Honda CBR900RR (1996-1998) [384/407] Assembly

Содержание

• E e ee eq 2
• Ee ke ee 2
• How to use this manual contents 2
• Symbols 3
• General info 4
• General information 4
• General safety 4
• General safety 1 1 lubrication seal points 1 19 4
• Model identification 1 3 emission control systems 4
• Service rules 1 2 cable harness routing 1 22 4
• Specifications 1 4 u s a only 1 36 4
• Tools 1 17 4
• Torque values 1 13 emission control information labels u s a only 1 39 4
• General information 5
• Service rules 5
• General information 6
• Model identification 6
• General 7
• General information 7
• Specifications 7
• General cont d 8
• General information 8
• Fuel system 9
• General information 9
• Lubrication system 9
• Service umit 9
• Cooling system 10
• Cylinder head valves 10
• General information 10
• Alternator starter clutch 11
• Clutch gearshift linkage 11
• General information 11
• Service limit 11
• Standard 11
• Crankshaft transmission 12
• General information 12
• General information 13
• Item standard service limit 13
• Nchn vvrilll ouor limoiuiv 13
• Battery charging system 14
• General information 14
• Hydraulic brake 14
• Standard 14
• Electric starter 15
• General information 15
• Ignition system 15
• Lights meters switches 15
• Specifications 15
• Engine 16
• General information 16
• Remarks 16
• Torque 16
• Torque values 16
• Engine cont d 17
• General information 17
• General information 18
• Frame cont d 19
• General information 19
• Description 20
• General information 20
• General information 21
• Engine 22
• General information 22
• Lubrication seal points 22
• Engine cont 23
• General information 23
• Engine cont d 24
• General information 24
• Location 24
• Cable harness routing 25
• General information 25
• General information 26
• General information 28
• General information 29
• General information 30
• General information 31
• General information 32
• General information 33
• 4 starter 36
• Atter 97 36
• General information 36
• General information 38
• Secondary air supply system routing california type only 38
• Crankcase emission control system 39
• Emission control systems u s a only 39
• General information______________________ ______________________________________________ 39
• Source of emissions 39
• Evaporative emission control system california type only 40
• General information 40
• Noise emission control system 40
• California only 41
• General information 41
• Emission control information 42
• General information 42
• Labels u s a only 42
• Vacuum hose routing diagram label california type only 42
• Vehicle emission control information update label 42
• Frame body exhaust 44
• Rhaivic duut thnelo tanhuoi otoilivi 44
• Service information 44
• Troubleshooting 44
• Frame body panels exhaust system 45
• Removal 45
• Seat fuel tank 45
• Frame body panels exhaust system 46
• Installation 46
• Pillion seat side cover 46
• Removal 46
• Frame body panels exhaust system 47
• Frame body panels exhaust system 48
• Installation 48
• Frame body panels exhaust system 49
• Middle lower cowl 49
• Removal 49
• Special bolts 49
• Frame body panels exhaust system 50
• Installation 50
• Rearview mirror removal 50
• Upper cowl 50
• Frame body panels exhaust system 51
• Upper cowl removal 51
• Frame body panels exhaust system 52
• Frame body panels exhaust system 54
• Upper cowl installation 54
• Frame body panels exhaust system 55
• Rearview mirror installation 55
• Frame body panels exhaust system 56
• Front fender 56
• Installation 56
• Removal 56
• Torque 56
• Frame body panels exhaust system 57
• Rear fender 57
• Removal 57
