING
DRIVEN GEAR
11-12
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
– Journals of the crankcase cover for wear or damage
JOURNALS
DRIVE BELT
REPLACEMENT
DRIVE PULLEY
REMOVAL
• The drive pulley can be serviced with the engine NUT/WASHER/ DRIVE PULLEY FACE
installed in the frame.
RATCHET PLATE
Remove the left crankcase cover (page 11-6).
Hold the drive pulley face with special tool and loosen
the drive pulley face nut.
TOOL:
Clutch center holder 07724-0050002
Remove the following:
– Nut
– Washer
– Starter ratchet plate DRIVE FACE FIN
– Drive face fin CLUTCH CENTER HOLDER
– Drive pulley face
11-13
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
Slide off the drive belt from the drive pulley boss by
squeezing the drive belt. BOSS
BELT
BOSS
INSTALLATION
Tonngokhong BikerVietNam
Be careful not to get
the movable drive
Clean any oil and grease from the drive face and the
drive belt.
Install the movable drive face assembly onto the
crankshaft while holding the ramp plate.
MOVABLE DRIVE FACE ASSEMBLY
face assembly
disassembled and
be sure to install the
assembly until fully
seated.
Compress the driven face spring by squeezing the drive DRIVE BELT
belt until there is enough slack to install the drive belt to
the drive pulley boss.
11-14
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
Be careful not to Set the drive belt onto the drive pulley boss by
DRIVE PULLEY FACE
damage the spline. squeezing it to obtain the clearance between the belt
and shaft.
Install the drive pulley face while aligning its splines with
crankshaft splines.
Align
Install the drive face fin and ratchet plate. WASHER DRIVE FACE FIN
Tonngokhong BikerVietNam
Apply engine oil to the drive pulley face nut threads and
seating surface then install it with the washer.
Hold the drive pulley face with the special tool and
tighten the nut to the specified torque. NUT
TOOL:
Clutch center holder 07724-0050002
11-15
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
DISASSEMBLY/ASSEMBLY
Remove the following:
– Drive face boss
– Ramp plate
– Slide pieces
– Weight rollers
Clean any oil and Assembly is in the reverse order of disassembly.
grease from the
weight rollers and
movable drive face.
Left crankcase
cover side
RAMP PLATE
WEIGHT ROLLERS
SLIDE PIECES
Tonngokhong BikerVietNam
INSPECTION
DRIVE PULLEY FACE
Check the drive pulley face for scratches, scoring or
damage. DRIVE PULLEY FACE
WEIGHT ROLLER
Check each roller for abnormal wear.
Measure the weight roller O.D.
SERVICE LIMIT: 17.5 mm (0.69 in)
11-16
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
MOVABLE DRIVE FACE BOSS
Check the drive face boss for wear or damage.
Measure the drive face boss O.D.
SERVICE LIMIT: 21.98 mm (0.865 in)
Tonngokhong BikerVietNam
CLUTCH/DRIVEN PULLEY
REMOVAL
FLYWHEEL HOLDER
11-17
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
Do not get grease Hold the clutch/driven pulley assembly and compress
on the drive shaft the drive face spring by turning movable driven face
splines from the clockwise until it stops.
driven face inside.
INSTALLATION
Tonngokhong BikerVietNam
Clean any oil and grease from the driven face and drive
belt.
Hold the clutch/driven pulley assembly and compress
the drive face spring by turning movable driven face
CLUTCH/DRIVEN
PULLEY ASSEMBLY
11-18
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
Do not get grease Install the clutch/driven pulley assembly onto the
on the drive shaft driveshaft.
splines from the
driven face inside.
Clean any oil and grease from the clutch outer. Align
Install the clutch outer while aligning its splines with
driveshaft splines.
CLUTCH OUTER
Tonngokhong BikerVietNam
Hold the clutch outer with the special tool and tighten
the clutch outer nut to the specified torque.
TOOL:
Flywheel holder 07725-0040001
FLYWHEEL HOLDER
DISASSEMBLY
CLUTCH/DRIVEN PULLEY
Set the clutch spring compressor onto the clutch/driven
pulley by aligning the bosses of the compressor with the CLUTCH SPRING COMPRESSOR
holes of the clutch. CLUTCH/DRIVEN
TOOL: PULLEY
Clutch spring compressor 07LME-GZ40201
11-19
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
To prevent loss of Hold the clutch/driven pulley by turning the clutch spring
tension, do not compressor clockwise.
compress the
driven face spring
more than
necessary to
remove the clutch/
driven pulley nut.
CLUTCH/DRIVEN
PULLEY
Tonngokhong BikerVietNam
–
–
–
Clutch assembly
Spring seat
Driven face spring SPRING SEAT
– Driven pulley assembly
DRIVEN FACE
DRIVEN PULLEY ASSEMBLY SPRING
CLUTCH
Remove the three E-clips and plate.
PLATE
E-CLIPS
11-20
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
Remove the clutch shoes from the drive plate.
Remove the clutch shoe springs. CLUTCH SHOES SPRINGS
Remove the damper rubbers from the drive plate.
DRIVEN PULLEY
Remove the seal collar.
SEAL COLLAR
Remove the guide pins and guide rollers from the
driven face.
O-RINGS
Remove the movable driven face from the driven face.
Remove the O-rings and oil seals from the movable
driven face.
OIL SEALS
GUIDE PINS
DRIVEN FACE
GUIDE
ROLLERS
11-21
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
ASSEMBLY
GUIDE PINS
GUIDE ROLLERS
OIL SEALS
O-RINGS
SEAL COLLAR
E-CLIPS
CLUTCH SHOES
DRIVEN PULLEY
Apply engine oil to new oil seal lips and install them into
the movable driven face. O-RINGS
Coat new O-rings with engine oil and install them into
Tonngokhong BikerVietNam
the movable driven face grooves.
OIL SEALS
11-22
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
Install the seal collar to the driven pulley.
SEAL COLLAR
CLUTCH
Install the damper rubbers onto the drive plate.
DRIVE PLATE
DAMPER RUBBERS
Tonngokhong BikerVietNam
Install the shoe springs into the clutch shoes as shown.
Install the clutch shoes into the drive plate by aligning
the shoe grooves and damper rubbers.
CLUTCH SHOES SPRINGS
E-CLIPS
11-23
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
CLUTCH/DRIVEN PULLEY
Assemble the following:
CLUTCH ASSEMBLY
– Driven pulley assembly
– Driven face spring
– Spring seat SPRING SEAT
– Clutch assembly
DRIVEN FACE
DRIVEN PULLEY ASSEMBLY SPRING
TOOL:
Clutch spring compressor 07LME-GZ40201
To prevent loss of
tension, do not
compress the
driven face spring
more than
necessary to
assemble the Align (CUTOUT/ Align (BOSSES/
clutch/driven pulley PLATE HOLES HOLES
nut.
Tonngokhong BikerVietNam
Do not damage the
pulley nut threads.
Hold the spring compressor in a vice.
Tighten the clutch/driven pulley nut using the socket
wrench to the specified torque.
SOCKET WRENCH NUT
TOOL:
Socket wrench, 39 x 41 mm 07GMA-KS40100
CLUTCH SPRING
COMPRESSOR
INSPECTION
CLUTCH OUTER
Check the clutch outer for wear or damage.
Measure the clutch outer I.D.
SERVICE LIMIT: 125.5 mm (4.94 in)
11-24
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
DRIVEN FACE SPRING
Measure the driven face spring free length.
DRIVEN FACE
Check the driven face for scratches, scoring or
damage.
Measure the driven face boss O.D.
SERVICE LIMIT: 33.94 mm (1.336 in)
Tonngokhong BikerVietNam
MOVABLE DRIVEN FACE
Check the movable driven face for scratches, scoring or
damage.
Check the guide grooves for stepped wear or damage.
Measure the movable driven face I.D.
SERVICE LIMIT: 34.06 mm (1.341 in)
DRIVEN FACE
11-25
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
DRIVEN FACE BEARING
REPLACEMENT
Remove the driven face needle bearing using the
special tools. BEARING REMOVER
TOOLS:
Bearing remover, 20 mm 07931-MA70000
ATTACHMENT
Fork seal driver attachment, 35.207947-KA20200
mm
NEEDLE BEARING
Remove the snap ring and drive the ball bearing out of
BEARING
the driven face.
SNAP RING
Tonngokhong BikerVietNam
Pack new ball bearing with grease (Shell ALVANIA R3
or IDEMITSU AUTOREX B or equivalent). DRIVER
The sealed side of Install the ball bearing into the driven face squarely until
ball bearing is it is fully seated, using the special tools.
facing the
drivenface.
TOOLS:
Driver 07749-0010000
Pilot, 28 mm 07746-0041100 PILOT
BALL BEARING
SNAP RING
11-26
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
Apply grease (Shell ALVANIA R3 or IDEMITSU
AUTOREX B or equivalent) to a new needle bearing. ATTACHMENT DRIVER
The sealed side of Press the needle bearing into the driven face squarely
as shown. 1.0 mm
needle bearing is
facing the special (0.04 in)
tools.
TOOLS:
Driver 07749-0010000
Attachment, 28 x 30 mm 07946-1870100
Pilot, 20 mm 07746-0040500
PILOT
NEEDLE BEARING
Tonngokhong BikerVietNam
11-27
MEMO
Tonngokhong BikerVietNam
12. FINAL REDUCTION
Tonngokhong BikerVietNam
12-1
FINAL REDUCTION
COMPONENT LOCATION
FINAL REDUCTION
Tonngokhong BikerVietNam
12-2
FINAL REDUCTION
SERVICE INFORMATION
GENERAL
• The final reduction can be serviced with the engine installed in the frame.
• When installing the driveshaft, be sure to use the special tools; position the special tools on the bearing inner race and pull the
driveshaft into the bearing until it is fully seated.
SPECIFICATIONS
Unit: mm (in)
ITEM SPECIFICATIONS
Final reduction oil capacity After draining 0.10 liter (0.11 US qt, 0.09 lmp qt)
After disassembly 0.12 liter (0.13 US qt, 0.11 lmp qt)
Recommended final reduction oil API classification: SE, SF or SG
(except oils labeled as energy conserving on the circular API
service label)
Viscosity: SAE 10W-30
JASO T 903 standard: MB
TOOLS
Case puller Remover weight Bearing remover shaft, 10 mm
07SMC-0010001 07741-0010201 07936-GE00100
Tonngokhong BikerVietNam
Bearing remover head, 10 mm Bearing remover shaft, 12 mm Bearing remover head, 12 mm
07936-GE00200 07936-1660120 07936-1660110
12-3
FINAL REDUCTION
Attachment, 32 x 35 mm Attachment, 37 x 40 mm Attachment, 40 x 42 mm
07746-0010100 07746-0010200 07746-0010900
Tonngokhong BikerVietNam
Assembly collar Assembly shaft Assembly collar attachment
07965-GM00100 07965-1660200 07965-GM00200
12-4
FINAL REDUCTION
TROUBLESHOOTING
Engine does start but scooter won’t move
• Damaged final reduction
• Seized final reduction
• Faulty drive pulley (page 11-16)
• Faulty driven pulley/clutch (page 11-24)
Abnormal noise
• Worn, seized or chipped gears
• Worn or damaged final reduction bearing
Oil leak
• Oil level too high
• Worn or damaged oil seal
• Cracked crankcase and/or final reduction case
Tonngokhong BikerVietNam
12-5
FINAL REDUCTION
FINAL REDUCTION CASE
SEPARATION
REMOVAL
• The final reduction can be serviced with the engine
installed in the frame. BREATHER HOSE
GASKET
12-6
FINAL REDUCTION
Remove the following:
– Counter gear COUNTER GEAR
– Final gear shaft
– Countershaft
COUNTERSHAFT
SPLINES
12-7
FINAL REDUCTION
Install the dowel pins and a new gasket.
DOWEL PINS
GASKET
BOLTS
Tonngokhong BikerVietNam
Install the following:
– Rear brake shoes (page 16-6)
– Rear wheel (page 15-5)
– Clutch/driven pulley (page 11-18)
Fill the final reduction case with the recommended oil
(page 4-15).
12-8
FINAL REDUCTION
FINAL REDUCTION CASE
Check the final reduction case bearings and final gear
shaft oil seal for wear or damage. COUNTERSHAFT BEARING FINAL GEAR
SHAFT
Turn each bearing inner race with your finger. BEARING
The bearing should turn smoothly without friction.
Check that there is no clearance between the outer
race and the final reduction case.
FINAL GEAR
SHAFT OIL SEAL
Tonngokhong BikerVietNam
GEAR/SHAFT
DRIVESHAFT
Check the driveshaft for bend, wear or damage.
DRIVESHAFT
12-9
FINAL REDUCTION
COUNTER GEAR/COUNTERSHAFT/FINAL GEAR
SHAFT
Check the countershaft, counter gear and final gear
shaft for wear or damage. FINAL GEAR SHAFT
LEFT CRANKCASE
COVER
BUSHING
10 x 15 x 9 OIL SEAL
20 x 32 x 6
COUNTERSHAFT
BEARING (6301)
12-10
FINAL REDUCTION
LEFT CRANKCASE COVER
Remove the left crankcase cover (page 11-6).
SNAP RING
Remove the snap ring from the left crankcase cover
groove.
DRIVESHAFT BEARING
12-11
FINAL REDUCTION
Install the snap ring Install the snap ring to the left crankcase cover groove.
SNAP RING
with the chamfered
Install the left crankcase cover (page 11-6).
edge facing the
bearing.
LEFT CRANKCASE
Separate the final reduction case (page 12-6).
SET PLATE
Remove the two bolts and set plate.
BOLTS
Tonngokhong BikerVietNam
Be careful not to
damage the final
reduction case
mating surface.
Remove the countershaft and final gear shaft bearings
using the special tools.
TOOLS:
Countershaft bearing:
Bearing remover head, 12 mm 07936-1660110
Bearing remover shaft, 12 mm 07936-1660120
Remover weight 07741-0010201
Final gear shaft bearing:
Bearing remover head, 15 mm 07936-KC10200
Bearing remover shaft, 15 mm 07936-KC10100
Remover weight 07741-0010201
FINAL GEAR COUNTERSHAFT
SHAFT BEARING BEARING
12-12
FINAL REDUCTION
Apply engine oil to each bearing cavity.
The marked side of Drive each new bearing into the left crankcase squarely
each bearing is until it is fully seated, using the special tools. COUNTERSHAFT
facing the special BEARING
tools.
TOOLS:
Countershaft bearing:
Driver 07749-0010000
Attachment, 37 x 40 mm 07746-0010200
Pilot, 12 mm 07746-0040200
Final gear shaft bearing:
Driver 07749-0010000
Attachment, 42 x 47 mm 07746-0010300
Pilot, 15 mm 07746-0040300 FINAL GEAR
SHAFT BEARING
DRIVER
ATTACHMENT
BEARING PILOT
Tonngokhong BikerVietNam
down.
Install the set plate with its "OUT" mark facing out.
Install and tighten the set plate bolts.
"OUT" MARK
6.5 ± 0.1 mm
(0.26 ± 0.04 in)
BOLTS
DRIVESHAFT
Separate the final reduction case (page 12-6).
SET PLATE
Remove the two bolts and set plate.
BOLTS
12-13
FINAL REDUCTION
Remove the driveshaft using the special tool. DRIVESHAFT
TOOL:
Case puller 07SMC-0010001
CASE PULLER
CASE PULLER
DRIVESHAFT
Tonngokhong BikerVietNam
DRIVESHAFT
12-14
FINAL REDUCTION
Remove the driveshaft oil seal.
DRIVESHAFT OIL SEAL
Tonngokhong BikerVietNam
Position the assembly collar on the driveshaft bearing
BEARING COLLAR
inner race and pull the driveshaft into the bearing until it
is fully seated.
TOOLS:
Assembly shaft 07965-1660200
Assembly collar 07965-GM00100
Assembly collar attachment 07965-GM00200
ASSEMBLY
COLLAR
DRIVESHAFT
ATTACHMENT
BEARING
ASSEMBLY
ASSEMBLY COLLAR SHAFT
12-15
FINAL REDUCTION
Install the snap ring Install the snap ring to the driveshaft groove.
SNAP RING
with the chamfered
edge facing the
bearing.
ASSEMBLY
COLLAR
ATTACHMENT
ASSEMBLY COLLAR ASSEMBLY
ATTACHMENT
Tonngokhong BikerVietNam
COLLAR
DRIVESHAFT ASSEMBLY
OIL SEAL SHAFT
6.5 ± 0.1 mm
(0.26 ± 0.04 in)
BOLTS
12-16
FINAL REDUCTION
FINAL REDUCTION CASE
Separate the final reduction case (page 12-6).
COUNTERSHAFT FINAL GEAR SHAFT
Be careful not to Remove the final gear shaft oil seal. BEARING BEARING
damage the final
Remove the final gear shaft bearing.
reduction case
mating surface. Remove the countershaft bearing using the special
tools.
TOOLS:
Bearing remover head, 12 mm 07936-1660110
Bearing remover shaft, 12 mm 07936-1660120
Remover weight 07741-0010201
OIL SEAL
Tonngokhong BikerVietNam
The marked side of
bearing is facing the
Apply engine oil to the final gear shaft bearing cavity.
Drive a new final gear shaft bearing into the final
reduction case squarely until it is fully seated, using the
DRIVER
FINAL GEAR
SHAFT BEARING PILOT
Apply engine oil to a new final gear shaft oil seal lip.
DRIVER
Install the oil seal with the flat side facing the rear wheel
side so that the depth from the final reduction case
surface is 1.5 ± 0.5 mm (0.06 ± 0.02 in) using the ATTACHMENT
special tools.
TOOLS:
Driver 07749-0010000
Attachment, 42 x 47 mm 07746-0010300
Assemble the final reduction case (page 12-7).
1.5 ± 0.5 mm
(0.06 ± 0.02 in)
FINAL GEAR SHAFT OIL SEAL
12-17
MEMO
Tonngokhong BikerVietNam
13. CRANKCASE/CRANKSHAFT
13
Tonngokhong BikerVietNam
13-1
CRANKCASE/CRANKSHAFT
COMPONENT LOCATION
CRANKCASE/CRANKSHAFT
Tonngokhong BikerVietNam
13-2
CRANKCASE/CRANKSHAFT
SERVICE INFORMATION
GENERAL
• This section covers the crankcase separation to service the crankshaft.
• The following parts must be removed before separating the crankcase.
– Engine (page 8-4)
– Cylinder head (page 9-14)
– Cylinder (page 10-4)
– Piston (page 10-7)
– Starter pinion (page 19-10)
– Drive pulley (page 11-13)
– Clutch/driven pulley (page 11-17)
– Starter motor (page 19-6)
– Flywheel/stator (page 17-7)
• In addition to the parts listed above, remove the following parts when the left crankcase must be replaced.
– Final reduction (page 12-6)
• In addition to the parts listed above, remove the following parts when the right crankcase must be replaced.
– Oil pump (page 5-4)
• Be careful not to damage the crankcase mating surfaces when separating and assembling the crankcase halves.
• Clean all disassembled parts with clean solvent and dry them using compressed air before inspection.
• When installing the crankshaft, be sure to use the special tools; position the special tools on the bearing inner race and pull the
crankshaft into the bearing until it is fully seated.
SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Crankshaft Connecting rod side clearance 0.10 – 0.35 (0.004 – 0.014) 0.55 (0.022)
Connecting rod radial clearance 0.004 – 0.016 (00002 – 0.0006) 0.05 (0.002)
Runout – 0.10 (0.004)
Tonngokhong BikerVietNam
13-3
CRANKCASE/CRANKSHAFT
TOOLS
Case puller Assembly shaft Assembly collar A
07SMC-0010001 07965-VM00200 07965-VM00100
Tonngokhong BikerVietNam
TROUBLESHOOTING
Abnormal noise
• Worn crankshaft bearing
• Worn connecting rod big end bearing
• Worn connecting rod small end (page 10-10)
13-4
CRANKCASE/CRANKSHAFT
CRANKCASE SEPARATION
Refer to service information (page 13-3) for the parts
which must be removed before separating the
crankcase.
Unhook the centerstand return spring.
RETURN SPRING
WASHER
Tonngokhong BikerVietNam
Remove the bolt and collar from the pivot shaft.
Pull out the pivot shaft and remove the centerstand.
BOLT COLLAR
Remove the bolt, set plate, spring and plunger from the
SET PLATE PLUNGER
right crankcase.
BOLT SPRING
13-5
CRANKCASE/CRANKSHAFT
Remove the crankcase bolts from the right crankcase.
BOLTS
Be careful not to Place the crankcase with the left crankcase facing
damage the down and separate the left and right crankcase. RIGHT CRANKCASE
crankcase mating
surface.
Tonngokhong BikerVietNam
DOWEL PINS
13-6
CRANKCASE/CRANKSHAFT
Lift the cam chain off the timing sprocket on the
crankshaft as shown, using a screwdriver. SCREWDRIVER
Hold the cam chain off the timing sprocket and remove
the crankshaft from the left crankcase using the case
puller.
Remove the cam chain.
TOOL:
Case puller 07SMC-0010001
CAM CHAIN
CRANKSHAFT
Tonngokhong BikerVietNam
CRANKSHAFT
13-7
CRANKCASE/CRANKSHAFT
Remove the left crankshaft bearing using the special
tool. CRANKSHAFT
TOOL:
Universal bearing puller 07631-0010000
– If the left crankshaft bearing remains in the
crankcase, remove it to the right side.
BEARING
BEARING PULLER
Remove the snap ring and oil seal from the left SNAP RING
crankcase.
Tonngokhong BikerVietNam
OIL SEAL
CRANKCASE ASSEMBLY
Be careful not to Clean the insides and mating surface of the
damage the crankcases. MATING SURFACE
crankcase mating Check for cracks or other damage.
surface. Remove any roughness or irregularities with an oil
stone.
