SM Nsc125 Elite Repa.

Shop Manual
NSC125SH
1. General Information
2. Fuel & Engine
3. Frame & Chassis
4. Electrical System
This book is Specific Shop Manual.

Refer to “Basic Shop Manual” for basic and
common maintenance instructions.
NSC125SH-H (2017)
1. GENERAL INFORMATION
A Few Words About Safety ················ 1-2 SPECIAL TOOL LIST ························ 1-14
How To Use This Manual ··················· 1-3 CABLE & HARNESS ROUTING ·········· 1-15
MODEL IDENTIFICATION ··················· 1-5 TECHNICAL FEATURE ····················· 1-24
SPECIFICATIONS······························ 1-6 MAINTENANCE SCHEDULE ·············· 1-27
TORQUE VALUE ······························1-11
1-1
GENERAL INFORMATION
A Few Words About Safety

GENERAL INFORMATION
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: May, 2017
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: NSC125SH-H
Code/Type Destination Front wheel 10 inch Front wheel 12 inch EVAP system Sidestand switch
KO, IIKO Korea –
AG, IIAG Argentine – – –
IIILA, IVLA Latin America – – –
PE, IIPE Peru – – –
KO type shown:
VEHICLE IDENTIFICATION NUMBER
ENGINE SERIAL NUMBER
COLOR LABEL
1-5
GENERAL INFORMATION
SPECIFICATIONS
GENERAL SPECIFICATIONS
ITEM SPECIFICATION
DIMENSIONS Overall length KO, IIKO type 1,737 mm
Except KO, IIKO type 1,772 mm
Overall width 692 mm
Overall height 1,120 mm
Wheelbase KO, IIKO type 1,228 mm
Except KO, IIKO type 1,246 mm
Seat height 770 mm
Ground clearance 132 mm
Curb weight 110 kg
Maximum weight capacity 174 kg
FRAME Frame type Under bone
Front suspension Telescopic
Front wheel travel 80 mm
Rear suspension Unit swing
Rear wheel travel 70 mm
Front tire size KO, IIKO type 100/90 – 10 56J
Except KO, IIKO type 90/90 – 12 44J
Rear tire size 100/90 – 10 56J
Front tire brand KO, IIKO type CY104R (CORDIAL)
Except KO, IIKO type C-922F (CHENG SHIN)
Rear tire brand KO, IIKO type CY104R (CORDIAL)
Except KO, IIKO type C-922 (CHENG SHIN)
Front brake Hydraulic single disc
Rear brake Mechanical leading trailing
Caster angle 26° 42’
Trail length KO, IIKO type 96 mm
Except KO, IIKO type 77 mm
Fuel tank capacity 6.4 liter
ENGINE Cylinder arrangement Single cylinder inclined 80° from vertical
Bore and stroke 52.4 x 57.9 mm
Displacement 125 cm3
Compression ratio 9.8 : 1
Valve train Chain driven, OHC
Intake valve opens 10° BTDC at 1 mm lift
closes 25° ABDC at 1 mm lift
Exhaust valve opens 25° BBDC at 1 mm lift
closes 5° ATDC at 1 mm lift
Lubrication system Forced pressure and wet sump
Oil pump type Trochoid
Cooling system Air cooled
Air filtration Viscous paper filter
Engine dry weight 22.7 kg
Emission control system Crankcase emission control system
Three-way catalytic converter
Evaporative emission control system (KO, IIKO type)
FUEL SYSTEM Type PGM-FI (Programmed Fuel Injection)
Throttle bore 22 mm
DRIVE TRAIN Clutch system Dry, automatic centrifugal clutch
Final reduction 8.615 (42/15 x 40/13)
ELECTRICAL Ignition system Full transistorized
Starting system Electric starter
Charging system Triple phase alternator
Regulator/rectifier SCR shorted, triple phase full wave rectification
Lighting system Battery
1-6
GENERAL INFORMATION
FUEL & ENGINE SPECIFICATIONS
FUEL SYSTEM
ITEM SPECIFICATIONS
Throttle body identification number KO, IIKO type GQREB
Except KO, IIKO type GQRNB
Idle speed 1,700 ± 100 rpm
Throttle grip freeplay 2 – 6 mm
Idle air screw initial opening 1-7/8 turns out from the fully seated position
Fuel pressure at idle 263 – 316 kPa
Fuel pump flow 82 cm3 minimum/10 seconds
LUBRICATION SYSTEM
Unit: mm
ITEM STANDARD LIMIT
Engine oil capacity After draining 0.7 liter –
After disassembly 0.8 liter –
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
CYLINDER HEAD/VALVES
Unit: mm
ITEM STANDARD SERVICE LIMIT
Cylinder compression 1,050 kPa at 550 rpm –
Valve clearance IN 0.16 ± 0.02 –
EX 0.25 ± 0.02 –
Camshaft Cam lobe height IN 32.305 – 32.545 32.275
EX 31.725 – 31.965 31.695
Rocker arm, Rocker arm shaft O.D. IN/EX 9.972 – 9.987 –
rocker arm shaft Rocker arm I.D. IN/EX 10.000 – 10.015 10.055
Valve, Valve stem O.D. IN 4.975 – 4.990 4.965
valve guide EX 4.955 – 4.970 4.945
Valve guide I.D. IN/EX 5.000 – 5.012 5.042
Valve guide projection
IN/EX 8.9 – 9.1 –
above cylinder head
Valve seat width IN/EX 1.0 1.5
Valve spring free length INNER 31.06 30.44
OUTER 31.56 30.93
Cylinder head warpage – 0.10
1-7
GENERAL INFORMATION
CYLINDER/PISTON
Unit: mm
Cylinder I.D. 52.400 – 52.410 52.51
Warpage – 0.10
Piston Piston O.D. 52.370 – 52.390 at 8 mm from bottom
52.28
of skirt
Piston pin bore I.D. 13.002 – 13.008 13.03
Piston pin O.D. 12.994 – 13.000 12.98
Piston rings Piston ring end gap Top 0.10 – 0.25 0.35
Second 0.10 – 0.25 0.35
Oil (side rail) 0.20 – 0.45 0.65
Piston ring-to-ring Top 0.030 – 0.065 –
groove clearance Second 0.015 – 0.050 –
DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
Unit: mm
Clutch Lining thickness – 2.0
Clutch outer I.D. 125.0 – 125.2 125.5
Drive belt width 20.0 19.0
Movable drive Bushing I.D. 22.035 – 22.085 –
face Boss O.D. 22.010 – 22.025 –
Weight roller O.D. 19.92 – 20.08 19.4
Driven pulley Face spring free length 121.1 118.7
Driven face O.D. 33.965 – 33.985 –
Movable driven face I.D. 34.000 – 34.025 –
FINAL REDUCTION

Final reduction After draining 0.10 liter –
oil capacity After disassembly 0.12 liter –
Recommended final reduction oil Honda “4-stroke motorcycle oil” or an
equivalent motor oil.
API service classification:
–
SG or higher
CRANKCASE/CRANKSHAFT
Unit: mm
Connecting rod Side clearance 0.10 – 0.35 0.45
Radial clearance 0 – 0.01 0.05
Small end I.D. 13.010 – 13.028 13.038
Crankshaft Runout – 2-32
1-8
GENERAL INFORMATION
FRAME & CHASSIS SPECIFICATIONS
FRONT WHEEL/SUSPENSION/STEERING
Unit: mm
Cold tire Driver only 175 kPa –
pressure Driver and passenger 175 kPa –
Axle runout – 0.2
Wheel rim Radial – 2.0
runout Axial – 2.0
Fork Spring free length Upper 115.5 113.2
Lower 110 107.8
(KO, IIKO type)
Lower 98.4 96.4
(Except KO, IIKO type)
Recommended fluid Honda Ultra Cushion Oil 10W –
Fluid level 60 –
Fluid capacity KO, IIKO type 85 ± 2.5 cm3 –
Except KO, IIKO type 80 ± 2.5 cm3
REAR WHEEL/SUSPENSION
Unit: mm
Cold tire Driver only 200 kPa –
pressure Driver and passenger 225 kPa –
Wheel rim Radial – 2.0
runout Axial – 2.0
BRAKE SYSTEM
Unit: mm
Front brake Specified brake fluid DOT 3 or DOT 4 –
Brake disc thickness 3.3 – 3.7 3.0
Brake disc runout – 0.30
Master cylinder I.D. 12.700 – 12.743 –
Master piston O.D. 12.657 – 12.684 –
Caliper cylinder I.D. 27.000 – 27.050 –
Caliper piston O.D. 26.918 – 26.968 –
Rear brake Lever freeplay 10 – 20 –
Drum I.D. 130.0 – 130.2 131.0
1-9
GENERAL INFORMATION
ELECTRICAL SYSTEM SPECIFICATIONS
PGM-FI SYSTEM
ITEM SPECIFICATIONS
IAT sensor resistance (40°C) 1.0 – 1.3 kΩ
EOT sensor resistance (20°C) 2.5 – 2.8 kΩ
Fuel injector resistance (24°C) 11 – 13 Ω
Fast idle solenoid valve resistance (24 °C) 24 – 27 Ω
IGNITION SYSTEM
ITEM SPECIFICATIONS
Spark plug CPR7EA-9 (NGK)
Spark plug gap 0.8 – 0.9 mm
Ignition coil peak voltage 100 V minimum
CKP sensor peak voltage 0.7 V minimum
Ignition timing ("F"mark) 10° BTDC at 1,700 rpm
BATTERY/CHARGING SYSTEM
ITEM SPECIFICATIONS
Battery Type YTX7L-BS
Capacity 12 V – 6 Ah (10HR)
Voltage Fully charged 12.8 V minimum
Needs charge Below 12.3 V
Charging Normal 0.6 A/5 – 10 h
current Quick 3.0 A/1.0 h
Current leakage 0.25 mA
Alternator Capacity 0.17 kW/5,000 rpm
Charging coil resistance
0.1 – 1.0 Ω
(20°C)
LIGHTS/METERS/SWITCHES
ITEM SPECIFICATIONS
Bulbs Headlight (Hi/Lo) LED
Position light LED
Brake/tail light 12 V – 21/5 W
Tail light 12 V – 5 W x 2
License light 12 V – 5 W
Turn signal light 12 V – 10 W x 4
Illumination light LED
Turn signal indicator LED
MIL LED
High beam indicator LED
Fuse Main fuse 20 A
Sub fuse 10 A x 3
Fuel level sensor resistance Full 6 – 10 Ω
Empty 90 – 100 Ω
1-10
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 SYSTEM
ITEM Q'TY DIA TRQ REMARKS
Fuel pump set plate nut 4 6 12 2-4
Air cleaner housing cover screw 7 5 1.1
Air cleaner connecting hose band 1 4 2.1
screw
Intake pipe stud bolt 2 6 6.0 2-8
Throttle cable A/B lock nut 2 8 8.5
(Throttle body side)
Fast idle solenoid valve mounting torx 2 5 3.4
screw
Throttle cable bracket screw 1 5 3.4
LUBRICATION SYSTEM
Engine oil drain bolt 1 12 24
Engine oil strainer screen cap 1 30 20
Oil pump plate screw 1 4 3.0
Oil pump mounting bolt 2 6 10
CYLINDER HEAD/VALVES
Cylinder head cover special bolt 2 6 12
Valve adjusting screw lock nut 2 5 10 Apply engine oil.
Cylinder head nut 4 7 18 Apply engine oil.
Cam sprocket bolt 2 5 9.0 Apply engine oil.
Cam stopper washer bolt 1 6 10
Cam chain tensioner lifter screw 1 6 4.0
Intake shroud screw 3 5 0.8
Exhaust shroud mounting bolt 1 6 7.0
CYLINDER/PISTON
Cylinder stud bolt 4 7 6.5 2-23
DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
Drive pulley face nut 1 14 116 Apply engine oil.
Clutch/driven pulley nut 1 28 54
Clutch outer nut 1 12 49
FINAL REDUCTION
Final reduction oil check bolt 1 8 13
Final reduction oil drain bolt 1 8 13
1-11
GENERAL INFORMATION
ALTERNATOR/STATOR
Stator mounting bolt 2 5 6
Flywheel nut 1 10 39
Cooling fan mounting bolt 3 6 10
ENGINE REMOVAL/INSTALLATION
Engine hanger link pivot nut 1 10 69
(Frame side)
Engine hanger link pivot nut 1 10 49
(Engine side)
FRAME/BODY PANELS/EXHAUST SYSTEM
Exhaust pipe joint nut 2 7 29 3-12
Muffler mounting bolt 2 10 59 3-12
Exhaust pipe stud bolt 2 7 7.5 3-12
Muffler protector cover screw 2 6 9.5
Cooling fan cover screw 2 5 0.8
Cooling fan cover bolt 2 6 9.0
Sidestand pivot bolt 1 10 10
Sidestand pivot nut 1 10 29
Centerstand spring bolt 1 8 22
FRONT WHEEL/SUSPENSION/STEERING
Front axle nut 1 12 59 Self lock nut
Front brake disc socket bolt 3 8 42 Pre-coated (ALOC) bolt; replace with a new
(Front disc brake type) one.
Handlebar post nut 1 10 39
Fork socket bolt 2 8 20 Apply locking agent.
Fork cap bolt 2 26 22
Fork pinch bolt 4 10 30
Steering stem lock nut 1 BC1 – 3-17
REAR WHEEL/SUSPENSION
Rear axle nut 1 16 118 Self lock nut
Apply engine oil.
BRAKE SYSTEM
Equalizer connecting 1 8 6.5 3-12
cable lock nut
Caliper mounting bolt 2 8 30 Pre-coated (ALOC) bolt; replace with a new
one.
Pad pin 2 10 18
Pad pin plug 2 10 2.5
Caliper bleed valve 1 8 8.0
Hose oil bolt 2 10 34
Master cylinder 2 6 12
holder bolt
Master cylinder 2 4 1.5
reservoir cap screw
Light switch screw 1 4 1.0
Front brake lever 1 6 1.0
pivot bolt
1-12
GENERAL INFORMATION
pivot nut
pivot nut
Rear brake lever 1 5 1.0
pivot screw
Rear brake lever 1 5 4.5 Self-lock nut
pivot nut
Rear brake arm bolt 1 6 10 Pre-coated (ALOC) bolt; replace with a new
one.
Equalizer rod pivot screw 1 5 1.0
Equalizer rod pivot 1 5 4.5 Self-lock nut
nut
Front brake hose clamp 2 6 12
Brake lock arm pivot 1 5 4.2
screw
Equalizer cover screw 2 5 4.2
PGM-FI SYSTEM
EOT sensor 1 10 14.5
O2 sensor 1 12 25
IGNITION SYSTEM
Spark plug 1 10 16
STARTER MOTOR
Starter motor terminal screw 1 4 2.0
LIGHTING SYSTEM
Headlight mounting screw 7 5 1.1
Front turn signal mounting screw 12 4 1.0
Tail/brake light mounting screw 8 4 1.0
Speedometer mounting screw 3 5 1.1
OTHERS
Throttle cable A lock nut 1 10 3.0
(Handlebar side)
Throttle cable B lock nut 1 10 3.0
(Handlebar side)
Throttle cable A adjuster lock nut 1 7 3.8
Centerstand spring bolt 1 8 22
Reflector mounting nut 1 5 1.7 Self-lock nut
Side reflector mounting nut 2 6 1.5 Self-lock nut
1-13
GENERAL INFORMATION
SPECIAL TOOL LIST

