Honda SH150i Service Manual - 62KTF00
Honda SH150i Service Manual - 62KTF00
Honda SH150i Service Manual - 62KTF00
62KTF00
Find the section you want on this page, then turn to the table of contents
on the first page of the section.
~~
Your safety, and the safety of others, is very important. To help you
make informed decisions we have provided safety messages and
other information throughout this manual. Of course, it is not
practical or possible to warn you about all the hazards associated
with servicing this vehicle.
You must use your own good judgement.
You will find important safely information in a variety of forms
including:
Safety Labels - o n the vehicle
Safety Messages - preceded by a safety alert symbol ,.f: and
one of three signal words, DANGER, WARNING, or CAUTION.
These signal words mean:
You WILL be KILLED or SERIOUSLY
HURT if you don't follow instructions.
As you read this manual, you will find information that is preceded by a
symbol. The purpose of this message IS to help prevent
damage to your vehicle, other property, or the environment.
recommended that you do not attempt to perform the procedures described Failure to properly follow instructions and
in this manual. precautions can cause you to be seriously hurt
or killed.
Some of the most important general service safety precautions are given
below. However, we cannot warn you of every conceivable hazard that can Follow the procedures and precautions in this
arise in performing service and repair procedures. Only you can decide manual carefully.
whether or not you should perform a given task.
Important Safety Precautions
Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and
using safety equipment. When performingany service task, be especially careful of the following:
Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills
required to perform the tasks safely and completely.
Protect your eyes by using proper safety glasses, goggles or face shields any time you hammer, drill, grind, pry or work around
pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye protection.
Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe
burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.
Protect yourself and others whenever you have the vehicle up in the air. Any time you lift the vehicle, either with a hoist or a jack,
make sure that it is always securely supported. Use jack stands.
Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise.
This will help eliminate several potential hazards:
Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine.
Burns from hot parts or coolant. Let the engine and exhaust system cool before working in those areas.
Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way.
Gasoline vapors and hydrogen gases from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when
working around gasoline or batteries.
Keep all cigarettes, sparks and flames away from the battery and all fuel-related parts.
SYMBOLS
The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to
these symbols, it would be explained specifically in the text without the use of the symbols.
Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1 : 1).
Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGl #2 or
equivalent).
Example: Molykotes BR-2 plus manufactured by Dow Corning U S A .
Multi-purpose M-2 manufactured by Mitsubishi Oil, Japan
Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGl #2 or
equivalent).
Example: Molykotes G-n Paste manufactured by Dow Corning U.S.A.
Honda Moly 60 (U.S.A. only)
Rocol ASP manufactured by Rocol Limited, U.K.
Rocol Paste manufactured by Sumico Lubricant, Japan
Apply a locking agent. Use a middle strength locking agent unless otherwise specified.
Apply sealant.
Use DOT 3 or DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified.
SH125
E U.K.
F France
I1 E U.K.: Type II
II F France: Type II
I CODE 1 AREATYPE
REAR WHEEL/SUSPENSION
GENERAL SPECIFICATIONS......................... 1-4 SPECIFICATIONS............................................ 1-9
FINAL REDUCTION SPECIFICATIONS ......... 1-8 LUBRICATION & SEAL POINTS ..................1-15
MODEL IDENTlFlCATlON
The registered number plate is attached on the left side of the frame
near the rear shock absorber. The Vehicle Identification Number (VIN)
is stamped on the registered number plate.
1-2
GENERAL INFORMATION
The Vehicle Identification Number (VIN) is stamped on the right side of
the frame near the rear shock absorber.
The engine serial number IS stamped on the crankcase near the rear
. - ... I
wheel.
The throttle body identification number are stamped on the lower side
of the throttle body.
The color label is attached on the luggage box. When ordering color-
coded parts, always specify the designated color code.
1-3
GENERAL INFORMATION
GENERAL SPECIFICATIONS
SH125
SPECIFICATION
DIMENSIONS Overall length 2,020 mm (79.5 in)
Overall w i d th 700 mm (27.6 in)
Overall height 1,140 mm (44.9 in)
Wheel base 1,335 mm (52.6 in)
Seat height 790 mm (31.1 in)
Ground clearance 140 mm (5.5 in)
Curb weight 134 kg (295 Ibs)
Ma x i mu m weight capacity 180 kg (397 Ibs)
FRAME Frame type Unde r-b o n e
Front suspension Telescopic fork
Front axle travel 89 mm (3.5 in)
Rear suspension Power unit swing (swingarm)
Rear axle travel 83 mm (3.3 in)
Front tire size 100/80-16M/C 50P
Rear tire size 120/80-16M/C 60P
Tire brand (Front/Rear) D451 (Dunlop)
Front brake Hydraulic single disc
Rear brake Mechanical d r u m (Leading-trailing)
Caster angle 27" 0 0
Trail length 85 mm (3.3 in)
Fuel tank capacity Z5 liters (1.98 US gal, 1.65 Imp gal)
ENGINE Cylinder arrangement Single cylinder inclined 80" from vertical
Bore and stroke 52.4 x 57.8 mm (2.06 x 2.28 in)
Displacement 124.6 cm3 (7.60 cu-in)
Compression ratio 11 : 1
Va Ive train Chain driven OHC with rocker arms
Intake valve opens 10" BTDC (at 1 mm lift)
closes 30" ABDC (at 1 mm lift)
Exhaust valve opens 35" BBDC (at 1 mm lift)
closes 5" ATDC (at 1 mm lift)
Lubrication system Forced pressure and wet sump
Oil p u mp type Trochoid
Cooling system Liquid cooled
Air filtration Viscous paper element
Engine dry weight 31.0 kg (68.3 Ibs)
FUEL DELIV- Tvpe PGM-FI (Programmed Fuel Injection)
ERY SYSTEM Throttle bore 26 mm (1.0 in)
DRIVE TRAIN Clutch system Automatic centrifugal clutch, dry
Gear ratio 2.64 - 0.82
Final reduction 11.423 (47/12 x 35/12)
ELECTRICAL Ignition system Full transistorized ignition
Starting system Electric starter motor
Charging system Triple phase output alternator
Regulatodrectifier SCR shorted, triple phase full-wave rectification
Lighting system Battery
GENERAL INFORMATION
SH150
ITEM. SPECIFICATION
DIMENSIONS Overall length 2,020 mm (79.5 in)
Overall width 700 mm (27.6 in)
Overall height 1,140 mm (44.9 in)
Wheel base 1,335 mm (52.6 in)
Seat height 790 mm (31.1 in)
Ground clearance 140 mm (5.5 in)
Curb weight 134 kg (295 lbs)
Maximum weight capacity 180 kg (397 Ibs)
FRAME Frame type U nder-bone
Front suspension Telescopic fork
Front axle travel 89 mm (3.5 in)
Rear suspension Power unit swing (swingarm)
Rear axle travel 83 mm (3.3 in)
Front tire size 100/80-16M/C 50P
Rear tire size 120/80-16M/C 60P
Tire brand (Front/Rear) D451 (Dunlop)
Front brake Hydraulic single disc
Rear brake Mechanical drum (Leading-trailing)
Caster angle 27" 00'
Trail length 85 mrn (3.3 in)
Fuel tank capacity 7.5 liters (1.98 US gal, 1.65 Imp gal)
Cylinder arrangement Single cylinder inclined 80" from vertical
Bore and stroke 58.0 x 57.8 mm (2.28 x 2.28 in)
Displacement 152.7 cm3 (9.31 cu-in)
Compression ratio 11 : 1
Valve t ra in Chain driven OHC with rocker arms
Intake valve opens 10" BTDC (at 1 mm lift)
closes 30" ABDC (at 1 mm lift)
Exhaust valve opens 35" BBDC (at 1 mm lift)
closes 5" ATDC (at 1 mm lift)
Lubrication system Forced pressure and wet sump
Oil pump type Trochoid
Cooling system Liquid cooled
Air filtration Viscous paper element
Engine dry weight 31.0 kg (68.3 Ibs)
FUEL DELIV- Type PGM-FI (Programmed Fuel Iniection)
ERY SYSTEM Throttle bore 26 mm (1.0 in)
DRIVE TRAIN Clutch system Automatic centrifugal clutch, dry
Gear ratio 2.64 - 0.82
Final reduction 10.544 (47113 x 35/12)
ELECTRICAL Ignition system Full transistorized ignition
Starting system Electric starter motor
Charging system Triple phase output alternator
Regulatorhectifier SCR shorted, triple phase full-wave rectification
Lighting system Batterv
1-5
LUBRICATION SYSTEM SPECIFICATIONS
ITEM STANDARD SERVICE LIMIT
Engine oil capacity After draining 0.9 liter (1.0 US qt, 0.8 I m p qt) -
After disassembly 1.0 liter (1.1 US qt, 0.9 Imp qt) -
Recommended engine oil Honda 4-stroke oil or equivalent motor -
oil
API service classification SE, SF or SG
Viscosity: SAE IOW-30
Oil p u m p rotor Tip clearance 0.15 (0.006) 0.20 (0.008)
Body clearance 0.15 - 0.20 (0.006 - 0.008) 0.25 (0.010)
Side clearance 0.04 - 0.09 (0.002 - 0.004) 0.12 (0.005)
r
Camshaft Cam lobe height IN 29.7377 - 29.8177 (1.17077 -'1.17392) 29.637 (1.1668)
EX 29.4953 - 29.5753 (1.16123- 1.16438) 29.395 (1.1573)
Rocker ar m A r m I.D. IN/EX 10.000 - 10.015 (0.3937 - 0.3943) 10.05 (0.396)
Shaft O.D.
-~ INlEX 9.972 - 9.987 (0.3926 - 0.3932) 9.937 (0.3912)
Arm-to-shaft clear- IN/EX 0.013 - 0.043 (0.0005 - 0.0017) 0.063 (0.0025)
ance
Valve clearance IN +
0.16 0.02 (0.006 f 0.0011 -
valve guide EX 0.25 k 0.02 (0.010 f 0.001) -
Valve stem O.D. IN 4.975 - 4.990 (0.1959 - 0.1965) 4.90 (0.193)
EX 4.955 - 4.970 (0.1951 - 0.1957) 4.90 (0.193)
Valve auide
" I.D. IN/EX 5.000 - 5.012 (0.1969 - 0.1973) 5.03 (0.198) J
Stem-to-guide clear- IN 0.010 - 0.037 (0.0004 - 0.001 5) 0.08 (0.003)
ance EX 0.030 - 0.057 (0.0012 - 0.0022) 0.10 (0.004)
Valve guide projection IN/EX 11.35 - 11.65 (0.447 - 0.459) -
above cvlinder head I
Valve seat width I IN/EX I 0.90 - 1.10 (0.035 - 0.043) I 1.8 (0.07)
lenoth I IN/EX 1 36.2 (1.43) I 34.4 (1.35)
roaae I - I 0.05 (0.002) I
1-6
GENERAL INFORMATION
CYLINDER/PISTON SPECIFICATIONS
Connecting rod-to-piston pin clearance j 0.016 - 0.040 (0.0006 - 0.0016) . 0.06 (0.002)
1-7
GENERAL INFORMATION
DRIVE AND DRIVEN PULLEYSKLUTCH SPECIFICATIONS
CRANKCASEKRANKSHAFT SPECIFICATIONS
ITEM STANDARD SERVICE LIMIT
Crankshaft runout - 0.10 (0.004)
Connecting rod big end side clearance 0.10 - 0.35 (0.004 - 0.014) 0.60 (0.024)
Connecting rod bicl end radial clearance 0 - 0.008 (0 - 0.0003) 0.05 (0.002)
1-8
GENERAL INFORMATION
FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS
ITEM STANDARD SERVICE LIMIT
Minimum tire tread depth - 1.5 (0.06)
Cold tire Driver only 175 kPa (1.75 kgf/cm2, 25 psi) -
pressure Driver and Dassenaer 175 kPa (1.75 kaf/cm2. 25 mi) -
Axle runout - 0.2 (0.01)
Wheel rim Radial - 2.0 (0.08)
runout Axial - 2.0 (0.08)
Wheel balance weight - 70 g (2.502)
max.
:
Fork
Tube runout
257.2 (10.13)
-
__________
252 (9.9)
0.2 (o.oi )
Recommended fork fluid Honda Ultra Cushion Oil 1OW -
or equivalent
Fluid level 106 (4.2) -
Fluid capacity * *
100 1 cm3(3.4 0.03 US 02,3.5 k 0.04 -
Imt, 0 2 )
1 Front brake
Brake disc thickness
Brake disc runout
Master cylinder I.D.
Master piston O.D.
-
~~
t-Rear brake
Caliper cylinder I.D.
Caliper piston O.D.
Brake lever free play
Brake drum I.D.
27.000 - 27.050 (1.0630 - 1.0650)
26.918 - 26.968 (1.0598 - 1.0617)
-
10 20 (2/5 - 3/4)
130 (5.1)
27.06 (1.065)
26.91 (1.059)
-
131 (5.2)
ITEM SPECIFICATION
Battery Capacity 12V-6Ah
Current leakage 0.2 mA max.
Vo Itage Fully charged 13.0 - 13.2 V
(20C/68"F) Needs charging Below 12.3 V
Charging cur- Normal 0.6 N 5 - 10 h
rent Quick 3.0 N1.0 h
Alternator Capacity ~
300 W/5,000 min-' (rpm)
Charging coil resistance (20C/68"F) 0.1 - 0.5 L2
1-9
GENERAL INFORMATION
IGNITION SYSTEM SPECIFICATIONS
ITEM SPECIFICATIONS
Spark plug Standard CR8EH-9 (NGK), U24FER9 (DENSO)
For extended high speed riding CR9EH-9 (NGK), U27FER9 (DENSO)
Spark plug gap 0.8 - 0.9 mm (0.031 - 0.035 in)
Ignition coil primary peak voltage 100 V minimum
Crankshaft position (CKP) sensor peak voltage 0.7 V minimum
Ignition timing ("F"mark) 10" BTDC a t idle
ITEM SPECIFICATIONS
Bulb Headlight (highllow beam) 12 V - 60155 W
Brakehaillight 12 V - 211
5' W
License light 12V-5W
Turn signal light 12v-21w x 4
Position light 12v-5 w x 2
Instrument light 12 V - 1.7 W x 3
High beam indicator 12 V - 1.7 W
Turn sianal
" indicator 12 v - 1.7 w x 2
PGM-FI malfunction indicator LED
Engine oil maintenance indicator LED
Fuse Main fuse 30 A
Su b-fuse 15Ax1.10Ax4
1-10
GENERAL INFORMATION
STANDARD TORQUE VALUES
TORQUE TORQUE
FASTENER TYPE FASTENER TYPE
N - m (kgf.m, Ibf-ft N-m (kgf-m, Ibf-ft)
5 m m bolt and nut 5 (0.5, 3.7) 5 m m screw 4 (0.4, 3.0)
6 m m bolt and nut 10 (1.0,7) 6 m m screw 9 (0.9, 6.6)
8 mm bolt and nut 22 (2.2, 16) 6 m m flange bolt (8 m m head; small flange) 10 (1.0, 7)
10 mm bolt and nut 34 (3.5, 25) 6 m m flange bolt (8 m m head; large flange) 12 (1.2,9)
12 m m bolt and nut 54 (5.5,40) 6 mm flange bolt (10 m m head) and nut 12 (1.2,9)
8 m m flange bolt and nut 27 (2.8, 20)
10 m m flange bolt and nut 39 (4.0, 29)
ENGINE
FRAME/BODY PANELS/EXHAUST SYSTEM
I ITEM
THREAD TORQUE
N.m (knf-m, Ibf-ft)
REMARKS
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N.m (kgf-m, Ibf.ft)
Spark plug 1 10 12 (1.2,9)
Valve adjusting screw lo& nut 2 5 10 (1.0,7) NOTE 1
Timing hole cap 1 14 6 (0.6, 4.4)
Engine oil strainer cap 1 30 20 (2.0, 15)
Final drive oil check bolt 1 8 13 (1.3. 10)
LUBRICATION SYSTEM
THREAD TORQUE
ITEM QTY REMARKS
DIA. (mm) N - m (kgf.m, Ibf.ft)
Oil pump cover screw 1 3 2 (0.2, 1.5)
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N - m (kgf-m, I b f W
Throttle body insulator band bolt 2 - page 5-40
Engine coolant temperature (ECT) sensor 1 23 (2.3, 17)
1-11
GENERAL INFORMATION
THREAD TORQUE
REMARKS
ITEM Q'TY DIA. (mm) N-m(kgf-m, Ibf-ft)
Camshaft holder nut 4 8 27 (2.8, 20) NOTE 1
Cam sprocket bolt 2 5 9 (0.9, 6.6)
Cylinder head cover bolt 2 6 12 (1.2,9)
THREAD TORQUE
ITEM REMARKS
'ITY DIA. (mm) N-m (kgf-m. Ibf-ft)
Cylinder stud bolt 4 8 6.6)
9 (0.9,
DRIVE AND DRIVEN PULLEYS/CLUTCH
THREAD TORQUE
ITEM REMARKS
'ITY DIA. (mm) N.m (kgf.m, Ibf-ft)
Clutch lock nut 1 28 54 (5.5,40)
Clutch outer nut 1 12 49 (5.0,36)
Drive pulley face nut 1 12 59 6.0, 44) NOTE 1
Left crankcase cover bolt 5 6 10 (1.0,7)
Belt case air cleaner housing bolt 2 6 - page 10-8
ALTERNATOR/STARTER CLUTCH
THREAD TORQUE
REMARKS
ITEM 'ITY DIA. (mm) N.m (kgfam, Ibf-ft)
Stator bolt 3 6 12 (1.2,9)
Crankshaft position (CKP) sensor bolt 2 5 5 (0.5, 3.7)
Starter clutch outer bolt 3 8 30 (3.1,22) NOTE 2
Flywheel nut - 1 16 116 (11.8,86) NOTE 1
THREAD TORQUE
ITEM REMARKS
'ITY DIA. (mm) N-m (kgf-m, IbfW
C a m chain tensioner pivot bolt 1 6 10 (1.0,7)
1-12
GENERAL INFORMATION
THREAD TORQUE
ITEM REMARKS
*ITY DIA. (mm) N.m (kgf.m, Ibf4tJ
Center stand pivot bolt 2 10 49 (5.0, 36) NOTE 3
Exhaust pipe joint nut 2 7 29 (3.0, 21)
Muffler mounting bolt 3 10 49 (5.0, 36)
Muffler protector bolt 2 5 5.2 (0.53, 3.8)
THREAD
ITEM TORQUE REMARKS
QTY DIA. (mm) N.m (kgf-m, Ibf-ft)
Brake joint cable adjuster lock nut 1 8 6 (0.6, 4.4)
ITEM
THREAD TORQUE
REMARKS
*ITY DIA. (mm) N-m (kgfmm, Ibf4t)
Fuel pump retaining plate nut 7 6 12 (1.2,9) page 5-36
sensor
0 2 1 18 44 (4.5, 32)
Bank angle sensor screw 2 4 1.2 (0.12,0.9)
THREAD TORQUE
ITEM REMARKS
QTY DIA. (mm) N.m (kgf-m, Ibf4t)
Cooling fan motor mounting bolt 2 6 J
8.4 (0.86, 6.2)
ENGINE REMOVAL/INSTALLATlON
___
ITEM THREAD TORQUE REMARKS
QTY DIA. (mm) N-m (kgf-m, Ibf-ft)
Engine hanger bracket bolt (frame side) 2 10 49 (5.0, 36)
I Enaine mountincr nut (enaine side) I l l 10 I 49 (5.0. 36) 1 NOTE 5 I
FRONT WHEEL/SUSPENSION/STEERlNG
I
THR- TORQUE
ITEM Q'TY REMARKS
DIA. (mm)
_____ _ _ N.m _ _ _ ~ IbfW
_ _ _ (kgf.m,
Steering stem lock nut 1 BC 1 68 (6.9, 50)
Steering bearing upper inner race 1 BC 1 - page 14-26
Fork socket bolt 2 8 20 (2.0, 15) NOTE 2
Handlebar post nut 1 10 39 (4.0, 29) NOTE 5
Brake disc bolt 4 8 42 (4.3, 31) NOTE 3
Front axle nut 1 12 68 (6.9, 50) NOTE 5
SDeedometer cable settina screw 1 5 2.2 (0.22. 1.6)
REAR WHEEL/SUSPENSION
_____
THREAD TORQUE
ITEM REMARKS
QTY DIA.
~.
(mm) N-m(kgf-m, Ibf.ft)
Rear axle nut 1 16 118 (12.0, 87) NOTE 5
BRAKE SYSTEM
THREAD TORQUE
ITEM REMARKS
QTY DIA. (mm) N.m (kgf-m, Ibf-ft)
Caliper bleed valve 1 8 5.5 (0.56,4.1)
Pad pin 2 10 18 (1.8, 13)
Pad pin plug 2 10 2.5 (0.25, 1.8)
Master cylinder reservoir cap screw 2 4 1.5 (0.15, 1.1)
Brake hose oil bolt 7 10 34 (3.5, 25)
Front brake lever pivot bolt 1 6 1 (0.1,0.7)
Front brake lever pivot nut 1 6 6 (0.6, 4.4)
Front brake light switch screw 1 4 1.2 (0.12,0.9)
Master cylinder holder bolt 2 6 12 (1.2,9)
Caliper mounting bolt 2 8 30 (3.1, 22) NOTE 3
Rear brake lever Divot screw 1 5 4.2 (0.43, 3.1 1
1-13
GENERAL INFORMATION
THREAD TORQUE
ITEM REMARKS
'ITY DIA. (mm) N.m (kgfam, Ibf-ft)
License light screw 1 - 1.5 (0.15, 1.1)
I Speedometer cable joint nut 1 12 3.4 (0.35, 2.5)
1-14
GENERAL INFORMATION
LUBRICATION & SEAL POINTS
ENGINE
LOCATION MATERIAL REMARKS
Alternatorkrankshaft position (CKP) sensor wire grommet Sea Iant
seating area
Crankcase mating surface
Starter clutch outer bolt threads Locking agent ~
Water pump shaft journal Molybdenum oil solu- Do not apply to the
tion-(amixture of mechanical seal sliding area
engine oil and molyb- (page 6-12).
Camshaft cam lobes denum disulfide
Starter driven gear inner surface (crankshaft sliding area) grease in a ratio of Avoid getting on the crank-
1:l) shaft and flywheel tapered
areas.
Driven face boss inner surface Multi-purpose grease 7 - 8 g (avoid getting shaft
spline and pulley face when
assemble)
Movable driven face guide grooves (guide pin areas) 2 - 2.5 g
Movable driven face ball and needle bearings
Final shaft groove and outer surface (swingarm fitting
area)
Valve adjusting screw lo& nut threads Engine oil
Final drive oil drain bolt threads and seating surface
Oil pump rotors and shaft sliding surface
Oil pump drive chain
Valve stem seal fitting area
Valve stem sliding surface
Rocker arm shaft sliding surface
Rocker arm slipper and sliding surfaces
Camshaft holder nut threads
Cam sprocket teeth
Cam chain
Piston rings
Piston ring grooves and piston pin hole
Piston pin outer surface
Piston and cylinder wall
Drive pulley face nut threads
Final reduction gear teeth and journals
Starter driven gear teeth and sprag clutch contacting area
Starter reduction gear teeth and sliding surface
Starter reduction gear shaft outer surface
Flywheel nut threads and seating surface
Right crankshaft hole (oil passage)
Connecting rod big end bearing and thrust surfaces 3 cc
Crankshaft main journal bearings 2 cc per eac.. bearing
Timing sprocket teeth
Oil pump drive sprocket teeth
Starter motor pinion teeth
Each bearing rotating area
Each oil seal lips and outer surface
Each 0-rina
GENERAL INFORMATION
FRAME
LOCATION MATERIAL REMARKS
Steering head bearings Urea based multi-pur- 3 - 5 g per each bearing
Steering head dust seal lips pose grease w i th
extreme pressure
(Example: Excelite EP2
manufactured by
Kyodo Yushi, Japan/
Shell Alvania EP2 or
equivalent)
1-16
GENERAL INFORMATION
CABLE & HARNESS ROUTING
THROTTLE CABLE
CONNECTORS
CO M BINAT1ON METER/
HANDLEBAR SWITCH WIRE
2 mm max.
CONNECTORS:
I i If CABLE
DIMMER/PASSING SWITCH
4P (Black) CONNECTOR
REAR BRAKE
FRONT BRAKE
CABLE HOLDER
1-18
GENERAL INFORMATION
SEAT LOCK
WATER I
SPEEDOMETER
CABLE
1-19
GENERAL INFORMATION
CABLE
GENERAL INFORMATION
BRAKE JOINT
\ CABLE
1-21
GENERAL INFORMATION
FRO"
1-22
GENERAL INFORMATION
REAR BRAKE
CABLE
STARTER MOTOR
---
STARTER RELAY
FLOOR SWITCH WIRE
CABLE
HARNESS
MAIN WIRE
GROUND WIRE
View from the bottom side: I HARNESS
I /
UP
t
-1
Inside 4
.=-
1-23
GENERAL INFORMATION
ALTERNATOR WIRE
1-24
GENERAL INFORMATION
02 SENSOR/PAIR
SOLENOID VALVE WIRE
STARTER -MOTOR
1-26
GENERAL fNFORMATlON
FUEL PUMP/LEVEL
SENSOR WIRE
GROUNDPOINT
1-27
GENERAL INFORMATION
v
-
SEAT LOCK CABLE
Left side
CABLE
I
I
FLOOR LOWER
COVER
GENERAL INFORMATION
REAR BRAKE
CABLE
GENERAL INFORMATION
;IGNAUBRAKE/
(White)
THROTTLE BODY
Fresh Air
1Blow-by Gas
1-32
GENERAL INFORMATION
EXHAUST EMISSION CONTROL SYSTEM
The exhaust emission control system is composed of a secondary air supply system and PGM-FI system, and no
adjustments should be made. The exhaust emission control system is separate from the crankcase emission control
system.
SECONDARY AIR SUPPLY SYSTEM
The secondary air supply system which introduces filtered air into the exhaust gases in the exhaust port. Fresh air is drawn
into the exhaust port by the function of the Pulse Secondary Air Injection (PAIR) solenoid valve.
This charge of fresh air promotes burning of the unburned exhaust gases and changes a considerable amount of
hydrocarbons and carbon monoxide into relatively harmless carbon dioxide and water vapor.