13-8
CRANKCASE/CRANKSHAFT
Apply engine oil to the bearing cavity.
ATTACHMENT
Press the left crankcase bearing into the left crankcase
DRIVER
squarely until it is fully seated, using the special tool.
TOOLS:
Driver 07749-0010000
Attachment, 72 x 75 mm 07746-0010600
Pilot, 35 mm 07746-0040800
Apply 2 cc minimum of engine oil to a new left
crankcase bearing.
LEFT CRANKSHAFT
PILOT BEARING BEARING
Inject more than 3 cc of engine oil to the connecting rod
ASSEMBLY COLLAR A ASSEMBLY SHAFT
big end bearing.
ADAPTOR
Install the crankshaft into the left crankcase bearing as
follows:
Install the assembly shaft adaptor to the left crankshaft.
Position the assembly collar A on the left crankcase
bearing inner race and set the assembly collar B to the
assembly collar A.
Install the assembly shaft to the assembly collar B and CONNECTING
screw it onto the crankshaft while aligning the center of ROD
the assembly collar B with the assembly shaft.
• When pulling the crankshaft into the bearing, be
careful not to damage the connecting rod. ASSEMBLY COLLAR B ASSEMBLY SHAFT
Pull the crankshaft into the bearing until it is fully seated ASSEMBLY SHAFT
while positioning the connecting rod in the cylinder
Tonngokhong BikerVietNam
sleeve opening on the left crankcase.
TOOLS:
Assembly shaft adaptor 07WMF-KFF0200
ASSEMBLY COLLAR A
ASSEMBLY SHAFT
ADAPTOR
ASSEMBLY COLLAR B
TIMING SPROCKET
13-9
CRANKCASE/CRANKSHAFT
Apply sealant (Three bond 1207B or Three bond 1215
or equivalent) to the right crankcase mating surface.
DOWEL PINS
Tonngokhong BikerVietNam
BOLTS
13-10
CRANKCASE/CRANKSHAFT
Apply engine oil to a new oil seal lip. FORK SEAL OIL SEAL DRIVER
Install the oil seal to the left crankcase squarely until it is DRIVER
fully seated, using the special tool. ATTACHMENT
TOOLS:
Oil seal driver 07965-KE80200
Fork seal driver attachment, 07947-KF00100
41.2 mm
OIL SEAL
SNAP RING
Tonngokhong BikerVietNam
Install the set plate with its OUT mark facing out and
tighten the bolt.
OUT
SPRING BOLT Mark
CENTERSTAND
13-11
CRANKCASE/CRANKSHAFT
Install the washer and new cotter pin.
COTTER PIN
WASHER
RETURN SPRING
CRANKSHAFT INSPECTION
Tonngokhong BikerVietNam
Remove the crankshaft (page 13-5).
Turn the outer race of the right crankshaft bearing with
your finger. The bearing should turn smoothly and
RIGHT CRANKCASE BEARING
quietly. Also check that the bearing inner race fits tightly
on the right crankshaft.
Replace the bearing if it does not turn smoothly, quietly,
or if it fits loosely on the right crankshaft.
If the timing Check the oil pump drive gear and timing sprocket teeth
sprocket teeth are for wear or damage. OIL PUMP DRIVE GEAR
worn or damaged,
check the cam
chain, tensioner
and cam sprocket.
TIMING SPROCKET
13-12
CRANKCASE/CRANKSHAFT
Measure the connecting rod big end side clearance with
FEELER GAUGE
a feeler gauge.
SERVICE LIMIT: 0.55 mm (0.022 in)
Tonngokhong BikerVietNam
using a dial indicator.
Actual runout is 1/2 of total indicator reading.
SERVICE LIMIT: 0.10 mm (0.004 in)
65 mm 35 mm
(2.6 in) (1.4 in)
13-13
MEMO
Tonngokhong BikerVietNam
14. FRONT WHEEL/SUSPENSION/STEERING
FRONT WHEEL···········································14-7
Tonngokhong BikerVietNam 14
14-1
FRONT WHEEL/SUSPENSION/STEERING
COMPONENT LOCATION
FRONT WHEEL/SUSPENSION/STEERING
Standard type:
Tonngokhong BikerVietNam
14-2
FRONT WHEEL/SUSPENSION/STEERING
SERVICE INFORMATION
GENERAL
Frequent inhalation of brake pad dust, regardless of material composition could be hazardous to your health.
• Avoid breathing dust particles.
• Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner.
• This section covers the front wheel, fork, handlebar and steering stem.
• When servicing the front wheel, fork or steering stem, support the scooter using a jack or other support.
• A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a
high quality brake degreasing agent.
• After the front wheel installation, check the brake operation by applying the brake lever.
• For brake system service, refer to page 16-3.
SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Minimum tire tread depth – To the indicator
Cold tire pressure Driver only 200 kPa (2.00 kgf/cm2, 29 psi) –
Driver and passenger 200 kPa (2.00 kgf/cm2, 29 psi) –
Axle runout – 0.2 (0.01)
Wheel rim runout Radial – 2.0 (0.08)
Axial – 2.0 (0.08)
Wheel hub-to-rim distance (Spoke wheel type) 0 ± 1.0 (0 ± 0.04) –
Fork Spring free length 307.0 (12.09) 301.0 (11.85)
Pipe runout – 0.2 (0.01)
Recommended fluid Fork fluid –
TORQUE VALUES
Front axle nut 59 N·m (6.0 kgf·m, 44 lbf·ft) U-nut
Front brake disc socket bolt 42 N·m (4.3 kgf·m, 31 lbf·ft) ALOC bolt; replace with new ones
Front spoke (Spoke wheel type) 3.7 N·m (0.4 kgf·m, 2.7 lbf·ft)
Handlebar post nut 59 N·m (6.0 kgf·m, 44 lbf·ft)
Rear brake lever pivot screw (Standard 1 N·m (0.1 kgf·m, 0.7 lbf·ft)
type)
Rear brake lever pivot nut (Standard type) 4.5 N·m (0.5 kgf·m, 3.3 lbf·ft) U-nut
Brake caliper mounting bolt 30.4 N·m (3.1 kgf·m, 22 lbf·ft) ALOC bolt; replace with new ones.
Bottom bridge pinch bolt 64 N·m (6.5 kgf·m, 47 lbf·ft)
Fork pipe seat socket bolt 23 N·m (2.3 kgf·m, 17 lbf·ft) Apply locking agent to the threads
Fork cap bolt 20 N·m (2.0 kgf·m, 15 lbf·ft)
Steering stem top thread – For tightening sequence; See page 14-23
Steering stem lock nut – For tightening sequence; See page 14-23
14-3
FRONT WHEEL/SUSPENSION/STEERING
TOOLS
Bearing remover shaft Bearing remover head, 12 mm Driver
07746-0050100 07746-0050300 07749-0010000
Fork seal driver body Fork seal driver attachment, 27.2 mm Pin spanner
07747-0010100 07747-0010300 07702-0020001
Tonngokhong BikerVietNam
14-4
FRONT WHEEL/SUSPENSION/STEERING
Socket wrench Steering stem socket Ball race remover shaft
07916-KM10000 07916-3710101 07GMD-KS40100
Tonngokhong BikerVietNam
14-5
FRONT WHEEL/SUSPENSION/STEERING
TROUBLESHOOTING
Hard steering
• Insufficient tire pressure
• Faulty tire
• Steering stem lock nut too tight
• Faulty steering head bearing
• Faulty steering head bearing race
• Bent steering stem
Steers to one side or does not track straight
• Bent front axle
• Wheel installed incorrectly
• Worn or damaged front wheel bearings
• Bent fork
• Worn or damaged engine mounting bushings
• Bent frame
• Faulty steering head bearing
Front wheel wobbles
• Loose front axle fasteners
• Bent rim
• Worn or damaged front wheel bearings
• Loose or distorted spokes (Spoke wheel type)
Front wheel turns hard
• Front brake drag
• Bent front axle
• Faulty front wheel bearings
Soft suspension
• Low tire pressure
• Deteriorated fork fluid
• Incorrect fork fluid weight
• Insufficient fluid in fork
Tonngokhong BikerVietNam
• Weak fork spring
Hard suspension
• High tire pressure
• Too much fluid in fork
• Incorrect fork fluid weight
• Bent fork pipes
• Clogged fork fluid passage
Suspension noisy
• Bent fork slider
• Insufficient fluid in fork
• Loose fork fasteners
14-6
FRONT WHEEL/SUSPENSION/STEERING
FRONT WHEEL
REMOVAL/INSTALLATION
Raise and support the scooter using safety stand.
Remove/install the following:
– Speedometer cable
– O-ring
– Axle nut
– Front axle
– Front wheel
– Side collar
– Speedometer gearbox
TORQUE: AXLE NUT
59 N·m (6.0 kgf·m, 44 lbf·ft)
Tonngokhong BikerVietNam
*
SPEEDOMETER GEARBOX
AXLE NUT
59 N·m (6.0 kgf·m, 44 lbf·ft)
SIDE COLLAR
Align the speedometer tabs with
the wheel hub grooves. FRONT WHEEL
GEARBOX SEAL
*: Shell BEARING GREASE HD or equivalent.
14-7
FRONT WHEEL/SUSPENSION/STEERING
DISASSEMBLY/ASSEMBLY
Remove/install the following:
– Dust seals
– Socket bolts
– Brake disc
– Wheel bearings
– Distance collar
TORQUE: BRAKE DISC SOCKET BOLT
42 N·m (4.3 kgf·m, 31 lbf·ft)
DUST SEAL
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SOCKET BOLTS
42 N·m (4.3 kgf·m, 31 lbf·ft)
Tighten the bolts in a criss-
cross pattern in 2 or 3 steps.
DISTANCE
COLLAR
BRAKE DISC
Install the brake disc with its
marked side facing up.
14-8
FRONT WHEEL/SUSPENSION/STEERING
BEARING REPLACEMENT
Install the bearing remover head into the bearing.
From the opposite side, install the bearing remover REMOVER HEAD REMOVER SHAFT
shaft and drive the bearing out of the wheel hub.
Remove the distance collar and drive out the other
bearing.
TOOLS:
Bearing remover head, 12 mm 07746-0050300
Bearing remover shaft 07746-0050100
REMOVER
BEARING HEAD
BEARINGS
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bearings have been
removed, the
bearings must be
replaced with new
TOOLS:
Driver
Attachment, 32 x 35 mm
07749-0010000
07746-0010100
ones. Pilot, 12 mm 07746-0040200
BEARING PILOT
14-9
FRONT WHEEL/SUSPENSION/STEERING
INSPECTION
AXLE
Place the axle on V-blocks and measure the runout with
a dial indicator.
WHEEL BEARING
Turn the inner race of each bearing with your finger, the
bearing should turn smoothly and quietly.
Also check that the bearing outer race fits tightly in the
hub.
Replace the Remove and discard the bearings if the races do not
bearings in pairs. turn smoothly, quietly, or if they fit loosely in the hub.
Tonngokhong BikerVietNam
WHEEL RIM
Check the wheel rim runout by placing the wheel on a
turning stand.
Spin the wheel by hand and read the runout using a dial
indicator.
Actual runout is 1/2 the total indicator reading.
SERVICE LIMIT:
Axial: 2.0 mm (0.08 in)
Radial: 2.0 mm (0.08 in)
14-10
FRONT WHEEL/SUSPENSION/STEERING
WHEEL CENTER ADJUSTMENT
(SPOKE WHEEL TYPE)
Remove the front wheel (page 14-7).
Place the rim on the work bench.
Adjust the hub position so that the distance from the
right end surface of the hub center to the side of the rim
is 0 ± 1.0 mm (0 ± 0.04 in) as shown.
Tighten the spokes in 2 or 3 progressive steps.
TOOL:
Spoke wrench, 5.8 x 6.1 mm 07701-0020300
FORK
REMOVAL
Remove the following:
– Front fender (page 3-4)
– Front wheel (page 14-7) LOWER
– Front brake caliper (page 16-19) PINCH BOLT
Support the front Remove the bolt and brake hose clamp from the left
brake caliper with a fork leg.
piece of wire so that
Remove the bottom bridge upper pinch bolts.
it does not hang
Loosen the bottom bridge lower pinch bolts and remove
from the front brake
the fork legs.
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hose.
Do not twist the
brake hose. INSTALLATION
Install the fork pipe into the steering stem.
Install the bottom bridge upper pinch bolts.
Tighten the bottom bridge pinch bolts to the specified
torque.
TORQUE: 64 N·m (6.5 kgf·m, 47 lbf·ft)
Install the brake hose clamp and tighten the bolt. UPPER PINCH
BOLT
Install the following:
– Front wheel (page 14-7) BOLT
– Front fender (page 3-4)
– Front brake caliper (page 16-19) FORK
BRAKE HOSE
CLAMP
DISASSEMBLY
Hold the fork slider in a vice with soft jaws or a shop
towel. FORK SLIDER SOCKET BOLT
Loosen the fork socket bolt but do not remove yet.
14-11
FRONT WHEEL/SUSPENSION/STEERING
Remove the fork cap bolt and O-ring.
FORK CAP BOLT
Remove the fork spring from the fork pipe.
FORK PIPE
O-RING
SPRING
Pour out the fork fluid by pumping the fork pipe several
times.
14-12
FRONT WHEEL/SUSPENSION/STEERING
Remove the socket bolt and sealing washer.
SEALING WASHER
SOCKET BOLT
REBOUND SPRING
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FORK PIPE
OIL SEAL
14-13
FRONT WHEEL/SUSPENSION/STEERING
ASSEMBLY
STOPPER RING
OIL SEAL
FORK SLIDER
O-RING
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SOCKET BOLT
SEALING WASHER REBOUND SPRING
FORK SPRING
FORK PIPE
Install the fork If removing the fork piston ring from the fork piston,
piston ring with its install a new fork piston ring to the fork piston groove. FORK PISTON
cut-out side facing
down.
Make sure that the Install the rebound spring and fork piston into the fork
fork piston ring is pipe.
seated in the
groove.
REBOUND SPRING
14-14
FRONT WHEEL/SUSPENSION/STEERING
Clean the socket bolt threads and apply locking agent
to the bolt threads.
SEALING WASHER
Install and tighten the socket bolt with a new sealing
washer to the fork piston.
SOCKET BOLT
Install the oil seal stopper ring into the stopper ring
STOPPER RING DUST SEAL
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groove on the fork slider.
Apply fork fluid to a new dust seal lip.
Do not tap the dust Install the dust seal until it is fully seated.
seal lip too hard.
14-15
FRONT WHEEL/SUSPENSION/STEERING
Be sure the oil level Compress the fork leg fully and measure the fluid level
is same in the both from the top of the fork pipe.
forks.
FORK FLUID LEVEL: 86.5 mm (3.41 in)
Pull the fork pipe up and install the fork spring with its
FORK CAP BOLT
tightly wound side facing up.
Coat a new O-ring with fork fluid and install it into the O-RING
groove in the fork cap bolt.
Install the fork cap bolt and tighten it to the specified
torque. FORK PIPE
SPRING
Tonngokhong BikerVietNam
towel. FORK SLIDER
Tighten the fork socket bolt to the specified torque.
TORQUE: 23 N·m (2.3 kgf·m, 17 lbf·ft)
SOCKET BOLT
14-16
FRONT WHEEL/SUSPENSION/STEERING
INSPECTION
FORK SPRING
Measure the fork spring free length.
FORK PIPE/SLIDER/PISTON
Check the fork pipe, fork slider and fork piston for score
mark, and excessive or abnormal wear. FORK SLIDER
FORK PIPE
REBOUND FORK
Tonngokhong BikerVietNam
Place the fork pipe on V-block and measure the runout.
SPRING FORK PISTON
PISTON
RING
14-17
FRONT WHEEL/SUSPENSION/STEERING
HANDLEBAR
REMOVAL/INSTALLATION
STANDARD TYPE
Loosen the rear brake cable by turning the adjusting
nut.
Remove/install the following:
– Rear handlebar cover (page 3-8)
– Rear brake lever pivot screw/nut
– Rear brake cable/lever
– Master cylinder/holder/bolts
– Screw/upper throttle housing/lower throttle housing
– Throttle cable/throttle pipe
– Left handlebar grip
– Nut/collars/bolt/handlebar post
TORQUE: HANDLEBAR POST NUT
59 N·m (6.0 kgf·m, 44 lbf·ft) ADJUSTING NUT
REAR BRAKE LEVER PIVOT SCREW
1 N·m (0.1 kgf·m, 0.7 lbf·ft)
REAR BRAKE LEVER PIVOT NUT
4.5 N·m (0.5 kgf·m, 3.3 lbf·ft)
Tonngokhong BikerVietNam
THROTTLE PIPE
Align the end of master
cylinder with the punch
Tighten the upper bolt first,
then the lower bolt.
SCREW mark on handlebar.
HOLDER
PIVOT SCREW
1 N·m (0.1 kgf·m, 0.7 lbf·ft) Set the holder with its
"UP" mark facing up.
PIVOT NUT
MASTER CYLINDER 4.5 N·m (0.5 kgf·m, 3.3 lbf·ft)
LOWER HOUSING
REAR BRAKE LEVER
THROTTLE CABLE
NUT
59 N·m (6.0 kgf·m, 44 lbf·ft)
14-18
FRONT WHEEL/SUSPENSION/STEERING
CBS TYPE
Loosen the rear brake cable by turning the adjusting
nut.
Remove/install the following:
– Rear handlebar cover (page 3-8)
– Rear brake lever bracket/holder/bolt
– Master cylinder/holder/bolts
– Screw/upper throttle housing/lower throttle housing
– Throttle cable/throttle pipe
– Left handlebar grip
– Nut/collars/bolt/handlebar post
TORQUE: HANDLEBAR POST MOUNTING NUT
59 N·m (6.0 kgf·m, 44 lbf·ft)
ADJUSTING NUT
THROTTLE PIPE
SCREW
HOLDER
Set the holder with its
"UP" mark facing up.
BOLTS
HOLDER BOLT
HOLDER
MASTER CYLINDER
LOWER HOUSING
NUT
BOLT COLLAR COLLAR 59 N·m (6.0 kgf·m, 44 lbf·ft)
14-19
FRONT WHEEL/SUSPENSION/STEERING
HANDLEBAR POST INSTALLATION
Install the handlebar post onto the steering stem while
aligning the bolt holes.
BOLT REAR COLLAR
Rear collar is taller Install the front/rear collars, bolt and nut.
than the front collar.
Tighten the nut to the specified torque.
TORQUE: 59 N·m (6.0 kgf·m, 44 lbf·ft)
PUNCH MARK
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THROTTLE HOUSING INSTALLATION
Install the throttle pipe.
Apply grease to the throttle cable sliding area and
connect it to the throttle pipe.
Install the lower throttle housing by aligning the hole on
the handlebar with the locating pin of the lower throttle
housing.
Align
THROTTLE CABLE
LOWER HOUSING
14-20
FRONT WHEEL/SUSPENSION/STEERING
STEERING STEM
REMOVAL
Remove the following: BOLT SPEEDOMETER CABLE
– Fork (page 14-11)
– Handlebar (page 14-18)
Remove the bolt and brake hose clamp.
Release the speedometer cable from the cable guide.
Hold the top thread using the pin spanner and loosen
the steering stem lock nut using the socket wrench. STEM LOCK NUT SOCKET
WRENCH
TOOLS:
Socket wrench 07916-KM10000
Pin spanner 07702-0020001
Remove the steering stem lock nut.
Tonngokhong BikerVietNam
Be careful not to
drop the steering
Hold the steering stem and loosen the top thread using
the stem socket.
PIN SPANNER
STEM
stem. SOCKET
TOOL:
Steering stem socket 07916-3710101
Remove the top thread while holding the steering stem.
TOP THREAD
Be careful not to • Always replace the steel balls and races as a set.
UPPER INNER STEEL
drop the steering
Remove the upper bearing inner race and the upper RACE BALLS (23)
stem and the upper
steel balls (23 balls) while holding the steering stem.
steel balls.
STEERING STEM
14-21
FRONT WHEEL/SUSPENSION/STEERING
Be careful not to Remove the steering stem and lower steel balls (29
STEERING STEM
drop the steering balls).
stem and the lower
steel balls.
STEEL
BALLS (29)
BALL RACE
REMOVER SHAFT
Tonngokhong BikerVietNam
TOOLS:
Ball race remover, 34.5 mm
Ball race remover shaft
07948-4630100
07GMD-KS40100
REMOVER SHAFT
14-22
FRONT WHEEL/SUSPENSION/STEERING
INSTALLATION
• Always replace the steel balls and races as a set.
DUST SEAL
WASHER
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STEERING STEM
BOLT
14-23
FRONT WHEEL/SUSPENSION/STEERING
Apply 3 g of grease with extreme pressure agent
(recommended: EXCELIGHT EP2 manufactured by
KYODO YUSHI, japan or Shell ALVANIA EP2 or
equivalent) to a new dust seal lip then install it to the
lower bearing inner race.
DUST SEAL
Drive a new upper bearing outer race into the head pipe
using the following tools. DRIVER/ATTACHMENT
TOOLS:
Driver 07749-0010000
Bearing driver attachment 07946-3710701
Drive a new lower bearing outer race into the head pipe
LOWER OUTER RACE
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using the following tools.
TOOLS:
Driver 07749-0010000
Attachment, 52 x 55 mm 07746-0010400
DRIVER/ATTACHMENT
STEERING STEM
14-24
FRONT WHEEL/SUSPENSION/STEERING
Apply 3 g of grease with extreme pressure agent
(recommended: EXCELIGHT EP2 manufactured by UPPER INNER RACE
KYODO YUSHI, japan or Shell ALVANIA EP2 or
equivalent) to the upper bearing races.
Install new steel balls (23 balls) onto the upper bearing
outer race.
Install a new upper bearing inner race onto the stem. STEEL BALLS
Be careful not to
drop the steering (23 balls)
stem and the upper
steel balls.
Tonngokhong BikerVietNam
seat the bearing.
