Honda CBR1100XX (1999-2002) [382/559] Front wheel suspension steering

Содержание

• General info 2
• General safety 2
• General safety 1 1 lubrication seal points 1 20 2
• I ucnchml iimtunivim i ivim 2
• Model identification 1 3 emission control systems 1 50 2
• Service rules 1 2 cable harness routing 1 24 2
• Specifications 1 4 emission control information labels 1 54 2
• Tools 1 18 2
• Torque values 1 13 2
• General information 3
• Service rules 3
• Alternator starter clutch 4
• Battery charging system 4
• Clutch gearshift linkage 4
• Cooling system 4
• Crankcase piston cylinder 4
• Crankshaft transmission balancer____________________ front wheel suspension steering 4
• Cylinder head valves 4
• Electric starter 4
• Engine removal installation 4
• Frame body panels exhaust 4
• Fuel system programmed fuel injection 4
• General information 4
• How to use this manual contents 4
• Hydraulic brake 4
• Ignition system 4
• Lights meters switches 4
• Lubrication system 4
• Maintenance 4
• Q z ш z 4
• Rear wheel suspension 4
• System 4
• Technical features 4
• Troubleshooting 4
• Wiring diagram 4
• Сл сл сл 4
• General information 6
• Model identification 6
• General information 7
• Specifications 7
• General information 8
• R general cont d 8
• Fuel system programmed fuel injection 9
• General information 9
• General information 10
• R cooling system 10
• Cl i itch прarqhift 1 1милпр 11
• Crankcasf pistûn cvi imdfr 11
• General information 11
• Crankshaft transmission balancer 12
• General information 12
• Front wheel suspension steering 13
• General information 13
• Rear wheel suspension 13
• Battery charging system 14
• General information 14
• Hydraulic brake 14
• Electric starter 15
• General information 15
• Ignition system 15
• R lights meters switches 15
• Engine 16
• General information 16
• Torque values 16
• Engine cont d 17
• General information 17
• Engine cont d 18
• General information 18
• General information 19
• Frame cont d 20
• General information 20
• General information_________________________________________ 21
• _________ 21
• General information 22
• Engine 23
• General information 23
• Lubrication seal points 23
• Engine cont d 24
• General information 24
• Engine cont d 25
• General information 25
• General information 26
• Cable harness routing 27
• General information 27
• General information 28
• General information 29
• General information 30
• General information 32
• General information 35
• General information 36
• General information 37
• General information 38
• General information 39
• General information 40
• General information 41
• General information 42
• General information 43
• General information 44
• General information 45
• General information 46
• General information 47
• General information 48
• General information 49
• General information 50
• General information 52
• Crankcase emission control system 53
• Emission control systems 53
• General information 53
• Source of emissions 53
• Exhaust emission control system secondary air supply system 54
• General information 54
• Evaporative emission control system california type only 55
• General information 55
• General information 56
• Noise emission control system 56
• Emission control information labels 57
• General information 57
• Vacuum hose routing diagram label california type only 57
• Frame body 59
• Body panel locations 2 0 upper cowl 2 8 60
• Frame body panels exhaust system 60
• General 60
• Lower cowl 2 3 muffler exhaust pipe 2 22 60
• Seat 2 2 rear fender 2 15 60
• Seat cowl 2 2 seat rail 2 20 60
• Service information 60
• Service information 2 1 wind guard ram duct 2 14 60
• Torque values 60
• Troubleshooting 60
• Troubleshooting 2 1 front fender 2 15 60
• Upper cowl cover inner panel 2 5 60
• Frame body panels exhaust system 61
• Installation 61
• Removal 61
• Seat cowl 61
• Frame body panels exhaust system 62
• Installation 62
• Lower cowl 62
• Removal 62
• Frame body panels exhaust system 63
• Frame body panels exhaust system 64
• Installation 64
• Removal 64
• Upper cowl cover inner panel 64
• Frame body panels exhaust system 65
• Frame body panels exhaust system 66
• Installation 66
• Frame body panels exhaust system 67
• Removal 67
• Upper cowl 67
• Frame body panels exhaust system 68
• Frame body panels exhaust system 69
• Frame body panels exhaust system 70
• Installation 70
• Frame body panels exhaust system 71
• Frame body panels exhaust system 72
• Frame body panels exhaust system 73
• Installation 73
• Removal 73
• Wind guard ram duct 73
• Frame body panels exhaust system 74
• Front fender 74
• Rear fender 74
• Removal 74
• Frame body panels exhaust system 75
• Frame body panels exhaust system 76
• Frame body panels exhaust system 77
• Installation 77
• Frame body panels exhaust system 78
• Frame body panels exhaust system 79
• Removal 79
• Seat rail 79
• Frame body panels exhaust system 80
• Installation 80
• Frame body panels exhaust system 81
• Muffler exhaust pipe 81
• Removal 81
• Frame body panels exhaust system 82
• Frame body panels exhaust system 83
• Installation 83
• Frame body panels exhaust system 84
• Frame body panels exhaust system 85
• General 86
• J main i tnanut 86
• Maintanance 86
• Service information 86
• Specifications 86
• Maintenance 87
• Torque values 87
• Maintenance 88
• Maintenance schedule 88
• Maintenance 89
• Fuel line 90
• Maintenance 90
• Throttle operation 90
• Air cleaner 91
• Maintenance 91
• Maintenance 92
• Maintenance 93
• Removal 93
• Sparkplug 93
• Inspection 99 94
• Maintenance 94
• Inspection after 99 95
• Maintenance 95
• Maintenance 96
• Inspection 97
• Maintenance 97
• Valve clearance 97
• Maintenance 98
• Maintenance 99
• Adjustment 100
• Maintenance 100
