Manual de Reparatie Honda CBR 1000 RR [PDF]

Zitiervorschau

HOW TO USE THIS MANUAL This service manual describes CBR 1000 RR-4.

the

servic e procedures

lor

CONTENTS

the

GENERAL INFORMATION

Follow the Maintenance SChedule (Section 4) recomm endations to ensure that the vehicle is in peak operating conditio n and the emiss ion levels are within the stand ards set by the U.S. Environmental Pr otection Agency, California Air Resources Board and Transport Canada .

TECHNICAL FEATURES FRAME/BODY PANELS/EXHAUST SYSTEM

Perl orm ing the first scheduled maintenance is very impor tant. 1\ co m pens ates for the initial we a r that occ urs du ring t he break-in pe rio d.

MAINTENANCE

Sectio ns 1 and 4 apply to the whole motorcycle. Secti on 3 illustrates procedures tor remov al/insta llation of compo nents thai may be requ ired 10perform service descr ibed in the following sections. Sectio n 5 through 20 descri be pari s of the motorcycle , grouped acco rding to location. Find the section you want on this page , then turn to the table of co ntents on the first page of the sectio n. Most sectio ns start with an ass embly or system illustra tion , service information and troubleshooting lor the section. The subsequent pages give detailed procedure. If you are not familiar with this motorcycle , read Technical Featu res in Section 2 . If you don't knOW" the source 'of the trouble, go to section 22 TroubleShooting .

LUBRICATION SYSTEM

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COOLING SYSTEM

w

ENGINE REMOVAUINSTALLATION

II: I-

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CYLINDER HEADNALVES

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CLUTCH/STARTER CLUTCH

z

ALTERNATOR

w

TRANSMISSION/GEARSHIFT LINKAGE

(J)

CRANKCASE/CRANKSHAFT/BALANCER/ PISTON/CYLINDER FRONT WHEEUSUSPENSION/ STEERING

w

Your safety, and the safety of othe rs, is very importa nt. To help you make informed decisions we have provide d safety messages and othe r informalion throughout this manual. Of course, it is not practical or possible to warn you about all the hazar ds associated with ser vicing this vehicle. You must use your own good jud gement. You will find important safety information in a variety of forms including : . • Safety Labels - on the vehicle • Safety Messages - preceded by a safety alert sym bol & and one of three signal words , DANGER, WARN ING , or CAUT ION. These signal words mean : ~ You WILL be KILLED or SERIOUSLY ~ HURT if you don't fellow instructions. ~ ~

You CAN be KILLED o r SERIOUSLY HU RT if you don't follOW" instructions.

~ ~

You CAN be HURT if you don 't follow instructions.

• Instructions - how to serv ice this vehicle correct ly and safely. As you read this manual , you will find information mat is preceded by a symbol . The purpose of this message is to help prevent damage to your vehicle, other property, Of the envi ronment.

CNOnC(]

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REAR WHEEUSUSPENSION

o

HYDRAULIC BRAKE

(J)

J:

BATTERY/CHARGING SYSTEM ..J

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IGNITION SYSTEM

I-

ELECTRIC STARTER

0:

U

W

..J

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LIGHTS/METERS/SWITCHES WIRING DIAGRAM TROUBLESHOOTING INDEX

Date of Issue: March, 2004

Contents

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

S~

Rep lace the part(s) with new one(s) before assembly.

-,

Use recomme nded engin e oil, unless otherwise specified.

~ _-$iiiffi

Use molybd enum oil solution (mixtur e of the engine oil and molybdenum grease in a ratio of 1 : 1).

Use mult i-purp ose grease (Lithium base d multi-purpose grease NLGI #2 or eq uivalent).

Use molybdenum disulfide grease (containing more than 3% molybdenum dis ulfide, NLGI #2 or equivalent).

~

Examp le: Molykote® BR-2 plus man ufactured by Dow Co rning U.S.A. MUlti-p urpose M-2 manufactured by Mitsubishi Oil, Japa n Use molybdenum disulfide pas te (containing more than 40% molybd enum disulfide, NLGI #2 or equivalent). Exampl e: Molykote® G-n Paste manufactu red by Dow Corning U.S.A.

~

Honda Moly 60 (U.S.A. only) Rocol ASP manufacture d by Rocol Limited, U.K. Rocol Paste manufactured by Sumico Lubricant, Japan

~ 0

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",,'Uill

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..

Use silicone grease.

Apply a locking agent. Use a midd le strength locking age nt unless otherwise specified.

Apply sea lant.

Use DOT 4 brake fluid. Use the recom mended brake fluid unless otherw ise spec ified.

Use Fork or Suspension Fluid.

Contents

1. GENERAL INFORMATION

• SERVICE RULES

1-2

REAR WHEEL:/SUSPENSION SPECIFICATIONS ·

·

·

·.. 1-9

MODEL IDENTIFiCATION..···························· 1-2 GENERAL SPECiFiCATIONS ..·..·..··..··..·........ 1-4

HYDRAULIC BRAKE SPECIFICATIONS..··..···..·..··..··..··......·..·....·..·1-10

LUBRICATION SYSTEM SPECiFiCATIONS··..····..··..·..··..··..··..·....··..····· 1-6

BATTERY/CHARGING SYSTEM SPECIFICATIONS..··..·....··....···..·..·..··..···..··..· 1-10

FUEL SYSTEM (Programmed Fuel Injection) SPECiFiCATIONS ·

IGNITION SYSTEM SPECIFICATIONS ........ 1-10 · 1-6 ELECTRIC STARTER SPECIFICATIONS ·....·1-10

COOLING SYSTEM SPECIFICATIONS ......... 1-6 CYLINDER HEADIVALVES SPECiFiCATIONS ....··......·..··..·····..··..···..···....· 1-7

LIGHTS/METERS/SWITCHES SPECIFICATIONS··..·..··......···........···..·..··...... 1-11 STANDARD TORQUE VALUES ......··..··..·.... 1-12

CLUTCH/STARTER CLUTCH SPECiFiCATIONS ..........··..··....····........·....·....· 1-7 TRANSMISSION/GEARSHIFT LINKAGE SPECIFICATIONS

ENGINE & FRAME TORQUE VALUES ....··..1-12 LUBRICATION & SEAL POINTS ......·........·.. 1-20

1-8 . CABLE & HARNESS ROUTING

·.. 1-24

CRANKCASE/CRANKSHAFT/BALANCER/ PISTON/CYLINDER SPECIFICATIONS 1-8

EMISSION CONTROL SYSTEMS ..··....····..·· 1-36

FRONT WHEEl/SUSPENSION/STEERING SPECiFiCATIONS ·..·..··..·......·....·..·........·..······ 1-9

EMISSION CONTROL INFORMATION LABEL (U.S.A. ONLY)·......····....··..··..···........·1-39

Contents

Chapter 1

1-1

GENERAL INFORMATION

SERVICE RULES 1. Use ge nu in e Hon da or Ho nda-reco mmen ded p arts and lubricant s o r the ir equ iva lent s. Part s that don't meet Hon da's design spe ci fi cat ions ma y cause damage to the motorcycle . 2. Us e th e speci al too ls designed fo r t his pr oduct to avoid damage and inco rrec t assembly.

3. Us e only metri c tools when servicing the motorcycle. Met ric bolt s, nuts an d screws a re not inte rcha ngea ble w ith Eng lish fa st en er s. 4. Insta ll new ga skets, Ovrinqs, cotter pins, and lock plates when reassem blin g . 5. Wh en tightening bolts o r nuts, begin with the larger diameter or inner bolt first . Then t ight en to the spec ified torque diag onally in in crem ent al steps unless a parti cular seque nce is sp eci fied . 6. Clean parts i n cle ani ng solve nt upon disassembly. Lubri cate an y slidi ng surfaces before reassembly. 7. After reassem bly, check all parts f or proper in sta llation and o pe ratio n. S. Rou t e all electrical w ir es as shown in the Cab le an d Harness Routing (page 1-24).

MODEL IDENTIFICATION

1-2

Contents

Chapter 1

GENERAL INFORMATION The frame serial number is stamped on the right side of the stee ring head .

The engine serial number is stamped on the rear side of the lower crankcase.

The th rottle body ide ntificatio n num ber is stamped o n the intake side of the throttl e body as shown .

THROTTLE BODY IDENT IFICATION " NUMBER

The co lor label is attached on th e rear f end er B as shown. W hen ordering co lo r-coded parts, always specify the desig nated color co de.

Contents

Chapter 1

1-3

GENERAL INFORMATION Th e Ve hicl e Ident ification Number (VIN ) is locat ed on the left side of the ma in frame on th e Safet y Certi fication Labe ls.

VEHICLE IDENTIFICATiON NUMBER (VIN)

GENERAL SPECIFICATIONS ITE M DIMENSIONS

Overa ll lengt h Overa ll width

Overa ll heig ht Wheelbase Seat heig ht Ground clea rance Dry weig ht Curb weight

FRAME

M ax imum w e ight capac ity Frame typ e Fro nt suspens ion Front axle tra vel Rea r suspension Rear axle tra ve l Front ti re size Rear t ire size Front tire brand Rear tire bra nd Front brake Rear brake Caster a ng le Trail length Fuel tank capacity

1-4

A, CM AC A, CM AC A. AC CM

type : type: type: ty pe: t ype : type :

Bridgesto ne: Pirell i: Bridgestone: Pirel li:

SPECIFICATIONS 2,035 mm (80.1 in ) 720 mm (28.3 in ) 1,120 mm (44.1 in) 10405 mm (55.3 in ) 820 mm (32.3 in ) 130 mm (5.1 in) 180 kg (397 Ibs) 181 kg (399 Ibs) 210 kg (463 lbs) 211 kg (465 Ibs) 166 kg (366 Ibs ) 170 kg (375 Ibs ) Diamond Telescopi c fork 110 mm (4.3 in) Swinga rm 135 mm (5.3 in) 120170 ZR17 M /C (58W) 190 /50 ZR17 M /C (73W) BT014F RADIAL G DiAB LO CORSA H BT014R RA DIAL G DIABLO CORSA H Hydraulic do uble disc Hydraulic singl e disc 23 0 4 5' 102 m m (4.0 in ) 18.0 liter (4.76 US gal, 3.96 Imp gal )

Contents

Chapter 1

GENERAL INFORMATION ITEM EN GINE

SPECIFICATIONS

Cyl inde r arra ngement Bo re and stroke Displacem ent Co m pression rat io Valve t rain Intake o pe ns: va lve closes: Exh aust ope ns:

valve

closes:

4 cylinde rs in-line, inclined 28 ° from vertica l

at at at at

1 mm 1 mm 1 mm 1 mm

Lubrication system

Oil pump type Cooling system Air f iltration

FUEL DELIVERY SYSTEM DRIVE TRAIN

ELECTRICAL

Engi ne d ry weight Fir ing o rder Ty pe Th rottle bo re Clutch system Clutch ope ration system Transm issio n Pri m ary re duction Final reduc tion Gear ratio 1st 2nd 3rd 4th 5th 6t h Gear shift pattern Ign ition syste m Starting system Charging syste m Reg ulator/rectifier Lighting system

Contents

Chapter 1

10.04 in ) lift 10.04 in ) lift (0.04 in) lift (0.04 in) lift

75.0 x 56.5 mm 12.95 x 2.22 in ) 998.4 em ' (60.92 cu-ln] 11 .9: 1 Chain dr iven, DO HC 18' BTDC 46' A BDC 39' BBDC 11 ' ATDC Fo rced pressu re and w et sump Trochoid Liquid coo led Paper eleme nt 65.8 kg (145.1 Ibs) 1 -2 -4 - 3 PG M -FI (Prog ram m ed Fu el Inj ection ) 44.0 mm (1.73 in) Multi-p late, we t Hydraulic o pe rati ng Constan t mes h, 6-speed s 1.604 (77/48T) 2.562 (16/41T) 2.538 (33 /13T) 1.941 133/17T) 1.578 130/19T) 1.380 (29/2 1T) 1.250 (25/20T) 1.160 (29/25T) 1 - N-2 -3 -4 -5-6 Co mpute r-co nt rolle d d igital transisto rized w ith elect ric adva nce Electr ic starte r motor Triple phase o utp ut alternator SCR shorted/triple pha se, full wave rect ificatio n Battery

1-5

GENERAL INFORMATION

LUBRICATION SYSTEM SPECIFICATIONS ITEM Eng i ne oil capacity

After draining After oi l f ilter change After disassembly

Recommen ded eng ine oil

Oil pressure at EOP (engine oil pre ssure ) switch

Tip clearance Body clearance Side clearance

Oil pump

Unit: mm (in) SERVICE LIMIT

STAN DARD 3.0 lit er (3.2 US qt. 2.6 Im p qt ) 3. 1 lit er (3.3 US qt, 2.7 Imp qt ) 3.8 lit er (4.0 US qt, 3.3 Imp qt ) Pro Ho nda GN4 o r HP4 (w it h out molybdenum additives ) 4·stroke oil (U.S.A. and Canada), or Honda 4- stroke oil (Canada only), or an equ ivalent motor oi l API se rv ice classificat ion: SG or Higher except oils labeled as ene rgy co nserving on the circular A PI service labe l JASO T 903 sta nda rd : MA Viscosity: SA E 10W-40 490 kPa 15.0 kgfle m ' , 7 1 p si) at 6,000 rpm /(80°C/176 °F ) 0. 15 (0.006 ) 0.15 - 0.21 (0.006 - 0.008 ) 0.04 0.0910.0 02 0.004 )

-

-

0.20 (0.008) 0.3510.014) 0.17 (0.007)

FUEL SYSTEM (Programmed Fuel Injection) SPECIFICATIONS ITEM

S PECIFICATIONS GQAOC GQAOB 20mm Hg No .1 1,200 ± 100 rpm 2 - 4 mm (1/16 - 3/16 in) 1 4 kQ 2.3 2.6 kQ

Throttl e bo dy identifi caI A, CM typ e t ion numbe r I A C type Starter valv e vacuum diff erenc e Base t hr ott le va lve for sy nchronizat io n

Idle speed . Throttle grip free play Intake air temperat ure sensor resistance (at 20°C/68° F) Engine coolant temperature sensor resistance (at 20°C/68 °F ) Fuel injection resistance I Primary injector (at 20°C 168' F) I Secondary injector PAIR control solenoid valve resistance (at 20 °C/68°F ) CM P (Cam shaft position) sensor peak voltage (at 20°CI 68' F) CKP (Crankshaft position ) sensor peak voltage (at 20°CI 68'F) M anifold absolute pressure at idle Fuel pressure at idle Fuel pump f low (at 12V )

10.5 14.5 Q 10.5 - 14.5 Q 20 24 Q 0.7 V m inimum 0.7 V min imum 150 250 m m Hg 343 kPa (3.5 kgf/em ' , 50 psi ) 189 em (6.4 US oz, 6.7 Imp oz) mi nimum /10 seconds

COOLING SYSTEM SPECIFICATIONS ITEM Coolant capacity

Radiator and engine I Reserve tank Radiator cap relief pressure The rmost at Begin to open Full y op en Valve lift Recom me nded antifreeze Standard coolant concentration

1-6

SPECIFICATIONS 3.15 lit er (3.33 US qt. 2.77 Im p qt ) 0.4 liter 10.42 US qt , 0.35 Imp qt ) 108 - 137 kPa 11.1 - 1.4 kgf/em ' , 16 - 20 ps i) 80 84 °C (176 183 OF) 90 °C 1194 ' F) 8 mm (0.3 in) m inimum High qual ity ethy lene glyco l ant ifreeze conta ining corrosion protection inhibitors 1:1 mixture with distilled w ater

Contents

Chapter 1

GENERAL INFORMATION

CYLINDER HEAD/VALVES SPECIFICATIONS Unit· mm (in) ITEM Cylinder co m pression Valve clearance

Camshaft

Cam lo be heig ht

IN EX IN EX

Runout Oil cle aran ce Valve lifter Valve , va lve g uide

Valve lifter 0 .0 . Valve lifter bo re 1. 0 . Valve stem 0 .0 . Valve guide 1. 0 . Ste m -ta -guide clear an ce Valve gu ide project ion above cylinde r head Valve sea t w idt h

IN

EX iN/EX IN EX IN

EX IN

EX Valve sp ring fre e leng th

IN

EX

STANDARD

SERVICE LIM IT

1,098 kPa (11.2 kgflc m ' , 159 psi ) at 350 rpm 0.1 6 + 0.03 (0.006 ± 0.001 ) 0.30 ± 0 .03(0.012 + 0.0 01) 37.02 - 37.10 (1.457 1.461 ) 36 .66 - 36 .74 (1.44 3 - 1.446 )

-

0.020 0.062 (0 .00 08 0 .0024) 25.978 - 25.993 (1.0228 - 1.0233 ) 26 .010 26 .026 (1.0240 1.0246) 3.97 5 3.990 (0.1565 0 .1571 ) 3.96 5 - 3.980 (0.156 1 - 0 .1567) 4.0 00 4 .01.2 (0. 1575 0 .1580) 0.010 - 0.037 (0 .00 04 0.00 15) 0.02 0 - 0.047 (0.0008 - 0 .0019 ) 16.I 16.4 (0.63 0.6 5) 15.5 - 15.8(0.61 0.62 ) 0.90 - 1.10 (0. 035 - 0 .043) 0.90 1.10 (0 .03 5 0 .043) 39 .5 (1.56) 39 .5 (1.56)

-

Cylinder head wa rpage

37.00 (1.457) 36 .64 (1.443) 0 .05 (0 .002) 0 .10 (0.0 04) 25.97 (1.022) 26.04 (1.0 25) 3 .965 (0.1561) 3 .955 (0.1557) 4.04 (0 .159 ) 0 .075 (0.0 030 ) 0.085 (0.00 33 )

1.5 (0.06) 1.5 (0.06) 38 .7 (1.52) 38 .7 (1.52) 0 .10 (0.0 04)

CLUTCH/STARTER CLUTCH SPECIFICATIONS Unit : mm (in) ITEM Spe cified clutch fluid Clutch master cylinde r

Spring free length

Disc A thickness Disc 8 th ickness Plate warpage Clutch ou te r guide A

(Wit ho ut 10 m a rk) Clutch o ute r guide 8

(With iD ma rk) Prim ary d rive n gea r 1. 0 . Oil pump drive spro cket gu ide Oil pump dri ve sprock et I.D.

1. 0 . 0 .0 . 1. 0 . 0 .0 . A B 1. 0 . 0 .0.

Main shaft 0 .0. at clutch oute r guide Ma inshaft 0.0 . at oil pump drive sprocket guide Start er idle gear I Ge ar 1.0 . I S ha ft 0 .0 . Starter driven gear boss 0. 0 .

Contents

Chapter 1

SERV ICE LIMIT

-

DOT 4 brak e flu id Ma ster cyl inde r 1.0.

Mast er piston 0 .0 .

Clutch

STANDARD

12,700 - 12.743 (0. 5000 0.5017) 12.657 - 12.684 (0.4983 - 0.4994) 56.8 (2.24 ) 3.72 3.88 (0.146 0.153 ) 3.22 3.38 (0.127 0.133)

-

27.993 28.003( 1.102 1 1.1025) 35.00 4 - 35.012 (1.378 1 1.3784 ) 27.993 - 28. 003 (1.102 1 - 1.1025 ) 34.996 - 35 .004 (1.377 8 - 1.37 81) 41.008 41.0 16(1.6145 -1.6 148 ) 41.0 00 - 41.0 08 (1.6142 - 1.6145 ) . 28.000 28.021 (1.1024 - 1.1032 1 34 .975 34 .99 1 (1.377 0 1.3776) 35 .025 - 35 .145 (1.3789 1.38 37 ) 27.980 - 27.990 (1.1016 - 1.10201 27.980 27.990 (1.1016 - 1.10201 10.013 -1 0 .035 (0.3942 - 0 .39511 9.991 - 10.000 (0.3933 0.3937 ) 45 .657 - 45.67 3 (1.7975 1.798 1)

12.7 55 (0. 5022) 12.645 (0.4 978) 55 .7 (2.19 ) 3.4 (0.13 ) 2.9 (0.11) 0 .30 (0.012) 28.012 (1.1028) 34.99 4( 1.3777) 28. 012 (1.1028 ) 34.986( 1.3774) 4 1.026 (1.6152) 41.018 (1.6149) 28 .030 (1.103 5) 34 .965 (1.376 6) 35.155 (1.384 11 27.96 (1.1011 27.96 (1.101) 10.05 (0.396) 9.98 (0.393) 4 5.642 (1.7969)

1-7

GENERAL INFORMATION

TRANSMISSION/GEARSHIFT LINKAGE SPECIFICATIONS ITEM S hift for k

1.0.

I Claw thick ness S hift fo rk shaft 0 .0. Gear 1.0.

Transm ission

Gea r bus ing 0. 0.

Gear-ta-bush ing clearance Gear bus hing 1.0.

Mai nsh aft 0 .0. Coun tershaft 0 .0.

Bus h ing to s haft clearance

M5, M6 Cl C2,C3, C4 M5, M6 C2 C3, C4 M5, M6 C2 C3, C4 M5 C2 at M5 at C2 M5 C2

STANDARD 12.0 0 0 12.018 (0.4724 - 0.47311 5.93 - 6.00 (0.233 0.236) 11 .957 - 11.968 (0.470 7 - 0.4712) 3 1.0 00 31.025 (1.220 5 - 1.221 5) 28 .000 28.02 1 (1.1024 1.1032 ) 33 .000 - 33 .025 (1.2992 - 1.3002) 30 .955 30 .980 (1.2187 1.2197 ) 32 .955 - 32 .980 (1.2974 - 1.2984) 32 .950 - 32 .975 (1.2972 - 1.2982) 0.020 - 0.0 70 (0.00 08 0.0028) 0.020 - 0.070 (0.00 08 - 0.0028) 0.025 - 0.075 (0.00 10 - 0.0 030) 27.985 28.006 (1.1018 1.1026) 29 .985 - 30.006( 1.1018 - 1.1026) 27.96 7 27.980 (1.1011 1.1016) 29 .967 29 .980 (1.1798 1.18031 0 .00 5 - 0 .039 (0.0002 0 .0 015 ) 0 .005 - 0 .039 (0.0002 - 0 .0 015)

Un it: m m (in) SERVICE LIM IT 12.03 (0.474) 5.9 (0. 23) 11 .95 (0.470) 31.04 (1.222) 28.04 (1.104 ) 33 .04 (1.301) 30 .935 (1.2179) 32 .935 (1.2967) 32 .930 (1.2964) 0 .10 (0.0 041 0 .10 (0.0041 0.11 (0.004) 28 .016 (1.1030) 30 .021 (1.1819) 27.957 (1.10 07) 29 .960 (1.1795) 0.06 (0.0021 0.06 (0.002)

CRANKCASE/CRANKSHAFT/BALANCER/PISTON/CYLINDER SPECIFICATIONS Cra nksha ft

Connecting rod side clea ran ce Crankpin be ar ing o il clea ran ce M ain jo urna l bearing oil cleara nce Runo ut

Piston, pisto n rings

Pis to n 0 .0 . at 4.0 (0. 16) from botto m

74 .960 - 74.980 (2.9512 - 2.9 520)

Un it: mm (in) SERVICE LIMIT 0.25( 0.0 98) 0.06 (0.002) 0.05 (0.002 ) 0 .05 (0.00 2) 74.895 (2.9486)

Pisto n pi n bore 1.0 .

