MT XR190L (62K79B0) 2017 OK

Shop Manual

XR190L 1. General Information 2. Fuel & Engine 3. Frame & Chassis 4. Electrical System

This book is Specific Shop Manual. Refer to “Basic Shop Manual” for basic and common maintenance instructions.

XR190L-H (2017)

1. GENERAL INFORMATION

A Few Words About About Safety ···················· ···················· 1-2

SPECIAL TOOL LIST·························· LIST····························· ··· 1-16

How To Use This Manual························ Manual························ 1-3

CABLE & HARNESS HARNESS ROUTING ROUTING············ ············ 1-17

MODEL IDENTIFICATION IDENTIFICATION ······················· ······················· 1-5

TECHNICAL FEATURES··················· FEATURES······················· ···· 1-24

SPECIFICATIONS SPECIFICATIONS ························ ···································· ············ 1-6

MAINTENANCE MAINTENANCE SCHEDULE················· SCHEDULE················· 1-25

TORQUE VALUE····················· VALUE·································· ··············· ·· 1-12

1-1

1. GENERAL INFORMATION

A Few Words About About Safety ···················· ···················· 1-2

SPECIAL TOOL LIST·························· LIST····························· ··· 1-16

How To Use This Manual························ Manual························ 1-3

CABLE & HARNESS HARNESS ROUTING ROUTING············ ············ 1-17

MODEL IDENTIFICATION IDENTIFICATION ······················· ······················· 1-5

TECHNICAL FEATURES··················· FEATURES······················· ···· 1-24

SPECIFICATIONS SPECIFICATIONS ························ ···································· ············ 1-6

MAINTENANCE MAINTENANCE SCHEDULE················· SCHEDULE················· 1-25

TORQUE VALUE····················· VALUE·································· ··············· ·· 1-12

1-1

GENERAL INFORMATION GENERALINFORMATION

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

For Your Customer’s Safety Proper service and maintenance are essential to the customer’s safety and the reliability of the vehicle. Any error or oversight while servicing a vehicle can result in faulty operation, damage to the vehicle, or injury to others.

Improper service or repairs can create an 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 professional service technician, technician, we do not provide warnings about many basic shop safety practices (e.g., Hot parts–wear gloves). If you have not received shop safety training or do not feel confident about your knowledge of safe servicing practice, we recommended that you do not attempt to perform the procedures described in this manual. Some of the most important general service safety precautions are given below. However, we cannot warn you of every conceivable hazard that can arise in performing service and repair procedures. Only you can decide whether or not you should perform a given task.

Failure to properly follow instructions and precautions can cause you to be seriously hurt or  killed. Follow the procedures and precautions in this manual carefully.

Important Safety Precautions Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and using safety equipment. When performing any service task, be especially careful of the following:  • Read all of the instructions before you begin, and make sure you you have the tools, tools, the replacement replacement or repair parts, parts, and the skills skills required to perform the tasks safely and completely.  • Protect your eyes by using proper safety glasses, goggles or face shields any time 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 protective wear when necessary, necessary, for example example gloves or safety safety shoes. Handling Handling hot or sharp parts can cause severe severe burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.  • Protect yourself yourself and others whenever you you have the vehicle up in the air. Any time time you lift the vehicle, vehicle, either with a hoist hoist or a jack, make sure that it is always securely supported. Use jack stands. Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will help eliminate several potential hazards:  • Carbon monoxide poisoning poisoning from engine engine exhaust. Be Be sure there is adequate adequate ventilation ventilation whenever you run the engine  • Burns from hot parts or coolant. coolant. Let the engine and exhaust system system cool before before working in those those areas.  • Injury from moving moving parts. If the instruction tells tells you to run the engine, be sure y your our 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 only a nonflammabl nonflammable e solvent, solvent, not gasolin gasoline, e, to clean clean parts.  • Never drain or or store store gasoline gasoline in in an open open container container..  • Keep all cigarettes, sparks and flames away from the battery and all fuel-related parts.

1-2

GENERAL INFORMATION

How To Use This Manual This manual is "Spec (Specific)" Service Manual. The service and repair information for this model is described in this manual as specific information. Refer to “Basic" Service Manual for basic/common service information and instructions. Follow the Maintenance Schedule recommendations to ensure that the vehicle is in peak operating condition. Performing the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the break-in period.

Your safety, and the safety of others, is very important. To help you make informed decisions we have provided safety messages and other information throughout this manual. Of course, it is not practical or p ossible to warn you about all the hazards associated with servicing this vehicle. You must use your own good judgement. You will find important safety information in a variety of forms including:  • Safety Labels – on the vehicle  • Safety Messages – preceded by a safety alert symbol and one of three signal words, DANGER, WARNING, or CAUTION. These signal words mean:  You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions.  You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions.  You CAN be HURT if you don’t follow instructions.  • Instructions – how to service this vehicle correctly and safely.  As you read this manual, you will find infor mation that is preceded by a is to help prevent damage to your vehicle, other property, or the environment.

symbol. The purpose of this message

 ALL INFORMATION, ILLUSTRATIO NS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THI S PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF  APPROVAL FOR PRINTING. Honda Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATSOEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT WRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTENANCE ON Honda MOTORCYCLES, MOTOR SCOOTERS OR ATVS.

 © Honda Motor Co., Ltd. SERVICE PUBLICATION OFFICE Date of Issue: July, 2016

1-3

GENERAL INFORMATION

SYMBOLS The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these symbols, it would be explained specifically in the text without the use of the symbols.

INSTRUCTION SYMBOL Removal or Disassembly procedure. Disconnect the connector.

Installation or Assembly procedure. Connect the connector.

Order of removal/disassembly with a point of note.

Order of installation/assembly with a point of  note.

Tighten specified torque.

Replace with a new one before assembly.

Check the part for an inspection.

Measure the part for an inspection.

Turn ignition switch to OFF.

Turn ignition switch to ON.

Start the engine.

Measure a resistance or check continuity.

Measure a voltage.

Measure an ampere.

Use the Honda special tool.

Refer to “Basic” Service Manual for the instruction.

LUBRICATION AND SEAL SYMBOL Use the recommend engine oil.

 Apply molybdenum oil solution (mixt ure of an engine oil and molybdenum grease in a ration of  1:1).

 Apply a specified grease. Use a multi-purpose grease unless otherwise specified.

 Apply a liquid sealant.

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

Use DOT 3 or DOT 4 brake fluid.

Use a specified fork oil or suspension fluid.

1-4

GENERAL INFORMATION

MODEL IDENTIFICATION  • Model name: XR190L-H

Code/Type LA PE CL DK

Destination Latin America Peru Chile General KILO

VEHICLE IDENTIFICATION NUMBER

ENGINE SERIAL NUMBER COLOR LABEL

1-5

GENERAL INFORMATION

SPECIFICATIONS GENERAL SPECIFICATIONS DIMENSIONS

FRAME

ENGINE

ITEM Overall length Overall width Overall height Wheelbase Seat height Footpeg height Ground clearance Curb weight Maximum weight capacity Frame type Front suspension Front wheel travel Rear suspension Rear wheel travel Front tire size Rear tire size Front tire brand Rear tire brand Front brake Rear brake Caster angle Trail length Fuel tank capacity Fuel tank reserve capacity Cylinder arrangement Bore and stroke Displacement Compression ratio Valve train Intake valve Exhaust valve Lubrication system Oil pump type Cooling system  Air filtration Engine dry weight Emission control system

FUEL SYSTEM

1-6

Type Throttle bore

opens closes opens closes

SPECIFICATION 2,075 mm 812 mm 1,124 mm 1,351 mm 835 mm 300 mm 242 mm 133 kg 155 kg Semi double cradle type Telescopic fork 161.5 mm Swingarm 147 mm 90/90 -19M/C 52P 110/90 - 17M/C 60P C6559F (CHENG SHIN) C6559 (CHENG SHIN) Hydraulic single disc Mechanical leading trailing 26° 12’ 95.9 mm 12.0 liter   3.9 liter   Single cylinder inclined 15° from vertical 61.000 x 63.096 mm 184.43 cm3 9.5 : 1 Chain driven OHC with rocker arm 10° BTDC at 1 mm lift 30° ABDC at 1 mm lift 35° BBDC at 1 mm lift 0° ATDC at 1 mm lift Forced pressure and wet sump Trochoid Air cooled Viscous paper filter  29.5 kg Crankcase emission control system Three-way catalytic converter  PGM-FI (Programmed Fuel Injection) 30 mm

GENERAL INFORMATION DRIVE TRAIN

ITEM Clutch system Clutch operation system Transmission Primary reduction Final reduction Gear ratio

Gearshift pattern ELECTRICAL

Ignition system Starting system Charging system Regulator/rectifier Lighting system

SPECIFICATION

1st 2nd 3rd 4th 5th

Multi-plate, wet Cable operating 5 speeds 3.136 (69/22) 3.000 (48/16) 2.785 (39/14) 1.789 (34/19) 1.368 (26/19) 1.090 (24/22) 0.928 (26/28) Left foot operated return system 1-N-2-3-4-5 Full transistorized Electric starter motor   Single phase output alternator   SCR opened, single phase half-wave rectification Alternator  

FUEL & ENGINE SPECIFICATIONS FUEL SYSTEM ITEM Throttle body identification number Idle speed Throttle grip freeplay Fuel pressure at idle Fuel pump flow (at 12 V)

SPECIFICATIONS GQ1QA 1,400 ± 100 rpm 2 – 6 mm 294 kPa 58.6 cm3 minimum/10 seconds

LUBRICATION SYSTEM ITEM Engine oil capacity After draining  After disassembly Recommended engine oil

Oil pump rotor

Tip clearance

STANDARD 1.0 liter 1.2 liter Honda “4-stroke motorcycle oil” or an equivalent motor oil.  API service classification: SG or hi gher  JASO T903 standard: MA Viscosity: SAE 10W-30 0.15 0.20

Unit: mm LIMIT – –

 –

1-7

GENERAL INFORMATION CYLINDER HEAD Unit: mm

ITEM Cylinder compression Valve clearance Camshaft

Cam lobe height

Rocker arm, Rocker arm shaft O.D. rocker arm shaft Valve, Valve stem O.D. valve guide Valve guide I.D. Valve guide projection above cylinder head Valve seat width Valve spring free length

IN EX IN EX

STANDARD 1,402 kPa at 650 rpm 0.08 ± 0.02 0.24 ± 0.02 34.249 – 34.489 34.079 – 34.319

IN/EX

9.988 – 10.000

IN EX IN/EX

4.975 – 4.990 4.955 – 4.970 5.000 – 5.012

IN/EX

16.8 – 17.0

IN EX INNER OUTER

1.2 – 1.4 1.0 – 1.2 35.59 39.46

LIMIT – – – 34.219 34.049 – 4.965 4.945 – –

Cylinder head warpage

–

1.8 1.6 34.88 38.67 0.05

CYLINDER/PISTON Unit: mm

ITEM Cylinder

STANDARD

Piston

I.D. Warpage Piston O.D.

61.00 – 61.01

Piston rings

Piston pin bore I.D. Piston pin O.D. Piston ring end gap

Piston ring-to-ring groove clearance

Top Second Oil (side rail) Top Second

– 60.981 – 60.997 at 13 mm from bottom of skirt 14.002 – 14.008 13.994 – 14.000 0.07 – 0.17 0.17 – 0.32 0.10 – 0.35 0.015 – 0.045 0.015 – 0.045

LIMIT 61.10 0.10 60.900 14.020 13.980 0.27 0.42 0.55 – –

CLUTCH/GEARSHIFT LINKAGE Unit: mm

ITEM Clutch lever freeplay Clutch

STANDARD Disc thickness Plate warpage Spring free length

Primary driven gear I.D. Clutch outer guide

O.D. I.D. Mainshaft O.D. at clutch outer guide

10 – 20 2.92 – 3.08 – 40.5 23.000 – 23.021 22.959 – 22.980 16.991 – 17.009 16.966 – 16.984

LIMIT – 2.70 0.15 39.5 – – – –

ALTERNATOR/STARTER CLUTCH Unit: mm

ITEM Starter driven gear boss O.D. Starter driven gear boss I.D.