• Maintenance 101
• Engine oil oil filter 102
• Maintenance 102
• Oil level inspection 102
• Engine oil filter change 103
• Maintenance 103
• Maintenance 104
• Cooling system 105
• Engine idle speed 105
• Maintenance 105
• Radiator coolant 105
• Maintenance 106
• Cooling system 107
• Engine idle speed 107
• Maintenance 107
• Radiator coolant 107
• Maintenance 108
• Secondary air supply system 108
• Adjustment 109
• Drive chain 109
• Drive chain slack inspection 109
• Evaporative emission control system california type only 109
• Maintenance 109
• Cleaning and lubrication 110
• Maintenance 110
• Sprocket inspection 110
• Maintenance 111
• Replacement 111
• Maintenance 112
• Brake fluid 113
• Front brake 113
• Maintenance 113
• Rear brake 113
• Brake pad wear 114
• Brake system 114
• Front brake pads 114
• Inspection 114
• Maintenance 114
• Rear brake pads 114
• Brake lever adjustment 115
• Maintenance 115
• Brake light switch 116
• Brake pedal height adjustment 116
• Headlight aim 116
• Maintenance 116
• Clutch fluid 117
• Clutch lever adjustment 117
• Clutch system 117
• Maintenance 117
• Front suspension inspection 118
• Maintenance 118
• Rear suspension inspection 118
• Side stand 118
• Suspension 118
• Maintenance 119
• Nuts bolts fasteners 119
• Rear suspension adjustment 119
• Maintenance 120
• Steering head bearings 120
• Wheels tires 120
• Lube system 121
• General 122
• Lubrication system diagram 4 0 oil starainer pressure relief valve 4 4 122
• Luonlbm i iui i oto i eivi 122
• Oil cooler 4 13 122
• Oil pressure inspection 4 3 122
• Oil pump 4 8 122
• Service information 122
• Service information 4 1 122
• Specifications 122
• Troubleshooting 4 2 122
• Lubrication system 123
• Torque values 123
• Troubleshooting 123
• Lubrication system 124
• Oil pressure inspection 124
• Lubrication system 125
• Oil strainer pressure relief valve 125
• Removal 125
• Inspection 126
• Installation 126
• Lubrication system 126
• Lubrication system 127
• Lubrication system 128
• Disassembly 129
• Lubrication system 129
• Oil pump 129
• Removal 129
• Inspection 130
• Lubrication system 130
• Assembly 131
• Lubrication system 131
• Lubrication system 132
• Installation 133
• Lubrication system 133
• Lubrication system 134
• Oil cooler 134
• Removal 134
• Inspection 135
• Installation 135
• Lubrication system 135
• Lubrication system 136
• Lubrication system 137
• Fuel system 139
• Fuel system programmed fuel injectioin 139
• B utlbybjtiyh ogramm 140
• General 140
• Service information 140
• Fuel system programmed fuel injection 141
• Specifications 141
• Fuel system programmed fuel injection 142
• Torque values 142
• Troubleshooting 142
• Fuel system programmed fuel injection 143
• System location 99 143
• Fuel system programmed fuel injection 144
• System diagram 99 144
• Fuel system programmed fuel injection 145
• Injecioh 145
• System location after 99 145
• Fuel system programmed fuel injection 146
• System diagram after 99 146
• Fuel system programmed fuel injection 147
• Pgm fi programmed fuel injection system 147
• Self diagnostic procedures 147
• Fuel system programmed fuel injection 148
• Self diagnosis reset proce 148
• Fuel system programmed fuel injection 149
• Peak voltage inspection proce dure 149
• Test harness connection 149
• Fuel system programmed fuel injection 150
• Test pin box terminal layout 150
• Fuel system programmed fuel injection 151
• Pgm fi self diagnosis malfunction indicator failure codes 151
• Fuel system programmed fuel injection 152
• Fuel system programmed fuel injection 153
• Pgm fi malfunction indicator 1 blink map sensor 153
• Fuel system programmed fuel injection 154
• Fuel system programmed fuel injection 155
• Pgm fi malfunction indicator 2 blinks map sensor 155
• Fuel system programmed fuel injection 156
• Fuel system programmed fuel injection 157
• Pgm fi malfunction indicator 7 blinks ect sensor 157
• Fuel system programmed fuel injection 158
• _______ 158
• Fuel system programmed fuel injection 159
• Pgm fi malfunction indicator 8 blinks tp sensor 159
• Fuel system programmed fuel injection 160
• Fuel system programmed fuel injection 161
• Fuel system programmed fuel injection 162
• Fuel system programmed fuel injection 163
• Pgm fi malfunction indicator 9 blinks iat sensor 163
• Fuel system programmed fuel injection 164
• Fuel system programmed fuel injection _______________________________ 165
• Pgm fi malfunction indicator 10 blinks baro sensor 99 only 165
• Fuel system programmed fuel injection 166
• Fuel system programmed fuel injection 167
• Pgm fi malfunction indicator 11 blinks vehicle speed sensor 167
• Fuel system programmed fuel injection 168
• _______ 168
• Fuel system programmed fuel injection 169
• Pgm fi warning indicator 12 blinks no injector 169
• Fuel system programmed fuel injection 170
• 6oôô ô e ûg sog 9ose s 000080000080 s ôsc qoûa ooodßo 171
• Aaoocqqcjo 171
• Fuel system programmed fuel injection 171
• Fuel system programmed fuel injection 172
• Pgm fi malfunction indicator 13 blinks no 2 injector 172
• Fuel system programmed fuel injection 173
• Fuel system programmed fuel injection 174
• No no 2 174
• Fuel system programmed fuel injection 175
• Pgm fi malfunction indicator 14 blinks no 3 injector 175
• Fuel system programmed fuel injection 176
• Fuel system programmed fuel injection 177
• ________i________ 177
• Fuel system programmed fuel injection 178
• Pgm fi malfunction indicator 15 blinks no 4 injector 178
• Fuel system programmed fuel injection 179
• Fuel system programmed fuel injection 180
• Fuel system programmed fuel injection 181
• Pgm fi malfunction indicator 18 blinks cam pulse generator 181
• Fuel system programmed fuel injection 182