• Frame body panels exhaust system 58
• Installation 58
• Removal 58
• Seat rail 58
• Frame body panels exhaust system 59
• Installation 59
• Muffler exhaust pipe 59
• Removal 59
• Frame body panels exhaust system 60
• Installation 60
• Frame body panels exhaust system 61
• Maintanance 62
• Maintenance 62
• Service information 62
• Maintenance 63
• Torque values 63
• Maintenance 64
• Maintenance schedule 64
• Fuel line 65
• Maintenance 65
• Throttle operation 65
• Air cleaner 66
• Carburetor choke 66
• Maintenance 66
• Spark plug 66
• Inspection 67
• Maintenance 67
• Replacing a spark plug 67
• Reusing a spark plug 67
• Inspection 68
• Maintenance 68
• Valve clearance 68
• Maintenance 69
• Exhaust vaives 70
• Maintenance 70
• Adjustment 71
• Maintenance 71
• Engine oil oil filter 72
• Maintenance 72
• Oil level inspection 72
• Oil viscosities 72
• Sae 10w40 72
• Sae 20w 50 72
• Engine oil filter change 73
• Maintenance 73
• Carburetor synchronization 74
• Maintenance 74
• Maintenance 75
• Engine idle speed 76
• Maintenance 76
• Radiator coolant 76
• California type only 77
• Cooling system 77
• Maintenance 77
• Secondary air supply system 77
• Drive chain 78
• Drive chain slack inspection 78
• Evaporative emission control 78
• Maintenance 78
• System california type only 78
• Adjustment 79
• Cleaning and lubrication 79
• Maintenance 79
• Maintenance 80
• Replacement 80
• Sprockets inspection 80
• Maintenance 81
• 3 cracked 82
• Brake fluid 82
• Front brake 82
• Maintenance 82
• Rear brake 82
• Brake pad wear 83
• Brake system 83
• Front brake pads 83
• Inspection 83
• Maintenance 83
• Rear brake pads 83
• Brake lever adjustment 84
• Brake light switch 84
• Brake pedal height adjustment 84
• Headlight aim 84
• Maintenance 84
• Clutch system 85
• Maintenance 85
• Front suspension adjustment 86
• Front suspension inspection 86
• Maintenance 86
• Side stand 86
• Suspension 86
• Maintenance 87
• Rear suspension inspection 87
• Maintenance 88
• Nuts bolts fasteners 88
• Rear suspension adjustment 88
• Front rear 89
• Maintenance 89
• Steering head bearings 89
• Wheels tires 89
• Lubrication system 91
• Lubrication system diagram 91
• Bibl tm 92
• Kiuaiiu 92
• Lubrication system 92
• Service information 92
• Lubrication system 93
• Troubleshooting 93
• Lubrication system 94
• Oil pressure inspection 94
• Inspection 95
• Lubrication system 95
• Oil str al n er pressu r e relief valve 95
• Removal 95
• Installation 96
• Lubrication system 96
• Disassembly 97
• Lubrication system 97
• Oil pump 97
• Removal 97
• Inspection 98
• Lubrication system 98
• Service limit 0 5 mm 0 14 in 98
• 3 pump shafi 99
• Assembly 99
• Lubrication system 99
• Installation 100
• Lubrication system 100
• Lubrication system 101
• Oil cooler 101
• Removal 101
• Inspection 102
• Installation 102
• Lubrication system 102
• Lubrication system 103
• Fuel system 106
• Njtlöybltm 106
• Service information 106
• Fuel system 107
• Specifications 107
• Torque values 107
• Fuel system 108
• Troubleshooting 108
• Air cleaner housing 109
• Fuel system 109
• Installation 109
• Removal 109
• Carburetor removal 110
• Fuel system 110
• 1 nuts 111
• Carburetor separation 111
• Fuel system 111
• Air funnel 112
• Carburetor disassembly 112
• Fuel system 112
• Diaphragm vacuum piston 113
• Fuel system 113
• Starting enrichment valve 113
• Caution 114
• Float and jets 114
• Fuel system 114
• 2 valve seat 115
• Fuel system 115
• Carburetor assembly 116
• Fuel system 116
• Fuel system 117
• 2 spring 118
• Diaphragm vacuum piston 118
• Fuel system 118
• Starting enrichment valve 118
• Air funnel 119
• Fuel system 119
• Fuel system 121