TITLE TOOL No. TOOL NAME
07746-0010700 Attachment, 24 x 26 mm
07946-1870100 Attachment, 28 x 30 mm
07746-0010600 Attachment, 72 x 75 mm
07965-GM00100 Assembly collar
07931-KF00100 Assembly collar
07965-VM00100 Assembly collar
07965-GM00200 Assembly collar attachment
07965-1660200 Assembly shaft
07965-VM00200 Assembly shaft
07WMF-KFF0200 Assembly shaft adaptor
07936-3710600 Bearing remover, 20 mm
070MG-0010100 Cam chain tensioner lifter stopper
07724-0050002 Clutch center holder
07LME-GZ40201 Clutch spring compressor
07SMC-0010001 Case puller
07749-0010000 Driver
07406-0040004 Fuel pressure gauge
070MJ-K260100 Fuel pressure gauge attachment
Fuel & Engine 07733-0010000 Flywheel puller
07725-0040001 Flywheel holder
07947-KF00100 Fork seal driver attachment, 41.2 mm
07965-KE80200 Oil seal driver, 40 mm
07746-0040500 Pilot, 20 mm
07746-0041100 Pilot, 28 mm
07746-0040800 Pilot, 35 mm
07936-3710100 Remover handle
07741-0010201 Remover weight
070PZ-ZY30100 SCS connector
07GMA-KS40100 Socket wrench, 39 x 41 mm
07725-0030000 Universal holder
07631-0010000 Universal bearing puller
07908-KE90000 Valve adjusting wrench
07757-0010000 Valve spring compressor
07959-KM30101 Valve spring compressor attachment
07984-MA60001 Valve guide reamer, 5.0 mm
07942-MA60000 Valve guide driver, 5.0 mm
07743-0020000 Valve guide adjusting driver
07746-0010100 Attachment, 32 x 35 mm
07746-0010300 Attachment, 42 x 47 mm
07946-6920100 Attachment, 45 x 50 mm
07916-1870101 Adjusting nut wrench
07JAC-PH80100 Adjustable remover head
07JAC-PH80200 Adjustable remover shaft
07746-0050100 Bearing remover shaft
Frame & Chassis 07749-0010000 Driver
07747-0010400 Fork seal driver attachment
07747-0010100 Fork seal driver body
07746-0030300 Inner driver, 30 mm
07748-0010001 Oil seal remover
07746-0040200 Pilot, 12 mm
07741-0010201 Remover weight
07746-0050300 Remover head, 12 mm
07916-KM10000 Socket wrench
07914-SA50001 Snap ring pliers
1-14
GENERAL INFORMATION
CABLE & HARNESS ROUTING
TURN SIGNAL RELAY

CBS CONNECTING CABLE 2P CONNECTOR
REAR BRAKE SWITCH

FRONT BRAKE SWITCH CONNECTOR
CONNECTOR REAR BRAKE
THROTTLE CABLE
CABLE A FRONT BRAKE
THROTTLE HOSE
CABLE B
FRONT SUB
THROTTLE HARNESS
FRONT SUB CABLE B
HARNESS
THROTTLE
CABLE A
ECM
FRONT BRAKE REAR BRAKE
HOSE CABLE
ECM 33P (Black)
CONNECTOR SEAT LOCK
CABLE
MAIN WIRE
HARNESS
RIGHT TURN SIGNAL LEFT TURN SIGNAL

LIGHT WIRE LIGHT WIRE
1-15
GENERAL INFORMATION
REAR BRAKE
CABLE
FRONT SUB
HARNESS FRONT SUB HARNESS 6P CONNECTOR
FRONT SUB HARNESS 4P CONNECTORS
OPTION WIRE 9P CONNECTOR
HORN WIRE
HEAD LIGHT WIRE 6P (Black) CONNECTOR
POSITION LIGHT WIRE 3P CONNECTOR
RIGHT TURN SIGNAL LIGHT WIRE 3P (Red)
CONNECTOR
THROTTLE LEFT TURN SIGNAL LIGHT WIRE 3P (Black)
CABLE B CONNECTOR
THROTTLE
CABLE A SEAT LOCK
CABLE
SEAT LOCK
CABLE THROTTLE
REAR BRAKE CABLE B
CABLE
THROTTLE
5 mm CABLE A
maximum
MAIN WIRE
HARNESS
MAIN WIRE
HARNESS
1-16
GENERAL INFORMATION
TURN SIGNAL RELAY

2P CONNECTOR
FRONT SUB
HARNESS
SEAT LOCK REAR BRAKE

CABLE CABLE
5 mm
maximum
SEAT LOCK
CABLE
FRONT BRAKE
HOSE
THROTTLE REAR BRAKE

THROTTLE CABLE A CABLE
CABLE A THROTTLE
2 mm CABLE B
MAIN WIRE
maximum
HARNESS
REAR BRAKE
CABLE
THROTTLE
CABLE B
SEAT LOCK
CABLE
THROTTLE
THROTTLE CABLE B
CABLE A
MAIN WIRE
HARNESS
FRONT BRAKE
HOSE
1-17
GENERAL INFORMATION
FRAME BODY
AIR TUBE
(KO, IIKO type only)
AIR TUBE
21 - 25mm (KO, IIKO type only)
SEAT LOCK
SEAT LOCK CABLE
CABLE REAR BRAKE
CABLE
THROTTLE THROTTLE
CABLE B CABLE B
THROTTLE
CABLE A
SEAT THROTTLE
LOCK REAR BRAKE CABLE A DRAIN TUBE
CABLE CABLE
THROTTLE
CABLE A
REAR BRAKE
CABLE
MAIN WIRE
THROTTLE HARNESS
CABLE B SEAT LOCK
MAIN WIRE CABLE
HARNESS
1-18
GENERAL INFORMATION
FUSE BOX
MAIN WIRE HARNESS
BATTERY STARTER RELAY
MAIN RELAY (to FUSE BOX and DLC)
NEGATIVE (-) CABLE WIRE
DLC
STARTER RELAY
SIDESTAND SWITCH 2P
(Blue) CONNECTOR
BATTERY
POSITIVE (+) CABLE
(to FUSE BOX)
BATTERY
FUEL INJECTOR
POSITIVE (+) CABLE
2P CONNECTOR
(to STARTER RELAY)
EOT SENSOR
2P CONNECTOR BATTERY
POSITIVE (+) CABLE
FAST IDLE
SOLENOID VALVE
2P CONNECTOR
CRANK CASE
BREATHER HOSE
O2 SENSOR 1P (Black)
CONNECTOR
SEAT LOCK
CABLE
EVAP PURGE HOSE
FUEL PUMP 5P
CONNECTOR
FUEL FEED HOSE
EVAP CHARGE HOSE

1-19
GENERAL INFORMATION
EVAP CHARGE HOSE

REAR COMBINATION LIGHT
9P CONNECTOR
REGULATOR/RECTIFIER
6P (Black) CONNECTOR
GROUND
TERMINAL
EVAP CANISTER
IAT SENSOR 2P
CONNECTOR
IGNITION COIL WIRE

(Yellow/Blue)
IGNITION COIL WIRE

(Black/White)
O2 SENSOR 1P (Black) MAIN WIRE

CONNECTOR HARNESS
STARTER MOTOR
CABLE (Black)
STARTER MOTOR
CABLE (Red/White)
STARTER MOTOR
CABLE (Green)
To be butted
1-20
GENERAL INFORMATION
To be butted
FUEL FEED HOSE
EVAP CHARGE HOSE

FUEL FEED HOSE
SEAT LOCK
CABLE
ALTERNATOR
WIRE
FUEL INJECTOR
2P CONNECTOR
EVAP PURGE HOSE

STARTER MOTOR
CABLE
IAT SENSOR 2P
CONNECTOR
CRANK CASE
BREATHER HOSE
IAT SENSOR 2P HIGH TENSION

CONNECTOR CORD
O2 SENSOR 1P (Black)
CONNECTOR
IAT SENSOR 2P
CONNECTOR
1-21
GENERAL INFORMATION
FUEL FEED HOSE
To be butted
To be butted
AIR TUBE (KO, IIKO type only)
FUEL FEED HOSE
STARTER MOTOR
CABLE EVAP CANISTER
ALTERNATOR WIRE (KO, IIKO type only)
MAIN WIRE
HARNESS FINAL REDUCTION CASE
BREATHER HOSE
5mm
maximum
FAST IDLE SOLENOID

VALVE 2P CONNECTOR
TP SENSOR 3P
CONNECTOR
VS SENSOR 3P
CONNECTOR
1-22
GENERAL INFORMATION
HEAD LIGHT WIRE
POSITION
LIGHT WIRE
LEFT TURN SIGNAL RIGHT TURN SIGNAL

