HOW TO USE THIS MANUAL

A Few Words About Safety

Service Information
The sel"llice and repair infonnatiofl contained in this manual is intended fO( use by qualified, professional technicians. Attempting
service or repairs without the proper training, tools, and equipment could cause injury to you or others . It could also damage the
vehicle or create an unsafe condition.
This manual describes the proper methods and procedures for performing service, maintenance and repairs. Some procedures
require the use of specially designed tools and dedicated eqUipment. Any person who Intends to use a replacement part. service
procedure or a tool thai is not recommended by Honda, must determine Ihe risks to their personal safety and the safe operation of
the vehICle.
If you need to replace a part. use Honda Genuine parts with the correct part number or an equivalent part. We strongly recommend
thai you do not use replacement parts of inferior quality.

For Your Customer's Safety

Proper servIce and maIntenance are essential to the customer's safety and the reliability of the vehicle Any error or oversight whIle
servicing a vehicle can resull in faulty operation, damage to the vehlde, or Injury to others.

AWARNING
tmproper service or repaIrs can create an unsafe
conditIon that can cause your customer to be
seriously hurt or killed
Follow the procedures and precautions in this
manual and other service materials carefully.

For Your Safety

Because this manual is Intended for the professIon al service techniCIan, we do not provIde wamings about many basic shop safety
practIces (e.g .. Hot parts-wear gloves). If you have not received shop safety training or do not feel confident about your knowledge
of safe servicing practice, we recommend thai you do not attempt to perfOf'1l1 the procedures described in this manual.
Some of the most important general service safety lX9Cautions are given betow However, we cannot warn you of every
conceivable hazard that can ansa in performing service or repair procedures. Only you can decide whether or not you should
perfoon a given task.

AWARNING
Failure to property follow instructions and
precautions can cause you to be seriously hurt or
killed
Follow the procedures and precautions In this
manuat carefully

Important Safety Precautions

Make sure you have a clear understanding of all basic shop safety practices and that you are weanng appropriate clothing and
using safety equipment. When perfooning any service task, be especially careful of the fol lOWIng
Read aU of the Instructions before you begin. and make sure you have the tools, the replacement or repair parts, and the skills
required to perform the tasks safely and complelely
Protect your eyes by using proper safety glasses. goggles or face shields any time you hammer, drill. grind, pry or work around
pressurIZed air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye protection.
Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe
bums or cu ts. Before you grab something that looks like it can hun you, stop and put on gloves.
Protect yourself and others whenever you have the vehicle up in the air. Any IJme you lift the vehicle. either with a hOist or a Jack,
make sure that II is always securely supported. Use jack stands.
Make sure the engine is off before you begin any servictng procedures unless the instructIon tells you to do otherwise. ThiS wilt
help eliminate several potential hazards:
Carbon monoxide poIsoning from engine exhaust. Be sure there IS adequate ventllatJon whenever you run the engine.
, Burns from hot parts or coolant. Let the engine and exhaust system cool before WOr1<lng In those areas.
• Injury from moving parts. If the instruction teUs you to run the engine. be sure your hands, fingers and clothing are out of the way.
Gasoline vapors and hydrogen gases from batteries are explOSive. To reduce the possibility of a fire or explosion, be careful when
WOrking around gasoline or batteries.
Use only a nonflammable solvent. not gasoline, to dean parts.
Never drain or store gasoline In an open container
Keep all Cigarettes, span.::s and flames away from the battery and all fuel-related parts.
 HOW TO USE THIS MANUAL
How To Use This Manual
This manual describes the service procedures for the TRX500FMIFElFPMfFPE.
Sections 1 and 3 apply to the whole vehicle. Section 2 illustrates procedures for removal/installation of components that may be
required to perform service described in the following sections.
Section 4 through 24 describe parts of the vehicle, grouped according to location.
Follow the Maintenance Schedule recommendations to ensure that the vehicle is in peak. operating condition.
Performing the first scheduled maintenance is very important. It compensates for the initial wear thai occurs during the break-in
period.
Find the section you want on this page, then turn to the table of contents on the first page of the section.
Most sections start with an assembly or system illustration , service Information and troubleshooting for the section. The subsequent
pages give detailed procedure.
Refer to the troubleshooting in each section according to the malfunction or symptom. In case of an engine trouble, refer to PGM-FI
section troubleshooting first.

Your safety, and the safety of others. is very important. To help you make informed decisions we have provided safely
messages and other information throughout this manual. Of course, it IS not practical or poSSible to warn you about all the
hazards associated with servicing this vehicle.
You must use your own good judgement.
You will find Important safety information in a variety of forms including:
Safety Labels - on the vehicle
• Safety Messages- preceded by a safety alert symbol ! and one of three signal words, DANGER, WARNING, orCAUTtON.
These signal words mean :

tti'Mdb;j' You WILL be KILLED or SERIOUSLY HURT if you don't follow instructions.
m?4i;!~ ii ml You CAN be KILLED or SERIOUSLY HURT if you don 't follow instructions.
tffitJiW.g. You CAN be HURT if you don't follow instructions.
• Instructions - how to service this vehicle correctly and safely.

As you read this manual , you will find information that is preceded by a ~HOIKt_ symbol. The purpose of this message is to help
prevent damage to your vehide , other property, or Ihe environment.
HOW TO USE THIS MANUAL
SYMBOLS
The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to
these symbols, it would be explained specifically in Ihe texl without Ihe use of Ihe symbols.

Replace the part(s) with new one(s) before assembly .

Use the recommended engine oil. unless otherwise specified.

Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1 :1).

Use multi-purpose grease (lithium based multi-purpose grease NlGI #2 or equivalent).

Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide , NLGI #2 or
equivalent).
Example:
• Molykote® BR-2 plus manufactured by Dow Coming U.S.A .
• Multi-purpose M-2 manufactured by Milsubishi Oil, Ja~pa~n:,--~~_ __
- -- - - - i - cUco''''e molybdenum disulfide paste (containing more than 40% molybdenum disulfide. NLGI #2 or
equivalent).
Example:
Molykole® G-n Paste manufactured by Dow Corning U.S.A.
Honda Moly 60 (U .S.A. only)
Rocol ASP manufactured by Rocollimited, U.K.
_ _ __ _ _--'R~o~co='P~'~'~le""
m"anufactured by Sumico lubricant, Japan
r

Use silicone grease.

Apply a locking agent. Use a medium strength locking agent unless otherwise specified .

Apply sealant.
..'€lID
----+-------------
Use DOT 4 brake fluid . Use the recommended brake fluid unless otherwise specified .

~___-=8= _____u_ '_e_ '_O_fk or suspension fluid.

 CONTENTS
GENERAL INFORMATION
FRAME/BODY PANELS/EXHAUST SYSTEM
MAINTENANCE
PGM-FI SYSTEM
~ ~~~~~==~========================~
IGNITION SYSTEM
~ ~~==~~~==========================~
>- ELECTRIC STARTER
~ F=~~~==~=============================
-' FUEL SYSTEM
w F=======================================~
o COOLING SYSTEM
~ F=~==~=============================
LUBRICATION SYSTEM
~ F=C~Y~L~I=N~D=E=R=H=E=A=D=N=A=L=V=E=======================
>- F=~~~~~========================
w CYLINDER/PISTON
~ F=~~~~====~==~================
o0:: CLUTC H/GEARSHIFT LINKAGE
WF=A~L~T=E=R~N~A=T=O=R=/S=T=A=R=T=E=R=C=L~U=T=C~H~===============
Z f======================================
Cl
Z
CRANKCASE/TRANSMISSION/CRANKSHAFT/BALANCER
w
ENGINE REMOVAUINSTALLATION
FRONT WHEEUSUSPENSION/STEERING
II> REAR WHEE USUS PENSION
~ F==B=R~A=K=E=S~Y=S=T=E=
M============================
J:
(J FRONT DRIVING MECHANISM
REAR DRIVING MECHANISM
BATIERY/CHARGING SYSTEM
LIGHTS/METERS/SWITCHES
ELECTRIC SHIFT PROGRAM (ESP: FE/FPE models)
ELECTRIC POWER STEERING (EPS: FPM/FPE models)
WIRING DIAGRAMS
INDEX
MEMO

J
 1. GENERAL INFORMATION

SERVICE RULES .... ······································ 1·2 LUBRICATION & SEAL POINTS ··············· 1·19

MODEL IDENTIFICATION ···························· 1·3 CABLE & HARNESS ROUTING················· 1·23

SPECIFICATIONS ········································· 1·6 EMISSION CONTROL SYSTEMS ·········· ···· 144

TORQUE VALUES· .. ··································· 1·13

1-1
GENERAL INFORMATION
SERVICE RULES
1. Use Honda Genuine or Honda-recommended parts and lubricants or their equi....alents. Parts that don't meet Honda's design
specifications may cause damage to the vehicle.
2. Use the special tools designed for this product to avoid damage and incorrect assembly.
3. Use only metric tools when servicing the vehicle. Metric botts, nuts and screws are not interchangeable with English fasteners .
4 . Install new gaskets, O-rings, cotter pins, and lock plates when reassembling.
5. When tightening bolts or nuts, begin with the larger diameter or Inner bolt first. Then tighten to the specified torque diagonally in
incremental sleps unless a particular sequence is specified.
6. Clean parts in deaning solvent upon disassembly. lubricate any sliding surfaces before reassembly.
7 After reassembly, check all parts for proper installation and operation.
8 Route all electrical wires as shown In the Cable & Harness Routing (page 1-23).
9. Do not bend or twist control cables. Damaged control cables will not operates smoothly and may slid( or bind.
10. Do not tow your ATV behind a car or other vehicle.

ABBREVIATION
Throughout this manual, the following abbreviation are used to identify the respective parts or systems.

L ""n;",Abbrev. term Full term

,- CKP sensor Crankshaft Position sensor
LCD liquid Crystal Display
DLC Data link Connector - -
DTC Diagnostic Trouble Code
PCM (FEfFPE models) Powertrain Control Module
ECM (FMfFPM modelstl ==i~E~n~g~ine Control Module
ECT sensor -~ Engine Coolant Temperature sensor
EEPROM ElectncaUy Erasable Programmable Read Only Memory
EPS Electnc Power Steering
ESP Electric Shift Program
ECU Electric Control U~
HDS Honda Diagnostic System
IACV _======~',dle Air Control Valve
IAT sensor Intake Air Temperature sensor
MAP sensor _ __ _ __ Manifold Absolute Pressure sensor
MIL Malfunction Indicator Lamp
PGM-FI Programmed Fuel Injection
SCS service connector I Service Check Short service connector
TP sens:~o~,_ _ __ _ __ ~I Throttle Position sensor
VS sensor ____ _ __ t
Vehicle Speed sensor
l 4WD !
_ _ _ __ _ _ _J -4 Wheel Drive =-_____

1·2
 GENERAL INFORMATION
MODEL IDENTIFICATION
This manual covers 4 types of TRXSOO models:
FM - 4WD/Left fool operated gearshift
FE - 4WDfElectric shift program (ESP)
• FPM - 4WD/Left foot operated gearshift/Electric Power Steering (EPS)
• FPE - 4WDfElectric shift program (ESP)fElectric Power Steering (EPS)
Be sure to refer to the procedure that pertains to the appropriate version of the TRX500.

SERIAL NUMBERS
The Vehicle Ideo(;fi08tloo N,mbe, (VI N) [1) Is stamped 00 the Imot "de 01
the frame through the front fender.
I

The engine serial o,mbe' [11 Is stamped 00 the leh side of the 'ea,
crankcase.
I

1-3
GENERAL INFORMATION
The throttle body identification number (1) is stamped on the lower side of
the throttle body.

LABELS
The certification label [1] (U.S.A. type) or safety certification label [2]
(Canada type) is attached on the left front frame down pipe.

The color label 11] is attached on the left front frame down pipe. When
ordering color-coded parts. always specify the designated color code .

1-4
 GENERAL INFORMATION
The vehicle emission control information label (11 is attached on the left f ront
frame pipe . U.S.A. and Canada type :

111

Canada type only:

1-5
GENERAL INFORMATION
SPECIFICAliONS
GENERAL SPECIFICATIONS
- - -- - ITEM SPECIFICATIONS
DIMENSIONS Overall length 2,127 mm (83.7 in)
Overall width 1,205 mm (47.4 in)
Overall height 1,197 mm (47.1 in)
Wheelbase 1,281 mm (50A in)
Front tread 915 mm (36.0 in)
Rear tread 925 mm (36.4 in)
Seat height 881 mm (34.7 in)
Footpeg height FMJFPM: 365 mm ( 14.4 in)
FElFPE: 355 mm (14.0 in)
Ground clearance 194 mm (7.6 in)
Curb weight FM : U.S.A.: 284 kg (626 Ibs)
Canada: 286 kg (631 Ibs)
FE: U.S.A.: 285 kg (628 Ibs)
Canada: 286 kg (631 Ibs)
FPM : U.S.A.: 291 kg (642 Ibs)
Canada : 293 kg (646 Ibs)
FPE: U.S.A. : 292 kg (644 Ibs)
Canada: 294 kg (648Ibs)
Maximum weight capacity 220 kg (48Slbs)
FRAME Frame type Double cradle
Front suspension Double wishbone
Front wheel travel
Front damper
171 mm (6.7 in)
Double tube
1
Rear suspension Swingarm (trailing type)
Rear wheellravel 174 mm (6.9 in)
Rear damper Double tube
Front tire size AT2S x 8-12 .. -
Rear tire size AT2S x 10-12 **
Front rim size 12x6.0AT
Rear rim size 12x7.5AT
Front tire brand M975 (MAXXIS )
Rear tire brand M978 (MAXXIS)
Front brake Hydraulic disc brake
Rear brake Mechanical drum brake
Caster angle 3·
T ra il length 11 rnm (0.4 in)
Camber angle O·
Fuel tank capacity 15.0 lilers (3.96 US gal , 3.30 Imp gal)
Fuel tank reserve capacity 4 .6 liters ( 1.22 US gal, 1.01 Imp gal )
ENGINE Cylinder arrangement Single cylinder, longitudinally installed
Bore and stroke 92.0 x 71.5 mm (3.62 x 2.81 in)
Displacement 475 cm l (29.0 cu-in)
Compression ratio 9.5 ' 1
Valve train OHV
Intake valve opens: at 1 mm (0.04 in) lift
7" BTOC
closes: at 1 mm (0.04 in) lift
43" ABOC
Exhaust opens: at 1 mm (0.04 in) lift
44 " BBOC
valve closes: at 1 mm (0.04 in) lift
1· ATOC
lubrication system Forced pressure and wet sump
Oil pump type Trochoid
Cooting system liquid cooled
Air filtration Oiled double urethane foam
Engine dry weight FMlFPM:
U.S.A .: 51.4 kg (113.3Ibs)
Canada: 52.5 kg (115.7Ibs)
FElFPE: U.S.A.: 52.3 kg (1l5.3Ibs)
Canada: 53.4 kg (117 .7Ibs)
V - -TT"yp" eC
FUEL DELIVERy - -- - -- - - - hpGM.FI (Programmed Fuel Injection)
SYSTEM _ _~_T "h",rott!e bore 36 mm (1.4 in)_ _

1-6
 GENERAL INFORMATION
ITEM'---_ _ __ SPECIFICATIONS
DRIVE TRAIN Clutch system Centrifugal and multi-plate, wet
Clutch operation system Automatic
Transmission Constant mesh, 5-speeds with reverse
Primary reduction 2.103 (61/29)
Secondary reduction 1.875 (30/16)
Final reduction Front 3.231 (42/13)
Rear 3.154 (41/13)
Gear ratio 1st 4.230 (55fI3)
2,d 2.388 (43/18)
3,d 1.608 (37/23)
41h 1.178 (33/28)
51h 0.848 (2S(33)
Reverse 5.743 (48/13 x 2af18)
Gearshift pattern R - N-I-2-3-4-5
FM/FPM: Left foot operated return system
--"F"EI"F",P",E'c'_~-:EO",;:eC,"I~ric__s"h'";f~(left
t hand operated) return sys__l"em
" '--_---"
ElECTRICAL Ignition system Full transistorized ignition
Starting system U.S.A.: Electric starter motor
Canada: Electric starter motor and emergency recoil slater
Charging system Triple phase output alternator
Regulator/rectifier FET shorted , triple phase full wave rectification
Lighting system Battery

PGM-FI SYSTEM SPECIFICATIONS

ITEM SPECIFICATIONS
tAT sensor resistance (20°C/68 F-' ) - - - - - - - - --
Q
2.2 2.7 kO
EeT sensor resistance (40 ± 5 Cf104 ± 4 1°F)
6
+ 0.86 1.55 kO
Fuel injector resistance (20°C/6,oS,,·F:l)_ _ _ _ _ _ _ _~+ 11.6-12.40

IGNITION SYSTEM SPECIFICATIONS

Spark plug
ITEM --=====:- ===+==
____ + ___ SPECIFICATIONS
--'S"'K"'RSE-l1 (NGK), KI6PR-Ul1 (DENSO)
Spark plug g~p ________ 1.0-1.1 mm (0.039-0.043 in)
Ignition coil primary peak voltage 100 V minimum
Ignition pulse generator peak voltage 0.7 V minimum
_ Ignition timing ("F" mark) 10 BTDC al idle
6

1
ELECTRIC STARTER SPECIFICATIONS
_ _~~~ Unit: mm (in)
ITEM STANDARD _ _+-,;;S..
ERo;,VICE LIMIT
-----starter motor brush length 12.0 (0.47) 6.5 (0.26)

FUEL SYSTEM SPECIFICATIONS

ITEM SPECIFICATIONS
Throttle body identification number GQ3RA
Idle speed 1,400 ± 100 rpm
Throttle lever freeplay 3-8mm(0. 1-0.3in)
Fuel pressure at idle 316 387 kPa (3.2 3.9 kgf/em2, 46 56 psi)
Fuel pump flow (at 12 V) 125 em (4.2 US oz, 4.4 Imp OZ) minimum/ l0 seconds

1-7
GENERAL INFORMATION
COOLING SYSTEM SPECIFICATIONS

Coolant capacity
ITEM
Radiator and en"9i,n,,
==::-:R.::e"s",
erve tank
,0 ______--f__
---==:;::;;:~S~
P~EC~I~F~ICATIONS;;:;::;;;====-j
1.51lters (1.6 USqt. 1.3 Imp qt)
0.3 liter (0.3 US ql. 0.31mp qt)
1
108-137 kPa (1 .1 - 1.4 kgffcm 2, 16 20 psi)
Radiator cap relief pressure --==========:1==--
Thermostat ~gin to open 80 84'C 1176 183' F)
Fully open 9S' C (203' F)
, Valve lift -o
8 ~m~mOff(0~.3~i~n~)m~in~imumat9~S"'C'"12~0~3"'F~)------
Recommended a~n" tif;:;re"eC;ze-;:----"-' Pro Honda HP Coolant or an equivalent high quality ethylene
~=====_______= == = = : - '- glycol antifreeze containing silica;te;~-f~ree
~CO~rrtOS~io~n~i~n~hi~b~
ito~rs=---t
Standard coolant concentration 1:1 mixture with di~illed water

LUBRICATION SYSTEM SPECIFICATIONS

::;::==~fT~E~MC::;~
Engine oil capacity After draining,""= ==o--__
STANDARD
+--;2.9 liters (3.1 US ql. 2.6 Imp ql)
Unit: mm (in)
SERVICE LIMIT 1
After draininglfilter change 3.0 liters (3 ,2 US qt, 2.6 Imp ql)
,-;;;;-;;;o==,-'-~After disassem
~b~I~Y ________+--i3;o:
.3 liters (3 .5 US qt, 2.9 Imp ql) ;r+--------------'
Recommended engine oil Pro Honda GN4 4-stroke oil (U.S,A. and
Canada) or Honda 4-stroke oil (Canada
only), or equivalent motor oil
API service classification: SG or higher
(except oils labeled as energy
conserving on the circular API service
label)
JASO T 903 standard: MA
_________--f--;Viscosity: SAE 10W-30
Oil pump L!!Pclearance 0.15 (0.006) ""'''''''''''_ _ 0~20J0008 ~
~y clearance 0.15 -0.24 (0.006 0.009) 0.25 (0.010)
___________L : .'S"'i
de clearance 0,02 - 0.09 (0.001 - 0.004) 0.11 (0.004)

CYLINDER HEADNALVE SPECIFICATIONS

Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Cylinder compression at 400 rpm 600 kPa (6 .1 kgf/cm3, 87 psi)
Valve clearance ~ 0.15±0.02(["006To.001)
EX 0.23 :t 0.02 (0.009 ± 0.001)
Valve, valve Valve stem 0 .0 . IN 5,975 5.9-90 (0.2352 0.2358) 5.95 (0.234)
9 uide EX 5.955 - 5. 970(0.2344 - 0.2350) 5.93 (0.233)
Valve guide 1.0 . IN/EX 6.000 6. 012 (0.2-362 - 0.2367 f-)---+-'6"'.;::02"1"'0~.2"37':)'---
Stem·to-guide clearance IN 0.010 O. 037 (0.0004 - 0.0015) 0.12 (0.005)

above ~~;1:'j~;c~~:t===~E~X~=~0.030
Valve guide
i
Valve seat width
IN/EX - 0.057
14.8 -15.0 (0.00
(0.58 12 - 0.0022)
- 0.59) 0.14 (0.006)

Valve sprin9 Free length

Rocker arm Arm 1.0.

Shaft 0.0.
r---Arm-to-shaft
Camshaft and Cam lobe height
cam follower
Cam follower 0 .0 .
Follower bore 1.0.
Follower-to-bore
Cylinder head warpage

1·8
 GENERAL INFORMATION
CYLINDER/PISTON SPECIFICATIONS
Unit: mm (in)
--.-~---,ITEM STANDARD SERVICE LIMIT
Cylinder 1.0.
Out-of·(ound
I
_-_-_-_-=--=-+f-
92.000' -9"'2".0"1"'0'"'(3.6220 _ 3.6224) 92 .10@:626)
0.10 (0,004)
Taper 0.10 (0.004)
Warpage 0.10 (0.004)
Piston, Piston 0.0. at 15 (0.6) from bottom 91.970 - 91.990 (3.6209 - 3.6216) 91 .90 (3.618)
pis-ton pin, Piston pin hole l.O. =~~t-'19.002 -19.008 (0.7481 - 0.7483) 19.04 (0.750)"
piston ring Piston pin 0.0 . 18.994 19.000 (0.7478 - 0.7480) 18.96 (0.746)
Piston-Ie-piston pin clearance 0.002 - 0.014 (0.0001 - 0.0006) 0.08 (0.003)
Piston ring end L.!op 0.15- 0.30 (0.006 0.012) ~~~_ 0.5 (O.02)
gap , Second .~;:=:=~O. 30 - 0.45 (0.012 0.018) 0.6 (0.02,,)_ _
~~_-,Oil (side r~il) 0.20 - 0.70 (0.008 0.028) 0.9 (0.04)
Piston ring-to-ring Top ~~~+-O.030 - 0.060 (0.0012 - 0.0024) 0.09 (0.064-)--
groove clearance ------second 0.030 - 0.060 (0.0012 - 0.0024) 0.09 (0.004)
i Cylinder-to-piston clearance 0.010 _ 0.040 (0.0004 - 0.0016) I 0 10 (0.004)-----1
Connecting rod small end 1.0 . 19.020 - 19.041 (0.7488 - 0.7496) 19.07 (0.751) I
Connecting rod-to-piston pin clearance 0.020 - 0.047 (0.0008 - 0.0019) 0.10 (0.004)

CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS

UOII: mm (in)

Centrifugal
clutch
1 ITEM
Drum 1.0.
Weight lining thickness 2.0 (0.08)
STANDARD
150.0 - 150.2 (5.906 - 5.913)
SERVICE LIMIT
150.4 (5.9c=2~)_ _
1.3 (0.05)
Clutch spring height -t- 2.96 (0.1 17) ~~~-+- 2.84 (0.112)
.=;;;-~~C::;;lutCh weight spring free len"g"th,---~~~I 24.72 (0.973) ~~_ _ 25.7 (1.01)
Change clulch Spring free length FM/FPM 52 .2 (2.06) _-=;:=:;:=:=- 50.7 (2.00)
FElFPE 46.8 (1.84) 45.3 (1.78)
Disc thickness _ _~~~ 2.62 - 2 ..78 (0.103 0.109) ~~_-;2.3 (0.09)
Plate warpage 0.20 (O.O~L
Outer [0. - _--=;:=:==29.000 - 29.021 {1.1417 - 1.1426)~--;29. 05 (1 .144)
Outer guide 1.0 . 22.000 - 22.021 (0.8661 - 0.8670) 22.05 (O.868).
0.0. ~~_ 28 . 959 - 28.980 (1.1401 - 1.1409) 28.93 (1 .139)
Mamshaft 0 .0 . at clutch outer guide 21 .967 - 21.980 (0.8648 - 0.8654) 21 .93 (0.863)
Primary drive Gear 1.0 29.000-29.021 (1. 1417 - 1.1426) - t -29 .05 (1 .144 )
gear Crankshaft 0 .0 . at drive gear 28.959 - 28.980 (1.1401 - 1.1409) 28.93 (1.139)

AL TERNATORISTARTER CLUTCH SPECIFICATIONS

Unit: mm (in)
:::-;:;;::;:==_tltTEM _ _---,"'_ STANDARD =.---~_...,S~E"iR"
VICE L1M IT
Starter driven gear boss 0.0. ~ .705 51.718 (2.0356 - 2.0361) 51 69 (2.035)
1.0. ~946 - 31.962 (1.2577 - 1.2583) 31 .90 (1.256)
i Crankshaft 0.0. at starter driven gea=,~~~_ 1- 31.884 - 31.900(1.2553-1.2559) 31.85(1.254)

1-9
GENERAL INFORMATION
CRANKCASEITRANSMISSION/CRANKSHAFT/BALANCER SPECIFICATIONS
Unit: mm (in)
~=~~ :::::r,T!iE[jM
'==--_--rc STANDARO SERVICE LIMIT
Shift fork 1.0. a,c -- ' - 13.00
Front, re"' ' 02:C,CC(O.5118 0.5126)
= 0- "3." 13.04 (O.5~
Center -==t~'~3.000 13.018 (0.5118 - 0.5125) 13.04 (O.S13)
Claw thickness _ 4,93 5.00(0.194 - 0.197) 4.5(0.18)
= = -1-' Shaft 0 .0 . 12.966 12.984 (O.5105-0.5112) 12.96 (0.510)
Transmission i Gear LD. M3 ---+-25.000 25.021 (0.9843 - 0.9851) 25.05 (0.986)
M5 20.000 - 20.021 (0.7874 - 0.7882) 20.05 (0.789)
t
CTC2, C4, CR
Reverse idle
28.020 28.041 (1 .1031-1 .1040)
13.000 13.021(0 .5118-0.5126)
28.07 (1.105)
13.04(0.513)
1
Gear bushing M3 24.959 24 ,980 (0,9826 - 0.9835) 24.93 (0.98 1)
0.0. M5 ! 19.966 19.984 (0.7861 0.7868) 19.94 (0.785)
C2 27.984 28.005(1 .1017-1 .1026) 27.94 (1.100)

~
"C4' CR 27.979 28.000(1 .1015 - 1.1024) 27.93(1 .100)
~ I 0.020 0.062 (0.0008 - 0.0024)
GeaHo-bushing
clearance
M3
M5
C2 0.D15 0.057 (0.0006 - 0 . ~~22)
0.10 (0.004)
0.016 0,055 (0.0006 - 0. 0;;0~2~2)t:::=:t 0.10 (0.004)
0.08 (0.003)
j
Cl. C4 , CR I
0.020 0.OS2 (0.0008 - 0.0024) 0.10 (0.004)
Gear bushing 1.0. M3 22 .000 22.021 (0.8661 - 0.8670) 22.04 (0.868)

t
M5 I 17.016 17.034 (0.6699 0.6706) 17.06 (0.672)
_ _-'-'_:C4 25.000 25.021 (0.9843 0.9851) 25.05 (0.986)
Mainshaft 0 .0 . at M~21 '959 21.980 (0.8645 - 0.8654) 21 ,93 (0.863) -f
I at M5 16.976 - 16.987 (0.6683 0.6688) 16.93 (0.667)
I Countershaft 0 .0 . I a t C4 24 .959 24.980 (0.9826 - 0.9835) 24 .93 (0.98 1)
~erse idle shaft 0 .0 . 12,966 - 12.984 (0.5105 - 0.5112) 12,94 (0.S09)

t
Bushlng-to-shaft M3 0.020 0.062 (0.0008 0.0024) 0.10 (0.004)
clearance M5 0.029 0.058 (0.0011 - 0.0023) 0.10 (0.004 )
C4 0.020 0.062 (0.0008 - 0.0024) 0.10 (0.004)
Reverse idle gear-tcrshaft clearance 0.016 0.055 (0.0006 0.0022) 0.10 (0.004)
Crankshaft Runout 0.15 (O.OOS)
Big end side clearance 0.05 0.65 (0.002 - 0.026) 0.8 (0.03)
Big end radial clearance 0.006 0.018 (0.0002 - 0.0007) 0.05(5J)02)

ENGINE REMOVAUINSTALLATION

Et
ITEM SPECIFICATIONS
Engine dry weight FMIFPM U.S,A. 51.4 kg (113.3 tbs)

FElFPE
Canada
U.SA
52.5 kg (115.7 !bs)
52.3 kg (llS.3Ibs)
1
Canada 53.4 kg (117.7Ibs)
Engine oifcapadty After draining 2.9 liters (3. 1 US ql. 2,6 Imp qt)f -_ _
4
After draining/fille~Change 3.0 liters (3.2 US qt. 2.6 Imp ql)
4
After disassembly 3.31iters (3.5 US ql. 2.9 Imp qt)
t
Coolant capacity (radiator and engine) __ 1.5 liters (l.G US qt, 1.3 Imp qt)
Reverse selector lever freeplay 2 4 mm (0.1 0.2 in) j
FRONT WHEEUSUSPENSION/STEERING SPECIFICATIONS
_ _, -oo,'""Unll: mm (in)

~
ITEM
Minimum tire tread dePth~~~==- ".
-.:::;;;::~S~T.ANDARD_-:;;;===
,--::
j, 4.0 (0.16)
SERVICE liMIT
L Standard 30 kPa (0.30 kgffcm2. 4.4:c'P:OS;~)_
Cold tire
pressure [ With cargo
Tie-rod distance between the ball joints _ _ _
30 kPa (0.30 kgflcm', 4.4 psi)
+~3~83.1 (15",.0;;08,,)=,-
_
1
Toe - - Toe-oul: 28± 15 (1.1:t0.6) I
L

1-10
 GENERAL INFORMATION
REAR WHEEUSUSPENSION SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD _ _-"S ERViCE LIMIT
Minimum lire tread depth _ _+-4.0 (0.16)
Cold tire pressure I Standard -==+p
~3'O kPa (0.30 kgf/cm7, 4.4 psi)
With cargo - ~ kPa (0.30 kgf/cm 2 , 4.4 psi)

BRAKE SYSTEM SPECIFICATIONS

Unit: mm (in)
ITEM STANDARD _ _ _ _ SERViCE LIMIT
Front b"',"'ak"e:-- Recommended brake fluid Honda DOT 4 brake fluid
Disc th,ckne,"s~s_ __ 3.8 - 4.2 (0.15 - 0.17) 3.0(0.12)
Disc runout 0.30 (0.012)
Master cylinder 1.0. 14.000 - 14.043 (0.5512 - 0.5529) _~'4 055 (0.5533)

t
Master piston 0.0. 13.957 - 13.984 (0.5495 - 0.5506) 13.945 (0 5490)
Caliper cylinder 1.0. r 32.030 - 32.080 (1.2610 - 1.2630) 32.090 (12634)
:-_~C;a!iper piston 0.0. - I 31 .984 - 31.998 (1.2578 - 1.2598) 31.94 (1.257).
Rear brake Drum 1.0. 180.0 - 180.2 (7.086 - 7.094) 181.0 (7 13)
Shoe lining thickness 5.3 (0.21) To index mark
Oa"""i"o9")"b",.,"ke lever freeplay'--_ _
Rear (p 15 20rnm(O.6 -0. 8in)
Rear brake ~al freeplay 15 20mm(O.6 -0.8 In)

FRONT DRIVING MECHANISM SPECIFICATIONS

VOl!. mmJin)
ITEM STANDARD SERVICE LIMIT
Front final Oil capacity After draining 200 em' (6.8 US oz, 7.0 Imp ozl
drive ="".--'A"ft",e,-"disassembly_..--'2~5:v0"icm3 {8.S US 02, 8.8 Imp ozl
Recommended oil Honda shaft drive oil or equivalent
hypoid gear oil. SAE # 80
Gear backlash 0.05 0.25 (0.002 - 0.010) 0.4 (0.02)
Backlash"'d"iff"e'c,e"'oce=-- 0.2 (0.01)
Slip torque 14 - 17 N·m (145 - 1.75 kgfm , 12Nm
10 - 13lbfft) (12 kgfm. 9lbfft)
Face cam-to-housing distance 3.3 3.7(0.13 -0. 15) 3.3 (0.13)
Differential ring gear depth 6.55 6.65 (0.258 - 0.262) _---+_6:.55 (0.258)
_ _ _ _--"
Cone spring free heighl 2.8(0.11) 2.6 (0.10)

REAR DRIVING MECHANISM SPECIFICATIONS

Unit mm (in)
ITEM STANDARD SERVICE LIMIT
Axle runout 3.0 (0. 12)
Rear final drive Oil capaCIty --!A~.~e;:,d~'2'a~lning 75 em l (2.5 US oz, 2.6 Imp oz)
After disassembly 100 cm 3 (3.4 US oz. 3.5 Imp ozl
Recommended oil Honda shaft drive oil or eqUivalent
hypoid gear oil, SAE # 80 ,
Gear backlash
Backlash difference
0.05 - 0.25 (0.002 - 0.0 10) 0.4 (0.02)
0.2 (0.01)
,
_~-"
R~in,g gear-Io-stop pin clearance 0.3 - 0.6 (0.01 - 0.02) i

1·11
GENERAL INFORMATION
BATTERY/CHARGING SYSTEM SPECIFICATIONS
ITEM SPECIFICATIONS
Battery GYZ16H
12V-16Ah
,62 mA,o
_ _-,;0", m:caCi'._ _ _ __ _
--:::=::;!'~3.0
_ Below -11~.4
; ,3~.2~VV7:=======-
_ _ _ _ _ __ ~ ' .~6Ax5 ~ '0~h~-­

Al temator Capacity
Charging coil resistance (20°C/68°F)
- n:;-i"".OiiA x 1 .0~h=_ _
0.416 kWfS,OOO rpm
0.1-1.00
--====-
_

LIGHTS/METERS/SWITCHES SPECIFICATIONS
ITEM SPECIFICATIONS

t l
Bulbs Headlight (high/low beam) 12 V - 30/30 W x 2
Assist headlight 12V-45W
BrakeJtaitlighl LEO
Neutral indicator LEO
Reverse indicator LEO
Coolant temperature indicator LEO
[ MIL LED
4WD indicator LED
Meterlighl LEO
EPS indicator (FPMlFPE) LEO
,
Fuse Main fuse FMlFPM 30A
t FElFPE 30Ax2
Sub-fuse 15Ax2,10Ax2
EPS fuse (FPMfFPE) 40A

1-12
 GENERAL INFORMATION
TORQUE VALUES
STANDARD TORQUE VALUES
TORQUE TORQUE
FASTENER TYPE
+- N'm (kgf'm, IbHt) _tJ~~~F~AwSTENER TYP_E_ --1i-._ .N·m (kgf'm, Ibf-ftl----j
5'-m
= m~b~o~lt~
and nul .t-I_-,5'i.2~(O . 5 , 3.8) 5 mm screw 4.2 (0.4, 3.1) _j
6 mm bolt and nut 10(1 .0, 7) 6mmscrew 9(0 .9. 6.6) - -
8 mm bott and nut _+t--_..2;;-2j;(2.2, 16 ) 6 mmflange bolt 10 (1. 0, 7)~
10 mm bolt and nut + 34 (3.5. 25) (8 mm head , small flang ~
. ),---_ _ __
12 mm bolt and nut 54 (5.5, 40) 6 mm flange bolt 12 (1 .2, 9)
(8 mm head, large flange)'--_ __
6 mm flange bolt 12 (1 .2, 9)
(10 mm head) and nul
8 mm flange bolt and nul
10 mm flange boll and nut
-==1==-- 27 (2 .8. 20)
39 (4 .0. 29)

ENGINE & FRAME TORQUE VALUES

. Torque specifications listed below are for important fasteners .
. Others should be lightened to standard torque values listed above .
FRAME/BODY PANELS/EXHAUST SYSTEM
THREAD TORQUE
ITEM a'TV DIA. (mm) N'm (kgf 'm , IbHt)
REMARKS
Rear carrier bolt 4 10 74 (7.5 . 55)
no! 8 8 32_(3.3. 24)
2 8 23 (2 .3, 17)
2 6 22 (2.2. 16)
band bolt 3 2 .0 (0.2, 1.5)
~
J
screw (front side) 1 2.0 (0 .2. 1.5)
screw (rear side) 1 3.2 (0.33, 2.4 )
stud bolt 2 8 6.0 (0.6. 4.4 ) See page 2·15

MAINTENANCE
THREAD TORQUE
ITEM a'TV DIA. (mm) N·m (kgf·m , IbHt)
REMARKS
Spark plug 1 14 22 (2.2. 16)
Valve adjusting screw lock nut 2 6 17 (1.7, 13)

1
Valve adjusting hole cap 2 36 12 (1 .2. 9)
Timing hole cap 1 14 10 (1 .0. 7)
Engine oil drain bolt 12 25 (2.5. 18)
Rear final gear case oil check bolt 8 12 (1.2 . 9 )
Rear final gear case oil filler cap 30 12 (1.2. 9 )
Rear final gear case 011 drain boll 1 8 12 (1.2. 9 )
Rear final gear case skid plate bolt 3 8 32 (3.3. 24) ALOe bolt: replace
with a new one.
oil filler cap 30 12 (1 .2. 9 ) I
case oil drain bolt 1 8 12 (1 .2. 9) I

II
cover bolt
reservolf cap screw
(knuckle side)
(steering arm side)
1 3
2
2
2
6
4
12
12
10 (1 .0. 7)
2 .0 (Q.2. 1.5)
54 (5.5. 40)
54 (5.5. 40)
b age3.26
Left hand threads .
See page 3·26

PGM·FI SVSTEM
THREAD TORQUE
ITEM Q'TV REMARKS
DIA. (mm) N·m (kgf·m . IbUt)
Sensor unit tone screw (T25)
EeT sensor
Bank ang~sensor mounting bolt
+ ,
3

2
5
10
6 i 3.4 (0 .3, 2.5.)
12 (1.2 . 9 )
10 (1 .0. 7)

1-13
GENERAL INFORMATION
IGNITION SYSTEM
- -'T-E-M- - - - - - - i - - , - - -a- '-T-Y--,- THREAD TORQUE REMARKS

L' JT~im~i~n~g~h~O'~e~ca~pP-----=_ _ _ _ _t (;m~m~)j:~N~.mi2

DIA.1~ lk~gi'·m
10(1 Qj,'lb~'.ft~):j======-_~
.0,7)
ELECTRIC STARTER
-----
ITEM a 'TY THREA
~TORQUE REMARKS
__ +~;-+--,O:cI"A'-i'(mm) N'm (k9['~.mj'~'ba,·~ft~)± = = == == - - j
s;;:,at.rtiie'~m~o~'~o'~"'~"'idbo~'~'
N~alive brush set screw
W---====~~tj2=i=-_
1 55 I 4.9 (0.5,
3.7 (0.4, 3.6)
2.7)
FUEL SYSTEM
---
ITEM Q'TY THREAD TORQUE REMARKS
+ ---,.----t-=:: c:...m
DIA. F"'---,----'N ~ (kgf'm, IbHt)
-~=~=-~:~(~Oi
·9~.6~.5~)c==t~
!~9. 66) S~~p:a~ge~1.~2~0==-1
34 (0.3. 2.5)

_~~==~~t-=-=-~r=~~34~0·E3.~2:5)==~~~B1I=~1 See page 7-25

See page 7-26
1.8 0.2.1.3)
2.1 (0.2, 1.5)
5 5.1 (0.5. 3.8)
COOLING SYSTEM
,----
I Cooling fan nul
ITEM
_ _ _ _ _+_
Q'TY THREADQ -
,_ + -DIA. (mm)
5
TORQUE
N'm (k~.!:m , !bHt)
2.7 (0.3. 2.0)
REMARKS
Apply locking agenllo
1
the threads.
Fan motor bolt
Fan motor stay bolt
CYLINDER HEADNALVE
_ : t:j3=
3 : : - --j56 t===r-=-=-
j52
; (0.5.
(0.9, 3.8;t) =:t==-:===:::1
<c.
8.4 6:.?,)

--- -'-
a-'T-y-'-~THREAD TORQU"E' - - ' - - -R-E-M-A-R-K-S- - '
ITEM
_-l---._ + -DIA. (mm),-+- "
N",
'm;,;( kgf'm, Ib",
' ."
ft)' -th= = = =
Cylinder head nul 4 10 48 (4.9, 35) Apply engine oil to the
threads and seating
surface.
Cam chain tensioner pivot bolt 6 12 (1 .2, 9) Apply locking agent to
Ihe threa.,d"s'~_ _--1
I Spark plug 14 22 (2 .2, 16)

Uppersensor
t EeT engine hanger nut (frame side) ,- ~==±=!'1~1::::J'~0==E~12
10 (1 .2,40)
54 (5.5, 9)
Upper engine hanger bolt (engine side) 2 B 32 (3.3, 24)
CYLINDER/PISTON
-a
-'T
-y-'r-T"HREAD;-~--T"O
~R"a
~U"E~-'---R-E-
M-A-R-K-
S--
ITEM
DIA. (mm) N'm (kgf'm, IbHt)
C linder slud bolt 4 10 12 (1.2,9) Seepage 11-B

1-14
 GENERAL INFORMATION
CLUTCH/GEARSHIFT LINKAGE
~~-

ITEM O 'TY THREAD'-~-'TORaUE REMARKS

~ IA . (mm) N'm (kgf'm, tbHt),_ _ __
Clutch spring boll 4-+- 6 13(1.3,10)
Centrifugal clutch lock nut 1 20 118 (12.0, 87) Lock nut: replace with
a new one.
Apply engine oil to the

1
threads and seating
surface . Slake.
Change clutch lock nul 18 108 (11.0. 8"'0")-~~lOCk nut: replace With
a new one.
Apply engine oil to the
threads and seating
surface. Stake.
Shift drum stopper arm pivot bolt 6~2(12,9) Apply locking agenll0
-+ Apply locki"ng=ag;:;e::nCCtt"'o- j
Gearshift cam bolt 6 1 :'6 (1.6.12)
the threads .

the threads .
Gearshift spindle return spring pin 8 22 (2.2. 16) Apply locking" a;:;g"e"' o~
n,"''''
the threads .
Gearshift spindle A stopper bolt (FM/FPM) 8 27 (2".8',"2"'0') - - - - iAio;p'"ply locking agent to
the threads

ALTERNATOR/STARTER CLUTCH
THREAD TORQUE
ITEM a 'TY REMARKS
DIA. (mm) N'm (kgf'm , Ibf-ft)
Slarter clutch bolt 6 8 37 (3.8, 27) Apply locking agent to
the threads.
Flywheel bolt (U.S.A. Iype) 1 12 108 (11 .0, 80) Apply engine oil to the
threads and seating
surface.
Flywheel/driven pulley boll (Canada Iype)'- - - - - , 12
j 108 (11.0. 80) Apply engine oil to the
threads and seating
surface.
CKP sensor boll 2 5 6.0 (0.6, 4.4) - t -Apply locking agent to
Ihe threads.

CRANKCASEfTRANSMISSION/CRANKSHAFTIBALANCER
THREAD TORQUE
ITEM Q' TY REMARKS
DIA. (mm) N'm (kgf-m , Ibf-ft)
Mainshaft bearing setting plale boll 2 6 12(1 .2, 9) Apply locking agenllo
the threads.

ENGINE REMOVAUINSTAlLATION

THR~~
TORQUE
ITEM Q' TY REMARKS
DIA. (mm) N'm ( kgf'm , Ibf-ft)
lower engine hanger nut (left and right) 2 10 54 (5.5, 40)
I r
Upper engine hanger nut (frame side) 1 10 54 (5.5, 40)
Upper engine hanger bolt (engine side) 2 8 32 (3.3, 24 )
Gearshift pedal pinch bolt (FM/FPM) 1 6 20 (2.0, 15)
Fronl final gear case mounting nul 2 10 44 (4.5, 32) lock nut: replace with
a new one.

1·15
GENERAL INFORMATION
FRONT WHEEU SUSPENSION/STEERING
Q'TY THREAO'---~-'TORQUEc--~
REMARKS
"o;~~~~IT~EC;M~==::-__-=+=~=1=D~IA. 4(mm)
Throttle ~~
N'm (kgf-m, IbUt)
1.5 (0.2 , 1.1)
5 4.2 (0.4 , 3.1)
6 7.0 (0.7, 5.2)
8 32(3.3, 24)
10 64 (6 .5, 47)- -
hub nut 16 78(8 .0, 58) Castle nul. tighten to
the specified torque
and further tighten
until its grooves align
with the cotter pin

~~6·c

1
Front brake disc botl 8 8 42 (4.3, 31) bolt replace
with a new one.
SplaSh guard bolt 6 6 11(1 .1. 8) AlOe bolt: replace ~
with a new one .
Shock absorber mounting nut 4 10 39 (4.0. 29) Lock nut: replace with
-+--,a newone.
Upper arm pivot nul 2 10 34 (3.5, 25) I Lock nut: replace with

t
a new one.
l ower arm pivot nut 4 10 39 (4.0 . 29) Lock nut: replace with
a new one.
Upper and lower arm ball joint nul 4 12 29 (3.0 . 21 ) Caslle nul: tighten to
the specified torque
and further lighten

-h-i
until its grooves align
with the cotter pin
hole.
Brake hose clamp boll 6 12 (1 .2, 9) ALOe boll: replace
with a new one.
Tie-rod joint nut 4 12 ---t--~~~(~5.<5~,4~0'
) Lock nut: replace with
a new one.
Steering shaft end nul 14 108 (11.0, 80) Lock nut: replace with
a new one.
I
Steenng shaft holder bott 2 8 32 (3.3, 24)
I
Steering shaft pinch bolt (FPM/FPE) 1 10 --i60(6.1, 44) ALOC bolt: replace
with a new one ,
EPS unit mounting nut (FPM/FPE) 2 8
- 22 (2.2 , 1.§)~-t--=:~~~~=~
Handlebar switch housing screw (FMlFPM) 2 5 4.2(0.4 , 3.1) 1
Handlebar switch housing screw (FE/FPE) 3 5

I-
Rear brake lever bracket holder screw
Front master cylinder holder bolt
2
2
5
6
4.2 3.1,!)=±~==~~~;:==
(0.4. 3.1)
4.~0.4.
12 (1 .2, 9)
Front brake caliper mounting boll 4 8
- 30 (3.1. 22) ALOC bolt: replace
with a new one.

REAR WHEE U SUSPENSION

THREAD TORQUE

~ Rear wheel nut

ITEM Q' TY
8 - -
DIA. (mm)
10
--..!:!:.m (kgf·m , IbHt)
64 (6.5, 47) I
REMARKS
1
Shock absorber upper mounting nut 1 10 39 (4.0 . 29) ~Lock nul: replace with
a new one.
1 10
I
Shock absorber lower mounting nut 39 (4.0 . 29) Lock nut: replace with
a new one.
Universal jOint guard bolt 2 6 10 (1.0. 7) AL6e bolt: replace
with a new one .
Swingarm pivot bolt 2 12 118(12.0. 87) Aloe boll. replace
with a new one.

1-16
 GENERAL INFORMATION
BRAKE SYSTEM

-
T HREAD TORQUE
ITEM O 'TY REMARKS

T S.4
DIA. (mm) N'm (kgf'm, IbHt)
Brake hose oil bolt 3 10 34 (3.5. 25)
Front brake caliper bleed valve
Front master cylinder reservoir cap screw
Pad pin
Pad pin plug
t 2
2
4
4
4
8

10
10
(0.6, 4 .0)
2.0 (0.2.1 .5)
17 (1.7, 13)
2.4 (0.2. 1.8)
j
Front brake lever pivot boll 6 ~1 .0(O. I ~ O.7)
Front brake lever pivot nut 6 5.9 (O.B, 4 4),
Front brake lighVinhibilor switch screw 4 12(0.1, 0.9) Apply locking agent to
the threads
Front master cylinder holder bolt 2 6 12(1 .2. 9)
Front brake caliper mounting bolt 4 B 30 (3.1, 22) ALOe bolt: replace
with a new one
Front brake caliper slide Pin 2 B 22 (2.2. 16) Apply locking agent to

--==t~
the threads.
Front brake caliper bracket pin B 17 (1.7.13)
Rear brake arm pinch bolt/nut
Rear wheel hub nut 2
B
20
20 (2.0.15)
137 (14.0, 101) Castle nut: tighle~
the specified torque
and further tighten
until its grooves align
with the colter pin
hole.
Rear brake panel drain bolt 1 B 12 (1.2, 9)
Brake pipe joint bolt 2 10 14(1.4, 10)

FRONT DRIVING MECHANISM

THREAD TORQUE
ITEM Q'TY REMARKS
DtA. (mm) N'm (kgf'm , IbHt)
F ronl final gear pinion bearing lock nut 1 60 98 (10.0. 72) lock nut: replace with

Differential ring gear bolt 11 8 49 (5.0. 36) -+--{~~~ :~: ~~;,~~

with a new one.
Front final gear case cover bolt 2 10 47 (4 8, 35) Apply locking agenl to
the t hreads.
4 B 25(2 .5. 18)
Front fin al clutch shift fork boll 1 6 10(1 .0 , 7) ALOe bolt: replace
with a new one.

l
Front final clutch housing bolt 3 B 25 (2.5. 18)

t
Front fin al gear case mounling nut 2 10 44 (4.5, 32) Lock nut: replace wi th
a new one.
4WD select switch 1 10 12 (1.2, 9)
4WD select switch wire clamp bolt 1 6 10(1 .0. 7)
Final clutch arm cover bolt 3 6 10 (1 .0, 7)

1-17
GENERAL INFORMATION
REAR DRIVING MECHANISM
- - -- - - , , ,
THR EAD TORQUE
REMARKS
ITEM Q'TY
D IA. (mm) N'm (kgf-m, IbHt)
Rear final gear case cover bolt 2 0 47 (4.8, 35) Apply locking agent to
the threads.
6 8 25 2.5,18)
I Rear final gear pinion bearing look nul 1 64 98 (10.0, 72) Lock nut: replace with
a new one. Stake.
Right axle housing mounting nul 4 0 52 (5.3, 38) lock nut: replace with
a new one.
Rear final gear case mounting nut 8 10 47 (4.8, 35) Lock nul. replace with
a new one
Shock absorber lower mounting nul 1 10 39 (4.0. 29) Lock nut: replace with
a new one.
Rear final gear case skid plate botl 3 8 I 32 (3.3, 24) +-- Aloe bolt: replace I
with a new one.
Rear brake panel mounting nul ~ 0o 47 (4.8, 35) Lock nut: replace with

~0
a newane.
Rear wheel hub nut 137 (14.0,101) CasUe n~1: tighten to
the speCified torque
and further tighten
until its grooves align
with the cotter pin
hole
For tightening
procedure: See page
20-24
Trailer hitch n·ucl.--- - -- 10 34 (3.5, 25) lock nul: replace with
a new one.

LIGHTS/METERS/SWITCHES
THREAD TOROUE
ITEM Q'TY REMARKS
DIA . (mm) N'm (kgfm . IbHt)
Combination meier mounting SCfew 3 5 0.8 (0.1. 0.6
Gear posilion switch wire damp bolt 2 6 12 (1.2,9) Apply locking agent to
the threads.
Rear brake light switch screw 1 4 1.2(0.1,0.9) Apply iocking agentto
the threads.
Front brake light/inhibitor switch screw 1 4 1.2 (0.1, 0.9) Apply locking agent to
the threads.
I 4WD selecl switch 1 10 12 (1.2, 9)
Fuel level sens;;o~r'ibo~It======- 3 6 9.0 (0.9, 6.6)
ElECTRIC SHIFT PROGRAM (ESP : FE/FPE models )

ITEM
--'I--'-a-'T-
Y ~~'
THREAD TOROUE
REMARKS
DIA . (mm) N'm (kgf·m . IbHt)
Shift angle sensor bolt 2 5 6.0 (0.6. 4.4) Apply locking agenllo
the threads.

OTHERS
THREAD
ITEM a 'TV TORQUE REMARK~
Ibff·.~)~E====
DIA. (mm)
Parking brake lever pivot screw 4 N'm (kgf'm ,
6.9(~.1)
Rear brake lever pivot bolt 6 9.8 (1.0. 7.2)
Rear brake lever pivot nut _ _'----'-----'-_ 6 9.8 (1.0, 7.2)

1-18
 GENERAL INFORMATION
LUBRICATION & SEAL POINTS
ENGINE
MATERIAL T LOCATION _ _ __ REMARKS
- Molybdenum oil solution (a T Camshaft cam lobes
mixture of 1/2 engine oil and Rocker arm shaft sliding surface
1/2 molybdenum disulfide Valve stem (valve guide sliding surface,'=~=
grease) Change clutch outer guide inner and ouler surfaces
Crankshaft starter driven gear sliding surfaces
Piston pin outer surf~a~
ce"c-~_
Starter reduction gear shaft whole surf.ace
~~_ _
Water pump shaft journal and thrust w~a~S~~,~_
he _
Mainshaft gear Ii surfaces _ _=~===-_

I~;~~~~~seating surface
surface
·~~~~~~~~tpin hOle_ __ __
E~~~ff~:;~iiC,~ plale boss ouler surtace- - - -- - t-
Change clutch disc lining whole surface~st=::;::==­
';,-~_ _f-
Change clutch lock nut threads and Sealing,;s~u~rt~a~ce
Centrifugal clutch drum sprag clutch contacting surface
Centrifugal clutch drive plate sprag clutch contacting
surface
clutch whole surface ~==~==
lock nul threads and seatjng~urface
gear teeth
__ 1
shaftand
threads journal surface
seating surface e-=E~~~~
U.SA type
pulley bolt threads and seating surface Canada type
clutch whole surface
t~~,,;rc~~~countershaft journal surfaces
whole surface
~~S~h;~ftjdEru~m~!g;;,OO~ves
Collar and bushing journal surfaces
Each bearing rotating area
Each O-ring whole surface

I
"'~""'"-tjRecoil
Mobilith SHC 100 (EXXON)
E~ac~hto~i~1starter
~seal lipdriven pulley oil seal lips Canada type

1-19
GENERAL INFORMATION
1
MATERIAL LOCATION REMARKS
Locking agent Cam chain tensioner lifter bolt threads Coaling width: 6.5 ± 1 mm

=W
0026 ± 0.04 in)
Cam chain tensioner pivot bolllhreads Coating width: 6.5 ± 1 mm
(0.26 ± 0.04 in),~~~_ _
Camshaft bearing setting plate bolt threads Coating width: 5 8 mm
(0.20 ± 0.31 in)
Shift drum stopper arm pivot bolt threads Coating width: 6.5 ± 2 mm
(0.26 ± O . 08 . ~;",\)~~~
Gearshift cam bolt threads Coaling width: 6.5 ± 1 mm
(0.26 ± O.• ~04:;;,;",\)~~~
Gearshift spindle return spring pin threads Coating width: 6.5 ± 1 mm
(0.26 ± 0 .04 ,;,"!1.)_ __
Gearshift spindle A stopper bolt threads FM/FPM

t-----sfarter clutch botl threads

CKP sensor bolll"h~,e~a~d;;;s---

Mainshaft bearing setting plale bolt threads

Gear position switch retaining boltiii:e.dS--------g~~~;,~:atii"eTt1,mmm:n~

Gear posilion switch wire clamp bolt Ihreads

Shift angle sensor boll threads

width: 5 :I: 1 mm
in)
Recoil starter assembly mounting boll
6.5:1: 1 mm

;
5 or i I

Reduction gear cover surface

UNIREX ·Ny3'g='~e=
a=seo-------;E~I=
ect
= ric== =uclion ge"'"PfiidhiQOaiTeOtii$,d i,owna;S-
sh~;·ft~'ed
(EXXON) (front crankcase cover and gear cover) 2 - 4 g (O.Ol - 0.14 oz)
_ _ __ "S'"ee'-!'page 2~
3-::
3"-
' _ _ _-----'

