Honda CBR929RR [6/488] Page 6

Содержание

• 1 lubrication seal points 1
• Cable harness routing 1
• Emission control information 1
• Emission control systems 1
• Formation 1
• General 1
• Model identification 1
• Page 1 1
• Service rules 1
• Specifications 1
• Torque values 1
• 2 the engine serial number is stamped on the right 2
• 3 the vehicle identification number vin is 2
• 4 the throttle body identification number is 2
• 5 the color label is attached as show 2
• Designated color cod 2
• Fhaivml 5eiiial jill r ihe 2
• Genera 2
• Information 2
• Located on left side of the main frame on the 2
• Ordering color coded parts always specify the 2
• Page 2 2
• Right side of the steering hea 2
• Safety certification labal 2
• Side of the upper crankcas 2
• Stamped on the intake side of the throttle body as 2
• The frame serial number is stamped on the 2
• 065 mm 8 3
• 125 mm 4 3
• 395 mm 5 3
• Abdc 40 bbdc 20 atdc 3
• Air filtration 3
• At 1 mm 3
• Bore and stroke 3
• Bridgestone 3
• Bt010r 3
• Bt01of rea 3
• California type 3
• Caster angle 3
• Chain drive and dohc 3
• Closes 3
• Closes lubrication system 3
• Compression ratio 3
• Cooling system 3
• Crankshaft type 3
• Curb weight 3
• Cylinder arrangement 3
• Displacement 3
• Dry weight 3
• Engine dry weight 3
• Exhaust valve open 3
• Firing order 3
• Footpeg height 3
• Forced pressure and wet sump 3
• Four cylinder inline 30 inclined from vertical 3
• Frame type 3
• Front brake 3
• Front suspension 3
• Front tire size 3
• Front wheel travel 3
• Fuel tank capacity 3
• Genera 3
• General 3
• Ground clearance 3
• Hydraulic double disc brake with 4 pot caliper 3
• Hydraulic single disc brake with 1 pot caliper 3
• Imp gal 3
• Information 3
• Intake valve 3
• Inverted telescopic fork 3
• Kg 353 ibs 164 kg 362 ibs 3
• Kg 379 ibs 174 kg 384 ibs 3
• Kg 434 ibs 199 kg 439 ibs 3
• Liquid cooled 3
• Maximum weight capacity 3
• Michelin 3
• Nitrogen gas filled damper 120 70 zr17 58w radial 190 50 zr17 73w radial 3
• Oil pum 3
• Overall length 3
• Overall width overall height 3
• Page 3 3
• Paper filter 3
• Pilot sport e 3
• Pilot sport e rea 3
• Rear brake 3
• Rear damper 3
• Rear suspension 3
• Rear tire size 3
• Rear wheel travel 3
• Seat height 3
• Specifications 3
• States canada type 3
• Tire brand 3
• Trail length 3
• Trochoid 3
• Unit type 3
• Valve train 3
• Wheelbase 3
• Advance 4
• Battery 4
• Cable operated type 4
• Charging system 4
• Clutch operation system 4
• Clutch system 4
• Computer controlled digital transistorized with electronic 4
• Constant mesh 6 speed 4
• Drive train 4
• Electrical 4
• Final reduction 4
• Foot operated return system 1 4
• Gear ratio 4
• Gearshift pattern 4
• Ignition system 4
• Lighting system 4
• Multi plate wet 4
• Page 4 4
• Pgm fi programmed fuel injection 4
• Primary reduction 4
• Scr shorted triple phase full wave rectification 4
• Specifications 4
• Starting system 4
• Transmission 4
• Triple phase output alternator 4
• 1 16 1 5
• 200 100 rpm 5
• 24 k 2 5
• 400 rpm 80 c 176 f 5
• A canada or honda 4 stroke 5
• Body clearanc 5
• Cam pulse generator 5
• Canada 5
• Disassembl 5
• Fuel pump flow at 12 v 5
• Fuel system programmed fuel injection 5
• General information 5
• Generator peak voltage at 20 c 68 f 5
• Idle speed 5
• Lubricatio 5
• Manifold absolut 5
• Minimum 10 seconds 5
• Oil pump rotor 5
• Page 5 5
• Pair solenoi 5
• Peak voltage at 20 c 68 f 5
• Pressure 5
• Pro honda gn4 or hp4 4 stroke oil 5
• Purge control solenoid valve resistance at 20 c 68 f 5
• Recommended engine oil 5
• Sae 1ow 40 5
• Service limit 5
• Side clearanc 5
• Specifications 5
• Standard 5
• System 5
• Tip clearanc 5
• V minimum 5
• Vacuum difference 5
• Viscosit 5
• __engin 5
• And engine 6
• Cam lobe height 6
• Camshaft 6
• Cooling system 6
• Cylinder compression 6
• Cylinder head valves 6
• General information 6
• Outer in e 6
• Page 6 6
• Recommended antifreeze 6
• Reserv 6
• Runout 6
• Service limit 6
• Specifications 6
• Standard 6
• Thermostat 6
• Valve lifter 6
• Valve stem 6
• Warpage 6
• 20 3 8 13 16 7
• Alternator starter clutch 7
• Clutch gearshift linkage 7
• Connectin 7
• Crankcase piston cylinder 7
• Cylinder 7
• Genera 7
• Groove clearanc 7
• I_13 mm 7
• Information 7
• Mainshaf 7
• Measurement poin 7
• Onnectin 7
• Page 7 7
• Service limit 7
• Standard 7
• Warpage 7
• Bushing 8
• Bushing to shaft 8
• Clearance 8
• Clutch outer guide i 8
• Countershaf 8
• Crankshaft 8
• Crankshaft transmission 8
• Gear to bushing 8
• Genera 8
• Information 8
• Main journal oil clearance 8
• Mainshaft 8
• Page 8 8
• Runout 8
• Service limit 8
• Standard 8
• Transmission 8
• 009 imp oz 9
• Adjuster standard positio 9
• Axle runout 9
• Capacity 9
• Cold tire pressure 9
• Drive chain 9
• Fluid capacity 9
• From full hard 9
• Front wheel suspension steering 9
• General information 9
• Kgf cm 9
• Kgf cmz 9
• Lepgth___ 9
• Minimum tire thread depth 9
• Page 9 9
• Pre load 9
• Pro honda suspension fluid ss 8 9
• Radial 9
• Rear wheel suspension 9
• Rk gb50hf 9
• Runout 9
• Service limit 9
• Shock absorber 9
• Spring 9
• Standard 9
• Steering head bearin 9
• Tensio 9
• Th groove 9
• Up to maximum weigh 9
• Up to maximum weight capacit 9
• Va8 c1 9
• Wheel rim runout 9
• With the tapered end facin 9
• Alternator 10
• Battery 10
• Battery charging system 10
• Below 1 10
• Brake peda 10
• Btdc at idle 10
• Calipe 10
• Caliper piston 10
• Capacity 10
• Charging coil resistance 20 c 68 f 10
• Charging current 10
• Coil peak voltag 10
• Curren 10
• Disc thickness 10
• Dot 4 75 30 10
• Fully charged 10
• General information 10
• Height 10
• Honda dot 4 brake fluid 10
• Hydraulic brake 10
• Ickness brake disc runout 10
• Ignition pulse generator peak voltage ignition timin 10
• Ignition system 10
• Iuh27d denso iuh24d denso 10
• Kw 5 000 rpm 10
• Leakage 10
• Master cylinder 10
• Master piston 10
• Minimum 10
• Needs charging_ 10
• Normal 10
• Optional 10
• Page 10 10
• Piston 10
• Runout 10
• Service limit 10
• Spark plu 10
• Spark plug 10
• Specifications 10
• Specifie 10
• Specified brake fluid 10
• Standard 10
• Upper lower 10
• V minimum 10
• Voltage 20 c 68 f 10
• _master cylinder 10
• _master piston 10
• 102 c 20 11
• 97 c 19 11
• Beam indicator 11
• Electric starter 11
• Fan motor 11
• Front turn signal running light 11
• Fuel reserve indicator 11
• General information 11
• Headlight 11
• Indicator lamp 11
• Instrument light 11
• Led led led led led 30a 11
• Lights meters switches 11
• Main fuse 11
• Malfunctio 11
• Neutral indicator oil pressure indicato 11
• Page 11 11
• Pgm fi fuse 11
• Rear tur 11
• Service limit 11
• Specifications 11
• Standard 11
• Starter motor brush length 11
• Stop to open 11
• Tachometer peak voltage 11
• Thermo sensor resistance 11
• V 21 5 11
• V 32 3 cp 23 8 w 11
• V m nimum 11
• _sub fuse 11
• Aloc bol 12
• And nut 12
• Apply a locking agent to the threads 12
• Apply clean engine oil to the o rin 12
• Apply grease to the threads 12
• Apply molybdenum disulfide oil to the threads and seating serface after removing anti rus 12
• Apply oil to the threads and flange surfac 12
• Apply sealant to the thread 12
• Cooling syste 12
• Ct bolt 12
• Drive sprocket special bolt 12
• Ect engine coolant temperature thermosensor 12
• Engine 12
• Engine mountin 12
• Fast idle wax unit link plate screw 1 3 12
• Fast idle wax unit mounting screw 12
• Fastener type 12
• Fuel pipe mounting bolt 12
• Fuel system programmed fuel injection 12
• General information 12
• Item q ty 12
• Lubrication syste 12
• Maintenanc 12
• Mm flange bolt 10 mm head 12
• Mm flange bolt 8 mm head 12
• Mm flange bolt and nut 12
• Mm hex bolt and nut 12
• Mm hex bolt and nut 6 mm hex bolt and nut 12
• Mm screw 12
• Note 1 12
• Note 3 12
• Note 9 note 2 note 6 12
• Note 9 note 9 12
• Oil cooler mounting bolt 12
• Oil pressure switch 12
• Oil pressure switch wire terminal screw 12
• Oil pump assembly flange bolt 12
• Oil pump driven sprocket bolt 12
• Others should be tightened to standard torque values listed above 12
• Page 12 12
• Pressure regulator mounting bolt 12
• Remarks 12
• Replace with a new on 12
• See page 1 14 12
• Spark plug 12
• Starter valve lock nut 12
• Starter valve synchronization plate screw 12
• Thermostat cover flange bolt 12
• Thread 12
• Throttle body insulator band screw 12
• Throttle cable bracket mounting bolt 12
• Timing hole cap 12
• Torque 12
• Torque specifications listed below are for important fasteners 12
• Torque values 12
• Vacuum joint plug bolt for synchronization 12
• Water pump cover flange bolt 12
• Alternator starter clutc 13
• Alternator wire clamp socket bolt flywheel flange bolt 13
• Breather plate flange bolt 13
• Cam chain guide mounting socket bolt 13
• Cam chain tensioner pivot socket bolt 13
• Cam sprocket bolt cam pulse generator rotor dowel bolt 13
• Camshaft holder flange bolt 13
• Clutch center lock nut 13
• Clutch gearshift linkag 13
• Clutch spring bolt washer 13
• Connecting rod nut 13
• Crankcase bolt 10 mm 13
• Crankcase piston cylinde 13
• Cylinder head cover bolt 13
• Cylinder head mounting bolt cylinder head mounting socket bolt washer 13
• Cylinder head sealing bolt 13
• Cylinder head stud bolt exhaust pipe stud bolt 13
• Cylinder head valve 13
• Gearshift return spring pin 13
• Lower crankcase sealing bolt 20 mm 13
• Mainshaft bearing set plate bolt 13
• Mm main journal bolt 13
• Note 10 note 2 note 2 note 2 note 2 13
• Note 2 13
• Note 2 note 2 note 5 note 2 note 5 13
• Note 4 5 13
• Note 5 13
• Note 5 note 2 note 2 note 2 13
• Note 9 13
• Page 13 13
• Pair reed valve cover flange bolt 13
• See page 1 14 13
• Shift drum bearing shift fork retaining bolt washer 13
• Shift drum center socket bolt 13
• Shift drum stopper arm pivot bolt 13
• Starter one way clutch socket bolt 13
• Stator mounting socket bolt 13
• Upper crankcase sealing bolt 13
• Electri 14
• Exhaust pipe stud bol 14
• Ignition pulse generator rotor mounting bolt 14
• Ignition syste 14
• Insulator clamp cylinder head side 14
• Insulator clamp throttle body side 14
• Lights meters switche 14
• Neutral switch 14
• Note 5 14
• Page 14 14
• Remarks 14
• Starte 14
• Starter motor terminal nut 14
• Bank sensor 15
• Clutch gearshift linkag 15
• Cooling fan nut 15
• Cooling syste 15
• Engine hanger nut front 15
• Engine hanger nut middle 15
• Engine hanger nut rear 15
• Engine mountin 15
• Exhaust pipe joint flange nut 15
• Exhaust valve cover mounting bolt 15
• Exhaust valve mounting bolt 15
• Exhaust valve pulley cover mounting bolt lower 15
• Exhaust valve pulley nut 15
• Fan motor nut 15
• Frame body panels exhaust syste 15
• Fuel pump mounting nut 15
• Fuel system programmed fuel injection 15
• General information 15
• Inner panel pan screw inner middle cowl pan screw 15
• Lower bracket mounting nut 15
• Lower bracket mounting pinch bolt 15
• Lower cowl pan screw 15
• Main footpeg bracket mounting socket bolt 15
• Main footpeg mounting bolt 15
• Middle cowl pan screw 15
• Note 7 15
• Note 8 15
• Page 15 15
• Pillion footpeg mounting socket bolt 15
• Pillion seat bracket mounting bolt nut 15
• Pillion seat mounting nut 15
• Rear cowl truss screw 15
• Rear engine hanger pinch bolt 15
• Remarks 15
• Seat rail mounting bolt 8 mm 15
• See tightening sequence below 15
• Sensor 15
• Side stand bracket bolt 15
• Side stand pivot bolt 15
• Side stand pivot lock nut 15
• Thread 15
• Torque 15
• Upper cowl stay mounting bolt 15
• Brake caliper bleeder 16
• Brake hose oil bolt 16
• Brake lever pivot nut 16
• Caliper body assembly torx bolt pad pin 16
• Driven sprocket nut 16
• Fan motor switch 16
• Fork bottom bridge pinch bolt 16
• Fork center bolt 16
• Fork top bridge pinch bolt 16
• Front axle holder pinch bolt 16
• Front brake caliper mounting bolt 16
• Front brake disc mounting bolt 16
• Front brake master cylinder cup mounting nut 16
• Front brake switch screw 16
• Front wheel suspension steerin 16
• Handlebar pinch bolt 16
• Handlebar weight mounting screw 16
• Hydraulic brak 16
• Ignition switch mounting one way bolt 16
• Lights meters switche 16
• Note 1 16
• Note 2 16
• Note 7 16
• Note 7 note 8 note 7 note 7 note 7 note 7 note 7 16
• Note 8 16
• Note 8 note 8 16
• Pad pin plug 16
• Page 16 16
• Rear axle nut 16
• Rear brake caliper pin bolt main 16
• Rear brake disc mounting bolt 16
• Rear brake hose clamp screw 16
• Rear master cylinder hose joint screw 16
• Rear master cylinder push rod nut 16
• Rear shock absorber upper mounting nut 16
• Rear wheel suspension 16
• Remarks 16
• Shock arm plate nut 16
• Shock link nut frame side 16
• Side stand switch mounting bolt 16
• Steering stem nut 16
• Swingarm pivot nut 16
• Swingarm pivot pinch bolt 16
• Thread 16
• Top thread a top thread b 16
• Torque 16
• 0010100 07780 0010300 07780 0012000 07780 0012900 07780 0014500 07780 0014000 17
• 0010300 17
• 0010400 07746 0010700 17
• 0010600 17
• 0010800 07746 0010900 07746 0030100 07746 0030300 07746 0040400 07746 0040600 17
• 0020001 17
• 0040002 07506 3000000 17
• 0040800 07746 0050100 07746 0050800 07749 0010000 07757 0010000 17
• 0050002 07725 0040000 17
• 07914 3230001 17
• 07916 3710100 17
• 14 14 14 12 12 14 17
• 3710001 17
• 3710101 17
• Assembly base 17
• Attachment 24 x 26 mm attachment 22 x 24 mm attachment 40 x 42 mm 17
• Attachment 30 mm 17
• Attachment 42 47 mm attachment 52 x 55 mm 17
• Ball race remover set 17
• Bearing remover a 17
• Bearing remover b 17
• Bearing remover head 25 mm 17
• Bearing remover shaft 17
• Can be used with the 17
• Clutch center holder 17
• Driver 17
• Driver 40 mm 17
• Driver attachment a 17
• Driver attachment b driver shaft assembly 17
• Driver attachment handle 17
• Equivalent commercially available in 17
• Flat cutter 25 mm 32 ex 17
• Flywheel holder 17
• Flywheel puller 17
• Following combination 17
• Fuel pressure gauge 17
• General information 17
• Haa pj70100 17
• Hgj 0020100 17
• Interior cutter 26 mm 60 ex 17
• Ka50100 17
• Km30101 17
• Km90001 17
• Km90100 07946 km90200 07946 km90300 17
• Km90401 17
• Km90500 07946 km90600 17
• M b00000 17
• Ma60000 17
• Ma70000 17
• Me90200 17
• Mj00100 17
• Mm 45 ex 17
• Newly designed too 17
• Newly provided too 17
• Not available in 17
• Note 1 17
• Note 5 17
• Oil pressure gauge attachment 17
• Oil pressure gauge set 17
• Page 17 17
• Peak voltage adaptor 17
• Peak voltage tester 17
• Pilot 17 mm pilot 25 mm pilot 35 mm 17
• Remarks 17
• Sa50001 17
• Seat cutter 29 mm 45 in 17
• Snap ring pliers 17
• Steering stem driver 17
• Steering stem socket 17
• Tool number 17
• Valve seat cutter 17
• Valve spring compressor 17
• Valve spring compressor attachment 17
• Vmf kz30200 17
• Compression gauge attachment 18
• Description 18
• Driver attachment 25 x 3 18
• Driver pilot 32 50 mm 18
• Ecu test harness 18
• Fork damper holder 18
• General information 18
• H m h m l00101 18
• H m h m loo10a 18
• Kmd kz30100 with 18
• Lmc kv30100 18
• Mad pr90200 18
• N m d kz30101 18
• N m d kz3010a 18
• Needle bearing remover 18
• Note 2 18
• Note 3 18
• Note 5 note 4 18
• Note 5 note 5 note 5 note 5 18
• Page 18 18
• R mj my50100 18
• Remover 14 x 16 mm 18
• Tappet hole protector 18
• Valve guide driver 18
• Ym b mcf0101 18
• Ymf mcjo100 07ymf mcj0200 07ymf mcj0300 07ymf mcj0400 18
• Ymz 0010100 18
• Page 19 19
• Camshaft holder bolt threads and seating surface 20
• Camshaft lobes journals and thrust surface 20
• Clutch outer primary driven gear sliding surface 20
• Connecting rod bearing surface 20
• Connecting rod nut threads 20
• Connecting rod small end inner surface 20
• Crankshaft thrust surface 20
• Cylinder head semi circular cut out 20
• Each 0 ring 20
• Each gear teeth and rotating surface 20
• Engine cont d 20
• Flywheel bolt threads and seating surface 20
• General information 20
• Main journal 9 mm bolt threads and seating surface 20
• Main journal bearing surface 20
• Material 20
• Page 20 20
• Remarks 20
• Sealant 20
• Cam chain guide a mounting bolt threads 21
• Cam sprocket bolt threads 21
• Coating widt 21
• Genera 21
• Information 21
• Locking agent 21
• Multi purpose grease 21
• Page 21 21
• Timing hole cap threads 21
• Absorber spring adjuster cam surface 22
• Brake master cylinder cups 22
• Brake pip 22
• Cable lubricant 22
• Clutch cable casing inner 22
• Dot 4 brake fluid 22
• Driven sprocket stud bolt threads 22
• Equivalent 22
• Footpeg sliding area 22
• Fork cap o ring 22
• General information 22
• Handle gri 22
• Honda bon 22
• Location 22
• Locking agent 22
• Material 22
• Molybdenum 22
• Molybdenum paste 22
• Motor switch threads 22
• Multi purpose grease 22
• Page 22 22
• Pin surface 22
• Radiato 22
• Rear brake calipe 22
• Rear brake pedal pivot sliding area 22
• Rear master cylinder boot inside and push rod tips 22
• Rear master cylinder hose joint screw threads 22
• Remarks 22
• Rubber inside 22
• Shell alvania ep2 or 22
• Shock absorber needle bearing shock absorber dus 22
• Side stand pivot surface 22
• Silicon grease 22
• Steering head bearing sliding surface 22
• Steering stem top thread 22
• Surface 22
• Swingarm pivot bearing 22
• Swingarm pivot dust seal lips 22
• Valve cable a b casing inner 22
• Variable exhaus 22
• Cable harness routing 23
• Combination meter 23
• Connectors 23
• Front brake hose 23
• Multi connector 23
• Natural connector 23
• Page 23 23
• Right handlebar 23
• Clutch cable 24
• Fan motor wire 24
• General information 24
• Headlight sockets 24
• Horn wire 24
• Inside 24
• Left handlebar 24
• Left turn signal wire 24
• Page 24 24
• Rightturn 24
• Signal wire 24
• Switch wire 24
• Throttle cables 24
• White tape 24
• Clutch cable 25
• General information 25
• Meter sub harness 25
• Page 25 25
• Right handlebar 25
• Switch wire 25
• Throttle cables 25
• Page 26 26
• Page 27 27
• Bypass hose 28
• Lower radiator hose 28
• Overflow tube 28
• Page 28 28
• Thermostat housing to 28
• Water pump hose 28
• Page 29 29
• Page 30 30
• Ect sensor 31
• Engine sub harness 31
• Fuel injector sub harness 31
• Generator2p 31
• Iat sensor 31
• Ignition pulse 31
• Map sensor 31
• P blue connector 31
• P gray connector 31
• Page 31 31
• Pressure regulator 31
• Red connector 31
• Fuel pump reserve sensor 32
• Fuel tank overflow tube 32
• Page 32 32
• R _lly 32
• Sensor wire 32
• Throttle sensor 32
• Bank angle sensor 33
• Connector 33
• Engine stop relay 33
• Fuel cut relay 33
• Fuse box 33
• Main wire harness 33
• Natural connector 33
• Page 33 33
• Service check connector 33
• Starter relay switch 33
• General information 34
• Page 34 34
• Alternator wire 35
• Breather tube 35
• California typ 35
• Cam pulse generator 2p 35
• Control cable 35
• Control cables 35
• Crankcase 35
• Engine sub harness 35
• Evap purge control solenoid valve 35
• Exhaust gas control valve 35
• General information 35
• Generator wire 35
• Natural connector 35
• P black connector 35
• P natural connector 35
• Page 35 35
• Pair control solenoid valve 35
• Sensor 35
• Sensor 4p natural connector 35
• Starter motor cable 35
• Starter motor ground cable 35
• Sub harness 35
• Switch 35
• Throttle 35
• Throttle cables 35
• Variable intake valve 35
• Vehicle speed sensor 35
• Fuel tank overflow tube 36
• General information 36
• Page 36 36
• Sensor wire 36
• Page 37 37
• Throttle sensor 37
• Page 38 38
• Page 39 39
• Air cleaner housing 40
• Control systems 40
• Emissio 40
• Page 40 40
• Throttle body 40
• Air cleaner housing 41
• And water vapo 41
• California typ 41
• Crankcase emission control system 41
• Ect iat tp map sensor and engine revolution 41
• Except idle speed adjustment with the throttle stop scre 41
• Fresh air is drawn into the exhaust port by the function of the pair pulse secondary air injection control valv 41
• Hydrocarbons and carbon monoxide into relatively harmless carbon dioxide and water vapo 41
• No adjustment to these systems should be made although periodic inspection of the components is recommende 41
• No adjustments to the secondary air supply system should be made although periodic inspection of the components is 41
• Oxygen senso 41
• Page 41 41
• Pair check valve 41
• Pair control valve 41
• Recommende 41
• Solenoid valve is controlled by the pgm fl unit and the fresh air passage is opened closed according the running condition 41
• The california type also equipped two three way warm up catalytic converters a three way catalytic converter and a heated 41
• The engine s exhaust to carbon dioxide co2 dinitrogen 41
• The exhaust emission control system consists of a secondary air supply system which introduces filtered air into the exhaust gases in the exhaust por 41
• The exhaust emission control system is composed of a lean fuel injection setting and no adjustments should be made 41
• The exhaust emission control system is separate from the 41
• The pair control valve is operated by the solenoid valv 41
• The reed valve prevents reverse air flow through the syste 41
• The three way catalytic converters are in the exhaust syste 41
• This charge of fresh air promotes burning of the unburned exhaust gases and changes a considerable amount of 41
• Throttle body 41
• Through chemical reactions they convert hc co and nox in 41
• 1 the removal or rendering inoperative by any person other than for purposes of maintenance repair or 42
• 2 the use of the vehicle after such device or element of 42
• Among those acts presumed to constitute tampering are the acts listed below 42
• By the manufacture 42
• Design has been removed or rendered inoperative by any person 42
• Evap canister 42
• Evap purge control valve 42
• Fresh air 42
• Fuel tank 42
• Fuel vapor 42
• Fuel vapor from the fuel tank is routed into the evaporative emission evap canister where it is absorbed and stored while 42
• Fuel vapor in the evap canister is drawn into the engine through the throttle body 42
• Its sale or delivery to the ultimate purchaser or while it is in us 42
• Lack of proper maintenanc 42
• Local law prohibits the following acts or the causing 42
• Page 42 42
• Removal of or puncturing of any part of the intake syste 42
• Removal of or puncturing of the muffler baffles header pipes or any other component which conducts exhaust gase 42
• Replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to 42
• Replacing any moving parts of the vehicle or parts of the exhaust or intake system with parts other than those specified 42
• Tampering with the noise control system is prohibite 42
• The engine is stoppe 42
• Thereo 42
• This model complies with california air resources board evaporative emission requirement 42
• Throttle body 42
• When the engine is running and the evaporative emission evap purge control solenoid valve is open 42
• Air cleaner housing cover as show 43
• An emission control information label is located 43
• California vehicle 43
• Canister 43
• Control 43
• Emission control information label 43
• Engine family i 43
• Evaporative family 43
• Forward 43
• General information 43
• Information 43
• It gives base tune up specification 43
• Label california type only 43
• On the storage compartment as show 43
• Page 3 4 for fuel tank openin 43
• Page 43 43
• Pair check valve 43
• Pressure regulate 43
• Refer to 43
• Sensor 43
• Solenoid 43
• The fuel tank must be opened to read i 43
• The seat must be removed to read i 43
• The vacuum hose routing diagram label is on the 43
• Throttle bcdy 43
• To acl 43
• To open 43
• Vacuum hose routing diagram 43
• Vacuum hose routing diagram label 43
• Frame body panels exhaust system 44
• Lower cowl 44
• Page 44 44
• Windscreen 44
• Page 1 45
• Align the seat hook with the fuel tank rear bracket 46
• And install the sea 46
• As shown 46
• Collar 46
• Ignition key 46
• Install and tighten the socket bolts securely 46
• Install the mounting collars into the seat brackets 46
• Open the pillion seat using the ignition ke 46
• Page 2 46
• Pillion seat 46
• Pillion seat rear cowl 46
• Remove the mounting collar 46
• Remove the rear cowl setting bolts collars 46
• Remove the seat see above 46
• Remove the two seat mounting socket bolts behind 46
• Rjj on 46
• Setting bolt 46
• Slide the seat back and then of 46
• Spacer 46
• The sea 46
• Assembl 47
• Assembly 47
• Bolt nut 47
• Brake tail light connectors 47
• Carefully spread the bottom of both sides of the 47
• Disconnect the rear brake tail light connector 47
• Note that these 47
• Nuts then remove the pillion seat bracket as an 47
• Page 3 47
• Pillion seat 47
• Previous ste 47
• Rear cowl 47
• Rear cowl then remove it from the seat rai 47
• Remove the pillion seat bracket mounting bolts 47
• Remove the two trim clips and two retaining 47
• Remove the two trim clips under the rear cow 47
• Removed in the 47
• Return spring 47
• Than those 47
• Thim clips are slightly different 47
• Trim clip 47
• Fied torqu 48
• Frame body panels exhaust system 48
• Gently spread the 48
• Install and tighten the mounting screws to the speci 48
• Install the lower trim clip 48
• Install the rear cowl over the side rail being careful 48
• Install the two trim clips 48
• Not to damage the wire harnes 48
• Page 4 48
• Pillion seat assembly 48
• Rectifie 48
• Sides to fit over 48
• The regulator 48
• Trim clip 48
• Brake tail light connectors 49
• Check the return spring hook position then install 49
• Connect the rear brake tail light connector 49
• Frame body panels exhaust system 49
• Hold the bolt and tighten the nut to the specified 49
• Install the pillion seat bracket assembly onto the 49
• Install the spacers setting collars and setting bolts 49
• Middle lower cowl 49
• Page 5 49
• Pillion seat 49
• Removal 49
• Remove the trim clips from the inner middle cowl 49
• Route the wire harness and clamp it as show 49
• Seat rai 49
• Setting bolt 49
• The bracket mounting bolts nuts 49
• Then tighten the bolts securel 49
• Trim clips 49
• And left lower cowl 50
• Bolt and inner 50
• Frame body panels exhaust system 50
• Grommet 50
• Grommet then remove the middle cow 50
• Lower cow 50
• Page 6 50
• Release the middle cowl boss from the inner panel 50
• Remove the four special bolt 50
• Remove the lower cowl assembly from the right 50
• Remove the six screws and special bol 50
• Remove the two screws special 50
• Remove the two trim clips and separate the right 50
• Right lower 50
• Special bolt 50
• Special bolts 50
• Assemble the inner lower cowl right and left lower 51
• Cowl groove 51
• Ends of the inner 51
• Inner lower cowl 51
• Inner middle cowl 51
• Install and tighten the inner lower cowl screw to the 51
• Install bottom 51
• Install the lower cowl onto the frame from the right 51
• Install the two trim clips and special bol 51
• Left lower cowl 51
• Lower cowl 51
• Middle cowl 51
• Middle cowl into 51
• Page 7 51
• Right lower 51
• Specified torqu 51
• The inner lower 51
• Four trim clip 52
• Frame body panels exhaust system 52
• Grommet 52
• Install and tighten the special bolt 52
• Install the middle cowl while aligning its boss with 52
• Install the special bolt and screw 52
• Page 8 52
• Secure the inner lower cowl and middle cowl using 52
• Special bolt 52
• Special bolts 52
• The inner panel grommet 52
• Tighten the screws to the specified torque 52
• Tighten the special bol 52
• Trim clips 52
• And rearview mirror 53
• From the upper cowl 53
• Heat guard 53
• Inner panel 53
• Page 9 53
• Rear view mirror 53
• Remove the middle cowl pag 53
• Remove the rearview mirror mounting socket bolts 53
• Remove the screw and heat guard on both sid 53
• Remove the screw and then remove the inner panel 53
• Remove the screws washers and windscree 53
• Remove the two trim clips from the inner panel 53
• Screws 53
• Socket bolts 53
• Upper cowl 53
• Washers 53
• Windscreen 53
• Connectors then remove the upper cow 54
• Disconnect the headlight sockets and turn signal 54
• Frame body panels exhaust system 54
• Front turn signal uni 54
• Page 10 54
• Pull the upper cowl forward 54
• Remove the nut and setting plate then remove the 54
• Remove the screws and air guar 54
• Remove the upper cowl mounting bolt and washe 54
• Screws 54
• Setting plate 54
• Washer 54
• Page 11 55
• And wires properly 56
• Connect the headlight connectors position light 56
• Connector and turn signal connector 56
• Frame body panels exhaust system 56
• Grommets 56
• Groove as show 56
• Install and tighten the nut securel 56
• Install the air guard and tighten two screw 56
• Install the upper cowl onto the upper cowl stay 56
• Ner middle cowl and setting plat 56
• Page 1 23 56
• Page 12 56
• Place the upper cowl onto the upper cowl stay 56
• Route the harness 56
• Route the turn signal wire into the inner middle 56
• Route the turn signal wire into the upper cowl in 56
• Screws 56
• Upper cowl stay grommet 56
• While aligning the headlight unit bosses with the 56
• Aligning its tab with the hole in the inner middle 57
• Heat guard 57
• Install and tighten the screw to the specified torqu 57
• Install the heat guard onto the inner middle cowl 57
• Install the rearview mirror and tighten the socket 57
• Install the washer and upper cowl mounting bolt 57
• Install the windscreen and washers then secure it 57
• Page 13 57
• Rear view mirror 57
• Screws 57
• Socket bolts 57
• Tighten the upper cowl mounting bolt securel 57
• Windscreen 57
• With screw 57
• And reflector 58
• Battery page 16 5 58
• Clamp nut 58
• Disconnect the turn signal connectors and license 58
• Front fender 58
• Inner middle cowl 58
• Inner panel 58
• Install 58
• Install and tighten the inner panel mounting screw 58
• Installation is in the reverse order of remova 58
• License light connector 58
• Light connecto 58
• Page 14 58
• Rear cowl page 2 2 58
• Rear fender 58
• Reflector 58
• Remove the brake hose clamp mounting nuts 58
• Remove the followin 58
• Remove the front fender forwar 58
• Remove the front fender mounting special bolts 58
• Secure the inner panel and inner middle cowl with 58
• Special bolts 58
• The inner 58
• To the specified torqu 58
• Turn signal connectors 58
• Two trim clip 58
• And regulator rectifier 4p natural connecto 59
• Collar 59
• Connecto 59
• Connectors 59
• Connectors them remove the ecm page 5 89 59
• Disconnect the alternator 3p natural connector 59
• Disconnect the ecm engine control module multi 59
• Disconnect the rear brake light switch 2p natural 59
• Frame body panels exhaust system 59
• Fuel cut relay 59
• Harness from the seat rail and rear fende 59
• Page 15 59
• Regulator rectifier wire 59
• Release the regulator rectifier wire and main wire 59
• Remove the fuel cut relay from the rear fende 59
• Remove the starter relay switch from the rear 59
• Remove the two rear fender mounting bolts and 59
• Starter relay 59
• Unhook the retaining tab and remove the fuse box 59
• Battery 60
• Fmil 3race 60
• Frame body panels exhaust system 60
• Fuel tank 60
• Fuse box 60
• Install the rear fender by aligning its lower groove 60
• Installation 60
• Ness properly 60
• Page 1 23 60
• Page 16 60
• Rear bracket 60
• Rear fender 60
• Rear fendff 60
• Route the wire har 60
• Starter relay switch 60
• The rear fender 60
• Then remove the rear fender backward 60
• Unhook the rear fender from the seat rail brace 60
• While installing 60
• With the seat rail brac 60
• Bolts nuts and seat rai 61
• Bracke 61
• Connect the license light connector and turn signal 61
• Connector 61
• Frame body panels exhaust system 61
• Install the removed parts in the reverse order of 61
• License light connector 61
• Mm bolts 61
• Page 15 4 61
• Page 17 61
• Pillion footpe 61
• Pillion footpeg bracket 61
• Properly page 61
• Regulator rectifier 61
• Remova 61
• Removal 61
• Remove the bolts and regulator rectifie 61
• Remove the muffler mounting bolt nu 61
• Remove the rear brake reservoir mounting 61
• Remove the rear fender page 2 14 61
• Remove the seat rail mounting 8 mm bolts 10 mm 61
• Remove the socket bolts and left pillion footpeg 61
• Remove the socket bolts and right pillion footpeg 61
• Route the wires 61
• Sfait r 61
• Socket bolts 61
• And nuts to the specified torqu 62
• Frame body panels exhaust system 62
• Ibf ft 62
• Install the left pillion footpeg bracket and tighten 62
• Install the regulator rectifier tighten the bolt 62
• Install the seat rail and tighten the mounting bolts 62
• Lbf ft 62
• Mm bol 62
• Mm bolt nu 62
• Mm bolts 62
• Page 18 62
• Pillion footpeg bracket 62
• Regulator rectifier 62
• Seat rail 62
• Socket bolts 62
• The socket bolts to the specified torqu 62
• Bolt nut 63
• Bracke 63
• California type 63
• Disconnect the 63
• Do not service the exhaust system while it is hot 63
• Instal 63
• Install the muffler mounting bolt washer and nut 63
• Install the removed parts in the reverse order of 63
• Muffl1er 63
• Muffler exhaust pipe 63
• P natural connector 63
• Page 19 63
• Pillion footpe 63
• Pillion footpeg 63
• Remova 63
• Removal 63
• Remove the 63
• Remove the exhaust pipe to muffler mounting 63
• Remove the gaske 63
• Remove the middle lower cowl pag 63
• Remove the muffler mounting bolt nut and washer 63
• S k et 63
• Sensor 4p natural connecto 63
• Sensor wire from the frame 63
• System 63
• The socket bolts to the specified torqu 63
• Then remove the muffle 63
• Tighten 63
• Tighten the nut securel 63
• Control cables 64
• Control valve pulley cove 64
• Disconnect the egcv control cables from the pulle 64
• Page 20 64
• Pulley 64
• Pulley cover 64
• Release the 0 sensor wire from the right step 64
• Remove the 64
• Remove the right step guard mounting bolts 64
• Remove the two bolts and egcv exhaust gas 64
• Right step guard 64
• Sensor wire 64
• Sensor wire clamp 64
• Bolt ni 65
• Bolt nut 65
• Exhaust pipe 65
• Exhaust pipe gaskets 65
• Exhaust pipe mounting bolt nut 65
• Frame body panels exhaust system 65
• Move the radiator forwar 65
• Page 21 65
• Remove the exhaust pipe joint nuts 65
• Remove the followin 65
• Remove the radiator lower mounting bolt nut then 65
• See page 5 100 for exhaust valve removal disas 65
• California typ 66
• Except california typ 66
• Exhaust pipe assembly 66
• Frame body panels exhaust system 66
• Kgf m 9 ib 66
• Muffler 66
• Page 22 66
• Sensor 66
• Always replace the 67
• Bolt and nut 67
• Bushing 67
• Collar into the lower bracket hol 67
• Exhaust pipe 67
• Exhaust pipe joint nuts and mounting bolt nu 67
• Exhaust ports of the cylinder hea 67
• First tighten the exhaust pipe joint nuts to the 67
• Frame body panels exhaust system 67
• Gaskets with new 67
• Install 67
• Install the exhaust pipe temporarily install the 67
• Install the new exhaust pipe gaskets onto the 67
• Install the washe 67
• M 9 ib 67
• Mounting 67
• Page 23 67
• Properl 67
• Specified torqu 67
• The exhaust 67
• Tighten the exhaust pipe mounting bolt nu 67
• Adjust the control cables page 5 95 68
• California type 68
• Clamp th 68
• Connect the egcv control cables to the exhaust 68
• Control cables 68
• Frame body panels exhaust system 68
• Install the egcv pulley cover and tighten the bolts 68
• Install the radiator lower mounting bolt nut and 68
• Lower mounting bol 68
• Olt nut 68
• Page 24 68
• Pulley 68
• Pulley cover 68
• Rac5 ia 68
• Right step guard 68
• Sensor wire 68
• Sensor wire to the right step guar 68
• Tighten the nu 68
• To the specified torqu 68
• Upper mounting bol 68
• Valve pulle 68
• Bolt nut 69
• Clamp the 0 sensor wire with the rear brake 69
• Connect the 69
• Gaskell 69
• Install the middle lower cowl pag 69
• Install the muffle 69
• Install the new gasket onto the exhaust pipe as 69
• Install the rigth step guard and rear master cylinder 69
• Page 25 69
• Reseroir hose using the hose clam 69
• Right step guard 69
• Route the 69
• Securel 69
• Sensor 4p natural connecto 69
• Sensor wire into the fram 69
• Temporarily install the muffler mounting bolt nu 69
• Then tighten the mounting bolt 69
• Tighten the muffler exhaust pipe mounting bolts 69
• Tighten the muffler mounting bolt nut securel 69
• Air cleaner 70
• Brake system 70
• Clutch system 70
• Cooling system 70
• Drive chain 70
• Engine idle speed 70
• Engine oil oil filter 70
• Evaporative emission control 70
• Fuel line 70
• General 70
• Headlight aim 70
• Intenance 70
• Maintenance schedule 70
• Nuts bolts fasteners 70
• Page 1 70
• Secondary air supply system 70
• Service information 70
• Side stand 70
• Spark plug 70
• Steering head bearings 70
• Suspension 70
• System california type only 70
• Throttle operation 70
• Valve clearance 70
• 70 zr17 58w 71
• Apply grease to the threads 71
• Bridgestone 71
• Bt01or 71
• Canada 71
• Ecommende 71
• Haa mr1010 71
• Haa pj70100 71
• Hmh mr10103 71
• Honda dot 4 brake fluid 71
• Iuh27d denso iuh24d denso 71
• Kgf cm 71
• Maintenance 71
• Mm 0 01 71
• Page 2 71
• Pilot sport e 71
• Pro honda gn4 or hp4 4 stroke oil 71
• Recommended engine oil 71
• Sae 10w 40 1 200 100 rpm 71
• Sfecificatons 71
• Specifications 71
• Standard 71
• Torque values 71
• Up to maximum 71
• Zr17 73w 71
• Air cleaner 72
• Air supply system 72
• Alve clearance 72
• Bolts fasteners 72
• Clutch system 72
• Control cable 72
• Cooling system 72
• Evaporative emission control system 72
• Frequency 72
• Light switc 72
• Maintenance 72
• Maintenance schedule 72
• Odometer reading note 1 72
• Pad wear 72
• Page 3 72
• Radiator coolant 72
• Secondar 72
• Side stand 72
• Spark plug 72
• Steering head bearings 72
• Suspension 72
• System q 72
• Throttle operation 72
• To page 72
• Wheels tires 72
• Check the fuel lines for deterioration damage or 73
• Fuel l j 73
• Fuel line 73
• Install a fuel tank mounting bol 73
• Install the fuel tank in the reverse order of remova 73
• Open and support the front end of fuel tank using a 73
• Page 4 73
• Remove the front and rear fuel tank mounting bolts 73
• Remove the fuel tank mounting collar temporarily 73
• Replace the fuel line if necessar 73
• Suitable support as shown 73
• 6 mm 1 1 74
• Adjust the free play by loosening the lock nut and 74
• Adjuste 74
• After adjustment tighten the lock nut securel 74
• Air cleaner 74
• Automatic full closing in all steering position 74
• Check the throttle cables and replace them if they are deteriorated kinked or damage 74
• Disconnect the iat intake air temperature sensor connector page 5 84 74
• For smooth throttle grip full opening and 74
• Free pla 74
• Lubricate the throttle cables if throttle operation is 74
• Maintenance 74
• Major adjustments are made with the lower adjust 74
• Measure the free play at the throttle grip flange 74
• Minor adjustments are made with the upper 74
• Not smoot 74
• Of the throttle cable 74
• Open and support the front end of fuel tank page 74
• Page 5 74
• Recheck the throttle operation 74
• Remove the air cleaner housing page 5 66 74
• Remove the screws and air cleaner housing cove 74
• Replace any damaged parts if necessar 74
• Throttle grip free play can be adjusted at either end 74
• Throttle operation 74
• Turning the adjuste 74
• Accordance with the maintenance schedule page 75
• Also replace the air cleaner element any time it is 75
• And discard 75
• Be careful not to damage the radiator fin 75
• Cleaner element 75
• Connecto 75
• Disconnect the fan motor sub harness 2p black 75
• Excessively dirty or damage 75
• Install the removed parts in the reverse order of 75
• Maintenance 75
• Mounti 75
• Notice 75
• P black connector 75
• Page 6 75
• R lt nut 75
• Removal 75
• Remove the middle cowl pag 75
• Remove the radiator lower mounting bolt nu 75
• Spark plug 75
• Special bolt 75
• Air before 76
• And be 76
• By moving it to the right then move the radiator 76
• Chamber 76
• Clean around the 76
• Direct ignition coils 76
• Disconnect the direct ignition coil connector 76
• F i pgug wreivlh 76
• Forwar 76
• I aimn f 76
• Inspect or replace as described in the maintenance 76
• Is allowed to enter 76
• Maintenance 76
• Nec ta 76
• Page 7 76
• Plug wrench or an equivalen 76
• Remove the direct ignition coils form the spark 76
• Remove the radiator grommet from the frame boss 76
• Remove the spark plug using a equipped spark 76
• Removin 76
• Schedule 76
• Spark plug bases 76
• Sure that no debris 76
• The combustion 76
• With compressed 76
• Always use 77
• As shown in the illustratio 77
• Burning condition coloration 77
• Check the following and replace if necessary rec 77
• Check the gap between the center and side 77
• Contacts the seat of the plug hol 77
• Contaminated 77
• Damaging the 77
• Do not adjust the 77
• Does not insert between the ga 77
• Electrod 77
• Electrode use a 77
• Electrodes for wear 77
• Electrodes is 77
• Electrodes with a wire type feeler gaug 77
• Equipped with 77
• Gauge to check the 77
• Hand tighten then torque to specification 77
• If the electrode is contaminated with accumulated 77
• If the gauge can be inserted into the gap replace the plug with a new on 77
• If using the new plug install as follows 77
• In plug gauge 77
• Install and hand tighten the new spark plug then 77
• Insulator for damage 77
• Iridium center 77
• Iuh27d denso 77
• K pl uc wrf cf 77
• Make sure that the o 77
• Motorcycle 77
• Objects or dirt replace the spark plug 77
• Ommended spark plu 77
• Page 3 1 77
• Page 8 77
• Plug if the 77
• Plugs on this 77
• Reinstall the spark plug in the cylinder head and 77
• Replace the plug if the center electrode is rounded 77
• Replace the spark 77
• Replace with a new 77
• Spark plug 77
• Spark plug ga 77
• Spark plug gap 77
• Specification 77
• Specified spark 77
• Specified spark plu 77
• The gap is out of 77
• This motorcycle s 77
• Tighten it about 1 2 turn after the sealing washer 77
• To prevent 77
• Wire type feeler 77
• Wire type feeler gauge 77
• Connect the direct ignition coil connector 78
• Connector to the 78
• Direct 78
• Ignition coi 78
• Install and tighten the radiator lower mounting bolt 78
• Install the blue 78
• Install the direct ignition coil 78
• Install the radiator grommet onto the frame boss 78
• Install the washer and radiator upper mounting bolt 78
• Maintenance 78
• O lt nut 78
• Page 9 78
• Taped wire 78
• Then tighten the bol 78
• And sealing washer 79
• Below 35 c 79
• Cam chain tensioner lifter 79
• Clearance while 79
• Connect 79
• Connector 79
• Inspect and adjust 79
• Install the middle cowl pag 79
• Maintenance 79
• P black connector 79
• Page 10 79
• Remove the cam chain tensioner lifter sealing bolt 79
• Remove the cylinder head cover pag 79
• Sealing washer 79
• Secure it using the mechanic s tensioner stopper 79
• Special bolt 79
• Stopper tool 79
• Sub harness 79
• The fan 79
• Tool pag 79
• Turn the cam chain tensioner lifter shaft fully and 79
• Valve clearance 79
• Adjustment is 80
• Check the valve clearance for the n 80
• Clearance for each 80
• Der head surface so they are facing outward 80
• If the timing marks on the cam sprockets are facing inward turn the crankshaft clockwise one full turn 360 and realign the timing marks with the cylin 80
• Iii g hole gap 80
• Inder intake valves using a feeler gaug 80
• Index iviahk 80
• Insert the feeler gauge between the valve lifter and 80
• Intake valves 80
• Mark on the right crankcase cove 80
• On the cam 80
• On the ignition pulse generator rotor with the index 80
• Page 11 80
• Record the 80
• Reference in shim 80
• Remove the timing hole cap and o rin 80
• Require 80
• Selection if 80
• Sprockets must be flush with the cylinder head 80
• Surface and facing outward as show 80
• The cam lob 80
• The timing marks 80
• Timing marks 80
• Turn the crankshaft clockwise align the t mark 80
• Valve for 80
• Adjustment is 81
• Check the valve clearance for the n 81
• Clearance for each 81
• Exhaust valves 81