1-8

STANDARD 45.660 – 45.673 29.000 – 29.021

LIMIT – –

GENERAL INFORMATION CRANKSHAFT/TRANSMISSION/BALANCER Unit: mm

ITEM Connecting rod Side clearance Radial clearance Connecting rod small end I.D. Crankshaft Runout Transmission Gear I.D.

Gear bushing O.D. Gear bushing I.D. Mainshaft O.D. Countershaft O.D.

Shift fork, shaft

STANDARD 0.10 – 0.35 0 – 0.008 14.010 – 14.028 – M4 M5 C1 C2 C3 C1 C2 C1 C2 at M4 at M5 at C1 at C2 at C3

fork Fork I.D. Fork shaft O.D. Claw thickness

20.000 – 20.018 17.000 – 17.018 20.500 – 20.521 23.020 – 23.041 20.020 – 20.038 20.459 – 20.480 22.984 – 23.005 17.000 – 17.018 20.020 – 20.041 19.968 – 19.980 16.968 – 16.980 16.966 – 16.984 19.978 – 19.989 19.988 – 20.000 10.000 – 10.018 9.986 – 9.995 4.93 – 5.00

LIMIT 0.45 0.05 14.038 0.03 – – – – – – – – – – – – – – – – 4.83

FRAME & CHASSIS SPECIFICATIONS FRONT WHEEL/SUSPENSION/STEERING Unit: mm

ITEM Driver only Driver and passenger

Cold tire pressure  Axle runout Wheel rim runout Radial  Axial Fork Recommended fork fluid Fluid level Fluid capacity

STANDARD

LIMIT – –

150 kPa 150 kPa – – –

0.2 1.0 1.0

CN10# 184 183 ± 2.5 cm3

– –  –

REAR WHEEL/BRAKE/SUSPENSION Unit: mm

ITEM Cold tire presDriver only sure Driver and passenger  Axle runout Wheel rim runout Radial  Axial Drive chain slack Drive chain size/link

STANDARD

LIMIT – –

150 kPa 200 kPa – – – 20 – 30 428V/128LE

0.2 1.0 1.0 60 –

1-9

GENERAL INFORMATION BRAKE SYSTEM Unit: mm Front

Rear

ITEM Specified brake fluid Brake disc thickness Brake disc warpage Master cylinder I.D. Master piston O.D. Caliper cylinder I.D. Caliper piston O.D. Pedal freeplay Drum I.D.

STANDARD DOT 3 or DOT 4 3.8 – 4.2 – 12.700 – 12.743 12.657 – 12.684 27.000 – 27.050 26.918 – 26.968 20 – 30 110

ELECTRICAL SYSTEM SPECIFICATIONS PGM-FI SYSTEM ITEM EOT sensor resistance (20°C) Fuel injector resistance (24°C)

SPECIFICATIONS 2.5 – 2.8 kΩ 11 – 13 Ω

IGNITION SYSTEM ITEM Spark plug Spark plug gap Ignition coil peak voltage CKP sensor peak voltage Ignition timing ("F" mark)

SPECIFICATION CPR8EA-9 (NGK) 0.80 – 0.90 mm 100 V minimum 0.7 V minimum 8° BTDC at idle

BATTERY/CHARGING SYSTEM Battery

 Alternator

1-10

ITEM Type Capacity Current leakage Voltage Fully charged (20°C) Needs charging Charging current Normal Quick Capacity Charging coil resistance (20°C)

SPECIFICATIONS YTX7L-BS 12 V – 6 Ah (10HR)/6.3 Ah (20HR) 0 mA 12.8 V minimum Below 12.3 V 0.6 A/5 – 10 h 3 A/1 h 0.165 kW/5,000 rpm 0.2 – 1.0 Ω

LIMIT – 3.5 0.3 – – – – – 111

GENERAL INFORMATION LIGHTS/METERS/SWITCHES ITEM Bulbs Headlight Hi/Lo Brake/tail light Front turn signal light Rear turn signal light Position light License light Instrument light 1 Instrument light 2 High beam indicator Neutral indicator Turn signal indicator MIL Fuse Main fuse Sub fuse Fuel level sensor resistance Full Empty

SPECIFICATIONS 12 V – 35/35 W 12 V – 21/5 W 12 V – 10 W x 2 12 V – 10 W x 2 12 V – 5 W 12 V – 5 W 12 V – 2 W 12 V – 1.7 W 12 V – 1.7 W 12 V – 3.4 W 12 V – 3.4 W 12 V – 3.4 W 15 A 10 A x 2 6 – 10 Ω 90 – 100 Ω

1-11

GENERAL INFORMATION

TORQUE VALUE  • Each fastener should be tightened to the standard torque value except the fasteners specified torque value.  • Q’TY: Quantity, DIA: Thread diameter (mm), TRQ: Tightening torque (N·m)

STANDARD TIGHTENING TORQUE FASTENER TYPE 5 mm hex bolt and nut 6 mm hex bolt and nut 8 mm hex bolt and nut 10 mm hex bolt and nut 12 mm hex bolt and nut

TRQ 5.2 10 22 34 54

FASTENER TYPE 5 mm screw 6 mm screw 6 mm flange bolt 8 mm flange bolt and nut 10 mm flange bolt and nut

TRQ 4.2 9.0 12 27 39

FUEL PUMP UNIT ITEM Fuel pump setting plate nut

Q'TY 4

DIA 6

TRQ 12

REMARKS

Q'TY 4 4 5

DIA 5 5 5

TRQ 1.0 1.0 1.0

REMARKS

Q'TY 1 1 1 2 3 2 2 2

DIA 6 6 5 6 5 4 5 5

TRQ 4.5 4.5 2.5 12 3.4 2.1 3.4 5.1

REMARKS

Q'TY 1 1

DIA 12 4

TRQ 30 3.0

REMARKS

Q'TY 1 1 1 2 4 1 2 2 4

DIA 32 14 6 5 9 6 5 6 9

TRQ 15 10 4.0 9.0 30 12 5.0 18 9.0

REMARKS Apply grease.

2-4

AIR CLEANER ITEM  Air cleaner cover screw  Air cleaner element screw  Air cleaner cover separate screw THROTTLE BODY ITEM Throttle cable A lock nut (throttle body side) Throttle cable B lock nut (throttle body side) Insulator band screw Insulator bolt Sensor unit torx screw IACV mounting torx screw Throttle cable stay screw Injector joint bolt LUBRICATION SYSTEM ITEM Oil drain bolt Oil pump cover screw

CYLINDER HEAD ITEM Crankshaft hole cap Timing hole cap Cam chain tensioner lifter plug Cam sprocket bolt Cylinder head nut Camshaft stopper bolt Rocker arm shaft stopper bolt Valve adjusting screw lock nut Cylinder stud bolt

1-12

Apply engine oil. Apply engine oil. Apply engine oil.

GENERAL INFORMATION CLUTCH/GEARSHIFT LINKAGE/BALANCER GEAR ITEM Clutch center lock nut Shift drum stopper arm bolt Shift drum stopper plate bolt Gearshift return spring pin Clutch lifter plate bolt Oil filter rotor lock nut Oil filter rotor cover screw

Q'TY 1 1 1 1 4 1 3

DIA 14 6 6 8 6 14 5

TRQ 83 12 12 22 12 83 4.0

REMARKS Apply engine oil. Apply locking agent. Apply locking agent. Apply locking agent.

Q'TY 6 3 1 2 1

DIA 6 6 14 6 6

TRQ 16 12 74 12 12

REMARKS Apply locking agent. Apply engine oil. Apply locking agent. Apply locking agent.

Q'TY 2 1 1 1

DIA 6 6 14 12

TRQ 12 10 64 55

REMARKS Apply locking agent. Apply locking agent. Apply engine oil. Apply engine oil.

Q'TY 3 1 1 1 2 2

DIA 8 8 10 10 8 6

TRQ 35 35 60 60 35 12

REMARKS

Q'TY 1 1

DIA 10 10

TRQ 10 39

REMARKS

Q'TY 2 2 3 1 1 1

DIA 8 8 6 6 8 6

TRQ 11 18 14 10 20 10

Q'TY 1 5

DIA 12 6

TRQ 44 15

Apply engine oil.

ALTERNATOR/STARTER CLUTCH ITEM Starter clutch socket bolt Stator mounting bolt Flywheel lock nut CKP sensor mounting bolt  Alternator harness stay bolt CRANKCASE/CRANKSHAFT/BALANCER ITEM Mainshaft bearing setting plate bolt Push plug bolt Balancer driven gear lock nut Balancer nut ENGINE UNIT ITEM Front engine hanger nut Front lower engine hanger nut Rear upper engine hanger nut Rear lower engine hanger nut Upper engine hanger nut Drive sprocket bolt SIDESTAND ITEM Sidestand pivot bolt Sidestand pivot nut

3-12

Self lock nut

3-12

EXHAUST PIPE/MUFFLER ITEM Exhaust pipe stud bolt Exhaust pipe joint cap nut Muffler front protector bolt Muffler protector socket bolt Muffler band bolt Exhaust pipe protector socket bolt

REMARKS 3-13

FRONT WHEEL ITEM Front axle nut Front brake disc nut

REMARKS Self lock nut

1-13

GENERAL INFORMATION FORK ITEM Top bridge pinch bolt Bottom bridge pinch bolt Brake hose clamper bolt Fork bolt Fork socket bolt

Q'TY 2 4 2 2 2

DIA 8 8 6 27 8

TRQ 22 32 12 22 20

REMARKS

Q'TY 4 1 1 1 1 1

DIA 8 6 6 7 10 12

TRQ 26 1.0 5.9 3.8 3.0 3.0

REMARKS

Q'TY 1 1

DIA 24 26

TRQ 103 –

REMARKS 3-19

Q'TY 1 6

DIA 16 8

TRQ 93 32

REMARKS Self lock nut Self lock nut

Q'TY 1 1 1 1

DIA 10 10 14 5

TRQ 44 44 88 6.0

REMARKS

Q'TY 2 2 2 1 1 1 1 1 2

DIA 4 6 10 6 6 4 10 10 8

TRQ 1.5 12 34 1.0 5.9 1.2 17 2.5 30

1 1

8 8

22 5.4

Q'TY 1

DIA 6

TRQ 10

Apply locking agent.

HANDLEBAR ITEM Handlebar upper holder bolt Clutch lever pivot bolt Clutch lever pivot nut Throttle cable A adjusting nut (grip side) Throttle cable A lock nut (grip side) Throttle cable B lock nut (grip side) STEERING STEM ITEM Steering stem nut Steering stem adjusting nut

REAR WHEEL ITEM Rear axle nut Driven sprocket nut REAR SUSPENSION ITEM Shock absorber upper bolt Shock absorber lower nut Swingarm pivot nut Drive chain slider screw

Self lock nut Self lock nut

FRONT BRAKE ITEM Front master cylinder reservoir cap screw Front brake master cylinder holder bolt Front brake hose oil bolt Brake lever pivot bolt Brake lever pivot nut Front brake light switch screw Front brake pad hanger pin Front brake pad pin plug Front brake caliper bolt Front brake caliper main slide pin Front brake caliper bleed valve

REMARKS

Pre-coated (ALOC) bolt, replace with a new one. Apply locking agent.

REAR BRAKE ITEM Rear brake arm nut

1-14

REMARKS Self lock nut

GENERAL INFORMATION PGM-FI SYSTEM ITEM EOT sensor O2 sensor Bank angle sensor

Q'TY 1 1 2

DIA 10 12 6

TRQ 15 25 5.8

REMARKS Apply engine oil.