1-20
 GENERAL INFORMATION
FRAME

~I
MATERIAL
I
I cable o,ter , (each end)
I , le,er pl,ot and dii,t ,eal lip
j I rl?~
j i
, Inner and o,ter d"t ,eal lip'
~~~ ~."~~ ;~~IOg 0.11 oz)

"haft I 1 ,lIding ,,'!~=====±12'~-·i:31~gllM7=O~f'

-' lj. l1"--"~=~
~haft d"t ,eal "f'
Rear brake cam ,plndle
Rear brake cam ,hoe I '-'.Ig ,- loz
' - '.Ig ,- 10'
3- 4 (0. 1- ' .140';

, panel d"t ,eal lip,

, pedal 'I,ot
~~ I t ,eal lip,
Front fina l gear ca,e 0;; ,eal lip' (fo, drl'e ,haft,)
Front final gear ca,e co,er O-ring

:~:: fina: cI,tch arm 'haft O-ring

Front final , , ,haft o'ter ,,"ace
I Inion J ~I!,! all i
Front I j
Rear I gear ca,e 0;; ,eal lip' (for II • ,haft)

I
I
Rear fina!gear case oil seal I;;
I~· i
~r~
rlng~,g~
ear~;~==========3
i ~. :>jde)
Rear final gea" .
Left axle I 1 5-ring
Left axle I I ld"t,eal llp, --------r---------------~

Fron lri'~llwneel "oel

grease '.""'n 'P";~',;~r pl,ot! '. ,I lip'
pper arm pl,ot I 1 inner

j lShaitsPline ~ c,,".:_
EPS """ , "pllne
'e."hoCk I I I land d,,"ealllp'

I 'I,ot d"t ,eal lip,

Front II "haft boo"lp
"ont I II t ,pllne, (both "de,) ~ ....: : ,s_h_~ft side: 5 89
\0.2 - 0.3 0')
5 - 8 g (0.2 - 0.3 oz;
-
'~ pinion joint splines
II j
,I jOint 'pllne, ,oth ,Ide,)
Rear II "pllne, (gear

Rear II O-ring
Rear axle 'pllne, (3 I
50 - 70 g (1 .8 - 2.5 oz;
; (Kyodo Y"hl) Front I ~Irrtl

1-21
GENERAL INFORMATION

Honda Handgrip Ce,me,nt

(U.S.A. only) or equivalent

Engine

nullhreads
t

1-22
 GENERAL INFORMATION
CABLE & HARNESS ROUTING

THROTTLE CABLE REAR (pARKING)

BRAKE CABLE

FRONT BRAKE HOSE A

HANDLEBAR
SWITCH WIRE

REVERSE REVERSE SELECTOR

SELECTOR CABLE
CABLE
HANDLEBAR
SWITCH WIRE

FRONT SUB-WIRE
':)..'::>--r\ HARNESS
REAR
(PARKING)
BRAKE CABLE
Front

REAR BRAKE LIGHT SWITCH (Lever side)

IGNITION HANDLEBAR
SWITCH WIRE SWITCH WIRE
II~
1 REVERSE
o

FRONT SUB·WIRE
REAR (PARKING) HARNESS
BRAKE CABLE
BAND Front
(Secure at the tape position)

1·23
GENERAL INFORMATION

HANDLEBAR SWITCH WIRE HAN DLEBAR SWITCH WIRE

(To front brake/light switch)

Front Front

t t
FUEL TANK IGNITION SWITCH
BREATHER HOSE

B3 Ol,--!{I

REAR BRAKE LIGHT

SWITCH WIRE
(lever side)
FRONT BRAKE
INHIBITOR SWITCH

GRAY TAPE

I
BRAKE

j
LIGHT SWITCH

1·24
 GENERAL INFORMATION

t
IGNITION SWITCH WIRE FRONT SUB-WIRE
HARNESS
Up
MAIN WIRE
HARNESS
BANK ANGLE SENSOR 3P

~
(Black) CONNECTOR

SIPHON HOSE
HANDLEBAR
SWITCH WIRE

Front

ACCESSORY
SOCKET WIRE

HEAOLIGHT WIRE

WATER HOSE
(Thermostat-Io-radlator)

PAINT
MARK

Up
, 45"
I
-----..
FAN MOTOR 2P 4WD SElECT ~Hr_r~ - Lett
(Natural) CONNECTOR SWITCH WIRE

PAINT
MARK
FMfFPM : HANDLEBAR SWITCH 10P (Green) CONNECTOR FRONT SUS-WIRE HARNESS
FElFPE : HANDLEBAR SWITCH 14P (Green) CONNECTOR 14P (Gray) CONNECTOR

1-25
GENERAL INFORMATION

ACCESSORY SOCKET
2P (Black) CONNECTOR

I 3P
(Black) CONNECTOR

Reverse side of radiator:

FAN MOTOR 2P
(Natural) CONNECTOR
FAN MOTOR

PAINT
MARK

~
45"

_. " .. Right

PAINT _
MARK

4WD SELECT SWITCH WIRE FAN MOTOR

WATER HOSE
BREATHER HOSE
(Radiator-Io-waler pump)

1-26
 GENERAL INFORMATION

FRONT BRAKE PIPE

4WD SELECT SWITCH WIRE

FRONT FINAL GEAR CASE

BREATHER HOSE

FRONT BRAKE HOSE B

o 0

FRONT FINAL GEAR CASE

BREATHER HOSE

4WD SELECT WIRE

4WD SELECT SWITCH

1·27
GENERAL INFORMATION

Inside of front fender:

FRONT FENDER
LID
HEADLIGHT HOUSING

H"""LI~'" WIRE

GROOVE GROOVE

HEJ'DL.IG>n WIRE
SOCKET SOCKET WIRE

1·28
 GENERAL INFORMATION

FUEL VAPOR RETURN HOSE

FRONT BRAKE HOSE A

J
~"'-~~~~~~~~~~S~~~~i=:::FUEL
'\ I 1
LEVEL SENSOR
2P (Red) CON NECTOR

FUEL OVERFLOW HOSE

FCOot~

-~
3 - 8 mm (0.1 - 0.3 in)

3-Bmm(O.1-0 .3in)

PAINT MARK Align pain t mark wi th arrow

1-29
GENERAL INFORMATION

FRONT BRAKE HOSE B

STOPPER

RIGHT FRONT BRAKE CALIPER

FRONT BRAKE HOSE B

STOPPER

LEFT FRONT BRAKE CALIPER

1-30
 GENERAL INFORMATION

FUEL VAPOR
Front RETURN HOSE
FUEL VAPOR RETURN
HOSE (From fuel lank)
FUEL HOSE

SUB-fUEL TANK!
FUEL PUMP

FUEL FEED
HOSE
L _ _---'-_ _ :..L'--- PAINT MARK

FRONT FINAL GEAR CASE

BREATHER HOSE

SIPHON HOSE
FUEL HOSE
REAR (PARKING )
BRAKE CABLE

REVERSE
SELECTOR CABLE

fAN MOTOR MAIN WIRE

BREATHER HOSE (Pink) HARNESS

o
THROTTLE CABLE

HEATGUI'RD
PLATE

Eer SENSOR!
IGNITION COIL WIRE

1-31
GENERAL INFORMATION
FPM/FPE :

TORQUE
SHIFT CONTROL FRONT FINAL GEAR
TORQUE SENSOR 3P SENSOR WIRE
MOTOR WIRE (FPE only) CASE BREATHER HOSE
(Gray) CONNECTOR

FAN MOTOR
BREATHER
HOSE (Pink)

EPS SUB-WIRE

I
EPS MOTOR EPS UNIT
EPS MOTOR 2P
(Gray) CONNECTOR

All models (FPMIFPE shown):

2WD/4WD SELECTOR
CABLE

1-32
 GENERAL INFORMATION
FM/FE :
WATER HOSE WATER HOSE
REVERSE REAR (PARKING)
SELECTOR CABLE BRAKE CABLE

SHIFT CONTROL MOTOR

WIRE (FE only)

Up
•

Up

WATER PUMP •
SHIFT CONTROL MOTOR 2P
BREATHER HOSE
(Black ) CONNECTOR (FE only)

SHIFT CONTROL
SHIFT CONTROL MOTOR WIRE
MOTOR WIRE (FE only) (FE only) FAN MOTOR
BREATHER
HOSE (Pink)

FRONT FINAL
GEAR CASE
BREATHER HOSE

FUEL HOSE

FAN Mo-roR
FUEL HOSE BREATHER HOSE (Pink)
FRONT FINAL GEAR CASE
BREATHER HOSE

1-33
GENERAL INFORMATION
FPMIFPE :
WATER HOSE WATER HOSE
REVERSE
SELECTOR CABLE

~=J~~~j~~~i~~1~-~~~:~:~-::-=S''::.-:
~ WIRE (FPE ooly)
SHIFT CONTROL MOTOR

)_~~ Up
•

WATER \
SHIFT MOTOR 2P
BREATHER HOSE
(Black) CONNECTOR (FPE only)

SHIFT CONTROL
EPS ECU 21 P (Gray) MOTQRWIRE
CONNECTOR TORQUE
(FPE only) FAN MOTOR
SENSOR WIRE
EPS ECU 2P (Gray) BREATHER
CONNECTOR HOSE (Pink)

FINAL

BREATHER HOSE

FUEL HOSE

FUEL FEED HOSE Mo-rOR 2P EPS ECU

(Gray) CONNECTOR

1-34
 GENERAL INFORMATION

Clamp tab position

/
PAINT MARK 0-3 mm
(0-0.1 in)

FUEL VAPOR RETURN HOSE FUEL TANK

FUEL HOSE
(To be butted to the
J:;;;;;;Q:;T fuel joint)
Up
•

FUEL JOINT
(it
·,'·T:·-

0-3 mm FUEL JOINT

(0-0.1 in) PAINT MARK

FUEL VAPOR
RETURN HOSE
~ ~
lHOSE
~
0- 10mm 0-5 mm
(0 - 0.4 in) (0-0. 2in)

rrn (j ( Me; ~

OD rrn
,
I I I
I

D=- 1;
~.
SUB-FUEL TANK/FUEL PUMP

1-35
GENERAL INFORMATION

FUEL FEED HOSE FUEL INJECTOR 2P (Gray) THROTTLE CABLE

CONNECTOR

SENSOR UNIT 5P CONNECTOR IACV 4P (Bllao.,j CONNECT'OR

REAR BRAKE PANEL FRONT FINAL GEAR

BREATHER HOSE CASE BREATHER HOSE

REAR FINAL GEAR FAN MOTOR BREATHER

CASE BREATHER HOSE HOSE (Pink)

INTAKE AIR DUCT FAN MOTOR BREATHER

HOSE (Pink)

FRONT FINAL GEAR

CASE BREATHER HOSE

REAR BRAKE PANEL

BREATHER HOSE

REAR FINAL GEAR

CASE BREATHER HOSE

1-36
 GENERAL INFORMATION

IGNITION COIL PRIMARY WIRE Eel SENSOR 2P

CONNECTOR II (Black) CONNECTOR SPARK PLUG W IRE

Up

Right

IGNITION COIL PRIMI,R" WIRE

CONNECTOR (BlaCk/red)

WATER HOSE
(Thermostat-la-radiator)

Right

Front .. ~ -
•, .. •• THROTTLE
BODY

AIR CLEANER HOUSING

BANDS CONNECTING TUBE BAND

AIR CLEANER HOUSING INTAKE AIR DUCT

CONNECTING TUBe BAND CONNECTING TUBe BAND

Up
t
Right ..
AIR CLEANER SUB CHAMBER
CONNECTING TUBe BAND

Up
t
le"

13·

~o § O~ I
1-37
GENERAL INFORMATION

GEAR POSITION SWITCH FMlFPM; ENGINE SUB-WIRE HARNESS 3P (Btack) CONNECTOR

BP (Gray) CONNECTOR FElFPE: ENGINE SUB·WIRE HARNESS 6P (Black) CONNECTOR
REVERSE
SELECTOR CABLE
SIPHON HOSE

REAR (PARKING)
BRAKE CABLE

REVERSE
SELECTOR
CABLE

FRAME
GROUND
POINT

SIPHON
Ql,~--HOSE

REAR LIGHT ALTERNATOR 5P GROUND CABLE

SWITCH WIRE (Natural) CONNECTOR (Engine-to-frame) REAR (pA.RKING) WIRE
BRAKE CABLE HARNESS

REVERSE Righi STARTER MOTOR BATIERY SIPHON HOSE

SELECTOR CABLE • CABLE NEGATIVE Up

REAR FINAL HCABlE

GEAR CASE
BREATHER HOSE

~~?l. ~i~~~~~~~~;~~~E~~r~
BATIERY
NEGATIVE H
CABLE
~ MAIN WIRE HARNESS
STARTER MOTOR CABLE

REAR BRAKE REAR BRAKE LIGHT SWITCH

2P (BlaCk) CONNECTOR

REAR FINAL GEAR

CASE BREATHER HOSE
Up
t

GROUND CABLE
(Engine-la-frame)
IAT 2P REAR BRAKE PANEL
(Black) CONNECTOR BREATHER HOSE

BATIERYNEGATlVE ENGINE SUB-WIRE HARNESS:

HCABLE - FM/FPM: To VS SENSOR
- FE/FPE: To SHIFT ANGLE SENSORNS SENSOR

STARTER MOTOR GEAR POSITION

CABLE SWITCH WIRE

1-38
 GENERAL INFORMATION

ENGINE SUB·WIRE HARNESS:

GEAR POSITION ALTERNATOR
- FMfFPM. To VS SENSOR GROUND CABLE
SWITCH WIRE WIRE
- FElFPE: To SHIFT ANGLE (Engine-ta-frame)
SHIFT ANGLE SENSOR SENSORNS SENSOR Up
WIRE (FElFPE only)
BATTERY
NEGATIVE (-)
CABLE

STARTER
MOTOR
CABLE
CLAMP
VS SENSOR 3P GEAR POSITION
(Black) CONNECTOR f\-~~;;-:;,'ll-=~ ~;f:~~~ ~ijCJ'l--.J SWITCH WIRE

REAR BRAKE PANEL

BREATHER HOSE

REAR FINAL GEAR

CASE BREATHER HOSE

REVERSE SELECTOR
CABLE

SHIFT ANGLE SENSOR 3P (Gray) CONNECTOR

(FElFPE only)

CRANKCASE BREATHER HOSE

fM IFPM :

\
\

~
h
VS SENSOR 3P CLAMP VS SENSOR 3P
(Black) CONNECTOR (Black) CONNECTOR

1·39
GENERAL INFORMATION

Clamp at paint mark position LEVER REAR (PARKING)

BRAKE CABLE

PEDAL REAR BRAKE CABLE

REAR FINAL
GEAR CASE
BREATHER HOSE

BREATHER HOSE

REAR BRAKE UGHT REAR BRAKE UGHT SWITCH

SWITCH WIRE

REVERSE SELECTOR CABLE

PEDAL REAR BRAKE CABLE

PEDAL RETURN SPRING

Spring installation direction: BRAKE LIGHT SWITCH SPRING

FRAME

BRI'KE PEDAL

1-40
 GENERAL INFORMATION

MAIN WIRE REAR FENDER

HARNESS SUB-WIRE HARNESS

STARTER MOTOR REAR FENDER

CABLE SUB-WIRE HARNESS

MAIN WIRE
HARNESS

SA TTERY NEGATIVE
CONDENSER 2P (Natural) (-)CABLE
CONNECTOR (Canada type )

BATTERY

RECTifiER 2P (Black) REAR FENDER SUB-WIRE HARNESS

CONNECTOR (Canada type) Ole (Red) lOP (G ray ) CONNECTOR

RADIATOR RESERVE TANK

BREATHER HOSE CONDENSER
(Canada type)
RECTIFIER
(Canada type)

REAR
FENDER

REGULATOR!
RECTIFIER WIRE
SIPHON HOSE
CONDENSER WIRE RECTtF IERWIRE
RECTIFIER (Canada type) (Canada type)

1-41
GENERAL INFORMATION
FM/FE :
FM: MAINfFAN FUSE 1P (Natural ) CONNECTOR
BRAKEfTAILLIGHT 3P STARTER RELAY SWITCH
FE: MAIN FUSE 2P (Natural) CONNECTOR
(Black) CONNECTOR 2P (Green) CONNECTOR

~
~~ __ DIODE
MAIN WIRE FUSE BOXf
HARNESS DIODE

PCI.vEC;M ';P (Bla"')

CONNECTOR

L
=li1<HN_ PCM/ECM 33P (Black)
CONNECTOR

POSITIVE (+)
CABLE
•
Front
STARTER
MOTOR CABLE RELAY SWITCH
PCI./ECM 33P (Gray)
CONNECTOR
POWER RELAY 8P (Gray)
PUMP RELAY 8P
(Gray) CONNECTOR

CONNECTOR (Canada type )

FPMIFPE:
fPM: MAIN/fAN FUSE 2P (Natural ) CONNECTOR
BRAKEfT AllLlGHT 3P STARTER RELAY SWITCH
FPE: MAIN fUSE 3P (Natural) CONNECTOR
(Black) CONNECTOR 2P CONNECTOR

~
~~ __ DIODE
MAIN WIRE FUSE BOX!
HARNESS DIODE

PC'NEC;M "P (Blaok)

CONNECTOR

L
1l""t-;.._ PCMlECM 33P (BlaCk)
_ CONNECTOR

FUEL RELAY 6P
(Gray) CONNECTOR
Front
POSITIVE (+) PCMIE:CM 33P (Gray) POWER 8P (Gray)
CABLE CONNECTOR CONNECTOR (Canada type)

1-42
 GENERAL INFORMATION

,, ,,

------,
BRAKElTAllLiGHT
WIRE

CUP

+ Right

BRAKE/TAllUGHT WIRE TOOL BOX LID

1-43
GENERAL INFORMATION
EMISSION CONTROL SYSTEMS
The U.S. Environmental Protection Agency (EPA), the California Air Resources Board (CARB). and Environment Canada (EC)
require that off-road ATVs comply with applicable exhaust emissions standards during their useful life, when operated and
maintained according to the instructions provided .

SOURCE OF EMISSIONS
The combustion process produces carbon monoxide (CO). oxides of nitrogen (NOx) and hydrocarbons (He). The control of
hydrocarbons and oxides of nitrogen is very important because, under certain conditions, they react to form photochemical smog
when subject to sunlight. Carbon monoxide does not react in the same way, but it is toxic. Uncontrolled fuel evaporation also
releases hydrocarbons to the atmosphere.
Honda Motor Co. , Ltd . utilizes various systems to reduce carbon monoxide, oxides of nitrogen, and hydrocarbons.
EXHAUST EMISSION CONTROL SYSTEM
The exhaust emission control system is composed of the PGM·FI system , and no adjustments should be made . The exhaust
emission control system is separate from the crankcase emission control system.
CRANKCASE EMISSION CONTROL SYSTEM
The engine is equipped with a dosed crankcase system to prevent discharging crankcase emissions into the atmosphere .
Blow-by gas is retumed to the combustion chamber through the air deaner and throttle body.

THROTILE BODY
AIR CLEANER

<
BREATHER HOSE

f Fresh air

_ Blow-by gas

SERVICING THE HONDA

U.S.A. Only
Maintenance , replacement or repair of the em ission con trol devices and syst em s m ay be perform ed by any ATV repair
establishm ent or individ ual usi ng parts that are "certifled" t o EPA stand ard s.
PROHIBITED ACTIONS
The following prohibitions apply to everyone with respect to the engine's emission control system.
You may not remove or disable any device or element of design that may affect an engine's emission levels. This restriction applies
before and after the engine In placed in service.

1-44
 GENERAL INFORMATION
NOISE EMISSION CONTROL SYSTEM
TAMPERING WITH THE NOISE EMISSION CONTROL SYSTEM IS PROHIBITED: U.S. Federal law prohibits, or Canadian
provincial law may prohibit the following acts or the causing thereof: (1) The removal or rendering inoperative by any person , other
than for purposes of maintenance, repair or replacemen t, of any device or element of design incorporated into any vehicle for the
purpose of noise control prior to its sale or delivery to the ultimate customer or while it is in use: or (2) the use of any vehicle after
such device or element of design has been removed or rendered inopera tive by any person .
AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE TH E FOLLOWI NG ACTS:
1. Removal of, or puncturing the muffler, baffles. header pipes or any other component which conducts exhaust gases.
2. Removal of, or puncturing of any part of the intake system.
3. l ack of proper maintenance.
4. Replacing any moving parts of the vehicle, or parts of the exhaust or intake system, with parts other then those specified by the
manufacturer.
FUEL PERMEATION EMISSION CONTROL SYSTEM
This ATV complies with the Fuel Permeation Emission Control regulations of the U.S. Environmental Protection Agency (EPA ). The
fuel tank, fuel hoses, and fuel vapor charge hoses used on this ATV incorporate fuel permeation control technologies. Tampering
with the fuel tank, fuel hoses, or fuel vapor charge hoses 10 reduce or defeat the effectiveness of the fuel permeation teChnologies
is prohibited by federal regulations.
REBUILT ENGINE
When you rebuild the engine including a major overhaul 10 which you replace the engine's piston or power assemblies or make
other changes that significantly increase the service life of the englOe, the vehicle will continue to comply with all emissions
regulations if you:
- Mak.e sure you are technically qualified 10 rebuild the engine and have the proper tools
- Diagnose and respond to all Diagnostic Trouble Codes (DTC), and erase all DTCs after addressing their cause
- Use only Honda Genuine parts or equivalents
- Make sure to maintain all specifications as described in thiS Service Manual

1-45
MEMO
 2. FRAME/BODY PANELS/EXHAUST SYSTEM

SERVICE INFORMATION ···························· ·2-2 ENGINE GUARD········ ·· ········· ··················· ····· 2-7

TROUBLESHOOTING···································2-2 FRONT GRILLE ·.. ·············· ······ ·············· ·······2-7

BOOY PANEL LOCATIONS ························· 2-3 FRONT FENDER/CARRIER ························· 2-8

SEAT······························································2-4 REAR FENDER COVER ........ ....................... 2·9

SlOE COVER ·················································2-4 TOOL BOX LID ··········································· 2-10

FUEL TANK SIDE COVER ····························2-S REAR FENDER/CARRIER ·········· ··············· 2·11

FUEL TANK COVER ·· ····· ·········· ····················2-S MUDGUARD BRACKET ····························· 2·13

MUDGUARD ·················································· 2-6 EXHAUST SYSTEM .............. ...................... 2·14

2-1
FRAME/BODY PANELS/EXHAUST SYSTEM
SERVICE INFORMATION
GENERAL
This section covers removal and Installation of the body panels and exhaust system.
For assist headlight cover removalfinstailation , refer to ~Lig hts/Meters/Swi lches· section (page 22-4),
For meter cover removal/installation. refer to "lights/Meters/Switches" section (page 22-6).
Always replace the gaskets when removing the exhaust system .
Always mspecllhe exhaust system for leaks after installation.

TORQUE VALUES
THREAD TORQUE
ITEM Q' TV REMARKS
DA.
I (mm) N'm (kgf'm, IbHt)
4 '0 74 (7.S, 55)
8 8 32 (3.3. 24)
2 8 23 (2.3,17)
Muffler cover bolt 2 6 22 (2.2. '6)
Exhaust pipe
Muffler cover
cover band boll
band screw (front side) ,,
3 2.0 (0.2. 1.5)
-l-_~2~'0',J(,"
0.2 . ' .5)
Muffler cover band screw (rear side) 3.2 (0.33, 2.4)
Exhaust pipe s_~tu
~d"bo
= " _ __ 2 8 6.0 (0.6. 4.4 ) See page 2-15

TROUBLESHOOTING
Excessive exhaust noise
• Broken exhaust system
• Exhaust gas leaks
Poor perlormance
Oeformed exhaust system
Exhaust gas leaks
• Clogged muffler

2·2
 FRAME/BODY PANELS/EXHAUST SYSTEM
BODY PANEL LOCATIONS
TRX500FE model shown :

[14J [21

(131

[lS[

[II]

[11 FRONT FENDER/CARRIER (page 2-8) [9) FUEL TANK SIDE COVER (page 2-5)
[2] SEAT (page 2-4) [10] REAR FENDER COVER (page 2-9)
[3] REAR FENDER/CARRIER (page 2-11) [11] TOOL BOX LID (page 2-10)
[4] MUDGUARD (page 2·6) [12) SIDE COVER (page 2-4)
[5] MUDGUARD BRACKET (page 2-13) [13] METER COVER (page 22-11)
[6] ENGINE GUARD (page 2-7) [14] ASSIST HEADLIGHT COVER (page 22-4)
(7) FRONT GRILLE (page 2-7) [IS] FRONT REFLECTOR (Canada type only) (page 2-9)
[8] FUEL TANK COVER (page 2-5) [16) REAR REFLECTOR (Canada type only) (page 2-12)

2-3
FRAME/BODY PANELS/EXHAUST SYSTEM
SEAT
REMOVAL
Unlock the seal 111 by turning the release lever 12] up.
Raise the rear of the seat. slide it rearward and remove
it.
INSTALLATION ~
12)
Install the seat by inserting the front prong (3) into the
fuel lank cover (4] and hooking the center prongs [5) to
the seal retainers [6J of the frame.
Push the seal forward and align the mounting bosses
[7] with the rubber mounts (8]. then press down to lock
it.

18)

SIDE COVER
Remove the seat (page 2-4 ),
Release the four bosses [1J from the grommets 121. then
release the tab 13] of the side cover 14J to remove the
side cover.
Be careful not to Installation is in the reverse order of removal.
dislodge the
grommets.

12)

P) 14)

~1.F.f- _ _ 13)

2-4
 FRAME/BOOY PANELS/EXHAUST SYSTEM
FUEL TANK SIDE COVER
Remove the side cover (page 2-4).
Remove the following:
- socket bolt [1]
- two trim clips [2]
- fuel tank side cover [3J (release the three tabs [4] by
sliding the cover rearward)
Installation is in the reverse order of removal.

['[

[2[

[11

FUEL TANK COVER

Remove the fuel tank side covers (page 2-5).
Remove the following:
- six trim clips [1]
- fuel fill cap [2J
- fuel tank cover [3J
Inslall the fuel fill cap after removing the lank cover.
Installation is in the reverse order of removal.

[1[

[3[

2-5
FRAME/BODY PANELS/EXHAUST SYSTEM
MUDGUARD
NOTE:
• Take care not to scratch the front and feaf fenders
when removing and installing the mudguard .
Remove the side cover (page 2-4).
Remove the following :
- nine trim clips [11
- socket bolt (rear side) [2J
- four flange bolts (3] and footpeg [4)
- Right mudguard only: water pump breather hose [5)
(from the hose guide 16] of the mudguard)
- mudguard (7)
installation is in the reverse order of removal.

[1
['[

I
(

[6[

[5[

2-6
 FRAME/BODY PANELS/EXHAUST SYSTEM
ENGINE GUARD
Remove the eight setting bolts [1] and two tnm clips [2].
Release the two hooks (3] of the engine guard [4] from
the frame and then remove the engine guard .
Installation is in the reverse order of removal .

[4}
[2}

FRONT GRILLE
Remove the engine guard (page 2-7).
Remove the following:
- two trim clips (1]
- front grille (2)
Installation is in the reverse order of removal.

j1} [1 }

2-7
FRAME/BODY PANELS/EXHAUST SYSTEM
FRONT FENDER/CARRIER
REMOVAL/INSTALLATION
Remove the fuel tank cover (page 2-5).
Remove the front grille (page 2-7)
Remove the following :
- accessory socket 2P (Black) connector (1 J
- headlight 3P (Black) connector [2] (release from the
side air guide plate and disconnect it)
- ten trim clips [3]
- six 8 mm bolts [4}
- fron t fender/carrier assembly [5J
Installation is in the reverse order of removal.

2·8
 FRAME/BODY PANELS/EXHAUST SYSTEM
DISASSEMBLY/ASSEMBLY
Remove the following fasteners and separate the front
fender [1 ). front luggage carrier [2] and front carry pipe
131·
- four bolts [4) and two collars [5]
- two setting bolts [6] (securing each head light
housing)
- two trim clips [7J
Remove the two nuts and (enectors [8] (Canada type
only)
Installation is in the reverse order of removal.
For headlight removal/ins tallation, see "LlghtsJmeterslSwitches' section (page 22-5).
(2{
IB)

~
11)

IS{

14{
17{

REAR FENDER COVER

Remove the seat (page 2-4).
Be careful not to Remove the following:
scratch the COY9r - retaining strap [1 J (from the tool box lid)
with (he carrier pipe - two bosses [2]
- rear fender cover [3] (release the two tabs [4] by
sliding the cover forward)
Be careful not to Installation is in the reverse order of removal.
dislodge the
grommets [5].

2-9
FRAME/BODY PANELS/EXHAUST SYSTEM
TOOL BOX LID
Remove the rear fender cover (page 2-9).
[1[
Remove the following:

~
[2[
- brakellaillighl 3P (Black) connector [1] (release from
the holder plate [2) and disconnect it}
- wire clip [31
- brakeltaillight wire (4] (from the wire guides)
- 1001 box lid [5] (from the pivots (6])
Installation is in the reverse order of removal.

[4[
[5[

2-10
 FRAME/BODY PANELS/EXHAUST SYSTEM
REAR FENDER/CARRIER
Remove the following:
- side covers (page 2-4)
- tool box lid (page 2-10)
- battery (page 21-8)
- air cleaner sub chamber (page 7·22)
Remove the following from the fear fender:
- regulator/rectifier wires [lJ (from the wire guide [2])
- battery H cable [3J (by releasing the cable guide [41)
- wire harnesses (5] (by releasing the wire clips [6])
- rear fender sub-wire harness lOP (gray) connector (7]

(2( 1'(

(4J (3(

- junction connectors [8)

(11( [211
- brakeflaillighl 3P (Black) connector [9]
- main fuse connector (10J
- starter relay switch 2P (Green) connector
(11(
- fuel pump relay [12]
- connector holder plate [13] (by releasing
the two tabs [14])
- fuse box [15J
- starter relay switch [16J
- PCMIECM 5P (Black) [17J
- PCM/ECM 33P (Black) connector [18J
and 33P (Gray) connector (19J
- PCM/ECM [20] (19(
- EPS fuse 1211 (FPMlFPE model)
- power relay [22] (Canada type)

-
[131

[141

2-11
FRAME/BODY PANELS/EXHAUST SYSTEM
Remove the following fasteners and remove the rear
fender/carrier assembly [11:
- six trim clips [2]
- two socket bolls [3]
- two 6·mm setting bolls [4J
- four 10-mm bolls 151
Remove the four bolts [6] and collars (7] . two trim clips
[8). and separate the rear fender (9] and carrier [10].
Remove the two screws (11) and muffler protector (12).
Remove the four nuls [13] and reflectors {141 (Canada
type only).
Installation is in the reverse order of removal.
TORQUE : 10 mm bolt (5] : 74 N'm (7.5 kgf-m . 551 bHt)

[5[

[3J

[9[

(141

[13J

[12J

,
[7J

[6J " [8J

2-12
 FRAME/BODY PANELS/EXHAUST SYSTEM
MUDGUARD BRACKET
Remove the mudguard (page 2-6).
Remove the following :
- 6-mm bolt (1)
6-mm boll 12) (securing lever rear brake cable)
rear fender stay 13]
four B-mm bolts and nuts [4)
mudguard bracket [5) and step bracket [6]
center mudguard stay [7)
When installmg the Installation Is in the reverse order of removal.
rear ((lndOf slay,
al.gn the locating
TORQUE : 8 mm nut [4] : 32 N·m (3.3 kgf'm, 24 IbHt)
pin IB} with the hole
in the frame

[1[
=

[3[

[4[

2-13
FRAME/BODY PANELS/EXHAUST SYSTEM
EXHAUST SYSTEM
REMOVAL
Remove the side covers (page 2-4 ).
Remove the left mudguard (page 2-6).
Loosen the two muffler band bolts [11.
Remove the following :
- two joint nuts (2]
- exhaust pipe (3]
- exhaust pipe gasket [4J
- muffler gasket [5]
- mounting bolt [6]
- muffler [7]

INSTALLATION
Install a new exhaust pipe gasket and muffler gasket.
Install the following by loosely lightening all the
fasteners :
- muffler (onto the stays)
- mounting bolt
- exhaust pipe (into the muffler and onto the cylinder
head)
- two joint nuts (by setting the exhaust pipe flange
property)
TIghten the mounting bolt first, then lighten the joint
nuts.
Tighten the muffler band bolts to the specified torque.
TORQUE : 23 N'm (2.3 kgf-m, 11lbHt)
After installation, inspect the exhaust system for leaks.

~
(1( (71

2-14
 FRAME/BODY PANELS/EXHAUST SYSTEM
EXHAUST PIPE STUD BOLT
REPLACEMENT
Thread two nuts to the stud boll and tighten them , -- -
together, then use a wrench on them to turn the stud 111
boll out.
Instell the stud bolts Install and tighten new stud bolls into the cylinder head
with their rounded to the specified torque.
end {1} facing out.
TORQUE : 6,0 N'm (0.6 kgf'm , 4.4 IbHt)
After tightening the stud bolts , check that the length
from the bolt head to the cylinder head surface is within
specification.

22.5 - 23.5 mm
(O.89 - 0.93 in)

DISASSEMBLY/ASSEMBLY
BAND SCREW (3 places)
2.0 N'm (0.2 kgfm, 1.SlbHt)

""-
, ,--->
,
-,
. -_.-
'" '''1l''' ,'.','",1,
_..... .... ~ .

" ,
"'" ..'.. ,
.v.~
'

" , f Up f Up

[- & i-~
t{!- I
3,2 N' m (0,33 kgf-m,
2.4 IbHI)
Up
I
No interference
7
'ig;;ri1~ mm
" in) MUFFLER Left
COVER

TAB
6 mm bolts and washers
, ~Nm(22kgfm.'6Ibfft)

MUFFLER BAND

... ,. - ..... --- .---- -_. -- _._-

!--i£:1~J Left
2.0 N'm (0.2 kgf·m, 1.5Ibf·ft)

2·15
MEMO
 3. MAINTENANCE

SERVICE INFORMATION ············ ·················3·2 2WD/4WD SELECT SYSTEM ····················· 3·19

MAINTENANCE SCHEDULE ··················· ·····3·3 BRAKE FLUID ······································ .... ·· 3·20

FUEL LINE······························ ·······················34 BRAKE SHOES WEAR ························· .... · 3·21

THROTTLE OPERATION ······························ 34 BRAKE PADS WEAR ........... ...................... 3·21

AIR CLEANER·················· ·· ···························3·5 BRAKE LIGHT SWITCH ·························· ···3·21

AIR CLEANER HOUSING DRAIN TUBE ······ 3·7 BRAKE SYSTEM ············ ···························· 3·22

SPARK PLUG ················································ 3·8 REVERSE LOCK SySTEM ························· 3·23

VALVE CLEARANCE ····································3·9 GUARDS .......... ........... ................................ 3·24

ENGINE OIL ················································ 3·12 CLUTCH SYSTEM ······································3·24

ENGINE OIL FILTER ···································3·14 SUSPENSION ············· ··· ······ ···················· ··· 3·25

ENGINE IDLE SPEED ·································3·15 SPARK ARRESTER ··································· 3·25

RADIATOR COOLANT ······························· 3·15 NUTS , BOLTS, FASTENERS ..................... 3·25

COOLING SYSTEM·· ··································· 3·16 WHEELSITIRES ............................. .......... ... 3·25

DRIVE TRAIN BOOTS ································ 3·17 TIE·ROD AND JOINT BOOTS ····················3·26

REAR FINAL GEAR CASE OIL AND STEERING SHAFT HOLDER BEARING ···· 3·26
DIFFERENTIAL OIL ····································3·17
STEERING SySTEM··································· 3·26

3-1
MAINTENANCE
SERVICE INFORMATION
GENERAL
• Place the vehicle on level ground before starting any work.

TORQUE VALUES
THREAD TORQUE
ITEM a 'TV REMARKS
DIA. (mm) N'm (kgf'm, IbHt)
Spark plug 1 +-- 14 22 (2.2, 16)
Valve adjusting screw lock nut 2 6 17 (1.7, 13)
Valve adjusting hole cap 2 36 12 (1.2,9)
Timing hole cap 1 14 10 (1.0, 7)
Engine oil drain bolt 1 12 25 (2.5,18)
Rear i1 1 8 12 (1.2, 9)
Rear i1 1 30 12 (1.2, 9)
Rear i1 1 8 12 (1.2, 9)
f Rear case 3 8 32 (3.3, 24) ALoe boll: replace
with a new one.
Front final gear case oil filler cap 30 12 (1.2, 9)
Front final gear case oil drain bolt 1 8 12 (1.2. 9)
Final clutch arm cover bolt 3 6 HlJ1Jl, 7)
Front master cylinder reservoir cap screw 2 4 2.0 (0.2, 1.5)
Tie-rod lock nut (knuckle side) 2 12 54 (5.5, 40) See page 3-26
Tie-rod lock nut (steering arm side) 2 12 54 (5.5, 40) left hand threads.
See page 3-26

TOOLS
Adjusting screwdriver Valve adjusting wrench
07GMA-KTB0110 07GMA·ML70120

3·2
 MAINTENANCE
MAINTENANCE SCHEDULE
Perform the PRE-RIDE INSPECTION in the Owner's Manual at each scheduled maintenance period.
I: Inspect and dean. adjust. lubricate or replace if necessary. C: Clean. R: Replace. A : Adjust. L: Lubricate.
FREQUENCY WHICHEVER
INITIAL I REGULAR MAINTENANCE

;f
COMES
FIRST
AI NTENANCE INTERVAL
REFER
mi 100~=:;:::=~'600 -+==~'1,200 TO
km 150 1.000 2,000 PAGE
MONTH 1 6 12
ITEMS
FUEL LINE
~;==~_ ===~H~O~URS
,",
20 - + - - -'00 _-r---_~2ooI 3-4

4= _" " 1 ~:: ;

THROITlE OPERATI..,.O",N'-----II--., I 3-4
AIR CLEANER NOTE 1 + C C
i~~T~~~~~R HOUSING
1i:
NOTE 2
SPARK PLUG
VALVE CLEARANCE I I I 3-9
ENGINE OIL INITIAL 100 mi (150 km), 20 operating hours or 1 month : R 3·ti'
~
ENGINE OIL FilTER REGULAR = Every 600 mi (1.000 km), 100 operating hours or 3·14
-I- 12 months: R
ENGINE IDLE SPEED -===;::.;:;:- -t-:l:15
RADIATOR COOLANT _ __ "N~OTE 3 3·t5
COOLING SYSTEM
-DRIVE TRAIN BOOTS
REAR FINAL GEAR CASE "O"IL~'---­
AND DIFFERENTIAL Oil
NOTE 2

~ (RE,e'Y
2 years)
L
~
• __ 2WD/4WD SELECT SY STEM I
• BRAKE FLUID NOTE 3 + I I 3·20
• BRAKE SHOES WEAR NOTE 1, 2- I 3·21
I

1
• . BRAKE PADS WEAR NOTE1 .2 I 3·21
BRAKE LIGHT SWITC H I I 3·21
BRAKE SYSTEM + ~
I I 3-22
REVERSE LOCK SYSTEM + I I 3·23
GUARDS I I I 3-24
I 3-24
CLUTCH SYSTEM I I
SUSPENSION
+ I I 3-25
SPARK ARRESTER C C I 3-25 I
NUTS, BOLTS. FASTENERS I t- 3.25'--j
~~:t===
•• WHEELSfTlRES
.. TIE·ROD AND JOINT BOOTS,-+_ __
•• STEERING SHAFT HOLDER
+
t
[ I 3-25
3-26
3·26
BEARING
. . I STEERING SYSTEM
I 3·26

Should be serviced by a dealer, unless the owner has proper tools and service data and is mechanically qualified.
•• In the interest of safety, we recommend these items be serviced only by a dealer.

NOTES:
1. Service more frequently when riding in dusty areas, sand or snow.
2. Service more frequently after riding in very wet or muddy condi tions.
3. Replace every 2 years. Replacement requires mechanical skill.

3-3
MAINTENANCE
FUEL LINE
Remove the fuel tank (page 7-20).
Check the fuel lines III for deterioration , cracks,
damage or leakage .
Replace the fuel hose if necessary.

THROTTLE OPERATION
Check for any deterioration or damage to the throttle
cable. Check the throttle lever 11] for smooth operation .
Check that the throttle opens and automatically closes
in all steering positions
If the throttle lever does nol return property, lubricate
the throttle cable and overhaul and lubricate the throtlle
housing (page 16-11).
If the throttle lever still does not return properly, replace
the throttle cable.
With the engine idling, turn the handlebar all the way to
the right and left to ensure that the idle speed does nol
change. If idle speed increases, check the throttle lever
free play and the throttle cable connections.
Measure the throttle lever freeplay at the tip of the
throttle lever.
THROITLE LEVER FREEPLAY:
3-8 mm (0.1 - 0.3In)

Throttle lever free play can be adjusted al either end of

the throttle cable . Minor adjustments are made with the
upper adjuster.
Slide the rubber boot (1 J off the adjuster [2].
Loosen the lock nut (3). lum the adjuster as requIred
and tighten the lock nut.
Install the rubber boot securely.

3-4
 MAINTENANCE
Major adjustments are made with the lower adjuster.
Remove the throttle body cover (page 7-13).
Slide the rubber boot (1] off the adjuster (2].
Loosen the lock nut (3]. turn the adjuster as required
and tighten the lock nut.
Install the rubber boot securely.
Recheck the throttle operation and install the throttle
body cover (page 7-13).

AIR CLEANER
NOTE :
• If the vehicle is used in dusty areas, sand or snow.
more frequent inspections are required.
Remove the seat (page 2-4).
Release the four retaining dips [lJ and remove the air
deaner cover (21 .

Loosen the band screw [1) and remove the air cleaner
element assembly 121.
Remove the dust filter [3] from the element holder in the
air cleaner housing.
Check the dust filter for dirt. and clean it if necessary.

3-5
MAINTENANCE
Remove the element band (1] and the element core [2J
from the air cleaner element 131.

I1J

Wash the element and filter In non-flammable or high

flash point solvent.
Squeeze out the solvent thoroughly. and allow the
[2J
'"[3[

element and filter to dry.

Wash Squeeze out

Apply approximately 20 9 (0.7 oz) of Pro Honda Foam

Filler Oil [11 or equivalent oil from the inside of the
element. ......_ _ [1[
Place the element into a plastic bag [2J and spread the
oil evenly by hand.

[2J

Install the element core III into the air cleaner element
[21 properly. [2J '---...
Install the element band [3] onlo the element flange.

[3[

3-6
 MAINTENANCE
Clean the inside of the air cleaner housing and cover.
Make sure the rubber seal in the cover is in position and
in good condi tion.
Install the dust filler [1) into the housing port.
Install the element assembly [2) over the connecting
tube on the housing.
Be sure to rest the element onto the stepped area [3} of
the housing and tighten the band screw [4].

Install the air cleaner cover [1] with the arrow [2) facing ~~~~~~~~IlIII~~~I~'I~"""""""""""
forward by aligning the stepped area (3) with the
element.
Secure the cover wi th the four retaining clips [4].
Install the seat (page 24).

~' ~ I . . .
~ ~.- ~
141
AIR CLEANER HOUSING DRAIN TUBE
NOTE '
• If the vehicle is used in very wet or muddy
conditions , more frequent inspections are required.
Remove the drain tube (1) from the bottom of the air
cleaner housing to empty any deposits.
Install the drain tube securely .

3-7
MAINTENANCE
SPARK PLUG
Remove the left side cover (page 24).
Clean around the Disconnect the spark plug cap (1) and clean around the
sparK plug base spark plug base.
with compress&(l air
Remove the spark plug (2).
before removing the
plug. end be sure
thaI no debris is
a/lowed to enter into
the combustion
chamber.

Check the insulator [1 ) for cracks or damage, and the ~~111111111111111111~~~"""'''''''''''==::~

electrodes for wear, fouling or discoloration. Replace 12J
the plug if necessary.

RECOMMENDED SPARK PLUG :

13J
BKR5E·11 (NGK). K16PR·U11 (DENSO)

Clean the spark plug center electrode (2) and side

electrode (3] with a wire-type brush or special plug
cleaner.

]1J
Check the spark plug gap between the center and side :==================~
electrodes with a wire-type feeler gauge.

SPARK PLUG GAP: 1.0 - 1.1 mm (0.039 - 0.043 in) 1.0-1.1mm

(O.039 - 0.043 in)
If necessary, adjust the gap by bending the side
electrode carefully.
Thread the spark plug in by hand to prevent cross-
threading and tighten it to the specified torque with a
spark plug wrench .
TORQUE : 22 N'm (2.2 kgf'm , 16 tbHtl

Connect the spark plug cap and install the left side
cover (page 2-4).

3-8
 MAINTENANCE
VALVE CLEARANCE
NOTE
Inspect and adjust the valve clearance while the
engine is cold (below 35°C/9S0F),
• Check the engine idle speed after the valve
clearance inspection (page 3-15).
Remove the following:
- fuel tank (page 7-20)
- intake air duct (page 7-22)
- right mudguard (page 2-6)
Remove the following:
- rubber plug [lJ (from the heat guard plate)
- intake valve adjusting hole cap 121
Release the cables [3], wire harness and hoses {4] oul
of the heat guard plate [5].

Be careful not /0 lift Ihe right side of the heat guard plate up (1) and
damage the fuel remove the exhaust valve adjusting hole cap [2J.
hooe.

Remove the following:

- three bolls [1]
- crankshaft hole cap [2]
- timing hole cap [3]

3·9
MAINTENANCE
If the ...,. marl( is Rotate the crankshaft clockwise to align the ~T· mark 111
passed when trymg on the flywheel with the index mark 121 on the
111
/0 align il with the crankcase.
Index mark. Make sure the piston is at TDC (Top Dead Center) on
contmue to rotate the compression stroke.
the crankshaft This position can be obtained by confirming that there is
cIockwlS6 to align. slack in both rocker arms. If there is no slack, rolale the
Do not rotate the crankshaft one full tum and match up the -rmark
crankshaft again .
counterclockwise.
This ;s 10 prevent
the one-way
decompressor
system from
functlOfllflg. whICh
would cause an
in~valve
clearance
measurement
W'hen checking the Check the valve clearances by inserting a feeler gauge
clearance. slide the (1) between the adjusting screw and valve stem,
feeler gauge from
the center toward VALVE CLEARANCE :
the outside. IN : 0.15:t: 0.02 mm (0.006:t: 0.001 in)
EX : 0.23:t: 0.02 mm (0.009 :t: 0.001 in)

Adjust by loosening the lock nut {1] and turning the

adjusting screw [2] until there is a slight drag on the
feeler gauge.

TOOLS:
(3] Valve adjusting wrench 07GMA·ML70120
[4] Adj usti ng screwdriver 07GMA·KTS0110
Hold the adjusting screw and tighten the lock nut to the
specified torque.
TORQUE : 17 N'm (1.7 kgf'm, 131bHt)

After tightening the lock nut, recheck the valve

clearance.

3-10
 MAINTENANCE
Coat new O-rings [1J with engine oil and install them
into the groove in each valve adjusting hole cap.
Install the valve adjusting hole caps and tighten them to
the specified torque.
TORQUE : 12 N'm (1.2 kgf'm, 9 tbHt)

Coat a new D-ring 111 with engine oil and install il onlo
Ihe timing hole cap 121.
Inslall the liming hole cap and tighten it 10 the specified
torque.
TORQUE: 10 N'm (1 .0 kgf'm, 7 lbHt)
Coat a new a-ring [31 with engine oil and Install It into
the crankcase cover groove.

Install the crankshaft hole cap {11 and tighten the three
bolts [2].
Install the removed parts in the reverse order of
removal.

Install the heat guard plate (1) on the frame while ~:::::::::::;;=:::~
rouling the cables (2). wire harness and hoses (3) into
the guides of the plate properly, being careful not to
damage them.
Install the rubber plug [4).
Be sure the routing items are in place and install the
following:
- right mudguard (page 2-6)
- intake air duct (page 7-22)
- fuel tank (page 7-20)

3-11
MAINTENANCE
ENGINE OIL
LEVEL CHECK
NOTE:
Check the oil level after starting the engine and
allowing the oil to circulate through the engine
thoroughly. It is especially important on a dry sump
engine . due to the comparatively large volume of oil.
Do nol snap the throttle while idling or the oil level
reading will be inaccurate.
Remove the left side cover (page 2-4).
Place the vehicle on level ground.
III
Start the engine and let it idle for 3 - 5 minutes.
If the air temperature is below lOoe (50°F). lei the
engine idle for an additional 5 minutes (a tolal of 10
minutes).
Slop the engine and wait 2 - 3 minutes.
Remove the oil filler capfdipSllck [1 J and wipe it clean.
Check the oil level by inserting the oil filler cap/dipstick
into the engine without screwing it in.
The engine contains a sufficient amount of oil if the oil
level is between the upper level [21 and lower level (3)
marks on the dipstick.
If the oil level is near or below the lower level mario:, add
the rerommended engine oil to the upper level mario;.
RECOMMENDED ENGINE OIL:
Pro Honda GN4 4·stroke 011 (U .S.A . and Canada)
or Honda 4·stroke oil (Canada only), or equivalent
motor 011
API service classification: SG or higher
(except oils labeled as energy conserving on the
circular API service label)
JASO T 903 standard: MA
Viscos ity: SAE 10W·30

NOTE ·
Other viscosities shown in the chart may be used
when the average temperature in your riding area is
wi thin the indicated range . OIL VISCOSITIES
Reinstall the oil filler capfdipstick.
Inslalilhe left side cover (page 2-4 ).
lDW·30

SW·30
10W·40

••
--30~ ,, '0
·20 0 -20
ow

0
30

40
'0 20 :10
10 to
•~50'C
.Go ,2o·F

3-12
 MAINTENANCE
OIL CHANGE
NOTE '
• Change the oil with the engine warm to assure
complete and rapid draining.
Remove the left side cover (page 2-4).
Place the vehicle on level ground.
Start the engine and let it idle for a few minutes.
Slop the engine.
Remove the drain 0011111 and the oil filler cap/dipstick
[2J to drain the engine oiL
After the oil has drained, install the drain bolt with a new
sealing washer (3] and tighten it to the specified torque.
TORQUE : 25 N'm (2.5 kgf'm, 181bHt)
Pour the recommended oil (page 3-12) into the engine
to the upper level mark on the dipstick.
OIL CAPACITY:
\
2.9 liters (3. 1 US qt, 2.6 Imp qt) after draining
3.0 liters (3.2 US qt, 2.6 Imp qt) after draininglfllter
change
3.3 liters (3.5 US qt, 2.9 Imp qt) after disassembly
Install the filler cap/dipstick.
Check the oil level (page 3-12).
Resel the 011 change indicator after changing the engine
oil as follows.

OIL CHANGE INDICATOR RESET

To reset the indicator [1] , press and hold the odometerl
tripmeter/hourmeter select button [2] and turn the
ignition switch ON for more than 5 seconds. The
indicator message win disappear. (R2~N2 (~[X2~2 [0) 111
--
--
1...... 1 !;
'-, - ,
If the oit is changed before the oil change indicator
appears, be sure to reset the oil change indicator after
changing the oil, except after the initial oil change.
Press and hold the odometerflripmeter/hourmeter
select button and tum the ignition switch ON for more
1\1
ouo
L'
- il
f>l E . .

2 "'l.I.
than 5 seconds . When the indicator lights for 2 seconds
and then turns off, the oil change indicator is reset.
n: /
121
\ )

3-13
MAINTENANCE
ENGINE OIL FILTER
Remove the right side cover (page 2-4 J.
Drain the engine oil (page 3-13).
Pface shop towels Remove the following:
under the filter three bolts [1]
-
cover because oil - filter cover [2] and O-ring
will flow out

- oil filler [1j

- selting spring (2)
- D-ring (3]

Coat new a-rings [1] with engine oil and install them
into each groove in the filter cover [2J and front
crankcase cover.
Installmg the oil Install the selling spring onto the lugs and a new oil filler
filter backwards will with the rubber seal [3] facing Qui, away from the
resul/insevere engine ("OUT.SIDE- mark [41 on the filler is visible).
engine damage. then set the filter cover onto the filter and lighten the
bolls while holding the cover.
Fill the crankcase with the engine oil (page 3-13).
Install the right side cover (page 2-4).

3-14
 MAINTENANCE
ENGINE IDLE SPEED
INSPECTION
NOTE:
Inspect the idle speed after all other engine
maintenance Items have been performed and are
within specifications.
Before checking the idle speed, check the following:
- OTC or MIL blinking (page 4-11)
- spark plug condition (page 3-8)
- air cleaner condition (page 3-5)
The engine must be warm for accurate idle speed
inspection.
This system eliminates the need for manual idle
speed adjustment compared 10 previous designs.
Use a tachometer with graduations of 50 rpm or
smaller thai will accurately indicate a 50 rpm
change.
Remove the left fuel lank side cover (page 2-5),
Start the engine and warm it up until the coolant
temperature rises to ao°c (176°F ).
SlOp the engine and connect a tachome ter according to
the tachometer manufacturer's instructions.
Start the engine and let it idle. Check the Idle speed.
ENGINE IDLE SPEED : 1,400 ± 100 rpm

If the idle speed is out of the specification, check the

following:
~ throttle operation and throttle lever free play
(page 3-4).
- intake air leak
- engine top-end problem (page 10-6)
- IACVoperation (page 7-26)

RADIATOR COOLANT
Check the coolant level of the reserve tank [11 with the
engine running at normal operating temperature.
The level should be between the upper 121 and lower
level lines [3] wi th the vehicle upright on a level surface.
If the level is low, add coolant as follows
Remove the rear fender cover (page 2-9).
Remove the reserve tank cap [41 and fill the lank up to
the upper level line with a 1:1 mixture of distilled wa ter
and antifreeze (coolant preparation: page 8-6).
RECOMMENDED ANTIFREEZE:
Pro Honda HP coolant or an equivalent high
quality ethylene g lycol antifreeze containing
silicate-free corrosion inhibitors

NOTICE
Using coo/ant with silicate corrosion inhibitors may
cause premature wear of w8ter pump se8/s or blockage
of radiator passages. Using tap water may cause
engine damage.
Check to see if there are any coolant leaks when the
coolant level decreases very rapidly.
If Ihe reserve tank becomes completely emply, there is
a possibility of air getting Into the cooling system.
Be sure to remove any air from the cooling system
(page 8-7).

3-15
MAINTENANCE
COOLING SYSTEM
NOTE:
• If the vehicle is used in very wei or muddy
conditions, more frequent inspections are required.
Remove the front grille (page 2·7).
Remove the side covers (page 2-4).

Be careful not /0 Remove the radiator grille under cover 11] by releasing
damage the radiator the four tabs {2] .
fins.
Remove the following :
- connector and wire [3J (from right side air guide
plale)
- two trim cUps [4J (from each side air guide plate by
pushing the center pin )
- side air guide plates (by releasing each lab)
- radiator grille (by releasing the two tabs)

121 111

Check for any coolant leakage from the water pump (1) .
water hoses [21 and hose joints.
Check the water hoses for cracks or deterioration and
replace if necessary.
Check that aU hose clamps are light.

Check the radiator air passage for clogs or damage.

Straighten bent fins with a small, fiat blade screwdriver
and remove insects, mud or other obstructions with
compressed air or low water pressure.
Also, clean the radiator grille thoroughly.
Replace the radiator if the air flow is restricted over
more than 20% of Ihe radiating surface.
Install Ihe removed parts in the reverse order of
removal.
NOTE :
When installing the trim clip, carefully align the clip
holes in the radiator, grille and air guide plate.

3-16
 MAINTENANCE
DRIVE TRAIN BOOTS
Raise all the wheels off the ground by supporting the
frame securely
Remove the left side cover (page 2-4).
Check the drive shaft boots (1), propeller shaft boots [2]
and universal Joint boot [3] for cuts, damage or leaking
grease.
If the boot is damaged , replace it
- front driving mechanism (page 19-2)
- rear driving mechanism (page 20-2)

121

REAR FINAL GEAR CASE OIL AND

DIFFERENTIAL OIL
FINAL GEAR CASE OIL
LEVEL CHECK
Place the vehicle on a level surface.
Remove the oil check bolt 11) and check that the oil
flows out of the check bolt hole.
Check for leaks if there is no oil flow.
Remove the oil filler cap [2) and pour the oil slowly
through the filler hole until oil starts to flow out of the
check bolt hole.
RECOMMENDED OIL: Honda shaft drive gear oil or
equivalent hypoid gear oil,
SAE # 80

Install the check bolt with a new sealing washer [3] and
tighten it to the specified torque .
TORQUE: 12 N'm (1.2 kgf·m, 9lbHt)
Coat a new O-ring [41 with grease and install it into the
cap groove.
Instan the filler cap and tighten illo Ihe specified torque.
TORQUE: 12 N·m (1 .2 kgf·m, 9lbHt)

3-17
MAINTENANCE
OIL CHANGE
Place the vehicle on a level surface.
Remove the three bolts {1] and fear final gear case skid
plate {2}.

Remove the drain bolt (1] and sealing washer [2J. and
the filler cap 13J to drain the oil.
When the oil is completely drained, install the drain bolt
with a new sealing washer and lighten ilia the specified
torque.
TORQUE : 12 N'm (1 .2 kgf'm , 9lbHt)

Fililhe gear case with the recommended oil

(page 3-17).
OIL CAPACITY:
75 em 1 (2.5 US OZ , 2.6 Imp oz) after draining
100 em) (3.4 US OZ, 3.5 Imp oz) after dis assembly

Inslal1 the skid plate with new three bolts and tighten the
bolts to the specified torque. L _ _ _ _-'-_ _- 'L _
TORQUE : 32 N'm (3.3 kgf-m, 24 IbHt)
DIFFERENTIAL OIL
LEVEL CHECK
Place the vehicle on a level surface.
Remove the oil filler cap (1] and check that the ailteval
is up to the lower edge of the oil filler hole 12].
Check for leaks if the oil level is low.
Pour the oil into the filler hole until it reaches the lower
edge of the hole.
RECOMMENDED OIL: Honda shaft drive gear o il or
equivalent hypoid gear o il ,
SAE # 80

Coat a new O-ring /31 with grease and install il into the
cap groove.
Install the filler cap and tighten it to the specified torque.
TORQUE: 12 N'm (1.2 kgf'm, 9lbHt)

3-18
 MAINTENANCE
OIL CHANGE
Place the vehicle on a level surface.
Remove the drain bolt [1] and sealing washer [21 . and
the oil filler cap [3] to drain the oil.
When the oil is completely drained , install the drain bolt
with a new sealing washer and tighten it to the specified
torque.
TORQUE: 12 N'm (1.2 kgf-m, 9lbHt)

Fill the gear case with the recommended oil

(page 3-18),
OIL CAPACITY:
200 cm 3 (6.8 US oz, 7.0 Imp oz) after draining
250 em 3 (8.5 US oz, 8.8 Imp 02) after disassembly

2WD/4WD SELECT SYSTEM

2WD/4WD SELECTOR CABLE
ADJUSTMENT
Remove Ihe boll [11 and the clutch arm cover 121 by I
releasing the two tabs [3].
Shift the select lever to the 2WD position. 13J

Ir~
Be sure the clutch arm [4] position is between the 2WD
marks [5].
Temporarily loosen the adjusting nut [6J by turning it
counterclockwise.
Tum the adjusting nut clockWise until the joint pin (7)
just touches the clutch arm slot (8) with the nut ends (9)
are contacted the joint pin (cutout is not seated). Then
further turn it clockwise 1f4 of a turn to seat Ihe cutout in
the nul onto the joint pin.
Make sure that the clearance between the joint pin and
arm slot is 0.25 - 2 mm.
\ 12J
I1J

After adJuslmenl. check the select lever for smooth

operation .
Install the arm cover by aligning the slits with the tabs
and tighten the bolt to the specified torque.
TORQUE : 10 N 'm (1.0 kgf'm , 7 Ibf-ft)

...
Touches O.2S-2mm
the slot

3-19
MAINTENANCE
BRAKE FLUID
I NOTICE
Spilling fluid can damage painted, plastic or rubber
parts. Place a rag over these parts whenever the
system Is serviced.
NOTE :
Do not mix different types of fluid, as they may not
be compa tible with each other.
Do nol allow foreign material to enter the system
when filling the reservoir.
When Ihe fluid level is low, check the brake pads for
wear (page 3-21 ). A low fluid level may be due to
wear of the brake pads. If the brake pads are worn
and the caliper pistons are pushed Qui, this accounts
for a low reservoir level. If the brake pads are nol
worn and the fluid level is low. check the entire
system for leaks (page 3-22).
Tum the handlebar to the left side so the reservoir is , - - - - - - - - - - - - -- ---...,
level and check the reservoir fluid level through the 121
sight glass.
If the fluid level is near the "LOWER" level mark [11.
remove the reservoir cap [2], set plate and diaphragm
and fill the reservoir with DOT 4 brake fluid from a
sealed container to the casting ledge [3].
Install the diaphragm , set plale and reservoir cap. and
tighten the cap screws 14] to the specified torque.
TORQUE : 2.0 N'm (0.2 kgf'm, 1.5 IbHt)

3-20
 MAINTENANCE
BRAKE SHOES WEAR
Replace the brake shoes if the wear Indicator plale [1]
aligns with the reference mark [2) on the brake panel
when the feaf brake lever or brake pedal is applied.
See Brake System section for brake shoe replacement
(page 18·16).

BRAKE PADS WEAR

Replace the brake pads if the wear indicator [1 ) aligns r------:---:--
with the reference mark (lug) [2] on the caliper body
?;l:;;;~;-
r
-:-
111 1
when the front brake is applied.
See Brake System section for brake pad replacement
(page 18-8).

BRAKE LIGHT SWITCH

NOTE
The front brake light switch cannot be adjusted. If
the front brake light switch actuation and brake
engagement are oul of synchronization, either
replace the switch unit or the malfunctioning parts of
the system.
Check that the brake light comes on just prior to the I
brake actually being engaged .
If the light fails to come on, adjust the rear brake light
SWitch PI so that the light comes on at the proper time.
Hold the switch body and tum the adjustmg nut [21. Do
not tum the switch body.

3·21
MAINTENANCE
BRAKE SYSTEM
FRONT BRAKE
Firmly apply the front brake lever and check that no air
has entered the system.
If the brake lever feels soft or spongy when operated,
bleed the system.
See Brake System section for alf bleeding procedures
(page 18-7).
Inspecllhe brake hoses (1) and fittings for deterioration,
cracks, damage or signs of leakage.
Tighten any loose fittings.
Replace hoses, pipes and fittings as required.

REAR BRAKE
Make sure theCheck the brake cable, brake lever and brake pedal for
brake pedal loose connections, excessive play or other damage.
operatos smoothly Replace or repair if necessary.
and that the broke
For cable lubrication: Disconnect the brake cable at the
pedal position is
brake lever or pedal. Thoroughly lubricate the cables
correct.
and their pivot points with a commercially available
Make sure the
cable lubricant or a lightweight oil.
brakes do not drag
Measure the rear brake lever free play at the end of the , - - - - ,....-..,,.,
lever.

FREEPLAY: 15 - 20 mm (0.6 - 0.8 in)

Measure the rear brake pedal freeplay at the end of the

pedaL

FREEPLAY: 15 - 20 mm (0.6 - 0.8 i n)

3·22
 MAINTENANCE
Make sure the Adjust the brake lever freeplay by turning the upper
indent In the adjustmg nut [11 at the brake arm.
adjusting nut is
Adjust the brake pedal free play by turning the lower
seated on the brake
adjusting nut [21 at the brake arm.
arm pin.

121

REVERSE LOCK SYSTEM

Check the reverse selector cable and lever for loose
connections , excessive play or other damage.
Replace or repair if necessary.
Release the dust cover [1] .
Measure the lever free play at the lever end near the
cable.
FREE PLAY: 2 - 4 mm (0.1 - 0.2 in)

NOTE
If necessary, watch the reverse selector arm on the
crankcase to see when it moves white determining
freeplay.

Slide the rubber boot [1] off the adjuster [2J.

Adjust by loosening the lock nut [31 and turning the
adjuster.
Tighten the lock nut.
Install the dust cover properly.

3-23
MAINTENANCE
GUARDS
Check the outboard guard [1 1. inboard guard (2), engine
guard [31 and rear final gear skid plate [41. for cracks,
damage or looseness.
Tighten any loose fasteners. Replace the skid plates or
guard as required .

CLUTCH SYSTEM
Remove Ihe left side cover (page 2-4).
Loosen the lock nut [11 and turn the adjusting screw [2]
one fuiliurn clockwise.
Slowly turn Ihe adjusting screw counterclockwise until
resistance is felt, then tum the adjusting screw 1/4 tum
clockwise.
Hold the adjusting screw and tighten the lock nul.
Start the engine and check for proper dutch operation.
Inslalithe side cover (page 2-4)

3-24
 MAINTENANCE
SUSPENSION
Loose. wom Of Check the action of the front and fear shock absorbers
damaged by compressing them severatlimes ,
suspension pans Check the entire shock absorber assembly for signs of
impair vehicle leaks, damage or loose fasteners ,
stability end control. Replace damaged components which cannot be
repaired
Tigh ten aU nuts and bolts.

Raise the rear wheel off the ground by supporting the

frame securely.
Check for worn swingarm beanngs by grabbing the rear
axle hOUSing and attempting 10 move the wheels side to
side.
Replace the bearings if any looseness IS noted
(page 17-8)

SPARK ARRESTER
Remove the arrester bolt [ 1].
Block the end of the muffler with a shop toweL
Start the engine with the transmisSIOn In neutral , and
purge accumulated carbon from the muffler by
momentarily revving the engine several times.
Stop the engine and allow the exhaust system to cool.
Install the boll and lighten it securely.

NUTS,BOLTS,FASTENERS
Check thai all chassis nuts and bolts are tightened to
Iheir correct torque values (page 1.13).
Check that all coller pins. safety clips , hose damps and
cable sl ays are in place and properly secured

WHEELS/TIRES
Tire pressure Check the tire pressure with a tire pressure gauge.
should be checked
when the tires are RECOMMENDED TIRE PRESSURE
cold Front:Standard : 30 kPa (0.30 kgflcm 1 , 4.4 psi)
With cargo: 30 kPa (0.30 kgflcm1 , 4.4 psi)
Rear: Standard : 30 kPa (0 .30 kgfl cm J , 4.4 psi)
With cargo: 30 k Pa (0.30 kgflcm1, 4.4 psi)

Check the tires for cuts, embedded nails, or other r~::'i:i;".ii~

damage. •
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/Rear) :
4.0 mm (0.16 in)
Raise the wheel off the ground and check the bearings
in the knuckle for excessive play or abnormal noise.

3-25
MAINTENANCE
TIE-ROD AND JOINT BOOTS
Check the lie-rod joint nuts {1] and the suspension arm
ball Joint nuts [21 for looseness,
Check the ball joint boots [3J of the tie-rod and
suspension arm for tears or other damage.
Check for looseness of the tie-rocl ball joints [41 or
bearings by grabbing each front wheel side to side with
the wheels on the ground.
If any looseness is noted, inspect the following .
- lie-rod (page 16-40)
- knuclde bearing (page 16-16)

[4] -===::::::1J'4

STEERING SHAFT HOLDER BEARING

Make sure the Raise the front wheels off the ground and support the
cables do not vehicle securely.
interfere with the
Check that the handlebar moves freely from side to
rot8tfO(l of the
side.
handlebar.
If the handlebar moves unevenly, binds, or has
horizontal or vertical movement, inspect the steering
shaft holder bushing and bearing.
- FMfFE model (page' 6-27)
- FPM/FPE model (page 16-32)

STEERING SYSTEM
Place the vehicle on level ground with the front wheels , - - - - - - - - - - - - - - , - - - - ,
facing straight ahead.
Mark the centers of the tires with chalk to indicate the
axle center height.
Align the toe-gauge (1] with the marlc;s on the tires as
shown.
Check the readings on the gauge scales.

3-26
 MAINTENANCE
Slowly move the vehide back until the wheels have
Front
turned 180· so the marks on the tires are aligned with
the gauge height on the rear side. t
Measure the toe on the rear part of the tires at the same
points with no load on the vehicle.
Toe-out: 28 ± 15 mm (1.1 :t 0.6 in)
NOTE-
Toe-In means the rear measurement is greater than
the front measurement.
Toe-out means the front measurement is greater
than the rear measurement.

When the loe is out of specification, adjust it by

changing the length of the lie-rods [1) equally by
r {11
loosening the lock nuts [2] and turning the tie-rods while
holding the ball joints [3J. [3)

After
sameadjusting
direction,each lie-rod
along the ,lie-rod
rotate both
axis ball
unliljoints
theyinstop
the ~:~l~~~~r:1~~~~~~~~;~
against the ball joint stud. [2]

131

Using a 22 mm wrench , hold the ball joint ends (flats)

(1) so that the relative angle of both ball joints may tum
[21
into specified angle. Then, tighten each lock nut (2)10
the specified torque, making sure nol to force the ball
jOint end against the ball joint slud [3]. [11

TORQUE : 54 N·m (5.5 kgf·m, 40 Ibf·ft)

After lightening the lock nuts, rotate the tie-rods to
make sure the ball joints have operate property and
have an equal range of movement.
Raise the wheel off the ground and check the knuckle
bearings or tie-rod ball joints for excessive play or
abnormal noise.

Steering arm side

121 {11

Front __
'""'<PH

Knuckle side
L J

3·27
MEMO
 4. PGM-FI SYSTEM

PGM·FI COMPONENT LOCATION ············.. 4·2 DTC TROUBLESHOOTING ························ 4·14

PGM·FI SYSTEM DlAGRAM ························· 4·3 MIL CIRCUIT INSPECTION ········ ··········· ····· 4·29

SERVICE INFORMATION ·····························4-4 FUEL PUMP RELAY ··· ·························· .. ·.. · 4·29

SYMPTOM TROUBLESHOOTING ··············· 4·5 SENSOR UNIT (MAPITP SENSOR) ··········-4-30

PGM·FI CONNECTOR LOCATION···············4·7 ECT SENSOR ································ ············· 4·32

PGM·FI TROUBLESHOOTING BANK ANGLE SENSOR ............ ..... ............ 4·33

INFORMATION ····························· ··············' 4·10
PCM/ECM ................................ .................... 4·34
PGM·FI DTC INDEX ················ ····················4·13

4-1
PGM-FI SYSTEM
PGM-FI COMPONENT LOCATION

MIL

Eer SENSOR "AiNKAN<;L. SENSOR

FUSE BOX:
- FM/FPM: MAINFUSE (30 A)
- FElFPE: MAIN FUSE, (30 A)
- FElFPE: MAIN FUSE 2 (30 A ) FUEL INJECTOR
- IGN FUSE ( 10 A)

.UIHIJ.LTANKI
FUEL PUMP FUEL PUMP ASSEMBLY
RELAY

IAT SENSOR eKP SENSOR

SENSOR UNIT:
- MAP SENSOR
- TP SENSOR GEAR POS!TIION SWITCH
VS SENSOR

4-2
 PGM-FI SYSTEM
PGM-FI SYSTEM DIAGRAM

PCM/ECM

..,
~"~ l Jl::f-I-t---t-
I c,,,,
______ .---1 ' '-1""<::::J
"J." ... _ __--,
-
B~~~~E ~",.",~
.",=j---1"''''''~;:::::J "
SENSOR
~I!<II
, CoM ~ = ~-
.,
~ ~
• =~
.,!.PLUG
919'

..
,~

~
oc:l!7'
F ~
_.
• • •
.'
.~
o:I® ~~,

''''- ' •• ,, ;:~{b

"
- .r- OLe SCSSERVlCECOOoHf:CTOII:

, M
AI< C' ~

~ -' COO!JNG floH. "'OTOfI:

WO _ ~""

..••, c_ ••

l~ll
~

,.,
.n "'-11
PCMIECM C-l C-3 ~, 8·1\
"'·12
~" ~"

,o, ....
U> loglll bIufI
MIL 81"'"
~-
EIIgIo:w _
_~OTC
nat ...,

.. == ~-
&
G
-
..... w_
0._

dl """'_
,~

'""""II OTC
Go Go"
Lg l.Jg/l1!11'Mn , ".,.
C-'I C_~ ... ·23 .0.-338-23 ~~

Y' (Bla<:*1 CONNECTOR 33P iBlacI<) CONNECTOR 33P IG,.~) CONNECTOR

4-3
PGM·FI SYSTEM
SERVICE INFORMATION
GENERAL
This section covers servICe of the electrical system of the PGM· FI system. For mechanical system service of the PGM-FI system
and the fuel supply system, see Fuel System section (page 7-2).
Bending or twisting the control cable will Impair smooth operation and could cause the cable to slick or bene!. resulting in loss of
vehicle control.
Work in a well ventilated area . Smoking or allowing flames or sparks in the work area or where gasoline is stored can cause a
fire or explosion.
Do not damage the throttle body. It may cause incorrect throttle valve operation .
Prevent dirt and debris from entering the sensor hole . Clean them using compressed air.
The throttle body is factory pre-set. Do not disassemble in a way other than shown in this manual.
Do not loosen or lighten the white painted screws and nut of the throttle body. Loosening or tightening them can cause throttle
body malfunction.
Tighten the yellow painted screws of the throttle body to the specified torque.
A faulty PGM-FI system is often related \0 poorty connected or corroded connectors. Check those connections before
proceeding.
When disassembling the PGM-FI parts, note the location of the O-rings. Replace them with new ones upon reassembly.
Use a digital tester for PGM-Fl system Inspection.
The engine stop switch line is connected to the PCMlECM on this vehicle. lis signal permits the PCMfECM to control the fuel
pump, injector and ignition coil.

SPECIFICATIONS

rf-;~~~~~~~~IT ~E~M~~~~~======~==============~SP~0.86
E~C~I~F-I~C1.55
~AT~I~kOO~N~S=============3
~AT sensor resistance (20"Cf68"F) 2.2 - 2 .7 kO
ECT sensor resistance (40 :i: SOC/104 :i: 41 °F)
Fuel in' tor resistance (20· C/66°F) 11 .6 - 12.4 0

TORQUE VALUES

h en
ITEM
sor unit torx screw T25)
1 Q'TY
3
THREAD
OIA. (mm)
5
TORQUE
N'm (kgf'm , IbHt)
3.4 (0.3. 2.5)
REMARKS

~ sensor
Bank angle sensor mounting bolt
1
2
10
6
12 (1 .2. 9)
10(1 .0. 7) I
TOOLS
SCS service connector Test probe HDS pocket tester
070PZ-ZY30100 07ZAJ-RDJA110 TDS 3557-0112-01 (U.S.A. Only)

4-4
 PGM·FI SYSTEM
SYMPTOM TROUBLESHOOTING
When the vehicle has one of these symptoms. check the Ole or Mil blinking, refer to the Ole index (page 4-13) and begin the
appropriate troubleshootmg procedure. If there are no DTCfMll blinking stored in the PCM/ECM memory. do the diagnostic
procedure for the symptom. in the sequence listed below, until you find the cause.

Symptom Diagnosis proce'~ d~u~,e--:-;:::;:::=+=::::;~ Also check for

Engine cranks but won't start 1. Check the spark plug (page 3-8). Sparl< plug condition
(No OTC and Mil blinking) 2. Inspect the ignition system Faulty ignition system
(page 5-5). No fuella fuel injector
3. Inspect the fuel supply system. - Pinched or clogged fuel tank breather hose
- fuel pressurelflow (page 7-11) - Pinched or clogged fuel hose
- fuel pump (page 7-13) - Pinched or clogged fuel feed hose
4. Inspect the cylinder compression - Clogged fuel tank strainer screen
(page 10-7) - Clogged fuel pump fitter
- Faulty fuel pump circuits
- Faulty fuel pump
Intake air leak
Contaminatedfdeteriorated fuel
Faulty fuel injector
IACV stuck closed
Low cylinder compression
- blown cylinder head gasket
- improper valve adjustment
- valve leakage
- worn piston nng or cylinder
Engine cranks but won't start 1. PCMfECM powerlground cl~,cu=iI~'--"" Open circuit in the power input andlor ground
(Gear position indicator malfunction (page 4-35). wire of the PCMIECM
continuously blinking .-.)=.-~.
Engine crank s but won'l start 1. PCMIECM engine stop switch Open circuit in the engine stop sWitch wire of
(No fuel pump operation circuit malfunction (page 4-36). Ihe PCMIEC M
sound when turning the 2. Inspeclthe fuel supply system Faulty fuel pump relay or related cirCUit
ignition switch ON and engine (page 7- 13). Faulty fuel pump or related circuits
stop switch "0")
Engine stalls, hard to start, 1, Check the spark plug (page 3-8) Spark plug condition
rough idling 2, Check the air cleaner (page 3-5). Air cleaner condition
3.
Check the Idle speed (page 3-15). Restncted fuel feed hose
Check the IACV (page 7-26).
4. Contaminaledldeterioraled fuel
5.
Insped the fuel supply system. Intake air leak
- fuel pressurel flow (page 7-11) Restricted fuel lank breather hose
- fuel pump (page 7-13) Faulty ignition system
6.
Inspect Ihe cylinder compression low cyhnder compression
(page 10-7) - blown cylinder head gasket
- improper valve adjustment
- valve leakage
- worn piston ring or cylinder
Engine stalls, rough idling, ' Troubleshoot the fuel line ( pa·~g~e~7"'5)'.--"Pinched or clogged fuel tank breather hose
lacks power (after warm up Pinched or clogged fuel hose
the engine) Pmched or clogged fuel feed hose
Clogged fuel tank strainer screen
Clogged fuel pump filter
Faulty fuel pump or related circuits
Backfiring or misfiring during Inspect the ignition system Faully igrlltion system
acceleration (page 5-5),
Poor performance 1. Check the brake system Brake dragged
(driveabillty) and poor fuel (page 3-22). Clogged muffler tail (spark arrester)
economy 2. Check the muffler lail (spar!< air cleaner condition
arrester) (page 3-25) Pinched or clogged fuel tank breather hose
3. Check the air cleaner (page 3-5). Pinched or clogged fuel hose
4. Inspecl the fuel supply system. Pinched or clogged fuel feed hose
- fuel pressurefflow (page 7-11) Clogged fuel tank strainer screen
- fuel pump (page 7-13) Clogged fuel pump filter
5. Inspect the ignition system Faulty fuel Injector
(page 5--5). Faully ignition syslem
6. Inspect the cylinder compression Low cylinder compression
(page 10-7) - blown cylinder head gasket
- improper valve adjustment
- valve leakage
- worn piston ring or cylinder

4·5
PGM -FI SYSTEM
Symptom Diagnosis procedure Also check for
h ''' pe:::ed ";~s'ibe:5.:'o;;wc----+-·1-
dI''e-:s::C , -"C"he"c"k,",l!:he='idle speed (page 3- f5 '),-+-,--O
s p:::a:::"= p'':::
g-:co:Cn3dilio"n""==- - --
specifications or fast Idle too 2. Check the spark plug (page 3-8). air cleaner condition
low (No DIG and Mil blinking ) 3. Check the air cleaner (page 3-5). IACV stuck closed
4. Check the IACV (page 7-26). Faulty fuel supply system
5. Inspect the fuel supply system. Faulty ignition system
- fuel pressure/flow (page 7-11)
- fuel pump (page 7-13)
6. Inspect the ignition system

I-"';;-;;====
Idle speed is above ___-+---.-_(~p"age 5-5). -c;;===="".-f-:
1. Checktheidle speed (page 3-15). - ====------
IACVSluck opened -
specifications or fas t idle too 2. Check the throttle operation and Faulty ignition system
high (No DTC and MIL lever freeplay (page 3-4). Intake air leak
blinkmg) 3. Check the tACV (page 7-26). Engine top end problem
4. Inspect the ignition system
,oc~~~-::::~~~___.~(p~age~5~),~~""-::::~ ~..--,r-~Faulty MI L~~'-----------------1
Inspect the Mil circuit (page 4 ~29).
Mil stays on but no OTCs set. circuit
or MIL never comes ON at all
hM:;,;'L~s~t=ay~s~o;n~a~t~a~lIr.t~;m~e~s""""'-'--;'=n=sp=e=c"'"th=e~D~L~C-=c=irc=u"'it (page 4-2"9"),--+~~S"hort Circuit in the OlC related,c;;w;;;;'~e-----1
(No OTC sel)

4-6
 PGM -FI SYSTEM
PGM-FI CONNECTOR LOCATION
NOTE 1: Remove the front fender/carrier (page 2-8).

m ..A. m
f 0)
BANK ANGLE SENSOR 3P (Black) CONNECTOR
(NOTE 1)

NOTE 2: Remove the throttle body cover (page 7-13).

FUEL INJECTOR 2P (Gray) CONNECTOR

(NOTE 2)

SENSOR UNIT 5P (Black) CONNECTOR IACV 4P (Black) CONNECTOR

(NOTE 2) (NOTE 2)

4-7
PGM·FI SYSTEM

IAT SENSOR 2P (Black) CONNECTOR

NOTE 1: Remove the left fuel tank side cover (page 2.5).

EeT SENSOR 2P (Black) CONNECTOR

(NOTE 1)

4-8
 PGM·FI SYSTEM
NOTE 1: Remove the seat (page 2-4 ).

OLe (NOTE 1)

NOTE 2: Remove the rear fender cover (page 2-9).

B33 B23 A33 A23

PCM/ECM 33P (Gray) CONNECTOR PCMlECM 33P (Black) CONNECTOR
(NOTE 2 ) (NOTE 2)

4-9
PGM-FI SYSTEM
PGM-FI TROUBLESHOOTING INFORMATION
GENERAL TROUBLESHOOTING
Intermittent Failure
The term -intermittent failure" means a system may have had a failure , but it checks OK now. If the Mil does not come on, check
for poor contact or loose pins at all connectors related to the circuil with the trouble. If the Mil was on , but then went oul, the original
problem may be intermittent.
Opens and Shorts
·Opens· and ·Shorts· are common electrical terms. An open is a break In a Wife or al a connection. A short is an accidental
connection of a wire to ground or to another wire. In simple electronics, this usually means something will not work at all. With peM/
ECMs this can mean something will work, but not the way it's supposed to.
If the MIL has come o n
Refer to DTe READOUT (page 4-11 ).
If the Mil did not stay on
If the MIL did not stay on , but there Is a driveability problem, do the SYMPTOM TROUBLESHOOTI NG (page 4-5).

SYSTEM DESCRIPTION
SELF·DIAGNOSIS SYSTEM
The PGM·FI system is equipped with the self-diagnostic system. When any abnormality occurs in the system , the PCMfECM turns
on the MIL and stores a OTC In its erasable memory.
FAll·SAFE FUNCTION
The PGM-FI system is provided with a fail-safe function to secure a minimum running capability even when there is trouble in the
system. When any abnormality is detected by the self-diagnosis function, running capability is maintained by pre-programed value
in the simulated program map. When any abnormality is detected in the fuel injector and crankshaft position (CKP) sensor, the fail-
safe function slops the engine to protect it from damage.
OTe (Diagnost ic Trouble Code)
The oTC is composed of a main code and a sub code and it is displayed as a hyphenaled number when retrieved from the
PCMlECM with the HDS pocket tester.
The digits in front of the hyphen are the main code, they indicate the component of function failure.
The digits behind the hyphen are the sub code, they detail the specific symptom of the component or function failure.
For example . in the case of the TP sensor:
- OIC 08 - 1 = (TP sensor voltage) - (lower than the specified value)
- OIC 08 - 2 = (TP sensor voltage) - (higher than the specified value).
The MAP, ECT, TP and JAT sensor diagnosis will be made according to the voltage output of the affected sensor.
If a fallure occurs , the PCMfECM determines the Function Failure , compares the sensor voltage output to the standard value.
and then outputs the corresponding oTC to the HDS Pocket Tes ter.
For example:
- If the output voltage line (A) on the MAP sensor is opened, the PCMfECM detects the output voltage is about 5 V. then the
OIC 1-2 (MAP sensor circui t high voltage) will be displayed.
- If the input voltage line (8) on the TP sensor is opened, the PCM fECM detects the output voltage Is 0 V, then the OIC 8-1 (TP
sensor circuit low voltage) will be displayed .

5V
MAP SENSOR 5V TP SENSOR 5V

.--9-- 18)--<:>--'
OUTPUT VOLTAGE
,....,..-<;>- (A)- -<)-- + - --9-----<>--;~
OUTPUT VOLTAGE

5V
~ .... ~ ": V
ECTSENSQR tAT SENSOR

* *
OuTPUTVOlTAGE OU TPUT VOLTAGE

-Jo -Jo
4-10
 PGM-FI SYSTEM
MIL Blink Pattern
If Ihe HDS pocket tester IS not available, OTG can be read from Ihe . - - - - - - - - - - - - - - - - - ( -
'1- ,
PCM/ECM memory by the MIL [1) blink pattern.
The number of MIL blinks is the equivalent the main code of the OTG
(the sub code cannot be displayed by the MIL).

,-, --,
The MIL will blink the current DIG , in case the PCMJECM detects Ihe (R) (N) (~ (I) ~ (qJ
problem at present, when the ignition switch ON or idling. The MIL will
stay ON when driving.
-- 1...... 1

The MIL has two types of blinks, a long blink and short blink. The long
blinking lasts for 1.2 seconds, the short blinking lasts for 0.4 seconds.
One long blink is the equivalent of ten short blinks. For example, when
two long blinks are followed by five short blinks, the MIL is 29 (two long
blinks = 20 blinks, plus nine short blinks).
[\1
vvO
'-,
2
- il
,. " II!!!!
WI LE
-
)
When the PCMIECM stores more than one OTC , the MIL will indicate
them by blinking in the order from the lowest number to highest number.
MIL Check I
\(5" / I
When the ignition switch is turned ON and engine stop switch "0", the MIL will stay on for a few seconds , then go off. If the MIL
does not come on, troubleshoot the MIL circuit (page 4-29),
CURRENT DTC/STORED DTC
The DTC is indicated in two ways according to the failure status .
In case the PCM/ECM detects the problem at present, the MIL will come on and the MIL will start to blink as its DTC. It is
possible to readout the MIL blink pattern as the current OTC.
In case the PCM/ECM does not detect any problem at present but has a problem stored in its memory, the MIL will not light and
blink. If it is necessary to retrieve the past problem. readout the stored DTC by following the OTC readout procedure.

HDS POCKET TESTER INFORMATION

• The HOS can readout the DTC , stored data, current data and other PCMfECM condition.
How to connect the HDS Poc ket Tester
Turn the ignition switch OFF.
Remove the seal (page 2-4).
Remove the OLC 11) from the dummy connector [2] .
Connect the HDS pocket tester to the Ole.
Tum the ignition switch ON and engine stop switch ·0·, check the OTC and
stored data.
NOTE '
• Stored data indicates the engine conditions when the first malfunction
was detected.
PCM/ECM reset
The HDS can reset the PCMfECM data including the OTC , stored data and
some learning memory.

DTC READOUT
When the ignition switch is turned ON and engine stop switch "0·, the '-----------------:I~
'J--,
Mil (1) will stay on for a few seconds, then go off.
After performing diagnostic troubleshooting, erase the problem code(s) I
(page 4-12) and test-ride the vehicle to be sure that the problem{s) have

-,
I (R) (N) If$)

-
been removed. (X) (~(OJ
If the MIL stays on or blinks, connect the HDS Pocket Tester to the OLC
(page 4-11 ).
Read the OTC, stored data and follow the troubleshooting index
--
f\I II
1....... 1

'-, - -il
(page 4-13). ,. " II!!!!
To read the DTC with the Mil blinking, refer to the following procedure.
vvv 2 "'11..E

(5" / \ )
I

4-11
PGM-FI SYSTEM
Reading DTC with the MIL
Start the engine and lei it idle. Read Ihe MIL blinking thai is indicated as Ihe , - - - - - -- - - - - - - - - -- - --,
currenl DIG and refer to the troubleshooting index (page 4-13).
When retrieving the stored DI C, refer to the following procedure.
Remove Ihe OLe from Ihe dummy connector (page 4-11).
Short the OLe [11 terminals using the special tool.
TOOL
[2] SCS service connector 070PZ-ZY30100

Connection : Brown/red - Green

Tum the ignition switch ON and engine stop switch ·0·, read , note the MIL
blinks and refer to the troubleshooting index (page 4-13).
NOTE :
• If the PCMfECM has any DTC in its memory. the MIL will start blinking.

ERASING DTC
Connect the HDS Pocket Tester to the OLC (page 4-11).
Erase the OTC with the HOS while the engine is stopped .
To erase the DTC without HDS, use the fOllowing procedure.
How to erase the OTC without HOS
1. Remove the OLC from the dummy connector (page 4-11 ).
11] 12]
2. Short the OLC [1J terminals using the special tool.
TOOL:
(2] SCS service connector 070PZ-ZY30100

Connection : Brown/red - Green

3. Tum Ihe ignition switch ON and engine stop switch ·0·,
4 . Remove Ihe special tool from the OLe.
5. The MIL will light for approximately 5 seconds. While Ihe MIL lights,
short the OLe terminals again with Ihe special tool. The self-diagnostic
memory is erased if Ihe malfunction indicator goes off and starts
blinking .
NOTE:
The OLe must be shorted while the MIL lights. If not, the MIL will not start blinking.
• Note that the self-diagnostic memory cannot be erased if the ignition switch is turned OFF before the MIL starts blinking.

CIRCUIT INSPECTION
INSPECTION AT PCM/ECM CONNECTOR
Always clean around and keep any foreign material away from the PCMI
ECM connector before disconnecting it.
A faulty PGM-FI system is often related to poorly connected or corroded
{1]
connections. Check those connections before proceeding .
Do not pull the wire harness while disconnecting the PCM/ECM
connectors.
In lesting al PCMfECM connector (wire harness side) terminal, always
use the test probe. Insert the test probe into the connector terminal , then
attach the digital multimeter probe to the test probe.
TOOL:
[1] Test probe 07ZAJ·ROJA 110

4-12
 PGM-FI SYSTEM
PGM-FI DTC INDEX
orc
Refer
(MIL Function Failure Symptom/Fail-safe function
10
bUnks)
MAP sensor circuillow voltage (less than 0.19 V) Engine operates normally
1-1 (1) 4· 14
• MAP sensor or its circuit malfunction Fail-safe value: 29 kPa
- + -'MAP sensor circuil high vollage (more than 3.9 V') ---t--:--~E~n~g;;;n~.~o~pe:::;;,"~,~.,;C:;;n~m;;;Cm'~II~y---t--
1-2 (1) • Loose or poor contact of the MAP sensor connector Fail-safe value: 29 kPa 4·15
• MAP sensor or its circuit malfunction --I-
--1h E"'C"r;csensor circuit low voltage (less than 007 V)'- - - - - - : -H=ard to start='t~'''-Iow=---­
• ECT sensor or its circuit malfunction temperature
7-1 (7) 4-16
Fall-safe value: 78 .6°Cl173.5"F
' ' ' '_ _ __ : -COOling fan~tu~m~s~o~n;;;-_ _ _

C t . ECT sensor circuit high voltage (more than 4.93 V)

• loose or poor contact of the ECT sensor connector
ECT sensor or its circuit malfunction
Hard to start at a low
temperature
Fail-safe value: 78.6"C/173.5·F
Cooling fan turns on
TP sensor circuit low voltage (less than 0.22 V) - - - - - - : -:Poor engin~.~,~cc~.~'~.~""U~o~n---
4-17

8-1 (8) • loose or poor contact of the TP sensor connector Fail-safe value: D· 4-18
o TP sensor or its circuit malfunction ESP does not work
TP sensor circuit high voltage (more than 4.93 V) Poor engine:e,~cce=~t.~"~t~k>=n-:---""'-
8-2 (8) • TP sensor or its circuit malfunction Fail-safe value: 0" 4-19

9-1 (9)
ESPdoesnotwo~~~ITn"I,-____-+I~~~
tAT sensor circuit low voltage (less than 0 07 V)
• tAT sensor or its circuit malfunction
r------ - -+-'IAT sensor circuit high vottage (more t'~h~ a ~n'4',9V3~V')~ ~
9-2 (9) • loose or poor contact of the tAT sensor connector
• IAT sensor or its circuit rnatfuncllOn
4-22 I I
-----+-'V7<S~sensor no signal ----- - -t-- Engine operates normally
11-1 (1 1) • Loose or poor contact of the rear VS sensor connector ESP does not work 23· 14
_ __ _ _, ,0;; Rear VS sensor or its circuit matfun"c~tI~o~ +
n _ __ __
Fuet Injector circuit malfUnction Engine does not start
12-1 (12) • loose or poor contact of the fuel injector connector Fuel Injector, fuel pump and 4-23
_ _ _ __, "o'Fuet Injector or its circuit malfunction _ _ ______--, ignition shut down
IACV circuit malfunction Engine stans, hard 10 start, rough
29- 1 (29) • loose or poor contact of the IACV connector idling 4-24
~_ _ , "o IACV or its circuit matfunction
33-2 ( ) PCMfECM EEPROM malfunction Engine operates normally 4-25
Gear position switch malfunction Engine does not start
• Loose or poor contact of the gear position switch ESP does not work
41-1 (41) 23-22
connector Gear position indicator blinks "-"
• Gear position switch or its circuit malfuncli,~o~n",m",_t--:--" ___+-_ _ __
----+'B"a~'nk angle sensor circuit low voltage (tess than 0.31 V) Engine operates normally
54-1 (54 ) • Bank angle sensor or its cirCUit malfunction Bank angle sensor slops the 4-26
control
Bank angle sensor circuit high vollage (more than 4.53 V) Engine operates normally
loose or poor contact of the bank angle sensor Bank angle sensor slops the
54-2 (54) 4·27
connector control
_ _ __ _ _ ---'-...:Bank angle sensor or its arcuil malfunction

4-13
PGM·FI SYSTEM
DTC TROUBLESHOOTING
OTe 1·1 (MAP SENSOR LOW
VOLTAGE)
1. MAP Sensor Syst em Inspection
Turn the ignition switch ON and engine stop switch
"0 ",
Check the MAP sensor with the HDS pocket tester.
Is about 0 V indicated?
YES - GO TO STEP 2.
NO - Intermittent failure.
2. MAP Sens or Input Voltage Inspection
Turn the ignition switch OFF.
Disconnect the sensor unlt SP (Black) connector [1). Brown/White Green/red
Turn the ignition switch ON and engine stop switch
1
n
·0 ".
Measure the voltage between the wire harness side
sensor unit 5P (Black) connector terminals. , 17
Connection: Brown/white (+) - Green/red H
-----L l l .
Is the voltage with'n 4.75 - 5.25 V?
YES - GO TO STEP 4 111
NO - GO TO STEP 3.

3. MAP Sensor Input line Open Circuit Inspection

Tum the ignition switch OFF.
Disconnect the PCMlECM 33P (Gray) connector 11\.
I [1\(
Check for continuity between the wire harness side (21
sensor unit 5P (Black) connector (2] and PCMfECM
33P (Gray) connector terminals.
Connection: B3 - Brown/white r
-- J-----l----:
TOOL:
Test probe 07ZAJ· RDJA 110
Is there continuity?
YES - Replace the PCMfECM with a known good
one (page 4-34). and recheck. 93 Brownlwhlte
NO - Open circuit in the Brownlwhite wire.
4. MAP Sensor Output line Short Ci rcuit
Inspection
Tum the ignition switch OFF .
(11 Light green
Check for continuity between the wire harness side

~~/
sensor unit 5P (Black) connector [1jterminal and
ground.
Connection: light green - Ground
Is there continuity?
YES - Shon clrcuitln Light green wire.
NO - GO TO STEP 5.

4-14
 PGM-FI SYSTEM
S. MAP Sensor Inspection
Replace the sensor unit with a known good one
(page 4-30).
Erase the DTG (page 4-12).
Tum the ignition switch ON and engine stop switch
~O·.

Check the MAP sensor with the HOS pocket lesler.

Is OTC 1·1 indicated?
YES - Replace the PCMfECM with a known good
one (page 4-34), and recheck.
NO - Faulty original sensor Unit (MAP sensor).

DTC 1-2 (MAP SENSOR HIGH

VOLTAGE)
Before starting the inspection, check for loose or
poor contact on the sensor unit 5P (Black) connector
and PCM/ECM 33P connectors, and recheck the
OTe .
1. MAP Sensor System Inspection
Turn the ignition switch ON and engine stop switch
·0 ",
Check the MAP sensor with the HDS pocket tesler.
Is about 5 V indica ted?
YES - GO TO STEP 2.
NO Intermittent failure.
• Loose or poor contact of the sensor unit
SP (Black) connector.
2. MAP Sensor Inspection
Turn the ignition switch OFF.
Disconnect the sensor unit SP (Black) connector (1). Green/red Light green
Connect Ihe wire harness side sensor unit SP
(Black) connector terminals with a jumper wire [2].
Connection: Light green - Green/red

Turn the ignition switch ON and engine stop switch

"C)".
Check the MAP sensor with the HDS pocket tester.
Is about 0 V indicated?
YES - Faulty sensor unit (MAP sensor). 111
NO - GO TO STEP 3.
121
3. MAP Sensor Input Voltage Inspection
Turn the ignition switch OFF.
Remove the jumper wire. 8rownlwtlite Green/red
Tum the ignition switch ON and engine stop SWitch
-f)-.
Measure the voltage between the wire harness side
sensor unit SP (Black) connector (1) terminals.
Connection : Brownlwhite (+) - Green/red (-)

Is the voltage within 4.75 - 5.25 V?

YES - GO TO STEP 4 . 111
NO - Open circuit in Ihe Brown/white or Green/
red wire.

j
4·15
PGM·FI SYSTEM
4. MAP Sensor Output Line Open Circuit
Inspection
Tum the ignition switch OFF.
Disconnecllhe PCM/ECM 33P (Gray) connector [1].
.25
Check for con tinuity between the wire harness side
sensor unit 5P (Black) connector (2) and PCM/ ECM
33P (Gray) connector terminals.
Connection : B25 - Ught green

TOOL:
Test probe 07ZAJ·RDJA 110

Is th ere continuity?
YES - Replace the PCMfECM with a known good
one (page 4-34). and recheck. (1( (2(
NO - Open circuit in the Ught green wire.

DTC 7·1 (ECT SENSOR LOW

VOLTAGE)
1. EeT Sensor System Inspection
Tum the Ignition switch ON and engine stop switch
·0··
Check the Eer sensor with the HDS pocket tester.
Is about 0 V Indfcated?
YES - GO TO STEP 2.
NO - Intermittent fail ure.
2. Eel Sensor Inspection
Tum the ignition switch OFF .
Disconnect the ECT sensor 2P (Black) connector,
Tum the ignition switch ON and engine stop sWitch
·0·,
Check the ECT sensor with the HOS pocket tester.
Is about 0 V indicated?
YES - GO TO STEP 3.
NO - Faulty ECT sensor.
3. ECT Sensor Output Line Short Circuit Inspection
Tum the ignition switch OFF, , - -- -- - - - - - - - - - - - - ,
Disconnect the PCM/ECM 33P (Gray) connector. Blacklblue (1(
Check for continuity between the wire hamess side
ECT sensor 2P (Black) connector 11) terminal and
ground .
Connection: Black/blue - Ground
Is there continuity?
YES - Short circuit in the Black/blue wire.
NO - Replace the PCM/ECM with a known good
one (page 4·34), and recheck.

4-16
 PGM-FI SYSTEM
DTC 7-2 (ECT SENSOR HIGH
VOLTAGE)
Before starting the inspection, check for loose or
poor contact on the Eel sensor 2P (Black)
connector and PCMfECM 33P connectors, and
recheck the DTG .
1. EeT Sensor System Inspection
Turn the ignition switch ON and engine slop switch
·0·,
Check the Eel sensor with the HOS pocket lester.
Is about 5 V indicated?
YES - GO TO STEP 2.
NO Intermittent failure.
. loose or poor contact of the Eel
sensor 2P (Black) connector.
2. EeT Sensor Inspection
Turn the ignition switch OFF .
Disconnect Ihe EeT sensor 2P (Black) connector Blacklblue Green/red
11].
Connect the wire harness side Eel sensor 2P
(Black) connector terminals with a jumper wire [2) .
Connection : Black/blue - Green/red
Turn the ignition switch ON and engine slop switch
-0-.
Check the Eer sensor with the HDS pocket tester.
Is about 0 V indicated?
111
YES - Faulty ECT sensor.
NO - GO TO STEP 3, 121
3. ECT Sensor Line Open Circuit Ins pection
Tum the ignition switch OFF .
Remove the jumper wire. 121 111
Disconnect the PCM/ECM 33P (Gray) connector 11]. B2
Check for continuity between the wire harness side
ECT sensor 2P (Black) connector [2] and PCMiECM
33P (Gray) connector terminals.
Connection : B2 - Green/red
B27 - Black/blue

TOOL:
Test probe 07ZAJ-ROJA 110

Is there c ontinuity? B27

YES - Replace the PCMfECM with a known good Blacklblue Green/red
one (page 4-34), and recheck .
NO - ' Open circuit in the Greenlred wire.
• Open circuit in the Black/blue wire.

4·17
PGM-FI SYSTEM
OTe 8-1 (TP SENSOR LOW VOLTAGE)
Before starting the inspection, check for loose or
poor contact on the sensor unit 5P (Black) connector
and PCMfECM 33P connectors, and recheck the
DTC.
1. TP Sensor System Inspection
Tum the ignition switch ON and engine stop switch
"0",
Check the TP sensor with the HDS pocket lester
with the throttle fully closed.
Is about 0 V Indicated?
YES - GO TO STEP 3.
NO - GO TO STEP 2.
2. TP Sensor Inspection
Check that the TP sensor voltage increases
continuously when the throttle is moved to fully
dosed position to fully open position. using the data
list menu of the HDS pockellester.
Does the voltage Increase continuously?
YES - Intermittent failure.
• Loose or poor contact of the sensor unit
SP (Black) connector.
NO - Faulty sensor unit (TP sensor),
3. TP Sensor Input Voltage Inspection
Tum the ignition switch OFF.
Disconnect the sensor unit 5P (Black) connector [1J. Brownlwhite Green/ted
Tum the ignition switch ON and engine stop switch
"0".
Measure the voltage between the wire harness side
sensor unit 5P (Black) connector terminals.
Connection: Brown/white (+) - Greenfred (-)

/s the voltage within 4.75 - 5.25 V?

YES - GO TO STEP 5. [1)

NO - GO TO STEP 4 .

4. TP Sensor Input Line Open Circuit Inspection

Tum the ignition switch OFF.
Disconnect the PCM/ECM 33P (Gray) connector [1J.
Check for continuity between the wire harness side 111
sensor unit 5P (Black) connector [2] and PCMfECM 121
33P (Gray) connector terminals.
Connection: B3 - Brown/white

TOOL:
Test probe 07ZAJ·RDJA110
Is there continuity?
YES - Replace the PCMIECM with a known good .3 Brown/white
one (page 4·34), and recheck.
NO - Open circuit in the BrownlWhite wire.

4-18
 PGM·FI SYSTEM
5. TP Sensor Output Line Open Ci rcuit Inspection
Turn the ignition switch OFF.
Disconnect the PCM/ECM 33P (Gray) connector [1]. .,4
Check for con tinuity between the wire harness side
sensor unit 5P (Black) connector [2) and PCM/ECM
33P (Gray) connector terminals.
Connection: 814 - Blue/black

TOOL:
Test probe 07ZAJ·RDJA1 10

Is th ere continuity ?
YES - GO TO STEP 6 .
NO - Open circuit in the Blue/black wire.

6. TP Sensor Output Line Short Circuit Inspection

Check for continuity between the wire harness side , - -
sensor unit 5P (Black) connector [1} terminal and Blue/blacKI
ground.
Connection : Blue/black - Ground
Is there continuity?
YES - Short circuil in the Bluelblack wire.
NO - GO TO STEP 7.
(11

7. TP Sensor Inspection
Replace the sensor unit with a known good one
(page 4·30).
Erase the OTC (page 4.12).
Tum the ignition switch ON and engine stop switch
wOw.
Check the TP sensor with the HOS pocket tester.
Is OTC B·1 indicated?
YES - Replace the PCM/ECM with a known good
one (page 4·34), and recheck.
NO - Faulty original sensor unit (TP sensor).

DTC 8·2 (TP SENSOR HIGH VOLTAGE)

1. TP Sensor System Inspection
Tum the ignition switch ON and engine stop switch
·0· ,
Check the TP sensor with the HOS pocket tester
with Ihe Ihrottle fuUy closed.
Is about 5 V indicated?
YES - GO TO STEP 3.
NO - GO TO STEP 2.

4·19
PGM-FI SYSTEM
2. TP Sensor Inspection
Check thai the TP sensor voltage incre ases
continuously when the throWe is moved to fully
closed position to fully open position, using the data
list menu of the HOS pocket tester.
Does the voltage increase continuously?
YES - Intermittent fa ilure.
NO - Faulty sensor unit (TP sensor).
3. TP Sensor Resistance Ins pection at PCM/ECM
Connector
Turn the ignition switch OFF.
Disconnect the PCMlECM 33P (Gray) connector [1]. 111
Measure the resistance between the wire harness
side PCM/ECM 33P (Gray) connector terminals.
93 92
Connection : B2 - B3

TOOL :
Test probe 07ZAJ ·ROJA 110

Standard: 1.0 - 3.0 kO (20°C/68°F)

Is the resistance within 1.0 - 3.0 kQ (20°C/68°F)'J
YES - GO TO STEP 5.
NO - GO TO STEP 4.
4. TP Sensor Ground Line Open Circuit Inspection
Disconnect the sensor unit 5P (Black) connector [1].
Check for continuity between the wire harness side
111
sensor unit 5P (Black) connector 121 and PCMlECM
33P (Gray) connector 121lerminals. 121
Connection : B2 - Green/red

TOOL:
Test probe 07ZAJ· RDJA 110
Is there continuity?
YES - GO TO STEP 5.
NO - Open circuit in the Green/red wire.
92 Green/red

5. TP Sensor Input Voltage Inspection

Disconnect the sensor unit SP (Black) connector (1].
Turn the ignition switch ON and engine stop switch Brownlwhite Green/red
·0 · .
Measure the voltage between the wire harness side
sensor unit SP (Black) connector terminals.
Connection : Brown/white (+) - Green/red 1-)
Is the voltage within 4.75 - 5.25 V?
YES - Replace the PCMlECM wi th a known good 111
one (page 4-34), and recheck.
NO - Faulty sensor unit (TP sensor).

4·20
 PGM·FI SYSTEM
OTe 9·1 (IAT SENSOR LOW VOLTAGE)
1. tAT Sensor System Inspection
Turn the IQnilion switch ON and engine stop switch
· O~ .

Check the tAT sensor with the HOS pocket tes ter.
Is about 0 V indicated?
YES - GO TO STEP 2.
NO - Intermittent failure.
2. tAT Sensor Inspection
Tum the .gnilion switch OFF.
DIsconnect the tAT sensor 2P (Black) connector.
Turn the ignition switch ON and engine stop switch
W
Check the tAT sensor wIth the HOS pocket tester.
Is about 0 V indicated?
YES - GO TO STEP 4.
NO - GO TO STEP 3.
3. tAT Sensor Resistance Inspection at PCMIECM
Connector
Tum the ignition switch OFF.
Connect the tAT sensor 2P (Black) connector.
Disconneci lhe PCMlECM 33P (Gray) connector [ 1).
111 826 82 I
Measure the resistance between the wire harness
side PCMfECM 33P (Gray) connector terminals.
Connection : 82 - 826
=~
TOOL:
Test probe 07ZAJ ·RDJA 110

Standard: 2.2 - 2.7 kO (20°C/68°F)

Is the res istance within 2.2 - 2.7 kD (20°Cl68°F)?
YES - Replace the PCMlECM with a known good
one (page 4-34). and recheck.
I
L.- - - - -
NO _. Faulty IAT sensor.
4. tAT Sensor Output Line Short Circuit Inspection
Disconnect the IAT sensor 2P (Black) connector [ 1].
Check for con tinuity between the wire harness side Gray 111
IAT sensor 2P (Black) connector terminal and
ground
Connection: Gray - Ground
Is there continuity?
YES - Short circUit In the Gray wire
NO - Replace the PCMfECM with a known good
one (page 4·34). and recheck.
Q

4·21
PGM·FI SYSTEM
DTC 9·2 (IA T SENSOR HIGH
VOLTAGE)
Before starting the inspection. check for loose or
poor contact on the tAT sensor 2P (Black) connector
and PCMJECM 33P connectors, and recheck the
Ole.
1. tAT Sensor System Inspection
Turn the ignition switch ON and engine stop switch
·0·,
Check the tAT sensor with the HOS pocket te ster.
Is about 5 V Indicated?
YES - GO TO STEP 2.
NO Intermittent failure ,
• loose or poor contact of the tAT sensor
2P (Black) connector.
2. tAT Sensor Inspection
Tum the ignition switch OFF .
Disconnect the tAT sensor 2P (Black) connector [1]. Gray Greenfred
Connect the wire harness side tAT sensor 2P
(Black) connector terminals with a jumper wire [2].
Connection: Gray - Green/red
Tum the ignition switch ON and engine SlOP switch
·0 ·,
Check the tAT sensor with the HDS pocket tester.
Is about 0 V Indicated?
[11
YES - Faulty IAT sensor
NO - GO TO STEP 3.
121
3. IAT Sensor Open Circuit Inspection
Tum the ignition switch OFF.
Remove the jumper wire. 82
Disconnect the PCMlECM 33P (Gray) connector (1J. 826
Check for continuity between the wire harness side
IAT sensor 2P (Black) connector (2) and PCMfECM
33P (Gray) connector terminals.
Connection : 82 - Greenlred 121
826 - Gray

TOOL:
Test probe 07ZAJ·RDJA 110
Is there continuity? [11
YES - Replace the PCMfECM with a known good Gray Greenfred
one (page 4·34). and recheck.
NO Open circuit in the Green/red wire.
• Open circuit in the Gray wire.

4·22
 PGM-FI SYSTEM
DTC 12-1 (FUEL INJECTOR)
Before starting the inspection , check for loose or
poor contact on the fuel injector 2P (Gray ) connector
and PCMIECM 33P connectors, and recheck the
DIG.
1. Fuel Injector System Inspection
Erase the DIC (page 4-12).
Turn the ignition switch ON and engine stop switch
"0",
Check the fuel injector with the HDS pocket tester.
Is the Dre 12·1 indicated?
YES - GO TO STEP 2.
NO Intermittent failure.
• Loose or poor contact of the connected
fuel injector 2P (Gray) connector.
2. Fuel Injector Resistance Inspection
Turn the ignition switch OFF.
Disconnect the fuel injector 2P (Gray) connector. 111
Measure the resistance at the injector side
connector [1J terminals.
Standard : 11.6 - 12.4 a (20 · e /68· F)
Is the r esistance within 11.6 - 12.4 .n (20 °C/
6B G F)?
YES - GO TO STEP 3.
NO - Fau!ty fuel injector.

Q
3. Fuel Injector Input Voltage Inspection
Turn the ignition switch ON and engine stop swilch , - - -- -- - - - - - - - - - -- - ,
·0". [1) Black/red
Measure the voltage between the wire harness side
fuel injector 2P (Gray) connector [1] terminal and
ground .
Connection : Black/re d(+) - Ground (-)
Is there battery voltage?
YES - GO TO STEP 4.
NO - Open circuit in the Black/red wire.

4. Fuel Injector Signal line Open Circuit Inspection

Turn Ihe ignition switch OFF.
Disconnect Ihe PCM/ECM 33P (Gray) connector [1]. B33 Greenfblack
Check for continuity between the wire harness side
fuel injector 2P (Gray) connector (2) and PCM/ECM
33P (Gray) connector terminals .
/
Connection : 833 - Green/black
, =
TOOL:
Test probe 07ZAJ-ROJA 110
\1 ff
Is there continuity? I ~
YES
NO
- GO TO STEP 5.
- Open circuit in the Green/black wire.
It 121

4-23
PGM·FI SYSTEM
5. Fuel Injector Signal Line Short Circuit Inspection
Check for continuity between the wire harness side , - -- - - - - - - -- - - - - - --
fuel injector 2P (Gray) connector [1J terminal and Greenlblack 111
ground .
Connection: Green/black - Ground
Is there continuity?
YES - Short circuit in the Green/black wire.
NO - Replace the PCM/ECM with a known good
one (page 4-34), and recheck.

DTC 29·1 (IACV)

Before starting the inspection, check for loose or
poor contact on the IACV 4P (BlaCk) connector and
PCMIECM 33P connectors , and recheck the DIG.
1. Recheck DIG
Erase the DIG (page 4-12).
Start the engine and recheck the DIG with the HDS
pocket lester.
Is the Dre 29-1 indicated?
YES - GO TO STEP 2 .
NO Intermittent failure .
• Loose or poor contact of the IACV 4P
(Black) connector.
2. IACV Short Circuit Inspection
Turn Ihe ignition switch OFF.
Disconnect the IACV 4P (Black) connector [1].
Check for continuity between the wire harness side Yellow/blue Brown/yellow
IACV 4P (Black) connector terminals and ground.
Connection: Yellow - Ground Yellow Yellow/green
Yellow/blue - Ground
Brownfy ellow - Ground
Yellowfgreen - Ground
/5 there continuity?
YES - Short circuit in the Yellow or Yellow/ [11
green wire.
Short circuit in the Yellow/blue or
Brown/yellow wire .
NO - GO TO STEP 3.

4-24
 PGM-FI SYSTEM
3. IACV Circuit Continuity Inspection
Disconnect the PCM/ECM 33P (Gray) connector [1). '--------~Y~e~II-0w-l~b~,"-e-B=,-o-w-o~ly-e~1I0-w'
Check for continuity between the wire harness side [1J
IACV 4P (Black) connector [21 and PCMIECM 33P
(Gray) connector terminals. B19 Yellow Yellow!

~ti
q ~
Connection: 819 - Yellow B30
829 - Yellow/green gleeo

~
B30 - Yellow/blue
831 - Brown/yellow

TOOL : '+\,~-{
Q l-=-----'
Test probe 07ZAJ·RDJA110 ~:=_----l [2[
B31
'-----'\--=-{:Q) -- ---'
Are there continuities?
B29
YES - GO TO STEP 4.
NO Open circuil in the Yellow or Yellowl
green wire.
Open circuit in the Yellow/blue or
Brown/yellow wire.
4. IACV Resistance Inspection at PCM/ECM
Connector
Measure the resistance between the wire harness
side PCM/ECM 33P (Gray) connector [1]lerminals. [11
Connection: 819 - 829 B19 B29
B30 - 831

TOOL:
Test probe 07ZAJ·RDJA110

Standard : 100 -120 0 (25 G Cf7rF)

Is the res/stance within 100 - 120 {J (20GC/68 GF)?
YES - Replace the PCM/ECM with a known good B31 B30
one (page 4-34), and recheck.
NO - Faulty IACV.

OTe 33-2 (EEPROM)

1. Recheck orc
Erase the DTC (page 4-12).
Turn the ignition switch ON and engine stop switch
~OH.

Recheck the PCM/ECM EEPROM with the HDS

pocket tes ter.
Is the DTe 33-2 indicated?
YES - Replace the PCM/ECM with a known good
one (page 4-34), and recheck.
NO - Intermittent failure.

4-25
PGM·FI SYSTEM
DTG 54·1 (BANK ANGLE SENSOR
LOW VOLTAGE)
1. Rec heck OTe
Erase Ihe oTe (page 4-12).
Turn Ihe ignition switch ON and engine stop switch
"0",
Check the bank angle sensor with the HOS pocket
tester.
Is the DTe 54-1Ind/cated?
YES - GO TO STEP 2.
NO Intermittent failure.
• loose or poor contact of Ihe bank angle
sensor 3P (Black) connector.
2. Bank Angle Sensor Power Input Voltage
Inspection
Turn Ihe ignition switch OFF.
Disconnect the bank angle sensor 3P (Black) 111
connector [1].
Turn the ignition switch ON and engine stop switch 1
·0 ",
Measure the voltage between the wire harness side
bank angle sensor 3P (Black) connector terminals. Green/red Brownlwhite
Connection : Brownlwhite (+) - Green/red (-)
Is the voltage within 4. 75 - 5.25 V?
YES - GO TO STEP 4.
NO - GO TO STEP 3.

3. Bank Angle Sensor Input Voltage Une Short

Circuit Inspection
Turn the ignition switch OFF.
Disconnect the PCM/ECM 33P (Gray) and (Black) III
connectors.
Check for continuity between the wire harness side Brown/white
bank angle sensor 3P (Black) connector (1 1 terminal
and ground.
Connection : Brown/white - Ground

Is there continuity?
YES - Short circuit in the Brownlwhite wire.
NO - Replace the PCMlECM with a known good
one (page 4-34). and recheck.

4-26
 PGM·FI SYSTEM
4. Bank Angle Sensor Output Une Short Circuit
Inspection
Turn the ignition switch OFF .
Disconnect the PCMfECM 33P (Gray) connector. [1J
Check for continuity between the wire harness side
bank angle sensor 3P (Black) connector [1) terminal
and ground .
Connection : Black/green - Ground

Is there continuity'?
YES - Short circuit in the Black/green wire.
NO - GO TO STEP 5.
Black/green

5. Bank Angle Sensor Inspection

Replace the bank angle sensor with a known good
one (page 4-33).
Erase the DIG (page 4-12).
Connect the bank angle sensor 3P (Black )
connector.
Turn the ignition switch ON and engine slop switch
"0",
Check the bank angle sensor wit h the HOS pocket
tester.
Is Dre 54-1 indicated?
YES - Replace the PCMIECM with a known good
one (page 4-34 ), and recheck.
NO - Faulty original bank angle sensor.

DTC 54·2 (BANK ANGLE SENSOR

HIGH VOLTAGE)
Before starting the inspection , check for loose or
poor contact on the bank angle sensor 3P (Black)
connector and PCMIECM 33P connectors, and
recheck the oTC .
1. Recheck DTe
Erase the oTC (page 4-12).
Tum the ignition switch ON and engine stop switch
"0 ".
Check the bank angle sensor wi th the HDS pocket
tester.
Is the DTC 54·2 indicated?
YES - GO TO STEP 2.
NO Intermittent failure .
Loose or poor contact of the bank angle
sensor 3P (Black) connector.

4·27
PGM-FI SYSTEM
2. Bank Angle Sensor Power Input Voltage
Inspection
Turn the ignition switch OFF.
Disconnect the bank angle sensor 3P (Black) 111
connector [1 }.
Turn the ignition switch ON and engine stop switch
~O·.

Measure Ihe voltage between the wire harness side

bank angle sensor 3P (Black) connector terminals. Greenlred Brownlwhite
Connection: Brown/white (+) - Green/red (-)
Is there within 4.75 - 5.25 V?
YES - GO TO STEP 4.
NO - GO TO STEP 3.

3. Bank Angle Sensor Input Voltage line Open

Circuit Inspection
Tum the ignition switch OFF.
Disconnect Ihe PCMIECM 33P (Gray) connector [1].
Check for continuity between the wire harness side Brownfwhite
B3

aII
bank angle sensor 3P (Black) connector [2] and
PCM/ECM 33P (Gray) connector terminals. [2]
Connection : B2 - Green/red B
B3 - Brown/white
'
TOOL:
Test probe 07ZAJ·ROJA 110

Are there continuities? '-------{Q)---------'

YES - Replace Ihe PCM/ECM with a known good Green/red
one (page 4-34), and recheck. 111
NO _. Open circuit in the Green/red wire .
• Open circuit in the Brownlwhite wire.
4. Bank Angle Sensor Output line Open Circuit
Inspectton
Turn the ignition switch OFF.
Disconnect the PCM/ECM 33P (Gray) connector [1]. [2)
Black/green B22
Check for continuity between the wire harness side
bank angle sensor 3P (Black) connector [2] and
PCM/ECM 33P (Gray) connector terminals.
Connection: B22 - Blacklgreen

TOOL:
Test probe 07ZAJ-ROJA110

Is there continuity?
YES - Inspect the bank angle sensor (page 4-34).
NO - Open circuit in the Black/green wire. 111

4-28
 PGM-FI SYSTEM
MIL CIRCUIT INSPECTION
NOTE:
Under normal conditions, the MIL will stay on for a
few seconds , then goes off when the ignition switch
is turned on with the engine stop switch YI".
Check that the MIL (1] comes on when the ignition
switch is turned ON and engine slop switch "0". jl
If the MIL does not come on al all , inspect the

-,
combination meter (page 22-7).
PS; (X) (Jl (oj

-
I C~(N)
If the MIL comes on for few seconds, then goes off with
the gear position indicator continuously blinking "-",
check the serial communication line (page 22-7). --
1\1 rl
1...... 1

- Iil
If the MIL does not go off within a few seconds comes
on and it, check as foUows:
LI • (p , -
000 2 U I L!;
- ,
\0 I \
Turn the ignition switch OFF.
111 85
Disconnect the PCM/ECM 33P (Gray) connector {1].
Check for continuity between the wire harness side ,----A
PCM/ECM 33P (Gray) connector and ground.
Connection : 8 5 - Ground

TOOL:
Tes t probe 07ZAJ ·RDJA110
If there is continuity, check for short circuit in the
Q
Brown/red wire between the DlC and PCMIECM.
If there is no continuity, replace the PCM/ECM with
a known good one (page 4-34), and recheck.
-

FUEL PUMP RELAY

INSPECTION
Remove the rear fender cover (page 2-9). "'
C~a~
oa~d~a~l~ype=-~'h~o~w~o~.-------;;[2~1----'

Disconnect the fuel pump relay BP (Gray) connector (11.

Remove the fuel pump relay [21 from the rear fender.

4·29
PGM·FI SYSTEM
Connect an ohmmeter to the fuel pump relay side 8P
connector [1J terminals as shown .

Connection : A - B r-®-: B
A .j ,
11)

~~.~
Connect the 12 V battery [21 to the fuel pump relay side
8P connector terminals as shown .
Connection : E - F E.A
There should be continuity with the battery connected
and no continuity with the battery disconnected. F
<±> 8
Ii,)
If the test result is abnormal. replace the fuel pump
relay.

SENSOR UNIT (MAP/TP SENSOR)

REMOVAL/INSTALLATION
NOTE:
If the sensor unit has been removed , perform the TP
sensor reset procedure (page 4~3 1 ) .
Always clean around the throttle body before the
sensor unit removal to prevent dirt and debris from
entering the air passage.
Remove the following:
- throttle body cover (page 7-13)
- left side cover (page 2-4)
Disconnect the sensor unit SP (Black) connector [1].
Remove the three torx screws (T2S) {2] and the sensor
unit [3} from the throttle body.

Install a new O-ring [1] into the groove of the throttle

body.
Instalilhe sensor unit [2] to the throttle body by aligning
the slot with the throttle shaft end.
Install and tighten the torx screws (T2S) to the specified
torque.
TORQUE: 3.4 N·m (O.3 kgf·m , 2.5 IbHt)

Install the removed parts in the reverse order of

removal.
Perform the TP sensor reset procedure (page 4-31).

4·30
 PGM-FI SYSTEM
TP SENSOR RESET PROCEDURE
NOTE
Make sure that the DIG is nol stored in the PCMf
ECM memory. If the DIG is stored, the reset mode
will not start.
1. Remove the following:
111 121
- seal (page 2-4)
left fuel tank side cover (page 2-5)
2. Turn the ignition switch OFF .
3. Remove the Ole from the dummy connector
(page 4· 1 1).
4 . Short the DLe 11jlerminals using the Special tool.
Connection: Brown/red - Green

TOOL:
(2] SCS service connector 070PZ-ZY30100

5. Disconnect the EeT sensor 2P (Black) connector ~;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;::=------.:===~

11 I· Green/red
Short the wire harness side connector terminals with
a jumper wire [2].
Connection: Black/blue - Green /red
6. Turn the ignition switch ON and engine stop switch
·0·, then disconnect the jumper wire from the EeT
sensor 2P (Black) connector wi thin 10 seconds
while the MIL is blinking (reset receiving pattern).

121
7. When the reset procedure is complete. the MIL blinking changes from Reset Receiving Pattern to
Confirmation Pattern.
Turn the ignition switch OFF .
If more than 10 seconds elapse or the procedures are incorrect. the MIL stays on . Repeat the reset
procedures from the step 4.

tti
tp -,
- ----""""-'="----
Within 10 sec.
UI;
I "1.3sec' I

. sec.,~ 03 sec.

0:: ~ -_ -_ -_ -_-_ ~-- -- n n,-----,n

• 0.1 sec.'··'·
• , .' 03 , •.

MIL nJUl_
Reset Receiving Pattern Reset Confirmation Pattern

ON - - - - - - +-___________________ (Stay on: Reset procedure is not complete)

IGNITION
SWITCH
OFF _ _ _-'

8. Connect the ECl sensor 2P (Black) connector.

g. Disconnect the special toot from the OLC.
10.ln5tall the dummy connector to the OLC (page 4-11 ).
11.Check the engine idle speed (page 3-15).
12.ln51all the removed parts in the reverse order of removal.

4-31
PGM·FI SYSTEM
ECT SENSOR
REMOVAUINSTALLATION
Drain the coolant (page 8-6).
Remove the left fuel lank side cover (page 2-5),
Disconnect Ihe spark plug cap [1] and Eel sensor 2P
(Black) connector [21.
Replace the ECT Remove Ihe EeT sensor [3J and O-ring 14].
sensor while the Install the a new O-ring onto Ihe Eel sensor.
&ngine is cok:J.
Install Ihe Eel sensor to the cylinder head and lighten
it to the specified torque.
TORQUE: 12 N'm (1.2 kg f-m, 9I bHt)
Connect the Eel sensor 2P (Black) connector and
spark plug cap.
Fill the cooling system with recommended coolant
(page 8-6).
Install the left fuel tank side cover (page 2-5).

INSPECTION
Remove the Eel sensor (I] (page 4-32).
121
Wear;nsulated Heat Ihe coolant (1:1 mixture) with an electric heating
gloves and element.
adequate eye Suspend the ECT sensor in heated coolant and check
protection. the continuity through the sensor as the coolant heats
Keep "ammable
up.
materials away from
me burner, NOTE :
Soak the ECT sensor in coolant up to its metal area •• HI
thoroughly with at least 40 mm (1.6 in) from the
bottom of the pan to the bottom of the sensor.
Slowly stir the coolant while heating and keep
temperature constant for 3 minutes before testing. A
sudden change of temperature will result in incorrect [1]
readings. Do not let the thermometer {2] or ECT L _ _ _ __ '-'-_ _ _ _ _ __ _ __ _.J
sensor touch the pan .
Measure the resistance between EeT sensor terminals.
Temperature 40 ± 5°C (104 ± 41 °F)
Resistance 0.86 1.55 kO
Replace the ECT sensor if it is out of specifications .
Install the ECT sensor (page 4·32).

4·32
 PGM·FI SYSTEM
BANK ANGLE SENSOR
REMOVAL/INSTALLA n ON
Remove the front fender/carrier (page 2·6).
Disconnect the bank angle sensor 3P (Black) connector
[11·
Remove the two mounting bolts [2] and bank angle
sensor [3J from the frame.

Inslalilhe bank angle sensor [1] with its MUpM mark [2]
facing up. It I
Install the removed parts in the reverse order of
removal.
TORQUE:
Bank angle sensor mounting bolt:
10 N·m (1.0 kgf·m , 7lbHt)

[21

OPERAT[ON INSPECTION
NOTE
• Before you perform this inspectJon. check that the
engine idle speed is normal (page 3·15).
Remove the bank angle sensor [1) with the bank angle , - -
60· ± 5° BANK ANGLE POSITION
sensor 3P (Black) connector is connected (page 4-33).
[lJ
• Do not disconnect the bank angle sensor 3P (Black)
connector during inspection.
Befora you perform Place the bank angle sensor is horizontal (normal

''
this test. first tum position) as shown, and turn the ignition SWitch ON and
the Ignition switch engine stop switch orr.

l
OFF, then tum Ihe
Ignition switch ON
Start the engine.

9/!
and engine stop Incline the bank angle sensor 60- ± 5- to the left or right
swirch ·0 · with keeping with the engine running. HORIZONTAL ."Ii
The bank angle sensor is normal if the engine stops
,
after a few seconds when the bank angle sensor
Inclined . '\ 60· ± 5·
If you repeat this test, first turn the ignition switch
OFF, then turn the ignition switch ON and engine
stop SWitch RO".

4·33
PGM-FI SYSTEM
INSPECTION WITH HOS POCKET
TESTER
Connect the HOS pocket tester (page 4.11).
60· ± S· BANK ANGLE POSITION
Remove the bank angle sensor [1) with the bank angle

~
',.
[11
sensor 3P (Black) connector is connected (page 4-33).
Place the bank angle sensor horizontal as shown . 'ii',.
Turn the ignition switch ON and engine stop switch ·0·,
Read the vollage with the HOS pocket tester. 60· ± 5° f'
Standard : 3.6 - 4.4 V

~
~ J
Incline the bank angle sensor 60· ± 5° to the left or right
with keeping the ignilion switch ON and engine slop HORIZONTAL
switch -0 · ,
Read the voltage with HOS pocket lester.
"\ I 60. ± 50
Standard : 0.7 - 1.3 V
If you repeat this test, first turn the ignition switch
OFF, then tum the ignition switch ON and engine
stop switch ·0·.

PCM/ECM
REMOVALIINSTALLATION
Remove the rear fender cover (page 2-9),
Release the following :
- fuse box (I]
- brake/taillight wire [2) from the wire guides (3]
Release the tabs (4J of the connector holder plate [SJ
from the rear fender, then remove the connector holder
plate.

Turn the ignition switch OFF.

Remove the PCM/ECM [11 from the rear fender,
Disconnect the 33P (Gray) connector [2J, 33P (Black)
connector (3J and SP (Black) connector (4] from the
PCM/ECM.
Installation is in the reverse order of removal.

4-34
 PGM·FI SYSTEM
POWERIGROUND LINE INSPECTION
Before starting the inspection, check for loose or
poor contact on the PCMfECM 33P (Gray)
connector.
1. PCM/ECM Power Line Inspection
Turn the ignition switch OFF.
Disconnect the PCM/ECM 33P (Gray) connector (1).
Turn the ignition switch ON and engine stop switch 81
"0 ".
Measure the voltage between the wire harness side
PCM/ECM 33P (Gray ) connector terminal and
ground .
Connection: 81 (+) - Ground H

TOOL:
Test probe 07ZAJ·RDJA 110
Does the battery voltage exis t?
YES - GO TO STEP 2.
NO Open circuit In the Black/red wire ' - - - _ _ _ _ __ _ _ _ _ _ _ _ _ _.1
between the fuse box and PCM/ECM .
Open circuil in the Black wire between
the ignition switch and fuse box .
Blown IGN fuse (10A)
Inspecllhe ignition switch (page 22-11 ).
2. PCMIECM Ground Line Inspection
Turn the ignition switch OFF.
Check for continuity between the wire harness side 810 821 813
PCM/ECM 33P (Gray) connector [1J terminal and