The PAIR check valve prevents reverse air flow through the system. The PAIR solenoid valve is controlled by the engine
control module (ECM), and the fresh air passage is opened and closed according to the running condition.
No adjustments to the secondary air supply system should be made, although periodic inspection of the components is
recommended.
1-33
GENERAL INFORMATION
~ ~~
1-34
2. FRAME/BODY PANELWEXHAUST SYSTEM
BODY PANEL LOCATIONS ........................... 2-3 FRONT INNER COVER ................................. 2-10
FRAME BODY COVER ................................... 2-5 GLOVE BOX INNER COVER ........................ 2-13
2-1
FRAME/BODY PANELWEXHAUST SYSTEM
SERVICE INFORMATION
GENERAL
This section covers removal and installation of the body panels and exhaust system.
When installing the covers, make sure the mating areas are aligned properly before tightening the fasteners.
Always replace the exhaust pipe gasket after removing the exhaust system.
When installing the exhaust system, loosely install all of the fasteners. Always tighten the exhaust joint first, then
tighten the mounting fasteners. If you tighten the mounting fasteners first, the exhaust pipe may not seat properly.
Always inspect the exhaust system for leaks after installation.
TORQUE VALUES
Center stand pivot bolt 49 N.m (5.0 kgf.m, 36 Ibf.ft) ALOC bolt: replace with a new one.
Center stand spring hook bolt 10 N.m (1.0 kgf.m, 7 Ibf.ft)
Exhaust pipe stud bolt 9 N.m (0.9 kgf.m, 6.6 Ibf.ft)
Exhaust pipe joint nut 29 N.m (3.0 kgf.m, 21 Ibf.ft)
Muffler mounting bolt 49 N.m (5.0 kgf.m, 36 Ibf.ft)
Muffler protector bolt 5.2 N.m (0.53 kgf.m, 3.8 Ibf.ft)
TROUBLESHOOTING
Excessive exhaust noise
Broken exhaust system
Exhaust gas leak
Poor performance
Deformed exhaust system
Exhaust gas leak
Clogged muffler
2-2
FRAMEIBODY PANELSEXHAUST SYSTEM
BODY PANEL LOCATIONS
(1) Maintenance Lid (page 2-4) (7) Front Fender (page 2-8) (12) Floor Panel (page 2-11 1
(2) Seat (page 2-41 (8) Floor Lower Cover (page 2-8) (13) Front Handlebar Cover (page 2-11)
(3) Luggage Box (page 2-51 (9) Front Upper Cover (page 2-81 (14) Rear Handlebar Cover (page 2-12)
(4) Frame body Cover (page 2-5) (10) Front Lower Cover (page 2-91 (15) Glove Box Inner Cover (page 2-13)
(5) Rear Fender A (page 2-7) (11) Front Inner Cover (page 2-10] (16) Mud Guard (page 2-14)
(6) Rear Fender B (page 2-71
(4) Frame Body Cover 4(10) Front Lower Cover I (14) Rear Handlebar Cover
f\ 1
I I
t
I I (11) Front Inner Cover 4 (8) Floor Lower Cover I
(15) Glove Box Inner Cover I (16) Mud Guard
2-3
FRAME/BODY PANELWEXHAUST SYSTEM
MAINTENANCE LID
Remove the three tapping screws.
Release the upper tabs from the frame body cover TAPPING SCREWS
and the lower tabs from the floor panel to remove
the maintenance lid. TABS /
Installation is in the reverse order of removal.
SEAT
Unlock the seat lock with the ignition key and open
the seat.
Remove the two nuts while supporting the seat to
remove it.
Installation is in the reverse order of removal.
SEAT
2-4
FRAME/BODY PANELWEXHAUST SYSTEM
LUGGAGE BOX
Remove the seat (page 2-4).
Remove the following:
- four bolts (front side; two setting boltshear side;
two washer-bolts)
- tapping screw
- luggage box (release from the two tabs of the
frame cross-bracket)
Installation is i n the reverse order of removal.
TAPPING SCREW
2-5
FRAME/BODY PANELSiEXHAUST SYSTEM
Remove the three bolts and grab rail.
GRAB RAIL
2-6
FRAME/BODY PANELWEXHAUST SYSTEM
REAR FENDER
FENDER A
Remove the frame body cover (page 2-5).
Remove the following:
- license light connectors
- two washer-bolts
- two flange bolts
- two tapping screws
- rear fender A (from between the fender B and
bracket)
Route the license Installation is in the reverse order of removal.
hght wire properly
(page 1-17). FLANGE BOLTS
CONNECTORS
WASHER-BOLTS
FENDER B
Remove the rear fender B (page 2-7).
Support the swingarm securely.
Remove either shock absorber upper mounting bolt
t o get the clearance for fender removal.
Remove the two setting bolts (upper side) and
release the fender off of the bolt hole studs.
Remove the two flange bolts and the rear fender B.
Installation is in the reverse order of removal.
STUDS
SETTING BOLTS
2-7
FRAME/BODY PANELWEXHAUST SYSTEM
FRONT FENDER
Remove the following:
- speedometer cable guide
- three setting bolts
- front fender
Installation is in the reverse order of removal.
BOLTS
\
SCREWS TAB
I TAPPING SCREWS
2-8
FRAMEIBODY PANELWEXHAUST SYSTEM
FRONT LOWER COVER
Remove the following:
- front upper cover (page 2-8)
- floor lower cover (page 2-8)
- front wheel (page 14-7)
- front fender (page 2-8)
Remove the ten tapping screws and the setting bolt.
Release the two bosses from the grommets and
raise the front lower cover t o release it from the
retainer on the frame.
While supporting the front lower cover and release
the turn signal and fan motor wires from the wire
guides.
Disconnect the turn signaVposition light 3P connec-
tors and remove the front lower cover.
Route the wires Installation is in the reverse order of removal.
properly
(page 1- 171.
NOTE:
Align the mating areas of the front lower cover
and front inner cover properly.
GUI
TABS
FRAMEIBODY PANELWEXHAUST SYSTEM
FLOOR PANEL
Remove the following:
- frame body cover (page 2-5)
- front inner cover (page 2-10) ?- STATER RELY SWITCH - -
2-11
FRAME/BODY PANELSIEXHAUST SYSTEM
Remove the two screws.
Push the rear handlebar cover and release the four 1 SCREWS FRONT HANDLEBAR COVER
tabs of the front handlebar cover.
Release the two bosses from the grommet.
Be careful not to Disconnect the headlight 3P connector to remove
scratch the front the front handlebar cover.
inner cover.
Installation is in the reverse order of removal.
NOTE:
Set the throttle cable into the guide groove in the
rear handlebar cover.
G SCREWS
2-12
FRAME/BODY PANELS/EXHAUST SYSTEM
GLOVE BOX INNER COVER
Open the glove box lid with the ignition key.
Remove the two tapping screws.
Release the five tabs of the cover from the glove
box.
Remove the relays and the fuse box by pushing the
lock tab to remove the inner cover.
Installation is in the reverse order of removal.
INNER COVER
RELAYS I
TAPPING SCREWS
2-13
FRAME/BODY PANELWEXHAUST SYSTEM
MUD GUARD
Remove the following:
- washer-screw
- two socket bolts
- mudguard
Ahgn the sht with Installation is in the reverse order of removal.
the tab on the a/r
cleaner housmg
CENTER STAND
Retract the center stand and support the scooter
securely.
Be careful not to Remove the following:
deform the springs. - Springs
- two bolts
- center stand
- pivot collars (from the inside of the stand)
Installation is in the reverse order of removal.
NOTE:
Always replace the pivot bolts with new ones.
Apply grease to the pivot areas.
The springs are installed from the upper side as
shown.
2-15
-
3. MAINTENANCE
SERVICE INFORMATION .............................. 3-2 BELT CASE AIR CLEANER ........................... 3-12
3-1
MAINTENANCE
SERVICE INFORMATION
GENERAL
Place the scooter on a level ground before starting any work.
The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and may lead to death.
Run the engine in an open area or with an exhaust evacuation system in an enclosed area.
TORQUE VALUES
Spark plug 12 NGm (1.2 kgf.m, 9 Ibf.ft)
Valve adjusting screw lock nut 10 N.m (1.0 kgf.m, 7 Ibf.ft) Apply engine oil to the threads.
Timing hole cap 6 N.m (0.6 kgf.m, 4.4 Ibf.ft)
Engine oil strainer cap 20 N,m (2.0 kgf.m, 15 Ibf.ft)
Belt case air cleaner housing bolt 10 N.m (1.0 kgf.m, 7 Ibf.ft)
Final drive oil check bolt 13 N.m (1.3 kgf.m, 10 Ibf.ft)
Master cylinder reservoir cap screw 1.5 N.m (0.15 kgf.m, 1.1 Ibf.ft)
Brake joint cable adjuster lock nut 6 N.m (0.6 kgf.m, 4.4 Ibf.ft)
3-2
MAINTENANCE
MAINTENANCE SCHEDULE
Perform the Pre-ride inspection in the Owners Manual at each scheduled maintenance period.
I: Inspect and Clean, Adjust, Lubricate or Replace if necessary. C: Clean. R: Replace. A: Adjust. L: Lubricate.
The following items require some mechanical knowledge. Certain items (particularly those marked * and **I m ay require
more technical information and tools. Consult an authorized Honda dealer.
* Should be serviced b y an authorized Honda dealer, unless the owner has proper tools and service data and is
mechanically qualified.
** In the interest of safety, w e recommend these items be serviced only by an authorized Honda dealer.
Honda recommends that an authorized Honda dealer should road test your scooter after each periodic maintenance is
carried out.
NOTES:
1. At higher odometer readings, repeat at the frequency interval established here.
2. Service more frequently when riding in unusually wet or dusty areas.
3. Service more frequently when riding i n rain or at full throttle.
4. Replace every 2 years. Replacement requires mechanical skill.
3-3
MAINTENANCE
FUEL LINE
Remove the luggage box (page 2-5). i
Check the fuel feed hose between the fuel pump
and injector for deterioration, damage or leakage.
Replace the fuel feed hose if necessary.
Also, check the feed hose fittings for damage or
looseness.
THROTTLE OPERATION
Check for any deterioration or damage to the throt-
tle cable. Check the throttle grip for smooth opera-
tion. Check that the throttle opens and automatically
closes in all steering positions.
If the throttle grip does not return properly, lubricate
the throttle cable and overhaul and lubricate the
throttle grip housing.
For cable lubrication; disconnect the throttle cable at
its upper end. Thoroughly lubricate the cable and its
pivot point with a commercially available cable
lubricant or a light weight oil.
If the throttle grip still does not return properly,
replace the throttle cable.
With the engine idling, turn the handlebar all the
way to the right and left to ensure that the idle
speed does not change. If idle speed increases,
check the throttle grip free play and the throttle
cable connection.
Measure the throttle grip free play a t the throttle
grip flange.
FREE PLAY 2 - 6 mm (1112 - 1/4 in)
3-4
Major adjustments are made with the lower
adjuster o n the throttle body.
Remove the luggage box (page 2-5).
Loosen the lock nut, turn the adjusting nut as
required and tighten the lock nut.
After adjustment, recheck the throttle operation.
AIR CLEANER
NOTE:
The viscous paper element type air cleaner can-
not be cleaned because the element contains a
dust adhesive.
If the scooter i s used in unusually wet or dusty
areas, more frequent inspections are required.
Remove the following:
- six screws
- air cleaner cover
3-5
CRANKCASE BREATHER
NOTE:
Service more frequently when ridden in rain, at
full throttle, or after the scooter is washed or
overturned. Service if the deposit level can be
seen in the transparent section of the tube.
Remove the crankcase breather tube plug and drain
the deposits into a suitable container, then reinstall
the plug securely.
SPARK PLUG
Remove the maintenance lid (page 2-4).
Clean around the Disconnect the spark plug cap and remove the spark
spark plug base plug.
with compressed
air before removing
the plug, and be
sure that no debris
is aNowed to enter
into the combustion
chamber
RECOMMENDEDSPARK PLUG:
Standard:
CR8EH-9 (NGK), U24FER9 (DENSO)
For extended high speed riding:
CR9EH-9 (NGK), U27FER9 (DENSO)
Clean the spark plug electrodes with a wire brush or
special plug cleaner.
/
SIDE ELECTRODE
INSU LATOR
MAINTENANCE
Check the gap between the center and side elec-
trodes with a wire-type feeler gauge.
I
SPARK PLUG GAP: 0.8 - 0.9 mm (0.031 - 0.035 in)
If necessary, adjust the gap by bending the side
electrode carefully.
Thread the spark plug in by hand to prevent cross-
threading and tighten it with a spark plug wrench.
TORQUE: 12 N-m (1.2 kgf-m, 19 IbfW
Connect the spark plug cap.
Install the maintenance lid (page 2-4).
VALVE CLEARANCE
INSPECTION
NOTE:
Inspect and adjust the valve clearance while the
engine is cold (below 35"C/95"F).
Remove the following:
- cylinder head cover (page 8-7)
- belt case air cleaner housing (page 3-12)
Remove the timing hole cap from the right crank-
case cover.
Apply engine oil to Adjust by loosening the lock nut and turning the
thelocknut adjusting screw until there is a slight drag o n the
threads. feeler gauge.
Hold the adjusting screw and tighten the lock nut.
TORQUE: 10 Nnm (1.0 kgfm, 7 Ibf.ft)
After tightening the lock nut, recheck the valve
clearance.
ENGINE OIL
NOTE:
For engine oil change procedure, see page 3-9
"Engine Oil Strainer Screen".
OIL LEVEL CHECK
Place the scooter o n its center stand o n a level sur-
face.
Start the engine and let it idle for 3 - 5 minutes.
Stop the engine and wait for 2 - 3 minutes.
Remove the oil filler cap/dipstick and wipe the oil
fro m the dipstick with a clean cloth.
Insert the filler cap/dipstick without screwing it in,
remove it and check the oil level.
The level should be between the upper and lower
level lines o n the dipstick.
3-8
MAINTENANCE
If the oil level is below or near the lower level line,
add the recommended oil to the upper level line. OIL VISCOSITIES
NOTE:
Other viscosities shown in the chart may be used
when the average temperature in your riding
area is within the indicated range.
Make sure the O-ring is in good condition and install
the oil filler cap/dipstick.
CLOCK SWITCH
OIL CHANGE AND STRAINER
CLEANING
Change the oil with Start the engine, warm it up and stop it.
the engine warm
Remove the filler cap/dipstick.
and the scooter on
its center stand to Remove the strainer cap, setting spring and oil
assure complete strainer, and drain the engine oil.
and rapid draining
3-9
Wash the strainer screen thoroughly in non-flam-
mable or high flash point solvent until all accumu-
lated dirt has been removed.
Blow dry it with compressed air to clean completely.
The screen mesh should be examined closely for
damage.
Coat a new O-ring with engine oil and install it onto - ,
the strainer cap.
After draining the oil completely, install the oil
strainer (with the round end facing down) and
O-RING
spring.
Install the strainer cap and tighten it.
TORQUE: 20 N-m (2.0 kgf-m, 15 I b f W 1
Pour the recommended oil into the crankcase to the
upper level line on the dipstick (page 3-9).
ENGINE OIL CAPACITY
0.9 liter (1.0 US qt, 0.8 Imp qt) at draining
1.0 liter (1.1 US qt, 0.9 Imp qt) at disassembly
Check the oil level (page 3-8).
Make sure there are no oil leaks.
RADIATOR COOLANT
Place the scooter on its center stand on a level sur-
face.
Remove the front upper cover (page 2-8).
With the engine running at normal operating tem-
perature and check the coolant level of the reserve
tank.
The level should be between the "UPPER" and
"LOWER" level lines.
If the level is low, remove the reserve tank cap and
fill the tank to the upper level line with a 1:l mixture
of distilled water and antifreeze (coolant prepara-
tion: page 6-7).
3-1I
MAINTENANCE
SECONDARY AIR SUPPLY SYSTEM
Remove the following :
- luggage box (page 2-5)
- maintenance lid (page 2-4)
Check the air supply hoses between the air cleaner
housing and pulse secondary air injection (PAIR)
check valve for cracks, deterioration, damage or
loose connections.
n
HOSES
PAIR SOLENOID
VALVE
VALVE PORT
3-12
MAINTENANCE
Remove the air cleaner element from the base.
DO not apply oil to Wash the element in non-flammable or high flash
the element. point solvent.
Squeeze out the solvent and let it dry thoroughly,
then install it onto the base core.
Replace the 0-rmg Install the air cleaner housing in the reverse order of
with a new one. removal.
TORQUE: 10 N.m (1.0 kgf-m, 7 Ibf-ft)
OIL CHANGE
Remove the oil check bolt and drain bolt, slowly
turn the rear wheel and drain the oil.
After the oil is completely drained, install the drain
bolt with a new sealing washer and tighten it
securely.
Fill the gear case with recommended oil up to the
correct level (page 3-13).
OIL CAPACITY:
190 cm3 (6.4 US oz, 6.9 Imp 0 2 ) at draining
220 cm3(7.4 US 02.7.7 Imp oz) at disassembly
3-13
MAINTENANCE
BRAKE FLUID
I NOTICE I
Spilling fluid can damage painted, plastic or rubber
parts. Place a rag over these parts whenever the
system is serviced.
NOTE:
Do not mix different types of fluid, as they are
not compatible with each other.
Do not allow foreign material to enter the system
when filling the reservoir.
When the fluid level of the front master cylinder
is low, check the brake pads for wear (page 3-15).
A low fluid level may be due to wear of the brake
pads. If the brake pads are worn, the caliper pis-
ton is pushed out, this accounts for a low reser-
voir level. If the brake pads are not worn and the
fluid level is low, check entire system for leaks
(page 3-15).
Turn the handlebar to the left so the reservoir is
level and check the brake reservoir fluid level
through the sight glass.
3-14
MAINTENANCE
BRAKE SHOEWPADS WEAR
FRONT BRAKE PADS
J
Check the brake pad for wear.
Replace the brake pads if either pad is w orn t o the
wear limit line.
See page 16-9 for brake pad replacement.
BRAKE SYSTEM
FRONT BRAKE (HYDRAULIC SYSTEM)
Firmly apply the front brake lever, and check that n o
air has entered the system.
If the lever feels soft or spongy when operated,
bleed the air fro m the system.
See page 16-8 for air bleeding procedures.
Inspect the brake hose and fittings for deterioration,
cracks, damage or signs of leakage.
Tighten any loose fittings.
Replace hose and fittings as required.
MAINTENANCE
REAR (COMBINED) BRAKE
REAR BRAKE LEVER FREE PLAY
Check the rear brake lever free play.
3-16
MAINTENANCE
BRAKE LIGHT SWITCH
NOTE:
The brake light switches cannot be adjusted. If
the brake light switch actuation and brake
engagement are not synchronized, either replace
the switch unit or the malfunctioning parts of the
system.
Check that the brake light comes on just prior to the
brake actually being engaged.
See page 20-14 for brake light switch inspection.
HEADLIGHT AIM
Support the scooter upright on a level surface.
Adjust the headhght Adjust the headlight beam vertically by turning the
beam as specified adjusting screw.
by local laws and
regulabons.
SUSPENSION
FRONT
Check the action of the front suspension by operat-
ing the front brake and compressing it several
times.
Check the entire assembly for damage or loose fas-
teners.
Replace damaged components which cannot be
repaired.
Tighten a l l fasteners.
Refer to page 14-12 for front fork service.
MAINTENANCE
REAR
Check the action o f the shock absorber b y com-
pressing it several times.
Check the entire shock absorber assembly for dam-
age or loose fasteners.
Replace damaged components which cannot be
repaired.
Tighten all fasteners.
Refer to page page 15-8 for rear shock absorber ser-
vice.
W HEELS/TIRES
Check the tire pressure with a tire pressure gauge
when the tires are cold.
4- 1
LUBRICATION SYSTEM
LUBRICATION SYSTEM DIAGRAM
CRANKSHAFT
7-
OIL STRAINER
OILPUMP
4-2
LUBRICATION SYSTEM
SERVICE INFORMATION
GENERAL
Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is
unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and
water as soon as possible after handling used oil.
0 The oil pump can be serviced with the engine installed in the frame.
When removing and installing the oil pump, use care not to allow dust or dirt to enter the engine.
If any portion of the oil pump is worn beyond the specified service limits, replace the oil pump as a n assembly.
Refer to page 3-8 for engine oil level check and oil change information.
TORQUE VALUES
Oil pump cover screw 2 N.m (0.2 kgf.m, 1.5 Ibf.ft)
TROUBLESHOOTING
Engine oil level too low, high oil consumption
Normal oil consumption
External oil leak
Worn piston rings or incorrect piston ring installation (page 9-6)
Worn cylinder (page 9-6)
Worn valve guide or stem seal (page 8-13)
Oil contamination
Oil not changed often enough
Faulty cylinder head gasket
0 Worn piston rings or incorrect piston ring installation (page 9-6)
Worn valve guide or stem seal (page 8-13)
Oil emulsification
Blown cylinder head gasket
Worn or damaged water pump mechanical seal
Water entry
4-3
LUBRlCATlON SYSTEM
OIL PUMP
REMOVAL
Remove the flywheel (page 12-10).
Remove the following:
- bolt
- sprocket cover
- snapring
- driven sprocket and drive chain
- two bolts
- sprocket housing
- oil pump
DISASSEMBLY
Remove the following from the oil pump body:
- pumpshaft
- screw
- pumpcover
4-4
LUBRICATION SYSTEM
- dowel pin
- inner rotor
- outer rotor
Wash all parts with a high flash point or non-flam-
mable solvent.
INSPECTION
NOTE:
Measure at several points and use the largest
reading to compare the service limit.
If any portion of the oil pump is worn beyond the
specified service limits, replace the oil pump as
an assembly.
Temporarily install the outer, inner rotors and oil
pump shaft into the oil pump body.
Measure the tip clearance between the outer rotor
and the inner rotors.
SERVICE LIMIT: 0.20 mm (0.008 in)
4-5
LUBRICATION SYSTEM
Measure the side clearance using a straight edge
and feeler gauge.
ASSEMBLY
Apply engine oil to the inner and outer rotors and
install them into the oil pump body.
Install the dowel pin into the oil pump body.
INSTALLATION
Position the oil Install the oil pump onto the crankcase by aligning
pump so the screw the bolt holes.
side is facing down
Install the sprocket housing with the two mounting
bolts and tighten them.
4-6
LUBRICATION SYSTEM
Make sure the Apply engine oil to the drive chain and the drive
pump shaft is sprocket of the crankshaft.
installed in the rotor
Set the drive chain over the driven sprocket, and
properly.
install them onto the drive sprocket and pump shaft.
Install the snap ring into the pump shaft groove
with the chamfered side facing the sprocket.
4-7
5. FUEL SYSTEM (Programmed Fuel Injection)
5-1
FUEL SYSTEM (Programmed Fuel Injection)
SYSTEM COMPONENTS
5-2
FUEL SYSTEM (Programmed Fuel Injection)
SERVICE INFORMATION
GENERAL
Before disconnecting fuel feed hose, relieve pressure from the system (page 5-31).
Bending or twisting the control cable will impair smooth operation and could cause the cable to stick or bend, resulting
in loss of vehicle control.
Work i n a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can
cause a fire o r explosion.
Do not apply commercially available carburetor cleaner t o the inside of the throttle bore, which is coated wit h molybde-
num.
Do not snap the throttle d ru m fro m full open to full close after the throttle cable has been removed. It may cause incor-
rect idle operation.
Seal the intake manifold with tape or a clean cloth to keep dirt and debris from entering the intake port after the throttle
body has been removed.
Prevent dirt and debris fro m entering the throttle bore and fuel feed hose, clean them using compressed air.
The engine control module (ECM) is mounted o n the throttle body (the throttle body with the built-in ECM). Do not dis-
assemble the throttle body/ECM assembly. Replace the throttle body/ECM as an assembly when the it is faulty.
The throttle body/ECM assembly may be damaged if dropped. Also if a connector is disconnected when current is flow-
ing, the excessive voltage may damage the ECM. Always turn off the ignition switch before servicing.
The throttle body/ECM assembly is factory pre-set. Do not disassemble i n a way other than shown in this manual. Loos-
ening the white painted fasteners can cause throttle body/ECM malfunction.
The programmed fuel injection (PGM-FI) system is equipped with the Self-Diagnostic System described o n page 5-7. If
the malfunction indicator lamp (MIL) blinks, follow the Self-Diagnostic Procedures to remedy the problem.
When checking the PGM-FI, always follow the steps in the troubleshooting fl ow chart (page 5-1 1 or 5-22).
The PGM-FI system is provided with fail-safe function to secure a mi ni mum running capability even when there is any
trouble in the system. When any abnormality is detected by the self-diagnosis function, running capability is secured b y
making use of the numerical values of a situation preset i n advance i n the simulated program map. It must be remem-
bered, however, that when any abnormality is detected i n injector the fail safe function stops the engine from the stand-
point of protecting it.
A faulty PGM-FI system is often related to poorly connected or corroded connectors. Check those connections before
proceeding.
The vehicle speed sensor sends digital pulse signal to the ECM (PGM-FI unit) and computation. Refer t o procedures for
vehicle speed sensor inspection (MIL trouble shooting:page 5-10 or DTC trouble shooting:page 5-19).
Use a digital tester for PGM-FI system inspection.
Refer t o page page 20-10 for fuel gauge/fuel level sensor inspection.
Refer t o page page 20-1 1 for coolant temperature gauge/ECT sensor inspection.
