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• Page 2: How To Use This Manual

  HOW TO USE THIS MANUAL This service manual describes the service procedures for the CBR954RR. Follow the Maintenance Schedule (Section 3) recommendations t o ensure that the vehicle is in peak operatlng condition. Performing the first scheduled maintenance is very important. It compen- sates for the initial wear that occurs during the break-in period.

• Page 3
  Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGl #2 or equivalent). Example: Molykote» G-n Paste manufactured by Dow Corning, U S A . Honda Moly 60 (U.S.A. only) Rocol ASP manufactured by Rocol Limited, U.K. Rocol Paste manufactured by Sumico Lubricant, Japan Use silicone grease.

• Page 4: General Information

  TOOLS SERVICE RULES 1 . Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Honda’s design specifications may cause damage t o the motorcycle. 2. Use the special tools designed for this product to avoid damage and incorrect assembly.

• Page 5
  GENERAL INFORMATION (2) The engine serial number is stamped on the right side of the upper crankcase. of the steering head. VEHICLE IDENTIFICATION NUMBER (VIN) THROTTLE BODY ID~NTIFICATION NUMBER The Vehicle Identification Number (VIN) is located o n The throttle body identification number is stamped o n the intake side of the throttle body as shown.

• Page 6: Specifications

  GENERAL INFORMATION SPECIFICATIONS GENERAL SPECIFICATIONS ITEM 2,025 mm (79.7 in) Overall length DIMENSIONS 680 mm (26.8 in) Overail width 1,135 m m (44.7 in) Overal I height 1,395 mm (54.9 in) Wheelbase (32.3 in) Seat height 383 mm (15.1 in) Footpeg height (5.1 in) Ground clearance…

• Page 7
  GENERAL INFORMATION GENERAL (Cont’d) ITEM SPECIFICATIONS PGM-FI (Programmed Fuel Injection) Throttle bore 42 mm (1.7 in) TRAIN DRIVE Clutch system Multi-plate, w e t Clutch operation system Cable operating Transmission Constant mesh, 6-speeds Primary reduction 1.520 (73/48) Final reduction 2.687 (43/16) Gear ratio 1 st 2.692 (35/13)
• Page 8
  3.7 liter (3.9 US qt, 3.3 Imp qt) A t disassembly 4.0 liter (4.2 US 3.5 Imp Pro Honda GN4 or HP4 (without molybde- n u m additives) 4-stroke oil or equivalent motor oil API service classification: SG or higher…

• Page 9: Cylinder Headnalves

  182°F) Fully open 95°C (203°F) Valve lift 8 rnm (0.3 in) minimum Recommended antifreeze Pro Honda HP Coolant or an equivalent high quality ethylene glycol antifreeze containing corrosion protection inhibitors Standard coolant concentration Unit: mm (in) CYLINDER HEADNALVES ITEM STANDARD…

• Page 10
  Unit: m m (in) ITEM STANDARD SERVICE LIMIT Clutch lever free play 20 (3/8 13/16) Clutch spring free length 48.8 (1.92) 47.4 (1.87) Clutch disc thickness 2.92 3.08 (0.115-0.121) 2.6 (0.10) Clutch plate warpage 0.30 (0.012) I.D. 25.000 25.021 (0.9843 0.9851) 25.03 (0.985) Clutch outer guide…
• Page 11
  GENERAL INFORMATION ITEM STANDARD SERVICE LIMIT Side clearance 0.05 — 0.20 (0.002 — 0.008) 0.30 (0.012) 0.03 (0.001) Main journal oil clearance 0.017 — 0.035 (0.0007 — 0.0014) 0.045 (0.0018) 31.000 — 31.025 (1.2205 — 1.2215) Gear I.D. M5, M 6 31.04 (1.222) 26.000 26.021 (1.0236…
• Page 12
  255.8 (10.07) 250.8 (9.87) Spring direction With the tapered end facing u p Fork pipe runout 0.20 (0.008) Recommended fork oil Pro Honda Suspension Fluid SS-8 Fluid level 73 (2.9) Fluid capacity 2.5 cm3 (17.3 0.08 US 18.1 0.09 Imp…
• Page 13
  GENERAL INFORMATION ITEM STANDARD SERVICE LIMIT Front Specified brake fluid Honda DOT 4 Brake Fluid Brake disc thickness 4.5 (0.18) 3.5 (0.14) Brake disc runout 0.30 (0.012) Master cylinder I.D. 17.460 — 17.503 (0.6874 — 0.6891) 17.515 (0.6896) Master piston O.D.
• Page 14
  GENERAL INFORMATION Starter motor brush length 10.0 10.5 (0.39 — 0.41) 3.5 (0.14) ITEM SPECIFICATIONS Bulbs 5 5 w 12V — 3 2 / 3 ~ p (23/8W) X 2 Front turn signal light Rear turn signal light License light Instrument light LED X Turn signal indicator…

• Page 15: Note

  GENERAL INFORMATION TORQUE VALUES TORQUE TORQUE FASTENER TYPE FASTENER TYPE 4 (0.4, 2.9) 5 m m hex bolt and nut 5 (0.5, 3.6) 5 mm screw small flange) 34 (3.5, 25) 12 (1.2, 9) 6 mm flange bolt (8 m m head, 12 m m hex bolt and nut 54 (5.5, 40) large flange)

• Page 16
  GENERAL INFORMATION ENGINE (Cont’d) TORQUE REMARKS ITEM CYLINDER HEADNALVES: Cylinder head cover bolt PAIR reed valve cover flange bolt 12 (1.2, 9) NOTE 2 NOTE 2 Breather plate flange bolt 12 (1.2, 9) Camshaft holder flange bolt 12 (1.2, 9) NOTE 5 Cylinder head sealing bolt 27 (2.8, 20)
• Page 17
  GENERAL INFORMATION ENGINE (Cont’d) ITEM REMARKS Q’TY DIA. NOTE Ignition pulse generator rotor mounting bolt ELECTRIC STARTER: Starter motor terminal nut Neutral switch Insulator clamp (Throttle body side): insulator clamp (Cylinder head side): m m (0.5 0.04 in) m m (0.3 0.04 in) Exhaust 1-14…

• Page 18: Frame

  GENERAL INFORMATION FRAME TORQUE REMARKS ITEM FRAME BODY PANELWEXHAUST SYSTEM: 26 (2.7, 20) Upper cowl stay mounting bolt 7 (0.7, 5.1) Upper cowl stay mounting bolt 1.5 (0.15, 1.1) Upper cowl pan screw 1.5 (0.15, 1.1) Lower cowl pan screw 1.5 (0.15, 1.1) Rear cowl truss screw NOTE7…

• Page 19
  GENERAL INFORMATION FRAME (Cont’d) TORQUE THREAD REMARKS ITEM Q’TY DIA. (mm) NOTE 8 Gearshift pedal link pinch bolt FRONT WHEEL/SUSPENSION/STEERING: Handlebar pinch bolt 26 (2.7, 20) NOTE 8 Handlebar weight mountign screw (1.0, 7) 13-30 Steering stem nut See page Steering stem adjusting nut Steering stem lock nut Fork top bridge pinch bolt…
• Page 20
  GENERAL INFORMATION TOOLS NOTES: 1. Equivalent commercially available in U.S.A. 2. Alternative tool. 3. Newly designed tool. 4. Not available i n U.S.A. REF. SEC. DESCRIPTION TOOL NUMBER REMARKS ECM test harness, 26P Fuel pressure gauge NOTE 2: 07406-OO4000A 07406-0040003 (U.S.A.
• Page 21
  GENERAL INFORMATION DESCRIPTION REF. SEC. TOOL NUMBER REMARKS Race remover NOTE 4 Driver attachment NOTE 4 Compression gauge attachment 07RMJ-MY50100 Fork damper holder handle Installer attachment, A U.S.A. only Installer attachment, 07VMF-MAT0200 U.S.A. only Remover attachment, A 07VMF-MAT0300 U.S.A. only Remover attachment, 07VMF-MAT0400 U.S.A.

• Page 22: Lubrication & Seal Points

  GENERAL INFORMATION LUBRICATION & SEAL POINTS REMARKS MATERIAL LOCATION Liquid sealant Crankcase mating surface (Three Bond 1207B or pressure switch threads not apply sealant to the thread m m (0.1 0.2 in) 1-19…

• Page 23
  GENERAL INFORMATION ENGINE (Cont’d) REMARKS MATERIAL LOCATION Cylinder head semi-circular cut-out Sealant Molybdenum disulfide Main journal bearing surface oil (a mixture of 1/2 Piston pin sliding surface engine oil and 1/2 Connecting rod bearing surface Connecting rod small end inner surface m o I ybdenum d isulfide Crankshaft thrust surface grease…
• Page 24
  GENERAL INFORMATION REMARKS MATERIAL LOCATION Multi-purpose grease Timing hole cap threads Each oil seal lip Locking agent Upper crankcase sealing bolt threads Lower crankcase sealing bolt threads Cam chain guide mounting bolt threads Cam pulse generator rotor bolt threads Cylinder head sealing bolt threads Cylinder head cover breather joint threads Coating width: 6.5 1 m m…
• Page 25
  Rear brake caliper slide pin surface Rear brake caliper slide pin threads Locking agent Rear master cylinder hose joint screw threads Driven sprocket stud bolt threads Handlebar grip rubber inside Honda Bond Fork fluid Fork cap O-ring Fork oil seal lips 1-22…

• Page 26: Cable & Harness Routing

  GENERAL INFORMATION CABLE & HARNESS ROUTING BANK ANGLE SENSOR RIGHT TURN ~ I G N A L HEAD LIGHT CONNECTOR (Hi) CON N ECTORS HEAD LIGHT CONNECTOR 1-23…

• Page 27
  GENERAL INFORMATION CLUTCH CABLE MAIN HORN WIRE 1-24…
• Page 28
  GENERAL INFORMATION FRONT 1-25…
• Page 29
  GENERAL INFORMATION ‘ I -26…
• Page 30
  GENERAL INFORMATION EXCEPT CALIFORNIA TYPE: STARTER MOTOR’GROUND CABLE 1-27…
• Page 31
  GENERAL INFORMATION CALIFORNIA TYPE: PAIR CONTROL SOLENOID VALVE 2P (NATURAL) CONNECTOR GROUND 1-28…
• Page 32
  GENERAL INFORMATION LOWER FAST UNIT 1-29…
• Page 33
  GENERAL INFORMATION THROTTLE STOP CONTROL CABLE FUEL TANK AIR VENT HOSE EGCV C O N T ~ O L CABLES 1-30…
• Page 34
  GENERAL INFORMATION PAIR SUCTION HOSE SIPHON HOSE FUEL TANK AIR VENT HOSE FUEL TANK OVERFLOW IGNITI O N PULSE GENERATOR WIRE RESERVOIR TANK OVERFLOW HOSE 1-31…
• Page 35
  GENERAL INFORMATION INJECTOR CONNECTORS 1-32…
• Page 36
  GENERAL INFORMATION IAT SENSOR H CONNECTOR KE VALVE SERVO MOTOR CONNECTOR MAP SENSOR SPEED SENSOR VACUUM HOSE CONNECTOR FUEL HOSE 1-33…
• Page 37
  GENERAL INFORMATION REAR BRAKE LIGHT SWITCH CON N ECTOR BATTERY NEGATIVE FUSE ECM 26P (LIGHT GRAY) CONNECTOR ECM 26P (BLACK) CON N ECTOR ALTERNATOR 3P (WHITE) CONNECTOR 1-34…
• Page 38
  GENERAL INFORMATION HEADLIGHT RELAY CONNECTOR BOOT: REAR TURN SIGNAL LIGHT CONNECTOR LICENSE LIGHT CONNECTOR CONNECTOR REAR BRAKE LIGHT SWITCH WlRE SENSOR WIRE (California type only) REAR BRAKE LIGHT SWITCH 1-35…
• Page 39
  GENERAL INFORMATION REAR BRAKE HOSE RESERVOIR HOSE REAR BRAKE SWITCH 1-36…

• Page 40: Crankcase Emission Control System

  Carbon monoxide does not react in the same way, but it is toxic. Honda Motor Co., Ltd. utilizes lean injection settings as well as other systems, t o reduce carbon monoxide and hydrocarbons. CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped with a closed crankcase system t o prevent discharging crankcase emissions into the atmosphere.