~~~~~
ground .
Connection: 810 - Ground
B13 - Ground
821 - Ground

TOOL :
Test probe 07ZAJ·ROJA 110
Is there continuity? Q Q
YES - Replace the PCM/ECM with a known good
one (page 4·34), and recheck.
NO - Open circuil in the Green wire.

4-35
PGM·FI SYSTEM
ENGINE STOP SWITCH LINE
INSPECTION
Before starting the inspection, check for loose or
poor contact on the PCM/ECM 33P (Black) and
(Gray) connectors.
ENGINE DOES NOT START (NO FUEL PUMP
OPERATION SOUND)
1. Fuse Inspection
Check the IGN fuse (10 A) for blown.
Is the fuse blown ?
YES - Replace the fuse.
NO - GO TO STEP 2.
2. Engine Stop Switch Line Inspection
Turn the ignition switch OFF .
Disconnect the PCMfECM 33P (Black) connector [1 [
[1 J. A4
Tum the ignition switch ON and engine Slop switch
·0·,
Measure the voltage between the wire hamess side
PCM/ECM 33P (Black) connector terminal and
ground.
Connection : A4 (+) - Ground H
TOOL:
Test probe 07ZAJ·RDJA 110

Does the battery voltage exist?

YES Inspect the fuel supply system
(page 7-13).
NO - ' Open circuit in the Black/while wire
between the engine stop switch and
PCM/ECM.
Open circuit In the Black/red wire
between the fuse box and engine stop
switch.
Inspect the engine stop switch
(page 22-11).
Open circuit in the Black wire between
the ignition switch and fuse box.
Inspect the ignition switch (page 22-11).

4·36
 5. IGNITION SYSTEM

COMPONENT LOCATION ····················· .... ··· 5-2 IGNITION COIL ............................................. 5-7

SYSTEM DIAGRAM ··········· ·········· ················· 5-2 IGNITION TIMING ......................................... 5-8

SERVICE INFORMATION ····························· 5-3 CONDENSER (Canada Iype) ....................... 5-8

TROUBLESHOOTING ··································· 5-4 RECTIFIER (Canada type) ......................... 5-10

IGNITION SYSTEM INSPECTION ················ 5-5

5·1
IGNITION SYSTEM
COMPONENT LOCATION
ENGINE STOP SWITCH
FUSE BOX: IGNITION SWITCH
- FMfFPM: MAINFUSE (30 A)
- FElFPE: MAIN FUSE 1 (30 A )
- IGN FUSE (to A)
CONDENSER
(Canada type)

PCMJECM
SPARK PLUG

RECTIFIER
(C anada type)

SYSTEM DIAGRAM
r--------,
"""",eM • CONDENSER '

~
BI Black
BuBtue
G Green
R Red
G R W While
y Yellow
I, I-- --._._._.
BuIY OfW G G!Y BUR 81M'
I Canada type

I, ~R <l From reguIator/rectJfoer I

,------------ ------,
! i, BIIW ~'"'--0--
! 1
ENGINE STOP
SWITCH
,- - - - - --------- ______ 1
I- ----- - ._._ .........., I,
1-------1 I,
I ' ,
I I I I
i
LR_~ R.i
BWY G G
~~R RIB> I R R~o--BI

d l~~~noN [ u IGNlTION
SWITCH
IGN FUSE (lOA)

o
CKPSENSOR
~ L
seAR ,--'-------'

PLUG t
RIBl ~ RIBl -
FMlFPM MAIN FUSE (3OA)
FEJFPEc MAIN FUSE 1 (3OA.)
---<0>--

BATIERY

5-2
 IGNITION SYSTEM
SERVICE INFORMATION
GENERAL

NOTICE
The PCMIECM may be damaged if dropped. Also, if the connector is disconnected when current is "owing, the excessive
voltage may damage the PCMIECM. Always tum the ignition switch OFF before servicing.
Use spark plugs with the correct heat range. Using spark plugs with an incorrect heat range can damage the engine.
Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch
is ON and current is present
When servicing the ignition system, always follow the checks described in the troubleshooting chart (page 5-4).
This ignition system is controlled by PCM/ECM .
The transistorized ignition system uses an electrically controlled ignition timing system. No adjustments can be made to the
ignition timing.
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.
The engine stop switch line is connected to the PCM/ECM on this vehicle . Its signal permits the PCM/ECM to conlrollhe fuel
pump, injector and ignition coil.
Refor to each section for the following components information.
- CKP sensor (page 13·6).
- Ignition switch (page 22-11).
- Engine stop switch (page 22-11).

SPECIFICATION

Spark plug
ITEM
T SPECIFICATIONS
BKR5E-11 (NGK), K16PR-U11 (DENSO) l,
Spark plug gap
Ignition coil primary peak voltage +
1.0 1.1 mm (0.039 0.043 in)
100 V minimum
,
Ignition pulse generator peak voltage + 0.7 V minimum
1
Ignition timing CF" mark) 10' BTDC at idle 1
~

TORQUE VALUES

; Timi"9 hole cap

ITEM Q' TV

1
THREAD
DIA. (mm)
TORQUE
N·m (kgf-m , IbUt)
14 _ - 1 _ - - ,1 0 (~ 7)
:h REMARKS

TOOLS
IgnitionMate peak voltage tester Peak voltage adaptor Test probe
MTP07-0286 (U.S.A. on ly) 07HGJ-0020100 07ZAJ-RDJA110

(not available in U.S.A .) with

commercially available digital
multimeter (impedance 10 MOIOCV
minimum)

5·3
IGNITION SYSTEM
TROUBLESHOOTING
Inspect the following before diagnosing Ihe system:
- Faulty spark plug
- Loose spark plug cap or spark plug wire connection
- Water got into the spark plug cap (leaking the ignition coil secondary voltage)
"Initial voltage" of the ignition primary coil is Ihe battery voltage with the ignition switch turned ON. (The engine is not cranked by
Ihe starter motor)
No spark at spark pl ug

iI ;
ignition switch ON. 2. An open circuit in the Black/red wire between the ignition coil and
voltage (Other electrical componen ts ignition switch.
are normal.) 3. l oose or poor connection of the primary terminal, or an open circuil in
the primary coil.

~~~;~~~~;~:~.::,:~;;-t_4~.~~~P~C~M~'~E~C~M~(;~n~c~ase when the initial voltage is njormal with the

I drops by 2 - 4 V while cranking voltage is over specifications reverse connections)
the engine. 2. Battery is undercharged. (Voltage drops largely when the engine is
started)
3. No voltage at the Black/red wire of the PCM/ECM (Gray) connector,
or loose or poorly connected PCM/ECM (Gray) connector
4. Loose or poor connection, or an open circuit in the Green (ground)
wire of the PCM/ECM .
5. Loose or poor connection, or an open circuit in the Green/yellow wire
between the ignition coil and PCM/ECM.
6. A short circuit in the ignition primary coil.
7. Faulty engine stop switch.
8. No voltage at the Blacklwhite wire of the PCM/ECM (Black)
connector, or loose or poorly connected PCM/ECM (Black) connector.
9. Faulty CKP sensor. (Measure the peak voltage)
10.Faulty PCMfECM (in case when above No. 1 through 9 are normal).
Initial voltage is normal but 1. Incorrect peak voltage adaptor connections. (System is normal if
there is no peak voltage while measured voltage is over the specifications with reverse connections)
cranking the engine. 2. Faulty peak voltage adaptor.
3. Faulty engine stop switch .
4. Faulty CKP sensor. (Measure the peak voltage)
5. Faulty PCM/ECM (in case when above No. 1 and 4 are normal).
Initial voltage is normal but 1. The mullimeter impedance is too low; below 10 MOIOCV.
peak voltage is lower than the 2. Cranking speed is too slow. (Battery is undercharged)
standard value. 3 . The sampling timing of the tester and measured pulse were not
synchronized . (System is normal if measured voltage is over the
standard voltage at least once)
4. Faulty PCM/ECM (in case when above No.1 through 3 are normal).
r---rnilial and peak voltages are 1. Faulty spark plug or leaking ignition coil secondary current.
normal but no spark jumps. 2. Faulty ignition coil.
CKP sensor Low peak voltage. 1. The multimeter impedance is too low; below 10 MO/OCV.
2. Cranking speed is too slow. (Battery is undercharged)
3. The sampling timing of the tester and measured pulse were not
synchronized. (System is normal if measured voltage is over the
standard voltage at least once)
4. Faulty CKP sensor (in case when above No. 1 through 3 are normal) .
t--No peak voltage. 1. Faulty peak voltage adaptor.
2. Faulty CKP sensor.

5-4
 IGNITION SYSTEM
IGNITION SYSTEM INSPECTION
NOTE:
If there is no spark at Ihe plug, check aU connections
for loose or poor contact before measuring the peak
voltage.
Use a commercially available digital mullimeler with
an impedance of 10 MO/DCV minimum.
The display value differs depending upon the
internal impedance of the multimeter.
Use the peak voltage tester or connect the peak voltage , - - - - -
adaptor [1] to the digital multimeter [2]. 121
TOOL:
Ig nition Mate peak voltage tester MTP07-0286
(U .S.A. only) or
Peak voltage adaptor 07HGJ-0020100
(not available in
U.S.A.)
with commercially available digital multimeter
(impedance 10 MO/DeV minimum)

111
IGNITION COIL PRIMARY PEAK
VOLTAGE
NOTE :
Check all system connections before this inspection.
Poor connected connectors can cause incorrect
readings.
Check thai the cylinder compression is normal and
the spark plug is installed correclly in the cylinder
head.
Remove the left fuel tank side cover (page 2- 5).
Disoonnectthe spark plug cap [1) from the spark plug .
Connect a known good spark plug [2) to the spark plug
cap and ground the spark plug to the cylinder head as
done in a spark test.

5·5
IGNITION SYSTEM
With the connector connected, connect the peak
voltage tester or adaptor probes to the ignition coil
primary terminals.

Connection: Green/yellow (+) - Black/red H

Turn the ignition switch ON and engine stop switch -ct.
Check the initial voltage al this time.
The battery voltage should be measured.
If the initial voltage cannot be measured, follow the
checks in the troubleshooting chart (page 5-4).
Shift the transmission into neutral.
Crank the engine with the starter motor and read the
ignition coil primary peak voltage.
PEAK VOLTAGE: 100 V minimum

If the peak voltage is lower than the standard value,

follow the checks described in the troubleshooting chart
(page 5-4).

CKP SENSOR PEAK VOLTAGE

NOTE:
Check that the cylinder compression is normal and
the spark plug is installed correctly in the cylinder
head.
Remove the rear fender cover (page 2-9). Canada type shown"
Seal the PCMlECM Turn the ignition switch OFF and disconnect the PCM!
connecfor with tape ECM 33P (Gray) connector [1].
/0 prevent dirt and
NOTE:
oil from en/enng Ihe
ronneclor after When reconnecting the PCM!ECM connector, check
disconnecting il. that there is no dirt and oil in the connector.

Connect the peak voltage tester or adaptor [1] probes to

the wire harness side PCM/ECM 33P (Gray) connector 121 912{-)

~~
[2J terminals
Connection:
B23 (Blue/yellow) (+) - B12 (Green /white) (-)

TOOL:
Test probe 07ZAJ-RDJA110
823 (+)
Shift the transmission into neutral.
Tum the ignition switch ON.
Crank the engine with the starter motor and measure
the CKP sensor peak voltage. [1)
PEAK VOLTAGE: 0.7 V minimum

If the voltage measured at the PCM/ECM connector is

abnormal, measure the peak vo!tage at the a!ternator
connector.

5-6
 IGNITION SYSTEM
Remove the right side cover (page 2-4).
Turn the ignition switch OFF and disconnect the
alternator 5P (Natural) connector (1).
Connect the peak voltage tester or adaptor [2J probes to
the alternator side connector terminals.
Connection : BluefyeUow (+) - Green (-)
In the same manner as at the PCMfECM connector,
measure the peak voltage and compare it to the voltage
measured at the PCMfECM connector.
If the peak voltage measured at the PCM/ECM
connector is abnormal and the one measured at the
alternator connector is normal, the Blue/yellow or
Greenlwhile wire has an open or short circuit, or
loose connection. Blue/yellow (+)
If both peak voltages are abnormal. follow the
checks described in the troubleshooting chart (page Green (-)
5-4).
If the CKP sensor is faulty, replace the alternator stator/
CKP sensor assembly (page 13-6). [2)

[1)

IGNITION COIL
REMOVALIINSTALLATION
Remove the left fuel tank side cover (page 2-5).
Disconnect the spark plug cap [1] from the spark plug.
Disconnect the ignition coil primary wire connectors {2J.
Remove the bolls [3] , spacers {4J and ignition coil (5].
Installation is in the reverse order of removal.

5-7
IGNITION SYSTEM
IGNITION TIMING
NOTE:
• Before you performing this inspection, check Ihe
engine idle speed (page 3-15).
Remove the fonowing:
- right mudguard (page 2-6)
- left fuel tank side cover (page 2-5)
Start Ihe engine and warm it up to operating
temperature.
SlOp the engine and remove the timing hole cap from
the rear crankcase cover.
Connect the timing light (1) and tachometer.
Start the engine, let it idle and check Ihe ignilion timing.
The ignition liming is correct if the ~F" mark (2] on the
flywheel aligns with Ihe index nolch [3] on the rear
crankcase cover at idle.
Coat a new O-ring [1 J with engine oil and install it onto
the liming hole cap [2).
Install and tighten Ihe timing hole cap to the specified
torque.
TORQUE : 10 N-m (1 .0 kgf'm , 7lbHt)
Install the removed parts in the reverse order of
removal.

CONDENSER (Canada type)

REMOVAUINSTALLA nON
Remove the seat (page 2-4).
Disconnect the battery negative (-) cable (page 21-8).
Disconnect the condenser 2P (Natural) connector [1].

5·8
I
 IGNITION SYSTEM
Release the condenser wire [1] from the wire guide [2)
of the rear fender.
Remove the condenser [3].
Installation is in the reverse order of removal.

INSPECTION
NOTE:
• Perform this inspection using a fully charged battery.
Disconnect the condenser 2P (Natural) connector [lJ
(page 5-8)
Red Green
Connect the battery negative (-) cable (page 21-8).
[11
Measure the voltage between the wire harness side
condenser 2P (Natural) connector terminals.
Connection : Red (+) - Green (-)

Standard : Battery voltage at all time

If there is no voltage, check the following:
- FM/FPM : main fuse (30A), FE/FPE: main fuse 1
(30A ) andlor related circui ts
- open circuit in the Red or Green wires
- rectifier and/or related circuits (page 5-10)
If there is voltage, check the condenser as following:
1. Disconnect the battery negative (-) cable (page 21-8)
111
and connect the condenser 2P (Natural) connector
111.
2. Connect the battery negative (-) cable for a few
seconds and charge the condenser.
3. Disconnect the battery negative (-) cable and
discharge the condenser.

Q
4. Disconnect the condenser 2P (Natural) connector
and check the resistance between the condenser
side connector terminals.
Select the kD range The condenser is normal if the resistance comes
of the tester. near 00 once and eventually becomes <Xl. L _ _ __
If the resistance stays at 00 or does not change,
replace the condenser.
NOTE :
If the inspection is interrupted, connect the
condenser 2P (Natural) connector and restart the
procedure from the step 1.

5-9
IGNITION SYSTEM
RECTIFIER (Canada type)
REMOVAUINSTALLATION
Remove the seal (page 2-4).
[11
Disconnect the battery negative H cable (page 21-8).
Disconnect the rectifier 2P (Black) connector [1).

Release the rectifier wire (1) from the wire guide [2] of
the rear fender.
;:::===================
Remove the mounting bolt [3) and rectifier [4).
Install the rectifier by aligning its boss with the hole of
the frame.
Install the removed parts in the reverse order of
removal.

131 Align

INSPECTION
Remove the rectifier (1) (page 5-10).
Check for continuity between the rectifier side 2P
(Black) connector terminals. [11
When there is continuity, a small resistance value will
register. .n n n
If there is continuity in one direction, the rectifier is
normal. I~ O~I
Red Red/black

Red n
I... ~ Red/black

5·10
i
 6. ELECTRIC STARTER

COMPONENT LOCATION ························ .. ·· 6-2 STARTER MOTOR ··············· ························ 6-6

SYSTEM DIAGRAM ············· ·························6-2 STARTER RELAY SWITCH ···· ····· ················ 6-8

SERVICE INFORMATION ·····························6-3 OIOOE ..... ................................................. ··· 6-10

TROUBLESHOOTING ···································6-4

6-1
ELECTRIC STARTER
COMPONENT LOCATION
FUSE BOX: STARTER SWITCH FRONT BRAKE
- FMlFPM: MAINFUSE (30 A) INHIBITOR SWITCH
- FElFPE: MAIN FUSE 1 (30 A)
-DIODE
IGN!T!ON SWITCH

SYSTEM DIAGRAM
ofl n
® 8

L
R
I c-::::J
iC~",d;-;;p.i
YIR - BATTERY
-
, - LgiR
E!

RlBI~RlBI I ~
R~~
STARTER RELAY :
SWITCH
FM/FPM. MAIN FUSE (30A) j ! IGNITION
SWITCH
FElfPE MAIN FUSE 1 (30A) ~~EC~IFI~~
BI

~ LgIBI
~ VIR - t- VIR --0 ~
STARTER
BIIW --0"----0--
ENGINE STOP
BIIR ~ IGN FUSE
DIODE SWITCH SWITCH (WA)
0
0 2 0
1 3

~
GEAR
LgiBI LglBl LgIR 0 POSITION
N 4 SWITCH
I STARTER
\.M MOTOR BI: Black
DIODE OR ,R
G: Green
~ 1
1
Lg: Light green
R: Red ' - - LgiBI 0-- G
FRONT BRAKE
W: While
INHIBITOR SWITCH L
Y: Yellow

6·2
 ELECTRIC STARTER
SERVICE INFORMATION
GENERAL
NOTICE
If the current is kept flowing through the starler motor to tum it while the engine is not cranking over, the starter motor may be
damaged.
Always turn the ignition switch OFF before servicing the starter motor. The motor could suddenly start. causing serious injury.
The starter motor can be serviced with the engine in the frame.
When checking the starter system, always follow the steps in the troubleshooting (page 6-4),
A weak battery may be unable to tum Ihe starter molor quickly enough, or supply adequate ignition current.
Refor to each section for the foUowing components information.
- Starter clutch (page 13-11)
- Ignition switch (page 22- 11 )
- Engine SlOp switch and starter switch (page 22-11 )
- Front brake inhibitor switch (page 22-12)
- Gear position switch (page 22-14)

SPECIFICATIONS
"'; - - - - - - r.. Unit: mm (in)
ITEM STANDARD SERVICE LlMIT~
Starter motor brush length _=~====::-112 .0 (0.47 ) 6.5 (0.26) -----r

TORQUE VALUES

ITEM
- -- --+
Q'TY
-+
THREAD
DIA. ),
lm,"m"IL .f-'N
TORQUE
m (kgf'm , IbHt)
"',,;
1 REMA~
~ Starter motor case bolt 2
5 4,9 10 ,5",;c3,~61c--+-_
: Negative brush set screw 1 5 3.7 (0.4 , 2.7)

6-3
ELECTRIC STARTER
TROUBLESHOOTING
NOTE·
The starter motor can be operated when the transmission is in neutral or when the transmission is in gear
and the front brake lever is squeezed.
Make sure the engine stop switch is turned · 0· before starting the engine. The starter motor does not
operate with the engine stop switch turned .~ •.
Starter motor does not turn
1. Fuse Inspection
Check for blown FM/FPM: main fuse (30A). FElFPE : main fuse 1 (30A) or IGN fuse (10 A).
Is the fuse blown ?
YES - Replace the fuse.
NO - GO TO STEP 2.
2. Battery Inspection
Check that the battery is fully charged and in good condition.
Is the battery In good condition ?
YES - GO TO STEP 3.
NO - Charge or replace the battery (page 21-8).
3. Starter Relay Switch Operation Inspection
Check the operation of the starter relay switch (page 6-8).
Does the starter relay switch click?
YES - GO TO STEP 4.
NO - GO TO STEP 5.
4. Starter Motor Inspection
Turn the ignition switch OFF.
Apply battery voltage to the slarter motor directly. (Do not use a thin wire because a large amount of current
flows)
Does the starter motor turn ?
YES _. loose or poorly connected battery cable or starter motor cable .
• Faulty starler relay switch (page 6-9).
NO - Faulty starter motor (page 6-6).
5. Relay Coil Ground line Inspection
Turn the ignition switch OFF.
Check the ground line of the starter relay switch (page 6-9).
Is the ground line normal ?
YES - GO TO STEP 6.
NO Faulty gear position switch (page 22-14).
Faulty diode (page 6-10).
Faulty front brake inhibitor switch (page 22-12).
loose or poor contact of the related connector.
Open circuit in the wire harness.
6. Relay Coil Power Input line Inspection
Check the power input line of the staner relay switch (page 6-9).
Is th e power input line normal?
YES - GO TO STEP 7.
NO Faulty ignition switch (page 22-11).
Faulty engine stop switch (page 22-11).
Faulty starter switch (page 22·11).
Faulty rectifier (Canada type) (page 5-10).
loose or poor contact of the related connector.
Open circuil in the wire harness.

6-4
 ELECTRIC STARTER
7. Starter Relay Switch Inspection
Check the function of the starter relay switch (page 6-9).
Does the starter relay switch function properly?
NO - Faulty starter relay switch.
YES - Loose or poor contact of the starter relay switch connector.
Starter motor turns engine slowly
Low battery voltage
Poorly connected battery cables
Poorly connected starter molor cable
Poorly connected ground cable
Faulty starter motor
Starter motor turns, but engine does not turn
Starter motor is running backwards
- Case assembled improperly
- Terminals connected improperly
Faulty starter clutch
Damaged Of faulty starter reduction gear
Starter relay switch clicks, but engine does not turn over
• Crankshaft does not turn due to engine problems

6·5
ELECTRIC STARTER
STARTER MOTOR
REMOVAL/INSTALLATION
Remove the intake air duct (page 7-22). 14) 151
Disconnect the battery negative H cable (page 21-8).
Remove the following:
- terminal nut [1) (open the rubber cap [2))
- starter motor cable [3]
two mounting bolts [4] and ground cable [5)

(1) (2) {31

Remove the starter motor [1J from the rear crankcase ~;;::;==='iiiiiiiir:;:::;:~:=::::::iiii~iiiiiiiii
cover.
Remove the D-ring [2] from the starter motor.
Coat a new D-ring with engine oil and install it into the
starter motor groove.
Apply molybdenum oil solution to the starter motor shaft
splines [3].
Install the removed parts in the reverse order of
removal.

DISASSEMBLY/ASSEMBL Y

I NOTICE I
The armature coil may be damaged if the magnet in the
motor case pulls the armature against the case.

~ SEAL RING

f!I O-RING
5
MOTOR CASE

ARMATURE

SEAL RING e~
~
BRUSH
SPRINGS OIL SEAL

TERMINAL
STOPPER
~ ~KJ POSITIVE
BRUSH SET

REAR COVER ~ Allgo

BRUSH HOLDER TERMINAL BOLT

FRONT COVER
NEGATIVE BRUSH SET

3.7 N·m (0.4 kgf-m. 2.7 Ibf-ft) 4.9 N·m (0.5 kgf-m. 3.6IbHt)

6·6
 ELECTRIC STARTER
INSPECTION
Check the oil seal [1J and ball bearing [2] in the front r - - - - - -- - - - - - - - - - - - ,
cover for wear or damage.

[1[

Check the commutator bars [1) for damage or abnormal

wear.
Check Ihe commutator bars of Ihe armature [2) for
discoloration.
Clean any metal debris from between commutator bars.
NOTE :
• Do not use emery or sand paper on the commutator.

[1 J
Check for continuity between pairs of commutator bars
CONTINUITY:
[1[.
There should be continuity.

Check for continuity between each commutator bar [1] ~N=O=C=O=N=T=,N=U~,~T~Y~'===========~

and the armature shaft [2].
There should be no continuity.

6-7
ELECTRIC STARTER
Check for continuity between the starter molor cable
terminal [1J and positive brushes (21.
There should be continuity.

Check for continuity between the positive brushes [1] ;:======:;~==:""~=====~

and the rear cover (2).
There should be no continuity.
Check for continuity between the negative brushes [3]
and the rear cover.
There should be continuity.
Check for continuity between the positive and negative
brushes.
There should be no continuity.

Remove the brushes from the brush holder (page 6-6).

Measure the brush length.

SERVICE LIMIT : 6.5 mm (0.26 in)

H

STARTER RELAY SWITCH

OPERATION INSPECTION
Remove the rear fender cover (page 2-9).
Shift the transmission into neutral.
Tum the ignition switch ON and engine stop switch "0",
Push the starter switch.
The relay coil is normal if the starter relay switch [1J
clicks.
If you don't hear the switch "CLICK", inspect the relay
switch using the procedure below.

6-8
 ELECTRIC STARTER
CIRCUIT INSPECTION
Ground Line:
Disconnect the starter relay switch 2P (Green)
connector (page 6-9). 11)
Ligh t green/black
Check for continuity between the wire harness side
starter relay switch 2P (Green) connector [1]lerminal
and ground ,
Connection: Light green/black - Ground
There should be continuity when the transmission is in
neutral or when the transmission is in gear and the front
brake lever is squeezed.

Power Input Line:

Disconnect the starter relay switch 2P (Green) ~-----------------,
connector (page 6-9). {1)
Yellow/red
Turn the ignition switch ON and engine stop switch "0 ",
Measure the vo!tage between the wire harness side
starter relay switch 2P (Green) connector [1] terminal
and ground .
Connection : Yellow/red (+) - Ground (- ) (TJ
There should be battery voltage only when the starter
switch is pushed. V
8
CONTINUITY INSPECTION
Remove the starter relay switch [1) (page 6-9).
11{
Connect the fully charged 12 V (2) battery to the starter
relay switch 2P (Green) connector [3] terminals.
13{
Connection: Battery (+) terminal - Yellow/red
Battery (-) terminal - Light green/red
There should be continuity between the cable terminals Light green/red
while the battery is connected, and no continuity when
the battery is disconnected.
®

Yellowlred
{2}

REMOVALIINST ALLA TION

Disconnect the battery negative (- ) cable (page 21-8).
Disconnect the starter relay switch 2P (Green)
connector (1).
Remove the terminal nuts (2] , spring washers ]3],
battery positive (+) cable [4) and starter motor cable [5].
Remove the starter relay switch ]6] from the rear fender
with the shock rubber [7].
Remove the starter relay switch from the shock rubber.
Installation is in the reverse order of removal.

6-9
ELECTRIC STARTER
DIODE
REMOVAUINSTALLATION
Remove the rear fender cover (page 2-9).
Remove the diode [1 J from the wire harness.
Remove the fuse box cover and the diode [2] from the
fuse box.
Installation is In the reverse order of removal.

INSPECTION
Remove the diode [1] (page 6-10).
Check for continuity between the diode terminals.
When there is continuity, a small resistance value will
register.
If there is continuity in one direction , the diode is
normal.

c
J

6-10
 7. FUEL SYSTEM

SYSTEM COMPONENTS ···· .. · .. · .. · ...... · .. · .... · .. 7-2 FUEL TANK ................................................ 7-18

SERVICE INFORMATION ............................ ·7-3 AIR CLEANER HOUSING .......................... 7-19

FUEL LINE TROUBLESHOOTING .............. ·7-5 THROTTLE BODY ...................................... 7-20

FUEL LINE INSPECTION · .. · .......................... 7-6 IACV .. ·.... ··· .. ·.... ·· .. · .. · ........ · .. ·· ...... ...... · .. · .. · .. ·7-24

SUB-FUEL TANK/FUEL PUMP .................. 7-13 FUEL INJECTOR ........................................ 7-25

7-1
FUEL SYSTEM
SYSTEM COMPONENTS

3.4 N'm (0.3 kgf.m, 2.SlbHt)

34 N'm 2.SlbHt)

1.8 N'm (0.2 kgf.m. 1.3IbHt)

7-2
 FUEL SYSTEM
SERVICE INFORMATION
GENERAL
This section covers service of the mechanical system of the PGM-FI system and Ihe fuel supply system. For electrical system
service of the PGM-FI system, see PGM-FI System section (page 4-2).
Before disconnecting the fuel feed hose, relieve pressure from the system (page 7-6),
Bending or twisting the control cable will impa ir smooth operation and could cause the cable to slick or bend . resulting in loss of
vehicle control.
Work in a well ventilated area. Smoking or allowing flames or sparks in Ihe work area or where gasoline is stored can cause a
fire or explosion.
Do not snap the throttle valve from full open to full close after the throttle cable has been removed. It may cause incorrect idle
operation .
Seal the cylinder head intake port with tape or a dean cloth to keep dirt and debris from entering the intake port after the throttle
body has been removed.
Do not damage the throttle body. It may cause incorrect throttle valve operation .
Prevent dirt and debris from entering the throttle bore, IACV. sensor hole and fuel feed hose. Clean them using compressed air.
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 screws and nut of the throttle body. Loosening or lightening them can cause throttle
body malfunction .
Tighten the yellow painted screws of the throtlle body to the specified torque.
When disassembling the fuel system parts . note the location of the O-rings. Replace them with new ones upon reassembly.
When servicing the fuel feed hose , be careful not to bend or kink it.
The engine stop switch line is connected to the PCM/ECM on this vehicle. Its signal permits the PCM/ECM to control the fuel
pump, fuel injector and ignition coil.

SPECIFICATIONS
,
ITEM SPECIFICATIONS
Throttle body identification number GQ3RA
Idle speed , 1,400 ± 100 rpm
Throllie lever free play 3 -8 mm (0.1 0.3 in)
Fuel pressure at idle 316 - 387 kPa (3.2 - 3.9 kgffcm . 46 56 psi)
Fuel pump flow (at 12 V) I 125 cm (4.2 US OZ, 4.4 Imp oz) minimumJ10 seconds

TORQUE VALUES
THREAD TORQUE
ITEM
Sub-fuel tank/fuel pump assembly bolt
Q'TY

6
OIA. (mm)
6
N'm (kgf'm, IbHt)
8.B (0.9, 6 .5)
REMARKS
See page 7-20
j
Fuel joint mounting bolt 2 6 9 .0 (0.9, 6.6)
~
Wire harness clamp slay screw 1 5 3.4 (0.3 . 2.5)
~
Fuel feed hose clamp slay screw
Insulator band screw (Cylinder head side) -1-'1 5
5
3.4 (0 .3, 2.5)
See page 7-25
1
Insulator band screw (Throllie body side) 1 5 ~

See page 7-26

Throttle drum cover screw
IACV torx screw (T20) t-: 2
4
4
1.8 (0.2 . 1.3)
2.1 (0.2 . 1.5)
Fuel injector mounting bolt 2 5 5.1 (0.5. 3.8)

7-3
FUEL SYSTEM
TOOLS
Fuel connecto""'co,".mo=,".",- -- - - -'F"u.;;;'-Op"',."sc;su","'.-og"."ug;c. ----~oPressure gauge manifold
07QMF·HP50200 07406-0040004 07ZAJ-SSA0111

or 07406-0040006 (U .S.A. OnIY)' -_---1c,N"O""". ", ." B""

able in U.S.A.
Hose attachment, 9 mm/9 mm Hose attachment. 6 mm/9 mm Attachment joint, 6 '=m=m! = gCCm=mo-- ----<
07ZAJ-S5A0120 07ZAJ-S5A0130 07ZAJ-S5A0 150

Not available in U.S.A. Not available in U.S.A. Not available in U.S.A.

Pressure manifoM
'd"h"o"'S.;;-- - - - - + 'Adapter, male - - - t -Adap ter, fem".:;;'.:------~
07AMJ-HW3A100 (U .S.A. only) 07AAJ-SSMA200 (U.S.A. only) 07AAJ-SSMA400 (U .S.A. only)

'-'

Hose clip
07614-0050101

or equivalent commercially available in

U.S.A.

7-4
 FUEL SYSTEM
FUEL LINE TROUBLESHOOTING
For the following symptoms, always follow the steps in the troubleshooting flow chart.
- engine slall after warm up the engine
- rough idling after warm up the engine
- engine lacks power after warm up the engine
Before starting the inspection, check for pinched or clogged fuel tank breather hose, fuel hose and fuel feed
hose .
1. Fuel pump operation inspection
Tum the ignition switch ON and engine stop switch -OM.
You should hear the fuel pump operation sound for a few seconds.
Is there fuel pump operation sound?
YES - GO TO STEP 3.
NO - GO TO STEP 2.
2. Fuel pump Input Voltage inspection
Inspect the fu el pump input voltage (page 7-13).
Is there battery voltage ?
YES - Faulty fuel pump.
NO open circuit in the Brown wire andlor Green wire.
blown IGN fuse (lOA).
faulty fuel pump relay (page 4-29) and its circuits.
open circuit in the engine stop switch line of the PCM/ECM (page 4-36).
open circuit in the power/ground lines of Ihe PCM/ECM (page 4-35).
3. Fuel flow inspection
Inspect the fuel flow (page 7-12).
Is the fuel flow as speciffed?
YES - GO TO STEP 5.
NO - GO TO STEP 4.
4. Fuel tank strainer screen i nspection
Inspect the fuel tank strainer screen for clogged (page 7-21).
Is the fuel tank strainer screen normal?
YES _ . Replace the fuel pump filter with a new one (page 7-14), and recheck the fuel flow (page 7-12).
If the fuel flow is less than specified, replace the fuel pump (page 7-14).
NO - Clean the strainer screen (page 7-21), and recheck the fuel flow (page 7-12).
5. Fuel pressure inspection
Inspect the fuel pressure (page 7- 11 ).
Is th e fuel pressure as specmed ?
YES _. Inspect the ignition system (page 5-5).
• Inspect the cylinder compression (page 10-7).
NO - Replace the fuel pump with a new one (page 7-14), and recheck.

7·5
FUEL SYSTEM
FUEL LINE INSPECTION
FUEL PRESSURE RELIEVING
NOTE:
Before disconnecting fuel feed hose, relieve
pressure from Ihe system as following procedures.
Do not bend or twist the fuel feed hose.
1. Remove the side cover (page 2-4),
2 . Turn Ihe ignition switch OFF.
3. Pull the rubber boot 11] off the sub-fuel lank/fuel
pump assembly and disconnect the fuel pump 2P
(Black) connector (2].
4. Start the engine, and let it idle until the it stalls.
5. Turn Ihe ignition switch OFF.
6 . Disconnect the battery negative (-) cable
(page 21-8).

QUICK CONNECT FITTING REMOVAL

NOTE:
• Do not bend or twist the fuel feed hose.
FUEL PUMP SID E
1. Relive the fuel pressure (page 7-6).
111
2. Check the fuel quick connect fitting [1] for dirt, and
clean if necessary.
Place a shop towel (21 over the quick connect fitting .

7-6
 FUEL SYSTEM
3. Pull and release the connector damper [1] from the I
retainer.
4. Hold the connector [2) with one hand and squeeze
the retainer [3] tabs with the other hand to release [2[
them from the locking pawls [4J.
If using the special tool:
Pull and release the connector damper [1] from the [4[
retainer as shown. [1[
Set the special tool to the retainer tabs and push and
release them from the locking pawls
TOOL:
[5J Fuel connector remover 070MF-HP50200 [3[

Pull the connector off, then remove the retainer and

connector damper from the pipe end.
NOTE :
Absorb the remaining fuel in the fuel feed hose from
Howing out with a shop towel. [1 [
Be careful not to damage the hose o r other parts.
Use the specified special tool only.
If the connector does not move, keep the retainer [5[
tabs pressed down, and alternately pull and push
the connector until il comes off easily
I
j
5. To prevent damage and keep foreign matter out, ~================--~
cover the disconnected connector and pipe end with
the plastic bags [1 ).
[1[

j
INJECTOR SIDE
1. Relive the fuel pressure (page 7-6).
Remove Ihe throttle body cover (page 7-13).
Remove the bolt (1] , clamp (2] and setting rubber (3].

7-7
FUEL SYSTEM
2. Check the fuel quick connect fitting (1) for dirt, and
clean if necessary.
Place a shop towel [2] over the quick connect fitting .

3. Pull and release the connector damper [1) from the ~==========(1=I=======~
retainer.
4. Hold the connector [2] with one hand and squeeze
the retainer [3J tabs with the other hand to release
Ihem from the locking pawls [4] .
If using the special tool: (31
Pull and release the connector damper II I from the
retainer as shown.
Set the special 1001 to the retainer tabs and push and
release them from the locking pawls.

~W ~
(5J Fuel connector remover 070MF· HP50200
Pull the connector off, then remove the relainer and III
connector damper from the pipe end. 15J
NOTE:
Absorb the remaining fuel in the fuel feed hose from
Howing out with a shop towel.
Be careful not to damage the hose or other parts.
Use the specified special tool only.
If the connector does not move , keep the retainer
tabs pressed down , and alternately pull and push
the connector until it comes off easily.

5. To prevent damage and keep foreign matter oul.

cover the disconnected connector and pipe end with
the plastic bags [1].

(1J

7-8
 FUEL SYSTEM
QUICK CONNECT FITTING
INSTALLATION
NOTE :
Always replace the retainer and connector damper
of the quick connect filting when the fuel feed hose is
disconnected.
If any retainer needs replacing. use the same
manufacturer's relainer as the ones being removed
(The various manufactures feature different retainer
specifications).
Do not bend or twist fuel feed hose.
FUEL PUMP SIDE
1. Insert a new retainer 111 into the connector [2].
121
NOTE
Align the retainer locking pawls with the connector
grooves.
(11 ~

2. Set a new connector damper 11] to the pipe end as

shown.
Then press the quick connect fitting 121 onlo the pipe
until both locking pawls (3) lock with a ~CLlCK· . 12(
NOTE ' _ __ 1 1
Align the retainer groove with the connector damper 3
tabs.
If it is hard to connect, put a small amount of engine
oil on the pipe end. Align

(11 ~
3. Make sure the connection is secure and thai the
locking pawls [1} are firmly locked into place; check
visually and by pulling the connector (2).
4. Make sure the connector damper [3] is positioned 121
correctly (between the pipe (4) and retainer tabs [5]). 141
5. Increase the fuel pressure and check that there is no
leakage in fuel supply system (page 7-11). (3(

(5(

7-9
FUEL SYSTEM
INJECTOR SIDE
1. Insert a new retainer (1] into the connector [2].
[21
NOTE:
Align the retainer locking pawls with the connector
grooves. [11 g

2. Set a new connector damper [1) to the injector joint ~=================~

as shown. [3]
,
Then press the quick connect fitting [2) onlo the pipe Align ,
until both locking pawls (3J lock with a ·CLlCK".
NOTE:
Align the re tainer groove wi th the connector damper
labs.
[21
If it is hard to connect, put a small amount of engine
oil on the injector joint.

III g
3. Make sure the connection is secure and that the ~=================~
locking pawls (1) are firmly locked into place: check [21
visually and by pulling the connector (2) .
4. Make sure the connector damper [3) is positioned
correctly (between the pipe [4] and retainer tabs (5]),

[31

5. Install the setting rubber (1 J and clamp (2).

[1 I

fA
NOTE :
Install the clamp by aligning its tab with the groove of
the fuel feed hose clamp stay.
Install and tighten the bolt [3J securely.
6. Increase the fuel pressure and check that there is no
leakage in fuel supply system (page 7·11).
Install the throttle body cover (page 7·13).

7-10
 FUEL SYSTEM
FUEL PRESSURE INCREASING
1. Connect the fuel pump 2P (Black) connector [1].
2. Connect the battery negative H cable (page 21-8).
3. Turn the ignition switch ON and engine stop switch
"0 ".
NOTE ~
Do not start the engine.
4. The fuel pump will run for about 2 seconds, and fuel
pressure will rise.
Turn the ignition switch OFF .
Repeat this procedure 2 or 3 times, and check. thai
there is no leakage in the fuel supply system.
S Install the rubber boot (2] on the sub-fuel tank/fuel
pump assembly properly.
6. Install the right side cover (page 2-4).
FUEL PRESSURE INSPECTION
Relieve the fuel pressure and disconnect the quick , - - - - - - -- - -- - - - -
connect fitting from the fuel injector (page 7-7). (1)
Attach the special tools between the fuel injector and
fuel feed hose.
Except U.S.A. TOOLS :
[1] Fuel pressure gauge 07406-0040004
(2) Pressure gauge manifold 07ZAJ·S5A0111
(3] Hose attachment, 9 mm /9 mm 07ZAJ -S5A0120
[4] Hose attachment, 6 mm /9 mm 01ZAJ-5SA0130
(5J Attachment JOint, 6 mml9 mm 07ZAJ ·S5A0150

U.S.A. TOOLS :
Fuel pressure gauge, 100 psi 01406-0040008
Pressure manifold hose
Adapter, male
Adapter, female
01AMJ-HW3A100
07AAJ-S6MA200
07AAJ-SSMA400
I
Connect the fuel pump 2P (Black) connector.
Temporarily connect the battery negative (-) cable
(page 21-8).
Start the engine and let it idle. L _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _~
Read the fuel pressure.
Standard :
316 - 387 kPa (3.2 - 3.9 kg flcml, 46 - 56 psi)

If the fuel pressure is higher than specified pressure ,

replace the fuel pump unit (faulty fuel pump or fuel
pressure regUlator).
If the fuel pressure is lower than specified, inspect the
following:
- pinched or clogged fuel feed hose, fuel hose or fuel
tank breather hose
- fuel flow (page 7-12)
- clogged fuel tank strainer screen (page 7-21 )
- clogged fuel pump filter (page 7-14)
- fuel pump (page 7- 13)
After Inspection, relieve the fuel pressure (page 7-6).
Wrap shop towel
iI Remove the special tools from the fuel injector and fuel
around the feed hose .
aflachment to soak
Connect the quick connect fitting to the fuel injector
up any spilled fuel.
(page 7- 10).

7-11
FUEL SYSTEM
FUEL FLOW INSPECTION
NOTE :
• Before starting the inspection, stan the engine and
let it idle for 30 minutes.
Relieve the fuel pressure and disconnect the quick
connect fitting from the fuel injector (page 7-7).
Connect the special tools to the fuel feed hose .
Except U.S.A. TOOLS :
[1J Hose attachment, 6 mmJ9 mm 07ZAJ-5SA0130
[2] Attachment Joint. 6 mml9 mm 07ZAJ -S5A0150

U.S.A. TOOLS :
Pressure manifold hose 07AMJ-HW3A100
Adapter, male 07AAJ -S6MA200
Fuel press ure gauge, 100 psi 0740S-004000B
Note: The fu el pressure gauge must be installed for
these tes ts.
Place the end of the hose attachment into an approved
gasoline container.
Connect the fuel pump 2P (Black) connector.
Temporarily connect the battery negative (-) cable to
the battery (page 21-8).
Turn the ignition switch ON and engine stop SWitch ~O~ .
Measure the amount of fuel flow.
NOTE:
The fuel pump operates for 2 seconds when the
ignition switch is turned ON and engine stop switch
·0·. Repeat 5 times so that the total measuring time.
Am ount of fuel flow:
125 cm' (4.2 US oz, 4 .4 Imp oz) minimuml
10 seconds at 12 V
If the fuel flow is less than specified. inspect the
following:
- pinched or clogged fuel feed hose, fuel hose or fuel
tank breather hose
- clogged fuel tank strainer screen (page 7-2 1)
- clogged fuel pump filler (page 7-14)
- fuel pump (page 7-13)
Turn the ignition switch OFF.
Wrap 8 shop towel Remove the special tools from the fuel feed hose.
around /he
Connect the quick connect fitling to the fuel injector
attachment /0 soak
(page 7-10),
up any spilled fuel.

7-12
 FUEL SYSTEM
THROTTLE BODY COVER REMOVAL!
INSTALLATION
Remove the seat (page 2-4).
131 _____.,.
Release the following:
- rear final gear case breather hose [1)
- rea r brake panel breather hose f2J
Remove the two trim dips [3] and the throttle body
cover [4] from the seal re tainer [5).
Installation is in the reverse order of removal.

151/"'_~

SUB-FUEL TANK/FUEL PUMP

INSPECTION
Remove the right side cover (page 2-4).
Turn the ignition switch ON and engine stop switch ~O",
and confirm that the fuel pump operates for a few
seconds.
If the fuel pump does nol operate. inspect as follows:
Turn the ignition switch OFF .
Pull the rubber boot [11 off the sub-fuel tank/fuel pump
assembly and disconnect the fuel pump 2P (Black)
connector [2).

Turn the ignition switch ON and engine SlOp switch "0·,

measure the voltage between the terminals of the wire
Brown Green
harness side 2P (Black) connector [1] .
111
Connection: B rown (+) - Green (- )
There should be battery voltage for a few seconds after
the ignition switch turned ON and engine stop switch
"0".
If there is battery vol tage, replace the fuel pump unit.
If there is no voltage. check the following:
- open circui t in the Brown or Green wires
- IG N fuse (10 A)
- fuel pump relay (page 4-29) and its circuits
- engine stop switch line of the PCM/ECM (page 4-36)
- power/ground lines of the PCM/ECM (page 4-35)

7-13
FUEL SYSTEM
REMOVAL/INSTALLATION
Remove the nghl mudguard (page 2-6).
Relieve the fuel pressure and disconnect the quick
connect filling from the sub-fuel lank/fuel pump
assembly (page 7-6).
Clamp the fuel hose (1 J althe point from the upper hose
end is 55 mm (2.2 in), using the hose dip.
TOOL :
(2] Hose clip 07614-0050101 or
equivalent
commercial ly
available in U.S.A.

Wipe off spilled ouf Disconnect the fuel hose and fuel vapor return hose (3].
gasoJine.
Remove the bolt (4]. collar [5] and the sub-fuel tank/fuel
pump assembly [6] from the frame.
Install the sub-fuel tank/fuel pump assembly [1] onto the , - - - - - - - - - - -- - -- - - - - ,
frame by aligning the bosses with the mounting
grommets.
Install the collar [2J and bolt [3], then tighten the bolt
securely.
Connect the fuel hose [4J and fuel vapor return hose [5]
to the sub-fuel tanklfuel pump assembly.
Remove the hose clip from the fuel hose.
Connect the quick connect fitting to the sub-fuel lank/
fuel pump assembty (page 7-9).
Install the removed paris in the reverse order of
removal.

131

Align
J
DISASSEMBLY
NOTE :
To prevent dirt and debris from entering the fuel
pump. always clean it before disassembly.
Clean the inside of the fuel pump case, fuel pump
unit and fuel pump filter with clean gasoline. Never
use commercially available carburetor cleaners.
Always replace all O-rings with new ones when the
fuel pump has been disassembled.
Be careful not to damage the fuel pump unit wire.
Drain the fuel from the fuel pump case [1] and store it in ~Vo~
'ewe<l
--:-:f,-o-
m-t~h-
e~fo-w-e-,-
,~~~
e-,---~I1~I--­
an approved container.
Do not over-tighten Set the fuet pump case in a vise with soft jaws as
the VIse shown.

L Setting Positions

7-14
 FUEL SYSTEM
Be careful nollo loosen the fuel pump assembly bolts [1 J in the
drop the fuel pump sequence as shown , and remove the bolts and spring 131 141
Unit. washers {2] . 6
Remove the cover plale (3] and fuel pump unit [4J from
the fuel pump case [51.
NOTE :
Be careful not to damage the fuel pump unit and its
wires.

Do not reuse the Remove the O-rings [11.

O.rings.
Clean the inside of the fuel pump case [21 with clean
gasoline.

Visually inspect the fuel pump filter [1) for dirt. debris or
any clogging, and replace it if necessary.
FA.
ype .
Type B:

Fuel pump filter replacement:

- Type A (page 7-15)
111
I
- Type B (page 7-17)

FUEL PUMP FILTER REPLACEMENT (TYPE A)

Be careful not /0 Hold the bottom of the fuel pump filler (1 J as shown.
damage the fuel
Disengage the fuel pump filter hook (2J from the fuel
pump filter and fuel
pump unit boss (3) by tuming the fuel pump filter
pumpuml {4}.
clockwise, then remove the fuel pump filter.

7·15
FUEL SYSTEM
Before installing a new fuel pump filter, check thai there
(2) (3(
is no dirt or dust on the fuel pump unit {11.
If necessary. clean the fuel pump unit with compressed
air.
NOTE:
Place a shop towel over the fuel pump unit to
prevent dirt from entering the feed pipe 12J and
suction port [3).
Do not blow compressed air directly into the feed
pipe or suction port.

(1(
Install a new fuel pump fitter [1) to the fuel pump unit 1---;::----'-'-----------------1
whife aligning the holes for the suction port [2].

Be careful nollO Hold the bottom of the fuel pump filter [1] as shown and
damage the fuel push in until it is fully seated on the fuel pump unit
pump filter and fuel holder 12].
pump umt.
Engage the fuel pump filter hook [3] to the fuel pump
unit holder boss [4] by turning the fuel pump filter
counterclockwise.

Make sure the fuel pump unit holder [1) securely ~=='IIIIIIIIIIII~===::-========:;
connected and that the locking tabs [2J are firmly locked [11
into place.

7-16
 I
FUEL SYSTEM
FUEL PUMP UNIT HOLDER REMOVAL (TYPE A)
(Only when Type A filter is repla ced with Type B)
Remo .... e the fuel pump fitter (page 7- 15)
121
Be careful not to Release the locking tabs 111 of the fuel pump unit holder
damage the hooks [2J from the grooves in the fuel unit base hooks [3] while
and labs. pushing the holder against the unit base [4] and slightly
spreading the unit base hooks ,
Remove the fuel pump unit holder from the fuel pump
base.

Be careful nol to Install a new fuel pump unit holder [lJ to the fuel pump
damage the fuel unit [2] while aligning the holes for the suction port and
pump umt holder three locking tabs wi th the grooves.
and fuel pump unit

Align

Make sure the fuel pump unit holder [1] securely

connected and that the locking tabs [2] are firmly locked I']

'"
into place.
Inslalilhe fuel pump filter (page 7-17) •
,'",

12]
FUEL PUMP FilTER REPLACEMENT (TYPE B)
Be careful not to Hold the side surfaces of fuel pump filter (1J as shown.
damage the fuel
Release and disengage the fuel pump filter hooks {2J
pump filler and fuel
from the fuel pump holder bosses [3} by turning the fuel
pump holder {5}.
pump filter In the direction as shown, then remove the
fuel pump filter and O-ring [4].

7-17
FUEL SYSTEM
Before installing a new fuel pump filter, check that there
is no dirt or dust on the fuel pump unit [1].
12J
If necessary, clean the fuel pump unit with compressed
air.
~
NOTE
Place a shop towel over the fuel pump unit 10
prevent dirt from entering the feed Pipe 121 and
suction port 131.
Do nol blow compressed air directly Inlo the feed
pipe or suction port.

I
11J
Apply SIlicone grease to a new O·ring [11 and install it to ~=¢!=:I= t ==========¢! =It ~====
the suction port [2] of the fuel pump unit holder. IIIIi'i' [3] [1] fIIIiiII' ......'iSitI
Install a new fuel pump fiUer [3J to the fuel pump unit
holder while aligning the suction ports.

Be careful not 10 Hold the fuel pump filter j1 J as shown and push in until it ~========"'==~=:;:~===;
damage the fum is fully sealed on the fuel pump unit holder [2J .
pump filler and fuel
Engage the fuel pump filter hooks [3] to the fuel pump
pump holder.
unit holder bosses [4] by turning the fuel pump filter in
the direction as shown.

14J

121
Make sure the fuel pump unit holder [1] securely ~====:::,,,,,....~~:::::::::=====---'
connected and that the locking tabs (2] are firmly locked III [11 (31
Into place. "" \ /
Make sure thatlhe "I'::." marks of the fuel unit holder and
fuel pump filter [3] are aligned .
,- , ,
-,0

7-18
 FUEL SYSTEM
ASSEMBLY
Type A:
BOLTS ----I.!2h O-RING ='.0:.-'
~1IIiiiiII'

SPRING WASHERS

COVER PLATE

FUEL PUMP UNIT

FUEL PUMP CASE

Type 8 :
BOLTS -_.Ir

SPRING WASHERS

COVER PLATE

FUEL PUMP UNIT

FUEL PUMP UNIT :.:.--:: c .

~ : ~ ••/ - '
HOLDER

~e" O.RING ~. / c
~ !1t
FUEL PUMP CASE
D-RING FUEL PUMP FILTER

7-19
FUEL SYSTEM
Apply silicone grease to new O-rings [1J.
121
Do no/ gel grease Install the O-rings onto the fuel pump unit [2J and into
on the pump unit the fuel pump case [31 groove.
and housing except
Wipe off any excess grease from the pump unit and
the O-ring seating
housing .
areas.

...-'iSioI11I 1'1
Set Ihe fuel pump case [1J in a vise (page 7-1 4 ).
Inslalilhe fuel pump unit [2J into the fuel pump case by
aligning the grooves wi th the bosses until the fuel pump
unit base is sealed against the fuel pump case.

Install the cover plate [1) with the chamfered edges r - - - - - - - - - -- ---.-",------="
facing up.
Install the spring washers [2J onto the fuel pump
assembly bolls [3J as shown.
Instalilhe fuel pump assembly bolts.
Be careful nol to Tighten Ihe fuel pump assembly bolts to the specified
drop the fuel pump torque in the sequence as shown.
unit.
TORQUE: 8.8 N 'm (0.9 kgf'm , 6.5 IbHt)

FUEL TANK
REMOVAUINSTALLATION
Remove the fuel tank cover (page 2-5).
Clamp the fuel hose (1) at the point from the upper hose
end is 55 mm (2.2 in), using the hose clip.
TOOL:
(2] Hose c lip 07614.(1050101 or
equivalent
commercially
available in U.S.A .

Pull the rubber boot (3) off the sub-fuel tanklfuel pump
assembly.
W(pe off spilled oul Disconnect the fuel hose from the sub-fuel tank/fuel
gasollflB. pump assembly.

7-20
 FUEL SYSTEM
Disconnecllhe following:
(11
- fuel tank breather hose [1 J from the meter cover
- fuel vapor return hose 12) from lhe fuel tank (6(
- fuel level sensor 2P (Red ) connector [3J
Release the fuel overflow hose (4) from the clamp. (71
131
Remove the two holder bands [5J .
Remove the two mounting bolts {6]. collars (7) and the
fuel lank [8J from the frame.
Installation IS in the reverse order of removal
NOTE
After installing the fuel tank. turn the IgrutJon switch
ON and engine stop SWitch wO', and check that there
is no fuel leak.

141

FUEL STRAINER SCREEN CLEANING

Remove the fuel tank (page 7·20).
(21
Drain the gasoline InlO an approved fuel container,
Remove the two mountmg bolts (1) and the fuel joinl12]
from the fuel tank

Remove the O-ring [1) and fuel strainer screen [2] from , - - - - - - - - - - - - - - - - - - - ,
the fuel joint
Clean the strainer screen with non-flammable or high
flash point solvent and compressed air for cleaning.
Dry the strainer screen thoroughly.
Install the strainer screen and a new D-ring onto the
fuel joint
Install the fuel joinl onto the fuel tank
Install and lighten the two mounting bolts to the
specified torque.
TORQUE : 9.0 N'm (0.9 kgf'm, 6.6 IbHt) ~."
"'.. (11
Install the fuel lank (page 7-20).

7·21
FUEL SYSTEM

AIR CLEANER HOUSING

REMOVAUINSTALLATION
Remove the following "
[6[~
- fuel tank cover (page 2·5)
- throttle body cover (page 7-13) [7[ .
Release the following :
- rear final gear case breather hose (1 J
[1 [
- rear brake panel breather hose (21
- front final gear case breather hose [3)
- fan molor breather hose (4J
Loosen the connecting lube band screw [51. [31
Remove the trim chp [6J and the intake air duct [71.

['[

loosen the connecting lube band screw [11.

Remove the two bolls [2J and the air cleaner sub
chamber [3].

[1 [

7-22
 FUEL SYSTEM
Disconnecllhe tAT sensor 2P (Black) connector [11 and r-

111~161
the crankcase breather hose (21 .
Release the rear final gear case breather hose clip (3)
from the air cleaner houSInQ (4).
loosen the connecting lube band screw [5J.
Be careful nollo Remove the two trim clips [61 and the air cleaner

-
damage the housing.
crankcase breather
Installation is in the reverse order of removal.

151

(41

,
~'
(21 131
THROTTLE BODY
NOTE :
If the sensor unit is removed from the throttle body,
the TP sensor reset procedure must be performed
after installing the throttle body (page 4·31).
REMOVAL
Relieve the fuel pressure and disconnect the quick ,----...--r.:,...,.
connect fitting from the fuel injector (page 7-7).
Remove the air cleaner housing (page 7-22).
Oisconnect the IACV 4P (Black) connector (1) . fuel
injector 2P (Gray) connector [21 and sensor unit SP
(Black) connector [3).

Loosen the throltle body side insulator band screw [11.

Remove the throttle body (21 from the insulator.

L
7-23
FUEL SYSTEM
Remove the screw [1].
Remove the throttle drum cover [2] while releasing its
tab [3) from the throttle body slot [41.
Slide the rubber boot [51 off the adjuster 16]
loosen the throttle cable adjuster lock nut 171. remove
the adjuster from the throtUe body and disconnect the
cable end [8] from the throttle drum 19).

loosen the cylinder head side Insulator band screw (1].

Remove the insulator 12] from the cylinder head.

DISASSEMBLY/ASSEMBLY

I NOTICE I
The throttle body is factory pre-set Do not , - - - - - - - - - -- - - - - - - - - ,
disassemble in a way other than shown in this [1]
manual.
Do not snap the throttle valve from full open to full
close after the throttle cable has been removed. It
may cause incorrect Idle operation.
Do not damage the throttle body. It may cause
incorrect throttle valve operation.
Do nolloosen or tighten the white painted screws (1J
and nut [2] of the throttle body. Loosening or
tightening them can cause thronle valve and idle
control failure.
Always Clean the throttle body before disassembly to
prevent dirt and debris from entering the passages.
Do not remove the sensor unit unless if Is replaced.
Remove the following:
- screw (1] and wire harness damp slay (2]
- screw (3) and fuel feed hose damp stay (4)
- IACV [5J (page 7·27)
- fuel injector [61 (page 7-28)
- sensor unit [7J (page 4-30)

111 12)

7-24
 FUEL SYSTEM
Cleanmg the air
passages and
Clean the air passage of the throttle body using
compressed air.
I
S6f)SCJf hole with a Check the air passage for clogs.
piece of wire will
damage the throttle
NOTE
body • Do not use high pressure air or bring the nozzle too
close to the throttle body.
Assembly IS In the reverse order of disassembly.
TORQUE:
Wire harness clamp stay screw:
3.4 N'm (0.3 kgf'm , 2.5 IbHt)
Fuel feed hose clam p stay screw:
3.4 N'm (0.3 kgf'm, 2.5 IbHt)
NOTE
Install the wire harness clamp stay and fuel feed
hose damp slay by aligning each stay hole wi th the
pin of the throttle body.

INSTALLATION
Face the "HRO· Install the insulator [1 J onto the cylinder head by
mark toward the aligning the groove with the lug.
throttle body
Align the cylinder head side Insulator band hole with the
Insulator boss.

Tighten the cylinder head side Insulator band screw (1]

so thai the distance between the band labs Is as
shown. 110-12.Smm
(043 - 0.49 In)

Connect the Ihrottle cable end [I ] to the throttle drum

12J
T'9h1en the lock nut Install the throttle cable adJuster [3] to the throttle body
and Install the and temporarily tighten the lock nut [4].
adjuster rubber boot
Install the throttle drum cover [51 by aligning the locating
[9} after adjustment
tab [6] with the slol f7] in the Ihrottle body
the tllrot//a lever
freeplay Install and tighten the screw [8]10 the specified torque
TORQUE : 1.8 N'm (0.2 kgf'm , 1.3 IbHt)

7-25
FUEL SYSTEM
Install the throttle body [1] into the insulator by aligning
the lug With the groove.
Align the throttle body side insulator band hole with the
insulator boss.

Tighten the throttle body side Insulator band screw /1 J ~=====::::::::/1:I::"'IIIIIIIIIIIIIIIIIIIIIIIII""'IIIIIIIIII~

so that the distance between the band tabs is as
shown. 5.5 - 7.0 mm
(0.22 - 0.28 in)

Connect the IACV 4P (Black) connector (I] , fuel injector

2P (Gray) connector 121 and sensor unit 5P (Black)
connector [3).
Install the air cleaner housing (page 7-22).
Adjust the throttle lever freepla y (page 3-4).
Connect the quick connect fitting to the fuel injector
(page 7-10).

IACV
INSPECTION
Remove the throttle body cover (page 7-13).
The IACV is installed on the throttle body and is
operated by the step molor. When the ignition switch is
turned ON, the IACV operates for a few seconds.
Tum the ignition switch ON and engine stop switch ·0·,
check the IACV (1J.
If the slep motor operating (beep) sound is heard , the
IACV is normal.

7-26
 FUEL SYSTEM
The IACV operation can be checked visually as follows:
1. Remove the IACV (page 7-27).
2. Connect the IACV 4P (Black) connector [1].
3. Turn the ignition switch ON and engine stop switch
"O~, check the IACV operation.

REMOVAUINSTALLATION
Remove the throttle body cover (page 7-13)
Clean the throllle body to prevent dirt and debris from
entering the IACV passage .
Turn the Ignition switch OFF
Disconnect the IACV 4P (Black) connector [11
Remove the two torx screws (T20) {2], relalner plate [31
and IACV [4].

Before installing the IACV. turn the slide valve [11

ctockwise until lightly seated on IACV.

Install a new a-ring {1) onto the IACV IlJ

Install the IACV into the throttle body by aligning Ihe
valve slit with the guide pin in the throttle body.

7-27
FUEL SYSTEM
Install the retainer plale (1) by aligning the groove with
Ihe valve boss.
Install and lighten the two lent screws (T20) [2]10 the
specified torque.
TORQUE: 2. 1 N'm (0.2 kgf'm , 1.5IbHt)
Connacllhe IACV 4P (Black) connector [3].
Install the throttle body cover (page 7-13).

FUEL INJECTOR
INSPECTION
Remove the throttle body cover (page 7-13),
Start the engine and lei it idle.
11 I
Confirm the fuel injector (1] operating sounds with a
sounding rod or stethoscope [2J.

(21

REMOVAL
Clean around Ihe fuel injector base with compressed alf
and be sure Ihal no debris is allowed to enter the
oombusllOn chamber.
Relieve the fuel pressure and disconnect the quick
connect fitting from Ihe fuel injector (page 7-7).
Remove the IACV (page 7-27).
Disconnect the fuel injector 2P (Gray) connector (1).
Remove the fuel injector mounting bolts [21 and fuel
injector assembly (3] from the throttle body.

Remove the fuel injector [1) from the injector joint 121
151

I
Remove the O-ring [31, cushion ring [4] and seal ring
[5].

7-28
 FUEL SYSTEM
INSTALLATION
Coal a new O-nn9 111 and seal ring (2] with engine oil.
InstaU a new O-nng, cushion ring [3] and seal ring to the
fuellnjec\or [4J. being careful nollo damage them.
Be careful not 10 Inslalithe fuel Injector into the Injector JOint [5J .
damage the O-ring.

l a"~ 1 1 141
Ahgn the boss [1 J of the injector jOint with the injector ~==================~
terminals [21 as shown

111

Bec8refulnollo Install the fuel injector assembly [lllnlO the throttle

damage the seal body.
nng Install and tighten the fuel InJe<:lor mounhng bolts (2J to
the specified torque
TORQUE : 5.1 N'm (0.5 kgf-m , 3,8IbHt)
Connect the fuel injector 2P (Gray) connector [3] by
aligning its groove with injector joint boss.
Inslalilhe IACV (page 7-27).
Connect the quick connect fitting to the fuel injector
(page 7- 10)

7·29
FUEL SYSTEM

7-30
 8. COOLING SYSTEM

SYSTEM FLOW PATTERN ··················· .. ··· .. ·S·2 THERMOSTAT ······················ ················· ·······8·8

SERVICE INFORMATION ·········· ···················8·3 RADIATOR/COOLING FAN ·························· 8·9

TROUBLESHOOTING···································8-4 RADIATOR RESERVE TANK ·····················8·11

SYSTEM TESTlNG ········································ 8·5 WATER PUMp ······································· .... · 8·11

COOLANT REPLACEMENT ························· 8·6

8·1
COOLING SYSTEM
SYSTEM FLOW PATTERN

RESERVE TANK RADIATOR

,
J
THERMOSTAT

WATER PUMP

8·2
 COOLING SYSTEM
SERVICE INFORMATION
GENERAL

"WARNING
Removing the radiator cap while the engine is hot can allow the coolant to spray out. seriously scalding you .
Always let the engine and radiator cool down before removing the radiator cap.

If any coolant gets in your eyes, rinse them wi th water and consult a doclor immediately.
If any coolant is swallowed, induce vomiting. gargle and consult a physician immediately
If any coolant gets on your skin or clothes, nose thoroughly with plenty of water.

I NOTICE I
Using coolant With silicate COlTOsion 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 or drain the system.
Avoid spilling coolant on painted surfaces.
After servicing the system, check for leaks wi th a cooling system tester.
For cooling fan motor inspection , refer to "Ughts/MetersfSwitches" section (page 22·15).

SPECIFICATIONS
ITEM = == =:;:::-::?SPECIFICATIONS
Coolant capacity Radiator and engine + 1.;=;5"'liters l16 us qt, 1.3 Imp qt)
_ _ _-',
~servetank 0.3 liter (0.3 US qt, 0.3 Imp qt)
Radiator cap relief pressure ~_~;;;~~~~~~-_-_-_-_ + - ---.'O"'.B - ·',.
37 kPa (1.1 - 1.4 kgf/cm 2, 16 20 psi)
Thermostat Begin to open + 80 B4°C (176 183-F)
I Fully ope,,"_ _ _ _ _ ---, 95' C (203'"F,,)~'70,
L-- Valve lift 8 mm (0.3 in) minimum at 9S"C (203°F) j
Recommended antifreeze ------ Pro Honda HP- Coolant or an eqUivalent high quality ethylene
glycol antifreeze containing silicate-free corrosion inhibitors
Standard coolant concentration 1:1 mixture With distilled water

TORQUE VALUES

ITEM Q'TY THREAD TORQU"E- - - - REMARKS

,-+-,O",I",A".(~m",m",)'--.-,N,-,.m (kgf·m , IbHt) = ,--1
Cooling fan nut 5 2.7 (0.3. 2 .0) Apply locking agent to
the threadS.
Fan motor bolt 3 5 5.2 (0 .5, 3.B)
Fan motor slay bolt 3 6 B.4 (0.9, 6.2)_--'--_ _ __

8·3
COOLING SYSTEM
TOOLS
Remover weIght Dnv'e~
,---- Remover shaft, 15 mm
07741-0010201 07749-0010000 07936·KC10100

or 07936-371020A or 07936-3710200
~U . S .A . only)
Remover head , 15'm~m;;;---- Bearing rem over, 15 mm Mechanical seat driver attachment
07936·KC 10200 Q7936·KC 10500 (U.S.A. only) 07945-4150400

(~
Mechanical seal installer
07965-415000A (U.SA only)

TROUBLESHOOTING
Engine temperature too high
Thermostat stuck closed
Faulty radiator cap
Insufficient coolant
Passage blocked in radiator, hoses or water jacket
Air in system
Faulty cooling fan motor
Faulty water pump
Eng ine temperature too low
• Thermostat stuck open
Coolant leaks
Faulty water pump mechanical seal
Deteriorated O-rings
Faulty radiator cap
Damaged or deteriorated cylinder head gasket
Loose hose connection or clamp
Damaged or deteriorated hoses

8-4
 COOLING SYSTEM
SYSTEM TESTING
COOLANT (HYDROMETER TEST)
Remove the screw [lJ and the maintenance lid [21
(1(

~\~~.~
The engine must be Remove the radiator cap [3).
cool before
removing the (2( ....
radiator cap

. t~

~ (3(

Test the coolant gravity using a hydrometer [lJ

STANDARD COOLANT CONCENTRATION:

1:1 mixture of distilled water and antifreeze
look 'or contamination and replace the coolant if
necessary (page 8-6).

Coolant temperature °C Cf)

0 5 10 15 20 25 30 3S 40 45 SO

0 018
(32) (41) (SO) (59l (68) (77 ) (86) (95) (104) (113) (122)
5 1.009 1.009 1008 1008 1007 1.00 6 1.005 1.003 1.001 o.999 0.997
1.017 i ' .017 ":016 ' ' :015 1 .01 4 1.013 1.011 1.009 1.007 1.005
15 1.028 1.027 , 1.026 1.025 1.024 1.02 2 1.020 1.018 1.016 1.014 1.012
20 1.036 1.035 1,034 1.033 1.031 1 .02 9 1.027 1.025 1.023 1.021 1.019
"'§
0
Q 25 1.045 1.044 1.043 1.042 ' .040 1.03 8 1036 1.034 1.031 1.028 1.025
30 1.053 1.052 ' .051 1.047 1.046 1.04 5 1.043 1.04 t 1.038 1 035 1.032 T
C 1.060 1.058 1.052 1.049 1.0461 043 1.040
35
40
1.063 1.062
1.070 10~t~ .054
1.068 1.066 1.064 1.062 1.059 1.056 1,053 1,050 1.047
& 45
1.072
1.080 '.078 ' .076 1074 1.072 1 1 069 1.066 I 1.063 1.060 1057 f 1.054 f
SO ' 1.086 1.084 1082 1.080 1.077 1074 1.071 1.068 1.065 1,062 , 1.059
55 I 1.095 1.093 1.082 1.079 1.076 1.073 1.070 1.067
60 1.100 1.098 1.095 I • 1.086 1.083 1.080 I 1.077 1,074 1.071

8·5
COOLING SYSTEM
RADIATOR CAP/SYSTEM PRESSURE
INSPECTION
Remove the radiator cap (page 8·5).
Wet the sealing surfaces of the cap 11), then install the
cap onto tester [2).
TOOLS:
Cooling system pressure lester SVTS4AH
Cooling system adaptor OTCJ33984A
Pressurize the radiator cap using the tester.
Replace the radiator cap if it does not hold pressure , or
if relief pressure is too high or too low. II must hold the
specified pressure for at least 6 seconds.
RADIATOR CAP RELIEF PRESSURE :
108 - 137 kPa (1 .1 -1 .4 kgf/cm Z, 16 - 20 psi)

Pressurize the radiator, engine and hoses using the

lester 111. and check for leaks.

I NOTICE I
EXC6SSMl pressure can damage the cooImg system
components. Do not exceed 137 kPa (1.4 kgflcm 1,
20 psi).
Repair or replace componen ts if the system will nol hold
the specified pressure for alleast 6 seconds.
Remove the tester and install the radiator cap.
Install the lid in the reverse order of removal.

COOLANT REPLACEMENT
PREPARATION

I NOTICE I
Usmg coolant with silicate corrosion inhibitors may
cause premature wear o( water pump seals or blockage
of radiator passages. USing lap waler may cause
engine damage.
NOTE
The effectiveness of coolant decreases With the
accumulation of rust or jf 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 water with the
recommended antifreeze .
RECOMMENDED ANTIFREEZE :
Pro Honda HP Coolant or an equivalent high
quality ethylene glycol antifreeze containing slli-
cate·free corrosion Inhibitors

RECOMMENDED MIXTURE :
1:1 (mixture with distilled water)

8-6
 COOLING SYSTEM
REPLACEMENT/AIR BLEEDING
NOTE '
• When filling the system with coolant, place the
vehicle on a flat, level surface.
The engme must be Remove the following:
cool before - right mudguard (page 2-6)
serviCmg the - rear fender cover (page 2·9)
cooling system. - maintenance lid (page 8-5)
Place a funnel Drain the coolant from the system by removing the
under the waler drain bolt (1) and sealing washer [2J on the water pump,
pump to catch and the radiator cap [3].
coolant wIth the
Reinstall the drain bolt with a new sealing washer
container.
securely.

Remove the two bolts [1] and reserve tank [2], then
open the tank cap (3] to drain the tank.
Disconnecllhe siphon hose (4) to remove the tank .
Rinse the inside of the reserve tank with water.
Reconnecllhe siphon hose and Install the reserve tank
with the two bolts.

Fill the system with the recommended coolant up to the

filler neck (1).
Bleed air from the system as follows:
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 filler neck.
4. Install the radiator cap.

8·7
COOLING SYSTEM
Fill the reserve lank to the upper level line [1) and install
the tank cap [2J.
Inslallthe following :
- maintenance tid (page 8-5)
- rear fender cover (page 2·9)
- right mudguard (page 2-6)

THERMOSTAT
REMOVAUINSTALLATION
Drain the coolant from Ihe system (page 8-7).
Remove the left fuel tank side cover (page 2-5).
Do not hang the Remove Ihe two bolts (1] and ignition coil stay assembly
assembly from the 12) .
wires.

Remove the two bolts (1] and thermostat cover [21.

Remove the thermostat [1] from the housing.

Make sure the rubber seal [2) on the thermostat is in
good condition.
Apply coolant to the rubber seal and install Ihe
thermostat into the housing with the bleed hole facing
[3] inboard.
Install the thermostat cover and lighten Ihe two bolts
securely,
Inslalithe left fuel tank side cover (page 2-5).
Fill and bleed the cooling system (page 8-6).

8-8
 COOLING SYSTEM
INSPECTION
Visually inspect the thermostat [11 for damage.
Replace the thermostat if the valve stays open a\ room [11
temperature.
00 not ler the Heat a container of water with an eleclric healing
thermostaf or element for 5 minutes.
thermometer f2} Suspend the thermostat in heated water to check its
touch the pan, or operation. - ,-

\
you will get a false f
THERMOSTAT BEGIN TO OPEN : ("1
reading.
80 - 84~C (176 _183°F)
I

L
VALVE LIFT:
8 mm (0.3 in) minimum at 95 C (203°F)
Q

Replace the thermostat if the valve opens al a

_ _ ___
- _-___/__/0 ,
temperature other than those specified

RADIATOR/COOLING FAN
RADIATOR REMOVAUINSTALLATION
NOTE
• Take care not to damage the radiator fins whIle
servicing the radialor.
Remove the fron t fenderlcarrier (page 2-8)
Drain the coolant from the system (page 8-7).
Remove the following:
- headlight 3P (black ) connector 11J and wire 12J (from
right side air guide plate)
- two trim clips {3] (from each side air guide plate by
pushing the center pin)
- side air guide plates {4] (by releasing each lab 15))
- radiator gnlle 16J (by releasing the two tabs)

- fan motor 2P (natural) connector [1J (disconnect)

- siphon hose [2J
- breather hose [3J (pink)

8-9
COOLING SYSTEM
- water hoses [1)
- two bolts [2)
- 4WO select switch wire 13] (from the wire guide ]4))
- radiator assembly (5) (release the mounting bosses
[6) from the grommets)
Installation is in the reverse order of removal.
Fill and bleed the cooling system (page 8·6).

131
141

COOLING FAN REMOVAU

INSTALLATION
Remove the following:
- three washer-bolts [1]
- molor/slay assembly [2) [21

- nut 11]

~
- cooling fan (2]

~
1
•
j
8-10
I
 COOLING SYSTEM
connector [1J
- three bolts [2J
- fan motor [3)
Apply lockmg agent Installation is in the reverse order of removal.
10 Ihe fan nul
threads. TORQUE :
Cooling fan nut : 2.7 N'm (0 .3 kgf- m , 2.0 IbHt )
Fan motor bott: 5.2 N'm (0 .5 kgf'm , 3.8 IbUt)
Fan motor s tay bo lt: 8.4 N'm (0.9 kgf-m , 6 .2 IbHt)

RADIATOR RESERVE TANK

REMOVAL/INSTALLA TION
Remove the rear fender cover (page 2-9).
Remove the two bolts [1) and reserve tank [2} from the
frame, then open the lank cap [3) to drain the tank.
Disconnect the siphon hose [4) to remove the tank.
Connect the siphon hose and install the reserve tank
with the two bolts.
Fill the reserve tank to the upper level line [5J and install
the tank cap.
Install the rear fender cover (page 2-9).

WATER PUMP
MECHANICAL SEAL INSPECTION

WV
Remove the right side cover (page 2-4).
Check the breed hose III of the water pump for signs of ( e
coolant leakage . I1J
If there is leakage, replace the mechanical seal
(page 8-12). r
Make sure that there are no continuous coolant leakage
from the bleed hose while operating the engine.
NOTE .

~
A small amount of coolant weeping from the bleed
hose is normal.
...
""

I'

8-11
COOLING SYSTEM
MECHANICAL SEAL REPLACEMENT
NOTE-
• When replacing the mechanical seal, the impeller
and pump shaft must be replaced with new ones.
Remove the front crankcase cover (page 12-6).
Remove the following:
- five bolls [1J and sealing washer [2]
- pump cover 13J
- O·ring [4) (from the cover)

Remove the impeller assembly from the pump shaft by ~"""IIIIIIIIIIIIIIIIIIIIIIIIIIIIII~IIIIII"'''::::::'''''~~==:;

tapping the inside of the impeller (1] through the pump 1')
shaft [21. using a screwdriver or equivalent.
Remove the mating ring and cup gasket of the 13)
mechanical seal from the impeller.
Remove the following:
- pump shaft
- thrust washer [3)

\ 121

Remove the mechanical seal (11.

TOOLS:
Remover head, 15 mm 07936·KC10200
Remover shaft, 15 mm 07936·KC10100
Remover weight 07741-0010201

U.S.A. TOOLS :
Bearing remover, 15 mm 07936·KC10S00
Remover weight 07936..J71020A or
07936·3710200

Remove the oil seal {1J.

Apply molybdenum oil solution to the lips of a new oil
seal.
Install the oil seal with the flat side facing oul until il is
fully sealed.

8-12
 COOLING SYSTEM
Be careful nol to Drive a new mechanical seal [lJ in until it is seated.
damage the sliding
surface of/he TOOLS :
mechanical seal [2J Driver 07749"{)010000
(3) Mechanical seal driver 07945-4150400 or
attachment
Mechanical seal Installer 07965-415000A
(U .S.A. only)

Be careful not 10 Install a new cup gasket [1 J over a new mating ring [2].
damage the sliding
Apply coolant around the cup gasket. Install the gaskeU
surface of the
ring assembly into a new impeller [3) with the gasket
mating ring.
facing t he impeller until it is fully seated .

~====------=~
l
Do not gel oil on the Apply molybdenum oil solution to the thrust washer [1]
mechanical seal and the journal [2) of a new pump shaft [3].
Install the washer onto the pump shaft, and insert the
shaft into the crankcase cover.

Never allow dirt or Degrease [1] the press fitting areas of the impeller [2]
dust to get onto the and shaft [3}. and the sliding surfaces of the mechanical (2(
sJKiing surfaces of seal and mating ring.
the mechanical seal Press the impeller assembly onto the shaft.
and mating nng.
Check that the pump shaft turns smoothly without
binding .

L f;' /.1011, '1

8-13
COOLING SYSTEM
Install a new O·ring (1) into the cover groove [2).
(1J 111

Install the pump cover [1) and the five bolts (2) with a :"'~~~~~~~~~"""~~~===",;;;~
new sealing washer [3J in position as shown (triangular (2)
mark (41). Tighten the bolts in a crisscross pattern in
several steps.
Install the front crankcase cover (page 12-23),

8-14
 9. LUBRICATION SYSTEM

LUBRICATION SYSTEM DIAGRAM .. ··········9-2 OIL PUMP ···························· ········· ·· ·············· 9-4

SERVICE INFORMATION ····················· ········9-3 RELIEF VALVE ............................................. 9-6

TROUBLESHOOTING···································9-3

9-1
LUBRICATION SYSTEM
LUBRICATION SYSTEM DIAGRAM

CYLINDER
HEAD COVER

CENTRIFUGAL
CLUTCH

FLYWHEEL

CRANKSHAFT
_ _ _ STATOR

RELIEF
VALVE

OIL FILTER REAR CRANKCASE COVER

FRONT C",INK'CA"E COVER

OIL

OIL ST'tAlNIER
SCREEN

9-2
 LUBRICATION SYSTEM
SERVICE INFORMATION
GENERAL

ACAUTION
Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely
unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and water as soon as
possible after handling used O
~;~
I. _ _ _ _ _

This section covers service of the oil pump and relief valve. The service procedures in this section can be performed with the
engine installed in the frame.
When removing and installing lhe oil pump, use care not to allow dust or dirt to enter the engine.
If any portion of the oil pump is worn beyond the spedfied service limits, replace the oil pump as an assembly.
For following service, see Maintenance section .
- oil level check and oil change (page 3-12)
- oil filter replacement (page 3-14)

SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVIC E LIMIT -
Engine oil capacity After draining 2.9 liters (3.1 US qt, 2.6 Imp qt)
- -=
After draining/filter change 3.0 liters (3.2 US ql. 2.6 Imp ql)
After disassembly 1 3.3 liters (3.5 US qt, 2.9 Imp qt)
Recommended engine oil Pro Honda GN4 4-stroke oil (U.S.A and
Canada) or Honda 4-stroke oil (Canada
only), or equivalent motor oil
API service classification : SG or higher
(except oils labeled as energy conserving
on the circular API service label)
JASO T 903 standard : MA
Viscosity: SAE 10W-30
Oil pump Tip clearance 0.15 (0.006) 0.20 (0,008)
Body clearance 0.15 0.24 (0.006 - 0.009) 0.25 (0,010)
Side clearance 0.02 0.09 (0.001 - 0.004 ) 0.11 (0,004)

TROUBLESHOOTING
Oil level too low - high oil cons umption
Oil consumption
External oil leak
Worn piston rings or incorrect piston ring installation
Worn cylinder
Worn valve guides or slem seals
Oil contam i nation
Oil or filter not changed often enough
• Worn piston rings or incorrect piston ring installalion
• Worn valve guides or stem seals
011emulsific ation
Blown cylinder head gasket
leaky coolant passage
• Water entry

9-3
LUBRICATION SYSTEM
OIL PUMP
REMOVAL
Remove the front crankcase cover (page 12-6).
Remove the three bolts PI and oil pump 12).

DlSASSEMBL Y/INSPECTION
Remove the boll [1] and rotor side plale [21·
111 121

Measure the rotor lip clearance.

SERVICE LIMIT: 0.20 mm (0.008 in)

Measure the pump body clearance.

SERVICE LIMIT: 0.25 mm (0.010 in)

Remove the oil pump shaft 11] and drive pin [2).

9-4
 LUBRICATION SYSTEM
Measure the pump side dearance.

SERVICE LIMIT: 0.11 mm (0.004 In)

ASSEMBLY
Dip all parts in clean engine oil.
[31 [51 [11
Install the outer rotor [1] and inner rotor [2] into the
pump body [3J.
Install the drive pin (4] into the pump shaft [5]. and
install the shaft into the inner rotor and pump body by
aligning the drive pin with the inner rotor groove.

Install the rotor side plate [11 and bolt 12].

Tighten the bolt securely.
L [41 [2)

INSTALLATION
Install the oil pump [11 onto the crankcase while aligning ,-..--,1'::::'"
the pump shaft end ]2] with the balancer shaft groove
[31·

9-5
LUBRICATION SYSTEM
Install the three bolts (1] and lighten them securely_
Install the front crankcase cover (page 12-23).

RELIEF VALVE
DISASSEMBL YliNSPECTION
Remove the front crankcase cover (page 12-6).
[11
Remove the relief valve assembly [1] from the front I
crankcase cover.
Remove the O-ring from the relief valve body _

Remove the snap ring [1), washer 121. spring [3J and
relief valve (4] from the valve body (5].
Check the relief valve and spring for wear or damage.
Replace the relief valve assembly if necessary.

ASSEMBLY
Install the relief valve into the body with the open end
facing to the spring.
Instalilhe relief valve spring, washer and snap ring .

[21

Coat a new D-ring (1] with oil and install I! Into the relief
valve body groove.
Install the relief valve assembly [2J into the fronl
crankcase cover.
Install the front crankcase cover (page 12-23),

9-6
 10. CYLINDER HEADNALVE

SYSTEM COMPONENTS ··· ························· 10·2 VALVE GUIOE REPLACEMENT ·············· 10·12

SERVICE INFORMATION ··························· 10-4 VALVE SEAT INSPECTION I

REFACING ·············· ··································10·13
TROUBLESHOOTING ············· ···················· 10·6
CYLINOER HEAO ASSEMBLY ················ 10·14
CYLINDER COMPRESSION ······················· 10·7
CYLINDER HEAD INSTALLAnON ··········1 0·16
CYLINDER HEAD COVER REMOVAU
DISASSEMBLY ···········································10·7 CYLINDER HEAD COVER ASSEMBLYI
INSTALLATION ····································· .. · 10·17
CYLINDER HEAD REMOVAL· .. ·················· 10·9
CAMSHAFT REMOVAL .. ···· ······· .. ············· 10·20
CYLINDER HEAD DISASSEMBLY···········10·10
CAMSHAFT INSTALLATION ···················10·23

10-1
CYLINDER HEADNALVE
SYSTEM COMPONENTS

12N·m ( 1.2 . 9Ibf·ft )

48 N'm (4.9 kgf.m , 351bHt)

~ 22 N'm (2.2 kgl·m. 161bl HI

:Q''A::.---- 48 N'm (4 .9 kgf.m, 35 IbHt)

54 N'm (5.5 kgf·m. 40 IbHt)

32 N'm (3.3 kgf·m. 24 IbNt)

10·2
 CYLINDER HEADNALVE

or:
()I

'J ____ :--..

12 N'm (12 kgf'm, 9lbHt)

10-3
 CYLINDER HEADNALVE
SERVICE INFORMATION
GENERAL
· This section covers service of the rocker arms, cylinder head , valves and camshaft. These services can be done with t he engine
Installed in the frame.
When disassembling , mar\( and store the disassembled parts to ensure that they are reinstalled in their original locatio",.
· Clean
· Rockerallarm
disassembled parts with deaning solvent and dry them by blowing them off with compressed air before inspection.
· before assembling
and valve lubricating oil is fed through oil passages in the cylinder head and head cover. Clean the oil passages
cylinder head.
· cylinder
Be careful not to damage the mating surfaces when removing the cylinder head cover and cylinder head. Do nol strike the
head too hard during removal.

SPECIFICATIONS
Uni I: mm (in)

,
ITEM
Cylinder compression at 400 rpm
STANDARD
600 kPa (6.1 kgffcm~87 psi) ~- LlMIT
SERVIC
1
Valve clearance
=s.[ 0.15 t 0.02 (O .OOB t 0.001)

~34)
-

i
,
EX 0.23 t 0.02 (0.009 t 0.001) -
Valve, valve Valve stem 0 .0. I IN 5.975 5.990 (0.2352 - 0.2358) 5.95 (0.2
guide . EX 5.955 5.970 (0.2344 0.2350) 5.93 (0.233)
Valve guide 1.0 . IN/EX 6.000 6.012 (0.2362 0.2367) 6.02 (0.2 37)
, Slem·lo-gulde Clea,a"ce~
t EX
0.010 0.037 (0.0004
0.030 0.057 (0.0012 0.0022)
0.0015) 012 (0.
005)
0.14 (0.0 06)
1
Valve guide projection IN/EX 14.8 15.0 (0.58 - 0.59)
above cylinder head
Valve seat width I IN/EX 1.2 (0.05) ~~5(0.06)
Valve spring Free length Inner 42.94 (1.691) 42.08 (1.657)
Outer 43.63 (1.718) 42 .76 (1 .683)
Rocker arm Arm 1.0 . I IN/EX 12.000 - 12.018 (0.4724 0.4731 ) 12.05 (0.474)
ShaRO.O. : : t'N/EX 11 .964 11.984(0.4710 0.4718) 11 .92(0. 469)
Arm-Io-shaft clearance IN/EX"'-- ~.016 0.054 (0.0006 0.0021) 0.08 (0.003)
Camshaft and Cam lobe height IN I 35.9400 36.1800 (1.41496 1.42441) 35.74 (1. 407)
earn follower EX 35.B811 35.9211 (1.40476 1.41421) 35.48 (1. 397)
Cam follower 0 .0 . IN/EX 22.467 22.482 (0.8845 0.8851) 22.46 (0.884)
I
Follower bore 1.0 . INIEX 22.510 - 22.526 (0.8862 0.8868) 22.54 (0.887)
, Follower-Ie-bore clearance INIEX 0.028-=-0.059 (0.0011 0.0023) 0.07 (0.003)
Cyhnder head warpage - 0.10 (0.004)

TORQUE VALUES
I , ,
THREAD TORQUE
ITEM Q'TY REMARK 5
OIA. (mm) N'm (kgf'm , Ibf-ft)
Cylinder head nul I 4 10 i 48 (4 . 9~35 ) Apply engine oiItothe
threads and se ating

;1 ~
surface.
Cam chain tensioner pivot bolt I 12(1 2.9) I Apply locking agent 10

Spark piug
, 1 14 22 (2.2, 16)
the threads.

ECT sensor 1 10 12 (1.2, 9)

I 1 I
Upper engine hanger nut (frame side) 10 54 (5.5. 40)
Upper engine hanger bolt (engine side) .I. 2 8 32 (3.3, 24) I

10-4
'-
 CYLINDER HEADNALVE
TOOLS
Valve spring compres,os~o~'-----'-'S'Ce~a"I~C~"""'e"r, 40 mm (45" IN) Seat cutter, 33 mm (45 0 EX)
07757-0010000 07780-0010500 07780-0010800

I
f~
)!J5P
) I

or equivalent commercially available in or equivalent commercially available in

V.SoA ~.S .A .
Flat cutter, 38.5 rnm (32" IN)
07780-0012400 Ii Flat cutter, 33 mm (32" EX)
07780-0012900
Interior cutter, 37.5 mm (60' IN)
07780-0014100

) /
I

or equivalent commercially available in or equivalent commercially available in or equivalent commercially available in

U.SA U.SA U.S.A.
r-1nter'ior cutter, 34 mm (60' EX) - - "'a"'lve g="c;d~e~d~nv
'V ='=er, 6 mm Cutter holder, 6 mm
07780-0014700 07942-6570100 07VMH-MBB0100

6
,."0
'<.
- ,,' :.•
./

or equivalent commercially available in or equivalent commercially available in

U.S.A. U.S ,A.
r-Valve guide reamer, 6 mm
I 07VMH-MBB0200

or 07VMH-MBB020A (U.S.A only)

~

10·5
CYLINDER HEADNALVE
TROUBLESHOOTING
Engine top-end problems usually affect engine performance. These problems can be diagnosed by a compression test. or by
tracing top-end noise with a sounding rod or stethoscope.
If the performance is poor at low speeds. check for a white smoke in the crankcase breather hose. If the hose is smoky, check
for seized piston ring (page 11-2).
Compression too low, hard starting or poor performance at low speed
Valves
- Incorrect valve adjustment
- Burned or bent valves
- Incorrect valve timing
- Broken valve spring
- Uneven valve seating
- Valve stuck open
Cylinder head
- leaking or damaged cylmder head gasket
- Warped or cracked cylinder head
- loose spark plug
Cylinder/piston problem (page 11-3)
Compression too high
• Excessive carbon build-up on piston head or combustion chamber
• Worn or damaged decompressor system
E}l:cessive smoke
Worn valve stem or valve guide
• Damaged stem seal
• Cylinder/piston problem (page 11-3)
Excessive noise
Incorrect valve dearance
Sticking ",al",e or broken valve spring
Excessively worn valve seat
Worn or damaged camshaft
Worn rocker arm andlor shaft
Worn rocker arm follower or valve stem end
Worn or damaged push rod and/or cam follower
Worn cam chain
Worn or damaged cam chain tensioner
Worn cam sprocketleeth
Cylinder/piston problem (page 11-3)
Rough idle
• Low cylinder compression

10-6
 CYLINDER HEADNALVE
CYLINDER COMPRESSION
Warm up the engine to normal operating temperature. I
SlOp the engine and remove the spark plug (page 3-8).
111
Install the compression gauge [1) into the spark plug
hole.
Shift the transmission into neutral.
Open the throttle all the way and crank the engine with
the starter motor until the gauge reading slops rising.
The maximum reading is usually reached within 4 - 7
seconds.
The cylinder COMPRESSIO N PRESSURE :
compress/(}() 600 kPa (6.1 kg flcm 2, 87 psi) at 400 rpm
specificallO IS
comparatively /ow Check that there is no leakage althe gauge connection.
because the Low compression can be caused by:
camshaft has 8 - blown cylinder head gasket
decompression - improper valve adjustment
device installed. - valve leakage
- wom piston ring or cylinder
\
High compression can be caused by:
- carbon deposits in combus tion chamber or on piston
head

CYLINDER HEAD COVER REMOVAL!

DISASSEMBLY
REMOVAL
Remove the following:
- fuel tank (page 7-20)
- injector side quick connect fitting (page 7-11)
Disconnect the ECT sensor 2P connector (1 J and
ignition coil primary wire connectors (2J.
Remove the ignition coil primary wire chp (3J from the
ignition coil bracket {4].

Remove the trim clip {1].

[21

\
B8 careful no/to Release the wires, cables and hoses from the clamps of
bend or kink the fuel the heat guard plate {2J.
feed hose.
Remove the heat guard plate from the frame

10-7
CYLINDER HEADNAlVE
Set the piston position to Top Dead Center on the
compression stroke (page 3-9).
If you plan 10 remove the rocker arms, loosen the two
rocker arm shaft retaining bolts [1).
Remove the following :
- eight cylinder head cover bolls (2]
- cylinder head cover (3)

Marle the push rods - push rods [1 J

so they can b& - gasket [2)
placed back In their - two dowel pins (3]
original locations.

DISASSEMBLY
Remove the two rocker arm shaft retaining bolls [1] and
sealing washers 12].

Push each rocker arm shaft (1] with a small screwdriver ~==================~
through the bolt hole until the O-ring [2J on the shaft is
removed oul of the head cover.
Remove the following :
- rocker arm shafts
- rocker arms (3)
- setting plates [4]
- O-rings

[1 [

10-8
 CYLINDER HEADNALVE
INSPECTION
ROCKER ARM /SHAFT
Check the rocker arms and shafts for wear or damage.
If the rocker arm follower is worn or damaged , check
the push rod and oil passage.
Measure the each rocker arm shaft 0 .0 .
SERVICE LIMIT: 11 .92 mm (0.469 in)
Measure each rocker arm I.D.
SERVICE LIMIT: 12.05 mm (0.474 in)
Subtract the rocker arm shaft 0 .0 . from the
corresponding rocker arm 1.0. to obtain the rocker arm·
to-shaft clearance.
SERVICE LIMIT : 0.08 mm (0.003 in)

PUSH ROD
Check the push rods for wear or damage.
If the push rod is worn or damaged . check the cam
followe r and camshaft (page 10-20).

CYLINDER HEAD REMOVAL

Remove the following:
- throttle body (page 7·23)
- exhaust system (page 2·14 )
- thermostat (page 8-8)
- upper engine hanger nut and boll (frame side) [11
- upper engine hanger bolts (engine side) [2]
- engine hanger bracket 13J and mounting rubbers [4]
- cylinder head cover (page 10· 7)

- spark plug [1]

- ECT sensor [2J and O-ring
Disconnect the water hose (3J from the cylinder head.

10-9
CYLINDER HEADNALVE
Loosen the two cylinder bolts [11.
Se careful not to leI Loosen the cylinder head bolt and nuts [2] in a Jl.......::-l
the nuts and crisscross pattern in several sleps, and remove the bolt,
washers fal/lnto Iha nuts and washers.
crankcase.
Remove the cylinder head [3J. being careful nol to
damage the mating su rfaces.

Remove the gasket [1] and two dowel pins [2].

CYLINDER HEAD DISASSEMBLY

Remove the cylinder head (page 10-9).
To prevent loss of Remove the valve spring colters using the valve spring
/enslOfl, donal compressor 11].
compress the valve TOOL:
spnngs mote than
necessary. Valve spring compressor 07757.0010000

Marl< an lhe pans Remove the following:

so they can be
- spring retainer [1]
placed back in their
- outer and inner valve springs 12J
origms/Iocations.
- valve [3]
[2[
- stem seal [4]

"\~
- spring seat [5)

• [4[

10-10
 CYLINDER HEADNALVE
INSPECTION
CYLINDER HEAD
Be careful not /0 Remove the carbon deposits from the combustion
damage the valve chamber [1). I1-~~=:::::::=::;:=;;JI~'I~l
seal and gasket Check the spark plug hole and valve areas for cracks.
surfaces.

Check the cylinder head for warpage with a straight ~iillIII":~::~~=::"::~~::-"'"

edge and feeler gauge across the stud holes.

SERVICE LIMIT : 0.10 mm (0.004 In)

VALVE SPRING
Check the valve springs for fatigue or damage .
Measure the valve spring free length.
SERVICE LIMITS: Inner: 42 .08 mm (1 .657 in)
Outer: 42.76 rnm (1.683 in)

VALVEI VALVE GUIDE

Check that the valve moves smoothly in the guide.
Check the valve for bending. burning or abnormal wear.
Measure each valve stem 0 .0 . and record it.
SERVICE LIMITS : IN : 5.95 mm (0.234 in)
EX: 5.93 mm (0.233 in)

10-11
CYLINDER HEADNALVE
Ream the valve guides to remove any carbon build-up
before measuring the guide.
Insert the valve guide reamer [1) from the combustion
chamber side of the cylinder head and always rotate the
reamer clockwise.
TOOL :
Valve guide reamer, 6 mm 07VMH·MBB0200 or
07VMH·MBB020A
(U .S.A. only)

Measure each valve guide 1.0. and record it.

SERVICE LIMITS : IN/EX : 6.02 mm (0 .237 in)

Subtract each valve slem 0 .0 . from the corresponding
guide 1.0. 10 obtain the stem-to-guide clearance.
SERVICE LIMITS : IN : 0.12 mm (0.005 In)
EX : 0.14 mm (0.006 in)

Inspect and reface If the stem-to-gulde clearance exceeds the service limit,
the valve seats delermine if a new guide with slandard dimensions
whenever the valve would bring the clearance within tolerance . If so,
guides are rep/aced replace any guides as necessary and ream to fit.
(page 1(). 13). If the stem-to-guide clearance exceeds the service limit
with a new guide, also replace the valve.

VALVE GUIDE REPLACEMENT

Mark new valve guide al the specified height indicated
below, using a marker.
Chill the new valve guides in a freezer for about an
hour.
Be sure to wear Heat the cylinder head 10 130 - 140~ C (275 - 290°F)
heaV)' gloves 10 with a hot plate or oven. Do not heal the cylinder head
allOid bums when beyond 150· C (300· F). Use temperature indicator
handling the healed sticks, available from welding supply stores, to be sure
cylinder head. the cylinder head Is heated to the proper temperature.
Using a lorch 10
Support the cylinder head and drive the valve guides
heat the cylinder
out of the cylinder head from the combustion chamber
head may cause
side.
warpage.
TOOL:
(1) Valve guide driver, 6 mm 07942-6570100
Remove the new valve guides from the freezer.
While the cylinder head is still heated. drive each valve
guide in the cylinder head from the rocker arm side until
the exposed height is at the specified value (at the
mark).
TOOL:
(1) Val ve guide driver, 6 mm 07942-6570100

VALVE GUIDE PROJECTION :

IN/EX: 14.8 - 15.0 mm (0.58 - 0.59 In)
Let the cylinder head cool to room temperature.

10·12
 CYLINDER HEADNALVE
Use cutting oil on Ream the new valve guides.
the reamer during Insert the reamer from the combustion chamber side of
this operation. Take the cylinder head and always rotate the reamer clock-
care not /0 tilt or wise.
lean the reamer in
the guide while TOOL:
reaming. [1J Valve guide reamer, 6 mm 07VMH-MBB0200 or
07VMH-MBB020A
(U.S.A. only)
Clean the cylinder head thoroughly to remove any
metal particles after reaming and reface the valve seat
(page 10-13).

VALVE SEAT INSPECTION/REFACING

INSPECTION
Clean all intake and exhaust valves thoroughly 10
remove carbon deposits.
Apply a lighl coating of Prussian Blue to each valve
seat.
Tap the valve against the valve seat several times using
the hand-lapping tool [1] without rotating the valve. to
check for proper valve seat contact.

The valve cannot Remove the valve and inspeclthe valve seat face.
be ground. If the The valve seat contact should be wilhin the specified
valve face is burned seat width {1] and even all around the circumference.
or badly worn or if it
contacts the seat
STANDARD: 1.2 mm (0.05 in)
unevenly, replace SERVICE LIMIT: 1.5 mm (0.06 in) t
the valve
If the seat width is not within specification. reface the
valve seat. t
Inspect the valve seat face for:
Damaged face :
- Replace the valve and reface the valve seat.
Uneven seat width:
;t '"
1'1

- Replace the valve and reface the valve seal.

Contact area (100 high or too low)
- Reface the valve seat.
REFACING
Follow the refacing Valve seat cutters/grinders or equivalent valve seat
manufacturer's refacing equipment are recommended to correct worn
operating valve seats.
instructions.
Using a 45 0 seat cutter, remove any roughness or
irregularities from the seat. 45"
TOOLS :
Seat cutter, 40 mm (45" IN) 07780-0010500
Seat cutter, 33 mm (45" EX) 07780-0010800
Cutter holder, 6 mm 07VMH-MBB0100 , " 60'

or equivalent commercially available in U.S.A .

32"
,

10-13
CYLINDER HEADNALVE
TOOLS :
Flat cutler, 38.5 mm (32· IN) 07780'()012400
Flat cutter, 33 mm (32- EX) 07780'()012900
Cutler holder, 6 mm 07VMH·MBB0100

or equivalent commercially available in U.S.A.

TOOLS:
Interior cutler, 37.5 mm (60· IN) 07780.()014100
Interior cutler, 34 mm (60 0 EX) 07780'()014700
Cutler holder, 6 mm 07VMH·MBB0100

or equivalent commercially available in U.S.A.

After cutting the seat. apply lapping compound to the , -- - -- - - - ,
valve face . and lap the valve using a hand·lapping tool
[1] with a light pressure.
NOTE :
Excessive lapping pressure may deform or damage
the seat.
Change the angle of the lapping tool frequently to
prevent uneven seat wear.
Do not allow lapping compound to enter the guides.
After lapping , wash any residual compound off the
cylinder head and valve and recheck the seat contact.

CYLINDER HEAD ASSEMBLY

R:::::: _----.~~~~~~
S::~:E INN
/ EVALVE
R SPRING

OUTERVAlVESPRING ~ ~
;el
STEMSEAL/---~~ ~~

SPRING SEAT

VALVE GUIDE

b
INTAKE VALVE

--1 - - - - - EXHAUST VALVE

10-14
 CYLINDER HEADNALVE
Blow through the oil passage in the cylinder head with
compressed air.
Install the spring seats [1) and new stem seals [2J.

Lubricate the valve [1) stem sliding surface with ;:::==~~=~~111';';:"~~:"~

molybdenum oil solution.
Insert the valve into the guide while turning it slowly to
avoid damaging the stem seal.
Install the inner and ouler valve springs [2] with the
lightly wound coils facing the combustion chamber.
Install the spring retainer [3].

{1{

(21

Combustion chamber side

Grease the cotters Install the valve spring cotters using the valve spring ;:::=================;
/0ease installation. compressor [1).
To prevent loss of
tension, do not TOOL:
compross the valve Valve spring compressor 07757.0010000
springs more than
necessary.

10-15
CYLINDER HEADNALVE
Suppott the cyfinder Tap the valve stems gently with a hammer (1] and a
head so the valve shaft [2] as shown to seal the cotters firmly.
heads WIll not
Install the cylinder head (page 10-16),
COIIlact anything
thar could cause
damage.

CYLINDER HEAD INSTALLATION

Clean the mating surfaces of the cylinder and cylinder , -------,.-------cc-- -- -,
head, being careful not to damage them. $" [2)
Install the two dowel pins [1 ) and a new gasket (2) with
the mark facing up.

Install the cylinder head on the cylinder.

Be careful not to leI Apply engine oil to the threads and seating surface of 1"0 ":.::
lhenu/sand the cap nuts [lJ and flange nuts [21. and inslalilhe
washers faNinlO the washers [3] and nuts.
Ctankcase. Tighten the nuts to the specified torque in a crisscross
pattern in several steps. I-'=ii!"'~.
TORQUE : 48 N'm (4.9 kgf'm , 35 IbUt)

Inslalilhe cylinder head bolt [4) and lighlen it securely.

Tighten the two cylinder bolts 15] securely.

Connecl the waler hose 11110 the cylinder head.

Inslall a new O-ring (21 onlo Ihe ECT sensor 131
Install the ECT sensor and tighlen it 10 the specified
lorque.
TORQUE : 12 N'm (1 .2 kgf'm , 9lbHt)

Inslall the spark plug (4) and tighten ilia the specified
torque.
TORQUE: 22 N'm (2.2 kgf'm , 16 IbHt)

10-16
 CYLINDER HEADNALVE
In,'all'he mounting rubbers (1) onlo Ihe hange, b",ekel
bushing (2) with the large 1.0. side facing in.
I 111

Insert the 10 mm Install the engine hanger bracket with the 8-mm bolts
(frame sIde) boll [1J. 10-mm bolt (2) and nut [3J.
from the from side.
Tighten the engine hanger bolts and nut 10 the specified
torque.
TORQUE :
10 rnm nut: 54 N-m (5.5 kgf-m, 40 IbHt)
8 mm bolt: 32 N'm (3.3 kgf'm, 24 IbHt)
Install the following:
- cylinder head cover (page 10-17)
- throttle body (page 7-25)
- exhaust system (page 2-14)
- thermostat (page 8-8)

CYLINDER HEAD COVER ASSEMBL YI

INSTALLATION
ASSEMBLY

EXHAUST ROCKER ARM

SEnlNG PLATE

~
,f ,]
, ).., 1~
'-" (' I, '1,./_

tNT AKE ROCKER ARM

---------® A'*'
SEALING W A S H E R : - l 1
o
RETAINING BOLT / q
.:::.-

ROCKER ARM SHAFT \

O-RING

10-17
CYLINDER HEADNALVE
Blow through the oil passages in the cylinder head
cover with compressed air.
Coat new O-rings [1) with engine oit and install them
into the grooves in the rocker arm shafts (2).
Apply molybdenum oil solution to the sliding surfaces of
the rocker arm shafts.

11'$1 1
1

Place the setting plates IlIon the cylinder head cover ~==================~
as shown .

Install the intake rocker arm \lJ and exhaust rocker arm ~~~~=~~~~~~~~:::====;
12] properly, and Insert the rocker arm shafts.
NOTE :
Intake rocker arm has "IN" mark 131 and exhaust rocker
arm has "EX' mark (41 .

III 131
Align the bolt holes in the cylinder head cover and ~iiiiiiiiiiiiiliiiiiiiiiiiiii_r.::;::;;:;;"Ii[====~
rocker arm shaft by turning the shaft with a screwdriver.
Instailihe rocker arm shaft retaining bolts (11 with new
sealing washers (21 .
Tighten the retaining boits securely.

10-18
 CYLINDER HEADNALVE
INSTALLATION
Clean the mating surfaces of Ihe head cover and
cylinder head, being careful nollo damage them. {11
Install the push rods [1J onlo the cam followers.
Make sure the piston is TDC (Top Dead Center) on the
compression stroke by checking the push rod height
If the exhaust side push rod height is high. rolate the
crankshaft clockwise one fuiliurn and align the "r mark
with the index mark again.

Install the two dowel pins 111 and a new gasket [2].
Rest the push rods onto the gasket grooves [31 as
shown.

Apply engine oil to the rocker arm followers and

adjusting screw lips, and install the cylinder head cover
[11 I'(;~g~
Make sure there is no clearance al the mating surface
of the cylinder head and cover.
Install the eight bolls (2) and tighten them in a
crisscross pattern in several sleps.
Tighten the rocker arm shaft retaining bolts [3J securely.
Adjust the valve clearance (page 3-9).

Be careful not to Install the heat guard plate [1] onto the frame .
damage the fuel
[11
Route the hoses, cables and wires into the Clamps of

\
feed hose.
the heat guard plate properly (page 1-23).
Install the trim dip 12).

10-19
CYLINDER HEADNALVE
Install the ignition coil primary wire clip [1) to Ihe ignition
coil bracket 12].
Connecllhe ECT sensor 2P connector 13] and ignition
coil primary connectors {4].
Inslalilhe following:
- quick connect fitting (page 7-9)
- fuel lank (page 7-20)

CAMSHAFT REMOVAL
Remove the following:
- cylinder(page 11-4)
- primary drive gear (page 12-13)
Malt the followers Remove Ihe cam followers [1 J from the crankcase.
so they can be
plaaxi back in their
anginal iocallOfls.

Push in the tensloner lifter shaft [1] while pressing Ihe

ratchet pawl (2] and insert a pin into the hole [3] to hold
the tensionar lifter shaft.
Remove the two bolts [4) and cam chain tensioner lifter
151·

Remove the following:

- tensioner pivot bolt [1J
- cam chain tensioner [2]
- washer [3]

10-20
 CYLINDER HEADNALVE
~ bolt [1] and bearing setting plate (21

Remove the bearing of the camshaft [1] from the

crankcase. derail the cam chain [21 from the timing
sprocket [3] of the crankshaft. and remove the camshaft
and cam chain.

INSPECTION
CAMSHAFT
Check the cam lobe surfaces [1] for scoring . scratches ' -- - - - -13-1- - - - - - - -1-'-1- ----,
or evidence of insufficient lubrication .
Check the cam sprocket teeth {2] for wear or damage.
Turn the outer race of the bearing [3] with your finger.
The bearing should turn smoothly and quietly.
Replace the camshaft assembly if the bearing does nol
turn smoothly and quietly.

Measure each cam lobe height.

SERVICE LIMITS : IN : 35.74 mm (1 .407 in)

EX: 35.48 mm (1.397 in )

10-21
CYLINDER HEADNALVE
Check the decompressor cam [1 J operation.
Press on the decompressor cam as shown.
As you press on one side, Ihe decompressor cam
should lock above the base circle of the exhaust cam
lobe.
As you press on other side, Ihe decompressor lobe will
drop below the base circle of the exhaust cam lobe.

CAM CHAIN TENSIONER

Check Ihe slipper surface (1] of Ihe tensioner for wear , - - - - - -- - - - - -- -- - - - ,
or damage.

Check Ihe tensioner lifter operation:

- The tensioner lifter shaft should not go into the body
when it is pushed .
- When the ratchet pawl is pressed in , the tensloner
shaft should be pushed into the lifter body and Ihe
shaft springs out of the body.

CAM FOLLOWER
Check Ihe cam follower and follower bore for scoring,
scratches or damage.
Measure each follower 0 .0 .
SERVICE LIMIT: 22.46 mm (0.884 in)

10-22
 CYLINDER HEADNALVE
Measure each follower bore 1.0 .

SERVICE LIMIT: 22.54 mm (0.887 In)

Subtract each follower 0 .0 . from the corresponding
bore 1.0. to obtain the follower-Io-bore clearance.
SERVICE LIMIT: 0.07 mm (0.003 in)

CAMSHAFT INSTALLATION
Coverlhepiston Rotate the crankshaft to align the "r mark (IJ on the
[2[
with a shop lowe/or flywheel with the index mark [2] on the crankcase coyer.
6qufllolent /0
protect it from
damage.

(1)
I

Lubricate the camshaft bearing and journal with engine

L
~l====--=============::;
oil.
Apply molybdenum oil solution to the cam lobes.

.~

lubricate the cam chain [1) whole surface with engine

oil and install it on the cam sprocket.
- ,•
~==:::;:;;:=::;;;;;;;;;;;;;;;_ii;::;"iiiiiiiiiiiiiiii~
Loosely install the camshaft [2] into the crankcase.

10-23
CYLINDER HEADNALVE
Do not tum the line up the camshaft pin [1) and index mark (V ) [2] on
cmnkshaft during the crankcase with the sprocket hole facing up and
installation. instatlthe cam chain [3] over the timing sprocket (4] on
the crankshaft.
Install the camshaft into the crankcase completely and
make sure that the camshaft pin and index mark (\7)
line up.

Apply locking agent to the threads of the setting plate ~===="~IIIIIIIIIIIIIIIIIIIIIIII~~~~

bolt (1].
Install the bearing selling plate [2J onto the crankcase
and tighten the bolt securely.

Apply locking agent to the threads of the tensioner pivot

bolt ]1].
Install the washer 12J (in between the tensioner and
crankcase), cam chain tensioner (3J and pivot bolt, and
tighten the bolt to the specified torque.
TORQUE : 12 N'm (1.2 kgf'm , 9lbHt)

Push in the tensioner lifter shaft (1] while pressing the

ralchet pawl (21 and insert a pin (31 into the hole to hold
the tensioner lifter shaft.

10-24
 CYLINDER HEADNALVE
Apply locking agent to the threads of the tensioner lifter
bolt [1).
Install the tensioner lifter [2] and lighten the boits
securely.
Remove the pin from the tensioner lifter.
Make sure that the camshaft pin and index mark M
line up when the "r mark on the flywheel is aligned with
the index mark on the crankcase cover.

Be careful not to Apply engine oil to the whole surfaces of the cam
followers [IJ and install them into the crankcase with the
scratch rile sliding
surfaces of the opening facing up.
followers and
Install the following:
bores.
- change clutch (page 12~17)
- cylinder (page 11 -9)

10-25
MEMO
 11. CYLINDER/PISTON

SYSTEM COMPONENTS ·················· ·········· 11-2 CYLINDER/PISTON REMOVAL ·········· ·······11-4

SERVICE INFORMATION ··························· 11 -3 CYLINDER/PISTON INSTALLATION ········· 11-8

TROUBLESHOOTING·································11-3

11-1
CYLINDER/PISTON
SYSTEM COMPONENTS

/1

. 0

I
I
I '"'
! ~ ~I

11-2
 CYLINDER/PISTON
SERVICE INFORMATION
GENERAL
The cylinder and piston can be serviced with the engine installed in the frame.
Take care not to damage the cylinder wal! and piston.
Be careful not to damage the mating surfaces when removing the cylinder.
Rocker arm and valve lubricating oil is fed through the oil passage in the cylinder. Clean the oil passage before installing the
cylinder.

SPECIFICATIONS
Unit· mm (in)
ITEM STANDARD SERVICE LIMIT
Cylinder J.D. 92.000 - 92.010 (3.6220 - 3.6224) 92.10 (3.626)
I Out-of~round - 0.10 (D.004)
Taper f- ?10 (0.004)
, Warpage
-
0.10 (0.004)
Piston, Piston 0.0. at 15 (0.6) from bottom 91.970 91.990 (3.6209 - 3.6216) +--91.90 (3.618)
pis-ton pin, Piston pin hole 1.0. 19.002 19.008 (0.7481 0.7483) 19.04 (0.750)
piston ring Piston pin 0.0 . 18.994 19.000 (0.7478 0.7480) 18.9S (0.74S)
Piston-to-piston pin clearance 0.002 - 0.014 (0.000 1 - O.OOOS) 0.08 (0.003)
Piston ring end Top 0.15 0.30 (0.006 0.012) 0.5 (0.02)
9'P Second 0.30 - 0.45 (0.012 0.016) O.S (0.02)
Oil (side rail ) I 0.20 - 0.70 (0.008 0.026) 0.9 (0.04)
I Piston ring-to-ring Top 0.030 - O.OSO (0.0012 - 0.0024) 0.09 (0.004)
groove clearance Second 0.030 - O.OSO (0.00 12 - 0.0024) 0.09 (0.004)
Cylinder-to-piston clearance
Connecting rod small end 1.0.
0.010 0.040 (9..0004 - 0.0016)
I 0.10 (0.004)
19.020 - 19.041 (0.7488 - 0.749S) _ _+-~"9';.~07 (0.751)
,---C"ouon"n",e",C1",;n",9,-"",
ode:-"lo",-p";'~luo
on,-"p;"n-"'",,le"",,",,,n'V"""--_ _ _ _ _ _--L_0"'."'02="0 - 0.047 (0.0008 - 0.0019) 0.10 (0.004) -

TORQUE VALUE
THREAD TORQUE J
ITEM Q 'TY REMARKS
DIA. (mm) N·m (kgf·m , IbHt)
Cylinder stud bolt 4 10 12 (1 .2, 9) See page 11-8

TROUBLESHOOTING
Compression too low, hard starting or poor performance at low speed
Leaking cylinder head gasket
• Worn, stuck or broken piston ring
• Worn or damaged cylinder and piston
Compression too high , overheati ng or knocking
• Excessive carbon build-up on piston head or combustion chamber
Excessive smoke
Worn cylinder. piston or piston rings
• Improper installation of piston rings
• Scored or scratched piston or cylinder wall
Abnormal noise
Worn piston pin or piston pin hole
Worn connecting rod small end
• Worn cylinder. piston or piston rings

11·3
CYLINDER/PISTON
CYLINDER/PISTON REMOVAL
CYLINDER REMOVAL
Remove the cylinder head (page 10-7)
Remove the two bolts [1].
Do not use a Lift the cylinder [2) and remove ii, being careful not to
screwdriver or other damage the piston and piston rings with the stud bolts.
tool/o pry the
cylinder off as il
could damage the
mating surface.

Remove the gasket [1 J and the two dowel pins [2).

PISTON REMOVAL
Place a clean shop towel over the crankcase to prevent . - - -...- -
the piston pin clip from falling into the crankcase.
Remove the piston pin clips [1) with the pliers.
Push the piston pin [2] out of the piston and connecting
rod, and remove the piston [3].

Do not damage the

piston ring by
Spread each piston ring and remove it by lifting up al a
point opposite the gap.
~~~~~~~~~~~~~::~~~~~
spreading the ends
too far.