17.002 - 17.0 08 (0.6694 - 0.66 96) 16.994 17.0 00 (0.6690 0 .6693 ) 0.002 - 0.014 (0.0001 0.0006 1 0.22 - 0.32 (0.009 - 0.013) 0.48 - 0.63 (0.019 0.02 51 0.2 - 0.7 (0.01 - 0.03)

17.030 (0. 6705) 16 .980 (0.668 5) 0.04 (0.002) 0.52 (0.020) 0.82 (0.032) 1.0 (0.04)

0 .050 0 .08 5 (0 .0 020 0.0033 ) 0 .015 - 0 .050 (0.00 06 - 0.0020) 75 .000 - 75 .015 (2.9528 2.9533 1

0.125 (0.0 049 ) 0.075 (0.0 030) 7 5.15 (2.959) 0.10 (0.004) 0 .10 (0.0 04) 0 .10 (0.004) 0 .10 (0.004) 17.048 (0.6712) 0 .07 (0.003)

ITEM

Piston pin 0 .0 . Piston-to-pist on pin clear ance Top Piston ring end gap Second Oil (side rai l) Piston ring-ta- ring Top groove clea rance Cylinde r

1. 0 .

Second

STANDARD 0.05 0.20 (0.00 2 - 0 .008) 0.030 - 0 .052 (0.0 012 - 0.0 020 ) 0.019 0.037 (0.0007 0.0 015)

Out of round Tap er

-

Warpage

-

Cylinder-ta-pi ston clearance Connecting rod small end 1.0. Connecting rod -to -pist on pin clea ra nce

1-8

0 .020 0 .055 (0.0 008 0.0022) 17.030 -17.042 (0.6705 - 0.6709) 0 .030 0.046 (0.00 12 0.0018)

Contents

Chapter 1

GENERAL INFORMATION

FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS IT EM Minimum tire tread depth Cold tire pr es- I Up to 90 kg (200 Ibs) load sure I Up to max imum we ight capacity Axle ru no ut Whe el rim I Radial runout I Ax ial Wheel balance weight

STANDARD

-

Unit: m m (i n) SERVICE LIMIT 1.5 (0.06)

250 kPa (2.50 kgl/cm'. 36 psi) 250 kPa (2.50 kqf/c m", 36 p si)

-

-

0.2 10.008) 2.0 (0.08) 2.0 (0.08) 60 9 (2.10l)

max . Fo rk

Spri ng Iree length Fork pipe runout Recommended fork fluid Flui d level Fluid capac ity

Pre-load adjuste r initia l settin g Reb ound adjuste r initial setting Comp ression adjuster initial sett ing Steering head bearing pre-loa d

218.2 (8.59)

213.8 (8.42) 0.20 (0.008)

Pro Hon da Suspe nsion Fluid, 55·5 5 or equiva lent 90 (3.5) 466 ± 2.5 cm' (15.8 ± 0.08 US oz, 16.4 ± 0.09 Im p o z) 7 turns from m inim um 2 turn s out from full hard 2 turn s out from full hard

-

12 - 19 N (1.2 - 1.9 kgf)

-

-

REAR WHEEL/SUSPENSION SPECIFICATIONS ItEM M inimum tire tread dept h Cold tire I Up t o 90 kg (200 tbs} loa d pressure I Up to maximum weight capacity Axle run out

Wheel rim

STANDARD

-

290 kPa (2.90 kqf/crrr', 42 psi) 290 kPa (2.90 kgl /cm . 42 psi )

-

Radial Axial

U nit : mm (i n ) SERVICE LIMIT 2.0 (0.08)

runo ut W heel bala nce we ight

0.2 (0.01) 2.0 (0.08) 2.0 (0.08) 60 9 (2 .1 oz) m ax.

Drive

Sizelli nk

chain Sho ck absorber

I I

DID RK

Slack Spr ing pre-loa d adjuster standard position Reb ound dam ping adjuster init ial setting Compression da mpi ng adjuster initial setting

Contents

Chapter 1

DID50VM 2-114YB RK50GFOZl -114LJFZ 25 35 (1 1-3/8) Position 4

-

2 - 1/2 tu rns out from full hard 9 clicks out from full hard

1-9

GENERAL INFORMATION

HYDRAULIC BRAKE SPECIFICATIONS Fro nt

ITEM Specified brake fluid

DOT 4 5.0 (0.20)

Brake disc th ickness Bra ke disc ru nout Ma ster cyl inder 1.0.

M aster piston 0 .0. Calipe r cylind er 1.0.

A B A B

Caliper piston 0 .0 .

Rear

Unit: mm (i n) SERV ICE LIMIT

STANDARD

Specified brake fluid Brake peda l height Brake disk thickness Brake disc ru nout Maste r cylinde r 1.0. Maste r piston 0.0. Cali per cy linder I.D. Caliper piston 0 .0.

4.0 (0.161 0.30 (0.0121 17.515 (0.6896 ) 17.309 (0.68 15) 32.140 (1.2654) 30.34 0 (1.1945) 3 1.957 (1.2581) 30.157 (1.1873)

17.460 17.503 (0.6874 0.6891) 17.321 17.367 (0.6819 0.6837) 32.080 - 32.130 (1.2630 - 1.2650) 30.280 30.330 (1.1921 1.194 1) 3 1.967 - 32.000 (1.258 5 1.2598) 30.167 - 30.200 (1.1877 - 1.18901 DOT 4 75 (3.0) 5.0 (0.20) 15.870 -15.913 15.827 - 15.854 38.180 - 38.230 38.098 - 38.148

(0.6248 (0.6231 (1.503 1 (1.4999

4.0 (0.16) 0.30 (0.012) 15.925 (0.6270) 15.815 (0.6226) 38.24 (1.506) 38.09 (1.5001

0.6265) 0.62421 1.5051) 1.5019)

BATTERYICHARGING SYSTEM SPECIFICATIONS Batt ery

ITEM Capacity

SPECIFICATIONS 12V 8.6 Ah 2.0 rnA max . 13.0 13.2 V Below 12.4 V

Cu rrent leakage

Vol ta ge (20°CI68°F)

Ful ly cha rg ed Needs charg ing

A ltern at or

0.9 Al5 10 h 4.5 Al l h 0.344 kW/5.000 rpm O.I 1.0 Q

Normal Qu ick

Cha rging current

Capacity Ch arg ing coil resistance (2 0°C/68 ° F)

IGNITION SYSTEM SPECIFICATIONS ITEM Spa rk plug (Iridium)

I

I

NGK DENSO

Spa rk plug gap Ignition coil peak voltage Ignition pulse generator peak voltag e Ignition timing ("F"mark)

0.80

SPECIFICATIONS IM R9C·9 HES VU H27ES 0.90 mm (0.031 0.035 in) 100 V minimum 0.7 V minimum 8° 12' BTDC at idle

ELECTRIC STARTER SPECIFICATIONS ITEM Starter motor brush length

1·10

STANDARD 12.0 - 13.0 (0.47 - 0.51)

Contents

U nit: mm (in) SERVICE LIMI T 6.5 (0.26)

Chapter 1

GENERAL INFORMATION

LIGHTS/METERS/SWITCHES SPECIFICATIONS SPECIFICATIONS

ITEM

Bulbs

Hea dlig ht

I Hi I lo

Positio n light

Brakelta il lig ht Front turn signal /runn ing light Rear tu rn sig nal light Instrument light Turn signa l ind icator High beam indicator Neutral indicator

Malfunction ind icato r la m p (Mil) Fuse

Ma in fu se PGM-FI fu se

Sub fuse Tachometer peak vo ltage ECT sensor resi stance

Contents

12V - 55 W 12V - 55 W 12V - 5 W l ED 12V - 2318 W x 2 (32/3 cp ) 12V 23W x 2 lED lED lED lED lED 30A 20A 10 A x 4, 20 A x 2 10.5 V min imum

I 80 °C (176 OF) I 120 -c 1248 OF)

Chapter 1

2.1 - 2.6 kfl 0.65 - 0.73 kfl

1-11

GENERAL INFORM ATION

STANDARD TORQUE VALUES FAST ENER TYPE

5 mm hex bolt and nut 6 m m hex bo lt a nd nut

8 mm he x bolt a nd nut 10 mm he x bo lt and nut 12 mm hex bo lt and nut

TORQUE Nm (kg f 'm, Ibf.ft ) 4.9 (0.5, 3.6) 9.8 (1.0, 7 ) 22 (2.2, 16) 34 (3.5, 25) 54 (5.5, 40)

TORQUE N 'm (kgf 'm, Ibf.ft) 3.9 (0.4, 2.9) 8.8 (0.9, 6.5) 9.8 (1.0, 7)

FASTENER TYPE

5 m m screw

6 mm screw 6 mm flang e bo lt (8 mm h ead, sma ll flan ge) 6 mm flan ge bol t (8 m m h ead , large fla nge) 6 m m flan ge bolt (10 mm head ) and nu t 8 m m flan ge bo lt and nut 10 mm flang e bolt and nut

12 (1.2, 9) 12 (1.2, 9) 26 (2.7, 20) 39 (4.0, 29)

ENGINE & FRAME TORQUE VALUES • Torque specifications listed below are for impo rtant faste ners. • Others should be tightened to standard torqu e va lues listed above . NOT E: 'l . App ly sea lant to th e threads . 2. Apply a locking agent to th e thr eads.

3. Stake . 4. App ly oil to the thr eads and flange surface.

5. 6. 7. 8. 9.

U-n ut . ALOe bol t/scr ew: repla ce w ith a new on e. App ly g rease to the t hreads. Apply molybden um disulfide oil to the th reads and seating surface CT bolt

ENGINE MAINTEN AN CE: ITEM Spa rk plug Timing hole cap Engine oil filter cartri dge

Engine oil drain bolt

Q'TY 4 1 1 1

THREAD DIA. (mm ) 10 45 20 12

TORQUE N ·m (kgf ·m , Ibf·ft) 16 (1.6, 12) 18 (1.8, 13) 26 (2.7, 20) 29 (3.0, 22)

REMARKS NOTE 7 NOTE 4

LUBRICATION SYSTEM: ITEM Oil pump asse mbly flang e bolt Engine oil drai n base bolt Oil filter boss

Q'TY 3 1 1

THREAD DIA .(m m) 6 6 20

TORQUE

Nrn [kgf-m, lbf -ttl 12 (1.2, 9) 12 (1.2, 9) See pa ge 1-15

REMARKS NOTE 9 NOT E 2

FUEL SYSTEM (Pro gra m med Fuel Inj ection): ITEM

Q'TY

EeT (Engi ne Coolant Temper atur e)/therm o senso r Throttle bo dy insu lator ban d screw

1 8 1 4 4 3 1 2

Serv ice chec k bolt Starte r valve lock nut Start er va lve sy nchronization plate screw Fuel pipe mounting bolt Fast idle w ax unit link plate screw Fast idle wax unit m oun ting screw

1-1 2

THREAD DIA.(mm) 12 5 6 10 3 6 3 6

TORQUE

Nrn (kgf' m , Ibf ·ft)

REMARKS

23 (2.3, 17) See page 1-15 12 (1.2, 9) 1.8 (0.18, 1.3) 0.9 (0.09, 0.7) 9.8 (1.0, 7) 0.9 (0.09, 0.7) 4.9 (0.5, 3.6)

Contents

Chapter 1

GENERAL INFORMATION COOLING SYSTEM: ITEM

Q'TV

Water pump assembly flang e bolt Therm ostat housing cover flange bolt

2 2

THREAD DIA .(mm) 6 6

TORQUE Nm (kgl·m, Ibf.ft) 12 (1.2, 9 ) 12 (1.2, 9 )

THREAD DIA .(mm) 10

TORQUE Non (kgl.m, Ibf.ft) 54 (5.5, 40)

THREAD DIA . (mm) 9 6 18 6 6 6 6 7 6 6 6 8

TORQUE N'm (kgl·m, Ibf.ft) 51 (5.2,38) 12 (J.2, 9) 27 (2.8 , 2O) 9.8 (1.0, 7 ) 12 (1.2, 9) 12 (1.2, 9) 12 (1.2, 9) 20 (2.0, 14 ) 12 (1.2, 9) 9.8 (1.0,7) 12 (1.2, 9 ) See page 1-15

THREAD DlA . (mm) 25 6 6 10

TORQUE N·m [kgf-m, Ibf·ft) 127 (13.0,94) 12 (1.2, 9 ) 15 (1.5,11) 83 (8.5, 61 )

THREAD DIA .(mm) 6 1O 6

TORQUE Nm [kqf-m, lbf-tt) 12 (1.2, 9) 103 (10.5, 76 ) 12 (1.2, 9 )

THREAD DIA .(mm) 8 6 8 6 8 6 6

TORQUE Nrn (kgf·m, lbf-ft] 29 (3.0, 22 1 12 (1.2, 9 ) 23 (2 .3, 17 ) 12 (1.2, 9 ) 23 (2.3,17) 12 (1.2, 9) 12 (1.2, 9)

REMARKS NOTE 9 NOTE 9

ENGINE REMOVAL/INSTALLATION: Q'TV

ITEM

1

Drive sprocket special bolt

REMARKS

CYLINDER HEADIVALVES: Q'TV

ITEM Cylinder head mo unting bolt/washer Cams haft ho lder fl ange bol t Cylinder head sea ling bolt Cylind er head cover bolt Breath er plate flange bolt PAIR reed v alve cove r bo lt Thrott le insulator socket bolt Cam sprocket fla nge bolt e M P (cams haft positio n) sensor roto r bolt Cam cha in tension er pivot bolt Cam chai n guid e torx bolt Exhaust pipe stud bo lt

10 20 2 4 3 4 8 4 2 1 1 8

REMARKS NOTE 8 NOTE 2 NOTE 2 NOTE 2 NOTE 2 NOTE 2 NOTE 2 NOTE 2

CLUTCH/STARTER CLUTCH : ITEM

Q'TV

Clutch ce nte r lock nut Clutch spring bo lt/w asher Oil pu mp dr iven sprocket bo lt Starter clutch outer bolt

1 5 1 1

REMARKS NOTE 3, 4 NOTE 2 NOTE 4

ALTERNATOR: ITEM

Q'TV

Stato r w ire clamp flange bolt

1 1 4

Flywh eel flange bolt Stat or mounting socket bolt

REMARKS NOTE 9 NOTE 4

TRANSMISSION/GEARSHIFT LINKAGE : ITEM

Q'TV

Transmi ssion holder flang e bolt Bearin g set plate bolt Shift drum center socket bolt Shift drum stopp er arm pivot bolt Gearshift spindle ret urn spring pin Shift dr um bolt/w ashe r Shift d rum stopper plate fl ange bo lt

Contents

Chapter 1

6 2 1 1 1 1 1

REMARKS NOTE 2 NOTE 2

NOTE 2 NOTE 2

1-13

GENERAL INFORMATION CRANKCASE/CRANKSHAFT/ BA LA NCER/ PISTON/CYLIN DER: ITEM Crankcase

Low er Low er Low er Lower

7 mm bol t 8 m m bol t 9 m m bol t (mai n jo urna l bolt)

cran kcase cra nkca se crankcase crankcase

seali ng bolt socket bolt sealin g bo lt socket bolt

Connecting rod bolt (new bolt) Connecting rod bolt (retightening)

Q'TV 12 6 10 1 1 1 1 8 8

THREAD D1A. (mm ) '7 8 9 22 10 20 8 8 8

TORQUE

Nrn [k qf- m, Ibf.ft) 18 (1.8, 13) 24 12.4, 17) See page 13·21 59 (6 .0, 43) 12 (1.2, 9) 29 13.0, 22) 23 (2.3. 17) See pa ge 13·2 1 Seepage 13· 12

REM AR KS

NOTE 4 NOTE 2 NOTE 2 NOTE 2 NOTE 2 NOTE 4 NOTE 4

ELECTRIC STARTER: ITEM Starter mo to r term inal nut

Q'TY

THREAD DIA .(mm)

1

6

TORQU E Nm {kqf-m , Ibf-ft] 12 (1.2, 9)

REM ARKS

LIGHTS / METE RS/SWITCHES: ITEM Oil pressu re sw itch Oil pressu re sw itch wire te rminal screw Neutral switch

1-14

Q'TY 1 1 1

THREAD D1A. (mm ) PT 1/8 4 10

TORQUE

Nrn (kgl·m, lbf-tt ] 12 11.2,9) 2.0 (0 .2, 1.4) 12 (1.2, 9)

Contents

REMARKS NOTE 1

Chapter 1

GENERAL INFORMATION Oil filter boss:

14 .9 ± 0.5 m m 10 .59 ± 0 .04 in)

Insulator clamp (Throttl e body side) :

7 ± 1 mm (0.3 ± 0.04 in)

Exhaust pip e stu d bolt:

1 1I1I1 11 11 11

~ l1 l1 l1 l i l l

-

Contents

Chapter 1

42.5 ± 0.5 mm (1.67 ± 0.04 in )

1-15

GENERAL INFORMATION FRAME FRAME /BODY PANELS /EXHAUST SYSTEM: ITEM

Q'TV

Exhaust joi nt pipe clamp SH bo lt

2 2 2 4 2 2 4 4 2 4 8 1 1

Ex haust valve pu lley nut Ex haust valve retainin g screw Exhaust valve pulley ho using flan ge S H bo lt Exhau st pipe cla mp bolt Up per cowl stay f lange bolt Cowl stay mou ntin g bolt W indsc ree n m ou nting screw M idd le cow l pan screw Mi ddle cowl spe cia l screw Und er cowl pan screw U nd er cowl special screw Inner cowl spec ia l screw Front fe nder pan screw Rearv iew m irror socket bolt

2 2 1 2 2 6 2 2 6 4 1 6 4

Seat rai l fl an ge socket bo lt/f lange nut Seat ra il spe cia l bolt/fl ang e nut Seat rail asse mbly flan ge bolt/nut Seat rai l brace socket bolt Passeng er seat b racket spe cial bolt Passen ger seat bra cket socket bolt Rider seat br acket m oun tin g bolt/nut Ride r footp eg bracket socket bo lt Bank se nsor Passeng er footpeq bracket socket bo lt Exh aust pipe joint nut Exha ust pipe m ou ntin g bolt

1

THBEAD DIA.(mm) 10 10 8 8 8 8 6 8 6 8 7 8 6 6 4 6 8 8 6 5 5 6 5 6 6 6 6

TORQUE Nm (kgf·m, lbf -ft) 59 (6.0, 43) 59 (6.0,43) 30 (3.1, 22) 26 (2.7, 20) 26 (2.7, 2O) 26 (2.7, 2O) 9.8 (1.0, 7 ) 37 (3.8, 27) 11 (1.1, 8 ) 26 (2.7, 2O) 12 (1.2, 9) 23 (2.3, 17) 9.8 (1.0, 7 ) 4 .9 (0.5, 3. 6) 1.5 (0.15, 1.1) 9.8 (1.0, 7 ) 18 (1.8, 13) 32 (3.3, 24 ) 12 (1.2, 9) 0.5 (0.0 5, 0.4 ) 1.5 (0. 15, 1.1 ) 9 .8 (1.0, 7) 1.5 (0.15, 1.1) 9. 8 (1.0, 7) 9.8 (1.0, 7) 12 (1.2, 9) 6.8 (0.7, 5.1)

THREAD DIA .(mm) 6

TORQ UE Nm [kqf-m, lbf-ttl 5.4 (0.55, 4. 0)

REMARKS

MAINTENANCE: -IT EM T hrott le cab le adjuster lock nut

1-16

Q'TV

2

Contents

REMARKS

Chapter 1

GENERAL INFORMATION FUEL SYSTEM IProgrammed Fuel Inje ct ion I:

1

THREAD D1A. lmm) 4 12 12

6

6

2

8

2 2 1 6

6 6 12 5

6 8

5 5

2 2 6

5 5

5 2

5 4

Q'TY

ITEM Fuel fil ler cap socket bol t Fuel feed hose ba njo bolt (fu el t ank side) Fuel hose sealing nu t It hrottle body side) Fuel pump flange nut

Fuel ta nk m ounting bolt (front) Fuel ta nk mounting bolt (rea r) Fuel rail jo int hose bolt Fuel rail joint hose seali ng nut Air cleane r housing/air fun nel pan screw Top ai r cleane r housing mo unting screw M idd le air cleaner housing mo unting screw IAT senso r mounting screw Ai r intake d uct jo int screw Air intak e d uct cove r screw Seco ndary injector base m ou nting bo lts Bank a ngle sensor mo unting screw

,

3

4

TORQUE N 'm (kgf·m , Ibf.lt) 1.8 (0.18, 1.3) 22 (2.2, 16) 22 (2.2, 16) 12 (1.2, 9)

26 (2.7, 20) 9.8 (to, 7 ) 9.8 (t o, 7 ) 22 (2.2, 16) 4.4 (0.45 , 3.3) 1.2 (0.12, 0.9) 1.2 10.12, 0.9) 1.2 (0. 12, 0.9) 2.5 10.25, 1.81 1.2 (0.12, 0.9) 5.4 (0.55, 4.0) 1.5 (0. 15, 1.1)

REM A RKS Yellow paint

Yellow paint Yellow paint

COOLIN G SYSTEM: ITEM

QTY

Cooling fan nut Fan motor nut Fan m otor bracket m oun ting bolt

1 3 3

THR EA D DIA.(mm) 5 5 6

TORQ UE

Nm [kqf-m, Ibf.ft) 2.9 (0.3, 2.2) 4.9 10.5, 3.6) 8.8 (0.9, 6.5)