Completely loosen the top thread.
14-25
FRONT WHEEL/SUSPENSION/STEERING
Hold the top thread using the pin spanner and tighten
the steering stem lock nut to the specified torque. STEM LOCK NUT
TOOLS:
Socket wrench 07916-KM10000
Pin spanner 07702-0020001
PIN SPANNER
Install the brake hose clamp and tighten the bolt. BOLT SPEEDOMETER CABLE
Route the speedometer cable through the cable guide.
Install the following:
– Handlebar (page 14-18)
– Fork (page 14-11)
Tonngokhong BikerVietNam
14-26
15. REAR WHEEL/SUSPENSION
Tonngokhong BikerVietNam 15
15-1
REAR WHEEL/SUSPENSION
COMPONENT LOCATION
REAR WHEEL/SUSPENSION
Tonngokhong BikerVietNam
118 N·m (12.0 kgf·m, 87 lbf·ft)
15-2
REAR WHEEL/SUSPENSION
SERVICE INFORMATION
GENERAL
Frequent inhalation of brake shoe dust, regardless of material composition could be hazardous to your health.
• Avoid breathing dust particles.
• Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner.
• Use genuine Honda replacement bolts and nut for all suspension pivots and mounting points.
• For brake system service, refer to section 16.
SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Minimum tire tread depth – To the indicator
Cold tire pressure Driver only 225 kPa (2.25 kgf/cm2, 33 psi) –
Driver and passenger 225 kPa (2.25 kgf/cm2, 33 psi) –
Wheel rim runout Radial – 2.0 (0.08)
Axial – 2.0 (0.08)
Wheel hub-to-rim distance (Spoke wheel type) 6.5 ± 1.0 (0.26 ± 0.04) –
TORQUE VALUES
Rear axle nut 118 N·m (12.0 kgf·m, 87 lbf·ft) U-nut, Apply engine oil to the threads and
seating surface
Rear spoke (Spoke wheel type) 3.7 N·m (0.4 kgf·m, 2.7 lbf·ft)
Engine hanger link nut (Engine side) 49 N·m (5.0 kgf·m, 36 lbf·ft)
Tonngokhong BikerVietNam
TOOL
Spoke wrench, 5.8 x 6.1 mm
07701-0020300
15-3
REAR WHEEL/SUSPENSION
TROUBLESHOOTING
Rear wheel wobbles
• Bent rim
• Faulty tire
• Loose or distorted spokes
• Axle nut and/or engine mounting bolt/nut not tightened properly
• Loose or worn final gear shaft bearing
• Insufficient tire pressure
Soft suspension
• Weak rear shock absorber spring
• Oil leakage from damper unit
• Low tire pressure
Stiff suspension
• Bent damper rod
• High tire pressure
Rear suspension noisy
• Loose mounting fasteners
• Faulty shock absorber
• Weak rear suspension bushings
Tonngokhong BikerVietNam
15-4
REAR WHEEL/SUSPENSION
REAR WHEEL/SWINGARM
REMOVAL
Remove the exhaust pipe/muffler (page 3-19).
LOWER MOUNTING BOLT
Support the scooter on its centerstand and remove the
following:
– Axle nut
– Right rear shock absorber lower mounting bolt
AXLE NUT
Remove the swingarm mounting bolts and swingarm.
MOUNTING BOLTS
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Remove the rear wheel.
SWINGARM
REAR WHEEL
INSTALLATION
Be careful not to Install the rear wheel onto the final shaft, aligning the
damage the splines.
splines.
Apply grease to grease groove and bearing fitting area
of the final shaft.
(GROOVE)
15-5
REAR WHEEL/SUSPENSION
Install the swingarm onto the final shaft.
MOUNTING BOLTS
Install and tighten the swingarm mounting bolts.
SWINGARM
AXLE NUT
WHEEL INSPECTION
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Check the wheel rim runout using dial indicators.
Actual runout is 1/2 the total indicator readings.
SERVICE LIMITS:
Radial: 2.0 mm (0.08 in)
Axial: 2.0 mm (0.08 in)
15-6
REAR WHEEL/SUSPENSION
SWINGARM BEARING INSPECTION/
REPLACEMENT
Remove the swingarm (page 15-5).
DUST SEALS
Remove the side collars and dust seals from the
swingarm.
SWINGARM
SIDE COLLARS
SWINGARM BEARING
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Remove the snap ring.
Drive the bearing out of the swingarm. SNAP RING
BEARING
TOOL:
Driver 07908-KE90000
Attachment, 42 x 47 mm 07746-0010300 BEARING ATTACHMENT
Pilot, 17 mm 07746-0040400
PILOT
15-7
REAR WHEEL/SUSPENSION
Install the snap ring into the swingarm groove securely
with the chamfered side facing the bearing. SNAP RING
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To avoid damage to
INSTALLATION
Install the rear shock absorber and tighten the bolts.
BOLTS
BOLTS
INSPECTION
Check the damper unit for leakage or other damage.
BUSHING
Check the shock absorber bushing for wear or damage.
Replace the shock absorber assembly if necessary.
SHOCK ABSORBER
15-8
REAR WHEEL/SUSPENSION
Check the rear shock absorber mount bushings for
wear or damage. REAR SHOCK ABSORBER MOUNT BUSHINGS
HANGER LINKAGE
REMOVAL
Remove the following:
– Engine (page 8-4)
– Exhaust pipe/muffler (page 3-19)
Remove the nut and engine hanger link bolt.
Remove the engine hanger link from the engine.
Tonngokhong BikerVietNam
INSTALLATION
Install the engine hanger link onto the engine.
BOLT/NUT ENGINE HANGER LINK
Install the engine hanger link bolt from the left side of
the engine.
Install the engine hanger link nut and tighten it to the
specified torque.
TORQUE: 49 N·m (5.0 kgf·m, 36 lbf·ft)
Install the following:
– Exhaust pipe/muffler (page 3-19)
– Engine (page 8-7)
INSPECTION
Check the hanger link bushings and stopper rubber for
wear or damage. HANGER LINK BUSHINGS
STOPPER RUBBER
15-9
REAR WHEEL/SUSPENSION
Check the engine mount bushings for wear or damage.
Tonngokhong BikerVietNam
15-10
16. BRAKE SYSTEM
Tonngokhong BikerVietNam
16
16-1
BRAKE SYSTEM
COMPONENT LOCATION
BRAKE SYSTEM
Tonngokhong BikerVietNam
16-2
BRAKE SYSTEM
SERVICE INFORMATION
GENERAL
Frequent inhalation of brake pad and shoe dust, regardless of material composition, could be hazardous to your heal
• Avoid breathing dust particles.
• Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner.
Spilled brake fluid will severely damage instrument lenses and painted surfaces. It is also harmful to some rubber parts.
Be careful whenever you remove the reservoir cap; make sure the master cylinder reservoir is horizontal first.
• A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a
high quality brake degreasing agent.
• Check the brake system by applying the brake lever after the air bleeding.
• Never allow contaminants (dirt, water, etc.) to get into an open reservoir.
• Once the hydraulic system has been opened, or if the brake feels spongy, the system must be bled.
• Always use fresh DOT 3 or DOT 4 brake fluid from a sealed container when servicing the system. Do not mix different types of
fluid, they may not be compatible.
• Always check brake operation before riding the scooter.
SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Brake lever freeplay 10 – 20 (0.4 – 0.8) –
Brake drum I.D. 130.0 (5.12) 131.0 (5.16)
Specified brake fluid DOT 3 or 4 –
Brake disc Thickness 3.3 – 3.7 (0.13 – 0.15) 3.0 (0.12)
Tonngokhong BikerVietNam
Master cylinder
Caliper
Warpage
Cylinder I.D.
Piston O.D.
Cylinder I.D.
–
12.700 – 12.743 (0.5000 – 0.5017)
12.657 – 12.684 (0.4983 – 0.4994)
25.400 – 25.450 (1.0000 – 1.0020)
0.10 (0.004)
12.755 (0.5022)
12.645 (0.4978)
25.460 (1.0024)
Piston O.D. 25.318 – 25.368 (0.9968 – 0.9987) 25.31 (0.996)
16-3
BRAKE SYSTEM
TORQUE VALUES
Rear axle nut 118 N·m (12.0 kgf·m, 87 lbf·ft) U-nut, Apply engine oil to the threads
and seating surface
Rear brake arm bolt 10 N·m (1.0 kgf·m, 7 lbf·ft) ALOC bolt; replace with new one.
Brake caliper bleed valve 5.4 N·m (0.6 kgf·m, 4.4 lbf·ft)
Brake master cylinder reservoir cap screw 1.5 N·m (0.2 kgf·m, 1.1 lbf·ft)
Brake pad pin 18 N·m (1.8 kgf·m, 13 lbf·ft)
Front brake lever pivot bolt 1 N·m (0.1 kgf·m, 0.7 lbf·ft)
(Standard type only)
Front brake lever pivot screw 1 N·m (0.1 kgf·m, 0.7 lbf·ft)
(CBS type only)
Front brake lever pivot nut 6 N·m (0.6 kgf·m, 4.4 lbf·ft)
Front brake light switch screw 1 N·m (0.1 kgf·m, 0.7 lbf·ft)
Brake hose oil bolt 34 N·m (3.5 kgf·m, 25 lbf·ft)
Brake caliper mounting bolt 30.4 N·m (3.1 kgf·m, 22 lbf·ft) ALOC bolt; replace with new ones.
Rear brake lever pivot screw 4.2 N·m (0.4 kgf·m, 3.1 lbf·ft)
(CBS type only)
Rear brake lever pivot nut 5.2 N·m (0.5 kgf·m, 3.8 lbf·ft) U-nut
(CBS type only)
Equalizer rod pivot screw 4.2 N·m (0.4 kgf·m, 3.1 lbf·ft)
(CBS type only)
Equalizer rod pivot nut 5.2 N·m (0.5 kgf·m, 3.8 lbf·ft) U-nut
(CBS type only)
Rear brake lever bracket cover screw 4.2 N·m (0.4 kgf·m, 3.1 lbf·ft)
(CBS type only)
Rear brake lever bracket cover special screw 4.2 N·m (0.4 kgf·m, 3.1 lbf·ft)
(CBS type only)
Brake caliper torque pin 22 N·m (2.2 kgf·m, 16 lbf·ft)
Brake caliper pin 18 N·m (1.8 kgf·m, 13 lbf·ft)
Equalizer connecting cable lock nut 6.4 N·m (0.7 kgf·m, 4.7 lbf·ft)
Tonngokhong BikerVietNam
(CBS type only)
TOOL
Snap ring pliers
07914-SA50001
16-4
BRAKE SYSTEM
TROUBLESHOOTING
Poor rear brake performance
• Incorrect adjustment of rear brake lever
• Contaminated brake shoes
• Worn brake shoes
• Worn brake cam
• Worn brake drum
• Improperly installed brake arm
• Improperly engaged brake arm serrations
Brake lever soft or spongy
• Air in hydraulic system
• Leaking hydraulic system
• Contaminated brake pad/disc
• Worn caliper piston seals
• Worn master cylinder piston cups
• Worn brake pad/disc
• Contaminated caliper
• Contaminated master cylinder
• Caliper not sliding properly
• Low brake fluid level
• Clogged fluid passage
• Warped/deformed brake disc
• Sticking/worn caliper piston
• Sticking/worn master cylinder piston
• Bent brake lever
Brake lever hard
• Clogged/restricted brake system
• Sticking/worn caliper piston
• Caliper not sliding properly
• Worn caliper piston seal
• Sticking/worn master cylinder piston
Tonngokhong BikerVietNam
• Bent brake lever
Brake drags
• Contaminated brake pad/disc
• Misaligned wheel
• Badly worn brake pad/disc
• Warped/deformed brake disc
• Caliper not sliding properly
• Clogged/restricted fluid passage
• Sticking caliper piston
• Improperly adjusted connecting cable (CBS type only)
16-5
BRAKE SYSTEM
REAR DRUM BRAKE
DISASSEMBLY/ASSEMBLY
• Always replace the brake shoes as a set.
• Mark all parts during disassembly so they can be
placed back in the original locations.
Remove the rear wheel (page 15-5).
Remove the adjusting nut and brake cable from the joint
pin.
Remove the joint pin and return spring.
Expand the brake shoes and remove the brake shoes/
shoe springs from the brake panel.
Remove the following:
– Brake arm bolt
– Brake arm/brake cam
– Dust seals
Install the removed parts in the reverse order of
removal.
TORQUE: BRAKE ARM BOLT
10 N·m (1.0 kgf·m, 7 lbf·ft)
• Apply grease to the new dust seals, brake cam
sliding surface and brake shoe contacting area.
• Replace the dust seals and brake arm bolt with new
ones.
• Adjust the rear brake lever freeplay (page 4-17).
Tonngokhong BikerVietNam
Align
DUST SEALS
*: Apply each 0.2 - 0.3 g of grease.
BRAKE ARM
ADJUSTING NUT
SHOE SPRINGS
JOINT PIN
16-6
BRAKE SYSTEM
INSPECTION
Measure the rear brake drum I.D.
Tonngokhong BikerVietNam
Turn the handlebar until the reservoir is parallel to the
ground before removing the reservoir cap.
Remove the screws, reservoir cap, diaphragm plate
and diaphragm.
RESERVOIR CAP SCREWS
DIAPHRAGM
PLATE
DIAPHRAGM
16-7
BRAKE SYSTEM
BRAKE FLUID FILLING/AIR BLEEDING
Do not mix different Fill the master cylinder reservoir with DOT 3 or DOT 4
UPPER LEVEL
types of fluid. They brake fluid from the sealed container to the upper level.
are not compatible.
• Check the fluid level often while bleeding the brake
to prevent air from being pumped into the system.
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system.
If the brake bleeder is not available, perform the
following procedure.
Pump up the system pressure with the brake lever until
the lever resistance is felt.
Check the fluid Connect a bleed hose to the bleed valve and bleed the
BLEED VALVE BLEED HOSE
level often while system as follows:
bleeding the brake
1. Squeeze the brake lever all the way and loosen the
to prevent air from
bleed valve 1/2 of a turn. Wait several seconds and
being pumped into
then close the bleed valve.
the system.
2. Release the brake lever slowly and wait several
Do not release the
seconds after it reaches the end of its travel.
brake lever until the
3. Repeat the steps 1 and 2 until there are no air
bleed valve has
bubbles in the bleed hose.
been closed.
After bleeding the system completely, tighten the bleed
valve to the specified torque.
TORQUE: 5.4 N·m (0.6 kgf·m, 4.4 lbf·ft)
16-8
BRAKE SYSTEM
Do not mix different Fill the reservoir to the upper level with DOT 3 or DOT 4
UPPER LEVEL
types of fluid. They brake fluid from a sealed container.
are not compatible.
DIAPHRAGM
PLATE DIAPHRAGM
BRAKE PAD/DISC
Tonngokhong BikerVietNam
Check the brake
fluid level in the
BRAKE PAD REPLACEMENT
Push the caliper pistons all the way in to allow
installation of new brake pads.
reservoir as this
operation causes
the level to rise.
BRAKE CALIPER
16-9
BRAKE SYSTEM
Remove the brake pads from the brake caliper.
BRAKE
PADS
Always replace the Install new brake pads so that they are set on the brake
Set the pads BRACKET PIN
brake pads in pairs caliper bracket and bracket pin.
to assure even disc
pressure.
BRAKE
PADS
Tonngokhong BikerVietNam
Install the pad pin by pushing the brake pads against
the pad spring to align the pad pin holes on the pads
and caliper hole.
O-RING
PAD PIN
After the brake pad Tighten the pad pin to the specified torque.
replacement, check
the brake operation TORQUE: 18 N·m (1.8 kgf·m, 13 lbf·ft)
by applying the
brake lever.
PAD PIN
16-10
BRAKE SYSTEM
BRAKE DISC INSPECTION
Visually inspect the brake disc for damage or cracks.
Measure the brake disc thickness at several points.
SERVICE LIMIT: 3.0 mm (0.12 in)
Tonngokhong BikerVietNam
16-11
BRAKE SYSTEM
BRAKE MASTER CYLINDER
REMOVAL/INSTALLATION
STANDARD TYPE
Drain the brake fluid (page 16-7).
Remove the rear handlebar cover (page 3-8).
Disconnect the front brake light switch wire (Green/
Yellow, Black) connectors.
Remove the oil bolt, brake hose and sealing washers.
Install the removed parts in the reverse order of
removal.
TORQUE: OIL BOLT
34 N·m (3.5 kgf·m, 25 lbf·ft)
• Replace the sealing washers with new ones.
• Fill and air bleed the hydraulic system (page 16-7).
SCREW BOLTS
1.5 N·m (0.2 kgf·m, 1.1 lbf·ft) Align the end of master
HOLDER cylinder with the punch
mark on handlebar.
RESERVOIR CAP
Tighten the upper
bolt first, then the
lower bolt.
DIAPHRAGM PLATE
Tonngokhong BikerVietNam
DIAPHRAGM
Set the holder with
its "UP" mark facing
up.
SEALING WASHERS
MASTER CYLINDER
ADJUSTING NUT
16-12
BRAKE SYSTEM
Loosen the lock nut and turn the adjuster until the play
LOCK NUT
of the connecting cable becomes maximum.
CONNECTING
Compress the return spring and disconnect the tip of CABLE
the connecting cable from the knocker joint.
Remove the return spring.
Remove the connecting cable.
Remove the master cylinder (page 16-12).
KNOCKER RETURN
JOINT SPRING ADJUSTER
RETURN CONNECTING
SPRING ADJUSTER CABLE
Tonngokhong BikerVietNam
If there is any gap, turn the adjuster until there is no gap
between the knocker pin and the end of the slot of the
knocker joint.
After adjustment, hold the adjuster and tighten the lock
nut to the specified torque.
TORQUE: 6.4 N·m (0.7 kgf·m, 4.7 lbf·ft)
After tightening the lock nut, check that there is no gap KNOCKER PIN
between the knocker pin and the end of the slot of the
knocker joint.
Apply rear brake lever several times and check that the KNOCKER JOINT
distance between the edges has not been changed
after applying the brake.
Recheck the edge surface of the knocker seats on the
INSPECTION
edge surface of the master cylinder body.
POINT
Adjust the rear brake lever freeplay (page 4-17).
Install the rear handlebar cover (page 3-8).
KNOCKER
16-13
BRAKE SYSTEM
DISASSEMBLY/ASSEMBLY
STANDARD TYPE
Remove/install the following:
SNAP RING PLIERS
– Brake lever pivot nut, bolt and brake lever
– Screw and brake light switch
– Boot
Remove/install the snap ring using the special tool.
TOOL:
Snap ring pliers 07914-SA50001
Remove/install the washer, master piston and spring.
TORQUE: FRONT BRAKE LEVER PIVOT BOLT
1 N·m (0.1 kgf·m, 0.7 lbf·ft)
FRONT BRAKE LEVER PIVOT NUT
6 N·m (0.6 kgf·m, 4.4 lbf·ft) SNAP RING
FRONT BRAKE LIGHT SWITCH SCREW
1 N·m (0.1 kgf·m, 0.7 lbf·ft)
• Keep the piston, cups, spring, snap ring and boot as
a set; do not substitute individual parts.
• When installing the cups, do not allow the lips to turn
inside out.
• Be sure that snap ring is firmly seated in the groove.
• Apply silicone grease to the pivot bolt sliding
surface, boots inside and lever to piston contact
area.
• Apply brake fluid to master piston, piston cups and
spring.
Tonngokhong BikerVietNam*
BOOT
MASTER
WASHER PISTON CUPS CYLINDER BODY
SNAP RING
MASTER PISTON
BRAKE LIGHT
BRAKE LEVER
SWITCH
16-14
BRAKE SYSTEM
CBS TYPE
Remove/install the following:
– Brake lever pivot nut/screw/brake lever/knocker/
return spring/spring
– Screw and brake light switch
– Boot
Remove/install the snap ring using the snap ring pliers
(page 16-14).
Remove/install the washer, master piston and spring.
TORQUE: FRONT BRAKE LEVER PIVOT SCREW
1 N·m (0.1 kgf·m, 0.7 lbf·ft)
FRONT BRAKE LEVER PIVOT NUT
6 N·m (0.6 kgf·m, 4.4 lbf·ft)
FRONT BRAKE LIGHT SWITCH SCREW
1 N·m (0.1 kgf·m, 0.7 lbf·ft)
• Keep the piston, cups, spring, snap ring and boot as
a set; do not substitute individual parts.
• When installing the cups, do not allow the lips to turn
inside out.
• Be sure that snap ring is firmly seated in the groove.
• Apply silicone grease to the pivot screw sliding
surface, boots inside and lever to piston contact
area.
• Apply brake fluid to master piston, piston cups and
spring.
Tonngokhong BikerVietNam
*
BOOT
MASTER
MASTER PISTON CYLINDER BODY
BRAKE LIGHT
SWITCH
SPRING
BRAKE LEVER
RETURN
SPRING
INSPECTION
Check the piston cups for wear, deterioration or
damage.
Check the master cylinder inner surface and piston
outer surface for scratches or damage.
Measure the master cylinder I.D.
SERVICE LIMIT: 12.755 mm (0.5022 in)
Measure the master piston O.D.
SERVICE LIMIT: 12.645 mm (0.4978 in)
16-15
BRAKE SYSTEM
COMBINED BRAKE EQUALIZER
(CBS TYPE)
REMOVAL/INSTALLATION
Remove the front handlebar cover (page 3-8).
Disconnect the connecting cable (page 16-12).