11-4
 CYLINDERIPISTDN
Never use a wire Clean carbon deposits from the ring grooves with a ring
brush, 11 will scratch that will be discarded.
the grooves.

/
(

INSPECTION
CYLINDER
Inspect the cylinder bore for scoring or scratches.
Measure the cylinder 1.0. at three levels in an X and Y
axis. Take the maximum reading to determine the
cylinder wear.
SERVICE LIMIT: 92.10 mm (3.626 in)
Calculate the cylinder-to-piston clearance. Refer to
page 11-6 for measurement of the piston 0 .0 .
SERVICE LIMIT: 0.10 mm (0.004 In)
Calculate the cylinder taper and out-of-round at three
levels in an X and Y axis. Take the maximum reading to
determine the taper and out-of-round.
SERVICE LIMIT: Taper: 0.10 mm (0.004 in)
Out-of-round : 0.10 mm (0.004 in)
The cylinder must be rebored and an oversize piston
fitted if the service limits are exceeded.
The 0.25 mm and 0.5 mm oversize pistons are
available.
The cylinder must be rebored so the clearance for an
oversize piston is 0.010 - 0.040 mm
(0.0004 - 0.0016 in).
Check the top of the cylinder for warpage with a straight
edge and feeler gauge across the stud bolt holes as
shown.
SERVICE LIMIT : 0.10 mm (0.004 i n)

11-5
CYLINDER/PISTON
PISTONfPISTON RING
Inspect the piston rings for smooth movement by
rotating them. The rings should be able to move in their
grooves without ca tching.
Push the ring untillhe outer surface of the piston ring is
nearly flush with the piston and measure the ring -la-ring
groove clearance.
SERVICE LIMIT: Top /Second : 0.09 mm (0.004 In)

squarely using the piston.

Measure the ring end gap.
SERVICE LIMITS : Top : 0.5 mm (0.02 in)
Second : 0.6 mm (0.02 in)
M'"
Insert each piston ring 111 into the bottom of the cylinder ;::=======1='=
•
1=========:;

Oil (side rail): 0.9 mm (0.04 In)

Measure the piston 0 .0 . at a point 15 mm (0.6 in) from

the bottom and 90· to the piston pin hole.

SERVICE LIMIT : 91 .90 mm (3.618 in)

Compare this measurement against the maximum

cylinder 1.0. measurement and calculate the piston-to-
cylinder clearance (page 11·5).

15mm
(D .6 in )

11-6 l
 CYLINDERIPISTON
Measure piston pin hole. Take the maximum reading 10 f
determine the J.D.
SERVICE LIMIT: 19.04 mm (0.750 in )
Measure the piston pin 0 .0. at three points.
SERVICE LIMIT: 18.96 mm (0.746 In)
Calculate the piston-to-piston pin clearance .
SERVICE LIMIT: 0.08 mm (0.003 in)

Measure the connecting rod small end 1.0.

SERVICE LIMIT : 19.07 mm (0 .751 in )
Calculate the connecting rod-to-piston pin clearance.
SERVICE LIMIT : 0.10 mm (0.004 In)

11-7
CYLINDER/PISTON
CYLINDER STUD BOLT
REPLACEMENT
Thread two nuts onto the stud and lighten them , - - - - -- -------------,
together, and use a wrench on them to tum the stud bolt
oul.
Install new stud bolts and lighten them to the specified
torque .
TORQUE : 12 N'm (1.2 kgf'm, 9lbHt)
Be sure to verify the stud height from the cylinder
mating surface of the crankcase.
Adjust the height if necessary.

CYLINDER/PISTON INSTALLATION
PISTON RING INSTALLATION
Carefully install the piston rings into the piston ring
grooves with the markings facing up. "RN" "R"
NOTE:
Do not confuse the lop (1J and second rings [2).
• To install the oil ring (3]. install the spacer [4] first,
then install the side rails [51 .
Stagger the piston ring end gaps 120 degrees apart
0

from each other.

Stagger the side rail end gaps as shown .

j
11-8
j
 CYLINDER/PISTON
PISTON INSTALLATION
Place a clean shop lowel over the crankcase to prevent r-...,.~::"I---'
the piston pin clip from falling into the crankcase.
Apply engine oil to the piston pin hole and connecting
rod inner surface.
Apply molybdenum oil solution to the outer surface of
the piston pin (1 ).
Install the piston (21 with the "IN" mark 131 loward the
intake side and Insert the piston pin through the piston
and connecting rod.
Install new piston pin clips [4] into the grooves in the
piston pin hole.

NOTE ~~~~~~::::~~~~~~~
Make sure that the piston pin clips [1J are seated r
securely.
Do nol align the piston pin clip end gap 12) with the
piston cutout 13\.

11 I

CYLINDER INSTALLATION
Clean the mating surfaces of the cylinder and ...~­
crankcase thoroughly, being careful nol to damage
them, and being careful not to allow gasket material to
enter the crankcase.
Blow through the oil passage in the cylinder with
compressed air.
Install the two dowel pins [1 ) and a new gasket [2].

Apply engine oil to the cylinder [1] wall, piston (2] outer ~::'~~~~~~';::;;:;:;~~~~~~
surface and piston rings (3).
Install the cylinder over the piston while compressing
the piston rings with your fingers.

11 -9
CYLINDERfPISTON
Make sure thai the cylinder touches the crankcase
evenly.
Install the two bolts [1).
Inslall the cylinder head (page 10-16).

11-10
 12. CLUTCH/GEARSHIFT LINKAGE

SYSTEM COMPONENTS .. ·· .. · .... · .. .. · .......... ·12-2 CENTRIFUGAL CLUTCH .......................... ·12-8

SERVICE INFORMATION .......................... ·12-3 CHANGE CLUTCH .................................. · 12-13

TROUBLESHOOTlNG .............. · .............. · .. ·12-5 GEARSHIFT LINKAGE ............................ ·12-19

FRONT CRANKCASE COVER

REMOVAL ...... · .. · .. · .. · ...... · .. ·· .. · .. · .. · ...... ·· ...... ·12-6
FRONT CRANKCASE COVER
INSTALLATION .......... .......... .............. ...... 12-23

..

12-1
CLUTCH/GEARSHIFT LINKAGE
SYSTEM COMPONENTS
FElFPE models shown:

118 N'm (12.0 kgf'm, 87 Ibf·ft)

\\
\
\
\

\\
\
\
\
\
108 N'm
(11 .0 kgf-m . ~ __
\
801bHt)

:----"";::7<:-r- 12 N·m
\
(1.2 kgf-m, 9Ibf.ft)

- j
~ \
22 N'm
(2.2 kgf'm, 16Ibf.ft)
'>
16 N'm
(1.6 kgf'm, 121bHt)

12-2
 CLUTCH/GEARSHIFT LINKAGE
SERVICE INFORMATION
GENERAL
This section covers service of the clutch (centrifugal clutch and change clutch) and gearshift linkage. To service the gearshift
spindles of the FMlFPM models and reverse stopper shaft, the engine must be removed from the frame .
The crankcase must be separated when the transmission, shift drum and shift forks require service (page 14-2).
Engine oil viscosity and level and the use of otl additives have an effect on clutch operation . Oil additives of any kind are
specifically not recommended. When the clutch does nol disengage or the vehicle creeps, inspect the engine oil and oil level
before servicing the clutch system.
Engine lubricating oil is fed through the oil passages in the front crankcase cover. Clean the oil passages before installing the
crankcase cover.
The FEiFPE models are equipped with the electric shift program (ESP). ESP service (page 23· 30).

SPECIFICATIONS
Unit: mm

clutch

gear

TORQUE VALUES
THREAD TORQUE
ITEM Q 'TY REMARKS
DIA. (mm) N'm (kgf'm, Ibf·ft)
Clutch spring bolt 4 6 13 (1.3 , 10)
Centrifugal clu tch lock nut 20 118 ( 12.0 , 87) Lock nut: replace with
a new one.
Apply engine oil to the
threads and seating
'--
Change clutch lock nut 1 18 108 (11 .D, 80)
surface. Stake.

:J
Lock nut: replace with
a new one.
Apply engine oil to the
threads and seating
surface. Stake.
I Shin drum stoppe' a,m p;,o' bott + -6 12 (1.2. 9) Apply locking agent to
the threads.
I
Gearshift cam bolt 1 6 16 (1 .6. 12) Apply locking agenllo
the Ihreads.
Gearshift spindle return spring pin 8 22 (2.2. 16) Apply locking agent to
the threads.
Gearshift spindle A stopper bolt (FM/FPM) 1 8 27 (2 .8. 20) Apply locking agent to
the threads.

12-3
CLUTCH/GEARSHIFT LINKAGE
TOOLS
Remover weight
07741-0010201
--------r-I Attachment, 32 x 35 mm
07746-0010100
Driver, 22 mm 1.0.
07746-0020100

or 07936-371020A or 0793&3710200
(U.S.A. only)
Pilot, 15 mm 'e::', - - - - - -------+"P'"
- - -- -----,f-D"":-: ul""e:O'.'3"5-:X;C'OC.Oi>Cmm~--------1
07746-0040300 07749-0010000 07933-HA80000

;;;;;---t--;= =====~~~_ _ + or 07933-HB3000A (U.S.A. only)

Bearing remover shaft, 1S- mm Bearing remover head, 15 mm Bearing remover, 15 mm
07936-KC10100 07936-KC10200 07936-KC 10500 (U .S.A. only)

CIUlch>C;;ce"o",e","h;oo'-'d"'e'C,- - -- -- +-,Clutch holder sel

07JMB-MN50302 07ZMB-HN20001

0' or 07ZMB-HN2A 101 (U.S.A. only)

07HGB-001010B or 07HGB-001010A
(U .S.A . only) with
07HGB-001020B or 07HG8-001020A
(U.S.A. only)

12-4 i
 CLUTCH/GEARSHIFT LINKAGE
TROUBLESHOOTING
Clutch slips when accelerating
Incorrect clutch adjustment (page 3·24)
Worn clutch discs
Weak clutch springs
Faulty clutch lifter
Improper oil viscosity or oil additive used
Clutch will not disengage
• Faulty clutch lifter
• Warped clutch plates
The vehicle creeps
• Faulty centrifugal clutch
Clutch operating feels rough
Worn clutch outer and center grooves
Warped clutch plates
Loose clutch lock nul
Faulty clutch lifter
Improper oil viscosity or oil level
Hard to shift
Incorrect clutch adjustment (page 3-24)
Worn or damaged gearshift linkage componen ts
Faulty clutch lifter
Improper engine oil viscosity
Faulty gearshift spindle
Faulty shift forks/shaft or shift d rum (page 14·6)
Transmission jumps out of gear
Broken shift drum stopper arm
Weak or broken shift linkage return springs
Worn or damaged gearshift cam
Faulty gearshift spindle
Faully shift forks/shaft or shift drum (page 14-6)
Faulty transmission gears (page 14-6)

12-5
CLUTCH/GEARSHIFT LINKAGE
FRONT CRANKCASE COVER
REMOVAL
Drain the engine oil (page 3-13).
Drain the coolant (page 8-7).
Remove the following:
- mudguards (page 2-6)
- front propeller shaft (page 19-12)
- FElFPE models only: shift control molor and
reduction gears (page 23-30)
Disconnect the waler hoses (1) from the front crankcase
cover.

Remove the following:

- fifteen bolls [lJ
- front crankcase cover (2)

- lifter cam plate [1 J

- two dowel pins [2)
- joint coliars and O-rings [3]
- O-ring [4]

- output shaft oil seal [IJ

- gearshift spindle oil seal (FElFPE models only) (2]

121

12·6
 CLUTCH/GEARSHIFT LINKAGE
CRANKSHAFT BEARING
REPLACEMENT
Check the crankshaft bearing [1J.
If the inner race does not turn smoothly. quietly. or if the
outer race fils loosely in the cover, replace the bearing
as follows.
Remove the crankshaft bearing with the special tools ,
TOOLS:
[2] Remo ver shaft, 15 mm 07936·KC1010a
[3] Remover head , 15 mm 07936·KC10200
[4] Remover weight 07741-0010201

U.S.A. TOOLS :
Bearing remover, 15 mm 07936·KC10500
Remover weight 07936·371020A or
07936·3710200
Apply engine oil 10 a new bearing .
Drive a new bearing squarely with the sealed side
facing down until it is fully sealed . I-_.- r

TOOLS :
11] Driver 07749-0010000
(2J Attachment, 32 x 35 mm 07746-0010100
(3J Pilot, 15 mm 07746"()040300

CLUTCH LIFTER
Check lhe clutch lifter plale assembly and cam plate for r..,,-- - -
wear or damage , replace them if necessary.
Remove the lock nut (1) and washer [2).

Remove Ihe adjusting bolUHfter plate assembly [1 ) and

O-nng [2) .
~~~~~~~!!!~~~~~
Remove the adjusting boll from the lifter plate
assembly.
Install the adjusting bolt into the lifter plate assembly.
Coat a new O-ring with engine oil and Install It onto the
adjusting bolt.
Instalilhe adjusting bolUlifter plate assembly by aligning
the groove with Ihe stopper pin [3]
Temporarily Install the washer and lock nut.

12-7
CLUTCH/GEARSHIFT LINKAGE
CENTRIFUGAL CLUTCH
REMOVAL
Remove the front crankcase cover (page 12-6).
Be careful not 10 Unslake the clutch lock nut (11.
damage lhe
crankshan threads

Hold the clutch drive plale using the special 1001 [I J and
loosen the lock nul 12].

TOOL:
Clutch holder set 07ZMB-HN20001
- holder plate 07ZMB-HN20101
- holder pin 07ZMB·HN20200

U.S.A. TOOL:
Clutch holder 07ZMB-HN2A 101

Remove the lock nut and washer PI.

Remove the centrifugal clutch assembly 111 using the ~=====

special tool.
TOOL:
[2] Puller, 35)( 1.0 mm 07933-HASOOOO or
07933-HB3000A
(U .S.A . only)

DISASSEMBLY/INSPECTION
ONE·WAY CLUTCH
You should be able 10 turn the clutch weight assembly .-1-'1- - - - - - - - - - - - - - - '
[I) counterclockwise smoothly, but the assembly should
nollurn clockwise.
Remove the clutch weigh t assembly from the clutch
drum (2] while turning it counterclockwise .

)
121

12-8
 CLUTCH/GEARSHIFT LINKAG E
CLUTC H DRUM
Check the weight contacting surface for scratches or
abnormal wear
Measure the drum 1.0.
SERVICE LIMIT: 150.4 mm (5.92 In)
Check the sprag clutch for abnormal wear, damage or
irregular movement.
Remove the sprag clutch [1] from the clutch drum.

[11

Check the sprag clutch contacting surface [1] for ~==--;;;;;;;;;;;;;;;;;;;;;. c----,
abnormal wear or damage.

DRIVE PLATE
Check the sprag clutch contacting surface [1) for
abnormal wear or damage
1

CLUTCH WEIGHT LINING

Replace the clUtch Measure the lining thickness
wfJlghfs as a set
SERVICE LIMIT : 1.3 mm (0.05 in)

12-9
CLUTCH/GEARSHIFT LINKAGE
CLUTCH SPRING
Remove the E·chps 111 uSing a screwdriver while [31
compressing the clutch spring 121.
Remove the following :
- outer plate (3)
- clutch spring
- inner plate [4J

Measure the clutch spring height.

SERVICE LIMIT: 2.84 mm (0.112 In)

WEIGHT SPRING
Replace the S(lnngs Check the weight springs [11 for wear or damage. 1
as 8 set. Remove the dutch weights [2J and springs from the
drive plale.

(2( (1)

Measure the spring length.

SERVICE LIMIT; 25.7 mrn (1 .01 in)

12·10
 CLUTCH/GEARSHIFT LINKAGE
ASSEMBLY
DRIVE PLATE
CLUTCH WEIGHTS

WEIGHT SPRINGS

CLUTCH SPRING

OUTER PLATE

CLUTCH DRUM

INNER PLATE

E-CUPS

SPRAG CLUTCH

Install with the Install the clutch weights [1] and springs [2] onto the , -- -- - - - -- -- - - - - - - ,
spring's open ends drive plate as shown. [t}
facing In

[21

InSlall the inner plate [1] with flange side facing up.
Install the clutch spring [2] with concavity side facing [1)
down .

[21

12-11
CLUTCH/GEARSHIFT LINKAGE
Install the outer plate [1] with the pins [2] facing up.
[11
Be careful not to
Inslall the E-clips [3J into the spindle grooves with its
damage the clutch gap facing towards the pin by using the phers while
weights while compressing the clutch spring
compressmg

Apply engine oil 10 the whole surface of the sprag dutch ~=============~.O~U=T~S~'=D=E~.~
(1] and the sprag dutch contacting surface of the clutch
drum.
Install the sprag dutch into the clutch drum with the
"OUT SIDE" mark facing up.

Apply engine oil the sprag clu tch contacting surface ~=================1:::;
10
of the drive plale boss.
Install the clutch weight assembly [1] while turning it
counterclockwise.

[11

INSTALLA T[ON
Sel the centrifugal clutch assembly (1] onto the , - - - - -
crankshaft by aligning the splines of the drive plate and
crankshaft, and the splines of the clutch drum and
primary drive gear.
Be careful not to Tap the drive plate 10 seat it.
damage the
crankshafi threads.
TOOL:
[2) Driver, 22 mm 1.0 . 07746.{)020100

12-12
 CLUTCH/GEARSHIFT LINKAGE
Install the washer (1].
And apply engine oil 10 the threads and seating surface
of a new lock nul [2) and install II.
Hold the drive plale of the centrifugal clutch assembly
with the special tool and tighten the lock nut to the
specified torque
TOOL:
(3) Clutch holder set 07ZMB ·HN20001
- holder plate 07ZMB· HN20101
- holder pin 07ZMB· HN20200

U.S.A. TOOL:
Clutch holder 07ZMB·HN2A101

TORQUE : 118 N'm (12.0 kgf'm, 87 Ibf·h)

Be careful not to Stake the lock nut into the crankshaft groove .
damage/he
Install the front crankcase cover (page 12-23).
crankshaft Ihreads

CHANGE CLUTCH
DISASSEMBLY
Remove the following:
- centrifugal clutch assembly (page 12-8)
- FEJFPE models: gearshift linkage (page 12-19)
- FMfFPM models: dutch lifter lever (page 12-20)
- lifter bearing (1] and collar [2]

Loosen the dutch spring bolts [1] in a crisscross pattern

in several steps, and remove Ihe bolls, lifter plale [2J
~~~;:!!;;=~=~::~~
and dutch springs [3].

12-13
CLUTCH/GEARSHIFT LINKAGE
Be careful nollo Unstake the clu tch cen ter lock nul [1).
damage/he
mainshaft threads

Install the clutch center holder 111 onlo the pressure ~;::;;:;;:;~
plale bosses with the four clutch spring bolts (2).

TOOL:
Clutch center holder 07JMB·MN50302

U.S.A . TOOLS :
Holder plate 07HGB-001010B or
07HGB·001010A
with
Holder collar A 07HGB-001020B or
07HGB-001020A
Hold the clutch center and loosen the dutch center lock
nut (3].
Remove the lock nul and washer [4].
Remove the following:
- clutch cen ter [1)
- clutch discs and plates [21
- pressure plale (3J

- thrust washer [1]

- clutch outer (2)

12-14
 CLUTCH/GEARSHIFT LINKAGE
- clutch outer guide [1]

Remove the pnmary drive gear

the crankshaft.
111 and washer 121 from ~~~~~~

INSPECTION
CLUTCH LIFTER
Tum the inner race of the lifter bearing
finger.
The bearing should tum smoothly and quietly_
111 with your F
FElFPE models shown: [1J

Replace if necessary.
Check the tifter cam plate [21, lifter plate (3] and oollar
[4) for deformation or damage

{4J
13J
CLUTCH SPRING
Replace the clutch Measure the clu tch spring free length
spnngs as a sel
SERVICE LIMITS : FM /FPM : 50.7 mm (2.00 in)
FElFPE : 45.3 rnm (1 .78 In)

12-15
CLUTCH/GEARSHIFT LINKAGE
CLUTCH DISC
Replace the clutch
discs and plales as
Check the clutch discs for signs of scoring 0'
discoloration.
I
s set Measure the clutch disc thickness.
SERVICE LIMIT: 2.3 mm (0.09 in)

CLUTCH PLATE
Replace the clutch Check the plates for discoloration .
diSCS and plates as Check the plate warpage on a surface plate using a
a sel feeler gauge.
SERVICE LIMIT: 0.20 mm (0.008 in)

CLUTCH CENTER
Check the clutch center and pressure plate for nicks,
Indentations or abnormal wear made by the plates.

CLUTCH OUTER
Check the pnmary driven gear teeth for wear or r - -- - - - - - - - - - -- - - - ,
damage.
Check the slots in the dutch outer for nicks, indentation
or abnormal wear made by the clutch discs.
Measure the clutch outer I D.
SERVICE LIMIT: 29.05 mm (1 .144 in)

12-16
 CLUTCH/GEARSHIFT LINKAGE
CLUTCH OUTER GUIDE
Check the outer guide for wear or damage .
Measure the clutch outer guide 1.0 . and 0 .0 .
SERVICE LIMITS : 1.0 .: 22.05 mm (0.868 In)
0 .0 .: 28.93 rnm (1 .139 in)

PRIMARY DRIVE GEAR

Check the gear teeth for wear or damage.
Measure the drive gear 1.0.
SERVICE LIMIT: 29.05 mm (1.144 in )

MAINS HAFT AND CRANKSHAFT

Measure the mainshaft 0 .0 at the clutch outer gUIde.

SERVICE LIMIT: 21 .93 mm (0 .863 in)

Measure the crankshaft 0 .0 . at the primary dnve gear.

SERVICE LIMIT: 28.93 mm (1.139 in)

ASSEMBLY
Apply engine oil to the primary drive gear Slidmg
surface of the crankshaft.
Install the thrust washer (11 and the primary drive gear
(2J onto the crankshaft.

12-17
CLUTCH/GEARSHIFT LINKAGE
Apply molybdenum oil solution to the inner and outer
surfaces of the clutch outer guide Pl.
Instalilhe outer guide onto the mainshaft (2).

Instalilhe clutch outer [11 and thrust washer (21

Coal the clutch discs with clean engine oil.

Ins/all the discs and Install the followi ng:
plaIa alternately. pressure plate [1]
-
staffing with a disc - clutch discs and plates 12]
Set/he outside - clutch center [4J
clutch dISC tabs mto
the Shallow slots (3)
In the dutch outer,

Install the washer [1 J to the malnshaft.

Apply engine oil 10 the threads and seating surface of a
new lock nul 12]. and install it. r.:;;......,..-
Install the clutch center holder [31 onlo the pressure
plate bosses with the four clutch spring bolts.
TOOL :
Clutch center holder 07JMB·MN50302

U.S.A. TOOLS :
Holder plate 07HGB..Q01010B or
07HGB.(I01 01 OA
with
Holder collar A 07HGB-001020B or
07HGB-001020A j
Hold the dutch center holder and tighten the lock nut to
the specified torque.
TORQUE : 108 N'm (11 .0 kgf'm , 80 IbUt)

12-18
 CLUTCH/GEARSHIFT LINKAGE
Be careful not to Stake the lock nul [1J into the mainshaft groove.
damage the
mamshaft fhrosds

Install the clutch springs [lJ and the lifter plate [2J Wtth ~=;;=::
the ·our mark facing out.
Install the clutch spring bolls [3] and lIghten them to the
specified torque In a crisscross paltern in several sleps.
TORQUE : 13 N'm (1.3 kgf'm, 10 IbHt)

Apply engine 01110 the lifter bearing 11], and install the
lifter collar [21 and bearing .
Install the following.
- FEJFPE models: gearshift linkage (page 12-22)
- FMfFPM models: liftarlever (page 12-22)
- litter bearing and collar
- centrifugal clutch assembly (page 12-12)

GEARSHIFT LINKAGE
REMOVAL
NOTE'
• To service the reverse stopper shaft. engine removal
is required (page 14-7).
Remove the centrifugal clutch (page 12-8).
Remove the following:
FElFPE models. - angle sensor (page 23-26)
- shift arm spring 111
- gearshift spindle assembly [2J and washer (3)

12-19
CLUTCH/GEARSHIFT LINKAGE
FMlFPM models: - clutch lifter lever (1)
- shift arm spring [2J
- return spring 13] and gearshift arm 14]
- washer [5)
To service the gearshift spindles 16J , remove the rear
crankcase cover (page 12-22).

- 0011[1)
- guide plate (2)

- gearshift plaia [1J

- FM/FPM models only: washer from the gearshift
spindle
- gearshift cam [2) (while holding stopper arm with a
screwdriver)

- bolt [1]
- stopper arm (2]
- washer (3)
- return spring (4]
- gearshift spindle return spring pin [5]

12-20
 CLUTCH/GEARSHIFT LINKAGE
INSTALLATION
Apply locking agent to the threads of the gearshift
return spring pin [1J.
Install the gearshift return spring pin and tighten it to the
specified torque.
TORQUE : 22 N·m (2.2 kgf'm , 16 1bHt)
Apply locking agent to the threads of the stopper arm
boll 121 .
Install the return spring [3], washer (41 (between the arm
and crankcase), stopper arm IS] and bolt, and tighten
the bolt to the specified torque.
TORQUE: 12 N'm (1 .2 kgf'm, 9lbHt)

Hold the stopper arm [1] with a screwdriver (2] and

install the gearshift cam [3] by aligning the pin hole (4)
with the dowel pin [5].

FM/FPM models only: Install the washer onto the

gearshift spindle
Inslallthe gearshift plate [1] onto the cam (2) as shown.
Install the guide plale [3] by aligning the tab with the
groove in the cam.

Apply locking agenllo the threads of the cam bolt (1).

Inslalilhe cam bolt and tighten it to the specified torque.
TORQUE : 16 N'm (1.6 kgf'm , 121bHt)

12-21
CLUTCH/GEARSHIFT LINKAGE
FEJFPE models: Install the washer (1 ) behind the gearshift plate and
insert the gearshift spindle assembly [2} into the
crankcase.
Align the relum spring ends (3) with the stopper pin [41.
Hook the shift arm spring [5) to the gearshift arm and
plate.
Install the angle sensor (page 23-28).

FMlFPM models Insert the gearshift spindle [1] from the rear crankcase ;"'''=~:::~~=~~~:':'~~~:':'~~~~
side, then instalilhe washer [21 in between the gearshift
plate [31 and crankcase.
Install the gearshift arm (4) and re turn spring (51.
aligning the spring ends with the stopper pin.
Hook the shift arm spring 16] to the gearshift arm and
plate.
Install the lifter lever £7] by aligning the wide groove with
the wide tooth of the splines.
Install the rear crankcase cover (page 13-9).
All models: Inslallthe centrifugal clutch (page 12-12).

171
GEARSHIFT SPINDLE A (FM/FPM
models only)
Remove the rear crankcase cover (page 13-6)
Remove the stopper bolt (1), washer 12) and gearshift
121 111 cg 141
spindle A 13] from the rear crankcase cover (4).
Remove the oil seal IS] from the rear crankcase cover.
Install a new oil seal.
Apply engine oil to the oil seal lip and Install the
gearshift spindle A.
Apply locking agent 10 the stopper bolt threads.
Install the washer and stopper bolt, and tighten the bolt.
TORQUE: 27 N·m (2.8 kg f 'm, 20 IbUt)
Install the rear crankcase cover (page 13-9)
131 tI~ 151

12-22
 CLUTCH/GEARSHIFT LINKAGE
FRONT CRANKCASE COVER
INSTALLATION
Clean the mating surfaces of the front crankcase cover
and crankcase thoroughly, being careful nol to damage
them.
Blow through the oil passages in the front crankcase
cover with compressed air.
Apply engine oil to the boss of the adjusting plate.

Install a new output shaft oil seal [1[ into the front
crankcase cover.
;:=~~===;::~~==~~::::~~
FElFPE models only: Install a new gearshift spindle oil
seal 12] into the front crankcase cover

Install the joint collars [1] and dowel pins [2].

Coal new O-rings 131 with engine oil and install them.
InSlalithe lifter cam plate 14].

Apply liquid sealant (TB1215 or equivalent) to the ~==

mating surface (shadowed area) of the front crankcase
cover as shown.

12-23
CLUTCH/GEARSHIFT LINKAGE
Apply engine oil to the tips of the oil seal 111.
Be careful nollo Install the crankcase cover 121. being careful not to
drop the lifter cam damage the oil seal lips.
plate.
Install the fifteen bolts (3] and lighten them in a
crisscross pattern in several sleps.

Connecllhe water hoses (lJ to the crankcase cover.

Inslallthe following:
- FElFPE models only: reduction gears and shift
control motor (page 23-31)
- front propeller shaft (page 19-37)
- mudguards (page 2-6)
Adjust the clutch system (page 3-24).
Fill the engine with recommended oil (page 3-13).
Fill and bleed the cooling system (page 8--6).
Check the engine oil level (page 3-12).

12-24
 13. ALTERNATORISTARTER CLUTCH

SYSTEM COMPONENTS .. ·· .. · .. · ................ ·· 13-2 RECOIL STARTER (Canada type) ............ 13-6

SERVICE INFORMATION .......................... ·13-4 ALTERNATOR STATOR ............................ 13-6

TROUBLESHOOTlNG .... · ...... · .................... ·13-5 FL YWHEEUSTARTER CLUTCH ............ · 13-11

13-1
ALTERNATOR/STARTER CLUTCH
SYSTEM COMPONENTS
U.S.A. type :

FElFPE models shown:

108 N-m (11 .0 kgf-m, 80 IbfftJ

13·2
 AL TERNATORISTARTER CLUTCH
Canada type:

FElFPE models shown:

t08N ·m(11 .0

13-3
ALTERNATOR/STARTER CLUTCH
SERVICE INFORMATION
GENERAL
This section covers service of the alternator stator, flywheel and starter clutch . To service these parts. the engine must be
removed from the frame (page 15-2).
Transmission lubricating oil is fed through the oil passages in the rear crankcase cover. Ctean the oil passages before installing
the cover.
For alternator stator inspection, see Battery/Charging System section (page 21 -10)
For starter motor servicing. see Electric Starter section (page 6-6).

SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Starter driven gear boss 0 .0 . 51 .705 - 51 .718 (2 .0356 - 2.0361) 51.69 (2.035)
= = =---'-
Crankshaft 0.0. at starter driven gear
I.D. ~._ _ _ -!--.;;31.946- 31 .962 (1 .2577 - 1.2583)
31 ,884 31 .900 (1 ,2553 - 1.2559)
31 .90 (1.256)
31.85 (1 .254)

TORQUE VALUES
THREAD TORQUE
ITEM C 'TY REMARKS
DIA. (mm) N'm (kgf'm , tbUt)
I Starter clutch bolt
~ Flywheel bolt (U.S,A. type)
6
+ 8

12
37 (3 .8. 27)

108 (11 .0, 80)

Apply tacking agent to
the threads.
Apply engine oil to the
threads and seating

FtywheeVdriven pulley bolt (Canada type) 1 12

I 108(11 .0. 80)
surface.
Apply engine oit to the

~644)
threads and seating
surface.
I CKP sensor boll 2 Apply locking agent to
the threads.

13-4
 AL TERNATORISTARTER CLUTCH
TOOLS
Flywheel holder Rotor puller Remover weight
07725-0040001 07733-0020001 07741-0010201

or 07933-3950000 or 07936-37 1020A or 07936-3710200

(U.S.A. only)
Attachment, 52 x 55 mm Attachment, 24 x 26 mm Pilot, 10 mm
07746-0010400 07746-0010700 07746-0040100

8
Pilot. 25mm Driver Bearing remover shaft, 10 mm
07746-0040600 07749-0010000 07936-GE00100

Bearing remover head , 10 mm Bearing remover, 10 mm Recoil pulley holder

07936-GE00200 07936-GEOAOOO (U .S.A. only) 07SMB-HM70100

TROUBLESHOOTING
Starter motor turns, but engine does not turn
Faulty starter clu tch
• Damaged starter reduction gear andlor driven gear

13-5
ALTERNATOR/STARTER CLUTCH
RECOIL STARTER (Canada type)
REMOVAUINSTALLA TION
Remove the mudguards (page 2-6),
Remove the following:
- four bolts 111 and clamp [2]
- recoil starter assembly [3}
Apply locking agent to the boll threads.
Instalilhe recoil starter assembly with the four bolts and
clamp, and lighten the bolts in a crisscross pattern In
several sleps.
Secure the wire with the cramp properly.
Install the mudguards (page 2-6).

STARTER ROPE REPLACEMENT

When the rope has Pull the starter rope (1) fully to align the rope holes in
broken or the pulley the drive pulley [2J and housing [3J, and secure the
I [4]
has rewound, align pulley with a vise pliers or equivalent 1001 to prevent Ihe
the rope holes by pulley from rewinding.
fUming the pulley 6-
Untie Ihe slarter rope and remove the rope.
112 tums
counterclockwise Insert a new slaner rope Ihrough Ihe pulley, housing
and hold it and grip (4], and tie the rope ends in a square knot. Sel
the pulley side rope end into the cavily as shown.

~
Carefully release the pulley and check the recoil slarter
for smooth operation by pulling the grip. Rope ends:

ALTERNATOR STATOR
REAR CRANKCASE COVER
REMOVAL 1
I
Remove the following:
- engine from the frame (page 15-4)
- Canada type only: recoil starter (page 13-6)
- FElFPE only: shift angle sensor (page 23-28)
Canada type. Hold the recoil starter driven pulley using the special , -- - -- - - - - - - - - - - - - - ,
tool and loosen the boll.
L
TOOL:
[ 1] Recoil pulley holder

13·6
 ALTERNATORISTARTER CLUTCH
Canada type: Remove the following:
bolt (1) and O-ring [2)
- driven pulley 131 ,'" (31
- oil seal [4]

The cover (stalor) is - thirteen bolls (1)

magnetically - rear crankcase cover [2)
aflracted to the
flywheel, be careful
during removal.

- two dowel pins [1]

- oil joint pipe and O-ring [2]
- countershaft thrust washer [3J
- reverse stopper shaft thrust washer (4]

- output shaft oil seal11J

- reverse lock lever oil seal [2)
- FElFPE models only: gearshift spindle oil seal [3]

13-7
ALTERNATOR/STARTER CLUTCH
STATOR AND CKP SENSOR
REMOVAL
Remove the following :
[3)
- two CKP sensor bolts (1]
- four stator bolts (2)
- grommet (3]
- slator/CKP sensor assembly [4]

[4[

STATOR AND CKP SENSOR

INSTALLAT[ON

.c:u:a "tmI.
Set the stator/CKP sensor assembly [1] onto the 0;::---:=- - - - --:[=2): -----:
alternator cover, (3)
::::,: ---
_

Apply seatanllo the sealing surface of the grommet [2]

and install the grommet into the cover groove securely,
\,\!'--l.>>¥""'~;':" ?"'''''''''
Apply locking agent to the threads of the CKP sensor
boll [3[ .
Install the stator bolts [4J and CKP sensor bolts, and
lighten them to the specified torque.
TORQUE :
CKP sensor bolt: 6.0 N'm (0.6 kgf'm, 4.4IbHt) [4J .....~:E:J:;~

[1 [

OUTPUT SHAFT BEAR[NG

REPLACEMENT
Turn the inner race of the bearing 11] with your finger.
The bearing should turn smoothly and quietly.
Also check that the bearing outer race fits tightly in the
rear crankcase cover.
Replace the bearing if the inner race does not turn
smoothly, quietly or if the outer race fits loosely in the
cover.
Drive the bearing out of the cover.
Apply engine oil to a new bearing .
Drive the bearing into the cover with the marked side
facing up.
TOOLS :
Driver 07749..()010000
Attachment, 52 x 55 mm 07746-0010400
Pilot, 25 mm 07746"()040600
!

13·8
1
 ALTERNATOR/STARTER CLUTCH
REAR CRANKCASE COVER
INSTALLATION
Clean the mating surfaces of the crankcase and rear
crankcase cover thoroughly, being careful nol to
damage them.
Blow through the oil passage in the rear crankcase
cover with compressed air.
Install the following:
- new output shaft oil seal [1]
- new reverse lock lever oil seal (2)
- FE/FPE models only: new gearshift spindle oil seal
131
Apply engine oil to the oil seal lips.

Apply liquid sealant (T81215 or equivalent) to the ;::=====~~~~~~~

mating surface (shadowed area) of the rear crankcase I
cover as shown.

Install the two dowel pins [1] and oil joint pipe 12].
Coat a new O-ring [3) with engine oil and install it onlo
the oil joint pipe.
Install the thrust washers (4J onto the countershaft and
reverse stopper shaft.

Shift the transmission into neutral to align the groove in ~~~~111~=~~~~~~=

the shift drum [1J with the lug [2J on the crankcase.
Align the long end (3] of the gear position switch pin / ~""\. [31
with the "N" mark [4J (lug [5]) on the rear crankcase
cover.
The cover (stalor) is Install the rear crankcase cover aligning the switch pin
magnetically with the shift drum groove properly, being careful not to
anracled to the damage the switch pin and oil seal lips.
"ywheel, be careful
not to get anything NOTE·
caught between FMfFPM models only: Align the arm of gearshift -,...
Ihese parts when 'Phindl~ A, W,,!th t,hhe arm hole in the gearshift spindle 7"-"1~':~
,'-'>
installing. w en inS a mg e cover.
Itl 141 151
If the cover doesn't install easily, remove it and check '-'--'--_ __ _ _ _ _---'--'-_ _ _ _ _ _-'-'~
Ihe alignment of the switch pin and the shift drum or the
switch for damage.

13·9
ALTERNATOR/STARTER CLUTCH
After installing the crankcase cover, make sure that the
oil seals in the cover are nol turned inside out.
Install the thirteen bolls [11 and tighten them in a
crisscross pattern in 2 or 3 sleps.

Canada type ' Apply specified grease to the lips of a new oil seal (1]
and inslall it into the crankcase cover unlil it is fully
sealed .
SPECIFIED GREASE: Mobilith SHe 100 (EXXON)

Coal a new O-ring 12] with engine oil and install it onto
the pulley bolt nanga.
[3[
Apply engine oil to the threads and sealing surface of
the pulley boll (3).
Install the driven pulley (4] with the bolt, aligning the
bosses with the grooves in the crankshaft.
1
Canada type: Hold the driven pulley using the special tool and tighten
thebett.

TOOL :
(1] Recoil pulley holder 07SMB·HM70100

TORQUE: 108 N'm (11 .0 kgf'm , 80 Ibf-ft) \ (

\

Install the following:

- FElFPE only: shift angle sensor (page 23· 28)
- Canada type only: recoil starter (page 13·6)
- engine into the frame (page 15·9)

13-10
 ALTERNATOR/STARTER CLUTCH
FL YWHEELISTARTER CLUTCH
REMOVAL
Remove the rear crankcase cover (page 13-6),
Remove the starter reduction gear shaft [1] and gear
{2{ .

U.S.A. type: Hold the flywheel using the special 1001111 and remove
the flywheel bolt 121 and collar (3J .
TOOL:
Flywheel holder 07725-0040001

Hold the f1~heel [1 J and remove it from the crankshaft 1":'::""11"""'::;;;;;0

using the speciallools.

TOOL:
(2) Rotor puller 07733-0020001 or
07933·3950000

Remove the woodruff key [1] from the crankshaft.

13-11
AL TERNA TOR/STARTER CLUTCH
STARTER CLUTCH DISASSEMBLY
Make sure that the starter driven gear (1] turns r c-- - -- - - - - - - - - - - - - - ,
dockwise smoothly and does not turn l1 I
counterclockwise.
RemOlle the driven gear while turning it clockwise. $

Hold the flywheel with the special tool (11 and remove 11)
the starter clutch bolts (T40) [2].

TOOL:
Flywheel holder 07725-0040001
Remove the starter clutch assembly from the flywheel.

121
INSPECTION
Check the starter driven gear teeth for wear or damage. , - - - - - - -- - - -- ------,
Measure the driven gear boss 0.0. and 1.0.
SERVICE LIMITS : 0 .0 .: 51 .69 mm (2 .035 In)
1.0.: 31 .90 mm (1 .256 In)

Measure the crankshaft 0 .0 . at the starter driven gear.

SERVICE LIMIT: 31 .85 mm (1 .254 in)

13·12
J
 ALTERNATORlSTARTER CLUTCH
Remove the sprag clutch [lJ from the clutch outer (2J.
Check the starter clutch outer and sprag dutch for
abnormal wear or damage.

(11

Check the starter reduction gear and shaft for wear or ~================;
damage,

STARTER CLUTCH ASSEMBLY

Lubricate the sprag clutch [1J with engine oil and install , - - - - - - -- - -- - - - - - - - - ,
it into the clutch outer [2J with the flange facing the
flywheel side.
Inslalithe starter clu tch onto the flywheel.

Apply locking agent to the threads of the starter clutch ~12=1===============~

(T401 bolt (11.
Align the bolt holes in the flywheel and staner clutch ,
and inslalilhe bolts.
Hold the flywheel with the special tool [2] and tighten
the bolts to the specified torque.
TOOL;
Flywheel holder 0772S'{)040001

TORQUE : 37 N'm (3.8 kgf'm , 27 IbHt)

13-13
ALTERNATOR/STARTER CLUTCH
Install the starter driven gear (1] while turning it
clockwise. 11 I

INSTALLATION
Install the woodruff key [1] into the key groove.
Apply molybdenum oil solution to the starter driven gear
sliding surface of the crankshaft.
Clean any oil from the tapered portions of the
crankshaft and flywheel.

Apply engine oil to the starter driven gear boss inner

surface.
Instalilhe flywheel ttl aligning the key way with the key
on the crankshaft.

u.S.A. type: Apply engine oil to the threads and seating surface of
the flywheel bolt [1] and install it with Ihe collar 121.
Hold the flywheel using the special tool 131 and lighten
Ihe flywheel bolt.
TOOL:
Flywheel holder 07725-0040001

TORQUE : 108 Nom (11 .0 kgf·m, 80 IbHt)

13-14
 ALTERNATOR/STARTER CLUTCH
Canada type: Temporanly tighten the pulley bolt to seal the flywheel
as follows.
Apply engine oil to the threads and sealing surface of
the pulley bolt [t).
Install the driven pulley (2] . aligning the bosses wi th the
grooves in the crankshaft, and secure it with the bolt.
Hold the driven pulley using the special tool and tighten
the bolt. ,
TOOL:
(3] Recoil pulley holder 07SMB·HM70100

TORQUE: 108 N'm (11 .0 kgf'm , 80 IbHt)

loosen the pulley bolt. Remove the tool, bolt and
pulley.
Apply molybdenum oil solution to the starter reduction
gear shaft [11.
Apply engine oil to the reduction gear teeth [2] .
Inslalithe gear and shaft.
Inslall the rear crankcase cover (page 13-9).

13·15
ALTERNATOR/STARTER CLUTCH
STARTER MOTOR BEARING
REPLACEMENT
Remove the rear crankcase cover (page 13-6).
Remove the starter reduction gear shaft 111 and gear
(21.
Turn the inner race of the bearing [3] with your finger.
The bearing should turn smoothly and quietly.
Also check that the bearing outer race fits tighlly in the
rear crankcase cover.
Replace the bearing if the inner race does not turn
smoothly, quietly or if the outer race fits loosely in the
cover.
Remove the bearing using the special tools.
TOOLS :
Bearing remover shaft, 10 mm 07936-GE00100
Bearing rem over head, 10 mm 07936-GE00200
Remover weight 07741-{l010201

U.S.A. TOOLS:
Bearing remover, 10 mm 07936-GEOAOOO
Remover weight 07936·371020A or
07936·3710200
Apply engine oil to a new bearing.
Drive a new bearing into the crankcase with the marked
side facing out. using the special tools.
TOOLS :
Driver 07749-{l010000
Attachment, 24 x 26 mm 07746-{l010700
Pilot, 10 mm 07746-{l040100
Apply molybdenum oil solution to the starter reduction
gear shaft, and install the gear and shaft.
Install the rear crankcase cover (page 13-9).