REMARKS NOT E 2

ENGINE REMOVAL/INSTALLATION: ITEM

Q'TY

Engine hange r adjusting bolt Engine hang er adjusting bolt lock nut Rear up per engi ne hange r nut Rear low e r eng ine hanger nut Front engine hanger bolt Midd le engine hanger bo lt

2 2

, 1

2 2

THREAD D1A. l m m ) 20 20 12 12 12 12

TORQUE Nrn [k qf -rn, Ibf·ft) 15 (1.5, 11) 54 (5.5, 40) 64 (6.5, 47) 64 (6.5, 47) 64 (6.5, 47 ) 64 (6.5, 47 1

REMAR KS

See page 89

CLUTCH /STARTER CLUTCH : ITEM

Q'TY

Clutch master cylinder o il cup screw Clutch lev er piv ot bolt Clutch lever piv ot nut Clutch sw itch screw Clutc h hos e o il bolt Clutch master cylinde r holde r bo lt Maste r cylind er bleed va lve

Contents

Chapter 1

1 1 1 1 2 2 1

THREAD D1A. (mm) 4 6 6 4 10 6 8

TORQUE

Nm [k qf -m, Ibf ·ft) 1.5 (0.15, 1.1) 1.0 (0.1, 0.7) 5.9 (0.6, 4.3) 1.0 (0.1, 0.7) 34 (3.5, 25) 12 (1.2, 9) 5.9 (0.6, 4.3)

REMARKS NOTE 2

1-17

GENERAL INFORMATION TRA NSMISSION/GEARSHIFT LINKAGE: ITEM Gears hift peda l pivot bo lt Gearshift pe dal link pinch bolt Link arm lock nut

Q'TV

1 1 2

THREAD DIA .(mm) '8 6 6

TORQUE N'm [kqf-m, lbf-ft} 22 (2.2, 16) 9.8 (1.0, 7) 9.8 (1.0, 7)

THREAD DIA.( mm) 6 8 18 8 6 10 46 14 14 8 8 6 6 6 26 26 24

TORQUE Nm Ikgf-rn. Ibf.ft) 9.8 (1.0, 7 ) 26 (2.7, 20) 78 (8.0, 58) 22 (2.2, 16 ) 20 (2.0, 14) 34 (3. 5, 25 ) 34 (3.5, 25) 25 (2.6, 19 ) 18 (1.8,1 3) 23 (2.3, 17 ) 23 (2.3, 17 ) 12 (1.2, 9) 8 .8 (0.9, 6.5 ) 8 .8 (0.9, 6.5 ) 20 (2.0, 14)

THREAD DIA .(mm) 22 8 10 10 10 10 10 10 6 36 36 22 6

TORQUE N·m (kgf'm, Ibf·ft) 113 (11.5, 83) 42 (4.3, 3 1) 64 (6.5, 47 ) 44 (4.5, 33) 44 (4 .5, 33 ) 44 (4 .5, 33) 44 (4.5, 33) 44 (4.5, 33) 12 (1.2, 9) 15 (1.5, 11) 64 (6.5, 47 1 113 (11.5, 83) 8.8 (0 .9, 6 .5)

REMARKS

FRONT WHEEl/SUSPENSION/STEERING: ITEM Han dlebar we ight m ou nting screw Han dlebar pinc h bolt Front axle bolt Front axle ho lder pinch bolt Front brake disc bolt Fork socket bolt

Fork bo lt Fork dam per lock nut Fork co mpressio n adj uste r plug bo lt

Fork to p bridge pi nch bolt Fork bott om bridge pinch bo lt Ste er ing dam per seco nd arm nut Steering dam per seco nd arm bolt Steerin g damper m ounti ng bo lt Stee ring stem adj ust ing nut Steer ing stem adj ust ing lock nut Steering stem nut

Q'TV

2 2 1 4 12 2 2 2 2 2 4 1 1 3 1 1 1

-

REMARKS NOTE 6

NOTE 6

NOTE 5

See pag e

14-42

103 (10.5, 76)

REAR WHEEL/S USPENSION: ITEM Rea r axle nut Rear brak e disc bolt Fina l driven sprock et nut Rea r shoc k absorbe r upper m ountin g nut Rea r shock a bsor be r low er m oun tin g nut Shock link-t o-fram e pivot nut . Shock arm-to -shock link nut Shock ar m-to-swinga rm nut D rive cha in case flange bolt Swinga rm pivot adj ust ing bolt Swingarm pivot adj ust ing bo lt lock nut Swinga rm pivot nut D riv e cha in slider bo lt

1-18

Q'TV

1 4 6 1 1 1 1 1 3 1 1 1 3

Contents

REMARKS NOTE 5 NOTE 6 NOTE 5 NOTE 5 NOTE 5 NOTE 5 NOTE 5 NOTE 5

NOTE 2

Chapter 1

GENERAL INFORMATION HYDRA ULI C BRAKE: IT EM

QTY

Brake hose oil bolt Rear brake cal ipe r pad pin Rear calipe r ble ed va lve Rear brake caliper slide pin bolt Rear brake caliper mounting bolt Rear brake hose cla m p bol t Rear mast er cylinder push rod joint nut Rear bra ke reservoir hose jo int screw Rear maste r cyli nder reservoir cap screw Rear master cyl inder reservoir m oun tin g bo lt Rear maste r cy linde r m o unting bo lt

Brake pedal piv ot bolt brake calipe r m o unt ing bolt brake cali pe r asse mb ly bo lt brake calipe r pa d pin cali pe r bleed va lve brake hose clamp brake hose 3-way joint bo lt brak e ho se clamp (left side) master cylinde r reservoi r cap screw master cylinde r reservoir stay bol t bra ke ligh t swi tch screw m aster cylinder reser vo ir mo un t ing nut brake lever pivot bo lt brake leve r pivot nut m aster cylind er bleed valve ma ster cyli nd e r ho lder bolt

Front Front Front Fro nt Front Front Front Front Front Front Front Front Front Fro nt Front

5 1 1 1 1 1 1 1 2 1 2 1 4 8 2 2 1 1 1 2 1 1 1 1 1 1 2

THR EAD DIA . (mm ) 10 10 8 12 8 5 8 4 4 6 6 8 10 8 10 8 6 6 6 4 6 4 6 6 6 8 6

TORQUE Nrn [kqf-m, Ibf ·ft) 34 (3.5, 25) 18 (1.8, 131 5.9 10.6. 4.3) 27 (2.8. 201 23 (2.3. 171 3.9 (0.4. 2.91 18 11 .8, 131 1.5 (0.15. 1.1) 1.5 (0.15. 1.1) 12 (1.2. 9) 9.8 (1.0. 71 18 (1.8. 131 45 (4.6. 33) 23 (2.3,17) 16 (1.6. 12) 7.8 10.8. 5.81 8.8 (0.9, 6.5) 9.811.0. 7) 9.81 1.0.71 1.5 (0.15, 1.11 12 (1.2. 9) 1.0 (0.1. 0.7) 5.9 (0.6, 4.31 1.0 (0.1, 0.7) 5.9 10.6. 4.31 5.9 10.6. 4.3) 12 11.2,9 1

REM ARKS

NOT E 2

NOT E 6 NOTE 2

N OT E 5

LIG HTS /METERS/SWITCHES: ITEM

Q'TV

Ignit io n switch mounting one -way bolt Right handlebar swi tch screw Combinati on m ete r assem bly screw Side stand switch special bolt

2 2 3 1

THREAD DlA. (mm) 8 4 5 6

TORQ UE

Nm [kqt-m. Ibf·ft) 26 (2.7, 20) 0.9 (0.09, 0.7) 1.0 (0.1, 0.71 9.8 (1.0, 7}

REMARKS

NOTE 6

OTHERS : ITEM

Q'TV

Side stand socket bo lt Side stand pivot bolt Si de sta nd pivot nut

Contents

2 1 1

Chapter 1

THREAD DIA . (m m ) 10 10 10

TORQUE

Nm (kgf·m , lbf -ft ]

REMARKS

54 15.5, 40) 9.8 11.0,7) 29 (3.0. 221

1-19

GENERAL INFORMATION

LUBRICATION & SEAL POINTS ENGINE LOCATION Crankcase matin g surface

REMARKS

MATERIAL Liquid sealant (T hree Bond 1207B o r equi val ent )

o

o

o

0

E~

E",

,

~o ,

0

EE

0 0

00

~

~s

0

EE

E~ ~o

E",

,

,

,

~o

~

,

~£

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00

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,

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$2'9-

,

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~ o ~

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;=s

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0 0

~

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0

Oil pan m ating surfac e

1-20

Contents

Chapter 1

GENERAL INFORMATION LOCATION Right crankcase cover mating surface

MATERIAL Liquid sealant (Three Bo nd 1207B or equiva lent)

REMARKS

Alternator cover mating surface

Oil pressure switch th read s Do not appl y sealant to the thread hea d 3 - 4 mm (0.' - 0.2 in)

Cylind er head semi-circ ular cut-ou t

Contents

Chapter 1

Sea lant

1-21

GENERAL INFORMATION LOCATION Ma in journal beari ng surface Piston pin sliding surface Connect ing rod bearing surface Connecti ng rod sma ll end inner surface Crankshaft thrust surface Camshaft lobes/journa ls and thrust surface

MATERIA L Molybden um d isulfide o il (a m ixt u re of 1/2 eng ine oi l and 1/2 molybde nu m d isulfid e g rease

REMARK S

Do not apply mating surf ace of the camshaft holder

Valve stem (valve guide sliding surface) Valve li ft e r oute r sl iding surface Wa ter pump shaft th rust washer sliding su rface Clutch outer/prima ry driven gear sliding surface Clutch outer gu ide slid ing surface Oil pump drive sprocket and collar slid ing surface M3/4, C5, C6 sh ifter gear (shift fork grooves) Starter reduction gear shaft sl iding surface Starter idle gear shaft sliding surface Cylinde r head special bolt (after re moving a nti - rust oil add itive) Clutch j o i nt p iece sliding surface Clu tch lifter rod outer area Piston and pisto n ring sliding area Oil straine r pack ing Clutch disc surface Starter one-wav clutch sliding surface Flywheel bo lt threads and seating surface Clutch center lo ck nut t hreads and seat ing surface Oil f ilter cartridge th reads and Ovrinq Camshaft ho l der bo lt threads and seat ing surface Starter clutch outer bo lt threads and seating surface Connecting rod bolt t hreads and seati ng surface Each gear teeth and rotating surface Each bearing Each O·ring Ot he r rotat ing area and sl iding su rface Timing ho le cap threads Balancer damper rubber f itting area Each oil seal lips Lo w er crankcase 22 mm sea ling bolt threads Lower crankcase 20 mm seali ng bolt threads Lower crankcase 10 mm seali ng bolt th reads Lower crankcase 8 m m seal ing bolt th reads Cam chain guide A bolt threads CMP (Camshaft positio n) senso r rotor bol t t hreads Cylinder head sea ling bolt t hreads Cy linder head cover b reat he r j o int threads Oi l orifice bolt threads Oi l pump d riven sprocket bolt threads Shift drum bearing set p late bo lt t hreads Oi l filter boss stud thread Mainshaftlcou ntershaft bea ring set plate bolt threads Cam sprocket bolt threads Cylinder head cover breather plate bolt t hread s Sh ift drum center bo lt t hreads Cam chain tensioner pivot bolt th reads Spindle plate tightening bolt threads Shift drum stopper plate bolt t h reads Oil pan d ra in base bolt threads Gearsh ift sp indle cove r bo lt threads

Engi ne o il

M u lt i-pu rpose g rease

Lo ckin g age nt

Coating Coati ng Coating Coati ng Coating Coating Coating Coati ng Coating Coating Coating Coating

w idth: 6.5 ± w id t h: 6.5 ± w idth: 6.5 ± w id th: 6.5 ± w idth : 6.5 ± width : 6.5 ± width: 6.5 ± widt h: 6.5 ± width: 6.5 ± width: 6.5 ± width: 6.5 ± width : 6.5 ±

1 1 1 1 1 1 1 1 1 1 1 1

mm mm mm mm mm mm mm mm mm mm mm mm

Ji;f1 ---~

I[\ \'

APPI Y IOCkmg agent ~

)

>~

1-22

Contents

Chapter 1

GENERAL INFORMATION FRAME LOCATION

Side st and pivot Rid er footpeg sliding area Passenger peg sliding area Rear brake pedal pi vot sli di ng area Th rott le gri p p ipe sl iding su rf ace Passenger seat catch hook slidi ng area Gear sh ift pedal pivot slidi ng ar ea Fro nt w heel d ust seal lips Rear w he el du st seal li ps Fin al dri ven f lange O-rin g Rear shock absorbe r pivot dust sea l lips Steering head bea ri ng adjusting nut threads Upper and lower stee ring he ad bea ri ng St eeri ng head du st seal lips

Swingarm pivot bea ri ngs

Swi nga rm pivot d us t seal lips Shock arm and shock link needl e bea ri ng s Shock arm and shock link dust sea l lips Gea rs hift peda l link t ie-rod ball join ts Thr ott le cable A, B cable ins ide Exhaust valve cable A, B cable inside Hand leb ar g rip rubbe r inside

Front brake lev er pivot/adjuster/pus h rod sliding area Front brake push rod and piston contacting area Rear brake calipe r boot ins ide Rear brak e ma st er pi st on-to-pu sh ro d co ntact area Brake cali per d ust seals Clutch lever sliding area and pi st on co ntact area Clutch pivot bus hing and piston contact area Brake master piston and cups Brake calipe r pisto n and pisto n sea ls Fork cap O-r ing Fo rk dust sea l and oil seal li ps Rear brake reservoir hose jo int screw threads Fro nt master cylinder oil cup stay mounting bolt threads Front bra ke calipe r asse m bly bolt t hr eads Rear bra ke cali pe r pin bol t th reads Clutch oil cup tig ht en ing screw th read s

Contents

Chapter 1

MATERIAL M u lt i-purp ose grease

U rea based multi-purpose grease with extreme pressur e (exa m ple : EXCELIGHT EP2 m anuf actured by KYODO YUS HI, Japan) , She ll st am ina EP2 o r eq uiva le nt M Ulti -purp ose grease (She ll A lv ania EP2 o r eq uiva lent)

REMARKS

0.1 - 0.3 9 3 - 5 9 (each)

Cable lubrica nt Molybdenum oi l Honda bond A, Pro Honda Handgr ip Cem ent (U .S.A. onl y) or eq uiv alent Silicone grease

DOT 4 brake fl uid Pro Hond a Suspension Flu id 5 5- 55 or equ iva lent Locki ng agent

1-23

GENERAL INFORMATION

CABLE & HARNESS ROUTING THROTTLE CABLES

CLUTCH HOS E

IGNITION SWITC H WIRE LEFT HANDLEBA R SWITCH WIRE RIGHT HA NDLEBAR SW ITCH WIRE

FRONT BRAKE HOSE

HORN WIR E

FRONT SUB- HA RNESS 12P (GRAY) CONN ECTOR

POSITION LIGHT 2P( NAT URAL) CONNECTOR

COMBIN ATION METER M ULTI-CONNE CTOR

RIGHT TURN SIGNAL 3P (LIGHT BLU E) CON NECTOR

BANK ANG LE SENSOR 3P (GREEN ) CONNECTO R

FRONT SUB -HARNESS 12P (GRAY) CON NECTOR HEADLIG HT SOCKET

1-24

Contents

Chapter 1

GENERAL INFORMATION

T HROTTL E CA BLES

CLUTCH HOSE

HORN WIRE

----f£~~~~:t/I_-L

FRONT BRA KE HOSE

Contents

Chapter 1

1-25

GENERAL INFORMATION

T HROTT LE CA BLES

ECM FRONT BRAK E HOSE

MAIN W IRE HARN ESS

RADIATOR SIPHON HOSE

RAD IATOR OVERFLOW HOSE

1-26

Contents

Chapter 1

GENERAL INFORMATION

SECONDARY INJECTOR

FUEL HOSE

VS (VEHICLE SPEED) SEN SOR 3P( NATU RA L) CON N ECTO R CMP (CA M SHA FT POSITION) SENSOR 2P (BLACK) CONNECTOR

Contents

Chapter 1

1-27

GENERAL INFORMATION

SECONOARY INJ ECTORS

PRIM ARY INJE CTORS

No.1

No.2

No.3

No.4

lAC T HERM A L VA LVE

ECT SENSOR 3P (GRAY) CONNECTOR

1-28

Contents

Chapter 1

GENERAL INFORMATION

REGULATOR/RECTIFIER 2P (NAT U RA L) CONNECTO R SIDE STAN D 2P (G REEN) CONN ECTOR FU EL TAN K BREATH ER HOSE

CLUTCH HOS E

-.

CM P (CA M SHA FT POSITION) SENSO R 2P (BLACK) CONN ECTOR

SID E STAND SWITCH W IRE

Contents

Chapter 1

1-29

GENERAL INFORMATION

IGNITIO N COIL SU B-HA RNESS ECM

MAIN WIR E HARN ESS

RA DIATOR SIPHON HOSE ENGINE SUB-HARNESS CKP (CRANKSHA FT POSITION ) SENSOR W IRE

1-30

RADI ATOR OVERFLOW HOSE

Contents

Chapter 1

GENERAL INFORMATION

REAR BRAK E LIGHT SWI TCH 2P (BLACK) CONN ECTOR CKP (CRA N KSHA FT POSITION ) SENSOR 2P (RED) CONNECTOR

IGNITION COIL SUB -HARN ESS 6P(NATU RALI CONN ECTOR

REAR BRAKE LIGHT SW ITCH WIRE

RAD IATOR SIPHON HOSE

RADIATOR OVERFLOW HOSE

Contents

Chapter 1

1-31

GENERAL INFORMATION

EGCV SERVOM OTOR 6P (NAT U RA LI CON N ECTOR VEHICLE SPEED SENSO R 3P (NATU RAL) CON NECTOR

EGCV SERVOMOTOR

EGCV CONTROL CAB LES

NEUT RAL SW ITCH

1-32

FUEL TAN K BREATH ER HOS E

D

Contents

Chapter 1

GENERAL INFORMATION MAI N W IRE HARNESS STARTER RELAY SWITCH

SEAT LOCK CABL E

TUR N SIGNAULICEN SE LIGHT CON NECTORS

STA RTER MOTOR GROUND CABL E

..----..-, STARTER MOTOR CA BLE

REAR BRA KE HOSE

Contents

Chapter 1

TAIUBRAKE LIGHT CONN ECTO R

REAR BRA KE LIGHT SWITCH W IRE

1-33

GENERAL INFORMATION CALIFORNIA TYPE:

FUEL TANK-TOCANISTER HOSE

EVAP CAN ISTER

1-34

THROTTLE BODY 5-WAY JOINT

EVAP PURGE CONTROL SOLENOID VALVE 2P (NATURAL) CONNECTOR

EVAP PURGE CONTROL SOLENOID VALVE

Contents

Chapter 1

GENERAL INFORMATION

To fuel tank

DRAIN HOSE

Contents

EVA P CA NISTER

Chapter 1

To 5-way joint

EVAP PURG E CONT ROL SO LENO ID VALVE

CAN ISTER-TO-SOLENOID VA LVE HOS E

1-35

GENERAL INFORMATION

EMISSION CONTROL SYSTEMS The U.S. Envir onm ent al Pro tecti o n Agency (EPA), T ranspo rt Canada and California Air Resources Boad (CA RBI req uire manufactu rers to certify that t heir moto rcycles comply with applicable- exhaust emissions standa rds durin g t heir useful life , when operate d and ma intained acco rding to the instructio ns provided. The EPA also req ui res t hat moto rcycles built after J an u ary 1. 1983 co mply w ith applicabl e noise em iss io n sta nda rds f o r one year or 6,000 km (3,730 miles) afte r th e time of sale t o th e ulti mate pu rchaser, whe n o perated and m ain tain ed according t o the instru ct io ns prov ided. Compl iance with th e t erm s of t he Distributor' s Lim it ed W arra nty fo r Hon da M o t o rcy cle Emi ssi on Control Syste m is necessary i n o rder to keep t he em ission sy stem warranty in effect .

SOURCE OF EMISSIONS T he com bust io n proce ss prod uces carbo n m o no xide. ox ides of nitrogen and hy d ro car bon s. Co nt ro l of hydrocarbon s and ox ides of nitrogen is ve ry import ant beca use, u nder ce rtai n co nd it io ns, th ey react to form ph otochem ical smog w he n su bject t o su nli ght. Carb on m on o xid e do es no t reac t in the same wa y . but it is tox ic. Hon da Motor Co., Ltd. utilizes lean inject ion sett ings as w ell as ot he r system s, to redu ce ox ides of nitrogen, carbo n monoxide an d hydroca rbo ns .

CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped with a closed crankcase system to prevent discharging cran kcase em issions in to th e atmosphere. Blow-by gas is ret urned to the combustion chamber throu gh t he ai r cleane r and throttle body. AI R CLEAN ER HOU SING

c::;::2.-- - - - -

1-36

FRESH A IR

0

BLOW-BY GAS

•

Contents

THROTTLE BODY

Chapter 1

GENERAL INFORMATION EXHAUST EMISSION CONTROL SYSTEM Th e ex haus t em ission control sy stem is com posed of a seco nda ry air su p p ly sys te m. a o xidat io n catalytic converte r and a lean fuel injectio n setting . No ad ju stm ent s sho u ld be ma de ex cept id le sp eed adj u st ment with th e th rottle stop scr ew. Th e ex ha ust em issi o n co nt ro l sys t em is sepa rate from the cra nk case emissio n control sy st em .

SECONDARY AIR SUPPLY SYSTEM Th e pulse secon d ary ai r supply sy st em introduces fil t er ed air into t he ex ha ust gases in t he exha ust port. Fresh ai r is drawn into the ex haust port by the f u nct ion of th e PA IR (Pu lse Secondary A ir Injecti on ) control v alve.

Th is char ge of fr esh air pro motes burn ing of t he unburned ex haust ga ses and cha nges a con sider ab le am o un t of hy dro carb on s and car bon monoxi de into r elativ ely harmless ca rbo n di ox id e and wa te r va po r. The reed val ve pr ev ents rever se air fl ow through th e system . The PAIR con trol v alve is operate d by th e so lenoid v alve. Th e so le noid va lve is co nt ro lled by th e PGM -Fl u n it, and t he f res h air passag e is op ened/closed accordi ng t o ru nning co nd ition s (ECT/IATfTP/MAP senso r and eng ine revolut io n). N o adj ust ment s t o th e seco ndary air sup pl y sys tem should b e m ade, alt hough periodi c ins pec t io n of the com po nent s is recom mended.