• Fuel system programmed fuel injection 184
• Fuel system programmed fuel injection 186
• Fuel system programmed fuel injection 187
• Pgm fi warning indicator 21 blink o2 sensor after 99 california type only 187
• Fuel system programmed fuel injection 188
• Fuel system programmed fuel injection 189
• Pgm fi warning indicator 23 blinks o2 sensor heater after 99 california type only 189
• Fuel system programmed fuel injection 190
• Fuel system programmed fuel injection 191
• Fuel system programmed fuel injection 192
• Fuel system programmed fuel injection 193
• Pgm fi malfunction indicator 25 blinks knock sensor 193
• Fuel line inspection 194
• Fuel pressure inspection 194
• Fuel system programmed fuel injection 194
• Fuel system programmed fuel injection 195
• Fuel flow inspection 196
• Fuel system programmed fuel injection 196
• Fuel pump 197
• Fuel system programmed fuel injection 197
• Inspection 197
• Fuel filter replacement 198
• Fuel system programmed fuel injection 198
• Installation 198
• Removal 198
• Fuel cut off relay 199
• Fuel system programmed fuel injection 199
• Inspection 199
• Fuel system programmed fuel injection 200
• Fuel tank 200
• Removal 200
• Fuel system programmed fuel injection 201
• Fuel system programmed fuel injection 202
• Fuel system programmed fuel injection 203
• Air cleaner housing 204
• Fuel system programmed fuel injection 204
• Removal 204
• Fuel system programmed fuel injection 205
• Installation 205
• Fuel system programmed fuel injection 206
• Fuel system programmed fuel injection 207
• Removal 99 207
• Throttle body 207
• Fuel system programmed fuel injection 208
• Fuel system programmed fuel injection 209
• Removal after 99 209
• Fuel system programmed fuel injection 210
• Fuel system programmed fuel injection 211
• Throttle body vacuum hose routing 99 211
• Fuel system programmed fuel injection 212
• Throttle body vacuum hose routing after 99 212
• Fuel system programmed fuel injection 213
• Installation 99 213
• Fuel system programmed fuel injection 214
• Fuel system programmed fuel injection 215
• Injector 215
• Inspection 215
• Installation after 99 215
• Fuel pipe assembly 216
• Fuel system programmed fuel injection 216
• Removal 216
• Fuel system programmed fuel injection 217
• Installation 217
• Disassembly 218
• Fuel system programmed fuel injection 218
• Install the throttle body page 5 74 218
• No 1 2 starter valve remove the screws and wax unit body mounting screws 218
• No 3 4 starter valve 218
• Record the number of turns 218
• Starter valve 218
• Tighten the mounting screw securely 218
• Turn each starter valve adjusting screw in counting 218
• Fuel system programmed fuel injection 219
• Assembly 220
• Fuel system programmed fuel injection 220
• Fuel system programmed fuel injection 221
• Fuel system programmed fuel injection 222
• Starter valve synchronization 222
• Fuel system programmed fuel injection 223
• Disassembly 224
• Fast idle wax unit 224
• Fuel system programmed fuel injection 224
• Assembly 225
• Fuel system programmed fuel injection 225
• Inspection 225
• Baro map sensors 226
• Baro sensor removal installation 99 only 226
• Fuel system programmed fuel injection 226
• Map sensor removal installa 226
• Output voltage inspection 226
• Cam pulse generator 227
• Ect sensor 227
• Fuel system programmed fuel injection 227
• Iat sensor 227
• Removal installation 227
• Fuel system programmed fuel injection 228
• Fuel system programmed fuel injection 229
• Inspection 229
• No 1 no 2 0 229
• Tp sensor 229
• Bank angle sensor 230
• Fuel system programmed fuel injection 230
• Inspection 230
• Red green i green 230
• White green 230
• Fuel system programmed fuel injection 231
• Removal installation 231
• Ecm engine control module 232
• Engine stop relay 232
• Fuel system programmed fuel injection 232
• Inspection 232
• Knock sensor 232
• Removal installation 232
• System inspection 232
• Fuel system programmed fuel injection 233
• Inspection 233
• No 2 no 1 233
• Pair solenoid valve 233
• Removal installation 233
• Evap purge control solenoid valve california type only 234
• Fuel system programmed fuel injection 234
• Inspection 234
• Removal 234
• Fuel system programmed fuel injection 235
• O2sensor after 99 california type only 235
• Removal 235
• Cooling system 237
• B uuulinu öyö i tivi 238
• Coolant replacement 6 4 238
• General 238
• Service information 238
• Service information 6 1 radiator 6 8 238
• Specifications 238
• System flow pattern 6 0 thermostat 6 5 238
• System testing 6 3 radiator reserve tank 6 16 238
• Torque values 238
• Troubleshooting 6 2 water pump 6 13 238
• Cooling system 239
• Troubleshooting 239
• Coolant hydrometer test 240
• Cooling system 240
• Nr wih 240
• System testing 240
• Coolant replacement 241
• Cooling system 241
• Preparation 241
• Radiator cap system pressure inspection 241
• Cooling system 242
• Replacement air bleeding 242
• Cooling system 243
• Removal 243
• Thermostat 243
• Cooling system 244
• Inspection 244
• Installation 244
• Cooling system 245
• Radiator 245
• Removal 245
• Cooling system 246
• Disassembly 246
• Assembly 247
• Cooling system 247
• Cooling system 248
• Cooling system 249
• Installation 249
• Cooling system 250
• Mechanical seal inspection 250
• Water pump 250
• Cooling system 251
• Removal 251
• Cooling system 252
• Installation 252
• Cooling system 253
• Radiator reserve tank 253
• Removal 253
• Cooling system 254
• Installation 254
• Engine removal installation 255
• 1 engine installation 256
• Engine removal 256
• General 256
• Service information 256
• Specifications 256
• Tnuint ktlviuval iimb i alla i lun 256
• Torque values 256
• Engine removal 257
• Engine removal installation 257
• Engine removal installation 258