• Inder exhaust valves using a feeler gaug 81
• Inder intake valves using feeler gaug 81
• Index line 81
• Index mark 81
• Intake valves 81
• Page 12 81
• Record the 81
• Reference in shim 81
• Require 81
• Required 81
• Selection if 81
• So that it is facing up as show 81
• The t mark on the ignition pulse generator rotor 81
• Turn the crankshaft clockwise 1 2 turn 180 align 81
• Turn the crankshaft clockwise 1 2 turn 180 align the index line on the ignition pulse generator rotor 81
• Valve clearanc 81
• Valve for 81
• With the index mark on the right crankcase cover 81
• Adjustment 82
• Adjustment is 82
• Check the valve clearance for the n 82
• Clean the valve shim contact area in the valve lifter 82
• Clearance for each 82
• Exhaust valves 82
• Inder exhaust valves using a feeler gaug 82
• Index line 82
• Maintenance 82
• Mark all valve lifters and shims to ensure correct 82
• Not allow the shims to fall into the crankcas 82
• Or magne 82
• Page 13 82
• Reassembly in their original location 82
• Record the 82
• Reference in shim 82
• Remove the camshaft pag 82
• Remove the valve lifters and shim 82
• Require 82
• Selection if 82
• Shiimf 82
• Shim may stick to the inside of the valve lifte 82
• So that it is facing up as shown 82
• The index line on the ignition pulse generator rotor 82
• The shims can be easily removed with a tweezers 82
• The valve lifter can be easily removed with a 82
• Turn the crankshaft clockwise 1 2 turn 18 82
• Valve clearanc 82
• Valve for 82
• Valve lapping tool or magne 82
• Valve lifter 82
• With compressed air 82
• And valve lifters in 83
• Apply molybdenum disulfide oil to the valve lifter 83
• Are available from 83
• Calculate the new shim thickness using the 83
• Calculated dimension of over 83
• Cam chain tensioner lifter 83
• Clockwise several time 83
• Different 83
• Equation belo 83
• In intervals of 83
• Install the camshaft page 8 24 83
• Install the new sealing washer and cam chain ten 83
• Install the newly selected shim on the valve retain 83
• Install the removed parts in the reverse order of 83
• Install the shims 83
• Install the valve lifters into the valve lifter hole 83
• Locations 83
• Maintenance 83
• Make sure of the correct shim thickness by meas 83
• Measure the shim thickness and record it 83
• Mm thickness shim 83
• New shim thickness 83
• Old shim thickness 83
• Page 14 83
• Recheck the valve clearanc 83
• Recorded valve clearance 83
• Reface the valve seat if carbon deposit result in a 83
• Remova 83
• Remove the cam chain tensioner stopper too 83
• Rotate the camshafts by rotating the crankshaft 83
• Sioner lifter sealing bol 83
• Sixty five 83
• Specified valve clearance 83
• Stopper tool 83
• The thickest 83
• The thinnest 83
• Their original 83
• Thickness shim to 83
• Thickness shims 83
• Tighten the bolt securely 83
• Uring the shim by micromete 83
• 1 ow 40 84
• Api service classificatio 84
• Canada or honda 4 stroke oil canada only 84
• Check the oil level through the inspection window 84
• Fill the recommended engine oil up to the upper 84
• Filler cap and fill the crankcase with recommended 84
• I 3n w 84
• If the level is below the lower line remove the oil 84
• Indicated rang 84
• Level lin 84
• Level surfac 84
• May be used when 84
• Minute 84
• Nj d j 84
• Oil filler t 84
• Oil up to the upper level lin 84
• Or equivalent motor oil 84
• Other viscosities 84
• Page 15 84
• Pro honda gn4 or hp4 4 stroke oil 84
• Recommended engine oi 84
• Reinstall the filler cap and dipstick 84
• Remove the oil filler ca 84
• Sae 20w 4m 84
• Sae tow 4m 84
• Sae zgw so 84
• Sf or sg 84
• Shown in the chart 84
• Start the engine and let it idle for 84
• Temperature in 84
• The average 84
• Turn off the engine and support the motorcycle 84
• Upper levt _ l 84
• Viscosit 84
• Within the 84
• Your riding area is 84
• 22 ibf ft 85
• Assure complete 85
• Change the engine 85
• Check that the sealing washer on the drain bolt is in 85
• Cil filler 85
• Drainin 85
• Good condition and replace if necessar 85
• Haa pj70100 85
• Install and tighten the drain bol 85
• Level ground to 85
• Maintenance 85
• Motorcycle on 85
• Oil filter cartridge 85
• Oil filter wrench 85
• Oil with the engine 85
• Page 16 85
• Remove and discard the oil filter cartridge using 85
• Remove the drain bolt and drain the oil completely 85
• Remove the middle lower cowl page 2 5 85
• Stop the engine and remove the oil filler cap 85
• The special too 85
• Ull drain bolt 85
• Warm and the 85
• Warm up the engin 85
• Apply oil to the new oil filter o ring 86
• Fied torqu 86
• Fill the crankcase with recommended engine oi 86
• Imp qt at draining 86
• Imp qt at oil filter change 86
• Install the middle lower cowl page 2 7 86
• Install the new oil filter and tighten it to the speci 86
• Install the oil filler cap 86
• Maintenance 86
• Make sure there are no oil leak 86
• Oil filer cap 86
• Oil filter cartridge 86
• Oil filter wrench 86
• Page 17 86
• Start the engine and let it idle for 2 to 3 minute 86
• Stop the engine and recheck the oil level 86
• 200 i 100 rpm 87
• And are within specifications 87
• Check the coolant level of the reserve tank with the 87
• Check the radiator air passages for clogging or 87
• Cooling system 87
• Corrosion protection inhibitor 87
• Engine maintenance items have been performed 87
• Engine running at normal operating temperatur 87
• High quality ethylene glycol antifreeze containing 87
• Idle spee 87
• If necessary add recommended coolan 87
• Inspect and adjust the idle speed after all other 87
• Lower level line 87
• More than 20 of the radiating surfac 87
• Other obstructions with compressed air or low wa 87
• Page 18 87
• Radiator coolant 87
• Reinstall the filler ca 87
• Remove the middle cowl pag 87
• Remove the middle lower cowl pag 87
• Remove the reserve tank filler cap and fill to the upper level line with 50 50 mixture of distilled water and antifreez 87
• Replace the radiator if the air flow is restricted over 87
• Reser u e tan 87
• Straighten bend fins and remove insects mud or 87
• Ter pressur 87
• The engine must be warm for accurate idle speed inspection and adjustmen 87
• The level should be between the upper and 87
• The specified idle speed 87
• Throttle stop screw 87
• Turn the throttle stop screw as required to obtain 87
• Upper level line 87
• Warm up the engine for about ten minute 87
• Air suction hose 88
• Any signs of heat 88
• Bons and carbon monoxide into relatively 88
• Check the air suction hose between the air cleaner 88
• Check the pair pulse secondary air injection 88
• Check the tightness of all hose clamps and fasten 88
• Cracke 88
• Cylinder head cover 88
• Cylinder head cover for deterioration damage or 88
• Damage inspect the pair check 88
• Deterioration and replace if necessar 88
• Deterioration damage of loose connections 88
• Exhaust port 88
• Exhaust system this charged secondary air 88
• For damage 88
• Harmless carbon dioxide and wate 88
• Housing and pair control solenoid valve for 88
• If the hoses show 88
• Inspect the radiator hoses for cracks or 88
• Loose connection 88
• Make sure that the hoses are 88
• Make sure that the hoses are not kinked pinched or 88
• Not cracke 88
• Page 19 88
• Pair control valve 88
• Pair reed valve 88
• Promotes burning of the unburned exhaust gases and changes a considerable amount of hydrocar 88
• Radiator hose 88
• Reed valve cover 88
• Remove the air cleaner housing page 5 58 88
• Secondary air supply system 88
• Supply syste 88
• System is located on the cylinder head cove 88
• Tered air into exhaust gases in the exhaust port 88
• The pulse secondary air supply 88
• The secondary air is drawn into the exhaust port 88
• The secondary air supply system introduces fil 88
• This model is equipped built in secondary air 88
• Tubes between the pair control solenoid valve and 88
• Valve in the pair 88
• Whenever there is negative pressure pulse in the 88
• 23 for tube connection 89
• Adjust the drive 89
• Both adjusting bolts until the correct drive chain 89
• Canister evap purge control solenoid valve for 89
• Chain slac 89
• Chain while the 89
• Check the evap canister for cracks or other 89
• Check the slack in the drive chain lower run 89
• Check the tubes between the fuel tank evap 89
• Damage the fram 89
• Deterioration damage or loose connection 89
• Drive chain 89
• Drive chain lubricant designed specifically for use 89
• Engine is runnin 89
• Evap canister 89
• Evap purge control solenoid valve 89
• Evaporative emission control 89
• Excessive chain slack 50 mm 89
• In or more may 89
• Lock nut h 89
• Loosen drive chain adjust bolt lock nuts and turn 89
• Loosen the rear axle nu 89
• Lubrican 89
• Lubricate the drive chain with 80 90 gear oil or 89
• Maintenance 89
• Make sure the index marks on the both adjusting 89
• Midway between the sprocket 89
• Neutral 89
• Never inspect and 89
• Notice 89
• On its side stand and shift the transmission into 89
• Page 1 43 and cable harness routing page 89
• Page 20 89
• Plate are aligned with the swingarm index mar 89
• Refer to the vacuum hose routing diagram label 89
• Slack is obtaine 89
• System california type only 89
• Tighten both drive chain adjusting bolt lock nut 89
• Tighten the rear axle nut to the specified torqu 89
• Turn the ignition switch off place the motorcycle 89
• Usti i bol 89
• Wipe off the excess oil or chain 89
• With o ring chain 89
• _axle nut 89
• 90 gear oil or 90
• And free wheel 90
• Be sure the chain has dried completely before 90
• Both chain and sprockets must be in good condi 90
• Cause the new chain to wear quickl 90
• Check the drive chain wear indicator label attached on the left swingar 90
• Clean the chain with non flammable or high flash 90
• Cleaning and lubrication 90
• Damage 90
• Drive chain with a new one page 3 22 90
• Excess oil or chain lubrican 90
• Fitting links or otherwise appears unserviceabl 90
• Gear oil or pro honda chain lube designed 90
• If the drive chain adjusting plate index mark 90
• Indicator label 90
• Inspect and replace the sprocket as necessar 90
• Inspect the drive and driven sprocket teeth for wear 90
• Inspect the drive chain for possible damage or 90
• Installing a new chain on badly worn sprockets will 90
• Lubricant 90
• Lubricate 90
• Lubricate the drive chain with 80 90 90
• Lubricate the drive chain with 80 90 gear oil or 90
• Lubricatin 90
• Maintenance 90
• Never use a new drive chain on worn sprockets 90
• Normal 90
• Or damage replace if necessar 90
• Page 21 90
• Point solvent and wipe it dr 90
• Pro honda chain lube designed specifically for use with o ring chain 90
• Rapidly 90
• Reaches red zone of the indicator label replace the 90
• Recheck 90
• Replace any chain that has damaged rollers loose 90
• Rotatio 90
• Specifically for use with o ring chains wipe off the 90
• Sprocket inspection 90
• The drive 90
• Tion or the new replacement chain will wear 90
• Wipe and dry ij 90
• Wipe off the excess oil or chain 90
• Assemble the special tool as show 91
• Check the attaching bolts and nuts on the drive and 91
• Drive chain tool set 91
• Drive sprocket 91
• Drive sprocket bol 91
• Driven sprocket 91
• Driven sprocket nu 91
• Hmh mr10103 or 91
• If any are loose torque the 91
• Instructio 91
• Locate the crimped pin ends of the master link from 91
• Loosen the drive chain page 3 20 91
• Maintenance 91
• Master link 91
• Page 22 91
• Remove the drive chai 91
• Replacement 91
• Special tool follow 91
• The drive chain tool se 91
• The manufacturer s 91
• The outside of the chain and remove the link with 91
• This motorcycle uses a drive chain with a staked 91
• When using the 91
• 108 links 92
• Assemble and set the drive chain tool se 92
• Assemble the new master link o rings and plate 92
• Chain and install 92
• Chain link 92
• Count the drive 92
• Drive chain tool set 92
• Drive chain with the drive chain tool se 92
• Hmh mr10103 or 92
• Hmh mr1010a 92
• Identification 92
• Include the master 92
• Insert the master 92
• Inside of the drive 92
• Link from the 92
• Link plate and 0 ring 92
• Link when you 92
• Mark facing the 92
• Master link 92
• Never reuse the oil drive chain master link master 92
• O rings 92
• Outsid 92
• Page 23 92
• Remove the excess drive chain links from the new 92
• Replacement chai 92
• Rk gb50hfoz5 92
• Route the drive chain into the swingarm as shown 92
• The plate with the 92
• Va8 c1 92
• A clip type master 93
• A drive chain with 93
• After staking check the staked area of the master 93
• If there is any cracking replace the master link o 93
• Link for crack 93
• Link must not be 93
• Maintenance 93
• Make sure that the master link pins are installed 93
• Make sure that the pins are staked properly by 93
• Measure the master link pin length projected from 93
• Measuring the diameter of the staked area using a 93
• Mm 0 17 93
• Page 24 93
• Properly 93
• Rings and plat 93
• Slide calipe 93
• Slide caliper 93
• Stake the master link pin 93
• The plat 93
• A low fluid level may be due 94
• Accounts for a low reservoir leve 94
• Are not worn and the fluid level is low check entire 94
• Avoid spilling fluid on painted plastic or rubber 94
• Bottom of wear limit groov 94
• Brake fluid 94
• Brake pad wear 94
• Brake pad wear see below 94
• Check the brake pad for wea 94
• Check the front brake fluid reservoir level 94
• Check the rear brake fluid reservoir level 94
• Compatible with each othe 94
• Do not allow foreign material to enter the system 94
• Do not mix different types of fluid as they are not 94
• For wear see below 94
• If the brake pads 94
• If the brake pads are 94
• If the level is near the lower level line check the 94
• Maintenance 94
• Page 25 94
• Place a rag over these parts whenever the 94
• Place the motorcycle on a level surface and sup 94
• Port it upright positio 94
• Refer to page 15 7 for brake pad replacemen 94
• Refer to page 15 8 for brake pad replacement 94
• Replace the brake pads if either pad is worn to the 94
• System for leaks see next page 94
• System is service 94
• To wear of the brake pad 94
• Turn the handlebar so that the reservoir is level and 94
• When filling the reservoi 94
• When the fluid level is low check the brake pads 94
• Worn the caliper piston is pushed out and this 94
• Adjust the brake light switch so that the brake light 95
• Adjuster 95
• Adjustmen 95
• Align the 95
• Allowance on the 95
• Ated bleed the air from the syste 95
• Brake hose 95
• Brake lever with 95
• Brake light switch 95
• Brake system 95
• Comes on just prior to the brake actually being 95
• Correct pedal height is obtaine 95
• Cracks and signs of leakag 95
• Do not 95
• Engaged 95
• Firmly apply the brake lever or pedal and check 95
• Hold the switch body and turn the adjuste 95
• If the lever or pedal feels soft or spongy when oper 95
• If the light fails to come on adjust the switch so 95
• Inspect the brake hose and fittings for deterioration 95
• Jidwstf 95
• L ck n 95
• Light switch does 95
• Loosen the lock nut and turn the push rod until the 95
• Maintenance 95
• Not require 95
• On the adjuster 95
• Page 26 95
• Push rod 95
• Refer to page 15 5 for brake bleeding procedures 95
• Replace hoses and fittings as required 95
• That no air has entered the system 95
• That the light comes on at the proper time 95
• The distance between the top of the brake lever and 95
• The front brake 95
• The grip can be adjusted by turning the adjuste 95
• The index number 95
• Tighten any loose fittings 95
• Turn the switch bod 95
• 20 mm 3 8 13 16 in 96
• A clockwise rotation moves the beam toward the 96
• A clockwise rotation moves the beam up and 96
• Adjust the 96
• Adjust the headlight beam horizontally by turning 96
• Adjust the headlight beam vertically by turning the 96
• Adjuster 96
• Adjusting scre 96
• As described as follo 96
• Clutch leve 96
• Clutch system 96
• Correct free play cannot be obtained turn the adjust 96
• Counterclockwise rotation moves the beam down 96
• Er all the way in and back out one turn 96
• Far out leaving minimal thread engagemen 96
• Free pla 96
• Headlight aim 96
• Headlight beam as 96
• If the adjuster is threaded out near its limit and the 96
• Juster at the clutch leve 96
• Laws and 96
• Lock nut 96
• Loosen the lock nut and turn the adjuste 96
• Measure the clutch lever free play at the end of the 96
• Minor adjustments are made using the upper ad 96
• Page 27 96
• Place the motorcycle on a level surface 96
• Regulation 96
• Right side of the ride 96
• Specified by local 96
• The adjuster may be damaged if it is positioned too 96
• The horizontal beam adjuste 96
• Tighten the lock nut and make a major adjustment 96
• Vertical beam adjuste 96
• Vertical beam adjusting screw 96
• Adjust free pla 97
• Age or loose fastener 97
• Al times 97
• Brakes and compressing the front suspension sever 97
• Check the action of the forks by operating the front 97
• Check the entire assembly for signs of leaks dam 97
• Check the side stand assembly for freedom of 97
• Check the side stand ignition cut off system 97
• Check the side stand spring for damage or loss of 97
• Clutch lever squeezed 97
• Clutch see section 9 97
• Control 97
• Damaged 97
• Hold the adjusting nut securely while tightening the 97
• If proper free play cannot be obtained or the clutch 97
• If there is a problem with the system check the side 97
• Impair motorcycle 97
• Lock nu 97
• Loose worn or 97
• Loosen the lock nut and turn the adjusting nut to 97
• Lowere 97
• Major adjustments are performed at the clutch ar 97
• Move the side stand full dow 97
• Movement and lubricate the side stand pivot if 97
• Necessary 97
• Or 1usstdn 97
• Page 28 97
• Refer to section 13 for fork servic 97
• Repaired 97
• Replace damaged components which cannot be 97
• Sit astride the motorcycle and raise the side 97
• Slips during test ride disassemble and inspect the 97
• Stability and 97
• Stand switch section 19 97
• Start the engine with the transmission in neutral 97
• Support the motorcycle on a level surfac 97
• Suspension 97
• Suspension parts 97
• Tensio 97
• The engine should stop as the side stand is 97
• Then shift the transmission into gear with the 97
• Tighten all nuts and bolt 97
• 1 2 turns from full hard 98
• Adjuste 98
• Adjusted by turning the adjusters 98
• Adjusters are firmly located in a detent and not 98
• Always start on full hard when adjusting the 98
• Be sure that the rebound and compression 98
• Between position 98
• Compression adjuster standard 98
• Compression and rebound damping adjusters 98
• Dampin 98
• Damping adjusters 98
• Decrease the spring pre load 98
• Decreases the damping force 98
• Direction 98
• Do not turn the adjuster screws more than the 98
• Fork bolt 98
• Given positions or the adjusters may be damage 98
• Iijinu19 98
• In from top of fork bolt 98
• Increase the spring pre load 98
• Increases the damping force 98
• Page 29 98
• Positio 98
• Pre load adjuster 98
• Pre load adjuster adjustable rang 98
• Pre load adjuster standard positio 98
• Sides equally set 98
• Spring pre load adjuster 98
• Spring pre load can be adjusted by turning the 98
• Stops then turn the adjuster counterclockwise 98
• The compression and rebound damping can be 98
• The right and left 98
• To adjust both 98
• To the same 98
• Turn the compression adjuster clockwise until it 98
• Check for worn swingarm bearings by grabbing the 99
• Check the entire shock absorber assembly for signs 99
• Compressing it several time 99
• Maintenance 99
• Of leaks damage or loose fasteners 99
• Page 30 99
• Refer to section 14 for shock absorber servic 99
• Repaired 99
• Replace the bearings if any are looseness is noted 99
• Sideways to see if the wheel bearings are worn 99
• Support the motorcycle securely and raise the rear wheel off the ground 99
• Swingarm side to sid 99
• Tighten all nuts and bolt 99
• Turn from full hard 99
• Turn the rebound adjuster clockwise until it stops then turn the adjuster counterclockwis 99
• Adjusted by turning the adjuster 100
• Adjuster 100
• Adjusting 100
• Adjustment 100
• Always 100
• Check that all chassis nuts and bolts are tightened 100
• Check that all safety clips hose clamps and cable 100
• Compress ic 100
• Dampin 100
• Decreases the damping force 100
• Direction 100
• Do not turn the adjuster screws more than the 100
• Given positions or the adjusters may be damage 100
• Increases the damping force 100
• Notice 100
• Nuts bolts fasteners 100
• On ful 100
• Page 31 100
• Positio 100
• Rear suspensio 100
• Stays are in place and properly secure 100
• Stops then turn the adjuster counterclockwise 100
• The compression and rebound damping can 100
• Then turn the adjuster counterclockwis 100
• To their correct torque values page 1 13 100
• Turn from full hard 100
• Turn the compression adjuster clockwise 100
• Turn the rebound adjuster clockwise until it stops 100
• Turns from full hard 100
• Until it 100
• 50 zr17 101
• 58w 73w 101
• 70 zr17 101
• Bearings section 13 101
• Bridgestone 101
• Bt01of 101
• Bt01or 101
• Check that the control cables do not interfere with handlebar rotatio 101
• Check that the handlebar moves freely from side to 101
• Check the front and rear wheels for trueness refer 101
• Check the tires for cuts embedded nails or other 101
• Following limit 101
• If the handlebar moves unevenly binds or has 101
• Kgf cm 101
• Measure the tread depth at the center of the tires 101
• Michelin 101
• Page 32 101
• Pressure and tire siz 101
• Replace the tires when the tread depth reaches the 101
• Sport e 101
• Steering head bearings 101
• Support the motorcycle securely and raise the front 101
• The pressure should be checked when the tires are 101
• Tire pressure 101
• Tire size 101
• To section 13 and 14 101
• Vertical movement inspect the steering head 101
• Wheel off the groun 101
• Wheels tires 101
• 400 rpm 80 c 176 f 102
• Akcaution 102
• At disassembl 102
• At drainin 102
• Body clearanc 102
• Canada or honda 4 stroke oil canada 102
• General 102
• Lubrication system diagram 102
• Oil cooler 102
• Oil pressure inspection 102
• Oil pump 102
• Oil pump rotor 102
• Oil strainer pressure relief 102
• Page 1 102
• Period 102
• Pro honda gn4 or hp4 4 stroke oi 102
• Recommended engine oil 102
• Sae 1ow 40 102
• Service information 102
• Service limit 102
• Side clearance 102
• Specifications 102
• Standard 102
• The oil pump can be serviced with the engine installed in the frame 102
• The service procedures in this section must be performed with the engine oil drained 102
• Tip clearanc 102
• Troubleshooting 102
• Unlikely unless you handle used oil on a daily basis it is still advisable to thoroughly wash your hands with soap and 102
• 3000000 103
• Apply a locking agent to the threads 103
• Clogged oil orifice 103
• Clogged oil strainer screen 103
• Ct bolt 103
• Engine oil level too low 103
• Equivalent commercially available in 103
• External oil leak 103
• Faulty cylinder head gasket 103
• Faulty oil cooler 103
• Faulty water pump mechanical seal 103
• From coolant mixing with oil 103
• Ft apply a locking agent to the threads 103
• High oil pressure 103
• Incorrect oil being used 103
• Internal oil leak 103
• Low oil level 103
• Low oil pressure 103
• Low or no oil pressure 103
• Lower crankcase sealing bolt 103
• Lubrication system torque values 103
• No oil pressure 103
• Oil consumption 103
• Oil contamination 103
• Oil cooler mounting bolt 103
• Oil drain bolt 103
• Oil filter cartridge 103
• Oil filter wrench 103
• Oil level too low 103
• Oil pressure gauge 103
• Oil pressure gauge attachment 103
• Oil pump assembly flange bolt 103
• Oil pump damaged pump shaft 103
• Oil pump drive sprocket broken 103
• Oil pump driven sprocket bolt 103
• Oil pump worn or damaged 103
• Page 2 103
• Plugged oil filter gallery or metering orifice 103
• T apply a locking agent to the threads 103
• T apply clean engine oil to the o ring 103
• Water leak in crankcase 103
• Worn piston ring or incorrect piston ring installation 103
• Worn valve guide or seal 103
• 3000000 104
• 80 c 176 f 104
• And read the oil pressur 104
• Apply a locking agent to the sealing plug thread 104
• Available i 104
• Check the oil level page 3 15 104
• Checking the oil 104
• Commercially 104
• Connect an oil pressure gauge and attachment to 104
• Drain the engine oil page 3 16 104
• Equivalent 104
• If the oil pressure 104
• Indicator light 104
• Install and tighten the sealing plug to the specified 104
• Kpa 5 kgf c 104
• Lbf ft 104
• Ma70000 104
• Oil pan 104
• Oil pressur 104
• Oil pressure gauge 104
• Oil pressure gauge attachment 104
• Oil pressure inspection 104
• Oil strainer pressure relief 104
• Page 3 104
• Pressur 104
• Psi at 5 400 rpm 104
• Remains on a few 104
• Remove the exhaust pipe page 2 18 104
• Remove the oil pan flange bolts and oil pan 104
• Sealing plug 104
• Seconds check 104
• Start the engine and increase the rpm to 5 400 rpm 104
• Stop the engine and remove the crankcase sealing 104
• Stop the engine and remove the tools 104
• System before 104
• The crankcas 104
• The indicator 104
• Ture approximately 80 c 176 f 104
• Warm up the engine to normal operating tempera 104
• Aligning its boss with the groove of the crankcas 105
• Apply oil to the new gasket and install it onto the oil 105
• Assemble the relief valve in the reverse order of 105
• Check the operation of the pressure relief valve by 105
• Clean the oil strainer scree 105
• Disassembl 105
• Disassemble the relief valve by removing the snap 105
• Inspect the piston for wear sticking or damag 105
• Inspect the spring for weakness or damag 105
• Inspection 105
• Install the oil strainer into the crankcase while 105
• Lubrication system 105
• Page 4 105
• Pushing on the pisto 105
• Relief valve 105
• Remove the oil strainer and gaske 105
• Remove the pressure relief valve and o rin 105
• Straine 105
• After installation check that there are no oil leak 106
• Apply oil to the new o ring and install it onto the 106
• Apply three bond 1207b or an 106
• Chain as an assembl 106
• Clean the oil pan mating surface thoroughl 106
• Clutch assembly page 9 4 106
• Do not apply 106
• Drive driven sprocket clutch outer guide and drive 106
• Equivalent to the 106
• Fill the crankcase with recommended oil page 106
• Install the exhaust pipe page 2 20 106
• Install the oil pan mounting bolts 106
• Install the oil pan onto the lower crankcas 106
• Install the relief valve into the crankcas 106
• Lubrication system 106
• Mating surfac 106
• Necessar 106
• O ring 106
• Oil pan 106
• Oil pump 106
• Oil strainer and pressure relief valve page 4 4 106
• Page 5 106
• Relief valv 106
• Relief valve 106
• Removal 106
• Remove the bolt washer then remove the oil pump 106
• Remove the followin 106
• Sealant more than 106
• Temporarily tighten the two bolts first then tighten 106
• The all bolts in a crisscross pattern in 2 3 step 106
• Assembly bolt 107
• Dowel pins 107
• Drive pin 107
• Inner rotor 107
• Install the outer and inner rotors into the oil pump 107
• Measure the tip clearanc 107
• Oil pump 107
• Oil pump cover 107
• Oil pump shaft 107
• Outer rotor 107
• Page 6 107
• Remove the dowel pin 107
• Remove the oil pump assembly bolt and oil pump 107
• Remove the three flange bolts and oil pump assem 107
• Remove the thrust washer drive pin 107
• Service limi 107
• Shaft outer rotor and inner rotor from the oil pump 107
• Temporarily install the oil pump shaf 107
• And feeler gauge 108
• Dowel pins 108
• Drive pin 108
• Inner rotor 108
• Lubrication system 108
• Measur 108
• Measure the pump body clearanc 108
• Oil pump body 108
• Oil pump cover 108
• Oil pump shaft 108
• Outer rotor 108
• Page 7 108
• Service limi 108
• Side clearance using a straight edge 108
• Washer 108
• And align the pin with the groove in the inner rotor 109
• And oil pump bod 109
• As show 109
• Assembly bolt 109
• Bolt to the specified torqu 109
• Check the oil pump operation by turning the pump 109
• Dowel pins 109
• Drive pi 109
• Groove 109
• If necessary reassemble the oil pum 109
• Ing the pump shaft lug with the water pump shaft 109
• Inner rotor 109
• Install and tighten the three flange bolt securely 109
• Install the dowel pins 109
• Install the drive pin into the hole in the pump shaft 109
• Install the oil pump cover and tighten the assembly 109
• Install the oil pump into the crankcase while align 109
• Install the oil pump shaft through the inner rotor 109
• Install the outer 109
• Install the outer and inner rotors into the oil pump 109
• Install the thrust washer 109
• Oil pubis 109
• Oil pump 109
• Oil pump shaft 109
• Outer rotor 109
• Page 8 109
• Punch mark facing 109
• Rotor with its 109
• System 109
• The oil pump coverr 109
• After installation fill the crankcase with recom 110
• And drive chain as an assembly 110
• And oil cooler 110
• Apply a locking agent to the oil pump driven sprock 110
• Apply oil to the clutch outer guide oil pump drive 110
• Cartridge page 3 16 110
• Check the oil cooler for damag 110
• Check the oil pressure page 4 3 110
• Clutch assembly page 9 9 110
• Cooler water hoses from the coole 110
• Dlt washer 110
• Drain the coolant from the system pag 110
• Drain the engine oil and remove the oil filter 110
• Drive sproci et 110
• Driven spro 110
• Driven sprocket 110
• Et bolt thread 110
• Install and tighten the driven sprocket bolt washer 110
• Install the clutch outer guide drive driven sprocket 110
• Install the followin 110
• Install the oil pump 110
• Loosen the hose bands and disconnect the oil 110
• M 11 lb 110
• Mark facing 110
• Mended oil and check that there is no oil leaks 110
• Mounting bolt 110
• Oil cooler 110
• Oil strainer oil pipe and oil pan page 4 5 110
• Outer guide 110
• Outward 110
• Page 9 110
• Removal 110
• Remove the o rin 110
• Remove the oil cooler mounting bolt lock washer 110
• Remove the radiator reserve tank page 6 17 110
• Sprocket driven sprocket and drive chai 110
• To the specified torqu 110
• Water hoses 110
• With its out 110
• 20 ibf 111
• And seating surfac 111
• Apply oil to the oil cooler mounting bolt threads 111
• Coat a new o ring with engine oil and install it into 111
• Concave side 111
• Cooler bolt 111
• Ibf ti 111
• Install the lock install the lock washer and oil cooler bol 111
• Install the oil cooler by aligning its guide groove 111
• Lock washer 111
• Mounting bolt 111
• O mark 111
• O mark facing 111
• O ring 111
• Oil cooler 111
• Oil filter cartridge 111
• Page 10 111
• The oil coole 111
• The oil cooler groov 111
• Washer 111
• Washer with its 111
• Water hoses 111
• With the rib on the crankcas 111
• Be sure the cooler 112
• Bolt collar slides 112
• Cooler 112
• Inside the oil 112
• Install the oil filter cartridge and fill the crankcase 112
• Lubrication system 112
• Mounting bolt 112
• Page 11 112
• Water hoses 112
• Fuel syste 113
• Page 12 113
• Page 1 114
• 200 100 rpm_ 115
• 250 mm hg 115
• 6 mm 1 16 1 115
• A faulty pgm fi system is often related to poorly connected or corroded connectors check those connections before 115
• Absolute pressure at idl 115
• Always replace the packing when the fuel pump is remove 115
• Always replace the sealing washers when the fuel tube banjo bolt is removed or loosened 115
• Available carburetor 115
• Base throttle valve for s nchronization 115
• Before disconnecting the fuel tube release the fuel pressure by loosening the fuel tube banjo bolt at the fuel tan 115
• C 68 f 115
• Californi 115
• Cam pulse generator peak voltage at 20 c 68 f 115
• Cleaners to 115
• Coated with 115
• Commercially 115
• Control solenoid valve resistance at 20 c 68 f 115
• Do not apply excessive force to the fuel pipe on the throttle body while removing or installing the throttle body 115
• Do not damage the throttle bod 115
• Do not disassemble in a way other than shown in this manual 115
• Do not loosen or tighten the white painted bolts and screws of the throttle bod 115
• Do not push the fuel pump base under the fuel tank when the fuel tank is stored 115
• Do not snap the throttle valve from full open to full close after the throttle cable has been remove 115
• Egcv is the abbreviation for exhaust gas control valv 115
• Engine coolant temperature sensor resistance at 20 c 68 f 115
• For fuel reserve sensor inspection see section 19 115
• For pgm fi system location see page 5 115
• For vehicle speed sensor 115
• Fuel injector resistanc 115
• Fuel pressure at idl 115
• Fuel pump flow at 12 v 115
• G q60 b 115
• Generator the fail safe function stops the engine from the standpoint of protecting it 115
• Idle operatio 115
• If the 115
• Ignition pulse generator peak voltage at 20 c 68 f 115
• Inside o 115
• Inspection see section 1 115
• Intake air temperature sensor resistance at 20 c 68 f 115
• It may cause incorrect 115
• It may cause incorrect throttle and idle valve synchronization 115
• It must be 115
• Loosening or tightening them can cause 115
• Making use of the numerical values of a situation preset in advance in the simulated program ma 115
• Malfunction indicator lamp blinks follow the self diagnostic procedures to remedy the problem 115
• Manifol 115
• Molybdenu 115
• Number 115
• Oz minimum 10 seconds 115
• Page 2 115
• Pair solenoid valve resistance at 20 c 68 f 115
• Prevent dirt and debris from entering the throttle bore fuel tube and return tube clean them using compressed ai 115
• Proceedin 115
• Programmed fuel injection 115
• Remembered however that when any abnormality is detected in four injectors and or the ignition and cam pulse 115
• Replace them with new ones 115
• Seal the cylinder head intake ports with tape or a clean cloth to keep dirt and debris from entering the intake ports after the 115
• Specifications 115
• Speed _ 115
• Starte 115
• States canada type 115
• The pgm f1 system is provided with fail safe function to secure a minimum running capability even when there is any 115
• The programmed fuel injection system is equipped with the self diagnostic system described on page 5 115
• The throttle 115
• The throttle body is factory pre se 115
• The vehicle speed sensor sends digital pulse signal to the ecm pgm fi unit and computatio 115
• Throttle and idle valve synchronization failur 115
• Throttle body has been remove 115
• Throttle body identification 115
• Throttle grip free play 115
• Trouble in the syste 115
• Upon reassembl 115
• Used a digital tester for pgm fi system inspectio 115
• V minimum 115
• Valve vacuum difference 115
• When any abnormality is detected by the self diagnosis function running capability is secured by 115
• When checking the pgm fi always follow the steps in the troubleshooting flowchart page 5 12 115
• When disassembling the programmed fuel injection parts note the location of the 0 ring 115
• Commercially available digital multimeter impedance 10 mq dcv 116
• Hgj 0020100 with 116
• Minimum 116
• Page 3 116
• Remover 14 16 mm 116
• Values 116
• Ymf mcj0400 116
• Ymf mcjo100 07ymf mcj0200 07ymf mcj0300 116
• Ymz 0010100 two required 116
• Page 4 117
• System location 117
• Page 5 118
• Bank angle sensor 119
• Battery 119
• Cam pulse generator 119
• Clutch switch 119
• Coolant temperature lcd 119
• Direct ignition coil spark plug 119
• Ect sensor 119
• Egcv and air intake valve servo motor 119
• Engine stop relay 119
• Engine stop switch sub fuse 10a 119
• Except california typ 119
• Fuel cut relay 119
• Fuel system programmed fuel injection 119
• Iat sensor 119
• Ignition pulse generator 119
• Ignition switch 119
• Injector 119
• Main fuse a 30a 119
• Main fuse b 20a 119
• Malfunction indicator lamp 119
• Neutral switch 119
• Page 6 119
• Pair check valve 119
• Pair solenoid valve 119
• Pressure regulator 119
• Service check connector 119
• Side stand switch 119
• Sub fuse 10a 119
• System diagram 119
• Tp sensor 119
• Vehicle speed sensor 119
• Bank angle sensor 120
• Battery 120
• California typ 120
• Cam pulse generator 120
• Clutch switch 120
• Coolant temperature lcd 120
• Direct ignition coil spark plug 120
• Ect sensor 120
• Egcv and air intake valve servo motor 120
• Engine stop relay 120
• Engine stop switch sub fuse 1oa 120
• Evap canister 120
• Evap purge control solenoid valve 120
• Fuel cut relay 120
• Fuel pump 120
• Iat sensor 120
• Ignition pulse generator 120
• Ignition switch 120
• Injector 120
• Main fuse a 30a 120
• Main fuse b 20a 120
• Malfunction indicator lamp 120
• Map sensor 120
• Neutral switch 120
• Page 7 120
• Pair check valve 120
• Pair solenoid valve 120
• Pressure regulator 120
• Sensor 120
• Service check connector 120
• Side stand switch 120
• Sub fuse 10a 120
• Tachometer 120
• Tp sensor 120
• Vehicle speed sensor 120
• 000 rp 121
• And determine the cause of the problem page 5 12 121
• Blinking only with 121
• Conditions the 121
• Data perform the followin 121
• Down and with the 121
• Engine off engine 121
• If the malfunction indicator blinks note how many times the malfunction indicator lamp mil blinks 121
• If the malfunction indicator lamp mil does not 121
• If you wish to read the pgm fi memory for trouble 121
• Ignition switch 121
• Illuminate and stay 121
• In any other 121
• Indicator lamp 121
• Injection 121
• Light or blink the system has no memory of 121
• Malfunction 121
• Malfunction indicator lamp mil 121
• Mil will 121
• Mil will start 121
• Page 8 121
• Place the motorcycle on its side stan 121
• Problem data 121
• Programme 121
• Remove the seat page 2 2 121
• Revs are below 121
• Run or engine 121
• Short the pgm fl system service check connector 121
• Start the engine and let it idl 121
• Stop switch in 121
• System 121
• Terminals using a jumper wir 121
• The malfunction 121
• The side stand 121
• Through 5 55 121
• Turn the ignition switch of 121
• Be erased if you turn off the ignition switch be 122
• Connecto 122
• Connector again with the jumper wir 122
• Data the mil 122
• Determine the cause of the problem page 5 12 122
• Does not blink 122
• Erased so try agai 122
• Even if the pgm 122
• Fi has memory 122
• Fore the mil starts blinkin 122
• If not the mil will not 122
• If the ecm has no self diagnosis memory data the 122
• If the ecm has self diagnosis memory data the mil 122
• If the mil blinks 20 times the data has not been 122
• Ignition switch 122
• Is runnin 122
• Jumper wire 122
• Malfunction indicator lamp mil 122
• Mil will illuminate when you turn the ignition 122
• Note how many times the mil blinks and 122
• Note that the self diagnosis memory data cannot 122
• Page 9 122
• Procedure 122
• Remove the jumper wire from the service check 122
• Self diagnosis memory data is erased if the mil 122
• Service check connector 122
• Short the service check connector of the pgm fi 122
• Start blinking 122
• Switch o 122
• Switch of 122
• System using a jumper wir 122
• The mil lights about 5 seconds 122
• The service check connector must be jumped 122
• Through 5 55 122
• Turn off and start blinkin 122
• Turn the engine stop switch to run and ignition 122
• Turn the ignition switch on 122
• Turn the ignition switch on and engine stop switch 122
• When the engine 122
• While the indicator light 122
• While the indicator lights short the service check 122
• Will start blinking when you turn the ignition switch 122
• Xmlr ein 122
• Age might be measured 123
• All spark plugs are installed correctl 123
• Avoid touching the 123
• Check all system connections before inspection 123
• Check cylinder compression and check that the 123
• Cially available digital multimeter with an 123
• Connect the peak voltage adaptor to the digital 123
• Digital multimeter 123
• Disconnect the fuel pump 3p black connecto 123
• Disconnect the fuel pump connector before check 123
• Hgj 0020100 123
• If the system is disconnected incorrect peak volt 123
• Impedance 10 m 2 dcv minimum 123
• Impedance of 10 m 2 dcv minimu 123
• Ing the peak voltag 123
• Internal impedance of the multimete 123
• Move the fuel tank rear bracket page 5 89 123
• Multimete 123
• Only or 123
• Open and support the front end of fuel tank page 123
• P black connector 123
• Page 10 123
• Peak voltage adaptor 123
• Peak voltage teste 123
• Prevent electric 123
• Remove the ecm cove 123
• Remove the fuel tank mounting bolts and then re 123
• Remove the seat pag 123
• Tester probes to 123
• The display value differs depending upon the 123
• Tor and cam pulse generator inspectio 123
• Use recommended digital multimeter or commer 123
• Use this procedure for the ignition pulse genera 123
• With commercially available digital multimeter 123
• 22p black connector 124
• 22p light gray connector 124
• A22 b12 124
• All bi 124
• Connect the ecu test harnesses between the main 124
• Disconnect the ecivi 22p black and 22p light 124
• Ecli test harness 124
• Ecu test harness 124
• For 22p black connector 124
• For 22p light gray connector 124
• Gray connectors from the uni 124
• Injection 124
• P black connector 124
• P light gray connector 124
• Page 11 124
• Shown in the illustratio 124
• The ecivi connector terminals as shown 124
• The ecm connector terminals are numbered as 124
• The test harness terminals are same layout as for 124
• Two required 124
• View from wire harness side 124
• Wire harness and we ecivi 124
• Ydoz nlcfoooo 124
• Blown pgm f1 fuse 20 a 125
• Blown sub fuse 10 a starter ignition 125
• C 194 f 125
• C 77 f 125
• Causes 125
• Engine does not start 125
• Engine operates normally 125
• Example if the indicator blinks once then two times two failures have occurre 125
• Failure codes 125
• Faulty bank angle sensor 125
• Faulty ecm 125
• Faulty ect sensor 125
• Faulty engine stop relay 125
• Faulty engine stop switch 125
• Faulty iat sensor 125
• Faulty map sensor 125
• Faulty tp sensor 125
• Follow code 12 on page 5 28 125
• Follow codes 1 and 2 on page 5 14 125
• For example a 125
• Fuel system programmed fuel injection 125
• Hard start at a low temperature 125
• Indicator 125
• Loose or poor connection of the map sen 125
• Loose or poor contact on ect sensor 125
• Loose or poor contact on iat sensor 125
• Loose or poor contact on tp sensor connec 125
• Loose or poor contacts on map sensor con 125
• Malfunction 125
• Nector 125
• No blinks 125
• Number of pgm fl 125
• Open circuit at the power input wire of the 125
• Open circuit in bank angle sensor related 125
• Open circuit in engine stop relay related wires 125
• Open circuit in engine stop switch ground 125
• Open circuit in engine stop switch related 125
• Open or short circuit in ect sensor wire 125
• Open or short circuit in iat sensor wire 125
• Open or short circuit in map sensor wire 125
• Open or short circuit in mil wire 125
• Open or short circuit in tp sensor wire 125
• Page 12 125
• Pgm fi 125
• Poor engine response when operat 125
• Second illumination and two blinks 125
• Self diagnosis 125
• Short circuit in service check connector 125
• Simulate using numerical value 125
• Sor vacuum tube 125
• Symptoms 125
• The pgm fi mil denotes the failure codes the number of blinks from 0 to 35 125
• Throttle opens 0 125
• When more than one failure occurs the mil shows the blinks in the order of lowest number to highest numbe 125
• Air intake valve servo 126
• Causes 126
• Does not hold the self diagnosis 126
• Engine does not start 126
• Engine operates normally 126
• Erator 126
• Faulty 126
• Faulty cam pulse generator 126
• Faulty egcv and 126
• Faulty egcv and air intake valve servo 126
• Faulty ignition pulse generator 126
• Faulty n 126
• Faulty o sensor 126
