Trx 680 сервис мануал

2006
SERVIC

ANUAL
RX680FA/FGA
A Few Words About Safety
Service Information
The service and repair information contained in this manual is intended for use by qualified, professional technicians.
Attempting service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also
damage the vehicle or create an unsafe condition.
This manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some procedures
require the use of specially designed tools and dedicated equipment. Any person who intends to use a replacement part, service
procedure or a tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of
the vehicle.
If you need to replace a part, use genuine Honda parts with the correct part number or an equivalent part. We strongly recommend
that you do not use replacement parts of inferior quality.
For Your Customer's Safety
Proper service and maintenance are essential to the customer's safety and
the reliability of the vehicle. Any error or oversight while servicing a vehicle
can result in faulty operation, damage to the vehicle, or injury to others.
For Your Safety
Because this manual is intended for the professional service technician, we
do not provide warnings about many basic shop safety practices (e.g., Hot
parts-wear gloves). If you have not received shop safety training or do not
feel confident about your knowledge of safe servicing practice, we
recommended that you do not attempt to perform the procedures described
in this manual.
Some of the most important general service safety precautions are given
below. However, we cannot warn you of every conceivable hazard that can
arise in performing service and repair procedures. Only you can decide
whether or not you should perform a given task.
AWARNING
Improper service or repairs can create an
unsafe condition that can cause your customer
or others to be seriously hurt or killed.
Follow the procedures and precautions in this
manual and other service materials carefully.
AWARNING
Failure to properly follow instructions and
precautions can cause you to be seriously hurt
or killed.
Follow the procedures and precautions in this
manual carefully.
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 performing any 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.
• Use only a nonflammable solvent, not gasoline, to clean parts.
• Never drain or store gasoline in an open container.
• Keep all cigarettes, sparks and flames away from the battery and all fuel-related parts.
HOW TO USE THIS MANUAL
CONTENTS
This service manual describes the service procedures for the TRX680FA
and TRX680FGA.
GENERAL
Follow the Maintenance Schedule (Section 4) recommendations to
ensure that the vehicle is in peak operating condition and the emission
levels are within the standards set by the California Air Resources Board
(CARB).
TECHNICAL
LUBRICATION SYSTEM
FUEL SYSTEM
Find the section you want on this page, then turn to the table of contents
on the first page of the section.
COOLING SYSTEM
Most sections start with an assembly or system illustration, service
information and troubleshooting for the section. The subsequent pages
give detailed procedure.
ENGINE
ACAUTION
You CAN be HURT if you don't follow
instructions.
REMOVAL/INSTALLATION
LU
Z
CYLINDER
o
CYLINDER/PISTON
HEAD/VALVE/CAMSHAFT
ALTERNATOR/STARTER
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 safety information in a variety of forms
including:
• Safety Labels - on the vehicle
• Safety Messages - preceded by a safety alert symbol fl and
one of three signal words, DANGER, WARNING, or CAUTION.
These signal words mean:
You WILL be KILLED or SERIOUSLY
i i DANGER HURT if you don't follow instructions.
You CAN be KILLED or SERIOUSLY HURT
if you don't follow instructions.
PANELS/EXHAUST
MAINTENANCE
Sections 1 and 4 apply to the whole vehicle.. Section 3 illustrates
procedures for removal/installation of components that may be required
to perform service described in the following sections.
Sections 5 through 23 describe parts of the vehicle, grouped according
to location.
AWARNING
FEATURES
FRAME/BODY
SYSTEM
Performing the first scheduled maintenance is very important. It
compensates for the initial wear that occurs during the break-in period.
If you are not familiar with this vehicle, read Technical Features in section
2.
If you don't know the source of the trouble, go to section 25
Troubleshooting.
INFORMATION
CLUTCH
SUB-TRANSMISSION/GEARSHIFT
CR AN KCASE/CR AN KSH AFT/BALANCER
DRIVE TRAIN SYSTEM
FRONT
(A
<
I
O
REAR
WHEEL/SUSPENSION/STEERING
WHEEL/SUSPENSION
BRAKE SYSTEM
FRONT DRIVING MECHANISM
Instructions - how to service this vehicle correctly and safely.
REAR DRIVING MECHANISM
As you read this manual, you will find information that is preceded by a
| NOTICE I symbol. The purpose of this message is to help prevent
damage to your vehicle, other property, or the environment.
BATTERY/CHARGING
<
ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN
THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT
THE TIME OF APPROVAL FOR PRINTING.
Honda Motor Co., Ltd. RESERVES THE RIGHT
TO MAKE CHANGES AT ANY TIME WITHOUT
NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATSOEVER. NO PART OF THIS
PUBLICATION MAY BE REPRODUCED WITHOUT WRITTEN PERMISSION. THIS MANUAL IS
WRITTEN
FOR
PERSONS
WHO
HAVE
ACQUIRED BASIC KNOWLEDGE OF MAINTENANCE ON Honda MOTORCYCLES, MOTOR
SCOOTERS OR ATVS.
Honda Motor Co., Ltd.
SERVICE PUBLICATION OFFICE
Date of Issue: Nov, 2005
©Honda Motor Co., Ltd.
LINKAGE
u
cc
o
UJ
UJ
SYSTEM
IGNITION SYSTEM
ELECTRIC STARTER
LIGHTS/METERS/SWITCHES
WIRING DIAGRAM
TROUBLESHOOTING
INDEX
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.
Replace the part(s) with new one(s) before assembly.
1
Use the recommended engine oil, unless otherwise specified.
1
Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1:1).
,.-¥iiitwn
Use multi-purpose grease (lithium based multi-purpose grease NLGI #2 or equivalent).
Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent).
Example: Molykote® 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, NLGI #2 or
equivalent).
Example: Molykote® 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
Use silicone grease.
Apply a locking agent. Use a medium strength locking agent unless otherwise specified.
Apply sealant.
1
Use DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified.
Use fork or suspension fluid.
1. GENERAL INFORMATION
SERVICE RULES
MODEL IDENTIFICATION
GENERAL SPECIFICATIONS
1-2
REAR WHEEL/SUSPENSION
SPECIFICATIONS
1-9
1-3
BRAKE SYSTEM SPECIFICATIONS
1-10
FRONT DRIVING MECHANISM
SPECIFICATIONS
•
1-10
REAR DRIVING MECHANISM
SPECIFICATIONS
1-10
BATTERY/CHARGING SYSTEM
SPECIFICATIONS
1-10
IGNITION SYSTEM SPECIFICATIONS
1-11
••• 1-5
LUBRICATION SYSTEM
SPECIFICATIONS
1-7
FUEL SYSTEM SPECIFICATIONS
1-7
COOLING SYSTEM SPECIFICATIONS
CYLINDER HEAD/VALVE/CAMSHAFT
SPECIFICATIONS
1-7
CYLINDER/PISTON SPECIFICATIONS
1-8
ELECTRIC STARTER SPECIFICATIONS
1-11
1-8
LIGHTS/METERS/SWITCHES
SPECIFICATIONS
1-11
STANDARD TORQUE VALUES
1-12
ENGINE & FRAME TORQUE VALUES
1-12
ALTERNATOR/STARTER CLUTCH
SPECIFICATIONS
SUB-TRANSMISSION/GEARSHIFT
LINKAGE SPECIFICATIONS
1-8
1-9
CRANKCASE/CRANKSHAFT/BALANCER
SPECIFICATIONS
1-9
LUBRICATION & SEAL POINTS
1-17
DRIVETRAIN SPECIFICATIONS
1-9
CABLE & HARNESS ROUTING
1-20
EMISSION CONTROL SYSTEMS
1-39
FRONT WHEEL/SUSPENSION/STEERING
SPECIFICATIONS
1-9
1-1
GENERAL INFORMATION
SERVICE RULES
1. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Honda's
design specifications may cause damage to the motorcycle.
2. Use the special tools designed for this product to avoid damage and incorrect assembly.
3. Use only metric tools when servicing the motorcycle. Metric bolts, nuts and screws are not interchangeable with
English fasteners.
4. Install new gaskets, O-rings, cotter pins, and lock plates when reassembling.
5. When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque
diagonally in incremental steps unless a particular sequence is specified.
6. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly.
7. After reassembly, check all parts for proper installation and operation.
8. Route all electrical wires as show in the Cable and Harness Routing (page 1-20).
ABBREVIATION
Throughout this manual, the following abbreviations are used to identify the respective parts or systems.
Abbrev. term
PGM-FI
MAP sensor
TP sensor
ECT sensor
IAT sensor
CKP sensor
VS sensor
EOT sensor
IACV
PCM
(ECM/TCM)
EEPROM
DLC
SCS connector
HDS
DTC
MIL
A/T
Clutch PC solenoid
4WD
ESP
GPS
1-2
Full term
Programmed Fuel Injection
Manifold Absolute Pressure sensor
Throttle Position sensor
Engine Coolant Temperature sensor
Intake Air Temperature sensor
Crankshaft Position sensor
Vehicle Speed sensor
Engine Oil Temperature sensor
Idle Air Control Valve
Powertrain Control Module
(Engine Control Module/Transmission Control Module)
Electrically Erasable Programmable Read Only Memory
Data Link Connector
Service Check Short connector
Honda Diagnostic System
Diagnostic Trouble Code
Malfunction Indicator Lamp
Automatic Transmission
Clutch Pressure Control solenoid
4 Wheel Drive
Electric Shift Program
Global Positioning System
GENERAL INFORMATION
MODEL IDENTIFICATION
SERIAL NUMBERS
The Vehicle Identification Number (V.I.N) is stamped on the front side
of the frame.
The engine serial number is stamped on the right side of the
crankcase.
VEHICLE IDENTIFICATION NUMBER VIN
ENGINE SERIAL NUMBER
1-3
GENERAL INFORMATION
The throttle body identification number is stamped on the left side of
the throttle body.
THROTTLE BODY
IDENTIFICATION NUMBER
LABELS
The name plate (U.S.A. and AUSTRALIA type) is located on the left
frame down tube.
U.S.A./AUSTRALIAtype
NAME PLATE
The safety certification label (Canada type only) is locate on the right
frame down tube.
Canada type
SAFETY CERTIFICATION LABEL
The color label is attached on the right side of the frame under the seat.
When ordering color coded parts, always specify the designated color
code.
1-4
GENERAL INFORMATION
The Vehicle Emission Control Information Label is attached on the left
side of the rear fender under the seat.
EMISSION CONTROL INFORMATION LABEL
GENERAL SPECIFICATIONS
DIMENSIONS
FRAME
ITEM
Overall length
Overall width
Overall height
Wheelbase
Front tread
Rear tread
Seat height
Footpeg height
Ground clearance
Curb weight
Maximum weight capacity
Frame type
Front suspension
Front wheel travel
Front damper
Rear suspension
Rear wheel travel
Rear damper
Front tire size
Rear tire size
Front rim size
Rear rim size
Front tire brand
Rear tire brand
Front brake
Rear brake
Caster angle
Trail length
Camber angle
Fuel tank capacity
Fuel tank reserve capacity
SPECIFICATIONS
2,113 mm (83.2 in)
1,189 mm (46.8 in)
1,207 mm (47.5 in)
1,289 mm (50.7 in)
915 mm (36.0 in)
945 mm (37.2 in)
875 mm (34.5 in)
341 mm (13.4 in)
234 mm (9.2 in)
291 kg (642 lbs)
220 kg (485 lbs)
Double cradle
Double wish-bone
175 mm (6.9 in)
Double tube
Double wish-bone
203 mm (8.0 in)
Single tube
AT25x8R12**
AT25x 1 0 R 1 2 * *
12x6.0 AT
12x7.5 AT
KT515(DUNLOP)
KT511 (DUNLOP)
Hydraulic disc brake
Hydraulic/mechanical disc brake
1.6°
2.1 mm (3/16 in)
0°
17 liters (4.5 US gal, 3.7 Imp gal)
4.1 liters (1.08 US gal, 0.90 Imp gal)
1-5
GENERAL INFORMATION
ENGINE
CARBURATION
DRIVE TRAIN
ITEM
Cylinder arrangement
Bore and stroke
Displacement
Compression ratio
Valve train
Intake valve opens at 1 mm (0.04 in) lift
Intake valve closes at 1 mm (0.04 in) lift
Exhaust valve opens at 1 mm (0.04 in) lift
Exhaust valve closes at 1 mm (0.04 in) lift
Lubrication system
Oil pump type
Cooling system
Air filtration
Engine dry weight
Type
Throttle bore
Transmission
Shift clutch (1st, 2nd and 3rd clutches)
Primary reduction
Secondary reduction
Final reduction
Transmission ratio
Gearshift pattern
Forward
Reverse
Front
Rear
1st
2nd
3rd
Reverse
Sub-transmission
D (Drive)
R (Reverse)
ELECTRICAL
Ignition system
Starting system
Charging system
Regulator/rectifier
Lighting system
1-6
SPECIFICATIONS
Single cylinder, longitudinally installed
102 x 82.6 mm (4.02 x 3.25 in)
674.9 cm3 (41.19 cu-in)
9.2: 1
OHV
8° BTDC
45° ABDC
45° BBDC
5° ATDC
Forced pressure (dry sump)
Trochoid
Liquid cooled
Oiled urethane foam
60.4 kg (133.2 lbs)
PGM-FI (Programmed Fuel Injection)
40 mm (1.57 in)
Automatic (Torque converter + 3-speed drive
system and reverse)
Multi-plate, wet (hydraulic clutch with electric
controlled)
1.333 (64/48)
2.000 (38/19)
2.375(38/16)
3.231 (42/13)
3.154(41/13)
2.053 (39/19)
1.375 (33/24)
0.933 (28/30)
2.138(39/19x25/24)
D-N-R
2-mode: 3-speed Automatic and Manual (ESP;
3 speeds)
1-mode (fixed low ratio)
Full Transistorized Ignition
Electric starter motor and emergency recoil
starter
Triple phase output alternator
FET shorted, triple phase full wave rectification
Battery
GENERAL INFORMATION
LUBRICATION SYSTEM SPECIFICATIONS
ITEM
After draining
Engine oil capacity
After draining/filter
change
After disassembly
Recommended engine oil
Oil pressure at 5,000 rpm (min1)/80°C (176°F)
Oil pump rotor
Tip clearance
Body clearance
Side clearance
STANDARD
2.7 liters (2.9 US qt, 2.4 Imp qt)
2.9 liters (3.1 US qt, 2.6 Imp qt)
4.1 liters (4.3 US qt, 3.6 Imp qt)
Pro Honda GN4 or HP4 (without molybdenum additives) 4-stroke oil (USA &
Canada), or Honda 4-stroke oil (Canada
only), or an equivalent motorcycle oil
API service classification: SG or Higher
(except oils labeled as energy conserving on the circular API service label)
JASO T 903 standard: MA
Viscosity: SAE 10W-40, 5W-30
785 kPa (8.0 kgf/cm2,114 psi)
0.15(0.006)
0.12-0.22(0.005-0.009)
0.02-0.09(0.001 -0.004)
Unit: mm (in)
SERVICE LIMIT
—
-
0.20 (0.008)
0.25 (0.010)
0.11 (0.004)
FUEL SYSTEM SPECIFICATIONS
ITEM
Throttle body identification number
Idle speed
Throttle lever free play
ECT sensor resistance (20°C/68°F)
Fuel injector resistance (at 20°C/68°F)
Fuel pressure
Fuel pump flow (at 12 V)
SPECIFICATIONS
GQ67A
1,400 ±50 rpm (min 1 )
3 - 8 mm (1/8-5/16 in)
2 . 3 - 2.6 k£2
11.1- 12.3 a
284 - 304 kPa (2.9 - 3.1 kgf/cm2,41 - 44 psi)
71 cm 3 (2.4 US oz, 2.5 Imp oz) minimum/10 seconds
COOLING SYSTEM SPECIFICATIONS
ITEM
Radiator and engine
Reserve tank
Radiator cap relief pressure
Thermostat
Begin to open
Fully open
Valve lift
Recommended antifreeze
Coolant capacity
Standard coolant concentration
SPECIFICATIONS
2.0 liters (2.1 US qt, 1.8 Imp qt)
0.46 liter (0.49 US qt, 0.40 Imp qt)
108- 137 kPa (1.1 - 1 . 4 kgf/cm2, 1 6 - 2 0 psi)
80 - 84°C
95°C
8 mm (0.3 in) minimum
Pro Honda HP Coolant or an equivalent high quality
ethylene glycol antifreeze containing silicate-free corrosion
inhibitors
1:1 mixture with distilled water
1-7
GENERAL INFORMATION
CYLINDER HEAD/VALVE/CAMSHAFT SPECIFICATIONS
ITEM
Cylinder compression at 350 rpm (min 1 )
Valve clearance
Valve,
valve guide
Valve stem O.D.
Valve guide I.D.
Stem-to-guide clearance
Valve spring
Rocker arm
Camshaft and
cam follower
Valve guide projection
above cylinder head
Valve seat width
Free length
Arm I.D.
Shaft O.D.
Arm-to-shaft clearance
Cam lobe height
Cam follower O.D.
Follower bore I.D.
Follower-to-bore clearance
Cylinder head warpage
IN
EX
IN
EX
IN/EX
IN
EX
IN
EX
IN/EX
Inner
Outer
IN/EX
IN/EX
IN/EX
IN
EX
IN/EX
IN/EX
IN/EX
STANDARD
550 kPa (5.6 kgf/cm2, 80 psi)
0.15(0.006)
0.33 (0.013)
5.475 - 5.490 (0.2156 - 0.2161)
5.455 - 5.470 (0.2148 - 0.2154)
5.500 - 5.512 (0.2165 - 0.2170)
0.010-0.037 (0.0004-0.0015)
0.030-0.057(0.0012-0.0022)
14.8-15.2(0.58-0.60)
17.3-17.7(0.68-0.70)
1.0-1.1 (0.039-0.043)
37.20 (1.465)
44.20 (1.740)
12.000 - 12.018 (0.4724 - 0.4731)
11.964 - 11.984 (0.4710 - 0.4718)
0.016 - 0.054 (0.0006 - 0.0021)
35.015 - 35.175 (1.3785 - 1.3848)
35.394 - 35.554 (1.3935 - 1.3998)
22.467 - 22.482 (0.8845 - 0.8851)
22.510 - 22.526 (0.8862 - 0.8868)
0.028 - 0.059 (0.0011 - 0.0023)
-
Unit: mm (in)
SERVICE LIMIT
5.45(0.215)
5.43 (0.214)
5.53(0.218)
0.12 (0.005)
0.14 (0.006)
1.4(0.06)
36.3 (1.43)
43.1 (1.70)
12.05(0.474)
11.92 (0.469)
0.08 (0.003)
34.840 (1.3717)
35.144(1.3824)
22.46 (0.884)
22.54 (0.887)
0.07 (0.003)
0.05 (0.002)
CYLINDER/PISTON SPECIFICATIONS
ITEM
Cylinder
I.D.
Out-of-round
Taper
Warpage
Piston,
Piston O.D. at 20 (0.8) from bottom
piston pin,
Piston pin hole I.D.
piston ring
Piston pin O.D.
Piston-to-piston pin clearance
Piston ring end
Top
gap
Second
Oil (side rail)
Piston ring-to-ring
Top
groove clearance
Second
Cylinder-to-piston clearance
Connecting rod small end I.D.
Connecting rod-to-piston pin clearance
STANDARD
102.000 - 102.015 (4.0157 - 4.0163)
101.960 - 101.990 (4.0142 - 4.0153)
23.002 - 23.008 (0.9056 - 0.9058)
22.994 - 23.000 (0.9053 - 0.9055)
0.002 - 0.014 (0.0001 - 0.0006)
0.25-0.35(0.010-0.014)
0.40-0.55(0.016-0.022)
0.20-0.70(0.008-0.028)
0.045 - 0.080 (0.0018 - 0.0031)
0.025 - 0.060 (0.0010 - 0.0024)
0.010 - 0.055 (0.0004 - 0.0022)
23.030 - 23.050 (0.9067 - 0.9075)
0.030 - 0.056 (0.0012 - 0.0022)
Unit: mm (in)
SERVICE LIMIT
102.05(4.018)
0.05 (0.002)
0.05 (0.002)
0.05 (0.002)
101.90(4.012)
23.03 (0.907)
22.98 (0.905)
0.04 (0.002)
0.5 (0.02)
0.7 (0.03)
0.9 (0.04)
0.095 (0.0037)
0.075 (0.0030)
0.19 (0.007)
23.06 (0.908)
0.08 (0.003)
ALTERNATOR/STARTER CLUTCH SPECIFICATIONS
ITEM
Starter driven gear boss O.D.
Torque limiter slip torque
1-8
STANDARD
51.705 - 51.718 (2.0356 - 2.0361)
53-84N-m(5.4-8.6kgf-m,
3 9 - 6 2 Ibf-ft)
Unit: mm (in)
SERVICE LIMIT
51.61 (2.032)
—
GENERAL INFORMATION
SUB-TRANSMISSION/GEARSHIFT LINKAGE SPECIFICATIONS
ITEM
Shift fork
Reverse idle
gear
I.D.
Claw thickness
Shaft O.D.
Collar I.D.
Shaft O.D.
Collar-to-shaft clearance
STANDARD
11.000-11.021 (0.4331-0.4339)
4.93-5.00(0.194-0.197)
10.966 - 10.984 (0.4317 - 0.4324)
13.000 - 13.034 (0.5118 - 0.5131)
12.966 - 12.984 (0.5105 - 0.5112)
-
Unit: mm (in)
SERVICE LIMIT
11.04 (0.435)
4.5(0.18)
10.96(0.431)
13.05(0.514)
12.93(0.509)
0.10 (0.004)
CRANKCASE/CRANKSHAFT/BALANCER SPECIFICATIONS
Crankshaft
0.05 (0.002)
0.05-0.65(0.002-0.026)
0.006 - 0.018 (0.0002 - 0.0007)
Unit: mm (in)
SERVICE LIMIT
0.15(0.059)
0.8 (0.03)
0.05 (0.002)
Line
1st, 2nd and 3rd clutch
STANDARD
785 kPa (8.0 kgf/cm2,114 psi)
785 kPa (8.0 kgf/cm2,114 psi)
Unit: mm (in)
SERVICE LIMIT
—
Initial clearance
Disc thickness
Plate thickness
Return spring free length
0.7-0.9(0.03-0.04)
1.88-2.00(0.074-0.079)
1.95-2.05(0.077-0.081)
33.8 (1.33)
worn out lining
discoloration
31.8(1.25)
ITEM
Runout
Big end side clearance
Big end radial clearance
STANDARD
DRIVETRAIN SPECIFICATIONS
ITEM
Oil pressure
at 5,000 rpm
(min-1)
Shift clutch
(1st, 2nd and
3rd)
FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS
ITEM
Minimum tire tread depth
Cold tire pressure
Standard
Minimum
Maximum
With cargo
Tie-rod distance between the ball joints
Toe
STANDARD
30 kPa (0.30 kgf/cm2, 4.4 psi)
26 kPa (0.26 kgf/cm2, 3.8 psi)
34 kPa (0.34 kgf/cm2, 5.0 psi)
30 kPa (0.30 kgf/cm2, 4.4 psi)
387.5 + 1 mm (15.26 ± 0.4 in)
Toe-out: 10.9 ± 15 mm (7/16 ± 9/16 in)
SERVICE LIMIT
4 mm (0.16 in)
-
REAR WHEEL/SUSPENSION SPECIFICATIONS
ITEM
Minimum tire tread depth
Cold tire pressure
Standard
Minimum
Maximum
With cargo
25
22
28
25
kPa
kPa
kPa
kPa
(0.25
(0.22
(0.28
(0.25
STANDARD
kgf/cm2, 3.6 psi)
kgf/cm2, 3.2 psi)
kgf/cm2, 4.0 psi)
kgf/cm2, 3.6 psi)
SERVICE LIMIT
4 mm (0.16 in)
-
1-9
GENERAL INFORMATION
BRAKE SYSTEM SPECIFICATIONS
ITEM
Recommended brake fluid
Front brake
Brake disc thickness
Brake disc runout
Master cylinder I.D.
Master piston O.D.
Caliper cylinder I.D.
Caliper piston O.D.
Rear brake
Brake disc thickness
Brake disc runout
Master cylinder I.D.
Master piston O.D.
Caliper cylinder I.D.
Caliper piston O.D.
Rear (parking) brake lever free play
STANDARD
Honda DOT 4 brake fluid
4.0(0.16)
14.000 - 14.043 (0.5512 - 0.5529)
13.957 - 13.984 (0.5495 - 0.5506)
33.960 - 34.010 (1.3370 - 1.3390)
33.878 - 33.928 (1.3338 - 1.3357)
7.5 (0.30)
15.870 - 15.913 (0.6248 - 0.6265)
15.827 - 15.854 (0.6231 - 0.6242)
30.230 - 30.280 (1.1902 - 1.1921)
30.165-30.198(1.1876-1.1889)
25-30(1-1-3/16)
Unit: mm (in)
SERVICE LIMIT
3.0(0.12)
0.30(0.012)
14.055(0.5533)
L_13.945 (0.5490)
34.02(1.340)
33.87(1.333)
6(0.2)
0.5 (0.02)
15.925(0.6270)
15.815(0.6226)
30.29(1.193)
30.14(1.187)
-
FRONT DRIVING MECHANISM SPECIFICATIONS
Front differential
ITEM
Oil capacity
At draining
At disassembly
Recommended oil
Gear backlash
Backlash difference
Slip torque
Face cam-to-housing distance
Differential ring gear depth
Cone spring height
STANDARD
175 cm3 (5.9 US oz, 6.2 Imp oz)
220 cm3 (7.4 US oz, 7.7 Imp 02)
Hypoid gear oil SAE #80
0.05-0.25(0.002-0.010)
14-17Nm(1.45-1.75kgfm,
10-13 Ibfft)
3.3-3.7(0.13-0.15)
6.55-6.65(0.2579-0.2618)
2.8(0.11)
Unit: mm (in)
SERVICE LIMIT
0.4 (0.02)
0.2(0.01)
12Nm(1.2
kgfm, 9 Ibfft)
3.3(0.13)
6.55 (0.2579)
2.6(0.10)
REAR DRIVING MECHANISM SPECIFICATIONS
Final drive
ITEM
Oil capacity
At draining
At disassembly
Recommended oil
Gear backlash
Backlash difference
Ring gear-to-stop pin clearance
STANDARD
78 cm3 (2.6 US 02, 2.7 Imp oz)
90 cm3 (3.0 US oz, 3.2 Imp oz)
Hypoid gear oil SAE #80
0.05-0.25(0.002-0.010)
0.3-0.6(0.01-0.02)
BATTERY/CHARGING SYSTEM SPECIFICATIONS
Battery
(YTX20LBS)
Alternator
1-10
ITEM
Capacity
Current leakage
Voltage
Fully charged
(20°C/68°F)
Needs charging
Charging curNormal
rent
Quick
Capacity
Charging coil resistance (20°C/68°F)
SPECIFICATIONS
12V-18 Ah
1 mA max.
13.0-13.2V
Below 12.3 V
1.8 A/5-10 h
9.0 A/1 .Oh
360 W/5,000 rpm (mirV1)
0 . 1 - 1.0 Q.
Unit: mm (in)
SERVICE LIMIT
0.4 (0.02)
0.2(0.01)
-
GENERAL INFORMATION
IGNITION SYSTEM SPECIFICATIONS
ITEM
Standard
Spark plug
SPECIFICATIONS
IFR5L11 (NGK)
VK16PRZ11 (DENSO)
IFR6L11 (NGK)
VK20PRZ11 (DENSO)
1.0-1.1 mm (0.039-0.043 in)
100 V minimum
0.7 V minimum
15°BTDCatidle
For extended high speed
riding
Spark plug gap
Ignition coil peak voltage
CKP sensor peak voltage
Ignition timing ("F" mark)
ELECTRIC STARTER SPECIFICATIONS
ITEM
Starter motor brush length
STANDARD
12.0-13.0(0.47-0.51)
Unit: mm (in)
SERVICE LIMIT
6.5 (0.26)
LIGHTS/METERS/SWITCHES SPECIFICATIONS
Bulb
Fuse
ITEM
Headlight
Brake/taillight
Neutral indicator
Reverse indicator
4WD indicator
Coolant/engine oil temperature
indicator
MIL (PGM-FI indicator)
Meter light
Main
Sub-fuse
SPECIFICATIONS
12V-40/40Wx2
12V-21/5Wx2
LED
LED
LED
LED
LED
LED x 10
30 A x 2
15Ax1,10Ax4
1-11
GENERAL INFORMATION
STANDARD TORQUE VALUES
FASTENER TYPE
5 mm hex bolt and nut
6 mm hex bolt and nut
8 mm hex bolt and nut
10 mm hex bolt and nut
12 mm hex bolt and nut
N-m (kgf-m, Ibfft)
5 (0.5, 3.6)
10(1.0,7)
22(2.2,16)
34 (3.5, 25)
54 (5.5, 40)
FASTENER TYPE
5 mm screw
6 mm screw
6 mm flange bolt (8 mm head, small flange)
6 mm flange bolt (8 mm head, large flange)
6 mm flange bolt (10 mm head) and nut
8 mm flange bolt and nut
10 mm flange bolt and nut
N-m (kgf-m, Ibfft)
4 (0.4, 2.9)
9 (0.9, 6.5)
10(1.0,7)
12(1.2,9)
12(1.2,9)
26 (2.7, 20)
39 (4.0, 29)
ENGINE & FRAME TORQUE VALUES
• Torque specifications listed below are for important fasteners.
• Others should be tightened to standard torque values listed above.
ENGINE
MAINTENANCE
ITEM
Spark plug
Valve adjusting screw lock nut
Timing hole cap
Engine oil drain bolt
Engine oil filter center bolt
QTY
1
4
1
1
1
THREAD
DIA. (mm)
14
6
14
12
20
TORQUE
N m (kgf-m, Ibfft)
22(2.2,16)
17(1.7,12)
10(1.0,7)
25(2.5,18)
18(1.8,13)
THREAD
DIA. (mm)
6
TORQUE
N-m (kgf-m, Ibfft)
12(1.2,9)
THREAD
DIA. (mm)
REMARKS
LUBRICATION SYSTEM
ITEM
Oil pump driven sprocket bolt
QTY
1
REMARKS
Apply locking agent
1
1
1
3
1
1
2
2
TORQUE
N-m (kgf-m, Ibfft)
1.5(0.15,1.1)
3.4(0.35,2.5)
4.2(0.43,3.1)
4.2(0.43,3.1)
5.1 (0.53, 3.8)
2.1 (0.21,1.5)
THREAD
DIA. (mm)
7
TORQUE
N-m (kgf-m, Ibfft)
12(1.2,9)
THREAD
DIA. (mm)
10
TORQUE
N-m (kgf-m, Ibfft)
55(5.6,41)
THREAD
DIA. (mm)
10
TORQUE
N-m (kgf-m, Ibfft)
-
CJl
Insulator band screw (throttle body side)
Insulator band screw (engine side)
Throttle drum cover screw
Sensor unit mounting screw
Fuel feed hose bracket screw
Harness guide bracket screw
Fuel injector/feed hose mounting bolt
IACV mounting torx screw
QTY
5
4
CJl CJl
ITEM
CJl
FUEL SYSTEM
5
5
REMARKS
page 6-42
page 6-46
COOLING SYSTEM
ITEM
Water pump impeller
QTY
4
REMARKS
CYLINDER HEAD/VALVE/CAMSHAFT
ITEM
Cylinder head cover cap nut
QTY
4
REMARKS
Apply engine oil
CYLINDER/PISTON
ITEM
Cylinder stud bolt
1-12
QTY
4
REMARKS
page 10-7
GENERAL INFORMATION
ALTERNATOR/STARTER CLUTCH
ITEM
CD t— CO CN
Starter clutch socket bolt
Recoil starter driven pulley bolt
Alternator stator bolt
CKP sensor mounting bolt
QTY
THREAD
DIA. (mm)
8
12
6
5
TORQUE
N-m (kgf-m, Ibf-ft)
30(3.1,22)
108(11.0,80)
10(1.0,7)
6 (0.6, 4.3)
TORQUE
N-m (kgf-m, Ibf-ft)
18(1.8,13)
108(11.0,80)
REMARKS
Apply locking agent
Apply engine oil
Apply locking agent
DRIVE TRAIN
Oil pass bolt
Primary driven gear lock nut
1
1
THREAD
DIA. (mm)
20
16
Stator shaft inner collar stopper pin
Torque converter lock nut
1
1
10
22
14(1.4,10)
108(11.0,80)
Oil feed pipe setting cap
1
24
21 (2.1,15)
THREAD
DIA. (mm)
10
10
TORQUE
N-m (kgf-m, Ibf-ft)
THREAD
DIA. (mm)
8
8
8
5
5
5
8
TORQUE
N-m (kgf-m, Ibf-ft)
37 (3.8, 27)
37 (3.8, 27)
23(2.3,17)
3.2 (0.33, 2.4)
5.4 (0,55, 4.0)
3.2 (0.33, 2.4)
32 (3.3, 24)
THREAD
DIA. (mm)
30
8
30
8
4
12
TORQUE
N-m (kgf-m, Ibf-ft)
12(1.2,9)
12(1.2,9)
12(1.2,9)
12(1.2,9)
2(0.2,1.4)
54 (5.5, 40)
THREAD
DIA. (mm)
4
TORQUE
N-m (kgf-m, Ibf-ft)
1.5(0.15, 1.1)
THREAD
DIA. (mm)
10
10
8
TORQUE
N-m (kgf-m, Ibf-ft)
54 (5.5, 40)
54(5.5,40)
32 (3.3, 24)
ITEM
QTY
REMARKS
Apply engine oil,
Lock nut: replace with
a new one
Stake
Apply locking agent
Apply engine oil,
Lock nut: replace with
a new one
Stake
LIGHTS/METERS/SWITCHES
ITEM
ECT sensor
EOT sensor
QTY
1
1
REMARKS
12(1.2,9)
12(1.2,9)
FRAME
FRAME/BODY PANELS/EXHAUST SYSTEM
ITEM
Front carrier and carry pipe bolt
Rear carrier bolt
Muffler band bolt
Front exhaust pipe cover screw
Muffler heat protector screw
Muffler cover screw
Footpeg bracket nut
QTY
8
6
2
3
3
2
4
REMARKS
MAINTENANCE
ITEM
QTY
Front differential oil filler cap
Front differential oil drain bolt
Rear final gear case oil filler cap
Rear final gear case oil drain bolt
Front master cylinder reservoir cap screw
Tie-rod lock nut
1
1
1
1
2
4
REMARKS
FUEL SYSTEM
ITEM
Bank angle sensor mounting bolt
QTY
2
REMARKS
ENGINE REMOVAL/INSTALLATION
ITEM
CN «CN
Lower engine hanger nut (left and right)
Upper engine hanger bolt
Upper engine hanger bracket bolt
QTY
REMARKS
1-13
GENERAL INFORMATION
SUB-TRANSMISSION/GEARSHIFT LINKAGE
ITEM
Q'TY
Gear selector lever pivot nut
Gear selector arm pinch bolt
Gear selector cable lock nut
THREAD
DIA. (mm)
12
6
14
TORQUE
N m (kgf-m, Ibfft)
9 (0.9, 6.5)
16(1.6,12)
26 (2.7, 20)
TORQUE
N m (kgf-m, Ibfft)
39 (4.0, 29)
REMARKS
FRONT WHEEL/SUSPENSION/STEERING
Handlebar lower holder nut
2
THREAD
DIA. (mm)
10
Front wheel nut
Front wheel hub nut
8
2
10
16
64 (6.5, 47)
78 (8.0, 58)
Front brake caliper bracket flange bolt
4
10
44 (4.5, 33)
Front brake disc bolt
8
8
42(4.3,31)
Front brake splash guard flange bolt
6
6
11 (1.1,8)
Shock absorber mounting nut
4
10
44 (4.5, 33)
Brake hose clamp flange bolt
Upper arm pivot nut
5
2
6
10
12(1.2,9)
34 (3.5, 25)
Lower arm pivot nut
4
10
44 (4.5, 33)
Upper and lower arm ball joint nut
4
12
29 (3.0, 22)
Tie-rod ball joint nut
4
12
54 (5.5, 40)
Combination meter stay mounting nut
Steering shaft end nut
Steering shaft holder bolt
Parking lock lever screw
Rear brake lever pivot bolt
Rear brake lever pivot nut
Parking stopper stay screw
Parking stopper stay screw
Brake light switch (left lever side)
2
1
2
1
1
1
1
1
1
8
14
8
6
6
6
4
6
4
25(2.5,18)
108(11.0,80)
32 (3.3, 24)
7(0.7,5.1)
1 (0.1,0.7)
6 (0.6, 4.3)
2(0.2,1.4)
2(0.2,1.4)
1 (0.1,0.7)
ITEM
1-14
QTY
REMARKS
Lock nut: replace
with a new one
Castle nut: tighten to
the specified torque
and further tighten
until its grooves
aligns with the cotter pin hole
ALOC bolt: replace
with a new one
ALOC bolt: replace
with a new one
ALOC bolt: replace
with a new one
Lock nut: replace
with a new one
Lock nut: replace
with a new one
Lock nut: replace
with a new one
Castle nut: tighten to
the specified torque
and further tighten
until its grooves
aligns with the cotter pin hole
Lock nut: replace
with a new one
Apply locking agent
GENERAL INFORMATION
REAR WHEEL/SUSPENSION
Rear wheel nut
Rear wheel hub nut
8
2
THREAD
DIA. (mm)
10
20
Upper arm pivot nut (frame side)
4
10
34 (3.5, 25)
Upper arm pivot nut (knuckle side)
2
12
54 (5.5, 40)
Lower arm pivot nut
4
10
34 (3.5, 25)
TORQUE
N-m (kgf-m, Ibf-ft)
34 (3.5, 25)
5.4 (0.55, 4.0)
23 (2.3, 17)
17(1.7,12)
1 (0.1,0.7)
5.9 (0.6, 4.3)
12(1.2,9)
5.4 (0.55, 4.0)
2(0.2,1.4)
27 (2.8, 20)
32 (3.3, 24)
23(2.3,17)
30(3.1,22)
ITEM
Q'TY
TORQUE
N-m (kgf-m, Ibf-ft)
64 (6.5, 47)
137(14.0,101)
REMARKS
Castle nut: tighten to
the specified torque
and further tighten
until its grooves
aligns with the cotter pin hole
Lock nut: replace
with a new one
Lock nut: replace
with a new one
Lock nut: replace
with a new one
BRAKE SYSTEM
Brake hose oil bolt
Front caliper bleed valve
Front caliper slide pin flange bolt
Front brake pipe
Front brake lever pivot bolt
Front brake lever pivot nut
Front master cylinder holder bolt
Rear brake caliper bleed valve
Rear brake reservoir hose joint screw
Rear brake caliper parking nut
Rear brake caliper bracket pin bolt
Rear brake caliper pin retaining bolt
Rear brake caliper mounting bolt
5
2
2
2
1
1
2
1
1
1
1
1
2
THREAD
DIA. (mm)
10
8
8
10
6
6
6
8
4
10
8
8
8
Rear brake disc bolt
5
6
20 (2.0, 14)
TORQUE
N-m (kgf-m, Ibf-ft)
49 (5.0, 36)
ITEM
Q'TY
REMARKS
Apply locking agent
ALOC bolt: replace
with a new one
ALOC bolt: replace
with a new one
FRONT DRIVING MECHANISM
Differential ring gear bolt
10
THREAD
DIA. (mm)
8
Differential case cover bolt
Differential final clutch bolt
Differential mounting bolt
Differential mounting nut
2
4
3
1
1
10
8
8
10
10
49 (5.0, 36)
25(2.6,19)
25(2.6,19)
44 (4.5, 33)
44 (4.5, 33)
Front vehicle speed sensor bolt
Rear vehicle speed sensor bolt
Speed sensor cover stay bolt
Rear vehicle speed sensor cover bolt
1
2
2
2
2
8
6
6
6
6
22(2.2, 16)
10(1.0,7)
10(1.0,7)
10(1.0,7)
7(0.7,5.1)
ITEM
Q'TY
REMARKS
Special bolt: replace
with a new one
Apply locking agent
Lock nut: replace
with a new one
1-15
GENERAL INFORMATION
REAR DRIVING MECHANISM
Final gear case pinion bearing lock nut
1
THREAD
DIA. (mm)
64
Pinion joint nut
Final gear case cover bolt
1
2
4
2
16
10
8
10
108(11.0,80)
49 (5.0, 36)
25(2.6,19)
34 (3.5, 25)
2
10
39 (4.0, 29)
4
10
34 (3.5, 25)
ITEM
Final gear case mounting nut (main
frame)
Final gear case mounting nut (sub-frame)
Sub-frame joint nut
1-16
Q'TY
TORQUE
N-m (kgf-m, Ibfft)
98(10.0,72)
REMARKS
Lock nut: replace
with a new one,
Stake
Apply locking agent
Apply locking agent
Lock nut: replace
with a new one
Lock nut: replace
with a new one
GENERAL INFORMATION
LUBRICATION & SEAL POINTS
ENGINE
MATERIAL
Molybdenum disulfide
solution (a mixture of
engine oil and molybdenum disulfide grease in a
ratio of 1:1)
Engine oil
Molybdenum disulfide
grease
Multi purpose grease
Locking agent
Sealant (Three Bond 1215
or equivalent)
LOCATION
Water pump impeller shaft sliding surface
Camshaft cam lobes
Rocker arm shaft sliding surfaces
Valve stems (valve sliding surface)
Piston pin outer surface
Starter driven gear bearing
Starter reduction gear shaft splines
Starter reduction gear teeth
Starter motor shaft splines
Crankshaft torque converter contact surface
Oil strainer rubber seal
Rocker arm followers and adjusting screw tips
Cam chain
Cam followers (entire surface)
Cylinder head cap nut threads and seating surfaces
Connecting rod small end inner surface
Piston outer surface and piston pin hole
Piston rings
Cylinder bore
Starter sprag clutch (entire surface)
Recoil starter driven pulley bolt threads and seating
surface
Shift fork shaft
Shift drum guide groove
Transmission gear teeth and sliding surfaces
Mainshaft, countershaft and output shaft journals
Primary driven gear lock nut threads and seating surface
Torque converter sprag clutch and bearings
Torque converter lock nut threads and seating surface
Oil feed pipes (entire surface)
Each bearing rotating area
Each O-ring
Each oil seal lips
REMARKS
Camshaft cam surface
Specified area (page 9-18)
Recoil starter driven pulley oil seal lips
Recoil starter drive pulley pivot
Recoil starter center bolt
Ignition pulse generator bolt threads
Starter clutch bolt threads
Shift return spring pin threads
Shift drum stopper arm pivot bolt threads
Oil pump driven sprocket bolt threads
Cam chain tensioner pivot bolt threads
Alternator wire grommet seating surface
Front crankcase cover mating surface
Crankcase mating surface
Specified area (page 14-58)
Specified area (page 13-13)
1-17
GENERAL INFORMATION
FRAME
MATERIAL
Multi purpose grease
(NLGI#2)
LOCATION
Throttle cable ends
Throttle cable adjuster threads
Throttle lever pivot and dust seal lips
Rear brake lever pivot
Parking lock arm pivot (screw)
Steering shaft bushing inner surface
Steering shaft dust seal lips
Front knuckle outer dust seal lips
Front knuckle inner dust seal lips
Front upper arm pivot bushings
Front upper arm pivot dust seal lips
Front shock absorber lower bearing (upper arm)
Front shock absorber lower pivot dust seal lips (upper
arm)
Rear knuckle dust seal lips
Rear upper arm pivot bearings (frame side)
Rear upper arm pivot bushings (knuckle)
Rear lower arm pivot bushings
Rear suspension arm pivot dust seal lips
Rear brake pedal pivot
Rear brake pedal pivot dust seal lips
Rear brake cable ends
Differential oil seal lips (2 places; drive shafts)
Differential O-rings (3 places)
Differential final clutch inside (dust seals and bearing)
Vehicle speed sensor O-rings
Final gear case oil seal lips (4 places)
Final gear case O-rings (3 places)
Gear selector lever pivot
Gear selector lever gate grooves
Molybdenum disulfide
grease
Molybdenum disulfide
paste
:
NKG205 (KYODO YUSHI)
Steering shaft splines
Rear suspension arm pivot bolt head and O-rings
(knuckle side)
Front propeller shaft seal outer surfaces (2 places)
Output shaft joint splines (front propeller shaft side)
Output shaft joint splines (engine side)
Differential pinion joint splines
Front drive shaft splines (wheel side)
Rear propeller shaft seal outer surface
Final gear case pinion joint splines (rear propeller
shaft side)
Universal joint bearing
Universal joint splines (both sides)
Rear drive shaft splines (each end)
Rear shock absorber pivot bushings (upper and lower)
Rear shock absorber pivot dust seal lips
Front drive shaft inboard joint inside
NKG106(KYODOYUSHI)
Front drive shaft outboard joint inside
NKG205 (KYODO YUSHI)
Rear drive shaft inboard joint inside
NKG106 (KYODO YUSHI)
Rear drive shaft outboard joint inside
Silicone grease
Front brake lever-to-master piston contacting area
Front brake lever pivot bolt
Brake caliper dust seal lips
Brake caliper slide pin boot grooves and boots inside
Throttle cable outer inside
Rear brake cable inside
Cable lubricant
1-18
REMARKS
Apply 2 - 3 g
Fill up 2.5-3 g
Fill up 2.5-3 g per each
seal
Fill up 3 g per each bearing
Fill up 5 - 8 g
Fill up 5 - 8 g
Fill up 5 - 8 g
Fill up 40 joint
Fill up 55 joint
Fill up 60 joint
Fill up 45 joint
60 g per each
75 g per each
80 g per each
65 g per each
GENERAL INFORMATION
MATERIAL
DOT4 brake fluid
Honda bond A or Honda
Hand Grip Cement (U.S.A.
only) or equivalent
Locking agent
LOCATION
Brake master cylinder piston and cups
Brake caliper piston and piston seals
Handlebar grip rubber inside
Air cleaner housing-to-connecting tube (throttle body
and intake duct) mating areas
Cooling fan motor shaft threads
REMARKS
1-19
GENERAL INFORMATION
CABLE & HARNESS ROUTING
2WD/4WD SELECT
SWITCH WIRE
DRIVE MODE SELECT
SWITCH WIRE
BRAKE LIGHT
SWITCH WIRE
THROTTLE CABLE
LEFT HANDLEBAR
SWITCH WIRE
REAR BRAKE CABLE
BRAKE HOSE
FRONT BRAKE SWITCH/
BRAKE LIGHT SWITCH WIRE
2WD/4WD SELECT
SWITCH WIRE
DRIVE MODE SELECT
SWITCH WIRE
GPS model:
GPS RECEIVER
BRAKE LIGHT
SWITCH WIRE
LEFT HANDLEBAR
SWITCH WIRE
GPS RECEIVER
6PCONNECTOR
COMBINATION METER
COMBINATION METER WIRE
IGNITION SWITCH WIRE
1-20
GENERAL INFORMATION
RIGHT HANDLEBAR:
THROTTLE CABLE
DRIVE MODE SELECT
SWITCH WIRE
THROTTLE CABLE
2WD/4WD SELECT
SWITCH WIRE
FRONT BRAKE SWITCH
(for starting inhibitor)
REAR BRAKE LIGHT
SWITCH (Lever side)
SKY BLUE WIRE (FRONT SIDE)
GRAY WIRE (REAR SIDE)
BLACK WIRE (FRONT SIDE)
GREEN WIRE (REAR SIDE)
LEFT HANDLEBAR:
FRONT BRAKE
SWITCH WIRE
LEFT HANDLEBAR
SWITCH WIRE
1-21
GENERAL INFORMATION
FUEL LEVEL
SENSOR WIRE
PCM (POWERTRAIN
CONTROL MODULE)
DLC
SIPHON HOSE
OVERFLOW HOSE
REAR BRAKE CABLE
MAIN WIRE HARNESS
THROTTLE CABLE
SHIFT SOLENOID
SUB-HARNESS
FINAL DRIVE!
BREATHER HOSE
DIFFERENTIAL
BREATHER HOSE
FUEL LEVEL SENSOR 2P
(NATURAL) CONNECTOR
FAN MOTOR
BREATHER HOSE
HEADLIGHT SUB-HARNESS
3P (BLACK) CONNECTOR
1-22
GENERAL INFORMATION
THROTTLE CABLE
ACCESSORY SOCKET
REAR BRAKE CABLE
FUEL TANK BREATHER HOSE
FUEL LEVEL SENSOR
FUEL LEVEL SENSOR WIRE
FRONT BRAKE HOSE
HARNESS CLIP:
- Combination meter wire
- 2WD/4WD select switch wire
- Ignition switch wire
- Left handlebar switch wire
- Drive mode select switch wire
- Front brake switch/brake light switch wire
- Accessory socket wire
1-23
GENERAL INFORMATION
HARNESS CLIP:
- Combination meter wire
- Ignition switch wire
- 2WD/4WD select switch wire
- Left handlebar switch wire
- Drive mode select switch wire
- Front brake switch/brake light switch wire
- Accessory socket wire
- Differential breather hose
- Final gear case breather hose
IGNITION SWITCH 4P
(NATURAL) CONNECTOR
HANDLEBAR SWITCH
10P (LIGHT GREEN)
CONNECTOR
HARNESS CLIP:
- Ignition switch wire
- Front brake switch/brake light switch wire
- Drive mode select switch wire
- Left handlebar switch wire
- Bank angle sensor wire
DIFFERENTIAL
BREATHER HOSE
FRONT FINAL
CLUTCH WIRE
ACCESSORY SOCKET
2P (WHITE)
CONNECTOR
REAR VS
SENSOR
FRONT VS
SENSOR
BRAKE HOSE
HARNESS CLIP:
- Front VS sensor wire
- Rear VS sensor wire
- Front final clutch wire
- Differential breather hose
1-24
GENERAL INFORMATION
DIFFERENTIAL BREATHER HOSE
FRONT FINAL CLUTCH 2P
(GREEN) CONNECTOR
REAR VS SENSOR
FRONT FINAL
CLUTCH WIRE
REAR VS SENSOR WIRE
DIFFERENTIAL
BREATHER
HOSE
FRONT VS SENSOR
1-25
GENERAL INFORMATION
RIGHT FRONT
BRAKE HOSE
RIGHT FRONT
BRAKE HOSE
1-26
GENERAL INFORMATION
FAN MOTOR BREATHER HOSE
COMBINATION METER
14P (GRAY) CONNECTOR
COMBINATION METER 4P
(NATURAL) CONNECTOR
ACCESSORY SOCKET
2P (WHITE)
CONNECTOR
COMBINATION
METER 4P
(NATURAL)
CONNECTOR
FAN MOTOR 2P
(NATURAL) CONNECTOR
FRONT FINAL CLUTCH 2P
(GREEN) CONNECTOR
4WD SWITCH 2P (BLACK)
CONNECTOR
FRONT VS SENSOR 3P
(BLUE) CONNECTOR
SHIFT SOLENOID
SUB-HARNESS 6P
(NATURAL)
CONNECTOR
REAR VS SENSOR 3P (YELLOW)
CONNECTOR
1-27
GENERAL INFORMATION
FINAL GEAR CASE
BREATHER HOSE
MAIN WIRE HARNESS
FUEL PUMP 2P (BLACK)
CONNECTOR
REAR BRAKE
CABLE
FRONT STOP SWITCH 4P
(NATURAL) CONNECTOR
BANK ANGLE
SENSOR 3P (GREEN)
CONNECTOR
MODE SELECT SWITCH
3P (BLACK) CONNECTOR
1-28
GENERAL INFORMATION
SPARK PLUG WIRE
IGNITION COIL
SHIFT SOLENOID B
2P (BROWN)
CONNECTOR
LOWER
RADIATOR
HOSE
SHIFT SOLENOID A
2P (BLACK)
CONNECTOR
OIL COOLER
HOSES
SHIFT SOLENOID
SUB-HARNESS
SHIFT CONTROL CABLE
CLUTCH PC SOLENOID
2P (BLACK) CONNECTOR
FINAL GEAR CASE
BREATHER HOSE
FRAME GROUND CABLE
MAIN WIRE HARNESS
MAIN WIRE
HARNESS
REAR BRAKE
CABLE
20 - 40
BYPASS HOSE
STARTER MOTOR CABLE
BATTERY GROUND CABLE
WATER HOSE
1-29
GENERAL INFORMATION
FUEL HOSE (TANK-TO-PUMP)
UPPER RADIATOR HOSE
THROTTLE CABLE
FUEL FEED HOSE
SHIFT CONTROL CABLE
THROTTLE CABLE
FUEL FEED HOSE
INJECTOR 2P (GRAY)
CONNECTOR
GEAR POSITION
SWITCH 3P
(NATURAL)
CONNECTOR
THROTTLE BODY
HARNESS
1-30
IACV 4P (BLACK)
CONNECTOR
GENERAL INFORMATION
MAP/TP SENSOR 5P
(BLACK) CONNECTOR
ECT SENSOR 2P
(BLACK) CONNECTOR
REAR BRAKE CABLE
GEAR POSITION SWITCH WIRE
STARTER MOTOR CABLE
ALTERNATOR WIRE
GEAR POSITION SWITCH 3P
(NATURAL) CONNECTOR
REAR BRAKE SWITCH
2P(GREEN)
CONNECTOR
MAIN WIRE HARNESS
ALTERNATOR
5P (NATURAL)
CONNECTOR
FINAL GEAR CASE
BREATHER HOSE
BATTERY GROUND CABLE
EOT SENSOR 2P (BLACK)
CONNECTOR
1-31
GENERAL INFORMATION
REAR BRAKE CABLE
7
REAR BRAKE CALIPER
V
REAR BRAKE HOSE
REAR MASTER CYLINDER
BRAKE/TAILLIGHT 3P (BLACK) CONNECTOR
f
MAIN WIRE
HARNESS
1-32
IAT SENSOR
2P (BLACK)
CONNECTOR
GENERAL INFORMATION
FUSE BOX
BATTERY SUB-HARNESS 2P
(NATURAL) CONNECTOR
STARTER RELAY 2P
(NATURAL) CONNECTOR
BRAKE RESERVOIR HOSE
BATTERY
STARTER RELAY
RELAY MODULE
REAR BRAKE
SWITCH WIRE
BATTERY GROUND
CABLE
MAIN WIRE
HARNESS
FINAL GEAR
CASE BREATHER
HOSE
STARTER
MOTOR CABLE
REGULATOR/
RECTIFIER
RELAY MODULE 8P (GRAY)
CONNECTOR
STARTER RELAY 2P
(NATURAL) CONNECTOR
1-33
GENERAL INFORMATION
FINAL GEAR CASE
BREATHER HOSE
REAR BRAKE CAUPER
REAR MASTER CYLINDER
REAR BRAKE HOSE
1-34
GENERAL INFORMATION
LEFT HEADLIGHT
RIGHT HEADLIGHT
HEADLIGHT SUBHARNESS
FRONT CARRIER PIPE
HEADLIGHT SUB-HARNESS
RIGHT TAILLIGHT
LEFT TAILLIGHT
TAILLIGHT SUB-HARNESS
1-35
GENERAL INFORMATION
AUSTRALIA type only:
2WD/4WD SELECT
SWITCH WIRE
DRIVE MODE SELECT
SWITCH WIRE
BRAKE LIGHT
SWITCH WIRE
LEFT HANDLEBAR
SWITCH WIRE
THROTTLE CABLE
REAR BRAKE CABLE
2WD/4WD SELECT
SWITCH WIRE
FRONT BRAKE SWITCH/
BRAKE LIGHT SWITCH WIRE
DRIVE MODE SELECT
SWITCH WIRE
BRAKE LIGHT
SWITCH WIRE
HORN WIRE
LEFT HANDLEBAR
SWITCH WIRE
LEFT HANDLEBAR:
HORN SWITCH
FRONT BRAKE
SWITCH WIRE
HORN WIRE
LEFT HANDLEBAR
SWITCH WIRE
1-36
GENERAL INFORMATION
AUSTRALIA type only:
HARNESS CLIP:
- Combination meter wire
- Ignition switch wire
- 2WD/4WD select switch wire
- Left handlebar switch wire
- Drive mode select switch wire
- Front brake switch/brake light switch wire
- Accessory socket wire
- Differential breather hose
- Final gear case breather hose
- Horn wire
IGNITION SWITCH 4P
(NATURAL) CONNECTOR
HANDLEBAR SWITCH
10P (LIGHT GREEN)
CONNECTOR
HARNESS CLIP:
- Ignition switch wire
- Front brake switch/brake light switch wire
- Drive mode select switch wire
'/
- Left handlebar switch wire
- Bank angle sensor wire
DIFFERENTIAL
BREATHER HOSE
FRONT FINAL
CLUTCH WIRE
REAR VS
SENSOR
WIRE
ACCESSORY SOCKET
2P (WHITE)
CONNECTOR
FRONTVS
SENSOR
WIRE
HORN
WIRE
BRAKE HOSE
HARNESS CLIP:
- Front VS sensor wire
- Rear VS sensor wire
- Front final clutch wire
- Differential breather hose
- Horn wire
1-37
GENERAL INFORMATION
AUSTRALIA type only:
REAR BRAKE CABLE
THROTTLE CABLE
FAN MOTOR
BREATHER HOSE
FINAL DRIVE
BREATHER HOSE
DIFFERENTIAL
BREATHER HOSE
FUEL LEVEL SENSOR 2P
(NATURAL) CONNECTOR
HORN WIRE
HEADLIGHT SUB-HARNESS
3P (BLACK) CONNECTOR
DIFFERENTIAL
BREATHER HOSE
HORN WIRE
REAR VS SENSOR WIRE
FRONT FINAL CLUTCH WIRE
FRONT VS SENSOR WIRE
1-38
HORN UNIT
GENERAL INFORMATION
EMISSION CONTROL SYSTEMS
The U.S. Environmental Protection Agency (EPA), and the California Air Resources Board (CARB) require that off-road
motorcycle or ATV comply with applicable exhaust emissions standards and evaporative emissions standards during its
useful life, when operated and maintained according to the instruction provided.
SOURCE OF EMISSIONS
The combustion process produces oxides of nitrogen (NOx), carbon monoxide (CO) and hydrocarbons (HC). Controlling
oxides of nitrogen and hydrocarbon emissions is very important because, under certain conditions, they react to form
photochemical smog when subjected to sunlight. Carbon monoxide does not react in the same way, but it is toxic.
Honda Motor Co., Ltd. utilizes various system to reduce carbon monoxide and hydrocarbons.
EXHAUST EMISSION CONTROL SYSTEM
The exhaust emission control system is composed of the PGM-FI system.
No adjustments should be made. The exhaust emission control system is separate from the crankcase emission control
systems.
CRANKCASE EMISSION CONTROL SYSTEM
The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere.
Blow-by gas is returned to the combustion chamber through the air cleaner and throttle body.
AIR CLEANER
THROTTLE BODY
CRANKCASE BREATHER HOSE
Fresh air
Blow-by gas
SERVICING THE HONDA
U.S.A. Only
Maintenance, replacement or repair of the emission control devices and systems may be performed by any motorcycle/
ATV repair establishment or individual using parts that are "certified" to EPA standards.
PROHIBITED ACTIONS
The following prohibitions apply to everyone with respect to the engines emission control system.
You may not remove or disable any device or element of design that may affect an engine's emission levels. This
restriction applies before and after the engine in placed in service.
Vehicles that are used only for competition are exempt from this prohibition.
1-39
GENERAL INFORMATION
NOISE EMISSION CONTROL SYSTEM
TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: US Federal laws prohibit, or Canadian provincial laws
may prohibit the following acts or the causing thereof: (1)The removal or rendering inoperative by any person, other than
for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle
for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use; or (2) the use of
the vehicle after such device or element of design has been removed or rendered inoperative by any person.
AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE FOLLOWING ACTS:
1. Removal of, or puncturing the muffler, baffles, header pipes or any other component which conducts exhaust gases.
2. Removal of, or puncturing of any part of the intake system.
3. Lack of proper maintenance.
4. Replacing any moving parts of the vehicle, or parts of the exhaust or intake system, with parts other then those
specified by the manufacturer.
REBUILT ENGINE
When you rebuild your engine including a major overhaul in which you replace the engine's pistons or power assemblies
or make other changes that significantly increase the service life of the engine, the vehicle will continue to comply with all
emissions regulations if you:
-
Make sure you are technically qualified to rebuild the engine and have the proper tools
Diagnose and respond to all Diagnostic Trouble Codes (DTC), and clear all DTCs after addressing their cause
Use only Genuine Honda parts or equivalents
Make sure to maintain all specifications as described in this Service Manual
1-40
2. TECHNICAL FEATURES
PCM (POWERTRAIN CONTROL
MODULE)
PGM-FI SYSTEM
-2-3
AUTOMATIC TRANSMISSION SYSTEM
2-7
2-2
2-1
TECHNICAL FEATURES
PCM (POWERTRAIN CONTROL MODULE)
The engine and drivetrain systems of this model are controlled by the PCM; the ECM (Engine Control Module) and TCM
(Transmission Control Module) are integrated into the PCM.
The PCM controls the following systems:
• Engine management system
- PGM-FI system
- Ignition system
- Cooling fan control system
• Drivetrain system
- A/T (Automatic Transmission) system
- Selectable 4WD system
PCM
PGM-FI SYSTEM
This PGM-FI system for the ATV is composed of the fuel pump, throttle body and its electronic control system by PCM.
This system controls and manages the engine operation, and enhances the emission control performance, fuel economy,
starting performance and driveability when compared to a conventional carburetor.
DRIVETRAIN SYSTEM
This manual describes the A/T system and selectable 4WD system as "drivetrain" system. The PCM controls the front final
clutch located in the differential by selecting the 2WD/4WD switch. The PCM also controls the A/T system as described in
AUTOMATIC TRANSMISSION system feature (page 2-7).
SELF-DIAGNOSTIC FUNCTION
The PCM has a fail-safe function and also a self-diagnostic function for the PGM-FI, A/T and selectable 4WD system. Some
detection items (sensors, etc..) are shared by the PGM-FI and drivetrain systems and so their failure may affect the operation of both systems.
If both PGM-FI and DRIVETRAIN DTCs are indicated at the same time, troubleshoot the PGM-FI system first then check all
DTCs again.
2-2
TECHNICAL FEATURES
PGM-FI SYSTEM
INTEGRATED SENSOR THROTTLE BODY
This model is equipped with a throttle body that integrates the following sensors and device. This throttle body achieves a
compact design with simplified inspection capabilities.
• MAP (Manifold Absolute Pressure) sensor: detects the intake air pressure
• TP (Throttle Position) sensor: detects the throttle opening position
• IACV (Idle Air Control Valve): controls the engine idle speed and enhances the starting
• These components can be removed from the throttle body.
INJECTOR
IACV
THROTTLE BODY
MAP SENSOR
TP SENSOR
2-3
TECHNICAL FEATURES
IACV (Idle Air Control Valve)
The IACV consists of a step motor and a slide valve, and controls the amount of air bypassed around the closed throttle
valve. With the ignition switch ON, the amount of idle air is determined from information detected by the ECT sensor. During engine start-up or while maintaining idle (throttle valve closed), the amount of inlet air is adjusted by various sensors'
information.
This system eliminates the need for a manual idle speed adjustment and high altitude adjustment settings.
THROTTLE BODY
IACV
STEP MOTOR
SLIDE VALVE
AIR BYPASS
OPERATION
The PCM controls the IACV during engine idling only, so the PCM stops controlling the IACV and leaves it in the closed
position when the PCM detects the following:
• Throttle valve open
• Neutral switch off (in gear)
During engine idling and warm up, from the time the ignition switch is turned ON, the PCM controls the IACV step motor
as follows:
With the ignition switch ON
• When the ignition switch is turned ON, the IACV is initialized and
the step motor will operate:
the slide valve goes from open-to close-to the open position
STEP MOTOR
Engine starting and warm up
• While the throttle valve is closed, the bypass opening is optimized
by the IACV, and the correct amount of inlet air passes through
allowing proper engine starting.
• After the engine has started, the PCM controls the IACV step motor
to adjust the slide valve position by processing various sensor's
information.This results in a reduced amount of bypassed air compared to the amount during engine start-up, and initiates engine
warm-up for several minutes.