• Fuel system 122
• Fuel system 123
• Carburetor installation 124
• Fuel system 124
• Fuel system 125
• Idle drop procedure 125
• Pilot screw adjustment 125
• Fuel system 126
• High altitude adjustment 126
• U s a only 126
• California type only 127
• Fuel system 127
• Secondary air supply system 127
• System inspection 127
• Diaphragm replacement 128
• Fuel auto valve inspection 128
• Fuel system 128
• Fuel valve 128
• Fuel strainer cleaning 129
• Fuel system 129
• Coolant replacement 6 4 132
• Cooling system 132
• General 132
• Service information 132
• Service information 6 1 radiator 6 8 132
• Specifications 132
• System flow pattern 132
• System testing 6 3 radiator reserve tank 6 14 132
• Thermostat 6 5 132
• Torque values 132
• Troubleshooting 6 2 water pump 6 11 132
• Cooling system 133
• Troubleshooting 133
• Coolant hydrometer test 134
• Cooling system 134
• Radiator cap system pressure inspection 134
• System testing 134
• Coolant replacement 135
• Cooling system 135
• Preparation 135
• Replacement air bleeding 135
• Cooling system 136
• Removal 136
• Thermostat 136
• Cooling system 137
• Inspection 137
• Cooling system 138
• Installation 138
• Cooling system 139
• Disassembly 139
• Radiator 139
• Removal 139
• Cooling system 140
• Cooling system 141
• Cooling system 142
• Mechanical seal inspection 142
• Water pump 142
• After 97 143
• Cooling system 143
• Installation 143
• Removal 143
• Cooling system 144
• Cooling system 145
• Installation 145
• Radiator reserve tank 145
• Removal 145
• Engine removal installation 147
• 1 engine installation 148
• Engine removal 148
• Engine removal installation 148
• Engine removauinstallation 148
• General 148
• Service information 148
• Specifications 148
• Torque values 148
• Engine removal 149
• Engine removal installation_______________ 149
• Engine removal installation 150
• Engine removal installation 151
• Engine rem oval installation 152
• Engine installation 153
• Engine removal installation 153
• Engine removal installation 154
• Engine removal installation 155
• Engine removal installation 156
• Engine removal installation 157
• Cylinder head valves 159
• Cam chain tensioner lifter 8 25 160
• Camshaft installation 8 20 160
• Camshaft removal 8 5 160
• Cylinder compression test 8 4 160
• Cylinder head assembly 8 17 160
• Cylinder head cover installation 8 24 160
• Cylinder head cover removal 8 4 160
• Cylinder head disassembly 8 10 160
• Cylinder head inspection 8 11 160
• Cylinder head installation 8 19 160
• Cylinder head removal 8 9 160
• Cylinder head valves 160
• General 160
• Service information 160
• Service information 8 1 160
• Specifications 160
• Troubleshooting 8 3 160
• Valve guide replacement 8 14 160
• Valve seat inspection refacing 8 15 160
• Ö utlilwun nchu vhlvcö 160
• 780 00122ü0 161
• Cylinder head valves 161
• Torque values 161
• Cylinder head valves 162
• Troubleshooting 162
• Cylinder compression test 163
• Cylinder head cover removal 163
• Cylinder head valves 163
• Camshaft removal 164
• Cylinder head valves 164
• Cylinder head valves 165
• Cylinder head valves 166
• Inspection 166
• Cylinder head valves 167
• Service limit 0 0 mm 0 04 in 167
• Cylinder head removal 168
• Cylinder head valves 168
• Cylinder head disassembly 169
• Cylinder head valves 169
• Tool tappet hole protector 169
• Cylinder head 170
• Cylinder head inspection 170
• Cylinder head valves 170
• Cam chain tensioner cam chain guide 171
• Cylinder head valves 171
• Valve lifter 171
• Valve spring 171
• Cylinder head valves 172
• Service limits 172
• Valve lifter bore 172
• Valve valve guide 172
• Caution 173