LIGHT WIRE LIGHT WIRE
POSITION
LIGHT WIRE
2 mm
LEFT TURN SIGNAL maximum
LIGHT WIRE HEAD LIGHT WIRE
RIGHT TURN SIGNAL

LIGHT WIRE
REAR COMBINATION
LIGHT WIRE
LICENSE LIGHT 3P CONNECTOR

REAR COMBINATION
LIGHT 9P CONNECTOR
LICENSE LIGHT WIRE
1-23
GENERAL INFORMATION
TECHNICAL FEATURE
EVAPORATIVE EMISSION CONTROL SYSTEM WITH ONE-WAY VALVE
OPERATED BY INTAKE VACUUM PRESSURE (KO, IIKO type)
Fuel vapor from the fuel tank [A] is routed into the evaporative emission (EVAP) canister [B] where it is absorbed and
stored while the engine is stopped. When the engine is running and the evaporative emission (EVAP) one-way valve
[C] is opened by the intake vacuum pressure, fuel vapor in the EVAP canister is drawn into the engine through the
purge port in the throttle body [D] via intake pipe [E].
[A]
[B]
[C]
[D]
[E]
1-24
GENERAL INFORMATION
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.
1-25
GENERAL INFORMATION
MIL SYSTEM
MIL INDICATION
In the existing PGM-FI system, if the existing 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, 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).
1-26
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 TO
X 1,000 km 1 4 8 12 16 20 24 CHECK REPLACE
PAGE
* FUEL LINE I I I I I I I
* THROTTLE OPERATION I I I I I I I
* AIR CLEANER NOTE 2 R 2-7
CRANKCASE BREATHER NOTE 3 C C C C C C C
SPARK PLUG I R I R I R 4-19
* VALVE CLEARANCE I I I I I I I 2-17
ENGINE OIL R R R R R R R R 2-14
ENGINE OIL STRAINER
C C
SCREEN
* ENGINE IDLE SPEED I I I I I I I I
* EVAPORATIVE EMISSION
CONTROL SYSTEM I I
(KO, IIKO type)
* DRIVE BELT I I R
* FINAL DRIVE OIL NOTE 4 2 years 2-28
BRAKE FLUID NOTE 4 I I I I I I I 2 years
BRAKE SHOES/PADS
I I I I I I I
WEAR
BRAKE SYSTEM I I I I I I I I 3-19
* BRAKE LOCK OPERATION I I I I I I I
HEADLIGHT AIM I I I I I I I 4-28
** CLUTCH SHOES WEAR I I I
SIDESTAND I I I I I I I
* SUSPENSION I I I I I I I
* NUTS, BOLTS,
I I I I I
FASTENERS
** WHEELS/TIRES I I I I I I I
** STEERING HEAD
I I I I
BEARINGS
• * 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.
1-27
MEMO
2. FUEL & ENGINE
FUEL LINE ······································· 2-2 CYLINDER HEAD····························· 2-17
FUEL PUMP UNIT······························ 2-4 CYLINDER/PISTON ·························· 2-23
FUEL TANK ······································ 2-6 DRIVETRAIN ··································· 2-24
AIR CLEANER ·································· 2-7 FINAL REDUCTION CASE················· 2-28
THROTTLE BODY ····························· 2-8 ALTERNATOR/STATOR···················· 2-31
EVAP SYSTEM (KO, IIKO type only) ···2-13 CRANKCASE/CRANKSHAFT············· 2-32
LUBRICATION SYSTEM ····················2-14 ENGINE UNIT ·································· 2-34
2-1
FUEL & ENGINE
FUEL LINE
FUEL & ENGINE
• This scooter uses resin for the part of materials in the fuel
feed hose. Do not bend or twist the fuel feed hose.
• Luggage box 3-6
• Fuel pump 5P connector
• Let it idle until the engine stalls.
• Battery negative (–) cable
• 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 pump joint/injector joint.
• Check the retainer condition and replace it 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 pump joint/injector 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 quanti-
ty. 2-3
FUEL PRESSURE TEST

• Quick connect fitting (fuel pump side).
[A]
• Attach the fuel pressure gauge and attachment.
[A] Fuel pressure gauge: 07406-0040004
[B] Fuel pressure gauge attachment: 070MJ-K260100
[B]
• Temporarily connect the negative cable to the battery and
fuel pump 5P connector.
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
to INJECTOR
(fuel feed hose)
pump assembly. 2-4
• If the fuel pressure is lower than specified, inspect the
following.
– Fuel line leaking
– Any erratic swing or vibration of the gauge needle in the
pressure gauge reading
• If the needle swings or vibrates, replace the fuel filter. 2-5
• If the needle does not swing or vibrate, 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
container. 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
• Place the vehicle on the level ground with its
centerstand. Adjust the fuel in the tank until the fuel
gauge segment [A] is positioned at the specified range,
and inspect the fuel flow.
SPECIFIED RANGE: One segment (Not blinking)
• If the fuel flow is above specification, check for other
malfunctioning parts.
• If the fuel flow is under specification, replace the fuel fil-
[A] ter. 2-5
2-3
FUEL & ENGINE
FUEL PUMP UNIT
12 N·m
1.0 g minimum
• Luggage box3-6
• Quick connect fitting (fuel pump side) 2-2
• Loosen the nuts in a crisscross pattern in several steps.
• Carefully remove the fuel pump unit from the fuel tank to prevent damaging the fuel level sensor.
• Install the fuel pump unit while bending the fuel filter as shown.
• Tighten the fuel pump set plate nuts in the specified sequence as shown.
• Clog or excessive damage
• Fuel pump malfunction and inspection.
2-4
FUEL & ENGINE
FUEL FILTER
• Release the hooks from the stoppers by slightly spreading the hooks.
• Then turn the filter clockwise.
• Pull up the filter and remove it from the fuel pump.
• Turn the filter counterclockwise until the hooks are completely secured by the stoppers.
• Align the triangle marks on the filter and fuel pump body.
2-5
FUEL & ENGINE
FUEL TANK
• Body cover 3-8

• Quick connect fitting (fuel pump side) 2-2
2-6
FUEL & ENGINE
AIR CLEANER
2.1 N·m
1.1 N·m
• Discard the air cleaner element in accordance with the maintenance schedule. 1-27
• Left side cover 3-5
• Replace the element any time if it is excessively dirty or damaged.
2-7
FUEL & ENGINE
THROTTLE BODY
8.5 N·m
2.1 N·m
35.9 – 37.9 mm
6.0 N·m
• Injector 2-13
• Perform this procedure when the throttle body is replaced with a new one 2-10
• Throttle body cleaning and inspection
2-8
FUEL & ENGINE
3.4 N·m
3.4 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.
• Perform the ECM initializing procedure if the idle air screw is replaced with a new one. 2-11
Idle air screw
• Before removing the idle air screw, turn it in carefully to count the number of turns until it seats lightly. Make
a note to use as a reference when reinstalling the idle air screw.
IDLE AIR SCREW STANDARD OPENING: 1-7/8 turns out from the fully seated position
Fast idle solenoid valve

• The fast idle solenoid valve can be serviced with the throttle body installed on the engine.
ENGINE IDLE SPEED ADJUSTMENT

• Start the engine and let it idle.
IDLE SPEED: 1,700 ± 100 min-1
• Idle air screw standard opening
STANDARD: 1-7/8 turns out from the fully seated posi-
tion.
2-9
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 won’t start by
following the procedure below.
• Perform this procedure when the throttle body is replaced
with a new one.
• Maintenance lid 3-4
• Connector cover from the DLC [A].
• Connect the special tool to the DLC.
SCS connector: 070PZ-ZY30100
[A]
• EOT sensor 2P connector [B].

• Short the EOT sensor terminals with jumper wire.
[B]
• Turn the ignition switch ON then disconnect the jumper

wire from the EOT sensor 2P connector within 10 seconds
while the MIL is blinking (reset receiving pattern).
[B] • Check if the MIL blinks.
After disconnection of the jumper wire, the MIL should start
blinking. (reset completed pattern)
If the jumper wire is connected for more than 10 seconds,
the MIL will stay ON (unsuccessful pattern). Try again from
within 10 sec. 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.
1.2 sec.
Reset receiving Reset completed
2-10
FUEL & ENGINE
ECM INITIALIZING PROCEDURE
• Make sure that DTC is not stored in ECM. If the DTC is
stored in ECM, ECM initializing mode won’t start.
• Perform this procedure when any of the following fuel
related part is replaced with a new one.
[A] – Idle air screw
– Fuel pump/fuel filter
– Injector
– O2 sensor
• Perform this procedure when any of the following engine
part is replaced or is overhauled.
– Cylinder head
– Valves/valve guides/valve seat
[A] – Cylinder/piston/piston ring
• Turn the idle air screw to standard opening.
Standard opening: 1-7/8 turns out from the fully seated
position
• Disconnect the dummy connector from the DLC [A] and
connect the special tool to the DLC.
• Open the throttle grip fully and hold.
• After 5 seconds the MIL start blinking rapidly.
Open and hold. Within 5 seconds after rapid blinking starts, close the
throttle grip and hold for more than 3 seconds.
• If the MIL does not start blinking rapidly, turn the ignition
switch OFF and try again.
• If you can not restart the procedure, recheck if the DTC is
not stored in ECM.
Rapid blink • If the DTC is not stored but you still can not restart the
procedure, replace the ECM with a known-good one and
5 sec. try again.
• When the ECM initializing is successful, the MIL will repeat
one short blink.
• If the successful pattern is indicated, turn the ignition
switch OFF.
Within 5 seconds after • If altitude is higher than 2,000 m, perform the altitude
rapid blink starts, close setting 2-12
and hold for more than • Check the engine idle speed.
3 seconds.
Successful pattern
(One short blink repeats)
2-11
FUEL & ENGINE
ALTITUDE SETTING
• Make sure that DTC is not stored in ECM. If stored, the
ECM cannot enter the setting mode.
• The setting will fail if the engine is started during the
procedure.
[A] • Select the appropriate MODE which meets the situation
described below.
MODE1: 0 – 2,000 m above sea level
MODE2: 2,000 – 2,500 m above sea level
MODE3: 2,500 – 3,500 m above sea level
MODE4: 3,500 m or higher above sea level
• Turn the idle air screw to standard opening.
[A]
Standard opening: 1-7/8 turns out from the fully seated
position
• Disconnect the dummy connector from the DLC [A] and
connect the special tool to the DLC.
Open • Open the throttle grip fully and hold.
and • After 5 seconds the MIL should start blinking rapidly.
hold. – MODE1:
Within 5 seconds after rapid blink starts, close the throttle
Rapid blink grip and hold for more than 3 seconds.
5 sec. – MODE2, 3, 4:
Within 5 seconds after rapid blink starts, snap the throttle
grip (close for 0.5 second/open for 0.5 second) as spec-
ified times, then close and hold for more than 3 seconds.
MODE 2: Snap 1 time
MODE 1: MODE 2, 3, 4:
MODE 3: Snap 2 times
Close 0.5 sec. MODE 4: Snap 3 times
• If the MIL does not start blinking rapidly, turn the ignition
Open 0.5 sec. switch OFF and try again.
Close and hold. • If you can not restart the procedure, recheck if the DTC is
not stored in the ECM.
• If the DTC is not stored but you still can not restart the
Within 5 seconds Within 5 seconds after rapid procedure, replace the ECM with a known-good one and
after rapid blink blink starts, snap (close 0.5 try again.
starts, close and sec./open 0.5 sec.), close and • The MIL will repeat the short blinks as the number of the
hold for more than hold for more than 3 seconds. selected MODE.
3 seconds. • If the desired successful pattern is indicated, turn the
MODE 2: Snap 1 time
ignition switch OFF.
• If the MIL starts blinking slowly during this step before
successful pattern is indicated, turn the ignition switch OFF
Successful patterns (Short blinks repeat): and try again.
• If the number of MIL blink and the number of desired
MODE 1: MODE is different, turn the ignition switch OFF and try
again.
MODE 2: • Turn the idle air screw to the specified opening and check
the engine idle speed.
MODE 3:
MODE 4:
2-12
FUEL & ENGINE
INJECTOR
• Quick connect fitting (injector side) 2-2
EVAP SYSTEM (KO, IIKO type only)
2-13
FUEL & ENGINE
LUBRICATION SYSTEM
SYSTEM DIAGRAM
OIL PUMP
OIL STRAINER SCREEN
ENGINE OIL LEVEL CHECK

