Honda Fireblade 929 Manual Download

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Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys.

email: info@motomatrix.co.uk

Summary of Contents for Fireblade 929

Page 1: ...not interchangeable with English fasteners 4 Install new gaskets O rings cotter pins and lock plates when reassembling 5 When tightening bolts or nuts begin with the larger diameter or inner bolt first Then tighten to the specified torque diagonally in incremental steps unless a particular sequence is specified 6 Clean parts in cleaning solvent upon disassembly Lubricate any sliding surfaces befor...

Page 2: ...R LABEL i 5 The color label is attached as shown When ordering color coded parts always specify the designated color code ENGINE SERIAL NUMBER 2 The engine serial number is stamped on the right side of the upper crankcase THROTTLE BODY IDENTIFICATION NUMBER 4 The throttle body identification number is stamped on the intake side of the throttle body as shown 0 0 0 Manuals by Motomatrix www motomatr...

Page 3: ...ngement Firing Order 2 065 mm 81 3 in 680 mm 26 8 in 1 125 mm 44 3 in 1 395 mm 54 9 in 820 mm 32 3 in 384 mm 15 1 in 130 mm 5 1 in 172 kg 379 Ibs 174 kg 384 Ibs 197 kg 434 Ibs 199 kg 439 Ibs 160 kg 353 Ibs 164 kg 362 Ibs Diamond Inverted telescopic fork 110 mm 4 3 in Swingarm 135 mm 5 3 in Nitrogen gas filled damper 120 70 ZR17 58W Radial 190 50 ZR17 73W Radial GENERAL INFORMATION SPECIFICATIONS F...

Page 4: ... FI Programmed Fuel Injection 40 mm 1 6 in Multi plate wet Cable operated type Constant mesh 6 speed 1 521 73 48 2 687 43 16 2 692 35 13 1 933 29 15 1 600 32 20 1 400 28 20 1 286 27 21 1 190 25 21 Left foot operated return system 1 N 2 3 4 5 6 Computer controlled digital transistorized with electronic advance Electric starter motor Triple phase output alternator SCR shorted triple phase full wave ...

Page 5: ...9 states Canada type_ number jCalifornia type _ Starter valve vacuum difference Base throttle valve for synchronization Idle speed Throttle grip free play _ _ _Intake air temperature sensor resistance at 20 C 68 F _ __Engine coolant_ temperature sensor resistance at 20 C 68 F Fuel injector resistance at 20 C 68 F _PAIR solenoid valve resistance at 20 C 68 F _Purge control solenoid valve resistance...

Page 6: ..._ IN EX 34 80 1 370 free length Outer IN EX 37 97 1 495 1 37 2 1 46 Valve lifter Valve lifter O D IN EX 25 978 _ 25 993 1 0228 1 0233 L25 97 1 022 Valve lifter bore I D _ IN EX 26 010 26 026 1 0240 1 0246 26 04 1 025 Camshaft Cam lobe height IN 36 48 36 72 1 43_ 6 1 446 36 45 1 435 i EX 36 08 36 32 1 420 1 430 36 50 1 437 _ L Runout 0 05 0 002 Oil clearance 0 020 0 062 0 0008 0 0024 0 10 0 004 Val...

Page 7: ...er Warpage Piston Piston mark direction IN mark facing toward the intake side piston rings Piston O D 73 965 73 985 2 9120 2 91 Piston O D measurement point i_13 mm 0 5 in from bottom of skirt Piston pin bore I D _ 17 002 17 008 0 6694 0 6696 r piston pin O D _ 16 994 _17 000 0 66 _ 9 1 0 6693 _ Piston to piston pin clearance 0 002 0 014 0 0001 0 0006 Piston ring to ring I Top 0 030 0 065 0 0012 0...

Page 8: ...1 M5 M6 _ 30 950 30 975 1 2185 1 2195 30 93 1 218 C3 32 950 32 975 l 2972 1 2982 1 32 93 1 296 32 950 32 975 1 2972 1 2982 32 93 1 296 27 985 28 006 1 1018 1 1026 28 02 1 103 29 985 30 006 1 1805 1 1813 30 02 1 182 0 025 0 0 _ 75 0 0010 0 0030 0 11 0 004 0 025 _ 0 0 _ 75 0 0010 0 0030 1 0 11 0 004 27 967 27 980 1 1011 1 1016 27 957 _ 1 1007 Clutch outer guide I 24 980 24 993 0 9835 0 9840 24 96 0 ...

Page 9: ...ack 40 50 1 6 2 0 Shock absorber Spring adjuster standard position 4th groove Tension adjuster initial settin 2 turns from full hard Compression adjuster initial setting 1 turn from full hard GENERAL INFORMATION I 2 0 0 08 0 20 0 008 Unit mm in SERVICE LIMIT 1 5 0 06 0 20 0 008 2 0 0 08 2 0 0 08 230 5 9 07 225 9 8 8 9 With the tapered end facing up 0 20 0 008 Pro Honda Suspension Fluid SS 8 90 3 5...

Page 10: ...n timing F mark STANDARD Honda DOT 4 Brake Fluid 4 5 0 18 _ 19 050 19 093 0 7500 0 7517 _ r 19 018 19 034 0 7487 0 7494 _ 33 960 34 010 1 3370 1 3390 30 250 30 280 1 1909 1 1921 _ 33 802 33 835 1 3308 1 3321 _ 30 082 30 115 1 1843 1 1856 DOT 4 75 30 5 0 0 20 4 0 0 16 _ 0 30 0 012 15 870 15 913 0 6248 0 6265 15 925 0 6270 15 827 15 854 0 6231 0 6242 15 815 0 6226 38 180 38 230 1 5031 1 5051 38 24 1...

Page 11: ...mp Fuel reserve indicator 80 C 120 C SPECIFICATIONS 12V 55W X 2 12V 55W 12V 21 5WX2 12V 32 3 cp 23 8 W X2 1 2V 21W X2 12V 5W GENERAL INFORMATION LED LED X2 LED LED LED LED LED 30A Fuse Main fuse PGM FI fuse _ _Sub fuse Tachometer peak voltage Thermo sensor resistance Fan motor Start to close ON 98 102 C 208 216 F switch Stop to open 93 97 C 199 207 F 20A 20A X 1 1OA X 5 10 5 V m nimum 2 1 2 6 k 2 ...

Page 12: ...RICATION SYSTEM Oil drain bolt 1 12 29 3 0 22 Oil cooler mounting bolt 1 20 74 7 5 54 Oil pump assembly flange bolt 1 6 8 0 8 5 8 Oil pump driven sprocket bolt 1 6 150 5 11 Oil filter cartridge 1 20 26 2 7 20 Oil pressure switch 1 PT 1 8 120 2 9 Oil pressure switch wire terminal screw 1 4 2 0 2 1 4 FUEL SYSTEM Programmed Fuel injection ECT Engine Coolant Temperature thermosensor 1 12 23 2 3 17 Thr...

Page 13: ...eel flange bolt Stator mounting socket bolt Starter one way clutch socket bolt CRANKCASE PISTON CYLINDER Mainshaft bearing set plate bolt Crankcase bolt 10 mm 9 mm main journal bolt 8mm Connecting rod nut Upper crankcase sealing bolt Lower crankcase sealing bolt 20 mm 10 mm THREAD DIA mm Q TY 22 6 8 6 8 6 6 10 6 6 6 10 9 8 8 8 20 10 TORQUE N m kgf m Ibf f t 100 0 7 120 2 9 120 2 9 120 2 9 27 2 8 2...

Page 14: ...ral switch Insulator clamp Throttle body side 7 y1 mm 0 3 L 0 04 in Exhaust pipe stud bolt 47 5 0 5 m m 1 87 0 02 in Q TY THREAD TORQUE DIA mm N m I gf m lbf t 59 6 0 43 120 2 9 120 2 9 REMARKS NOTE 5 Insulator clamp Cylinder head side 12 1 mm 0 5 0 04 in 0 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 15: ...otpeg bracket mounting socket bolt 4 8 Main footpeg mounting bolt 2 I 10 Bank sensor 2 8 Lower bracket mounting nut 1 10 Lower bracket mounting pinch bolt Engine hanger nut front Engine hanger nut middle Engine hanger nut rear Rear engine hanger pinch bolt Side stand bracket bolt Side stand pivot bolt Side stand pivot lock nut CLUTCH GEARSHIFT LINKAGE Gearshift pedal link pinch bolt 1 THREAD DIA m...

Page 16: ...se clamp screw Rear master cylinder push rod nut Rear master cylinder hose joint screw Rear brake caliper pin bolt main Rear brake caliper pin bolt sub Brake hose oil bolt LIGHTS METERS SWITCHES Ignition switch mounting one way bolt Side stand switch mounting bolt Fan motor switch ITEM Q TY 2 1 1 THREAD TORQUE DIA mm N m kgf m Ibf ft 22 8 10 10 10 10 24 8 6 8 6 16 26 2 7 20 10 1 0 7 NOTE8 103 10 5...

Page 17: ...andle Valve spring compressor attachment Oil filter wrench Peak voltage adaptor TOOL NUMBER 07406 0040002 07506 3000000 07510 MA70000 07724 0050002 07725 0040000 07733 0020001 07746 0010300 07746 0010400 07746 0010700 07746 0010800 07746 0010900 07746 0030100 07746 0030300 07746 0040400 07746 0040600 07746 0040800 07746 0050100 07746 0050800 07749 0010000 07757 0010000 07780 0010100 07780 0010300 ...

Page 18: ...07HMG MR70002 07 H M D M LOO 101 07 H M H M L00101 07HMH MR10103 07LMC KV30100 07MAD PR90200 07 R MJ MY50100 07YM B MCF0101 07YMD MCFO100 07YMD MCJO100 07YMF MCJO100 07YMF MCJ0200 07YMF MCJ0300 07YMF MCJ0400 07YMZ 0010100 NOTE 2 NOTE 3 07H M H M LOO10A U S A only NOTE 3 07HMH MR1010B U S A only NOTE 3 07KMD KZ30100 with 07 N M D KZ30101 except U S A 07 N M D KZ3010A U S A only NOTE 5 NOTE 5 NOTE 5...

Page 19: ...e switch threads Do not apply sealant to the thread head 3 4 mm 0 1 0 2 in MATERIAL Liquid sealant Three Bond 1207B or equivalent EE E Eco Lo L 71 7 1 00 0 00 714 E E Woo E E E co E LOo Ta 0 2 GENERAL INFORMATION REMARKS 0 0 0 4 0 00 0 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 20: ...ng sliding area Oil strainer packing Clutch disc surface Starter one way clutch sliding surface Connecting rod nut threads Flywheel bolt threads and seating surface Main journal 9 mm bolt threads and seating surface after removing anti rust oil additive Cylinder head special bolt after removing anti rust oil additive Clutch center lock nut threads Oil filter cartridge threads and O ring Camshaft h...

Page 21: ...Oil pump driven sprocket bolt threads Shift drum bearing set plate bolt threads Mainshaft bearing set plate bolt threads Cam sprocket bolt threads Cylinder head cover breather plate bolt threads Shift drum center bolt threads Cam chain tensioner pivot bolt threads Cam chain guide pivot bolt threads Gearshift return spring pin MATERIAL REMARKS Multi purpose grease Locking agent GENERAL INFORMATION ...

Page 22: ...ead Throttle cable casing inner Brake pipe joint threads Throttle cable A B casing inner Clutch cable casing inner Variable intake valve cable inner Variable exhaust valve cable A B casing inner Brake master cylinder cups Brake caliper _piston seals Brake caliper dust seals Front brake lever pivot and piston tips Rear master cylinder boot inside and push rod tips Rear brake caliper slide pin surfa...

Page 23: ...URN SIGNAL CONNECTORS LEFT HANDLEBAR SWITCH 12P NATURAL CONNECTOR IGNITION SWITCH 4P NATURAL CONNECTOR a 1 RIGHT HANDLEBAR SWITCH 6P RED CONNECTOR HEADLIGHT SOCKETS GENERAL INFORMATION CLUTCH CABLE HORN WIRE WHITE TAPE LEFT TURN SIGNAL CONNECTORS Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 24: ... WHITE TAPE RIGHTTURN SIGNAL WIRE 0 0 S J S ill to 11 dill HEADLIGHT SOCKETS II CLUTCH CABLE LEFT HANDLEBAR 1 SWITCH WIRE HORN WIRE FAN MOTOR WIRE 2 LEFT TURN SIGNAL WIRE r I N OW I X LI AN INSIDE Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 25: ...Ial 0 0 0 O 0 o 0 0 c 0 0 0 0 o l 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 00 0 0 0 0 0 RIGHT HANDLEBAR SWITCH WIRE GENERAL INFORMATION METER SUB HARNESS Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 26: ...OW TUBE l o f 11 T crime LEFT HANDLEBAR SWITCH WIRE RIGHT HANDLEBAR SWITCH WIRE IS Y SIPHON TUBE OIL COOLER WATER HOSES FRONT SUB HARNESS 20P CONNECTOR Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 27: ...N CONTROL CABLE 1 1 AOO S O T WICH SSURE l_o EGCV EXHAUST GAS CONTROL VALVE CONTROL CABLES 1 I ENGINE SUB HARNESS oi l s ALTERNATOR WIRE I STARTER MOTOR GROUND CABLE THROTTLE CABLES PAIR CONTROL SOLENOID VALVE 2P NATURAL CONNECTOR THROTTLE GENERAL INFORMATION IGNITION COIL SUB HARNESS 9P BLACK CONNECTOR VEHICLE SPEED SENSOR SENSOR Manuals by Motomatrix www motomatrix co uk The Solution For Lost Mo...

Page 28: ... UNIT TUBES BYPASS HOSE l r slit mmi l l asm 0 a 000 11 z THERMOSTAT HOUSING TO WATER PUMP HOSE SIPHON TUBE Is 00 AIR BLEED TUBE OVERFLOW TUBE UPPER RADIATOR HOSE Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 29: ...IN WIRE HARNESS FUEL TANK AIR VENT TUBE GENERAL INFORMATION mago 44 o 1 x M l O i k o 0 G FUEL TANK OVERFLOW TUBE SIDE STAND SWITCH WIRE EGCV EXHAUST GAS CONTROL VALVE Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 30: ... 0 z o Is w au y BRAKE LIGHT SWITCH WIRE IGNITION COIL SUB HARNESS PAIR SOLENOID VALVE WIRE AIR BLEED TUBE IGNITION PULSE GENERATOR WIRE 14 00 CLUTCH WIRE SIPHON TUBE UPPER RADIATOR HOSE 0 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 31: ...AT SENSOR No 3 INJECTOR No 4 INJECTOR MAP SENSOR FUEL INJECTOR SUB HARNESS 9P GRAY CONNECTOR GENERAL INFORMATION IGNITION PULSE GENERATOR2P RED CONNECTOR ENGINE SUB HARNESS 2P BLUE CONNECTOR Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 32: ...ot 1 11 r _lly Tt ICIrrra _ I J 10 20A 41 11 w FUEL TUBE FUEL TANK BREATHER TUBE 0 FUEL PUMP RESERVE SENSOR 3P BLACK CONNECTOR FUEL TANK OVERFLOW TUBE THROTTLE SENSOR Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 33: ...TOR FUEL CUT RELAY FUSE BOX BANK ANGLE SENSOR Awlft ENGINE STOP RELAY ALTERNATOR 3P WHITE CONNECTOR REGULATOR RECTIFIER 4P NATURAL CONNECTOR GENERAL INFORMATION I of if fli ECM 22P BLACK CONNECTOR STARTER RELAY SWITCH BATTERY POSITIVE CABLE Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 34: ...NESS SERVICE CHECK CONNECTOR REAR BRAKE HOSE REAR BRAKE LIGHT SWITCH 2P NATURAL CONNECTOR RESERVOIR HOSE BRAKE LIGHT SWITCH WIRE Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 35: ...TOR CABLE II STARTER MOTOR GROUND CABLE THROTTLE CABLES 1 GENERAL INFORMATION PAIR CONTROL SOLENOID VALVE 2P NATURAL CONNECTOR IGNITION COIL SUB HARNESS 9P BLACK CONNECTOR 00 r 0 THROTTLE SENSOR IGNITION PULSE GENERATOR WIRE OIL PRESSURE SWITCH ENGINE SUB HARNESS EVAP CANISTER VEHICLE SPEED SENSOR Oz SENSOR 4P NATURAL CONNECTOR EVAP PURGE CONTROL SOLENOID VALVE Manuals by Motomatrix www motomatrix...

Page 36: ... 02 SENSOR WIRE BRAKE LIGHT SWITCH WIRE IGNITION COIL SUB HARNESS PAIR SOLENOID VALVE WIRE AIR BLEED TUBE O V 4rolo p Low IGNITION PULSE GENERATOR WIRE CLUTCH WIRE SIPHON TUBE UPPER RADIATOR HOSE 0 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 37: ...UBE FUEL PUMP RESERVE FUEL TANK OVERFLOW TUBE SENSOR WIRE GENERAL INFORMATION m r all i II v FUEL PUMP RESERVE SENSOR 3P BLACK CONNECTOR EVAP CANISTER THROTTLE SENSOR 1 37 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 38: ... CONNECTOR BATTERY NEGATIVE CABLE ECM 22P LIGHT GRAY CONNECTOR BRAKE LIGHT SWITCH 2P 0 NATURAL CONNECTOR BATTERY POSITIVE CABLE MAIN WIRE HARNESS SERVICE CHECK CONNECTOR PGM FI FUSE HOLDER FUSE BOX A p AF E l fy IN J 1 a STARTER RELAY SWITCH S I Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 39: ...7k 1C 414 10 0 ArUlthas 1 I 1d 1 r REAR BRAKE HOSE S O SENSOR WIRE GENERAL INFORMATION REAR BRAKE LIGHT SWITCH 2P NATURAL CONNECTOR RESERVOIR HOSE BRAKE LIGHT SWITCH WIRE Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 40: ...sary in order to keep the emissions system warranty in effect SOURCE OF EMISSIONS The combustion process produces carbon monoxide and hydrocarbons Control of hydrocarbons is very important because under certain conditions they react to form photochemical smog when subjected to sunlight Carbon monoxide does not react in the same way but it is toxic Honda Motor Co Ltd utilizes lean injection setting...

Page 41: ...The PAIR control valve is operated by the solenoid valve The solenoid valve is controlled by the PGM Fl unit and the fresh air passage is opened closed according the running condition ECT IAT TP MAP sensor and engine revolution No adjustments to the secondary air supply system should be made although periodic inspection of the components is recommended AIR CLEANER HOUSING N9 PI P I 0 PAIR CONTROL ...

Page 42: ...n other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUT...

Page 43: ...l tank must be opened to read it Refer to page 3 4 for fuel tank opening VACUUM HOSE ROUTING DIAGRAM LABEL GENERAL INFORMATION EMISSION CONTROL INFORMATION LABEL VACUUM HOSE ROUTING DIAGRAM ENGINE FAMILY I EVAPORATIVE FAMILY I CALIFORNIA VEHICLE FORWARD PAIR SOLENOID VALVE m u 1 ENG HEAD TO ACL i C PURGE CONTROL SOLENOID VALVE PRESSURE REGULATE PAIR CHECK VALVE O THROTTLE BCDY 8 O 10 TO OPEN AIR J...

Page 44: ...UARD INNER PANEL WINDSCREEN UPPER COWL FRONT FENDER 0 o MIDDLE COWL INNER MIDDLE COWL LOWER COWL O 40 0 V J 420 H SEAT PILLION SEAT REAR COWL REAR FENDER I Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 45: ...l pan screw Inner panel pan screw Inner middle cowl pan screw Rear cowl truss screw Pillion seat bracket mounting bolt unt Pillion seat mounting nut Seat rail mounting bolt 8 mm Seat rail mounting bolt 10 mm Pillion step mounting socket bolt Exhaust pipe joint flange nut Exhaust valve cover mounting bolt Exhaust valve pulley cover mounting bolt 1 N m 0 15 kgf m 1 1 Ibf ft TROUBLESHOOTING Excessive...

Page 46: ... fuel tank rear bracket and install the seat Install and tighten the socket bolts securely PILLION SEAT REAR COWL REMOVAL Remove the seat see above Open the pillion seat using the ignition key Remove the rear cowl setting bolts collars and spacers SEAT COLLAR BOLT SEAT HOOK COLLAR BOLT PILLION SEAT IGNITION KEY 10110 rjj On SPACER SETTING BOLT a COLLAR Manuals by Motomatrix www motomatrix co uk Th...

Page 47: ... Remove the two trim clips under the rear cowl Remove the two trim clips and two retaining screws Carefully spread the bottom of both sides of the rear cowl then remove it from the seat rail FRAME BODY PANELS EXHAUST SYSTEM RETURN SPRING PILLION SEAT ASSEMBLY BOLT NUT t BRAKE TAIL LIGHT CONNECTORS V T TRIM CLIP TRIM CLIP REAR COWL SCREW r Manuals by Motomatrix www motomatrix co uk The Solution For...

Page 48: ...nstall the two trim clips Install and tighten the mounting screws to the speci fied torque TORQUE 1 N m 0 15 kgf m 1 1 Ibf ft Install the lower trim clips 2 4 PILLION SEAT ASSEMBLY 1 N m 0 15 kgf m 1 1 lbf ft or g7 ry V REAR COWL TRIM CLIP SCREW 4 REAR COWL TRIM CLIP Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 49: ...ed torque TORQUE 12 N m 1 2 kgf m 9 lbf ft Install the spacers setting collars and setting bolts then tighten the bolts securely MIDDLE LOWER COWL REMOVAL Remove the trim clips from the inner middle cowl FRAME BODY PANELS EXHAUST SYSTEM 1 BRAKE TAIL LIGHT CONNECTORS RETURN SPRING PILLION SEAT ASSEMBLY BOLT NUT Y SPACER n 11 1 SETTING BOLT COLLAR TRIM CLIPS K u e 0 i Manuals by Motomatrix www motom...

Page 50: ... lower cowl assembly from the right side Remove the two screws special bolt and inner lower cowl Remove the two trim clips and separate the right and left lower cowls SPECIAL BOLT SCREWS GROMMET V MIDDLE COWL a SPECIAL BOLTS LOWER COWL LEFT LOWER COWL RIGHT LOWER COWL INNER LOWER COWL Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk...

Page 51: ... 0 15 kgf m 1 1 lbf f t Install bottom Install the lower cowl onto the frame from the right ends of the inner side middle cowl into the inner lower cowl grooves FRAME BODY PANELS EXHAUST SYSTEM I I I T e RIGHT LOWER COWL LEFT LOWER COWL 6 INNER LOWER COWL INNER MIDDLE COWL N INNER LOWER COWL m I ALIGN 2 7 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email ...

Page 52: ...ighten the screws to the specified torque TORQUE 1 N m 0 15 kgf m 1 1 Ibf ft Tighten the special bolt Secure the inner lower cowl and middle cowl using four trim clips II SPECIAL BOLTS LOWER COWL GROMMET MIDDLE COWL i e SPECIAL BOLT V St a SCREWS TRIM CLIPS 11 0 aQ dl i e Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 53: ... heat guard on both side Remove the rearview mirror mounting socket bolts and rearview mirror Remove the screws washers and windscreen FRAME BODY PANELS EXHAUST SYSTEM TRIM CLIPS INNER PANEL HEAT GUARD SCREW REAR VIEW MIRROR 0 SOCKET BOLTS WINDSCREEN h WASHERS SCREWS r 2 9 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 54: ...ectors then remove the upper cowl Remove the screws and air guard Remove the nut and setting plate then remove the front turn signal unit r BOLT i WASHER SOCKETS AND CONNECTORS UPPER COWL L e AIR GUARD i SCREWS SETTING PLATE TURN SIGNAL UNIT NUT 9 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 55: ...EAR VIEW MIRROR UPPER COWL v a a FRAME BODY PANELS EXHAUST SYSTEM Install the inner middle cowl into the upper cowl and secure it with trim clips INNER MIDDLE COWL y J om TIM CLIPS INNER MIDDLE COWL HEAT GUARD INNER PANEL INNER MIDDLE COWL TIM CLIPS 2 11 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 56: ...er cowl stay connect the headlight connectors position light connector and turn signal connectors Route the harness Install the upper cowl onto the upper cowl stay and wires properly while aligning the headlight unit bosses with the page 1 23 upper cowl stay grommets SETTING PLATE NUT i a TURN SIGNAL UNIT AIR GUARD SCREWS SOCKETS AND CONNECTORS UPPER COWL BOSSES t 91 GROMMETS Z_ I Manuals by Motom...

Page 57: ...wl mounting bolt Tighten the upper cowl mounting bolt securely Install the windscreen and washers then secure it with screws Install the rearview mirror and tighten the socket bolts FRAME BODY PANELS EXHAUST SYSTEM BOLT 4a WASHER WINDSCREEN SCREWS m0 WASHERS REAR VIEW MIRROR SOCKET BOLTS 0 J 0 HEAT GUARD SCREW 2 13 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded K...

Page 58: ... Remove the front fender mounting special bolts and reflectors Remove the front fender forward INSTALLATION Installation is in the reverse order of removal Remove the following Rear cowl page 2 2 Battery page 16 5 Disconnect the turn signal connectors and license light connector SCREW TRIM CLIPS y INNER PANEL REFLECTOR CLAMP NUT FRONT FENDER 11 o 4 0 O 0 0 0 0 o a SPECIAL BOLTS FRONT FENDER TURN S...

Page 59: ...r 4P Natural connector Remove the fuel cut relay from the rear fender Release the regulator rectifier wire and main wire harness from the seat rail and rear fender Remove the two rear fender mounting bolts and collars FRAME BODY PANELS EXHAUST SYSTEM FUSE BOX STARTER RELAY 2P NATURAL CONNECTOR ALTERNATOR CONNECTORS t N i ECM FUEL CUT RELAY MAIN WIRE HARNESS OF a w REGULATOR RECTIFIER WIRE BOLTS CO...