SLIDE VALVE
2-4
TECHNICAL FEATURES
After warming up - idling
• When the PCM receives input signals that indicate the completion
of engine warm-up, it operates the step motor to move the slide
valve to the downward. This results in a reduced amount of
bypassed air compared to the amount during engine warm-up,
which maintains proper engine idle speed.
STEP MOTOR
SLIDE VALVE
BANK ANGLE SENSOR
The bank angle sensor is located under the steering cover, it detects a vehicle rollover and interrupts the ignition/fuel system control. The bank angle sensor system controls the power supply for the injector, ignition coil and fuel pump directly
through the engine stop relay.
MAIN4
FUSE £
IGNITION ST/ECM
SWITCH
FUSE
BATTERY
INJECTOR
IGNITION
COIL
FUEL PUMP
OPERATION
When the vehicle topples over or tilts over 70 degrees horizontal or 135
degrees cross direction, the pendulum magnet inside the bank angle
sensor tilts and turns the reed switch on. Then, the bank angle sensor
opens the engine stop relay.
70° BANK ANGLE POSITION
NORMAL
POSITION
70° /(approximately)
70° (approximately)
2-5
TECHNICAL FEATURES
FUEL SUPPLY SYSTEM
The fuel supply system is composed of the fuel tank, sub fuel tank, fuel hoses, fuel vapor return hose, throttle body, and
injector. While riding in bumpy conditions, the fuel supply from the fuel tank may be unstable because of changes in the
vehicle attitude. To stabilize the supply of fuel, this system is equipped with a sub fuel tank between the fuel tank and throttle body. The fuel pump and pressure regulator are located inside the sub fuel tank.
The fuel hose has a quick connector at the sub fuel tank joint. Before disconnecting the quick connector, always relieve the
fuel pressure (page 6-32).
FUEL TANK
SUB FUEL TANK
-FUEL PUMP
- PRESSURE REGULATOR
THROTTLE BODY
OPERATION
Fuel flows through the fuel strainer inside the fuel tank to the fuel hose (low pressure). Inside the sub fuel tank, fuel flows
though the fuel filter and is fed by the fuel pump though the fuel hose (high pressure) to the injector.
The fuel pressure through the fuel pump is regulated by a pressure regulator that is located in the fuel passage in the sub
fuel tank and always kept under 343 kPa.
Fuel vapor generated in the sub fuel tank is returned to the fuel tank through the fuel vapor return hose.
FUEL FLOW CHART
FUEL TANK
FUEL STRAINER
VAPOR RETURN HOSE
FUEL FEED HOSE (HIGH PRESSURE)
- ^ ^
SUB FUEL TANK
-FUEL PUMP
- PRESSURE REGULATOR
2-6
FUEL HOSE (LOW PRESSURE)

FUEL FLOW
< # I • FUEL VAPOR
THROTTLE BODY
TECHNICAL FEATURES
AUTOMATIC TRANSMISSION SYSTEM
OUTLINE
This three-speed A/T (Automatic Transmission) system controls gear selection by means of the A/T mechanism that consists of the torque converter and the 3 shift clutches (hydraulic clutch).
To control the hydraulic clutch and to shift, the system changes the supply of hydraulic pressure to each clutch (1st, 2nd,
3rd) by activating the respective spool valves with the corresponding solenoid valves. Each solenoid valve is controlled by
the PCM, that detects the signal from each sensor and switch.
The hydraulic oil for this system is the engine oil, which is supplied from the ordinary oil pump for engine lubrication (page
5-2).
The valve body which incorporates solenoid valves and spool valves that control the clutch hydraulic pressure is laid out
independently on the crankcase cover to facilitate maintenance (page 14-47)
The sub-transmission is laid out in front of the output shaft, and selecting Drive-Neutral-Reverse can be made mechanically by operating the selector lever located near the drivers seat.
TORQUE CONVERTER
PRIMARY DRIVE GEAR
PRIMARY DRIVEN GEAR
SUB-TRANSMISSION
(COUNTERSHAFT)
COUNTERSHAFT
2nd SHIFT CLUTCH
OUTPUT SHAFT
3rd SHIFT CLUTCH
OUTPUT DRIVEN GEAR
2-7
TECHNICAL FEATURES
TORQUE CONVERTER
STRUCTURE
• Pump
The pump, directly connected to the crankshaft, converts engine output (torque) into oil flow.
• Turbine
Receiving the oil from the pump, the turbine transmits the torque to the transmission by way of the primary drive gear.
• Stator
The stator changes the direction of the oil flow drained from the turbine. It drains the oil toward the pump.
• Stator Shaft
It transmits the stator rotation to the one-way clutch.
• Stator One-way Clutch
The stator one-way clutch locks the stator at stalling and it releases (rotates) the stator at coupling (page 2-8).
• Inner Collar
The inner collar, prevented from turning by the stopper pin fixed on the crankcase, stops the rotation force at stalling,
which is transmitted from the stator by way of the one-way clutch.
• Engine Brake One-way Clutch
When the engine braking is applied, the engine brake one-way clutch directly transmits the input torque from the primary drive gear to the crankshaft. This allows the machine to slow down by engine braking.
• Seal Ring and Seal Collar
The seal ring and seal collar are provided to prevent oil leakage.
TURBINE BLADES
PUMP BLADES
ENGINE BRAKE ONE-WAY CLUTCH
SEAL RINGS
STATOR ONE-WAY CLUTCH
STATOR BLADES
Hydraulic Oil
INNER COLLAR
SEAL COLLAR
PRIMARY DRIVE GEAR
STOPPER PIN
OPERATION PRINCIPLE
1. Oil Flow:
The oil in the torque converter flows in this order; from the pump, to the turbine, and to the stator. The oil is supplied
from the inside of the pump, and the excess oil is drained from the turbine. The torque converter is cooled down by
draining (exchanging) the excess oil.
2. Stall Range:
When the difference of rotation speed between the pump and turbine is large, the stator turns in the reverse direction
from that of the turbine by receiving the reaction force from the turbine. As this motion is locked by the one-way clutch,
the counter torque is applied to the stator. To balance the rotation direction, the turbine torque (output torque) becomes
the sum of the pump torque and counter torque of the stator. Therefore, the output torque is amplified by the amount of
counter torque of the stator.
3. Coupling Range:
When the difference of rotation speed between the pump and turbine is small (0.8 or more), the reaction force applied
from the turbine to the stator is small and the stator turns in the same direction as that of the turbine. As the torque is
not amplified this time, the torque ratio is about 1.0 and the torque transfer efficiency to speed ratio changes in the ratio
of 1:1.
4. Engine Braking:
The input force from the primary drive gear is directly transmitted to the crankshaft by the one-way clutch, which produces the engine braking (Same as the conventional ATV).
2-8
TECHNICAL FEATURES
HYDRAULIC VALVE FUNCTION
• A/T Clutch Pressure Control Solenoid Valve (Linear Solenoid Valve)
The A/T Clutch PC solenoid valve controls the vehicle creep by diverting the hydraulic pressure that flows to the entire
clutch system to the linear valve.
• Shift Solenoid Valves (A and B)
The shift solenoid valves control the shift timing by supplying and shutting off hydraulic pressure to activate the shift
valves.
• Shift Valves (1-2 and 2-3)
The shift valves switch the hydraulic circuits to the three clutches.
• Orifice Control Valve (2nd and 3rd)
The orifice control valves operate when clutch fluid pressure rises during shifting. It releases the pressure to reduce
shift shock.
• Emergency Valve
The emergency valve is used when the hydraulic pressure is shut off by a faulty clutch PC solenoid valve (stuck;
mechanical lock), and the vehicle is hindered from running. Open the bypass oil circuit manually to supply hydraulic
fluid. (In this case, the transmission is held in 2nd range and the vehicle creeps during idling.)
3rd SHIFT CLUTCH
2nd SHIFT CLUTCH
3rd ORIFICE
CONTROL
VALVE
x
1st SHIFT CLUTCH
2ndORIFICE
CONTROL
VALVE x
SHIFT
SOLENOID
VALVE A
2-3 SHIFT VALVE
TORQUE CONVERTER
1-2 SHIFT
SHIFT
SOLENOID
VALVE B
EMERGENCY VALVE
Cylinder head
Alternator
Sub-transmission -«-
c
A/T CLUTCH PC
SOLENOID VALVE
OIL PUMP
2-9
TECHNICAL FEATURES
SHIFT CLUTCH HYDRAULIC CIRCUIT AND OPERATION
This system activates the A/T clutch PC solenoid valve, shift solenoid valve A and B as the PCM detects the following signals:
-
throttle angle,
vehicle speed
sub-transmission gear position (D - N - Ft)
drive mode (AUTO - ESP)
-
engine oil temperature
It controls the shift clutches for the situation according to the combination of the respective solenoid valves operation.
Gear in Neutral
Gear position
Neutral
Clutch PC
Solenoid
ON
Shift Solenoid
A
B
OFF
OFF
1st
-
Shift Clutch
2nd
-
3rd
-
• The hydraulic passage is the same as the transmission being in the 2nd range. The A/T clutch PC solenoid valve is on
(valve closed) and the hydraulic oil that flows to all shift clutches is shut off. Therefore, all clutches are inactive.
3rd SHIFT CLUTCH
2nd SHIFT CLUTCH
3rd ORIFICE
CONTROL
VALVE
1st SHIFT CLUTCH
2nd ORIFICE
CONTROL
VALVE
x
A_
SHIFT
SOLENOID
VALVE
TORQUE CONVERTER
EMERGENCY
VALVE
A/T CLUTCH PC
SOLENOID VALVE
OIL PUMP
2-10
TECHNICAL FEATURES
1st gear and Reverse gear
Gear position
1st/Reverse (idling)
1st/Reverse (riding)
A/T Clutch
PC Solenoid
ON
OFF
Shift Solenoid
A
B
ON
OFF
ON
OFF
1st
"Engaged"
"Engaged"
Shift Clutch
2nd
-
3rd
-
The hydraulic passage is connected to supply hydraulic oil to the 1st shift clutch, and the clutch is engaged.
Oil is supplied by way of: A/T clutch PC solenoid valve O 1-2 Shift valve =!> 1st Shift clutch
(Oil is drained by way of:
2nd Shift clutch O 2-3 Shift valve => 1-2 Shift valve
3rd Shift clutch d> 2-3 Shift valve)
At idling, the A/T clutch PC solenoid valve is on (valve closed) to eliminate vehicle creep.
At start up, the A/T clutch PC solenoid valve controls the clutch hydraulic pressure to the linear valve according to the
signal from the PCM.
At riding, the A/T clutch PC solenoid valve is off (valve open) supplying sufficient hydraulic oil to the shift clutch.
Control of the hydraulic passage during driving in Reverse gear is the same. However, the vehicle can be driven only in
the 1st-hold mode (no shift).
3rd SHIFT CLUTCH
2nd SHIFT CLUTCH
3rd ORIFICE
CONTROL
VALVE
x
"
1st SHIFT CLUTCH
2nd ORIFICE
CONTROL
VALVE
A
M
SHIFT
SOLENOID
VALVE
TORQUE CONVERTER
EMERGENCY
VALVE
A/T CLUTCH PC
SOLENOID VALVE
OIL PUMP
2-11
TECHNICAL FEATURES
Riding in 2nd range
Gear position
2nd gear
A/T Clutch
PC Solenoid
OFF
Shift Solenoid
A
B
OFF
OFF
1st
-
Shift Clutch
2nd
"Engaged"
3rd
-
The hydraulic passage is connected to supply hydraulic oil to the 2nd shift clutch.
Oil is supplied by way of: A/T clutch PC solenoid valve <^> 1-2 Shift valve <=> 2-3 Shift valve O 2nd Shift clutch
(Oil is drained by way of:
1st Shift clutch •=> 1-2 Shift valve •=> 2nd Orifice control valve
3rd Shift clutch d> 2-3 Shift valve)
When shifting from 1st to 2nd position, the draining volume of the 1st clutch hydraulic oil is controlled by the ordinary
orifice and the 2nd orifice control valve to reduce shift shock.*
*When the PCM detects system failure (fail-safe mode), the hydraulic passage is the same as above. (Therefore, the
vehicle can be ridden only in the 2nd-hold mode and creeping can occur at idle)
3rd SHIFT CLUTCH
2nd SHIFT CLUTCH
3rd ORIFICE
CONTROL
VALVE
1st SHIFT CLUTCH
2nd ORIFICE
CONTROL
VALVE
A
SHIFT
SOLENOID
VALVE
TORQUE CONVERTER
-EMERGENCY
VALVE
A/T CLUTCH PC
SOLENOID VALVE
OIL PUMP
2-12
TECHNICAL FEATURES
Riding in 3rd range
Gear position
3rd gear
A/T Clutch
PC Solenoid
OFF
Shift Solenoid
A
B
OFF
ON
1st
-
Shift Clutch
2nd
j
-
3rd
"Engaged"
The hydraulic passage is connected to supply hydraulic oil to the 3rd shiftclutch.
Oil is supplied by way of: A/T clutch PC solenoid valve O 1-2 Shift valve <=$ 2-3 Shift valve <=> 3rd Shift clutch
(Oil is drained by way of:
1st Shift clutch O 1-2 Shift valve >=> 2nd Orifice control valve
2nd Shift clutch ^ 2-3 Shift valve <=£ 3rd Orifice control valve)
When shifting from 2nd to 3rd position, the draining volume of the 2nd clutch hydraulic oil is controlled by the ordinary
orifice and the 3rd orifice control valve to reduce shift shock.
3rd SHIFT CLUTCH
2nd SHIFT CLUTCH
1st SHIFT CLUTCH
3rd ORIFICE
CONTROL
VALVE
2nd ORIFICE
CONTROL
VALVE
x
SHIFT
SOLENOID
VALVE
TORQUE CONVERTER
EMERGENCY
VALVE
A/T CLUTCH PC
SOLENOID VALVE
OIL PUMP
2-13
TECHNICAL FEATURES
AUTOMATIC TRANSMISSION PERFORMANCE CURVE
See the following graph for the relationship between vehicle speed and throttle angle,
It shows the shift timing (shift-up shown with the solid lines and shift-down with the dotted lines) and the ranges of shift
position.
100
90
10
15
20
25
30
35
40
45
Vehicle Speed (mph)
The vehicle condition is brake (s) not applied.
2-14
3. FRAME/BODY PANELS/EXHAUST SYSTEM
SERVICE INFORMATION
3-2
FRONT GRILLE
•3-10
TROUBLESHOOTING
3-2
FRONT CARRY PIPE-
•3-10
BODY PANEL LOCATIONS
3-3
FRONT CARRIER
•3-11
TRIM CLIP
3-4
FRONT FENDER
-3-11
SEAT-
3-4
MUFFLER PROTECTOR
•3-12
RIGHT SIDE COVER
3-5
REAR CARRIER/MUD GUARD
3-13
STEERING COVER
3-5
REAR FENDER
3-14
FUEL TANK COVER-
3-5
OUTER FENDER
•3-16
FUEL TANK SIDE COVER
3-6
ENGINE GUARD-
•3-17
CENTER MUD GUARD
3-7
ENGINE SIDE COVER-
•3-17
FRONT MUD GUARD-
3-8
METER COVER
INNER FENDER
3-9
EXHAUST SYSTEM-
3-18
•3-19
3-1
FRAME/BODY PANELS/EXHAUST SYSTEM
SERVICE INFORMATION
GENERAL
• This section covers removal and installation of the body panels and exhaust system.
• Always replace the gaskets after removing the exhaust system.
• Always inspect the exhaust system for leaks after installation.
TORQUE VALUES
Front carrier and carry pipe bolt
Rear carrier bolt
Muffler band bolt
Front exhaust pipe cover band screw
Muffler heat protector screw
Muffler cover screw
Footpeg bracket nut
TROUBLESHOOTING
Excessive exhaust noise
• Broken exhaust system
• Exhaust gas leak
Poor performance
• Deformed exhaust system
• Exhaust gas leak
• Clogged muffler
3-2
37 N-m (3.8 kgf-m, 27 Ibf-ft)
37 N-m (3.8 kgf-m, 27 Ibf-ft)
23 N-m (2.3 kgf-m, 17 Ibf-ft)
3.2 N-m (0.33 kgf-m, 2.4 Ibf-ft)
5.4 N-m (0.55 kgf-m, 4.0 Ibf-ft)
3.2 N-m (0.33 kgf-m, 2.4 Ibf-ft)
32 N-m (3.3 kgf-m, 24 Ibf-ft)
FRAME/BODY PANELS/EXHAUST SYSTEM
BODY PANEL LOCATIONS
(1) Seat (page 3-4)
(1)
(2) Right side cover (page 3-5)
(3)
(3) Steering cover (page 3-5)
(4) Fuel tank top/center cover (page 3-5)
(5) Fuel tank side cover (page 3-6)
(6) Center mud guard (page 3-7)
(7) Front mud guard (page 3-8)
(8) Inner fender (page 3-9)
(9) Front grille (page 3-10)
(10) Front carry pipe (page 3-10)
(11) Front carrier (page 3-11)
(12) Front fender (page 3-11)
(13) Muffler protector (page 3-12)
(14) Rear carrier/mud guard (page 3-13)
(15) Rear fender (page 3-14)
(16) Outer fender (page 3-16)
(17) Engine guard (page 3-17)
(18) Engine side cover (page 3-17)
(19) Meter cover (page 3-18)
(8)
(10)
(13)
3-3
FRAME/BODY PANELS/EXHAUST SYSTEM
TRIM CLIP
REMOVAL AND RETAINING PROCEDURE
When installing the
trim clip, carefully
align the clip holes
to avoid damaging
the clip.
Release by pulling the center pin up using a snap
ring pliers or a flat blade screwdriver and remove
the trim clip.
Install the clip and lock it by pushing the center pin
securely.
Remove and install
Release
SEAT
REMOVAL
Unlock the seat by pulling the release lever up.
Pull the seat back and remove it.
INSTALLATION
Install the seat by inserting the prongs into the seat
retainer on the frame.
Push the seat forward and align the mounting
bosses with the rubber mounts, then press down to
lock it.
SEAT
PRONGS
RETAINERS
LEVER
RUBBER MOUNTS
3-4
FRAME/BODY PANELS/EXHAUST SYSTEM
RIGHT SIDE COVER
Remove the right side cover by releasing the three
bosses from the grommets.
Be careful not to Install the right side cover in the reverse order of
dislodge the grommets.
BOSSES
removal.
COVER
STEERING COVER
Release the two bosses from the grommets by pulling the rear portion of the cover up and release the
two tabs to remove the steering cover.
Be careful not to
dislodge the grommets.
COVER
BOSSES
Install the cover in the reverse order of removal.
TABS
FUEL TANK COVER
Top Cover
Remove the following:
-
steering cover (page 3-5)
two trim clips
breather hose and fuel fill cap
HOSE
TRIM CLIPS
CAP
Release the four tabs, remove the fuel tank top
cover by sliding the cover forward.
Installation is in the reverse order of removal.
TABS
3-5
FRAME/BODY PANELS/EXHAUST SYSTEM
Center Cover
Remove the seat (page 3-4).
TRIM CLIPS
Release the four trim clips and remove the fuel tank
center cover.
Installation is in the reverse order of removal.
COVER
FUEL TANK SIDE COVER
Right side:
Remove the following:
-
TRIM CLIPS
seat (page 3-4)
right side cover (page 3-5)
fuel tank top cover (page 3-5)
setting bolt
four trim clips
COVER
Release the two tabs of the fuel tank side cover,
then remove the cover.
Installation is in the reverse order of removal.
TABS
BOLT
3-6
FRAME/BODY PANELS/EXHAUST SYSTEM
Left side:
Remove the following:
-
TRIM CLIPS
seat (page 3-4)
fuel tank top cover (page 3-5)
Turning the compartment lid quick screw counterclockwise
Release the two tabs, then remove the compartment lid.
TABS
SCREW
COVER
Release the two bosses and tabs, then remove the
oil filler lid.
Remove the following:
Be careful not to
dislodge the grommets when installing the filler lid.
setting bolt
six trim clips
fuel tank side cover
LID
Installation is in the reverse order of removal.
CENTER MUD GUARD
Right side:
Remove the right side cover (page 3-5).
Remove the two trim clips and then remove the
mud guard lid by releasing the three tabs.
Remove the following:
- two flange bolts and footpeg
- five trim clips
- socket bolt
- • right center mud guard
Installation is in the reverse order of removal.
SOCKET
BOLT
TRIM CLIPS
FOOTPEG
MUDGUARD
3-7
FRAME/BODY PANELS/EXHAUST SYSTEM
Left side:
Release the two bosses and tabs, then remove the
oil filler lid.
BOSSES
Remove the following:
-
two flange bolts and footpeg
seven trim clips
socket bolt
left center mud guard
Be careful not to Installation is in the reverse order of removal.
TABS
dislodge the grommets when installing the lid.
FLANGE
BOLTS
TRIM
CLIPS
SOCKET
BOLT
FOOTPEG
MUDGUARD
FRONT MUD GUARD
Remove the eight trim clips, then remove the front
mud guard from the mud guard stay.
Right side shown
MUDGUARD
Installation is in the reverse order of removal.
STAY
TRIM CLIPS
3-8
FRAME/BODY PANELS/EXHAUST SYSTEM
INNER FENDER
Right side:
Remove the following:
Hook the guide
over the frame
pipe.
TRIM CLIPS
two stay bolts
two trim clips
two tapping bolts
setting bolt
right inner fender
TAPPING BOLTS
Installation is in the reverse order of removal.
FENDER
STAYS
SETTING BOLT
Left side:
Remove the compartment lid (page 3-7).
WASHER
Remove the following:
Hook the guide
over the frame
pipe.
two stay bolts
trim clip and setting washer (inside the
storage compartment)
trim clip
tapping bolt
setting bolt
left inner fender
TAPPING BOLT
TRIM
CLIP
Installation is in the reverse order of removal.
FENDER
SETTING BOLT
STAYS
3-9
FRAME/BODY PANELS/EXHAUST SYSTEM
FRONT GRILLE
Center Grille
Remove the stone guard (page 3-10).
GRILLE
Remove the four setting bolts and the center front
grille.
BOLTS
Side Grille
Remove the following:
-
two trim clips
three bolts
side front grille
BOLTS
TRIM CLIPS
Installation is in the reverse order of removal.
GRILLE
FRONT CARRY PIPE
Remove the following:
-
TRIM CLIPS
four bolts
stone guard
center front grill (page 3-10)
four trim clips
six bolts
carry pipe
Installation is in the reverse order of removal.
TORQUE: 37 N m (3.8 kgf m, 27 Ibf-ft)
CARRY PIPE
BOLTS
BOLTS
STONE GUARD
3-10
FRAME/BODY PANELS/EXHAUST SYSTEM
FRONT CARRIER
The front carrier
and fender can be
removed as an
assembly for service. If removed,
use the procedure
described on page
3-12.
Remove the following:
-
center front grille (page 3-10)
wire band (that secured the headlight wire on the
carrier pipe)
two 6-mm bolts and collars (attached to fender)
two 6-mm bolts and collars (attached to headlight case)
four8-mm bolts
front carrier
CARRIER
8 mm
BOLTS
Installation is in the reverse order of removal.
•BAND
TORQUE: 8 mm bolt: 37 N-m (3.8 kgf-m, 27 Ibfft)
6 mm BOLTS AND COLLARS
FRONT FENDER
The front carrier
and fender can be
removed as an
assembly for service. If removed,
use the procedure
described on page
3-12.
Remove the following:
-
fuel tank side covers (page 3-6).
front carrier (page 3-11).
Remove the following connector and fasteners:
-
headlight 3P (Black) connector (from the frame
and disconnect it)
14 trim clips and setting washer (inside the storage compartment)
setting bolt and square nut
three tapping bolt (loosen)
FENDER
HEADLIGHT CONNECTOR
TAPPING
BOLTS
SQUARE NUT
TRIM CLIPS
Remove the front fender while spreading the rear
portion of it.
Installation is in the reverse order of removal.
SETTING
BOLT
CONNECTOR
WASHER
3-11
FRAME/BODY PANELS/EXHAUST SYSTEM
Carrier/Fender Assembly Removal
Procedure
Remove the following:
-
fuel tank side covers (page 3-6)
center front grille (page 3-10)
headlight connector and fender fasteners (page
3-11)
four 8-mm bolt (carrier mounting fasteners).
Loosen the three tapping bolts.
Remove the front carrier/fender assembly while
spreading the rear portion of the fender.
Installation is in the reverse order of removal.
TORQUE: 8 mm bolt: 37 N m (3.8 kgf-m, 27 Ibf-ft)
SQUARE NUT
HEADLIGHT
CONNECTOR
FRONT FENDER
8 mm BOLTS
TAPPING BOLTS (loosen)
TRIM CLIPS
TRIM CLIPS
BOLT
MUFFLER PROTECTOR
Remove the following:
-
SOCKET BOLTS
two setting bolts
four socket bolts
muffler protector
Installation is in the reverse order of removal.
COVER
SETTING BOLTS
3-12
FRAME/BODY PANELS/EXHAUST SYSTEM
REAR CARRIER/MUD GUARD
The rear carrier and Remove the f o l l o w i n g :
rear side body pan- _
(
K a
es can be removed
'
,
,
,
_ „_,
as an assembly for " rear corner outer fenders (page 3-16)
service. If removed. Disconnect the brake/taillight 3P (Black) connector.
use the procedure Release the wires from the clips and remove the 3P
described on page connector from the frame.
3-15.
Remove the following:
-
Only loosen the two lower inner
bolts. -
four trim clips and wire clamps
two setting bolts
two bolts and collars
four 8 mm bolts (two flange bolts and two
washer-bolts)
rear carrier assembly
BRAKE/TAILLIGHT CONNECTOR
CARRIER
ASSEMBLY
SETTING BOLTS
TRIM CLIPS
CLIPS
CONNECTOR
v
CLAMPS
8 mm BOLTS
-
Loosen
muffler protector (page 3-12)
two bolts, collars and rear mud guard
three bolts and muffler protector
wire bands and wire harness
BOLTS AND COLLARS
CARRIER
Secure the wires Installation is in the reverse order of removal.
with the bands
TORQUE: 8 mm bolt: 37 N-m (3.8 kgf-m, 27 Ibfft)
properly (page 120).
PROTECTOR
MUDGUARD
BOLTS AND COLLARS
3-13
FRAME/BODY PANELS/EXHAUST SYSTEM
REAR FENDER
The rear carrier and
rear side body panels can be removed
as an assembly for
service. If removed,
use the procedure
described on page
3-15.
Remove the seat (page 3-4).
Right side:
Remove the following:
-
right side cover (page 3-5)
fuse box (by releasing the tab from the reverse
side of the fender)
2P (White) connector
two setting bolts
bolt and collar (front side)
bolt, collar and setting rubbers (rear side)
socket bolt
seven trim clips, setting washer and wire clamp
right rear fender
Left side:
Remove the following:
-
oil filler lid (page 3-8)
setting bolt (attached with the fuel tank side
cover)
bolt and collar (front side)
bolt, collar and setting rubbers (rear side)
socket bolt
eight trim clips, setting washer and wire clamp
left rear fender
Installation is in the reverse order of removal.
Right side shown:
FUSE BOX
SETTING BOLTS
SETTING RUBBER
CLAMP
TRIM CLIPS
SETTING RUBBER
WASHER
SOCKET BOLT
BOLTS AND COLLARS
CONNECTOR
FENDER
3-14
FRAME/BODY PANELS/EXHAUST SYSTEM
Carrier/Fender Assembly Removal
Procedure
Remove the following:
-
seat (page'3-4)
right side cover (page 3-5)
oilfiller lid (page 3-8)
Disconnect the brake/taillight 3P (Black) connector.
Release the wires from the bands and remove the
3P connector from the frame.
Remove the following:
-
fuse box (by releasing the tab from reverse side
of the fender)
2P (White) connector
three setting bolts
two socket bolts
six trim clips
Only loosen the - four 8-mm bolts (carrier mounting bolts)
two lower inner - rear carrier/fender assembly
0 fs
Installation is in the reverse order of removal.
TORQUE: 8 mm bolt: 37 N-m (3.8 kgf-m, 27 Ibfft)
Right side shown:
SETTING BOLTS
FUSE BOX
2PCONNECTOR
3P CONNECTOR
8 mm WASHERBOLTS
WIRE CLIPS
8 mm BOLTS
SOCKET BOLTS
TRIM CLIPS
3-15
FRAME/BODY PANELS/EXHAUST SYSTEM
OUTER FENDER
Front Outer Fender
Remove the following:
RETAINING CLIPS
WASHERS
- retaining clips
- seven trim clips and three setting washers
- front outer fender
Installation is in the reverse order of removal.
FRONT OUTER FENDER
TRIM CLIPS
Rear Outer Fender
Remove the following:
- retaining clip
- seven trim clips and four setting washers
- rear outer fender
Installation is in the reverse order of removal.
RETAINING CLIP
WASHERS
TRIM CLIPS
REAR OUTER FENDER
Rear Corner Outer Fender
Remove the following:
- taillight assembly (page 23-5)
- three trim clips and setting washer
- socket bolt
- bolt, collar and setting rubbers
- corner outer fender
Installation is in the reverse order of removal.
WASHER
SETTING RUBBERS
TRIM CLIPS
SOCKET
BOLT
BOLT AND COLLAR
FENDER
3-16
FRAME/BODY PANELS/EXHAUST SYSTEM
ENGINE GUARD
Remove the following:
-
four 8 mm bolts and collars
four 6 mm bolts
engine guard
Hook the guide Installation is in the reverse order of removal.
over the frame
pipe.
GUIDE
ENGINE GUARD
6 mm BOLTS
8 mm BOLTS
AND COLLARS
ENGINE SIDE COVER
Right side only: Remove the right mudguard (page 3-7).
Remove the flange bolts and the right engine side
cover.
Remove the two bolts, two flange bolts, two flange
collars and left engine cover.
Install the engine side cover in the reverse order of
removal.
3-17
FRAME/BODY PANELS/EXHAUST SYSTEM
METER COVER
If the lower meter Remove the following:
cover will be
replaced, remove
the accessory
socket (page 23-6).
screw and collar (rear side)
cover lid (release tabs)
two setting bolts
tapping screw (front side)
lower meter cover (release tabs
on the upper meter cover)
TABS
LOWER METER COVER
TAPPING
SCREW
SETTING BOLTS
If the upper meter
cover will be
replaced, remove
the ignition switch
(page 23-6).
breather hose
two bracket nuts
upper meter cover
TABS
UPPER METER COVER
SCREW AND COLLAR
BREATHER HOSE
GUIDE
NUTS
GPS type only: Disconnect the GPS receiver 6P (Natural) connector.
BOLTS
Remove the bolts and GPS receiver/bracket
assembly.
6P (NATURAL) CONNECTOR

UPPER METER COVER
GPS RECEIVER/BRACKET
COMBINATION METER
3-18
FRAME/BODY PANELS/EXHAUST SYSTEM
Remove the screws and then remove the combination meter from the upper meter cover.
Installation is in the reverse order of removal.
Insert the hose guide into the steering shaft hole
(page 3-18).
COMBINATION METER
SCREWS
EXHAUST SYSTEM
REMOVAL
Remove the left engine side cover (page 3-17).
EXHAUST PIPE
Remove the left side cover (page 3-7).
Loosen the muffler band bolts.
MUFFLER BAND BOLTS
Remove the joint nuts and pull the exhaust pipe forward gradually to disconnect it from the muffler.
Remove the joint gasket and muffler gasket.
JOINT NUTS
3-19
FRAME/BODY PANELS/EXHAUST SYSTEM
MUFFLER
Remove the rear carrier assembly (page 3-13).
Loosen the muffler band bolts.
Remove the mounting nuts and bolts, and the muffler.
Remove the joint gasket.
INSTALLATION
Install new joint gasket and muffler gasket.
Install the muffler and exhaust pipe in the reverse
order of removal by loosely tightening all the fasteners.
When tightening,
adjust the clearance
between the
exhaust pipe and
cover stay as
shown so they do
not interfere.
Tighten the joint nuts first, then tighten the mounting nuts and the band bolts.
TORQUE:
Muffler band bolt: 23 N m (2.3 kgf-m, 17 Ibf-ft)
After installation, inspect the exhaust system for
leaks.
Install the removed covers in the reverse order of
removal.
MOUNTING BOLTS
JOINT NUTS
BAND BOLTS
MOUNTING NUTS
MUFFLER
3-20
FRAME/BODY PANELS/EXHAUST SYSTEM
DISASSEMBLY/ASSEMBLY
3 places:
3.2 N-m (0.33 kgf-m,
2.4 Ibf-ft)
FRONT EXHAUST PIPE COVER
MUFFLER COVER
5.4 N-m (0.55 kgf-m, 4.0 Ibf-ft)
Section BB
(3 places):
3.2 N-m (0.33 kgf-m,
2.4 Ibf-ft)
Section AA
(2 places):
REAR EXHAUST PIPE COVER
3-21
4. MAINTENANCE
SERVICE INFORMATION
MAINTENANCE SCHEDULE
FUEL LINE
THROTTLE OPERATION
AIR CLEANER
AIR CLEANER HOUSING DRAIN HOSE
SPARK PLUG
VALVE CLEARANCEENGINE OIL
ENGINE OIL FILTER
RADIATOR COOLANTCOOLING SYSTEM
DRIVE SHAFT BOOTS
4-2
REAR FINAL GEAR CASE OIL AND
DIFFERENTIAL OIL
4-15
BRAKE FLUID
4-17
BRAKE PADS WEAR
4-18
BRAKE LIGHT SWITCH
4-19
BRAKE SYSTEM
4-19
SKID PLATE, ENGINE GUARD
4-20
SUSPENSION
4-21
SPARK ARRESTER
4-21
NUTS, BOLTS, FASTENERS
4-22
WHEELS/TIRES
4-22
STEERING SHAFT HOLDER BEARING
4-22
STEERING SYSTEM
4-23
4-3
4-4
4-4
4-5
4-7
4-7
4-8
4-10
4-12
4-12
4-13
4-14
4-1
MAINTENANCE
SERVICE INFORMATION
GENERAL
• Place the vehicle on a level ground before starting any work.
SPECIFICATIONS
ITEM
Throttle lever free play
Spark plug
Standard
For extended high speed riding
Spark plug gap
Valve clearance
IN
EX
Recommended engine oil
Engine oil
capacity
After draining
After draining/filter change
After disassembly
Engine idle speed
Recommended final gear case oil
Final gear case
At draining
oil capacity
At disassembly
Recommended differential oil
At draining
Differential oil
capacity
At disassembly
Recommended brake fluid
Rear (parking) brake lever free play
Cold tire presFront
sure
Rear
Standard
Minimum
Maximum
With cargo
Standard
Minimum
Maximum
With cargo
Tire size
Front
Rear
Tire bland
Front
Rear
Minimum tire tread depth (Front/Rear)
Toe
SPECIFICATIONS
3 - 8 mm (1/8-5/16 in)
IFR5L11 (NGK), VK16PRZ11 (DENSO)
IFR6L11 (NGK), VK20PRZ11 (DENSO)
1.0- 1.1 mm (0.039 - 0.043 in)
0.15 mm (0.006 in)
0.33 mm (0.013 in)
Pro Honda GN4 or HP4 (without molybdenum additives) 4stroke oil (U.S.A. and Canada), or Honda 4-stroke oil (Canada only), or an equivalent motorcycle oil
API service classification SG or Higher (except oils labeled
as energy conserving on the circular API service label)
JASO T 903 standard: MA
Viscosity: SAE 10W-40, 6W-30
2.7 liters (2.9 US qt, 2.4 |mp qt)
2.9 liter (3.1 US qt, 2.6 Imp qt)
4.1 liter (4.3 US qt, 3.6 Imp qt)
1,400 ±50 rpm (min'1)
Hypoid gear oil SAE #80
78 cm3 (2.6 US oz, 2.7 Imp oz)
90 cm3 (3.0 US oz, 3.2 Imp oz)
Hypoid gear oil SAE #80
175 cm 3 (5.9 US oz, 6.2 Imp oz)
220 cm3 (7.4 US oz, 7.7 Imp oz)
Honda DOT 4 brake fluid
2 5 - 3 0 mm (1 -1-3/16 in)
30 kPa (0.30 kgf/cm2, 4.4 psi)
26 kPa (0.26 kgf/cm2, 3.8 psi)
34 kPa (0.34 kgf/cm2, 5.0 psi)
30 kPa (0.30 kgf/cm2, 4.4 psi)
25 kPa (0.25 kgf/cm2, 3.6 psi)
22 kPa (0.22 kgf/cm2, 3.2 psi)
28 kPa (0.28 kgf/cm2, 4.0 psi)
25 kPa (0.25 kgf/cm2, 3.6 psi)
AT25x8R12**
AT25x10R12**
KT511 (DUNLOP)
KT515(DUNLOP)
4.0 mm (0.16 in)
Toe-out: 10.9 ± 15 mm (7/16 ±9/16 in)
TORQUE VALUES
Spark plug
Valve adjusting screw lock-nut
Timing hole cap
Engine oil drain-bolt
Engine oil filter center bolt
Rear Final gear case oil filler cap
Rear Final gear case oil drain-bolt
Front Differential oil filler cap
Front Differential oil drain-bolt
Tie-rod lock nut
4-2
22 N m
17 N-m
10 N-m
25 N m
18 N-m
12 N-m
12 N-m
12 N-m
12 N-m
54 N-m
(2.2 kgfm, 16 Ibfft)
(1-7 kgfm, 12 Ibf-ft)
(1.0 kgfm, 7 Ibf-ft)
(2.5 kgfm, 18 Ibfft)
(1.8 kgfm, 13 Ibfft)
(1.2 kgfm, 9 Ibfft)
(1.2 kgfm, 9 Ibfft)
(1.2 kgfm, 9 Ibfft)
(1.2 kgfm, 9 Ibf-ft)
(5.5 kgfm, 40 Ibf-ft)
MAINTENANCE
MAINTENANCE SCHEDULE
Perform the PRE-RIDE INSPECTION in the Owner's Manual at each scheduled maintenance period.
I: Inspect and Clean, Adjust, Lubricate or Replace if necessary. C: Clean. R: Replace. A: Adjust. L: Lubricate.
FREQUENCY WHICHEVER
COMES
FIRST
(""I
INITIAL
MAINTENANCE
^>
100
150
20
mi
km
ITEMS
* FUEL LINE
THROTTLE OPERATION
AIR CLEANER
AIR CLEANER HOUSING DRAIN HOSE
*
HOURS
ENGINE OIL
ENGINE OIL FILTER
RADIATOR COOLANT
* COOLING SYSTEM
DRIVE SHAFT BOOTS
REAR FINAL GEAR CASE OIL
AND DIFFERENTIAL OIL
* BRAKE FLUID
BRAKE PADS WEAR
BRAKE LIGHT SWITCH
BRAKE SYSTEM
SKID PLATE, ENGINE GUARD
* SUSPENSION
* SPARK ARRESTER
* NUTS, BOLTS, FASTENERS
* * WHEELS/TIRES
## STEERING SHAFT HOLDER BEARING
## STEERING SYSTEM
NOTE 3
NOTE 2
NOTE 3
NOTE 1,2
600
1,000
100
C
I
NOTE1
NOTE 2
SPARK PLUG
VALVE CLEARANCE
REGULAR MAINTENANCE
INTERVAL
1,200
2,000
200
I
I
C
I
I
I
I
I
INITIAL=100mi(150km),
20 operating hours or 1 month: R
REGULAR = EVERY 600 mi (1000 km),
100 operating hours or 12 month: R
R
R
R
I
I
I
(R: Every
2 years)
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I
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I
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C
(
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REFER
TO
PAGE
4-4
4-4
4-5
4-7
4-7
4-8
4-10
4-12
4-12
4-13
4-14
4-15
4-17
4-18
4-19
4-19
4-20
4-21
4-21
4-22
4-22
4-22
4-23
*
Should be serviced by an authorized Honda dealer, unless the owner has proper tools and service data and is
mechanically qualified.
* * In the interest of safety, we recommend these items be serviced only by an authorized Honda dealer.
NOTES:
1. Service more frequently when riding in dusty areas, sand or snow.
2. Service more frequency after riding in very wet or muddy conditions.
3. Replace every 2 years. Replacement requires mechanical skill.
4-3
MAINTENANCE
FUEL LINE
Remove the following:.
-
seat (page 3-4)
fuel tank side covers (page 3-6)
Remove the trim clip and throttle body cover.
Check the fuel lines for deterioration, damage or
leakage.
And also check the fuel hose (fuel tank to fuel pump)
and fuel vapor return hose.
Replace the fuel hoses if necessary.
THROTTLE OPERATION
Check for any deterioration or damage to the throttle cable. Check that the throttle lever for smooth
operation.
Check the throttle opens and automatically closes in
all steering positions.
If the throttle lever does not return properly, lubri
cate the throttle cable and overhaul and lubricate
the throttle housing (page 15-10).
Reusing an abnormally bent or kinked
throttle cable can
prevent proper
throttle slide operation and may lead
to a loss of throttle
control while riding.
If the throttle lever 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 lever free play and the throttle
cable connection.
Measure the throttle lever free play at the tip of the
throttle lever.
THROTTLE LEVER FREE PLAY:
3 - 8 mm (1/8-5/16 mm)
Throttle lever free play can be adjusted at either end
of the throttle cable.
4-4
THROTTLE BODY COVER
MAINTENANCE
Minor adjustments
adjuster.
are made with the
upper
ADJUSTER
LOCK NUT
Slide the rubber boot off the adjuster. Loosen the
lock nut, turn the adjuster as required and tighten
the lock nut.
Install the rubber boot securely.
Major adjustments
adjuster.
are made with the
lower *
Remove the seat (page 3-4).
Remove the throttle body cover (page 4-4).
Slide the rubber boot off the adjuster. Loosen the
lock nut, turn the adjuster as required and tighten
the lock nut.
Install the rubber boot securely.
Recheck the throttle operation
Install the throttle body cover (page 4-4).
Install the seat (page 3-4).
AIR CLEANER
Remove the seat (page 3-4).
Release the retaining clips and lid springs from the
air cleaner housing cover and remove the cover.
NOTE:
• If the vehicle is used in dusty areas, sand or
snow, more frequent inspections are required.
Loosen the air cleaner element band screw.
Remove the air cleaner element holder and then
remove the air cleaner element assembly from the
housing.
4-5
MAINTENANCE
Remove the element band and the element core
from the air cleaner element.
CORE
ELEMENT
Wash the element and filter in non-flammable or
high flash point solvent.
Squeeze out the solvent thoroughly, and allow the
element and filter to dry.
Install the sub-air cleaner filter onto the air cleaner
hose joint and secure it with the clip.
Wash
Apply approximately 20 g (0.7 oz) of Pro Honda
Form Filter Oil or equivalent oil from the inside of
the element.
Place the element into a plastic bag and spread the
oil evenly by hand.
Squeeze out
PRO HONDA FOAM FILTER OIL
PLASTIC BAG
Install the element core into the air cleaner element
properly.
BAND
ELEMENT
4-6
CORE
MAINTENANCE
Install the element band onto the air cleaner element and the element assembly over the connecting tube flange of the housing securely.
Tighten the band screw.
NOTE:
• Failure to properly tighten the band screw will
allow the air cleaner element to fall off and
engine damage could result.
Install the air cleaner element holder while aligning
the element core boss with the retainer hole.
Install the air cleaner element housing cover while
aligning the cover boss with the element holder as
shown.
Secure the air cleaner housing cover with the retaining clips and lid springs.
Install the seat (page 3-4).
AIR CLEANER HOUSING DRAIN HOSE
Remove the drain hose from the bottom of the air
cleaner housing to empty any deposits.
Install the drain hose securely.
NOTE:
• If the vehicle is used in very wet or muddy conditions, more frequent inspections are required.
SPARK PLUG
Remove the seat (page 3-4).
Disconnect the spark plug cap and clean around the
spark plug base with compressed air.
Remove the spark plug.
4-7
MAINTENANCE
This vehicle's spark Check the insulator for cracks or damage, and the
plug is equipped electrodes for wear, fouling or discoloration.
with an iridium type Replace the plug if necessary.
center electrode.
Do not clean the
electrodes.
INSULATOR
SIDE ELECTRODE
CENTER ELECTRODE
Replace the plug if the center electrode is rounded
as shown.
Always use the
specified spark plug
on this vehicle.
SPECIFIED SPARK PLUG:
Standard:
IFR5L11 (NGK), VK16PRZ11 (DENSO)
For extended high speed riding
IFR6L11 (NGK), VK20PRZ11 (DENSO)
To prevent damaging the iridium coating of the center
electrode, use a
wire-type feeler
gauge to check the
spark plug gap. If
the gap is out of
specification,
replace the spark
plug with a new
one. Do not adjust
the gap
Measure the spark plug gap between the center and
side electrodes with a wire-type feeler gauge.
Make sure the 1.20 mm (0.047 in) wire-type feeler
gauge cannot be inserted into the gap.
If the gauge can be inserted into the gap, replace the
plug with a new one.
Screw the spark plug into the cylinder head by hand
to prevent cross-threading.
Tighten the spark plug.
TORQUE: 22 N m (2.2 kgf m, 16 Ibf ft)
Install the removed parts in the reverse order of
removal.
VALVE CLEARANCE
NOTE:
• Inspect and adjust the valve clearance while the
engine is cold (below 35795°F).
• After the valve clearance inspection, check the
engine idle speed (page 6-55).
Remove the following:
-
right side cover (page 3-5)
steering cover (page 3-5)
fuel tank cover (page 3-5)
rear tank cover (page 3-6)
right fuel tank side cover (page 3-6)
left fuel tank side cover (page 3-7)
fuel tank (page 6-39)
intake duct (page 6-41)
fuel tank heat guard plate (page 6-40)
Remove the timing hole cap.
4-8
ROUNDED
ELECTRODE
WIRE TYPE FEELER GAUGE
X
MAINTENANCE
Remove the four bolts, intake and exhaust valve
adjusting hole caps.
Rotate the crankshaft using the recoil starter knob
and align the "T" mark on the flywheel with the
index mark on the rear crankcase cover.
Make sure the piston is at TDC (Top Dead Center) on
the compression stroke.
This position can be obtained by confirming that
there is slack in the rocker arm. If there is no slack, it
is because the piston is moving through the exhaust
stroke to TDC. Rotate the crankshaft one full turn
and match up the "T" mark again.
VALVE ADJUSTING HOLE CAP
INDEX MARK
"T" MARK
When checking the
clearance, slide the
feeler gauge from
the center toward
the outside.
Check the clearance of each valve by inserting a
feeler gauge between the adjusting screw and valve
stem.
VALVE CLEARANCES: IN: 0.15 mm (0.006 in)
EX: 0.33 mm (0.013 in)
Adjust by loosening the lock nut and turning the
adjusting screw until there is a slight drag on the
feeler gauge.
Hold the adjusting screw and tighten the lock nut.
TORQUE: 17 N-m (1.7 kgf-m, 12 Ibf-ft)
After tightening the lock nut, recheck the valve
clearance.
4-9
MAINTENANCE
Coat new O-rings with oil and install them into the
grooves in the valve adjusting hole caps.
Install the valve adjusting hole caps and tighten the
bolts securely.
Coat a new O-ring with oil and install it onto the timing hole cap.
Install the timing hole cap and tighten it.
TORQUE: 10 N-m (1.0 kgfm, 7 Ibf ft)
Install the removed parts in the reverse order of
removal.
ENGINE OIL
A CAUTION
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.
LEVEL CHECK
NOTE:
• Check the oil level after starting the engine and
allowing the oil to circulate through the engine
thoroughly. It is especially important on a dry
sump engine, due to the comparatively large volume of oil.
• Do not snap the throttle while idling or the oil
level reading will be inaccurate.
Place the vehicle on level ground.
Start the engine and let it idle for 3 - 5 minutes. If
the air temperature is below 10C (50°F), let the
engine idle for an additional 5 minutes (a total of 10
minutes).
Stop the engine, wait for 2 - 3 minutes, and remove
the dipstick and wipe it clean.
Check the oil level by inserting the dipstick into the
engine without screwing it in.
4-10
DIPSTICK
MAINTENANCE
The engine contains a sufficient amount of oil if the
oil level is between the upper and lower level marks
on the dipstick.
DIPSTICK
Q
UPPER
LEVEL LOWER
LEVEL
If the oil level is near or below the lower level mark,
remove the oil filler cap cover and oil filter cap, and
add the recommended engine oil up to the upper
level mark.
RECOMMENDED ENGINE OIL:
Pro Honda GN4 or HP4 (without molybdenum
additives) 4-stroke oil (U.S.A. and Canada), or
Honda 4-stroke oil (Canada only), or an equivalent
motorcycle oil
API service classification: SG or higher (except
oils labeled as energy conserving on the circular
API service label)
JASO T 903 standard: MA
Viscosity; SAE 10W-40, 5W-30
NOTE:
• Other viscosities shown in the chart may be used
when the average temperature in your riding
area is within the indicated range.
OIL VISCOSITIES
Reinstall the oil filler cap, oil filler cap cover and dipstick.
-30 - 2 0 - 1 0
0
10 20 30 40 50"C
-20
6
20
40
60
80
100120T
OIL CHANGE
NOTE:
• Pour the engine oil after replacing the oil filter
(page 4-12).
• Change the oil with the engine warm to assure
complete and rapid draining.
OIL DRAIN BOLT
Start the engine and let it idle for a few minutes.
Stop the engine and remove the oil filler cap.
Remove the oil drain bolt and drain the engine oil.
4-11
MAINTENANCE
Remove the O-ring and sealing washer from the
drain bolt.
Install a new sealing washer onto the drain bolt.
Coat a new O-ring with oil and install it into the
groove in the drain bolt.
O-RING
After draining the oil completely, install the drain
bolt and tighten it.
TORQUE: 25 N-m (2.5 kgf m, 18 Ibf-ft)
OIL DRAIN BOLT
SEALING WAHSER
Be careful not to Pour the recommended oil into the engine to the
upper level mark on the dipstick (page 4-11).
spill the oil out of
the filler neck.
ENGINE OIL CAPACITY:
2.7 liters (2.9 US qt, 2.4 Imp qt) after draining
2.9 liters (3.1 US q t 2.6 Imp qt) after draining/
filter change
4.1 liters (4.3 US qt, 3.6 Imp qt) after disassembly
Install the oil filler cap.
Check the oil level (page 4-10).
Make sure there are no oil leaks.
ENGINE OIL FILTER
Drain the engine oil (page 4-11).
O-RINGS
Remove the oil filter center bolt, cover, spring
washer and oil filter.
Remove the O-rings from the oil filter cover and
center bolt.
Coat new O-rings with oil and install them into the
grooves in the oil filter cover and center bolt.
Install a new oil filter.
Reinstall the washer, spring, cover and center bolt.
Tighten the center bolt.
TORQUE: 18 N m (1.8 kgf m, 13 Ibf-ft)
Fill the engine with the recommended oil (page 411).
RADIATOR COOLANT
Check the coolant level of the reserve tank with the
engine running at normal operating temperature.
The level should be between the "UPPER" and
"LOWER" level lines with the vehicle upright on a
level surface.
4-12
OIL FILTER
CENTER BOLT
MAINTENANCE
If the level is low, remove the steering cover (page
3-5).
Remove the reserve tank cap, and fill the tank up to
the "UPPER" level line with a 1:1 mixture of distilled
water and antifreeze (coolant preparation: page 7-6).
RECOMMENDED ANTIFREEZE:
Pro Honda HP coolant or an equivalent high quality ethylene glycol antifreeze containing silicatefree corrosion inhibitors
NOTICE
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.
Check to see if there are any coolant leaks when the
coolant level decreases very rapidly.
If the reserve tank becomes completely empty, there
is a possibility of air getting into the cooling system.
Be sure to remove any air from the cooling system
(page 7-7).
COOLING SYSTEM
Check for any coolant leakage from the water pump,
water hoses (radiator and by-pass hoses) and hose
joints.
Check the water hoses for cracks or deterioration
and replace if necessary.
Check that all hose clamps are tight.
Remove the radiator grille by releasing the four
retaining clips.
RETAINING CLIPS
RADIATOR GRILLE
4-13
MAINTENANCE
Check the radiator air passage for clogs or damage.
Straighten bent fins with a small, flat blade screwdriver and remove insects, mud or other obstructions with compressed air or low pressure water.
Replace the radiator if the air flow is restricted over
more than 20% of the radiating surface.
Install the radiator grille.
DRIVE SHAFT BOOTS
Check the drive shaft boots for cuts or other damage.
FRONT:
If a boot is damaged, replace it:
-
Front drive shaft boot replacement (page 18-7)
Rear drive shaft boot replacement (page 19-6)
REAR:
DRIVE SHAFT BOOTS
4-14
MAINTENANCE
REAR FINAL GEAR CASE OIL AND
DIFFERENTIAL OIL
FINAL GEAR CASE OIL
LEVEL CHECK
Place the vehicle on a level surface.
Remove the oil filler cap.
Check that the oil level is to the lower edge of the oil
filler hole.
Check for leaks if the oil level is low.
Pour the oil through the filler hole until it reaches
the lower edge of the hole.
RECOMMENDED OIL: Hypoid gear oil SAE #80
Coat a new O-ring with grease and install it into the
oil filler cap groove.
Install the oil filler cap and tighten it.
TORQUE: 12 N m (1.2 kgf-m, 9 Ibfft)
OIL CHANGE
Place the vehicle on a level surface.
Remove the oil filler cap and drain bolt to drain the
oil.
When the oil is completely drained, install the drain
bolt with a new sealing washer.
TORQUE: 12 N m (1.2 kgfrn, 9 Ibfft)
Fill the final gear case with the recommended oil
(page 4-15).
OIL CAPACITY:
78 cm3 (2.6 US oz, 2.7 Imp oz) at draining
90 cm3 (3.0 US oz, 3.2 Imp oz) at disassembly
4-15
MAINTENANCE
DIFFERENTIAL OIL
LEVEL CHECK
Place the vehicle on a level surface.
Remove the oil filler cap.
Check that the oil level is up to the lower edge of the
oil filler hole.
Check for leaks if the oil level is low.
Pour the oil through the filler hole until it reaches
the lower edge of the hole.
RECOMMENDED OIL: Hypoid gear oil SAE #80
Coat a new O-ring with grease and install it into the
oil filler cap groove.
Install the oil filler cap and tighten it.
TORQUE: 12 N m (1.2 kgf m, 9 Ibf-fft)
OIL CHANGE
Place the vehicle on a level surface.
Remove the oil filler cap and drain bolt to drain the
oil.
When the oil is completely drained, install the drain
bolt with a new sealing washer.
TORQUE: 12 N m (1.2 kgf m, 9 Ibf ft)
Fill the differential case with the recommended oil
(page 4-16).
OIL CAPACITY:
175 cm3 (5.9 US oz, 6.2 Imp oz) at draining
220 cm3 (7.4 US oz, 7.7 Imp oz) at disassembly
4-16
MAINTENANCE
BRAKE FLUID
NOTICE
• Do not mix different types of fluid, as they may
not be compatible with each other.
• Do not allow foreign material to enter the system
when filling the reservoir.
• Avoid spilling fluid on painted, plastic or rubber
parts. Place a rag over these parts whenever the
system is serviced.
NOTE.
• When the fluid level is low, check the brake pads
for wear (page 4-18).
• A low fluid level may be due to worn brake shoes
or pads. If the brake pads are worn, the caliper
piston is pushed out, and this causes a low reservoir level. If the brake pads are not worn and the
fluid level is low, check entire system for leaks
(page 4-19).
FRONT BRAKE
Turn the handlebar to the left side so the reservoir is
level and check the fluid level through the sight
glass.
RESERVOIR CAP
SIGHT GLASS J LOWER LEVEL MARK
If the level is near the "LOWER" level mark, remove
the reservoir cap, set plate and diaphragm and fill
the reservoir with Honda DOT 4 brake fluid from a
sealed container to the casting ledge.
CASTING LEDGE
Install the diaphragm, set plate and reservoir cap,
and tighten the cap screws.
4-17
MAINTENANCE
REAR BRAKE
Place the vehicle on a level surface.
Remove the right fuel tank side cover (page 3-6).
Check the fluid level in the rear brake reservoir.
If the level is near the "LOWER" level line, remove
the reservoir mounting bolt, reservoir cap, set plate
and diaphragm and fill the reservoir with Honda
DOT 4 brake fluid from a sealed container to the
"UPPER" level line.
Install the diaphragm, set plate, reservoir cap and
mounting bolt, and tighten the bolt.
Install the right fuel tank side cover (page 3-6).
BRAKE PADS WEAR
NOTE:
• The front and rear brake has audible brake wear
indicator. When the brake pads need replacing,
the brake will screech while applying the brake.
FRONT
Remove the front wheel (page 15-11).
Check the brake pads for wear.
Replace the front brake pads if the wear limit indicator mark on the caliper aligns with the reference
mark on the caliper bracket when the front brake
lever is applied.
REFERENCE MARK
Refer to front brake pad replacement (page 17-10).
WEAR LIMIT
INDICATOR
REAR
Check the rear brake pads for wear.
Replace the brake pads if the wear limit indicator
mark on the caliper aligns with the reference mark
on the caliper bracket when the rear brake is
applied.
Refer to rear brake pad replacement (page 17-11).
WEAR LIMIT INDICATOR
4-18
MAINTENANCE
BRAKE LIGHT SWITCH
NOTE.
• The front brake light switch cannot be adjusted. If
the front brake light switch actuation and brake
engagement are off, 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.
BRAKE LIGHT SWITCH
If the light fails to come on, adjust the switch so that
the light come on at the proper time.
Hold the switch body and turn the adjusting nut. Do
not turn the switch body.
ADJUSTING NUT
BRAKE SYSTEM
FRONT BRAKE
Firmly apply the front brake lever and check that no
air has entered the system.
If the brake lever feels soft or spongy when operated, bleed the system.
Refer to brake bleeding (page 17-7).
Inspect the brake hose and fittings for deterioration,
clacks, damage or signs of leakage.
Tighten any loose fittings.
Replace hoses, pipes and fittings as required.
REAR BRAKE
Firmly apply the brake pedal and check that no air
has entered the system.
If the brake pedal feels soft or spongy when operated, bleed the system.
Refer to brake bleeding (page 17-7).
Inspect the brake hoses and fittings for deterioration, cracks, damage or signs of leakage.
Tighten any loose fittings.
Replace hoses, pipes and fittings as required.
4-19
MAINTENANCE
PARKING BRAKE
Check the brake lever and brake cable for loose connections or other damage. Replace or repair if necessary.
For cable lubrication: Disconnect the brake cable at
the brake lever. Thoroughly lubricate the cable and
its pivot point with a commercially available cable
lubricant or a lightweight oil.
Measure the parking brake lever free play at the end
of the lever.
FREE PLAY: 25 - 30 mm (1 - 1-3/16 in)
Make sure the cut- Adjust the parking brake lever free play by turning
out in the adjusting the adjusting nut at the brake arm.
nut is seated on the
brake arm joint.
SKID PLATE, ENGINE GUARD
Check the skid plates and engine guard for cracks,
damage or looseness.
Tighten any loose fasteners.
Replace the skid plates and engine guard as
required.
SKID PLATE
4-20
ENGINE GUARD
MAINTENANCE
SUSPENSION
Loose, worn or
damaged suspension parts impair
vehicle stability and
control.
Check the action of the front and rear shock absorbers by compressing them several times.
Check the entire shock absorber assembly for signs
of leaks, damage or loose fasteners.
Replace damaged components which cannot be
repaired.
Tighten all nuts and bolts.
REAR:
SPARK ARRESTER
Remove the three bolts and the spark arrester with
the gasket.
Use a brush to remove carbon deposits from the
screen mesh, being careful not to damage the
screen mesh.
The screen mesh must be free of breaks and holes.
Replace the spark arrester if necessary.
4-21
MAINTENANCE
Install the spark arrester with a new gasket and
tighten the bolts securely.
NUTS, BOLTS, FASTENERS
Check that all chassis nuts and bolts are tightened to
their correct torque values (page 1-13).
Check that all cotter pins, safety clips, hose clamps
and cable stays are in place and properly secured.
WHEELS/TIRES
Tire pressure Check the tire pressure with the tire pressure gauge.
should be checked
when the tires are RECOMMENDED TIRE PRESSURE:
Front: Standard: 30 kPa (0.30 kg/cm2, 4.4 psi)
cold.
Minimum: 26 kPa (0.26 kg/cm2, 3.8 psi)
Maximum: 34 kPa (0.34 kg/cm2, 5.0 psi)
With cargo: 30 kPa (0.30 kg/cm2, 4.4 psi)
Rear: Standard: 25 kPa (0.25 kg/cm2, 3.6 psi)
Minimum: 22 kPa (0.22 kg/cm2, 3.2 psi)
Maximum: 28 kPa (0.28 kg/cm2, 4.0 psi)
With cargo: 25 kPa (0.25 kg/cm2, 3.6 psi)
Check the tires for cuts, embedded nails, or other
damage.
Measure the tread depth at the center of the tires.
Replace the tires when the tread depth reaches the
following limit.
MINIMUM TREAD DEPTH (Front/rear):
4.0 mm (0.16 in)
Raise the wheel off the ground and check the hub,
knuckle bearings or tie-rod ball joints for excessive
play or abnormal noise.
STEERING SHAFT HOLDER BEARING
Raise the front wheels off the ground and support
the vehicle securely.
Check that the handlebar moves freely from side to
side.
If the handlebar moves unevenly, binds, or has horizontal movement, inspect the steering shaft holder
bushing and bearing (page 15-28).
4-22
MAINTENANCE
STEERING SYSTEM
Place the vehicle on level ground with the front
wheels facing straight ahead.
Mark the centers of the tires with chalk to indicate
the axle center height.
Align the gauge with the marks on the tires as
shown.
TOE-GAUGE
Slowly move the vehicle back until the wheels have
turned 180° so the marks on the tires are aligned
with the gauge height on the rear side.
Measure the toe on the rear part of the tires at the
same points with no load on the vehicle.
FRONT
Toe-out: 10.9 ± 15 mm (7/16 + 9/16 in)
NOTE.
• Toe-out means the front measurement is greater
than the rear measurement.
When the toe is out of specification, adjust it by
changing the length of the tie-rods equally by loosening the lock nuts and turning the tie-rods while
holding the ball joints.
After adjusting each tie-rod, rotate both tie-rod
ends in the same direction, along the tie-rod axis,
until they stop against the ball joint stud.
Rotate both tie-rod ends in the same direction
4-23
MAINTENANCE
Using a 17 mm wrench, hold the tie-rod ends so that
the relative angle of both tie-rods may turn into 16
degrees 30 minutes. Then, using a suitable torque
wrench, tighten the tie-rod lock nuts, making sure
not to force the tie-rod ends against the ball joint
studs.
STEERING SIDE
TIE-ROD END
TORQUE: 54 N-m (5.5 kgf-m, 40 Ibfft)
After tightening the lock nuts, rotate the tie-rods to
make sure the ball joints have operate properly and
have an equal range of movement.
Raise the wheel off the ground and check the hub,
knuckle bearings or tie-rod ball joints for excessive
play or abnormal noise.
4-24
LOCK NUT
KNUCKLE SIDE
5. LUBRICATION SYSTEM
LUBRICATION SYSTEM DIAGRAM
5-2
OIL PRESSURE CHECK
5-5
SERVICE INFORMATION
5-3
OIL PUMP
5-5
TROUBLESHOOTING
5-4
OIL COOLER
5-12
5-1
LUBRICATION SYSTEM
LUBRICATION SYSTEM DIAGRAM
ROCKER ARMS
CYLINDER HEAD COVER
FLYWHEEL/
STARTER CLUTCH
CAMSHAFT
REVERSE IDLE
GEAR
OIL STRAINER SCREEN
5-2
LUBRICATION SYSTEM
SERVICE INFORMATION
GENERAL
ACAUTION
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.
This section covers service of the oil pump and oil cooler.
For oil level check, oil change and filter replacement, refer to page 4-10.
The service procedures in this section can be performed 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 an assembly.
After oil pump, oil cooler and/or oil hoses have been installed, check for oil leaks.
SPECIFICATIONS
ITEM
Engine oil capacity
After draining
After draining/filter
change
After disassembly
Recommended engine oil
Oil pressure at 5,000 rpm (min1)/80°C (176°F)
Oil pump rotor
Tip clearance
Body clearance
Side clearance
STANDARD
2.7 liters (2.9 US qt, 2.4 Imp qt)
2.9 liters (3.1 US qt, 2.6 Imp qt)
4.1 liters (4.3 US qt, 3.6 Imp qt)
Pro Honda GN4 or HP4 (without molybdenum additives) 4-stroke oil (U.S.A.
and Canada), or Honda 4-stroke oil
(Canada only), or an equivalent motorcycle oil
API service classification SG or Higher
(except oils labeled as energy conserving on the circular API service label)
JASO T 903 standard: MA
Viscosity: SAE 10W-40, 5W-30
785 kPa (8.0 kgf/cm2,114 psi)
0.15(0.006)
0.12-0.22(0.005-0.009)
0.02-0.09(0.001 -0.004)
Unit: mm (in)
SERVICE LIMIT
—
-
0.20 (0.008)
0.25(0.010)
0.11 (0.004)
TORQUE VALUES
Oil pump driven sprocket bolt
12N-m(1.2kgf-m, 9 Ibf-ft)
Apply locking agent to the threads.
TOOLS
Oil pressure gauge set
07406-0020005
or 07ZMJ-HN2A100 and 07AMJHN8A100 (U.S.A. Only)
5-3
LUBRICATION SYSTEM
TROUBLESHOOTING
Oil level too low - high oil consumption
• Oil consumption
• External oil leak
• Worn piston rings or incorrect piston ring installation
• Worn cylinder
• Worn valve guides or stem seals
• Oil pump worn or damaged
Low oil pressure
• Oil level low
• Oil pressure relief valve wear
• Clogged oil strainer or filter
• Faulty oil pump
• Internal oil leak
• Incorrect oil being used
No oil pressure
• Oil level too low
• Oil pressure relief valve stuck open
• Broken oil pump drive chain
• Broken oil pump drive or driven sprocket
• Damaged oil pump
• Internal oil leak
High oil pressure
• Oil pressure relief valve stuck closed
• Clogged oil gallery or orifice
• Incorrect oil being used
Oil contamination
• Oil or filter not changed often enough
• Worn piston rings or incorrect piston ring installation
• Worn valve guides or stem seals
Oil emulsification
• Blown cylinder head gasket
• Leaky coolant passage
• Water entry
5-4
LUBRICATION SYSTEM
OIL PRESSURE CHECK
Failure to warm the Check the oil level and add the recommended oil if
engine will cause necessary (page 4-10).
very high oil pres- Also, warm the engine to normal operating tempersure readings. ature and check for external leaks.
External leaks will
Remove the oil gallery sealing bolt and washer on
cause low oil presthe
left side of the front crankcase cover.
sure readings.
NOTE:
• Clean around the sealing bolt with compressed
air before removing the bolt, and be sure that no
dirt enters the oil gallery.
Connect an oil pressure gauge and adapter to the oil
gallery hole.
OIL PRESSURE GAUGE
TOOLS:
Pressure gauge set
07406-0020005
or
Oil pressure gauge 0-160 psi 07ZMJ-HN2A100 and
Adapter, banjo 8 x 1.25 mm 07AMJ-HN8A100
Start the engine and check the oil pressure.
OIL PRESSURE (80°C/176°F):
785 kPa (8.0 kgf/cm2,114 psi) at 5,000 rpm (min1)
Stop the engine and remove the oil pressure gauge
and hose.
Install the sealing bolt with a new sealing washer
and tighten the bolt securely.
Start the engine and make sure there are no oil
leaks.
OIL PUMP
REMOVAL
Remove the torque converter (page 14-60).
Remove the three mounting bolts.
Release the oil pump drive chain from the driven
sprocket, then remove the oil pump from the crankcase.
5-5
LUBRICATION SYSTEM
Remove the two O-rings from the oil joint.
Remove the oil pass pipe and O-rings from the oil
strainer pipe.
Remove the two bolts, oil pipe and O-ring from the
crankcase.
DISASSEMBLY
Remove the following:
-
5-6
two oil pump assembly bolts
ASSEMBLY BOLTS
LUBRICATION SYSTEM
oil pump body D
outer rotor
inner rotor
drive pin
two dowel pins
Mark the rotors so
they can be reinstalled in their original locations.
DOWEL PINS
PUMP BODY D
OUTER ROTOR
DRIVE PIN
-
oil pump body C
outer rotor
inner rotor
drive pin
PUMP BODY C
OUTER ROTOR
DRIVE PIN
-
oil pump body B
pressure relief valve
-
bolt
oil pump driven sprocket
INNER ROTOR
RELIEF VALVE
INNER ROTOR
PUMP BODY B
DRIVEN SPROCKET
BOLT
5-7
LUBRICATION SYSTEM
-
oil pump shaft
drive pin
outer rotor
inner rotor
PUMP BODY A
INNER ROTOR
/
OUTER ROTOR
Clean all the disassembled parts thoroughly.
PUMP SHAFT
INSPECTION
Remove the O-ring from the pressure relief valve.
PISTON
Check the operation of the pressure relief valve by
pushing on the piston.
O-RING
Temporarily assemble each inner rotor, outer rotor
and drive pin on the pump shaft, and install them
into each pump body individually.
Measure the rotor tip clearance.
SERVICE LIMIT: 0.20 mm (0.008 in)
Measure the pump body clearance.
SERVICE LIMIT: 0.25 mm (0.010 in)
5-8
DRIVE PIN
LUBRICATION SYSTEM
Remove the oil pump shaft and drive pin.
Measure the oil pump side clearance.
SERVICE LIMIT: 0.11 mm (0.004 in)
ASSEMBLY
DRIVEN SPROCKET
DRIVE PINS
RELIEF VALVE
O-RING
PUMP BODY A
PUMP BODY D
PUMP BODY B
PUMP BODYC
OUTER ROTORS
ASSEMBLY BOLTS
Dip all parts in clean engine oil.
PUMP BODY A
Install the outer and inner rotors into oil pump body
A.
Insert the drive pin onto the pump shaft.
Install the pump shaft into the inner rotor and pump
body A, aligning the drive pin with the inner rotor
grooves.
INNER ROTOR
OUTER ROTOR
PUMP SHAFT
5-9
LUBRICATION SYSTEM
Install the oil pump driven sprocket onto the pump
shaft, aligning the flats.
Apply locking agent to the driven sprocket bolt
threads.
Install and tighten the driven sprocket bolt.
DRIVEN SPROCKET
TORQUE: 12 N m (1.2 kgf-m, 9 Ibf ft)
BOLT
Coat a new O-ring with oil and install it into the
relief valve groove.
O-RING
Install the pressure relief valve into oil pump body
B.
Install oil pump body B onto pump body A.
RELIEF VALVE
Insert the drive pin into the pump shaft.
Install the inner rotor onto the pump shaft, aligning
its grooves with the drive pin.
Install the outer rotor into oil pump body C.
Install pump body C onto pump body B.
PUMP BODY C
OUTER ROTOR
DRIVE PIN
5-10
PUMP BODY B
INNER ROTOR
LUBRICATION SYSTEM
Install the dowel pins into pump bodies C, B and A.
Insert the drive pin into the pump shaft.
Install the inner rotor onto the pump shaft, aligning
its grooves with the drive pin.
Install the outer rotor into oil pump body D.
Install pump body D onto pump body C.
DOWEL PINS
PUMP BODY D
OUTER ROTOR
DRIVE PIN
Install and tighten the two oil pump assembly bolts.
INNER ROTOR
ASSEMBLY BOLTS
INSTALLATION
Apply oil to a new O-ring and install it onto the oil
pipe.
Install the oil pipe onto the crankcase.
Set the retainer plate and tighten the two bolts
securely.
RFTAINER PLATE
OIL PIPE
5-11
LUBRICATION SYSTEM
Apply oil to new O-rings and install them onto the
oil pass pipe.
Install the oil pass pipe to the oil strainer pipe.
Coat new O-rings with oil and install them onto the
oil joint pipes.
Install the oil pump drive chain onto the driven
sprocket of the oil pump, and install the oil pump
onto the crankcase.
Install the three mounting bolts and tighten them
securely.
Install the torque converter (page 14-73).
^ ^ i
OIL PUMP
OIL COOLER
REMOVAL
Remove the front fender (page 3-11).
- RETAINING CLIPS
Remove the radiator grille by releasing the four |
retaining clips.
5-12
LUBRICATION SYSTEM
Check the oil cooler hose joints and seams for leaks.
Check the oil cooler air passage for clogging or
damage.
Straighten bent fins using a small flat blade screwdriver and remove insects, mud or other obstructions with compressed air or low pressure water.
OIL COOLER
Remove the bolts and oil pipes from the oil cooler.
Remove the O-rings from the oil pipes.
Remove the four mounting screws and oil cooler
from the radiator.
INSTALLATION
Install the oil cooler onto the radiator and tighten
the mounting screws securely.
SCREWS
Coat new O-rings with oil and install them onto the
oil pipes.
Install the oil pipes onto the oil cooler and tighten
the bolts securely.
Install the removed parts in the reverse order of
removal.
Check the oil level and add the recommended oil if
the level is low (page 4-10).
5-13
6. FUEL SYSTEM (PGM-FI)
SYSTEM COMPONENTS
6-2
FUEL PUMP RELAY
6-38
SERVICE INFORMATION
6-3
FUEL TANK
6-39
SYMPTOM TROUBLESHOOTING
6-5
AIR CLEANER HOUSING
6-41
PGM-FI SYSTEM LOCATION
6-6
THROTTLE BODY
6-43
PGM-FI SYSTEM DIAGRAM
6-7
INJECTOR
6-48
PGM-FI CONNECTOR LOCATION
6-8
ECT SENSOR
6-50
BANK ANGLE SENSOR
6-51
ENGINE STOP RELAY
6-52
PGM-FI TROUBLESHOOTING
INFORMATION
•
6-13
PGM-FI DTC INDEX
6-17
DTC TROUBLESHOOTING
6-18
MIL CIRCUIT INSPECTION
6-31
FUEL LINE INSPECTION
6-32
SUB FUEL TANK/FUEL PUMP
6-36
PCM (POWERTRAIN CONTROL
MODULE)
6-53
ENGINE IDLE SPEED
6-55
IACV
6-56
6-1
FUEL SYSTEM (PGM-FI)
SYSTEM COMPONENTS
6-2
FUEL SYSTEM (PGM-FI)
SERVICE INFORMATION
GENERAL
• This FUEL SYSTEM section covers service of the electrical and mechanical system of the PGM-FI system, fuel supply
system and air cleaner.
• Before disconnecting the fuel feed hose, relieve pressure from the system by disconnecting the quick connect fitting in
the sub fuel tank (page 6-32).
• 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 in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can
cause a fire or explosion.
• Do not snap the throttle valve from full open to full close after the throttle cable has been removed. It may cause incorrect idle operation.
• Seal the cylinder head intake port with tape or a clean cloth to keep dirt and debris from entering the intake port after
the throttle body has been removed.
• Do not damage the throttle body. It may cause incorrect throttle valve operation.
• Prevent dirt and debris from entering the throttle bore, IACV, sensor hole and fuel feed hose, clean them using compressed air.
• The throttle body is factory pre-set. Do not disassemble in a way other than shown in this manual.
• Do not loosen or tighten the white painted bolts, nuts and screws of the throttle body. Loosening or tightening them can
cause throttle body malfunction.
• Tighten the yellow painted bolts of the throttle body to the specified torque.
• A faulty PGM-FI system is often related to poorly connected or corroded connectors. Check those connections before
proceeding.
• When disassembling the PGM-FI parts, note the location of the O-rings. Replace them with new ones upon reassembly.
• Use a digital tester for PGM-FI system inspection.
• Refer to procedures for fuel level sensor inspection (page 23-10).
SPECIFICATIONS
ITEM
Throttle body identification number
Idle speed
Throttle lever free play
ECT sensor resistance (20°C/68°F)
Fuel injector resistance (at 20°C /68°F)
Fuel pressure
Fuel pump flow (at 12 V)
SPECIFICATIONS
GQ67A
1,400 + 50 rpm (min 1 )
3 - 8 mm (1/8-5/16 in)
2.3-2.6 kQ
11.1- 12.3 Q
284 - 304 kPa (2.9 - 3.1 kgf/cm2, 41 - 44 psi)
71 cm3 (2.4 US oz, 2.5 Imp oz) minimum/10 seconds
TORQUE VALUES
Insulator band screw (throttle body side)
Insulator band screw (cylinder head side)
Throttle drum cover screw
Sensor unit mounting screw
Fuel feed hose bracket screw
Harness guide bracket screw
Fuel injector/feed hose mounting bolt
IACV mounting torx screw
Bank angle sensor mounting bolt
See page 6-42
See page 6-46
1.5 N-m (0.15 kgf-m, 1.1 Ibf-ft)
3.4 N-m (0.35 kgf-m, 2.2 Ibf-ft)
4.2 N-m (0.43 kgf-m, 3.1 Ibf-ft)
4.2 N-m (0.43 kgf-m, 3.1 Ibf-ft)
5.1 N-m (0.53 kgf-m, 3.8 Ibf-ft)
2.1 N-m (0.21 kgf-m, 1.5 Ibf-ft)
1.5 N-m (0.15 kgf-m, 1.1 Ibf-ft)
6-3
FUEL SYSTEM (PGM-FI)
TOOLS
Fuel pressure gauge
07406-0040004
Pressure gauge manifold
07ZAJ-S5A0111
Pressure gauge hose attachment A
07ZAJ-S5A0120
or 07406-00400B (U.S.A. only)
Not available in U.S.A.
Not available in U.S.A.
Pressure gauge hose attachment B
07ZAJ-S5A0130
Hose attachment B joint
07ZAJ-S5A0150
Pressure manifold hose
07AMJ-HW3A100 (U.S.A. only)
Adaptor, male
07AAJ-S6MA200 (U.S.A. only)
Adaptor, female
07AAJ-S6MA400 (U.S.A. only)
SCS connector
070PZ-ZY30100
HDS pocket tester
TDS 3557-0112-01 (U.S.A. Only)
Inspection test harness
07GMJ-ML80100
Test probe
07ZAJ-RDJA110
6-4
FUEL SYSTEM (PGM-FI)
SYMPTOM TROUBLESHOOTING
When the vehicle has one of these symptoms, check the DTC or MIL blinking, refer to the DTC index (page 6-17) and begin
the appropriate troubleshooting procedure. If there are no DTC/MIL blinking stored in the PCM memory, do the diagnostic
procedure for the symptom, in the sequence listed below, until you find the cause.
Symptom
Engine cranks but won't
start
(No DTC and MIL blinking)
Diagnosis procedure
1. Inspect the ignition system
(page 21-5).
2. Inspect the fuel supply system
(page 6-36).
Engine cranks but won't
start
(No fuel pump operation
sound when the turning the
ignition ON and engine stop
switch "O")
1. PCM power/ground circuits
malfunction (page 6-53)
2. Inspect the fuel supply system
(page 6-36).
Engine stalls, hard to start,
rough idling
1. Check the idle speed (page 655).
2. Check the IACV (page 6-56).
3. Inspect the fuel supply system
(page 6-36).
Check the ignition system.
Backfiring or misfiring during acceleration
Poor performance
(driveability) and poor fuel
economy
Idle speed is below specifications or fast idle too low
(No DTC and MIL blinking)
Idle speed is above specifications or fast idle too high
(No DTC and MIL blinking)
MIL stays on but no DTCs
set, or MIL never comes on
at all
MIL stays on at all times
(No DTC set)
Inspect the fuel supply system
(page 6-36).
1. Check the idle speed (page 655)
2. Check the IACV (page 6-56).
1. Check the idle speed (page 655)
2. Check the throttle operation
and lever free play (page 4-4)
3. Check the IACV (page 6-56).
Troubleshoot the MIL circuit (page
6-31).
Check the DLC circuit (Brown/red
wire) for short circuit.
Also check for
» No fuel to injector
- Clogged fuel filter
- Pinched or clogged fuel feed hose
- Pinched or clogged fuel tank breather
hose
- Faulty fuel pump
- Faulty fuel pump circuits
1
Intake air leak
» Contaminated/deteriorated fuel
» Faulty fuel injector
4•
IACV stuck closed
4•
Open circuit in the power input and/or
ground wire of the PCM
> Faulty bank angle sensor or related circuit
> Faulty engine stop relay or related circuit
> Faulty engine stop switch or related circuit
« BlownFI/IGNfuse(10A)
> BlownST./ECMfuse(10A)
> Restricted fuel feed hose
> Contaminated/deteriorated fuel
• Intake air leak
• Restricted fuel tank breather hose
• Faulty ignition system
• Faulty ignition system
> Pinched or clogged fuel feed hose
> Faulty injector
> Faulty ignition system
IACV stuck closed
Faulty fuel supply system
> Faulty ignition system
> IACV stuck opened
> Faulty ignition system
Intake air leak
Engine top end problem
Air cleaner condition
• Faulty MIL circuit
• Short circuit in the DLC related wire
6-5
FUEL SYSTEM (PGM-FI)
PGM-FI SYSTEM LOCATION
PCM
INJECTOR
DLC
MAP SENSOR/TP SENSOR
BANK ANGLE SENSOR
FUSE BOX
FRONTVS
SENSOR
SUB FUEL
TANK
IAT SENSOR
REAR VS SENSOR
RELAY MODULE
CKPSENSOR
IACV
ECT SENSOR
6-6
FUEL SYSTEM (PGM-FI)
PGM-FI SYSTEM DIAGRAM
ENGINE STOP
SWITCH
ENGINE STOP
RELAY
BANK ANGLE
SENSOR
B1 MAIN
ENG STOP
U
G/w
-
A4
INJ B33
B23 PCP
B12 PCM
INJ
@(29)St
IGN B11
B3 VCC
B14 TH
B2 SG
A
FLR B21
IGNITION  ]
COIL
SPARK
PLUG
B25 PB
FUEL PUMP
IAT
SENSOR
B26 TA
©(9)
„ _ , ,
B27 TW
PCM
STEP1A B20
STEP1B B32 — Br/R •
STEP2A B30 — Br/Bu STEP2B B31 — Br/Y •
ECT
SENSOR
IACV
©(29)
I— BVBu —f
©(7)
K • LINE B17 — O/W •
SCS B6 — Br/R •
L
DLC/SCS
jr
MIL
COMBINATON
METER
WARN B19
LCD
CPU
B4
FRVSP
A15 SenVB2
B13 LG
FRONT VS
SENSOR
Bl
Y
Bu
G
R
W
: BLACK
: YELLOW
: BLUE
: GREEN
: RED
: WHITE
B22 PG1
RRVSP
B5
SenVBI A16
REAR VS
SENSOR
B10 PG2
©(11)
Br
O
Lg
P
Gr
: BROWN
: ORANGE
: LIGHT GREEN
: PINK
: GRAY
A-23
A-33
B-23
B-33
6-7
FUEL SYSTEM (PGM-FI)
PGM-FI CONNECTOR LOCATION
FRONT CONNECTOR LOCATIONS
Note 1:
Note 2:
Remove the steering cover (page 3-5).
Remove the left inner fender (page 3-9).
PCM 33P BLACK CONNECTOR (Note 1)
PCM 5P BLACK CONNECTOR (Note 1)
PCM (Note 1)
PCM 33P GRAY CONNECTOR (Note 1)
REAR VS SENSOR 3P (YELLOW)
CONNECTOR (Note 2)
6-8
FUEL SYSTEM (PGM-FI)
Note 1:
Remove the right inner fender (page 3-9).
FUEL PUMP 2P (BLACK) CONNECTOR
ENGINE STOP RELAY 3P (GREEN)
CONNECTOR (Note 1)
6-9
FUEL SYSTEM (PGM-FI)
MIDDLE/REAR CONNECTOR
LOCATIONS
Note 1:
Note 2:
Remove the seat (page 3-4).
Remove the fuel tank side cover (page 3-6).
INJ2P (GRAY) CONNECTOR
(Note 1)
IACV 4P (BLACK)
CONNECTOR (Note 1)
ECT SENSOR 2P (BLACK)
CONNECTOR (Note 2)
6-10
MAP/TP SENSOR 5P (BLACK)
CONNECTOR (Note 2)
FUEL SYSTEM (PGM-FI)
Note 1:
Remove the battery case (page 20-6).
IAT SENSOR 2P (BLACK)
CONNECTOR
RELAY MODULE 8P (GRAY)
CONNECTOR (Note 1)
6-11
FUEL SYSTEM (PGM-FI)
Note 1:
Remove the right side cover (page 3-5).
ALTERNATOR 5P (NATURAL)
CONNECTOR (Note!)
6-12
FUEL SYSTEM (PGM-FI)
PGM-FI TROUBLESHOOTING INFORMATION
GENERAL TROUBLESHOOTING
Intermittent Failure
The term "intermittent failure" means a system may have had a failure, but it checks OK now. If the MIL does not come on,
check for poor contact or loose pins at all connectors related to the circuit with the trouble. If the MIL was on, but then went
out, the original problem may be intermittent.
Opens and Shorts
"Opens" and "Shorts" are common electrical terms. An open is a break in a wire or at a connection. A short is an accidental
connection of a wire to ground or to another wire. In simple electronics, this usually means something will not work at all.
With PCMs this can mean something will work, but not the way it's supposed to.
If the MIL has come on
Refer to DTC READ OUT (page 6-14).
If the MIL did not stay on
If the MIL did not stay on, but there is a driveability problem, do the SYMPTOM TROUBLESHOOTING (page 6-5).
SYSTEM DESCRIPTION
SELF-DIAGNOSIS SYSTEM
The PGM-FI system is equipped with the self-diagnostic system. When any abnormality occurs in the system, the PCM
turns on the MIL and stores a DTC in its erasable memory.
FAIL-SAFE FUNCTION
The PGM-FI system is provided with a fail-safe function to secure a minimum running capability even when there is trouble
in the system. When any abnormality is detected by the self-diagnosis function, running capability is maintained by preprogramed value in the simulated program map. When any abnormality is detected in the injector and crankshaft position
(CKP) sensor, the fail-safe function stops the engine to protect it from damage.
DTC (Diagnostic Trouble Code)
• The DTC is composed of a main code and a sub code and it is displayed as a hyphenated number when retrieved from
the PCM with the HDS pocket tester.
The digits in front of the hyphen are the main code, they indicate the component of function failure.
The digits behind the hyphen are the sub code, they detail the specific symptom of the component or function failure.
For example, in the case of the TP sensor:
- DTC 08 - 1 = (TP sensor voltage) - (lower than the specified value)
- DTC 08 - 2 = (TP sensor voltage) - (higher than the specified value).
• The MAP, ECT, TP and IAT sensor diagnosis will be made according to the voltage output of the affected sensor.
If a failure occurs, the PCM determines the Function Failure, compares the sensor voltage output to the standard value,
and then outputs the corresponding DTC to the HDS Pocket Tester.
For example:
- If the input voltage line (A) on the MAP sensor is opened, the PCM detects the output voltage is about 5 V, then the
DTC 1-2 (MAP sensor circuit high voltage) will be displayed.
- If the input voltage line (B) on the TP sensor is opened, the PCM detects the output voltage is 0 V, then the DTC 8-1 (TP
sensor circuit low voltage) will be displayed.
5V
MAP SENSOR
5V
TP SENSOR
OUTPUT VOLTAGE
OUTPUT VOLTAGE
5V
ECT SENSOR
I
OUTPUT VOLTAGE
5V
IAT SENSOR
h.
OUTPUT VOLTAGE
6-13
FUEL SYSTEM (PGM-FI)
MIL Blink Pattern
• If the HDS pocket tester is not available, DTC can be read from the
PCM memory by the MIL blink pattern.
• The number of MIL blinks is the equivalent the main code of the
DTC (the sub code cannot be displayed by the MIL).
• The MIL will blink the current DTC, in case the PCM detects the
problem at present, when the ignition switch ON or idling. The MIL
will stay ON when driving (engine speed is over 2,000 rpm (min ')).
• The MIL has two types of blinks, a long blink and short blink. The
long blinking lasts for 1.3 seconds, the short blinking lasts for 0.5
seconds. One long blink is the equivalent of ten short blinks. For
example, when two long blinks are followed by five short blinks, the
MIL is 25 (two long blinks = 20 blinks, plus five short blinks).
• When the PCM stores more than one DTC, the MIL will indicate
them by blinking in the order from the lowest number to highest
number.
MIL Check
When the ignition switch is turned ON and engine stop switch is "O", the MIL will stay on for a few seconds, then go off. If
the MIL does not come on, troubleshoot the MIL circuit (page 6-31).
CURRENT DTC/FREEZE DTC
The DTC is indicated in two ways according to the failure status.
• In case the PCM detects the problem at present, the MIL will come on and the MIL will start to blink as its DTC. It is possible to readout the MIL blink pattern as the current DTC.
• In case the PCM does not detect any problem at present but has a problem stored in its memory, the MIL will not light
and blink. If it is necessary to retrieve the past problem, readout the freeze DTC by following the DTC readout procedure.
HDS POCKET TESTER INFORMATION
• The HDS can readout the DTC, freeze data, current data and other powertrain control module condition.
How to connect the HDS Pocket Tester
Turn the ignition switch to OFF.
Remove the steering cover (page 3-5).
Remove the dummy connector from the DLC.
Connect the HDS pocket tester to the DLC.
Turn the ignition switch to ON and engine stop switch "O", check the
DTC and freeze data.
NOTE:
• Freeze data indicates the engine conditions when the first malfunction was detected.
PCM reset
The HDS can reset the PCM data including the DTC, freeze data and
some learning memory.
DTC READOUT
• When the ignition switch is turned ON, the MIL will stay on for a few
seconds, then go off.
• After performing diagnostic troubleshooting, erase the problem
code(s) (page 6-15) and test-ride the vehicle to be sure that the
problem(s) have been removed.
If the MIL stays on or blinks, connect the HDS Pocket Tester to the DLC
(page 6-14).
Then read the DTC, freeze data and follow the troubleshooting index
(page 6-17).
To read the DTC with the MIL blinking, refer to the following procedure.
6-14
FA model shown:
1(
(RESET)
NT
MIL
A*
I" &3S _
;6,svy
i ADJ
l V H::
FUEL SYSTEM (PGM-FI)
Reading DTC with the MIL
Start the engine and let it idle. Read the MIL blinking
that is indicated as the current DTC and refer to the
troubleshooting index (page 6-17).
When retrieving the freeze DTC, refer to the following procedure.
Turn the ignition switch to OFF.
Remove the steering cover (page 3-5).
Remove the dummy connector and short DLC terminals using the special tool.
TOOL:
SCS connector
070PZ-ZY30100
CONNECTION: Brown/red - Green
Turn the ignition switch to ON and engine stop
switch "O", read, note the MIL blinks and refer to the troubleshooting index (page 6 17).
NOTE:
If the PCM has any DTC in its memory, the MIL will start blinking.
CLEARING DTC
Connect the HDS Pocket Tester to the DLC (page 6-14).
Clear the DTC with the HDS while the engine is stopped.
To clear the DTC without HDS, refer to the following procedure.
How to clear the DTC with SCS connector
1. Remove the steering cover (page 3-5).
2. Turn the ignition switch to OFF.
Make sure the 3. Remove the dummy connector and short the
engine stop switch
DLC using the special tool.
is turned to " O "
TOOL1
SCS connector
070PZ-ZY30100
CONNECTION: Brown/red - Green
4. Turn the ignition switch to ON.
5. Remove the special tool from the DLC.
6. The MIL will light for approximately 5 seconds.
While the MIL lights, short the DLC terminals
again with the special tool. The self-diagnostic
memory is erased if the malfunction indicator goes off and starts blinking.
NOTE:
• The DLC must be jumped while the MIL lights. If not, the MIL will not start blinking.
• Note that the self-diagnostic memory cannot be erased if the ignition switch is turned OFF before the
MIL starts blinking.
6-15
FUEL SYSTEM (PGM-FI)
CIRCUIT INSPECTION
INSPECTION AT PCM CONNECTOR
• Always clean around and keep any foreign material away from the PCM connector before disconnecting it.
• A faulty PGM-FI system is often related to poorly
connected or corroded connections. Check those
connections before proceeding.
• Do not pull the wire harness while disconnecting
the PCM connectors.
• In testing at PCM connector (wire harness side)
terminal, always use the test probe. Insert the
test probe into the connector terminal, then
attach the digital multimeter probe to the test
probe.
TOOL:
Test probe
6-16
07ZAJ-RDJA110
FUEL SYSTEM (PGM-FI)
PGM-FI DTC INDEX
DTC
(MIL blinks)
1-1(1)
1-2(1)
7-1 (7)
7-2 (7)
8-1 (8)
Function Failure
MAP sensor circuit low voltage (less than 0.19 V)
• MAP sensor or its circuit malfunction
MAP sensor circuit high voltage (more than 3.9 V)
• Loose or poor contact of the MAP sensor connector
• MAP sensor or its circuit malfunction
ECT sensor circuit low voltage (less than 0.07 V)
• ECT sensor or its circuit malfunction
ECT sensor circuit high voltage (more than 4.93 V)
• Loose or poor contact of the ECT sensor connector
• ECT sensor or its circuit malfunction
TP sensor circuit low voltage (less than 0.22 V)
• TP sensor or its circuit malfunction
8-2 (8)
TP sensor circuit high voltage (more than 4.93 V)
• Loose or poor contact of the TP sensor connector
• TP sensor or its circuit malfunction
9-1 (9)
IAT sensor circuit low voltage (less than 0.07 V)
• IAT sensor or its circuit malfunction
IAT sensor circuit high voltage (more than 4.93 V)
• Loose or poor contact of the IAT sensor connector
• IAT sensor or its circuit malfunction
Rear VS sensor no signal
• Loose or poor contact of the VS sensor connector
• VS sensor or its circuit malfunction
9-2 (9)
11-1 (11)
12-1 (12)
29-1 (29)
33-2 (-)
Injector circuit malfunction
• Loose or poor contact of the injector connector
• Injector or its circuit malfunction
IACV circuit malfunction
• Loose or poor contact of the IACV connector
• IACV or its circuit malfunction
PCM EEPROM malfunction
Symptom/Fail-safe function
•
•
»
<»
Engine operates normally
Fail-safe value: 29 kPa
Engine operates normally
Fail-safe value: 29 kPa
Refer to
6-18
6-19
» Hard start at a low temperature
6-20
• Fail-safe value: 78.6°C/173.5°F
1» Cooling fan turns on
1
1
Hard start at a low temperature
6-22
i
• Fail-safe value: 78.6°C/173.5°F
» Cooling fan turns on
• Poor engine acceleration
6-23
• Fail-safe value: 0°
• A/T shift function and anti-creep
function does not work (2nd gear
only)
• Poor engine acceleration
6-24
• Fail-safe value: 0°
• A/T shift function and anti-creep
function does not work (2nd gear
only)
• Engine operates normally
6-25
• Pre-program value: 25°C/77°F
• Engine operates normally
6-26
• Fail-safe value: 25°C/77°F
4
4
6-27
• Engine operates normally
• Selectable 4WD system does not
work (2WD mode only)
• A/T shift function and anti-creep
function does not work (2nd gear
only)
• Engine does not start
6-28
• Injectors, fuel pump and ignition
shut down
• Engine stalls, hard to start, rough 6-29
idling
• Engine operates normally
6-53
6-17
FUEL SYSTEM (PGM-FI)
DTC TROUBLESHOOTING
DTC 1-1 (MAP SENSOR LOW
VOLTAGE)
1. MAP Sensor System Inspection
Turn the ignition switch ON and engine stop
switch "O".
Check the MAP sensor with the HDS pocket
tester.
Is about 0 V indicated?
YES
- GO TO STEP 2.
NO
- • Intermittent failure
• Loose or poor contact on the MAP
sensor connector
2. MAP Sensor Input Voltage Inspection
Remove the fuel tank left side cover (page 3-6).
Turn the ignition switch OFF.
Disconnect the MAP/TP sensor 5P (Black) connector.
MAP/TP SENSOR 5P (BLACK) CONNECTOR
(Wire side of female terminal)
Turn the ignition switch ON and engine stop
switch "o".
Measure the voltage at the wire harness side.
Connection: Brown (+) - Green/red (-)
Is the voltage within 4.75 - 5.25V?
YES - GO TO STEP 4.
NO - GO TO STEP 3.
3. MAP Sensor Input Line Inspection
Turn the ignition switch OFF.
Disconnect the PCM 33P (Gray) connector.
Check for continuity of the Brown wire between
the MAP/TP sensor 5P (Black) connector terminal
and the PCM 33P (Gray) connector terminals.
TOOL:
Test probe
07ZAJ-RDJA110
MAP/TP SENSOR 5P (BLACK) CONNECTOR
(Wire side of female terminal)
Connection: B3 - Brown
Is there continuity?
YES
- Replace the PCM with a known good
one, and recheck.
NO
- Open circuit in Brown wire
PCM 33P (GRAY) CONNECTOR
(Wire side female terminal)
4. MAP Sensor Output Line Short Circuit Inspection
Check for continuity between the MAP/TP sensor
5P (Black) connector terminal of the wire harness
side and ground.
Connection: Light green - ground
Is there continuity?
6-18
YES
- Short circuit in Light green wire
NO
- GO TO STEP 5.
MAP/TP SENSOR 5P (BLACK) CONNECTOR
(Wire side of female terminal)
FUEL SYSTEM (PGM-FI)
5. MAP Sensor Inspection
Replace the MAP/TP sensor with a known good
one (page 6-43).
Clear the DTC (page 6-14).
Turn the ignition switch ON and engine stop
switch "o".
Check the MAP sensor with the HDS pocket
tester.
Is DTC 1-1 indicated?
YES
- Replace the PCM with a known good
one, and recheck
NO
- Faulty original MAP/TP sensor
DTC 1-2 (MAP SENSOR HIGH
VOLTAGE)
• Before starting the inspection, check for loose or
poor contact on the MAP/TP sensor 5P (Black)
connector and recheck the DTC.
1. MAP Sensor System Inspection 1
Turn the ignition switch ON and engine stop
switch "o".
Check the MAP sensor with the HDS pocket
tester.
Is about 5 V indicated?
YES
- GO TO STEP 2.
NO
- • Intermittent failure
Loose or poor contact on the MAP/TP
sensor connector
2. MAP Sensor System Inspection 2
Turn the ignition switch OFF.
Disconnect the MAP/TP sensor 5P (Black) connector.
Jump the MAP sensor terminals at the wire harness side with a jumper wire.
Connection: Light green - Green/red
Turn the ignition switch ON and engine stop
switch "o"Check the MAP sensor with the HDS pocket
tester.
Is about 0 V indicated?
YES
- Faulty MAPfTP sensor
NO
- GO TO STEP 3.
MAP/TP SENSOR 5P (BLACK) CONNECTOR
(Wire side of female terminal)
G
\
JUMPER WIRE
6-19
FUEL SYSTEM (PGM-FI)
3. MAP Sensor Input Voltage Inspection
Turn the ignition switch OFF.
Remove the jumper wire.
MAP/TP SENSOR 5P (BLACK) CONNECTOR
(Wire side of female terminal)
Turn the ignition switch ON and engine stop
switch "O".
Measure the voltage at the wire harness side terminals.
Connection: Brown (+) - Green/red (-)
te the voltage within 4.75 - 5.25V?
YES - GO TO STEP 4.
NO
- Open circuit in Green/red or Brown wire
4. MAP Sensor Output Line Open Circuit Inspection
Turn the ignition switch OFF.
Disconnect the PCM 33P (Gray) connector.
Check for continuity of the Light green wire
between the MAP/TP sensor 5P (Black) connector terminal and the PCM 33P (Gray) connector
terminal.
TOOL:
Test probe
07ZAJ-RDJA110
Connection: B25 - Light green
MAP/TP SENSOR 5P (BLACK) CONNECTOR
(Wire side of female terminal)
[
I—I
- J
I
r
I
w
/
j
B25
te there continuity?
YES
- Replace the PCM with a known good
one, and recheck
NO
- Open circuit in Light green wire
DTC 7-1 (ECT SENSOR LOW
VOLTAGE)
1. ECT Sensor System Inspection
Turn the ignition switch ON and engine stop
switch "O".
Check the ECT sensor with the HDS pocket
tester.
te about 0 V indicated?
6-20
NO
- • Intermittent failure.
• Loose or poor contact on the ECT
sensor connector.
YES
- GO TO STEP 2.
PCM 33P (GRAY) CONNECTOR
(Wire side of female terminal)
Lg ->
FUEL SYSTEM (PGM-FI)
2. ECT Sensor Inspection
Remove the fuel tank left side cover (page 3-6).
2P BLACK CONNECTOR
Turn the ignition switch OFF.
Disconnect the ECT sensor 2P (Black) connector.
Turn the ignition switch ON and engine stop
switch "O".
Check the ECT sensor with the HDS pocket
tester.
Is about 0 V indicated?
NO
- GO TO STEP 3.
YES
- GO TO STEP 4.
3. ECT Sensor Resistance Inspection
Turn the ignition switch OFF.
Measure the resistance at the ECT sensor terminals.
Connection: White - Green/red
Standard: 2.3 - 2.6 kn (20°C/68°F)
ECT SENSOR 2P (BLACK) CONNECTOR
(Sensor side of male terminal)
Is the resistance within 2.3 - 2.6 kn ?
YES
- Replace the PCM with a new one, and
recheck.
No
- Faulty ECT sensor.
G/R
W
4. ECT Sensor Short Circuit Inspection
Disconnect the PCM 33P (Gray) connector from
the PCM (page 6-53).
Check for continuity between the ECT sensor 2P
(Black) connector terminal of the wire harness
side and ground.
ECT SENSOR 2P (BLACK) CONNECTOR
(Wire side of female terminal)
Connection: White - Ground
Is there continuity?
YES - Short circuit in White wire.
NO
- Replace the PCM with a new one, and
recheck.
6-21
FUEL SYSTEM (PGM-FI)
DTC 7-2 (ECT SENSOR HIGH
VOLTAGE)
• Before starting the inspection, check for loose or
poor contact on the ECT sensor 2P (Black) connector and recheck the DTC.
1. ECT Sensor System Inspection
Turn the ignition switch ON and engine stop
switch "o".
Check the ECT sensor with the HDS pocket
tester.
Is about 5 V indicated?
NO
- • Intermittent failure.
• Loose or poor contact on the ECT
sensor 2P (Black) connector.
YES
- GO TO STEP 2.
2. ECT Sensor Inspection
Remove the fuel tank left side cover (page 3-6).
Turn the ignition switch OFF.
Disconnect the ECT sensor 2P (Black) connector.
Jump the ECT sensor terminals with a jumper
wire.
Connection: White - Green/red
ECT SENSOR 2P (BLACK) CONNECTOR
(Wire side of female terminal)
Turn the ignition switch ON and engine stop
switch "O".
Check the ECT sensor with the HDS pocket
tester.
Is about 0 V indicated?
YES
- Faulty ECT sensor.
NO
- GO TO STEP 3.
3. ECT Sensor Open Circuit Inspection
Turn the ignition switch OFF.
Disconnect the jumper wire.
Disconnect the PCM 33P (Gray) connector (page
6-53).
Check for continuity between the PCM 33P
(Gray) connector terminals and ECT sensor 2P
(Black) connector terminals of the wire harness
side.
TOOL:
Test probe
07ZAJ-RDJA110
Connection: B27-White
B2- Green/red
Is there continuity?
6-22
YES
- Replace the PCM with a new one, and
recheck.
NO
- • Open circuit in White wire.
• Open circuit in Green/red wire.
JUMPER WIRE
ECT SENSOR 2P (BLACK) CONNECTOR
(Wire side of female terminal)
B2
B27