Q'TY 1

DIA 10

TRQ 16

REMARKS

Q'TY 4

DIA 10

TRQ 19

REMARKS

Q'TY 3

DIA 4

TRQ 1.2

REMARKS

IGNITION SYSTEM ITEM Spark plug

LIGHTING SYSTEM ITEM Turn signal light mounting nut SPEEDOMETER ITEM Meter screw

1-15

GENERAL INFORMATION

SPECIAL TOOL LIST TITLE

Fuel & Engine

Frame & Chassis

1-16

TOOL No. 07406-0040004 070MJ-K260100 070MF-KVS0300 070PZ-ZY30100 07708-0030200 07908-KE90000 070MG-0010100 07757-0010000 07984-MA60001 07942-MA60000 07724-0010200 07GMB-KT70101 07725-0040001 07933-KM10001 07746-0050300 07746-0050100 07746-0010200 07746-0040200 07749-0010000 07748-0010001 07747-0010100 07747-0010300 07747-0010400 07916-KA50100 07746-0050500 07746-0040400 07953-MJ10000 07746-0010300 07914-SA50001

TOOL NAME Fuel pressure gauge Fuel pressure gauge attachment Fuel pump case remover  SCS short connector   Locknut wrench, 10 x 12 mm Tappet adjusting wrench, 3 x 4 mm Tensioner stopper   Valve spring compressor   Valve guide reamer, 5.0 mm Valve guide driver, 4.8 mm Gear holder   Clutch center holder  Flywheel holder   Flywheel puller   Bearing remover head, 12 mm Bearing remover shaft Attachment, 37 x 40 mm Pilot, 12 mm Driver   Oil seal remover   Fork seal driver weight Fork seal driver attachment Fork seal driver attachment Lock nut wrench Bearing remover head, 17 mm Pilot, 17 mm Ball race remover set Attachment 42 x 47 mm Snap ring pliers

GENERAL INFORMATION

CABLE & HARNESS ROUTING COMBINATION SWITCH WIRE

RIGHT HANDLEBAR SWITCH WIRE

LEFT HANDLEBAR SWITCH WIRE

HEADLIGHT WIRE

RIGHT HANDLEBAR SWITCH WIRE

LEFT HANDLEBAR SWITCH WIRE

TURN SIGNAL LIGHT WIRE

MAIN WIRE HARNESS

MAIN WIRE HARNESS INSIDE BOOT CONNECTORS: · LEFT HANDLEBAR 9P · LEFT HANDLEBAR SWITCH WIRE

MAIN WIRE HARNESS INSIDE BOOT CONNECTORS: · RIGHT HANDLEBAR SWITCH 6P · LEFT FRONT TURN SIGNAL LIGHT WIRE · RIGHT FRONT TURN SIGNAL LIGHT WIRE · FRONT TURN SIGNAL LIGHT GROUND WIRE

5 – 10 mm

1-17

GENERAL INFORMATION

THROTTLE CABLE A

2 – 4 mm

THROTTLE CABLE B

SPEEDOMETER CABLE

WHITE IDENT MARK  AREA (15 mm)

WHITE IDENT MARK

1-18

GENERAL INFORMATION

INSIDE BOOT CONNECTORS: · REAR BRAKE LIGHT SWITCH 2P · ALTERNATOR 3P · ALTERNATOR 2P · NEUTRAL SWITCH WIRE

BATTERY NEGATIVE (–) CABLE

NEUTRAL SWITCH WIRE

To be butted.

O2 SENSOR 2P CONNECTOR  ALTERNATOR WIRE

EOT SENSOR 2P CONNECTOR

DLC ECM 33P CONNECTOR

STARTER MOTOR CABLE

BATTERY NEGATIVE (–) CABLE 45° ± 5°  ALTERNATOR WIRE BATTERY NEGATIVE (–) CABLE

NEUTRAL SWITCH WIRE

1-19

GENERAL INFORMATION

NEUTRAL SWITCH WIRE

NEUTRAL SWITCH WIRE

DRIVE SPROCKET COVER NEUTRAL SWITCH WIRE

DRIVE SPROCKET COVER

DRIVE SPROCKET COVER

CKP SENSOR WIRE

 ALTERNATOR WIRE

1-20

GENERAL INFORMATION

BANK ANGLE SENSOR 3P CONNECTOR

IGNITION COIL WIRE

1-21

GENERAL INFORMATION

MAIN WIRE HARNESS

INJECTOR 2P CONNECTOR

MAIN WIRE HARNESS

IACV 4P CONNECTOR

MAIN WIRE HARNESS

TURN SIGNAL LIGHT WIRE

INSIDE BOOT CONNECTORS: · LICENSE LIGHT 2P · BRAKE/TALE LIGHT 3P · LEFT REAR TURN SIGNAL LIGHT WIRE · RIGHT REAR TURN SIGNAL LIGHT WIRE · REAR TURN SIGNAL LIGHT GROUND WIRE

1-22

GENERAL INFORMATION

FUEL FEED HOSE

1-23

GENERAL INFORMATION

TECHNICAL FEATURES FUEL PUMP SYSTEM WITH A FUEL FILTER BLOCKAGE REMINDER FUNCTION

FUEL TANK BREATHER FILTER FUEL PUMP FUEL LEVEL

BREATHER PASSAGE PUMP CHAMBER To FUEL INJECTOR FUEL FILTER

: Air suction passage under fuel filter blockage : Air discharge passage under normal fuel filter condition : Fuel flow under normal fuel filter condition

The fuel pump system of this model consists of the following components:  –  –  –  –

Fuel pump chamber  Fuel filter  Breather passage Breather filter 

Under normal condition, the fuel pump chamber sucks fuel through the fuel filter and then supplies it to the injector. When the fuel filter is clogged, the fuel is sucked into the pump chamber through the breather passage in order to keep the vehicle running. The breather filter is located in the upper inner side of fuel tank. When the fuel is consumed to the point where the breather filter is exposed above the fuel level, a certain amount of air will be drawn into the pump chamber via the breather filter and breather passage. This incoming air produces "a lack of fuel", which impairs engine performance in order to notify the rider of the fuel filter blockage. This symptom works as a reminder for the filter replacement. This system eliminates the need of fuel filter replacement according to a fixed interval, as the rider will experience the symptom and notice the filter blockage during vehicle usage. The driveability remains normal as long as the fuel level in tank is maintained above the breather filter because no air  will be drawn into the pump chamber, even when the fuel filter is clogged. If the fuel in tank is sufficient but such symptom as poor engine performance, lack of fuel, or engine start failure exist, perform the fuel supply test.

1-24

GENERAL INFORMATION

MAINTENANCE SCHEDULE  • Perform the Pre-ride inspection in the Owner’s Manual at each scheduled maintenance period.  • I: Inspect and Clean, Adjust, Lubricate or Replace if necessary. C: Clean. R: Replace. A: Adjust. L: Lubricate.  • The following items require some mechanical knowledge. Certain items (particularly those marked * and **) may require more technical information and tools. Consult a dealer.  • Refer to “Basic" Service Manual for each maintenance instruction except the instructions described in this manual.

ITEMS * FUEL LINE * THROTTLE OPERATION * AIR CLEANER CRANKCASE BREATHER SPARK PLUG * VALVE CLEARANCE ENGINE OIL ** ENGINE OIL STRAINER SCREEN ** ENGINE OIL CENTRIFUGAL FILTER * ENGINE IDLE SPEED DRIVE CHAIN DRIVE CHAIN SLIDER BRAKE FLUID BRAKE SHOES/PADS WEAR BRAKE SYSTEM BRAKE LIGHT SWITCH HEADLIGHT AIM CLUTCH SYSTEM SIDESTAND * SUSPENSION * NUTS, BOLTS, FASTENERS ** WHEELS/TIRES ** STEERING HEAD BEARINGS

FREQUENCY (NOTE 1) NOTE X1,000 km 1 6 12 18 24 X1,000 mi 0.6 4 8 12 16 I I I I I I I I NOTE2 R NOTE3 C C C C I R I R I I I I R R R R R

NOTE4 NOTE5

NOTE4 NOTE4

30 20 I I C I I R

REFER  ANNUAL REGULAR TO 36 CHECK REPLACE PAGE 24 I I I I R 2-7 C R 4-22 I 2-14 R R 2-13

C

C

C

2-13

C

C

C

2-21

I I I Every 1000 I I I I I I I I I I I I I I I I I I I I I I I I I

I Km I I I I I I I I I I

I I I (600 mi) I, L I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I

I

I I I I I I I I I I I

2 years

4-33

 • * Should be serviced by a dealer, unless the owner has proper tools and service data and is mechanically qualified.  • ** In the interest of safety, we recommend these items be serviced only by a dealer.  • Honda recommends that a dealer should road test the vehicle after each periodic maintenance is carried out. NOTES: 1. 2. 3. 4. 5.

At higher odometer readings, repeat at the frequency interval established here. Service more frequently when riding in unusually wet or dusty areas. Service more frequently when riding in rain or at full throttle. Service more frequently when riding OFF-ROAD. Replacement requires mechanical skill.

1-25

MEMO

2. FUEL & ENGINE

FUEL LINE················································ 2-2

CYLINDER/PISTON ······························· 2-20

FUEL PUMP UNIT ···································· 2-4

CLUTCH/GEARSHIFT LINKAGE ·········· 2-21

FUEL TANK ·············································· 2-6

ALTERNATOR/STARTER CLUTCH······ 2-24

AIR CLEANER·········································· 2-7

CRANKCASE/CRANKSHAFT/ BALANCER············································ 2-26

THROTTLE BODY···································· 2-8 TRANSMISSION ···································· 2-28 LUBRICATION SYSTEM························ 2-12 ENGINE UNIT········································· 2-31 CYLINDER HEAD···································2-14

2-1

FUEL & ENGINE FUEL& ENGINE

FUEL LINE  • This vehicle uses resin for the part of materials in the fuel feed hose. Do not bend or twist the fuel feed hose.  • Seat 3-4  • Fuel tank shroud 3-8  • Fuel pump 5P connector    • Let the engine idle until it stops.

 • Battery negative (–) cable 4-28

• Do not use tools in removal. If the connector does not move, alternately pull and push the connector until it comes off easily.  • Check the fuel quick connect fitting for dirt, and clean if  necessary.  • Place a shop towel over the quick connect fitting.  • Push the retainer tab forward.  • Press down the retainer and disconnect the connector  from the fuel pump joint/injector joint. • Check the retainer condition and replace the fuel feed hose if necessary.  • To prevent damage and keep foreign matter out, cover the disconnected connector and pipe end with the plastic bags. • Press the connector onto the fuel joint until the retainer  locks with a “CLICK”. If it is hard to connect, put a small amount of engine oil on the pipe end.  • Make sure the connection is secure; check visually and by pulling the connector.  • After installing the removed parts, turn the ignition switch ON. (Do not start the engine.) The fuel pump will run for about 2 seconds, and fuel pressure will rise. Repeat 2 or 3 times, and check that there is no leakage in the fuel supply system.

2-2

FUEL & ENGINE

FUEL SUPPLY TEST  • If the fuel in tank is sufficient but such symptom as poor engine performance, lack of fuel, or engine start failure exist, perform the following.  – Perform the fuel pressure test. 2-3  – Fuel flow inspection if the fuel pressure is within specification. 2-3  – Fuel flow inspection in the specified fuel quantity. 2-3

FUEL PRESSURE TEST  • Quick connect fitting (fuel pump side)

[A]

[B]

to INJECTOR (fuel feed hose)

from FUEL PUMP

 • Attach the fuel pressure gauge and attachment. [A] Fuel pressure gauge: 07406-0040004 [B] Fuel pressure gauge attachment: 070MJ-K260100  • Temporarily connect the negative cable to the battery and fuel pump 5P connector. Start the engine and let it idle, and read the fuel pressure. Standard: 294 kPa  • If the fuel pressure is higher than specified, replace the fuel pump assembly. 2-4  • If the fuel pressure is lower than specified, inspect the following.  – Fuel line leaking  – Any erratic swing or vibr ation of the gauge needle in t he pressure gauge reading.  • If the needle is swing or vibration, replace the fuel filter. 2-5  • If the needle is not swing or vibration, replace the fuel pump unit. 2-4

FUEL FLOW INSPECTION from FUEL PUMP

[A]

 • Quick connect fitting (injector side) 2-2  • Place the end of the hose into an approved gasoline container. Wipe off spilled out gasoline.  • Turn the ignition switch ON (Do not start the engine.) and the fuel pump operates for 2 seconds. Repeat 5 times to meet the total measuring time. Standard: 58.6 cm3 minimum/10 seconds  • If fuel flow is less than specified, inspect the following:  – Clogged fuel hose  – Fuel pump unit  • Place the vehicle on the level ground with its sidestand.  Adjust the fuel in the tank so that the fuel gauge is positioned the specified range [A], and inspect the fuel flow.  – If the fuel flow is above specification, check for other malfunctioning parts.  – If the fuel flow is under specification, replace the fuel filter. 2-5

2-3

FUEL & ENGINE

FUEL PUMP UNIT 12 N·m

 • Quick connect fitting (fuel pump side) 2-2  • Fuel tank 2-6  • Loosen the nuts in a crisscross pattern in several steps.  • Carefully remove the fuel pump unit from the fuel tank to prevent damaging the fuel level sensor.  • Install a new outer packing onto the fuel pump unit groove by aligning the tab with the boss.  • Set the setting plate onto the fuel pump by aligning the hole and boss.  • Install the fuel pump into the fuel tank by aligning the setting plate triangle mark with the fuel tank triangle mark.  • Tighten the fuel pump setting plate nuts in the specified sequence as shown.  • Make sure that the outer packing tab can be seen in the setting plate hole.  • Fuel pump malfunction and inspection

2-4

FUEL & ENGINE

FUEL FILTER Y

G

G

Y

G

Y

R

Bl

Y

G

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

2-5

FUEL & ENGINE

FUEL TANK

 • Quick connect fitting (injector side) 2-2

2-6

FUEL & ENGINE

AIR CLEANER 1.0 N·m

1.0 N·m

1.0 N·m

 • Discard the air cleaner element in accordance with the maintenance schedule. 1-25  • Replace the element any time if it is excessively dirty or damaged.  •  •  •  •

Seat 3-4 Side cover 3-7 Rear center cowl 3-5 Battery box 3-11

2-7

FUEL & ENGINE

THROTTLE BODY 12 N·m

2.5 N·m

4.5 N·m

 • Injector

2-11

 • If the throttle body is replaced, perform the TP sensor reset procedure. 2-10  • Throttle body cleaning and inspection

2-8

FUEL & ENGINE 3.4 N·m

[A]

2.1 N·m

3.4 N·m

 • The throttle body is factory pre-set. Do not disassemble in a way other than shown in this manual.  • Do not loosen or tighten the white painted fastener. Loosening or tightening it can cause throttle body malfunction.