Page 60: ...FUEL TANK REAR BRACKET FUSE BOX ECM STARTER RELAY SWITCH while installing Install the rear fender by aligning its lower groove the rear fender with the seat rail brace route the wire har ness properly page 1 23 FMIL 3RACE REAR FENDFF bHACE Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 61: ...on footpeg bracket Remove the socket bolts and left pillion footpeg bracket Remove the bolts and regulator rectifier Remove the seat rail mounting 8 mm bolts 10 mm bolts nuts and seat rail FRAME BODY PANELS EXHAUST SYSTEM TURN SIGNAL CONNECTORS LICENSE LIGHT CONNECTOR PILLION FOOTPEG BRACKET BOL T1 NUT 8 mm BOLTS n MUFFLER MOUNTING BOL F N SOCKET BOLTS 7 PILLION FOOTPEG BRACKET REGULATOR RECTIFIER...

Page 62: ... Install the left pillion footpeg bracket and tighten the socket bolts to the specified torque TORQUE 39 N m 4 0 kgf m 29 Ibf ft 39 N m 4 0 kgf m 29 lbf ft lop b BOLT JU SEAT RAIL REGULATOR RECTIFIER PILLION FOOTPEG BRACKET 39 N m 4 0 kgf m 29 lbf ft mm BOLTS AI SOCKET BOLTS REGULATOR RECTIFIER i 1 PILLION FOOTPEG BRACKET 2 18 39 N m 4 0 kgf m 29 Ibf ft i Manuals by Motomatrix www motomatrix co uk...

Page 63: ... hot Remove the middle lower cowl page 2 7 Remove the exhaust pipe to muffler mounting bolts Remove the muffler mounting bolt nut and washer then remove the muffler Remove the gasket California type Disconnect the 0 2 sensor 4P Natural connector only Remove the 0 2 sensor wire from the frame FRAME BODY PANELS EXHAUST SYSTEM PILLION FOOTPEG SOCK BRACKET MUFFLER MOUNTING BOLT NUT MUFFL1ER if S K ET ...

Page 64: ...ard Remove the two bolts and EGCV Exhaust Gas Control Valve pulley cover Disconnect the EGCV control cables from the pulley CLAMP RIGHT STEP GUARD BOLTS 0 SENSOR WIRE RIGHT STEP GUARD D BOLTS I I PULLEY COVER i13 CONTROL CABLES mWoo 0 0 PULLEY Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 65: ...t pipe mounting bolt nut Washer Collar Exhaust pipe Exhaust pipe gaskets See page 5 100 for exhaust valve removal disas sembly FRAME BODY PANELS EXHAUST SYSTEM BOLT NUT EXHAUST PIPE A Vi i BOLT Ni 7 N 1 I i Il JOINT NUTS a T Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 66: ...ornia type MUFFLER California type MUFFLER v 1 0 SENSOR N 9 o A 4 41 Loa A EXHAUST PIPE ASSEMBLY 12 N m 1 2 kgf m 9 Ibf ft EXHAUST PIPE ASSEMBLY Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 67: ...exhaust pipe temporarily install the bolt and nut exhaust pipe joint nuts and mounting bolt nut properly First tighten the exhaust pipe joint nuts to the specified torque 0 TORQUE 12 N m 1 2 kgf m 9 Ibf ft Tighten the exhaust pipe mounting bolt nut FRAME BODY PANELS EXHAUST SYSTEM BOLT NUT EXHAUST PIPE 41 BUSHING COLLAR GASKETS I JOINT NUTS Manuals by Motomatrix www motomatrix co uk The Solution F...

Page 68: ...1 2 kgf m 9 lbf ft Lower mounting bolt 12 N m 1 2 kgf m 9 lbf ft Install the radiator lower mounting bolt nut and tighten the nut California type Clamp the 02 sensor wire to the right step guard only CONTROL CABLES 0 0 PULLEY IL 0 0 11 0 d 7 Z 1 BOLTS 0 PULLEY COVER 3OLT NUT RAC5 IA 1 f Y 02 SENSOR WIRE RIGHT STEP GUARD i 0 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycl...

Page 69: ... new gasket onto the exhaust pipe as shown Install the muffler Temporarily install the muffler mounting bolt nut Tighten the muffler exhaust pipe mounting bolts securely Tighten the muffler mounting bolt nut securely Install the middle lower cowl page 2 7 y FRAME BODY PANELS EXHAUST SYSTEM CLAMP RIGHT STEP GUARD O 1 1 C BOLTS BOLT NUT MUFFL 44 n GASKEll Manuals by Motomatrix www motomatrix co uk T...

Page 70: ... in an open area or with an exhaust evacuation system in and enclosed area 3 INTENANCE SERVICE INFORMATION 3 1 MAINTENANCE SCHEDULE 3 3 FUEL LINE 3 4 THROTTLE OPERATION 3 5 AIR CLEANER 3 5 SPARK PLUG 3 6 VALVE CLEARANCE 3 10 ENGINE OIL OIL FILTER 3 15 ENGINE IDLE SPEED 3 18 RADIATOR COOLANT 3 18 COOLING SYSTEM 3 18 SECONDARY AIR SUPPLY SYSTEM 3 19 EVAPORATIVE EMISSION CONTROL SYSTEM CALIFORNIA TYP...

Page 71: ... 7 Q 3 9 US qt 3 3 Imp qt Pro Honda GN4 or HP4 4 stroke oil U S A Canada Honda 4 stroke oil Canada only or equivalent motor oil API service classification SF or SG Viscosity SAE 10W 40 1 200 100 rpm __ 40 50 mm 1 6 2 0 in Honda DOT 4 Brake Fluid Front 120 70 ZR17 58W Rear 190 50 ZR17 73W FrontBT010F __ Rear BT01OR Front Pilot SPORT E Rear Pilot SPORT E F ront 1 250 kPa 2 50 kqf cmz 36 psi Rear 290...

Page 72: ...NG HEAD BEARINGS NOTE NOTE 2 I R NOTE 3 NOTE 3 ODOMETER READING NOTE 1 REFER X 000 mi 0 6 4 8 12 16 2024 TO PAGE X100 km 10 64 128 192256 320 384 I I I 3 4 I EVERY__ 500 mi 800 km I L II R I i R I I I I 1 I 1 I I I 1 t I I 3 4 R R 3 6 I R I I R 3 7 1 R R R III I I I I I 1 MAINTENANCE 3 9 3 12 R 3 12 I 3 14 R 3 15 1 3 15 1 3 16 I _ I 3 16 EVERY 16 000 mi 5 95 25 600 km 1 L 1 1 1 1 3 17 3 22 3 23 3 ...

Page 73: ...nd of fuel tank using a suitable support as shown Check the fuel lines for deterioration damage or leakage Replace the fuel line if necessary Install the fuel tank in the reverse order of removal BOLTS WASHERS FUEL TANK B 0 LAT7 C SUITABLE SUPPORT 0 n l l FUEL L j 0 0 0 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 74: ...y by loosening the lock nut and turning the adjuster Major adjustments are made with the lower adjust er Remove the air cleaner housing page 5 66 Adjust the free play by loosening the lock nut and turning the adjuster After adjustment tighten the lock nut securely Recheck the throttle operation Replace any damaged parts if necessary AIR CLEANER Open and support the front end of fuel tank page 3 4 ...

Page 75: ...parts in the reverse order of removal NOTICE Be careful not to damage the radiator fins Remove the middle cowl page 2 5 Disconnect the fan motor sub harness 2P Black connector Remove the radiator lower mounting bolt nut MIDDLE COWL SPECIAL BOLT 11 SCREWS 2P BLACK CONNECTOR lul l c ta WER MOUNTI s ELEMENT R LT NUT Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Key...

Page 76: ...k plug bases with compressed air before removing and be sure that no debris is allowed to enter the combustion chamber Remove the radiator upper mounting bolt and washer Disconnect the direct ignition coil connectors Remove the direct ignition coils form the spark plug UPPER MOUNTING BOLT WASHER MET BOSS w a ON MAINTENANCE NEC TA R DIRECT IGNITION COILS F I PGUG WREivLH Manuals by Motomatrix www m...

Page 77: ...e the plug if the center electrode is rounded as shown in the illustration SPECIFIED SPARK PLUG IUH27D DENSO Check the gap between the center and side electrodes with a wire type feeler gauge Make sure that the ol 0 mm 0 04 in plug gauge does not insert between the gap If the gauge can be inserted into the gap replace the plug with a new one Reinstall the spark plug in the cylinder head and hand t...

Page 78: ...adiator grommet onto the frame boss Install the washer and radiator upper mounting bolt then tighten the bolt Install and tighten the radiator lower mounting bolt nut NIMET BOSS MAINTENANCE V DIRECT IGNITION COILS UPPER MOUNTING BOLT WASHER V IL3 O LT NUT Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 79: ...over page 8 5 Remove the cam chain tensioner lifter sealing bolt and sealing washer Turn the cam chain tensioner lifter shaft fully and secure it using the mechanic s tensioner stopper tool page 8 8 w 2P BLACK CONNECTOR MIDDLE COWL SPECIAL BOLT SCREWS CAM CHAIN TENSIONER LIFTER BOLT SEALING WASHER STOPPER TOOL III I Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded ...

Page 80: ...e cam sprockets are facing inward turn the crankshaft clockwise one full turn 360 and realign the timing marks with the cylin der head surface so they are facing outward Insert the feeler gauge between the valve lifter and the cam lobe Check the valve clearance for the No 1 and No 3 cyl inder intake valves using a feeler gauge VALVE CLEARANCE IN 0 16 0 03 mm 0 006 k 0 001 in MAINTENANCE A TIMING M...

Page 81: ...sing a feeler gauge VALVE CLEARANCE EX 0 27 0 03 mm 0 011 0 001 in Turn the crankshaft clockwise 1 2 turn 180 align the T mark on the ignition pulse generator rotor with the index mark on the right crankcase cover Check the valve clearance for the No 2 and No 4 cyl inder intake valves using feeler gauge VALVE CLEARANCE IN 0 16 0 03 mm 0 006 0 001 in INDEX LINE 0 Ti 0 1 0111 C 1 No 2 EXHAUST VALVES...

Page 82: ... shims Shim may stick to the inside of the valve lifter Do not allow the shims to fall into the crankcase Mark all valve lifters and shims to ensure correct reassembly in their original locations The valve lifter can be easily removed with a valve lapping tool or magnet The shims can be easily removed with a tweezers or magnet Clean the valve shim contact area in the valve lifter with compressed a...

Page 83: ...calculated dimension of over 2 800 mm Install the newly selected shim on the valve retain er Apply molybdenum disulfide oil to the valve lifters Install the valve lifters into the valve lifter holes Install the camshaft page 8 24 Rotate the camshafts by rotating the crankshaft clockwise several times Recheck the valve clearance Remove the cam chain tensioner stopper tool Install the new sealing wa...

Page 84: ...th recommended oil up to the upper level line Remove the oil filler cap Fill the recommended engine oil up to the upper level line RECOMMENDED ENGINE OIL Pro Honda GN4 or HP4 4 stroke oil U S A Canada or Honda 4 stroke oil Canada only or equivalent motor oil API service classification SF or SG Viscosity 1 OW 40 Reinstall the filler cap and dipstick INS i 3N W NJ D J P I OIL FILLER t r MAINTENANCE ...

Page 85: ...emove and discard the oil filter cartridge using the special tool TOOL Oil filter wrench 07HAA PJ70100 Check that the sealing washer on the drain bolt is in good condition and replace if necessary Install and tighten the drain bolt TORQUE 29 N m 3 0 kgf m 22 Ibf ft CIL FILLER uIL DRAIN BOLT SEALING WASHER OIL FILTER CARTRIDGE OIL FILTER WRENCH IV 4 I J ulL DRAIN BOLT SEALING WASHER Manuals by Moto...

Page 86: ...at draining 3 7 2 3 9 US qt 3 3 Imp qt at oil filter change Install the oil filler cap Start the engine and let it idle for 2 to 3 minutes Stop the engine and recheck the oil level Make sure there are no oil leaks Install the middle lower cowl page 2 7 OIL FILTER CARTRIDGE O RING OIL FILTER CARTRIDGE OIL FILTER WRENCH do 7J OIL FILER CAP MAINTENANCE Manuals by Motomatrix www motomatrix co uk The S...

Page 87: ... coolant RECOMMENDED ANTIFREEZE High quality ethylene glycol antifreeze containing corrosion protection inhibitors Remove the middle cowl page 2 5 Remove the reserve tank filler cap and fill to the UPPER level line with 50 50 mixture of distilled water and antifreeze Reinstall the filler cap Remove the middle lower cowl page 2 5 Check the radiator air passages for clogging or damage Straighten ben...

Page 88: ...es burning of the unburned exhaust gases and changes a considerable amount of hydrocar bons and carbon monoxide into relatively harmless carbon dioxide and water Remove the air cleaner housing page 5 58 Check the PAIR pulse secondary air injection tubes between the PAIR control solenoid valve and cylinder head cover for deterioration damage or loose connections Make sure that the hoses are not cra...

Page 89: ...CK 40 50 mm 1 6 2 0 in NOTICE Excessive chain slack 50 mm 2 0 in or more may damage the frame Lubricate the drive chain with 80 90 gear oil or drive chain lubricant designed specifically for use with O ring chains Wipe off the excess oil or chain lubricant ADJUSTMENT Loosen the rear axle nut Loosen drive chain adjust bolt lock nuts and turn both adjusting bolts until the correct drive chain slack ...

Page 90: ...itting links or otherwise appears unserviceable Installing a new chain on badly worn sprockets will cause the new chain to wear quickly Inspect and replace the sprocket as necessary Lubricate the drive chain with 80 90 gear oil or Pro Honda chain lube designed specifically for use with O ring chains Wipe off the excess oil or chain lubricant SPROCKET INSPECTION Inspect the drive and driven sprocke...

Page 91: ...k Loosen the drive chain page 3 20 Assemble the special tool as shown TOOL Drive chain tool set 07HMH MR10103 or 07HMH MR101OA U S A only Locate the crimped pin ends of the master link from the outside of the chain and remove the link with the drive chain tool set TOOL Drive chain tool set 07HMH MR10103 or 07HMH MR1010A U S A only Remove the drive chain BOLT DRIVE SPROCKET u DRIVE CHAIN TOOL SET M...

Page 92: ... CHAIN DID DID 50VA8 C1 RK RK GB50HFOZ5 Route the drive chain into the swingarm as shown NOTICE Never reuse the oil drive chain master link master link plate and 0 rings Assemble the new master link O rings and plate Assemble and set the drive chain tool set TOOL Drive chain tool set 07HMH MR10103 or 07HMH MR1010A U S A only MAINTENANCE 1 LINK II 108 LINKS AID O RINGS PLATE MASTER LINK I DRIVE CHA...

Page 93: ...er of the staked area using a slide caliper DIAMETER OF THE STAKED AREA DID 5 50 5 80 mm 0 217 0 228 in RK 5 45 5 85 mm 0 215 0 230 in A drive chain with After staking check the staked area of the master a clip type master link for cracks link must not be If there is any cracking replace the master link O usedd rings and plate MASTER LINK PINS SLIDE CALIPER GOOD O O O NO GOOD CRACKED Manuals by Mo...

Page 94: ...is level and check the front brake fluid reservoir level If the level is near the lower level line check the brake pad wear see below REAR BRAKE Place the motorcycle on a level surface and sup port it upright position Check the rear brake fluid reservoir level If the level is near the lower level line check the brake pad wear see below BRAKE PAD WEAR FRONT BRAKE PADS Check the brake pad for wear R...

Page 95: ...can be adjusted by turning the adjuster brake lever with the index number on the adjuster BRAKE PEDAL HEIGHT ADJUSTMENT Loosen the lock nut and turn the push rod until the correct pedal height is obtained BRAKE LIGHT SWITCH The front brake Adjust the brake light switch so that the brake light light switch does comes on just prior to the brake actually being not require engaged adjustment If the li...

Page 96: ... of the clutch lever FREE PLAY 10 20 mm 3 8 13 16 in Minor adjustments are made using the upper ad juster at the clutch lever Loosen the lock nut and turn the adjuster NOTICE The adjuster may be damaged if it is positioned too far out leaving minimal thread engagement If the adjuster is threaded out near its limit and the correct free play cannot be obtained turn the adjust er all the way in and b...

Page 97: ...the transmission in neutral then shift the transmission into gear with the clutch lever squeezed Move the side stand full down The engine should stop as the side stand is lowered If there is a problem with the system check the side stand switch section 19 SUSPENSION FRONT SUSPENSION INSPECTION Loose worn or Check the action of the forks by operating the front damaged brakes and compressing the fro...

Page 98: ... turn the adjuster screws more than the given positions or the adjusters may be damaged Be sure that the rebound and compression adjusters are firmly located in a detent and not between positions The compression and rebound damping can be adjusted by turning the adjusters DIRECTION H Increases the damping force DIRECTION S Decreases the damping force Turn the compression adjuster clockwise until i...

Page 99: ...orn swingarm bearings by grabbing the rear swingarm and attempting to move the swingarm side to side Replace the bearings if any are looseness is noted Check the action of the shock absorber by compressing it several times Check the entire shock absorber assembly for signs of leaks damage or loose fasteners Replace damaged components which cannot be repaired Tighten all nuts and bolts Refer to sec...

Page 100: ...s then turn the adjuster counterclockwise COMPRESSION ADJUSTER STANDARD POSITION 1 turn from full hard Turn the rebound adjuster clockwise until it stops then turn the adjuster counterclockwise REBOUND ADJUSTER STANDARD POSITION 2 turns from full hard NUTS BOLTS FASTENERS Check that all chassis nuts and bolts are tightened to their correct torque values page 1 13 Check that all safety clips hose c...

Page 101: ...Measure the tread depth at the center of the tires Replace the tires when the tread depth reaches the following limits MINIMUM TREAD DEPTH FRONT 1 5 mm 0 06 in REAR 2 0 mm 0 08 in STEERING HEAD BEARINGS Check that the control cables do not interfere with handlebar rotation Support the motorcycle securely and raise the front wheel off the ground Check that the handlebar moves freely from side to si...

Page 102: ...ngine If any portion of the oil pump is worn beyond the specified service limits replace the oil pump as an assembly After the oil pump has been installed check that there are no oil leaks and that oil pressure is correct SPECIFICATIONS ITEM STANDARD Unit mm in SERVICE LIMIT Engine oil capacity At draining 3 5 Q 3 7 US qt 3 1 Imp qt At disassembly 4 0 Q 4 2 US qt 3 5 Imp qt At oil filter change 3 ...

Page 103: ...haft Internal oil leak 29 N m 3 0 kgf m 22 Ibf f t 74 N m 7 5 kgf m 54 Ibf f t Apply a locking agent to the threads 8 N m 0 8 kgf m 5 8 Ibf ft CT bolt 15 N m 1 5 kgf m 11 Ibf f t Apply a locking agent to the threads 26 N m 2 7 kgf m 20 Ibf f t Apply clean engine oil to the O ring 30 N m 3 1 kgf m 22 Ibf ft Apply a locking agent to the threads Low oil pressure Clogged oil strainer screen Oil pump w...

Page 104: ...0 MA70000 Start the engine and increase the rpm to 5 400 rpm and read the oil pressure OIL PRESSURE 490 kPa 5 0 kgf cm 2 71 psi at 5 400 rpm 80 C 176 F Stop the engine and remove the tools Apply a locking agent to the sealing plug threads Install and tighten the sealing plug to the specified torque TORQUE 30 N m 3 1 kgf m 22 lbf ft OIL STRAINER PRESSURE RELIEF VALVE REMOVAL Drain the engine oil pa...

Page 105: ...icking or damage Inspect the spring for weakness or damage Assemble the relief valve in the reverse order of disassembly Apply oil to the new gasket and install it onto the oil strainer Install the oil strainer into the crankcase while aligning its boss with the groove of the crankcase RELIEF VALVE 0 qx RELIEF VALVE BODY SPRING SNAP RING 0 PISTON WASHER 0 GASI E1 I 3 N OIL STRAINER Manuals by Moto...

Page 106: ...scross pattern in 2 3 steps Install the exhaust pipe page 2 20 Fill the crankcase with recommended oil page 3 15 After installation check that there are no oil leaks REMOVAL Remove the following Clutch assembly page 9 4 Oil strainer and pressure relief valve page 4 4 Remove the bolt washer then remove the oil pump drive driven sprocket clutch outer guide and drive chain as an assembly LUBRICATION ...

Page 107: ... the outer and inner rotors into the oil pump body Measure the tip clearance SERVICE LIMIT 0 20 mm 0 008 in OIL PUMP BOLTS 0 0 DISASSEMBLY DOWEL PINS ASSEMBLY BOLT I Remove the dowel pins Remove the oil pump assembly bolt and oil pump cover OIL PUMP COVER 0 INNER ROTOR OUTER ROTOR OIL PUMP SHAFT DRIVE PIN WASHER 0 0 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded ...

Page 108: ...ROTOR r o Measure the pump body clearance SERVICE LIMIT 0 35 mm 0 014 in ASSEMBLY DOWEL PINS INNER ROTOR 0 DRIVE PIN OIL PUMP SHAFT WASHER m LUBRICATION SYSTEM Y 0 OIL PUMP COVER 8 N m 0 8 kgf m 5 8 Ibf ft Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 109: ...stall the oil pump cover and tighten the assembly bolt to the specified torque TORQUE 8 N m 0 8 kgf m 5 8 Ibf ft Check the oil pump operation by turning the pump shaft If necessary reassemble the oil pump iNSTALLATiON Install the oil pump into the crankcase while align ing the pump shaft lug with the water pump shaft groove Install and tighten the three flange bolt securely DRIVE PIN OIL PUMP INNE...

Page 110: ...age 9 9 After installation fill the crankcase with recom mended oil and check that there is no oil leaks Check the oil pressure page 4 3 Drain the engine oil and remove the oil filter cartridge page 3 16 Drain the coolant from the system page 6 4 Remove the radiator reserve tank page 6 17 Loosen the hose bands and disconnect the oil cooler water hoses from the cooler Remove the oil cooler mounting...

Page 111: ...roove with the rib on the crankcase Apply oil to the oil cooler mounting bolt threads and seating surface Install the lock Install the lock washer and oil cooler bolt washer with its concave side O mark facing the oil cooler 0 wi I NO m COOLER BOLT VA 74 N m 7 5 kgf V O RING WATER HOSES OIL COOLER T _ _ O RING 01 ALIGN MOUNTING BOLT O MARK Q WASHER Manuals by Motomatrix www motomatrix co uk The So...

Page 112: ...the oil cooler water hoses tighten the hose band securely Install the oil filter cartridge and fill the crankcase with recommended oil page 3 15 Fill the cooling system and bleed air page 6 4 LUBRICATION SYSTEM MOUNTING BOLT OIL COOLER WATER HOSES I Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 113: ...7 22 N m 2 2 kgf m 16 Ibf ft 3 N m 0 35 kgf m 2 5 Ibf ft qe IO O 1 r lip o 4 11 p 1 0 f CO of a I IS V 0 1 Aft 22 N m 2 2 kgf m 16 Ibf ft Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 114: ...ration resulting in loss of vehicle control 5 1 MAP SENSOR 5 83 5 3 IAT SENSOR 5 84 5 4 ECT SENSOR 5 85 5 6 CAM PULSE GENERATOR 5 85 TP SENSOR 5 86 BANK ANGLE SENSOR 5 88 ENGINE STOP RELAY 5 89 ECM ENGINE CONTROL MODULE 5 89 5 56 PAIR SOLENOID VALVE 5 91 5 59 PURGE CONTROL SOLENOID VALVE 5 60 CALIFORNIA TYPE ONLY 5 92 5 61 02 SENSOR CALIFORNIA TYPE ONLY 5 92 5 66 EGCV AND AIR INTAKE VALVE INSPECTI...

Page 115: ...map It must be remembered however that when any abnormality is detected in four injectors and or the ignition and cam pulse generator the fail safe function stops the engine from the standpoint of protecting it For PGM FI system location see page 5 4 A faulty PGM FI system is often related to poorly connected or corroded connectors Check those connections before proceeding For fuel reserve sensor ...

Page 116: ...m Engine stall hard to start rough idling Intake air leak Fuel contaminated deteriorated Pinched or clogged fuel tube Idle speed misadjusted Starter valve synchronization misadjusted FUEL SYSTEM Programmed Fuel injection 23 N m 2 3 kgf m 17 Ibf ft See page 1 14 3 N m 0 35 kgf m 2 5 lbf ft 10 N m 1 0 kgf m 7 Ibf ft 10 N m 1 0 kgf m 7 Ibf ft 1 N m 0 09 kgf m 0 7 Ibf ft 1 N m 0 09 kgf m 0 7 Ibf ft 5 ...

Page 117: ...BANK ANGLE SENSOR FUEL CUT RELAY ECM At w tee o 00 o 1_ y 01 II II ECT SENSOR VEHICLE SPEED SENSOR IGNITION PULSE GENERATOR FULL NAME ABBREVIATIONS Manifold absolute pressure sensor __ M AP sensor Throttle_position sensor _TP sensor Intake air temperature sensor j IAT sensor Engine coolant temperature _ senso r ECT sensor Engine control module ECM Manuals by Motomatrix www motomatrix co uk The Sol...

Page 118: ...ENSOR VEHICLE SPEED SENSOR IGNITION PULSE GENERATOR TP SENSOR IAT SENSOR MAP SENSOR FUEL SYSTEM Programmed Fuel Injection FULL NAME ABBREVIATIONS Manifold absolute pressure sensor MAP sensor Throttle position sensor TP sensor _ Intake air temperature sensor IAT sensor Engine coolant temperature sensor ECT sensor Engine control module ECM Manuals by Motomatrix www motomatrix co uk The Solution For ...

Page 119: ...AIR solenoid valve TP sensor EGCV and air intake valve servo motor MAP sensor 6 0 ze 9 24 23 U J 30 31 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Injector Cam pulse generator PAIR check valve ECT sensor Ignition pulse generator Coolant temperature LCD Fuel cut relay Fuel pump Vehicle speed sensor Neutral switch Clutch switch Side stand switch Malfunction indicator lamp Service check connector Ta...