r-i
PCM 33P (GRAY) CONNECTOR
(Wire side of female terminal)
FUEL SYSTEM (PGM-FI)
DTC 8-1 (TP SENSOR LOW VOLTAGE)
• Before starting the inspection, check for loose or
poor contact on the MAP/TP sensor 5P (Black)
connector and recheck the DTC.
1. TP Sensor System Inspection
Turn the ignition switch ON and engine stop
switch "o".
Check the TP sensor with the HDS when the
throttle is fully closed.
Is about 0 V indicated?
YES
- GO TO STEP 3.
NO
- GO TO STEP 2.
2. TP Sensor Inspection
Check that the TP sensor voltage is increasing
uninterrupted when moving the throttle from
fully closed to fully opened using the data list
menu of the HDS pocket tester.
Does the voltage increase continuously?
YES
- • Intermittent failure.
• Loose or poor contact on the MAP/TP
sensor connector
NO
- Faulty TP sensor.
3. TP Sensor Input Voltage Inspection
Turn the ignition switch OFF.
Disconnect the MAP/TP sensor 5P (Black) connector.
MAP/TP SENSOR 5P (BLACK) CONNECTOR
(Wire side of female terminal)
Turn the ignition switch ON and engine stop
switch "O"Measure the voltage at the wire harness side terminals.
Connection: Brown (+) - Green/red (-)
to the voltage within 4.75 - 5.25 V?
YES
- GO TO STEP 5.
NO
- G O TO STEP 4.
4. TP Sensor Circuit Inspection
Turn the ignition switch OFF.
MAP/TP SENSOR 5P (BLACK) CONNECTOR
(Wire side of female terminal)
Disconnect the PCM 33P (Gray) connector.
Check for continuity at the Brown wire between
the MAP/TP sensor 5P (Black) connector terminal
and the PCM 33P (Gray) connector terminal.
TOOL:
Test probe
07ZAJ-RDJA110
Connection: B3 - Brown
Is there continuity?
YES
- Replace the PCM with a known good
one, and recheck
NO
- Open circuit in Brown wire
B3
[
i—i
Br
 :
-—i
—
i
[
j
1
7
' '
' ' '
PCM 33P (GRAY) CONNECTOR
(Wire side of female terminal)
6-23
FUEL SYSTEM (PGM-FI)
5. TP Sensor Output Line Open Circuit Inspection
Check for continuity at the Yellow wire between
the MAP/TP sensor 5P (Black) connector terminal
and the PCM 33P (Gray) connector terminal.
TOOL:
Test probe
07ZAJ-RDJA110
MAP/TP SENSOR 5P (BLACK) CONNECTOR
(Wire side of female terminal)
B14
(
r-i
 1
Connection: B14 - Yellow
Is there continuity?
YES
- GO TO STEP 6.
NO
- Open circuit in Yellow wire
PCM 33P (GRAY) CONNECTOR
(Wire side of female terminal)
6. TP Sensor Output Line Short Circuit Inspection
Disconnect the MAP/TP sensor 5P (Black) connector.
Check for continuity between the MAP/TP sensor
5P (Black) connector terminal of the wire harness
side and ground.
Connection: Yellow - Ground
Is there continuity?
YES
- Short circuit in Yellow wire
NO
- GO TO STEP 7.
7. TP Sensor Inspection
Replace the MAP/TP sensor with a known good
one.
Reset the PCM (page 6-14).
Turn the ignition switch ON and engine stop
switch "O".
Check the TP sensor with the HDS pocket tester.
Is DTC 8-1 indicated?
YES - Replace the PCM with a known good
one, and recheck
NO
- Faulty original MAP/TP sensor
DTC 8-2 (TP SENSOR HIGH VOLTAGE)
1. TP Sensor System Inspection
Turn the ignition switch ON and engine stop
switch "O".
Check the TP sensor with the HDS pocket tester.
Is about 5 V indicated?
6-24
YES
- GO TO STEP 3.
NO
- GO TO STEP 2.
MAP/TP SENSOR 5P (BLACK) CONNECTOR
(Wire side of female terminal)
V
FUEL SYSTEM (PGM-FI)
2. TP Sensor Inspection
Check that the TP sensor voltage is increasing
continuously when moving the throttle from
fully closed to fully opened using the data list menu.
Is the voltage increasing continuously?
YES
- • Intermittent failure.
• Loose or poor contact on the MAP/TP
sensor connector
NO
- Faulty TP sensor.
3. TP Sensor Resistance Inspection
Turn the ignition switch OFF.
Disconnect the MAP/TP sensor 5P (Black) connector.
Measure the resistance at the TP sensor side terminals.
MAP/TP SENSOR 5P (BLACK) CONNECTOR
(Sensor side of male terminal)
Connection: Brown - Green/red
Is the resistance within 1.0 - 3.0 ki2
YES
- GO TO STEP 4.
NO
- Faulty TP sensor
G/R
4. TP Sensor Input Voltage Inspection
Turn the ignition switch ON and engine stop
switch "O".
Measure the voltage at the wire harness side terminals.
MAP/TP SENSOR 5P (BLACK) CONNECTOR
(Wire side of female terminal)
Connection: Brown (+) - Green/red (-)
Is the voltage within 4.75 - 5.25 V?
YES - Replace the PCM with a known good
one, and recheck
NO
- Open circuit in Green/red or Brown
wires
G/R
DTC 9-1 (IAT SENSOR LOW VOLTAGE)
1. IAT Sensor System Inspection
Turn the ignition switch ON and engine stop
switch "O".
Check the IAT sensor with the HDS pocket tester.
Is about 0 V indicated?
YES
- GO TO STEP 2.
NO
- • Intermittent failure
• Loose or poor contact on the IAT
sensor connector
6-25
FUEL SYSTEM (PGM-FI)
2. IAT Sensor Inspection
Turn the ignition switch OFF.
Disconnect the IAT sensor 2P (Black) connector.
Turn the ignition switch ON and engine stop
switch "O"Check the IAT sensor with the HDS pocket tester.
Is about 0 V indicated?
YES
- GO TO STEP 3.
NO
- Faulty IAT sensor
2P (BLACK) CONNECTOR •
3. IAT Sensor Output Line Short Circuit Inspection
Disconnect the PCM 33P (Gray) connector from
the PCM (page 6-43).
Check for continuity between the IAT sensor 2P
(Black) connector terminal of the wire harness
side and ground.
IAT SENSOR 2P (BLACK) CONNECTOR
(Wire side of female terminal)
Connection: Gray/blue - ground
te there continuity?
YES - Short circuit in Gray/blue wire
NO
- Replace the PCM with a known good
one, and recheck
DTC 9-2 (IAT SENSOR HIGH VOLTAGE)
• Before starting the inspection, check for loose or
poor contact on the IAT sensor connector and
recheck the DTC.
1. IAT Sensor System Inspection
Turn the ignition switch ON and engine stop
switch "O".
Check the IAT sensor with the HDS pocket tester.
Is about 5 V indicated?
YES
- GO TO STEP 2.
NO
- • Intermittent failure
• Loose or poor contact on the IAT
sensor connector
2. IAT Sensor Inspection
Turn the ignition switch OFF.
Disconnect the IAT sensor 2P (Black) connector.
Jump the IAT sensor terminals with a jumper
wire.
Connection: Gray/blue - Green/red
IAT SENSOR 2P (BLACK) CONNECTOR (Wire
side of female terminal)
Turn the ignition switch ON and engine stop
switch "O".
(>
pj
Check the IAT sensor with the HDS pocket tester.
Is about 0 V indicated?
6-26
YES
- Faulty IAT sensor
NO
- GO TO STEP 3.
Gr/Bu
G/R
JUMPER WIRE
FUEL SYSTEM (PGM-FI)
3. IAT Sensor Open Circuit Inspection
Turn the ignition switch OFF.
IAT SENSOR 2P( BLACK) CONNECTOR
(Wire side of fern ale terminal)
/
B2
B26

^ ^ ^ G/R/
i
Vi
j
Disconnect the PCM 33P (Gray) connector.
Check for continuity at the Gray/blue and Green/
red wire between the IAT sensor 2P (Black) connector terminals and the PCM 33P (Gray) connector terminals.
TOOL:
Test probe
07ZAJ-RDJA110
Connection: B2 - Green/red
B26- Gray/blue
te there continuity?
YES
- Replace the PCM with a known good
one, and recheck.
NO
- • Open circuit in Gray/blue wire
• Open circuit in Green/red wire
i
i
i
r
I
I
J
'
-2
1
'
(3D
Gr/Bu
PCM 33P (GRAY) CONNECTOR
(Wire side of female terminal)
DTC 11-1 (REAR VS SENSOR NO
SIGNAL)
• Before starting the inspection, check for loose or
poor contact on the rear VS (Vehicle Speed) sensor 3P (Yellow) connector and recheck the DTC.
1. Rear VS Sensor System Inspection
Test-ride the vehicle and check the rear VS sensor with HDS pocket tester.
Is vehicle speed indicated normally?
YES
- Intermittent failure.
NO
- GO TO STEP 2.
2. Rear VS Sensor Input Voltage Inspection
Turn the ignition switch OFF.
Disconnect the rear VS sensor 3P (Yellow) connector (page 23-9).
REAR VS SENSOR 3P (YELLOW) CONNECTOR
(Wire side of male terminal)
Turn the ignition switch ON and engine stop
switch "O".
Measure the voltage at the rear VS sensor connector terminals of the wire harness side.
Connection: Black/pink (+) - Green (-)
Is there battery voltage?
NO
- • Open or short circuit in the Black/
pink wire.
• Open circuit in the Green wire.
YES
Bl/P
- GO TO STEP 3.
6-27
FUEL SYSTEM (PGM-FI)
3. Rear VS Sensor Output Line Inspection
Measure the voltage between the wire harness
side rear VS sensor 3P (Yellow) connector terminals.
Connection: Pink/green (+) - Green (-)
REAR VS SENSOR 3P (YELLOW) CONNECTOR
(Wire side of male terminal)
Is the voltage about 5 V?
NO
- Open or short circuit in the Pink/green
wire.
YES
- GO TO STEP 4.
4. Rear VS Sensor Inspection
Turn the ignition switch OFF.
Replace the rear VS sensor with a new one (page
23-9).
Clear the DTC, test ride the vehicle and recheck
the DTC.
Is the DTC 11-1 indicated?
YES
- Replace the PCM with a new one, and
recheck.
NO
- Faulty original rear VS sensor.
DTC 12-1 (INJECTOR)
• Before starting the inspection, check for loose or
poor contact on the injector 2P (Gray) connector
and recheck the DTC.
1. Injector System Inspection
Clear the DTC (page 6-15).
Turn the ignition switch ON and engine stop
switch "o", or start the engine, recheck the DTC.
te the DTC 12-1 indicated?
NO
- • Intermittent failure.
Loose or poor contact on the injector
2P (Gray) connector.
YES
- GO TO STEP 2.
2. Injector Resistance Inspection
Remove the seat (page 3-4).
Remove the trim clip and throttle body cover
(page 6-43).
Disconnect the injector 2P (Gray) connector.
INJ 2P (GRAY) CONNECTOR
(Injector side of male terminal)
Turn the ignition switch ON and engine stop
switch "o"Measure the resistance of the injector connector
terminals on the injector side.
Connection: Black/yellow - Green/blue
Standard: 11.1 - 12.3 Q (20°C/68°F)
te the resistance within 11.1 - 12.3 £2 (20°C/
68°F)?
6-28
NO
- Faulty injector.
YES
- GO TO STEP 3.
Bl/Y
G/Bu
FUEL SYSTEM (PGM-FI)
3. Injector Open Circuit Inspection
Turn the ignition switch OFF.
Disconnect the PCM 33P (Gray) and 33P (Black)
connector (page 6-43).
Check for continuity between the PCM 33P (Gray
and Black) connectors and injector 2P (Gray)
connector of the wire harness side.
TOOL:
Test probe
07ZAJ-RDJA110
PCM 33P (BLACK) CONNECTOR
(Wire side of female terminal)
A4
i

„,,[—iV
IS
Bl/Y
B33
h1
INJ2P
(GRAY)
CONNECTOR
(Wire side of
female
terminal)
G/Bu
Connection: B33 - Green/blue
A4 - Black/yellow
Is there continuity?
NO
- • Open circuit in Green/blue wire.
• Open circuit in Black/yellow wire.
YES
- GO TO STEP 4.
PCM 33P (GRAY) CONNECTOR
(Wire side of female terminal)
4. Injector Signal Line Short Circuit Inspection
Be sure to disconnect the
PCM connector.
Check for continuity between the injector connector terminal and ground.
Connection: Green/blue - Ground
INJ 2P (GRAY) CONNECTOR
(Wire side of female terminal)
fe there continuity?
YES
- Short circuit in the Green/blue wire.
NO
- Replace the PCM with a new one, and
recheck.
DTC 29-1 (IACV)
• Before starting the inspection, check for loose or
poor contact on the IACV 4P (Black) connector
and recheck the DTC.
1. Recheck DTC
Clear the DTC (page 6-15).
Start the engine and recheck the DTC.
Is the DTC 29-1 indicated?
NO
- • Intermittent failure.
• Loose or poor contact on the IACV
connector.
YES
- GO TO STEP 2.
6-29
FUEL SYSTEM (PGM-FI)
2. lACV Short Circuit Inspection
Remove the seat (page 3-4).
Remove the trim clip and throttle body cover
(page 6-43).
lACV 4P (BLACK) CONNECTOR
(Wire side of female terminal)
Turn the ignition switch OFF.
Disconnect the lACV 4P (Black) connector.
Check for continuity between the lACV 4P (Black)
connector and ground on all wires.
Connection: Black - Ground
Brown/blue - Ground
Brown/yellow - Ground
Brown/red - Ground
Bl
Br/Bu
Br/Y
Br/R
Is these continuity on all wires?
YES
- • Short circuit in Black or Brown/red
wire.
• Short circuit in Brown/blue or Brown/
yellow wire.
NO
- GO TO STEP 3.
3. lACV Circuit Continuity Inspection
Disconnect the PCM 33P (Gray) connector.
Check for continuity between the PCM 33P
(Gray) connector and the lACV 4P (Black) connector.
TOOL:
Test probe
07ZAJ-RDJA110
Connection: B20 B30 B31 B32 -
lACV 4P (WHITE) CONNECTOR
(Wire side of female terminal)
Black
Brown/blue
Brown/yellow
Brown/red
Are there continuities?
YES
- GO TO STEP 4.
NO
- • Open or loose contact in Black or
Brown/red wire.
• Open or loose contact in Brown/blue
or Brown/yellow wire.
Br/Y
•{§)
Br/R •
PCM 33P (GRAY) CONNECTOR
(Wire side of female terminal)
4. lACV Resistance Inspection
Measure the resistance at the terminals of the
lACV 4P (Black) connector on the valve side
Connection: Black - Brown/red
Brown/blue - Brown/yellow
Standard:
120-140 Q (20°C/68°F)
lACV 4P (BLACK) CONNECTOR
(Valve side of male terminal)
te the resistance within 120 - 140 Q {20°C/68°F)7
YES
- Replace the PCM with a new one, and
recheck.
NO
- Faulty lACV.
Br/Bu
6-30
^-^
Br/Y
J
FUEL SYSTEM (PGM-FI)
MIL CIRCUIT INSPECTION
If the engine can be started but the MIL does not
come on with the ignition switch ON and engine
stop switch "O", check as follows:
FA model shown:
MIL
Check the various functions of the combination
meter.
-
If they do not function, check the combination
meter power input line (page 23-8).
If they function properly, check as follows:
Turn the ignition switch OFF.
Disconnect the PCM 33P (Gray) connector.
Ground the White/blue (B19) wire terminal of the
wire harness side connector with a jumper wire.
TOOL:
Test probe
PCM 33P (GRAY) CONNECTOR
(Wire side of female terminal)
07ZAJ-RDJA110
B19
V
Turn the ignition switch ON and engine stop switch
"O", the MIL should come on.
-
If the MIL comes on, replace the PCM.
If the MIL does not come on, check for open circuit in the White/blue wire between the combination meter and PCM.
If the wire is OK, replace the combination meter.
—
r
v
i
1
i
1
6-31
FUEL SYSTEM (PGM-FI)
FUEL LINE INSPECTION
FUEL PRESSURE RELIEVING/QUICK
CONNECT FITTING REMOVAL
• Before disconnecting fuel feed hose, relieve pressure from the system as following procedures.
• Do not bent or twist fuel feed hose.
1. Turn the ignition switch OFF.
QUICK CONNECT FITTING
Pull up the rubber boot and disconnect the fuel
pump 2P (Black) connector.
2. Start the engine, and let it idle until it stalls.
3. Turn the ignition switch OFF.
4. Disconnect the battery cable (page 20-6).
5. Check the fuel quick connect fitting for dirt, and
clean if necessary.
Place a shop towel over the quick connect fitting.
2P (BLACK) CONNECTOR
6. Hold the connector with one hand and squeeze
the retainer tabs with the other hand release
them from the locking pawls.
Pull the connector off.
• Prevent the remaining fuel in the fuel feed hose
from flowing out with a shop towel.
• Be careful not to damage the hose 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 releases.
CONNECTOR
RETAINER TABS
JOINT RUBBER
7. To prevent damage and keep foreign matter out,
cover the disconnected connector and pipe end
with the plastic bags.
6-32
PLASTIC EiAGS
LOCKING PAWLS
FUEL SYSTEM (PGM-FI)
QUICK CONNECT FITTING
INSTALLATION
• Always replace the retainer of the quick connect
fitting and joint rubber when the fuel feed hose is
disconnected.
• If any retainer needs replacing, use the same
manufacture's retainer as the ones being
removed (The several manufactures feature different retainer specifications).
• If any damage or cut-out on the rubber cap,
replace it with a new one.
• Do not bent or twist the fuel feed hose.
1. Insert a new retainer into the connector.
RETAINER
CONNECTOR
2. Set a new joint rubber to the fuel pipe as shown.
3. Align the quick connect fitting with the pipe and
align the new retainer locking pawls with the
connector grooves in the rubber lock piece.
Then press the quick connect fitting onto the
pipe until both retainer pawls lock with a
"CLICK".
If it is hard to connect, put a small amount of
engine oil on the pipe end.
CONNECTOR
LOCKING
PAWLS
JOINT RUBBER
4. Make sure the connection is secure and that the
pawls are firmly locked into place; check visually
and by pulling the connector.
CONNECTOR
6-33
FUEL SYSTEM (PGM-FI)
5. Connect the fuel pump 2P (Black) connector.
Install the boot properly.
2P (BLACK CONNECTOR
Temporarily connect the positive cable and negative cable to the battery.
Turn the ignition switch ON and engine stop
switch "O".
Do not start the
engine.
The fuel pump will run for about 2 seconds, and
fuel pressure will rise.
Repeat 2 or 3 times, and check that there is no
leakage in the fuel supply system.
FUEL PRESSURE TEST
Relieve the fuel pressure and disconnect the quick
connect fitting (page 6-32).
MANIFOLD
FUEL PRESSURE GAUGE
Attach the fuel pressure gauge, attachment and
manifold between the fuel pump and quick connector.
TOOLS:
Fuel pressure gauge
Pressure gauge manifold
Pressure gauge hose attachment A
Pressure gauge hose attachment B
Hose attachment B joint
07406-0040004
07ZAJ-S5A0111
07ZAJ-S5A0120
07ZAJ-S5A0130
07ZAJ-S5A0150
U.S.A. TOOLS:
Fuel pressure gauge, lOOpsi
Pressure manifold hose
Adaptor, male
Adaptor, female
07406-004000B
07AMJ-HW3A100
07AAJ-S6MA200
07AAJ-S6MA400
Temporarily connect the positive cable and negative
cable to the battery.
Start the engine and let it idle.
Read the fuel pressure.
Standard: 284 - 304 kPa
(2.9 - 3.1 kgf/cm2, 4 1 - 4 4 psi)
If the fuel pressure is higher than specified, replace
the fuel pump assembly (faulty fuel pump or fuel
pressure regulator).
If the fuel pressure is lower than specified, inspect
the following:
-
6-34
Check the fuel flow
Pinched or clogged fuel feed hose or fuel tank
breather hose
Fuel pump (page 6-36)
Clogged fuel filter (Faulty fuel pump assembly)
HOSE ATTACHMENTS
FUEL SYSTEM (PGM-FI)
Wrap a shop towel After inspection, relieve the fuel pressure by starting
around the attach- the engine and let it idle until it stalls.
ment to soak up
Remove the fuel pressure gauge, attachment and
any spilled fuel.
manifold from the fuel pump.
Connect the quick connect fitting (page 6-33).
FUEL FLOW INSPECTION
Relieve the fuel pressure and disconnect the quick
connect fitting (page 6-32).
Turn the ignition switch OFF.
RELAY MODULE 8P (GRAY) CONNECTOR
(Wire side of female terminal)
Disconnect the relay module 8P (Gray) connector.
Jump the Black/yellow and Violet wire terminals of
the wire harness side using a jumper wire.
B/Y
JUMPER WIRE
Connect the hose attachment to the fuel pump joint.
TOOL:
Pressure gauge hose attachment
U.S.A. TOOLS:
Pressure manifold hose
Adaptor, female
HOSE ATTACHMENT
07ZAJ-S5A0130
07AMJ-HW3A100
07AAJ-S6MA400
Wipe spilled gaso- Place the end of the hose into an approved gasoline
line out of the con- container.
tamer. j e m p O r a r j | y COnnect the positive cable and negative
cable to the battery.
Turn the ignition switch ON, engine stop switch "o"
for 10 seconds.
Measure the amount of fuel flow.
Amount of fuel flow:
71 cm3 (2.4 US oz, 2.5 Imp oz) minimum
/10 seconds at 12 V
If the fuel flow is less than specified, inspect the following:
-
Fuel pump (page 6-36).
Clogged fuel filter (Faulty fuel pump assembly)
Connect the quick connect fitting (page 6-33).
6-35
FUEL SYSTEM (PGM-FI)
SUB FUEL TANK/FUEL PUMP
INSPECTION
Turn the ignition switch ON, engine stop switch "O"
and confirm that the fuel pump operates for a few
seconds.
If the fuel pump does not operate, inspect as follows:
Turn the ignition switch OFF.
Pull up the rubber boot and disconnect the fuel
pump 2P (Black) connector.
2P (BLACK CONNECTOR
Turn the ignition switch ON, engine stop switch "O"
and measure the voltage between the terminals.
FUEL PUMP 2P (BLACK) CONNECTOR
(Wire side of female terminal)
Connection: Violet (+) - Green (-)
There should be battery voltage for a few seconds.
If there is battery voltage, replace the sub fuel tank
assembly.
If there is no battery voltage, inspect the following:
-
open circuit in Violet wire and/or Green wire
fuse
fuel pump relay (page 6-38)
engine stop relay (page 6-52)
engine stop switch (page 23-7)
bank angle sensor (page 6-51)
PCM (page 6-53)
REMOVAL
NOTE:
• Do not disassemble the sub fuel tank.
After disconnecting
the fuel pump 2P
(Black) connector,
be sure to relieve
the fuel pressure by
starting the engine
and let it idle until it
stalls.
6-36
Remove the following:
-
fuel
fuel
fuel
fuel
pump 2P (Black) connector
feed hose
vapor return hose
hose
2P (BLACK) CONNECTOR
FUEL SYSTEM (PGM-FI)
Remove the bolts and sub fuel tank/bracket assembly.
, SUB FUEL TANK/BRACKET ASSEMBLY
Remove the bolts, then remove the sub fuel tank
and collars from the bracket.
BRACKET
BOLTS/COLLARS
Check the sub-fuel tank for damage.
Replace the sub fuel tank as necessary.
SUB FUEL TANK ASSEMBLY
INSTALLATION
Install the collars into the pump mounting rubbers.
BRACKET
BOLTS/COLLARS
Install the fuel pump onto the bracket while aligning
the boss with the grommet on the bracket.
Install and tighten the fuel pump mounting bolts.
Align
SUB FUEL TANK ASSEMBLY
Install the sub fuel tank/bracket assembly onto the
frame, tighten the bolts securely.
I_SUB FUEL TANK/BRACKET ASSEMBLY
6-37
FUEL SYSTEM (PGM-FI)
Connect the fuel hose and fuel vapor return hose to
the sub fuel tank/fuel pump.
2P BLACK) CONNECTOR
Connect the fuel feed hose (page 6-33).
Connect the fuel pump 2P (Black) connector.
FUEL PUMP RELAY
INSPECTION
Remove the battery and battery case (page 20-6).
Disconnect the relay module 8P (Gray) connector.
8P (GRAY) CONNECTOR
Connect an ohmmeter to the 8P (Gray) connector of
the module side connector terminals.
RELAY MODULE 8P (GRAY) CONNECTOR
(Module side of male terminal)
Connection: Black/yellow - Violet
Connect the 12V battery to the 8P (Gray) connector
of the module side connector terminals.
Connection: Yellow/black - Yellow/blue
There should be continuity only when the 12V battery is connected.
If there is no continuity when the 12V battery is connected, replace the fuel pump relay.
6-38
Bl/Y
FUEL SYSTEM (PGM-FI)
FUEL TANK
REMOVAL/INSTALLATION
Remove both fuel tank side covers (page 3-6).
Disconnect the fuel level sensor 2P (Natural) connector.
Release the sensor wire from the clamp.
2P NATURAL) CONNECTOR
Disconnect the fuel vapor return hose from the fuel
tank joint.
FUEL VAPOR RETURN HOSE
Release the return hose from the hose guide.
Remove the two fuel tank holder bands and mounting bolts.
6-39
FUEL SYSTEM (PGM-FI)
Lift the fuel tank and disconnect the fuel hose from
the fuel tank joint.
Unhook the heat guard rubbers from the heat guard
plate bosses and frame bosses.
Remove the heat guard rubbers.
FUEL TANK JOINT
HEAT GUARD RUBBERS
BOSSES
BOSSES
Remove the fuel feed hose, radiator hose and throttle cable from the clamp on the heat guard plate.
Remove the heat guard plate from the frame by
releasing the two bosses.
BOSSES
RADIATOR HOSE
FUELHOSE
Install the heat guard plate, rubber heat guard and
fuel tank in the reverse order of removal.
NOTE:
• After installing the fuel tank, turn the ignition
switch ON and check that there is no fuel leak.
THROTTLE CABLE
FUEL STRAINER SCREEN CLEANING
Remove the fuel tank (page 6-39).
Drain the gasoline into an approved fuel container.
Remove the two mounting bolts, collars and the fuel
joint.
6-40
HEAT GUARD PLATE
FUEL SYSTEM (PGM-FI)
Remove the O-ring and fuel strainer screen.
Clean the strainer screen with non-flammable or
high flash point solvent.
Dry the strainer screen thoroughly.
Install the strainer screen and a new O-ring onto the
fuel valve.
Install the fuel joint onto the fuel tank.
Install the collars and mounting bolts, and tighten
the bolts securely.
Install the fuel tank (page 6-39).
AIR CLEANER HOUSING
REMOVAL/INSTALLATION
Remove the following:
-
seat (page 3-4)
right side cover (page 3-5)
fuel tank rear cover (page 3-6)
Loosen the screw and remove the retaining clip.
Loosen the band screw and remove the resonator
chamber from the air duct.
RESONATOR CHAMBER
Remove the trim clip, loosen the band screw and
remove the intake duct from the air cleaner housing.
Disconnect the crankcase breather hose from the
cylinder.
6-41
FUEL SYSTEM (PGM-FI)
Disconnect the IAT sensor 2P (Black) connector.
2P (BLACK CONNECTOR
Loosen the air cleaner connecting hose band screw
For ease of air cleaner housing removal, remove the
rear fender mounting bolts.
Be careful not to Remove the two bolts and the air cleaner housing
damage the con- from the frame.
nectmg hose.
HOUSING MOUNTING BOLTS
Installation is in the reverse order of removal.
Tighten the connecting hose band screw as shown.
6-42
12 ± 1 mm(0.5 + 0.04in)
FUEL SYSTEM (PGM-FI)
THROTTLE BODY
REMOVAL
NOTICE
Before disconnecting fuel feed hose, relieve pressure from the system (page 6-32).
Remove the following:
-
relieve the fuel pressure and disconnect the
quick connect fitting (page 6-32).
seat (page 3-4)
air cleaner housing (page 6-41)
Remove the trim clip and throttle body cover.
Unhook and remove the MAP/TP sensor connector
cover, then disconnect the MAP/TP sensor 5P
(Black) connector.
Disconnect the IACV 4P (Black) connector, injector
2P (Gray) connector and release the wire harness
from the wire clamp.
5P (BLACK) CONNECTOR
4PJBLACK) CONNECTOR
2P (GRAY) CONNECTOR
6-43
FUEL SYSTEM (PGM-FI)
Remove the fuel feed hose clamp screw.
Remove the bolts and fuel injector holder and fuel
injector.
Remove the screw and throttle drum cover.
THROTTLE DRUM COVER
Loosen the throttle cable lock nut and adjusting nut
then disconnect the throttle cable from the throttle
drum and throttle body.
Loosen the insulator band screw.
Remove the throttle body from the insulator.
6-44
ADJUSTING NUT
OCK NUT
FUEL SYSTEM (PGM-FI)
DISASSEMBLY
NOTICE
• The throttle body is factory preset. Do not disassemble in a way other than shown in this manual.
• Do not snap the throttle valve from full open to
full close after the throttle cable has been
removed. It may cause incorrect idle operation.
• Do not damage the throttle body. It may cause
incorrect throttle valve operation.
• Do not loosen or tighten the white painted bolts,
nuts and screws of the throttle body.
• Always clean the throttle body before disassembly to prevent dirt and debris from entering the
passages.
• Do not remove the sensor unit unless it is
replaced.
For IACV replacement (page 6-56).
If necessary, remove the screws and MAP/TP sensor
unit from the throttle body.
SENSOR UNIT
Install a new O-ring into the groove of the throttle
body.
Install the new MAP/TP sensor unit while aligning
the lug in the sensor unit with the throttle shaft.
SCREWS
SENSOR UNIT
Align
Tighten the screws to the specified torque.
TORQUE: 3.4 N m (0.35 kgfm, 2.5 Ibfft)
6-45
FUEL SYSTEM (PGM-FI)
TOP VIEW:
YELLOW PAINTED
THROTTLE DRUM VIEW:
LEFT SIDE VIEW:
YELLOW PAINTED
WHITE PAINTED
INSTALLATION
Install the insulator and throttle body by aligning
the boss and groove.
Tighten the insulator band screws.
5.5+ 1 mm(0.22±0.04in)
— •
EJ
6-46
FUEL SYSTEM (PGM-FI)
Connect the throttle cable to the throttle drum and
throttle body.
ADJUSTING NUT
LOCK NUT
THROTTLE DRUM
THROTTLE CABLE END
Install the throttle drum cover while aligning its
boss with the groove in the throttle body.
Install and tighten the screw.
TORQUE: 1.5 N-m (0.15 kgf-m, 1.1 Ibf-ft)
THROTTLE DRUM COVER
Install the injector onto the throttle body.
Connect the fuel feed hose and tighten the bolts to
the specified torque.
FUEL INJECTOR
TORQUE: 5.1 N-m (0.53 kgf-m, 3.8 Ibf-ft)
Install the fuel feed hose guide while aligning it hole
with the throttle body boss, then install and tighten
the screw to the specified torque.
TORQUE: 4.2 N-m (0.43 kgf-m, 3.1 Ibf-ft)
FEED HOSE CLAMP
Route the wire harness to the throttle body and
clamp it with wire clamp.
Connect the fuel injector 2P (Gray) connector and
IACV 4P (Black) connector.
4P (BLACK) CONNECTOR
2P (GRAY CONNECTOR
WIRE CLAMP
6-47
FUEL SYSTEM (PGM-FI)
Connect the MAP/TP sensor 5P (Black) connector.
Install the MAP/TP sensor connector cover.
After throttle cable disconnection, adjust the throttle
lever free play (page 4-4).
Install the throttle body cover and secure it with a
trim clip.
Install the air cleaner housing (page 6-41).
Install the seat (page 3-4).
INJECTOR
REMOVAL
NOTICE
Before disconnecting fuel feed hose, relieve pressure from the system (page 6-32).
Relieve the fuel pressure and disconnect the quick
connect fitting (page 6-32).
Remove the seat (page 3-4).
Remove the trim clip and throttle body cover.
6-48
5P (BLACK) CONNECTOR
FUEL SYSTEM (PGM-FI)
Clean around the injector base with compressed air
before removing the injector, and be sure that no
debris is allowed to enter into the combustion
chamber.
2P (GRAY) CONNECTOR
Disconnect the injector 2P (Gray) connector.
Remove the injector holder bolts.
Release the fuel feed hose from the hose guide.
Remove the injector from the fuel feed hose.
Remove the O-ring and seal ring.
SEAL RING • I N J E C T O R
4
CUSHION RING
INSTALLATION
Coat a new O-ring and new seal ring with engine oil.
Replace the O-ring Install a new O-ring, new cushion ring and new seal
and seal ring with ring, being careful not to damage them.
new ones as a set.
INJECTOR
CUSHION RING
Install the injector into the fuel feed hose, being
careful not to damage the O-ring by aligning the
boss of the injector and groove of the hose.
6-49
FUEL SYSTEM (PGM-FI)
Set the fuel feed hose into the hose guide.
Install the fuel feed hose/injector assembly to the
throttle body, being careful not to damage the seal
ring.
2P (GRAY) CONNECTOR
Install and tighten the injector holder bolts to the
specified torque.
TORQUE: 5.1 N m (0.53 kgf-m, 3.8 Ibf-ft)
Connect the injector 2P (Gray) connector.
Install the throttle body cover and secure it with trim
clip.
ECT SENSOR
REMOVAL/INSTALLATION
Drain the coolant (page 7-6).
Remove the left engine side cover (page 3-17).
ECT SENSOR •
2P (BLACK) CONNECTOR
Replace the ECT Disconnect the ECT sensor 2P (Black) connector
sensor while the from the sensor.
engine is cold. Remove the ECT sensor and O-ring.
Always replace the Install the new O-ring and ECT sensor.
O-ring with a new Tighten the ECT sensor to the specified torque.
°ne
TORQUE: 12 N-m (1.2 kgf m, 9 Ibf-ft)
Connect the ECT sensor 2P (Black) connector.
Install the fuel tank right side cover (page 3-6).
Fill the cooling system with recommended coolant
(page 7-6).
6-50
O-RING ^ H
ECT SENSOR
FUEL SYSTEM (PGM-FI)
BANK ANGLE SENSOR
INSPECTION
Remove the right inner fender (page 3-9).
Disconnect the bank angle sensor 3P (Green) connector and connect the inspection test harness.
TOOL:
Inspection test harness
07GMJ-ML80100
Turn the ignition switch ON and engine stop switch
to "O".
Measure the voltage between the test harness terminals.
CONNECTION
White(+) - Red(-)
Red(+) - Green(-)
STANDARD
Battery voltage
0-1 V
Turn the ignition switch OFF.
Do not disconnect Remove the right bolt and loosen the left bolt.
the bank angle Remove the bank angle sensor from left side of
sensor connector grommet.
during inspection.
Connect the bank angle sensor 3P (Green) connector.
Before you per- Place the bank angle sensor is normal position as
form this test, turn shown, and ignition switch ON and engine stop
the ignition switch switch "O", bank angle sensor is normal if the
OFF, then turn the engine stop relay clicks and power supply is closed.
ignition switch ON
Incline the bank angle sensor approximately 70° to
and engine stop
the left or right with keep the ignition switch ON and
switch 'O".
engine stop switch "o" the bank angle sensor is normal if the engine stop relay clicks and power supply
is open.
70° BANK ANGLE POSITION
NORMAL
POSITION
70° (approximately)
(approximately)
REMOVAL/INSTALLATION
Remove the right inner fender (page 3-9).
Disconnect the bank angle sensor 3P (Green) connector.
3P (GREEN) CONNECTOR
6-51
FUEL SYSTEM (PGM-FI)
Remove the right side screw and loosen the left side
screw.
Remove the bank angle sensor from the left side
grommet.
Route the sensor Install the bank angle sensor with its "UP" mark facwire correctly ing up.
(page 1-20). Tighten the mounting bolts to the specified torque.
TORQUE: 1.5 N m (0.15 kgf m, 1.1 Ibf-ft)
Connect the bank angle sensor 3P (Green) connector.
Install the right inner fender (page 3-9).
ENGINE STOP RELAY
INSPECTION
Remove the battery and battery case (page 20-6).
Disconnect the relay module 8P (Gray) connector.
8P (GRAY) CONNECTOR
6-52
FUEL SYSTEM (PGM-FI)
Connect the ohmmeter to the 8P (Gray) connector of
the module side connector terminals.
Connection: Black/blue - Red/yellow
Connect a 12V battery to the 8P (Gray) connector of
the module side connector terminals.
RELAY MODULE 8P (GRAY) CONNECTOR
(Module side of male terminal)
—*
A
1