SPECIFICATIONS
ITEM SPECIFICATIONS
Throttle body identifica- SH125 GQMIA
tion number SH150 GQM2A
Idle speed 1,500 f 100 min-' (rpm)
Throttle grip free play 2 - 6 mm (0.08 - 0.24 in)
ECT sensor resistance (at 2OoC/68"F) 2.3 - 2.6 kC1
Fuel injector resistance (at 20C /68"F) 11.1 - 12.3 R
Fuel pressure 294 kPa (3.0 kgf/cm2, 43 psi)
Fuel p u m p f low (at 12 V) 22 cm3 (0.7 US 02.0.8 ImD 02) minimum/lO seconds
TORQUE VALUES
Fuel pump retaining plate nut 12 N.m (1.2 kgf.m, 9 I b f W
Throttle body insulator band bolt See page 5-40
Engine coolant temperature (ECT) sensor 23 N.m (2.3 kgf.m, 17 Ibf.ft)
02 sensor 44 N.m (4.5 kgf.m, 32 Ibf.ft)
Bank angle sensor screw 1.2 N.m (0.12 kgf.m, 0.9 Ibf.ft)
5-3
FUEL SYSTEM (Proarammed Fuel Iniection)
TOOLS
DLC short connector ECM test harness, 32P Fuel pressure gauge
070Pz-zY30100 070MZ-0010201 07406-0040003
TROUBLESHOOTING
Engine cranks but will not start
Intake air leak
Fuel contaminated/deteriorated
Pinched or clogged fuel feed hose
Faulty fuel pu mp
Clogged fuel injector
Sticking injector needle
Faulty fuel pump operating system
Faulty idle air control (IAC) valve in the engine control module (ECM)
Engine stall, hard to start, rough idling
Intake air leak
Fuel contaminated/deteriorated
Pinched or clogged fuel feed hose
Faulty IAC valve in the ECM
Afterburn when engine braking is used
Faulty secondary air supply system
- Faulty pulse secondary air injection (PAIR) solenoid valve
- Faulty PAIR check valve
- Clogged hose o f the secondary air supply system
Faulty ignition system (page 18-4)
Backfiring or misfiring during acceleration
Faulty ignition system (page 18-4)
Poor performance (driveability) and poor fuel economy
Pinched or clogged fuel feed hose
Faulty ignition system (page 18-4)
5-4
FUEL SYSTEM (Programmed Fuel Injection)
SYSTEM LOCATION
5-5
FUEL SYSTEM (Programmed Fuel Injection)
SYSTEM DIAGRAM
Fuel Pump
-
-
Ir
IFLR
BliW
CKP SENSOR
ECM [lGP
-
19R 12 R
@C WIY
1- 1INJ PIBU
I
GI0 I
OSG
IDLE AIR
CONTROI
(IAC)VAL\
29
E CT
SENSOR
TO Coolant
Temprature----- 7
GIBu
Gauge
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-
-
lFANC
IIGPLS
WIBU mMIL
w BVBr
L r-iFl
9 PGll
IEX-AI: P
PAIR SOLENOID
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I t U U i t
5-6
FUEL SYSTEM (Programmed Fuel Injection)
PGM-FI SELF-DIAGNOSIS
INFORMATION
SELF-DIAGNOSTIC PROCEDURE
Place the scooter on its center stand.
Turn the ignition switch to ON.
The malfunction indicator lamp (MIL) comes on for
a few seconds, then goes off.
Start the engine and let it idle.
NOTE:
If the engine control module (ECM) detects any
problem at the moment, the MIL will be follow-
ing status depending on the engine speed:
- under 2,000 min-' (rpm), idle speed; the MIL
brinks as detection item
- over 2,000 min~'(rpm), during riding; the MIL
turns on (stays lit)
If the MIL does not blink, the ECM has no problem
data.
If the MIL blinks, the PGM-FI system has a problem.
Confirm the problem either way as follows:
Read how many times the MIL blink. Determine
the cause of the problem (page 5-10).
Read the diagnosis trouble code (DTC) with the
Honda Diagnosis System (HDS) Pocket Tester.
Determine the cause of the problem (page 5-19).
To read the ECM memory of the MIL code or DTC,
perform the following:
MIL CODE
Remove the maintenance lid (page 2-4).
Turn the ignition switch to OFF.
Remove the dummy connector from the data link
connector (DLC).
Short the DLC terminals using the special tool.
TOOL:
DLC short connector 07OPZ-ZY30100
5-7
FUEL SYSTEM (Programmed Fuel Injection)
DTC (with the HDS pocket tester)
Remove the maintenance lid (page 2-4).
Turn the ignition switch to OFF.
Remove the dummy connector from the data link
connector ( DLC 1.
Connect the HDS Pocket Tester to the DLC.
Turn the ignition switch to ON.
Read the DTC and determine the cause of the prob-
lem (page 5-19). Also, check the freeze data.
NOTE:
Refer to the user's manual of the HDS Pocket
Tester for tester operation.
The freeze data indicates the engine condition
where the first malfunction was detected.
5-8
FUEL SYSTEM (Pronrammed Fuel Injection)
TEST HARNESS CONNECTION
Remove the luggage box (page 2-5).
Turn the ignition switch to OFF.
Disconnect the ECM 32P connector from the ECM by
releasing the lock lever.
TOOL:
ECM test harness, 32P 070MZ-0010201
I _
I? 18 a"!@21 22 23 24 25-2K 27 28 29 30 31 31 1
ECM:
" 1" 6"
5-9
FUEL SYSTEM (Proarammed Fuel Iniection)
MIL CODE INDEX
The PGM-FI malfunction indicator lamp (MIL) denotes the failure codes (the number of blinks from 0 to 29). The MIL has
two type of blinks, a long blink and short blink. The long blink lasts for 1.3 seconds, the short blink lasts for 0.5 second.
When two long blinks occur, and three short blinks, that failure code is 23 (two long blinks = 20 blinks, three short blinks
= 3 blinks). Then, go to the flow chart and see failure code 23.
When the engine control module (ECM) stores some failure codes, the MIL shows the failure codes in the order from the
lowest number to highest number. For example, when the MIL blinks once, then seven times, two failures have
occurred. Follow the flow chart for failure codes 1 and 7.
I
No blinks ECM power1 Open circuit in the power input Engine does not start 5-48
ground circuits wire of the ECM
ma Ifunctio n Open circuit in the engine stop
relay related wires
Faulty engine stop relay
Open circuit in the bank angle
sensor related wires
Faulty bank angle sensor
Blown sub-fuse 10 A (IGN, At,
- START, FUEL PUMP)
MIL circuit Open or short circuit in the MIL Engine operates nor- -
malfunction wire mally
Data link circuit Short circuit in the data link con- Engine operates nor- -
malfunction nector terminals mally
Short circuit in the data link con-
nector wire
Faulty ECM
MAP sensor Faulty MAP sensor (in the ECM) Engine operates nor- 5-11
circuit mally
malfunction
ECT sensor Loose or poorly connected ECT Hard start at a low tem- 5-11
circuit sensor connector perature (ECM controls
malfunction Open or short circuit in the ECT using preset value; cool-
sensor wire ant temperature: 90 C/
r
Faulty ECT sensor 194 O F )
8 blinks TP sensor circuit Faulty TP sensor (in the ECM) Poor engine response 5-13
malfunction when operating the
throttle quickly (ECM
controls using preset
value; throttle opening:
0)
IAT sensor circuit Faulty IAT sensor (in the ECM) Engine operates nor- 5-13
malfunction mally (ECM controls
using preset value;
intake air temperature:
25 CI77 OF)
Fuel injector Loose or poorly connected injec- Engine does not start 5-13
circuit tor connector
malfunction Open or short circuit in the injec-
tor wire
r-
Faulty 0 2 sensor
23 Blinks sensor heater
0 2 Loose or poorly connected 0 2 Engine operates nor- 5-17
malfunction sensor connector mally
Open or short circuit in the 0 2
sensor heater wire
Faulty 0 2 sensor
IAC valve circuit Faulty IAC valve (in the ECM) Engine operates nor- 5-18
malfunction mally
FUEL SYSTEM (Programmed Fuel Injection)
MIL TROUBLESHOOTING
MIL 1 BLINK (MAP SENSOR)
1. Recheck MIL
Erase the self-diagnostic memory to reset the
ECM (page 5-81,
Start the engine and let it idle. Check that the
7 MIL
MIL blinks.
Is the MIL blinking?
NO - Temporarily failure; the system is nor-
mal.
YES - Replace the throttle body/ECM assem-
bly with a new one, and inspect again.
I ECTSENSOR
FUEL SYSTEM (Proarammed Fuel Iniection)
MIL 8 BLINKS (TP SENSOR)
1. Recheck MIL
Erase the self-diagnostic memory to reset the
ECM (page 5-8).
Start the engine and let it idle. Check that the
MIL blinks.
Is the MIL blinking?
NO - Temporarily failure; the system is nor-
mal.
YES - Replace the throttle body/ECM assem-
bly with a new one, and inspect again.
.
NOTE:
Before starting the troubleshooting, check the
injector 2P connector for loose contacts or cor-
roded terminals, and recheck the MIL.
1. Injector Resistance Inspection
Remove the luggage box (page 2-5).
Turn the ignition switch to OFF.
Disconnect the injector 2P connector.
Measure the resistance between the injector ter-
minals.
Standard: 11.1 - 12.3 2
! (20C/68"F)
Is the resistance within 11.1 - 12.3 R /20"c/
68 OF)?
NO - Faulty injector.
YES - GO TO STEP 2.
5-13
FUEL SYSTEM (Programmed Fuel Injection)
2. Injector Power Input Line Inspection
Measure the voltage between the wire harness
side 2P connector terminal and ground with the
ignition switch turned to ON.
-
Connection: Black/white (+) Ground (-1
Does the battery voltage exit?
NO - Open circuit in BlacWwhite wire.
YES - GO TO STEP 3.
I PinMblue
OR
#31- Greedorange
Is there continuity?
NO - Open circuit in the BlacWorange or
Greedorange wire. 4P
YES - GO TO STEP 3. CONNECTOR
5-16
FUEL SYSTEM (Programmed Fuel Injection)
MIL 23 BLINKS ( 0 2 SENSOR HEATER)
NOTE:
Before starting the troubleshooting, check the 02
sensor 4P connector for loose contacts or cor-
roded terminals, and recheck the MIL.
1. 0 2 Sensor Heater Resistance Inspection
Turn the ignition switch t o OFF.
Disconnect the 0 2 sensor 4P (black) connector
(page 5-47).
Measure the resistance between the sensor side
4P connector terminals.
Connection: White - White
Is the resistance below 13 L2 [2OoC/68"F)?
NO - Faulty 0 2 sensor.
YES - GO TO STEP 2.
2. 0
2 Sensor Heater Power Input Line inspection
Measure the voltage between the wire harness
side 4P connector terminal and ground with the
ignition switch turned to ON.
Connection: Black/white (+) - Ground (-1
Does the battery voltage exit?
NO - Open circuit in the BlacWwhite wire.
YES - GO TO STEP 3.
3. 0
2 Sensor Heater Open circuit inspection
Connect the test harness between the ECM con-
nectors (page 5-9). .___-
5 R i 8 9 ' ( i l l 1 2 1 3 4l5W
Check for continuity between the test harness I I
terminal and wire harness side 4P connector ter- 0600000000060000
J-_I1-C
minal. 0 b 0 Q 0 0 0: 0'0 0 0 0 0
Connection:#23 - White
Is there continuity?
NO - Open circuit in White wire.
YES - GO TO STEP 4.
0 2 SENSOR 4P CONNECTOR
(Harness side)
5-17
FUEL SYSTEM (Programmed Fuel Injection)
4. 0 2 Sensor Heater Short Circuit Inspection
Disconnect the test harness.
Check for continuity between the 4P connector
terminal and ground.
Connection: White - Ground
Is there continuity?
YES - Short circuit i n the White wire.
NO - Replace the throttle body/ECM assern-
bly with a n e w one, and inspect again.
5-18
FUEL SYSTEM (Programmed Fuel Injection)
DTC INDEX
The Diagnostic Trouble Codes (DTC) are based upon Malfunction Indicator Lamp (MIL) codes and are displayed as
hyphenated numbers. The digits in front of the hyphen are equal to an MIL code and indicate the Function Failure. The
digit behind the hyphen details the symptom. For example, in the case of the TP sensor, the ECM stores two levels of
information, a function failure and a detail of the symptom:
(08 - 1) = TP sensor voltage - lowerthan the specified value
or
(08 - 2) = TP sensor voltage - higher than the specified value.
The MAP, ECT, TP and IAT sensor can be mean diagnosis according to the sensor output voltage value.
If the failure occurs, the ECM determines the failure function, the output voltage is high or low compared to the stan-
dard voltage, then read out the DTC to the HDS pocket tester.
For example:
- If the input voltage line (A) on the MAP sensor is opened, the ECM detects the output voltage is about 5 V, then the
DTC 1-2 (MAP sensor circuit high voltage) will be read out.
- If the input voltage line (B)on the TP sensor is opened, the ECM detects the output voltage is 0 V, then the DTC 8-1 (TP
sensor circuit low voltage) will be read out.
-
5v
MAP SENSOR -t 5 v TP SENSOR
5v
1
I,
OUTPUT VOLTAGE
- OUTPUT VOLTAGE
ECT SENSOR
n e OUTPUT VOLTAGE
IAT SENSOR
b
t5v
OUTPUT VOLTAGE
FUEL SYSTEM (Programmed Fuel Injection)
Refer
DTC Function Failure Causes Symptoms to
Page
ECM power/ Open circuit at the power input Engine does not start 5-48
ground circuits wire of the ECM MIL does not blink
malfunction Open circuit in engine stop relay
related wires
Faulty engine stop relay
Open circuit in bank angle sensor
related circuit
Faulty bank angle sensor
Blown sub-fuse 10 A (IGN, Al,
START, FUEL PUMP)
MIL circuit Faulty ECM Engine operates nor- -
malfunction Open or short circuit in the MIL ma Ily
wire MIL does not blink
Data link circuit Short circuit in the data link con- Engine operates nor- -
malfunction nector terminals mally
Short circuit in the data link con- MIL stays lit
nector wire
~.
Faulty ECM
MAP sensor Faulty MAP sensor (in the ECM) Engine operates nor- 5-22
_circuit
~____ l o_w_voltage
_- mally
MAP sensor Faulty MAP sensor (in the ECM) Engine operates nor- 5-22
circuit high mally
~
voltage
7- 1 ECT sensor circuit Short circuit i n the ECT sensor Hard start at a l o w tem- 5-23
l o w voltage wire perature (ECM controls
Faulty ECT sensor using preset value; cool-
ant temperature: 90 "C/
______
194 OF)
7-2 ECT sensor circuit Loose or poorly connected ECT Hard start at a l o w tem- 5-24
high voltage sensor connector perature (ECM controls
Open circuit i n the ECT sensor wire using preset value; cool-
Faulty ECT sensor ant temperature: 90 "C/
194 OF)
8- 1 TP sensor circuit Faulty TP sensor (in the ECM) Poor engine response 5-25
l o w voltage when operating the
throttle quickly (ECM
controls using preset
value; throttle opening:
~
0")
8-2 TP sensor circuit Faulty TP sensor (in the ECM) Poor engine response 5-25
high voltage when operating the
throttle quickly (ECM
controls using preset
value; throttle opening:
0)
9-1 IAT sensor circuit Faulty IAT sensor (in the ECM) Engine operates nor- 5-25
l o w voltage mally (ECM controls
using preset value;
intake air temperature:
25 "GI77 OF)
9-2 IAT sensor circuit Faulty IAT sensor (in the ECM) Engine operates nor- 5-25
high voltage mally (ECM controls
using preset value;
intake air temperature:
25 "CI77 OF)
12-1 Fuel injector Loose or poorly connected injector Engine does not start 5-26
circuit connector
malfunction Open or short circuit i n the injector
wire
Faulty injector
21-1 sensor circuit
0 2 Loose or poorly connected 0 2 sen- Engine operates nor- 5-28
malfunction sor connector mally
Open or short circuit in the 02 sen-
sor wire
Faulty 0 2 sensor
5-20
FUEL SYSTEM (Programmed Fuel Injection)
Refer
DTC Function Failure Causes Symptoms to
Page
____
23-1 sensor heater
0 2 Loose or poorly connected 0 2 sen- Engine operates nor- 5-29
malfunction sor connector mally
Open or short circuit in the 0 2 sen-
sor heater wire
Faulty 0 2 sensor
________ ~ -___
29-1 IAC valve circuit Faulty IAC valve (in the ECM) Engine operates nor- 5-30
malfunction mallv
33-2 ECM E2-PROM Faulty ECM Engine operates nor- 5-30
malfunction mally
FUEL SYSTEM (Programmed Fuel Injection)
DTC TROUBLESHOOTING
DTC 1-1 (MAP SENSOR LOW
VOLTAGE)
1. Recheck DTC
Erase the self-diagnostic memory to reset the
ECM (page 5-8).
Start the engine and let it idle.
Stop the engine.
Turn the ignition switch to ON and check the
MAP sensor with the HDS.
Is the DTC I - I indicated?
NO - Temporarily failure; the system is nor-
mal.
YES - Replace the throttle body/ECM assern-
bly with a new one, and inspect again.
5-22
FUEL SYSTEM (Proarammed Fuel Iniection)
DTC 7-1 (ECT SENSOR LOW
VOLTAGE)
1. ECT Sensor System Inspection
Turn the ignition switch to ON.
Check the ECT sensor with the HDS.
Is about 0 Vindicated?
NO - Temporarily failure; the system is nor-
mal.
YES - GO TO STEP 2.
2. ECT Sensor Inspection
Remove the luggage box (page 2-5).
Turn the ignition switch to OFF.
Disconnect the ECT sensor 3P (gray) connector.
Turn the ignition switch to ON.
Check the ECT sensor with the HDS.
Is about 0 V indicated7
NO - GO TO STEP 3.
YES - GO TO STEP 4.
ECT SENSOR I
4. ECT Sensor Short Circuit Inspection
Turn the ignition switch to OFF.
Disconnect the ECM 32P connector by releasing
the lock lever.
Check for continuity between the wire harness
side ECT sensor connector terminal and ground.
Connection: Pinklwhite - Ground
Is there continuity?
YES - Short circuit in P i n W h i t e wire.
NO - Replace the throttle body/ECM assem-
bly with a new one, and inspect again.
5-23
FUEL SYSTEM IProarammed Fuel Iniection)
DTC 7-2 (ECT SENSOR HIGH
VOLTAGE)
NOTE:
Before starting the troubleshooting, check the
ECT sensor 3P connector for loose contacts or
corroded terminals, and recheck the DTC.
1. ECT Sensor System Inspection
Turn the ignition switch to ON.
Check the ECT sensor with the HDS.
Is about 5 Vindicated?
NO - Loose or poorly connected ECT sen-
sor 3P connector.
Temporarily failure; the system is
normal.
YES - GO TO STEP 2.
2. ECT Sensor Inspection
Turn the ignition switch t o OFF.
Disconnect the ECT sensor 3P (gray) connector.
Connect the wire harness side connector termi-
nals with a jumper wire.
Connection: Pinklwhite - Greenlorange
Turn the ignition switch to ON.
Check the ECT sensor with the HDS.
Is about 0 Vindicated?
YES - Faulty ECT sensor.
NO - GO TO STEP 3.
5-25
FUEL SYSTEM (Programmed Fuel Injection)
DTC 12-1 (FUEL INJECTOR)
NOTE:
Before starting the troubleshooting, check the
injector 2P connector for loose contacts or cor-
roded terminals, and recheck the DTC.
1. Injector System Inspection
Erase the self-diagnostic memory to reset the
ECM (page 5-8).
Start the engine and check the injector with the
HDS.
Is the DTC 12-1 indicated?
YES - Loose or poorly connected injector
2P connector.
Temporarily failure; the system is
normal.
NO - GO TO STEP 2.
2. Injector Resistance Inspection
Remove the luggage box (page 2-5).
Turn the ignition switch to OFF.
Disconnect the injector 2P connector.
Measure the resistance between the injector ter-
minals.
Standard: 11.1 - 12.3 R (2OoC/68"F)
Is the resistance within 11.1 - 12.3 0 (20C/
68 O F ) ?
NO - Faulty injector.
YES - GO TO STEP 3.
5-26
FUEL SYSTEM (Proarammed Fuel Iniection)
4. Injector Signal Line Open Circuit Inspection
Turn the ignition switch to OFF.
Disconnect the ECM 32P connector by releasing ECM 32P CONNECTOR
the lock lever.
Check for continuity between the PinWblue wire
terminals of the injector 2P connector and ECM
32P connector.
Is there continuity?
NO - Open circuit in Pink/blue wire.
YES - GO TO STEP 5.
INJECTOR 2P CONNECTOR
5-27
FUEL SYSTEM (Programmed Fuel Injection)
DTC 21-1 ( 0 2 SENSOR)
NOTE:
Before starting the troubleshooting, check the 0 2
sensor 4P connector for loose contacts or cor-
roded terminals, and recheck the DTC.
1. 0 2 Sensor System Inspection
Start the engine and warm it up until the cooling
fan comes on.
Check the 0 2 sensor with the HDS.
Standard: 0.1 - 0.3 V
Is the voltage within the standard value?
YES - Check the fuel supply system (page
5-33).
If the system is normal, GO TO STEP
4.
NO - GO TO STEP 2.
2. 0 2 Sensor Open Circuit Inspection
Turn the ignition switch to OFF.
Disconnect the ECM 32P connector by releasing Green/ ECM 32P CONNECTOR
the lock lever, and the 0 2 sensor 4P (black) con-
nector (page 5-47).
Check each wire for continuity between the ECM
connector and 0 2 sensor connector.
Connection: Black/orange - Black/orange
Greenlorange - Greedorange
Is there continuity?
NO - Open circuit in the Blacklorange or
Greenlorange wire. 0 2 SENSOR 4P
CON NECTO R
YES - GO TO STEP 3.
5-28
FUEL SYSTEM (Proarammed Fuel Iniection)
4. Recheck DTC
Replace the 0 2 sensor with a known-good one
(page 5-47).
Connect the ECM 32P connector.
Erase the self-diagnostic memory to reset the
ECM (page 5-8).
Start the engine and warm it up until the cooling
fan comes on.
Check the 0 2 sensor with the HDS.
Is the DTC 21-1 indicated?
NO - Faulty original 0 2 sensor.
YES - Replace the throttle body/ECM assem-
bly with a new one, and inspect again.
5-29
FUEL SYSTEM (Programmed Fuel Injection)
3. 0 2 Sensor Heater Open circuit Inspection
Turn the ignition switch to OFF.
Disconnect the ECM 32P connector by releasing
the lock lever. ECM 32P CONNECTOR
Check for continuity between the White termi-
nals of the 0 2 sensor 4P connector and ECM 32P
connector.
Is there continuity?
NO - Open circuit in White wire.
YES - GO TO STEP 4. White
0 2 SENSOR 4P CONNECTOR
(Harness side)
Cleanaroundthe 4. Release the feed hose from the clip on the fuel
quick-connect fit-
ting before discon-
necting the hose,
pump retaining plate.
Take the rubber seal off of the hose joint. I RUBBER
SEAL HOSE JOINT
Prevent the remain- 5. Place a shop towel over the quick-connect fitting.
ing fuelin the hose Hold the connector with one hand and press CONNECTOR
from flowing out down the retainer tabs with the other hand, then
with a shop towel. pull the connector off.
NOTE:
Be careful not t o damage the joint retainer or
other parts. Do not use tools.
If the connector does not move, keep the retainer
tabs pressed down, and alternately pull and push
the connector until it comes off easily.
R ETA1N E R
TABS
5-31
FUEL SYSTEM (Programmed Fuel Injection)
6. To prevent damage and keep foreign material
out, cover the hose and joint ends with plastic
bags.
INSTALLATION
NOTE:
Always replace the retainer with a new one when
the feed hose is disconnected.
Check the hose joint contact area for dirt, and clean
if necessary. CONNECTOR
Make sure the rubber seal is i n good condition and
replace it if necessary.
Install the rubber seal onto the hose joint properly
as shown.
Insert a new retainer into the connector by aligning
the retainer pawls with the connector grooves.
Do not twist the Press the connector onto the hose joint until both
feedhose retainer pawls lock w i th a clicking sound.
NOTE:
If it is hard t o connect, put a small amount of
engine oil o n the hose joint end.
Make sure the connection is secure and the pawls
are firmly locked into place.
5-32
FUEL SYSTEM (Programmed Fuel Injection)
FUEL PRESSURE INSPECTION
Remove the luggage box (page 2-5).
Remove the hose clamp bolt.
Disconnect the fuel feed hose from the fuel pump
after relieving the fuel pressure (page 5-31).
TOOLS:
Fuel pressure gauge 07406-0040003
Pressure gauge manifold 07ZAJ-S5A0110
Pressuregauge hose 07ZAJ-S5A0120
Connect the fuel pump 5P connector.
Start the engine and let it idle, and read the fuel
pressure.
STANDARD: 294 kPa (3.0 kgf/cm2, 43 psi)
If the fuel pressure is higher than the specified pres-
sure, replace the fuel pump.
If the fuel pressure is lower than the specified pres-
sure, inspect the following:
- fuel line leaking
- fuel p u mp (page 5-33)
Remove the pressure gauge, manifold and hose.
Install the feed hose clamp and tighten the bolt.
Connect the fuel feed hose (page 5-32).
Br own
f-
)R Front +
5-33
FUEL SYSTEM (Proqrammed Fuel Injection)
Connect an appropriate fuel hose t o the hose joint
of the fuel pump.
Place the hose end into the an approved gasoline
container.
Turn the ignition switch to ON, let the fuel flow into
the container for 10 seconds and turn the ignition
switch t o OFF.
Measure the amount of fuel flow.
FUEL PUMP FLOW CAPACITY
22 cm3 (0.7 US oz,0.8 Imp o z ) minimum/
10 seconds
If the fuel flow is less than the specified capacity,
replace the fuel pump (page 5-35).
If the fuel flow is normal, inspect the fuel pump sys-
tem (page 5-35).
Connect the fuel feed hose (page 5-32).
install the removed parts in the reverse order of
removal.
5-34
FUEL SYSTEM (Programmed Fuel Injection)
FUEL PUMP
SYSTEM INSPECTION
Turn the ignition switch to ON and confirm that the
fuel pump operates for a few seconds.
If the fuel pump does not operate, inspect as fol-
lows:
Remove the luggage box (page 2-5).
Disconnect the fuel pump 5P (white) connector.
Measure the voltage between the Brown wire termi-
nal (+) and Green wire terminal (-1 of the 5P connec-
tor.
There should be battery voltage for few seconds
with the ignition switch turned to ON.
If there is voltage, check the fuel flow (page 5-33).
If there is no voltage, check the related wires as
follows.
Check for continuity between the Green wire termi-
nal of the 5P connector and ground.
There should be continuity.
Remove the frame body cover (page 2-51.
Remove the fuel pump relay.
Check for continuity between the Brown wire termi-
nals of the 5P connector and relay connector.
There should be continuity.
If the wires are normal, check the fuel pump relay
and its circuits (page 5-43).