Remove/install the following:
– Special screw/set rubber
– Screws/bracket cover
Be careful when – Lock lever/return spring
removing the lock – Bolt/holder/lever bracket
lever. The return – Brake lever pivot screw/nut
spring may pop out. – Equalizer rod pivot screw/nut
– Brake lever
– Brake cable/connecting cable
– Brake light switch/grommet
TORQUE: BRACKET COVER SCREW
4.2 N·m (0.4 kgf·m, 3.1 lbf·ft)
BRACKET COVER SPECIAL SCREW
4.2 N·m (0.4 kgf·m, 3.1 lbf·ft)
REAR BRAKE LEVER PIVOT SCREW
4.2 N·m (0.4 kgf·m, 3.1 lbf·ft)
REAR BRAKE LEVER PIVOT NUT
5.2 N·m (0.5 kgf·m, 3.8 lbf·ft)
EQUALIZER ROD PIVOT SCREW
4.2 N·m (0.4 kgf·m, 3.1 lbf·ft)
EQUALIZER ROD PIVOT NUT
5.2 N·m (0.5 kgf·m, 3.8 lbf·ft)
Tonngokhong BikerVietNam
• Apply grease to the pivot screws and equalizer sliding surface.
BRAKE CABLE
EQUALIZER
BRAKE LEVER
CONNECTING CABLE
PIVOT NUTS
BOOT GROMMET 5.2 N·m (0.5 kgf·m, 3.8 lbf·ft)
RETURN
SPRING
BRACKET
SPECIAL SCREW COVER
4.2 N·m (0.4 kgf·m, 3.1 lbf·ft) LOCK LEVER
SCREWS
4.2 N·m (0.4 kgf·m, 3.1 lbf·ft)
16-16
BRAKE SYSTEM
Install the rear brake light switch while aligning its tab
WIRE CONNECTORS
with the groove on rear brake lever bracket.
Connect the brake light switch wire connectors.
Align
BOOT
CONNECTING CABLE "F" MARK GROMMET
Set the rear brake lever to the rear brake lever bracket EQUALIZER ROD
and the equalizer.
Tonngokhong BikerVietNam
Apply grease to the sliding surface of the rear brake
lever pivot screw.
Install and tighten the pivot screw to the specified
torque.
PIVOT SCREW
BRAKE LEVER
PIVOT SCREW
Align
(Tab and hole)
16-17
BRAKE SYSTEM
Install and tighten the holder bolt.
HOLDER BOLT
LOCK LEVER
Tonngokhong BikerVietNam
Tighten the bracket cover screws to the specified
torque.
TORQUE: 4.2 N·m (0.4 kgf·m, 3.1 lbf·ft)
SCREWS
Install the set rubber to the rear brake lock lever and
SET RUBBER SPECIAL SCREW
tighten the bracket cover special screw to the specified
torque.
16-18
BRAKE SYSTEM
BRAKE CALIPER
REMOVAL
Avoid spilling fluid Drain the brake fluid (page 16-7).
on painted, plastic,
Remove the following:
or rubber parts.
Place a shop towel – Oil bolt/sealing washers
over these parts – Brake pads (page 16-9)
whenever the – Mounting bolts
system is serviced. – Brake caliper
INSTALLATION
Install the front brake caliper onto the left fork leg.
Install new mounting bolts and tighten them to the
specified torque.
TORQUE: 30.4 N·m (3.1 kgf·m, 22 lbf·ft)
Connect the brake hose to the brake caliper with the oil
bolt and new sealing washers.
Tighten the oil bolt Tighten the oil bolt to the specified torque.
while pushing the
brake hose eyelet
TORQUE: 34 N·m (3.5 kgf·m, 25 lbf·ft)
joint against the Install the brake pads (page 16-9).
stopper. Fill the brake fluid and bleed the hydraulic system (page
16-7).
BRAKE HOSE
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OIL BOLT
34 N·m (3.5 kgf·m, 25 lbf·ft)
SEALING WASHERS
BRAKE CALIPER
BRAKE CALIPER MOUNTING BOLTS
30.4 N·m (3.1 kgf·m, 22 lbf·ft)
16-19
BRAKE SYSTEM
DISASSEMBLY/ASSEMBLY
Remove the following:
– Caliper bracket
– Pin boots
– Pad spring
Place a shop towel over the piston.
Do not use high Position the caliper body with the piston facing down
pressure air or bring and apply small squirts of air pressure to the fluid inlet
the nozzle too close to remove the piston.
to the inlet.
Remove the dust seal/piston seal.
Install the removed parts in the reverse order of
removal.
• Apply silicone grease to the dust seal and bracket
pin boots.
• Apply brake fluid to the piston and piston seal.
• Replace the dust seal and piston seal with new ones.
BLEED VALVE
5.4 N·m (0.6 kgf·m, 4.4 lbf·ft)
Tonngokhong BikerVietNam
PISTON SEAL
CALIPER BODY
CALIPER PISTON
Install the caliper piston with
its opened end facing the
brake pads. * *: Apply 0.4 g minimum of silicone grease
BRACKET PIN BOOT
INSPECTION
Check the caliper cylinder for scoring, scratches or
damage.
Measure the caliper cylinder I.D.
SERVICE LIMIT: 25.460 mm (1.0024 in)
Check the caliper piston for scoring, scratches or
damage.
Measure the caliper piston O.D.
SERVICE LIMIT: 25.31 mm (0.996 in)
16-20
17. BATTERY/CHARGING SYSTEM/ALTERNATOR
Tonngokhong BikerVietNam
17
17-1
BATTERY/CHARGING SYSTEM/ALTERNATOR
SYSTEM LOCATION
BATTERY/CHARGING SYSTEM/ALTERNATOR
BATTERY
REGULATOR/RECTIFIER
Tonngokhong BikerVietNam
ALTERNATOR
SYSTEM DIAGRAM
G: Green
R: Red
W: White
MAIN FUSE 15 A
ALTERNATOR
BATTERY REGULATOR/
RECTIFIER
17-2
BATTERY/CHARGING SYSTEM/ALTERNATOR
COMPONENT LOCATION
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17-3
BATTERY/CHARGING SYSTEM/ALTERNATOR
SERVICE INFORMATION
GENERAL
• The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charg-
ing.
• The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective clothing
and a face shield.
– If electrolyte gets on your skin, flush with water.
– If electrolyte gets in your eyes, flush with water for at least 15 minutes and call a physician immediately.
• Electrolyte is poisonous.
– If swallowed, drink large quantities of water or milk and call your local Poison Control Center or a call a physician imme-
diately.
• Always turn off the ignition switch before disconnecting any electrical component.
• Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch
is ON and current is present.
• This model comes with a maintenance free (MF) battery. Remember the following about MF batteries.
– Use only the electrolyte that comes with the battery.
– Use all of the electrolyte.
– Seal the battery properly.
– Never open the seals after installation.
• For extended storage, remove the battery, give it a full charge, and store it in a cool, dry space. For maximum service life,
charge the stored battery every two weeks.
• For a battery remaining in a stored scooter, disconnect the negative battery cable from the battery terminal.
• The maintenance free battery must be replaced when it reaches the end of its service life.
• The battery can be damaged if overcharged or undercharged, or if left to discharge for long period. These same conditions
contribute to shortening the "life span" of the battery. Even under normal use, the performance of the battery deteriorates after 2-
Tonngokhong BikerVietNam
3 years.
• Battery voltage may recover after battery charging, but under heavy load, battery voltage will drop quickly and eventually die out.
For this reason, the charging system is often suspected as the problem. Battery overcharge often results from problems in the
battery itself, which may appear to be an overcharging symptom. If one of the battery cells is shorted and battery voltage does
not increase, the regulator/rectifier supplies excess voltage to the battery. Under these conditions, the electrolyte level goes
down quickly.
• Before troubleshooting the charging system, check for proper use and maintenance of the battery. Check if the battery is
frequently under heavy load, such as having the headlight and taillight ON for long periods of time without riding the scooter.
• The battery will self-discharge when the scooter is not in use. For this reason, charge the battery every two weeks to prevent
sulfation from occurring.
• When checking the charging system, always follow the steps in the troubleshooting flow chart (page 17-6).
• For battery charging, do not exceed the charging current and time specified on the battery. Use of excessive current or charging
time may damage the battery.
• The flywheel, alternator and ignition pulse generator services can be done with the engine installed in the frame.
• Refer to page 18-6 for CKP sensor inspection.
BATTERY CHARGING
• Turn the power ON/OFF at the charger, not at the battery terminal.
• For battery charging, do not exceed the charging current and time specified on the battery. Using excessive current or extending
the charging time may damage the battery.
• Quick charging should only be done in an emergency; slow charging is preferred.
BATTERY TESTING
Refer to the instruction of the Operation Manual for the recommended battery tester for details about battery testing.
The recommended battery tester puts a "load" on the battery so that the actual battery condition of the load can be measured.
Recommended battery tester: BM-210 or BATTERY MATE or equivalent
17-4
BATTERY/CHARGING SYSTEM/ALTERNATOR
SPECIFICATIONS
ITEM SPECIFICATIONS
Battery Capacity 12 V – 3 Ah
Current leakage 0.1 mA max.
Voltage Fully charged 13.0 – 13.2 V
Needs charging Below 12.4 V
Charging cur- Normal 0.3 A/5 – 10 h
rent Quick 3.0 A/0.5 h
Alternator Capacity 0.160 kW/5,000 min-1 (rpm)
TORQUE VALUES
Flywheel nut 59 N·m (6.0 kgf·m, 44 lbf·ft)
Stator mounting socket bolt 10 N·m (1.0 kgf·m, 7 lbf·ft)
TOOLS
Universal Holder Flywheel puller
07725-0030000 07733-0010000
Tonngokhong BikerVietNam
17-5
BATTERY/CHARGING SYSTEM/ALTERNATOR
TROUBLESHOOTING
BATTERY IS DAMAGED OR WEAK
1. Battery Test
Remove the battery (page 17-11).
Check the battery condition using the recommended battery tester.
RECOMMENDED BATTERY TESTER:BM-210 or BATTERY MATE or equivalent
Is the battery in good condition?
YES – GO TO STEP 2.
NO – Faulty battery
2. Current Leakage Test
Install the battery (page 17-11).
Check the battery current leakage (page 17-12).
Is the current leakage below 0.1 mA?
YES – GO TO STEP 4.
NO – GO TO STEP 3.
3. Current Leakage Test Without Regulator/rectifier
Disconnect the regulator/rectifier connector and recheck the battery current leakage.
Is the current leakage below 0.1 mA?
YES – Faulty regulator/rectifier
NO – • Shorted wire harness
• Faulty ignition switch
4. Alternator Charging Coil Inspection
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Check the alternator charging coil (page 17-11).
Is the alternator charging coil resistance within 0.2 – 1.0 ǡ (20°C/68°F)?
YES – GO TO STEP 5.
NO – Faulty charging coil
5. Charging Voltage Inspection
Measure and record the battery voltage using a digital multimeter (page 17-12).
Start the engine.
Measure the charging voltage (page 17-13).
Compare the measurements to result of the following calculation.
STANDARD:Measured BV < Measured CV < 15.5 V
• BV = Battery Voltage (page 17-12)
• CV = Charging Voltage
Is the measured charging voltage within the standard voltage?
YES – Faulty battery
NO – GO TO STEP 6.
6. Regulator/rectifier System Inspection
Check the voltage and resistance at the regulator/rectifier connectors (page 17-13).
Are the results of checked voltage and resistance correct?
YES – Faulty regulator/rectifier
NO – • Open circuit in related wire
• Loose or poor contacts of related terminal
• Shorted wire harness
17-6
BATTERY/CHARGING SYSTEM/ALTERNATOR
RIGHT SIDE COVER
REMOVAL/INSTALLATION
Remove the cooling fan (page 7-10). RIGHT SIDE COVER BOLTS
Remove the mounting bolts and right side cover.
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FLYWHEEL/ALTERNATOR STATOR
DOWEL PINS
REMOVAL
Remove the following:
UNIVERSAL HOLDER NUT/WASHER
– Right main pipe side cover (page 3-16)
– Right side cover (page 17-7)
Hold the flywheel with the special tool and loosen the
flywheel nut.
TOOL:
Universal holder 07725-0030000
Remove the flywheel nut and washer.
FLYWHEEL PULLER
17-7
BATTERY/CHARGING SYSTEM/ALTERNATOR
Disconnect the alternator/CKP sensor 3P connector.
ALTERNATOR/CKP SENSOR
Release the alternator/CKP sensor wire from the wire 3P CONNECTOR
band and guide.
WIRE GUIDE
WIRE BAND
Tonngokhong BikerVietNam
Remove the two bolts and set plate from the CKP
sensor.
SET PLATE
BOLT
SOCKET
BOLTS
17-8
BATTERY/CHARGING SYSTEM/ALTERNATOR
Be careful not to Remove the woodruff key.
WOODRUFF KEY
damage the key
and groove.
INSTALLATION
Be careful not to Install the woodruff key into the crankshaft key groove.
WOODRUFF KEY
damage the key
Clean any oil and grease from the crankshaft.
and groove.
Tonngokhong BikerVietNam
Set the stator onto the stator base.
Install and tighten the stator mounting socket bolts to
the specified torque.
TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft)
STATOR
SOCKET
BOLTS
Install the set plate onto the CKP sensor and tighten the
WIRE HOLDER GROMMET
mounting bolts
Route the wire properly and set the wire grommet into
the right crankcase groove.
Set the wire holder and tighten the holder bolt.
SET PLATE
BOLT
17-9
BATTERY/CHARGING SYSTEM/ALTERNATOR
Route the Install the wire band bosses.
alternator/CKP ALTERNATOR/CKP
sensor wire SENSOR WIRE
properly
(page 1-14).
WIRE GUIDE
WIRE BAND
Install the flywheel onto the crankshaft by aligning the Align (WOODRUFF KEY/KEY WAY)
key way on the flywheel with the key on the crankshaft.
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FLYWHEEL
WASHER
17-10
BATTERY/CHARGING SYSTEM/ALTERNATOR
Install the flywheel nut.
NUT
Hold the flywheel with the special tool and tighten the
nut to the specified torque.
TOOL:
Universal holder 07725-0030000
ALTERNATOR INSPECTION
Remove the front lower cover (page 3-17).
Disconnect the alternator/CKP sensor 3P connector.
Check the resistance between the following terminals.
STANDARD:
Charging coil (White – ground):
0.2 – 1.0 ǡ (at 20°C/68°F)
Replace the alternator stator if measured readings are
far beyond the standard.
ALTERNATOR/CKP SENSOR
3P CONNECTOR
Tonngokhong BikerVietNam
W
BATTERY
REMOVAL/INSTALLATION
17-11
BATTERY/CHARGING SYSTEM/ALTERNATOR
VOLTAGE INSPECTION
Measure the battery voltage using a commercially
available digital multimeter.
VOLTAGE (20°C/68°F):
Fully charged: 13.0 – 13.2 V
Under charged: Below 12.4 V
BATTERY TESTING
Refer to the instructions that are appropriate to the
battery testing equipment available to you.
TOOL:
Battery tester BM-210, BATTERY
MATE or equiva-
lent
CHARGING SYSTEM
CURRENT LEAKAGE TEST
Remove the front top cover (page 3-4).
(–) PROBE (+) PROBE
Turn the ignition switch to OFF and disconnect the
Tonngokhong BikerVietNam
negative (–) cable from the battery.
Connect the ammeter (+) probe to the negative (–)
cable and the ammeter (–) probe to the battery (–)
terminal.
With the ignition switch turned to OFF, check for current
leakage.
17-12
BATTERY/CHARGING SYSTEM/ALTERNATOR
CHARGING VOLTAGE INSPECTION
REGULATOR/RECTIFIER
REMOVAL/INSTALLATION
Remove the fuel lid/center cover (page 3-18).
REGULATOR/
Turn the ignition switch to OFF. RECTIFIER BOLTS
Disconnect the regulator/rectifier 6P (White) connector.
Remove the bolts and the regulator/rectifier.
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Installation is in the reverse order of removal.
6P (White) CONNECTOR
SYSTEM INSPECTION
Remove the fuel lid/center cover (page 3-18).
Disconnect the regulator/rectifier 6P (White) connector
and check it for loose contact or corroded terminals.
If the battery charging voltage reading (page 17-13) is
out of the specification, inspect the connector terminals
(wire harness side) as follows:
Item Terminal Specification
Battery charging Red/white (+) and Battery voltage
line ground (–) should register
Charging coil White and 0.2 – 1.0 Ω
line ground (at 20° C/68° F)
REGULATOR/RECTIFIER
Ground line Green and ground Continuity should
6P (White) CONNECTOR
exist
17-13
BATTERY/CHARGING SYSTEM/ALTERNATOR
If all components of the charging system are normal
and there are no loose connections, replace the
regulator/rectifier unit.
R R/W W G W
REGULATOR/RECTIFIER
6P (White) CONNECTOR
R R/W W G W
REGULATOR/RECTIFIER
6P (White) CONNECTOR
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R R/W W G W
REGULATOR/RECTIFIER
6P (White) CONNECTOR
17-14
18. IGNITION SYSTEM
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18
18-1
IGNITION SYSTEM
SYSTEM LOCATION
IGNITION SYSTEM
IGNITION SWITCH
SIDESTAND
SWITCH
IGNITION COIL
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CKP SENSOR
SPARK PLUG ENGINE CONTROL
MODULE (ECM)
SYSTEM DIAGRAM
Bl: Black
Y: Yellow
Bu: Blue
G: Green
MAIN FUSE R: Red
15 A IGNITION SWITCH
W: White
Bl
G R
G/R Bl
BATTERY IGNITION
CKP SENSOR COIL
Bl G/W G/Bl G/W
Bu/Y
G R/W R/Bl W G/R G G/Bl G G
W/Y
REGULATOR/ ECM
ALTERNATOR
RECTIFIER SPARK
PLUG
SIDESTAND
SWITCH
18-2
IGNITION SYSTEM
SERVICE INFORMATION
GENERAL
• The ECM may be damaged if dropped. Also, if the connector is disconnected when current is flowing, the excessive voltage may
damage the ECM. Always turn the ignition switch OFF before servicing.
• Use spark plug with the correct heat range. Using spark plug with an incorrect heat range can damage the engine.
• Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch
is turned ON and current is present.
• When servicing the ignition system, always follow the steps in the troubleshooting (page 18-4).
• The ignition timing cannot be adjusted since the ECM is factory preset.
• A faulty ignition system is often related to poor connections. Check those connections before proceeding.
• Make sure the battery is adequately charged. Using the starter motor with a weak battery results in a slower engine cranking
speed as well as no spark at the spark plug.
• Inspect the following:
– Spark plug (page 4-7)
– Ignition switch (page 20-14)
• Refer to CKP sensor service (page 17-7).
SPECIFICATIONS
ITEM SPECIFICATIONS
Spark plug CPR 7EA – 9 (NGK), U22EPR9 (ND)
Spark plug gap 0.8 – 0.9 mm (0.03 – 0.04 in)
Ignition coil peak voltage 100 V minimum
CKP sensor peak voltage 0.7 V minimum
Ignition timing 10° BTDC at idle speed
TOOLS
Imrie diagnostic tester (model 625) Test probe
Tonngokhong BikerVietNam
Peak voltage adaptor
07HGJ-0020100
07ZAJ-RDJA110
18-3
IGNITION SYSTEM
TROUBLESHOOTING
• Inspect the following before diagnosing the system.
– Faulty spark plug
– Loose spark plug cap or spark plug wire connection
– Water in the spark plug cap (Leaking the ignition coil secondary voltage)
• “Initial voltage” of the ignition primary coil is the battery voltage with the ignition switch turned ON. (The engine is not cranked by
the starter motor.)
No spark at spark plug
UNUSUAL CONDITION PROBABLE CAUSE (Check in numerical order)
Ignition coil pri- No initial voltage with the ignition 1. An open circuit or loose connection in black wire.
mary voltage switch turned ON. (Other electrical 2. Loose or poor connection of the ignition coil primary wire ter-
components are normal) minal or an open circuit in primary coil.
3. Faulty ECM (in case when the initial voltage is normal when
ECM 33P (Black) connector is disconnected).
Initial voltage is normal, but it drops 1. Incorrect peak voltage adaptor connections. (System is nor-
by 2 – 4 V while cranking the engine. mal if measured voltage is over the specifications with reverse
connections.)
2. Battery is undercharged. (Voltage drops largely when the en-
gine is started.)
3. Loose or poor connection or an open circuit in Green wire of
the ECM.
4. Loose or poor connection or an open circuit in Green/Red wire
between the ignition coil and ECM.
5. A short circuit in the ignition primary coil.
6. Faulty CKP sensor. (Measure peak voltage.)
7. Faulty ECM (in case when above No. 1 through 6 are normal).
Initial voltage is normal but there is 1. Incorrect peak voltage adaptor connections. (System is nor-
no peak voltage while cranking the mal if measured voltage is over the specifications with reverse
engine. connections.)
2. Open circuit or poor connection in Green/white wire or Green
wire of the sidestand switch.
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Initial voltage is normal but peak volt-
3. Faulty sidestand switch.
4. Faulty peak voltage adaptor.
5. Faulty ECM (in case when above No. 1 and 4 are normal).
1. The multimeter impedance is too low; below 10 MΩ/DCV.
age is lower than the standard value. 2. Cranking speed is too slow. (Battery is undercharged.)
3. The sampling timing of the tester and measured pulse were
not synchronized. (System is normal if measured voltage is
over the standard voltage at least once.)
4. Faulty ECM (in case when above No. 1 through 3 are normal).
Initial and peak voltages are normal 1. Faulty spark plug or leaking ignition coil secondary current.
but no spark jumps. 2. Faulty ignition coil.
CKP sensor Peak voltage is lower than the stan- 1. The multimeter impedance is too low; below 10 MΩ/DCV.
dard value. 2. Cranking speed is too slow. (Battery is undercharged.)
3. The sampling timing of the tester and measured pulse were
not synchronized. (System is normal if measured voltage is
over the standard voltage at least once.)
4. Faulty CKP sensor (in case when above No. 1 through 3 are
normal).
No peak voltage. 1. Faulty peak voltage adaptor.