• Support the scooter with its centerstand on a level surface.
• Let it idle for 3 – 5 minutes.
UPPER • Wait for 2 – 3 minutes.
LOWER • Remove the oil filler cap/dipstick and wipe off the oil from
the dipstick with a clean cloth.
• Insert the oil filler cap/dipstick without screwing it in,
remove it and check the oil level.
• If the oil level is below or near the lower level line on the
dipstick, add the recommended oil to the upper level.
• RECOMMENDED ENGINE OIL:
Honda “4-stroke motorcycle oil” or an equivalent mo-
tor oil.
API service classification: SG or higher
2-14
FUEL & ENGINE
ENGINE OIL CHANGE
• Remove the drain bolt and sealing washer. 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:
0.7 liter after draining
0.8 liter after disassembly
24 N·m
ENGINE OIL STRAINER SCREEN
20 N·m
• Screen clog or excessively damaged.
2-15
FUEL & ENGINE
OIL PUMP
3.0 N·m
(Oil pump shaft 10 N·m

sliding area)
• Engine oil 2-14

• Stator 2-31
• Install the oil pump shaft to the oil pump driven gear by aligning the pin of the pump shaft with groove of the
driven gear.
• Install the oil pump shaft to the oil pump by aligning the oil pump shaft cut-out with oil pump cut-out.
• Oil pump inspection.
2-16
FUEL & ENGINE
CYLINDER HEAD
• This service can be serviced with the engine installed in the frame.
VALVE CLEARANCE
• Inspect and adjust while the engine is cold (below 35 °C).
• Timing hole cap
• Center cover 3-6
• Cylinder head cover 2-17
• Rotate the crankshaft clockwise and align the T mark on
the flywheel with the index mark.
• Make sure the piston is at TDC (Top Dead Center) on the
compression stroke.
This position can be confirmed by checking that there is
slack in the rocker arm.
• Valve clearance (Insert a feeler gauge between the valve

adjusting screw and valve stem).
IN: 0.16 ± 0.02, EX: 0.25 ± 0.02
Valve adjusting wrench: 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.
10 N·m
CYLINDER HEAD COVER
12 N·m
• Apply liquid sealant (Three bond 5211C,1215,SHIN-ETSU-SILICONE KE45T,LOCTITE 5060S or

equivalent) to the semicircular area of seal rubber as shown.
2-17
FUEL & ENGINE
INTAKE/EXHAUST SHROUDS
0.8 N·m
7.0 N·m
• Inlet pipe 2-8

• Exhaust pipe/muffler 3-12
• Cooling fan cover 3-5
• Floor panel 3-9
• Be sure to align the IN mark on the rubber seal with the inlet side of cylinder head.
2-18
FUEL & ENGINE
CYLINDER HEAD
• Drain the engine oil. 2-15
[B] • Intake/exhaust shrouds 2-18
• Cylinder head cover 2-17
[A] • Set the piston to the TDC (Top Dead Center) on the
compression stroke 2-17
• Make sure that the index line [A] on the cam sprocket is
flush with the top surface of cylinder head and that the
mark [B] on the cam sprocket is facing up as shown (TDC
on the compression stroke).
If the cam sprocket mark is not facing up, turn the cooling
fan (crankshaft) one revolution and realign the T mark with
the index mark on the right crankcase.
4.0 N·m • Install the special tool into the tensioner body and turn the
tool clockwise until it stops turning. Hold the tensioner lifter
by pushing the tool while aligning the tabs of the tool with
the grooves of the tensioner lifter.
Cam chain tensioner lifter stopper: 070MG-0010100
2-19
FUEL & ENGINE
18 N·m
9.0 N·m
• Spark plug 4-19

• O2 sensor 4-17
• EOT sensor 4-16
• Rear suspension lower bolt 3-18
• Intake/exhaust shrouds 2-18
• Remove the cylinder head bolts.
• Loosen the cylinder head nuts in a crisscross pattern in two or three steps.
• Install the cam chain guide while aligning its pins with the grooves on the cylinder and its end with the
groove on the left crankcase.
2-20
FUEL & ENGINE
8.9 – 9.1 mm
10 N·m
[A]
• Remove the camshaft from the cylinder head while holding the rocker arms to ease removal.
• Remove the valve cotters using the special tool.
Valve spring compressor: 07757-0010000
Valve spring compressor attachment: 07959-KM30101
• 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, 5.0 mm: 07984-MA60001
• Support the cylinder head and drive the valve guides out of the cylinder head from the combustion
chamber side.
Valve guide driver, 5.0 mm: 07942-MA60000
• Turn the decompressor with finger. Make sure that the decompressor operates smoothly and that the weight
returns back in position.
• Drive new valve guides into the cylinder head to the specified height from the cylinder head.
VALVE GUIDE PROJECTION: 8.9 – 9.1 mm
Valve guide adjusting driver: 07743-0020000
• Intake and exhaust rocker arms have identification marks, “I” is for the intake rocker arm and “E” is for the
exhaust rocker arm.
• Install the camshaft into the cylinder head while holding the rocker arms to ease installation. Make sure
the tab [A] of the camshaft is facing the cylinder head cover side.
• Camshaft inspection
• Valve and valve spring inspection
• Valve guide inspection
• Valve seat inspection
2-21
FUEL & ENGINE
CAM CHAIN TENSIONER
• Intake shroud 2-18
4.0 N·m
• Cam chain tensioner lifter screw and O-ring
• Install the special tool into the tensioner body and turn the
tool clockwise until it stops turning. Hold the tensioner lifter
by pushing the tool while aligning the tabs of the tool with
the grooves of the tensioner lifter.
Cam chain tensioner lifter stopper: 070MG-0010100
• Check the cam chain tensioner lifter operation:

– The tensioner shaft should not go into the body when it
is pushed.
– When it is turned clockwise with the tensioner stopper,
the tensioner shaft should be pulled into the body. The
shaft should protrude from the body as soon as the ten-
sioner stopper is released.
2-22
FUEL & ENGINE
CYLINDER/PISTON
181.0 – 182.0 mm
6.5 N·m
181.0 – 182.0 mm
6.5 N·m
• Cylinder head 2-17

• 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
2-23
FUEL & ENGINE
DRIVETRAIN
DRIVE PULLEY/DRIVE BELT
116 N·m
49 N·m
• Connect the air duct to the left crankcase cover by aligning the air duct cut-off with the left crankcase cover
tab.
2-24
FUEL & ENGINE
116 N·m
• Left crankcase cover 2-24

• Hold the drive pulley face with special tool and loosen the drive pulley face nut.
Clutch center holder: 07724-0050002
• 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.
• 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.
• Weight roller, movable drive face, boss and drive pulley face inspection.
2-25
FUEL & ENGINE
CLUTCH/DRIVEN PULLEY
49 N·m

• Hold the clutch outer with the special tool when loosening the nut. Holding the rear wheel or rear brake
will damage the final reduction system.
Flywheel holder: 07725-0040001
• Hold the clutch/driven pulley assembly and compress the drive face spring by turning movable driven face
clockwise until it stops.
Remove the drive belt from the clutch/driven pulley assembly while removing the clutch/driven pulley
assembly from the drive shaft.
• Clean any oil and grease from the driven face and drive belt.
• Hold the clutch/driven pulley assembly and compress the drive face spring by turning movable driven face
clockwise until it stops, then install the drive belt.
2-26
FUEL & ENGINE
2.0 – 2.5 g
54 N·m
• 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 2.0 – 2.5 g of grease (Shell ALVANIA R3, IDEMITSU AUTOREX B, SHIN-NIHON POWERNOC
WB3 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
2-27
FUEL & ENGINE
Bearing replacement
[A], [C]
6-7g
[B]
• [A] Bearing remover, 20 mm: 07936-3710600, Remover handle: 07936-3710100, Remover weight:
07741-0010201
• [B] Driver: 07749-0010000, Pilot, 28 mm: 07746-0041100
• [C] Driver: 07749-0010000, Attachment, 28 x 30 mm: 07946-1870100, Pilot, 20 mm: 07746-0040500
• Pack new ball bearing with grease (KYODO YUSHI SUPER N or equivalent). Install the ball bearing into
the driven face squarely until it is fully seated with its sealed side facing down, using the special tools.
• Apply 6 – 7 g of grease (Shell ALVANIA R3, IDEMITSU AUTOREX B, SHIN-NIHON POWERNOC WB3
or equivalent) to the driven face inner surface as shown.
• Apply grease (KLUBERLUB BM 71-152 CN 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 fully seated using the special
tools.
FINAL REDUCTION CASE

REDUCTION OIL REPLACEMENT
• Support the scooter with its centerstand.
13 N·m • Place an oil drain pan under the final reduction case to col-
lect the oil.
• Slowly turn the rear wheel and drain the oil.
• Fill the final reduction case with recommended oil up to the

correct level.
Lower level
13 N·m
2-28
FUEL & ENGINE
• Final drive oil 2-28

• Clutch/driven pulley 2-26
• Rear brake shoes 3-24
• VS sensor 4-31
• Loosen the final reduction case bolts in a crisscross pattern.
• Apply liquid sealant (Three bond 1207B,1215,LOCTITE 5060S,5020 or equivalent) to the final reduction
case mating surface.
• Tighten the final reduction case bolts in a crisscross pattern.
2-29
FUEL & ENGINE
BEARING REPLACEMENT
[C] [A] LEFT CRANKCASE FINAL REDUCTION

[B]
CASE
0 – 0.5 mm
[B] [A] [C]
0 – 0.5 mm
0 – 0.5 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.
• Drive shaft/oil seal
– [A] Assembly collar: 07965-GM00100
– [B] Assembly shaft: 07965-1660200
– [C] Assembly collar attachment: 07965-GM00200
2-30
FUEL & ENGINE
ALTERNATOR/STATOR
• This service can be serviced with the engine installed in the frame.
6.0 N·m
Degrease.
10 N·m
[B]
[A]
39 N·m

• Cooling fan cover 3-5
• Hold the flywheel with the special tool for the nut removal.
[A] Universal holder: 07725-0030000
• Flywheel
[B] Flywheel puller: 07733-0010000
• Install the flywheel onto the crankshaft by aligning the key way on the flywheel with the woodruff key.
2-31
FUEL & ENGINE
CRANKCASE/CRANKSHAFT
[B]
[A]
The following parts must be removed before separating the crankcase.

• Engine 2-34
• Cylinder/piston 2-23
• Drive pulley 2-24
• Clutch/driven pulley 2-26
• Alternator/stator 2-31
• Remove the crankcase bolts in a crisscross pattern in 2 – 3 steps.
• Place the crankcase with the left crankcase facing down and separate.
• [A] Case puller: 07SMC-0010001
• [B] Universal bearing puller: 07631-0010000
CRANKSHAFT RUNOUT INSPECTION

• Set the crankshaft on V-blocks and measure the runout
R
using a dial indicator.
L
• Runout
Standard: (L) 0.05 mm/(R) 0.03 mm
65 mm 35 mm
2-32
FUEL & ENGINE
[K], [L]
2 cm3 minimum
[A], [B], [C]
0 - 0.5 mm
[D]
[F] [H]
3 cm3 minimum
0 - 1 mm
[I], [J]
3
2 cm minimum
[E] [G]
• Drive the left crankcase bearing into the left crankcase squarely until fully seated.
[A] Driver: 07749-0010000: [B] Attachment, 72 x 75 mm: 07746-0010600
[C] Pilot, 35 mm: 07746-0040800
• Pull the crankshaft into the bearing until it is fully seated while positioning the connecting rod [D] in the
cylinder sleeve opening on the left crankcase.
[E] Assembly shaft adaptor: 07WMF-KFF0200, [F] Assembly collar: 07931-KF00100
[G] Assembly collar: 07965-VM00100, [H] Assembly shaft: 07965-VM00200
• Install the oil seal to the right crankcase squarely, using the special tools.
[I] Driver: 07749-0010000, [J] Attachment, 24 x 26 mm: 07746-0010700
• Apply sealant (Three bond 1207B or 1215 or LOCTITE 5060S or 5020 or equivalent) to the right crank-
case mating surface.
• Install the dowel pins.
• Assemble the left and right crankcase.
• Install the crankcase bolts and tighten them in a crisscross pattern.
• Install the cam chain.
• Install the oil seal to the left crankcase squarely, using the special tools.
[K] Oil seal driver, 40 mm: 07965-KE80200, [L] Fork seal driver attachment, 41.2 mm: 07947-KF00100
• Crankshaft inspection
• Connecting rod inspection
2-33
FUEL & ENGINE
ENGINE UNIT

69 N·m
49 N·m
• Quick connect fitting (injector side) 2-2

• Throttle cable A/B (throttle body side) 2-8
• Under cover 3-5
• Centerstand 3-11
• Connect the air duct to the left crankcase cover by aligning the air duct cut-off with the left crankcase cover
tab.
2-34
3. FRAME & CHASSIS
BODY PANELS ································· 3-2 STEERING STEM ····························· 3-17
CENTERSTAND ·······························3-11 REAR WHEEL ································· 3-18
SIDESTAND ····································3-11 REAR SUSPENSION ························ 3-18
EXHAUST PIPE/MUFFLER·················3-12 CBS ··············································· 3-19
FRONT WHEEL ································3-13 FRONT BRAKE································ 3-21
FORK ·············································3-14 REAR BRAKE ································· 3-24
HANDLEBAR ···································3-16
3-1
FRAME & CHASSIS
BODY PANELS
FRAME & CHASSIS
KO type shown: [1]