REMOVAL
Disconnect the fuel feed hose from the fuel pump Y
after relieving the fuel pressure (page 5-31).
Remove the following:
- seven nuts
- retaining plate
FUEL SYSTEM (Programmed Fuel Injection)
- fuel pump assembly
- rubberseal
INSTALLATION
Check the mating surfaces (seal contact areas) for
dirt, and clean if necessary.
Apply 1 g o f engine oil t o the inner surface of a new
rubber seal and install it o n to the fuel pump.
Install the fuel p u mp assembly into the fuel tank,
being careful not to damage the float arm.
5-36
FUEL SYSTEM (Programmed Fuel Iniection)
Remove the two mounting bolts and washers, and
release the air cleaner housing from the air cham-
ber.
BAND
THROTTLE BODY
REMOVAL
Remove the following:
- luggage box (page 2-5)
- air cleaner housing (page 5-36)
Release the fuel feed hose from the clamp on the air
chamber.
Disconnect the air supply hose.
5-37
FUEL SYSTEM (Proarammed Fuel Iniection)
Remove the mounting bolt.
Loosen the connecting tube band screw (chamber
side) and remove the air chamber.
INSTALLATION
NOTE:
Route the hoses and cable properly (page 1-17).
The insulator is Install the insulator onto the throttle body by align-
installed with the ing the groove with the lug.
"THROT BODY"
side facing the
throttle body.
5-39
FUEL SYSTEM (Programmed Fuel Injection)
Install the throttle body/ECM assembly onto the
intake manifold by aligning the insulator groove
with the lug.
Tighten the band bolts alternately until the band
ends are contacted to the collars.
5-40
FUEL SYSTEM (Proarammed Fuel Iniection)
Connect the air supply hose to the chamber.
Secure the fuel feed hose with the clamp.
Adjust the throttle grip free play (page 3-41.
Install the following:
- air cleaner housing (page 5-36)
- luggage box (page 2-5)
INJECTOR
5-41
FUEL SYSTEM (Proarammed Fuel Iniection)
Carefully pull up the injector out of the intake mani-
fold to remove it with the feed hose.
Remove the setting plate.
Remove the injector from the hose joint.
Remove the O-rings.
INSTALLATION
Coat a new O-rings with engine oil.
Install the O-rings into the injector grooves in posi-
tion as shown, being careful not to damage them.
Install the injector into the hose joint by aligning the
tab with the hole.
Install the stay and two bolts onto the hose joint,
and tighten them securely.
Install the hose clamp and tighten the bolt.
5-42 -~
FUEL SYSTEM (Programmed Fuel Injection)
Connect the injector 2P connector and ECM 32P
connector.
Connect the fuel feed hose (page 5-32).
SIGNAL LINE
Check for continuity between the Brown/black wire
terminal of the relay connector and ground. Brownlblack
\
There should be no continuity with the ignition
switch turned to OFF.
If there is continuity, check for a short circuit in
the Brown/black wire between the relay connec-
tor and engine control module (ECM).
Turn the ignition switch to ON.
There should be continuity for a few seconds.
If there is no continuity, check for an open circuit
i n the Brownlblack wire between the relay con-
nector and ECM.
5-43
FUEL SYSTEM (Programmed Fuel Injection)
FUNCTION TEST
Connect an ohmmeter to the switching side relay
terminals. BATTERY
I I I T
CONNECTION: Black/white #2 - Brown
Connect a 12-V battery to the signal line side relay
terminals.
CONNECTION: Black/white #I (+) - Brownlblack (-)
There should be continuity while the battery is con-
nected to the relay terminals and there should be no
continuity when the battery is disconnected.
SIGNAL LINE
Check for continuity between the Redlorange wire
terminal of the relay connector and ground.
There should be no continuity with the ignition
switch turned to OFF.
If there is continuity, check for a short circuit in
the Red/orange wire between the relay connector
and bank angle sensor.
Turn the ignition switch to ON.
9
There should be continuity for a few seconds. Redlorange
If there is no continuity, check for an open circuit
in the Redlorange wire between the relay con-
nector and bank angle sensor.
-
&r
--
I k
CONNECTION: Black #I(+) - Red/orange (-1 Black #
' (+) orange (-1
There should be continuity while the battery is con-
nected to the relay terminals and there should be no
continuity when the battery is disconnected. 1 Black#2
k
\
BlacWwhite
0 -
-
(Viewed from the harness side)
5-45
FUEL SYSTEM (Proarammed Fuel Iniection)
3. Turn the ignition switch to OFF.
Remove the bank angle sensor (page 5-46).
Green Redlorange
Connect the 3P connector.
4. Measure the voltage between the Redlorange
wire terminal (+) and Green wire terminal (-) of
the 3P connector.
Place the bank angle sensor horizontal and turn
the ignition switch to ON.
There should be 0 - 1 V.
Angle the sensor approximately 60 degrees to
the left or right with the ignition switch to ON.
There should be battery voltage.
(Viewed from the harness side)
NOTE:
If you repeat this test, first turn the ignition
switch to OFF, then back to ON before you try the
test again.
REMOVAL/INSTALLATION
Remove the frame body cover (page 2-5).
Remove the three bolts and frame bracket.
Take care not to Release the connectors and wires from guides t o
damage the sensor remove the sensor cover.
wire.
Disconnect the 0 2 sensor 4P connector.
5-47
FUEL SYSTEM (Programmed Fuel Injection)
ENGINE COOLANT TEMPERATURE
(ECT) SENSOR
REMOVAL/ INSTALLATION
Drain the coolant (page 6-8).
Remove the luggage box (page 2-5).
Disconnect the ECT sensor 3P (gray) connector.
Remove the ECT sensor and sealing washer.
Alwaysreplace the Install the ECT sensor in the reverse order of
seahng washer with removal.
a new one.
TORQUE: 23 N - m (2.3 kgf.m, 17 Ibf.ft)
Fill and bleed the cooling system (page 6-7).
5-48
FUEL SYSTEM (Programmed Fuel Iniection)
ENGINE IDLE SPEED
INSPECTlON
NOTE:
Make sure the malfunction indicator lamp (MIL)
does not indicate any failure codes before
inspecting the engine idle speed.
Use a tachometer with graduations of 100 min-
(rpm) or smaller that will accurately indicate a
100 min (rpm) change.
Remove the maintenance lid (page 2-4).
Start the engine and w a rm it u p t o normal operating
temperature.
Stop the engine and connect a tachometer accord-
ing t o the tachometer manufacturers instructions.
Start the engine and let it idle. Check the idle speed.
ENGINE IDLE SPEED: 1,500 k 100 min (rpm)
If the engine hard to start or the idle speed is out of
specification, refer to the Troubleshooting (page 5-
4).
IDLE AIR CONTROL (IAC) VALVE
The IAC valve is incorporated i n the throttle body/
ECM assembly which it operating by the step motor.
When the ignition switch is turned t o ON, the IAC
valve operates for a few seconds.
Check the step motor operating (beep) sound with
the ignition switch turned t o ON.
5-49
FUEL SYSTEM (Proarammed Fuel Iniection)
Start the engine and open the throttle slightly to be
certain that air is sucked in through the air supply PAIR SOLENOID AIR SUPPLY
hose. VALVE HOSE
If the air is not drawn in, check the air supply hoses
for clogs and the PAIR solenoid valve (page 5-511.
I VALVE (Output)
5-50
-
FUEL SYSTEM (Proarammed Fuel Iniection)
PAIR CHECK VALVE INSPECTION
Remove the maintenance lid (page 2-4).
Remove the following:
- t w o bolts
- check valve cover
- PAIR check valve
5-51
FUEL SYSTEM (Programmed Fuel Injection)
Remove the following fro m the PAIR solenoid valve:
- solenoid valve stay
- air supply hoses
Installation is in the reverse order of removal.
FUEL TANK
R EMOVAL/ INSTALLATION
Remove the frame body cover (page 2-5).
Disconnect the fuel feed hose from the fuel pump
after relieving the fuel pressure (page 5-31 1.
Remove th e following:
- wire clip (securing the fuel drain hose)
- wire band (securing the fuel pump wire)
- t w o 8 -m m bolts and frame cross-bracket
- four 6-mm bolts
- fuel tank
Installation is in the reverse order of removal.
5-52
6. COOLING SYSTEM
6-I
COOLING SYSTEM
SYSTEM FLOW PATTERN
SIPHON HOSE
TANK
WATER PUMP
6-2
COOLING SYSTEM
SERVICE INFORMATION
GENERAL
Removing the radiator cap while the engine is hot can allow the coolant to spray out, seriously scalding you.
Always let the engine and radiator cool down before removing the radiator cap. I
I NOTICE I
Using coolant with silicate inhibitors may cause premature wear of water pump seals or blockage of radiator passages.
Using tap water may cause engine damage.
Add coolant at the reserve tank. Do not remove the radiator cap except to refill or drain the system.
All cooling system services can be done with the engine in the frame.
Avoid spilling coolant on painted surfaces.
After servicing the system, check for leaks with a cooling system tester.
For coolant temperature gaugelECT sensor information, see page 20-11.
SPEC1FlCATlONS
ITEM SPECIFICAT~ONS
Coolant capacity Radiator and engine 0.95 liter (1.00US qt, 0.84 Imp qt)
Reserve tank 0.4 liter (0.42US qt, 0.35 Imp qt)
TORQUE VALUES
Water pump impeller 12 N.m (1.2kgf.m, 9 Ibf.ft) Left-hand threads
Cooling fan motor mounting bolt 8.4 N.m (0.86kgf.m, 6.2Ibf.ft)
6-3
COOLING SYSTEM
TOOLS
Bearing remover head, 14 mm Bearing remover shaft Remover weight
07WMC-KFG0100 07936-KC10100 07741-0010201
6-4
COOLING SYSTEM
TROUBLESHOOTING
Engine temperature too high
Insufficient coolant
Air i n system
Faulty radiator cap
Thermostat stuck closed
Passage blocked in radiator, hoses or water jacket
Faulty water pump
Faulty cooling fan motor or fan motor circuit
Faulty coolant temperature gauge circuit or ECT sensor (page 20-11)
Engine temperature too low
Thermostat stuck open
Faulty cooling fan motor or fan motor circuit
Faulty coolant temperature gauge circuit or ECT sensor (page 20-11)
Coolant leaks
Faulty water pump mechanical seal
Deteriorated O-rings
Damaged or deteriorated seals and gaskets
Faulty radiator cap
Loose hose connection or clamp
Damaged or deteriorated hoses
6-5
COOLING SYSTEM
SYSTEM TESTING
COOLANT (HYDROMETER TEST)
The engine must be Remove the front upper cover (page 2-81,
cool before remov- Remove the radiator cap.
ing the radiator cap.
6-6
COOLING SYSTEM
RADIATOR CAPISYSTEM PRESSURE
INSPECTION
Remove the radiator cap (page 6-6).
Wet the sealing surfaces of the cap, then install the
cap onto tester.
Pressurize the radiator cap using the tester.
Replace the radiator cap if it does not hold pressure,
or if relief pressure is too high or too low. It must
hold the specified pressure for a t least 6 seconds.
RADIATOR CAP RELIEF PRESSURE:
-
108 - 137 kPa (1.1 1.4 kgf/cm2, 16 - 20 psi)
C I
COOLANT REPLACEMENT
PREPARATION
I NOTICE I
Using coolant with silicate corrosion inhibitors may
cause premature wear of water pump seals or
blockage of radiator passages. Using tap water may
cause engine damage.
NOTE:
The effectiveness of coolant decreases with the
accumulation of rust or if there is a change in the
mixing proportion during usage. Therefore, for
best performance change the coolant regularly
as specified i n the maintenance schedule.
Mix only distilled, low mineral water with the rec-
ommended antifreeze.
RECOMMENDED ANTIFREEZE: SOLUTION) OR DISTILLED
High quality ethylene glycol antifreeze containing
corrosion protection inhibitors
RECOMMENDED MIXTURE:
1:l (distilled water and the recommended
antifreeze)
6-7
COOLING SYSTEM
REPLACEMENT/AIR BLEEDING
The engme must be Place the scooter o n its center stand o n a level sur-
cool before serwc- face.
Ing the coolng -Remove the front upper cover (page 2-8).
tern.
Drain the coolant from the system by removing the
drain bolt and sealing washer, and the radiator cap.
Reinstall the drain bolt with a new sealing washer
securely.
6-8
COOLING SYSTEM
Fill the reserve tank to the upper level line and
install the tank cap.
Bleed air from the system as follows:
1. Start the engine and let it idle for 2 - 3 minutes.
2. Snap the throttle 3 - 4 times t o bleed air from the
system.
3. Stop the engine and add coolant u p t o the filler
neck.
4. Install the radiator cap.
Install the front upper cover (page 2-8).
THERMOSTAT
REMOVALANSTALLATION
Drain the coolant f r o m the system (page 6-8).
Remove the maintenance lid (page 2-4).
Remove the following:
- spark plug cap
- wire band (from the stay)
- thermostat
Installation is in the reverse order of removal.
NOTE:
The thermostat is installed with the bleed hole
facing up.
Fill and bleed the cooling system (page 6-7).
6-9
COOLING SYSTEM
INSPECTION
Visually inspect the thermostat for damage and the
rubber seal for deterioration.
Replace the thermostat if the valve stays open at
room temperature.
Do not let the ther- Heat a container of water with an electric heating
mostat or ther- element for 5 minutes.
mometer touch the Suspend the thermostat in heated water to check its
pan, or you will get operation.
a false reading.
THERMOSTAT BEGINS TO OPEN:
80 - 84 "C (176 - 183 OF)
VALVE LIFT:
4.5 mm (0.18 in) minimum at 95 "C (203 OF)
Replace the thermostat if the valve opens at a tem-
perature other than those specified.
WATER PUMP
MECHANICAL SEAL INSPECTION
Inspect the telltale hole for signs of coolant leakage.
If there is leakage, the water p u m p mechanical seal I WATER PUMP
is defective and the mechanical should be replaced.
TOOLS:
Bearing remover head, 14 m m 07WMC-KFG0100
Remover shaft, 15 mm 07936-KC10100
Remover weight 07741-0010201
6-11
Drive a new mechanical seal.
TOOL:
Mechanical seal driver 07PMD-KBP0100
Install each snap Install the bearing onto the pump shaft and secure it
ring with the cham- with the snap ring.
fered
edge Degrease the pump shaft thoroughly and apply
facing the bearing.
molybdenum oil solution to the shaft journal.
I NOTICE I
Do not apply molybdenum oil solution to the
mechanical seal sliding area.
I
Connect a 12-V battery positive (+) terminal to the
relay Blue # I wire terminal and negative (-) terminal BATTERY
to the Black/blue wire terminal.
There should be continuity between the Blue #2 and
Black wire terminals while the battery is connected,
and n o continuity when the battery is disconnected.
Black/
blue (-1
I I IJ
-+Blue #2
-\
Black
6-13
COOLING SYSTEM
SYSTEM INSPECTION
Fan motor does not stop
Check the fan motor relay (page 6-13)
If the relay is faulty, replace the fan motor relay.
If the relay function is normal, check as follows.
Remove the luggage box (page 2-5).
Install the fan motor relay.
Disconnect the engine control module (ECM) 32P
connector.
Turn the ignition switch to O N and check the fan
motor.
If the fan motor does not stop, check for a short
circuit in the BlacUblue wire between the fan
motor relay and ECM.
If the fan motor stops, replace the throttle body/
ECM assembly.
i
Green (-) wire terminals of the wire harness side Black
motor 2P connector.
There should be battery voltage with the ignition
switch turned to ON.
If there is no voltage, check for an open circuit in
the Black and Green wires.
If there is battery voltage, check as follows.
REMOVALANSTALLATION
Remove the following:
- front upper cover (page 2-8)
- front lower cover right side fasteners (page 2-9) 2P CONNECTOR
- front fender (page 2-8)
Release the fan motor wire from the three wire
guides located on the body covers and air guide
plate.
Disconnect the fan motor 2P (white) connector.
GUIDES
6-15
COOLING SYSTEM
Disconnect the siphon hose from the radiator and
release it from the clamp.
Be careful not to Remove the two mounting bolts and clamp, and the
damage the radiator fan motor assembly.
fins.
Route the motor Installation is in the reverse order of removal.
wire properly
TORQUE: 8.4 N.m (0.86 kgf.m, 6.2 IbfW
(page 1-17),
6-16
COOLING SYSTEM
RADIATOR
R E MOVA LANSTALLATION
Remove the following:
- reserve tank (page 6-16)
- fan motor (page 6-15)
Drain the coolant from the system (page 6-8).
Remove the following:
- four screws
- front air guide plate
6-17
7. ENGINE REMOVALANSTALLATION
7- 1
ENGINE REMOVAL/INSTALLATION
SYSTEM COMPONENTS
7-2
ENGINE REMOVAL/INSTALLATION
SERVICE INFORMATION
GENERAL
When removing/installing the engine, tape the frame around the engine beforehand for frame orotection.
A hoist or equivalent is required to support the frame when removing and installing
-
the engine. Support the engine
using a jack or other adjustable support to ease engine mounting bolt removal.
The crankcase and crankshaft require engine removal for service. Other components can be serviced with the engine
installed in the frame.
ITEM SPECIFICATIONS
Engine dry weight 31.0 kg (68.3 Ibs)
Engine oil capacity After draining 0.9 liter (1.0 US qt, 0.8 Imp qt)
After disassembly 1.0 liter (1.1 US qt, 0.9 Imp qt)
Coolant capacity (radiator and engine) 0.95 liter (1.00 US qt, 0.84 Imp qt)
TORQUE VALUES
Engine hanger bracket bolt (frame side) 49 N.m (5.0 kgf.m, 36 Ibf.ft)
Engine mounting nut (engine side) 49 N - m (5.0 kgf.m, 36 IbfW U-nut.
7-3
ENGINE REMOVAL/INSTALLATION
ENGINE REMOVAL
Drain the engine oil (page 3-9).
Drain the coolant (page 6-8).
Remove the following:
- frame body cover (page 2-5)
- floor lower cover (page 2-8)
- rear fender A (page 2-7)
- mud guard (page 2-14)
- exhaust system (page 2-15)
- throttle body/ECM assembly (page 5-37)
- fuel injector (page 5-41)
Remove the following:
- bolt and fuel feed hose
- wire band (from the engine hanger bracket)
7-4
ENGINE REMOVAL/INSTALLATION
- crankshaft position (CKP) sensor 3P (white) con-
nector
- engine coolant temperature (ECT) sensor 3P
(gray) connector
- wire bands (from the wire retaining stay)
- wires (main harness, alternator and CKP sensor;
fro m the wire guide)
7-5
ENGINE REMOVAL/INSTALLATION
- brake cable clamp bolt
- adjusting nut
- joint pin
- brake arm spring
- brake cable (from the cable holder)
7-6
ENGINE REMOVAL/INSTALLATION
Remove the engine mounting nuts, bolt and engine
hanger bracket.
ENGINE INSTALLATION
NOTE:
Route the wires, hoses and cables properly (page
1-17).
Install the hanger bracket onto the engine with the
rubber stoppers facing to the right by inserting the
mounting bolt from the left side.
Install the mounting nut. Set the angle of the
bracket as shown and temporarily tighten the nut.
7-7
ENGINE REMOVALANSTALLATION
Thelack he/ght Carefully place the frame over the hanger bracket
must beadlusted to on the engine. Align the bracket bolt holes in the
reheve stress for bracket and frame, using a jack or other adjustable
ease of bolt support.
insta//at/on. Install the bracket bolts.
27
8-2
CYLINDER HEADNALVES
SERVICE INFORMATION
GENERAL
This section covers service of the rocker arms, camshaft, valves and cylinder head. These parts can be serviced with the
engine installed in the frame.
When disassembling, mark and store the disassembled parts to ensure that they are reinstalled in their original loca-
tions.
Clean all disassembled parts with cleaning solvent and dry them by blowing them off with compressed air before
inspection.
The rocker arm and camshaft lubricating oil is fed through the oil passages in the cylinder head and head cover. Clean
the oil passages before assembling.
Be careful not to damage the mating surfaces when removing the cylinder head cover and cylinder head.
SPECIFICATIONS
Unit: mm (in)
TORQUE VALUES
Camshaft holder nut 27 N.m (2.8 kgf.m, 20 1bf.ft) Apply engine oil to the threads.
Cam sprocket bolt 9 N.m (0.9 kgf.m, 6.6 Ibf.ft)
Timing hole cap 6 N.m (0.6 kgf.m, 4.4 Ibf.ft)
Cylinder head cover bolt 12 N - m (1.2 kgfem, 9 1bf.e)
8-3
CYLINDER HEADNALVES
TOOLS
~
Cam chain tensioner holder Valve spring compressor Valve guide reamer, 5.0 mm
070M G-0010100 07757-0010000 07984-MA60001
Flat cutter, 25 m m (32" EX) Interior cutter, 26 mm (60" IN) Interior cutter, 22 m m (60" EX)
07780-0012000 07780-0014500 07780-0014202
8-4
CYLINDER HEADNALVES
For the SH150:
Seat cutter, 33 mm (45"IN) Seat cutter, 24 mm (45"EX) Flat cutter, 33 mm (32"IN)
07780-0010800 07780-0010600 07780-0012900
8-5
CYLINDER HEADIVALVES
TROUBLESHOOTING
0 Engine top-end problems usually affect engine performance. These problem can be diagnosed by a compression test,
or by tracing top-end noise with a sounding rod or stethoscope.
If the performance is poor at low speeds, check for white smoke in the crankcase breather hose. If the hose is smoky,
check for a seized piston ring (page 9-21.
Compression too low, hard starting or poor performance at low speed
Valves:
- Incorrect valve adjustment
- Burned or bent valve
- Incorrect valve timing
- Broken valve spring
- Uneven valve seating
- Valve stuck open
Cylinder head:
- Leaking or damaged head gasket
- Warped or cracked cylinder head
- Loose spark plug
Cylinder/piston problem (page 9-41.
Compression too high, overheating or knocking
Excessive carbon build-up on piston head or on combustion chamber
Excessive smoke
Worn valve stem or valve guide
Damaged stem seal
Cylinder/piston problem (page 9-4)
Excessive noise
Incorrect valve adjustment
Sticking valve or broken valve spring
Excessive worn valve seat
Worn or damaged camshaft
Worn cam chain
Worn cam sprocket teeth
Worn rocker arm and/or shaft
Worn or damaged cam chain tensioner
Cylinder/piston problem (page 9-41.
Rough idle
Low cylinder compression
8-6
CYLINDER HEADIVALVES
CYLINDER COMPRESSION TEST
Remove the maintenance lid (page 2-4).
Warm up the engine to normal operating tempera-
ture.
Stop the engine and remove the spark plug cap and
spark plug (page 3-6).
Install a compression gauge into the spark plug
hole.
To avoid discharging Open the throttle all the way and crank the engine
the battery, do not with the starter motor until the gauge reading stops
operate the starter rising. The maximum reading is usually reached
motor for more within 4 - 7 seconds.
than 7 seconds.
COMPRESSION PRESSURE:
1,373 kPa (14.0 kg/cm2, 199 psi) at 600 min- (rpm)
Low compression can be caused by:
- blown cylinder head gasket
- improper valve adjustment
- valve leakage
- worn piston ring or cylinder
High compression can be caused by:
- carbon deposits in the combustion chamber or
o n the piston head
8-7
CYLINDER HEADNALVES
CAMSHAFT/ROCKER ARM REMOVAL
CAMSHAFT HOLDER REMOVAL
Remove the following:
- cylinder head cover (page 8-7)
- belt case air cleaner housing (page 3-12)
Drain the coolant (page 6-8).
Release the crankcase breather hose and the throt-
tle cable out of each clamp.
8-9
CYLINDER HEADIVALVES
- snap ring
- camshaft
INSPECTION
NOTE:
For cam chain tensioner lifter inspection, see
page 8-15.
ROCKET ARMISHAFT
Inspect the sliding surfaces of the rocker arms and
shafts for wear or damage.
Check the oil holes for clogs.
Measure the O.D. of each shaft at the rocker arm
sliding areas.
SERVICE LIMIT: 9.937 mm (0.3912 in)
Measure the I.D. of each rocker arm.
SERVICE LIMIT: 10.05 mm (0.396 in)
Calculate the rocker arm-to-shaft clearance.
SERVICE LIMIT: 0.063 mm (0.0025 in)
CAMSHAFT
Check each bearing t o turn the outer race. The bear-
ing should turn smoothly and quietly.
Check the cam lobes for scoring, scratches or evi-
dence of insufficient lubrication.
Check the cam sprocket for wear or damage.
8-10
CYLINDER HEAD/VALVES
_____ ~ ~ _ _ _ ~
8-1I
CYLINDER HEADNALVES
- two bolts and PAIR solenoid valve stay
- thermostat housing assembly (from the cylinder
head)
- O-ring
- gasket
- cam chain guide
- two dowel pins
CYLINDER HEADNALVES
CYLINDER HEAD DISASSEMBLY
Remove the cylinder head (page 8-11).
Toprevent loss of Remove the valve spring cotters using the spring
tension, do not compressor.
compress the valve
springs more than
TOOL:
necessary, Valve spring compressor 07757-0010000
INSPECTION
CYLINDER HEAD
Be careful not to Remove the carbon deposits from the combustion
damage the valve chamber.
seat and gasket
Check the spark plug hole and valve areas for
surfaces.
cracks.
VALVENALVE GUIDE
Check that the valve moves smoothly in the guide.
Check the valves for bending, burning or abnormal
wear.
Measure each valve stem O.D. and record it.
SERVICE LIMIT: IN/EX: 4.90 mm (0.193 in)
The valve cannot be Remove the valve and inspect the valve seat face.
ground. / f the valve The valve seat contact should be within the speci-
face Is burned or fied width and even all around the circumference. I
badly worn or rf it
contacts the seat
STANDARD: 0.90 - 1.10 mm (0.035 - 0.043 in)
unevenly, replace
the valve.
SERVICE LIMIT: 1.8 mm (0.07 in) .c
If the seat width is not within specification, reface
the valve seat. f
SEAT WIDTH
CYLINDER HEADIVALVES
Inspect the valve seat face for:
Damaged face:
- Replace the valve and reface the valve seat.
Uneven seat width:
- Replace the valve and reface the valve seat.