AIR CLEANER HOUSING

PAIR CHECK VALVE

i-'c;:-- - __ THROTTLE BODY

EXHAU ST PORT PAIR CONTROL VALVE

FRESH AIR

¢

EXHAUST GAS . .

OXIDATION CATALYTIC CONVERTER (CALIFORN IA TYPE ONLY) Th is motorcycle is eq uip pe d with a oxidat io n cata lytic co nve rte r. T he ox id at io n cata lytic converter is in t he exhaust sy st em. Through ch emical reaction s, it con v erts HC, CO, and NOx in th e engine 's ex ha ust to car bo n diox ide (C0 2), dinitrogen (N2), and w ate r va p or.

No adjustment to these systems should be ma de alt hough periodic inspectio n of the compo nent s is recomme nded.

Contents

Chapter 1

1-37

GENERAL INFORMATION EVAPORATIVE EMISSION CONTROL SYSTEM (CALIFORNIA TYPE ONLY) This model com plies w ith CARB evaporat ive emis sion requi rem ents. Fu el va po r from t h e fuel t an k is rout ed int o th e evaporat iv e em iss io n (EVAP) ca niste r wh ere is it absorbed an d sto red w hile the engi ne is stopped . Whe n th e eng ine is runni ng and t he eva p orati v e em iss io n (EVA P) pu rge control so lenoid va lve is open, fuel v apo r in the EVA P canister is d rawn in to th e eng ine through the th ro ttle body .

FUEL TANK

IIII

EVAP PURGE CONTROL SOLENOID VALVE

\ THROTILE BODY

EVAP CANISTER

NOISE EMISSION CONTROL SYSTEM TAMPERING WIT H THE NO ISE CONTROL SYSTEM IS PROHIBITED: U.S. Federal Law proh ibits o r Canad ian Provin cial Law may pr ohibit th e follow ing act s or the ca us ing there of: (1) T he rem o val o r rend eri ng inoperative by any person. ot her th an for purp oses of mai nte nance, repai r o r replacement, of an y device o r ele m ent of des ign in co rp orat ed into any new ve hicl e fo r th e purpose of noise control prior to its sa le o r deli v ery t o th e ultimate purchaser or whi le it is in use; (2) t he u se of the ve hicle aft er suc h device or elem ent of des ign has been rem o ved or rendered inoperati ve by an y pe rso n. AMONG THOSE ACTS PRESUM ED TO CON STITUTE TAMPERING ARE THE ACTS LISTED BELOW: 1. Rem ova l of, o r pun cturing of the muffler, baffl es,h eader pipes or any othe r com ponent wh ich co nducts ex haust ga ses. 2. Rem o v al o f, o r puncturing of an y pa rt of the intake system . 3. Lack of pr op er m aint ena nce. 4. Repl acin g any m oving parts of the v ehicl e, o r parts of t he ex haus t o r intake syste m, w ith parts other then th ose spe ci tied by t he manufacturer.

1-38

Contents

Chapter 1

GENERAL INFORMATION

EMISSION CONTROL INFORMATION LABEL (U.S.A. ONLY) An Em issio n Control Inf o rm atio n Label is loca te d on th e 'st oraqe ,------------------~ EMISSION CONTROL IN FORMATION LABEL compartment as shown.

Contents

Chapter 1

1-39

MEMO

Contents

Chapter 1

2. TECHN ICAL FEATURES

.. HESD (Hond a Electronic Steering Damper)

2-2

RADIAL-MOUNTED FRONT BRAKE CALIPER

2-5

EGCV (Exhaust Gas Control Valve)......·...... ·2-6

Contents

Chapter 2

2-1

TECHNICAL FEATURES

HESD (Honda Electronic Steering Damper) This m ot or cycl e is eq ui pped with the Ho nda Electro nic St eeri ng Damper (HESD). Th e HESD system co nsists of th e fo ll ow ing compo ne nts. - Stee ring damper asse mbly with lin ear so le noid - VS (vehicle speed) senso r - ECM - Malfunction indicator lamp (M IL) and HESO ind icator The stee ring damper assem bly is installed o n the main frame near t he steering hea d pi pe and the linkage arm is installed on the top fork br idge. The damping characteristics are au to matically co ntrolled by the ECM in response to vehicle speed and acceleration and offers optimum handling over a wide range of riding conditions. HESO employs a hydraulic rotary dam pe r unit. The hyd ra ulic o il is filled into the steering damper an d is sealed per m anentl y . Th e steering damper unit is not serviceab le.

r - - - - -- - - - - - -- - - - - - --, HESD DAMPI NG CHARACTERISTICS:

DAMPING CHARACTERISTICS

Each co mponent of HESD fu nct io ns as fol lows. -

Damper oil cha m b er/V ane The dam per oil cha m be r is d ivi ded in tw o by a movi ng va ne co nnec t ed intern ally t o th e linkage arm . The edge of the va ne is cove red w it h an oi l seal so t hat th e left and ri ght cha m be rs are sea led f ro m each ot her. Th er ef or e oil m oves betwee n t he left and rig ht side s of th e ch amb er v ia ch eck va lve co nt ro lled hy drauli c passages. Ch eck v alve Four one-way chec k va lves en sure th at o il fl ow s throu gh th e m ain va lve in only one d irection , w het her t he va ne is m ove d left o r right. Accumul at or Acc umulator co mpensates f o r t em peratu re-indu ced cha nges i n o il vo lume. M ain valve/Lin ear sole noid Th e openi ng of th e main v alve is co nt ro ll ed by a lin ear solenoid t hat receives its con t rol sig nals f rom the ECM. Th e da mpi ng characteristics are va rie d by th e ma in va lve/l inea r so lenoid. Reli ef v alve The relief va lve controls and sets a li mit t o th e m aximum dampin g f o rce.

VAN E

DAMPER OIL CHAM BER

ACCU MU LATOR

RELIEF VALVE

2-2

M AI N VA LVE/LINEA R SOLENO ID

Contents

Chapter 2

TECHNICAL FEATURES DAMPER OIL FLOW DIAGRAM

W HEN THE STEERING MOVES TO LEFT:

Contents

Chapter 2

W HEN THE STEERING MOVES TO RIGHT:

2-3

TECHNICAL FEATURES CONTROL SYSTEM Receiv ing the sig nal fro m the VS sens or, t he ECM calc ulat es t he v ehicle spe ed and rat e of accelerat io n. T he ECM o ut puts th e con t rol curr ent t o th e linear sole no id coil base d up o n th e v ehicl e speed and accelerat io n. The linear so lenoid depresses t he m ain va lve acco rd in g t o th e con t ro l curr ent w hich passe s t hroug h t he linear soleno id, an d co ntrols t he dampin g characte ristics of HESD.

"..

.,," BATIERY ECM MI L AN D HESD

~ I N DICATOR

~ 0 0

(0' :

SYSTEM CONTROL : VS (VEHICLE SPEED) SENSOR

:

TURNING LEFT

CHECK VALVES

QV-n ~I Q I

'i-...

~

TURNING RIGHT

~ CHECK Y VALVES

b=~=====~= E=L1E=F==1=LV==E=d~="M"~>O" LINEAR SOLENOID/MAIN VALVE

....... SENSOR

.....

................... STEERING DAMPER

.

SELF-DIAGNOSTIC SYSTEM The HESD syste m is equipped with a self-d ia gnostic and f ail-sa fe sys te m t h at is linked t o th e PGM -FI sy stem . Wh en t he ECM detects any f ail ure of the lin ear so leno id o r VS sensor, it stops con t ro lli ng t h e linear so lenoid and in f orm s t he rider of sys t em trouble by tu rn in g on th e M IL and d isplayi ng th e HESD in d icat or. If th e m alfun ct ion ind icato r lam p (M IL) bli nks, follow t he Se lf- Diaq nostic Procedu res (pa ge 6·9) to rem edy the pro bl em . The fail-safe system secures a m in imum run ning capa bi lity w hen t he re is any trouble in t h e system. When any ab no rm al it y is detected by t he self-diagnosis funct ion, t he ECM stops th e HESD sys tem control by sh utting off the cu rre nt supply to the linear solenoid and the HESD will operate under minimum dam pin g cha racte ristics. The HESD sys t em is also eq uipped wit h the Functio n Test M ode so t hat a t ec hn ician can co m pare the m inimum w it h m axim um dam ping character istics witho ut rid in g. Th e HESD system is set t o m inim um dampi ng at no ve hicl e spee d under no rma l co nd iti ons. By usin g t he Functi o n Test M od e, th e ECM op erat es t he linear so len oid wi th ma xim um cu rre nt so th e HESD system is t em p orar ily set t o m axi m um dam pin g.

2-4

Contents

Chapter 2

TECHNICAL FEATURES

RADIAL-MOUNTED FRONT BRAKE CALIPER The CBR1000RR's new front brake system fea tures a set of radial-m oun t ed cali pe rs. These cali pe rs f eatu re distin cti v e turret-like m ounts t hat are perpendicular t o t he f ron t axl e, on to w hich t he caliper s bo lt str aight down. Th e calipe r hal v es are held t og et her by t hree lat era l bo lt s f o r a m ore rig id design t hat pr ovid es both st ro nger g ri p an d more eve n pressu re dist ri bution across t he enti re surface area of th e pa ds fo r hig hly efficie nt br aki ng wi th

excellent feel at the lever.

Along with t hese new rad ial-m ou nt ed fro nt br ake calipe rs, the new front brake system features a new ly developed vertical piston lay o ut master cy linde r. This system mi nimizes lo st m oti o n an d m ov es the lever piv ot farther away from the end of the lever w hi ch off ers high b rakin g effi cie ncy w it h excellent f eel and cont ro ll abi lity.

Contents

Chapter 2

2-5

TECHNICAL FEATURES

EGCV (Exhaust Gas Control Valve) Th is motorcycl e is equi ppe d w ith th e EGCV that provides high perform an ce and d riveability esp ecially at lo w to middle speed ra nge by va ryi ng t he ex hau st gas flow. Th is syste m consists of th e va ria ble exhaust co nt rol v alve lo cated in the muffler and a servom otor lo cated under the fu el

tan k. The v ariable exhaust co nt rol v alve is o pe rated by cables from the servom o to r that is co nt ro ll ed by ECM . Basi cally, the EGCV is po sit ioned middle at low to middle speed rang e and opens fully at high spe ed range .

EGCV OPENING ANGLE: Ignition

Gear position

switch ON ON ON ON ON

(Clutch switch OFF) N eutral Neutral

Wit h ou t neut ra l With out n eutral With ou t n eutra l

Engin e speed

Idle Id le 5.000 - 6.00 0 rp m over 6.000 rpm

EGCV opening an gl e from fully closed

Approx.50° Approx.50° Approx .80°

Approx. 75° - 90° Approx.90°

NOTE : It is necessary to ins pect t he EGCV co ndit io n and ca ble adjust ment in accordanc e w ith th e m ain t enan ce schedul e (page 4-41. .

EGCV PULLEY

EGCV SERVO MOTOR

EGCV CONTROL CAB LES

2-6

Contents

Chapter 2

3. FRAME/BODY PANELS/EXHAUST SYSTEM

.. BODY PANEL LOCATIONS ··························· 3-2

UPPER COWL ···..····..····....·....················..·····3-12

SERVICE INFORMATION ········ ······· ···············3-3

TOP SHELTER···············..···..·······..........··..··..3-16

TROUBLESHOOTING

3-3

FRONT FENDER·························· ··················3-19

RIDER SEAT

3-4

REAR FENDER

3-19

PASSENGER SEAT·· ·············· ························ 3-4

SEAT RAIL·····················································3-27

REAR SEAT COWL ········································ 3-5

EXHAUST PIPE/MUFFLER···········..·..·..·..···..3-30

UNDER COWLS/MIDDLE COWLS·········· ..···· 3-7

Contents

Chapter 3

3-1

FRAME/BODY PANELS/EXHAUST SYSTEM

BODY PANEL LOCATIONS FRONT SIDE COVER W IN DSCREEN RIDER SEAT PASSE NGER SEAT REAR SEAT COW L UP PER COW L

FRONT FENDER

REAR FENDER A

U ND ER COW L

MIDDLE COWL

o IN NER MIDDLE COWL

3-2

Contents

Chapter 3

FRAME/BODY PANELS/EXHAUST SYSTEM

SERVICE INFORMATION GENERAL • • • •

This sectio n covers removal a nd insta llat ion of the body pane ls, ex haust syste m a nd seat rail. Se rious burn s m ay result if t he exhaust system is not allowed to cool before components are removed or serviced . Always replace the exhaust pipe gaskets wi th a new one after remov ing th e exhaust pipe f ro m t he engine. When installing the exhaust system, loo sely install all of the exhaust pipe fasteners. Always tighten the exhau st pipe clamps first. then tighten the mounting fasteners . • Always inspect the exhaust system for leaks afte r installation.

TORQUE VALUES Seat ra il flange socket bolt/flange nut Sea t rail specia l bolt/flange nut Seat rail assembly flange nut Seat rail brace socket bolt Passenger seat bracket special bolt Passenge r seat bracket socket bolt Rider seat bracket m ou nti ng bolt/ nut Rider f oot peg bracket socket bolt Bank se nso r Passenge r foo tpe g br acket socket bolt Exhaust pipe jo int nut Exhaust pipe mounting bolt Exhaust joint pipe clamp SH bolt Exhaust valve pulley nut Exhaust valve reta ini ng screw Exh au st valve pu lley housi ng fla nge S H

bol t Muffl er pipe clamp bo lt Upper cowl stay f lange bo lt

59 Nrn (6.0 kqf-rn, 43 lbf- ft) 59 Nm (6.0 kqf-m, 43 Ibf·ft) 30 Nm (3.1 kqf-m, 22 Ibf·ft) 26 Nm (2.7 kqf-rn , 20 lbf-ft) 26 N ·m (2.7 kgf·m, 20 Ibf·ft ) 26 Nm (2.7 kqf-rn, 20 Ibf·ft) 9.8 N·m (1.0 kqf-m , 7 lbf-ft} 37 Nm (3.8 kgf·m , 27 Ibf ·ft ) 11 N·m 11.1 kqf-rn, 8 Ibf ·ft ) 26 Nrn (2.7 kqf-rn, 20 lbf -tt) 12 N ·m (1.2 kgf·m, 9Ibf·ft) 23 Nm (2.3 kqf-rn, 17 Ibf·ft ) 9.8 Nm (1.0 kgf·m , 7 Ibf·ft) 4.9 N ·m (0.5 kqf -m, 3.6 Ibf·ft) 1.5 Nm (0.15 kqf-rn , 1.1 Ibf·ft ) 9.8 N·m (1.0 kgf· m, 7 Ibf·ft) 18 Nm 11.8 kgf ·m , 13 Ibf ·ft ) 32 Nrn (3.3 kqf-m. 24 Ibf·ft ) 12 Nm (1.2 kqf-m, 9 lbf -tt l 0.5 Nm (0.05 kgf·m, 0.4 lbf-tt) 1.5 N·m (0.15 kqf-rru L'l Ibf-ft} 9.8 Nm (1.0 kqf-m, 7 lbf-ft) 1.5 Nm 10.15 kqf-m, 1.1 lbf -ft ] 9.8 Nrn (1.0 kqf-m. 7 lbf-ft) 9.8 Nm (1.0 kqf-m , 7 Ibf·ft ) 12 N·m 11.2 kqf-m, 9 Ibf·ft) 6.8 Nm (0.7 kqf-rn, 5.1 lbf-ttl

Cowl stay mounti ng bolt Windscreen mounting screw Middle cow l pan screw M idd le cowl special screw Upper cowl pan screw U pp er cowl special screw Inne r cow l specia l screw Front fend er pa n screw Rea rview m irror socket bolt

TROUBLESHOOTING Exce ssive exhaust no ise • Broken ex haust syste m • Exh au st gas leak Poor performance • Defo rme d exhaust syste m • Exhaust gas leak

• Clogged muffler

Contents

Chapter 3

3-3

FRAME/BODY PANELS/EXHAUST SYSTEM

RIDER SEAT REMOVALIINSTALLATION Rem ov e th e t w o seat mou nting pan screws and col- r - - -lars. Rem ove the seat by pull in g it bac kward .

- - - - - - - - ---------, PAN SCREW S

RIDER SEAT

Install th e seat hook s unde r th e seat bracket o n t he seat rail.

HOOKS

Install t he co lla rs and seat m ountin g pan sc rews, tig hten th e screws .

PASSENGER SEAT REMOVALIINSTALLATION Un hoo k t he pas seng er seat loc k u sin g the ig nit io n , - - --

key.

- - - - - - - - -- - -- , PA SSENGER SEAT

Remove t he passe nge r seat by pull ing it fo rward. Inst all t he passeng er seat in t he rev erse o rder of

re mova l.

IGN ITION KEY

3-4

Contents

Chapter 3

FRAME/BODY PANELS/EXHAUST SYSTEM

REAR SEAT COWL REMOVAL Remove t he fo ll ow ing: -

Rider seat (pag e 3-4) Passen ger seat (page 3·4 )

Rem ov e t he fo ur special screws . Carefully pull ou t both sides of the rear .seat cowl , t he n rem ov e it upwa rd .

REAR SEAT COWL

L

f---::;;~~

Disconn ect th e t ail/b rake li gh t co nne cto r.

TA IUBRAKE LIGHT CONNECTOR

DISASSEMBLY/ASSEMBLY Rem ov e the screws and ta i l/brake ligh t unit.

TA IU BRA KE LIGHT UNIT

Remove the two screws, trim clip and a ir duet. Install the air duct and ta il/brake lig ht un it in t he rev er se o rde r of rem ov al.

Contents

Chapter 3

3-5

FRAME/BODY PANELS/EXHAUST SYSTEM INSTALLATION PASSENGER SEAT

RIDER SEAT

REAR SEAT COWL

Make sure that the mating surfaces of the cow! bottom

Connect th e ta il/brake lig ht co nnector. Install the rear seat cowl over the seat rail and rea r fe nde r bei ng careful not t o d amag e th e w ir e har-

are seated onto the

ness.

rear fender propertv before tightening the cone .

Align t he t ai l/b rake light bolt st uds w ith t he gromm et s on the rear fender as shown.

REA R SEAT COWL

Install and tighten the rear seat cowl mounti ng

sc rews. In st all t he remo v ed parts in th e rev er se o rde r of rem ov al.

TAIUBRAKE LIGHT CONNE CTOR

3-6

Contents

Chapter 3

FRAME/BODY PANELS /EXHAUST SYSTEM

UNDER COWLS/MIDDLE COWLS REMOVAL Be careful not to damage the tabs and groo ves.

Rem ov e the spec ia l screw and f our trim clips from t he bottom of th e u nder cowls.

TRI M CLIPS Remove the six tri m cl ip s from the inner lower co w l and inne r middle cow l.

TRIM CLIPS

Rem ove the un der cowl-to -m iddle cowl pan screws . Rem ov e t he un der cowl mount ing spe cia l screws and th en remove t he under cowls and inner low er cowl.

PA N SCREWS

SPECIAL SCREWS

Contents

Chapter 3

3-7

FRAME/BODY PANELS/EXHAUST SYSTEM Remove t he m iddle cowl-to-Inn er m iddle cowl trim

clips.

Rem ove the midd le cowl-ta- upper cowl pan screws . Rem ov e th e middl e cowl-to -inner mid d le cowl specia l screws and mi ddle cowl mounting special

SPECIAL SCREWS

PAN SCREWS

screw.

M IDDLE COW L Rem o v e t he m id dl e cowl w hil e rel easin g t he ho o ks o n t he u p per cowl.

HOO KS

Di sco n nect the t u rn sign al co n nector.

TURN SIGNAL CONNECTOR

3-8

Contents

Chapter 3

FRAME/BODY PANELS/EXHAUST SYSTEM Rem ove the inner m iddle cowls

INSTALLATION RIGHT MIDDLE COWL

LEFT M IDDLE COWL

~ , ~, INNER LOWER COW L

~j LEFT UNDER COW L

Contents

Chapter 3

3-9

FRAME/BODY PANELS/EXHAUST SYSTEM Install the inner m idd le cow ls.

INNER MID DLE COWL Con ne ct the turn signal conne ctor.

HOOKS

Install the m idd le cowl onto the upper cowl while aligning the slits in the middle cowl with the hooks on the upper cowl.

TURN SIGNAL CONN ECTOR Install and tighte n the upper cow l-to-m iddle cowl pan screws to the specified to rque.

~================~ PAN SCREW S SPECIAL SCREWS

TORQUE: 1.5 N·m (0.15 kgf·m .l.llbf.ft) Install and tighte n the midd le cow l special screw s to the specified to rque.

TORQUE: 9.8 Nm (1.0 kqf-m, 7 Ibf.ft)

MIDD LE COW L

3-10

Contents

Chapter 3

FRAME/BODY PANELS/EXHAUST SYSTEM Install th e trim clips.

TRIM CLIPS Install the right and left under cowls by aligning the botto m end.

PAN SCREWS

Install and tighten the under cow l-to- m iddle cow l pan screw s to the specified torqu e.

TORQUE: 1.5 Nrn (0.15 kgl·m ,l.l lbl·lt) Install and tighten the under cowl mounting special screw to the specified torque.

TORQUE: 9.8 N·m (1.0 kqf-m, 7 Ibl·lt)

SPECIA L SCREWS Secure the bottom of the under cow ls using the fou r trim clips and pan screw . Tigh ten the specia l screw to the specified to rque.

TORQUE: 9.8 Nm (1.0 kqf-m, 7 Ibl·It) . .