Bl/W
R/W
s
Connection: Black/white - Red/white
k
n
00DOis
DC][ ] •
There should be continuity only when the 12V battery is connected.
UL-JU
If there is no continuity when the 12V battery is connected, replace the relay.
R/Y
Bl/Bu
I
—@—
_J
PCM (POWERTRAIN CONTROL
MODULE)
PCM POWER GROUND LINE
MALFUNCTION
Engine does not start (No DTC and MIL blinking)
1. PCM Power Input Voltage Inspection
• Before starting the inspection, check for loose
or poor contact on the PCM 33P connectors
and recheck the MIL blinking.
Disconnect the PCM 33P connectors.
Turn the ignition switch ON and engine stop
switch "O".
Measure the voltage between the PCM 33P
(Gray) connector terminal and ground.
TOOL:
Test probe
07ZAJ-RDJA110
PCM 33P (GRAY) CONNECTOR
(Wire side of female terminal)
Connection: B1 {+) - Ground (-)
Does battery voltage exit?
YES
- GO TO STEP 2.
NO
- GO TO STEP 3.
2. PCM Ground Line Inspection
Turn the ignition switch OFF.
Check for continuity between the PCM33P (Gray)
terminals and ground.
TOOL:
Test probe
07ZAJ-RDJA110
PCM 33P (GRAY) CONNECTOR
(Wire side of female terminal)
1
Connection: B2-Ground
B10-Ground
Is there continuities?
YES
- Replace the PCM with a new one, and
recheck.
NO
- Open circuit in the Green wire.
B1O
B2
6-53
FUEL SYSTEM (PGM-FI)
3. Engine Stop Relay Inspection 1
Turn the ignition switch OFF.
Disconnect the relay module 8P (Gray) connector.
Turn the ignition switch ON and engine stop
switch "o".
Measure the voltage at the engine stop relay
connector terminal of the wire harness side.
RELAY MODULE 8P (GRAY) CONNECTOR
(Wire side of female terminal)
*
1r
If >~
Til
"
1
Does battery voltage exist?
NO
- • Faulty sub fuse.
• Open circuit in the Black/blue wire.
YES
1
Bl/Bu
Connection: Black/blue (+) - Ground (-)
(v)
- G O TO STEP 4.
4. Engine Stop Relay Inspection 2
Turn the ignition switch OFF.
Jump the engine stop relay connector terminals
with jumper wire.
Connection: Black/white - Red/white
Turn the ignition switch ON and engine stop
switch "(")"•
Measure the voltage at the PCM 33P (Gray) terminal and ground.
Connection: B1 -Ground (-)
Does battery voltage exit?
YES - • Inspect the engine stop relay
(page 6-52).
• Inspect the engine stop switch
(page 23-7).
• Inspect the bank angle sensor
(page 6-51).
NO
- Open circuit in Black/white wire
between the engine stop relay and the
PCM.
REMOVAL/INSTALLATION
Remove the steering cover (page 3-5).
Remove the PCM from the holder bracket.
6-54
JUMPER WIRE
R/W
|
>
/
Bl/W
/
^~A
RELAY MODULE 8P (GRAY) CONNECTOR
(Wire side of female terminal)
FUEL SYSTEM (PGM-FI)
Do not pull the wire Disconnect the PCM 33P (Black), 33P (Gray) and 5P
harness while dis- (Black) connectors and then remove the PCM.
connecting the
PCM connectors.
33P (GRAY) CONNECTOR
Install the PCM in the reverse order of removal.
5P (BLACK)
CONNECTOR
ENGINE IDLE SPEED
IDLE SPEED INSPECTION
NOTE:
• Inspect the idle speed after all other engine maintenance items have been performed and are
within specifications.
• Before checking the idle speed, inspect the following items.
- No DTC and MIL blinking
- Spark plug condition (page 4-7)
- Air cleaner condition (page 4-5)
• The engine must be warm for accurate idle speed
inspection.
• This system eliminates the need for manual idle
speed adjustment compared to previous
designs.
• Use a tachometer with graduations of 50 rpm
(min 1 ) or smaller that will accurately indicate a
50 rpm (min"') change.
Remove the fuel tank left side cover (page 3-6).
Start the engine and warm it up to coolant temperature 80 °C (176 °F).
Stop the engine and connect a tachometer according to the tachometer manufacturer's instructions.
Start the engine and let it idle. Check the idle speed.
ENGINE IDLE SPEED: 1,400 + 50 rpm (min 1)
If the idle speed is out of the specification, check the
following:
• Throttle operation and throttle lever free play
(page 4-4).
• Intake air leak or engine top-end problem
(page 9-3)
• IACV operation (page 6-56)
6-55
FUEL SYSTEM (PGM-FI)
lACV
INSPECTION
The lACV is installed on the throttle body and is
operated by the step motor. When the ignition
switch is turned ON, the lACV operates for a few
seconds.
Check the step motor operating (beep) sound with
the ignition switch turned ON.
NOTE:
The lACV operation can be checked visually as following:
• Remove the lACV from the throttle body with its
4P (Black) connector in place, then turn the ignition switch ON.
REMOVAL
• Always clean the throttle body before the lACV
removal to prevent dirt and debris from entering
the lACV passage.
Disconnect the lACV 4P (Black) connector.
Remove the two screws, lACV retainer and lACV.
lACV •4P(BLACK)CONNECTOR
INSTALLATION
Install new O-ring and seal plate onto the lACV.
Install the lACV into the throttle body while aligning
the valve slit with the guide pin in the throttle body.
6-56
FUEL SYSTEM (PGM-FI)
Install the IACV retainer while aligning the valve
boss with the groove in the retainer.
Install and tighten the two screws to the specified
torque.
TORQUE: 2.1 N m (0.21 kgf-m, 1.5 Ibfft)
Connect the IACV 4P (Black) connector.
IACV H 4 P BLACK CONNECTOR
6-57
7. COOLING SYSTEM
SYSTEM FLOW PATTERN
7-2
THERMOSTAT-
SERVICE INFORMATION
7-3
RADIATOR RESERVE TANK
7-9
TROUBLESHOOTING
7-4
RADIATOR/COOLING FAN
7-10
SYSTEM TESTING
7-5
WATER PUMP
7-13
COOLANT REPLACEMENT-
7-6
•7-8
7-1
COOLING SYSTEM
SYSTEM FLOW PATTERN
RADIATOR
THERMOSTAT
RESERVE TANK
WATER PUMP
7-2
COOLING SYSTEM
SERVICE INFORMATION
GENERAL
iiWARNING
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.
ACAUTION
Radiator coolant is toxic. Keep it away from eyes and mouth.
• If any coolant gets in your eyes, rinse them with water and consult a physician immediately.
• If any coolant is swallowed, induce vomiting, gargle and consult a physician immediately.
• If any coolant gets on your skin or clothes, rinse thoroughly with plenty of water.
NOTICE
Using coolant with silicate inhibitors may cause premature wear of water pump seals or blockage of radiator passage.
Using tap water may cause engine damage.
Add coolant to the system at the reserve tank. Do not remove the radiator cap except to refill or drain the system.
All cooling system service 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 ECT sensor information (page 6-3).
For coolant temperature indicator information (page 23-13).
SPECIFICATIONS
ITEM
Radiator and engine
Reserve tank
Radiator cap relief pressure
Begin to open
Thermostat
Fully open
Valve lift
Recommended antifreeze
Coolant capacity
Standard coolant concentration
SPECIFICATIONS
2.0 liters (2.1 US qt, 1.8 Imp qt)
0.46 liter (0.49 US qt, 0.40 Imp qt)
108 - 137 kPa (1.1 - 1.4 kgf/cm 2 ,16-20 psi)
80 - 84°C
95°C
8 mm (0.3 in) minimum
Pro Honda HP Coolant or an equivalent high quality
ethylene glycol antifreeze containing silicate-free corrosion
inhibitors
1:1 mixture with distilled water
TORQUE VALUE
Water pump impeller
12 N-m (1.2 kgfm, 9 Ibf-ft)
7-3
COOLING SYSTEM
TOOLS
Bearing remover shaft
07936-KC10100
Bearing remover head, 15 mm
07936-KC10200
Remover weight
0/741-0010201
or 07936-KC10500
or 07936-KC10500
or 07936-371020A or 07936-3710200
(U.S.A. only)
Mechanical seal driver attachment
07945-4150400
or 07965-415000A (U.S.A. only)
TROUBLESHOOTING
Engine temperature too high
Thermostat stuck closed
Faulty radiator cap
Insufficient coolant
Passage blocked in radiator, hoses or water jacket
Air in system
Faulty cooling fan motor
Faulty water pump
Faulty temperature indicator drive circuit (page 23-13)
Coolant leaks
Faulty water pump mechanical seal
Deteriorated O-rings
Faulty radiator cap
Damaged or deteriorated cylinder head gasket
Loose hose connection or clamp
Damaged or deteriorated hoses
7-4
COOLING SYSTEM
SYSTEM TESTING
COOLANT (HYDROMETER TEST)
Remove the steering cover (page 3-5).
The engine must be Remove the radiator cap.
cool before removing the radiator cap,
or severe scalding
may result.
Test the coolant gravity using a hydrometer.
STANDARD COOLANT CONCENTRATION:
1:1 (distilled water and the recommended
antifreeze)
Look for contamination and replace the coolant if
necessary.
C
CO
o
o
5
10
15
20
25
30
35
40
45
50
55
60
0
(32)
1.009
1.018
1.028
1.036
1.045
1.053
1.063
1.072
1.080
1.086
1.095
1.100
5
(41)
1.009
1.017
1.027
1.035
1.044
1.052
1.062
1.070
1.078
1.084
1.093
1.098
10
(50)
1.008
1.017
1.026
1.034
1.043
1.051
1.060
1.068
1.076
1.082
1.091
1.095
Coolant temperature C (
30
15
20
25
(86)
(68)
(77)
(59)
1.008 1.007 1.006 1.005
1.016 1.015 1.014 1.013
1.025 1.024 1.022 1.020
1.033 1.031 1.029 1.027
1.042 1.040 1.038 1.036
1.047 1.046 1.045 1.043
1.058 1.056 1.054 1.052
1.066 1.064 1.062 1.059
1.074 1.072 1.069 1.066
1.080 1.077 1.074 1.071
1.088 1.085 1.082 1.079
1.092 1.089 1.086 1.083
F)
35
(95)
1.003
1.011
1.018
1.025
1.034
1.041
1.049
1.056
1.063
1.068
1.076
1.080
40
(104)
1.001
1.009
1.016
1.023
1.031
1.038
1.046
1.053
1.060
1.065
1.073
1.077
45
50
(113) (122)
0.999 0.997
1.007 1.005
1.014 1.012
1.021 1.019
1.028 1.025
1.035 1.032
1.043 1.040
1.050 1.047
1.057 1.054
1.062 1.059
1.070 1.067
1.074 1.071
7-5
COOLING SYSTEM
RADIATOR CAP/SYSTEM PRESSURE
INSPECTION
Remove the radiator cap (page 7-5).
TESTER
RADIATOR CAP
Wet the sealing surfaces of the cap, then install the
cap onto tester.
TOOLS:
Cooling system pressure tester
Cooling system adaptor
SVTS4AH
OTCJ33984A
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 at least 6 seconds.
RADIATOR CAP RELIEF PRESSURE:
108 - 137 kPa (1.1 - 1.4 kgf/cm2, 16 - 20 psi)
Excessive pressure
can damage the
cooling system
components- Do
not exceed 137 kPa
(1.4 kgf/cm2, 20
psi).
Pressure test the radiator, engine and hoses, and
check for leaks.
TESTER
Repair or replace components if the system will not
hold the specified pressure for at least 6 seconds.
Remove the tester and install the radiator cap.
Install the steering cover (page 3-5).
COOLANT REPLACEMENT
PREPARATION
NOTICE
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 in the maintenance schedule.
Mix only distilled, low mineral water with the recommended antifreeze.
RECOMMENDED ANTIFREEZE:
Pro Honda HP Coolant or an equivalent high
quality ethylene glycol antifreeze containing
silicate-free corrosion inhibitors
RECOMMENDED MIXTURE:
1:1 (distilled water and the recommended
antifreeze)
7-6
ANTIFREEZE
SOLUTION
(ETHYLENE
GLYCOLBASE
SOLUTION)
LOW MINERAL
OR DISTILLED
WATER
'COOLANT
COOLING SYSTEM
REPLACEMENT/AIR BLEEDING
NOTE:
• When filling the system with a coolant, place the
vehicle on a flat, level surface.
Remove the steering cover (page 3-5).
The engine must be
cool before removing the radiator cap,
or severe scalding
may result.
Drain the coolant from the system by removing the
drain bolt and sealing washer on the water pump,
and the radiator cap.
Reinstall the drain bolt with a new sealing washer
securely.
DRAIN BOLT AND WASHER
Disconnect the siphon hose from the reserve tank
and drain the reserve coolant.
Empty the coolant, remove the reserve tank cap and
rinse the inside of the reserve tank with water.
Reconnect the siphon hose.
Fill the system with the recommended coolant up to
the filler neck.
Bleed air from the system as follows:
1. Shift the transmission into neutral. Start the
engine and let it idle for 2 - 3 minutes.
2. Snap the throttle 3 - 4 times to bleed air from the
system.
3. Stop the engine and add coolant up to the filler
neck.
4. Install the radiator cap.
Fill the reserve tank to the upper level line and
install the tank cap.
Install the steering cover (page 3-5).
7-7
COOLING SYSTEM
THERMOSTAT
REMOVAL
Drain the coolant from the system (page 7-7).
Remove the fuel tank covers (page 3-5).
Remove the throttle body cover (page 6-48).
Loosen the band screw.
Remove the trim clip and the air intake duct from
the air cleaner housing.
Remove the two bolts and thermostat cover.
Remove the thermostat from the housing.
INSPECTION
Visually inspect the thermostat for damage.
Replace the thermostat if the valve stays open at
room temperature.
Wear insulated
gloves and adequate eye protection.
Keep flammable
materials away
from the electric
heating element.
Do not let the thermostat or thermometer touch the
pan, or you will get
a false reading
7-8
Heat a container of water with an electric heating
element for 5 minutes.
Suspend the thermostat in heated water to check its
operation.
THERMOSTAT BEGIN TO OPEN:
80-84°C(176-183°F)
VALVE LIFT:
8 mm (0.3 in) minimum at 95 C (203 F)
Replace the thermostat if the valve opens at a temperature other than those specified.
THERMOSTAT
THERMOMETER
COOLING SYSTEM
INSTALLATION
Make sure the rubber seal on the thermostat is in
good condition.
Install the thermostat into the housing, aligning the
hole with the lug.
Install the thermostat and tighten the two bolts
securely.
Insert the air intake duct against the connecting tube
and secure it onto the heat guard with the trim clip.
Tighten the band screw securely.
Fill and bleed the cooling system (page 7-6).
Install the injector cover (page 6-48).
Install the fuel tank covers (page 3-5).
RADIATOR RESERVE TANK
REMOVAL/INSTALLATION
Remove the front fender (page 3-12).
BREATHER HOSE
Remove the breather hose from the grill cover.
Remove the mounting bolt.
Release the boss on the tank bottom from the radia- |
tor and drain the coolant.
Disconnect the siphon hose to remove the reserve
tank.
Install the reserve tank in the reverse order of
removal.
Fill the reserve tank to the upper level line.
7-9
COOLING SYSTEM
RADIATOR/COOLING FAN
RADIATOR REMOVAL
Remove the following:
-
GRILL COVEiR
oil cooler (page 5-12)
radiator reserve tank (page 7-9)
left inner fender (page 3-9)
Drain the coolant from the system (page 7-7).
Remove the two trim clips (page 3-4) and each grill
cover.
Disconnect the breather hose (pink) from the frame
pipe.
Release the clip to free the fan motor wire and disconnect the motor 2P (White) connector.
The engine must be Remove the radiator cap and the rubber heat guard
cool before remov- from the filler neck.
ing the radiator cap, Reinstall the radiator cap.
or severe scalding
may result.
2P (WHITE) CONNECTOR
Disconnect the upper and lower water hoses.
Be careful not to
damage the radiator
fins with the oil
pipe.
Remove the two mounting bolts.
Release the mounting bosses on the radiator bottom from the frame and remove the radiator assembly while pulling the oil pipes aside.
PIPES
COOLING FAN DISASSEMBLY
Release the fan motor wire and breather hose from
the clamp of the motor stay, and disconnect the
breather hose.
Remove the three washer-bolts and stay/motor
assembly from the radiator.
HOSE
CLAMP
BOLTS
7-10
STAY/MOTOR
COOLING SYSTEM
Remove the nut and cooling fan.
Remove the three bolts and fan motor.
FLANGE NUT
* COOLING FAN
STAY
MOTOR
ASSEMBLY
RADIATOR
COOLING FAN
FAN MOTOR
STAY
7-11
COOLING SYSTEM
Install the fan motor on the motor stay in the direction as shown and tighten the three bolts securely.
CTAV
Install the cooling fan on the fan motor shaft, aligning the flat surfaces.
Apply locking agent to the motor shaft threads.
Install the nut and tighten it.
Install the stay/motor assembly onto the radiator
and tighten the three washer-bolts securely.
Connect the breather hose to the motor breather
joint. Route the fan motor wire and breather hose
through the clamp.
FLANGE NUT
HOSE
CLAMP
BOLTS
7-12
* COOLING FAN
STAY/MOTOR
COOLING SYSTEM
INSTALLATION
Be careful not to
damage the radiator
fins with the oil
Pipe-
Insert the bosses on the radiator bottom into the
holes (mounting rubbers) in the frame to install the
radiator assembly.
Install the mounting bolts and tighten them.
RADIATOR
Connect the upper and lower water hoses, and
tighten the hose clamps securely.
Route the wire and Connect the fan motor 2P (White) connector and
hose properly (page secure the wires with the clip.
1-20).
Connect the breather hose (pink) to the frame pipe.
Remove the radiator cap and install the rubber heat
guard over the filler neck. Reinstall the radiator cap.
Set the rubber heat guard properly (page 1-20).
2P WHITE) CONNECTOR
Install the left and right grill covers with the trim
clips (page 3-4). For the left grill cover, align the tab
with the groove in the radiator.
Install the following:
-
oil cooler (page 5-13)
-
radiator reserve tank (page 7-9)
Fill and bleed the cooling system (page 7-6).
After bleeding, install the following:
-
left inner fender (page 3-9)
front fender (page 3-12)
WATER PUMP
MECHANICAL SEAL INSPECTION
Check the drain hose for signs of coolant leakage.
If there is leakage, the mechanical seal is defective,
and the mechanical seal should be replaced.
7-13
COOLING SYSTEM
REMOVAL
Remove the following:
- mud guard lid (page 3-7)
- right front mud guard (page 3-8)
- right inner fender (page 3-9)
Drain the coolant from the system (page 7-7).
Disconnect the water hoses and bypass hose from
the water pump.
Remove the following:
-
drain hose
three cover bolts and sealing washer
drain hose guide
two mounting bolts
pump cover
O-ring
water pump body
O-ring
GUIDE
DRAIN HOSI
BOLTS/SEALING WASHERS
MECHANICAL SEAL REPLACEMENT
Loosen the impeller by turning it counterclockwise
while holding the pump shaft slot.
WASHER
IMPELLER
Remove the following:
-
impeller assembly
washer
pump shaft
thrust washer
WASHER
Remove the mechanical seal using the special tools.
TOOLS:
Remover head, 15 mm
Bearing remover shaft
Bearing remover, 15 mm
Remover weight
SHAFT
MECHANICAL SEAL
07936-KC10200
07936-KC10100 or
07936-KC10500
07741-0010201 or
07936-371020A or
07936-3710200
(U.S.A. only)
BEARING REMOVER
7-14
COOLING SYSTEM
Remove the oil seal.
Apply engine oil to a new oil seal lips. Install the oil
seal with the flat side facing out until it is flush with
the pump body edge.
Press a new mechanical seal in until it is seated.
TOOL:
Mechanical seal driver
attachment
Mechanical seal installer
07945-4150400 or
07965-415000A
(U.S.A. only)
Do not get oil on Install the thrust washer onto the pump shaft.
the pump shaft Apply molybdenum disulfide solution to the sliding
threads, surface of the pump shaft and insert the shaft into
the pump body.
IMPELLER
WASHER
Install the washer and impeller assembly, and
tighten the impeller.
TORQUE: 12 N-m (1.2 kgf-m, 9 Ibf-ft)
WASHER
INSTALLATION
Coat a new O-ring with engine oil and install it on
the stepped section of the pump body.
Install the water pump while turning the impeller
engage the pump shafts.
7-15
COOLING SYSTEM
Align the mounting bolt holes in the pump body
and crankcase cover, and be sure the water pump is
fully seated.
Install a new O-ring into the pump body groove.
Install the pump cover with the two mounting bolts fm'ii.DVraicD
but do not tighten them.
I PUMP COVER
Install the drain hose guide while aligning its cut-out
with the boss on the water pump cover.
Note the installation Install the three cover bolts with a new sealing
location of the seal- washer as shown, and tighten all the bolts in a crissing washer. cross pattern in several steps being careful not to
pinch the O-ring.
BOLTS/SEALING WASHERS
Connect the water hoses and bypass hose, and
secure them with the hose clamps.
Fill and bleed the cooling system (page 7-6).
Install the following:
-
7-16
inner fender (page 3-9)
front mud guard (page 3-8)
mud guard lid (page 3-7)
8. ENGINE REMOVAL/INSTALLATION
SYSTEM COMPONENTS
8-2
ENGINE REMOVAL
8-4
SERVICE INFORMATION
8-3
ENGINE INSTALLATION
8-8
8-1
ENGINE REMOVAL/INSTALLATION
SYSTEM COMPONENTS
54 N-m (5.5 kgfm, 40 Ibf-ft)
54 N-m (5.5 kgfm, 40 Ibf-ft)
32 N-m (3.3 kgfm, 24 Ibf-ft)
6 kgfm, 12 Ibfft)
8-2
ENGINE REMOVAL/INSTALLATION
SERVICE INFORMATION
GENERAL
• When removing/installing the engine, tape the frame around the engine beforehand for frame protection.
• The following components require engine removal for service:
- mainshaft and 2nd/3rd shift clutch (countershaft) (page 14-62)
- crankshaft/balancer (page 13-2)
SPCIFICATIONS
ITEM
SPECIFICATIONS
Engine dry weight
Engine oil capacity
60.4 kg (133.2 lbs)
2.7 liters (2.9 US qt, 2.4 Imp qt)
2.9 liters (3.1 US qt, 2.6 Imp qt)
After draining
After draining/filter
change
After disassembly
Coolant capacity (radiator and engine)
4.1 liters (4.3 US qt, 3.6 Imp qt)
2.0 liters (2.1 US qt, 1.8 Imp qt)
TORQUE VALUES
Lower engine hanger nut (left and right)
Upper engine hanger bolt
Upper engine hanger bracket bolt
Differential mounting bolt (10 mm)
Differential mounting nut (10 mm)
Differential mounting nut (8 mm)
Gear selector arm pinch bolt
54 N-m
54 N-m
32 N-m
44 N-m
44 N-m
22 N-m
16 N-m
(5.5 kgf-m, 40 Ibf-ft)
(5.5 kgf-m, 40 Ibf-ft)
(3.3 kgf-m, 24 Ibf-ft)
(4.5 kgf-m, 33 Ibf-ft)
(4.5 kgf-m, 33 Ibf-ft)
(2.2 kgf-m, 16 Ibf-ft)
(1.6 kgf-m, 12 Ibf-ft)
8-3
ENGINE REMOVAL/INSTALLATION
ENGINE REMOVAL
Drain the engine oil (page 4-11).
Drain the coolant (page 7-7).
Remove the following:
-
front center grille (page 3-10)
center mud guards (page 3-7)
front mud guards (page 3-8)
inner fenders (page 3-9)
rear fender assembly (page 3-15)
engine side covers (page 3-17)
exhaust system (page 3-19)
throttle body (page 6-43)
heat guard plate (page 6-39)
Remove the bolt and the left mud guard stays from
the footpeg bracket.
Disconnect the ECT sensor 2P (Black) connector.
2P(BLACK)CONNEClOH
Remove the spark plug cap from the spark plug.
Disconnect the water hose from the thermostat
housing.
Disconnect the alternator 5P (Natural) connector.
Disconnect the gear position switch 3P (Natural)
connector.
3P NATURAL CONNECTOR
5P NATURAL) CONNECTOR
8-4
ENGINE REMOVAL/INSTALLATION
Disconnect the EOT sensor 2P (Black) connector.
2P (BLACK) CONNECTOR
Remove the terminal cap, terminal nut and starter
motor cable from the starter motor terminal.
Remove the each bolt and then remove the each
ground cable from the engine and frame.
MOTOR CABLE
GROUND CABLE
Release the gearshift switch wire from the wire
clamp.
Remove the gearshift arm A pinch bolt and then
remove the arm from the gearshift spindle.
Remove the two holder bolts and gear selector
cable.
Reinstall the valve
body cover after
disconnecting the
connectors to avoid
damaging the solenoid valve.
Remove the wire clip.
Remove the two set bolts and shift valve body
cover, and disconnect the following connectors:
-
shift solenoid A 2P (Black) and shift solenoid B 2P
(Brown) connectors
clutch PC solenoid 2P (Black) connector
8-5
ENGINE REMOVAL/INSTALLATION
Remove the following:
-
oil pipes (by removing each joint bolt)
water hose (from the water pump)
Remove the differential mounting fasteners, spacer
and bracket.
Move the front differential forward to get the clearance for front propeller shaft removal.
Pull the propeller shaft joint out of the output shaft.
Remove the boot band from the dust boot and
release the boot off the pinion joint of the differential.
Pull the propeller shaft to force the stopper ring at
the shaft end past the groove in the pinion joint and
remove the propeller shaft.
PROPELLER
SHAFT JOINT
Remove the upper engine hanger bolt and nut.
Remove the upper engine hanger bracket bolts,
bracket and mounting rubbers.
8-6
MOUNTING RUBBERS
MOUNTING
BOLT/NUT
ENGINE REMOVAL/INSTALLATION
Set suitable
wooden blocks
between the
engine and lower
frame pipe to support the engine for
ease of bolt
removal.
Remove the left lower engine hanger nut, bolt and
mounting rubbers.
Remove the two bolts and hanger bracket.
MOUNTING RUBBERS
Remove the right lower engine hanger nut, bolt,
spacer and mounting rubbers.
SPACER
•
BOLT
Move the engine forward and disconnect the output
shaft from the rear propeller shaft.
Remove the universal joint.
Hold the engine Remove the engine out of the frame toward the left
securely and take side.
care not to damage
the frame and
NOTICE
engine.
Do not hold or strike the solenoid valves on the shift
valve body during engine removal. Holding the
solenoid valve or excessive shock may damage the
solenoid valve.
Remove the engine hanger bushings and dust seals.
DUST SEAL
8-7
ENGINE REMOVAL/INSTALLATION
Check the mounting rubbers, hanger bushings and
dust seals for wear or damage.
BUSHING
MOUNTING RUBBERS
ENGINE INSTALLATION
NOTE:
• Before installing the engine, install the valve
body cover onto the shift valve body to avoid
damaging the solenoid valve (page 8-11).
• Route the wires, cables and hoses properly (page
1-20).
Install the lower hanger bushings into the engine
lower mounts.
SEAL LIPS
Install the dust seals with the lip side facing out.
BUSHING
Hold the engine Place the engine in the frame from the left side and
securely and be support it with suitable wooded blocks.
careful not to damage the frame and
NOTICE
engine.
Do not hold or strike the solenoid valves on the shift
valve body during engine removal. Holding the
solenoid valve or excessive shock may damage the
solenoid valve.
Coat new O-rings with molybdenum disulfide
grease and install them into the grooves in the output shaft and rear propeller shaft.
Apply molybdenum disulfide grease to the universal joint splines (both sides) and install the universal
joint onto the output shaft.
Carefully move the engine and engage the universal
joint on the engine with the propeller shaft.
8-8
ENGINE REMOVAL/INSTALLATION
Be sure the univer- Set the right lower mounting portion of the engine
sal joint is not dis- between the hanger stays on the frame.
engaged.
Install the mounting rubbers onto the right lower
hanger bushing with the large I.D. side facing in.
Install the spacer and the hanger bolt (from the front
side) while aligning the bolt holes carefully.
Loosely install the hanger nut.
Install the mounting rubbers onto the left lower
hanger bushing in the same manner as above.
Install the hanger bracket and bolts, and the hanger
bolt (from the front side) while aligning the bolt
holes carefully.
Loosely install the hanger nut.
Install the mounting rubbers onto the upper hanger
bushing in the same manner as above. Install the
upper engine hanger bracket and the three bolts.
After installing all the mounting fasteners and seat
them, tighten the fasteners in order as follows:
- left and right lower engine hanger nuts
TORQUE: 54 N m (5.5 kgf-m, 40 Ibfft)
-
left lower engine hanger bracket bolts
upper engine hanger bracket bolts
TORQUE: 32 N m (3.2 kgf m, 24 Ibfft)
-
upper engine hanger bolt
TORQUE: 54 N m (5.5 kgf-m, 40 Ibfft)
Install a new stopper ring into the groove on the
propeller shaft end.
Apply 5 - 8 g of molybdenum disulfide grease to the
pinion joint splines of the differential.
Place the boot band over the propeller shaft.
Install the propeller shaft into the pinion joint, aligning the joint and shaft splines until the stopper ring
seats in the groove.
Make sure the stopper ring is seated properly by
pulling the propeller shaft lightly.
Install the boot over the pinion joint securely and
the boot band into the boot groove.
8-9
ENGINE REMOVAL/INSTALLATION
Coat a new O-ring with molybdenum disulfide
grease and install it in the output shaft groove.
Apply molybdenum disulfide grease to the propeller
shaft joint splines.
Engage the propeller shaft joint over the output
shaft, aligning the joint and shaft splines while moving the differential rearward.
PROPELLER SHAFT JOINT
Upper side: Align the mounting points of the differential and
frame, and install the spacer (between the left side
of the differential and frame) and 10-mm bolt from
the right side. Install a new 10-mm nut.
Lower side: Install the 10-mm bolt from the right side.
Front side: Install the mounting bracket, 8-mm bolts and nut.
Tighten the all the differential mounting fasteners.
TORQUE:
10 mm nut: 44 N-m (4.5 kgf m, 33 Ibfft)
8 mm nut: 22 N-m (2.2 kgf m, 16 Ibfft)
Coat new O-rings with engine oil and install them
into each oil pipe grooves.
Install the oil pipes to the joint with the oil pipe lug
facing forward and tighten the bolts securely.
Connect the water hose and tighten the clamp
screw securely.
8-10
ENGINE REMOVAL/INSTALLATION
Connect the clutch PC solenoid 2P (Black) connector
and shift solenoid 2P (Black and Brown) connectors.
Install the valve body cover and tighten the two set
bolts. Install the wire clip over the wire and into the
cover.
Install the gear selector arm A by aligning the
groove with the wide tooth of the spindle. Install the
pinch bolt and tighten it.
SELECTOR CABLE
PINCH BOLT
TORQUE: 16 N-m (1.6 kgfm, 12 Ibf-ft)
Secure the selector cable onto the engine with the
two cable holder bolts.
Route the starter motor cables and ground cable
properly.
Install the ground cable onto the engine and frame,
tighten the bolts securely.
Install the starter motor cable eyelet to the motor
terminal and install and tighten the terminal nut.
Install the terminal rubber.
MOTOR CABLE
GROUND CABLE
8-11
ENGINE REMOVAL/INSTALLATION
Connect the EOT sensor 2P (Black) connector.
2P(BLACKi CONNECTOR
Connect the gear position switch 3P (Natural) connector.
Connect the alternator 5P (Natural) connector.
3P (NATURAL) CONNECTOR
5P (NATURAL) CONNECTOR
Connect the water hose to the thermostat housing,
tighten the hose band.
Install the spark plug cap to the plug.
Connect the ECT sensor 2P (Back) connector.
8-12
ENGINE REMOVAL/INSTALLATION
Hook the mud guard stays to the footpeg bracket
and install the rear side stay on the frame with the
washer-bolt.
Check the gear selector lever for smooth operation.
Install the following:
-
heat guard plate and fuel tank (page 6-39)
throttle body (page 6-43)
exhaust system (page 3-19)
engine side covers (page 3-17)
rear fender assembly (page 3-15)
inner fenders (page 3-9)
front mud guards (page 3-8)
center mud guards (page 3-7)
front center grille (page 3-10)
Fill the engine with recommended oil (page 4-11).
Fill and bleed the cooling system (page 7-6).
Check the engine oil level (page 4-10).
8-13
9. CYLINDER HEAD/VALVE/CAMSHAFT
SYSTEM COMPONENTS
9-2
CYLINDER HEAD INSPECTION
9-11
SERVICE INFORMATION
9-3
VALVE GUIDE REPLACEMENT
9-12
TROUBLESHOOTING
9-5
VALVE SEAT INSPECTION/REFACING
9-13
CYLINDER COMPRESSION
9-6
CAMSHAFT
9-16
CYLINDER HEAD COVER REMOVAL/
DISASSEMBLY
CYLINDER HEAD ASSEMBLY
9-19
9-6
CYLINDER HEAD INSTALLATION
9-20
CYLINDER HEAD REMOVAL
9-9
CYLINDER HEAD COVER ASSEMBLY/
INSTALLATION
9-22
CYLINDER HEAD DISASSEMBLY
- 9-10
9-1
CYLINDER HEAD/VALVE/CAMSHAFT
SYSTEM COMPONENTS
55 N-m (5.6 kgfm, 41 Ibf ft)
32 N-m (3.3 kgf-m, 24 Ibf-ft)
18Nm
12 N-m (1.2 kgfm, 9 Ibf-ft)
54 N-m (5.5 kgf-m, 40 Ibf-ft)
9-2
CYLINDER HEAD/VALVE/CAMSHAFT
SERVICE INFORMATION
GENERAL
• This section covers service of the rocker arms, cylinder head, valves and camshaft. These services can be done with the
engine installed in the frame.
• When disassembling, mark and store the disassembled parts to ensure that they are reinstalled in their original locations.
• Clean all disassembled parts with cleaning solvent and dry them by blowing them off with compressed air before
inspection.
• Rocker arm, valve and camshaft lubricating oil is fed through oil passages in the cylinder head and head cover. Clean
the oil passages before assembling cylinder head and head cover.
• Be careful not to damage the mating surfaces when removing the cylinder head cover and cylinder head.
SPECIFICATIONS
ITEM
Cylinder compression at 350 rpm (min 1 )
Valve clearance
Valve,
valve guide
Valve stem O.D.
Valve guide I.D.
Stem-to-guide clearance
Valve spring
Rocker arm
Camshaftand
cam follower
Valve guide projection
above cylinder head
Valve seat width
Free length
Arm I.D.
Shaft O.D.
Arm-to-shaft clearance
Cam lobe height
Cam follower O.D.
Follower bore I.D.
Follower-to-bore clearance
Cylinder head warpage
IN
EX
IN
EX
IN/EX
IN
EX
IN
EX
IN/EX
Inner
Outer
IN/EX
IN/EX
IN/EX
IN
EX
IN/EX
IN/EX
IN/EX
STANDARD
550 kPa (5.6 kgf/cm2, 80 psi)
0.15 (0.006)
0.33(0.013)
5.475 - 5.490 (0.2156 - 0.2161)
5.455 - 5.470 (0.2148 - 0.2154)
5.500 - 5.512 (0.2165 - 0.2170)
0.010 - 0.037 (0.0004 - 0.0015)
0.030 - 0.057 (0.0012 - 0.0022)
14.8-15.2(0.58-0.60)
17.3-17.7(0.68-0.70)
1.0-1.1 (0.039-0.043)
37.20 (1.465)
44.20 (1.740)
12.000 - 12.018 (0.4724 - 0.4731)
11.964 - 11.984 (0.4710 - 0.4718)
0.016 - 0.054 (0.0006 - 0.0021)
35.015 - 35.175 (1.3785 - 1.3848)
35.394 - 35.554 (1.3935 - 1.3998)
22.467 - 22.482 (0.8845 - 0.8851)
22.510 - 22.526 (0.8862 - 0.8868)
0.028 - 0.059 (0.0011 - 0.0023)
-
Unit: mm (in)
SERVICE LIMIT
5.45(0.215)
5.43 (0.214)
5.53(0.218)
0.12 (0.005)
0.14(0.006)
1.4 (0.06)
36.3 (1.43)
43.1 (1.70)
12.05 (0.474)
11.92 (0.469)
0.08 (0.003)
34.840 (1.3717)
35.144(1.3824)
22.46 (0.884)
22.54 (0.887)
0.07 (0.003)
0.05 (0.002)
TORQUE VALUE
Cylinder head cover cap nut
Upper engine hanger bolt
Upper engine hanger bracket bolt
ECT sensor
55 N-m
54 N-m
32 N-m
12 N-m
(5.6 kgf-m, 41 Ibf-ft)
(5.5 kgfm, 40 Ibf-ft)
(3.3 kgf-m, 24 Ibf-ft)
(1.2 kgf-m, 9 Ibf-ft)
Apply engine oil
9-3
CYLINDER HEAD/VALVE/CAMSHAFT
TOOLS
Valve spring compressor
07757-0010000
Valve guide driver, 5.5 mm
07742-0010100
Valve guide reamer, 5.5 mm
07984-2000001
or 07984-200000D (U.S.A. only)
Valve seat cutter, 35 mm (45° IN/EX)
07780-0010400
Flat cutter, 38.5 mm (32° IN)
07780-0012400
Flat cutter, 35 mm (32° EX)
07780-0012300
or equivalent commercially
available in U.S.A.
or equivalent commercially
available in U.S.A.
dr equivalent commercially
available in U.S.A.
Interior cutter, 34 mm (60° IN/EX)
07780-0014700
Cutter holder, 5.5 mm
07781-0010101
lensioner holder B
072MG-MCAA400
or equivalent commercially
available in U.S.A.
or equivalent commercially
available in U.S.A.
cir 07AMG-001A100 (U.S.A. only)
9-4
CYLINDER HEAD/VALVE/CAMSHAFT
TROUBLESHOOTING
• Engine top-end problems usually affect engine performance. These 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 a white smoke in the crankcase breather hose. If the hose is smoky,
check for seized piston ring (page 10-2).
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 cylinder head gasket
- Loose spark plug
- Warped or cracked cylinder head
• Cylinder/piston problem (page 10-3)
Compression too high, overheating or knocking
• Excessive carbon build-up on piston head or combustion chamber
• Worn or damaged decompressor system
Excessive smoke
• Worn valve stem or valve guide
• Damaged stem seal
• Cylinder/piston problem (page 10-3)
Excessive noise
• Incorrect valve clearance
• Sticking valve or broken valve spring
• Excessively worn valve seat
• Worn or damaged camshaft
• Worn rocker arm and/or shaft
• Worn rocker arm follower or valve stem end
• Worn or damaged push rod and/or cam follower
• Worn cam chain
• Worn or damaged cam chain tensioner
• Worn cam sprocket teeth
• Cylinder/piston problem (page 10-3)
Rough idle
• Low cylinder compression
9-5
CYLINDER HEAD/VALVE/CAMSHAFT
CYLINDER COMPRESSION
Warm up the engine to normal operating temperature.
Stop the engine, disconnect the spark plug cap and
remove the spark plug (page 4-7).
COMPRESSION GAUGE
Install the compression gauge into the spark plug
hole.
TOOLS:
Compression tester
Adaptor
EEPV303A
MT26J200
Shift the transmission in neutral.
Open the throttle all the way and crank the engine
with the starter motor until the gauge reading stops
rising. The maximum reading is usually reached
within 4 - 7 seconds.
COMPRESSION PRESSURE:
510 kPa (5.2 kgf/cm2, 74 psi) at 390 rpm (min1)
Check that there is no leakage at the gauge connection.
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 combustion chamber or on
piston head
CYLINDER HEAD COVER REMOVAL/
DISASSEMBLY
REMOVAL
Remove the fuel tank and heat guard plate (page 639).
Remove the following and set the piston position to
Top Dead Center on the compression stroke (page
4-8):
-
9-6
timing hole cap
four bolts and valve adjusting hole caps
VALVE ADJUSTING HOLE CAPS
CYLINDER HEAD/VALVE/CAMSHAFT
Remove the following:
-
spark plug cap
seven bolts and three washers
four cap nuts and washers
cylinder head cover
BOLTS AND SEALING WASHERS
push rods
gasket
dowel pins
Mark the push rods
so they can be
placed back in their
original locations.
-
cam followers
DISASSEMBLY
Remove the two bolts and sealing washers.
Push the rocker arm shaft with the small screwdriver through the bolt hole until the O-ring on the
shaft is removed out of the head cover.
BOLTS AND WASHERS
ROCKER ARM SHAFTS
9-7
CYLINDER HEAD/VALVE/CAMSHAFT
Mark all the parts Remove the following:
so they can be _ r o c k e r a r m shafts
placed back mthe.r _ r o c k e r a r m s
ongmal locavons. _ w a v e w a s h e r s
WAVE WASHERS
ROCKER ARMS
INSPECTION
ROCKER ARM/SHAFT
Check the rocker arms and shafts for wear or damage.
If the rocker arm follower is worn or damaged,
check the push rod and oil passages.
Measure each rocker arm shaft O.D.
SERVICE LIMIT: 11.92 mm (0.469 in)
Measure each rocker arm I.D.
SERVICE LIMIT: 12.05 mm (0.474 in)
Subtract each rocker arm shaft O.D. from the corresponding rocker arm I.D. to obtain the rocker armto-shaft clearance.
SERVICE LIMIT: 0.08 mm (0.003 in)
PUSH ROD
Check the push rods for wear or damage.
If the push rod is worn or damaged, check the cam
follower and camshaft.
CAM FOLLOWER
Check the cam follower and follower bore in the cylinder head for scoring, scratches or damage.
Measure each follower O.D.
SERVICE LIMIT: 22.46 mm (0.884 in)
9-8
CYLINDER HEAD/VALVE/CAMSHAFT
Measure each follower bore I.D.
SERVICE LIMIT: 22.54 mm (0.887 in)
Subtract each follower O.D. from the corresponding
bore I.D. to obtain the follower-to-bore clearance.
SERVICE LIMIT: 0.07 mm (0.003 in)
CYLINDER HEAD REMOVAL
Remove the following:
-
thermostat (page 7-8)
throttle body (page 6-43)
exhaust pipe (page 3-19)
cylinder head cover (page 9-6)
Disconnect the ECT sensor 2P (Black) connector.
If necessary, remove the ECT sensor and O-ring
from the cylinder head.
2P BLACK CONNECTOR
Remove the spark plug cap.
Loosen the band screw and remove the insulator.
Remove the following:
-
bypass hose from the cylinder head
upper engine hanger bracket bolts
upper engine hanger bolt
hanger bracket and mounting rubbers
9-9
CYLINDER HEAD/VALVE/CAMSHAFT
Do not strike the cylinder head too hard and do not
damage the mating
surface with a
screwdriver.
five bolts
cylinder head
CYLINDER HEAD
-
gasket
dowel pins
DOWEL PINS
CYLINDER HEAD DISASSEMBLY
To prevent loss of
tension, do not
compress the valve
springs more than
necessary.
Remove the valve spring cotters using the valve
spring compressor.
TOOL:
Valve spring compressor
07757-0010000
Mark all the parts Remove the following:
so they can be
- spring retainer
placed back in their
- inner and outer valve springs
original locations.
- valve
- stem seal
- spring seat
VALVE
SPRING SEAT
STEM SEAL
9-10
CYLINDER HEAD/VALVE/CAMSHAFT
CYLINDER HEAD INSPECTION
CYLINDER HEAD
Be careful not to Remove the carbon deposits from the combustion
damage the gasket chamber, being careful not to damage the gasket
surface, surface.
Check the spark plug hole and valve areas for
cracks.
COMBUSTION CHAMBER
Check the cylinder head for warpage with a straight
edge and feeler gauge.
SERVICE LIMIT: 0.05 mm (0.002 in)
VALVE SPRING
Measure the valve spring free length.
SERVICE LIMITS: Inner: 36.3 mm (1.43 in)
Outer: 43.1 mm (1.70 in)
VALVE/VALVE GUIDE
Check that the valve moves smoothly in the guide.
Check the valve for bending, burning or abnormal
wear.
Measure each valve stem O.D. and record it.
SERVICE LIMITS: IN: 5.45 mm (0.215 in)
EX: 5.43 mm (0.214 in)
9-11
CYLINDER HEAD/VALVE/CAMSHAFT
Ream the valve guide to remove any carbon buildup before measuring the guide.
Insert the reamer from the combustion chamber
side of the cylinder head and always rotate the
reamer clockwise.
TOOLS:
Valve guide reamer, 5.5 mm
REAMER
07984-2000001 or
07984-200000D
(U.S.A. only)
Measure each valve guide I.D. and record it.
SERVICE LIMIT: 5.53 mm (0.218 in)
Subtract each valve stem O.D. from the corresponding guide I.D. to obtain the stem-to-guide clearance.
SERVICE LIMITS: IN: 0.12 mm (0.005 in)
EX: 0.14 mm (0.006 in)
Inspect and reface If the stem-to-guide clearance exceeds the service
the valve seats limit, determine if a new guide with standard
whenever the valve dimensions would bring the clearance within toler
guides are replaced ance.
(page 9-13). If so, replace any guides as necessary and ream to
fit.
If the stem-to-guide clearance exceeds the service
limit with a new guide, also replace the valve.
VALVE GUIDE REPLACEMENT
Mark new valve guides at the specified height indicated below, using a marker. Chill the new valve
guides in a freezer for about an hour.
Be sure to wear
heavy gloves to
avoid burns when
handling the heated
cylinder head.
Using a torch to
heat the cylinder
head may cause
warpage.
Heat the cylinder head to 130°C-140°C (275'F290°F) with a hot plate or oven. Do not heat the cylinder head beyond 150°C (300°F). Use temperature
indicator sticks, available from welding supply
stores, to be sure the cylinder head is heated to the
proper temperature.
Support the cylinder head and drive the valve
guides out of the cylinder head from the combustion chamber side using the special tool.
TOOL:
Valve guide driver, 5.5 mm
07742-0010100
While the cylinder head is still heated, remove the
new valve guides from the freezer and drive them
into the cylinder head from the rocker arm side until
the exposed height is at the specified value (at the
mark).
TOOL:
Valve guide driver, 5.5 mm
07742-0010100
VALVE GUIDE PROJECTION:
IN: 14.8-15.2 mm (0.58-0.60 in)
EX: 17.3-17.7 mm (0.68-0.70 in)
Let the cylinder head cool to room temperature.
9-12
VALVE GUIDE DRIVER
CYLINDER HEAD/VALVE/CAMSHAFT
Take care not to tilt
or lean the reamer
in the guide while
reaming.
Use cutting oil on
the reamer during
this operation.
Ream the new valve guides.
Insert the reamer from the combustion chamber
side of the head and always rotate the reamer clockwise.
TOOL:
Valve guide reamer, 5.5 mm
REAMER
07984-2000001 or
07984-200000D
(U.S.A. only)
Clean the cylinder head thoroughly to remove any
metal particles after reaming and reface the valve
seat (page 9-14).
VALVE SEAT INSPECTION/REFACING
INSPECTION
Clean all intake and exhaust valves thoroughly to
remove carbon deposits.
Apply a light coat of Prussian Blue to each valve
seat.
Tap the valve against the valve seat several times
without rotating the valve, to check for proper valve
seat contact.
The valve cannot be
ground. If the valve
face is burned or
badly worn or if it
contacts the seat
unevenly, replace
the valve.
Remove the valve and inspect the valve seat face.
The valve seat contact should be within the specified width and even all around the circumference.
STANDARD:
1.0 - 1.1 mm (0.039 - 0.043 in)
SERVICE LIMIT: 1.4 mm (0.06 in)
If the valve seat width is not within specification,
reface the valve seat.
¥ mmmmawK
'
I
SEAT WIDTH
Inspect the valve face for:
• Damaged face:
- Replace the valve and reface the valve seat.
• Uneven seat width:
- Replace the valve and reface the valve seat.
DAMAGED FACE
UNEVEN SEAT WIDTH
9-13
CYLINDER HEAD/VALVE/CAMSHAFT
• Contact area (too high or too low)
- Reface the valve seat.
TOO HIGH
TOO LOW
REFACING
NOTE:
• Follow the refacer manufacturer's operating
instructions.
• Be careful not to grind the seat more than necessay.
45°
60°
32°
If the contact area is too high on the valve, the seat
must be lowered using a 32° flat cutter.
CONTACT tOO HIGH
If the contact area is too low on the valve, the seat
must be raised using a 60° interior cutter.
CONTACT TOO LOW
OLD SEAT WIDTH
Using a 45° seat cutter, remove any roughness or
irregularities from the seat.
TOOLS:
Seat cutter, 35 mm (IN/EX)
Cutter holder, 5.5 mm
ROUGHNESS
07780-0010400
07781-0010101
or equivalent commercially available in U.S.A.
9-14
CYLINDER HEAD/VALVE/CAMSHAFT
Using a 32° flat cutter, remove 1/4 of the existing
valve seat material.
TOOLS:
Flat cutter, 38.5 mm (IN)
Flat cutter, 35 mm (EX)
Cutter holder, 5.5 mm
OLD SEAT WIDTH
07780-0012400
07780-0012300
07781-0010101
or equivalent commercially available in U.S.A.
Using a 60° interior cutter, remove 1/4 of the existing valve seat material.
OLD SEAT WIDTH
TOOLS:
Interior cutter, 34 mm (IN/EX) 07780-0014700
Cutter holder, 5.5 mm
07781-0010101
or equivalent commercially available in U.S.A.
Using a 45° seat cutter, cut the seat to the proper
width.
SEAT WIDTH
VALVE SEAT WIDTH: 1.0 - 1.1 mm (0.039 - 0.043 in)
Make sure all pitting and irregularities are removed.
Excessive lapping
pressure may
deform or damage
the seat.
Do not allow lapping compound to
enter the guides.
After cutting the seat, apply lapping compound and
engine oil to the valve face, and lap the valve using
light pressure.
Change the angle of lapping tool frequently to prevent uneven seat wear.
HAND-LAPPING TOOL
After lapping, wash any residual compound off the
cylinder head and valve. Recheck the seat contact
after lapping.
9-15
CYLINDER HEAD/VALVE/CAMSHAFT
CAMSHAFT
REMOVAL
Remove the cylinder head (page 9-9).
Remove the sealing bolt and washer on the cam
chain tensioner lifter.
Install the special tool so its blade is into the
tensioner lifter and the tabs are just above the slots
in the lifter (there should be space between the bottom of tool and lifter body).
Then turn the tool clockwise until it stops turning
and engage the tabs with the slots (the lifter shaft is
fully secured with the special tool).
TOOL:
Tensioner holder B
07ZMG-MCAA400 or
07AMG-001A100
(U.S.A. only)
Remove the four camshaft holder bolts.
Suspend the cam
chain with a piece
of wire to prevent it
from falling into the
crankcase.
Raise the holder plate so the dowel pins fitted in the
camshaft holders are removed off the cylinder.
Release the cam chain from the cam sprocket to
remove the camshaft assembly and holder plate.
Remove the camshaft holder B from the camshaft
assembly.
Do not forcibly
remove the dowel
pins from the camshaft holders.
Remove the dowel pins.
INSPECTION
For cam chain ten- Check the sprocket teeth for wear or damage.
sioner i er mspec y u m t ^ e c a r n s n a f t holder to check each bearing.
ion, seepage Replace the camshaft assembly if the bearing does
not turn smoothly and quietly.
Check the cam surfaces for scoring, scratches or evidence of insufficient lubrication.
Measure each cam lobe height.
SERVICE LIMITS: IN: 34.840 mm (1.3717 in)
EX: 35.144 mm (1.3824 in)
9-16
DOWEL PINS
HOLDER B
CYLINDER HEAD/VALVE/CAMSHAFT
Check the decompressor cam operation.
Press on the decompressor cam as shown.
As you press on one side, the decompressor cam
should lock above the base of the exhaust cam lobe.
As you press on other side, the decompressor cam
lobe should extend below the base of the exhaust
cam lobe.
Push
Push
DECOMPRESSOR CAM
INSTALLATION
Carefully rotate the
crankshaft while
holding the cam
chain to avoid jamming the cam chain
against the timing
sprocket of the
crankshaft.
Turn the crankshaft clockwise using the recoil
starter and align the "T" mark on the flywheel with
the index notch in the crankcase cover.
Retract the tensioner lifter shaft and secure it with
the stopper tool (page 9-16).
INDEX NOTCH
Install the dowel pins if they are removed.
Install the camshaft holder B onto the camshaft
assembly.
"T" MARK
DOWEL PINS
HOLDER B
Before installing the
camshaft, be sure
the cylinder bolt
(under the cam
shaft) is tightened
securely (page 109).
Lubricate the camshaft bearings and cam chain with
engine oil.
Install the camshaft holder plate onto the camshaft
holders, aligning the holes with the dowel pins.
Place the camshaft assembly onto the cylinder and
install the cam chain over the sprocket while aligning the timing marks (index lines) on the sprocket
with the cylinder top surface and holder plate edge.
Locate the dowel pins into the holes in the cylinder
securely.
Be sure the timing marks lines up with the cylinder
top surface and holder plate edge.
9-17
CYLINDER HEAD/VALVE/CAMSHAFT
Install the four holder bolts and tighten them.
Apply molybdenum oil solution to the cam lobes.
Make sure the tim- Remove the stopper tool, and install the sealing bolt
ing mark on the with a new sealing washer and tighten it.
sprocket aligns with
Install the cylinder head (page 9-20).
the cylinder surface when the "T"
mark is aligned with
the index notch.
9-18
SEALING WASHER
BOLT
CYLINDER HEAD/VALVE/CAMSHAFT
CYLINDER HEAD ASSEMBLY
COTTERS
SPRING RETAINER
OUTER VALVE SPRING
INNER VALVE SPRING
STEM SEAL
SPRING SEAT
VALVE GUIDE
INTAKE VALVE
EXHAUST VALVE
Blow through the oil passage (stud bolt hole) in the
cylinder head with compressed air.
Install the valve spring seats and new stem seals.
Lubricate the valve stem sliding surface with molybdenum oil solution.
Insert the valve into the guide while turning it
slowly to avoid damaging to the stem seal.
VALVE SPRINGS
RETAINER
VALVE
SPRING SEAT
STEM SEAL
Install the inner and outer valve springs with the
tightly wound coils facing the combustion chamber.
Install the spring retainer.
Combustion chamber side
9-19
CYLINDER HEAD/VALVE/CAMSHAFT
Grease the cotters Install the valve cotters using the valve spring cornto ease installation, pressor.
To prevent loss of
tension, do not TOOL:
compress the valve Valve spring compressor
springs more than
necessary.
07757-0010000
Support the cylin- Tap the valve stems gently with two plastic hamder head so the mers to seat the cotters firmly.
valve heads will not
contact anything
that cause damage.
CYLINDER HEAD INSTALLATION
Clean the mating surface of the cylinder and head.
Install the dowel pins and a new gasket.
Install the cylinder head on the cylinder.
Tighten the cylin- Install the five bolts and temporarily tighten them.
der head bolts after
installing the cylinder head cover.
9-20
CYLINDER HEAD/VALVE/CAMSHAFT
Install the mounting rubbers on the upper engine
hanger bushing with the large I.D.side facing in.
Install the upper engine hanger bracket and the
three hanger bolts.
Tighten the hanger Temporarily tighten the three bolts.
bolts after installing
Connect the bypass hose to the thermostat housing
the cylinder head
of the cylinder head.
cover.
Connect the sensor connector.
Install the carburetor insulator, aligning the groove
with the lug on the cylinder head. Tighten the insulator band screw until the band ends clearance is 5.5
mm.
If the ECT sensor is removed, install a new O-ring
onto the sensor.
Install and tighten the ECT sensor to the specified
torque.
TORQUE: 12 N-m (1.2 kgf-m, 9 Ibfft)
Connect the ECT sensor 2P (Black) connector.
Install the following:
-
spark plug (page 4-7)
cylinder head cover (page 9-22)
thermostat (page 7-9)
throttle body (page 6-43)
exhaust pipe (page 3-19)
2P (BLACK) CONNECTOR
J
9-21
CYLINDER HEAD/VALVE/CAMSHAFT
CYLINDER HEAD COVER ASSEMBLY/
INSTALLATION
ASSEMBLY
INTAKE ROCKER ARM
EXHAUST ROCKER ARM
WAVE WASHERS
ROCKER ARM SHAFTS
SEALING WASHERS
SETTTING BOLTS
Coat new O-rings with engine oil and install them in
each groove on the rocker arm shafts.
Apply molybdenum oil solution to the rocker arm
shaft sliding surface.
.—j^.
' Q
•
ROCKER ARM SHAFTS
WAVE WASHERS
Install the rocker arms, wave washers (setting bolt
side) and arm shafts.
Align the bolt holes in the head cover and rocker
arm shaft by turning the shaft.
Install the setting bolts with new sealing washers
and tighten the bolts securely.
SEALING WASHER
9-22
ROCKER ARM SHAFT
CYLINDER HEAD/VALVE/CAMSHAFT
INSTALLATION
Turn the crankshaft using the recoil stater knob and
align the "T" mark with the index notch, then check
the cam lobes through the cam follower holes.
If the cam lobes face up, rotate the crankshaft one
full turn and match up the "T" mark again so the
cam lobes face down.
"T" MARK
INDEX NOTCH
Coat the cam followers with engine oil and install
them into the cylinder head.
Install the dowel pins and a new gasket.
GASKET H
PUSH RODS
Install the push rods in the cam followers and rest
them on the gasket cutout as shown.
DOWEL PINS
Apply engine oil to the rocker arm followers and
adjusting screw tips.
Installing the head
cover incorrectly
will result in severe
engine damage. Do
not tighten the
head cover fasteners when the rocker
arm are not aligned
with the push rod
end.
HEAD COVER
Install the cylinder head cover while holding the
rocker arms that align the rocker arm followers with
the push rod ends.
Be sure to seat the rocker arm followers to the push
rods properly by turning the crankshaft slowly with
the recoil starter.
9-23
CYLINDER HEAD/VALVE/CAMSHAFT
Apply engine oil to the cap nut threads and seating
surfaces and install the following fasteners:
-
four washers and cap nuts
three new washers and seven bolts
Tighten the nuts and bolts in a crisscross pattern in
several steps.
TORQUE: Cap nut:55 N m (5.6 kgf m, 41 Ibf-ft)
Install the spark plug cap.
If the cylinder and/or cylinder head were removed,
tighten the following:
- three cylinder bolts
- five cylinder head bolts
- upper engine hanger bracket bolts
TORQUE: 32 N m (3.3 kgf m, 24 Ibf-ft)
-
upper engine hanger bolt
TORQUE: 54 N m (5.5 kgf m, 40 Ibf-ft)
Install the following:
-
9-24
valve adjusting hole caps and timing hole cap
(page 4-10)
heat guard plate and fuel tank (page 6-39)
10. CYLINDER/PISTON
SYSTEM COMPONENTS
10-2
CYLINDER/PISTON REMOVAL
10-4
SERVICE INFORMATION
10-3
CYLINDER/PISTON INSPECTION
10-5
TROUBLESHOOTING
10-3
CYLINDER/PISTON INSTALLATION
10-8
10-1
CYLINDER/PISTON
SYSTEM COMPONENTS
10-2
CYLINDER/PISTON
SERVICE INFORMATION
GENERAL
•
•
•
•
The cylinder and piston can be serviced with the engine installed in the frame.
Take care not to damage the cylinder wall and piston.
Be careful not to damage the mating surfaces when removing the cylinder.
Rocker arm and valve lubricating oil is fed through the oil passage in the cylinder. Clean the oil passage before installing the cylinder.
• When disassembling, mark and store the disassembled parts to ensure that they are reinstalled in their original locations.
SPECIFICATIONS
Unit: mm (in)
ITEM
Cylinder
Piston,
piston pin,
piston ring
I.D.
Out-of-round
Taper
Warpage
Piston O.D. at 20 (0.8) from bottom
Piston pin hole I.D.
Piston pin O.D.
Piston-to-piston pin clearance
Piston ring end
Top
gap
Second
Oil (side rail)
Piston ring-to-ring
groove clearance
Cylinder-to-piston clearance
Connecting rod small end I.D.
Connecting rod-to-piston pin clearance
Top
Second
STANDARD
102.000 - 102.015 (4.0157 - 4.0163)
101.960 - 101.990 (4.0142 - 4.0153)
23.002 - 23.008 (0.9056 - 0.9058)
22.994 - 23.000 (0.9053 - 0.9055)
0.002 - 0.014 (0.0001 - 0.0006)
0.25-0.35(0.010-0.014)
0.40-0.55(0.016-0.022)
0.20-0.70(0.008-0.028)
0.045 - 0.080 (0.0018 - 0.0031)
0.025 - 0.060 (0.0010 - 0.0024)
0.010 - 0.055 (0.0004 - 0.0022)
23.030 - 23.050 (0.9067 - 0.9075)
0.030 - 0.056 (0.0012 - 0.0022)
SERVICE LIMIT
102.05(4.018)
0.05 (0.002)
0.05 (0.002)
0.05 (0.002)
101.90(4.012)
23.03 (0.907)
22.98 (0.905)
0.04(0.002)
0.5 (0.02)
0.7 (0.03)
0.9 (0.04)
0.095 (0.0037)
0.075 (0.0030)
0.19 (0.007)
23.06 (0.908)
0.08 (0.003)
TORQUE VALUES
Cylinder stud bolt
See page 10-7
TROUBLESHOOTING
Compression too low, hard starting or poor performance at low speed
• Leaking cylinder head gasket
• Worn, stuck or broken piston ring
• Worn or damaged cylinder and piston
Compression too high, overheating or knocking
• Excessive carbon built-up on piston head or combustion chamber
Excessive smoke
• Worn cylinder, piston or piston rings
• Improper installation of piston rings
• Scored or scratched piston or cylinder wall
Abnormal noise
• Worn piston pin or piston pin bore
• Worn connecting rod small end
• Worn cylinder, piston or piston rings
10-3
CYLINDER/PISTON
CYLINDER/PISTON REMOVAL
CYLINDER REMOVAL
Remove the camshaft (page 9-16).
Remove the following:
-
two bolts and cam chain tensioner lifter
gasket
bolt and water pipe
O-ring
TENSIONER LIFTER
Do not strike the
cylinder head too
hard and do not
damage the mating
surface with a
screwdriver.
four bolts
cylinder
cam chain guide
gasket
dowel pins
PISTON REMOVAL
Place a clean shop towel over the crankcase to prevent the piston pin clip from falling into the crankcase.
Remove the piston pin clips with pliers.
Push the piston pin out of the piston and connecting
rod, and remove the piston.
10-4
CYLINDER/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 end
too far.
Never use a wire Clean carbon deposits from the piston ring grooves
brush; it will scratch with a ring that will be discarded.
the groove.
^
CYLINDER/PISTON INSPECTION
CYLINDER
Inspect the cylinder bore for scratch or wear.
Measure the cylinder I.D. at three levels in an X and
Y axis. Take the maximum reading to determine the
cylinder wear.
SERVICE LIMIT: 102.05 mm (4.018 in)
Calculate the cylinder-to-piston clearance.
Refer to page 10-6 for measurement of the piston
O.D.
SERVICE LIMIT: 0.19 mm (0.007 in)
Calculate the cylinder taper and out-of-round at
three levels in an X and Y axis. Take the maximum
reading to determine the taper and out-of-round.
1
SERVICE LIMITS:
Taper:
0.05 mm (0.002 in)
Out of round: 0.05 mm (0.002 in)
TOP
1
. . - - • • •
N
MIDDLE
/
BOTTOM
N
V
10-5
CYLINDER/PISTON
Check the top of the cylinder for warpage with a
straight edge and feeler gauge across the stud
holes.
SERVICE LIMIT: 0.05 mm (0.002 in)
PISTON/PISTON RING
Inspect the piston rings for smooth movement by
rotating the them. The rings should be able to move
in their grooves without catching.
Push the ring until the outer surface of the piston
ring is nearly flush with the piston and measure the
ring-to-ring groove clearance.
SERVICE LIMITS:
Top:
0.095 mm (0.0037 in)
Second: 0.075 mm (0.0030 in)
Insert the piston ring into the bottom of the cylinder
squarely using the piston crown.
Measure the ring end gap.
SERVICE LIMITS:
Top:
0.5 mm (0.02 in)
Second:
0.7 mm (0.03 in)
Oil (side rail): 0.9 mm (0.04 in)
Measure the piston O.D. at a point 20 mm (0.8 in)
from the bottom and 90° to the piston pin hole.
SERVICE LIMIT: 101.90 mm (4.012 in)
Compare this measurement against the maximum
cylinder I.D. measurement and calculate the cylinder-to-piston clearance (page 10-5).
10-6
CYLINDER/PISTON
Measure the piston pin hole I.D. Take the maximum
reading to determine the I.D.
SERVICE LIMIT: 23.03 mm (0.907 in)
Measure the piston pin O.D. at three points.
SERVICE LIMIT: 22.98 mm (0.905 in)
Calculate the piston-to-piston pin clearance.
SERVICE LIMIT: 0.04 mm (0.002 in)
CONNECTING ROD
Measure the connecting rod small end I.D.
SERVICE LIMIT: 23.06 mm (0.908 in)
Calculate the connecting rod-to-piston pin clearance.
SERVICE LIMIT: 0.08 mm (0.003 in)
CAM CHAIN TENSIONER LIFTER
The lifter shaft should not go into the lifter body
when it is pushed.
When the shaft (inside of the body) is turned clockwise with a screwdriver, the lifter shaft should be
pulled into the lifter body. The shaft should spring
out of the body as soon as the screwdriver is
released.
CYLINDER STUD BOLT
REPLACEMENT
Thread two nuts onto the stud and tighten them
together, and use a wrench on them to turn the stud
bolt out.
Install a new stud bolt in the direction as shown.
-
Front crankcase: 90033-HN8-0000
(Yellow mark on bolt head)
Rear crankcase: 90032-HN8-0000 (No mark)
Be sure to verify the stud height from the crankcase
surface.
Adjust the height if necessary.
10-7
CYLINDER/PISTON
CYLINDER/PISTON INSTALLATION
PISTON RING INSTALLATION
Be careful not to Carefully install the piston rings into the piston ring
damage the piston grooves with the markings facing up.
and rings.
NOTE:
• Do not confuse the top and second rings.
• To install the oil ring, install the spacer first, then
install the side rails.
Stagger the piston ring end gaps 120° apart from
each other.
Stagger the side rail end gaps as shown.
PISTON INSTALLATION
Place a clean shop towel over the crankcase to prevent the piston pin clip from falling into the crankcase.
Apply molybdenum oil solution to the piston pin
outer surface.
Apply engine oil to the piston pin hole and connecting rod inner surface.
Install the piston with the "IN" mark toward the
intake side and insert the piston pin through the piston and connecting rod.
Instal new piston pin clips.
NOTE:
• Make sure the piston pin clips are seated
securely.
• Do not align the clip end gap with the piston cutout.
10-8
MARKING
TOP RING
SECOND RING
CYLINDER/PISTON
CYLINDER INSTALLATION
Clean the gasket surface of the crankcase thoroughly, being careful not to damage them, and
being careful not to allow gasket material into the
crankcase.
Blow through the oil passage (stud bolt hole) in the
cylinder with compressed air.
CHAIN GUIDE
Install the cam chain guide into the crankcase so its
end rests in the groove properly.
Install the dowel pins and a new gasket.
Apply engine oil to the cylinder wall, piston outer
surface and piston rings.
Be careful not to Route the cam chain through the cylinder and install
damage the piston the cylinder over the piston while compressing the
rings and cylinder piston rings with your fingers.
wall. Align the cam chain guide bosses with the grooves
in the cylinder properly to seat the cylinder on the
crankcase.
Tighten the three Make sure that the cylinder touches the crankcase
outside bolts again evenly. Install the four cylinder bolts and tighten
after installing the them securely.
cylinder head cover.
BOLTS
10-9
CYLINDER/PISTON
Install the cam chain tensioner lifter with a new gasket and tighten the two mounting bolts.
Coat a new O-ring with coolant and install it on the
water pipe. Connect the water pipe and secure it
with the bolt.
Install the camshaft (page 9-17).
10-10
11. ALTERNATOR/STARTER CLUTCH
SYSTEM COMPONENTS
11-2
RECOIL STARTER
11-5
SERVICE INFORMATION
11-3
ALTERNATOR STATOR/STARTER
REDUCTION GEARS
11-9
TROUBLESHOOTING
11-4
FLYWHEEL/STARTER CLUTCH
11-14
11-1
ALTERNATOR/STARTER CLUTCH
SYSTEM COMPONENTS
108 Nm (11.0 kgfm, 80 Ibf-ft)
11-2
ALTERNATOR/STARTER CLUTCH
SERVICE INFORMATION
GENERAL
• This section covers service of the recoil starter, alternator stator and flywheel/starter clutch. These parts can be serviced
with the engine installed in the frame.
• Crankshaft lubricating oil is fed through the oil passage in the alternator cover. Clean the oil passage before installing
the alternator cover.
• Be careful not to damage the mating surfaces of the alternator and crankcase covers when servicing.
• Rear crankcase cover removal/installation (page 12-5).
• Alternator stator inspection (page 20-8).
• Starter motor servicing (page 22-6).
SPECIFICATION
ITEM
Starter driven gear boss O.D.
Torque limiter slip torque
STANDARD
51.705 - 51.718 (2.0356 - 2.0361)
53-84N-m(5.4-8.6kgfm,
3 9 - 6 2 Ibfft)
Unit: mm (in)
SERVICE LIMIT
51.61 (2.032)
TORQUE VALUES
Starter clutch socket bolt
Recoil starter driven pulley bolt
30 N-m (3.1 kgf-m, 22 Ibfft)
108 N-m (11.0 kgfm, 80 Ibfft)
Alternator stator bolt
CKP sensor mounting bolt
10 N-m (1.0 kgfm, 7 Ibfft)
6 N-m (0.6 kgfm, 4.3 Ibfft)
Apply locking agent to the threads
Apply engine oil to the threads and seating
surface
Apply locking agent to the threads
TOOLS
Flywheel holder
07725-0040000
Rotor puller
07733-0020001
Remover weight
07741-0010201
or equivalent commercially
available in U.S.A.
or 07933-3950000 (U.S.A. only)
or 07936-371020A or 07936-3710200
(U.S.A. only)
Attachment, 42 x 47 mm
07746-0010300
Attachment, 24 x 26 mm
07746-0010700
Pilot, 10 mm
07746-0040100
11-3
ALTERNATOR/STARTER CLUTCH
Pilot, 30 mm
07746-0040700
Driver
07749-0010000
Searing remover shaft, 10 mm
07936-GE00100
dr 07936-GEOOAOO (U.S.A. only)
Bearing remover head, 10 mm
07936-GE00200
Recoil pulley holder
07SMB-HM70100
or 07936-GEOOAOO (U.S.A. only)
Torque limiter attachment D
070MJ-HN80100
riot available in U.S.A.
Remover handle
07936-3710100
not available in U.S.A.
TROUBLESHOOTING
Starter motor turns, but engine does not turn
• Faulty starter clutch
• Damaged reduction gears or torque limiter
11-4
Ibrque limiter attachment B
rj7YMJ-MCF0200
ALTERNATOR/STARTER CLUTCH
RECOIL STARTER
REMOVAL
Remove the right side cover (page 3-5).
CLAMP
Remove the following:
-
four bolts and clamp
recoil starter assembly
BOLTS
STARTER ROPE REPLACEMENT
When the rope has
broken or the pulley
has rewound, align
the rope holes by
turning the pulley 51/2 turns counterclockwise and hold
it.
Pull the starter rope fully to align the rope holes in
the drive pulley and housing, and secure the pulley
with a vise pliers or equivalent tool to prevent the
pulley from rewinding.
GRIP
HOUSING
PULLEY
Untie the starter rope and remove the rope.
Insert a new starter rope through the pulley, housing and grip, and tie the rope ends in a square knot.
Set the pulley side rope end into the cavity as
shown.
Carefully release the pulley and check the recoil
starter for smooth operation by pulling the grip.
Rope ends
DISASSEMBLY
Replace the recoil Untie the starter rope and remove the starter grip to
starter as an release the starter rope slowly while holding the
assembly. drive pulley.
Remove the center bolt (T30), and friction plate and
spring.
ROPE
BOLT
Remove the ratchet and spring.
11-5
ALTERNATOR/STARTER CLUTCH
Wear eye pmtec- Carefully remove the starter drive pulley.
tion and use care
when removing the
drive pulley and
starter spring. The
spring can pop out
of the housing if
care is not used.
PULLEY
Remove the starter rope from the drive pulley.
Check the starter rope for wear or damage.
Check the recoil starter spring for damage or broken.
OUTER END
ASSEMBLY
Be sure to wear Install the starter spring by hooking the outer end
heavy gloves when onto the starter housing as shown.
installing the spring.
SPRING
OUTER END
11-6
ALTERNATOR/STARTER CLUTCH
Insert the starter rope into the drive pulley and tie
the rope end in a square knot (page 11-5). Set the
rope end into the cavity as shown.
SQUARE KNOT
Wrap the rope around the pulley in a counterclockwise direction as viewed from the ratchet side as
shown.
Set the rope into the pulley cutout.
ROPE
CUTOUT
Apply grease to the pulley pivot.
PULLEY
Install the pulley while hooking the inner end of the
spring onto the pulley hook.
Preload the starter spring by turning the pulley 2
turns counterclockwise and hold it.
Route the rope end through the starter housing and
starter grip holes while the pulley remains held in
place. Tie the rope end in a square knot.
11-7
ALTERNATOR/STARTER CLUTCH
Install the ratchet return spring by inserting the long
end into the hole in the pulley.
Apply grease to the ratchet pivot pin.
Install the starter ratchet onto the pivot pin while
setting the spring short end onto the ratchet groove
properly.
Install the friction spring onto the friction plate with
the ends facing the pulley.
Install the friction plate, aligning the holes in the
plate with the pins on the pivot boss so the friction
spring loop is against the ratchet pawl.
Apply locking agent to the center bolt threads.
Install the center bolt and tighten it.
Check the recoil starter for smooth operation by
pulling the grip.
INSTALLATION
Install the recoil starter assembly with the four bolts
and clamp, and tighten the bolts in a crisscross pattern in several steps.
Secure the alternator wire with the clamp.
Install the right side cover (page 3-5).
11-8
SPRING
HOLES
PLATE
ALTERNATOR/STARTER CLUTCH
ALTERNATOR STATOR/STARTER
REDUCTION GEARS
ALTERNATOR COVER REMOVAL
Remove the following:
-
air cleaner housing (page 6-41)
recoil starter (page 11-5)
-
engine guard (page 3-17)
5P NATURAL CONNECTOR
Drain the engine oil (page 4-11).
Disconnect the alternator 5P (Natural) connector.
Hold the recoil starter driven pulley using the special tool and loosen the bolt.
TOOL:
Recoil pulley holder
07SMB-HM70100
Remove the following:
-
bolt and O-ring
driven pulley
B
PULLEY
BOLT
The cover (stator) is
magnetically
attracted to the flywheel, be careful
during removal.
ten bolts and four sealing washers
alternator cover
11-9
ALTERNATOR/STARTER CLUTCH
-
starter torque limiter
reduction gear
gear shaft
LIMITER
SHAFT
-
dowel pins
gasket
GASKET
DOWEL PINS
INSPECTION
Check the bearings in the alternator and rear crankcase covers.
Turn the inner race of each bearing with your finger.
The bearing should turn smoothly and quietly.
Also check that the outer race of the bearing fits
tightly in the covers.
Check the teeth of the reduction gears and torque
limiter for abnormal wear or damage.
11-10
BEARINGS
ALTERNATOR/STARTER CLUTCH
Hold the torque limiter in a vise with the special
tool.
ATTACHMENT D
Replace the torque Check the slip torque with the special tool and a
limiter as an assem- torque wrench.
bly
- TOOLS:
Torque limiter attachment B 07YMJ-MCF0200 (not
available in U.S.A.)
Torque limiter attachment D 070MJ-HN80100 (not
available in U.S.A.)
STANDARD SLIP TORQUE:
53 - 84 N m (5.4 - 8.6 kgf-m, 39 - 62 Ibfft)
LIMITER
/ ; / ATTACHMENT B
STATOR/CKP SENSOR REMOVAL/
INSTALLATION
Remove the CKP sensor mounting bolts.
STATOR
BOLTS
Release the wire grommet off the alternator cover.
Remove the three bolts and alternator stator/CKP
sensor assembly.
For bearing replacement (page 11-11).
IGNITION PULSE GENERATOR
Install the stator/CKP sensor assembly onto the
alternator cover.
Apply sealant to the wire grommet seating surface
and install the grommet into the cover groove
securely.
STATOR
BOLTS
Install and tighten the stator mounting bolts to the
specified torque.
TORQUE: 10 N m (1.0 kgfm, 7 Ibfft)
Apply locking agent Install and tighten the CKP sensor mounting bolts to
to the CKP sensor the specified torque.
mountmg bolt
threads.
T0RQUE
.6
N . m (Q 6 k g f , m
4
3
|bf.ft)
CKPSENSOR
BEARING REPLACEMENT
Remove the stator and CKP sensor (page 11-11).
FLYWHEEL BEARING
OIL SEAL
Remove the driven pulley oil seal.
Drive the flywheel bearing out of the alternator
cover.
11-11
ALTERNATOR/STARTER CLUTCH
Remove the torque limiter bearings in the alternator
and rear crankcase covers, using the special tools.
BEARING REMOVER
TOOLS:
Bearing remover head, 10 mm 07936-GE00200
Remover shaft, 10 mm
07936-GE00100
Remover weight
07741-0010201
U.S.A. only tools:
Bearing remover, 10 mm
Remover handle
Remover weight
07936-GE00A00
07936-3710100
07936-371020A or
07936-3710200
Drive new bearings in with the marks facing up.
TOOLS:
Torque limiter bearing:
Driver
Attachment, 24 x 26 mm
Pilot, 10 mm
Flywheel bearing:
Driver
Attachment, 42 x 47 mm
Pilot, 30 mm
07749-0010000
07746-0010700
07746-0040100
07749-0010000
07746-0010300
07746-0040700
Install the stator and CKP sensor (page 11-11).
ATTACHMENT/PILOT
ALTERNATOR COVER INSTALLATION
Blow through the oil passage in the alternator cover
with compressed air.
Clean the cover mating surfaces.
Apply molybdenum oil solution to the gear teeth
and splines.
Install the reduction gear shaft into the crankcase
and the reduction gear onto the gear shaft.
Install the torque limiter.
Install the two dowel pins and a new gasket.
DOWEL PINS
11-12
ALTERNATOR/STARTER CLUTCH
The cover (stator) is
magnetically
attracted to the flywheel, be careful
not to get anything
caught between
these parts when
installing.
Carefully install the alternator cover.
COVER
Install the ten bolts with four new sealing washers
and the clip stay, and tighten them in a crisscross
pattern in several steps.
NOTE:
• The location for the bolt with sealing washer is
marked A on the cover (inside of the recoil
starter housing).
Apply engine oil to the lips of a new oil seal, and
install it into the alternator cover until it is seated.
BOLTS/ «&
Install the starter driven pulley, aligning the bosses
with the grooves in the crankshaft.
SEALING WASHER
PULLEY
Coat a new O-ring with engine oil and install it onto
the pulley bolt.
Apply engine oil to the pulley bolt threads and seating surface, and install the bolt.
BOLT
Hold the driven pulley using the special tool and
tighten the bolt.
TOOL:
Recoil pulley holder
07SMB-HM70100
TORQUE: 108 N-m (11.0 kgf-m, 80 Ibfft)
Route the wires Connect the alternator 5P (Natural) connector.
properly
Install the following:
(page 1-20).
5P (NATURAL) CONNECTOR
- recoil starter (page 11-8)
- air cleaner housing (page 6-41)
- engine guard (page 3-17)
Fill the engine with recommended oil (page 4-11).
11-13
ALTERNATOR/STARTER CLUTCH
FLYWHEEL/STARTER CLUTCH
REMOVAL
Remove the rear crankcase cover (page 12-5).
Remove the flywheel and starter driven gear using
the special tool.
TOOL:
Rotor puller
07733-0020001 or
07933-3950000
(U.S.A. only)
Remove the needle bearing and thrust washer, and
the woodruff key.
STARTER CLUTCH DISASSEMBLY/
INSPECTION
Make sure that the starter driven gear turns clockwise smoothly and does not turn counterclockwise.
Remove the driven gear while turning it clockwise.
Hold the flywheel with the special tool and remove
the starter clutch bolts (T40).
TOOL:
Flywheel holder
07725-0040000 or
equivalent commercially available in
U.S.A.
Remove the starter clutch assembly from the flywheel.
11-14
DRIVEN GEAR