REFAClNG
Follow the refacing Valve seat cutterdgrinders or equivalent valve seat
manufacturer's refacing equipment are recommended t o correct
operating instruc- worn valve seats.
tions
1 I
CONTACT TOO LOW
L
32"
OLD SEAT
I I
CYLINDER HEADNALVES
Reface the seat Use a 45" seat cutter to remove any roughness or
with a 45"cutter irregularities from the seat.
whenever a valve
g u d e I S replaced. TOOLS:
ROUGHNESS
SH125:
Seat cutter, 27.5 mm (45" IN) 07780-0010200
Seat cutter, 24 mm (45" EX) 07780-0010600
Cutter holder, 5.0 mm 07781-0010400
SH150:
Seat cutter, 33 mm (45" IN) 07780-0010800
Seat cutter, 24 mm (45" EX) 07780-0010600
Cutter holder, 5.5 mm 07781-0010101
I
I ~~ ~
8-18
Lubricate the valve stem sliding surface with engine
oil.
Insert the valve into the guide while turning it
slowly to avoid damaging to the stem seal.
Toprevent loss of Install the valve spring cotters using the valve
tension, do not spring compressor.
compress the valve
springs more than
necessary. Valve spring compressor 07757-0010000
Supportthecyh- Tap the valve stems gently with two plastic ham-
der head so the mers to seat the cotters firmly.
valve heads wilnot Install the cylinder head (page 8-21).
contact anything
that cause damage.
CYLINDER HEADNALVES
CYLINDER HEAD INSTALLATION
Be carefulnot to Clean the mating surfaces of the cylinder head and
damage the mating cylinder thoroughly.
surfaces. Blow out the oil passages in the cylinder head with
compressed air.
Install the cam chain guide by aligning the bosses
with the grooves in the cylinder.
8-21
CYLINDER HEADNALVES
Install the two bolts and clamp stay in the direction
as shown, and tighten them.
8-22
CYLINDER HEADNALVES
Install the following if the cylinder was removed:
- newgasket
- tensioner lifter
- clamp stay
- two bolts
Do not exchange Apply engine oil to the sliding surface of the rocker
the intake and arm and shaft. Place the rocker arms into the head
exhaustrockerarm cover in the direction as shown, and install the
shafts. rocker arm shafts with the thread ends facing the
sprocket side.
Install each snap ring into the camshaft holder
groove with the chamfered (rolled) edge facing the
rocker arm side.
8-24
CYLINDER HEADNALVES
~ ~ ~~
8-25
CYLINDER HEADNALVES
Cover the cylinder head with a shop towel to pre-
vent sprocket bolt from falling into the crankcase.
Align the bolt holes in the sprocket and camshaft.
Install the sprocket bolts and tighten them while
holding the drive pulley (crankshaft).
TORQUE: 9 N-m (0.9 kgf-m, 6.6 Ibf.ft)
The "UP"markof install the head cover, and the cover bolts with the
the washeris facing special washers by aligning each bolt tip with the
the bolt head. bolt hole in the cylinder head.
9-1
CYLINDER/PISTON
SYSTEM COMPONENTS
i
\
\
\
\,
9-2
CYLINDER/PISTON
SERVICE INFORMATION
GENERAL
This section covers maintenance of the cylinder and piston.
The cylinder and piston can be serviced with the engine installed in the frame.
Be careful not to damage the mating surfaces when removing the cylinder.
Take care not to damage the cylinder wall and piston.
The rocker arm and camshaft lubricating oil is fed through the oil passage (stud bolt hole) in the cylinder. Clean the oil
passage before installing the cylinder.
SPECIFICATIONS
SH125: Unit: mm (in)
ITEM STANDARD ] SERVICE LIMIT
Cylinder I.D. 1 52.400- 52.410(2.0630- 2.0634) I 52.44 (2.065)
Out-of-round - 0.05(0.002)
Taper - 0.05 (0.002)
Warpage - 0.05(0.002)
Piston O.D. at 10 (0.4)
from bottom 52.37- 52.39(2.062- 2.0634) 52.30(2.059)
piston pin, Piston oin hole I.D. 14.002- 14.008(0.5513- 0.5515) 14.02(0.552)
piston ring
TORQUE VALUES
Cylinder stud bolt 9 N.m (0.9kgf.m, 6.6Ibf-ft)
9-3
CY LINDER/PISTON
TROUBLESHOOTING
Compression too low, hard starting or poor performance at low speed
Worn, stuck or broken piston ring
Worn or damaged cylinder and piston
Cylinder headhalve problem (page 8-6)
Compression too high, overheating or knocking
Excessive carbon build-up on piston head or on combustion chamber
Excessive smoke
Worn cylinder, piston or piston ring
Improper installation of piston rings
Scored or scratched piston or cylinder wall
Cylinder headhalve problem (page 8-6)
Abnormal noise
Worn piston pin or piston pin hole
Worn connecting rod small end
Worn cylinder, piston or piston rings
Piston ring stickinglscuffing, bearing damage
Clogged oil gallery or oil strainer screen
Internal oil leak
Use of poor quality engine oil
9-4
CYLlNDER/PISTO N
CYLlNDER/PISTON REMOVAL
CYLINDER REMOVAL
Remove the cylinder head (page 8-8).
Remove the cylinder being careful not to damage
the piston with the stud bolts.
PISTON REMOVAL
Place a clean shop towel over the crankcase to pre-
vent the piston pin clip from falling into the crank-
case.
Remove the piston pin clips with pliers.
Push the piston pin out of the piston and connecting
rod, and remove the piston.
Do not damage the Spread each piston ring and remove it by lifting up
piston ring by at a point opposite the gap.
spreading the ends
too far.
9-5
CYLINDER/PISTON
- ~~ ~~~
Never use a wire Clean carbon deposits from the ring grooves with a
brush, it w / / /scratch ring that will be discarded.
the groove.
CYLINDER/PISTON INSPECTION
CYLINDER
Inspect the cylinder wail for scratches or wear.
Measure the cylinder I.D. a t three levels i n the X and
Y axis. Take the maximum reading to determine the
cylinder wear.
SERVICE LIMITS:
SH125: 52.44 mm (2.065 in)
SH150: 58.04 mm (2.285 in)
Calculate the taper and out-of-round at three levels
in the X and Y axes. Take the maximum reading to
determine both measurements.
SERVICE LIMITS:
Taper: 0.05 mm (0.002 in)
Out-of-round: 0.05 mm (0.002 in)
The cylinder must be rebored and an oversize pis- Y
ton/piston rings fitted if the service limits are
exceeded.
The following oversize pistons/piston rings are
available:
0.25 mm (0.010 in)
0.50 mm (0.020 in)
The piston-to-cylinder clearance for the oversize pis-
ton must be 0.010 - 0.040 mm (0.0004 - 0.0016 in).
9-6
~~
CYLINDER/PISTON
Check the cylinder for warpage with a straight edge
and feeler gauge in the directions shown.
SERVICE LIMITS:
FES125: 52.30 mm (2.059 in)
FESIBO: 57.90 mm (2.280 in)
Calculate the cylinder-to-piston clearance (cylinder
I.D.: page 9-6).
SERVICE LIMIT: 0.10 mm (0.004 in)
9-8
CYLINDER/PISTON
PISTONKYLINDER INSTALLATION
PISTON INSTALLATION
Apply engine oil to the ring grooves.
Be careful not to Carefully install the piston rings into the piston ring
damage the piston grooves with the marks facing up. MARK "R"
and rings. Do not confuse the top and second rings.
To install the oil ring, install the spacer first, then
I MARK "R N
I'
20 mm or more
Placeashop towel Apply engine oil to the piston pin and piston pin
at the opening of hole.
the crankcase to
Install the piston with the "IN" mark facing the intake
prevent the piston
side.
Din c l i ~ sfrom fallina
' into the crankcase. Install the piston pin and new pin clips.
Make sure the piston pin clips are seated
securely.
Do not align the piston pin clip end gap with the
piston cut-out.
CYLINDER INSTALLATION
Be careful not to Clean the mating surfaces of the cylinder and crank-
damage the mating case thoroughly.
surfaces. Blow out the oil passage (stud bolt hole) in the cylin-
der with compressed air.
Install the dowel pins and a new gasket.
9-9
CYLINDER/ PISTON ~~~~ ~
9-10
10. DRIVE AND DRIVEN PULLEYWCLUTCH
36 Ibf.ft)
, 7 I bf.ft)
10-2
DRIVE AND DRIVEN PULLEYSKLUTCH
SERVICE INFORMATION
GENERAL
This section covers maintenance of the drive pulley, driven pulley and clutch.
These services can be done with the engine installed in the frame.
Avoid getting grease and oil on the drive belt and driveldriven pulley faces in order to prevent belt slippage.
Do not apply grease to the weight rollers.
SPECIFICATIONS
ITEM STANDARD SERVICE LIMIT
Drive belt width 22.5 (0.89) 21.5 (0.85)
Movable Bushing I.D. 23.989 - 24.052 (0.9444 - 0.9469) 24.09 (9.484)
drive face Boss O.D. 23.960 - 23.974 (0.9433 - 0.9439) 23.93 (0.942)
Weight roller O.D. 19.92 - 20.08 (0.784 - 0.791) 19.5 (0.77)
Clutch Clutch outer I.D. 125.0 - 125.2 (4.92 - 4.93) 125.5 (4.94)
Lining thickness 4.0 (0.16) 2.0 (0.08)
Driven Dullev . " free lenath
Face smina " 143.3 (5.64) 123.0 (4.84)
Driven face boss O.D. 33.965 - 33.985 (1.3372 - 1.3380) 33.94 (1.376)
Movable driven face I.D. 34.000 - 34.025 (1.3386 - 1.3396) 34.06 (1.341)
TORQUE VALUES
Clutch lock nut 54 N.m (5.5 kgf.m, 40 let.ft)
Clutch outer nut 49 N.m (5.0 kgfm, 36 let31
Drive pulley face nut 59 N.m (6.0 kgf.m, 44 Ibf.ft) Apply engine oil to the threads and seating surface.
Left crankcase cover bolt 10 N.m (1.0 kgfm, 7 Ibf.ft)
Belt case air cleaner housing bolt See page 10-8.
10-3
DRIVE AND DRIVEN PULLEYS/CLUTCH
TOOLS
Universal holder Flywheel holder Clutch spring compressor
07725-0030000 07725-0040000 07LME-GZ40200
10-4
DRIVE AND DRIVEN PULLEYWCLUTCH
TROUBLESHOOTING
Engine starts but scooter won't move
Worn drive belt
Damaged ramp plate
Worn or damaged clutch shoe
Broken driven face spring
Engine stalls or scooter creeps
Broken clutch shoe spring
Poor performance at high speed or lack of power
Worn drive belt
Weak driven face spring
Worn weight rollers
Contaminated pulley faces
10-5
DRIVE AND DRIVEN PULLEYSICLUTCH
LEFT CRANKCASE COVER
REMOVAL
Remove the following:
- floor lower cover (page 2-8)
- air cleaner housing (page 5-36)
- two bolts and belt case air cleaner
- O-ring
BOLTS
- five bolts
- left crankcase cover
DRIVE AND DRIVEN PULLEYSKLUTCH
- rubberseal
- two dowel pins
INSTALLATION
Check the rubber seal and replace it if necessary.
Clean the rubber seal groove i n the left crankcase
cover.
Install the rubber seal onto the left crankcase cover.
Install the two dowel pins into the left crankcase.
Be careful not to Install the left crankcase cover onto the left crank-
damage the rubber case by aligning the holes with the dowel pins.
seal.
Install the left crankcase cover bolts and tighten
them in a crisscross pattern in two or three steps to
the specified torque.
TORQUE: 10 N.m (1.0 kgf-m, 7 Ibf-ft)
Route the rear Install the left passenger footrest and tighten the
brake cable and fuel two bolts.
drain hose properly
(page 1-77).
10-7
DRIVE AND DRIVEN PULLEYSKLUTCH ~ ~~ ~~
Install the belt case air cleaner and tighten the two
bolts.
Take care not to ruin TORQUE: 10 N-m (1.0 kgf-m, 7 Ibf-ft)
the female threads
that were made If the left crankcase cover was replaced, tighten the
when the bolt (CT bolt with the following torque value.
bolt) was tightened TORQUE: 14 N-m (1.4 kgf-m, 10 Ibf.ft)
first time.
Install the following:
- air cleaner housing (page 5-36)
- floor lower cover (page 2-8)
DRIVE BELT
REMOVAL
Remove the following:
- left crankcase cover (page 10-6)
- drive pulley face (page 10-9)
- clutch outer (page 10-12)
Remove the clutch/driven pulley assembly with the
drive belt from the drive shaft.
Remove the drive belt from the driven pulley.
Check the drive belt for cracks, separation or abnor-
mal or excessive wear.
DRIVE BELT
Measure the drive belt width. \
INSTALLATION
Clean any oil and grease from the driven faces.
Spread the driven pulley width by compressing the
driven face spring while turning the movable driven
face clockwise, and install the drive belt into the
driven pulley.
Jake care not to get Install the clutch/driven pulley assembly onto the
grease of the driven drive shaft, and the drive belt onto the drive face
face inner surface boss.
to the splines and
Install the following:
Of
drive - clutch outer (page 10-20)
shaft. - drive pulley face (page 10-11)
- left crankcase cover (page 10-7)
DRIVE PULLEY
REMOVAL
Remove the left crankcase cover (page 10-6).
Hold the drive pulley face with special tool and
loosen the drive pulley face nut.
TOOL:
Universal holder 07725-0030000
Remove the nut, washer and drive pulley face.
10-9
DRIVE AND DRIVEN PULLEYWCLUTCH
Remove the drive belt from the crankshaft.
INSPECTlON
WEIGHT ROLLER
Check each roller for wear or damage.
Measure the weight roller O.D.
SERVICE LIMIT: 19.5 mm (0.77 in)
DRIVE AND DRIVEN PULLEYS/CLUTCH
MOVABLE DRIVE FACE
Check the drive face boss for wear or damage.
Measure the face bushing I.D.
SERVICE LIMIT: SH125: 24.09 mm (9.484 in)
SH150: 24.064 mm (9.4740 in)
Measure the boss O.D.
SERVICE LIMIT: SH125: 23.93 mm (0.942 in)
SH150: 23.956 mm (0.9431 in)
INSTALLATI0N
Clean any oil and grease from the weight rollers.
Install the weight rollers on the movable drive face.
Install the slide piece and ramp plate.
Clean any oil and grease from the drive face and the
drive belt.
Install the drive face boss into the movable drive
face assembly.
Install the movable drive face assembly onto the
crankshaft while holding the ramp plate.
Install the drive belt onto the drive face boss.
Clean any oil and grease from the drive pulley face.
Install the drive pulley face and washer.
Apply engine oil to the threads and seating surface
of the drive pulley face nut, and install the nut.
~~~
10-11
DRIVE AND DRIVEN PULLEYSICLUTCH
Hold the drive pulley face with the special tool and
tighten the nut to the specified torque.
TOOL:
Universal holder 07725-0030000
CLUTCHIDRIVEN PULLEY
REMOVAL
Remove the drive pulley face (page 10-9).
Hold the clutch outer with the special tool and
loosen the clutch outer nut.
TOOL:
Flywheel holder 07725-0040000
Remove the nut, washer and clutch outer.
CLUTCH
Remove the E-clips and clutch side plate.
10-13
DRIVE AND DRIVEN PULLEYWCLUTCH
Remove the rubber dampers f r o m the drive plate.
DRIVEN PULLEY
Remove the seal collar f r o m the driven pulley.
10-14
DRIVE AND DRIVEN PULLEYWCLUTCH
DRIVEN FACE BEARING
REPLACEMENT
Set the special tools to the driven face.
TOOLS:
Fork seal driver
attachment, 37.2 mm 07747-0010600
Bearing remover, 20 mm 07931-MA70000
Remove the driven face needle bearing using the
special tools.
INSPECTlON
DRIVEN FACE SPRING
Measure the driven face spring free length.
SERVICE LIMIT: 123.0 mm (4.84 in)
DRIVEN FACE
Check the driven face for scratches, scoring or dam-
age.
Measure the driven face boss O.D.
SERVICE LIMIT: 33.94 mm (1.376 in)
10-16
DRIVE AND DRIVEN PULLEYSICLUTCH
ASSEMBLY
MOVABLE DRIVEN FACE
BALL BEARING SNAP RING
\ GUIDEPINS
/
\ \ ROLLERS
\
?/ /
\
NEEDLE 'BEARING
9
,
- 'CLUTCH SIDE PLATE
CLUTCH/DRIVEN PULLEY NUT
/ \ SHOE SPRINGS
DRIVE PLATE RUBBER DAMPERS
I NOTICE I
Apply specified quantity of grease to the inside
of the driven face and the guide grooves in the
movable driven face.
Avoid getting grease or oil on the clutch shoe lin-
ings and driven faces. Discard contaminated
shoes and clean contaminated faces with a high
quality degreasing agent.
7-89
6
DRIVEN PULLEY
Apply engine oil to new oil seal lips and outer sur-
faces, and install them into the movable driven face.
Coat new O-rings with engine oil and install them
into grooves in the movable driven face.
DRIVE AND DRIVEN PULLEYWCLUTCH
Clean any oil and grease from the pulley face.
Install the movable driven face onto the driven face.
Install the rollers and guide pins.
Apply 2 - 2.5 g of grease to the guide grooves.
CLUTCH
Install the rubber dampers onto the drive plate.
10-18
~ _ _
DRIVE AND DRIVEN PULLEYS/CLUTCH
Install the clutch side plate and secure it with the E-
clips
CLUTCHIDRIVEN PULLEY
Assemble the fo Ilowing:
- clutch assembly
- spring collar SPRING SEAT
- driven face spring
- spring cap
- spring seat
- driven pulley assembly
DRIVEN
PULLEY
I SPRING COLLAR I
Set the clutch spring compressor over the clutch/
driven pulley assembly by aligning the bosses with
the holes in the clutch.
TOOL:
Clutch spring compressor 07LME-GZ40200
Toprevent loss of Compress the driven face spring while aligning the
tension, do not flat surfaces of the driven pulley and clutch.
compress the Install the clutch/driven pulley nut.
spring Hold the spring compressor in a vice and tighten the
than necessary to
clutch/driven pulley nut using the special tool to the
install the clutch/ specified torque.
driven pulley nut.
TOOL:
Socket wrench, 39 x 41 mm 07GMA-KS40100
INSTALLATlON
Install the drive belt onto the clutch/driven pulley
assembly and drive face boss (page 10-9).
Clean any oil and grease from the clutch outer.
Install the clutch outer, washer and clutch outer nut.
Hold the clutch outer with the special tool and
tighten the clutch outer nut to the specified torque.
TOOL:
Flywheel holder 07725-0040000
11-2
FINAL REDUCTION
SERVICE INFORMATION
GENERAL
The final reduction can be serviced with the engine installed in the frame.
Refer to page 3-13 for final reduction oil level check and change.
When installing the drive shaft, be sure to use the special tools; position the special tools against the bearing inner race
and pull the drive shaft into the bearing until it is fully seated.
ITEM SPECIFICATIONS
Final drive oil capacity After draining 190 cm3 (6.4 US oz, 6.9 Imp oz)
After disassembly 220 cm3 (7.4 US 02.7.7 Imp oz)
Recommended final drive oil Hypoid gear oil, SAE #90 or
Honda 4-stroke oil or equivalent motor oil
API service classification SE, SF or SG
Viscositv: SAE IOW-30
TOOLS
Case puller Bearing remover set, 12 mm Bearing remover head, 12 mm
07SMC-0010001 07936-1660101 07936-1660110
11-3
FINAL REDUCTION
Attachment, 37 x 40 mm Attachment, 42 x 47 mm Attachment, 44 x 49.5 mm
07746-0010200 07746-0010300 07945-3330300
Assembly collar
07LMF-KAB0110
FINAL REDUCTION
TROUBLESHOOTING
Engine does start but scooter wont move
Damaged final reduction
Seized final reduction
Faulty drive pulley and driven pulley/clutch (page 10-5)
Abnormal noise
Worn, seized or chipped gears
Worn or damaged final reduction bearing
Oil leak
Oil level too high
Worn or damaged oil seal
Cracked crankcase and/or final reduction case
FINAL REDUCTION
FINAL REDUCTION DISASSEMBLY/
INSPECTION
Remove the following:
- clutch/driven pulley (page 10-12)
- rear brake shoes and arm (page 16-18)
Drain the final drive oil (page 3-13)
Remove the brake cable from the reduction case.
Remove the seven bolts, sealing washer and clamp.
Remove the final reduction case.
11-6
~
11-7
FINAL REDUCTION
Check the countershaft, counter gear, final gear
shaft and drive shaft for wear or damage.
BEARING REPLACEMENT
Disassemble the final reduction (page 11-6).
LEFT CRANKCASE
Becarefulnot to Remove the drive shaft bearing if it is left in the
damage the final crankcase.
reduction case Remove the countershaft and final gear shaft bear-
mating surface. ings using the special tools.
TOOLS:
Countershaft bearing:
Bearing remover set, 12 mm 07936-1660101
- Bearing remover head, 12 mm 07936-1660110
- Bearing remover shaft 07936-1660120
Remover weight 07741-0010201
Final gear shaft bearing:
Bearing remover, 20 mm 07936-3710600
Bearing remover handle 07936-3710100
Remover weight 07741-0010201
Apply engine oil to new bearing cavities.
Drive the bearings into the left crankcase with the
marked side facing the attachment until it is fully
seated, using the special tools.
TOOLS:
Countershaft bearing:
Driver 07749-0010000
Attachment, 37 x 40 mm 07746-0010200
Pilot, 12 mm 07746-0040200
Final gear shaft bearing:
Driver 07749-0010000
Attachment, 42 x 47 mm 07746-0010300
Pilot, 20 mm 07746-0040500
Drive shaft bearing:
Driver 07749-0010000
Attachment, 44 x 49.5 mm 07945-3330300
Pilot, 22 mm 07746-0041000
11-8
FINAL REDUCTION CASE
Be careful not to Drive the final gear shaft bearing out of the reduc-
damage the final tion case.
reduction case mat-
Remove the drive shaft and countershaft bearings
ing surface.
using the special tools.
TOOLS:
Bearing remover set, 12 mm 07936-1660101
- Bearing remover head, 12 mm 07936-1660110
- Bearing remover shaft 07936-1660120
Remover weight 07741-0010201
11-11
12. ALTERNATORISTARTER CLUTCH
86 Ibf.ft)
12-2
ALTERNATOWSTARTER CLUTCH
SERVICE INFORMATION
GENERAL
This section covers the removal and installation of the flywheel, starter clutch and alternatorkrankshaft position (CKP)
sensor.
These service can be done with the engine installed in the frame.
Refer to page 17-8 for alternator inspection.
Refer to page 18-6 for CKP sensor inspection.
SPECIFICATIONS
ITEM STANDARD SERVICE LIMIT
Starter driven gear Boss O.D. 39.622 - 39.635 (1.5599 - 1.5604) 39.58 (1.558)
Bushing I.D. 22.026 - 22.045 (0.8672 - 0.8679) 22.10 (0.870)
Starter clutch outer I.D. 56.279 - 56.309 (2.2157 - 2.2169) 56.36 (2.219)
TORQUE VALUES
Stator bolt 12 N.m (1.2 kgf.m, 9 Ibf.ft)
Crankshaft position (CKP) sensor bolt 5 N.m (0.5 kgf.m, 3.7 1bf.R)
Starter clutch outer bolt 30 N.m (3.1 kgfm, 22 Ibf.ft) Apply locking agent to the threads.
Flywheel nut 116 N.m (11.8 kgfm, 86 Ibf.ft) Apply engine oil to the threads and seating sur-
face.
12-3
ALTERNATOR/STARTER CLUTCH
TOOLS
~ ~~~
TROUBLESHOOTING
Engine does not turn
Faulty starter one-way clutch
Damage starter reduction gear
12-4
ALTERNATORISTARTER CLUTCH
RIGHT CRANKCASE COVER
REMOVAL
Drain the engine oil (page 3-91,
Drain the coolant (page 6-8).
Remove the following:
- luggage box (page 2-51,
- floor under cover (page 2-8).
- exhaust pipe/muffler (page 2-15).
Remove the alternator 3P (white) connector from
the frame and disconnect it.
Remove the alternator wire from the clamp.
12-5
ALTERNATORISTARTER CLUTCH
~~ ~
12-6
ALTERNATORISTARTER CLUTCH
INSTALLATION
Take care not to Remove the snap ring.
damage the stator. Remove the oil seal using the special tools.
TOOLS:
Bearing remover set, 15 mm 07936-KC10500
- Bearing remover head, 15 mm 07936-KC10200
- Bearing remover shaft 07936-KC10100
Remover weight 07741-0010201
Apply engine oil to a new oil seal lip.
Install the oil seal into the right crankcase cover with
the marked side facing up until it is fully seated
using the special tools.
TOOLS:
Driver 07749-0010000
Attachment, 22 x 24 mm 07746-0010800
Pilot, 14 mm 07746-0041200
Install the snap ring into the right crankcase cover
groove securely.
Install the dowel pins and a new gasket.
12-7
ALTERNATOR/STARTER CLUTCH
Install the dowel pins into the right crankcase cover.
Install a new O-ring into the water pump cover
groove.
Install the water pump cover.
Route the wires Install the CKP sensor and alternator wires into the
properly (page 1- wire guide and install the two wire bands onto the
171. stay.
Connect the CKP sensor 3P (white) connector
through the stay.
STATORKRANKSHAFT POSITION
(CKP) SENSOR
REMOVAL
Remove the right crankcase cover (page 12-51,
Remove the following from the right crankcase
cover:
- two flange bolts and CKP sensor
- three socket bolts and stator
- wire grommet
12-9
ALTERNATOR/STARTER CLUTCH
INSTALLATI0N
Install the stator and tighten the three socket bolts.
TORQUE: 12 Nmm
(1.2 kgf-m, 9 Ibf-ft)
FLYWHEELBTARTER CLUTCH
REMOVAL
Remove the right crankcase cover (page 12-51,
Remove the starter reduction gear shaft and reduc-
tion gear.
TOOL:
Flywheel holder 07725-0040000
Remove the flywheel nut and washer.
12-10
ALTERNATORSTARTER CLUTCH
Remove the flywheel using the special tool.
TOOL:
Flywheel puller 07KMC-HE00100
DISASSEMBLY
Remove the starter driven gear from the starter
clutch on the flywheel while turning it clockwise.
