Tài liệu hướng dẫn sửa chữa xe máy SH150

82K0SF00.
book 1 ページ２０１９年９月１８日水曜日午後２時５８分
http://hocsuaxemay.edu.vn
1. GENERAL INFORMATION
A Few Words About Safety ···················· 1-2 SPECIAL TOOL LIST····························· 1-18
How To Use This Manual························ 1-3 CABLE & HARNESS ROUTING ············ 1-19
MODEL IDENTIFICATION ······················· 1-5 TECHNICAL FEATURES ······················· 1-29
SPECIFICATIONS ···································· 1-6 MAINTENANCE SCHEDULE················· 1-34
TORQUE VALUE···································· 1-13
1-1
82K0SF00.book 2 ページ２０１９年９月１８日水曜日午後２時５８分
GENERAL INFORMATION
GENERAL INFORMATION
A Few Words About Safety

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.
Improper service or repairs can create an un-

safe condition that can cause your customer
to be
seriously hurt or killed.
Follow the procedures and precautions in this
manual and other service materials carefully.
For Your Safety

Because this manual is intended for the professional service technician, we do not provide warnings about many basic shop safety
practices (e.g., Hot parts–wear gloves). If you have not received shop safety training or do not feel confident about your knowledge
of safe servicing practice, we recommended that you do not attempt to perform the procedures described in this manual.
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.
Failure to properly follow instructions and

precautions can cause you to be seriously
hurt or killed.
Follow the procedures and precautions in this
manual carefully.
Important Safety Precautions

Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and
using safety equipment. When performing any service task, be especially careful of the following:
• Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills
required to perform the tasks safely and completely.
• Protect your eyes by using proper safety glasses, goggles or face shields any time you hammer, drill, grind, pry or work around
pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye protection.
• Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe
burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.
• Protect yourself and others whenever you have the vehicle up in the air. Any time you lift the vehicle, either with a hoist or a jack,
make sure that it is always securely supported. Use jack stands.
Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will
help eliminate several potential hazards:
• Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine
• Burns from hot parts or coolant. Let the engine and exhaust system cool before working in those areas.
• Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way.
Gasoline vapors and hydrogen gases from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when
working around gasoline or batteries.
• Use only a nonflammable solvent, not gasoline, to clean parts.
• Never drain or store gasoline in an open container.
• Keep all cigarettes, sparks and flames away from the battery and all fuel-related parts.
1-2
GENERAL INFORMATION
How To Use This Manual

This manual is "Spec (Specific)" Service Manual. The service and repair information for this model is described in this
manual as specific information. Refer to “Basic" Service Manual for basic/common service information and
instructions.
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.
Your safety, and the safety of others, is very important. To help you make informed decisions we have provided
safety messages and other information throughout this manual. Of course, it is not practical or possible to warn you
about all the hazards associated 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.
You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions.
You CAN be HURT if you don’t follow instructions.
• 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 Motor 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 PERMISSION. THIS MANUAL IS WRITTEN FOR
PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTENANCE ON Honda MOTORCYCLES,
MOTOR SCOOTERS OR ATVS.
© Honda Motor Co., Ltd.

SERVICE PUBLICATION OFFICE
Date of Issue: September, 2019
1-3
GENERAL INFORMATION
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.
INSTRUCTION SYMBOL
Removal or Disassembly procedure. Installation or Assembly procedure.

Disconnect the connector. Connect the connector.
Order of installation/assembly with a point of

Order of removal/disassembly with a point of note.
note.
Tighten specified torque. Replace with a new one before assembly.
Check the part for an inspection. Measure the part for an inspection.
Turn ignition switch to OFF. Turn ignition switch to ON.
Start the engine. Measure a resistance or check continuity.
Measure a voltage. Measure an ampere.
Refer to “Basic” Service Manual for the instruc-

Use the Honda special tool.
tion.
LUBRICATION AND SEAL SYMBOL

Apply molybdenum oil solution (mixture of an
Use the recommend engine oil. engine oil and molybdenum grease in a ration of
1:1).
Apply a specified grease. Use a multi-purpose
Apply a liquid sealant.
grease unless otherwise specified.
Apply a locking agent. Use a medium strength

Use DOT 3 or DOT 4 brake fluid.
one unless otherwise specified.
Use a specified fork oil or suspension fluid.
1-4
GENERAL INFORMATION
MODEL IDENTIFICATION
• Model name: SH125D/AD-L, SH150D/AD-L
DESTINATION
TYPE CODE REGION CBS ABS
CODE
SH125D V Vietnam O –
SH125AD V Vietnam – O
SH150D V Vietnam O –
SH150AD V Vietnam – O
SH150AD IN Indonesia – O
VEHICLE IDENTIFICATION NUMBER
ENGINE SERIAL NUMBER
1-5
GENERAL INFORMATION
SPECIFICATIONS
GENERAL SPECIFICATIONS
SH125D/AD
ITEM SPECIFICATIONS
DIMENSIONS Overall length 2,090 mm
Overall width 739 mm
Overall height 1,129 mm
Wheelbase 1,353 mm
Seat height 799 mm
Footpeg height 289 mm
Ground clearance 146 mm
Curb weight SH125D 133 kg
SH125AD 134 kg
Maximum weight capacity 180 kg
FRAME Frame type Under bone
Front suspension Telescopic fork
Front axle travel 90 mm
Rear suspension Unit swing
Rear axle travel 85 mm
Front tire size 100/80-16M/C 50P
Rear tire size 120/80-16M/C 60P
Front tire brand SS-530F (IRC), SS-530F D (IRC)
Rear tire brand SS-530R (IRC)
Front brake Hydraulic single disc
Rear brake Hydraulic single disc
Caster angle 26° 0’
Trail length 86 mm
Fuel tank capacity 7.0 liters
ENGINE Cylinder arrangement Single cylinder inclined 80° from vertical
Bore and stroke 53.500 x 55.502 mm
Displacement 124.77 cm3
Compression ratio 11.5 : 1
Valve train Chain driven OHC
Intake valve opens 0° BTDC at 1 mm lift
closes 20° ABDC at 1 mm lift
Exhaust valve opens 35° BBDC at 1 mm lift
closes -10° TDC at 1 mm lift
Lubrication system Forced pressure and wet sump
Oil pump type Trochoid
Cooling system Liquid cooled
Air filtration Viscous paper filter
Engine dry weight 31.3 kg
Emission control system Crankcase emission control system
Three-way catalytic converter
Evaporative emission control system
FUEL SYSTEM Type PGM-FI
Throttle bore 28 mm
DRIVE TRAIN Clutch system Automatic centrifugal clutch, dry
Final reduction 11.423 (54/16 x 44/13)
ELECTRICAL Ignition system Full transistorized
Starting system Electric starter
Charging system Triple phase output alternator
Regulator/rectifier Triple phase full wave energizing angle con-
trol system
Lighting system Battery
1-6
GENERAL INFORMATION
SH150D/AD
ITEM SPECIFICATIONS
DIMENSIONS Overall length 2,090 mm
Overall width 739 mm
Overall height 1,129 mm
Wheelbase 1,353 mm
Seat height 799 mm
Footpeg height 289 mm
Ground clearance 146 mm
Curb weight SH150D 133 kg
SH150AD 134 kg
Maximum weight capacity V model 180 kg
IN model 150 kg
FRAME Frame type Under bone
Front suspension Telescopic fork
Front axle travel 90 mm
Rear suspension Unit swing
Rear axle travel 85 mm
Front tire size 100/80-16M/C 50P
Rear tire size 120/80-16M/C 60P
Front tire brand V model SS-530F (IRC), SS-530F D (IRC)
IN model SS-530F D (IRC)
Rear tire brand SS-530R (IRC)
Front brake Hydraulic single disc
Rear brake Hydraulic single disc
Caster angle 26° 0’
Trail length 86 mm
Fuel tank capacity 7.0 liters
ENGINE Cylinder arrangement Single cylinder inclined 80° from vertical
Bore and stroke 60.000 x 55.502 mm
Displacement 156.93 cm3
Compression ratio 12.0 : 1
Valve train Chain driven OHC
Intake valve opens 0° BTDC at 1 mm lift
closes 40° ABDC at 1 mm lift
Exhaust valve opens 35° BBDC at 1 mm lift
closes 0° ATDC at 1 mm lift
Lubrication system Forced pressure and wet sump
Oil pump type Trochoid
Cooling system Liquid cooled
Air filtration Viscous paper filter
Engine dry weight 33.1 kg
Emission control system Crankcase emission control system
Three-way catalytic converter
Evaporative emission control system
FUEL SYSTEM Type PGM-FI
Throttle bore 28 mm
DRIVE TRAIN Clutch system Automatic centrifugal clutch, dry
Final reduction 10.552 (53/17 x 44/13)
ELECTRICAL Ignition system Full transistorized
Starting system Electric starter
Charging system Triple phase output alternator
Regulator/rectifier Triple phase full wave energizing angle con-
trol system
Lighting system Battery
1-7
GENERAL INFORMATION
FUEL & ENGINE SPECIFICATIONS
FUEL SYSTEM
ITEM SPECIFICATIONS
Throttle body identification number GQPHA
Idle speed 1,700 ± 100 rpm
Throttle grip freeplay 2 – 6 mm
Fuel pressure at idle 263 – 316 kPa
Fuel pump flow (at 12 V) 82 cm3 minimum/10 seconds
LUBRICATION SYSTEM
Unit: mm
ITEM STANDARD LIMIT
Engine oil capacity After draining 0.8 liters –
After disassembly 0.9 liters –
Recommended engine oil Honda “4-stroke motorcycle oil” or an
equivalent motor oil.
API service classification:
–
SG or higher
JASO T903 standard: MB
Viscosity: SAE 10W-30
Oil pump rotor Tip clearance 0.15 0.20
COOLING SYSTEM
ITEM STANDARD LIMIT

Coolant capacity Replacement 0.43 liters –
Radiator cap relief pressure 107.9 – 137.3 kPa –
Thermostat Begin to open 84 – 88°C –
Fully open 95°C –
Valve lift 5.3 mm minimum –
Recommended antifreeze Honda PRE-MIX Coolant –
CYLINDER HEAD/VALVES
Unit: mm
ITEM STANDARD LIMIT
Cylinder compression 1,098 kPa at 850 rpm –
Valve clearance IN 0.10 ± 0.02 –
EX 0.24 ± 0.02 –
Camshaft Cam lobe SH125D/AD IN 33.5731 – 33.7331 33.5431
height EX 33.2245 – 33.3845 33.1945
SH150D/AD IN 34.0980 – 34.2580 34.0680
EX 33.7267 – 33.8867 33.6967
Rocker arm I.D. 11.000 – 11.018 11.058
Rocker arm shaft O.D. 10.972 – 10.987 –
Valve, Valve guide Valve stem O.D. IN 4.475 – 4.490 4.465
EX 4.460 – 4.485 4.450
Valve guide I.D. IN/EX 4.500 – 4.512 4.542
Valve guide projection IN 15.35 – 15.65 –
above cylinder head EX 14.35 – 14.65 –
Valve seat width IN/EX 0.90 – 1.10 1.5
Valve spring free length IN/EX 36.21 35.5
Cylinder head warpage – 0.05
Exhaust pipe stud bolt height 14.5 – 15.5 –
1-8
GENERAL INFORMATION
CYLINDER/PISTON (SH125D/AD)
Unit: mm
ITEM STANDARD LIMIT
Cylinder I.D. 53.500 – 53.510 53.400
Warpage – 0.05
Piston, Piston pin Piston O.D. at 5 mm from
53.475 – 53.490 53.590
bottom of skirt
Piston pin bore I.D. 14.002 – 14.008 14.020
Piston pin O.D. 13.994 – 14.000 13.980
Piston rings Piston ring end gap Top 0.10 – 0.15 0.25
Second 0.20 – 0.30 0.40
Oil (side rail) 0.10 – 0.35 0.55
Piston ring-to-ring
Top/Second 0.015 – 0.055 –
groove clearance
Connecting rod small end I.D. 14.010 – 14.028 14.038
CYLINDER/PISTON (SH150D/AD)
Unit: mm
ITEM STANDARD LIMIT
Cylinder I.D. 60.000 – 60.010 59.900
Warpage – 0.05
Piston, Piston pin Piston O.D. at 5 mm from
59.975 – 59.990 60.090
bottom of skirt
Piston pin bore I.D. 14.002 – 14.008 14.020
Piston pin O.D. 13.994 – 14.000 13.980
Piston rings Piston ring end gap Top 0.10 – 0.15 0.25
Second 0.20 – 0.30 0.40
Oil (side rail) 0.10 – 0.35 0.55
Piston ring-to-ring
Top/Second 0.015 – 0.055 –
groove clearance
Connecting rod small end I.D. 14.010 – 14.028 14.038
DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
Unit: mm
ITEM STANDARD LIMIT
Drive belt width 24.8 23.8
Movable drive face Bushing I.D. 23.989 – 24.052 –
Boss O.D. 23.960 – 23.974 –
Weight roller O.D. 19.92 – 20.08 19.4
Clutch Clutch outer I.D. 125.0 – 125.2 125.5
Lining thickness – 2.0
Driven pulley Face spring free length 145.4 142.5
Driven face O.D. 33.965 – 33.985 –
Movable driven face I.D. 34.000 – 34.025 –
FINAL REDUCTION
ITEM STANDARD LIMIT

Final reduction oil capacity After draining 0.12 liters –
Recommended final reduction oil Honda “4-stroke motorcycle oil” or an
equivalent motor oil.
API service classification:SG or higher –
1-9
GENERAL INFORMATION
CRANKCASE/CRANKSHAFT
Unit: mm
ITEM STANDARD LIMIT
Connecting rod Side clearance 0.10 – 0.35 0.45
Radial clearance 0 – 0.008 0.05
Crankshaft Runout – 2-40
FRAME & CHASSIS SPECIFICATIONS

FRONT WHEEL/SUSPENSION/STEERING
Unit: mm
ITEM STANDARD LIMIT
Cold tire pressure Driver only 200 kPa –
Driver and passenger 200 kPa –
Axle runout – 0.2
Wheel rim runout Radial – 2.0
Axial – 2.0
Fork Spring free length 264.5 259.2
Recommended fluid Honda Ultra Cushion Oil 10W –
Fluid level 101 –
Fluid capacity 103 ± 2.5 cm3 –
REAR WHEEL/SUSPENSION
Unit: mm
ITEM STANDARD LIMIT
Cold tire pressure Driver only 225 kPa –
Driver and passenger 225 kPa –
Wheel rim runout Radial – 2.0
Axial – 2.0
HYDRAULIC BRAKE (SH125D/SH150D)
Unit: mm
ITEM STANDARD LIMIT
Front Specified brake fluid DOT 3 or 4 brake fluid –
Brake disc thickness 3.8 - 4.2 3.5
Brake disc warpage – 0.30
Brake master cylinder I.D. 11.000 – 11.043 –
Brake master piston O.D. 10.957 – 10.984 –
Caliper cylinder I.D. Upper 25.400 – 25.450 –
Center 22.650 – 22.700 –
Lower 25.400 – 25.450 –
Caliper piston O.D. Upper 25.335 – 25.368 –
Center 22.585 – 22.618 –
Lower 25.335 – 25.368 –
Rear Specified brake fluid DOT 3 or 4 brake fluid –
Caliper cylinder I.D. 38.180 – 38.230 –
Caliper piston O.D. 38.115 – 38.148 –
1-10
GENERAL INFORMATION
HYDRAULIC BRAKE (SH125AD/SH150AD)
Unit: mm
ITEM STANDARD LIMIT
Front Specified brake fluid DOT 3 or 4 brake fluid –
Rear Specified brake fluid DOT 3 or 4 brake fluid –
ELECTRICAL SYSTEM SPECIFICATIONS
PGM-FI SYSTEM
ITEM SPECIFICATIONS
IAT sensor resistance (20°C) 1.849 – 2.331 kΩ
ECT sensor resistance (20°C) 2.364 – 2.726 kΩ
Fuel injector resistance 11.4 – 12.6 Ω
O2 sensor heater resistance (20°C) 13.0 – 18.5 Ω
EVAP purge control solenoid valve resistance (20°C) 31.4 – 37.4 Ω
IACV resistance (25°C) 117 – 143 Ω
ABS SYSTEM
ITEM SPECIFICATIONS
Air gap (between the caliper Front 0.40 – 0.99 mm
bracket and pulser ring) Rear 0.40 – 1.13 mm
IGNITION SYSTEM
ITEM SPECIFICATIONS
Spark plug LMAR8L-9 (NGK)
Spark plug gap 0.8 – 0.9 mm
Ignition coil peak voltage 100 V minimum
Ignition timing ("F"mark) 10° BTDC at idle speed
1-11
GENERAL INFORMATION
BATTERY/CHARGING SYSTEM
ITEM SPECIFICATIONS
Battery Type V model GTZ6V/WTZ6V IS
IN model GTZ6V
Capacity 12 V – 5 Ah (10HR)
Voltage Fully charged 12.8 V minimum
(20°C) Needs charging Below 12.3 V
Charging Normal 0.5 A/5 – 10 h
current Quick 2.5 A/1 h
Current leakage SH125D/AD 0.7 mA maximum
SH150D 1 mA maximum
SH150AD V model 1 mA maximum
IN model 0.7 mA maximum
Alternator Capacity SH125D/AD 390 W/5,000 rpm
SH150D/AD 570 W/5,000 rpm
Charging coil resis- SH125D/AD 0.05 – 0.20 Ω
tance (20°C) SH150D/AD 0.03 – 0.20 Ω
LIGHTS/METERS/SWITCHES
ITEM SPECIFICATIONS
Fuse Main fuse A 20 A
Sub fuse 7.5 A x 7, 10 A x 1
ABS motor fuse 30 A
(SH125AD, SH150AD)
ABS solenoid fuse 15 A
(SH125AD, SH150AD)
ABS main fuse 7.5 A
(SH125AD, SH150AD)
Fuel level sensor resistance Full 6 – 10 Ω
Empty 325 – 335 Ω
1-12
GENERAL INFORMATION
TORQUE VALUE
• Each fastener should be tightened to the standard torque value except the fasteners specified torque value.
• Q’TY: Quantity, DIA: Thread diameter (mm), TRQ: Tightening torque (N·m)
STANDARD TIGHTENING TORQUE
FASTENER TYPE TRQ FASTENER TYPE TRQ
5 mm hex bolt and nut 5.2 5 mm screw 4.2
6 mm hex bolt and nut 10 6 mm screw 9.0
8 mm hex bolt and nut 22 6 mm flange bolt 12
10 mm hex bolt and nut 34 8 mm flange bolt and nut 27
12 mm hex bolt and nut 54 10 mm flange bolt and nut 39
FUEL PUMP UNIT
ITEM Q'TY DIA TRQ REMARKS
Fuel pump set plate nut 4 6 12 2-4
AIR CLEANER
Air cleaner housing cover screw 7 5 1.1
Air cleaner housing bolt 2 6 11
Rear fender C bolt (air cleaner side) 2 6 3.5
THROTTLE BODY
Throttle cable A/B lock nut 2 8 8.5
(Throttle body side)
Sensor unit screw 2 4 2.1
IACV screw 3 4 2.1
Throttle cable bracket bolt 1 5 3.4
Insulator band bolt 2 5 5.0
LUBRICATION SYSTEM
Engine oil drain bolt 1 12 24
Engine oil strainer screen cap 1 30 20
Oil pump bolt 2 6 10
Oil pump plate screw 1 4 3.2
COOLING SYSTEM
Radiator drain bolt 1 10 1.0
Radiator cover bolt 3 6 6.0
Radiator top cover screw 2 4 3.2
Radiator base screw 3 4 0.8
Radiator mounting bolt 4 6 10
CYLINDER HEAD
Valve adjusting screw lock nut 4 5 10 Apply engine oil.
Cam sprocket bolt 2 5 8.0 Apply engine oil.
Camshaft stopper bolt 1 6 10
Rocker arm shaft stopper bolt 2 5 5.0 Apply engine oil.
Cylinder head nut 4 8 30 Apply engine oil.
CYLINDER/PISTON
Cylinder stud bolt 4 8 – 2-30
1-13
GENERAL INFORMATION
DRIVETRAIN
Left crankcase cover duct socket bolt 3 6 10
Drive pulley face nut 1 14 59 Apply engine oil.
Clutch outer nut 1 12 49
Clutch/driven pulley nut 1 28 54
FINAL REDUCTION CASE

Final reduction oil drain bolt 1 8 23
Final reduction case oil check bolt 1 8 23
Final reduction case bolt 6 8 23
ALTERNATOR/STARTER
Cooling fan bolt 3 6 8.5
Flywheel nut 1 12 69
Stator socket bolt 3 6 10
CKP sensor bolt 1 6 10
CRANKCASE
Crankshaft bearing set plate bolt 2 6 12 Apply locking agent.
Engine top cover bolt 1 6 10
Piston oil jet bolt 1 6 10 Apply locking agent.
ENGINE UNIT
Engine hanger link pivot nut 1 10 69 Self lock nut
Engine hanger link bolt 2 10 49
BODY PANELS
Rearview mirror lock nut 2 10 34 Left-hand threads
Rearview mirror adapter bolt 2 10 34
Combination meter mounting screw 2 5 1.2
Rear reflector nut 1 5 1.5 Self lock nut
Rear fender C bolt (air cleaner hous- 2 6 3.5
ing side)
Rear fender C bolt (swingarm side) 2 6 10
SIDESTAND
Sidestand pivot bolt 1 10 10
Sidestand pivot nut 1 10 29 Tighten while holding the pivot
bolt.
EXHAUST PIPE/MUFFLER
Exhaust pipe stud bolt 2 7 – 3-19
Exhaust pipe joint nut 2 7 29 3-19
Muffler mounting bolt 3 10 49 3-19
Muffler protector bolt 2 6 10
1-14
GENERAL INFORMATION
FRONT WHEEL
Front axle nut 1 12 59 Self lock nut
Front brake disc bolt 4 8 42 Pre-coated (ALOC) bolt,
replace with a new one.
Front pulser ring torx bolt 4 5 7.0 Pre-coated (ALOC) bolt,
(SH125AD, SH150AD) replace with a new one.
FORK
Bottom bridge pinch bolt 4 10 39
Fork bottom bolt 2 8 20 Apply locking agent.
HANDLEBAR
Front master cylinder holder bolt 4 6 12
Handlebar post nut 1 10 44 Self lock nut
STEERING STEM
Steering stem top thread 1 26 – 3-25
Steering stem nut 1 26 – 3-25
REAR WHEEL
Rear axle nut 1 16 118 Self lock nut, apply engine oil.
Swingarm mounting bolt 2 10 49
Brake disc bolt 4 8 42 Pre-coated (ALOC) bolt,
Rear pulser ring torx bolt 4 5 7.0 Pre-coated (ALOC) bolt,
(SH125AD, SH150AD) replace with a new one.
REAR SUSPENSION
Shock absorber upper bolt 2 10 39
Shock absorber lower bolt 2 8 27
FRONT BRAKE
Front brake master cylinder reservoir 2 4 1.5
cap screw
Brake hose oil bolt 3 10 34
(SH125D, SH150D)
(SH125AD, SH150AD)
Front brake lever pivot bolt 1 6 1.0
Front brake lever pivot nut 1 6 6.0
Front master cylinder holder bolt 2 6 12
Front brake light switch screw 1 4 1.2
Front brake pad pin 1 10 17
Front brake caliper mounting bolt 2 8 30 Pre-coated (ALOC) bolt,
Brake caliper bleed valve 2 8 5.5
(SH125D, SH150D)
(SH125AD, SH150AD)
Front brake caliper main slide pin 1 8 22 Apply locking agent.
Front brake caliper sub slide pin 1 8 12 Apply locking agent.
1-15
GENERAL INFORMATION
CBS (SH125D/SH150D)
Brake pipe joint nut 2 10 14
REAR BRAKE
Rear brake lever pivot bolt 1 6 1.0
Rear brake lever pivot nut 1 6 6.0
Rear brake master cylinder reservoir 2 4 1.5
cap screw
Rear master cylinder holder bolt 2 6 12
Rear brake light switch screw 2 4 1.2
Rear brake caliper mounting bolt 2 8 30 Pre-coated (ALOC) bolt,
Rear brake caliper main slide pin 1 8 22 Apply locking agent.
Rear brake caliper sub slide pin bolt 1 8 22 Pre-coated (ALOC) bolt,
PGM-FI SYSTEM
ECT sensor mounting bolt 1 6 10
O2 sensor 1 12 24.5
VS sensor protector bolt (SH125D/ 2 6 10 Apply locking agent.
SH150D)
VS sensor mounting bolt (SH125D/ 1 6 10
SH150D)
IGNITION SYSTEM
Spark plug 1 10 16
ABS (SH125AD/SH150AD)
ABS modulator mounting bolt 2 6 10
LIGHTING SYSTEM
License light unit screw 2 4 1.2
Position light mounting screw 4 5 1.2
Front turn signal light mounting screw 2 5 1.2
2 4 1.2 Right side only
Rear combination light mounting 4 5 1.2
screw
ELECTRICAL COMPONENT
Sidestand switch bolt 1 6 10 Pre-coated (ALOC) bolt,
Honda SMART Key SYSTEM
Emergency opener cover screw 1 4 1.2
Ignition switch mounting screw 2 6 9.0 Pre-coated (ALOC) bolt,
1-16
GENERAL INFORMATION
OTHERS
Throttle cable adjuster lock nut 1 6 3.8
Throttle cable A lock nut 1 10 1.5
(Handlebar side)
Throttle cable B lock nut 1 12 1.5
(Handlebar side)
Breather separator plate screw 4 4 3.2
1-17
GENERAL INFORMATION
SPECIAL TOOL LIST