• Faulty vehicle speed sensor 126
• Generator connector 126
• Loose or poor contact on cam pulse gener 126
• Loose or poor contact on ignition pulse 126
• Loose or poor contact on n 126
• Loose or poor contact on vehicle speed 126
• Mil blinks 126
• Motor potentio meter voltage 126
• Nector 126
• Number of pgm fl 126
• Open or short circuit in cam pulse genera 126
• Open or short circuit in ignition pulse gen 126
• Open or short circuit in n 126
• Open or short circuit in vehicle speed sen 126
• Page 13 126
• Programmed fuel injection 126
• Prom in ecm 126
• Sensor connector 126
• Sensor heater 126
• Sor connector 126
• Symptoms 126
• Check for loose or poor contact on the map sen sor connecto 127
• Connect the map sensor connecto 127
• Connectio 127
• Disconnect the map sensor 3p connecto 127
• Fuel system programmed fuel injection 127
• Loose or poor contact on the ecm connectors 127
• Loose or poor contact on the map sensor connec 127
• Make sure the engine stop switch is in run 127
• Measure the voltage at the wire harness side con 127
• Measure the voltage between the connector ter 127
• Minals of the wire harness sid 127
• No blinks 127
• Open or short circuit in green orange wire 127
• Open or short circuit in yellow red wire 127
• Out of range 127
• Page 14 127
• Pgm fi mil 1 blink map sensor 127
• Place the motorcycle on its side stan 127
• Standar 127
• Start the engine and check that the mil blinks 127
• Turn the ignition switch o 127
• Turn the ignition switch of 127
• Turn the ignition switch off 127
• Voltage exists 127
• Yellow red 127
• Connect the map sensor 3p connecto 128
• Connect the test harness to ecm connector 128
• Connectio 128
• Disconnect the ecm connector 128
• Exists 128
• Faulty map sensor 128
• L191010101001 128
• Light green yellow green orang 128
• Loose or poor contact on the ecm connectors 128
• Measure the voltage at the test harness terminals 128
• Measure the voltage between the terminals of 128
• Open or short circuit in light green yellow wire 128
• Out of range 128
• Page 15 128
• Replace the ecm with a new one and inspect it 128
• Standar 128
• Telslelole 128
• The wire harness sid 128
• Turn the ignition switch o 128
• Turn the ignition switch of 128
• V 760 mm hg 1 013 kpa 128
• Voltag 128
• Voltage exists 128
• Absolute pressure at idle spee 129
• Body and the map sensor using a 3 way join 129
• Check the tube installation 129
• Connect the test harness to the ecm connecto 129
• Connect the vacuum gauge between the throttle 129
• Disconnect the ecm connector 129
• Disconnect the vacuum gauge and connect the 129
• Fuel system programme 129
• Out of range 129
• Page 16 129
• Pgm fl mil 129
• Standar 129
• Tube to the map senso 129
• Turn the ignition switch off 129
• Fuel system programmed fuel injection 130
• Page 17 130
• Turn the ignition switch on measure the voltage at the test harness terminals page5 9 130
• Blinks 131
• Check for loose or poor contact on the ect sen 131
• Check that the mil blink 131
• Connect the ect sensor connecto 131
• Disconnect the ect sensor 3p connecto 131
• Disconnect the ect sensor connecto 131
• Faulty ect sensor 131
• Fuel system programmed fuel injection 131
• K sq 20 c 68 f 131
• Loose or poor contact on the ect sensor connec 131
• Measure the resistance at the ect sensor termi 131
• No blinks 131
• Page 18 131
• Pgm fi mil 7 blinks ect sensor 131
• Place the motorcycle on its side stan 131
• Sensor side terminals 131
• Sor connecto 131
• Turn the ignition switch of 131
• Turn the ignition switch on 131
• Connectio 132
• Connector terminal of the wire harness side and 132
• Loose or poor contacts on the ecm connector 132
• Measure the voltage at the ect sensor connector 132
• Of the wire harness sid 132
• Open or short circuit in green orange wire 132
• Open or short circuit in pink and pink white wire 132
• Ou of range 132
• Out of range 132
• Page 19 132
• Replace the ecm with a new one and inspect it 132
• Standar 132
• Turn the ignition switch o 132
• Voltage exists 132
• Blinks 133
• Check for loose or poor contact on the tp sensor 133
• Connect the tp sensor connecto 133
• Disconnect the tp sensor 3p connecto 133
• Fuel system programmed fuel injection 133
• Ground 133
• Loose or poor contact on the ecm connector 133
• Loose or poor contact on the tp sensor connec 133
• No blinks 133
• Open or short circuit in the yellow red wire 133
• Out of range 133
• Page 20 133
• Pgm fi mil 8 blinks tp sensor 133
• Place the motorcycle on its side stan 133
• Side connector terminal and ground 133
• Start the engine and check that the mil blinks 133
• Turn the ignition switch of 133
• Turn the ignition switch on 133
• Voltage exists 133
• Connectio 134
• Connector terminal of the wire harness side and 134
• Continuity 134
• Disconnect the ecm 22p connectors 134
• Loose or poor contact on the ecm connectors 134
• Measure the voltage at the tp sensor terminals 134
• No continuity 134
• Of the wire harness sid 134
• Open or short circuit in green orange wire 134
• Out of range 134
• Page 21 134
• Red yellow 134
• Sensor 134
• Short circuit in red yellow wire 134
• Standar 134
• Turn the ignition switch of 134
• Voltage exists 134
• Yellow red 134
• Check for continuity between the test harness 135
• Cnntinuiry 135
• Connect the test harness to the ecm nonnevor 135
• Connect the tp sensor 3p connecto 135
• Connectio 135
• Connection 135
• Continuity 135
• Faulty tpsensor 135
• Measure the vokage at the test harness terminal 135
• No continuity 135
• Normal 135
• Open or short circuit in red yellow wire 135
• Out of range 135
• Page 22 135
• Red yellow 138 135
• Replace the ecm with a new one and inspect it 135
• Standar 135
• Terminal and the tp sensor connector termina 135
• Turn the ignition switch o 135
• V throttle fully closed 135
• V throttle fully open 135
• Fuel system programmed fuel injection 136
• Page 23 136
• Thus the solution is 136
• Blinks 137
• Check for loose or poor contact on the iat sensor 137
• Check that the mil blink 137
• Connect the iat sensor 2p connecto 137
• Connecto 137
• Disconnect the iat sensor 2p connecto 137
• Faulty iat sensor 137
• Loose or poor contact on the iat sensor connec 137
• Measure the resistance at the iat sensor at 2 137
• No blinks 137
• Page 24 137
• Place the motorcycle on its side stan 137
• Pom fi mil 9 blinks iat sensor 137
• Standar 137
• Turn the ignition switch of 137
• Turn the ignition switch on 137
• Fuel system programmed fuel injection 138
• Gray blue groun 138
• Open or short circuit in gray blue wire 138
• Open or short circuit in green orange wire 138
• Out of range 138
• Page 25 138
• Standar 138
• The wire harness sid 138
• Voltage exists 138
• Blinks 139
• Check for loose or poor contact on the vehicle 139
• Connect the vehicle speed sensor 3p connecto 139
• Connecto 139
• Disconnect the vehicle speed sensor 3p connec 139
• Fuel system programmed fuel injection 139
• No blinks 139
• Open or short circuit in black brown wire 139
• Out of range 139
• Page 26 139
• Pgm fi mil 11 blinks vehicle speed sensor 139
• Put the side stand down and check that the mil 139
• Sensor connector 139
• Speed sensor connecto 139
• Start the engin 139
• Turn the ignition switch of 139
• Turn the ignition switch on 139
• Voltage exists 139
• With the side stand up and keep the engine rev more than 5 000 rpm about 20 seconds or mor 139
• Connect the speed sensor 3p connecto 140
• Connect the test harness to the wire harness 140
• Connector 140
• Disconnect the ecm connector 140
• Fuel system programmed fuel injection 140
• Measure the voltage at the test harness terminals 140
• Open or short circuit in pink green wire 140
• Page 27 140
• Rear wheel off the groun 140
• Repeat 0 to 5v 140
• Replace the ecm with a new one and inspect it 140
• Shift the transmission into neutra 140
• Standar 140
• Support the motorcycle securely and place the 140
• Turning the rear wheel by han 140
• Abnormal 141
• Black white pink yellow 141
• Blinks 141
• Check for loose or poor contact on the n 141
• Check that the mil blink 141
• Connect the n 141
• Connectio 141
• Connector 141
• Disconnect the n 141
• Faulty n 141
• Fuel system programmed fuel injection 141
• Injecto 141
• Injector 141
• Injector 2p connecto 141
• Injector 2p connector and 141
• Loose or poor contact on the n 141
• Measure the resistance of the n 141
• No blinks 141
• Normal 141
• Page 28 141
• Place the motorcycle on its side stan 141
• S2 20 c 68 f 141
• Standar 141
• Turn the ignition switch of 141
• Turn the ignition switch on 141
• Battery voltage 142
• Black white 142
• Check for continuity between the n 142
• Connect the test harness to the wire harness con 142
• Connector of the wire harness side and ground 142
• Continuity 142
• Disconnect the ecm connector 142
• Faulty n 142
• Fuel system programmed fuel injection 142
• Injector 142
• Injector connecto 142
• Nector 142
• No continuity 142
• Open or short circuit in black white wire 142
• Out of range 142
• Page 29 142
• Turn the ignition switch o 142
• Turn the ignition switch off 142
• Voltage exists 142
• 00000 00 143
• 15 2 20 c 68 f 143
• A14 b6 143
• Check for continuity between the test harness 143
• Co oiozozo o zozozoz9 143
• Connectio 143
• Continuity 143
• Harness 143
• Measure the resistance 143
• No continuity 143
• O t0 i mtotow 143
• Open circuit in black white and or pink yellow 143
• Out of range 143
• Page 30 143
• Replace the ecm with a new one and inspect it 143
• Short circuit in pink yellow wire 143
• Standar 143
• Terminal 143
• Terminal and ground 143
• 20 c 68 f 144
• Black white pink blu 144
• Blinks 144
• Check for loose or poor contact on the n 144
• Check that the mil blinks 144
• Connect the n 144
• Connectio 144
• Disconnect the n 144
• Faulty n 144
• Fuel system programmed fuel injection 144
• Injecto 144
• Injector 144
• Injector 2p connecto 144
• Injector 2p connector and 144
• Injector con 144
• Loose or poor contact on the n 144
• Measure the resistance of the n 144
• Nector 144
• No blinks 144
• Normal 144
• Page 31 144
• Pgm fl mil 13 blinks n 144
• Place the motorcycle on its side stan 144
• Standar 144
• Turn the ignition switch o 144
• Turn the ignition switch of 144
• Battery voltage 145
• Black whit 145
• Black white groun 145
• Connect the n 145
• Connect the test harness to the wire harness con 145
• Connector of the wire harness side and groun 145
• Continuity 145
• Disconnect the ecm connector 145
• Faulty n 145
• Fuel system programmed fuel injection 145
• Injector 145
• Injector connector 145
• Nector 145
• No continuity 145
• Open or short circuit in black white wire 145
• Out of range 145
• Page 32 145
• Turn the ignition switch of 145
• Turn the ignition switch on 145
• Voltage exists 145
• 010101161 146
• 15 s1 20 c 68 f 146
• Check for continuity between the test harness 146
• Connectio 146
• Continuity 146
• Fuel system programmed fuel injection 146
• Measure the resistance at the test harness termi 146
• No continuity 146
• Normal 146
• Open circuit in black white and or pink blue 146
• Out of range 146
• Page 33 146
• Replace the ecm with a new one and inspect it 146
• Short circuit in pink blue wire 146
• Standar 146
• Terminal and groun 146
• 20 c 68 f 147
• Black white pink gree 147
• Blinks 147
• Check that the mil blink 147
• Connect the n 147
• Connectio 147
• Disconnect the n 147
• Faulty n 147
• Fuel system programmed fuel injection 147
• Injecto 147
• Injector 147
• Injector 2p connecto 147
• Injector 2p connector and 147
• Injector con 147
• Loose or poor contact on the n 147
• Measure the resistance of the n 147
• Nector 147
• No blinks 147
• Page 34 147
• Pgm fi mil 14 blinks n 147
• Place the motorcycle on its side stan 147
• Standar 147
• Turn the ignition switch o 147
• Turn the ignition switch of 147
• Battery voltage 148
• Black white 148
• Check for continuity between the n 148
• Connect the n 148
• Connector of the wire harness side and groun 148
• Continuity 148
• Disconnect the ecm connector 148
• Faulty n 148
• Fuel system programmed fuel injection 148
• Injecto 148
• Injector 148
• Injector connecto 148
• No continuity 148
• Open or short circuit in black white wire 148
• Out of range 148
• Page 35 148
• Turn the ignition switch o 148
• Turn the ignition switch of 148
• Voltage exists 148
• Fuel system programmed fuel injection 149
• Page 36 149
• Abnormal 150
• Black white pink blac 150
• Blinks 150
• Check for loose or poor contact on the n 150
• Check that the mil blink 150
• Connect the n 150
• Connectio 150
• Disconnect the n 150
• Faulty n 150
• Injecto 150
• Injector 150
• Injector 2p connecto 150
• Injector 2p connector and 150
• Injector con 150
• Loose or poor contact on the n 150
• Measure the resistance of the n 150
• Nector 150
• No blinks 150
• Normal 150
• Page 37 150
• Place the motorcycle on its side stand 150
• Sq 20 c 68 f 150
• Standar 150
• Turn the ignition switch of 150
• Turn the ignition switch on 150
• Battery voltage 151
• Black white r ground 151
• Check for continuity between the n 151
• Connect the n 151
• Connect the test harness to the wire harness con 151
• Connector of the wire harness side and groun 151
• Continuity 151
• Disconnect the ecm connector 151
• Faulty n 151
• Fuel syste 151
• Injector 151
• Injector connecto 151
• Measure the voltage between the n 151
• Nector 151
• No continuity 151
• Open or short circuit in black white wire 151
• Out of range 151
• Page 38 151
• Standar 151
• Turn the ignition switch of 151
• Turn the ignition switch on 151
• Voltage exists 151
• 15 q 20 c 68 f 152
• Check for continuity between the test harness 152
• Connectio 152
• Continuity 152
• Fuel system programmed fuel injection 152
• Harness 152
• Measure 152
• Minim a 152
• No continuity 152
• Normal 152
• Open circuit in black white and or pink black 152
• Out of range 152
• Page 39 152
• Replace the ecm with a new one and inspect it 152
• Resistance 152
• Short circuit in pink black wire 152
• Standar 152
• Terminal 152
• Terminal and groun 152
• Winton 152
• Blinks 153
• Check for loose or poor contact on the cam pulse 153
• Check the continuity between the cam pulse gen 153
• Connect the cam pulse generator 2p connector 153
• Connectio 153
• Continuity 153
• Disconnect the cam pulse generator 2p connec 153
• Erator connector terminal and ground 153
• Faulty cam pulse generator 153
• Fuel syste 153
• Generator 2p connecto 153
• Loose or poor contact on the cam pulse genera 153
• Mil blink 153
• No blinks 153
• No continuity 153
• Page 40 153
• Place the motorcycle on its side stan 153
• Standar 153
• Switch of 153
• Tor 2p connecto 153
• Turn the ignition switch of 153
• Turn the ignition switch off and the engine stop 153
• Turn the ignition switch on and check that the 153
• White ground 153
• B22 groun 154
• Connect the cam pulse generator 2p connecto 154
• Connect the test harness to ecm connector 154
• Connectio 154
• Crank the engine 154
• Crank the engine with the starter motor and 154
• Disconnect the ecm connector 154
• Faulty cam pulse generator 154
• Fuel system programmed fuel injection 154
• Measure the cam pulse generator peak voltage at 154
• Measure the cam pulse generator peak voltage at the cam pulse generator 2p connecto 154
• Open circuit in white yellow and or gray wire 154
• Out of range 154
• Page 41 154
• Replace the ecm with a new one and inspect it 154
• Standar 154
• Starter 154
• The test harness terminal 154
• V minimum 20 c 68 f 154
• Ator 2p connector 155
• Blinks 155
• Continuity 155
• Faulty ignition pulse generator 155
• Fuel system programmed fuel injection 155
• Loose or poor contact on the ignition pulse gener 155
• Mil blink 155
• No continuity 155
• Page 42 155
• Pgm fi mil 19 blinks ignition pulse generator 155
• Place the motorcycle on its side stan 155
• Turn the ignition switch off 155
• Yellow ground 155
• Age at the ignition pulse generator 2p connecto 156
• Age at the test harness terminal 156
• Connect the ignition pulse generator 2p connec 156
• Connect the test harness to ecm connector 156
• Connectio 156
• Crank the engine with the starter motor and 156
• Disconnect the ecm connector 156
• Engine 156
• Faulty ignition pulse generator 156
• Measure the ignition pulse generator peak volt 156
• Normal 156
• Open circuit in white yellow wire 156
• Open circuit in yellow wire 156
• Out of range 156
• Page 43 156
• Replace the ecm with a new one and inspect it 156
• Standar 156
• Starter 156
• V minimum 20 c 68 f 156
• Yellow white yello 156
• Check for loose or poor contact on the 157
• Check the continuity between the 157
• Check the continuity between the test harness 157
• Connect the test harness to ecm connector 157
• Connectio 157
• Connector terminal and groun 157
• Continuity 157
• Disconnect the 157
• Disconnect the ecm connectors 157
• Ground 157
• No continuity 157
• Open circuit in 157
• Orange whit 157
• Orange white a5 157
• Page 44 157
• Sensor 157
• Sensor connecto 157
• Sensor connector termina 157
• Sensor orange white wire 157
• Short circuit in 157
• Standar 157
• Terminal and 157
• Turn the ignition switch of 157
• Check the fuel supply system if the system is 158
• Check the voltage between the test harness 158
• Connect the 158
• Connectio 158
• Correct replace the ecm and inspect agai 158
• Engine up to coolant temperature is 80 c 176 f 158
• Faulty 158
• Fuel system programmed fuel injection 158
• Operate the throttle grip and snap the engine 158
• Out of range 158
• Page 45 158
• Potstotow 158
• Re00 707 e 158
• Sensor 158
• Sensor connecto 158
• Speed from idle to 5 000 rp 158
• Standar 158
• Terminal 158
• Turn the ignition switch on and warm up the 158
• V minimum 158
• With the throttle fully ope 158
• With the throttle quickly closed 158
• 40 c_2 159
• Blinks 159
• Check for loose or poor contact on the 0 159
• Connect the 159
• Connectio 159
• Connecto 159
• Connector white terminal 159
• Disconnect the 159
• Faulty 159
• Fuel system programmed fuel injection 159
• Out of range 159
• Page 46 159
• Pgm fl mil 23 blinks 159
• Sensor 159
• Sensor 4p connecto 159
• Sensor connecto 159
• Sensor connector 159
• Sensor heater california type only 159
• Short the service check connector pag 159
• Standar 159
• Start the engine and check that the mil blink 159
• Turn the ignition switch of 159
• Turn the ignition switch off 159
• Battery voltage 160
• Black white black gree 160
• Check for continuity white terminal and groun 160
• Continuity 160
• Disconnect the ecm 22p connector 160
• Faulty 160
• Fuel system programmed fuel injection 160
• Inspect again 160
• Measure the voltage at the 160
• Ness side connector terminal 160
• No continuity 160
• No voltage 160
• Open circuit in 160
• Page 47 160
• Replace the ecm and 160
• Sensor 160
• Sensor wire har 160
• Sor black green wires 160
• Turn the ignition switch o 160
• Turn the ignition switch of 160
• Turn the ignition switch on 160
• White ground 160
• Battery voltage 161
• Fuel syste 161
• Ness side connector terminal and ground 161
• No voltage 161
• Open circuit in black white wire between the 0 161
• Page 48 161
• Programmed fuel injection 161
• Sensor 4p connector 161
• Sensor and engine stop relay 161
• Sensor wire har 161
• Turn the ignition switch of 161
• Fuel system programmed fuel injection 162
• Page 49 162
• Blinks 163
• Check for loose or poor contact of the ecm con nector 163
• Connector pag 163
• Except 33 blinks 163
• Fuel system programmed fuel injection 163
• Mil blink 163
• Other than 33 blinks 163
• Page 50 163
• Short the service check connector with a jumper 163
• Turn the ignition switch of 163
• Turn the ignition switch on and check that the 163
• Wire page 5 8 163
• Blinks 164
• Except 33 blinks 164
• Fuel system programmed fuel injection 164
• Mil blink 164
• Page 51 164
• Replace the ecm 164
• Blinks 165
• Connect the servo motor 6p connecto 165
• Connector terminals 165
• Disconnect the servo motor 6p connecto 165
• Faulty servo motor 165
• Fuel system programmed fuel injection 165
• K s 20 c 68 f 165
• Loose or poor contact on the servo motor 6p con necto 165
• Mil blink 165
• Motor 6p connecto 165
• No blinks 165
• Onnectio 165
• Page 52 165
• Pgm fi mil 34 blinks egcv and air intake valve servo motor potentiometer voltage 165
• Place the motorcycle on its side stan 165
• Switch of 165
• Turn the ignition switch of 165
• Turn the ignition switch off and the engine stop 165
• Turn the ignition switch on and check that the 165
• 5 k4 20 c 68 f 166
• A12 blue 166
• Abnormal 166
• Check for continuity between the test harness ter 166
• Connect the test harness to the wire harness con 166
• Connectio 166
• Continuity 166
• Disconnect the ecm connector 166
• Faulty servo motor 166
• Fuel system programmed fuel injection 166
• Green orang 166
• Light green pink 166
• Measure the resistance at the servo motor 6p con 166
• Minal and servo motor 6p connector terminals of 166
• Nector 166
• Nector terminal 166
• No continuity 166
• Open circuit in related wire 166
• Page 53 166
• Replace the ecm with a new one and inspect it 166
• The wire harness sid 166
• Blinks 167
• Check for loose or poor contact on the servo 167
• Check the intake exhaust valve and cable 167
• Connect the servo motor 6p connecto 167
• Disconnect the control cables from the servo 167
• Disconnect the servo motor 6p connecto 167
• Disconnect the servo motor 6p connector 167
• Fuel system programmed fuel injection 167
• Loose or poor contact on the servo motor 6p con 167
• Mil blink 167
• Motor 6p connecto 167
• Nector 167
• No blinks 167
• Page 54 167
• Place the motorcycle on its side stan 167
• Switch of 167
• Turn the ignition switch of 167
• Turn the ignition switch off and the engine stop 167
• Turn the ignition switch on and check that the 167
• Check for continuity between the test harness 168
• Connect the 12 v battery to the servo motor 168
• Connect the test harness to the wire harness con 168
• Connectio 168
• Connector terminals and check the servo motor 168
• Continuity 168
• Disconnect the ecm connector 168
• Faulty servo motor 168
• Fuel system programmed fuel injection 168
• Functio 168
• Nector 168
• No continuity 168
• Of the wire harness sid 168
• Open circuit in related wire 168
• Page 55 168
• Remove the servo motor page 5 86 168
• Replace the ecm with a new one and inspect it 168
• Terminal and servo motor 6p connector terminals 168
• Always replace the sealing washers when the 169
• And plug the vacuum tub 169
• Battery termina 169
• Before disconnecting fuel tubes release the fuel 169
• Cover the fuel tube banjo bolt with a rag or shop 169
• Disconnect the battery negative cable from the 169
• Disconnect the pressure regulator vacuum tube 169
• Fuel line inspection 169
• Fuel pressure inspection 169
• Fuel tube banjo bolt is removed or loosene 169
• Notice 169
• Open and support the front end of fuel tank page 169
• P ressure regulator 169
• Page 56 169
• Pressure by loosening the fuel tube banjo bolt at 169
• Remaining fuel using a approved gasoline container 169
• Remove the seat pag 169
• Slowly loosen the fuel tube banjo bolt and catch the 169
• The fuel tan 169
• 0040002 170
• 200 100 rpm 170
• After inspection remove the fuel tube banjo bolt 170
• Always replace the 170
• And reinstall and tighten the original fuel tube 170
• Banjo bolt 170
• Banjo bolt 12 mm 170
• Banjo bolt is 170
• Banjo bolt using the new sealing washers 170
• Connect the battery negative cabl 170
• Connect the pressure regulator vacuum tub 170
• Fuel line leaking clogged fuel filter 170
• Fuel pressure gauge 170
• Fuel pump page 5 59 170
• Fuel system programmed fuel injection 170
• Idle spee 170
• If the fuel pressure is higher than specified 170
• If the fuel pressure is lower than specified 170
• Inspect 170
• Install the removed parts in the reverse order of 170
• Kgf cmz 50 psi 170
• Loosene 170
• M 16 ib 170
• P ssure regulator 170
• Page 57 170
• Parts n 170
• Pd6 003 170
• Pinched or clogged fuel return tube 170
• Pp4 e02 170
• Pressure gauge with the following honda genuine 170
• Pressure regulator 170
• Read the fuel pressure at idle speed 170
• Remova 170
• Remove the fuel tube banjo bolt and attach the fuel 170
• Removed or 170
• Sealing washer 12 mm 170
• Sealing washer 6 mm 170
• Sealing washers 170
• Start the engin 170
• The followin 170
• When the fuel tube 170
• After inspection connect the fuel return tube 171
• Amount of fuel flo 171
• And drain the gasoline 171
• Approved gasoline container underneath the tube 171
• Clogged fuel filter 171
• Cm 6 us oz 171
• Disconnect the fuel return tube at the pressure 171
• Followin 171
• Fuel flow inspection 171
• Fuel pump page 5 59 171
• Gasoline will spill out from the tub 171
• If the fuel flow is less than specified inspect the 171
• Jump the brown and black white wire terminals of 171
• Measure the amount of fuel flow 171
• Open and support the front end of fuel tank page 171
• Oz minimum 10 seconds 171
• Page 58 171
• Pinched or clogged fuel tube and fuel return tube 171
• Place an 171
• Pressure regulator 171
• Regulator plug the pressure regulator inlet join 171
• Relay connecto 171
• Remove the ecm cover and disconnect the fuel cut 171
• Remove the seat pag 171
• Start the engine and check for leaks 171
• The wire harness side using a jumper wire 171
• Turn the ignition switch on for 10 second 171
• When the fuel return tube is disconnected 171
• Wipe off spilled out gasolin 171
• Always replace the sealing washers when the 172
• Bank angle sensor page 5 88 172
• Before disconnecting the fuel tube release the 172
• Bolt at the fuel tan 172
• Brown gree 172
• Connectio 172
• Disconnect the fuel pump 3p black connecto 172
• Ecm page 5 89 172
• Engine stop relay page 5 89 172
• Engine stop switch page 19 18 172
• Follow 172
• Fuel cut relay page 5 60 172
• Fuel pressure by loosening the fuel tube banjo 172
• Fuel pump 172
• Fuel pump operates for a few second 172
• Fuel tube banjo bolt is removed or loosene 172
• If the fuel pump does not operate inspect as 172
• If there is battery voltage replace the fuel pum 172
• If there is no battery voltage inspect the followin 172
• Li iti 172
• Main fuel 30a 172
• Notice 172
• Open and support the front end of fuel tank page 172
• P black connector 172
• Page 59 172
• Removal 172
• Remove the fuel pump assembly and packin 172
• Remove the fuel pump mounting nut 172
• Remove the fuel tank page 5 61 172
• Sub fuse 10a 20a 172
• There should be battery voltage for a few second 172
• Turn the ignition switch on and confirm that the 172
• Turn the ignition switch on and measure the volt age between the terminal 172
• 12 n m 173
• Always replace 173
• Disconnect the fuel cut relay 4p connector remove 173
• Disconnect the fuel tubes from the fuel filter 173
• Fuel cut relay 173
• Fuel filter 173
• Fuel pump 173
• Fuel pump assembly 173
• Fuel tubes 173
• Inspection 173
• Install and tighten the fuel pump mounting nuts in 173
• Install the fuel filter in the reverse order of remova 173
• Install the fuel pump being careful not to damage the fuel pump wir 173
• J a rte 173
• M 9 lb 173
• New on 173
• Note the direction 173
• Of the fuel filte 173
• Packii 173
• Packing with a 173
• Page 5 89 173
• Page 60 173
• Place a new packing onto the fuel tan 173
• Programmed fuel injection 173
• Remove the fuel tank rear bracket and ecm cover 173
• Remove the screws and fuel filte 173
• The fuel cut rela 173
• The sequence show 173
• Battery is connecte 174
• Black white brown 174
• Bolt collar 174
• Brown black black white 174
• Connect the 12 v battery to the following fuel cut 174
• Connect the ohmmeter to the fuel cut relay connec 174
• Connected replace the fuel cut relay 174
• Fuel cut relay 174
• Fuel tank 174
• If there is no continuity when the 12 v battery is 174
• Page 61 174
• Relay connector terminal 174
• Removal 174
• Remove the fuel tank front mounting bolts and 174
• Remove the fuel tank rear mounting bolt and colla 174
• Temporarily install the fuel tank rear mounting bolt 174
• There should be continuity only when the 12 v 174
• Tor terminal 174
• Washer 174
• Air ven tube 175
• Always hold the fuel pipe nut while removing the 175
• And sealing washers to the fuel tube banjo then 175
• Connecto 175
• Disconnect the fuel pump reserve sensor 3p black 175
• Disconnect the fuel tank air vent tube and overflow 175
• Do not apply excessive force to the 175
• Fuel pipe 175
• Fuel pipe nut 175
• Fuel tube 175
• Fuel tube sealing nu 175
• Hi lcuw fube 175
• Hold the fuel pipe nut and remove the fuel tube 175
• Lift and support the front of the fuel tank and 175
• Mm bolt pitch 175
• P black connector 175
• Page 62 175
• Release the fuel pressure page 5 56 175
• Sealing nut 175
• Sealing nut and sealing washers then disconnect 175
• Suitable support 310 mm 175
• Support it using a suitable support 310 mm 175
• Temporarily install a 1 175
• The fuel tub 175
• Tighten the sealing nu 175
• Banjo bolt 176
• Be careful not to 176
• Damage the fuel 176
• Disconnect the fuel return tube at the pressure 176
• Disconnect the fuel return tube from the fuel pump 176
• Do not apply excessive force to the fuel pipe 176
• F ifs return tube 176
• Fuel system programmed fuel injection 176
• Fuel tank 176
• Fuel tube 176
• Page 63 176
• Place the fuel tank upside dow 176
• Refer to page 5 59 for fuel pump removal 176
• Regulato 176
• Remove the fuel tank from the frame 176
• Remove the fuel tank rear mounting bolt and them 176
• Remove the fuel tube banjo bolt and sealing 176
• Return tube 176
• Washers then remove the fuel tube from the fuel 176
• Air vent tube 177
• Align the fuel tube 177
• Connect the fuel return tube to the fuel pump 177
• Connect the fuel tube to the fuel pump with new 177
• Do not apply excessive force to the fuel pip 177
• Eyelet joint with 177
• Fuel return tube 177
• Fuel system programmed fuel injection 177
• Fuel tube 177
• Iel return tube 177
• Install and tighten the fuel tube banjo bolt to the 177
• Install the fuel tank onto the frame temporarily 177
• Install the fuel tank rear mounting bolt and support 177
• Lbf ft 177
• Page 64 177
• Regulator 177
• Sealin 177
• Sealing washers 177
• Specified torque 177
• Suitable support 310 mm 177
• The front end of fuel tank using a suitable support 177
• The stopper on the 177
• Tube to the fuel tan 177
• Tue pum 177
• Always hold the fuel pipe nut while tightening 178
• Bolt collar 178
• Connect the fuel pump reserve sensor 3p black 178
• Connect the fuel tube banjo to the throttle body 178
• Connecto 178
• Do not apply excessive force to the fuel pip 178
• Fueltube 178
• Install the fuel tank mounting collar and bol 178
• Mounting bolt 178
• Page 65 178
• R black connector 178
• Remove the supporting tool and close the fuel tan 178
• Sealing nut 178
• Sealing washers 178
• The fuel tube sealing nut 178
• The specified torqu 178
• Throttle body install and tighten the sealing nut to 178
• Washers then tighten the front and rear fuel tank 178
• While pushing the fuel tube banjo stopper to the 178
• With new sealing washer 178
• A senser cc l 179
• Air cleaner hc1 j l 179
• Air cleaner housing 179
• Air suction tube 179
• Bracket and disconnect the intake valve control 179
• Cable from the servo motor pulle 179
• Control valve air suction tube from the air cleaner 179
• Disassembly assembl 179
• Disconnect the crankcase breather tube and pair 179
• Disconnect the map sensor connector and vacuum tub 179
• Fuel system programme 179
• Housin 179
• Ing screws then remove the air funnel 179
• Page 66 179
• Removal 179
• Remove the air cleaner element pag 179
• Remove the air cleaner housing 179
• Remove the air funnel air cleaner housing mount 179
• Remove the egcv and air intake valve servo motor mounting bol 179
• Remove the servo motor assembly from the 179
• See page 5 107 for intake air control valve 179
• Air cleaner housih 180
• Air suction tube 180
• And pair 180
• Bracket then 180
• Connect the crankcase breather tube 180
• Connect the map sensor connector and vacuum 180
• Connect the variable air intake control cable to the 180
• Control 180
• Control valve air suction tube to the air cleaner 180
• Fuel system programmed fuel injection 180
• Housin 180
• I hem t 180
• Install and tighten the air funnel air cleaner housing 180
• Install the air cleaner element pag 180
• Install the air funnels in their proper location 180
• Install the servo motor onto the 180
• Installation 180
• Intake air 180
• Mounting screw 180
• Nm fig ji cvab 180
• Page 67 180
• Properly then install the air cleaner housing onto 180
• Servo motor pulle 180
• Servo motor rh1ll 180
• The throttle bod 180
• Tighten the bolt securely 180
• Variable 180
• Air cleaner housing page 5 66 181
• Always replace the sealing washers when the 181
• Been remove 181
• Before disconnecting the fuel tube release the 181
• Bracke 181
• Close after the 181
• Connecto 181
• Disconnect the throttle body sub harness multi 181
• Disconnect the throttle cable ends from the throttle 181
• Disconnect the tp sensor connector and fuel 181
• Do not snap the 181
• Drain the coolant from the cooling system page 181
• Fast idle wax unit water hoses from the wax unit 181
• Fuel pressure by loosening the fuel tube banjo 181
• Fuel syste 181
• Fuel tank page 5 61 181
• Fuel tube banjo bolt is removed or loosene 181
• Full open to full 181
• If you will not be disassembling the throttle body 181
• Incorrect idle 181
• Injector connector 181
• Loosen the hose band screws and disconnect the 181
• May cause 181
• Operation 181
• Page 68 181
• Removal 181
• Remove the followin 181
• Remove the throttle cable guide bracket mounting 181
• Remove the throttle stop screw knob from the 181
• Throttle body 181
• Throttle cable has 181
• Throttle valve from 181
• Wax l nl 181
• Been remove 182
• Clean cloth to keep dirt and debris from entering the intake ports after the throttle body has been 182
• Do not damage the throttle bod 182
• Do not disassemble in a way other than shown in this manua 182
• Do not hold the fuel pipe on the throttle body while 182
• Do not loosen or tighten the white painted bolts and screws of the throttle body loosening or 182
• Do not snap the 182
• Fuel injection 182
• Fuel system programme 182
• Incorrect idle 182
• Insulator band screws 182
• Insulators 182
• It may cause incorrect throttle and idle valve synchronizatio 182
• Loosen the engine side insulator band screws 182
• May cause 182
• Notice 182
• Operation 182
• Page 69 182
• Remove 182
• Remove the insulators from the throttle body 182
• Remove the throttle body from the cylinder hea 182
• Removing the throttle bod 182
• Seal the cylinder head intake ports with tape or a 182
• The throttle body is factory pre se 182
• Throttle body 182
• Throttle valve from 182
• Tightening them can cause throttle and idle valve synchronization failur 182
• Top vie 182
• Wiilml 182
• Ibf ft 183
• Injection 183
• Page 70 183
• Programme 183
• Rear vie 183
• Starter valve link vie 183
• Throttle drum vie 183
• Throttle link vie 183
• White painted 183
• Apply oil to the insulator inside surfaces for ease of 184
• California typ 184
• Check the insulator band angl 184
• Except california typ 184
• Fuel system programmed fuel injection 184
• Install the throttle body onto the cylinder head 184
• Installation 184
• Installin 184
• Insulator band screws 184
• Insulators 184
• Notice 184
• Page 71 184
• Routing 184
• The fuel pipe on the throttl 184
• The throttl 184
• Throttle body 184
• Throttle body installatio 184
• Throttle body vacuu 184
• Band distance is 12 1 mm 185
• Body then tighten the bolts to the specified torque 185
• Connect the fast idle wax unit water hoses to the 185
• Connect the fuel injector connectors and tp sensor 185
• Connector 185
• Diagram page 1 23 185
• Fuel system programmed fuel injection 185
• Install the removed parts in the reverse order o 185
• Install the throttle cable guide bracket to the throttle 185
• Insulato 185
• Page 72 185
• Remova 185
• Route the injector sub harness referring the wiring 185
• So that the insulator 185
• Tighte 185
• Tsracket 185
• Unit then tighten the tube bands securel 185
• Wa x u n i 1 185
• Confirm the injector operating sounds with a 186
• Fuel injector 186
• Fuel pipe assembl 186
• Fuel syste 186
• Injector 186
• Operates 186
• Page 73 186
• Removal 186
• Remove the bolts and fuel pipe assembl 186
• Remove the injectors from the fuel pip 186
• Remove the seal ring o ring and cushion rin 186
• Remove the throttle body page 5 68 186
• Replace 186
• Seal ring 186
• Sounding rod or stethoscop 186
• Start the engine and let it idl 186
• And 0 ring with 187
• Apply oil to the new 0 rin 187
• Being careful not to damage the o rin 187
• Being careful not to damage the seal ring 187
• Careful not to damage the 0 ring and cushion rin 187
• Cushion ring 187
• Fuel injector 187
• Fuel injectors 187
• Fuel pipe assembly 187
• Fuel pipe asstimbl r 187
• Fuel syste 187
• Install and tighten the fuel pipe mounting bolts to 187
• Install the fuel injectors into the fuel pipe being 187
• Install the fuel pipe assembly onto the throttle body 187
• Install the new seal ring cushion ring and o rin 187
• Install the throttle body page 5 71 187
• M 7 ib 187
• New ones as a se 187
• O ring 187
• Page 74 187
• Replace the seal 187
• Ring cushion ring 187
• Seal ring 187
• The specified torqu 187
• And adjusting nut 188
• Connect the vacuum tube to the pressure regulato 188
• Disconnect the vacuum tube from the pressure 188
• Do not apply excessive force to the fuel pipe 188
• Do not loosen or 188
• Fast idle wax unit 188
• Hold the fuel pipe securely remove the pressure 188
• Hold the fuel pipe securely tighten the pressure 188
• Install a new o ring into the pressure regulator 188
• Install the pressure regulator onto the fuel pip 188
• M 7 ib 188
• O ring 188
• Page 75 188
• Pressure regulator 188
• Regulato 188
• Regulator mounting bolts then remove the pres 188
• Regulator mounting bolts to the specified torque 188
• Remove the wax 188
• Remove the wax unit mounting screw 188
• Screws 188
• Sure regulato 188
• Unit shaft lock nut 188
• Vacuum 188
• Wax unit 188
• Element cover 189
• Page 76 189
• Release the wax unit shaft joint piece from the wax 189
• Remove the three wax element cover mounting 189
• Remove the wax element spring seat and compres 189
• Return spring for fatigue or damag 189
• Screws in a criss cross pattern in 2 3 step 189
• Sion sprin 189
• Spring 189
• Spring seat 189
• Unit link arm then remove the wax unit assembl 189
• Visually inspect the wax element for damage and 189
• Wax element 189
• Assembly 190
• Element cover 190
• Fuel system programmed fuel injection 190
• Install a new 0 ring into the groove of the wax element cove 190
• Install and tighten the wax unit mounting screws to 190
• Install new 0 rings onto the wax element grooves 190
• Install the wax element cover and mounting screw 190
• Install the wax element spring seat and compres 190
• Install the wax unit shaft joint piece to the wax unit 190
• Joint pie f 190
• Link ar 190
• O ring 190
• Page 77 190
• Sion sprin 190
• Spring 190
• Spring seat 190
• The specified torqu 190
• Tighten the screws in a criss cross pattern in 2 3 190
• 2 starter valv 191
• Ah i t 191
• Assembl 191
• Loosen the lock nut and remove the starter valve 191
• Number of turns until it seats lightl 191
• Page 78 191
• Programmed fuel injection 191
• Record the number of turn 191
• Remove the fast idle wax unit page 5 75 191
• Remove the fuel pipe and injectors page 5 73 191
• Remove the screw and fast idle wax unit link ar 191
• Remove the starter valve arm screws and starter 191
• Remove the starter valve arm screws and starter valve arm 191
• Starter valv 191
• Starter valve 191
• Turn each starter valve adjusting screw in counting 191
• Valve ar 191
• Available 192
• Carburetor 192
• Clean the starter valve bypass using compressed 192
• Cleaners to the 192
• Collars 192
• Commercially 192
• Do not apply 192
• Fuel pipe 192
• Fuel system programmed fuel injection 192
• Injector 192
• Inside of the 192
• Page 79 192
• Pressure regulator 192
• Remove the starter valve shaft three collars and 192
• Spring 192
• Star tie 192
• Starter valve 192
• Thrnnic 192
• Throttle bore 192
• Thrust spring 192
• Val1ve shaft 192
• Which is coated 192
• With molybdenum 192
• 4 starter valv 193
• 4 starter valve 193
• Compress the thrust spring and install the n 193
• H ring 193
• Ibf ft 193
• Injection 193
• Install and tighten the starter valve arm mounting 193
• Install the 193
• Install the starter valve assembly into the valve 193
• Page 80 193
• Programme 193
• Screws to the specified torque 193
• Sta i er 193
• Starte 193
• Starter valve arm onto the starter valves 193
• Three collars thrust spring and starter 193
• Tighten the starter valve lock nut to the specified 193
• Valve shaft 193
• 2 starter valv 194
• Change 194
• Connect the tachomete 194
• Connect the vacuum gauge adaptors to the vacuum 194
• Fuel system programmed fuel injection 194
• Install and tighten the starter valve arm mounting 194
• Install the fast idle wax unit link arm and tighten the 194
• Install the fast idle wax unit page 5 77 194
• Install the no 1 2 starter valve arm to the starter 194
• Install the throttle body page 5 71 194
• Joints then connect the tubes to the vacuum gauge 194
• Open and support the front end of fuel tank page 194
• Page 81 194
• Remove the vacuum joint screw 194
• Screw to the specified torqu 194
• Screws to the specified torqu 194
• Smaller that will accurately indicate 50 rpm 194
• Starter valv 194
• Starter valve 194
• Starter valve synchronization 194
• Synchronize the starter valve with the engine at 194
• The normal operating temperature and with the 194
• Then back it out as noted during removal 194
• Transmission in neutra 194
• Turn the starter valve screw until it seats lightly 194
• Use a tachometer with graduations of 50 rpm or 194
• Adjust each intake vacuum pressure with the n 195
• Adjusted it is the 195
• Air suction hose 195
• Base starter valv 195
• Cylinde 195
• Disconnect 195
• Hoses to the reed valve cover 195
• Idle spee 195
• Page 82 195
• Pair ai 195
• Pair reed valve cover 195
• Reed valve covers and plug the cove 195
• Remove the plugs and connect the pair air suction 195
• Start the engine and adjust the idle speed 195
• Starter 195
• Suction hose 195
• Valve cannot be 195
• 1 650 3 300 4 950 6 600 feet 196
• 200 100 rpm 196
• Adjust the idle speed if the idle speed differs from 196
• Check the sea level measurement and be sure that 196
• Connect the test harness to the ecm pag 196
• Distance above sea level because the 196
• Idle spee 196
• Install and tighten the intake port vacuum joint 196
• Map sensor 196
• Measure the voltage at the test harness terminals 196
• Output 196
• Page 83 196
• Remove the vacuum gauge and adaptor 196
• Screws to the specified torqu 196
• The map sensor output voltage above is meas 196
• The map sensor output voltage is affected by the 196
• The measured voltage falls within the specified 196
• The specified spee 196
• Throttle stop screw 196
• Ured under the standard atmosphere 1 atm 1 030 196
• Vacuum joint screws 196
• Voltage is changed by atmospher 196
• Acttri ionii 197
• Cleaner housin 197
• Cleaner housing cover 197
• Disconnect the iat sensor connecto 197
• Disconnect the map sensor connecto 197
• Disconnect the vacuum tub 197