TOOL:
Flywheel holder 07725-0040000
Remove the starter clutch assembly from the fly-
wheel.
Remove the sprag clutch from the clutch outer.
INSPECTION
Check the starter driven gear and reduction gear
teeth for wear or damage.
Measure the starter driven gear bushing I.D.
SERVICE LIMIT: 22.10 mm (0.870 in)
Measure the starter driven gear boss O.D.
SERVICE LIMIT: 39.58 mm (1.558 in)
ASSEMBLY
Apply engine oil to the sprag clutch.
Install the sprag clutch into the clutch outer with the
marked side facing to the flywheel side.
Install the clutch outer onto the flywheel with the
marked side facing to the starter driven gear side.
12-12
Apply locking agent to the starter clutch outer bolt
threads and install them.
Hold the flywheel with the special tool and tighten
the bolts.
TOOL:
Flywheel holder 07725-0040000
INSTALLATION
Install the woodruff key in the crankshaft key
groove.
Apply molybdenum oil solution to the starter driven
gear sliding surface of the crankshaft.
12-14
13. CRANKCASEKRANKSHAFT
I
CRANKCASEICRANKSHAFT
SERVICE INFORMATION
GENERAL
This section covers the crankcase separation to service the crankshaft.
The following parts must be removed before separating the crankcase.
- engine (page 7-2)
- cylinder head (page 8-2)
- cylinder and piston (page 9-2)
- starter motor (page 19-2)
- flywheel (page 12-2)
- oil pump (page 4-3)
- drive pulley and clutch/driven pulley (page 10-2)
In addition t o the parts listed above, remove the final reduction (page 11-2) when the left crankcase half must be
replaced.
Be careful not to damage the crankcase mating surfaces when separating and assembling the crankcase halves.
Clean all disassembled parts with clean solvent and dry them using compressed air before inspection.
When installing the crankshaft, be sure to use the special tools; position the special tools against the bearing inner race
and pull the crankshaft into the bearing until it is fully seated.
Prior t o assembling the crankcase halves, apply sealant to their mating surfaces, Wipe off excess sealant thoroughly.
SPECIFICATIONS
ITEM STANDARD SERVICE LIMIT
Crankshaft runout - 0.10 (0.004)
Connecting rod big end side clearance 0.10 - 0.35 (0.004 - 0.014) 0.60 (0.024)
Connecting rod big end radial clearance 0 - 0.008 (0- 0.0003) 0.05 (0.002)
TORQUE VALUES
Cam chain tensioner pivot bolt 10 N.m (1.0 kgf.m, 7 Ibf.ft)
13-3
CRANKCASEKRANKSHAFT
TOOLS
Attachment, 72 x 75 m m Pilot, 35 mm Driver
07746-0010600 07746-0040800 07749-0010000
~~
TROUBLESHOOTING
Abnormal noise
Worn crankshaft bearing
Worn connecting rod big end bearing
Worn connecting rod small end
13-4
CRANKCASEKRANKSHAFT
CRANKCASE SEPARATION
Be carefulnot to Remove the following:
damage the crank- -
engine (page 7-4)
case mating sur- -
cylinder head (page 8-8)
-
faces. cylinder and piston (page 9-5)
- starter motor (page 19-6)
- flywheel (page 12-10)
- oil pump (page 4-4)
- drive pulley (page 10-9)
- clutch/driven pulley (page 10-12)
- two bolts
- oil seal stopper plate
CRANKCASE ASSEMBLY
Be careful not to Remove the crankshaft bearings if they are left in
damage the crank- the crankcases.
case mating sur-
faces.
13-7
CRANKCASE/CRANKSHAFT
Apply 2 cc minimum of engine oil to each new
crankshaft bearing.
Drive in each new crankshaft bearing into the crank-
case with the marked side facing up until it is fully
seated.
TOOLS:
Driver 07749-0010000
Attachment, 72 x 75 mm 07746-0010600
Pilot, 35 mm 07746-0040800
After installation, check that the height from the
crankcase mating surface to the bearing surface is
within specification.
SPECIFIED HEIGHT:
Right side: 24.54 - 24.62 mm (0.966 - 0.969 in)
Left side: 21.55 - 21.63 mm (0.848 - 0.852 in)
Clean the insides and mating surface of the crank-
cases.
Check for cracks or other damage.
Dress any roughness or irregularities with an oil
stone.
Apply engine oil to a new oil seal lip and outer sur-
face.
Install a new oil seal squarely until it is flush with
the left crankcase.
Install the oil seal stopper plate onto the left crank-
case and tighten the bolts.
Install the following:
- clutch/driven pulley (page 10-20)
- drive pulley (page 10-11)
- oil pump (page 4-6)
- flywheel (page 12-13)
- starter motor (page 19-11)
- cylinder and piston (page 9-91
- cylinder head (page 8-21 1
- engine (page 7-7)
14. FRONT WHEEL/SUSPENSION/STEERlNG
39 N
i
i
+
Ad-1,
-...-
/
30 N.m (3.1 kgf.m,
22 Ibf.ft)
14-2
FRONT WHEEL/SUSPENSION/STEERlNG
SERVICE INFORMATION
GENERAL
Raise the front wheel off the ground by supporting the frame securely when servicing the front wheel, suspension and
steering stem. A hoist or equivalent is required to support the scooter.
A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc
with a high quality brake degreasing agent.
After installing the front wheel, check the brake operation by applying the front brake lever.
Use only tires marked "TUBELESS" and tubeless valves on rim marked "TUBELESS TIRE APPLICABLE".
Refer to page 16-2 for brake system service.
Refer to page 20-14 for handlebar switch inspection.
SPECIFICATIONS
ITEM STANDARD SERVICE LIMIT
Minimum tire tread depth - 1.5 (0.06)
Cold tire Driver only 175 kPa (1.75 kgf/cm2, 25 psi) -
pressure Driver and passenger 175 kPa (1.75 kgf/cm2, 25 psi) -
Axle runout - 0.2 (0.01 1
Wheel rim Radial - 2.0 (0.08)
runout Axial - 2.0 (0.08)
Wheel balance weight - 70 g (2.50~)
max.
Fork Spring free length 257.2 (10.13) 252 (9.9)
Tube runout - 0.2 (0.01
Recommended fork fluid Honda Ultra Cushion Oil 1OW -
or equivalent
Fluid level 106 (4.2) -
Fluid capacity 100 f 1 cm3(3.4 f 0.03 US 02, 3.5 f 0.04 -
ImD 02)
TORQUE VALUES
Steering stem lock nut 68 N.m (6.9 kgf.m, 50 Ibf.ft)
Steering bearing upper inner race See page 14-26
Fork socket bolt 20 N.m (2.0 kgf.m, 15 Ibf.ft) Apply locking agent to the threads.
Handlebar post nut 39 N.m (4.0 kgf.m, 29 Ibf.f&)U-nut.
Master cylinder holder bolt 12 N.m (1.2 kgf.m, 9 Ibf.ft)
Brake disc bolt 42 N.m (4.3 kgf.m, 31 1bf.h) ALOC bolt: replace with a new one.
Front axle nut 68 N.m (6.9 kgfem, 50 Ibf.ft) U-nut.
Speedometer cable setting screw 2.2 N.m (0.22 kgf.m, 1.6 Ibf.ft)
Caliper mounting bolt 30 N.m (3.1 kgf.m, 22 Ibf.ft) ALOC bolt: replace with a new one.
FRONT WHEEL/SUSPENSION/STEERlNG
TOOLS
Bearing remover shaft Bearing remover head, 12 m m Driver
07746-0050100 07746-0050300 07749-0010000
Fork seal driver weight Fork seal driver attachment, Socket wrench
07747-0010100 33 m m I.D. 07916-KM10000
07747-0010501
14-4
FRONT WHEEL/SUSPENSION/STEERlNG
Bearing remover weight Ball race remover Oil seal driver
07741-0010201 07948-4630100 07947-SB00200
Attachment, 35 mm I.D.
07746-0030400
14-5
FRONT WHEEL/SUSPENSION/STEERlNG
TROUBLESHOOTING
Hard steering
Insufficient tire pressure
Faulty tire
Steering top thread too tight
Worn or damaged steering head bearings
Worn or damaged steering head bearing races
Bent steering stem
Steers to one side or does not track straight
Bent front axle
Wheel installed incorrectly
Worn or damaged wheel bearings
Bent fork leg
Damaged or loose steering head bearings
Damaged frame
Worn or damaged engine mounting bushings (page 7-2)
Front wheel wobbles
Bent rim
Worn or damaged wheel bearings
Loose axle fasteners
Faulty tire
Wheel turns hard
Faulty wheel bearings
Bent front axle
Brake drag (page 16-5)
Soft suspension
Low tire pressure
Weak fork spring
Low fluid level i n fork
Incorrect fluid weight (low viscosity)
Stiff suspension
High tire pressure
Bent fork tube
Fork slider binds
High fluid level in fork
Incorrect fluid weight (high viscosity)
Clogged fork fluid passage
Suspension noise
Loose fork fasteners
Incorrect fluid weight (low viscosity)
Worn guide bushing
14-6
FRONT WHEEL/SUSPENSION/STEERr"
FRONT WHEEL
REMOVAL
Remove the screw and disconnect the speedometer
cable.
Loosen the axle nut.
Support the scooter securely using a hoist or equiv-
alent and raise the front wheel off the ground.
INSPECTlON
AXLE
Set the axle in V-blocks
Turn the axle and measure the r u n o u t using a dial
indicator.
Actual runout is 112 the total indicator reading.
SERVICE LIMIT: 0.2 mm (0.01 in)
14-7
FRONT WHEEL/SUSPENSION/STEERlNG
WHEEL
Check the rim runout by placing the wheel in a tru-
ing stand.
Spin the wheel slowly and read the runout using a
dial indicator.
Actual runout is 1/2 the total indicator reading.
SERVICE LIMITS:
Radial: 2.0 mm (0.08 in)
Axial: 2.0 mm (0.08 in)
I
WHEEL BEARING
Turn the inner race of each bearing with your finger;
the bearings should turn smoothly and quietly.
Also check that the bearing outer race fits tightly in
the hub.
Replace the wheel Remove and discard the bearings if the races do not
bearings in pairs. turn smoothly, quietly, or if they fit loosely in the
hub.
DISASSEMBLY
Remove the four bolts and brake disc.
Remove the dust seal.
14-8
FRONT WHEEL/SUSPENSION/STEERlNG
~~ ~~
Replace the bear- Install the remover head into the bearing.
ings m pars Do not From the opposite side of the wheel, install the
reuse old beanng bearing remover shaft and drive the bearing out of
the wheel hub.
TOOLS:
Bearing remover shaft 07746-0050100
Bearing remover head, 12 mm 07746-0050300
Remove the distance collar and drive out the other
bearing.
ASSEMBLY
BEARING (6201U)
GEAR
BEARING (6201U)
BOLTS
BRAKE DISC
WHEEL BALANCE
NOTE:
Mount the tire with the arrow mark facing in the
direction of rotation.
For optimum balance, the tire balance mark (light
mass point: a paint dot on the side wall) must be
located next to the valve stem. Remount the tire
if necessary.
The wheel balance must be checked when the
front tire is remounted.
I \ STAND
I
Be carefulnot to Install a new gear retainer into the right side of the
damage the seallip. hub until it is fully seated.
INSTALLATION
Apply grease to the speedometer gear teeth and
sliding surface, and install the washers and gear.
Apply grease to the dust seal lip, and install the gear
box so the tabs o n the gear and retainer are not
interfered.
Be carefulnot to Place the wheel between the fork legs while insert-
damage the brake ing the brake disc between the pads in the caliper so
pads. the lug on the gear box is positioned against the
stopper as shown.
Carefully align the axle holes and insert the axle
from the right side.
14-1I
FRONT WHEEL/SUSPENSION/STEERlNG
Install the axle nut and tighten it.
TORQUE: 68 N.m (6.9 kgf-m, 50 Ibf-ft)
FORK
REMOVAL
Support the brake Remove the following left fork:
caliper so it does - bolt and brake hose clamp
not hang from the - two bolts and brake caliper
brake hose.
Remove the front fender (page 2-8).
twist the brake
Remove the front wheel (page 14-7).
hose.
14-12
FRONT WHEEL/SUSPENSION/STEERI"
DISASSEMBLY
Hold the fork slider in a vise with soft jaws or shop
towels.
Remove the socket Loosen the fork socket bolt.
bolt after draining
the fork f l u d
14-13
FRONT WHEEL/SUSPENSION/STEERlNG
~ ~~
- forktube
- oil lock piece
- dustseal
- stopper ring
- oil seal
- back-up ring
INSPECTION
Measure the fork spring free length.
14-14
FRONT WHEEL/SUSPENSION/STEERlNG
Check the fork tube, slider and fork piston for score
marks, and excessive or abnormal wear.
Check the fork piston ring for wear or damage.
Check the rebound spring for fatigue or damage.
Replace any damaged component if necessary.
SPRING SEAT
/
i
\ FORK SPRING
REBOUND
SPRING
SOCKET BOLT
14-16
FRONT WHEEL/SUSPENSION/STEERlNG
Install the back-up ring. 7
Wrap vinyl tape around the fork tube top end to I DUSTSEAL 11
avoid damaging the oil seal lip.
Apply fork fluid to a new oil seal lip. Install the oil
seal with the marking facing up.
Drive the oil seal until the stopper ring groove is vis-
ible.
TOOLS:
Fork seal driver weight 07747-0010100
Driver attachment, 33 mm I.D. 07747-0010501
Make sure to pull Set the fork leg, spring seat and stopper ring onto a
the fork leg up into hydraulic press.
the spring seat. Press the spring seat until the stopper ring groove is
visible.
Do not compress the fork spring more than neces-
sary.
INSTALLATION
Install the fork leg into the fork bridge and align the
fork tube groove with the bolt hole, then install the
upper mounting bolt.
Tighten the two mounting bolts securely.
Install the following:
- front wheel (page 14-11)
- front fender (page 2-8)
Left fork only: Install the brake caliper with new mounting bolts
and tighten the bolts.
TORQUE: 30 N-m (3.1 kgfam, 22 Ibf-ft)
Install the brake hose clamp and tighten the bolt.
FRONT WHEEL/SUSPENSION/STEERING
HANDLEBAR
REMOVAL
Remove the combination meter (page 20-8).
Loosen the brake joint cable lock nut and screw the
adjuster fully.
Disconnect the joint cable from the cable joint on
the brake arm and remove the setting spring.
Keep the reservoir Remove the two bolts and master cylinder holder,
upright to prevent and the brake master cylinder off of the handlebar.
air from entering Remove the joint cable from the cable holder on the
the hydraulic sys-
master cylinder by turning the adjuster.
tem.
14-21
FRONT WHEEL/SUSPENSION/STEERlNG
Be careful not to Install the joint cable into the cable holder on the MASTER CYLINDER
cross-thread the master cylinder and screw the adjuster fully. MASTER
adjuster. CYLINDER
Align the edge of Install the brake master cylinder and holder with the
the master cylinder "UP"mark facing up.
with the punch Tighten the upper bolt first, then tighten the lower
mark on the handle- bolt.
bar.
TORQUE: 12 N.m (1.2 kgf-m, 9 Ibf.ft)
Install the setting spring into the cable holder and
connect the cable to the cable joint.
Adjust the rear brake lever and joint cable free play
(page 3-16).
Install the combination meter (page 20-8).
STEERING STEM
REMOVAL
NOTE:
Always replace the bearings and races as a set.
Remove the following:
- handlebar (page 14-19)
- fork legs (page 14-12)
Remove the bolt and brake hose clamp.
14-22
FRONT WHEEL/SUSPENSION/STEERlNG
Remove the lock nut.
Loosen the upper inner race.
TOOLS:
Lock nut wrench 07SMA-GBC0100
TOOLS:
Adjustable bearing remover 07JAC-PH80100
Remover shaft 07JAC-PH80200
Remover weight 07741-0010201
14-23
FRONT WHEEL/SUSPENSION/STEERlNG
Remove the lower outer race using the special tool
and a drift.
TOOL:
Ball race remover 07948-4630100
INSTALLATION
ER INNER RACE
LOWER INNER
ER STEERING BEARING
LOWER DUST SEAL
UPPER OUTER RACE
STEERING STEM
CLAMP
14-24
FRONT WHEEL/SUSPENSION/STEERlNG
~~ _ _ ~
NOTE:
Use urea based multi-purpose grease with
extreme pressure agent for the steering bearings
and dust seals:
- Excelite EP2 (Kyodo Yushi) or
- Alvania EP2 (Shell) or equivalent
Apply grease to a new lower dust seal lip and install
it onto the steering stem.
Press a new lower bearing inner race using the spe-
cial tool.
TOOL:
Attachment, 35 mm I.D. 07746-0030400
14-25
FRONT WHEEL/SUSPENSION/STEERI"
Apply 3 - 5 g of grease to each new steering bearing
and fill it up. Install the lower steering bearing onto
the stem.
Donotgetgrease Insert the steering stem into the steering head pipe
on the stern and install the following while holding the stem:
threads.- upper steering bearing
- upper inner race (and temporarily tighten it)
14-26
3. Loosen the upper inner race fully and finger
tighten it all the way.
Turn the inner race counterclockwise 45" (1/8)
from above (finger tightened) position.
14-27
15. REAR WHEEL/SUSPENSlON
I
,,/" i
\
118 N.m (12.0 kgf.m, 87 Ibf.ft)
15-2
REAR WHEEL/SUSPENSION
SERVICE INFORMATION
GENERAL
Frequent inhalation of brake shoe dust, regardless of material composition could be hazardous to your health.
Avoid breathing dust particles.
Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner.
A contaminated brake drum or shoe reduces stopping power. Discard contaminated shoes and clean a contaminated
drum with a high quality brake degreasing agent.
Use only tires marked "TUBELESS" and tubeless valve stems on rims marked "TUBELESS TIRE APPLICABLE".
Use genuine Honda replacement bolts for all suspension pivots and mounting points.
Refer to page 16-2 for brake system service.
TORQUE VALUES
Rear axle nut 118 N.m (12.0 kgf.m, 87 Ibf.ft) U-nut.
TOOLS
Driver Attachment, 42 x 47 mm Pilot, 17 rnm
07749-0010000 07746-0010300 07746-0040400
15-3
REAR WHEEL/SUSPENSION
TROUBLESHOOTING
Rear wheel wobbles
Insufficient tire pressure
Bent rim
0 Axle or swingarm fasteners not tightened properly
Loose or worn final shaft bearings
Faulty tire
Improperly tightened engine mount fasteners (page 7-2)
Wheel turns hard
Brake drag (page 16-5)
Soft suspension
Insufficient tire pressure
Weak rear shock absorber spring
Oil leakage from damper unit
Stiff suspension
Tire pressure too high
Bent damper rod
Damaged shock absorber bushings
Damaged engine mount bushings (page 7-2)
Rear suspension noise
Loose shock absorber fasteners
Worn or damage shock absorber bushings
Faulty damper unit
15-4
REAR WHEEL/SUSPENSION
REAR WHEEL
INSPECTION
Check the wheel rim runout.
Spin the wheel slowly and read the runout using a
dial indicator.
Actual runout is 1/2 the total indicator reading.
SERVICE LIMITS:Radial: 2.0 mm (0.08 in)
Axial: 2.0 mm (0.08 in)
Check the wheel rim for distortion or damage.
REMOVAL
Remove the following:
- exhaust system (page 2-15).
- mud guard (page 2-14)
Lock the rear brake.
Lower the rear wheel and ground it, then loosen the
axle nut.
Support the left crankcase and remove the follow-
ing:
- shock absorber lower mounting bolt (and secure
the shock absorber with a piece of rope)
- axle nut
- swingarm bolts and washers
- swingarm
- inside collar
- outside collar
- rearwheel
NOTE:
Refer to page 14-10 for note of the tire replace-
ment.
15-5
REAR WHEEL/SUSPENSION
BEARING INSPECTION/
REPLACEMENT
Remove dust seals from the both sides of the swin-
garm.
TOOLS:
Driver 07749-0010000
Attachment, 42 x 47 mm 07746-0010300
Pilot, 17 mm 07746-0040400
15-6
REAR WHEEL/SUSPENSION
INSTALLATI0N
Install the rear wheel onto the final shaft, aligning
the splines.
Apply grease to grease groove and bearing fitting
area of the final shaft.
15-7
REAR WHEEL/SUSPENSION
REAR SHOCK ABSORBER
REMOVAL/ INSTALLATION
For left side: Remove the air cleaner housing mounting fasteners
t o get the clearance for lower mounting bolt
removal (page 5-36).
For right sde: Remove the exhaust system (page 2-15).
Support the engine with a jack or adjustable support
to relieve stress from the shock absorber.
Remove the lower mounting bolt.
INSPECTlON
Check the pivot bushings in the shock absorber and
engine or swingarm for wear, deterioration or dam-
age.
Check the damper rod for bend or damage.
Check the damper unit for leaks or other damage.
15-8
16. BRAKE SYSTEM
16-1
BRAKE SYSTEM
SYSTEM COMPONENTS
FRONT:
kgf.m, 9 Ibf.ft)
k g f m , 25 Ibf.ft)
16-2
BRAKE SYSTEM
REAR:
16-3
BRAKE SYSTEM
SERVICE INFORMATION
GENERAL
Frequent inhalation of brake pad and shoe dust, regardless of material composition, could be hazardous t o your
health.
Avoid breathing dust particles.
Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner.
I NOTICE I
Spilled brake fluid will severely damage the plastic parts and painted surfaces. It is also harmful to some rubber parts. Be
careful whenever you remove the reservoir cap; make sure the master cylinder reservoir is horizontal first.
This scooter is equipped with combined brake system that is designed to engage both front and rear brakes when the
rear brake lever is used. This system is connecting the rear brake lever to the front master cylinder with the joint cable
via the mechanical equalizer.
A contaminated brake disclpad and brake drumlshoe reduces stopping power. Discard contaminated pads and shoes,
and clean a contaminated disc and drum with a high quality brake degreasing agent.
Always use fresh DOT 3 or DOT 4 brake fluid from a sealed container when servicing the system. Do not mix different
types of fluid as they may not be compatible.
Never allow contaminants (dirt, water, etc.) to enter an open reservoir.
Once the hydraulic system has been opened, or if the brake feels spongy, the system must be bled.
Always check brake operation before riding the scooter.
SPEC1FlCATlONS
Unit: mm (in)
TORQUE VALUES
Caliper bleed valve 5.5 N.m (0.56 kgf.m, 4.1 Ibf-ft)
Pad pin 18 N.m (1.8 kgfam, 13 Ibf.ft)
Pad pin plug 2.5 N.m (0.25 kgf.m, 1.8 Ibf.ft)
Master cylinder reservoir cap screw 1.5 N.m (0.15 kgf.m, 1.1 Ibf.ft)
Brake hose oil bolt 34 N.m (3.5 kgf.m, 25 Ibfdt)
Front brake lever pivot bolt 1 Nsm (0.1 kgf.m, 0.7 Ibf.ft)
Front brake lever pivot nut 6 Nsm (0.6 kgf.m, 4.4 Ibfaft)
Front brake light switch screw 1.2 N.m (0.12 kgf.m, 0.9 Ibf.ft)
Master cylinder holder bolt 12 N.m (1.2 kgf.m, 9 Ibf.ft)
Caliper mounting bolt 30 N.m (3.1 kgf.m, 22 Ibf.ft) ALOC bolt: replace with a new one.
Rear brake lever pivot screw 4.2 N.m (0.43 kgf.rn, 3.1 Ibf.ft)
Rear brake lever pivot nut 5.2 N.m (0.53 kgf.m, 3.8 Ibf.ft)
Rear brake lever equalizer joint screw 4.2 N.m (0.43 kgf.m, 3.1 IbfW ALOC screw: replace with a new one.
Rear brake arm bolt 10 N.m (1.0 kgf.m, 7 Ibf-ft)ALOC bolt: replace with a new one.
16-4 ~
BRAKE SYSTEM
TOOL
Snap ring pliers
07914-SA50001
TROUBLESHOOTING
FRONT BRAKE
Brake lever soft or spongy
Air i n hydraulic system
Leaking hydraulic system
Contaminated brake pad/disc
Worn caliper piston seal
Worn master piston cups
Worn brake padldisc
Contaminated caliper
Contaminated master cylinder
Caliper not sliding properly
Low brake fluid level
Clogged fluid passage
Warped/deformed brake disc
Sticking/worn caliper piston
Sticking/worn master piston
Bent brake lever
Brake lever hard
Clogged/restricted fluid passage
Sticking/worn caliper piston
Caliper not sliding properly
Worn caliper piston seal
Sticking/worn master piston
Bent brake lever
Brake drags
Incorrect adjustment of brake (page 3-16)
Contaminated brake pad/disc
Misaligned wheel
Badly worn brake pad/disc
Warped/deformed brake disc
Caliper not sliding properly
Clogged/restricted fluid passage
Sticking caliper piston
16-5
BRAKE SYSTEM
REAR BRAKE
Poor brake performance
Incorrect adjustment of brake (page 3-16)
Worn brake shoe linings
Worn brake drum
Worn brake cam and shoes
Contaminated brake shoe linings and drum
Brake sliding areas needs lubrication
Brake lever hard
Bent brake lever
Improper actuation of equalizer linkage
Brake squeaks
Worn brake shoe linings
Worn brake drum
Contaminated brake shoe linings and drum
Brake drags
Incorrect adjustment of brake (page 3-16)
BRAKE SYSTEM
BRAKE FLUID REPLACEMENTIAIR
BLEEDING
I NOTICE I
Spilling fluid can damage painted, plastic or rubber
parts. Place a rag over these parts whenever the
system is serviced.
NOTE:
Do not mix different types of fluid, as they are
not compatible with each other.
Do not allow foreign material to enter the system
when filling the reservoir.
BRAKE FLUID DRAINING
Turn the handlebar so the reservoir is level before
removing the reservoir cap.
Remove the screws, reservoir cap, set plate and dia-
phragm.
16-7
BRAKE FLUID FILLING/AIR BLEEDING
Close the bleed valve.
Fill the front master cylinder reservoir with DOT 3 or
DOT 4 brake fluid from a sealed container.
Follow the manu- Connect a commercially available brake bleeder to
facturer's operating the bleed valve.
instructions.
Operate the brake bleeder and loosen the bleed
valve.