TITLE TOOL No. TOOL NAME
07406-0040004 Fuel pressure gauge
070MJ-K260100 Fuel pressure gauge attachment set
070MF-KVS0300 Fuel pump case remover
070MZ-0010300 SCS connector
070MK-K400100 Cooling system tester adapter
07908-KE90000 Valve adjusting wrench, 3 x 4 mm
07757-0010000 Valve spring compressor
070ME-MCW0100 Valve spring compressor attachment
07HMH-ML00101 Valve guide reamer, 4.5 mm
07HMD-ML00101 Valve guide driver, 4.3 mm
07743-0020000 Valve guide adjusting driver
07725-0040001 Flywheel holder
07725-0030000 Universal holder
07LME-GZ40201 Clutch spring compressor
Fuel & Engine
07GMA-KS40100 Socket wrench, 39 x 41 mm
07SMC-0010001 Case puller
07965-GC70100 Assembly collar A
07965-1660302 Assembly collar B
07965-VM00200 Assembly shaft
07733-0010000 Flywheel puller
07631-0010000 Universal bearing puller
07WMF-KFF0200 Assembly shaft adapter
07965-VM00100 Assembly collar A
07931-KF00100 Assembly collar B
07965-VM00200 Assembly shaft
07749-0010000 Driver
07947-6340400 Attachment, 62 x 64 mm
07746-0030100 Inner driver handle
07HMD-MR70100 Inner driver attachment, 35 mm
07746-0050300 Bearing remover head, 12 mm
07746-0050100 Bearing remover shaft, 9 x 200L
07749-0010000 Driver
07746-0010100 Attachment, 32 x 35 mm
07746-0040200 Pilot, 12 mm
07748-0010001 Oil seal remover
07946-6920100 Attachment, 45 x 50 mm
Frame & Chassis
07702-0020001 Pin spanner
07916-KM10000 Socket wrench
07GMD-KS40100 Ball race remover shaft
07948-4630100 Ball race remover, 34.5 mm
07746-0030400 Attachment, 35 mm I.D
07947-SB00200 Oil seal driver, 53.5 mm
07914-SA50001 Spring ring pliers
070MZ-0010300 SCS connector
Electrical system
07XMZ-MBW0101 Inspection adapter
1-18
GENERAL INFORMATION
CABLE & HARNESS ROUTING

ALL TYPE
DIMMER/PASSING
IDLING STOP SWITCH COMBINATION METER SWITCH 4P (Black)
3P CONNECTOR 24P (Gray) CONNECTOR CONNECTOR
HORN SWITCH
3P (Black)
CONNECTOR
TURN SIGNAL SWITCH

3P (Red) CONNECTOR
MULTI SWITCH WIRE
STARTER SWITCH FRONT BRAKE LIGHT
REAR BRAKE LIGHT/
3P (Black) CONNECTOR SWITCH CONNECTORS
INHIBITOR SWITCH WIRE
CBS TYPE
FRONT BRAKE HOSE
REAR BRAKE HOSE
THROTTLE CABLE B
THROTTLE CABLE A
RIGHT TURN
SIGNAL WIRE
LEFT TURN SIGNAL WIRE
HEADLIGHT
UNIT WIRE BLUETOOTH UNIT WIRE
(SH150D/AD only)
FRONT BRAKE HOSE

CONNECTORS: (CBS)
· FRONT SUB-HARNESS
– 9P (Black)
– 9P FRONT BRAKE HOSE
– 4P (Black)
– 4P
1-19
GENERAL INFORMATION
ABS TYPE
FRONT BRAKE HOSE
REAR BRAKE HOSE
THROTTLE CABLE B
THROTTLE CABLE A
RIGHT TURN
SIGNAL WIRE
LEFT TURN SIGNAL WIRE
HEADLIGHT
UNIT WIRE BLUETOOTH UNIT WIRE
(SH150D/AD only)
CONNECTORS: FRONT BRAKE HOSE

· FRONT SUB-HARNESS
– 9P (Black)
– 9P
– 4P (Black)
– 4P
FRONT WHEEL SPEED
SENSOR WIRE
1-20
GENERAL INFORMATION
CBS TYPE
FRONT BRAKE HOSE
REAR BRAKE HOSE
REAR BRAKE PIPE
IGNITION SWITCH
4P (Gray)
CONNECTOR
DELAY VALVE
FRONT BLUETOOTH UNIT WIRE

BRAKE HOSE (SH150D/AD only)
SEAT LOCK CABLE
FUEL TRAY DRAIN HOSE
CBS BRAKE HOSE

SMART HANDLE
LOCK 7P (Green)
CONNECTOR
15 mm max.
REAR BRAKE PIPE
15 mm max.
MAIN WIRE
HARNESS
1-21
GENERAL INFORMATION
ABS TYPE
FRONT BRAKE HOSE
REAR BRAKE HOSE
IGNITION SWITCH
4P (Gray)
CONNECTOR
REAR BRAKE PIPE

(To caliper) REAR BRAKE PIPE
(From master cylinder)
FRONT WHEEL SPEED

SENSOR WIRE
FRONT BRAKE PIPE

FRONT (From master cylinder)
BRAKE HOSE
FRONT BRAKE PIPE
(To caliper)
BLUETOOTH UNIT WIRE

(SH150D/AD only)
SEAT LOCK CABLE
FUEL TRAY DRAIN HOSE
SMART HANDLE
LOCK 7P (Green)
CONNECTOR
FRONT WHEEL
SPEED SENSOR 2P
(Black) CONNECTOR
15 mm max.
REAR BRAKE PIPE
15 mm max.
MAIN WIRE
HARNESS
1-22
GENERAL INFORMATION
CBS type:
TURN SIGNAL
RELAY
FRONT SUB-HARNESS
MAIN WIRE HARNESS

FRONT
BRAKE HOSE FUEL LID
OPENER WIRE
CHARGE HOSE
(to EVAP CANISTER)
CBS BRAKE
HOSE
ABS type:
THROTTLE CABLE A TURN SIGNAL
RELAY
THROTTLE CABLE B MAIN WIRE
HARNESS
FRONT SUB-HARNESS
MAIN WIRE HARNESS

FRONT
BRAKE HOSE FUEL LID
OPENER WIRE
CHARGE HOSE
(to EVAP CANISTER)
FRONT WHEEL
SPEED SENSOR
THROTTLE CABLE A
THROTTLE CABLE B MAIN WIRE

HARNESS
1-23
GENERAL INFORMATION
BATTERY
LICENSE LIGHT WIRE
VS SENSOR 2P
(Black) CONNECTOR
(CBS type only)
EVAP CANISTER-to-
PURGE CONTROL
SOLENOID VALVE
HOSE
AIR CLEANER
HOUSING DRAIN
TUBE
CRANKCASE
BREATHER
DRAIN TUBE
SIDESTAND
CRANKCASE
SWITCH
BREATHER HOSE
FUEL PUMP UNIT 5 mm max.

5P CONNECTOR
SEAT LOCK
CABLE
5 mm max.
MAIN WIRE
HARNESS
1-24
GENERAL INFORMATION
LICENSE PLATE
LIGHT 2P (Black)
SMART
CONNECTOR CKP SENSOR 6P
CONTROL UNIT
(Black) CONNECTOR
REAR COMBINATION
LIGHT 8P (Black) ENGINE SUB-HARNESS 12P
CONNECTOR (Black) CONNECTOR B
ENGINE SUB-HARNESS 12P

(Black) CONNECTOR A
FRAME GROUND
TERMINAL
BUZZER
ECM 39P (Black)

CONNECTOR
REAR WHEEL SPEED SENSOR

(ABS type only) EVAP CANISTER
AIR HOSE
FRAME GROUND TERMINAL
REAR BRAKE
HOSE
MAIN WIRE HARNESS
1-25
GENERAL INFORMATION
SEAT LOCK CABLE
BUZZER WIRE CONNECTOR
INJECTOR 2P
CONNECTOR EVAP PURGE CONTROL
SOLENOID VALVE-to-
FUEL PUMP UNIT INTAKE PIPE HOSE
5P CONNECTOR
FUEL TRAY
DRAIN HOSE
ENGINE GROUND
TERMINAL
CHARGE HOSE
(to EVAP CANISTER)
IACV 4P (Black)
CONNECTOR EVAP PURGE CONTROL SOLENOID
SENSOR UNIT 5P VALVE 2P (Black) CONNECTOR
(Black) CONNECTOR
ECT SENSOR 2P EVAP CANISTER-to-EVAP

(Black) CONNECTOR PURGE CONTROL
SOLENOID VALVE HOSE
1-26
GENERAL INFORMATION
EVAP CANISTER-to-
EVAP PURGE CONTROL PURGE CONTROL
SOLENOID VALVE-to- SOLENOID VALVE HOSE
INTAKE PIPE HOSE FUEL PUMP 5P
CONNECTOR
SIDESTAND SWITCH Tab
SIPHON HOSE
FUSE/RELAY BOX
SMART
REAR WHEEL SPEED
CONTROL UNIT
SENSOR 2P (Black)
CONNECTOR
(ABS type only)
ECM 39P (Black)

CONNECTOR
ALTERNATOR/STARTER
3P (Brown) CONNECTOR
SEAT LOCK CABLE
LICENSE LIGHT
WIRE
ECM 5P (Black), 3P (Black)
CONNECTORS
1-27
GENERAL INFORMATION
ALTERNATOR/STARTER CKP SENSOR 6P (Black) CONNECTOR

3P (Brown) CONNECTOR
RESERVE TANK
OVERFLOW HOSE
Left
REAR WHEEL SPEED SIPHON

SENSOR WIRE HOSE
FUEL FEED
HOSE
CRANKCASE
BREATHER HOSE
REAR BRAKE HOSE
Right O2 SENSOR WIRE
Front
Left
1-28
GENERAL INFORMATION
TECHNICAL FEATURES
FUEL PUMP SYSTEM WITH A FUEL FILTER BLOCKAGE REMINDER FUNCTION
FUEL TANK
BREATHER FILTER
FUEL PUMP
FUEL LEVEL
BREATHER
PASSAGE
PUMP CHAMBER
To FUEL INJECTOR
FUEL FILTER
: Air suction passage under fuel filter blockage
: Air discharge passage under normal fuel filter condition
: Fuel flow under normal fuel filter condition
The fuel pump system of this model consists of the following components:
– Fuel pump chamber
– Fuel filter
– Breather passage
– Breather filter
Under normal condition, the fuel pump chamber sucks fuel through the fuel filter and then supplies it to the injector.
When the fuel filter is clogged, the fuel is sucked into the pump chamber through the breather passage in order to
keep the vehicle running. The breather filter is located in the upper inner side of fuel tank. When the fuel is consumed
to the point where the breather filter is exposed above the fuel level, a certain amount of air will be drawn into the
pump chamber via the breather filter and breather passage. This incoming air produces "a lack of fuel", which impairs
engine performance in order to notify the rider of the fuel filter blockage. This symptom works as a reminder for the
filter replacement.
This system eliminates the need of fuel filter replacement according to a fixed interval, as the rider will experience the
symptom and notice the filter blockage during vehicle usage.
The driveability remains normal as long as the fuel level in tank is maintained above the breather filter because no air
will be drawn into the pump chamber, even when the fuel filter is clogged.
If the fuel in tank is sufficient but such symptom as poor engine performance, lack of fuel, or engine start failure exist,
perform the fuel supply test .2-3
If the fuel filter is replaced, the ECM must be initialized to avoid a rich fuel condition.
1-29
GENERAL INFORMATION
HYDRAULIC CAM CHAIN TENSIONER LIFTER
The engine of this vehicle is equipped with a hydraulic cam chain
OIL LEAKAGE INNER SHAFT
tensioner lifter, which contributes to improvement of the fuel mileage
and also has a longer service-life compared with a conventional CLEARANCE
screw type cam chain tensioner lifter.
The attenuation occurs due to a small amount of oil leaks out from
the clearance between the inner shaft and outer shaft.
The resistance between the tensioner and cam chain is reduced as CLIP
the cam chain reaction force is reduced by oil attenuation.
Tensioner lifter cap – Tensioner lifter cap composes one of
the oil path of the hydraulic system
and regulates the oil volume. CHECK
Inner shaft – Inner shaft retains the main spring VALVE
and check valve.
Main spring – Main spring makes the tensioner fol-
low the movement of the cam chain.
Outer shaft – Outer shaft conveys the main spring OUTER SHAFT MAIN SPRING
force to the tensioner, and also builds
the high pressure chamber.
Oil leakage clearance – Oil leaks out of the outer shaft and at-
tenuation occurs.
Engine oil pressurized from the oil pump is sent to the inner shaft (low pressure chamber) via the tensioner lifter cap
through the oil path which branched from the cylinder stud hole. Moreover, oil passes a check valve, and is sent into
the outer shaft.
The movement of the cam chain tensioner follows a motion of the cam chain by the main spring in the outer shaft.
When receiving reaction force from the cam chain, a high-pressure chamber is composed in the outer shaft by closing
the check valve, and then the tensioner is caught by the lifter. At the same time, by the attenuation which occurs due
to oil leakage clearance, the chain reaction force decreases and also resistance between the tensioner and lifter is
reduced.
If the tensioner lifter is removed from the engine, it is necessary to refill the engine oil into the tensioner lifter when
reassembling.
OIL ENTRANCE HOLE OIL PATH

LOW PRESSURE
CHAMBER
TENSIONER
CAM CHAIN LIFTER CAP
TENSIONER LIFTER OIL RETURN
PASSAGE
CAM CHAIN HIGH PRESSURE

TENSIONER CHAMBER GASKET
CAM CHAIN
1-30
GENERAL INFORMATION
ENGINE OIL CIRCUIT DIAGRAM:
CYLINDER HEAD
OIL
PUMP
TENSIONER LIFTER
CRANKCASE
PISTON OIL JET
HSTC (Honda Selectable Torque Control; SH125AD/SH150AD)

This vehicle adopts the HSTC (Honda Selectable Torque Control). HSTC offers reassurance to the rider while running
on the road surface which tends to slip.
System description:
ABS
MODULATOR
FRONT WHEEL REAR WHEEL

SPEED SIGNAL SPEED SIGNAL
INDICATOR
SENSOR SIGNAL SENSOR SIGNAL
PGM-FI ECM
OVER-TRACTION
SIGNAL
FRONT WHEEL ENGINE TORQUE REAR WHEEL

SPEED SENSOR CONTROL SPEED SENSOR
SLIP CONTROL
ENGINE
ECM calculates the slip rate of the rear wheel by receiving the sensor signals sent from the wheel speed sensors
nearby front and rear wheels.
The engine torque is controlled by regulation of fuel injection and a slip of a rear wheel is restrained.
HSTC indicator installed in the combination meter informs the rider that the system is activated by flashing the HSTC
indicator.
According to the situation of the road surface, the system can be switched to ON or OFF by operating the left
handlebar switch.
• HSTC is the system to help rider's operation, not the system that a vehicle does not slip.
1-31
GENERAL INFORMATION
OBD (On-Board Diagnostic) SYSTEM
Existing PGM-FI system already equips the self-diagnostic system that detects the PGM-FI system malfunction, and
that malfunction data can be read by MCS (Motorcycle Communication System as the DTCs or freeze data.
Based on existing PGM-FI diagnostic system, for OBD, following items are equipped with this vehicle.
– Additional self-diagnostic function for the fuel emission control
– MIL indication pattern for malfunction
– GST (General Scan Tool) connection to the vehicle
MIL INDICATION
In the existing PGM-FI system, if the PGM-FI system detects the malfunction at the present, the MIL blinks the number
of trouble code with idle engine speed or sidestand switch ON. But in this PGM-FI system for OBD, when the system
detects the malfunction, it turns the MIL ON without blinking unless otherwise the SCS circuit short (reading DTC with
DLC connector).
Existing PGM-FI This PGM-FI
At Idle Riding SCS short At Idle Riding SCS short
Current trouble Blinking ON Blinking ON ON Blinking
Past trouble OFF OFF Blinking *ON *ON *Blinking
* This system turn off the MIL if the system does not detect the same trouble again in three driving cycle (three times
repeat of ignition-ON, riding and ignition-OFF).
GST (General Scan Tool)
The PGM-FI system of this vehicle supports the connection of the GST that is commercially available as the diagnostic
tool for the vehicle. As same as MCS (Motorcycle Communication System; Honda genuine diagnostic tool), the GST
can be used for DTC, freeze data and ECM data reading.
The DTCs read by GST are standardized by ISO standard, those are different code system from existing Honda code
system read by MCS. Refer to DTC INDEX 4-2 for each DTC and troubleshooting detail.
To connect the GST to the vehicle, remove the 6P dummy connector and connect the GST.
For using the GST, refer to the instruction manual attached each GST.
DLC 6P
GST
1-32
GENERAL INFORMATION
OBD harness circuit connection (General allocation in ISO 15031-3)
DLC 6P 16P
Signal ground A 5
– B –
Discretionary (SCS line) C 9
K-line D 7
– E –
Permanent positive battery F 16
1-33
GENERAL INFORMATION
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 a dealer.
• Refer to “Basic" Service Manual for each maintenance instruction except the instructions described in this
manual.
FREQUENCY (NOTE 1) REFER

ANNUAL REGULAR
ITEMS NOTE X1,000 km 1 6 12 18 24 30 36 TO
CHECK REPLACE
X1,000 mi 0.6 4 8 12 16 20 24 PAGE
* FUEL LINE I I I I I I I
* THROTTLE OPERATION I I I I I I I
* AIR CLEANER NOTE2 R R 2-9
CRANKCASE BREATHER NOTE3 C C C C C C
SPARK PLUG I R I R I R 4-33
* VALVE CLEARANCE I I I I I I 2-24
ENGINE OIL R R R R R R R R 2-17
ENGINE OIL STRAINER
C C C 2-17
SCREEN
* ENGINE IDLE SPEED I I I I I I I I
RADIATOR COOLANT NOTE4 I I I I 3 years 2-19
* COOLING SYSTEM I I I I
* EVAPORATIVE EMISSION
I I
CONTROL SYSTEM
* DRIVE BELT I R I
* FINAL DRIVE OIL NOTE4 2 years 2-35
* BATTERY I I I I I I I
BRAKE FLUID NOTE4 I I I I I I I 2 years 3-34
BRAKE PADS WEAR I I I I I I I
BRAKE SYSTEM I I I I I I I I
HEADLIGHT AIM I I I I I I I 4-61
** CLUTCH SHOES WEAR I I I
SIDESTAND I I I I I I I
* SUSPENSION I I I I I I I
* NUTS, BOLTS, FASTENERS I I I I I
** WHEELS/TIRES I I I I I I I
** STEERING HEAD BEARINGS I I I I
• * Should be serviced by a dealer, unless the owner has proper tools and service data and is mechanically qualified.
• ** In the interest of safety, we recommend these items be serviced only by a dealer.
• Honda recommends that a dealer should road test the vehicle after each periodic maintenance is carried out.
NOTES:
1. At higher odometer readings, repeat at the frequency interval established here.
2. Service more frequently when riding in unusually wet or dusty areas.
3. Service more frequently when riding in rain or at full throttle.
4. Replacement requires mechanical skill.
1-34
2. FUEL & ENGINE
FUEL LINE················································ 2-2 CYLINDER HEAD ·································· 2-24
FUEL PUMP UNIT ···································· 2-4 CYLINDER/PISTON ······························· 2-30
FUEL TANK·············································· 2-7 DRIVETRAIN ·········································· 2-31
AIR CLEANER·········································· 2-9 FINAL REDUCTION CASE ···················· 2-35
THROTTLE BODY·································· 2-10 ALTERNATOR/STARTER ····················· 2-38
EVAP SYSTEM······································· 2-15 CRANKCASE/CRANKSHAFT ··············· 2-39
LUBRICATION SYSTEM························ 2-16 ENGINE UNIT ········································· 2-42
COOLING SYSTEM································ 2-19
2-1
FUEL & ENGINE
FUEL & ENGINE
FUEL LINE
• This vehicle uses resin for the part of materials in the fuel
hose. Do not bend or twist the fuel hose.
• Center cover 3-6
• Luggage box 3-4
• Fuel pump 5P connector 2-7
• Let the engine idle until it stops.
• Battery negative (–) cable 4-58
• Do not use tools in removal. If the connector does not

move, alternately pull and push the connector until it
comes off easily.
• Check the fuel quick connect fitting for dirt, and clean if
necessary.
• Place a shop towel over the quick connect fitting.
• Push the retainer tab forward.
• Press down the retainer and disconnect the connector
from the fuel joint.
• Check the retainer condition and replace the fuel hose if
necessary.
• To prevent damage and keep foreign matter out, cover the
disconnected connector and pipe end with the plastic
bags.
• Press the connector onto the fuel joint until the retainer
locks with a “CLICK”. If it is hard to connect, put a small
amount of engine oil on the pipe end.
• Make sure the connection is secure; check visually and by
pulling the connector.
• After installing the removed parts, turn the ignition switch
ON. (Do not start the engine.)
The fuel pump will run for about 2 seconds, and fuel
pressure will rise. Repeat 2 or 3 times, and check that
there is no leakage in the fuel supply system.
2-2
FUEL & ENGINE
FUEL SUPPLY TEST
• If the fuel in tank is sufficient but such symptom as poor en-
gine performance, lack of fuel, or engine start failure exist,
perform the following.
• Perform the fuel pressure test. 2-3
If the fuel pressure is within specification, perform the fuel
flow inspection. 2-3
• Perform the fuel flow inspection in the specified fuel quan-
tity. 2-3
FUEL PRESSURE TEST

• Quick connect fitting (fuel pump side)
• Attach the fuel pressure gauge, attachments and manifold.