2. Faulty CKP sensor.
18-4
IGNITION SYSTEM
IGNITION SYSTEM INSPECTION
• If there is no spark present at the plug, check all
connections for loose or poor contact before
measuring the peak voltage.
• Use a commercially available digital multimeter
(impedance 10 MΩ/DCV minimum).
• The display value differs depending upon the
internal impedance of the multimeter.
• If the Imrie diagnostic tester (model 625) is used,
follow the manufacturer's instruction.
Connect the peak voltage adapter to the digital
multimeter, or use the imrie diagnostic tester. DIGITAL MULTIMETER
TOOL:
Imrie diagnostic tester (model 625) or
Peak voltage adaptor 07HGJ-0020100
with commercially available digital multimeter (im-
pedance 10 MΩ/DCV minimum)
Tonngokhong BikerVietNam
• Check cylinder compression and check that the
spark plug is installed correctly.
Support the scooter with its centerstand on a level
surface. KNOWN-GOOD SPARK PLUG
Remove the maintenance lid (page 3-9).
Disconnect the spark plug cap from the spark plug.
Connect a known-good spark plug to the spark plug cap
and ground it to the cylinder head cover bolt as done in
a spark test.
18-5
IGNITION SYSTEM
With the ignition coil primary wires connected, connect Black
the imrie diagnostic tester or peak voltage adaptor IGNITION COIL
probes to the ignition coil primary terminal and ground.
TOOL:
Imrie diagnostic tester (model 625) or
Peak voltage adaptor 07HGJ-0020100
with commercially available digital multimeter (im-
pedance 10 MΩ/DCV minimum)
Tonngokhong BikerVietNam
CKP SENSOR PEAK VOLTAGE
• Check all system connections before inspection. If
the system is disconnected, incorrect peak voltage
might be measured.
• Check cylinder compression and check that the
spark plug is installed correctly.
Turn the ignition switch OFF.
Disconnect the ECM 33P (Black) connector (page 6- ECM 33P (Black) CONNECTOR
42). (Wire side/female terminals)
18-6
IGNITION SYSTEM
Remove the front lower cover (page 3-17).
CKP SENSOR 3P CONNECTOR
Turn the ignition switch OFF.
Disconnect the CKP sensor 3P connector and connect
the imrie diagnostic tester or peak voltage adaptor
probes to the connector terminals of the CKP sensor
side.
TOOL:
Imrie diagnostic tester (model 625) or
Peak voltage adaptor 07HGJ-0020100
with commercially available digital multimeter (im-
pedance 10 MΩ/DCV minimum)
IGNITION COIL
Tonngokhong BikerVietNam
REMOVAL/INSTALLATION
Remove the following:
SPARK PLUG CAP
– Body cover (page 3-14)
– Maintenance lid (page 3-9)
Disconnect the spark plug cap.
Release the wire band boss from the radiator cover and
wire guide. GUIDE
IGNITION COIL
18-7
IGNITION SYSTEM
IGNITION TIMING
• The ignition timing can not be adjusted since the
ECM is factory preset.
Start the engine, warm it up to normal operating
temperature and stop it. INDEX
MARK
Read the Connect the timing light to the spark plug wire.
instructions for "F" MARK
timing light
Start the engine and let it idle (1,700 ± 100 min-1 (rpm)).
operation. The ignition timing is correct if the index mark on the
right crankcase aligns with the "F" mark on the flywheel.
If the ignition timing is incorrect, inspect the CKP sensor
(page 18-6).
TIMING LIGHT
SIDESTAND SWITCH
REMOVAL/INSTALLATION
Remove the left main pipe side cover (page 3-16).
SIDESTAND SWITCH 3P
Disconnect the sidestand switch 3P (Green) connector. (Green) CONNECTOR
Release the sidestand switch wire from the wire guide.
Tonngokhong BikerVietNam
WIRE GUIDE
WIRE GUIDES
18-8
IGNITION SYSTEM
Remove the bolt and sidestand switch.
Install the sidestand switch while aligning its groove BOLT
with the spring pin.
Install and tighten the sidestand switch bolt.
Route the wire Secure the sidestand switch wire with the frame
harness properly clamps.
(page 1-14).
Connect the sidestand switch 3P (Green) connector.
Install the left main pipe side cover (page 3-16).
INSPECTION
Remove the right main pipe side cover (page 3-16).
Turn the ignition switch "OFF".
Disconnect the ECM 33P (Black) connector.
Tonngokhong BikerVietNam
Check for continuity between the ECM 33P (Black)
33P (Black) CONNECTOR
Green/
White
18-9
MEMO
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19. ELECTRIC STARTER SYSTEM
TROUBLESHOOTING·································19-4
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19
19-1
ELECTRIC STARTER SYSTEM
SYSTEM LOCATION
ELECTRIC STARTER SYSTEM
STARTER MOTOR
RESISTOR
MAIN FUSE 15A
BATTERY
ENGINE CONTROL
Bl: Black
Y: Yellow
G: Green
R: Red
MAIN FUSE LIGHTING SUB FUSE W: White
15 A CUT RELAY 10 A Br: Brown
R R/W R/W R/Y Bl/Br P: Pink
R R/W
Bl
REGULATOR/ Bl Bl
R/Bl
RECTIFIER FRONT REAR
G IGNITION BRAKE BRAKE
BATTERY SWITCH LIGHT LIGHT
SWITCH SWITCH
G/Y G/Y
G R Bl
STARTER
G/Y
RELAY
Bl W/Bl P
19-2
ELECTRIC STARTER SYSTEM
SERVICE INFORMATION
GENERAL
• Always turn the ignition switch "OFF" before servicing the starter motor. The motor could suddenly start, causing serious injury.
• A weak battery may be unable to turn the starter motor quickly enough, or supply adequate ignition current.
• The starter motor can be serviced with the engine in the frame.
• When checking the starter system, always follow the steps in the troubleshooting (page 19-4).
• If the current is kept flowing through the starter motor to turn it while the engine is not cranking over, the starter motor may be
damaged.
• Refer to the following component information.
– Ignition switch (page 20-13)
SPECIFICATION
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Starter motor brush length 7.0 (0.28) 3.5 (0.14)
Starter switch resistor resistance (20°C/68°F) 9 – 12 Ω –
TORQUE VALUE
Starter motor cable screw 2 N·m (0.2 kgf·m, 1.5 lbf·ft)
Starter motor case screw 2 N·m (0.2 kgf·m, 1.5 lbf·ft)
TOOL
Test probe
07ZAJ-RDJA110
Tonngokhong BikerVietNam
19-3
ELECTRIC STARTER SYSTEM
TROUBLESHOOTING
Starter motor does not turn
1. Standard inspection
Check the following:
– Battery condition
– Burned fuses
– Brake light operation (page 4-19)
– Lighting cut relay operation (page 20-19)
Are the above items in good condition?
YES – GO TO STEP 2.
NO – Replace or repair the malfunction part(s).
2. Starter relay operation
Turn the ignition switch ON.
Squeeze the brake lever fully and push the starter switch.
You should hear the relay "CLICK" when the starter switch is depressed.
Is the "CLICK" heard?
YES – GO TO STEP 3.
NO – GO TO STEP 5.
3. Starter motor inspection
Turn the ignition switch OFF.
Apply battery voltage to the starter motor directly and check the operation. (A large amount of current flows,
so do not use a thin wire.)
Does the starter motor turn?
YES – GO TO STEP 4.
Tonngokhong BikerVietNam
NO – Inspect the starter motor (page 19-9).
4. Starter relay continuity Inspection
Check the starter relay for continuity (page 19-11).
Is there continuity?
YES – • Loose or poorly connected starter motor cable.
• Loose or poorly connected starter relay connector terminal.
• Open circuit in starter motor ground cable.
• Open circuit in Red wire between the battery and starter relay.
• Open circuit in Red/white wire between the starter relay and starter motor.
NO – Faulty starter relay.
5. Engine control module (ECM) system circuit inspection
Turn the ignition switch ON and check the PGM-FI malfunction indicator lamp (MIL).
Does the indicator stay off?
YES – Inspect the ECM power/ground line (page 6-43).
NO – GO TO STEP 6.
6. Starter relay coil line inspection
Turn the ignition switch OFF.
Disconnect the ECM 33P (Black) connector.
Turn the ignition switch ON and measure the battery voltage between the ECM 33P (Black) connector and
ground.
CONNECTION: No.33 (Yellow/Green) (+) – Ground (–)
Does the battery voltage exist?
YES – GO TO STEP 7.
NO – • Loose or poorly connected connector.
• Open circuit in Black wire between the starter relay and ignition switch.
• Open circuit in Yellow/Green wire between the starter relay and ECM.
19-4
ELECTRIC STARTER SYSTEM
7. Brake light switch/starter switch line inspection
Disconnect the ECM 33P (Black) connector.
Ground the ECM 33P connector White/Black terminal of the wire harness side with a jumper wire.
Turn the ignition switch ON.
Squeeze the brake lever fully and push the starter switch then measure the battery voltage between the
ECM 33P connector and ground.
CONNECTION: No.29 (Yellow/Green) (+) – Ground (–)
Does the battery voltage exist?
YES – Replace the ECM with a known good one and recheck.
NO – • Loose or poorly connected connector.
• Open circuit in Green/Yellow wire between the brake light switch and starter switch.
• Faulty starter switch (page 20-15).
• Open or short circuit in Yellow/Green wire between the starter switch and ECM.
• Open or short circuit in Black/Brown or Black wire between the brake light switch and sub fuse.
• Open or short circuit in Red/Yellow wire between the sub fuse and lighting cut relay.
• Open circuit in Red/White wire between the lighting cut relay and main fuse.
Tonngokhong BikerVietNam
– Terminals connected improperly.
• Faulty starter pinion.
19-5
ELECTRIC STARTER SYSTEM
STARTER MOTOR
REMOVAL
Remove the air cleaner housing (page 6-32).
MOUNT BOLT
Remove the mount bolts and ground cable.
MOUNT BOLT/
GROUND CABLES
Tonngokhong BikerVietNam
Remove the O-ring from the starter motor.
SCREW/GROUND CABLES
STARTER
MOTOR
O-RING
INSTALLATION
Coat a new O-ring with engine oil and install it into the
starter motor groove. STARTER
MOTOR
O-RING
19-6
ELECTRIC STARTER SYSTEM
Install the starter motor cable and screw, then tighten
the screw to the specified torque. SCREW/STARTER DUST COVER
MOTOR CABLE
TORQUE: 2 N·m (0.2 kgf·m, 1.5 lbf·ft)
Put the dust cover back in the appropriate position.
Install the ground cable and screw, then tighten the
screw to the specified torque.
TORQUE: 2 N·m (0.2 kgf·m, 1.5 lbf·ft)
SCREW/GROUND CABLES
MOUNT BOLT/
GROUND CABLES
DISASSEMBLY
Tonngokhong BikerVietNam
Remove the screws and starter motor case.
Remove the following:
– Armature
– Bracket
– Springs
– Gasket
MOTOR CASE
ARMATURE
SPRINGS
GASKET
BRACKET
19-7
ELECTRIC STARTER SYSTEM
ASSEMBLY
Install the springs in the brush holders.
BRUSH HOLDERS
SPRINGS
BRUSHES
Tonngokhong BikerVietNam
The coil may be
damaged if the
magnet pulls the
Install a new gasket onto the bracket.
Install the bracket and armature to the motor case while
holding the bracket side armature shaft tightly.
BRACKET MOTOR CASE
armature against
the case.
ARMATURE
GASKET
19-8
ELECTRIC STARTER SYSTEM
INSPECTION
BRUSH
Inspect the brushes for damage and measure the brush
length.
ARMATURE
Do not use emery Inspect the commutator bars of the armature for
or sand paper on discoloration. COMMUTATOR BARS
the commutator.
Bars discolored in pairs indicate shorted coils.
Tonngokhong BikerVietNam
Check for continuity between each pair of commutator
CONTINUITY:
bars.
There should be continuity.
19-9
ELECTRIC STARTER SYSTEM
STARTER PINION
REMOVAL
Remove the left crankcase cover (page 11-6).
STARTER PINION HOLDER
Remove the starter pinion holder.
Tonngokhong BikerVietNam
INSTALLATION
Apply 0.1 – 0.3 g of grease (Shell ALVANIA R3 or
STARTER PINION
IDEMITSU AUTOREX B or equivalent) to the ends of
the starter pinion.
Install the starter pinion into the left crankcase.
19-10
ELECTRIC STARTER SYSTEM
INSPECTION
Check that the starter pinion operates smoothly.
DRIVEN GEAR
Check the pinion gear teeth and shaft for wear or
damage.
Check the starter driven gear teeth of the drive pulley
face for wear or damage.
PINION GEAR
STARTER RELAY
REMOVAL/INSTALLATION
Remove the front top cover (page 3-4).
Remove the starter relay from the stay. STARTER RELAY
Tonngokhong BikerVietNam
Disconnect the starter relay 5P connector.
Installation is in the reverse order of removal.
5P CONNECTOR
OPERATION INSPECTION
Remove the front top cover (page 3-4).
Turn the ignition switch "ON".
Squeeze the brake lever fully and push the starter
switch.
The system is normal if the starter relay clicks.
If you don’t hear the relay "CLICK", inspect the
following:
– Starter relay coil circuit (page 19-12)
– Brake light switch/starter switch circuit (page 20-17)
– ECM power/ground circuit (page 6-43)
If you hear the relay "CLICK", but starter does not turn, STARTER RELAY
inspect the starter relay continuity (page 19-14).
19-11
ELECTRIC STARTER SYSTEM
STARTER RELAY COIL CIRCUIT
INSPECTION
Remove the right main pipe side cover (page 3-16).
ECM 33P (Black) CONNECTOR
Disconnect the ECM 33P (Black) connector.
Turn the ignition switch "ON".
Measure the voltage between the ECM connector of the
wire harness side and ground.
TOOL:
Test probe 07ZAJ-RDJA110
IGNITION
SWITCH From
REGULATOR
Y/G Bl /RECTIFIER
STARTER
RELAY
Tonngokhong BikerVietNam
19-12
ELECTRIC STARTER SYSTEM
BRAKE LIGHT SWITCH/STARTER
SWITCH CIRCUIT INSPECTION
Remove the body cover (page 3-14).
ECM 33P (Black) CONNECTOR
Disconnect the ECM 33P (Black) connector.
Ground the ECM 33P connector White/Black terminal of
the wire harness side with a jumper wire.
CONNECTION: White/Black – Ground
Turn the ignition switch "ON".
Squeeze the brake lever fully and push the starter
switch.
Measure the voltage between the ECM connector of the
wire harness side and ground.
TOOL:
Test probe 07ZAJ-RDJA110
ECM 33P (Black)
CONNECTION: No.29 (Yellow/Green) (+) – Ground (–) CONNECTOR
JUMPER
If the battery voltage appears only when the ignition WIRE
switch is "ON", the brake lever is fully squeezed and the
starter switch is pushed, the circuit is normal.
W/Bl
Y/G
From
LIGHTING STARTER
CUT SWITCH
RELAY
G/Y
Bl Bl
From LIGHTING
CUT RELAY
19-13
ELECTRIC STARTER SYSTEM
STARTER RELAY CONTINUITY
INSPECTION
Remove the starter relay (page 19-11).
Connect a fully charged 12 V battery positive wire to the
relay switch terminal A and negative wire to the terminal
B.
Check for continuity at the terminal C and terminal D.
There should be continuity between the C and D
terminals while the battery is connected, and no
continuity when the battery is disconnected.
A C
B
D STARTER RELAY
A B C D
Tonngokhong BikerVietNam
19-14
20. LIGHTS/METERS/SWITCHES
Tonngokhong BikerVietNam
COOLANT TEMPERATURE
WARNING INDICATOR·····························20-10
LIGHTING CUT RELAY ····························20-19
RESISTOR·················································20-21
20
20-1
LIGHTS/METERS/SWITCHES
ELECTRICAL SYSTEM LOCATION
LIGHTS/METERS/SWITCHES
SPEEDOMETER
TURN SIGNAL LIGHT RELAY
DIMMER SWITCH
FRONT BRAKE
LIGHT SWITCH
TURN SIGNAL SWITCH
STARTER SWITCH
REAR BRAKE LIGHT
SWITCH
IGNITION SWITCH
STARTER MOTOR
HORN SWITCH
STARTER RELAY
RESISTOR
SUB FUSE 10A
BATTERY
REGULATOR/
RECTIFIER
ECT SENSOR
SPARK PLUG
SIDESTAND SWITCH
ALTERNATOR
20-2
LIGHTS/METERS/SWITCHES
SERVICE INFORMATION
GENERAL
• Check the battery condition before performing any inspection that requires proper battery voltage.
• Use an electric heating element to heat the coolant for the ECT sensor inspection. Keep all flammable materials away from the
electric heating element. Wear protective clothing, insulated gloves and eye protection.
• A continuity test can be made with the switches installed on the scooter.
• Route the wires and cables properly after servicing each component (page 1-14).
• Refer to the ECT sensor for PGM-FI systems inspection (page 6-45).
• The following color codes are used throughout this section.
Bu: Blue G: Green Lg: Light Green W: White
Bl: Black Gr: Gray O: Orange Y: Yellow
Br: Brown Lb: Light Blue R: Red
SPECIFICATIONS
ITEM SPECIFICATIONS
Bulbs Headlight 12 V – 25/25 W x 2
Tail light 12 V – 5 W
Brake light LED
Front turn signal light 12 V – 10 W x 2
Rear turn signal light 12 V – 10 W x 2
Instrument light 12 V – 1.7 W x 2
PGM-FI malfunction indicator lamp 12 V – 1.7 W
(MIL)
High beam indicator 12 V – 1.7 W
Turn signal indicator 12 V – 3 W x 2
Coolant temperature warning indi- LED
cator
Fuse Main fuse 15 A x 1
Tonngokhong BikerVietNam
Sub fuse
Resistor resistance (20°C/68°F)
10 A x 1
9.5 – 10.5 ǡ
TOOL
Test probe
07ZAJ-RDJA110
20-3
LIGHTS/METERS/SWITCHES
LIGHTING CIRCUIT INSPECTION
HEADLIGHT/METER LIGHTS/TEAIL
LIGHT DO NOT COME ON
Standard Inspection
Check the following:
– Burned out bulb or bulb with unspecified wattage
– Loose connector
– Dimmer switch
If the above items are normal, check as follows:
Lighting Circuit Inspection
Remove the fuel lid/center cover (page 3-18).
HEADLIGHT 6P
Disconnect the following connectors: CONNECTOR
– Headlight 6P connector
– Regulator/rectifier 6P (White) connector
Turn the dimmer switch to Lo position.
Check the continuity between the White terminal of the
headlight 6P connector and Yellow terminal of the
regulator/rectifier 6P connector.
Turn the dimmer switch to Hi position. REGULATOR/
Check the continuity between the Blue terminal of the RECTIFIER 6P
headlight 6P connector and Yellow terminal of the (White)
regulator/rectifier 6P connector. CONNECTOR
If there is continuity, check the following:
HEADLIGHT 6P
CONNECTOR
Tonngokhong BikerVietNam
Bu W
DIMMEW SWITCH
Lo
Hi
Y
REGULATOR/RECTIFIER
6P (White) CONNECTOR
20-4
LIGHTS/METERS/SWITCHES
Ground Inspection
Check the continuity between the Green terminal of the
headlight 6P connector and ground. HEADLIGHT 6P CONNECTOR
Tonngokhong BikerVietNam
Install the dust
Install the bulb socket by aligning the tabs on the bulb
socket with the slots on the headlight unit.
Push the bulb socket in, turn it clockwise.
Install the dust cover tightly on the headlight unit.
cover with its "TOP"
Install the main pipe upper cover (page 3-5).
mark facing up.
HEADLIGHT BULB
"TOP" MARK
DUST COVER
20-5
LIGHTS/METERS/SWITCHES
FRONT TURN SIGNAL LIGHT
Remove the main pipe upper cover (page 3-5).
BULB SOCKET
Remove the front turn signal light bulb socket from the
light unit.
Remove the bulb from the socket and replace it with a
new one.
Install the turn signal light bulb socket.
Install the main pipe upper cover (page 3-5).
Tonngokhong BikerVietNam
lever applied.
If any LED does not turn on, replace the rear
combination light unit.
BRAKE LIGHT
BULB REPLACEMENT
TAILLIGHT
Be careful not to Remove the screws and taillight lens.
damage the lens. TAILLIGHT BULB
Remove the taillight bulb from the socket and replace it
with a new one.
Installation is in the reverse order of removal.
SCREWS
TAILLIGHT LENS
20-6
LIGHTS/METERS/SWITCHES
REAR TURN SIGNAL LIGHT
Remove the following:
TURN SIGNAL LIGHT BULB
– Body garnish (page 3-10)
– Tail light lens (page 20-6)
Be careful not to Remove the screw.
damage the lens. Remove the rear turn signal light lens backward.
Remove the rear turn signal light bulb from the socket
and replace it with a new one.
Installation is in the reverse order of removal.
TURN SIGNAL
SCREW
LIGHT LENS
SPEEDOMETER
Tonngokhong BikerVietNam
BULB REPLACEMENT
Remove the front handlebar cover (page 3-8).
Installation is in the reverse order of removal.
BULB
BULB SOCKET
20-7
LIGHTS/METERS/SWITCHES
REMOVAL/INSTALLATION
Remove the rear handlebar cover (page 3-8).
Disconnect the following connectors: SCREWS
SPEEDOMETER
Tonngokhong BikerVietNam
20-8
LIGHTS/METERS/SWITCHES
DISASSEMBLY/ASSEMBLY
Remove the following:
– Turn signal light relay
– Bulb sockets
– Terminal screws and wire terminals
– Wire band screw and speedometer sub harness
– Four screws and meter lens
– Two meter unit screws/washers and speedometer/
fuel meter unit
– Coolant temperature warning indicator unit
– Meter case
Assembly is in the reverse order of disassembly.