FLYWHEEL
HOLDER
BOLTS
ALTERNATOR/STARTER CLUTCH
Remove the sprag clutch from the clutch outer.
Check the clutch outer and sprag clutch for abnormal wear or damage.
CLUTCH OUTER
SPRAG CLUTCH
Check the starter driven gear teeth and needle bearing for wear or damage.
Measure driven gear boss O.D.
SERVICE LIMIT: 51.61 mm (2.032 in)
STARTER CLUTCH ASSEMBLY
Lubricate the sprag clutch with engine oil and install
it into the clutch outer with the flanged side facing
the flywheel side.
Apply locking agent to the starter clutch bolt
threads. Install the flywheel onto the clutch outer
and the clutch bolts (T40).
FLYWHEEL
HOLDER
Hold the flywheel with the special tool and tighten
the bolts.
TOOL:
Flywheel holder
07725-0040000 or
equivalent commercially available in
U.S.A.
TORQUE: 30 N m (3.1 kgf-m, 22 Ibfft)
11-15
ALTERNATOR/STARTER CLUTCH
Install the starter driven gear while turning it clock-
_„..„..
wise.
INSTALLATION
Lubricate the needle bearing with molybdenum oil
solution. Install the washer and bearing onto the
crankshaft.
Install the woodruff key into the key groove.
Clean any oil from the tapered portion of the crankshaft and flywheel thoroughly.
Install the flywheel/starter driven gear by aligning
the key-way with the key on the crankshaft.
Apply engine oil to the pulley bolt threads and seating surface.
Install the starter driven pulley, aligning the bosses
with the grooves in the crankshaft, and secure it
with the bolt.
Hold the driven pulley using the special tool and
tighten the bolt.
TOOL:
Recoil pulley holder
07SMB-HM70100
TORQUE: 108 N-m (11.0 kgf-m, 80 Ibf-ft)
Loosen the pulley bolt, and remove the tool, bolt
and driven pulley.
Install the rear crankcase cover (page 12-7).
11-16
PULLEY HOLDER
12. SUB-TRANSMISSION/GEARSHIFT LINKAGE
SYSTEM COMPONENTS
12-2
SUB-TRANSMISSION
12-9
SERVICE INFORMATION
12-3
GEAR SELECTOR LEVER LINKAGE
12-14
TROUBLESHOOTING
12-4
SELECTOR CABLE ADJUSTMENT
12-15
REAR CRANKCASE COVER
12-5
12-1
SUB-TRANSMISSION/GEARSHIFT LINKAGE
SYSTEM COMPONENTS
16N-m(1.6kgfm,12lbfft)
12N-m(1.2kgfm, 9 Ibfft)
25 N-m (2.5 kgf-m, 18 Ibfft)
12-2
SUB-TRANSMISSION/GEARSHIFT LINKAGE
SERVICE INFORMATION
GENERAL
• This section covers service of the sub-transmission and gearshift linkage (forward-reverse). These parts can be serviced
with the engine installed in the frame.
• Sub-transmission lubricating oil is fed through the oil passage in the rear crankcase cover. Clean the oil passage before
installing the crankcase cover.
• Be careful not to damage the crankcase and cover mating surfaces when servicing.
• For automatic transmission service (page 14-3).
SPECIFICATIONS
ITEM
Shift fork
Reverse idle
gear
STANDARD
11.000-11.021 (0.4331-0.4339)
4.93-5.00(0.194-0.197)
10.966 - 10.984 (0.4317 - 0.4324)
13.000 - 13.034 (0.5118 - 0.5131)
12.966 - 12.984 (0.5105 - 0.5112)
-
I.D.
Claw thickness
Shaft O.D.
Collar I.D.
Shaft O.D.
Collar-to-shaft clearance
Unit: mm (in)
SERVICE LIMIT
11.04 (0.435)
4.5(0.18)
10.96(0.431)
13.05(0.514)
12.93 (0.509)
0.10 (0.004)
TORQUE VALUES
Gear selector lever pivot nut
Gear selector arm pinch bolt
Gear selector cable lock nut
Engine oil drain bolt
9 N-m (0.9 kgfm, 6.5 Ibfft)
16 N-m (1.6 kgf-m, 12 Ibfft)
26 N-m (2.7 kgf-m, 20 Ibfft)
25 N-m (2.5 kgf-m, 18 Ibfft)
TOOLS
Remover weight
07741-0010201
Attachment, 37 x 40 mm
07746-0010200
Pilot, 17 mm
07746-0040400
Driver
07749-0010000
Attachment, 28 x 30 mm
07946-1870100
or 07936-371020A or 07936-3710200
(U.S.A. Only)
Pilot, 25 mm
07746-0040600
12-3
SUB-TRANSMISSION/GEARSHIFT LINKAGE
Bearing remover, 17 mm
07936-3710300
Remover handle
07936-3710100
TROUBLESHOOTING
NOTE:
• Be sure the gear position indicator is not blinking
(No drivetrain DTC) before checking the following (page 14-3).
Excessive shift shock or Abnormal noise when
shifting sub-transmission (D-N-R)
1. Shift condition check
Check shift lever free play between the NeutralDrive and Neutral-Reverse.
Is the free play the same for each gear?
NO
- Faulty gearshift linkage (page 12-4).
YES
- GO TO STEP 2.
2. Vehicle creep check
Start the engine.
Shift the sub-transmission in Drive position with
the brake applied.
Wait several seconds. Release the brake and
check the vehicle condition.
Does the vehicle creep?
YES
- Perform the inspection "Vehicle creeps
when idling" on page 14-8 while applying the brake as same manner as above.
NO
- Adjust the selector cable (page 12-15).
Hard to shift
Bent shift fork claw
Bent shift fork shaft
Damaged shift drum guide groove
Damaged shift fork guide pin
Damaged gearshift spindle and drum teeth
Damaged selector lever linkage
Improperly adjusted selector cable
Improperly installed gearshift spindle and drum
Transmission jumps out of gear
Worn gear and shifter dogs
Worn gear shifter groove
Bent shift fork shaft
Broken shift drum stopper arm
Weak or broken stopper arm spring
Damaged shift drum center plate
12-4
SUB-TRANSMISSION/GEARSHIFT LINKAGE
REAR CRANKCASE COVER
REMOVAL
Remove the following:
-
3P (NATURAL) CONNECTOR
left front mud guard (page 3-8)
inner fenders (page 3-9)
front center grille (page 3-10)
center mud guards (page 3-7)
engine side covers (page 3-17)
engine guard (page 3-17)
starter motor (page 22-6)
final drive/sub-frame assembly (page 19-12)
Disconnect the front propeller shaft from the output
shaft (page 8-6).
Disconnect the oil temperature sensor 2P (Black)
connector and gear position switch 3P (Natural)
connector.
2P (BLACK) CONNECTOR
Release the gear position switch wire from the
clamp on the cable holder.
Shift the sub-transmission into neutral.
Remove the following:
-
two cable holder bolts
pinch bolt
selector arm A
Release the gear position switch wire from the wire
clip on the oil filler pipe.
GEAR POSITION SWITCH
Remove the bolts, gear position switch and O-ring.
Remove the following:
-
alternator cover and reduction gears (page 11-9)
two pipe bolts
oil filler pipe and O-ring
two 8-mm bolts
oil drain bolt, sealing washer and O-ring
eleven 6-mm bolts
side cover stays
rear crankcase cover
REAR CRANKCASE COVER
DRAIN BOLT
12-5
SUB-TRANSMISSION/GEARSHIFT LINKAGE
-
two dowel pins
oil joint collar and O-rings
gasket
JOINT COLLAR
GASKET
DOWEL PINS
BEARING REPLACEMENT
For replacement of the bearings in the crankcase,
refer to page 13-10.
OUTPUT SHAFT BEARING
OUTPUT SHAFT BEARING
Remove the output shaft oil seal.
Press the needle bearing out of the crankcase cover.
TOOLS:
Driver
Attachment, 28 x 30 mm
Pilot, 25 mm
07749-0010000
07946-1870100
07746-0040600
Press in a new bearing until it is seated.
TOOLS:
Driver
Attachment, 37 x 40 mm
Pilot, 25 mm
07749-0010000
07746-0010200
07746-0040600
COUNTERSHAFT BEARING
Remove the bearing using the special tools.
TOOLS:
Bearing remover, 17 mm
Remover handle
Remover weight
07936-3710300
07936-3710100
07741-0010201 or
07936-371020A or
07936-3710200
(U.S.A. only)
Drive a new bearing in with the sealed side facing
down.
TOOLS:
Driver
Attachment, 37 x 40 mm
Pilot, 17 mm
12-6
07749-0010000
07746-0010200
07746-0040400
COUNTERSHAFT BEARING
SUB-TRANSMISSION/GEARSHIFT LINKAGE
INSTALLATION
Blow through the oil passage in the crankcase cover
with compressed air.
Clean the crankcase and cover mating surfaces.
Apply engine oil to the lips of new oil seals, and
install them into the crankcase cover until they are
fully seated.
Coat new O-rings with engine oil and install them
into the joint collar grooves. Install the oil joint collar into the crankcase.
Install the two dowel pins and a new gasket.
Make sure that the washers are installed on the output shaft, reverse idle shaft and gearshift spindle,
and that the shift drum position is neutral as shown
(switch pin groove is in positioned lengthwise).
GASKET
Install a new sealing washer onto the drain bolt.
Coat a new O-ring with engine oil and install it into
the drain bolt groove.
DOWEL PINS
6 mm
BOLTS
STAYS
Install the rear crankcase cover with the following
fasteners:
-
eleven 6-mm bolts (with the side cover stays)
two 8-mm bolts
oil drain bolt
Tighten the bolts in a crisscross pattern in several
steps.
TORQUE: Drain bolt: 25 N m (2.5 kgf-m, 18 Ibfft)
REAR CRANKCASE COVER
DRAIN BOLT
Coat a new O-ring with engine oil and install it onto
the oil filler pipe.
Install the filler pipe with the two bolts.
FILLER PIPE
12-7
SUB-TRANSMISSION/GEARSHIFT LINKAGE
Coat a new O-ring with engine oil and install it into
the groove in the gear position switch.
Be careful not to
damage the switch
pin during installstion.
O-RING I GEAR POSITION SWITCH
Align the long end of the switch pin with the " N "
mark. Install the switch by aligning the switch pin
with the slot in the crankcase cover.
Install the bolts and tighten it.
Install the wire clip into the stay of the filler pipe.
Install the alternator cover and reduction gears
(page 11-12).
Install the gear selector arm A by aligning the
groove with the wide tooth of the spindle. Install the
pinch bolt and tighten it.
TORQUE: 16 N m (1.6 kgf m, 12 Ibf ft)
Secure the selector cable onto the engine with the
two cable holder bolts.
Route the gear position switch wire properly, secure
the wire with the clamp on the cable holder.
Route the wires Connect the oil temperature sensor 2P (Black) conproperly (page 1- nector and gear position switch 3P (Natural) con20). nector.
3P (NATURAL) CONNECTOR
Adjust the gear selector cable if necessary (page 12-
15).
Connect the front propeller shaft over the output
shaft (page 8-10).
Install the following:
-
final drive/sub-frame assembly (page 19-27)
starter motor (page 22-11)
engine guard (page 3-17)
engine side covers (page 3-17)
center mud guards (page 3-7)
inner fenders (page 3-9)
front mud guard (page 3-8)
front center grille (page 3-10)
Fill the engine with recommended oil (page 4-10).
12-8
2P (BLACK) CONNECTOR
SUB-TRANSMISSION/GEARSHIFT LINKAGE
SUB-TRANSMISSION
DISASSEMBLY
Remove the rear crankcase cover (page 12-5).
SHAFT/COLLAR/WASHER
Remove the following:
-
washer
idle gear (25T)
gear shaft and gear collar (inner and outer)
washer
idle gear (16T)
The output shaft can be removed at this time (page
12-10).
(OUTPUT SHAFT)
Remove the following:
-
FORK SHAFT
shift fork shaft
shift fork
countershaft assembly
Remove the shift drum while lifting the stopper arm
with a screwdriver.
Remove the following:
-
washer
gearshift spindle
pivot bolt
stopper arm
washer
return spring
STOPPER ARM
RETURN'S PR ING
GEARSHIFT SPINDLE j g BOLT B
WASHER
12-9
SUB-TRANSMISSION/GEARSHIFT LINKAGE
-
washer
output shaft (while holding the driven gear)
output driven gear
OUTPUT SHAFT
Remove the washers on the shaft ends with a
screwdriver and disassemble the countershaft.
INSPECTION
COUNTERSHAFT
Check the gear dogs and teeth for abnormal wear or
damage.
COUNTERSHAFT
SHIFTER
Check the gear shifter for smooth operation.
Check the gear shifter groove, dogs and splines for
abnormal wear or damage.
Check the counter shaft and bearings for abnormal
wear or damage.
R. GEAR
D. GEAR
OUTPUT SHAFT
Check the gear teeth and splines for abnormal wear
or damage.
Check the output shaft for abnormal wear or damage.
12-10
SUB-TRANSMISSION/GEARSHIFT LINKAGE
REVERSE IDLE GEAR
Check the gear teeth for abnormal wear or damage.
Check the splines of the gears and collar for abnormal wear or damage.
COLLAR
SHAFT
Check the gear shaft and collar for abnormal wear
or damage.
Measure each end of the gear collar I.D.
SERVICE LIMIT: 13.05 mm (0.514 in)
Measure the shaft O.D.
SERVICE LIMIT: 12.93 mm (0.509 in)
Calculate the collar-to-shaft clearance.
SERVICE LIMIT: 0.10 mm (0.004 in)
SHIFT FORK AND SHAFT
Check shift fork guide pin for abnormal wear or
damage.
Measure each shift fork claw thickness.
SERVICE LIMIT: 4.5 mm (0.18 in)
Measure the shift fork I.D.
SERVICE LIMIT: 11.04 mm (0.435 in)
Measure the shift fork shaft O.D.
SERVICE LIMIT: 10.96 mm (0.431 in)
SHIFT DRUM
Replace the shift Check the guide groove for abnormal wear or dam-
GEAR
drum as an assem- age.
bly.
CENTER PLATE
Check the drum center plate and shifter gear for
abnormal wear or damage.
GUIDE GROOVE
12-11
SUB-TRANSMISSION/GEARSHIFT LINKAGE
GEARSHIFT SPINDLE
Check the shifter gear and splines for abnormal
wear or damage.
INSTALLATION
Apply locking agent to the pivot bolt threads.
Install the spring, washer (between the crankcase
and arm) and stopper arm with the bolt as shown
and tighten the bolt.
Install the snap ring into the spindle groove with the
chamfered edge facing the crankcase cover side
Install the shifter gear with the index line facing the
snap ring, aligning the wide groove with the wide
tooth.
Install the gearshift spindle and rest it onto the stopper on the crankcase.
Install the washer onto the spindle.
Apply engine oil to the shift drum guide groove.
Lift the stopper arm and install the shift drum so the
index line on the spindle shifter gear is aligned
between the punch marks.
Turn the shift drum clockwise and set it in neutral
position so its groove position is lengthwise.
12-12
SUB-TRANSMISSION/GEARSHIFT LINKAGE
Apply engine oil to the bearings, gear teeth and sliding areas.
Assemble the countershaft.
WASHER
LOCK WASHER
GEAR SHIFTER
REVERSE GEAR
WASHER
BEARING (20x24x17)
OUTPUT DRIVE GEAR
BEARING (20x24x12)
LOCK WASHER
: Bearings, Gear teeth and
Sliding areas
BEARING (20x24x17)
The output shaft Install the countershaft assembly by engaging the
may be installed splines.
before installing the
countershaft (page
12-13).
COUNTERSHAFT
Apply engine oil to the fork shaft outer surface.
FORK SHAFT
Before installation, Install the shift fork into the gear shifter groove and
be sure that the drum guide groove.
switch pin groove in Insert the fork shaft through the fork and install it
the shift drum is into the crankcase.
lengthwise as
shown above.
Apply engine oil to the gear teeth and set the output
driven gear into the crankcase.
Insert the output shaft through the driven gear and
install it into the crankcase.
Install the washer.
OUTPUT SHAFT
12-13
SUB-TRANSMISSION/GEARSHIFT LINKAGE
Install the gear shaft with the washer into the crank- I „ _ . . . „
case.
'UULLAM
Install the idle gear (16T) onto the gear collar and
install them onto the gear shaft.
Install the idle gear (25T) and washer.
Install the rear crankcase cover (page 12-5).
GEAR SELECTOR LEVER LINKAGE
DISASSEMBLY
Remove the fuel tank (page 6-39).
PIVOT NUT
AND BOLT
Loosen the pivot nut and remove the following:
-
return spring
pinch bolt
selector arm B
lever/shaft assembly (from the pivot pipe)
Remove the pivot nut and bolt to separate the selector lever from the pivot shaft.
ASSEMBLY
Apply grease to the pivot bolt groove.
Install the selector lever into the pivot shaft with the
pivot bolt and nut so the guide rod is facing toward
the punch mark on the shaft bottom.
Before installing,
mark the spline of
the shaft at the
same position with
the punch mark to
indicate the aligning
point for installing
the selector arm.
12-14
Install the lever/shaft assembly while setting the
guide rod into the selector gate slot.
LEVER/SHAFT ASSEMBLY
SUB-TRANSMISSION/GEARSHIFT LINKAGE
Install the arm B by aligning the slit with the mark
(punch mark).
Install the pinch bolt and tighten it.
TORQUE: 16 N m (1.6 kgf m, 12 Ibf-ft)
Tighten the pivot nut.
TORQUE: 9 N m (0.9 kgf m, 6.5 Ibf-ft)
Install the return spring in the direction as shown.
Apply grease to the gate groove.
Check the selector lever for smooth operation.
Adjust the selector cable if necessary (page 12-15).
Install the fuel tank (page 6-39).
SELECTOR CABLE ADJUSTMENT
Remove the following:
-
fuel tank and head guard plate (page 6-39).
left engine side cover (page 3-17)
Loosen the cable lock nuts fully.
12-15
SUB-TRANSMISSION/GEARSHIFT LINKAGE
Turn the ignition Operate the selector lever several times and shift
switch ON and the sub-transmission into neutral.
check that the neutral indicator comes
on at this time.
Make sure that the selector arm A stops at the center (neutral) position when setting the guide rod of
the lever into the center (neutral) groove in the
selector gate.
Turn one of the lock nuts until it touches the cable
holder while holding the cable. Then, turn the other
nut in the same manner.
Be sure the nuts are seated on the cable holder and
tighten them together to secure the cable.
TORQUE: 26 N m (2.7 kgf m, 20 Ibf-ft)
Check that the selector lever operates properly.
Install the following:
-
12-16
left engine side cover (page 3-17)
head guard plate and fuel tank (page 6-39).
LEVER
13. CRANKCASE/CRANKSHAFT/BALANCER
SYSTEM COMPONENTS
13-2
CRANKSHAFT
SERVICE INFORMATION
13-3
CRANKCASE BEARING
REPLACEMENT
13-10
CRANKCASE ASSEMBLY
13-12
TROUBLESHOOTING
CRANKCASE SEPARATION
13-7
13-5
13-6
13-1
CRANKCASE/CRANKSHAFT/BALANCER
SYSTEM COMPONENTS
13-2
CRANKCASE/CRANKSHAFT/BALANCER
SERVICE INFORMATION
GENERAL
• The crankcase halves must be separated to service the crankshaft and A/T (mainshaft and 2nd/3rd shift clutch
[countershaft]). To service these parts, the engine must be removed from the frame (page 8-2).
• For A/T service (page 14-2).
• Be careful not to damage the crankcase mating surfaces when servicing.
SPECIFICATIONS
Unit: mm (in)
Crankshaft
ITEM
Runout
Big end side clearance
Big end radial clearance
STANDARD
0.05 (0.002)
0.05-0.65(0.002-0.026)
0.006 - 0.018 (0.0002 - 0.0007)
SERVICE LIMIT
0.15(0.059)
0.8 (0.03)
0.05 (0.002)
TOOLS
Remover weight
07741-0010201
Attachment, 37 x 40 mm
07746-0010200
Attachment, 42 x 47 mm
07746-0010300
Attachment, 52 x 55 mm
07746-0010400
Attachment, 62 x 68 mm
07746-0010500
Attachment, 20 mm I.D.
07746-0020400
Pilot, 17 mm
07746-0040400
Pilot, 20 mm
07746-0040500
Pilot, 35 mm
07746-0040800
or 07936-371020A or 07936-3710200
(U.S.A. only)
13-3
CRANKCASE/CRANKSHAFT/BALANCER
Pilot, 40 mm
07746-0040900
Pilot, 28 mm
07746-0041100
Driver
07749-0010000
Remover handle
07936-3710100
Bearing remover, 17 mm
07936-3710300
Bearing remover, 20 mm
07&36-3710600
Assembly shaft
07965-VM00200
Threaded adaptor
07965-VM00300
Attachment, 78 x 90 mm
07GAD-SD40101
or 07931-ME4010B and
07931-HB3020A (U.S.A. Only)
or 07931-KF00200 (U.S.A. only)
Ball joint remover/installer
07WMF-HN00100
Assembly collar spacer
07AMF-HM8A100 (U.S.A. only)
13-4
Assembly collar
07&65-VM00100
CRANKCASE/CRANKSHAFT/BALANCER
TROUBLESHOOTING
Excessive engine noise
• Worn or damaged connecting rod bearing
• Worn crankshaft main journal bearing
• Worn connecting rod small end
• Worn balancer bearing
• Worn, seized or chipped transmission gear
• Worn transmission bearings
Abnormal vibration
• Improper balancer timing
13-5
CRANKCASE/CRANKSHAFT/BALANCER
CRANKCASE SEPARATION
Remove the following:
CAM CHAIN
engine (page 8-2)
cylinder and piston (page 10-4)
sub-transmission/gearshift linkage (page 12-9)
flywheel/starter clutch (page 11-14)
torque converter (page 14-60)
1st shift clutch (page 14-62)
oil pump (page 5-5)
cam chain
oil pump drive chain
pivot bolt
cam chain tensioner and collar
BOLT
The crankcase bolts
are loosened in a
crisscross pattern
in several steps.
Remove the nine rear crankcase bolts.
REAR CRANKCASE
BOLTS
Remove the five front crankcase bolts.
FRONTCRANKCASE
Place the crankcase assembly with the rear crankcase down.
Do not pry the Remove the front crankcase while tapping it at sevcrankcase apart eral locations with a soft hammer.
with a screwdriver. D
. , .,
Remove the following:
- crankshaft bearing inner race
- two dowel pins
- oil joint collar and O-rings
JOINT COLLAR
13-6
INNER RACE
CRANKCASE/CRANKSHAFT/BALANCER
Remove the oil strainers.
1
Clean each strainer screen thoroughly.
Install the oil tank Install the strainers properly as shown.
strainer with the
thin edge facing the
crankcase.
OIL PAN STRAINER
CRANKSHAFT
REMOVAL
Separate the crankcase (page 13-6).
MAINSHAFT
COUNTERSHAFT
Remove the following:
-
oil strainers (page 13-7)
mainshaft and countershaft
For A/T service, see (page 14-64).
Be careful not to Remove the crankshaft and balancer from the rear
damage the crank- crankcase using a hydraulic press. Be sure to hold
case mating sur- the crankshaft and balancer while pressing them
face and crankshaft out of the crankcase.
assembly.
Remove crankshaft bearing using a bearing puller
with a suitable protector.
PULLER(Commercially
available)
BEARING
NOTE:
• Always replace the rear crankshaft bearing with a
new one whenever the crankshaft is removed.
PROTECTOR
13-7
CRANKCASE/CRANKSHAFT/BALANCER
INSPECTION
Set the crankshaft in a stand or V-blocks and measure the runout using a dial indicator.
SERVICE LIMIT: 0.15 mm (0.059 in)
6 mm
Measure the side clearance between the connecting
rod big end and crank weight with a feeler gauge.
SERVICE LIMIT: 0.8 mm (0.03 in)
Measure the radial clearance at the connecting rod
big end in an X and Y directions.
SERVICE LIMIT: 0.05 mm (0.002 in)
Check the balancer gear for wear or damage.
13-8
14 mm
CRANKCASE/CRANKSHAFT/BALANCER
CRANKSHAFT AND BALANCER
INSTALLATION
Apply engine oil to a new rear crankshaft bearing.
Drive the crankshaft bearing into the rear crankcase
with the marking side facing up.
TOOLS:
Driver
Attachment, 78 x 90 mm
Pilot, 40 mm
DRIVER
07749-0010000
07GAD-SD40101
07746-0040900
For other bearing replacement in the crankcase
halves, see page 13-10.
ATTACHMENT/PILOT
Engage the crankshaft and balancer by aligning the
index lines on the sides of the balancer drive and
driven gears as shown, and install them together
into the rear crankcase.
BALANCER DRIVEN GEAR
BALANCER DRIVE GEAR
Assemble the special tools onto the crankshaft.
Be careful not to let
the connecting rod
press against the
crankcase mating
surface while drawing.
Draw the crankshaft into the bearing inner race by
turning the assembly shaft while holding the shaft
nut.
TOOLS:
Ball joint remover/installer
Attachment, 20 mm I.D.
Assembly shaft
Threaded adapter
U.S.A. only:
Puller shaft
Special nut
Threaded adapter
Assembly collar
Assembly collar spacer
REMOVER/INSTALLER
ATTACHMENT
07WMF-HN00100
07746-0020400
07965-VM00200
07965-VM00300
07931-ME4010B
07931-HB3020A
07931-KF00200
07965-VM00100
07AMF-HN8A100
SHAFT
ADAPTER
After installing the crankshaft in, make sure the
index line on the crank weight is aligned between
the index lines on the balancer driven gear.
13-9
CRANKCASE/CRANKSHAFT/BALANCER
Install the mainshaft and countershaft assemblies
as a set into the rear crankcase.
MAINSHAFT
Install the oil strainers (page 13-7).
Assemble the crankcase halves (page 13-12).
CRANKCASE BEARING REPLACEMENT
REAR CRANKCASE
Remove the balancer, mainshaft and shift drum
bearings with the special tools.
TOOLS:
Balancer and Shift Drum Bearings:
Bearing remover, 17 mm
07936-3710300
Remover handle
07936-3710100
Remover weight
07741-0010201 or
07936-371020A or
07936-3710200
(U.S.A. only)
Mainshaft Bearing:
Bearing remover, 20 mm
Remover handle
Remover weight
07936-3710600
07936-3710100
07741-0010201 or
07936-371020A or
07936-3710200
(U.S.A. only)
Drive the countershaft and output shaft bearings
out of the rear crankcase.
COUNTERSHAFT BEARING
MAINSHAFT BEARING
I BALANCER HEARING
FOUTPUT SHAFT BEARING
13-10
CRANKCASE/CRANKSHAFT/BALANCER
Apply engine oil to new bearings.
Drive the bearings in with the marks facing up.
The mainshaft bearing is installed with
the sealed side facmg down.
TOOLS:
Mainshaft Bearing
Driver
Attachment, 42 x 47 mm
Pilot, 20 mm
07749-0010000
07746-0010300
07746-0040500
Countershaft Bearing
Driver
Attachment, 52 x 55 mm
Pilot, 28 mm
07749-0010000
07746-0010400
07746-0041100
ATTACHMENT/PILOT
Balancer and Shift Drum Bearing
Driver
07749-0010000
Attachment, 37 x 40 mm
07746-0010200
Pilot, 17 mm
07746-0040400
Output Shaft Bearing
Driver
Attachment, 62 x 68 mm
Pilot, 28 mm
07749-0010000
07746-0010500
07746-0041100
FRONT CRANKCASE
Remove the balancer and countershaft bearings
with the special tools.
TOOLS:
Balancer Bearing:
Bearing remover, 17 mm
Remover handle
Remover weight
Countershaft Bearing:
Bearing remover, 20 mm
Remover handle
Remover weight
BEARING REMOVER
07936-3710300
07936-3710100
07741-0010201 or
07936-371020A or
07936-3710200
(U.S.A. only)
07936-3710600
07936-3710100
07741-0010201 or
07936-371020A or
07936-3710200
(U.S.A. only)
Remove the oil feed pipe oil seal.
Drive the mainshaft and crankshaft bearings out of
the front crankcase.
Apply engine oil to the lips of a new feed pipe oil
seal. Install the oil seal with the flat side facing the
crankcase until it is fully seated.
COUNTERSHAFT BEARING
MAINSHAFT BEARING
BALANCER BEARING
CRANKSHAFT BEARING
13-11
CRANKCASE/CRANKSHAFT/BALANCER
Apply engine oil to new bearings.
Drive the bearings in with the marks facing up.
TOOLS:
Mainshaft Bearing
Driver
Attachment, 62 x 68 mm
Pilot, 35 mm
The countershaft Countershaft Bearing
bearing is installed Driver
with the sealed Attachment, 42 x 47 mm
side facing down.
pj|ot
2n
mm
07749-0010000
07746-0010500
07746-0040800
07749-0010000
07746-0010300
07746-0040500
ATTACHMENT/PILOT
Crankshaft Bearing
Driver
Attachment, 78 x 90 mm
07749-0010000
07GAD-SD40101
Balancer Bearing
Driver
Attachment, 37 x 40 mm
Pilot, 17 mm
07749-0010000
07746-0010200
07746-0040400
CRANKCASE ASSEMBLY
Before installing the front crankcase cover, make
sure the gear side surfaces (C1 and M l gears) of the
countershaft and mainshaft are flush.
Clean the front and rear crankcase mating surfaces
thoroughly, being careful not to damage them.
Blow through the oil passages in the crankcases
with compressed air.
Coat new O-rings with engine oil and install them
into the joint collar grooves. Install the oil joint collar into the crankcase.
13-12
MAINSHAFT
N
COUNTERSHAFT
CRANKCASE/CRANKSHAFT/BALANCER
Install the two dowel pins.
DOWEL PINS
Install the bearing inner race onto the crankshaft
with the flange side facing in.
Make sure the mat- Apply liquid sealant (Three Bond 1215 or equivaing surfaces evenly lent) to the mating surface of the front crankcase.
touch, that there is
no clearance
between the cases.
Install the front crankcase over the rear crankcase,
aligning the oil strainer pipe with the pipe hole.
Install the five front crankcase bolts.
Check that the mainshaft and crankshaft turns
smoothly and quietly.
BOLTS
Install the nine rear crankcase bolts.
REAR CRANKCASE
Tighten all the crankcase bolts in a crisscross pattern in several steps.
BOLTS
13-13
CRANKCASE/CRANKSHAFT/BALANCER
Apply locking agent to the threads of the tensioner
pivot bolt.
Install the cam chain tensioner and pivot collar with
the flange side of the collar facing to the crankcase.
Install and tighten the cam chain tensioner pivot
bolt.
Install the oil pump drive and cam chains onto the
crankshaft.
Install the following:
-
oil pump (page 5-11)
1st shift clutch and torque converter (page 14-72)
flywheel/starter clutch (page 11-16)
sub-transmission/gearshift linkage (page 12-12)
cylinder and piston (page 10-8)
engine (page 8-8)
PUMP DRIVE!
13-14
14. DRIVETRAIN SYSTEM
SYSTEM COMPONENTS
14-2
GEARSHIFT SWITCH
14-45
SERVICE INFORMATION
14-3
DRIVE MODE SELECT SWITCH
14-46
SYMPTOM TROUBLESHOOTING
14-6
SHIFT VALVE BODY
14-47
DRIVETRAIN SYSTEM LOCATION
14-15
FRONT CRANKCASE COVER
14-54
DRIVETRAIN SYSTEM DIAGRAM
14-16
TORQUE CONVERTER REMOVAL
14-60
TORQUE CONVERTER INSPECTION
14-61
SHIFT CLUTCH/MAINSHAFT
DISASSEMBLY
14-62
DRIVETRAIN CONNECTOR
LOCATION
•
14-17
DRIVETRAIN TROUBLESHOOTING
INFORMATION
14-20
DRIVETRAIN DTC INDEX
14-24
SHIFT CLUTCH/MAINSHAFT
ASSEMBLY
14-67
DRIVETRAIN DTC
TROUBLESHOOTING
14-26
TORQUE CONVERTER
INSTALLATION
14-73
GEAR POSITION SWITCH
14-44
14-1
DRIVETRAIN SYSTEM
SYSTEM COMPONENTS
14 N-m (1.4 kgf-m, 10 Ibfft)
108 N-m (11.0 kgf-m, 80 Ibfft)
108 N-m (11.0 kgfm, 80 Ibf-ft)
21 N-m (2.1 kgfm, 15 Ibfft)
14-2
DRIVETRAIN SYSTEM
SERVICE INFORMATION
GENERAL
• This "Drivetrain System" section covers service of the electrical system of the A/T (Automatic Transmission), selectable
4WD system and the mechanical system of the A/T.
• Refer to "Front driving mechanism" for the front final clutch service (page 18-14).
• Refer to "Technical Features" for the control and function of each components by the PCM (page 2-7).
• Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can
cause a fire or explosion.
• A faulty drivetrain system is often related to poorly connected or corroded connectors. Check those connections before
proceeding.
• Read "Drivetrain Troubleshooting Information" carefully, and inspect and troubleshoot the drivetrain system according
to the DTC. Observe each step of the procedures one by one. Note the DTC and probable faulty part before starting
diagnosis and troubleshooting.
• The PCM may be damaged if dropped. Also, if a connector is disconnected when current is flowing, the excessive voltage may damage the PCM. Always turn off the ignition switch before servicing.
• The drive mode (2WD or 4WD) is changed electrically by operating front final clutch with the 2WD/4WD select switch.
• The torque converter and 1st shift clutch can be serviced with the engine installed in the frame. To service the mainshaft
and 2nd/3rd shift clutch (countershaft), the crankcase halves must be separated. For crankcase separation and assembly
(page 13-6).
• For sub-transmission (Forward-Neutral-Reverse) service (page 12-2).
• The engine oil is used for A/T oil. For lubrication system service (oil pump and oil cooler) (page 5-2).
• A/T and lubricating oil is fed through the oil passage in the front crankcase cover. Clean the oil passages before installing the crankcase cover.
• Be careful not to damage the crankcase and cover mating surfaces when servicing.
• Replace the torque converter as an assembly, when it is faulty.
For Drivetrain System Troubleshooting
The PCM (Powertrain Control Module) is integrated with the ECM (Engine Control Module), the TCM (Transmission Control
Module) and the selectable 4WD system control. Therefore some detection items that are shared in the PGM-FI and drivetrain system and they may affect the operation of both systems.
Before starting any troubleshooting, check the items as follows and refer to the appropriate troubleshooting.
1. MIL blinks or DTC for the Fuel system (page 6-13).
2. Gear position indicator blinks, 4WD indicator or DTC for the Drivetrain system (page 14-20).
3. Symptom of the A/T and selectable 4WD system operation (page 14-6).
Refer to "PGM-FI Troubleshooting Information" for the general troubleshooting information (page 6-13).
SPECIFICATIONS
Line
1st, 2nd and 3rd clutch
STANDARD
785 kPa (8.0 kgf/cm2, 114 psi)
785 kPa (8.0 kgf/cm2,114 psi)
Unit: mm (in)
SERVICE LIMIT
—
Initial clearance
Disc thickness
Plate thickness
Return spring free length
0.7 - 0.9 (0.03 - 0.04)
1.88-2.00(0.074-0.079)
1.95-2.05(0.077-0.081)
33.8(1.33)
worn out lining
discoloration
31.8(1.25)
ITEM
Oil pressure
at 5,000 rpm
(min 1 )
Shift clutch
(1st, 2nd and
3rd)
TORQUE VALUES
Oil pass bolt
Primary driven gear lock nut
18 N-m (1.8 kgf-m, 13 Ibf-ft)
108 N-m (11.0 kgfm, 80 Ibfft)
Stator shaft inner collar stopper pin
Torque converter lock nut
14 N-m (1.4 kgf-m, 10 Ibf-ft)
108 N-m (11.0 kgf-m, 80 Ibf-ft)
Oil feed pipe setting cap
21 N-m (2.1 kgf-m, 15 Ibf-ft)
Lock nut: replace with a new one.
Apply engine oil to the threads and seating
surface. Stake.
Apply locking agent to the threads.
Lock nut: replace with a new one.
Apply engine oil to the threads and seating
surface. Stake.
14-3
DRIVETRAIN SYSTEM
TOOLS
Pressure gauge set
07406-0020005
Bearing remover weight
07741-0010201
Attachment, 42 x 47 mm
07746-0010300
or 07ZMJ-HN2A100 and 07AMJHN8A100 (U.S.A. only)
Pilot, 17 mm
07746-0040400
or 07936-371020A or 07936-3710200
(U.S.A. only)
Pilot, 25 mm
07746-0040600
Driver
CI7749-0010000
Puller, 35 x 1.0 mm
07933-HA80000
Bearing remover handle
07936-3710100
Bearing remover, 17 mm
07936-3710300
or 07933-HB3000A (U.S.A. only)
Compressor bolt assembly
07GAE-PG40200
Clutch compressor attachment
07LAE-PX40100 (2 required)
Inspection adaptor
07GMJ-ML80100
or 07GAE-PG4020A (U.S.A. only)
14-4
DRIVETRAIN SYSTEM
SCS connector
070PZ-ZY30100
HDS pocket tester
TDS 3557-0112-01 (U.S.A. only)
Test probe
07ZAJ-RDJA110
14-5
DRIVETRAIN SYSTEM
SYMPTOM TROUBLESHOOTING
GENERAL INFORMATION
If the ATV has any A/T trouble, check the DTC or gear position indicator blinking, refer to the DTC index
and begin the appropriate troubleshooting procedure (page 14-24)
If there are no DTC stored in the PCM memory, do the troubleshooting as following symptom and then
inspect the oil pressure and diagnose according to the troubleshooting chart (page 14-14).
Symptom
Acceleration control failure
Shift control failure
Gear position indicator indicates "--"
but no DTC set
Gear position indicator indicates
" - - " and MIL is
stays ON at all (No
DTC set)
Diagnosis procedure
Refer to the following symptom troubleshooting
(page 14-6):
• Vehicle does not accelerate
• Excessive starting shock
• Vehicle creeps (vehicle does not stop) when idling
• Driving power falls off when accelerating (insufficient engine brake)
• Engine stalls when accelerating
Refer to the following symptom troubleshooting
(page 14-9):
• A/T does not shift
• When shifting in the AUTO (automatic:) mode,
excessive shift shock, engine rpm ( m i l ) ' rises or
driving power falls off
Refer to the following symptom troubleshooting
(page 14-10):
• A/T does not shift
• Gear position indicator displays " - - " and drive
mode indicator "ESP" stays on
Check the DLC circuit (Brown/red wire) for short circuit.
Also check for
• Engine oil
level (page 410)
• Oil pressure
(page 14-12)
• Emergency
valve
• Engine oil
level (page 410)
• Oil pressure
(page 14-12)
• Combination
meter circuit
• Short circuit
in the DLC
related wire
STARTING CONTROL FAILURE
Vehicle Does Not Accelerate
1. A/T Clutch Pressure Control Solenoid Operation
Sound Check
Put the gear selector lever in the Drive or
Reverse position.
Check for a "click" sound from the A/T clutch
pressure control solenoid when the ignition
switch is ON.
Is there sound?
14-6
NO
- GO TO STEP 2.
YES
- G O TO STEP 3.
A/T CLUTCH PRESSURE
CONTROL SOLENOID
DRIVETRAIN SYSTEM
2. A/T Clutch Pressure Control Solenoid Operation
Check
Remove the valve body cover (page 14-47).
Disconnect the A/T clutch pressure control solenoid 2P (Black) connector.
Connect a 12 V battery to the solenoid terminals.
It should operate (sounds) when the battery is
connected.
2P BLACK CONNECTOR
Does the solenoid operate?
NO
- Faulty A/T clutch pressure control solenoid.
YES
- Test-ride the vehicle and check the gear
position indicator (page 14-44).
3. Vehicle Test-riding
Accelerate the vehicle with the mode select
switch at ESP. Check the acceleration performance with the transmission in the 2nd and 3rd
ranges.
Does the vehicle accelerate with the transmission in 2nd and 3rd?
YES
- Faulty 1st shift clutch system (page I486)
NO
- Hydraulic circuit malfunction is the
likely cause. Check the oil pressure
(page 14-12).
Excessive Acceleration Shock
1. Vehicle Test-riding
Accelerate the vehicle with the mode select
switch at ESP. Check for acceleration shock with
the transmission in the 2nd and 3rd ranges.
Is there acceleration shock with the transmission in 2nd and 3rd?
NO
- Faulty 1st shift clutch system (page 1466)
YES
- Hydraulic circuit malfunction is the
likely cause. Check the oil pressure
(page 14-12).
14-7
DRIVETRAIN SYSTEM
Vehicle Creeps (vehicle does not stop) When Idling
1. Vehicle Test-riding
NOTE:
• Be sure the emergency valve is not active,
that the stopper bolt is secured with the lock
plate as shown. If it is turned all the way in
(active), the transmission will be fixed in 2nd
range and the vehicle creeps when idling. For
emergency valve information (page 14-47).
LOCK PLATE
Start the engine and shift the sub-transmission
in drive position with the mode select switch at
ESP. Check the acceleration performance (creep)
with the transmission in the 2nd and 3rd ranges.
Does the vehicle creep with the transmission in
2nd and 3rd?
NO
- Faulty 1st shift clutch system (page I486)
YES
- Hydraulic circuit malfunction is the
likely cause. Check the oil pressure
(page 14-12).
Driving Power Falls Off
(insufficient engine brake)
When
STOPPER EiOLT
Accelerating
1. A/T Clutch Pressure Control Solenoid Operation
Sound Check
Put the gear selector lever in the Drive or
Reverse position.
Check for a "click" sound from the A/T clutch
pressure control solenoid when the ignition
switch is ON.
ATT CLUTCH PRESSURE
CONTROL SOLENOID
Is there sound?
NO
- GO TO STEP 2.
YES
- GO TO STEP 3.
2. A/T Clutch Pressure Control Solenoid Operation
Check
Remove the valve body cover (page 14-47).
Disconnect the A/T clutch pressure control solenoid 2P (Black) connector.
Connect a 12 V battery to the solenoid terminals.
It should operate when the battery is connected.
Does the solenoid operate?
14-8
NO
- Faulty A/T clutch pressure control solenoid.
YES
- Test-ride the vehicle and check the gear
position indicator (page 14-20).
2P (BLACK) CONNECTOR
DRIVETRAIN SYSTEM
3. Vehicle Test-riding
Test-ride the vehicle with the mode select switch
at ESP.
Check for engine braking with the transmission
in the 2nd and 3rd ranges.
Is there engine braking with the transmission in
any range except 1st?
YES
- Faulty 1st shift clutch system (page I486)
NO
- Hydraulic circuit malfunction is the
likely cause. Check the oil pressure
(page 14-12).
Engine Stalls When Accelerating
1. Vehicle Creep Check
NOTE:
• Perform this test after engine idle speed
inspection (page 6-55).
Start the engine.
Shift the sub-transmission in drive position with
the brake applied.
Wait several seconds. Release the brake and
check the vehicle condition.
Does the vehicle creep?
YES
- Perform the inspection "Vehicle creeps
when idling" on while applying the
brake in the same manner as above
(page 14-8).
NO
- Hydraulic circuit malfunction is the
likely cause. Check the oil pressure
(page 14-12).
SHIFT CONTROL FAILURE
A/T Does Not Shift
1. Vehicle Test-riding
Test-ride the vehicle with the mode select switch
at ESP. Check that it shifts to each range.
Does the vehicle shift?
YES
- • Faulty throttle position sensor system. Check the installation condition
(page 6-43).
• Faulty VS sensor system. Check the
installation condition (page 18-30).
NO
- GO TO STEP 2.
2. Shift Solenoid Valve Operation Check
Disconnect the shift solenoid valve 2P (Black)
and 2P (Brown) connectors. Connect a 12 V battery to each solenoid terminals.
It should operate (sounds) when the battery is
connected.
Does the solenoid valves operate?
NO
- Faulty shift solenoid valve A and/or B.
YES
- Hydraulic circuit malfunction is likely
cause. Check the oil pressure (page 1412).
14-9
DRIVETRAIN SYSTEM
When Shifting in the AUTO (automatic) Mode,
Excessive Shift Shock, Engine rpm (min') Rises or
Driving Power Falls Off
1. Vehicle Test-riding
Test-ride the vehicle with the mode select switch
at ESP. Check above symptoms when shifting
with the ESP shift switch.
Are there repeated symptoms?
YES
- • Faulty throttle position sensor system. Check the installation condition
(page 6-43).
• Faulty VS sensor system. Check the
installation condition (page 18-30).
NO
- Hydraulic circuit malfunction is likely
cause. Check the oil pressure (page 1412).
" - - " GEAR POSITION INDICATOR
INDICATE BUT NO DTC SET
A/T Does Not Shift
1. Shift Solenoid Valve Inspection When Shifting
to " 1 "
Put the gearshift lever in "D" (drive) and turn the
drive mode select switch to "ESP".
Shift the transmission into " 1 " (first gear) with
the gearshift switch and check shift solenoid
valve A.
SHIFT SOLENOID VALVE B
Does Shift Solenoid Valve A Operate?
NO
- Faulty shift solenoid valve A.
YES
- GO TO STEP 2.
SHIFT SOLENOID VALVE A
2. Shift Solenoid Valve Inspection When Shifting
to "2"
Shift the transmission into " 2 " (second gear)
with the gearshift switch and check shift solenoid valves A and B.
Do Shift Solenoid Valves A or B Operate?
NO
- GO TO STEP 3.
YES
- • Faulty shift solenoid valve A.
• Faulty shift solenoid valve B.
3. Shift Solenoid Valve Inspection When Shifting
to "3"
Shift the transmission into "3" (third gear) with
the gearshift switch and check shift solenoid
valve B.
Does Shift Solenoid Valve B Operate?
14-10
NO
- Faulty shift solenoid valve B.
YES
- No problem (Temporary Failure).
t
DRIVETRAIN SYSTEM
GEAR POSITION INDICATOR DISPLAYS "- -" AND
DRIVE MODE INDICATOR "ESP" STAYS ON
1. PCM Connector Inspection
Turn the ignition switch OFF.
Remove the steering cover (page 3-5).
Seal the PCM
connector with
tape to prevent
dirt and oil from
entering the
connector after
disconnecting
the 33P
connector.
Disconnect the PCM 33P connectors.
Check the connector for loose contacts or corroded terminals.
Is the connector in good condition?
NO
- Loose or poorly connected PCM 33P
connectors.
YES
- GO TO STEP 2.
2. Combination Meter Connector Inspection
Remove the combination meter 14P (Gray) connector and disconnect it.
Check the connector for loose contacts or corroded terminals.
Is the connector in good condition?
NO
- Loose or poorly connected combination
meter 14P (Gray) connector.
YES
- GO TO STEP 3.
14P (GRAY) CONNECTOR
3. LCD Line Open Circuit Inspection
Be careful not
to bend the
connector
terminals.
Check the LCD wires for continuity between the
combination meter and PCM connectors terminals.
COMBINATION METER 14P (GRAY)
CONNECTOR (Wire side of male terminal)
Is there continuity?
NO
YES
- •
•
•
•
•
Open circuit
Open circuit
Open circuit
Open circuit
Open circuit
- GO TO STEP 4.
in the
in the
in the
in the
in the
Pink/blue wire.
Blue/white wire.
Light blue wire.
Blue wire.
Orange wire.
PCM 33P
(BLACK)
CONNECTOR
(Wire side of
female
terminal)
14-11
DRIVETRAIN SYSTEM
4. LCD Short Circuit Inspection
Check the LCD wires for continuity between the
combination meter connector terminals of the
wire harness side and ground.
COMBINATION METER 14P (GRAY)
CONNECTOR (Wire side of male terminal)
Is there continuity?
YES
- • Short
Short
Short
Short
Short
circuit
circuit
circuit
circuit
circuit
NO
- GO TO STEP 5.
in the
in the
in the
in the
in the
Pink/blue wire.
Blue/white wire.
Light blue wire.
Blue wire.
Orange wire.
5. Shift Solenoid Valve Inspection
Connect the PCM 33P and combination meter
14P (Gray) connectors.
Perform the troubleshooting of "A/T Does Not
Shift" (page 14-10).
When
connecting the
PCM 33P
connectors,
check that
there is no dirt
and oil in the
connector.
Are the shift solenoid valves in good condition?
NO
- Faulty shift solenoid valves A and/or B.
YES
- Faulty PCM.
OIL PRESSURE CHECK
NOTE:
• After checking each oil pressure, perform the
inspection and cleaning according to the troubleshooting chart (page 14-14).
• Failure to warm the engine will cause very high
oil pressure readings.
External leaks will cause low oil pressure readings.
Check the oil level and add the recommended
engine oil if necessary (page 4-10).
Also, warm the engine to normal operating temperature and check for external leaks.
Be careful not touch
the rotating wheels
during inspection.
Support the vehicle using a hoist or equivalent and
raise all the wheels off the ground.
For line pressure:
Remove the sealing bolt and washer on the right
side of the shift valve body.
For 1st, 2nd and 3rd
clutch pressure:
14-12
NOTE:
• Clean around the sealing bolts with compressed
air before removing the bolts, and be sure that
no dirt is allowed to enter the oil gallery.
Remove the following:
-
left engine side cover (page 3-17)
left front mud guard (page 3-8)
BOLTANDWASHER
(LINE PRESSURE)
DRIVETRAIN SYSTEM
Remove the sealing bolts and washers on the bottom of the shift valve body.
Connect the oil pressure gauge and adapter to each
inspection hole (hole threads; M8 x 1.25).
Line pressure:
PRESSURE GAUGE
TOOLS:
Pressure gauge set
07406-0020005
or
Oil pressure gauge 0-160 psi 07ZMJ-HN2A100 and
Adapter, banjo 8 x 1.25 mm
07AMJ-HN8A100
(U.S.A. only)
Start the engine and check the oil pressure as follows.
For line pressure: Shift the sub-transmission into Neutral (set the
selector lever in center position) and measure the
oil pressure.
LINE OIL PRESSURE (80°C/176°F):
785 kPa (8.0 kgf/cm2,114 psi) at 5,000 rpm (min ')
For 1st, 2nd and 3rd Shift the sub-transmission in Drive position with the
clutch pressure: mode select switch at "ESP".
Shift to the respective transmission position (1st,
2nd and 3rd) with the ESP shift switch and measure
the each clutch oil pressure.
HOSE
1st/2nd/3rd pressure:
PRESSURE
GAUGE SET
SHIFT CLUTCH OIL PRESSURE (80°C/176°F):
1st, 2nd, 3rd:
785 kPa (8.0 kgf/cm2,114 psi) at 5,000 rpm (min ')
Stop the engine.
Remove the pressure gauge and hose(s).
Install the new sealing washer and bolt to the right
side of the shift valve body, tighten the bolt
securely.
14-13
DRIVETRAIN SYSTEM
Remove the sealing bolts and washers on the bottom of the shift valve body.
After the oil pressure check is completed, start the
engine and make sure there are no oil leaks.
TROUBLESHOOTING CHART OF HYDRAULIC
CIRCUIT
PRESSURE CHECK SECTION
MEASUREMENT RESULT (•: Abnormal / Blank: Normal)
Line pressure
•
1st clutch pressure
•
2nd clutch pressure
3rd clutch pressure
0
Emergency valve
0
2-3 shift valve
0
0
Shift solenoid valve A
Probable Faulty Part (applied to 0)
•
•
•
A/T clutch pressure control
solenoid
1-2 shift valve
Shift solenoid valve B
0
0
0
0
Refer
to page
0
14-48
0
2nd orifice control valve
3rd orifice control valve
Shift valve body
Orifice control valve body
1st clutch
3rd clutch
0
0
0
0
0
0
0
0
0
2nd clutch
14-66
0
0
Feed pipe A
0
Feed pipe B
0
0
0
Feed pipe C
0
0
0
14-56
Torque converter
0
14-60
Oil pump
0
5-5
Oil pipe setting collar
0
Oil filter
0
0
0
14-55
0
4-12
Oil strainer
0
13-7
Oil level
0
4-10
For function of each component (page 2-7).
14-14
•
•
•
• I •
•
•
•
•
•
•
DRIVETRAIN SYSTEM
DRIVETRAIN SYSTEM LOCATION
COMBINATION METER
IGNITION SWITCH
DRIVE MODE SELECT SWITCH
PCM
GEARSHIFT SWITCH
2WD/4WD SELECT
SWITCH
FRONT VS SENSOR
SHIFT SOLENOID VALVE A
TPSENSOR
GEAR POSITION SWITCH
FRONT FINAL CLUTCH
REAR VS SENSOR
A/T CLUTCH PRESSURE
CONTROL SOLENOID
SHIFT SOLENOID VALVE B
BATTERY
CKP SENSOR
EOT SENSOR
14-15
DRIVETRAIN SYSTEM
DRIVETRAIN SYSTEM DIAGRAM
B^Bu
I
BANK ANGLE
Bl MAIN
Br
- B3 VCC
Y — B14 TH
G/R - B2 SG
SENSOR
ENG STOP
A4
SFT SOL A
A2 — Y/BI -
Y — B2S TOM
SHIFT
SOLENOID A
SFT SOL A Lo A13 — Q/W —
W/H
- A3
A6
W/Bu-
SelV
u
SelUP
--(15)
SHIFT
SFT SOL B A12 — Y/G —
SOLENOID B
W/Y — A5
an -
Sel DOWN
LJ
--(16)
StopLamp
A23 SW
LINP A26 — Y/R —
A/T CLUtCH PC
SOLENOID
LINM A27 — B u / R -
Bu/O-
A1B MODE SW
PCM
Br/BI — A7
G — Bl]
Lb/W-
ONDP
A6
0NDM
AS
--(4)
ONDSW
LG
FR FINAL CLUTCH
A24 GPD
L s f R - A17 GPN
COMBINATON
ONDIND A20
METER
Gr — A2S GPR
TWIND A19
G/BI
- A28 StopSlg SW
P/W — B4 FRVSP
Bl/O — A15 SenVB2
LODI
LCD2
LCD3
LCD4
LOD5
A22
A21
A32 A31 A30
LCD
Lb
CPU
Bu
RRVSP BS
SenVBI A16
I
~
.
G
.
Y|
REAR VS
SENSOR
W --©in)
B-11
Bl:BLACK
Y : YELLOW
Bu:BLUE
G :GREEN
B :RED
W : WHITE
14-16
Br : BROWN
0 :ORANGE
Lb : LIGHT BLUE
Lg : LIGHT GREEN
P :PINK
Gr :GRAY
A-23
A-33
B-23
B-33
DRIVETRAIN SYSTEM
DRIVETRAIN CONNECTOR LOCATION
FRONT CONNECTOR LOCATIONS
Note 1:
Note 2:
Remove the steering cover (page 3-5).
Remove the VS sensor cover (page 18-12).
PCM 33P (BLACK) CONNECTOR (Note 1)
PCM (Note 1)
PCM 5P (BLACK) CONNECTOR (Note 1)
PCM 33P (GRAY) CONNECTOR (Note 1)