Check the fluid level If an automatic refill system is not used, add fluid
often while bleed- when the fluid level in the reservoir is low.
ing the brake to pre-
Perform the bleeding procedure until the system is
vent air from being
completely flushed/bled.
pumped into the
s ys tem. After bleeding air, operate the front brake lever. If it
If air enters the still feels spongy, bleed the system again.
bleeder from
Tighten the bleed valve.
around the bleed
valve threads, seal TORQUE: 5.5 N - m (0.56 kgf-m, 4.1 I b f W
the threads with
teflon tape.
16-8
BRAKE SYSTEM
BRAKE PAD/DISC
BRAKE PAD REPLACEMENT
Remove the pad pin plugs and loosen the pad pins.
Remove the two bolts and brake caliper.
Check the fluid Push the caliper pistons all the way to allow installa-
level in the master tion of new brake pads.
cylinder reservoir as
Pull the pad pins out of the caliper while pushing in
this operation
the pads against the pad spring.
causes the fluid
level to rise.
Make sure the pad Install new pads and insert the pad pins by pushing
spring is installed in the pads against the pad spring to align the pad
correctly. pin holes.
Always replace the Temporarily tighten the pad pins.
brake pads in pairs
to ensure even disc
pressure.
16-9
BRAKE SYSTEM
BRAKE DISC INSPECTION
Visually inspect the brake disc for damage or crack.
Measure the brake disc thickness at several points.
SERVICE LIMIT:3.5 mm (0.14 in)
16-10
BRAKE SYSTEM
FRONT MASTER CYLINDER
DISASSEMBLY
Remove the rear handlebar cover (page 2-12).
Drain the brake fluid from the hydraulic system
(page 16-71.
Remove the brake light switch connectors.
I CONNECTORS /
1
i
I
Loosen the brake joint cable lock nut and screw the
adjuster fully.
- pivot nut
- pivot bolt and return spring
- brake lever
- brake arm
BRAKE SYSTEM
~ ~~ ~~~
- snapring
TOOL:
Snap ring pliers 07914-SA50001
- master piston
- spring
Clean the master cylinder, reservoir and master pis-
ton in clean brake fluid.
INSPECTlON
Check the piston cups and boot for wear, deteriora-
tion or damage.
Check the spring for damage.
Check the master cylinder and piston for scoring,
scratches or damage.
16-12
BRAKE SYSTEM
ASSEMBLY
SNAP RING
rivu i
I
DULI
\ MASTER PISTON /
PISTON SPRING
SWITCH
SCREW
Make sure the snap Install the snap ring into the groove in the master
ring is firmlyseated cylinder with the chamfered side facing the piston.
in the groove.
TOOL:
Snap ring pliers 07914-SA50001
BRAKE SYSTEM
Install the boot into the master cylinder and piston
groove.
Apply silicone grease to the brake lever contacting
surface of the piston.
Rest the hose joint Connect the brake hose to the master cylinder with
pin against the the oil bolt and new sealing washers.
stopper. Tighten the oil bolt.
TORQUE: 34 N-m (3.5 kgf-m, 25 Ibf-ft)
Install the setting spring into the cable holder and
connect the cable to the cable joint.
Adjust the rear brake lever and joint cable free play
(page 3-16).
I
i
CONNECTORS
i
FRONT BRAKE CALIPER
DISASSEMBLY
Drain the brake fluid from the hydraulic system
(page 16-7).
When removing the Disconnect the brake hose from the brake caliper by
oil bolt, cover the removing the oil bolt and sealing washer.
the hose to Remove the brake pads (page 16-9).
prevent contamina-
tion.
BRAKE SYSTEM ~-
- caliper bracket
- padspring
- boots
Be careful not to Push the dust and Diston seals in and lift them out.
damage the piston
Clean the seal grooves, caliper cylinder and piston
sliding surface.
with clean brake fluid.
INSPECTION
Check the caliper cylinder and piston for scoring,
scratches or damage.
Measure the caliper cylinder I.D.
SERVICE LIMIT: 27.06 mm (1.065 in)
Measure the caliper piston O.D.
SERVICE LIMIT: 26.91 mm (1.059in)
16-16
BRAKE SYSTEM
ASSEMBLY
CALIPER BRACKET
\ PIN BOOT B
PIN
PAD SPRING
BRAKE PADS
Resrrhe hosejoint Connect the brake hose to the caliper with the oil
against the caliper bolt and new sealing washers.
body. Tighten the oil bolt.
TORQUE: 34 N-m (3.5 kgf-m, 25 IbfW
Fill and bleed the hydraulic system (page 16-8).
REAR D R U M BRAKE
Remove the rear wheel (page 15-5).
INSPECTION
NOTE:
For brake shoe inspection, see page 3-15
(inspected at the wear indicator).
Measure the rear brake drum I.D.
SERVICE LIMIT: 131 mm (5.2 in)
DISASSEMBLY
Always replace the Expand the brake shoes and remove them.
brake shoes in
Remove the shoe springs from the brake shoes.
pairs.
BRAKE SYSTEM
~~ ~
- brake cam
- lockwasher
- dust seals
BRAKE SYSTEM
ASSEMBLY
BRAKE CAM
0 2 mm
Wheel side
16-21
BRAKE SYSTEM
- locklever
- return spring
ASSEMBLY
NOTE:
Do not exchange the rear brake cable and joint
cable.
Route the cables properly (page 1-17).
Apply grease to the link sliding area.
Place the equalizer link into the equalizer housing of
the lever bracket through the link rod hole in the
direction as shown.
Install the joint Connect the cables to the link arm and install them
cable first, then the into the housing.
cable.
Install the boot onto the link rod, and set the boot
ribs into the groove in the rod and into the groove in
the housing.
BRAKE SYSTEM
Apply grease t o the brake lever and link rod pivots.
Install the brake lever and pivot screw, and tighten
it.
TORQUE: 4.2 N.m (0.43 kgf-m, 3.1 Ibf-ft)
Install the pivot nut and tighten it.
TORQUE: 5.2 N-m (0.53 kgf-m, 3.8 IbfW
Connect the lever to the link rod with a new joint
screw, and tighten the screw.
TORQUE: 4.2 N-m (0.43 kgf-m, 3.1 Ibf-ft)
Set the spring ends Install the lock lever and return spring.
against the lever
plate inner surface
(long end) and
housing wall (short
end).
REG ULATOR/RECTIFlER
ALTERNATOR
SYSTEM DIAGRAM
BI -R/BI
IY Y
FUSE (10 A)
IGNITION
Y SWITCH
MAIN FUSE
BI: Black
G:Green
R: Red
W White
Y Ye II ow
+
-
I
REG U LATOR/RECTIFIER BATTERY -
-
BATTERYKHARGING SYSTEM
SERVICE INFORMATION
GENERAL
The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when
charging.
The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective
clothing and a face shield.
- If electrolyte gets on your skin, flush with water.
- If electrolyte gets in your eyes, flush with water for at least 15 minutes and call a physician immediately.
Electrolyte is poisonous.
- If swallowed, drink large quantities of water or milk and call your local Poison Control Center or a physician
immediately.
Always turn OFF the ignition switch before disconnecting any electrical component.
Some electrical components may be damaged if terminals or connectors are connected or disconnected while the igni-
tion switch is in the ON position and current is present,
For extended storage, remove the battery, give it a full charge, and store it in a cool, dry space. For maximum service
life, charge the stored battery every two weeks.
For a battery remaining in a stored scooter, disconnect the negative battery cable from the battery terminal.
The maintenance free (MF) battery must be replaced when it reaches the end of its service life.
The battery can be damaged if overcharged or undercharged, or if left to discharge for long period. These same condi-
tions contribute to shortening the "life span" of the battery. Even under normal use, the performance of the battery dete-
riorates after 2 - 3 years.
Battery voltage may recover after battery charging, but under heavy load, battery voltage will drop quickly and eventu-
ally die out. For this reason, the charging system is often suspected as the problem. Battery overcharging often results
from problems in the battery itself, which may appear to be an overcharging symptom. If one of the battery cells is
shorted and battery voltage does not increase, the regulatorhectifier supplies excess voltage to the battery. Under these
conditions, the electrolyte level goes down quickly.
Before troubleshooting the charging system, check for proper use and maintenance of the battery. Check if the battery
is frequently under heavy load, such as having the headlight and taillight ON for long periods of time without riding the
scooter.
The battery will self-discharge when the scooter is not in use. For this reason, charge the battery every two weeks to
prevent sulfation from occurring.
Filling a new battery with electrolyte will produce some voltage, but in order to achieve its maximum performance,
always charge the battery. Also, the battery life is lengthened when it is initially charged.
When checking the charging system, always follow the steps in the troubleshooting flow chart (page 17-5).
For alternator service, refer to page 12-9.
Battery charging
This model comes with a maintenance free (MF) battery. Remember the following about MF batteries
- Use only the electrolyte that comes with the battery.
- Use all of the electrolyte.
- Seal the battery properly.
- Never open the seals after installation.
For battery charging, do not exceed the charging current and time specified on the battery. Using excessive current or
extending the charging time may damage the battery.
Battery testing
Refer to the battery instruction of the Operation Manual for the recommended battery tester. The recommended battery
tester puts a "load" on the battery so the actual battery condition of the load can be measured.
Recommended battery tester: BM210 or BATTERY MATE or equivalent
ITEM SPECIFICATION
Battery Capacity 12V-6Ah
Current leakage 0.2 mA max.
Vo Ita g e Fully charged 13.0 - 13.2 V
(20C/68"F) Needs charging Below 12.3 V
Charging cur- Normal 0.6N 5 - 10 h
rent I
Quick 3.0 N1.0 h
Alternator Capacity 300 W/5,000 min-' (rpm)
Charging coil resistance (2OoC/68"F) 0.1 - 0.5 R
17-4
BATTERYKHARGING SYSTEM
TROUBLESHOOTING
BATTERY IS DAMAGED OR WEAK
1. BATTERY TEST
Remove the battery (page 17-6).
Check the battery condition using the recommended battery tester.
RECOMMENDED BAlTERY TESTER: BM210 or BATTERY MATE or equivalent
Is the battery good condition?
YES - GO TO STEP 2.
NO - Faulty battery.
2. CURRENT LEAKAGE TEST
Install the battery (page 17-6).
Check the battery current leakage (Leak test; page 17-7).
Is the current leakage below 0.2 mA?
YES - GO TO STEP4.
NO - GO TO STEP 3.
3. CURRENT LEAKAGE TEST WITHOUT REGURETOR/RECTIFIRE CONNECTOR
Disconnect the regulatorhectifier 3P black connector and recheck the battery current leakage.
Is the current leakage below 0.2 mA?
YES - Faulty regulatorlrectifier.
NO - Shorted wire harness.
Faulty ignition switch.
4. ALTERNATOR CHARGING COIL INSPECTION
Check the alternator charging coil (page 17-8).
Is the alternator charging coil resistance within 0.7 - 0.5 l2 (20C/68"F)?
YES - GO TO STEP 5.
NO - Faulty charging coil.
5. CHARGING VOLTAGE INSPECTION
Measure and record the battery voltage using a digital multimeter (page 17-6).
Start the engine.
Measure the charging voltage (page 17-71,
Compare the measurement to result of the following calculation.
STANDARD: Measured battery Voltage e Measured charging voltage e 15.5 V at 5,000 min-'(rpm)
Is the measured charging voltage within the standard voltage?
YES - Faulty battery.
NO - GO TO STEP 6.
6. REGULATOR/RECTIFIER WIRE HARNESS INSPECTION
Check the voltage and continuity a t the regulatorhectifier connector (page 17-8).
Are the results of checked voltage and continuity correct?
YES - Faulty regulator/rectifier.
NO - Open circuit in related wire.
Loose or poor contacts of related terminal.
Shorted wire harness.
BATTERY/CHARGING SYSTEM
BATTERY
REMOVAL/I NSTALLATION
Always turn the Remove the maintenance lid (page 2-4).
ignition switch OFF
Remove the two screws and battery setting plate.
before removing
the battery.
VOLTAGE INSPECTION
Remove the maintenance lid (page 2-4).
Measure the battery voltage using a commercially
available digital multimeter.
VOLTAGE (2OoC/68"F):
Fully charged: 13.0 - 1 3 . N
Under charged: Below 12.3V
BATTERY CHARGING
Remove the battery (page 17-6).
BATTERY I
Turn power O N / O f f Connect the charger positive (+) cable to the battery
at the charger, not positive (+) terminal.
at the battery termi- Connect the charger negative (-) cable to the battery
na/. negative (-1 terminal.
CHARGING CURRENT/TIME:
Standard: 0.6 A15 - 10 h
Quick: 3 All h
Quick-charging should only be done i n an emer-
gency; slow charging is preferred.
For battery charging, do not exceed the charging
current and time specified on the battery. Using
excessive current or extending the charging time
may damage the battery.
BATTERYKHARGING SYSTEM
CHARGING SYSTEM INSPECTION
CURRENT LEAKAGE INSPECTION
Remove the battery setting plate (page 17-6).
Turn the ignition switch to OFF and disconnect the
negative (-) cable from the battery.
Connect the ammeter (+) probe to the negative (-1
cable and the ammeter (-) probe to the battery (-1
terminal.
With the ignition switch turned to OFF, check for
current leakage.
When measuring current using a tester, set it to a
high range, and then bring the range down to an
appropriate level. Current flow higher than the
range selected may blow out the fuse in the
tester.
While measuring current, do not turn the ignition
switch to ON. A sudden surge of current may
blow out the fuse in the tester.
STANDARD: 0.2 mA max.
If current leakage exceeds the specified value, a
shorted circuit is likely.
Locate the short by disconnecting connections one
by one and measuring the current.
REGULATOR/RECTIFIER
WIRE HARNESS INSPECTION
Remove the luggage box (page 2-5).
Remove the regulatorhectifier 3P white connector
from the frame and disconnect it.
Check the following at the wire harness side con-
nector:
Measure the voltage between the Red/white wire
terminal (+) and ground (-1.
There should be battery voltage at all times.
Measure the voltage between the Black wire ter-
minal (+) and ground (-).
There should be battery voltage when the igni-
tion switch is turned to ON.
Check for continuity between the Green wire ter-
minal and ground.
There should be continuity a t all times.
REMOVAL/INSTALLATION
Remove the frame body cover (page 2-5).
Remove the regulatorhectifier 3P connectors from
the frame and disconnect them.
Remove the two mounting bolts and the regulator/
rectifier.
Apply locking agent to the mounting bolt threads.
Install the regulator/rectifier onto the frame and
tighten the two mounting bolts.
Connect the regulator/rectifier 3P connectors and
install them onto the frame.
Install the frame body cover (page 2-5).
18. IGNITION SYSTEM
18-1
IGNITION SYSTEM
SYSTEM LOCATION
SYSTEM DIAGRAM
1-p-q
- -
aEzsE R~*R/BI-BI-
IGNITION
SWITCH
FUSE (10A)
BI: Black
~
Bu: Blue
BATTERY G: Green
0: Orange
P: Pink
R: Red
W. White
YYellow
-
ENGINE CONTROL ENGINE COOLANT CAMSHAFT ENGINE STOP BANK ANGLE -
MODULE (ECM) TEMPERATURE POSlTlON RELAY SENSOR
(ECT) SENSOR (CKP) SENSOR
IGNITION SYSTEM
SERVICE INFORMATION
GENERAL
Some electrical components may be damaged if terminals or connectors are connected or disconnected while the igni-
tion switch is turned to ON and current is present.
When servicing the ignition system, always follow the steps in the troubleshooting sequence o n page 18-4.
This scooter's Ignition Control Module (ICM) is built into the Engine Control Module (ECM).
The ignition timing cannot be adjusted since the ECM is factory preset.
The ECM may be damaged if dropped. Also, if the connector is disconnected when current is flowing, the excessive
voltage may damage the ECM. Always turn the ignition switch to OFF before servicing.
A faulty ignition system is often related to poor connections. Check those connections before proceeding.
Make sure the battery is adequately charged. Using the starter motor with a weak battery results in a slower engine
cranking speed as well as no spark at the spark plug.
Use a spark plug of the correct heat range. Using a spark plug with an incorrect heat range can damage the engine.
For ignition switch servicing, refer to page 20-12.
For crankshaft position (CKP) sensor removal/installation, refer to page 12-9.
SPECIFICATION
ITEM SPECIFICATIONS
Spark plug Standard CR8EH-9 (NGK), U24FER9 (DENSO)
For extended high speed riding CR9EH-9 (NGK), U27FER9 (DENSO)
%ark d u o aaD 0.8 - 0.9 mm (0.031 - 0.035 in1
TOOL
Peak voltage adaptor
07HGJ-0020100
TOOLS:
lmrie diagnostic tester (model 625) or
Peak voltage adaptor 07HGJ-0020100
with commercially available digital multimeter
(impedance 10 MWDCV minimum)
TOOLS:
lmrie diagnostic tester (model 625) or
Peak voltage adaptor 07HGJ-0020100
with commercially available digital multimeter
(impedance 10 MCUDCV minimum)
18-6
Turn the ignition switch to OFF.
Disconnect the CKP sensor 3P white connector.
Connect the lmrie diagnostic tester or peak voltage
adaptor probes to the CKP sensor side connector
terminals.
In the same manner as at the ECM connector, mea-
sure the peak voltage and compare it to the voltage
measured at the ECM connector.
If the peak voltage measured at the ECM is
abnormal and the one measured at the CKP sen-
sor is normal, the wire harness has an open or
short circuit, or loose connection.
If both peak voltages are abnormal, check each
item in the troubleshooting chart (page 18-4).
See page 12-9 for CKP sensor replacement.
Install the removed parts in the reverse order of
removal.
IGNITION COIL
REMOVAL/INSTALLATION
Remove the maintenance lid (page 2-4).
Disconnect the spark plug cap.
Remove the wire band from the stay.
Read the instruc- Connect the timing light to the spark plug wire.
tions for timing light
Start the engine, let it idle and check the ignition
operation.
timing.
SYSTEM DIAGRAM
1- I MAINFUSE
I
R
IGNITION
SWITCH
I
BAlTERY -ISTARTER
RELAY
SWITCH
STARTER
MOTOR (M)
Y
1
BI: Black
Br: Brown
I I '7
REAR BRAKE
G: Green LIGHT SWITCH
R: Red
YYellow I -
- -
MAIN RELAY
19-2
ELECTRIC STARTER
SERVICE INFORMATION
GENERAL
Always turn the ignition switch to OFF before servicing the starter motor. The motor could suddenly start, causing seri-
ous injury.
A weak battery may be unable to turn the starter motor quickly enough, or supply adequate ignition current.
The starter motor can be serviced with the engine in the frame.
When checking the starter system, always follow the steps in the troubleshooting (page 19-4).
If the current is kept flowing through the starter motor to turn i t while the engine is not cranking over, the starter motor
may be damaged.
Refer to page 12-10 for starter clutch servicing.
Refer to page 20-12 for ignition switch inspection servicing.
Refer to page 20-14 for starter switch inspection.
Refer to page 20-14 for brake light switch inspection.
ELECTRIC STARTER
TROUBLESHOOTING
Starter motor does not turn
1. Fuse Inspection
Check for b l o w n main fuse (30 A) or sub-fuse (15 A).
Is the fuse blow?
YES - Replace the fuse.
NO - GO TO STEP 2.
2. Battery Inspection
Check the battery is fully charged and i n good condition.
Is the battery in good condition7
YES - GO TO STEP 3.
NO - Charge or replace the battery (page 17-6).
3. Starter Relay Switch Operation Inspection
Turn the ignition switch to ON.
Squeeze the brake lever fully and push the starter switch.
You should hear the starter relay switch "CLICK" when the starter switch is pushed.
Is the "CLICK" hear7
YES - GO TO STEP 4.
NO - GO TO STEP 5.
4. Starter Motor Inspection
Turn the ignition switch to OFF.
Apply battery voltage t o the starter motor directly and check the operation.
Dose the starter motor turn7
YES - Loose or poorly connected starter motor cable.
Faulty starter relay switch.
NO - Inspect the starter motor (page 19-6).
5. Starter Relay Coil Power Input Line Inspection
Check the relay coil power input line of the starter relay switch (page 19-12).
Is the power input line normal7
YES - GO TO STEP 6.
NO - Faulty ignition switch (page 20-12).
Faulty main relay (page 20-15).
Faulty brake light switch (page 20-14).
Faulty starter switch (page 20-14).
Loose or poor contact of the related connector terminal.
Open circuit in the wire harness between the ignition switch and starter relay switch.
6. Starter Relay Coil Ground Line Inspection
Check the ground line of the starter relay switch (page 19-12).
Is the ground line normal7
YES - Faulty starter relay.
NO - Loose or poor contact of the ground terminal
Open circuit in the wire harness between the starter relay switch and ground terminal.
ELECTRIC STARTER
Starter motor turns engine slowly
Low battery voltage
Poorly connected battery cable
Poorly connected starter motor cable
Faulty starter motor
Poor connected ground cable
Starter motor turns, but engine does not turn
Faulty starter clutch
Damaged or faulty starter drive gear
Starter relay "CLICK",but engine does not turn over
Crankshaft does not turn due to engine problems
19-5
ELECTRIC STARTER
STARTER MOTOR
REMOVAL
Turn the ignition switch to OFF.
Remove the air cleaner housing (page 5-36).
Slide the rubber cap off the starter motor terminal,
and remove the terminal nut and starter motor
cable.
Pull the starter motor cable out of the frame.
Remove the tw o mounting bolts, ground cable and
starter motor from the crankcase.
Remove the O-ring from the starter motor.
DISASSEMBLYANSPECTION
Remove the following:
- starter motor case bolts and O-rings
19-7
ELECTRIC STARTER
Remove the following fro m the rear cover:
- nut
- washer
- insulators
- O-ring
- brush holder
ASSEMBLY
LOCK WASHER
O-RING
\ SEAL RING
w
/
/
BOLTS
HERS
INSULATOR PLATE
INsuLATED WASHER
BRUSH SPRINGS
ARMATURE /=-@ip
/
BRUSHHOLDER f &(
I
SEAL RING REAR COVER
19-9
Install the brush holder assembly into the rear cover
by aligning the tab with the groove in the rear cover.
Install the following:
- new O-ring
- insulators
- washer
- nut
Thecoilmaybe Install the armature into the motor case while hold-
damagedif the ing the armature tightly to keep the magnet of the
magnetpulls the case from pulling the armature against it.
armature against
the case.
INSTALLATI0N
Coat a n e w O-ring with engine oil and install it into
the starter motor groove.
Install the starter motor into the crankcase.
GROUND LINE
Remove the maintenance lid (page 2-4).
Turn the ignition switch to OFF.
Release the connector cover and disconnect the
starter relay 4P red connector.
Check for continuity between the wire harness side
connector terminal and ground.
CONNECTION: Green - Ground
There should be continuity at all times.
CONTlNUITY INSPECTION
Remove the maintenance lid (page 2-4).
Yellow/red (+)
Turn the ignition switch to OFF.
Disconnect the negative (-1 cable from the battery.
Disconnect the starter relay switch 4P red connec-
tor.
Remove the battery (+) cable and starter motor
cable from the starter relay switch.
Connect the fully charged 12 V battery positive ter-
minal to the Yellowhed wire terminal and negative
C
terminal to the Green wire terminal of the starter
relay switch. T
19-12
20. LIGHTS/METERS/SWITCHES
20- 1
LIGHTS/METERS/SWITCHES
COMPONENT LOCATION
FRONT BRAKE \
20-2
LIGHTS/METERS/SWITCHES
SERVICE INFORMATION
GENERAL
m
Note the following when replacing the halogen headlight bulb.
- Wear clean gloves while replacing the headlight bulb. Do not put fingerprints on the headlight bulb, as they may create
hot spots on the bulb and cause it to fail.
- If you touch the bulb with your bare hands, clean it with a cloth moistened with alcohol to prevent its early failure.
A halogen headlight bulb becomes very hot while the headlight is on, and remains hot for a while after it is turned off.
Be sure t o let it cool down before servicing.
Be sure to install the dust cover after replacing the bulb.
Use an electric heating element to heat the water/coolant mixture for the ECT sensor inspection. Keep all flammable
materials away from the electric heating element. Wear protective clothing, insulated gloves and eye protection.
Check the battery condition before performing any inspection that requires proper battery voltage.
A continuity test can be made with the switches installed on the scooter.
The following color codes used are indicated through out this section.
Bu: Blue G: Green Lg: Light Green W: White
El: Black Gr: Gray 0: Orange Y Yellow
Br: Brown Lb: Light Blue R: Red
ITEM SPECIFICATIONS
Bulb Headlight (high/low beam) 12 V - 60155 W
Brakehailliaht 12 V - 2115 W
TORQUE VALUES
License light screw 1.5 N.m (0.15 kgf.m, 1.1 Ibf.fi)
Speedometer cable joint nut 3.4 N.m (0.35 kgf.m, 2.5 Ibfeft)
20-3
LIGHTS/METERS/SWITCHES
HEADLIGHT
BULB REPLACEMENT
Remove the front handlebar cover (page 2-11).
Be careful not to Release the dust cover and disconnect the bulb con-
scratch the nector.
headlight lens
during servicing. I NOTICE I
Avoid touching a new halogen bulb. Finger prints
can create hot spots that cause a bulb to break.
Remove the bulb retainer by turning it counterclock-
wise.
Remove the headlight bulb and replace it with a
new one.
Installation is in the reverse order of removal.
NOTE:
Align the bulb tab with the grooves properly.
When installing the dust cover, align the wires
with the cutout in the headlight housing and set
the dust cover tightly against the housing.
BULB
REMOVAL/ INSTALLATION
Remove the front handlebar cover (page 2-11).
Remove the three screws and the headlight assem-
bly while spreading the handlebar cover upward.
LIGHTS/METERS/SWITCHES
FRONT TURN SIGNAL/POSITION
LIGHT
BULB REPLACEMENT
TURN SIGNAL BULB
Remove the bulb socket by turning it counterclock-
wise.
Remove the socket/bulb out of the front lower
cover, being careful not to damage the its wire.
While pushing the bulb in, turn it counterclockwise
t o remove it, and replace it with a new one.
Check the rubber seal is in good condition and
replace it with a new one if necessary.
Installation is i n the reverse order of removal.
REMOVAL/I NSTALLATION
Remove the frame body cover (page 2-5).