[2]
[10] [3]
[15]
[12]
[9]
[5]
[18]
[11] [13]
[4]
[17]
[16]
[14] [7] [8] [6]
[1] Front handlebar cover 3-3 [7] Cooling fan cover 3-5 [13] Front fender 3-7
[2] Rear handlebar cover 3-3 [8] Under cover 3-5 [14] Rear inner fender 3-7
[3] Front upper cover 3-4 [9] Luggage box 3-6 [15] Body cover 3-8
[4] Maintenance lid 3-4 [10] Grab rail 3-6 [16] Rear fender 3-9
[5] Front cover 3-4 [11] Center cover 3-6 [17] Floor panel 3-9
[6] Side cover 3-5 [12] Seat 3-6 [18] Front inner cover 3-10
3-2
FRAME & CHASSIS
FRONT HANDLEBAR COVER
REAR HANDLEBAR COVER
• Front handlebar cover 3-3
3-3
FRAME & CHASSIS
FRONT UPPER COVER/MAINTENANCE LID
FRONT COVER
• Front upper cover 3-4
3-4
FRAME & CHASSIS
SIDE COVER
Right side only
COOLING FAN COVER/UNDER COVER
9.0 N·m
0.8 N·m
• Side covers 3-5
3-5
FRAME & CHASSIS
LUGGAGE BOX/GRAB RAIL
CENTER COVER/SEAT

3-6
FRAME & CHASSIS
FRONT FENDER
KO type shown:
REAR INNER FENDER
3-7
FRAME & CHASSIS
BODY COVER
• Center cover 3-6

• License light unit 4-25
3-8
FRAME & CHASSIS
REAR FENDER
Except KO, IIKO type shown:
KO type shown:

• EVAP canister (KO, IIKO type only) 2-13
FLOOR PANEL

• Side covers 3-5
• Battery 4-25
3-9
FRAME & CHASSIS
FRONT INNER COVER
Rear hand brake type
• Front cover 3-4

• Floor panel 3-9
3-10
FRAME & CHASSIS
CENTERSTAND
22 N·m
2.0 mm
SIDESTAND
Except KO, IIKO type shown:
10 N·m
29 N·m

• Sidestand switch (KO, IIKO type) 4-33
3-11
FRAME & CHASSIS
EXHAUST PIPE/MUFFLER
7.5 N·m
15.0 – 16.0 mm
29 N·m
59 N·m
Tightening procedure: 9.5 N·m

[3]
[1], [2]
[4]
3-12
FRAME & CHASSIS
FRONT WHEEL
KO type shown:
59 N·m
[B] [A]
42 N·m
• Install the bearing remover head into the bearing. From the opposite side, install the bearing remover shaft
and drive the bearing out of the wheel hub.
Remover head, 12 mm: 07746-0050300
Bearing remover shaft: 07746-0050100
• Drive in a new left bearing [A] squarely with its sealed side facing up 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 [B] squarely with its sealed side facing up 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
3-13
FRAME & CHASSIS
FORK
KO type shown:
30 N·m
12 N·m
30 N·m
• Front fender 3-7

• Front wheel 3-13
3-14
FRAME & CHASSIS
60 mm
KO type shown: 22 N·m
20 N·m
• Remove the oil seal using the special tool.

Oil seal remover: 07748-0010001
• Drive in a new oil seal until it is fully seated.
Fork seal driver body: 07747-0010100
Fork seal driver attachment: 07747-0010400
• Pour the specified amount of recommended fork fluid into the fork pipe.
RECOMMENDED FORK FLUID: Honda Ultra Cushion Oil 10W
FORK FLUID CAPACITY
KO, IIKO type: 85 ± 2.5 cm3
Except KO, IIKO type: 80 ± 2.5 cm3
• Compress the fork leg fully and measure the fluid level from the top of the fork pipe.
FORK FLUID LEVEL: 60 mm
• Pull the fork pipe up and install the upper fork spring with its tightly wound coil side facing up.
• Fork disassembly and inspection
3-15
FRAME & CHASSIS
HANDLEBAR
12 N·m
39 N·m
• Rear handlebar cover 3-3

• 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.
• Install the brake lever bracket by aligning the hole on the handlebar with the locating pin of the brake
lever bracket.
• Install the throttle holder by aligning the hole on the handlebar with the locating pin of the throttle holder.
3-16
FRAME & CHASSIS
STEERING STEM
[A]
[B]
KO type shown: 68 N·m

3g
[C] [E] [G]
3g 3g
(bearing sliding surface)
3g 3g
[D]
3g
[C] [E] [F]
Multi-purpose extreme pressure

grease NLGI #2 (ALVANIA EP2
manufactured by Shell, EXCELITE
EP2 manufactured by KYODO
12 N·m YUSHI CO., LTD. or equivalent)
• Handlebar 3-16
• Fork 3-14
• STEERING STEM:
[A] Adjusting nut wrench: 07916-1870101, [B] Socket wrench: 07916-KM10000
• STEERING STEM BEARINGS
[C] Adjustable remover head: 07JAC-PH80100, Adjustable remover shaft: 07JAC-PH80200, Remover
weight: 07741-0010201
• STEERING STEM BEARINGS:
[D] Inner driver, 30 mm: 07746-0030300, [E] Driver: 07749-0010000
[F] Attachment, 42 x 47 mm: 07746-0010300, [G] Attachment, 45 x 50 mm: 07946-6920100
• STEERING STEM:
[A] Adjusting nut wrench: 07916-1870101, [B] Socket wrench: 07916-KM10000
• Install the upper inner race/adjusting nut. Hold the steering stem and tighten the stem upper inner race/
adjusting nut to the initial torque using the special tool. TORQUE: Actual: 10 N·m/Indicated: 8.1 N·m
• Turn the steering stem lock-to-lock several times to seat the bearing. Completely loosen the upper inner
race/adjusting nut.
• Tighten the upper inner race/adjusting nut fully by hand while holding the steering stem, then turn and
loosen the upper inner race/adjusting nut counterclockwise about 45 degrees.
• Install the lock washer and tighten the steering stem lock nut to the specified torque. TORQUE: 68 N·m
• Steering disassembly/assembly and inspection
3-17
FRAME & CHASSIS
REAR WHEEL
118 N·m
• Exhaust pipe/muffler 3-12
• Wheel inspection
REAR SUSPENSION
3-18
FRAME & CHASSIS
CBS
1.0 N·m
1.0 N·m
4.5 N·m 4.5 N·m
4.2 N·m 4.2 N·m

• Loosen the connecting cable 3-21
• F mark of the equalizer facing front

• Adjust the CBS. 3-20
3-19
FRAME & CHASSIS
CBS ADJUSTMENT
• Before inspection, check the front and rear brake free-
play.
• Inspect the following operation.
– Apply the rear brake lever and make sure that the rear
wheel does not rotate.
– Release the rear brake lever. Lift the front wheel off the
ground and rotate it by hand. And, make sure that the
front wheel rotates smoothly.
– Lift the front wheel off the ground and apply the rear
brake lever. Make sure that the front wheel does not ro-
tate while the rear brake lever is applied.
• If it is abnormal, adjust the CBS as follows:
Inspection point
• Measure the distance between the edge surface of the
knocker and the edge surface of the master cylinder body
with the feeler gauge.
STANDARD: 0 – 0.1 mm
[B]
• If the distance exceeds the standard, loosen the lock nut
[A] and turn the adjuster [B] until the distance between the
edge surfaces is within standard.
[A]
• Check that there is no gap between the knocker pin and

the end of the slot of the knocker joint.
• If there is any gap, loosen the lock nut and turn the adjust-
er until there is no gap between the knocker pin and the
end of the slot of the knocker joint.
• After the adjustment, hold the adjuster and tighten the
lock nut.
No gap
• After tightening the lock nut, check that there is no gap
between the knocker pin and the end of the slot of the
knocker joint.
Apply rear brake lever several times and check that the
distance between the edges has not been changed after
applying the brake.
6.5 N·m
• Recheck that the distance between the edge surface of

the knocker and the edge surface of the master cylinder
body.
3-20
FRAME & CHASSIS
FRONT BRAKE
BRAKE FLUID REPLACEMENT
• Add the reservoir with brake fluid from a sealed container
to the set line.
RECOMMENDED BRAKE FLUID: DOT 3 or 4
1.5 N·m
Set line
BRAKE MASTER CYLINDER
[A]
12 N·m
6.5 N·m
[B]
34 N·m
[C]
• Rear handlebar cover 3-3

• Loosen the lock nut [A] and turn the adjuster [B] until the play of the connecting cable becomes maxi-
mum.
Compress the return spring and hold it by inserting the proper tool through the holes of the cable holder.
Disconnect the connecting cable end [C] from the knocker joint.
• 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.
• Adjust the CBS. 3-20
3-21
FRAME & CHASSIS
Silicone grease
6.0 N·m
1.0 N·m
Silicone
grease
1.0 N·m
• Remove the snap ring using the special tool.

Snap ring pliers: 07914-SA50001
• Master cylinder inspection
BRAKE CALIPER
BRAKE PAD REPLACEMENT
KO type shown:
18 N·m
2.5 N·m
30 N·m
3-22
FRAME & CHASSIS
BRAKE CALIPER
KO type shown:
34 N·m
30 N·m
Silicone grease
8.0 N·m
Silicone grease
Silicone grease
• Brake caliper inspection
3-23
FRAME & CHASSIS
REAR BRAKE
0.2 – 0.3 g
10 N·m
• Rear wheel 3-18
• Drum brake inspection
3-24
4. ELECTRICAL SYSTEM
PGM-FI SYSTEM ······························· 4-2 LIGHTING SYSTEM ·························· 4-25
IGNITION SYSTEM ···························4-18 SPEEDOMETER ······························ 4-28
ELECTRICAL STARTER ····················4-21 ELECTRICAL COMPONENT ·············· 4-33
BATTERY/CHARGING SYSTEM ·········4-24
4-1
ELECTRICAL SYSTEM
PGM-FI SYSTEM
ELECTRICAL 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
DTC CODE INDEX

DTC Function Failure Symptom/Fail-safe function Page
EOT sensor malfunction • Hard to start at a low temperature
7-1 4-5
• EOT sensor low voltage
EOT sensor malfunction • Hard to start at a low temperature
7-2 4-6
• EOT sensor high voltage
TP sensor malfunction • Poor engine acceleration
8-1 4-7
• TP sensor low voltage
TP sensor malfunction • Poor engine acceleration
8-2 4-8
• TP sensor high voltage
IAT sensor malfunction • Engine operates normally
9-1 4-9
• IAT sensor low voltage
IAT sensor malfunction • Engine operates normally
9-2 4-10
• IAT sensor high voltage
Injector malfunction • Engine does not start
12-1 4-11
• Injector, fuel pump and ignition coil shut down
O2 sensor malfunction • Engine operates normally
21-1 4-12
• O2 sensor low voltage
O2 sensor malfunction • Engine operates normally
21-2 4-13
• O2 sensor high voltage
ECM EEPROM malfunction • Engine stalls, hard to start, rough idling
• Self diagnosis data is not held
33-2 4-13
• Self diagnosis data cannot be erased with
SCS short connector
Fast idle solenoid valve malfunction • Engine operates normally
• Loose or poor contact of the fast idle solenoid • Engine stalls, hard to start, rough idling
82-1 valve connector 4-14
• Fast idle solenoid valve or its circuit malfunc-
tion
Ignition coil primary circuit malfunction • Engine does not start
91-1 4-15
• Ignition coil or its circuit malfunction • Injector and ignition coil shut down
4-2
ELECTRICAL SYSTEM
PGM-FI SYSTEM LOCATION
IGNITION SWITCH
FAST IDLE SOLENOID VALVE
FUEL PUMP
INJECTOR
DLC
ECM
REGULATOR/
RECTIFIER
FUSE BOX
MAIN RELAY
TP SENSOR BATTERY
STARTER RELAY
IGNITION COIL
EOT SENSOR
O2 SENSOR
SIDESTAND SWITCH
IAT SENSOR CKP SENSOR
IDLE AIR SCREW
FAST IDLE SOLENOID VALVE
TP SENSOR
4-3
ELECTRICAL SYSTEM
PGM-FI SYSTEM DIAGRAM
G R
Bl
MAIN RELAY
R/W
R
BATTERY G TURN,HORN,METER,
TAIL,POSITION,HEADLIGHT FUSE
REGULATOR/ MAIN FUSE 10A
RECTIFIER 20A
R/W R/Y Bl/Br
IGNITION
SWITCH Bl/W
R/W IGN,START,
G Y Y Y FUEL PUMP FUSE
10A
R/W R/Bl Bl/W
Bl/W
G/Bl G G/W 25 S STAND SOLV 28 Y/O Bl/W
SIDESTAND 82-1
SWITCH
KO, IIKO type FAST IDLE
SOLENOID VALVE
(33-2)
ECM
Y Bu/Y 12 PCP INJ 16 P/Bu Bl/W
CKP
SENSOR W/Y 23 PCM
12-1
INJECTOR
Y/Bl 6 VCC(5V)
8-1,8-2 W/R 5 THL
TP SENSOR G/O 4 SG1(THL) Except KO, IIKO type
IGP 1 Bl/Bu Bl/W
9-1,9-2 W/Bu 14 TA
IAT SENSOR G/O 32 SG3(TA)
IGPLS 11 Y/Bu Bl/W