FINAL CLUTCH 2P (GREEN)
CONNECTOR (Note 2)
14-17
DRIVETRAIN SYSTEM
Note 1:
Note 2:
Note 3:
Remove the fuel tank (page 6-39).
Remove the left inner fender (page 3-9).
Remove the right inner fender (page 3-9).
LEFT HANDLEBAR
SWITCH 10P (GREEN)
(NoteD
COMBINATION METER 14P (GRAY)
CONNECTOR (NoteD
COMBINATION METER 4P
(BLACK) CONNECTOR (Note 1)
COMBINATION
METER 4P
(NATURAL)
CONNECTOR
(Note!)
FINAL CLUTCH 2P (GREEN)
CONNECTOR (Note 2)
SHIFT SOLENOID
SUB-HARNESS 6P
(NATURAL)
CONNECTOR (Note 2)
FRONT VS SENSOR 3P (BLUE)
CONNECTOR (Note 2)
REAR VS SENSOR 3P (YELLOW)
CONNECTOR (Note 2)
14-18
4WD SWITCH 2P (BLACK)
CONNECTOR (Note D
MODE SELECT SWITCH 3P
(BLACK) CONNECTOR (Note 3)
DRIVETRAIN SYSTEM
MIDDLE/REAR CONNECTOR LOCATIONS
Note 1:
Note 2:
Remove the seat (page 3-4).
Remove the fuel tank side cover (page 3-6).
SHIFT SOLENOID 2P
(BROWN) CONNECTOR
A/T CLUTCH PRESSURE
CONTROL SOLENOID 2P
(BLACK) CONNECTOR
MAP/TP SENSOR 5P (BLACK)
CONNECTOR (Note 1)
SHIFT SOLENOID 2P
(BLACK) CONNECTOR
GEAR POSITION SWITCH 3P
(NATURAL) CONNECTOR
(Note 2)
14-19
DRIVETRAIN SYSTEM
DRIVETRAIN TROUBLESHOOTING
INFORMATION
Refer to "PGM-FI Troubleshooting Information" for
the general troubleshooting information (page 613).
SYSTEM DESCRIPTION
SELF-DIAGNOSIS SYSTEM
The PCM (Powertrain Control Module) integrates
the ECM (Engine Control Module), the TCM (Transmission Control Module) and the selectable 4WD
system control. Therefore some detection items are
shared by the PGM-FI and drivetrain system and
they may affect the system operation of both systems.
And the drivetrain system is equipped with the selfdiagnostic system. When any abnormality occurs in
the A/T or selectable 4WD system, the PCM turns on
the indicators blinking and stores a DTC in its erasable memory for the relevant system failure.
FA model shown:
GEAR POSITION INDICATOR
In case of a function failure in the A/T system (e.g.:
Shift solenoid valve failure), the gear position indicator will blink "- -" to indicate the DTC.
In case of a function failure in the both, A/T and
selectable 4WD, system, both the indicators will
blink at the same time to indicate the DTC.
FAIL-SAFE FUNCTION
The drivetrain system is provided with a fail-safe
function to secure a minimum running capability
even when there is trouble in the system.
When the PCM detects a problem in the A/T system,
the PCM stops the automatic shift function and anticreep function, and defaults the transmission into
2nd gear. Also, the gear position indicator blinks
" - - " to indicate the DTC.
When the PCM detects a problem in the selectable
4WD system, the PCM stops controlling the system
and defaults into the 2WD mode. Also, the 4WD
indicator blinks to indicate the DTC.
DTC (Diagnostic Trouble Code)
Refer to the DTC information in "Fuel system (PGMFI)" (page 6-13).
14-20
4WD INDICATOR
DRIVETRAIN SYSTEM
INDICATOR BLINK PATTERN
• The number of indicator blinks is the equivalent the main code of the DTC (the sub code cannot be
displayed by the indicator blinking).
• The indicator has two types of blinks, a long blink and short blink. The long blink lasts for 1.3 seconds, the short blink lasts for 0.5 seconds. One long blink is the equivalent of ten short blinks. For
example, when one long blink is followed by five short blinks, the DTC is 15 (one long blink = 10
blinks, plus five short blinks).
3 sec.
1 sec.
. 1 sec.
1 sec..
-"ON
Pattern
repeated
OFF
One Blink
Blinking 3 times
Blinking 8 times
problem code
(Example:
Blinking 3 times =
Problem code 3)
• When the PCM stores more than one DTC, the indicator displays in the order from the lowest number
to highest number.
CURRENT DTC/FREEZE DTC
The DTC is indicated in two ways according to the
failure status.
• If the PCM detects the problem at present, the
gear position indicator and 4WD indicator will
blink at all time. It is possible to readout the indicator blink pattern as the current DTC.
• If the PCM does not detect any problem at
present but has a problem stored in its memory,
the indicator will not blink. If it is necessary to
retrieve the past problem, readout the freeze DTC
by following the DTC readout procedure.
HDS POCKET TESTER INFORMATION
Refer to the "How to connect the HDS Pocket Tester"
and "ECM Reset" information in "Fuel system (PGMFl)" (page 6-13).
DTC READOUT
Reading DTC with the indicator
NOTE:
• If the MIL blinks, refer to the "PGM-FI Troubleshooting Information" and troubleshoot the
PGM-FI system first. Then recheck the Drivetrain
system after clearing the PGM-FI DTC.
• After performing diagnostic troubleshooting,
erase the problem code(s) (page 14-22) and testdrive the vehicle to be sure that the problem(s)
have been removed.
Turn the ignition switch on and connect the HDS
Pocket Tester to the DLC (page 6-14).
Read the DTC, freeze data and follow the troubleshooting index (page 14-24).
To read the DTC without the HDS pocket tester, refer
to the following procedure.
14-21
DRIVETRAIN SYSTEM
Turn the ignition switch ON, read the gear position
indicator " — " or 4WD indicator blinks, the number
of blinks indicates the current DTC.
Refer to the troubleshooting index (page 14-24).
When retrieving the Freeze DTC, refer to the following procedures.
1. Turn the ignition switch OFF and remove the
steering cover (page 3-5).
2. Remove the dummy connector and short the
DLC terminals using the special tool.
TOOL:
SCS connector
070PZ-ZY30100
CONNECTION: Brown/red - Green
3. Turn the ignition switch to ON, read the gear
position indicator " — " or 4WD indicator blinks,
the number of blinks indicates the freeze DTC.
Refer to the troubleshooting index (page 14-24).
CLEARING DTC
Connect the HDS Pocket Tester to the DLC (page 614).
Clear the DTC with the HDS while the engine is
stopped.
To clear the DTC without HDS, refer to the following
procedure.
How to clear the DTC without HDS
NOTE:
• When clearing the Drivetrain DTC as follows, the
PGM-FI DTC would also be cleared at the same
time, check the MIL blinks and troubleshoot the
PGM-FI system before readout/clearing the Drivetrain DTC.
1. Turn the ignition switch OFF and remove the
steering cover (page 3-5).
14-22
GEAR POSITION INDICATOR
DRIVETRAIN SYSTEM
2. Remove the dummy connector and short the
Brown/red and Green wire terminals of the DLC
using the special tool.
TOOL:
SCS connector
070PZ-ZY30100
CONNECTION: Brown/red - Green
3. Turn the ignition switch ON.
4. Remove the special tool from the DLC.
5. The indicator will light for approximately 5 seconds. While the indicator lights, short the DLC
terminals again with the special tool. The selfdiagnostic memory is erased if the malfunction
indicator goes off and starts blinking.
NOTE:
• The DLC must be jumped while the indicator
lights. If not, the indicator will not start blinking.
• Note that the self-diagnostic memory cannot be
erased if the ignition switch is turned OFF before
the indicator starts blinking.
14-23
DRIVETRAIN SYSTEM
DRIVETRAIN DTC INDEX
• When the gear position indicator"- -" is lighting constantly, but no problem code is indicated and retrievable, refer to
the symptom troubleshooting (page 14-6).
DTC
(Refer to)
3-1
(14-26)
3-2
(14-27)
3-3
(14-26)
4-1
(14-28)
4-2
(14-30)
4-3
(14-28)
8-1
(6-23)
8-2
(6-24)
11-1
(6-27)
Function Failure
Front final clutch Low input
• Loose or poor contact of the front
final clutch related connector
• Front final clutch or its circuit malfunction
Front final clutch High input
• Front final clutch or its circuit malfunction
Front final clutch drive circuit
• Front final clutch or its circuit malfunction
A/T clutch pressure control solenoid
valve Low input
• Loose or poor contact of the A/T
clutch pressure control solenoid
valve related connector
• A/T clutch pressure control solenoid valve or its circuit malfunction
A/T clutch pressure control solenoid
valve High input
• A/T clutch pressure control solenoid valve or its circuit malfunction
A/T clutch pressure control solenoid
valve drive circuit
• A/T clutch pressure control solenoid valve or its circuit malfunction
TP sensor circuit Low voltage (less
than 0.22 V)
• TP sensor or its circuit malfunction
TP sensor circuit High voltage (more
than 4.93 V)
• Loose or poor contact of the TP
sensor connector
• TP sensor or its circuit malfunction
Rear VS sensor no signal
• Loose or poor contact of the Rear
VS sensor connector
• Rear VS sensor or its circuit malfunction
12-1
(14-31)
Front VS sensor no signal
• Loose or poor contact of the Front
VS sensor connector
• Front VS sensor or its circuit malfunction
15-1
(14-32)
Shift solenoid valve A (short)
• Shift solenoid valve A or its circuit
malfunction
Shift solenoid valve A (open)
• Shift solenoid valve A or its circuit
malfunction
15-2
(14-33)
14-24
Symptom/Fail-safe Function
• Selectable 4WD systerh
does not work (2WD
mode only)
• Selectable 4WD systerh
does not work (2WD
mode only)
• Selectable 4WD system
does not work (2WD
mode only)
• A/T shift function and
anti-creep function does
not work (2nd gear only)
Indicator
Blinks
4WD
A/T
3
PGMFIDTC
4
• A/T shift function and
anti-creep function does
not work (2nd gear only)
• A/T shift function and
anti-creep function does
not work (2nd gear only)
• Poor engine acceleration
• Fail-safe value: 0°
• A/T shift function and
anti-creep function does
not work (2nd gear orjly)
• Poor engine acceleration
• Fail-safe value: 0°
• A/T shift function and
anti-creep function ddes
not work (2nd gear orlly)
8
8-1
• A/T shift function and
anti-creep function ddes
not work (2nd gear only)
• Selectable 4WD system
does not work (2WD
mode only)
• A/T shift function and
anti-creep function ddes
not work (2nd gear only)
• Selectable 4WD system
does not work (2WD
mode only)
• A/T shift function and
anti-creep function dwes
not work (2nd gear only)
• A/T shift function and
anti-creep function does
not work (2nd gear only)
11
11
12
12
8-2
15
11-1
DRIVETRAIN SYSTEM
DTC
(Refer to)
16-1
(14-35)
16-2
(14-36)
31-1
(14-37)
Function Failure
Symptom/Fail-safe Function
Shift solenoid valve B (short)
• Shift solenoid valve B or its circuit
malfunction
Shift solenoid valve B (open)
• Shift solenoid valve B or its circuit
malfunction
System voltage Low (less than 9.3 V)
• PCM power input circuit malfunction
• A/T shift function and
anti-creep function does
not work (2nd gear only)
• A/T shift function and
anti-creep function does
not work (2nd gear only)
• A/T shift function and
anti-creep function does
not work (2nd gear only)
• Selectable 4WD system
does not work (2WD
mode only)
• A/T shift function and
anti-creep function does
not work (2nd gear only)
—
32-1
(14-38)
Fail-safe relay circuit
• Fail-safe relay circuit malfunction
33-2
(6-53)
41-1
(14-39)
EEPROM malfunction
42-1
(14-40)
44-1
(14-41)
44-2
(14-42)
Gear position switch circuit
• Gear position switch circuit malfunction (Short)
Shift (UP/DOWN) switch circuit
• Shift (UP/DOWN) switch circuit
malfunction (Short)
EOT sensor circuit low voltage (less
than 0.07 V)
• EOT sensor or its circuit malfunction
EOT sensor circuit high voltage
(more than 4.85 V)
• Loose or poor contact of the EOT
sensor connector
• EOT sensor or its circuit malfunction
• A/T shift function and
anti-creep function does
not work (2nd gear only)
• A/T shift function and
anti-creep function does
not work (2nd gear only)
• A/T shift function and
anti-creep function does
not work (2nd gear only)
• Cooling fan turns on
• A/T shift function and
anti-creep function does
not work (2nd gear only)
• Cooling fan turns on
Indicator
Blinks
A/T
4WD
16
31
31
32
32
—
—
PGMFIDTC
33-2
41
42
44
44
14-25
DRIVETRAIN SYSTEM
DRIVETRAIN DTC TROUBLESHOOTING
NOTE:
• The connector location and the necessary parts
, to disconnect the connector (page 14-17).
• Perform inspection with the ignition switch
turned OFF, unless otherwise specified.
• After troubleshooting, erase the problem code
and test-ride the vehicle to be sure that the system is normal.
DTC 3-1 (FRONT FINAL CLUTCH LOW
INPUT),
DTC 3-3 (FRONT FINAL CLUTCH DRIVE
CIRCUIT)
• Before starting the troubleshooting, check for
loose or poor contact on the front final clutch 2P
(Green) connector and PCM 33P (Black) connector and then recheck the DTC.
1. Recheck DTC
Turn the ignition switch ON and test-ride the
vehicle with 4WD, then recheck the current DTC.
Is DTC 3-1 or 3-3 indicated?
YES
- GO TO STEP 2.
NO
- Intermittent failure
2. Front Final Clutch Inspection
Turn the ignition switch OFF.
Disconnect the front final clutch 2P (Green) connector.
Measure the resistance between the front final'
clutch 2P (Green) connector terminals of the
clutch side.
Connection: Orange/black - Pink/black
fe the resistance within 5.1- 5.8 Cl (20°C/68°F)7
YES
- GO TO STEP 3.
NO
- Faulty front final clutch.
FRONT FINAL CLUTCH 2P (GREEN)
CONNECTOR (Clutch side of male terminal)
P/BI
O/BI
3. Front Final Clutch Circuit Inspection
Turn the ignition switch ON.
Measure the voltage between the front final
clutch 2P (Green) connector terminals of the wire
harness side.
Connection: Orange/black - Pink/black
FRONT FINAL CLUTCH 2P (GREEN)
CONNECTOR (Wire side of female terminal)
Is the voltage about 11 V with the select switch
into 4WD?
14-26
YES
- GO TO STEP 6.
NO
- GO TO STEP 4.
O/BI
P/BI
DRIVETRAIN SYSTEM
4. Front Final Clutch Line Open Circuit Inspection
Be careful not
to bend the
connector
terminals.
Check for continuity between the PCM 33P
(Black) and front final clutch 2P (Green) connector terminals.
TOOL:
Test probe
07ZAJ-RDJA110
FRONT FINAL CLUTCH 2P (GREEN)
CONNECTOR (Wire side of female terminal)
A9
A8
/
Connection: A8 - Pink/black
A9 - Orange/black
Is there continuity?
NO
- • Open circuit in the Orange/black
wire.
• Open circuit in Pink/black wire.
YES
- GO TO STEP 5.
PCM 33P (BLACK) CONNECTOR
(Wire side of female terminal)
5. Front Final Clutch Line Short Circuit Inspection
Check for continuity between the front final
clutch 2P (Green) connector terminals of the wire
harness side and ground.
Connection: Pink/black - Ground
Orange/black - Ground
FRONT FINAL CLUTCH 2P (GREEN)
CONNECTOR (Wire side of female terminal)
Is there continuity?
YES
- • Short circuit in the Orange/black
wire.
• Short circuit in Pink/black wire.
NO
- GO TO STEP 6.
O/BI
P/BI
6. Recheck DTC
Turn the ignition switch ON and test-ride the
vehicle with 4WD, then recheck the current DTC.
te DTC 3-1 or 3-3 indicated?
YES
- Replace the PCM with a new one and
recheck.
NO
- Intermittent failure
DTC 3-2 (FRONT FINAL CLUTCH HIGH
INPUT)
1. Recheck DTC
Turn the ignition switch ON and test-ride the
vehicle with 4WD, then recheck the current DTC.
te DTC 3-2 indicated?
YES
- GO TO STEP 2.
NO
- Intermittent failure
14-27
DRIVETRAIN SYSTEM
2. Front Final Clutch Inspection
Turn the ignition switch OFF.
Disconnect the front final clutch 2P (Green) connector.
Measure the resistance between the front final
clutch 2P (Green) connector terminals of the
clutch side.
Connection: Orange/black - Pink/black
Is the resistance within 5.1- 5.8 D (20°C/68°F)?
YES
- GO TO STEP 3.
NO
- Faulty front final clutch.
FRONT FINAL CLUTCH 2P (GREEN)
CONNECTOR (Clutch side of male terminal)
IP/BI
O/BI
3. Front Final Clutch Line Short Circuit Inspection
Check the for continuity between the front final
clutch 2P (Green) connector terminals of the wire
harness side and ground.
Connection: Pink/black - Ground
Orange/black - Ground
te there continuity?
YES
- • Short circuit in the Orange/black
wire.
• Short circuit in Pink/black wire.
NO
- GO TO STEP 4.
4. RecheckDTC
Turn the ignition switch ON and test-ride the
vehicle with 4WD, then recheck the current DTC.
Is DTC 3-2 indicated?
YES
- Replace the PCM with a new one and
recheck.
NO
- Intermittent failure
DTC 4-1 (A/T CLUTCH PRESSURE
CONTROL SOLENOID LOW INPUT),
DTC 4-3 (A/T CLUTCH PRESSURE
CONTROL SOLENOID DRIVE CIRCUIT)
• Before starting the troubleshooting, check for
loose or poor contact on the A/T clutch pressure
control solenoid 2P (Black) connector, solenoid
sub-harness 6P (Natural) connector and PCM 33P
(Black) connector and then recheck the DTC.
1. RecheckDTC
Turn the ignition switch ON and test-ride the
vehicle, then recheck the current DTC.
Is DTC 4-1 or 4-3 indicated?
14-28
YES
- GO TO STEP 2.
NO
- Intermittent failure
FRONT FINAL CLUTCH 2P (GREEN)
CONNECTOR (Wire side of female terminal)
O/BI
P/BI
DRIVETRAIN SYSTEM
2. A/T Clutch Pressure Control Solenoid Inspection
Turn the ignition switch OFF.
Disconnect the A/T clutch pressure control solenoid 2P (Black) connector.
Measure the resistance between the A/T clutch
pressure control solenoid 2P (Black) connector
terminals of the solenoid side.
A/T CLUTCH PC SOLENOID 2P (BLACK)
CONNECTOR (Solenoid side of male terminal)
V
Y/R
Bu/R
Connection: Yellow/red - Blue/red
fe the resistance within 4.5 - 10.0 D ?
YES - GO TO STEP 3.
NO
- Faulty A/T clutch pressure control solenoid valve.
3. A/T Clutch Pressure Control Solenoid Circuit
Inspection
Turn the ignition switch ON.
Measure the voltage between the A/T clutch
pressure control solenoid 2P (Black) connector
terminals of the wire harness side.
Connection: Yellow/red - Blue/red
A/T CLUTCH PC SOLENOID 2P (BLACK)
CONNECTOR (Wire side of female terminal)
Bu/R
Y/R
Is the voltage about 11 V with the ignition
switch ON?
YES - GO TO STEP 6.
NO - GO TO STEP 4.
4. A/T Clutch Pressure Control Solenoid Line Open
Circuit Inspection
Be careful not
to bend the
connector
terminals.
Check for continuity between the PCM 33P
(Black) and the A/T clutch pressure control solenoid 2P (Black) connector terminals.
TOOL:
Test probe
07ZAJ-RDJA110
Connection: B26 - Blue/red
B27 - Yellow/red
A/T CLUTCH PC SOLENOID 2P (BLACK)
CONNECTOR (Wire side of female terminal)
B27
i—
r
L
i
Is there continuity?
NO
- • Open circuit in the Blue/red wire.
• Open circuit in Yellow/red wire.
YES
- GO TO STEP 5.
B26
/
"rT
i
—i
1
i
1—~l

/
T
.
ftm
I
r
1
L
/
f—,
J
'
p.
i/D
-Y/R
PCM 33P (BLACK) CONNECTOR
(Wire side of female terminal)
14-29
DRIVETRAIN SYSTEM
5. A/T Clutch Pressure Control Solenoid Line Short
Circuit Inspection
Check the for continuity between the A/T clutch
pressure control solenoid 2P (Black) connector
terminals of the wire harness side and ground.
Connection: Blue/red - Ground
Yellow/red - Ground
ATT CLUTCH PC SOLENOID 2P (BLACK)
CONNECTOR (Wire side of female terminal)
Is there continuity?
YES
- • Short circuit in the Blue/red wire.
• Short circuit in Yellow/red wire.
NO
- GO TO STEP 6.
6. RecheckDTC
Turn the ignition switch ON and test-ride the
vehicle, then recheck the current DTC.
Is DTC 4-1 or 4-3 indicated?
YES
- Replace the PCM with a new one and
recheck.
NO
- Intermittent failure
DTC 4-2 (A/T CLUTCH PRESSURE
CONTROL SOLENOID HIGH INPUT)
1. RecheckDTC
Turn the ignition switch ON and test-ride the
vehicle, then recheck the current DTC.
te DTC 4-2 indicated?
YES
- GO TO STEP 2.
NO
- Intermittent failure
2. A/T Clutch Pressure Control Solenoid Inspection
Turn the ignition switch OFF.
Disconnect the A/T clutch pressure control solenoid 2P (Black) connector.
Measure the resistance between the A/T clutch
pressure control solenoid 2P (Black) connector
terminals of the solenoid side.
Connection: Yellow/red - Blue/red
Is the resistance within 4.5 -10.0 £2 ?
14-30
YES
- GO TO STEP 3.
NO
- Faulty A/T clutch pressure control solenoid valve.
A/T CLUTCH PC SOLENOID 2P (BLACK)
CONNECTOR (Solenoid side of male terminal)
Y/R
V
Bu/R
DRIVETRAIN SYSTEM
3. A/T Clutch Pressure Control Solenoid Line Short
Circuit Inspection
Check for continuity between the A/T clutch
pressure control solenoid 2P (Black) connector
terminals of the wire harness side and ground.
Connection: Blue/red - Ground
Yellow/red - Ground
A/T CLUTCH PC SOLENOID 2P (BLACK)
CONNECTOR (Wire side of female terminal)
Is there continuity?
YES
- • Short circuit in the Blue/red wire.
• Short circuit in Yellow/red wire.
NO
- GO TO STEP 4.
4. RecheckDTC
Turn the ignition switch ON and test-ride the
vehicle, then recheck the current DTC.
Is DTC 4-2 indicated?
YES
- Replace the PCM with a new one and
recheck.
NO
- Intermittent failure
DTC 12-1 (FRONT VS SENSOR)
• Before starting the troubleshooting, check for
loose or poor contact on the front VS sensor 3P
(Blue) connector and PCM 33P (Gray) connector
and then recheck the DTC.
1. Front VS Sensor System Check
Clear the DTC, test-ride and check the front VS
sensor signal with the HDS pocket tester.
Is the front VS sensor signal indicated normally?
YES
- I nte rm itte nt fa i I u re
NO
- GO TO STEP 2.
2. Front VS Sensor Ground Line Inspection
Turn the ignition switch OFF.
Disconnect the front VS sensor 3P (Blue) connector.
Turn the ignition switch ON, measure the voltage between the front VS sensor 3P (Blue) connector terminals of the wire harness side.
FRONT VS SENSOR 3P (BLUE) CONNECTOR
(Wire side of male terminal)
Connection: Black/orange {+) - Green (-)
Is there battery voltage?
NO
- • Open or short circuit in the Black/
orange wire.
• Open circuit in the Green wire.
YES
Bl/O
- GO TO STEP 3.
14-31
DRIVETRAIN SYSTEM
Front VS Sensor Output Line Inspection
Measure the voltage between the front VS sensor 3P (Blue) connector terminals of the wire
harness side.
Connection: Pink/white (+) - Green (-)
Is the voltage about 5 V?
NO
- Open or short circuit in the Pink/white
wire.
YES
- GO TO STEP 4.
FRONT VS SENSOR 3P (BLUE) CONNECTOR
(Wire side of male terminal)
1 4-4J
P/W
4. Front VS Sensor Inspection
Turn the ignition switch OFF.
Replace the front VS sensor with a new one
(page 18-12).
Clear the DTC, test ride the vehicle and recheck
the DTC.
Is the DTC 12-1 indicated?
YES
- Replace the PCM with a new one, and
recheck.
NO
- Faulty original front VS sensor.
DTC 15-1 (SHIFT SOLENOID "A"
SHORT)
1. Recheck DTC
Turn the ignition switch ON and test-ride the
vehicle, then recheck the DTC.
Is DTC 15-1 indicated (or can not shift)?
YES
- GO TO STEP 2.
NO
- Intermittent failure
2. Shift Solenoid Valve "A" Inspection
Turn the ignition switch OFF.
Disconnect the shift solenoid "A" 2P (Black) connector.
Measure the resistance between the shift solenoid valve "A" 2P (Black) connector terminals of
the solenoid side.
Is the resistance within 14.6 - 16.2 ii
68T)?
YES
- GO TO STEP 3.
NO
- Faulty shift solenoid valve A.
(20C/
2P BLACK CONNECTOR
14-32
DRIVETRAIN SYSTEM
3. Shift Solenoid "A" Line Short Circuit Inspection
Turn the ignition switch OFF.
Disconnect the shift solenoid "A" 2P (Black) connector.
Check for continuity between the shift solenoid
"A" 2P (Black) connector terminals of the wire
harness side and ground.
Connection: Green/white - Ground
Yellow/black- Ground
SHIFT SOLENOID "A" 2P (BLACK)
CONNECTOR (Wire side of male terminal)
Is there continuity?
YES
- • Short circuit in the Yellow/black wire.
• Short circuit in the Green/white wire.
NO
- G O TO STEP 4.
4. Failure Reproduction
Connect the shift solenoid "A" 2P (Black) connector.
Turn the ignition switch ON.
Test-ride the vehicle for several minutes under
the same conditions as those indicated by the
freeze data.
Is DTC 15-1 indicated ?
NO
- Intermittent failure
YES
- Replace the PCM with a new one and
recheck.
DTC 15-2 (SHIFT SOLENOID "A" OPEN)
• Before starting the troubleshooting, check for
loose or poor contact on the shift solenoid 2P
(Black) connector and PCM 33P (Black) connector
and then recheck the DTC.
1. Recheck DTC
Turn the ignition switch ON and test-ride the
vehicle, then recheck the DTC.
fe DTC 15-2 indicated ?
YES
- GO TO STEP 2.
NO
- Intermittent failure
14-33
DRIVETRAIN SYSTEM
2. Shift Solenoid Valve "A" Inspection
Turn the ignition switch OFF.
Disconnect the shift solenoid "A" 2P (Black) connector.
Measure the resistance between the shift solenoid valve 2P (Black) connector terminals of the
solenoid side.
Is the resistance within 14.6 - 16.2 Q (20 C/
68W
YES
- GO TO STEP 3.
NO
- Faulty shift solenoid valve "A".
2P BLACK) CONNECTOR
3. Shift Solenoid Valve "A" Line Open Circuit
Inspection
Be careful not
to bend the
connector
terminals.
Connect the shift solenoid "A" 2P (Black) connector.
Disconnect the PCM 33P (Black) connector.
Measure the resistance at the PCM connector
terminals.
TOOL:
Test probe
07ZAJ-RDJA110
Connection: A2 - A13
Is the resistance within 14.6 - 16.2 n (20 C/
68°F)?
NO
- • Open circuit in the Yellow/black wire.
• Open circuit in the Green/white wire.
YES
A13
PCM 33P (BLACK) CONNECTOR
(Wire side of female terminal)
- GO TO STEP 4.
4. Shift Solenoid "A" Line Short Circuit Inspection
Turn the ignition switch OFF.
Disconnect the shift solenoid "A" 2P (Black) connector.
Check for continuity between the shift solenoid
"A" 2P (Black) connector terminals of the wire
harness side and ground.
Connection: Green/white - Ground
Yellow/black- Ground
Is there continuity?
14-34
YES
- • Short circuit in the Yellow/black wire.
• Short circuit in the Green/white wire.
NO
- GO TO STEP 5.
SHIFT SOLENOID "A" 2P (BLACK)
CONNECTOR (Wire side of male terminal)
DRIVETRAIN SYSTEM
5. Failure Reproduction
Connect the shift solenoid "A" 2P (Black) connector and PCM 33P (Black) connector.
Turn the ignition switch ON.
Test-ride the vehicle for several minutes under
the same conditions as those indicated by the
freeze data.
Is DTC 15-2 indicated ?
NO
- Intermittent failure
YES
- Replace the PCM with a new one and
recheck.
DTC 16-1 (SHIFT SOLENOID "B "
SHORT)
1. Recheck DTC
Turn the ignition switch ON and test-ride the
vehicle, then recheck the DTC.
Is DTC 16-1 indicated ?
YES
- GO TO STEP 2.
NO
- Intermittent failure
2. Shift Solenoid Valve "B" Inspection
Turn the ignition switch OFF.
Disconnect the shift solenoid "B" 2P (Brown)
connector.
Measure the resistance between the shift solenoid valve "B" 2P (Brown) connector terminals of
the solenoid side.
Is the resistance within 14.6 - 16.2 Q (20°C/
68°F)?
YES
- GO TO STEP 3.
NO
- Faulty shift solenoid valve "B".
2P (BROWN) CONNECTOR
3. Shift Solenoid "B" Line Short Circuit Inspection
Turn the ignition switch OFF.
Disconnect the shift solenoid "B" 2P (Brown)
connector.
Check for continuity between the both shift solenoid "B" 2P (Brown) connector terminals of the
wire harness side and ground.
Connection: Yellow/green - Ground
Green - Ground
SHIFT SOLENOID "B" 2P (BROWN)
CONNECTOR (Wire side of male terminal)
Is there continuity?
YES
- • Short circuit in the Yellow/green
wire.
• Short circuit in the Green wire.
NO
- GO TO STEP 4.
14-35
DRIVETRAIN SYSTEM
4. Failure Reproduction
Connect the shift solenoid "B" 2P (Brown) connector.
Turn the ignition switch ON.
Test-ride the vehicle for several minutes under
the same conditions as those indicated by the
freeze data.
Is DTC 16-1 indicated ?
NO
- Intermittent failure
YES
- Replace the PCM with a new one and
recheck.
DTC 16-2 (SHIFT SOLENOID "B" OPEN)
• Before starting the troubleshooting, check for
loose or poor contact on the shift solenoid "B" 2P
(Brown) connector and PCM 33P (Black) connector and then recheck the DTC.
1. Recheck DTC
Turn the ignition switch ON and test-ride the
vehicle, then recheck the DTC.
Is DTC 16-2 indicated ?
YES
- GO TO STEP 2.
NO
- Intermittent failure
2. Shift Solenoid Valve "B" Inspection
Turn the ignition switch OFF.
Disconnect the shift solenoid "B" 2P (Brown)
connector.
Measure the resistance between the shift solenoid valve "B" 2P (Brown) connector terminals of
the solenoid side.
Is the resistance within 14.6 - 16.2 ii (20 C/
68°F)7
YES
- GO TO STEP 3.
NO
- Faulty shift solenoid valve B.
2P (BROWN) CONNECTOR
3. Shift Solenoid Valve "B" Line Open Circuit
Inspection
Be careful not
to bend the
connector
terminals.
Connect the shift solenoid "B" 2P (Brown) connector.
Disconnect the PCM 33P (Black) connector and
5P (Black) connector.
Measure the resistance at the PCM connectors
terminals.
TOOL:
Test probe
07ZAJ-RDJA110
PCM 5P (BLACK) CONNECTOR
(Wire side of female terminal)
A12
Connection: A12 - Green
te the resistance within 14.6 - 16.2 Q (20 C/
68 F)?
14-36
NO
- • Open circuit in the Yellow/green
wire.
• Open circuit in the Green wire.
YES
- GO TO STEP 4.
PCM 33P (BLACK) CONNECTOR
(Wire side of female terminal)
DRIVETRAIN SYSTEM
4. Shift Solenoid "B" Line Short Circuit Inspection
Turn the ignition switch OFF.
Disconnect the shift solenoid "B" 2P (Brown)
connector.
Check for continuity between the shift solenoid
"B" 2P (Brown) connector terminals of the wire
harness side and ground.
Connection: Yellow/green - Ground
Green - Ground
SHIFT SOLENOID "B" 2P (BROWN)
CONNECTOR (Wire side of male terminal)
te there continuity?
YES
- • Short circuit in the Yellow/green
wire.
• Short circuit in the Green wire.
IMO
- GO TO STEP 5.
5. Failure Reproduction
Connect the shift solenoid "B" 2P (Brown) connector, PCM 33P (Black) and 5P (Black) connector.
Turn the ignition switch ON.
Test-ride the vehicle for several minutes under
the same conditions as those indicated by the
freeze data.
te DTC 16-2 indicated ?
NO
- Intermittent failure
YES
- Replace the PCM with a new one and
recheck.
DTC 31-1 (SYSTEM VOLTAGE LOW)
• Before starting the troubleshooting, check the
combination meter function or starter motor
function.
If these have malfunction, inspect the battery,
fuses or ignition switch.
• Before starting the troubleshooting, check for
loose or poor contact on the PCM 33P connectors
and then recheck the DTC.
1. PCM System Voltage Inspection
Turn the ignition switch ON.
Check the battery voltage in the Data List menu
of HDS pocket tester.
te the voltage less than 9.3 V?
YES
- GO TO STEP 2.
NO
- Intermittent failure.
14-37
DRIVETRAIN SYSTEM
2. PCM Power Input Line Inspection
Be careful not
to bend the
connector
terminals.
Turn the ignition switch OFF.
Disconnect the PCM 33P (Gray) connector.
Turn the ignition switch ON.
Measure the voltage between the wire harness
side connector terminal and ground.
TOOL:
Test probe
B1

m
1
1

—(3
07ZAJ-RDJA110
Connection: B1 (+) - Ground {-)

i
_—i
i
1
i
1
Is there battery voltage?
NO
- • Inspect the battery/charging system
(page 20-7).
• Open or short circuit in the Black/
blue wire.
• Blown IGN fuse.
YES
- GO TO STEP 3.
3. Failure Reproduction
Clear the DTC, test-ride or check the vehicle
under the conditions indicated as the freeze data
and recheckthe DTC.
te the DTC 31-1 indicated ?
NO
- Intermittent failure
YES
- Replace the PCM with a new one and
recheck.
DTC 32-1 (FAIL SAFE RELAY CIRCUIT)
1. Recheck DTC
Clear the DTC, turn the ignition switch ON and
recheck the current DTC.
Is the DTC 32-1 indicated?
14-38
NO
- Intermittent failure.
YES
- Replace the PCM with a new one and
recheck.
PCM 33P (GRAY) CONNECTOR
(Wire side of female terminal)
—
/
^
DRIVETRAIN SYSTEM
DTC 41-1 (GEAR POSITION SWITCH
CIRCUIT)
• Before starting the troubleshooting, check for
loose or poor contact on the gear position switch
3P (Natural) connector and PCM 33P (Black) connector and then recheck the DTC.
1. Gear Position Switch Line Inspection at PCM
Connector
Turn the ignition switch OFF.
Disconnect the PCM 33P (Black) connector.
Be careful not to
bend the connector
terminals.
Perform the gear position switch inspection
(page 14-44).
Also check for the short circuit between each
gear position switch terminals.
Is there normal continuity?
NO - GO TO STEP 2.
YES - GO TO STEP 3.
2. Gear Position Switch Line Inspection at the
Connector
Disconnect the gear position switch connector.
Check for continuity between the gear position
switch 3P (Natural) connector of the switch side
and ground (page 14-44).
Also check for the short circuit between each
gear position switch terminals.
Connection: Light green/red - Ground'
Gray - Ground
Light blue/white - Ground
GEAR POSITION SWITCH 3P (NATURAL)
CONNECTOR (Switch side of female terminal)
U if U
Lb/W
Gr
Lg/R
Is there normal continuity?
NO
- Faulty gear position switch.
YES
- • Open or short circuit in the Light
green/red wire.
• Open or short circuit in the Light
blue/white wire.
• Open or short circuit in the Gray
wire.
3. Failure Reproduction
When
connecting the
PCM 33.P
connectors,
check that
there is no dirt
and oil in the
connector.
Connect the PCM and gear position switch connectors.
Clear the DTC, turn the ignition switch ON, select
the gear position "D", "R" and check the current
DTC.
fe the DTC 41-1 indicated?
NO
- Intermittent failure.
YES
- Replace the PCM with a new one and
recheck.
14-39
DRIVETRAIN SYSTEM
DTC 42-1 (SHIFT UP/DOWN SWITCH
CIRCUIT)
• Before starting the troubleshooting, check for
loose or poor contact on the handlebar switch
10R (Green) connector and PCM 33P (Black) connector and then recheck the DTC.
1. Shift Switch Status Inspection
Turn the ignition switch ON.
Check the shift switch status and voltage in the
Data List Menu of HDS as follows:
UP
DOWN
"Up" ON
3.64 - 4.08 V
1.76-2.09 V
"Down" ON
1.76-2.09 V
3.64 - 4.08 V
Both ON
4.0 - 4.99 V
4.0 - 4.99 V
Both OFF
0 - 0.99 V
0 - 0.99 V
Is the shift switch status normal?
YES
- Intermittent failure
NO
- GO TO STEP 2.
2. Shift Switch Line Inspection (PCM side)
Turn the ignition switch OFF.
Disconnect the PCM 33P (Black) connector.
Check for continuity between the PCM 33P
(Black) connector terminals in each switch position (page 14-45).
TOOL:
Test probe
07ZAJ-RDJA110
PCM 33P (BLACK) CONNECTOR (Wire side
of female terminal)
Connection: A 3 - A 6
A3-A5
Is there normal continuity?
NO - GO TO STEP 3.
YES - GO TO STEP 4.
A5
3. Gearshift Switch Inspection (Handlebar Switch
Side)
Remove the left handlebar switch 10P (Green)
connector from the frame and disconnect it.
Check for continuity at the switch side 10P
(Green) connector terminals in each switch position (page 14-45).
Connection: White/red - White/blue
White/red - White/yellow
Is there normal continuity?
14-40
NO
- Check the shift switch condition or
replace the shift switch with a new one
and recheck.
YES
- • Open or short circuit in the wires
between the PCM 33P (Black) and
handlebar switch 10P (Green) connector.
- White/red wire.
- White/yellow wire.
- White/blue wire.
HANDLEBAR SWITCH 10P (GREEN)
CONNECTOR (Switch side of male terminal)
DRIVETRAIN SYSTEM
4. Failure Reproduction
Connect the PCM and gearshift switch connectors.
Clear the DTC, turn the ignition switch ON and
recheck the current DTC.
Is the DTC 42-1 indicated?
NO
- Intermittent failure.
YES
- Replace the PCM with a new one and
recheck.
DTC 44-1 (EOT SENSOR LOW
VOLTAGE)
1. EOT Sensor System Inspection
Turn the ignition switch ON and engine stop
switch "o"Check the EOT sensor with the HDS.
Is about 0 V indicated?
NO
- • Intermittent failure.
• Loose or poor connection on the ECT
sensor 2P (Black) connector.
YES
- GO TO STEP 2.
2. EOT Sensor Inspection
Turn the ignition switch OFF.
Disconnect the EOT sensor 2P (Black) connector.
2P (BLACK) CONNECTOR
Turn the ignition switch ON and engine stop
switch "O".
Check the EOT sensor with the DTC pocket
tester.
Is about 0 V indicated?
NO
- G O TO STEP 3.
YES
- GO TO STEP 4.
3. EOT Sensor Resistance Inspection
Turn the ignition switch OFF.
Measure the resistance at the EOT sensor terminals.
Connection: Yellow - Green/red
Standard: 2.3 - 2.6 kii (20°C/68°F)
EOT SENSOR 2P (BLACK) CONNECTOR
(Sensor side of male terminal)
Is the resistance within 2.3 - 2.6 kQ?
YES
No
- Replace the PCM with a new one, and
recheck.
G/R
- Faulty EOT sensor.
14-41
DRIVETRAIN SYSTEM
4. EOT Sensor Short Circuit Inspection
Disconnect the PCM 33P (Gray) connector from
the PCM (page 6-54).
Check for continuity between the EOT sensor 2P
(Black) connector terminal of the wire harness
side and ground.
EOT SENSOR 2P (BLACK) CONNECTOR
(Wire side of female terminal)
Connection: Yellow - Ground
Is there continuity?
YES - Short circuit in Yellow wire.
NO
- Replace the PCM with a new one, and
recheck.
DTC 44-2 (EOT SENSOR HIGH
VOLTAGE)
• Before starting the inspection, check for loose or
poor contact on the EOT sensor 2P (Black) connector and recheck the HDS.
1. EOT Sensor System Inspection
Turn the ignition switch ON and engine stop
switch "O".
Check the EOT sensor with the HDS pocket
tester.
Is about 5 V indicated?
NO
- • Intermittent failure.
• Loose or poor contact on the EOT
sensor 2P (Black) connector.
YES
- GO TO STEP 2.
2. EOT Sensor Inspection
Turn the ignition switch OFF.
Disconnect the EOT sensor 2P (Black) connector.
Jump the EOT sensor terminals with a jumper
wire.
Connection: Yellow - Green/red
EOT SENSOR 2P (BLACK) CONNECTOR
(Wire side fof female terminal)

V-fnr-inU
Turn the ignition switch ON and engine stop
switch "o".
Check the EOT sensor with the HDS pocket
in <
%
<
tester.
Is about 0 V indicated?
14-42
YES
- Faulty EOT sensor.
NO
- GO TO STEP 3.
G/R
Y

JUMPER WIRE
DRIVETRAIN SYSTEM
3. EOT Sensor Open Circuit Inspection
Turn the ignition switch OFF.
Remove the jumper wire.
EOT SENSOR 2P (BLACK) CONNECTOR
(Wire side of female terminal)
Disconnect the PCM 33P (Gray) connector (page
B2
6-54).
Check for continuity between the PCM 33P
(Gray) connector terminals and ECT sensor 2P
(Black) connector terminals of the wire harness
side.
TOOL:
Test probe
07ZAJ-RDJA110
Connection: B28-Yellow
B2 - Green/red
B28
7
PCM 33P (GRAY) CONNECTOR
(Wire side of female terminal)
Is there continuity?
YES
- Replace the PCM with a new one, and
recheck.
NO
- • Open circuit in Yellow wire.
• Open circuit in Green/red wire.
14-43
DRIVETRAIN SYSTEM
GEAR POSITION SWITCH
INSPECTION
Turn the ignition switch OFF.
Disconnect the PCM 33P (Black) connector (page 216).
Check for continuity between each gear position
switch wire terminal of the PCM connector and
ground.
PCM 33P (BLACK) CONNECTOR (Wire side
of female terminal)
A16
A25
A24
There should be continuity only at the terminals that
correspond to the gearshift lever positions shown
below, and there should be no continuity at the
other terminals.
You must test each of the three wires in each gearshift lever position. Therefore, you need to make 9
tests, between each gear position switch wire terminal and ground.
If the test result is abnormal, disconnect the gear
position switch 3P (Natural) connector.
Perform the continuity test at the 3P (Natural) connector in the same manner (page 14-44).
Color
Position
Light
blue/
white
DRIVE
NEUTRAL
REVERSE
o-
Light
green
o
Gray
GND
-o
-o
If the test result at the PCM is abnormal and the
one at the 3P connector is normal, check for open
or short circuit, or loose or poor connector contact.
If the both test results are abnormal, replace the
gear position switch.
3P(NATURAL CONNECTOR
REPLACEMENT
Remove the following:
- seat (page 3-4)
- right side cover (page 3-5)
- left fuel tank side cover (page 3-7)
Disconnect the gear position switch 3P (Natural)
connector.
Release the gear position switch wire from the
clamps.
3P(NATURAL CONNECTOR
14-44
DRIVETRAIN SYSTEM
Shift the sub-transmission into neutral.
Remove the two bolts and the gear position switch
from the crankcase cover.
GEAR POSITION SWITCH
Coat a new O-ring with engine oil and install it onto
a new gear position switch.
Align the long end of the switch pin with the " N "
mark.
Install the gear position switch by aligning the
switch pin with the slot in the crankcase cover being
careful not to damage the switch pin.
Install the bolts and tighten them.
Route the gear position switch wire properly (page
1-20).
GEARSHIFT SWITCH
NOTE.
• The A/T can shift and the meter indicates the
shift position (1 through 3) with the following
conditions:
- Mode select switch at ESP (Electric Shift Program)
- Gearshift lever in D range
- Ignition switch turned ON
INSPECTION
Turn the ignition switch OFF.
Disconnect the PCM 33P (Black) connector (page 216).
NOTE:
• When reconnecting the PCM 33P connector,
check that there is no dirt and oil in the connector.
Check for continuity between the PCM connector
terminals in each switch position.
PCI/I33P(B LACK) corsINECTOR (Wire sicie
jrminal)
off
P
A6
[email protected]

 "
i
[
i
Continuity should exist between the color coded
wires as follows:
Perform the continuity test at the 10P (Green) connector in the same manner (page 14-45).
1
y
J
]
/
/
A5
If the test result is abnormal, remove the right inner
fender (page 3-9).
Disconnect the left handlebar switch 10P (Green)
connector.
v
DOWN
^Color White/ White/ White/ White/
yellow red
Positioft blue red
Up
Free
Down
o - -o
o- —o
14-45
DRIVETRAIN SYSTEM
If the test result at the PCM is abnormal and the
one at the 10P (Green) connector is normal,
check for open or short circuit, or loose or poor
connector contact.
If the both test results are abnormal, replace the
handlebar switch (gearshift switch).
DRIVE MODE SELECT SWITCH
INSPECTION
Turn the ignition switch OFF.
Disconnect the PCM 33P (Black) connector (page 216).
PCM 33P (BLACK) CONNECTOR
(Wire side of female terminal)
Green
Black/blue
NOTE:
• When reconnecting the PCM 33P connector,
check that there is no dirt and oil in the connector.
Check for continuity between the PCM connector
terminals in each switch position.
TOOL:
Test probe
07ZAJ-RDJA110
Continuity should exist between the color coded
wires as follows:
A18
PCM 5P (BLACK) CONNECTOR
(Wire side of female terminal)
If the test result is abnormal, remove the right inner
fender (page 3-9).
Disconnect the drive mode select switch 3P (Black)
connector.
Perform the continuity test at the 3P (Black) connector in the same manner (page 14-46).
Color Blue/ Black/
Green
Position  orange green
ESP
o
•o
D
If the test result at the PCM is abnormal and the
one at the 3P (Black) connector is normal, check
for open or short circuit, or loose or poor connector contact.
If the both test results are abnormal, replace the
drive mode select switch.
3P BLACK CONNECTOR
14-46
DRIVETRAIN SYSTEM
SHIFT VALVE BODY
NOTICE
Do not drop or strike the solenoid valves when servicing. Excessive shock may damage the solenoid
valve.
EMERGENCY VALVE FUNCTION
NOTE:
• The emergency valve is used when the hydraulic
pressure is shut off by the faulty A/T clutch pressure control solenoid (stuck; mechanical lock),
and the vehicle is hindered from running. Open
the bypass oil circuit manually to supply hydraulic pressure (In this case, the transmission will be
fixed in the 2nd range and the vehicle creeps during idling.)
• The stopper bolt that operates the emergency
valve is secured with the lock plate. When trouble occurs, remove the lock plate and turn the
stopper bolt all the way in to activate the emergency valve.
STOPPER BOLT
REMOVAL
Remove the following:
-
Clean around the
valve body with
compressed air to
remove dust, dirt
and foreign
material.
left engine side cover (page 3-17)
left front mud guard (page 3-8)
left inner fender (page 3-9)
wire clip
two setting bolts
valve body cover
shift solenoid valve 2P (Black and Brown) con- '
nectors
A/T clutch pressure control 2P (Black) connector
SHIFT SOLENOID CONNECTORS
A/T CLUTCH PC SOLENOID CONNECTOR
14-47
DRIVETRAIN SYSTEM
six bolts (small head)
shift valve body assembly
If the valve body
will be
disassembled,
loosen the six
solenoid valve bolts
and four sealing
bolts (large head;
gold). Place a shop
towel under the
valve body.
-
gasket
four oil joint collars
O-rings
JOINT COLL4RS/O-RINGS
DISASSEMBLY/INSPECTION
NOTE:
• Keep dust and dirt away from all the parts.
• Take care not to damage the mating surfaces of
the valve bodies.
The emergency SOLENOID AND EMERGENCY VALVES
valve is built in the Remove the following from the valve body cover:
A/T clutch pressure
control solenoid. - bolts
-
shift solenoid valve A and B (by pulling out of the
body cover)
screw and lock plate
four bolts and A/T clutch pressure control solenoid assembly
rubber seal (from the valve body)
A/T clutch pressure
control solenoid
Use a hand- Connect a pressure pump to the input port (filter
operated air pump side) of the shift solenoid valve.
only. Do not use a
high pressure air
Connect a 12 V battery to the solenoid valve
short the positive terminals and check for air flow conditions (do not
and negative use a thin wire because a large amount of current
terminals. flows).
-
valve A: Yellow/black (+) - Green/white (-)
valve B: Yellow/green (+) - Green (-)
Air should not flow (the pressure should maintained) while the battery is connected, and should
flow out of the output ports that goes to the shift
valve when the battery is disconnected.
14-48
SCREW AND
LOCK PLATE
11
J
T
OUTLET PORTS
INLET PORT
DRIVETRAIN SYSTEM
Be careful not to Connect the 12 V battery positive terminal to the
short the positive Yellow/red terminal and negative terminal to the
and negative Blue/red terminal of the A/T clutch pressure control
terminals. solenoid 2P (Black) connector, and check the spool
valve through the oil passages for operation.
The valve should move to away from the solenoid
side when the battery is connected, and should
return by spring force when the battery is disconnected.
SPOOL VALVE
Remove the following from the linear solenoid
assembly:
-
valve stopper bolt
emergency valve
valve spring
Blow through all the
oil passages Wash all the parts with a high flash point or nonthoroughly flammable solvent and blow dry them with com(including solenoid pressed air to clean completely.
valves).
Check the emergency valve and valve bore for scoring, scratch or abnormal wear.
SPRING
EMERGENCY VALVE
STOPPER BOLT
ORIFICE CONTROL AND SHIFT VALVES
Remove the following:
-
four bolts
orifice control valve body
ORIFICE CONTROL VALVE BODY
-
separator plate
shift valve body
SHIFT VALVE BODY
14-49
DRIVETRAIN SYSTEM
-
separator plate
two dowel pins
four sealing bolts and washers
PLATE
BOLTS AND
WASHERS
DOWEL PINS
Remove the following from the orifice control valve
body:
-
spring seats
valve springs
orifice control valves (2nd and 3rd)
ORIFICE CONTROL
VALVE (2nd)

SPRING
SPRING
SEAT
Remove the following from the shift valve body:
-
ORIFICE CONTROL
VALVE (3rd)
SHIFT VALVE (1-2)
spring seats
valve springs
shift valves (1-2 and 2-3)
Blow through all the Wash all the parts with a high flash point or nono/7passages flammable solvent and blow dry them with comthoroughly. pressed air to clean completely.
Check the spool valves (orifice control and shift
valves) and valve bores for scoring, scratch or
abnormal wear.
SPRING
SEAT
14-50
SHIFT VALVE (2-3)
DRIVETRAIN SYSTEM
ASSEMBLY
NOTE:
• Before assembly, clean all the parts with compressed air. Make sure that there is no dust or lint on
any parts.
A/T clutch
pressure control
solenoid
VALVE SPRING
EMERGENCY VALVE
STOPPER BOLT
SCREW
LOCK PLATE
VALVE BODY COVER
SHIFT VALVE BODY
SHIFT SOLENOID
VALVE B