Be careful not to Remove the eight screws and rear combination light
damage the cover assembly.
tab
Release the tab and separate the left and right body
covers.
Installation is in the reverse order of removal.
LIGHT ASSEMBLY
LIGHTS/METERS/SWITCHES
LICENSE LIGHT
BULB REPLACEMENT
Remove the screw and washer, and license light
housing from the rear fender.
Pull the bulb socket out of the light housing.
Pull the bulb out of the socket and replace it with a
new one.
Installation is i n the reverse order of removal.
TORQUE: 1.5 N-m (0.15 kgf.m. 1.1 Ibf4-t)
COMBINATION METER
POWERIGROUND LINE INSPECTION
Remove the front lower cover (page 2-8).
Disconnect the meter 9P (white) and 6P (white) con-
nectors.
Check the following at each wire harness side con-
nector.
POWER INPUT LINE
Measure the voltage between the Black/brown wire
terminal (+) of the 6P connector and ground (-).
There should be battery voltage with the ignition
switch turned to ON.
If there is no voltage, check for open circuit in Black/
brown wire.
GROUND LINE
Check for continuity between the Green wire termi-
nal of the 9P connector and ground.
There should be continuity at all times.
If there is no continuity, check for an open circuit i n
the Green wire.
BACK-UP VOLTAGE LINE
Measure the voltage between the Light greedblack
wire terminal (+) of the 9P connector and ground (-).
There should be battery voltage at all times.
If there is no voltage, check the following:
- open circuit in the Light greedblack wire
- blown "CLOCK" fuse (10 A)
- open circuit in the Red wire in the fuse box
20-7
LIGHTS/METERS/SWITCHES
BULB REPLACEMENT
Remove the front handlebar cover (page 2-11).
Pull the bulb socket out of the meter housing.
Pull the bulb out of the socket and replace it with a
new one.
If the lower side instrument bulb will be replaced,
remove the rear handlebar cover off of the handle-
bar without disconnecting the switch connectors
(page 2-12).
Installation is i n the reverse order of removal.
REMOVAL/INSTALLATlON
Remove the following:
- front lower cover (page 2-9)
- front handlebar cover (page 2-11)
Remove the handlebar post lid by sliding it rear-
ward.
Loosen the speedometer cable joint nut (but do not
disconnect it yet).
Remove the rear handlebar cover (page 2-12).
Disconnect each brake light switch connectors.
Release the wire band from the rear air guide plate.
Disconnect the 6P (white) and 9P (white) connec-
tors.
TS
20-9
LIGHTS/METERS/SWITCHES
FUEL GAUGEIFUEL LEVEL SENSOR
NOTE:
The fuel level sensor is mounted on the fuel
pump (the fuel pump with the built-in level sen-
sor). Do not disassemble the fuel pump. Replace
the fuel pump as an assembly when the it is
fa uIty .
SYSTEM INSPECTION
Make sure that the coolant temperature gauge and
indicator function properly.
Remove the luggage box (page 2-5).
Disconnect the fuel pump 5P connector.
Check for continuity between the Greenlblack
(ground) wire terminal of the wire harness side 5P
connector and ground.
There should be continuity.
Remove the front handlebar cover (page 2-11).
Check the Greenlblack and the Yellowlwhite wires
for continuity between the fuel gauge and level sen-
so r
There should be continuity.
If the above checks are abnormal, check for open
circuit or loose connection in the related wires.
If the wires are normal, check the fuel level sen-
sor (page 20-10). If it is OK, replace the combina-
tion meter.
Yellow/white
I Yellow/white
Gravlblack
- 450 - 750 R
20-10
LIGHTS/METERS/SWITCHES
COOLANT TEMPERATURE GAUGE/
ECT SENSOR
SYSTEM INSPECTION
Make sure that the fuel gauge and indicator function
properly.
Remove the luggage box (page 2-5).
Disconnect the engine coolant temperature (ECT)
sensor 3P (gray) connector.
Ground the Greedblue wire terminal of the 3P con-
nector with a jumper wire.
Turn the ignition switch to ON and check the tem-
perature gauge.
The gauge needle should move to "H".
If the needle moves, check the ECT sensor (page
20-12).
If the needle does not move, check as follows.
20-1I
LIGHTS/METERS/SWITCHES
The coolant temperature is low, but the gauge
remains "H"
Remove the following:
- luggage box (page 2-5)
- front handlebar cover (page 2-11)
Disconnect the ECT sensor 3P (gray) connector.
Disconnect the Greedblue wire terminal of the tem-
perature gauge by removing the terminal screw.
Check for continuity between the Greedblue termi-
nal and ground.
There should be no continuity.
If there is continuity, check for short circuit in the
Greerdblue wire.
If there is no continuity, check the ECT sensor
(page 20-12). If the sensor is normal, replace the
combination meter.
IGNITION SWITCH
INSPECTION
Remove the following:
- front upper cover (page 2-8)
- front lower cover right side fasteners (page 2-9)
Disconnect the ignition switch 2P (white) connector.
Check for continuity between the switch side con-
nector terminals in each switch position.
Continuity should exist between the color coded
wire terminals as follows:
COLOR
LOCK
OFF
ON
20-12
LIGHTS/METERS/SWITCHES
REMOVAL/INSTALLATION
Remove the radiator (page 6-17).
Release the following and remove the rear air guide
plate.
- ignition switch wire (from the wire guide)
- two wire bands
STARTER
TURN SIGNAL
20- 14
LIGHTS/METERS/SWITCHES
MAIN RELAY
INSPECTION
Remove the glove box inner cover (page 2-13).
MAIN RELAY
Remove the main relay.
Check the connector for loose contacts or corroded
terminals.
FUNCTION TEST
Connect an ohmmeter to the switching side relay I
terminals. BATTERY
-\
Red/yelI ow
LIGHTS/METERS/SWITCHES
TURN SIGNAL RELAY
INSPECTION
All turn signal lights does not blink
Remove the glove box inner cover (page 2-13).
I RELAY
Disconnect the 3P connector to remove the turn sig-
nal relay.
Check the connector for loose contacts or corroded
terminals.
Connect the BlacVbrown and Gray wire terminals of
the 3P connector with a jumper wire.
Turn the ignition switch to ON and check the turn
signal lights by operating the turn signal switch.
If the light does not come on, check for an open
circuit i n the BlacVbrown and Gray wires.
If the light comes on, check for open circuit in the
Green wire. If it is OK, replace the relay.
HORN
INSPECTION
Remove the front upper cover (page 2-8).
Disconnect the horn connectors.
Connect a 12-V battery to the horn terminals.
The horn is normal if it sounds when the 12-V bat-
tery is connected across the horn terminals.
REMOVAL/ INSTALLATION
Remove the radiator without disconnecting the
water hoses (page 2-8).
Disconnect the horn connectors.
Be careful not to Move the rear air guide plate and radiator forward
damage the radiator to get the clearance for mounting bolt removal.
fm. Remove the bolt and horn.
Installation is in the reverse order of removal.
20-16
22.TROUBLESHOOTING
ENGINE LACKS POWER ............................. 22-3 POOR PERFORMANCE AT HIGH SPEED .---22-6
22- 1
TROUBLESHOOTING
ENGINE DOES NOT START OR IS HARD TO START
1. Spark Plug Inspection
Remove and inspect spark plug.
Is there spark plug in good condition?
NO - Incorrect spark plug heat range
Incorrect spark plug gap
Dirty air cleaner element
YES - GO TO STEP 2.
2. SparkTest
Perform spark test.
Is the spark good?
NO - Faultysparkplug
Fouled spark plug
Faulty ignition system (page 18-4)
YES - GO TO STEP 3.
3. Fuel Injection System Inspection
Check the fuel injection system (page 5-7).
Is the fuel injection system normal?
NO - Faulty fuel injection system.
YES - GO TO STEP 4.
4. Fuel Line Inspection
Check the fuel line (page 5-31).
Is the fuel line normal?
NO - Faulty fuel line or fuel pump system.
YES - GO TO STEP 5.
5. Cylinder Compression Inspection
Test cylinder compression.
Is the compression within specification?
NO - Valvestuckopen
W o r n cylinder and piston rings
Seized valve
Incorrect valve seat contact
improper valve timing
YES - GO TO STEP 6.
6. Engine Starting Condition
Start the engine by following the normal procedure.
Does the engine start but then stops?
YES - lntakeair leak
Faulty idle air control (IAC) valve in engine control module (ECM)
Improper ignition timing (faulty ECM or CKP sensor)
Contaminated fuel
22-2
TROUBLESHOOTING
ENGINE LACKS POWER
1. Brake Drag Inspection
Raise the wheel off the ground and spin it by hand.
Does the wheel spin freely?
NO - Brake dragging
YES - GO TO STEP 2.
2. Tire Pressure Inspection
Check the tire pressure.
Is the pressure correct?
NO - Faulty tire valve
Punctured tire
YES - GO TO STEP 3.
3. Clutch Inspection
Accelerate rapidly.
Does the engine speed change accordingly?
NO - Clutch slipping
Worn clutch shoes or outer
0 Weak driven face spring
Additive in engine oil
Weight roller stuck
YES - GO TO STEP 4.
4. Engine Performance Inspection
Accelerate lightly.
Does the engine speed increase?
NO - 0 Faulty idle air control (IAC) valve in ECM
Clogged air cleaner
Clogged muffler
Faulty fuel pump
YES - GO TO STEP 5.
5. Spark Plug Inspection
Remove and inspect the spark plug.
Is the spark plug in good condition?
NO - Plug not serviced frequently enough
Incorrect spark plug heat range
Incorrect spark plug gap
YES - GO TO STEP 6.
6. Engine Oil Inspection
Check the oil level and condition.
Is the engine oil in good condition?
NO - Oil level too high
Oil level too low
0 Contaminated oil
YES - GO TO STEP 7.
22-3
TROUBLESHOOTING
7. Ignition Timing Inspection
Check the ignition timing.
Is the ignition timing correct?
NO - Faulty ECM
Faulty crankshaft position (CKP) sensor
Improper valve timing
YES - GO TO STEP 8.
8. Cylinder compression Inspection
Test the cylinder compression.
Is the compression within specification?
NO - Valvestuckopen
Worn cylinder and piston rings
Seized valve
Incorrect valve seat contact
Improper valve timing
YES - GO TO STEP 9.
9. Fuel Injection System Inspection
Check the fuel injection system (page 5-7).
Is the fuel injection system normal?
NO - Faulty fuel injection system.
YES - GO TO STEP 10.
10. lubrication Inspection
Remove the cylinder head cover and inspect for sings of proper lubrication
Is the valve train lubricated properly?
NO - Clogged oil passage.
YES - GO TO STEP 11.
11. Overheating Inspection
Check for engine overheating.
Is the engine overheating?
YES - Coolant level too low
Faulty radiator fan
Thermostat stuck closed
Excessive carbon build-up in combustion chamber
Use of poor quality fuel
Clutch slipping
Lean fuel mixture
NO - GO TO STEP 12.
12. Engine Knocking Inspection
Accelerate or run a t high speed.
Is the engine knocking?
YES - Worn piston and cylinder
Wrong type of fuel
Excessive carbon build-up in combustion chamber
Ignition timing too advanced (faulty ECM)
Lean fuel mixture
NO - Engine does not knock
22-4
TROUBLESHOOTING
POOR PERFORMANCE AT LOW AND IDLE SPEED
1. Spark Plug Inspection
Remove and inspect the spark plug.
Is the spark plug in good condition?
NO - Plug not serviced frequently enough
Incorrect spark plug heat range
Incorrect spark plug gap
YES - GO TO STEP 2.
2. ignition Timing inspection
Check the ignition timing.
Is the ignition timing correct?
NO - Faulty ECM
Faulty crankshaft position (CKP) sensor
Improper valve timing
YES - GO TO STEP 3.
3. Intake Air Leaking Inspection
Check for leaks around the intake manifold.
Does it leak?
YES - Loose manifold mounting bolt
Damaged insulator
Damaged O-ring
NO - GO TO STEP 4.
4. SparkTest
Perform spark test.
Is the spark good?
NO - Faultysparkplug
Fouled spark plug
Faulty ignition system (page 18-4)
YES - Faulty idle air control (IAC) valve
Improperly adjusted valve clearance
22-5
TROUBLESHOOTING
~~
22-7
23.INDEX
AIR CLEANER .................................................................. 3-5 FRONT BRAKE CALIPER ............................................. 16-15
AIR CLEANER HOUSING .............................................. 5-36 FRONT FENDER............................................................... 2-8
ALTERNATOR CHARGING COIL .................................. 17-8 FRONT HANDLEBAR COVER ....................................... 2-1 1
BANK ANGLE SENSOR ................................................ 5-45 FRONT INNER COVER .................................................. 2-1 0
B A n E R Y ....................................................................... 17-6 FRONT LOWER COVER ................................................... 2-9
BEARING REPLACEMENT ............................................ 11-8 FRONT MASTER CYLINDER ....................................... 16-1 1
BELT CASE AIR CLEANER ............................................ 3-12 FRONT UPPER COVER .................................................... 2-8
BODY PANEL LOCATlONS ............................................. 2-3 FRONT WHEEL .............................................................. 14-7
BODY PANEL REMOVAL CHART ................................... 2-3 FUEL GAUGE/FUEL LEVEL SENSOR ......................... 20-10
BRAKE FLUID ................................................................ 3-14 FUEL LINE ........................................................................ 3-4
BRAKE FLUID REPLACEMENT/AIR BLEEDING........... 16-7 FUEL LINE lNSPECTlON ............................................... 5-31
BRAKE LIGHT SWITCH FUEL PUMP ................................................................... 5-35
LIGHTS/METERS/SWITCHES................................. 20-14 FUEL PUMP RELAY ....................................................... 5-43
MAINTENANCE ........................................................ 3-17 FUEL TANK .................................................................... 5-52
BRAKE LOCK OPERATION ........................................... 3-17 GLOVE BOX INNER COVER .......................................... 2-13
BRAKE PAD/DISC .......................................................... 16-9 HANDLEBAR ................................................................ 14-19
BRAKE SHOES/PADS WEAR ........................................ 3-15 HANDLEBAR SWITCH ................................................. 20-14
BRAKE SYSTEM ............................................................ 3-15 HEADLIGHT ................................................................... 20-4
CABLE & HARNESS ROUTING .................................... 1-17 HEADLIGHT AIM ........................................................... 3-17
CAMSHAFT/ROCKER ARM INSTALLATION ...............8-24 HORN ........................................................................... 20-1 6
CAMSHAFT/ROCKER ARM REMOVAL .......................... 8-8 IGNITION COIL .............................................................. 18-7
CENTER STAND ............................................................ 2-14 IGNITION SWITCH ...................................................... 20-1 2
CHARGING SYSTEM lNSPECTlON .............................. 17-7 IGNITION SYSTEM lNSPECTlON ................................. 18-5
CLUTCH/DRIVEN PULLEY .......................................... 10-12 lGNlTlON TIMING ......................................................... 18-8
COMBlNATlON METER ................................................ 20-7 INJECTOR ...................................................................... 5-41
COMBINED BRAKE EQUALIZER ................................ 16-21 LEFT CRANKCASE COVER ........................................... 10-6
COOLANT REPLACEMENT............................................. 6-7 LICENSE LIGHT ............................................................. 20-7
COOLANT TEMPERATURE GAUGE/ECT LIGHTS/METERS/SWITCHES COMPONENT
SENSOR ....................................................................... 20-1 1 LOCATION ..................................................................... 20-2
COOLING FAN MOTOR ................................................ 6-13 LUBRICATION & SEAL POINTS ................................... 1-15
COOLING SYSTEM ....................................................... 3-1 1 LUBRlCATlON SYSTEM DIAGRAM ............................... 4-2
COOLING SYSTEM FLOW PATTERN ............................ 6-2 LUGGAGE BOX ............................................................... 2-5
COOLING SYSTEM TESTING ......................................... 6-6 MAIN RELAY................................................................ 20-1 5
CRANKCASE ASSEMBLY ............................................. 13-7 MAINTENANCE LID ........................................................ 2-4
CRANKCASE BREATHER ................................................ 3-6 MAINTENANCE SCHEDULE ........................................... 3-3
CRANKCASE SEPARATION ......................................... 13-5 MIL CODE INDEX .......................................................... 5-10
CRANKSHAFT lNSPECTlON ......................................... 13-7 MIL TROU BLESHOOTlNG ............................................ 5-1 1
CYLINDER COMPRESSlON TEST .................................. 8-7 MODEL lDENTlFlCATlON ............................................... 1-2
CYLINDER HEAD ASSEMBLY ...................................... 8-19 MUD GUARD ................................................................. 2-14
CYLINDER HEAD COVER INSTALLATION ..................8-27 NUTS, BOLTS, FASTENERS......................................... 3-18
CYLINDER HEAD COVER REMOVAL ............................. 8-7 0 2 SENSOR ................................................................... 5-47
CYLINDER HEAD DISASSEMBLY ................................ 8-13 OIL PUMP......................................................................... 4-4
CYLINDER HEAD INSTALLATION ................................ 8-21 PGM-FI SELF-DIAGNOSIS INFORMATION ...................5-7
CYLINDER HEAD REMOVAL ........................................ 8-1 1 PISTON/CYLINDER INSTALLATION .............................. 9-9
CYLINDER/PISTON lNSPECTlON ................................... 9-6 RADIATOR ..................................................................... 6-17
CYLINDER/PISTON REMOVAL ....................................... 9-5 RADIATOR COOLANT ................................................... 3-10
DRIVE BELT ................................................................... 10-8 RADIATOR RESERVE TANK ......................................... 6-16
DRIVE PULLEY............................................................... 10-9 REAR DRUM BRAKE ................................................... 16-18
DTC INDEX .................................................................... 5-19 REAR FENDER ................................................................. 2-7
DTC TROUBLESHOOTlNG ........................................... 5-22 REAR HANDLEBAR COVER .......................................... 2-12
EMISSION CONTROL SYSTEMS ................................. 1-32 REAR SHOCK ABSORBER ............................................ 15-8
ENGINE CONTROL MODULE (ECM) ........................... 5-48 REAR TURN SlGNAUBRAKE/TAlLLlGHT .................... 20-6
ENGINE COOLANT TEMPERATURE (ECT) REAR WHEEL .................................................................
SENSOR ......................................................................... 5-48 REGULATOR/RECTIFIER............................................... :I;:
ENGINE IDLE SPEED..................................................... 5-49 RIGHT CRANKCASE COVER ......................................... 12-5
ENGINE INSTALLATION ................................................. 7-7 SEAT.. ............................................................................... 2-4
ENGINE OIL ..................................................................... 3-8 SECONDARY AIR SUPPLY SYSTEM
ENGINE OIL STRAINER SCREEN ................................... 3-9 FUEL SYSTEM .......................................................... 5-49
ENGINE REMOVAL ......................................................... 7-4 MAINTENANCE ........................................................ 3-12
ENGINE STOP RELAY ................................................... 5-44 SERVICE INFORMATION
EXHAUST SYSTEM ...................................................... 2-15 ALTERNATOR/STARTER CLUTCH........................... 12-3
FINAL DRIVE OIL ........................................................... 3-13 BATTERY/CHARGING SYSTEM ............................... 17-3
FINAL REDUCTION ASSEMBLY .................................. 11-9 BRAKE SYSTEM ....................................................... 16-4
FINAL REDUCTION DlSASSEMBLY/INSPECTlON...... 11-6 COOLING SYSTEM ..................................................... 6-3
FLOOR LOWER COVER ................................................... 2-8 CRANKCASE/CRANKSHAFT .................................... 13-3
FLOOR PANEL ............................................................... 2-1 1 CYLINDER HEAD/VALVES .......................................... 8-3
FLYWHEEUSTARTER CLUTCH .................................. 12-10 CYLINDER/PISTON ..................................................... 9-3
FORK ............................................................................ 14-12 DRIVE AND DRIVEN PULLEYS/CLUTCH .................10-3
FRAME BODY COVER ..................................................... 2-5 ELECTRIC STARTER ................................................. 19-3
~
23-1
SERVICE INFORMATION SYSTEM DIAGRAM
ENGINE REMOVALANSTALLATION ......................... 7-3 6ATl-ERY/CHARGI NG SYSTEM ............................... 17-2
FINAL REDUCTION ................................................... 11-3 ELECTRIC STARTER .................................................. 19-2
FRAME/BODY PANELS/EXHAUST SYSTEM ............2-2 FUEL SYSTEM (Programmed Fuel Injection) ...........5-6
FRONT WHEEUSUSPENSION/STEERI" .............. 14-3 IGNITION SYSTEM ................................................... 18-2
FUEL SYSTEM (Programmed Fuel Injection)........... 5-3 SYSTEM LOCATION
IGNITION SYSTEM ................................................... 18-3 BATTERY/CHARGING SYSTEM ............................... 17-2
LIGHTS/METERS/SWITCHES ................................... 20-3 ELECTRIC STARTER .................................................. 19-2
LUBRlCATlON SYSTEM ............................................. 4-3 FUEL SYSTEM (Programmed Fuel Injection) ...........5-5
MAINTENANCE .......................................................... 3-2 IGNITION SYSTEM ................................................... 18-2
REAR WHEEUSUSPENSlON ................................... 15-3 THERMOSTAT ................................................................. 6-9
SERVICE RULES .............................................................. 1-2 THROTTLE BODY ........................................................... 5-37
SPARK PLUG ................................................................... 3-6 THROTTLE OPERATION .................................................. 3-4
SPECIFICATIONS TORQUE VALUES
ALTERNATORISTARTER CLUTCH ............................ 1-8 ENGINE & FRAME ..................................................... 1-11
BATTERY/CHARGING SYSTEM ................................. 1-9 STANDARD ................................................................ 1-11
BRAKE SYSTEM ......................................................... 1-9 TROUBLESHOOTING
COOLING SYSTEM ..................................................... 1-6 ALTERNATOR/STARTER CLUTCH ........................... 12-4
CRANKCASEJCRANKSHAFT...................................... 1-8 BATTERY/CHARGING SYSTEM ............................... 17-5
CYLINDER HEAD/VALVES .......................................... 1-6 BRAKE SYSTEM ........................................................ 16-5
CYLINDER/PISTON ..................................................... 1-7 COOLING SYSTEM ..................................................... 6-5
DRIVE AND DRIVEN PULLEYS/CLUTCH ...................1-8 CRAN KCASE/CRANKSHAFT .................................... 13-4
ELECTRIC STARTER ................................................. 1-10 CyLl N DER HEADNALVES .......................................... 8-6
FINAL REDUCTION ..................................................... 1-8 CyLl N DER/P[STON...................................................... 9-4
FRONT WHEEUSUSPENSION/STEERlNG ................1-9 DRIVE AND DRIVEN PULLEYS/CLUTCH..................10-5
FUEL SYSTEM (Programmed Fuel Injection) ...........1-6 ELECTRIC STARTER.................................................. 19-4
GENERAL .................................................................... 1-4 ENGINE DOES NOT START OR IS HARD TO
IGNITION SYSTEM ................................................... 1-10 START ........................................................................ 22-2
LIGHTS/METERS/SWITCHES ................................... 1-10 ENGINE LACKS POWER ........................................... 22-3
LUBRICATION SYSTEM ............................................. 1-6 FINAL REDUCTION ................................................... 11-5
REAR WHEEuSUSPENSlON ..................................... 1-9 FRAMEBODY PANELS/EXHAUST SYSTEM....... ......2-2
STARTER MOTOR ......................................................... 19-6 FRONT WHEEUSUSPENSION/STEERlNG ..............14-6
STARTER RELAY SWITCH .......................................... 19-11 FUEL SYSTEM (Programmed Fuel Injection) ...........5-4
STATOR/CRANKSHAFT POSITION (CKP) SENSOR ... 12-9 IGNITION SYSTEM ................................................... 18-4
STEERING HEAD BEARINGS ....................................... 3-19 LUBRICATION SYSTEM ............................................. 4-3
STEERING STEM ......................................................... 14-22 POOR HANDLING ..................................................... 22-7
SUSPENSlON ................................................................ 3-17 POOR PERFORMANCE AT HIGH SPEED .................22-6
SYSTEM COMPONENTS POOR PERFORMANCE AT LOW AND IDLE
ALTERNATOR/STARTER CLUTCH .......................... 12-2 SPEED ........................................................................ 22-5
BRAKE SYSTEM ....................................................... 16-2 REAR WHEEuSUSPENSlON .................................... 15-4
CRANKCASEICRANKSHAFT .................................... 13-2 TURN SIGNAL LIGHT .................................................... 20-5
CYLINDER HEAD/VALVES .......................................... 8-2 TURN SIGNAL RELAY ................................................. 20-16
CYLlN DER/PISTON ..................................................... 9-2 VALVE CLEARANCE ........................................................ 3-7
DRIVE AND DRIVEN PULLEYSKLUTCH .................10-2 VALVE GUIDE REPLACEMENT ..................................... 8-15
ENGINE REMOVALANSTALLATION ......................... 7-2 VALVE SEAT INSPECTION/REFACING ........................ 8-16
FINAL REDUCTION ................................................... 11-2 WATER PUMP ................................................................ 6-10
FRONT WHEEUSUSPENSION/STEERlNG..............14-2 WHEELS/TIRES .............................................................. 3-18
FUEL SYSTEM (Programmed Fuel Injection)........... 5-2 WIRING DIAGRAM ........................................................ 21-3
REAR WH E E US U S PEN SION ................................... 15-2
23-2
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in the page range.
1. General Information 5 - 38
2. Frame/Body panels/Exhaust system 39 - 53
3. Maintenance 54 - 72
4. Lubrication system 73 - 79
5. Fuel system
(Programmed Fuel Injection) 80 - 131
6. Cooling system 132 - 148
7. Engine removal/Installation 149 - 156
8. Cylinder head/Valves 157 - 183
9. Cylinder/Piston 184 - 193
10. Drive pulley/Driven pulley/Clutch 194 - 213
11. Final Reduction 214 - 224
12. Alternator/Starter clutch 225 - 238
13. Crankcase/Crankshaft 239 - 248
14. Front wheel/Suspension/Steering 249 - 275
15. Rear wheel/Suspension 276 - 283
16. Brake System 284 - 306
17. Battery/Charging system 307 - 314
18. Ignition system 315 - 322
19. Electric Starter 323 - 334
20. Lights/Meters/Switches 335 - 350
21. Wiring diagram 351
22. Troubleshooting 352 - 358
23. Index 359 - 360
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