• Page 41
  GENERAL INFORMATION EXHAUST EMISSION CONTROL SYSTEM (SECONDARY AIR SUPPLY SYSTEM) The exhaust emission control system is composed of a lean fuel injection setting, and no adjustments should be made except idle speed adjustment with the throttle stop screw. The exhaust emission control system is separate from the crankcase emis- sion control system.
• Page 42
  GENERAL INFORMATION EVAPORATIVE EMISSION CONTROL SYSTEM (CALIFORNIA TYPE ONLY) This model complies with CARB evaporative emission requirements. Fuel vapor from the fuel tank is routed into the evaporative emission (EVAP) canister where it is absorbed and stored while the engine is stopped. When the engine is running and the evaporative emission (EVAP) purge control solenoid valve is open, fuel vapor in the EVAP canister is drawn into the engine through the throttle body.
• Page 43
  GENERAL INFORMATION EMISSION CONTROL INFORMATION EMISSION CONTROL INFORMATION LABEL LABELS An Emission Control Information Label is located on the storage compartment as shown. The seat must be removed t o read it. It gives base tune-up specifications. N C O ~ T R O L I N FO R MATI EM I LABEL (Canada only) VACUUM HOSE ROUTING DIAGRAM…
• Page 44
  FRAME/BODY PANELS/EXHAUST SYSTEM BODY PANEL LOCATIONS COWL COVER D U C T…

• Page 45: Service Information

  EL EXHAUST SYST 2, FRAME/BODY P BODY PANEL LOCATIONS LOWER COWL SERVICE INFORMATION 2- 1 INNER MIDDLE COWL TROUBLESHOOTING WINDSCREEN SEAT FRONT FENDER PILLION SEAT/REAR COWL REAR FENDER DUCT COVER SEAT RAIL 2-1 1 UPPER COWL MUFFLER/EXHAUST PIPE 2-1 3 SERVICE INFORMATION GENERAL This section covers removal and installation of the…

• Page 46
  FRAME/BODY PANELS/EXHAUST SYSTEM SEAT REMOVAL BOLTS Remove the t w o seat mounting bolts behind the seat. COLLARS Slide the seat back and then off. Remove the mounting collars. I NSTALLATI 0 N Install the collars into the seat bottom plate as shown. Align the seat hook with the fuel tank rear bracket and install the seat.
• Page 47
  FRAME/BODY PANELS/EXHAUST SYSTEM Remove the t w o trim clips. Remove the screws, special screws, setting bolts, COI- lars and spacers. Push down the pillion seat mounting bracket and SETTING BOLT SCREWS carefully spread the bottom of both sides of the rear cowl, then remove from the seat rail.
• Page 48
  FRAME BODY PANELS/EXHAUST SYSTEM Connect the tail light connector. Install the rear cowl over the seat rail being careful not to damage the wire harness. SETTING BOLT SCREWS Install the spacers, setting collars and setting bolts. Install the special screws and truss screws. COLLAR Install the t r i m clips.
• Page 49
  UPPER COWL BOLTS REMOVAL Remove the duct cover (page 2-41. Remove the socket bolts and rearview mirrors. Disconnect the turn signal light connectors. Remove the nuts, set plates and turn signal lights from the inner middle cowl. Remove the t r i m clips. Remove the windscreen-to-upper cowl bracket screws.
• Page 50
  IN STALL AT10 N TURN SIGNAL LIGHT Connect the headlight connectors t o the headlight sockets o n the upper cowl. Install the upper cowl onto the upper cowl stay while aligning the headlight unit bosses w i t h the upper cowl stay grommets.

• Page 51: Lower Cowl

  LOWER COWL Remove the t r i m clip f r o m the inner middle cowl. Remove the four t r i m clips from the lower cowl. Remove the upper cowl-to-lower cowl screws. Remove the lower cowl mounting screw, special bolts and then remove the lower cowl.

• Page 52: Front Fender

  WINDSCREEN WINDSCREEN SCREWS Remove the rearview mirrors (page 2-5). Remove the screws, n y l o n washers and rubber washers. Remove the windscreen b y pulling out the setting nuts f r o m the upper cowl bracket. Windscreen mounting fasteners are plastic screws. Do not overtighten the screws.

• Page 53: Rear Fender

  FRAME/BODY PANELS/EXHAUST SYSTEM REAR FENDER REAR FENDER A REMOVAL/ INSTALLATION Remove the rear cowl (page 2-2). CON N ECTORS Disconnect the turn signal light connectors and license light connector. Remove the nuts, set plates and turn signal lights. Remove the nut and reflector, then remove rea fender A.

• Page 54
  Disconnect the turn signal connectors and license light connector. CON N E ~ T O R S Remove the headlight relay, engine stop relay and fan HEADLIGHT RELAY FAN CONTROL RELAY control relay f r o m the rear fender. ENGINE STOP RELAY Remove the reflector mounting nut.

• Page 55: Rear Fender Installation

  REAR FENDER INSTALLATION CONNECTORS Install the rear fender aligning its lower groove w i t h the seat rail brace. Connect the license light connector and turn signal connectors. Install the removed parts i n the reverse order of removal. SEAT RAIL REMOVAL…

• Page 56
  Remove the socket bolts and left pillion bracket. Remove the bolts and regulator/rectifier. Remove the fuel tank rear bracket bolts. Remove the seat rail mlounting 8 mm bolts, 10 mm I N STALL AT1 0 N 39 N * m (4.0 kgf-m, 29 Ibf-ft) 39 N — m 39 N-rn (4.0 kgf-m, 29 Ibf-ft) PILLION FOOTPEG…
• Page 57
  boll :s a md Install the seat rail and tighten the mounting nuts t o the specified torque. TORQUE: m m bolt: 39 N . m (4.0 nut: 39 N-m (4.0 kgf-m, 29 Install the regulator/rectifier, tighten the bolts. Install the left pillion footpeg bracket and tighten the socket bolts t o the specified torque.
• Page 58
  Remove the gasket. Disconnect the sensor 4P (Natural) connector. Remove the sensor wire f r o m the frame. Remove the sensor wire clamp. Caiifornia :ype CLAMP COLLARS Remove the right step guard mounting bolts and col- lars. Rele sensor wire f r o m the right step guard. SENSOR WIRE RIGHT STEP GUARD 2-1 4…
• Page 59
  Remove the t w o bolts and EGCV (Exhaust Gas Control Valve) pulley cover. Disconnect the EGCV control cables f r o m the pulley. CONTROL CABLES PULLEY Remove the exhaust pipe joint nuts. Remove the following: — Exhaust pipe mounting bolt/nut — Washer — Collar — Exhaust pipe…
• Page 60
  FRAME/BODY PANELS/EXHAUST SYSTEM INSTALLATION Non-California type: 12 N-m (1.2 kaf-m, 12 N*m (1.2’kgf*rn, 9 Ibf-ft) EXH A U S T PIPE California type: 2-16…
• Page 61
  Install the exhaust pipe mounting rubber and collar into the lower bracket hole. NTI N G RU BB Check the protrusion of the exhaust pipe stud bolt (page 1-14). Install the n e w exhaust pipe gaskets onto the exhaust ports of the cylinder head.
• Page 62
  FRAME/BODY PANELS/EXHAUST SYSTEM Connect the EGCV control cables to the cable pulley. CONTROL CABLES PUL L EY the bolts t o Install the EGCV pulley cover and tighten the specified torque. TORQUE: 12 N-m (1.2 kgfsm, 9 Ibf-ft) Clamp the 0 2 sensor wire to the right step guard. Install the rear master cylinder, collars and right step guard, then tighten the mounting bolts.
• Page 63
  Route the 0 2 sensor wire into the frame. Connect the sensor 4P (Natural) connector. Install the new gasket onto the exhaust pipe shown. Install the muffler. Temporarily install the muffler mounting bolt/nut and muffler joint nuts. Tighten all of the muffleriexhaust pipe mounting tighten exhaust pipe ~ o i n t nuts…
• Page 64
  3. MAINTE DRIVE CHAIN 3-20 SERVICE INFORMATION BRAKE FLUID 3-24 MAINTENANCE SCHEDULE 3-25 BRAKE PAD WEAR FUEL LINE BRAKE SYSTEM 3-25 THROTTLE OPERATION 3-26 BRAKE LIGHT SWITCH AIR CLEANER HEADLIGHT AIM 3-27 SPARK PLUGS 3-27 CLUTCH SYSTEM VALVE CLEARANCE 3-10 SIDE STAND 3-28 ENGINE OIL/OIL FILTER…

• Page 65: Torque Values

  At oil filter change 3.7 liter (3.9 US qt, 3.3 Imp qt) 40 — 50 mm (1.6 — 2.0 in) Drive chain slack Recommended brake fluid Honda DOT 4 Brake Fluid Rear Rear Front Pilot SPORT E Pilot SPORT E…

• Page 66
  5-93 CONTROL CABLE EVERY 500 mi (800 km): I, L 3-20 Should be serviced b y an authorized Honda dealer, unless the owner has proper tools and service data and is mechani- cally qualified. In the interest of safety, w e recommend these items be serviced only b y an authorized Honda dealer.
• Page 67
  MAINTENANCE FUEL Remove the front fuel tank mounting bolts and washers. Remove the right and left duct cover mounting bolts. Remove the seat and then remove the fuel tank sup- After fueiiine FUEL TANK SUPPORT ROD inspection, mstaii port rod f r o m the seat. the rod ends into the seat properly as shown…

• Page 68: Throttle Operation

  MAINTENANCE Check the fuel lines for deterioration, damage or leak- age. Replace the fuel line if necessary. Install the fuel tank in the reverse order of removal. THROTTLE OPERATION Check for smooth throttle grip full opening and auto- matic full closing in all steering positions. Check the throttle cables and replace them if they are deteriorated, kinked or damaged.

• Page 69: Air Cleaner

  MAINTENANCE Major adjustments are made with the lower adjuster. Remove the air cleaner housing (page 5-64). Adjust the free play by loosening the lock nut and turning the adjuster. After adjustment, tighten the lock nut securely. Recheck the throttle operation. Replace any damaged parts, if necessary.