Sensor unit  • Throttle body 2-8  •

Install the sensor unit to the throttle body by aligning the clip of the sensor unit with the boss of the throttle valve.  • Perform the TP sensor reset procedure. 2-10

IACV  • Throttle cable cover 2-8  • Turn the slide valve [A] clockwise until lightly seated on IACV.  • Align the slot in the set plate with the lug of the IACV.  • Align the slide valve groove with the pin.  • Check the IACV for wear or damage.  • The IACV operation can be checked visually as follows: 1. Connect the IACV 4P connector. 2. Turn ignition switch ON, check the slide valve operation.

2-9

FUEL & ENGINE

TP SENSOR RESET PROCEDURE • Make sure that DTC is not stored in ECM. If the DTC is stored in ECM, TP sensor reset mode won’t start by following the procedure below.  • Left side cover 3-7  • Connector cover from the DLC [A].  • Connect the special tool to the DLC. SCS short connector: 070PZ-ZY30100

[A]

 • EOT sensor 2P connector [B].  • Short the EOT sensor 2P connector terminals with jumper  wire. Connection: Y/Bu – G/W

Y/Bu

G/W

[B]

 • Turn the ignition switch ON, and then disconnect the  jumper wire from the EOT sensor 2P connector within 10 seconds while the MIL is blinking (reset receiving pattern).  • Check for the MIL blinks.  After disconnecting the jumper wire, the MIL should start short blinking. (reset completed pattern) If the jumper wire is connected for more than 10 seconds, the MIL will stay ON (unsuccessful pattern). Try again from the first.  • Check the engine idle speed.

[B]

within 10 sec.

Reset procedure and MIL blinking pattern

within 10 sec.

0.3 sec. 0.3 sec.

0.1 sec. 1.3 sec.

Reset receiving

2-10

Reset completed

FUEL & ENGINE

INJECTOR 5.1 N·m

 • Throttle cable cover 3-11  • Quick connect fitting (injector side) 2-2

2-11

FUEL & ENGINE

LUBRICATION SYSTEM SYSTEM DIAGRAM OIL PUMP

OIL STRAINER SCREEN

CENTRIFUGAL OIL FILTER

ENGINE OIL LEVEL CHECK  • Place the vehicle on the level ground.  • Let the engine idle for 3 – 5 minutes. UPPER

LOWER

2-12

 • Wait for 2 – 3 minutes.  • Hold the vehicle in an upright position.  • Clean and insert the oil filler cap/dipstick without screwing it in, remove it and check the oil level.  • If the oil level is below or near the lower level line on the dipstick, add the recommended oil to the upper level.  • Check that the O-ring on the oil filler cap is in good condition, and replace it if necessary.  • RECOMMENDED ENGINE OIL: Honda “4-stroke motorcycle oil” or an equivalent motor oil. API service classification: SG or higher  JASO T903 standard: MA Viscosity: SAE 10W-30

FUEL & ENGINE

ENGINE OIL CHANGE  • Drain oil completely. 30 N·m

 • Fill the crankcase with the recommended engine oil.  • ENGINE OIL CAPACITY: 1.0 liter after draining 1.2 liter after disassembly

ENGINE OIL STRAINER SCREEN/OIL PUMP

3.0 N·m

 • Right crankcase cover 2-21  •

Align the cutouts of the oil pump drive shaft and inner rotor.

 • Oil pump inspection

2-13

FUEL & ENGINE

CYLINDER HEAD  • The following services can be serviced with the engine installed in the frame.

VALVE CLEARANCE  • Inspect while the engine is cold (below 35°C).  • Cylinder head cover 2-15

10 N·m

 • Rotate the crankshaft counterclockwise and align the "T" mark on the flywheel with the index notch on the left crankcase cover.

15 N·m

 • The index lines on the cam sprocket are aligned with the cylinder head tabs [A].  • Make sure that the mark [B] on the cam sprocket is in the position shown (TDC). If the cam sprocket mark is not in position shown, rotate the crankshaft one full turn.

[B]

[A]

 • Valve clearance (Insert a feeler gauge between the valve adjusting screw and valve stem). IN: 0.08 ± 0.02 mm, EX: 0.24 ± 0.02 mm Locknut wrench, 10 x 12 mm: 07708-0030200 Tappet adjusting wrench, 3 x 4 mm: 07908-KE90000  • Loosen the lock nut and turn the adjusting screw until there is a slight drag on the feeler gauge.  • Hold the adjusting screw and tighten the lock nut.  • Recheck the valve clearance after tightening.

18 N·m

2-14

FUEL & ENGINE

CYLINDER HEAD COVER

 • Fuel tank shroud 3-8

2-15

FUEL & ENGINE

CAMSHAFT/ROCKER ARM  • Set the piston to the TDC on the compression stroke. 2-14  • Install the special tool into the tensioner body and turn the tool clockwise until it stops. Hold the tensioner lifter by pushing the tool while aligning the tabs of the tool with the grooves of the tensioner lifter. Tensioner stopper: 070MG-0010100

4.0 N·m

Intake:

Cam chain side

[B]

[A]

9.0 N·m

5.0 N·m 12 N·m

Exhaust:

Cam chain side

 •  •

Install the camshaft with its flange tab facing up. Insert the rocker arm shafts into the cylinder head as shown using a flat-tip screwdriver and align the bolt holes in the shafts and the cylinder head.  • The index lines on the cam sprocket are align with the cylinder head tabs [A]. Make sure that the mark [B] on the cam sprocket is in the position shown.  • Camshaft inspection

2-16

FUEL & ENGINE

7.4 – 12 mm

30 N·m

9.0 N·m

Camshaft/rocker arm 2-16 Exhaust pipe/muffler 3-13 Insulator 2-8 Upper engine hanger bracket 2-31 Spark plug 4-22 EOT sensor 4-19 O2 sensor 4-20 Remove the cylinder head bolts. Loosen the cylinder head nuts in a crisscross pattern in several steps. Remove the stud bolts. Install the cam chain guide while aligning its pins with the grooves on the cylinder and its end with the groove on the left crankcase.  • After tightening the cylinder head nuts, check that the length from the cylinder stud bolt head to the cylinder  head nut upper surface is within specification.  •  •  •  •  •  •  •  •  •  •  •

2-17

FUEL & ENGINE

 •  •  •

 •

 •  •  •

2-18

Remove the valve cotters. Valve spring compressor: 07757-0010000 Ream the valve guide to remove any carbon build up before measuring the guide. Insert the reamer from the combustion chamber side of the cylinder head and always rotate the reamer clockwise. Valve guide reamer, 5.0 mm: 07984-MA60001 Support the cylinder head and drive the valve guides out of the cylinder head from the combustion chamber side. Valve guide driver, 4.8 mm: 07942-MA60000 Drive new valve guides into the cylinder head until they are fully seated. Valve guide driver, 4.8 mm: 07942-MA60000 VALVE GUIDE PROJECTION: (Reference) 16.8 – 17.0 mm Valve and valve spring inspection Valve guide inspection Valve seat inspection

FUEL & ENGINE

CAM CHAIN TENSIONER  • Install the special tool into the tensioner body and turn the tool clockwise until it stops. Hold the tensioner lifter by pushing the tool while aligning the tabs of the tool with the grooves of the tensioner lifter. Tensioner stopper: 070MG-0010100

4.0 N·m

 • Check the cam chain tensioner lifter operation:  – The tensioner shaft should not go into the body when it is pushed.  – When it is turned clockwise with the tensioner stopper, the tensioner shaft should be pulled into the body. The shaft should protrude from the body as soon as the tensioner stopper is released.

2-19

FUEL & ENGINE

CYLINDER/PISTON  • This service can be serviced with the engine installed in the frame.

 • Cylinder head 2-14  • Cam chain tensioner 2-19  • Spread each piston ring and remove it by lifting up at a point opposite the gap.  • Carefully install the piston rings into the piston ring grooves with the markings facing up. Top ring: “1R” or “TOP-1” mark Second ring: “RN” or “TOP-2” mark  • Install the piston with the “IN” mark facing the intake side.  • Do not align the piston pin clip end gap with the piston cut-out.  • Piston and piston rings inspection  • Cylinder inspection

2-20

FUEL & ENGINE

CLUTCH/GEARSHIFT LINKAGE

1.0 mm

0.5 – 1.0 mm

2-21

FUEL & ENGINE 22 N·m

12 N·m

12 N·m

83 N·m

12 N·m 4.0 N·m

83 N·m

Each bearing Each gear tooth Coating width: 6.5 ± 1 mm from the tip

 • Shift change pedal 3-9  • Loosen the oil filter rotor lock nut. Gear holder: 07724-0010200  • Loosen the clutch center lock nut. Clutch center holder: 07GMB-KT70101  • Align the punch marks of the balancer driven gear and drive gear.

2-22

FUEL & ENGINE

[A]

[B]

 • Install the two types of clutch discs properly as shown. [A] 22201-KRE-G01 [B] 22201-KTT-900  • Assemble clutch discs, clutch plates and pressure plate onto clutch center, while aligning " " marks of  clutch center and pressure plate.  • Install the tabs of the clutch disc (outside) into the shallow slots in the clutch outer.  • Clutch inspection

2-23

FUEL & ENGINE

ALTERNATOR/STARTER CLUTCH  • This service can be serviced with the engine installed in the frame. Clean.

74 N·m

 • Drive sprocket cover 3-9  • Hold the flywheel with the special tool for the nut removal. Flywheel holder: 07725-0040001  • Flywheel Flywheel puller: 07933-KM10001  • Clean any oil and grease from crankshaft and flywheel contact area. Install the flywheel onto the crankshaft by aligning the key way with the woodruff key.

2-24

FUEL & ENGINE

16 N·m

Coating width: 6.5 ± 1 mm from the tip

12 N·m

12 N·m

12 N·m

Coating width: 6.5 ± 1 mm from the tip

 •

Apply sealant (TB 1141G, 1215, 1207G, or equivalent) to the seating surface.