Page 120: ...jector 32 0 25 3 FUEL SYSTEM Programmed Fuel Injection 126 9 777 24 23 I 29 30 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 Cam pulse generator PAIR check valve ECT sensor Ignition pulse generator Coolant temperature LCD Fuel cut relay Fuel pump Vehicle speed sensor Neutral switch Clutch switch Side stand switch Malfunction indicator lamp Service check connector Tachometer EVAP purge control...

Page 121: ...MIL does not light or blink the system has no memory of problem data If the malfunction indicator blinks note how many times the malfunction indicator lamp MIL blinks and determine the cause of the problem page 5 12 through 5 55 If you wish to read the PGM FI memory for trouble data perform the following Turn the ignition switch OFF Remove the seat page 2 2 Short the PGM Fl system service check co...

Page 122: ... the service check connector 5 The MIL lights about 5 seconds While the indicator lights short the service check connector again with the jumper wire Self diagnosis memory data is erased if the MIL turn off and start blinking The service check connector must be jumped while the indicator lights If not the MIL will not start blinking Note that the self diagnosis memory data cannot be erased if you ...

Page 123: ...s depending upon the internal impedance of the multimeter Disconnect the fuel pump connector before check ing the peak voltage Open and support the front end of fuel tank page 3 4 Disconnect the fuel pump 3P Black connector Connect the peak voltage adaptor to the digital multimeter TOOLS Peak voltage tester U S A only or Peak voltage adaptor 07HGJ 0020100 with commercially available digital multim...

Page 124: ...t harness terminals are same layout as for the ECIVI connector terminals as shown FUEL SYSTEM Programmed Fuel Injection 22P LIGHT GRAY CONNECTOR RA L I 22P BLACK CONNECTOR ECIVI ECLI TEST HARNESS ECIVI O NT Wt VIEW FROM WIRE HARNESS SIDE Al All BI A12 A22 B12 Bll B22 A 22P BLACK CONNECTOR B 22P LIGHT GRAY CONNECTOR FOR 22P BLACK CONNECTOR FOR 22P LIGHT GRAY CONNECTOR 34 2 W NONES IN illec TioTiOTM...

Page 125: ...tch ground Blown sub fuse 10 A Starter ignition O Open or short circuit in MIL wire Engine operates normally No blinks Faulty ECM Causes Short circuit in service check connector wire Faulty ECM Loose or poor contacts on MAP sensor con nector Open or short circuit in MAP sensor wire Faulty MAP sensor Loose or poor connection of the MAP sen sor vacuum tube Blinks Faulty MAP sensor Loose or poor cont...

Page 126: ... circuit in cam pulse genera tor Blinks Faulty cam pulse generator Loose or poor contact on ignition pulse generator connector 19 Open or short circuit in ignition pulse gen erator Blinks Faulty ignition pulse generator Faulty O sensor 21 Blinks Faulty 02 sensor heater 23 Blinks Faulty EGCV and motor air intake valve servo FUEL SYSTEM Programmed Fuel Injection Symptoms Fail safe contents Engine op...

Page 127: ...asure the voltage at the wire harness side con nector Connection Yellow Red Ground Standard 4 75 5 25 V Measure the voltage between the connector ter minals of the wire harness side Connection Yellow Red l Green Orange Standard 4 75 5 25 V 1 blink Voltage exists I V Voltage exists No blinks Out of range Out of range a v Loose or poor contact on the MAP sensor connec tor Open or short circuit in Ye...

Page 128: ...the ECM connectors Connect the test harness to ECM connectors Turn the ignition switch ON rc I 0 ev is i n 7 w 7 si z 1z 7 s n Connection B7 B1 Standard 2 7 3 1 V 760 mm Hg 1 013 kPa Out of range Out of range FUEL SYSTEM Programmed Fuel Injection Open or short circuit in Light green Yellow wire Loose or poor contact on the ECM connectors Faulty MAP sensor Voltage exists Replace the ECM with a new ...

Page 129: ...sing a 3 way joint Start the engine and measure the manifold absolute pressure at idle speed Standard 150 250 mm Hg Disconnect the vacuum gauge and connect the tube to the MAP sensor j Disconnect the ECM connectors Connect the test harness to the ECM connector 9 Out of range Check the tube installation Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email inf...

Page 130: ...W 19 z zoz z 1 A T T T T T Connection B7 B1 Standard 2 7 V maximum 6 Voltage exists 6 W Out of range Out of range Voltage exists FUEL SYSTEM Programmed Fuel Injection Faulty MAP sensor Faulty MAP sensor Replace the ECM with a new one and inspect it again Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 131: ... the ignition switch ON H Check that the MIL blinks 7 blinks Turn the ignition switch OFF Disconnect the ECT sensor connector Measure the resistance at the ECT sensor termi nals Connection Pink White Green Orange sensor side terminals Standard 2 3 2 6 k SQ 20 C 68 F Normal No blinks Abnormal Loose or poor contact on the ECT sensor connec tor Faulty ECT sensor Manuals by Motomatrix www motomatrix c...

Page 132: ...reen Orange Standard 4 75 5 25 V Voltage exists Ou of range Out of range Voltage exists FUEL SYSTEM Programmed Fuel Injection Open or short circuit in Pink and Pink White wire Loose or poor contacts on the ECM connector Open or short circuit in Green Orange wire Loose or poor contacts on the ECM connector I Replace the ECM with a new one and inspect it again Manuals by Motomatrix www motomatrix co...

Page 133: ...e ignition switch OFF 8 blinks Disconnect the TP sensor 3P connector Turn the ignition switch ON Measure the voltage between the wire harness side connector terminal and ground Connection Yellow Red Ground Standard 4 75 5 25 V Voltage exists No blinks Out of range is Loose or poor contact on the TP sensor connec tor Open or short circuit in the Yellow Red wire Loose or poor contact on the ECM conn...

Page 134: ...ed Green Orange Standard 4 75 5 25 V 1 Voltage exists Turn the ignition switch OFF Disconnect the ECM 22P connectors No continuity Out of range Continuity FUEL SYSTEM Programmed Fuel Injection Open or short circuit in Green Orange wire Loose or poor contact on the ECM connectors qrl 12 e 4 a Ck I a Short circuit in Red Yellow wire Manuals by Motomatrix www motomatrix co uk The Solution For Lost Mo...

Page 135: ... Cnntinuiry Connect the TP sensor 3P connector Turn the ignition switch ON Measure the vokage at the test harness terminals Connection B8 8l Standard 0 4 0 0V throttle fully closed 4 2 4 8 V throttle fully open No continuity Normal Out of range Open or short circuit in Red Yellow wire Replace the ECM with a new one and inspect it again Faulty TPsensor Manuals by Motomatrix www motomatrix co uk The...

Page 136: ...tage of 4 75 V at the TP sensor 3P connector 0 4 X 4 75 5 0 0 38 V 0 6 X 4 75 5 0 0 57 V Thus the solution is 0 38 0 57 V with the throttle fully closed Replace 0 4 and 0 6 with 4 2 and 4 8 respectively in the above equations to determine the throttle fully open range FUEL SYSTEM Programmed Fuel injection Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email ...

Page 137: ...ide stand Turn the ignition switch ON Check that the MIL blinks Turn the ignition switch OFF Disconnect the IAT sensor 2P connector Measure the resistance at the IAT sensor at 20 30 C 68 86 F r Standard 1 4 k 2 Turn the ignition switch ON 9 blinks Normal No blinks Abnormal i P Loose or poor contact on the IAT sensor connec tor I Faulty IAT sensor Manuals by Motomatrix www motomatrix co uk The Solu...

Page 138: ...tandard 4 75 5 25 V Out of range Out of range Voltage exists FUEL SYSTEM Programmed Fuel Injection Open or short circuit in Gray Blue wire Loose or poor contact on the ECM connectors Open or short circuit in Green Orange wire Loose or poor contact on the ECM connectors Replace the ECM with a new one and inspect it again Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Co...

Page 139: ... about 20 seconds or more Put the side stand down and check that the MIL blinks Turn the ignition switch OFF 11 blinks Disconnect the vehicle speed sensor 3P connec tor Turn the ignition switch ON Measure the voltage at the wire harness side connector 1 V Connection Black Brown Green Black Standard 12 V Voltage exists No blinks Out of range Loose or poor contact on the vehicle speed sensor connect...

Page 140: ...easure the voltage at the test harness terminals with the ignition switch is ON while slowly turning the rear wheel by hand 1771 CONNECTION B17 Ground STANDARD Repeat 0 to 5V Abnormal Normal FUEL SYSTEM Programmed Fuel Injection Open or short circuit in Pink Green wire I Replace the ECM with a new one and inspect it again Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle ...

Page 141: ... stand Turn the ignition switch ON Check that the MIL blinks T 4 4v 12 blinks Turn the ignition switch OFF Disconnect the No 1 injector 2P connector and measure the resistance of the No 1 injector I Connection Black White Pink Yellow Standard 11 1 12 3 S2 20 C 68 F Normal No blinks Abnormal 11 I Faulty No 1 injector Loose or poor contact on the No 1 injector connector Manuals by Motomatrix www mot...

Page 142: ...Black White Ground Standard Battery voltage Voltage exists Turn the ignition switch OFF Connect the No 1 injector connector Disconnect the ECM connectors Connect the test harness to the wire harness con nectors 4 q Iz T Continuity Out of range FUEL SYSTEM Programmed Fuel Injection Faulty No 1 injector Open or short circuit in Black White wire Manuals by Motomatrix www motomatrix co uk The Solution...

Page 143: ...00000009 Check for continuity between the test harness terminal and ground CO OIOZOZO O ZOZOZOZ9 O T0 I MTOTOW Out of range Continuity No continuity Open circuit in Black White and or Pink Yellow wire Short circuit in Pink Yellow wire Replace the ECM with a new one and inspect it again Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co u...

Page 144: ... ON Check that the MIL blinks Q 61 Connection Black White Pink Blue Standard 11 1 12 3 2 20 C 68 F 13 blinks Turn the ignition switch OFF Disconnect the No 2 injector 2P connector and measure the resistance of the No 2 injector Normal No blinks Abnormal FUEL SYSTEM Programmed Fuel Injection 14 Ilk M Faulty No 2 injector Loose or poor contact on the No 2 injector con nector Manuals by Motomatrix ww...

Page 145: ...wire harness side and ground I Connection Black White Ground Standard Battery voltage Voltage exists Turn the ignition switch OFF Connect the No 2 injector connector to Disconnect the ECM connectors Connect the test harness to the wire harness con nectors Continuity Out of range Faulty No 2 injector Open or short circuit in Black White wire Manuals by Motomatrix www motomatrix co uk The Solution F...

Page 146: ...ion A3 Ground Standard No continuity Normal too 0101011611 1 1010101010 100 T IP TONT 01 Out of range Continuity No continuity FUEL SYSTEM Programmed Fuel Injection Open circuit in Black White and or Pink Blue wire Short circuit in Pink Blue wire Replace the ECM with a new one and inspect it again Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info mot...

Page 147: ...stand Turn the ignition switch ON Check that the MIL blinks Turn the ignition switch OFF Disconnect the No 3 injector 2P connector and measure the resistance of the No 3 injector Lt G Connection Black White Pink Green Standard 11 1 12 3 2 20 C 68 F i W4 I 9 14 blinks Normal No blinks Abnormal Faulty No 3 injector Loose or poor contact on the No 3 injector con nector Manuals by Motomatrix www motom...

Page 148: ...tion Black White Ground Standard Battery voltage Voltage exists Turn the ignition switch OFF Connect the No 3 injector connector Disconnect the ECM connectors Connect the test harness to the wire harness connectors Continuity Out of range FUEL SYSTEM Programmed Fuel Injection Faulty No 3 injector Open or short circuit in Black White wire Manuals by Motomatrix www motomatrix co uk The Solution For ...

Page 149: ...uity Normal Check for continuity between the test harness terminal and ground aa Out of range Continuity No continuity Open circuit in Black White and or Pink Green wi re Short circuit in Pink Green wire Replace the ECM with a new one and inspect it again Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 150: ...that the MIL blinks Turn the ignition switch OFF Disconnect the No 4 injector 2P connector and measure the resistance of the No 4 injector mar Connection Black White Pink Black Standard 11 1 12 3 SQ 20 C 68 F to 1 GW I 15 blinks r Normal No blinks Abnormal FUEL SYSTEM Programmed Fuel Injection Faulty No 4 injector J I Loose or poor contact on the No 4 injector con nector Manuals by Motomatrix www ...

Page 151: ...arness side and ground 1 I Connection Black White r Ground Standard Battery voltage Voltage exists Turn the ignition switch OFF Connect the No 4 injector connector r is Disconnect the ECM connectors Connect the test harness to the wire harness con nectors 1 Out of range Open or short circuit in Black White wire Continuity Faulty No 4 injector a Manuals by Motomatrix www motomatrix co uk The Soluti...

Page 152: ... a 0000 0009 Connection A13 Ground Standard No continuity Normal MINIM a 1 WINTON Out of range Continuity No continuity FUEL SYSTEM Programmed Fuel Injection Open circuit in Black White and or Pink Black wire Short circuit in Pink Black wire Replace the ECM with a new one and inspect it again Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatr...

Page 153: ...he MIL blinks 1 18 blinks No continuity No blinks Turn the ignition switch OFF and the engine stop switch OFF Disconnect the cam pulse generator 2P connec tor Turn the ignition switch OFF Check the continuity between the cam pulse gen erator connector terminal and ground Connection Gray Ground White Ground Standard No continuity Continuity t a t r r 1 Loose or poor contact on the cam pulse genera ...

Page 154: ...nnectors rm 1 Crank the engine with the starter motor and measure the cam pulse generator peak voltage at the test harness terminals c1 Connection B22 Ground Standard 0 7 V minimum 20 C 68 F Out of range Out of range Normal FUEL SYSTEM Programmed Fuel Injection Faulty cam pulse generator Open circuit in White Yellow and or Gray wire Replace the ECM with a new one and inspect it again Manuals by Mo...

Page 155: ...k that the MIL blinks Turn the ignition switch OFF and the engine stop switch OFF Disconnect the ignition pulse generator 2P con nector 1 Check the continuity between the ignition pulse generator side connector terminal and ground Connection Yellow Ground White Yellow Ground Standard No continuity 19 blinks No continuity No blinks Continuity 11 FCC All y Loose or poor contact on the ignition pulse...

Page 156: ... V 1 Crank the engine with the starter motor and measure the ignition pulse generator peak volt age at the test harness terminals O UO 910088 UP I Z Connection B11 Ground Standard 0 7 V minimum 20 C 68 F Out of range Out of range Normal FUEL SYSTEM Programmed Fuel Injection Faulty ignition pulse generator Open circuit in White Yellow wire Open circuit in Yellow wire Replace the ECM with a new one ...

Page 157: ...between the test harness terminal and 02 sensor connector terminal Connection Orange White A5 Standard Continuity 1 Continuity Check the continuity between the 0 2 sensor connector terminal and ground Connection Orange white Ground Standard No continuity No continuity No continuity Continuity cco h Ir J TWO Open circuit in 02 sensor Orange White wire Short circuit in 0 2 sensor Orange White wire M...

Page 158: ...ess terminals 00000 to 010016101 ORSTOTOT 911POTSTOTOW Connection B1 B4 Standard With the throttle fully open 0 6 V minimum With the throttle quickly closed 0 4 V maximum re00 707 e Out of range FUEL SYSTEM Programmed Fuel Injection Faulty 02 sensor Normal Check the fuel supply system if the system is correct replace the ECM and inspect again Manuals by Motomatrix www motomatrix co uk The Solution...

Page 159: ...tch OFF Connect the 0 2 sensor connector Short the service check connector page 5 8 Start the engine and check that the MIL blinks 23 blinks f Disconnect the 02 sensor 4P connector Measure the resistance at the sensor side connector White terminals l c Connection White White Standard 10 40 C_2 Normal Out of range Faulty 0 2 sensor Manuals by Motomatrix www motomatrix co uk The Solution For Lost Mo...

Page 160: ... SYSTEM Programmed Fuel Injection Faulty 02 sensor Turn the ignition switch OFF Disconnect the ECM 22P connector Turn the ignition switch ON Measure the voltage at the O z sensor wire har ness side connector terminals r Connection Black White Black Green Standard Battery voltage 1 Open circuit in O z sen sor Black Green wires 1 Battery voltage No voltage Replace the ECM and inspect again Manuals b...

Page 161: ...ltage Battery voltage Turn the ignition switch OFF Connect the 02 sensor 4P connectors 1 1 Disconnect the ECM connectors Connect the test harness to the wire harness connectors No voltage Open circuit in Black White wire between the 0 sensor and engine stop relay Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 162: ...ltage No voltage Battery voltage FUEL SYSTEM Programmed Fuel Injection Open circuit in Black Green wire between the ECM connector and O z sensor 4P connector Replace the ECM and inspect again Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 163: ...nd check that the MIL blinks Remove the jumper wire from the service check connector page 5 9 r 1 Except 33 blinks I 1 Turn the ignition switch ON and check that the MIL blinks 33 blinks 33 blinks Other than 33 blinks Except 33 blinks Reset the self diagnosis memory data page 5 9 Turn the ignition switch ON and check that the MIL blinks No problem no blinks 33 blinks Replace the ECM Manuals by Mot...

Page 164: ...Reset the self diagnosis memory data page 5 9 Turn the ignition switch ON and check that the MIL blinks Except 33 blinks Except 33 blinks 33 blinks FUEL SYSTEM Programmed Fuel Injection No problem no blinks No problem no blinks I Replace the ECM Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 165: ...tand Turn the ignition switch ON and check that the MIL blinks 1 34 blinks Normal No blinks Turn the ignition switch OFF and the engine stop switch OFF Disconnect the servo motor 6P connector Measure the resistance at the servo motor 6P connector terminals d i i J Connection Yellow Red Green Orange Standard 5 k S 20 C 68 F Abnormal ur Loose or poor contact on the servo motor 6P con nector Faulty s...

Page 166: ... harness ter minal and servo motor 6P connector terminals of the wire harness side Connection Al Red A12 Blue B1 Green Orange B5 Yellow Red B16 Light green Pink Standard Continuity Abnormal No continuity Continuity FUEL SYSTEM Programmed Fuel Injection Faulty servo motor Open circuit in related wire Replace the ECM with a new one and inspect it again Manuals by Motomatrix www motomatrix co uk The ...

Page 167: ... switch ON and check that the MIL blinks 35 blinks Turn the ignition switch OFF and the engine stop switch OFF Disconnect the servo motor 6P connector 1041 r J _J Disconnect the control cables from the servo motor Turn the ignition switch ON and check that the MIL blinks 35 blinks No blinks No blinks H 11h 0 W 1 0 Loose or poor contact on the servo motor 6P con nector 0 Check the intake exhaust va...

Page 168: ...continuity between the test harness terminal and servo motor 6P connector terminals of the wire harness side F1_ 1 Connection Al Red A12 Blue Standard Continuity Normal Abnormal No continuity Continuity FUEL SYSTEM Programmed Fuel Injection Faulty servo motor Open circuit in related wire Replace the ECM with a new one and inspect it again Manuals by Motomatrix www motomatrix co uk The Solution For...

Page 169: ...t the battery negative cable from the battery terminal Open and support the front end of fuel tank page 5 61 Disconnect the pressure regulator vacuum tube and plug the vacuum tube Cover the fuel tube banjo bolt with a rag or shop towel Slowly loosen the fuel tube banjo bolt and catch the remaining fuel using a approved gasoline container NEGATIVE TERMINAL BATTERY P RESSURE REGULATOR M TUBE II I i ...

Page 170: ... following Pinched or clogged fuel return tube Pressure regulator Fuel pump page 5 59 If the fuel pressure is lower than specified the following Fuel line leaking Clogged fuel filter Pressure regulator Fuel pump page 5 59 After inspection remove the fuel tube banjo bolt and reinstall and tighten the original fuel tube banjo bolt using the new sealing washers TORQUE 22 N m 2 2 kgf m 16 Ibf ft Conne...

Page 171: ...ne Disconnect the fuel return tube at the pressure regulator plug the pressure regulator inlet joint Turn the ignition switch ON for 10 seconds Measure the amount of fuel flow Amount of fuel flow 188 cm 6 4 US oz 6 6 Imp oz minimum 10 seconds If the fuel flow is less than specified inspect the following Pinched or clogged fuel tube and fuel return tube Clogged fuel filter Pressure regulator Fuel p...

Page 172: ...fuel 30A Sub fuse 10A 20A Engine stop switch page 19 18 Fuel cut relay page 5 60 Engine stop relay page 5 89 Bank angle sensor page 5 88 ECM page 5 89 REMOVAL NOTICE Before disconnecting the fuel tube release the fuel pressure by loosening the fuel tube banjo bolt at the fuel tank Always replace the sealing washers when the fuel tube banjo bolt is removed or loosened Remove the fuel tank page 5 61...

Page 173: ...fuel pump being careful not to damage the fuel pump wire Install and tighten the fuel pump mounting nuts in the sequence shown TORQUE 12 N m 1 2 kgf m 9 lbf ft FUEL CUT RELAY INSPECTION Remove the fuel tank rear bracket and ECM cover page 5 89 Disconnect the fuel cut relay 4P connector remove the fuel cut relay FUEL FILTER SCREV PACKII FUEL TUBES FUEL PUMP ASSEMBLY 4 Me FUEL PUMP 2 N UTS 0 FUEL CU...

Page 174: ...there is no continuity when the 12 V battery is connected replace the fuel cut relay FUEL TANK REMOVAL Remove the fuel tank front mounting bolts and washers Remove the fuel tank rear mounting bolt and collar Temporarily install the fuel tank rear mounting bolt FUEL SYSTEM Programmed Fuel Injection FUEL CUT RELAY BATTERY fLlEl 0 h LFRS BOLT COLLAR MOUNTING BOLT Manuals by Motomatrix www motomatrix ...

Page 175: ...g nut and sealing washers then disconnect the fuel tube Do not apply excessive force to the fuel pipe NOTICE Always hold the fuel pipe nut while removing the fuel tube sealing nut Temporarily install a 12 x 30 mm bolt pitch 1 25 and sealing washers to the fuel tube banjo then tighten the sealing nut SUITABLE SUPPORT 310 mm O HI LCUW FUBE 3P BLACK CONNECTOR AIR VEN TUBE FUEL TUBE FUEL PIPE NUT 11 W...

Page 176: ...uel return tube from the fuel pump Remove the fuel tube banjo bolt and sealing washers then remove the fuel tube from the fuel pump Refer to page 5 59 for fuel pump removal INSTALLATION n r h FUEL TANK a r 22 N m 2 2 kgf m 16 lbf f t J o La FUEL SYSTEM Programmed Fuel Injection BANJO BOLT FUEL RETURN TUBE FUEL TUBE 22 N m 2 2 kgf m 16 lbf f t F IFS RETURN TUBE 5 63 Manuals by Motomatrix www motoma...

Page 177: ...to the frame temporarily install the fuel tank rear mounting bolt and support the front end of fuel tank using a suitable support 310 mm Connect the fuel tank air vent tube and overflow tube to the fuel tank Connect the fuel return tube to the pressure regulator Do not apply excessive force to the fuel pipe BANJO BOLT FUEL RETURN TUBE a SEALING WASHERS FUEL TUBE SUITABLE SUPPORT 310 mm OVEF F 1 AI...

Page 178: ... 2 kgf m 16 lbf ft 40 0 0 0 S NOTICE Connect the fuel pump reserve sensor 3P Black connector Remove the supporting tool and close the fuel tank Install the fuel tank mounting collar and bolt FUEL SYSTEM Programmed Fuel Injection FUELTUBE SEALING NUT 11 SEALING WASHERS Install the fuel tank front mounting bolts and ERS washers then tighten the front and rear fuel tank mounting bolts I 3R BLACK CONN...

Page 179: ... and vacuum tube Remove the air funnel air cleaner housing mount ing screws then remove the air funnels Disconnect the crankcase breather tube and PAIR control valve air suction tube from the air cleaner housing Remove the air cleaner housing See page 5 107 for intake air control valve disassembly assembly SERVO MOTOR BOLT AIR CLEANER HC1 J l B E e BLI I MOTOR PULL REWS 1A SENSER CC l F R i IBE AI...

Page 180: ...ng mounting screws Connect the MAP sensor connector and vacuum tube Connect the variable air intake control cable to the servo motor pulley Install the servo motor onto the bracket then tighten the bolt securely Install the air cleaner element page 3 5 FUEL SYSTEM Programmed Fuel Injection AIR CLEANER HOUSIHH R E I HEM T AIR SUCTION TUBE REWS MA SENSnR niv VEC T OR t NM Fig jI CvAB SERVO MOTOR Rh1...

Page 181: ...k page 5 61 Air cleaner housing page 5 66 Remove the throttle cable guide bracket mounting bolts Disconnect the throttle cable ends from the throttle drum Remove the throttle stop screw knob from the bracket Loosen the hose band screws and disconnect the fast idle wax unit water hoses from the wax unit Disconnect the TP sensor connector and fuel injector connectors If you will not be disassembling...

Page 182: ...fter the throttle body has been removed NOTICE Do not damage the throttle body It may cause incorrect throttle and idle valve synchronization 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 bolts and screws of the throttle body Loosening or tightening them can cause throttle and idle valve synchronization f...

Page 183: ...AINTED THROTTLE LINK VIEW WHITE PAINTED 0 10 N m 1 0kgf m 7 Ibf ft 1 N m 0 09 kgf m 0 7 Ibf ft RIGHT SIDE VIEW O 0 0 WHITE PAINTED STARTER VALVE LINK VIEW WHITE PAINTED I lId 0 REAR VIEW THROTTLE DRUM VIEW 1 N m 0 09 kgf m 0 7Ibf ft Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 184: ...ion Install the throttle body onto the cylinder head NOTICE 1tW I M IA looi 9m1 l ij 1 m 1 _ mar t 1 Do not hold the fuel pipe on the throttle body while installing the throttle body FUEL SYSTEM Programmed Fuel Injection r INSULATORS p Tam an v s 1 THROTTLE BODY n INSULATOR BAND SCREWS 0 r L 5 71 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info moto...