7-1,7-2 P/W 24 TO
EOT SENSOR G/O 31 SG2(TO)
91-1
IGNITION
COIL
SPARK PLUG
Bl Bl/O 3 O2 FFP 8 Br/Bl Bl R Bl/W
21-1,21-2 FUEL PUMP

O2 SENSOR
ST-RLY 33 Y/R Bl/W
R
R/W STARTER RELAY
Bl/W To starter motor

SCS
CONNECTOR O/W 30 K-LINE FI-IND 18 W/Bu Bl/Br
Br MIL
15 SCS
G/Bl G 2 LG
DLC
ST-SW 29 Y/G G/Y Bl/Br
STARTER
10 PG2 9 PG1 SWITCH
BRAKE LIGHT
: MIL G G SWITCHES
11
1
: Engine does not start
22
when detecting MIL 12
: Short terminals for 33
reading MIL 23
ECM 33P CONNECTOR
ECM side of the male terminals
4-4
ELECTRICAL SYSTEM
DTC TROUBLESHOOTING
DTC 7-1 (EOT SENSOR LOW VOLTAGE)
EOT Sensor Diagram
EOT sensor 2P
connector ECM 33P (Black) connector
G/O P/W
G/O P/W
5V
TO
P/W
EOT sensor ECM

SG2
G/O
1. EOT Sensor System Inspection
• Check the EOT sensor voltage with MCS. No • Intermittent failure

• Is the voltage about 0 V indicated? ► • Loose or poor contact at the connector
Yes ▼
2. EOT Sensor Inspection
• Check the EOT sensor voltage with MCS. No • Replace the EOT sensor with a new one 4-16, and
• Is the voltage about 0 V indicated? ► recheck.
Yes ▼
3. EOT Sensor Output Line Inspection
• Check a short circuit in P/W wire.

• If there is no short circuit, replace the ECM with
a new one 4-16, and recheck.
4-5
ELECTRICAL SYSTEM
DTC 7-2 (EOT SENSOR HIGH VOLTAGE)

EOT Sensor Diagram
EOT sensor 2P
connector ECM 33P (Black) connector
G/O P/W
G/O P/W
5V
TO
P/W
EOT sensor ECM

SG2
G/O
1. EOT Sensor System Inspection
• Check the EOT sensor voltage with MCS. No • Intermittent failure

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

Connection: P/W – G/O Yes • Replace the EOT sensor with a new one 4-16,
• Check the EOT sensor voltage with MCS. ► and recheck.
• Is the voltage about 0 V indicated?
No ▼
3. EOT Sensor Output Line Inspection
• Check an open circuit in P/W and G/O wire.

• If there is no open circuit, replace the ECM with a
new one 4-16, and recheck.
4-6
ELECTRICAL SYSTEM
DTC 8-1 (TP SENSOR LOW VOLTAGE)
TP Sensor Diagram
TP sensor 3P connector ECM 33P (Black) connector
Y/Bl W/R G/O
W/R
G/O Y/Bl
5V
VCC
Y/Bl
TP sensor THL ECM
W/R
SG1
G/O
1. TP Sensor System Inspection
• Check the TP sensor voltage with MCS. No • Intermittent failure

Yes ▼
2. TP Sensor Power Input Voltage Inspection
• Faulty Y/Bl wire

• Connection: Y/Bl (+) – 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 4-16, and recheck.
Yes ▼
3. TP Sensor Output Line Inspection
• Check an open or short circuit in W/R wire. Yes

• Faulty W/R wire
• Is there open or short circuit? ►
No ▼
4. TP Sensor Inspection
• Replace the TP sensor (throttle body) with a

new one 2-8
• Erase the DTC’s.
• Check the TP sensor with MCS.
• If DTC 8-1 is indicated, replace the ECM with a
4-7
ELECTRICAL SYSTEM
DTC 8-2 (TP SENSOR HIGH VOLTAGE)

TP Sensor Diagram
TP sensor 3P connector ECM 33P (Black) connector

Y/Bl W/R G/O
W/R
G/O Y/Bl
5V
VCC
Y/Bl
TP sensor THL ECM
W/R
SG1
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 TP sensor (throttle body) with a new one 2-
8, 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 TP sensor (throttle body) with a new

one 2-8
• Check the TP sensor with MCS.
4-8
ELECTRICAL SYSTEM
DTC 9-1 (IAT SENSOR LOW VOLTAGE)
IAT Sensor Diagram
IAT sensor 2P ECM 33P (Black) connector

connector
G/O W/Bu
G/O W/Bu
5V
TA
W/Bu
ECM
IAT sensor
SG3
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 IAT sensor with a new one 4-17, and
• Is the voltage about 0 V indicated? ► recheck.
Yes ▼
3. IAT Sensor Output Line Inspection
• Check a short circuit in W/Bu wire.

• If there is no short circuit, replace the ECM with
4-9
ELECTRICAL SYSTEM
DTC 9-2 (IAT SENSOR HIGH VOLTAGE)

IAT Sensor Diagram
IAT sensor 2P ECM 33P (Black) connector

connector
G/O W/Bu
G/O W/Bu
5V
TA
W/Bu
ECM
IAT sensor
SG3
G/O
1. IAT Sensor System Inspection
• Check the IAT sensor voltage with MCS. No • Intermittent failure

Yes ▼
2. IAT sensor Inspection
• Install a jumper wire between the terminals.

Connection: W/Bu – G/O Yes • Replace the IAT sensor with a new one 4-17,
• Check the IAT sensor voltage with MCS. ► and recheck.
No ▼
3. IAT Sensor Voltage Input Line Inspection
• Check an open circuit in W/Bu and G/O wire.

• If there is no open circuit, replace the ECM with a
4-10
ELECTRICAL SYSTEM
DTC 12-1 (INJECTOR)
Injector Diagram
Injector 2P connector Injector 2P connector ECM 33P (Black) connector
(Injector side) (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

• Open circuit in 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 4-16, and

recheck.
4-11
ELECTRICAL SYSTEM
DTC 21-1 (O2 SENSOR LOW VOLTAGE)
• Right side cover 3-5
O2 Sensor Diagram
O2 sensor 1P (Black) connector ECM 33P (Black) connector
Bl/O
Bl
O2
Bl Bl/O
ECM
O2 sensor
1. O2 Sensor System Inspection
• Test-ride the vehicle and check the O2 sensor

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

• Faulty Bl/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 fuel
• Is the fuel pressure within specification? ► filter. 2-5
– 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

segment is positioned the specified range, and No
• Replace the fuel filter. 2-5
inspect the fuel flow.2-3 ►
• Is the fuel flow within specification?
Yes ▼
5. O2 Sensor Inspection
• Replace the O2 sensor with a new one. 4-17

• Test-ride the vehicle and check the O2 sensor
with MCS.
• If DTC 21-1 is indicated, replace the ECM with
4-12
ELECTRICAL SYSTEM
DTC 21-2 (O2 SENSOR HIGH VOLTAGE)

O2 Sensor Diagram
O2 sensor 1P (Black) connector ECM 33P (Black) connector
Bl/O
Bl
O2
Bl Bl/O
ECM
O2 sensor
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 21-2 indicated?
Yes ▼
2. O2 Sensor Circuit Inspection
• Check the open circuit in Bl/O wires. Yes

• Faulty Bl/O wire.
• Are there open circuit? ►
No ▼
3. O2 Sensor Inspection
• Replace the O2 sensor with a new one. 4-17

• Test-ride the vehicle and check the O2 sensor with
MCS.
DTC 33-2 (EEPROM)
1. EEPROM System Inspection
• Check the EEPROM with MCS. No • Intermittent failure

• Is the DTC 33-2 indicated? ► • Loose or poor contact at the connector
Yes ▼
• Replace the ECM with a new one 4-16, and re-

check.
4-13
ELECTRICAL SYSTEM
DTC 82-1 (FAST IDLE SOLENOID VALVE)
Fast Idle Solenoid Valve Diagram

Fast idle solenoid valve Fast idle solenoid valve ECM 33P (Black) connector
2P connector 2P connector
Y/O
A B Y/O Bl/W
From Battery
Bl/W
Fast idle
ECM
solenoid valve
SOLV
Y/O
1. Fast Idle Solenoid Valve System Inspection
• Check the fast idle solenoid valve with MCS. No • Intermittent failure
• Is the DTC 82-1 is indicated? ► • Loose or poor contact at the connector
Yes ▼
2. Fast Idle Solenoid Valve Input Voltage Inspection

• Open circuit in Bl/W wire
Yes ▼
3. Fast Idle Solenoid Valve Signal Line Inspection
• Check an open or short circuit in Y/O wire. Yes

• Faulty Y/O wire
No ▼
4. Fast Idle Solenoid Valve Resistance Inspection
• Connection: A – B No
• Faulty fast idle solenoid valve
• Is the resistance within 24 – 27 Ω (24 °C)? ►
Yes ▼
• Replace the ECM with a new one 4-16, and

recheck.
4-14
ELECTRICAL SYSTEM
DTC 91-1 (IGNITION COIL PRIMARY CIRCUIT)

Ignition Coil Primary Circuit Diagram
ECM 33P (Black) connector
Y/Bu
Ignition coil
connector
From Battery
ECM
Ignition Bl/W
coil Y/Bu IGPLS
1. Ignition Coil Primary Circuit System Inspection
• Check the Ignition coil with MCS. No • Intermittent failure

• Is the DTC 91-1 indicated? ► • Loose or poor contact at the connector
Yes ▼
2. Ignition Coil Primary Circuit Input Voltage Inspection

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

• Faulty Y/Bu wire
No ▼
4. Ignition Coil Inspection
• Replace the ignition coil with a new one 4-18

• Test-ride the vehicle and check the ignition coil
with MCS.
4-15
ELECTRICAL SYSTEM
ECM
• ECM power circuit and ground circuit inspection
EOT SENSOR
14.5 N·m
• EOT sensor inspection
4-16
ELECTRICAL SYSTEM
IAT SENSOR
• Rear inner fender 3-7
• Install the IAT sensor with the connector tab facing up.
O2 SENSOR
25 N·m
[A]

• Remove the O2 sensor using the special tool.
Flare nut socket [A]: FRXM17 (Snap on) or equivalent
4-17
ELECTRICAL SYSTEM
IGNITION SYSTEM
IGNITION SYSTEM LOCATION
FUSE BOX IGNITION SWITCH

· 20 A
· 10 A
IGNITION COIL
ECM
BATTERY
SPARK PLUG
SIDESTAND SWITCH
CKP SENSOR
IGNITION SYSTEM DIAGRAM
IGNITION
20 A SWITCH 10 A
R/W R/Bl Bl/W
SIDESTAND Bl/W
SWITCH
(KO, IIKO)
G G/W Bl/W
(KO, IIKO)
Y Bu/Y Bl/Bu Bl/W
G R G/Bl (Except KO, IIKO)
W/Y Y/Bu
Bl G
IGNITION
COIL
ECM
BATTERY
SPARK
CKP SENSOR
PLUG
4-18
ELECTRICAL SYSTEM
SPARK PLUG REPLACEMENT
16 N·m
INSPECTION
IGNITION COIL PRIMARY PEAK VOLTAGE
• Refer to "Basic Shop Manual" for the detail information of

ignition coil primary peak voltage inspection.
• 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 ground terminal as done in a
spark test.
• With the ignition coil primary wires connected, connect
the peak voltage adaptor probes to the ignition coil
primary terminal and ground.
CONNECTION: Y/Bu (+) – Ground (–)
• Check the initial voltage at this time.