• Fuel system programmed fuel injection 197
• Iat sensor 197
• Installation is in the reverse order of remova 197
• Installation is in the reverse order of removal 197
• Map sensor 197
• Nnector 197
• Open and support the front end of fuel tank page 197
• Page 84 197
• Remove the screw and map sensor from the air 197
• Remove the screws and iat sensor from the air 197
• Sco re 197
• Always replace a 198
• Cam pulse generator 198
• Connect the ect sensor connector 198
• Connecto 198
• Cylinder hea 198
• Disconnect the cam pulse generator 2p natural 198
• Disconnect the ect sensor connector from the 198
• Drain the coolant from the system pag 198
• Ect sensor 198
• Ect sf ns 198
• Eiv or 198
• Engine is col 198
• Fill the cooling system with recommended coolant 198
• Install the new sealing washer and ect senso 198
• Ir1j ction 198
• Open and support the front end of fuel tank page 198
• P natural connector 198
• Page 6 5 198
• Page 85 198
• Remove the air cleaner housing page 5 66 198
• Remove the bolt and cam pulse generator from the 198
• Remove the ect sensor and sealing washe 198
• Replace the ect 198
• Sealing washer 198
• Sensor while the 198
• Tighten the ect sensor to the specified torqu 198
• U vvasher 198
• With a new one 198
• And main wire harnes 199
• Check the connector for loose or corroded termi 199
• Connect the ecu test harness between the ecm 199
• Disconnect the ecm 22p black and 22p light 199
• Ecu test harness 199
• Fuel system programme 199
• Gray connector 199
• If the measurement is out of specification check 199
• Input voltage inspection 199
• Inspection 199
• Install and tighten the mounting bolt securely 199
• Install the cam pulse generator into the cylinder 199
• Install the new 0 ring onto the cam pulse generato 199
• Install the removed parts in the reverse order of 199
• Loose connection of the ecm multi connector 199
• Nals using a digital multimete 199
• Nect the 2p natural connecto 199
• Open circuit in wire harness 199
• Ot t t tw 199
• P natural connector 199
• Page 86 199
• Record the input voltage at the test harness termi 199
• Removal 199
• Remove the ecm cover page 5 89 199
• Route the cam pulse generator wire properly con 199
• Standar 199
• The followin 199
• Tp sensor 199
• Turn the ignition switch on and measure and 199
• Two required 199
• Ymz 0010100 199
• At throttle fully closed 200
• At throttle fully open 200
• Calculate result comparison 200
• Check for continuity between the ecm and tp 200
• Circuit in wire harnes 200
• Compare the measurement to the result of the fol 200
• Connection 200
• Continuity inspection 200
• Cord the output voltage at the test harness termi 200
• Cord the output voltage with the throttle fully closed 200
• Disconnect the ecm 22p light gray connector and 200
• Fuel system programmed fuel injection 200
• If there is no continuity check the open or short 200
• Lowing calculatio 200
• Measured input voltage x 200
• Oe0s0 00z0z0z0z 200
• Open and support the front end of fuel tank page 200
• Opened graduall 200
• Output voltage inspection with throt 200
• P light gray connector 200
• Page 87 200
• Roe egos 200
• T0tr0tototst0 200
• The sensor is normal if the measurement output 200
• The sensor is normal if the throttle closed output 200
• The tp sensor 3p connector 200
• Tle fully closed 200
• Tle fully open 200
• Turn the ignition switch on and measure and re 200
• Using an analog meter check that the needle of the 200
• Voltage measured in step 2 is within 10 of vo 200
• Voltage measured in step 3 is within 10 of vc 200
• Voltmeter swings slowly when the throttle is 200
• With the throttle fully closed 200
• With the throttle fully ope 200
• Age between the following terminals of the bank 201
• Angle sensor connector with the connector connec 201
• Approxim 201
• Approximatery 201
• Bank angle position 201
• Bank angle sensor 201
• Battery voltage 201
• Connect the bank angle sensor 3p green connec 201
• Connector 201
• Degrees to the left or right with the ignition switch 201
• Disconnect the bank angle sensor 3p green con 201
• Do not disconnect 201
• During inspection 201
• If you repeat this test first turn the ignition switch 201
• Incline the bank angle sensor approximately 60 201
• Off then turn the ignition switch on 201
• Open and support the front end of fuel tank page 201
• Page 88 201
• Position 201
• Red whit 201
• Relay clicks and power supply is close 201
• Relay clicks and power supply is ope 201
• Remove the screws and bank angle senso 201
• Remove the two screws nuts and bank angle sen 201
• Screws 201
• Sensor connector 201
• Standard 201
• Support the motorcycle level surfac 201
• Termina 201
• The bank angle 201
• The bank angle sensor is normal if the engine stop 201
• Tor and place the bank angle sensor horizontal as shown and ignition switch o 201
• Turn the ignition switch of 201
• Turn the ignition switch on and measure the volt 201
• White gree 201
• Angle sensor with 202
• Battery 202
• Battery is connecte 202
• Connect the 12v battery to the following engine 202
• Connect the ohmmeter to the engine stop relay con 202
• Connected replace the engine stop rela 202
• Disconnect the engine stop relay 4p connector 202
• Ecm engine control module 202
• Engine stop relay 202
• Facing up 202
• If there is no continuity when the 12v battery is 202
• Install the bank 202
• Installation is in the reverse order of remova 202
• Its up mark 202
• Nector terminal 202
• Page 89 202
• Red orang 202
• Red white black white 202
• Remove the bolts and fuel tank rear bracke 202
• Remove the engine stop rela 202
• Remove the fuel tank mounting bolts page 5 61 202
• Stop relay connector terminals 202
• There should be continuity only when the 12v 202
• Tighten the mounting screws securely 202
• A20 terminal and ground between the b1 terminal 203
• And bank angle 203
• And ground and between the b12 terminal 203
• C0 z z 1ez z z 203
• Check for continuity between the ecm test harness 203
• Connect the test harness between the main wire harness and ecm pag 203
• Connect the test harness page 5 7 203
• Connector a9 terminal and ground between the 203
• Connector b6 terminal and ground 203
• Disconnect the ecm 22p black and 22p 203
• Ecm cover 203
• Ecu test harness 203
• Gray connector 203
• Green pink wire and green wire 203
• Ground line 203
• If the wire is ok check for the bank angle sensor 203
• If there is no continuity check for open circuit in 203
• If there is no voltage check for open circuit in black 203
• Measure the voltage between the ecm test harness 203
• O e ooo 203
• Oeoeoc o ooo 203
• P black connector 203
• P light gray connector 203
• Page 90 203
• Power input line 203
• Relay page 5 88 203
• Remove the ecm cove 203
• Sensor rela 203
• Switch in run positio 203
• There should be battery voltag 203
• There should be continuity at all time 203
• Tot t ta7 203
• Turn the ignition switch on wire the engine stop 203
• Two required 203
• White wire between the ecm 203
• Ymz 0010100 203
• 24 kd 20 c 68 f 204
• Air suction hoses 204
• Check that the air should not flow a to 204
• Check the resistance between the terminals of the 204
• Connector 204
• Disconnect the pair air suction hoses 204
• Disconnect the pair solenoid valve 2p natural 204
• If the resistance is out of specification replace the 204
• Installation is in the reverse order of remova 204
• P natural connector 204
• Page 91 204
• Pair control 204
• Pair solenoid valv 204
• Pair solenoid valve 204
• Remove the air cleaner housing page 5 66 204
• Remove the bolt and pair solenoid valve 204
• Remove the pair solenoid valv 204
• Solenoid valve 204
• Solenoid valve terminal 204
• Standar 204
• When the 12 v battery is connected to the pair 204
• 34 k 2 20 c 68 f 205
• Bracket assembly 205
• Check that the air should not flow a to b only 205
• Check the resistance between the terminals of the 205
• Connecto 205
• Control valv 205
• Disconnect the air tubes from the evap purge 205
• Disconnect the evap purge control valve 2p 205
• Disconnect the o sensor 4p natural connector 205
• Do not get grease oil or other materials in the 0 205
• Do not service the 205
• Evap purge control valv 205
• Evap purge control valve 205
• Fuel injection 205
• Fuel system programme 205
• Handle the 0 sensor with car 205
• If the resistance is out of specification replace the 205
• Installation is in the reverse order of remova 205
• Open and support the front end of fuel tank page 205
• P connector 205
• P natural connecto 205
• Page 92 205
• Purge control valve terminal 205
• Remove the 205
• Remove the bolt and evap purge control valve 205
• Remove the evap purge control valv 205
• Sensor air hol 205
• Sensor california type only 205
• Sensor while it is ho 205
• Sensor wire from the fram 205
• Standar 205
• Type only 205
• When the 12 v battery is connected to the evap 205
• 25 n m 206
• Be careful not to damage the sensor wir 206
• Do not use an impact wrench while removing or 206
• Install the o sensor uni 206
• Installing the oz senso 206
• M 19 ib 206
• Page 93 206
• Release the oz sensor wire from the right step 206
• Remove the o sensor wire clam 206
• Remove the oz sensor uni 206
• Remove the right step guard mounting bolt 206
• Right step guard 206
• Sensor unit 206
• Sensor wire 206
• Tighten the unit to the specified torque 206
• Before operating inspection check that the pgm fl 207
• Clamp the 0 sensor wire to the right step guard 207
• Clamp the 0 sensor wire with the rear brake 207
• Connect th 207
• Fuel system programmed fuel injection 207
• Install the right step guard and rear master cylinder 207
• O sensor wire 207
• P natural connector 207
• Page 94 207
• Pulley cover 207
• Remove the air cleaner element pag 207
• Remove the bolts and egcv pulley cove 207
• Remove the middle lower cowl pag 207
• Reservoir hose using the hose clam 207
• Right step guard 207
• Route the 207
• Sensor 4p natural connecto 207
• Sensor wire into the fram 207
• Then tighten the mounting bolt 207
• Warning indicator does not indicate egcv failur 207
• Also check that the intake flap valve is opened at 208
• As show 208
• Cable guide pulley position 208
• Check that the egcv cable pulley is moved to 180 208
• Facing forward as shown 208
• For each related part 208
• Fuel system programmed fuel injection 208
• Gradually increase the engine rev u 208
• If the intake and egcv operation is incorrect check 208
• If the intake and egcv position is incorrect adjust 208
• Jumper wire 208
• Make sure that the egcv cable pulley is moved to 208
• Make sure that the pulley index line is positioned 208
• Page 95 208
• Pulley index line facing down at about 8 000 rpm 208
• Pulley index line facing up at about 3 000 rpm 208
• Remove the seat pag 208
• Service check connector 208
• Short the service check connector with a jumper 208
• Start the engine warm up the engine to operating 208
• Temperature 208
• The cables see following steps 208
• The same tim 208
• Turn the ignition switch on and check for egcv 208
• Turn the ignition switch on and engine stop switch 208
• Adjust the egcv position by loosening the n 209
• Adjusting cable lock nut and turning the adjusting nu 209
• Adjusting cable spring 209
• Adjusting nut 209
• Cable adjusting nut then tighten the 209
• Cable lock nut and adjust the cable 209
• Cable lock nut securel 209
• Connecto 209
• Control cable 209
• Egcv control cable adjustment 209
• Equipped cable lock nut and adjusting nut 209
• Fully loosen the n 209
• Hold the n 209
• If the index lines do not aligned adjust the egcv 209
• Index lines 209
• Line is aligned with the egcv cover index lin 209
• Lock nut 209
• Lock nut securel 209
• Make sure that the egcv cable guide pulley index 209
• Move the cable several times and recheck the index 209
• Page 96 209
• Remove the jumper wire from the service check 209
• So that there is no free play 209
• Tighten the n 209
• Turn the n 209
• At this point turn back the cable adjuster 1 2 tur 210
• Check connector with a jumper wire page 5 95 210
• Connecto 210
• Disconnect the servo motor 6p natural connecto 210
• Egcv and air intake valve 210
• Fuel system programmed fuel injection 210
• If the index lines are not aligned adjust as follow 210
• Index line 210
• Index line on the valve shaf 210
• Intake valve cable adjuster 210
• Intake valve cable guide pulley index line with the 210
• Intake valve control cable adjustment 210
• Loosen the intake valve cable adjuster lock nut 210
• Make sure the index lines between the intake valve 210
• Open and support the front end of fuel tank page 210
• Out the servo motor from the bracke 210
• P natural connector 210
• Page 97 210
• Remove the air cleaner element pag 210
• Remove the jumper wire from the service check 210
• Remove the servo motor mounting bolt and pull 210
• Servo motor 210
• Shaft pulley and air guide are aligne 210
• Tighten the lock nut securel 210
• Turn the ignition switch on and short the service 210
• Turn the intake valve cable adjuster align the 210
• Cables from the servo motor pulley then remove 211
• Connect the 12 v battery to the servo motor 6p 211
• Connect the servo motor 6p natural connector 211
• Connectio 211
• Disconnect the intake air valve and egcv control 211
• If the resistance is out of range replace the servo 211
• If the servo motor does not turn replace the servo 211
• Installation 211
• Light green pink green orange 211
• Mar_1141w 211
• Measure the resistance between the servo motor 211
• Motor operatio 211
• Motor with a new one 211
• Natural connector terminals and check that the 211
• P natural connector 211
• P natural connector terminal 211
• Page 98 211
• Red blu 211
• Standar 211
• The servo moto 211
• Yellow red green orange 211
• A 3 mm socket bolt as shown 212
• Adjust the intake and exhaust valve control cables 212
• Connect the egcv control cables to each position 212
• Connect the servo motor 6p natural connecto 212
• Fuel system programmed fuel injection 212
• If you using the 212
• Install and tighten the servo motor mounting bol 212
• Install the servo motor onto the bracke 212
• It is not necessary 212
• Mcj 640 212
• New servo motor 212
• Page 5 95 212
• Page 99 212
• Part numbe 212
• Procedures 212
• Remove the 3 mm socket bolt from the servo motor 212
• Secure the servo motor pulley at this position using 212
• Short the service check connector page 5 95 212
• Socket bolt 3 x 28 m 212
• The servo motor turns then stop 212
• Then connect the intake valve control cable 212
• To do this 212
• Turn the ignition switch on 212
• A 3 mm socket bolt as shown 213
• Adjust the intake and exhaust valve control cables 213
• Connect the egcv control cables to each position 213
• Connect the servo motor 6p natural connector 213
• If you using the 213
• Install and tighten the servo motor mounting bolt 213
• Install the servo motor onto the bracke 213
• It is not necessary 213
• Mcj 640 213
• New servo motor 213
• Page 100 213
• Page 5 95 213
• Part numbe 213
• Procedures 213
• Pulley 213
• Remove the 3 mm socket bolt from the servo motor 213
• Secure the servo motor pulley at this position using 213
• Short the service check connector page 5 95 213
• Socket bolt 3 x 28 m 213
• The servo motor turns then stop 213
• Then connect the intake valve control cabl 213
• To do this 213
• Turn the ignition switch on 213
• Carbon 214
• Check the egcv pre load using a torque wrenc 214
• Deposits in the egcv and valve body page 5 90 214
• Disconnect the egcv control cables page 2 18 214
• Front exhaust pipe 214
• Fuel injection 214
• Fuel system programme 214
• If operation 214
• If pre load is excessive disassemble and inspect 214
• Is not smooth check for 214
• M 25 lbf ft maximum 214
• Operating inspection 214
• Page 101 214
• Pre loa 214
• Rear exhaust pipe 214
• Remove the bolts front exhaust pipe and gasket 214
• Remove the bolts rear exhaust pipe and gasket 214
• Remove the exhaust pipe assembly page 2 18 214
• Smooth operatio 214
• The egc 214
• Turn the egcv pulley from 0 to 180 and check the 214
• And seat its tab with the stopper on the valve cove 215
• Be careful not to damage the thrust washer 215
• Cable guide pulle 215
• Cable stay 215
• Check that the egcv body for wear or damag 215
• Check that the egcv for wear or damag 215
• Check the thrust washer b for wear or damage 215
• Do not apply any lubricant to the egcv bushing 215
• Do not apply any lubricant to the thrust washer 215
• Do not use any cleaning solution to clean the 215
• Egcv bushing 215
• Egcv cover and metal gaske 215
• Exhaust valve 215
• Loosen and remove the nut then remove the valve 215
• Page 102 215
• Pulley 215
• Remove carbon deposits from the egcv and valve 215
• Remove the egcv cover mounting bolts cable stay 215
• Remove the egcv from the valve bod 215
• Remove the followin 215
• Replace the thrust washer b if it is wear or damage 215
• Spring 215
• Spring retainer 215
• Thrust spring 215
• Thrust washer 215
• Thrust washer a 215
• Thrust washer b 215
• Turn the egcv cable guide pulley counterclockwise 215
• Valve cover 215
• Bushing until its 216
• Egcv shaft bushing replacement 216
• End below 216
• Fuel system programmed fuel injection 216
• In from the 216
• Install the egcv cap into the egcv body until it 216
• Installer shaft 216
• Installer shaft guide 216
• Page 103 216
• Press the egcv 216
• Press the egcv bushing in using the special too 216
• Press the valve cover side egcv bushing out using 216
• Remove the valve body side egcv bushing and cap 216
• Remover 1 216
• Seats using the special tool 216
• Shaft guide 216
• The following too 216
• Using the following tool 216
• Valve body surface as show 216
• Ymf mcj0100 216
• Ymf mcj0200 216
• Ymf mcj0400 216
• Assembly 217
• Bushing 217
• Cable guide 217
• Exhaust valve 217
• Exhaust valve body 217
• Fuel system programmed fuel injection 217
• Installer shaft 217
• Metal gasket 217
• Page 104 217
• Pulley 217
• Pulley cover 217
• Spring 217
• Spring retainer 217
• Thrust washer a 217
• Thrust washer b 217
• Valve cover 217
• Ymf mcj0300 217
• Page 105 218
• Be careful not to damage the thrust washer 219
• Cable stay 219
• Chamfered side 219
• Cover boss 219
• Cover with its 219
• Do not apply any lubricant to the thrust washer 219
• Do not use any cleaning solution to clean the 219
• Egcv cover mounting bolts to the specified torque 219
• Exhaust valve 219
• Facing to the 219
• Index line facing 219
• Index mark 219
• Install the egcv 219
• Install the egcv cable stay and tighten the four 219
• Install the metal gasket and egcv cove 219
• Install the spring retainer assembly onto the thrust 219
• Install the thrust 219
• Install the thrust spring onto the egcv cover 219
• Install the thrust washer b and a onto the spring 219
• M 9 ib 219
• Make sure that the 219
• Notice 219
• Page 106 219
• Retaine 219
• Seated on the 219
• Spring retainer 219
• Thrust spring 219
• Thrust spring is 219
• Thrust washer 219
• Valve cover 219
• Valve cover boss 219
• Washer b with its 219
• Check the egcv pre load using a torque wrenc 220
• Groove 220
• If pre load is excessive reassemble the egcv 220
• Install the metal gasket and rear exhaust pipe onto 220
• Install the valve cable guide pulley by aligning its cut out with the valve shaft tab as show 220
• Install the valve cable guide pulley flange nut 220
• Metal gasket 220
• Page 107 220
• Pre loa 220
• Pulley 220
• Rear exhaust pipe 220
• T maximum 220
• The egcv bod 220
• The pulley tab with the stopper on the valve cove 220
• Tighten the nut to the specified torque 220
• Turn the valve cable guide pulley clockwise seat 220
• Valve body 220
• Front exhaust pipe 221
• Fuel system programme 221
• Page 108 221
• Pulley cover 221
• Rear exhaust pipe 221
• The egcv bod 221
• Tighten the egcv mounting bolt to the specified 221
• Valve body 221
• Air guide a 222
• Air guide b 222
• Control cable 222
• Flap shaft assembly 222
• Guide a and 222
• Housin 222
• If necessary loosen the control cable nut and 222
• Iiiiip 222
• Illlli 222
• Intake valve cable end from the drum 222
• Open the intake valve flap by hand disconnect the 222
• Page 109 222
• Remove the air cleaner housing page 5 66 222
• Remove the air guide a and b mounting screw 222
• Remove the control cable from the air cleaner 222
• Remove the intake valve flap shaft assembly air 222
• Remove the intake valve shaft holder mounting 222
• Return spring 222
• Screws 222
• Screws and holde 222
• Unhook the return spring ends from the hooks 222
• Valve flap 222
• Assembly 223
• Flap shaft assembly 223
• Flap valve shaft assembly 223
• Page 110 223
• Return spring 223
• Return springs 223
• Adjust the variable air intake valve control cable 224
• And then install it onto the hook as shown 224
• Cable to the left 224
• Face the control 224
• Fuel system programmed fuel injection 224
• Install the air cleaner housing page 5 67 224
• Intake valve cable adjuster 224
• Intake valve control cable end to the drum 224
• Lock nu 224
• Open the intake valve flap by hand connect the 224
• Page 111 224
• Page 5 95 224
• Then tightening the 224
• Tighten the cable lock nut securely if it is remove 224
• Turn the return spring end counterclockwise turn 224
• 1 radiator 225
• 2 water pump 225
• Add cooling system at the reserve tan 225
• After servicing the system check for leaks with a cooling system tester 225
• All cooling system services can be done with the engine in the frame 225
• Avoid spilling coolant on painted surface 225
• Coolant replacement 225
• Do not remove the radiator cap except to refill or drain the syste 225
• Engine damag 225
• General 225
• If any coolant gets in your eyes rinse them with water and consult a doctor immediately 225
• If any coolant gets on your skin or clothes rinse thoroughly with plenty of water 225
• If any coolant is swallowed induce vomiting gargle and consult a physician immediately 225
• Information 225
• Inhibitor 225
• Keep it away from eyes mouth skin and clothe 225
• May cause premature wea 225
• Notice 225
• Page 1 225
• Radiator coolant is toxi 225
• Radiator passage 225
• Radiator reserve tank 6 16 225
• Refer to section 19 for fan motor switch and coolant temperature sensor inspection 225
• Removing the cap while the engine is hot and the coolant is under pressure may cause serious scalding 225
• Servic 225
• System 225
• System flow pattern 225
• Testing 225
• Thermostat 225
• Troubleshooting 225
• Using coolant with silicat 225
• Using tap water may caus 225
• Wait until the engine is cool before slowly removing the radiator ca 225
• Water pump seals or blockag 225
• 137 kpa 226
• 20 psi 226
• Air in system 226
• And engine 226
• Apply sealant to the threads 226
• C 177 182 f 226
• Coolant capacity 226
• Coolant leak 226
• Cooling fan nut 226
• Ct bolt 226
• Damaged or deteriorated gasket 226
• Damaged or deteriorated hose 226
• Deteriorated 0 rings 226
• Ect engine coolant temperature thermo sensor 226
• Engine temperature too high 226
• Engine temperature too low 226
• Fan motor nut 226
• Fan motor switch 226
• Faulty cooling fan motor 226
• Faulty cooling fan motor switch 226
• Faulty fan motor switch 226
• Faulty radiator cap 226
• Faulty temperature gauge or coolant temperature sensor 226
• Faulty temperature gauge or ect thermo sensor 226
• Faulty water pump 226
• Faulty water pump mechanical seal 226
• Fully open 226
• High quality ethylene glycol antifreeze containing corrosion 226
• Ibf ft apply a locking agent to the threads 226
• In minimum 226
• Loose hose connection or clamp 226
• Mixture with soft water 226
• Page 2 226
• Passages blocked in radiator hoses or water jacket 226
• Radiato 226
• Recommended antifreeze 226
• Reserve tank 226
• Specifications 226
• Standard coolant concentration 226
• Thermostat 226
• Thermostat stuck closed 226
• Thermostat stuck open 226
• To open 226
• Water pump cover sh bolt 226
• 1 62 1 59 1 56 227
• 1 82 1 80 1 77 1 74 227
• 15 20 25 30 35 227
• 1_0341 227
• Below for coolant gravity chart 227
• Coolant gravity chart 227
• Coolant ratio 227
• Coolant temperature c f 227
• For maximum corrosion protection a 50 227
• Look for contamination and replace the coolant if 227
• Necessar 227
• Page 3 227
• Radiator cap 227
• Recommended pag 227
• Remove the radiator ca 227
• Remove the right heat guard pag 227
• Solution of ethylene glycol and distilled water is 227
• System testing 227
• Test the coolant gravity using a hydrometer see 227
• 137 kpa 228
• 50 distilled water and antifreeze 228
• Accumulation of rust or if there is a change in the 228
• Antifreez 228
• Antifreeze 228
• As specified in the maintenance schedul 228
• Before installing 228
• Best performance change the coolant regularly 228
• Checking coolant 228
• Component 228
• Coolant 228
• Coolant replacement 228
• Do not exceed 137 kpa 228
• Ethylene 228
• Excessive pressure can damage the cooling system 228
• For leak 228
• Glycol base 228
• High quality ethylene glycol antifreeze containing corrosion protection inhibitors 228
• Hold specified pressure for at least 6 second 228
• It must hold the specified pressure for at least 6 228
• Kgf cm 228
• Kgf cmz 16 20 psi 228
• Level place the 228
• Low mineral 228
• Mix only distilled low mineral water with the 228
• Mixing proportion during usag 228
• Motorcycle in a 228
• On a flat level 228
• Or distilled 228
• Or if the relief pressure is too high or too lo 228
• Page 4 228
• Pressure test the radiator ca 228
• Pressure the radiator engine and hoses and check 228
• Radiator cap 228
• Radiator cap relief pressur 228
• Radiator cap tester 228
• Recommended antifreez 228
• Recommended mixtur 228
• Remove the radiator ca 228
• Remove the radiator cap see previous page 228
• Repair or replace components if the system will not 228
• Replace the radiator cap if it does not hold pressure 228
• Sealing surfaces 228
• Second 228
• Solution 228
• Surface 228
• System or reserve 228
• Tank with a coolant 228
• Tester wet the 228
• The cap in the 228
• The effectiveness of coolant decreases with the 228
• Therefore for 228
• Vertical position 228
• When filling the 228
• And drain the system coolan 229
• Bleed air from the system as follo 229
• Check the level of coolant in the reserve tank and 229
• Coolant from the cylinde 229
• Disconnect the siphon tube from the radiato 229
• Drain the reserve tank coolan 229
• Engine and let it idle for 2 3 minutes 229
• F ll r cap 229
• F sealingkv 229
• Fill to the upper level if it is lo 229
• Level if necessar 229
• Open and support the front end of fuel tank page 229
• Page 5 229
• Reinstall the drain bolt with the new sealing washer 229
• Reinstall the radiator ca 229
• Reinstall the radiator siphon tub 229
• Remove the radiator reserve tank cap and fill the 229
• Reserve 229
• Reserve tank to the upper level lin 229
• Reserve tank with wate 229
• Shift the transmission into neutra 229
• Siphon tube 229
• Snap the throttle 3 4 times to bleed air from the 229
• Start the 229
• Stop the engine and add coolant up to the proper 229
• Through the filler opening up to filler nec 229
• Check for damage of the seal rin 230
• Cooling system 230
• Do not let the 230
• Drain the coolant pag 230
• Heat the water with an electric heating element to operating temperature for 5 minute 230
• Heating element 230
• In minimum at 95 c 203 f 230
• Its operation 230
• Keep flammable materials away from the electric 230
• Other than those specifie 230
• Page 6 230
• Reading 230
• Remove the bolts and thermostat housing cover 230
• Remove the thermostat from the housing 230
• Remove the throttle body page 5 68 230
• Replace the thermostat if the valve stays open at 230
• Room temperature or if it responds at temperatures 230
• Seal ring 230
• Suspend the thermostat in heated water to check 230
• Thermometer 230
• Thermostat 230
• Thermostat begin to ope 230
• Thermostat hni icl 230
• Thermostat or 230
• Thermostat removal 230
• Touch the pan or 230
• Valve lif 230
• Visually inspect the thermostat for damage 230
• Wear insulated gloves and adequate eye protectio 230
• You will get false 230
• Bleed hole facing rearward 231
• Bypass hos 231
• Connect the ect sensor connecto 231
• Connect the fast idle wax unit water hose and 231
• Cylinder hea 231
• Disconnect the ect sensor connecto 231
• Disconnect the fast idle wax unit water hose and bypass hose from the thermostat housin 231
• H i3aeee1fti 231
• Ing bolt 231
• Install and tighten the thermostat housing mount 231
• Install the thermostat housing onto the cylinder 231
• Install the thermostat into the housing with its air 231
• Page 7 231
• Remove the bolts and thermostat housing from the 231
• Thermostat bod 231
• Thermostat housing 231
• Thermostat housing removal 231
• Thfrm stv i vsin 231
• Air bleed tube 232
• Bleed the air pag 232
• Connecto 232
• Connector 232
• Cover onto 232
• Disconnect the fan motor switch connector from 232
• Disconnect the lower radiator hose and oil cooler 232
• Disconnect the radiator sub harness 2p black 232
• Disconnect the siphon tube and air bleed tube from 232
• Disconnect the upper radiator hos 232
• Drain the coolant pag 232
• Fan motor switch connector 232
• Fill the system with recommended coolant and 232
• Heat guard page 2 9 232
• Housin 232
• Housing 232
• Install and tighten the housing cover bolt 232
• Install the 232
• Ithermostatho 232
• L s f r f ddiato r hose 232
• Middle lower cowl page 2 5 232
• Oil c0 232
• P black 232
• Page 8 232
• Radiator 232
• Remove the followin 232
• Siphon tube 232
• The radiato 232
• The switch release the wire from the inner middle 232
• Thermostat 232
• Upper radiator hose 232
• Water hos 232
• And washe 233
• Be careful not to 233
• Bolt washeit 233
• Cooling fan motor assembly 233
• Damage the 233
• Disassembly 233
• Fan motor assembl 233
• Ground eyelet 233
• Mounting 233
• Page 9 233
• Radiator 233
• Radiator cor 233
• Release the 233
• Release the fan motor sub harness connector from 233
• Remove 233
• Remove the radiator assembl 233
• Remove the radiator lower mounting bolt nu 233
• Remove the three bolts ground eyelet and cooling 233
• Slide the radiator to the right then 233
• The fan motor bracke 233
• The radiator 233
• Upper grommet from the frame boss 233
• Collar 234
• Cooling fan 234
• Fan motor 234
• Fan motor bracket 234
• Flange nuts 234
• For fan motor switch information refer to page 234
• I of ft 234
• Lbf ft 234
• Motor bracke 234
• Page 10 234
• Radiator 234
• Remove the flange nuts and fan motor from the fan 234
• Remove the nut cooling fan and distance colla 234
• Aligning the flat surfaces 235
• Apply a locking agent to the cooling fan nut threads 235
• Cooling fan 235
• Cooling system 235
• Distance collar 235
• Install and tighten the bolt 235
• Install and tighten the nut to the specified torqu 235
• Install the cooling fan motor assembly onto the 235
• Install the cooling fan onto the fan motor shaft by 235
• Install the distance collar onto the fan motor shaf 235
• Install the fan motor onto the fan motor bracket and 235
• Install the radiator sub harness connector to the fan 235
• Motor bracke 235
• N m 0 7 kg 235
• Page 11 235
• Radiato 235
• Route the ground eyelet properl 235
• Tighten the frange nuts to the specified torqu 235
• Be careful not to 236
• Connect the lower radiator hose and oil collar 236
• Connecto 236
• Connector 236
• Cooling system 236
• Damage the 236
• Install the radiator assembly aligning its grommet 236
• Install the radiator lower mounting bolt nut tighten 236
• Install the washer and upper mounting bolt then 236
• Installation 236
• Oil c _ l ef 236
• P black 236
• Page 12 236
• Radiator core 236
• The nut securel 236
• Tighten the bol 236
• Upper grommet 236
• Vvaters i 236
• Water hos 236
• With the frame boss 236
• Air bleed tube 237
• And oil cooler water hose from the water pump 237
• And replace the water pump as an assembl 237
• Bypass hose 237
• Connect the siphon tube and air bleed tube to the 237
• Connect the upper radiator hos 237
• Disconnect the lower radiator hose bypass hose 237
• Drain the coolant pag 237
• Fan motor switch connector 237
• Fill the system with recommended coolant page 237
• Heat guard page 2 15 237
• If there is leakage the mechanical seal is defective 237
• Inspect the inspection hole for signs of coolant 237
• Inspection 237
• Install the followin 237
• Leakag 237
• Lower radiator hose 237
• Middle lower cowl page 2 7 237
• Oil cooler water hose 237
• Page 13 237
• Radiator 237
• Route the fan motor switch wire properly connect 237
• Siphon tube 237
• The connector to the switc 237
• Upper radiator hose 237
• Water pump 237
• Cooling system 238
• Disconnect the water pump to water joint hose 238
• From the water pump bod 238
• O ring 238
• Page 14 238
• Remove the o ring from the water pump bod 238
• Remove the two sh bolts two flange bolts and water pump cove 238
• Remove the water pump body from the crankcas 238
• Water hose 238
• Aligning the water pump shaft groove with the oil 239
• Apply engine oil to a new o ring and install it onto 239
• Connect the water pump to water joint hose to the 239
• Install the water pump into the crankcase while 239
• Installation 239
• O ring 239
• Page 15 239
• Pump shaft en 239
• The stepped portion of the water pump 239
• Water hose 239
• Water pump and tighten the clamp scre 239
• Water pump body 239
• Water pump cover 239
• Align the mounting bolt holes in the water pump 240
• And crankcase and make sure the water pump is 240
• Bypass hose 240
• Connect the lower radiator hose bypass hose and 240
• Disconnect the siphon tube and drain coolant from 240
• Fill the system with recommended coolant page 240
• Flange bolt 240
• Install a new o ring into the groove in the water 240
• Install the water pump cover two sh bolts and two 240
• Kgf m 9 ibf ft 240
• Lower radiator hose 240
• Lrlft w 240
• Oil cooler water hose 240
• Oil cooler water hose then tighten the clamp screw 240
• Page 16 240
• Pump bod 240
• Radiator reserve tank 240
• Remove the middle lower cowl pag 240
• Remove the radiator reserve tank lower mounting 240
• Reserve tank 240
• Securely installe 240
• Siphon tube 240
• The reserve tan 240
• Tighten the flange bolts to the specified torqu 240
• Tighten the two sh bolt 240
• Water pump body 240
• Water pump cover 240
• Cooling system 241
• Installation 241
• Overflow tube 241
• Page 17 241
• Upper bracket 241
• Cooling system 242
• Page 18 242
• Reserve tank 242
• Siphon tube 242
• At disassembly 243
• Bank sensor lower bracket mounting nut 10 mm 243
• Coolan 243
• Engine installation 243
• Engine removal 243
• Engineremoval installation 243
• Lower bracket installation 243
• Lower bracket removal 243
• Notice 243
• Page 1 243
• Service data 243
• Service information 243
• Specifications 243
• Water pump section 6 243
• Bracket removal 244
• Disconnect the side stand 2p green connecto 244
• Loosen the rear socket bolt pinch bol 244
• Muffler exhaust pipe page 2 19 rear fender page 2 14 244
• Open and support the front end of fuel tank page 244
• P green connector 244
• Page 2 244
• Pinch bolt 244
• Remove the bolts and side stand bracket assembly 244
• Remove the followin 244
• Remove the lower bracket front socket bolt and nu 244
• Side stand bracket 244
• Suspension linkage page 14 9 rear shock absorber page 14 11 244
• Swingarm page 14 14 244
• Disconnect the alternator 3p white connecto 245
• Disconnect the following connector 245
• Egcv and air intake valve servo motor page 245
• Engine removal 245
• Engine removal installation 245
• Engine sub harness 2p blue connector 245
• Fuel tank page 5 61 245
• Ignition coil spark plug sub harness page 8 5 245
• Ignition coil sub harness 245
• Ignition pulse generator 2p red connector 245
• Lower bracket page 7 2 245
• P blue connector 245
• P natural connector 245
• P red connector 245
• P white connector 245
• Page 3 245
• Pair control 245
• Pair control solenoid valve assembly page 8 5 245
• R socket bolt 245
• Remove the following 245
• Remove the lower bracket rear socket bolt and nut 245
• Solenoid valve 245
• Speed sensor 3p natural connector 245
• Then remove the lower bracket from the engine 245
• Throttle body 245
• Throttle body page 5 68 245
• Aal housinrr 246
• Cable guide 246
• Cylinder hea 246
• Disconnect the air bleed tube and upper radiator 246
• Disconnect the clutch cable from the clutch lifter 246
• Disconnect the ect sensor connecto 246
• Ground c 246
• Hose from the thermostat housing cove 246
• I lehmus 246
• Liftei i e 246
• Lutch cable 246
• Or con i 246
• Page 4 246
• Remove the bolts and clutch cable guide then 246
• Remove the bolts and thermostat housing from the 246
• Remove the starter motor mounting bolt and 246
• Remove the terminal nut and starter motor cable 246
• Remove the thermostat housing cover and 246
• Starter motor ground cabl 246
• Ter motor cable 246
• Thermostat pag 246
• 12 mm engine hanger bolt 247
• Collar 247
• Disconnect the lower radiator hose from the water 247
• Disconnect the oil cooler to radiator water hose 247
• Disconnect the siphon tube from the radiator 247
• Engine removal installation 247
• From the oil coole 247
• Middle 12 mm engine hanger bolts and distance 247
• Mm hangef h 247
• Mm hanger bolt 12 mm hanger bolt 247
• Page 5 247
• Pump cove 247
• Radiator lower mounting bracket 247
• Remove left side of the front 10 mm and middle 247
• Remove the bolts radiator reserve tank and 247
• Remove the radiator lower mounting bracket bolt 247
• Remove the right side of the front 10 mm and 247
• Reserve tan 247
• Support the engine using a jack or other adjustable 247
• Support to ease of engine hanger bolts remova 247
• Water hose 247
• Be careful not to install the engine into the frame 248
• Carefully maneuver the engine into place 248
• Chain tensioner install the rear engine hanger socket bolt and nut 248
• Engine installation 248
• Engine removal installation 248
• Note the direction of the hanger bolts 248
• Page 6 248
• Rear hanger bolt 248
• 12 mm engine hanger bolt 249
• Damage the cylinder hea 249
• Distance collar 249
• Engine removal installation 249
• Far hanger bolt 249
• Hold the rear engine hanger socket bolt then 249
• Improper installation will 249
• Install the left side of the front 10 mm and middle 249
• Install the right and left front engine hanger bolts in 249
• Install the right side of the front 10 mm and 249
• Middle 12 mm engine hanger bolts with the 249
• Page 7 249
• Pinch bolt 249
• Specified torqu 249
• Their proper location 249
• Tighten the nut to the specified torqu 249
• Tighten the rear engine hanger pinch bolt to the 249
• Connect the lower radiator hose to the water pump 250
• Connect the oil cooler to radiator water hose to the 250
• Connect the siphon tube to the reserve tan 250
• Cover and tighten the hose band scre 250
• Engine removal installation 250
• Front 10 mm 250
• Install the radiator lower mounting bolt nut tighten 250
• Install the radiator reserve tank and mounting bolts 250
• Kgf m 40 lb 250
• Lower radiati r hose 250
• Middle 12 mm 250
• Middle 12 mm engine hanger bolt to the specified 250
• Mm hanger bolt 250
• Oil cooler tighten the hose band securely 250
• Page 8 250
• Reserve tank 250
• Siphon tube 250
• The nut securel 250
• Tighten the bolt 250
• Tighten the left side of the front 10 mm and 250
• Tighten the right side of the front 10 mm and 250
• And tighten the starter motor mounting bol 251
• Connect the clutch cable end to the clutch lifter 251
• Connect the ect sensor connecto 251
• Connect the starter motor cable to the motor 251
• Connect the starter motor ground cable and install 251
• Cover and tighten the mounting bolts securel 251
• Engine removal installation 251
• Ground 251
• Hermosithyi_huv 251
• Hermosttait housint 251
• Ing bolt 251
• Install a new o ring into the thermostat housing 251
• Install and tighten the thermostat housing mount 251
• Install the clutch cable guide to the right crankcase 251
• Install the thermostat housing to the cylinder hea 251
• Page 9 251
• Terminal tighten the terminal nu 251
• And bleed the air pag 252
• Connect the air bleed tube and upper radiator hose 252
• Connect the following connecto 252
• Cover pag 252
• Egcv and air intake valve servo motor page 252
• Engine sub harness 2p blue connector 252
• Fill the cooling system with recommended coolant 252
• Fuel tank page 5 63 252
• Hose band scre 252
• Housing 252
• Ignition coil spark plug sub harness page 8 31 252
• Ignition coil sub harness 252
• Ignition pulse generator 2p red connector 252
• Install the 252
• Install the followin 252
• Level page 3 15 252
• Lower bracket page 7 11 252
• P blue connector 252
• P natural connector 252
• P red connector 252
• P white connector 252
• Page 10 252
• Pair control 252
• Pair control solenoid valve assembly page 8 31 252
• Pour recommended engine oil up to the proper 252
• Route the alternator wire connect the alternator 3p 252
• Solenoid valve 252
• Speed sensor 3p natural connector 252
• Thermostat 252
• Thermostat houq 252
• Throttle body 252
• Throttle body page 5 71 252
• To the thermostat housing cover and tighten the 252
• White connecto 252
• 12 kgf m 253
• Hold the swingarm pivot bolt then tighten the pivot 253
• Install the lower bracket onto the engine 253
• Install the swingarm page 14 23 253
• Lbf ft 253
• Mm socket bolt nut 253
• Mrri ocket bolt i 253
• Nut to the specified torque 253
• Page 11 253
• Pinch bolt 253
• Swingarm pivot bolt 253
• Swingarm pivot nut 253
• Temporarily install the front and rear 10 mm bolts and nuts 253
• Temporarily tighten the 10 mm nut 253
• Engine removal installation 254
• Hold the rear 10 mm socket bolt tighten the nut to 254
• Install the side stand bracket assembly tighten the 254
• Mm socket bo 254
• Mm socket bolt 254
• Mm socket bolt nut 254
• New bolts to the specified torqu 254
• Page 12 254
• Pinch bolt 254
• Side stand bracket 254
• Socket bolts 254
• Specified torqu 254
• The specified torqu 254
• Tighten the 10 mm socket pinch bolt to the 254
• Tighten the front 10 mm socket bolt and nut to the 254
• Page 13 255
• Cam chain tensioner lifter 256
• Camshaf 256
• Camshaft installation 256
• Compression test 256
• Cylinde 256
• Cylinder hea 256
• Cylinder head assembly 256
• Cylinder head cover 256
• Cylinder head cover assembly 256
• Cylinder head inspection 256
• Cylinder head installation 256
• Cylinder head removal 256
• Disassembly 256
• General 256
• Information 256
• Installation 256
• Page 1 256
• Removal 256
• Replacement 256
• Servic 256
• Troubleshooting 256
• Valve guid 256
• Valve seat inspection jrefacing 256
• Above cylinder head 257
• Apply a locking agent to the threads 257
• Apply a locking agent to the threads apply a locking agent to the threads apply a locking agent to the threads apply a locking agent to the threads 257
• Apply molybdenum disulfide oil to the 257
• At 350 rpm 257
• Cam chain guide mounting socket bolt 257
• Cam chain tensioner pivot socket bolt 257
• Cam lobe height 257
• Cam pulse generator rotor dowel bolt 257
• Cam sprocket bolt 257
• Camshaft 257
• Camshaft holder flange bolt 257
• Cylinde 257
• Cylinder compression 257
• Cylinder hea 257
• Cylinder head cover blot 257
• Cylinder head mounting bolt 8 mm 257
• Cylinder head mounting socket bolt washer 257
• Head valves 257
• Kgf m 20 lbf ft 257
• M 38 ib 257
• Page 2 257
• Pair reed valve cover flange bolt 257
• Runout 257
• See page 1 14 257