• Be careful not to put fingerprints on the meter panel.
• Route the speedometer sub harness as shown.
METER CASE
FUEL METER
COOLANT TEMPERATURE
TERMINAL SCREWS
WARNING INDICATOR UNIT
BULB SOCKETS
SCREWS
METER LENS
Tonngokhong BikerVietNam
WIRE
BAND
SCREW
WIRE BAND
SCREWS/
WASHERS
SPEEDOMETER
SUB HARNESS
SPEEDOMETER/
FUEL METER UNIT
SPEEDOMETER WIRE
ROUTING: FUEL METER WIRE (Bu/W)
COOLANT TEMPERATURE
WARNING INDICATOR (Bl)
METER LIGHT
COOLANT TEMPERATURE WARNING MIL (Bl, G)
INDICATOR (Lg/R) (Bl, Bu/Y)
20-9
LIGHTS/METERS/SWITCHES
COOLANT TEMPERATURE WARNING
INDICATOR
SYSTEM INSPECTION
• Coolant temperature warning indicator turns on
when the coolant temperature becomes higher than
certain temperature.
• Before performing the system inspection, make sure
that the following item are normal.
– Cooling system flow
– Battery condition
– Burned fuse
– Other meter indicators
Turn the ignition switch ON and check the coolant
temperature warning indicator.
When the engine is cold, the indicator should not come
on.
Remove the luggage box (page 3-11).
Disconnect the engine coolant temperature (ECT)
sensor 2P (Black) connector.
Short the ECT sensor connector terminals of the wire
harness side with the jumper wire.
CONNECTION: Pink/White – Green/Orange
Tonngokhong BikerVietNam
causes damage to
the following:
the coolant
temperature – Light green/Red wire between the meter and ECM
warning indicator. for short circuit
– Pink/White wire between the ECT sensor and ECM
for short circuit
– ECT sensor (page 6-45)
– Indicator unit for short circuit
If the indicator goes off with the ECT sensor connector
shorted, check the following:
– Light green/Red wire between the meter and ECM
for open circuit
– ECT sensor wire for open circuit
– Indicator unit for open circuit COOLANT TEMPERATURE
If above inspections are normal, replace the ECM with a WARNING INDICATOR
new one and recheck.
SUB FUSE
10A
Bl Bl/Br
Lg/R
From
P/W G/O LIGHTING
CUT
ECM RELAY
JUMPER WIRE
ECT SENSOR 2P
(Black) CONNECTOR
20-10
LIGHTS/METERS/SWITCHES
FUEL METER/FUEL LEVEL SENSOR
SYSTEM INSPECTION
WHEN FUEL IS ABOUT FULL BUT NEEDLE DOES
NOT MOVE
Before performing the system inspection, check the
following: FUEL PUMP/FUEL LEVEL
SENSOR 5P CONNECTOR
– Battery condition
– Burned fuse
– Horn operation
Remove the right main pipe side cover (page 3-16).
Disconnect the fuel pump/fuel level sensor 5P
connector.
Short the connector terminals of the wire harness side
with the jumper wire.
CONNECTION: Yellow/White – Green/Black
Do not leave the Turn the ignition switch ON, check if the fuel meter
terminals needle moves to "F".
connected with The needle moves if the system circuit is normal.
jumper wire for a In that case, check the fuel level sensor (page 20-11). FUEL METER
long time, as it
If the needle does not move, check the following:
causes damage to
the fuel meter. – Yellow/White wire between the fuel pump/fuel level
sensor and speedometer for open or short circuit
– Black wire between the speedometer 4P connector
and fuel meter for open circuit Bl Bu/W Y/W
– Green/Black and Blue/White wire between the fuel
pump/fuel level sensor and ground for open circuit JUMPER
Tonngokhong BikerVietNam
– Green/Black and Blue/White wire between the WIRE
speedometer and ground for open circuit Bl/Br G/B Y/W
If the wire is normal, replace the speedometer panel G/B
with a new one, and recheck.
From
LIGHTING
CUT
RELAY FUEL PUMP/FUEL LEVEL
SENSOR 5P CONNECTOR
20-11
LIGHTS/METERS/SWITCHES
FUEL LEVEL SENSOR REMOVAL/
INSTALLATION
Remove the fuel pump unit (page 6-29).
Black Red
Disconnect the fuel level sensor Red and Black wire
connectors.
Release the wires from the guides of the fuel pump unit.
Install the fuel level sensor in the reverse order of
removal.
CONNECTORS
Tonngokhong BikerVietNam
Remove the fuel level sensor from the fuel pump unit by
GUODES WIRES
20-12
LIGHTS/METERS/SWITCHES
IGNITION SWITCH
REMOVAL
Remove the steering stem (page 14-21).
CABLE
Disconnect the ignition switch 2P connector.
Release the fuel lid cable from the cable holder and
disconnect the cable from the opener.
2P CONNECTOR
KEY SHUTTER/
Tonngokhong BikerVietNam
INSTALLATION
Set the ignition switch while aligning its grooves with the
SCREWS IGNITION SWITCH
GROOVES
TABS
Align
20-13
LIGHTS/METERS/SWITCHES
Set the key shutter and ignition switch in position.
BOLT
Install and tighten the bolt and new screws.
• Push the key shutter against the ignition switch
during installation. If the key shutter is not seated on
the ignition switch, it will prevent the ignition key
from being inserted completely.
KEY SHUTTER/
SCREWS IGNITION SWITCH
Connect the fuel lid cable onto the opener and install
the cable onto the cable holder. CABLE
Connect the ignition switch 2P connector.
Install the steering stem (page 14-23).
2P CONNECTOR
INSPECTION
Tonngokhong BikerVietNam
Remove the main pipe upper cover (page 3-5).
Disconnect the ignition switch 2P connector.
Check for continuity at the terminals of the switch side
connector in each switch position.
Continuity should exist between the color coded wires
as follows:
IGNITION SWITCH 2P
CONNECTOR
IGNITION SWITCH
IGNITION
SWITCH
BAT BAT1
ON
OFF
LOCK
COLOR R/Bl Bl
20-14
LIGHTS/METERS/SWITCHES
HANDLEBAR SWITCHES
RIGHT HANDLEBAR SWITCH
INSPECTION
Remove the front handlebar cover (page 3-8).
Disconnect the starter switch 3P (Black) connector.
Check for continuity between the terminals of the starter
switch connector in each switch position.
Continuity should exist between the color coded wires
as follows:
STARTER SWITCH 3P
(Black) CONNECTOR
Tonngokhong BikerVietNam
STARTER SWITCH
STARTER SWITCH
ST ECM
FREE
PUSH
COLOR G/Y Y/G
20-15
LIGHTS/METERS/SWITCHES
LEFT HANDLEBAR SWITCH
INSPECTION
Remove the front handlebar cover (page 3-8).
DIMMER SWITCH TURN SIGNAL
Disconnect the following: SWITCH 3P (Red)
3P CONNECTOR
– Dimmer switch 3P connector CONNECTOR
– Turn signal light switch 3P (Red) connector
– Horn switch 3P (Black) connector
Check for continuity between the wire terminals of the
dimmer switch, turn signal switch and horn switch
connector in each switch position.
Continuity should exist between the color coded wires
as follows:
HORN SWITCH
3P (Black)
CONNECTOR
DIMMER SWITCH
TURN SIGNAL
LIGHT SWITCH
HORN SWITCH
WR W WL
ON
OFF
LOCK
COLOR Lb GR O
DIMMER SWITCH
Hi Lo HL
HI
(N)
LO
COLOR Bu W Y
HORN SWITCH
BAT HO
FREE
PUSH
COLOR Bl Lg
20-16
LIGHTS/METERS/SWITCHES
BRAKE LIGHT SWITCH
FRONT
Remove the front handlebar cover (page 3-8).
Disconnect the front brake light switch wire connectors
and check for continuity of the switch side.
CONNECTION: Green/Yellow – Black
There should be continuity with the front brake lever
squeezed, and there should be no continuity when the
front brake lever is released.
REAR
Remove the front handlebar cover (page 3-8).
Disconnect the rear brake light switch wire connectors
and check for continuity at the wire connector terminals
of the switch side.
CONNECTION: Green/Yellow – Black
There should be continuity with the rear brake lever
squeezed, and there should be no continuity when the
rear brake lever is released.
HORN
REMOVAL/INSTALLATION
Remove the front lower cover (page 3-17).
CONNECTORS
Disconnect the horn connectors from the horn.
Remove the bolt and horn.
Installation is in the reverse order of removal.
BOLT HORN
20-17
LIGHTS/METERS/SWITCHES
INSPECTION
Remove the front lower cover (page 3-17).
HORN
Disconnect the horn connectors from the horn.
Connect a 12 V battery to the horn terminals.
The horn is normal if it sounds when the 12 V battery is
connected to the horn terminals.
Tonngokhong BikerVietNam
Short the turn signal light relay 2P connector terminals
of the wire harness side with a jumper wire.
CONNECTION: Black – Gray
TURN SIGNAL LIGHT RELAY
2P CONNECTOR
O
Bl Gr
Lb
G
Bl/Br
SUB FUSE
10A TURN SIGNAL
LIGHT SWITCH
20-18
LIGHTS/METERS/SWITCHES
LIGHTING CUT RELAY
REMOVAL/INSTALLATION
Remove the main pipe upper cover (page 3-5).
LIGHTING CUT RELAY
Remove the lighting cut relay.
Installation is in the reverse order of removal.
OPERATION INSPECTION
Remove the main pipe upper cover (page 3-5).
LIGHTING CUT RELAY
Turn the ignition switch ON.
The lighting cut relay coil is normal if the lighting cut
relay clicks.
If you hear the lighting cut relay "CLICK", but horn does
not operate when the horn switch is pushed, inspect the
following:
– Lighting cut relay continuity (page 20-19)
– Lighting cut relay switch line (page 20-20)
If you do not hear the relay "CLICK", inspect the
Tonngokhong BikerVietNam
following:
– Lighting cut relay coil line (page 20-20)
– Lighting cut relay continuity (page 20-19)
CONTINUITY INSPECTION
Turn the ignition switch OFF.
LIGHTING CUT RELAY
Remove the lighting cut relay (page 20-19).
Connect the ohmmeter to the following lighting cut relay
terminals.
Connection: A – B
Connect the 12 V battery to the following lighting cut
relay terminals.
Connection: C – D
There should be continuity between the relay terminals
A B
while the battery is connected, and no continuity when
the battery is disconnected.
C D
D C B A
20-19
LIGHTS/METERS/SWITCHES
SWITCH LINE INSPECTION
Turn the ignition switch OFF.
LIGHTING CUT JUMPER
Remove the lighting cut relay (page 20-19). RELAY CONNECTOR WIRE
Short the relay connector terminals of the wire harness
side with a jumper wire.
Connection: Red/White – Red/Yellow
MAIN FUSE
Remove the sub fuse 10 A. 15 A
R/W
Measure the voltage between the sub fuse 10 A
connector of the wire harness side and ground. R/Y
R (–)
Connection: Red/Yellow (+) – Ground (–)
If the battery voltage appears, the lighting cut relay G (+)
switch line is normal.
SUB FUSE 10 A
If the battery voltage does not appear, inspect the
CONNECTOR
following:
– Open circuit in Red and/or Red/White wire between
the battery and lighting cut relay
– Open circuit in Red/Yellow wire between the lighting
cut relay and sub fuse 10 A
Tonngokhong BikerVietNam
Measure the voltage between the lighting cut relay
connector of the wire harness side and ground.
Connection: Black (+) – Ground (–)
MAIN FUSE
IGNITION
SWITCH
Bl
20-20
LIGHTS/METERS/SWITCHES
RESISTOR
INSPECTION
Remove the luggage box (page 3-11).
WIRE CONNECTORS
Disconnect the resistor Pink wire connectors.
Measure the resistance between the Pink wire
terminals of the resistor side and ground.
STANDARD: 9.5 – 10.5 ǡ (20°C/68°F)
If the measured value is far beyond the standard,
replace the resistor.
P P
RESISTOR
REMOVAL/INSTALLATION
Tonngokhong BikerVietNam
Remove the body cover (page 3-14).
Disconnect the resistor Pink wire connectors.
WIRE CONNECTORS
RESISTOR
20-21
MEMO
Tonngokhong BikerVietNam
21. WIRING DIAGRAM
Tonngokhong BikerVietNam
21
21-1
WIRING DIAGRAM
STARTER LIGHTING
SWITCH REGULATOR/ IGNITION CUT STARTER
TURN RELAY RELAY BATTERY
21-2
RECTIFIER SWITCH ECM
SIGNAL MAIN SUB 12V3AH
RELAY FUSE FUSE
NO
15A 10A
BAT
BAT1
LAMP
BATT OUT
EARTH
CHARGE
V OUT
IGP
LG
O2
SG
THL
VCC (5V)
PRC
FLR
PG1
PG2
IGPLS
PCP
TA
SCS
INJ
TW WARN
IACV2A
IACV1A
FI WARN
PCM
TW
SSTAND
PB
STSW
K-LINE
IACV2B
IACV1B
S/RELAY
ST
ECM
DLC
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
HEADLIGHT
12V25W/25W WPC WPC 5P
2P 3P 6P 2P
MINI 4P 33P
Bl W R
6P Bl
Bu Bu
Y
R
R
R
R
G
G
G
Bl
Bl
Bl
Bl
Bl
Bl
W
Br
Br
Gr
W W
Y/R
R/Y
R/Y
G/Y
Y/G
Y/O
Y/G
Y/G
Y/G
G/R
G/O
R/Bl
R/Bl
W/Y
P/W
Bl/R
R/W
G/Bl
G/Bl
Bl/O
W/R
G/Bl
R/W
R/W
R/W
O/W
Br/R
G/W
O/W
W/Bl
Lg/R
Lg/R
Gr/R
W/Bl
Br/Bl
Bu/Y
P/Bu
Bu/Y
Bl/Br
W/Bu
Lb Lb
HEADLIGHT O O
12V25W/25W G G
WIRING DIAGRAM
STANDARD TYPE:
RIGHT FRONT
TURN SIGNAL Lb
LIGHT G RIGHT REAR
12V10W
WIRING DIAGRAMS
G/Y
G
Bl
P
P
O
12V
Bl
G
MIL
Y/R
Y/O
G/O
P/W
Bl/R
Lg
Bl/O
W/R
Br/R
Lg/R
Gr/R
P/Bu
W/Bu
P
P
1.7W
WPC
COOLANT 14P
TEMPERATURE Gr
WARNING
INDICATOR
Bl
Y/R
Y/O
G/O
P/W
Bl/R
Bl/O
W/R
Br/R
Lg/R
Gr/R
P/Bu
W/Bu
REAR BRAKE HORN
LIGHT SWITCH
Bl Bl
G
G
W
W/Y
RESISTOR RESISTOR
Bl/O
R/W
G/W
Bu/Y
Y
O
Bl
W
G
G
G
G
Bl
Bl
Bl
Lb
Gr
Lg
W
Bu
Y/R
Y/O
G/R
G/O
G/O
P/W
Bl/R
Y/W
W/Y
W/R
Bl/O
G/Bl
G/Bl
G/Bl
R/W
Br/R
G/W
Lg/R
Gr/R
P/Bu
Br/Bl
Bu/Y
W/Bu
Hi
W
Lo
MAP TP IAT IACV
HL
Ho
WL
WR
BAT
O2 IGNITION
SENSOR COIL E F
G/W
TA
PB
THL
UP FUEL ALTERNATOR
CKP
IACV1A
IACV1B
IACV2A
IACV2B
NO
15A 10A
BAT
BAT1
LAMP
BATT OUT
EARTH
CHARGE
V OUT
IGP
LG
O2
SG
THL
VCC (5V)
PRC
FLR
PG1
PG2
IGPLS
PCP
TA
SCS
INJ
TW WARN
IACV2A
IACV1A
FI WARN
PCM
TW
SSTAND
PB
STSW
K-LINE
IACV2B
IACV1B
S/RELAY
ST
ECM
DLC
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
HEADLIGHT
CBS TYPE:
Y
R
R
R
R
G
G
G
Bl
Bl
Bl
Bl
Bl
Bl
W
Br
Br
Gr
W W
Y/R
R/Y
R/Y
G/Y
Y/G
Y/O
Y/G
Y/G
Y/G
G/R
G/O
R/Bl
R/Bl
W/Y
P/W
Bl/R
R/W
G/Bl
G/Bl
Bl/O
W/R
G/Bl
R/W
R/W
R/W
O/W
Br/R
G/W
O/W
W/Bl
Lg/R
Lg/R
Gr/R
W/Bl
Br/Bl
Bu/Y
P/Bu
Bu/Y
Bl/Br
W/Bu
Lb Lb
HEADLIGHT O O
12V25W/25W G G
RIGHT FRONT
TURN SIGNAL Lb
LIGHT G RIGHT REAR
12V10W TURN SIGNAL LIGHT
12V10W
FRONT BRAKE
LIGHT SWITCH Lb
G/Y G/Y
G
Bl Bl
P
P
O
12V
Bl
G
MIL
Y/R
Y/O
G/O
P/W
Bl/R
Lg
Bl/O
W/R
Br/R
Lg/R
Gr/R
P/Bu
W/Bu
P
P
1.7W
WPC
COOLANT 14P
TEMPERATURE Gr
WARNING
INDICATOR
Bl
Y/R
Y/O
G/O
P/W
Bl/R
Bl/O
W/R
Br/R
Lg/R
Gr/R
P/Bu
W/Bu
G
W
W/Y
RESISTOR RESISTOR
Bl/O
R/W
G/W
Bu/Y
Y
O
Bl
W
G
G
G
G
Bl
Bl
Bl
Lb
Gr
Lg
W
Bu
Y/R
Y/O
G/R
G/O
G/O
P/W
Bl/R
Y/W
W/Y
W/R
Bl/O
G/Bl
G/Bl
G/Bl
R/W
Br/R
G/W
Lg/R
Gr/R
P/Bu
Br/Bl
Bu/Y
W/Bu
Hi
W
Lo
MAP TP IAT IACV
HL
Ho
WL
WR
BAT
O2 IGNITION
SENSOR COIL E F
G/W
TA
PB
THL
UP FUEL ALTERNATOR
CKP
IACV1A
IACV1B
IACV2A
IACV2B
21-3
WIRING DIAGRAM
MEMO
Tonngokhong BikerVietNam
22. TROUBLESHOOTING
Tonngokhong BikerVietNam
22
22-1
TROUBLESHOOTING
ENGINE DOES NOT START OR IS HARD TO START
TROUBLESHOOTING
Tonngokhong BikerVietNam
4. PGM-FI System Inspection
Check the PGM-FI system (page 6-5).
Is the PGM-FI system normal?
NO – Faulty PGM-FI system
YES – GO TO STEP 5.
5. Cylinder Compression
Test cylinder compression (page 9-7).
Is the compression as specified?
NO – • Valve stuck open
• Worn cylinder and piston rings
• Damaged cylinder head gasket
• Seized valve
• Improper valve timing
YES – GO TO STEP 6.
6. Engine Starting Condition
Start by following normal procedure.
Does the engine start then stops?
YES – • Leaking insulator or intake manifold
• Improper ignition timing (Faulty ECM or CKP sensor)
• Contaminated fuel
• Clogged IACV passage
22-2
TROUBLESHOOTING
ENGINE LACKS POWER
1. Drive Train Inspection
Raise wheel off the ground and spin it by hand.
Does the wheel spin freely?
NO – • Brake dragging
• Damaged final reduction system
• Worn or damaged wheel bearings
• Incorrect connecting cable adjustment (CBS type)
YES – GO TO STEP 2.
2. Tire Pressure Inspection
Check tire pressure (page 4-23).
Are the tire pressures low?
YES – • Faulty tire valve
• Punctured tire
NO – GO TO STEP 3.
3. Drive Train Inspection
Check the drive train.
Is the drive train normal?
NO – • Fouled or faulty drive belt
• Fouled or faulty drive pulley
• Fouled or faulty driven pulley
• Worn clutch shoes
YES – GO TO STEP 4.
4. Engine Performance Inspection
Tonngokhong BikerVietNam
Accelerate lightly.
Does the engine speed increase?
NO – • Dirty air cleaner
• Restricted fuel flow
• Clogged exhaust system
YES – GO TO STEP 5.
5. Spark Plug Inspection
Remove and inspect spark plug (page 4-7).
Is the spark plug fouled or discolored?
YES – • Plugs not serviced frequently enough
• Incorrect spark plug heat range
• Incorrect spark plug gap
NO – GO TO STEP 6.
6. Engine Oil Inspection
Check oil level and condition (page 4-10).
Is the engine oil in good condition?
NO – • Oil level too high
• Oil level too low
• Contaminated oil
YES – GO TO STEP 7.
7. Ignition Timing Inspection
Check ignition timing (page 18-8).
Is the ignition timing as specified?
NO – • Faulty ECM
• Faulty CKP sensor
YES – GO TO STEP 8.
22-3
TROUBLESHOOTING
8. Cylinder Compression Inspection
Test cylinder compression (page 9-7).
Is the compression as specified?
NO – • Valve stuck open
• Worn cylinder and piston rings
• Damaged cylinder head gasket
• Improper valve timing
• Improper valve clearance
• Seized valve
• Faulty decompressor
YES – GO TO STEP 9.
9. Fuel Pump Inspection
Inspect the fuel flow (page 6-5).
Is the fuel pump unit normal?
NO – Faulty fuel pump unit
YES – GO TO STEP 10.
10. PGM-FI System Inspection
Check the PGM-FI system (page 6-5).
Is the PGM-FI system normal?
NO – Faulty PGM-FI system
YES – GO TO STEP 11.
11. Lubrication Inspection
Remove the cylinder head cover and inspect lubrication.
Is the valve train lubricated properly?
Tonngokhong BikerVietNam
NO
YES
– • Clogged oil passage
• Faulty oil pump
• Oil strainer screen not serviced frequently enough
– GO TO STEP 12.