~~

~~~"

TRIM CLIPS

\ Y/it

y

~//~I !j :#

TRIM CLIPS

Contents

Chapter 3

3-11

FRAME/BODY PANELS/EXHAUST SYSTEM Secure the under cowl betw een the inner lower cowl and inner mi ddle cow l using th e six tr im clips.

TRIM CLIPS

UPPER COWL WINDSCREEN REMOVAL Remove the under cow ls/m idd le cowls (page 3-7). Rem ove the screws, plastic a nd rubber was hers, then remove the wi ndscree n.

SCREW PLASTI C WAS HER

WI NDSCREEN

UPPER COWL REMOVAL Remove t he rea rview mirror m oun tin g soc ket bolts

REARVIEW MI RROR

and rearview mirrors.

SOC KET '~_~~ BOLTS '

3-1 2

Contents

Chapter 3

FRAME/BODY PANELS/EXHAUST SYSTEM Discon nect the comb ination meter m ult i-connector.

COMBINATION M ETER MU LTI-CONN ECTOR Relea se the uppe r cow l off t he rearview m irror bolt hol e studs and bosses of th e upper cowl f ro m th e meter stay g rommets, then rem o v e th e upper cowl assembly.

GROM M ETS

-------

~.

;/ -~

BOSS ES Disconn ect th e fron t sub- ha rne ss multi -con nect or. See page 20-5 for hea dlight unit re mova l/insta llation .

SU B-HARN ESS MULTI-CONN ECTOR

Contents

Chapter 3

3-13

FRAME/BODY PANELS/EXHAUST SYSTEM INSTALLATION WIN DSCREEN

REARVIEW M IRROR /

0.5 Nm (0.05 kqf-rn, 0.4I bf·ft)

'if

U PPER COW L

3-14

Contents

Chapter 3

FRAME/BODY PANELS/EXHAUST SYSTEM Con nect th e front su b-ha rnes s connectors. combi-

nation meter mu lti-connecto r.

SUB-HARNESS M ULTI-CONNECTOR Inst all t he upper cowl, alig ning t he bos ses w ith the grommets o n t he upper cowl stay.

GROMM ETS

----=~-

0~~_~2f::::._ 1.0 m m (0.04 In) plug gauge does not Insert betwee n t he ga p.

spar k plug gap.

00 not adjust the spark plug gap. If

ROUN DED ELECTRODE

If t he gaug e can be inse rted into t he gap, replace th e plug w it h a new one .

WI RE TYPE FEELER GAU GE

a/ x

the gap is out of specification, replace the plug with a new one

INSTALLATION Instal l the spar k plug in t he cyl inder head and hand ti ght en, t hen torq ue to spec if icat io n.

TORQUE : 16 Nm (1.6 kqf-m, 12 Ibf.ft)

4-12

Contents

Chapter 4

MAINTENANCE Install t he di rect ignition coils . Co nnect each connector to each direct ignition co il.

DIRECT IGNITION COILS

CONN ECTORS

Rem ov e the rig ht fro nt side cover (page 3-16). Inst all the int ake air duc t assembly, w hi le alig nin g it s tab w it h t he low er ai r cl ean er hou si ng base. M ake sure t h at th e in t ake ai r du ct is proper ly seated o n t he ho us ing.

Inst all and t ig hten th e int ake air duct mount i ng

screws. TORQUE: 2.5 Nrn (0.25 kqt -rn, 1.8 Ibl ·lt)

Inst all and tig hten th e air du ct moun t ing bo lt s.

Contents

Chapter 4

4-13

MAINTENANCE Co n nect t he v acuum ho se to t he v ari abl e air in tak e diap hr agm.

Insta ll t he ai r int ake gr ill a nd secu re it with t rim cl ips.

Inst all the radi ator on to the bracket whil e al igning the g ro m met and fram e bos s.

__=~~

Insta ll and t igh te n th e rad iat o r upper mounting bolt. ...~=

4-14

Contents

Chapter 4

MAINTENANCE Insta ll the radiat or lower bracket to the eng ine and tighten t he bo lt.

Install and tig ht en the rad iat or lower m ounting bolt.

LOWER MOUNTING BOLT Con nect th e fa n m ot or 2P (Black) co nnector.

Install and tighten th e rad iator reserve t ank m ou nt ing bolt and filler neck mounti ng bo lt.

Contents

Chapter 4

4-15

MAINTENANCE Conne ct t he CMP senso r 2P (Black) connector. Remove t he unde r cowls/m iddl e cowls (page 3-7).

VALV E CLEA RANCE IN SPECTION Inspect and adjust the valve clearance while the engine is cold (below 35 DC/ 95"F)

Remove the cy lin de r head co ver (page 9-6 ). Remove t he cam chain tenstoner lifter sea ling bolt and sea ling washer.

SEALING WAS HER

SEALING BOLT Turn t he t ensi on er lift er shaft full y in (cloc kw ise) and se cure it using t he spe ci al t 60 1t o p rev en t dam aging t he cam chain.

TOOL: Cam chai n ten sioner hold er

CA M CHA IN TENSIONER HOLDER

07ZMG -MCAA400 or 07NMG-M Y90100

Remo ve t he tim ing hol e cap and O-r ing .

4-16

Contents

Chapter 4

MAINTENANCE Turn t he cra nkshaft clockwise, alig n th e "T" m ar k on the crankshaft position sensor roto r with the index mark on t he right crankcase cover.

Th e ti m ing marks ("IN" and "EX ") on t he ca m sprockets m ust be fl us h wit h t he cyli nder head surface and faci ng outward as shown. If th e ti mi ng ma rks on the cam sprockets are facing

inward, tu rn th e crankshaft clockwise one fu ll turn (360°) and realign the timing ma rks with the cylin der head surface so they are facing outward.

Insert the fe ele r gau ge betw een t he v alv e lift er and

ca m lo be. Record the clearance for each valve for reference in shim selec tion if adj ustme nt is required.

Che ck t he v alve cleara nce for the No.1 and No .3 cy linder intake valves usin g a feeler ga uge. VALVE CLEARANCE: IN: 0.16 ± 0.03 mm (0.006 ± 0.001 i n)

NO .3 INTAK E VALVES NO .1 INTAKE VALVES Turn t he cra nks haft clockwise 1/2 turn (180°), alig n t he index line on t he c ranksh aft posit ion senso r rot o r so t hat it i s facin g up as shown.

Contents

Chapter 4

4-17

MAINTENANCE Record the clearance for each valve for re ference in shim select ion If

adjus tm ent is

Check t he va lve clea ra nce f o r the No.2 and No .4 cvlinder exhaust valves using a fee ler gauge.

NO.4 EX HA UST VALVES NO.2 EX HAUST VALVES

VALVE CLEARANCE: EX: 0.30 ± 0.03 mm (0.012 ± 0.001 in)

required.

Turn the crankshaft clockwise 1/2 turn (180°), alig n th e "T" mark on the cra nkshaft position senso r roto r with t he index mark o n the right c rankcase cove r.

Reco rd the clearance for each valve for reference in shim se lection if adjustment is required.

Check t he val ve clearance for the No .2 and No .4 cylinder in take valves us ing f eeler gauge. VALV E CLEA RANC E: IN: 0.16 ± 0 .03 mm (0.006 ± 0.001 i n )

NO.2 INTAKE VA LVES NO.4 INTAKE VA LVES Turn t he cra nksh aft clockwise 1/2 tu rn (180°), alig n th e index line on the cra nks haft p ositi on se nsor rotor so that it is faci ng u p as shown.

4-18

Contents

Chapter 4

MAINTENANCE Reco rd the c1earance for each valve for refere nce in shim selec tion if

adjustment is

Check the v alve clearance f or the No .1 and No.3 cyl inder exhaust valves using a feeler gauge.

NO.1 EXHAUST VALVES

VA LVE CLEARA NCE: EX: 0.30 ± 0.03 mm (0.012 ± 0 .001 in)

required

ADJUSTMENT It is not necessary to remove the cam sprocket from the camshaft except when replacing the camshaft and/or cam sprocket.

Remove t he cams hafts (page 9-81. Remove the valve lifters and shims. • Shim m ay stick to the inside of the v alv e lift er. Do not allow the shim s t o fall into th e crankcase . • M ark all valve lifters and shims t o ensure corr ect reassem bly in their origina l locat ions. • T he valv e lifter can be eas ily rem ov ed with a

valve la pping tool or magnet. • T he sh ims ca n be easily rem ov ed with a tweezers or m ag net .

Clean the valve shim contact ar ea in th e va lve lift er with co mp ressed air .

M easure the shim t hi ckness and reco rd it .

Contents

Chapter 4

4-19

MAINTENANCE Calculate the new shim thickness using th e equation below. A= (B-C)+D A: Ne w shim thickness thickness s him to B: Recorded valve clea ran ce the thick e st 2.900 C: Specified valve clea rance mm thickness shim D: Old shi m t hickness

Sixty-nine different thickness shims are availab le from the thinnest 1.200mm

in intervals of 0.025 mm

Install the shims and valve lifters in theirorigi nafloca-

tions

• Make sure of the correct shim th ickness by measuri ng the shim by m icrom ete r. • Reface the valve seat if carbon deposit result in a calculated dimension of over 2 .900 m m .

eeee 1.80 m m

1.825 mm

1.85 mm

1.87 5 mm

Insta ll the new ly selected shim on the va lve spring retai ner. App ly mo lybde nu m dis ulfide oil to th e valve lift ers. Instal l the va lve lifte rs into the v alve lifte r holes.

Inst al l th e cams hafts (page 9-26) . Rotate the cams hafts by rotating the crankshaft clockwise several times. Reche ck the v alve clea rance .

Rem ove the cam chai n te nsion e r ho lder too l.

CAM CHA IN TEN SIONER HOLDER

Insta ll the new sealing w asher a nd cam cha in tensioner lifter sealing bo lt. Tighten the bolt securely.

S~ SEALING WASH ER

/ G2@

\

SEALING BOLT

4-20

Contents

Chapter 4

Check that the D- A pply grease t o t he ti ming ho le cap th read s. ring is in good con- Ti gh t en th e t imin g hol e cap to t he spec if ied to rque. ditio n, replace if TORQUE: 18 N ·m (1.8 kqf-m, 13 lbf-ft) necessary.

Inst all the rem ov ed parts in th e reverse ord er of remova l.

ENGINE OIL/OIL FILTER OIL LEVEL INSPECTION Sta rt th e engine and let it id le for 3 - 5 m inutes. Stop the engi ne and w ait 2 - 3 minutes. Hold th e m otorcycle in an upright pos ition. Check t he oi l lev el th rou gh t he inspect ion window .

If the level is below the lo w er level line, rem ove th e oil fi ll er ca p and f ill th e crankcase wi t h th e recom mended oi l up t o the upper level line as follows:

Rem o ve the oil filler cap .

Contents

Chapter 4

4-21

MAINTENANCE Fill the recommended engine o il up to the upper level line. Other visco sities shown in the chart may be us ed when the averag e remperature In your riding area is w it hin the indicated range.

RECOMMENDED ENGINE OIL: SA! 201-40 201-50

Pro Honda GN4 or HP4 (w it ho ut molybdenum

additives) a-stroke oil or equivalent motor oil API service classification: SG or high er JASO T 903 st andard : MA Viscosity; SAE 10W-40

I~

, .,

Rein st al l th e oil fi ller cap.

o - 20

10

60

40

20

o

10

80

20

30

400C

ENGINE OIL & FILTER CHANGE Change the engine oil with the warm and the motorcycle on level ground to assure complete draining.

Start the engine and let it id le fo r 3 - 5 minutes.

Stop the engine and wait 2 - 3 minutes. Hold the motorcycle in an upright position. Remove the under cowls (page 3-7) . Remove the oil filler cap .

Rem ov e th e dra in bolt a nd sea ling was he r, d rain th e oil comp letely .

Rem ov e and discard th e oil f ilt e r cart ridge usi ng t he special tool.

TOOL :

Oil filter wrench

4-22

07HAA-PJ70101

Contents

Chapter 4

MAINTENANCE Chec k t hat t he sea ling was her o n t he dra in bol t is i n go od co nd it io n, and replace if neces sary. Install and tighte n the d rai n boll. TORQUE: 29 Nm 13.0 kqf-m , 22 lbf -ft]

Ap pl y cle an engine oi l t o th e oil filter ca rt ri dge threads and new O· rin g.

Install the new oi l fi lter and tighte n it to th e specified t orque . TOOL: Oil filter wre nch

07HAA·PJ70101

TORQUE: 26 Nrn 12.7 kqf-m, 20 Ibf·ft) Install the radi ato r reser v oir tank and bolt .

Fill th e cra nkcase w ith rec o m me nd ed engine o il. OIL CAPACITY: 3.0 liter (3.2 US qt. 2.6 Imp qt) after draining 3.1 liter (3.3 US qt, 2.7 Imp qtl after oil filter ch an ge Check t hat the a-rin g o n th e o il f iller cap is in good co nditio n, and repla ce it if necessary . Install t he oil fill er cap. St art th e engine and let it idl e fo r 3 - 5 m i nut es. Stop the engine and wait 2 - 3 m inu t es and rec heck the oil lev el. M ake su re th ere are no o il leaks. Install th e under cowls {page 3-71.

Contents

Chapter 4

4-23

MAINTENANCE

ENGINE IDLE SPEED Iiii=:' ':'''T ....~----'l!';;

• Inspect an d adju st t he id le speed after all other , .• • • • • engine ma intenance items have bee n performed and are w ithin specifica tio n. • The eng ine m ust be wa rm f or acc urate idl e speed ins pec tio n and adjust ment. Wa rm t he engi ne f or about 10 m in utes. Turn th e th rottle sto p scr ew as req uired t o obtai n t he spe cified id le speed. IDLE SPEED: 1.200 ± 100 rpm

RADIATOR COOLANT Check t he coo lant lev el of th e reserv e t an k with th e ,-- - - - -- - - - - - - - - - - -- , U PPER LEVEL LINE engine ru nni ng at no r mal ope rati ng tem pe rature. Th e level should be betw een the "U PPER" and "LOW ER" level li nes. If necessary , add reco mmended coo lan t. RECOMMENDED ANTIFREEZE:

High q ua lity ethy le ne g lyco l a nti freeze containi n g co rrosio n protection inh ibitor s .

LOWER LEVEL LIN E Remo ve t he unde r cowls/m iddle cow ls (page 3-7). Rem o v e t he reserve t ank fill er ca p and fill t o t he "U PPER" lev el line with 1:1 m i xtu re of d ist illed water and ant ifreeze. Rei nstall the filler cap . In st all the under cowls/middle cowls (page 3-9 ).

COOLING SYSTEM Rem ov e t he under cowls/m idd le cow ls (page 3-7) . Check th e rad iato r air passages f or clog g ing o r damage . St raighten bent fins, and rem o v e in sects. mud o r other obstru ctions with compressed air o r low water pr essure. Replace the radiato r if the air flow is rest ricted ov er m or e than 20% of the radiat ing surface.

4-24

Contents

Chapter 4

MAINTENANCE Insp ect the rad iator hoses fo r cracks o r deteri o rat ion, and replace them if necessa ry .

Check the tig htness of all hos e clam ps and fasten e rs .

SECONDARY AIR SUPPLY SYSTEM • This model is equipped built-in secon dary air supply syste m. Th e p ul se seco nd ary ai r supp ly sy st em is loca t ed on th e cyl ind er head co ver. • Th e seco ndary air supply syste m int rodu ces f ilte red ai r into exha ust gases in t he ex haust port. The secondary air is d rawn into t he ex haust po rt w hen ev er th er e is nega t ive pr essu re pulse in the exhaust syst em . T his charged seco ndary air prom ot es burning of the unburned exh aust gas es and change s a co nsiderable amount of hy drocarbon s and ca rbon mon o xide int o relatively harmless ca rbo n dioxide and wa te r.

PAIR REED VA LVE

EXH AU ST PORT

Rem ov e the ai r cleane r housing (page 6-40) . If the hoses show any signs of heat damage, inspect the PAIR reed valves in the PAIR check valves for damage .

Check th e PA IR (pulse seco ndary air i njectio n) hoses betw een the PAIR con tro l so lenoid v alv e and cvlinder head cove r f or det er ioratio n, da m age o r loos e co nnect ions. M ake su re th at t he h oses ar e not cra cked . Check t he ai r suction hose betwee n th e air cl eaner hou si ng and PAIR con tro l so lenoid va lve f o r deteri oratio n, dam age or loose con nect ion s. M ake su re th at the hoses are not ki nked, pin ch ed or cracked .

Contents

Chapter 4

4-25

MAINTENANCE

EVAPORATIVE EMISSION CONTROL SYSTEM (CALIFORNIA TYPE ONLY) Check th e hoses between th e fu el t an k, EVA? ca nist er, EVA? purge co nt rol sole noid v alve fo r d et eri ora t ion , damage or loose con nection . Chec k t he EVA ? ca niste r fo r cla cks or othe r damage . Refer t o t he Cab le & Harn ess Rout in g (page 1-24) for hose con nec tio ns . EVAP CA NISTER

DRIVE CHAIN DRIVE CHAIN SLACK INSPECTION Turn th e ig nit io n switch OFF, plac e th e motor cycle on it s sid e sta nd and shift t he t ra nsm ission int o neu-

t ra l. Check th e slac k in t he d ri v e cha in low er run midway be tween t he sprockets. CHA IN SLACK: 25 - 35 m m (1 - 1-3/ 8 in )

I NOTICE I Excessive chain slack, 50 rom (2.0 in) or m ore, ma y damage the fram e. Lubri cat e the d riv e chai n w it h #80 - 90 gear oi l o r chain lubric a nt desig ned speci fica lly f o r u se w it h D ri ng chains . W ip e off th e excess o il o r cha in lubrica nt.

ADJUSTMENT Lo o sen the rea r axle nu t . Turn bot h adjusting bol t s until t he co rrect d rive ~;;,;,;;;;,;.,;,;;.~ cha in slac k is obta ine d. M ak e sure t he ind ex m ar ks on bo th ad ju stin g pl at es are alig ned w it h th e end o f t he swing a rm. Ti g ht en the rear axle nut to t he specified torq u e.

TORQU E: 113 N -m 111.5 kqf- m , 83 Ibf·ftj

4-26

Contents

Chapter 4

MAINTENANCE Rech eck the d ri ve chain slack and fr ee wheel rot atio n. Lubricat e th e drive chain with #80 - 90 ge ar oil or d rive chain lubric ant desig ned speci f ica lly for use with O-r ing chai ns. W ip e off t he exc ess o il o r chain lubricant. Che ck the d rive chain w ear ind icato r label attached on th e left d rive chai n adju sting plate. If the swi ng arm in dex mark reaches red zo ne of th e indicato r label, replace t he dri ve ch ain wit h a new on e (page 4- 28 1.

CLEANING AND LUBRICATION Clea n t he chain with non -fl ammable or high flash point solvent and w ipe it dry . Be su re the chai n has dr ied completely before lubricati ng. Inspect t he dri ve chain f or possible dam age o r w ear. Rep lace any chain that has da m aged ro lle rs, loose fi tting links, o r oth erwise ap pea rs un serv iceabl e. Inst allin g a new chain o n badly worn sproc kets wi ll cause the new chain to wear q uic kly. Inspect and rep lace sp rocket as necessary.

CLEAN SOFT BRASH

00 C 0

W IPE A ND DRY Lub ricat e the d ri ve chain w it h #80 - 90 gear o il or drive chain lubrica nt desig ned specif ically fo r use with O-ring chains. Wi pe off the excess o il o r chain lubricant.

6 "t.--=~

LUBRICATE

SPROCKET INSPECTION Insp ect the driv e an d d ri ven sprock et teeth f or wea r or dam age, repl ace if necessary . Never use a new drive chain o n wo rn sprocket s. Both cha in and sprockets must be in good cond ition , o r t he new repla cem ent chai n w il l we ar rapidl y.

WEAR

NO RMAL

Contents

Chapter 4

4-27

MAINTENANCE Check the attaching bolts and nuts on th e drive and driven sp ro ckets. If an y are lo o se. to rque them .

TORQUE :

Drive sprocket s pecia l b olt: 54 Nm (5.5 kq-m , 40 Ibf.ft) Final driv en s p roc ket nut: 64 Nm (6.5 kqf-m, 47 Ibf·ft)

REPLACEMENT This m ot o rcycle u ses a drive chain with a st aked ,-- - - - - - - - - - - - - -- - - ----, maste r li n k. Lo osen the drive cha i n (pa ge 4-26) . When using the special tool, follow the manufacturer 's

ins truction.

Assemble th e speci al tool as sho w n.

TOOL:

Drive cha in too l set

07H MH-MR10l03 or 07HM H-MR10l0C (U.S.A.o nly)

DRIVE CHAIN TOO L SET Lo cat e th e cri mped pin end s of th e ma st er link from th e o utside o f t h e ch ai n, and remove t he link with t he drive chai n t ool set.

TOOL:

Drive chai n t o ol s et

--

MASTER LINK

07HMH-MR10103 or 07HMH-MR1010C (U .S.A .only)

Remove th e dr iv e c hai n.

DRIVE CHAIN TOO L SET

4-28

Contents

Chapter 4

MAINTENANCE Include the master lin k w hen you

Rem ov e th e exc ess drive chai n li n ks f ro m t he new d rive chai n wit h t he d rive cha in too l set.

coun t the drive cham links.

STANDARD LINKS: 114 LINKS REPLACEMENT CHAIN DID : DIDsOVM2-120ZB RK: RKsOGFOZ1-120LJFZ

1 LIN K

•

...--

• Never reuse the old d rive cha in, master lin k. mast er link plate and O-rings. Insert the master link from the inside of the drive chain, and install the plate w it h the identifi cation mark facing the outside .