• Engine removal installation 259
• Engine removal installation 260
• Engine installation 261
• Engine removal installation 261
• Engine removal installation 262
• Engine removal installation 263
• Engine removal installation 264
• Engine removal installation 265
• Engine removal installation 266
• Cylinder head valves 267
• B uylinutk 268
• Service information 268
• Valves 268
• Cylinder head valves 269
• Specifications 269
• Torque values 269
• Cylinder head valves 270
• Troubleshooting 270
• Cylinder compression test 271
• Cylinder head valves 271
• Cylinder head cover removal 272
• Cylinder head valves 272
• Cylinder head cover disassembly 273
• Cylinder head valves 273
• Packing 273
• Remove bolts and breather separator and gasket 273
• Camshaft removal 274
• Cylinder head valves 274
• Cylinder head valves 275
• Cylinder head valves 276
• Inspection 276
• Cylinder head valves 277
• Cylinder head removal 278
• Cylinder head valves 278
• Crisscross patter 279
• Cylinder head valves 279
• Dowel pins 279
• In 2 3 steps 279
• Loosen the 9 m 279
• Special bolts in a 279
• Cylinder head disassembly 280
• Cylinder head valves 280
• Cam chain tensioner cam chain guide 281
• Cylinder head 281
• Cylinder head inspection 281
• Cylinder head valves 281
• Valve spring 281
• Cylinder head valves 282
• Valve lifter 282
• Valve lifter bore 282
• Valve valve guide 282
• Cylinder head valves 283
• Valve guide replacement 283
• Cylinder head valves 284
• Valve seat inspection refacing 284
• Cylinder head valves 285
• Valve seat refacing 285
• Cylinder head valves 286
• Cylinder head assembly 287
• Cylinder head valves 287
• Cylinder head installation 288
• Cylinder head valves 288
• Cylinder head valves 289
• Camshaft installation 290
• Cylinder head valves 290
• Cylinder head valves 291
• Cylinder head valves 292
• Cylinder head valves 293
• Cylinder head cover assembly 294
• Cylinder head cover installation 294
• Cylinder head valves 294
• Cylinder head valves 295
• Cylinder head valves 296
• Cam chain tensioner lifter 297
• Cylinder head valves 297
• Removal 297
• Cylinder head valves 298
• Installation 298
• Sealing washer 298
• Tensioner lifter 298
• Clutch gearshift linkage 299
• Clutch 9 13 300
• Clutch fluid replacement air bleeding 9 4 gearshift linkage 9 21 300
• Clutch master cylinder 9 6 right crankcase cover installation 9 27 300
• Clutch slave cylinder 9 10 300
• General 300
• Service information 300
• Service information 9 1 right crankcase cover removal 9 12 300
• Specifications 300
• Troubleshooting 9 3 300
• Y glu i bh utakönif 300
• Clutch gearshift linkage 301
• Torque values 301
• Clutch gearshift linkage 302
• Troubleshooting 302
• Clutch fluid draining 303
• Clutch fluid filling air bleeding 303
• Clutch fluid replacement air bleeding 303
• Clutch gearshift linkage 303
• Clutch gearshift linkage 304
• Avoid spilling fluid on painted plastic or rubber parts place a rag over these parts whenever the system is serviced 305
• Caution 305
• Clutch gearshift linkage 305
• Clutch master cylinder 305
• Disassembly 305
• Removal 305
• Clutch gearshift linkage 306
• Inspection 306
• Assembly 307
• Clutch gearshift linkage 307
• Clutch gearshift linkage 308
• Clutch gearshift linkage 309
• Clutch slave cylinder 309
• Disassembly 309
• Removal 309
• Assembly 310
• Clutch gearshift linkage 310
• Inspection 310
• Clutch gearshift linkage 311
• Installation 311
• Right crankcase cover removal 311
• Clutch 312
• Clutch gearshift linkage 312
• Removal 312
• Clutch gearshift linkage 313
• Clutch gearshift linkage 314
• Inspection 314
• Clutch gearshift linkage 315
• Clutch gearshift linkage 316
• Clutch outer needle bearing replacement 316
• Clutch gearshift linkage 317
• I ockwasher 317
• Installation 317
• Clutch gearshift linkage 318
• Clutch gearshift linkage 319
• Clutch gearshift linkage 320
• Gearshift linkage 320
• Gearshift linkage removal 320
• Clutch gearshift linkage 321
• Gearshift linkage inspection 321
• Shift drum shift fork removal 321
• Clutch gearshift linkage 322
• Service limit 11 5 mm 0 70 in 322
• Service limit 12 3 mm 0 74 in 322
• Service limit 5 mm 0 3 in 322
• Shift drum shift fork inspection 322
• Clutch gearshift linkage 323
• L for left 323
• Shift drum shift fork installation 323
• Clutch gearshift linkage 324
• Gearshift linkage installation 324
• Clutch gearshir linkage 325
• Clutch gearshift linkage 326
• Right crankcase cover installation 326
• Alternator starter clutch 327
• Alterna i ur 5 iah i er ulu i uh 328
• Alternator cover removal 10 2 flywheel installation 10 7 328
• General 328
• Service information 328
• Service information 10 1 flywheel removal 10 3 328
• Specifications 328
• Stator 10 2 alternator cover installation 10 8 328
• Torque values 328
• Troubleshooting 328
• Troubleshooting 10 1 starter clutch 10 5 328
• Alternator cover removal 329
• Alternator st arter clutch 329
• Caution 329
• Removal 329
• Stator 329
• The alternator cover stator is magnetically attached to the flywheel be careful during removal 329
• Alternator starter clutch 330
• Flywheel removal 330
• Installation 330
• Torque 330
• Alternator starter clutch 331
• Alternator starter clutch 332
• Disassembly 332
• Inspection 332
• Remove the starter one way clutch assembly 332
• Service limit 332
• Starter clutch 332
• Tool flywheel holder 332
• Alternator starter clutch 334
• Flywheel installation 334
• Tool flywheel holder 334
• Alternator cover installation 335
• Alternator starter clutch 335
• Alternator starter clutch 336
• Caution 336
• Crankcase piston cylinder 337
• Crankcase piston cyunder 337
• Crankcase separation 11 3 338
• General 338
• Service information 338
• Service information 11 1 piston connecting rod 11 4 338