2-25

FUEL & ENGINE

CRANKCASE/CRANKSHAFT/BALANCER [A]

Coating width: 6.5 ± 1 mm from the tip

64 N·m

Each bearing Each gear tooth [B]

1 – 2 cm 3

[A] 10 N·m [B] 55 N·m

 •  •  •  •  •  •  •  •  •  •  •  • •  •

2-26

Engine unit 2-31  • Oil pump 2-13 Cylinder/piston 2-20  • Neutral switch 4-26 Clutch/gearshift linkage 2-21  • Starter motor 4-25 Alternator/starter clutch 2-24 Remove the crankcase bolts in a crisscross pattern in 2 – 3 steps. Place the crankcase with the left crankcase facing down and separate. Install the gear holder [A]. Temporarily install the balancer drive gear and loosen the right side of the balancer driven gear lock nut [B]. Gear holder: 07724-0010200 Install the gear holder [A] and loosen the left side of the balancer nut [B]. Gear holder: 07724-0010200 Align with the cut-outs of the crankshaft and balancer shaft. Install the push plug by aligning its flat surface with the crankshaft bearing outer race. Temporarily install the balancer drive gear and align with the punch marks of the balancer driven gear and drive gear. Apply sealant (TB1215, 1207G, or equivalent) to the left crankcase mating surface. Crankshaft inspection Connecting rod inspection

FUEL & ENGINE

 • Balancer inspection

CRANKSHAFT RUNOUT INSPECTION  • Set the crankshaft on V-blocks and measure the runout using a dial indicator. Limit: 0.03 mm

47.5 mm

45.0 mm

2-27

FUEL & ENGINE

TRANSMISSION Coating width: 6.5 ± 1 mm from the tip Each bearing Each gear tooth

R/L

C 12 N·m

0.5 – 1.0 mm

0.5 – 1.0 mm

 • Separate the crankcase 2-26  • Each shift fork has an identification mark. R/L: right and left C: center • Install the oil seal to the left crankcase so that the depth as shown.  • Align the wide tooth with the wide groove of the kickstarter spindle.

2-28

FUEL & ENGINE MAINSHAFT

Each gear tooth

 • Transmission inspection

COUNTERSHAFT

Each gear tooth

 • Transmission inspection

2-29

FUEL & ENGINE

 •

Hook the return spring to the hole of the kickstarter spindle, and then install the collar by aligning its cutout with the spring.

 • Kickstarter inspection

2-30

FUEL & ENGINE

ENGINE UNIT 35 N·m 60 N·m 35 N·m

60 N·m

35 N·m

12 N·m 35 N·m

 •  •  •  •

Exhaust pipe/muffler 3-13 Drive sprocket cover 3-9 Fuel tank 2-6 Throttle cable cover 3-11

2-31

MEMO

3. FRAME & CHASSIS

BODY PANELS ········································ 3-2

STEERING STEM··································· 3-19

SIDESTAND ··········································· 3-12

REAR WHEEL········································ 3-21

EXHAUST PIPE/MUFFLER····················3-13

REAR SUSPENSION ····························· 3-23

FRONT WHEEL······································ 3-14

FRONT BRAKE······································ 3-24

FORK ······················································ 3-16

REAR BRAKE ········································ 3-27

HANDLEBAR ········································· 3-18

3-1

FRAME & CHASSIS FRAME& CHASSIS

BODY PANELS [1] [2]

[3]

[8]

[4]

[5] [7]

[6] [9] [16]

[15]

[10]

[14]

[13]

[11] [12]

[1] [2] [3] [4] [5] [6] [7] [8]

Rearview mirror 3-3 Battery box 3-11 Seat 3-4 Tool box 3-12 Drive chain case 3-7 Drive sprocket cover 3-9 Shift change pedal 3-9 Fuel tank shroud 3-8

3-2

[9] Front cowl 3-3 [10] Front fender 3-4 [11] Brake pedal 3-10 [12] Side cover 3-7 [13] Rear fender 3-6 [14] Rear grip 3-5 [15] Rear center cowl 3-5 [16] Throttle cable cover 3-11

FRAME & CHASSIS

REARVIEW MIRROR

FRONT COWL

3-3

FRAME & CHASSIS

FRONT FENDER

SEAT

 • Side cover

3-4

3-7

FRAME & CHASSIS

REAR CENTER COWL

 • Seat

3-4

REAR GRIP

 • Rear center cowl 3-5

3-5

FRAME & CHASSIS

REAR FENDER

 • Rear center cowl 3-5  • Rear turn signal light 3-5

CL only :

3-6

FRAME & CHASSIS

SIDE COVER

DRIVE CHAIN CASE

3-7

FRAME & CHASSIS

FUEL TANK SHROUD CL only :

 • Side cover

3-8

3-7

FRAME & CHASSIS

SHIFT CHANGE PEDAL

98 mm

DRIVE SPROCKET COVER

3-9

FRAME & CHASSIS

BRAKE PEDAL

108 mm

3-10

FRAME & CHASSIS

BATTERY BOX

 • Battery 4-28  • Seat 3-4

THROTTLE CABLE COVER

3-11

FRAME & CHASSIS

TOOL BOX

SIDESTAND 39 N·m

10 N·m Sliding surface

 •  •

3-12

After tightening the pivot bolt to the specified torque, turn it 45 – 90 ° counterclockwise. When tightening the pivot nut, hold the pivot bolt securely.

FRAME & CHASSIS

EXHAUST PIPE/MUFFLER

14 N·m

10 N·m 20 N·m

2   1 .5   ± 1  .0  m m 

11 N·m

10 N·m

18 N·m

 • Muffler 3-13

3-13

FRAME & CHASSIS

FRONT WHEEL

44 N·m

 • Wheel inspection

3-14

FRAME & CHASSIS

15 N·m

 • Install the bearing remover head into the bearing. From the opposite side, install the bearing remover shaft and drive out the bearing from the wheel hub. Bearing remover head, 12 mm: 07746-0050300 Bearing remover shaft: 07746-0050100  • Drive in a new bearing squarely with its marked side facing outside until it is fully seated. Driver: 07749-0010000 Attachment, 37 x 40 mm: 07746-0010200 Pilot, 12 mm: 07746-0040200  • Install the distance collar.  • Drive in a new bearing squarely with its marked side facing outside until it is seated on the distance collar. Driver: 07749-0010000 Attachment, 37 x 40 mm: 07746-0010200 Pilot, 12 mm: 07746-0040200  • Wheel disassembly and inspection

3-15

FRAME & CHASSIS

FORK

22 N·m

32 N·m

12 N·m

 • Front fender 3-4  • Front wheel 3-14  • Front brake caliper 3-26  • Align the mating surface with the top surface of the top bridge.

3-16

FRAME & CHASSIS

184 mm

22 N·m

20 N·m LEFT

 •

RIGHT

Remove the oil seal. Oil seal remover: 07748-0010001

 •

Drive in a new oil seal squarely with its marked side facing up until it is fully seated. Fork seal driver weight: 07747-0010100 Fork seal driver attachment: 07747-0010400  • Pour the specified amount of recommended fork fluid into the fork pipe. RECOMMENDED FORK FLUID: CN10# or equivalent FORK FLUID CAPACITY: 183 ± 2.5 cm 3  • Compress the fork leg fully and measure the fluid level from the top of the fork pipe. FORK FLUID LEVEL: 184 mm  • Pull the fork pipe up and install the fork spring with its tightly wound coil side facing down.  • Fork disassembly and inspection

3-17

FRAME & CHASSIS

HANDLEBAR 3.0 N·m 3.8 N·m

26 N·m

3.0 N·m

1.0 N·m

5.9 N·m

 • Front brake master cylinder 3-25  • Rearview mirror 3-3  •  •  •  •

3-18

Align the punch mark with the top surface of the top bridge. Align the punch mark with the mating surface. Align the punch mark with the lower throttle housing index line. Align the locating pin with the handlebar hole.

FRAME & CHASSIS

STEERING STEM TOP BRIDGE 22 N·m 103 N·m

 • Speedometer 4-34  • Handlebar 3-18

3-19

FRAME & CHASSIS BOTTOM BRIDGE

[A]

3–5g

3–5g

3–5g [B] [C] [D]

3–5g [B] [C] [D]

Multi-purpose extreme pressure grease NLGI #2 (EXCELITE EP2 manufactured by KYODO YUSHI CO., LTD. or equivalent)

3–5g

3–5g

[E]

 • STEERING STEM: [A] Lock nut wrench: 07916-KA50100  • STEERING STEM BEARING: [B] Ball race remover set: 07953-MJ10000  • STEERING STEM BEARING: [C] Driver: 07749-0010000 [D] Attachment 42 x 47 mm: 07746-0010300  • STEERING STEM: [A] Lock nut wrench: 07916-KA50100 [E] Fork seal driver attachment: 07747-0010300  • Install the adjusting nut. Hold the steering stem and tighten the adjusting nut to the initial torque. TORQUE: 5.0 N·m  • Turn the steering stem lock-to-lock several times to seat the bearing. Completely loosen the top thread.  • Tighten the steering stem adjusting nut to the specified torque using the special tool. TORQUE: 5.0 N·m  • Steering disassembly/assembly and inspection

3-20

FRAME & CHASSIS

REAR WHEEL 93 N·m

 • Wheel inspection

3-21

FRAME & CHASSIS 32 N·m

 • Install the bearing remover head into the bearing. From the opposite side, install the bearing remover shaft and drive out the bearing from the wheel hub. Remover head, 17 mm: 07746-0050500 Bearing remover shaft: 07746-0050100  • Drive in a new bearing squarely until it is fully seated. Driver: 07749-0010000 Attachment, 37 x 40 mm: 07746-0010200 Pilot, 17 mm: 07746-0040400  • Install the distance collar.  • Drive in a new bearing squarely with its marked side facing outside until it is seated on the distance collar. Driver: 07749-0010000 Attachment, 42 x 47 mm: 07746-0010300 Pilot, 17 mm: 07746-0040400  • Wheel disassembly and inspection

3-22

FRAME & CHASSIS

REAR SUSPENSION 44 N·m 40 mm

44 N·m

 • Left side cover 3-7  • If you dispose of the shock absorber, drill at the specified point as shown.

88 N·m

44 N·m

 • Rear wheel 3-21  • Drive chain case 3-7

3-23

FRAME & CHASSIS

8 – 9 mm

6.0 N·m

 •

Press the bearings with the marked side facing out.

FRONT BRAKE BRAKE FLUID REPLACEMENT 1.5 N·m

Set line

 • Fill the reservoir with brake fluid from a sealed container to the set line. RECOMMENDED BRAKE FLUID: DOT 3 or DOT 4

3-24

FRAME & CHASSIS

BRAKE MASTER CYLINDER 12 N·m

34 N·m

 •

Install the brake master cylinder and holder with the "UP" mark facing up. Align the edge of the master  cylinder with the punch mark on the handlebar.

1.0 N·m Silicone grease

Silicone grease

1.2 N·m 5.9 N·m

 • Brake fluid 3-24  • Remove the snap ring. Snap ring pliers: 07914-SA50001  • Master cylinder inspection

3-25

FRAME & CHASSIS

BRAKE CALIPER BRAKE PAD REPLACEMENT

17 N·m

2.5 N·m

 •

Install brake pads so that they are set on the brake caliper bracket.

34 N·m

30 N·m

3-26

FRAME & CHASSIS Silicone grease

5.4 N·m

Silicone grease

22 N·m

Silicone grease

 • Brake Brake calipe caliperr inspe inspectio ction n

REAR BRAKE 0.2 – 0.3 g

0.2 – 0.3 g

0.2 – 0.3 g

0.2 – 0.3 g

10 N·m

 • Rear Rear whe wheel 3-21  •

Align Align the the pun punch ch mar marks ks of the the brake brake arm arm and and brak brake e cam. cam.

3-27

MEMO

4. ELECTRICAL SYSTEM

PGM-FI SYSTEM···································· SYSTEM······································ ·· 4-2

LIGHTING SYSTEM ························· ······························· ······ 4-28

IGNITION SYSTEM ························ ································ ········ 4-21

SPEEDOMETER SPEEDOMETER ························ ···································· ············ 4-34

ELECTRICAL ELECTRICAL STARTER ······················· ······················· 4-23

ELECTRICAL ELECTRICAL COMPONENT COMPONENT··········· ················· ······ 4-37

BATTERY/CHARGING BATTERY/CHARGING SYSTEM··········· SYSTEM··········· 4-27

4-1

ELECTRICAL SYSTEM ELECTRICALSYSTEM

PGM-FI SYSTEM  • Refer to "Basic Shop manual" manual" for the following following information. information.  – PGM-FI technical feature and each sensor function.  – Symptom troubleshooting for the PG M-FI system.  – MCS (Motorcycle Communication System) information.