• Page 70
  Remove the radiator lower mounting b o l t h u t . Remove t h e radiator upper m o u n t i n g b o l t a n d washer. Remove the radiator grommet f r o m the frame boss by moving t o the right, then move the radiator forward.
• Page 71
  MAINTENANCE Remove the spark plug using the equipped spark plug wrench or an equivalent. Inspect or replace as described i n the maintenance schedule. INSPECTION ELECTRODE Check the following and replace if necessary (recom- mended spark plug: page 3-2) Insulator for damage Electrodes for wear Burning condition, coloration the electrodes are contaminated with accumulated…
• Page 72
  MAINTENANCE Reinstall the spark plug in the cylinder head and hand tighten, then torque to specification. TORQUE: 12 N-m (1.2 If using the new plug, install as follows: Install and hand tighten the new spark plug, then tighten it about 1/2 turn after the sealing washer con- tacts the seat of the plug hole.
• Page 73
  MAINTENANCE Install a n d tighten the radiator lower m o u n t i n g Connect the fan motor wire (Black) connector. Install the lower cowl (page 2-7). VALVE CLE CHAIN TENSIONER LIFTER BOLT INSPECTION inspect and adjust the valve Remove t h e cylinder head cover (page 8 the engine is coid…
• Page 74
  MAINTENANCE Remove the timing hole cap and O-ring. Turn the crankshaft clockwise, and align the «T» mark o n the ignition pulse generator rotor with t h e index mark on the right crankcase cover. The timing marks («IN» and «EX») on the cam sprock- ets must be flush with the cylinder head surface and facing outward as shown.
• Page 75
  MAINTENANCE Turn the crankshaft clockwise 1/2 turn (180″), align the index line o n the ignition pulse generator rotor so that it is facing up as shown. Check the valve clearance for the No.2 and No.4 cylin- Record the ciear- ance for each der exhaust valves using a feeler gauge.
• Page 76
  MAINTENANCE Turn the crankshaft clockwise turn (ISO»), and align the index line on the ignition pulse generator rotor so facing up as shown. Check the valve clearance for the cylin- Record the dear- der exhaust valves using a feeler gauge. vaive for refer- VALVE CLEARANCE: EX: 0.27…
• Page 77
  MAINTENANCE Measure the shim thickness and record it. SHIM Sixty-five different shim thicknesses Calculate the n e w shim thickness using the equation from 1200 New shim thickness B: Recorded valve clearance C: Specified valve clearance D: Old shim thickness Make sure o f the correct shim thickness b y measur- ing the shim w i t h a micrometer.

• Page 78: Oil Level Inspection

  Fill the recommended engine oil up t o the upper level line. RECOMMENDED ENGINE OIL: Other viscosities shown In the Pro Honda GN4 or HP4 (without molybdenum chart may be additives) $-stroke oil or equivalent motor oil used when the API service classification: SG or higher…

• Page 79
  MAINTENANCE Remove the drain bolt and drain the oil completely Remove and discard the oil filter cartridge using the special tool. TOOL: Oil filter wrench Check that the sealing washer on the drain bolt is in good condition, and replace if necessary. Install and tighten the drain bolt.
• Page 80
  MAINTENANCE filter and tighten t o the specified Install the new oil torque. TOOL: Oil filter wrench (2.7 kgf-m, 20 I b f W TORQUE: 26 N-m Fill the crankcase with the recommended engine oil. OIL CAPACITY: 3.5 liter (3.7 US qt, 3.1 Imp qt) at draining 3.7 liter (3.9 US qt, 3.3 Imp qt) at oil filter change Install the oil filler cap.
• Page 81
  The level should be between the «UPPER» and «LOWER» level lines. If necessary, add the recommended coolant. RECOMMENDED ANTIFREEZE: Pro Honda Coolant an equivalent high quali- ty ethylene glycol antifreeze containing corrosion protection inhibitors. LOWER LEVEL LINE Remove the lower cowl (page 2-71.
• Page 82
  MAINTENANCE SECONDARY AIR SUPPLY SYSTEM PAIR REED VALVE This model is equipped with a built-in secondary air supply system. The pulse secondary air supply system is located on the cylinder head cover. The secondary air supply system introduces fil- tered air into exhaust gases in the exhaust port. The secondary air is drawn into the exhaust port whenever there are negative pressure pulses in the exhaust system.

• Page 83: Drive Chain

  MAINTENANCE DRIVE CHAIN Never inspect and Turn the ignition switch t o ”OFF”, place the motorcy- cle on its side stand and shift the transmission into neutral. Check the slack in the drive chain lower run midway between the sprockets. 2.0 in) CHAIN SLACK: rnrn (1.6…

• Page 84: Cleaning And Lubrication

  MAINTENANCE CLEANING AND LUBRICATION NON-FLAMMABLE OR HIGH FLASH-POINT SOLVENT Clean the chain with non-flammable or high flash- point solvent and wipe dry. Be sure the chain has dried completely before lubri- cating. Inspect the drive chain for possible damage or wear. Replace any chain that has damaged rollers, loose fit- ting links, or otherwise appears unserviceable.

• Page 85
  MAINTENANCE REPLACEMENT This motorcycle uses a drive chain w i t h a staked mas- ter link. Loosen the drive chain (page 3-20). Assemble the special tool as shown. turer’s instruction (U.S.A. only) DRIVE CHAIN-TOOL S ET Locate the crimped pin ends of the master link f r o m MASTER LINK the outside the chain, and remove the link w i t h the…
• Page 86
  MAINTENANCE Route the drive chain through the swingarm as shown. O-RINGS PLATE Never reuse the old drive chain, master link, master link plate and O-rings. Assemble the new master link, O-rings and plate. insert the master inside of the drive chain, and instaii the plate with the identification mark…

• Page 87: Front Brake

  MAINTENANCE Make sure the pins are staked properly by measuring SLIDE CALIPER the diameter of the staked area using a slide caliper. DIAMETER OF THE STAKED AREA: DID: 5.50 5.80 (0.217 0.228 5.45 5.85 mm (0.215 0.230 After staking, check the staked area of the master link drive with chain…

• Page 88: Brake Pad Wear

  MAINTENANCE BRAKE PAD WEAR WEAR INDICATOR FRONT BRAKE PADS Check the brake pads for wear. Replace the brake pads if either pad is w o r n t o the bottom o f the wear limit groove. Refer t o page 15-8 for brake pad replacement. REAR BRAKE PADS Check the brake pads for wear.

• Page 89: Brake Lever Adjustment

  MAINTENANCE BRAKE LEVER ADJUSTMENT The distance between the top of the brake lever and the grip can be adjusted turning the adjuster. brake /ever with the inaex number on the adiuster BRAKE PEDAL HEIGHT ADJUSTMENT Loosen the lock nut and turn the push rod until the correct pedal height obtained.

• Page 90
  MAINTENANCE HEADLIG HT AIM Place the motorcycle o n a level surface. light beam as specified by Iocai Adjust the headlight beam vertically by turning the laws and regula- vertica I beam adjuster. tions A clockwise rotation moves the beam u p and counter- clockwise rotation moves the beam down.

• Page 91: Side Stand

  MAINTENANCE SIDE STAND Support the motorcycle o n a level surface. Check the side stand spring for damage or loss of tension. Check the side stand assembly for smooth movement and lubricate the side stand pivot if necessary. Check the side stand ignition cut-off system: — Sit astride the motorcycle and raise the side stand.

• Page 92
  MAINTENANCE COMPRESSION AND REBOUND DAMPING ADJUSTERS Do not turn the adjuster screws more than the given positions or the adjusters may be damaged. Always start on full hard when adjusting the damping. Be sure that the rebound and compression adjusters are firmly located in a detent, and not between posi- tions.

• Page 93: Rear Suspension Adjustment

  MAINTENANCE Check for w o r n swingarm bearings b y grabbing the rear swingarm and attempting t o move the swingarm side t o side. Replace the bearings if any looseness is noted. Check the action of the shock absorber b y compress- ing it several times.

• Page 94
  MAINTENANCE Turn the rebound adjuster clockwise until stops, then turn the adjuster counterclockwise. REBOUND ADJUSTER STANDARD POSITION: turns from full hard BOLTS, FASTE Check that all chassis nuts and bolts are tightened t o their correct torque values (page 1-12). Check that all safety clips, hose clamps and cable stays are in place and properly secured.

• Page 95: Steering Head Bearings

  MAINTENANCE STEERING HEAD BEARINGS Check that the control cables do not interfere with handlebar rotation. Support the motorcycle securely and raise the front wheel off the ground. Check that the handlebar moves freely from side to side. If the handlebar moves unevenly, binds, or has verti- cal movement, inspect the steering head bearings (Section 13).

• Page 96
  LUBRICATION SYSTEM DIAGRAM CAMSHAFTS CRANK S HAFT OIL FILTER CARTRIDGE PUMP OIL STRAINER…
• Page 97
  A t disassembly 4.0 liter (4.2 US 3.5 Imp qt) Recommended engine oil Pro Honda GN4 or HP4 (without molybde- n u m additives) 4-stroke oil or equivalent motor oil API service classification: SG or higher JASO T 903 standard:…

• Page 98: Lubrication System

  LUBRICATION SYSTEM TORQUE VALUES 29 N * m (3.0 kgf-m, 22 Ibfeft) Oil drain bolt 74 N — m (7.5 kgf-m, 54 lbf-ft) Oil cooler mounting bolt CT bolt 8 N * m (0.8 kgf-m, 5.8 Ibf*ft) Oil pump assembly flange bolt Apply a locking agent t o the threads.

• Page 99: Oil Pressure Inspection

  LUBRICATION SYSTEM OIL PRESSURE INSPECTION Check the oil level (page 3-15). indicator light Warm u p the engine t o normal operating temperature Sto’p the engine and remove the crankcase sealing system before bolt. checking the pressure. Connect an oil pressure gauge and attachment t o the GAUGE crankcase.

• Page 100
  LUBRICATION SYSTEM Remove the pressure relief valve and O-ring. Remove the oil strainer and gasket. Clean the oil strainer screen. INSPECTION Check the operation of the pressure relief valve by pushing o n the piston. Disassemble the relief valve by removing t h e snap ring.

• Page 101: Oil Pump

  Apply oil t o the new O-ring and install it onto the relief valve. Install the relief valve into the crankcase. Clean the oil pan mating surface thoroughly. Apply Three Bond 12078 or an equivalent to the mat- Do not apply ing surface.

• Page 102
  LUBRICATION SYSTEM and oil three flai Remove the DISASSEMBLY ASS E M B LY BOLT DOWEL PINS Remove the dowel pins. Remove the oil pump assembly bolt and p u m p cover. OIL PUMP COVER Remove the thrust washer, drive pin, oil p u m p shaft, INNER ROTOR OUTER ROTOR outer rotor and inner rotor from the oil p u m p body.
• Page 103
  LUBRICATION SYSTEM Measure the pump body clearance. SERVICE LIMIT: 0.35 mm (0.014 Measure the side clearance using a straight edge and feeler gauge. SERVICE LIMIT: 0.10 mm (0.004 ASSEMBLY PINS INNER ROTOR OUTER ROTOR (0.8 kif-rn, 5.8 I b f W…
• Page 104
  LUBRICATION SYSTEM Install the outer and inner rotors into the oil p u m p INNER ROTOR OUTER ROTOR rotor with its body. punch mark facing Install the oil pump shaft through the inner rotor and pump oil pump body. cover.