• Cylinder head valves 173
• Not available in u s a 173
• Valve guide replacement 173
• Cylinder head valves 174
• Valve seat inspecti0n refacing 174
• Valve seat refacing 174
• Cylinder head valves 175
• Cylinder head assembly 176
• Cylinder head valves 176
• Cylinder head valves 177
• Tool tappet hole protector 07hmg mr70002 not available in u s a 177
• Tool valve spring compressor 07757 0010000 177
• Valve spring compressor attachment 07959 km30101 177
• Cylinder head installation 178
• Cylinder head valves 178
• Camshaft installation 179
• Cylinder head valves 179
• Cylinder head valves 180
• Cylinder head valves 181
• Cylinder head valves 182
• Cylinder head cover installation 183
• Cylinder head valves 183
• Torque 10 n m 1 kgfm 7 ihf ft 183
• Cam chain tensioner lifter 184
• Cylinder head valves 184
• Removal 184
• Cylinder head valves 185
• Installation 185
• Cylinder head valves 186
• Clutch gearshift linkage 187
• Clutch gearshift linkage 188
• General 188
• Right crankcase cover installation 9 16 188
• Right crankcase cover removal 9 3 188
• Service information 188
• Service information 9 1 clutch 9 4 188
• Specifications 188
• Torque values 188
• Troubleshooting 9 2 gearshift linkage 9 11 188
• Ulu i un utanbnlf i lin k abt 188
• Clutch gearshift linkage 189
• Troubleshooting 189
• Clutch gearshift linkage 190
• Clutch lifter inspection 190
• Right crankcase cover removal 190
• 2 dus1 seal 191
• Clutch 191
• Clutch gearshift linkage 191
• Removal 191
• Clutch gearshift linkage 192
• 96 97 49 mm 1 3 in 193
• Clutch gearshift linkage 193
• Inspection 193
• Clutch gearshift linkage 194
• Attachment 37 x 40 mm 195
• Clutch gearshift linkage 195
• Clutch outer needle bearing replace ment 195
• Installation 195
• Clutch gearshift linkage 196
• 4 clutch pi atfs 197
• Clutch gearshift linkage 197
• Clutch gearshift linkage 198
• Gearshift linkage 198
• Gearshift linkage removal 198
• Clutch gearshift linkage 199
• Gearshift linkage inspection 199
• Shift drum shift fork removal 199
• Clutch gearshift linkage 200
• Shift drum shift fork inspection 200
• Clutch gearshift linkage 201
• Shift drum shift fork installation 201
• Clutch gearshift linkage 202
• Gearshift linkage installation 202
• Clutch gearshift linkage 203
• Installation 203
• Right crankcase cover 203
• Clutch gearshift linkage 204
• Altern ato k sl ak i tk llui uh 206
• Alternator clutch 206
• Alternator cover removal 10 2 flywheel installation 10 7 206
• General 206
• Service information 206
• Service information 10 1 flywheel removal 10 4 206
• Specifications 206
• Stator 10 3 alternator cover installation 10 8 206
• Torque values 206
• Troubleshooting 206
• Troubleshooting 10 1 starter clutch 10 5 206
• Alternator cover removal 207
• Alternator starter clutch 207
• Alternator starter clutch 208
• Installation 208
• Removal 208
• Stator 208
• Torque 12 n m 1 kgf m 9 ibf ft 208
• 3950000 209
• Alternator starter clutch 209
• Flywheel holder 07725 0040000 209
• Flywheel removal 209
• Alternator starter clutch 210
• Disassembly 210
• Inspection 210
• Starter clutch 210
• 1 one way assembly 211
• Alternator starter clutch 211
• Assembly 211
• Alternator starter clutch 212
• Equivalent commercially 212
• Flywheel installation 212
• Alternator cover installation 213
• Alternator starter clutch 213
• Alternator starter clutch 214
• Crankcase piston cylinder 215
• 1 piston connecting rod 11 4 216
• 2 crankcase combination 11 12 216
• Crankcase piston cylinder 216
• Crankcase separation 216
• General 216
• Service information 216
• Specifications 216
• Troubleshooting 216
• Ukankuaot rlo i un uylinutn 216