13-16
 14. CRANKCASEfTRANSMISSION/CRANKSHAFT/BALANCER

SYSTEM COMPONENTS· ...... · .. · ...... · .. · .... · .. 14-2 TRANSMISSION ...... · .................................. 14-8

SERVICE INFORMATION .......................... ·14-3 CRANKSHAFT/BALANCER · .. · .. · .......... · .. · 14-15

TROUBLESHOOTING··.... · .... ·.... · .... ·.... · ...... 14-6 CRANKCASE BEARING .......................... 14-18

CRANKCASE SEPARATION ...... ·· ...... ........ 14-7 CRANKCASE ASSEMBLY ...................... · 14-21

14-1
CRANKCASEITRANSMISSION/CRANKSHAFT/BALANCER
SYSTEM COMPONENTS

14-2
 CRANKCASEITRANSMISSION/CRANKSHAFT/BALANCER
SERVICE INFORMATION
GENERAL
The crankcase halves must be separated to service the transmission and crankshaft. To service these parts . the engine must be
removed from the frame (page 15-4).
Be careful not to damage the crankcase mating surfaces when servicing.
Engine lubricating oil Is fed through the oil passages in the crankcase. Clean the oil passages before assembling the crankcase
halves.

SPECIFICATIONS
_____ ITEM \1~==:::::;:::~ _~:::;;;::;:::::;;::.;;~~.
STANDARD --::::===~
,. Unit:LIMIT
SERVICE mm (in).
Shift fOrk.~D Front. rear 13.000 13.021 (0.5118 - 0 5126) 1304 (0 51=!)
Center 13.000 13.018 (0.5118 - 0.5125) 13.04 (0.513)
Claw thic'kko:e:,:,=~~~~== 4.93 5.00 (0.194 0.197) 4.5 (D.'!!)
I--= = = =_ - ;Shaft O.~ 12.966 12.984 (0.5105 - 0.5112) 12.96 (0.510)
Transmission Gear 1.0 . M3 25.000 25.021 (O.9843 - 0.985 1) 25.05 {O.9861_
M5 20.000 20.021 (0.7874 - 0.7882) 20.05 (0.789f
C1 , C2. C4 , CR 28.020 28 .041 (1.1031 - 1.1040) 28 .07 (1 .105)
Reverse idle 13.000 13.021 (0.5118 - 0.5126) 13.04 (0. 51~)
Gear bushing M3 24.959 24 .980 (0.9826 - 0.9835) 24.93 (0.981)
0 .0 . M5 19.966 19.984 (0.7861 - 0.7868) 19.94 (0.785)
C2 27 .984 28.005( 1'.1017-1 .1026) 27.94(1 .100)
C1 , C4 , CR 27.979 28.000 (1 .1015-1.1024) 27.93 (1 .100)
r---Gear-Io-bushing M3 0.020 0.062 (0.0008 - 0.0024) 0.10 (0. 004 )t-_--1
clearance M5 0.016 0.055 (0.0006 - 0.0022) 0.10 '({f""{}Q4

r
C2 0.015 - 0.057 (0.0006 - 0.0022) 0.08 (0.003)
C1, C4. CR 0.020 0.062 (0.0008 0.0024) 0-:10 (0.QQ±l
Gear bushing 1.0. M3 22.000 22.021 (0.8661 0.8670) 22.04 (0 .868)

M5
~=",,,_+-;;'i'C4, 1---:==~!lr7.~01~6~-~'
~7~.0~34~(0~
25.000 - 25.021 . 66;.9:9~0].6;706~)==~:17.06
(0.9843 - 0.9851) 25.05 (0.672)
(0.986) I

Malnshaft 0 .0 . at M3 21 .959 - 21 .980 (0.8645 - 0.6654) 21 .93 (0.863)

at M5 16.976 -16.987 (0.6683 - 0.6688) 16.93 (0.667)
Cou::;nl"'e:;o
"iCha'"ft~O".o'.-+
I at C4 --+--i2T4.ii95'"9~24.980 (0.9826 - 0.9835) 24 .93 (0.981)
Reverse idle shaft 0 .0 . 12.966 -12.984 (0.5105 - 0.5112) 12.94 (0.509)
. M3 0.020 - 0.062 (0.0008 - 0.0024) 0.10 (0.004)

~
BUShing_tO-Shaft
clearance M5 0.029 - 0.058 (0.0011 - 0.0023) 0.10 (0.004)
C4 0.020-0.0620.0008 - 0.0024) 0.10 (0.004)

Crankshaft
Reverse idle gear-to-shaft
Runoul
clearan",c",e'=1~
-
0~.0~'6~-;0~.0~S:5:10:.~00~0~6~-:0~.~00~2~2~)===S0.15
O. 10 (0.004)
(0.006)
Big end side clearance 0.05 - 0.65 (0.002 - 0.026) 0.8 (0.03) -
Big end radial clearance 0.006 - 0.018 (0.0002 - 0.0007) 0.05' (0.002)

TORQUE VALUE
ITEM Q'TY THREAD TORQUE REMARKS
,c;o.;= , . -- --'- -.,_+-coO"IA,,·t1m=mL) -t~
N .m (kgf'm , Ib"-
'.ft,,)' -i--,====== c-'
Mainshaft bearing selling plate bolt 2 6 12 (1 .2. 9) Apply locking agent to
the threads.

14-3
CRANKCASEITRANSMISSION/CRANKSHAFT/BALANCER
TOOLS
I Universal bearing puller Remover weight Attachment, 32 x 35 mm
07631-0010000 07741 -00 10201 07746-0010100

orequivalenl commercially available in or Q7936·371020A or 07936·3710200

I U.S.A.
Attachment, 37 x 40 mm
=-______~~(U~.S~.~A=.o=n~'y) ~~--------~..,~~,.~~~--------~
Attachment, 42 x 47 mm Attachment, 62 x 68 mm
07746-0010200 07746-0010300 07746-0010500

Attachment, 72 x 75 mm ----------hp>Oi"'o't,<'<s-;;m"m;;-- - - Pilot, 17 mm

07746-0010600 07746-0040300 07746-0040400

Pilot, 2n
O"m;;;m;;-----------------+-CPi""o"t,·2"SCOm
;;;mo;;-----------------t--·Pi"lo"t, 3'"'S-;;m;;;m
; ;---------------
07746-0040500 07746-0040600 07746-0040800

I I

14-4
 CRANKCASEITRANSMISSION/CRANKSHAFT/BALANCER
Pilot, 40 mm Pilot. 22 mm Driver
07746-0040900 07746-004 1000 07749-0010000

-'S~pe~a~·a~ln~"",-------------------r'P>'""lIers~h~a'ft-------------------r'R~e~mo~,~e~'h~a~n~d~leC---
07931-HB3020A (U.S.A. only) 07931-ME4010B (U.S.A. only) 07936-3710 100

:J
Bearing remover, 17 mrn
07936-3710300
Bearing remover, 20 mm
07936-3710600 TI BeaMng ..mo,., shaft, 15 mm
Q7936-KC10100

Bearing remover head, 15 mm Beanng-o'e=m

=o='''eO"',' I''S-Om=m=-----------j-' Attachment. 45x50 mm
07936-KC10200 07936-KC1 0500 (U.S.A. only) 07946-6920100

Assembly collar ------------r,P~"'"""ershaftand'cn="71-------------+-.

Th='=e=ad7e~d~a~d~a=pl~.='---
07965-VM00100 Q7965-VM00200 07965-VM00300

or 07931-KF00200 (U .S.A. only)

14-5
CRANKCASEITRANSMISSION/CRANKSHAFT/BAlANCER
Attachment, 78 x 90 mm Pilol, 32 mm
07GAO-S040101 07MAD-PR90200

11

TROUBLESHOOTING
Excessive engine noise
Worn , seized or chipped transmission gears
Worn transmission bearings
Worn connecting rod big end bearing
Worn crankshaft. main journal bearing
Worn balancer bearing
Improper balancer installation
Transmission Jumps out of gear
Worn gear dogs or dog holes
Worn shift drum guide groove
Worn shift fork guide pin
Worn gear shifter groove
Worn shift fork
Bent shift fork shaft
Faulty gearshift linkage (page 12-5)
Hard to sh ift
Damaged shift fori<:;
Benl shift fork shaft
Damaged shift fork guide pin
Damaged shift drum guide groove
Benl gearshift spindle
Faulty gearshift linkage (page 12-5)
Abnormal vibration
• Improper balancer timing

14-6
 CRANKCASEITRANSMISSION/CRANKSHAFT/BALANCER
CRANKCASE SEPARATION
Remove the following:
- engine (page 15-4)
cylinder head (page 10-9)
cylinder and piston (page 11-4)
gearshift linkage (page 12.19)
change clutch (page 12-13)
oil pump (page 9-4)
flywheel and starter clutch (page 13-11)
reverse stopper shaft assembly 11]
output shaft drive gear [2J, driven gear [3J and output
shaft [4]

- two front crankcase bolts [1]

Loosenthe - fifteen rear crankcase bolls (1)

crankcase bolts in a
Place the crankcase assembly with the rear crankcase
cnssClOSS pattem in
down.
several steps.

Do not PlY the Remove the front crankcase while tapping It at several
cnmkCBS6 apart locations with a soft hammer.
with a screwdriver. Remove the three dowel pins (1).
Remove any sealant material from the crankcase
mating surfaces.

111

14·7
CRANKCASEITRANSMISSION/CRANKSHAFT/BALANCER
OIL STRAINER CLEANING
Remove the oil strainer (1] and strainer plate (2).
Wash the strainer thoroughly in non-flammable or high
flash point solvent unlil all accumulated dirt has been
removed.
Blow dry the strainer with compressed air completely.
Before installing the strainer, the screen mesh should
be examined closely for damage.
Install the strainer and plate with the wedge facing the
crankcase.

[2[

TRANSMISSION
DISASSEMBLY
Separate the crankcase (page 14-7).
Remove the following:
- shift fork shaft [1]
- shift forks [21
- shift drum [3J

- reverse idle shaft [1) and idle gear [2J

PoSitlOfllhe crank - mainshaft (1], countershaft [21 and washer [3J as an ~~~~~~~~~~=I.I:~IIIl~~~
weights so rnat they assembly
do not interfere with
the m8inshat!
gears.

14-8 j
 CRANKCASEITRANSMISSIONfCRANKSHAFTfBALANCER
Do not expand the Disassemble the mainshaft (1) and counlershaft (2].
snap ring more thall 1'1
Clean all disassembled parts in solvent thoroughly.
necessary for
removal. NOTE:
Keep track of the disassembled parts (gears,
bushings. washers and snap ring) by sliding them
onto a 1001 or slipping them onto a piece of wire.

111
INSPECTION
GEARIBUSHINGISHAFT
Check the shifter groove [1) for abnormal wear or r - - -- -- - -1c31:---
:- - -- - ---:cIc':-I'
damage .
Check the gear dogs [21. dog slots [3) and teeth for
abnormal wear or damage.

Measure the 1.0. of each gear.

SERVICE LIMITS :
M3 : 25.05 mm (0.986 in)
M5: 20.05 mm (0.789 in)
C1, C2, C4, CR : 28.07 mm (1 .105 in)
Reverse idle: 13.04 mm (0 .513 i n)

Measure the gear bushing 0 .0 .

SERVICE LIMITS :
M3 : 24.93 mrn (0.981 i n)
M5: 19.94 mrn (0.785 in)

-8-
C2 : 27.94 mm (1 .100 in)
C1 , C4, CR : 27.93 mm (1 .100 in)
Calculate the gear-to-bushing clearance.
SERVICE LIMITS:
M3, MS, C1 , C4, CR: 0.10 mm (0.004 in)
C2 : 0.08 mm (0.003 in)
Measure the gear bushing 1.0 .
SERVICE LIMITS:
M3: 22.04 mm (0.868 in)
MS: 17.06 mm (0.672 In)
C4: 25.05 mm (0.986 in)

14-9
CRANKCASEfTRANSMISSION/CRANKSHAFT/BALANCER
Check the mainshaft and counlershafl for abnormal
wear or damage.
Measure the shaft 0 .0 . [31

SERVICE LIMITS:
At M3(11 : 21 .93 mm (0.863 in)
At M5 (21 : 16.93 mm (0.667 in)
At C4 [31 : 24.93 mm (0.981 in)
Reverse Idle: 12.94 mm (0.509 in)
Calculate the bushing-(O+shatt clearance.
SERVICE LIMIT: 0.10 mm (0.004 in) [1[ 12[

OUTPUT SHAFT/GEAR
Check the output shaft drive gear [1), driven gear (2]
13[
teeth and each gear, output shaft [3] splines for
abnormal wear or damage.

SHIFT FORK/SHAFT
Check the shift forks for abnormal wear or damage.
Measure each shift fork 1.0.
SERVICE LIMIT: 13.04 mm (0.513 in)

Measure the claw thickness of each shift fork.

SERVICE LIMIT: 4.5 mm (0.18 in)

Check the shift fork shaft for damage or bending .

Measure the shift fork shaft 0 .0 .
SERVICE LIMIT: 12.96 mm (0.510 in)

14·10
J
 CRANKCASEITRANSMISSION/CRANKSHAFT/BALANCER
SHIFT DRUM
Check the gUide grooves [l J for abnormal wear or r-----------c-11~1----------,
damage.
Check the shift drum journals for scoring. scratches or
evidence of insufficienllubrication.

ASSEMBLY
NOTE
Always install the thrust washers and snap ring with
the chamfered (rolled) edge facing away from the Ends aligned Ends aligned
thruslload. with grooves with splines
Install the snap ring 111 so its ends aligns With the
grooves in the splines.
Make sure the snap ring is fully seated in the shaft Correct Incorrect
groove after installing it
Clean all parts in solvent and dry them thoroughly.
Apply molybdenum oil solutIOn to lhe gear and bushing
sliding surfaces.
Assemble lhe mainshaft and counlershaft.

[11

14-11
CRANKCASEITRANSMISSION/CRANKSHAFT/BALANCER
MAINSHAFT

M3 BUSHING
THRUST WASHER

M5 GEAR (33T)

\
M2IMR GEAR (18T) SPECIAL WASHER

MAINSHAFT

r
M5 BUSHING

THRUST WASHER

SNAP RING
M4 GEAR (28T)
MS GEAR (33T )
SPLINE WASHER
M4 GEAR (28T)

M3 GEAR (23T)
M3 GEAR (23T)

---"78 :Gear and bushing sliding surfaces

SPLINE WASHER SNAP RING

Washer and snap ring direction:

14-12
 CRANKCASEITRANSMISSION/CRANKSHAFT/BALANCER
COUNTERSHAFT

C 1 GEAR (SST)
CR GEAR (48T)

C21CR GEAR SHIFTER l

C2 GEAR (43T)

~
,~ ,

THRUST WA:SHE.R

C4 GEAR (33T)
C3 GEAR (37T) -+- '11('
SPLINE COLLAR
C1 GEAR (SST)
C4 GEAR (33T)
CR GEAR (48T )
C3 GEAR (37T)
C2 GEAR (43T) C5 (28T)

~ : Gear and bushing sliding surfaces

THRUST WASHER

Washer direction:

14-13
CRANKCASEITRANSMISSION/CRANKSHAFT/BALANCER
Check the gears for freedom of movement or rota tion
on the shaft.
121
Apply engine oil to the journals of the mainshaft [1 J and
counlershaft [2].
Engage the mainshaft and counlershaft gears.

111
Position the crank weights so Ihalthey do not interfere
with the mainshaft {1].
;:'===:==========:=::====
Inslall the mainshaft, counlershafl. [2] and washer (3]
assemblies as a set into the rear crankcase.

Apply molybdenum oil solution to the sliding surface of , ...... ..

the reverse idle gear [11.
Install the reverse idle gear and shaft [2] .

Each shift fork has an identification mark; "RR" [1] for ~"""IIIIIIIIIIIIIIIIII"""'IIIIIIIIIIII"""'::~=~=I11111~==~
Ihe rear fork . ·C· (2) for the center fork and "FR" [3] for
the front fork.

14·14
 CRANKCASEITRANSMISSION/CRANKSHAFT/BALANCER
Apply engine oil 10 the shift drum guide pin grooves and
install the shift drum 11].
Install each shift fork into the gear shifter grooves and
shift drum groove with their identification marKs facing
up (front crankcase side).
- rear shift fork into the M4 gear
- center shift fork into the C3 gear
- front shift fork into the C2Ireverse gear shifter
Apply engine oil 10 the fork shaft [2].
Install the fork shaft through the shift forks [31 and into
the crankcase.
Assemble the crankcase halves (page 14-21).

CRANKSHAFT/BALANCER
REMOVAL
Separate the crankcase halves (page 14-7).
Remove the transmission (page 14-8).
Be careful not to Remove the crankshaft (1] and balancer (2J from the
damage the feaf crankcase using a hydraulic press.
crankcase mating Be sure to hold the crankshaft and balancer while
surface and pressing them out of the crankcase.
crankshaft
assembly.

Remove the rear crankshaft bearing [11 using the

bearing puller [2J wi th a suitable protector [31 and
discard the bearing.

TOOL:
Universal bearing puller 07631-0010000 o r
equivalent commerci ally
available in U.S.A.

NO TE'
Always replace the rear crankshaft bearing with a
new one when the crankshaft is removed.

INSPECTION
Check the balancer drive and driven gears for wear or , - - - - - - - - - - - - - - - - - ,
damage.

14-15
CRANKCASEITRANSMISSION/CRANKSHAFT/BALANCER
Sel the crankshaft in a stand or V-blocks (1] and
measure the runoul using a dial indicator (2).

SERVICE LIMIT: 0.15 mm (0.006 in) [2[ [2[

Measure the side clearance between the connecting

rod big end and crank weight with a feeler gauge.
,----===============
SERVICE LIMIT: 0.8 mm (0.03 in)

Measure Ihe radial clearance at the connecting rod big , - - - - -- - - - - - - - - - - - -

end in an X and Y directions.

SERVICE LIMIT: 0.05 mm (0.002 in)

INSTALLAT[ON
Apply engine oil to a new rear crankshaft bearing.
[1 [
Drive the crankshaft bearing into Ihe rear crankcase
with the marking side facing up.
TOOLS:
[1] Driver 07749-0010000
[2] Attachment, 72 x 75 mm 07746-0010600
[3] Pilot, 32 mm 07MAD·PR90200

Other bearing replacement in the crankcase halves

(page 14-18).

[2[

14-16
 CRANKCASE/TRANSMISSION/CRANKSHAFT/BALANCER
Install the special 1001111 onto the rear crankshaft end .

TOOL:
Threaded adapter 07965·VM00300 or
07931·KF00200
(U.S.A. only)

111
Be careful nollO Engage the balancer and cranksha ft by aligning the ~=================~
disengage the index lines [1 ] on the crank weight [2) and balancer [3]
gears. driven gear [3), and install them together In to the rear
crankcase.

Take care thai the Install the special tools onto the crankshaft and
crankshaft and crankshaft bearing .
balan~r do not fall
out of/he TOOLS :
crankcase when [1) Assembly collar 07965-VM00100
installing the [2J Puller shaft and nut 07965·VM00200 or
speclalloo/s. 07931·ME4010B and
07931·HB3020A
(U.S.A. only)

88 careful nOllo Ie/ Draw the crankshaft into the bearing inner race.
the connecting rod
13} press against the
crankcase mating
surface.

After installing the crankshaft, make sure the index lines

[1) on the crank weight (2) and balancer driven gear (3)
are aligned.
Install the transmission (page 14-11).
Assemble the crankcase halves (page 14-21).

14-17
CRANKCASEITRANSMISSIONICRANKSHAFTIBALANCER
CRANKCASE BEARING
INSPECTION
Remove the crankshaft and balancer (page 14-15).
Tum the inner race of each crankcase bearing with your
finger. The bearing should tum smoothly and quietly.
Also check that the bearing outer race fits tighlty in the
crankcase.
Replace any bearing if the inner race does not turn (
smoothly, quietly or if the outer race fils loosely in the
crankcase.

FRONT CRANKCASE BEARING

REPLACEMENT
Remove the balancer bearing [11 and counlershaft ~-----~~--~--------,
bearing [21 with the special tools.

TOOLS:
Countershaft bearing:
[3J Remover handle 07936-3710100
[4] Bearing remover, 20 mm 07936-3710600
[5) Remover weight 07741-0010201 or
07936-3110200 or
07936·371020A
(U.S.A. only)
Balancer bearing :
Remover handle 07936·3710100
Bearing remover I 17 mm 07936·3710300
Remover weight 07741-0010201 or
07936·3710200 or
07936·371020A
(U.S.A. only)
Drive the crankshaft bearing (6]. output shaft bearing [7]
and shift drum bearing [8] out of the fron t crankcase.

Remove the two bolts (1 ] and mainshaft bearing setting ~~=~==~~==:;:=====-=~

plale [21.
Drive the mainshaft bearing [3J oul of the front
crankcase.

14-18
 CRANKCASEITRANSMISSION/CRANKSHAFT/BALANCER
Apply engine oil 10 new bearings.
Drive the bearings in with the marked side facing up.
TOOLS:
Crankshaft bearing:
[1] Driver 07749-0010000
[2] Attachment, 78 )( 90 mm 07GAD·SD40101
[3] Pilot, 40 mm 07746-0040900
Balancer bearing :
(1] Driver 07749-0010000
[2] Attac hment, 37 )( 40 mm 07746-0010200
[3] Pilot, 17 mm 07746-0040400
Mainshaft bearing:
[1] Driver 07749-0010000
(2] Attachment, 45 x 50 rnm 07946-6920100
(3] Pilot, 22 mm 07746.{l041 000
Countershaft bearing :
(1] Driver 07749·0010000
[2] Attachment, 42 x 47 mm 07746-0010300
(3) Pilot, 20 mm 07746-0040500
Output shaft bearing :
{1] Driver 07749-0010000
(21 Attachment, 42 )( 47 mm 07746-0010300
(3) Pilot, 22 mm 07746-0041000
Shift drum bearing :
(1} Driver 07749-0010000
(2] Attac hment, 42 x 47 mm 07746-0010300
[3] Pilot, 35 mm 07746-0040800
Apply locking agent to the threads of the selling plate
bolts [1].
Install the mainshaft setting plate [21 with the bolts and
tighten them to the specified torque.
TORQUE : 12 N'm (1.2 kgf'm, 9 IbHt)

14-19
CRANKCASE/TRANSMISSION/CRANKSHAFT/BALANCER
REAR CRANKCASE BEARING
REPLACEMENT
Remove the mainshaft bearing/plate {1] and camshaft .-------,""c-::.----~--------,
bearing [2] with the special tools.

TOOLS :
Mainshaft bearing :
[3] Bearing remover, 17 mm 07936·3710300
[4J Remover handle 07936-3710100
[5] Remover weight 07741-0010201 or
07936·3710200 or
07936-371020A
(U.S.A. only)
Camshaft bearing :
Bearing remover shaft, 15 mm 07936·KC10100
Bearing remo ver head , 15 mm 07936· KC10200
Remover w eight 07741-0010201

U.S.A . TOOLS:
Bearing remover, 15 mm 07936· KC10500
Remover weight 07936·3710200 or
07936·371020A
Drive the countershaft bearing [6] and balancer bearing
(7) out of the rear crankcase.

Apply engine oil to new bearings .

Drive the bearings in wi th the marked side facing up.

TOOLS :
Balancer bearing :
[1] Driver 07749-0010000
[2J Attachment, 37 x 40 mm 07746-0010200
[3] Pilot, 17 mm 07746-0040400
Malnshaft bearing:
[1] Driver 07749-0010000
[2J Attachment, 37 x 40 mm 07746-0010200
Countershaft bearing :
[1) Driver 07749-0010000
[21 Attachment, 62 x 68 mm 07746-0010500
[3J Pilot, 25 mm 07746-0040600
Camshaft bearing:
[11 Driver 07749-0010000
[2] Attachment, 32 x 35 mm 07746-0010100
[3] Pilot, 15 mm 07746-0040300

14·20
 CRANKCASEITRANSMISSION/CRANKSHAFT/BALANCER
CRANKCASE ASSEMBLY
Clean the front and rear crankcase mallng suriaces
thoroughly, being careful not to damage them,
I. __
Blow through the oil passages in the crankcases with ~
~~
":.~.c'<~>:::::~,
compressed air. h' c, :j.

Apply liquid sealant (TB1215 or equivalent) to the /J

mating surface (shadowed area) of the front crankcase ....-I. '\.
as shown. , 1
~

0 '
~

Install the thcee dowel pin, 11 1to the ceac ccankc",e. I

Make sure all the parts are installed in the rear
crankcase.
Install the fronl crankcase over the rear crankcase.

111
Install the fifteen rear crankcase bolts [1)
111

InslaUthe two front crankcase bolls [1}

Tighten aU the bolts in a crisscross pattern In several
steps.

14-21
CRANKCASEITRANSMISSION/CRANKSHAFT/BALANCER
Insert the output shaft (I] Inlo the crankcase unlil it
seals against the bearing in the front crankcase.
Instal! the output shaft drive and driven gears [2).
Apply engine oil to the journal surfaces of the reverse
stopper shaft 13].
Install the reverse stopper shaft assembly into the
crankcase as shown.
Install the following:
- fl~heel and starter clutch (page 13-14)
oil pump (page 9-5)
change clutch (page 12- 17)
gearshift linkage (page 12-21)
cylinder and piston (page 11-8)
cylinder head (page 10-16)
engine (page 15-9)

14-22
 15. ENGINE REMOVAUINSTALLATION

SYSTEM COMPONENTS ··············· .. ·· ........ ·15·2 ENGINE REMOVAL························ ·······.... · 15-4

SERVICE INFORMATION ··························· 15·3 ENGINE INSTALLATION .. ···· ·· ····················15·9

15·1
ENGINE REMOVAUINSTALLATION
SYSTEM COMPONENTS
FE model shown:
44 N'm (4 .5 kgf'm, 32Ibf-ft)

~
44 N'm (4.5 kgf-m, 32 IbHt)

54 N m (55 kgfm. 40 Ibf·tt)

~,

32 N'm (3.3 kgf·m. 24 Ibf·ft) - """,--'

~

1
15-2
 ENGINE REMOVAU INSTALLATION
SERVICE INFORMATION
GENERAL
When removing and installing lhe engine, tape the frame around the engine beforehand for frame protection ,
The following components require engine removal for service
- alternator/slaner clutch (page 13-2)
- crankcase/lransmission/crankshaftlbalancer (page 14-2)

SPECIFICATIONS
~~ ~ SPECi'FICAT10NS
I Engine dry weight U.S.A. -+--~~.4 kg (113.3Ibs)
Canada 52_5 kg (115.7 Ibs)
U.S,A, 523kg(11S-:-3 Ibs)
~=~ Canada 53.4 kg (117.7Ibs)
Engine oil capacity After draining 2,ghlers (3.1 US qt, 2.6 Imp ql)
After draining/filter change 3,0 liters (3.2 US qt, 2.6 Imp qt)
After disassembly 3,3 liters (3.5 US qt, 2.9 Imp ql)
Coolant capacity (radiator and engine)- - TII"li9rs (1.6 US""Cjt1.3 Imp qt)- -
~se seleclor1eVer freeplay 2 - 4 rnm (0. 1 - 0.2 in) ~~

TORQUE VALUES
r - -- -
ITEM C'TY THREAD TORQUE REMARKS

~
~~~~~~~;~~~1;~~~~~ 2~ 1
'~o-=~~_
OIA.1~
(mm)
54 (5.5, 40)
N'm (kg f'm, lbHt),_
54 (5.5, 40) -t= _ _
2
1 --+-
2
8
6
10
=t==
I 32 (3.3.24)
20 (2.0, 15)
44 (4.5, 32) lock nut: replace with
a new one.

15-3
ENGINE REMOVAUINSTALLATION
ENGINE REMOVAL
Remove the following :
- mudguards (page 2-6)
- engine guard (page 2.7) FMlFPM models:

Drain the engine oil (page 3-13). [21

Drain the coolant (page 8·7).
Remove the following:
- heal guard plale (page 10·7)
- throttle body (page 7-23)
- exhaust system (page 2·14)
- bal1ery H cable (page 21.8)
FMfFPM only: Remove the pinch bolt [1[ and the
gearshift pedal 12]

[11

Disconnect the following :

- VS sensor 3P (Black) connector [1]
- FElFPE only: shift angle sensor 3P (Gray) connector
[21
- sub-wire harness (from the clamp (3])

- wire band [I)

- bolt 121 and ground cable [3]
- nut 14] and starter motor cable 15J
- two bolls [6) and battery (-) cable [7J
- starter motor [8J

- gear position switch 8P (Gray) connector [IJ

(remove from the frame and disconnect it)
- alternator 5P (Natural) connector (2) (remove from
the frame and disconnect it)

15-4
 ENGINE REMOVAUINSTAllATION
Loosen the adjuster of the reverse selector cable (page
3-23).
Remove the following:
- bolt (1] and selector arm 12J (10 disconnect the
selector cable)
- selector cable [3] (from the cable holder 14] of the
engine)

- spark plug cap (11

- bolts [2J and ignition ooillbrackel [3]
- water hose [4]

- water hose (1]

- shift control motor connector [2) (FElFPE only)

- bolt [1] and clutch arm cover [2J (release from the 1~=!IIIII!IIIII!IIIII~1~3 I!IIIII!IIIII!IIIII!IIIII~~~"""!IIIII!IIIII~
two tabs [3])
f

(1)
--

15-5
ENGINE REMOVAL/INSTALLATION
- adjusting nul {1J
- cable retaining plale (21
- 2WO!4WD selector cable (3] (remove from the cable
holder [4] and joint pin (5))
- cable spring [61
- joint pin

- final gear case mounting nuts 11] and bolts 12)

- two bolts [31 and mounting bracket (4)

Move the gear case assembly (11 forward for maximum

clearance between the propener shaft joint and engine.
NOTE
Turn the handlebar aU the way to the right to move
the gear case assembly.
Put some cloth on the gear case to avoid scratch or
damage the lie-rod end [21.

15-6
 ENGINE REMOVAUINSTALLATION
Pull the shaft joint [1] out of the output shaft [2] from the
engine .
Remove the O-ring [3] from the output shaft.

Remove the boot band [ 1J and release the propeller

shaft boot [2] off the pinion joint [3] of the gear case
assembly.
Pull the propeller shaft [4] to force the stopper ring [5)
past the groove in the pinion joint to remove the
propeller shaft.
Remove the stopper ring from the propeller shaft.

Remove the following from the engine upper mount:

- tvo engine hanger bolts [11 (engine side)
- engine hanger nut and bolt [21 (frame side)
- hanger bracket (3)
- mounting rubbers [4]

15·7
ENGINE REMOVAUINSTALLATION
Set suitable Remove the following from each engine lower mount:
wooden blocks
- engine hanger nut [1] and bolt (2)
between the engine
- spacer [3)
and lower frame
- mounting rubbers [4]
pipe to support the
engine.

Move the engine forward and disconnect the output

shaft [1] from the universal joint 121.
Hold the engine Remove the engine out of the frame from the left side .
securely and take
Remove the O·ring [3] from the output shaft.
care 001 to damage
the frame and
engine.

Remove the engine mounting bushings [1] and dust

seals (2).

15·8
 ENGINE REMOVAUINSTALLATION
Check the mounting rubbers [1], bushings 12] and dust
seals for deterioration, wear or damage.

[2[

[1 )

ENGINE INSTALLATION
Install the lower engine mounting bushings [1] into the
(3) (3)
engine.
Install the dust seals (2J with the lip side [3) facing out.

P)
Hold the engine Place the engine in the frame from the left side and ~;:::7===::=~:===:;;____iiiiiiii~
securely and be support it with suitable wooden blocks.
careful not to
Coat a new O-ring [1] with molybdenum disulfide
damage the frame
grease and install it into the output shaft [2] groove.
and engine.
Apply molybdenum disulfide grease to the splines of the
universal joint [3}.
Carefully move the engine and engage the output shaft
with the universal jOint.

15-9
ENGINE REMOVAL/INSTALLATION
Be sure the Install the mounting rubbers [1] onto the lower mounting
universal join/IS not bushing with the larger I.D. side facing in .
disengaged. Install the spacer [2] and the hanger bolt 13] (from the
front side) while aligning the bolt holes carefully.
Loosely install the hanger nut [4] .
Install the other side mounting fasteners in the same
manner as above.

Install the mounting rubbers [1] onto the upper

mounting bushing in the hanger bracket [2] wi th the
large I.D. side facing in.
Inslalilhe hanger bracket with the 10 mm hanger bolt
[3] (from the front side) and nul [4] .
Inslall the two 8 mm hanger bolts [5] .
After installing all the mounting fasteners and seal
them, tighten the fasteners to the specified torque in
order as follows:
- left and right lower engine hanger nuts
TORQUE : 54 N'm (5.5 kgf'm , 40 Ibf-ft)
- engine side upper engine hanger bolts
TORQUE : 32 N'm (3.3 kgf·m , 24 Ibf·ft)

- frame side upper engine hanger nut

TORQUE: 54 N'm (5.5 kgf·m , 40 Ibl-ft)

Install a new stopper ring (1] into the groove in the

propeller shaft [2] end.
Apply 5 - 8 9 of molybdenum disulfide grease to the
splines of the pinion joint [3}.
Apply molybdenum disulfide grease to the front end of
the propeller shaft.
Place the boot band [4} over the pinion joint temporarily.
Install the propeller shaft into the pinion joint. aligning
the splines until the stopper ring seats in the groove.
Make sure the stopper ring is seated properly by pulling
the propeller shaft lightly.
Install the boot [5] over the pinion joint groove securely
and the boot band into the boot groove.

15-10
 ENGINE REMOVAUINSTALLATION
Coat a new O-ring [1) with molybdenum disulfide
grease and install it into the output shaft [2) groove.
Apply molybdenum disulfide grease to the splines of the
propeller shaft joint [3).
Move the gear case assembly [4] forward for maximum
clearance between the shaft jOint and output shaft.
NOTE ·
Turn the handtebar all the way to the right to move
the gear case assembly.
Put some ctoth on the gear case to avoid scratch or
damage the tie-rod end [5) .
Engage the shaft joint over the output shaft and move
the gear case assembly rearward.
[5]

[4[

Align the rear mounting bolt holes in the gear case [1]
and frame, then install the mounting bolt [2] from the
right side and a new mounting nut (3).
Install the mounting bracket [4] with the two bolts [5].
Install the front mounting bolt [6] from the right side and
a new mounting nut (7).
Tighten all the gear case mounting fasteners in the
following sequence.
- Rear mounting nut
- Mounting bracket bolts
- Front mounting nut
TORQUE:
Rear mounting nut: 44 N·m (4.5 kgf-m, 32 IbUt)
Front mounting nut: 44 N·m (4.5 kgf-m , 32 IbHt)

15-11
ENGINE REMOVAUINSTALLATION
Install the spring [1] onto the selector cable (2J.
Insert the cable into Ihe cable holder (3J and connect it
to the clutch arm [4] with the Joint pin [5] and adjusting
nut 16].
Sellhe groov8 in the cable grommet [7] onto the cover
base end properly.
Install the retaining plate [8] onto Ihe cable with the
concave side facing the cable holder to secure the
cable.

Inslalilhe water hose [1].

Connect the shift control molor connector [2] (FElFPE
only).

Inslallthe water hose [1].

Inslallths ignition coil/bracket [2) and bolts [3].
Tighten the bolts securely,
Connect Ihe spark plug cap {4J .

Connect the following and install them onto the frame:

- alternator SP (Natural ) connector 111
- gear position switch 8P (Gray) connector [2]

15-12
 ENGINE REMOVAU[NSTALLAT[ON
Install the reverse selector cable (lJ into the cable
holder [2] of the engine.
Connect the cable to the selector arm [3] and install the
arm by aligning the flat surlaces. and tighten the bolt
[4[.

Install the starter motor [lJ (page 6-6).

Connect the ground cable [2) to the engine with the
bolts [3]. Tighten the bolt securely.
Secure the wires and cables with the wire band [4].
[4[

[l[

Connect the fOllowing and secure the wire with the

clamp [1 1:
i~~~~=~~j~~~~~iiii~
~ FEIFPE only: shift angle sensor 3P (Gray) connector
[2[
- VS sensor 3P (Black) connector [3]

FMlFPM only:
of the pedal joint [21 is parallel with the frame pipe [3].
=.,.~======:""
Install the gearshift pedal (1] so thai the bottom surface ;"'":"............
FM/FPM models:
. . .......';
Install the pinch bolt [4J and lighten it to the specified [l[
torque.
TORQUE : 20 N'm (2.0 kgf'm , 151bHt)
Adjust the following:
- reverse selector cable (page 3-23),
- 2WO/4WD selector cable (page 3-19)
Install the following:
- exhaust system (page 2-14)
throttle body (page 7-25)
engine guard (page 2-7)
mudguards (page 2-6) [2[
heat guard plale (page 10-19)
battery (- ) cable (page 21-8)
Fill the engine with recommended oil (page 3-13).
Fill and bleed the cooling system (page 8-6).
Check the engine oil level (page 3-12).

15-13
MEMO
 16. FRONT WHEEUSUSPENSION/STEERING

SYSTEM COMPONENTS····························16-2 WHEEL HUB AND KNUCKLE········ ··········16-16

SERVICE INFORMATION ········ ··················· 16-4 SUSPENSION ARM ·····························.. ·.. 16-23

TROUBLESHOOTING································· 16-7 FRONT SHOCK ABSORBER· .. ················ 16-26

HANDLEBAR ·········· ······· ··· ····· ····················· 16-8 STEERING SHAFT (FM/FE models) ····· ··· 16-27

THROTTLE HOUSING ······························16-11 STEERING SHAFT/EPS UNIT

(FPM/FPE models) ····· ······························ 16-32
FRONT WHEEL······················ ··· ················ 16-13
TIE-ROD ················································· ··· 16-40
TIRES························································· 16-13

16-1
FRONT WHEEUSUSPENSION/STEERING
SYSTEM COMPONENTS
FM/FE mo dels
FE model shown:

39 N'm (4 0 kgf-m, 291bHt)

i
/-------- 34 N'm (3.5 kgl'm, 251bHt)

,,-
54 N'm (55 kgf-m, _ _-::,,£...;;-
401bHt)

39 N'm (4.0 kgf'm, 11 Nm (1.1 kgf'm,

29Ibf-ft) BlbHt)

108 N m kgf-m, 80 Ibf ftl

29 N'm (3.0 kgf'm, 211bHt)

V
78 N 'm (8.0 kgf m, 58lbHt)
30 N'm (3.1 kgf-m . 22Ibf·ft)

64 N'm (6.5 kgf'm, 47 IbHI)

16-2
 FRONT WHEEUSUSPENSIONISTEERING
FP M/FPE models
FPE model shown :

39 N'm kgf-m. 29 IbHt)

32 N'm (3.3 kg"m , 24 IbUt)

22 N'm (2.2 kgfrn.

161bHt)

60 N'm (6.1 kgf'm,

44 IbHt) 34 N·m {3.5 kgf-m,
25 Ibf ttl

39 N'm (4.0
291bHt) 11 N'm (1.1 kgf-m,
8IbH!)
108 N'm (1 1.0 kg! m , 80 Ibf-ft)
.-
/ \.
1/
- - .... \ \

78 N'm (B.O kgf 'm , 58lbf tt)

64 N m (6.5 kgf-m, 47Ibf-ft)

16·3
FRONT WHEEUSUSPENSIONfSTEERING
SERVICE INFORMATION
GENERAL
This seclJon covers service of the front wheel , suspension and steering (including EPS unit; FPM/FPE models). For electrical
system servICe of the EPS. see Electric Power Steering (EPS) section (page 24-2).
A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a
high quality brake degreasing agel'll.
A Jack or other support is required to support the vehicle.
Adjust toe whenever the tie-rod , knuckle or steering shaft are replaced or removed (page 3-26).
00 not twist or bend the brake hose when servicing.
Use Honda Genuine replacement bolts and nuts for all suspension pivots and mounting points.
For brake system service , see Brake System section (page 18-2).
For each sWitch inspection. see LightslMeterslSwitches section.
- handlebar switch (page 22-11)
- front brake sWitch (page 22·12)
- rear brake light sWitch (page 22-13)

Service Location
Cables and harness around handlebar
t
FPMfFPE model only: Perform the torque sensor initialization when you service the following components (page 24-13)
Replacement
INITIALIZE
Removal/Installation
INITIALlZE:_ _ _ _---1

Handlebar ;~:f!~~~=:!=I~N~IT~'~A~LI~ZjE=:=
Sleenng shaft and steenng shaft bushing INITIALIZE _~::;::~INITIALI~E
IN~'tTI~A~LlZ;,Et===:::j
Steenng arm and nul INITIALIZE _ _ _~'Nc.ITIAlIZE;..-----l
EPS unit INITIALIZE ___ '.i'N"ITIALlZc-E~____ j
EPS ECU INITIALIZE _ __ L-'N-",O NEE0c--_ _ _ --'

SPECIFICATIONS

i
Unit: mm (in)
1J
1T~EjlMC=:-~___===:--===~S~
TA"NDAR,!O'-.::=== SERVICE LIMIT
;.-----+--0""""=",=='"
Minimum tire tread depth
Cold tire I Standard 30 kPa (0.30 kgf/cm , 4 .4ic'OPS~;~)- - -
4.0 (0.16)
1
pressuredistance between the ball joints
Tie-rod With~ca=,g~oC--- 30 kPa(15.08)
383.1 0.30 kgf/cm2, 4~4~PS~;~)===~-t==~===-
Toe_ ______ Toe-out:28±15(1 .1 to.6)

16-4
 FRONT WHEEUSUSPENSION/STEERING
TORQUE VALUES

ITEM C 'TY THREAD TORQUE ~ REMARKS

DIA. (rnm) N'm (kgf'm, Ibf.ft)
-,-+~ -~~, ---~
~3t::==- 4
_2

r 64
1.5(0 .2, 1.1)
5 4.2(04, 3.1)( -_ _

~~~~~~st~ay~~-- 1 6 7.0 (0.7. 5.2),_ _ _ _

r Frontwheel nute =,---_

Front wheel hub nut
2 •
8;---+-_ _.'0
2 16
I 32 (3.3, 24) _ _ _ _
(6.5. 47):_ _ -,-:;.
78 (8.0. 58) Castle nut: tighten to
the specified torque
and further lighten
until its grooves align
with Ihe cotter pin
~~_,-'hOIe .
8 8
~331)
Front brake disc bolt ALoe bolt: replace
with a new one.
Splash guard bolt 6 6 11(1 . 1.8) ALOe bolt: replace

==t
with a new one.
Shock absorber mounting nut 4 10 39 (4 .0, 29) lock nut: replace with
a new one.
Upper arm pivot nut 2 10 34 (3.5. 25) lock nut. replace with
a new one.
I
' Lower arm pivot nut 4 10 39 (4 .0, 29) lock nut: replace with
a new one.
Upper and lower arm ball jOint nut 4 12 29 (3.0. 21) Castle nut: lighten ~
the specified torque
and further tighten
unliliis grooves align
with the coller pin
hole.
Brake hose clamp bolt 7 6 12 (1.2 . 9) ALOe bolt: replace

=-+i
with a new one.
Tie-rod joint nut 4 54 (5.5, 40) Lock nut: replace with
- - + - -'2 a new one.
7teering shaft end nut 14 108 (11 0 . 80) Lock nut replace wlth-
a new one
I Steering shaft holder bolt 3-2 (3.3. 24 )
2 8
I 10 60(6 .1, 44 ) "'--A LOC bolt· replace
Steering shah ","ch bolt (FPMlFPE)
with a new one.
EPS unit mounting nut (FPMIFPE)
Handlebar switch housing screw (FMfFPM)
2
2
8 : 22(2 .2. t6~
f f i4.2 (0.4. 3.1)
Handlebar switch housing screw (FElFPE ) 3 5 4.2 (0.4, 3.1)
Rear brake lever bracket holder screw 2 5 4.2 (0.4 , 3.1)
Front master cylinder holder bolt 2 6 I 12 (12, 9)
Front brake caliper mounting bolt 4 8 30 (3. 1. 22) ALOe bolt: replace
wi th a new one.

16-5
FRONT WHEEUSUSPENSION/STEERING
TOOLS
Attachment, 42 x 47 mm Attachment, 52 )( 55 mm Attachment, 40 x 42 mm
07746-0010300 07746-0010400 07746·0010900

Attachment, 20 mm I,O·- -- - - + -OP'-ilo"t,-,2m

O-;;m"m;;- ---r'Phljlo~t~
, 30mm~-----
07746·0020400 07746-0040500 07746-0040700

---- - I
Pilot. 22----rnm- - - - - - - - I - - - cOriver
07746-0041000 07749-0010000 I Attachment, 28 x 30"m=m, --
07946-1870100
--

/'
r Fork seal driver attachm"."'
n't
&
- ---t-I-DriC'eC::;'- -- Compressor boll assembly
I 07947-KA40200 07949-3710001 07GAE-PG40200

o
07GAE-PG4020A (U.S.A. only)

16·6
 FRONT WH EEU SUSPENSION/STEERING
Oil seal driver attachment Clutch compressor attachment Ball joint remover, 28 mm
07JAD-PH80101 07LAE·PX40100 07MAC-SLOO201

Ball jOint removerlinst;alo;;le~,-----+- Attachment. 34 mm- - -

----t 07MAC-SL00202

07WMF·HNQ0100 07ZMD·MBW0100

I
~

TROUBLESHOOTING
Hard steering
Steering shaft holder too tight
Damaged steering shaft bearing/bushing
• Insufficienllire pressure
• Faulty EPS (FPM/FPE models) (page 24-9)
Steers one side or does not track straight
Incorrect wheel alignment
Unequal Ure pressure
Ben' tle·rod, suspension arm or frame
Worn or damaged knuckle bearing or wheel hub beanng
Weak shock absorber
Front wheel wobbling
Benl rim
Worn or damaged knuckle bearing or wheel hub bearing
• Faulty lire
• loose wheel hub nul
Soft suspens ion
• Weak shock absorber spnng
• Dilleakage from damper unit
Stiff suspension
Damaged shock absorber damper
Faulty shock absorber pivot bushings
• Improperly Installed suspension arms
• Faulty suspension arm bushings
Front sus pension noise
Faulty front shock absorber
loose front suspension fasteners
Wom front suspension Piliot bushings
Damaged suspension components

16-7
FRONT WHEEUSUSPENSION/STEERING
HANDLEBAR
REMOVAL
Remove the assist headlight cover (page 22-4).
Remove Ihe fuel tank breather hose [1] from the meter
cover (2).
Remove the screw (3] and meter cover.

Disconnect the 21P connector [1) from the combination

meier.
Remove the following:
- two wire bands (2)
- two bolts and collars (3]
- meter cover stay (4J

Remove the two screws [1J. throttle housing holder [2) ~~=~~;~~==::"'~~==~~~~
and throttle housing 13].
Disconnect the connectors [4].
Keep the mas/ar Remove Ihe two bolls 151, master cylinder holder [6] and
cy//fldef reservoir brake master cylinder (7).
upngfll to p!8ven/
81r from enlenng the
hydraulic system

Remove the two screws [1 j, lever bracket holder (2J and ~~~""':::=~=========~=~
rear brake lever brackel(3).
FElFPE mod&/s. Remove the three screws [4J and handlebar sWitch [5].
FMlFPM models: Remove the two screws and handlebar switch .

16·8
 FRONT WHEEUSUSPENSIONfSTEERING
Remove the grip ends (1) (tum the grip end to release
the setting tabs (2) and pry it using a screwdriver).
Remove the handlebar grips {3J.

Remove the four bolts (11. upper holders 121 and

handlebar {3] .

INSTALLATION
AJign the punch Install the handlebar and upper holders with the punch
mark on the mark (4] facing forward. Tighten the front bolls first, then
handlebar with the tighten the rear botts.
top edge o( the
lower holder.

Apply Honda Bond A or Pro Honda Handgrip Cement r-----------1~~a~~J

(U.S.A. onty) to the inside surface of each handlebar I
grip (1J and to the ctean surfaces of the handlebar.
Allow rne adhesive Wait 3 - 5 minutes and install the grips. Rotate the grip
to dry for an hour for even application of the adhesive .
befo", uSlf1g.
Install new grip ends (2) by aligning the tabs [3] with the
holes in the handlebar.

FMlFPM models: Install the handlebar switch (1). Tighten the upper screw ~I=
F==P
MIf =M
c-m
-od-=.'='=h=O
=
W='='========='~
Align the Iocalrng first, then tighten the lower screw to the specified
pin on the switch torque. ~
housing with the
TORQUE , 4 .2 N·m (0.4 kgf'm, 3.1 'bf·ftl
[2J ,"t.
~/. W-~y
Align
nole in the
handlebar

Ir " r~
Install the brake lever bracket 121 and holder [3] with the
A lign the edge of
the bracket with the
punch mark on the
punch marl< [4] facing up.
Tighten the upper screw first, then lighten the lower
handlebar. screw to the specified torque.
TORQUE : 4.2 N'm (0.4 kgf'm , 3.1tbHt)
,.#~'7
~ r / [4]
'\
P]
[11

Align

16-9
 I,

FRONT WHEEUSUSPENSION/STEERING
FEJFPE models: Install the handlebar switch [1). Tighten the inside
screw [21 first, then tighten the outside screws [3] to the
FElFPE models: [11
Allfln the seam of
the switch with the specified torque.
punch mark on/he
TORQUE: 4.2 N'm (0.4 kgf·m. 3.1Ibf·ft)
handlebar.

FElFPE models: Instalilhe brake lever bracket (1] and holder [2) with the
Align the locating punch mark (3) facing up. Tighten the upper screw fi rs t,
pm Of! the bracket then tighten the lower screw to the specified torque,
with the hole in the
switch housing. TORQUE : 4.2 N'm (0 .4 kgf-m, 3.1 Ibf-ft)

Align the edge of Inslall the brake master cylinder (1] and holder [2) with
the mas/ef cylinder the "UP· mark [3) facing up. Tighten the upper boll first,
with the punch then tighten the lower bolt to the speCified torque.
mark {4} on the
handlebar. TORQUE : 12 N'm (1.2 kgf'm , 9lbHt)

COOneG't the gray Connect the connectors [1J to the inhibitor switch [2J
tape (4) Wlf9 and brake tight switch (3J.
connectors 10 Ihe
upper terrmna/s.
11[ 121

[4[
/
131

16-10
 FRONT WHEEUSUSPENSION/STEERING
Al,gn the lug {5Jon Inslall the throttle housing [1] and holder (2] against the
tile throttle housing master cylinder 13]. Tighten the front screw first, then
with the mating line lighlen the rear screw 14] to the specified torque.
01 the master
cylinder and holder. TORQUE: 4.2 N'm (0.4 kgf'm, 3. 1 IbHt)

Install the meter cover stay (lJ with the two bolts and
collars (2J, and tighten them to the specified torque.

TORQUE : 32 N'm (3.3 kgf'm, 24 Ibfoft)

Secure the wires with the two wire bands (3].
Connect the 21P connector (4] to the combination
meter.

Install the meter cover (1) and tighten the screw 12).
Install the fuel tank breather hose [31 into the meter
cover.
Install the assist headlight cover (page 22--4).
FPMlFPE only: Perform the torque sensor initialization (page 24-13).
Refer to "Service
Information" for
serviCe location of
the initializatiOn
(page 16-4).

THROTTLE HOUSING
DISASSEMBLY
Remove the following:
- three SCl'ews (11
- throttle housing cover 12]
- gasket (3]
Slide the boot 141 off the throttle cable adjuster.

16-11
FRONT WHEEUSUSPENSION/STEERING
Loosen the lock nut [1] and cable adjuster [2).
Bend down the lock washer tab and remove the
fallowing:
- pivot nut [3]
- lock washer [4]
- throttle lever [5] and plastic washer [6]
- return spring [7]
- throttle arm [8] (by disconnecting the cable [9])
- dust seal (from the housing)

ASSEMBLY
Coat the lips of a new dust seal [1] with grease and ~---­
install it into the housing until it is fully seated .
Apply grease to the throttle lever pivot in the housing
and to the throttle cable end.
Connect the cable (2) to the throttle arm (3] .
Insert the throttle lever [4] with the plastic washer (5)
into the housing.
Install the throttle arm with the spring (6) over the
throttle lever pivot by aligning the flat surfaces .
Install a new lock washer [7] and the nut [8]. and tighten
the it to the specified torque.
TORQUE : 7.0 N·m (0.7 kgf·m, 5.2 IbHt)
Bend up the lock washer tab against the nut.

Install the housing cover (1) with a new gasket [2] and
tighten the three screws (3) to the specified torque.
TORQUE : 1.5 N·m (0 .2 kgf·m, 1.1IbHt)
Adjust the throttle lever freeplay (page 3-4).

16-12
 FRONT WHEEUSUSPENSION/STEERING
FRONT WHEEL
REMOVAL
Loosen the wheel nuts [1].
Support the vehicle using a hoist or equivalent and
raise the front wheels off the ground.
Remove the wheel nuts and wheel.
INSTALLATION
Do nol interchange Install the front wheel with the lire valve facing out and
the left and right the arrow mark [2J facing in the normal rotating
wheels direction .
Inslatl the wheel nuts with the lapered side (3] facing
inward and tighten them to the specified torque.
TORQUE : 64 N'm (6.5 kgf-m, 47 tbf-ft)

TIRES
REMOVAL
NOTE"
This service requires the A TV Bead Buster
(KLS379024).
Remove and install the tire from the rim side
opposite the valve slem.
Remove the core from the valve stem.
Use a pneumatic lire changer or equivalent to remove
the tire from the rim. If a tire changer is not available,
rim protectors and tire irons may be used.
Adjust the bottom rim supports [1] to the proper rim
size. Align the flat side of the support with the 111
corresponding rim size indicator.
Useonlywaleras8
lubricant when
removing ex
lube the bead area of the tire with water, pressing
down on the tire sidewaltlbead area in several places to
allow the water to run into and around the bead.
~
~ ./
_ ,-,
..... o
mountmg /Ires. o
Soap or some
mountmg lubricants
may leave a
slippery residue that 00
can cause the lire 10
shift on the rim and
lose tire pressure
during nding.
j
Place the wheel assembly over the center shaft (1] and , - -- - - - -- --
use the correct size cone (2) to keep the wheel centered
during operation. 111------... 131
Instal! the bottom hold down nut [3J. bearing side down.
and finger tighten it so the wheel can rotate freely 121
during operation.

I~

(,
I' U;:.
I
l'-
~.
\ '-
-------'

16-13
FRONT WHEEUSUSPENSION/STEERING
Install the breaker arm assembly [1) over the center
shaft and adjust the upper rim supports {2] to fit the [1)
outside rim diameter.
Install the top hold down nut (3] and tighten it finger
tight.

Failure to back out Puilihe leverage bar 11 J down so the breaker shoe [2] is
the breaker shoe just below the rim lip, Turn the crank [3) to fully push the
two tums will cause breaker shoe between the tire bead and rim . Once the
the shoe to scratch shoe contacts the rim, back the crank out two turns to
the bead lock, allow the shoe to clear the rim's bead lock.
whICh may cause
the tire to leak.

Push down on the leverage bar [1J to push the lire bead
over the bead lock. Use only short strokes on the
~ _ _ _ [1)
handle. While the shoe (2] is still engaged , turn the
wheel as far as it will go between strokes as you break
the bead around Ihe rim .
Remove Ihe breaker arm assembly and flip Ihe wheel
over. Inslall the breaker arm assembly, adjust the shoe
1
property and break the other bead by following the
above procedures.
Remove the tire from the rim using a tire changing
machine or lire irons and rim protectors. [2)

~---

TIRE REPAIR
NOTE;
Use the manufacturer's Instructions for the tire repair
kit you are using . If your kit does not have
Instructions, use the procedures provided here.
Check the lire for puncturing objecls.
Chalk mark the punctured area and remove the
puncturing object.
Inspect and measure the puncture hole.
Tire repairs for puncture holes larger than 15 mm (0.6
in) should be a section repair.
Section repairs should be done by a professional tire
repair shop.
If the puncture hole is smaller than 15 mm (0.6 in).
proceed with the repair as described here.

16·14
 FRONT WHEEUSUSPENSION/STEERING
Install a rubber plug into the puncture hole as follows:
Apply a cement to a plug inserting needle and work the
needle into the puncture hole to clean and lubricate it.
00 this three limes.
Do not let the cement dry.
Be careful not /0 Insert and center a rubber plug through the eye of the
push the plug all the inserting needle.
way into the tire 10
Apply cement to the rubber plug .
prevent it from
Push the inserting needle with plug Into the puncture
falling inside
hole untillhe plug is slightly above the lire.
Twist the needle and remove it from the tire; the plug
will slay in the tire.

Trim the plug 6 mm (0 .2 in) above the tire surface.

Repeat the above procedure if the puncture is large.
Do not use more than two plugs per puncture hole.
Allow the repair to dry. Drying lime will vary with air
temperature. Refer to the tire repair kit manufacturer's
recommendations.
Inflate the tire and test the seal by dabbing a small
amount of cement around the plug . Escaping air will
cause a bubble in the cement. If there is leakage.
remove the tire (page 16-13) and apply a cold patch to

~~
the inside of the tire as described below.

If a plug has been inserted , trim it even with the inner ~I=====:....:===========~
tire surface.
Temporarily place a rubber patch thai is alleas! twice
the size of the puncture hole over 1I. Make a mark
around the patch. stightly larger than the patch itself.
Rough the area marked inside the tire with a tire buffer
or a wire brush. Clean the rubber dust from the buffed
area
Apply cement over the area marked and allow it to dry
unlil tacky.
Do not touch the cement with dirty or greasy hands.
Remove the lining from the patch and center it over the
puncture hole.

Press the patch against the puncture hole using a

special roller.
I

16-15
FRONT WHEEUSUSPENSION/STEERING
ASSEMBLY
Install the lire onto the rim, where the rim shoulder , -- - - -- - - -
width is the narrowest, to simplify installation.
Clean the rim bead seal and flanges.
Use only water 8S 8Apply clean water to the rim fl anges. bead seal and
lubricant when base.
removing or
Install the valve core in the valve slem.
mountmg tires.
Install the lire with the arrow mark facing in the normal
Soap or some
rotating direction.
mounting lubncants
Inflate the tire to seat the lire bead .
may !eave a
slippery residue Deflate the tire. Wail 1 hour and inflate the lire to the
whICh can causa the specified pressure.
tire /0 shift on the
RECOMMENDED TIRE PRESSURE
rim and /0$8 8;r
pressure dunng Front: Standard: 30 kPa (0.30 kgflcm 2 , 4.4 psi)
riding. With cargo: 30 kPa (0.30 kgf/cm 2, 4.4 psi)
Rear: Standard : 30 kPa (0.30 kgflcm 2, 4.4 psi)
With cargo: 30 kPa (0.30 kgfl cm l , 4.4 psi)

Check for air leaks and install the valve cap.

WHEEL HUB AND KNUCKLE

REMOVAL
Remove the engine guard if the suspension arm will be
removed (page 2-7).
Remove the front wheel (page 16-13).
Remove the two hose clamp bolts (1) from the upper
arm.

Remove the two selling bolts [1] and outboard guard (2).
Support the caliper Remove the following:
so that it does nol - two mounting bolts [3J
hang from the brake - brake caliper [4J
hose. Do not (WiSf or
bend the brake
"""".

16-16
 FRONT WHEEUSUSPENSION/STEERING
- cotter pin [1]
- hub nul (2]
- wheel hub [3]

- three socket bolts [1J

- splash guard [2]

11J

- coller pin [1 J (from the lie-rod ball joint stud)

- ball jOint nul {2] (by holding the joint stud nat
surfaces [3])
- tie-rod [4]

- cotter pins [1]

Loosen the ball joint nuts [2) . but do not remove them
yet.

16-17
FRONT WHEEUSUSPENSION/STEERING
Release the ball joints, using the special tool according
to the following instructions.

TOOL:
(1] Batt joint remover, 28 mm 07MAC·Sl00201 o r
07MAC·Sl00202
(U.S.A. only )

111
Apply grease to the ball joint remover at the point (1) ~=================~
shown. \2)
This will ease installation of the tool and prevent
damage to the pressure bolt [2J threads.
Insert the jaws carefully, making sure that you do not
damage the ball joint boot.
If necessaty. appJy Adjust the jaw spacing by turning the pressure boll. ,
penetf1ltmg type
lubricant /0 loosen
the bal/pnt.

To prevenllhe tool from dropping, tie the strap [ 1] on a ;:=================~

neighboring solid part such as the suspension arm, tie-
rod , etc. before operation.
NOTE :
Do not tie the strap on the brake hose, brake pipe,
rubber boot. and other parts that can be damaged
easily.

Once the 1001 is in place, turn the adjusting bolt [1] as ;:======::::==========~
necessary to make the jaws parallel.
Then hand-lighten the pressure bolt [2] and recheck the
jaws to make sure they are still parallel [3].
Tighten the pressure bolt with a wrench until the ball
joint stud pops loose.
Remove the ball joint nuts and the knuckle from the I
upper and lower arms. I \31
L

\11

16-18
 FRONT WHEEUSUSPENSION/STEERING
INSPECTION
Remove the dust seals (1J from the knuckle [2] .
Turn the inner race of each bearing (3) in the knuckle
with your finger. The bearings should turn smoothly and
quietly. Also check that the bearing outer race fils tightly
in the hub or knuckle.
Inspect the knuckle for damage or cracks.
Inspect the ball jOint boot [4] for tears or other damage
by moving the ball joint stud.
It should move freely and smoothly.

BRAKE DISC REPLACEMENT

Remove the four disc bolts [1] and brake disc \21 from
the wheel hub [3]. $I
Do not get grease Inslall a new brake disc with new disc bolts and lighten
on the brake disc or them to the specified torque.
stopping power will
be reduced. TORQUE : 42 N'm (4.3 kgf'm , 31 IbHt)

121
BEARING REPLACEMENT
Remove the inner dust seal [1) and Quter dust seal (2]
from the knuckle.

16-19
FRONT WHEEUSUSPENSIONfSTEERING
Remove the snap ring (1) and drive the bearings [2] out
of the knuckle.

TOOLS ;
Driver 07749-0010000
Attachment, 40 x 42 mm 07746-0010900
Pilot, 30 mm 07746-0040700
Pack the cavities of a new bearings with grease.
Drive in the bearing squarely with the marked side
facing up until l hey are fully sealed .
TOOLS :
(3] Driver 07749-0010000
[4] Attachment, 52 x 55 mm 07746-0010400
(51 Pilot, 30 mm 07746"()040700
Inslall the snap ring into the knuckle groove with the
chamfered side facing in .
13]

14]

Apply grease to the lips of new inner dust seal [1) and
Quter dust seal [2] and install each seal until it is fl ush
with the knuckle, being careful not to damage the lip.

TOOLS: (31
Inner dust seal:
[3] Driv er 07749-0010000
[4} Oil seal driver attachment 07 JAD·PH801 01
Outer dust s eal:
Fork seal dr iv er attachment 07947·KA40200
Pack the seal lips of the inner dust seal with 2.5 - 3 g of
grease.

(2.S - 3g)

16-20
 FRONT WHEEUSUSPENSIONfSTEERING
BALL JOINT REPLACEMENT
Remove the snap ring (1) from the ball jOint [2).

Set the knuckle [11 and speciallools with "A" mark [21
side of the remover/installer facing to the ball joint in the
vise as shown,
Press the ball jOint [3) out of the knuckle.
TOOLS :
[4] Ball joint remover/installer 07WMF·HN00100
[5J Attachment, 28 x 30 mm 07946·1870100

Set the knuckle [1] and special tools with "8" mark [2]
side of the removerlinstaller facing to the ball joint [3] in
the vise as shown.
Press the ball joint into the knuckle until it is fully
sealed .
TOOLS :
[4] Ball joint remover/installer 07WMF·HN00100
[5] Attachment, 20 mm 1.0. 07746-0020400

I NOTICE I
If you feel strong resistance when compressing the
vise, stop. Reset the attachment of the tool so that the
ball joint head can go into the hollow of the attachment
and try again.
Install the snap ring [1] with the chamfered edge facing
in.

16·21
FRONT WHEEL/SUSPENSION/STEERING
iNSTALLATION
Inslallthe knuckle [1] onto the drive shaft [2]. and lower
[1J
and upper arms with the ball jOint nuts {3J .
Tighten each joint nut to the specified torque and further
tighten unlil its grooves align with the cotter pin hole.
[2[
TORQUE : 29 N'm (3.0 kgf-m , 21 IbHt)

Install new cotter pins [4].

[4J I!t

Inslall the tie-rod [1 J into the knuckle with a new joint nul
[2i·
Tighten the nut to the specified torque by holding the
joinl stud flat surfaces [3] .
TORQUE : 54 N'm (5.5 kgf'm , 40 IbHt)
Install a new cotter pin [41.

Install the splash guard [1] with new bolts [2J and
tighten them to the specified torque .

TORQUE : 11 N'm (1.1 kgf'm, 8lbHt)

[2J I!t

[1i

Apply molybdenum disulfide grease to the drive shaft ~;;;;;;;;;;;;;;;;;;;;;;;;;;;;;.;,;;;;;;;=======~

splines.
Pack the dust seal lips with 2.5 ~ 3 9 of grease.

(2.5 -3 g)

16-22
 FRONT WHEEUSUSPENSION/STEERING
Install the wheel hub 11) and hub nut [2].
Tighten the nut to the specified torque and further
lighten until its grooves align wi th the cotter pin hole.
TORQUE: 78 N'm (8.0 kgf'm, 58 IbHt)
Install a new cotter pin [3].

111
Install the brake caliper [1] with new mounting bolls [2]
and lighten them to Ihe specified torque.
;========;,;;;;;;;;;;;,;;;;;;;;;;;;;;;;
TORQUE: 30 N'm (3.1 kgf-m , 22 Ibf·ft)

Install the outboard guard {3] and lighten the bolts [4].
~ 12J

Install the hose clamps (1] with new clamp bolts [2) and
tighten t hem to Ihe specified torque.

TORQUE: 12 N'm (1 .2 kgf-m , 9 IbUl)

Install the front wheel (page 16-13).

SUSPENSION ARM
REMOVAL
Remove the wheel hub and knuckle (page 16-16).
Remove the following :
- pivot nuts [1] and bolls [2]
- lower arm [3]

16-23
FRONT WHEEUSUSPENSION/STEERING
- shock absorber lower mounting nut [11 and bolt (2]
- pivot nut [3] and bolt [4]
- upper arm [5J
- dust seal caps [6J

INSPECTION
Check the pivot bushings [1) for wear or damage. IrI1i]1~======:::~foi;----l
Inspect the ball joint boot (2] on the upper arm [3J for I :) . @)
lears or other damage by moving the ball joint stud [4).
It should move freely and smoothly.
Remove the bolt [5) and inboard guard [6] from the
lower arm [7] if necessary.

131
14J
16J

BALL JOINT REPLACEMENT

Remove the snap ring [1] from the ball joint [2] .

16·24
 FRONT WHEEUSUSPENSION/STEERING
Sel the upper arm (1) and special tools with "A" marl< 12)
side of the remove r/installer facing to the ball joint [3) in
the hydraulic press as shown.
Press the ball ;oint out of the upper arm.
TOOLS :
[4) Ba ll joint remover/installer 07WMF·HN001 00
(5J Attachment, 28)( 30 mm 07946-1870100

Set the upper arm PI and special lools with "8" mark 121
side of t he remover/installer facing to the ball joint (3] as
shown.
Press the ball joint into the upper arm until it is fully
seated.
TOOLS:
(4) Ball joint remover/installer 07WMF·HN00100
[5] Attachment, 20 mm I.D. 07746-0020400

I NOTICE I
If you feel strong resistance when lowering the press,
stop. Reset the attachment of the tool so that the ball
Joint head can go into the hollow of the attachment and
try again.
Install the snap ring (1) with the chamfered edge facing
in .

INSTALLATION
Apply molybdenum disulfide grease to the inner
surfaces of the pivot bushings (1 J and install the pivot
collar (2) into the upper arm.
~~
131

j
Apply molybdenum disulfide grease to the lips of new
dust seal caps (3) and inslalilhem onto the upper arm .
111 ~

,- 131 ~
121

16·25
FRONT WHEEUSUSPENSION/STEERING
Insert the bolts from Install the upper arm [1] into the frame with the bolt (2]
the front skie. and a new nut (3]10 the specified torque.

TORQUE : 34 N'm (3.5 kgf-m, 25 IbHt)

Insert the bolt from Connect the shock absorber to the upper arm with the
the rear side. bott (4J (10 x 45 mm) and a new nut [5] to the specified
torque.
TORQUE : 39 N'm (4.0 kg f'm , 29 IbHt)

Insert the bolts from Instalilhe lower arm (1) with the pivot bolts [2] and new
the front side. nuts [3]. and loosely lighten them.
Install the knuckle and wheel hub (page 16-22).
Install the front wheel (page 16-13).
Place the vehicle on level ground and tighten the lower
arm pivot nuts to the specified torque.
TORQUE : 39 N'm (4.0 kgf-m , 29 IbHt)
Install the engine guard (page 2-7).

FRONTSHOCKABSORBER
REMOVAL
Support the vehicle using a hoist or equivalent and
raise the front wheels off the ground.
Support the lower arm. Remove the mounting nuts and
bolts (1), and front shock absorber [2).

INSPECTION
Remove the pivot coilar 11).
Check the pivol bushings [2] for wear or damage.
Check the damper unit for leakage or other damage.
Replace the shock absorber assembly if necessary.

16-26
 FRONT WHEEUSUSPENSION/STEERING
INSTALLATION
Install new dust seals [1] into the lower pivot with the lip
side facing the bushing until they are fully seated.
Apply molybdenum disulfide grease to the lower pivot
bushing [2] and dust seal lips.
Install the pivot collar [3].

12)

[3) ~

Insert the bolts from Install the shock absorber [ 1] with the mounting bolls ~:!iiilliiiiiii_.illiiiiiii~;;;;;;;;;;rr::::;;;::ir.!~
/herearside. (upper: 10 x 42 mm, lower: 10 x45 mm) and new nuts
[2], and tighten them to the specified torque.

TORQUE: 39 N'm (4.0 kgf'm , 29 IbHt)

STEERING SHAFT (FM/FE models)

REMOVAL
Remove the following:
- mudguards (page 2-6)
- front fender/carrier (page 2-8)
- front wheels (page 16-13)
- meier cover stay (page 16-8)
Release the wire clip [1J.
Remove the following connectors from the frame and
disconnect them :
- FM model : handlebar switch 10P (Green) [2]
FE model: handlebar switch 14P (Green) [2]
- ignition switch 4P (White) [3]
- front sub-wire harness 14P (Gray) [4J

Remove the following :

- colter pins [1J (from the tie-rods )
joint nuts [2] (by holding the joint stud flat surfaces)
tie-rods [3] (from the steering arm)
cotter pin [4J (from the steering shaft)
shaft end nut and washer [5]
steering arm [6]

16-27
FRONT WHEEUSUSPENSION/STEERING
Supporllhe - hose clamp bolt [1]
I
handlebar securely - wire band [2]
whi~ keeping the - cables [3) and wires [4] (from the upper guide IS])
master cylinder - two nuts and washers [6)
reservoir upright. - handlebar assembly (7] (from the steering shaft)

- brake hose (1) (from the clamp [2])

- connector clip [31
- cables [4J and wires [5J (from the lower guide)
- two holder bolts (6]
- steering shaft holder [7] 1'1

131

- steering shaft [1] (from the shaft bearing)

- shaft bushing [2J 1'1

- dust seals [1]

16-28
 FRONT WHEEUSUSPENSION/STEERING
INSPECTION
SHAFT BUSHING
Check the shaft bushing for wear or damage.

STEERING SHAFT
Check the steering shaft for distortion or damage.

STEERING SHAFT BEARING

Turn the mner race of the sleermg shaft bearing with
your finger.
The bearing should turn smoothly and quietly. Also
check thai the bearing ouler race fits tightly in the
frame.

BEARING REPLACEMENT
Remove the snap ring (11.

111

16-29
FRONT WHEEUSUSPENSION/STEERING
Assemble the special toots and a 10 mm washer (1 ]

--n
onto the steering shaft bearing [21. [4[
Remove the bearing by tightening the nut (3]. [51-

TOOLS :
[4] Clutch compressor 07LAE·PX40100
aHachment
[5] Compressor bolt assembly 07GAE·PG40200 or
I- -n I
07GAE·PG4020A [2[
(U.S.A. only) fV
[6] Attachment, 34 mm 07ZMD·MBW0100 [6}- , , -_ _
['I
[3}

Drive a new bearing into the frame with the marked side ~===============~
facing up.
TOOLS:
[1] Driver 07949·37 10001
[2] AHachment, 42 x 47 mm 07746-0010300
(3] Pilot, 22 mm 07746-0041000

Make sure lhe snap Install the snap ring into the groove properly with the
nng Is firmly sealed chamfered edge facing down.
in /he groove

[NSTALLATION
Coa' 'he Hp, of "ew dust ,eal, with 9,ea,e.
Install each dust seal [1] with the flat side facing oul so
I
that it is flush with the frame edge.

" "\'
~~~ce~ - 3 g of grease to the shaft bushing inner ~=======~=['=[=_=~
=~=(2=-=3=9=1~
InstaH the shaft bushing [1] onto the steering shaft (2]
with the arrow mark (3] facing up.
Install the steering shaft into the bearing.

16-30
 FRONT WHEEUSUSPENSION/STEERING
Temporarily install Inslall the steering shaft holder (1] with the guide 121
the handlebar facing down while rouling the wires and cables into the
assembly onto the guide. Inslall the two holder bolts (3).
sleenng shaff.
Install the brake hose [4] into the damp 151 .
Install the 2P (Red) connector [6) onlo the shaft holder.
Tighten the holder bolts alternately in several sleps.
TORQUE : 32 N'm (3.3 kgf·m. 24 IbHt)
161

Apply molybdenum disulfide grease to the steering

shaft spline 111.
Install the steering arm [21 over the steering shaft with
the marked side facing down by aligning the wide looth
with the wide groove.
Inslallthe washer and a new end nul (3). and lighten the
nut to the specified torque.
TORQUE : 108 N'm (11 .0 kgf'm,80 IbHt)
. ,
----'--
Install a new cotler pin (4].
Install the tie-rods [5] into the steering arm. Align , \
Install new joint nuts [61 and tighten them to the
specified torque by holding the joint stud flat surfaces. 121
TORQUE : 54 N·m (5.5 kgf·m, 40 Ibf-ft)
Install new coller pins (7) into the ball joint studs.

Install the handlebar assembly (1] onto steering shaft

with the washers and new lower holder nuts [2].
Tighten the nuts.
Install the wires (3] and cables 14] into the guide [5].
Secure the wires to the guide with the wire band [6].

!
Install the hose clamp 171 with a new clamp bolt [8] and
tighten it to the specified torque.
TORQUE : 12 N·m (1.2 kgf·m, 9 tbl-fl)

Connect the following connectors and install them onto

the frame.

• -
-
-
front sub·wire harness 14P (Gray) {1]
ignition switch 4P (White) 12]
FM model : handlebar switch 1QP (Green) (3]
FE model : handlebar switch 14P (Green) 13]
Secure the wires with the wire clip (4] .
Install the following:
- meter cover stay (page 16-9)
- front wheels (page 16-13)
- front fender/carrier (page 2-8)
- mudguards (page 2-6)
131 12J 111

16-31
FRONT WHEEUSUSPENSION/STEERING
STEERING SHAFT/EPS UNIT (FPM/FPE
models)
REMOVAL
Remove the following:
- mudguards (page 2·6)
front fender/carrier (page 2-8)
- front wheels (page 16-13)
- meter cover slay (page 16-8)
131 I!
- bolt [11 and clutch arm cover (2] (release from the
two tabs (3])
- adjusting nut (4]
- cable retaining plate (5]
- 2WD/4WD selector cable (6) (remove from the cable
holder [7) and joint pin [8])
- cable spring (9J
- jOint pin

121

16J
[7J "{
\',:- --

18J
Release the wire clip [1).
Remove the following connectors from the frame and
disconnect them:
- FPM: handlebar switch 10P (Green) [2)
FPE: handlebar switch 14P (Green) [2]
- ignition switch 4P (While) [3]
- front sub-wire harness 14P (Gray) [4)

Remove the following:

- EPS motor 2P (Gray) connector (1]
- torque sensor 3P (Gray) connector 121

,
16-32 1
 FRONT WHEEUSUSPENSIONfSTEERING
- cotler pins (1J (from Ihe lie-rods)
- Joint nuts (2J (by holding the joint stud flat surfaces)
- tie-rods (3] (from the steering arm)
- cotler pin (4] (from the steering shaft)
- shaft end nut and washer [5]
- sleering arm (6]

Suppor1the - hose clamp bolt (1)

handlebar securely - wire band [2]
while keeping the - cables [3] and wires [4] (from the upper guide (5])
master cylinder - two nuts and washers [6]
reservoir upright. - handlebar assembly 17] (from the steering shaft)

- brake hose [1] (from the clamp)

- connector clip [2] (from the shaft hOlder)
- cables [3] and wires (4] (from the lower guide)
- two holder bolts (5]
- steering shaft holder [6J

131

16-33
FRONT WHEEUSUSPENSION/STEERING
- steering shaft pinch bott [11
Loosen the EPS unit mounting fasteners [2].

Hold the EPS unit Remove the following:

securely and - steering shaft [3]
maneuver it auto! - shaft bushing [41
the frame to the left - mounting nuts and bolts [2]
side, being careful - EPS unit [51
nor to damage lhe
shaft splines.

- dust seals [1)

INSPECTION
STEERING SHAFT
Check the steering shaft for distortion or damage.

16·34
 FRONT WHEEUSUSPENSIONfSTEERING
SHAFT BUSHING
Check the shaft bushing for wear or damage.

EP$ UNIT
Check each shaft [11 of the EPS unit for wear or , - - - - - - - - -- - - -- - ----,
damage.

111

STEERING SHAFT BEARING

Turn the inner race of the steering shaft bearing with
your finger.
The bearing should turn smoothly and quietly. Also
check that the bearing outer race fits lighUy in the
frame.

BEARING REPLACEMENT
Remove the snap ring (I].

16-35
FRONT WHEEUSUSPENSION/STEERING
Assemble the special tools and a 10 mm washers [1J
onto the steering bearing {2J. 151 __ . 141
Remove the bearing by tlgh tening the nut [3). 1

TOOLS :
[4] Clutch compressor 07LAE·PX40100
attachment
[5] Compressor bolt assembly 07GAE·PG40200 or
07GAE·PG4020A

[6) Attachment, 34 mm
(U .S.A. only)
07ZMD-MBW0100 (6) - - '1:=cf-__
11 I

(3)

Drive a new bearing into the frame with the marked side
facing up.
~=================~
TOOLS:
[1J Driver 01949·3710001
{21 Attachment, 42 x 47 mm 07746-0010300
(21
[3) Pilot, 20 mm 07746-0040500

Make sure the snap Install the snap ring [1] into the groove properly with the
nng is firmly sealed chamfered edge facing down.
in the groove.

INSTALLATION
Pack the seal lips of new dust seals [1] wi th grease.
Install each dust seal with the flat side facing out so that
it is flush with the frame edge.

16-36
 FRONT WHEEUSUSPENSION/STEERING
Hold the EPS unil Place the EPS unit [1] into Ihe frame and install it into
securely and the bearing.
carefully maneuver
Install the mounting bolts [2] from the right side and Ihe
i/ into place, being
nuts [3]. but do not lighten them yet.
careful nolto
damage the dust
seal in the frame
and shaft splines_

Apply molybdenum disulfide grease to the splines.

Inslall the steering arm [1) with Ihe marked side [21
facing down by aligning Ihe wide tooth with the wide
groove in the shaft.
Inslallthe washer [3J and a new end nut [4}, and tighten
it to the specified torque.
TORQUE: 108 N'm (11 .0 kgf'm , 80 tbUt)

Install a new cotter pin [5].

16·37
FRONT WHEEL/SUSPENSION/STEERING
Apply 2 - 3 9 of grease to the shaft bushing inner
surface.
Install the shaft bushing [1] onto the steering shaft [2)
with the arrow mark [3] facing up.
Install the steering shaft over the input shaft [4] of the
EPS unit by aligning the wide tooth with the wide
groove. Install a new pinch bolt (5] .

Temporarily install Install the steering shaft holder (1] with the guide [2]
the handlebar facing down while routing the wires and cables into the
assembly onto the guide. Install the two holder bolts (3].
steering shaft.
Install the brake hose [4] into the clamp [5].
Install the 2P (Red) connector (6] onto the shaft holder.
Be sure the steering shaft is fully seated onto the EPS
unit. Install and lighten a new pinch bolt (7] to the
specified torque.
TORQUE : 60 N'm (6.1 kgf'm, 44 IbHt)
Tighten the holder bolts alternately in several steps.
TORQUE : 32 N'm (3.3 kgf'm , 24 IbHt)

Tighten the EPS unit mounting nut [11 to the specified

torque.

TORQUE : 22 N·m (2.2 kgf·m , 161bHt)

16-38
1
 FRONT WHEEUSUSPENSIONfSTEERING
Install the tie-rods 11J into the sleering arm [21.
Install new joint nuts [3] and lighten them to the
specified torque by holding the joint stud flat surfaces.
TORQUE : 54 N'm (5.5 kgf'm, 40 IbHt)
Install new cotter pins (4J into the ball joint studs.

Install the handlebar assembly [11 onto steering shaft

with the washers and new lower holder nuts [21 .
Tighten the nuls.
Install the wires (3] and cables [4) into the guide 151.
Secure the wires to the guide with the wire band {61 .
Install the hose clamp [71 with a new clamp bolt [8J and
lighten it to the specified torque,
TORQUE: 12 N'm (1.2 kgf-m , 9Ibf-ft)

Connect the torque sensor 3P (Gray) connector !1] and

the EPS motor 2P (Gray) connector [2].

Connect the following connectors and install them onto

the frame.
- front sub-wire harness 14P (Gray) [11
- ignition switch 4P (White) [2]
- FPM : handlebar switch 10P (Green) 13]
FPE : handlebar switch 14P (Green ) [3]
Secure the wires with the wire clip [4].

[3J [2J

16-39
FRONT WHEEUSUSPENSIONfSTEERING
Install the spring [1] onto the selector cable [2] .
Insert the cable into the cable holder [3] and connect it
to the clutch arm with the joint pin {4] and adjusting nut
[51·
Set the groove in the cable grommet [6J onto the cover
base end properly.
Install the retaining plate [7J onto the cable with the
concave facing the cable holder to secure the cable.
Adjust the 2WQ/4WD selector cable (page 3-19).
InstaU the following:
- meier cover stay (page 16-9)
[1 I
- front wheels (page 16-13) [41
- front fender/carrier (page 2-8)
- mudguard (page 2-6)
Referto ·Service Perform the torque sensor initialization (page 24-13).
Information" for
service location of
the initialization
(page 16-4).

TIE-ROD
REMOVAL
Remove the following :
- mudguards (page 2-6)
- front wheel (page 16-13)
Remove the cotler pins [1J.
Remove the joint nuts [2] by holding the jOint stud flat
surfaces [3] with an open end wrench.
Remove the lie-rod (4] from the steering arm and
knuckle.

16-40
 FRONT WHEEL/SUSPENSION/STEERING
INSPECTION
Inspecllhe lie-rod [1] for distortion or damage.
Inspecllhe ball joint boots 12J for tears or other damage
and the ball joints [3] for looseness by moving the ball
jOint studs [4J.
They should move freely and smoothly without binding.

111

[41

DISASSEMBLY/ASSEMBLY
loosen the lock nuts (1), and remove the ball joints and r - - - - - - - - - - - - - - - - -- ,
lock nuts from the tie-rod.
Install the right-hand threads nul and unmarked ball [11
joint on the flat (wrench holding area for loe adjustment)
side [2) of the lie-rod, and the lefl-hand threads nut and
"L" marked [3) ball joint on the opposite side.

121 131

Note the reference distances (between the lock nut and ~=================~
thread end).

REFERENCE DISTANCES:
A: 8.0 rnm (0.3 1 in)
B: 8.0 mm (0.3 1 in)
A difference between distances A and B should be 3
mm (0.12 in) max.
Tighten these nuts
after installing the
Temporarily tighten the lock nuts while the ball joint
positions are approximately 180' from each other.
1-
B A
tie-rod and
adjusting the too.

16-41
FRONT WHEEUSUSPENSIONISTEERING
Install the tie-rod [11 with the flats (2] of the rod toward
the knuckle [3).
Install new joint nuts (4) and lighten them to the
specified torque by holding the joint stud flat surfaces
15J.
TORQUE: 54 N'm (5.5 kgf'm , 40 IbHt)

Install new cotter pins {6].

Install the front wheel (page 16-13).
Adjust the loe (page 3-26).
Inslalilhe mudguards (page 2-6).

16-42
 17. REAR WHEEUSUSPENSION

SYSTEM COMPONENTS····························17-2 REAR WHEEL .. ··········································· 17·6

SERVICE INFORMATION··· ········ ················ 17-3 REAR SHOCK ABSORBER ·······················17-6

TROUBLESHOOTING·································17 -5 SWINGARM ················································ 17-8

17-1
REAR WHEEUSUSPENSION
SYSTEM COMPONENTS

39 N'm (4.0 kgf·m, 29Ibf-ft)

64 N'm (6.5 kg f·m. 47 IbUt)

39 N'm (4 0 kgf'm, 29Ibf.ft)

118 N'm (12.0 kgf-m. 87Ibf-ft)

17-2
 REAR WHEEUSUSPENSION
SERVICE INFORMATION
GENERAL
This section covers service of the rear wheel , rear shock absorber and swingarm.
A jack Of other support is required to support the vehicle.
Use Honda Genuine replacement bolts and nuts for all suspension pivots and mounting points.
For tire information . see Front Wheel/Suspension/Steering section (page 16-13).
For brake system service, see Brake System section (page 18-2).
For driving mechanism service , see Rear Driving Mechanism section (page 20-2).

SPECIFICATIONS
ITE M STANDARD _~ ERV I C E LIMI T
-
r- - 4.0mm 0.16 in)
E standard 30 kPa (0.30 kgf/cm2, 4.4 psi )
With cargo 30 kPa (O .30- kgf/cm1, 4:4 psi )
-

TORQUE VALUES
THREAD TORQUE
ITEM Q'TY REMARKS
OIA. (mm) N'm (kgf'm, IbHl)
Rear wheel nut 6 10 64 (6.5, 47)
Shock absorber upper mounting nut 1 10 39 (4 .0, 29) Lock nut: replace with
a new one.
Shock absorber lower mounting nut 1 10
-- 39 (4 .0 , 29) Lock nut: replace with
a new one.
Universal joint guard bolt 2 6 10 (1 .0 , 7 ) ALOe bolt: replace -
with a new one.
t -Swingarm pivot bolt 2 12 118 (12.0, 87 ) ALoe bolt: replace
with a new one.

17·3
REAR WHEEUSUSPENSION
TOOLS
Attachment, 24 x 26 mm Pilol, 12 mm Pilot, 20 mm
07746-0010700 07746-0040200 07746-0040500

B
Pilot, 25 mm Driver Attachment, 28 )( 30 mm
07746-0040600 07749·0010000 07946-1870100

Driver
07949-3710001

17-4
 REAR WHEEUSUSPENSION
TROUBLESHOOTING
Rear wheel wobbling
Bent rim
Worn or damaged rear axle bearings
Faulty lire
Loose wheel hub nut
Faulty swingarm pivot bearings
Rear wheel hard to turn
Faulty rear axle bearings
• Bent rear axle
• Rear brake drag
Soft suspension
• Weak shock absorber spring
• Oil leakage from damper unit
Stiff suspension
Damaged shock absorber damper
• Faulty shock absorber pivot bushings
• Damaged swingarm pivot bearing
Rear suspension noise
Faulty rear shock absorber
• Loose rear suspension fasteners
• Worn rear suspension pivot bearings or bushings
Steering is heavy
Steering shaft nut or holder too tight
• Damaged steering shaft bushing
• Damaged steering shaft bearing
Any wheel is wobbling
Excessive knuckle or hub bearing play
Bent rim
Improperly installed wheel hub
Loose suspension arm
Bent frame
Vehicle pulls to one side
Tire air pressure incorrect
Faulty shoCk absorber
Bent tie-rod
Incorrect tie-rod adjustment
Improper wheel alignment
Bent frame

17·5
REAR WHEEUSUSPENSION
REAR WHEEL
REMOVAL
Loosen the wheel nuts [1].
Support Ihe vehicle using a hoist or equivalent and
raise the rear wheels off the ground .
Remove the wheel nuts and rear wheel.
For life removal/installation and repair, see Front
Wheel/Suspension/Steering section (page 16-13).

INSTALLATION
Do not interchange Install the rear wheel with the tire valve facing out and
the left and right the arrow mark. [2] facing in the normal rotating
wheels direction.
Install the wheel nuts wi th the tapered side facing
inward and tighten them to Ihe specified torque.
TORQUE : 64 N'm {6.S kgf'm, 47 IbHtl

REAR SHOCK ABSORBER

REMOVAL
Remove the skid plate (page 3-18).
Support the vehicle using a hoist or equivalent and
raise the rear wheels off the ground.
Support the swingarm. Remove the nuts and bolts [1[,
and the shock absorber [2).

17-6
 REAR WHEEL/SUSPENSION
INSPECTION
Check the upper pivot bushing [1] for wear or damage.
Check the damper unit [2] for leakage or other damage.
Replace the shock absorber assembly jf necessary.
Remove the lower pivot collar [3).

Check the lower pivot bushing [1] and collar (2) for wear ~;;;;;;;;;;;:::;:=============~
or damage.

INSTALLATION
Inslall new dust seals (1] into the lower pivot with the flat
side facing out unlillhey are fully seated.
Apply molybdenum disulfide grease to the lower pivot
bushing [21 and dust seal lips.
Inslall the pivot collar [3].

131~ 121 ~

17·7
REAR WHEEUSUSPENSION
Insert/he bolts from Instal! the shock absorber [1) with the mounting bolls (2)
the right side. and new nuts [3]. and tighten them to the specified
torque.

TORQUE :
Upper: 39 N-m (4.0 kgf'm, 29 Ibf·tt)
Lower: 39 N'm (4.0 kgf'm, 29 IbHt)
Ins18llll'le skid plate (page 3-18) .

SWINGARM
REMOVAL
Remove the mudguards (page 2-6)
Remove the final gear assembly (page 20-9) ,
Remove the following:
- breather hose [1] (from the clamp [2])
- pivot nuts and bolts [3]
- swingarm [4]

- two bolts (1) and universal joint guard [2]

- pivot collars [3]
- dust seals [4J
Check the bearings in the pivots for wear or damage.

/
131
\J
131

17-8
 REAR WHEEL/SUSPENSION
BEARING REPLACEMENT
REMOVAL
Press the needle bearing out of the right pivot using the side (needle
special tool.
[1[~_.
TOOLS :
[1] Driver 07949·3710001
[21 Attachment, 24 x 26 mm 07746..(}010700
(3] Pltot, 20 mm 07746"(}040500
Press the ball bearing and setting collar oul of the left
pivot.
TOOLS :
[4] Driver 07949·3710001
[5] Attachment, 24 x 26 mm 07746..(}010700
[6) Pilot, 12 mm 07746"(}040200

14[ _ _

[51_~

INST ALLA liON

Apply molybdenum disulfide grease to the rollers of a ~'~~ilill.~~~--------l
new needle bearing. ~

Press in the bearing Press the needle bearing into the right pivot until the 7.0 - 7.5 mm
wilhthemarked depth from the Quter surface is 7.0 - 7.5 mm (0.28- (0.28 - 0.30 in)
side facing up. 0.30 in).

TOOLS :
(1) Driver 07749-0010000
(2] Attachment, 24 x 26 mm 07746-0010700
(3] Pilot, 20 mm 07746-0040500

Pack molybdenum disulfide grease into the cavity of a

new ball bearing [11. II~~~~~iiiiiii~i~===l
Press in /he bearing Press the ball bearing and the collar [2] into the left
with the marked pivot until they are futly seated . [31
side facing up.
TOOLS :
Bearing :
[3] Driver
141
07749·0010000
[4] Attachment, 28 x 30 mm 07946·1870100 [21
Pilot, 12 mm 07746-0040200
Collar:
Driver 07749-0010000
Attachment, 28 x 30 mm 07946·1870100
[5] Pilot, 25 mm 07746-0040600

17-9
REAR WHEEUSUSPENSION
INSTALLATION
Pack molybdenum disulfide grease into the seal lip r - - -- - - - -- - - -- - - -- -
cavity of each new dust seal Pl. ~~ , ~", ~
Install the dust seals until the depth from the outer ...... ~ lllliil'

'u.".", mm. 1)\11 ~ {11 I

l
1 mm
(4 places)

Right side: Left side:

Install the pivot collars [11 in position as shown.

Install the universal joint guard [2] with new bolts [3] and
tighten them to the specified torque.
TORQUE : 10 N'm (1 .0 kgf'm, 7 IbHt)

~\f
{11
{21
111
Insert the bolts from Install the swingarm [1 1 with new pivot bolls [2J and nuts ~==========~=====:::;::;
the outside. (3], and tighten them to the specified torque.

TORQUE : 118 N'm (12.0 kgf'm , 87 IbHt)

Install the breather hose [4J into the damp [5].

111
Install the following:
- final gear assembly (page 20-22)
- mudguards (page 2-6)

17-10
 18. BRAKE SYSTEM

SYSTEM COMPONENTS .... ··· .. · .. ················ 18-2 BRAKE PAD/DISC ·················· ··············· .... · 18-8

SERVICE INFORMATION ···························18-4 FRONT MASTER CYLINDER ··················· 18-10

TROUBLESHOOTlNG ·································18-6 FRONT BRAKE CALlPER········ ················18-12

BRAKE FLUID REPLACEMENT/AIR REAR BRAKE DRUM/SHOES ················· 18-16

BLEEDING ······· ······· ····································· 18-7
REAR BRAKE PEDAL··········· ··················· 18-20

18-1
BRAKE SYSTEM
SYSTEM COMPONENTS

12 N'm (1.2 kgf-m, 9lbHt)

2.0 N'm (0.2 kgf·m, 1.5IbHt)

34 N'm (3.5 kgf-m, 251bHt)

~v
2.4 N'm (0.2 kgf-m, 1.8 IbHt)

17 N'm (1.7 kgf-m, 13 IbHt)

34 N'm (3.5 kgf-m, 251bHt)

30 N'm (3.1 kgf'm, 221bHt)

18-2
 BRAKE SYSTEM

20 N"m (2.0 kgf-m, 1SlbHt)

137 N·m (14.0 • 101 Ibf-ft)

18-3
BRAKE SYSTEM
SERVICE INFORMATION
GENERAL

ACAUTION
Frequent inhalation of brake pad or lining dust, regardless of material composition could be hazardous to your health.
Avoid breathing dust particles.
• Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner.
~~~--------~

NOTICE I
Spilled brake fluid will severely damage the plastic parts and painted suriaces. It is a/so harmful to some rubber parts. Be careful
whenever you mmove the reservoir cap; make sure the front reservoir is horizontal first.
A contaminated brake disc, pad, drum or shoe reduces stopping power. Discard contaminated pads or shoes. and clean a
contaminated disc or drum with a high quality brake degreasing agent.
Never allow contaminants (dirt, water. etc.) to get into an open reservoir.
Once the hydraulic system has been opened. or if the brake feels spongy. the system must be bled.
Always use fresh DOT 4 brake fluid from a sealed container when servicing the system. Do not mix different types of fluid as
they may not be compatible.
Always check brake operation before riding the vehicle.