• Page 105: Oil Cooler

  LUBRICATION SYSTEM Apply oil t o the clutch outer guide, oil p u m p drive sprocket, driven sprocket and drive chain. Install the clutch outer guide, driveidriven sprocket pump driven and drive chain as an assembly. sprocket wfth «OUT» mark fac- ing outward Apply a locking agent t o the oil p u m p driven sprocket…

• Page 106
  LUBRICATION SYSTEM INSTALLATION WATER HOSES O I L F I L T ~ R CARTRIDGE 26 N — m (2.7 kgf-m, 20 I b f W LOCK WASHER Coat a new O-ring with engine oil and install it into the oil cooler groove.
• Page 107
  LUBRICATION SYSTEM Tighten the oil cooler mounting bolt t o the specified torque. TORQUE: 74 N-m (7.5 Connect the oil cooler water hoses, and tighten the hose bands securely. Install the oil filter cartridge and fill the crankcase w i t h t h e recommended oil (page 3-16).
• Page 109
  5-81 MAP SENSOR SERVICE INFORMATION 5-82 IAT SENSOR TROUBLESHOOTING 5-82 ECT SENSOR SYSTEM LOCATION 5-83 CAM PULSE GENERATOR SYSTEM DIAGRAM 5-84 TP SENSOR PGM-FI (PROGRAMMED FUEL INJECTION) SYSTEM 5-85 BANK ANGLE SENSOR PGM-FI SELF-DIAGNOSIS MALFUNC- 5-86 ENGINE STOP RELAY TION INDICATOR LAMP (MIL) 5-87 5-10 ECM (ENGINE CONTROL MODULE)
• Page 110
  FUEL SYSTEM (Proarammed Fuel Iniection) not apply commercially available carburetor cleaners t o the inside of the throttle bore, which is coated with molybde- num. Do not snap the throttle valve from full open t o full closed after the throttle cable has been removed. It may cause incorrect idle operation.
• Page 111
  FUEL SYSTEM (Programmed Fuel Injection) TORQUE VALUES 23 N * m (2.3 kgf-m, 17 I b f W ECT (Engine Coolant Ternperature)/thermo sensor See page 1-14 Throttle body insulator band screw 3 N-m (0.35 kgfom, 2.5 I b f W Throttle cable bracket mounting screw Fuel pipe mounting bolt Pressure regulator mounting bolt…
• Page 112
  SYSTEM FUEL (Programmed Fuel Injection) SYSTEM LOCATION PAIR SOLENOID VALVE TP SENSOR IGNITION PULSE GENERATOR FULL NAME ABBREVIATIONS Manifold absolute Dressure sensor Throttle position sensor Intake air temperature sensor Engine coolant temperature sensor Engine control module…
• Page 113
  FUEL SYSTEM (Programmed Fuel Injection) SYSTEM DIAGRAM Cam pulse generator Engine stop relay PAIR check valve Main fuse B (20A) ECT sensor Engine stop switch Ignition pulse generator Sub-fuse (10A) Water temperature Ignition switch Fuel cut-off relay Main fuse A (30A) Fuel p u m p Bank angle sensor Vehicle speed sensor…
• Page 114
  FUEL SYSTEM (Proclrarnrned Fuel Iniection) PGM-FI (PROGRAMMED FUEL MALFUNCTION INDICATOR LAMP (MIL) INJECTION) SYSTEM SELF-DIAGNOSTIC PROCEDURES Place the motorcycle o n its side stand. Start the engine and let it idle. If the malfunction indicator lamp (MIL) does not light The malfunction indicator lamp or blink, the system has n o memory of problem data.
• Page 115
  FUEL SYSTEM (Programmed Fuel Injection) Turn the ignition switch to «ON» and engine stop switch to «RUN». If the ECM has no self diagnosis memory data, the MIL will illuminate, when you turn the ignition switch to «ON». If the ECM has self diagnosis memory data, the MIL will start blinking, when you turn the ignition switch to «ON».
• Page 116
  FUEL SYSTEM (Programmed Fuel Injection) PEAK VOLTAGE INSPECTION PROCE- 3P (BLACK) CONNECTOR DURE Use this procedure for the ignition pulse generator and cam pulse generator inspection. Check all system connections before inspection. If the system is disconnected, incorrect peak voltage might be measured.
• Page 117
  FUEL SYSTEM (Programmed Fuel Injection) Disconnect the ECM 26P (Black) and 26P (Light gray) connectors f r o m the unit. 26P (BLACK) CONNECTOR Connect the ECM test harnesses between the main wire harness and the ECM. TOOL: test harness, (two required) Install the battery and connect the positive terminal, then connect the negative terminal.
• Page 118
  FUEL SYSTEM (Programmed Fuel Iniection) PGM-FI SELF-DIAGNOSIS MALFUNCTION INDICATOR LAMP (MIL) FAILURE CODES The PGM-FI malfunction indicator lamp (MIL) denotes the failure codes (the number of blinks from 0 t o 35). The MIL has t w o types of blinks, a long blink and short blink. The long blink lasts for 1.3 seconds, the short blink lasts for 0.5 seconds. When t w o long blinks occur, and one short blink, that problem code is 21 (two long blinks 20 blinks, one short blink blink).
• Page 119
  FUEL SYSTEM (Programmed Fuel Injection) Refer t o Symptoms Number of PGM-FI Causes (Fail-safe contents) MI L bli n ks Engine operates normally Loose or poor contact on vehicle speed sensor connector 5-24 Open or short circuit in vehicle speed sensor connector Blinks Faulty vehicle speed sensor…
• Page 120
  FUEL SYSTEM (Programmed Fuel Injection) BLINK PGM-FI MIL (MAP SENSOR) Does not blink Connect the MAP sensor connector. Loose or poor contact o n the MAP sensor connec- Place the motorcycle o n its side stand. Start the engine and check that the MIL blinks. blink Turn the ignition switch t o «OFF».
• Page 121
  FUEL SYSTEM (Programmed Fuel Injection) Out of range Open or short circuit i n Light greenpellow wire Measure the voltage between the terminals of Loose or poor contact on the ECM connectors the wire harness side. Connection: Light green/Yellow Standard: 4.75 5.25 Voltage exists Turn the ignition switch t o «OFF».
• Page 122
  FUEL SYSTEM (Programmed Fuel Injection) PGM-FI MIL 2 BLINKS (MAP SENSOR) Turn the ignition switch to «OFF». Out of range Disconnect the vacuum hose from the MAP sen- Check the hose installation sor. Connect the vacuum gauge between the throttle body and the MAP sensor using a 3-way joint.
• Page 123
  FUEL SYSTEM (Programmed Fuel Injection) range Faulty MAPsensor «ON». Turn the ignition switch Measure the voltage at the test harness termi- nals (page 5-9). Measure the voltage at the test harness termi- nals (page 5-91. Connection: Standard: 2.7 maximum Voltage exists Replace the ECM with a new one, and inspect again…
• Page 124
  FUEL SYSTEM (Programmed Fuel Injection) PGM-FI MIL 7 BLINKS (ECT SENSOR) Turn the ignition switch to «OFF». Loose or poor contact o n the ECT sensor connec- Connect the ECT sensor connector. Place the motorcycle o n its side stand. Turn the ignition switch t o «ON».
• Page 125
  FUEL SYSTEM (Programmed Fuel Injection) range Loose or poor contacts on the ECM connector Measure the voltage between the ECT sensor connector terminal of the wire harness side and ground. Connection: Pink/White Ground Standard: 4.75 5.25 V Voltage exists Out of range Measure the voltage at the ECT sensor connec- Open or short circuit i n Green/Orange wire Loose or poor contacts o n the ECM connector…
• Page 126
  FUEL SYSTEM (Programmed Fuel Injection) PGM-FI MIL 8 BLINKS (TP SENSOR) Turn the ignition switch t o «OFF». Disconnect the TP sensor 3P connector. Check for loose or poor contact on the TP sen- sor connector. Place the motorcycle on its side stand. Start the engine and check that the MIL blinks.

• Page 127: Fuel System

  FUEL SYSTEM (Programmed Fuel Injection) Out of range Open or short circuit i n Greedorange wire Loose or poor contact on the ECM connectors of the wire harness side. Connection: Yellow/Red Standard: 4.75 5.25 V Turn the ignition switch to ”OFF”. Disconnect the ECM connectors.