• Crankcase piston cylinder 217
• Engine vibration 217
• Torque values 217
• Troubleshooting 217
• Crankcase piston cylinder 218
• Crankcase separation 218
• Caution 219
• Crankcase piston cylinder 219
• Piston connecting rod 219
• Piston connecting rod removal 219
• Piston disassembly 219
• Piston removal 219
• Crankcase piston cylinder 220
• Piston inspection 220
• Service limits 220
• Crankcase piston cylinder 221
• Cylinder inspection 221
• Connecting rod inspection 222
• Crankcase piston cylinder 222
• Crankpin bearing inspection 222
• Crankcase piston cylinder 223
• Crankpin bearing selection 223
• Service limit 0 06 mm 0 02 in 223
• Crankcase piston cylinder 224
• Crankpin bearing selection table 224
• Crankcase piston cylinder 225
• Piston assembly 225
• Piston installation 225
• Caution 226
• Crankcase piston cylinder 226
• Crankcase combination 227
• Crankcase piston cylinder________________ 227
• Cranksh aft transmission 230
• Crankshaft transmission 230
• General 230
• I 19 i 230
• Service information 230
• Service information 12 1 crankshaft 12 3 230
• Specifications 230
• Troubleshooting 12 2 transmission 12 9 230
• Crankshaft transmission 231
• Hard to shift 231
• Torque values 231
• Troubleshooting 231
• Crankshaft 232
• Crankshaft transmission 232
• Removal 232
• Crankshaft transmission 233
• Primary drive sub gear installation 233
• Primary drive sub gear removal 233
• Caution __________________________ 234
• Crankshaft transmission 234
• Starter clutch needle bearing replacement 234
• Tool attachment b collar 07964 mb00200 234
• Crankshaft transmission 235
• Inspection 235
• Crankshaft transmission 236
• Main journal bearing selection 236
• C green 237
• Crankshaft transmission 237
• Installation 237
• Main journal bearing selection table 237
• Crankshaft transmission 238
• Removal disassembly 238
• Transmission 238
• Crankshaft transmission 239
• Measure the i d nt each gear 239
• Measure the ld and o d of each gear hushing 239
• Wear or damage 239
• Crankshaft transmission 240
• Crankshaft transmission 242
• Install the dowel pins on the upper crankcase holes 242
• Installation 242
• Torque 12 n m 1 kgf m 9 ibt ft 242
• Front wheel suspension steering 243
• Front wh eel sus pens 10 n steerin g 244
• Front wheel suspension steering 244
• General 244
• Handlebars 13 3 steering stem 13 23 244
• Service information 244
• Service information 13 1 front wheel 13 8 244
• Specifications 244
• Troubleshooting 13 2 fork 13 14 244
• Front wheel suspension steering 245
• Torque values 245
• Troubleshooting 245
• Unbalanced tire and wheel 245
• Front wheel suspension steering 246
• Handlebars 246
• Removal 246
• Front wheel suspension steering 247
• Front wheel suspension steering 248
• Installation 248
• Front wheel suspension steering 249
• Front wheel suspension steering 250
• Front wheel 251
• Front wheel suspension steering 251
• Removal 251
• Front wheel suspension steering 252
• Inspection 252
• Front wheel suspension steering 253
• Disassembly 254
• Front wheel suspension steering 254
• Front wheel suspension steering 255
• Installation 255
• Torque 20 n m 2 kgf m 14 ibf ft 255
• Front wheel suspension steering 256
• Torque 22 n m 2 kgf m 16 lbf ft 256
• Front wheel suspension steering 257
• Removal 257
• Disassembly 258
• Front wheel suspension steering 258
• Front wheel suspension steering 259
• Fork spring 260
• Front wheel suspension steering 260
• Inspection 260
• Service limit 260
• Wmwwwm 260
• 2 back up ring 261
• Compression adjuster 261
• Front wheel suspension steering 261
• 12 fork damper 262
• Assembly 262
• Front wheel suspension steering 262