-

-

-

1' 4 LINK S - - - -_

•

~=================~ PLATE

Asse mble the new master li n k. a -rings and plate.

Ass embl e and set t he d rive chai n too l set . TOOL:

Drive ch ain tool set

07HMH-MR10l03 or 07HM H-M R101OC (U.S.A .only)

Make su re t h at th e master li n k pi ns are ins talled properly . M easu re t he m ast er link p in leng t h p roj ect ed f ro m t he p late.

MASTER LIN K PINS

STANDARD LENGTH: DID: 1.15 - 1.55 mm (0.045 - 0.061 in) RK: 1.2 - 1.4 m m (0.05 - 0.06 in) Stake t h e master link pins.

Contents

Chapter 4

4-29

MAINTENANCE Ma ke su re th at t he pin s a re stake d properly by m ea SLIDE CA LIPER

su ri ng th e dia me te r of t he stake d area usi ng a slid e cal iper. DIAMETER OF THE STAKED AREA: DID : 5.50 - 5.80 mm (0.217- 0.228 in) RK: 5.30 - 5.70 mm (0.209 - 0.224 in )

A drive chain w ith a clip-type master link

must not be used

Aft er sta king, chec k th e staked area of t he mas te r lin k for crac ks. If the re is any crac king, replace the mas te r li nk, 0ri ng s an d p late.

~===================~ GOO D

NO GOO D

(O\ ~ 'bvJb ~ ~

\$;jj

f{j'Jf

W

~/.

....--....:::=~~

CRACKED

BRAKE FLUID I

NOTICE

Spilled fl u id can da m ag e p ainted, p lastic or rubber parts. Place a rag over these parts wh en ever th e system is se rviced.

• Do not m i x different t yp es of fl u id, as t hey are

not co m pati ble w ith e ach ot he r. •

Do no t al low f orei g n m at eri al to e nter the system w hen fil lin g the rese rvo ir.

W he n t he f luid level is low , ch eck t he bra ke pads f or wea r (page 4 ~31 ). A low fl ui d lev el may be du e t o wea r of th e br ake pads. If th e bra ke pads are worn, t he calipe r piston is pus hed ou t, an d t his acco u nts f or a low reserv oir lev el. If the bra ke pad s are not wo rn and th e fl uid lev el is low , check ent ire syste m fo r leaks (page 4-32) .

FRONT BRAKE Tu rn th e hand leb ar so that th e reser v oir is lev el and check th e f ron t bra ke flu id lev el. If t he level is near th e low er lev el lin e, chec k th e b rake p ad wea r (pa ge 4-31 ).

4-30

Contents

Chapter 4

MAINTENANCE REAR BRAKE Place th e motorcy cl e on a lev el surface, and suppo rt it an upr ig ht pos ition. Chec k t he rear brak e flu id lev el. If th e level is ne ar t he lower level lin e, check the bra ke pad wear (p age 4-31 ).

.

...

LOWER LEVEL LINE.

,-

BRAKE PAD WEAR FRONT BRAKE PADS Check t he bra ke pad s for wea r. Repl ace the brake pads if eithe r pad is wo rn t o th e bottom of wea r lim it groove. Refer t o brak e pa d re p lacem ent (page 16-11).

REAR BRAKE PADS Chec k the brake pad s fo r w ear. Repl ace t he brake p ads if eit he r pad is wo rn t o t he

bott o m of w ea r lim it g roove. Ref er t o bra ke pad repl acem en t (page 16- 13 ).

Contents

Chapter 4

4-31

MAINTENANCE

BRAKE SYSTEM INSPECTION Firm ly apply t he brake lever or pedal, an d check th at no air has entered the syste m. If t he lever or pe da l fee ls soft or spon gy w he n ope rated, bleed th e ai r fro m t he system (p ag e 16-8), Inspect t he brake hose and fitt ings for dete rioratio n, crac ks and sig ns of leakage. Tig hte n any loose fitt ings. Replace hoses and fitti ngs as req uired.

Refer the pro cedure fo r b rake b leeding (page 16-7).

BRAKE LEVER ADJUSTMENT Align the allo w m ark on the brake lever with the inde x number on the

T he distance bet w een the to p of th e bra ke lever and t he grip can be adjusted by tu rning the adj uste r.

adjuster,

BRAKE PEDAL HEIGHT ADJUSTMENT Loosen the Jock nut and tu rn t he pus h rod until th e co rrect pedal heigh t is o btained .

Make su re the push rod t hr ea ds can be seen through the pedal jo int hole. Afte r adjustment, tighten th e lock nut to th e specifi ed torq ue .

LOCK NU T

TORQUE: 18 Nrn (1.8 kqf-rn, 13 lbf-ttl

X HOLE

4-32

Contents

PEDA L JO INT

," M I II

"

Chapter 4

MAINTENANCE

BRAKE LIGHT SWITCH The front brake light switch does nor require adjust-

Adjust the bra ke light switch so that t he brake light comes on just prior to the brak e actually being

m enlo

If th e light fa ils t o com e on , adj ust th e switc h so t hat the li ght co m es on at the pro pe r ti m e. Hold th e sw itc h bo dy and tu rn the adju st er. Do not tu rn the swi tc h body.

engaged.

HEADLIGHT AIM Place th e m ot o rcycle on a leve l surface. Adjust the hea dlight aim as spe cified by local laws and requ lations.

Adjust the head li ght aim vertically by t urning the vertica l beam adjust i ng screw. A clockw ise rotati o n moves t h e beam up and coun te rclockwise rotat ion moves t he beam down.

A dj ust the head lig ht aim ho rizontall y by tu rning t he ho ri zon tal bea m adjusting screw. Left Headligh t:

A clockw ise rot ation m ov es th e be am towa rd the rig ht and cou nter c lockw ise ro tat ion moves t he beam t ow ard t he left side of th e r ider.

Righr Headlight:

A clockwise rot ati o n moves the bea m t ow ar d the left and count ercl ockwi se rotation moves the beam towa rd the ri gh t side of the rider.

HORIZONTAL BEAM ADJU STING SCREW

CLUTCH SYSTEM CLUTCH LEVER ADJUSTMENT The d ist an ce between t he ti p o f the clutch lev er and t he g rip can be adjusted by turn ing th e adju ster.

Contents

Chapter 4

4-33

MAINTENANCE

CLUTCH FLUID

I

NOTICE

$piJI ed fl uid can d amage pain ted, plastic o r rubber parts. Place a rag ove r th ese pa rts when ever th e system is servic ed. • Do no t m ix differe nt types of f luid, as th ey ar e

not co m pat ible w ith ea ch o the r. • Do not all o w f o re ign mater ial t o ent er t he system whe n filling the reser v oi r. When the fluid level is tow. check entire sys tem for leaks.

Turn t he handl eb ar to the right so t hat the reserv o ir is lev el and check th e clutch f luid lev el. Fir ml y apply th e clutch lev er, and ch eck th at no air has ente red th e syste m. If th e lev er f eels soft or spo ngy whe n operated, blee d the air from the system.

In spect the clutch hose an d fitt ings for dete rioratio n, crac ks an d si g ns of leak ag e. Tigh t en any loose fitti ngs . Replace hoses and fi tting s as req uired . Ref er th e proced ure fo r cl utc h fl uid bleed ing (pag e 10-6).

EXHAUST GAS CONTROL VALVE CABLE OPERATING INSPECTION Rem ov e t he left m idd le cowl (page 3-7). Turn th e ig nit io n sw it ch to "O N" . Sho rt th e Dat a Lin k Co nn ector (OLe) t erm ina ls us in g t he speci al t ool.

TOOL : SCS se rvice connector

4-34

070PZ-ZY30100

Contents

Chapter 4

MAINTENANCE M ake sure that the EGCV (Ex haust Gas Cont ro l Va lve) cable gu ide pull ey index li ne is alig ned wi th th e EGCV housing index line as sho w n. If th e pull ey index lin e is n ot w ith in the to ler ance, adjust the EGCV co nt ro l cab les . Turn th e ignit ion switch OFF and rem o v e t he SCS

service co nnecto r.

IN DEX LINES

BEARING INSPECTION M ov e th e exhaust va lve pulley w ith yo ur hand , , .- -- - - - - - - - - - ----------, check th e ex h aust va lve shaft for ex cess ive play. If th er e is ex cessi ve pl ay, replace the ex ha ust v alve shaft beari ngs w ith new ones .

CABLE ADJUSTMENT 1. Fully loosen th e sp ring equipped si de cable lock , .- - - - - - - - - - - - -- - - ------, LOCK NUT nut and adju sting nu t . 2. Sho rt the Data Link Conn ect or (OLe ) te rm ina ls u sing the special too l (p age 4-34 ).

A DJUSTING NUT

3. Loosen th e adjusti ng cable lock nu t and adjust in g n ut.

~=================~ LDCK NU T

4. A dj ust the pu ll ey posit ion by turnin g t he adjust in g nut. 5. T ighten th e lock nut securely .

A DJ USTING NU T

Contents

Chapter 4

4-35

MAINTENANCE 6. Move the cable several times a nd rec heck the

LOCK NUT

index li ne. 7 . Seat th e adjusting nut to th e housing and t ight e n the lock nut securely.

-: ADJ USTING NUT

SIDE STAND Supp ort th e motorcycle on a lev el su rface . Check th e sid e stand sp ri ng for d am ag e o r loss of te nsio n. Chec k the sid e sta nd assembly fo r f reedom of movem ent and lub ricate th e side st a nd p ivot if nec -

es sa ry.

Check t he side stand ig ni tion cut- off system : -

Si t ast ri de the motorcycle and raise the side stand. Start the e ng ine w ith the t ransmission in neutra l, the n shift t he t rans m ission into gear, with the clutch lever squeezed . M ov e t he side stand f ul l down. The engine sho uld stop as th e sid e stand is lo w -

e red. If t here is a pro blem w ith the system, check t he side sta nd switch (page 20-22 ).

4-36

Contents

Chapter 4

MAINTENANCE

SUSPENSION FRONT SUSPENSION INSPECTION Che ck the act ion of the f orks by ope rat ing the f ront bra kes and co m pressin g t he fro nt sus pe ns io n several times.

Check t he enti re assem bly fo r signs of leaks, dam a g e o r loose fastene rs. Replace dam ag ed co m po nen ts wh ich cannot be

repa ire d. Tighten all nuts and bolts. Refe r to f o rk service (p ag e 14-2 1).

Check for worn steering stem bearin gs by grabbing the fr ont fo rk leg s and att em pt ing t o m o ve the fro nt fo rk fro nt to back. Rep la ce the bea rings if any lo o se ness is noted .

FRONT SUSPENSION ADJUSTMENT SPRING PRE·LOAD ADJUSTER Spring pre -lo ad can be adjusted by turn in g the adju st er.

TURN CLOCKWISE : Increase th e spring pre-l o ad TURN COUNTERCLOCKWISE: Decrea se th e s p ring pre-l o ad PRE·LOAD ADJUSTER ADJ USTABLE RANGE: 15 turn s PRE-LOAD ADJUSTER STANDARD POSITION : 7 turn s in from m inim u m

Contents

Chapter 4

4-37

MAINTENANCE COMPRESSION AND REBOUND DAMPING ADJUSTERS

I NOTICE I Do not turn the adjusters more than the given positions or the adj usters may be damaged. • All damping adjustments are refe renced f rom the full hard position. • Be sure t h at the rebound and compression adjusters are firmly located in a detent, and not

between pos itions. To adjust both sides equally, set the right and le f t damping adjusters

The compression and rebound damping can be adjusted by turni ng the adjusters.

DIRECTION H: Inc rease th e d ampi ng f orce to the same oost- DIRECTION S: Decr ease th e dampin g force cion.

Turn t he co m pressio n adju ster clockwise u ntil it stops (f uJI hard posit ion), t hen t urn t he adj uster co un tercloc kw ise.

COMPRESSION ADJUSTER STANDARD POSITION: 2 turns out from full h ard

Turn the rebo und adjuste r clockwise until it stops (fu ll hard position), then turn the adjuster counterclockwise.

REBOU ND ADJUSTER STANDARD POSITIO N: 2 turns o ut from f uJI ha rd

4-38

Contents

Chapter 4

MAINTENANCE REAR SUSPENSION INSPECTION Support the motorcycle secu rely and raise t he rear wheel off th e groun d . Ho ld t he swi ngarm and m ov e the rear w hee l side w ays w ith f o rce to see if the ax le bea ring s are w o rn.

Check f or worn sw inga r m bea ring s by g rab bi ng t he rea r e nd of t he swin g arm a nd att empting to m ov e th e sw ing ar m si de to side .

Repl ace t he bearings if any ar e looseness is not ed .

Check th e act ion of t he sho ck abso rbe r by co rnpr essin g it seve ral t imes. Check the ent ire shock absorber asse m bly f or sig ns of leaks, damage or loose fastene rs .

Repl a ce damaged components which cannot be

repaired. Tight en all nu ts and bol ts.

Ref er to the shock absorber service (page 15-14).

Contents

Chapter 4

t

4-39

MAINTENANCE REAR SUSPENSION ADJUSTMENT COMPRESSIO N AND REBOUND DAMPING ADJUSTERS

I NOTICE I Do no t turn the adju s te rs more tha n the given poeitions or the adjusters m ay be damaged. • All damping adj ustments ar e refer enced fro m the f ull hard p os it ion. The co mpressi o n and reb ound d amping can be adjusted by turni ng the ad ju ster s.

DIRECTION H: In crea se th e dampin g force DIRECTIO N S: Decrease the damping force

Turn th e co m p ressio n adj us te r clockwise until it sto ps (full ha rd position), th en turn th e adjust er

co u nte rcloc kwise. COM PRESSION ADJUSTER STANDARD POSITION :

9 clicks o ut from full hard

Tu rn t he reb oun d adjuster clo ckw ise u ntil it stops (ful l hard pos itio n ), t he n t u rn t he ad j ust er co u nt erclockw ise.

REBOU ND ADJUSTER STANDARD POSITI ON : 2 - 1/ 2 turn s ou t from full hard

REBOUND A DJ UST ER

4-40

Contents

Chapter 4

MAINTENANCE

NUTS, BOLTS, FASTENERS Check that a ll chassis nut s and bolts are tighte ned to their correct torqu e val ues (page 1·12 ). Check that all safety clips, hose clam ps and cable stays are in place and pro perly secured .

WHEELS/TIRES T ire pre ssure should be checked when th e tires are COLD.

RECOMMENDED TIRE PRESSURE AND TIRE SIZE: FRONT T ire pressure kPa (kgf/ cm ', p si) Tire size

Tire bland

Bridgestone Pirelli

REAR

25012.50.36) 290 (2.90, 42) 120n O ZR 17 MIC 158W ) BT014F RA DIAL G DIAB LO CORSA H

190/50 ZR 17 MIC (73WI BT014R RAD IAL G DIAB LO CORSA H

Check the tires fo r cuts, embedded nails, or othe r L = "..::;.,..:= = ..:::::r..oa_ _ damage. Check th e fro nt whe el (page 14- 16) and rear w hee l (page 15·7) for truen ess. Measure the tread depth at the cente r of the tires. Replace the tires wh en the tread dep th reaches the followi ng limits .

MINIMUM TREAD DEPTH: FRONT: 1.5 mm 10.06 in) REAR: 2.0 mm (0.08 in)

STEERING HEAD BEARINGS Check th at th e contro l cables do not inte rfe re with handleb ar rotation . Support the m otorcycle securely and raise the front whee l off th e ground . Check that th e ha ndle ba r moves fr eely from side t o side. If the handlebar m oves unevenl y, binds, or has ve rtical mo vement, inspect the stee ring head bearings (page 14-351.

Contents

Chapter 4

4-41

MEMO

Contents

Chapter 4

5. LUBRICATION SYSTEM

LUBRICATION SYSTEM DIAGRAM

• 5-2

OIL STRAINER/PRESSURE RELIEF VALVE··5-6

SERVICE INFORMATION ···················· ·········· 5-3

OIL PUMp······································ ······ ············5-8

TROUBLESHOOTING ····································5-4

OIL COOLER··················································5-13

OIL PRESSURE INSPECTION························ 5-5

Contents

Chapter 5

5-1

LUBRICATION SYSTEM

LUBRICATION SYSTEM DIAGRAM •

"

• • •

" " v

• ••

" v "

CAMSH AFTS

..

PISTON -_.~~~~

PISTON OIL JET

CRANKSHAFT

r

OIL COOLER

J . BALANC ER EOP SWITCH MAINSHAFT

-

COUNTERSHAFT

OIL FILTER CA RTRIDGE

OIL PUMP

OIL PRESSURE RELIEF VALVE OIL STRA INER

5-2

Contents

Chapter 5

LUBRICAT ION SYSTEM

SERVICE INFORMATION GENERAL

ACAUTION Used engine oil may cause skin cance r if repeatedly left in contact with the skin for pro longed pe riods. Alt hough this is unlikely unless you handle used oil on a daily basis, it is still advisa ble to tho roughly wash your hands wi th soap and water as soon as possible afte r handling used oil. • • • • •

The oil pum p can be serviced w ith the eng ine installed in the fram e. T he service procedures in this section m ust be perform ed w ith the engine oil draine d. W hen rem oving and installing the oil pump , use care not to allow du st or dirt to enter th e engine. If any portion of the oil pu mp is wo rn beyon d th e specified service limits, replace the oil pum p as an assem bly. Afte r the oil pump has been installed, check th at there are no oil leaks and that oil pre ssure is correct .

SPECIFICATIONS ITEM Engine oil capacity

Aft er drain ing After oil filter change Afte r disassembly

Recom me nded engine oil

Oil pressure at EOP (engine oil pressure) switch

Oil pump

Tip clea rance Body clearance Side clearance

STANDARD 3.0 lit er (3.2 US qt , 2.6 Im p qt ) 3.1 lit er (3.3 US qt , 2.7 Imp qt ) 3.8 lite r (4.0 US qt. 3.3 Imp qt ) Pro Honda GN4 or HP4 (without moly bde num additives) 4-stroke oi l (U .S.A. and Canada), or Honda a- st ro ke oil (Canada only) , or an equivalent motor oil API service classification: SG or Highe r except oils labeled as energy conse rving on th e circular API service label JASO T 903 st anda rd: MA Viscosity: SAE 10W-40 490 kPa (5.0 kgl/cm', 71 psi) at 6,000 rpm/(80 'c/176'F) 0.15 (0.006) 0. 15 0.2 1 (0.006 - 0.0081 0.04 - 0.09 (0.002 - 0.004)

Unit: mm (in) SERVICE LIM IT

-

0.20 (0.0081 0.35 (0.014) 0.17 (0.007)

TORQUE VALUES Engine oil filte r cartridge Engine oil drain bolt Engine oil drain base bolt Oil pu mp assembly flange bol t Oil filte r boss EOP (engine oil pressure) switch EO? (eng ine oil pressure) switch wi re termin al screw Oil pump driven sprocket bolt

Contents

26 Nrn (2.7 kqf -rn, 20 Ibf.ftl 29 Nm (3.0 kqf-rn , 22 lbf -ft] 12 N'm (1.2 kqf-m, 9 Ibl·ft) 7.8 N'm (0 .8 kgl ·m , 5.8 Ibl·ft) Seepage 1-15 12 Nm (1.2 kgl' m, 9 Ibl·ft) 2.0 Nrn (0.2 kqf -rn. 1.4 Ibl· ft) 15 Nrn (1.5 kqf- rn, 11 lbf-tt!

Chapter 5

Apply clea n engine oil to the O-ring Apply a locking agent to the threads CT bolt

App ly sealant to the threads

Appl y a loc ki ng age nt to th e thre ads

5-3

LUBRICATION SYSTEM TOOLS Oil pressure gauge set 07506 ·3000001

Oil pr essur e gauge att achment 07406-0030000

o r equivalent commercially av ail able in U.S.A . (MT37A)

o r eq uivalent com mercia lly ava ilab le in U.S.A. (AT77A HI

TROUBLESHOOTING Oil lev el too low • Oi l co ns u m pt io n • Ext ern al o il leak • • • • •

Wo rn pisto n rin g s Im p ro p er ly i nst alle d pist o n rings Wo rn cy li nde rs Wo rn v alve ste m sea ls Wo rn v alve g ui de

Low oil pressure • Oil lev el low • Clog ged o il st raine r

• Intern al oil leak • In cor rect oi l be ing used .

No oil pressu re • O il lev el t o o lo w • Oil pressure relief va lv e st uck ope n • Broken o il pump drive chain • Brok en oil pump d rive o r drive n sp rocket

• Da mag ed o il p u mp • Int ern al oi l leak

Hig h o il p ress u re • Oil press ure reli ef val ve stuck closed • Clogged oi l f il t er , o il coole r gall ery o r m et eri ng ori fi ce • Incorrect oil being used Oil co nt am in ati o n • Oil or f ilter not changed ofte n en ough • Worn pisto n ring s Oil em ul si ficatio n • Bl ow n cyli nder head gasket • Leaky coolant passage • Ent ry of water

5-4

Contents

Chapter 5

LUBRICATION SYSTEM

OIL PRESSURE INSPECTION If the oil pressure indicator light remains on a few seconds, ch eck the ind icator system before check ing the oil pressure .

Rem ov e the un d er cowls (page 3-7),

Rem ov e t he screw and discon nect t he EOP switch

wire . Remove the EO? swit ch whi le holding the switch base.

Install the oil pressure gauge attachm ent to the

switch ba se.

~~:::~~:;~~~~

Connect t he oi l pressure gauge t o t he oi l pressure

g a uge attac h me nt . TOOLS:

Oil pre s s ur e ga uge set

07506-3000001 or

equ iva le nt co mm er cially avail-

Oil pressu re gaug e atta chm ent

ab le in U.S.A . (M T37A ) 07406-00300 00 o r equiv ale nt