SPECIFICATIONS

I .

Rear brake

~I
18-4
 BRAKE SYSTEM
TORQUE VALUES
I
ITEM
Brake hose oil 00"'''.---- -
O'TY
3
l
THREAD
OlA.
10
(mm1a'm TORQUE
(kgf'm , Ibl-ft)
34 (3.5. 25)
REMARKS

Front brake caliper bleed valve 2 = = =18 5.4 (0.6. 4.0)f =:::::= =-
"'".w'"--__
Front master cylinder reservoir cap s... 2 _ _ _.4 2.0 (0.2. 1.5)_ _ _
Pad pin 4 -+_--;'0 17 (1 .7, 13) ,
Pad pin plug
Front brake lever pivot bolt
4_
1 ~==-'~O
6 2.4
1.0 (0.2. 1.8)~
(0.1. 0.7)
Front brake lever pivot nut 1 ---+_ _:6 5.9 (0.6. 4.4)
Front brake lighVinhibilor switch screw
1 1 4
-+-
1.2 (0.1. 0.9) Apply locking agent to
the threads .
Front master cylinder holder bolt 2 6 I
12 (1.2,9)
Front brake caliper mounting bolt 4 8 30(3T22-) - ALOe- boil: replace
with a newone.
Front brake caliper slide pin 2 8 22 (2.2. 16) Apply locking agent to
the threads.
;---Front brake caliper bracket pin_ _ __
~ar brake arm pinch bolUnul _ __ _
Rear wheel hub nul tEE 2
8
8

20
17 (1 .7, 13)
20 (2 .0. 15)
137 (14.0, 101) Castle nul' tighten to
the specified torque
and funher tighten
until Its grooves align
with the cotter pin
hole.
Rear brake panel drain bolt 8 12 (1.2. 9)
Brake pipe joint bott 10 14 (1.4, 10)

TOOLS
Oil seal driver ---~'Attachment 72 x 75 mm Driver
070MF-MEG0300 07746·0010600 07749-0010000

~
I
\ )

18-5
BRAKE SYSTEM
TROUBLESHOOTING
FRONT DISC BRAKE
Brake lever soft or spongy
Air in hydraulic system
leaking hydraulic system
Contaminated brake pad/disc
Worn caliper piston seal
Worn master cylinder piston cups
Worn brake pad/disc
Contaminated caliper
Contaminated master cylinder
Caliper not sliding properly
Low brake fluid level
Clogged fluid passage
Warpedldeformed brake disc
Slickinglwom caliper piston
Slicking/worn master cylinder piston
Bent brake lever
Brake lever hard
Clogged/restricted brake system
Slicking/wom caliper piston
Slickinglwom master cylinder piston
Caliper nol sliding properly
Bent brake lever
Brake drags
Contaminated brake pad/disc
Badly worn brake pad/disc
Warped/deformed brake disc
Caliper nol sliding properly
Clogged/restricted fluid passage
Slicking caliper piston

REAR DRUM BRAKE

Poor brake periormance
Brake not adjusted properly
Worn or oontaminated brake shoes
Worn or oontaminated brake drum
Water in brake drum
Inoorreclly installed rear brake arm
Worn rear brake cam

18-6
 BRAKE SYSTEM
BRAKE FLUID REPLACEMENT/AIR
BLEEDING
BRAKE FLUID DRAINING
Turn the handlebar to the left until the reservoir is level
before removing the reservoir cap.
Remove the screws [1J. reservoir cap [2), set plate and
diaphragm .

Connect a bleed hose [1} to the front brake caliper

bleed valve [2J.
Loosen the bleed valve and pump the front brake lever
until no more fluid flows out of the bleed valve.
Perform above procedure for the other side bleed valve.

BRAKE FLUID FILLING/BLEEDING

Close each brake caliper bleed valve.
Fill the master cylinder reservoir with DOT 4 brake fluid
from a sealed container.
Follow the Connect a commercially available brake bleeder [1J to
manufacturer's the bleed valve.
operating
instructions. Operate the brake bleeder and loosen the bleed valve
121.
Check the fluid level If an automatic refill system is not used, add fluid when
often while bleeding the fluid level in the reservoir is low.
the brake to prevent
air from being
pumped into the
system.
If air enters the Perform the bleeding procedure until the system is
bleeder from completely flushed/bled.
around the bleed
Tighten the bleed valve to the specified torque.
valve threads, seal
the threads with TORQUE : 5.4 N-m (0.6 kgf·m , 4.0 Ibf·ft )
teflon rape.
Perform air bleeding for the other side bleed valve.
After bleeding air, operate the front brake lever. If it still
feels spongy, bleed the system again.

18-7
BRAKE SYSTEM
If the brake bleeder is not available, perform the
following procedure;
Pump up the system pressure with the front brake lever
until the lever resistance is felt.
Connect a bleed hose [I] to the front brake caliper
bleed valve (2) and bleed the system as follows:
Do not releaSJJ the 1. Squeeze the brake lever all the way and loosen the
brake /everunti/ the bleed valve 1/4 of a turn. Wail several seconds and
bleed valve has then close the bleed valve.
been Closed. 2. Release the brake lever slowly and wail several
seconds after it reaches the end of its travel.
3. Repeal the steps 1 and 2 until there are no air
bubbles in the bleed hose.
Tighten the bleed valve to the specified torque.
TORQUE: 5.4 N'm (0.6 kgf'm, 4.0 IbHt)
Perform air bleeding for the other side bleed valve.
After bleeding air, operate the front brake lever. If it still
feels spongy, bleed the system again.
Fill the master cylinder reservoir to the casting ledge [11
with DOT 4 brake fluid from a sealed container.
Install the diaphragm, set plate and reservoir cap. and
tighten the screws to the specified torque.
TORQUE: 2.0 N'm (0.2 kgf'm , 1.5IbHt)

BRAKE PAD/DISC
BRAKE PAD REPLACEMENT
Remove the front wheel (page 16-13).
Remove the pad pin plugs.
Loosen the pad pins (1].
Remove the two mounting bolts 121 and brake caliper
(3].
Check the fluid level Push the caliper piston all the way in by prying the
In the master brake pads to allow installation of new pads.
cylInder reservoir as
this operatIOn
causes the fluid
leve/to rise.

18-8
 BRAKE SYSTEM
Pull the pad pins (1) oul of the caliper while pushing the
brake pads (2] in againslthe pad spring [3], and remove
the pads.
Make sure the pad Install new brake pads into the caliper body.
spnng is installed Align the pad pin holes in the caliper body and pads by
correctly. pushing the pads in against the pad spring , and install
Always rep/ace the the pad pins.
brake pads in pairs
to ensure even disc
pressure.

Install the brake caliper (1] so the disc is positioned

between the pads. being careful not to damage the
pads.
Install new mounting bolts [2J and tighten them to the
specified torque.
TORQUE: 30 N'm (3.1 kgf·m. 221bHt)
Tighten the pad pins (3] to the specified torque.
TORQUE: 17 N-m (1 .7 kgf'm , 13 IbHt)
Install the pad pin plugs and tighten them to the
specified torque.
TORQUE : 2.4 N-m (0.2 kgf'm , 1.8 IbHt)
Squeeze the front brake lever to seat the caliper piston
against the pad .
Install the front wheel (page 16-13).

BRAKE DISC INSPECTION

Remove the brake caliper without disconnecting the
brake hose (page 18-12).
Visually inspect the brake disc for damage or crack.
Measure the brake disc thickness al several points.
SERVICE LIMIT: 3.0 mm (0.12 in)
Replace the brake disc if the smallest measurement is
less than service limit.

Check the brake disc for warpage.

SERVICE LIMIT: 0.30 mm (0.012 in)

Check the knuckle bearing for excessive play, if the
warpage ex.ceeds the service limit.
Replace the brake disc if the bearings are normal.
Brake disc replacement (page 16-19).

18-9
BRAKE SYSTEM
FRONT MASTER CYLINDER
REMOVAL
Drain the brake fluid (page 18-7).
Remove the dust cover [1[ and disconnect the
connectors [21 from the switches .
When removing the Disconnect the brake hose by (emoving the oil boll [3)
oil boll, cover the and sealing washers 14].
end of the hose to
Remove the two bolts (5] , holder [61 and master cylinder
prevent
con/emine/IOII.
[II-

DISASSEMBLY/ASSEMBL Y

SEPARATOR

~
CUP 5.9 N·m (0.6 kgf-m .
4.4 Ibf-ft)

I MASTER
PISTON

SNAP RING ----::~~

SWITCHES

PISTON BOOT

BRAKE LEVER 1,2 N 'm (0.1 kgf-m, 0.9Ibf-ft)

18·10
 BRAKE SYSTEM
INSPECTION
Check the piston cups and boot for wear, deterioration , - - - - - - - - -- - - - - -- - - - - - ,
or damage.
Check the spring for damage.
Check the master cylinder and piston for scoring.
scratches or damage.
Measure the master cylinder 1.0.
SERVICE LIMIT : 14.055 mm (0.5533 in)

Measure the master piston O.D.

SERVICE LIMIT: 13.945 mm (0.5490 in)

INSTALLATION
Align the edge of Instalilhe brake master cylinder [1] and holder [2] with ~=------------__.._--,
the master cylinder the "UP· mark facing up. Tighten the upper bolt f3J first,
with the punch then lighten the lower bolt [4] to the speCified torque.
mark {51 on the
handlebar. TORQUE : 12 N'm (1.2 kgf-m , 9 IbUt)

Set the brake hose joint between the stopper groove in

the master cylinder.
Connect the brake hose with the oil bolt [6] and new
sealing washers (7] . and tighten the oil bolt to the
specified torque,
TORQUE: 34 N'm (3.5 kgf'm , 25 Ibf-ft)

Connect the gray Connect the connectors [1] to the switches [2].
Jape (4J wire
Insta!1 the dust cover {3] properly.
connectors 10 the
(1(
upper terminals. Fill and bleed the hydraulic system (page 18-7). [21 (for starting inhibitor)

I- _ 131
(4( ~?!IJ;;" ~
(21 (for brake light)

18-11
BRAKE SYSTEM
FRONT BRAKE CALIPER
DISASSEMLBY
Remove the front wheel (page 16-13).
Drain the brake fluid (page 18-7).
Remove the two bolts [1] and outboard guard [2].
Remove the slide pin plug [3] .

Disconnect the brake hose by removing the oil bolt [1]

and sealing washers [2J.
loosen the slide pin [3].
Remove Ihe brake pads (page 18-8).

Remove the following:

- caliper brackel11] (loosen the slide pin)
- spring washer (2]
- pad spring (3[ 161
- slide pin (4) (by releasing the boot rib from the pin
groove)
- slide pin boot [5J
- bracket pin boot [6J

Take care nOl to Remove caliper piston [1] out of the cylinder by pushing ,---~_"",,;;:---========~
damage the PIs/on it through Ihe fluid inlel.
with the caliper Release the piston boot [2] from the piston groove to
body. remove them.

18-12
 BRAKE SYSTEM
Be careful not to Push the piston seal [1) in and lift it out.
damage the piston
sliding surface.
Clean the seal and boot grooves , caliper cylinder. and
piston with clean brake fluid.

INSPECTION
Check the caliper cylinder and piston for scoring, ~----------------.
scratches or damage.
Measure the caliper cylinder 1.0.
SERVICE LIMIT: 32.090 mm (1 .2634 in)
Measure the caliper piston 0.0.
SERVICE LIMIT: 31.94 mm (1 .257 in)

ASSEMBLY

...-'iiSioI '1m CALIPER BODY

SLIDE PIN
22 N·m (2.2 kgf·m , 16 1b,",t) PISTON SEAL I
SLIDE PIN PLUG
e" ...-'iiSioI
~ PISTON BOOT

~, ~
CALIPER PISTON I
cr6
PAO SPRING

~:::l~~ BRACKET PIN

17 N·m (1.7 kg f·m, 131bHt)

e" ...-'iiSioI
SLIDE PIN BOOT
(

SPRING WASHER
CALIPER BRACKET

18-13
BRAKE SYSTEM
Coal a new piston seal (lJ with dean brake fluid and
install it into the seal groove in the caliper cylinder.
Apply 0.2 9 of silicone grease to the inside and seal
areas (boot ribs) of a new piston boot [21.
Install the inside boot rib of piston boot into the boot
groove in the caliper cylinder properly.
Coat the caliper piston [3] with dean brake fluid and
place it into the caliper body with the open side toward
the brake pad. Cover the piston with the boot carefully.
then push the piston and sel the outside boot rib into
fII [l[
the boot groove in the piston to seallhe piston.
fII [2[

Install a new bracket pin bool [1) into the caliper body
and pack the inside of the boot with 0.4 9 of silicone

~~
grease.
Install a new slide pin boot [21 into the groove in the
caliper body.
Apply 0.4 9 of silicone grease to the grease groove and
sliding area of the slide pin (3] . Install the slide pin and [3J
set the boot rib into the boot groove in the stide pin.

,
Q-----=- [2J fII

18-14
 BRAKE SYSTEM
Inslalithe pad spring [1] as shown.
Install the spnng washer (2] onlo the slide pin with the
concavity toward the bracket side.
"1m
[3[ _ __
Apply locking agent to the slide pin threads.
Inslalithe caliper bracket (4] ovef the caliper body and
thread the slide pin [5] into the bracket, being careful
not damage the slide pin boot (6).
Make sure the boot ribs are sealed into the boot

--
grooves in the slide and bracket pins properly. f-B~,-a-'k-e-t---'
InslaUthe brake pads (page 18-9). SideJ [l[

[2[
-

Tighten the slide pin [1]10 the specified torque.

TORQUE : 22 N'm (2.2 kgfm, 16Ibf-ft)

Rest the brake hose joint onto the stopper on the
caliper body_
Connect the brake hose with the oil bolt [21 and new
sealing washers [3), and tighten the oil bolt to the
specified torque.
TORQUE : 34 N'm (3.5 kgf'm, 25 IbHt)

Inslallthe slide pin plug [1].

Inslalithe outboard guard 121 and lighten the bolts [31.
Fill and bleed the hydraulic system (page 18-7).
Inslallthe front wheel (page 16-13),

18-15
BRAKE SYSTEM
REAR BRAKE DRUM/SHOES
BRAKE DRUM REMOVAL
Remove the right rear wheel (page 17-6),
Remove the following:
- coUerpin(1)
- hub nut (2]
- wheel hub (3)

- six bolts 111

- drum cover [2J
- dust seal [3]

- Q-ring [lJ
- brake drum [2]

(2)

INSPECTION
Measure the brake drum 1.0.

SERVICE LIMIT: 181 .0 mm (7.13 in)

L
18-16
 BRAKE SYSTEM
DISASSEMBLY
Always repJace the Remove Ihe following:
brake shoes in - cotter pins [1)
pairs. - selling plale [2J
- brake shoes 13]
- springs [4]

131
121 ~
I
- adjusting nuts [ 1]
- brake cables [2)
- joint pins [3J
- springs [4)
- brake panel drain bolt [5J and washer [61

- nut and bolt [lJ

- brake arm [2]
- wear indicator [3]
- return spring (4]
- brake cam (5)
- felt seal
- dust seat

f---(5)

j
ASSEMBLY
Apply grease to the lips of a new dust seal [1) and
install it with the flat side facing toward the brake arm
until II is fully seated.
Apply 0.2 - 0.3 9 of grease to the brake cam [2] spindle
and install it.

18·17
BRAKE SYSTEM
Apply engine oil to a new felt seal [1] and Install it over
the brake cam.
Installthe return spring (2) by aligning its end wi th the
hole [3] .
InslaUthe wear indicator (4J by aligning the wide teeth
with the wide groove altha brake cam (5).

Install the brake arm (1] by aligning the punch marks

(2( .
Install the pinch bolt [3] from the punch mark side and
the nut (4]. and lighten ilia the specified torque.
TORQUE: 20 N'm (2.0 kgf'm , 151bHt)

Install the brake cables 11] into the cable holders on the
brake panel (upper holder for lever brake cable and
lower holder for pedal brake cable).
InslaUthe cable springs (2] onto the cables and the jOint
pins (3)Inlo the brake arm. Connect the brake cables to
the brake arm with the adjusting nuts [4).
Install the brake panel drain bolt with a new searing
washer [5) and tighten the bolt (6] to the specified
torque.
TORQUE : 12 N'm (1.2 kgf'm , 9lbHt)

Apply 0.2 - 0.3 g of grease to each anchor pin groove ;::~~::':':::;;;;:

and the brake cam sliding surfaces.
Do not get grease Assemble the brake shoes 11] and springs [2] so that
OIl/he shoe linings. the spring ends are facing outside as shown and install
the assembly onto the brake panel.
The cotter pins are Install the setting plate (3) with the chamfered side
installtKJ from the (rolled edge side) facing in and secure it with new cotter
front side. pins (4].

18-18
 BRAKE SYSTEM
BRAKE DRUM INSTALLATION
Apply molybdenum disulfide grease to the axle splines.
Donotgetgrnase Inslalithe brake drum [1] onto the axle until il is fully
on the brake drum seated.
and shoes.
Coal a new D-ring [2J with grease and install it into the
groove in the brake panel [31.

[1[

Pack the seal lips of a new dust seal [1J with 3 - 4 9 of ;::=================~
grease. [2J
Install the dust seal into the drum cover so thai it is flush
with the cover surface.
[3[
TOOL:
[4[

......
[2J Driver 07749-0010000
[3J Attachment 72 x 75 mm
[4J Oil seal driver
07746-0010600
070MF·MEG0300
[1) 111
(3 - 4g)

Install the drum cover [1]. aligning the bolt holes.

Install the six bolts [2] and tighten them.

Apply grease to the lips of a new dust seal (1) and

install it into the wheel hub (2J with the flat side facing in
until it is fully seated.
Do nol getgfl3ase Install the wheel hub onto the axle.
on the axle threads.

18-19
BRAKE SYSTEM
Install the hub nul (1) and tighten it to the specified
torque and further tighten until its grooves align wi th the
coller pin hole.
TORQUE : 137 N'm (14.0 kgf'm, 1011bHt)
Install a new cotter pin 12).
Inslall the rear wheel (page 17-6).
Adjust the rear brake (page 3-22).

REAR BRAKE PEDAL

REMOVAL
Remove the right mudguard (page 2-6).
Disconnect the pedal brake cable from the brake arm
(page 18-17).
Remove the following:
- switch spring [1)
- return spring [2)
- brake cable (3) (from the cable holder [4] and pedal
[511

- cotter pin [1]

- washer [2]
- brake pedal [3)
- dust seals (4]

[NSTALLAT[ON
Apply grease to the lips of new dust seals (1).
Install the dust seals with the flat side facing out so that
they are flush with the pedal [2j.
Apply grease to the groove In the pivot shaft and install
the brake pedal.

18-20
 BRAKE SYSTEM
Install the washer (1] and a new cotter pin (21.

Install the brake cable [11 into the pedal [21 and cable
holder [3/.
Install the return spring [41 and switch spring [51 in the
direction as shown.
Connect the brake cable to the brake arm (page 18-18).
Adjust the brake pedal freeplay (page 3-22).
Install the right mudguard (page 2-6).

Spring installation direction:

___ Front

[4[

18-21
MEMO
 19. FRONT DRIVING MECHANISM

SYSTEM COMPONENTS ·· .... · .. · ............ · .... ·19-2 FRONT FINAL CLUTCH .......................... · 19-16

SERVICE INFORMATION .......................... ·19-3 FRONT FINAL GEAR DISASSEMBLYI

INSPECTION · .. · ........ · .. ·· ...... · ................ · .. ·· 19-22
TROUBLESHOOTlNG ........ .............. · .. · .. · .... 19-6
GEAR CASE BEARING
FRONT DRIVE SHAFT ...................... .......... 19-7 REPLACEMENT ........ .. ............................ · 19-30

FRONT FINAL DRIVE REMOVAL ............ 19-12 FRONT FINAL GEAR ASSEMBLY .......... 19-33

FRONT PROPELLER SHAFT .................. ·19-14 FRONT FINAL DRIVE INSTALLATION "" 19-37

19-1
FRONT DRIVING MECHANISM
SYSTEM COMPONENTS

44 N'm (4.5 kgf'm,

321bHt)

~ \

--1--- 44 N'm (4.5 kgf-m,

, 32 Ibf-ft)

10 N'm kgf'm,
7Ibf-ft)

19·2
 FRONT DRIVING MECHANISM
SERVICE INFORMATION
GENERAL
Perform the gear contact pattern and backlash inspection whenever you replace the bearings , gears or gear case. The
extension lines from the gear engagement surfaces should Intersect at one point.
Protect the gear case with a shop towel or soft jaws while holding it in vise. Do nol clamp it too tight as it could damage the gear
case.
When using the lock nul wrench , use a deflecting beam type torque wrench 20 inches long. The lock nut wrench increases the
torque wrench's leverage, so the torque wrench reading will be less than the torque actually applied to the lock nut. The
specification given is the actuallorque applied 10 the lock nut, not the reading on the torque wrench. Do not overtighten the lock
nut. The specification later In the text gives both actual and indicated.
Replace the ring and pinion gears as a set.
Replace the cam followers (12 pieces) as a set, and the cam followers, face cams and differential housing as an assembly if the
face cam or differential hOUSing IS faulty.
Do not confuse the left and right drive shaft parts.

SPECIFICATIONS
- - -- -,--.c;; Unit: mm (in)
~
ITEM STANDARD SERVICE LIMIT
Front final
drive
Oil capacity After draining
After disassembly
200 em {6.S US
250 em (S.5 US
OZ,
OZ, 7.0 Imp OZ)C==t:::~'::;=--==---i
8.8 Imp oz)
Recommended oil Honda shaft drive oil or equivale~n"I------
hypoid gear oil. SAE # 80
I--Gear backlash: - -- - -- - - 0.05 0.25 (0.002 - 0.010) 0.4 (0.02()_ __
Backlash diffe~'e~n~c~e----­ 0.2 (0.01)
Slip torque 14-17N·m(1.45 - 1.75kgf·m, t2N 'm
10 - 13 IbHt) (1.2 kgf·m. 9lbHt)
Face cam-to-housing distance ------[i'3 - 3.7 (033 - 0.15 )=..---_ _ _-!-C3 ·3 (0.13)
ii (0.258) ----.:J
Differential ring gear depth _ } ~ . 55 -=-~,65 (0.258 - 0.262) 6.55 ~
_.L~
C~o~
n=e spring free height ~--,2",.8~( 0.11) 2.6 (0.10)

TORQUE VALUES
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N'm (k gf'm, IbHt)
Front final gear pinion bearing lock nut 60 98 (10.0, 72) Lock nul ,ePla~
a new one Stake.
Differential ring gear bolt + 11 8 49 (5.0. 36) AlOe boll replace
--t-flth a new one
Front final gear case cover bolt 2 10 47 (4.8, 35) Apply locking agent to
the threads.

Front final clutch shift fork bolt

4
1
8
6
25 (2 .5. 18)
10(1 .0. 7)
I AlOe bolt: replace
with a new one.
Front final clutch hOUSing bolt 3 8 25 (2.5, 18)
Front final gear case moun\lng nul 2 10 44 (4.5, 32) lock nut: replace with

4WD select switch 10 12 (1.2. 9)

a new one. J
r
4WD select switch wire clamp bolt
Final clutch arm cover bolt
1
3 4- 6
6 -I-
10 (1.0, 7)
10 (1 .0, 7) -----=:j

19-3
FRONT DRIVING MECHANISM
TOOLS
Bearing clip compressor, 25 mrn Threaded adaptor Remover weight
070ME·HNB0100 070MF·HP50100 07741·0010201

r
Of 070ME-HN8Al00 (U.S. A. only) or 070MF·HPSA100 (U.S.A. only) or 07936-371 020A or 07936.3710200

1
(U.S.A. only)
Attachment, 52 x 55 mm Attachment, 22 x 24 mm Attachment, 30 mm 1.0.
07746-0010400 07746-0010800 07746-0030300

"P~i~ ,·,·'"2~m=mo-----------------r,P~i~'O'I."<5~m~m~----------------1-'P~iI~o",'30" m~mC---------------- j

07746-0040200 07746-0040300 07746-0040700

h F"o""""."a'"d"'n"'v"e'"we""'' gh'' '- ----------+nOOiri,,''.'''";;a"tta'' c'>h;;;m''.;;;n.I.'3'3 m"m;;T'.D".- ---- -1-'0'-'"",.=,- --

07747·0010100 07747-0010501 07749-0010000

19-4
 FRONT DRIVING MECHANISM
lock nul wrench, 34 x 44 mm Special nut ~puller shaft
07916-ME50001 07931-HB3020A (U.SA only) I
0793 1-ME4010B (U.SA only)

Bearing remover, 12 mm Remover head , 12 mm Remover shaft, 12 mm

07936-166010A (U.S.A. only) 07936-1660110 07936-1660120

Remover handle Remover shaft, 15 mm Remover head, 15 mm

07936-37101 00 07936-KCl 01 00 07936-KC10200

h B"e"a"ri"ng;c-;;re"m
"o"';;;e;-
07936-KC10500 (U.SA only)
r, <'''S-;;m''m
;;-- - - - +' Altachment. 45 x 50 mm
07946-6920100
-----r-~;~~:~--3-7-'O-O-O-,-------
I
I

<P~u"' ;er-;s"ha~ft'a;n;d~n;u"'--------.A~.a;c~h~m;e;nt.----------t-'cp;"n;~;n-;p~u"' 'e; r~b~as~ec-----~

07965-VM00200 07GAF-SEOO200 07HMC-MM80110

~-
=
(J
or 07HMC-MM8011A (U.SA only)
J
19-5
 1

FRON T DRIVING MECHANISM

Differential inspection tool Pilot, 32 mm
07KMK-HCS0101 07MAD-PR90200

or07KMK-HC5010A~(U
~ .S~.A~.~O~O~IY~)__~__________________________-"

TROUBLESHOOTING
Consistent noise duri ng cruising
Oil level 100 low
Foreign matter contaminating gear oil
Worn or damaged bearing
Worn or damaged ring gear and pinion gear
Deformed ring gear Of gear case
Improper tooth contact between ring gear and pinion gear
Gear noises while running
Oil level 100 low
Foreign matter contamina ting gear oil
• Chipped or damaged gears
• Improper tooth contact between ring gear and pinion gear
Gear noises whi le coasting
• Chipped or damaged gears
Abnormal noises when turn ing
Worn or damaged ring gear bearing
Worn or damaged face cams and cam followers
• Worn or damaged differential housing grooves
• Worn cone spring or shim
Abnormal noises at start or duri ng accelerat ion
Excessive backlash between ring gear and pinion gear
Worn differential splines
• Loose fasteners
• Worn cone spring or shim
Oil leak
Oil level too high
Clogged breather
• Damaged seals
• Loose case cover bolt
Overheating
Oil level too low
• Insufficient backlash between ring gear and pinion gear

19-6
 FRONT DRIVING MECHANISM
FRONT DRIVE SHAFT
REMOVAL
Remove the knuckle (page 16-16).
To prevent damage Hold the inboard joint [1] of the drive shaft and tug firmly
to the differonlial oil to force the stopper ring on the inboard joint end past
seal, hold the the groove while prying with a screwdriver.
inboard joint
horizontal until/he
drive shaft IS clear
of the differential.

Remove the stopper ring [1) from the inboard joint.

DISASSEMBLYIINSPECTION
Check the boots (11 fO( cuts or other damage.
Check the drive shaft joints (2) for excessive play or
noise by moving the joints in a CIrcular direction.
If the outboard joint seems to be worn or damaged , the
drive shaft must be replaced.
NOTE '
To replace the ou tboard boot, first remove the
inboard boot as described in following steps.
Then remove bands and the outboard boot off the
inboard end of the shaft
The outboard joint can nol be disassembled.

Outboard

Replace the bands Bend up the lock tabs /11 and raise the band ends (2) to ~==-===========:-----=~
With new ones loosen the boot bands A [3) and B [41 on the inboard
whenever removing side. 121
them. Remove the band B.
Remove the boot from the inboard joint.

19-7
FRONT DRIVING MECHANISM
Remove the following :
- stopper ring 11]
- inboard joint 12]

- snap ring [1]

- bearing (2]
- inboard boot [3J
- boot band A [4]

Replace these Check the following for wear or damage.

components as an - bearing cage [1]
assembly. - race [2] [41
- steel balls (3)
- inboard joint {4]

[21
Remove the following :
- shaft boot band [1]
- outboard boot band (2]
- outboard boot [3)

19-8
 FRONT DRIVING MECHANISM
ASSEMBLY

DRIVE SHAFT
INBOARD JOINT
SHAFT BOOT BAND :tI
j OUTBOARD BOOT

INBOARD BOOT
BANDA :It ~1Ip OUTBOARD BOOT
____ BAND

The outboard boot [1 ) is larger than the inboard boot [2] . , - - - -- -- - - -- -

Do not interchange them.
[2[ 11[

Nole the installation direction of the boot bands (1] .

Forward rotation directIon

___ Tabs

19·9
FRONT DRIVING MECHANISM
Pack the outboard joint with 50 - 70 9 of specified
grease.
SPECIFIED GREASE : NKG106 (Kyodo Yusht)

Instalilhe following:
- outboard boot [1)
- new shaft boot band (2J
- new band A 13]
- inboard boot 14]
Do not tighten the bands at this time . NKG106
(50- 70 9)

Install the bearing (1] with the small 0.0. facing the
.... ....
~ 121 131 ~",

~=============:_;;~
drive shatto
Install the snap ring [21 with the chamfered side facing
the bearing.

Pack the inboard joint 111 with 40 - 60 9 of specified ~==::;;;;;;;;;;;;;;;;;;;;;;;===-~

grease.
SPECIFIED GREASE : NKG205 (Kyodo Vus ht)
Install the inboard joint over the bearing .
InslaUlhe stopper ring [2] into the groove in the inboard
joint properly.
Install the boot over the inboard joint.

Adjust the length of the drive shaft to the figure given ~====~~~~~~~~===::;
below.

DRIVE SHAFT LENGTH : Left: 363.2 mm (14.30 in)

Right: 383 mm (15.1 in)

19-10
 FRONT DRIVING MECHANISM
NOla the installa/ion Inslall the band A (1] and a new band B [2] onto the
direction of the inboard boot.
band (page 19-9). Bend down each band end and secure it with the lock
tabs [3J. Tap the lock tabs with a plastic hammer.

[1

....
[2[ !It!~

Install the shaft boot band [1 J and a new outboard boot

band [2] onto the outboard boot.
Bend down the band end and secure it with the lock
labs [3J. Tap the lock tabs with a plastic hammer.

INSTALLATION
Install a new stopper ring [1] into the groove In the
inboard joint spline.

B6 careful not 10 Install the drive shaft by holding the inboard joint [1]
damage (he oil seal until the stopper ring seats in the groove of the
In the gear case. differential.

Make sure that the stopper ring is sealed properly by

pulling on the inboard jOint lightly.
Install the knuckle (page 16-22).

19-11
FRONT DRIVING MECHANISM
FRONT FINAL DRIVE REMOVAL
Remove the following :
- left mudguard (page 2-6)
- engine guard (page 2-7)
- left drive shaft (page 19-7)
Drain the differential oil (page 3-19).
Remove the following from the final gear case:
- breather hose [1 )
- select switch connector [2J (disconnect it and
remove its wire from the guide (3] and clamp [4))

- cover boll [1)

- clutch arm cover [2) (by releasing the two tabs (3])

. '"
{ I 1~
-j
'-
/
{II

{21

- adjusting nut (1)

- cable retaining plate (2]
- selector cable [3] (remove from the cable holder (4)
and joint pin [5])
- cable spring 16]
- joint pin

- base bolts [1 J
- arm cover base (2]
- holder bracket [31

19-12
 FRONT DRIVING MECHANISM
- final gear case mounting nuts and bolts (1J
- two bolts [2] and mounting bracket (3J

Move the gear case assembly (1J forward for maximum

clearance between the propeller shaft joint and engine.
12J
NOTE
Turn the handlebar all the way to Ihe right to move
the gear case assembly.
Put some cloth on the gear case to avoid scratch or
damage the lie-rod end [2).

Puilihe shaft joint (1) oul of the output shaft (2) of Ihe
engine.
Remove the boot band [3) and release the propeller
shaft boot [4) off the pinion joint (5J of the gear case
assembly.
Pull the propeller shaft [6) to force the stopper ring [71
past the groove in the pinion jOint to remove the
propeller shaft,
Remove the stopper ring from the propeller shaft .
Remove the O-ring (8) from the output shaft.

19·13
FRONT DRIVING MECHANISM
loosen the left lower arm pivot nuts and lower the lower
arm.
Separate the right drive shaft [1] from the final gear
case assembly \21 by tapping the right drive shaft end
lightly through the gear case, using a screwdriver or
equivalent.
Remove the gear case assembly from the frame.

OPERATION CHECK
Turn the pinion joint (1) while the clutch arm [2] is sel to r - - - -- - -- - - -- - ------,
the rear (4WD position), and check that the gear turns
smoothly and quietly without binding.
If the gear does nollurn smoothly or quietly, the pinion
gear, ring gear, bearing and/or clutch components may
be damaged or faulty. They must be checked after
disassembly; replace them if necessary.
Operate the change-over mechanism while turning the
pinion joint, check for smooth engagementl
disengagement

FRONT PROPELLER SHAFT

DISASSEMBL Y/INSPECTION
Remove the outer boot band (1) and the shaft boot 121 r - - - -- - -- - - - - - - - - - - - ,
from the propeller shaft jOint [3) to remove the shaft
joint.

L 121

----------------~
Remove the following :
- jOint spring {11
- inner boot bands [2J
- shaft boots (3]
Check the splines (41 of the propeller shaft and joint for
wear or damage.
If they are damaged. check the splines of the output
shaft and pinion joint.
Check the boots for cuts, deterioration or damage.
Check the seal lip in each boots for damage.

19·14
 FRONT DRIVING MECHANISM
ASSEMBLY

~ ~
SEAL LIP SEAL LIP

PROPELLER
~ SPLINES PROPELLER
SHAFT
SHAFT JOINT
IS - 8 91

Place the inner boot bands [1 J on the propeller shaft,

Do nola/low /he Apply molybdenum disulfide grease to the seal lip of 121 ~
sea/ lip 10 tum inside each boot.
OUI. Install the boots (2) onto the shaft grooves, being
careful nol to damage the seal lip.
Install the boot bands into the each boot groove.
Install the jOint spring [31 into the propeller shaft
securely.

131

Apply 5 - 8 9 of molybdenum disulfide grease to the

propeller shaft joint splines.
Set the shaft joint [1 J onto the propeller shaft while
compressing the spring, then install the boot [2J over ~ 15-8gl
the shaft joint groove and the outer boot band 131 into
the boot groove to secure it.

121

19-15
FRONT DRIVING MECHANISM
FRONT FINAL CLUTCH
DISASSEMBLY
The housing Is Remove the following:
under spring - select switch and sealing washer 11]
pressure, hold the three bolts (2J
"""""9 when final clutch housing (3J (by releasing the shift fork [4]
loosening the bolt. from the clutch sleeve (5])
clutch sleeve
O-ring [6]
dowel pins [7]
Check the splines of the pinion joint [8], dutch sleeve
and pinion gear shaft [gl for wear or damage.
Check the needle bearing [10J in the pinion gear shaft
for wear or damage.

Release the clutch spring end 11] from the stopper plate ~1IIIIII1IIIIII1IIIIII~=="""'~~~=I111111~==~
[2J by pulling the arm shaft [3].

Remove the shift fork bolt (1J.

Pry the dutch arm tab [2] to release it from the collar 13]
and slide the clutch arm shaft {4] outward.

141

19·16
 FRONT DRIVING MECHANISM
Remove the following :
- clutch spring (1]
stopper plale [2]
shift fork 131
clutch arm shaft (4]
lock spring 15J
collar (6]
O-ring (7J
oil seal [81

14J
INSPECTION
Check the shift fork craws for wear or damage.
Check the arm shaft and stopper plale for deformation
or damage.

Check the each spring for fatigue or damage

PINION JOINT BALL BEARING

REPLACEMENT
Remove the snap ring [1) and dnve the pinion joint [2]
out of the bearing.

Remove the oil seal [1 ] and the snap ring [2] .

l
Drive the beanng [3] out of the housing.

19-17
FRONT DRIVING MECHANISM
Drive a new bearing into the housing.

TOOLS:
[1] Driver 07749"()010000
[21 Attachment, 52 x 55 mm 07746-0010400
[3J Pilot, 32 mm 07MAD·PR90200

Install the snap ring [1] into the housing groove securely ~====~IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII~====~
with the chamfered edge facing the bearing.
Pack the seal lips of a new oil seal [2] with grease.
Install the oil seal so thaI its rubber area flush wilh the
housing end.

Be carerlJl not 10 Hold the bearing inner race and press the pinion joint :========;;;;;::=="'IIIIIIII~=:"'~
damage the 0,1 seal [11 into the bearing until it is fully seated.
lips.
TOOLS :
121 Fork seal driver weight 07747"{)010100
(3] Driver aUachment, 33 mm I.D. 07747"()010501

Install the snap ring [1] into the pinion joint groove
securely wilh the chamfered edge facing the bearing .

19·18
 FRONT DRIVING MECHANISM
ASSEMBLY

OIL SEAL
PINION JOINT

~ 6Y
SNAP RtNG ~

BEARING (32,58, 13)

C-'-:::~ C(\ .
CLUTCH SPRING SNAP R~ ; 1\ (~~~,'" ~'t
(
OIL SEAL ~ .....
"---- " 'OJ,. ')'
""~. ",,-;.
~cr~U'f"" p~L~l
V ~
STOPPER PWE / / LJ ~
/n," C}J
17 \ ::---...
/ ' SHIFT FORK ----- CLUTCH ARM
10 N"m (1.0 kgf-m, LOCK ~.qJ~-- SHAFT
7lbHt) .......
., SPRING COLLAR
~ O-RING

~ ,..urn..
Coat a new O-ring [1] with grease and install it into the ,----- - -
clutch arm shaft groove.
Apply grease to the clutch arm shaft outer surface,
,..urn..
Instalilhe collar (2) and the lock spring [3] with the short
end toward the coliar, and set the spring end into the
hole [4] in the collar. [31

Coliar side
[3[

Jillillill= ----+- Collar

side
Fork side

19,19
FRONT DRIVING MECHANISM
Apply grease to the lips of a new oil seal (1] and install it
into the clutch housing until it is fully seated.
Take car& nollo leI Install the clutch arm shaft assembly [21. being careful
the lock spring nollo damage the oil seal.
come off the coI/af
during assembly.

Install the shift fork [1J and align the groove with the end
of the lock spring [2].

While hOldmg the Instalilhe stopper plate (1] by aligning the flat surfaces ~===~"""'IIIIIIIIIIIIIIIIII~========~
shiff fOlk, push the so the plate is attached onto the fork lug (2).
arm shaft to slide it
inward and install Install the clutch spring [3] with the bended end (4)
toward the shift forlc
the sheft end into
the piVoI hole III the
houSing.

,
I

l
I
~

19-20
 FRONT DRIVING MECHANISM
Turn the clutch arm shaft [1J clockwise by holding the
collar [2] with a open end wrench and align the arm tab
with the collar groove. then tap the shaft to fit them
securely. ',,,,
."-.
\
Align the bolt hole in the fork with the groove in the shaft
and install a new fork bolt [3J.
Tighten the fork bolt to the specified torque.
TORQUE : 10 N'm (1 .0 kgf'm , 7Ibf·ft) - - : - - Align

[1 J

Turn the clutch arm shaft (1] and set the ends of the
clutch spring [2J onto the housing groove [3] and the
reverse side of the stopper plate [4] as shown.
Check the clutch arm shaft for smooth operation.

Install the clutch sleeve (1] with the large 0.0. side
facing the inside. ~ [2[
Coat a new O-ring [2] with grease and install it into the
case groove.
Inslalilhe two dowel pins [31.

19-21
FRONT DRIVING MECHANISM
Aligning the fork claws [1) with the sleeve groove [2),
install the final clutch housing [3] while turning the
clutch arm [4], then secure it with the bolls [5].
Tighten Ihe three bolts to Ihe specified torque.
TORQUE: 25 N'm (2.5 kgf'm , 18 IbHt)
Install the selecl switch [6J with a new sealing washer
[7] and lighten it to the specified torque .
TORQUE : 12 N'm (1.2 kgf'm , 9 IbUI)

FRONT FINAL GEAR DISASSEMBLVI

INSPECTION
Remove the final clutch housing (page 19-16).

BACKLASH INSPECTION
Sel the final gear case into a jig or vise with soft jaws.
Remove the oil filler cap.
Cover the clutch Hold the pinion gear [1 J with the special 10015.
housing mating
s(Jrface wilhTOOLS:
protectIVe lape f2][3] Pinion puller base 07HMC·MMB0110
or an equivalent to [4] Puller shaft and nut 07965·VM00200
prevent damage. [5] Threaded adaptor 070MF·HP50100

U.S.A . TOOLS:
Pinion puller base 07HMC·MMB011A
Puller shaft 07931·ME4010B
Special nut 07931·HB3020A
Threaded adaptor 070MF·HP5A 100
InslaUlhe differential inspection 1001 inlo Ihe (eft side of
the gear case.
TOOL:
[6J Differential inspection tool 07KMK·HC501010r
07KMK·HC5010A
(U .S.A . only)

19-22
 FRONT DRIVING MECHANISM
Set a horizontal type dial indicator on the ring gear
through the filler hole.
Tum the ring gear back and forth to read backlash.
STANDARD: 0.05 - 0.25 mm (0.002 - 0.010 in)
SERVICE LIMIT: 0.4 mm (0.02 in)

Remove the dial indicator. Turn the ring gear 1200 and
measure backlash. Repeal this procedure once more.
Compare the difference of the three measurements. C
SERVICE LIMIT: 0.2 mm (0.01 In ) '--"'~"'
If the difference in measurements exceeds the service
limit, it indicates that the bearing is not installed
squarely, or the case is deformed .
Inspect the bearings and case.
If the backlash is excessive, replace the ring gear left r------------------,
side shim with a thinner one.
If the backlash is too small, replace the ring gear left
side shim with a thicker one. Right Shim
The backlash is changed by about 0.06 mm (0.002 in)
when the thickness of the shim is changed by 0.10 mm
(0.004 in). left Shim
NOTE-
Twenty-three different thickness shims are available
from the thinnest (0.50 mm thickness: A) shim to the
thickest (1.60 mm thickness: W) in intervals of . ....-.-
0.05 mm.

Ring gear shims :

A : (thinnest): 0.50 mm (0.020 In)
K : (standard): 1.00 mm (0.039 in)
W: (th ickest): 1.60 mm (0.063 in)

Change the right side shim as follows: If the left shim

was replaced with a 0.10 mm (0.004 in) thicker shim,
replace the right shim with one that is 0.10 mm
(0.004 in) thinner.

DIFFERENTIAL REMOVAL
loosen the sil( cover bolts [1] in a crisscross pattern in
several steps and remove them.
Pry the final gear case cover [2] at the points (3] as
shown by using a screwdriver and remove it.

19-23
FRONT DRIVING MECHANISM
Remove the O-ring (1] .
Remove the differential assembly (2) and shims [31.

BEARING INSPECTION
Turn the inner race of each bearing 111 in the gear case
and case cover with your finger. The bearings should
tUfn smoothly and quietly. Also check that the bearing
outer race fits tightly in the case or cover.

GEAR TOOTH CONTACT PATTERN

CHECK
Keep dust and dirt Apply thin coal of Prussian Blue to the pinion gear teeth
out of the case and for a tooth contact pattern check.
cover. [1J (Left Shim)
install the ring gear shims 11) onlo the differential
assembly.
Inslallthe differential assembly (2) into the gear case.

Apply Prussian Blue

19-24
 FRONT DRIVING MECHANISM
It is important 10 lostall the case cover and lighten the bolts [ 1] in several
tum /fie pinion gear steps untillhe cover [2] evenly touches the gear case.
mm)
while tightening Ihe Then. while rotating the pinion gear, lighten the bolts to
bolts. /f the ring the specified torque in a crisscross pattern in several
gesr shIm Is 100 steps.
thICk, the gears will
lock after only light TORQUE : 10 mm bolt: 47 N'm (4.8 kgf'm , 351bHt)
lightening. 8 mm bolt: 25 N'm (2.5 kgf'm, 181bHI)

Rotate the ring gear several limes in both directions of

rotation.
~=================~
Normal : Heel ~
Check the gear tooth contact pattern through the oil ; ~'I\
filler hole. .... Toe
The pattern is indicated by the Prussian Blue appliecllo
the pinion. Face __ __ Face
Contact is normal if the Prussian Blue is transferred 10
the approxImate center of each tooth, but slightly to the
heel side and to the flank side. I~~I
Flank
If the patterns are not correct, remove and change the
pinion shim with one of an alternate thickness. Coast side

Replace the pinion shim [1J With a thicker one if the

contact pattern is too high, toward the face.
~====~~~~~~~======;
Too High:
[1[

Fa",

Ie? ~I
Drive side Coast side
Replace the pinion shim [1]with a thinner one if the
contact pattern is too low, toward the flank.
~T=OO=l="="'==============~
The pattern will shift about 0.5 - 1.0 mm (0.02 - 0.04 in)
when the thickness of the shim is changed by 0. 12 mm
(0.005 in).
NOTE :
Fifleen different thickness shims are available from
the thinnest (1.64 mm thickness: A) shim to the
thickest (2.48 mm thickness: 0) in intervals of
0.06 mm.
Pinion shims:
Drive side I ~ ~ I Coast side
A: (thinnest): 1.64 mm (0.065 In)
G: (standard): 2.00 mm (0.079 In) Flank Flank
0 : (thickest): 2.48 mm (0.098 In)
Pinion shim replacement (page 19-29).

19-25
FRONT DRIVING MECHANISM
DIFFERENTIAL INSPECTION
Install the inspection tools into both sides of the , - - - - - - - - - - - - - - - - - - ,
differential.

TOOL:
[1J Differential inspection tool 07KMK·HC50101or
07KMK·HC5010A
(U .S.A. only)
Hold the flat surface of the tool with a bench vise (2).
111
Attach a torque wrench to the other 1001 and measure
the limited slip torque. 121
STANDARD:
14 - 17 N'm (1.45 - 1.75 kgf'm, 10 - 13IbHI)
SERVICE LIMIT: 12 N'm (1 .2 kgf'm, 9lbHt) L_____=='::~:::::~_____J
If the slip torque is out of specification, disassemble the
differential and perform Ihe components inspection
(page 19· 27) since Ihe differential may be faully.
DIFFERENTIAL DISASSEMBLY
NOTE
When assembling the differential, both drive shafts
are required to perform the face cam.to-housing
alignment (page 19-34). The other drive shaft must
be removed from the knuckle (page 16-16).
Remove the eleven bolts [1], then place the differential , - - - -- -- - - -- - -- - - - - ,
assembly with the ring gear side [2) up.
111

121
Remove the following:
- ring gear (1]
- side cone spring (2) 121
- shim (3]

131

111

19-26
 FRONT DRIVING MECHANISM
~ face cam (11

- six cam followers A and six cam followers B (11

- face cam (2J 11

- '\
\, -
I
-
-if-
•
• , 1 •
• \
, •

--.
• •
, ~

DIFFERENTIAL COMPONENTS
INSPECTION
RING GEAR
Check the sliding surface of the ring gear for damage or I
discoloration.
Measure the depth of the ring gear from the mating
surface as shown.
SERVICE LIMIT: 6.55 mm (0.258 In)

j ~DD~
DIFFERENTIAL HOUSING/FACE CAM/
CAM FOLLOWER
If the djfferential Check the sliding surface and grooves of the housing
housing orface [1) for damage or discoloration.
cam are faulty.
repJace the
differential as an
assembly.

19-27
FRONT DRIVING MECHANISM
Rep/ace the cam Check the shim, face cams (1] and followers [21 for
followers as a set damage.
(12 pieces).

12J
Temporarily assemble the differential housing, face

•
cams and cam followers (page 19-34). 1.47 kN (1sa kgf)
Measure the height of the face cam from the housing
mating surface as shown while applying a load of 1.4 7
kN (150 kgf) to the face cam boss using a hydraulic
press.
SERVICE LIMIT: 3.3 mm (0.13 in)

If the height is less than the limit, replace the differential

as an assembly.

SIDE CONE SPRING

Check the cone spring for damage.
Measure the height of the spring.
SERVICE LIMIT: 2.6 mm (0.10 in)

PINION GEAR REMOVAL

Be careful that Unslake the bearing lock nut [1] with a drill or grinder.
me/al particles do
not enter the
bearing and /he
threads of the case
are not damaged.

19-28
 FRONT DRIVING MECHANISM
Remove the lock nut and discard it.

TOOL:
[1J Lock nut wrench, 34 x 44 mm 07916·ME50001

Cover the clutch

housing mating
Install the special tools onto the pinion gear shaft and
gear case.
~~~~~~::~IIIIIIIIIIIIIIIIII~~~~==l
~
surface with
protective tape [4] TOOLS :
oran equivalent to [1J Pinion puller base 07HMC·MM80110
prevent damage. [2J Puller shaft and nut 07965·VM00200
(3J Threaded adaptor 070MF·HP50100

U.S.A. TOOLS :
Pinion puller base 07HMC·MM8011A
Puller shaft 07931 ·ME4010B
Special nut 07931·HB3020A
Threaded adaptor 070MF·HP5A100
Pull the pinion assembly 151 out from the gear case.

PINION BALL BEARING AND SHIM

REPLACEMENT
Protect the shaft Pull the bearing [1] from the pinion gear (2J with a
end with the pilot Of commercially available bearing puller.
an equivalent.
Remove the bearing and pinion shim. {2]
Replace the pinion joint needle beanng in the shaft end
if necessary (page 19-30).

Install the pinion shim (1 J and bearing [2] onto the pinion
gear [3].
NOTE:
{2]
When the gear set, differential bearing, differential
housing andlor gear case has been replaced, use a
2.00 mm (0.079 in) thick shim for Initial reference.

{3]

19·29
FRONT DRIVING MECHANISM
Press the pinion gear into a new bearing until it is fully
sealed by supporting the bearing inner race.

TOOL:
[1] Attachment, 30 mm 1.0 . 07746-0030300

PINION JOINT NEEDLE BEARING

REPLACEMENT
Remove the pinion ball bearing (page 19-29).
Be sure to wear Heat the pinion gear [1] to about 80°C (ll6"F) and [2[
heavy gloves to remove the needle bearing [21. using the special tools.
avo«! bums when
f1andilflg /fie f1ealed
TOOLS :
gear. Remover head, 12 mm 07936·1660110
USlfIg a torch to Remover shaft, 12 mm 07936-1660120 or
heallhe gear may Bearing remover, 12 mm 07936·166010A I' ,:
cause warpage (U.S.A . only) with · 1 '
~ ."l 1
07936·3710100
Remover weight 07741-0010201 or
07936-371020A or
07936-3710200 ,
(U .S.A . only) [11

Press a new bearing into the pinion gear with the ' - - - -liiiiiiii
marking facing up so that it is flush with the shaft end . I
[11
TOOLS;
[1] Driver 07749-0010000
(2) Attachment, 22 lit 24 mm 07746-0010800
[3] Pilot, 12 mm 07746-0040200 [21
Install the pinion ball bearing (page 19-29).

- - -[3[

GEAR CASE BEARING REPLACEMENT

DIFFERENTIAL BEARING
Remove the oil seals [1) from the gear case and cover.
Dnve the bearings (2) out of the case and cover.

19-30
 FRONT DRIVING MECHANISM
Drive the new bearings into the gear case and cover.

TOOLS :
[1] Driver 07749-0010000
[2] Attachment, 52 x 5S rnm 07746-0010400
[3] Pilot, 30 mm 07746-0040700

121

Apply grease to the seal lips of new dust seals [1J.

Install each dust seal into the case and cover with the
metal side facing out.
TOOLS :
[2] Driver 07749-0010000
[3] Attachment, 45 x 50 mm 0794606920100
~ _ _ 131

PINION NEEDLE BEARING

Rotate the stopper ring [1) until its end appears in the
access hole [2J.
Strike genlly near the end of the ring with a punch to
bend the end upward.
Grasp the end of the ring with needle-nose pliers and
pull the stopper ring out through the access hole.
Remove the oil filler cap.
Be sure to weer Heat the gear case to about BO°C (176°F) and remove
heavy gloves 10 the needle bearing [3J, using the special tools.
avoid bums when
handling the heated
TOOLS :
gearcese. Remover head, 15 mm 07936·KC10200
Using a lorch to Remover shaft, 15 mm 07936·KC10100
heat the gear case Remover weight 07741-0010201
may cause
warpage. U.S.A. TOOLS:
Bearing remover, 15 mm 07936·KC10500
Remover weight 07936·371020A or
07936·3710200

Make sure the

stopper ring stays in
Install a new stopper ring [1] into the groove in a new
bearing .
Install the bearing into the compressor {2] unl il the
stopper ring is flush with the end of the tool.
. ..
111 ~.,

the groove.
TOOL:
Bearing c lip compressor, 25 mm 070ME·HN80100 or
070ME·HN8A100
(U .S.A . only)

121

19-31
FRONT DRIVING MECHANISM
Place the driver. attachment and pilot on the lop of the
bearing and tape the driver to the compressor (1).

TOOLS :
[2] Oriver 07949-3710001
[3] Attachment, 22 x 24 mm 07146"()010800
[4] Pilot, 15 mm 07746"()040300
Place Ihe bearing and tool assembly into a freezer for al
leasl 30 minutes.
Heat the gear case to ao°c (176°F).
Remove Ihe bearing and tool assembly from the freezer
and drive Ihe bearing into Ihe gear case using the
special tools.
Only strike Ihe driver once. If you strike it more than
once, the ring 15] may slip out of the groove. If this
happens. remove the ring and bearing, and Install a
new ring.
Make sure Ihe stopper ring is securely set in the groove
afthe gear case.

19·32
 FRONT DRIVING MECHANISM
FRONT FINAL GEAR ASSEMBLY
PINION JOINT PINION BALL
NEEDLE BEARING 98 N'm (10.0 kgf-m,

SIDE CONE SPRING

10 N'm (1.0 kgf.m, 7lbHt) (12x18x12)

STOPPER
RING
....
72lbftt) ¢!~

DIFFERENTIAL
SH IM RING GEAR PINION NEEDLE
BEARING
(15x25x

DIFI'ERENl "IAL BEARING

(30x56x 13)

DIFFERENTIAL 4WO SELECT SWITCH

BEARING (6006) 12 N'm (1 .2kgf-m. 9lbHt)

SEALING FINAL CLUTCH

WASHER HOUSING

fI SLEEVE
DOVVELPINS

~---..
Bmm T
25 N'm (2.5 kgf·m,
181bOt)

D-RING

fI~ ' L E F T FACE CAM

~
HOUSING CAM FOLLOWERS

49 N 'm (5.0 kgf-m. RIGHT CAM

36Ibf-ft)

PINION GEAR INSTALLATION

Drive the pinion gear assembly into the gear case .

TOOLS :
[1] Driver 07749-0010000
[2] Attachment 07GAF-SE00200

19-33
FRONT DRIVING MECHANISM
Inslall a new lock nul [11 and lighten it.

TOOL:
[2] Lock nut wrench, 34 x 44 mm 07916-ME50001

Retena ·Service TORQUE : Actual: 98 N'm (10.0 kgf'm, 72lbHt)

Information" for
torque wrench
Indicated : 89 N'm (9 .1 kgf-m, 661bHtj 11] 18"
readlflg information
(page 19-3).

Be careful not to Slake [1) the lock nut into the case groove.
damage the threads
orrhe case.

DIFFERENTIAL ASSEMBLY
Keep dust and dirt Install the face cam into the differential housing.
out of/he
Install six cam followers A (rib) (1J and six followers B
differential housing. (flat) [2] into the specified grooves in the housing [3] by
two and two as shown.
For easy installation, find the reference point that is
lined up Ihe bolt hole and housing lug in a straight line,
and mark the housing using a marker. Start follower
setting from the housing groove near by this point in 12]
successively.
NOTE:
The housing grooves are sized differently to
accommodate the differently sized A and B cam
followers. Make sure to install the followers
correctly.

13] o o

19-34
 FRONT DRIVING MECHANISM
Install the face cam [1 ] onto the cam followers.
Measure the following dimensions and record them. [11
- depth of the ring gear (page 19-27)
- height of the housing-ta-cam (page 19-28)
Calculate the shim thickness using the equation below.
The correct shim is nearly this dimension.
A = B - C - 1.6 mm
A: New shim thickness
B: Recorded ring gear depth
C: Recorded cam height

Select the shim [1] and install it onto the face cam .
[21
Differential shims :
A : 1.3 mm (0.051 in) E: 1.7 mm (0.067 in)
B : 1.4 mm (0.055 in) F: 1.8 mm (0.071 in)
C: 1.5 mm (0.059 in) G: 1.9 mm (0.075 in)
D: 1.6 mm (0.063 in)
Inslall the cone spring [2) with the concave side facing
up (ring gear side).
Inslalilhe ring gear [3] . {I]

[31
Install new ring gear bolls [ 11 and screw them until the
seating surfaces of all the bolts touches the housing,
but do not lighten them yet. """"~
~

Temporarily install the drive shafts [11 into the

differential assembly without the stopper rings until they 131
are fully seated to align the face cams {2] with the
differential housing [3]. [11
Tighten the ring gear bolts 14] to the specified torque in
a crisscross pattern in several steps .
TORQUE : 49 N'm (5.0 kgf-m , 36 Ibf-ft)
Remove the drive shafts .
Inspect the slip torque (page 19-26). :
If the slip torque is out of specification . perform the shim
adjustment. Replace Ihe differential assembly when the
replacement shim is changed by 0.3 mm or more from [4]
the selected shim . L _ __ _ _ __ _ __ __ _ __ _ _~

19-35
FRONT DRIVING MECHANISM
FINAL GEAR CASE ASSEMBLY
NOTE:
When the gear set. bearing. differential housing and!
or gear case has been replaced, check the following :
- tooth contact pattern (page 19-24)
- gear backlash (page 19-22)
Keepduslanddirt Blow compressed air through Ihe breather hole [1J in , - - - -- - - - - - - - - . , - -...., - ,
oul of lIle case and the case cover.
cover.

Install the proper ring gear shims [1] onto the differential ~=============_
=.
~=_=~
=:o::~
assembly [21. ~...,. o--1!lmDI
Before installing the Install the differential assembly into the gear case 131 . ~ [4)
assembly, be sure
Coat a new O-ring [4] with grease and install it into the
to verify the
groove in the case cover [51.
alignment using the
drive shafts Install the cover over the gear case.
(page 19-35).

15J

/I is important to tum Apply locking agent to the threads of the two 10 mm

the pinion gear bolls.
mm)
while tightening the Instalilhe six bolts [1) and screw them until the cover
bolts. If/he ring gear evenly touches the case. Then, while rotating the pinion
shim is too thick, the gear, tighten the bolls to the speCified torque in a
gears will lock after crisscross pattern in several steps.
only light lightening.
TORQUE: 10 mm bolt: 47 N·m (4.8 kgf-m, 351bHt)
8 mm bolt: 25 N'm (2.5 kgf·m , 181bHt)
Make sure that the gear assembly rotates smoothly
without binding.
Install the final clutch housing (page 19·21).

19-36
 FRONT DRIVING MECHANISM
FRONT FINAL DRIVE INSTALLATION
Place the final gear case assembly into the frame.
If both drive shafts Install Ihe right drive shaft [1) into Ihe gear case [2] .
8re removed, install (page 19-11).
them after mounting
Ihe gear case
assembly
comp/etely.

Install a new stopper ring [1) into the groove in the ~...~::::,............",,:=========~
propeller shaft [2]. S~ [1]
131 ~
Apply molybdenum disulfide grease to the seal lip [3) of
the front side boot [4].
Make sure Ihe seal lip is not turned outside in.
Apply molybdenum disulfide grease to the front end of
the propeller shaft. \

121
141
Apply 5 - 8 9 of molybdenum disulfide grease to the
splines of the pinion jOint [1].
Place Ihe boot band [2] over the pinion joint tempora rily.
Install the propeller shaft [3] into the pinion joint,
aligning the splines until the stopper ring seats in the
groove.
Make sure the stopper ring is seated properly by pulling
the propeller shaft lightly.
Instalilhe boot (4) over the pinion jOint groove securely
and the boot band into the boot groove.

19-37
FRONT DRIVING MECHANISM
Coat a new O-ring [1) with molybdenum disulfide
grease and install it into the groove of the output shaft
121.
Apply molybdenum disulfide grease to the splines of the
propeller shaft joint (3).
Move the gear case assembly [4] forward for maximum
clearance between the shaft joint and output shaft.
NOTE:
Turn the handlebar al( the way to the righllo move
the gear case assembly.
Put some cloth on the gear case to avoid scratch Of
damage the tie-rod end (5] .
Engage the shaft joint over the output shaft and move
the gear case assembly rearward .

Align the rear mounting bolt holes in the gear case and
frame, then instalilhe mounting boll [1) from the right
side and a new mounting nut [2].
Install the mounting bracket [3] with the two bolts (4].
Inslallthe front mounting bolt [S) from the right side and
a new mounting nut.
Tighten all the gear case mounting fasteners in the
following sequence.
- Rear mounting nut
- Mounting bracket boits
- Front mounting nut
TORQUE :
Rear mounting nut:
44 N'm (4.5 kgf'm, 32 IbHt)
Front mounting nut:
44 N'm (4.5 kgf'm, 32 IbHt)
Connect the 4WD switch connector [1} and install the
wire grommet into the guide 12] in the gear case.
Secure the wire with the clamp [3].
Connect the breather hose [4] .

19-38
 FRONT DRIVING MECHANISM
Install the holder bracket [1) and cover base (2) with the
two bolts (3), and tighten them to the specified torque_

TORQUE : 10 N·m (1 .0 kgf'm, 7 IbHt)

Install the spring (1) onto the selector cable [21-

Insert the cable into the cable holder (31 and connect it
13] 12]
to the clutch arm with the joint pin (41 and adjusting nut
[5).
Set the groove in the cable grommet (6) onto the cover
base end properly _
Install the retaining plate [7} onto the cable with the
concave facing the cable holder to secure the cable .
Adjust the selector cable (page 3- 19).
Install the following :
- drive shaft{s) (page 19-11 )
- en9ine 9uard (page 2-7)
- mudguards (page 2-6)
171
11]
141
Fill the gear case with the recommended oil
(page 3-19).

19-39
MEMO
 20. REAR DRIVING MECHANISM

SYSTEM COMPONENTS .... · .. ·····················20-2 REAR FINAL GEAR DISASSEMBL YI

INSPECTION .................. ............. ..... ......... 20-12
SERVICE INFORMATION ··· ························20-3
GEAR CASE BEARING
TROUBLESHOOTING································· 20-6 REPLACEMENT ······························ ········· 20-17

REAR AXLE REMOVAL ···························· ·20-7 REAR FINAL GEAR ASSEMBLY ············· 20-19

REAR FINAL DRIVE REMOVAL ················20-9 REAR FINAL DRIVE INSTALLATION """ 20-22

REAR AXLE INSTALLATION ................... 20-24

20-1
REAR DRIVING MECHANISM

SYSTEM COMPONENTS

137 N'm (14.0 kgl·m, 1011bHt)

52 N'm (S.3 kgf'm, 381bHt)

47 N'm (4.8 kgf-m. 351bHt)

39 N'm (4.0 kgf' m,

@j
291bHI) I
)

~
Ii I
"'0"---,

~~
@
@

"-

~
~
(
34 N'm (3.5 kgf.m.
25Ibf-ft)
,~
... ... ~
@

47 N'm (4.8 kgf-m,

3SlbHt)
47 N'm (4.8 kgf 'm,
35 Ibf·ft)

~I

32 N'm (3.3 kgf-m, 24 IbU t)

20-2
 REAR DRIVING MECHANISM
SERVICE INFORMATION
GENERAL
Perform the gear contact pattern and backlash inspection whenever you replace the bearings, gears or gear case. The
extension lines from the gear engagement surfaces should intersect at one point.
Protect the gear case with a shop towel or soft jaws while holding it in vise. Do not clamp it too light as it could damage the gear
case.
When using the lock nul wrench, use a deflecting beam type torque wrench 20 inches long. The lock nut w rench increases the
torque wrench's leverage, so the torque wrench reading will be less than the torque actually applied to the nut. The specification
given is the aclualtorque applied to the lock nul, not the reading on the torque wrench . Do not overtighten the lock nut. The
specification later in the text gives both actual and indicated.
Replace the ring and pinion gears as a set.

SPECIFICATIONS

~
ITEM STANDARD

r Axle runout
Rear final drive I Oil capacity After draining
===~J,~A~fter disassembly
75 cm (2.5 US oz, 2.6 Imp oz)
100 cm 3 (3.4 US oz, 3 .5 Imp oz)
Recommended oil Honda shaft drive oil or equivalent
• ~~~~:==-._ _ _==:::;jhi2YPOid gear oil, SAE II 80 - - 0.4 (0.02)
Gea~l.backlash 0 .05 - 0-:-25 (0.002 - 0 .010) ~
Backlash difference 0.2 (0 .01L) - - - i
Ring gear-Io-stop pin clearance 0.3 - 0.6 (0.01 - 0.02)

TORQUE VALUES
THREAD -,- TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N'm (kgf·m. IbUt)
Rear final gear case cover boll 2 10 47 (4.8, 35) I Appl Y locking agent to
me 1hreads.
6 , 8 25 (2 .5. 18)
Rear final gear pinion bearing lock nut 1 64 98 (10.0, 72)Lock nut: replace With
an ew one. Stake
Right axle housing mounling nut 4 10 52 (5.3. 38) Lock nut replace with
a no wane.
Rear final gear case mounting nut 8 10 47 (4 .8, 35) Lock nut: replace with
a no wane.
Shock absorber lower mounting nut 1 10 39 (4.0. 29) Lock nut: replace wilh
a no wane.
Rear final gear case skid plate bolt 3 8 32 (3 .3. 24) ALOC bolt: replace
with a new one.
Rear brake panel mounting nut 4 -·1"0--~-'4e;7·(4.8, 3<;5),-~-iL"OC:O:k nul: replace with
a new one.
Rear wheel hub nul 2 20 137(14.0. 101) Castle nut: lighten to
the specified torque
and further tighten
until its grooves align
with the cotter pin
hole .
For tightening
procedure: See page
20·24
Trailer hitch nut 2 10 +-
34 (3.5. 25) Lock nut replace With
a new one.

20·3
REAR DRIVING MECHANISM
TOOLS
Bearing clip compressor, 26 mm Remover weight Attachment, 42 x 47 mm
070ME·HPS0100 07741-0010201 07746-0010300

or 07936-371020A or 07936-3710200
(U.S.A. only)
I Atlachm." , 52 x 55 mm
07746-0010400
Attachment, 62 x 68 mm
07746-0010500
Attachment, 24 x 26 mrn
07746-0010700

I-cA"''',a''ch'''m
''.;:;'''t.' 3''5''m''m
' ''t.''O'.- - - - -h pi1o;;o'-, "15' m=m; - - - - - - - - - + -Dp,'-'oOi",' 3"5"m
"m
;;;-- - -- - ----j
07746-0030400 07746-0040300 07746-0040800

o
Pilot, 28 m
= m, - - - - - - - - -h F"O
07746-0041100
"'k' :sc.."a'""d;,c,v;;;.", =
07747-0010100
w.'''gh''', - - - - - - l--,O''river
07749-0010000 l

20-4
 REAR DRIVING MECHANISM
lock nut wrench, 30 x 64 mm Special nul Puller shaft and nul
07916-MBOOOO2 07931-HB3020A (U .S.A. only) 07931 -ME40000

Puller shaft Remover shaft, 15 mm.- - - - - - - l' R"e;;;m"oOCv"e'Oih"e"aO<d-. ,"SfCm:;;;;m,--------

07931-ME4010B (U.S.A . only) 07936-KC10100 07936-KC10200

Bearing remover, 15 mm ---t-'Attachm~e;;;n,

, ---------t-nD·
riv~e~,-----
07936·KC10500 (U .S.A. only) 07946-3290000 07949-3710001

Pinion puller base Oil seal driver attachment Pilot, 32 mm

07HMC·MMB0110 07JAD·PH80101 Q7MAD-PR90200

l or07HMC-MMB011A (U.S.A . only)

20·5
REAR DRIVING MECHANISM
TROUBLESHOOTING
Excessive noise
Worn or scored ring gear and 8xle splines
Worn or scored pinion gear and propener shaft splines
Worn or damaged bearing
Worn pinion and ring gears
Excessive backlash between pinion and ring gears
0 11level too low
Wobble or vibration in vehicle
• Axle not tightened properly
• Bent axle
Oil leak
011 Ie \lei too high
Clogged breather
Damaged seals
Loose case cover bolt

20-6
 REAR DRIVING MECHANISM
REAR AXLE REMOVAL
Remove the rear wheels (page 17-6).
Remove the rear brake drum (page 18- 16).
Do not gel grease Support the swingarm and remove the following:
on the brake shoe - breather hose (1]
linings. adjusting nuts [2]
joint pins [3]
springs [41
brake cables [5J
fOUf nuts [6]
brake panel assembly (7)
O-ring [8](from the brake panel)

- cotter pin [1]

- hub nut [2J
- left wheel hub [3)

- four nuts [11

- left axle housing (2]

- Side collar [1)

- O·ring (2)

20-7
REAR DRIVING MECHANISM
Remove the rear axle 111 by driving it from the left side
using a rubber malleI.

INSPECTION
AXLE
Set the axle in V·blocks and measure the axle runout , -- - -- - - - - - -- -- - - - - ,
wi th a dial indicator.
Axle runoul is 112 the tolal indicator reading. 263 mm 357 mm

f 1[[~99~
SERVICE LIMIT: 3.0 mm (0.12 In) (10.4 in) (14.1 in)

ocpu ' • ::i;==l

~ D

I Hold Hold I

AXLE BEARING
Remove the dust seals [11 from the axle housing and
brake panel.
Tum the inner race of the bearing 12) with your finger.
The bearings should tum smoothly and quietly.
Also check thai the bearing Quter race fits lightly in the
housing or panel.

BEARING REPLACEMENT
AXLE HOUSING
Remove the dust seal and drive the axle bearing Oul of ,-----;~---,----------,
the axle housing. 11 .0-11.5mm
(0.43 - 0.45 in)
Press the bearing (1) into the axle housing until the
depth from the housing edge is 11.0 - 11 .5 mm I
(0.43 - 0.45 in). 121 1 -'-- ~

TOOLS :
(2) Driver 07749-0010000
[3] Attachment, 52 )( 55 mm 07746-0010400 131
[4] Pilot, 32 mm 07MAD·PR90200

20-8
 REAR DRIVING MECHANISM
Apply grease to the lips of a new dust seal [1].
Install the dust seal with the metal plate side facing up
until it is flush with Ihe housing end .
TOOLS :
[2J Driver 07749-0010000
[3] Attachment, 62 x 68 mm 07746-0010500

Remove the snap ring [1].

Drive Ihe bearings [2] oul of the brake panel.
Suppon the bearing Drive a new bearing into the brake panel with the
housing section of sealed side facing down (brake drum side).
the brake panel
TOOLS:
when installing.
(3J Driver 07749·0010000
(4] Oil seal driver attachment 07JAD·PH80101
[5) Pitot, 28 mm 07746-0041100
Drive a new bearing with the sealed side facing up (axle
housing side) using the same tools.
Install the snap ring into the groove with the chamfered
edge facing the bearing .

Apply grease to the seal lips of a new dust seal [1].

Install the dust seal into the brake panel so that it is
flush with the brake panel.

REAR FINAL DRIVE REMOVAL

Drain the gear case oil if the final gear case will be , - -
disassembled (page 3-17).
Remove the rear axle (page 20-7).
Support the swingarm and remove the following:
- breather hose (1 ) (from the gear case)

20-9
REAR DRIVING MECHANISM
If the gear case - breather hose (1] (off of the clamps (2J on the
wil/be housing)
disassembled. - shock absorber lower mounting nut and boll [3]
-
loosen the four gear four nuts and bolts [4] (attaching to the swingarm;
case mounting nuts while supporting the gear case securely)
sllghlly before - gear case/axle housing assembly [5J
removing the
housmg-to-
swingarTn
fasteners.

14)
- joint spring [lJ
- propeller shaft [2]
- universal joint 131
- O-rings [4] (from the propeller shaft and output shaft)

- four nuts [1)

- right axle hosing (2)
_ _"--_ .131
- O-ring (3) (from the gear case)

INSPECTION
PROPELLER SHAFT
Check the splines (1] of the drive shaft for wear or dam- r - - - -- - - - - - - - - - - - - - - ,
age.
If the they are damaged. check the pinion and universal
joint splines also.

20-10
 REAR DRIVING MECHANISM
UNIV ERSAL J OINT
Check the boot (1] for cuts or other damage.
Check that the joint moves smoothly without binding or
noise.

OPERATION CHECK
Temporarily install the propeller shaft 11J.
Turn the pinion gear and check thaI the gear turns
smoothly and quietly withou t binding .

If the gears do not turn smoothly or quietly, the gears i'-;;:::'::~:i~.J.'t'~

andlor bearing may be damaged or faulty.
They must be checked after disassembly; replace them
jf necessary.

JOINT BOOT REPLACEMENT

Bend up the lock tabs [1] and raise each band end [2] to , - - - - - - - -- - - - - - -- -,
loosen the boot bands. {2{
Remove the joint boot [3] .
Install the boot and set it onto the universal jOint
properly. {11

13]

Install new boot bands [1) so the band ends [2J are ~=================~
facing opposite the forward direction. Viewed from the rear:
Bend down each band end and secure it with the lock
tabs [3] . Tap the lock tabs with a plastic hammer.
Forward direction ~
11-_- 131

121

11] S..,

20-11
REAR DRIVING MECHANISM
REAR FINAL GEAR OISASSEMBLYI
INSPECTION
BACKLASH INSPECTION
Remove the oil filler cap.
Set the gear case assembly in a vise.
Hold the pinion gear with the special lools.
TOOLS:
[1] Puller shaft and nut 07931·ME40000
[2) Pinion puller base 07HMC·MMB0110

U.S.A. TOOLS :
Puller shaft 07931·ME4010B
Special nut 07931·HB3020A
Pinion puller base 07HMC·MMB011A

Install the axle {3J into the gear case assembly from the
righl side (filler hole side).
Set a horizontal type dial indicator [1 1 on the ring gear
(2) through the oil filler hole.
Turn the ring gear back and forth with the axle to read
backlash.
12]
STANDARD: 0.05- 0.25 mm (0.002 - 0.010 in)
SERVICE LIMIT: 0.4 mm (0.02 in) ~
({(~
I (
Remove the dial indicator. Turn the ring gear 120· and
measure backlash. Repeat this procedure once more.
Compare the difference of the three measurements.
SERVICE LIMIT: 0.2 mm (0.01 in)

If the difference in measurements exceeds Ihe service [1]

limit, it indicates thai the bearing is not installed
squarely, or the case is deformed.
Inspect the bearings and case.
If Ihe backlash is excessive, replace the ring gear right , - - - -- - - - - -- - - - - - - ,
side shim with a thinner one.
If the backlash is too small, replace the ring gear right Left Shim
side shim with a thicker one.
Backlash changed by about 0.06 mm (0.002 in) when
thickness of Ihe shim is changed by 0.12 mm (0.005 in).
Ring gear shims :
A: 1.82 mm (0.072 in) F: 2.12 mm (0.OB3 in)
B: 1.88 mm (0.074 in) G: 2.1B mm (0.OB6 In)
c: 1.94 mm (0.076 in) H: 2.24 mm (O.OBB In)
0 : 2.00 mm (0.079 in) I: 2.30 mm (0.091 In)
E: 2.06 mm (0.081 in) Right Shim
Change the left side shim as follows: If the right shim
was replaced with a 0,12 mm (O.OOS in) thicker shim, L _ _ _ __ _ _ _ _ _ _ _ _ _ _ _ _--'
replace Ihe left shim with one that is 0.12 mm (0.005 in)
thinner.

20·12
 REAR DRIVING MECHANISM
REAR FINAL GEAR CASE
DISASSEMBLY
Loosen the eight cover bolts {1] in a crisscross pattern , - - - - - - - - - - - - - " ' - - - - ,
in several steps and remove them.
Be careful not 10 Pry the case cover (2) at the prying points [3] using a
damage the mating screwdriver and remove it.
surfaces.

Remove the ring gear [1] and shims [2).

121

BEARING INSPECTION
Turn the inner race of each bearing [1] in the gear case
and cover with your finger. The bearings should turn
smoothly and quietly. Also check that the bearing outer
race fits tightly in the case or cover.
Ring gear bearing replacement (page 20-17).

GEAR TOOTH CONTACT PATTERN

CHECK
Keep dust and dirt Clean sealing material off the mating surfaces of the r;:;~;::::~:-----------l
out of/he case and gear case and cover, being careful not to damage them. I Apply Blue
cover.
Apply thin coat of Prussian Blue to the pinion gear teeth
for a tooth contact pattern check.
Install the right shim [1 J onto the ring gear [2J.

20-13
REAR DRIVING MECHANISM
Instalilhe ring gear [1) wi th the shim into the gear case.
Install the left shim [2J onto the ring gear. 111

It is important 10 Install the case cover [1) and tighten Ihe bolts [2} in
fum the pinion gear several sleps until the cover evenly touches the gear
while tightening Ihe case. Then, while rotating the pinion gear, tighten Ihe
bolts. If Ihe ring bolts to Ihe specified torque in a crisscross pattern in
gear shim is 100 several steps.
thick, Ihe gears will
lock after only light TORQUE : 10 mm bolt: 47 N'm (4.8 kgf-m , 35 IbUt)
lightening. 8 mm bolt: 25 N'm (2.5 kgf·m. 18 IbUt)

Remove the oil filler cap.

Normal:
Rotate the ring gear several times in both directions of
rotation.
Check the gear tooth contact pattern through the oil
filler hole.
Heel ~
The pattern is indicated by Ihe Prussian Blue applied to ...., Toe
the pinion gear.
Contact is normal if the Prussian Blue is transferred to Face_ _ Face

1<9~1
the approximate center of each tooth. but slightly to the
heel side and to the flank side.
Flank Flank
If the patterns are not correct. remove and change the
pinion shim with one of an alternate thickness. Drive side Coast side

Replace the pinion shim [11 with a thicker one if the

Too High:
contact pattern is too high . toward the face.

Face Face

Drive side
L--
Ie=::> ~ I Coast side

20-14
 REAR DRIVING MECHANISM
Replace the pinion shim [1] with a thinner one if the
Too Low: [1]
contact pattern is too tow, toward the flank.
The pattern will shift about 0.5 - 1.0 mm (0.02 - 0.04 in)
when the thickness of the shim [1] is changed by
0.12 mm (0.005 in),
Pinion shims:
A: 1.82 mm (0.072 in) F: 2.12 mm (0.083 in)
B: 1.88 mm (0.074 in) G: 2.18 mm (0.086 in)
c: 1.94 mm
I~ ~ I
(0.076 in) H: 2.24 mm (0.088 in)
0 : 2.00 mm (0.079 in) t: 2.30 mm (0.091 in)
E: 2.06 mm (0.081 in) Drive side Coast side
Pinion shim replacement (page 20-16).
Flank Flank
PINION GEAR REMOVAL
Remove the oil seal [1) from the gear case.

Be careful that Unstake [1] the bearing lock nul [2J with a drill or ~==~IIII!IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII~=~~IIIIIIIIIIII=~
melal particles do grinder.
not enter the
bearing and the
threads of the case
are not damaged

Remove the lock nut [1] and discard it.

121
TOOL:
[2] Lock nut w ren ch, 30 x 64 mm 07916·MB00002

20-15
REAR DRIVING MECHANISM
Install the special lools onto the pinion gear shaft and
gear case.
TOOLS:
[1] Puller shaft and nut 07931 ·ME40000
[2] Pinion puller base 07HMC·MM80110

U.S.A. TOOLS:
Puller shaft 07931·ME4010B
Special nut 07931·HB3020A 12J
Pinion puller base 07HMC·MM8011A
Pull the pinion assembly [3] out from the gear case.
13J
PINION BEARING AND SHIM
REPLACEMENT
Pull the bearing from the shaft with a commercially , - - - - - - - - - -- - -- - . . . ,
available bearing puller.
Remove the bearing and shim.

Install the shim [1] and bearing [2] onto the pinion gear ~~~":':'::===:':'::=====::::~
131·
NOTE:
When the gear set, ring gear bearing , and/or gear
case has been replaced. use a 2.00 mm (0.079 in)
thick. shim for initial reference.

Press the pinion gear into a new bearing until It is fully

seated by supporting the bearing inner race.

TOOL:
[1] Attachment, 35 mm 1.0. 07146-0030400

20·16
 REAR DRIVING MECHANISM
GEAR CASE BEARING REPLACEMENT
RING GEAR BEARING
Remove the oil seals [1] from the gear case and cover.
Drive the bearings [2) out of the gear case and cover.

Drive new bearings into Ihe gear case and cover.

TOOLS :
Cover Side;
(1J Driver 07749-0010000
[2) Attachment, 62 x 68 mm 07746-0010500
(3] Pilot, 35 mm 07746-0040800
Case Side:
[1J Driver 07749-0010000
[4] Oil seal driver attachment 07JAO·PH80101
[3J Pilot, 35 m m 07746-0040800

Case Side:

131- -

20-17
REAR DRIVING MECHANISM
Apply grease to the seal lips of new oil seals [1].
Inslall each oil seal with the flat side facing oul so thai it
is flush with the cover or case .
TOOLS :
(2] Driver: 07749-0010000
[3] Attachment 07946·3290000

PINION NEEDLE BEARING

Rotate the stopper ring [tl until its end appears in the , - - -
access hole [2].
Strike gently near the end of the ring with a punch to
bend the end upward.
Grasp the end of the ring with needle-nose pliers and
pull the stopper ring 01..11through the access hole.
Remove the oil filler cap.
Be sure /0 wear Heat the gear case to about eo·e
(176"F) and remove
heavy gloves to the needle bearing (3] , using the speciallools.
avoid bums when
handling Ihe healad TOOLS:
gear case Remover head, 15 mm 07936·KC10200
Usmg 8 loreh to Remover shaft, 15 mm 07936-KC1 01 00
heal the gear case Remover weight 07741-0010201
may cause
warpage U.S.A. TOOLS:
Bearing remover, 1S mm 07936·KC10S00
Remover weight 07936-371 020A or
07936-3710200

....
Install a new stopper ring [1J into the groove in a new , - - - - - - - - - - - - - - ~
beaciog. (11 ¢!~
Make sure Ihe install the beating into the compressor [2J until ihe
stopper ring slays in stopper ring is nush with the end of the tool.
the groove.
TOOL:
Bearing clip compressor, 26 mm 070ME-HPS0100

121

20-18
 REAR DRIVING MECHANISM
Place the driver, attachment and pilot on the top of the
bearing and tape the driver to the compressor [1J.

TOOLS :
[2J Driver 07949-3710001
[3] Attachment, 24 x 26 mm 07746-0010700
[4] Pilot, 15 mm 07746-0040300
Place the bearing and tool assembly into a freezer for at
least 30 minutes.
Heat the gear case to aooe (176"F).
Remove the bearing and tool assembly from the freezer
and drive the bearing into the gear case using the
special lools.
Only strike the driver once . If you slrlke it more than
once, the stopper ring [5] may slip oul of the groove. If
this happens, remove the stopper ring and bearing , and
install a new stopper ring.
Make sure the stopper ring is securely set in the groove
of the gear case.

REAR FINAL GEAR ASSEMBLY

g _..s;;;;;
OIL SEAL
(35 x 49 x 6)

$I
STOPPER RING
~jjff
T.(JJ)c
(35x60)(14)

PINION NEEDLE RING GEAR

BEARING
(15x26x 17) RING GEAR BEARING
(6007)

BmmBOLT
25 N'm (2.5 kgf-m,
18 Ibf·tt)

g~
OIL SEAL
(39x70xI2)

SHIM

PINION BALL BEARING GEAR CASE COVER

(6007)

~
98 N'm (10.0 kgf'm,
cu
10 mm BOLT
OIL SEAL
(35 x 49 x 6)

72 Ibf tt) 47 N'm (4 .8 kgf'm, 35 1bHt)

20-19
REAR DRIVING MECHANISM
,
PINION GEAR INSTALLATION
Blow compressed air through the breather hole [1] in , - - - - - - - -...,.. ,--.._
the gear case.

Drive the pinion gear assembly [I] into the gear case.

TOOLS:
(2] Driver 07749-0010000
(3] Attachment, 42 x 47 mm 07746-0010300
[4] Fork seal driver weight 07747-0010100

InstaU a new lock nul [I] and tighten it to the specified ~====~;II""IIIIIIIIIIIIIIIIII~~====~
torque. [2]

TOOL :
(2) Lock nut wrench, 30 x 64 mm 01916·MB00002

Referto "Service TORQUE: Actual: 98 N'm (10.0 kgf'm , 72 IbHt)

fnformatJon"for Indicated: 89 N'm (9.1 kgf'm, 66 1bHt)
torque wrench
reading information
(page 20-3).

Be careful not to Slake [I] the lock nut into the case groove.
damage the threads
arrha case. [1[

20-20
 REAR DRIVING MECHANISM
Apply grease to the lips of a new oil seal [1] and install it
so that it is flush wilh Ihe gear case.

RING GEAR CLEARANCE

INSPECTION
Install the ring gear [1) with the left shim into the case
cover [2].
Measure the clearance between the ring gear and stop
pin [3] with a feeler gauge.
CLEARANCE: 0.3 - 0.6 mm (0,01 - 0 .02 in)
Remove the ring gear.
Be sure to wear If Ihe clearance exceeds Ihe standard value. heat the
heavy gloves 10 case cover to approximately 80°C (176°F) and remove
avoid bums when the stop pin by tapping the cover.
handling the heated
Install a stop pin shim [4] to obtain the correct
case cover.
clearance.
Using a lorch 10
heal the cover may Stop pin shims:
cause warpage. A: 0.10 mm (0.004 in)
B: 0.15 mm (0.006 in)
Inslall the shim and drive the stop pin inlo the case
cover.
FINAL GEAR CASE ASSEMBLY
NOT E:
When the gear sel, bearing, and/or gear case has
been replaced, check the following:
- looth contact pattern (page 20-13)
- gear backlash (page 20-12)
Keep dusl and dirt Clean Ihe mating surface of the gear case and cover. ~-----------------~
out of the case and being careful nol to damage them. 12J
cover.
Inslall the proper ring gear shims [1] onto Ihe ring gear
[2] and install them into the gear case.

I1J

20·21
REAR DRIVING MECHANISM
Apply liquid sealant (T81215 or equivalent) to the
mating surface of the case cover 11). [11
Inslallthe cover onlo the gear case 121.

1/ is important /0 Apply locking agent to the threads of the two 10 mm ~=============~~==;~

tum the pinion while bolts [1].
'lfIflfening the bolts. Install the eight bolts and tighten them several steps
/( the nng gear shim until the cover [2] evenly touches the case. Then. while PJ
is too thick, the rotating the pinion gear. lighten the bolts to the
gear$ will lock after specified torque In a crisscross pattern in several steps.
only Il!Iht lighfenmg.
TORQUE: 10 mm bolt: 47 N'm (4.8 kgf'm, 35 IbHt)
8 mm bolt: 25 N'm (2.5 kgf'm, 181bHI)
Make sure that the gear assembly rotales smoothly
without binding .

REAR FINAL DRIVE INSTALLATION

Coal a new O-ring [1J with molybdenum disulfide
grease and install it into the groove in the output shaft.
Apply molybdenum disulfide grease to the splines of
both sides in the universal joint [21.
InstaJl with the small Install the universal joint onto the output shaft until it is
0.0. side facing the fully seated.
engine.

Coat a new O-ring 111 with molybdenum disulfide

grease and install it into the groove in the propeller
shaft [2).
Install the propeller shaft into the universal joint until it is
fully seated .

20-22
 REAR DRIVING MECHANISM
Install the joint spring [11 into the propeller shaft firmly.
Apply molybdenum disulfide grease to the splines of the
propeller shaft.

Coat a new O-ring 11] with grease and install it into the
gear case groove_
Install the axle housing [2] onto the gear case with new
nuts 13] and temporarily tighten them.

Support the swmgarm securely.

Insert the OoIts from Install the gear case assembly Into the swingarm while
the nght side connecting the propeller shaft [1). then install the four
bolts [2] and new nuts [3). Temporarily tighten the nuts.
Connect the breather hose [4] to the gear case.
Tighten the four (axle housing-to-swingarm ) nuts (3) to
the specified torque.
TORQUE : 52 N'm (5.3 kgf-m, 38 IbHt)
Tighten the four (axle housing-to-gear case) nuts [5] to
the specified torque.
TORQUE: 47 N-m (4.8 kgf·m. 351bHt)

Insert the bolt from Connect the shock absorber with the bolt [6J and a new
the right side nut [7] and tighten it to the specified torque.
TORQUE: 39 N'm (4.0 kgf'm, 29 IbNt)
Install the breather hose (8] into the clamps [9J on the
axle housing .

12J

20-23
REAR DRIVING MECHANISM
Inslallthe skid plate (11 with new bolts [21 and lighten
them to the specified torque.

TORQUE : 32 N'm (3.3 kgf'm , 24 IbHt)

Install the rear axle (page 20-24).

REAR AXLE INSTALLATION

Apply molybdenum disulfi de grease to the center
splines [11of the axle (2J.
Inslall the axle into the final gear case from right side
until it is fully seated.

121

Coat a new O-ring 111 with grease and install it into the ~===:::::===::;:=======~
groove in the left axle housing.
Install the side collar 12J onlo the rear axle wIth the 111
tapered side facing inward.

121

Install the axle housing [11 into the gear case.

Installihe four new nuts 121 and tighten the them to the
specified torque.
TORQUE : 47 N'm (4.8 kgf'm , 35 IbHt)

20·24
 REAR DRIVING MECHANISM
Apply grease to the lips of a new dust seal (11 and
install it into the wheel hub 121 with the flat side facing in
until it is fully seated.
Apply molybdenum disulfide grease to the axle splines
13].
Do nol get grease Install the wheel hub onto the left side of the axle.
on the axle /hreads. - 13)
Do not tighten it yel. Install the hub nut loosely.
~
12)

Apply grease to the lips of a new dust seal [1 ].

Install the dust seal into the brake panel so that it is
flush with the brake panel.
Coal a new O-ring [21 with grease and install it into the
brake panel groove.
Do nol get grease Install the brake panel assembly onto the axle.
the brake shoe
OIl
limngs.

Install four new nuts [1] and tighten them to the

specified torque.
TORQUE : 47 N'm (4.8 kgf'm, 35 IbUt)

Install the brake cables 121 into the cable holders on the
brake panel (upper holder for lever brake cable and
lower holder for pedal brake cable).
Install the cable springs [3] onto the cables . Connect
the brake cables to the brake arm with the joint pins {41
and adjusting nuts [5].
Connect the breather hose [6].
Whenever Install the rear brake drum (torque Ihe hub nut)
removingbolhhub (page 18- 19).
nuts, firs/lighten
nght sKie, then
tighten the /eft side.

Tighten the hub nut [11 to the specified torque and

further tighten untit its grooves align with the cotter pin
' -----::::::0
I
hole.

TORQUE: 137 N'm (14.0 kgf'm , 101 IbHt)

Install a new cotter pin 12].
Inslall the left rear wheel (page 17-6).
Fill the gear case with Ihe recommended oil
(page 3-17).
....
12) ~

20-25
MEMO
 21. BATTERY/CHARGING SYSTEM

COMPONENT LOCATION ··························21-2 CHARGING SYSTEM INSPECTION ··········21-9

SYSTEM DIAGRAM ····································21-2 ALTERNATOR CHARGING COIL ············ 21-10

SERVICE INFORMATION ···························21-4 REGULATOR/RECTIFIER ........................ 21·10

TROUBLESHOOTING·································21-6 POWER RELAY (Canada type) ···············21·11

BATTERY ····················································21-8

21-1
BATTERY/CHARGING SYSTEM
COMPONENT LOCATION

FUSE BOX:
- FMfFPM: MAINFUSE (30 A )
- FElFPE: MAIN FUSE 1 (30 A ) BATIERY

PO.,ERRELA Y
(Canada type )

PCMIECM

RECTIFIER
I I
(Canada type )

SYSTEM DIAGRAM
U.S.A. type :

FMfFPM : MAIN FUSE (30A)

FElFPE : MAIN FUSE 1 (30A)
RlBI ----Q....../"O RlBI

ALTERNATOR

REGULATOR/RECTIFIER BATTERY

21-2
 BATTERY/CHARGING SYSTEM
Canada type:
PCMIECM POWER RELAY POWER RELAY

--0 ( " " 0 -

WIBIBIIR R W/BI BIIR RlBI R W/BI BIIR RlBI

I
BIIR ---<:r-.....O-
IGN FUSE (lOA)
BI]
R~~al
IGNITION
~ R [EJ RlBI ~ SWITCH

RECTIF IER
RlB I
8 1: Black
G Green
R: Red
FMlFPM, MAIN FUSE (30A) Y: Yellow
FE/FPE ' MAIN FUSE 1 (30A) W:Wh ite

~ b
rrrI I - RlBI --+- R -~-n=t__ J:1o:'- '
G 8
ALTERNATOR

REGULATOR/RE CTIFIER BATIERY

21-3
BATTERY/CHARGING SYSTEM
SERVICE INFORMATION
GENERAL

AWARNING
The battery gives off explosive gases; keep sparks, flames and cigarettes away . Provide adequate ven tilation when
charging.
The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective clothing
and a face shield.
- If electrolyte gets on your skin , flush with water.
- If electrolyte gets in your eyes, flush with water for at least 15 minutes and call a physician immediately.
Electrolyte is poisonous.
- If swallowed . drink large quantities of water or milk and call your local Poison Control Center or a physician immediately .

NOTICE I
Always tum OFF the ignition switch before disconnecting any electrical component.
Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch
is ON and current is present.
For extended storage , remove the battery, give it a full charge, and store it in a cool , dry space.
For a battery remaining in a stored vehicle, disconnect the negative battery cable from the battery.
The maintenance free battery must be replaced when it reaches the end of its service life.
The battery can be damaged if overcharged or undercharged . or if left to discharge for long period. These same conditions
contribu te to shortening the "life span" of the battery. Even under normal use, the performance of Ihe battery deteriorates after
2 - 3 years .
Battery voltage may recover after battery charging , but under heavy toad, the battery vol tage will drop quickly and eventually die
out. For this reason. the charging system is often suspected as the problem . Battery overcharge often results from problems in
the battery itself, which may appear to be an overcharging symptom . If one of the battery cells is shorted and battery voltage
does not increase, the regulator/rectifier supplies excess voltage to the battery. Under these conditions, the electrolyte level
goes down quickly.
Before troubleshooting the charging system, check for proper use and maintenance of the battery. Check if the battery is
frequently under heavy load, such as having the headlight and taillight on for long periods of time without riding the vehicle.
The battery will self-discharge when the vehicle is not in use. For this reason , charge the battery every two weeks to prevent
sulfation from occurring.
When checking the charging system , always follow the steps in the troubleshooting (page 21-6).
For alternator removallinstallation, refer to Alternator/Starter Clutch section (page 13-6).
BATIERY CHARGING
Turn power ON/OFF at the charger, not at the battery terminal.
For battery charging, do not exceed the charging current and time speCified on the battery. Using excessive current or extending
the charging time may damage the battery.
Quick charging should only be done in an emergency; slow charging is preferred.
BATIERY TESTING
Refer to the instructions in the Operation Manual for Ihe recommended battery tester for details about battery testing. The
recommended battery tester puts a "load" on the battery so that the actual battery condition can be measured.

Recommended battery t ester: Mic ro 404XL (U.S.A . only)

SPECIFICATIONS
ITEM SPECIFICATIONS
Battery Type , GYZ16H
r----tapacily 12V 16 Ah
Current leakage 0.62 mA max .
Vol tage Fully charged 13.0 13.2 V
(20°C/6S"F) Needs charging - t- Below 12.4 V
Charging Normal 1.6Ax5 10 h
current Quick 8.0Ax1 .0h
Alternator Capacity 0.416 kWI5,OOO rpm
Charging coil resistance (20· Cf6BOF) 0 .1 1.00

21-4
 BATIERY/CHARGING SYSTEM
TOOLS
--..M"'
ot;;;
o,o;cy;;octehb""'
"' t"'te"'
''''"'a'''na"t'yz
= e', ------,''Chh.''ist
"'fui.' ''' = ch"a';;',g"eCC
batlery , - -- -
,
Micro 404XL (U.S.A. only) MC1012/2T (U.S.A. only)

21·5
BATTERY/CHARGING SYSTEM
TROUBLESHOOTING
BATIERY IS DAMAGED OR WEAK
1. Battery Test
Remove the battery (page 21-8).
Check the battery condition using Ihe recommended battery tester.
Recommended battery tester: Micro 404XL (U.S.A. only)
Is the battery in good condition?
YES - GO TO STEP 2.
NO - Faulty battery.
2. Current Leakage Test
tnstallthe battery (page 21-8).
Check the battery current leakage (page 21 -9).
Is the current leakage be/ow 0.62 mA ?
YES - GO TO STEP 4.
NO - GO TO STEP 3.
3. Current Leakage Test With Regulator/Rectifier Connector Disconnected
Disconnect the regulatorlrectifl8r connector and recheck the battery current leakage.
Is the current leakage below 0.62 mA ?
YES - Faulty regulator/rectifier.
NO - ' Shorted wire harness .
• Faulty ignition switch .
4. Alternator Charging Coli Inspection
Measure the alternator charging coil resistance (page 21 -10).
Standard : 0.1 -1.0 n (20°CI68°F)
Is the alternator charging coli resistance within the standard value?
YES - GO TO STEP 5.
NO - Faulty charging coil.
5. Charging Voltage Inspection
Measure and record the battery voltage using a digital multimeter (page 21-8).
Start the engine.
Measure the charging vol tage (page 21-9).
Compare the measurements to the results of the following calculation .
Standard : Measured BV < Measured CV < 15.5 V
• BV = Battery voltage (page 21-8)
• CV:: Charging voltage
Is the measured charging voltage within the standard voltage ?
YES - Faulty battery.
NO - Canada type: GO TO STEP 6.
U.S.A. type : GO TO STEP 7.
6. Power Relay In spection (Canada type)
Check the power relays and their circuits (page 21-11).
Are the relay and circuits normal?
YES - GO TO STEP 7.
NO Faulty power relay.
Loose or poor con tacts of related connector terminal.
Open or short circuit in related wire.
Faulty PCMJECM.

21-6
 BATTERY/CHARGING SYSTEM
7. Regulator/Rectifier Wire Harness Inspection
Perform the regulator/rectifier wire harness inspection (page 21-10).
Are the measurements correct?
YES - Faulty regulator/rectifier.
NO - ' Open circuit in related wire.
loose or poor contacts of related terminal.
Shorted wire harness.

21-7
BATIERY/CHARGING SYSTEM
BATTERY
REMOVAUINSTALLATION
Remove the rear fender cover (page 2-9).
Tum the ignition switch OFF and disconnect the
negative (-) cable (1J first, then disconnect the positive
(+) cable (21 by removinglhe terminal bolts.
Remove the battery holder band (3].
Remove the battery [4) and battery rubber (51.
Installation is in the reverse order of removal.
NOTE
Connect the positive (+) cable first and then the
negative H cable.

VOLTAGE INSPECTION
Remove the rear fender cover (page 2-9).
Measure the battery voltage using a commercially
available digital multimeter.
VOLTAG E (20 ~C f6 8 ° F ) :
Fully charged: 13.0 - 13.2 V
Under charged: Below 12.4 V

BATIERY TESTING
Remove the battery (page 21-8).
Refer to the instructions that are appropriate to the
battery testing equipment available to you.
TOOL:
Battery tester Micro 404XL (U.S.A. only)

BATIERY CHARGING (U .S.A. only)

Remove the battery (page 21-8).
Refer to the instructions that are appropriate to the
battery charging equipment available to you.
TOOL:
Christie battery charger MC 1012/2T (U .S.A. only)

21-8
 BATTERY/C HARGING SYSTEM
CHARGING SYSTEM INSPECTION
CURRENT LEAKAGE INSPECTION
Remove the rear fender cover (page 2-9).
Tum the ignition switch OFF and disconnect the
negative (-) cable [1) from the battery.
Connect the ammeter (+) probe [2] to the negative (-)
cable and the ammeter (-) probe [3] to the battery H
terminal (4].
Wi th the ignition switch turned OFF , check for current
leakage .
NOTE '
When measuring current using a lesler, set It to a
high range , and then bring the range down to an
appropriate level. Current now higher than the range
selected may blowout the fu se in the tester.
While measuring current, do not turn the ignition
switch ON . A sudden surge of current may blowout
the fuse In the tester.

SPECIFIED CURRENT LEAKAGE :

0.62 rnA maximum
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

NOTE :
• Be sure the battery is in good condition before
performing this test.
Remove the rear fender cover (page 2-9).
Warm up the engine to normal operating temperature.
Connect the multimeter between the battery positive (+)
and negatIVe (-) terminals.
NOTE:
To prevent a short, make absolutely certain which
are the positive (+) and negative (-) terminals or
cables.
Do not disconnect the battery or any cable in the
charging system without first switching off the
ignition switch. Failure to follow this precaution can
damage the tester or electrical components.
Restart the engine and turn the headlight on .
Measure the voltage on the multimeter when the engine
runs at 5,000 rpm.
Standard :
Measured BV < Measured CV < 15.5 V
• BV = Battery voltage (page 21-8)
• cv = Charging voltage

21-9
BATIERY/CHARGING SYSTEM
ALTERNATOR CHARGING COIL
INSPECTION
Remove the right side cover (page 24).
Disconnect the alternator 5P (Natural) connector (1] .
Check the connector for loose contacts or corroded
terminals.
Measure the resistance between the Yellow wire
terminals of the alternator side connector.
Standard : 0.1 - 1.0 a (20°C/68°F)
Check for continuity between each Yellow wire terminal
of the alternator side connector and ground .
There should be no continuity.
Replace the alternator stator if resistance is out of
specification, or If any wire has continui ty to ground.
For alternator stator replacement (page 13-6).

REGULATOR/RECTIFIER
REMOVAUINSTALLATION
Release the regulator/rectifier wire [1) from the wire Canada type shown: [2J
band (2]. [11
Remove the two mounting bolts (3] and regulatorl (6) ~
rectifier 14). -:::::S;::;;11~~ [5[
Disconnect the regulator/reclifier 3P (Gray) [5] and -
(Black) 16] connectors.
Installation is in the reverse order of removal.

13J [4J
WIRE HARNESS INSPECTION
Disconnect the regulator/rectifier 3P (Gray) [1] and , - - - - - - - - - - - - - - - - - - ,
(Black) [2) connectors (page 21.10).
Yellow Yellow Yellow
Check the connectors for loose contacts or corroded
terminals. [11
Check the following at the wire hamess side
connectors.
Battery Une (Black connector) :
Measure the voltage between the Red wire terminal
1Xi
}X~
and ground. [2J
There should be battery voltage at all times.
Ground Une (Black connector):
Check for continuity between the Green wire terminal Gcee" Red
and ground.
There should be continuity at all times.
Charging Coil Line (Gray c onnector) :
Measure the resistance between the Yellow wire
terminals.
Standard : 0.1 - 1.0 a (20°C/68- F)
Check for continuity between each Yellow wire terminal
and ground.
There should be no continuity.

21-10
 BATTERY/CHARGING SYSTEM
POWER RELAY (Canada type)
RELAY INSPECTION
Remove the rear tender cover (page 2-9).
Disconnect the power relay BP (Gray) connector [1J.
Remove the power relay [2J from the rear fender.

Connect an ohmmeter to the power relay side 8P

connector [1] terminals as shown.
I
Connection : C
A (Red/black)
(Red/black) -- B (Red)
0 (Red) r--S~~I;~~~~:::: 111

Connect the 12 V battery (2] to the power relay side 8P

connector terminals as shown.
Connection : E (Black/red) - F (White/black)
G (BlaCk/red) - H (White/black)
There should be continuity wi th the battery connected
and no continuity with the battery disconnected.
If the test result is abnormal , replace the power relay.

CIRCUIT INSPECTION
Olsconnect the power relay 8P (Gray) connector (1) r - - -
(page 21-11).
Redlblack Red
Check the following al the wire harness side power
relay 8P (Gray) connector. Rod Redlbfack

Charging Line (Battery side): 111

Measure the voltage between the Red/black wire
terminal (+) and ground (-),
There should be battery voltage at all times.
Charging LIne (Regulator/rectifier side):
Measure the voltage between the Red wire terminal (+) Whitelblack Black/red
and ground (- ).
There should be battery voltage al all times. Black/red White/black
Relay Coil Input Line :
Measure the voltage between the Black/red wire
terminal (+ ) and ground (-).
There should be battery voltage when the ignition
switch is turned ON.
Relay Coli Ground Une:
Check for continuity between the White/black wire
terminal and ground.
There should be continuity when the engine speed is
more than 100 rpm.

21-11
MEMO

f
 22. LIGHTS/METERS/SWITCHES

COMPONENT LOCATION ···················.. ·····22-2 HANDLEBAR SWITCH ····························· 22 -11

SERVICE INFORMATION ······················ ·····22-3 FRONT BRAKE SWITCH ········· ················ 22 -12

ASSIST HEADLIGHT ·································· 22-4 REAR BRAKE LIGHT SWITCH· ·········· ····· 22-13

HEADLIGHT ········································· ·······22-5 GEAR POSITION SWITCH ....................... 22-14

BRAKEfTAILLIGHT ............................... ······ 22-6 COOLING FAN ·········································· 22-15

COMBINATION METER ······························22-6 4WD SELECT SWITCH ···························· 22-17

ACCESSORY SOCKET ···························· 22-10 FUEL GAUGE/FUEL LEVEL SENSOR .... 22-18

IGNITION SWITCH ····················· ····· ··········22-11

22·1
LIGHTS/METERS/SWITCHES
COMPONENT LOCATION

COMBINATION METER

FRONT BRAKE LIGHT SWITCH

FRONT BRAKE INHIBITOR SWITCH
REAR BRAKE LIGHT
SWITCH SIDE)
IGNITION
SWITCH

HANDLEBAR SWITCH

GEAR pmilTl(]N SWITCH W<JLI"G FAN MOTOR

4WD SElEGlr SVVlTe:H

REAR LIGHT
SWITCH (PEDAL SIDE)

22-2
 LIGHTS/METERS/SWITCHES
SERVICE INFORMATION
GENERAL
All plastic connectors have locking tabs that must be released before disconnecting, and must be aligned when reconnecting.
To isolate an electrical failure, check the continuity of the electrical path through the part. A continuity check can usuaUy be
made without removing Ihe part from the vehicle. Simply disconnect the connectors and connect a continuity tester to the
terminals or connections.
The following color codes are used throughout this section .

81 : Black G: Green 19: Ught green R: Red

Br: Brown Gr: Gray 0: Orange W: White
Bu: Blue lb: Light blue P: Pink Y: Yellow

SPECIFICATIONS

Bulb, ~ • beam)
SPECIFICATIONS
12V·30/30Wx 2
-
M,;,t! 12V-45W