• Service limit 257
• Specifications 257
• Standard 257
• Stem to guide clearance 257
• Threads and seating surface after 257
• Torque values 257
• Vacuum joint plug for synchronization 257
• Valve clearance 257
• Valve guide 257
• Valve guide projection 257
• Valve seat width 257
• Valve spring 257
• Valve stem 257
• Warpage _ 257
• 0010000 258
• 0010100 07780 0010300 07780 0012000 07780 0012900 07780 0014500 07780 0014000 07781 0010600 258
• At low speed 258
• Broken valve spring 258
• Burned or bent valve 258
• By a compression test or by 258
• Compression gauge attachment 258
• Compression too high overheating or knocking 258
• Compression too low hard starting or poor performance 258
• Cutter holder 258
• Cylinder hea 258
• Damaged or worn camshaft 258
• Damaged stem seal 258
• Engine top end problems usually affect engine performanc 258
• Equivalent commercially available in 258
• Excessive carbon build up on piston crown or on combustion chamber 258
• Excessive noise 258
• Excessive smoke 258
• Flat cutter 25 mm 32 in 258
• Flat cutter 33 mm 32 ex 258
• For a seized piston ring section 11 258
• H m d m loo101 258
• H m h m l00101 258
• If the performance is poor at low speeds check for white smoke in the crankcase breather tube 258
• If the tube is smoky check 258
• Incorrect valve adjustment 258
• Incorrect valve timing 258
• Interior cutter 26 mm 60 in 258
• Interior cutter 30 mm 60 ex 258
• Km30101 258
• Leaking or damaged head gasket 258
• Loose or worn cam chain 258
• Low cylinder compression 258
• Mm 45 in seat cutter 29 mm 45 ex 258
• Not available in 258
• Page 3 258
• Rough idle 258
• Seat cutter 2 258
• Sticking valve or broken valve spring 258
• Tappet hole protector 258
• These are commercially available in 258
• These problem can be diagnose 258
• Tracing engine noises to the top end with a sounding rod stethoscop 258
• Troubleshooting 258
• Uneven valve seating 258
• Valve guide driver 258
• Valve guide reamer 258
• Valve seat cutters 258
• Valve spring compressor 258
• Valve spring compressor attachment 258
• Warped or cracked cylinder head 258
• Worn cam sprocket teeth 258
• Worn cylinder piston or piston rings section 11 258
• Worn or damaged cam chain 258
• Worn or damaged cam chain tensioner 258
• Worn valve stem or valve guide 258
• 226 kpa 1 259
• 7 second 259
• Available in 259
• Battery do not 259
• Blown cylinder head gasket 259
• Coil spark plug caps and spark plug 259
• Commercially 259
• Compression gauge 259
• Compression pressur 259
• Connecto 259
• Cylinder compression test 259
• Cylinder head valves 259
• Discharging the 259
• Disconnect the fuel pump reserve sensor 3p black 259
• Equivalent 259
• High compression can be caused b 259
• Improper valve adjustment 259
• Install a compression gauge into the spark plug 259
• Low compression can be caused b 259
• Motor for more 259
• Open and support the front end of fuel tank page 259
• Open the throttle all the way and crank the engine 259
• Operate the starter 259
• Page 4 259
• Piston head 259
• Psi at 350 rpm 259
• Second 259
• Stop the engine and remove the all direct ignition 259
• Than seven 259
• To avoid 259
• Valve leakage 259
• Warm up the engine to normal operating tempera 259
• With the starter motor until the gauge reading stops 259
• Worn piston ring or cylinder 259
• Air cleaner housing page 5 66 260
• Bolts and washer 260
• Bolts to avoid 260
• Connecto 260
• Connector and sub harness 260
• Cover re oval 260
• Crankcase breather tube 260
• Disconnect the cam pulse generator 2p natural 260
• Disconnect the crankcase breather tub 260
• Disconnect the ignition coil sub harness 9p black 260
• Disconnect the pair control solenoid valve 2p nat 260
• Disconnect the pair control solenoid valve air suc 260
• Disconnect the radiator sub harness 2p black 260
• Disconnect the throttle cable ends from the throt 260
• Dropping them 260
• I c bracke 260
• Into the engine 260
• Middle cowl page 2 5 260
• Noid valve assembl 260
• P black connector 260
• Page 5 260
• Pair control solenoid valve 260
• Place a cloth 260
• Remove the followin 260
• Remove the heat guard rubbe 260
• Remove the mounting bolt and pair control sole 260
• Remove the throttle cable guide bracket mounting 260
• Tion hose 260
• Tle dru 260
• Underneath the 260
• Ural connector 260
• Cylinder head cover 261
• Disassembly 261
• From the cylinder head 261
• Page 6 261
• Remove the cylinder head cover bolts and washer 261
• Remove the cylinder head cover packin 261
• Remove the cylinder head cover rearwar 261
• Remove the sh bolts and pair reed valve covers 261
• _ uh e 261
• Breather separator 262
• Camshaft removal 262
• Check the pair check valves for wear or damage 262
• Page 7 262
• Pair check v 262
• Pulse generator from the cylinder hea 262
• Remove bolts and breather separator and gasket 262
• Remove the cylinder head cover pag 262
• Remove the timing hole cap and o rin 262
• Replace if necessar 262
• To avoid damaging the cam pulse generator while removing the camshafts remove the bolt and cam 262
• And sealing washe 263
• And secure it using the stopper tool 263
• Be careful not to 263
• Cam chain tensioner lifter 263
• Cam spro 263
• Cam sprocke 263
• Camshaft and or 263
• Camshaft except 263
• Center on the compression stroke 263
• Drop the cam 263
• Exhaust camshafts 263
• Follow 263
• If you plan to replace the camshaft and or cam 263
• Index mart 263
• It is not necessary 263
• Make sure the n 263
• Mark on the right crankcase cove 263
• Material thicknes 263
• Mm 19 mm 263
• On the ignition pulse generator rotor with the index 263
• Page 8 263
• Piston is at tdc top dead 263
• Remove the cam chain tensioner lifter sealing bolt 263
• Remove the cam sprocket bolts from intake and 263
• Sealing washer 263
• Sprocket bolts into 263
• Sprocket from the 263
• Sprocket remove the cam sprocket bolts as 263
• Stopper tool 263
• The crankcase 263
• Thickness piece of stee 263
• This tool can easily be made from a thin 1 mm 263
• To remove the cam 263
• Turn the crankshaft clockwise align the t mark 263
• Turn the tensioner lifter shaft fully in clockwise 263
• When replacing the 263
• Be careful not to 264
• Bolts into the 264
• Bolts then remove the camshaft holders and 264
• Camshaft 264
• Camshafts 264
• Chain guide b 264
• Chain with a piece 264
• Crankcas 264
• Crankcase 264
• Drop the rotor or 264
• Falling into the 264
• Holder might brea 264
• Inside loosen the bolts in a criss 264
• Loosen and remove the remaining camshaft holder 264
• Notice 264
• Of wire to prevent 264
• Or the 264
• Outsid 264
• Page 9 264
• Pattern 264
• Remove the bolts and cam chain guide b 264
• Remove the bolts and cam pulse generator roto 264
• Remove the bolts and camshaft holder a first 264
• Remove the cam sprocket from the camshaft 264
• Severa 264
• Suspend the cam 264
• The chain from 264
• The other cam sprocket bolts from the camshafts 264
• Turn the crankshaft one full turn 360 remove 264
• And check the camshaft runout with a dial gaug 265
• Be careful not to damage the valve lifter bor 265
• Cam lobe height 265
• Camshaft holder a 265
• Camshaft holder b 265
• Camshaft holder c 265
• Cylinde 265
• Er for scoring scratches or evidence of insufficient 265
• Head valves 265
• Inspect the bearing surface of each camshaft hold 265
• Inspect the oil orifices of the holders for cloggin 265
• Lubricatio 265
• Mark all valve lifters and shims to ensure correct 265
• Not allow the shims to fall into the crankcas 265
• Or magne 265
• Page 10 265
• Reassembly in their original location 265
• Remove the valve lifters and shim 265
• Service limi 265
• Service limit 265
• Shim may stick to the inside of the valve lifter do 265
• Support both ends of the camshaft with v blocks 265
• The shims can be easily removed with a tweezers 265
• The valve lifter can be easily removed with a 265
• Using a micrometer measure each cam lobe 265
• Valve lapping tool or magne 265
• 12 n m 266
• A crisscross pattern in 2 3 step 266
• A set if the clearance still exceeds the service limi 266
• Camshaft and recheck the oil clearanc 266
• Camshaft journa 266
• Camshaft when 266
• Chain guide for wear or damag 266
• Cylinde 266
• Cylinder head and camshaft holder 266
• Do not rotate the 266
• Head vanes 266
• Ibf ft 266
• Inspect the cam chain slipper surface of the cam 266
• Install the camshaft holders and tighten the bolts in 266
• Lay a strip of plastigauge lengthwise on top of each 266
• Page 11 266
• Remove the camshaft holders and measure the 266
• Remove the cylinder head and valves page 8 12 266
• Replace the cylinder head and camshaft holders as 266
• Service limi 266
• The widest thickness determines the oil clearance 266
• Using plastigaug 266
• When the service limits are exceeded replace the 266
• Width of each plastigaug 266
• Wipe any oil from the journals of the camshaft 266
• And gaske 267
• Bolts in a 267
• Check the sealing washer is in good condition re 267
• Crisscross pattern 267
• Cylinder head removal 267
• Cylinder head valves 267
• Drain coolant from cylinder 267
• Head and cylinder 267
• Loosen the 9 mm 267
• Page 12 267
• Place if necessar 267
• Reinstall the sealing washer and drain bol 267
• Remove the bolts and cam chain tensioner lifter 267
• Remove the camshaft page 8 7 267
• Remove the cylinder drain bolt and sealing washer 267
• Remove the cylinder hea 267
• Remove the dowel pins and cylinder head gasket 267
• Remove the engine from the frame pag 267
• Remove the ten 9 mm bolts washer 267
• Remove the two 8 mm flange bolt 267
• An equivalent tool can easily be made from 268
• And collar 268
• Cam chain 268
• Cam chain guide 268
• Crankcase 268
• Hle protector 268
• Hmg mr70002 268
• Ignition 268
• Install the tappet hole protector into the valve lifter 268
• M chain tensionier 268
• Not available i 268
• Page 13 268
• Plastic 35 mm film container as show 268
• Pulse generator rotor page 17 7 268
• Remove 268
• Remove the cam chain and timing sprocket from 268
• Remove the socket bolt cam chain tensioner and 268
• Remove the socket bolt washer cam chain guide 268
• Remove the spark plugs from the cylinder head 268
• Tappet hole protector 268
• The crankshaf 268
• Timing 268
• Top view 268
• When compressed 268
• 0010000 269
• Attachment 269
• Avoid damaging 269
• Back in their 269
• Chamber 269
• Check the cylinder head for warpage with a straight 269
• Check the spark plug hole and valve areas for 269
• Cotter 269
• Cracks 269
• Cylinder head 269
• Cylinder head inspection 269
• Cylinder head valves 269
• During disassembly so 269
• Edge and feeler gaug 269
• Inner spring 269
• Km30101 269
• Mark all parts 269
• Notice 269
• Original location 269
• Outer and inner valve springs 269
• Page 14 269
• Remove carbon deposits from the combustion 269
• Remove the followin 269
• Remove the valve spring cotters using the special 269
• Retainer 269
• Service limi 269
• Spring retainer 269
• Spring seat 269
• Stem seal 269
• The gasket surfac 269
• They can be placed 269
• To prevent loss of tension do not compress the valve springs more than necessary to remove the 269
• Tools as show 269
• Valve spring compressor 269
• Valve spring seat 269
• Cam chain tensioner cam chain guide 270
• Chain tensione 270
• Cylinder head valves 270
• Excessiv 270
• Inspec 270
• Inspect each valve lifter bore for scratches or abnor 270
• Inspect each valve lifter for scratches or abnormal 270
• Mal wea 270
• Measure the each valve lifer 270
• Measure the each valve lifter bore 270
• Measure the free length of the inner and 270
• Necessar 270
• Page 15 270
• Replace 270
• Replace the springs if they are shorter than the 270
• Service limi 270
• Service limit 270
• Service limits 270
• Valve lifter 270
• Valve lifter bore 270
• Valve spring 270
• Are replaced 271
• Before checking clearance 271
• Check valve movement in the guide measure and 271
• Clockwis 271
• Cylinder bead valves 271
• Determine if a new guide with standard dimensions 271
• From the correspond 271
• H m h m l001 oa 271
• Hmh mloo101 271
• If the stem to guide clearance is out of standard 271
• Ing guide 271
• Insert the reamer from the combustion chamber 271
• Inspect each valve for bending burning or abnor 271
• Mal stem wear 271
• Measure and record each valve guide 271
• Page 16 271
• Page 8 18 271
• Ream the guides to remove any carbon deposits 271
• Record each valve stem 271
• Reface the valve 271
• Replace any guides as necessary and ream to fi 271
• Seats whenever 271
• Standard 271
• Subtract each valve stem 271
• The valve guides 271
• To obtain the stem to guide clearance 271
• Valve guide reamer 271
• Valve valve guide 271
• With the new guides replace the valves and guides 271
• Would bring the clearance within toleranc 271
• C 212 300 f 272
• Cause warpin 272
• Clean the cylinder head thoroughly to remove any 272
• Clockwis 272
• Der head 272
• Drive in the guide to the specified depth from the 272
• Guides 272
• H m h m loo 10a 272
• H m h m loo101 272
• Heat the cylinder head to 100 272
• Hmd mlo0101 272
• Hmd mloo101 272
• Insert the reamer from the combustion chamber 272
• It may 272
• Let the cylinder head cool to room temperature 272
• Metal particle 272
• Page 17 272
• Ream the new valve guide after installatio 272
• Reface the valve seat see next page 272
• Replacemen 272
• Section of a refrigerator for about an hou 272
• Side of the head and also always rotate the reamer 272
• Specified dept 272
• Support the cylinder head and drive out the valve guides from combustion chamber side of the cylin 272
• The freezer 272
• The heated cylinder hea 272
• The reamer during 272
• This operatio 272
• To avoid burns wear heavy gloves when handling 272
• Top of the cylinder hea 272
• Use a torch to heat the cylinder hea 272
• Use cutting oil on 272
• Valve guide driver 272
• Valve guide reamer 272
• Valve guide replacement 272
• With a hot plate or ove 272
• Apply a light coating of prussian blue to the valve 273
• Be groun 273
• Burned or badly 273
• Clean the intake and exhaust valves thoroughly to 273
• Contacts the seat 273
• Cutter whenever a 273
• Cylinder head valves 273
• Follow the 273
• If the seat is too wide too narrow or has low stops 273
• Inspect the width of each valve sea 273
• Instruction 273
• Irregularities from the sea 273
• Lap the valves and seats using a rubber hose of 273
• Manufacturer s 273
• Operating 273
• Other hand lapping too 273
• Page 18 273
• Reface the seat 273
• Refacing 273
• Refacing equipment are recommended to correct 273
• Remove and inspect the valve 273
• Remove carbon deposits 273
• Replace 273
• The seat must be groun 273
• The valv 273
• The valves cannot 273
• Unevenly replace 273
• Use a 45 degree cutter to remove any roughness or 273
• Valve face is 273
• Valve guide is 273
• Valve seat cutters grinders or equivalent valve seat 273
• Valve seat inspection refacing 273
• Valve seat refacing 273
• With a 45 degree 273
• Worn or if it 273
• Worn valve seat 273
• Contact too high 274
• Cylinder head valves 274
• Existing valve seat material 274
• Good sealing 274
• If the contact area is too high on the valve the seat 274
• Install a 45 degree finish cutter and cut the seat to 274
• Must be lowered using a 32 degrees flat cutte 274
• Old seat 274
• Page 19 274
• Refaced 274
• Refinish if necessar 274
• Relation to the 274
• The location of 274
• The old sea 274
• The seat to make a clear patter 274
• The valve seat in 274
• Use a 32 degree cutter to remove the top 1 4 of the 274
• Valve face is very important for 274
• Blow through all oil passages with compressed air 275
• Clean the cylinder head assembly with solvent and 275
• Coils facing the combustion chambe 275
• Do not interchange 275
• Exhaust stem seal 275
• Exhaust valve 275
• Fide oil and insert the valve into the valve guid 275
• Hmg mr70002 275
• Inlet stem seal 275
• Inner spring 275
• Install the new stem seal 275
• Install the tappet hole protector into the valve lifter 275
• Install the valve spring retaine 275
• Install the valve spring seat 275
• Install the valve springs with the tightly wound 275
• Lubricate the valve stems with molybdenum disul 275
• Not available i 275
• Outer spring 275
• Page 20 275
• Retainer 275
• Slowly when insertin 275
• Spring seat 275
• Stem seal 275
• Tappet hole protector 275
• The inlet and 275
• To avoid damage to the stem seal turn the valve 275
• 0010000 276
• Above the work 276
• Attachment 276
• Cam chain 276
• Cylinder hea 276
• Hammers as shown to seat the cotters firml 276
• Install the cam chain 276
• Install the timing sprocket by aligning the wide 276
• Installation 276
• Km30101 276
• Page 21 276
• Tap the valve stems gently with two 276
• Teeth between the crankshaft and sprocket 276
• Timing sprocket 276
• To prevent loss of tension do not compress the 276
• Valve damage 276
• Valve spring compressor 276
• Valve spring more than necessar 276
• Apply a locking agent to the cam chain guide sock 277
• Apply a locking agent to the cam chain tensioner 277
• Cam chain guide 277
• Cam chain guide socket bol 277
• Cam chain tensioner 277
• Cam chain tensioner socket bol 277
• Crankcase cover page 17 8 277
• Cylinder head valves 277
• Dowel pins 277
• Et bolt thread 277
• Gasket as show 277
• Install the collar cam chain guide washer and 277
• Install the dowel pins and a new cylinder head 277
• Install the ignition pulse generator rotor and right 277
• Install the washer cam chain tensioner and socket 277
• Page 22 277
• Socket bol 277
• Socket bolt thread 277
• Tensioner socket bolts to the specified torqu 277
• Tighten the cam chain guide and cam chain 277
• 3 steps to the specified torque 278
• 51 n m 278
• Apply molybdenum disulfide oil to the outer sur 278
• Apply molybdenum disulfide oil to the threads and seating surface of the 9 mm bolts washers and in 278
• Apply oil to the 8 mm flange bolt threads and 278
• Der head with new gaske 278
• E 1 t h 278
• Face of the each valve lifte 278
• From the bol 278
• If using the new bolt remove anti rust additive 278
• Install and tighten the mounting bolt 278
• Install the cam chain tensioner lifter onto the cylin 278
• Install the cylinder hea 278
• Install the engine into the frame pag 278
• Install the shims and valve lifters into the valve 278
• Install the two 8 mm flange bolt 278
• Lifter bore 278
• M 17 ib 278
• Mm bolts 278
• Page 23 278
• Seating surfac 278
• Stall the 278
• Tensioner lifter 278
• Tighten the 8 mm flange bolts to the specified 278
• Tighten the 9 mm bolts in a crisscross pattern in 278
• Camshaft lobes 279
• Clean and apply a locking agent to the cam pulse 279
• Clean and apply a locking agent to the cam sprock 279
• Cylinder cam lobes 279
• Cylinder head valves 279
• Et bolt thread 279
• Facing down as 279
• Facing up and 279
• Generator rotor thread 279
• If the cam sprockets are removed install the cam sprockets onto the camshaft 279
• Index mark 279
• Index mark on the right crankcase cove 279
• Install the cam 279
• Install the cam pulse generator rotor and mounting 279
• Install the cam sprocket bolt 279
• Install the exhaust cam sprocket with the timing 279
• Install the intake cam sprocket with the timing mark in facing outward and the no cam lobes facing up and out as show 279
• Intake cam sprocket 279
• Lobes facing up and out as show 279
• Mark ex facing outward and the n 279
• Mark on the ignition pulse generator rotor with the 279
• Page 24 279
• Pulse generator 279
• Rotor out mark 279
• Rotor with the n 279
• Turn the crankshaft clockwise and align the t 279
• And c s center 280
• Apply molybdenum disulfide oil to the camshaft 280
• Camshaft holder a 280
• Camshaft holder b 280
• Camshaft holder b camshaft holder c 280
• Center camshaft holder 280
• Exhaust camshaft 280
• Four bolts as 280
• Ing washer 280
• Install the cam chain over the cam sprockets and 280
• Install the each camshaft holder onto the camshafts 280
• Install the each camshaft holder to the correct loca tions with the identification mark 280
• Install the each camshaft to the correct locations with the identification mark 280
• Install the sealing 280
• Intake camshaft 280
• Journals of the cylinder head and camshaft holde 280
• Left camshaft holder 280
• Make sure that the timing marks on the cam 280
• Page 25 280
• Q amshaft 280
• Right camshaft holder 280
• Sprockets are facing outward and flush with the cylinder head upper surface as shown 280
• Temporarily install the twelve holder bolts and seal 280
• Then install the intake and exhaust camshafts 280
• Timing marks 280
• Washers onto the 280
• And tighten the other cam sprocket bolt 281
• Cam pulse generator rotor 281
• Cam sfrc 281
• Camshaft holders 281
• Cylinder head surfac 281
• Cylinder head valves 281
• First gradually tighten the four bolts n 281
• Gradually tighten the other camshaft holder bolts 281
• In case the cam pulse generator rotor bolts were 281
• In case the cam sprockets were removed tighten 281
• In the numerical order casted on the 281
• Install and tighten the rotor bolts to the specified 281
• Install the cam chain guide b and tighten the bolts 281
• M 14 ib 281
• M chain guide b 281
• Page 26 281
• Removed apply locking agent to the 281
• Rotor bolt 281
• Side might cause a camshaft holder to brea 281
• The cam sprocket bolts to the specified torqu 281
• Thread 281
• Tighten all camshaft holder bolts in the numerical order casted on the camshaft holder 281
• Tightening the camshaft holder bolts on only one 281
• Turn the crankshaft clockwise one full turn 360 281
• Until the camshaft holders lightly contact the 281
• Apply oil to the new o ring and install it onto the 282
• Cam pulse generato 282
• Cylinde 282
• Head valves 282
• I iijg 282
• Install a new sealing washer and tighten the sealing 282
• Install and tighten the mounting bolt securel 282
• Install the cam pulse generator into the cylinder 282
• Page 27 282
• Recheck the valve timin 282
• Sioner lifter 282
• Stopper tool from the cam chain ten 282
• Apply a locking agent to the crankcase breather 283
• Breather separator 283
• Cylinder head cove 283
• Cylinder head cover assembly 283
• Install and tighten the bolts to the specified torqu 283
• Install the new gasket and crankcase breather sepa 283
• Install the pair check valve port plates into the 283
• Install the pair check valves into the cylinder head 283
• M 1 kg 283
• Page 28 283
• Pair check vai ec 283
• Port plates 283
• Rator to the cylinder head cover 283
• Separator mounting bolt threads 283
• Apply sealant to the cylinder head semi circular cutouts as show 284
• Cylinder head cover 284
• Cylinder headjvalves 284
• Install the cylinder head cover onto the cylinder 284
• Install the cylinder head packing into the groove of 284
• Install the washers with their up mark facing u 284
• Installation 284
• Page 29 284
• The cylinder head cove 284
• Bolts to the specified torque 285
• Connect the cam pulse generator 2p natural con 285
• Connect the crankcase breather tube 285
• Connect the pair solenoid valve 2p natural con 285
• Connect the throttle cables from the throttle dru 285
• Harness 285
• Head valves 285
• Install and tighten the cylinder head cover special 285
• Install and tighten the pair solenoid valve 285
• Install and tighten the throttle cable guide bracket mounting bolts to the specified torque 285
• Install the direct ignition coils and spark plug sub 285
• Install the pair reed valve covers and tighten the 285
• Install the pair solenoid valve assembly and con nect the air suction hoses to the pair reed valve 285
• Kgf m 9 lb 285
• Lbf ft 285
• Mounting bol 285
• Page 30 285
• Pair control solenoid valve 285
• Reed valve cover 285
• Sh bolts to the specified torque 285
• Cam chain tensioner lifter 286
• Connect the radiator sub harness 2p black connec 286
• Cure it using the stopper tool to prevent damaging 286
• Cylinder head valves 286
• Install the air cleaner housing page 5 59 286
• Install the heat guard rubber onto the cylinder head 286
• Open and support the front end of fuel tank page 286
• Page 31 286
• Removal 286
• Remove the cam chain tensioner sealing bolt and 286
• Sealing washe 286
• See page 8 8 for detail of the too 286
• The cam chai 286
• Turn the tensioner shaft fully in clockwise and se 286
• Cylinder head valves 287
• Der hea 287
• Gasket 287
• Install and tighten the mounting bolt 287
• Install the cam chain tensioner lifter into the cylin 287
• Install the new gasket onto the cam chain tensioner 287
• Lifter 287
• Page 32 287
• Remove the bolts and cam chain tensioner lifte 287
• Remove the gaske 287
• Remove the stopper tool 287
• Stopper tool 287
• Tensioner lifter 287
• Page 33 288
• 20 3 8 289
• Clutch 289
• Crankcas 289
• Formation 289
• Gearshift linkage 289
• General 289
• Installation 289
• Page 1 289
• Removal 289
• Right crankcase cove 289
• Service 289
• Service information 289
• Service limit 289
• Specifications 289
• Standard 289
• Torque values 289
• Troubleshooting 289
• Warpage 289
• Page 2 290
• C coutr 291
• Clutch gearshift linkage 291
• Clutch lifter arm counterclockwise to disengage the 291
• Connect the clutch cable end from the clutch lifter 291
• Cover mating surface 291
• Crankcase cover 291
• Disconnect the ignition pulse generator 2p red 291
• Drain the engine oil page 3 16 291
• Lifter arm spindle from the lifter piec 291
• Lifter piece inside 291
• Lifterile 291
• Open and support the front end of fuel tank page 291
• Page 3 291
• Remove the bolts and clutch cable guide then dis 291
• Remove the middle lower cowl pag 291
• Remove the right crankcase cover sh bolt 291
• Remove the right crankcase cover while turning the 291
• Remove the two dowel pin 291
• Right crankcase cover removal 291
• Spindle is engaged 291
• The lifter arm 291
• The right 291
• Wit the clutch 291
• Check the lifter lever oil seal and needle bearings 292
• Check the lifter lever spindle for wear or damage 292
• Check the return spring for fatigue or damag 292
• Clutch 292
• Clutch lifter lever 292
• Eight clutch plates 292
• For wear or damag 292
• Install the clutch lifter lever with the washer and 292
• Judder spring 292
• Judder spring seat 292
• Lifter lever 292
• Lutch d 292
• Needle bearings 292
• Nine clutch discs 292
• Oil seal 292
• Page 4 292
• Pressurf4 292
• Remove the clutch lifter lever return spring and 292
• Remove the clutch lifter piece from the lifter bear 292
• Remove the clutch spring bolts springs and pres 292
• Remove the followin 292
• Remove the right crankcase cover pag 292
• Return spring 292
• Spring in the reverse order of remova 292
• Sure plat 292
• Washer from the right crankcase cove 292
• 0050002 293
• Cially available i 293
• Clutch center holder 293
• Discard the lock nu 293
• Equivalent commer 293
• Hold the clutch center with the clutch center holder 293
• Page 5 293
• Remove the lock washer thrust washer and clutch 293
• Remove the washe 293
• Then remove the lock nu 293
• Unstake the clutch center lock nu 293
• Clutch gearshif 294
• Clutch lifter bearing 294
• Clutch spring 294
• Drive chain as an assembl 294
• Five ch 294
• I ch ou f r 294
• I rilvc 294
• If necessary replace the bearing 294
• Lifter bearing 294
• Measure the clutch spring free length 294
• Out excessive pla 294
• Page 6 294
• Primary drive 294
• Pull out the clutch oute 294
• Remove the clutch outer guid 294
• Remove the oil pump drive driven sprocket and 294
• Remove the oil pump driven sprocket bolt washer 294
• Service limi 294
• Sub gea 294
• The bearing should turn smoothly and freely with 294
• Turn the inner race of the lifter bearing with your 294
• U _r c 294
• With a screwdriver as shown 294
• Check the clutch lifter piece for damage or abnor 295
• Check the grooves of the clutch center for damage 295
• Clutch center 295
• Clutch disc 295
• Clutch lifte 295
• Clutch plate 295
• Measure the disc thickness of each dis 295
• Or wear caused by the clutch plates 295
• Page 7 295
• Plate using a feeler gaug 295
• Replace if necessary 295
• Scoring or discoloratio 295
• 0010000 296
• 0010300 296
• 0040800 296
• At clutch outer guide 296
• Attachment 4 296
• C utch outer clutch cuter guide 296
• Check the slots of the clutch outer for damage or 296
• Driver 296
• Mainshaft 296
• Measure the 296
• Measure the mainshaft 296
• Of the clutch outer guid 296
• Page 8 296
• Pilot 35 mm 296
• Press the needle bearing out of the clutch 296
• Replace if necessar 296
• Replacement 296
• Service limi 296
• Service limits 296
• Sliding surface 296
• Using the special tool 296
• Wear caused by the clutch discs 296
• Page 9 297
• 15 n m 298
• Align the primary drive gear and sub gear teeth 298
• Apply a locking agent to the threads of the oil pump 298
• Be sure the clutch 298
• Clutch 0earshift linkage 298
• Clutch outer to 298
• Driven sprocket bol 298
• Facing ou 298
• Ing tabs of the oil 298
• Install the clutch cente 298
• Install the clutch outer 298
• Install the lock washer with its outside mark 298
• Install the thrust washer 298
• Install the washer onto the clutch oute 298
• M 11 ib 298
• Onto the position 298
• Outer sits securely 298
• Page 10 298
• Properly seat it 298
• Pump drive chain 298
• Pump drive spro 298
• Rini r snri 298
• Rotate the oil 298
• S h e r 298
• T h r u s jv 298
• Tighten the driven sprocket bolt to the specified 298
• While installing the 298
• With a screwdriver as shown 298
• 0050002 299
• 127 n m 1 299
• Cially available i 299
• Clutch center holder 299
• Clutch disc green 299
• Clutch discs purple 299
• Coat the clutch discs and plates with clean engine 299
• Coat the large id clutch disc with clean engine 299
• Disc on the outside of 299
• Equivalent commer 299
• Gears hft linkage 299
• Green colored disc 299
• Hold the clutch center with the clutch center holder then tighten the lock nut to the specified torqu 299
• Install the green colored 299
• Install the green colored outer clutch disc in the 299
• Install the judder spring seat and judder sprin 299
• Install the new lock nu 299
• Oil and install it 299
• Page 11 299
• R a v nut 299
• Shallow slot on the clutch oute 299
• Stack the clutch discs and plates alternatel 299
• Stake lock nut into the mainshaft groove with a 299
• The clutch assembl 299
• Clutch assembly page 9 4 300
• Clutch gearshift linkage 300
• Er out of the crankcas 300
• Gearshift linkage removal 300
• In 2 3 300
• Install the clutch lifter piece into the lifter bearin 300
• Install the clutch springs and spring bolt 300
• Install the lifter bearing into the pressure plate 300
• Install the pressure plat 300
• Install the right crankcase cover page 9 17 300
• Page 12 300
• Pull the gearshift spindle assembly and thrust wash 300
• Remove the bolt and gearshift pedal link 300
• Right crankcase cover page 9 3 300
• Steps then tighten them to the specified torqu 300
• Tighten the bolts in a crisscross pattern 300
• Bending 301
• Cam removal page 9 12 301
• Check the gearshift spindle for wear damage or 301
• Check the return spring for fatigue or damage 301
• Dowel pins 301
• Gearshift cam 301
• Gearshift linkage through socket bolt gearshift 301
• Gearshift spindle 301
• Oil pan page 4 3 301
• Page 13 301
• Removal 301
• Remove the bolts and shift drum bearing set plate 301
• Remove the f 301
• Remove the followin 301
• Remove the shift fork shaft and shift fork 301
• Return spring 301
• S t cpfer r rne 301
• Set plates 301
• Shift drum shift for 301
• Socket bolt 301
• Stopper arm 301
• Stopper arm socket bolt 301
• Washer 301
• Check the shift fork and fork shaft for wear or 302
• Clutch gearshift linkage 302
• Inspect the shift drum grooves for wear or damage 302
• Inspection 302
• Measure the 302
• Measure the shift fork claw thickness 302
• Of the shift for 302
• Of the shift fork shaf 302
• Page 14 302
• Remove the shift drum bearing and shift dru 302
• Shift drum shift fork 302
• Apply molybdenum disulfide oil to shifter fork 303
• C for center 303
• Groove of the shift gears 303
• Hif i ti uivi 303
• Identification marks 303
• If necessary replace the bearing 303
• Install the shift drum and shift drum bearing 303
• Install the shift fork shafts with their identification 303
• Install the shift forks on the transmission 303
• L for left 303
• Left shift fork 303
• Mark facing to righ 303
• Page 15 303
• R for right 303
• Right shift fork 303
• Shift fork 303
• The bearing should turn smoothly and freely 303
• The shift forks have location marks 303
• Turn the outer race of the shift drum bearing with 303
• Without excessive pla 303
• Your finger 303
• 12 n m 304
• Align the dowel 304
• Apply a locking agent to the threads of the set plate 304
• Arm using a screwdriver as show 304
• Clutc jigeafshft linkage 304
• Drum center with 304
• Gearshift linkage installation 304
• Gearshift viv 304
• Groove 304
• Install and set plates and bolts tighten the bolts to 304
• Install the dowel pin onto the shift dru 304
• Install the followin 304
• Install the gearshift cam while holding the stopper 304
• Install the gearshift linkage see following steps 304
• Install the shift fork shaft 304
• Lbf ft 304
• M 9 lb 304
• On the gearshift 304
• Opper ar 304
• Page 16 304
• Pin on the shift 304
• Return spring 304
• Soc et bolt 304
• Socket bolt 304
• Stopper arm 304
• T iasher 304
• The specified torqu 304
• The wide groove 304
• Tighten the stopper arm socket bolt to the specified 304
• Torque 304
• 23 n m 305
• Apply a locking agent to the gearshift cam socket 305
• Apply a sealant to the mating surfaces of the crank 305
• Arshif 305
• Assembly into the crankcase while aligning the 305
• Bolt thread 305
• Case as show 305
• Gearshift spindle 305
• I iark 305
• Install and tighten the pinch bolt to the specified 305
• Install and tighten the socket bolt to the specified 305
• Install the clutch assembly pag 305
• Install the gearshift pedal link by aligning its slit 305
• Install the thrust washer and gearshift spindle 305
• Installation 305
• Ket bolt 305
• M 17 lbf ft 305
• M 7 ib 305
• Page 17 305
• Right crankcase cover 305
• Spring ends with the crankcase stopper pi 305
• Torque 305
• With the punch mark on the gearshift spindl 305
• Apply sealant to the mating surface of the right 306
• Clutch gearshif 306
• Cover sh bolt 306
• Crankcase cove 306
• Install and temporarily tighten the right crankcase 306
• Install the right crankcase cover while turning the 306
• Install the two dowel pin 306
• Lifter arm clockwise to engage the lifter arm groove 306
• Page 18 306
• Right c 306
• With the lifter piece flang 306
• Cable en 307
• Clutch 307
• Connect 307
• Connect the ignition pulse generator 2p red con necto 307
• In 2 3 step 307
• Lever then install the clutch cable bracket with the 307
• Liftep h je 307
• Lifter 307
• P red connector 307
• Page 19 307
• Pour the recommended engine oil page 3 15 307
• Right cr 307
• Tighten the right crankcase cover crisscross pattern 307
• Two bolt 307
• 0020001 308
• 0040000 308
• Alternator cover installation 10 8 308
• Alternator cover removal 308
• Alternator wire clamp bolt 308
• Apply a locking agent to the threads 308
• Ct bolt 308
• Damaged idle gear shaft 308
• Engine does not turn 308
• Equivalent commercially available in 308
• F r i ytio l 308
• Flywheel flange bolt 308
• Flywheel holder 308
• Flywheel installation 308
• Flywheel removal 308
• Gener al 308
• Or 07933 3950000 308
• Page 1 308
• S rvic 308
• S t a 0r 308
• Service limit 308
• Seth ice 1 form t 308
• Specifications 308
• Standard 308
• Starter clutch 308
• Starter driven gear boss 308
• Starter one way clutch socket bolt 308
• Stator mounting socket bolt 308
• Troj3i esnc0tinng 308
• Alternator cover 309
• Alternator starter clutch 309
• Careful during 309
• Casket 309
• Cover is remove 309
• Cover stator is 309
• Disconnect the alternator 3p white connecto 309
• Engine and add the recommended oil to the speci 309
• Fled level after installatio 309
• For cove 309
• Lywhee 309
• Magnetically at 309
• Nator cove 309
• O1mmet 309
• P white connector 309
• Page 2 309
• Page 5 89 309
• Removal 309
• Remove the alternator cover sh bolts and alterna 309
• Remove the alternator wire grommet from the alter 309
• Remove the fuel tank rear bracket and ecm cover 309
• Remove the gasket and dowel pin 309
• Remove the middle lower cowl pag 309
• Remove the socket bolt and stator wire clam 309
• Remove the socket bolts and stato 309
• Set a clean oil pan under the 309
• Socket bolts 309
• Tached to the 309
• The alternator 309
• The engine oil will run out when the alternator 309
• Wire clamp 309
• Alternator cover 310
• Flywheel removal 310
• Page 3 310
• Socket bolts 310
• Statop 310
• Stator 310
• Wire clamp 310
• 0020001 or 311
• 0040000 311
• 3950000 311
• Alternator starter clutch 311
• Check the starter idle gear and shaft for wear or 311
• Cially available i 311
• Flywheel holder 311
• Gi y vheel 311
• Hold the flywheel using the flywheel holder then 311
• Page 4 311
• Remove the flywheel bolt 311
• Remove the flywheel using the special too 311
• Remove the woodruff ke 311
• Rotor puller 311
• Woodruff key 311
• 0040000 312
• Alternator starte 312
• Check the one way clutch for wear or damage and 312
• Check the operation of the one way clutch by turn 312
• Check the starter driven gear for abnormal wear or 312
• Clockwise 312
• Clockwise smoothly but the gear should not turn 312
• Disassembly 312
• Flywheel holder 312
• Hold the flywheel with a flywheel holder and re 312
• Ing the driven gea 312
• Measure the starter driven gear boss 312
• Move the starter clutch mounting torx bolt 312
• Page 5 312
• Remove the starter driven gear by turning it coun terclockwis 312
• Remove the starter one way clutch assembl 312
• Replace if necessary 312
• Service limi 312
• Starter clutch 312
• You should be able to turn the driven gear counter 312
• Apply oil to the starter one way clutch 313
• Assembly 313
• Clutch outer 313
• Driven gear 313
• Flywhee 313
• Flywheel 313
• Install the one way clutch into the clutch outer with 313
• Install the starter one way clutch assembly onto the 313
• One way clutc 313
• One way clutch 313
• Page 6 313
• The flange side facing ou 313
• 0040000 314
• Alternator starter clutch 314
• Apply a locking agent to the starter clutch outer mounting bolt threads 314
• Apply oil to the flywheel bolt threads and seating 314
• Cially available i 314
• Clean any oil from the crankshaft tape 314
• Clockwise smoothly but the gear should not turn clockwis 314
• Equivalent commer 314
• Flywheel holder 314
• Flywheel installation 314
• Flywheel with the woodruff key on the crankshaf 314
• Hold the flywheel with a flywheel holder and 314
• Install the flywheel aligning the key way in the 314
• Install the starter driven gear into the one way 314
• Install the washer and flywheel bol 314
• Install the woodruff key on the crankshaf 314
• Page 7 314
• Recheck the one way clutch operation 314
• Surfac 314
• Tighten the starter clutch mounting torx bolt 314
• Washer 314
• You should be able to turn the driven gear counter 314
• 0040000 315
• Alternator cover installation 315
• Apply molybdenum disulfide oil to the starter idle 315
• Apply oil to the starter idle gea 315
• Apply sealant to the mating surface of the crank 315
• Case as show 315
• Cially available i 315
• Dobvhl pi 315
• E e co 315
• Equivalent commer 315
• Flywheel h01 der 315
• Flywheel holder 315
• Gasket 315
• Gear shaft 315
• Hold the flywheel using the flywheel holder then 315
• Idle gear 315
• Install the dowel pin and new gaske 315
• Install the starter idle gear and shaft onto the 315
• Page 8 315
• Tighten the bolt to the specified torque 315
• 12 n m 316
• Alternator starter clutch 316
• Attached to the 316
• Careful during in 316
• Connect the alternator 3p white connecto 316
• Cover stator is 316
• Flywheel be 316
• Install and tighten the sh bolts to the specified 316
• Install the alternator cove 316
• Install the ecm cover and fuel tank rear bracket 316
• Install the middle lower cowl page 2 7 316
• Magnetically 316
• P white connector 316
• Page 5 89 316
• Page 9 316
• Stallation 316
• The alternator 316
• Apply molybdenum 317
• Clearance 317
• Code tables after installing new bearings recheck them with plastigauge to verify clearanc 317
• Connecting rod smal 317
• Connecting rod to piston pin clearance 317
• Crankcase combination 317
• Crankcase separation 317
• Crankpin oil clearance 317
• Cylinder 317
• Cylinder head cam chain section 8 317
• General 317
• Mark and store the bearing inserts to be sure of their correct locations for reassembl 317
• Measurement point 317
• Out of round 317
• Page 1 317
• Pin clearance 317
• Piston 317
• Piston connecting rod 317
• Piston ring end gap cylinder to piston clearance 317
• Second 317
• Second_ 317
• Select replacement bearings from the 317
• Service information 317
• Service limit 317
• Specifications 317
• Standard 317
• The following parts must be removed before separating the crankcas 317
• Troubleshooting 317
• Warpage 317
• Water pump section 6 317
• Apply a locking agent to the threads 318
• Apply a locking agent to the threads apply a locking agent to the threads apply a locking agent to the threads 318
• Apply oil to the threads 318
• Bent connecting rod 318
• Bent valve or bent and deteriorated valve seat 318
• Blown cylinder head gasket 318
• Carbon deposits on the cylinder head and or piston 318
• Connecting rod nut 318
• Crankcase bolt 10 mm 318
• Cylinder compression is too high or engine overheats or 318
• Cylinder compression is too low or engine is hard to 318
• Engine vibration 318
• Excessive crankshaft runout 318
• Excessive noise 318
• Excessive smoke 318
• Knocks 318
• Lower crankcase sealing bolt 20 mm 318
• Mainshaft bearing set plate bolt 318
• Mm main journal bolt 318
• Page 2 318
• Piston sounds 318
• Troubleshooting 318
• Upper crankcase sealing bolt 318
• Worn connecting rod big end bearing 318
• Worn connecting rod small end 318
• Worn crankshaft main journal bearing 318
• Worn cylinder piston and or piston ring 318
• Worn or damaged cylinder or piston 318
• Worn piston pin hole and piston pin 318
• Worn stuck or broken piston ring 318
• Worn transmission bearing 318
• Worn valve stem seal 318
• Al of necessary parts before separating the crank 319
• And oil orifice 319
• Bolts and sealing washer 319
• Crankcase istonjcylinder 319
• Crankcase separation 319
• Crisscross pattern in 2 3 steps then remove the 319
• Et plate 319
• Loosen the ten lower crankcase 9 mm bolts in a 319
• Mm bolts seven and 10 mm bol 319
• Oil orifices 319
• Page 3 319
• Refer to service information page 11 1 for remov 319
• Remove the lower crankcase 6 mm bolts ten 8 319
• Remove the mainshaft bearing set plate bolts and 319
• Remove the swingarm pivot collars dowel 319
• Remove the upper crankcase 6 mm bolts 8 mm 319
• Separate the lower crankcase from the upper crank 319
• Be installed in their original locations or the correct 320
• Bearing cap 320
• Bearing oil clearance may not be obtained 320
• Do not damage the 320
• Do not interchange the bearing insert 320
• During removal so 320
• Mark all parts 320
• Original location 320
• Page 4 320
• Piston connectih rod asse 320
• Piston connecting rod 320
• Piston pin 320
• Piston removal 320
• Piston rings during 320
• Placed in their 320
• Press the piston pin out of the piston and remove 320
• Remova 320
• Removal 320
• Remove the nuts and connecting rod bearing ca 320