• Specifications 338
• Troubleshooting 11 2 crankcase combination 11 12 338
• Ukankuabt riö i un uylinutk 338
• Crankcase piston cylinder 339
• Torque values 339
• Troubleshooting 339
• Crankcase piston cylinder 340
• Crankcase separation 340
• Dowel pins 340
• Crankcase piston cylinder 341
• Piston connecting rod 341
• Piston connecting rod removal 341
• Piston disassembly 341
• Piston removal 341
• Crankcase piston cylinder 342
• Piston inspcetion 342
• Second 342
• Service limit 342
• Service limits 342
• Crankcase piston cylinder 343
• Cylinder inspection 343
• Service limit 79 0 mm 3 14 in 343
• Connecting rod inspection 344
• Crankcase piston cylinder 344
• Crankpin bearing inspection 344
• Crankcase piston cylinder 345
• Crankpin bearing selection 345
• Service limit 345
• Torque 345
• B green j 346
• Bearing thickness 346
• C yellow thin 346
• Crankcase piston cylinder 346
• Crankpin bearing selection table 346
• Crankcase piston cylinder 347
• Piston assembly 347
• Piston installation 347
• Crankcase piston cylinder 348
• Crankcase combination 349
• Crankcase piston cylinder 349
• Crankcase piston cylinder 350
• Crankshaft tranny balancer 351
• Crankshaft 12 3 352
• General 352
• Service information 352
• Service information 12 1 transmission 12 9 352
• Specifications 352
• Troubleshooting 12 2 balancer 12 14 352
• Z ukankshaft transmission balancer 352
• Crankshaft transmiss10n balancer 353
• Torque values 353
• Troubleshooting 353
• Crankshaft 354
• Crankshaft transmission balancer 354
• Primary drive sub gear removal 354
• Removal 354
• Crankshaft transmission balancer 355
• Primary drive sub gear instal lation 355
• Crankshaft transmission balancer 356
• Starter clutch needle bearing replacement 356
• Crankshaft runout 357
• Crankshaft transmission balancer 357
• Inspection 357
• Main journal bearing 357
• Service limit 357
• Torque 357
• A black thick b brown c green d yellow e pink thin 358
• After selecting new bearings recheck the 358
• Bearing thickness 358
• Caution 358
• Clearance with a plastigauge incorrect clearance can cause severe engine damage 358
• Crankshaft transmission balancer 358
• Main journal bearing selection 358
• Crankshaft transmission balancer 359
• Installation 359
• Countershaft 360
• Crankshaft transmission balancer 360
• Removal disassembly 360
• Service limits 360
• Transmission 360
• Crankshaft transmission balancer 361
• Bearing replacement 362
• Crankshaft transmission balancer 362
• Tools driver 40 mm i d attachment 30 mm 362
• Assembly 363
• Crankshaft transmissiom balancer 363
• Crankshaft transmission balancer 364
• Installation 364
• Balancer 365
• Crankshaft transmission balancer 365
• Front balancer removal 365
• Rear balancer removal 365
• Crankshaft transmission balancer 366
• Crankshaft transmission balancer 367
• Disassembly 367
• Inspection 367
• 17591 0 081 0 283 368
• 18 00 17 91 17 96 u 7085 0 087 07083 0 085 368
• Balancer bearing selection table 368
• Crankshaft transmission balancer 368
• Idle gear 368
• Needle bearings 368
• Or blue 2 or black 368
• Or red 368
• Assembly 369
• Crankshaft transmission balancer 369
• Crankshaft transmission balancer 370
• I zx z 7 370
• Rear balancer installation 370
• Crankshaft transmission balancer 371
• Crankshaft transmission balancer 372
• Backlash adjustment 373
• Crankshaft transmission balancer 373
• Crankshaft transmiss10n balancer 374
• Front wheel suspension steering 375
• General 376
• Handlebars 13 3 steering stem 13 27 376
• Ló rnun i vvnttl bubrtl lölui l ö i ttnllmu 376
• Service information 376
• Service information 13 1 front wheel 13 9 376
• Specifications 376
• Torque values 376
• Troubleshooting 13 2 fork 13 16 376
• Front wheel suspension steering 377
• Troubleshooting 377
• Front wheel suspension steering 378
• Handlebars 378
• Right handlebar removal 378
• Front wheel suspension steering 379
• Left handlebar removal 379
• Switch housing 379
• Front wheel suspension steering 380
• Left handlebar installation 380
• Front wheel suspension steering 381
• Front wheel suspension steering 382
• Install the spacer into the handlebar 382
• Right handlebar installation 382
• Switch groove 382
• Front wheel suspension steering 383
• A contaminated brake disc or pad reduces stopping power discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent 384
• Awarning 384
• Caution 384
• Front wheel 384
• Front wheel suspension steering 384
• Removal 384
• Support the brake caliper with a piece of wire so that it does not hang from the brake hose do not twist the brake hose 384
• Torque 384
• Caution 385
• Front wheel suspension steering 385
• Caution 386
• Front wheel suspension steering 386
• Handling and oyer all safety of the motorcycle always check balance when the tire has been removed from the rim 386
• Ings in pairs 386
• Inspection 386
• Replace the bear 386
• Service limit 386
• Service limits 386
• Wheel balance 386
• Wheel balance directly affects the stability 386
• Wheel rim runout 386
• Disassembly 387
• Front wheel suspension steering 387
• Assembly 388
• Front wheel suspension steering 388
• Front wheel suspension steering 389
• Installation 389
• Check the brake operation by applying the brake lever and pedal 390
• Front wheel suspension steering 390
• Warning 390
• Caution _______________________________________ 391
• From the delay 391
• Front wheel suspension steering 391
• It is not necessary 391
• Keep the brake and clutch master cylinders upright 391
• Removal 391
• To remove the oil bolts and oil pipe 391
• Top pinch bolt 391
• Be careful not to scratch the fork tube or damage the dust seal 392
• Caution 392
• Disassembly 392
• Front wheel suspension steering 392