• Page 128
  FUEL SYSTEM (Programmed Fuel Injectian) Connect the test harness t o the ECM connec- Open or short circuit in Redflellow wire Check for continuity between the test harness terminal and the sensor connector terminal. Connection: Red/Yellow Standard: Continuity Connect the sensor connector.
• Page 129
  FUEL SYSTEM (Programmed Fuel Injection) Normal Replace the ECM with a new one, and inspect it Turn the ignition switch t o «ON». again Measure the voltage at the test harness termi- nals. Connection: B22 Standard: *0.4 (throttle fully closed) 4.8 V (throttle fully open)
• Page 130
  FUEL SYSTEM (Programmed Fuel Injection) Turn the ignition switch to «OFF» Disconnect the IAT sensor 2P connector. Check for loose or poor contact on the IAT sen- sor connector. Does not blink Connect the IAT sensor 2P connector. Loose or poor contact on the IAT sensor connector Place the motorcycle on its side stand.
• Page 131
  FUEL SYSTEM (Programmed Fuel Injection) range Open or short circuit in GrayiBlue wire Loose or poor contact on the ECM connectors the wire harness side. Connection: Ground Standard: 4.75 5.25 Out of range Open or short circuit in Greedorange wire Measure the voltage between the terminals Loose or poor contact on the ECM connectors the wire harness side.
• Page 132
  FUEL SYSTEM (Programmed Fuel Injection) eck for loose or poor contact on the vehicle Does not blink Loose or poor contact on the vehicle speed sensor Connect the vehicle connector Start the engine. With the side stand and keep the engine rev more than 5,000 r p m about 20 seconds or more.
• Page 133
  FUEL SYSTEM (Programmed Fuel Injection) Connect the vehicle speed sensor connector. Disconnect the ECM connectors. Connect the test harness to the wire harness connectors. Abnormal Support the motorcycle securely and place the Open or short circuit in Pink/Green wire rear wheel off the ground. Shift the transmission into gear.
• Page 134
  FUEL SYSTEM (Programmed Fuel Injection) PGM-FI MIL 12 BLINKS (No.1 INJECTOR) Turn the ignition switch to «OFF». Disconnect the No.1 injector 2P connector. Check for loose or poor contact on the No.1 injector 2P connector. Loose or poor contact on the No.1 injector connec- Connect the No.1 injector 2P connector.
• Page 135
  FUEL SYSTEM (Programmed Fuel Injection) Continuity Faulty No.1 injector Check for continuity between the No.1 injector and ground. Connection: Ground Standard: continuity Out of range Turn the ignition switch t o «ON». Measure the voltage between the No.1 injector connector the wire harness side and ground.
• Page 136
  FUEL SYSTEM (Programmed Fuel Injection) Disconnect the ECM connectors. Connect the test harness t o the wire harness connectors. Out of range Measure the resistance at the test harness ter- Open circuit in BlackWhite and/or P i n W e l l o w wire minals.
• Page 137
  FUEL SYSTEM (Programmed Fuel Injection) PGM-FI MIL BLINKS (No.2 INJECTOR) Check for loose or poor contact on the injector 2P connector. Does not blink Connect the No.2 injector 2P connector. Loose or poor contact o n the N o 2 injector connec- Place the motorcycle on its side stand.
• Page 138
  FUEL SYSTEM (Programmed Fuel Injection) Continuity Faulty No.2 injector Check for continuity between the No.2 injector and ground. Connection: Ground Standard: continuity No continuity Out of range Open or short circuit in Blackwhite wire Turn the ignition switch t o «ON». Measure the voltage between the No.2 injector connector of the wire harness side and ground.
• Page 139
  FUEL SYSTEM (Programmed Fuel Injection) Disconnect the connectors. Connect the test harness t o the wire harness connectors. Out of range Open circuit i n Blackwhite and/or Pink/Blue wire Measure the resistance at the test harness ter- minals. Connection: A16 Standard: 9 Normal Continuity…
• Page 140
  FUEL SYSTEM (Programmed Fuel Injection) PGM-FI MIL BLINKS (NO.3 INJECTOR) Turn the ignition switch t o «OFF». Disconnect the No.3 injector 2P connector. Check for loose or poor contact o n the No.3 injector 2P connector. t o r Place the motorcycle on its side stand. Turn the ignition switch t o «ON».
• Page 141
  FUEL SYSTEM (Programmed Fuel Injection) Continuity Faulty No.3 injector Check for continuity between the No.3 injector and ground. Connection: Ground Standard: N o continuity No continuity Out of range Turn the ignition switch t o «ON». Measure the voltage between the No.3 injector connector of the wire harness side and ground.
• Page 142
  FUEL SYSTEM (Programmed Fuel Injection) Disconnect the ECM connectors. Connect the test harness t o the wire harness connectors. Out of range Open circuit i n Black/White and/or Pink/Green wire Measure the resistance at the test harness ter- minals. Connection: A4 Standard: 9 Normal Check for continuity between the test harness…
• Page 143
  Injection) FUEL SYSTEM (Programmed Fuel PGM-FI MIL BLINKS (NO.4 INJECTOR) Does not blink Loose or poor contact o n the No.4 injector connec- Connect the No.4 injector connector. Place the motorcycle on its side stand. Turn the ignition switch t o «ON». Check that the blinks.
• Page 144
  FUEL SYSTEM (Programmed Fuel Injection) Continuity Check for continuity between the No.4 injector Faulty No.4 injector and ground. Connection: Ground Standard: No continuity No continuitv Out of range Open or short circuit i n Blackwhite wire Turn the ignition switch to «ON». Measure the voltage between the No.4 injector connector of the wire harness side and ground.
• Page 145
  FUEL SYSTEM (Programmed Fuel Injection) Disconnect the ECM connectors. Connect the test harness the wire harness connectors. range Open circuit in Blackwhite and/or Pink/Black wire Measure the resistance at the test harness ter- minals. Connection: 15 R [2OoC/68’F) Standard: 9 Normal Continuity Short circuit i n Pink/Black wire…
• Page 146
  FUEL SYSTEM (Programmed Fuel Injection) PGM-FI MIL 18 BLINKS (CAM PULSE GENERATOR) Turn the ignition switch to «OFF». Does not blink Loose or poor contact on the cam pulse generator Place the motorcycle on its side stand. Turn the ignition switch to «ON» and check that the MIL blinks.
• Page 147
  Fuel FUEL SYSTEM (Programmed Injection) Crank the engine with the starter motor, and measure the cam pulse generator peak voltage at the cam pulse generator connector. Connection: Gray Black Standard: 0.7 V minimum (2OoC/68’FF) Normal Connect the cam pulse generator 2P connector. Disconnect the ECM connectors.
• Page 148
  FUEL SYSTEM (Proqrammed Fuel Iniection) PGM-FI MIL 19 BLINKS (IGNITION PULSE GENERATOR) Turn the ignition switch to «OFF». Disconnect the ignition pulse generator 2P con- n ecto r. Check for loose or poor contact on the ignition pulse generator 2P connector. Loose or poor contact on the ignition pulse gener- Connect the ignition pulse generator 2P con-…
• Page 149
  FUEL Fuel SYSTEM (Programmed Injection) Crank the engine with the starter motor, and measure the ignition pulse generator peak volt- age at the ignition pulse generator 2P connec- Connection: Yellow Standard: 0.7 minimum (20″C/68″F) Normal Connect the ignition pulse generator 2P con- nector.
• Page 150
  FUEL SYSTEM (Proarammed Fuel Iniection) ( 0 2 Turn the ignition switch t o «OFF». Disconnect the sensor connector. Check for loose or poor contact on the sen- connector. Disconnect the ECM connectors.. Connect the test harness to ECM connectors. continuity Open circuit in sensor Orangewhite wire…
• Page 151
  FUEL SYSTEM (Programmed Fuel Injection) Continuity Short circuit in sensor Orangewhite wire Check the continuity between the sensor connector terminal and ground. Connect the sensor connector. Turn the ignition switch t o «ON» and warm up the engine until the coolant temperature is 80°C Operate the throttle grip and snap the engine speed from idle t o 5,000 rpm.
• Page 152
  FUEL SYSTEM (Programmed Fuel Injection) PGM-FI MIL 23 BLINKS SENSOR HEATER/CALIFORNIA TYPE ONLY) Disconnect the sensor connectors. Check for loose or poor contact on the 0 2 sen- sor connector. Loose or poor contact on the sensor connector Turn the ignition switch to «OFF». Out of range Faulty sensor…
• Page 153
  FUEL (Programmed Fuel Injection) SYSTEM Continuity Faulty Ozsensor Check for continuity White terminal and ground. Connection: White Ground Standard: N o continuity Normal Turn the ignition switch t o «ON». Disconnect the ECM 26P connector. Measure the voltage at the sensor wire har- ness side connector terminals.
• Page 154
  FUEL SYSTEM (Programmed Fuel Injection) No voltage Open circuit i n Blackwhite wire between the Measure the voltage at the sensor wire har- sensor and engine stop relay ness side connector terminal and ground. Connection: Black/White Ground Standard: Battery voltage Battery voltage Turn the ignition switch t o «OFF».
• Page 155
  FUEL SYSTEM (Programmed Fuel Injection) No voltage Open circuit in Black/Green wire between the ECM connector and sensor connector Measure the voltage at the test harness termi- nals. Connection: B20 Standard: Battery voltage Battery voltage Replace the ECM and inspect again 5-47…
• Page 156
  FUEL SYSTEM (Programmed Fuel Injection) PGM-FI MIL 33 BLINKS (E2-PROM) «OFF». Turn the ignition switch t o Disconnect the ECM connectors. Check for loose or poor contact of the ECM con- 33 blinks Reset the self-diagnosis memory data (page 5-7). Connect the ECM connectors.
• Page 157
  FUEL SYSTEM (Programmed Fuel Injection) 33 times No problem Short the service check connector with a jumper wire (page 5-6). Turn the ignition switch «ON» and check the MIL blinks. Reset the self-diagnosis memory data (page problem Turn the ignition switch to «ON» and check the MIL blinks.
• Page 158
  FUEL SYSTEM (Programmed Fuel Injection) PGM-FI MIL 34 BLINKS (EGCV AND AIR INTAKE VALVE SERVO MOTOR VOLTAGE) Turn the ignition switch t o «OFF». Disconnect the servo motor 6P connector. Check for loose or poor contact o n the servo motor 6P connector.
• Page 159
  Fuel FUEL SYSTEM (Programmed Injection) Abnormal Faulty servo motor Measure the resistance at the servo motor 6P connector terminals. Connection: Light greedpink Standard: 0 5 kR (20″C/68″F) Normal Disconnect the ECM connectors. Connect the test harness t o the wire harness connectors.
• Page 160
  FUEL SYSTEM (Programmed Fuel Injection) PGM-FI MIL 35 BLINKS (EGCV AND AIR INTAKE VALVE SERVO MOTQR) Turn the ignition switch t o «OFF». Disconnect the servo motor 6P connector. Check for loose or poor contact on the servo motor 6P connector. Loose or poor contact o n the servo motor 6P con- Connect the servo motor 6P connector.
• Page 161
  (Programmed Fuel FUEL SYSTEM Injection) Abnormal Faulty servo motor Remove the servo motor (page 5-95). Connect the 12 V battery to the servo motor connector terminals and check the servo motor function. Connection: Red Blue Normal Disconnect the ECM connectors. Connect the test harness t o the wire harness connectors.

• Page 162: Fuel Pressure Inspection

  FUEL SYSTEM (Programmed Fuel Injection) FUEL PRESSURE INSPECTION NOTICE Before disconnecting fuel hoses, release the fuel pressure by loosening the fuel hose banjo bolt at the fuel tank. Always replace the sealing washers when the fuel hose banjo bolt is removed or loosened. Remove the seat (page 2-21, Disconnect the battery negative cable f r o m the bat- tery terminal.

• Page 163
  FUEL SYSTEM (Programmed Fuel Injection) Remove the fuel hose banjo bolt and attach the fuel BANJO BOLT pressure gauge with the following Honda genuine parts. Banjo bolt, 12 mm Parts No. 90008-PD6-010 Sealing washer, 12 mm Parts No. 90428-PD6-003 Sealing washer, Parts No.
• Page 164
  FUEL SYSTEM (Programmed Fuel Injection) FUEL FLOW INSPECTION Remove the seat (page 2-2). Open and support the front end of the fuel tank (page Remove the ECM cover and disconnect the fuel cut-off relay connector. J u m p the Brown and Blackwhite wire terminals of JUMPER WIRE FUEL CUT-OFF RELAY the wire harness side using a jumper wire.

• Page 165: Fuel Pump

  FUEL SYSTEM (Programmed Fuel Injection’) FUEL PUMP INSPECTION Turn the ignition switch t o «ON» and confirm that the fuel pump operates for a few seconds. If the fuel p u m p does not operate, inspect as follows: Open and support the front end of the fuel tank (page 3-4).

• Page 166
  FUEL SYSTEM (Programmed Fuel Injection) FUEL FILTER REPLACEMENT Disconnect the fuel hoses f r o m the fuel filter. Remove the screws and fuel filter. Note the direction Install the fuel filter in the reverse order of removal. the fuel fiirer INSTALLATION Place a new packing onto the fuel pump.

• Page 167: Fuel Tank

  (Programmed FUEL SYSTEM Fuel Injection) Connect the ohmmeter t o the fuel cut-off relay con- BATTERY FUEL CUT-OFF RELAY nector terminals. CONNECTION: Black/White Brown Connect the 12V battery t o the following fuel cut-off relay connector terminals. CONNECTION: Brown/Black There should be continuity only when the 12V battery is connected.

• Page 168
  FUEL SYSTEM (Programmed Fuel Injection) Disconnect the fuel tank air vent hose and overflow hose. Hold the fuel pipe nut and remove the fuel hose seal- ing nut and sealing washers, then disconnect the fuel hose. Do not apply excessive force to the fuel pipe. Always hold the fuel pipe nut while removing the fuel hose sealing nut.
• Page 169
  Fuel FUEL SYSTEM (Programmed Injection) Remove the fuel tank bracket bolts and then remove BOLTS Place the fuel tank upside down. Be careful not to BANJOBOLT FUEL RETURN HOSE damage the fuel tank. Remove the fuel hose banjo bolt and sealing washers, then remove the fuel hose from the fuel pump.
• Page 170
  FUEL SYSTEM (Programmed Fuel Injection) Connect the fuel hose t o the fuel pump with new seal- BANJOBOLT FUEL RETURN HOSE ing washers. with the stopper Install and tighten the fuel hose banjo bolt t o the spec- ified torque. TORQUE: 22 N-m (2.2 Connect the fuel return hose t o the fuel pump.
• Page 171
  FUEL SYSTEM Fuel Iniection) Connect the fuel return hose the pressure regulator. Connect the fuel hose banjo t o the throttle body with new sealing washers. While pushing the fuel hose banjo stopper t o the throttle body, install and tighten the sealing nut t o the specified torque.