• Front wheel suspension steering 263
• Front wheel suspension steering 264
• Ih mwwwm 264
• Front wheel suspension steering 265
• Installation 265
• Removal 266
• Steering stem 266
• Front wheel suspension steering 267
• Attachment 268
• Bearing replacement 268
• Front wheel suspension steering 268
• Front wheel suspension steering 269
• Front wheel suspension steering 270
• U s a only 270
• Front wheel suspension steering 271
• Front wheel suspension steering 272
• Front wheel suspension steering 273
• Installation 273
• Front wheel suspension steering 274
• Torque 25 n m 2 kgf m 18 ibf ft 274
• Front wheel suspension steering 275
• Steering head bearing pre load 275
• General 278
• Rear wheel 14 3 swingarm 14 16 278
• Rear wheel suspension 278
• Rear wnttuduortnblun 278
• Service information 278
• Service information 14 1 shock absorber 14 9 278
• Specifications 278
• Troubleshooting 14 2 suspension linkage 14 14 278
• Rear wheel suspension 279
• Torque values 279
• Troubleshooting 279
• Inspection 280
• Rear wheel 280
• Rear wheel suspension 280
• Removal 280
• Disassembly 281
• Rear wheel suspension 281
• Rear wheel suspension 282
• Assembly 283
• Rear wheel suspension 283
• Rear wheel suspension 284
• Installation 285
• Rear wheel suspension 285
• Disassembly 286
• Rear wheel suspension 286
• Removal 286
• Shock absorber 286
• Inspection 287
• Rear wheel suspension 287
• Rear wheel suspension 288
• Shock absorber disposal procedure 288
• Rear wheel suspension 289
• Installation 290
• Rear wheel suspension 290
• Inspection 291
• Rear wheel suspension 291
• Removal disassembly 291
• Suspension linkage 291
• Installation 292
• Rear wheel suspension 292
• Rear wheel suspension 293
• Removal 293
• Swingarm 293
• Rear wheel suspension 294
• Disassembly inspection 295
• Rear wheel suspension 295
• Rear wheel suspension 296
• 0010000 07746 0010200 07746 0040500 297
• 0010000 07746 0010200 07746 0041100 297
• Driver attachment 37 x 40 mm pilot 20 mm 297
• Driver attachment 37 x 40 mm pilot 28 mm 297
• Rear wheel suspension 297
• Assembly 298
• Cover a 298
• Cover b 298
• Rear wheel suspension 298
• Installation 299
• Rear wheel suspension 299
• Rear wheel suspension 300
• Rear wheel suspension 301
• Hydraulic brake 303
• Air bleeding 15 3 brake pedal 15 29 304
• Brake fluid replacement rear brake caliper 15 26 304
• Brake pad disc 15 5 304
• Front master cylinder 15 10 304
• General 304
• Hydraulic brake 304
• Lb nyunaulil bnakt 304
• Service information 304
• Service information 15 1 rear master cylinder 15 14 304
• Specifications 304
• Troubleshooting 15 2 front brake caliper 15 18 304
• Brake drag 305
• Brake grab or pull to one side 305
• Brake lever pedal hard 305
• Brake lever pedal soft or spongy 305
• Hydraulic brake 305
• Not available in u s a 305
• Torque values 305
• Troubleshooting 305
• Bleeding 306
• Brake fluid draining 306
• Brake fluid filling 306
• Brake fluid replacement air 306
• Hydraulic brake 306
• Brake bleeding 307
• Hydraulic brake 307
• Brake pad disc 308
• Front brake pad replacement 308
• Hydraulic brake 308
• Caution 309
• Hydraulic brake 309
• Torque 2 n m 0 5 kgf m 1 ibf ft 309
• Hydraulic brake 310
• Hydraulic brake 311
• Rear brake pad replacement 311
• Brake disc inspection 312
• Hydraulic brake 312
• Disassembly 313
• Front master cylinder 313
• Hydraulic brake 313
• Removal 313
• Hydraulic brake 314
• Inspection 314
• 11 snap hing 315
• Assembly 315
• Hydraulic brake 315
• Install the boot 315
• Install the snap ring using the special tool 315
• Hydraulic brake 316
• Disassembly 317
• Hydraulic brake 317