Page 185: ... water hoses to the unit then tighten the tube bands securely Install the throttle cable guide bracket to the throttle body then tighten the bolts to the specified torque TORQUE 3 N m 0 35 kgf m 2 5 lbf ft Install the removed parts in the reverse order o removal 12 1 mm 0 5 0 04 in TP SENSOR CONNECTOR N INJECTOR CONNECTORS WA X U N i 1 I WATER HOSE I K11 L 11 L tsRACKET Manuals by Motomatrix www m...

Page 186: ...e the throttle body page 5 68 Remove the bolts and fuel pipe assembly Remove the injectors from the fuel pipe Remove the seal ring O ring and cushion ring FUEL SYSTEM Programmed Fuel Injection SOUNDING ROD INJECTOR FUEL PIPE ASSEMBL SEAL RING FUEL INJECTOR BOLTS CUSHION RING 0 RING Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 187: ...ge the 0 ring and cushion ring Install the fuel pipe assembly onto the throttle body being careful not to damage the seal rings Install and tighten the fuel pipe mounting bolts to the specified torque TORQUE 10 N m 1 0 kgf m 7 Ibf ft Install the throttle body page 5 71 SEAL RING s FUEL PIPE ASStiMBL r FUEL INJECTORS 14 0 0 3 1 CUSHION RING O RING FUEL PIPE ASSEMBLY 0 0 0 FUEL INJECTOR S 11 0 Manua...

Page 188: ...ulator body Install the pressure regulator onto the fuel pipe FUEL SYSTEM Programmed Fuel Injection PRESSURE REGULATOR BOLTS 7O RING Hold the fuel pipe securely tighten the pressure regulator mounting bolts to the specified torque TORQUE 10 N m 1 0 kgf m 7 Ibf ft Connect the vacuum tube to the pressure regulator FAST IDLE WAX UNIT DISASSEMBLY Remove the wax unit mounting screws PRESSURE REGULATOR ...

Page 189: ...in a criss cross pattern in 2 3 steps Remove the wax element spring seat and compres sion spring INSPECTION Visually inspect the wax element for damage and return spring for fatigue or damage vaX UNIT WAX ELEMENT 0 0 ARM 0 VV n ELEMENT COVER SCREWS 0 WAX ELEMENT SPRING SPRING SEAT Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 190: ...oss pattern in 2 3 steps Install the wax unit shaft joint piece to the wax unit link arm Install and tighten the wax unit mounting screws to the specified torque TORQUE 5 N m 0 5 kgf m 3 6 lbf ft FUEL SYSTEM Programmed Fuel Injection WAX ELEMENT SPRING 0 RINGS SPRING SEAT ELEMENT COVER SCREWS JOINT PIE F X UNIT WAX UNIT I SCREWS W 0 5 1 O RING a1 Manuals by Motomatrix www motomatrix co uk The Solu...

Page 191: ...tarter valve arm No 1 2 starter valve Remove the fast idle wax unit page 5 75 Remove the starter valve arm screws and starter valve arms Remove the screw and fast idle wax unit link arm Loosen the lock nut and remove the starter valve assembly STARTER VALVE tj No 3 4 STARTER VALVE S P QR E i No 1 2 STARTER VALVE STARTER VALVE ARM LINIK AR 3T T R CREW i D Ah I tH v AL4 r i f Manuals by Motomatrix w...

Page 192: ... collars and thrust spring INJECTOR ASSEMBLY 10 N m 1 0 kgf m 7 lbf ft i FUEL PIPE Q A 71 i FUEL SYSTEM Programmed Fuel Injection PRESSURE REGULATOR 10 N m 1 0 kgf m 7 Ibf ft STARTER VALVE Ilk COLLARS ti 5 N m 0 5 kgf m 3 6 Ibf ft STAR TIER VAL1VE SHAFT THRNNIcT SPRING 1 N m 0 09 kgf m 0 7 Ibf ft 5 79 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info...

Page 193: ...f m 1 3 Ibf ft No 3 4 starter valve Compress the thrust spring and install the No 3 4 starter valve arm onto the starter valves Install and tighten the starter valve arm mounting screws to the specified torque TORQUE 1 N m 0 09 kgf m 0 7 Ibf ft COLLARS STARTE R L L f H RING I JE LOCK NUT STA I ER i No 3 4 STARTER VALVE 1 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle C...

Page 194: ...SYNCHRONIZATION Synchronize the starter valve with the engine at the normal operating temperature and with the transmission in neutral Use a tachometer with graduations of 50 rpm or smaller that will accurately indicate 50 rpm change Open and support the front end of fuel tank page 3 4 Remove the vacuum joint screws Connect the vacuum gauge adaptors to the vacuum joints then connect the tubes to t...

Page 195: ...m pressure with the No 1 valve cannot be cylinder adjusted it is the base starter valve Remove the plugs and connect the PAIR air suction hoses to the reed valve covers PLUG AIR SUCTION HOSE PAIR REED VALVE COVER THROTTLE STOP SCREW q Well Irr No 4 SCREW No 3 SCREW No 2 SCREW PLUG i PAIR REED VALVE COVER AIR SUCTION HOSE Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle C...

Page 196: ... MAP sensor output voltage above is meas ured under the standard atmosphere 1 atm 1 030 hPa The MAP sensor output voltage is affected by the distance above sea level because the output voltage is changed by atmosphere Check the sea level measurement and be sure that the measured voltage falls within the specified value FUEL SYSTEM Programmed Fuei Injection 1W THROTTLE STOP SCREW VACUUM JOINT SCREW...

Page 197: ...g Installation is in the reverse order of removal IAT SENSOR REMOVAL INSTALLATION Open and support the front end of fuel tank page 3 4 Disconnect the IAT sensor connector Remove the screws and IAT sensor from the air cleaner housing cover Installation is in the reverse order of removal r SCO RE 1ACttri IoNII THE 1 TL i MAP SENSOR NNECTOR Manuals by Motomatrix www motomatrix co uk The Solution For ...

Page 198: ...nstall the new sealing washer and ECT sensor sealing washer Tighten the ECT sensor to the specified torque with a new one TORQUE 23 N m 2 3 kgf m 17 lbf ft Connect the ECT sensor connector Fill the cooling system with recommended coolant page 6 5 0 w Disconnect the cam pulse generator 2P Natural connector Remove the bolt and cam pulse generator from the cylinder head FUEL SYSTEM Programmed Fuel Ir...

Page 199: ...loose or corroded termi nals Connect the ECU test harness between the ECM and main wire harness TOOLS ECU test harness 07YMZ 0010100 two required 1 INPUT VOLTAGE INSPECTION Turn the ignition switch ON and measure and record the input voltage at the test harness termi nals using a digital multimeter CONNECTION B5 B1 Standard 4 5 5 5 V If the measurement is out of specification check the following L...

Page 200: ...measured in step 2 is within 10 of Vo With the throttle fully closed Measured input voltage X 0 1 Vc The sensor is normal if the throttle closed output voltage measured in step 3 is within 10 of Vc Using an analog meter check that the needle of the voltmeter swings slowly when the throttle is opened gradually CONTINUITY INSPECTION Open and support the front end of fuel tank page 3 4 Disconnect the...

Page 201: ... shown and ignition switch ON The bank angle sensor is normal if the engine stop relay clicks and power supply is closed Incline the bank angle sensor approximately 60 degrees to the left or right with the ignition switch ON The bank angle sensor is normal if the engine stop relay clicks and power supply is open If you repeat this test first turn the ignition switch OFF then turn the ignition swit...

Page 202: ...ollowing engine stop relay connector terminals CONNECTION Red Orange Black There should be continuity only when the 12V battery is connected If there is no continuity when the 12V battery is connected replace the engine stop relay ECM ENGINE CONTROL MODULE SYSTEM INSPECTION Remove the fuel tank mounting bolts page 5 61 Remove the bolts and fuel tank rear bracket FUEL SYSTEM Programmed Fuel Injecti...

Page 203: ...at all times If there is no continuity check for open circuit in Green Pink wire and Green wire POWER INPUT LINE Turn the ignition switch ON wire the engine stop switch in RUN position Measure the voltage between the ECM test harness connector B6 terminal and ground There should be battery voltage If there is no voltage check for open circuit in Black White wire between the ECM and bank angle sens...

Page 204: ...ould not flow A to B only when the 12 V battery is connected to the PAIR solenoid valve terminals Check the resistance between the terminals of the PAIR solenoid valve STANDARD 20 24 kD 20 C 68 F If the resistance is out of specification replace the PAIR solenoid valve FUEL SYSTEM Programmed Fuel Injection 2P NATURAL CONNECTOR may 0 t i 1 r PAIR CONTROL SOLENOID VALVE W 11 BOLT AIR SUCTION HOSES B...

Page 205: ...minals Check the resistance between the terminals of the EVAP purge control valve STANDARD 30 34 k 2 20 C 68 F If the resistance is out of specification replace the EVAP purge control valve O2 SENSOR CALIFORNIA TYPE ONLY REMOVAL Do not service the 0 2 sensor while it is hot NOTICE Handle the 0 sensor with care Do not get grease oil or other materials in the 0 sensor air hole Open and support the f...

Page 206: ...n impact wrench while removing or installing the Oz sensor Install the O sensor unit Tighten the unit to the specified torque TORQUE 25 N m 2 6 kgf m 19 Ibf ft FUEL SYSTEM Programmed Fuel Injection CLAMP RIGHT STEP GUARD C BOLTS 02 SENSOR WIRE w S ZD RIGHT STEP GUARD r 02 SENSOR UNIT 6 02 SENSOR UNIT Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info ...

Page 207: ...nnector EGCV AND AIR INTAKE VALVE INSPECTION Before operating inspection check that the PGM Fl warning indicator does not indicate EGCV failure Remove the middle lower cowl page 2 5 Remove the air cleaner element page 3 5 Remove the bolts and EGCV pulley cover O SENSOR WIRE RIGHT STEP GUARD D D 0 D D D 0 0 n D 1 O 0 CLAMP 11 RIGHT STEP GUARD w 1 t BOLTS 4P NATURAL CONNECTOR 0V I 0 L A II BOLTS it ...

Page 208: ... about 8 000 rpm Also check that the intake flap valve is opened at the same time If the intake and EGCV position is incorrect adjust the cables see following steps If the intake and EGCV operation is incorrect check for each related parts CABLE ADJUSTMENT Remove the seat page 2 2 Turn the ignition switch ON and engine stop switch in RUN Short the service check connector with a jumper wire FUEL SY...

Page 209: ...rning the adjusting nut Move the cable several times and recheck the index line Hold the No 1 cable adjusting nut then tighten the lock nut securely Turn the No 2 cable lock nut and adjust the cable so that there is no free play Tighten the No 2 cable lock nut securely Remove the jumper wire from the service check connector 0 0 I ift 000 0 1k I INDEX LINES ADJUSTING NUT 0 O No 1 CABLE LOCK NUT ADJ...

Page 210: ...the index line on the valve shaft At this point turn back the cable adjuster 1 2 turn Tighten the lock nut securely Remove the jumper wire from the service check connector EGCV AND AIR INTAKE VALVE SERVO MOTOR REMOVAL Open and support the front end of fuel tank page 3 4 Disconnect the servo motor 6P Natural connector Remove the servo motor mounting bolt and pull out the servo motor from the bracke...

Page 211: ...rn replace the servo motor with a new one Measure the resistance between the servo motor 6P Natural connector terminals Connection Yellow Red Green Orange Standard 5 k 2 Connection Light green Pink Green Orange Standard 0 5 k2 If the resistance is out of range replace the servo motor INSTALLATION Connect the servo motor 6P Natural connector 004 1010 a J t O O n o u OOH 6P NATURAL CONNECTOR mar_114...

Page 212: ...es to each position then connect the intake valve control cable Adjust the intake and exhaust valve control cables page 5 95 Remove the 3 mm socket bolt from the servo motor pulley Install the servo motor onto the bracket Install and tighten the servo motor mounting bolt Connect the servo motor 6P Natural connector FUEL SYSTEM Programmed Fuel Injection 3 mm SOCKET BOLT l 1 PULLEY 01 0 SERVO MOTOR ...

Page 213: ...each position then connect the intake valve control cable Adjust the intake and exhaust valve control cables page 5 95 Remove the 3 mm socket bolt from the servo motor pulley Install the servo motor onto the bracket Install and tighten the servo motor mounting bolt Connect the servo motor 6P Natural connector FUEL SYSTEM Programmed Fuel Injection 3 mm SOCKET BOLT l i PULLEY I D I 4 m 4 I SERVO MOT...

Page 214: ...the EGCV pre load using a torque wrench PRE LOAD 34 N m 3 5 kgf m 25 lbf ft maximum If pre load is excessive disassemble and inspect the EGCV REMOVAL Remove the exhaust pipe assembly page 2 18 Remove the bolts front exhaust pipe and gasket Remove the bolts rear exhaust pipe and gasket 0 90 0 0 O 180 0 MIN FRONT EXHAUST PIPE BOLTS REAR EXHAUST PIPE 0 4 0 0 BOLTS Manuals by Motomatrix www motomatrix...

Page 215: ...he thrust washer B if it is wear or damage Remove the EGCV cover mounting bolts cable stay EGCV cover and metal gasket Remove the EGCV from the valve body Remove carbon deposits from the EGCV and valve body NOTICE Do not use any cleaning solution to clean the EGCV bushings Do not apply any lubricant to the EGCV bushings Check that the EGCV for wear or damage Check that the EGCV body for wear or da...

Page 216: ...eats using the special tools TOOLS Installer shaft guide 07YMF MCJ0100 Installer shaft 07YMF MCJ0200 Press the EGCV bushing in using the special tool TOOLS Installer shaft guide 07YMF MCJ0100 Installer shaft 07YMF MCJ0200 Press the valve cover side EGCV bushing out using the following tool TOOL Remover 14 X 16 mm 07YMF MCJ0400 REMOVER CAP BUSHING INSTALLER SHAFT CAP SHAFT GUIDE 0 3 0 5mm 0 01 0 02...

Page 217: ...ing the special tool bushing until its end projected 0 3 TOOL 0 5 mm 0 01 Installer shaft 14 X 30 mm 07YMF MCJ0300 0 02 in from the valve cover surface as shown VALVE COVER EXHAUST VALVE Install the EGCV into the EGCV body FUEL SYSTEM Programmed Fuel Injection INSTALLER SHAFT 0 3 0 5mm 0 01 0 02 in z J BUSHING CABLE GUIDE 12 N m 1 2 kgf m 9 lbf f t EGCV 0 4 q0 o A 5 103 Manuals by Motomatrix www m...

Page 218: ...6 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 219: ...he thrust washer B Install the thrust Install the thrust washer B and A onto the spring washer B with its retainer chamfered side facing to the spring retainer Make sure that the Install the thrust spring onto the EGCV cover thrust spring is seated on the Install the spring retainer assembly onto the thrust exhaust valve spring cover boss METAL GASKET 0 VALVE COVER a INDEX MARK VALVE COVER ro CABL...

Page 220: ... the valve shaft tab as shown Check the EGCV pre load using a torque wrench PRE LOAD 34 N m 3 5 kgf m 25 lbf ft maximum If pre load is excessive reassemble the EGCV EGCV INSTALLATION Install the metal gasket and rear exhaust pipe onto the EGCV body FUEL SYSTEM Programmed Fuel Injection PULLEY GROOVE i nN TAB e NUT e PULLEY VALVE BODY 4 10 c REAR EXHAUST PIPE METAL GASKET 5 105 Manuals by Motomatri...

Page 221: ...xhaust pipe assembly page 2 20 Connect the EGCV control cables and adjust the control cables page 5 95 Remove the EGCV cover front upper bolt Install EGCV cable guide pulley cover and tighten the bolts to the specified torque TORQUE 12 N m 1 2 kgf m 9 Ibf f t REAR EXHAUST PIPE 1 BOLTS FRONT EXHAUST PIPE a VALVE BODY dJ METAL GASKET FRONT EXHAUST PIPE BOLTS ILKL BOLTS IV 0I PULLEY COVER Manuals by ...

Page 222: ... the air cleaner housing Remove the intake valve shaft holder mounting screws and holder Remove the air guide A and B mounting screws Remove the intake valve flap shaft assembly air guide A and B FUEL SYSTEM Programmed Fuel Injection CONTROL CABLE VALVE FLAP N DRUM 0 i RETURN SPRING CONTROL CABLE n I AIR GUIDE A AIR GUIDE B illlli IIIIIP FLAP SHAFT ASSEMBLY SCREWS 5 107 Manuals by Motomatrix www m...

Page 223: ...shaft assembly onto the air cleaner housing Install the air guide A and B then tighten the mounting screws Install the intake valve shaft holder plate with its UPPER mark facing up Install and tighten the mounting screws FLAP VALVE SHAFT ASSEMBLY AIR GUIDE AIR GUIDE B RETURN SPRING L FLAP SHAFT ASSEMBLY AIR GUIDE RETURN SPRINGS AIR GUIDE A IIIIIIg N ItIIIIIIN FLAP SHAFTASSEMBLY SCREWS AIR GUIDE B ...

Page 224: ...l the air cleaner housing page 5 67 Open the intake valve flap by hand connect the intake valve control cable end to the drum Adjust the variable air intake valve control cable page 5 95 FUEL SYSTEM Programmed Fuel Injection CONTROL CABLE DRUM U RETURN SPRING CONTROL CABLE INTAKE VALVE CABLE ADJUSTER 5 109 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email...

Page 225: ...nduce vomiting gargle and consult a physician immediately If any coolant gets on your skin or clothes rinse thoroughly with plenty of water NOTICE G SYSTEM Using coolant with silicate inhibitors may cause premature wear of water pump seals or blockage of radiator passages Using tap water may cause engine damage Add cooling system at the reserve tank Do not remove the radiator cap except to refill ...

Page 226: ...re gauge or ECT thermo sensor Thermostat stuck open Faulty cooling fan motor switch 3 22 3 4USgt 2 8Impgt 0 4 a 0 4 US qt 0 4 Imp qt _ 10 _ 8_ 137 kPa 1 1 1 4 kgf cm 2 16 20 psi 80 5 83 5 C 177 182 F 95 C 203 F SPECIFICATIONS 8 mm 0 3 in minimum High quality ethylene glycol antifreeze containing corrosion protection in hibitors 50 mixture with soft water 12 N m 1 2 kgf m 9 lbf ft CT bolt 23 N m 2 ...

Page 227: ... 017 1 016 1 015 1 014 1 013 1 01111 009 1 007 1 005 1 028 1 027 1 026 1 025 1 024 1 022 1 020 1 018 1 018 1 016 1 014 1 012 1 036 1 035 1_03411 033 1 031 1 029 1 02711 025 1 023 1 021 1 019 1 04411 043 1 1 042 1 040 1 038 1 0361 1 034 1 031 1 028 1 025 1 053 1 052 1 051 1 047 1 046 1 045 1 043 1 041 1 03811 035 1 032 1 063 1 062 1 060 1 058 i 1 056 1 054 1 052 1 049 1 046 1 0431 1 040 1 072 1 070...

Page 228: ... psi Repair or replace components if the system will not hold specified pressure for at least 6 seconds COOLANT REPLACEMENT PREPARATION The effectiveness of coolant decreases with the accumulation of rust or if there is a change in the mixing proportion during usage Therefore for best performance change the coolant regularly as specified in the maintenance schedule Mix only distilled low mineral w...

Page 229: ...d coolant through the filler opening up to filler neck Remove the radiator reserve tank cap and fill the reserve tank to the upper level line Bleed air from the system as follow 1 Shift the transmission into neutral Start the engine and let it idle for 2 3 minutes 2 Snap the throttle 3 4 times to bleed air from the system 3 Stop the engine and add coolant up to the proper level if necessary Reinst...

Page 230: ...ect the thermostat for damage Check for damage of the seal ring Heat the water with an electric heating element to operating temperature for 5 minutes Suspend the thermostat in heated water to check its operation Replace the thermostat if the valve stays open at room temperature or if it responds at temperatures other than those specified THERMOSTAT BEGIN TO OPEN 80 5 83 5 C 177 182 F VALVE LIFT 8...

Page 231: ... thermostat housing onto the cylinder head Install and tighten the thermostat housing mount ing bolts Connect the fast idle wax unit water hose and bypass hose Connect the ECT sensor connector THERMOSTAT INSTALLATION Install the thermostat into the housing with its air bleed hole facing rearward a COOLING SYSTEM BOLTS ECT SENSORCDNNI THERMOSTAT H BOLTS SOF r THFRM STV I vSIN I AND W 2 4h i3AEEE1Ft...

Page 232: ...om the radiator Disconnect the upper radiator hose Disconnect the fan motor switch connector from the switch release the wire from the inner middle cowl Disconnect the radiator sub harness 2P Black connector Disconnect the lower radiator hose and oil cooler water hose ItHERMOSTATHO IW k SIPHON TUBE i n n UPPER RADIATOR HOSE AIR BLEED TUBE FAN MOTOR SWITCH CONNECTOR t v2P BLACK CONNECTOR i OIL C0 A...

Page 233: ...rame boss Remove the radiator assembly DISASSEMBLY Release the fan motor sub harness connector from the fan motor bracket Remove the three bolts ground eyelet and cooling fan motor assembly iT COOLING SYSTEM 4 BOLT WASHEIT UPPER GROMMET r RADIATOR GROUND EYELET CONNECTOR BOLTS q W Ak COOLING FAN MOTOR ASSEMBLY Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys e...

Page 234: ...itch information refer to page 19 14 ASSEMBLY 18 N m 1 8 kgf m 13 lbf ft ID RADIATOR a NUT COOLING FAN N FLANGE NUTS FAN MOTOR 3 N m 0 27 kgf m 2 0 Ibf ft COOLING FAN b 04 COLLAR 5 N m 0 5 kgf m O 3 6 I of ft FAN MOTOR FAN MOTOR BRACKET Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 235: ...all and tighten the nut to the specified torque TORQUE 3 N m 0 27 kgf m 2 0 Ibf ft Install the cooling fan motor assembly onto the radiator Route the ground eyelet properly Install and tighten the bolts Install the radiator sub harness connector to the fan motor bracket FLANGE NUTS FAN MOTOR DISTANCE COLLAR ALIGN LOCK N UT COOLING FAN COOLING SYSTEM GROUND EYELET CONNECTOR BOLTS f wyJ A i COOLING ...

Page 236: ... Install the radiator lower mounting bolt nut tighten the nut securely Connect the fan motor sub harness 2P Black connector Connect the lower radiator hose and oil collar water hose UPPER GROMMET i d I r n r 1 I RADIATOR BOLT WASHE 2P BLACK CONNECTOR OIL C _ L EF VVATERs I Ov E RA IATOR HOSE Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatri...

Page 237: ...s of coolant leakage If there is leakage the mechanical seal is defective and replace the water pump as an assembly f REMOVAL Drain the coolant page 6 4 Disconnect the lower radiator hose bypass hose and oil cooler water hose from the water pump cover COOLING SYSTEM SIPHON TUBE UPPER RADIATOR HOSE AIR BLEED TUBE C FAN MOTOR SWITCH CONNECTOR m s INSPECTION t HOLE OIL COOLER WATER HOSE BYPASS HOSE H...

Page 238: ... the water pump body from the crankcase Disconnect the water pump to water joint hose from the water pump body I f k I 401 n 0 A L01 ri WATER PUMP COVER BOLTS WATER PUMP BODY 10 0 O RING WATER HOSE WATER PUMP BODY Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 239: ... it onto the stepped portion of the water pump Install the water pump into the crankcase while aligning the water pump shaft groove with the oil pump shaft end WATER PUMP BODY 00m r GO A I 1 FRI FA 1 4 k a limp Or a WATER HOSE I ICI ILI i w WATER PUMP BODY O RING COOLING SYSTEM Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 240: ... hose bypass hose and oil cooler water hose then tighten the clamp screws Fill the system with recommended coolant page 6 5 RADIATOR RESERVE TANK REMOVAL Remove the middle lower cowl page 2 5 Disconnect the siphon tube and drain coolant from the reserve tank Remove the radiator reserve tank lower mounting bolt WATER PUMP BODY WATER PUMP COVER 1 _nom a iI rill lrlft w 61 O BOLTS OIL COOLER WATER HO...

Page 241: ...HON TUBE OVERFLOW TUBE 0 RESERVE TANK Route the overflow tube properly page 1 23 Install and tighten the reserve tank upper mounting bolt COOLING SYSTEM OVERFLOW TUBE BOLT RESERVE TANK 0 0 OVERFLOW TUBE 0 J ME Ar BOLT 0 o RESERVE TANK Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 242: ...g bolt Connect the siphon tube to the reserve tank Install the removed parts in the reverse order of removal RESERVE TANK SIPHON TUBE BOLT Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 243: ...ting socket bolt Main step mounting bolt Bank sensor Lower bracket mounting nut 10 mm Lower bracket mounting pinch bolt Engine hanger nut front Engine hanger nut middle Engine hanger nut rear Rear engine hanger pinch bolt Side stand bracket bolt Drive sprocket special bolt ITEM Radiator and engine 11 i At disassembly SPECIFICATIONS 62 1 kg 136 9 Ibs 3 2 a 3 4USgt 2 8Impgt 4 0 Q 4 2 US qt 3 5 Imp q...

Page 244: ...11 Swingarm page 14 14 Disconnect the side stand 2P Green connector Remove the bolts and side stand bracket assembly Remove the lower bracket front socket bolt and nut Loosen the rear socket bolt pinch bolt s 1 2P GREEN CONNECTOR BOLTS A 1 0 0 0 SIDE STAND BRACKET I FRONT SOCKET BOLT NUT REAR SOCKL BOLT PINCH BOLT 0 0 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Code...

Page 245: ...e 8 5 Disconnect the following connectors Ignition pulse generator 2P Red connector Speed sensor 3P Natural connector Engine sub harness 2P Blue connector Disconnect the alternator 3P White connector ENGINE REMOVAL INSTALLATION R SOCKET BOLT PAIR CONTROL THROTTLE BODY SOLENOID VALVE L V 9 is IGNITION COIL SUB HARNESS 3P NATURAL CONNECTOR 2P RED CONNECTOR 2P BLUE CONNECTOR i lowls Am rJ 1 a l P 3P ...