• Page 172: Air Cleaner Housing

  FUEL SYSTEM (Programmed Fuel Injection) Install and tighten the duct cover-to-fuel tank bolts. AIR CLEANER HOUSING REMOVAL Remove the air cleaner element (page 3-6). Remove the EGCV and air intake valve servo motor mounting bolt. Remove the servo motor assembly from the bracket and disconnect the intake valve control cable f r o m the servo motor pulley.

• Page 173
  FUEL SYSTEM (Programmed Fuel Injection) Remove the air funneliair cleaner housing mounting screws, then remove the air funnels. Disconnect the crankcase breather hose and PAIR control valve air suction hose f r o m the air cleaner INSTALLATIQN AIR CLEANER HOUSING Install the air funnels in their proper locations.
• Page 174
  FUEL SYSTEM (Programmed Fuel Injection) Connect the MAP sensor connector and vacuum hose. Connect the sensor connector. Connect the variable air intake control cable t o t h e serve motor pulley. Install the servo motor onto the bracket, tighten the SERVO MOTOR bolt securely.

• Page 175: Throttle Body

  FUEL SYSTEM (Programmed Fuel Injection) THROTTLE BODY REMOVAL not snap the NOTICE throttle valve from Before disconnecting the fuel hose, release the fuel pressure b y loosening the fuel hose banjo bolt. throttle been removed Always replace the sealing washers when the fuel may cause incor- hose banjo bolt is removed or loosened.

• Page 176
  FUEL SYSTEM (Programmed Fuel Injection) Loosen the engine side insulator band screws. Remove the throttle body from the cylinder head. Do not hold the fuel pipe on the throttle body while removing the throttle body. Do not snap the Remove the insulators from the throttle body. INSULATORS throttle valve from fuii open to fuii…
• Page 177
  FUEL SYSTEM (Programmed Fuel Injection) REAR VIEW: RIGHT SIDE VIEW: THROTTLE DRUM VIEW: (0.35 kgf-m, 2.5 Ibf-ft) WHITE PAINTED WHIT E PAINTED STARTER VALVE LINK VIEW: THROTTLE LINK VIEW: WHITE PAINTED 1 N*m (0.09 kgf-m, 0.7 Ibf-ft)
• Page 178
  FUEL SYSTEM (Proarammed Fuel Iniection) THROTTLE BODY VACUUM HOSE ROUTING California type:…
• Page 179
  FUEL SYSTEM (Programmed Fuel Injection) INSTALLATION I N S U LATO Check the insulator band angle. Apply oil to the insulator inside surfaces for ease of throttle body installation. not hold the fuel pipe on the throttle while body installing the throttle body.
• Page 180
  FUEL SYSTEM (Programmed Fuel Injection) Connect the fast idle unit water hoses t o the unit, then tighten the hose bands securely. Connect the throttle cable ends t o the throttle drum. Install the throttle cable guide bracket t o the throttle body, then tighten the bolts t o the specified torque.
• Page 181
  FUEL SYSTEM (Programmed Fuel Injection) Remove the injectors from the fuel pipe. FUEL INJECT0 Remove the seal ring, O-ring and cushion ring. O-RING CUSHION RING SEAL RING N STAL LATlO N Apply oil t o the new O-ring. Install the new seal ring, cushion ring and O-ring, being careful not t o damage the O-ring.
• Page 182
  FUEL SYSTEM (Programmed Fuel Injection) Install the fuel pipe assembly onto the throttle body, FUEL INJECTORS being careful not t o damage the seal rings. Install and tighten the fuel pipe mounting bolts t o the FUEL PIPE ASSEMBLY specified torque. TORQUE: 7 Ibf-ft) Install the throttle body (page 5-71).

• Page 183: Fast Idle Wax Unit

  FUEL SYSTEM (Programmed Fuel Injection) Hold the fuel pipe securely, tighten the pressure regu- VACUUM HOSE PRESSURE REGULATOR lator mounting bolts t o the specified torque. TORQUE: 10 (1.0 kgf-m, 7 Ibf-ft) Connect the vacuum hose t o the pressure regulator FAST IDLE WAX UNIT REMOVAL not ioosen or…

• Page 184
  FUEL SYSTEM (Programmed Fuel Injection) STARTER VALVE STARTER VALVE DISASSEMBLY Turn each starter valve adjusting screw in, counting the number of turns until it seats lightly. Record the number of turns. Remove the fuel pipe and injectors (page 5-72). Remove the starter valve a r m screws and starter valve arm.
• Page 185
  FUEL SYSTEM (Programmed Fuel Injection) Clean t h e starter valve bypass using compressed air. apply com- carburetor clean- ers to the inside of the throttle bore, which coated wilh Remove the starter valve shaft a n d three’ collars. COLLARS ASSEMBLY PRESSURE REGULATOR…
• Page 186
  FUEL SYSTEM (Programmed Fuel Injection) Install the three collars and starter valve shaft. COLLARS Install the starter valve assembly into the valve hole Tighten the starter valve lock nut t o the specified torque. TORQUE: 2 N — m (0.18 kgf-m, 1.3 Ibf-ft) Compress the thrust spring and install the No.3/4 starter valve arm onto the starter valves.
• Page 187
  FUEL SYSTEM (Programmed Fuel Injection) Install the No.l/2 starter valve arm t o the starter valves. Install and tighten the starter valve arm mounting screws t o the specified torque. TORQUE: 1 N — m (0.09 kgf-m, 0.7 Ibf-ft) Install the fast idle wax unit link arm and tighten the screw t o the specified torque.
• Page 188
  FUEL SYSTEM (Programmed Fuel Injection) Disconnect the PAIR air suction hoses f r o m the reed PLUG AIR SUCTION HOSE valve covers and plug the cover. PAIR REED ALVE COVER Start the engine and adjust the idle speed. IDLE SPEED: 1,200 The No 7 starrer Adjust each intake vacuum pressure w i t h the No.1 adjusted, it is the…

• Page 189: Hydraulic Brake

  HYDRAULIC BRAKE the brake /ever or open the bleed valve 112 turn and then close the pedai untii the valve has been closed. Repeat steps 1 and 2 until bubbles cease t o appear i n the fluid coming out of the bleed valve. Tighten the bleed valve.

• Page 190
  HYDRAULIC BRAKE On the front brake, install the reservoir cap, and tight- en the screws. Tighten the master cylinder reservoir mounting nut securely. On the rear brake, install the reservoir cap securely, then install the reservoir onto the frame and tighten the mounting bolt.
• Page 191
  HYDRAULIC BRAKE Remove the Clean the inside of the caliper especially around the caliper pistons. Install the new brake pads. Install the pad spring with its arrow mark facing up (page 15-23). Push the pad spring, then install the pad pin. Install the brake caliper to the fork leg so the disc is Be careful not damage the pads.
• Page 192
  HYDRAULIC BRAKE REAR BRAKE PAD REPLACEMENT the brake pads in pairs Check the brake fluid level i n the brake master cylin- der reservoir as this operation causes the level t o rise. sure Push the caliper pistons all the w a y in b y pushing the caliper body inward t o allow installation of new brake pads.

• Page 193: Brake Disc Inspection

  HYDRAULIC BRAKE Make sure the brake pad spring is in place. Install the new brake Dads. Lower the caliper while pushing the pads against the pad spring so the pad ends are positioned onto the retainer on the caliper bracket. Install the pad pin.

• Page 194
  HYDRAULIC BRAKE Measure the brake disc warpage w i t h a dial indicator. SERVICE LIMIT: 0.30 mm (0.012 in) Check the wheel bearings for excessive play, warpage exceeds the service limit. Replace the brake disc if the wheel bearings are nor- mal.
• Page 195
  HYDRAULIC BRAKE Remove the pivot b o l t h u t and brake lever assembly. PIVOT BOLT BRAKE ‘LEVER Remove the screw and brake light switch. SCREW BRAKE LIGHT SWITCH Remove the boot. Remove the snap ring the master cylinder body from SNAP RING using the special tool as shown.
• Page 196
  HYDRAULIC BRAKE INSPECTION Check the piston boot, primary cup and secondary cup for fatigue or damage. Check the master cylinder and piston for abnormal scratches. Measure the master cylinder I.D. SERVICE LIMIT: 17.515 mm (0.6896 Measure the master cylinder piston O.D. SERVICE LIMIT: 17.309 mm (0.6815 in) ASSEMBLY…
• Page 197
  HYDRAULIC BRAKE Coat all parts w i t h clean brake fluid before assembly. MASTER CYLINDER SPRING Keep the pisron, cups, spring, snap ring and boot as a set do not sumti- tute indiv/duai Dip the piston in brake fluid. When instaiiing the cups, do Install the spring into the piston.
• Page 198
  HYDRAULIC BRAKE Apply silicone grease t o the contact surfaces of the brake lever and piston tip. Install the brake lever assembly, tighten the pivot bolt PIVOT BOLT t o the specified torque. TORQUE: Hold the pivot bolt and tighten the pivot nut to the specified torque.

• Page 199: Rear Master Cylinder

  HYDRAULIC BRAKE Place the master cylinder assembly on the handlebar. Align the end of the master cylinder w i t h the punch mark on the handlebar. Install the master cylinder holder with the “UP” mark facing up. Tighten the upper bolt first, then the lower bolt. Install the brake hose eyelet with the oil bolt and new sealing washers.

• Page 200
  HYDRAULIC BRAKE Remove and discard the brake pedal joint cotter pin. Remove the joint pin. Remove the master cylinder mounting bolts, collars (California type only), step guard and master cylinder. DISASSEMBLY RESERVOIR JOINT Remove the screw and reservoir hose joint from the master cylinder.
• Page 201
  HYDRAULIC BRAKE INSPECTION Check the piston boot, primary cup and secondary cup for fatigue or damage. Check the master cylinder and piston for abnormal scratches. Measure the master cylinder I.D. SERVICE LIMIT: 15.925 mm (0.6270 in) Measure the master cylinder piston O.D. SERVICE LIMIT: 15.815 (0.6226 in)
• Page 202
  BRAKE HYDRAULIC Coat all parts w i t h clean brake fluid before assembly. Keep the piston cups spring, snap ring and boo? as a MASTER PISTON set, do not substi- tute individual parts ASSEMBLY Dip the piston i n brake fluid. When instaiiing Install the spring t o the primary cup.

• Page 203: Front Brake Caliper

  HYDRAULIC BRAKE INSTALLATION Place the master cylinder onto the main footpeg bracket, install the collars (California type only), step guard and master cylinder mounting bolts. Connect the brake pedal to the push rod lower joint. Install the joint pin andsecure it w i t h a new cotter pin. Clamp the 0 2 sensor wire t o the wire guide behind the OIL BOLT right step guard.

• Page 204
  HYDRAULIC BRAKE DISASSEMBLY Install corrugated cardboard or equivalent between the pistons. Apply small squirts of air pressure t o the fluid inlet to Do not use high pressure air or remove the pistons. bnng rhe nozzle too close to the inlet Remove the following: Mark the pistons…
• Page 205
  HYDRAULIC BRAKE INSPECTION Check the caliper cylinder for scoring or other dam- age. Measure the caliper cylinder I.D. SERVICE LIMITS: Cylinder A (Upper): 32.05 mm (1.262 in) Cylinder B (Lower): 30.29 mm (1.193 in) Check the caliper pistons for scratches, scoring or other damage.
• Page 206
  HYDRAULIC BRAKE Coat the new piston seals w i t h clean brake fluid. Coat the new dust seals with silicone grease. Install the piston and dust seal into the groove o f the caliper body. Coat the caliper pistons w i t h clean brake fluid and install t h e m into the caliper cylinder w i t h their open ends toward the pad.