• Front wheel suspension steering 393
• Caution 394
• Do not scratch the fork tube sliding surface 394
• Front wheel suspension steering 394
• Fork damper 395
• Fork pipc slider damper 395
• Fork spring 395
• Front wheel suspension steering 395
• Inspection 395
• Brake caliper pivot bearings replacement 396
• Front wheel suspension steering 396
• Press out the pivot hearings using the special tool 396
• Tool driver shaft 07946 ka5000o 396
• Assembly 397
• Front wheel suspension steering 397
• Front wheel suspension steering 398
• Fork fluid capacity 399
• Fork oil level 399
• Front wheel suspension steering 399
• Install the spring joint plate 399
• Note _______________________ _____ 399
• Recommended fork fluid 399
• Front wheel suspension steering 400
• Nut to the 400
• Front wheel suspension steering 401
• Installation 401
• Top pinch bolt 401
• Front wheel suspension steering 402
• Removal 402
• Steering stem 402
• Front wheel suspension steering 403
• Always replace the 404
• Bearing remover a 4 bearing remover b 5 assembly base 6 404
• Bearing replacement 404
• Dearings and 404
• Driver attachment nu i a 404
• Driver shaft assembly 3 404
• Except u s a 404
• Front wheel suspension steering 404
• Km9o001 404
• Note the installa 404
• Races as a set 404
• Steering stem 404
• The assembly base 404
• Tion direction of 404
• Tools ball race remover set driver attachment a 1 driver attachment b 2 404
• Front wheel suspension steering 405
• Front wheel suspension steering 406
• Front wheel suspension steering 407
• Fork seal driver weight 408
• Front wheel suspension steering 408
• Installer 408
• Lower inner race 408
• Remove the dust seal 408
• Tool steering stem driver 408
• 76 ibf ft 409
• Front wheel suspension steering 409
• Installation 409
• Torque 409
• Front wheel suspension steering 410
• Front wheel suspension steering 411
• Install the following 411
• Steering head bearing pre load 411
• Rear wheel suspension 413
• General 414
• Ktan wmttl bubmtnblun 414
• Rear wheel 14 3 swingarm 14 12 414
• Service information 414
• Service information 14 1 shock absorber 14 9 414
• Specifications 414
• Suspension linkage 414
• Torque values 414
• Troubleshooting 414
• Rear wheel suspension 415
• Troubleshooting 415
• Inspection 416
• Rear wheel 416
• Rear wheel suspension 416
• Removal 416
• Disassembly 417
• Rear wheel suspension 417
• Driven flange bearing removal 418
• Rear wheel suspension 418
• Assembly 419
• Attachment 52 55 mm 419
• Bearing remover head 20 mm bearing remover shaft 419
• Caution 419
• Never install the old bearings once the bearings has been removed the bearing must be replaced with new ones 419
• Pilot 20 mm 419
• Rear wheel suspension 419
• Wheel bearing installation 419
• Wheel bearing removal 419
• Driven flange bearing installation 420
• Rear wheel suspension 420
• Tools driver attachment 62 x 68 mm pilot 25 mm 420
• Installation 421
• Rear wheel suspension 421
• Damper r 422
• Inspection 422
• Rear wheel suspension 422
• Removal 422
• Shock absorber 422
• Always wear eye protection to avoid getting 423
• Build up of excessive heat and pressure inside the damper leading to explosion and severe 423
• Do not use a dull drill bit which could cause a 423
• Installation 423
• Metal shavings in your eyes when the gas pressure is released the plastic bag is only intended to shield you from the escaping gas 423
• Oil under high pressure do not drill any farther down the damper case than the measurement given above or you may drill into the oil chamber oil escaping under high pressure may cause serious personal injury 423
• Personal injury 423
• Rear wheel suspension 423
• Shock absorber disposal procedure 423
• The shock absorber contains nitrogen gas and 423
• Warning 423
• Attachment 24 424
• Inspection 424
• Rear wheel suspension 424
• Removal disassembly 424
• Shock link needle bearing replacement 424
• Suspension linkage 424
• Tool pin driver 424
• Tools driver 424
• Installation 425
• Rear wheel suspension 425
• Removal 425
• Swingarm 425
• Rear wheel suspension 426
• Disassembly inspection 427
• Rear wheel suspension 427
• Driver shaft 428
• Pivot bearing replacement 428
• Rear wheel suspension 428
• Remover handle 428
• Remover set sliding weight 428
• Tools bearing remover set 428
• Tools needle bearing remover 428
• Rear wheel suspension 429
• Tools driver attachment 37 x 40 mm pilot 20 mm 429
• Tools driver attachment 37 x 40 mm pilot 28 mm 429
• Assembly 430
• Rear wheel suspension 430
• Rear wheel suspension 431
• Adjusting bolt 432
• Ble to install the 432
• Does protrude it will not be possi 432
• If the end of the 432
• Install the swingarm adjusting bolt 432
• Install the swingarm and pivot bolt 432
• Installation 432
• Rear wheel suspension 432
• Screw the adjusting nut hy turning the pivot holt 432
• Swingarm 432
• Rear wheel suspension 433
• Hydraulic brake 435
• Hydraulic brakes 435
• Hydraulic brake 436
• General 437
• Hydraulic brake 437
• Service information 437
• Specifications 437
• Hydraulic brake 438
• Torque values 438
• Hydraulic brake 439
• Troubleshooting 439
• Avoid spilling fluid on painted plastic or rubber 440
• Brake fluid draining 440
• Brake fluid replacement air bleeding 440
• Caution 440
• Contaminated brake disc or pad reduces 440
• Do not allow foreign material to enter the 440
• Hydraulic brake 440
• Lever brake line 440
• Parts place a rag over these parts whenever the system is serviced 440
• Stopping power discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent 440
• System when filling the reservoir 440
• Warning 440
• Hydraulic brake 441
• Pedal brake line 441
• Brake fluid filling air bleeding 442
• Caution 442
• Hydraulic brake 442
• Hydraulic brake 443