co m m e rcia llyavailab le in U.S.A . (AT77AHI Che ck th e oi l level (page 4-21 ). W arm . t he engine to no r mal ope rating t emp erature (ap p roxim at ely 80°C'17 6°F) and increa se the engin e spe ed to 6,000 rpm and read t he o il p res sure. OIL PRESSURE: 490 kPa (5.0 k9f/ cm', 71 p si ) at 6,000 rpml (80 °C/176°Fj Stop the eng ine and remove t he too ls. Apply a sealant t o the EO? sw itc h thread s as shown. ,..-- - - -- - -- - -- - -- - - - - - - , Do not apply sealant t o t he thread he ad 3 - 4 mm (0. 1 - 0.2 in)

I ..

EOPSWITC H

Contents

Chapter 5

5-5

LUBRICATION SYSTEM Insta ll and t igh t en t h e EO? switch to the specifie d to rq ue w hile ho ldi ng th e switc h b ase.

TORQUE: 12 N'rn (1.2 kqf-m , 9 lbf.ttl

Co nnect th e EO? switch wire terminal t o the switc h and t igh t en the screw to the specified torque .

TORQUE: 2.0 Nm (0.2 kq f-m , 1.4 Ibl·lt) Inst all t he dust cove r.

Inst all the u nd er cowl s (p age 3-7) .

OIL STRAINER/PRESSURE RELIEF VALV E REMOVAL Dr ain th e en gi ne o il (pag e 4 ~ 2 2 ) . Rem o ve the ex ha ust pipe (page 3·30).

Remove the o il pa n SH f lan ge bo lts and o il pan.

Remove the oil strainer and packing . Clean the oi l straine r screen.

5-6

Contents

Chapter 5

LUBRICATION SYSTEM Remov e t he pr essur e rel ief v alve and O-ring .

INSPECTION Check t he operat io n of t he pressure relief val v e by pus hing o n th e piston . Disassemble the relief valve by removi ng the snap ring. Insp ect t he pisto n fo r wea r, un smooth mov em ent or da ma ge. Inspe ct the spring fo r fatigue or damage. Asse mble t he reli ef va lve in the reve rse ord er o f d isassembly.

PISTON

~

W~""

"""AI SNAP RING

...--0

INSTALLATION A pply o il t o a new pa ckin g and inst all it onto th e oil strainer flange. Install the oil st rainer into the oil pump wh ile alignin g t he oil strain er bo ss with t he g roove of t he oi l pump.

OIL STRAINER

Ap ply oil t o a new O- ring and in stall it o nto the reli ef va lve. Insta ll t he reli ef valve into the crankcase.

Contents

Chapter 5

5-7

LUBRICATION SYSTEM If the oi l pan dra in base is rem o ved , insta ll th e follo w in g: -

BOLT

OIL PA N DRAIN BASE

Install a n ew O-ring int o th e oil pan d ra in base

groove. Inst all th e oil pa n d rai n base onto the oil pa n, and

tem po rar ily insta ll and tigh ten the oil d ra in bolt. A pp ly a locki ng agen t t o th e oil pa n d rai n base mounting bo lt t hrea ds . Install and ti ghte n the oil pan drain ba se mounting bolt to the speci fi ed to rque . TORQU E: 12 Nrn (1.2 kqf-m, 9 Ibf ·lt)

~

~

O-RING

Clean the oil pa n matin g surfa ce thoro ughly . Do not apply more sealant than nece s-

Apply sealant (Three Bond 12078 o r an eq uivalent) to t he m at ing surf ace.

eerv.

. ",,'mill Inst al l the oil pan o nto th e low er crankcase . Inst all th e oil pan SH f lan ge bo lts. Tighten t he bolts in a cr isscross pattern in two or t hr ee steps. In stall the ex ha ust pipe (p age 3-36) . Fill the cra nkcas e w ith t h e recommend ed oil (page 4-22 ). After install ation, check t hat th ere are no oil leaks.

OIL PUMP REMOVAL Drain the eng ine o il (page 4-22). Remove the clutc h (page 10-16 ). To gain access to the oil pump driven sprocket bolt, first rem ove the oil pan.

5-8

Remove the bolt, w ashe r and oil pum p driv en sprocket .

Contents

Chapter 5

LUBRICATION SYSTEM Rem ove th e oi l pan (page 5-6). Remove th e following :

-

Oil pump mo unt ing bolts

-

Oil p u m p assembly Do w el pins Oi l pass colla r/O vri n q

-

DISASSEMBLY Rem ov e the oil pu m p asse m b ly bo lts .

ASSEM BLY BOLTS Rem ove the oil pum p cove r and dow el pi ns.

OIL PUMP BODY

Remove the thrust wa sher, drive pi n, oil pump shaft, o uter ro tor and in ner ro to r from the o il pu mp

bo dy. Clea n all dis asse m b ly pa rts th o rou gh ly .

OIL PUM P SHA FT

INNER ROTOR

Contents

Chapter 5

DRIVE PIN

5-9

LUBRICATION SYSTEM INSPECTION If any portion of the

Tempo rar ily inst all th e o uter an d in ner rot o rs in to

oil pump is worn t he oil pu mp body. beyond the service Tempora ri ly in st all the d riv e pi n and oil pum p shaft . . limit, replace the oil M easur e th e roto r tip clear an ce. pump as an assem-

bly.

TIP CLEARANCE:

SERVICE LIMIT: 0.20 mm 10.008 in)

Me asure th e pump bod y clearance.

BODY CLEARAN CE:

SERVICE LIMIT: 0.35 mm 10.014 in)

M easure th e side clear an ce using a st raig ht edge and fe eler ga uge . SERVICE LIMIT: 0.17 mm (0.007 in)

5-1 0

Contents

Chapter 5

LUBRICATION SYSTEM ASSEMBLY INNER ROTOR DRIVE PIN OUTER ROTOR OIL PUMP SHAFT

WA SHER

~-DOW EL PINS

OIL PUMP BODY

12 Nrn (1.2 kqf -rn, 9 lbf -ft) Dip all part s in clean eng ine oil. Install the outer roto r into th e oil pump body . Install the inne r rotor into the oute r rotor w ith its drive pin groove faci ng the oil pump cover .

DRIVE PIN GROOVE Install the oil pump shaft through the inner rotor and oil pum p body. Install th e drive pin into the hole in the oil pum p shaft and align th e drive pin with th e gro ove in the inner rotor. Install the thrust was her.

OIL PU M P SHAFT

DRIVE PIN

Contents

Chapter 5

5-11

LUBRICATION SYSTEM Install the dowel pins in t o th e oil pu mp cover.

OIL PUMP BOOY

Install the oil pump cover to the oil pump body.

Install and t ig ht en the oil pump assembly bolts to the specified torque .

TORQUE: 12 Nm {1.2 kqf-m, 9 lbf-tt) Check the oi l pump operation by turning th e pum p

sh aft. If necessary, reassembl e the oil pump.

ASS EMBLY BOLT S

INSTALLATION Install the dowel pi ns. Apply oil to a new O-ring and install it w ith the oil pa ss coll ar.

. Install the oil pump assembly onto the crankcase w hi le align in g the oil pump shaft lug with th e wa te r pum p shaft groov e by tu rn ing t he oil pump shaft.

5-12

Contents

Chapter 5

LU BRICATI ON SYSTEM Insta ll and tighten th e th ree flan ge bol ts secu rely.

A ppl y oil to t he o il pump d riven sprocke t an d d rive chai n Insta ll t he driv en sprocket w it h it s "OUT" m ark faci ng out.

A pply a loc ki ng age nt t o th e oil sp rock et bolt threads.

pum p driven

Insta ll an d tig hten t he driv en sprocket bo lt/washe r t o the specified t orque.

TORQUE : 15 Nm (1.5 kg!·in . 11 Ibf.ft) Insta ll th e oil pan (pa ge 5-7). Inst all th e rig ht cra nkcase cov er (page 10-34). A ft er in stallatio n, fi ll t he crankcase w ith th e recom mended oil (pag e 4-22) and chec k that th ere is no oi l leaks. Che ck th e oi l pressure (page 5-5 ).

OIL COOLER REMOVAL Drain th e engine oil (p age 4-22). Dra in th e coo lant f ro m the sys te m (pa ge 7·6 ). Remove t h e ex haust pipe (pa ge 3-30) . Lo osen the hose clamp screws and disco nnect the oi l coo ler w ater hoses from th e oil cool er.

Contents

Chapter 5

5-13

LUBRICATION SYSTEM Remove the t h ree bolts and oil cooler. Rem ov e the O-rin g f ro m th e oil coo le r.

INSPECTION Check t he o il coo ler fo r damage.

INSTALLATION Coat a new O-ring w it h e ng ine oil a nd install it into the oil cool er groove.

Inst all t he oil coo ler o n t h e cran kcase.

Inst all a nd tighten the three bolts.

Connect th e oil cooler water hoses into t he oil coo le r an d tighte n th e ho se clam p sc rews sec u rely. Install t he ex h au st pi p e (pag e 3-36).

Fill the crankca se wit h th e rec omm end ed oi l (page 4-22) and check that th ere is no oil leaks. Fill th e co o li ng sys t em and bleed any air (page 7-6).

5-1 4

Contents

Chapter 5

6. FUEL SYSTEM (Programmed Fuel Injection)

COMPONENT LOCATION ···..························ 6-2 SERVICE INFORMATION

•

·6-3

·

TROUBLESHOOTING

IDLE AIR CONTROL (lAC) VALVE

·6-57

lAC VALVE SYNCHRONIZATION

6-61

MAP SENSOR

6-64

6-6

SYSTEM LOCATION SYSTEM DIAGRAM

IDLE AIR CONTROL (lAC) THERMAL VALVE ·......·........·..........·..··....·..··6-56

·

·..·

·

· ·

6-7 ·

6-8 IAT SENSOR

PGM-FI SELF-DIAGNOSIS INFORMATION

6-9

·

··..·

ECT SENSOR

·6-65

·

MIL TROUBLESHOOTING·

BANK ANGLE SENSOR ··....·......··..·..··........·6-67

FUEL LINE INSPECTION FUEL PUMP UNIT

6-31 ·

· 6-33

FUEL CUT-OFF RELAy

·

·..·..· 6-35

FUEL TANK

6-36

AIR CLEANER HOUSING

6-40

·

·6-65

CMP SENSOR ..·

· 6-15

·..··

·

MIL CODE INDEX· ........·..........··....·..........·..· 6-13 ·

·

·

·6-66

ENGINE STOP RELAY

·..·6-68

ENGINE CONTROL MODULE (ECM) ........·..6-69 PAIR CONTROL SOLENOID VALVE

6-71

EVAP PURGE CONTROL SOLENOID VALVE (CALIFORNIA TYPE ONLY) · ·6-72 INTAKE AIR DUCT ..·

·

···

·

6-73

SECONDARY INJECTOR ....·........·..·..·......·.. 6-43 EGCV (Exhaust Gas Control Valve}- ......·..··6-76 THROTTLE BODy

·

· 6-47 EGCV SERVOMOTOR

PRIMARY INJECTOR

Contents

·

·6-78

6-54

Chapter 6

6-1

FUEL SYSTEM (Programmed Fuel Injection)

COMPONENT LOCATION 4.4 N·m (0 .45 kqf -rn, 3.3 lbf-ft) 5.4 Nm (0.55 kqf-m, 4 .0 Ibf·ft)

1.2 N·m (0.12 kqf-m , 0.9 Ibl ·ft)

1.2 Nrn (0 .12 kqf-rn. 0.9 lbf -tt)

1.2 Nrn (0. 12 kqf-rn, 0.9 Ibl ·ft)

22 Nvm (2.2 kqf-rn , 16Ibl·ft)

6-2

Contents

Chapter 6

FUEL SYSTEM (Programmed Fuel Inj ect ion)

SERVICE INFORMATION GENERAL • Be sure to reli eve th e fuel pressure w hile the engi ne is OFF. • Bending or twisti ng th e control cables w ill im pai r smooth o perat ion and cou ld cause the cables t o stick o r bind, resulting in loss of ve hicle con trol. • W ork in a w ell ve nt ilate d area. Smoking o r allow in g flames o r spark s in th e wo rk ar ea o r wh ere gasoli ne is stored can cau se a fire or exp losio n. • Do no t apply commercia lly avail able car bu reto r cleane rs to the in side of th e throttle bo re, w hi ch is co ated with mo lybdenum. • Do not snap the t hrottl e va lv e from full ope n t o full clo se after th e throttle cable ha s been re m oved. It m ay cause inco rreet idle operation . • Sea l the cy linder head intake ports with tape or a clea n clo t h to keep dirt and debris fr o m entering t he intake po rt s after th e throttle bod y has been rem oved . • Do not apply ex cessive f orce to t he f uel pip e on the thro ttle bod y wh ile rem ov ing o r in st alling th e throttle bo dy. • Do not damag e t he t hrottle body . It may cause inc orrect throttle and idl e val ve sy nchron izat ion. • Prev ent dirt and de bris f ro m ent eri ng th e throttle bore, fu el hos e and return hose, clean them using co m pressed air. • Th e throttl e body is f act ory pr e-set . Do not disassem ble in a way ot her than shown in this m anu al. • Do not push the fuel pu m p base un de r the fuel ta nk w hen th e f uel t ank is stored. • Always rep lace the packing whe n the fuel pump is removed. • Th e programmed fuel in jecti on (PGM-FI) system is equipped with a Self-Diagnostic System, described page 6-9. If the m alf unction indicator lamp (MI Ll bl inks, f oll ow th e Self-Diag nost ic Procedures to re m edy th e problem . • W hen ch ecking th e PGM-Fl, alw ays follow t he step s in the tro ubleshooting fl ow chart (page 6-15). • Th e PGM -FI sys tem is provided with f ail -saf e f unctio n to secure a mi nim um ru nni ng capabilit y w hen th ere is any tro uble in t he syst em . W hen any abno rma lity is detected by the self- diag nosis fu nct ion , run ni ng capa bili ty is secured by using num erical va lues pr eset in advance in the pro gr am m ap. It mu st be rem em bered , however, th at w hen any abnorm ality is detected in 8 in jecto rs and/or the CKP (Cran kshaft Positi o n) sensor and CM P (Camshaft Positi o n) sensor, t he fail safe function stops the engine to protect it f ro m damage. • Refer to PGM-FI system loca tio n Ipage 6-7). • A f aulty PGM -FI system is ofte n rela te d t o poorl y con nected o r corro ded co nnecto rs. Che ck those co nnect io ns befo re proceeding . • Refe r to procedures for fuel re serve sen sor in sp ecti on (pag e 20-17). • The ve hicle spee d sensor sends a digi tal pu lse sig nal t o th e ECM (PGM-FI unit) fo r com puta tio n. Refer t o pr ocedur es f or vehicle speed sensor inspection (page 20-12) . • When disassembling the programmed fuel injection parts, note the location of the O-rings. Replace them wit h new ones upon reassembly . • Before disconnecting the f uel hose , release the fuel press ure by loosen ing th e fuel hose banjo bo lt at the fue l t ank. • A lways replace th e seali ng w ashe rs w he n the fuel ho se ban jo bo lt is rem oved o r loosened. • Use a di gita l t est m et er fo r PGM -Fl sys tem inspect ion .

SPECIFICATIONS ITEM T hro tt le body identiflca- I A, CM type t ion number I AC ty pe Idl e air cont ro l (lAC) va lve vac uum difference Base throttle va lv e fo r sy nchronization Idl e spee d Thr ottle gri p f ree play Intake air t em per ature senso r resistance (at 20°C/68°F) Engine coolant t em per at ure sensor resist ance (at 20°C/68°F) Fuel in jec tio n res ist ance I Prim ary in ject or (at 20°C 168° F) I Secondary in j ecto r PAIR contro l solenoi d valve resista nce (at 20 °C/68 ° F) CM P (Camshaft positi on ) senso r pea k vo ltage (at 20°CI 68°F) CKP (Crankshaft posi tio n) senso r peak vol tage (at 20°C/ 68°F) M anifold absol ute pr essure at idle Fuel pr essure at id le Fuel pump f lo w (at 12V)

Contents

Chapter 6

SPECIFICATIONS GQA OC GQAOS 20 m mHg No. 1 1,20 0 ± 100 rpm 2-4m m( 1/16 3/16 in) 1 4 kn 2.3 - 2.6 kn 10.5 14.5 n 10.5 14.5 n 20 - 24 n 0.7 V mi ni m um 0.7 V minimum 150 250 m m Hg 343 kPa 13.5 kgf/em ' , 50 ps i) 189 em 16.4 US OZ, 6.7 Imp oz) m inim um/l0 seco nds

6-3

FUEL SYSTEM {Programmed Fuel Injection} TORQUE VALUES ECT (Engine Coolant Tem peratu re)/ thermo sensor Th rottle body insulator band screw Serv ice check bolt

lAC valve lock nut lAC valve synchronization plate screw Fuel pipe mounting bolt lAC thermal valve link plate screw lAC thermal valve mounting screw Fuel filler cap socket bolt Fuel feed hose banjo bolt (fuel tank side) Fuel hose sealing nut (throttle body side) Fuel pump flange nut Fuel tank mounting bolt (fro nt) Fuel tank mounting bolt (rear) Fuel rail joint hose SH bolt Fuel rail joint hose sealing nut Air cleane r housi ng/ai r funne l pan screw To p air cleaner housing mounti ng screw M iddle air clea ner hous ing mo unting screw IAT sensor mou nting screw Ai r int ake duct jo int screw Air intake duct flap screw Seco nda ry injecto r base m ounting bolt Bank ang le sensor mounting screw

6-4

23 Nm 12.3 kgf·m, 17 Ibf.ftl See page 1-15 12 Nm (1.2 kgf·m, 9 Ibf.ft) 1.8 N·m 10.18 kqf-rn. 1.3Ibf.fl ) O.S Nrn (O.OS kgf·m, 0.7 Ibf·ft ) S.8 N·m (1.0 kqf- m, 7 Ibf·ft) O.S Nrn 10.OS kqf- rn, 0.7 lbf-ft] 4.S N·m 10.5 kgf·m , 3.6 lbf- ft} 1.8 N'rn 10.18 kq f-rn, 1.3 Ibf·ft) 22 Nrn (2.2 kgf-m , te tbf-tt 22 N·m (2.2 kgf·m, 16 lbf·ftl 12 Nm (1.2 kqf-m , 9 lbf·ftl 26 Nm (2.7 kqf-rn, 20 lbf-ft ) 9.8 Nm (1.0 kq f-rn, 7 lbf- ft) 9.8 Nm (1.0 kq f -m, 7 Ibf· ft) 22 Nm (2.2 kqf-rn, 16 lbf·ft l 4.4 N·m (0.45 kqf -rn, 3.3 Ibf·ft ) 1.2 Nrn 10.12 kqf- rn. O.S lbf·ftl 1.2 Nrn 10.12 kqf-m, O.S lbf ·ft )

Yellow paint See page ' · 17 fo r tightening sequence

Yellow paint Yellow pai nt

1.2 Nm 10.12 kg f·m , O.S lbf ·ftl 2.5 Nrn (0.25 kgf· m, 1.8 lbf-tt l 1.2 Nm 10.12 kqf-rn, O.S lbf·ft l 5.4 N·m 10.55 kgf ·m , 4.0 lbf-ft ) 1.5 Nrn 10.15 kqf-rn, 1.1 lb f·ft l

Contents

Chapter 6

FUEL SYSTEM (Programmed Fuel Injecti on) TOOLS Fuel pressu re gauge 07406-0040003

Peak vo ltage ad aptor 07HGJ-0020100

ECM te st harn ess, 32 P 070M Z-0010201

or 07406-004000B or 07406-004000A (U.S.A. on ly)

(not avai lable in U.S.A.)

(tw o required )

wi th com mercially avai lable d igita l

m ultim et er (im pedance 10 M nJD CV mi nimum )

SCS serv ice connecto r 070PZ-ZY30100

Igni tionM ate peak vo ltage teste r MTP07-0286 (U.S.A . on ly)

Vacuu m gauge set 07LMJ-0 01000B

o r 07LMJ -001000A tnspect ion adapto r 07GM J- M L80100

Contents

Chapter 6

6-5

FUEL SYSTEM (Programmed Fuel Injection)

TROUBLESHOOTING Eng ine won't start • Intake air leak • Fue l contaminated/dete rio rated • • • • • •

Pinched or clog ged fuel hose Faulty fuel pump un it Clogged fu el til ter/stra in er Clo gged fue l in jecto r fi lt er Sticki ng fue l inje ctor needl e Fau lty f ue l pum p operat ing sy stem

Engine stalls, hard to start. rough idling • • • • •

Int ake air leak Fue l co nt am i nat ed/ de t eriorate d Pi nch ed or cl ogged fu el hose Idle speed m isadju sted lA C va lve sy nc hro nization misa djust ed

Backfiring or misfiring during acceleration • Ig nit io n system malfunction Poor performa nce (drive ability) and poor fuel economy

• Pinched or clogge d fue l hose • Faul ty p ress u re reg u lat o r

6-6

Contents

Chapter 6

FUEL SYSTEM (Programmed Fuel In jection)

SYSTEM LOCATION PAIR CONTROL SOLENO ID VA LVE IAT SENSOR ECM

FUEL PUMP ECT SENSO R

DLC

CMP SENS OR

EGCV SERVOMOTOR CKP SENSOR VS SENS OR

FULL NAME M anifold absolute pressu re sensor Throttle position senso r Intake air tempe rat ure se nsor

Engine coolant tem perature sensor Cam shaft positio n se nsor Cranks ha ft posi t io n senso r Vehicle speed senso r Eng ine control module

Contents

Chapter 6

ABBREVIATIONS

MAP sensor TP sensor IAT sensor Ee l se nsor CMP se nsor CKP senso r VS sensor ECM

6-7

FUEL SYSTEM (Programmed Fuel Injection )

SYSTEM DIAGRAM I

'"

'"

'31

,; J

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

/

/

/

Th e cy li nder mu st be reb o red and an overs ize p isto n fi tted if t he serv ic e limit s are exceeded.

MIDDLE

Th e following oversize piston is av ailabl e :

MAIN BEARING DRIVER ATTACHM ENT

LOWER OU TER RACE

'::::::

~ ~ LOW ER NU T

Install a new upper bearing outer race w ith t he spe-

cia I tools as shown. Wh ile hold ing th e installer shaft w ith a wr ench, turn the low er nut grad ually unti l the race is ful ly seate d.

rc-nr.- -

UPPER OUT ER RACE

INSTA LLER SHA FT INSTA LLER ATTACHME NT B

OIL SEAL DRIVER

---

FORK SEAL DRIVER WE IGHT

~ ---'l=rr­

M AI N BEARING DRIVER ATIAC HM ENT

14-40

Contents

~ ~ LOWER NU T

Chapter 14

FRONT WHEEL/SUSPENSION/STEERING In sta ll a new low er bea r ing ou t er race w it h th e special tools as shown.

While holding th e ins ta lle r s haft with a w re nc h, turn th e u pp er nu t gradua ll y until t he rac e i s fully se at ed .

MAIN BEARIN G DRIVER ATIACH-

UPPER NU T

MENT~ FORK SEA L DRIVER W EIGHT

-----...

INSTA LLER ATIAC HM ENTA

INSTALLER SHA FT UPPER OUTER RACE INSTALLER ATIAC HM ENT B

LOWER INNER RACE REPLACEMENT Tem po rar il y install t he steeri ng stem nut o nto t h e

st e m to pr eve nt the t hre a ds fro m be ing d a maged wh en rem ovi np the lower bearing inn e r race fro m the ste m.

DUST SEAL

Rem o v e the lower bear in g inner race wit h a chisel o r equiva lent t o o l, being careful not to d a ma g e t h e

st em. Rem ov e the du st seal.