~~~~~
LED
I
- ..... " i i LED
; LED
I LED
t LED I
8"JD; I LED
LED
EPS indicator (FPMlFPE) LED
Fuse Main fuse FM/ FPM 30A
FE/FPE 30Ax 2
Sub-fuse 15Ax2, 10Ax2
I
EP$ fuse (FPM/ FPE) 40A ,

TORQUE VALUES
,
THREAD TORQUE REMARKS
ITEM Q'TY
DIA_Imm ) N'm (kgf 'm , Ibf-ft)
Combination meter mounting screw 3 5 0 . 8~ . 0 . 6 L
Gear position switch wire clamp bolt 2 6 12 (1.2. 9) Apply locking agent to
the threads.
Rear brake light switch screw 1 4 1.2 (0.1, 0 .9) Apply locking agent to -
the threads.
Front brake light/inhibitor switch screw 1 4 1.2 (0. 1, 0.9) Apply locking agent to
the threads.
4WD select switch 1 10 12 (1 .2. 9)
Fuel level sensor bolt 3 6 9.0 (0.9. 6.6)

TOOL
Test probe
07ZAJ-ROJA 11 0

22·3
LIGHTS/METERS/SWITCHES
ASSIST HEADLIGHT
BULB REPLACEMENT
Remove the two screws (1) and two trim clips 12J.
Disengage the adjusting screw [3] by push in on the
headlight unit [4] until the screw head clears the ridge.
then slide the screw head over into the opening . [5[

Remove the assist headlight cover (5].

Disconnect the assist headlight connector [11.

Remove the re taining ring [2] by turning it
I
counterclockwise and remove the bulb [3] from the
assist headlight [4] .
Align the bulb tab [51 with housing groove [6).
[2[
Install a new bulb and removed parts in the reverse
order of removal.
After installing the removed parts, adjust the assist
headlight aiming (page 22-4). (1)
I
~,
REMOVAUINSTALLATION
Remove the assist headlight bulb (page 22-4 ).
[1 [
Remove the assist height unit [1] from the stays [2).

[2[

Inslalithe assist headlight unit and removed pans in the

[1 [
reverse order of removal.
After installing the headlight. align the reference marks
[1) on the assist headlight with the index marks [21 on
the cover by turning the adjusting screw (3). . "-

I [3[~gp --r~
22-4
 LIGHTS/METERS/SWITCHES
HEADLIGHT
BULB REPLACEMENT
Remove the headlight cover cap [11.
Disconnect the headlight 3P connector 12J.
Remove the headlight bulb (3] by turning it clockwise for
the right headlight and counterclockwise for Ihe left
headlight.
Align the bulb labs Install a new bulb in the reverse order of removal.
with the headlight
grooves proper/y,

REMOVALIINSTALLATION
Remove the front grille (page 2-7),
Remove Ihe following:
- headlight cover cap [1]
- headlight 3P connector from the bulb [2]
- three trim clips [3]
two lapping screws [4)
- mounting bolt [5}
- headlight assembly [6]

'\
~,

131
- adjusting screw [1]
- washer [2] 161
-
-
-
nut [3)
spring [4}
headlight unit (5] from the cover [6] by releasing the
1'(\
bosses from Ihe holes 141

. ~' /
(5) ~-~[31
--

Route the headlight Inslalilhe headlight unit in the reverse order of removal.
wire into the groove
After installing the headlight. align the reference mark
in the headlight
[1[ on the headlight with the top o f the index mark [2J on
/1
121
cover properly_
the cover by turning the adjusting screw {3J.

~, ".
,-.,
\

--c ~----=-- ~

.~

.-
---- ]31 111

22-5
LIGHTS/METERS/SWITCHES
BRAKEITAILLIGHT
REPLACEMENT
Unhook the retaining strap and open the tool box lid.
Remove the two wire clips [1] and brakellaillighl wire
from the guides of the tool box lid [2 ].
Remove the brake/taillight [3] from the tool box lid by
releasing the bosses (4) from the grommets [5).
Disconnect the 3P connector [6] from the brake/taillight.
Be careful not to Install a new brake/taillight in the reverse order of
damage the seal removal.
rubber.

COMBINATION METER
REMOVAUINSTALLATION
Remove the assist headlight cover (page 22-4).
Remove the fuel tank breather hose [1) from the meter
cover [21.
Remove the screw (3).
Remove the meter cover from the meIer cover slay.

III

Remove the three tapping screws [1].

Disconnect the 21P connector [2] from the combination
meIer [3].
Inslallalion is in the reverse order of removal.
TORQUE: 131
Combination meter mounting screw:
0.8 N'm (0.1 kgf'm, O.6IbHt)

121

22-6
 LIGHTS/METERS/SWITCHES
POWER/GROUND LINE INSPECTION
Disconnect the combination meier 21 P connector
(page 22-6) ,
Check the power and ground lines at the wire harness
side connector.
POWER INPUT LINE
Measure the voltage between the combination meter
[1 [
21 P connector [1] terminal and ground.

Connection : Black/red (+) - Ground (-)

There should be battery voltage with the ignition switch 0000000
turned ON. , - - t t " !OOOOOO
If there is no voltage, check Ihe following: CJOOOOO
-
-

-
IGN fuse ( 10 A)
Black/red wire between the combination meter and
fuse box for an open circuit
ignition switch (page 22-11)
v Black/red (+)
- Black wire between the ignition switch and fuse box
for an open circuit

GROUND LINE
Check for continui ty between the combination meter
21P connector [11 terminal and ground.
[1 [
There should be continuity all times.
Connection : Green - Ground
0000000
If there is no continuity, check for an open circui t in the OOOO'fteetf------,
Green wire. 000(:)00

Green

SERIAL COMMUNICATION LINE

Gear position indicator continuously blinks "-", MIL
and engine coolant temperature indicator do not
come on
1. PCMIECM Power Input Inspection
Check that the engine can be started normally.
Can the engine s taff?
YES - GO TO STEP 2.
NO - Check the PCM/ECM power/ground line
(page 4-35).
2. Connector Inspection
Check the combination meter 21 P connector and
PCM/ECM 33P (Black) connector for loose contacts
or corroded terminals.
Are the connectors in good condition?
YES - GO TO STEP 3.
NO - Loose or poor contacts at the combina tion
meter 21P connector or PCMIECM 33P
(Black) connector.

22-7
LIGHTS/METERS/SWITCHES
3. Combination Meter Serial Line Short Circuit
Inspection
Turn the ignition switch OFF. [1 [
Disconnect Ihe PCM/ECM 33P (Black) connector [1]
and combination meter 21P connector.
Check for continuity between the wire harness side
PCM/ECM 33P (Black) connector terminal and
ground.
TOOL:
Test probe 07ZAJ·RDJA 110

Connection:
Orange (A21) - ground Q }-----,
Is there continuity? Orange (A21)
YES - Short circuit in the Orange wire.
NO - GO TO STEP 4.
4. Combination Meter Serial Une Open Circuit
Inspection
Check Ihe continuity between the PCM/ECM 33P r - - - - - - - - - - - - - - - - ----,
(Black) connector 111 and combination meter 21P (1\1 [21

\
connector 12] terminals.
TOOL:
Test probe 07ZAJ·RDJA 110

Connection:
Orange (A2l) - Orange
t, +,
0000006'1
OO)\~
00 000

~g,
Is there continuity?
Q
YES
NO
- GO TO STEP 5.
- Open circuit in the Orange wire.
-,
Orange (A21)

5. PCMIECM Circuit Inspection

Connect the PCM/ECM 33P (Black) connector.
[11
Turn the ignition switch ON and wait 5 seconds or
more. Measure resistance atlhe combination meter
21P connector [1] terminals.
Connection: Orange - Green Orange Green

Is the resistance 0.1 kD - 100 kD ?

000000
rn-e.;,.O·t>E;e+h
YES - Replace the combination meter with a 0000000
known good one, and recheck .
NO - Replace the PCM/ECM with a known good
one, and recheck.

22·8
 LIGHTS/METERS/SWITCHES
SPEEDOMETER
Speedometer does not operate
1. Combination Meter Power/Ground Line
Inspection
Check the odometer/trip meier and indicators
functions .
Do they function properly?
YES - GO TO ST EP 2.
ND - Check the combination meter powerl
ground lines (page 22-7).
2. ESP System OTe Inspection
Check the ESP system OTe (page 23-11).
Is DTe 11-1 indicated?
YES - Perform the DlC 11-1 troubleshooting
(page 23-14).
NO - GO TO STEP 3.
3. Speedometer Line Open Circuit Inspection
Remove the left side cover (page 2-4).
Disconnect the VS sensor 3P (Black) connector [1].

Disconnect the combination meter 21 P connector ~----------=--------,

(page 22-6). [1 1 [2[
Check the continuity between the combination
meter 21P connector [1) and VS sensor connector
[2]lerminals.
Connection : Pink/green - Pink
0000000
Is there continuity? 000 000
OO( 000
YES - Replace the combination meter
(page 22-6).
NO Open circuit in the Pink/green or Pink
wire.
Pink/green Q Pink
Loose or poorly connected related
connectors.

22-9
LIGHTS/METERS/SWITCHES
ACCESSORY SOCKET
INSPECTION
Remove the accessory sockel2P (Black) connector (1)
from the frame and disconnect it.
Measure the voltage between the While/black (+) and
Green (-) wire terminals of the wire harness side
connector.
There should be battery vollage with the ignition switch
turned ON .
If there is no voltage, check for brown ACe fuse (10 A)
and an open cirruil in the wire harness.

Remove the accessory socket cap [1].

Check for continuity between the White/black wire
terminal of the socket side 2P connector and bottom
center terminal 121 of the sockel, and between the
Green wire terminal and side wall terminal [3).
There should be continuity.
If there is no continuity, replace the accessory socket
(page 22-10).

REPLACEMENT
Remove the left fuel tank side cover (page 2-5).
Disconnect the accessory sub harness 2P (Black)
connector (1) from the accessory socket (2).
Remove the nut (3) and inner spacer [4]. accessory
socket, outer spacer [5).
Assemble the outer spacer and a new accessory socket
by aligning the groove with the lug, and place them into
the fender.
Install the inner spacer while aligning the holes with the
outer spacer bosses.
Install the nut and tighten it securely.
Connect the accessory sub harness 2P (Black)
connector.
Install the left fuel tank side cover (page 2-5).

tftJ'~
141 131 [11

22-10
 LIGHTS/METERS/SWITCH ES
IGNITION SWITCH
INSPECTION
Remove the front fender/carrier (page 2-8).
Remove the ignition switch 4P connector (1] from the
frame and disconnect it.
Check for continuity between the switch side connector
terminals in each switch position.
Continui ty should exist between the color coded wires
as follows:

~
Position
RIBI P R BI

ON 0- r-o 0--0
OFF

REPLACEMENT
Disconnect the ignition switch 4P connector
(page 22-11).
Remove the meter cover (page 22-6),
Release the ignition switch wire from the wire band ,
wire dips and wire guides.
Remove the ignition switch [lJ from the meter cover by
pushing in the two stoppers (21 .
Install a new ignition switch by aligning the locating tab
PI with the covef groove.
Install the removed parts in the reverse order of
removal.

HANDLEBAR SWITCH
INSPECTION
Remove the front fender/carrier (page 2-8),
Remove the handlebar switch connector [1) from the
frame and disconnect it.
- FMlFPM : 10P (Green)
- FElFPE: 14P (Green)

111

22-11
LIGHTS/METERS /SWITCHES
For gearshift Che ck for continuity between the switch side connector FEJFPE shown:
swl/ch inspectIOn term; nals in each switch position.
(page 23-29)

."
Conti nuity should eXist between the color coded wires
hown below:

lIG HTING SWITCH (1]/OIMMER SWITCH [2]

""
Posilion
Color
BlIBr B,
Color

Position
w BulBI

•
-IT-
liD
(N)
','
~D

ENG INE STOP SWITCH (3)/STARTER SWITCH 14]

""
Position
Color
BUR BIIW
Color

Position
BlfIIV Y /R

FREE
PUSH

FRONT BRA KE SWITCH

INS PECTION
NOT E,
The mhlbltor sWItch . The lower switch is the brake fight switch and the , - - -- -- -
WIre has gl1iY tape u pper switch is the inhibitor switch.
{1}.
Dis connect the brake light switch connectors (21 and the
inhibilor swi tch connectors (3).
Che ck for continuity between the switch terminals .
There should be continuity with the fron t brake lever
squeszed and no continuity with the lever released .

22-12
 LIGHTS/METERS/SWITCHES
REPLACEMENT
Disconnect the brake light swit ch connectors III and the
inhibitor switch connectors [2) from the switches.
Remove the dust cover [3] from the switches.

Squeeze the front brake lever and secure it.

Remove the screw [1 ], brake light switch (2J, inhibitor
switch [3) and spacer [4] from the master cylinder.
Apply locking agent to the screw threads,
Install the switches and spacer by aligning the switch
cutout with the lug of the master cylinder and spacer.
Install and lighten the screw to the specified torque.
TORQUE : 1.2 N'm (0.1 kgfm, O.9Ibf-ft)

Install the dust cover onto the switches properly.

Connect the connectors to the switches.

REAR BRAKE LIGHT SWITCH

LEVER SWITCH INSPECTION
Remove the dust cover [1) from the brake light switch.
Disconnect the rear brake lever switch connectors [2)
and check for continuity between the switch terminals.
There should be continuity with the rear brake lever
squeezed and no continuity with the lever released .

LEVER SWITCH REPLACEMENT

Remove the dust cover [1] from the brake light switch
121·
Disconnect the rear brake lever switch connectors [3].
Remove the screw [4) and switch from the brake lever
bracket.
Apply locking agent to the screw threads.
Install the switch by aligning the switch cutout with the
lug of the brake lever bracket.
Install and tighten the screw to the speCified torque.
TORQUE: 1.2 N'm (0.1 kgf'm , 0.9IbHt)
Connect the connectors to the switch.
Instalilhe dust cover onto the switch proper1y.

22-13
LIGHTS/METERS/SWITCHES
PEDAL SWITCH INSPECTION
Remove the right side cover (page 2-4).
Disconnect the rear brake pedal switch 2P connector
!11 and check for continuity between the switch side
connector terminals.
There should be continuity with the rBar brake pedal
depressed and no continuity with the pedal released.

GEAR POSITION SWITCH

INSPECTION
Remove the right side cover (page 2-4).
Remove the gear position switch BP connector [1] from
the frame and disconnect it.
Check for continuity at the switch side connector
If the tranSlntsslO/1
terminals.
wJii not shift with tho
gearshift switches, There should be continuity in each gear position as
use the gear follows:
change tool
included with the Gear position Connection
tool kit (FElFPE Reverse Gray - ground
models),
~N"e::""I="~I~~~~~~!~L",I!!c9~hl:,9~,.::.=.fjnjf:.:,::e:.:d",---::9;;'-o:=-~"-:-:n:::d~----1
1s t White/green - ground
2nd White/red - ground
3rd Blue - ground
4th Yellow - ground
5th Light bluelwhite - ground

REPLACEMENT
Remove the rear crankcase cover (page 13-6).
Remove the two wire clamp bolts 111. 111 0 , .
Remove the wire grommet (21 from the rear crankcase [4)
cover.
Remove the retaining bolt (31 and gear position switch
[4] from the rear crankcase cover.
o
Apply locking agent to all the bolt threads.
Install a new gear position switch onto the rear
crankcase cover and tighten the retaining bolt.
Apply liquid sealant to the grommet seating surface.
Route the wire as shown and install the grommet into
the crankcase cover groove properly.
Install the two clamp bolts and tighten them to the
specified torque. .,(1lW 121
TORQUE : 12 N·m (1.2 kgf·m, 9lbHt)
Install the rear crankcase cover (page 13-9).

22-14 I
I
 LIGHTS/METERS/SWITCHES
COOLING FAN
Cooling fan does not start
1. Fuse Inspection
Check the FAN fuse (15 A).
Is the (use blown?
YES - Replace the FAN fuse.
NO - GO TO STEP 2.
2. PGM·FI System OTC Inspection
Check the PGM-FI system OTe (page 4-11).
Is OTe 7·1 and/or 7·2 indicated?
YES - Perform the DTG 7-1 troubleshooting
(page 4-16).
Perform the DTG 7·2 troubleshooting
(page 4-17),
NO - GO TO STEP 3.
3. Ground Line Inspection
Remove the rear fender cover.
Disconnect the PCM/ECM 5P (Black) connector [1}.

Check for continuity between the PCM/ECM SP ~==== 111

(Black) connector 11J terminal and ground .
Connection : Green - ground
Is there continuity?
YES - GO TO STEP 4.
NO - Open circuit in the Green wire.

Green

L-=-

22·15
LIGHTS/METERS/SWITCHES
4. Cooling Fan Operation Inspection
Connect the PCMlECM 5P (Black) connector [1]
terminals with jumper wire (2]. 111
Connection: Greenfblack - green
Green/black
Check the cooling fan when connecting the jumper
wire.
121
Does the cooling fan start?
YES - Replace the PCMlECM with a known good
one, and recheck.
NO - GO TO STEP 5.

Green

5. Cooling Fan Ground Line Inspection

Remove the fron t fender/carrier (page 2-8).
Remove the cooling fan 2P connector [1] from the
frame and disconnect it.

With the jumper wire connected to the PCM/ECM

5P connector, check for continuity between the fan Greenlblack 111
motor 2P connector (2] terminal and ground.
Connection : Green/black - ground
Is there continuity?
YES - GO TO STEP 6.
NO - Open circuil in the Green/black wire.

6. Cooling Fan Powe r Input line Inspection

Measure the voltage between the fan motor 2P 111
terminal (+ ) and ground (_). PI Blue
Is there battery voltage?
YES - Replace the cooling fan with a new one
(page 8-9).
NO - Open circuit in the Blue wire between the
cooling fan and fuse box.

22·16
 LIGHTS/METERS/SWITCHES
4WD SELECT SWITCH
SYSTEM INSPECTION
Release the wire grommet from the guide of the gear
case and disconnecllhe 4WD select switch connector
11].
Ground the switch connector terminal with a jumper
wire (2].
Turn the ignition switch ON and check the 4WD
indicator.
The indicator should light when the connector terminal
is grounded .
The indicator should not light when the jumper wire is
removed.
FPMlFPE models: If the 4WD indicator 13J operation is abnormal , check
the 8rawnfwhite wire between the 4WD select switch
and EPS ECU, and the Bluelwhite wire between the
EPS ECU and combination meter. FPMfFPE shown: 13]
FMlFE models: If the 4WD indicator operation is abnormal, check the
Blue/white wire between the 4WD select switch and
combination meier.
R N

SWITCH INSPECTION
Disconnect the select switch connector [1].
Check for continuity between the switch terminal [21 and
ground.
There should be continuity when the 2WD/4WD select
lever is 4WD position, and no continuity when the lever
is 2WD position.

REPLACEMENT
Disconnect the select switch connector [1] .
Remove the 4WD select switch [2) and sealing washer
131·
Install the 4WO select switch with a new seating washer
and tighten it.
TORQUE: 12 N·m (1.2 kgfm , 9lbHt)
Connect the switch connector and install its wire
(grommet [4]) in the wire guide.

22-17
LIGHTS/METERS/SWITCHES
FUEL GAUGE/FUEL LEVEL SENSOR
REMOVAL/INSTALLATION
Remove the fuel tank cover (page 2-5).
Disconnect the fuel level sensor 2P (Red) connector [1].

Release the sensor wire [1] out of the sensor cover 12].
Be careful not to Remove the three bolts (3). fuel level sensor [4] and 0-
deform the noat ring [51 from the fuel tank.
,~

Install a new O-ring (1] onto the fuel tank .

Install the fuel level sensor [2] into the fuel lank while
aligning the groove [3] with the boss (4] on the fuel tank .
Install and tighten the bolts to the specified torque.
TORQUE : 9.0 N'm (0.9 kgf'm , 6.6 Ibf-ft)

Install the removed parts in the reverse order of

removal.

22-18 1
 LIGHTS/METERS/SWITCH ES
SYSTEM INSPECTION
Check that the speedometer and indicators funct ion
properly.
If they do not function , check the power/ground line
(page 22-7).
If they function, check as follows:
Remove the fuel level sensor 2P (Red) connector
(page 22-18).
Turn the ignition switch ON and check the fuel gauge.
All segments [1] should blink. (x) (j) (0)
Turn the ignition switch OFF .
Connect the meter side connector terminals with a
jumper wire.
Turn the ignition switch ON and check the fuel gauge.
AI! segments should blink.
If the fuel gauge does not function properly, replace the
combination meter (page 22-6).
Turn the ignition switch OFF.

Remove the fuellevei sensor (page 22-18).

Connect the fuel level sensor 2P (Red) connector. I']
With the fuel level sensor float [1[ at the top (FULL)
position (2), turn the ignition switch ON and check the
fuel gauge.

All segments up to segment "F" [1[ should come on.

Turn Ihe ignition switch OFF. 111
(x) (~/i)
P /

Move the float to the bottom (RESERVE) pOSition , turn

L
~==~---======~----­
the ignition swilch ON and check the fuel gauge .
Segment "E" [1] and low fuel indicator [2] should blink.
If the fuel gauge does not function properly, check the 1
fuel level sensor (page 22-20).
II .
If the fuel level sensor is OK, replace the combination
meter.
Ir all segments blink during inspection, replace the
combination meter.
LI *
Turn the ignition switch OFF.
11]
Inslall the fuel level sensor (page 22-18).

22-19
LIGHTS/METERS/SWITCHES
FUEL LEVEL SENSOR INSPECTION
Remove the fuel level sensor (page 22-18),
Measure the fuel level sensor resistance with the float 1')
[1] at the lop (FULL) [2) and bollom (RESERVE) [3J
positions.
Connection : Green/yellow - Yellow/white
[2[

pF'[L~O~A~T~P~O~S~IT~I02iN"==,R"E,,S",ISS'T~ANCE (20·C/6S0F)
TOP WULl) 11-130
cB"O"TT
-= O"
M,-,("
R"ES
",E,"R~V~E~)~_ _ 204 - 210 0

22-20
23. ELECTRIC SHIFT PROGRAM (ESP: FElFPE models)

ESP COMPONENT LOCATlON·············· ····23 -2 ESP OTC INDEX ······································· 23-13

ESP SYSTEM DIAGRAM ····························23-3 OTC TROUBLESHOOTING ......... ............. 23-14

SERVICE INFORMATION ·············· ············· 23-4 VS SENSOR .............................................. 23 -27

BEFORE TROUBLESHOOTING ·················23-5 SHIFT ANGLE SENSOR ·········· ················· 23-27

SYMPTOM TROUBLESHOOTING ············· 23-5 GEARSHIFT SWITCH ............................... 23-29

ESP CONNECTOR LOCATION ·················· 23-7 SHIFT CONTROL MOTORIREDUCTION

GEARS ...................................................... 23-30
ESP TROUBLESHOOTING
INFORMATION ··········································23-10

23-1
ELECTRIC SHIFT PROGRAM (ESP: FE/FPE models)
ESP COMPONENT LOCATION

UPSHIFT SWITCH DOWNSHIFT SWITCH

GEAR POSITION
INDICATOR
FUSE BOX:
- MAIN FUSE 1 (30 A)
- MAIN FUSE 2 (30 A)
- IGN FUSE (10 A) BATTERY

SENSOR UNIT:
- MAP SENSOR
SHIFT CONTROL MOTOR
- TP SENSOR

VS SENSOR GEAR POSITION SWITCH

SHIFT SENSOR

23-2
 ELECTRIC SHIFT PROGRAM (ESP: FE/FPE models)
ESP SYSTEM DIAGRAM

IGNITION ION FUSE

SWITCH (lOA)
,- -§-.--B- .. ---,--+------,

ENGIN E STOP SWITCH

",w-B-Il<"

~~ .w _ - - - - - l
~N Bl ~ ______________________________ _!

E=~::::~'l'~~~= : =====rrf.1\
~ Ei'IW~~~ONTROl

PC~ c·, "'-\ "'_II 5 -1 8-11

"'·Zl

..
A-l, 11-12 B·n

Ge&r~""''''''oc BI: Black lb If!l'l' t>Iuo

~, Br" Brown O~~
Su: Blue ~

d} Sl'I<lo1lem'1ona1S to<
rMCI"'ll DTC
G. Gr .......
Gr: Gray
R. R!!d
W:WMo
Lg Wtllf'H'" y. y..."..

I>P(BlKt.I CONNECTOR 331' (SI»)CONNECTOR J3f' (Gr~YI CONNECTOR

23-3
ELECTRIC SHIFT PROGRAM (ESP: FE/FPE models)
SERVICE INFORMATION
GENERAL
Refer to "Before Troubleshooting" first and begin the troubleshooting (page 23-5).
When performing the DlC troubleshooting, read "ESP Troubleshooting Information" carefully , and Inspect and troubleshoot
according to the DTG. Observe each step of the procedures one by one. Note the DIG and probable faulty part before starting
diagnosis and troubleshooting.
The PCM may be damaged jf dropped. Also, if Ihe connector is disconnected when current is flowing. the excessive voltage may
damage the PCM . Always turn off the ignition switch before disconnecting or connecting the connectors.
Use a digital lester for ESP system inspection.
For ESP Troubleshooting
The PCM con trols the PGM-Ft and ESP systems. Therefore some detection items are shared by the PGM-FI and ESP and they
may affect the operation of both systems.
Before starling any troubleshooting . check the items as follows and refer to the appropriate troubleshooting .
1. MIL blinks or DTC forthe PGM-FI system (page 4-10).
2. Gear position indicator blinks or DTC for the ESP (page 23-10).
3. Symptom of the ESP opera tion (page 23-5).
Refer to PGM-FI System section for "General Troubleshooting" information (page 4-10),

TORQUE VALUE
~-Q-'T-y--Ti
THREAO TORQUE
ITEM REMARKS
_ +_.,----+- " ' (mm)
OIA. N'm (kgf·m. IbHt
Shift angle sensor bolt 2 5 6.0 (0.6. 4 .4) Apply locking agent to
the threads.

TOOLS
SCS service connector Test probe ------wHirD"'S~pocket lester
070PZ-ZY30100 07ZAJ-RDJA 11 0 TDS 3557-0112-01 (U .S.A. Only)

23-4
 ELECTRIC SHIFT PROGRAM (ESP: FE/FPE models)
BEFORE TROUBLESHOOTING
NOTE:
If the ATV has any ESP trouble, the gear position indicator brinks to indicate Ihe DTC (Diagnostic Trouble Code) (page 23-10).
Check the DTC and refer to the OTG index and begin the appropriate troubleshooting procedure (page 23-13),
If there are no DTG stored in the PCM memory, do the troubleshooting as "Symptom Troubleshooting" (page 23-5).
VERIFY THE COMPLAINT
Check the accuracy of the customer complaint by lest riding the A TV.
Note the symptoms.
Do not begin disassembly or testing untll you have determined if the problem is electrical or mechanical by shifting the gear
manually (page 23-6).
Temporarily failures can occur. Under certain conditions, the ESP system can "miss a shift." When this happens, the PCM may
record a DTC. Be sure to note and erase any stored OTC(s) when verifying the customer's complaint. If the customer's
complaint is duplicated during the test-ride , and the blinking gear position indicator displays a OTC. proceed with
troubleshooting.
PRELIMINARY ESP SYSTEM INSPECTION
Inspect the following before diagnosing the system .
- Make sure the battery is fully charged and in good condition (page 21-8)
- Make sure the clutch is adjusted properly (page 3-24)
- Check the main fuse 1 (30A), main fuse 2 (30A) and IGN fuse (10A) for blown

SYMPTOM TROUBLESHOOTING
Sympto m Diag nosis Also check for
Shift control failure but no Toroubleshoot the "Electric clutch adjustment (page 3-24 )
OlC set Shift Does Not Operate"
(page 23-6)
Gear position indicator blinks Inspect the serial
~";-~
" _c~o~n~s~ta~n~tI~Y~(N~O~D~T~C~se~tL
) -+~communication line (page 22-7)
Gear position indicator is no Inspect the OLC circuit Short circuit in the OlC rela ted wire
indication and MIL stays on . (page 4-29)
but no OIC is set

23-5
ELECTRIC SHIFT PROGRAM (ESP: FE/FPE models)
ELECTRIC SHIFT DOES NOT
OPERATE
1. Shifting Operation Check
OTe 23·1 will Remove the left side cover (page 2-4).
be Ind,ca fed Turn the ignition swi tch OFF.
with /he igmtlOfl Manually shift the transmission by ro tating the
SWitch lumed gearshift spindle [11 with the emergency gear
ON. change 100112].
Can the gears be changed manually?
YES - GO TO STEP 2.
NO - Check the gearshift linkage (page 12·19) Dow"
and the transmission (page 14-8).

2. Gearshift Switch Inspection at PCM Connector

Disconnect the PCM 33P (Black.) connector [1\.
Check for continuity between the wire harness side [1[
PCM 33P (Black) connector terminals while pushing A5
the gearshift sWitch.
TOOL:
Test probe 07ZAJ·RDJA 110

Connection :
With the upshift switch pushed :
A3 - A6
With the downshift s witch pushed :
A3 - A5 A6 A3
Is there c ontinuity?
YES - Loose or poor contact of the PCM 33P ' - - - - - - - - - -
(Black) connector.
NO - GO TO STEP 3.
3. Gearshift Switch Inspection
Check the gearshift switch (page 23-29).
Is the gearshift switch normal?
YES _ . Open circuit in the following wire
between the handlebar switch 14P
(Green) connector and PCM 33P
(Black) connector.
- While/red or WhiteJblue
- White/red or White/yellow
NO - Faulty gearshift switch.

23-6
 ELECTRIC SHIFT PROGRAM (ESP: FEIFPE models)
ESP CONNECTOR LOCATION
NOTE 1: Remove the front fender/carrier (page 2-8).

I:[:D~ (Switch side connector)

HANDLEBAR SWITCH 14P (Green)

CONNECTOR (NOTE 1)

NOTE 2: Remove the right mudguard (page 2-6).

SHIFT CONTROL MOTOR 2P (Black) CONNECTOR

(NOTE 2)

23-7
ELECTRIC SHIFT PROGRAM (ESP: FElFPE models)
NOTE 1: Remove the right side cover (page 24).

ENGINE SUB-WIRE HARNESS 6P (Black) CONNECTOR

(NOTE 1)

(Switch side connector)

GEAR POSITION SWITCH 8P (Grav) CONNECTOR

(NOTE 1)

NOTE 2: Remove the left side cover (page 24).

NOTE 3: Remove the left mudguard (page 2-6).

{D }
VS SENSOR 3P (Black) CONNECTOR SHIFT ANGLE SENSOR 3P (Gray) CONNECTOR
(NOTE 2) (NOTE 3)

23·8
,I
 ELECTRIC SHIFT PROGRAM (ESP: FE/FPE models)
NOTE 1: Remove the rear fender cover (page 2·9).

C3 C1

B33
PCM 33P (Gray) CONNECTOR
B23 A33 A23
PCM 33P (Black) CONNECTOR
C5
P9: C4
PCM 5P (Black) CONNECTOR
(NOTE 1) (NOTE 1) (NOTE 1)

l
NOTE 2: Remove the seal (page 2-4).

DLC (NOTE 2)

23-9
ELECTRIC SHIFT PROGRAM (ES-:P_:F-:E;..'::FP-:E-::::-m:-,O-:d-:el::S,-:):-:-:_ _ _ _ _ _ _ _ _ _ __
ESP TROUBLESHOOTING INFORMATION
• Refer to PGM-FI System section for "General Troubleshooting" information (page 4-10).

SYSTEM DESCRIPTION
SELF·DIAGNOSIS SYSTEM
The PCM controls the PGM-Ft and ESP systems. Therefore some detection
items are shared by the PGM-FI and ESP and they may affect the operation
[11
of both systems. \
The ESP system is equipped with the self·diagnostic system. If the PCM

,-,'-, --,
detects an ESP failure. it stops the sys tem function and turns on the gear ,\R) (N) (~ (I) (J',) ~

-
position indicator (1] blinking In failed gear position to indicate the DlG, and 1...... 1
stores a DTG in ils erasable memory for the relevant system failure .
To reset the ESP system, turn the ignition switch from ON to OFF and back
to ON again. However, if the PCM still detects a problem, It will continue to
I'"J 101.
- il
I!!!I
stop the ESP system function When this occurs, the gear position indicator 000
" WltE
will blink a certain number of times to indicate the oTC.
To indicate the oTC , the gear position indicator blinks ~-~; depending on the
=-u
kind of trouble \U / \ I
DTC (Diagnostic Trouble Code)
Refer to PGM-fl System section for oTe information (page 4-10).
INDICATOR BUNKING PATIERN
The number of indicator blinks IS the equivalent of the main code of the OTC (the sub code cannot be displayed by the indicator
blinking).
The indicator has two types of blinks, a long blink and short blink. The long blink lasts for 1.3 seconds, the short blink lasts for
0.3 seconds. One long blink is the equivalent of ten short blinks. For example, when two long blinks are followed by Ihree short
blinks, Ihe OTG is 23 (two long blink = 20 blinks, plus three short blinks).

',,\
0.5 sec. 0.3 sec.

GEAR
POSITION
ON

INDICATOR OFF _ _..J - Pattern

repeated

One Blink - 0 _ _ __ _

Long Blinking Short Blinking

2 limes 3 times

OTC 23

When the PCM stores more than one o TC, the indicator displays in the order from the lowest number to highest number.
CURRENT DTCf$TORED DTe
The OTC is indicated in two ways according 10 the failure status.
If the PCM detects the problem at present, the gear position Indicator will blink at all times. It is possible to readout th e indicator
blink pattern as the curre nt OTC.
If the PCM does not detect any problem at present but has a problem stored in its memory. the indicator will not blink. If it is
necessary to retrieve the past problem , readout the stored OTC by following the OTC readout procedure.

I
j
23-10
 ELECTRIC SHIFT PROGRAM (ESP: FE/FPE models)
HDS POCKET TESTER INFORMATION
• The HOS can readout the OTe , stored data, current data and other peM condition.
How to connect the HDS Pocket Tester
Turn the Ignition sWitch OFF .
Remove the seat (page 2-4).
Remove the OLe 111 from the dummy connector 12].
Connect the HOS pocket tester to the Ole .
Turn the ignition switch ON and engine stop sWitch ·0", check the OlG and
stored data.
NOTE '
• Stored data indicates the engine and ESP conditions when the first
malfunction was detected.
PCM reset
The HOS can reset the peM data including the OTG. stored data and some L -_ _ _ _ _---'[1[
learning memory.

DTC READOUT
NOTE
If the MIL blinks, refer to "PGM-FI Troubleshooting Information" and troubleshoot the PGM-FI system first. Then recheck the
ESP after erasing the PGM-FI OTC.
After performing diagnostic troubleshooting, erase the problem OTC(s) (page 23-12) and test -ride the vehicl e to be sure that the
problem(s) have been removed.
Connect the HOS pocket tester to the OLC (page 23-11 ).
Read the DTC , stored data and follow the troubleshooting index (page 23-13).
To read the OTC without the HOS pocket tester, refer to the following procedure.
Reading DTe with the gear position indicator
Turn the ignition switch ON and engine stop switch ·0·, read and note the rl-:-
[1~[---------­
gear poSition indicator {II blinks "- ".
The number of blinks Indicates the current OTC.
Refer to the troubleshooting Index (page 23-13). ['(R) (N) (ps) (X) (41~)
1--1

1"'-- J rl -=F
il
LI,=, I!!!I
000 2 . .·
LE

When retrieving the stored OTC , refer to the following procedures

1. Remove the OLC from the dummy connector (page 23-11 ).
[11 [2[ 1
2. Short the OLC [1) terminals using the special tool.
TOOL:
[2] SCS service connector 070PZ-ZY30100

Connection : Brown/red - Green

3. Turn the ignition switch ON and engine slop SWitch "0". read and note
the gear position indicator blinks.
The number of blinks indicates the stored OTG.
Refer to the troubleshooting index (page 23-13).

23-11
ELECTRIC SHIFT PROGRAM (ESP : FE/FPE models)
ERASING DTC
NOTE '
• When erasIng the ESP OTe as follows, the PGM-FI oTe would also be erased at the same time, check the MIL blinks and
troubleshoot the PGM-Ft system before readout/erasing the ESP oTC.
Connect the HOS pockellester to Ihe OLe (page 23-11).
Erase the OTC with the HOS while the engine is stopped.
To erase the OTC without HOS, refer to Ihe following procedure.
How to erase the oTC without HOS
1. Remove Ihe OLe from the dummy connector (page 23-11).
(1( (2J
2. Short the OLe [1] terminals using the special tool.
TOOL:
[2) SCS service connector 070PZ·ZY30100

Connection: Brown/red - Green

3. Tum the ignition switch ON and engine stop switch "0 ".
4. Remove the special tool from Ihe OLe.
5. The indicator will light for approximately 5 seconds. While the indicator
tights, short the OLC terminals again with the special tool. The self·
diagnostic memory is erased if the malfunction indicator goes off and
starts blinking.
NOTE:
The OLC must be shorted while the indicator lights. If not, the indicator will not start blinkIng .
• Note that the self-diagnostic memory cannot be erased if the ignition switch is turned OFF before the indicator starts blinking.

CIRCUIT INSPECTION
INSPECTION AT PCM CONNECTOR
Always dean around and keep any foreign material away from the PCM
connector before disconnecting it.
A faulty ESP system is often related to poorly connected or corroded
(1J
connections. Check those connections before proceeding .
Do not pull the wire harness while disconnecting the PCM connectors.
In testing at PCM connector (wire harness side) terminal, always use the
test probe. Insert the test probe into the connector terminal, then attach
the digital multimeter probe to the test probe.
TOOL:
[1] Test probe 07ZAJ·ROJA 110

23-12
 ELECTRIC SHIFT PROGRAM (ESP: FE/FPE models)
ESP DTe INDEX
NOTE
When the gear position indicator"-" is blinking constanlly (and the Mil and coolant temperature indicator lights are dark). but no
DTG is indicated or retrievable, check the serial communication line (page 22-7).
There are some OTCs (21-1 Ihru 23-1) related to the shift angle sensor circuit that have different conditions of malfunction
detection. In case of the low voltage (about 0 V) or high voltage (about 5 V) in the shift angle sensor circuil, DIG 22-2 will be
Indicated when the control motor does not operate.

Ole Function Failure Symptom/Fail-safe function

Refer
("-" blinks) to
TP sensor circuit low voltage (less than 0.22 V) --'---:--'Poor engine acceleration
8-' (8) • TP sensor or its circuit malfunction Fail·safe value: O~ 4·18
ESP does not work
TP sensor circuil High voltage (more than 4.93 V) Poor engine acceleration
8-2 (8) • Loose or poor contact of the TP sensor connector Fail-safe value: O· 4·19

r t
• TP sensor or its circuil malfunction _ __ _ _t--:-,;ESP does not work
VS sensor no Signal Engine operates normally
• loose or poor contact of the Rear VS sensor ESP does not work 23-14
11·1 (11 )
connector
• Rear VS sensor or its circuit malfunction
Shift angle sensor circuit low vol tage (less than T ESP does not work
21·1 (21) 0.37 V) 23-15
• Shift angle sensor or its circuit malfunction
- -- - -- Shift angle sensor circuit High voltage (more than 4.62 V) • ESP does not work
21.2 (21) • loose or poor contact of the Sub-gearshift spindle 23-17
angle sensor connector

----- ---h
• Shift angle sensor or its circuil malfunction _cc-----:-,
Shift angle sensor response (Control motor lock)
PCM activates the motor but the angle sensor voltage
• ESP does not work

22-1 (22) does not change in middle position 23-18

Control motor or its circui t malfunction
Shift angle sensor or its circui t malfun~c~tio~nic;",_ _
----~--.Shift angle sensor response (Control motor stuck)
-r_
• ESP does not work
;;;;;.____-+_
PCM does not activate the motor but angle sensor
22·2 (22)
voltage stays out of middle position (195 - 3.05 V) 23-18
• Control motor or its circuit malfunction
• Shift angle sensor or its cirCUit malfunction
Shift angle sensor response (VOltage variation) - ESP does not work

.
• PCM does not activate the motor but angle sensor
voltage varies constantly
23·1 (23)
• Shift angle sensor installation problem I 23-'9 j

:-+
Shift angle sensor or its circuit malfunction

t
• Control motor or its circuit malfunction
Shift control motor drive circuit + E SP does not wo,k
24-1 (24) • Control motor or its circuit malfunction 23-20
• Control motor drive circuit malfunction
Fail·safe relay circuit ESP does not work
32-' (32) 23-21
• Fail·safe relay circuit malfunction
33-2 ( ) EEPROM malfunction _ _ _ __ _--j_,- Engine operates normally 4-25
Gear posiliOn switch circuit Engine does not start
41 ·1 (41) • Gear position switch cirCUit malfunction (Short) ESP does not work 23·22
_ __ _--!_ :-iGear position indicator bhnks "-_"--!_ _ _--1
" --
Gear position switch circuit ESP does not work 23-23
41·2 (41)
• Gear position switch circuit malfunction (Op~e~n~)_ ___l-"G~e~a~'_!:_o::sition indicator blinks "-"
Gearshift (UP/DOWN) switch circuil ESP does not work
42·1 (42) Gearshift (UP/DOWN) switch circuit malfunction 23-25
_ _ _ - '("'5....
hort)_ __ _ __

23-13
ELECTRIC SHIFT PROGRAM (ESP: FE/FPE models)
DTC TROUBLESHOOTING
NOTE :
Refer to "ESP Connector Location" for the connector
location and the necessary parts to disconnect the
connector (page 23-7),
After troubleshooting , erase the oTC and test-ride
the vehicle to be sure that the system is normal.
VERIFY PROPER CONNECTOR
CONTACT
Many ESP shifting problems and subsequent olCs are
caused by poor connector contacts. The first step in
troubleshooting any OTG is to inspect the affected
connectors.
CONNECTOR INSPECTION
Check for moisture in the affected connector
Check for corrosion
Check for folded pins on the male side of the
connector
Check for loose pins and/or pins pushed out of the
connector

DTC 11-1 (VS SENSOR NO SIGNAL)

NOTE '
Before starting the troubleshooting , check for loose or
poor contact of the following connectors, and recheck
the OTC (page 23-14 )
- VS sensor 3P (Black)
- engine sub-wire harness 6P (Black)
- PCM 33P (Black and Gray)
Make sure the battery is fuUy charged.
1. VS Sensor System Inspection
Erase the OTC (page 23- 12).
Test-ride the vehicle and check the VS sensor
signal with the HOS pocket tester.
Is the VS sensor signal indicated normally?
YES - ' Intermittent failure.
• Loose or poor contact of the connector.
NO - GO TO STEP 2.
2. VS Sensor Input Voltage Inspection
Tum the ignition switch OFF.
~isconnect the VS sensor 3P (Black) connector (11 . 111 Blacklwhite Green
Turn the ignition sWitch ON and engine stop switch
~O" .
Measure the voltage between the wire harness side
VS sensor 3P (Black) connector terminals.
Connection : Blacklwhlte (+) - Green H
Is the voltage more than 10 V?
YES - GO TO STEP 3.
NO - ' Open or short circui t In the Black/white
or Black/pink wire.
Open circuit in the Green wire.

,
23-14 1
I
 ELECTRIC SHIFT PROGRAM (ESP: FE/FPE models)
3. VS Sensor Signal line Open Circuit Inspection
Turn the ignition switch OFF.
Disconnecllhe peM 33P (Gray) connector [1). 121
Check for continuity between the wire harness side Pink 816
PI
VS sensor 3P (Black) connector [2J and peM 33P
(Gray) connector terminals .
Connection : 816 - Pink

TOOL:
Test probe 07ZAJ·RDJA110
Is there continuity'?
YES - GO TO STEP 4.
NO - Open circuit in the Pink or Pink./green wire .

4. VS Sensor Signal line Short Circuit Inspection

Check for continuity between the wire harness side
VS sensor 3P (Black) connector [1] and ground.
Connection : Pink - Ground
PI Pink

Is there continuity?
YES - Short circuit in the pink or Pink/green wire .
NO - GO TO STEP 5.

5. VS Sensor Inspection
Turn the ignition switch OF F.
Replace the VS sensor wi th a new one (page 23-27).
Erase the DTC (page 23-12).
Test-ride the vehicle and recheck the DTC .
Is the ore 11-1 indicated ?
YES - Replace the PCM with a known good one
(page 4-34), and recheck.
NO - Faulty original VS sensor.

DTC 21·1 (SHIFT ANGLE SENSOR

LOW VOLTAGE)
NOTE :
Before starting the troubleshooting, check for loose or
poor contact of the following connectors, and recheck
the DTC (page 23-14).
- shift angle sensor 3P (Gray)
- engine sub-wire harness 6P (Black)
- PCM 33P (Black)
1. Shift Angle Sensor System Inspection
Turn the ignition switch ON and engine stop switch
·0·.
Check the shift angle sensor with the HDS pocket
tester.
Is about 0 V (low voltage) indicated?
YES - GO TO STEP 2.
NO Intermittent failure.
• Loose or poor contact of the connector.

23-15
ELECTRIC SHIFT PROGRAM (ESP: FE/FPE models)
2. Shift Angle Sensor Resistance Inspection
Turn the ignition switch OFF.
Disconnect the shift angle sensor 3P (Gray)
connector. 111
Measure the resistance at the shift angle sensor B
side connector [11 terminals.
Connection: A- C
Standard : 4- 6 kG (20°C/68°F)
Connection: A- B
Standard: 2- 3 kG (20°C/68°F)
Is the resistance within specification? A c
YES - GO TO STEP 3.
NO - Faulty shift angle sensor.

3. Shift Angle Sensor Input Voltage Inspection

Turn the ignition switch ON and engine stop switch , - - - - -- - - - - - -- -- - --
"0". 11)
Brown/white Green/red
Measure the voltage between the wire harness side
shift angle sensor 3P (Gray) connector (1) terminals.
Connection : Brownfwhite (+) - Green/red (-)
Is the voltage within 4.75 - 5.25 V?
YES - GO TO STEP 4.
NO - Open circuit in Brown/whi te or Green/red
wire. If the wire is normal, faulty PCM.

ffiV e
4. Shift Angle Sensor Output Line Open/short
Circuit Inspection
Turn the ignition switch OFF .
A14 Green/yellow
Disconnect the PCM 33P (Black) connector [1 ).
Check for continuity between the wire harness side
shift angle sensor 3P (Gray) connector [2] and peM
33P (Black) connector terminals.
IIf~:::;"i'~~~~~~?:;=;l
Connection: A14 - Green/yellow

TOOL:
Test probe 07ZAJ·RDJA110
There should be continuity.
Check for continuity between the wire harness side
shift angle sensor 3P (Gray) connector terminal and [11 [21
ground.
Connection: Green/yellow - Ground [2) Green/yellow
There should be no continuity.
Is there normal condition ?
YES - Replace the peM wi th a known good one
(page 4-34). and recheck.
NO - Open or short circuit in Green/yellow or
Green/blue wire.

23-16
 ELECTRIC SHIFT PROGRAM (ESP: FE/FPE models)
OTC 21·2 (SHIFT ANGLE SENSOR
HIGH VOLTAGE)
1. Shift Angle Sensor System In spection
Turn the ignition switch ON and engine slop switch
~O".

Check the shift angle sensor with the HDS pocket

tester.
Is about S V indicated?
YES - GO TO STEP 2.
NO - ' Intermittent failure.
• Loose or poor contact of Ihe connector.
2. Sh ift Angle Sensor Resistance Inspection
Turn the ignillon switch OFF .
Disconnect the shift angle sensor 3P (Gray)
connector (1).
Measure the resistance at the shift angle sensor
side connector (1) terminals.
Connection: A - C
Standard : 4 - 6 kO (20"e /68"F)
Connection : A - B
Standard : 2 - 3 kO (20°C/58"F)

L
Is the resis tance within specification ?
YES - GO TO STEP 3.
NO - Faulty shift angle sensor.

3. Shift Angle Sensor Input Voltage Inspection

Turn the ignition switch ON and engine stop switch I [lJ
"C)",
Brown/While Green/red
Measure the voltage between the wire harness side
shift angle sensor 3P (Gray) connector [1) terminals.
Connection : Brown/white (+)- Green/red (-)
/s the voltage within 4.75 - 5.25 V?
YES - Replace the PCM with a known good one
(page 4-34). and recheck .
NO - Open circuit in Brown/white or Greenlred
wire.
ffiV e

23·17
ELECTRIC SHIFT PROGRAM (ESP: FEIFPE models)
OTC 22·1/22·2 (SHIFT ANGLE SENSOR
RESPONSE: CONTROL MOTOR LOCK!
STUCK)
NOTE :
Before starting the troubleshooting, check for loose or
poor contact of the following connectors, and reelleck
the OTe (page 23-14).
- shift angle sensor 3P (Gray)
- engine sub-wire harness 6P (Black)
- peM 33P (Black)
1. Shift Angle Sensor System Inspection
Tum the ignition switch ON and engine slop switch
~O~.

Check the shift angle sensor with the HOS pocket

tester.
Is about Low voltage (about 0 V) or High voltag e
(about 5 V) Indicated?
YES _. 0 V : Refer to OTe 21·1 (page 23- 15),
• 5 V: Refer to OTe 21-2 (page 23-17),
NO - GO TO STEP 2 .
2. Sh ifting Operation Check
OTe 23·' will Remove the left side cover (page 2-4).
(2)
be IndICated Tum the tgnltion switch OFF.
with the ignition Manually shift the transmission by rotating the
sWitch turned gearshift spindle [lJ with the emergency gear
ON. change tool [21.
Can the gears be changed manually?
YES - GO TO STEP 3.
NO - Check the gearshift linkage (page 12-19) Dow"
and the transmission (page 14-8).

3. Shift Angle Sensor Operation Resistance

Inspection
Disconnect the shift angle sensor 3P (Gray)
connector.
Measure the resistance at the shift angle sensor (1)
side connector [1] terminals varies while shifting the
gear manually (page 23-27). B
Connection: A - B

When shifti ng up : Resistance increase

When shifti ng down: Resistance decreases
Does the resistance vary properly?
YES - GO T O STEP 4 . A
NO - Faulty shift angle sensor.

4. Shift Angle Sensor Condition Check

Check. Ihe shift angle sensor for installation
condition or any damage (page 23-28).
Is the shift angle sensor installed properly and
in normal condition ?
YES - GO TO STEP 5.
NO - Inslall properly or replace the angle
sensor.

23-18
 ELECTRIC SHIFT PROGRAM (ESP: FE/FPE models)
5. Reduction Gear Condition Check
Check the reduction gears and control motor for
installation condition or any damage (page 23-30).
Are the reduction gears and control motor
ins talled properly and in normal condition?
YES - Replace the PCM with a known good one
(page 4-34), and recheck.
NO - Install properly or replace faulty part.

OTC 23-1 (SHIFT ANGLE SENSOR

RESPONSE: VOLTAGE VARIATION)
NOTE :
Before starting the troubleshooting, check for loose or
poor contact of the following connectors, and recheck
the DTe (page 23- 14 ).
- shift angle sensor 3P (Gray)
- engine sub-wire harness 6P (Black)
- PCM 33P (Black)
This code will be indicated when shifting the gear
manually while the ignition switch is turned ON.
1. Shift Angle Sensor System Inspection
Turn the ignition switch ON and engine stop switch
·0 ".
Check the shift angle sensor with the HDS pocket
tester.
Is about Low voltage (about 0 V) or High voltage
(about 5 V) indicated?
YES _ . OV:RefertoDTC21-1 (page 23-15) .
• 5 V: Refer to OTC 21-2 (page 23-17)
NO - GO TO STEP 2.
2. Shift Angle Sensor Condition Check
Check the shift angle sensor for looseness (page
23-28).
Is the shift angle sensor installed properly?
YES - GO TO STEP 3.
NO - Install properly or replace the shift angle
sensor.
3. Shift Angle Sensor Operation Resistance
Inspection
Turn the ignition switch OFF.
Disconnect the shift angle sensor 3P (Gray)
connector. (11
Measure the resistance at the shift angle sensor
side connector [1) terminals varies while shifting the
Q B
gear manua lly (page 23-27).

tV,
Connection : A - B

When shifting up: Resistance increase

When shifting down : Resistance decreases
Does the resistance vary properly?
A
YES - Replace the PCM with a known good one
(page 4-34), and recheck.
NO - Faulty shift angle sensor.

23-19
ELECTRIC SHIFT PROGRAM (ESP: FE/FPE models)
DTC 24-1 (SHIFT CONTROL MOTOR
DRIVE CIRCUIT)
NOTE
Before starting the troubleshooting, check for loose
or poor contact of the control motor 2P (Black) and
PCM 5P (Black) connectors, and recheck the DTe
(page 23-14).
1. PCM Motor Power Input Line Inspection
Turn the ignition switch OFF.
Disconnect the PCM 5P (Black) connector (1).
Measure the voltage between the wire harness side
I\, [1]
peM 5P (Btack) connector terminal and ground. -r""y-,
Connection: C4 (+) - Ground (- ) t~~~:J-1
Is there battery voltage '?
YES - GO TO STEP 2.
NO - ' Blown main fuse 2 (30 A).
Open circuit in the Redlwhite or Red C4
wire .

2. PCM Motor Power Ground Line Inspection

Check for continuity between the wire harness side , - -- -- - - - - - - - - - - - - - - ,
PCM 5P (Black) connector [lJ terminal and ground. [1]
Connection : C5 - Ground
Is there continuity'?
YES - GO TO STEP 3.
NO - Open circuit In the Green wire.
C5

3. Control Motor Line Open Circuit Inspection

Disconnect the control motor 2P (Black) connector r
~~ ~
Check for continuity between the wire harness side
control motor 2P (Black) connector and PCM 5P C2
(Black) connector 12jterminats.
Connection: C1 - Red
C2 - Green
Is there continuity'?
YES - GO TO STEP 4.
NO Open circuit in the Red wire . C1
• Open circuit in the Green wire.
111

23-20
 ELECTRIC SHIFT PROGRAM (ESP: FE/FPE models)
4. Control Motor line Short Circuit Inspection
Check for continuity between the wire harness side
PCM 5P (Black) connector [1J terminals and ground.
[11
C2 C1
Connection : C1 - Ground
C2 - Ground
Is there continuity?
YES _. Short circuit in the Green wire.

NO
• Short circuit in the Red w ire .
- GO TO STEP 5.
Q

5. Control Motor Inspection

Connect a fully charged 12 V battery [1] to the r-----------------~

control molor side 2P connector [2] terminals.

Does the motor turn ?
YES - GO TO STEP 6.
NO - Faulty control moior.

[2[ 111
6. Electric Shift Failure Checking
Connect the PCM SP (Black) and control moior 2P
(Black) connectors.
Erase the DTG (page 23-12),
Turn the ignition switch OFF.
Turn the ignition switch ON and engine stop switch
·0",
Recheck the gear shifting operation and oTC.
Is the DTC 24·1 indicated?
YES - Replace the PCM with a known good one
(page 4-34), and rechec k. If the DTC
indicated again, replace the control motor
(page 23-30).
NO - Intermittent failure.

OTC 32·1 (FAIL·SAFE RELAY CIRCUIT)

1. Recheck OTe
Erase the OTC (page 23-12) .
Turn the ignition switch OFF.
Turn the ignition switch ON and engine stop switch
~O~.

Recheck the DTC.

Is the DTC 32·1 indicated?
YES - Replace the PCM with a known good one
(page 4-34), and recheck.
NO - Intermittent failure.

23-21
ELECTRIC SHIFT PROG RAM (ESP: FE/FPE models)
DTC 41-1 (G EAR POSITION SWITCH
CIRCUIT: SH ORT)
NOTE :
. Before starting the troubleshooting, check for loose or
poor contact of the following connectors, and recheck
the DTe (page 23-14).
- gear position switch 8P (Gray)
- peM 5P (Bla ok)
1. Gear Positio n Switch Inspection with HOS
Check the gear position switch status with the HDS
data list menu
Is the gear p ositfon s tatus normal?
YES - Intermitten! failure.
NO o GO TO STEP 2.
2. Gear Positio n Switch Inspection
Turn the igniti on switch OFF.
Disconnect th e gear position switch 8P (Gray)
connector.
Check for co
switch side 8 pnt~~~:~) ~~~~~O/~~l fe~~in~~sSi~~~ ~~i~~ G~,~a~
blue/,__ o~~~i"I~~":V1~~~htl:'leenl
~ ~
ground.
There should be continuity in each gear position, .
and should be NO continuity in the other position.
Gear positi
Reverse
Neutral
1st Blue White/red
2nd
3,d
4th
5th
Is the gear p osition switch normal?
YES o GO TO STEP 3.
NO - Fault y gear position switch.

I
1

23-22
 ELECTRIC SHIFT PROGRAM (ESP: FE/FPE models)
3. Gear Position Switch Inspection at PCM
Connector
Connect the gear position switch BP (Gray)
connector and disconnect the peM 33P (Black) [1 [ A17 A2
connector {1].
A12
Cneck for continuity between the wire harness side
peM 33P (Black) connector terminals and ground.
There should be continuity in each gear position,
and should be NO continuity in the other position.
TOOL:
••
Test probe 07ZAJ·RDJA110

Gear position Connection A27

A26 A25 A24
Reverse A25 - Ground
Neutral A 17 - Ground
1st.-______-+~A2~4--~G~'o~u~n~dc_----------~
12nd A27 - Ground
r'3~'~d,---______~~
A~2~6_- Ground
14th A2 - Ground
~ ____-LA
~12~-~G~m~U~n~d,:_~~~~~~~~~~~
Is the continuity normal condition?
YES - GO TO STEP 4.
NO - Open or short circuit in the wire harness
between Ihe peM and gear position
switch.
4. Recheck oTe
Connect the PCM 33P (Black) connector.
Erase the OTC (page 23~ 12).
Turn the ignition switch OFF .
Turn the ignition switch ON and engine stop switch
"0".
Shift the transmission into each gear and check the
DTC.
Is the OTC 41-1 indicated?
YES - Replace the PCM with a known good one
(page 4-34). and recheck.
NO - Intermittent failure.

DTC 41 -2 (GEAR POSITION SWITCH

CIRCUIT: OPEN)
NOTE :
Before starting the troubleshooting. check for loose or
poor contact of the following connectors, and recheck
Ihe DTC (page 23-14).
- gear position switch 8P (Gray)
- PCM 5P (Black)
1. Gear Position Switch Inspection with HDS
Check the gear position switch status with the HOS
data list menu.
Is the gear position s tatus normal?
YES - Intermittent failure.
NO - GO TO STEP 2.