[A] [A] Fuel pressure gauge: 07406-0040004
[B] Pressure gauge attachment set: 070MJ-K260100
• Temporarily connect the negative cable and fuel pump 5P
connector.
[B]
Start the engine and let it idle, and read the fuel pressure.
Standard: 263 – 316 kPa
• If the fuel pressure is higher than specified, replace the fuel
pump unit. 2-4
to INJECTOR • If the fuel pressure is lower than specified, inspect the
(fuel hose) following.
– Fuel line leaking
– Any erratic swing or vibration of the gauge needle in the
pressure gauge reading.
• If the needle is swing or vibration, replace the fuel fil-
ter. 2-6
• If the needle is stable, replace the fuel pump unit.
2-4
from FUEL PUMP
FUEL FLOW INSPECTION

• Quick connect fitting (injector side)
from FUEL PUMP
• Place the end of the hose into an approved gasoline con-
tainer. Wipe off spilled out gasoline.
• The fuel pump operates for 2 seconds. Repeat 5 times to
meet the total measuring time.
Standard: 82 cm3 minimum/ 10 seconds
• If fuel flow is less than specified, inspect the following:
– Clogged fuel hose
– Fuel pump unit
• Adjust the fuel in the tank so that only one segment (E)
of the fuel gauge is displayed, and inspect the fuel flow.
• If the fuel flow is above specification, check for other mal-
functioning parts.
• If the fuel flow is under specification, replace the fuel filter.
2-6
2-3
FUEL & ENGINE
FUEL PUMP UNIT

12 N·m
Not painting area

• Floor side cover 3-14
• Fuel pump side quick connect fitting (fuel pump side) 2-2
• Remove the four bolts and pull off the floor step stay.
• Loosen the nuts in a crisscross pattern in several steps.
• Carefully remove the fuel pump from the fuel tank to prevent damage the fuel level sensor.
• Fuel clog or excessively damaged
• If the fuel pump filter is clogged, replace it with a new one.
• Apply 1 g maximum of engine oil to the O-ring and install it to the fuel pump unit.
• Tighten the fuel pump set plate nuts in the specified sequence as shown.
• Install the floor step stay and tighten the four bolts.
• Fuel pump malfunction and inspection
2-4
FUEL & ENGINE
G Y G
Y
Y
Y Bl
G R
• Fuel filter 2-6

• To prevent dirt and debris from entering the fuel pump unit, always clean it before disassembly.
• Clean the fuel pump unit and fuel pump filter with clean gasoline. Never use commercially available
carburetor cleaners.
• Fuel pump motor wires (G and Y wire).
• Release the hooks from the stoppers by slightly spreading the hooks using the special tool.
Fuel pump case remover: 070MF-KVS0300
• Before installing the fuel pump filter, check the fuel pump unit for dirt. If necessary, clean the fuel pump unit
with compressed air. Do not blow into the fuel pump unit.
• If the R or Bl wire connector is disconnected, replace the fuel level sensor with a new one.
• Make sure the "CLICK" when the fuel pump unit is assembled.
• Connect the fuel pump motor wires to the specified position.
• Route the fuel pump motor wires and fuel level sensor wires to the guide and terminals properly.
2-5
FUEL & ENGINE
FUEL FILTER
• Fuel pump unit 2-4

• Release the hooks from the stoppers by slightly spreading the hooks.
• Turn the filter clockwise.
• Pull up the filter and remove it from the fuel pump.
• Align the triangle marks on the filter and fuel pump body.
• Turn the filter counterclockwise until the hooks are completely secured by the stoppers.
2-6
FUEL & ENGINE
FUEL TANK
• Floor step 3-17

• Quick connect fitting (fuel pump side) 2-2
2-7
FUEL & ENGINE
2-8
FUEL & ENGINE
AIR CLEANER
Right 3.5 N·m
1.1 N·m
11 N·m
• Discard the air cleaner element in accordance with the maintenance schedule. 1-34
• Replace the element any time if it is excessively dirty or damaged.
2-9
FUEL & ENGINE
THROTTLE BODY
Left
5.0 N·m
8.5 N·m

• Quick connect fitting (injector side) 2-2
• Loosen the insulator band bolts and turn the throttle body to right side to disconnect the throttle cables.
• TP Sensor reset procedure 2-13
• Throttle body cleaning and inspection
2-10
FUEL & ENGINE
5.0 N·m
2-11
FUEL & ENGINE
2.1 N·m
[A]
3.4 N·m
2.1 N·m
• 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 fasteners. Loosening or tightening it can cause throttle body malfunction.
• Do not hold the throttle drum when installing the sensor unit.
Sensor unit
• Install the sensor unit to the throttle body by aligning the clip of the sensor unit and boss of the throttle
valve.
• Perform the TP sensor reset procedure. 2-13
IACV
• Check the IACV for wear or damage.

• The IACV operation can be checked visually as follows:
1. Connect the IACV 4P connector.
2. Turn the ignition switch ON, check the slide piece [A] operation.
2-12
FUEL & ENGINE
TP SENSOR RESET PROCEDURE
• Make sure that DTC is not stored in ECM. If the DTC is
stored in ECM, TP sensor reset mode will not start by fol-
[A] lowing the procedure below.
• Battery box lid 3-4
• Connector cover from the DLC [A].
• Connect the special tool to the DLC.
SCS connector: 070MZ-0010300
[A]
[B]
• ECT sensor 2P (Black) connector [B]
• Short the ECT sensor terminals with jumper wire.
Connection: P/W – G/O
P/W G/O
[B]
• Turn the ignition switch ON then disconnect the
jumper wire from the ECT sensor 3P (Gray) connector
within 10 seconds while the MIL is blinking (reset receiving
[B] pattern).
• Check for the MIL blinks.
After disconnecting the jumper wire, the MIL should start
blinking. (reset completed pattern)
If the jumper wire is connected for more than 10 seconds,
within 10 sec. the MIL will stay ON (unsuccessful pattern). Try again from
the first.
• Check the engine idle speed.
Reset procedure and MIL blinking pattern
within 10 sec. 0.3 sec.

0.3 sec.
0.1 sec.
1.3 sec.
Reset receiving Reset completed
2-13
FUEL & ENGINE
INJECTOR

• Quick connect fitting (injector side) 2-2
• Install the injector joint to the injector by aligning with the both tabs.
2-14
FUEL & ENGINE
EVAP SYSTEM
• Floor step 3-17

• Remove the washer-bolts of the rear fender B. Lower the rear fender B to get the clearance and remove the
EVAP canister from the stays.
2-15
FUEL & ENGINE
LUBRICATION SYSTEM
SYSTEM DIAGRAM
OIL PUMP
CAM CHAIN TENSIONER LIFTER
PISTON OIL JET
OIL STRAINER SCREEN
ENGINE OIL LEVEL CHECK

• Place the vehicle on the level ground with its centerstand.
• Let the engine idle for 3 – 5 minutes.
• Wait for 2 – 3 minutes.
Upper
• Clean and insert the oil filler cap/dipstick without screwing
it in, and then remove it and check the oil level.
• If the oil level is below or near the lower level line on the
Lower dipstick, add the recommended oil to the upper level.
• Check that the O-ring on the oil filler cap is in good
condition, and replace it if necessary.
• RECOMMENDED ENGINE OIL:
Honda “4-stroke motorcycle oil” or an equivalent mo-
tor oil.
API service classification: SG or higher
2-16
FUEL & ENGINE
ENGINE OIL CHANGE
• Drain oil completely.
• Fill the crankcase with the recommended engine oil.

• Check that the O-ring on the oil filler cap is in good
condition, and replace it if necessary.
• ENGINE OIL CAPACITY:
0.8 liter after draining
0.9 liter after disassembly
24 N·m
ENGINE OIL STRAINER SCREEN
20 N·m
• Screen clog or excessively damaged
2-17
FUEL & ENGINE
OIL PUMP
3.2 N·m
10 N·m
• Engine oil 2-17

• Alternator/stator 2-38
• Install the oil seal to the stator base squarely until it is flush with the stator base surface.
• Align the groove with the pin.
• Oil pump inspection
• The oil pump driven gear may discolor in light green due to characteristics of material. Even if this occurs, it
does not influence the efficiency of gear operation.
2-18
FUEL & ENGINE
COOLING SYSTEM
• This service can be serviced with the engine installed in the frame.
SYSTEM DIAGRAM
When the engine is cold:
RADIATOR SIPHON HOSE
RESERVE TANK
OVERFLOW HOSE
THERMOSTAT
RESERVE TANK
RADIATOR
WATER PUMP
COOLANT REPLACEMENT
Coolant drain
• Cooling system testing and inspection
• Radiator cover 2-22

• Drain the coolant from the radiator.
• Carefully remove the radiator cap.
1.0 N·m
2-19
FUEL & ENGINE
• Drain coolant completely.
Air bleeding/Adding
• Fill the system with the coolant through the filler opening to
the filler neck.
RECOMMENDED ANTIFREEZE:
Honda PER-MIX Coolant
• Start the engine and let it idle for 2 – 3 minutes.
• Stop the engine and add coolant up to the filler neck.

• Reinstall the radiator cap.

• Remove the radiator reserve tank cap.
• Fill the reserve tank with the coolant to the upper level line.
2-20
FUEL & ENGINE
COOLING SYSTEM TESTING
RADIATOR CAP/SYSTEM PRESSURE INSPECTION
• Radiator cap.
• Apply coolant to the O-ring whole surface then install the

radiator cap onto the tester adapter.
[A] RC-3B (TOYOTEC) or equivalent
[C] [B] Cooling System Tester Adapter 070MK-K400100
• Pressurize the radiator cap.
[A] RADIATOR CAP RELIEF PRESSURE: 107.9 – 137.3
kPa
If the system can hold the specified pressure for at least 6
seconds, cooling system is normal.
• If the system cannot hold the specified pressure for 6 sec-
onds, remove the radiator cap.
• Inspect the O-rings [C] for deterioration, cuts or other dam-
ages and replace if necessary.
• Apply coolant to the O-rings [C] whole surface and reinstall
[B] the radiator cap.
Recheck if the system can hold the specified pressure for
at least 6 seconds.
• Pressurize the radiator, engine and hoses using the tester,
[A]
and check for leaks.
[B]
[A] RC-3B (TOYOTEC) or equivalent
[B] Cooling System Tester Adapter 070MK-K400100
• Excessive pressure can damage the cooling system com-
ponents. Do not exceed 137.3 kPa.
• Repair or replace components if the system will not hold
the specified pressure for at least 6 seconds.
2-21
FUEL & ENGINE
RADIATOR
6.0 N·m
1.0 N·m
• Right floor side cover 3-14

• Muffler cover 3-19
RADIATOR RESERVE TANK
2-22
FUEL & ENGINE
WATER PUMP/THERMOSTAT
• Coolant 2-19
• Engine unit 2-42
• Do not apply engine oil to this O-ring.
• Apply molybdenum disulfide paste (SUMICO Molypaste 300, Three Bond 1901, or equivalent) to the water
pump shaft mating area with camshaft. Align the pin with the groove.
• Thermostat inspection
2-23
FUEL & ENGINE
CYLINDER HEAD
VALVE CLEARANCE
• Inspect and adjust while the engine is cold (below 35°C).
• After the valve clearance inspection, check the engine idle
speed.
• Radiator (Cooling fan visible without draining coolant)
• Cylinder head cover 2-25
• Turn the crankshaft in rotating direction slowly and align
the cut-out ("T" mark) with the lug on the right crankcase.
• Confirm the TDC (Top Dead Center) on the compression
stroke by checking the tab [A] on the camshaft flange faces
engine top side. If the tab can not be seen, rotate the
crankshaft one full turn slowly and recheck.
[A]
• Valve clearance (Insert a feeler gauge between the valve

10 N·m adjusting screw and valve stem).
IN: 0.10 ± 0.02 mm, EX: 0.24 ± 0.02 mm
Valve adjusting wrench 3 x 4 mm: 07908-KE90000
• Loosen the lock nut and turn the adjusting screw until there
is a slight drag on the feeler gauge.
• Hold the adjusting screw and tighten the lock nut.
• Recheck after tightening.
2-24
FUEL & ENGINE
CYLINDER HEAD COVER
CAMSHAFT/ROCKER ARM
• Coolant 2-19
• Engine oil 2-17
[B] • Engine unit 2-42
• Exhaust pipe/muffler 3-19
• Cylinder head cover 2-25
• Water pump 2-23
• Cam chain tensioner lifter 2-29
• Spark plug 4-33
[A]
• Set the piston to the TDC on the compression stroke.
2-24
• Make sure that the index lines [A] on the cam sprocket
aligns with the index marks of cylinder head and that the
"K0R" mark [B] on the cam sprocket is in position shown
(TDC).
If the cam sprocket mark is not in position shown, rotate
the crankshaft one full turn.
2-25
FUEL & ENGINE
30 N·m
"IN"
"EX"
8.0 N·m
• Remove the cam sprocket.

• Remove the cylinder head bolts.
• Loosen the cylinder head nuts in a crisscross pattern in several steps.
• Align the pins with the grooves.
• Confirm the tab [A] of the camshaft flange faces to engine top side.
• Set the piston to the TDC and install the cam sprocket with aligning its index lines with the index marks
on the cylinder head as shown.
• Temporary tighten the cam sprocket bolts in numerical order, then retighten the bolts to the specified
torque.
2-26
FUEL & ENGINE
5.0 N·m
Whole surfaces
10 N·m
• Turn the decompressor with your finger. Make sure that the decompressor operates smoothly and that the
weight returns back in position.
• Install the camshaft with its flange tab facing backward.
• Turn the camshaft 180° so that the tab on the camshaft flange is facing forward as shown.
• Intake and exhaust rocker arms have identification marks, "I" is for the intake rocker arm and "E" is for the
exhaust rocker arm.
• Insert the rocker arm shafts into the cylinder head using a screwdriver while aligning with the bolt holes of
the shaft and cylinder head.
• Camshaft inspection
2-27
FUEL & ENGINE
IN: 15.35 – 15.65 mm

EX: 14.35 – 14.65 mm
• Remove the valve cotters.

Valve spring compressor: 07757-0010000
Valve spring compressor attachment: 070ME-MCW0100
• Ream the valve guide to remove any carbon build up before measuring the guide. Insert the reamer from
the combustion chamber side of the cylinder head and always rotate the reamer clockwise.
Valve guide reamer, 4.5 mm: 07HMH-ML00101
• Support the cylinder head and drive the valve guides out of the cylinder head from the combustion
chamber side.
Valve guide driver, 4.3 mm: 07HMD-ML00101
• Drive new valve guides into the cylinder head to the specified height from the cylinder head.
VALVE GUIDE PROJECTION: IN: 15.35 – 15.65 mm, EX: 14.35 – 14.65 mm
Valve guide adjusting driver: 07743-0020000
• Valve and valve spring inspection
• Valve guide inspection
• Valve seat inspection
2-28
FUEL & ENGINE
CAM CHAIN TENSIONER LIFTER
• Throttle body 2-10
• Loosen the bolts alternately while holding the tensioner lift-
er cap, then remove the bolts, cap, gasket and cam chain
tensioner lifter.
• Check the cam chain tensioner lifter operation:

– The inner shaft should go into the outer shaft without
sticking when it is pushed, and should return smoothly.
• Fill the inner shaft with clean engine oil.

• Gentry push the inner shaft to penetrate the oil into the
outer shaft.
Repeat the above procedures once again.
• Cover around the tensioner lifter base on the cylinder

with a rag.
Install the cam chain tensioner lifter into the opening of the
cylinder.
• Refill the inner shaft with clean engine oil.
• Install the tensioner lifter cap with a new gasket in the re-
verse order of removal.
2-29
FUEL & ENGINE
CYLINDER/PISTON
186.2 – 187.2 mm
• Cylinder head 2-24

• Cam chain tensioner 2-29
• Spread each piston ring and remove it by lifting up at a point opposite the gap.
• Carefully install the piston rings into the piston ring grooves with the markings facing up.
• Install the piston with the “IN” mark facing the intake side.
• Do not align the piston pin clip end gap with the piston cut-out.
• Piston and piston rings inspection
• Cylinder inspection
2-30
FUEL & ENGINE
DRIVETRAIN
DRIVE PULLEY/DRIVE BELT
10 N·m
• Left floor side cover 3-14
• Clean any oil and grease from the bearing bushing on the left crankcase cover.
2-31
FUEL & ENGINE
59 N·m
49 N·m
• Left crankcase cover 2-31

• Hold the drive pulley face with special tool and loosen the drive pulley face nut.
Universal holder: 07725-0030000
• Hold the clutch outer with the special tool and loosen the outer nut. Holding the rear wheel or rear brake
will damage the final reduction system.
Flywheel holder: 07725-0040001
• Clean any oil and grease from the driven face and drive belt.
• Hold the clutch/driven pulley assembly and compress the driven face spring by turning movable driven
face clockwise until it stops. Install the clutch outer while aligning its splines with driven shaft splines.
• Set the drive belt and install the drive pulley face while aligning its splines with crankshaft splines.
Make sure that the drive pulley face is fully seated on the drive face boss.
• Drive pulley face inspection
2-32
FUEL & ENGINE
• Left crankcase cover 2-31

• Drive pulley face 2-31
• Remove the movable drive face assembly while holding the back of the face and drive face boss.
• Clean any oil and grease from the weight rollers and movable drive face.
• Clean any oil and grease from the drive face and drive belt.
Install the movable drive face assembly onto the crankshaft while holding the ramp plate and drive face boss.
• Weight roller, movable drive face, and boss inspection
2-33
FUEL & ENGINE
CLUTCH/DRIVEN PULLEY
54 N·m
• Driven pulley 2-31

• Set the clutch spring compressor onto the clutch/driven pulley by aligning the bosses of the compressor
with the holes of the clutch.
Clutch spring compressor: 07LME-GZ40201
• Remove the clutch/driven pulley nut.
Socket wrench, 39 x 41 mm: 07GMA-KS40100
• Clean any oil and grease from the pulley face.
Install the movable driven face onto the driven face. Install the guide rollers and guide pins.
• Apply 1.7 – 2.2 g of grease (Shell ALVANIA R3, NIPPON OIL POWERNOC WB3, IDEMITSU AUTOREX
B, or equivalent) to each guide groove.
• Hook the shoe spring ends to the clutch shoe holes with their long ends facing the center holes and short
ends facing the neighboring shoe holes as shown.
• Set the clutch spring compressor over the clutch/driven pulley assembly aligning the bosses of the
compressor with the holes of the clutch.
Clutch spring compressor: 07LME-GZ40201
Compress the driven face spring while aligning the cutout of the driven face threads with the drive plate hole,
and install the clutch/driven pulley nut and tighten it.
• Clutch outer, clutch shoe and driven face inspection
2-34
FUEL & ENGINE
Bearing replacement
1.00 – 1.75 mm
• Pack new ball bearing with grease (NIPPON OIL P/U N6B, N6C, or equivalent). Install the ball bearing
into the driven face squarely until it is fully seated with its sealed side facing down.
• Apply 7.3 – 8.3 g of grease (Shell ALVANIA R3, NIPPON OIL POWERNOC WB3, IDEMITSU AUTOREX
B, or equivalent) to the driven face inner surface as shown.
• Apply grease (Shell RETINEX LX2, NIPPON OIL P/U N6B, or equivalent) to a new needle bearing. Set
the needle bearing with its sealed side facing up. Press the needle bearing into the driven face until the depth
from the driven face surface is 1.00 –1.75 mm as shown.
FINAL REDUCTION CASE

REDUCTION OIL REPLACEMENT
• Place an oil drain pan under the final reduction case to
23 N·m
collect the oil.
• Slowly turn the rear wheel and drain the oil.
• Fill the final reduction case with recommended oil up to the

correct level.
23 N·m
Correct level
2-35
FUEL & ENGINE
23 N·m
: Each teeth, each bearing
• Final drive oil 2-35

• Air cleaner housing 2-9
• Clutch/driven pulley 2-34
• Rear wheel 3-26
• VS sensor (SH125D/SH150D) 4-31
• Loosen the final reduction case bolts in a crisscross pattern.
• Drive shaft from the left crankcase
Case puller: 07SMC-0010001
2-36
FUEL & ENGINE
BEARING REPLACEMENT
[A] [B] [C]
LEFT CRANKCASE FINAL REDUCTION CASE
[A] [B] [C]
0.2 – 0.8 mm
0.4 – 0.8 mm
• Pull the drive shaft into the bearing until it is fully seated.
• Install the oil seal to the left crankcase so that the depth as shown.
– [A] Assembly shaft: 07965-VM00200
– [B] Assembly collar: 07965-GC70100
– [C] Assembly collar: 07965-1660302
2-37
FUEL & ENGINE
ALTERNATOR/STARTER
Degrease.
69 N·m
8.5 N·m
10 N·m
10 N·m
• Body cover 3-7

• Radiator2-22
• Hold the flywheel with the special tool for the nut removal.
Universal holder: 07725-0030000
• Flywheel
Flywheel puller: 07733-0010000
• Degrease the crankshaft and flywheel thoroughly.
• Install the flywheel onto the crankshaft by aligning the key way on the flywheel with the woodruff key.
• Install the cooling fan while aligning its boss with the hole on the flywheel.
2-38
FUEL & ENGINE
CRANKCASE/CRANKSHAFT
• Engine unit 2-42 • Drive pulley 2-31 • Oil pump 2-18