• Page 207: Rear Brake Caliper

  HYDRAULIC BRAKE Push the brake hose eyelet to the stopper on the caliper, then tighten the oil bolt to the specified torque. TORQUE: (3.5 Fill and bleed the front brake hydraulic system (page REAR BRAKE CALIPER REMOVAL Drain the rear brake hydraulic system (page 15-4). Remove the oil bolt, sealing washers and brake hose Avoid spiiiing fiwd eyelet joint.

• Page 208
  HYDRAULIC BRAKE Place a shop towel over the piston. Position the caliper body w i t h the piston d o w n and Do not use high pressure air or apply small squirts of air pressure t o the fluid inlet t o bring the nozzle remove the piston.
• Page 209
  HYDRAULIC BRAKE ASSEMBLY Coat the new piston seal with clean brake fluid. Coat the new dust seal w i t h silicone grease. Install the piston seal and dust seal into the groove of the caliper body. Coat the caliper piston with clean brake fluid and install it into the caliper cylinder w i t h its opening end toward the pad.
• Page 210
  HYDRAULIC BRAKE Install the pad retainer into the bracket. INSTALLATION Apply silicone grease t o the caliper pin and install the caliper onto the bracket. Install the rear brake pads (page 15-11). Install and tighten the caliper mounting bolt t o the specified torque.
• Page 211
  HYDRAULIC BRAKE Apply grease to the sliding surface of the brake pedal and footpeg. Assemble the brake pedal, footpeg and wave washer. Install a new footpeg mounting bolt and tighten it t o the specified torque. TORQUE: 44 N-m (4.5 kgfom, 33 I b f W Attach the brake pedal return spring.
• Page 212
  HYDRAULIC BRAKE Clamp the sensor wire t o the wire guide behind the SENSOR WIRE right step guard. Install the right main footpeg bracket assembly onto the lower bracket. Install and tighten the right main footpeg bracket socket bolts to the specified torque. TORQUE: (4.0 kgf-m, RIGHT…
• Page 213
  SYSTEM DlAGRAM REG U LATORI RECTIFIER ALTERNATOR G..GREEN 16-0…
• Page 214
  SYSTEM DIAGRAM 16-0 CHARGING SYSTEM INSPECTION 16-6 SERVICE INFORMATION ALTERNATOR CHARGING COIL 16-7 TROUBLESHOOTING 16-3 REG U LATOR/RECTI FI E R 16-7 BATTERY 16-4 SERVICE INFORMATION GENERAL The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charging.
• Page 215
  The battery will self-discharge when the motorcycle is not in use. For this reason, charge the battery every weeks t o pre- vent sulfation f r o m occurring. When checking the charging system, always follow the steps i n t h e troubleshooting f l o w chart (page 16-3). For battery charging, do not exceed the charging current and t i m e specified o n the battery.
• Page 216
  TROUBLESHOOTING BATTERY IS DAMAGED OR WEAK Incorrect Faulty battery Remove the battery (page 16-4). Check the battery condition using the recom- mended battery tester. RECOMMENDED BATTERY TESTER: BM-210-AH or BM-210 (U.S.A. only) Correct Incorrect Disconnect the regulatorhectifier connector and Install the battery (page 16-4). recheck the battery current leakage.

• Page 217: Voltage Inspection

  BATTERY NEGATIVE TERMINAL POSITIVE TERMINAL RE MOVAL/IN STALLATI O N Remove the seat (page 2-21, Always turn the ignition switch to «OFF» before Remove the battery holder band. removing the bat- Disconnect the negative cable and then the positive terv cable, and remove the battery.

• Page 218
  «OFF» and disconnect the clamps. EW BATT 7. Let the battery cool for at least 10 minutes or until gassing subsides after charging. 8. Retest the battery using the Honda battery tester and recharge necessary using the above steps.

• Page 219: Charging Voltage Inspection

  CHARGING SYSTEM INSPECTION NEGATIVE CABLE A M M,ETER CURRENT LEAKAGE INSPECTION Turn the ignition switch off and disconnect the nega- tive battery cable from the battery. Connect the ammeter probe to the ground cable and the ammeter probe to the battery terminal.

• Page 220: Alternator Charging Coil

  ALTERNATOR CHARGING COIL (WHITE) CONNECTOR INSPECTION Remove the ECM cover (page 5-87). Do not disconnect the battery Disconnect the alternator 3P (White) connector. cable in the charg- ing system with- Check the resistance between all three Yellow termi- out first switching nals.

• Page 221
  3P (WHITE) CONNECTOR Remove the rear cowl (page 2-2). Remove the ECM cover (page 5-87). Disconnect the alternator 3P (White) connector. Disconnect the regulator/rectifier 6P (Natural) connec- tor. 6P (NATURAL) CONNECTOR Remove the regulator/rectifier unit mounting SH bolts and regulator/rectifier. Install the regulatorhectifier unit in the reverse order wire in the seat raii properiy…

• Page 222: Ignition System

  IGNITION SYSTEM SYSTEM DIAGRAM ENGINE STOP SWITCH Tachometer ENGINE STOP RELAY CLUTCH SWITCH SENSOR DIODE (RED) NEUTRAL IGNITION PULSE GENERATOR SWITCH … BLACK ..GREEN BLUE SPARKPLUGS ….. YELLOW ..’IGNITION COILS ..ORANGE LIGHT GREEN …

• Page 223: Ignition Pulse Generator

  IGNITION SYSTEM 17-0 IGNITION SYSTEM INSPECTION 17-4 SYSTEM DIAGRAM 17-6 SERVICE INFORMATION 17-1 IGNITION PULSE GENERATOR 17-3 IGNITION TIMING 17-8 TROUBLESHOOTING SERVICE INFORMATION GENERAL Some electrical components may be damaged if terminals or connectors are connected or disconnected while the igni- tion switch is turned to «ON»…

• Page 224
  IGNITION SYSTEM TORQUE VALUES Apply grease to the threads. 18 N-m (1.8 kgf-m, 13 Ibf-ft) Timing hole cap 12 N-m (1.2 kgf-m, 9 Ibf*ft) Spark plug Apply oil to the threads. Ignition pulse generator rotor special bolt 59 N-m (6.0 kgf-m, 43 Ibf-ft) TOOLS 07HGJ-0020100 (not available in U.S.A.) Peak voltage adaptor…
• Page 225
  IGNITION SYSTEM TROUBLESHOOTING Inspect the following before diagnosing the system. Faulty spark plug Loose spark plug cap or spark plug wire connection Water got into the direct ignition coil (leaking the ignition coil secondary voltage) spark test. If there is spark, the exchanged direct ignition coil is faulty. «Initial voltage»…
• Page 226
  IGNITION SYSTEM SYSTEM INSPECTION DIGITAL M U LTIMETER If there is no spark at any plug, check all connec- tions for loose or poor contact before measuring each peak voltage. Use recommended digital multimeter or commer- cially available digital multimeter w i t h an imped- ance of 10 MQ/DCV minimum.
• Page 227
  IGNITION SYSTEM With the ignition coil sub-harness 4P (Black) connec- 4P (BLACK) CONNECTOR tor connected, connect the peak voltage adaptor or terminal and ground. CONNECTION: Body ground Body ground Body ground Body ground PEAK VOLTAGE ADAPTOR Turn the ignition switch to «ON» and engine stop Avoidtouching switch to «RUN».
• Page 228
  IGNITION SYSTEM Connect the peak voltage tester or peak voltage-adap- PEAK VOLTAGE ADAPTOR tor probes t o the connector terminal of the wire har- ness side and ground. TOOLS: Peak voltage adaptor 07HGJ-0020100 (not available in with commercially available digital multimeter (impedance 10 M W D C V minimum) CONNECTION: Yellow terminal…
• Page 229
  IGNITION SYSTEM Remove the right crankcase cover (page 9-3). from Remove the wire grommet the cover. Remove the bolts and ignition pulse generator. Shift the transmission into 6th gear and apply the rear if the engine out of the frame, brake.

• Page 230: Ignition Timing

  iftheengines Shift the transmission into 6th gear and apply rear out of the frame, brake. t o the specified torque. TORQUE: 59 N-m (6.0 kgf-m, 43 Ibf-ft) then tlghten the Install the ignition pulse generator into the cover. Apply sealant t o the wire grommet, then install it into the groove of the cover.

• Page 231
  Connect the timing light t o the direct ignition coil Read wire. for timing operation Start the engine and let it idle. IDLE SPEED: 1,200 The ignition timing is correct if the «F» mark aligns with the index mark on the ignition pulse generator rotor cover.

• Page 232: Electric Starter

  ELECTRIC STARTER SYSTEM DIAGRAM ENGINE STOP SWITCH RELAY SWITCH/ SIDE STAND SWITCH NEUTRAL INDICATOR SIDE STAND ..SWITCH ..GREEN ..YELLOW ..WHITE ..BLACK ..BLUE ..BROWN ..LIGHT GREEN 18-0…

• Page 233
  18. ELECTRIC STARTER 18-4 SYSTEM DIAGRAM 18-0 STARTER MOTOR SERVICE INFORMATION 18-1 STARTER RELAY SWITCH 18-10 TROUBLESHOOTING DIODE 18-11 18-2 SERVICE INFO R MATI 0 N GENERAL ausing s ri- «OFF» before servicing the starter mo Always turn the ignition switch t o ous injury.
• Page 234
  ELECTRIC STARTER TROUBLESHOOTING Starter motor does not turn Check for blown main or sub fuses before servicing. Make sure the battery is fully charged and in good condition. C I i c k» h ea rd Apply battery voltage t o the starter motor direct- Check the starter relay switch operation.
• Page 235
  ELECTRIC STARTER The starter motor turns when the transmission is in neutral, but does not turn with the transmission i n any position except neutral, with the side stand up and the clutch lever pulled in. Normal Faulty clutch switch Normal Check the side stand switch.

• Page 236: Starter Motor

  ELECTRIC STARTER STARTER MOTOR STARTER MOTOR CABLE REMOVAL Drain the coolant (page Remove the throttle body (page 5-67). Remove the thermostat housing (page 6-7). With the ignition switch turned t o «OFF», remove negative cable at the battery before servicing starter motor.

• Page 237
  ELECTRIC STARTER Remove the following: REAR COVER SEAL RING — Rear cover assembly Seal ring Shims Record the h a — Armature and number of shims ARM ATU RE SHIMS INSPECTION BUSHING Check the oil seal and needle bearing i n the front OIL SEAL cover for deterioration, wear or damage.
• Page 238
  ELECTRIC STARTER pairs of commutator Check for continuity between bars. There should be continuity. Check for continuity between each commutator bar and the armature shaft. There should be no continuity. Check for continuity between the insulated brush and cable terminal (the indigo colored wire or the insulat- ed brush holder).
• Page 239
  ELECTRIC STARTER Remove the following: BRUSH HOLDER — Nut — Washer — Insulators — O-ring Brush holder assembly — Brushkerminal Inspect the brushes for damage and measure the brush length. SERVICE LIMIT: (0.14 ASSEMBLY REAR COVER…
• Page 240
  ELECTRIC STARTER Install the brushes into the brush holder. ALIGN Install the cable terminal and brush holder into the Install the following: — N e w O-ring Insulators Washer I N S U LATORS WASHER Install the armature in the motor case. When installing the armature into the motor case, hold the armature tightly t o keep the magnet of the case f r o m pulling the armature against it.
• Page 241
  ELECTRIC STARTER Install the shims and insulated washer onto the arma- Install the insula- tors properly as ture shaft. noted during Install a new seal ring onto the motor case. removal. Apply grease t o the oil seal lip and needle bearing i n the front cover.