• Remove the piston connecting rod assembly from 320
• Remove the piston pin clip with plier 320
• Remove the piston ring 320
• Resulting in engine damag 320
• The piston from the connecting ro 320
• The top of the cylinde 320
• They can be re 320
• They must 320
• Crankcase piston cylinder 321
• Grooves using an old piston ring as show 321
• In from the bottom and 90 degrees to the piston 321
• In the cylinde 321
• Insert the piston ring squarely into the bottom of the cylinder and measure the ring end ga 321
• Inspect the piston for wear or damage 321
• Measure the diameter of the piston at 13 mm 321
• Measure the piston ring to ring groove clearance 321
• Oil side rail 321
• Page 5 321
• Pin hole 321
• Piston inspection 321
• Piston to be sure 321
• Position with the mark facing u 321
• Push the rings into 321
• Temporarily install the piston rings to their proper 321
• The cylinder with 321
• The top of the 321
• They are squarely 321
• With the rings pushed into the groove 321
• Calculate the piston to cylinder clearance 322
• Calculate the piston to piston pin clearanc 322
• Crankcase p 322
• Cylinder inspection 322
• Der wear 322
• In x and y axis at three 322
• Inspect the cylinder bore for wear or damage 322
• Inspect the top of the cylinder for warpag 322
• Measure the 322
• Measure the cylinder 322
• Measure the piston pin bor 322
• Of the piston pi 322
• Page 6 322
• Refer to page 11 5 for measurement of the piston 322
• Standar 322
• Take the maximum reading to determine the cylin 322
• Ton cylinder 322
• Bottom 323
• Calculate the taper and out of round at three levels 323
• Connecting rod inspection 323
• Crankcase piston cylinder 323
• Crankpi 323
• Crankpin bearing inspection 323
• Do not put the plastigauge over the oil hole in the 323
• Do not rotate the crankshaft during inspectio 323
• In obi 323
• In x and y axis take the maximum reading to de 323
• Install the bearing inserts and bearing cap and 323
• Measure the connecting rod side clearanc 323
• Measure the connecting rod small end 323
• Of roun 323
• Page 7 323
• Put a piece of plastigauge on each crankpi 323
• Service limi 323
• Service limit 323
• Temporarily install the connecting rod to the crank 323
• Termine the 323
• The cylinder must be rebored and an oversize pis 323
• The following oversize pistons are available 323
• The piston to cylinder clearance for the oversize pis 323
• Tighten the bolt 323
• Ton fitted if the service limits are exceede 323
• Ton must b 323
• Wipe all oil from the bearing inserts and crankpin 323
• Bearing cap 324
• Code number 1 or 2 324
• Code number a or b 324
• Codes for the 324
• Connecting rod 324
• Correct crankpins and tighten the cap nuts to the 324
• Crankcase piston cylinder 324
• Crankpin 324
• Crankpin bearing selection 324
• If you are replacing the crankshaft record the corre 324
• If you are reusing the crankshaft measure the 324
• Install the bearing caps and connecting rods on a 324
• M 26 ib 324
• Numbers a or b 324
• On the crank 324
• Or measure the 324
• Page 8 324
• Record the connecting rod 324
• Specified torqu 324
• Sponding crankpin 324
• Starting from the 324
• Tolerance selects replacement bearing 324
• Weight are the 324
• With the bearing cap installed without bearing inserts 324
• With the micromete 324
• A blue 325
• And bearing and 325
• And bearing ca 325
• And bearing cap 325
• Bearing thicknes 325
• Between the 325
• C brown 325
• Connecting rod 325
• Crank pin 325
• Crankpin bearing selection table 325
• Cross reference the crankpin and rod codes to de 325
• D code 325
• D green 325
• E yellow 325
• Identification collar 325
• Install the bearing inserts into the connecting rod 325
• Page 9 325
• Termine the replacement bearing colo 325
• Yellow 325
• After installation the rings should rotate freely in 326
• Apply molybdenum disulfide oil to the piston pin 326
• Apply oil to the piston ring 326
• Assemble the piston and connecting ro 326
• Avoid piston and piston ring damage during in 326
• Clean the piston ring grooves thoroughly and 326
• Connecting rod 326
• Do not align the 326
• Do not align the gaps in the oil rings side rails 326
• Do not mix the top and second ring 326
• End gap with the 326
• In mark 326
• Install the 326
• Install the piston pin and secure it using a new pis 326
• Install the piston ring 326
• Install the piston rings with the marking r fac 326
• Is narrower than the second ring in width 326
• Mark on the piston crown 326
• Oil hole 326
• Outer surfac 326
• Page 10 326
• Piston 326
• Piston assembly 326
• Piston cut out 326
• Piston pin 326
• Piston pin clips 326
• Second ring 326
• Side facing the 326
• Side rails 326
• Space the piston ring end gaps 120 degrees apar 326
• Stallatio 326
• The ring groove 326
• The top ring 326
• Ton pin clip 326
• Top ring 326
• With its oil hole 326
• Apply molybdenum disulfide oil to the crankpin 327
• Apply oil to the connecting rod nut threads and seat ing surface 327
• Apply oil to the cylinder sleeves and piston rings 327
• Assembly with the 327
• Be careful not to damage the cylinder sleeve and 327
• Bearing surface 327
• Compressor tool 327
• Connecting rod 327
• Crankcase piston cylinder 327
• Crankpin with the connecting rod bolt threads 327
• Cylinder 327
• Damage the top surface of the cylinder especial 327
• Facing to the 327
• Gradually and alternately then tighten them to the 327
• Install the bearing ca 327
• Install the connecting rod nuts and tighten the nuts 327
• Install the piston 327
• Install the piston connecting rod assembly into the cylinder using a commercially available piston ring 327
• Insure that the marks on the caps are aligned with 327
• Intake sid 327
• Ly around the cylinder bor 327
• M 26 ib 327
• Make sure ring 327
• Notice 327
• Page 11 327
• Sits flush with top 327
• Specified torqu 327
• Surface of the 327
• The marks on the connecting rod 327
• Ton into the cylinde 327
• Use the handle of a plastic hammer to tap the pis 327
• While installing the piston be careful not to 327
• Apply clean engine oil to the 9 mm bolt threads and 328
• Area and the oil passage area as show 328
• Clean the new crankcase 9 mm bolts thoroughly 328
• Coating 328
• Crankcase combination 328
• Groove in the upper crankcas 328
• Install oil orifices by aligning their cut out with the 328
• Install the lower crankcase onto the upper crank 328
• Install the swingarm pivot collar 328
• Install the three dowel pins 328
• Liquid 328
• Loosely install all the lower crankcase bolts 328
• Make sure the swingarm pivot collar flanges are 328
• Make sure the upper and lower crankcase are 328
• Oil orifices 328
• Page 12 328
• Sealant to the crankcase mating surface except to 328
• Seated securel 328
• Seated the crankcase securel 328
• Seating surface and install the 328
• The main bearing journal bolt lower crankcase bolt 328
• Thorough 328
• With solvent and blow them dr 328
• Are indicated on 329
• Bolts in numerical 329
• Case 9 mm bolts in a crisscross pattern in 2 3 329
• Crankcase piston cylinder 329
• Crankcase using 329
• From the inside to outside tighten the lower crank 329
• Install the upper crankcase 8 mm bolts sealing 329
• Mm bol 329
• Mm bolt 329
• Mm bolts 329
• Mm bolts sealing washers 329
• Order as shown in 329
• Page 13 329
• Sealing washers 329
• The g mark 329
• The illustratio 329
• The sealing 329
• The upper 329
• Tighten the 10 mm bolt and then 8 mm bolts and 6 329
• Tighten the 6 mm bol 329
• Tighten the 8 mm bolts to the specified torque 329
• Tighten the 9 mm 329
• Washer locations 329
• Washers and 6 mm bol 329
• Crankcase piston cylinder 330
• Install the removed parts in the reverse order of 330
• Outside mark 330
• Page 14 330
• Plate bolt thread 330
• T plate 330
• Tighten the mounting bolts to the specified torqu 330
• Apply molybdenum 331
• Be separated to service the crankshaft and transmissio 331
• Bushing 331
• Clearance 331
• Countershaft 331
• Crankcase 331
• Crankshaft 331
• Gear to bushing 331
• General 331
• M5 m6 30 50 3 331
• Mainshaft 331
• Page 1 331
• Runout 331
• Separation assembl 331
• Service information 331
• Service limit 331
• Specifications 331
• Standard 331
• Transmission 331
• Troubleshooting 331
• Page 2 332
• Bearing cap 333
• Before removal 333
• Bolt thread 333
• Connecting rod 333
• Crankcase 333
• Crankpin with the 333
• Crankshaft 333
• Damaging the 333
• Friction spring 333
• I irn i b 333
• Page 3 333
• Pistons at tdc 333
• Position all the 333
• Remove the connecting rod bearing cap nuts and 333
• Remove the crankshaf 333
• Remove the main journal bearings from both the 333
• Remove the special snap ring and friction sprin 333
• Separate the crankcase halves page 11 3 333
• To prevent 333
• Top dead center 333
• Apply molybdenum disulfide oil to the area shown 334
• Crankshaft transmission 334
• Drive gear aligning the holes between the gea 334
• Friction spring 334
• In the illustratio 334
• Install the friction spring and new special snap ring 334
• Install the primary drive sub gear onto the primary 334
• Install the springs into the primary drive gear as 334
• Notice 334
• Page 4 334
• Primary drive sub gear 334
• Remove the primary drive sub gear and spring 334
• Ring can cause severe engine damag 334
• The snap 334
• Using a snap ring other than specified or reusin 334
• You must use the new special sna 334
• Assemble the above items and screw the bolt grad 335
• Available universal bearing pulle 335
• Bearing puller 335
• Bearings 335
• Bearings are 335
• Ble collar washer and 10 mm flange bolt exampl 335
• Claws cover the 335
• Collar 335
• Crankshaft main 335
• Cut outs 335
• Cutouts as show 335
• Driver shaft 335
• Facing to the right and the chamfered side facing 335
• Flange bolt 335
• Flywheel bolt for the bearing installation 335
• If the special tool is not available prepare a suita 335
• Install the new special snap ring with its large tab 335
• Journal 335
• Journal from the 335
• Large tab 335
• Main journal 335
• Make sure the new special snap ring end gap is aligned with the right angle of the crankshaft 335
• Mb00200 335
• Needle bearing 335
• Page 5 335
• Press a new needle bearing onto the crankshaft 335
• Properl 335
• Protectors 335
• Remove the needle bearing with a commercially 335
• Snap ring 335
• To protect the 335
• Ually then install the new needle bearin 335
• Usable as 335
• Using a hydraulic press and special tool 335
• Washer 335
• Worn main 335
• 26 lbf ft 336
• 35 n m 336
• Assemble the crankcase halve 336
• Crankshaft transmission 336
• Damage or separatio 336
• Do not put the plastigauge over the oil hole in the 336
• Do not rotate the crankshaft during inspection 336
• Hold the crankshaft both en 336
• Ing inserts then carefully lower the crankshaft in 336
• Inspect the main journal bearing inserts for 336
• Inspection 336
• Main bearing journal of the crankshaf 336
• Mm bolts 336
• Page 6 336
• Put a piece of plastigauge on each journal 336
• Reinstall the upper crankcase s main journal bear 336
• Rotate the crankshaft two revolutions and read 336
• Runout at the center journal 336
• Service limi 336
• Set a dial indicator on the center main journal of 336
• The crankshaf 336
• Tighten the 9 mm bolts to the specified torqu 336
• Wipe the oil from the bearing inserts and journals 336
• After selecting new bearings recheck the clearance 337
• B brown 337
• C green 337
• Codes for the main 337
• Crank weight are 337
• Crankcase are the 337
• Crankshaft transmission 337
• Cross reference the case and journal codes to deter 337
• D yellow 337
• E pink 337
• From left to right 337
• Identification color 337
• If main bearing clearance is beyond tolerance se 337
• Journal 337
• Lect a replacement bearing 337
• Left to righ 337
• Letters from the pad on 337
• Main journal 337
• Main journal bearing 337
• Measure the compressed plastigauge on each jour 337
• Mine the replacement bearing color code 337
• Numbers from the crank weigh 337
• Or 3 on the 337
• Or c on the upper 337
• Page 7 337
• Record the corresponding main journal 337
• Record the crankcase 337
• Remove the 9 mm bolts and lower crankcase 337
• S from 337
• Service limit 337
• Severe engine damag 337
• The codes for the 337
• The left side of the upper crankcase as show 337
• The letters a b 337
• The numbers 0 1 337
• With a plastigauge incorrect clearance can cause 337
• 35 n m 338
• Alternatel 338
• Apply molybdenum disulfide oil to the upper and 338
• Apply oil to the connecting rod nut threads and seat 338
• Assemble the upper and lower crankcase page 338
• Be ring caps 338
• Ch ankshaft 338
• Connecting rod 338
• Crankcase 338
• Crankshaft transmission 338
• Damaging the 338
• Ijrnal beari 338
• Ing surface 338
• Install and tighten the nuts gradually and 338
• Install the connecting rod bearing cap 338
• Install the main journal bearings into the upper and 338
• Lower crankcas 338
• Lower main journal bearing 338
• M 26 ib 338
• Main journal bearing selection table 338
• Page 8 338
• Pistons at tdc 338
• Threads 338
• Top dead center 338
• Yellow 338
• C2 c3 c 339
• Check the gear dogs dog holes and teeth for abnor 339
• D of each gea 339
• Disassemble the mainshaft and countershaf 339
• Mainshaft 339
• Mal wear or lack of lubricatio 339
• Measure the 339
• Of each gear bushin 339
• Page 9 339
• Remove the dowel pins and countershaft bearing 339
• Remove the mainshaft and countershaft assembly 339
• Separate the crankcase halves page 11 3 339
• Service limit 339
• Set rin 339
• Set ring 339
• Transmission 339
• Also check that the bearing inner race fits tightly on 340
• As an assembl 340
• Assembly if the race does not turn smoothly 340
• Bearing from the 340
• Bearing is worn or 340
• Check the shift fork groove of the shifter gear for 340
• Clutch outer 340
• Clutch outer guid 340
• Countershaft 340
• Crankshaft transmission 340
• Damaged replace 340
• Do not try to 340
• Excessive wear or damag 340
• If the 340
• Of the mainshaft and counter 340
• On the mainshaf 340
• Page 10 340
• Quietly or fits loosely on the countershaf 340
• Race does not turn smoothly quietly or fits loosely 340
• Remove and discard the mainshaft bearing if the 340
• Remove the 340
• Replace the countershaft collar and bearing as an 340
• Service limit 340
• The bearings should turn smoothly and quietl 340
• The countershaft 340
• The shaf 340
• Turn the outer race of each bearing with your finge 340
• 0030100 341
• 0030300 341
• Attachment 30 mm 341
• Bearing 341
• Driver 40 mm 341
• Hydraulic pres 341
• Install a new mainshaft bearing onto the mainshaft by pressing the mainshaft bearing inner race using 341
• M2 gear 15t 341
• M3 4 gear 20 20t 341
• M5 gear 21t 341
• M6 gear 21t 341
• Mainshaft 341
• Mainshaft m1 gear 13t 341
• Out the mainshaft from the bearing using a 341
• Page 11 341
• The special too 341
• C5 gear 27t 342
• Countershaft 342
• Crankshaft transmission 342
• Page 12 342
• Also align the countershaft bearing stopper pin 343
• Apply molybdenum disulfide oil to the shift fork 343
• Assemble the crankcase page 11 12 343
• Assemble the transmission gear and shaft 343
• Coat each gear with clean engine oil and check for 343
• Countershaft 343
• Grooves in the m3 4 c5 and c6 gea 343
• Holes with the dowel pin 343
• Install the countershaft bearing set ring into the up 343
• Install the dowel pins in the upper crankcase hole 343
• Install the mainshaft and countershaft by aligning 343
• Mainshaftt 343
• On the crankcase and aligning the bearing cap 343
• Page 13 343
• Per crankcase groov 343
• Set ring 343
• Smooth movemen 343
• Stopper pin 343
• The countershaft bearing groove with the set ring 343
• With the groove in the crankcas 343
• A contaminated brake disc or pad reduces stopping powe 344
• And clean a contaminated disc 344
• Axle runout 344
• Discard contaminated pad 344
• End facing up 344
• Front wheel 344
• General 344
• Handlebars 344
• Kgf cm 344
• Minimu 344
• Page 1 344
• Recomme 344
• Runout 344
• Service information 344
• Service limit 344
• Specifications 344
• Standard 344
• Steering head bearing pre load 344
• Steering stem 344
• Suspensio 344
• Tensio 344
• To maximum weight capacity 344
• Troubleshooting 344
• Use only tires marked tubeless and tubeless valves on rim marked tubeless tire applicable 344
• Wheel rim runout i 344
• With the tapere 344
• 0010000 07746 0010300 07746 0040600 345
• 0050100 07746 0050800 345
• 1 m90100 345
• 3710101 345
• Aloc bolt 345
• Assembly base 345
• Attachment 4 345
• Bearing remover a 345
• Bearing remover b 345
• Bearing remover head 25 mm 345
• Bearing remover shaft 345
• Bent frame 345
• Brake drag 345
• Clogged fork fluid passage 345
• Driver attachment a driver attachment b driver shaft assembly 345
• Faulty or damaged steering head bearings 345
• Faulty steering head bearings 345
• Faulty wheel bearing 345
• Fork bottom bridge pinch bolt 345
• Fork damper holder 345
• Front brake disc mounting bolt 345
• Front suspension noisy 345
• Front wheel wobbling 345
• Handlebar pinch bolt 345
• Handlebar weight mounting screw 345
• Hard steering 345
• Hard suspension 345
• Ka50100 345
• Km90001 345
• Km90200 07946 km90300 345
• Km90401 345
• Km90500 07946 km90600 345
• M b00000 345
• M e90200 345
• Ma60000 345
• Nmd kz3010 345
• Nmd kz30101 excep 345
• Or 07916 371010 345
• Or 07kmd kz30100 with 345
• Or 07vmf mato100 345
• Page 2 345
• See page 13 29 345
• Soft suspension 345
• Steering head bearing adjustment nut too tight 345
• Steering stem nut 345
• Steering stem socket 345
• Top thread a 345
• Top thread b 345
• Unbalanced tire and wheel 345
• Vmf kz30200 345
• Vmf mat0200 345
• Vmf mat0300 07vmf mat0400 345
• Weak fork springs 345
• Wheel suspension steering 345
• Wheel turns hard 345
• Worn front wheel bearings 345
• Worn swingarm pivot components 345
• Worn wheel bearing 345
• Ymb mcf0101 345
• Ymd mcfo100 345
• And master cylinder assembl 346
• Disconnect the front brake switch wires connectors from the switch 346
• Front wheel suspension steer ng 346
• Handlebars 346
• Page 3 346
• Removal 346
• Remove the master cylinder holder bolts holder 346
• Remove the right handlebar switch housing and 346
• Remove the right handlebar switch throttle housing 346
• Remove the screw and the handlebar grip en 346
• Throttle pipe from the right handleba 346
• Disconnect the clutch switch wire connectors from 347
• Disconnect the throttle cable ends from the throttle 347
• Front wheel suspension steering 347
• Grip end 347
• Holder and clutch lever bracket assembl 347
• Housin 347
• Page 4 347
• Pipe and remove the housin 347
• Remove the clutch lever bracket holder bolts 347
• Remove the handle grip from the handleba 347
• Remove the screw and handlebar grip end 347
• Remove the screws and left handlebar switch 347
• Screws 347
• The switc 347
• Throttle pipe 347
• Bridge lower surface then tighten the handlebar 348
• Front wheel suspension steering 348
• Groove 348
• Handlebar pinch bolt 348
• Handlebar stopper pin 348
• Ibf ft 348
• Install the handlebar stopper ring onto the fork tube 348
• Install the handlebars onto the fork tub 348
• Install the top bridge while aligning its grooves 348
• Installation 348
• Loosen the top bridge pinch bolts and handlebar 348
• M 76 ibf ft 348
• Op ring 348
• Page 5 348
• Pinch bol 348
• Pinch bolt 348
• Pinch bolt to the specified torqu 348
• Remove the handlebars from the fork tube 348
• Remove the steering stem nut and remove the top 348
• Seat the handlebar pivot upper surface with the top 348
• Tighten the steering stem nu 348
• Tighten the top bridge pinch bolts to the specified 348
• Top bridge 348
• Top bridge pinch bolt 348
• Torque 348
• With the handlebar stopper pi 348
• Aligning its boss with the slot in the handlebar 349
• Allow the adhesive 349
• Apply honda bond a or honda hand grip cement 349
• Apply lubricant 349
• Before usin 349
• Clean surfaces of the left handlebar and throttle 349
• Discard the retaine 349
• Driver or punc 349
• Easy remova 349
• Handleba 349
• Handlebar weight replacement 349
• Inner weight 349
• Insert the handlebar weight assembly into the 349
• Install a new mounting scre 349
• Install the grip end onto the handlebar weight 349
• Install the new retainer onto the handlebar weight 349
• Only to the inside of the grip and to the 349
• Page 6 349
• Remove the grip end from the handlebar weigh 349
• Remove the grip from the handleba 349
• Remove the handlebar weight by turning the grip 349
• Retainer hole 349
• Retainer ring 349
• Retainer tab 349
• Rotate the grip for even application of the adhesiv 349
• Spray through the 349
• Straighten the weight retainer tab by the screw 349
• Tab locking hole to 349
• Tab with the hole in the handleba 349
• Temporarily install the grip end and screw then 349
• The rubber for 349
• To dry for an hour 349
• Turn the handlebar weight and hook the retainer 349
• Wait 3 5 minutes and install the gri 349
• Connect the clutch switch wires 350
• Connect the throttle cable ends to the throttle pip 350
• Handleba 350
• Install the clutch lever bracket assembly by aligning 350
• Install the clutch lever bracket holder with the up 350
• Install the left handlebar switch aligning its locating 350
• Lever bracket 350
• M 9 ib 350
• Mark facing u 350
• Page 7 350
• Pin with the hole in the handleba 350
• Switch housing 350
• The end of the bracket with the punch mark on the 350
• Throttle pipe 350
• Tighten the forward screw first then the rear screw 350
• Tighten the upper bolt first then the lower bol 350
• Apply grease to the sliding surface of the throttle 351
• By aligning its locating pin with the hole in the 351
• Connect the brake switch wire 351
• Front wheel suspension steering 351
• Handleba 351
• I ldep 351
• Install the master cylinder by aligning the end of 351
• Install the master cylinder holder with the up 351
• Install the right handlebar switch throttle housing 351
• Install the throttle pipe into the right handleba 351
• Itier h 351
• L4ttt f 351
• Mark facing u 351
• Page 8 351
• Right handlebar 351
• Switch housing 351
• The master cylinder with the punch mark on the 351
• Throttle pipe 351
• Tighten the forward screw first then the rear screw 351
• Tighten the upper bolt first the lower bol 351
• Axle bol 352
• Brake lever after 352
• Caliper 352
• Clamp nut 352
• Do not operate the 352
• Do not twist the brake hos 352
• Front fender 352
• Front wheel 352
• Grip end 352
• Install the grip end and tighten the new mounting 352
• Is removed 352
• Loosen the right axle pinch bolts 352
• Page 9 352
• Reflector 352
• Reflector and front fende 352
• Removal 352
• Remove the axle bol 352
• Remove the brake hose clamp nuts special bolts 352
• Remove the mounting bolts and both brake 352
• Screw to the specified torqu 352
• Special bolts 352
• Stand or a hois 352
• Support the brake caliper with a piece of wire so 352
• Support the motorcycle securely using a safety 352
• That it does not hang from the brake hos 352
• The brake caliper 352
• Actual runout is 1 2 the total indicator reading 353
• Also check that the bearing outer race fits tightly in 353
• Bearings in pair 353
• Install the new bearings into the hub using the 353
• Loosen the left axle pinch bolt 353
• Page 10 353
• Pin i i 353
• Remove and discard the bearings if they do not 353
• Remove the axle and the front whee 353
• Remove the side collar 353
• Replace the 353
• Service limi 353
• Set the axle in v block and measure the runou 353
• Special tools page 13 12 353
• The bearings should turn smoothly and quietl 353
• The hu 353
• Turn smoothly quietly or if they fit loosely in the 353
• Turn the inner race of each bearing with your finge 353
• Wheel bearing 353
• Wheel suspension steering 353
• A dial indicato 354
• Actual runout is 1 2 the total indicator readin 354
• Add just enough weight so the wheel will no 354
• Always check the balance when the tire has been 354
• An inspection stan 354
• B 91 l o 10 354
• Balance mark a 354
• Balance the tire 354
• Check the rim runout by placing the wheel in a 354
• Do not add more than 60 grams to the wheel 354
• Do this two or three times to verify the heaviest 354
• For optimum 354
• Front wheel suspension steering 354
• Handling and over all safety of the motorcycl 354
• Highest side of the rim the side opposite the chalk 354
• If the wheel is balanced it will not stop consistently 354
• In the same positio 354
• Located next to the 354
• Longer stop in the same position when it is spu 354
• Lowest heaviest point of the wheel with a chal 354
• Mount the wheel tire and brake discs assembly in 354
• Necessar 354
• Note the rotating direction marks on the wheel and 354
• Page 11 354
• Paint dot on the 354
• Remount the tire if 354
• Remove the dust seals from the wheel 354
• Removed from the ri 354
• Side wall must be 354
• Spin the wheel allow it to stop and mark the 354
• Spin the wheel by hand and read the runout using 354
• To balance the wheel install wheel weights on the 354
• Turning stan 354
• Valve ste 354
• Wheel rim runout 354
• Page 12 355
• 0010000 356
• 0010300 356
• 0040600 356
• Apply grease to the dust seal lips then install them 356
• Apply thin layer of grease to the front axle surfac 356
• Attachment 4 356
• Bearing must be 356
• Bearing using the special too 356
• Been removed the 356
• Brake disc 356
• Do not get grease 356
• Drive in a new right bearing squarel 356
• Driver 356
• Front wheel suspension steering 356
• Install and tighten the new mounting bolts to the 356
• Install the brake discs on the wheel hu 356
• Install the distance collar then drive in the left 356
• Install the front axle from the left sid 356
• Install the front wheel between the fork leg 356
• Install the side collar 356
• Into the wheel hu 356
• M 14 ib 356
• Never install the 356
• Old bearings once 356
• On the brake discs 356
• Or stopping power 356
• Pachmenmr pil 356
• Page 13 356
• Pilot 25 mm 356
• R_ti n 356
• Replaced with new 356
• Rotatimn ni 356
• Specified torqu 356
• The bearings has 356
• Will be reduce 356
• 22 n m 357
• Boh ts 357
• Brake operatio 357
• Check the brake operation by applying the brake 357
• Fiij h b 357
• Front wheel suspension steering 357
• Install the both brake caliper and tighten the new 357
• M 16 ib 357
• M 22 ib 357
• M 58 ib 357
• Mounting bolts to the specified torqu 357
• Page 14 357
• Specified torqu 357
• Tighten the left axle pinch bolts to the specified 357
• Tighten the right axle pinch bolts to the specified 357
• With the front brake applied pump the fork up and 357
• Be careful not to 358
• Caliper bracket on each side after installation 358
• Check the clearance between the brake disc and 358
• Fork cap but do not remove it ye 358
• Fork tube from the fork top bridge and steering 358
• Handlebar stop ring 358
• I iajdlebar pinch rol 358
• Keep the brake 358
• Loosen the fork bottom pinch bolts and remove the 358
• Loosen the handlebar pinch bolt and top bridge 358
• Master cylinders 358
• Ot i unl f n i b3lts 358
• Page 15 358
• Pinch bolt 358
• Remove the front wheel page 13 9 358
• Remove the handlebar stop rin 358
• Remove the stop rin 358
• Scratch the fork 358
• Stop ring 358
• The clearance should be at least 358
• The dust seal 358
• Tube or damage 358
• Uprigh 358
• When the fork leg will be disassembled loosen the 358
• And gently seat the dust seal onto the axle holde 359
• Fork spring 359
• Front wheel suspension steering 359
• Hold the rebound adjuster then loosen and remove 359
• Joint plate 359
• Page 16 359
• Push down the spring seat and install the 17 mm 359
• Push the fork slider slowly down the fork slider 359
• Remove the followin 359
• Remove the fork bolt from the fork tub 359
• Spanner into the groove of the rebound adjuste 359
• Spring collar 359
• Spring joint plate 359
• Spring seat stopper 359
• The fork bolt from the rebound adjuste 359
• Turn the pre load adjuster counterclockwise then remove the pre load adjuster and adjusting plat 359
• Centering plate 360
• Dust seal 360
• Fork damper 360
• Fork damper holder 360
• Hold the axle holder in a vice with soft jaws or a 360
• Hold the fork damper with the fork damper holder 360
• Page 17 360
• Plate from the fork tub 360
• Pour out the fork fluid by pumping the fork tube 360
• Pour out the fork fluid from the fork damper by 360
• Pumping the damper rod several time 360
• Remove the dust sea 360
• Remove the fork damper assembly and centering 360
• Several time 360
• Shop towe 360
• Then remove the fork socket bol 360
• Ymb mcfo101 360
• Actual runout is 1 2 the total indicator readin 361
• Back up ring 361
• Bushing 361
• Check the back up rin 361
• Check the fork damper for damag 361
• Check the fork tube and fork slider for score marks 361
• Check the oil lock valve for wear or damag 361
• Copper surface appears on more than 3 4 of the 361
• Distortion at the points show 361
• Entire surfac 361
• Fork slider 361
• Fork tube bushing 361
• Fork tube slider damper 361
• Front wheel suspension steering 361
• Nent are damage 361
• Oil lock valve 361
• Or scratching or if the teflon is worn so that the 361
• Page 18 361
• Place the fork tube in v block and measure the 361
• Replace any components 361
• Replace it if there is any 361
• Replace the bushings if there is excessive scoring 361
• Replace the fork damper assembly if any compo 361
• Scratches or excessive or abnormal wea 361
• Service limi 361
• Visually inspect the slider and fork tube bushing 361
• Adjusting plate 362
• Apply fork fluid to the oil seal lip 362
• Back up ring 362
• Back up ring and slider bushin 362
• Before assembly wash all parts with a high flash or 362
• Centering plate 362
• Drive the oil seal in using the special tools 362
• Dust seal 362
• Fork bolt 362
• Fork damper 362
• Fork slider 362
• Fork spring 362
• Fork tube 362
• Fork tube bushing 362
• Install a new fork tube bushin 362
• Install the dust seal stopper ring new oil seal 362
• Install the fork tube into the fork slide 362
• Install the oil seal 362
• Kmd kz30100 with 362
• N m d kz301 oa 362
• Nmd kz30101 362
• Non flammable solvent and wipe them dry 362
• Oil seal 362
• Oil seal driver 362
• Page 19 362
• Pre load adjuster 362
• Seat stopper 362
• Side facing u 362
• Slider bushing 362
• Spring collar 362
• Spring joint plate 362
• Stopper ring 362
• With its marked 362
• Ymd mcf0100 or 362
• Apply a locking agent to the fork socket bolt 363
• Dust seal 363
• Install the centering plate onto the end of the fork 363
• Install the dust sea 363
• Install the fork damper assembly into the fork tub 363
• Install the socket bolt with a new sealing washe 363
• Install the stopper ring into the fork slider groove 363
• Page 20 363
• Securel 363
• Stopper ring 363
• Thread 363
• After the oil level stabilizes measure the oil level 364
• Be sure the oil 364
• Bleed the air as follows 364
• Extend the fork cover the top of the fork slider 364
• Fluid into the fork tub 364
• Fork damper holder 364
• Fork fluid capacit 364
• Fork oil leve 364
• From top of fork slide 364
• Hold the axle holder in a vise with soft jaws or a 364
• Hold the fork damper with the fork damper holder 364
• Imp oz 364
• In the both forks 364
• Level is the same 364
• Minute 364
• Page 21 364
• Pour the specified amount of recommended fork 364
• Pro honda suspension fluid ss 8 364
• Pump the damper rod slowly 8 10 time 364
• Pump the fork slider slowly 8 10 time 364
• Recommended fork flui 364
• Shop towe 364
• Slowly push down the fork slider and gently set 364
• The dust seal onto the axle holder and leave it for 5 364
• Then tighten the fork socket bolt to the specified 364
• Us oz 1 364
• With your hand and compress the fork slowl 364
• Ymb mcf0101 364
• Adjuste 365
• And tighten the fork bolt to the specified torqu 365
• Apply fork fluid to the new o rin 365
• Apply fork fluid to the pre load adjuster o ring 365
• Front wheel suspension steering 365
• Hold the rebound adjuster with a 17 mm spanner 365
• Install new o ring onto the fork bol 365
• Install the adjusting plate into the fork bolt aligning 365
• Its pins with the holes in the fork bolt 365
• Joint plate 365
• M 25 ib 365
• Page 22 365
• Pull the damper rod up and install the fork spring 365
• Remove the followin 365
• Screw the fork bolt into the fork tub 365
• Screw the fork bolt to the rebound adjuster until it seat 365
• Screw the pre load adjuster onto the rebound 365
• Spring collar 365
• Spring joint plate 365
• Spring seat stopper 365
• With the tapered end facing u 365
• Adjuste 366
• Fork tube 366
• Handlebar and top bridg 366
• I bolts 366
• If the fork bolt was loosened tighten it to the 366
• Install the fork leg through the bottom bridge 366
• Install the front wheel page 13 13 366
• Install the handlebar stop rin 366
• Install the stop ring into the groove of the rebound 366
• Installation 366
• Page 23 366
• Pinch boltt 366
• Position the top end of the fork tube flush with the 366
• Specified torqu 366
• Tighten the bottom bridge pinch bolts to the 366
• Tighten the handlebar pinch bolt to the specified 366
• Tighten the top bridge pinch bolt to the specified 366
• Top bridge 366
• Upper surface of the top bridge as show 366
• Wheel suspension steering 366
• 3710100 367
• 3710101 or 367
• Adjusting nut 367
• Fork legs page 13 15 367
• Front wheel page 13 9 367
• Handlebar page 13 3 367
• Lock nut 367
• Lock washer tab 367
• Page 24 367
• Remove the bolt and horn uni 367
• Remove the followin 367
• Remove the lock nut and lock washe 367
• Remove the steering stem bearing adjusting nut 367
• Remove the stem nut and the top bridg 367
• Steering stem 367
• Steering stem socket 367
• Straighten the tabs of the lock washe 367
• Upper cowl page 2 11 367
• Using the special too 367
• Align bearing remover a with the groove in the 368
• Always replace the 368
• As described in the following procedure 368
• Assembly bas 368
• Assembly base 6 368
• Ball race remover set 368
• Bearing 368
• Bearing remover a 4 368
• Bearing remover b 5 368
• Bearing replacement 368
• Bearings and 368
• Direction of the 368
• Driver attachment 368
• Driver attachment a 1 368
• Driver attachment b 2 368
• Driver shaft 368
• Driver shaft assembly 3 368
• Dust seal 368
• G stem 368
• Holding the driver shaft with a wrench turn nut a gradually to remove the upper outer rac 368
• Install the ball race remover into the head pipe as 368
• Installation 368
• Km90001 368
• Km90100 368
• Km90200 368
• Km90300 368
• Km90401 368
• Km90500 368
• Km90600 368
• Lightly tighten nut b with a wrenc 368
• Low r bearing 368
• Lower bearing 368
• Nner race upper bearing 368
• Note the 368
• Page 25 368
• Races as a se 368
• Remove the followin 368
• Replace the races using the ball race remover set 368
• Steering hea 368
• Steering stem 368
• Upper bearing 368
• Upper bearing inner race 368
• Align the bearing remover with the groove in the 369
• Aligns with the upper end of the steering hea 369
• Bearing 369
• Driver attachment 369
• Driver shaft 369
• Driver shft 369
• For the upper outer rac 369
• Gradually until the groove in driver attachment a 369
• Hold the driver shaft with a wrench and turn nut a 369
• Install a new upper outer race and the ball race 369
• Install ball race remover b as shown and remove 369
• Page 26 369
• Remover as show 369
• Remover b 369
• Steering hea 369
• The lower outer race using the same procedure as 369
• Will allow you to install the upper outer rac 369
• Align remover attachment a with the groove in the 370
• Aligns with the upper end of the steering hea 370
• As shown 370
• Attachment 370
• Bearing outer race 370
• Driver 370
• Driver attachment 370
• Driver shaft 370
• Driver weight 370
• Fork seal 370
• Fork seal driver weight 370
• Front wheel suspension steering 370
• Gradually until the groove in driver attachment b 370
• Holding the driver shaft with a wrench turn nut a 370
• Install 370
• Install the special tools into the steering head pipe 370
• Installer 370
• Installer attachment a 370
• Installer attachment b 370
• Installer shaft 370
• Ka50100 370
• Lower nut 370
• Ma60000 370
• Main bearing 370
• Main bearing driver 370
• Me90200 370
• Oil seal driver 370
• Outer race 370
• Page 27 370
• Remover as shown 370
• Remover attachment a 370
• Remover attachment b 370
• Replace the steering head bearing outer races 370
• Steering hea 370
• Turn the upper nut gradually to remove the upper 370
• Upper bearing 370
• Upper nut 370
• Using the special tools listed belo 370
• Vmf kz30200 370
• Vmf mat0100 370
• Vmf mat0200 370
• Vmf mat0300 370
• Vmf mat0400 370
• While holding the installer shaft with the wrench 370
• Will allow you to install the lower outer race 370
• Align remover attachment b with the groove in the 371
• As show 371
• Attachment a 371
• Attachments into 371
• Be careful not to 371
• Bearing outer rac 371
• Driver weight 371
• Drop the 371
• Fork seal 371
• Front wheel suspension steering 371
• Install a new upper bearing outer race and the 371
• Install the special tools into the steering head pipe 371
• Installer 371
• Installer attachment a aligns with the upper end of 371
• Installer shaft 371
• Main bearing 371
• Oil seal driver 371
• Page 28 371
• Remover 371
• Special tools as show 371
• Steering hea 371
• The frame 371
• The steering hea 371
• This will allow you to install the 371
• Turn the lower nut gradually to remove the lower 371
• Turn the lower nut gradually until the groove in 371
• Upper bearing 371
• Upper bearing outer rac 371
• While holding the installer shaft with the wrench 371
• Apply grease to new dust seal lips and install it 372
• Attachment a 372
• Attachment b 372
• Bearin 372
• Driver 372
• Driver attachment 372
• Driver weight 372
• Dust seal 372
• Fork seal 372
• Install 372
• Install a new lower bearing inner race using a 372
• Installer 372
• Installer attachment b aligns with the lower end of 372
• Installer shaft 372
• Lower bearin 372
• Lower bearing outer rac 372
• Lower inner race 372
• Lower nut 372
• Main bearing 372
• Mb00000 372
• Or equivalent tool being careful not to damage the 372
• Outer race 372
• Over the steering ste 372
• Page 29 372
• Remove the dust sea 372
• Remove the lower bearing inner race with a chisel 372
• Special tool and a hydraulic pres 372
• Special tools as shown 372
• Steering stem 372
• Steering stem driver 372
• Stem to prevent the threads from being damaged 372
• Temporarily install the steering stem nut onto the 372
• The ste 372
• The steering hea 372
• This will allow you to install the 372
• Turn the upper nut gradually until the groove in 372
• Upper nut 372
• Weriii n nerir a e 372
• When removing the lower bearing inner race from 372
• While holding the installer shaft with the wrench 372
• 3710100 373
• 3710101 or 373
• Apply grease to upper and lower bearing 373
• Bearing races 373
• Bearing races dust seals 373
• Bearings 373
• Dust seal 373
• Front wheel suspension steering 373
• Insert the steering stem into the steering head pip 373
• Install the lower bearing onto the steering ste 373
• Install upper bearing inner race and dust sea 373
• Installation 373
• Listing nut 373
• Lock nut 373
• Lock washer 373
• Low r bearing 373
• Lower bearing 373
• Lower dust seal 373
• Lower inner race 373
• Lower outer race 373
• Of r0race upper bearing 373
• Page 30 373
• Steering stem 373
• Steering stem s 373
• Steering stem socket 373
• Top thread 373
• Upper bearing 373
• Upper dust seal 373
• Upper inner race 373
• Upper outer race 373
• Adjusting nu 374
• Adjusting nut 374
• Align the tabs of the lock washer with the grooves 374
• Bend the lock washer tabs up into the lock nut 374
• Enough to align its grooves 374
• Five times to seat the bearing 374
• Hold the lock nut and further tighten the lock nut 374
• I i sting nut 374
• In the adjustment nut and bend two opposite tabs 374
• Install and finger tighten the lock nu 374
• Install the new lock washer onto the steering stem 374
• Lock nut 374
• Lock washer 374
• Lock washer tab 374
• M 22 ib 374
• Make sure that the steering stem moves smoothly 374
• Move the steering stem right and left lock to lock 374
• Page 31 374
• Recheck that the steering stem moves smoothly 374
• Retighten the bearing adjusting nut to the specified 374
• Shorter down into the adjustment nut groove 374
• Steering stem socket 374
• With the lock washer tab 374
• Within 1 4 turn 9 374
• Without play or bindin 374
• Without play or binding then loosen the bearing 374
• 9 hin u n i i 375
• Front w eel suspension steering 375
• Front wheel page 13 13 375
• Handlebar page 13 5 fork legs page 13 24 375
• Head bearing pre load 375
• Hook a spring scale to the fork tube and measure 375
• If the readings do not fall within the limits 375
• Install the followin 375
• Install the following 375
• Install the horn unit assembly and tighten the 375
• Install the top bridge and steering stem nu 375
• Interferenc 375
• Jack up the motorcycle to raise the front wheel off 375
• Lower the front wheel to the ground and adjust the 375
• Make sure that 375
• Mounting bol 375
• Or wire harness 375
• Page 32 375
• Positio 375
• Position the steering stem to the straight ahead 375
• Steerin 375
• Steering bearing adjusting nu 375
• Stem nut 375
• The groun 375
• The pre load should be within 1 375
• The steering head bearing pre loa 375
• There is no cable 375
• Tighten the steering stem nut to the specified 375
• Upper cowl page 2 11 375
• Before disposal of the shock absorber release the nitrogen page 14 13 376
• Cold tire pressure 376
• Contaminated brake disc or pad reduces stopping powe 376
• Discard contaminated pads and clean a contaminated disc 376
• Drive chain 376
• General 376
• Kgf cm 376
• Minimum tire trea 376
• Page 1 376
• Radial 376
• Rear wheel 376
• Refer to section 15 for brake system information 376
• Rk rk gb50hfoz5 376
• Service information 376
• Service limit 376
• Shock absorber 376
• Specifications 376
• Spring adjuster standard positio 376
• Standard 376
• Suspension linkage 376
• Swingarm 376
• Th groove 376
• The shock absorber contains nitrogen under high pressur 376
• Troubleshooting 376
• Up to 9 376
• Up to maximum weight capacity 376
• Use genuine honda replacement bolts and nuts for all suspension pivot and mounting poin 376
• Use only tires marked tubeless and tubeless valves on rim marked tubeless tire applicable 376
• Va8 c1 376
• Wheel rim runout 376
• When servicing the rear wheel support the motorcycle using a safety stand or hoist 376
• With a high quality brake degreasing agen 376
• _axle runout 376
• 0010000 07746 0010300 07746 0010400 07746 0010700 07746 0010800 07946 0010900 07746 0040400 07746 0040600 07746 0050100 07746 0050800 377
• 3710001 377
• Aloc bolt 377
• Attachmen 377
• Attachment 377
• Axle alignment chain adjustment not equal on both 377
• Bent damper rod 377
• Bent rim 377
• Damaged shock absorber mounting bearing 377
• Damaged suspension linkage bearings 377
• Damaged swingarm pivot bearings 377
• Faulty swingarm pivot bearings 377
• Handle 377
• Hard suspension 377
• Lmc kv30100 377
• Mad pr90200 377
• Mj00100 377
• Page 2 377
• Rear axle nutrear brake disc mounting bolt driven sprocket nut shock absorber upper mounting nut shock arm plate nut shock link nut frame side swingarm pivot nut swingarm pivot pinch bolt drive chain slider bolt main footpeg bracket socket bolt drive sprocket special bolt 377
• Rear wheel wobbling 377
• Remove 377
• Remover 377