• Hydraulic brake 444
• Lett front caliper center bleed valve 444
• Torque 1 n m 0 5 kgf m 1 lbf ft 444
• Hydraulic brake 445
• Hydraulic brake 446
• Brake pad disc 447
• Front brake pad replacement 447
• Hydraulic brake 447
• Note ____________________________ 447
• Hydraulic brake 448
• Hydraulic brake 449
• Rear brake pad replacement 449
• Brake disc inspection 450
• Hydraulic brake 450
• Disassembly 451
• Front master cylinder 451
• Hydraulic brake 451
• Removal 451
• Hydraulic brake 452
• Inspection 452
• Assembly 453
• Caution 453
• Hydraulic brake 453
• Hydraulic brake 454
• Caution 455
• Hydraulic brake 455
• Removal 455
• Secondary master cylinder 455
• Hydraulic brake 456
• Inspection 456
• Assembly 457
• Hydraulic brake 457
• Hydraulic brake 458
• Rear master cylinder 458
• Removal 458
• Disassembly 459
• Hydraulic brake 459
• Hydraulic brake 460
• Inspection 460
• Hydraulic brake 461
• Installation 461
• Hydraulic brake 462
• Delay valve 463
• Hydraulic brake 463
• Proportional control valve 463
• Removal 463
• Removal installation 463
• Avoid spilling fluid on painted plastic or rubber parts place a rag over these parts whenever the system is serviced 464
• Caution 464
• Front brake caliper 464
• Hydraulic brake 464
• Installation 464
• Left caliper removal 464
• Torque 464
• Disassembly 465
• Hydraulic brake 465
• Right caliper removal 465
• Awarning 466
• Be careful not to damage the piston sliding surface 466
• Caution 466
• Do not use high pressure air or bring the nozzle too close to the inlet 466
• Hydraulic brake 466
• Inspection 466
• Lower 25 60 mm 1 024 in 466
• Mark the pistons to ensure correct 466
• Piston seai dust sfai 466
• Reassembly 466
• Hydraulic brake 467
• Hydraulic brake 468
• Hydraulic brake 469
• Left caliper installation 469
• Right caliper installation 469
• Caution 470
• Disassembly 470
• Hydraulic brake 470
• Rear brake caliper 470
• Removal 470
• Awarning 471
• Be careful not to damage the piston sliding surface 471
• Caution 471
• Do not use high pressure air or bring the nozzle too close to the inlet 471
• Hydraulic brake 471
• Inspection 471
• Mark the pistons to ensure correct 471
• Reassembly 471
• Assembly 472
• Hydraulic brake 472
• Hydraulic brake 473
• Installation 473
• Note the installa 473
• Tion direction of the pad spring 473
• Brake pedal 474
• Hydraulic brake 474
• Removal 474
• Installation 475
• Hydraulic brake 476
• Battery charging system 477
• Battery 16 6 478
• Service information 16 2 alternator charging coil 16 10 478
• System diagram 16 0 charging system inspection 16 8 478
• Troubleshooting 16 4 regulator rectifier 16 10 478
• Battery charging system 479
• General 479
• Service information 479
• Battery charging system 480
• Specifications 480
• Battery charging system 481
• Troubleshooting 481
• Battery charging system 482
• Ai ways turn the ignition switch tn 483
• Always clear the work area of flammable materials such as gasoline brake fluid electrolyte or cloth towels when operating the tester the heat 483
• Awarning 483
• Battery 483
• Battery charging system 483
• Battery testing 483
• Bm 210 ah or bm 210 u s a only 483
• Generated by the tester may cause a fire 483
• Off before removing the 483
• Removal installation 483
• Tool digital multimeter 483
• Voltage 483
• Voltage inspection 483
• Battery charging 484
• Battery charging system 484
• Battery charging system_________________________________________________ _______ 485
• Charging system inspection 485
• Charging voltage inspection 485
• Note ____________ ___________ 485
• Battery charging system 486
• Current leakage inspection 486
• Alternator charging coil 487
• Battery charging system 487
• Inspection 487
• Regulator rectifier 487
• System inspection 487
• Battery charging system 488
• Removal installation 488
• Ignition 489
• Ignition pulse genertor 489
• Ignition system 489
• System diagram 489
• To tachometer 489
• Caution 490
• General 490
• Ignition system 490
• Ignition system inspection 17 4 490
• Service information 490
• Service information 17 1 ignition pulse generator 17 7 490
• Specifications 490
• System diagram 17 0 ignitioncoil 17 6 490
• Troubleshooting 17 3 ignition timing 17 10 490
• Warning 490
• Ignition system 491
• Torque values 491
• Ignition system 492
• Troubleshooting 492
• Ignition coil primary peak volt age 493
• Ignition system 493
• Ignition system inspection 493
• Ignition pulse generator peak voltage 494
• Ignition system 494
• Note ____________________________ 494
• Ignition coil 495
• Ignition system 495
• Removal installation 495
• Ignition pulse generator 496
• Ignition system 496
• Removal 496
• Ignition system 497
• Installation 497
• Ignition system 498
• A warning 499
• Ide gas that may cause loss of consciousness and may lead to death 499
• Idle speed 499
• If the engine must be running to do some work 499
• Ignition system 499
• Ignition timing 499
• Instructions tor 499
• Make sure the area is well ventilated never run the engine in an enclosed area 499
• Operation 499
• Read th 499
• The exhaust contains poisonous carbon monox 499
• Timing light 499
• Ignition system 500
• Electric starter 501
• System diagram 501
• Electric starter 502
• General 502
• Service information 502
• Specification 502
• Starter relay switch 502
• Electric starter 503
• Troubleshooting 503
• Electric starter 504
• Caution 505
• Disassembly 505
• Electric starter 505
• Removal 505
• Remove the following 505
• Starter motor 505
• Warning 505
• Electric starter 506
• Inspection 506
• Electric starter 507
• Electric starter 508
• Electric starter 509
• Caution 510
• Electric starter 510
• Installation 510
• Electric starter 511
• Ground line inspection 511
• Operation inspection 511