• Page 242: Operation Inspection

  ELECTRIC STARTER Install a new O-ring into the thermostat housing groove. Install the thermostat housing to the cylinder head. Install and tighten the mounting bolts. Install the following: — Thermostat housingithermostat (page 6-7). — Throttle body (page 5-71). Fill the system with the recommended coolant (page STARTER RELAY SWITCH OPERATION INSPECTION Remove the seat (page 2-21.

• Page 243
  ELECTRIC STARTER STARTER RELAY VOLTAGE INSPECTION Connect the starter relay switch connector. Shift the transmission into neutral. Measure the voltage between the Yellow/Red wire ter- minal and ground If the battery voltage appears only when the starter switch is pushed with the ignition switch t o » ON» and engine stop switch at «RUN», it is normal.
• Page 244
  SYSTEM LOCATION HEADLIGHT RELAY FRONT BRAKE LIGHT SWITCH ENGINE STOP RELAY IGNITION SWITCH LIGHT SWITCH…
• Page 245
  LIGHTS/ ETERS/SWITCHES OIL PRESSURE SWITCH 19-14 SYSTEM LOCATION 19-0 FUEL RESERVE SENSOR 19-15 SERVICE INFORMATION 19-1 19-16 TROUBLESHOOTING IGNITION SWITCH 19-3 19-17 HEADLIGHT HANDLEBAR SWITCHES 19-4 TURN SIGNAL BRAKE LIGHT SWITCH 19-18 19-6 CLUTCH SWITCH 19-1 8 19-6 19-18 NEUTRAL SWITCH LICENSE LIGHT 19-7 19-19…
• Page 246
  SPECIFICATIONS ITEM SPECIFICATIONS Bulbs Headlight 5 5 w 12V — 55W Front turn signal light 12V — 3 2 1 3 ~ ~ Rear turn signal light 12V — 32cp (23W) x 2 License light 12V — 5W Instrument light LED x 2 Turn signal indicator High beam indicator…
• Page 247
  TROUBLESHOOTING SPEED SENSOR/SPEEDOMETER The odometer/trip meter operates normally, but the speedometer does not operate Faulty speedometer The speedometer operates normally, but the odometerltrip meter does not operate Faulty odometerhrip meter Abnormal Check for loose or poor contact of the speed Loose or poor contact of related terminals Open circuit i n Black/Brown or GreeniBlack wires sensor 3P (Natural) connector.

• Page 248: Bulb Replacement

  HEADLIGHT BULB REPLACEMENT Disconnect the headlight bulb connector. Remove the dust cover. Avoid touching Unhook the bulb retainer and remove the headlight the halogen head- bul bkocket. light bulb Finger prints can create If you touch the bulb w i t h your bare hands, clean hot spots that with cloth moistened with denatured alcohol t o pre- cause a bulb…

• Page 249
  Hook the bulb retainer into the headlight unit groove. Install the dust cover tightly against the headlight unit with its arrow mark facing up. Connect the headlight connector. Remove the upper cowl (page Remove the seven screws and headlight unit. Install the headlight unit in the reverse order of rem ova I.
• Page 250
  TURN SIGNAL TURN SIGNAL LENS BULB REPLACEMENT For turn signai unit Remove the screw and turn signal lens. and 2-9 SCREW While pushing in, turn the bulb counterclockwise t o remove it and replace with a new one. Install the turn signal lens i n the reverse order removal.

• Page 251: License Light

  Remove the brakeitail light unit mounting screws. Pull out the bosses f r o m the grommet, then remove the brakehail light unit. BOSS LICENSE LIGHT BULB REPLACEMENT Remove the screws, packing and lens. Pull out the license light bulb and replace it w i t h a n e w one.

• Page 252
  Remove the combination meter mounting screw. SCREW Release the combination meter case bosses f r o m the bracket grommets, then remove the combination meter. DISASSEMBLY REAR COVER Remove the screws and combination meter rear cover. SCREWS Remove the combination meter print board assembly PRINT BOARD f r o m the front cover.
• Page 253
  SCREW Install the combination meter onto the bracket. nation meter case bosses w/?h the Install and tighten the mounting screw. meter bracke?. Connect the combination meter multi-connector. COMBINATION METER Install the bank angle sensor (page 5-86) Install the upper cowl (page 2-6). M U LTI-CO’N N ECTOR VOLTAGE INSPECTION Open and support the front end of the fuel tank (page…
• Page 254
  Remove the upper cowl (page 2-51. MULTI-CONNECTOR Check for loose or poor connection of the combina- tion meter multi-connector. With the ignition switch turned t o «ON» and measure the voltage at the multi-connector terminals. Connection: BlacklBrown Standard: Battery voltage If there is no voltage, repair or replace the wire har- ness.
• Page 255
  Remove the bolts and speed sensor. Check the O-ring i n good condition, replace nec- essary. Install the speed sensor into the upper crankcase. Install and tighten the mounting bolts securely. Route the sensor wire. Connect the speed sensor (Natural) connector.
• Page 256
  TACHOMETER INSPECTION Remove the upper cowl (page 2-5). Check for loose or poor contact terminals of the c o m Connect the peak voltage adaptor to the tachometer TOOLS: PEAK V ~ L T A G E ADAPTOR Peak voltage adaptor (not available in U.S.A.) with commercially available digital multimeter…
• Page 257
  Suspend the ECT/thermo sensor in a pan of coolant (50 — 50 mixture) an electric heating element and measure the resistance through the sensor as the coolant heats up. Soak the ECT/thermo sensor in coolant u p t o its 40 mm threads w i t h at least (1.6 in) f r o m the b o t t o m…

• Page 258: Oil Pressure Switch

  OIL PRESSURE SWITCH I NSPECTI 0 N If the oil pressure warning indicator stays on while the engine is running, check the engine oil level before inspection. Make sure that the oil pressure warning indicator comes on with the ignition switch turned t o «ON». OIL P R E S S U R ~ WARNING INDICATOR If the indicator does not come on, inspect as follows: Remove the fuel tank (page 5-59).

• Page 259: Fuel Reserve Sensor

  Apply sealant to the oil pressure switch threads as not apply sealant to shown. the thread head 3 — 4 mm (0.1 — 0.2 in). Install the oil pressure switch onto the crankcase, tighten it to the specified torque. TORQUE: 12 N*m (1.2 kgf.m, 9 I b f a ) Connect the oil pressure switch terminal to the switch and tighten the screw t o the specified torque.

• Page 260: Ignition Switch

  IGNITION SWITCH 4P (NATURAL) CONNECTOR INSPECTION Remove the air cleaner housing (page 5-64). Disconnect the ignition switch wire 4P (Natural) con- n ect o r. Check for continuity between the wire terminals of the ignition switch 4P (Natural) connector in each switch position.

• Page 261: Handlebar Switches

  HANDLEBAR SWITCHES ENGINE STOP SWITCH Remove the air cleaner housing (page 5-64). Disconnect the handlebar switch connectors. Check for continuity between the wire terminals of the handlebar switch connector. Continuity should exist between the color coded wire terminals as follows: STARTER SWITCH BAT3 FREE…

• Page 262: Clutch Switch

  BRAKE LIGHT SWITCH FRONT Disconnect the front brake light switch connectors and check for continuity between the terminals. There should be continuity w i t h the brake lever applied, and there should be no continuity w i t h the brake lever released.

• Page 263
  INSPECTION Open and support the front end of the fuel tank (page 3-4). Disconnect the side stand switch 2P (Green) connec- tor. Check for continuity between the wire terminals of the side stand switch 2P (Green) connector. Continuity should exist only when the side stand is REMOVAL Disconnect the side stand switch 2P (Green) connector.
• Page 264
  LIGHTS/ M ETERS/S W ITCH ES INSTALLATION SIDE STAND SWITCH the return spring holding pin. Secure the side stand switch with a new bolt. SIDE STAND SWITCH TORQUE: 10 N m 7 Ibf-ft) (1.0 Connect the side stand switch 2P (Green) connector. HORN Disconnect the wire connectors from the horn.

• Page 265: Turn Signal Relay

  TURN SIGNAL RELAY I M SPECTI ON Remove the upper cowl (page 2-51, Check the following: — Battery condition — Burned bulbs or non-specified wattage Burnedfuse — Ignition switch and turn signal switch function Loose connectors If the above items are all normal, check the following: Disconnect the combination meter multi-connector from the combination meter.

• Page 266
  21 TROUBLESHOOTING ENGINE DOES NOT START OR POOR PERFORMANCE AT HIGH HARD TO START 21-1 SPEED 21-4 ENGINE LACKS POWER 21-2 POOR HANDLING POOR PERFORMANCE AT LOW AND IDLE SPEED 21 -3 ENGINE DOES NOT START OR HARD TO START Possible cause Faulty fuel pump (Section 5 ) 1.

• Page 267: Engine Lacks Power

  TROUBLESHOOTING ENGINE LACKS POWER Possible cause Raise wheel off the ground and spin by Wheels d o not spin Brake dragging hand freely Worn damaged wheel bearing Wheel spins freely Check tire pressure Pressure l o w Faulty tire valve Punctured tire Pressure normal Clutch slipping…

• Page 268
  TROUBLESHOOTING Possible cause Coolant level low Check for engine overheating Overheating Fan motor not working (faulty fan motor switch) Not overheating Thermostat stuck close Excessive carbon build-up in com- bustion chamber Use of poor quality fuel Wrong type of fuel Clutch slipping Worn piston and cylinder Engine knocks…

• Page 269: Poor Performance At High Speed

  TROUBLESHOOTING POOR PERFORMANCE AT HIGH SPEED Possible cause Faulty ECM Incorrect Correct Faulty pressure regulator (Section 5) 2. Inspect the fuel flow Abnormal Normal See section 5 3. Inspect the fuel injector Abnormal Normal Camshaft not installed properly 4. Check valve timing Incorrect Correct Faulty valve spring…

• Page 270: Table Of Contents

  INDEX AIR CLEANER EVAPORATIVE EMISSION CONTROL SYSTEM AIR CLEANER HOUSING (California type only) 5-64 3-19 ALTERNATOR CHARGING COIL FAN CONTROL RELAY 16-7 6-17 ALTER NATO R COVER I N STA LLATlO N FAST IDLE WAX UNIT 10-8 5-7 5 ALTERNATOR COVER REMOVAL FLYWHEEL I N STALL AT1 0 N 10-2 10-7…

• Page 271: Table Of Contents

  INDEX REAR MASTER CYLINDER 15-17 5-84 TP SENSOR REAR WHEEL TRANSMISSION 12-9 14-3 REG U LATORIRECTIFI ER 16-7 TROUBLESHOOTING RIGHT CRANKCASE COVER INSTALLATION 10-1 9-17 (ALTERNATORISTARTER CLUTCH) RIGHT CRANKCASE COVER REMOVAL 16-3 SEAT SEAT RAIL 2-1 1 (COOLING SYSTEM) SERVICE RULES (CRAN KCASE/PISTON/CYLI NDER) 11-2 SECONDARY AIR SUPPLY SYSTEM…