• Centerstand 3-18 • Driven pulley 2-34 • Final reduction case 2-35
• Cylinder/piston 2-30 • Alternator/starter 2-38
• Remove the crankcase bolts in a crisscross pattern.
• Place the crankcase with the left crankcase facing down and separate.
• Remove the bolts and crankshaft bearing set plate.
• Crankshaft from the left crankcase
Case puller: 07SMC-0010001
• If the crankshaft bearing remains in the left crankcase, remove it to the right side.
• Bearing from the crankshaft or left crankcase
Universal bearing puller: 07631-0010000
• Remove the right crankshaft roller bearing outer ring using a industrial dryer or heat gun. Do not remove
the outer ring except when replacing the crankshaft.
2-39
FUEL & ENGINE
CRANKSHAFT RUNOUT INSPECTION
• Set the crankshaft on V-blocks and measure the runout us-
ing a dial indicator.
Runout: (L) 0.05 mm/(R) 0.03 mm
69.3 mm (L) 56.0 mm (R)
0.2 – 0.8 mm
12 N·m
2 cm3 minimum
3 cm3 minimum
Coating width: 6.5 ± 1 mm
exclude 2 – 3 mm from tip
2 cm3 minimum
10 N·m 10 N·m
Coating width:
6.5 ± 1 mm exclude
2 – 3 mm from tip
[B] [D]
[A] [C]
2-40
FUEL & ENGINE
• Right crankshaft roller bearing outer ring:
Driver: 07749-0010000
Attachment, 62 x 64 mm: 07947-6340400
• Left crankshaft bearing:
Driver: 07749-0010000
Attachment, 72 x 75 mm: 07746-0010600
Pilot, 35 mm: 07746-0040800
• Pull the crankshaft into the bearing until it is fully seated while positioning the connecting rod in the cylinder
sleeve opening on the left crankcase.
[A] Assembly shaft adapter: 07WMF-KFF0200
[B] Assembly collar A: 07965-VM00100
[C] Assembly collar B: 07931-KF00100
[D] Assembly shaft: 07965-VM00200
• Install a new oil seal to the left crankcase so that the depth from the left crankcase surface is 0.2 – 0.8 mm.
Inner driver, 40 mm: 07746-0030100
Inner driver attachment, 35 mm: 07HMD-MR70100
• Apply locking agent to the set plates bolts. Install the crankshaft bearing set plate and bolts, and tighten
them to the specified torque.
TORQUE: 12 N·m
• Apply sealant (Three bond 1215, 1207B, LOCTITE 5060S, 5020, or equivalent) to the right crankcase
mating surface.
• Crankshaft inspection
• Connecting rod inspection
2-41
FUEL & ENGINE
ENGINE UNIT
39 N·m
39 N·m
49 N·m
49 N·m
30 N·m
69 N·m
• Rear fender A 3-8

• SH125D/SH150D: VS sensor 4-31
• Release the harness clips and disconnect the alternator/starter 3P (Brown) connector and CKP sensor 6P
(Black) connector.
• Disconnect the rear wheel speed sensor 2P (Black) connector (SH125AD/SH150AD only), ECT sensor
2P (Black) connector, O2 sensor 4P (Black) connector and ignition coil wire connectors.
2-42
3. FRAME & CHASSIS
BODY PANELS ········································ 3-2 STEERING STEM··································· 3-25
CENTERSTAND ····································· 3-18 REAR WHEEL ········································ 3-26
SIDESTAND ··········································· 3-18 REAR SUSPENSION ····························· 3-28
EXHAUST PIPE/MUFFLER···················· 3-19 FRONT BRAKE ······································ 3-29
FRONT WHEEL······································ 3-20 CBS ························································ 3-33
FORK ······················································ 3-22 REAR BRAKE ········································ 3-35
HANDLEBAR ········································· 3-24
3-1
FRAME & CHASSIS
FRAME & CHASSIS
BODY PANELS
[1]
[17]
[26]
[18] [13]
[5]
[28]
[25]
[15] [6]
[3] [14]
[4] [8]
[11]
[16]
[24]
[21]
[19] [9]
[10] [12]
[2]
[23]
[7]
[27]
[22] [20]
[1] Rearview mirror 3-3 [11] Rear fender A 3-8 [21] Footpeg cover 3-14
[2] Front fender 3-3 [12] Rear fender C 3-8 [22] Floor side cover 3-14
[3] Battery box lid 3-4 [13] Battery box 3-9 [23] Front side cover 3-15
[4] Luggage box 3-4 [14] Meter top cover 3-10 [24] Under cover 3-15
[5] Luggage carrier 3-5 [15] Front handlebar cover 3-10 [25] Inner cover 3-16
[6] Rear center garnish 3-5 [16] Front top cover 3-11 [26] Seat 3-16
[7] Center cover 3-6 [17] Handle cover garnish 3-11 [27] Floor step 3-17
[8] License light cover 3-6 [18] Rear handlebar cover 3-12 [28] SMART emergency lid 3-17
[9] Rear combination light garnish 3-7 [19] Front lower garnish 3-13
[10] Body cover 3-7 [20] Front lower cover 3-13
3-2
FRAME & CHASSIS
REARVIEW MIRROR
34 N·m
34 N·m
(Left-hand threads)
FRONT FENDER
3-3
FRAME & CHASSIS
BATTERY BOX LID
LUGGAGE BOX

• USB charger unit 4-69
3-4
FRAME & CHASSIS
LUGGAGE CARRIER
REAR CENTER GARNISH
• Luggage carrier 3-5
3-5
FRAME & CHASSIS
CENTER COVER
LICENSE LIGHT COVER
3-6
FRAME & CHASSIS
REAR COMBINATION LIGHT GARNISH
• Rear center garnish 3-5
BODY COVER
• License light cover 3-6

• Rear combination light garnish 3-7
• Right and left floor side covers 3-14
3-7
FRAME & CHASSIS
REAR FENDER A
REAR FENDER C
3.5 N·m
(SH125AD, SH150AD only)
10 N·m
3-8
FRAME & CHASSIS
BATTERY BOX
• Rear wheel 3-26

• Right and left rear shock absorbers 3-28
• Battery 4-58
• Rear fender C 3-8
• Remove the fuse box and harness clips from the battery box.
• Disconnect the ECM 39P (Black) connector.
3-9
FRAME & CHASSIS
METER TOP COVER
[B]
[A]
• Front upper cover 3-11

• Release the both side tabs [A] and then pull off the snap fit clips [B].
FRONT HANDLEBAR COVER
• Rearview mirrors 3-3

• Meter top cover 3-11
3-10
FRAME & CHASSIS
FRONT TOP COVER
[A]
• Front handlebar cover 3-10

• Release the snap fit clips [A].
HANDLE COVER GARNISH
[B]
[A]
• Release the both side tabs [A] and then pull off the snap fit clips [B].
3-11
FRAME & CHASSIS
REAR HANDLEBAR COVER
1.2 N·m
3-12
FRAME & CHASSIS
FRONT LOWER GARNISH
• Front top cover 3-11
FRONT LOWER COVER
3-13
FRAME & CHASSIS
FOOTPEG COVER
FLOOR SIDE COVER
• Footpeg cover 3-14
3-14
FRAME & CHASSIS
FRONT SIDE COVER
[A]
• Front lower garnish 3-13

• Front lower cover 3-13
• Floor side cover 3-14
• Release the snap fit clip [A].
UNDER COVER
• Front lower cover 3-13

• Right and left floor side cover 3-14
3-15
FRAME & CHASSIS
INNER COVER
• Right and left front side covers 3-15
SEAT
3-16
FRAME & CHASSIS
FLOOR STEP

• Inner cover 3-16
SMART EMERGENCY LID
[A]
• Release the snap fit clip [A].
3-17
FRAME & CHASSIS
CENTERSTAND
SIDESTAND
10 N·m
10 N·m
29 N·m
• Sidestand switch 4-68
3-18
FRAME & CHASSIS
EXHAUST PIPE/MUFFLER
[1] to [5]: Tightening sequence
10 N·m
[5]
[3]
[4]
14.5 – 15.5 mm
[1]
[2]
49 N·m
29 N·m
3-19
FRAME & CHASSIS
FRONT WHEEL
59 N·m
3-20
FRAME & CHASSIS
42 N·m
7.0 N·m
(SH125AD, SH150AD)
Install the bearing according
to the number of the figure.
• Install the bearing remover head into the bearing. From the opposite side, install the bearing remover shaft
and drive out the bearing from the wheel hub.
Remover head, 12 mm: 07746-0050300
Bearing remover shaft, 9 x 200L: 07746-0050100
• Drive in a new left bearing squarely with its sealed side facing outside until it is fully seated.
Driver: 07749-0010000
Attachment, 32 x 35 mm: 07746-0010100
Pilot, 12 mm: 07746-0040200
• Install the distance collar.
• Drive in a new right bearing squarely with its sealed side facing outside until its inner race is seated on the
distance collar.
Driver: 07749-0010000
Attachment, 32 x 35 mm: 07746-0010100
Pilot, 12 mm: 07746-0040200
• Wheel disassembly and inspection
3-21
FRAME & CHASSIS
FORK
39 N·m
• Front wheel 3-20

• Front brake caliper 3-30
3-22
FRAME & CHASSIS
101 mm
20 N·m
• Remove the oil seal.

Oil seal remover: 07748-0010001
• Drive in a new oil seal squarely with its marked side facing up until it is fully seated.
Driver: 07749-0010000
Attachment, 45 x 50 mm: 07946-6920100
• Pour the specified amount of recommended fork fluid into the fork pipe.
RECOMMENDED FORK FLUID: Honda Ultra Cushion Oil 10W
FORK FLUID CAPACITY: 103 ± 2.5 cm3
• Compress the fork pipe fully and measure the fluid level from the top of the fork pipe.
FORK FLUID LEVEL: 101 mm
• Pull the fork pipe up and install the fork spring with its tightly wound coil side facing down.
• Fork disassembly and inspection
3-23
FRAME & CHASSIS
HANDLEBAR
12 N·m
44 N·m
Narrow Wide
• Rear handlebar cover 3-12

• Install the front brake lever bracket and holder with the "UP" mark facing up align the edge of the front
brake lever bracket with the punch mark on the handlebar.
• Install the rear brake lever bracket and holder with the "UP" mark facing up align the edge of the rear brake
lever bracket with the punch mark on the handlebar.
3-24
FRAME & CHASSIS
STEERING STEM
[B]
[A]
(3.0 – 5.0 g)
74 N·m
[E]
(3.0 – 5.0 g)
[C] [F] [G]
Multi-purpose extreme
pressure grease NLGI #2
(ALVANIA EP2
manufactured by Shell,
EXCELITE EP2
manufactured by
KYODO YUSHI CO.,
[C] [D] [H] LTD. or equivalent)
• Handlebar 3-24
• Fork 3-22
• STEERING STEM:
[A] Pin spanner: 07702-0020001, [B] Socket wrench: 07916-KM10000
• STEERING STEM BEARINGS:
[C] Ball race remover shaft: 07GMD-KS40100, [D] Ball race remover, 34.5 mm: 07948-4630100
• STEERING STEM:
[E] Attachment, 35 mm I.D.: 07746-0030400
• STEERING STEM BEARINGS:
[F] Driver: 07749-0010000[G] Attachment, 45 x 50 mm: 07946-6920100 [H] Oil seal driver, 53.5 mm:
07947-SB00200
• Install the top thread. Hold the steering stem and tighten the stem top thread to the initial torque.
TORQUE: Actual: 24.5 N·m/Indicated: 17 N·m
• Turn the steering stem lock-to-lock several times to seat the bearing. Completely loosen the top thread.
• Tighten the top thread fully by hand while holding the steering stem, then turn and loosen the top thread
counterclockwise about 45 degrees.
• Hold the top thread using the pin spanner and tighten the steering stem lock nut to the specified torque.
TORQUE: 74 N·m
• Steering disassembly/assembly and inspection
3-25
FRAME & CHASSIS
REAR WHEEL
(SH125AD/SH150AD)
27 N·m
49 N·m
30 N·m
118 N·m

• Rear fender C 3-8
• Apply 0.03 – 0.04 g of multi purpose grease to the final gear shaft grease groove.
Apply multi purpose grease to the swingarm bearing fitting area of the final gear shaft.
• Wheel inspection
3-26
FRAME & CHASSIS
(SH125AD, SH150AD only)
42 N·m
7.0 N·m
• Swingarm bearing
Driver: 07749-0010000
Attachment 37 x 40 mm:07746-0010200
Pilot, 17 mm: 07746-0040400
3-27
FRAME & CHASSIS
REAR SUSPENSION
39 N·m
27 N·m

3-28
FRAME & CHASSIS
FRONT BRAKE
BRAKE MASTER CYLINDER
12 N·m
34 N·m
• Install the brake master cylinder and holder with the "UP" mark facing up. Align the edge of the master
cylinder with the punch mark on the handlebar.
1.0 N·m
Silicone grease
(0.1 g)
Silicone 6.0 N·m 1.2 N·m

grease (0.1 g)
• Remove the snap ring.

Snap ring pliers: 07914-SA50001
• Master cylinder inspection
3-29
FRAME & CHASSIS
BRAKE CALIPER
BRAKE PAD REPLACEMENT
SH125D, SH150D:
17 N·m
SH125AD, SH150AD:
17 N·m
• Install brake pads so that they are set on the brake caliper bracket and bracket pin.
3-30
FRAME & CHASSIS
SH125D, SH150D:
34 N·m
30 N·m
SH125AD, SH150AD:
34 N·m
30 N·m
3-31
FRAME & CHASSIS
SH125D, SH150D:
Silicone grease
(0.4 g)
5.5 N·m
SH125AD, SH150AD:
12 N·m Silicone grease

(0.4 g)
5.5 N·m
Silicone grease
(0.4 g)
• Brake caliper inspection
3-32
FRAME & CHASSIS
CBS
DELAY VALVE
14 N·m
34 N·m
• Brake fluid (CBS line) 3-34

• Headlight 4-59
3-33
FRAME & CHASSIS
BRAKE FLUID REPLACEMENT
5.5 N·m
1.5 N·m
: FRONT BRAKE LINE

: CBS BRAKE LINE
5.5 N·m 5.5 N·m
1.5 N·m

• Turn the handlebar until the reservoir is parallel to the ground before removing the reservoir cap.
• Connect a bleed hose. Loosen the bleed valve and pump the brake lever until no more fluid flows out of
the bleed valve. Tighten the front brake line bleed valve.
• Turn the handlebar until the reservoir is parallel to the ground before removing the reservoir cap.
• Connect a bleed hose. Loosen the bleed valve and pump the brake lever until no more fluid flows out of
the bleed valve. Tighten the CBS brake line bleed valve.
• Detail instruction of the brake fluid replacement
3-34
FRAME & CHASSIS
REAR BRAKE
BRAKE MASTER CYLINDER
12 N·m
34 N·m
• Install the brake master cylinder and holder with the "UP" mark facing up. Align the edge of the master
cylinder with the punch mark on the handlebar.
1.0 N·m
Silicone grease
(0.1 g)
1.2 N·m
Silicone grease
(0.1 g)
6.0 N·m
• Remove the snap ring.

Snap ring pliers: 07914-SA50001
• Master cylinder inspection
3-35
FRAME & CHASSIS
BRAKE CALIPER
BRAKE PAD REPLACEMENT
22 N·m
30 N·m
• Install the pads so that their ends are set in the pad retainers on the caliper bracket properly.
34 N·m
30 N·m
3-36
FRAME & CHASSIS
22 N·m
Silicone grease
(0.4 g)
5.5 N·m
Silicone grease
Silicone grease
(0.4 g)
• Brake caliper inspection
3-37
MEMO
4. ELECTRICAL SYSTEM
PGM-FI SYSTEM······································ 4-2 LIGHTING SYSTEM ······························· 4-59
IGNITION SYSTEM ································ 4-32 COMBINATION METER························· 4-62
ELECTRICAL STARTER ······················· 4-35 ELECTRICAL COMPONENT ················· 4-68
IDLE STOP SYSTEM ····························· 4-38 Honda SMART Key SYSTEM················ 4-70
ABS························································· 4-42 Honda SMART Key ····························· 4-100
BATTERY/CHARGING SYSTEM··········· 4-57 ANSWER BACK/ALARM SYSTEM ····· 4-104
4-1
ELECTRICAL SYSTEM
ELECTRICAL SYSTEM
PGM-FI SYSTEM
• Refer to "Basic Shop manual" for the following information:
– PGM-FI technical feature and each sensor function.
– Symptom troubleshooting for the PGM-FI system.
– MCS (Motorcycle Communication System).
DTC CODE INDEX

SH125D/SH150D
DTC Function Failure Symptom/Fail-safe function Page

P0107 MAP sensor malfunction • Engine operates normally
4-7
(1-1) • MAP sensor low voltage
4-8
(1-2) • MAP sensor high voltage
P0117 ECT sensor malfunction • Hard to start at a low temperature
4-9
(7-1) • ECT sensor low voltage
4-10
(7-2) • ECT sensor high voltage
P0122 TP sensor malfunction • Poor engine acceleration
4-11
(8-1) • TP sensor low voltage
4-12
(8-2) • TP sensor high voltage
P0112 IAT sensor malfunction • Engine operates normally
4-13
(9-1) • IAT sensor low voltage
4-14
(9-2) • IAT sensor high voltage
P2158 VS sensor malfunction • Engine operates normally
4-15
(11-1) • Idling stop system shut down
P0201 Injector malfunction • Engine does not start
4-16
(12-1) • Injector, fuel pump and ignition coil shut down
P0131 O2 sensor malfunction • Engine operates normally
4-17
(21-1)
P0135 O2 sensor heater malfunction • Engine operates normally
4-18
(23-1)
P0511 IACV malfunction • Engine stalls, hard to start, rough idling
4-19
(29-1)
ECM EEPROM malfunction • Rough idling
P062F • Self diagnosis data is not held
4-20
(33-2) • Self diagnosis data cannot be erased with
SCS short connector
P0335 CKP sensor malfunction • Engine stops
4-21
(52-1) • CKP sensor or its circuit malfunction • Engine does not restart
P0335 Alternator malfunction • Engine stops
4-22
(52-2) • Alternator or its circuit malfunction • Engine does not restart
EVAP purge control solenoid valve malfunction • Engine operates normally
• Loose or poor contact of the EVAP purge
P0443
control solenoid valve connector 4-25
(88-1)
• EVAP purge control solenoid valve or its cir-
cuit malfunction
P0351 Ignition coil primary circuit malfunction • Engine does not start
4-26
(91-1) • Ignition coil or its circuit malfunction • Injector and ignition coil shut down
CAN communication malfunction • Engine does not restart
U0001 • Faulty ECM
4-27
(103-1) • Faulty combination meter
• CAN communication circuit malfunction
CAN communication malfunction - Combination • Engine does not restart
U0155 meter
4-28
4-2
ELECTRICAL SYSTEM
SH125AD/SH150AD

4-7
(1-1) • MAP sensor low voltage
4-8
(1-2) • MAP sensor high voltage
4-9
(7-1) • ECT sensor low voltage
4-10
(7-2) • ECT sensor high voltage
4-11
(8-1) • TP sensor low voltage
4-12
(8-2) • TP sensor high voltage
4-13
(9-1) • IAT sensor low voltage
4-14
(9-2) • IAT sensor high voltage
P0201 Injector malfunction • Engine does not start
4-16
(12-1) • Injector, fuel pump and ignition coil shut down
P0131 O2 sensor malfunction • Engine operates normally
4-17
(21-1)
P0135 O2 sensor heater malfunction • Engine operates normally
4-18
(23-1)
P0511 IACV malfunction • Engine stalls, hard to start, rough idling
4-19
(29-1)
ECM EEPROM malfunction • Rough idling
P062F • Self diagnosis data is not held
4-20
(33-2) • Self diagnosis data cannot be erased with
SCS short connector
P0335 CKP sensor malfunction • Engine stops
4-21
(52-1) • CKP sensor or its circuit malfunction • Engine does not restart
P0335 Alternator malfunction • Engine stops
4-22
(52-2) • Alternator or its circuit malfunction • Engine does not restart
Rear wheel speed signal malfunction • Engine operates normally
• Loose or poor contact of the rear wheel speed • Idling stop system shut down
P2158 sensor connector • HSTC does not operate
4-23
(66-1) • Rear wheel speed sensor or its circuit mal-
function
• ABS modulator or its circuit malfunction
Front wheel speed signal malfunction • Engine operates normally
• Loose or poor contact of the front wheel • Idling stop system shut down
P0500 speed sensor connector • HSTC does not operate
4-24
(67-1) • Front wheel speed sensor or its circuit mal-
function
• ABS modulator or its circuit malfunction
EVAP purge control solenoid valve malfunction • Engine operates normally
• Loose or poor contact of the EVAP purge
P0443
control solenoid valve connector 4-25
(88-1)
• EVAP purge control solenoid valve or its cir-
cuit malfunction
4-3
ELECTRICAL SYSTEM
P0351 Ignition coil primary circuit malfunction • Engine does not start
4-26
(91-1) • Ignition coil or its circuit malfunction • Injector and ignition coil shut down
CAN communication malfunction • Engine does not restart
U0001 • Faulty ECM
4-27
CAN communication malfunction - Combination • Engine does not restart
U0155 meter
4-28
4-4
ELECTRICAL SYSTEM
PGM-FI SYSTEM LOCATION
IGNITION SWITCH
ABS MODULATOR
(SH125AD/SH150AD)
BATTERY DLC
IACV ECM
FRONT WHEEL
SPEED SENSOR
(SH125AD/
SH150AD)
SENSOR UNIT
(MAP/IAT/TP SENSORS)
EVAP PURGE CONTROL

SOLENOID VALVE
REAR WHEEL
SPEED SENSOR
FUEL INJECTOR (SH125AD/
SH150AD)
IGNITION COIL ECT ALTERNATOR/

SENSOR STARTER
VS SENSOR
O2 SENSOR CKP SENSOR (SH125D/SH150D)
4-5
ELECTRICAL SYSTEM
PGM-FI SYSTEM DIAGRAM
FUSE/RELAY BOX
R R/W R/W R/G R/G R/G Bl/Bu

MAIN FUSE METER FUSE (7.5 A)
(20 A) IGNITION G
SWITCH R/G Bl/W
G R IGN•INJ FUSE (7.5 A)
R/G
R/W Bl/Y
R FUEL PUMP FUSE (10 A)
BATTERY
MAIN RELAY
G B-2 N(-) (33-2) Bl/Y
W/R A-20 IHU ECM
W/Bu A-21 IHV
W/Bl A-34 IHW S/RELAY A-28 Y Bl/W
(52-1)
CKP SENSOR Bu/Y A-22 PCB STARTER/CHARGING
Br/Bl Br/R A-2 VOUT RELAY
P(+) B-1 R/Y
G Bu/G A-39 P-GND
SENSOR UNIT
BATT A-4 Bl/W
Y/O A-13 VCC(5V)
PCS A-1 Bu/W Bl/W
(1-1,1-2)
Y/R A-9 PB
MAP SENSOR (88-1) EVAP PURGE CONTROL
SOLENOID VALVE
F-PUMP A-5 G Y
(8-1,8-2)
Y/Bu A-36 THR FUEL PUMP
TP SENSOR
IGN A-27 Y/G Bl/W
W/G A-24 TA
(9-1,9-2) (91-1)
IGNITION COIL
IAT SENSOR
SPARK PLUG
P/W A-37 TW
(7-1,7-2) G/O
ECT SENSOR
G/O G/O A-12 SG INJ A-8 P/Bu Bl/W
(21-1,21-2, G/O
Gr
(12-1)
23-1) Bl A-38 O2 FUEL INJECTOR
O2 SENSOR
Bl/W W W B-5 O2HEATER
DLC IACV1A A-31 Lg/R
Bl/W
IACV1B A-3 Gr/R (29-1)
O/W A-29 K-LINE
IACV2A A-15 Br/R IACV
Br A-30 SCS
G/Bl IACV2B A-10 Bl/R
G/Bl A-26 LG
SCS SHORT
G/Bl U PHASE C-3 R/Y
CONNECTOR
G/Bl Bl/G A-23 ID-SW
V PHASE C-2 R/W ALTERNATOR/STARTER
IDLING STOP SWITCH
G/Bl G/W A25 SSTAND-SW W PHASE C-1 R/Bu

COMBINATION METER
SIDESTAND SWITCH
Bl/Bu
Bl/W Y/G G/W A-32 ST-SW CAN L A-6 R
Bu/G
STARTER SWITCH INHIBITOR SWITCH MIL P/G
CAN H A-7 W
P/G
(11-1) Y A-18 FVW
ABS MODULATOR
(ABS type only) P/G P/G A-19 VSP/RVW
P/G
(11-1)
P/G
VS SENSOR
(CBS type only) Bu/G
B-3 B-1
A-13 A-1 B-2 C-2
( ) : DTC / MIL number
A-26 A-14 B-5 C-1
: Engine does not start
when detecting DTC / MIL A-39 A-27 B-4 C-3
: Short terminals for ECM 39P (BLACK) CONNECTOR ECM 5P 3P (BLACK) CONNECTOR
reading DTC / MIL (ECM side of the male terminals) (ECM side of the male terminals)
4-6
ELECTRICAL SYSTEM
DTC TROUBLESHOOTING
P0107 (MAP SENSOR LOW VOLTAGE)
MAP Sensor Diagram

Sensor unit 5P (Black) connector ECM 39P (Black) connector
Y/O Y/O
Y/R G/O
Y/R G/O
5V
VCC
Y/O 5V
Sensor unit PB ECM
(MAP sensor) Y/R
SG
G/O
1. MAP Sensor System Inspection
• Check the MAP sensor voltage with MCS. No • Intermittent failure

• Is the voltage about 0 V indicated? ► • Loose or poor contact at the connector
Yes ▼
2. Sensor unit Power Input Voltage Inspection
• Faulty Y/O wires

• Connection: Y/O (+) – G/O (–) No
• If there is no open or short circuit, replace the ECM
• Is the voltage within 4.75 – 5.25 V? ►
with a new one 4-29, and recheck.
Yes ▼
3. MAP Sensor Output Voltage Inspection
• Connection: Y/R (+) – G/O (–) Yes • Replace the sensor unit (MAP sensor) with a new
• Is the voltage within 3.80 – 5.25 V? ► one 2-10, and recheck.
No ▼
4. MAP Sensor Output Line Inspection
• Check a short circuit in Y/R wire.