Page 246: ...arter motor mounting bolt and starter motor ground cable Remove the terminal nut and starter motor cable Remove the bolts and clutch cable guide then disconnect the clutch cable from the clutch lifter lever i GROUND Co RL F LIFTEI I E I TERM ka l T H ll iclr BOLTS E I 3OR CON I M F TER MOTOR CABLE 0 0 I LI 1Y v 7 i lEHMUSI AAl HOUSiNrr 0 I 0 0 LUTCH CABLE CABLE GUIDE 0 T i Manuals by Motomatrix ww...

Page 247: ...ack or other adjustable support to ease of engine hanger bolts removal Remove left side of the front 10 mm and middle 12 mm engine hanger bolts Remove the right side of the front 10 mm and middle 12 mm engine hanger bolts and distance collars ENGINE REMOVAL INSTALLATION WATER HOSE LOWER BRACKET SIPHON TUBE RESERVE TANK I LOWER RADIAiTOR HOSE mm HANGER BOLT 12 mm HANGER BOLT ti 2 mm HANGER BOLT 10 ...

Page 248: ...into the frame damage the cam chain tensioner Install the rear engine hanger socket bolt and nut lifter Note the direction of the hanger bolts Use a floor jack or other adjustable support to carefully maneuver the engine into place REAR HANGER BOLT PINCH BOLT REAR HANGER BOLT NUT REAR HANGER BOLT NUT Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info ...

Page 249: ...nce collars NOTICE Hold the rear engine hanger socket bolt then tighten the nut to the specified torque TORQUE 54 N m 5 5 kgf m 40 lbf ft ENGINE REMOVAL INSTALLATION inm HANGER BOLT 10 mm HANGER BOLT NCE COLL mm HANGER BOLT 12 mm HANGER BOLT REAR HANGER BOLT NUT 3t Tighten the rear engine hanger pinch bolt to the FAR HANGER BOLT specified torque TORQUE 26 N m 2 7 kgf m 20 Ibf ft PINCH BOLT A Manua...

Page 250: ...bf f t Connect the lower radiator hose to the water pump cover and tighten the hose band screw Connect the oil cooler to radiator water hose to the oil cooler tighten the hose band securely Install the radiator reserve tank and mounting bolts tighten the bolts Connect the siphon tube to the reserve tank Install the radiator lower mounting bolt nut tighten the nut securely 7 h 1 r LOWER RADIATI R H...

Page 251: ...ighten the mounting bolts securely Install and tighten the thermostat housing mount ing bolts Connect the ECT sensor connector GROUND ENGINE REMOVAL INSTALLATION CLUTCH CABLE CABLE GUIDE k 3 BOLTS F cep cn MOTOR CH LE Install a new O ring into the thermostat housing 0 RING groove Install the thermostat housing to the cylinder head S v r HERMOSTTAiT HOUSINt niF Tn HERMOSiTHyi_hUVo vG Manuals by Mot...

Page 252: ...n coil spark plug sub harness page 8 31 PAIR control solenoid valve assembly page 8 31 Lower bracket page 7 11 Throttle body page 5 71 EGCV and air intake valve servo motor page 5 98 Fuel tank page 5 63 Pour recommended engine oil up to the proper level page 3 15 Fill the cooling system with recommended coolant and bleed the air page 6 4 I THERMOSTAT HOUq JVE P11 0 L IN 3P WHITE CONNECTOR 2P RED C...

Page 253: ...REMOVAL INSTALLATION PINCH BOLT 26 N m 2 7 kgf m 20 lbf ft PINCH BOLT I 26 N m 2 7 kgf m SWINGARM PIVOT BOLT 1 20 lbf ft J Jor 26 N m 2 7 kgf m 20 lbf ft 10 mm SOCKET BOLT NUT 10 mm SOCKET BOLT NUT 10 mrri OCKET BOLT I 10 mm SOCKET BOLT NUT 41 1 11V I SWINGARM PIVOT NUT Hold the swingarm pivot bolt then tighten the pivot nut to the specified torque TORQUE 118 N m 12 0 kgf m 87 lbf ft Manuals by Mo...

Page 254: ... mm socket pinch bolt to the specified torque TORQUE 26 N m 2 7 kgf m 20 Ibf f t Install the side stand bracket assembly tighten the new bolts to the specified torque TORQUE 44 N m 4 5 kgf m 33 Ibf f t too 10 mm SOCKET BOLT NUT 10 mm SOCKET BOLT NUT I I PINCH BOLT III 10 mm SOCKET BOLT 611 0 0 41 0 SOCKET BOLTS SIDE STAND BRACKET 004 0 Manuals by Motomatrix www motomatrix co uk The Solution For Lo...

Page 255: ...he following Rear shock absorber page 14 13 Suspension linkage page 14 11 Rear fender page 2 16 Muffler exhaust pipe page 2 20 ENGINE REMOVAL INSTALLATION i N J u 2P GREEN CONNECTOR Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 256: ...re assembling cylinder head Be careful not to damage the mating surfaces when removing the cylinder head cover and cylinder head Li ER HEAD VALVES SERVICE INFORMATION 8 1 TROUBLESHOOTING 8 3 CYLINDER COMPRESSION TEST 8 4 CYLINDER HEAD COVER REMOVAL 8 5 CYLINDER HEAD COVER DISASSEMBLY CAMSHAFT REMOVAL CYLINDER HEAD REMOVAL CYLINDER HEAD DISASSEMBLY CYLINDER HEAD INSPECTION VALVE GUIDE REPLACEMENT 8...

Page 257: ...IN 0 010 0 037 0 0004 0 0015 EX 0 020 0 047 0 0008 0 0019 IN 14 3 14 6 0 56 0 57 EX 12 4 12 7 0 49 0 50 IN EX 0 90 1 10 0 035 0 043 _ 1 5 0 06 IN EX 34 80 1 370 34 1 1 34 IN EX 37 97 1 495 37 2 1 46 _ IN EX 25 978 25 993 1 0228 1 0233 25 97 1 022 IN EX 26 010 26 026 1 0240 1 0246 26 04 1 025 IN 36 _ 48 36 72 1 436 1 446 EX 36 08 36 32 1 420 1 430 0 020 0 062 0 0008 0 0024 10 N m 1 0 kgf m 7 Ibf ft...

Page 258: ...nce is poor at low speeds check for white smoke in the crankcase breather tube If the tube is smoky check for a seized piston ring Section 11 Compression too low hard starting or poor performance at low speed Valves Incorrect valve adjustment Burned or bent valve Incorrect valve timing Broken valve spring Uneven valve seating Cylinder head Leaking or damaged head gasket Warped or cracked cylinder ...

Page 259: ...ge attachment 07RMJ MY50100 Equivalent commercially available in U S A Open the throttle all the way and crank the engine with the starter motor until the gauge reading stops rising The maximum reading is usually reached within 4 7 seconds Compression pressure 1 226 kPa 12 5 kgf cm 2 178 psi at 350 rpm Low compression can be caused by Blown cylinder head gasket Improper valve adjustment Valve leak...

Page 260: ...t and PAIR control sole noid valve assembly Disconnect the crankcase breather tube Disconnect the ignition coil sub harness 9P Black connector and sub harness Place a cloth Remove the throttle cable guide bracket mounting underneath the bolts and washers bolts to avoid Disconnect the throttle cable ends from the throt dropping them tle drum into the engine area HEAT GUARD RUBBER 2P BLACK CONNECTOR...

Page 261: ...head cover bolts and washers S WAS 3s s Remove the cylinder head cover rearward _ uh ER HEADa OVER REED VALVE COVER CYLINDER HEAD COVER PACKING DISASSEMBLY Remove the cylinder head cover packing Z 4 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 262: ...emove the cylinder head cover page 8 5 To avoid damaging the cam pulse generator while removing the camshafts remove the bolt and cam pulse generator from the cylinder head S Remove the timing hole cap and O ring CYLINDER HEAD VALVES 7 AM PULSE GENERATOR OL 1 J I Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 263: ...er lifter sealing bolt and sealing washer Turn the tensioner lifter shaft fully in clockwise and secure it using the stopper tool This tool can easily be made from a thin 1 mm thickness piece of steel 15 mm 15 mm 19 mm 4 3mm 4 5 mm MATERIAL THICKNESS 1 0 mm 8 5 mm If you plan to replace the camshaft and or cam sprocket remove the cam sprocket bolts as follows Remove the cam sprocket bolts from int...

Page 264: ...cam sprocket from the camshaft Remove the bolts and camshaft holder A first Loosen and remove the remaining camshaft holder bolts then remove the camshaft holders and camshafts NOTICE From outside to inside loosen the bolts in a criss cross pattern in several steps or the camshaft holder might break CAM PULSE GENERATOR ROTOR Y fT BOLTS 4M CHAIN GUIDE B F 0 fi CYLINDER HEAD VALVES CAM SPRnCKET BOLT...

Page 265: ...AFT HOLDER Inspect the bearing surface of each camshaft hold er for scoring scratches or evidence of insufficient lubrication Inspect the oil orifices of the holders for clogging CAMSHAFT RUNOUT Support both ends of the camshaft with V blocks and check the camshaft runout with a dial gauge SERVICE LIMIT 0 05 mm 0 002 in CAM LOBE HEIGHT Using a micrometer measure each cam lobe height SERVICE LIMITS...

Page 266: ...ve the camshaft holders and measure the width of each plastigauge The widest thickness determines the oil clearance SERVICE LIMIT 0 10 mm 0 004 in When the service limits are exceeded replace the camshaft and recheck the oil clearance Replace the cylinder head and camshaft holders as a set if the clearance still exceeds the service limit CAM CHAIN GUIDE B Inspect the cam chain slipper surface of t...

Page 267: ...ing washer and drain bolt Remove the bolts and cam chain tensioner lifter and gasket Remove the two 8 mm flange bolts Loosen the 9 mm Remove the ten 9 mm bolts washers bolts in a crisscross pattern Remove the cylinder head in 2 3 steps Remove the dowel pins and cylinder head gasket CYLINDER DRAIN BOLT SEALING WASHFI GASKET TENSIONER LIFTER BOLTS 9 mm BOLTS 8 mm BOLTS DOWEL PINS N GASKET Manuals by...

Page 268: ...from the cylinder head Install the tappet hole protector into the valve lifter bore TOOL Tappet hole protector 07HMG MR70002 Not available in U S A An equivalent tool can easily be made from a plastic 35 mm film container as shown Ci M CHAIN TENSIONIER CYLINDER HEAD VALVES ROtH T TAF HLE PROTECTOR CAM CHAIN GUIDE CAM CHAIN 5 mm 15 mm 5 mm 4 kr o 3 mm 25 mm I D when compressed TOP VIEW 8 13 Manuals...

Page 269: ...llowing Spring retainer Outer and inner valve springs Valve Stem seal Valve spring seat CYLINDER HEAD INSPECTION CYLINDER HEAD Avoid damaging Remove carbon deposits from the combustion the gasket surface chambers Check the spark plug hole and valve areas for cracks Check the cylinder head for warpage with a straight edge and feeler gauge SERVICE LIMIT 0 10 mm 0 004 in INNER SPRING OUTER SPRING RET...

Page 270: ...ey are shorter than the service limits VALVE LIFTER Inspect each valve lifter for scratches or abnormal wear Measure the each valve lifer O D SERVICE LIMIT 25 97 mm 1 022 in VALVE LIFTER BORE Inspect each valve lifter bore for scratches or abnor mal wear Measure the each valve lifter bore I D SERVICE LIMIT 26 04 mm 1 025 in CAM CHAIN TENSIONER CYLINDER HEAD VALVES CAM CHAIN GUIDE r1 Manuals by Mot...

Page 271: ...D SERVICE LIMIT IN EX 4 540 mm 0 1787 in Subtract each valve stem O D from the correspond ing guide I D to obtain the stem to guide clearance STANDARDS IN 0 010 0 037 mm 0 0004 0 0015 in EX 0 020 0 047 mm 0 0008 0 0019 in Reface the valve If the stem to guide clearance is out of standard seats whenever determine if a new guide with standard dimensions the valve guides would bring the clearance wit...

Page 272: ... the cylinder head SPECIFIED DEPTH IN 14 3 14 6 mm 0 56 0 57 in EX 12 4 12 7 mm 0 49 0 50 in TOOL Valve guide driver 07HMD MLOO101 Let the cylinder head cool to room temperature Use cutting oil on Ream the new valve guide after installation the reamer during Insert the reamer from the combustion chamber this operation side of the head and also always rotate the reamer clockwise VALVE GUIDE REAMER ...

Page 273: ...the valves and seats using a rubber hose of other hand lapping tool Remove and inspect the valves Inspect the width of each valve seat STANDARD 0 90 1 10 mm 0 035 0 043 in SERVICE LIMIT 1 5 mm 0 06 in If the seat is too wide too narrow or has low stops the seat must be ground VALVE SEAT REFACING Valve seat cutters grinders or equivalent valve seat refacing equipment are recommended to correct worn...

Page 274: ...t to the proper width Make sure that all pitting and irregularities are removed Refinish if necessary Apply a thin coating of Prussian Blue to the valve seat Press the valve through the valve guide and onto the seat to make a clear pattern If the contact area is too high on the valve the seat must be lowered using a 32 degrees flat cutter CYLINDER HEAD VALVES OLD SEAT WIDTH 32 1 0 mm 0 04 in 45 CO...

Page 275: ... 0 Lubricate the valve stems with molybdenum disul fide oil and insert the valve into the valve guide To avoid damage to the stem seal turn the valve slowly when inserting INNER SPRING OUTER SPRING RETAINER Install the valve springs with the tightly wound coils facing the combustion chamber Install the valve spring retainer CYLINDER HEAD VALVES TAPPET HOLE PROTECTOR EXHAUST STEM SEAL INLET STEM SE...

Page 276: ...ve stems gently with two plastic cylinder head hammers as shown to seat the cotters firmly above the work bench surface to prevent possible valve damage CYLINDER HEAD INSTALLATION Install the timing sprocket by aligning the wide teeth between the crankshaft and sprocket Install the cam chain 8 22 ALIGN VALVE SPRING COMPRESSOR PLASTIC HAMMERS TIMING SPROCKET CAM CHAIN Manuals by Motomatrix www moto...

Page 277: ...ASHER WASHER SOCKET BOLT Tighten the cam chain guide and cam chain CAM CHAIN TENSIONER tensioner socket bolts to the specified torque TORQUE Cam chain tensioner socket bolt 10 N m 1 0 kgf m 7 Ibf ft Cam chain guide socket bolt 12 N m 1 2 kgf m 9 lbf ft Install the ignition pulse generator rotor and right crankcase cover page 17 8 SOCKET BOLT CAM CHAIN TENSIONER CYLINDER HEAD VALVES n QCK CAM CHAIN...

Page 278: ...m 5 2 kgf m 38 lbf ft Tighten the 8 mm flange bolts to the specified torque TORQUE 24 N m 2 4 kgf m 17 Ibf ft Install the cam chain tensioner lifter onto the cylin der head with new gasket Install and tighten the mounting bolts Install the engine into the frame page 7 6 CAMSHAFT INSTALLATION Apply molybdenum disulfide oil to the outer sur face of the each valve lifter Install the shims and valve l...

Page 279: ... shown Clean and apply a locking agent to the cam sprock et bolt threads Install the cam sprocket bolts Clean and apply a locking agent to the cam pulse generator rotor threads Install the cam pulse generator rotor and mounting bolts Turn the crankshaft clockwise and align the T mark on the ignition pulse generator rotor with the index mark on the right crankcase cover CYLINDER HEAD VALVES NO 1 CY...

Page 280: ...ake sure that the timing marks on the cam sprockets are facing outward and flush with the cylinder head upper surface as shown Install the each camshaft holder onto the camshafts Install the each camshaft holder to the correct loca tions with the identification marks A Right camshaft holder B Center camshaft holder C Left camshaft holder Temporarily install the twelve holder bolts and seal ing was...

Page 281: ...ighten the bolts In case the cam sprockets were removed tighten the cam sprocket bolts to the specified torque TORQUE 20 N m 2 0 kgf m 14 Ibf f t Turn the crankshaft clockwise one full turn 360 and tighten the other cam sprocket bolts In case the cam pulse generator rotor bolts were removed apply locking agent to the rotor bolt threads Install and tighten the rotor bolts to the specified torque TO...

Page 282: ... the new O ring and install it onto the cam pulse generator Install the cam pulse generator into the cylinder head Install and tighten the mounting bolt securely STOPPER TOOL F CAM CHAIN TENSIONER LIFTER BOLT i SEALING WASHER i iiJG NERATOR CAM PULSE GENERATOR LT Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 283: ...tighten the bolts to the specified torque TORQUE 12 N m 1 2 kgf m 9 Ibf ft Install the PAIR check valve port plates into the cylinder head cover Install the PAIR check valves into the cylinder head cover CYLINDER HEAD VALVES BREATHER SEPARATOR BOLTS BREATHER SEPARATOR PORT PLATES PAIR CHECK VAI EC Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info mot...

Page 284: ...ly sealant to the cylinder head semi circular cutouts as shown Install the cylinder head cover onto the cylinder head Install the washers with their UP mark facing up PACKING SEAL O CYLINDERIH 0 VER s r 00 011 VP UP MARK Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 285: ...nstall the direct ignition coils and spark plug sub harness Connect the cam pulse generator 2P Natural con nector Install the PAIR solenoid valve assembly and con nect the air suction hoses to the PAIR reed valve cover Install and tighten the PAIR solenoid valve mounting bolt Connect the PAIR solenoid valve 2P Natural con nector Connect the crankcase breather tube CYLINDER HEAD VALVES REED VALVE C...

Page 286: ...l tank page 3 4 Remove the cam chain tensioner sealing bolt and sealing washer Turn the tensioner shaft fully in clockwise and se cure it using the stopper tool to prevent damaging the cam chain See page 8 8 for detail of the tool 2P BLACK CONNECTOR J HEAT GUARD RUBBER CAM CHAIN TENSIONER LIFTER l i SEALING WASHER a BOLT STOPPER TOOL Manuals by Motomatrix www motomatrix co uk The Solution For Lost...

Page 287: ...ll the cam chain tensioner lifter into the cylin der head Install and tighten the mounting bolts Remove the stopper tool CYLINDER HEAD VALVES TENSIONER LIFTER GASKET i BOLTS 0 0 0 GASKET 0 99 TENSIONER LIFTER BOLTS STOPPER TOOL A 8 33 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 288: ...a new sealing washer and tighten the sealing bolt securely CAM CHAIN TENSIONER LIFTER BOLT l N i i fl SEALING WASHER Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 289: ...121 25 000 25 021 0 9843 0 9851 34 975 34 991 1 3770 1 3776 24 980 24 993 0 9835 0 9840 12 000 7 12 018 0 4724 0 4731 5 93 6 00 0 233 0 236 11 957 11 968 0 4707 0 4712 SERVICE LIMIT 47 4 1 87 2 6 0 10 2 6 0 10 0 30 0 012 25 03 0 985 34 97 1 377 24 96 0 983 12 03 0 474 5 9 0 23 11 95 0 470 TORQUE VALUES Clutch center lock nut Clutch spring bolt washer Shift drum center socket bolt Shift drum stoppe...

Page 290: ... clutch lifter mechanism Clutch lifter piece installed improperly Hard to shift Improper clutch operation Improper oil viscosity Bent shift fork Bent shift fork shaft Bent fork claw Damaged shift drum cam groove Loose stopper plate bolt Damaged stopper plate and pin Damaged gearshift spindle Equivalent commercially available in U S A Transmission jumps out of gear Worn shift drum stopper arm Weak ...

Page 291: ...ARSHIFT LINKAGE 7 nU LI The lifter arm Remove the right crankcase cover SH bolts RIGHT CRANK f c COUtr BOLTS spindle is engaged Remove the right crankcase cover while turning the wit the clutch clutch lifter arm counterclockwise to disengage the lifter piece inside lifter arm spindle from the lifter piece the right crankcase cover 11 Remove the two dowel pins Clean any sealant off from the right c...

Page 292: ... with the washer and spring in the reverse order of removal REMOVAL Remove the right crankcase cover page 9 3 Remove the clutch spring bolts springs and pres sure plate Remove the clutch lifter piece from the lifter bear ing Remove the following Nine clutch discs Eight clutch plates Judder spring Judder spring seat RETURN SPRING LIFTER LEVER NEEDLE BEARINGS P _ PRESSURF4 Q PP _ I T u r 0 0 r OIL S...

Page 293: ...Clutch center holder 07724 0050002 Equivalent commer cially available in U S A Discard the lock nut Remove the lock washer thrust washer and clutch center Remove the washer CLUTCHIG ARSH FT Lei AG U 1 i LOCH F HRUST I Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 294: ...CTION Clutch lifter bearing Turn the inner race of the lifter bearing with your finger The bearing should turn smoothly and freely with out excessive play If necessary replace the bearing Clutch spring Measure the clutch spring free length SERVICE LIMIT 47 4 mm 1 87 in i CH OU f r FIVE CH 0 i rilvc IR E HER LIFTER BEARING 1 0 0 0 0 SUB GEAR OUTER TIDE DRIVE u _r c 4 I Manuals by Motomatrix www mot...

Page 295: ...Clutch plate Check each disc plate for warpage on a surface plate using a feeler gauge Clutch disc Replace the clutch discs if they show signs of scoring or discoloration Measure the disc thickness of each disc SERVICE LIMIT 2 6 mm 0 10 in SERVICE LIMIT 0 30 mm 0 012 in CLUTCHIGEARSHIFT LINKAGE Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motoma...

Page 296: ...25 03 mm 10 985 in Mainshaft Measure the mainshaft O D at clutch outer guide sliding surface SERVICE LIMIT 24 96 mm 0 983 in CLUTCH OUTER NEEDLE BEARING REPLACEMENT Press the needle bearing out of the clutch outer using the special tools TOOLS Driver 07749 0010000 Attachment 42 X 47 mm 07746 0010300 Pilot 35 mm 07746 0040800 a 0 0 0 0 9 0 Manuals by Motomatrix www motomatrix co uk The Solution For...

Page 297: ...UST WASHER CLUTCH DISC GREEN 40 LOCK NUT u 127 N m 13 0 kgf m 941bf ft LARGE ID CLUTCH DISC OUTER GUIDE Install the oil pump Install the clutch outer guide oil pump drive driven driven sprocket sprocket and drive chain as an assembly with its OUT mark facing out G 0 0L U7CH GEATaSH1 17 4 1 1_1Nj A 4W 0 DRIVE SPROCKET l I ON 15 N m 1 5 kgf m 11 Ibf ft CLUTCH OUTER WASHER 11 of LIFTER PLATE OUTERTC ...

Page 298: ...ket bolt to the specified torque TORQUE 15 N m 1 5 kgf m 11 Ibf ft Align the primary drive gear and sub gear teeth with a screwdriver as shown Install the clutch outer Install the washer onto the clutch outer Install the clutch center Install the thrust washer Install the lock washer with its OUTSIDE mark facing out 0 MH i SHFR OUT SIDE A S H E R RINI R SnRi T H R U S JV ri F F 0 0 4 0 1 It Manual...

Page 299: ...ge ID clutch disc with clean engine oil and install it Coat the clutch discs and plates with clean engine oil Install the green colored Stack the clutch discs and plates alternately disc on the outside of the clutch assembly Install the green colored outer clutch disc in the shallow slot on the clutch outer CLUTCH Cl iu CLUTCH GEARS HFT LINKAGE E ALDER I f r A v NUT CLUTCH DISC GREEN 10 191I 40 3 ...

Page 300: ...QUE 12 N m 1 2 kgf m 9 lbf ft Install the right crankcase cover page 9 17 GEARSHIFT LINKAGE GEARSHIFT LINKAGE REMOVAL Remove the following Right crankcase cover page 9 3 Clutch assembly page 9 4 Remove the bolt and gearshift pedal link Pull the gearshift spindle assembly and thrust wash er out of the crankcase 1 PRESSURE rAk HIF Fr I INI GEARSHIFT SPINDLE LIFTER BEARING 0A r LIFTER PIECE Manuals b...

Page 301: ...M SHIFT FORK REMOVAL Remove the following Gearshift linkage through socket bolt gearshift cam removal page 9 12 Oil pan page 4 3 Remove the bolts and shift drum bearing set plates Remove the shift fork shaft and shift forks a CLOT HIGF REH1 FT LIB IaKAG L RINC S T CPFER r RNE SET PLATES HW I RI S LT APSHIF PAP RETURN SPRING GEARSHIFT SPINDLE ITQ Manuals by Motomatrix www motomatrix co uk The Solut...

Page 302: ...D of the shift fork SERVICE LIMIT 12 03 mm 0 474 in Measure the shift fork claw thickness SERVICE LIMIT 5 9 mm 0 23 in Measure the O D of the shift fork shaft SERVICE LIMIT 11 95 mm 0 470 in Inspect the shift drum grooves for wear or damage l SHIFT DRUM T t 4 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 303: ...y molybdenum disulfide oil to shifter fork groove of the shift gears Install the shift forks on the transmission Install the shift fork shafts with their identification mark facing to right SHIFT DRUM SHIFT FORK INSTALLATION Install the shift drum and shift drum bearing CLUTCH ARSH FT Ll j CENTE SHIFT FORK LEFT SHIFT FORK RIGHT SHIFT FORK HiF I ti uivi Manuals by Motomatrix www motomatrix co uk Th...

Page 304: ...lowing steps GEARSHIFT LINKAGE INSTALLATION Install the following Washer Return spring Stopper arm Socket bolt Tighten the stopper arm socket bolt to the specified torque TORQUE 12 N m 1 2 kgf m 9 lbf ft Install the dowel pin onto the shift drum Install the gearshift cam while holding the stopper arm using a screwdriver as shown y J SET PLATES SOC ET BOLT T IASHER OPPER AR I DOWEL PIN B STS RETURN...