• Rear master cylinder 317
• Removal 317
• Hydraulic brake 318
• Inspection 318
• Assembly 319
• Caution 319
• Hydraulic brake 319
• Hydraulic brake 320
• Installation 320
• Caution 321
• Front brake caliper 321
• Hydraulic brake 321
• Removal 321
• Caution __________ 322
• Disassembly 322
• Hydraulic brake 322
• Assembly 323
• Hydraulic brake 323
• Inspection 323
• Hydraulic brake 324
• Installation 324
• Disassembly 325
• Hydraulic brake 325
• Removal 325
• Hydraulic brake 326
• Inspection 326
• 2 piston a 327
• Assembly 327
• Hydraulic brake 327
• Hydraulic brake 328
• Installation 328
• Caution 329
• Disassembly 329
• Hydraulic brake 329
• Rear brake caliper 329
• Removal 329
• Hydraulic brake 330
• Inspection 330
• Assembly 331
• Hydraulic brake 331
• Brake pedal 332
• Hydraulic brake 332
• Installation 332
• Removal 332
• Hydraulic brake 333
• Hydraulic brake 334
• Installation 334
• Hydraulic brake 335
• Step guard 335
• Torque 26 n m 2 kgf m 20 ibt ftl 335
• Battery charging system 337
• System diagram 337
• Battery charging system 338
• I tny uhanülnü öyöieivi 338
• Battery charging system 339
• Specifications 339
• Battery charging system 340
• Troubleshooting 340
• _________________________________________ 340
• Battery charging system 341
• Battery overcharging regulated voltage too high 341
• Battery 342
• Battery charging 342
• Battery charging system 342
• Installation 342
• Removal 342
• Voltage inspection 342
• Battery charging system 343
• Charging system inspection 343
• Regulated voltage inspection 343
• Battery charging system 344
• Current leakage inspection 344
• Alternator charging coil 345
• Battery charging system 345
• Inspection 345
• Regulator rectifier 345
• System inspection 345
• Battery charging system 346
• Removal installation 346
• Ignition system 347
• System diagram 347
• After 97 348
• Ignition system 348
• Caution 349
• General 349
• Ignition system 349
• Ignition system inspection 17 4 ignition timing 17 11 349
• Service information 349
• Service information 17 2 ignition pulse generator 17 7 349
• Specifications 349
• System diagram 17 0 ignition coil 17 6 349
• Torque values 349
• Troubleshooting 17 3 throttle sensor 17 10 349
• Ignition system 350
• No spark at all plugs 350
• Troubleshooting 350
• Ignition coil primary peak voltage 351
• Ignition system 351
• Ignition system inspection 351
• Ignition pulse generator peak voltage 352
• Ignition system 352
• Ignition coil 353
• Ignition system 353
• Removal installation 353
• Ignition pulse generator 354
• Ignition system 354
• Removal 354
• Ignition system 355
• Installation 355
• Ignition system 356
• Ignition system 357
• Inspection 357
• Throttle sensor 357
• 100 100 rpm 358
• California type 1 200 100 rpm 358
• Continuity inspection 358
• Ignition system 358
• Ignition timing 358
• Ignition system 359
• Electric stater 361
• System diagram 361
• Electric starter 362
• Electric stater 362
• Service information 362
• Electric stater 363
• Normal 363
• Troubleshooting 363
• Electric stater 364
• Normal 364
• Disassembly 365
• Electric starter 365
• Removal 365
• Starter motor 365
• Electric starter 366
• Inspection 366
• Electric starter 367
• Assembly 368
• Electric starter 368
• 1 bhush 369
• Electric starter 369
• Electric starter 370
• Installation 370
• Connect the starter relay switch connector 371
• Continuity inspection 371
• Electric starter 371
• Ground line inspection 371
• Operation inspection 371
• Starter relay switch 371
• Voltage inspection 371
• Electric starter 372
• Inspection 372
• Installation 372
• Removal 372
• 11 speed sensor 373
• 2 ignition switch 373