• If there is no short circuit, replace the ECM with a
new one 4-29, and recheck.
4-7
ELECTRICAL SYSTEM
P0108 (MAP SENSOR HIGH VOLTAGE)
MAP Sensor Diagram

Y/O Y/O
Y/R G/O
Y/R G/O
5V
VCC
Y/O 5V
Sensor unit PB ECM
(MAP sensor) Y/R
SG
G/O
1. MAP Sensor System Inspection
• Check the MAP sensor voltage with MCS. No • Intermittent failure

Yes ▼
2. MAP Sensor Inspection
• Install a jumper wire between the terminals.

Connection: Y/R – G/O Yes • Replace the sensor unit (MAP sensor) with a new
• Check the MAP sensor voltage with MCS. ► one 2-10, and recheck.
• Is the voltage about 0 V indicated?
No ▼
3. MAP Sensor Output Line Inspection
• Check an open circuit in Y/R and G/O wire.

• If there is no open circuit, replace the ECM with a
4-8
ELECTRICAL SYSTEM
P0117 (ECT SENSOR LOW VOLTAGE)
ECT Sensor Diagram
ECT sensor 2P (Black) connector ECM 39P (Black) connector
G/O
P/W G/O
P/W
5V
TW
P/W
ECT sensor ECM
SG
G/O
1. ECT Sensor System Inspection
• Check the ECT sensor voltage with MCS. No • Intermittent failure

Yes ▼
2. ECT Sensor Inspection
• Check the ECT sensor voltage with MCS. No • Replace the ECT sensor with a new one 4-30,
• Is the voltage about 0 V indicated? ► and recheck.
Yes ▼
3. ECT Sensor Output Line Inspection
• Check a short circuit in P/W wire.

4-9
ELECTRICAL SYSTEM
P0118 (ECT SENSOR HIGH VOLTAGE)
ECT Sensor Diagram
ECT sensor 2P (Black) connector ECM 39P (Black) connector
G/O
P/W G/O
P/W
5V
TW
P/W
ECT sensor ECM
SG
G/O
1. ECT Sensor System Inspection
• Check the ECT sensor voltage with MCS. No • Intermittent failure

Yes ▼
2. ECT Sensor Inspection

Connection: P/W – G/O Yes • Replace the ECT sensor with a new one 4-30,
• Check the ECT sensor voltage with MCS. ► and recheck.
No ▼
3. ECT Sensor Output Line Inspection
• Check an open circuit in P/W and G/O wire.

4-10
ELECTRICAL SYSTEM
P0122 (TP SENSOR LOW VOLTAGE)
TP Sensor Diagram
Y/O G/O Y/O
Y/Bu G/O
Y/Bu
5V
VCC
Y/O
Sensor unit THR ECM
(TP sensor) Y/Bu
SG
G/O
1. TP Sensor System Inspection
• Check the TP sensor voltage with MCS. No • Intermittent failure

Yes ▼
2. Sensor unit Power Input Voltage Inspection
• Faulty Y/O wire

• Connection: Y/O (+) – G/O (–) No
• If there is no open or short circuit, replace the ECM
• Is the voltage within 4.75 – 5.25 V? ►
Yes ▼
3. TP Sensor Output Line Inspection
• Check an open or short circuit in Y/Bu wire. Yes

• Faulty Y/Bu wire
• Is there open or short circuit? ►
No ▼
4. TP Sensor Inspection
• Replace the sensor unit (TP sensor) with a new

one 2-10
• Erase the DTC’s.
• Check the TP sensor with MCS.
• If DTC 8-1 is indicated, replace the ECM with a
4-11
ELECTRICAL SYSTEM
P0123 (TP SENSOR HIGH VOLTAGE)
TP Sensor Diagram
Y/O G/O Y/O
Y/Bu G/O
Y/Bu
5V
VCC
Y/O
Sensor unit THR ECM
(TP sensor) Y/Bu
SG
G/O
1. TP Sensor System Inspection
• Check the TP sensor voltage with MCS when op-

erating the throttle from fully closed to fully
• Check the TP sensor voltage with MCS when the
No opened.
throttle fully closed.
► • If the voltage is not increase continuously, replace
the sensor unit (TP sensor) with a new one 2-
10, and recheck.
Yes ▼
2. TP Sensor Ground Line Inspection
• Check an open circuit in G/O wire. No

• Faulty G/O wire
• Is there no open circuit? ►
Yes ▼
3. TP Sensor Inspection
• Replace the sensor unit (TP sensor) with a new

one 2-10
• Check the TP sensor with MCS.
4-12
ELECTRICAL SYSTEM
P0112 (IAT SENSOR LOW VOLTAGE)
IAT Sensor Diagram

G/O
G/O W/G
W/G
5V
TA
W/G
Sensor unit ECM
(IAT sensor)
SG
G/O
1. IAT Sensor System Inspection
• Check the IAT sensor voltage with MCS. No • Intermittent failure

Yes ▼
2. IAT Sensor Inspection
• Check the IAT sensor voltage with MCS. No • Replace the sensor unit (IAT sensor) with a new
• Is the voltage about 0 V indicated? ► one 2-10, and recheck.
Yes ▼
3. IAT Sensor Output Line Inspection
• Check a short circuit in W/G wire.

4-13
ELECTRICAL SYSTEM
P0113 (IAT SENSOR HIGH VOLTAGE)
IAT Sensor Diagram

G/O
G/O W/G
W/G
5V
TA
W/G
Sensor unit ECM
(IAT sensor)
SG
G/O
1. IAT Sensor System Inspection
• Check the IAT sensor voltage with MCS. No • Intermittent failure

Yes ▼
2. IAT sensor Inspection

Connection: W/G – G/O Yes • Replace the sensor unit (IAT sensor) with a new
• Check the IAT sensor voltage with MCS. ► one 2-10, and recheck.
No ▼
3. IAT Sensor Voltage Input Line Inspection
• Check an open circuit in W/G and G/O wire.

4-14
ELECTRICAL SYSTEM
P2158 (SH125D/SH150D: VS SENSOR)

• VS sensor protector 4-31
VS Sensor Diagram
VS sensor 2P connector ECM 39P connector
P/G*2
Bu/G P/G*1
VSP
Bu/G P/G*2
VS sensor
P/G*1 G/W ECM
Combination meter 24P

(Gray) connector
Bu/G P/G*2 Speedometer
1. VS Sensor System Inspection
• Check the VS sensor with MCS. No • Intermittent failure

• Is the DTC 11-1 indicated? ► • Loose or poor contact at the connector.
Yes ▼
2. VS Sensor Input Voltage Inspection
• Faulty P/G*1 wire

• Connection: P/G*1 (+) – Ground (–) No • If there is no open or short circuit, replace the com-
• Is about 9 V indicated? ► bination meter with a new one 4-62, and re-
check.
Yes ▼
3. VS Sensor Signal Line Inspection
• Check an open or short circuit in Bu/G and

Yes
P/G*2 wires. • Faulty Bu/G or P/G*2 wire
►
• Is there open or short circuit?
No ▼
4. VS Sensor Inspection
• Replace the VS sensor with a new one 4-31

• Test-ride the vehicle and check the VS sensor with
MCS.
4-15
ELECTRICAL SYSTEM
P0201 (INJECTOR)
Injector Diagram
Injector 2P (Black) Injector 2P (Black)

ECM 39P (Black) connector
connector (Injector side) connector (Wire side)
P/Bu
A B Bl/W P/Bu
From Battery
Bl/W
Injector ECM
INJ
P/Bu
1. Fuel Injector System Inspection
• Check the fuel injector with MCS. No • Intermittent failure

• Is the DTC 12-1 is indicated? ► • Loose or poor contact at the connector
Yes ▼
2. Fuel Injector Input Voltage Inspection
• Connection: Bl/W (+) – Ground (–) No

• Faulty Bl/W wire
• Does the battery voltage exist? ►
Yes ▼
3. Fuel Injector Signal Line Inspection
• Check an open or short circuit in P/Bu wire. Yes

• Faulty P/Bu wire
No ▼
4. Fuel Injector Resistance inspection
• Connection: A – B No
• Faulty fuel injector
• Is the resistance within 11 – 13 Ω (24°C)? ►
Yes ▼
• Replace the ECM with a new one 4-29, and re-

check.
4-16
ELECTRICAL SYSTEM
P0131 (O2 SENSOR)

O2 Sensor Diagram
O2 sensor 4P (Black) connector ECM 5P (Black) connector
G/O Bl
Bl/W W W
W Bl/W
W W O2 HEATER
O2 sensor ECM
Gr G/O SG
Bl Bl O2
G/O
Bl
1. O2 Sensor System Inspection
• Test-ride the vehicle and check the O2 sensor with

No • Intermittent failure
MCS.
► • Loose or poor contact at the connector
• Is the DTC 21-1 indicated?
Yes ▼
2. O2 Sensor Circuit Inspection
• Check an open or short circuit in Bl and G/O wires. Yes

• Faulty Bl or G/O wire
• Are there short circuit? ►
No ▼
3. Fuel Supply Test (Fuel Pressure Test)
• Check that there is any erratic swing or vibration of

the gauge needle in the pressure gauge reading.
• Perform the fuel pressure test. 2-3 No – If the needle is swing or vibration, replace the
• Is the fuel pressure within specification? ► fuel filter. 2-6
– If the needle is stable, replace the fuel pump
unit. 2-4
Yes ▼
4. Fuel Supply Test (Fuel Flow Test)
• Adjust the fuel in the tank until the fuel gauge seg-
ment is positioned the specified range, and in- No
• Replace the fuel filter. 2-6
spect the fuel flow.2-3 ►
• Is the fuel flow within specification?
Yes ▼
4-17
ELECTRICAL SYSTEM
5. O2 Sensor Inspection
• Replace the O2 sensor with a new one. 4-30

• Test-ride the vehicle and check the O2 sensor with
MCS.
P0135 (O2 SENSOR HEATER)

O2 Sensor Diagram
O2 sensor 4P (Black)
connector (wire side) ECM 5P (Black) connector
G/O Bl
Bl/W W W
W Bl/W
W W O2 HEATER
O2 sensor ECM
Gr G/O SG
Bl Bl O2
O2 sensor 4P (Black) ECM 39P (Black) connector

connector (sensor side)
G/O
A B
Bl
1. O2 Sensor Heater System Inspection
• Clear the ECM self-diagnosis memory data, and

check the O2 sensor heater with MCS.
Yes ▼
2. O2 Sensor Heater Input Voltage Inspection

• Faulty Bl/W wire.
Yes ▼
4-18
ELECTRICAL SYSTEM
3. O2 Sensor Heater Circuit Inspection
• Check an open or short circuit in W wire. Yes

• Faulty W wire.
Yes ▼
4. O2 Sensor Heater Resistance Inspection
• Connection: A – B Yes
• Faulty O2 sensor.
• Is the resistance within 13.0 – 18.5 Ω (20°C) ►
Yes ▼

check.
P0511 (IACV)
IACV Diagram
IACV 4P connector IACV 4P connector
(IACV side) (Wire side) ECM 39P connector
Br/R Bl/R Gr/R Bl/R
A B C D
Lg/R Gr/R
Br/R Lg/R
Lg/R IACV1A
Gr/R IACV1B
IACV ECM
Br/R IACV2A
Bl/R IACV2B
1. IACV System Inspection
• Check the IACV with MCS. No • Intermittent failure

• Is the DTC 29-1 indicated? ► • Loose or poor contact at the connector
Yes ▼
4-19
ELECTRICAL SYSTEM
2. IACV Circuit Inspection
• Check a open or short circuit in Lg/R, Gr/R, Br/R

Yes
and Bl/R wires. • Faulty Lg/R, Gr/R, Br/R or Bl/R wire
►
No ▼
3. IACV Resistance Inspection
• Connection: A – D, B – C No
• Faulty IACV
Yes ▼
4. IACV Short Circuit Inspection
• Connection: A – B, C – D Yes
• Faulty IACV
• Is there continuity? ►
No ▼

check.
P062F (EEPROM)
1. EEPROM System Inspection
• Check the EEPROM with MCS. No • Intermittent failure

Yes ▼

check.
4-20
ELECTRICAL SYSTEM
P0335 (CKP SENSOR)
CKP Sensor Diagram
CKP sensor 6P (Black) connector ECM 39P (Black) connector
Br/R Br/R Bu/Y
Bu/Y Bu/G
Bu/G
Bu/Y PCB
CKP
SENSOR Br/R VOUT ECM
G Bu/G P-GND
1. CKP Sensor System Inspection
• Check the CKP sensor with MCS. No • Intermittent failure

Yes ▼
2. CKP Sensor Circuit Inspection
• Check an open or short circuit in Bu/Y, Br/R and

Yes
Bu/G wires. • Faulty Bu/Y, Br/R or Bu/G wire
►
No ▼
3. CKP Sensor Inspection
• Replace the alternator/starter with a new one.

• Erase the DTC’s,
• Test-ride the vehicle and check the CKP sensor
with MCS.
4-21
ELECTRICAL SYSTEM
P0335 (ALTERNATOR)
Alternator Diagram
CKP sensor 6P (Black) connector ECM 39P (Black) connector
W/Bl W/R W/R W/Bu
W/Bu
W/Bl
W/R IHU
CKP
SENSOR W/Bu IHV ECM
G W/Bl IHW
1. Alternator System Inspection
• Check the CKP sensor with MCS. No • Intermittent failure

Yes ▼
2. Alternator Circuit Inspection
• Check an open or short circuit in W/R, W/Bu and

Yes
W/Bl wires. • Faulty W/R, W/Bu or W/Bl wire
►
No ▼
3. Alternator Inspection
• Replace the alternator/starter with a new one.

• Erase the DTC’s,
• Test-ride the vehicle and check the CKP sensor
with MCS.
4-22
ELECTRICAL SYSTEM
P2158 (SH125AD/SH150AD: REAR WHEEL SPEED SENSOR)

• Headlight unit 4-59
Speed signal Diagram

ABS modulator 18P (Black) connector ECM 39P (Black) connector
P/G P/G
ABS MODULATOR DFAH P/G RVW ECM
1. Speed signal System Inspection
• Erase the DTC and test-ride the vehicle above 30

km/h, then recheck the DTC.
► • Loose or poor contact at the connector.
Yes ▼
2. ABS DTC Check
• Check the ABS DTC. 4-42 Yes

• Refer to "ABS Troubleshooting" 4-42
• Does the ABS modulator have any DTC? ►
No ▼
3. Rear Wheel Speed Sensor Signal Line Circuit Inspection
• Check an open or short circuit in P/G wire. Yes

• Faulty P/G wire
No ▼
4. ECM Inspection
• Replace the ECM with a new one. 4-29

• Erace the DTC’s. Yes • Replace the ABS modulator with a known good
• Test-ride the vehicle above 30 km/h. ► one and recheck. 4-56
No ▼
• Faulty original ECM.
4-23
ELECTRICAL SYSTEM
P0500 (SH125AD/SH150AD: FRONT WHEEL SPEED SENSOR)

• Headlight unit 4-59
Speed signal Diagram

ABS modulator 18P (Black) connector ECM 39P (Black) connector
ABS MODULATOR DFAV Y FVW ECM
1. Speed signal System Inspection

km/h, then recheck the DTC.
► • Loose or poor contact at the connector.
Yes ▼
2. ABS DTC Check
• Check the ABS DTC. 4-42 Yes

• Refer to "ABS Troubleshooting" 4-42
• Does the ABS modulator have any DTC? ►
No ▼
3. Rear Wheel Speed Sensor Signal Line Circuit Inspection
• Check an open or short circuit in Y wire. Yes

• Faulty Y wire
No ▼
4. ECM Inspection
• Replace the ECM with a new one. 4-29

• Erace the DTC’s. Yes • Replace the ABS modulator with a known good
• Test-ride the vehicle above 30 km/h. ► one and recheck. 4-56
No ▼
• Faulty original ECM.
4-24
ELECTRICAL SYSTEM
P0443 (EVAP PURGE CONTROL SOLENOID VALVE)
EVAP Purge Control Solenoid Valve Diagram
EVAP purge control solenoid valve EVAP purge control solenoid valve
2P (Black) connector (Valve side) 2P (Black) connector (Wire side) ECM 39P (Black) connector
Bu/W
A B Bu/W Bl/W
From Battery
Bl/W
EVAP purge control
solenoid valve ECM
PCS
Bu/W
1. EVAP Purge Control Solenoid Valve System Inspection
• Check the EVAP purge control solenoid valve with

MCS.
Yes ▼
2. EVAP Purge Control Solenoid Valve Input Voltage Inspection

Yes ▼
3. EVAP Purge Control Solenoid Valve Signal Line Inspection
• Check an open or short circuit in Bu/W wire. Yes

• Faulty Bu/W wire
No ▼
4. EVAP Purge Control Solenoid Valve Resistance inspection
• Connection: A – B No
• Faulty EVAP purge control solenoid valve
Yes ▼

check.
4-25
ELECTRICAL SYSTEM
P0351 (IGNITION COIL PRIMARY CIRCUIT)
Ignition Coil Primary Circuit Diagram

Ignition coil
connector Y/G
From Battery
ECM
IGNITION Bl/W
COIL Y/G IGN
1. Ignition Coil Primary Circuit System Inspection
• Check the Ignition coil with MCS. No • Intermittent failure

Yes ▼
2. Ignition Coil Primary Circuit Input Voltage Inspection

Yes ▼
3. Ignition Coil Primary Circuit Signal Line Inspection
• Check an open or short circuit in Y/G wire Yes

• Faulty Y/G wire
No ▼
4. Ignition Coil Inspection
• Replace the ignition coil with a new one 4-32

• Test-ride the vehicle and check the ignition coil
with MCS.
4-26
ELECTRICAL SYSTEM
U0001 (CAN COMMUNICATION MALFUNCTION)

CAN Communication Diagram

Combination meter 24P (Gray) connector ECM 39P (Black) connector
R W
R W
COMBINATION R R CAN L
ECM
METER W W CAN H
1. CAN Communication System Inspection
• Erase the DTC and recheck the CAN communica-

tion system with MCS.
Yes ▼
2. CAN Communication Circuit Inspection
• Check an open or short circuit in R and W wires. Yes

• Faulty R or W wire
No ▼

check.
4-27
ELECTRICAL SYSTEM
U0155 (CAN COMMUNICATION MALFUNCTION - COMBINATION METER)

CAN Communication Diagram

Combination meter 24P (Gray) connector ECM 39P (Black) connector
R W
R W
COMBINATION R R CAN L
ECM
METER W W CAN H
1. CAN Communication System Inspection
• Erase the DTC and recheck the CAN communica-

tion system with MCS.
Yes ▼
2. CAN Communication Circuit Inspection
• Check an open or short circuit in R and W wires. Yes

• Faulty R or W wire
No ▼
3. Combination Meter Inspection
• Replace the combination meter with a known good

one.
No
• Erase the DTC’s. • Faulty original combination meter.
►
• Check the DTC with MCS.
• Is the DTC 103-2 is indicated?,
Yes ▼

check.
4-28
ELECTRICAL SYSTEM
ECM

• Remove the battery box side screws and lower the rear end of the battery box.
• ECM power circuit and ground circuit inspection
4-29
ELECTRICAL SYSTEM
ECT SENSOR
10 N·m

• Coolant 2-19
• ECT sensor inspection
O2 SENSOR
24.5 N·m

• Remove the O2 sensor using the special tool.
Flare nut socket: FRXM17 (Snap-on) or equivalent
• Notice of O2 sensor removal/installation.
4-30
ELECTRICAL SYSTEM
VS SENSOR (SH125D/SH150D)
10 N·m
10 N·m
10 N·m
• Air cleaner 2-9
4-31
ELECTRICAL SYSTEM
IGNITION SYSTEM
IGNITION SYSTEM LOCATION
IGNITION SWITCH
FUSE/RELAY BOX
· 20 A (MAIN)
· 7.5 A (IGN. INJ)
ECM
SPARK PLUG
IGNITION COIL CKP SENSOR
IGNITION SYSTEM DIAGRAM

20 A 7.5 A
R R/W R/G Bl/W Bl/W
IGNITION SWITCH
G
Bl/W
BATTERY
CKP SENSOR Y/G
W/R
W/Bu
IGNITION
W/Bl COIL
ECM
Bu/Y
Br/Bl Br/R
G Bu/G
SPARK PLUG
4-32
ELECTRICAL SYSTEM
SPARK PLUG REPLACEMENT
• Spark plug inspection
• Center body cover 3-6
16 N·m
• Discard the spark plug in a accordance with the mainte-
nance schedule. 1-34
INSPECTION
IGNITION COIL PRIMARY PEAK VOLTAGE
• Refer to "Basic Shop Manual" for the detail information of

ignition coil primary peak voltage inspection.
• Support the vehicle with its centerstand on a level
surface.
• 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 stay bolt as done in a
spark test.
• With the ignition coil primary wires connected, connect
the peak voltage adapter probes to the ignition coil
primary terminal and ground.
CONNECTION: Y/G (+) – Ground (–)
• Check the initial voltage at this time.