• Tire pressure too low 377
• U nut u nut u nut u nut u nut 377
• Unbalanced tire and wheel 377
• Weak shock absorber spring 377
• Worn rear wheel bearings 377
• Ymd mcjo100 377
• Actual runout is 1 2 the total indicator readin 378
• Derail the drive chain from the driven sprocket 378
• From the left side and remove the rear wheel 378
• Hoist raise the rear wheel off the groun 378
• Inspection 378
• Motorcycle 378
• Page 3 378
• Place the axle in v blocks and measure the runou 378
• Push the rear wheel forwar 378
• Rear wheel 378
• Rear wheel suspension 378
• Removal 378
• Remove the axle and drive chain adjusting plate 378
• Remove the axle nut and drive chain adjusting 378
• Remove the side collar 378
• U iusting fljarlif 378
• Actual runout is 1 2 the total indicator readin 379
• Bearings in pair 379
• Bearings should turn smoothly and quietl 379
• Brake disc 379
• Chain and sprocket must be in good condition or 379
• Check that the bearing outer race fits tightly in the 379
• Check the condition of the final driven sprocket 379
• Check the rim runout by placing the wheel in a 379
• Dial indicato 379
• Driven sprocket 379
• Dust1se 379
• If the final driven sprocket requires replacement inspect the drive chain and drive sprocke 379
• Never install a new drive chain on a worn 379
• Not turn smoothly and quietly or if they fit loosely in the hu 379
• Page 4 379
• Rapidl 379
• Remove and discard the bearings if the races do 379
• Remove the bolts and brake dis 379
• Remove the right dust seal 379
• Replace 379
• Replace the sprocket if worn or damaged 379
• Replace the wheel 379
• See page 13 11 for wheel balanc 379
• Service limit 379
• Spin the wheel slowly and read the runout using a 379
• Sprocket or a worn chain on new sprocket 379
• The replacement chain or sprocket will wear 379
• Turn the inner race of each bearing with your finger 379
• Turning stand 379
• Wheel balance 379
• Wheel bearing 379
• Wheel rim runout 379
• Before removing 380
• Disassemble the 380
• Drive out the driven flange bearing 380
• Driven flange 380
• Driven flange bearing removal 380
• From the wheel 380
• If you will be 380
• Iv flani 380
• Loosen the driven 380
• Loosen the driven sprocket nut 380
• M ti l v 380
• Page 5 380
• Rear wheel suspension 380
• Remove the 0 rin 380
• Remove the driven flange assembly from the left 380
• Remove the driven flange colla 380
• Remove the driven flange from the wheel hub then 380
• Remove the driven sprocket nuts and sprocke 380
• Remove the dust sea 380
• Remove the wheel damper rubber 380
• Sprocket nuts 380
• Sri en sprockf 380
• The driven flange 380
• Wheel hub 380
• 0010000 381
• 0010400 381
• 0040600 381
• 0050100 381
• 0050800 381
• 27x52 x2 381
• Achme uani ie n 381
• Attachment 5 381
• Bearin 381
• Bearing 6205 381
• Bearing must be 381
• Bearing remover head 25 mm 381
• Bearing remover shaft 381
• Been removed the 381
• Brake disc 381
• Damper rubbers 381
• Distance collar 381
• Drive in a new right bearing squarel 381
• Driven flange 381
• Driven flange bearing 381
• Driven flange collar 381
• Driven sprocket 381
• Driver 381
• From the opposite side install the bearing remover 381
• Install the bearing remover head into the bearin 381
• Left dust seal 381
• Left wheel bearing 381
• Never install the 381
• O ring 381
• Old bearings once 381
• Page 6 381
• Pilot 25 mm 381
• Remove the distance collar and drive out the other 381
• Replaced with new 381
• Right dust seal 381
• Right wheel 381
• Shaft and drive the bearing out of the wheel hub 381
• The bearings has 381
• Wheel bearing installation 381
• Wheel bearing removal 381
• 0010000 382
• 0010300 382
• 0010400 382
• 0040600 382
• Att hment pilot 382
• Attachment 4 382
• Attachment 5 382
• Attachment pilot 382
• Distanc 382
• Drive in the left side bearing 382
• Drive the new driven flange bearing into the driven 382
• Driven flange bearing 382
• Driven flange bearing installation 382
• Driven flange collar 382
• Driver 382
• Flange bearin 382
• Flange using the special tool 382
• Install the distance colla 382
• Install the driven flange collar into the new driven 382
• Page 7 382
• Pilot 25 mm 382
• Apply grease to the dust seal lips then install it into 383
• Apply grease to the side collar inside and grooves 383
• Apply oil to the new 0 ring and install it into the 383
• Driven sprocket and tighten the nuts 383
• Dust seal 383
• Groove of the wheel hu 383
• If the driven sprocket was removed install the 383
• Install and tighten the new bolts to the specified 383
• Install the brake disc with its rotating direction 383
• Install the driven flange assembly into the left 383
• Install the side collar 383
• Install the wheel damper rubbers into the wheel 383
• Installation 383
• M 31 ib 383
• M 47 lb 383
• Mark facing ou 383
• Otating d rection mark 383
• Page 8 383
• Rake dofs 383
• Side collars 383
• The driven flang 383
• Wheel hu 383
• Wr ivipef jwbbr h 383
• Adjust the drive chain slack page 3 20 384
• Alipeh bracket 384
• Collar mounting rubber 384
• Install the drive chain adjusting plate and axle from 384
• Install the drive chain adjusting plate and axle nut 384
• Install the drive chain over the driven sprocket 384
• Install the rear brake caliper bracket onto the guide 384
• Justing plate 384
• Mounting rubbe 384
• Of the swingar 384
• Page 9 384
• Place the rear wheel into the swingar 384
• Remove the exhaust pipe mounting collar and 384
• Remove the muffler and exhaust pipe page 2 18 384
• Support the motorcycle using a hoist or equivalent 384
• Suspension linkage 384
• The left sid 384
• Tighten the axle nut to the specified torqu 384
• Ydji is ng pl a i f 384
• 0010800 385
• 0040400 385
• 3710001 385
• Attachment 2 385
• Attachment pilot 385
• B lt ini i 385
• Bearing into the 385
• Check that the suspension linkage components for 385
• Damage replace any damaged component 385
• Driver attachment handle 385
• Dust seals 385
• Facing ou 385
• In from the end of the shock arm 385
• Inspection 385
• Link plate bolt nut 385
• Link plate bolts nuts 385
• Link plates 385
• Marked side 385
• Page 10 385
• Pilot 17 mm 385
• Pivot collar 385
• Press a new needle bearing into the shock arm so 385
• Press out the needle bearing out of the shock arm 385
• Rear wheel suspension 385
• Remove the followin 385
• Remove the pivot collar and dust seals 385
• Shock arm 385
• Shock arm bolt nut 385
• Shock arm with the 385
• That the needle bearing surface is lower 385
• The needle 385
• Using the same tool 385
• Using the special tool 385
• 44 n m 386
• Apply grease to the new dust seal lips install them 386
• Collar mounting rubber 386
• Dust seals 386
• Forwar 386
• Hocf arm 386
• Hold the socket bolt and tighten the nut to the 386
• Ink plates 386
• Install the exhaust pipe and muffler page 2 20 386
• Install the exhaust pipe mounting rubber and colla 386
• Install the link plate bolts nuts then tighten the nuts 386
• Install the link plates with its fr 386
• Install the pivot collar 386
• Install the shock arm into the lower bracket install 386
• Into the shock ar 386
• Link plate bolt nut 386
• Link plate bolts nut 386
• Lower mjjnting bolt nut 386
• Lt nut 386
• M 33 ib 386
• M 33 lb 386
• Mark facing 386
• Page 11 386
• Page 15 27 386
• Pivot collar 386
• Place the motorcycle using a hoist or equivalen 386
• Removal 386
• Remove the link plate bolts nuts and link plates 386
• Remove the rear brake light switch and switch stay 386
• Remove the shock absorber lower mounting bolt 386
• Shock absorber 386
• Shock arm 386
• Specified torqu 386
• The mounting bolt nu 386
• To the specified torqu 386
• 0010800 387
• 0040400 387
• 3710001 387
• Absorber 387
• Absorber lower mount using the special tool 387
• Assembl 387
• Attachment 2 387
• Bearing into the 387
• Bump rubber for wear or damage 387
• Check for th 387
• Damper rod for bend or damage 387
• Damper unit for deformation or oil leaks 387
• Driver attachment handle 387
• Facing out 387
• If necessary replace the shock absorber as an 387
• In from the end of the lower mount using the 387
• Inspect all the other parts for wear or damag 387
• Loosen and 387
• Lower mount with 387
• Lower the shock absorber then remov 387
• Mounting nu 387
• Page 12 387
• Pilot 17 mm 387
• Pivot collar 387
• Press a new needle bearing into the lower mount 387
• Press out the needle bearing out of the shock 387
• Press the needle 387
• Rear wheel suspension 387
• Remove the 387
• Remove the pivot collar and dust seal 387
• Same tools 387
• So that the needle bearing surface is lower 387
• The marked side 387
• Upper mt7njnitilivk 387
• Visually inspect the shock absorber for damage 387
• Apply grease to the new dust seal lips install them 388
• Before disposal of the shock absorber release 388
• Bottom and install the upper mounting bolt nu 388
• Depressing the valve cor 388
• Do not remove the 388
• Dust seals 388
• Getting in your eye 388
• Install the pivot colla 388
• Install the shock absorber into the frame from the 388
• Into the lower moun 388
• M 33 lb 388
• Page 13 388
• Pivot collar 388
• Point th 388
• Pressure is 388
• Prevent debris 388
• Procedure 388
• Releace 388
• Release the nitrogen from the reservoir by 388
• Remove the damper reservoir ca 388
• Remove the valve from the shock absorber 388
• Reservoi 388
• Reservoir cap 388
• Shock absorber disposal 388
• The nitrogen by pressing the valve cor 388
• Tighten the nut to the specified torqu 388
• Valve away from yo 388
• Valve core until 388
• Wheel suspension 388
• Boi t nu 389
• Brake hose 389
• Drive sprocket cover 389
• I ink plate bolts nut 389
• Ijides 389
• Install the link plates link plate bolts nuts 389
• Install the removed parts in the reverse order of 389
• Lowe 1 389
• Page 14 389
• Removal 389
• Remove the drive sprocket bolt washer and drive 389
• Remove the rear wheel page 14 3 389
• Remove the screws and brake hose guides 389
• Remove the two sh bolts and drive sprocket cover and space 389
• S ingar 389
• Shock absorber lower mounting bolt nu 389
• Sprocket 389
• Tighten the nuts to the specified torqu 389
• And main footpeg bracke 390
• Behind the right step guar 390
• California type 390
• Gearshift spindl 390
• Jnting bolt nut 390
• Lff i fo tfeg bracket 390
• Link plat 390
• Loosen the swingarm pivot pinch bolt 390
• Page 15 390
• Release the 0 sensor wire from the wire guide 390
• Remove the bolt and gearshift link arm from the 390
• Remove the left main footpeg bracket socket bolts 390
• Remove the link plate to swingarm bolt nu 390
• Remove the right main footpeg bracket socket bolts 390
• Remove the shock absorber lower mounting bolt 390
• Right footpeg bracket 390
• Sensor wire 390
• Swingarm bolt nut 390
• Disassembly inspection 391
• Drive chain case a 391
• Drive chain case b 391
• Hold the pivot bolt using a 24 mm socket wrench 391
• Page 16 391
• Rear wheel suspension 391
• Remove the sh bolt trim clip and drive chain case 391
• Remove the sh bolts and drive chain case 391
• Swingarm from the lower bracket and engin 391
• Then loosen and remove the swingarm pivot nut 391
• Trim clip 391
• Using the same too 391
• Also check that the bearing outer race fits tightly in 392
• Check the drive chain slider for wear or damag 392
• Check the dust seals and collar for damage or 392
• Check the dust seals and side collar for damage or 392
• Drive chain slider 392
• Dust seals 392
• Fatigu 392
• In the pivo 392
• Not turn smoothly and quietly or if they fit loosely 392
• Page 17 392
• Pivot collar 392
• Remove and discard the bearings if the races do 392
• Remove the pivot collar and dust seals from the 392
• Remove the side collar and dust seals from the 392
• Remove the three sh bolts and drive chain slide 392
• Side collar 392
• Swingarm left pivo 392
• Swingarm right pivo 392
• The bearings should turn smoothly and quietly 392
• The hu 392
• Turn the inner race of right pivot bearings with 392
• Your finge 392
• Also check that the bearing outer race fits tightly in 393
• Check the drive chain slider for wear or damag 393
• Check the dust seals and collar for damage or 393
• Check the dust seals and side collar for damage or 393
• Drive chain slider 393
• Dust seals 393
• Fatigu 393
• In the pivo 393
• Not turn smoothly and quietly or if they fit loosely 393
• Page 18 393
• Pivot collar 393
• Remove and discard the bearings if the races do 393
• Remove the pivot collar and dust seals from the 393
• Remove the side collar and dust seals from the 393
• Remove the three sh bolts and drive chain slide 393
• Side collar 393
• Swingarm left pivo 393
• Swingarm right pivo 393
• The bearings should turn smoothly and quietly 393
• The hu 393
• Turn the inner race of right pivot bearings with 393
• Your finge 393
• 0010000 394
• 0010900 394
• 0040600 394
• Attachment 40 394
• Bearings and distance collar from the swingarm 394
• Distance collar 394
• Driver 394
• Driver attachment 25 x 3 394
• Driver shaft 394
• Hydraulic pres 394
• Install the distance colla 394
• Mj00100 394
• Page 19 394
• Pilot 25 mm 394
• Pivot bearin 394
• Pivot until it seats using the special tools and 394
• Pivot using the special tools and hydraulic pres 394
• Press the inner bearing into the swingarm right 394
• Remove the right pivot bearings radial ball 394
• Remove the snap rin 394
• Snap ring 394
• Ymd mcjo100 394
• 0010000 395
• 0010000 attachment 395
• 0010900 395
• 0040600 395
• Attach m e nt pi lot 395
• Attachment 395
• Bearing into the 395
• Driver 395
• Driver pilot 395
• Facing out 395
• From the 395
• In from the end of the 395
• Install the outer bearing using the special tool 395
• Install the snap ring into the groove securel 395
• Into the 395
• Is lower 8 9 mm 395
• Mad pr90200 395
• Marked side 395
• Page 20 395
• Press a new left pivot needle bearing 395
• Press the needle 395
• Remove the left pivot needle bearing 395
• Snap ring 395
• Swingarm pivot so that the needle bearing surface 395
• Swingarm pivot surface using the special tools 395
• Swingarm pivot using the special tools 395
• Swingarm with the 395
• Wheel suspension 395
• 024 in from the end of 396
• Apply grease to the dust seal lips then install the dust seals and pivot collar into the swingar 396
• Dust seals 396
• Install the shock link pivot needle bearing into the 396
• Link plate pivo 396
• Lmc kv30100 396
• Needle bearing remover 396
• Page 21 396
• Pivot collar 396
• Remove the pivot collar and dust seals from the 396
• Remove the shock link pivot needle bearing using 396
• Swingarm so that the needle bearing surface is 396
• The special too 396
• The swingarm pivot surface using the same tool 396
• Apply grease to the dust seal lips then install the 397
• Distance collar 397
• Drive chain case a 397
• Drive chain case b 397
• Drive chain slider 397
• Dust seal 397
• Dust seals 397
• Dust seals and pivot collar into the left swingarm 397
• Dust seals and side collar into the right swingarm 397
• I dust seals 397
• Left pivot needle bearings 397
• Page 22 397
• Pivot collar 397
• R f dust seal 397
• Rear wheel suspension 397
• Right pivot bearings 397
• Side collar 397
• Snap ring 397
• Page 23 398
• Apply thin coat of grease to the swingarm pivot 399
• Bolt surfac 399
• Bracket and tighten the socket bolts to the specified 399
• Buntts 399
• Engine then install the pivot bolt from the left sid 399
• Hold the pivot bolt using a 399
• Install the gearshift pedal link to the gearshift 399
• Install the left main footpeg bracket onto the lower 399
• Install the swingarm between the lower bracket and 399
• Install the swingarm pivot nu 399
• Left fo 399
• Mm hex wrench 399
• On the spindl 399
• Page 24 399
• Peg bracket 399
• Specified torqu 399
• Specified torque 399
• Spindle while aligning its slit with the punch mark 399
• Tighten the gearshift pedal link pinch bolt to the 399
• Tighten the swingarm pivot nut to the specified 399
• Tighten the swingarm pivot pinch bolts to the 399
• Torque using the same too 399
• Brake hose guides 400
• Drive sprocket 400
• Page 25 400
• Rear wheel suspension 400
• Right footpeg bracket 400
• Ver mounting bolt nut 400
• Page 26 401
• Air bleeding 402
• Brake fluid replacement 402
• Brake pedal 402
• Caliper 402
• Cylinder 402
• Front brake caliper 402
• Front maste 402
• Pad disc 402
• Page 1 402
• Rear master cylinder 15 16 402
• Service information 402
• Troubleshooting 15 3 402
• A contaminated brake disc or pad reduces stopping powe 403
• A high quality brake degreasing agen 403
• Aca ti 403
• Always check brake operation before riding the motorcycle 403
• Always use fresh dot 4 brake fluid from a sealed container when servicing the syste 403
• Avoid breathing dust particle 403
• Be careful whenever you remove the reservoir ca 403
• Brake disc runout 403
• Brake disc thickness 403
• Brake pedal height 403
• Caliper piston 403
• Check the brake system by applying the brake lever or pedal after the air bleeding 403
• Discard contaminated pads and clean a contaminated disc with 403
• Frequent inhalation of brake pad dust regardless of material composition could be hazardous to your health 403
• General 403
• Honda dot 4 brake fluid 403
• Hydraulic brake 403
• It is also harmful to some rubber part 403
• Master cylinder 403
• Never allow contaminates dirt water et 403
• Never use an air hose or brush to clean brake assemblie 403
• Once the hydraulic system has been opened or if the brake feels spongy the system must be bled 403
• Page 2 403
• Piston 403
• Service information 403
• Service limit 403
• Specifications 403
• Specified brake fluid 403
• Spilled brake fluid will severely damage instrument lenses and painted surface 403
• Standard 403
• They may not be compatible 403
• Use an osha approved vacuum cleane 403
• Air in hydraulic system 404
• Aloc bolt 404
• Apply a locking agent to the threads 404
• Bent brake lever pedal 404
• Brake caliper bleeder 404
• Brake drags 404
• Brake hose oil bolt 404
• Brake lever pedal hard 404
• Brake lever pedal soft or spongy 404
• Brake lever pivot nut 404
• Caliper body assembly torx bolt pad pin 404
• Clogged fluid passage 404
• Clogged master cylinder port 404
• Clogged restricted brake hose joint 404
• Clogged restricted brake hydraulic system 404
• Clogged restricted brake system 404
• Clogged restricted fluid passage 404
• Contaminated brake pad disc 404
• Contaminated caliper 404
• Contaminated master cylinder 404
• Front brake caliper mounting bolt 404
• Front brake master cylinder cup mounting nut 404
• Front brake switch screw 404
• Leaking hydraulic system 404
• Misaligned wheel 404
• Pad pin plug 404
• Page 3 404
• Rear brake caliper slide pin main 404
• Rear brake hose clamp screw 404
• Rear master cylinder hose joint screw 404
• Rear master cylinder push rod nut 404
• Sa50001 or 07914 3230001 404
• Snap ring pliers 404
• Sticking worn caliper piston 404
• Sticking worn master cylinder piston 404
• Warped deformed brake disc 404
• Worn brake pad disc 404
• Worn caliper piston seal 404
• Worn master cylinder piston cups 404
• Air bleeding 405
• Avoid spilling fluid on painted plastic or rubber 405
• Brake fluid replacement 405
• Diaphragm 405
• Diaphragm plate 405
• Do not allow foreign material to enter the system 405
• Ervoir is parallel to the ground before removing 405
• For the front brake turn the handlebar until the res 405
• For the rear brake remove the rear brake reservoir 405
• Iaphrog 405
• Mounting bol 405
• Page 4 405
• Place a rag over these parts whenever the 405
• Remove the diaphragm plate and diaphrag 405
• Remove the diaphragm plate and diaphragm 405
• Remove the reservoir cap 405
• Remove the screws and reservoir ca 405
• Reservoir ca 405
• Screws 405
• System is service 405
• The reservoir ca 405
• When filling the reservoi 405
• Adding fluid when the fluid level in the master cylin der reservoir is lo 406
• Appear in the plastic hos 406
• Bleed valve threads seal the threads with teflon 406
• Brakes to prevent air from being pumped into the 406
• Check the fluid level often while bleeding the 406
• Close the bleed valv 406
• Compatibl 406
• Connect a bleed hose to the caliper bleed valv 406
• Connect a commercially available brake bleeder to 406
• Cylinder and operate the brake lever or pedal to 406
• Do not mix different types of flui 406
• Fill the reservoir with dot 4 brake fluid from a 406
• Fill the syste 406
• Fluid flows out of the bleed valv 406
• Hydraulic brake 406
• If a brake bleeder is not available fill the master 406
• If air is entering the bleeder from around the 406
• Loosen the bleed valve and pump the brake lever 406
• Manufacturer s operating instruction 406
• Next perform the bleeding procedure 406
• Notice 406
• Oo _o i _t 406
• Or peda 406
• Page 5 406
• Pump the brake bleeder and loosen the bleed valve 406
• Repeat the previous steps until air bubbles do not 406
• Sealed containe 406
• Stop pumping the lever or pedal when no more 406
• The bleed valv 406
• There are not 406
• Use only dot 4 brake fluid from a sealed contain 406
• When using a brake bleeding tool follow the 406
• Al until there are no air bubbles in the fluid flowing 407
• Been close 407
• Bleed hose 407
• Bleed valve 407
• Bleed valve has 407
• Brake lever or 407
• Connect a clear bleed hose to the bleed valve 407
• Diaphragm lm6tif 407
• Do not release the 407
• Fill the fluid reservoir to the upper level 407
• I iaph 407
• In the fluid coming out of the bleed valv 407
• On the front brake install the reservoir cap and 407
• On the rear brake install the reservoir cap securely 407
• Open the bleed valve 1 2 turn and then close the 407
• Out of the master cylinder and lever or pedal resis 407
• Page 6 407
• Pedal until the 407
• Pump up the system pressure with the lever or ped 407
• Reinstall the diaphragm and diaphragm plate 407
• Release the brake lever or pedal until the bleed 407
• Repeat steps 1 and 2 until bubbles cease to appear 407
• Rese voir ca 407
• Reservoir ca 407
• Squeeze the brake lever or push the brake pedal 407
• Tance is fel 407
• The mounting bol 407
• Then install the reservoir onto the frame and tighten 407
• Tighten the bleed valv 407
• Tighten the screw 407
• Valve has been close 407
• Always replace the 408
• Brace pad disc 408
• Brake caliper 408
• Brake master cylin 408
• Brake pads in 408
• Caliper piston 408
• Causes the level to 408
• Check the brake 408
• Clean the inside of the caliper especially around the 408
• Der reservoir as 408
• Even disc pressur 408
• Fluid level in the 408
• Front brake pad replacement 408
• Hydraulic brake 408
• Loosen the pad pin 408
• Pad pins 408
• Page 7 408
• Pairs to assure 408
• Push the caliper pistons all the way in to allow in stallation of new brake pad 408
• Remove the bolts and brake calipe 408
• Remove the pad pins pad spring and brake pads 408
• This operation 408
• Ad plf 409
• Always replace th 409
• Be careful not to 409
• Brake pad 409
• Brake pads in 409
• Check the brake fluid level in the brake master cylin 409
• Damage the pad 409
• Der reservoir as this operation causes the level to 409
• Even disc pressur 409
• Hydrauli 409
• Install and tighten the new brake caliper mounting 409
• Install the brake caliper to the fork leg so the disc is 409
• Install the new brake pads 409
• Install the pad spring with its arrow mark facing up 409
• M 13 ib 409
• Page 8 409
• Pairs to assure 409
• Positioned between the pad 409
• Push the caliper pistons all the way in by pushing 409
• Push the pad spring then install the pad pin 409
• Rear brake pad replacement 409
• Remove the pad pin plu 409
• The caliper body inward to allow installation of new 409
• Tighten the pad pin 409
• 22 n m 410
• Ad pin 410
• Install and tighten the caliper bracket bol 410
• Install the new brake pad 410
• Install the pad pi 410
• Loosen the pad pi 410
• Make sure the brake pad spring is in plac 410
• Onto the retainer on the caliper bracke 410
• Page 9 410
• Pivot the caliper u 410
• Remove the caliper bracket bolt 410
• The pad spring so that the pad ends are positioned 410
• Tighten the pad pi 410
• And brake hose eyele 411
• Avoid spilling fluid 411
• Check the wheel bearings for excessive play if the 411
• Disconnect the brake light switch wire connectors 411
• Drain the front hydraulic system page 15 4 411
• Front master cylinder 411
• Install and tighten the pad pin plug 411
• Is less than the service limi 411
• Lbf ft 411
• Measure the brake disc thickness with a microme 411
• Measure the brake disc warpage with a dial indica 411
• On painted plastic 411
• Or rubber part 411
• Page 10 411
• Place a rag over 411
• Removal 411
• Remove the brake hose oil bolt sealing washers 411
• Replace the brake disc if the smallest measurement 411
• Replace the brake disc if the wheel bearings are nor 411
• Service limi 411
• Service limit 411
• System is service 411
• These parts 411
• Visually inspect the brake disc for damage or 411
• Vvit h onnec i 411
• Warpage exceeds the service limi 411
• Whenever the 411
• Brake lever 412
• Brake light switch 412
• Dust over 412
• I iiaste 412
• Page 11 412
• Pivot bolt 412
• Pivot nut 412
• Remove the bolt and brake reservoir from the mas 412
• Remove the bolts from the master cylinder holder and remove the master cylinder assembly 412
• Remove the dust cover and snap rin 412
• Remove the o rin 412
• Remove the pivot bolt nut and brake lever assem 412
• Remove the screw and brake light switc 412
• Snap ring 412
• Ter cylinde 412
• 3230001 413
• Body using the special tool as show 413
• Brake flui 413
• Check the master cylinder and piston for abnormal 413
• Check the piston boot primary cup and secondary 413
• Clean the inside of the cylinder and reservoir with 413
• Cup for fatigue or damage 413
• Hydrauli 413
• Inspection 413
• Measure the master cylinder 413
• Measure the master cylinder piston 413
• Page 12 413
• Remove the boo 413
• Remove the master piston and sprin 413
• Remove the snap ring from the master cylinder 413
• Sa50000 or 413
• Scratches 413
• Snap ring pliers 413
• 3230001 414
• Allow the lips to 414
• Assembly 414
• Be certain the 414
• Brake light switch 414
• Coat all parts with clean brake fluid before assem 414
• Cups spring snap 414
• Diaphragm 414
• Dip the piston in brake fluid 414
• Do not 414
• Groove 414
• Hydrauli 414
• Individual part 414
• Install the piston assembly into the master cylinde 414
• Install the snap rin 414
• Install the spring into the piston 414
• Keep the piston 414
• M 7 lb 414
• Master cylinder 414
• Master piston 414
• Page 13 414
• Piston cups 414
• Reservoir 414
• Reservoir cap 414
• Ring and boot as a 414
• Sa50000 or 414
• Seated in the 414
• Snap ring 414
• Snap ring is firmly 414
• Snap ring pliers 414
• Spring 414
• Substitute 414
• The cups do not 414
• Turn inside ou 414
• When installing 414
• Apply silicone grease to the contact surfaces of the 415
• Bolt to the specified torqu 415
• Brake lever 415
• Brake lever and piston ti 415
• Hold the pivot bolt and tighten the pivot nut to the 415
• Install the boo 415
• Install the brake lever assembly tighten the pivot 415
• Install the brake light switch and tighten the screw 415
• Lbf ft 415
• M 7 ib 415
• Page 14 415
• Pivot nut 415
• Specified torqu 415
• To the specified torqu 415
• Align the end of the master cylinder with the punch 416
• Apply brake fluid to the new reservoir joint o ring 416
• Brake system page 15 4 416
• Connect the brake light switch wire connector 416
• Fill the reservoir to the upper level and bleed the 416
• Hydraulic brake 416
• Install and tighten the reservoir mounting bol 416
• Install the brake hose eyelet with the oil bolt and 416
• Install the dust cove 416
• Install the master cylinder holder with the up 416
• Install the master cylinder reservoir joint into the 416
• Mark facing u 416
• Mark on the handleba 416
• Master cylinder 416
• Master cylinder and secure the joint with a snap 416
• New sealing washer 416
• Nnec t 416
• O ring 416
• Page 15 416
• Place the master cylinder assembly on the handle 416
• Push the eyelet joint against the stopper then 416
• Reservoir joint 416
• Snap ring 416
• Tighten the oil bolt to the specified torque 416
• Tighten the upper bolt first then the lower bolt 416
• And brake hose 417
• Avoid spilling fluid 417
• Behind the light step guard 417
• Brake reservuil 417
• California type 417
• Cotter pin 417
• Cylinoff 417
• Disassembly 417
• Drain the rear hydraulic system page 15 4 417
• Footpeg bracket 417
• Guard and master cylinder 417
• Hydraulic brake 417
• Ing bol 417
• Loosen the rear master cylinder mounting bolts 417
• Mounting bolts 417
• Oil bolt 417
• On painted plasti 417
• Or rubber part 417
• Page 16 417
• Place a rag over 417
• Rear master cylinder 417
• Release the 417
• Removal 417
• Remove and discard the brake pedal joint cotter pi 417
• Remove the brake hose oil bolt sealing washers 417
• Remove the joint pi 417
• Remove the main footpeg bracket socket bolts and main footpeg bracket assembl 417
• Remove the master cylinder mounting bolts step 417
• Remove the rear master cylinder reservoir mount 417
• Remove the screw and reservoir hose joint from 417
• Reservoir joint 417
• Sealing 417
• Sensor 417
• Sensor wire from the wire guide 417
• System is service 417
• The master cylinde 417
• These parts 417
• Whenever the 417
• 3230001 418
• Body using the special tool as shown 418
• Check the master cylinder and piston for abnormal 418
• Check the piston boot primary cup and secondary 418
• Clean the inside of the cylinder with brake fluid 418
• Cup for fatigue or damage 418
• Hydraulic brake 418
• Inspection 418
• Measure the master cylinder 418
• Measure the master cylinder piston 418
• Page 17 418
• Pliers 418
• Primary cup 418
• Remove the boo 418
• Remove the push rod master piston and spring 418
• Remove the snap ring from the master cylinder 418
• Sa50000 or 418
• Scratche 418
• Service limi 418
• Snap rin 418
• Snap ring 418
• Snap ring pliers 418
• 3230001 419
• Apply silicone grease to the piston contact area of 419
• Assembl 419
• Assembly 419
• Coat all parts with clean brake fluid before assem 419
• D iaphragm plate 419
• Diaphragm 419
• Hydraulic brake 419
• Install the push rod into the master cylinde 419
• Install the spring primary cup and master piston 419
• Lower joint 419
• Master cylinder 419
• Master piston 419
• O ring 419
• Page 18 419
• Primary cu 419
• Primary cup 419
• Push rod 419
• Push rod assembly 419
• Reservoir cap 419
• Reservoir joint 419
• Sa50000 or 419
• Secondary cup 419
• Snap ring 419
• Snap ring pliers 419
• Spring 419
• The push ro 419
• After adjustment tighten the lock nut to the speci fied torqu 420
• Apply a locking agent to the reservoir joint screw 420
• Apply brake fluid to a new o ring and install it onto 420
• Bracket install the step guard and master cylinder 420
• Connect the brake pedal to the push rod lower joint 420
• Cotter pin 420
• If the push rod is disassembled adjust the push rod 420
• Install and tighten the screw to the specified torque 420
• Install the joint pin and secure it with a new cotter 420
• Install the reservoir joint into the master cylinde 420
• Length as show 420
• Lock nut 420
• Lower joint 420
• M 13 ib 420
• Master cylinder onto the main footpeg 420
• Master cylindf 420
• Mounting bolt 420
• O ring 420
• Page 19 420
• Reservoir joint 420
• The reservoir join 420
• Thread 420
• Apply small squirts of air pressure to the fluid inlet 421
• Avoid spilling fluid 421
• Between the piston 421
• Bracket tighten the socket bolts to the specified 421
• Brake caliper 421
• Brake pads page 15 6 421
• Brake reservoif 421
• Brake system page 15 4 421
• Bring the nozzle 421
• California type 421
• Caliper 421
• Clamp the o sensor wire to the wire guide behind 421
• Do not use high 421
• Drain the front brake hydraulic system page 15 4 421
• En the oil bolt to the specified torque 421
• Fill the reservoir to the upper level and bleed the 421
• Footpeg bracket 421
• Hose eyelet join 421
• Ing washer 421
• Install and tighten the brake reservoir mounting 421
• Install corrugated cardboard or soft wood sheet 421
• Install the brake hose with the oil bolt and new seal 421
• Install the main footpeg bracket onto the lower 421
• M 29 lb 421
• Mounting bolts 421
• Oil bolt 421
• On painted plastic 421
• Or rubber parts 421
• Page 20 421
• Place a rag over 421
• Pressure air or 421
• Push the eyelet joint against the stopper then tight 421
• Remove the caliper mounting bolts caliper and the 421
• Remove the oil bolt sealing washers and brake 421
• Sealing 421
• Sealing washers 421
• Sensor 421
• System is serviced 421
• The right step guar 421
• These parts 421
• Tighten the master cylinder mounting bolt 421
• To remove the piston 421
• Too close to the 421
• Torque 421
• Washers 421
• Whenever the 421
• Assembly bolts 422
• Be careful not to 422
• Caliper piston a 422
• Caliper piston b 422
• Caliper pistons 422
• Check the caliper cylinder for scoring or other 422
• Clean the seal grooves with clean brake flui 422
• Dust seal 422
• Hydraulic brake 422
• Joint seal 422
• Joint seals 422
• Mark the pistons 422
• Measure the caliper cylinder 422
• Page 21 422
• Piston seal 422
• Push the dust seals and piston seals in and lift them damage the piston 422
• Rate the caliper halve 422
• Reassembly 422
• Remove the followin 422
• Remove the four caliper assembly bolts and sepa 422
• Service limit 422
• Sliding surfac 422
• To ensure correct 422
• Brake pads 423
• Caliper 423
• Caliper piston a 423
• Caliper piston b 423
• Check the caliper pistons for scratches scoring or 423
• Coat the caliper pistons with clean brake fluid and 423
• Coat the new dust seals with silicone greas 423
• Coat the new piston seals with clean brake flui 423
• Dust seal 423
• Hydrauli 423
• Ing ends toward the pa 423
• Install the piston and dust seal into the groove of 423
• Measure the caliper piston 423
• Oint seal 423
• Other damag 423
• Pad spring 423
• Page 22 423
• Piston 423
• Piston seal 423
• Service limit 423
• The caliper bod 423
• Assemble the caliper halves and install and tighten 424
• Brake caliper 424
• Caliper then tighten the oil bolt to the specified 424
• Eyelet joint 424
• Fill and bleed the front brake hydraulic system pag 424
• Install and tighten the new caliper mounting bolts 424
• Install the brake hose eyelet to the caliper body 424
• Install the brake pads and caliper onto the fork leg 424
• Install the new joint seal into the fluid passage on 424
• Joint seal 424
• M 17 ib 424
• Oil bolt 424
• Page 23 424
• Push the brake hose eyelet to the stopper on the 424
• Sealing washers 424
• Stopper 424
• The new caliper assembly bolts to the specified 424
• With two new sealing washers and oil bolt 424
• Apply small squirts of air pressure to the fluid inlet 425
• Avoid spilling fluid 425
• Brake caliper 425
• Bring the nozzle 425
• Caliper bod 425
• Collar 425
• Do not use high 425
• Drain the rear brake hydraulic system page 15 5 425
• Hose eyelet join 425
• On painted plastic 425
• Or rubber part 425
• Pad spring 425
• Pads page 15 8 425
• Page 24 425
• Pivot the caliper up and remove i 425
• Place a rag over 425
• Place a shop towel over the pisto 425
• Position the caliper body with the piston down and 425
• Pressure air or 425
• Rear brake caliper 425
• Remove the caliper bracket bolts and the brake 425
• Remove the oil bolt sealing washers and brake 425
• Remove the pad spring collar and boot from the 425
• System is service 425
• These parts 425
• To remove the pisto 425
• Too close to the 425
• Washfrs 425
• Whenever the 425
• Be careful not to 426
• Brake pads 426
• Caliper piston 426
• Check the caliper cylinder for scoring or other 426
• Check the caliper pistons for scratches scoring or 426
• Clean the seal grooves with clean brake flui 426
• Collar 426
• Damage the piston 426
• Dust seal 426
• Hydrauli 426
• Inspection 426
• Measure the caliper cylinder 426
• Measure the caliper piston 426
• Other damag 426
• Pad spring 426
• Page 25 426
• Piston seal 426
• Push the dust seal and piston seal in and lift them 426
• Service limi 426
• Sliding surfac 426
• 4sealing washers 427
• Apply silicone grease to the caliper pin and install 427
• Apply silicone grease to the inside of the bracket 427
• Brake caliper 427
• Calipe 427
• Caliper 427
• Caliper piston 427
• Coat the caliper piston with clean brake fluid and 427
• Coat the new dust seal with silicone grease 427
• Coat the new piston seal with clean brake fluid 427
• Collar 427
• Deteriorated replace them with new one 427
• Dust seal 427
• End toward the pa 427
• Fill and bleed the rear brake hydraulic system 427
• Hydraulicbrake 427
• If the caliper and bracket pin boots are hard or 427
• Ii e dlt 427
• Instal 427
• Install and tighten the caliper bracket bolt to the specified torque 427
• Install it into the caliper cylinder with its opening 427
• Install the bracket pin boot and collar into the 427
• Install the brake pads page 15 8 427
• Install the pad retainer into the bracke 427
• Install the pad spring into the caliper bod 427
• Install the piston seal and dust seal into the groove of the caliper bod 427
• M 25 lb 427
• Pad spring 427
• Page 15 4 427
• Page 26 427
• Pin boo 427
• Piston seal 427
• Retainer 427
• Sealin 427
• Specified 427
• Stoppe 427
• The caliper onto the bracke 427
• Tighte 427
• Washers an 427
• And bracket assembly from the lower bracke 428
• Behind the right step guar 428
• Brake light switch 428
• Brake pedal 428
• California type 428
• Cotter pin 428
• Except california typ 428
• Footpeg bar 428
• Hydraulic brake 428
• Installation 428
• Joint pin 428
• Light switch from the step holde 428
• M 33 ib 428
• M 4 kgf m 428
• Main footpeg 428
• O sensor wire 428
• Page 27 428
• Pedal and wave washe 428
• Release 428
• Removal 428
• Remove and discard the brake pedal joint cotter pin 428
• Remove the footpeg mounting bolt footpeg brake 428
• Remove the joint pin 428
• Remove the main footpeg bracket mounting bolts 428
• Return spring 428
• Right footpeg bracket 428
• Sensor 428
• Spring 428
• Switch 428
• Switch spring 428
• Unhook the brake pedal return sprin 428
• Unhook the return spring and remove the brake 428
• W 44 n m 428
• Wave washer 428
• Apply grease to the sliding surface of the brake 429
• Assemble the brake pedal footpeg and wave 429
• Bolt 1cotter pin footpeg bar 429
• Brake light switch 429
• Brake pedal 429
• Connect the brake pedal to the push rod lower joint 429
• Cotter pin 429
• Except california typ 429
• Footpeg 429
• Hook the brake pedal return sprin 429
• Install a new footpeg mounting bolt and tighten it 429
• Install the brake light switch and hook the switch 429
• Install the joint pin and secure it with a new cotter 429
• Joint pin 429
• Kgf m 33 lbf ft 429
• M 1 kg 429
• Main footpeg 429
• Page 28 429
• Pedal and footpe 429
• Return spring 429
• Sensor wire 429
• Spring 429
• Switch 429
• Switch spring 429
• To the specified torqu 429
• Wave washer 429
• Hydraulic brake 430
• Page 29 430
• Alternator charging coil 431
• Always turn off the ignition switch before disconnecting any electrical component 431
• Battery 431
• Battery overcharge often 431
• Battery voltage may recover after battery charging but under heavy load battery voltage will drop quickly and 431
• Before troubleshooting the charging system check for proper use and maintenance of the batter 431
• Charge the stored battery every two week 431
• Chargin 431
• Check if the battery is 431
• Clothing and a face shiel 431
• Conditions contribute to shortening the life span of the batter 431
• Contact with skin or eyes may cause severe burn 431
• Deteriorates after 2 3 year 431
• Electrolyte is poisonou 431
• Even under normal use the performance of the battery 431
• Eventually die ou 431
• For a battery remaining in a stored motorcycle disconnect the negative battery cable from the battery terminal 431
• For extended storage remove the battery give it a full charge and store it in a cool dry spac 431
• For maximum service life 431
• For this reason the charging system is often suspected as the proble 431
• Frequently under heavy load such as having the headlight and taillight on for long periods of time without riding the 431
• General 431
• If electrolyte gets in your eyes flush with water for at least 15 minutes and call a physician immediately 431
• If electrolyte gets on your skin flush with wate 431
• If one of the battery cells 431
• If swallowed drink large quantities of water or milk and call your local poison control center or a physician 431
• Ignition switch is on and current is presen 431
• Immediately 431
• Is shorted and battery voltage does not increase the regulator rectifier supplies excess voltage to the batter 431
• Keep sparks flames and cigarette 431
• Motorcycl 431
• Page 1 431
• Provide adequate ventilation when 431
• Regulator rectifier 431
• Results from problems in the battery itself which may appear to be an overcharging sympto 431
• Service information 16 1 431
• Some electrical components may be damaged if terminals or connectors are connected or disconnected while the 431
• System 431
• System diagram 16 0 charging system inspection 16 6 431
• The battery can be damaged of overcharged or undercharged or of left to discharge for long perio 431
• The battery contains sulfuric acid electrolyte 431
• The battery gives off explosive gase 431
• The maintenance free battery must be replaced when it reaches the end of its service life 431
• These conditions the electrolyte level goes down quickl 431
• These same 431
• Troubleshooting 431
• Wear protective 431
• Alternator 432
• Batter 432
• Battery 432
• Battery charging system 432
• Below 1 432
• Bm 210 ah bm 210 or battery mate or equivalent 432
• Capacity 432
• Charging coil resistance 20 c 68 f 432
• Charging current 432
• Charging time may damage the batter 432
• Current leakage 432
• For battery charging do not exceed the charging current and time specified on th 432
• For this reason charg 432
• Fully charged 432
• Kw 5 000 rpm 432
• Load on the battery so that the actual battery condition of the load can be measured 432
• Needs charging 432
• Normal 432
• Page 16 3 432
• Page 2 432
• Prevent sulfation from occurrin 432
• Recommended battery tester 432
• Recommended battery tester puts a 432
• Refer to the instruction of the operation manual for the recommended battery teste 432
• Specifications 432
• The battery every two weeks to 432
• The battery will self discharge when the motorcycle is not in us 432
• Use of excessive current or 432
• Voltage 20 c 68 f 432
• When checking the charging system always follow the steps in the troubleshooting flow chart 432
• 20 c 68 f 433
• Battery charging system 433
• Bm 210 ah bm 210 or battery mate or equivalent 433
• Check the alternator charging coil page 16 7 433
• Check the battery condition using the recom 433
• Check the battery current leakage leak tes 433
• Correct 433
• Digital multimeter page 16 5 433
• Disconnect the regulator rectifier connector and 433
• Faulty battery 433
• Faulty charging coil 433
• Faulty ignition switch 433
• Faulty regulator rectifier 433
• Following calculation 433
• Incorrect 433
• Install the battery page 16 5 433
• Measure and record the battery voltage using a 433
• Measure the charging voltage page 16 6 433
• Mended battery tester 433
• Page 16 7 433
• Page 3 433
• Recheck the battery current leakag 433
• Remove the battery page 16 5 433