DTC CODE INDEX DTC 1-1 1-2 7-1 7-2 8-1 8-2 9-1 9-2 12-1 21-1 29-1

Function Failure MAP sensor malfunction  • MAP MAP sens sensor or low low volt voltag age e MAP sensor malfunction  • MAP sensor sensor high high volta voltage ge EOT sensor malfunction  • EOT EOT sens sensor or low low vol volta tage ge EOT sensor malfunction  • EOT EOT senso sensorr high high volt voltage age TP sensor malfunction  • TP sen senso sorr low low volta voltage ge TP sensor malfunction  • TP sen senso sorr high high vol voltag tage e IAT sensor malfunction  • IAT sens sensor or low low volta voltage ge IAT sensor malfunction  • IAT sensor sensor high high voltag voltage e Injector malfunction O2 se  s ensor malfunction IACV malfunction ECM EEPROM malfunction

33-2

54-1 54-2

4-2

Bank angle sensor malfunction  • Bank Bank angle angle sens sensor or low low voltag voltage e Bank angle sensor malfunction  • Bank Bank angle angle senso sensorr high high voltage voltage

Symptom/Fail-safe function  • Engine Engine operate operates s normal normally ly  • Engine Engine operate operates s normal normally ly  • Hard Hard start start at a low temp temperat erature ure  • Hard Hard start start at a low temp temperat erature ure  • Poor Poor engin engine e accel accelera eration tion  • Poor Poor engin engine e accel accelera eration tion  • Engine Engine operate operates s normal normally ly  • Engine Engine operate operates s normal normally ly • • • • •  • •  •  •  •  •

Engine does not start Injector, Injector, fuel pump and and ignition ignition coil shut shut down down Engine operates normally Engine stalls, hard to start, rough idling Engine stalls, hard to start, rough idling Does Does not hold hold the self self diagn diagnosi osis s data Does not not erase the self diagnosis diagnosis data with SCS connector  Engine Engine operate operates s normal normally ly Engine Engine stop stop functi function on does does not not operate operate Engine Engine operate operates s normal normally ly Engine Engine stop stop functi function on does does not not operate operate

Page 4-5 4-6 4-7 4-8 4-9 4-10 4-11 4-12 4-13 4-14 4-15 4-16

4-17 4-18

ELECTRICAL SYSTEM

PGM-FI SYSTEM LOCATION

FUEL PUMP IGNITION SWITCH INJECTOR IACV

DLC

BANK ANGLE SENSOR

O2 SENSOR

EOT SENSOR CKP SENSOR

SENSOR UNIT: · MAP SENSOR · IAT SENSOR · TP SENSOR

ECM

4-3

ELECTRICAL SYSTEM

PGM-FI SYSTEM DIAGRAM

R

15A

R

R/W

10A

R/Bu

Bl/R

IGNITION SWITCH REGULATOR/ RECTIFIER LOAD CUT RELAY R

BATTERY

Bl/R

Bl/G

(33-2) Bl/R

(54-1,54-2)

R/Bu

BANK ANGLE SENSOR

1

IGP

26

BA

ECM

Bl/R

Bl/R

PCR

7

FFP

8

FUEL PUMP

Bl/O

10A Y/R

6

VCC

27

PB

5

THL

INJ

16

(12-1)

P/Bl

INJECTOR

SENSOR UNIT

(1-1,1-2)

Lg/Y

MAP SENSOR

(8-1,8-2)

Y

TP SENSOR Gr/Bu

(9-1,9-2) IAT SENSOR

Y/Bu

(7-1,7-2)

G/W

Bl/R

14

TA

24

TO

4

SG

EOT SENSOR

SCS

15

K-LINE

30

LG

2

FI-IND

18

Y G/Bl

DLC

W/Bu

Bl MIL

Bu/Y CKP SENSOR

W/Y

(21-1)

Bl/W

O2 SENSOR

12

PCP

23

PCM

3

O2

IACV2A

20

IACV1A

21

IACV2B

31

IACV1B

32

PG1

9

PG2

10

( ) : DTC : Engine does not start when detecting DTC :Short terminals for  reading DTC

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

ECM 33P CONNECTOR (ECM side of the male terminals)

4-4

SCS SHORT CONNECTOR

Bu

Br/W Bu/W Br/Bl Bu/Bl

G G

IACV

(29-1)

ELECTRICAL SYSTEM

DTC TROUBLESHOOTING DTC 1-1 (MAP SENSOR LOW VOLTAGE)  • Fuel tank shroud 3-8

MAP Sensor Diagram Sensor unit 5P connector

ECM 33P connector G/W

Y/R

Y/R

G/W

Lg/Y

Lg/Y

5V VCC

Y/R Sensor unit (MAP sensor)

PB

Lg/Y

5V ECM

SG

G/W

1. MAP Sensor System Inspection  • Check the MAP sensor voltage with MCS.  • Is the voltage about 0 V indicated?

No ►

• Intermittent failure  • Loose or poor contact at the connector 

Yes ▼

2. Sensor unit Power Input Voltage Inspection

 • Connection: Y/R (+) – G/W (–)  • Is the voltage within 4.75 – 5.25 V?

No ►

• Open or short circuit in Y/R wires  • If there is no open or short circuit, replace the ECM with a new one 4-19, and recheck.

Yes ▼

3. MAP Sensor Output Voltage Inspection

 • Connection: Lg/Y (+) – G/W (–)  • Is the voltage within 3.80 – 5.25 V?

Yes ►

• Replace the sensor unit (MAP sensor) with a new one 2-8, and recheck.

No ▼

4. MAP Sensor Output Line Inspection  • Check a short circuit in Lg/Y wire.  • If there is no short circuit, replace the ECM with a new one 4-19, and recheck.

4-5

ELECTRICAL SYSTEM DTC 1-2 (MAP SENSOR HIGH VOLTAGE)  • Fuel tank shroud 3-8

MAP Sensor Diagram Sensor unit 5P connector

ECM 33P connector G/W

Y/R

Y/R

G/W

Lg/Y

Lg/Y

5V VCC

Y/R Sensor unit (MAP sensor)

PB

Lg/Y

5V ECM

SG

G/W

1. MAP Sensor System Inspection  • Check the MAP sensor voltage with MCS.  • Is the voltage about 5 V indicated?

No ►

• Intermittent failure  • Loose or poor contact at the connector 

Yes ▼

2. MAP Sensor System Inspection 2

 • Install a jumper wire between the terminals. Connection: Lg/Y – G/W  • Check the MAP sensor voltage with MCS.  • Is the voltage about 0 V indicated? No

▼

3. MAP Sensor Output Line Inspection  • Check an open circuit in Lg/Y and G/W wire.  • If there is no open circuit, replace the ECM with a new one 4-19, and recheck.

4-6

Yes ►

• Replace the sensor unit (MAP sensor) with a new one 2-8, and recheck.

ELECTRICAL SYSTEM DTC 7-1 (EOT SENSOR LOW VOLTAGE)  • Fuel tank shroud 3-8

EOT Sensor Diagram ECM 33P connector

EOT sensor 2P connector 

G/W

G/W

Y/Bu

Y/Bu 5V TO

Y/Bu EOT sensor 

ECM SG G/W

1. EOT Sensor System Inspection  • Check the EOT sensor voltage with MCS.  • Is the voltage about 0 V indicated?

No ►

• Intermittent failure  • Loose or poor contact at the connector 

Yes ▼

2. EOT Sensor Inspection

 • Check the EOT sensor voltage with MCS.  • Is the voltage about 0 V indicated?

No ►

• Replace the EOT sensor with a new one 4-19, and recheck.

Yes ▼

3. EOT Sensor Output Line Inspection  • Check an short circuit in Y/Bu wire.  • If there is no short circuit, replace the ECM with a new one 4-19, and recheck.

4-7

ELECTRICAL SYSTEM DTC 7-2 (EOT SENSOR HIGH VOLTAGE)  • Fuel tank shroud 3-8

EOT Sensor Diagram ECM 33P connector

EOT sensor 2P connector 

G/W

G/W

Y/Bu

Y/Bu 5V TO

Y/Bu EOT sensor 

ECM SG G/W

1. EOT Sensor System Inspection  • Check the EOT sensor voltage with MCS.  • Is the voltage about 5 V indicated?

No ►

• Intermittent failure  • Loose or poor contact at the connector 

Yes ▼

2. EOT Sensor Inspection

 • Install a jumper wire between the terminals. Connection: Y/Bu – G/W  • Check the EOT sensor voltage with MCS.  • Is the voltage about 0 V indicated? No

▼

3. EOT Sensor Output Line Inspection  • Check an open circuit in Y/Bu and G/W wire.  • If there is no open circuit, replace the ECM with a new one 4-19, and recheck.

4-8

Yes ►

• Replace the EOT sensor with a new one and recheck.

4-19,

ELECTRICAL SYSTEM DTC 8-1 (TP SENSOR LOW VOLTAGE)  • Fuel tank shroud 3-8

TP Sensor Diagram Sensor unit 5P connector

ECM 33P connector Y

Y/R

G/W

Y

G/W

Y/R 5V VCC

Y/R Sensor unit (TP sensor)

THL

Y

ECM

SG

G/W

1. TP Sensor System Inspection  • Check the TP sensor voltage with MCS.  • Is the voltage about 0 V indicated?

No ►

• Intermittent failure  • Loose or poor contact at the connector 

Yes ▼

2. Sensor unit Power Input Voltage Inspection

 • Connection: Y/R (+) – G/W (–)  • Is the voltage within 4.75 – 5.25 V?

No ►

• Open or short circuit in Y/R wire  • If there is no open or short circuit, replace the ECM with a new one 4-19, and recheck.

Yes ▼

3. TP Sensor Output Line Inspection  • Check a open or short circuit in Y wire.  • Is there open or short circuit?

Yes ►

• Faulty Y wire

No ▼

4. TP Sensor Inspection • Replace the sensor unit (TP sensor) with a new one 2-8  • Erase the DTC’s.  • Check the TP sensor with MCS. • If DTC 8-1 is indicated, replace the ECM with a new one 4-19, and recheck.

4-9

ELECTRICAL SYSTEM DTC 8-2 (TP SENSOR HIGH VOLTAGE)  • Fuel tank shroud 3-8

TP Sensor Diagram Sensor unit 5P connector

ECM 33P connector Y

Y/R

G/W

Y

G/W

Y/R 5V VCC

Y/R Sensor unit (TP sensor)

THL

Y

ECM

SG

G/W

1. TP Sensor System Inspection

 • Check the TP sensor voltage with MCS when the throttle fully closed.  • Is the voltage about 5 V indicated?

No ►

• Check the TP sensor voltage with MCS. • Operate the throttle from fully closed to fully opened.  • If the voltage is not increase continuously, replace the sensor unit (TP sensor) with a new one 2-8, and recheck.

Yes ▼

2. TP Sensor Ground Line Inspection  • Check a open circuit in G/W wire.  • Is there open circuit? Yes ▼

3. TP Sensor Inspection • Replace the sensor unit (TP sensor) with a new one 2-8  • Erase the DTC’s.  • Check the TP sensor with MCS. • If DTC 8-2 is indicated, replace the ECM with a new one 4-19, and recheck.

4-10

No ►

• Faulty G/W wire

ELECTRICAL SYSTEM DTC 9-1 (IAT SENSOR LOW VOLTAGE)  • Fuel tank shroud 3-8

IAT Sensor Diagram Sensor unit 5P connector

ECM 33P connector G/W

G/W

Gr/Bu

Gr/Bu

5V Gr/Bu

TA

Sensor unit (IAT sensor)

ECM G/W

SG

1. IAT Sensor System Inspection  • Check the IAT sensor voltage with MCS.  • Is the voltage about 0 V indicated?

No ►

• Intermittent failure  • Loose or poor contact at the connector 

Yes ▼

2. IAT Sensor Inspection

 • Check the IAT sensor voltage with MCS.  • Is the voltage about 0 V indicated?

No ►

• Replace the sensor unit (IAT sensor) with a new one 2-8, and recheck.

Yes ▼

3. IAT Sensor Output Line Inspection  • Check an short circuit in Gr/Bu wire.  • If there is no short circuit, replace the ECM with a new one 4-19, and recheck.