STANDARD VOLTAGE: Battery voltage
• Squeeze the brake lever fully and retract the sidestand.
Crank the engine with the starter and measure the
ignition coil primary peak voltage.
PEAK VOLTAGE: 100 V minimum
IGNITION TIMING
• Radiator (Cooling fan visible without draining coolant) 2-

22
• Remove the four radiator mounting bolts and move it so
that the cooling fan is visible. Warm it up to normal
operating temperature.
• Connect the timing light to the spark plug wire.
• Start the engine and let it idle
IDLE SPEED: 1,700 ± 100 rpm
• The ignition timing is correct if the index mark on the
radiator base aligns with the "F" mark on the cooling fan.
4-33
ELECTRICAL SYSTEM
IGNITION COIL
Y/G
Bl/W

4-34
ELECTRICAL SYSTEM
ELECTRICAL STARTER
ELECTRICAL STARTER SYSTEM LOCATION
IGNITION SWITCH STARTER SWITCH
FUSE/RELAY BOX
· MAIN RELAY
· STARTER/CHARGING RELAY
· 20 A (MAIN)
BATTERY · 7.5 A (IGN. INJ)
INHIBITOR SWITCH ECM
ALTERNATOR/
SIDESTAND SWITCH STARTER
CKP SENSOR
ELECTRICAL STARTER SYSTEM DIAGRAM
R
20 A 7.5 A
R R/W R/G Bl/W
IGNITION Bl/W
G SWITCH
Bl/Y
STARTER
MAIN STARTER/
SWITCH
RELAY CHARGING
G
RELAY
Y/G
BATTERY R/W
SIDESTAND
SWITCH INHIBITOR
SWITCH
G/W R/Y Bl/W

G/Bl Y G/W
R/Bu
ALTERNATOR/ R/Y
STARTER
R/W
CKP SENSOR
W/R ECM
W/Bu
W/Bl
Bu/Y
Br/Bl Br/R
G Bu/G
4-35
ELECTRICAL SYSTEM
ELECTRICAL STARTER TROUBLESHOOTING
ALTERNATOR/STARTER DOES NOT WORK
• Loose or poor contacts of related terminal/connector

• Battery condition
• Burned fuse
• DTC (PGM-FI system)
Connector Diagram
ECM 5P (Black) connector STARTER/CHARGING

RELAY connector
R/Y R

G/Bl ECM 3P (Black) connector
R/W
Y G/W*1 G/W*2 R/Bu R/Y
1. Starter/Charging Relay Switch Circuit inspection 1
• Inspect the following.

– Main relay
• Connection: R/Y (+) – Ground (–) No – Starter/charging relay
• Does the battery voltage exist? ► – Fuse/relay box (Between the main relay and start-
er/charging relay)
– Faulty R/Y wire
Yes ▼
2. Starter/Charging Relay Switch Circuit inspection 2
• Connection: R (+) – Body ground (–) No

• Faulty R wire
Yes ▼
4-36
ELECTRICAL SYSTEM
3. Starter/Charging Relay Coil Circuit inspection
• Inspect the following.

• Connection: Y – G/W*1
– Inhibitor switch
• Squeeze the rear brake lever and push the No
– Starter switch
starter switch. ►
– Starter/charging relay
• Is there continuity?
– Open circuit in B/W, Y/G or G/W*1 wire
Yes ▼
4. Sidestand Switch Circuit inspection
• Connection: G/Bl – G/W*2 • Open or short circuit in G/Bl wire or G/W*2 wire
No
• Is there continuity only when the sidestand re- • If there is no open circuit, replace the sidestand
►
tracted? switch with a new one 4-68, and recheck.
Yes ▼
5. Stator Resistance Inspection
• Connection: R/Y – R/W, R/Y – R/Bu,

R/W – R/Bu • Open or short circuit in R/Y, R/W or R/Bu wire
No
• Is the resistance within SH125D/AD: 0.05 – • If there is no open or short circuit, replace the stator
►
0.20 Ω (20 °C), SH150D/AD: 0.03 – 0.20 Ω (20 with a new one 2-38, and recheck.
°C)?
Yes ▼
6. Starter/Charging relay Inspection
• Replace the starter/charging relay with a new

one.
• If the alternator/starter still does not work after
starter/charging relay replacement, replace the
ECM with a new one 4-29, and recheck.
4-37
ELECTRICAL SYSTEM
IDLE STOP SYSTEM

IDLE STOP SYSTEM LOCATION (SH125D/SH150D)
IGNITION SWITCH IDLING STOP SWITCH
FUSE BOX
· MAIN RELAY
· 20 A (MAIN)
BATTERY · 7.5 A (IGN. INJ)
· 7.5 A (METER)
TP SENSOR
ECM
ECT SENSOR
ALTERNATOR/
STARTER
SIDESTAND SWITCH VS SENSOR

CKP SENSOR
IDLE STOP SYSTEM DIAGRAM (SH125D/SH150D)

R
20 A 7.5 A
R R/W R/G R/G Bl/W
IGNITION Bl/Y
G SWITCH
MAIN
7.5 A RELAY
G
G
STARTER/
R/W CHARGING
BATTERY RELAY
SIDESTAND IDLING STOP
SWITCH SWITCH
VS Y
SENSOR
R/Y
Bu/G
P/G
G/W G/Bl Bl/G
Bl/Bu
R
IDLING
STOP W
INDICATOR G/W Bl/W
ECM G/O
Y/Bu TP
R/Bu SENSOR
Y/O
ALTERNATOR/ R/Y
STARTER G/O ECT
R/W P/W SENSOR
4-38
ELECTRICAL SYSTEM
IDLE STOP SYSTEM LOCATION (SH125AD/SH150AD)
IGNITION SWITCH IDLING STOP SWITCH
FUSE BOX
· MAIN RELAY
ABS MODULATOR · STARTER/CHARGING RELAY
BATTERY · 20 A (MAIN)
· 7.5 A (IGN. INJ)
TP SENSOR · 7.5 A (METER)
ECM
ECT SENSOR
ALTERNATOR/
STARTER
FRONT WHEEL
SPEED SENSOR
REAR WHEEL
SIDESTAND SWITCH CKP SENSOR SPEED SENSOR
IDLE STOP SYSTEM DIAGRAM (SH125AD/SH150AD)

R
20 A 7.5 A
G R R/W R/G R/G Bl/W
IGNITION Bl/Y
SWITCH
G
7.5 A MAIN
RELAY
BATTERY R/W G
STARTER/
CHARGING
Bu FRONT RELAY
WHEEL SIDESTAND IDLING STOP
W SPEED SWITCH SWITCH
ABS SENSOR
MODULATOR Y
Bu/Y Bu REAR
WHEEL
SPEED R/Y
W/Bl W
SENSOR
G/W G/Bl Bl/G
Bl/Bu
R
IDLING W
STOP
INDICATOR G/W
P/G Bl/W
P/G
ECM G/O
Y
Y/Bu TP
R/Bu SENSOR
Y/O
ALTERNATOR/ R/Y G/O
STARTER ECT
P/W SENSOR
R/W
4-39
ELECTRICAL SYSTEM
IDLE STOP SYSTEM TROUBLESHOOTING
IDLING STOP SWITCH IS TURNED "IDLING STOP" BUT IDLING STOP SYSTEM DOES NOT OPERATE
• This model utilizes the battery voltage detection in order to determine if the idling stop system should be activated.
When the detected voltage while cranking the engine is lower than the specified value, the idling stop system does
not activate even if the engine can be started.
Connector Diagram
G/Bl
Bl/G
1. Idling Stop System Operation Check
• Turn the idling stop switch to "IDLING STOP"

and start the engine.
• Warm up the engine and test-ride the scooter
above 10 km/h.
Yes
• Turn the throttle grip to completely closed posi- • Intermittent failure
►
tion.
Stop the scooter completely and wait more than
3 seconds with the sidestand retracted.
• Does the engine stop?
No ▼
2. PGM-FI System Inspection
• Check the MIL. Yes

• Inspect the PGM-FI system
• Does the MIL illuminate? ►
No ▼
3. Idling Stop Switch Inspection
• Loose or poorly connected connector

• Connection: Bl/G – G/Bl No • Open circuit in Bl/G wire and/or G/Bl wire
• Is there continuity? ► • Faulty idling stop switch (Inspect the idling stop
switch)
Yes ▼
4-40
ELECTRICAL SYSTEM
4. Battery Replacement
• Replace the recommended battery.

• Turn the idling stop switch to "IDLING STOP"
and start the engine.
• Warm up the engine and test-ride the scooter
above 10 km/h. Yes
• Faulty original battery
• Turn the throttle grip to completely closed posi- ►
tion.
Stop the scooter completely and wait more than
3 seconds with the sidestand retracted.
• Does the engine stop?
No ▼
• Open or short circuit in R/Y, R/W or R/Bu wire

• Replace the ECM with a new one 4-29, and No
• If there is no open or short circuit, replace the stator
recheck. ►
4-41
ELECTRICAL SYSTEM
ABS
• Refer to "Basic Shop manual" for the following information.
– ABS technical feature and each
function.
– Troubleshooting for the ABS.
– MCS (Motorcycle Communication System) information.
DTC CODE INDEX

Detection
*A *B
ABS indicator malfunction • ABS indicator never come
4-46
• ABS modulator voltage input line ON at all
• Indicator related wires • ABS indicator stays ON
–
• Combination meter
4-46
• ABS modulator
• ABS MAIN fuse (7.5 A)
Front wheel speed sensor circuit malfunction • Stops ABS operation
• Wheel speed sensor or related wires • No vehicle speed signal out-
1-1 4-48
put to the meter. (Meter dis-
play is 0 km/h.)
Front wheel speed sensor malfunction • Stops ABS operation
• Wheel speed sensor, pulser ring or related
1-2 4-48
wires
• Electromagnetic interference
Rear wheel speed sensor circuit malfunction • Stops ABS operation
• Wheel speed sensor or related wires • No vehicle speed signal out-
1-3 4-49
play is 0 km/h.)
Rear wheel speed sensor malfunction • Stops ABS operation
• Wheel speed sensor, pulser ring or related
1-4 4-49
wires
• Electromagnetic interference
Wheel speed sensor signal malfunction • Stops ABS operation
2-1 • Front or rear wheel speed sensor, pulser 4-48
ring or related wires
3-1 Solenoid valve malfunction (ABS modulator) • Stops ABS operation
3-2
4-50
3-3
3-4
Front wheel lock (Wheelie) • Stops ABS operation
4-2 4-48
• Riding condition
Pump motor lock • Stops ABS operation
• Pump motor (ABS modulator) or related
5-1 4-51
wires
• ABS MOTOR fuse (30 A)
Pump motor relay stuck off • Stops ABS operation
5-2 4-51
wires
Pump motor relay stuck on • Stops ABS operation
5-3 4-51
wires
Valve relay malfunction • Stops ABS operation
• Valve relay (ABS modulator) or related
5-4 4-51
wires
• ABS SOL fuse (15 A)
4-42
ELECTRICAL SYSTEM
Detection
*A *B
Power circuit under voltage • Stops ABS operation
• Input voltage (too low) • No vehicle speed signal out-
6-1 4-53
• ABS MAIN fuse (7.5 A) put to the meter. (Meter dis-
play is 0 km/h.)
Power circuit over voltage • Stops ABS operation
• Input voltage (too high) • No vehicle speed signal out-
6-2 4-53
play is 0 km/h.)
ABS control unit • Stops ABS operation
• ABS control unit malfunction (ABS modula- • No vehicle speed signal out-
8-1 4-54
tor) put to the meter. (Meter dis-
play is 0 km/h.)
*A: Pre-start self-diagnosis
*B: Ordinary self-diagnosis: diagnoses while the vehicle is running (after pre-start self-diagnosis)
How To Erase the DTC Without MCS
• Connect the DLC.

• Squeeze the brake lever.
• The ABS indicator should come on 2 seconds and go off.
• After the ABS indicator is off, release the brake lever imme-
diately.
• After the ABS indicator is on, squeeze the brake lever im-
mediately.
• After the ABS indicator is off, release the brake lever imme-
diately.
– When code erasure is complete, the ABS indicator blinks
2 times and stay on.
– If the ABS indicator is not blink, the data has not been
erased, so try again.
4-43
ELECTRICAL SYSTEM
ABS LOCATION
FUSE BOX:
- 20 A (MAIN)
- 30 A (ABS MOTOR)
- 15 A (ABS SOL)
- 7.5 A (ABS MAIN)
- 7.5 A (IGN. INJ)
- 7.5 A (METER)
DLC
BATTERY
ABS MODULATOR
REAR WHEEL
SPEED SENSOR
FRONT WHEEL
SPEED SENSOR
4-44
ELECTRICAL SYSTEM
ABS DIAGRAM
FUSE/RELAY BOX
Bl/Bu
Bl/W
METER FUSE FRONT BRAKE
(7.5A) LIGHT SWITCH
Br Br G/Y
TURN•STOP•TAIL•
POSI FUSE (7.5A)
Br G/Y TO BRAKE LIGHT
REAR BRAKE
LIGHT SWITCH
G/Y 6 BLS
R/Bl R/W
ABS MODULATOR
R/G R/W (8-1)
ABS MAIN FUSE IGNITION SWITCH
(7.5 A)
Bl/Y 4 UZ (6-1, 6-2)
IGN•INJ FUSE
(7.5 A)
Bl/W PUMP MOTOR
(5-1, 5-2, 5-3)
R/W
MAIN FUSE
(20 A)
B/W 9 UBVR (5-4)
ABS SOL FUSE
(15 A)
R 18 UBMR
ABS MOTOR FUSE
(30 A) SCS SHORT
CONNECTOR
SOLENOID VALVE
(3-1, 3-2, 3-7,
3-8) COMBINATION
R G
METER
DLC
NABSSILA 17 R/Bl
LG A26 G/Bl ABS INDICATOR
BATTERY ECM SCS A30 Br 7 DIAGL DFAH 16 P/G
K-LINE A29 O/W 5 DIAGK SPEEDOMETER
P/G A19 RVW FVW A18 Y 8 DFAV

GND 1 G
FRONT WHEEL
SPEED SENSOR
(1-2)
MGND 10 G
FRONT PULSER W W 3 DSV
RING (1-1, 1-2, 4-2)
(1-2, 2-1) Bu Bu 12 DPV
REAR PULSER W/Bl W/Bl 14 DSH

RING (1-3, 1-4, 4-2)
Bu Bu/Y 13 DPH
(1-4, 2-1)
REAR WHEEL
SPEED SENSOR
(1-4)
1 2 3 4 5 6 7 8 9
( ) : ABS indicator blink
: Short terminals for reading 10 11 12 13 14 15 16 17 18
DTC (with ABS indicator)
ABS MODULATOR 18P (Black) CONNECTOR (MODULATOR SIDE)
4-45
ELECTRICAL SYSTEM
DTC TROUBLESHOOTING
• Before starting this troubleshooting, check the burned fuse and initial function of the meter.
• Use a fully charged battery. Do not diagnose with a charger connected to the battery.
• Perform inspection with the ignition switch OFF, unless otherwise specified.
• All connector diagrams in the troubleshooting are viewed from the terminal side.
• When the ABS modulator assembly is detected to be faulty, recheck the wire harness and connector connections
closely before replacing it.
• After diagnostic troubleshooting, erase the DTC and test-ride the vehicle to check that the ABS indicator operates
normally during pre-start self-diagnosis.
ABS INDICATOR MALFUNCTION

ABS indicator does not come ON (When the ignition switch ON)
Combination meter 24P (Black) connector ABS modulator 18P (Black) connector
R/Bl
R/Bl
From Battery
IGN
COMBINATION ABS IND R/Bl NABSSILA ABS MODULATOR
METER
1. ABS Indicator Inspection
• Check the ABS indicator. No

• Faulty ABS modulator
• Does not the ABS indicator come on? ►
Yes ▼
2. ABS indicator Line Inspection
• Check a short circuit in R/Bl wire. No

• Faulty meter
• Is there short circuit? ►
Yes ▼
• Faulty R/Bl wire
4-46
ELECTRICAL SYSTEM
ABS indicator stays ON (Indicator does not go off when the motorcycle is running, but DTC is not stored)
ABS modulator 18P (Black) connector
Br R/Bl Bl/Y
From Battery
DLC
Bl/Y UZ
Br DIAGL
ABS MODULATOR
ABS IND R/Bl NABSSILA

COMBINATION
G GND
METER
1. Service Check Line Inspection
• Check a short circuit in Br wire. Yes

• Faulty Br wire
No ▼
2. ABS Indicator Line Inspection
• Install a jumper wire between the terminal and

ground. No • Faulty R/Bl wire
Jumper terminal: R/Bl ► • If wire is ok, combination meter is faulty.
• Does the ABS indicator go off?
Yes ▼
3. ABS Modulator Ground Line Inspection
• Check an open circuit in G wire. No

• Faulty G wire
• Is there no open circuit? ►
Yes ▼
4. ABS Modulator Power Line Inspection
• Connection: Bl/Y (+) – Ground (–) No

• Faulty Bl/Y wire
Yes ▼
4-47
ELECTRICAL SYSTEM
DTC 1-1, 1-2, 2-1, 4-2
(Front wheel speed sensor circuit / Front wheel speed sensor / Wheel slipping / Front wheel lock)
Front wheel speed sensor 2P (Black) connector ABS modulator 18P (Black) connector
W Bu W
Bu
FRONT WHEEL Bu Bu DSV

SPEED SENSOR W W DPV ABS MODULATOR
1. Air Gap Inspection
• Measure the air gap. No • Check each part for deformation, looseness and
• Is the air gap correct? ► correct accordingly. Recheck the air gap.
Yes ▼
2. Speed Sensor and Pulser Ring Inspection
• Check the speed sensor and pulser ring.

No • Remove any deposits.
• Are the sensor and pulser ring in good condition
► • Install properly or replace faulty part.
and proper installed?
Yes ▼
3. Speed Sensor Line Inspection 1
• Install a jumper wire between the terminals of the

ABS modulator 18P connector.
No
Jumper terminal: W and Bu • Faulty Bu or W wire
►
• Check the continuity between the above wires.
Yes ▼
• Check a short circuit in Bu and W wires. Yes

• Faulty Bu or W wire
No ▼
5. Failure Reproduction
• Replace the speed sensor with a new one. 4-55

• Erase the DTC and test-ride the vehicle above 30 No
• Faulty original speed sensor
km/h, then recheck the DTC. ►
• Is the DTC 1-1, 1-2, 2-1, 4-2 indicated?
Yes ▼
4-48
ELECTRICAL SYSTEM
DTC 1-3, 1-4, 2-1
(Rear wheel speed sensor circuit / Rear wheel speed sensor / Wheel slipping)
Rear wheel speed sensor 2P connector ABS modulator 18P connector
W/Bl Bu/Y
W/Bl Bu/Y
REAR WHEEL
SPEED SENSOR Bu Bu/Y DPH ABS MODULATOR
W W/Bl DSH
1. Air Gap Inspection
• Measure the air gap. No • Check each part for deformation, looseness and
• Is the air gap correct? ► correct accordingly. Recheck the air gap.
Yes ▼
2. Speed Sensor and Pulser Ring Inspection
• Check the speed sensor and pulser ring.

No • Remove any deposits.
• Are the sensor and pulser ring in good condition
► • Install properly or replace faulty part.
and proper installed?
Yes ▼
• Install a jumper wire between the terminals of the

ABS modulator 18P connector.
No
Jumper terminal: Bu/Y and W/Bl • Faulty Bu/Y or W/Bl wire
►
• Check the continuity between the above wires.
Yes ▼
• Check a short circuit in Bu/Y and W/Bl wires. Yes

• Faulty Bu/Y or W/Bl wire
No ▼
• Replace the speed sensor with a new one. 4-55

• Erase the DTC and test-ride the vehicle above 30 No
• Faulty original speed sensor
km/h, then recheck the DTC. ►
• Is the DTC 1-3, 1-4, 2-1 indicated?
Yes ▼
4-49
ELECTRICAL SYSTEM
DTC 3-1, 3-2, 3-3, 3-4
(Solenoid valve)
From Battery
ABS MODULATOR
SOLENOID
VALVE

No
km/h, then recheck the DTC. • Intermittent failure
►
• Is the DTC 3-1, 3-2, 3-3, 3-4 indicated?
Yes ▼
4-50
ELECTRICAL SYSTEM
DTC 5-1, 5-2, 5-3
• Front cover 3-15
(Pump motor lock / Pump motor stuck on / Pump motor stuck off)
ABS modulator 18P (Black) connector
R
From Battery
R UBMR
ABS MOTOR
30 A ABS MODULATOR
PUMP
MOTOR
• Connection: R (+) – Ground (–) No

• Faulty R wire
Yes ▼

No
►
• Is the DTC 5-1, 5-2, 5-3 indicated?
Yes ▼
4-51
ELECTRICAL SYSTEM
DTC 5-4
(Valve relay)
ABS modulator 18P connector
Bl/W
From Battery
Bl/W UBVR
ABS SOL
15 A ABS MODULATOR
1. ABS Modulator Solenoid Valve Line Inspection

Yes ▼

No
►
Yes ▼
4-52
ELECTRICAL SYSTEM
DTC 6-1, 6-2
(Power circuit)
ABS modulator 18P connector
Bl/Y
From Battery
Bl/Y UZ
ABS MAIN
7.5 A ABS MODULATOR
1. Charging Voltage Inspection
• Measure the charging voltage. No

• Faulty regulator/rectifier
• Is the charging voltage below 15.5 V? ►
Yes ▼
• Connection: Bl/Y (+) – Ground No

• Faulty Bl/Y wire
Yes ▼

No
►
• Is the DTC 6-1, 6-2 indicated?
Yes ▼
4-53
ELECTRICAL SYSTEM
DTC 8-1
(ABS control unit)

No
►
Yes ▼
4-54
ELECTRICAL SYSTEM
WHEEL SPEED SENSOR
• Wheel speed sensor inspection
• Wheel speed sensor inspection
4-55
ELECTRICAL SYSTEM
ABS MODULATOR
14 N·m
10 N·m
• Remove the front wheel speed sensor wire clip and Bluetooth unit 8P (Blue) connector from the ABS mod-
ulator stay.
Disconnect the ABS modulator 18P (Black) connector.
4-56
ELECTRICAL SYSTEM
BATTERY/CHARGING SYSTEM
BATTERY/CHARGING SYSTEM LOCATION
IGNITION SWITCH
FUSE/RELAY BOX
· MAIN RELAY
· 20 A (MAIN)
· 7.5 A (IGN. INJ)
BATTERY
ECM
ALTERNATOR/
STARTER
BATTERY/CHARGING SYSTEM DIAGRAM

20 A 7.5 A
R R/W R/G R/G Bl/W
IGNITION Bl/Y
G SWITCH
G
STARTER/
MAIN
CHARGING
RELAY
RELAY
BATTERY
G
R/W
Y
R/Y Bl/W
R/Bu
ECM
ALTERNATOR/ R/Y
STARTER
R/W
• Battery/charging system information, troubleshooting and inspection
4-57
ELECTRICAL SYSTEM
BATTERY
4-58
ELECTRICAL SYSTEM
LIGHTING SYSTEM
• Right and left front side covers 3-15
• Headlight aim 4-61
1.2 N·m
• Front handle bar cover 3-10
4-59
ELECTRICAL SYSTEM
Right front side cover only:

1.2 N·m
• Front side cover 3-15
1.2 N·m
4-60
ELECTRICAL SYSTEM
1.2 N·m
HEADLIGHT AIM
Beam up
Beam down
4-61
ELECTRICAL SYSTEM
COMBINATION METER
4-62
ELECTRICAL SYSTEM
CLOCK ADJUST
• Press and hold the INFO A button [1] and INFO B button
[1]
[2].
• The clock will be set in the adjust mode with the clock dis-
[3] play flashing.
[2]
• Press the INFO A button, or turn the knob switch [3] to right
or left to select "12 hr" or "24 hr".
• Press the INFO B button. The time format is set, and then
the display moves to the clock setting.
• Press the INFO A button, or turn the knob switch to right
until the desired hour is displayed.
• Press and hold the INFO A button or knob switch to right
to advance the hour fast.
• Press the INFO B button. The minute digits start flashing.