23-23
ELECTRIC SHIFT PROGRAM (ESP: FE/FPE models)
2. Gear Position Switch Inspection
Turn the ignition swit ch OFF .
Disconnect the gear position switch 8P (Gray)
connector. Light bluel
Check for continuit y between the gear position white
switch side 8P (Gra y) connector [1] terminals and
ground .
There should be con tinuity in each gear position.
Gear position Connection
Reverse Gray - Ground
Neutral light green/red - Ground
1st White/green - Ground

L
Yellow Blue White/red
2nd White/red - Ground
3rd Blue - Ground
- -------'
14th Yellow - Ground
5th ILight blue/white - Ground
Is there continuity ?
YES - GO TO STEP 3.
NO - Faulty gear position switch.
3. Gear Position Switch Inspection at PCM
Connector
Connect 'he gear position switch BP (Gray)
connector and disconnect the PCM 33P (Black) !1] A17
connector (1).
A12
Check for continuity between the wire harness side
peM 33P (Black) co nnector terminals and ground.
There should be con tinuily in each gear position .
TOOL:
•
Test probe 07ZAJ-ROJA110

L
Gear position Connection
A27
Reverse A
---!~
A26 A25 A24
Neutral A17 - Ground 1
2"5c--->Gc:cro,,u=
nd: ;-_ _ _
.1st
2nd
A24 - Ground
A27 - Ground
-
3rd A26 - Ground
4th A2 - Ground
5th A12 - Ground
Is there continuity ,
YES - GOTOST EP4 .
NO - Open circu it in the wire harness between
the peM a nd gear position switch.
4. Recheck DTC
Connect the peM 33P (Black) connector.
Erase the DTC (pag e 23-12).
Test-ride the vehicle and check the OTC .
Is the DTe 41-2 indicated?
YES - Replace Ihe PCM with a known good one
(page 4-34 ). and recheck.
NO - Intermittent failure .

23-24
 ELECTRIC SHIFT PROGRAM (ESP : FE/FPE models)
DTC 42 -1 (GEARSHIFT SWITCH
CIRCUIT)
NOTE
Before starting the troubleshooting , check for loose or
poor con tact of the following connectors , and recheck
the DTC (page 23-14).
- handlebar switch 14P (Green)
- PCM SP (Black)
1. Gearshift Switch Inspection
Check the gearshift switch status with Ihe HOS data
list menu .
UP - - DOWN !
I ~

"Up" ON 3.64 - 4.08 V 1.76 - 2.09 V

" Down" ON
---
3.64 -4.08 V
, 1.76 - 2.09 V
Both ON ' 4.0 4.99 V 4.0 - 4.99 1
Both OFF I O_D .99V O-O.g9V
Is the gearshift switch status normal?
YES - Intermittent failure
NO - GO TO STEP 2.
2. Gearshift Switch Inspection at Handlebar Switch
Connector
Turn the ignition switch OFF .
Disconnect Ihe handlebar switch 14P (Green) Whltelblue
connector [1].
Check for continuity between the handlebar switch White/yellow
side 14P (Green) connector terminals while pushing
the gearshift switch.
Connection :
With the upshift switch pushed :
White/red - White/blue
With the downshift switch pushed :
White/red - White/yellow
Is there continuity? White/red
YES - GO TO STEP 3. 111
NO - Faulty handlebar switch .
3. Gearshift Switch Inspection at PCM Connector
Connect the handlebar switch 14P (Green)
conneclor and disconnect the PCM 33P (Black) 111
connector [11. A5
Check for continuity between the wire harness side Q
PCM 33P (Black) connector terminals while pushing
the gearshift switch.
TOOL:
Test probe 07ZAJ-ROJA110

Connection :
With the upshift switch pushed:
A3 (White/red) - A6 (White/blue) A6 A3
With the downshift switch pushed :
A3 (White/red) - AS (White/yellow)
/s there continuity?
YES - GO TO STEP 4.
NO - Open circuit in the Whitelred, White/blue or
White/yellow wire between the sWitch and
PCM .

23-25
ELECTRIC SHIFT PROGRAM (ESP: FE/FPE models)
4. Recheck OTe
Connect the handlebar switch 14P (Green) and
PCM 33P (Black) connectors.
Erase the OlC (page 23-12).
Tum the ignition switch OFF.
Tum the ignition switch ON and engine stop switch
-O~ .

Check the shift operation and the Ole.

Is the ore 42-1 Indicated?
YES - Replace the PCM with a known good one
(page 4-34). and recheck.
NO - Intermittent failure.

23-26
 ELECTRIC SHIFT PROGRAM (ESP: FE/FPE models)
VS SENSOR
REMOVAUINSTALLA TION
Remove the left side cover (page 2-4).
Disconnect the VS sensor 3P (Black) connector [1].
Remove the bolt (2] and VS sensor [31 from the rear
crankcase cover.
J

Coal a new O-ring [1] with engine oil and install it onto
the VS sensor [2] .
L
~:;:....::.=~=;;_r==i;:;:;:====:;:';
Install the VS sensor to the rear crankcase cover and
tighten the bolt securely.
Connect the VS sensor 3P (Black) connector.
Install the left side cover (page 2-4),

SHIFT ANGLE SENSOR

INSPECTION
Remove the left mudguard (page 2-6),
Disconnecllhe shift angle sensor 3P (Gray) connector
111.
SENSOR RESISTANCE
Measure the resistance at the shift angle sensor side
connector [21 terminals.
Connection : A - C

Standard : 4 - 6 kO (20°CJ68°F)

Measure the resistance at the shift angle sensor side

connector 111 terminals varies while shifting Ihe gear
manually with the emergency gear change 1001 (page
23-6).
Connection: A - 8

When shifting up : Resistance Increase

When s hifting down: Resista nce decreases

23·27
ELECTRIC SHIFT PROGRAM (ESP : FE/FPE models)
INPUT VOLTAGE
Turn the ignition switch ON and engine stop switch ·0·,
Measure the voltage between the wire harness side
111 Green/red
Brownlwhite
shift angle sensor 3P (Gray) connector 111 terminals.
Connection : Brown/white (+) - Green/red H
Standard: 4.75 - 5.25 V
If the input voltage is out of specification , check for
open or short circuit in the Brown/white or Green/red
wires between the shift angle sensor and PCM.

L ffi V _
8 _
REMOVAL
Remove the left mudguard (page 2-6) .
Disconnect the shift angle sensor 3P (Gray) connector
(11-
Remove the two socket bolts [2) and shift angle sensor
131_
Remove the O-ring [4J from the shift angle sensor.
Check the shift angle sensor for wear or damage.

INSTALLATION
I
Coat a new O-ring 111 with engine oil and install it into r - - : - - - - - - - - - - - - - - - - - - - - - ,
the shift angle sensor [21 groove. ~ --"'1 111
Apply locking agent to the threads of the shift angle [2]
sensor socket bolts PI.
Carefully install the shift angle sensor by aligning the
nat surtaces of the sensor shaft hole and gearshift
spindle end.
Install and lighten the two socket bolts to the specified
torque.
TORQUE : 6.0 N-m (0.6 kgf'm, 4.4IbHt)
Connect the shift angle sensor 3P (Gray) connector [41.
Install the mudguard (page 2-6).
Alig~

23·28
 ELECTRIC SHIFT PROGRAM (ESP: FE/FPE models)
GEARSHIFT SWITCH
SYSTEM INSPECTION
Remove the front fender/carrier (page 2-8).
Remove the handlebar switch 14P (Green) connector
11] from the frame and disconnect it.

Check for continuity between the switch side connector

[1]
terminals with each switch pUShed.
Continuity should exisl between the color coded wires
as follows:
UPSHIFT SWITCH [II /DOWNSHIFT SWITCH [2J
Color
White! White! Whitel
Position red blue yellow
Upshift pushed
Free
Downshift pushed ...)
[2]

INPUT VOLTAGE
Remove the handlebar switch 14P (Green) connector , - - - - - - - - - - - - - - - - -,
from the frame and disconnect it (page 23-29), White/red [1[

Turn the ignition switch ON and engine stop switch "0",

Measure the input voltage between the wire harness
side handlebar switch 14P (Green) connector [I]
terminal and ground .
Connection : White/red (+) - Ground (-)

Standard : 4.75 - 5.25 V v

If the input vol tage is out of specification , or if there is
no input voltage, check for open or short circuit in the 8
White/red wire, or loose or poor contact of the PCM 33P
(Black) connector.

23-29
ELECTRIC SHIFT PROGRAM (ESP: FElFPE models)
SHIFT CONTROL MOTOR/REDUCTION
GEARS
REMOVAL
CONTROL MOTOR
Remove the following:
- left side cover (page 2-4)
- right mudguard (page 2-6)
- right frontwtleet (page 16-13)
Disconnect the con trol motor 2P (Black) connector [1).
Remove the three bolts (2J and Ihe control motor (3).

REDUCTION GEARS
Remove the three bolls (1J and the gear cover (2J.

Remove the following:

- reduction gear PI
- spindle gear [2]
- two dowel pins [3]
Check the gear teeth and splines for wear or damage.

23·30
 ELECTRIC SHIFT PROGRAM (ESP: FE/FPE models)
INSTALLATION

SPINDLE GEAR

GEAR COVER

S", G-RING

REDUCTION GEAR

DUST SEAL

CONTROL MOTOR

Remove any grease from the gears, gear cover and , - - - - - - - - - - - - - - - - -,

crankcase cover. UNIREX N3 GREASE
Clean the mating surfaces of the covers thoroughly,
being careful not to damage them.
Install the spindle gear 11] by aligning with the reference
marks on the crankcase cover.
Apply 2 - 4 9 (0.07 - 0. 14 oz) of specified grease to the
gear journals (both sides of the reduction gear) and
gears teeth as shown .
Install the reduction gear [2).
SPECIFIED GREASE : UN1REX N3 grease (EXXON)

Install the dowel pins [31 into the crankcase cover.

23-31
ELECTRIC SHIFT PROGRAM (ESP: FE/FPE models)
Apply engine oil to the seal lips of a new dust seal [1[.
Install the dust seal into the gear cover {2] with the flat
side facing out until it is fully seated.
Apply liquid sealant (ThreeBond 1215 or equivalent) to
the mating surface of the gear cover as shown.
Tighten the bolts Install the gear cover with the three bolts [3J.
after installing the
control motor.

Coat a new O·ring [11 with engine oil and install it into
the control motor (2] groove.

Install the con trol motor [lJ with the three bolts [2].
Tighten the sil( bolts in a crisscross pattern in several
steps.
Connect the control motor 2P (Black) connector [31.
Install the following:
- right front wheel (page 16·13)
- tight mudguard (page 2·6)
- left side cover (page 2-4)

23-32
24. ELECTRIC POWER STEERING (EPS: FPM/FPE models)

EPS COMPONENT LOCATION·· ················24-2 EPS TROUBLESHOOTING

INFORMATION ··········································· 24-9
EPS SYSTEM DIAGRAM ····························24-3
EPS DTC INDEX ········· ······························ 24-16
SERVICE INFORMATION ···························24-4
DTC TROUBLESHOOTING ······················ 24-18
SYMPTOM TROUBLESHOOTING ············· 24-4
EPS INDICATOR CIRCUIT
INSPECTION ..................... ........................ 24-32
EPS CONNECTOR LOCATION ··················24-5
EPS ECU ..................................... .............. 24-35

24·1
ELECTRIC POWER STEERING (EPS : FPM/FPE models)
EPS COMPONENT LOCATION

EPS INDICATOR 4WD INDICATOR

EPS UNIT (Including EPS

EPS FUSE BOX (40A) MOlor and Torque Sensor)

FUSE BOX:
- FPM: MAINFUSE (30 A)
- FPE: MAIN FUSE 1 (30 A)
- IGN A) EPS ECU

4WD SELECT
PCMlECM
SWITCH
CKP SENSOR

VS SENSOR

24-2
 ELECTRIC POWER STEERING (EPS: FPM/FPE models)
EPS SYSTEM DIAGRAM

FPM MAIN fUSE 13OA)

IGNITKlN IGN FUSE
BAnERY FPE. MAlNFUSE 1130A) ; - - - ---u-S-A. ~- - - , SWITCH (IDA)
R- "'.. BI-- - -t"L."''8I J . ---------1~ -~~~
4-- --_ canada
_ " .
rypo; - . -,
i-'~ .~ ~
i rtl RECTIFIER R!
, ~ I
I' ,
I

" ' -
,-t'oo'l-t~-------'- •• ------I
•
••
A' ·R

..." e,."

COMBINATION
MEIER
VSSENSOR~
_. :. ;_j£;";::;<~;;::==
.
81 11 )124 1 ~c.-.
EP$ ECU

811 3)(161
(17)118)
(33)(35)

-, .,
'~ ~~~OFl
~

L_+-__ w. r;~::::w:-L_"_
•••

.. ---"----,
>eM e1l ""p
[==;;cLJet-
... B2 R 0 (131114)
(181(21)

n,
SCS SERVICE CONNECTOR ~ <WI

qjLf;:;-"'"
~;l

81 Black Lb L>ghl blue

EPS EeU c,
s,: Brown 0: Orange
Bu: Blue P' P,nk
G Green R R""
Gr- Gray W While
19_ Ughl green '( VallO>\'

@( ) EPS i,,(hcator bhnk

Shon terminals lor
readmg OTC

C-21 C·15
2P (Brown) CONNECTOR 2P (Gray) CONNECTOR 21P (Gray) CONNECTOR

24·3
ELECTRIC POWER STEERING (EPS: FPM/FPE models)
SERVICE INFORMATION
GENERAL
This section covers electrical system service of the EPS (FPMIFPE models). For other service of the steering system , see Front
WheelfSuspension/Steering section (page 16-32).
When performing the DIG troubleshooting, read "EPS Troubleshooting Informalion" carefully (page 24-9), and inspect and
troubleshoot according to the OTe. Observe each slep of the procedures one by one. Note the DTC and probable faulty part
before starting diagnosis and troubleshooting.
The EPS ECU may be damaged if dropped. Also. if the connector is disconnected when current is flowing, the excessive voltage
may damage the EPS ECU . Always turn off the ignition switch before disconnecting or connecting the connectors.

TOOLS
SCS service connector • Test probe HOS pocket tester
070PZ-ZY30100 07ZAJ-RDJA110 TOS 3557-0112-01 (U.S.A. Only)

SYMPTOM TROUBLESHOOTING
Symptom o;,~.g~n~o~S~iS;:;:::::::::=,=+= Also check for
EPS indicator does not come Inspect the EPS indicator circuit Short circuit between the com~bi:"
na~t~io~o~m~e~te-r and
00 (page 24-32) ECU

EPS indicator does not go Inspect the EPS indicator circuit combination meter and
off, and no DTCs are stored (page 24-33)
Short circuit in the OLC related wire
Open circuit in
Open circuit in
the EPS ECU line
the motor power input line
I
L Open circuit in the power ground line

24-4
 ELECTRIC POWER STEERING (EPS: FPM/FPE models)
EPS CONNECTOR LOCATION
NOTE 1: Remove the assist headlight cover (page 22-4)

COMBINATION METER 21P (Black) CONNECTOR

(NOTE 1)

NOTE 2: Remove the right side cover (page 2-4).

Cl C7
= /
I' IX
CB r 'X ...J C14
,X X X IX IX
EPS MOTOR 2P (Gray) CONNECTOR
CIS C21 (NOTE 2)
EPS ECU 21P (Gray) CONNECTOR
(NOTE 2)

EPS EeU 2P (Gray) CONNECTOR

(NOTE 2)

EPS ECU 2P (Brown) CONNECTOR

(NOTE 2)

24-5
ELECTRIC POWER STEERING (EPS: FPM/FPE models)
NOTE 1: Remove the right side cover (page 2-4).

(Motoe "de co""ectoe) (n;n)

TORQUE SENSOR 3P (Gray) CONNECTOR EPS MOTOR 2P (Gray) CONNECTOR
(NOTE 1) (NOTE 1)

NOTE 2: Remove the right side cover (page 2-4).

FPM: ENGINE SUB-WIRE HARNESS 3P (Black) CONNECTOR (NOTE 2)

FPE: ENGINE SUB-WIRE HARNESS 6P (Black) CONNECTOR (NOTE 2)

I
I

24-6
 ELECTRIC POWER STEERING (EPS: FPM/FPE models)
NOTE 1: Remove the left side cover (page 2-4).

\I \\
\

~ :
-
-- 1--'--

{n ~
v s SENSOR 3P (Black) CONNECTOR
(NOTE 1)

NOTE 2: Remove the seat (page 2-4).

OLe (NOTE 2)

24-7
ELECTRIC POWER STEERING (EPS : FPM/FPE models)
NOTE 1: Remove the rear fender cover (page 2·9).

~:Mtt 8lifE g'

~ ~
A12

A33 A23
PCM/ECM 33P (Gray) CONNECTOR PCMfECM 33P (Black) CONNECTOR
(NOTE 1) (NOTE 1)

24·8
 ELECTRIC POWER STEERING (EPS: FPM/FPE models)
EPS TROUBLESHOOTING INFORMATION
SYSTEM DESCRIPTION
SELF·DlAG NOSIS SYSTEM
The EPS system is equIpped with the self-diagnostic system. If the EPS
ECU detects a system failure. it functions as follows: 111
/
1. Turns on the EP$ indicator 11110 notify the rider of the problem. /

-,
2. Stores a DTG (Diagnostic Trouble Code) in Its erasable memory.
I (R) (~ ( I ) (4) (a)

--
3. Slops power assist (manual steering operation begins or reduces the (N)

-
assist power),
Self-diagnosis can be classified into three categories:
Initial diagnosis: performed right after the engine starts and until the EPS
--
[\I rl
LI
1..... 1

- il
Indicator goes off I ll' I!!!I
000
- Regular diagnosIs: performed right after the mitial diagnosIs until the 2 '~

\c5' /
igmtion switch is turned OFF .
- Revest: The EPS indicator turns on when the OlG is set. The EPS
indicator will turn off after the vehicle has recovered from the fall-safe
condition , but the OTC will be stored in the EPS ECU. There was a
temporary problem, but the system is now fully operational.
I \ J

DTC (Diagnost ic Trouble Code)

The OTC(s) is memorized in the EEPROM (nonvolatile memory) therefore the memorized OTC(s) cannot be erased by
disconnecting the battery. Perform the specified procedures to erase the OTC(s) (page 24.11) ,
EPS IN DICATOR
Under normal condItions, the EPS indicator comes on when the ignitIon switch Is turned ON , then goes off after startIng the engIne .
This indicates thai the LED and tts circuit are operating correctly
If there is any trouble in the system after the engine IS started, the EPS indicator will stay on and the EPS ECU memorizes the OTC.
(When the oTC 22 is stored; No initializing the torque sensor neutral position. the EPS indicator will blink .)
When a problem is detected and the EPS indicator comes on. there are cases that the indicator stays on until the ignition switch is
turned OFF, and the indicator goes off automatically when the system returns to normal.
If a problem is continuing after restartIng the engIne . the EPS indIcator stays on and the EPS ECU stops the EPS function.
When the oTC 23 (torque sensor problem) is slored in the EPS ECU , the EPS indicator win slay on until the OTC is erased .

RESTRICTION ON POWER ASSIST OPERATION

Repeated extreme steering force , such as turning the handlebar continuously back-and-forth WIth the vehicle stopped, causes an
increase of power consumption in the EPS motor. The increase of electric current causes the motor to heat up. Because thIS heat
adversely affects the system, the EPS ECU monitors the electric current of the motor. When the EPS ECU detects heat build-up in
the motor. it reduces the electric current to the motor graduany to protect the system (motor and EPS ECU) , this restricts the power
assist operation . The EPS indIcator does not come on during this function . When steering torque is not applied to the handlebar, or
when the ignition is turned off, and the system cools, the EPS ECU wilt gradually restore the power assist.

TORQUE SENSOR NEUTRAL POSITION (Torque Sensor Inilializalion)

The EPS ECU stores the torque sensor neutral poSItion in the EEPROM. The torque sensor must be initialized whenever the EPS
unit. the EPS ECU , etc is serviced (page 24-1 3).
Perform the Torque Sensor InitializatIon when you service the follOWIng components.

MAINTENANCE L OCATI ON._

--------r
---+- REPLACEMENT
RE"M" O""V"'
IN STALLATION
A'U'----

Cables and harness around handlebar INITIALIZE INITtALIZE

Handlebar INITIALIZE INITIALIZE
SteerlllgShaft and steering shaft bushing INITIALIZE INITIA~L~IZ~Ec---
Steenng arm and end nut - +IN ITIALIZE INITIALIZE
EPS unit INIT IALIZE 1 INITIAlIZ~
EPS ECU INITIALIZE : - NO NEED~
NOTE
• The torque sensor neutral poslilon is not effected when erasing the OTC.

24-9
ELECTRIC POWER STEERING (EPS : FPM/FPE models)
HOW TO TROUBLESHOOT EPS DTC
1, Questton the customer about the conditions when the problem occurred. and try to reproduce the same conditions lor
troubleshooting . Find out when the EPS indicator came on, such as during EPS control , after EP$ control, when the vehicle was
al a certain speed, etc.
2. When the EPS indicator does not come on during the lest-ride, but troubleshooting is done based on the DTC, check for loose
connectors, poor terminal contact, etc., in the affected circuil before you start troubleshooting.
3. After troubleshooting, erase the DlC(s) and test-ride the vehicle to be sure that the EPS indicator does not come on.

HDS POCKET TESTER INFORMATION

• The HDS can readout and erase the DIG (without the torque sensor neutral position).
How to connect the HOS Pocket Tester
Turn the ignition switch OFF,
121
Remove the seat (page 2-4 ),
Remove the OLC [1) from the dummy conneclor [2),
Connect Ihe HDS pockel tesler 10 the OLC,
Turn Ihe ignilion switch ON and engine slop swilch ·0 ", check the DTC and
stored data.

DTC READOUT
NOTE
If Ihe HoS pocket tester is not available, oTC can be read from the EPS ECU memory by the EPS indicator blinking pattern
(page 24-10).
After pettorn-ling diagnostJc troubleshooting, erase the OTC(s) (page 24-11) and test-ride the vehicle to be sure Ihal the
problem(s) have been removed ,
Start Ihe engine and check the EPS indicator (1),

~
NOTE
~I
Under normal conditions, the EPS indicalor stays on with the ignition

,-, --,
switch is turned ON until the engine slans, and it goes off after starting IPS) I
R NI ,1,) '"
the engine.
If the EPS indicator stays on or blinks wi th the engine running, connect the
HDS pocket tester to the OLC (page 24-10).
Read the OTC, stored data and follow the troubleshooting index
--
1\1
1...... 1

LI I:- e ilII!!!I
(page 24-16).
2 ",lE

,n
To read the OTC without the HoS pocket tester, refer to the following
procedure. u

\
Read ing DTC wi th the EPS indicator
1 Remove the OLC from the dummy connector (page 24-10),
11 I 121
2. Short the OLe [1) terminals using the special tool.
TOOL:
(2] SCS service co nnecto r 070PZ-ZY30100

Connection : Brown/red - Green

3, Turn the ignition switch ON and engine stop switch "0 ", read , note the
EPS Indicator blinks and refer to the troubleshooting index (page 24-16).

24-10
 ELECTRIC POWER STEERING (EPS: FPM/FPE models)
EP$ Indicator Blinking Pattern
The number of EPS indicator blinks is the equivalent to the main code of the ore (the sub-code cannot be displayed by the
indicator blinking).
The indicator has two types of blinks, a long blink and short blink. The long blink lasts for 1.3 seconds, the short blink lasts for
0.3 seconds . One long blink is the equivalent of len short blinks. For example, when two long blinks are followed by one short
blink, the DIG is 21 (two long blink = 20 blinks, plus one short blink).
When the EPS ECU stores more than one DIG, the indicator blinks in the order from Ihe lowest number to highest number.

0.3 sec 0.3 sec 0.3 sec

0.5 ,ec \ 04 " ; / , '

1.3 sec 1.3 sec \ _ I... ~sec 0.4 sec / 2.6,ec

- I '--l
Pattern
@OFF .... ... ------ f- --- --------- - --------- - - Repealed
10 2

OTCI2 OTC21

ERASING DTC
NOTE-
• Perform this procedure using fully charged battery. The EPS indicator will stay Iii and the EPS ECU will abort the process If you
use a low or dead battery.
How to erase the OTC with HOS
Connect the HOS pocket tester to the OLC (page 24-10).
Erase the OTC with Ihe HOS while the engine IS stopped.
To erase the OTe without HOS. refer to the following procedure.
How to erase the OTC without HOS
I . Raise the fronl wheets off the ground and support the vehicle securely.
,
[11 121
2. Remove the OLe from the dummy connector (page 24-10).
3. Short the OLC (II terminals using the special 1001.
TOOL:
[2] SCS service connector

Connection: Brown/red - Green

070PZ-ZY30100
1£

4. Place a 6 mm width screwdriver [1] between the right side of the steering
stopper [2] and steering arm [31 as shown. [2]

131

[11

24-11
ELECTRIC POWER STEERING (EPS: FPM/FPE models)
5. Make sure the engine stop switch is turned ·0-, 131
Fully lum the handlebar [1) to the left to apply a toad and hold it firmly.
• • •
.."@"
6. Turn the ignition switch [2] ON .
The EPS indicator [3[ comes on and it goes off after 4 seconds.
• 6
.. .. ~

: 1\

~
~
4 seconds
11 I 121
7. Within 4 seconds after the EPS indicator [1J goes off, turn the handlebar I
Straight 111

- 'wi~"
(2] in the straight ahead position and release it immediately.
I
The EPS indicator comes on again 4 seconds . ,
~
~
• 1 •
::~.:.
.6.· : .".
4 seconds
121
8. Within 4 seconds after the EP$ indicator (1) comes on, fully turn the
handlebar [2J to the left and hold it immediately. 111
The EPS Indicator goes off after 4 seconds.
•••
-"@".-
."

,
.':\

~
4 seconds
121
9. Within 4 seconds after the EPS indicator [1] goes off, lurn the handlebar
[2] in the straight ahead position and release it immediately . Straight 11 I
The EPS indicator blinks twice. I
Turn the ignition switch (3J OFF within 5 seconds after the EPS indicator
blinks twice (o Te erasure is completed at this time).
NOTE·
The ignition switch must be turned OFF at this time .
If it is not, the system will be changed to the torque sensor initialization
~
•• ••
,
• •
(page 24-14). ::~-:.
If the EPS indicator does nol blink twice, an error was made in the
procedure and the o Te was not erased. Turn the ignition switch OFF,
and repeal the operation from step 4.
~/ ......
: .
Blinks
10.Remove Ihe special tool from the Ol e and inslallthe Ole to the dummy 121 131
connector.
Remove the screwdriver inserted in Step 4 .
1Unstailihe seat (page 2-4).

24·12
 ELECTRIC POWER STEERING (EPS : FPM/FPE models)
TORQUE SENSOR INITIALIZATION
NOTE :
Perform this procedure using a fully charged battery. The EP$ indicator will stay lit and the EPS EeU will abort the process if
you use a low or dead battery.
The DTC will be erased when Initializing the torque sensor.
How to Initialize the Torque Sensor with HOS
1. Raise the front wheels off the ground and support the vehicle securely.
Straight
2 . Connect the HOS Pocket Teslarto the OLe (page 24-10). I
3. Turn the ignition switch ON and engine slop switch ·0 · ,
Tum the handlebar (1) straight ahead.
Initialize the torque sensor With the HOS while the engine is stopped .
Follow the Instructions on the HOS display.

(11

How to Initialize the Torque Sensor without HOS

l
1. Raise the front wheels off the ground and support the vehicle securely.
(11 (21
2. Remove Ihe OLe from the dummy connector (page 24-10).
3. Short the OLe [ 1jterminals using the special tool.
TOOL:
(2) SCS service connector 070PZ-ZY30100

Connection: Brownfred - Green

4. Place a 6 mm width screwdriver (1 ) between Ihe fight side of the steenng

stopper (21 and steering arm (31 as shown.

(11

24·13
ELECTRIC POWER STEERING (EPS: FPM/FPE models)
5. Make sure the engine stop switch is turned ·0·. 131
,
Fully turn the handlebar [1J to the left to apply a load and hold it firmly.
6. Tum the ignition switch (2) ON . ·: .
::~.:.
·•· I ...••
,
The EPS indicator 13] comes on and it goes off after 4 seconds.
~

®
4 seconds
111 121
7. Within 4 seconds after the EPS indicator (1 J goes off, tum the handlebar
12] in the straight ahead position and release it immediately. Straight 1'1

The EPS indicator comes on again 4 seconds. .

I

®
,
.:...®:.. •

·"
•r•
4 seconds
[2[
8. Within 4 seconds after the EPS indicator [1J comes on , fully turn the
handlebar [2]10 the left and hold it immediately.
The EPS indicator goes off after 4 seconds.
['I
I
• •I
..."@" ..
·•· : ..•.
~

,
®
4 seconds
[21
9. Tum the handlebar I1J in the straight ahead position (fully tum-to-
straight ahead lime: within 1 second) and release it immediately after the Straight [21
EPS indicator [2] goes oft I

®
,
The EPS indicator blinks twice. Wait for 5 seconds and the EPS indicator
blinks 3 times. r
NOTE
Do not touch the handlebar after releasing the handlebar.
Tum the ignition switch [31 OFF after the EPS indicator blinks 3 times
(torque sensor initialization Is completed at this time).
..®.,
~"
1/.~
. ~

~ •t ~ • ..
NOTE • I .
If the EPS indicator does nol blink 3 times, an error was made in the
procedure and the torque sensor was not Initialized. Tum the ignition
switch OFF, and repeat the operation from slep 4.
[' [ [3[ B
: :J
10.Remove the special tool from the OlC and install the DlC to the dummy connector.
Remove the screwdriver inserted in Step 4.
11 .lnslall the seat (page 2-4).

24-14
 ELECTRIC POWER STEERING (EPS: FPM/FPE models)
CIRCUIT INSPECTION
INSPECTION AT EPS ECU AND PCM/ECM CONNECTOR
Always clean around and keep any foreign material away from the EPS ,----------------~,
ECU and PCM/ECM connector before disconnecting it.
A faulty EPS system is often related to poorly connected or corroded
connections. Check Ihose connections before proceeding.
Do not pull the wire harness while disconnecting the EPS ECU and
PCMfECM connector.
In lesting al EPS ECU 21 P (Gray) and PCMIECM connector (wire
harness side) terminal, always use the test probe. Insert the test probe
into the connector terminal, then attach the digital multimeter probe to
the test prObe.
TOOL :
{1] Test pro be 07ZAJ-RDJA 110

24-15
ELECTRIC POWER STEERING (EPS : FPM/FPE models)
EPS DTC INDEX
DEFINITIONS
Latch : The EPS indicator turns on and stays on whenever the ignition switch is in the ON position, or until the DTG is erased.
Reset: The EPS indicator turns on when the DIG is set The EPS indicator will not turn on after the ignition switch is cycled from
ON to OFF, but the OTG will be stored in the EPS ECU.
Revest: The EPS indicator turns on when the DTG is sel. The EPS indicator will turn off after vehicle has recovered from the fail-
safe condition, but the DTC will be stored in the EPS ECU. There was a temporary problem. but the system is now fully operational.
Initial diagnosis: Performed right after the engine starts and untillhe EPS indicator goes off.
Regular diagnosis: Performed right after the initial diagnosis until the ignition switch is turned OFF.
r--oTC - ----,----- - , ----,
(EPS Symptom/Fail-safe Detection Refer
Function Failure Type
indicator function timing to
blinks)
Excessive change of vehicle speed Indicator ON/Substitution Regular Revest 24-18
11-01 (II) signal control of the engine rpm
Comparison between vehicle speed Indicator ON/Substitution Regular Revest 24-19
11-02 (11) and en.gine speed signal control of the engine ~,p~m"-_~_ _ _ _-+ ____ _ _ _-j
13-01 (13) EPS EGU internal circuit Indicator ON/Disables Initial Reset 24-19
'--_ _ __ +_ (Lower FET stuck ON) _ __ _ _~'~te~e~'~i"~g_":assist immediately
I 13-02 (13) EPS EGU internal circuit Indicator ON/Disables Initial Reset 24-20
'--____ +--a*~FDE~T;;;;:~ ON) steering assist ..im,,",m~e~d~;a~te~ty,--+_ _ __
I 13-03 (13) i circuit Indicator ON/DTSables Reset 24-20
Regular
) _':--=-"'''-+~fJ:~~,~k;ON <over current» steering assist immediately
r 13-04 (13) internal circuit Indicator ON/Disables Regular Reset 24-20
I steering assist immediately
Indicator ONfDisables
13-05 (13) steering assist immediately Regular Reset 24-20

Regular Reset 24-21

assist
Initial Reset 24-21
i
Initial Reset 24-21

Regular Reset 24-21

;;:;~~,~~~J~R~e~g~Ular
Revest 24-21

15-02 (15)
h~~~~-n~i~
power stabilized or EPS
i Regular
-+-
Revest 24-22
operation is normally
Indicator ON/Disables
16-01 (16) Regular Reset 24-23

16-02 (16) Initial Reset 24-23

17-01 (17) Initial Reset 24-23

i
17-02 (17) (Voltage raise transformation circuit) assist under the Regular Reset 24-23

18-01 (18) Initial Reset 24-23

18-02 (18) Regular Reset 24-23

18-03 (18) Initial Reset 24-24

assist i i
ONfDisables
18-04 (18) Regular Reset 24-25
i i
-I
; i
18-05 (18) Regular Reset 24-23
(Motor current deflection) _ _ _--;'~te~e2:ring assist i i
EPS EGU internal circuit Indicator ONfDisables
18-06 (18) Regular Reset 24-23
(tM2) steering assist i

24·16
 ELECTRIC POWER STEERING (EPS : FPM/FPE models)
Ole
(EPS Sy mptom/Fail-safe Detection Refer
Function Failure Type
indicator function timing to
blink s)
21-01 (21)
Abnormal motor terminal voltage Ind;oato, ON/D;,able, ~
steering assist immediately nl 13 Re'~t24-25
Abnormal motor terminal voltage Indicator ON/Disables R I
21·02 (21) Reset 24-25
steering assist immediately egu ar
f 21-03 (21)
Open in the motor harness Indicator ON/Disables
steering assist immediately
I
Regular Reset 24-25
Failure to initialize the torque sensor Indicator blinkJDisables
22-01 (22) steering assist until the Regular Latch' 24-25
torque sensor is initialized
Low/high voltage for the torque sensor Indicator ON/Disables
23-01 (23) (VT1 and VT2) steenng assist unlll the DTG Regular Latch 24·26
is erased

~
;t,Torque sensor Indicator ONfDisables

Reg~
23-02 (23) (VT3 Differential·amplification Function) steering assist until the DTG

t
is erased
Torque sensor Indicator ONfDisables
23·03 (23) (VT1, VT2 rapid change) steering assist until the DTG Regular Latch 24·28
is erased
Torque sensor Indicator ONfDisables
23-04 (23) Regular Reset 24·28
(Temperature sensorl
Torque sensor ;
23·05 (23) (Sensor Goil) steering assist until the DTG Regular Latch 24·29
is erased
Engine speed signal Indicator ONlDisables
24·01 (24) steering assist under the Regular Revest 24·29
j
I
SpeCified condition
Low/high IG1·terminal vol tage Indicator ON/Disables
31-01 (31) steering assist under the Initial R evest 24·30
Specified condition
Low/high IG1·terminal voltage Indicator ON/Disables
31·02 (31) steering assist under the Regular Revest 24·30
Specified condition
Lowlhigh VBU voltage Indicator ONlDisables
32·01 (32) steering assist under the Regular Reset 24·31
Specified condition
33-02 (33)

35-01 (35)

35-03 (35)
EPS ECU Internal Circuit
(EEPROM)
EPS EGU internal circuit
(CPU)
EPS EGU internal circuit
Indicator ON/Disables
steering assist immediately
Indicator ON/ Disables
steering assist immediately
Indicator ON/Disables
Initial

lo;"al and
Regular
Initial
t Reset

Re,et

Reset
24·23

24·23

24·23
I
(CPU communication) steering assist immediately
EPS EGU internal circuil Indicator O NlDisables
35·04 (35) (CPU communication) steering assist under the Regular Reset 24·23
Specified condition

'The stored DTC is erased by perfonning the torque sensor initialization.

24-17
ELECTRIC POWER STEERING (EPS: FPM/FPE models)
DTC TROUBLESHOOTING
NOTE '
Refer to "EPS Connector Location" for the connector
location and the necessary parts to disconnect the
connector (page 24-5),
After troubleshooting, erase the o TC(s) and test-ride
the vehicle to be sure that the EPS indicator does
not come on.
VERIFY PROPER CONNECTOR
CONTACT
Many EPS problems and subsequent oTCs are caused
by poor connector contacts. The first step in
troubleshooting any DTC is to inspect the affected
connectors.
CONNECTOR INSPECTION
Check for moisture In the affected connector
Check for corrosion
Check for folded pins on the male side of the
connector
Check for loose pins andlor pins pushed out of the
connector

DTC 11·01 : EXCESSIVE CHANGE OF

VEHICLE SPEED SIGNAL (REGULAR
DIAGNOSIS)
NOTE:
Before starting the troubleshooting, check for loose or
poor contact of the following connectors, and recheck
the EPS indicator (page 24-18).
- engine sub-wire harness connector
- 3P (Black): FPM
- 6P (Black): FPE
- EPS ECU 21P (Gray)
- VS sensor 3P (Black)
The system is reducing the assist power, the EPS
indicator will come on when the EPS ECU detects
conditions of orc 11·01 and OTC 11-02.
1. VS Sensor Signal line Open Circuit Inspection
Turn the ignition switch OFF.
Disconnect the VS sensor 3P (Black) connector [1] [l [ Pink
and EPS ECU 21P (Gray) connector [2J.
Check for continuity between the wire harness side
VS sensor 3P (Black) connector and EPS ECU 21P
(Gray) connector terminals,
Connection: C17 - Pi nk
ell
TOOL: Q
Test probe 07ZAJ-RDJA110 x
Is there continuity?
YES - GO TO STEP 2.
x
NO - Open circuit in the Pink or Pink/green wire. [2[

24-18
 ELECTRIC POWER STEERING (EPS: FPMfFPE models)
2. VS Sensor Signal line Short Circuit Inspection
Check for continuity between the wire harness side
EPS ECU 21P (Gray) connector (1J terminal and C17
ground
Connection : C17 - Ground

TOOL: /
Test probe 07ZAJ·ROJA 110
Is there continuity?
YES - Short Clrcuil in the Pmk/green or Pink wire. Q
NO - Replace the EPS ECU with a known good
one (page 24-35), and recheck

L
DTC 11·02: COMPARISON BETWEEN
VEHICLE SPEED AND ENGINE SPEED
SIGNAL
(REGULAR DIAGNOSIS)
Refer to DTC 11-01 (page 24-18)

DTC 13·01 : EPS ECU INTERNAL

CIRCUIT (LOWER FET STUCK ON)
(INITIAL DIAGNOSIS)
NOTE -
Before starting the troubleshooting, check fo r loose or
poor contact of the following connectors, and recheck
the DTC (page 24-18),
- EPS ecu 21 P (Gray)
- EPS motor 2P (Gray)
1. EPS EeU System Inspection
1 Erase the DTC (page 24-11).
2. Start the engine.
3. Fully turn the handlebar to the left or right and
hold II 10 seconds.
4. Check the EPS indicator
Does the EPS indicator come on?
YES - GO TO STEP 2.
NO - Intermittent failure.
2. Molor Line Short Circuit Inspection
Turn the ignilion swilch OFF.
Disconnecllhe EPS ECU 2P (Gray) connector (1].
Black Red
Check for contmuity between the wire harness sid e
EP$ ECU 2P (Gray) connector terminals and
ground.
Connection : Black - Ground
Red - Ground
Is there continuity?
YES - GO TO ST EP 3.
111
NO - GO TO STEP 4.

L
24·19
ELECTRIC POWER STEERING (EPS: FPM/FPE models)
3. Motor Short Circuit Inspection
Disconnect the EPS molor 2P (Gray) connector.
Check for continuity between the motor side 2P Red Black
connector /1] terminals and ground .
111~

S
Connection : Red - Ground
Black - Ground
{5 there continuity?
YES - Replace the EPS unit with a new one
(page 16-32), and recheck.
NO - Short circuil in the Red or Black wire.

4. EPS sub-wire harness Short Circuit Inspection

Check for continuity between the wire harness side , - -- ----
EPS ECU 2P (Gray) connector [1) terminal s.
Connection : Black - Red
BlaCk~=~~~=;Red
Is there continuity?
YES - Short circUit in the EPS sub-wire harness.
NO - Recheck for loose or poor contact on the
EPS EeU 2P (Gray) connector and EPS
motor 2P (Gray) connector. If they are OK,
replace the EP$ ECU with a new one
(page 24-35).
111

DTC 13-02: EPS ECU INTERNAL

CIRCUIT (UPPER FET STUCK ON)
(INITIAL DIAGNOSIS)
Refer 10 Ole 13-01 (page 24-19)

DTC 13-03: EPS ECU INTERNAL

CIRCUIT (FET STUCK ON <OVER
CURRENT» (REGULAR DIAGNOSIS)
Refer 10 Ole 13-01 (page 24-19)

DTC 13-04: EPS ECU INTERNAL

CIRCUIT (FET STUCK ON
(VM<VOLTAGE MOTOR»
(REGULAR DIAGNOSIS)
Refer to Ole 13-01 (page 24-19)

DTC 13-05: EPS ECU INTERNAL

CIRCUIT (FET STUCK ON (OVER
CURRENT<ACCUMULATED»
(REGULAR DIAGNOSIS)
Refer to Ole 13-01 (page 24-19)

24·20
 ELECTRIC POWER STEERING (EPS: FPM/FPE models)
DTC 14-01: EPS ECU INTERNAL
CIRCUIT (POWER RELAY STUCK ON)
(REGULAR DIAGNOSIS)
Refer to OTG 13-01 (page 24-19)

DTC 14-02 : EPS ECU INTERNAL

CIRCUIT (FAIL-SAFE RELAY 1 STUCK
ON) (INITIAL DIAGNOSIS)
Refer to OTG 13-01 (page 24-19)

DTC 14-03: EPS ECU INTERNAL

CIRCUIT (FAIL-SAFE RELAY 2 STUCK
ON) (INITIAL DIAGNOSIS)
Refer to oTC 13-01 (page 24-19)

DTC 14-04: EPS ECU INTERNAL

CIRCUIT (POWER RELAY STUCK
OPEN) (REGULAR DIAGNOSIS)
Refer to DlG 13-01 (page 24-19)

DTC 15-01 : 2WD/4WD SELECT SIGNAL

BLINKING (REGULAR DIAGNOSIS)
NOTE :
Before starting the troubleshooting, check for loose or
poor contact of the following connectors, and recheck
the 4WD indicator (page 24-18).
- 4WD select switch
- EPS ECU 21 P (Gray)
- combination meter 21 P (Black)
When this problem occurs, there are some of
problem of 2WDf4WD select system.
Question the customer about the conditions when
the problem occurred, and try to reproduce the same
conditions for troubleshooting. Find oul when the
4WD indicator blinked, such as during 4WO-to-2WD
selecting. 2WO-lo-4WD selecting, al what speed,
etc.
1. EPS ECU System Inspection
Erase the Drc (page 24.11).
Perform the test·ride and check the 4WD indicator
11].
Does the 4WD indicator blinking ?
YES - Check the 4WD select switch (page 22·17).
If it is OK, inspect the 2WD/4WD select
system (front final clutch; page 19·16).
NO Intermittent failure.
Loose or poor contact of the following
connectors:
- 4WD select switch
- EP$ ECU 21P (Gray)
- combination meter 21 P (Black)

24·21
ELECTRIC POWER STEERING (EPS: FPM/FPE models)
DTC 15-02: 2WD/4WD SELECT SIGNAL
INPUT LINE (REGULAR DIAGNOSIS)
NOTE:
Question the customer about the conditions when
the problem occurred, and try to reproduce the same
conditions for troubleshooting. Find out when the
4WD indicator blinked, such as during 4WO-to-2WD
selecting , 2WO-to-4WD selecting, at what speed,
etc.
1. EPS ECU System Inspection
Erase the DIG (page 24-11).
Start the engine and check the EPS indicator.
Does the indicator come on ?
YES - GO TO STEP 2.
NO - Intermittent failure.
2. 4WD Indicator Inspection
Turn the ignition switch ON and engine stop switch r - -- - - - - -- - - - ( c -,-(- --
"0"·
Operate the 2WD/4WD select lever several times /
and check the 4WD indicator (1). /

-,
(R) (N) (ps) (X) (~ (0)

,I
Is the 4WD indicator operated normally?

1-1 •-
YES

NO
- Replace the EPS ECU with a known good
one (page 24-35), and recheck.
- Check the 4WD select switch (page 22-17).
--
[\I
1 ....... 1

-il
o 0 2 ~ , le
'" '' I!!!I

~"

I
.0 / \

24-22
 ELECTRIC POWER STEERING (EPS: FPM/FPE models)
DTC 16-01,16-02,17-01,17-02,18-01,
18-02,18-05,18-06, 33-02,35-01 , 35-03,
or 35-04: EPS ECU INTERNAL CIRCUIT
Perform the troubleshooting according to the OTC in the
following table.

l
16.01 ~'E"piiS'E"C"U internal circuit (Direction determine logic circuit)
(Regular diagnosis)
16-02 EPS ECU internal circuit (INH output circuit)
(Initial diagnosis)
17..()1 EPS ECU internal circuit (Voltage raise transformation circuit)

==J
(Initial diagnosis)
17..()2 EP$ ECU internal circuit (Voltage raise transformation circuit)
(Regular diagnosis)
18..()1 EPS ECU internal circuit (Current sensor)
(Initial diagnosis)
r 18"'(}2 EPS ECU internal circuit (Current sensor off set)
(Regular diagnosis)
18-05 EPS ECU Internal circuit (Motor current deflection)
(Regular diagnosis)
18-06 EPS ECU internal circuit (1M2) I
(Regular diagnosis)
33.()iC2.-+--iEPS ECU internal circuit (EEPR'''O'''M")- -- - -
(Regular diagnosis)
35-01 EPS ECU internal circuit (CPU)
(Initial and regular diagnosis)
35.()1 :EPS ECU internal circuit (CPU communication)
(Initial diagnosis)
35-04 EPS ECU Internal circuit (CPU communication)
(Regular diagnosis)

1. EPS ECU System Inspection

1. Erase the DTG {page 24· 11 J.
2. Start the engine.
3 Fully lum the handlebar to the left or right and
hold it 10 seconds.
4. Check the EPS indicator.
Does the EPS indicator come on?
YES - GO TO STEP 2.
NO - Intermittent failure.
2. OTC Inspection
1. Check the DIG (page 24-10).
Is Dre 1S.01, 16-02, 17-01, 17.02, 18-01, 18-02,
18-05, 18-06, 33-02, 3S.01, 35-03 or 35-04
indicated?
YES - Replace the EPS EeU with a known good
one (page 24-35), and recheck.
NO - Perform the troubleshooting for the
indicated DTC (page 24-16).

24-23
ELECTRIC POWER STEERING (EPS : FPMfFPE models)
DTC 18-03: EPS ECU INTERNAL
CIRCUIT (CURRENT SENSOR STUCK
LOW) (INITIAL DIAGNOSIS)
NOTE :
Before starting the troubleshooting, check for loose or
poor contact of the following connectors, and recheck
the DTG (page 24-18).
- EPS ECU 2P (Gray)
- EPS motor 2P (Gray)
1. EP$ ECU System Inspection
1. Erase the DIC (page 24-11).
2. Start the engine.
3. Fully tum the handlebar to the left or right and
hold il10 seconds.
4. Check the EPS indicator.
Does the EP$ Indicator come on?
YES - GO TO STEP 2.
NO - Intermittent failure.
2. Motor Line Open Circuit Inspection
Turn the ignition switch OFF.
Disconnect the EPS EGU 2P (Gray) connector Ill.
Check for continUIty between the wire harness side
EPS EGU 2P (Gray) connector terminals.
Connection: Black - Red
Is there continuity?
YES - Replace the EPS ECU with a known good
one (page 24-35), and recheck. I
NO - GO TO STEP 3. I

~
[11

3. Motor Open Circuit Inspection

Oisconnecllhe EPS motor 2P (Gray) connector,
Check for continuity between the motor side 2P
I 111 Red Black
connector [1) terminals,
Connection : Red - Black
Is there continuity?
YES - Open circuit in the EPS sub-wire harness
NO - Replace the EPS unit with a new one
(page 16-32), and recheck.

24·24
 ELECTRIC POWER STEERING (EPS: FPM/FPE models)
DTC 18·04: EPS ECU INTERNAL
CIRCUIT (CURRENT SENSOR STUCK
LOW) (REGULAR DIAGNOSIS)
Refer to OIC 18-03 (page 24-24)

DTC 21 ·01: ABNORMAL MOTOR

TERMINAL VOLTAGE (INITIAL
DIAGNOSIS)
Refer to OTC 18-03 (page 24-24)

DTC 21·02 : ABNORMAL MOTOR

TERMINAL VOLTAGE (REGULAR
DIAGNOSIS)
Refer to DIG 18-03 (page 24-24)

DTC 21·03: OPEN IN THE MOTOR

HARNESS (REGULAR DIAGNOSIS)
Refer to OTe 18-03 (page 24-24)

DTC 22·01: FAILURE TO INITIALIZE

THE TORQUE SENSOR (INITIAL
DIAGNOSIS)
NOTE
The EPS EeU stores the torque sensor neutral
position The torque sensor must be initialized
whenever the EP$ unit, the EPS EeU , etc is
serviced (page 24- 13).
Refer to torque sensor neutral position information
for detail of the initialization parts (page 24-9).
The OIC will nol stofe in the EPS ECU. (The stored
DIG is erased by performing the torque sensor
initialization) (page 24-13)
The torque sensor neutral position is not effected
when erasing the OTC.
1. Initializing Torque Sensor
Perform the torque sensor initialization (page 24-13)
and check the EPS indicator.
Does the EP$ indicator come on ?
YES - Check the OlC (page 24-10) and perform
the troubleshooting for the indicated Ole
(page 24-16).
NO - Intermittent failure.

24-25
ELECTRIC POWER STEERING (EPS: FPM/FPE models)
DTC 23·01 : LOW/HIGH VOLTAGE FOR
THE TORQUE SENSOR (VT1 AND VT2)
(REGULAR DIAGNOSIS)
NOTE'
Before starting the troubleshooting. check for loose or
poor contact of the following connectors. and recheck
the o TC (page 24-18).
- EPS ECU 21P (Gray)
- torque sensor 3P (Gray)
1. EP$ ECU System Inspection
, . Erase the DTC (page 24-11).
2. Start the engine.
3. Fully tum the handlebar to the left or right and
hold il10 seconds.
4. Check the EPS indicator.
Does the EPS indicator come on ?
YES - GO TO STEP 2.
NO - Intermittent failure .
2. Torque Sensor line Short Circuit Inspection
Tum the ignition SWitch OFF .
Disconnect the EPS ECU 21P (Gray) connector (1).
Measure the resis tance between the wire harness
Q) - - - - ,
side EPS ECU 21 P (Gray) connector terminals.
111
Connection : C1 - C2
C1 - C3
C2 - C3

TOOL:
Test probe 07ZAJ ·RDJA110
C1
Is the resis tance less than 10 n (at 20°Cl68°F) ?
YES
NO
- GO TO STEP 3.
- GO TO STEP 4.
3. Torque Sensor Colt Short Circuit Inspection
L C3

Disconnect the torque sensor 3P (Gray) connector. I

~
Measure the resistance between the torque sensor
side connector [1) terminals in the EPS unit.
Connection: A - B
A- C 8
8- C
Is the res istance less than 10 n (at 20-Cl68-F) ?
YES - Replace the EPS unit with a new one
(page 16·32), and recheck (short circuit in
the torque sensor coil). C A
NO - ' Short circuit in the Yellow/red or Green/
orange wire (1)
Short Circuit in the Yellow/red or Whitel L _ _ _ _ __ __ _ _ _ _ _ _ _ _-1
blue wire.
Short circuit in the Green/orange or
White/blue wire.

24-26
 !,LECTRIC POWER STEERING (EPS: FPM/FPE models)
4. Torque Sensor Line and Ground Short Circuit
Inspection
Check for continuity between the wire harness side , - - - - - - - - -- - - - - -- -
EPS ECU 21P (G ray) connector [11 terminals and C1 C3
ground .
Connection: C1 - Ground
C3 - Ground

TOOL:
Test probe 07ZAJ·RDJA 110
Is there continuity?
YES - GO TO STEP 5.
NO - GO TO STEP 6 .
(11

5. Torque Sensor Coil Short Circuit Inspection

Check for continuity between the torque sensor side , -- -- - - - -- -- - - - -- --
connector [11terminals in the EPS unit and ground .
C A
Connection : A - Ground
C - Ground
Is there continuity?
CJ
YES - Replace the EPS unit with a new one
(page 16-32), and recheck (short circui t in
the torque sensor coil).
NO - ' Short circuit in the Yellow/red wire.
• Short circuit in the Whitelblue wire.
[11

6. Torque Sensor Line Open Circuit Inspection

Check for continuity between the wire harness side r - - -- - -W
.,--h-itel-b'-'-e- - - - - - - ,
EPS ECU 21P (Gray) connector 111 and torque Green/orange
sensor 3P (Gray) connector [2) terminals. ~
Connection: C1 - Yellow/red / . / Yellow/red
C2 - Green/orange V-
C3 - White/blue C2 g
TOOL : C1 ~ C3

m ii
[2[
Test probe 07ZAJ·ROJA 110
Is there continuity?
YES - GO TO STEP 7.
NO Open circuit in the Yellow/ red wire. [1[
Open circuit in the Green/orange wire.
Open circuit in the White/blue wire.

24-27
ELECTRIC POWER STEERING (EPS : FPM/FPE models)
7. Torque Sensor Open Circ uit Inspection
Measure the resistance between the torque sensor , - -- - - - -- - - - -- ------,
side connector (1] terminals in the EPS unit.
Connection: A - B
8-C
Is the resistance within 10 - 40 n (20"Cl6S"Fj ? A
YES - Replace the EPS ECU with a known good
one (page 24-35), and recheck.
NO - Replace the EPS unit with a new one
(page 16-32), and recheck (Short circuit in
the torque sensor coil).

DTC 23·02: TORQUE SENSOR (VT3

DIFFERENTIAL AMPLIFICATION
FUNCTION) (REGULAR DIAGNOSIS)
NOTE
Before starting the troubleshooting. check for loose or
poor contact of the following connectors, and recheck
the OTe (page 24-18).
- EPS ECU 21 P (Gray)
- torque sensor 3P (Gray )
1. EP$ ECU System Inspection
1. Erase the oTC (page 24-11).
2. Start the engine.
3. Fully turn the handlebar to the left or right and
hold it 10 seconds.
4. Check the EPS indicator.
Does the EP$ indica tor come on?
YES - GO TO STEP 2.
NO - Intermittent failure .
2. Rec heck OTC
Check the DTC (page 24-10).
Is DTC 23-02 indica ted?
YES - Replace the EPS ECU with a known good
one (page 24-35). and recheck.
NO - Perform the troubleshooting for the
indicated DTC (page 24-16),

DTC 23·03: TORQUE SENSOR

(VT1, VT2 RAPID CHANGE) (REGULAR
DIAGNOSIS)
Refer to DTC 23-0 1 (page 24-26).

DTC 23·04: TORQUE SENSOR

(TEMPERATURE SENSOR) (REGULAR
DIAGNOSIS)
Refer to DTC 23-01 (page 24-26),

I
!
24-28
1
 ELECTRIC POWER STEERING (EPS: FPM/FPE models)
DTC 23·05: TORQUE SENSOR
(SENSOR COIL) (REGULAR
DIAGNOSIS)
Refer to DTG 23-01 (page 24-26).

DTC 24·01: ENGINE SPEED SIGNAL

(REGULAR DIAGNOSIS)
NOTE :
Before starting the troubleshooting, check for loose or
poor contact of the following connectors, and recheck
the EPS indicator (page 24-18).
- EP$ EeU 21P (Gray)
- PCM/ECM 33P (Black)
1. CKP Sensor Signal Une Open Circuit Inspection
Turn the ignition switch OFF. , :-:-:-- - - -- -- - - : - - : : - - - - - - ---,
Disconnect the EPS ECU 21P (Gray) connector [1J [1J C19
and PCM/ECM 33P (Black) connector [2] .
Check for con tinuity between the wire harness side
EPS ECU 21P (Gray) connector and PCMfECM
33P (Black) connector terminals.
Connection : C19 (EPS EeU) - A20 (PCM /ECM)

TOOL: (2)

t T.l fffi :1'1

Test probe 07ZAJ-ROJA110
Is there continuity? 1

YES - GO TO STEP 2.
ND - Open circuit in the Blue/yellow wire. A20

2. CKP Sensor Signal Line Short Circuit Inspection

Check for con tinuity between the wire harness side '-(1-1
EPS ECU 21P (Gray) connector {1] terminal and
ground. e19
Connection : C19 - Ground

TOOL :
Test probe 07ZAJ·ROJA 110
Is there continuity?
YES - Short circuit in the Blue/yellow wire.
NO - Replace the EPS ECU with a known good
one (page 24-35), and recheck.

24-29
ELECTRIC POWER STEERING (EPS: FPM/FPE models)
DTC 31-01 : LOW/HIGH IG1-TERMINAL
VOLTAGE (INITIAL DIAGNOSIS)
NOTE:
Before starting the troubleshooting, check the following
items:
- check for loose or poor contact on the EPS ECU 21P
(Gray) connector, and recheck the EPS indicator
(page 24.18).
- check for blown IGN fuse (10A)
- battery condition (must use a fully charged battery)
(page 21-8)
1. IG1line Open Circuit Inspection
Turn the ignition switch OFF .
Disconnect the EPS ECU 21 P (Gray) connector [1). 111
C7
Turn the ignition switch ON and engine slop switch
"0".
Measure the vol tage between the wire harness side
EPS ECU 21 P (Gray) connector terminal and
ground.
Connection: C7 (+) - Ground (-) ffi
TOOL:
V
Test probe
Is there battery voltage?
07ZAJ-RDJA 110
e
YES - GO TO STEP 2.
NO - Open circuit in the Black/red wire.
2. Battery Inspection
Perform the Battery/Charging System
troubleshooting (page 21-6).
Is the battery and charging system in good
condition?
YES - Replace the EPS ECU with a known good
one (page 24-35), and recheck.
NO - Repair the batteryfcharging system
(page 21-8).

DTC 31-02: LOW/HIGH IG1-TERMINAL

VOLTAGE (REGULAR DIAGNOSIS)
Refer to DIG 31-01 (page 24-30)

24-30
 ELECTRIC POWER STEERING (EPS: FPM/FPE models)
DTC 32-01: LOW/HIGH VBU VOLTAGE
(REGULAR DIAGNOSIS)
NOTE'
Before starting the troubleshooting, check the following
items:
- check for loose or poor contact on the EPS ECU 2P
(Brown) connector. and recheck the EPS indicator
(page 24·18).
- check for blown EPS fuse (40A) and lGN fuse (IDA)
- battery condition (must use a fully charged battery)
(page 21 -8)
1. EP$ ECU +8 Line Open Circuit Inspection
Turn the ignition switch OFF .
Disconnect the EPS ECU 2P (Brown) connector [1]. 11 I
Turn the ignition switch ON and engine stop switch
"0".
Measure the vol tage between the wire harness side
EPS ECU 2P (Brown) connector terminal and
ground ,
Connection : Red (+) - Ground {-I
Is there battery voltage ?
YES - GO TO STEP 2.
NO - Open drcuit in the Red wire.

2. Battery Inspection
Perform the Battery/Charging System troubleshooting
(page 21-6).
Is the banery and charging system In good
condition?
YES - Replace the EPS ECU with a known good
one (page 24-35), and recheck.
NO - Repair the batterylcharging system
(page 21-8).

24·31
ELECTRIC POWER STEERING (EPS: FPM/FPE models)
EPS INDICATOR CIRCUIT INSPECTION
Refer (0 "EPS Connector Location" for the connector
location and the necessary parts to disconnect the
connector (page 24-5).
EPS INDICATOR DOES NOT COME ON
NOTE :
Under normal conditions. the EPS indicator comes
on when the ignition switch is turned ON, then goes
off after starting the engine.
Before starting the troubleshooting . check for loose
or poor contact on the combination meter 21P
(Black) connector and EPS ECU 21P (Gray)
connector. and recheck the EPS indicator.
1. Combination Meter Inspection
Check that (he combination meter functions
properly.
Does the combination function properly?
YES - GO TO STEP 2.
NO - Perform the combination meter inspection
(page 22-7).
2. Indicator Operation Check (Short Circuit
inspection)
Turn the ignition switch OFF.
Disconnect the EPS ECU 21P (Gray) connector.
Turn the ignition switch ON and engine stop switch
~O· .

Check the EPS indicator.

Does the Indicator come on?
YES - Recheck for loose or poor contact on the
combination meter 21P (Black) connector
and EPS ECU 21 P (Gray) connector. If
they are OK . replace the EPS ECU with a
known good one (page 24-35), and
recheck.
NO - GO TO STEP 3.
3. Indicator Une Short Ci rcuit inspection
Turn the ignition switch OFF.
Disconnect the combination meter 21P (Black) 111
connector [1].
Check the for continuity between the wire harness
.)
side combination meter 21P (Black) connector
terminal and ground. -Y"')OOOO
,~ I
Connection : Yellow/green - Ground >000)

TOOL:
Test probe 07ZAJ -RDJA 110
Yellow/green
Is there continuity?
YES - Short circuit in the Yellow/green wire.
NO - Recheck for loose or poor contact on the
combination meier 21 P (Black) connector ' - - - - - - - - - - - - - -- - -- - - '
and EPS ECU 21P (Gray) connector. If
they are OK. replace the combination
meter with a known good one (page 22-6).

24·32
 ELECTRIC POWER STEERING (EPS: FPM/FPE models)
EPS INDICATOR DOES NOT GO OFF ,
AND NO DTCs ARE STORED
NOTE
Under normal conditions, Ihe EPS Indicator comes
on when the ignition switch is turned ON. then goes
off after starting the engine .
Before starting the troubleshOO!lng check the
following ilems:
- check for loose or poor contact of the following
connectors, and recheck Ihe EPS indicator.
- EPS EeU 21P (Gray)
- EPS ECU 2P (Brown)
- combination meter 21 P (Black)
- check for blown EPS fuse (40A) and IGN fuse
( lOA)
- battery condition (must use a fully charged
battery) (page 21-8)
1. Fus e Inspection
Check the EPS fuse (40A) and IGN fuse (10A).
Is the fuse OK?
YES - GO TO STEP 2.
NO - Replace Ihe fuse and recheck If the fuse
is blown, check for short to ground in this
fuse circuit.
2. Rec hec k OTC
Check the DTG (page 24-10).
Are th ere any DTCs ?
YES - Perform the troubleshooting for the
indicated DTC (page 24.16).

I
NO - GO TO STEP 3.
3. Indica tor Operation Check (Open Circuit
Inspection)
Turn the ignition switch OFF .
Disconnect the EPS ECU 21 P (Gray) connector 11J.
Ground the wire harness side EPS ECU 21P (Gray) [11 C5

""?r==r=r=ffi~
connector terminal with a jumper wire.
Connection : C5 - Ground

TOOL:
Test pro be 07ZAJ·ROJA110
Turn the ignition switch ON and engine stop SWitch
"0 ",
Check the EPS indicator.
Does the indicator go off?
YES - Recheck for loose or poor contact on the
EPS ECU 21 P (Gray) connector. If they
are OK, replace the EPS ECU with a
L
known good one (page 24·35), and
recheck.
NO - GO TO STEP 4.

24·33
ELECTRIC POWER STEERING (EPS : FPM/FPE models)
4. Indicator Line Open Ci rcu it Inspection
Tum the ignition switch OFF.
Disconnect the combination meier 21P (Black) C5 Yellow/green
connector [1].
Check for continuity between the wire harness side
combination meter 21 P (Black) connector and EPS
ECU 21P (Gray) connector 121 terminals. ~ ""
00' 000§
Connection : C5 - Yellow/green oc )0000
o r)OOOG 9
TOOL:
Test probe 07ZAJ·RDJA110

Is there continuity?
YES - GO TO STEP 5. [21 111
NO - Open circuil in the Yellow/green wire.
5. SCS Line Short Circuit Inspection
Disconnect the PCMfECM 33P (Gray) connector.
Check for continuity between the wire harness side 111 C9
EPS ECU 21P (Gray) connector [1] terminal and
ground .
Connection: C9 - Ground

TOOL:
Test probe 07ZAJ·ROJA110
Is there continu ity?
YES - Short circui t in the Brown/red wire between
the EPS ECU and DLC,
NO - GO TO STEP 6.

6. IG1 Line Open Circuit Inspection

Tum the ignition switch ON and engine stop sWitch r-I-'I- - -- - - - - - - - - - - - - '
·0 · ,
C7
Measure the voltage between the wire harness side
EP$ EeU 21P (Gray) connector 111 terminal and
ground .
Connection: C7 - Ground H

TOOL:
Test probe 07ZAJ ·RDJA110
Is there battery voltage ?
YES - GO TO STEP 7 .
NO - Open circuit in the Black/red wire.

7. EPS ECU +8 Line Open Circuit Inspection

Tum the ignition switch OFF.
Disconnect the EPS ECU 2P (Brown) connector \11. Red
Measure the voltage between the wire harness side
EPS ECU 2P (Brown) connector terminal and
ground .
Connection: Red (+) - Ground (-)
Is there battery voltage?
YES - GO TO STEP 8.
NO - Open circuit in the Red wire.

24-34
 ELECTRIC POWER STEERING (EPS: FPM/FPE models)
8. EPS Eeu PG Line Open Circuit Inspection
Check for continuity between the wire harness side , - - - - - - - - - - - - - - - - - - - ,
EPS ECU 2P (Brown) connector [1] terminal and ]1J Green
ground.
Connection : Green - Ground
Is there continuity?
YES - GO TO STEP 9.
NO - Open circuit in the Green wire.

9. Battery Inspection
Perform the Battery/Charging System
troubleshooting (page 21 ·6 ).
Is the battery and charging system In good
condition ?
YES - Recheck for loose or poor contact on the
combination meter 21 P (Black) connector,
EPS ECU 21 P (Gray) connector and EPS
ECU 2P (Brown). If they are OK. replace
the EPS EeU with a known good one
(page 24-35), and recheck.
NO - Repair the bal1eryfcharging system
(page 21-8).

EPS ECU
REMOVALIINSTALLATION
Remove the right mudguard (page 2-6).
Disconnect the following connectors :
- EPS ECU 21P (Gray) (1)
- EPS ECU 2P (Gray) [2)
- EPS ECU 2P (Brown) (3)
Remove the EPS ECU [4) from the stays on the EC U
holder [5).
Installation is in the reverse order of remova1.
Perform the torque sensor initialization if the EPS ECU
replaced (page 24-13).

24-35
MEMO
 25. WIRING DIAGRAMS

FM model .. ···· ·············································· 25-2 FPM model ·················································· 25-4

FE model ····················································· 25-3 FPE model ·················································· 25-5

25-1
MEMO
MEMO
MEMO
 INDEX
2WD/4WD SELECT SYSTEM ·· ............................ ····· 3-19 ELECTRIC SHIFT PROGRAM (ESP)····· .. ············· 23-14
4WD SELECT SWITCH ············ ............. ·······22-17 PGM-FI···································· .............. ················· 4-14
ACCESSORY SOCKET ··· ........ ............... "' 22-10 ECT SENSOR .......................................... ················· 4-32
AIR CLEANER ...................... -.- ···································· 3-5 EMISSION CONTROL SYSTEMS ............. ················ 1-44
AIR CLEANER HOUSING ................................. ········· 7-19 ENGINE GUARD ···········-···························· .. ·················· 2-7
AIR CLEANER HOUSING DRAIN TUBE· ·······················3-7 ENGINE IDLE SPEED ······ ··············· ··· ·· ························ 3-15
ALTERNATOR CHARGING COIL ······························21-10 ENGINE INSTALLATION · .................................. ····· ··,5-9
ALTERNATQRSTATOR ...................................... 13-6 ENGINE OIL '" .................... ····························3-12
ASSIST HEADLIGHT ······ .. · .. ·· .... ····· .. ··· ...... ··· .. ·.. ·.... ·· ,,, 22.-4 ENGINE OIL FILTER ··············· ................................... 3-14
BANK ANGLE SENSOR ···· .. ············· .. ············ .. ·········· .. 4-33 ENGINE REMOVAL ......... .... ..................................... 15-4
BATIERy ············· ...................................................... '· 21-8 EPS ECU ................................................................... 24-35
BODY PANEl LOCATIONS ...................................... "' 2-3 EPS INDICATOR CIRCUIT INSPECTION ................. 24-32
BRAKE FLUiD· ····· ... ..... .......................... ................ ···· 3-20 ESP BEFORE TROUBLESHOOTING· ······ ... 23-5
BRAKE FLUID REPLACEMENT/AIR BLEEDING .... "' 18-7 EXHAUST SySTEM ·········································· .. ········· 2-14
BRAKE LIGHT SWITCH ···············································3-21 FL YWHEEUSTARTER CLUTCH .......................... -.... 13-11
BRAKE PAD/DISC ,... .......................... ·· ·· ······ ,8-8 FRONT BRAKE CALiPER ·········································· 18-12
BRAKE PADS WEAR ······················,····························3-21 FRONT BRAKE SWiTCH ·······································,··· 22-12
BRAKE SHOES WEAR ··' ........... - .. ········ ··_-_············· 3-21 FRONT CRANKCASE COVER INSTALLATION··· .. ··· 12-23
BRAKE SYSTEM ........................ ································ 3-22 FRONT CRANKCASE COVER REMOVAL········ ...... 12-6
BRAKEIT AILLlGHT · .... ... .... -........................................ 22-6 FRONT DRIVE SHAFT··············· .. ································ 19· 7
CABLE & HARNESS ROUTING ··································· 1-23 FRONT FENDER/CARRIER ··········································2-8
CAMSHAFT INSTALLATION ······································ 10-23 FRONT FINAL CLUTCH .. ····································· ···· 19-16
CAMSHAFT REMOVAL .. .. ............... . ........ 10-20 FRONT FINAL DRIVE INSTALLATION '" .................. 19-37
CENTRIFUGAL CLUTCH ············································· ,2-8 FRONT FINAL DRIVE REMOVAL·· .. ·························· 19-12
CHANGE CLUTCH ············································.. ··· ···· 12· 13 FRONT FINAL GEAR ASSEMBLY························-··· 19-33
CHARGING SYSTEM INSPECTION ····························21-9 FRONT FINAL GEAR CASE BEARING
CLUTCH SySTEM ····· ···· ············ ·· ············· ··· ··· ···3-24 REPLACEMENT ... .. .................................................... 19-30
COMBINATION METER ... ······22-6 FRONT FINAL GEAR DISASSEMBL YI
COMPONENT LOCATION INSPECTION ......... ......... ··································· 19-22
BATTERY/CHARGING SYSTEM " ................... ······ 21-2 FRONT GRILLE······························································ 2-7
ELECTRIC POWER STEERING (EPS) ··················· 24-2 FRONT MASTER CYLINDER ···································· 16-10
ELECTRIC SHIFT PROGRAM (ESP) ······················23-2 FRONT PROPELLER SHAFT ········_······· ··_··············· 19-14
ELECTRIC STARTER .......... ,......................... "'6-2 FRONT SHOCK ABSORBER ................ ··············16-26
IGNITION SySTEM ········ ....................... ··················· 5-2 FRONT WHEEL································ ·························· ,6-13
LIGHTS/METERS/SWITCHES ................................. 22-2 FUEL GAGEiFUEL LEVEL SENSOR .. ·········· .. ··········· 22-16
PGM-FI SYSTEM ...................................................... '4-2 FUEL INJECTOR································ ........................ 7-25
CONDENSER (Canada type) ········································· 5-8 FUEL LINE .................... ··········, ········ ························ ·· ·· 3-4
CONNECTOR LOCATION FUEL LINE INSPECTION ···· ................................... ···· · 7-6
ElECTRIC POWER STEERING (EPS) ··········· 24-5 FUEL PUMP RELAY ......................................... ·········· 4-29
ELECTRIC SHIFT PROGRAM (ESP)······················23-7 FUEL TANK ·································································· 7-18
PGM-FI SYSTEM ,,, ..................................... ············· 4-7 FUEL TANK COVER ······················································ 2-5
COOLANT REPLACEMENT ............................... ··-········ 8-6 FUEL TANK SIDE COVER ············································· 2-5
COOLING FAN · .... ........... ........ . .......... ········ 22-15 GEAR POSITION SWITCH ..................................... 22-14
COOLING SySTEM ······················· ·········· 3-16 GEARSHIFT LINKAGE ···· .................. .. ..................... 12-19
COOLING SYSTEM FLOW PATTERN .. ························· 8-2 GEARSHIFT SWITCH ............... ,.......................... ···· 23-29
COOLING SYSTEM TESTING ·······································8-5 GUARDS .................................................................... 3-24
CRANKCASE ASSEMBLY ···············-························· 14·21 HANDLEBAR ············· .............. •............. .. .................. 16-8
CRANKCASE BEARING ······· .................. ··················14-18 HANDLEBAR SWiTCH ······ ·· ................... ······· 22-11
CRANKCASE SEPARATION ··················· ········,· 14-7 HEADLIGHT ................................ ............. ··················22-5
CRANKSHAFTIBALANCER .................... ......... 14·15 IACV .................................................................... ····· 7-24
CYLINDER COMPRESSiON ···· ·· ············· ..... ........ 10-7 IGNITION COIL .............................. -........................... 5-7
CYLINDER HEAD ASSEMBL Y··································· ,0-14 IGNITION SWiTCH·····················,·······························22-11
CYLINDER HEAD COVER ASSEMBL YI IGNITION SYSTEM INSPECTION .............................. 5-5
INSTALLATION ··· ............................................... ········ ,0-17 IGNITION TIMING .......................................................... 5--8
CYLINDER HEAD COVER REMOVAU LUBRICATION & SEAL POINTS .. ······"""""""""""""1-19
DISASSEMBLY .......................................................... , 10-7 LUBRICATION SYSTEM DIAGRAM .............................. 9-2
CYLINDER HEAD DiSASSEMBLy ···· ························ 10-10 MAINTENANCE SCHEDULE ...... ·································3-3
CYLINDER HEAD INSTALLATION .......................... ' 10-16 Mil CIRCUIT INSPECTION ................... ····················· 4-29
CYLINDER HEAD REMOVAL .............. ····················10-9 MODEL IDENTIFICATION ............................................. 1-3
CYLINDER/PISTON INSTALLATION .... .... ................. " 11-6 MUDGUARD··································································· 2-6
CYLINDER/PISTON REMOVAL ························· .. ········ 11-4 MUDGUARD BRACKET .......... .................................... 2-13
DIODE· ·························· ............................. ······ 6-10 NUTS, BOLTS . FASTENERS" ................................ ··· 3-25
DRIVE TRAIN BOOTS ....... . ...... . ............... ········3-17 Oil PUMP ' ..................................................................... 9-4
DTCINDEX PCMlECM ·········· .. ·· .. ···· .. ························•··· •.......... ······· 4-34
ELECTRIC POWER STEERING (EPS) ......... ·······24 -16 POWER RELAY (Canada type)············ ·· ···················· 21-11
ELECTRIC SHIFT PROGRAM (ESP) ····················23-13 RADIATOR COOLANT ····· ············ ··· ········ ......... -... ······3- 15
PGM-FI SYSTEM ......... ················ 4-13 RADIATOR RESERVE TANK ...................................... 8-1 1
DTC TROUBLESHOOTING RADIATORlCOOUNG FAN ... ....................................... 8-9
ELECTRIC POWER STEERING (EPS) ' .... ·········· 24· 16 REAR AXLE INSTALLATION ........... ····················· .. ·· 20-24
INDEX
REAR AXLE REMOVAL ··············································· 20·7 ELECTRIC POWER STEERING (EPS) ..... ·.. ·.. ·.... -24-4
REAR BRAKE DRUMfSHOES ........... .. ............ .. ... ... 18·16 ELECTRIC SHIFT PROGRAM (ESP) .. .. .. ........... .. ... 23-5
REAR BRAKE LIGHT SWiTCH·· ··· .... ··· .... ··· .. ···· ...... · .. 22-13 PGM-FI SYSTEM ...... ..... .......... ..... ·.. ···· ··· .. ······ .. ······ 4·5
REAR BRAKE PEDAL···· .. · .... ··· .. ··· .. ·.. ·· .. ················ . 18-20 SYSTEM COMPONENTS
REAR FENDER COVER ········ .. · .. ······· .. ····, .... ......... ···· 2-9 ALTERNATOR/STARTER CLUTCH ······· ············· .. ,· 13-2
REAR FENDER/CARRIER ··· ··· ········ ···· ··· ····· .. ··· ···· ····· .. · 2-11 BRAKE SYSTEM .. ··· .. ,······· .. ·····,····,· ·.. ··· ·· ········· .... ··· 18-2
REAR FINAL DRIVE INSTALLATION ·· ··········· .......... 20-22 CLUTCHfGEARSHIFT LINKAGE .... ·.................. ·.. ·.. 12-2
REAR FINAL DRIVE REMOVAL ·············· .. ··· .......... '" 20-9 CRANKCASEfTRANSMISSIONfCRANKSHAFTf
REAR FINAL GEAR ASSEMBLy ····················· ·········· 20-19 BALANCER ... ........... ... .. ........... ... ........... .. ........... .... 14-2
REAR FINAL GEAR CASE BEARING CYLINDER HEADNALVE ........ ·.. ·........ ·.. ·.. ·.. ·........ ' 10-2
REPLACEMENT························ ................ ······ ····· ···· 20-17 CyLINDER/PiSTON .. ······ .... ·.... ·.. ···.... 11-2
REAR FINAL GEAR CASE OIL AND ENGINE REMOVAUINSTALLATION · .. .............. ' 15-2
DIFFERENTIAL OIL ········ .. ·· ··· .. ··········· ·· .. .. ···· .. ·· ·· ·· ·.... ·· 3·17 FRONT DRIVING MECHANISM .. · ........ .... .......... .. .. 19·2
REAR FINAL GEAR DISASSEMBL Yf FRONT WHEEUSUSPENSIONfSTEERING ,.. ·.... 16·2
INSPECTION ·.... ···· .... ···· .. ·· .. ·· .. ·· .... ··· .. ··· .. · .. ·· .. ·· ··· .. ·., .. 20-12 FUEL SYSTEM ..................................................... .. 7-2
REAR SHOCK ABSORBER .. ·· .................... .......... 17-6 REAR DRIVING MECHANiSM ·.. ···· .. ,···· ··.. ·········· .. ·· 20-2
REAR WHEEL ""'"''''''''''''' '' ''''''''''''''' ......... .... .. ..... 17·6 REAR WHEEUSUSPENSION ...................... ·.. .. .... 17-2
RECOIL STARTER (Canada type) ...... ....... ................. 13-6 SYSTEM DIAGRAM
RECTIFIER (Canada type) ..... .. ....................... -............ 5-10 BATIERYfCHARGING SySTEM .............. ·.... · ........ 21-2
REGULATOR/RECTIFIER ·,······ ····· .. ··· .... ····,· ,·· .. ········ 21-10 ELECTRIC POWER STEERING (EPS) ··.. ·· ·.. ,··,····· ·24-3
RELIEF VALVE ........................................................... 9-6 ELECTRIC SHIFT PROGRAM (ESP) ................ ,-... , 23-3
REV ERSE LOCK SySTEM .. ·.............. ·.. · .................. 3·23 ELECTRIC STARTER .. ·...... · ............................ ·.. · 6-2
SEAT ........... , ........ ,......... .. .............. ...................... ,... 2-4 IGNITION SYSTEM ......................... .... .... · .... .. .. .. ·.. · 5-2
SENSOR UNIT (MAPfTP SENSOR) .. ...... .................... 4·30 PGM-FI SySTEM ·,···· ·· ·········· ·.. ················ .... ··· .. ··· .. ··" 4-3
SERVICE INFORMATION THERMOSTAT .... ......................... ·.... ·.... ·........ ·.... · 8·8
ALTERNATOR/STARTER CLUTCH .... ,...... ,.... ... 13-4 THROTILE BODy .. ·· .... ·.. ··· .. ··· .. ··· .. ··, ..... .......... ,.. ····· 7-20
BATIERYfCHARGING SYSTEM ................ ............ 21-4 THROTILE HOUSING .... .. ...... · .. .. ·.... · ...... · .. ·, .. ·.... ·.. .. 16- 11
BRAKE SYSTEM ............. .. ............................. ......... 18-4 THROTILE OPERATION .. ' .................................... 3-4
CLUTCH/GEARSHIFT LINKAGE .......................... 12-3 TIE·ROD .... ·· .. ·· .... ·· .. ,·· .. ··· .. ···· ...... ·· .... ·· .. ···· .. ·· .. ······· ·.. · 16-40
COOLING SySTEM ···· .. ··· .... ··· .... ··· .. ··· ···,··· .. ···· .. ·····," 8-3 TIE·ROD AND JOINT BOOTS .. ·.. .. .... ·.... ·.... ·........ ·.... ·.. 3·26
CRANKCASElTRANSMISSIONfCRANKSHAFTI TIRES ... .... ,..... ............... ... ........... .. ..................... ,· .. ···· 16·13
BALANCER ·............................................................ 14·3 TOOL BOX LID ........ .. ............................... ....... · 2· 10
CYLINDER HEADNALVE .. .... · .... ·........ · ................ 10-4 TORQUE VALUES ............... ,................................. 1·13
CYLINDER/PISTON ...... ... .......... ................... .......... 11·3 TRANSMiSSiON·· ··,·· .. ··· .. ,····,··· .. ··· .. ···· .. ······ .. ··· .. ·· .. ·· ·· .. 14-8
ELECTRIC POWER STEERING (EPS)·· .. ···· .. ········· 24-4 TROUBLESHOOTING
ELECTRIC SHIFT PROGRAM (ESP)··· .... ·· .. · .. ·.... ··· 23-4 ALTERNATOR/STARTER CLUTCH .............. .. ..... 13·5
elECTRIC STARTER .... ,................... ............... ,...... 6-3 BATIERYfCHARGING SySTEM ········ .. ··· ··.. ······ ··· .. 21 -6
ENGINE REMOVAUINSTALLATlON ...... ·...... ·........ 15-3 BRAKE SYSTEM ··· .. ·.... ·····,· .... ······ .. ···· .. ····· ······ .. ··· ·· 18·6
FRAME/BODY PANElSfEXHAUST SYSTEM .......... 2·2 CLUTCH/GEARSHIFT LINKAGE ·.. ··· .. ··· .... ·· .. ··· .. ·· .. 12-5
FRONT DRIVING MECHANiSM .... ·.... ·................ ·.. 19-3 COOLING SYSTEM ·· .. ··· .. ··· .. ··· .. ········ .... ·· .. ·· .. ··· .. ····· .. 8-4
FRONT WHEEUSUSPENSIONISTEERING ,.. ... ,.... 16-4 CRANKCASElTRANSMISSIONfCRANKSHAFTf
FUEL SYSTEM ....... .................................................. 7-3 BALANCER ............. .. .. . ......... ... ......... ........ ·...... · 14·6
IGNITION SYSTEM ............. ,............................... -..... 5-3 CYLINDER HEADN ALVE .............................. ·.. ··· .. ·10-6
LlGHTSfMETERS/SWITCHES .... ............................ 22-3 CYLINDER/PISTON ··· ··· ··,·· .. ·········· .. ······ .. ··········,·,· .. 11· 3
LUBRICATION SySTEM ··· ···.. ···· ····· .. ··· .... ·· ·.... ·· .. ··· .. · 9·3 ELECTRIC STARTER ······· .. ········· .... ······ ·.. ······· .. ········ 6-4
MAINTENANCE ...... .................. .......... . 3-2 FRAME/BODY PANELSfEXHAUST SYSTEM .......... 2-2
PGM·FI SySTEM ·· .. ···· .... ·.. ·.. ··· ...... ·.... ·· .... ·•·.. ··.... ,·· .. 4-4 FRONT WHEEUSUSPENSIONfSTEERING .. ···· ··.. · 16-7
REAR DRIVING MECHANISM ...... .. .. ........ 20·3 FUEL LINE ... ............ ...... ,... ................ ···· ····· ···· ··· .. ···· 7-5
REAR WHEEUSUSPENStON ·········· .. ·· .... ··· .. ····· .. ··· 17-3 IGNITION SySTEM· ·· .... ·· .. ·, .... ·· .. ··· .. ···· ·· · .. ··· ···· .. ·.. ·· 5-4
TROUBLESHOOTING .... ··· .................................... 19-6 LUBRICATION SYSTEM ............. , ···· .. · .. · 9·3
SERVICE RULES .. ·.................................................. 1-2 REAR DRIVING MECHANiSM···.. ··········· .... ·· ·20·6
SHIFT ANGLE SENSOR ·.... ··· .. ····· .. ···· .. ··· ·.. ·· ········ .... · 23-27 REAR WHEEUSUSPENSION .. .. ........... ,............... , 17-5
SHIFT CONTROL MOTOR/REDUCTION GEARS .... 23-30 TROUBLESHOOTING INFORMATION
SIDE COVER ............... ...... ......... .. .............. 2-4 ELECTRIC POWER STEERING (EPS) ..... .. .......... 24-9
SPARK ARRESTER .. ·............ ·.. ·........................ · ........ · 3-25 ELECTRIC SHIFT PROGRAM (ESP) ..... .. ............. 23-10
SPARK PLUG ...... ·.... .. .. ·· .............. .. .......................... 3-8 PGM·Fl SYSTEM ............................................... ·.... 4-10
SPECiFiCATIONS ·.. ·· ··· .. · .............................................. 1-6 VALVE CLEARANCE ..........................................· .. ·.. · 3-9
STARTER MOTOR ............................................... ' ,···· ··6-6 VALVE GUIDE REPLACEMENT .... ·.. ·...... ·.. .. .. · ........ · 10-12
STARTER RELAY SWITCH .......... .. .. .... ........... 6-8 VALVE SEAT lNSPECTlONfREFACING .. ·.. .. .. · .. · .. ·.. · 10· 13
STEERING SHAFT (FMfFE models) ...... ·.. ·............ .... 16-27 VS SENSOR ......................... -.............. ,...................... 23-27
STEERING SHAFT HOLDER BEARING .................... 3-26 WATER PUMp .. ·.. ··· .. ···· .. ·· .... ····· ·.. ···· ···· .. ·· .. ···, ·.. ·· ·.. ··.. 8-11
STEERING SHAFTfEPS UNIT (FPMJFPE models) '" 16-32 WHEEL HUB AND KNUCKlE ·· ·· .. ··· ·.. ···· .. ····· ·.. ··· .. ·· .. ·16-16
STEERING SYSTEM .... ,..... .. ........... .. ........... ..... ... ....... 3-26 WHEElSfT1RES ......................................................... 3-25
SUB-FUEL TANK/FUEL PUMp .. · ........................ ·...... 7-13 WIRING DIAGRAMS
SUSPENSION ..... ,..... ,............................ ,..................... 3-25 FE model ··· .. ··· .. ····,··· .. ··· .. ·········· .. ······ .. ··· .. ····, ····· ···· 25-3
SUSPENSION ARM" """""" "" """"""" ,,,,,,, ,,,,, ,,, ,,,, 16-23 FM model .............. ,.... ,................... ,................ ·· .. ···25·2
SWINGARM .... . ....... . ........................................ 17-8 FPE model ·.... ·· .. ·· .... ·· .. ··.. ··· .. ·· .. ····••••·· .. ··· .. ••· "' 25-5
SYMPTOM TROUBLESHOOTING FPM model .. · .. ,.. ··· .. ·· .. ··.. ···· ·• •·.. ···• .. ··•·· .... ··· .. · ·· .. ·· ·· 25-4