4-11

ELECTRICAL SYSTEM DTC 9-2 (IAT SENSOR HIGH VOLTAGE)  • Fuel tank shroud 3-8

IAT Sensor Diagram Sensor unit 5P connector

ECM 33P connector G/W

G/W

Gr/Bu

Gr/Bu

5V TA

Gr/Bu Sensor unit (IAT sensor)

ECM SG

G/W

1. IAT Sensor System Inspection  • Check the IAT sensor voltage with MCS.  • Is the voltage about 5 V indicated?

No ►

• Intermittent failure  • Loose or poor contact at the connector 

Yes ▼

2. IAT sensor Inspection

 • Install a jumper wire between the terminals. Connection: Gr/Bu – G/W  • Check the IAT sensor voltage with MCS.  • Is the voltage about 0 V indicated? No

▼

3. IAT Sensor Voltage Input Line Inspection  • Check an open circuit in Gr/Bu and G/W wire.  • If there is no open circuit, replace the ECM with a new one 4-19, and recheck.

4-12

Yes ►

• Replace the sensor unit (IAT sensor) with a new one 2-8, and recheck.

ELECTRICAL SYSTEM DTC 12-1 (INJECTOR)  • Fuel tank shroud 3-8

Injector Diagram ECM 33P connector

Injector 2P connector (Wire side)

Injector 2P connector (Injector side)

P/Bl

B

 A

P/Bl

Bl/R

From Battery Bl/R Injector 

ECM INJ

P/Bl

1. Fuel Injector System Inspection  • Check the fuel injector with MCS.  • Is the DTC 12-1 is indicated?

No ►

• Intermittent failure  • Loose or poor contact at the connector 

Yes ▼

2. Fuel Injector Input Voltage Inspection

 • Connection: Bl/R (+) – Ground (–)  • Does the battery voltage exist?

No ►

• Open circuit in Bl/R wire

Yes ▼

3. Fuel Injector Signal Line Inspection  • Check a open or short circuit in P/Bl wire.  • Is there open or short circuit?

Yes ►

• Faulty P/Bl wire

No ▼

4. Fuel Injector Resistance inspection

 • Connection: A – B  • Is the resistance within 11 – 13 Ω (24 °C)?

No ►

• Faulty fuel injector 

Yes ▼  • Replace the ECM with a new one 4-19, and recheck.

4-13

ELECTRICAL SYSTEM DTC 21-1 (O2 SENSOR)  • Fuel tank shroud 3-8

O2 Sensor Diagram O2 sensor 2P connector

ECM 33P connector Bl/W

Bl/W

Bl/W

O2 ECM

O2 sensor 

1. O2 Sensor System Inspection  • Test-ride the vehicle and check the O2 sensor with MCS.  • Is the DTC 21-1 is indicated?

No ►

• Intermittent failure  • Loose or poor contact at the connector 

Yes ▼

2. O2 Sensor Circuit Inspection  • Check an open or short circuit in Bl/W wire.  • Is there open or short circuit? No

▼

3. O2 Sensor Inspection  • Replace the O2 sensor with a new one. 4-20  • Erase the DTC’s.  • Test-ride the vehicle and check the O2 sensor with MCS. • If DTC 21-1 is indicated, replace the ECM with a new one 4-19, and recheck.

4-14

Yes ►

• Faulty Bl/W wire

ELECTRICAL SYSTEM DTC 29-1 (IACV)  • Fuel tank shroud 3-8

IACV Diagram IACV 4P connector (IACV side)

IACV 4P connector (Wire side) Br/W

 A

B

ECM 33P connector

Bu/W

Br/Bl

Br/W

C D Bu/Bl

Bu/W

Bu/Bl

IACV1A

Bu/W Bu/Bl

IACV

Br/Bl

Br/W

IACV1B

ECM

IACV2A Br/Bl

IACV2B

1. IACV System Inspection  • Check the IACV with MCS.  • Is the DTC 29-1 is indicated?

No ►

• Intermittent failure  • Loose or poor contact at the connector 

Yes ▼

2. IACV Circuit Inspection  • Check a open or short circuit in Bu/W, Br/W, Br/Bl and Bu/Bl wires.  • Is there open or short circuit?

Yes ►

• Faulty Bu/W, Br/W, Br/Bl or Bu/Bl wire

No ▼

3. IACV Resistance Inspection

 • Connection: A – D, B – C  • Is the resistance within 110 – 150 Ω (25 °C)?

No ►

• Faulty IACV

Yes ▼

4. IACV Short Circuit Inspection  • Connection: A – B, C – D  • Is there continuity?

Yes ►

• Faulty IACV

No ▼  • Replace the ECM with a new one 4-19, and recheck.

4-15

ELECTRICAL SYSTEM DTC 33-2 (EEPROM) 1. EEPROM System Inspection  • Check the EEPROM with MCS.  • Is the DTC 33-2 is indicated? Yes ▼  • Replace the ECM with a new one. 4-19, and recheck.

4-16

No ►

• Intermittent failure  • Loose or poor contact at the connector 

ELECTRICAL SYSTEM DTC 54-1 (BANK ANGLE SENSOR LOW VOLTAGE)  • Fuel tank shroud 3-8

Bank Angle Sensor Diagram Bank angle sensor 3P connector 

ECM 33P connector G/W

G/W

R/Bu

Y/R Y/R

VCC

Y/R Bank angle sensor 

BANK

R/Bu

R/Bu

5V 5V ECM

SG

G/W

1. Bank Angle Sensor System Inspection  • Check the bank angle sensor voltage with MCS.  • Is the voltage about 0 V indicated?

No ►

• Intermittent failure  • Loose or poor contact at the connector 

Yes ▼

2. Bank Angle Sensor Power Input Voltage Inspection

 • Connection: Y/R (+) – G/W (–)  • Is the voltage about 5 V indicated?

No ►

• Faulty Y/R wire  • If there is no open or short circuit, replace the ECM with a new one 4-19, and recheck.

Yes ▼

3. Bank Angle Sensor Output Line Inspection  • Check a short circuit in R/Bu wire.  • Is there short circuit?

Yes ►

• Faulty R/Bu wire

No ▼

4. Bank Angle Sensor Inspection • Replace the bank angle sensor with a new one. 4-20  • Erase the DTCs.  • Check the bank angle sensor with MCS.  • If DTC 54-1 is indicated, replace the ECM with a new one 4-19, and recheck.

4-17

ELECTRICAL SYSTEM DTC 54-2 (BANK ANGLE SENSOR HIGH VOLTAGE)  • Bank angle angle sensor sensor (Connector (Connector is connected.) connected.) 4-20

Bank Angle Sensor Diagram Bank angle sensor 3P connector 

ECM 33P connector G/W

G/W

R/Bu

Y/ R Y/R

VCC

Y/R Bank angle sensor 

BANK

R/Bu

R/Bu

5V 5V ECM

SG

G/W

1. Bank Angle Sensor System Inspection  • Check the bank bank angle angle sensor sensor voltage voltage with with MCS.  • Is the the voltag voltage e about about 5 V indica indicated? ted?

No ►

• Inter Intermit mitte tent nt failu failure re  • Loose Loose or poor poor contact contact at at the conne connecto ctor  r 

Yes ▼

2. Bank Angle Sensor Power Input Voltage Inspection

 • Connec Connection tion:: Y/R (+) – G/W (–) (–)  • Is the voltag voltage e about about 5 V indica indicated ted? ?

No ►

• Faul Faulty ty G/W G/W wir wire e

Yes ▼

3. Bank Angle Sensor Output Line Inspection  • Check Check an open open circui circuitt in R/Bu R/Bu wire. wire.  • Is the there re ope open n circ circuit uit? ? No

▼

4. Bank Angle Sensor Inspection • Replace Replace the bank bank angle angle sensor sensor with a new one. one. 4-20  • Eras Erase e the the DTCs DTCs..  • Check Check the the bank bank angle angle sensor sensor with with MCS. MCS. • If DTC 54-2 54-2 is indicat indicated, ed, replace replace the the ECM with with a new one 4-19, 4-19, and recheck.

4-18

Yes ►

• Faul Faulty ty R/B R/Bu u wire wire

ELECTRICAL SYSTEM

ECM

 • Left Left sid side e cov cover er 3-7  • ECM power power circuit circuit and and ground ground circuit circuit inspection inspection

EOT SENSOR

15 N·m

 • EOT sen senso sorr inspe inspect ctio ion n

4-19

ELECTRICAL SYSTEM

O2 SENSOR

25 N·m

 • Fuel Fuel tank tank shro shroud ud 3-8  • Remove the O2 sensor. Flare nut socket: FRXM17 (Snap on) or equivalent

BANK ANGLE SENSOR

5.8 N·m

 • Fuel Fuel tank tank shro shroud ud 3-8  • Bank Bank angle angle sens sensor or inspe inspectio ction n

4-20

ELECTRICAL SYSTEM

IGNITION SYSTEM IGNITION SYSTEM LOCATION IGNITION SWITCH

MAIN FUSE 15 A ECM IGNITION COIL

SPARK PLUG

FUSE BOX: · 10 A

CKP SENSOR

BATTERY

IGNITION SYSTEM DIAGRAM

15 A

IGNITION SWITCH

10 A Bl/R

R/Bu REGULATOR/ RECTIFIER

Bl/R

BATTERY Bu/Y CKP SENSOR

Bl/R ECM P/Bu

W/Y G G/Bl

G IGNITION COIL SPARK PLUG

4-21

ELECTRICAL SYSTEM

SPARK PLUG REPLACEMENT  • Spark plug inspection.

16 N·m

INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE  • Refer to "Basic Shop Manual" for the detail information of  ignition coil primary peak voltage inspection.  • Support the vehicle on a level surface.  • Fuel tank shroud 3-8  • Disconnect the spark plug cap from the spark plug.  • Connect a known-good spark plug to the spark plug cap and ground it to the cylinder head as done in a spark test.  • With the ignition coil primary wires connected, connect the peak voltage adaptor probes to the ignition coil primary terminal and ground. CONNECTION: P/Bu (+) – Ground (–)

 • Check the initial voltage at this time. STANDARD VOLTAGE: Battery voltage  • Shift the transmission in neutral, and then crank the engine with the starter and measure the ignition coil primary peak voltage. PEAK VOLTAGE: 100 V minimum

IGNITION TIMING  • Warm the engine up to normal operating temperature.  • Timing hole cap 2-14  • Connect the timing light to the spark plug wire.  • Start the engine and let it idle IDLE SPEED: 1,400 ± 100 rpm  • The ignition timing is correct if the "F" mark on the flywheel aligns with the index notch on the left crankcase cover.

4-22

ELECTRICAL SYSTEM

ELECTRICAL STARTER ELECTRICAL STARTER SYSTEM LOCATION IGNITION SWITCH

STARTER SWITCH

CLUTCH SWITCH MAIN FUSE 15 A

STARTER RELAY SWITCH

STARTER MOTOR

NEUTRAL SWITCH

BATTERY

FUSE BOX: · 10 A

ELECTRICAL STARTER SYSTEM DIAGRAM IGNITION SWITCH

10 A R/Bu

STARTER MOTOR

R

R/W REGULATOR/ RECTIFIER R

BATTERY STARTER RELAY SWITCH

Bl/R

MAIN 15 A G/R Y/R STARTER SWITCH

Bl Lg/R

CLUTCH SWITCH

NEUTRAL SWITCH G

4-23

ELECTRICAL SYSTEM

ELECTRICAL STARTER TROUBLESHOOTING STARTER MOTOR DOES NOT TURN  • Fuel tank shroud 3-8  • Loose or poor contacts of related terminal/connector   • Battery condition  • Burned fuse

Connector Diagram Starter relay switch 4P connector (View from harness side)

G/R

Y/R

1. Starter Relay Coil Input Circuit inspection

 • Connection: Y/R (+) – Ground (–) (Connector connected)  • Push and hold the starter button.  • Does the battery voltage exist?

No ►

• Inspect the following.  – Ignition switch  – Starter switch  – Regulator/rectifier   – Starter relay coil input related circuit

Yes ▼

2. Starter Relay Coil Ground Circuit inspection

 • Connection: G/R – Ground • Squeeze the clutch lever or shift the transmission in neutral position.  • Is there continuity?