STANDARD VOLTAGE: Battery voltage
• Squeeze the brake lever fully.
• Retract the sidestand. (KO, IIKO type only)
• Crank the engine with the starter and measure the
ignition coil primary peak voltage.
PEAK VOLTAGE: 100 V minimum
4-19
ELECTRICAL SYSTEM
CKP SENSOR PEAK VOLTAGE

• Disconnect the CKP sensor 3P (Black) connector.
• Connect the peak voltage adaptor probes to the following
terminals.
CONNECTION: W/Y (+) – Y (–)
• Crank the engine with the starter and measure the CKP
sensor peak voltage.
PEAK VOLTAGE: 0.7 V minimum
– If the value is abnormal, replace the CKP sensor with a
known-good one and recheck.
W/Y Y – If the value is normal, check for open circuit or loose
connection between the CKP sensor 3P (Black)
connector and ECM 33P (Black) connector.
IGNITION TIMING
• Timing hole cap

• Warm the engine 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 min-1
• The ignition timing is correct if the "F" mark on the fly-
wheel aligns with the index mark on the right crankcase.
4-20
ELECTRICAL SYSTEM
ELECTRICAL STARTER
ELECTRICAL STARTER SYSTEM LOCATION
REAR BRAKE
STARTER SWITCH
LIGHT SWITCH
FRONT BRAKE
LIGHT SWITCH
IGNITION SWITCH
MAIN RELAY
ECM
FUSE BOX
· 20 A
· 10 A
· 10 A
BATTERY
STARTER RELAY
STARTER MOTOR SIDESTAND SWITCH
ELECTRICAL STARTER SYSTEM DIAGRAM
20 A
R/W R/W
IGNITION
R/W
SWITCH 10 A
R/Bl Bl/W
Bl/W
G R/Y
R
STARTER STARTER MAIN
RELAY SWITCH RELAY
Y/R
R/W G/Y Bl/Br
R 10 A
SIDESTAND
Bl SWITCH BRAKE
Y/G (KO, IIKO) LIGHT
G G/W G SWITCHES
G
ECM G G/Bl
BATTERY
4-21
ELECTRICAL SYSTEM
ELECTRICAL STARTER TROUBLESHOOTING
STARTER MOTOR DOES NOT TURN

• Loose or poor contacts of related terminal/connector
• Battery condition
• Burned fuse
Connector Diagram
Starter relay 5P connector ECM 33P (Black) connector
Bl/W Y/R
R R/W Y/R Y/G G/W
1. Starter Switch/Brake Light Switch Circuit Inspection
• Connection: Y/G (+) – Ground (–) • Inspect the following.

• Squeeze the brake lever fully. No – Brake light switch
• Depress the starter button. ► – Starter switch
• Does the battery voltage exist? – Starter switch/brake light switch related circuit
Yes ▼
2. Sidestand Switch Circuit inspection (KO, IIKO type only)
• Connection: G/W – Ground • Open or short circuit in G/W wire

No
• Is there continuity only when the sidestand retract- • If there is no open circuit, replace the sidestand
►
ed? switch with a new one 4-33, and recheck.
Yes ▼
3. Starter Relay Coil Input Circuit Inspection
• Inspect the following.

– Ignition switch
– Starter relay coil input related circuit
Yes ▼
4. Starter Relay Coil Output Circuit Inspection
• Check an open circuit in Y/R wire. No • Faulty Y/R wire

• Is there open circuit? ►
Yes ▼
4-22
ELECTRICAL SYSTEM
5. Starter Relay Inspection
• Replace the starter relay with a new one, and re- • Faulty original starter relay
Yes
check.
►
• Does the starter motor turn?
No ▼
6. Starter Motor Inspection
• Check a short or open circuit in starter motor

cable.
Yes
• If there is no faulty circuit, replace the starter motor • Faulty original starter motor
►
with a new one, and recheck.
• Does the starter motor turn?
No ▼
• Replace the ECM with a new one, and recheck.
STARTER MOTOR
2.0 N·m

• Air cleaner 2-7
0.1 – 0.3 g
0.1 – 0.3 g
4-23
ELECTRICAL SYSTEM
BATTERY/CHARGING SYSTEM
BATTERY/CHARGING SYSTEM LOCATION
FUSE BOX
· 20 A
REGULATOR/
RECTIFIER
BATTERY
ALTERNATOR
BATTERY/CHARGING SYSTEM DIAGRAM
20 A
R/W
Y Y
R G Bl G
ALTERNATOR
REGULATOR/
BATTERY RECTIFIER
• Battery/charging system information, troubleshooting and inspection.
4-24
ELECTRICAL SYSTEM
BATTERY
LIGHTING SYSTEM
1.1 N·m
1.0 N·m
• Front cover 3-4
4-25
ELECTRICAL SYSTEM
1.0 N·m
4-26
ELECTRICAL SYSTEM
BULB REPLACEMENT
FRONT
REAR
• License light unit 4-25
4-27
ELECTRICAL SYSTEM
HEADLIGHT AIM
Beam down
Beam up
SPEEDOMETER
1.1 N·m
Rear handlebar cover 3-3
4-28
ELECTRICAL SYSTEM
SPEEDOMETER 4-28
4-29
ELECTRICAL SYSTEM
CLOCK ADJUST
• Turn the ignition switch to the On position.
• With odometer displayed, press and hold the SET button
until the clock digits start flashing.
• Press the SET button until the desired time is displayed.

• The time is advanced by one minute, each time the SET
button is pressed.
• The time is advanced by ten minutes, when the SET button

is pressed and held.
• Wait for a few seconds and press the SET button. The
clock is set.
• The time can also be set by turning the ignition switch to
the Off position.
• If the SET switch was not pressed during the adjustment
for about 30 seconds, the display will stop flashing
automatically and the adjustment will be set.
4-30
ELECTRICAL SYSTEM
VS SENSOR
• Air cleaner 2-7
FUEL LEVEL SENSOR
R
Bl
• Fuel pump unit 2-4
• Route the fuel level sensor wires to the guide properly.
4-31
ELECTRICAL SYSTEM
FUEL METER TROUBLESHOOTING
FUEL METER NEEDLE DOES NOT MOVE
• Fuel pump unit 2-4
• Loose or poor contacts of related terminal/connector
Open circuit indication
A B
FULL
Short circuit indication
EMPTY
1. Fuel Level Sensor Circuit Inspection
• Check the Y/W and G or G/Bl wire. Yes • Faulty Y/W, G or G/Bl wire
No ▼
2. Fuel Level Sensor Inspection
• Connection: A – B
No • Replace the fuel level sensor with a new one 4-31,
• Standard: FULL 6 – 10 Ω, EMPTY 90 – 100 Ω.
► and recheck.
• Does the standard resistance exist?
Yes ▼
Replace the speedometer with a new one 4-28,

and recheck.
4-32
ELECTRICAL SYSTEM
ELECTRICAL COMPONENT
IGNITION SWITCH
• Front inner cover 3-10
SIDESTAND SWITCH (KO, IIKO type only)
• Side cover 3-5

• Install the sidestand switch while aligning its pin with the hole of the sidestand.
4-33
ELECTRICAL SYSTEM
HORN
4-34
INDEX
dummytext
INDEX
A Few Words About Safety······································1-2 FUEL LINE ··························································2-2
A
AIR CLEANER······················································2-7 FUEL PUMP UNIT·················································2-4

ALTERNATOR/STATOR ······································ 2-31 FUEL TANK ·························································2-6
ALTITUDE SETTING ··········································· 2-12 HANDLEBAR ····················································· 3-16
H
BATTERY/CHARGING SYSTEM···························· 4-24 HORN······························································· 4-34

B
BODY PANELS ····················································3-2 How To Use This Manual ········································1-3

BRAKE FLUID REPLACEMENT····························· 3-21 IGNITION SYSTEM ············································· 4-18
I
BULB REPLACEMENT ········································ 4-27 INJECTOR························································· 2-13

CABLE & HARNESS ROUTING ····························· 1-15 LIGHTING SYSTEM ············································ 4-25
C L
CBS·································································· 3-19 LUBRICATION SYSTEM ······································ 2-14

CBS ADJUSTMENT ············································ 3-20 MAINTENANCE SCHEDULE································· 1-27
M
CENTERSTAND ················································· 3-11 MODEL IDENTIFICATION ······································1-5

CRANKCASE/CRANKSHAFT ································ 2-32 PGM-FI SYSTEM ··················································4-2
P
CYLINDER HEAD ··············································· 2-17 REAR BRAKE ···················································· 3-24

R
CYLINDER/PISTON ············································ 2-23 REAR SUSPENSION··········································· 3-18

DRIVETRAIN······················································ 2-24 REAR WHEEL···················································· 3-18
D
ECM INITIALIZING PROCEDURE ·························· 2-11 REDUCTION OIL REPLACEMENT························· 2-28

E
ELECTRICAL COMPONENT ································· 4-33 SIDESTAND ······················································ 3-11

S
ELECTRICAL STARTER ······································ 4-21 SIDESTAND SWITCH (KO, IIKO type only) ·············· 4-33
ENGINE OIL CHANGE ········································· 2-15 SPARK PLUG REPLACEMENT ····························· 4-19
ENGINE OIL LEVEL CHECK ································· 2-14 SPECIAL TOOL LIST··········································· 1-14
ENGINE OIL STRAINER SCREEN ························· 2-15 SPECIFICATIONS·················································1-6
ENGINE UNIT ···················································· 2-34 SPEEDOMETER················································· 4-28
EVAP SYSTEM (KO, IIKO type only)······················· 2-13 STEERING STEM ··············································· 3-17
EXHAUST PIPE/MUFFLER ··································· 3-12 TECHNICAL FEATURE········································ 1-24
T
FINAL REDUCTION CASE ··································· 2-28 THROTTLE BODY ················································2-8

F
FORK ······························································· 3-14 TORQUE VALUE ················································ 1-11