• Press the INFO A button, or turn the knob switch to right
until the desired minute is displayed.
• Press and hold the INFO A button or knob switch to right
to advance the minute fast.
• Press the INFO B button. The clock is set. To end the ad-
justing mode, push the INFO B button three times.
• The established setting can also be set by turning the igni-
tion switch to the Off position.
4-63
ELECTRICAL SYSTEM
OIL CHANGE/MAINTENANCE INDICATOR RESET
• The oil change indicator [A] and maintenance indicator [B]
are turned on whenever the running distance reaches the
programmed oil change interval or maintenance interval.
• When the running distance reaches about 1,000 km, the
indicators appear first time.
[A] [B] • The indicators are appeared when the running distance
reaches every 6,000 km after each indication was reset.
• The indicator does not go off until it is reset.
• Press and hold the INFO A [1] and INFO B [2] button until
[1] the clock display starts flashing.
• Press the INFO B button four times to enter the oil change
indicator reset mode. The oil change indicator and remain-
ing distance start flashing.
INFO B
(4 times)
[2]
• Press and hold the A button to reset the oil change indica-
tor and remaining distance.
• Press the INFO B button to enter the maintenance indica-
tor reset mode. The maintenance indicator and remaining
distance start flashing.
• Press and hold the A button to reset the maintenance indi-
cator and remaining distance.
• Press the B button to return the ordinary display.
COMBINATION METER TROUBLESHOOTING

COMBINATION METER INDICATION WHEN THE CAN COMMUNICATION LINES ARE ABNORMAL
[2]
• If there is any problem in the CAN communication line, the
combination meter shows following:
– MIL stays on [1]
– HSTC indicator [2] (SH125AD/SH150AD) stays on and
cannot be changed the HSTC mode to ON or OFF
– Fuel mileage (average or section mileage) meter [3]
"––.–" flashes
– RANGE display [4] "–––" flashes
[1]
• When the combination meter shows the above symptoms
on each indicator, check the DTC (U0001, U0155) and
troubleshoot it first.
[3], [4]
4-64
ELECTRICAL SYSTEM
BLUETOOTH® TROUBLESHOOTING
BLUETOOTH CONNECTION IS ABNORMAL
• The dedicated application is requred to connect the smartphone to Bluetooth unit on the vehicle. If the Bluetooth
unit has been replaced, check the connection using a smartphone with the dedicated application installed.
• The failure of Bluetooth unit is diagnosed by replacing itself.
• Left front side cover 3-15
Connector Diagram
Bluetooth unit 8P connector

Combination meter 24P (Gray) connector
G
Lg/Bl Bl/Bu
Lg/Bl Bl/Bu Bl Bu
Bl Bu
From fuse/relay box
Bu
Bl BLUETOOTH
COMBINATION Bl/Bu UNIT
METER Lg/Bl
G
1. Circuit inspection
• Check an open or short circuit in Bu, Bl, Lg/Bl

Yes
and Bl/Bu wires. • Faulty Bu, Bl, Lg/Bl or Bl/Bu wire
►
No ▼
2. Ground line inspection
• Check the continuity of the G wire. No

• Faulty G wire
• Is there continuity? ►
Yes ▼
• Replace the Bluetooth unit with a known good

No
one 4-65. • Faulty original Bluetooth unit
►
• Is the Bluetooth connection abnormal?
Yes ▼
Faulty combination meter
4-65
ELECTRICAL SYSTEM
FUEL LEVEL SENSOR
Bl
Bl
• Route the fuel level sensor wires to the guide and terminals properly.
4-66
ELECTRICAL SYSTEM
FUEL METER TROUBLESHOOTING
FUEL GAUGE FAILURE INDICATION
• Loose or poor contacts of related terminal/connector
OPEN CIRCUIT:
A B
FULL
SHORT CIRCUIT:
EMPTY
1. Fuel Level Sensor Circuit Inspection (Wire harness side)
• Check the G/W and Y/W wire. Yes

• Faulty G/W or Y/W wire
No ▼
2. Fuel Level Sensor Inspection
• Connection: A – B
No • Replace the fuel level sensor with a new one 4-
• Standard: FULL 6 – 10 Ω, EMPTY 325 – 335 Ω
► 66, and recheck.
• Does the standard resistance exist?
Yes ▼
• Replace the meter with a new one 4-62, and re-

check.
4-67
ELECTRICAL SYSTEM
ELECTRICAL COMPONENT
SIDESTAND SWITCH
10 N·m
HORN
• Right front side cover 3-15
4-68
ELECTRICAL SYSTEM
USB CHARGER UNIT
BLUETOOTH® UNIT
• Left front side cover 3-15
4-69
ELECTRICAL SYSTEM
Honda SMART Key SYSTEM

• Keep the Honda SMART Key away from the other Honda SMART Key when using it. The jamming of the key code
signal may occur and the proper operation of the system will be obstructed.
• The Honda SMART Key has built-in electronic part. Do not drop or strike the Honda SMART Key against a hard
object, and do not leave the Honda SMART Key in the vehicle. where the temperature will rise. Do not leave the
Honda SMART Key in the water for a prolonged time such as by washing the clothes.
• Bring the emergency key and ID tag with you separately from the Honda SMART Key. If you lost the Honda
SMART Key and emergency key at the same time, it is impossible to unlock the seat.
• Do not put the emergency key in the luggage box. If so, the key cannot be taken out in emergency, and the seat
may not be unlocked in the worst case.
• Once the new Honda SMART Key is registered, it is not usable for other vehicle.
• To replace the smart control unit, replace the smart control unit and the smart-authentication-completed Honda
SMART Key as a set.
• The smart control unit can store up to four Honda SMART Key codes. (The four Honda SMART Keys can be
registered.)
• For ignition system inspection. 4-32
Honda SMART Key SYSTEM LOCATION
IGNITION SWITCH
SMART
CONTROL UNIT SMART HANDLE LOCK
ECM
Honda SMART Key
Honda SMART
ANSWER BACK Key LED
BUTTON
ENTRY MODE
CONNECTOR
EM MODE CONNECTOR
ANTI-THEFT
ALARM BUTTON
Honda SMART Key
ON/OFF BUTTON
4-70
ELECTRICAL SYSTEM
Honda SMART Key SYSTEM DIAGRAM
G R
BATTERY
R/W
MAIN FUSE (20 A)
R/W Lg/Bl Lg/Bl

BACK UP (7.5 A)
Lg/Bl SMART CONTROL UNIT
Bl Lg/Bl 33 BACK UP
SMART HANDLE LOCK

LF ANTENNA
Bl 9 FACE LED
IGNITION SWITCH
RING LED RF UNIT
Bl 5 ALARM IND Honda SMART Key

ALARM INDICATOR
Bl 32 SOL - COMBINATION METER

SOLENOID
Bl 29 SOL+ SMART IND 10 Gr
Honda SMART Key
INDICATOR
Bl Bl 26 KNOB SW
KNOB SWITCH
G
HAZARD L 11 W G
IGNITION SWITCH
LEFT TURN SIGNAL
LIGHT
R/W
IGN・INJ HAZARD R 22 Bu G
(7.5 A) RIGHT TURN SIGNAL G
R/G Bl/W 7 MAIN SW LIGHT
INSPECTION G/Bl 18 ENTRY MODE

BUZZER1 21 Bu
ADAPTER BUZZER
ENTRY MODE BUZZER2 31 G/P G
CONNECTOR
Bl/Br 15 EM MODE
IMOID 6 Bu/R
EM CONNECTOR
G To ECM
EM MODE IMOAU 16 O/Bu
CONNECTOR G 25 GND
SMART CONTROL UNIT 33P CONNECTOR

SMART CONTROL UNIT side of male terminals
4-71
ELECTRICAL SYSTEM
Honda SMART Key SYSTEM TROUBLESHOOTING
• Before starting the troubleshooting, check the following:
– DTC (PGM-FI system) 4-2
– Battery voltage
– Honda SMART Key battery
– Each fuse condition
– Loose or poor contact of related terminal/connector
– Communication errors 4-87
– Answer back 4-72
The Honda SMART Key indicator comes on for approximately two seconds then it goes off, when the ignition switch is
turned ON with the properly registered Honda SMART Key and the Honda SMART Key system functions normally.
Answer Back Malfunction
Turn Signal Light Does Not Come On (When the Answer Back Button is Pushed)
Smart control unit 33P (Gray) connector
W
From Battery G
Bu
G FR R Bu
Lg/Bl
G FR L W
Lg/Bl BACK UP
SMART
Bu HAZARD R
CONTROL
G RR L W W HAZARD L UNIT
G GND
G RR R Bu
• If one side of the turn signal light does not turn on, check the W or Bu wire.
1. Turn Signal Light Line Inspection
• Check an open or short circuit in turn signal line. Yes

• Faulty turn signal related circuit
No ▼
2. Smart Control Unit Backup Line Inspection
• Connection: Lg/Bl (+) – Ground (–) No

• Faulty Lg/Bl wire
Yes ▼
3. Smart Control Unit Ground Line Inspection
• Check an open circuit in G wire. Yes

• Faulty G wire
• Is there open circuit? ►
No ▼
• Faulty smart control unit
4-72
ELECTRICAL SYSTEM
Honda SMART Key Indicator Malfunction

Honda SMART Key Indicator Does Not Come On (When the Knob Switch is Pushed)
Meter 24P (Gray) connector Smart control unit 33P connector
Lg/Bl G/W Gr
Gr
From Battery From Battery
BATT Lg/Bl BACK UP SMART

COMBINATION BACK UP
Gr SMART IND CONTROL
METER SMART IND
G/W GND UNIT
GND
1. Meter Backup Line Inspection
• Connection: Lg/Bl (+) – Ground (–) No

• Faulty Lg/Bl wire
Yes ▼
2. Meter Ground Line Inspection
• Check an open circuit in G/W wire. Yes

• Faulty G/W wire
No ▼
3. Honda SMART Key Indicator Line Inspection
• Check an open circuit in Gr wire. Yes

• Faulty Gr wire
No ▼
4. Meter Inspection

Yes
check. • Faulty original meter
►
• Does the Honda SMART Key indicator come on?
No ▼
4-73
ELECTRICAL SYSTEM
Honda SMART Key Indicator Does Not Turn Off Within a Few Seconds (When the Ignition Switch is ON)
Smart control unit 33P (Gray) connector
Gr Bl/W
Meter 24P (Gray) connector
20 A
R/W R
Gr
IGNITION
From Battery SWITCH
7.5 A
IGN R/G Bl/W MAIN SW SMART
SMART IND Gr SMART IND CONTROL
GND GND UNIT
COMBINATION METER
1. Honda SMART Key Indicator Line Inspection
• Check an short circuit in Gr wire. Yes

• Faulty Gr wire
No ▼
2. Ignition Switch Line Inspection
• Connection: Bl/W (+) – Ground (–) No • Faulty Bl/W or R/G or R/Bl or R wire
• Does the battery voltage exist? ► • Faulty ignition switch
Yes ▼
3. Meter Inspection

Yes
check. • Faulty original meter
►
• Does the Honda SMART Key indicator come on?
No ▼
4-74
ELECTRICAL SYSTEM
Ignition Switch Ring LED Malfunction

Ignition Switch Ring LED Does Not Come On (When the Knob Switch is Pushed)
Smart handle lock 7P (Green) connector Smart control unit 33P (Gray) connector
Bl (KNOB SW +) Bl (KNOB SW –) Bl (FACE LED)
Bl (LED +) Bl (FACE LED –) Bl (KNOB SW)
LED + Bl BACK UP
SMART SMART
FACE LED – Bl FACE LED
HANDLE CONTROL
LOCK KNOB SW + Bl KNOB SW UNIT
KNOB SW – Bl GND
G
1. Knob Switch Line (knob SW + and SW –) Inspection
• Check an open circuit in each Bl wire. Yes

• Faulty either Bl wire
No ▼
2. Ignition Switch Ring LED Power Line (LED +) Inspection
• Connection: Bl (+) – Ground (–) No

• Faulty Bl wire
Yes ▼
3. Ignition Switch Ring LED Line (FACE LED –) Inspection
• Check an open circuit in Bl wire. Yes

• Faulty Bl wire
No ▼
4. Smart Handle Lock Inspection
• Replace the smart handle lock with a new one

Yes
4-86, and recheck. • Faulty original smart handle lock
►
• Does the ignition switch ring LED come on?
No ▼
4-75
ELECTRICAL SYSTEM
Ignition Switch Ring LED Stays On (When the Ignition Switch is ON)
Bl (FACE LED)
Bl (FACE LED –)
LED + BACK UP
SMART SMART
FACE LED – Bl FACE LED
HANDLE CONTROL
LOCK KNOB SW + KNOB SW UNIT
KNOB SW – GND
1. Ignition Switch Ring LED Line (FACE LED –) Inspection
• Check a short circuit in Bl wire. Yes

• Faulty Bl wire
No ▼

Yes
►
• Does the ignition switch ring LED turn off?
No ▼
4-76
ELECTRICAL SYSTEM
Alarm Indicator Malfunction

Alarm Indicator Does Not Come On (When the Alarm Button is Pushed)
Bl (ALARM LED –) Bl (ALARM IND)
Bl (LED +)
LED + Bl BACK UP
SMART SMART
ALARM LED – Bl ALARM IND
HANDLE CONTROL
LOCK UNIT
1. Alarm Indicator Power Line (LED +) Inspection
• Connection: Bl (+) – Ground (–) No

• Faulty Bl wire (LED +)
Yes ▼
2. Alarm Indicator Line (ALARM LED –) Inspection
• Check an open circuit in Bl wire. Yes

• Faulty Bl wire (ALARM LED –)
No ▼

Yes
►
• Does the alarm indicator come on?
No ▼
4-77
ELECTRICAL SYSTEM
Knob Lock Solenoid Malfunction

Ignition Switch Cannot be Turned ON

(The Honda SMART Key Indicator and Ignition Switch Ring Come On)
Bl (SOL1)
Bl (SOL2) Bl (SOL –) Bl (SOL +)
From Battery
BACK UP
SMART SMART
SOL 1 Bl SOL +
HANDLE CONTROL
LOCK SOL 2 Bl SOL –
UNIT
GND
• Before starting the troubleshooting, check that the EM or entry mode connectors are not connected.
1. Knob Lock Solenoid Line (SOL1 and SOL2) Inspection
• Check an open or short circuit in each Bl wire. Yes

• Faulty Bl either wire
No ▼

Yes
►
• Does the ignition switch can be turned ON?
No ▼
4-78
ELECTRICAL SYSTEM
Immobilizer Malfunction

Engine Does Not Start (The Ignition Switch Can be Turned ON)
Smart control unit 33P (Gray) connector ECM 39P (Black) connector
Bl/W Bu/R
IGNITION
O/Bu SWITCH O/Bu Bu/R
20 A
R R/W R/G
7.5 A
MAIN SW Bl/W Bl/W BATT

SMART Bu/R IMOID
IMOID ECM
CONTROL
IMOAU O/Bu IMOAU
UNIT
LG
1. Immobilizer Communication Line Inspection
• Faulty Bu/R wire

• Check open or short circuit in Bu/R and O/Bu wire. Yes
(Honda SMART Key indicator blinks)
• Faulty O/Bu wire
No ▼
2. Ignition Switch Line Inspection
• Connection: Bl/W (+) – Ground (–) No • Faulty Bl/W or R/G or R/W or R wire
• Does the battery voltage exist? ► • Faulty ignition switch
Yes ▼
3. Smart Control Unit Inspection
• Replace the smart control unit with a new one 4-

Yes
85, and recheck. • Faulty original smart control unit
►
• Does the engine start?
No ▼
• Faulty ECM
4-79
ELECTRICAL SYSTEM
EM Mode Malfunction (Engine Starting Procedure in Emergency Mode)
The EM Connector Connected but Honda SMART Key Indicator and

Ignition Switch Ring Does Not Come On
Smart control unit 33P (Gray) connector EM mode 2P (Blue) connector
G Bl/Br
Bl/Br
From Battery
BACK UP
SMART
CONTROL EM MODE Bl/Br EM
UNIT CONNECTOR
GND G
• Before starting the troubleshooting, check the ignition switch ring LED malfunction. 4-75
1. EM Mode Connector Line Inspection
• Check an open circuit in Bl/Br and G wire. Yes

• Faulty Bl/Br or G wire
No ▼
4-80
ELECTRICAL SYSTEM
Honda SMART Key Registration Mode Malfunction
Cannot be Started the Honda SMART Key Registration Mode

Smart control unit 33P (Gray) connector Entry mode 2P (Red) connector
G/Bl
G/Bl
From Battery
SMART BACK UP
CONTROL ENTRY MODE G/Bl INSPECTION
UNIT ADAPTER
• Before starting the troubleshooting, check the immobilizer malfunction. 4-79
1. Entry Mode Connector Line Inspection
• Check an open circuit in G/Bl wire. Yes

• Faulty G/Bl wire
No ▼
4-81
ELECTRICAL SYSTEM
Smart Control Unit Registration Mode Malfunction
Cannot be Started Smart Control Unit Registered Mode

Smart control unit 33P (Gray) connector ECM 39P (Black) connector
Bu/R
G/Bl O/Bu Bl/Br O/Bu Bu/R
From
From Battery Ignition switch
BACK UP BATT
IMOID Bu/R IMOID
SMART ECM
IMOAU O/Bu IMOAU
CONTROL
UNIT ENTRY MODE G/Bl
EM MODE Bl/Br
GND
G
INSPECTION
ADAPTER
G
EM
CONNECTOR
EM mode 2P (Blue) connector Entry mode 2P (Red) connector
G Bl/Br G/Bl
• Check the following:

– Immobilizer malfunction 4-79
– EM mode malfunction 4-80
– Honda SMART Key registration mode malfunction 4-81
4-82
ELECTRICAL SYSTEM
EMERGENCY MODE
• Emergency key is used to unlock the seat without using the Honda SMART Key, and smart control unit provides an
emergency mode to start the engine in an emergency such as when the vehicle’s battery runs out or the Honda
SMART Key is lost or battery runs out.
• Before starting the engine in emergency mode, check the vehicle’s battery voltage.
How to Unlock the Seat Using the Emergency Key
• Smart emergency lid 3-17

• Turn the emergency cylinder using the emergency key to
unlock the seat.
• The emergency cylinder will not be returned automatically
to the condition before unlocking. After unlocking the seat,
use the emergency key to return it to the condition before
unlocking.
[1]
4-83
ELECTRICAL SYSTEM
Engine Starting Procedure in Emergency Mode:
• Check the ID number indicated on the ID tag of the Honda SMART Key registered in the vehicle.
• To input “0,” do not press the knob switch and wait until the Honda SMART Key indicator and ignition switch ring
are blinking once.
• Emergency mode is released by the following condition:
– Press the knob switch for more than 2 seconds when the ignition switch is not ON.
– Leave for more than 6 minutes when the ignition switch is not ON.
• Battery maintenance lid 3-4
How to input the 9-digit ID number to start the engine:
[3] • Connect the EM connector [1] to the EM mode connector

[1] [2].
– The Honda SMART Key indicator [3] and ignition switch
ring [4] come on.
[2]
[4]
• Use the knob switch to input 9-digit ID number.

– [A]:
Press 5 times, then wait 5 sec.
Honda SMART Key indicator and ignition switch ring
blink once.
– [B]:
Do not press, then wait 5 sec.
[A] [B] [C to H] [I]
blink once.
– [C to H]:
Example [A]: Repeat the above procedure.
– [I]:
Wait 5 Press 3 times, then wait 5 sec.
x5 sec. After 9-digit ID number is input, the Honda SMART Key
Blinking once indicator and ignition switch ring start blinking as shown
below.
Input completed:
ON: 0.5 sec.
OFF: 2.0 sec.
Input failure:
ON: 1.0 sec.
OFF: 1.0 sec.
• Disconnect the EM connector.

– Input completed:
The Honda SMART Key indicator and ignition switch ring
come on. (Buzzer sounds twice)
The ignition switch unlocked.
Turn the ignition switch ON and start the engine.
– Input failure:
Try again from the beginning.
4-84
ELECTRICAL SYSTEM
REPLACEMENT PARTS FOR Honda SMART Key SYSTEM PROBLEM
Replacement parts
Honda Smart Smart Seat
Problem Emergency
SMART control ECM handle and fuel
opener
Key unit lock opener
All Honda SMART Key have been lost.
(Registered smart authentication ID number can be con-
firmed)
All Honda SMART Key have been lost.
(Registered smart authentication ID number and immobi-
lizer authentication ID number cannot be confirmed)
Smart control unit is faulty.
(Registered immobilizer authentication ID number can be
confirmed)
Smart control unit is faulty.
(Registered immobilizer authentication ID number can-
not be confirmed)
ECM is faulty.
Smart handle lock is faulty.
Seat and fuel opener is faulty.
Emergency opener is faulty or all emergency key have
been lost.
SMART CONTROL UNIT
4-85
ELECTRICAL SYSTEM
IGNITION SWITCH (SMART HANDLE LOCK)
9.0 N·m
1.2 N·m
• Handlebar 3-25
• Align the pin with the hole.
• Set the emergency opener in the position shown.
4-86
ELECTRICAL SYSTEM
SMART AUTHENTICATION ID REGISTRATION PROCEDURE
• Each Honda SMART Key has its particular ID number that cannot be changed or deleted.
• The Honda SMART Key that was registered once in the smart control unit cannot be registered in another smart
control unit.
COMMUNICATION ERRORS INSPECTION
To register the smart authentication ID, use a radio communication. Before registration, check the below items that
may cause communication error.
• A TV tower, power generation plant, broadcast station, airport or other facility that generates strong radio wave or
noise is not situated nearby.
• The Honda SMART Key is not brought together with a wireless communications device such as wireless
applications and mobile phone or laptop.
• The Honda SMART Key does not make contact with or is not covered by a metallic product.
• The vehicle battery voltage is not low
• The Honda SMART Key battery power is not low
• The Honda SMART Key does not have any trouble
• The smart control unit does not have any trouble
• The associated circuits of the smart control unit do not have any trouble
SMART AUTHENTICATION DIAGNOSTIC CODE
If the smart authentication ID is registered and not completed normally, the following error codes appear.
Honda SMART Key
Symptom Remedy
indicator blinking pattern
ON Communication error between the Check for any communication error.
Honda SMART Key and smart control
OFF unit
ON Failure to register the Honda SMART Perform the registration procedure
Key again.
OFF
ON The Honda SMART Key has already Check the behavior with the previously
registered. registered Honda SMART Key.
OFF
ON The Honda SMART Key has already Use a new Honda SMART Key to per-
registered in other vehicle. form the registration procedure again.
OFF
4-87
ELECTRICAL SYSTEM
Procedure for additional registration of a spare Honda SMART Key:
• Register all registered spare Honda SMART Key again.
• Use a Honda SMART Key registered in the vehicle and an inspection adapter to shift the Honda SMART Key
system from normal mode to Honda SMART Key registration mode for additional registration.
• 4 ID codes can be registered in one smart control unit, so that it is possible to register up to 4 Honda SMART Keys.
• Prepare a new Honda SMART Key and confirm that the ON/OFF buttons of all Honda SMART Keys are set to OFF.
• Confirm that the seat is locked with the ignition switch set to OFF (the ignition switch is not turned).
• Operate the Honda SMART Key ON/OFF button within the communication range.
How to register the additional Honda SMART Key:
[3]
[1] • Connect the inspection adapter (07XMZ-MBW0101) [1] to
the entry mode connector [2] and the battery positive (+)
terminal [3].
Within
2 min.
[2]
Green LED • Push and hold the ON/OFF button of the registered Honda
SMART Key [4] to activate the system.
– Red LED blinks five times and then Green LED blinks
once.
– If 2 minutes have passed, remove the inspection adapter
and try again from the beginning.
[4]
[5] [6]
• Press the knob switch.