Page 305: ...igning its slit with the punch mark on the gearshift spindle Install and tighten the pinch bolt to the specified torque TORQUE 10 N m 1 0 kgf m 7 Ibf ft Install the clutch assembly page 9 8 RIGHT CRANKCASE COVER INSTALLATION Apply a sealant to the mating surfaces of the crank case as shown B CLUTCH JGEARSH1FT LINKAGE KET BOLT IGN GEARSHIFT SPINDLE ARSHIF I IARK E E E O 0 10o Iv Oo 0 C C0 t0 O 0 0 ...

Page 306: ...crankcase cover SH bolts Z e Install the two dowel pins I ff Install the right crankcase cover while turning the lifter arm clockwise to engage the lifter arm groove with the lifter piece flange RIGHT C DLTS 0 0 10 0 0 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 307: ...e clutch cable end to the clutch lifter lever then install the clutch cable bracket with the two bolts Pour the recommended engine oil page 3 15 CLUTCHIGEARSHIFT LINK AGE LIFTEP h JE CLOT r BOLT RIGHT CR BOLTS 2P RED CONNECTOR Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 308: ...ES Alternator wire clamp bolt 12 N m 1 2 kgf m 9 lbf ft CT bolt Flywheel flange bolt 103 N m 10 5 kgf m 76 lbf ft Apply oil to the threads Stator mounting socket bolt 12 N m 1 2 kgf m 9 lbf ft Starter one way clutch socket bolt 16 N m 1 6 kgf m 12 lbf ft Apply a locking agent to the threads TOOLS Flywheel holder 07725 0040000 Equivalent commercially available in U S A Rotor puller 07733 0020001 or...

Page 309: ...r flywheel be cover is removed Set a clean oil pan under the careful during engine and add the recommended oil to the speci removal fled level after installation Remove the gasket and dowel pin REMOVAL Remove the alternator wire grommet from the alter nator cover Remove the socket bolt and stator wire clamp Remove the socket bolts and stator 3P WHITE CONNECTOR r i 4 ALTERNATOR COVER k1wa t r1 BOLT...

Page 310: ...m 1 2 kgf m 9 Ibf ft Install the wire clamp and tighten the bolt to the specified torque TORQUE 12 N m 1 2 kgf m 9 Ibf ft 0 0 0 C k FLYWHEEL REMOVAL Remove the alternator cover page 10 2 Remove the starter idle gear shaft and idle gear STATOR ALTERNATOR STARTER CLUTCH WIRE CLAMP SEAL GROMMET A 12 N m 1 2 kgf m 9 lbf ft 12 N m 1 2 kgf m 9 lbf ft SOCKET BOLTS WIRE CLAMP STATOP IDLE GEAR IDLE GEAR II...

Page 311: ...lable in U S A Remove the washer Remove the flywheel using the special tool TOOL Rotor puller 07733 0020001 or 07933 3950000 Remove the woodruff key Check the starter idle gear and shaft for wear or damage EEL F GI Y VHEEL WOODRUFF KEY IDLE GEAR SHAFT Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 312: ...lder and re move the starter clutch mounting torx bolts TOOL Flywheel holder 07725 0040000 Remove the starter one way clutch assembly Check the starter driven gear for abnormal wear or damage Measure the starter driven gear boss O D SERVICE LIMIT 51 684 mm 2 0348 in Check the one way clutch for wear or damage and replace if necessary ALTERNATOR STARTER CLUTCH FLYWHEEL HOLDER TORX BOLTS ONE WAY CLU...

Page 313: ...to the clutch outer with the flange side facing out i CLUTCH OUTER I ONE WAY CLUTCH ONE WAY CLUTCH Install the starter one way clutch assembly onto the ONE WAY CLUTCH ASSEMBLY flywheel FLYWHEEL sSf to A U N DRIVEN GEAR CLUTCH OUTER Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 314: ...e driven gear counter clockwise smoothly but the gear should not turn clockwise FLYWHEEL INSTALLATION Clean any oil from the crankshaft taper Install the woodruff key on the crankshaft Install the flywheel aligning the key way in the flywheel with the woodruff key on the crankshaft Apply oil to the flywheel bolt threads and seating surface Install the washer and flywheel bolt ALTERNATOR STARTER CL...

Page 315: ...starter idle gear shaft Apply oil to the starter idle gear Install the starter idle gear and shaft onto the crankcase ALTERNATOR COVER INSTALLATION Apply sealant to the mating surface of the crank case as shown Install the dowel pin and new gasket FLYWHEEL H01 DER IDLE GEAR E E E co Ln o 0 E E co 0 In o 0 0 0 0 IMP 00 0 I e 00 0 i GASKET DObvHl PI E 4 r Manuals by Motomatrix www motomatrix co uk T...

Page 316: ...torque TORQUE 12 N m 1 2 kgf m 9 Ibf ft Connect the alternator 3P White connector Install the middle lower cowl page 2 7 Install the ECM cover and fuel tank rear bracket page 5 89 ALTERNATOR STARTER CLUTCH ALTERNATOR COVER 1 011 1 611 v Y r 3P WHITE CONNECTOR BOLTS o Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 317: ...clearance Apply molybdenum disulfide oil to the crank pin during assembly SPECIFICATIONS Unit mm in ITEM Cylinder 1 I D Out of round Taper Warpage Piston piston Piston mark direction rings Piston O D Piston O D measurement point Piston pin bore I D L Piston pin O D _ Piston to piston pin clearance Piston ring to ring groove clearance Piston ring end gap Cylinder to piston clearance Connecting rod ...

Page 318: ...nd piston pin Worn connecting rod small end 12 N m 1 2 kgf m 9 lbf ft 39 N m 4 0 kgf m 29 lbf ft 35 N m 3 6 kgf m 26 lbf ft 24 N m 2 4 kgf m 17 Ibf ft 35 N m 3 6 kgf m 26 lbf ft 22 N m 2 2 kgf m 16 lbf ft 30 N m 3 1 kgf m 22 lbf ft 12 N m 1 2 kgf m 9 lbf ft Apply a locking agent to the threads Apply oil to the threads Apply oil to the threads Apply a locking agent to the threads Apply a locking ag...

Page 319: ... mm bolt Loosen the ten lower crankcase 9 mm bolts in a crisscross pattern in 2 3 steps then remove the bolts and sealing washers Separate the lower crankcase from the upper crank case Q 6 mm BOLTS Remove the swingarm pivot collars dowel pins COLLARS and oil orifices CRANKCASE ISTONJCYLINDER BOLTS 10 mm BOLT DOWEL PINS m BOLTS SEALING WASHERS u mug 1000 3ET PLATE 8 mm BOLTS 9 mm BOLTS OIL ORIFICES...

Page 320: ...gine damage Remove the nuts and connecting rod bearing cap Remove the piston connecting rod assembly from the top of the cylinder PISTON REMOVAL Remove the piston pin clip with pliers Press the piston pin out of the piston and remove the piston from the connecting rod PISTON DISASSEMBLY Do not damage the Remove the piston rings piston rings during removal BEARING CAP NUTS PISTON CONNECTIH ROD ASSE...

Page 321: ... the grooves SERVICE LIMITS Top 0 08 mm 0 003 in Second 0 06 mm 0 002 in Inspect the piston for wear or damage Insert the piston ring squarely into the bottom of the cylinder and measure the ring end gap SERVICE LIMITS Top 0 5 mm 0 02 in Second 0 7 mm 0 03 in Oil side rail 0 9 mm 0 04 in Measure the diameter of the piston at 13 mm 0 5 in from the bottom and 90 degrees to the piston pin hole SERVIC...

Page 322: ...MIT 0 05 mm 0 002 in Inspect the cylinder bore for wear or damage Measure the cylinder I D in X and Y axis at three levels Take the maximum reading to determine the cylin der wear SERVICE LIMIT 74 15 mm 2 919 in Calculate the piston to cylinder clearance Take a maximum reading to determine the clear ance Refer to page 11 5 for measurement of the piston O D STANDARD 0 020 0 055 mm 0 0008 0 0022 in ...

Page 323: ...re the connecting rod small end I D SERVICE LIMIT 17 04 mm 0 671 in Temporarily install the connecting rod to the crank shaft Install the bearing inserts and bearing cap and tighten the bolts Measure the connecting rod side clearance SERVICE LIMIT 0 30 mm 0 012 in CRANKPIN BEARING INSPECTION Wipe all oil from the bearing inserts and crankpins Put a piece of plastigauge on each crankpin Do not put ...

Page 324: ...ap installed without bearing inserts If you are replacing the crankshaft record the corre sponding crankpin O D code number A or B If you are reusing the crankshaft measure the crankpin O D with the micrometer CONNECTING ROD I D CODE BEARING CAP r Remove the connecting rod caps and measure the compressed plastigauge on each crankpin SERVICE LIMIT 0 062 mm 0 0024 in If the connecting rod bearing cl...

Page 325: ...O D CODE Thick Thin 1 39 000 39 006 1 5354 1 5357 A 35 997 36 003 E 1 4172 1 4174 Yellow 35 991 35 997 D 1 4170 1 4172 Green 35 985 35 991 C 1 4167 1 4170 Brown Install the bearing inserts into the connecting rod and bearing cap CRANKCASE PISTON CYLINDER IDENTIFICATION COLLAR CONNECTING ROD I D CODE 2 39 006 39 012 1 5357 1 5359 D 3 39 012 39 018 1 5359 1 5361 C Green Brown C Brown B Black BEARING...

Page 326: ...ond rings the top ring is narrower than the second ring in width Space the piston ring end gaps 120 degrees apart Do not align the gaps in the oil rings side rails After installation the rings should rotate freely in the ring grooves PISTON INSTALLATION Assemble the piston and connecting rod Apply molybdenum disulfide oil to the piston pin outer surface Install the piston pin and secure it using a...

Page 327: ...r sleeve and crankpin with the connecting rod bolt threads Use the handle of a plastic hammer to tap the pis ton into the cylinder Apply molybdenum disulfide oil to the crankpin bearing surfaces Install the bearing cap Insure that the marks on the caps are aligned with the marks on the connecting rods Apply oil to the connecting rod nut threads and seat ing surfaces Install the connecting rod nuts...

Page 328: ...ower crankcase onto the upper crank case Clean the new crankcase 9 mm bolts thoroughly with solvent and blow them dry Apply clean engine oil to the 9 mm bolt threads and seating surface and install them Loosely install all the lower crankcase bolts Make sure the upper and lower crankcase are seated securely Make sure the swingarm pivot collar flanges are seated the crankcase securely SEAL III 0 0 ...

Page 329: ...ft The sealing Install the upper crankcase 8 mm bolts sealing washer locations washers and 6 mm bolt are indicated on the upper Tighten the 8 mm bolts to the specified torque crankcase using the G mark TORQUE 24 N m 2 4 kgf m 17 Ibf ft Tighten the 6 mm bolt CRANKCASE PISTON CYLINDER 6 mm BOLTS 9 mm BOLTS 07 1 0 01 I I A ff 8 mm BOLTS 10 mm BOLTS 6 mm BOLTS SEALING WASHERS 0 0 1 1 I OW V 0 o 9 r 8 ...

Page 330: ... set plate with its OUTSIDE mark facing out Tighten the mounting bolts to the specified torque TORQUE 12 N m 1 2 kgf m 9 lbf ft Install the removed parts in the reverse order of removal BOLTS OUTSIDE MARK T PLATE Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 331: ...ing assembly SPECIFICATIONS Unit mm in ITEM Crankshaft Side clearance_ 0 05 0 20 0 002 0 008 Runout Main journal oil clearance Transmission Gear I D Bushing O D Bushing I D _ C2 Gear to bushing IM5 M6 clearance C3 Mainshaft O D No 1 and No 5 0 017 0 035 0 0007 0 0014 No 2to No 4 0 027 0 045 0 0011 0 0018 M5 M6 31 000 31 025 1 2205 1 2215 C1 26 000 26 021 1 0236 1 0244 C2 3 4 33 000 33 025 1 2992 1...

Page 332: ...rk Bent fork shaft Bent fork claw Damaged shift drum cam groove Bent shift spindle 35 N m 3 6 kgf m 26 Ibf ft Apply oil to the threads and seating surface 35 N m 3 6 kgf m 26 lbf ft Apply oil to the threads and seating surface 07746 0030100 07746 0030300 07964 MB00200 Transmission jumps out of gear Worn gear dogs and slots Bent fork shaft Broken shift drum stopper Worn or bent shift forks Broken s...

Page 333: ...he connecting rod bearing cap nuts and bearing caps Remove the crankshaft Remove the main journal bearings from both the crankcases PRIMARY DRIVE SUB GEAR REMOVAL Remove the special snap ring and friction spring CRANKSHAFT TRANSM SSIOi1 N INC MAIJ i IRN I B SINGS r FT SNAG FRICTION SPRING Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix c...

Page 334: ...r Apply molybdenum disulfide oil to the area shown in the illustration Install the friction spring and new special snap ring NOTICE You must use the new special snap ring Using a snap ring other than specified or reusing the snap ring can cause severe engine damage J 1 1 SPRINGS 0 0 SUB GEAR SUB GEAR r 47 15 ALIGN S FRICTION SPRING I SNAP RING U Manuals by Motomatrix www motomatrix co uk The Solut...

Page 335: ...haft cutouts as shown Press a new needle bearing onto the crankshaft using a hydraulic press and special tool TOOL Driver shaft 07964 MB00200 If the special tool is not available prepare a suita ble collar washer and 10 mm flange bolt example flywheel bolt for the bearing installation Assemble the above items and screw the bolt grad ually then install the new needle bearing CRANKSHAFT TRANSMISSION...

Page 336: ...erts and journals Reinstall the upper crankcase s main journal bear ing inserts then carefully lower the crankshaft in place Put a piece of plastigauge on each journals Do not put the plastigauge over the oil hole in the main bearing journal of the crankshaft Do not rotate the crankshaft during inspection Assemble the crankcase halves Tighten the 9 mm bolts to the specified torque TORQUE 35 N m 3 ...

Page 337: ...ankcase I D letters from the pad on the left side of the upper crankcase as shown Record the corresponding main journal O D code numbers from the crank weight Cross reference the case and journal codes to deter mine the replacement bearing color codes BEARING THICKNESS B Brown Thick C Green A D Yellow E Pink F Red j G White Thin NOTICE After selecting new bearings recheck the clearance with a plas...

Page 338: ...the upper and lower main journal bearings Install the crankshaft Install the connecting rod bearing caps Apply oil to the connecting rod nut threads and seat ing surfaces Install and tighten the nuts gradually and alternately TORQUE 35 N m 3 6 kgf m 26 Ibf f t Assemble the upper and lower crankcase page 11 12 CRANKCASE I D CODE A B G F White Red F E Red Pink E D Pink Yellow D Yellow Green C MAIN i...

Page 339: ...r or lack of lubrication Measure the I D of each gear SERVICE LIMITS M5 M6 31 04 mm 1 222 in Cl 26 04 mm 1 025 in C2 C3 C4 33 04 mm 1 301 in Measure the I D and O D of each gear bushing SERVICE LIMITS O D M5 M6 30 93 mm 1 218 in C3 32 93 mm 1 296 in C4 32 93 mm 1 296 in I D M5 28 02 mm 1 103 in C2 30 02 mm 1 182 in MAINSHAFT CRANKSHAFT TRANSMISSION COUNTERSHAFT f S SET RING Manuals by Motomatrix w...

Page 340: ...EARING REPLACEMENT Turn the outer race of each bearing with your finger The bearings should turn smoothly and quietly Also check that the bearing inner race fits tightly on the shaft Remove and discard the mainshaft bearing if the race does not turn smoothly quietly or fits loosely on the mainshaft Replace the countershaft collar and bearing as an assembly if the race does not turn smoothly quietl...

Page 341: ...ing the special tool TOOLS Driver 40 mm I D 07746 0030100 Attachment 30 mm 07746 0030300 ASSEMBLY M2 GEAR 15T M5 GEAR 21T MAINSHAFT DRIVER 40 mm I D ATTACHMENT r V r i BEARING M6 GEAR 21T CRANKSHAFT TRANSMISSION MAINSHAFT M1 GEAR 13T M3 4 GEAR 20 20T Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 342: ...OUNTERSHAFT C4 GEAR 28T n C2 GEAR 29T C5 GEAR 27T Cl GEAR 35T ow a ft l I 11 r im C6 GEAR 25T v v C3 GEAR 32T i Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 343: ... ring on the crankcase and aligning the bearing cap i holes with the dowel pins Also align the countershaft bearing stopper pin with the groove in the crankcase Assemble the crankcase page 11 12 MAINSHAFTT CRANKSHAFT TRANSMISSION COUNTERSHAFT m M 1 f INr Install the dowel pins in the upper crankcase holes Install the countershaft bearing set ring into the up 1 per crankcase groove SET RING STOPPER...

Page 344: ...mm in ITEM Minimum tire tread depth Cold tire pressure Up to 90 kg 200 Ib load upto maximum weight capacity 250 kPa 2 50 kgf cmz 36 psi _ 250 kPa 2 50 kgf cm2 36 psi 0 20 0 008 2 0 0 08 _ 2 0 0 08 230 5 9 07 _ 225 9 8 89 With the tapered end facing UP 0 20 0 008 Pro Honda Suspension Fluid SS 8 90 3 5 488 2 5cm3 16 5 0 08USoz 17 2 0 09 Imp oz Pre load adjuster initial setting 18 mm 0 7 in from top ...

Page 345: ... bearing Worn swingarm pivot components Front wheel wobbling Bent rim Worn front wheel bearings Faulty tire Unbalanced tire and wheel 07749 0010000 07746 0010300 07746 0040600 07746 0050100 07746 0050800 22 N m 2 2 kgf m 16 lbf ft 26 N m 2 7 kgf m 20 lbf ft 78 N m 8 0 kgf m 58 Ibf f t 22 N m 2 2 kgf m 16 Ibf ft 20 N m 2 0 kgf m 14 lbf ft 22 N m 2 2 kgf m 16 lbf ft 34 N m 3 5 kgf m 25 lbf ft 07916 ...

Page 346: ...r cylinder assembly Remove the right handlebar switch throttle housing screws FRONT WHEEL SUSPENSION STEER NG H ER t i HuLi SWITCH HOUSING SCREWS Remove the right handlebar switch housing and SWITCH HOUSING THROTTLE PIPE throttle pipe from the right handlebar i w GRIP END Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 347: ... bracket holder bolts holder and clutch lever bracket assembly Remove the screws and left handlebar switch housing Remove the screw and handlebar grip end Remove the handle grip from the handlebar CABLE ENDS THROTTLE PIPE LEVER BRACKET o o BOLTS HOLDER SWITCH HOUSING SCREWS GRIP END GRIP Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co...

Page 348: ... m 76 Ibf ft Tighten the top bridge pinch bolts to the specified torque TORQUE 22 N m 2 2 kgf m 16 Ibf ft Seat the handlebar pivot upper surface with the top bridge lower surface then tighten the handlebar pinch bolt to the specified torque TORQUE 26 N m 2 7 kgf m 20 Ibf ft FRONT WHEEL SUSPENSION STEERING HANDLEBAR TOP BRIDGE TOP BRIDGE PINCH BOLT HANDLEBAR PINCH BOLT 1ANDLEBAR OP RING TOP BRIDGE ...

Page 349: ... new mounting screw Insert the handlebar weight assembly into the handlebar Turn the handlebar weight and hook the retainer tab with the hole in the handlebar Apply Honda Bond A or Honda Hand Grip Cement U S A only to the inside of the grip and to the clean surfaces of the left handlebar and throttle grip Wait 3 5 minutes and install the grip Allow the adhesive Rotate the grip for even application...

Page 350: ...r bracket holder with the UP mark facing up Tighten the upper bolt first then the lower bolt TORQUE 12 N m 1 2 kgf m 9 Ibf ft Connect the clutch switch wires Connect the throttle cable ends to the throttle pipe FRONT WHEEL SUSPENSION STEERING HOLE SWITCH HOUSING All PIN SWITCH HOUSING SCREWS a BOLTS 1 LEVER BRACKET Oll UP vMARK A I x HOLDER CABLE ENDS I THROTTLE PIPE Manuals by Motomatrix www moto...

Page 351: ...e master cylinder by aligning the end of the master cylinder with the punch mark on the handlebar Install the master cylinder holder with the UP mark facing up Tighten the upper bolt first the lower bolt TORQUE 12 N m 1 2 kgf m 9 Ibf ft Connect the brake switch wires RIGHT HANDLEBAR THROTTLE PIPE r SWITCH HOUSING UP MARK PIN HOLE 1I LDEP r SWITCH HOUSING SCREWS r C 4J L i THROTTLE PIPE iTiER h L4T...

Page 352: ...ng bolts and both brake brake lever after calipers the brake caliper is removed Support the brake caliper with a piece of wire so that it does not hang from the brake hose Do not twist the brake hose Loosen the right axle pinch bolts 1 Remove the axle bolt I 1 FRONT WHEEL SUSPENSION STEERING REFLECTOR CLAMP NUT FRONT FENDER 0 1 j L 0 0 r AXLE BOLT 0 0 ft 1 SPECIAL BOLTS GRIP END A B LTS V 11301 13...

Page 353: ...f each bearing with your finger The bearings should turn smoothly and quietly Also check that the bearing outer race fits tightly in the hub Replace the Remove and discard the bearings if they do not bearings in pairs turn smoothly quietly or if they fit loosely in the hub Install the new bearings into the hub using the special tools page 13 12 s PIN I I AXLE 111 AXLE 7 _ WHEEL BEARING 6 Manuals b...

Page 354: ...he wheel and tire Remove the dust seals from the wheel Mount the wheel tire and brake discs assembly in an inspection stand Spin the wheel allow it to stop and mark the lowest heaviest point of the wheel with a chalk Do this two or three times to verify the heaviest area If the wheel is balanced it will not stop consistently in the same position To balance the wheel install wheel weights on the hi...

Page 355: ... out the other bearing TOOLS Bearing remover head 25 mm 07746 0050800 Bearing remover shaft 07746 0050100 RIGHT BRAKE DISC C 0 Vs 600 O 5T WHEEL BEARING 0 I 0 1 0 2 0 1 10 o OJ RIGHT DUST SEAL DISTANCE COLLAR LEFT DUST SEAL BOLT BRAKE DISC titfJlt 1 E Isi REf Ek AFT ASSEMBLY owl 11 1 LEFT WHEEL BEARING 6005 49 LEFT BRAKE DISC I0 0 0 0 0 O 20 N m 2 0 kgf m 14 Ibf ft 0 I 0 Manuals by Motomatrix www ...

Page 356: ...on the wheel hub Install and tighten the new mounting bolts to the specified torque TORQUE 20 N m 2 0 kgf m 14 Ibf ft Apply grease to the dust seal lips then install them into the wheel hub INSTALLATION Install the side collars Install the front wheel between the fork legs Apply thin layer of grease to the front axle surface Install the front axle from the left side FRONT WHEEL SUSPENSION STEERING...

Page 357: ...specified torque TORQUE 30 N m 3 1 kgf m 22 Ibf f t Install the front fender page 2 15 With the front brake applied pump the fork up and down several times to seat the axle and check brake operation Check the brake operation by applying the brake lever Tighten the left axle pinch bolts to the specified torque TORQUE 22 N m 2 2 kgf m 16 Ibf ft I AXLE BOLT p FIIJ H B L TS BOh TS r t Manuals by Motom...

Page 358: ...remove the fork tube from the fork top bridge and steering stem 0 FORK Keep the brake master cylinders upright 16 Be careful not to scratch the fork tube or damage the dust seal REMOVAL Remove the front wheel page 13 9 DISASSEMBLY Remove the handlebar stop ring Remove the stop ring FRONT WHEEL SUSPENSION STEERING if 41 I t t H H FI I IAJDLEBAR PINCH ROL 1 OT I unl F N i B3LTS r STOP RING i HANDLEB...

Page 359: ...eat and install the 17 mm spanner into the groove of the rebound adjuster Hold the rebound adjuster then loosen and remove the fork bolt from the rebound adjuster Remove the following Spring joint plate Spring seat stopper Spring collar Fork spring ADJUSTING PLATE 1 FORK BOLT SPRING JOINT PLATE FORK SPRING SEAT STOPPER S SPRING COLLAR PRE LOAD ADJUSTER V JOINT PLATE 0 0 0 0 0 Manuals by Motomatrix...

Page 360: ...el Hold the fork damper with the fork damper holder then remove the fork socket bolt TOOL is Fork damper holder 07YMB MCFO101 Remove the fork damper assembly and centering plate from the fork tube Remove the dust seal FRONT WHEEL SUSPENSION STEER G In I f ef 0 CENTERING PLATE FORK DAMPER DUST SEAL Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info mot...

Page 361: ...SERVICE LIMIT 0 20 mm 0 008 in Fork tube bushing Visually inspect the slider and fork tube bushings Replace the bushings if there is excessive scoring or scratching or if the teflon is worn so that the copper surface appears on more than 3 4 of the entire surface Check the back up ring replace it if there is any distortion at the points shown FRONT WHEEL SUSPENSION STEERING FORK SLIDER FORK DAMPER...

Page 362: ... fork tube bushing Apply fork fluid to the oil seal lips Install the fork tube into the fork slider Drive the oil seal in using the special tools v CENTERING PLATE FORK SPRING FORK DAMPER SLIDER BUSHING TOOL Oil seal driver 07YMD MCF0100 or 07KMD KZ30100 with 07NMD KZ30101 except U S A 07 N M D KZ301 OA U S A only FORK TUBE BUSHING BACK UP RING STOPPER RING I PRE LOAD ADJUSTER ADJUSTING PLATE FORK...

Page 363: ...rk damper assembly into the fork tube Apply a locking agent to the fork socket bolt threads Install the socket bolt with a new sealing washer FRONT WHEEL SUSPENSIONJSTEEPINO Lack STOPPER RING DUST SEAL CENTERING PLATE FORK DAMPER SEALING WASHER c1 SOCKET BOLT Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 364: ... 5 0 08 US oz 17 2 0 09 Imp oz Bleed the air as follows 1 Pump the damper rod slowly 8 10 times 2 Extend the fork cover the top of the fork slider with your hand and compress the fork slowly 3 Pump the fork slider slowly 8 10 times Slowly push down the fork slider and gently set the dust seal onto the axle holder and leave it for 5 minutes Be sure the oil After the oil level stabilizes measure the...