12. Over Heating Inspection
Check for engine over heating.
Is the engine over heating?
YES – • Excessive carbon build-up in combustion chamber
• Use of poor quality fuel
• Wrong type of fuel
NO – GO TO STEP 13.
13. Engine Knocking Inspection
Accelerate or run at high speed.
Is there knocking?
YES – • Worn piston and cylinder
• Wrong type of fuel
• Excessive carbon build-up in combustion chamber
• Ignition timing too advance (Faulty ECM or CKP sensor)
22-4
TROUBLESHOOTING
POOR PERFORMANCE AT LOW AND IDLE SPEED
1. Spark Plug Inspection
Remove and inspect the spark plug.
Is the spark plug in good condition?
NO – • Plug not serviced frequently enough
• Incorrect spark plug heat range
• Incorrect spark plug gap
YES – GO TO STEP 2.
2. Ignition Timing Inspection
Check the ignition timing (page 18-8).
Is the ignition timing as specified?
NO – • Faulty ECM
• Faulty CKP sensor
• Improper valve timing
YES – GO TO STEP 3.
3. Fuel Pump Inspection
Inspect the fuel flow (page 6-5).
Is the fuel pump unit normal?
NO – Faulty fuel pump unit
YES – GO TO STEP 4.
4. PGM-FI System Inspection
Check the PGM-FI system (page 6-5).
Is the PGM-FI system normal?
Tonngokhong BikerVietNam
NO
YES
– Faulty PGM-FI system
– GO TO STEP 5.
5. IACV Inspection
Check the IACV (page 6-38).
Is the IACV normal?
NO – • Faulty IACV
• Clogged IACV passage
YES – GO TO STEP 6.
6. Intake Pipe Leaking Inspection
Check for leaks at the insulator.
Are there leaks?
YES – • Loose insulator
• Damaged insulator
22-5
TROUBLESHOOTING
POOR PERFORMANCE AT HIGH SPEED
1. Ignition Timing Inspection
Check the ignition timing (page 18-8).
Is the ignition timing as specified?
NO – • Faulty ECM
• Faulty CKP sensor
• Improper valve timing
YES – GO TO STEP 2.
2. Fuel Pump Inspection
Inspect the fuel flow (page 6-5).
In the fuel pump unit operation normal?
NO – Faulty fuel pump unit
YES – GO TO STEP 3.
3. PGM-FI System Inspection
Check the PGM-FI system (page 6-5).
Is the PGM-FI system normal?
NO – Faulty PGM-FI system
YES – GO TO STEP 4.
4. Valve Timing Inspection
Check the valve timing (page 9-12).
Is the valve timing correct?
NO – Cam sprocket not installed properly.
Tonngokhong BikerVietNam
YES – GO TO STEP 5.
5. Valve Spring Inspection
Check valve springs (page 9-23).
Is the valve spring free length as specified?
NO – Faulty valve spring
YES – GO TO STEP 6.
6. Camshaft Inspection
Remove and inspect the camshaft (page 9-13).
Is the cam lobe height as specified?
NO – Faulty camshaft
POOR HANDLING
Steering is heavy
• Steering top thread too tight
• Damaged steering head bearings
• Insufficient tire pressure
Either wheel is wobbling
• Excessive wheel bearing play
• Bent rim
• Improperly installed wheel hub
• Excessively worn engine mounting bushings
• Bent frame
Scooter pulled to one side
• Front and rear wheels not aligned
• Bent fork
• Faulty shock absorber
• Bent axle
• Bent frame
22-6
23. ANC110AVC-A ADDENDUM
Tonngokhong BikerVietNam
23
23-1
ANC110AVC-A ADDENDUM
A Few Words About Safety
ANC110AVC-A ADDENDUM
Service Information
The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attempting
service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also damage the
vehicle or create an unsafe condition.
This manual describes the proper methods and procedures for performing service, maintenance and repairs. Some procedures
require the use of specially designed tools and dedicated equipment. Any person who intends to use a replacement part, service
procedure or a tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of
the vehicle.
If you need to replace a part, use genuine Honda parts with the correct part number or an equivalent part. We strongly recommend
that you do not use replacement parts of inferior quality.
For Your Customer’s Safety
Proper service and maintenance are essential to the customer’s safety and the reliability of the vehicle. Any error or oversight while
servicing a vehicle can result in faulty operation, damage to the vehicle, or injury to others.
Tonngokhong BikerVietNam
Some of the most important general service safety precautions are given below. However, we cannot warn you of every
conceivable hazard that can arise in performing service and repair procedures. Only you can decide whether or not you should
perform a given task.
23-2
ANC110AVC-A ADDENDUM
INTRODUCTION
This addendum contains information for ANC110.
Refer to ANC110 SHOP MANUAL (No.82KVG00) for service procedures and data not included in this addendum.
Your safety, and the safety of others, is very important. To help you make informed decisions we have provided safety messag-
es and other information throughout this manual. Of course, it is not practical or possible to warn you about all the hazards as-
sociated with servicing this vehicle.
You must use your own good judgement.
You will find important safety information in a variety of forms including:
• Safety Labels – on the vehicle
• Safety Messages – preceded by a safety alert symbol and one of three signal words, DANGER, WARNING, or CAUTION.
These signal words mean:
You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions.
As you read this manual, you will find information that is preceded by a symbol. The purpose of this message is to help
prevent damage to your vehicle, other property, or the environment.
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 Mo-
tor Co., Ltd. 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 PER-
MISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTENANCE
ON Honda MOTORCYCLES, MOTOR SCOOTERS OR ATVS.
Tonngokhong BikerVietNam
© Honda Motor Co., Ltd.
SERVICE PUBLICATION OFFICE
Date of Issue: June.: 2009
23-3
ANC110AVC-A ADDENDUM
MODEL IDENTIFICATION
Tonngokhong BikerVietNam
The engine serial number is stamped on the lower left side of the
crankcase.
The throttle body identification number is stamped on the lower side of the
throttle body.
23-4
ANC110AVC-A ADDENDUM
GENERAL SPECIFICATIONS
ITEM SPECIFICATIONS
DIMENSIONS Overall length 1,894 mm (74.6 in)
Overall width 680 mm (26.8 in)
Overall height 1,119 mm (44.1 in)
Wheelbase 1,273 mm (50.1 in)
Seat height 767 mm (30.2 in)
Footpeg height 258 mm (10.2 in)
Ground clearance 135 mm (5.3 in)
Curb weight 107.0 kg (235.9 lbs)
FRAME Frame type Under bone type
Front suspension Telescopic fork
Front axle travel 81.0 mm (3.19 in)
Rear suspension Unit swing
Rear axle travel 80.0 mm (3.3 in)
Front tire size 80/90 - 14M/C 40P
Rear tire size 90/90 - 14M/C 46P
Tire brand Front/Rear NR73TZ/NR73T (IRC)
Front brake Hydraulic disc brake
Rear brake Mechanical leading trailing
Caster angle 26°40’
Trail length 80.0 mm (3.15 in)
Fuel tank capacity 4.5 liter (1.19 US gal, 0.99 lmp gal)
ENGINE Bore and stroke 50.0 x 55.0 mm (1.97 x 2.17 in)
Displacement 108.0 cm3 (6.59 cu-in)
Compression ratio 11.0 : 1
Valve train 2 valve, single chain driven SOHC
Intake valve opens at 1 mm (0.04 in) lift 5° BTDC
closes at 1 mm (0.04 in) lift 30° ABDC
Tonngokhong BikerVietNam
Exhaust valve
Lubrication system
Oil pump type
opens
closes
at 1 mm (0.04 in) lift
at 1 mm (0.04 in) lift
30° BBDC
0° ATDC
Forced pressure and wet sump
Trochoid
Cooling system Liquid cooled
Air filtration Paper filter
Engine dry weight 27.3 kg (60.2 lbs)
FUEL DELIV- Type PGM-FI (Programmed Fuel Injection)
ERY SYSTEM Throttle bore 22 mm (0.9 in) or equivalent
DRIVE TRAIN Clutch system Dry, automatic centrifugal clutch
Drive belt ratio 2.53 : 1 - 0.85 : 1
Final reduction 10.624 (51/18 x 45/12)
ELECTRICAL Ignition system Full transistorized
Starting system Kickstarter with electric starter motor
Charging system Single phase output alternator
Regulator/rectifier SCR opened/single phase, half wave rectifi-
cation
Lighting system Alternator
23-5
ANC110AVC-A ADDENDUM
LUBRICATION SYSTEM SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Engine oil capacity After draining 0.7 liter (0.7 US qt, 0.6 lmp qt) –
After disassembly 0.8 liter (0.8 US qt, 0.7 lmp qt) –
Recommended engine oil API classification: SE, SF or SG
(except oils labeled as energy conserving
on the circular API service label) –
Viscosity: SAE 10W-30
JASO T 903 standard: MB
Oil pump rotor Tip clearance 0.15 (0.006) 0.20 (0.008)
Body clearance 0.15 – 0.21 (0.006 – 0.008) 0.35 (0.014)
Side clearance 0.05 – 0.10 (0.002 – 0.004) 0.12 (0.005)
23-6
ANC110AVC-A ADDENDUM
CYLINDER HEAD/VALVES SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Cylinder compression 932 kPa (9.5 kgf/cm2, 135 psi)
–
at 550 min-1 (rpm)
Cylinder head warpage – 0.05 (0.002)
Rocker Rocker arm I.D. IN/EX 10.000 – 10.015 (0.3937 – 0.3943) 10.04 (0.395)
arm Rocker arm shaft O.D. IN/EX 9.972 – 9.987 (0.3926 – 0.3932) 9.91 (0.390)
Arm to shaft clearance IN/EX 0.013 – 0.043 (0.0005 – 0.0017) 0.08 (0.003)
Camshaft Cam lobe height IN 32.525 – 32.765 (1.2805 – 1.2900) 32.50 (1.280)
EX 32.227 – 32.467 (1.2688 – 1.2782) 32.20 (1.268)
Valve, Valve clearance IN 0.14 ± 0.02 (0.006 ± 0.001) –
valve EX 0.20 ± 0.02 (0.008 ± 0.001) –
guide Valve stem O.D. IN 4.975 – 4.990 (0.1959 – 0.1965) 4.90 (0.193)
EX 4.955 – 4.970 (0.1951 – 0.1957) 4.90 (0.193)
Valve guide I.D. IN/EX 5.000 – 5.012 (0.1969 – 0.1973) 5.03 (0.198)
Stem-to-guide clearance IN 0.010 – 0.037 (0.0004 – 0.0015) 0.08 (0.003)
EX 0.030 – 0.057 (0.0012 – 0.0022) 0.10 (0.004)
Valve guide projection above IN/EX 9.1 – 9.3 (0.36 – 0.37) –
cylinder head
Valve seat width IN/EX 1.0 (0.04) 1.5 (0.06)
Valve spring free length Inner IN/EX 31.53 (1.241) 30.66 (1.207)
Outer IN/EX 38.33 (1.509) 37.04 (1.458)
CYLINDER/PISTON SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Cylinder I.D. 50.000 – 50.010 (1.9685 – 1.9689) 50.10 (1.972)
Out-of-round – 0.05 (0.002)
Tonngokhong BikerVietNam
Piston,
piston rings,
Taper
Warpage
Piston O.D.
Piston O.D. measurement point
–
–
49.975 – 49.995 (1.9675 – 1.9683)
6.0 (0.24) from bottom of skirt
0.05 (0.002)
0.05 (0.002)
49.95 (1.967)
–
piston pin Piston pin bore I.D. 13.002 – 13.008 (0.5119 – 0.5121) 13.04 (0.513)
Piston pin O.D. 12.994 – 13.000 (0.5116 – 0.5118) 12.96 (0.510)
Piston-to-piston pin clearance 0.002 – 0.014 (0.0001 – 0.0006) 0.02 (0.001)
Piston ring-to-ring Top 0.015 – 0.045 (0.0006 – 0.0018) 0.08 (0.003)
groove clearance Second 0.015 – 0.045 (0.0006 – 0.0018) 0.08 (0.003)
Piston ring end gap Top 0.10 – 0.25 (0.004 – 0.0020) 0.45 (0.018)
Second 0.10 – 0.25 (0.004 – 0.0020) 0.45 (0.018)
Oil (side rail) 0.20 – 0.70 (0.008 – 0.028) –
Cylinder-to-piston clearance 0.005 – 0.035 (0.0002 – 0.0014) 0.09 (0.004)
Connecting rod small end I.D. 13.010 – 13.028 (0.5122 – 0.5129) 13.05 (0.514)
Connecting rod-to-piston pin clearance 0.010 – 0.034 (0.0004 – 0.0013) 0.05 (0.002)
23-7
ANC110AVC-A ADDENDUM
FINAL REDUCTION SPECIFICATIONS
Unit: mm (in)
ITEM SPECIFICATIONS
Final reduction oil capacity After draining 0.10 liter (0.11 US qt, 0.09 lmp qt)
After disassembly 0.12 liter (0.13 US qt, 0.11 lmp qt)
Recommended final reduction oil API classification: SE, SF or SG
(except oils labeled as energy conserving on the circular API
service label)
Viscosity: SAE 10W-30
JASO T 903 standard: MB
CRANKCASE/CRANKSHAFT SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Crankshaft Connecting rod side clearance 0.10 – 0.35 (0.004 – 0.014) 0.55 (0.022)
Connecting rod radial clearance 0.004 – 0.016 (00002 – 0.0006) 0.05 (0.002)
Runout – 0.10 (0.004)
Tonngokhong BikerVietNam
Wheel rim runout Radial – 2.0 (0.08)
Axial – 2.0 (0.08)
Fork Spring free length 318.3 (12.53) 311.9 (12.28)
Pipe runout – 0.2 (0.01)
Recommended fluid Fork fluid –
Fluid level 71 (3.41) –
Fluid capacity 69 ± 1.0 cm3
–
(2.11 ± 0.05 US oz, 2.20 ± 0.05 Imp oz)
23-8
ANC110AVC-A ADDENDUM
BRAKE SYSTEM SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Rear brake lever freeplay 10 – 20 (0.4 – 0.8) –
Brake drum I.D. 130.0 (5.12) 131.0 (5.16)
Specified brake fluid DOT 3 or 4 –
Brake disc Thickness 3.3 – 3.7 (0.13 – 0.15) 3.0 (0.12)
Warpage – 0.10 (0.004)
Master cylinder Cylinder I.D. 12.700 – 12.743 (0.5000 – 0.5017) 12.755 (0.5022)
Piston O.D. 12.657 – 12.684 (0.4983 – 0.4994) 12.645 (0.4978)
Caliper Cylinder I.D. 25.400 – 25.450 (1.0000 – 1.0020) 25.460 (1.0024)
Piston O.D. 25.318 – 25.368 (0.9968 – 0.9987) 25.31 (0.996)
Tonngokhong BikerVietNam
ITEM SPECIFICATIONS
Spark plug CPR7EA – 9 (NGK), U22EPR9 (ND)
Spark plug gap 0.8 – 0.9 mm (0.03 – 0.04 in)
Ignition coil peak voltage 100 V minimum
CKP sensor peak voltage 0.7 V minimum
Ignition timing 10° BTDC at 1,500 min-1 (rpm)
LIGHTS/METERS/SWITCHES SPECIFICATION
ITEM SPECIFICATIONS
Bulbs Headlight 12 V – 35/35 W
Tail light 12 V – 5 W
Brake light LED
Front turn signal light 12 V – 10 W x 2
Rear turn signal light 12 V – 10 W x 2
Instrument light 12 V – 1.7 W x 2
PGM-FI malfunction indicator lamp 12 V – 1.7 W
(MIL)
High beam indicator 12 V – 1.7 W
Turn signal indicator 12 V – 3 W x 2
Coolant temperature warning indi- LED
cator
Fuse Main fuse 15 A x 1
Sub fuse 10 A x 1
Resistor resistance (20°C/68°F) 9.5 – 10.5 ǡ
23-9
ANC110AVC-A ADDENDUM
STANDARD TORQUE VALUES
FASTENER TYPE TORQUE FASTENER TYPE TORQUE
N·m (kgf·m, lbf·ft) N·m (kgf·m, lbf·ft)
5 mm hex bolt and nut 5.2 (0.5, 3.8) 5 mm screw 4.2 (0.4, 3.1)
6 mm hex bolt and nut 10 (1.0, 7) 6 mm screw 9.0 (0.9, 6.6)
(Include SH flange bolt) 6 mm flange bolt 12 (1.2, 9)
8 mm hex bolt and nut 22 (2.2, 16) (Include NSHF) and nut
10 mm hex bolt and nut 34 (3.5, 25) 8 mm flange bolt and nut 27 (2.8, 20)
12 mm hex bolt and nut 54 (5.5, 40) 10 mm flange bolt and nut 39 (4.0, 29)
Tonngokhong BikerVietNam
Engine oil strainer screen cap
Final reduction oil check bolt
Final reduction oil drain bolt
Air cleaner housing cover screw
1
1
1
4
30
5
8
8
20 (2.0, 15)
13 (1.3, 10)
13 (1.3, 10)
1.1 (0.1, 0.8)
Equalizer connecting cable lock nut 1 8 6.4 (0.7, 4.7)
LUBRICATION SYSTEM
ITEM Q'TY THREAD TORQUE REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Oil pump plate screw 1 4 3 (0.3, 2.2)
Oil pump mounting bolt 2 6 10 (1.0, 7)
FUEL SYSTEM (PGM-FI)
ITEM Q'TY THREAD TORQUE REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
ECT sensor 1 12 17.7 (1.8, 13)
Sensor unit torx screw 3 5 3.4 (0.3, 2.5)
Throttle cable stay mounting screw 1 5 3.4 (0.3, 2.5)
IACV torx screw 2 4 2.1 (0.2, 1.5)
O2 sensor 1 12 25 (2.5, 18)
COOLING SYSTEM
ITEM Q'TY THREAD TORQUE REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Cooling fan mounting bolt 3 6 8 (0.8, 5.9)
Radiator drain bolt 1 10 1 (0.1, 0.7)
Thermostat mounting bolt 2 6 9 (0.9, 6.6)
Water pump impeller 1 6 10 (1.0, 7)
23-10
ANC110AVC-A ADDENDUM
ENGINE REMOVAL/INSTALLATION
ITEM Q'TY THREAD TORQUE REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Engine hanger link pivot nut 1 10 69 (7.0, 51)
(Frame side)
CYLINDER HEAD/VALVES
ITEM Q'TY THREAD TORQUE REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Cylinder head cover special bolt 2 6 12 (1.2, 9)
Cylinder head nut 4 7 18 (1.8, 13) Apply oil to the threads and
seating surface.
Cylinder head bolt 2 6 12 (1.2, 9) Apply oil to the threads and
seating surface.
Cam sprocket bolt 2 5 8 (0.8, 5.9) Apply oil to the threads and
seating surface.
Cam chain tensioner lifter screw 1 6 4 (0.4, 3.0)
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
ITEM Q'TY THREAD TORQUE REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Left crankcase cover plate screw 5 4 3 (0.3, 2.2)
Drive pulley face nut 1 14 108 (11.0, 80) Apply oil to the threads and
seating surface.
Clutch/driven pulley nut 1 28 54 (5.5, 40)
Clutch outer nut 1 12 49 (5.0, 36)
FRONT WHEEL/SUSPENSION/STEERING
ITEM Q'TY THREAD TORQUE REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Tonngokhong BikerVietNam
Front axle nut 1 12 59 (6.0, 44) U-nut
Front brake disc socket bolt 4 8 42 (4.3, 31) ALOC bolt:
replace with new ones
Handlebar post nut 1 10 59 (6.0, 44)
Bottom bridge pinch bolt 4 10 64 (6.5, 47)
Fork pipe seat socket bolt 2 8 20 (2.0, 15) Apply locking agent to the
threads.
Steering stem top thread 1 26 – For tightening sequence;
see page 14-25
Steering stem lock nut 1 26 – For tightening sequence;
see page 14-26
REAR WHEEL/SUSPENSION
ITEM Q'TY THREAD TORQUE REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Rear axle nut 1 16 118 (12.0, 87) U-nut, Apply oil to the
threads and seating sur-
face.