Lighting ring [6] come on.
Within
2 min.
4-88
ELECTRICAL SYSTEM
Red LED • Push and hold the registered Honda SMART Key ON/OFF
button to deactivate the system.
– Green LED blinks five times and then Red LED blinks
once.
REGISTRATION
MODE:
Green LED
• Push and hold the ON/OFF button of a new Honda SMART
Key [1] to activate the system.
once.
[1]
Within
2 min.
• Turn the ignition switch ON.

– The Honda SMART Key indicator and ignition switch ring
go off.
Blinking
Green LED • Check the blinking pattern of the Honda SMART Key indi-
cator and Honda SMART Key LED.
– Registration completed:
After the Honda SMART Key indicator lights for about 2
Blinking
seconds, it repeats blinking 4 times.
The new Honda SMART Key LED blinks Green 5 times.
– Registration failure:
The Honda SMART Key indicator displays the smart di-
agnosis code.
4-89
ELECTRICAL SYSTEM
• Turn the ignition switch OFF.

come on.
• Push and hold the registered new Honda SMART Key ON/
OFF button to deactivate the system.
Red LED – Green LED blinks five times and then Red LED blinks
once.
– To continue the additional registration:
Push and hold the other new Honda SMART Key to ON
within 2 minutes. Restart the additional "registration
mode".
If 2 minutes have passed, remove the inspection adapter
– To complete the additional registration:
Remove the inspection adapter or pass 2 minutes.
Confirm that the ignition switch can be set to ON using
the all registered Honda SMART Keys.
4-90
ELECTRICAL SYSTEM
Honda SMART Key registration procedure when all Honda SMART Keys were lost:
• When all Honda SMART Keys registered in the vehicle are lost and the smart authentication is disabled, input the
ID number manually to perform the smart authentication, shift the Honda SMART Key system from the normal
mode to the Honda SMART Key registration mode and register a new Honda SMART Key.
• It is possible to register up to 3 Honda SMART Keys when all Honda SMART Keys were lost.
• Confirm the ID number indicated on the ID tag of the lost Honda SMART Key.
• Prepare a new Honda SMART Key.
• Confirm that ON/OFF buttons of all Honda SMART Keys are set to OFF.
• Use the emergency key to unlock the seat.
• To input “0,” do not press the knob switch and wait until the Honda SMART Key indicator and ignition switch ring
are blinking once.
How to input the 9-digit ID number and register the Honda SMART Key:
[3]
[1]
• Connect the inspection adapter (07XMZ-MBW0101) [1] to
terminal [3].
[2]

[4] [5] ring [5] come on.
4-91
ELECTRICAL SYSTEM
• Use the knob switch to input 9-digit ID number.

– [A]:
Press 5 times, then wait 5 sec.
blink once.
– [B]:
Do not press, then wait 5 sec.
[A] [B] [C to H] [I] blink once.
– [C to H]:
Example [A]: Repeat the above procedure.
– [I]:
Wait 5 Press 3 times, then wait 5 sec.
x5 sec.
Blinking once
• Check the Honda SMART Key indicator and ignition switch

ring.
– Input completed:
goes off in 5 seconds, and then come on.
– Input failure:
start blinking.
Remove the inspection adapter and try again from the
beginning.
REGISTRATION
MODE:
Green LED • Push and hold the ON/OFF button of a new Honda SMART
once.
[1]
Within
2 min.

go off.
4-92
ELECTRICAL SYSTEM
• Check the blinking pattern of the Honda SMART Key indi-

Blinking cator and Honda SMART Key LED.
Green LED After the Honda SMART Key indicator lights for about 2
seconds, it repeats blinking 4 times.
The new Honda SMART Key LED blinks Green 5 times.
Blinking – Registration failure:
The Honda SMART Key indicator displays the smart di-
agnosis code.

come on.
• Push and hold the registered new Honda SMART Key ON/
OFF button to deactivate the system.
Red LED
once.
– To continue the additional registration:
Push and hold the other new Honda SMART Key to ON
within 2 minutes. Restart the additional "registration
mode".
If 2 minutes have passed, remove the inspection adapter
– To complete the additional registration:
Remove the inspection adapter or pass 2 minutes.
Confirm that the ignition switch can be set to ON using
the all registered Honda SMART Keys.
4-93
ELECTRICAL SYSTEM
IMMOBILIZER AUTHENTICATION ID REGISTRATION PROCEDURE
• To change the immobilizer authentication ID in the smart control unit, use the ignition switch to register the ID
number manually.
• The ECM where the immobilizer authentication ID was registered once cannot delete or change the immobilizer ID.
IMMOBILIZER AUTHENTICATION DIAGNOSTIC CODE

If the immobilizer authentication ID is registered and not completed normally, the following error codes appear.
Honda SMART Key
Symptom Remedy
indicator blinking pattern
Failure to register the im- Perform the registration procedure again.
ON mobilizer authentication
OFF
Other immobilizer authenti- Check the immobilizer authentication ID

cation ID has already been registered in the ECM and perform the
ON registered in the ECM. smart control unit registration procedure.
• If the immobilizer authentication ID regis-
OFF tered in the ECM cannot be confirmed,
replace the ECM with a new one and per-
form the ECM registration procedure.
The ECM has any error. Use a new ECM to perform the ECM regis-
ON tration procedure again.
OFF
Communication error be- Perform the registration procedure again.

ON tween the smart control unit
and the ECM
OFF
Communication from the Perform the registration procedure again. If

ON ECM to smart control unit is same failure appears again, replace the
abnormal. ECM with a new one and perform the ECM
OFF registration procedure.
4-94
ELECTRICAL SYSTEM
Registration procedure when the smart control unit is replaced:
• To replace the smart control unit, replace the smart control unit and the smart-authentication-completed Honda
SMART Key as a set because the Honda SMART Key that has been used cannot be reregistered
• To replace the smart control unit, manually input the immobilizer authentication ID number for registration.
• The factory preset immobilizer authentication ID number ( + 9 digit ID) is the same as the smart authentication ID
number.
• When the smart control unit is replaced, use the factory preset ID number that has been registered in the ECM for
the immobilizer authentication ID number.
• It is necessary to store the factory preset ID tag of the Honda SMART Key or note down the ID number after the
smart control unit was replaced.
• If you don’t remember the immobilizer authentication ID number, you need to replace the engine control unit, too.
• If the Honda SMART Key indicator and ignition switch ring start blinking while perform the registration procedure,
remove the EM connector, and try again from the step of connecting the EM connector if necessary.
How to register the immobilizer authentication ID number in the new smart control unit:
Green LED
• Push and hold the ON/OFF button of the Honda SMART

once.
[1]
[2] [3]
ring [3] come on, and then go off. (Buzzer sounds twice)
[4]
• Connect the EM connector [4] to the EM mode connector.
Within
1 min.
4-95
ELECTRICAL SYSTEM
Red LED • Push and hold the Honda SMART Key ON/OFF button to
deactivate the system.
once.
– If 1 minute or more have passed, restart from the step of
Within connecting the EM connector.
1 min.

come on.
connecting the EM connector.
Press Press
• Push the Honda SMART Key ON/OFF button twice.
Within
1 min.

blink once.
Blinking once – If 1 minute or more have passed, restart from the step of
x3 connecting the EM connector.
(Repeat this procedure
three times.)
• Repeat this procedure (push the Honda SMART Key ON/
OFF button twice then press the knob switch) three times.
[3]
[1]
• Connect the inspection adapter (07XMZ-MBW0101) [1] to

terminal [3].
Within
1 min.
[2]
4-96
ELECTRICAL SYSTEM

Within – If 1 minute or more have passed, restart from the step of
1 min. connecting the EM connector.
• Use the Honda SMART Key ON/OFF button and knob

switch to input 9-digit ID number.
– [A]:
Push the Honda SMART Key ON/OFF button 5 times.
blink once. (Buzzer sounds once)
Then Press the knob switch once.
– [B]:
Do not push the Honda SMART Key ON/OFF button,
[A] [B] [C to H] [I]
then press the knob switch once.
Example [A]: – [C to H]:
Repeat the above procedure.
– [I]:
Push the Honda SMART Key ON/OFF button 3 times.
x5 Honda SMART Key indicator and ignition switch ring
Blinking once
Then press the knob switch once.
Within Honda SMART Key indicator and ignition switch ring
1 min.
– If 1 minute or more have passed after starting input of
each number, restart from the step of connecting the EM
connector.
Blinking once
ring.
blink twice. (Buzzer sounds twice)
ON: 1.0 sec.
OFF: 1.0 sec.
Remove the EM connector and inspection adapter.
If the EM connector or inspection adapter is still connect-
ed after 1 minute have passed since the completion of
the registration, Honda SMART Key indicator and ignition
switch ring will start blinking. This is a reminder function
not to forget removing them.
The Honda SMART Key indicator displays the immobiliz-
er diagnosis code.

Disconnect the EM connector and inspection adapter.
Confirm that the engine can be started using the replaced
smart control unit.
4-97
ELECTRICAL SYSTEM
Registration procedure when the ECM is replaced
• To replace the ECM with a new one, you need to register the immobilizer authentication ID number registered in
the smart control unit to the ECM. The ID number is automatically registered.
• The immobilizer authentication ID number can be registered only once in the ECM. It cannot be deleted or
changed.
• To replace the ECM with a known-good one (Immobilizer authentication ID number is already registered), confirm
the registered immobilizer authentication ID number, follow the “Registration procedure when the smart control unit
is replaced” and register the immobilizer authentication ID number that is registered in the ECM to the smart control
unit.
• Confirm that the Honda SMART Key ON/OFF buttons of the all Honda SMART Keys are set to OFF.
• Confirm that the seat is locked with the ignition switch set to OFF (the ignition switch is not turned).
Register the immobilizer authentication ID number in the ECM:
Green LED
• Push and hold the ON/OFF button of the Honda SMART

once.
[1]
[2] [3]

ring [3] come on. (Buzzer sounds twice)
4-98
ELECTRICAL SYSTEM

go off.

ring.
repeats blinking.
(Repeat sounds the buzzer)
The Honda SMART Key indicator displays the immobiliz-
er diagnosis code.

Confirm that the engine can be started using the replaced
ECM.
Registration procedure when the ECM and smart control unit are replaced at the same time
To replace the ECM with a new one:
• Replace the smart control unit and Honda SMART Key as a set.
• Replace the ECM with a new one.
• To register the immobilizer authentication ID number that was registered in the replaced smart control unit to the
ECM, follow the “Registration procedure when the ECM is replaced”.
• Confirm that the engine can be started with the replaced smart control unit and ECM.
To replace the ECM with a known-good one (Immobilizer authentication ID number is already registered):
• Replace the smart control unit and Honda SMART Key as a set.
• Replace the ECM with a known-good one (Immobilizer authentication ID number is already registered).
• Confirm the registered immobilizer authentication ID number, follow the “Registration procedure when the smart
control unit is replaced” and register the immobilizer authentication ID number that is registered in the ECM to the
smart control unit.
• Confirm that the engine can be started with the replaced smart control unit and ECM.
4-99
ELECTRICAL SYSTEM
Honda SMART Key
Switch the buzzer sounding when the ignition switch locked/unlocked
Enable:
Red LED
• Push and hold the Honda SMART Key ON/OFF button to
once.
• Lightly press the Honda SMART Key ON/OFF button.

Red LED – Red LED of the Honda SMART Key comes on.
Within
2 sec.
• Push the Honda SMART Key answer back button while the
Red LED is on.
Red LED
(Blinking) • Red LED of the Honda SMART Key starts blinking when
the buzzer sounding is properly enabled.
4-100
ELECTRICAL SYSTEM
Disable:
Red LED
once.
• Lightly press the Honda SMART Key ON/OFF button.

Red LED
(Blinking)
– Red LED of the Honda SMART Key starts blinking.
Within
2 sec.
• Push the Honda SMART Key answer back button while the
Red LED is blinking.
Red LED
(Stays on) • The Honda SMART Key LED stops blinking and stays on
when the buzzer sounding is properly disabled.
4-101
ELECTRICAL SYSTEM
Temporary silence mode
• If you enable the silent mode, alert sounds at various registration procedure will no longer.
Enable:
• Push and hold the Honda SMART Key answer back button
about 2 seconds.
Red LED
• The Honda SMART Key LED turns Red, the temporary si-
lence mode is properly enabled.
Disable:
• Push and hold the Honda SMART Key answer back button
about 2 seconds.
Green LED
• The Honda SMART Key LED turns Green, the temporary

silence mode is properly disabled.
4-102
ELECTRICAL SYSTEM
Setting the ANTI-THEFT ALARM SYSTEM
• Turn the ignition switch OFF or lock.
• Push the Honda SMART Key alarm button.
• The turn signal light blinks once (Buzzer sounds once).

After 2 seconds, the buzzer sounds once.
The ANTI-THIEF ALARM SYSTEM is activated.
Cancelling the ANTI-THEFT ALARM SYSTEM
• Push the Honda SMART Key alarm button or press the

knob switch.
or
• When the Honda SMART Key alarm button is pushed:

– The turn signal light and alarm indicator blink twice
(Buzzer sounds twice).
The ANTI-THIEF ALARM SYSTEM is cancelled.
• When the knob switch is pressed:
– The turn signal light blinks twice (Buzzer sounds twice).
(Alarm indicator goes off)
The ANTI-THIEF ALARM SYSTEM is cancelled.
4-103
ELECTRICAL SYSTEM
Stopping the ANTI-THEFT ALARM SYSTEM
• Push the Honda SMART Key alarm button or answer back

button or press the knob switch.
or or The ANTI-THEFT ALARM system is stopped.
– After stopping the ALARM activation, ALARM system will
be cancelled.
ANSWER BACK/ALARM SYSTEM

Adjusting the answer back buzzer sound volume level
Green LED
activate the system.
once.
[1] [2]

[3] – The Honda SMART Key indicator and ignition switch ring
Within go off.
1 min. – If 1 minute have passed, restart from the step of connect-
ing the EM connector.
4-104
ELECTRICAL SYSTEM

come on.
Within
1 min.
• Push the Honda SMART Key answer back button twice.
Press Press
Within
1 min.
blink once.
Blinking once • Repeat this procedure (push the Honda SMART Key an-
swer back button twice then press the knob switch) three
x3 times.
three times.)
• Press the Honda SMART Key answer back button to select

from 3 levels for the sound volume.
Wait for about 10 seconds until the ignition switch ring

starts blinking or remove the EM connector.
The sound volume level is set.
4-105
ELECTRICAL SYSTEM
Changing the answer back buzzer sound pattern
Green LED
once.
[1] [2]
[3]
Within – The Honda SMART Key indicator and ignition switch ring
1 min. go off.
– If 1 minute have passed, restart from the step of connect-
ing the EM connector.
4-106
ELECTRICAL SYSTEM

come on.
Within
1 min.
• Push the Honda SMART Key answer back button three

times.
Press
Press
Press
Within
1 min.

blink once.
Blinking once
• Repeat this procedure (push the Honda SMART Key an-
x3 swer back button three times then press the knob switch)
(Repeat this procedure three times.
three times.)
4-107
ELECTRICAL SYSTEM
• Press the answer back button to select from 3 buzzer

sound patterns.
Buzzer sound pattern: 1

Beep Beep

Beep Beep Beep

Beeeep Beeeep
Wait for about 10 seconds until ignition switch ring starts

blinking or remove the EM connector.
The sound pattern is set.
Adjusting the sensitivity of Anti-Theft Alarm system

Green LED
once.

[1] [2] ring [2] come on. (Buzzer sounds twice)
4-108
ELECTRICAL SYSTEM

[1]
go off.
Within – If 1 minute have passed, restart from the step of connect-
1 min. ing the EM connector.

come on.
• Push the Honda SMART Key alarm button twice.

Press Press
Within
1 min.

blink once.
Blinking once
x3 • Repeat this procedure (push the Honda SMART Key alarm

button twice then press the knob switch) three times.
three times.)
4-109
ELECTRICAL SYSTEM
• Press the Honda SMART Key alarm button to select from

3 sensitivity level of ANTI-THEFT ALARM SYSTEM.
3 times of buzzer sound: sensitivity level: 3 (high) 2 times

of buzzer sound: sensitivity level: 2 (middle)
1 time of buzzer sound: sensitivity level: 1 (low)
Wait for about 10 seconds until the ignition switch ring

starts blinking or remove the EM connector.
The sensitivity level is set.
BUZZER
4-110
INDEX
dummytext
INDEX
A Few Words About Safety ·············································1-2 FUEL PUMP UNIT·························································· 2-4
A
ABS ···············································································4-42 FUEL TANK ···································································· 2-7

AIR CLEANER ································································2-9 HANDLEBAR································································ 3-24
H
ALTERNATOR/STARTER ············································2-38 Honda SMART Key ···················································· 4-100

ANSWER BACK/ALARM SYSTEM ····························4-104 Honda SMART Key SYSTEM······································· 4-70
BATTERY/CHARGING SYSTEM ·································4-57 HORN ··································································· 4-68,4-69
B
BLUETOOTH UNIT·······················································4-69 How To Use This Manual ··············································· 1-3

BODY PANELS·······························································3-2 IDLE STOP SYSTEM ··················································· 4-38
I
BRAKE FLUID REPLACEMENT···································3-34 IGNITION SYSTEM ······················································ 4-32

CABLE & HARNESS ROUTING ···································1-19 INJECTOR···································································· 2-14
C
CBS···············································································3-33 LIGHTING SYSTEM ····················································· 4-59

L
CENTERSTAND ···························································3-18 LUBRICATION SYSTEM·············································· 2-16

COMBINATION METER ···············································4-62 MAINTENANCE SCHEDULE ······································· 1-34
M
COOLANT REPLACEMENT·········································2-19 MODEL IDENTIFICATION ············································· 1-5

COOLING SYSTEM······················································2-19 PGM-FI SYSTEM ··························································· 4-2
P
CRANKCASE/CRANKSHAFT ······································2-39 RADIATOR ··································································· 2-22

R
CYLINDER HEAD ·························································2-24 RADIATOR RESERVE TANK ······································ 2-22

CYLINDER/PISTON······················································2-30 REAR BRAKE ······························································ 3-35
DRIVETRAIN ································································2-31 REAR SUSPENSION ··················································· 3-28
D
ELECTRICAL COMPONENT········································4-68 REAR WHEEL ······························································ 3-26

E
ELECTRICAL STARTER ··············································4-35 REDUCTION OIL REPLACEMENT······························ 2-35

ENGINE OIL CHANGE ·················································2-17 SIDESTAND ································································· 3-18
S
ENGINE OIL LEVEL CHECK········································2-16 SPARK PLUG REPLACEMENT··································· 4-33

ENGINE OIL STRAINER SCREEN CHANGE ··············2-17 SPECIAL TOOL LIST ··················································· 1-18
ENGINE UNIT ·······························································2-42 SPECIFICATIONS·························································· 1-6
EVAP SYSTEM·····························································2-15 STEERING STEM ························································ 3-25
EXHAUST PIPE/MUFFLER ··········································3-19 TECHNICAL FEATURES ············································· 1-29
T
FINAL REDUCTION CASE···········································2-35 THROTTLE BODY························································ 2-10

F
FORK ············································································3-22 TORQUE VALUE·························································· 1-13

FRONT BRAKE·····························································3-29 TP SENSOR RESET PROCEDURE ···························· 2-13
FRONT WHEEL ····························································3-20 VALVE CLEARANCE ··················································· 2-24
V
FUEL LEVEL SENSOR·················································4-66 WATER PUMP/THERMOSTAT···································· 2-23

W
FUEL LINE ······································································2-2
5-1

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book 1 ページ ２０１９年９月１８日 水曜日 午後２時５８分

MODEL IDENTIFICATION ······················· 1-5 TECHNICAL FEATURES ······················· 1-29

SPECIFICATIONS ···································· 1-6 MAINTENANCE SCHEDULE················· 1-34

TORQUE VALUE···································· 1-13

A Few Words About Safety

For Your Customer’s Safety

Improper service or repairs can create an un-

For Your Safety

Failure to properly follow instructions and

Important Safety Precautions

How To Use This Manual

You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions.

You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions.

You CAN be HURT if you don’t follow instructions.

• Instructions – how to service this vehicle correctly and safely.

ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS

© Honda Motor Co., Ltd.

Removal or Disassembly procedure. Installation or Assembly procedure.

Order of installation/assembly with a point of

Tighten specified torque. Replace with a new one before assembly.

Turn ignition switch to OFF. Turn ignition switch to ON.

Start the engine. Measure a resistance or check continuity.

Measure a voltage. Measure an ampere.

Refer to “Basic” Service Manual for the instruc-

LUBRICATION AND SEAL SYMBOL

Apply a locking agent. Use a medium strength

Use a specified fork oil or suspension fluid.

VEHICLE IDENTIFICATION NUMBER

ENGINE SERIAL NUMBER

ITEM STANDARD LIMIT

ITEM STANDARD LIMIT

FRAME & CHASSIS SPECIFICATIONS

FINAL REDUCTION CASE

SPECIAL TOOL LIST

CABLE & HARNESS ROUTING

TURN SIGNAL SWITCH

FRONT BRAKE HOSE

REAR BRAKE HOSE

LEFT TURN SIGNAL WIRE

FRONT BRAKE HOSE

FRONT BRAKE HOSE

REAR BRAKE HOSE

LEFT TURN SIGNAL WIRE

CONNECTORS: FRONT BRAKE HOSE

REAR BRAKE HOSE

REAR BRAKE PIPE

FRONT BLUETOOTH UNIT WIRE

SEAT LOCK CABLE

FUEL TRAY DRAIN HOSE

CBS BRAKE HOSE

REAR BRAKE PIPE

REAR BRAKE PIPE

FRONT WHEEL SPEED

FRONT BRAKE PIPE

BLUETOOTH UNIT WIRE

SEAT LOCK CABLE

FUEL TRAY DRAIN HOSE

REAR BRAKE PIPE

MAIN WIRE HARNESS

MAIN WIRE HARNESS

THROTTLE CABLE B MAIN WIRE

FUEL PUMP UNIT 5 mm max.

ENGINE SUB-HARNESS 12P

book 1 ページ２０１９年９月１８日水曜日午後２時５８分