FRONT BRAKE ·················································· 3-21 TP SENSOR RESET PROCEDURE ······················· 2-10
FRONT WHEEL ·················································· 3-13 VALVE CLEARANCE··········································· 2-17
V
FUEL LEVEL SENSOR ········································ 4-31
5-1
NSC125SH-H (KO, IIKO)
FUSE BOX
TURN/HORN/
METER/TAIL/
HEAD LIGHT
FUEL PUMP UNIT
FUEL PUMP
IGN/START/
POSITION/
FUEL FUEL LEVEL
CLOCK
PUMP SENSOR
MAIN
RIGHT FRONT
TURN SIGNAL REGULATOR/
STARTER LIGHT RECTIFIER
ECM
SWITCH (12V 10W) MAIN STARTER
SG2 (TO)
VCC (5V)
SG1 (TH)
S STAND
SG3 (TA)
RELAY RELAY BATTERY
ST-RLY
K-LINE
ST-SW
IGPLS
FI-IND
SOLV
PCM
SCS
PCP
PG2
PG1
FFP
THL
IGP
10A
10A
10A
20A
INJ
TO
O2
LG
TA
DLC 12V 6AH
JOINT
BAT
A-33
A-32
A-31
A-30
A-29
A-28
A-27
A-26
A-25
A-24
A-23
A-22
A-21
A-20
A-19
A-18
A-17
A-16
A-15
A-14
A-13
A-12
A-10
A-11
ST
Bl
Bl
R
R
A-9
A-8
A-7
A-6
A-5
A-4
A-3
A-2
A-1
4P 33P 6P 5P
3P (R) (Bl) 5P
(R) (Bl) (Gr)
5P
W/Bu
W/Bu
R/Bu
Bu/Y
P/Bu
Y/Bu
Br/Bl
Br/Bl
Bl/Br
Bl/Br
Bl/W
Bl/W
Bl/W
Bl/W
Bl/W
Bl/W
Bl/W
Bl/W
Bl/W
Bl/W
Bl/W
Bl/W
Bl/W
Bl/W
Bl/W
O/W
G/W
O/W
G/Bl
W/R
Bl/O
G/Bl
R/W
R/W
R/W
R/W
R/W
R/W
W/Y
P/W
Y/W
R/Bl
G/O
G/O
Y/Bl
G/O
G/Y
Y/G
Y/G
Y/O
Y/R
R/Y
R/Y
Y/R
Lb
Br
Br
G
G
G
G
G
G
G
G
R
R
R
Y
Y
Y
3P
(R)
Lb
G
W/Bu W/Bu
G/Bu G/Bu
W/G W/G
P P
4P
FRONT SL
BRAKE G/Y G/Y
LIGHT Bl/Br Bl/Br
SWITCH BAT
SPEEDOMETER
Y/W Y/W
TURN R 1 Lb RIGHT REAR
- 2 Bl/Br Bl/Br Lb TURN SIGNAL
FI INPUT 3 W/Bu R/Bu R/Bu G LIGHT
LT SW INPUT 4 Bl/Br Br (12V 10W)
SP SENS GND 5 G/Bu
GND 6 G/Bl
4P
SP SENS IGN 7 W/G
FUEL INPUT 8 Y/W
TURN L 9 O G TAIL LIGHT
HI-BEAM 10 Bu Br (12V 5W)
Y/G Y/G
- 11 G/Bl G/Bl
SP INPUT 12 P G G 9P
- 13
Lb Lb
- 14 G/Y G/Y G/Y
BATT 15 R/Bu
G/Y G/Y BRAKE/
G G G TAIL LIGHT
IGN 16 Bl/Br
Lb Lb Bl/Br Br Br (12V 21W/5W)
16P
O O O O
6P
Bl/Br Br TAIL LIGHT
TURN SIGNAL Gr
RELAY G (12V 5W)
2P
G LEFT REAR
POSITION Br Bl/Br O TURN SIGNAL
LIGHT G G LIGHT
(12V 10W)
3P
Br Bl/Br LICENSE LIGHT
Bu/Y
R/W
W/Y
G
Y
Y
Y
G G (12V 5W)
HEAD Bu Bu 3P
G G 3P 3P 2P
LIGHT (Bl)
W W
R/W
W/Y
Bl
Y
Y
Y
Y
6P(BI)
G/Bu
G/W
G/Bl
W/G
Bl/O
P
REAR SL
BRAKE G/Y G/Y
LIGHT Bl/Br Bl/Br
1P 2P
BAT 3P (Bu)
SWITCH (Bl)
G
Bl
R/W
HORN
W/Bu
G/Bu
Y/Bu
P/Bu
Bl/W
Bl/W
Bl/W
W/G
G/W
R/W
W/R
G/Bl
G/Bl
G/Bl
G/Bl
G/Bl
G/Bl
R/Bl
P/W
Y/Bl
G/O
G/O
G/O
Y/O
Lg
G
G
G
G
G
P
Y
O
G
Bl
3P
(BI)
3P 2P 3P 2P 2P 2P 3P
G M
Bl
BAT2
STARTER
Bl/Br
Bl/Br
THL
VCC
SG1
O
G
Bu
Gr
Lb
Lg
O
MOTOR
BAT1
3P 3P 3P ALTER
W/Y
VS SENSOR
(R) (BI) JOINT NATOR
IGNITION FAST
HL
BAT
W
HO
SWITCH IDLE
SOLENOID TP EOT IAT FUEL O2 SENSOR FRAME FRAME FRAME SIDE CKP ENGINE FRAME ENGINE
VALVE SENSOR SENSOR SENSOR INJECTOR GROUND GROUND GROUND STAND SENSOR GROUND GROUND GROUND
LO
HI
R
L
LEFT FRONT SWITCH

DIMMER TURN TURN SIGNAL
SWITCH SIGNAL HORN LIGHT IGNITION
SWITCH SWITCH (12V 10W) COIL
Bl Black Br Brown
Y Yellow O Orange
Bu Blue Lb Light Blue
TURN SIGNAL SWITCH DIMMER SWITCH G Green Lg Light Green
IGNITION SWITCH R W L Hi Lo HL HORN SWITCH STARTER SWITCH R Red P Pink
BAT1 BAT2 BAT HO BAT ST W White Gr Gray
ON (N) (N) FREE FREE
OFF PUSH PUSH TWO COLORED WIRE (EXAMPLE:YELLOW/RED)
COLOR R/W R/Bl COLOR Lb Gr O COLOR Bu Bu/W COLOR Bl/Br Lg COLOR G/Y Y/G
NSC125SH-H (AG, IIAG, IIILA, IVLA, PE, IIPE)
FUSE BOX
TURN/HORN/
METER/TAIL/
HEAD LIGHT
FUEL PUMP UNIT
FUEL PUMP
IGN/START/
POSITION/
FUEL FUEL LEVEL
CLOCK
PUMP SENSOR
MAIN
RIGHT FRONT
TURN SIGNAL REGULATOR/
STARTER LIGHT RECTIFIER
ECM
SWITCH (12V 10W) MAIN STARTER OPTION
SG2 (TO)
VCC (5V)
SG1 (TH)
SG3 (TA)
RELAY RELAY BATTERY
ST-RLY
K-LINE
ST-SW
IGPLS
FI-IND
SOLV
PCM
SCS
PCP
PG2
PG1
FFP
THL
IGP
10A
10A
10A
20A
INJ
TO
O2
LG
TA
Bl/W
DLC 12V 6AH
JOINT
BAT
A-33
A-32
A-31
A-30
A-29
A-28
A-27
A-26
A-25
A-24
A-23
A-22
A-21
A-20
A-19
A-18
A-17
A-16
A-15
A-14
A-13
A-12
A-10
A-11
ST
Bl
Bl
R
R
A-9
A-8
A-7
A-6
A-5
A-4
A-3
A-2
A-1
4P 33P 6P 5P
3P (R) (Bl) 5P 9P
(R) (Bl) (Gr)
5P
W/Bu
W/Bu
Bl/Bu
Bl/Bu
R/Bu
Bu/Y
P/Bu
Y/Bu
Br/Bl
Br/Bl
Bl/Br
Bl/W
Bl/W
Bl/W
Bl/W
Bl/W
Bl/W
Bl/W
Bl/W
Bl/W
Bl/W
Bl/W
Bl/W
Bl/W
Bl/W
Bl/W
O/W
O/W
G/Bl
W/R
Bl/O
G/Bl
R/W
R/W
R/W
R/W
R/W
R/W
R/W
R/W
W/Y
P/W
Bl/R
Y/W
R/Bl
Bl/R
G/O
G/O
Y/Bl
G/O
G/Y
Y/G
Y/G
Y/O
Y/R
R/Y
R/Y
Y/R
Lb
Lb
Br
Br
G
G
G
G
O
G
G
G
G
G
R
R
R
Y
Y
Y
3P
(R)
Lb
G
W/Bu W/Bu
G/Bu G/Bu
W/G W/G
P P
4P
FRONT SL
BRAKE G/Y G/Y
LIGHT Bl/Br Bl/Br
SWITCH BAT
SPEEDOMETER
Y/W Y/W
TURN R 1 Lb RIGHT REAR
- 2 Bl/Br Bl/Br Lb TURN SIGNAL
FI INPUT 3 W/Bu R/Bu R/Bu G LIGHT
LT SW INPUT 4 Bl/Br Br Br (12V 10W)
SP SENS GND 5 G/Bu
GND 6 G/Bl
4P
SP SENS IGN 7 W/G
FUEL INPUT 8 Y/W
TURN L 9 O G TAIL LIGHT
HI-BEAM 10 Bu Br (12V 5W)
Y/G Y/G
- 11 G/Bl G/Bl
SP INPUT 12 P G G 9P
- 13
Lb Lb
- 14 G/Y G/Y G/Y
BATT 15 R/Bu
G/Y G/Y BRAKE/
G G G TAIL LIGHT
IGN 16 Bl/Br
Lb Lb Br Br Br (12V 21W/5W)
16P
O O O O
6P
Bl/Br Br TAIL LIGHT
TURN SIGNAL Gr
RELAY G (12V 5W)
2P
G LEFT REAR
POSITION Br Bl/Br O TURN SIGNAL
LIGHT G G LIGHT
(12V 10W)
3P
Br Br LICENSE LIGHT
Bu/Y
R/W
W/Y
G
Y
Y
Y
G G (12V 5W)
HEAD Bu Bu 3P
G G 3P 3P 2P
LIGHT (Bl)
W W
R/W
W/Y
Bl
Y
Y
Y
Y
6P(BI)
G/Bu
W/G
Bl/O
P
REAR SL
BRAKE G/Y G/Y
LIGHT Bl/Br Bl/Br
BAT 1P 3P
SWITCH (Bl)
G
Bl
R/W
HORN
W/Bu
G/Bu
Y/Bu
P/Bu
Bl/W
Bl/W
Bl/W
W/G
R/W
W/R
G/Bl
G/Bl
G/Bl
G/Bl
G/Bl
R/Bl
P/W
Y/Bl
G/O
G/O
G/O
Y/O
Lg
G
G
G
G
G
P
Y
O
G
Bl
3P
(BI)
3P 2P 3P 2P 2P 2P 3P
G M
Bl
BAT2
STARTER
Bl/Br
Bl/Br
THL
VCC
SG1
O
G
Bu
Gr
Lb
Lg
O
MOTOR
BAT1
3P 3P 3P ALTER
W/Y
VS SENSOR
(R) (BI) JOINT NATOR
IGNITION FAST
HL
BAT
W
HO
SWITCH IDLE
SOLENOID TP EOT IAT FUEL O2 SENSOR FRAME FRAME FRAME CKP ENGINE FRAME ENGINE
VALVE SENSOR SENSOR SENSOR INJECTOR GROUND GROUND GROUND SENSOR GROUND GROUND GROUND
LO
HI
R
L
LEFT FRONT
DIMMER TURN TURN SIGNAL
SWITCH SIGNAL HORN LIGHT IGNITION
SWITCH SWITCH (12V 10W) COIL
Bl Black Br Brown
Y Yellow O Orange
Bu Blue Lb Light Blue
TURN SIGNAL SWITCH DIMMER SWITCH G Green Lg Light Green
IGNITION SWITCH R W L Hi Lo HL HORN SWITCH STARTER SWITCH R Red P Pink
BAT1 BAT2 BAT HO BAT ST W White Gr Gray
ON (N) (N) FREE FREE
OFF PUSH PUSH TWO COLORED WIRE (EXAMPLE:YELLOW/RED)
COLOR R/W R/Bl COLOR Lb Gr O COLOR Bu Bu/W COLOR Bl/Br Lg COLOR G/Y Y/G
© Honda Motor Co.,Ltd. 2017 Book#: 62K80B0
Published by Honda Motor Co.,Ltd. A.2017.5
Printed in Japan

SM Nsc125 Elite Repa.

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Shop Manual

2. Fuel & Engine

3. Frame & Chassis

This book is Specific Shop Manual.

MODEL IDENTIFICATION ··················· 1-5 TECHNICAL FEATURE ····················· 1-24

SPECIFICATIONS······························ 1-6 MAINTENANCE SCHEDULE ·············· 1-27

TORQUE VALUE ······························1-11

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.

ENGINE SERIAL NUMBER

ITEM STANDARD SERVICE LIMIT

SPECIAL TOOL LIST

CABLE & HARNESS ROUTING

TURN SIGNAL RELAY

REAR BRAKE SWITCH

RIGHT TURN SIGNAL LEFT TURN SIGNAL

TURN SIGNAL RELAY

SEAT LOCK REAR BRAKE

THROTTLE REAR BRAKE

FUEL FEED HOSE

EVAP CHARGE HOSE

EVAP CHARGE HOSE

IGNITION COIL WIRE

IGNITION COIL WIRE

O2 SENSOR 1P (Black) MAIN WIRE

EVAP CHARGE HOSE

EVAP PURGE HOSE

IAT SENSOR 2P HIGH TENSION

FUEL FEED HOSE

FAST IDLE SOLENOID

HEAD LIGHT WIRE

LEFT TURN SIGNAL RIGHT TURN SIGNAL

RIGHT TURN SIGNAL

LICENSE LIGHT 3P CONNECTOR

LICENSE LIGHT WIRE

: Air suction passage under fuel filter blockage

: Air discharge passage under normal fuel filter condition

: Fuel flow under normal fuel filter condition

FREQUENCY (NOTE 1) REFER

FUEL LINE ······································· 2-2 CYLINDER HEAD····························· 2-17

FUEL PUMP UNIT······························ 2-4 CYLINDER/PISTON ·························· 2-23

FUEL TANK ······································ 2-6 DRIVETRAIN ··································· 2-24