• Starter relay switch 511
• Continuity inspection 512
• Electric starter 512
• Inspection 512
• Installation 512
• Removal 512
• Voltage inspection 512
• Lights meters switches 513
• General 514
• Liu hl i o iviu i uho ovvi i unco 514
• Service information 514
• Lights meters switches 515
• Torque values 515
• Lights meters switches 516
• Normal 516
• Speed sensor speedometer 516
• The speedometer operates normally but the odometer trip meter does not operate 516
• The speedometer operation is abnormal 516
• Troubleshooting 516
• Lights meters switches 517
• Thermo sensor digital coolant gauge 517
• Lights meters switches 518
• Bulb replacement 519
• Headlight 519
• Lights meters switches 519
• Bulb replacement 520
• Lights meters switches 520
• Removal installation 520
• Turn signal 520
• Lights meters switches 521
• Lights meters switches 522
• Removal installauon 522
• Bulb replacement 523
• License light 523
• Lights meters switches 523
• Tail brake light 523
• Bulb replacement 524
• Combination meter 99 524
• Lights meters switches 524
• Removal 524
• Removal installation 524
• Disassembly 525
• Lights meters switches 525
• Assembly 526
• Combination meter after 99 526
• Installation 526
• Lights meters switches 526
• Removal 526
• Disassembly assembly 527
• Installation 527
• Lights meters switches 527
• Lights meters switches 528
• Output signal inspection 991 528
• Speedometer vehicle speed sensor 528
• Voltage inspection 99 528
• Lights meters switches 529
• Voltage inspection after 99 529
• Lights meters switches 530
• Output signal inspection after 99 530
• Removal installation 530
• Inspection 99 531
• Lights meters switches 531
• Tachometer 531
• Inspection after 99 532
• Lights meters switches 532
• Caution 533
• Coolant temperature gauge sensor 99 533
• Immediately disconnect the sensor wire connector from the ground when the needle moves to h hot to prevent damage to the gauge ect thermo sensor connector 533
• Inspection 533
• Lights meters switches 533
• A warning 534
• Always replace the 534
• Ect thermo sensor 534
• Electric heating element 534
• Keep flammable materials away from the 534
• Lights meters switches 534
• Note ____________________________ 534
• Protection 534
• Sealing washer with a new one 534
• Thermo sensor unit inspection 534
• Wear insulated gloves and adequate eye 534
• Coolant temperature sensor after 99 535
• Inspection 535
• Lights meters switches 535
• Cooling fan motor switch 99 536
• Inspection 536
• Lights meters switches 536
• Removal installation 536
• Connection black green 537
• Cooling fan motor inspection after 99 537
• Cooling fan relay 537
• Cooling fan relay inspection 537
• Ground inspection 537
• Lights meters switches 537
• P connector 537
• Unit inspection 537
• Voltage inspection 537
• Connection black green 538
• Continuity inspection 538
• Cooling fan motor system inspection 538
• Fan motor does not start 538
• Fan motor does not stop 538
• Lights meters switches 538
• Cooling fan inspection 539
• Inspection 539
• Lights meters switches 539
• Oil pressure switch 539
• Oli pressure warning indicator 539
• Fuel level sensor reserve sensor 540
• Lights meters switches 540
• Removal 540
• Fuel meter inspection 99 541
• Fuel reserve sensor inspection 99 541
• Fuel sensor inspection 99 541
• Lights meters switches 541
• Digital fuel meter inspection 542
• Fuel level sensor inspection after 99 542
• Installation 542
• Lights meters switches 542
• Ignition switch 543
• Inspection 543
• Lights meters switches 543
• Removal installation 543
• Handlebar switches 544
• Lights meters switches 544
• Brake light switch 545
• Clutch switch 545
• Lights meters switches 545
• Neutral switch 545
• Inspection 546
• Installation 546
• Lights meters switches 546
• Removal 546
• Side stand switch 546
• Inspection 547
• Lights meters switches 547
• Turn signal relay 547
• Lights meters switches 548
• Siaivh9viq dnihim 02 550
• Wiring diagrams 550
• 12v4cp 551
• B10a c10a d10a e10a 551
• Headligh 551
• I á i 551
• O w co o w 551
• V1 wx2 551
• V32 3cp 551
• V32 3cpx2 551
• Z mat l200 only 551
• Automatic first idle system 552
• Automatic first idle system 21 1 knock sensor 21 2 552
• Technical features 552
• Zi i tunlmiual rta i unto 552
• Knock sensor 553
• Technical features 553
• Engine does not start or is hard to start 554
• Engine does not start or is hard to start 22 1 554
• Engine lacks power 22 2 poor handling 22 4 554
• I ci i iwvc ai 554
• I kuudltdnuu i inb 554
• Ii lopcul opai piuy 554
• Poor performance at high speed 22 4 554
• Poor performance at low and idle speed 22 3 554
• Trouble shooting 554
• Engine lacks power 555
• Troubleshooting 555
• Poor performance at low and idle speed 556
• Troubleshooting 556
• Abnormal 557
• Bent fork 557
• Check valve spring 557
• Faulty ecm 557
• Poor handling 557
• Poor performance at high speed 557
• Possible cause 557
• See sections 557
• Troubleshooting 557
• 0 inula 558

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FRONT WHEEL SUSPENSION STE Install the spacer into the handlebar switch groove Install the left handlebar switch aligning its locating pin with the hole in the handlebar Tighten the forward screw first then the rear screw Install the clutch master cylinder assembly by aligning the end of the punch mark on the handlebar master cylinder with the Install the clutch UP mark facing up cylinder holder with the master Tighten the upper bolt first then the lowei boll TORQUE 12 N m 1 2 kgf m 9 Ibf ft Connect the clutch switch wires RIGHT HANDLEBAR INSTALLATION Install the right handlebar onto the fork aligning its boss with the groove of the top bridge Make sure the handlebar is sealed bridge on pipe the while top