Page 365: ...specified torque TORQUE 34 N m 3 5 kgf m 25 Ibf ft Screw the fork bolt into the fork tube Install the adjusting plate into the fork bolt aligning its pins with the holes in the fork bolt Apply fork fluid to the pre load adjuster O ring Screw the pre load adjuster onto the rebound adjuster FRONT WHEEL SUSPENSION STEERING FORK SFklNJ SEAT STOPPER JOINT PLATE f 1 SPRING COLLAR FORK BOLT FORK O RING a...

Page 366: ...cified torque TORQUE 26 N m 2 7 kgf m 20 Ibf ft If the fork bolt was loosened tighten it to the specified torque TORQUE 22 N m 2 2 kgf m 16 Ibf ft Tighten the top bridge pinch bolt to the specified torque TORQUE 22 N m 2 2 kgf m 16 Ibf ft Tighten the handlebar pinch bolt to the specified torque TORQUE 26 N m 2 7 kgf m 20 Ibf ft Install the front wheel page 13 13 HANDLEBA PINCH BOLtT STOP RING HAND...

Page 367: ...ighten the tabs of the lock washer Remove the lock nut and lock washer Remove the steering stem bearing adjusting nut using the special tool TOOL Steering stem socket 07916 3710101 or 07916 3710100 U S A only FRONT WHEEL SUSPENSION STEERING Li STEM NUT LOCK NUT LOCK WASHER TAB STEERING STEM SOCKET ADJUSTING NUT ORN L 13 25 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle...

Page 368: ...haft assembly 3 07946 KM90300 Bearing remover A 4 07946 KM90401 Bearing remover B 5 07946 KM90500 Assembly base 6 07946 KM90600 Install the ball race remover into the head pipe as shown Align bearing remover A with the groove in the steering head Lightly tighten nut B with a wrench Holding the driver shaft with a wrench turn nut A gradually to remove the upper outer race NNER RACE UPPER BEARING DU...

Page 369: ... and turn nut A gradually until the groove in driver attachment A aligns with the upper end of the steering head This will allow you to install the upper outer race FRONT WHEEL SUSPENSION STEERING DRIVER ATTACHMENT LOWER OUTER RACE DRIVER ATTACHMENT a DRIVER SHFT BEARING REMOVER B NUT A ASSEMBLY BASE DRIVER ATTACHMENT DRIVER SHAFT 1 ASSEMBLY BASE DRIVER ATTACHMENT 13 27 Manuals by Motomatrix www m...

Page 370: ...taller attachment A 07VMF MAT0100 Installer attachment B 07VMF MAT0200 Remover attachment A 07VMF MAT0300 Remover attachment B 07VMF MAT0400 Install the special tools into the steering head pipe as shown Align remover attachment A with the groove in the steering head While holding the installer shaft with the wrench turn the upper nut gradually to remove the upper bearing outer race DRIVER ATTACHM...

Page 371: ...il the groove in installer attachment A aligns with the upper end of the steering head This will allow you to install the upper bearing outer race FRONT WHEEL SUSPENSION STEERING INSTALLER ATTACHMENT A INSTALLER SHAFT UPPER NUT REMOVER ATTACHMENT B LOWER BEARING OUTER RACE OIL SEAL DRIVER FORK SEAL DRIVER WEIGHT MAIN BEARING DRIVER ATTACHMENT LOWER NUT UPPER BEARING OUTER RACE INSTALLER SHAFT INST...

Page 372: ...om the stem Remove the lower bearing inner race with a chisel or equivalent tool being careful not to damage the stem Remove the dust seal Apply grease to new dust seal lips and install it over the steering stem Install a new lower bearing inner race using a special tool and a hydraulic press TOOL Steering stem driver 07946 MB00000 FORK SEAL DRIVER WEIGHT INSTALLER ATTACHMENT A UPPER NUT MAIN BEAR...

Page 373: ...EERING Nus N O I d Rr 0 0 m r S Etnl 1 TEM Apply oil to the bearing adjustment nut threads STEERING STEM SO Install and tighten the stem bearing adjusting nut to the initial torque 07916 3710101 or 07916 3710100 U S A only r LISTING NUT TOP THREAD VV LOWER OUTER RACE LOWER BEARING LOWER INNER RACE LOWER DUST SEAL of r0RACE UPPER BEARING T LOCK NUT LOCK WASHER UPPER DUST SEAL UPPER INNER RACE UPPER...

Page 374: ... washer onto the steering stem Align the tabs of the lock washer with the grooves in the adjustment nut and bend two opposite tabs shorter down into the adjustment nut groove Install and finger tighten the lock nut Hold the lock nut and further tighten the lock nut within 1 4 turn 90 enough to align its grooves with the lock washer tabs Bend the lock washer tabs up into the lock nut groove STEERIN...

Page 375: ...EERING HEAD BEARING PRE LOAD Jack up the motorcycle to raise the front wheel off the ground Position the steering stem to the straight ahead position Hook a spring scale to the fork tube and measure the steering head bearing pre load The pre load should be within 10 15 N 1 0 1 5 kgf If the readings do not fall within the limits lower the front wheel to the ground and adjust the steering bearing ad...

Page 376: ...stem information Use only tires marked TUBELESS and tubeless valves on rim marked TUBELESS TIRE APPLICABLE Use genuine Honda replacement bolts and nuts for all suspension pivot and mounting point SPECIFICATIONS Unit mm in _Axle runout Wheel rim runout Drive chain Shock absorber ITEM Radial r Axial E Minimum tire tread_depth Cold tire pressure Up to 90 kg 200 Ib load Up to maximum weight capacity R...

Page 377: ...m 11 5 kgf m 83 lbf ft 42 N m 4 3 kgf m 31 lbf ft 64 N m 6 5 kgf m 47 Ibf ft 44 N m 4 5 kgf m 33 lbf ft 44 N m 4 5 kgf m 33 lbf ft 44 N m 4 5 kgf m 33 Ibf ft 118 N m 12 0 kgf m 87 lbf ft 26 N m 2 7 kgf m 20 Ibf ft 9 N m 0 9 kgf m 6 5 lbf ft 39 N m 4 0 kgf m 29 Ibf ft 54 N m 5 5 kgf m 40 Ibf ft 07749 0010000 07746 0010300 07746 0010400 07746 0010700 07746 0010800 07946 0010900 07746 0040400 07746 0...

Page 378: ... axle and drive chain adjusting plate from the left side and remove the rear wheel Remove the side collars INSPECTION Axle Place the axle in V blocks and measure the runout Actual runout is 1 2 the total indicator reading SERVICE LIMIT 0 20 mm 0 008 in AXLE REAR WHEEL SUSPENSION i SI1 E l11 SRS r LC iI JUT U iUSTING FLJArliF C AXLE Manuals by Motomatrix www motomatrix co uk The Solution For Lost M...

Page 379: ...ICE LIMITS Radial 2 0 mm 0 08 in Axial 2 0 mm 0 08 in Driven sprocket Check the condition of the final driven sprocket teeth Replace the sprocket if worn or damaged If the final driven sprocket requires replacement inspect the drive chain and drive sprocket Never install a new drive chain on a worn sprocket or a worn chain on new sprockets Both chain and sprocket must be in good condition or the r...

Page 380: ...eel hub Driven flange bearing removal Loosen the driven sprocket nuts Remove the driven flange from the wheel hub then remove the driven sprocket nuts and sprocket Remove the dust seal Remove the driven flange collar Drive out the driven flange bearing REAR WHEEL SUSPENSION US SEA SRI EN SPROCKF iV FLAnI DRIVER L JUTS A T HMENT PILOT Manuals by Motomatrix www motomatrix co uk The Solution For Lost...

Page 381: ...7746 0050100 ASSEMBLY 42 N m 4 3 kgf m 31 Ibf ft RIGHT DUST SEAL BRAKE DISC RIGHT WHEEL BEARING 6205 WIA 4W 1 i Drive in a new right bearing squarely TOOLS Driver 07749 0010000 Attachment 52 55 mm 07746 0010400 Pilot 25 mm 07746 0040600 DISTANCE COLLAR HEAD O RING DRIVEN FLANGE COLLAR DRIVEN FLANGE BEARING 27x52 X23 8 441 0 1 DRIVEN SPROCKET DAMPER RUBBERS 0 10 0m f 4111 LEFT WHEEL BEARING DRIVEN ...

Page 382: ... 0040600 0 0 Install the distance collar TOOLS Driver 07749 0010000 Attachment 42 X 47 mm 07746 0010300 Pilot 25 mm 07746 0040600 Install the driven flange collar into the new driven flange bearing REAR WHEEL SUSP NS9 4w DISTANCE COLD 46 DRIVER ATTACHMENT PILOT DRIVEN FLANGE COLLAR DRIVEN FLANGE BEARING DRIVER ATT HMENT PILOT Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcy...

Page 383: ... grease to the dust seal lips then install it into the driven flange Install the brake disc with its rotating direction mark facing out Install and tighten the new bolts to the specified torque y TORQUE 42 N m 4 3 kgf m 31 Ibf ft INSTALLATION Apply grease to the side collar inside and grooves Install the side collars r DUST SEAL OTATING D RECTION MARK OR I EN wr IVIPEF jWBbr H NUTS RAKE DoFS 0 0 0...

Page 384: ... N m 11 5 kgf m 83 Ibf ft 0 Install the rear brake caliper bracket onto the guide ALIPEH BRACKET of the swingarm Remove the exhaust pipe mounting collar and mounting rubber SUSPENSION LINKAGE REMOVAL Support the motorcycle using a hoist or equivalent Remove the muffler and exhaust pipe page 2 18 LL REAR WHEEL SUSPENSION AXL 6 yDJI IS NG PL A i F A INII COLLAR MOUNTING RUBBER Y 0 JUSTING PLATE Manu...

Page 385: ... 04949 3710001 Attachment 22 X 24 mm 07746 0010800 Pilot 17 mm 07746 0040400 Press the needle Press a new needle bearing into the shock arm so bearing into the that the needle bearing surface is lower 5 2 5 7 shock arm with the mm 0 20 0 22 in from the end of the shock arm marked side using the same tools facing out LINK PLATE BOLT NUT SHOCK 9M B LT INi I LINK PLATES SHOCK ARM DUST SEALS 04 0 PIVO...

Page 386: ...ock absorber lower mounting bolt nut Remove the link plate bolts nuts and link plates REAR WHEEL SUSPENSION LINK PLATE BOLTS NUT PIVOT COLLAR DUST SEALS 4 LINK PLATE BOLT NUT HOCf ARM LT NUT Install the link plates with its FR mark facing forward Install the link plate bolts nuts then tighten the nuts to the specified torque INK PLATES SHOCK ARM TORQUE 44 N m 4 5 kgf m 33 Ibf ft Install the exhaus...

Page 387: ...ust seals Press out the needle bearing out of the shock absorber lower mount using the special tools TOOLS Driver attachment handle 04949 3710001 Attachment 22 X 24 mm 07746 0010800 Pilot 17 mm 07746 0040400 Press the needle Press a new needle bearing into the lower mount bearing into the so that the needle bearing surface is lower 8 0 mm lower mount with 0 31 in from the end of the lower mount us...

Page 388: ...is getting in your eyes Before disposal of the shock absorber release the nitrogen by pressing the valve core Then remove the valve from the shock absorber reservoir INSTALLATION Install the shock absorber into the frame from the bottom and install the upper mounting bolt nut Tighten the nut to the specified torque TORQUE 44 N m 4 5 kgf m 33 lbf ft DUST SEALS REAR WHEEL SUSPENSION RESERVOIR CAP Of...

Page 389: ...val S INGAR REMOVAL Remove the rear wheel page 14 3 Remove the two SH bolts and drive sprocket cover and spacer Remove the drive sprocket bolt washer and drive sprocket Remove the screws and brake hose guides I INK PLATE BOLTS NUT SPACER DRIVE SPROCKET COVER V a Ny AW p r BOLTS BOLT j LOWE 1 BRAKE HOSE IJIDES f TI BOI T NUT S Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcy...

Page 390: ...mounting bolt nut Remove the link plate to swingarm bolt nut California type Release the 0 sensor wire from the wire guide only behind the right step guard i Loosen the swingarm pivot pinch bolts REAR WHEEL SUSPENSION LINK PLATF TO SWINGARM BOLT NUT 02 SENSOR WIRE BOLTS 100 0 0 0 0 RIGHT FOOTPEG BRACKET 0 JNTING BOLT NUT LFF i FO TFEG BRACKET ni Manuals by Motomatrix www motomatrix co uk The Solut...

Page 391: ...he swingarm from the lower bracket and engine DISASSEMBLY INSPECTION Remove the SH bolt trim clip and drive chain case A Remove the SH bolts and drive chain case B 10 24 mm SOCKET WRENCH F I N0 ARM TRIM CLIP DRIVE CHAIN CASE A SH BOLT DRIVE CHAIN CASE B SH BOLTS Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 392: ...lar for damage or fatigue Turn the inner race of right pivot bearings with your finger The bearings should turn smoothly and quietly Also check that the bearing outer race fits tightly in the hub Remove and discard the bearings if the races do not turn smoothly and quietly or if they fit loosely in the pivot REAR WHEEL SUSPENSION DRIVE CHAIN SLIDER BOLTS PIVOT COLLAR DUST SEALS s DUST SEALS I SIDE...

Page 393: ...damage or fatigue Turn the inner race of right pivot bearings with your finger The bearings should turn smoothly and quietly Also check that the bearing outer race fits tightly in the hub Remove and discard the bearings if the races do not turn smoothly and quietly or if they fit loosely in the pivot REAR WHEEL SUSPENSION DRIVE CHAIN SLIDER BOLTS PIVOT COLLAR DUST SEALS DUST SEALS 00 SIDE COLLAR o...

Page 394: ...ent 25 X 38 5 mm 07YMD MCJO100 Press the inner bearing into the swingarm right pivot until it seats using the special tools and hydraulic press TOOLS Driver 07749 0010000 Attachment 40 X 42 mm 07746 0010900 Pilot 25 mm 07746 0040600 Install the distance collar SNAP RING DRIVER SHAFT ATTACHMENT 2 5 DRIVER ATTACHMENT PILOT 0 Q 1 DISTANCE COLLAR Manuals by Motomatrix www motomatrix co uk The Solution...

Page 395: ... Press a new left pivot needle bearing into the bearing into the swingarm pivot so that the needle bearing surface swingarm with the is lower 8 9 mm 0 3 0 4 in from the end of the marked side swingarm pivot surface using the special tools facing out TOOLS Driver 07749 0010000 Attachment 40 X 42 mm 07746 0010900 S Driver Pilot 32 X 50 mm 07MAD PR90200 DRIVER ATTACHMENT PILOT REAR WHEEL SUSPENSION S...

Page 396: ...needle bearing surface is lower 5 5 6 0 mm 0 22 024 in from the end of the swingarm pivot surface using the same tool TOOL Needle bearing remover 07LMC KV30100 Apply grease to the dust seal lips then install the dust seals and pivot collar into the swingarm DUST SEALS PIVOT COLLAR NEEDLE BEARING REMOVER Nj ON 5 5 6 0 m m 0 22 0 24 in I DUST SEALS PIVOT COLLAR Manuals by Motomatrix www motomatrix c...

Page 397: ...ls and side collar into the right swingarm pivot Apply grease to the dust seal lips then install the dust seals and pivot collar into the left swingarm pivot DISTANCE COLLAR 0 REAR WHEEL SUSPENSION DRIVE CHAIN CASE A 9 N m 0 9 kgf m 6 5 Ibf ft am r cv DRIVE CHAIN SLIDER I DUST SEALS SIDE COLLAR ap PIVOT COLLAR DUST SEALS e 14 21 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Moto...

Page 398: ...Install the collars and bolts then tighten the bolts to the specified torque TORQUE 9 N m 0 9 kgf m 6 5 Ibf ft Install the drive chain case B and tighten the SH bolt securely DRIVE CHAIN CASE B SH BOLT a 0 a a Install the drive chain case A and secure it with a TRIM CLIP DRIVE CHAIN CASE A SH bolt and trim clip a a 40 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Code...

Page 399: ...n the swingarm pivot pinch bolts to the specified torque Install the left main footpeg bracket onto the lower BUNTtS LEFT FO 1 i PEG BRACKET bracket and tighten the socket bolts to the specified s torque TORQUE 39 N m 4 0 kgf m 29 lbf ft Install the gearshift pedal link to the gearshift spindle while aligning its slit with the punch mark on the spindle Tighten the gearshift pedal link pinch bolt t...

Page 400: ...ft Install the brake hose guides and tighten the screws to the specified torque TORQUE 4 N m 0 4 kgf m 2 9 lbf ft Install the drive sprocket with its ML7 mark facing out Install the washer and special bolt then tighten the bolt to the specified torque TORQUE 54 N m 5 5 kgf m 40 Ibf ft 14 24 0 2 SENSOR WIRE C RIGHT FOOTPEG BRACKET BOLTS l s mv VER MOUNTING BOLT NUT LINK PLATE BRAKE HOSE GUIDES 1 J ...

Page 401: ... rear wheel page 14 8 Install the removed parts in the reverse order of removal REAR WHEEL SUSPENSION SPACER DRIVE SPROCKET COVER r o Ao C I O 10 BOLTS 1 31 14 25 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 402: ...7 REAR California type shown 2 N m 0 25kgf m 1 8 Ibf ft 22 N m 2 2kgf m 16 Ibf f t 34 N m 3 5 kgf m 25 lbf f t 18 N m 1 8 kgf m 13 Ibf if i vF i 01 39 N m 4 0 kgf m 29 Ibf ft Vill t G 14 1 i q Ole V0 401 1 o o o YDRAULIC BRAKE 1111101111 00 1 gel 0 111 10 34 N m 3 5 kgf m 25 Ibf ft l 0 0 T r 4 N m 0 4 kgf m 2 9 Ibf ft 15 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle C...

Page 403: ...r when servicing the system Do not mix different types of fluid they may not be compatible Always check brake operation before riding the motorcycle SPECIFICATIONS Unit mm in Front Specified brake fluid Brake disc thickness Brake disc runout Rear Specified brake fluid Brake pedal height Brake disc thickness ITEM Caliper piston O D Brake disc runout Lower STANDARD Honda DOT 4 Brake Fluid 45 0 18 3 ...

Page 404: ...king worn caliper piston Caliper not sliding properly rear Clogged restricted fluid passage Worn caliper piston seal Sticking worn master cylinder piston Bent brake lever pedal 6 N m 0 6 kgf m 4 3 lbf ft U nut 10 N m 1 0 kgf m 7 lbf ft 6 N m 0 6 kgf m 4 3 lbf ft 1 N m 0 12 kgf m 0 9 lbf ft 30 N m 3 1 kgf m 22 lbf f t ALOC bolt 23 N m 2 3 kgf m 17 lbf f t ALOC bolt 18 N m 1 8 kgf m 13 lbf f t 2 N m...

Page 405: ...ndlebar until the res ervoir is parallel to the ground before removing the reservoir cap Remove the screws and reservoir cap Remove the diaphragm plate and diaphragm For the rear brake remove the rear brake reservoir mounting bolt Remove the reservoir cap Remove the diaphragm plate and diaphragm SCREWS J IAPHRoG a DIAPHRAGM PLATE RESERVOIR CA BOLT DIAPHRAGM PLATE 0 0 1 4 0 0 0 0 DIAPHRAGM X Manual...

Page 406: ...voir is low Check the fluid level often while bleeding the brakes to prevent air from being pumped into the system When using a brake bleeding tool follow the manufacturer s operating instructions Repeat the previous steps until air bubbles do not appear in the plastic hose If air is entering the bleeder from around the bleed valve threads seal the threads with teflon tape If a brake bleeder is no...

Page 407: ...eed valve has been closed Repeat steps 1 and 2 until bubbles cease to appear in the fluid coming out of the bleed valve Tighten the bleed valve TORQUE 6 N m 0 6 kgf m 4 3 Ibf ft Fill the fluid reservoir to the upper level Reinstall the diaphragm and diaphragm plate On the front brake install the reservoir cap and tighten the screws On the rear brake install the reservoir cap securely then install ...

Page 408: ...ove the bolts and brake caliper Push the caliper pistons all the way in to allow in stallation of new brake pads Remove the pad pins pad spring and brake pads Clean the inside of the caliper especially around the caliper pistons BOLTS PAD PINS r 1 J s l O BRAKE CALIPER 0 0 4W J P I dh 0 111 A afN HYDRAULIC BRAKE PAD d HK FFA 1l 00 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Mo...

Page 409: ...ten the pad pins TORQUE 18 N m 1 8 kgf m 13 Ibf ft Always replace the REAR BRAKE PAD REPLACEMENT brake pads in pairs to assure Check the brake fluid level in the brake master cylin even disc pressure der reservoir as this operation causes the level to rise Push the caliper pistons all the way in by pushing the caliper body inward to allow installation of new brake pads Remove the pad pin plug AD P...

Page 410: ...st the pad spring so that the pad ends are positioned onto the retainer on the caliper bracket Install the pad pin AD PIN Install and tighten the caliper bracket bolt TORQUE 22 N m 2 2 kgf m 16 Ibf ft Tighten the pad pin TORQUE 18 N m 1 8 kgf m 13 lbf ft D HYDRAULIC BRAKE IALIPER BRACKET BOLT 4 ALIPER BRACKET BOLT Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Ke...

Page 411: ...lest measurement is less than the service limit Measure the brake disc warpage with a dial indica tor SERVICE LIMIT 0 30 mm 0 012 in Check the wheel bearings for excessive play if the warpage exceeds the service limit Replace the brake disc if the wheel bearings are nor mal FRONT MASTER CYLINDER REMOVAL Drain the front hydraulic system page 15 4 Disconnect the brake light switch wire connectors Re...

Page 412: ...ylinder holder and remove the master cylinder assembly Remove the pivot bolt nut and brake lever assem bly Remove the screw and brake light switch i IiASTEr UNDER SNAP RING DUST OVER PIVOT BOLT BRAKE LEVER PIVOT NUT BRAKE LIGHT SWITCH SCREW HYDRAULIC BRAKE BOLTS BOLT Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 413: ...ir with brake fluid INSPECTION Check the piston boot primary cup and secondary cup for fatigue or damage Check the master cylinder and piston for abnormal scratches Measure the master cylinder I D SERVICE LIMIT 19 105 mm 0 7522 in Measure the master cylinder piston O D SERVICE LIMIT 19 006 mm 0 7483 in BOOT SNAP RING PLIERS SNAP RING Manuals by Motomatrix www motomatrix co uk The Solution For Lost...

Page 414: ... clean brake fluid before assem bly Dip the piston in brake fluid Install the spring into the piston Install the piston assembly into the master cylinder Install the snap ring TOOL Snap ring pliers 07914 SA50000 or 07914 3230001 6 N m 0 6 kgf m 4 3 Ibf ft Off DIAPHRAGM J BRAKE LIGHT SWITCH 2 N m 0 25 kgf m 1 8 lbf ft MASTER CYLINDER MASTER PISTON SPRING 1 PISTON CUPS SNAP RING SNAP RING PLIERS HYD...

Page 415: ...piston tip Install the brake lever assembly tighten the pivot PIVOT BOLT bolt to the specified torque TORQUE 10 N m 1 0 kgf m 7 Ibf ft Hold the pivot bolt and tighten the pivot nut to the specified torque TORQUE 6 N m 0 6 kgf m 4 3 lbf ft BOOT BRAKE LIGHT SWITCH Q i BRAKE LEVER PIVOT NUT 9 0 0 i 0 0 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info m...

Page 416: ... Tighten the upper bolt first then the lower bolt Install the brake hose eyelet with the oil bolt and new sealing washers Push the eyelet joint against the stopper then tighten the oil bolt to the specified torque TORQUE 34 N m 3 5 kgf m 25 lbf ft Connect the brake light switch wire connectors Fill the reservoir to the upper level and bleed the brake system page 15 4 II BOLT 1 L WASHE ITCH NNEC T ...

Page 417: ... system is serviced California type Release the 02 sensor wire from the wire guide only behind the light step guard Remove and discard the brake pedal joint cotter pin Remove the joint pin Remove the master cylinder mounting bolts step guard and master cylinder DISASSEMBLY Remove the screw and reservoir hose joint from the master cylinder MOUNTING BOLTS 02 SENSOR WIRE r O 0 I 0 1 L FOOTPEG BRACKET...

Page 418: ...t primary cup and secondary cup for fatigue or damage Check the master cylinder and piston for abnormal scratches Measure the master cylinder I D SERVICE LIMIT 15 925 mm 0 6270 in Measure the master cylinder piston O D SERVICE LIMIT 15 815 mm 0 6226 in HYDRAULIC BRAKE SNAP RING BOOT SNAP RING PLIERS SPRING PRIMARY CUP SECONDARY CUP MASTER PISTON PUSH ROD ASSEMBLY Manuals by Motomatrix www motomatr...

Page 419: ... in brake fluid Install the spring to the primary cup Install the spring primary cup and master piston assembly Apply silicone grease to the piston contact area of the push rod Install the push rod into the master cylinder Install the snap ring TOOL Snap ring pliers 07914 SA50000 or 07914 3230001 Install the boot 1 N m 0 15 kgf m 1 1 Ibf ft RESERVOIR CAP PUSH ROD 18 N m 1 8kgf m 13 Ibf f t 1410000...

Page 420: ...he lock nut to the speci fied torque TORQUE 18 N m 1 8 kgf m 13 Ibf ft INSTALLATION Place the master cylinder onto the main footpeg bracket install the step guard and master cylinder mounting bolts Connect the brake pedal to the push rod lower joint Install the joint pin and secure it with a new cotter pin 1 Of O RING RESERVOIR JOINT SCREW HYDRAULIC BRAKE RESERVOIR JOINT LOCK NUT LOWER JOINT M lor...

Page 421: ...BRAKE CALIPER REMOVAL Drain the front brake hydraulic system page 15 4 Avoid spilling fluid on painted plastic or rubber parts Place a rag over these parts whenever the system is serviced Do not use high pressure air or bring the nozzle too close to the inlet 15 20 Remove the oil bolt sealing washers and brake hose eyelet joint Remove the caliper mounting bolts caliper and the brake pads page 15 6...