• 3 combination meter 373
• 4 front brake light 373
• 5 fan motor switch 373
• 6 neutral switch 373
• 7 side stand switch 373
• 8 oil pressure switch 373
• After 97 373
• After 97 1 clutch switch 373
• Blnsuh 373
• Brake light switch 373
• Lights meters switches 373
• Sensor 373
• Switch 373
• Ycj ov 373
• Lights meters switches 374
• Service information 374
• Lights meters switches 375
• Specifications 375
• Torque values 375
• Lights meters switches 376
• Speed sensor speedometer 376
• Troubleshooting 376
• Bulb replacement 377
• Headlight 377
• Lights meters switches 377
• Bulb replacement 378
• Lights meters switches 378
• Position light 378
• Removal installation 378
• Bulb replacement 379
• Lights meters switches 379
• Removal installation 379
• Turn signal 379
• Bulb replacement 380
• License light 380
• Lights meters switches 380
• Tail brake light 380
• Combination meter 381
• Lights meters switches 381
• Removal 381
• Bulb replacement 382
• Disassembly 382
• Lights meters switches 382
• Lights meters switches 383
• Assembly 384
• Lights meters switches 384
• Assembly 385
• Indica tor 385
• Lights meters switches 385
• Installation 386
• Lights meters switches 386
• Sensor inspection 386
• Speedometer speed sensor 386
• After 97 387
• Connection black red green black standard repeat 0 to 5 v 387
• Connection pink green green black standard repeat 0 to 5 v 387
• Lights meters switches 387
• Output signal inspection 387
• Lights meters switches 388
• Removal installation 388
• Wire harness inspection 388
• Lights meters switches 389
• Removal installation 389
• Speed sensor 389
• After 97 390
• Connection black yellow and ground 390
• Inspection 390
• Lights meters switches 390
• Peak voltage 10 v minimum 390
• Tachometer 390
• Coolant temperature gauge sensor 391
• Inspection 391
• Lights meters switches 391
• Lights meters switches 392
• Thermo sensor unit inspection 392
• Cooling fan motor switch 393
• Inspection 393
• Lights meters switches 393
• Removal installation 393
• Inspection 394
• Lights meters switches 394
• Oil pressure switch 394
• Ignition switch 395
• Inspection 395
• Lights meters switches 395
• Removal installation 395
• Handlebar switches 396
• Lights meters switches 396
• Brake lightswitch 397
• Clutch switch 397
• Lights meters switches 397
• Neutral switch 397
• Inspection 398
• Installation 398
• Lights meters switches 398
• Removal 398
• Side stand switch 398
• Torque 10 n m 1 0 kgfm 7 ibf ft 398
• Broken ground wire 399
• Inspection 399
• Lights meters switches 399
• Turn signal relay 399
• A о o 400
• Wiring diagram 400
• Z mas 6700 400
• Д b c d 400
• О о о о 400
• О оо 400
• О р ю 400
• After 97 401
• Wiring diagram 401
• Z mas a000 401
• Engine does not start or is hard to start 402
• Engine does not start or is hard to start 21 1 402
• Engine lacks power 21 2 poor handling 21 4 402
• Poor performance at high speed 21 4 402
• Poor performance at low and idle speed 21 3 402
• Trouble shooting 402
• Zl inuubltônuuiinü 402
• Engine lacks power 403
• Possible cause 403
• Troubleshooting______________________________________________________ 403
• Poor performance at low and idle speed 404
• Troubleshooting 404
• Poor handling 405
• Poor performance at high speed 405
• Possible cause 405
• Troubleshooting 405
• Service information 407

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LIGHTS METERS SWITCHES ASSEMBLY 96 97 NOTE ______________ ______________________________ Connect the terminals and install the sockets arc accord ing to the color codes indicated on the lower case Route the sub harness as shown in the illustration