Engine hanger link nut (Engine side) 1 10 49 (5.0, 36)
23-11
ANC110AVC-A ADDENDUM
BRAKE SYSTEM
ITEM Q'TY THREAD TORQUE REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Rear brake arm bolt 1 6 10 (1.0, 7) ALOC bolt: replace with a
new one
Brake caliper bleed valve 1 8 5.4 (0.6, 4.4)
Brake master cylinder reservoir cap screw 2 4 1.5 (0.2, 1.1)
Brake pad pin 1 10 17.2 (1.8, 13)
Front brake lever pivot screw 1 6 1 (0.1, 0.7)
Front brake lever pivot nut 1 6 6 (0.6, 4.4)
Front brake light switch screw 1 4 1 (0.1, 0.7)
Brake hose oil bolt 2 10 34 (3.5, 25)
Rear brake lever pivot screw 1 5 4.2 (0.4, 3.1)
Rear brake lever pivot nut 1 5 5.2 (0.5, 3.8) U-nut
Equalizer rod pivot screw 1 5 4.2 (0.4, 3.1)
Equalizer rod pivot nut 1 5 5.2 (0.5, 3.8) U-nut
Rear brake lever bracket cover screws 2 5 4.2 (0.4, 3.1)
Rear brake lever bracket cover special 1 5 4.2 (0.4, 3.1)
screw
Brake caliper mounting bolt 2 8 30.4 (3.1, 22) ALOC bolt: replace with
new ones
Brake caliper torque pin 1 8 22(2.2, 16)
Brake caliper pin 1 8 17.2 (1.8, 13)
BATTERY/CHARGING SYSTEM/ALTERNATOR
ITEM Q'TY THREAD TORQUE REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Stator mounting socket bolt 3 6 10 (1.0, 7)
Flywheel nut 1 12 59 (6.0, 44)
Tonngokhong BikerVietNam
ELECTRIC STARTER SYSTEM
ITEM Q'TY THREAD TORQUE REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Starter motor cable screw 1 4 2 (0.2, 1.5)
Starter motor case screw 3 4 2 (0.2, 1.5)
OTHERS
ITEM Q'TY THREAD TORQUE REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Muffler protector mounting bolt 2 6 10 (1.0, 7)
Brake shoe anchor pin nut 1 8
(When using the stake nut) 20 (2.0, 15)
(When using the normal nut) 18 (1.8, 13)
Sidestand pivot nut 1 10 29 (3.0, 21)
Sidestand pivot bolt 1 10 10 (1.0, 0.7)
23-12
ANC110AVC-A ADDENDUM
LUBRICATION & SEAL POINTS
ENGINE
MATERIAL LOCATION REMARKS
Liquid sealant (recommend- Right crankcase mating surface see page 13-10
ed: Three Bond 1207B or
Three Bond 1215 or equiva-
lent)
Liquid sealant (recommend- Cylinder head mating surface (semicircular area) see page 9-8
ed: Three Bond 5211C or
SHINETSU-SILICONE
KE45T or Three Bond 1215
or equivalent)
Locking agent (recommend- Driveshaft bearing set plate bolt threads see page 12-13
ed: Three Bond 2415 or
1322N or LOCKTITE 200 or
equivalent)
Molybdenum disulfide oil (a Camshaft cam lobes
mixture of 1/2 engine oil and
1/2 molybdenum disulfide
grease)
Molybdenum disulfide paste Kickstarter spindle sliding surface 0.1 – 0.3 g
Kickstarter driven gear shaft 0.2 – 0.3 g
Kickstarter driven gear friction spring sliding area
Grease (Shell ALVANIA R3 Driven face inner surface 7.0 – 8.0 g
or IDEMITSU AUTOREX B Movable driven face cam groove 1.5 – 2.0 g
or equivalent) Starter pinion gear shaft (both end) 0.1 – 0.3 g
Driven face ball bearing and needle bearing
Bearing area of final shaft
Engine oil (Without molybde- Oil pump drive gear teeth
Tonngokhong BikerVietNam
num additives) Oil pump rotor whole surface
Oil pump shaft and pump cover sliding area
Oil pump driven gear teeth
Rocker arm shaft sliding surface
Rocker arm roller sliding area
Camshaft decompressor rotating surface 0.5 – 1.0 cc
Camshaft bearing
Cam sprocket teeth
Cam chain whole surface
Timing sprocket teeth
Piston and cylinder sliding surfaces
Piston ring whole surface and ring grooves
Piston pin outer surface
Connecting rod small end inner surface
Crankshaft bearings Fill up 2 cc minimum
Connecting rod big end bearing Fill up 3 cc minimum
Valve stem (valve guide sliding area)
Valve stem seal inner surface
Bearing area of drive and counter shaft
Drive, counter and final gear teeth
Water pump shaft sliding area
Water pump chain whole surface
Water pump driven gear teeth
Ball/needle bearing sliding area
Each O-ring whole surface
Oil seal lips and outer surfaces
Degrease Right crankshaft tapered area
Drive/driven pulley face and drive belt
Left crankcase cover bearing bushing inner surface
23-13
ANC110AVC-A ADDENDUM
FRAME
MATERIAL LOCATION REMARKS
Multi-purpose grease with Steering bearing race Spread each 3 g minimum
extreme pressure (recom- Steering stem dust seal lip Spread each 3 g minimum
mended: EXCELIGHT EP2
manufactured by KYODO
YUSHI, japan. or Shell AL-
VANIA EP2 or equivalent)
Grease (Shell BEARING Speedometer gear box inside
GREASE HD or equivalent)
Multi-purpose grease Front/rear wheel dust seal lip
Front wheel axle sliding surface
Front wheel distance collar whole surface
Speedometer gear box seal lip
Throttle cable-to-throttle drum sliding area Apply 0.1 - 0.2 g
Rear brake cam and shaft Spread each 0.2 - 0.3 g
Rear brake anchor pin shaft Spread 0.2 - 0.3 g
Rear brake dust seal lip
Rear brake lever pivot screw sliding surface
Equalizer rod pivot screw sliding surface
Equalizer sliding surface
Seat catch contact area Apply 2.2 g minimum
Fuel lid lock pin contact area Apply 2.2 g minimum
Centerstand pivot area
Sidestand pivot area
Silicone grease Rear brake cable cap boot inside
Front brake lever-to-master piston contacting area Spread each 0.1 g
Front brake lever pivot sliding area
Brake caliper pin sliding area Spread 0.4 g minimum
Brake caliper pad pin O-ring whole surface.
Tonngokhong BikerVietNam
Brake caliper dust seal whole surface
Brake equalizer cable cap boot inside
Speedometer cable
Throttle cable boot inside Fill up 0.1 g
Throttle cable inside Fill up 0.2 g minimum
Brake fluid Master cylinder inside and sliding area
(DOT 3 or DOT 4) Brake caliper piston seal whole surface
Brake caliper piston whole surface
Master cylinder piston cup
Fork fluid Fork dust seal and oil seal lips
Fork spring seat O-ring whole surface
Adhesive (Honda bond A or Handlebar grip rubber inside
equivalent) Air cleaner connecting hose-to-housing mating area
23-14
ANC110AVC-A ADDENDUM
CABLE & HARNESS ROUTING
LIGHTING SWITCH 3P DIMMER SWITCH 3P CONNECTOR
CONNECTOR
TURN SIGNAL SWITCH 3P
LIGHTING SWITCH 3P (Red) (Red) CONNECTOR
CONNECTOR
Tonngokhong BikerVietNam
FRONT BRAKE HOSE
THROTTLE CABLE
SPEEDOMETER CABLE
SPEEDOMETER
SUB HARNESS
THROTTLE
CABLE
REAR
DLC (DATA LINK CONNECTOR) BRAKE
CABLE
SPEEDOMETER CABLE
SEAT LOCK CABLE
STARTER RELAY
23-15
ANC110AVC-A ADDENDUM
THROTTLE CABLE
MAIN FUSE 15A
SUB FUSE 10A
FUEL LID OPENER CABLE
BATTERY POSITIVE
(+) CABLE
SEAT LOCK CABLE
CONNECTORS:
· SPEEDOMETER SUB HARNESS 9P
· SPEEDOMETER SUB HARNESS 6P
Tonngokhong BikerVietNam
· IGNITION SWITCH 2P
CONNECTORS:
· STARTER MOTOR 2P
· SIDESTAND SWITCH 3P (GREEN)
· ALTERNATOR 3P
SPEEDOMETER
CABLE
SPEEDOMETER CABLE
23-16
ANC110AVC-A ADDENDUM
BATTERY
NEGATIVE
(–) CABLE
REGULATOR/
RECTIFIER
SPEEDOMETER SPEEDOMETER WIRE
CABLE SUB HARNESS
SPEEDOMETER
CABLE
STARTER RELAY
REAR BRAKE
CABLE REGULATOR/
RECTIFIER
FRONT BRAKE
HOSE THROTTLE
CABLE
THROTTLE CABLE STARTER
RELAY REAR BRAKE
WIRE CABLE
FRONT BRAKE
HOSE
Tonngokhong BikerVietNam
FRONT BRAKE HOSE
HORN WIRE
THROTTLE CABLE
SIDESTAND SWITCH
WIRE
OVERFLOW HOSE
OVERFLOW HOSE
23-17
ANC110AVC-A ADDENDUM
FUEL LID
OPENER CABLE
Tonngokhong BikerVietNam
HORN WIRE
SEAT
LOCK
CABLE
SPEEDOMETER
CABLE
RADIATOR SIPHON
HOSE CONNECTORS:
· STARTER MOTOR 2P
· SIDESTAND SWITCH 3P (GREEN)
FUEL PUMP WIRE · ALTERNATOR 3P
23-18
ANC110AVC-A ADDENDUM
CONNECTORS:
· SPEEDOMETER SUB HARNESS 9P
· SPEEDOMETER SUB HARNESS 6P
· IGNITION SWITCH 2P
OVERFLOW HOSE
Tonngokhong BikerVietNam
FUEL TRAY
DRAIN HOSE
THROTTLE CABLE
23-19
ANC110AVC-A ADDENDUM
HEADLIGHT WIRE
Tonngokhong BikerVietNam
HEADLIGHT 6P CONNECTOR
23-20
ANC110AVC-A ADDENDUM
BODY PANEL LOCATIONS
(7)
(23) (6)
(22) (8) (10)
(12)
(2) (13)
(1)
(5)
(3)
(11)
(4)
(24) (15)
Tonngokhong BikerVietNam
(7) Front handlebar cover (page 3-8)
(8) Rear handlebar cover (page 3-8)
(15) Fuel lid/center cover (page 3-18)
(16) Body cover (page 3-14)
(23) Grab rail (page 3-12)
(24) Radiator cover (page 3-12)
(25) Rear inner lower fender
(page 23-24)
(15) Fuel lid/center cover (4) Side garnish (22) Rearview mirror
(13) Rear center cover (14) Pillion step bracket (7) Front handlebar cover
(16) Body cover (18) Front side cover (8) Rear handlebar cover
(19) Main pipe side cover (21) Under cover (25) Rear inner
lower fender
23-21
ANC110AVC-A ADDENDUM
FRONT TOP COVER
REMOVAL/INSTALLATION
Remove the screws/washers.
Be careful not to Slightly slide the front top cover downward and release
damage the hooks the hooks and tab from the slots, then remove the front
and tab. top cover by sliding it forward.
Installation is in the reverse order of removal.
SCREWS/WASHERS
HOOKS
Tonngokhong BikerVietNam
TAB
23-22
ANC110AVC-A ADDENDUM
FRONT COVER
REMOVAL/INSTALLATION
Remove the following:
– Front top cover (page 23-22)
– Side garnish (page 3-5)
– Front inner cover (page 3-6)
Disconnect the headlight 6P connector.
Remove the following:
– Two bolt/washers from the battery side
– Four screws from the front side cover
Be careful not to Release the hooks on the front side cover from the slots
damage the hooks, on the front cover.
slots and the boss. Release the boss from the grommet, then remove the
front cover.
Installation is in the reverse order of removal.
BOLT/WASHERS 6P CONNECTOR
Tonngokhong BikerVietNam
BOSS
FRONT COVER
SCREWS
HOOKS
GROMMET
23-23
ANC110AVC-A ADDENDUM
DISASSEMBLY/ASSEMBLY
Remove the following:
– Two screws/washers RIGHT FRONT COVER
– Four screws
– Headlight unit
Be careful not to Separate the right and left front covers by releasing the TABS
damage the tabs. tabs.
Assembly is in the reverse order of disassembly. SCREWS
HEADLIGHT UNIT
SCREWS/
WASHERS
LEFT FRONT COVER
Tonngokhong BikerVietNam
Remove the five screws and rear inner lower fender.
Installation is in the reverse order of removal. SCREWS
SCREWS
23-24
ANC110AVC-A ADDENDUM
HEADLIGHT AIM
• Adjust the headlight beam as specified by local laws
and regulations.
ADJUSTING GEAR
Place the scooter on a level ground.
Adjust the headlight beam vertically by turning the
headlight aim adjusting gear using the screwdriver.
A clockwise rotation moves the beam down and
counterclockwise rotation moves the beam up.
Tonngokhong BikerVietNam
23-25
ANC110AVC-A ADDENDUM
FRONT WHEEL
REMOVAL/INSTALLATION
Raise and support the scooter using safety stand.
Remove/install the following:
– Axle nut cap
– Speedometer cable
– O-ring
– Axle nut
– Front axle
– Front wheel
– Side collar
– Speedometer gearbox
Tonngokhong BikerVietNam
SPEEDOMETER GEARBOX
AXLE NUT CUP
AXLE NUT
59 N·m (6.0 kgf·m, 44 lbf·ft)
SIDE COLLAR
FRONT WHEEL
Align the speedometer tabs with
the wheel hub grooves. GEARBOX SEAL
*: Shell BEARING GREASE HD or equivalent.
23-26
ANC110AVC-A ADDENDUM
FORK
DISASSEMBLY/ASSEMBLY
SUITABLE TOOL
STOPPER RING
SCREWDRIVER
Tonngokhong BikerVietNam
STOPPER RING
OIL SEAL
FORK SLIDER
O-RING
FORK SPRING
SOCKET BOLT
SEALING WASHER REBOUND SPRING
20 N·m (2.0 kgf·m, 15 lbf·ft)
23-27
ANC110AVC-A ADDENDUM
HEADLIGHT/FRONT TURN SIGNAL
LIGHT
BULB REPLACEMENT
HEAD LIGHT
Remove the main pipe upper cover (page 3-5)
RETAINER
Disconnect the headlight 3P connector.
Remove the dust cover.
Release the headlight bulb retainer and remove the
socket.
Install a new headlight bulb by aligning the tab on the
headlight bulb with the groove on the headlight unit.
Install the retainer.
Install the dust Install the dust cover tightly on the headlight unit.
cover with its " "
Connect the headlight 3P connector.
mark facing up.
Install the main pipe upper cover (page 3-5).
HEADLIGHT
BULB
Tonngokhong BikerVietNam
Remove the bulb from the socket and replace it with a
new one.
Install the turn signal light bulb socket by turning it
clockwise.
Install the main pipe upper cover (page 3-5).
23-28
ANC110AVC-A ADDENDUM
SPEEDOMETER
REMOVAL/INSTALLATION
Remove the rear handlebar cover (page 3-8).
Disconnect the following connectors: SCREWS
– Dimmer switch 3P connector CONNECTORS
– Turn signal switch 3P (Red) connector
– Horn switch 3P (Black) connector
– Starter switch 3P (Black) connector
– Lighting switch 3P connector
– Lighting switch 3P (Red) connector
Remove the three screws and the speedometer
assembly from the rear handlebar cover.
Installation is in the reverse order of removal.
SPEEDOMETER
Tonngokhong BikerVietNam
23-29
LIGHT SWITCH STATER SWITCH REGULATOR/ IGNITION LIGHTING STARTER
RECUTIFIER SWITCH ECM RELAY RELAY BATTERY
WINKER RESISTOR1 RESISTOR2 MAIN SUB 12V3AH
RELAY 10 20W 10 20W FUSE FUSE
NO
15A 10A
BAT
BAT1
LAMP
BATT OUT
EARTH
CHARGE
V OUT
IGP
LG
O2
SG
THL
VCC (5V)
PRC
FFP
PG1
PG2
IGPLS
PCP
TA
SCS
INJ
TW WARN
IACV2A
IACV1A
FI WARN
PCM
TW
SSTAND
PB
STSW
K-LINE
IACV2B
IACV1B
S/RELAY
HL
C1
C1
TL
ST
ECM
23-30
1
2
3
4
5
6
7
8
9
DLC
11
10
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
WPC WPC 5P
3P 3P 2P 3P 6P 2P 4P 33P
R Bl W R Bl
Y
Y
P
P
Y
R
R
R
R
G
G
G
Bl
Bl
Bl
Bl
Bl
Bl
Br
Br
Br
Gr
R/Y
R/Y
Y/R
G/Y
Y/G
Y/O
Y/G
Y/G
Y/G
G/R
G/O
W/Y
R/Bl
R/Bl
P/W
Bl/R
R/W
G/Bl
G/Bl
Bl/O
W/R
G/Bl
R/W
R/W
R/W
O/W
Br/R
G/W
O/W
W/Bl
Lg/R
Lg/R
Gr/R
W/Bl
Bu/Y
Bu/Y
Br/Bl
P/Bu
Bl/Br
Bu/W
W/Bu
RIGHT FRONT
TURN SIGNAL G
LIGHT Lb
12V10W
P
P
FRONT BRAKE
LIGHT SWITCH
G/Y G/Y
Bl Bl
POSITION LIGHT Br
12V3.4W G
WIRING DIAGRAMS
ANC110AVC-A ADDENDUM
HEAD LIGHT
12V35W/35W MINI
6P
G G G
Bu Bu Bu
W W W
RIGHT REAR
Br Br TURN SIGNAL LIGHT
Lb Lb 12V10W
SPEEDOMETER O O
Lb
Bu/W
G
FUEL METER Bl MINI
Y/W 6P
Y Y TAIL LIGHT
RIGHT 12V 5W
TURN SIGNAL 12V Lb
G G
INDICATOR 3W G Y
Bu/W G/Bl
MINI
Bl Bl/Br 6P
COOLANT G
TEMPERATURE Lg/R Br Br Br Y
WARNING
INDICATOR Bl Y/G Y/G G G BRAKE LIGHT
Lb Lb Lb Lb
INSTRUMENT 12V Bl O O O O
LIGHT 1.7W G G/Y G/Y G/Y G/Y G
Y/W Y/W
Bl G/Y
INSTRUMENT 12V Bu/Y Bu/Y
LIGHT 1.7W G
Lg/R Lg/R
Lg Lg LEFT REAR
Bu MINI TURN SIGNAL LIGHT
HIGH BEAM 12V 9P 12V10W
INDICATOR 1.7W G
G
12V Bu/Y
MIL O
1.7W Bl
LEFT O
TURN SIGNAL 12V
INDICATOR 3W G
Bl
Y/R
Y/O
G/O
P/W
Bl/R
Bl/O
W/R
Br/R
Lg/R
Gr/R
P/Bu
W/Bu
REAR BRAKE WPC
LIGHT SWITCH 14P
Gr
Bl Bl
G/Y G/Y
Bl
Y/R
Y/O
G/O
P/W
Bl/R
Bl/O
W/R
Br/R
Lg/R
Gr/R
P/Bu
W/Bu
POSITION LIGHT Br
12V3.4W G
G
G
W
W/Y
Bl/O
R/W
G/W
Bu/Y
O
Bl
W
G
G
G
G
G
Bl
Bl
Bl
Lb
Gr
Lg
W
Bu
Lg
Y/R
Y/O
G/R
G/O
G/O
W/Y
P/W
Bl/R
Y/W
W/R
Bl/O
G/Bl
G/Bl
G/Bl
R/W
Br/R
G/W
Lg/R
Gr/R
Bu/Y
P/Bu
Br/Bl
Bu/W
W/Bu
Hi
W
Lo
MAP TP IAT IACV
HL
Ho
WL
WR
BAT
O2 IGNITION
SENSOR COIL E F
G/W
TA
PB
THL
UP FUEL ALTERNATOR
CKP
IACV1A
IACV2A
IACV1B
IACV2B
INDEX
A Few Words About Safety ·····································0-1,23-2 DRIVE BELT
A
Tonngokhong BikerVietNam
BATTERY/CHARGING SYSTEM/ALTERNATOR····17-3
BRAKE SYSTEM······················································16-2
COOLING SYSTEM ···················································7-3
CRANKCASE/CRANKSHAFT ··································13-2
FRONT WHEEL·················································· 14-7,23-26
FRONT WHEEL/SUSPENSION/STEERING
SPECIFICATIONS·················································· 1-7,23-8
FUEL LID/CENTER COVER ········································ 3-18
CYLINDER HEAD/VALVES ·······································9-2 FUEL LID/SEAT OPENER ··········································· 3-13
CYLINDER/PISTON ·················································10-2 FUEL LINE ····································································· 4-5
ENGINE REMOVAL/INSTALLATION·························8-2 FUEL LINE INSPECTION············································· 6-25
FINAL REDUCTION ·················································12-2 FUEL METER/FUEL LEVEL SENSOR ······················ 20-11
FRONT WHEEL/SUSPENSION/STEERING ···········14-2 FUEL PUMP UNIT························································ 6-29
FUEL SYSTEM (Programmed Fuel Injection) ············6-2 FUEL SYSTEM (PGM-FI) SPECIFICATIONS········ 1-5,23-6
KICKSTARTER/DRIVE PULLEY/ FUEL TANK ·································································· 6-31
DRIVEN PULLEY/CLUTCH······································11-2 GENERAL SPECIFICATIONS································ 1-4,23-5
G
24-1
INDEX
LUBRICATION SYSTEM SPECIFICATIONS········· 1-5,23-6 LUBRICATION SYSTEM ··········································· 5-3
LUGGAGE BOX ··························································· 3-11 MAINTENANCE ························································· 4-2
MAIN PIPE SIDE COVER ············································ 3-16 REAR WHEEL/SUSPENSION ································· 15-3
M
MAIN PIPE UPPER COVER ·········································· 3-5 SERVICE RULES ··························································· 1-2
MAINTENANCE LID······················································· 3-9 SIDE GARNISH ······························································ 3-5
MAINTENANCE SCHEDULE········································· 4-4 SIDESTAND ································································· 4-21
MIL CIRCUIT INSPECTION ········································· 6-24 SIDESTAND SWITCH ·················································· 18-8
MIL CODE INDEX ························································ 6-14 SPARK PLUG ································································· 4-7
MIL TROUBLESHOOTING ·········································· 6-15 SPEEDOMETER ················································20-7,23-29
MODEL IDENTIFICATION ····································· 1-2,23-4 STANDARD TORQUE VALUES···························1-9,23-10
NUTS, BOLTS, FASTENERS ······································ 4-22 STARTER MOTOR······················································· 19-6
N
Tonngokhong BikerVietNam
SPECIFICATIONS·················································· 1-7,23-8
REAR WHEEL/SWINGARM········································· 15-5
REGULATOR/RECTIFIER ········································· 17-13
RESISTOR ································································· 20-21
CYLINDER HEAD/VALVES ······································· 9-6
CYLINDER/PISTON ················································· 10-3
ELECTRIC STARTER SYSTEM ······························ 19-4
ENGINE DOES NOT START OR
RIGHT SIDE COVER ··················································· 17-7 IS HARD TO START ················································ 22-2
SEAT ············································································ 3-10 ENGINE LACKS POWER ········································ 22-3
S
24-2