• Shorted wire harness 433
• Start the engin 433
• Troubleshooting 433
• Voltage 1 433
• Battery charging system 434
• Page 4 434
• Shorted wire harness 434
• After installing the battery coat the terminals with 435
• Always turn the 435
• Available 435
• Batter 435
• Battery 435
• Battery charger 435
• Battery negativ 435
• Battery positive termina 435
• Battery termina 435
• Below 1 435
• Cable and remove the batter 435
• Cable to the 435
• Charger not at the 435
• Clean greas 435
• Commercially 435
• Connect the 435
• Connect the charger negative 435
• Connect the charger positive cable to the 435
• Current and time specified on the batter 435
• Digital multimeter 435
• Disconnect the negative cable and then the positive 435
• Excessive current or extending the charging time 435
• First and then the 435
• For battery charging do not exceed the charging 435
• Fully charge 435
• Holder band 435
• Ignition switch 435
• Install the battery in the reverse order of removal 435
• May damage the batter 435
• Measure the battery voltage using a digital 435
• Multimete 435
• Negative cable 435
• Negative terminal 435
• Off before 435
• On off at the 435
• Page 5 435
• Positive terminal 435
• Quick charging should only be done in an emergenc 435
• Remove the battery holder ban 435
• Remove the battery see above 435
• Remove the seat page 2 2 435
• Removing the 435
• Slow charging is preferred 435
• Termina 435
• Turn power 435
• Undercharge 435
• Voltag 435
• With the proper wiring as shown 435
• Page 6 436
• 000 rp 437
• A sudden surge of current may blow out the 437
• And disconnect the 437
• Appropriate leve 437
• At 5 000 rpm 437
• Battery 437
• Battery charging system 437
• Be sure the battery is in good condition before 437
• Cable and the ammeter 437
• Cable in the 437
• Charging syste 437
• Charging system 437
• Charging voltage inspection 437
• Components 437
• Connect the ammeter probe to the ground 437
• Current flow higher than the 437
• Current leakag 437
• Current leakage inspection 437
• Damage the tester 437
• Do not disconnect 437
• Failure to follow 437
• Fuse in the teste 437
• High range and then bring the range down to an 437
• If current leakage exceeds the specified value a 437
• Ignition 437
• Ignition switc 437
• Inspection 437
• Locate the short by disconnecting connections one by one and measuring the curren 437
• Ma max 437
• Measured battery voltage page 16 5 437
• Measured charging voltage see above 437
• Negativ 437
• Negative battery cable from the batter 437
• Or electrical 437
• Page 7 437
• Performing this tes 437
• Probe to the batter 437
• Range selected may blow out the fuse in the 437
• Restart the engin 437
• Shorted circuit is likel 437
• Specified current leakag 437
• Standar 437
• Stop the engine and connect the multimeter as 437
• Switch 437
• Switching off the 437
• Terminal with the ignition switch off check for 437
• The battery or any 437
• This precaution can 437
• To prevent a short make absolutely certain 437
• Voltage on the multimeter when the engine runs at 437
• Warm up the engine to normal operating tempera 437
• When measuring current using a tester set it to a 437
• Which are the positive and negative terminals or 437
• While measuring current do not turn the ignition 437
• With the headlight on hi beam measure the 437
• Without first 437
• Alternator charging coil 438
• And groun 438
• At 20 c 68 f 438
• Battery 438
• Battery charging system 438
• Battery voltage 438
• Between connector terminals wire harness side as 438
• Charging coil 438
• Charging line 438
• Check for continuity between all three yellow 438
• Check it for loose contact or corroded terminals 438
• Check the resistance between all three yellow 438
• Continuity 438
• Disconnect the alternator 3p natural connecto 438
• Disconnect the regulator rectifier connectors and 438
• Follow 438
• Green and 438
• Ground line 438
• If readings are far beyond the standard or if any 438
• If the regulated voltage reading see page 16 6 is 438
• Inspection 438
• It is not necessary 438
• Li at 20 c 68 f 438
• Out of the specification measure the voltage 438
• P natural connector 438
• Page 5 81 438
• Page 5 89 438
• Page 8 438
• Red white 438
• Refer to section 10 for stator remova 438
• Remove the fuel tank rear bracket and ecm cover 438
• Remove the rear cowl pag 438
• Should exist 438
• Should register 438
• Specification 438
• Standar 438
• Stator coil to make 438
• System inspection 438
• Terminal 438
• Terminals and groun 438
• There should be no continuit 438
• This tes 438
• To remove the 438
• Tor stato 438
• Wire has continuity to ground replace the alterna 438
• Yellow 438
• Yellow and 438
• All components 439
• Battery charging system 439
• Bolts and regulator rectifier 439
• Charging 439
• Disconnect the alternator 3p natural connecto 439
• Disconnect the alternator 4p natural connecto 439
• Install the regulator rectifier unit in the reverse 439
• Normal and there are no loose connections at the 439
• Order of remova 439
• Page 9 439
• Regulator rectifier connectors replace the regula 439
• Removal installation 439
• Remove the regulator rectifier unit mounting sh 439
• System 439
• Tor rectifier uni 439
• A faulty ignition system is often related to poor connection 440
• Also if the connector is disconnected when current is flowing the excessive 440
• Always turn off the ignition switch before servicin 440
• Battery is adequately charge 440
• Btdc at idle 440
• Check those connections before proceedin 440
• Direct ignition coil that the ignition coil and spark plug cap are integrated is adopted in this motorcycle 440
• General 440
• Generato 440
• Ignitio 440
• Ignition pulse generator 440
• Ignition switch is on and current is present 440
• Ignition system inspection 440
• Ignition timin 440
• Ignition timing 440
• Information 440
• Ion sys em 440
• Iuh27d denso iuh24d denso 440
• Make sure the 440
• Optional 440
• Page 1 440
• Peak voltage 440
• Refer to section 5 for throttle position tp sensor cam pulse generator and ecm inspection 440
• Servic 440
• Some electrical components may be damaged if terminals or connectors are connected or disconnected while the 440
• Spark plug 440
• Spark plug gap 440
• Specifications 440
• Standard 440
• System diagram 440
• The ecm may be damaged if droppe 440
• The ignition timing does not normally need to be adjusted since the ecm is factory preset 440
• This motorcycle s ignition control module icm is built into the engine control module ecm 440
• Troubleshooting 440
• Use spark plug of the correct heat rang 440
• Using spark plug with an incorrect heat range can damage the engine 440
• Using the starter motor with a weak battery results in a slower engine cranking speed as 440
• V minimum 440
• Voltage 440
• Voltage may damage the modul 440
• Well as no spark at the spark plu 440
• When servicing the ignition system always follow the steps in the troubleshooting sequence on page 17 3 440
• Page 2 441
• 3 are normal 442
• An open circuit in black white wire between the direct 442
• An open circuit or loose connection in blue black 442
• An open circuit or loose connection in green wir 442
• An open circuit or loose connection in n 442
• And body 442
• At the ecm connector 442
• At the ecm multi connector or loosen ecm 442
• Below 10 m 2 dc 442
• Below 10 m2 dc 442
• Cal components are normal 442
• Circuit wire 442
• Connectio 442
• Cranking speed is too low battery under charged 442
• Current amper 442
• Disconnecting ecm connector 442
• Does not spark 442
• Down to 2 4 v while cranking the 442
• Engine stop switches o 442
• Faulty ecm when above n 442
• Faulty ecm when the initial voltage is normal while 442
• Faulty engine stop switc 442
• Faulty ignitio 442
• Faulty ignition pulse generato 442
• Faulty ignition pulse generator measure the peak 442
• Faulty peak voltage adapto 442
• Faulty peak voltage adaptor connection 442
• Faulty side stand switch or neutral switc 442
• Faulty spark plug 442
• Faulty spark plug or leaking ignition coil secondary 442
• Green white wire 442
• If there is no spark at either cylinder temporarily exchange the direct ignition coil with the other good one and perform the 442
• If there is spark the exchanged direct ignition coil is fault 442
• Ignition 442
• Ignition coil 442
• Ignition coil and engine stop switch 442
• Ignition system 442
• Incorrect peak voltage adaptor connections 442
• Initial and peak voltage are normal but 442
• Initial voltage is normal but it drops 442
• Initial voltage is normal but no peak 442
• Initial voltage is normal but peak 442
• Initial voltage of the ignition primary coil is the battery voltage with the ignition switch on and engine stop switch at 442
• Inspect the following before diagnosing the syste 442
• Light green and light green red wire 442
• Loose or poor connect of the direct ignition coil primary 442
• Loose spark plug cap or spark plug wire connection 442
• Neutral switch lin 442
• No initial voltage with ignition and 442
• No peak voltag 442
• No spark at all plugs 442
• No voltage between the black white 442
• Normal 442
• Other electri 442
• Page 3 442
• Peak voltage is lower than standard 442
• Primary volt 442
• Probable cause check in numerical order 442
• Pulse gener 442
• Related 442
• Run the engine is not cranked by the starter motor 442
• Short circuit in ignition primary coil 442
• Side stand switch lin 442
• Spark tes 442
• The direct ignition coils and ec 442
• The multimeter impedance is too lo 442
• The sampling timing of the tester and measured pulse 442
• Troubleshooting 442
• Undercharged batter 442
• Unusual condition 442
• Voltage 442
• Voltage is lower than standard valu 442
• Voltage is over the standard voltage at least once 442
• Voltage while cranking the engin 442
• Water got into the direct ignition coil leaking the ignition coil secondary voltage 442
• Were not synchronized system is normal if measured 442
• Wire terminal or an open circuit in primary coil check 442
• Yellow white red blue and red yellow wires between 442
• Adaptor to the digital multimete 443
• Check all system connections before inspectio 443
• Check cylinder compression and check that the 443
• Cially available digital multimeter with an 443
• Connect a known good spark plugs to the direct 443
• Connect the direct ignition coil 2p connectors to the 443
• Connect the peak voltage tester or peak voltage 443
• Cylinder head as done in a spark tes 443
• Digital multimeter 443
• Direct ignition coi 443
• Disconnect the direct ignition coils from the spark plug pag 443
• Good known 443
• Hgj 0020100 443
• If the system is disconnected incorrect peak 443
• If there is no spark at any plug check all connec 443
• If using peak voltage tester 443
• Ignition coil primary peak 443
• Ignition coils and ground the spark plugs to the 443
• Impedance 10 m u dcv minimum 443
• Impedance of 10 m q dcv minimu 443
• Internal impedance of the multimete 443
• Only follow 443
• Only or 443
• Page 4 443
• Peak voltage adaptor 443
• Peak voltage teste 443
• Shift the transmission into neutra 443
• Spark plug 443
• Spark plugs are installed correctl 443
• The display value differs depending upon the 443
• The manufacturer s instructions 443
• Tions for loose or poor contact before measuring each peak voltag 443
• Use recommended digital multimeter or commer 443
• Voltage might be measure 443
• With commercially available digital multimeter 443
• Adaptor or imrie tester to the 9p black connector 444
• Avoid touching the 444
• Blue black terminal body groun 444
• Body groun 444
• Check all system connections before inspection 444
• Check cylinder compression and check that the 444
• Check for initial voltage at this tim 444
• Circuit or poor connection in yellow blue and blue 444
• Connected connect 444
• Connecto 444
• Crank the engine with the starter motor and read 444
• Disconnect the 22p light gray connector from the 444
• If no defects are found in the harness refer to the 444
• If the initial voltage cannot be measured check the 444
• If the peak voltage is abnormal check for an open 444
• If the system is disconnected incorrect peak 444
• Ignition 444
• Ignition coil primary peak voltage 444
• Ignition pulse generator peak 444
• Ignition system 444
• P light gray connector 444
• Page 17 3 444
• Page 5 444
• Page 5 81 444
• Power supply circuit refer to the troubleshooting 444
• Prevent electric 444
• Primary wire terminal and groun 444
• Red blue terminal 444
• Red yellow terminal body groun 444
• Remove the fuel tank rear bracket and ecm cover 444
• Spark plugs and 444
• Spark plugs are installed correctl 444
• Sub harness 444
• Switch to run 444
• Tester probes to 444
• The battery voltage should be measured 444
• Troubleshooting chart on page 17 444
• Turn the ignition switch on and engine stop 444
• V minimum 444
• Voltage 444
• Voltage might be measured 444
• Yellow white terminal 444
• Yellow wire 444
• Abnormal and the one measured at the ignition 445
• All items are normal the ignition pulse generator 445
• An open circuit or loose connectio 445
• At the ignition pulse generator connecto 445
• Avoid touching the 445
• Check each item in the troubleshooting char 445
• Connect the peak voltage tester or peak voltage adaptor probes to the connector terminal of the 445
• Connecto 445
• Connector and connect the tester probes to the 445
• Connector is abnormal measure the peak voltage 445
• Crank the engine with the starter motor and read 445
• Dcv minimum 445
• Disconnect the ignition pulse generator 2p red 445
• Hgj 0020100 445
• If both peak voltages measure are abnormal 445
• If the peak voltage measured at ecm multi 445
• If the peak voltage measured at the ecm is 445
• Ignition pulse generator 445
• Impedance 10 445
• In the same manner as at the ecm connector 445
• Is fault 445
• Measure the peak voltage and compare it to the 445
• Only or 445
• Open and support the front end of fuel tank page 445
• P light gray connector 445
• P red connector 445
• Page 6 445
• Peak voltage adaptor 445
• Peak voltage teste 445
• Prevent electric 445
• Pulse generator is normal the wire harness has 445
• Removal 445
• Replacemen 445
• See following steps for ignition pulse generator 445
• Spark plugs and 445
• Terminal yellow and white yellow 445
• Tester probes to 445
• The peak voltag 445
• V minimum 445
• Voltage measured at the ecm connecto 445
• Wire harness side and groun 445
• With commercially available digital multimeter 445
• Yellow terminal groun 445
• Page 7 446
• 07725 0040000 447
• And hold the 447
• Apply sealant to the wire grommet then install it 447
• Connect the 2p red connecto 447
• Cover page 10 2 447
• Flywheel holder 447
• Flywheel with the 447
• If the engine is out 447
• Ignition pulse genf 447
• Ignition timing 447
• Install and tighten the ignition pulse generator bolt 447
• Install the ignition pulse generator into the cover 447
• Install the removed parts in the reverse order of 447
• Install the right crankcase cover page 9 17 447
• Into the groove of the cove 447
• Lbf ft 447
• Of frame remove 447
• P red connector 447
• Page 8 447
• Remova 447
• Route the ignition pulse generator wire properly 447
• Shift the transmission into 6th gear and apply rear 447
• Stop the engine and remove the timing hole cap 447
• The alternator 447
• The specified torqu 447
• Then tighten the 447
• Tighten the ignition pulse generator rotor bolt to 447
• Tlf l1 447
• Ulse generator r 447
• Warm up the engin 447
• Apply grease to the timing hole cap and install the 448
• Approximately 1 500 rp 448
• Check the o ring is in good condition replace if 448
• Connect the timing light to the n 448
• F mark 448
• Ignition system 448
• Increase the engine speed by turning the throttle 448
• Page 9 448
• Ring and timing hole cap 448
• Rotor cove 448
• Spark plug 448
• Start the engine and let it idl 448
• Stop screw and make sure the f mark begins to 448
• The ignition timing is correct if the f mark aligns 448
• Tighten the timing hole cap to the specified torqu 448
• With the index mark on the ignition pulse generator 448
• Page 1 449
• Page 2 450
• Page 3 451
• Be careful not to 452
• Cable at the batter 452
• Case bolts 452
• Damage the water 452
• Drain the coolant pag 452
• Electri 452
• Gro nd cab e 452
• Ground cabl 452
• Location and 452
• Number of shim 452
• Open and support the front end of fuel tank page 452
• Page 4 452
• Pull the starter motor out of the crankcas 452
• Rear cover 452
• Rear cover assembly 452
• Record the 452
• Remove the followin 452
• Remove the nut and the starter motor cable from 452
• Remove the starter motor mounting bolts and 452
• Remove the thermostat housing pag 452
• Remove the throttle body page 5 60 452
• Seal ring 452
• Starter motor 452
• Starter motor case bolts 452
• T a1rrl 452
• The starter moto 452
• With the ignition switch off remove the negative 452
• _rm stra i 452
• And the brush wire the indigo colored wire or the 453
• Armature 453
• Brush lengt 453
• Check for continuity between the cable terminal 453
• Check for continuity between the motor case and 453
• Eal ring 453
• Electric starter 453
• Front cover assembly 453
• Inspect the brushes for damage and measure the 453
• Inspection 453
• Insulated brush holder 453
• Insulated washer 453
• Lock washer 453
• Page 5 453
• Remove the followin 453
• Seal ring 453
• Service limi 453
• The cable termina 453
• There should be continuit 453
• There should be no continuit 453
• Armature 454
• Armature coils in which case the starter motor 454
• Check the bushing of the rear cover for wear or 454
• Check the front cover oil seal for fatigue or other 454
• Check the needle bearing for damag 454
• Do not use emery 454
• Electri 454
• Inspect the commutator bars for discoloratio 454
• Must be replace 454
• Mutator bar 454
• Oil seal 454
• Orsandpaperon 454
• Page 6 454
• Starter 454
• The commutator 454
• There should be continuity 454
• Also check for continuity between individual 455
• Armature 455
• Assembly 455
• Brush holder 455
• Brush holder assembly 455
• Brush terminal 455
• Commutator bars and the armature shaf 455
• Front cover 455
• Insulated washer 455
• Insulators 455
• Lock washer 455
• Motor case 455
• O ring 455
• Oil seal 455
• Page 7 455
• Rear cover 455
• Remove the followin 455
• Seal ring 455
• Should be no continuit 455
• Washer 455
• Align the terminal 456
• Armature 456
• Armature shaf 456
• As noted during 456
• Assemble the motor case and rear cover aligning 456
• During remova 456
• During removal 456
• Front cover 456
• Holder plate boss 456
• Install the 456
• Install the armature in the motor cas 456
• Install the brush holder onto the motor case 456
• Install the followin 456
• Install the insulated washer and lock washer on the 456
• Install the seal ring on the motor case 456
• Install the seal ring onto the motor case 456
• Install the shims 456
• Install the shims on the armature shaf 456
• Insulated washer 456
• Insulators 456
• Insulators properly 456
• Lock washer 456
• O ring 456
• Page 8 456
• Properly as noted 456
• Rear cover 456
• Remova 456
• Seal ring 456
• Set the brushes on the brush holde 456
• The brush holder boss with the groove in the rear 456
• The motor cas 456
• Washer 456
• With the groove of 456
• Apply clean engine oil to the new o ring 457
• Be careful not to 457
• Case bolts 457
• Damage the water 457
• Index lines 457
• Install a new o ring onto the starter motor boss 457
• Install and tighten the case bolts securely 457
• Install the front cover to the motor cas 457
• Install the starter motor cables then tighten the 457
• Install the starter motor into the crankcas 457
• Make sure the index lines are aligne 457
• Mounting bolts and terminal nut securel 457
• O ring 457
• Page 9 457
• Q tr f tfr ni0toi 457
• Route the starter motor cable and ground cabl 457
• Startef 457
• And groun 458
• Check for continuity between the green red wire 458
• Disconnect the relay connecto 458
• Fill the system with the recommended coolant 458
• If the switch click is not heard inspect the relay 458
• If there is continuity when the transmission is in 458
• Imhsinu 458
• In neutral there is a slight resistance due to the 458
• Install 458
• Install and tighten the mounting bolt 458
• Install the followin 458
• Install the thermostat housing to the cylinder head 458
• Neutral or when the clutch is disengaged and the 458
• New o ring into the thermostat housing 458
• Ostfa 1t 458
• Page 10 458
• Relay switch 458
• Remove the seat pag 458
• Shift the transmission into neutral 458
• Side stand switch is up the ground circuit is normal 458
• Starter relay switch 458
• Switch butto 458
• Switch using the procedure belo 458
• The coil is normal if the starter relay switch click 458
• Thermostat housing thermostat pag 458
• Throttle body page 5 63 458
• Turn the ignition switch on and depress the starter 458
• And ground at the starter relay switch 459
• Battery is disconnected 459
• Check for continuity between the starter relay 459
• Check for continuity with an ohmmete 459
• Connect a fully charged 12v battery to the starter 459
• Connect an ohmmeter to the starter relay switch 459
• Connect the starter relay switch connecto 459
• Connected to the starter relay switch connector 459
• Connecto 459
• Continuity 459
• Continuity inspection 459
• Disconnect the starter relay connector and cables 459
• Electric starter 459
• Fuse box 459
• Green red 459
• Install the diode in the reverse order of remova 459
• Installation 459
• Large terminal 459
• Measure the voltage between the yellow red wire 459
• No continuity 459
• Normal directio 459
• Open the fuse box and remove the diod 459
• Page 11 459
• Relay switch connector terminals yellow red and 459
• Remove the seat pag 459
• Reverse directio 459
• Shift the transmission into neutra 459
• Starter relay switch 459
• Starter switch button is depressed with the ignition 459
• Switch is o 459
• Switch terminal 459
• Terminals and should be no continuity when the 459
• There should be battery voltage only when the 459
• There should be continuity while 12v battery is 459
• Brake light switch 460
• Clutch switch 460
• Combination meter 460
• Coolant temperature gauge 460
• Cooling fan motor switch 460
• Fuel reserve sensor 19 17 460
• General 460
• Handlebar switches 460
• Headlight 460
• Ignition switch 460
• License light 460
• Neutral switch 460
• Notice 460
• Oil pressure switch 19 15 460
• Page 1 460
• Sensor 460
• Service information 460
• Side stand switch 460
• Speedometer vehicle speed 460
• System location 460
• Tachometer 460
• Tail brake light 460
• Troubleshooting 19 3 460
• Turn signal 460
• Turn signal relay 460
• 102 c 208 216 f 461
• 97 c 19 461
• A 1 10a x 5 461
• Aloc bolt 461
• Apply sealant to the threads 461
• Coolant temperature ect sensor 461
• Fan motor switch 461
• Front tur 461
• Fuel reserve indicator 461
• Headlight 461
• High beam indicator 461
• Ignition switch mounting one way bolt side stand switch mounting bolt 461
• Instrument ligh 461
• Led led led led led 30a 20a 461
• Led x 2 461
• Malfunctio 461
• Neutral switch 461
• Oil pressure indicator 461
• Oil pressure switch 461
• Oil pressure switch wire terminal screw 461
• Page 2 461
• Peak voltage 461
• Pgm fl fuse 461
• Rear turn signal light_ 461
• Signal runnin 461
• Specifications 461
• Stop to open 461
• Sub fuse 461
• Tachomete 461
• Thermo sensor resistance 461
• V 21 5w x 2 461
• V 32 3 cp 23 461
• V 5w led 461
• V minimum 461
• Between the battery and speed sensor 462
• Between the battery and speedometer 462
• Blown main or sub fuses 462
• Check for loose or poor contact of the combina 462
• Check for loose or poor contact of the speed 462
• Check for the following before diagnosing 462
• Discharged batter 462
• Faulty odometer trip meter 462
• Faulty speed sensor 462
• Faulty speedometer 462
• Loose or corroded terminals of the connectors 462
• Loose or poor contact of related terminals 462
• Loose speed sensor mounting bolts 462
• Measure the output voltage sensor signal at the 462
• Normal 462
• Of the pink green wire between the terminals of 462
• Open circuit in black brown or green black wires 462
• Open circuit or loose connection in pink green 462
• Page 3 462
• Sensor 3p natural connector 462
• Slowly turning the rear wheel by your han 462
• Speedometer with the ignition switch is on while 462
• Support the motorcycle using a hoist or other 462
• Support to rise the rear wheel off the groun 462
• The odometer trip meter operate normally but the speedometer does not operate 462
• The speed sensor and speedomete 462
• The speedometer operate is abnormal 462
• The speedometer operate normally but the odometer trip meter does not operate 462
• Tion meter multi connector 462
• Troubleshooting 462
• Voltage at the bottom of the speedometer termi 462
• Voltage at the speed sensor connecto 462
• With the ignition switch off check for continuity 462
• With the ignition switch on and measure the 462
• Avoid touching 463
• Bulb replacement 463
• Bulb socke 463
• Bulb socket 463
• Bulb to brea 463
• Bulbisuc kl i 463
• Can create hot 463
• Disconnect the headlight bulb connectors 463
• Fingerprints 463
• Halogen headlight 463
• Headlight 463
• If you touch the bulb with your bare hands clean it 463
• Install a new bulb into the socke 463
• Install the new headlight bulb socket by aligning its tabs with the groove in the headlight uni 463
• Page 4 463
• Prevent early bulb failur 463
• Remove the dust cove 463
• Remove the headlight bulb from the socke 463
• Spots that cause a 463
• Unhook the bulb retainer and remove the headlight 463
• With cloth moistened with denatured alcohol to 463
• Connect the headlight connector 464
• Connect the white 464
• Groove 464
• Headlight bulb 464
• Headlight unit 464
• Hook the bulb retainer into the headlight unit 464
• Install the dust cover tightly against the headlight 464
• Install the headlight unit in the reverse order of re 464
• Page 5 464
• Remove the four bolts and headlight uni 464
• Remove the upper cowl pag 464
• Socket lo beam 464
• Tape connector to 464
• The center 464
• Unit with its arrow mark facing u 464
• Disconnect the turn signal connecto 465
• For front turn signal unit removal see upper cowl 465
• For rear turn signal removal remove the following 465
• Install the turn signal lens in the reverse order of re 465
• Install the turn signal unit in the reverse order of 465
• Ly page 1 24 465
• Page 6 465
• Release the turn signal wire and remove the turn 465
• Remova 465
• Removal pag 465
• Remove it and replace with a new on 465
• Remove the screw and turn signal len 465
• Remove the turn signal mounting nu 465
• Route the turn 465
• Seat rear cowl page 2 2 465
• Setting plate 465
• Signal uni 465
• Signal wire proper 465
• Turn signal 465
• Turn signal connectors 465
• Turn signal lens 465
• Turn signal unit 465
• While pushing in turn the bulb counterclockwise to 465
• Align the tail 466
• Bracket hole 466
• Brake light unit 466
• Connectors 466
• Disconnect the tail brake light connector 466
• Install the tail brake light sockets in the reverse 466
• Installation is in the reverse order of remova 466
• License light 466
• License light assembl 466
• Move the bulb socke 466
• Order of remova 466
• Page 7 466
• Remove the license light bracket bolts and the 466
• Remove the rear cowl pag 466
• Remove the two screws and tail brake light uni 466
• Screws 466
• Tabs with the 466
• Tail brake light 466
• Tail brake light unit 466
• To remove them and replace with new ones 466
• Turn the bulb socket counterclockwise then re 466
• While pushing in turn the bulbs counterclockwise 466
• Combination meter 467
• Disassembly 467
• Disconnect the combination meter multi connector 467
• Install the license light assembly in the reverse 467
• Lights meters switches 467
• Order of remova 467
• Page 8 467
• Rear cover 467
• Release the combination meter case bosses from the bracket grommets then remove the combina 467
• Remove it and replace with a new on 467
• Remove the combination meter mounting bolt 467
• Remove the screws and combination meter rear 467
• Remove the screws license light cover and len 467
• Remove the upper cowl pag 467
• Tion mete 467
• While pushing in turn the bulb counterclockwise to 467
• Page 9 468
• Age at the multi connector terminal 469
• Battery voltage 469
• Black brown green blac 469
• Check for loose or poor connection of the combina tion meter multi connecto 469
• Connectio 469
• Connector and check for loose or poor contact of 469
• Connector and combination meter multi connector 469
• Disconnect the speed sensor 3p natural 469
• Harnes 469
• If there is no continuity repair or replace the wire 469
• If there is no voltage repair or replace the wire har 469
• Ness sid 469
• Of the pink green wire between the speed sensor 469
• Open and support the front end of fuel tank page 469
• P natural connector 469
• Page 10 469
• Remove the upper cowl pag 469
• Sensor 469
• Speedometer vehicle speed 469
• Standar 469
• The connecto 469
• There should be continuity 469
• Voltage at the 3p natural connector of the wire har 469
• With the ignition switch is off check for continuity 469
• With the ignition switch is on and measure the 469
• With the ignition switch is on and measure the volt 469
• Check the 0 ring is in good condition replace if nec 470
• Connect the speed sensor 3p natural connecto 470
• Disconnect the speed sensor 3p natural connec 470
• Essary 470
• Green blac 470
• If the measurement is out of specification inspect 470
• Install the speed sensor into the upper crankcase 470
• Lights meters switches 470
• Measure the voltage at the combination meter ter 470
• Minals with the ignition switch is on while slowly 470
• Open and support the front end of fuel tank page 470
• Page 11 470
• Pink gree 470
• Removal installation 470
• Remove the bolts and speed senso 470
• Repeat 0 to 5 v 470
• Shift the transmission into gea 470
• Speed se 470
• Standar 470
• Support the motorcycle securely and place the rear wheel off the groun 470
• The open circuit in wire harness 470
• Turning the rear wheel by han 470
• Check for loose or poor contact terminals of the combination meter multi connecto 471
• Connect the peak voltage adaptor to the tachome 471
• Connect the speed sensor 3p natural connecto 471
• Hgj 0020100 471
• If the measured value is below 1 471
• If the value is normal replace the tachometer 471
• Impedance 10 m 2 dcv minimum 471
• Imrie diagnostic tester model 625 or 471
• Inspection 471
• Install and tighten the mounting bolts securely 471
• P natural connector 471
• Page 12 471
• Peak voltag 471
• Peak voltage adaptor 471
• Remove the upper cowl page 2 9 471
• Route the sensor wir 471
• Start the engine and measure the tachometer input 471
• Tachometer 471
• Ter black yellow terminal and groun 471
• V minimum 471
• V replace the 471
• With commercially available digital multimeter 471
• Yellow green and groun 471
• A sudden change of temperature 472
• An open circui 472
• Before testin 472
• Bottom of the pan to the bottom of the senso 472
• Check for continuity between the tachometer termi 472
• Combination 472
• Coolant 50 50 mixture an electric heating ele ment and measure the resistance through the sen 472
• Coolant temperature 472
• Disconnect the ect thermo sensor wire connector 472
• Disconnect the wire connector from the ect 472
• Do not let the 472
• Drain the coolant pag 472
• Ect thermo sensor 472
• Ect thermo sensor connector 472
• For tachometer replacement see 19 472
• From the senso 472
• Gauge sensor 472
• If the value is 0 v perform the followin 472
• If there is continuity replace the tachometer uni 472
• If there is no continuity check the wire harness for 472
• In from the 472
• Keep the temperature constant for 3 minutes 472
• Lights meters switches 472
• Meter disassembly and assembl 472
• Nal and the ecm multi connector yellow green ter 472
• Open and support the front end of fuel tank page 472
• Page 13 472
• Remove the ecm cover page 5 81 and disconnect 472
• Soak the ect thermo sensor in coolant up to its 472
• Sor as the coolant heats u 472
• Suspend the ecm thermo sensor in a pan of 472
• The ecm multi connecto 472
• Thermo sensor and remove the senso 472
• Thermo sensor terminal 472
• Thermometer or ect thermo sensor touch the 472
• Threads with at least 40 mm 472
• Will result in incorrect reading 472
• Always replace the 473
• Before testing warm up the engine to operating 473
• C 248 f 473
• C 68 f 473
• Check for a blown fuse before inspectio 473
• Connect the ect thermo sensor connecto 473
• Cooling fan motor switch 473
• Disconnect the connector from the fan motor 473
• Ect thfrfv1o sensor 473
• Fan motor does not start 473
• Fan motor does not stop 473
• Fan motor switch 473
• Fill the system and bleed the air pag 473
• If the fan motor does not stop check for a shorted 473
• If the fan motor stops replace the fan motor switc 473
• If the motor starts check the connection at the fan 473
• Ignition switch on agai 473
• Inspection 473
• Install and tighten the ect thermo sensor to the 473
• It is ok replace the fan motor switc 473
• Jumper wir 473
• Lights meters switches 473
• M 17 lb 473
• Middle lower cowl page 2 5 473
• More than 10 at any temperature liste 473
• Motor switch terminal 473
• Nector from the fan motor switch and turn the 473
• Page 14 473
• Remove the followin 473
• Replace the sensor if it is out of specification by 473
• Resistance 473
• Sealing washer 473
• Seat page 2 2 473
• Specified torqu 473
• Switch and ground the connector to the body with a 473
• Temperatur 473
• Temperature 473
• Turn the ignition switch off disconnect the con 473
• Turn the ignition switch on and check the fan mo 473
• Wire between the fan motor and switc 473
• With a new on 473
• Apply sealant to the fan motor switch thread 474
• Before inspectio 474
• Came on with the ignition switch o 474
• Connector 474
• Disconnect the fan motor switch connector and 474
• F ust cover 474
• Fan motor switch 474
• If battery voltage is measured replace fan moto 474
• If the indicator does not come on inspect as follo 474
• If the motor does not start check for voltage be 474
• If the oil pressure warning indicator stays on while 474
• If there is no battery voltage check for poor connec 474
• Inspection 474
• Install a new o ring onto the fan motor switc 474
• Install and tighten the fan motor switc 474
• Install the removed parts in the reverse order of 474
• Lights meters switches 474
• M 13 lb 474
• Make sure that the oil pressure warning indicator 474
• O ring 474
• Oil pressure switch 474
• Oil pressure warning indicator 474
• Open and support the front end of fuel tank page 474
• Page 15 474
• Remova 474
• Removal installation 474
• Remove the dust cove 474
• Remove the screw and oil pressure switch termina 474
• Remove the switc 474
• Tehfvllk l 474
• The engine running check the engine oil level 474
• Tion of the connector or broken wire harnes 474
• Tween the fan motor switch connector and groun 474
• Apply sealant to the oil pressure switch threads as 475
• Circui 475
• Connect the oil pressure switch terminal 475
• Do not apply sealant to the thread 475
• Ground using a jumper wir 475
• Head 3 4 mm 475
• If the light does not comes on check the sub fuse 10 a and wires for a loose connection or an open 475
• If the light does not go out check the oil pressure 475
• If the oil pressure is normal replace the oil pres 475
• Install the dust cove 475
• Install the oil pressure switch onto the crankcase 475
• L pressure switch 475
• Oil pressure switch 475
• Page 16 475
• Remove the boot terminal screw and wire termina 475
• Remove the oil pressure switch from the crankcase 475
• Short the oil pressure switch wire terminal with the 475
• St cover 475
• Start the engine and make sure that the light goes ou 475
• Sure switch see below 475
• Switch and tighten the screw to the specified torque 475
• The ignition switch in o 475
• The oil pressure warning indicator comes on with 475
• Tic j 1p 475
• Tighten it to the specified torqu 475
• To the 475
• Ust cover 475
• V inal 475
• And green black terminals with a jumper wir 476
• Assembl 476
• Check for continuity between the wire terminals of the ignition switch connector in each switch posi 476
• Continuity should exist between the color coded 476
• Disconnect the fuel reserve sensor 3p black con necto 476
• Disconnect the ignition switch wire 4p natural con 476
• Erly check for the followin 476
• Fuel reserve indicator 476
• Fuel reserve indicator comes on 476
• If the fuel reserve indicator does not indicate prop 476
• If the indicator come on replace the fuel pump 476
• If the indicator still not come on check for open or 476
• Ig i bat1 476
• Ignition switch 476
• Jumper wire 476
• Key off 476
• Key on 476
• Lights meters switches 476
• Lock pin 476
• Nector 476
• P natural connector 476
• Page 17 476
• Remove the right inner panel page 2 9 476
• Short circuit in wire harnes 476
• Short the wire harness side connector brown black 476
• Turn the ignition switch in on and make sure the 476
• Turn the ignition switch is on and make sure the 476
• Wires as follow 476
• X1e0 rqnin 476
• Check for continuity between the wire terminals of 477
• Connector 477
• Continuity should exist between the color coded 477
• Disconnect the handlebar switch connector 477
• Disconnect the ignition switch wire 4p natural 477
• Engine stop switch 477
• I gnition switch 477
• Install the ignition switch in the reverse order of 477
• Lights meters switches 477
• P natural connector 477
• Page 18 477
• Remova 477
• Removal installation 477
• Remove the bolts and ignition switc 477
• Remove the top bridge page 13 5 477
• Remove the wire clam 477
• Starter switch 477
• The handlebar switch connecto 477
• Wire terminals as follow 477
• Page 19 478
• And groun 479
• Applied and there should be no continuity with the 479
• Check for continuity between the wire terminals of 479
• Clutch lever is released 479
• Clutch switch 479
• Continuity between the light green wire terminal 479
• Continuity should exist only when the side stand is 479
• Disconnect the clutch switch connectors 479
• Disconnect the neutral switch connector from the switc 479
• Disconnect the side stand switch 3p green connec 479
• In neutral and no continuity when the transmission 479
• Is into gea 479
• Neutral switch 479
• Neutral switch connector 479
• Open and support the front end of fuel tank page 479
• P green connector 479
• Page 20 479
• Shift the transmission into neutral and check for 479
• Side stand switch 479
• The side stand switch connecto 479
• There should be continuity with the clutch lever 479
• There should be continuity with the transmission is 479
• Connect the side stand switch 3p green connecto 480
• Disconnect the side stand switch 3p green connec 480
• Install the side stand switch by aligning the switch 480
• Lights meters switches 480
• M 7 ib 480
• P green connector 480
• Page 21 480
• Pin with the side stand hole and the switch groove 480
• Removal 480
• Remove the bolt and side stand switch 480
• Secure the side stand switch with a new bol 480
• Side stand switch 480
• With the return spring holding pi 480
• Battery condition 481
• Broken ground wire 481
• Broken wire harness 481
• Burned fuse 481
• Burned out bulb or non specified wattage 481
• Check for continuity between the green terminal of the relay connector and ground 481
• Check the followin 481
• Connect the 12 v battery to the horn terminal direct 481
• Continuity 481
• Disconnect the turn signal connectors from the 481
• Disconnect the wire connectors from the horn 481
• Faulty turn signal rela 481
• If the above items are all normal check the follow 481
• Ignition switch and turn signal switch function 481
• Ing the switch on 481
• Light comes on 481
• Light dose not come on 481
• Loose connectors 481
• No continuity 481
• Page 22 481
• Poor connection of the connecto 481
• Remove the upper cowl pag 481
• Short the black and gray terminals of the turn 481
• Signal relay connector with a jumper wir 481
• Tery is connected across the horn terminal 481
• The engine and check the turn signal light by turn 481
• The horn is normal if it sounds when the 12 v bat 481
• Turn signal relay 481
• Both the variable intake and egcv exhaust gas control valve are controlled by the same servo motor 482
• Engine torqu 482
• Features 482
• For the low and medium speed setting 482
• Generally the 180 exhaust collector design is used for high speed setting and the 360 exhaust collector design is used 482
• H vix is the new technology to provide high performance in all speed ranges 482
• In the high speed range the exhaust collector is in the 180 position to maximize high engine power 482
• In the high speed range the intake valve is opened by the servo motor and maximizes engine power in combination with 482
• In the low and middle speed ranges the exhaust collector is in the 360 position to produce more engine torqu 482
• In the low and middle speed ranges the intake valve is closed and in combination with the exhaust valve produces more 482
• Page 1 482
• Technica 482
• The egcv has a 180 collector and 360 collector in the same exhaust system 482
• The exhaust valve 482
• The intake valve is controlled by the same servo motor used for the egcv to control intake air volum 482
• The servo motor is controlled by the ec 482
• This system consists of the variable exhaust control valve variable intake air control valve and a servo motor 482
• Page 2 483
• At high speed rang 484
• At low and middle speed range 484
• At the same time the intake flap valve is opened by the control cable from servo moto 484
• Page 3 484
• Page 1 485
• Accelerate lightly 486
• Accelerate rapidly from low to 486
• Additive in engine oil 486
• Air cleaner dirty 486
• Brake dragging 486
• By hand 486
• Change accordingly when 486
• Check ignition timing 486
• Check oil level and condition 486
• Check tire pressure 486
• Clogged muffler 486
• Clogged oil control orifice 486
• Clogged oil passage 486
• Clutch is released 486
• Clutch slipping 486
• Contaminated oil 486
• Correct 486
• Engine lacks power 486
• Engine speed does not 486
• Engine speed increase 486
• Faulty ecm 486
• Faulty ignition pulse generator 486
• Faulty pressure regulator section 5 486
• Faulty spark plug 486
• Faulty tire valve 486
• Fouled or discolored 486
• Improper valve timing 486
• Incorrect 486
• Increase 486
• Inspect fuel flow 486
• Inspect lubrication 486
• Inspect the fuel injector 486
• Is released 486
• Leaking head gasket 486
• Not fouled or discolored 486
• Oil level too high 486
• Oil level too low 486
• Page 2 486
• Pinched fuel tank breather 486
• Possible cause 486
• Pressure low 486
• Pressure normal 486
• Properly 486
• Punctured tire 486
• Raise wheel off the ground and spin 486
• Remove cylinder head cover and 486
• Remove spark plugs 486
• Restricted fuel flow 486
• See section 5 486
• Test cylinder compression 486
• Troubleshooting 486
• Valve stuck open 486
• Valve train lubricated properly 486
• Valve train not lubricated 486
• Warped clutch discs plates 486
• Weak clutch spring 486
• Wheel spins freely 486
• Wheels do not spin freely 486
• Worn clutch discs plates 486
• Worn cylinder and piston rings 486
• Worn or damaged wheel bearing 486
• Page 3 487
• Page 4 488