LOWER INNER RACE A p ply specif ied g re ase (page 1-23) t o new d ust sea l lips and inst all it over th e steering ste m . Inst all new lo w er bearin g in ne r ra ce usin g a sp ecia l tool and a hyd raulic pr ess.

TOOL : Steerin g st em driver

0794 6-MBOOOOO

STEERING STEM DRIVER

S ~ _.$IDffi DUST SEA U LOW ER INNE R RACE

-.

Contents

Chapter 14

14-41

FRONT WHEEL/SUSPENSION/STEERING INSTALLATION

~..!ijij.ffi

LOCK NUT

: BEARINGS : BEARING RACES : DUST SEALS STEERING STEM

UPPER BEARIN G

WAS HER

1f2:f\

~ A DJUSTING NUT

UPPER OUTER RACE

~

~OCK

\

~ -------- UPPER DUST SEAL

~~ 0 / ---- ------> UPPER INNER RACE

Apply specified grease (p age ' -23) to the up per and low er bear ings, bearing races and upper dust sea l

lips. Install the lowe r bea ring onto the stee ring stem. Insert the stee ring ste m into th e stee ring head pipe. Install the up per bea ring, inner race and upper du st sea I. I-:==:;-;::~:

App ly specified grease (page 1-23 ) to the steer ing stem adjusting nut threads. Install and tighten the steering stem adju sting nut to the initia l torq ue.

TOOL: St e ering s te m so cket

07916-3710101 or 07916-3710100

TORQUE: 20 N'm (2.0 kqt -m, 14 rbl·ltl

14-42

Contents

Chapter 14

FRONT WHEEL/SUSPENSION/STEERING Mov e the st eering ste m right and left, lock-to-lo ck, seve ra l ti m es to seat t he bearings. Make sure th at t he st eering st em moves smoothly w it hout play or binding, then loosen th e ad ju stin g nut. .

Ret ighten the ste eri ng ste m adj usting nut t o t he sp ecifie d t o rqu e.

TORQUE: 20 Nrn (2.0 kqf-rn , 14 Ibf ·ft) Rech eck that the stee ri ng stem m ov es smoot hly w it hout pla y or binding.

Insta ll a new lo ck washer onto the st eering stem . Align the t abs o f t he lock w ashe r with t he gr oo v es in the adjust ing nu t and be nd tw o opposite t ab s (sho rte r) down into th e adj ust ing nut g ro ov e.

Do not over tigh ten the lock nut until the lock wash er being flat.

¢!~

.....

~ LOCK NUT ~.......--

LOCK W~

Install an d f inger tig ht en the lock nut. Hold the adjust ing nut and furt her tighten th e lock nut no more t h an 1/4 tu rn (goo), enough to alig n it s g rooves wi t h t he lock washe r tabs. Ben d t he loc k washe r ta bs up into th e lock nut g ro oves .

Contents

Chapter 14

14-43

FRONT WHEEL/SUSPENSION /STEERING In stall th e front brake hose cla m p and tighten the bolt t o t he specifi ed torqu e. TORQUE: 8.8 Nm (0.9 kqf- rn , 6.5 Ibf.ft)

Install t he horn unit and tighten t he bolt sec u re ly . Instal l t he wi nd protector and t ighten the bo lts .

HOR N UNIT" -WIN D PROTECTOR

Inst all t he f ol low ing: -

Fo rk leg s (page 14-331 Ha nd leb ar s (pag e 14-11)

Instal l t he t o p brid g e and stee ring ste m nut. Tighten th e ste ering st em nut t o t he specified

torq ue . TORQUE: 103 N-m (10.5 kqf -rn. 76 lb f -ft]

Install the fo llo w ing: -

Ste erin g damper (pag e 14 -34) T op shelter (page 3-16 ) Up pe r co w l (pag e 3-12 ) Fro nt fende r (pag e 3-19 ) Fro nt wh eel (pag e 14-20)

STEERING HEAD BEARING PRE-LOAD Su p po rt th e m ot or cy cl e securely u sin g a hoist or , - -- - - -- - - - - - - - - - - -----, equi val en t a nd raise th e fro nt w he el off t he g ro und . Po sit io n t he stee ring st em to th e st ra ig ht ahead po sit ion . Make sure that there is no cable or wire harness int erfer enee.

14-44

Ho ok a sprin g sca le t o th e fork sl id er and m easu re the stee ring head be ar ing pre-load. Th e p re -load should be w ith in 12 - 19 N (1.2 - 1.9 kg!) . If th e read ings do not fall w ithin the limits. read ju st the steering ste m adjusting nut (page 14-42 ).

Contents

Chapter 14

15. REAR WHEEL/SUSPENSION

COMPONENT LOCATION· ·························· 15·2

SHOCK ABSORBER

SERVICE INFORMATION ····························15-3

SUSPENSION LINKAGE ·

TROUBLESHOOTING

SWINGARM

REAR WHEEL

·

Contents

15-6 ·

·

·

·

·

· 15· 14 · 15-17 ·

15-20

·.. 15-7

Chapter 15

15-1

REAR WHEEL/SUSPENSION

COMPONENT LOCATION

54 Nrn (5.5 kgf. m , 40 lbf-ft)

__ -

64 Nrn (6.5 kqf-m. 47 Ibf ·ft )

15 Nrn (1.5 kqf-m , 11 Ibf.ft)

44 Nrn (4.5 kqf-m. 33 lbf-ft)

44 N' m (4.5 kqfrn, 33 lbf -ft) 113 Nm (11. 5 kq f-rn . 83 lb f .tt )

44 Nm (4.5 kqf-m, 33 lbf -ft )

44 N 'm (4.5 kqf -rn, 33 Ibf ·ft l

15-2

Contents

Chapter 15

REAR WHEEL/SUSPENS ION

SERVICE INFORM ATION GENERAL • A contam inate d bra ke disc or pad reduces sto pping pow er. Discard con ta m inated pads and clean a contami nated disc with a high qual ity brake degreasing agent . • After the rear whee l installation, check the brake ope ration by applyi ng the brake pedal. • The shock absorb er conta ins nitrogen under high pre ssure. Do not al low fire or heat near the shock absorbe r. • Before disposal of the shock ab sorber, release the nitr ogen (pag e 1 5 ~1 6 ) . • When servicing the rear wheel and suspension, support the m otor cycle using a safety stand or hoist . • Use on ly t ires m ark ed "TU BELESS" and t ub eless valves on rim m ar ked "TUB ELESS TIRE APPLICAB LE". • Use ge nuine Honda replacem ent bo lts and nuts for all suspe nsion pivot a nd m ounting point. • When installing the swingarm, be sure to tighten the swi nga rm pivot fastene rs to the specified to rque in the specified sequence. If yo u mistake the tightening 'torque or sequence, loosen all pivot fasteners, the n tighten them again to the specified torque in th e cor rect sequence . • W hen using the lock nut w renc h for the swinga rm pivot use a 20-in ch long defl ecting beam typ e tor que w rench. T he lock nut wrench increases the torque wrench's leverage, so the torque w renc h reading will be less than the to rque actually applied to th e lock nut. Th e specificatio n give n on this page is actua l to rque applied to the lock nut, not the readin g on the torque w rench w hen used w ith th e lock nut wrench. The pro cedu re later in the text gives the actua l and indica ted torque. • Refer to the brake system infor mation (page 16-4).

SPECIFICATIONS ITEM

STA NDARD

Minimum tire tread depth Cold tire I U p to 90 kg (200 Ib s) loa d pressur e I Up to m aximum we ight capacity Axle runout Wheel rim I Radi al runout I Axia l Wheel balance weight Drive chain

Sizel link

I DID I RK

Shock absorber

Slack Spring pre-loa d adju ster sta nda rd position Rebound damping adjuster initial setting Compression damping adjuster ini tial setti ng

290 kPa (2.90 kgf/em", 42 psi) 290 kPa (2.90 kgf/em", 42 psi)

DID50VM2-114YB RK50GFOZ 1-114LJFZ 25 - 35 (1 -1-318) Position 4 2- 1/2 turns out from full hard 9 cl icks o ut f rom f u ll hard

Unit : mm (in) SERV ICE LIMIT 2.0 (0.08 )

0.2 (0.011 2.0 (0.08) 2.0 (0.08 ) 60 g (2. 1 oz) max.

-

-

TORQUE VALUES Rear axle nut Rear brake disc bolt Final drive n sprocket nut Rear shock absorber upp er m ount ing nut Rea r shock abso rbe r lower mounting nut Shock link-to- fr ame pivot nut Shock arm -to -shock link nut Shock arm-to-swingarm nut Drive chain case flange bolt Sw inga rm pivot adjusting bo lt Swlngarm pivo t adj usting bolt lock nut Swingarm pivot nut Drive chain slider bolt

Contents

113 Nm (11. 5 kqf -m . 83 lbf-ft] 42 Nrn (4.3 kqf-m, 31 lbf -ft] 64 N· m (6.5 kgf· m , 47 lbf-ft) 44 Nrn (4.5 kqf -rn . 33 lbf-tt} 44 N'm (4.5 kqf-m, 33 lbf-ft) 44 Nm (4.5 kqf-m, 33 Ibf·ft ) 44 N'm (4.5 kqf -m. 33 Ibf·ft ) 44 N'm (4.5 kqf-m, 33 Ibf·ft l 12 Nrn (1.2 kqf-m, 9Ibf·ft) 15 N 'm (1.5 kqf-rn, 11 Ibf· ft) 64 Nrn (6.5 kg f·m , 47 Ib f·ft ) 113 Nm (11.5 kqf-m. 83Ibf·ft) 8.8 Nm (0.9 kqf -rn, 6.5 lbf-tt)

Chapter 15

U- nut A LOC bolt; replace wi th a new one U-nut U- nut U-nut U-nut U-nut U-n ut

See page 15-29 Ap p ly a locking agent to the th reads

15-3

REAR WHEE L/SUSPENSION TOOLS Rem ov er weight

07741 -0010201

Attachm ent, 32 x 35 mm 07746-0010100

Attachmen t, 42 x 47 mm 07746-00 10300

'~,~/ ~~

07936-371020A (U.S .A. o nly ) o r 07936-37 10200 (U.S .A. on ly) Atta chm ent, 52 x 55 mm

Attachme nt, 24 x 26 mm

Att achm ent , 22 x 24 mm

07746-0010400

07746-0010700

07746-00 10800

o r 07746-00 1A800 (U.S .A. on ly)

07746-0010900

Pilot, 17 mm 07746-00 40 400

Pilo t, 25 mm 07746-0040600

Pilot, 28 rnm 07746-0041100

Pilot, 19 m m 07746-004 1400

Bearing remover head, 25 mm 07746-0050800

Attachm ent, 40 x 42 mrn

15-4

Contents

Chapter 15

REAR WHEEL/SUSPENSION Driver 07749-0010000

Remove r handle 07936-3710100

Bearing rem over, 17 mm 07936-3710300

Attachment, 28 x 30 m m 07946 -1870100

Ball race remove r 07948-4630100

Driver 079 49-37 10001

Driver 070GD-0010100

Bearing rem over shaft 07GG D-00 10100

Bearing driver 07G M D-KT80 100

Attachment, 42 mm 07QAD-POA0100

5.8 x 47 mm

or 070GD-001A 100 (U.S.A. only) Pilot. 32 mm 07MAD-PR90200

Swingarm lock nut wrench,

07YMA-MCF0100

-a )

::::::::-:-:---:::::>

o r 07YMA-M CFA100 (U .S.A. o nly)

Contents

Chapter 15

15-5

REAR WHEEl/SUSPENSION Attachme nt, 34 mrn 07ZM D-M BW0 100

o r 07ZM D-M BW A 100 (U.S .A . on ly )

TROUBLESHOOTING Soft suspens i o n • Wea k shock ab sorber spring • Incorrect sus pension adj ust me nt • Oil leakage from dam pe r un it • Insufficient ti re p ressure Stiff su spen sion Incorrect suspen sion adjustment • Dam age d rear sus pe nsion piv ot bearin gs • Bent d amper ro d Bent swing ar m pi v ot • Tir e press ure too hi g h Rear wh eel wobbling

• Bent rim • Worn or damag ed rear wh ee l bea ring s • • • •

Fau lt y rear tire Un bala nced rea r t ire and whee l Insuffic ient rear tire press u re Faulty swin g ar m pivot bear in g s

Rear wh e el hard to turn • Fault y rear w heel bearin gs • Bent rea r axle • Rear brake d rag

• Drive chai n too tight Rear suspe nsion noise • Fau lty rear shock abso rbe r • Lo o se rear su spe ns io n fastene rs • Wo rn rear su spension pi vot be aring s

Steers to one side o r does not track st ra ig ht • Bent rear ax le • Axl e al ignment/chain adj ust m ent not eq ual o n both sides

15-6

Contents

Chapter 15

REAR WHEEL/SUSPENSION

REAR WHEEL REMOVAL Loosen th e lock nuts and drive ch ain adju sti ng bolts. (p age 4-26 ) Loosen the rear axle nut. Support the m ot orcy cl e using a saf ety st and or ho ist and ra ise the rear wh eel o ff the ground. Remov e th e axl e nut , wash er and dri v e ch ain adjust-

ing pla te.

Push th e rear wheel fo rward and der ai l th e d riv e cha in from the d rive n sproc ket. Do not operate the brake pedal after remo ving the {ear wh eel.

Remo ve the rear ax le an d d riv e chai n adju sting plate from th e left si de , th en rem o ve th e rear wh eel.

Remove the side coll ars.

INSPECTION Axle Place the axle on V-blocks and m easure th e run out.

Actual runout is 1/2 the total ind icator read ing . SERVICE LIMIT: 0.2 mm (0.01 in)

Contents

Chapter 15

15-7

REAR WHEEL/SUSPENSION Wh ee l bearing Turn the inner race of ea ch bear in g wit h yo u r fi ng e r. Bearings sho uld t u rn sm ooth ly an d qu ietly . A lso check t h at the bearing o uter race f it s t ig htly in th e hub o r d rive n fl ange. Replace the wheel bearings in pairs.

Remove and discard the bearings if th e races do not t urn sm oot h ly and qu iet ly , or if they fit lo o sely in the hub o r driven flange .

Rem ov e th e w hee l bearings, if nec essa ry (page 1510 ).

W HEEL BEA RIN G

Wheel rim ru nout Check th e rim run out by placing th e wh eel in a tru ing st a nd . Sp in th e w heel slo w ly and read th e r unout usi ng a di al indicator. Act u al ru nout is 1/2 the tot al in dicato r reading . SERVICE LIMITS: Rad ial: 2 .0 mm (0.08 in ) Axial : 2 .0 mm (0.08 in)

Dr iv en sp ro cke t

Chec k t he co ndi t io n of th e fina l d ri v en sproc ket teeth . Repla ce th e sprocket if worn o r d ama g ed . • If t he fin al driven sprocket requires re pl acem e nt, inspect th e drive cha in and driv e sp ro cket . • Ne v er in st all a new drive cha in o n a worn sprocket o r a w orn ch ain o n new sprockets. Both ch ain and sp roc ket must be in g ood co nd iti o n o r th e repl acement cha in o r sp rock et w ill wear ra p-

id ly. Wh eel b al anc e

GOOD

REPLACE

o X ~~~

Refe r to th e wheel bal an ce se rvi ci ng (pag e 14- 18).

DISASSEMBLY Rem ov e th e rig ht du st seal. Remove th e bo lts and brake di sc.

15-8

Contents

Chapter 15

REAR WHEEL/SUSPENSION If you wilf aieesse mble the driven flange, loos en the d riven sprocke r nut s and bolts before rem oving the driven flange from the wheel hub.

Remove the left dust seal.

Rem ov e the d ri v en fl ange assem bly fro m th e left w heel hu b.

L._-:=::::::~~

Remov e the wh eel ru bber dampers and O-ring .

Driv en fl an ge b earin g rem oval Rem ov e the nuts, washer. bolts and driven sprocket from the driven flange .

Contents

Chapter 15

15-9

REAR WHEEL/SUSPENSION Dr iv e t he driv en f lang e co llar o ut of t he driv e n f lang e bear ings usin g th e sp ecial too ls.

TOOLS : Driver

Pilot, 28 rnm

07749-0010000 07746-0041100

Dr ive ou t the d riv en fl an g e bea rin g s using th e spe -

cia l to ols. TOOLS: Dri v er Atta chment. 4 0 x 42 mm Pilot, 28 mm

07749-0010000 07746-0010900 07746-0041100

Wh e el bearing removal Install the bearin g rem o v er head i nt o the bearing . From th e o pposite sid e, ins ta ll th e bearing remo v er shaft and d rive th e beari ng out of t he wheel hub. Rem o ve the distance col lar an d d ri ve out the oth er

be a ring . TOOLS:

Bearing remover he ad. 25 mm 07746-0050800 07GGD-0010100

Bearin g remover shaft

15-10

Contents

Chapter 15

REAR WHEEL/SUSPENSION ASSEMBLY

DISTAN CE COLLAR

~

~

LEFT W HEEL BEAR IN G BRAK E DISC

~ ...w:;;, ~~~ RIGHT DUS T SEA L

DRIVEN SPROCKET

Never install the old

bearings, once the bearings has been remo ved, the bear-

Wh ee l bearing ins t a llati on • In st all t he right w hee l be a rin g p rev io usly . Dri v e in a new right be a ri ng sq ua re ly , un t il it is fu lly

ings mus t be seated . replaced w ith new

ones.

TOOLS: Driv er

Attach m e nt, 52 x 55 mm Pilot. 25 mm

07749-0010 000 07746-0010400 077 46 -00 40600

Inst all th e d i st ance collar

Driv e in a new left bea ring squarely.

TOOLS: Dri v er

Attachm e nt, 42 x 47 m m Pilot, 25 mm

Contents

07749-0010000 07746-0010300 07746-0040600

Chapter 15

15- 11

REAR WHEEL/SUSPENSION Driven flange bearing installation Press t he d riven f la ng e co lla r i n th e new driv en flange bearings u nti l it is fu lly sea ted .

TOOLS : Driver

Attachment, 32 x 35 mm Pilot. 25 mm

07749·0010000 07746·0010100 07746·0040600

DRIVEN FLAN GE BEARINGS Driv e the new driven flange bear ing s with the colla r into the dri ven f lange usin g th e specia l tools.

TOOLS : Driver Attachm ent, 52 x 55 mm Pilot, 25 mm

DRIVER

07749·0010000 07746·0010400 07746-0040600

Install t he wh eel ru bber d am pers into the left whe el hub. Ap p ly g rease t o new O-ring and i nsta ll it to th e groove of th e w heel h u b.

Install t he driven f lange assemb ly into the left wheel hub. fnst alf the washers with their chamfered side facing

toward the sprocket.

If th e driven sp rocket was rem ov ed , insta ll t he driven sprocket bolts. driv en sprocket, washe rs and nut s. Tig ht en the nu ts to th e speci fied to rque.

TORQUE: 64 Nrn (6.5 kqf -m, 47 Ibf-ft] A pply grease to new du st seal li ps. t he n inst all it to the driven f la nge.

15-12

Contents

Chapter 15

REAR WHEEL/SUSPENSION Install the brake d isc w ith it s rotating direction m ark fa cing out. Tighten the new brake di sc bo lt s to the sp ecified

torque. TORQUE: 42 Nm (4.3 kq f -m, 31 Ibf.lt l Apply grease to new du st seal lips, then insta ll it to the right wheel hu b.

INSTALLATION Insta ll th e sid e co ll ars .

M ake sure t hat the rear brake caliper bracket is position ed in t he gu ide of th e sw inga rm .

Be careful not to damage the brake pads .

Place t he rea r wheel in t he sw in garm . Inst al l t he drive chain ove r the dr iven sp ro cket. App ly a thin coat of grease to t he rear ax le. Inst all t he dr ive cha in adj usting pla te and rear axle from t he left side.

Contents

Chapter 15

15-1 3

REAR WHEEL/SUSPENSION Instal l th e adj u sti ng pla t e, w as he r and ax le nu t. Adj ust th e d rive chai n slack (page 4-26). Tighten the axle nut to t he specified torque. TORQUE : 113 N ·m (11.5 kqt -m, 83 lbf-ft]

SHOCK ABSORBER REMOVAL Sup p ort the m ot orcy cl e sec ure ly u sing a saf ety stan d or ho i st and ra ise t he rea r wheel off the ground. Rem ove th e bol t s/nuts and shock link .

BOLTS/NUTS Remov e the sho ck ab sorbe r lowe r m o unting bol t/

nut .

Remove the shock ab sorber u pper m ounting bo lt / nut. Remove t he shock absorbe r to dow nw ar d th ro u g h the swinga rm .

15-14

::~~~~;:.:~~~~~~-,~~

Contents

Chapter 15

REAR WHEEL/SUSPENSION INSPECTION Visually inspect the shock ab sorber for damage . Check t he following: -

DAMPER UNIT

Damper rod for bends o r da mage Dam per un it f or deformation or oil leaks Rubber bumper fo r wea r or damage

RUBBER BUM PER

Inspect all the othe r parts for wea r or damage. If necessary, replace th e shock ab so rbe r as an assembly .

DA M PER ROD

SPHERICAL BEARING REPLACEMENT Rem ove t he d ust seal s. Remove th e stopper ring from t he left sid e pivot.

Prepare the m etal pipe (as a base holder; I.D. 27 mm or ot her suitable collar) for the sphe rical bearing rem ov al.

STOPPER RING

BEARING DRIVER (17 mm COLLAR I

Press the sph er ica l bear in g out of the shock absorber pivot using the metal pipe and specia l

tool . TOOLS:

Bearing d river

07GMD-KT80100

SPHERICAL BEARING

_--;,~

(U se only 17 mm co llar)

BASE HOLDER Press new sp he rica l beari ng into the shock absorber piv ot from the left sid e until it is fully seated, using the special tool and hydra ul ic pres s.

TOOLS: Bearing driver (Us e only 17 m m coll ar)

BEARING DRIVER (17 mm COLLAR )

"'>

07GMD-KT80100

I

SPHERICAL BEARING

Contents

Chapter 15

15-15

REAR WHEEL/SUSPENSION Instal l a new stoppe r r ing int o the g roove of th e shock absorber pivot secure ly . The le ft pivot dus t seal 0 .0. is larger

Apply grease to t he new dust sea l lips and insta ll them into the shock a bsorber p ivot.

e

~

STOPPER RING

than right pivot dus t seal 0.0.

SHOCK ABSORBER DISPO SAL PROCEDURE Do not remo ve the valve core until pressure IS release d.

Remove the shock abso rbe r reservoi r cap . Put on safety glasses, the n re lease t he nitro gen from t he rese rvo ir by dep res sing t he va lve core. • Poin t the valve away from you to p revent debris

getting in yo u r eyes. • Before dispo sal of the sho ck abso rbe r, re lease the nit roge n by press ing t he valve co re. The n rem ov e the valve from the shock absorbe r reser vo ir.

RESERVOIR CAP \

»