No ►

• Inspect the following.  – Diode  – Clutch switch  – Neutral switch  – Starter relay coil ground r elated circuit

Yes ▼

3. Starter Relay inspection • Replace the starter relay with a new one, and recheck.  • Does the starter motor turn? No ▼  • Check a short or open circuit in starter motor  cable. • If there is no faulty circuit, replace the starter  motor with a new one, and recheck.

4-24

Yes ►

• Faulty original starter relay

ELECTRICAL SYSTEM

STARTER MOTOR

 • Electric starter inspection

4-25

ELECTRICAL SYSTEM

NEUTRAL SWITCH

 • Drive sprocket cover

4-26

3-9

ELECTRICAL SYSTEM

BATTERY/CHARGING SYSTEM BATTERY/CHARGING SYSTEM LOCATION IGNITION SWITCH

REGULATOR/ RECTIFIER

MAIN FUSE 15 A

 ALTERNATOR BATTERY

BATTERY/CHARGING SYSTEM DIAGRAM

15 A R

W

R  ALTERNATOR

BATTERY

G

G REGULATOR/ RECTIFIER

 • Battery/charging system information, troubleshooting and inspection

4-27

ELECTRICAL SYSTEM

BATTERY

 • Left side cover 3-7

LIGHTING SYSTEM

 • Front cowl 3-3  • Headlight aim 4-33

4-28

ELECTRICAL SYSTEM

19 N·m

 • Rear center cowl 3-5

 • Rear fender 3-6

4-29

ELECTRICAL SYSTEM

 • Rear fender 3-6

BULB REPLACEMENT

 • Front cowl 3-3

4-30

ELECTRICAL SYSTEM

 • Front cowl 3-3

4-31

ELECTRICAL SYSTEM

4-32

ELECTRICAL SYSTEM

HEADLIGHT AIM

Beam up

Beam down

4-33

ELECTRICAL SYSTEM

SPEEDOMETER

1.2 N·m

 • Front cowl 3-3

4-34

ELECTRICAL SYSTEM

FUEL LEVEL SENSOR

R

R

Bl

 •  •

Y

G

Bl

Fuel pump unit 2-4 Route the fuel level sensor wires properly as shown.

4-35

ELECTRICAL SYSTEM

FUEL METER TROUBLESHOOTING FUEL METER NEEDLE DOES NOT MOVE  •

Fuel pump unit 2-4

 • Loose or poor contacts of related terminal/connector 

FULL

EMPTY

 A

B

1. Fuel Level Sensor Circuit Inspection  • Check the Y/W and G/Bl wire.  • Is there open or short circuit?

Yes ►

• Faulty Y/W or G/Bl wire

No ▼

2. Fuel Level Sensor Inspection

 • Connection: A – B  • Standard: FULL 6 – 10 Ω, EMPTY 90 – 100  • Does the standard resistance exist?

Ω.

Yes ▼ Replace the meter with a new one 4-34, and recheck.

4-36

No ►

• Replace the fuel level sensor with a new one 4-35, and recheck.

ELECTRICAL SYSTEM

ELECTRICAL COMPONENT IGNITION SWITCH

 • Top bridge

3-19

HORN

4-37

MEMO

INDEX dummytext

INDEX  A Few Words About Safety·············································1-2  AIR CLEANER ································································2-7  ALTERNATOR/STARTER CLUTCH·····························2-24 BATTERY/CHARGING SYSTEM ·································4-27 BODY PANELS·······························································3-2 BRAKE FLUID REPLACEMENT···································3-24 BULB REPLACEMENT·················································4-30 CABLE & HARNESS ROUTING ···································1-17 CLUTCH/GEARSHIFT LINKAGE ·································2-21 CRANKCASE/CRANKSHAFT/BALANCER ··················2-26 CYLINDER HEAD ·························································2-14 CYLINDER/PISTON······················································2-20 ELECTRICAL COMPONENT········································4-37 ELECTRICAL STARTER ··············································4-23 ENGINE OIL CHANGE ·················································2-13 ENGINE OIL LEVEL CHECK ········································2-12 ENGINE OIL STRAINER SCREEN ······························2-13 ENGINE UNIT ·······························································2-31 EXHAUST PIPE/MUFFLER ··········································3-13 FORK ············································································3-16 FRONT BRAKE·····························································3-24 FRONT WHEEL ····························································3-14 FUEL LEVEL SENSOR·················································4-35 FUEL LINE ······································································2-2 FUEL PUMP UNIT ··························································2-4 FUEL TANK ····································································2-6

HANDLEBAR································································ 3-18 HORN ··········································································· 4-37 How To Use This Manual ··············································· 1-3 IGNITION SYSTEM······················································ 4-21 INJECTOR···································································· 2-11 LIGHTING SYSTEM····················································· 4-28 LUBRICATION SYSTEM·············································· 2-12 MAINTENANCE SCHEDULE ······································· 1-25 MODEL IDENTIFICATION ············································· 1-5 PGM-FI SYSTEM ··························································· 4-2 REAR BRAKE ······························································ 3-27 REAR SUSPENSION ··················································· 3-23 REAR WHEEL······························································ 3-21 SIDESTAND ································································· 3-12 SPARK PLUG REPLACEMENT··································· 4-22 SPECIAL TOOL LIST ··················································· 1-16 SPECIFICATIONS·························································· 1-6 SPEEDOMETER ·························································· 4-34 STEERING STEM ························································ 3-19 TECHNICAL FEATURES ············································· 1-24 THROTTLE BODY·························································· 2-8 TORQUE VALUE·························································· 1-12 TP SENSOR RESET PROCEDURE···························· 2-10 TRANSMISSION ·························································· 2-28 VALVE CLEARANCE ··················································· 2-14

 A

H

B

I

C

E

F

L

M

P

R

S

T

V

5-1

5

STARTER MOTOR FUSE BOX SUB1 SUB2 TURN SIGNAL RELAY

IGNITION SWITCH

   A    0    1

   1    T    A    B

   R

   A    0    1

  u    l    l   R    /   B   B   l    /    B   R    l    /    B    R   B

   B   B   E    A   A    1   2    W    1   2    D    S    K    V   V   N    I   S    N    J   S    2   1   P   R   C    M    V   V    I    P   L    N    L    P   G    P    L    C   C    2   G   -   L    B   A    O    C    C   C    C    G    G    F   C   C    H    A    C   -   A    A   K    A  -   IF  -   N    G    G  I    I    N  - P   B  - T   P  -   A I   I I   S   T  - P   I    P   P   F   P   V   T   S   O    L   I

   T  c   D    U  c   N    O    V   G 3P

BATTERY 12V 6Ah

   R    /   R    /   R   R    /   R    Y   G    G

ECM

BANK  ANGLE SENSOR

   R 4P R

  u    W    B    /   /    R   R

   l   r    B   G

DC-LOAD CUT RELAY

15A

   1    O    V

2P

STARTER RELAY SWITCH

   R    /   G    /   R    /    l    l    l    R    B   B   B

IACV 4P Bl

  u    B   R    /   W    /    /    Y   G    R

DLC

REAR BRAKE LIGHT SWITCH

   3   2   1   0   9   8   7   6   5   4   3   2   1   0   9   8   7   6   5   4   3   2   1   0   9   8   7   6   5   4   3   2   1    3   -   3   -   3   -   3   -   2   -   2   -   2   -   2   -   2   -   2   -   2   -   2   -   2   -   2   -   1   -   1   -   1   -   1   -   1   -   1   -   1   -   1   -   1   -   1   -   -   -   -   -   -   -   -   -      A   A   A   A   A   A   A   A   A   A   A   A   A   A   A   A   A   A   A   A   A   A   A   A   A   A   A   A   A   A   A   A   A 33P

   l   l    B    W    W    B    /   /    /   r   /   u  r   u    B   B   B   B

   l   l   u    Y  u    l   u    l    Y  u   u   Y    B   B    O    /   B   u   B    /    /   W    B    B    /    R    /    /   G    /   R    /    B    /    B   /    W    /   Y   W    /   B    /    /   W    /   R    /   B    l    l    G G   l    l   r    /   u  r   Y   /   g   /   u   /   r   u   /    B    B   B   Y    G    B   G    B   B    G    L   R    Y   W    B   B    W    P    G    B   P

4P R

   l    R    /   u   Y   B    /    l    B   B    G

   l    Y    /    B   G

2P 2P

Bl

FRONT BRAKE LIGHT SWITCH

6P G/Y

STARTER ST SWITCH

BAT

Bl G/Y Y/R Bl/R

Y/R Bl/R

FUEL METER

Bl Y/W G/Bl

HI-BEAM IND 12V 1.7W

Bu G

FI IND 12V 3.4W

Bl W/Bu

N IND 12V 3.4W

Bl Lg/R

TURN IND 12V 3.4W

Lb O

METER ILLUMI 2 12V 1.7W

Y G

METER ILLUMI 1 12V 2.0W

Y G

DIODE

9P Bl Bl Y/W Bu W/Bu

Bl Y/W Bu W/Bu

Lg/R Y

Lg/R Y

Lb O G/Bl G

Lb O G/Bl G

LICENSE LIGHT 12V 5W G Y

RIGHT REAR TURN SIGNAL LIGHT 12V 10W 2P G Y Lb G

Lb G

Lb G

G Y Lb G G O G/Y G Y

O G/Y G Y

BRAKE/TAIL LIGHT 12V 5W/21W G/Y G Y

3P

LEFT REAR TURN SIGNAL LIGHT 12V 10W 4P Bl Y Bl W G G G Lb O

Bl W G

POSITION LIGHT 12V 5W

Y G

LEFT FRONT TURN SIGNAL LIGHT 12V 10W

Y Bu W G

G O

   R   /    R    R    /    /    Y   Y   Y

G Lb O

3P

  u    Y   B    R   /    /    W    /   g   /   r   Y    Y   G    L   G

   W    /    l    B

   Y    /    /    Y   u   G    W    W    B

   R    /   g    L

O G

5P

2P Bl

2P

  u    Y   B    R    /   W    /   /   g   /   r   Y    Y   G    L   G

   Y    Y    /    /   u   G    W    B    W 9P Bl

L W R LO HL HI

HORN SWITCH

2P

G/R G/R Lg/R Lg/R

HEAD LIGHT 12V 35W/35W

DIMMER SWITCH

Bl G/Y Y/R Bl/R

4P R

RIGHT FRONT TURN SIGNAL LIGHT 12V 10W

TURN SIGNAL SWITCH

   l    Y    /    B   G

  u    W    B    /   /    R   R

HO BAT

CLUTCH SWITCH

O Gr  Lb

O Gr  Lb Bl W Y Bu G Lg Bl

W Y Bu Lg Bl

O Gr  Lb G/R W Y Bu G Lg Bl   u   W    B   /    /    Y   G

  g    L    G

Bl G

   l    R    O    /    /    l   /    /   B    l    W    B   B   Y   G

   W    Y   /    R    G W    R

5P

2P    R   /    O    /    l    l    B   B

   l    B    W    /    /    Y   G

   R    /   g    L

NEUTRAL SWITCH

HORN

   Y    /   u    B

   Y    /    W

   W

IGNITION SWITCH

STARTER SWITCH

BAT1 VO1

HORN SWITCH

BAT ST

TURN SIGNAL SWITCH

BAT HO

W

R

DIMMER SWITCH L

HL LO

ON

FREE

FREE

R

LO

OFF

PUSH

PUSH

N

N

L

HI

HI

   l    R    B    /    l    /    B   P

   R   /    R    R    R   /    R    R   /    R    R    /    /    /    /    /    l    l   l    l    l   l    l   l    B   B   B   B   B   B   B   B

  u    R    /    B    l    /    B   P

   l    B

O2 SENSOR

CKP  ALTERNATOR SENSOR

REGULATOR /RECTIFIER

   l    l    B   /    B    /    G G    G    G

G

   Y    R   /    /    W    /   g    Y   G    L

  u    B   /    W    /   r    G    G

   R    W    /    Y   /    Y    G

2P

   G

EOT SENSOR FUEL FUEL PUMP LEVEL SENSOR

6P

   W    W    W    W    /    /    /    /    G    G    G    G

MAP SENSOR IAT SENSOR

INJECTOR

TP SENSOR

IGNITION COIL Bl Y Bu G R W

Black Yellow Blue Green Red White

Br  O Lb Lg P Gr 

Brown Orange Light Blue Light Green Pink Gray

TWO COLORED WIRE (EXAMPLE:YELLOW/RED)