Page 422: ...in and lift them damage the piston out sliding surface Clean the seal grooves with clean brake fluid S S INSPECTION Check the caliper cylinder for scoring or other damage Measure the caliper cylinder I D SERVICE LIMITS A 34 02 mm 1 339 in B 30 29mm 1 193in HYDRAULIC BRAKE CALIPER PISTONS PISTON SEAL DUST SEAL ASSEMBLY BOLTS JOINT SEAL Manuals by Motomatrix www motomatrix co uk The Solution For Los...

Page 423: ...m 17 Ibf ft Coat the new piston seals with clean brake fluid Coat the new dust seals with silicone grease Install the piston and dust seal into the groove of the caliper body 6 N m 0 6 kgf m 4 3 lbf ft 0 0 0 0 DUST SEAL CALIPER PISTON A l I 1 i PISTON SEAL CALIPER I PISTON Coat the caliper pistons with clean brake fluid and install them into the caliper cylinder with their open 0 ing ends toward t...

Page 424: ...30 N m 3 1 kgf m 22 Ibf ft Install the brake hose eyelet to the caliper body with two new sealing washers and oil bolt Push the brake hose eyelet to the stopper on the caliper then tighten the oil bolt to the specified torque TORQUE 34 N m 3 5 kgf m 25 Ibf ft Fill and bleed the front brake hydraulic system page 15 4 HYDRAULIC BRAKE a Q JOINT SEAL 0 ASSEMBLY BOLTS SEALING WASHERS 0 0 o BRAKE CALIPE...

Page 425: ...and brake hose eyelet joint Remove the caliper bracket bolts and the brake pads page 15 8 Pivot the caliper up and remove it DISASSEMBLY Remove the pad spring collar and boot from the caliper body Place a shop towel over the piston Position the caliper body with the piston down and apply small squirts of air pressure to the fluid inlet to remove the piston I Rl WASHFRS COLLAR BOOT PAD SPRING r BRA...

Page 426: ...liper pistons for scratches scoring or other damage Measure the caliper piston O D SERVICE LIMIT 38 090 mm 1 4996 in ASSEMBLY PAD SPRING BRAKE PADS 0 2 N m 0 25 kgf m 1 8 Ibf ft 18 N m 1 8 kgf m 13 Ibf ft tl1 COLLAR 27 N m 2 8 kgf m 20 Ibf ft BOOT PISTON SEAL 1 gp 1 01 AN r z 0 7 HYDRAULIC BRAKE d PISTON SEAL DUST SEAL CALIPER PISTON DUST SEAL BOOT 6 N m 0 6 kgf m 4 3 Ibf ft 15 2 5 Manuals by Moto...

Page 427: ...er into the bracket INSTALLATION Apply silicone grease to the caliper pin and install the caliper onto the bracket Install the brake pads page 15 8 Install and tighten the caliper bracket bolt to the specified torque TORQUE 22 N m 2 2 kgf m 16 lbf ft Install the brake hose eyelet to the caliper body with two new sealing washers and oil bolt Push the brake hose eyelet to the stopper on the caliper ...

Page 428: ... spring Remove the footpeg mounting bolt footpeg brake pedal and wave washer INSTALLATION Except California type JOINT PIN W 44 N m 4 5 kgf m 33 Ibf ft i WAVE WASHER MAIN FOOTPEG RETURN SPRING 12 N m 1 2 kgf m 9 Ibf ft BRAKE PEDAL 39 N m 4 0 kgf m 29 lbf ft O SENSOR WIRE i i RIGHT FOOTPEG BRACKET BOLTS BOLT SWITCH SPRING COTTER PIN 4 FOOTPEG BAR A 441111111 y RETURN SPRING BRAKE PEDAL COTTER PIN C...

Page 429: ...RQUE 44 N m 4 5 kgf m 33 lbf ft Hook the brake pedal return spring Install the brake light switch and hook the switch spring Connect the brake pedal to the push rod lower joint Install the joint pin and secure it with a new cotter pin COTTER PIN SWITCH SPRING 39 N m 4 0 kgf m 29 Ibf ft 02 SENSOR WIRE BRAKE LIGHT SWITCH 1BOLT BRAKE PEDAL OOOO C D Ire FOOTPEG WAVE WASHER BOLT 1COTTER PIN FOOTPEG BAR...

Page 430: ...ssembly onto the lower bracket Install and tighten the right main footpeg bracket socket bolts to the specified torque TORQUE 39 N m 4 0 kgf m 29 Ibf ft HYDRAULIC BRAKE 02 SENSOR WIRE RIGHT FOOTPEG BRACKET BOLTS 15 2 9 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 431: ...d battery every two weeks For a battery remaining in a stored motorcycle disconnect the negative battery cable from the battery terminal The maintenance free battery must be replaced when it reaches the end of its service life The battery can be damaged of overcharged or undercharged or of left to discharge for long period These same conditions contribute to shortening the life span of the battery...

Page 432: ... of the Operation Manual for the recommended battery tester The recommended battery tester puts a load on the battery so that the actual battery condition of the load can be measured Recommended battery tester BM 210 AH BM 210 or BATTERY MATE or equivalent SPECIFICATIONS Battery Capacity Current leakage Voltage 20 C 68 F Alternator ITEM Fully charged Needs charging Charging current Normal Quick Ca...

Page 433: ...e using a digital multimeter page 16 5 Start the engine Measure the charging voltage page 16 6 Compare the measurement to result of the following calculation STANDARD Measured battery voltage Matured charging voltage 15 5 V Incorrect Incorrect Incorrect Incorrect Correct Faulty battery Faulty charging coil Faulty battery BATTERY CHARGING SYSTEM Disconnect the regulator rectifier connector and rech...

Page 434: ...r rectifier connector page 16 8 Correct Incorrect Open circuit in related wire Loose or poor contacts of related terminal Shorted wire harness Faulty regulator rectifier Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 435: ...ter VOLTAGE Fully charged 13 0 13 2 V Undercharged Below 12 3 V TOOL Digital multimeter Commercially available BATTERY CHARGING Remove the battery see above Connect the charger positive cable to the battery positive terminal Connect the charger negative cable to the battery negative terminal Quick charging should only be done in an emergency slow charging is preferred For battery charging do not e...

Page 436: ...Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 437: ...he ignition on A sudden surge of current may blow out the fuse in the tester SPECIFIED CURRENT LEAKAGE 0 2 mA max If current leakage exceeds the specified value a shorted circuit is likely Locate the short by disconnecting connections one by one and measuring the current CHARGING VOLTAGE INSPECTION Be sure the battery is in good condition before performing this test Warm up the engine to normal op...

Page 438: ...wl page 2 2 Remove the fuel tank rear bracket and ECM cover page 5 89 Disconnect the regulator rectifier connectors and check it for loose contact or corroded terminals If the regulated voltage reading see page 16 6 is out of the specification measure the voltage between connector terminals wire harness side as follows Item Battery charging line Charging coil line Ground line Terminal Specificatio...

Page 439: ... alternator 3P Natural connector Disconnect the alternator 4P Natural connector Remove the regulator rectifier unit mounting SH bolts and regulator rectifier Install the regulator rectifier unit in the reverse order of removal 3P NATURAL CONNECTOR 4P NATURAL CONNECTOR 10 J REGULATOR RECTIFIER 00000 r j BOLTS Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys ema...

Page 440: ...e servicing A faulty ignition system is often related to poor connections Check those connections before proceeding Make sure the battery is adequately charged Using the starter motor with a weak battery results in a slower engine cranking speed as well as no spark at the spark plug Use spark plug of the correct heat range Using spark plug with an incorrect heat range can damage the engine The dir...

Page 441: ... t Ignition pulse generator rotor special bolt 59 N m 6 0 kgf m 43 Ibf ft TOOLS Peak voltage tester U S A only or Peak voltage adaptor 07HGJ 0020100 with Commercially available digital multimeter impedance 10 M 2 DCV minmum Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 442: ... Blue and Red Yellow wires between the direct ignition coils and ECM 6 Short circuit in ignition primary coil 7 Faulty side stand switch or neutral switch 8 An open circuit or loose connection in No 7 related circuit wires Side stand switch line Green White wire Neutral switch line Light Green and Light Green Red wire 9 Faulty ignition pulse generator measure the peak voltage 10 Faulty ECM when ab...

Page 443: ... commercially available digital multimeter impedance 10 M U DCV minimum IGNITION COIL PRIMARY PEAK VOLTAGE Check all system connections before inspection If the system is disconnected incorrect peak voltage might be measured Check cylinder compression and check that the spark plugs are installed correctly Disconnect the direct ignition coils from the spark plug page 3 6 Connect the direct ignition...

Page 444: ...7 3 Crank the engine with the starter motor and read ignition coil primary peak voltage PEAK VOLTAGE 100 V minimum If the peak voltage is abnormal check for an open circuit or poor connection in Yellow Blue and Blue Yellow wires If no defects are found in the harness refer to the troubleshooting chart on page 17 3 IGNITION PULSE GENERATOR PEAK VOLTAGE Check all system connections before inspection...

Page 445: ...nect the tester probes to the terminal Yellow and White Yellow In the same manner as at the ECM connector measure the peak voltage and compare it to the voltage measured at the ECM connector If the peak voltage measured at the ECM is abnormal and the one measured at the ignition pulse generator is normal the wire harness has an open circuit or loose connection If both peak voltages measure are abn...

Page 446: ...the transmission into 6th gear and apply rear brake Remove the ignition pulse generator rotor bolt INSTALLATION Install the ignition pulse generator rotor by aligning the wide groove with the wide teeth of the crank shaft Apply oil to the ignition pulse generator rotor bolt threads then install the washer and rotor bolt v R0MMEI ALIGI I NITION PL r A W A S H E Bl IGNITION SYSTEM T Manuals by Motom...

Page 447: ...the cover Apply sealant to the wire grommet then install it into the groove of the cover Install and tighten the ignition pulse generator bolts Install the right crankcase cover page 9 17 Route the ignition pulse generator wire properly connect the 2P Red connector Install the removed parts in the reverse order of removal Warm up the engine Stop the engine and remove the timing hole cap ULSE GENER...

Page 448: ...ke sure the F mark begins to move counterclockwise when the engine speed at approximately 1 500 rpm Check the O ring is in good condition replace if necessary Apply grease to the timing hole cap and install the 0 ring and timing hole cap Tighten the timing hole cap to the specified torque TORQUE 18 N m 1 8 kgf m 13 Ibf ft IGNITION SYSTEM IP I L TIMING LIGHT INDEX MARK F MARK 1 I Manuals by Motomat...

Page 449: ...FICATION a 0 I 0 SYSTEM DIAGRAM 18 0 STARTER MOTOR 18 4 SERVICE INFORMATION 18 1 STARTER RELAY SWITCH 18 10 TROUBLESHOOTING 18 2 DIODE 18 11 18 ELECTRIC ST TER Unit mm in ITEM STANDARD SERVICE LIMIT Starter motor brush length 12 0 13 0 0 47 0 51 4 5 0 18 18 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 450: ...nd the starter switch pushed measure the starter relay voltage at the starter switch connector between Yellow Red and ground Battery voltage registered i Check the starter relay switch operation Abnormal CLICK heard Abnormal No voltage Normal Apply battery voltage to the starter motor directly and check the operation Normal Poorly connected Faulty starter motor starter motor cable page 18 4 Faulty...

Page 451: ...starter motor Poor connected battery ground cable Starter motor turns but engine does not turn Starter motor is running backwards Case assembled improperly Terminals connected improperly Faulty starter clutch Damaged or faulty starter drive gear Starter relay switch Clicks but engine does not turn over Crankshaft does not turn due to engine problems Normal Normal Faulty clutch switch Faulty clutch...

Page 452: ...r motor mounting bolts and ground cable Pull the starter motor out of the crankcase location and number of shims With the ignition switch OFF remove the negative cable at the battery DISASSEMBLY Record the Remove the following Starter motor case bolts Rear cover assembly Seal ring Shims BOLTS E f 1 A GRO ND CAB E LTS SHIMS _RM STrA I H J ING f I T A1RRL 1 1 R CASE BOLTS SEAL RING REAR COVER a a 0 ...

Page 453: ...ush holder There should be continuity Check for continuity between the motor case and the cable terminal There should be no continuity Inspect the brushes for damage and measure the brush length SERVICE LIMIT 4 5 mm 0 18 in EAL RING ARMATURE FRONT COVER SHIM INSULATED WASHER LOCK WASHER ELECTRIC STARTER Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email in...

Page 454: ...ator bars for discoloration orsandpaperon Bars discolored in pairs indicate grounded the commutator armature coils in which case the starter motor must be replaced Check for continuity between individual com mutator bars there should be continuity BUSHING OIL SEAL NEEDLE BEARING ARMATURE Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co...

Page 455: ...ush holder assembly Brush terminal ASSEMBLY INSULATED WASHER MOTOR CASE OIL SEAL SEAL RING SHIM AP cr LOCK WASHER Q 001 SEAL RING ARMATURE NUT t WASHER o INSULATORS O RING BRUSH HOLDER ASSEMBLY BRUSH TERMINAL SHIMS il ELECTRIC STARTER REAR COVER BRUSH HOLDER BRUSH Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 456: ...Install the insulated washer and lock washer on the armature shaft Install the seal ring onto the motor case Install the shims properly as noted during removal Install the seal ring on the motor case Install the shims on the armature shaft Assemble the motor case and rear cover aligning the brush holder boss with the groove in the rear cover J NUT WASHER INSULATORS O O RING J SEAL RING ARMATURE FR...

Page 457: ... the starter motor into the crankcase lve ELECTRIC STARTER Route the starter motor cable and ground cable 773k q Tr F TFR NI0TOI STARTEF I R Be careful not to Install the starter motor cables then tighten the damage the water mounting bolts and terminal nut securely hose RO ND CABLE B0LTS INDEX LINES CASE BOLTS O RING TARTER MOT Manuals by Motomatrix www motomatrix co uk The Solution For Lost Moto...

Page 458: ...n The coil is normal if the starter relay switch clicks If the switch CLICK is not heard inspect the relay switch using the procedure below GROUND LINE INSPECTION Disconnect the relay connector Check for continuity between the Green Red wire and ground If there is continuity when the transmission is in neutral or when the clutch is disengaged and the side stand switch is up the ground circuit is n...

Page 459: ...erminals Yellow Red and Green Red Check for continuity between the starter relay switch terminals There should be continuity while 12V battery is connected to the starter relay switch connector terminals and should be no continuity when the battery is disconnected REMOVAL Remove the seat page 2 2 Open the fuse box and remove the diode INSPECTION Check for continuity with an ohmmeter Normal directi...

Page 460: ...r the thermosensor inspection Keep all flammable materials away from the electric heating element Wear protective clothing insulated gloves and eye protection Note the following when replacing the halogen headlight bulb Wear clean gloves while replacing the bulb Do not put fingerprints on the headlight bulb as they may create hot spots on the bulb and cause it to fail If you touch the bulb with yo...

Page 461: ... bolt Fan motor switch Coolant temperature ECT sensor Oil pressure switch Oil pressure switch wire terminal screw Neutral switch 120 C SPECIFICATIONS 12V 55W X 2 12V 55W 12V 21 5W X 2 12V 32 3 cp 23 8 W X 2 12V 21 W X 2 12V 5W LED LED X 2 LED LED LED LED LED 30A 20A 20A 1 10A X 5 10 5 V minimum 2 1 2 6 k S 0 65 0 73 kQ 98 102 C 208 216 F _ 93 97 C 199 207 F 26 N m 2 7 kgf m 20 lbf ft 10 N m 1 0 kg...

Page 462: ... Normal With the ignition switch OFF check for continuity of the Pink Green wire between the terminals of the speed sensor and speedometer Normal Support the motorcycle using a hoist or other support to rise the rear wheel off the ground Measure the output voltage sensor signal at the speedometer with the ignition switch is ON while slowly turning the rear wheel by your hand Normal Abnormal Abnorm...

Page 463: ... touch the bulb with your bare hands clean it with cloth moistened with denatured alcohol to prevent early bulb failure Remove the headlight bulb from the socket Install a new bulb into the socket r t t n IN NJ ECTOR H R BULB SOCKET 1 1 1 I BULBiSUC KL i 1 Install the new headlight bulb socket by aligning its tabs with the groove in the headlight unit I BULB SOCKET 1 I Manuals by Motomatrix www mo...

Page 464: ...lts and headlight unit Install the headlight unit in the reverse order of re moval S Hook the bulb retainer into the headlight unit groove Install the dust cover tightly against the headlight unit with its arrow mark facing up LIGHTS METERS SWITCHES 3 S 4 1 BOLTS HEADLIGHT UNIT Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 465: ...For rear turn signal removal remove the following Seat rear cowl page 2 2 Disconnect the turn signal connector Remove the turn signal mounting nut Route the turn Release the turn signal wire and remove the turn signal wire proper signal unit ly page 1 24 Install the turn signal unit in the reverse order of removal TURN SIGNAL LENS REVV I t I I 4P41 11 I O TURN SIGNAL CONNECTORS NUT SETTING PLATE J...

Page 466: ...tail brake light sockets in the reverse order of removal REMOVAL INSTALLATION Remove the rear cowl page 2 9 Remove the two screws and tail brake light unit Installation is in the reverse order of removal LICENSE LIGHT BULB REPLACEMENT Remove the license light bracket bolts and the license light assembly LIGHTS METERS SWITCHES i CONNECTORS BULB I J TAIL BRAKE LIGHT UNIT SCREWS LICENSE LIGHT BOLTS M...

Page 467: ...sconnect the combination meter multi connector Remove the combination meter mounting bolt Release the combination meter case bosses from the bracket grommets then remove the combina tion meter DISASSEMBLY Remove the screws and combination meter rear cover COVER BULB 14 SCREWS COMBINATION METER i MULTI CONNECTOR r BOLT COMBINATION METER I S GROMMETS REAR COVER SCREWS 7 Manuals by Motomatrix www mot...

Page 468: ...n the screws secure ly INSTALLATION Install the combination meter onto the bracket Install and tighten the mounting bolt 0 Connect the combination meter multi connector Install the upper cowl page 2 11 0 REAR COVER SCREWS LIGHTS METERS S I IITCHES PRINT BOARD FRONT COVER BOLT COMBINATION METER i T GROMMETS COMBINATION METER MULTI CONNECTOR 19 9 Manuals by Motomatrix www motomatrix co uk The Soluti...

Page 469: ... connection of the combina tion meter multi connector With the ignition switch is ON and measure the volt age at the multi connector terminals Connection Black Brown Green Black Standard Battery voltage If there is no voltage repair or replace the wire har ness OUTPUT SIGNAL INSPECTION With the ignition switch is OFF check for continuity of the Pink Green wire between the speed sensor connector an...

Page 470: ...measurement is out of specification inspect the open circuit in wire harness REMOVAL INSTALLATION Open and support the front end of fuel tank page 3 4 Disconnect the speed sensor 3P Natural connec tor Remove the bolts and speed sensor Check the 0 ring is in good condition replace if nec essary Install the speed sensor into the upper crankcase Y MULTI CONNECTOR r 3P NATURAL CONNECTOR LIGHTS METERS ...

Page 471: ...S Imrie diagnostic tester model 625 or Peak voltage adaptor 07HGJ 0020100 with commercially available digital multimeter impedance 10 M 2 DCV minimum CONNECTION Yellow Green and Ground Start the engine and measure the tachometer input peak voltage PEAK VOLTAGE 10 5 V minimum If the value is normal replace the tachometer If the measured value is below 10 5 V replace the ECM 4 S1 F F Vti Fl 3P NATUR...

Page 472: ... coolant page 6 3 Disconnect the wire connector from the ECT thermo sensor and remove the sensor Suspend the ECM thermo sensor in a pan of coolant 50 50 mixture an electric heating ele ment and measure the resistance through the sen sor as the coolant heats up Soak the ECT thermo sensor in coolant up to its threads with at least 40 mm 1 6 in from the bottom of the pan to the bottom of the sensor K...

Page 473: ... OFF disconnect the con nector from the fan motor switch and turn the ignition switch ON again If the fan motor does not stop check for a shorted wire between the fan motor and switch If the fan motor stops replace the fan motor switch Fan motor does not start Before testing warm up the engine to operating temperature Disconnect the connector from the fan motor switch and ground the connector to t...

Page 474: ... of removal OIL PRESSURE SWITCH INSPECTION If the oil pressure warning indicator stays on while the engine running check the engine oil level before inspection Make sure that the oil pressure warning indicator came on with the ignition switch ON If the indicator does not come on inspect as follow OIL PRESSURE SWITCH Open and support the front end of fuel tank page 3 4 Remove the dust cover Remove ...

Page 475: ...ON Remove the boot terminal screw and wire terminal Remove the oil pressure switch from the crankcase Apply sealant to the oil pressure switch threads as shown Install the oil pressure switch onto the crankcase tighten it to the specified torque TORQUE 12 N m 1 2 kgf m 9 lbf ft Connect the oil pressure switch terminal to the switch and tighten the screw to the specified torque TORQUE 2 N m 0 2 kgf...

Page 476: ...check for open or short circuit in wire harness IGNITION SWITCH INSPECTION Remove the right inner panel page 2 9 Disconnect the ignition switch wire 4P Natural con nectors Check for continuity between the wire terminals of the ignition switch connector in each switch posi tion Continuity should exist between the color coded wires as follows IGNITION SWITCH ON OFF LOCK FAN COLOR I Bu O R BI IG I BA...

Page 477: ...tch connectors Check for continuity between the wire terminals of the handlebar switch connector Continuity should exist between the color coded wire terminals as follows ENGINE STOP SWITCH OFF RUN COLOR BI IG BAT2 W BI STARTER SWITCH ST IG BAT3 FREE C PUSH COLOR Y R 1 61 BI Br 1 Bu W HL 4P NATURAL CONNECTOR BOLTS 1 0 Jr Jim c IL 1W I GNITION SWITCH STARTER SWITCH ENGINE STOP SWITCH Manuals by Mot...

Page 478: ... REAR Remove the seat page 2 2 Disconnect the rear brake light switch connector and check for continuity between the terminals There should be continuity with the brake pedal applied and there should be no continuity with the brake pedal is released DIMMER SWITCH TURN SIGNAL SWITCH HORN SWITCH W R R N L COLOR GR I Lb LIGHTS METERS SWITCHES BAT5 PR PL 0 BI Br Lb W O W 00 V I BRAKE LIGHT SWITCH BRAK...

Page 479: ...round There should be continuity with the transmission is in neutral and no continuity when the transmission is into gear SIDE STAND SWITCH INSPECTION Open and support the front end of fuel tank page 3 4 Disconnect the side stand switch 3P Green connec to r Check for continuity between the wire terminals of the side stand switch connector Continuity should exist only when the side stand is UP r Al...

Page 480: ...he switch groove with the return spring holding pin Secure the side stand switch with a new bolt TORQUE 10 N m 1 0 kgf m 7 Ibf f t Connect the side stand switch 3P Green connector LIGHTS METERS SWITCHES 3P GREEN CONNECTOR SIDE STAND SWITCH ALIGN SIDE STAND SWITCH a BOLT 3P GREEN CONNECTOR Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix c...

Page 481: ...e items are all normal check the follow ing Disconnect the turn signal connectors from the relay 1 Short the black and gray terminals of the turn signal relay connector with a jumper wire Start the engine and check the turn signal light by turn ing the switch ON Light comes on Light dose not come on Broken wire harness 2 Check for continuity between the green terminal of the relay connector and gr...

Page 482: ...lector in the same exhaust system In the low and middle speed ranges the exhaust collector is in the 360 position to produce more engine torque In the high speed range the exhaust collector is in the 180 position to maximize high engine power INTAKE VALVE CONTROL The intake valve is controlled by the same servo motor used for the EGCV to control intake air volume In the low and middle speed ranges...

Page 483: ...dex line facing down by the control cables from servo motor At this position the exhaust gases flow directly through the EGCV 360 collector 180 When the engine revolution increase and pass 8 000 rpm the EGCV cable pulley is moved to 180 pulley index line facing down by the control cables from servo motor At this position the No 1 and No 2 and the No 4 and No 3 exhaust pipe gases are crossed by the...

Page 484: ... opened by the control cable from servo motor At low and middle speed ranges At high speed range Ie 11 a I 111 11 TECHNICAL FEATURES Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 485: ...l Abnormal Abnormal Low compression Engine starts but stops Wet plug Faulty pressure regulator ection 5 See section 5 Weak or no spark Faulty spark plug Fouled spark plug Faulty ECM Broken or shorted spark plug wire Faulty ignition switch Faulty ignition pulse generator Faulty engine stop switch Loose or disconnected ignition system wires Valve stuck open Worn cylinder and piston ring Damaged cyli...

Page 486: ...Fouled or discolored Incorrect Valve train not lubricated properly Possible cause Brake dragging Worn or damaged wheel bearing Faulty tire valve Punctured tire Clutch slipping Worn clutch discs plates Warped clutch discs plates Weak clutch spring Additive in engine oil Air cleaner dirty Restricted fuel flow Clogged muffler Pinched fuel tank breather Faulty ECM Faulty ignition pulse generator Valve...

Page 487: ...Wrong type of fuel Clutch slipping 12 Accelerate or run at high speed Engine knocks Worn piston and cylinder Wrong type of fuel Excessive carbon build up in combus Engine does not knock tion chamber Ignition timing to advanced faulty ECM Lean fuel mixture TROUBLESHOOTING Abnormal Faulty pressure regulator Section 5 Abnormal See section 5 Leaking Loose insulator clamp Damaged insulator Weak or inte...

Page 488: ...lve spring Not weak POOR HANDLING Possible cause 1 If steering is heavy 2 If either wheel is wobbling 3 If the motorcycle pulled to one side Possible cause Steering stem adjusting nut too tight Damaged steering head bearings Excessive wheel bearing play Bent rim Improper installed wheel hub Swingarm pivot bearing excessively worn Bent frame Faulty shock absorber Front and rear wheel not aligned Be...

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