~
SHIFT SOLENOID VALVE A
SHIFT VALVE (1-2)
VALVE SPRING
SPRING
SEAT
ORIFICE CONTROL
VALVE (2nd)
VALVE SPRING
ORIFICE CONTROL VALVE BODY
SPRING
SEAT
ORIFICE CONTROL
VALVE (3rd)
SHIFT AND ORIFICE CONTROL VALVES
Apply engine oil to the outer surface of the spool
(shift and orifice control) valves.
SHIFT VALVE/SPRING
Install the spring Insert each shift valve (1-2 and 2-3) and spring into
seats with the slit the shift valve body and secure it with the spring
facing away from seat.
the orifice control
valve body (page
14-51).
SHIFT VALVE BODY
14-51
DRIVETRAIN SYSTEM
Install the spring Insert each orifice control valve (2nd and 3rd) and
seats with the slit spring into the shift valve body and secure it with
facing away from the spring seat.
the shift valve body
(page 14-51).
ORIFICE CONTROL VALVE BODY
CONTROL
VALVE/
SPRING
SPRING SEAT
Install the four sealing bolts with new sealing washers.
VALVE BODY
PLATE
Install the following onto the valve body cover:
-
dowel pins
separator plate
shift valve body
BOLTS AND
WASHERS
BODY
COVER
Install the following onto the shift valve body:
-
separator plate
orifice control valve body
PLATE
Install the four valve body bolts and tighten them
securely.
Tighten the four sealing bolts.
14-52
SEALING BOLTS
DRIVETRAIN SYSTEM
SOLENOID AND EMERGENCY VALVES
Coat a new O-ring with engine oil and install it into
the stopper bolt groove.
Apply engine oil to the emergency valve.
SCREW
LOCK PLATE
STOPPER BOLT
Install the spring and emergency valve into the A/T
clutch pressure control solenoid body with the concave head end portion of valve facing in.
Install the valve stopper bolt and screw it in until the
groove edge is aligned with the valve body surface.
Install the lock plate and screw as shown.
Coat a new rubber seal with engine oil and install it
into the groove in the A/T clutch pressure control
solenoid body.
Install the A/T clutch pressure control solenoid
assembly with the four bolts.
A/T CLUTCH
PRESSURE
CONTROL
SOLENOID
BOLTS
Coat new O-rings with engine oil and install them
into the grooves in each shift solenoid valve.
Do not interchange
A and B.
B (Brown)
A (Black)
Install the shift solenoid valve A and B with the
bolts.
Tighten the six solenoid valve bolts and lock plate
screw securely.
SCREW
INSTALLATION
Clean the mating surface of the valve body assembly and front crankcase cover.
Coat new O-rings with engine oil and install them
into the grooves in the oil joint collars.
Install the four joint collars and a new gasket.
JOINT COLLARS/O-RINGS , *W'
14-53
DRIVETRAIN SYSTEM
Install the shift valve body assembly with the six
bolts and tighten them securely.
BOLTS
Connect the solenoid valve 2P (Black and Brown) '
connectors.
Connect the A/T clutch pressure control 2P (Black)
connector.
SHIFT SOLENOID CONNECTORS
A/T CLUTCH PC SOLENOID
CONNECTOR (long wire)
Install the valve body cover with the two setting
bolts and tighten them.
Install the wire clip over the wire harness and into
the body cover.
Perform the transmission oil pressure check, if necessary (page 14-12).
Install the following:
-
inner fender (page 3-9)
front mud guard (page 3-8)
engine side cover (page 3-17)
FRONT CRANKCASE COVER
REMOVAL
Remove the following:
-
front mud guards (page 3-8)
inner fenders (page 3-9)
front center grille (page 3-10)
center mud guards (page 3-7)
engine side covers (page 3-17)
engine guard (page 3-17)
front propeller shaft (page 8-6).
water pump (page 7-14)
shift valve body (page 14-47)
OILPIPCS
oil pipes (by removing each joint bolt)
O-rings
O-RINGS
14-54
DRIVETRAIN SYSTEM
pipe setting cap and O-ring
oil feed pipe C
pipe setting collar (by pulling it out with a needle
nose pliers) and O-rings
SETTING COLLAR
SETTING CAP
-
oil feed pipe B and O-ring
CRANKCASE
SETTING CAP
SETTING COLLAR
O-RING
fourteen bolts
side cover stays and hose guide
front crankcase cover
two oil joint pipes and O-rings
oil orifice and O-rings
two dowel pins
14-55
DRIVETRAIN SYSTEM
CLEANING/INSPECTION
Remove the following:
OIL PIPE JOINT
- oil filter (page 4-12)
- dipstick
- sealing bolts and washers
- three bolts and oil pipe joint
Wash the crankcase cover with solvent and blow
through all the passages with compressed air to
clean them thoroughly.
DIPSTICK
The feed pipes are
supplying engine oil
to each shift clutch;
A: 1st, B: 2nd and
C: 3rd.
Check the feed pipe A, B and C for abnormal wear or
damage.
The hydraulic oil in
the torque
converter is
supplied through
the crankshaft.
Check the crankshaft seal collar behind the bearing
for abnormal wear or damage.
BOLTS AND WASHERS
For replacement, see page 14-56.
BEARING REPLACEMENT
Remove the crankshaft bearing using the special
tools.
TOOLS:
Bearing remover, 17 mm
Remover handle
Remover weight
CRANKSHAFT BEARING
OIL SEAL
BEARING PEMOVER
OUTPUT SHAFT
BEARING
07936-3710300
07936-3710100
07741-0010201 or
07936-371020A or
07936-3710200
(U.S.A. only)
Remove the output shaft oil seal.
Drive the output shaft bearings out of the crankcase
cover.
14-56
DRIVETRAIN SYSTEM
Remove the snap ring and washer, and the seal collar.
Coat a new O-ring with engine oil and install it into
the groove in a new collar.
Be careful not to Install the collar until it is seated. Install the washer
damage the inner and the snap ring into the cover groove properly.
surface of the
collar.
Drive a new bearing in with the marked side facing
up.
TOOLS:
Crankshaft bearing:
Driver
Attachment, 42 x 47 mm
Pilot, 17 mm
07749-0010000
07746-0010300
07746-0040400
Output shaft bearing:
Driver
Attachment, 42 x 47 mm
Pilot, 25 mm
07749-0010000
07746-0010300
07746-0040600
ATTACHMENT/PILOT
INSTALLATION
Blow through the oil passage in the crankcase cover
with compressed air.
OIL PIPE JOINT
Clean the crankcase and cover mating surfaces.
Install the following if they were removed:
-
sealing bolts with new washers
oil pipe joint with a new O-ring
dip stick
oil filter (page 4-12)
BOLTS AND WASHERS
Apply engine oil to the lips of a new oil seal, and
install it into the crankcase cover until it is fully
seated.
14-57
DRIVETRAIN SYSTEM
Coat new O-rings with engine oil and install them
onto the joint pipe.
Install the joint pipes into the oil pump.
Apply liquid sealant (Three Bond 1215 or equivalent) to the mating surface of the crankcase cover.
Blow the oil orifice with compressed air to clean the
passage.
Coat new O-rings with engine oil and install them
into the orifice groove.
Install the oil orifice with the stepped side facing
out.
Install the two dowel pins.
14-58
DRIVETRAIN SYSTEM
Install the following:
-
CRANKCASE COVER
front crankcase cover
14 bolts with the side cover stays and hose guide
Make sure the
mating surfaces Tighten the bolts in a crisscross pattern in several
touch evenly, there steps securely.
should be no
clearance between
the cover and
crankcase.
BOLTS
STAYS
Coat a new O-ring with engine oil and install it onto
the flange of the feed pipe B.
Apply engine oil to the outer surface of pipe B.
Align the flange Carefully insert pipe B into the crankcase cover
tabs with the while turning it slowly to avoid damaging the oil
grooves in the seal in the crankcase.
cover.
Coat new O-rings with engine oil and install them
into the setting collar grooves.
Install the setting collar until it is seated.
O-RINGS
Apply engine oil to the outer surface of feed pipe C.
Align the flange Insert pipe C while turning it slowly to avoid damagtabs with the ing the O-ring in the setting collar.
grooves in the C o g t g n e w o . r j n g w j t h engine oil and install it into
collar
the setting cap groove.
Install the setting cap and tighten it.
TORQUE: 21 N-m (2.1 kgf-m, 15 Ibf-ft)
PIPEC
SETTING CAP
14-59
DRIVETRAIN SYSTEM
Coat new O-rings with engine oil and install them
into the oil pipe grooves.
Connect the pipe B Connect the oil pipes with the bolts and tighten
(flange lug) to the them securely.
front side
Install the following:
-
shift valve body (page 14-53)
water pump (page 7-15)
front propeller shaft (page 8-10)
engine side covers (page 3-17)
center mud guards (page 3-7)
front center grille (page 3-10)
inner fenders (page 3-9)
front mud guards (page 3-8)
TORQUE CONVERTER REMOVAL
Remove the front crankcase cover (page 14-54).
Be careful not to Unstake the lock nut.
damage the
Loosen the lock nut while holding the converter
crankshaft threads.
boss with an open end wrench (width across flats:
32 mm).
Remove the lock nut and washer.
Remove the torque converter assembly using the
special tools.
TOOL:
Puller, 35 x 1.0 mm
07933-HA80000 or
07933-HB3000A
(U.S.A. only)
Remove the following:
-
stator shaft (while turning it counterclockwise)
needle bearings
| STATOR SHAFT
14-60
DRIVETRAIN SYSTEM
washers
inner collar
needle bearings
THRUSTNEEDLE
BEARING
TORQUE CONVERTER INSPECTION
NOTE:
• Replace the torque converter as an assembly
(from converter to inner collar).
Check the primary drive gear teeth for abnormal
wear or damage.
Hold the torque converter and turn the drive gear to
check the one-way clutch in the torque converter.
The gear should turn counterclockwise smoothly
and should not turn clockwise.
DRIVE GEAR
Check the needle bearings for abnormal wear or
damage.
Check the one-way clutch sprag in the stator shaft
for abnormal wear, damage or irregular movement.
Check the sprag contacting surface for abnormal
wear or damage.
STATOR SHAFT
INNER COLLAR
14-61
DRIVETRAIN SYSTEM
Check the seal ring on the stator shaft for abnormal
wear or damage.
Assemble the stator shaft and inner collar.
Hold the inner collar and turn the stator shaft.
The shaft should turn counterclockwise smoothly
and should not turn clockwise.
SHIFT CLUTCH/MAINSHAFT
DISASSEMBLY
NOTE:
• For 2nd/3rd shift clutch (countershaft)
mainshaft removal (page 13-2).
and
1st SHIFT CLUTCH REMOVAL
Remove the torque converter (page 14-60).
Be careful not to
damage the
mainshaft threads.
Unstake the lock nut.
Loosen the lock nut while holding the driven geai
boss with an open end wrench (width across flats;
29 mm).
Remove the following:
-
14-62
lock nut
washer
1st shift clutch assembly
DRIVETRAIN SYSTEM
-
washer
M1 gear guide
O-rings
1st SHIFT CLUTCH DISASSEMBLY
Remove the following from the clutch drum:
-
DRIVEN GEAR
primary driven gear
O-rings
stopper ring
end plate
STOPPER RING
END PLATE
-
three clutch discs and plates
wave spring
WAVE SPRING
Remove the return spring and clutch piston (page
14-65).
CLUTCH PLATES
CLUTCH DISCS
14-63
DRIVETRAIN SYSTEM
2nd/3rd SHIFT CLUTCH AND
MAINSHAFT DISASSEMBLY
Remove the countershaft (2nd/3rd shift clutch) and
mainshaft (page 13-7).
C3GEAR
C2 GEAR
Remove the end washers with a screwdriver and
disassemble the countershaft:
-
C1 gear
thrust washer
C2 gear
bearing
lock washer
C3gear
bearing
thrust washer
2nd/3rd shift clutch assembly
O-rings
C1 GEAR
SHIFT CLUTCH ASSEMBLY
END WASHER
LOCK WASHER
THRUST WASHER
i
THRUST WASHER
END WASHER
BEARING
Remove the following from each clutch drum:
-
stopper ring
end plate
END PLATE
-
three clutch discs and plates
wave spring
WAVE SPRING
Remove the return spring and clutch piston (page
14-65).
CLUTCH PLATES
CLUTCH DISCS
14-64
DRIVETRAIN SYSTEM
CLUTCH PISTON REMOVAL
Install the following special tools onto the shift
clutch.
COMPRESSOR BOLT
ATTACHMENTS
(07LAE-PX40100)
TOOLS:
Clutch compressor attachment 07LAE-PX40100
(2 required)
Compressor bolt assembly
07GAE-PG40200 or
07GAE-PG4020A
(U.S.A. only)
If either support
block end of the
special tool is set
over an area of the
spring retainer
which is
unsupported by the
return spring, the
retainer may be
damaged.
NOTE:
• Be sure the special tool is adjusted to have full
contact the stepped areas with the spring
retainer.
SUPPORT
BLOCKS
RETAINER
To prevent loss of Compress the return spring by tightening the nut.
spring tension, do
Remove the snap ring from the boss.
not compress more
than necessary. Loosen the special tool and remove the following:
-
SNAP RING
snap ring
spring retainer
return spring
RETAINER
SPRING
Wrap a shop towel around the clutch drum. Apply
air pressure to the oil hole while closing the other
holes with your finger to remove the clutch piston.
Remove the O-rings from the piston.
Clean all the parts of the shift clutch in solvent thoroughly and blow dry them with compressed air.
14-65
DRIVETRAIN SYSTEM
MAINSHAFT DISASSEMBLY
Remove the mainshaft (page 13-7).
M3 GEAR
Disassemble the mainshaft:
-
M2GEAR
M1 gear
bearing
washer
M3 gear
snap rings
M2 gear
M1 GEAR
SNAP RINGS
WASHER
BEARING
INSPECTION
MAINSHAFT
The M1 gear Check each gear tooth and bearing for abnormal
bearing has one wear or damage.
roller missing from C h e c | < t h f i QJ| h o | e s j n t h e m a i n s h a f t f o r d
M3GEAR
M2 GEAR
each cage by
design.
M1 GEAR
SNAP RINGS
WASHER
/
BEARING
CLUTCH DRUM AND PISTON
Check the clutch drum for nicks, indentations or
abnormal wear made by the clutch plates.
CHECK VALVE
Check the oil holes in the drum boss and check
valve in the piston for clogs.
CLUTCH DRUM
PISTON
CLUTCH DISC AND PLATE
Replace the clutch Check the linings of the clutch discs for wear (disc
discs and plates as groove disappearance).
a set.
Check the clutch plates for discoloration.
DISC
14-66
DRIVETRAIN SYSTEM
CLUTCH RETURN SPRING
Measure the spring free length.
SERVICE LIMIT: 31.8 mm (1.25 in)
SHIFT CLUTCH/MAINSHAFT
ASSEMBLY
MAINSHAFT ASSEMBLY
Blow through the oil passages in the mainshaft with
compressed air.
I
M2 GEAR
Apply engine oil to the each gear teeth and bearing.
Install the snap ring Install the following onto the mainshaft:
and washer with
- M2 gear
the chamfered
- snap rings (so that its end gap aligns with the
(rolled) edge facing
groove in the splines)
away from the
- M3 gear (with the ribs facing out)
thrust load.
M3 GEAR
RIBS
SNAP RINGS
The Ml gear - washer
bearing has one - bearing
roller missing from - M1 gear
each cage by
Make sure the snap rings are fully seated in the
design.
shaft grooves.
M1 GEAR
Install the mainshaft assembly with the countershaft
(2/3 shift clutch) (page 13-10).
WASHER
BEARING
14-67
DRIVETRAIN SYSTEM
SHIFT CLUTCH ASSEMBLY
1st SHIFT CLUTCH
CLUTCH PLATES (3 pcs)
CLUTCH DISCS (3 pcs)
END PLATE
STOPPER RING
RETURN SPRING
PRIMARY DRIVEN GEAR
SPRING RETAINER
O-RINGS
CLUTCH PISTON
SNAP RING
2nd/3rd SHIFT CLUTCH
CLUTCH DRUM
O-RINGS
CLUTCH PISTON
WAVE SPRING
CLUTCH PLATES (3 pcs)
CLUTCH DISCS (3 pcs)
END PLATE
RETURN SPRING
SPRING RETAINER
SNAP RING
STOPPER RING
14-68
DRIVETRAIN SYSTEM
All shift clutches Clean the inner surface of the clutch drum thorDRUM
(1st, 2ndand3rd) oughly and blow through the oil holes in the drum
use the following boss and check valve in the piston.
proce ure. ^pp|y e n g | n e o j | t 0 n e w O-rings and install them
into the piston groove.
Place the clutch piston into the clutch drum in the
direction shown.
Be careful not to Install the piston while turning it to ensure proper
PISTON
pinch the O-rings seating.
with too much
force.
Place the following into the clutch drum.
-
SPECIAL TOOLS
return spring
spring retainer
snap ring
Install the special tools while adjusting their position carefully (page 14-65).
To prevent loss of Compress the return spring by tightening the nut.
spring tension, do
not compress more
than necessary.
SPRING
RETAINER
SNAP RING
Align the end gap Install the snap ring into the groove in the drum
with the groove (3 boss properly.
places) in the spring
Loosen the special tools and remove them.
retainer.
SNAP RING
14-69
DRIVETRAIN SYSTEM
Install the wave spring into the piston groove.
WAVE SPRING
Coat the clutch discs with clean engine oil.
Install the three clutch plates and discs alternately,
starting with the plate.
Install the end plate with the stepped side facing
out.
STOPPER RING
Install the stopper ring into the drum grooves properly.
Perform the initial clearance inspection (page 1470).
END PLATE
CLUTCH INITIAL CLEARANCE CHECK
Assemble the shift clutch.
Measure the clearance between the end plate and
top disc.
Set a dial indicator on the end plate with the plate is
lowered.
Lift the end plate up against the stopper ring and
read the clearance, and record it.
Perform this inspection at the three points from
120° apart.
STANDARD: 0.7 - 0.9 mm (0.03 - 0.04 in)
If the clearance is not within the standard value,
replace the end plate with a new one as follows.
Remove the stopper ring and end plate.
Measure the flange thickness of the end plate at
several points and record it.
Calculate the new plate thickness using the equation below. Choose a new plate as close to this
dimension as possible.
A = (B-0.8) + C
A: New plate thickness
B: Recorded clearance
C: Old plate thickness
14-70
END PLATE
DRIVETRAIN SYSTEM
If the calculated Select the end plate, and install it and the stopper
dimension is over ring drum grooves properly.
the thickest plate
1st CLUTCH
2nd/3rd CLUTCH
thickness, replace
Mark Thickness Mark Thickness
the clutch discs and
plates as a set.
1
2.1 mm
1
2.3 mm
2
3
4
5
6
7
8
9
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
mm
mm
mm
mm
mm
mm
mm
mm
2
3
4
5
11
12
13
14
15
16
2.6 mm
2.9 mm
3.2 mm
3.5 mm
2.15 mm
2.45 mm
2.75 mm
3.05 mm
3.35 mm
3.65 mm
2nd/3rd shift clutch: Install the countershaft and transmission gears
(page 14-71).
1st shift clutch: Install the primary drive gear (page 14-72).
COUNTERSHAFT ASSEMBLY (2nd/3rd Shift Clutch)
Blow through the oil passages in the countershaft
with compressed air.
O-RINGS
Coat new O-rings with engine oil and install them
into the shaft grooves as shown.
Install the countershaft into the shift clutch by aligning the splines.
Apply engine oil to the gear teeth and the bearings
and assemble the countershaft.
NOTE:
• Install the washer with the chamfered (rolled)
edge facing away from the thrust load.
• Align the lock washer groove with the tabs on
the clutch drum boss.
C2 GEAR
LOCK WASHER
THRUST WASHER
C1 GEAR
END WASHER
END WASHER
C3 GEAR
NEEDLE BEARING
THRUST WASHER
2nd/3rd SHIFT CLUTCH ASSEMBLY
Install the countershaft assembly with the mainshaft
(page 13-10).
14-71
DRIVETRAIN SYSTEM
PRIMARY DRIVEN GEAR INSTALLATION (1st Shift
Clutch)
Blow through the oil holes in the driven gear boss
with compressed air.
DRIVEN GEAR
Coat new O-rings with engine oil and install them
into the boss grooves.
Install the primary driven gear into the shift clutch
until it is fully seated.
Install the 1st shift clutch assembly (page 14-72).
SHIFT
CLUTCH
1st SHIFT CLUTCH INSTALLATION
Install the following:
-
M1 gear guide (apply engine oil to the gear teeth)
washer
new O-rings (apply engine oil)
Line up the tabs of the three clutch discs in the shift
clutch.
Align the disc tabs Carefully install the shift clutch assembly onto the
with the gear guide mainshaft and onto the M1 gear guide until it is fully
teeth, seated (the whole of the shaft threads are exposed).
Apply engine oil to the threads of a new lock nut.
Install the washer and lock nut.
Tighten the lock nut while holding the driven gear
boss with an open end wrench (width across flats:
29 mm).
TORQUE: 108 N m (11.0 kgf-m, 80 Ibf-ft)
Be careful not to Stake the lock nut into the shaft groove.
damage the | n s t a | | t h e torque
converter H(page
14-73).
M
a
mainshaft threads.
14-72
DRIVETRAIN SYSTEM
TORQUE CONVERTER INSTALLATION
Apply engine oil to the bearings, gear teeth and clutch sprag.
INNER COLLAR
WASHERS
STATOR SHAFT
TORQUE CONVERTER
Install the needle bearing into the inner collar.
Install the inner collar and onto the crankshaft by
aligning the cutout with the stopper pin.
THRUSTNEEDLE
BEARING
Install the thrust needle bearing onto the inner collar with the needle roller side facing in.
Install the washers.
WASHER
•mmmmmmi
Install the three bearings onto the stator shaft.
NEEDLE BEARINGS
14-73
DRIVETRAIN SYSTEM
Install the stator shaft while turning it counterclockwise.
Install the torque converter, aligning the splines P-TORQUE CONVERTER
carefully.
Install the washer.
Apply engine oil to the threads of a new lock nut.
Install the lock nut and tighten it while holding the
converter boss with an open end wrench (width
across flats: 32 mm).
TORQUE: 108 N m (11.0 kgf m, 80 ibf-ft)
Be careful not to Stake the lock nut into the crankshaft groove.
damage the {nstM t h e f r o n t c r a n | < c a s e c o v e r ( p a g e 14.57)
crankshaft threads.
14-74
a
15. FRONT WHEEL/SUSPENSION/STEERING
SYSTEM COMPONENTS
15-2
SERVICE I N F O R M A T I O N
••••• 15-3
TIRES
15-11
WHEEL HUB AND KNUCKLE-
•15-15
TROUBLESHOOTING
15-5
FRONT SHOCK ABSORBER
•15-22
HANDLEBAR
15-6
SUSPENSION ARM-
•15-23
•15-28
THROTTLE HOUSING
15-10
STEERING SHAFT
FRONT WHEEL
15-11
TIE-ROD
•
15-33
15-1
FRONT WHEEL/SUSPENSION/STEERING
SYSTEM COMPONENTS
32 N-m (3.3 kgf-m, 24
44 N-m (4.5 kgf
34 N-m (3.5 kgf-
44 N-m (4.5
29 N-m (3.0 kgf-m
78 N-m (8.0 kgf-m, 58 Ibfft)
64 N-m (6.5 kgf-m, 47 Ibfft)
15-2
FRONT WHEEL/SUSPENSION/STEERING
SERVICE INFORMATION
GENERAL
• A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc
with a high quality brake degreasing agent.
A jack or other support is required to support the vehicle.
Adjust toe whenever the tie-rod, knuckle or steering shaft are replaced or removed (page 4-23).
Do not twist or bend the brake hose and pipe when serving.
Use genuine Honda replacement bolts and nuts for all suspension pivots and mounting points.
For brake system information (page 17-2).
For handlebar switch inspection (page 23-7).
SPECIFICATIONS
ITEM
Minimum tire tread depth
Cold tire pressure
Standard
Minimum
Maximum
With cargo
Tie-rod distance between the ball joints
Toe
STANDARD
30 kPa (0.30 kgf/cm2, 4.4 psi)
26 kPa (0.26 kgf/cm2, 3.8 psi)
34 kPa (0.34 kgf/cm2, 5.0 psi)
30 kPa (0.30 kgf/cm2, 4.4 psi)
387.5 ± 1 mm (15.26+ 0.4 in)
Toe-out: 10.9+15 mm (7/16 ±9/16 in)
SERVICE LIMIT
4 mm (0.16 in)
-
TORQUE VALUES
Handlebar lower holder nut
Front wheel nut
Front wheel hub nut
39 N-m (4.0 kgf-m, 29 Ibf-ft)
64 N-m (6.5 kgf-m, 47 Ibf-ft)
78 N-m (8.0 kgf-m, 58 Ibf-ft)
Front brake caliper bracket flange
bolt
Front brake disc bolt
Front brake splash guard flange bolt
Shock absorber mounting nut
Brake hose clamp flange bolt
Upper arm pivot nut
Lower arm pivot nut
Upper and lower arm ball joint nut
44 N-m (4.5 kgf-m, 33 Ibf-ft)
Tie-rod stud joint nut
Combination meter stay mounting
nut
Steering shaft end nut
Steering shaft holder bolt
Parking lock lever screw
Rear brake lever pivot bolt
Rear brake lever pivot nut
Parking stopper stay screw
Brake light switch (left lever side)
42 N-m (4 3 kgf-m, 31
11 N-m(1 1 kgf-m, 8
44 N-m (4 ,5 kgf-m, 33
12 N-m (1 ,2 kgf-m, 9
34 N-m (3. 5 kgf-m, 25
44 N-m (4. 5 kgf-m, 33
29 N-m (3. 0 kgf-m. 21
Ibf-ft)
Ibf-ft)
Ibf-ft)
Ibf-ft)
Ibf-ft)
Ibf-ft)
Ibf-ft)
54 N-m (5.5 kgf-m, 40 Ibf-ft)
25 N-m (2.5 kgf-m, 18 Ibf-ft)
108 N-m (11.0 kgf-m, 80 Ibf-ft)
32 N-m (3.3 kgf-m, 24 Ibf-ft)
7 N-m (0.7 kgf-m, 5.1 Ibf-ft)
1 N-m (0.1 kgf-m, 0.7 Ibf-ft)
6 N-m (0.6 kgf-m, 4.3 Ibf-ft)
2 N-m (0.2 kgf-m, 1.4 Ibf-ft)
1 N-m (0.1 kgf-m, 0.7 Ibf-ft)
Lock nut: replace with a new one.
Castle nut: tighten to the specified torque
and further tighten until its grooves aligns
with the cotter pin hole.
ALOC bolt: replace with a new one
ALOC bolt: replace with a new one
ALOC bolt: replace with a new one
Lock nut: replace with a new one.
Lock nut: replace with a new one.
Lock nut: replace with a new one.
Castle nut: tighten to the specified torque
and further tighten until its grooves aligns
with the cotter pin hole.
Lock nut: replace with a new one.
Apply locking agent
15-3
FRONT WHEEL/SUSPENSION/STEERING
TOOLS
Attachment, 42 x 47 mm
07746-0010300
Attachment, 52 x 55 mm
07746-0010400
Attachment, 22 x 24 mm
07746-0010800
Attachment, 20 mm I.D.
07746-0020400
Pilot, 30 mm
07746-0040700
Pilot, 16 mm
07746-0041300
Attachment, 28 x 30 mm
07946-1870100
Compressor bolt assembly
07GAE-PG40200
or 07746-0020300 or 07746-0020200
Driver
07749-0010000
or 07GAE-PG4020A (U.S.A. only)
Oil seal driver
07JAD-PH80101
Clutch compressor attachment
07LAE-PX40100
Ball joint remover, 28 mm
07MAC-SL00201
07ilvlAC-SL0202 (U.S.A.only) or
07IV1AC-SL00200 and
07MAC-SL0A300 (U.S.A.only)
15-4
FRONT WHEEL/SUSPENSION/STEERING
Ball joint remover/installer
07WMF-HN00100
ATV Bead Buster
KLS379024
(U.S.A. only)
TROUBLESHOOTING
Hard steering
• Steering shaft holder too tight
• Damaged steering shaft bearing/bushing
• Insufficient tire pressure
Steers to one side or does not track straight
• Incorrect wheel alignment
• Unequal tire pressure
• Bent tie-rod, suspension arm or frame
• Worn or damaged knuckle bearing
• Weak shock absorber
Front wheel wobbling
• Bent rim
• Worn or damaged knuckle bearing
• Faulty tire
• Wheel hub nut not tightened properly
Soft suspension
• Weak shock absorber spring
• Faulty shock absorber damper
Hard suspension
• Bent shock absorber damper rod
• Improperly installed suspension arms
• Faulty suspension arm bushings
Front suspension noise
• Loose front suspension fasteners
• Damaged suspension components
15-5
FRONT WHEEL/SUSPENSION/STEERING
HANDLEBAR
REMOVAL
Remove the meter covers (page 3-18).
FGA model shown: •
COMBINATION METER
Remove the following:
-
two nuts
combination meter/stay assembly
brake hose (from the hose clamp)
-
three wire bands
WIRE BANDS
Keep the master cylinder upright to prevent air from entering the hydraulic system. -
-
AUSTRALIA type only: -
-
two screws
throttle housing holder
throttle housing
connectors
two bolts
master cylinder holder
brake master cylinder
MASTER CYLINDER
screw
nut
horn switch
HORN SWITCH
15-6
THROTTLE HOUSING
NUT
FRONT WHEEL/SUSPENSION/STEERING
two screws
bracket holder
rear brake lever bracket
three screws
handlebar switch
HANDLEBAR SWITCH
LEVER BRACKET
bolts
grip ends and collars
handlebar grips
GRIP
BOLT/COLLAR/GRIP END
four bolts
upper holders
handlebar
INSTALLATION
Align the punch
mark on the handlebar with the with
the top edge of the
lower holder.
Install the handlebar and upper holders with the
punch marks facing forward. Tighten the front bolts
first, then tighten the rear bolts.
PUNCH MARKS
HANDLEBAR
15-7
FRONT WHEEL/SUSPENSION/STEERING
Apply Honda Bond A or Honda Hand Grip Cement
(U.S.A only) to the inside surface of each handlebar
grip and to the clean surfaces of the handlebar.
Wait 3-5 minutes and install the grips. Rotate the
grips for even application of the adhesive.
GRIP
Install the grip ends with the collars and tighten the
bolts.
BOLT/COLLAR/GRIP END
Align the seam of Install the left handlebar switch, and tighten the
the switch with the inside screw (1) first, then tighten the outside
punch mark on the screws (2).
handlebar.
Align the locating
pin on the bracket
with the hole in the
switch housing.
Install the brake lever bracket and holder with the
punch mark facing up. Tighten the upper screw first,
then tighten the lower screw.
AUSTRALIA type Install the horn switch and tighten the screw and
only: nut.
HORN SWITCH
15-8
" NUT
FRONT WHEEL/SUSPENSION/STEERING
Align the edge of
the master cylinder
with the punch
mark on the handlebar.
Install the brake master cylinder and holder with the
"UP" mark facing up. Tighten the upper bolt first,
then tighten the lower bolt.
HOLDER
TORQUE: 12 N m (1.2 kgf m, 9 Ibf-ft)
Connect the connectors to the brake and brake light
switches.
CONNECTORS
Align the lug on the Install the throttle housing and holder against the
throttle housing master cylinder. Tighten the front screw first, then
with the mating line tighten the rear screw.
of the master cylinder.
LUG
THROTTLE HOUSING
Align
Secure the switch wires with the three wire bands.
Route the wires Install the combination meter/stay and tighten the
and hose properly two nuts.
(page 1-20).
COMBINATION METER
TORQUE: 25 N-m (2.5 kgf m, 18 Ibf-ft)
Install the brake hose into the clamp.
15-9
FRONT WHEEL/SUSPENSION/STEERING
THROTTLE HOUSING
DISASSEMBLY
Remove the following:
-
three screws
throttle housing cover
gasket
BOOT
Slide the boot off the throttle cable adjuster.
Loosen the lock nut and cable adjuster.
Bend down the lock washer tab and remove the following:
-
pivot nut and lock washer
throttle lever and washer
return spring
throttle arm (by disconnecting the throttle cable)
dust seal (from the housing bottom)
ASSEMBLY
Coat a new dust seal lip with grease and install it
into the throttle housing until it is fully seated.
Apply grease to the throttle lever pivot in the housing and to the throttle cable end.
Connect the cable to the throttle arm.
Install the washer onto the throttle lever and insert
the throttle lever into the throttle housing.
Install the throttle arm with the spring over the lever
pivot by aligning the flat surfaces as shown.
Install a new lock washer and the pivot nut, and
tighten it. Bend up the washer tab against the nut.
15-10
WASHER
FRONT WHEEL/SUSPENSION/STEERING
Install the throttle housing cover with a new gasket
and tighten the three screws.
COVER
Adjust the throttle lever free play (page 4-4).
FRONT WHEEL
REMOVAL
Loosen the wheel nuts.
Support the vehicle using a hoist or equivalent and
raise the front wheels off the ground.
Remove the nuts and wheel.
INSTALLATION
NOTE:
• Do not interchange the left and right tires.
Install the wheel with the arrow mark facing in the
normal rotating direction.
Install the wheel nuts and tighten them.
TORQUE: 64 N m (6.5 kgf-m, 47 Ibf-ft)
TIRES
REMOVAL (U.S.A. only)
NOTE.
• This service requires the ATV Bead Buster
(KLS379024).
• Remove and install the tire from the rim side
opposite the valve stem.
Remove the core from the valve stem.
Use a pneumatic tire changer or equivalent to
remove the tire from the rim. If a tire changer is not
available, rim protectors and tire irons may be used.
Adjust the bottom rim supports to the proper rim
size. Align the flat side of the support with the corresponding rim size indicator.
Use only water as a
lubricant when
removing or mounting tires. Soap or
some mounting
lubricants may
leave a slipperly
residue which can
cause the tire to
shift on the rim and
lose tire pressure
during riding.
Lube the bead area of the tire with water, pressing
down on the tire sidewall/bead area in several
places to allow the water to run into and around the
bead.
15-11
FRONT WHEEL/SUSPENSION/STEERING
Place the wheel assembly over the center shaft and
use the correct size cone to keep the wheel centered
during operation.
Install the bottom hold down nut, bearing side
down, and finger tighten it so the wheel can rotate
freely during operation.
Install the breaker arm assembly over the center
shaft and adjust the upper rim supports to fit the
outside rim diameter.
Install the top hold down nut and tighten it finger
tight.
CENTER SHAFT
BREAKER ARM ASSY.
NUT
NUT
UPPER RIM SUPPORTS
Failure to back out Pull the leverage bar down so the breaker shoe is
the breaker shoe just below the rim lip. Turn the crank to fully push
two turns will cause the breaker shoe between the tire bead and rim.
the shoe to scratch Once the shoe contacts the rim, back the crank out
the bead lock, two turns to allow the shoe to clear the rim's bead
which may cause lock.
LEVERAGE BAR
the tire to leak.
Push down on the leverage bar to push the tire bead
over the bead lock. Use only short strokes on the
handle. While the shoe is still engaged, turn the
wheel as far as it will go between strokes as you
break the bead around the rim.
Remove the breaker arm assembly and flip the
wheel over. Install the breaker arm assembly, adjust
the shoe properly and break the other bead by following the above procedures.
Remove the tire from the rim using a tire changing
machine or tire irons and rim protectors.
15-12
LEVERAGE BAR
FRONT WHEEL/SUSPENSION/STEERING
TIRE REPAIR
NOTE:
• Use the manufacturer's instructions for the tire
repair kit you are using. If your kit does not have
instructions, use the procedures described
below.
Check the tire for puncturing objects.
Chalk mark the punctured area and remove the
puncturing objects.
Inspect and measure the injury.
Tire repairs for injuries larger than 15 mm (5/8 in)
should be a section repair.
Section repairs should be done by a professional
tire repair shop.
If the injury is smaller than 15 mm (5/8 in), proceed
with the repair as described here.
Install a rubber plug into the injury as follows:
Apply a cement to a plug inserting needle and work
the needle into the injury to clean and lubricate it.
Do this three times.
Do not let the cement dry.
Insert and center a rubber plug through the eye of
the inserting needle.
Apply cement to rubber plug.
Push the inserting needle with plug into the injury
until the plug is slightly above the tire.
Be careful not to
push the plug all the
way into the tire to
prevent from falling
inside.
Twist the needle and remove it from the tire; the
plug will stay in the tire.
Trim the plug 6 mm (1/4 in) above the tire surface.
Repeat the above procedure if the puncture is large.
Do not use more than two plugs per injury.
Allow the repair to dry. Drying time will vary with air
temperature. Refer to the tire repair kit manufacturer's recommendations.
Inflate the tire and test the seal by dabbing a small
amount of cement around the plug. Escaping air will
cause a bubble in the cement. If there is leakage,
remove the tire (page 15-11) and apply a cold patch
to the inside of the tire.
15-13
FRONT WHEEL/SUSPENSION/STEERING
If a plug has been inserted, trim it even with the
inner tire surface.
Temporarily place a rubber patch that is at least
twice the size of the puncture over the injury. Make
a mark around the patch, slightly larger than the
patch itself.
Rough the area marked inside the tire with a tire
buffer or a wire brush. Clean the rubber dust from
the buffed area.
Apply cement over the area marked and allow it to
dry until tacky.
Do not touch the cement with dirty or greasy hands.
Remove the lining from the patch and center over
the injury.
Press the patch against the injury using a special
roller.
ASSEMBLY
Install the tire onto the rim, where the rim shoulder
width is the narrowest, to simplify installation.
Clean the rim bead seat and flanges.
Use only water as a
lubricant when
removing or mounting tires. Soap or
some mounting
lubricants may
leave a slippery residue which can
cause the tire to
shift on the rim and
lose air pressure
during riding.
Apply clean water to the rim flanges, bead seat and
base.
Install the valve core in the valve stem.
Install the tire with the arrow mark facing in the normal rotating direction.
Inflate the tire to seat the tire bead.
Deflate the tire. Wait 1 hour and inflate the tire to
the specified pressure.
RECOMMENDED TIRE PRESSURE:
FRONT:
Standard:
30 kPa (0.30 kgf/cm2, 4.4 psi)
Minimum: 26 kPa (0.26 kgf/cm2, 3.8 psi)
Maximum: 34 kPa (0.34 kgf/cm2, 5.0 psi)
With cargo: 30 kPa (0.30 kgf/cm2, 4.4 psi)
REAR:
Standard:
25 kPa (0.25 kgf/cm2, 3.6 psi)
Minimum: 22 kPa (0.22 kgf/cm2, 3.2 psi)
Maximum: 28 kPa (0.28 kgf/cm2, 4.0 psi)
With cargo: 25 kPa (0.25 kgf/cm2. 3.6 psi)
Check for air leaks and install the valve cap.
15-14
FRONT WHEEL/SUSPENSION/STEERING
WHEEL HUB AND KNUCKLE
REMOVAL
Remove the front wheel (page 15-11).
BRAKE CALIPER
Support the caliper Remove the following:
so that it does not
mounting bolts
hang from the brake
front brake caliper
hose. Do not twist
or bend the brake
hose.
-
cotter pin
hub nut
wheel hub
WHEEL HUB
-
socket bolts
splash guard
Remove the cotter pin from the tie-rod ball joint
Stud.
Remove the ball joint nut by holding the joint stud
flat surfaces.
15-15
FRONT WHEEL/SUSPENSION/STEERING
Remove the brake disc cover flange bolts and brake
disc cover.
Remove the cotter pins from the ball joint studs.
Loosen the ball joint nuts, but do not remove them
yet.
FLANGE BOLTS
DISC COVER
COTTER PINS, BALL JOINT NUTS
Release the ball joints, using the special tool according to the following instructions.
TOOL:
Ball joint remover, 28 mm
07MAC-SL00201 or
07MAC-SL0202
(U.S.A. only) or
07MAC-SL00200 and
07MAC-SL0A300
(U.S.A. only)
BALL JOINT REMOVER
Apply grease to the ball joint remover at the point
shown.
This will ease installation of the tool and prevent
damage to the pressure bolt threads.
Insert the jaws carefully, making sure that you do
not damage the ball joint boot.
If necessary, apply Adjust the jaw spacing by turning the pressure bolt.
penetrating type
lubricant to loosen
the ball joint.
15-16
Apply grease here
PRESSURE BOLT
FRONT WHEEL/SUSPENSION/STEERING
To prevent the tool from dropping, tie the strap on a
neighboring solid part such as the lower arm, tierod, etc. before operation.
STRAP
• Do not tie the strap on the brake hose, brake
pipe, rubber boot, and other parts that can be
damaged easily.
Once the tool is in place, turn the adjusting bolt as
necessary to make the jaws parallel.
Then hand-tighten the pressure bolt and recheck the
jaws to make sure they are still parallel.
PRESSURE BOLT
Tighten the pressure bolt with a wrench until the
ball joint stud pops loose.
Remove the ball joint nuts and the knuckle from the
upper and lower arms.
ADJUSTING BOLT
INSPECTION
Turn the inner race of the bearing in the knuckle
with your finger. The bearings should turn smoothly
and quietly. Also check that the bearing outer race
fits tightly knuckle.
BEARING
Inspect the knuckle for damage or cracks.
Inspect the ball joint boot for tears or other damage
by moving the ball joint stud.
It should move freely and smoothly.
BOOT
BRAKE DISC REPLACEMENT
Remove the four socket bolts and brake disc from
the wheel hub.
BRAKE DISC
Install a new brake disc with new socket bolts and
tighten the bolts.
TORQUE: 42 N m (4.3 kgf-m, 31 Ibf-ft)
BOLTS
15-17
FRONT WHEEL/SUSPENSION/STEERING
BEARING REPLACEMENT
Remove the dust seals from the knuckle.
DUST SEALS
Remove the snap ring and drive the bearings out of
the knuckle.
TOOLS:
Driver
Attachment, 42 x 47 mm
Pilot, 30 mm
07749-0010000
07746-0010300
07746-0040700
Pack the cavities of a new bearings with grease.
Drive in the bearing squarely with the marked side
facing up until they are fully seated.
TOOLS:
Driver
Attachment, 52 x 55 mm
Pilot, 30 mm
07749-0010000
07746-0010400
07746-0040700
PILOT
Install the snap ring into the knuckle groove with the
chamfered side facing in.
15-18
ATTACHMENT/PILOT
SNAP RING
FRONT WHEEL/SUSPENSION/STEERING
Apply grease to a new outer dust seal lip and install
seal using the same tools until it is flush with the
knuckle end.
OUTER DUST SEAL
Apply grease to the lips of a new inner dust seal and
install seal until it is flush with the knuckle end,
being careful not to damage the lip.
TOOLS:
Driver
Oil seal driver
07749-0010000
07JAD-PH80101
OIL SEAL DRIVER
INNER DUST SEAL
BALL JOINT REPLACEMENT
Remove the snap ring from the ball joint.
SNAP RING
Set the knuckle and special tools with "A" mark side
of the remover/installer facing to the ball joint in the
vise as shown.
Press the ball joint out of the knuckle.
TOOLS:
Ball joint remover/installer
Attachment, 28 x 30 mm
07WMF-HN00100
07946-1870100
15-19
FRONT WHEEL/SUSPENSION/STEERING
Set the knuckle and special tools with "B" mark side
of the remover/installer facing to the ball joint in the
vise as shown.
Press the ball joint into the knuckle until it is fully
seated.
TOOLS:
Ball joint remover/installer
Attachment, 20 mm I.D.
07WMF-HN00100
07746-0020400
NOTICE
If you feel strong resistance when compressing the
vise, stop. Reset the attachment of the tool so that
the ball joint head can go into the hollow of the
attachment and try again.
Install the snap ring with the chamfered edge facing
in.
INSTALLATION
Install the knuckle onto the drive shaft, and lower
and upper arms with the ball joint nuts.
COTTER PINS, BALL JOINT NUTS
Install the tie-rod ball joint into the knuckle with a
new nut.
Tighten each arm ball joint nut to the specified
torque and further tighten until its grooves align
with the cotter pin hole.
TORQUE: 29 N-m (3.0 kgf-m, 21 Ibf-ft)
Install new cotter pins.
Install the brake disc cover and tighten the brake
disc cover flange bolts.
15-20
DISC COVER
FRONT WHEEL/SUSPENSION/STEERING
Tighten the tie-rod ball joint nut by holding the joint
stud flat surfaces.
TIF.DOD BALL JOINT
TORQUE: 54 IMm (5.5 kgf-m, 40 Ibf-ft)
Install a new cotter pin.
COTTER PIN ^ S S i
Apply molybdenum disulfide grease to the drive
shaft splines.
BALL JOINT NUT
SOCKET BOLTS
Install the splash guard with new bolts and tighten
the bolts.
TORQUE: 11 N m (1.1 kgf m, 8 Ibf-ft)
SPLASH GUARD
Install the wheel hub and hub nut.
Tighten the nut to the specified torque and further
tighten until its grooves align with the cotter pin
hole.
TORQUE: 78 N m (8.0 kgf-m, 58 Ibf-ft)
Install a new cotter pin.
WHEEL HUB
Install the front brake caliper with new mounting
bolts and tighten the bolts.
MOUNTING BOLTS
BRAKE CALIPER
TORQUE: 44 N m (4.5 kgf m, 32 Ibf-ft)
Install the front wheel (page 15-11).
15-21
FRONT WHEEL/SUSPENSION/STEERING
FRONT SHOCK ABSORBER
REMOVAL
Support the vehicle using a hoist or equivalent and r
raise the front wheel off the ground.
Support the lower arm. Remove the mounting nuts,
bolts and shock absorber.
INSPECTION
Check the upper pivot bushing for wear or damage.
Check the damper unit for leaks or other damage.
Replace the shock absorber assembly if necessary.
BUSHING
For lower pivot bearing inspection and replacement
(page 15-26).
INSTALLATION
Install the shock absorber in the frame and over the r
upper arm, and insert the mounting bolts from the
front side.
Install new mounting nuts and tighten them.
TORQUE: 44 N m (4.5 kgf m, 33 Ibf-ft)
NUT
15-22
FRONT WHEEL/SUSPENSION/STEERING
SUSPENSION ARM
REMOVAL
Remove the front carry pipe (page 3-10)
Remove the front wheel (page 15-11).
1
COTTER PINS, BALL JOINT NUTS
Remove the cotter pins from the ball joint studs.
Loosen the ball joint nuts, but do not remove them
yet.
Release the ball joints, using the special tool according to the instructions (page 15-16).
TOOL:
Ball joint remover, 28 mm
07MAC-SL00201 or
07MAC-SL0202
(U.S.A. only) or
07MAC-SL00200 and
07MAC-SL0A300
(U.S.A. only)
Support the wheel hub/knuckle assembly securely.
BALL JOINT REMOVER
Remove the following:
-
pivot nut, bolt and lower arm
LOWER ARM
Remove the two brake hose clamp bolts.
BOLT/NUT I
Remove the following:
-
shock absorber lower mounting nut and bolt
pivot nuts, bolts and upper arm
UPPER ARM
BOLTS
15-23
FRONT WHEEL/SUSPENSION/STEERING
INSPECTION
Remove the seal caps and pivot collar from the
upper arm.
DUST SEAL CAPS
BOOT
For ball joint Inspect the ball joint boot for tears or other damage
replacement by moving the ball joint stud.
(page 15-25) It should moves freely and smoothly.
PIVOT COLLAR
Check the pivot bushings in the upper arm for wear
or damage.
BUSHINGS
Remove the shock absorber lower pivot collar.
NEEDLE BEARING
Forbearing Check the pivot bearing for wear or damage.
replacement
(page 15-26)
PIVOT COLLAR
Remove the two flange bolts and lower arm guard if
necessary.
BUSHINGS
Check the pivot bushings in the lower arm for wear
or damage.
ARM GUARD
15-24
FRONT WHEEL/SUSPENSION/STEERING
BALL JOINT REPLACEMENT
Remove the snap ring from the ball joint.
BALL JOINT
SNAP RING
Set the upper arm and special tools with "A" mark
side of the remover/installer facing to the ball joint
as shown.
Press the ball joint out of the upper arm.
TOOLS:
Ball joint remover/installer
Attachment 28 x 30 mm
ATTACHMENT
07WMF-HN00100
07946-1870100
Set the upper arm and special tools with " B " mark
side of the remover/installer facing to the ball joint
as shown.
Press the ball joint into the upper arm until it is fully
seated.
TOOLS:
Ball joint remover/installer
Attachment, 20 mm I.D.
Attachment, 17 mm I.D.
Attachment, 15 mm I.D.
07WMF-HN00100
07746-0020400 or
07746-0020300 or
07746-0020200
NOTICE
If you feel strong resistance when lowering the
press, stop. Reset the attachment of the tool so the
ball joint head can go into the hollow of the attachment and try again. Failure to reset the attachment
will damage the ball joint and/or the upper arm.
Install the snap ring with the chamfered edge facing
in.
SNAP RING
15-25
FRONT WHEEL/SUSPENSION/STEERING
SHOCK ABSORBER LOWER PIVOT
BEARING REPLACEMENT
Remove the dust seals.
NEEDLE BEARING
Press the bearing out of the upper arm using the
special tools.
TOOLS:
Driver
Attachment, 22 x 24 mm
Pilot, 16 mm
07749-0010000
07746-0010800
07746-0041300
Press the bearing Carefully press in a new bearing until it is flush with
with the marked the pivot edge (until the press stops).
side facing up.
TOOLS:
Driver
Attachment, 22 x 24 mm
Pilot, 16 mm
07749-0010000
07746-0010800
07746-0041300
Install new dust seals with the flat side facing in
until the depth from the pivot outer surface is 1 mm
(0.04 in).
Apply grease to the dust seal lips and the needle
rollers of the bearing.
Install the pivot collar.
PIVOT COLLAR
15-26
FRONT WHEEL/SUSPENSION/STEERING
INSTALLATION
Apply grease to the pivot collar outer surface and
install the collar into the upper arm.
Apply molybdenum disulfide grease to the dust seal
lips and install the dust seal caps onto the upper
arm.
g—JifitM.1^
DUST SEAL CAPS
Install the upper arm into the frame with the pivot
bolt and a new nut, and tighten the nut to the specified torque.
TORQUE: 34 N m (3.5 kgf-m, 25 Ibf-ft)
Install the shock absorber lower mount to the upper
arm with the mounting bolt and a new nut, and
tighten the nut to the specified torque.
TORQUE: 44 N m (4.5 kgfm, 32 Ibf-ft)
Install and tighten the two new brake hose clamp
bolts to the specified torque.
TORQUE: 12 N m (1.2 kgf m, 9 Ibf-ft)
Install the lower arm into the frame with the pivot
bolts and new nuts, and loosely tighten the nuts.
BOLTS AND ^ f e NUTS
LOWER ARM
Install the wheel hub/knuckle assembly onto the
upper and lower arms and install the ball joint nuts.
Tighten each nut to the specified torque and further
tighten until its grooves align with the cotter pin
hole.
BALL
INLJ I o/
COTTER PINS
TORQUE: 29 N-m (3.0 kgf m, 21 Ibf-ft)
Install new cotter pins.
15-27
FRONT WHEEL/SUSPENSION/STEERING
Install the front wheel (page 15-11).
Place the vehicle on level ground and tighten the
lower arm pivot nuts.
TORQUE: 44 N m (4.5 kgf m, 32 Ibf-ft)
Install the front carrier pipe (page 3-10).
STEERING SHAFT
REMOVAL
Remove the following:
-
front wheels (page 15-11)
inner fenders (page 3-9)
front fender (page 3-12)
lower meter covers (page 3-18)
-
brake hose (from the clamp)
wires (from the clip)
CLIP
| CLAMP
two nuts
combination meter/stay assembly
brake hose (from the hose clamp)
IFGA model shown
METER/STAY
IBRAKE HOSE
I CLAMP ^ ^ ^ ^ H
Keep the master cylinder reservoir upright.
15-28
handlebar lower holder nuts and washers
handlebar assembly (from the steering shaft)
NUTS I
HANDLEBAR ASSEMBLY
FRONT WHEEL/SUSPENSION/STEERING
cotter pins
tie-rod ball joint nuts (while holding the joint
stud flats with an open end wrench)
tie-rods (from the steering shaft arm)
cotter pin
shaft end nut and washer
shaft arm
brake hose (release from clamp)
two holder bolts
shaft holder
steering shaft (from the shaft bearing)
shaft bushing
15-29
FRONT WHEEL/SUSPENSION/STEERING
INSPECTION
Check the steering shaft bushing for wear or damage.
Check the steering shaft for distortion or damage.
Turn the inner race of the steering shaft bearing
with your finger. The bearing should turn smoothly
and quietly. Also check that the bearing outer race
fits tightly in the frame.
BEARING REPLACEMENT
Remove the upper and lower dust seals.
Remove the snap ring.
[DUST SEALS*
15-30
FRONT WHEEL/SUSPENSION/STEERING
Assemble the special tools onto the steering shaft
bearing.
COMPRESSOR
ATTACHMENT
Remove the bearing from the frame by tightening
the nut.
TOOLS:
Clutch compressor attachment 07LAE-PX40100
Compressor bolt assembly
07GAE-PG40200 or
07GAE-PG4020A
(U.S.A. only)
Attachment, 28 x 30 mm
07946-1870100
10 mm washer
Common hardware
COMPRESSOR
BOLT
ATTACHMENT
WASHER
NUT
Draw a new bearing into the frame with the marked
side facing up until it is fully seated.
TOOLS:
Clutch compressor attachment 07LAE-PX40100
Compressor bolt assembly
07GAE-PG40200 or
07GAE-PG4020A
(U.S.A. only)
Attachment, 42 x 47 mm
07746-0010300
10 mm washer
Common hardware
NUT
fly
COMPRESSOR
BOLT
ATTACHMENT
Install the snap ring into the groove properly with
the chamfered edge facing up.
WASHER
*
JS.
COMPRESSOR
ATTACHMENT
The upper seal is Coat new dust seal lips with grease and install
flush with the
frame edge and the
lower seal is seated
onto the bearing.
them.
INSTALLATION
NOTE:
• Route the wires, hose and cables properly (page
1-20).
Apply grease to the shaft bushing inner surface.
PTTrrjTTr^1
Install the shaft bushing onto the steering shaft with '
the arrow mark facing up.
Install the steering shaft into the shaft bearing.
15-31
FRONT WHEEL/SUSPENSION/STEERING
Install the shaft holder with the hose clamp facing
the right side and tighten the two bolts alternately,
then tighten to the specified torque.
TORQUE: 32 N-m (3.3 kgf m, 24 Ibfft)
Install the brake hose to the hose clamp.
CLAMP
Apply molybdenum disulfide grease to the steering
shaft splines.
WASHER •
Align
Install the shaft arm over the steering shaft by aligning the wide tooth with the wide groove.
Install the washer and end nut, and tighten it.
TORQUE: 108 N m (11.0 kgf-m, 80 Ibf-ft)
Install a new cotter pin.
Install the tie-rods into the steering shaft arm.
Install new joint nuts and tighten them by holding
the ball joint stud flats with an open end wrench.
TORQUE: 54 N-m (5.5 kgf-m, 40 Ibfft)
Install new cotter pins.
Install the handlebar assembly onto the steering
shaft with the washers and new lower holder nuts.
Tighten the nuts.
TORQUE: 39 N-m (4.0 kgf-m, 29 Ibf ft)
15-32
HANDLEBAR ASSEMBLY
FRONT WHEEL/SUSPENSION/STEERING
Route the wires Install the combination meter/stay and tighten the
, model shown:
wm
and hose properly t w o nuts.
(page 1-20).
I BRAKE HOSE
TORQUE: 25 IMm (2.5 kgf-m, 18 Ibf-ft)
Install the brake hose into the clamps on the steering shaft and shaft holder (see below).
Make sure all the Secure the wires with the wire clip.
wires and hose are | n s t a | | t h e b r a k e h o s e j n t Q t h e d a
properly routed i n g s h a f t h o | d e r .
on the
steer.
a
(page 1-20).
Install the following:
-
lower meter covers (page 3-18)
front fender (page 3-12)
inner fenders (page 3-9)
front wheels (page 15-11)
TIE-ROD
REMOVAL
Remove the following:
- front wheel (page 15-11)
- inner fender (page 3-9)
Remove the cotter pins.
Remove the tie-rod ball joint nuts while holding the
joint stud flats with an open end wrench.
Remove the tie-rod from the knuckle and steering
shaft arm.
INSPECTION
Inspect the tie-rod for distortion or damage.
Inspect the ball joint boots for tears or other damage by moving the ball joint studs.
They should move freely and smoothly.
BALL JOINT BOOTS
Replace the ball joint if necessary.
15-33
FRONT WHEEL/SUSPENSION/STEERING
DISASSEMBLY/ASSEMBLY
Loosen the lock nuts and remove the ball joints and
lock nuts from the tie-rod.
NUTS
Install the unmarked ball joint and gold colored nut
on the flat (wrench holding area) side of the tie-rod,
and the "L" marked ball joint and silver nut on the
opposite side.
&-4^0—
FLATS
The ball joint positions are 180° from
each other. Tighten
these nuts after
installing the tierod.
Hand-tighten the lock nuts and measure the distance between the lock nut and thread end.
STANDARD DISTANCE: A/B: 8.3 mm (0.33 in)
The difference between distance A and B should be
3 mm (0.1 in) or less.
INSTALLATION
Install the tie-rod with the flat side of the rod toward
the knuckle. Install new joint nuts and adjust the
toe-out (page 4-23).
Tighten the joint nuts by holding the ball joint stud
flats with an open end wrench.
TORQUE: 54 N m (5.5 kgf-m, 40 Ibf-ft)
Install new cotter pins.
Install the following:
-
inner fender (page 3-9)
front wheel (page 15-11)
Adjust the toe and ball joint angle (page 4-23)
15-34
"L" MARK
A
16. REAR WHEEL/SUSPENSION
SYSTEM COMPONENTS
16-2
REAR WHEEL
16-6
SERVICE INFORMATION-
16-3
WHEEL HUB/KNUCKLE
16-6
TROUBLESHOOTING
16-5
REAR SHOCK ABSORBER/
SUSPENSION ARM
16-10
16-1
REAR WHEEL/SUSPENSION
SYSTEM COMPONENTS
34 N-m (3.5 kgf-m, 25 Ibf-ft)
34 N-m (!3.5 kgf-m, 25 Ibf-ft)
m (5.5 kgf-m,
40 Ibf-ft)
34 N-m (3.5 kgf-m,
2 5 Ibf-ft)
137 N-m (14.0 kgf-m, 101 Ibf-ft)
64 N-m (6.5 kgf-m, 47 Ibf-ft)
16-2
REAR WHEEL/SUSPENSION
SERVICE INFORMATION
GENERAL
This section covers service of the rear wheel and rear suspension.
For tire information (page 15-11).
For brake system service (page 17-2).
For rear driving mechanism service (page 19-2).
A jack or other support is required to support the vehicle.
Use genuine Honda replacement bolts and nuts for all suspension pivots and mounting points.
SPECIFICATIONS
ITEM
Minimum tire tread depth
Cold tire pressure
Standard
Minimum
Maximum
With cargo
25 kPa (0.25
22 kPa (0.22
28 kPa (0.28
25 kPa (0.25
STANDARD
kgf/cm2, 3.6 psi)
kgf/cm2, 3.2 psi)
kgf/cm2, 4.0 psi)
kgf/cm2, 3.6 psi)
SERVICE LIMIT •
4 mm (0.16 in)
-
TORQUE VALUES
Rear wheel nut
Rear wheel hub nut
64 N-m (6.5 kgf-m, 47 Ibf-ft)
137 N-m (14.0 kgf-m, 101 Ibf-ft)
Upper arm pivot nut (frame side)
Upper arm pivot nut (knuckle side)
Lower arm pivot nut
34 N-m (3.5 kgf-m, 25 Ibf-ft)
54 N-m (5.5 kgf-m, 40 Ibf-ft)
34 N-m (3.5 kgf-m, 25 Ibf-ft)
Castle nut: tighten to the specified
torque and further tighten until its
grooves aligns with the cotter pin
hole.
Lock nut: replace with a new one.
Lock nut: replace with a new one.
Lock nut: replace with a new one.
16-3
REAR WHEEL/SUSPENSION
TOOLS
Driver
07749-0010000
Fork seal driver body
07947-KA50100
Spherical bearing driver
0~/HMF-HC00100
not available in U.S.A., use a
suitable collar.
Oil seal driver
07JAD-PH80101
16-4
Oil seal driver
07LAD-SM40100
REAR WHEEL/SUSPENSION
TROUBLESHOOTING
Rear wheel wobbling
• Bent rim
• Worn or damaged knuckle bearing
• Faulty tire
• Wheel hub nut not tightened properly
• Loose rear suspension fasteners
Steers to one side or does not track straight
• Unequal tire pressure
• Bent suspension arm or frame
• Worn or damaged knuckle bearing
• Weak shock absorber
Soft suspension
• Weak shock absorber spring
• Faulty shock absorber damper
Stiff suspension
• Bent shock absorber damper rod
• Improperly installed suspension arms
• Faulty suspension bushings or bearings
Rear suspension noise
• Loose rear suspension fasteners
• Damaged suspension components
16-5
REAR WHEEL/SUSPENSION
REAR WHEEL
REMOVAL
Loosen the wheel nuts.
Support the vehicle using a hoist or equivalent and
raise the rear wheels off the ground.
Remove the nuts and wheel.
For tire removal/installation and repair (page 15-11).
INSTALLATION
NOTE:
• Do not interchange the left and right tires.
Install the wheel with the arrow mark facing in the
normal rotating direction.
Install the wheel nuts and tighten them.
TORQUE: 64 N m (6.5 kgf-m, 47 Ibf-ft)
WHEEL HUB/KNUCKLE
REMOVAL
Remove the rear wheel (page 16-6).
Remove the following:
-
cotter pin
hub nut
wheel hub
COTTE R PIN
16-6
REAR WHEEL/SUSPENSION
lower arm pivot nut and bolt
upper arm pivot nut and bolt
seal caps (from the knuckle)
BOLTS
NUT
pivot collar (to disconnect the shock absorber)
knuckle (from the drive shaft)
COLLAR
KNUCKLE
INSPECTION
Remove the dust seals.
BEARING
Turn the inner race of the bearing in the knuckle
with your finger. The bearing should turn smoothly
and quietly. Also check that the bearing outer race
fits tightly in the knuckle.
Inspect the knuckle for damage or cracks.
For suspension pivot inspection (page 16-13).
DUST SEALS
BEARING REPLACEMENT
Remove the snap ring.
SNAP RING
Press the bearing out of the knuckle using a suitable
collar.
16-7
REAR WHEEL/SUSPENSION
Pack the cavities of a new bearing with grease.
Carefully press the bearing in the knuckle with the
marking side facing up until it is fully seated.
TOOLS:
Driver
Oil seal driver
DRIVER
07749-0010000
07JAD-PH80101
Install the snap ring into the knuckle groove with the
chamfered edge facing in.
When installing the
dust seals, be careful not to damage
the seal lip.
Support the knuckle
with the driver
weight to avoid
damaging the outer
dust seal.
Coat the lips of new dust seals with grease and
install them until they are flush with the knuckle surface.
Install the outer seal first, then install the inner seal.
TOOLS:
OUTER SEAL:
Driver
Oil seal driver
07749-0010000
07LAD-SM40100
INNER SEAL:
Driver
Oil seal driver
Fork seal driver body
07749-0010000
07LAD-SM40100
07947-KA50100
SEAL DRIVER
INSTALLATION
KNUCKLE
Apply grease to the pivot bushings and dust seal
lips on the knuckle.
Apply molybdenum disulfide paste to the pivot
bushing in the shock absorber.
Install the knuckle onto the shock absorber with the
pivot collar.
Pack the lip cavities of the inner dust seal with 2.5 3 g of grease and set the knuckle over the drive
shaft.
Install the seal caps onto the dust seals on the
knuckle.
Coat new O-rings with molybdenum disulfide
grease and install them into the pivot bolt grooves.
Apply molybdenum disulfide grease to each bolt
head (between the O-rings).
Connect the upper and lower arms to the knuckle
with the pivot bolts.
16-8
REAR WHEEL/SUSPENSION
Install new nuts and tighten them.
TORQUE:
Upper arm: 54 N-m (5.5 kgfm, 40 Ibf-ft)
Lower arm: 34 N-m (3.5 kgf-m, 25 Ibfft)
WHEEL HUB
Install a new dust seal into the hub with the metal
side facing out until it is flush with the hub surface.
j
HUB
S*
' DUST SEAL
M
s
-—^-4
»
Apply molybdenum disulfide grease to the drive
shaft splines.
Pack the lip cavities of the outer dust seal with 2.5 3 g of grease.
Apply molybdenum disulfide grease to the dust seal
and install the wheel hub.
HUB
16-9
REAR WHEEL/SUSPENSION
Install the hub nut and tighten it to the specified
torque and further tighten until its grooves align
with the cotter pin hole.
TORQUE: 137 N m (14.0 kgf m, 101 Ibf-ft)
Install a new cotter pin.
Install the wheel (page 16-6).
COTTER PIN
REAR SHOCK ABSORBER/
SUSPENSION ARM
SHOCK ABSORBER REMOVAL
Remove the rear wheel (page 16-6).
Remove the seat (page 3-4).
Support the knuckle with a support block.
Remove the following:
-
upper arm pivot nut and bolt (to disconnect the
upper arm)
seal caps
NUT
-
pivot collar (to disconnect the knuckle)
mounting nut and bolt
shock absorber
16-10
SHOCK ABSORBER~1
REAR WHEEL/SUSPENSION
SUSPENSION ARM REMOVAL
UPPER ARM
Remove the pivot collar (page 16-10).
Right upper arm:
Left upper arm:
Remove the right side cover (page 3-5).
Remove the oil filler lid (page 3-8).
Remove the following:
-
stabilizer link nut (to disconnect the link)
two pivot nuts and bolts
upper arm
UPPER ARM
PIVOT BOLT/NUT/COLLAR
LOWER ARM
Remove the following:
- lower arm pivot nut and bolt (to disconnect the
knuckle)
-
PIVOT BOLT
lower arm pivot nut and bolt
lower arm
LOWER ARM
STABILIZER ARM AND LINK
Remove the following:
-
link nuts
stabilizer links
LINK NUT
16-11
REAR WHEEL/SUSPENSION
-
four bolts and arm holders
stabilizer arm
stabilizer bushings
INSPECTION
SUPENSION ARMS
Check the stabilizer bushings for wear or damage.
Check the stabilizer arm for distortion or damage.
Inspect the ball joint boot of the link for tears or
other damage.
Replace the nuts Remove the seal caps and pivot collars from the
with new ones, lower arm.
Remove the four nuts, bolts and arm guard if necessary.
Check the pivot bushings for wear or damage.
JOINT BOOTS
CAPS
COLLAR
16-12
ARM GUARD
REAR WHEEL/SUSPENSION
Remove the pivot collars and the dust seals from
the upper arm.
Check the pivot bearings for wear or damage.
For bearing replacement (page 16-13).
COLLARS
Check the pivot bushings in the knuckle for wear or
damage.
BUSHINGS
SHOCK ABSORBER
Remove the upper pivot collar.
Check the pivot bushings for wear or damage.
Check the damper unit for leaks or other damage.
BUSHING
PIVOT BEARING REPLACEMENT
Clean any grease from the upper arm pivot thoroughly.
Remove the stopper rings from the pivot.
BEARING DRIVER
Press the bearing out of the upper arm using the
special tool.
TOOL:
Spherical bearing driver
07HMF-HC00100
(not available in
U.S.A., use a suitable
collar)
STOPPER RINGS
16-13
REAR WHEEL/SUSPENSION
Install a new stopper ring into the inner groove in
the pivot securely.
Carefully press in a new bearing until it contacts the
stopper ring (the depth from the outer surface is
12.8 mm), using the same tool.
Install a new stopper ring.
Pack each pivot (between bearing and dust seals)
with 3 g of grease.
Apply grease to the new dust seal lips and install
them until they are flush with the outer surface.
Install the pivot collars.
SHOCK ABSORBER INSTALLATION
Install new dust seals into the pivots with the lip
side facing out until they are seated.
Apply molybdenum disulfide paste to the pivot
bushings and dust seal lips.
COLLAR
Install the seal caps and pivot collar.
CAPS
Install the shock absorber into the frame with the
mounting bolt. Install a new nut.
Connect the shock absorber to the knuckle and
upper arm (page 16-16).
Install the seat (page 3-4).
16-14
REAR WHEEL/SUSPENSION
SUSPENSION ARM INSTALLATION
STABILIZER ARM AND LINK
Install the stabilizer arm and bushings with the arm
holders so the rounded side of the bushings are
toward the frame.
Tighten the four holder bolts alternately.
Install with the Install the stabilizer links with new nuts and tighten
short threads into
the stabilizer arm.
them.
LINK NUT
LOWER ARM
Install new dust seals with the lip side facing out
until the depth from the bushing end is 0.5 mm (0.02
in).
COLLAR
BUSHINGS
0.5 mm
Apply grease to the pivot bushings in the lower arm
and install the pivot collar.
Apply grease to the seal lips and install the seal
caps over the dust seals securely.
DUST
SEAL
DUST SEALS
CAPS
Install the lower arm into the frame. Align the bolt
holes in the frame and arm, and insert the pivot bolt
from the rear side.
Install a new pivot nut.
LOWER ARM
16-15
REAR WHEEL/SUSPENSION
Coat new O-rings with molybdenum disulfide
grease and install them into the pivot bolt groove.
Apply molybdenum disulfide grease to the bolt
head (between the O-rings) and insert the pivot bolt
through the knuckle and lower arm.
Install a new pivot nut and tighten each pivot nut.
TORQUE: 34 N m (3.5 kgf m, 25 Ibf ft)
UPPER ARM
Insert the pivot Install the upper arm into the frame with the pivot
bolts from the bolts and new nuts.
inside.
PIVOT BOLT/NUT/COLLAR
Install new inner dust seals
with the lip side facing the
seated.
Install new outer dust seals
out until the depth from the
(0.02 in).
into the knuckle pivots
bushing until they are
with the lip side facing
bushing end is 0.5 mm
Apply grease to the pivot bushings and dust seal
lips.
16-16
REAR WHEEL/SUSPENSION
Apply molybdenum disulfide paste to the pivot
bushing in the shock absorber.
SHOCK ABSORBER!
Connect the knuckle to the shock absorber with the
pivot collar and install the seal caps over the dust
seals.
Coat new O-rings with molybdenum disulfide
grease and install them into the pivot bolt grooves.
Apply molybdenum disulfide grease to the bolt
head (between the O-rings).
Connect the knuckle to the upper arm with the pivot
bolt. Install a new pivot nut.
Tighten the each pivot nut.
PIVOT BOLT
TORQUE:
Frame side: 34 N-m (3.5 kgf-m, 25 Ibfft)
Knuckle side: 54 N-m (5.5 kgf-m, 40 Ibfft)
Connect the stabilizer link with a new nut and
tighten it.
Flight side: Install the right side cover (page 3-5).
Leftside: Install the oil filler lid (page 3-8).
Install the rear wheel (page 16-6).
16-17
17. BRAKE SYSTEM
SYSTEM COMPONENTS
17.-2
FRONT MASTER CYLINDER
17-13
17-4
FRONT BRAKE CALIPER
17-17
TROUBLESHOOTING
17-6
REAR BRAKE MASTER CYLINDER/
BRAKE FLUID REPLACEMENT/
AIR BLEEDING
17-7
SERVICE INFORMATION
BRAKE PAD/DISC
•
•
BRAKE PEDAL
•
17-21
REAR BRAKE CALIPER
17-27
REAR BRAKE DISC
17-34
17-10
17-1
BRAKE SYSTEM
SYSTEM COMPONENTS
34 N-m (3.5 kgf-m, 25 Ibf-ft)
12 NTn (1.2 kgfm,
9 Ibf-ft)
44 N-m (4.5 kgfm, 32 Ibf-ft)
42 N-m (4.3 kgfm,
31 Ibf-ft)
11 N-m (1.1 kgfm,
8 Ibf-ft)
34 N-m (3.5 kgfm, 25 Ibf-ft)
78 N-m (8.0 kgf-m, 58 Ibf-ft)
17-2
BRAKE SYSTEM
30 N-m (3.1 kgfm,
22 Ibf-ft)
2 N-m (0.2 kgfm, 1.4 Ibf-ft)
34 N-m (3.5 kgfm, 25 Ibf-ft)
34 N-m (3.5 kgfm, 25 Ibf-ft)
32 N-m (3.3 kgfm, 24 Ibf-ft)
17-3
BRAKE SYSTEM
SERVICE INFORMATION
GENERAL
ACAUTION
Frequent inhalation of brake pad 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-approve)d vacuum cleaner.
A contaminated brake disc or pad reduces stopping power. Discard contaminated pads, and clean a contaminated disc
with a high quality brake degreasing agent.
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 silre the reservoir is horizontal first.
Never allow contaminates (dirt, water, etc.) to get into an open reservoir.
Once the hydraulic system has been opened, or if the brake feels spongy, the system must be bled.
Always use fresh 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.
Always check brake operation before riding the vehicle.
SPECIFICATIONS
ITEM
Recommended brake fluid
Front brake
Brake disc thickness
Brake disc runout
Master cylinder I.D.
Master piston O.D.
Caliper cylinder I.D.
Caliper piston O.D.
Rear brake
Brake disc thickness
Brake disc runout
Master cylinder I.D.
Master piston O.D.
Caliper cylinder I.D.
Caliper piston O.D.
Rear (parking) brake lever free play
STANDARD
DOT 4 brake fluid
4.0(0.16)
14.000 - 14.043 (0.5512 - 0.5529)
13.957 - 13.984 (0.5495 - 0.5506)
33.960 - 34.010 (1.3370 - 1.3390)
33.878 - 33.928 (1.3338 - 1.3357)
7.5 (0.30)
15.870 - 15.913 (0.6248 - 0.6265)
15.827 - 15.854 (0.6231 -• 0.6242)
30.230 - 30.280 (1.1902 - 1.1921)
30.165 - 30.198 (1.1876 - 1.1889)
25-30(1-1-3/16)
Unit: mm (in)
SERVICE LIMIT
3.0(0.12)
0.30 (0.012)
14.055 (0.5533)
13.945 (0.5490)
34.02 (1.340)
33.87 (1.333)
6(0.2)
0.5 (0.02)
15.925 (0.6270)
15.815(0.6226)
30.29(1.193)
30.14(1.187)
-
TORQUE VALUES
Brake hose oil bolt
Front caliper bleed valve
Front caliper slider pin flange bolt
Front brake pipe
Front Brake lever pivot bolt
Front brake lever pivot nut
Front master cylinder holder bolt
Rear brake caliper bleed valve
Rear brake reservoir hose joint screw
Rear brake caliper parking nut
Rear brake caliper bracket pin bolt
Rear brake caliper pin retaining bolt
Rear brake caliper mounting bolt
Rear brake disc bolt
17-4
34 N-m (3.5 kgf-m, 25 Ibf-ft)
5.4 N-m (0.55 kgf-m, 4.0 Ibf-ft)
23 N-m (2.3 kgf-m, 17 Ibf-ft)
17 N-m (1.7 kgf-m, 12 Ibf-ft)
1 N-m (0.1 kgf-m, 0.7 Ibf-ft)
5.9 N-m (0.6 kgf-m, 4.3 Ibf-ft)
12 N-m (1.2 kgf-m, 9 Ibf-ft)
5.4 N-m (0.55 kgf-m, 4.0 Ibf-ft)
2 N-m (0.2 kgf-m, 1.4 Ibf-ft)
27 N-m (2.8 kgf-m, 20 Ibf-ft)
32 N-m (3.3 kgf-m, 24 Ibf-ft)
23 N-m (2.3 kgf-m, 17 Ibf-ft)
30 N-m (3.1 kgf-m, 22 Ibf-ft)
20 N-m (2.0 kgf-m, 14 Ibf-ft)
Apply locking agent to the threads.
ALdC bolt: replace with a new one.
ALOC bolt: replace with a new one.
BRAKE SYSTEM
TOOLS
Lock nut wrench
07716-0020100
Snap ring pliers
07914-SA50001
w
or 07914-3230001
17-5
BRAKE SYSTEM
TROUBLESHOOTING
FRONT DISC BRAKE
Brake lever soft or spongy
Air in hydraulic system
Leaking hydraulic system
Contaminated brake pad/disc
Worn caliper piston seal
Worn master cylinder piston cups
Worn brake pad/disc
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 cylinder piston
Bent brake lever
Brake lever hard
Clogged/restricted brake system
Sticking/worn caliper piston
Sticking/worn master cylinder piston
Caliper not sliding properly
Bent brake lever
Brake drags
Contaminated brake pad/disc
Badly worn brake pad/disc
Warped/deformed brake disc
Caliper not sliding properly
Clogged/restricted fluid passage
Sticking caliper piston
REAR DISC BRAKE
Rear brake pedal soft or spongy
Air in hydraulic system
Leaking hydraulic system
Contaminated brake pad/disc
Worn caliper piston seal
Worn master cylinder piston cups
Worn brake pad/disc
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 pedal
Rear brake pedal hard
Clogged/restricted hydraulic system
Sticking/worn caliper piston
Sticking/worn master piston
Caliper not sliding properly
Bent brake pedal
Brake drags
Contaminated brake pad/disc
Badly worn brake pad/disc
Warped/deformed brake disc
Caliper not sliding properly
Clogged/restricted fluid passage
Sticking caliper piston
Misaligned disc
17-6
BRAKE SYSTEM
BRAKE FLUID REPLACEMENT/AIR
BLEEDING
NOTICE
Do not allow foreign material to enter the system
when filling the reservoir. Foreign material can
cause brake system failure.
Avoid spilling fluid on painted, plastic, or rubber
parts. Place a rag over these parts whenever the
system is serviced. Brake fluid will damage these
types of materials.
Use only DOT 4 brake fluid from a sealed container.
Do not mix different types of fluid. They are not
compatible. Mixed fluid types can cause brake
system failure.
BRAKE FLUID DRAINING
FRONT BRAKE
Turn the handlebar to the left side so that the reservoir is level before removing the reservoir cap.
SCREWS
RESERVOIR CAP
Remove the screws, reservoir cap, set plate and diaphragm from the front master cylinder.
Connect the bleed hose to the wheel cylinder bleed
valve.
Loosen the bleed valve and pump the brake lever
until no more fluid flows out of the bleed valve.
Perform above procedure for other side bleed valve.
17-7
BRAKE SYSTEM
REAR BRAKE
Remove the right side cover (page 3-5).
Remove the rear brake reservoir cap, set plate and
diaphragm.
Connect the bleed hose to the rear brake caliper
bleed valve.
Loosen the bleed valve and pump the brake lever
until no more fluid flows out of the bleed valve.
BRAKE FLUID FILLING/BLEEDING
FRONT BRAKE
Close the front brake caliper bleed valve.
Fill the front master cylinder reservoir with 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.
Check the fluid level Operate the brake bleeder and loosen the bleed
often while bleed- valve.
ing the brake to.pre- , f a n
vent air trom being w h e n
automatjc
refiM s y s t e m
is not used, add fluid
|ow
t h e f | u j d |ev(j| jn t h e r e s e r v o j r js
pumped into the
system.
If air enters the Perform the bleeding procedure until the system is
bleeder from completely flushed/bled.
around the bleed -,-. , .
., , .
, .
, Tighten the bleed valve.
valve threads, seal
the threads with TORQUE: 5.4 N m (0.55 kgf-m, 4.0 Ibf-ft)
teflon tape.
Perform air bleeding for the other side bleed valve.
17-8
BLEED VALVE M S I BLEED HOSE
BRAKE SYSTEM
If the brake bleeder is not available, perform the following procedure:
Pump up the system pressure with the front brake
lever until the lever resistance is felt.
Connect a bleed hose to the front brake caliper
bleed valve and bleed the system as follows:
Do not release the 1. Squeeze the brake lever all the way and loosen
the bleed valve 1/2 of a turn. Wait several seconds and then close the bleed valve.
brake lever until the
bleed valve has
been closed.
2. Release the brake lever slowly and wait several
seconds after it reaches the end of its travel.
3. Repeat the steps 1 and 2 until there are no air
bubbles in the bleed hose.
Tighten the bleed valve.
TORQUE: 5.4 N-m (0.55 kgfm, 4.0 Ibf-ft)
Perform air bleeding for the other side bleed valve.
After bleeding air, operate the front brake lever. If it
still feels spongy, bleed the system again.
Fill the front master cylinder reservoir to the casting
ledge with DOT 4 brake fluid from a sealed container.
Install the diaphragm, set plate and reservoir cap,
and tighten the screws.
TORQUE: 1.5 N-m (0.2 kgfm, 1.1 Ibf-ft)
REAR BRAKE
Close the caliper bleed valve.
Fill the rear brake reservoir with DOT 4 brake fluid
from a sealed container.
Connect a commercially available brake bleeder to
the bleed valve.
Operate the brake bleeder and loosen the bleed
valve.
If not using an automatic refill system, add brake
fluid when the fluid level in the reservoir is low.
NOTE:
• Check the fluid level often while bleeding the
brake to prevent air from being pumped into the
system.
• When using a brake bleeding tool, follow the
manufacturer's operating instructions.
Perform the bleeding procedure until the system is
completely flushed/bled.
NOTE:
• If air is entering the bleeder from around the
bleed valve threads, seal the threads with teflon
tape.
Close the bleed valve and operate the brake pedal. If
it is still feels spongy, bleed the system again.
17-9
BRAKE SYSTEM
If a brake bleeder is not available, use the following
procedure:
Pump up the system pressure with the rear brake
pedal until the pedal resistance is felt.
Connect a plastic hose to the bleed valve and bleed
the system as follows:
1. Depress the rear brake pedal, open the bleed
valve 1/4 turn and then close it.
NOTE:
• Do not release the brake pedal until the bleed
valve has been closed.
2. Release the brake pedal slowly and wait several
seconds after it reaches the end of its travel.
Repeat the steps 1 and 2 until air bubbles do not
appear in the bleed hose.
Tighten the bleed valve.
TORQUE: 5.4 N m (0.55 kgf m, 4.0 Ibf ft)
Fill the reservoir to the "UPPER" level with DOT 4
brake fluid from a sealed container.
Install the diaphragm, set plate and reservoir cap.
Install the right side cover (page 3-5).
BRAKE PAD/DISC
FRONT BRAKE PAD REPLACEMENT
Remove the front wheel (page 15-11).
CALIPER BODY
Check the fluid level Push the caliper piston all the way in by pushing the
in the master cylin- caliper body against the disc to allow installation of
der reservoir as this new brake pads.
° P r T w ':aUS,eS Remove the caliper pin bolt.
the fluid level to
rise.
SLIDE PIN BOLT
17-10
BRAKE SYSTEM
Pivot the caliper body up and remove the brake
pads from the caliper bracket.
BRAKE PADS
Always replace the Install new brake pads into the caliper bracket propbrake pads in pairs erly as s h o w n .
to ensure even disc
pressure.
Lower the caliper body, install the caliper pin bolt
and tighten it.
CALIPER BODY
TORQUE: 23 IM m (2.3 kgf-m, 17 Ibf-ft)
Squeeze the front brake lever to seat the caliper piston against the pad.
SLIDE PIN BOLT
REAR BRAKE PAD REPLACEMENT
Remove the right rear wheel (page 16-6).
Remove the bracket pin retaining bolt and bracket
pin bolt.
Remove the caliper body from the caliper bracket.
RETAINING BOLT
Remove the brake pads from the caliper bracket.
BRAKE PADS
Always replace the Install new pad onto the caliper bracket properly so
brake pads in pairs that the pin on the pad is facing to the piston.
to ensure even disc
pressure.
17-11
BRAKE SYSTEM
Rotate the caliper piston clockwise using the special
tool or equivalent to retract it and align the piston
groove with the index mark on the caliper body.
INDEX MARK
TOOL:
Lock nut wrench, 20 x 24 mm 07716-0020100
GROOVE
Install the caliper body over the pads and caliper I BRACKET PIN BOLT
bracket, aligning the groove in the piston with the
pin on the pad.
Install the bracket pin bolt and bracket pin retaining
bolt, and tighten them.
TORQUE:
Bracket pin bolt: 32 N m (3.3 kgf m, 24 Ibf ft)
Retaining bolt: 23 N m (2.3 kgf m, 17 Ibf ft)
Install the right rear wheel (page 16-6).
Operate the brake pedal to seat the caliper piston
against the pad.
FRONT BRAKE DISC INSPECTION
Remove the front wheel (page 15-11).
Remove the caliper body (page 17-17).
Visually inspect the brake disc for damage or crack.
Measure the brake disc thickness at several points.
SERVICE LIMIT: 3.0 mm (0.12 in)
Replace the brake disc if the smallest measurement
is less than service limit.
Check the brake disc for warpage.
SERVICE LIMIT: 0.30 mm (0.012 in)
Check the front wheel hub bearings or rear axle
bearings for excessive play, if the warpage exceeds
the service limit.
Replace the brake disc if the bearings are normal.
17-12
BRAKE SYSTEM
REAR BRAKE DISC INSPECTION
Visually inspect the disc for damage or cracks.
Measure the brake disc thickness at several points.
SERVICE LIMIT: 6 mm (0.2 in)
Replace the brake disc if the smallest measurement
is less than the service limit.
Check the brake disc for warpage.
SERVICE LIMIT: 0.5 mm (0.02 in)
Replace the brake disc if the warpage exceeds the
service limit.
FRONT MASTER CYLINDER
DISASSEMBLY
Drain the brake fluid from the front brake hydraulic
system (page 17-7).
SEALING WASHERS
Disconnect the brake hose by removing the oil bolt
and sealing washers.
OIL BOLT
Disconnect the front brake switch connectors.
MASTER CYLINDER
HOLDER
Remove the master cylinder holder bolts, holder
and master cylinder.
BOLTS
17-13
BRAKE SYSTEM
Remove the pivot nut, bolt and brake lever.
Remove the screw and brake switches.
PIVOT BOLT/NUT
SWITCHES
BRAKE LEVEIR
SCREW
Remove the boot from the master cylinder and master piston.
BOOT
Remove the snap ring using the special tool.
TOOL:
Snap ring pliers
SNAP RING
07914-SA50001 or
07914-3230001
SNAP RING PLIERS
Remove the master piston and spring.
Remove the oil seal
MASTER CYLINDER
SPRING
Clean the master cylinder, reservoir and master piston in clean brake fluid.
PISTON CUPS
OIL SEAL
17-14
MASTER PISTON
BRAKE SYSTEM
INSPECTION
Check the master cylinder and master piston for
scoring, scratches or damage.
Check the piston cups and oil seal for wear, deterioration or damage.
Measure the master cylinder I.D.
SERVICE LIMIT: 14.055 mm (0.5333 in)
Measure the master cylinder piston O.D.
SERVICE LIMIT: 13.945 mm (0.5490 in)
ASSEMBLY
Coat the master piston, piston cups and oil seal with
clean DOT 4 brake fluid.
Install the oil seal into the master cylinder.
MASTER CYLINDER
SPRING
Install the spring onto the piston end.
Do not allow the
piston cup lips to
turn inside out.
Install the spring and master piston into the master
cylinder.
PISTON CUPS
MASTER PISTON
Be certain the snap Install the snap ring into the groove in the master
ring is firmly seated cylinder with the chamfered edge facing in using
in the groove, the special tool.
TOOL:
Snap ring pliers
SNAP RING
07914-SA50001 or
07914-3230001
SNAP RING PLIERS
Install a new boot into the master cylinder and the
groove in the piston
Apply silicone grease to the brake lever pivot-tomaster piston contact area.
BOOT
17-15
BRAKE SYSTEM
Apply silicone grease to the brake lever pivot bolt
sliding surface.
PIVOT BOLT
SWITCHES
Install the pivot bolt and tighten it.
TORQUE: 1 N m (0.1 kgfm, 0.7 Ibf ft)
Install the pivot nut and tighten it.
TORQUE: 5.9 N m (0.6 kgf m, 4.3 Ibf ft)
Install the brake light switch and tighten the screw.
TORQUE: 1.2 N m (0.12 kgf m, 0.9 Ibfft)
PIVOT NUT
Install the front brake master cylinder and holder
with the "UP" mark facing up, and install the bolts.
MASTER CYLINDER
Connect the front brake light switch connectors.
Align the end of the master cylinder with the lug on
the throttle housing, and tighten the upper bolt first,
then tighten the lower bolt.
TORQUE: 12 N m (1.2 kgf m, 9 Ibfft)
BOLTS
Rest the brake hose joint between the stoppers on
the master cylinder.
Connect the brake hose with the oil bolt and new
sealing washers, and tighten the oil bolt.
SEALING WASHERS
TORQUE: 34 N-m (3.5 kgfm, 25 Ibf ft)
Fill and bleed the front brake hydraulic system
(page 17-7).
OIL BOLT
17-16
HOSE JOINT
BRAKE SYSTEM
FRONT BRAKE CALIPER
DISASSEMBLY
Drain the brake fluid from the front brake hydraulic
system (page 17-7).
BOLTS
Remove the two bolts and guard plate.
Disconnect the brake hose from the brake caliper by
removing the oil bolt and sealing washer.
T
SEALING WASHERS
Loosen the two caliper pin bolts.
Remove the two mounting bolts and brake caliper
assembly.
CALIPER PIN BOLTS
MOUNTING BOLTS
Remove the two caliper pin bolts and separate the
caliper bracket from the caliper body.
CALIPER
ASSEMBLY
CALIPER PIN BOLTS
Remove the brake pads.
CALIPER BODY
CALIPER BRACKET
BRAKE PADS
17-17
BRAKE SYSTEM
Remove the bracket pin, boot and pad springs from
the caliper bracket.
BRACKET PIN AND BOOT
PAD SPRINGS
Remove the caliper pin and boot from the caliper
body.
CALIPER PIN AND BOOT
Place a shop towel over the piston.
Do not use high Position the caliper body with the piston down and
pressure air or bring apply small squirts of air pressure to the fluid inlet
the nozzle too close to remove the piston.
to the inlet. R e m o v e t h e c a | j p e r p j s ton boot.
Be careful not to Push the piston seal in and lift it out.
damage the piston C | e g n t h g b o Q t g n d s e g |
caliper cylinder,
0
sliding surface.
and piston with clean brake fluid.
PISTON SEAL
INSPECTION
Check the caliper cylinder and piston for scoring,
scratches or damage.
CALIPER CYLINDER
PISTON BOOT
PISTON SEAL
CALIPER PISTON
17-18
BRAKE SYSTEM
Measure the caliper cylinder I.D.
SERVICE LIMIT: 34.020 mm (1.3394 in)
Measure the caliper cylinder piston O.D.
SERVICE LIMIT: 33.870 mm (1.3335 in)
ASSEMBLY
CALIPER PIN
PAD SPRINGS
BRAKE PADS
CALIPER BRACKET
PISTON SEAL
CALIPER PIN BOOT
CALIPER BODY
BRACKET PIN
PISTON BOOT
BRACKET PIN
BOOT
Coat new piston seal with clean brake fluid and
install it into the seal groove in the caliper cylinder.
CALIPER PISTON
CALIPER CYLINDER
Apply silicone grease to the inside of a new piston
boot and install it into the caliper cylinder groove
properly.
Coat the caliper piston with clean brake fluid and
install them into the caliper cylinder with the open
side toward the pads, and install the piston boot
into the piston groove properly.
PISTON SEAL
CALIPER PISTON
17-19
BRAKE SYSTEM
Install the pad springs onto the caliper body as
shown.
Apply silicone grease to the insides of new pin
boots.
Install the caliper pin boot and pin into the caliper
body.
Install the bracket pin boot and pin into the caliper
bracket.
BRACKET p N A N D
B 0 0 T
PAD SPRINGS
CALIPER PIN AND BOOT
Install the brake pads onto the caliper bracket.
Install the caliper body onto the bracket.
Loosely install the caliper pin bolts.
CALIPER PIN BOLTS
CALIPER BODY
CALIPER BRACKET
Install the brake caliper assembly onto the knuckle
with new mounting bolts, and tighten the bolts.
BRAKE PADS
CALIPER PIN BOLTS
TORQUE: 44 N m (4.5 kgf m, 32 Ibf-ft)
Tighten the caliper pin bolts.
TORQUE: 23 N-m (2.3 kgf m, 17 Ibf-ft)
CALIPER
ASSEMBLY
Connect the brake hose with the oil bolt and new
sealing washers while inserting the stopper pin into
the hole in the caliper body.
Tighten the oil bolt.
TORQUE: 34 N m (3.5 kgf m, 25 Ibf-ft)
SEALING WASHERS
17-20
BRAKE SYSTEM
Install the guard plate with new bolts and tighten
the bolts securely.
BOLTS
Fill and bleed the front brake hydraulic system
(page 17-7).
REAR BRAKE MASTER CYLINDER/
BRAKE PEDAL
DISASSEMBLY
Drain the brake fluid from the rear brake hydraulic
system (page 17-8).
Remove the right center mud guard (page 3-7).
Remove the screw and reservoir hose joint from the
master cylinder.
Remove the O-ring.
Disconnect the brake hose from the master cylinder
by removing the oil bolt and sealing washers.
Remove the master cylinder mounting bolts while
holding the brake pedal.
17-21
BRAKE SYSTEM
Remove the brake pedal pivot bolt and dust seals.
Unhook the brake switch spring from the return
spring.
Unhook the return spring from the pedal and frame.
PIVOT BOLT
Separate the master cylinder from the brake pedal
by removing the cotter pin and joint pin.
MASTER CYLINDER
COTTER PIN
Remove the boot from the master cylinder.
BOOT
Remove the snap ring using the special tool.
TOOL:
Snap ring pliers
Remove the push rod.
17-22
07914-SA50001 or
07914-3230001
SNAP RING
BRAKE SYSTEM
Remove the master piston, primary cup and spring.
SPRING
Clean the master cylinder, spring and master piston
in clean brake fluid.
MASTER PISTON
PRIMARY CUP
INSPECTION
Check the piston cups and boot for wear, deterioration or damage.
SPRING
Check the spring for damage.
MASTER PISTON
PRIMARY CUP
Check the master cylinder and piston for scoring,
scratches or damage.
Measure the master cylinder I.D.
SERVICE LIMIT: 14.055 mm (0.5533 in)
Measure the master piston O.D.
SERVICE LIMIT: 13.945 mm (0.5490 in)
17-23
BRAKE SYSTEM
ASSEMBLY
MASTER CYLINDER
MASTER PISTON
SNAP RING
SPRING
BOOT
PRIMARY CUP
PUSH ROD
Coat the master piston and piston cups and with
clean brake fluid.
SPRING
Install the primary cup onto the spring.
Do not allow the Install the spring, primary cup and master piston
piston cup lips to into the master cylinder.
turn inside out. A p p | y s i | i c o n e g r e a s e t 0 t h e p u s h roc j cont act area
of the master piston.
Install the push rod into the master cylinder.
Be certain the snap
ring is firmly seated
in the groove,
SNAP RING PLIERS
Install the snap ring into the groove in the master
cylinder with the chamfered edge facing in using
the special tool.
TOOL:
Snap ring pliers
07914-SA50001 or
07914-3230001
SNAP RING
17-24
BRAKE SYSTEM
Install the boot into the master cylinder.
BOOT
If the push rod joint is reinstalled, adjust the push
rod length so that the distance between the centers
of the master cylinder lower mounting bolt hole and
the centers of the joint pin hole is 80 ± 1 mm (3.15 ±
0.04 in). After adjustment, tighten the joint nut.
TORQUE: 18 N m (1.8 kgf m, 13 Ibf-ft)
80 ± 1 mm
(3.15 ±0.04 in)
Connect the master cylinder to the brake pedal with
the joint pin and a new cotter pin.
BRAKE PEDAL
COTTER PIN
Apply grease to new dust seal lips.
Install the dust seals into the brake pedal.
I RETURN SPRING
MASTER CYLINDER
JOINT PIN
SwiTcH SPRING
Hook the return spring to the pedal and frame as
shown.
Connect the brake switch spring to the return
spring.
Install and tighten the brake pedal pivot bolt.
17-25
BRAKE SYSTEM
Install the master cylinder onto the frame and
tighten the mounting bolts securely.
Connect the brake hose to the master cylinder with
the oil bolt and new sealing washers.
Rest the hose joint pin against the stopper and
tighten the oil bolt.
TORQUE: 34 N m (3.5 kgf m, 25 Ibf-fft)
Coat a new O-ring with brake fluid and install it into
the master cylinder.
Install the reservoir hose joint onto the master cylinder.
Route the wires Apply locking agent to the hose joint screw threads.
and hose properly Install and tighten the hose joint screw.
(page 1-20). T O R Q U E . 2 N m {Q2 kgfm
•, 4 | b f f t )
Fill and bleed the rear brake hydraulic system (page
17-7).
Install the right center mud guard (page 3-7).
17-26
BRAKE SYSTEM
REAR BRAKE CALIPER
DISASSEMBLY
Remove the right rear wheel (page 16-6).
Drain the brake fluid from the rear brake hydraulic
system (page 17-8).
Remove the rear brake adjusting nut and disconnect
the brake cable from the brake arm.
Remove the brake cable from the caliper body.
Disconnect the brake hose from the caliper body by
removing the oil bolt and sealing washers.
SEALING !
WASHERS '.
Loosen the bracket pin bolt.
Remove the two mounting bolts and the brake caliper from the frame.
Remove the bracket pin bolt and pivot the caliper
body.
CALIPER BODY
BRACKET PIN BOLT
17-27
BRAKE SYSTEM
Remove the brake pads and pad spring.
BRAKE PADS
PAD SPRING
Separate the caliper body from the caliper bracket.
CALIPER BODY
CALIPER BRACKET
Remove the boots and collar from the caliper
bracket.
COLLAR
BOOT
Remove the caliper piston by turning it counterclockwise.
Remove the piston dust cover.
Be careful not to Push the piston seal in and lift it out.
damage the piston
sliding surface.
17-28
BOOT
DUST COVER
BRAKE SYSTEM
Remove the snap ring using the snap ring pliers.
TOOL:
Snap ring pliers
qrviAP RINC
07914-SA50001 or
07914-3230001
SNAP RING PLIERS
Remove the following:
-
spring guide
adjusting spring B
spacer
bearing A
adjusting bolt
cup
sleeve piston
rod
O-ring
ROD
PISTON
BOLT
SPACER
-
return spring
parking nut
spring washer
brake arm
-
brake cam
dust cover
GUIDE
BRAKE ARM
Clean the disassembled parts in clean brake fluid.
BRAKE CAM
DUST COVER
17-29
BRAKE SYSTEM
INSPECTION
Check the caliper cylinder and piston for scoring or
other damage.
Measure the caliper cylinder I.D.
SERVICE LIMIT: 30.29 mm (1.193 in)
Measure the caliper piston O.D.
SERVICE LIMIT: 30.14 mm (1.187 in)
ASSEMBLY/INSTALLATION
PAD SPRING
BOOTS
CALIPER BRACKET
COLLAR
ROD
CALIPER BODY
DUST COVER
BRAKE CAM
SPRING GUIDE
PIST0N
SEAL
BRAKE ARM
CUP
RETURN
SPRING
WASHER
CALIPER PISTON
ADJUSTING BOLT
SPACER
ADJUSTING SPRING Ei
PARKING NUT
SNAP RING
DUST COVER
Apply silicone grease to the dust cover lips and
install it into the caliper body.
Apply silicone grease to the brake cam groove and
install it into the caliper body with the groove facing
the caliper cylinder.
/
BRAKE CAM
17-30
DUST COVER
BRAKE SYSTEM
Install the brake arm, washer and parking nut.
Tighten the parking nut.
BRAKE ARM
TORQUE: 27 N m (2.8 kgf m, 20 Ibf ft)
Install the return spring as shown.
Coat a new O-ring with silicone grease and install it
into the sleeve piston groove.
Coat a new cup with silicone grease and install it
onto the adjusting bolt.
Install the adjusting bolt into the sleeve piston.
Coat the rod with silicone grease and install it into
the sleeve piston.
Install the piston assembly in the caliper cylinder by
aligning the pins of the piston with the holes in the
caliper.
Install bearing A, spacer, adjusting spring B and
spring guide onto the adjusting bolt.
ROD
PISTON
BOLT
SPACER
Install the snap ring using the snap ring pliers.
TOOL:
Snap ring pliers
GUIDE
SNAP RING
07914-SA50001 or
07914-3230001
SNAP RING PLIERS
Coat a new piston seal with clean brake fluid and
install it into the seal groove in the caliper.
Coat the caliper piston with clean brake fluid.
Apply silicone grease to the lips of a new dust
cover.
Install the dust cover onto the caliper piston.
Install the dust cover into the groove in the caliper.
Install the caliper piston into the caliper cylinder and
onto the adjusting bolt by turning it clockwise.
Install the dust cover into the groove in the caliper
piston.
DUST COVER
CALIPER PISTON
17-31
BRAKE SYSTEM
Apply silicone grease to the lips of new boots and
install them into the caliper bracket.
Coat the collar with silicone grease and install it into
the caliper bracket.
Coat the caliper pin of the caliper body with silicone
grease and install it into the caliper bracket.
Install the pad spring in the caliper body as shown.
Install the brake pads onto the caliper bracket.
PAD SPRING
Pivot the caliper body over the pads and bracket.
CALIPER BODY
Temporarily install the bracket pin bolt.
BRACKET PIN BOLT
Install the brake caliper with new mounting bolts
and tighten the bolts.
TORQUE: 30 N m (3.1 kgf m, 22 Ibf ft)
Tighten the bracket pin bolt.
TORQUE: 32 IM m (3.3 kgf m, 24 Ibf ft)
17-32
MOUNTING BOLTS BRACKET PIN BOLT
BRAKE SYSTEM
Connect the brake hose to the brake caliper with the
oil bolt and new sealing washers, and tighten the oil
bolt.
TORQUE: 34 N m (3.5 kgf m, 25 Ibf-ft)
Install the rear brake cable into the caliper body and
connect it to the brake arm with the joint pin.
Install the rear brake adjusting nut.
Fill and bleed the rear brake hydraulic system (page
17-7).
Adjust the rear (parking) brake lever free play (page
4-20).
Install the right rear wheel (page 16-6).
17-33
BRAKE SYSTEM
REAR BRAKE DISC
REMOVAL
Remove the following:
-
oil filler lid
right side cover (page 3-5)
engine guard (page 3-17)
both rear wheels (page 16-6)
bolt and rear brake hose clamp
two rear brake caliper mounting bolts
two link nuts
four rear upper arm bolts and nuts
rear shock absorber upper mounting bolts.
Lift the rear of the frame and place a jack or stand
under the sub-frame at the final gear case.
Disconnect the breather hose from the final gear
case.
Remove the following:
-
four sub-frame joint nuts and bolts
two final gear case upper mounting nuts and
bolts
Remove the final drive assembly from the frame by moving it rearward.
UPPER ARM BOLTS
SHOCK ABSORBER UPPER MOUNTING BOLTS
UPPER ARM BOLTS
GEAR CASE UPPER
MOUNTING BOLTS
BRAKE HOSE
CLAM'P BOLT
LINK NUTS
SUB-FRAMEJOINT
BOLTS
BRAKE CALIPER
MOUNTING BOLTS
17-34
FINAL DRIVE ASSEMBLY
BRAKE SYSTEM
Remove the following:
-
boot band
boot (off the pinion joint)
propeller shaft
spring
-
five disc bolts
brake disc
BOOT
PROPELLER SHAFT
INSTALLATION
Install the brake disc with the stamp facing to the
engine side. Install new disc bolts and tighten them
in a crisscross pattern in several steps.
BRAKE DISC
TORQUE: 20 N m (2.0 kgf m, 14 Ibf ft)
Apply 5 - 8 g of molybdenum disulfide grease to the
pinion joint splines.
Install the spring into the propeller shaft.
Set the propeller shaft into the pinion joint while
compressing the spring, then install the boot over
the pinion joint groove securely and secure it with
the boot band.
Be sure the propeller shaft is installed properly by
pulling on the shaft lightly.
BOOT
17-35
BRAKE SYSTEM
Coat a new O-ring with molybdenum disulfide
grease and install it into the propeller shaft groove.
Put the final drive assembly on a floor jack or other
adjustable support and place the assembly under
the main frame.
While adjusting the jack height, move the final drive
assembly forward and connect the propeller shaft
into the universal joint.
Be careful not to
disconnect the propeller shaft and universal joint.
Set the final drive assembly into the main frame and
seat the propeller shaft securely to align the bolt
holes, then insert the mounting bolts from the left
side.
Install new mounting nuts but do not tighten them
yet.
Route the breather hoses properly (page 1-20) and
connect them.
BOLTS AND «S» NUTS
Insert the sub-frame joint bolt bolts from the inside.
Install new joint nuts.
Tighten the four mounting nuts and joint nuts alternately.
TORQUE:
Joint nut:
34 N-m
Mounting
34 N-m
Mounting
39 N-m
(3.5 kgf-m, 25 Ibfft)
bolt (main frame):
(3.5 kgf-m, 25 Ibfft)
bolt (sub-frame):
(4.0 kgf m, 29 Ibfft)
Install the rear shock absorber upper mounting
bolts and nuts, and tighten them.
17-36
UPPER MOUNTING BOLTS
BRAKE SYSTEM
Insert the pivot Install the upper arm into the frame with the pivot
bolts from the bolts and new nuts, and tighten the nuts.
inside.
Connect the stabilizer links to the stabilizer arms
with new nuts and tighten them.
Install the rear brake caliper onto the final gear case,
and install and tighten the mounting bolts.
TORQUE: 30 N m (3.1 kgf m, 22 Ibf-ft)
Align the shapes of
the brake hose
clamp and grommet properly.
Install the rear brake hose clamp onto the sub-frame
and tighten the bolt securely.
Install the following:
-
both rear wheels (page 16-6)
engine guard (page 3-17)
right side cover (page 3-5)
oil filler lid
CLAMP BOLT
17-37
18. FRONT DRIVING MECHANISM
SYSTEM COMPONENTS
SERVICE INFORMATION
18-2
18-14
CASE BEARING REPLACEMENT
18-22
DIFFERENTIAL ASSEMBLY
18-25
DIFFERENTIAL INSTALLATION
18-30
18-3
TROUBLESHOOTING
18-6
FRONT DRIVE SHAFT
18-7
DIFFERENTIAL REMOVAL
DIFFERENTIAL DISASSEMBLY/
INSPECTION
18-12
18-1
FRONT DRIVING MECHANISM
SYSTEM COMPONENTS
44 N-m (4.5 kgf m, 33
7 N-m (0.7
10 N-m (1
7 Ibf-ft)
22 N-m (2.2 kgf
18-2
FRONT DRIVING MECHANISM
SERVICE INFORMATION
GENERAL
• Perform the gear contact pattern and backlash inspection whenever you replace the bearings, gears or gear case. The
extension lines from the gear engagement surfaces should intersect at one point.
• Protect the gear case with a shop towel or soft jaws while holding it in vise. Do not clamp it too tight as it could damage
the gear case.
• Replace the ring and pinion gears as a set.
• Replace the cam followers (12 pieces) as a set, and the cam followers, face cams, differential housing and cap as an
assembly if the face cam, differential housing or cap is faulty.
SPECIFICATIONS
Unit: mm (in)
Front differential
Recommended oil
Gear backlash
Backlash difference
Slip torque
STANDARD
175 cm 3 (5.9 US oz, 6.2 Imp oz)
220 cm 3 (7.4 US oz, 7.7 Imp oz)
Hypoid gear oil SAE #80
0.05-0.25(0.002-0.010)
14-17N-m(1.45-1.75kgf-m,
Face cam-to-housing distance
Differential ring gear depth
Cone spring height
10-13 Ibfft)
3.3-3.7(0.13-0.15)
6.55-6.65(0.2579-0.2618)
2.8(0.11)
ITEM
Oil capacity
At draining
At disassembly
SERVICE LIMIT
0.4(0.02)
0.2(0.01)
12 N-m (1.2
kgf-m, 9 Ibfft)
3.3(0.13)
6.55 (0.2579)
2.6(0.10)
TORQUE VALUES
Differential ring gear bolt
Differential case cover 10-mm bolt
Differential case cover 8-mm bolt
Differential final clutch bolt
Differential mounting bolt
Differential 10-mm mounting nut
Differential 8-mm mounting nut
Front vehicle speed sensor bolt
Rear vehicle speed sensor bolt
Speed sensor cover stay bolt
Rear vehicle speed sensor cover bolt
49 N-m (5.0 kgf-m 36 Ibfft)
49 N-m (5.0 kgf-m 36 Ibfft)
25 N-m (2.6 kgf-m 19 Ibfft)
25 N-m (2.6 kgf-m 19 Ibfft)
44 N-m (4.5 kgf-m ,33 Ibfft)
44 N-m (4.5 kgf-m , 33 Ibfft)
22 N-m (2.2 kgf-m 16 Ibfft)
10 N-m (1.0 kgf-m,, 7 Ibfft)
10 N-m (1.0 kgf-m,, 7 Ibfft)
10 N-m (1.0 kgf-m,, 7 Ibfft)
7 N-m (0.7 kgf-m, 5.1 Ibfft)
Special bolt: replace with a new one.
Apply locking agent to the threads.
Lock nut: replace with a new one.
18-3
FRONT DRIVING MECHANISM
TOOLS
Universal bearing puller
07631-0010000
Remover weight
07741-0010201
or equivalent commercially
available in U.S.A.
or 07936-371020A or 07936-3710200
(U.S.A. only)
Attachment, 22 x 24 mm
07746-0010800
Attachment, 20 mm I.D.
07746-0020400
Driver, 40 mm I.D.
07746-0030100
Attachment, 30 mm I.D.
07746-0030300
Pilot, 15 mm
07746-0040300
Pilot, 28 mm
CI7746-0041100
Driver
07749-0010000
Remover handle
07936-3710100
Rearing remover set, 30 mm
07936-8890300
18-4
Attachment, 52 x 55 mm
07746-0010400
FRONT DRIVING MECHANISM
Bearing remover shaft
07936-KC10100
Bearing remover head, 15 mm
07936-KC10200
or 07936-KC10500 (U.S.A. only)
or 07936-KC10500 (U.S.A. only)
Bearing clip compressor, 25 mm
070ME-HN8A100
Differential inspection tool
07KMK-HC50101
Driver
07949-3710001
Press attachment
07LME-GE20100
or 07KMK-HC5010A (U.S.A. only)
18-5
FRONT DRIVING MECHANISM
TROUBLESHOOTING
Consistent noise during cruising
• Oil level too low
• Foreign matter contaminating gear oil
• Worn or damaged bearing
• Worn or damaged ring gear and pinion gear
• Deformed ring gear or differential case
• Improper tooth contact between ring gear and pinion gear
Gear noises while running
• Oil level too low
• Foreign matter contaminating gear oil
• Chipped or damaged gears
• Improper tooth contact between ring gear and pinion gear
Gear noise while coasting
• Chipped or damaged gears
Abnormal noises when turning
• Worn or damaged ring gear bearing
• Worn or damaged face cams and cam followers
• Worn or damaged differential housing grooves
• Worn cone spring or shim
Abnormal noises at start or during acceleration
• Excessive backlash between ring gear and pinion gear
• Worn differential splines
• Loose fasteners
• Worn cone spring or shim
Oil leak
• Oil level too high
• Clogged breather
• Damaged seals
• Loose case cover bolt
Overheating
• Oil level too low
• Insufficient backlash between ring gear and pinion gear
18-6
FRONT DRIVING MECHANISM
FRONT DRIVE SHAFT
REMOVAL
It is not necessary
to remove the
splash guard.
To prevent damage
to the differential oil
seal, hold the
inboard joint horizontal until the drive
shaft is clear of the
differential.
Remove the knuckle (page 15-15)
Hold the inboard joint of the drive shaft and tug
firmly to force the stopper ring on the inboard joint
end past the groove while prying with a screwdriver.
Remove the stopper ring from the inboard joint.
INBOARD JOINT
DISASSEMBLY/INSPECTION
Check the boots for cuts or other damage.
Check the drive shaft joints for excessive play or
noise by moving the joints in a circular direction.
If the outboard joint seems to be worn or damaged,
the drive shaft must be replaced.
INBOARD JOINT
BOOTS
NOTE.
• To replace the outboard boot, first remove the
inboard boot as described in the following steps.
Then remove the bands and outboard boot from
the inboard end of the shaft.
• The outboard joint cannot be disassembled.
OUTBOARD JOINT
Replace the band
with new ones
whenever removing them.
Bend up the lock tabs and raise the band ends to
loosen the bands on the inboard side.
Remove band B.
Remove the boot from the inboard joint.
BAND END
BAND A
TABS
BAND B
18-7
FRONT DRIVING MECHANISM
Remove the following:
-
stopper ring
inboard joint
-
snap ring
bearing
inboard boot
inboard band A
STOPPER RING
INBOARD JOINT
SNAP RING
BOOT
Replace the compo- Check the following for wear or damage:
nentsasanassem- _ b e a r i n g c a g e
y
'
-
race
steel balls
inboard joint
Remove the following:
-
INBOARD JOINT
BEARING
OUTBOARD BOOT BAND
shaft boot band
outboard boot band
outboard boot
SHAFT BOOT BAND
18-8
BOOT
FRONT DRIVING MECHANISM
ASSEMBLY
DRIVESHAFT
INBOARD JOINT
SHAFT BOOT BAND
OUTBOARD BOOT
OUTBOARD JOINT
SNAP RING
BEARING
STOPPER RING
BEARING RACE
BANDB
OUTBOARD BOOT BAND
INBOARD BOOT
BEARING CAGE
Each boot has an identification mark; "BJ71" for the
outboard and "UJ68" for inboard.
Inboard:
UJ68
Outboard: BJ71
BAND A
BJ71
UJ68
Vfl/n
flVMYi
Nl
1
INBOARD BOOT

OUTBOARD BOOT
Note the installation direction of the boot bands.
Forward rotation direction
BAND
18-9
FRONT DRIVING MECHANISM
Pack the outboard joint with 55 - 75 g of specified
grease.
OUTBOARD BOOT
BAND A
Specified grease:
NKG106 (KYODO YUSHI)
INBOARD BOOT
Install the following:
- outboard boot
- new shaft boot band
- new inboard band A
- inboard boot
Do not tighten the bands at this time.
58S SHAFT BOOT BAND
Install the bearing with the small O.D. facing the
drive shaft.
Install the snap ring with the chamfered side facing
the bearing.
BEARING
SNAP RING
BOOT
Pack the inboard joint with 40 - 60 g of specified
grease.
Specified grease:
NKG205 (KYODO YUSHI)
Install the inboard joint over the bearing.
Install the stopper ring into the groove in the
inboard joint properly.
Adjust the length of the drive shaft to the figure
given below.
DRIVE SHAFT LENGTH:
Left: 363.3 mm (14.30 in)
Right: 383.1 mm (15.08 in)
18-10
STOPPER RING
FRONT DRIVING MECHANISM
For band installs- Install inboard band A and a new inboard band B.
tlon direction Bend down the band end and secure it with the lock
See page 18-9. tabs. Tap the lock tabs with a plastic hammer.
BAND END
BAND A
Install the shaft boot band and a new outboard boot
band onto the outboard boot.
Bend down the band end and secure it with the lock
tabs. Tap the lock tabs with a plastic hammer.
OUTBOARD BOOT BAND
TABS
SHAFT BOOT BAND
INSTALLATION
Install a new stopper ring into the groove in the
inboard joint spline.
STOPPER RING
INBOARD JOINT
Be careful not to
damage the oil seal
in the differential
gear case.
Install the drive shaft by holding the inboard joint
until the stopper ring seats in the groove of the
differential.
I INBOARD JOINT;
Make sure that the stopper ring is seated properly
by pulling on the inboard joint lightly.
Install the knuckle (page 15-20).
18-11
FRONT DRIVING MECHANISM
DIFFERENTIAL REMOVAL
Drain the differential oil (page 4-16).
Remove the following:
-
left front mud guard (page 3-8)
both inner fenders (page 3-9)
front grille (page 3-10)
left drive shaft (page 18-7)
two bolts, guard plate and front Vehicle Speed
Sensor (VS sensor).
-
two bolts and VS sensor cover
Remove the rear VS sensor wire and front final
clutch wire from the clamp.
Remove the three bolts, VS sensor cover stay and
rear VS sensor.
Disconnect the front final clutch 2P (Green) connector.
Remove the following:
-
8 mm mounting nut and bolt
two 8 mm bolts and mounting bracket
10 mm mounting nut, bolt and spacer
2P (GREEN)CONNECTOR
REAR VS SliNSOR
10 mm NUT AND BOLT
8 mm NUT AND BOLT | MOUNTING BRACKET |
18-12
FRONT DRIVING MECHANISM
breather tube
10 mm mounting bolt
Move the differential forward for maximum clearance between the propeller shaft joint and engine.
PROPELLER SHAFT JOINT
Pull the propeller shaft joint out of the output shaft
of the engine.
Remove the O-ring.
Remove the boot band and propeller shaft boot
from the pinion joint.
PROPELLER SHAFT BOOT
Pull the propeller shaft to force the stopper ring past
the groove in the pinion joint and remove the propeller shaft.
Remove the stopper ring from the propeller shaft
end.
18-13
FRONT DRIVING MECHANISM
Separate the other drive shaft from the differential
as you remove it.
Remove the differential assembly from the frame.
DIFFERENTIAL DISASSEMBLY/
INSPECTION
PROPELLER SHAFT INSPECTION
Remove the boot band and boot from the propeller
shaft joint, and remove the propeller shaft joint and
spring.
BOOT BAND
PROPELLER SHAFT
BOOT
PROPELLER SHAFT JOINT
Check the splines of the propeller shaft and joint for
wear or damage.
If damaged, check the output shaft and the pinion
joint also.
Check the seal rubbers for fatigue or damage.
Check the boots for cuts, deterioration or damage.
BOOTS
SEAL RUBBERS
SPRING
OPERATION CHECK
Install a 8 mm nut onto the pinion gear.
PINION GEAR
8 mm NUT
18-14
FRONT DRIVING MECHANISM
Turn the 8 mm nut and check the pinion gear turns
smoothly and quietly without binding.
If the pinion gear does not turn smoothly or quietly,
the pinion gear, ring gear and/or bearing may be
damaged or faulty. They must be checked after disassembly; replace them if necessary.
BACKLASH INSPECTION
Hold the pinion gear with the 8 mm nut.
Set the differential case into a jig or vise with soft
jaws.
Install the differential inspection tool into the right
side of the differential.
TOOL:
Differential inspection tool
07KMK-HC50101 or
07KMK-HC5010A
(U.S.A. only)
Remove the oil filler cap and set a horizontal type
dial indicator on the ring gear through the filler
hole.
Turn the ring gear back and forth to read backlash.
STANDARD:
0.05 - 0.25 mm (0.002 - 0.010 in)
SERVICE LIMIT: 0.4 mm (0.02 in)
Remove the dial indicator. Turn the ring gear 120°
and measure backlash. Repeat this procedure once
more. Compare the difference of the three measurements.
SERVICE LIMIT: 0.2 mm (0.01 in)
If the difference in measurements exceeds the service limit, it indicates that the bearing is not
installed squarely, or the case is deformed. Inspect
the bearings and case.
18-15
FRONT DRIVING MECHANISM
If the backlash is excessive, replace the ring gear left
side shim with a thinner one.
If the backlash is too small, replace the ring gear left
side shim with a thicker one.
The backlash is changed by about 0.06 mm (0.002
in) when the thickness of the shim is changed by
0.10 mm (0.004 in).
NOTE:
• Twenty-three different thickness shims are available from the thinnest (0.50 mm) shim to the
thickest (1.60 mm) shim in increments of 0.05
mm.
1
A ^ " ^ - - - R I G H T SHIM
J
Im
LEFT SHIM
gP^ 1
i
"-•
Ring gear shims:
A: (thinnest): 0.50 mm (0.020 in)
K: (standard): 1.00 mm (0.039 in)
W: (thickest): 1.60 mm (0.063 in)
Change the right side shim an equal thickness and
opposite amount of what the left side shim was
changed; If the left shim was replaced with a 0.10
mm (0.004 in) thicker shim, replace the right shim
with one that is 0.10 mm (0.004 in) thinner.
DIFFERENTIAL REMOVAL
Loosen the six cover bolts in a crisscross pattern in
several steps and remove them.
PRYING POINTS
Pry the case cover at the points as shown by using a
screwdriver and remove the cover.
CASE COVER
BOLTS
Remove the differential assembly and shims.
SHIMS
DIFFERENTIAL ASSEMBLY
18-16
FRONT DRIVING MECHANISM
BEARING INSPECTION
Turn the inner race of each bearing in the gear case
and cover with your finger. The bearings should
turn smoothly and quietly. Also check that the bearing outer race fits tightly in the case or cover.
BEARING
GEAR TOOTH CONTACT PATTERN
CHECK
Keep dust and dirt Clean sealing material off the mating surfaces of the
out of the case and differential case and cover, being careful not to
cover. damage them.
LEFT SHIM
Apply thin coat of Prussian Blue to the pinion gear
teeth for a tooth contact pattern check.
Install the ring gear shims onto the differential
assembly.
Apply Prussian Blue
Install the differential assembly into the gear case.
RIGHT SHIM
DIFFERENTIAL ASSEMBLY
It is important to Install the case cover and tighten the bolts in several
turn the pinion gear steps until the cover evenly touches the gear case.
while tightening the Then, while rotating the pinion gear, tighten the
bolts. If the ring bolts to the specified torque in a crisscross pattern
gear shim is too in several steps.
thick, the gears will
lock after only light TORQUE: 10 mm bolt: 49 N m (5.0 kgf m, 36 Ibf-ft)
8 mm bolt: 25 N m (2.6 kgf-m, 19 Ibf-ft)
tightening.
10 mm BOLTS
8 mm BOLTS
18-17
FRONT DRIVING MECHANISM
Remove the oil filler cap.
NORMAL:
Rotate the ring gear several times in both directions
of rotation.
HEEL
Check the gear tooth contact pattern through the oil
filler hole.
TOE
FACE
The pattern is indicated by the Prussian Blue
applied to the pinion.
Contact is normal if the Prussian Blue is transferred
to the approximate center of each tooth, but slightly
to the heel side and to the flank side.
FLANK
FLANK
Drive side Coast side
If the patterns are not correct, remove and change
the pinion shim with one of an alternate thickness.
Replace the pinion shim with a thicker one if the
contact pattern is too high, toward the face.
TOO HIGH:
FACE
Drive side
Replace the pinion shim with a thinner one if the
contact pattern is too low, toward the flank.
TOO LOW:
PINION SHIM
FACE
Coast side
PINION SHIM
The pattern will shift about 0.5 - 1.0 mm (0.02 - 0.04
in) when the thickness of the shim is changed by
0.12 mm (0.005).
NOTE:
• Fifteen different thickness shims are available
from the thinnest (1.64 mm) shim to the thickest
(2.18 mm) shim in intervals of 0.06 mm.
Ring gear shims:
A: (thinnest): 1.64 mm (0.064 in)
G: (standard): 2.00 mm (0.079 in)
J: (thickest): 2.18 mm (0.086 in)
For pinion shim replacement (page 18-21)
18-18
FACE
FLANK
Drive side
FLANK
Coast side
FRONT DRIVING MECHANISM
DIFFERENTIAL INSPECTION
Install the inspection tools into both sides of the differential.
TOOL:
Differential inspection tool
07KMK-HC50101 or
07KMK-HC5010A
(U.S.A. only)
Hold the flat surface of the tool with a vise.
Attach a torque wrench to the other tool and measure the limited slip torque.
STANDARD:
14 - 17 N m (14.5 - 17.5 kgfm, 10 - 13 Ibf-ft)
SERVICE LIMIT: 12 N m (1.2 kgf m, 9 Ibf-ft)
If the slip torque is out of specification, disassemble
the differential and perform the components inspection (page 18-20) since the differential may be
faulty.
DIFFERENTIAL DISASSEMBLY
Remove the ten bolts, then place the differential
assembly with the ring gear side up.
BOLTS
RING GEAR
Remove the following:
-
SIDE CONE SPRING
ring gear
side cone spring
shim
SHIM
RING GEAR
18-19
FRONT DRIVING MECHANISM
-
face cam
six cam followers A and six cam followers B
face cam
CAM FACE
CAM FOLLOWERS A AND B
DIFFERENTIAL COMPONENTS
INSPECTION
RING GEAR
Check the sliding surface of the ring gear for damage or discoloration.
Measure the depth of the ring gear from the mating
surface as shown.
SERVICE LIMIT: 6.55 mm (0.2568 in)
DIFFERENTIAL HOUSING/FACE CAM/CAM
FOLLOWERS
Check the sliding surface and grooves of the housing for damage or discoloration.
18-20
DIFFERENTIAL HOUSING
CAM FACE
FRONT DRIVING MECHANISM
Replace the cam Check the shim, face cams and followers for damfollowers as a set age.
112 pieces).
FACE CAM
CAM FOLLOWERS
Temporarily assemble the differential housing, face
cams and cam followers (page 18-27).
Measure the height of the face cam from the housing mating surface as shown while applying a load
of 1.47 kN (150 kgf) to the face cam boss using a
hydraulic press.
SERVICE LIMIT: 3.3 mm (0.13 in)
If the height is smaller than the service limit, replace
the differential as an assembly.
SIDE CONE SPRING
Check the cone spring for damage.
Measure the height of the cone spring.
SERVICE LIMIT: 2.6 mm (0.10 in)
PINION GEAR REMOVAL
Remove the three bolts and front final clutch assembly from the differential.
BOLTS
Remove the O-ring from the final clutch assembly.
FINAL CLUTCH ASSEMBLY
18-21
FRONT DRIVING MECHANISM
Press the pinion gear out of the final clutch assembly using the special tools.
TOOLS:
Driver
Pilot, 15 mm
Be sure to wear
heavy gloves to
avoid burns when
handling the heated
final clutch.
Using a torch to
heat the final clutch
may damage the
clutch.
DRIVER
ATTACHMENT
07749-0010000
07746-0040300
Heat the final clutch to about 100°C (212°F).
REMOVER WEIGHT
Remove the pinion gear bearing from the final
clutch using the special tools.
TOOLS:
Bearing remover, 30 mm
Remover handle
Remover weight
07936-8890300
07936-3710100
07936-371020A or
07936-3710200
REMOVER HANDLE
BEARING REMOVER
CASE BEARING REPLACEMENT
DIFFERENTIAL BEARING
Remove the oil seals from the differential case and
cover.
Drive the differential bearing out of the case and
cover.
Drive new bearings into the differential case and
cover.
TOOLS:
Driver
Attachment, 52 x 55 mm
Pilot, 28 mm
07749-0010000
07746-0010400
07746-0041100
ATTACHMENT/PILOT
18-22
FRONT DRIVING MECHANISM
Apply grease to new oil seal lips and install them
into the differential case and cover.
TOOL:
Attachment, 20 mm I.D.
ATTACHMENT
07746-0020400
PINION NEEDLE BEARING
Rotate the stopper ring until the end of the stopper
ring appears in the access hole.
Strike gently near the end of the ring with a punch
to bent the end upward.
Grasp the end of the ring with needle-nosed pliers
and pull the stopper ring out through the access
hole.
Be sure to wear
heavy gloves to
avoid burns when
handling the heated
gear case.
Using a torch to
heat the gear case
may cause
warpage.
Heat the gear case to about 80°C (176°F) and
remove the needle bearing by using the special
tools.
TOOLS:
Remover head, 15 mm
Bearing remover shaft
Bearing remover, 15 mm
Remover weight
07936-KC10200
07936-KC10100 or
07936-KC10500
07741-0010201 or
07936-371020A or
07936-3710200
(U.S.A. only)
Install a new stopper ring into the groove in a new
bearing.
18-23
FRONT DRIVING MECHANISM
Install the bearing into the compressor until it is
flush with the end of the tool.
TOOL:
Bearing clip compressor, 25 mm 070ME-HN8A100
Place the driver, attachment and pilot on the top of
the bearing and tape the driver to the compressor.
TOOLS:
Driver
Attachment, 22 x 24 mm
Pilot, 15 mm
07949-3710001
07746-0010800
07746-0040300
Place the bearing and tool assembly into a freezer
for at least 30 minutes.
COMPRESSOR
NEEDLE BEARING
Heat the gear case to 80°C (176°F).
Remove the bearing and tool assembly from the
freezer and drive the bearing into the gear case
using the special tools.
Only strike the driver once. If you strike it more than
once, the ring may slip out of the groove. If this happens, remove the ring and bearing, and install a
new ring.
1
s
= 5 ^
DRIVER
COMPRESSOR
PILOT ^
Make sure that the stopper ring is securely set in the
groove of the gear case.
(O'l
STOPPER RING
18-24
FRONT DRIVING MECHANISM
DIFFERENTIAL ASSEMBLY
PINION BEARING
CONE SPRING
PINION SHIM
RING GEAR SHIM

RING GEAR
DIFFERENTIAL BEARING
STOPPER RING
10 mm BOLT
NEEDLE BEARING
GEAR CASE
OIL SEAL
FRONT FINAL CLUTCH
8 mm BOLT
/
GEAR CASE COVER
DIFFERENTIAL BEARING
DIFFERENTIAL SHIM
LEFT FACE CAM
DIFFERENTIAL CASE
CAM FOLLOWERS
I
RIGHT FACE CAM
DIFFERENTIAL BEARING,
2 9 x 5 2 x 1 2 mm
PINION BEARING, 6006 C5
DIFFERENTIAL BEARING,
29 x 52 x 12 mm
NEEDLE BEARING
15 x 25 x 16 mm
18-25
FRONT DRIVING MECHANISM
PINION GEAR INSTALLATION
Install the shim and bearing onto the pinion gear.
NOTE:
• When the gear set, differential bearing, differential housing and/or gear case has been replaced,
use a 2.00 mm (0.079 in) thick shim for initial reference.
PINION BEARING
PINION GEAR
PINION SHIM
Press the pinion bearing onto the pinion gear.
TOOLS:
Driver, 40 mm I.D.
Attachment, 30 mm I.D.
DRIVER
07746-0030100
07746-0030300
ATTACHMENT
BEARING
PINION GEAR
Be careful not to Press the pinion gear/bearing assembly into the
damage the oil seal front final clutch using the special tools.
lips in the final
clutch. TOOLS:
Press attachment
Universal bearing puller
Be sure to wear
heavy gloves to
avoid burns when
handling the heated
final clutch case.
UNIVERSAL
BEARING PULLER
ATTACHMENT
N.
07LME-GE20100
07631-0010000 or
equivalent commercially available in
U.S.A.
U.S.A. only:
Heat the final clutch case to about 100°C (212°F).
Drop the pinion gear assembly into the warm final
clutch case.
PINION GEAR/BEARING
Coat a new O-ring with grease and install it into the
groove in the front final clutch assembly.
FINAL CLUTCH ASSEMBLY
18-26
FRONT DRIVING MECHANISM
Install the final clutch assembly onto the differential.
Install and tighten the three bolts.
BOLTS
TORQUE: 25 N m (2.6 kgf-m, 19 Ibfft)
FINAL CLUTCH ASSEMBLY
Keep dust and dirt
out of the differential housing.
DIFFERENTIAL ASSEMBLY
Install the face cam into the differential housing.
Install the six cam followers A (rib) and six cam followers B (flat) into the specified grooves in the
housing by two and two as shown.
CAM FOLLOWERS
HOUSING
Install the face cam onto the cam followers.
CAM FACE
Measure the depth of the ring gear and record it
(page 18-20).
Measure the height of the housing-to-cam and
record it (page 18-20).
Calculate the shim thickness using the equation
below. The correct shim is nearly this dimension.
A = B - C - 1.6 mm
A: New shim thickness
B: Recorded ring gear depth
C: Recorded face cam height
Select the shim and install it onto the face cam.
Differential shims:
A: 1.3 mm (0.051 in)
B: 1.4 mm (0.055 in)
C: 1.5 mm (0.059 in)
D: 1.6 mm (0.063 in)
SIDE CONE SPRING
E: 1.7 mm (0.067 in)
F: 1.8 mm (0.071 in)
G: 1.9 mm (0.075 in)
Install the cone spring with the concaved side facing
up (ring gear side).
Install the ring gear.
SHIM
RING GEAR
18-27
FRONT DRIVING MECHANISM
Install new ring gear bolts and tighten them in a
crisscross pattern in several steps.
BOLTS
TORQUE: 49 N m (5.0 kgf m, 36 Ibf ft)
Inspect the slip torque (page 18-19).
If the slip torque is out of specification, perform the
shim adjustment. Replace the differential assembly
when the replacement shim is changed by 0.3 mm
or more from the selected shim (page 18-27).
RING GEAR
DIFFERENTIAL CASE ASSEMBLY
NOTE:
• When the gear set, bearing, differential housing
and/or gear case has been replaced, check the
tooth contact pattern (page 18-17).
Check the gear backlash (page 18-15).
Keep dust and dirt Clean the mating surface of the gear case and cover,
out of the case and being careful not to damage them.
cover. g | o w c o m p r e s S e d air through the breather hole in
the case cover.
Install the proper ring gear shims onto the differential assembly and install the assembly into the gear
case.
18-28
SHIMS
FRONT DRIVING MECHANISM
Coat a new O-ring with grease and install it into the
gear case cover groove.
GEAR CASE
CASE COVER
Install the case cover over the gear case.
DIFFERENTIAL ASSEMBLY
It is important to Apply locking agent to the threads of the two 10 mm
turn the pinion gear bolts.
while tightening the Install the bolts and tighten them in several steps
bolts. If the ring until the cover evenly touches the gear case. Then,
gear shim is too while rotating the pinion gear, tighten the bolts to
thick, the gears will the specified torque in a crisscross pattern in sevlock after only light eral steps.
tightening.
TORQUE: 10 mm bolt: 49 N m (5.0 kgfm, 36 Ibf-ft)
8 mm bolt: 25 IM m (2.6 kgfm, 19 Ibf-ft)
Make sure that the gear assembly rotates smoothly
without binding.
PROPELLER SHAFT ASSEMBLY
PINION JOINT
e ^ i
SEAL RUBBER
SEAL RUBBER
(5-8g)
Apply molybdenum disulfide grease to the seal rubbers.
Apply 5 - 8 g of molybdenum disulfide grease to the
propeller shaft joint splines.
PROPELLER SHAFT JOINT
SEAL RUBBERS
Set the spring and propeller shaft joint onto the propeller shaft.
SPRING
PROPELLER SHAFT JOINT
18-29
FRONT DRIVING MECHANISM
Install the boot over the propeller shaft joint while
compressing the spring.
Install the boot band into the boot groove.
PROPELLER SHAFT
BOOT
BOOT BAND
PROPELLER SHAFT JOINT
DIFFERENTIAL INSTALLATION
Place the differential into the frame.
Install the right drive shaft onto the differential in
the same manner as on (page 18-11).
Install a new stopper ring into the groove in the propeller shaft.
Apply 5 - 8 g of molybdenum disulfide grease to the
propeller shaft joint splines.
Install the propeller shaft assembly into the differential until the stopper ring seats in the pinion joint
groove.
Make sure that the stopper ring is seated properly
by pulling on the pinion joint lightly.
Install the propeller shaft boot over the pinion joint
securely and the boot band into the boot groove.
PROPELLER SHAFT BOOT
18-30
FRONT DRIVING MECHANISM
Coat a new O-ring with molybdenum disulfide
grease and install it into the groove in the output
shaft.
Apply molybdenum disulfide grease to the output
shaft splines.
PROPELLER SHAFT JOINT
Apply molybdenum disulfide grease to the propeller
shaft joint splines.
Move the differential forward for maximum clearance between the propeller shaft joint and output
shaft.
Install the propeller shaft joint over the output shaft.
OUTPUT SHAFT
Align the bolt holes in the differential and frame,
and install the 10 mm mounting bolt.
BREATHER HOSE '.
Connect the breather hose.
Install the spacer, 10 mm mounting bolt and nut.
Install the mounting bracket, 8 mm bolts, 8 mm
mounting bolt and nut.
Tighten the all mounting fasteners.
TORQUE: 10 mm: 44 N-m (4.5 kgf-m, 33 Ibfft)
8 mm: 22 N-m (2.2 kgf-m, 16 Ibfft)
8 mm NUT AND BOLT • MOUNTING BRACKET i
Connect the front final clutch 2P (Green) connector
and install it onto the sensor cover stay.
Install the rear VS sensor, VS sensor cover stay and
three bolts, and tighten the bolts.
2P(GREEN) CONNECTOR
MUM
REAR VS SENSOR
TORQUE: 10 N-m (1.0 kgfm, 7 Ibfft)
Clamp the rear VS sensor wire and front final clutch
wire.
18-31
FRONT DRIVING MECHANISM
Install the VS sensor cover while hooking it on the
boss on the case, and install and tighten the two
bolts.
TORQUE: 7 N m (0.7 kgf m, 5.1 Ibf-ft)
Install the front VS sensor, guard plate and two
bolts, and tighten the bolts.
TORQUE: 10 N m (1.0 kgf m, 7 Ibf-ft)
Install the following:
-
left drive shaft (page 18-7)
front grille (page 3-10)
inner fenders (page 3-9)
left front mud guard (page 3-8)
Fill the differential with the recommended oil (page
4-16).
18-32
19. REAR DRIVING MECHANISM
SYSTEM COMPONENTS
19-2
UNIVERSAL JOINT
19-15
SERVICE INFORMATION
19-3
FINAL DRIVE DISASSEMBLY/
TROUBLESHOOTING
19-5
INSPECTION
19-16
REAR DRIVE SHAFT •
19-6
CASE BEARING REPLACEMENT
19-21
FINAL DRIVE REMOVAL
19-12
FINAL DRIVE ASSEMBLY
19-23
FINAL DRIVE INSPECTION
19-14
FINAL DRIVE INSTALLATION
19-27
19-1
REAR DRIVING MECHANISM
SYSTEM COMPONENTS
34 N-m (3.5 kgf m,
25 Ibf ft)
34 N-m (3.5 kgf m, 25 Ibf ft)
34 N-m (3.5 kgf m, 25 Ibfft)
30 N-m (3.1 kdf-m, 22 Ibfft)
39 N-m (4.0 kgfm, 29 Ibfft)
19-2
REAR DRIVING MECHANISM
SERVICE INFORMATION
GENERAL
• Perform the gear contact pattern and backlash inspection whenever you replace the bearings, gears or gear case. The
extension lines from the gear engagement surfaces should intersect at one point.
• Protect the gear case with a shop towel or soft jaws while holding it in vise. Do not clamp it too tight as it could damage
the gear case.
• When using the lock nut wrench, use a deflecting beam type torque wrench 20 inches long. The lock nut wrench
increases the torque wrench's leverage, so the torque wrench reading will be less than the torque actually applied to the
lock nut. The specification given is the actual torque applied to the lock nut, not the reading on the torque wrench. Do
not overtighten the lock nut. The specification later in the text gives both actual and indicated.
• Replace the ring and pinion gears as a set.
• For bearing replacement in the knuckle (page 16-7).
SPECIFICATIONS
Final drive
ITEM
Oil capacity
At draining
At disassembly
Recommended oil
Gear backlash
Backlash difference
Ring gear-to-stop pin clearance
STANDARD
78 cm3 (2.6 US oz, 2.7 Imp oz)
90 cm 3 (3.0 US oz, 3.2 Imp oz)
Hypoid gear oil SAE #80
0.05-0.25(0.002-0.010)
0.3-0.6(0.01-0.02)
Unit: mm (in)
SERVICE LIMIT
0.4(0.02)
0.2(0.01)
-
TORQUE VALUES
Final gear case pinion bearing lock nut
Pinion joint nut
Final gear case cover bolt (10 mm)
Final gear case cover bolt (8 mm)
Final gear case mounting nut (main frame)
Final gear case mounting nut (sub frame)
Sub-frame joint nut
Rear brake disc bolt
98 N-m (10.0 kgf-m, 72 Ibf-ft) Lock nut: replace with a new one. Stake.
108 N-m (11.0 kgfm, 80 Ibf-ft) Apply locking agent to the threads.
49 N-m (5.0 kgf-m, 36 Ibf-ft) Apply locking agent to the threads.
25 N-m (2.6 kgf-m, 19 Ibf-ft)
34 N-m (3.5 kgf-m, 25 Ibf-ft) Lock nut: replace with a new one.
39 N-m (4.0 kgf-m, 29 Ibf-ft) Lock nut: replace with a new one.
34 N-m (3.5 kgf-m, 25 Ibf-ft)
20 N-m (2.0 kgf-m, 14 Ibf-ft) ALOC bolt: replace with a new one.
19-3
REAR DRIVING MECHANISM
TOOLS
Attachment, 52 x 55 mm
07746-0010400
Attachment, 62 x 68 mm
07746-0010500
Driver, 40 mm I.D.
07746-0030100
Attachment, 25 mm I.D.
07746-0030200
Attachment, 35 mm I.D.
07746-0030400
Pilot, 30 mm
07746-0040700
Driver
07749-0010000
Lock nut wrench, 30 x 64 mm
07916-MB00002
Puller shaft
07931-ME40000
Remover handle
07936-3710100
Bearing remover set, 17 mm
07936-3710300
Remover weight
07741-0010201
or 07936-371020A or 07936-3710200
(U.S.A. only)
or 07931-ME4010B and 07931HB3020A (U.S.A. only)
19-4
REAR DRIVING MECHANISM
Oil seal driver
07965-KE80200
Bearing clip compressor, 28 mm
070ME-HN8A200
not available in U.S.A.
Driver attachment
07LAD-PW50500
Pinion puller base
07HMC-MM80110
or 07HMC-MM8011A (U.S.A. only)
Pinion holder
07SMB-HM70200
Puller attachment
07YMC-GCS0100
(not available in U.S.A.) or 079493710001, 07746-0010700 and 077460040400
TROUBLESHOOTING
Excessive noise
• Worn or damaged bearing
• Worn or scored splines
• Worn or damaged drive shaft, propeller shaft or universal joint
• Worn pinion and ring gears
• Excessive backlash between pinion and ring gears
• Oil level too low
Wobble or vibration in vehicle
• Axle not tightened properly
• Bent axle
Oil leak
• Oil level too high
• Clogged breather
• Damaged seals
• Loose case cover
19-5
REAR DRIVING MECHANISM
REAR DRIVE SHAFT
REMOVAL
Remove the following.
-
wheel hub (page 16-6)
seat (page 3-4)
Flight drive shaft: Remove the right side cover (page 3-5).
Left drive shaft: Remove the oil filler lid (page 3-8).
Support the lower arm with a support block.
Remove the following:
-
stabilizer link nut (to disconnect the link)
two upper arm pivot nuts and bolts
-
shock absorber upper mounting nut and bolt
Remove the shock absorber and upper arm off the
frame, and pivot the knuckle outward to release it
from the drive shaft.
KNUCKLE
To prevent damage Hold the inboard joint of the drive shaft and tug I INBOARD JOINT
to>the
thegear
gearcase
caseoiloil firmly
firmlytotoforce
forcethe
thestopper
stopperring
ringat, the drive shaft end U ^ ^ ^ a . .
seal, hold the past the groove while prying with a screwdriver.
inboard joint horiRemove the stopper ring.
zontal until the drive
shaft is clear of the
gear case.
19-6
REAR DRIVING MECHANISM
DISASSEMBLY/INSPECTION
Check the boots for cuts or other damage.
Check the drive shaft joints for excessive play or
noise by moving the joints in a circular direction.
If the outboard joint seems to be worn or damaged,
the drive shaft must be replaced.
OUTBOARD JOINT
BOOTS
NOTE:
• To replace the outboard boot, first remove the
inboard boot as described in the following steps.
Then remove the bands and outboard boot from
the inboard end of the shaft.
• The outboard joint cannot be disassembled.
INBOARD JOINT
Replace the band
with new ones
whenever removing them.
Bend up the lock tabs and raise the band ends to
loosen the boot bands on the inboard side.
Remove the inboard boot band.
TABS
BAND END
Remove the boot from the inboard joint.
INBOARD BOOT BAND
BAND B
Remove the following:
-
stopper ring
inboard joint
STOPPER RING
snap ring
bearing
inboard boot
boot band B
BOOT
SNAP RING
BEARING
19-7
REAR DRIVING MECHANISM
Replace their com- Check the following for wear or damage:
ponentsasan _ b e a r j
assembly.
-
INBOARD JOINT
steel balls
inboard joint
BEARING
Remove the following:
-
BOOT
shaft boot band
outboard boot band
outboard boot
SHAFT BOOT BAND
OUTBOARD BOOT BAND
ASSEMBLY
DRIVE SHAFT
SHAFT BOOT BAND
INBOARD JOINT
OUTBO/SRDBOOT
OUTBOARD JOINT
SNAP RING
BEARING
STOPPER RING
INBOARD BOOT BAND
BEARING RACE
INBOARD BOOT
BEARING CAGE
19-8
BANDB
OUTBOARD BOOT BAND
REAR DRIVING MECHANISM
Each boot has an identification mark; "85-71L" for
the outboard and "BJ75" for inboard.
"85-71L"
OUTBOARD BOOT
"BJ75"
INBOARD BOOT
Note the installation direction of the boot bands.
Pack the outboard joint with 45 - 65 g of specified
grease.
-,, ,-ronADn D/~>I-VT
OUTBOARD BOOT
Specified grease: NKG106 (KYODO YUSHI)
BANDB
Install the following:
-
outboard boot
new shaft boot band
new boot band B
inboard boot
Do not tighten the bands at this time.
INBOARD BOOT
Install the bearing with the small O.D. facing the
drive shaft.
Install the snap ring with the chamfered side facing
to the bearing.
SNAP RING
BEARING
19-9
REAR DRIVING MECHANISM
Pack the inboard joint with 60 - 80 g of specified
grease.
Specified grease: NKG205 (KYODO YUSHI)
Install the inboard joint over the bearing.
Install the stopper ring into the groove in the
inboard joint properly.
Install the inboard boot over the inboard joint
securely.
STOPPER RING
Pack 60 - 8C
Be sure the length of the drive shaft to be set the figure given below.
DRIVE SHAFT LENGTH: 425.2 mm (16.74 in)
For band Install the shaft boot band and a new outboard boot
installation direction band onto the outboard boot.
(page 19-9). Bend down each band end and secure it with the
lock tabs. Tap the lock tabs with a plastic hammer.
TABS

SHAFT BOOT BAND
Install the boot band B and a new inboard boot
band onto the inboard boot.
Bend down each band end and secure it with the
lock tabs. Tap the lock tabs with a plastic hammer.
OUTBOARD
BOOT BAND
INBOARD BOOT BAND
BANDB
INBOARD JOINT
19-10
REAR DRIVING MECHANISM
INSTALLATION
Install a new stopper ring into the groove in the
inboard joint splines.
STOPPER RING
Be careful not to Install the drive shaft by holding the inboard joint
damage the oil seal until the stopper ring seats in the groove.
e gear case. ^a^Q s u r e t n e s ^ O pp e r r j n g j s seated properly by
pulling on the inboard joint lightly.
Pack the lip cavities of the inner dust seal with 2.5 3 g of grease.
Set the upper arm and shock absorber into the
frame properly to fit the knuckle over the drive
shaft.
Insert the pivot Install the upper arm pivot bolts and new nuts, and
bolts from the tighten them.
inside.
TORQUE: 34 IM-m (3.5 kgfm, 25 Ibf-ft)
Connect the stabilizer link into the upper arm with a
new nut and tighten it securely.
UPPER ARM
19-11
REAR DRIVING MECHANISM
Install the shock absorber upper mounting bolt and
a new nut, and tighten it securely.
Install the following:
- wheel hub (page 16-9).
Right side: - right side cover (page 3-5)
Leftside: - oil filler lid (page 3-8)
- seat (page 3-4).
FINAL DRIVE REMOVAL
Drain the final gear case oil (page 4-15).
Remove the following:
-
engine guard (page 3-17)
rear brake caliper without disconnecting the
brake hose (page 17-27)
drive shafts (page 19-6)
Remove the following from the frame:
-
pivot nuts and bolts
suspension arm/shock absorber assemblies
Remove the brake hose clamp bolt.
BOLT
Place a floor jack or other adjustable
support under the
sub-frame.
sub-frame joint nuts and bolts
SUB-FRAME
19-12
BOLTS AND NUTS
REAR DRIVING MECHANISM
breather hose
upper mounting nuts and bolts
Lower the jack slightly and move it rearward to dis- I O-R|"N<~
connect the propeller shaft. Remove the final drive
assembly out of the vehicle.
Remove the following:
-
universal joint
O-rings (from the propeller shaft and output
shaft of the engine)
boot band
joint boot (off the pinion joint)
propeller shaft
spring
disc bolts
brake disc
DISC
mounting nuts and bolts
final drive assembly
! FINAL DRIVE ASSEMBLY i
19-13
REAR DRIVING MECHANISM
FINAL DRIVE INSPECTION
PROPELLER SHAFT
For boot and seal Check the splines for wear or damage.
replacement (page If damaged, check the universal joint and output
shaft also.
Check the seal rubber for fatigue or damage.
Check the boot for cuts or damage.
SEAL RUBBER
BOOT
UNIVERSAL JOINT
Check the boot for cuts or other damage.
Check that the joint moves smoothly without binding or noise.
FINAL DRIVE OPRRATION
Turn the pinion joint and check that the gear turns
smoothly and quietly without binding.
If the
gears
They
faulty
19-14
gears do not turn smoothly or quietly, the
and/or bearing may be damaged or faulty.
must be checked after disassembly; replace
parts/assemblies as required.
REAR DRIVING MECHANISM
UNIVERSAL JOINT
UNIVERSAL JOINT DISASSEMBLY/
ASSEMBLY
Bend up the lock tabs and raise the band ends to
loosen the boot bands.
Remove the joint boot.
Apply molybdenum disulfide grease to the joint
bearing.
BAND END
Install the boot and set it onto the universal joint
properly.
TABS
Install new boot bands so the band ends are facing
opposite the forward direction.
Bend down each band end and secure it with the
lock tabs. Tap the lock tabs with a plastic hammer.
BOOT
Viewed from the rear side:
AI T — ^
Forward direction
//
f
. — TABS

/
s

END
f
BAND
19-15
REAR DRIVING MECHANISM
FINAL DRIVE DISASSEMBLY/
INSPECTION
BACKLASH INSPECTION
Remove the oil filler cap.
PINION
HOLDER
Install the special tool into the pinion joint, and set
the final drive assembly and tool in a vise.
TOOL:
Pinion holder
07SMB-HM70200
Install the drive shaft into the final drive assembly
and hold it.
Set a horizontal type dial indicator on the ring gear
through the filler hole.
Turn the ring gear back and forth with the drive
shaft to read backlash.
RING GEAR
STANDARD:
0.05-0.25 mm (0.002-0.010 in)
SERVICE LIMIT: 0.4 mm (0.02 in)
Remove the dial indicator. Turn the ring gear 120"
and measure backlash.
Repeat this procedure once more.
Compare the difference of the three measurements.
SERVICE LIMIT: 0.2 mm (0.01 in)
If the difference in measurements exceeds the service limit, it indicates that the bearing is not
installed squarely, or the case is deformed.
Inspect the bearings and case.
LEFT SHIM
If the backlash is excessive, replace the ring gear
right shim with a thinner one.
If the backlash is too small, replace the ring gear
right shim with a thicker one.
Backlash is changed by about 0.06 mm (0.002 in)
when thickness of the spacer is changed by 0.12
mm (0.005 in).
NOTE:
• Ten different shims (from A to J) are available in
thickness increments of 0.06 mm (0.002 in).
Ring gear shims:
A: 1.64 mm (0.064 in)
B: 1.70 mm (0.067 in)
C: 1.76 mm (0.069 in)
D: 1.82 mm (0.072 in)
E: 1.88 mm (0.074 in)
F: 1.94 mm (0.076 in)
G: 2.00 mm (0.079 in)
H: 2.06 mm (0.081 in)
I: 2.12 mm (0.083 in)
J: 2.18 mm (0.086 in)
Change the left shim thickness in an opposite
amount of what the right shim was changed; If the
right shim was replaced with a 0.12 mm (0.005 in)
thicker one, replace the left shim with a 0.12 mm
(0.005 in) thinner one.
19-16
RIGHT SHIM
REAR DRIVING MECHANISM
FINAL GEAR CASE DISASSEMBLY
Loosen the cover bolts in a crisscross pattern in several steps and remove them.
Pry the cover at the prying points using a screwdriver and remove the case cover.
Remove the O-ring.
PRYING POINTS
Remove the ring gear and shims.
BEARING
RING GEAR
SHIMS
BEARING INSPECTION
Turn the inner race of each bearing in the gear case
and case cover with your finger. The bearings
should turn smoothly and quietly. Also check that
the bearing outer race fits tightly in the case and
cover.
BEARING
BEARING
For ring gear bearing replacement (page 19-21).
19-17
REAR DRIVING MECHANISM
GEAR TOOTH CONTACT PATTERN
CHECK
Keep dust and dirt Clean the mating surfaces of the gear case and
out of the case and cover.
cover.
thin coat of Prussian Blue to the pinion gear
teeth for a tooth contact pattern check.
RING GEAR
Apply Prussian Blue
Install the ring gear shims onto the ring gear.
Install the ring gear with the shims into the gear
case.
LEFT SHIM
Align the bolt holes and install the case cover.
It is important to
turn the pinion
while tightening the
bolts. If the ring
gear shims is too
thick, the gears will
lock after only light
tightening.
10 mm BOLTS
COVER
Install the cover bolts and tighten them in several
steps until the cover evenly touches the gear case.
Then, while rotating the pinion gear, tighten the
bolts to the specified torque in a crisscross pattern
in several steps.
TORQUE:
10 mm bolt: 49 N m (5.0 kgf m, 36 Ibfft)
8 mm bolt: 25 N m (2.6 kgf m, 19 Ibfft)
mm BOLTS
Remove the oil filler cap.
NORMAL:
Rotate the ring gear several times in both directions
of rotation.
Check the gear tooth contact pattern through the oil
filler hole.
The pattern is indicated by the Prussian Blue
applied to the pinion.
Contact is normal if the Prussian Blue is transferred
to the approximate center of each tooth, but slightly
to the heel side and to the flank side.
If the pattern are not correct, remove and change
the pinion shim with one of an alternate thickness.
19-18
FACE
FLANK
DRIVE
SIDE
FLANK
COAST
SIDE
REAR DRIVING MECHANISM
Replace the pinion shim with a thicker one if the
contact pattern is too high, toward the face.
TOO HIGH:
DRIVE SIDE
Replace the pinion shim with a thinner one if the
contact pattern is too low, toward the flank.
COAST SIDE
TOO LOW:
The pattern will shift about 0.5 - 1.0 mm (0.02 - 0.04
in) when the thickness of the shim is changed by
0.12 mm (0.005 in).
Pinion gear shims:
A: 1.82 mm (0.072 in)
B: 1.88 mm (0.074 in)
C: 1.94 mm (0.076 in)
D: 2.00 mm (0.079 in)
E: 2.06 mm (0.081 in)
F: 2.12 mm (0.083 in)
G: 2.18 mm (0.086 in)
FLANK
For pinion shim replacement (page 19-20).
DRIVE SIDE
FLANK
COAST SIDE
PINION GEAR REMOVAL
Install the special tool into the pinion joint, and set
the final drive assembly and tool in a vise.
TOOL:
Pinion holder
07SMB-HM70200
Take care not to Loosen the pinion joint nut, and remove the joint
drop the final drive nut and pinion joint.
assembly from the
vise.
PINION HOLDER
Remove the oil seals and O-ring.
OIL SEALS
19-19
REAR DRIVING MECHANISM
Be careful that Unstake the pinion bearing lock nut with a drill or
metal particles do grinder.
Unstake
LOCK NUT
not enter the bearing and the threads
of the case are not
damaged.
Remove the lock nut using the special tool.
TOOL:
Lock nut wrench, 30 x 64 mm
_
LUCK NUI
WRENCH
07916-MB00002
Install the special tools onto the pinion gear shaft
and gear case.
TOOLS:
Pinion puller base
Puller shaft
07HMC-MM80110 or
07HMC-MM8011A
(U.S.A. only)
07931-ME40000 or
07931-ME4010B and
07931-HB3020A
(U.S.A. only)
Pull the pinion gear assembly out from the gear
case.
PINION GEAR BEARING/SHIM
REPLACEMENT
Pull the pinion bearing from the shaft with a commercially available bearing puller.
Remove the pinion shim.
19-20
PULLER BASE •
REAR DRIVING MECHANISM
Install the shim and bearing onto the pinion gear.
SHIM
NOTE:
• When the gear set, ring gear bearing, and/or gear
case has been replaced, use a 2.00 mm (0.79 in)
thick shim for initial reference.
BEARING
PINION GEAR
Press the pinion gear in the bearing until it is seated
by supporting the bearing with the special tool.
TOOL:
Attachment 25 mm I.D.
07746-0030200
CASE BEARING REPLACEMENT
RING GEAR BEARING
Remove the oil seals from the case and cover.
OIL SEAL
BEARING
Drive the bearings out of the case and cover.

Drive each new bearing using the special tools.
TOOLS:
Case cover:
Driver
Attachment, 62 x 68 mm
Pilot, 30 mm
Gear case:
Driver
Attachment, 52 x 55 mm
Pilot, 30 m m
DRIVER
07749-0010000
07746-0010500
07746-0040700
07749-0010000
07746-0010400
07746-0040700
ATTACHMENT/PILOT
19-21
REAR DRIVING MECHANISM
Apply grease to new oil seal lips.
Install each oil seal with the metal side facing out so
the exposed height is 4 mm (0.16 in) evenly (the
rubber edge flush with the cover).
TOOLS:
Attachment, 35 mm I.D.
Driver, 40 mm I.D.
DRIVER
07746-0030400
07746-0030100
: IACHMENT
PINION NEEDLE BEARING
Remove the stopper ring by rotating it until the end
of the stopper ring appears in the access hole.
Strike gently near the end of the ring with a punch
to bend the end upward.
Grasp the end of the ring with needle-nosed pliers
and pull the stopper ring out through the access
hole.
Be sure to wear
heavy gloves to
avoid burns when
handling the heated
gear case. Using a
torch to heat the
gear case may
cause warpage.
Heat the gear case to 80°C (176°F) and remove the
needle bearing by using the special tool.
TOOLS:
Bearing remover, 17 mm
Remover handle
Remover weight
07936-3710300
07936-3710100
07741-0010201 or
07936-371020A or
07936-3710200
(U.S.A. only)
Remove the bearing cage and bearings from the
inside of the pinion bearing to allow the special tool
to grip the bearing.
STOPPER RING
Install the stopper ring into the groove in the bearing.
Install the bearing into the special tool until the
bearing is flush with the end of the tool.
TOOL:
Bearing clip compressor, 28 mm
070ME-HN8A200
Freeze the pinion bearing with the tool on ice or in a
freezer.
Heat the gear case to 80 C (176°F).
COMPRESSOR
Tape the clip com- Drive the pinion bearing into the gear case using the
pressor to the special tools as follows.
driver for bearing
installation. TOOLS:
Puller attachment
Driver
Attachment, 24 x 26 mm
Pilot, 17 mm
07YMC-GCS0100
(not available in
U.S.A.) or
07949-3710001
07746-0010700
07746-0040400
Only strike the driver once. If you strike it more than
once, the stopper ring may slip out of the groove.
If this happens, remove the ring and bearing, and
install a new one again.
Make sure that the stopper ring is securely set in the
groove of the gear case.
19-22
DRIVER
REAR DRIVING MECHANISM
FINAL DRIVE ASSEMBLY
GEAR CASE
OIL SEAL
RING GEAR BEARING
STOPPER RING
SHIM
PINION NEEDLE BEARING
RING GEAR
PINION GEAR
SHIM
SHIM
RING GEAR BEARING
PINION BEARING
V)
STOP PIN
INNER OIL SEAL
SHIM
OIL SEAL
OUTER OIL SEAL
GEAR CASE COVER
PINION JOINT
BRAKE DISC
PINION GEAR INSTALLATION
Keep the driver Drive the pinion gear assembly into the gear case.
centered with the
bearing outer race TOOL:
during installation. Oil seal driver
OIL SEAL DRIVER
07965-KE80200 (not
available in U.S.A.)
19-23
REAR DRIVING MECHANISM
Be sure to wear
heavy gloves to
avoid burns when
handling the heated
gear case. Using a
torch to heat the
gear case may
cause warpage.
U.S.A. only:
Freeze the pinion gear and bearing.
Heat the gear case to 80°C (176°F).
Drop the cold pinion assembly into the warm gear
case.
Install a new lock nut and tighten it using the special
tool.
TOOL:
Lock nut wrench, 30 x 64 mm
LOCK NUT WRENCH
07916-MB00002
Refer to torque TORQUE:
wrench reading
Actual:
98 N m (10.0 kgfm, 72 Ibfft)
information on
Indicated: 89 N m (9.1 kgfm, 66 Ibf ft)
"Service Information" (page 19-3).
Be careful not to
damage the threads
of the case.
Stake the lock nut into the case groove.
Coat a new O-ring with grease and install it onto the
pinion gear shaft.
Apply grease to the lips of new oil seals
Install the inner oil seal (70 mm O.D.) into the gear
case until it is flush with the stepped edge.
TOOL:
Driver attachment
19-24
07LAD-PW50500
Stake
LOCK NUT
REAR DRIVING MECHANISM
Install the outer oil seal (75 mm O.D.) into the gear
case until it is flush with the gear case outer surface,
using the same tool.
OIL SEAL
Clean the threads of the pinion gear shaft thoroughly.
Install the pinion joint onto the pinion gear shaft,
being careful not to damage the oil seal lips.
Apply locking agent to the threads of the pinion
joint nut and screw it in by hand as far as it goes.
Hold the pinion joint with the special tool and
tighten the joint nut.
TOOL:
Pinion holder
07SMB-HM70200
TORQUE: 108 N m (11.0 kgf-m, 80 Ibfft)
RING GEAR CLEARANCE INSPECTION
Install the ring gear with the shim into the case
cover.
RING GEAR
Measure the clearance between the ring gear and
stop pin with a feeler gauge.
CLEARANCE: 0.3 - 0.6 mm (0.01 - 0.02 in)
CASE COVER
STOP PIN
Remove the ring gear.
Be sure to wear
heavy gloves to
avoid burns when
handling the heated
case cover. Using a
torch to heat the
case cover may
cause warpage.
If the clearance is not within specification, heat the
case cover to approximately 80°C (176°F) and
remove the stop pin by tapping the cover.
Install a stop pin shim to obtain the correct clearance.
STOP PIN SHIMS:
A: 0.10 mm (0.004 in)
B: 0.15 mm (0.006 in)
Drive the stop pin into the case cover.
STOP PIN
SHIM
19-25
REAR DRIVING MECHANISM
FINAL GEAR CASE ASSEMBLY
NOTE:
• When the gear set, bearing, and/or gear case has
been replaced, check the tooth contact pattern
check (page 19-18).
Check the gear backlash (page 19-16).
Keep dust and dirt Clean the mating surface of the gear case and cover,
out of the case and being careful not to damage them.
cover. g | o w compressed air through the breather holes in
the gear case and cover.
Install the proper ring gear shims onto the ring gear
and install them into the gear case.
Coat a new O-ring with grease and install it into the
cover groove.
Install the case cover onto the gear case.
O-RING
Apply locking agent to the threads of the two 10mm bolts.
It is important to
turn the pinion
while tightening the
bolts. If the ring
gear shim is too
thick, the gears will
lock after only light
tightening.
1
TE33 10 mm BOLTS
COVER
Install the cover bolts and tighten them in several
steps until the cover evenly touches the case. Then,
while rotating the pinion gear, tighten the bolts to
the specified torque in a crisscross pattern in several steps.
TORQUE:
10 mm bolt: 49 N m (5.0 kgf m, 36 Ibf-ft)
8 mm bolt: 25 N m (2.6 kgf m, 19 Ibf ft)
Check that the gear assembly turns smoothly without binding.
8 mm BOLTS
19-26
REAR DRIVING MECHANISM
FINAL DRIVE INSTALLATION
Install the final drive assembly onto the sub-frame
by inserting the mounting bolts from the left side.
Install new mounting nuts but do not tighten them
yet.
FINAL DRIVE ASSEMBLY i
BOLTS AND +3*
Install the brake disc with the stamp facing the
engine side. Install new disc bolts and tighten them
in a crisscross pattern in several steps.
NUTS
BOLTS
TORQUE: 20 N-m (2.0 kgf-m, 14 Ibf-ft)
Install a new seal rubber onto the seal groove in the
propeller shaft in the direction as shown.
Install the joint boot onto the boot groove and the
boot band into the band groove in the boot.
Apply molybdenum disulfide grease to the seal rubber outer surface.
Apply 5 - 8 g of molybdenum disulfide grease to the
pinion joint splines.
Install the spring into the propeller shaft.
Set the propeller shaft into the pinion joint while
compressing the spring, then install the boot over
the pinion joint groove securely and secure it with
the boot band.
Be sure the propeller shaft is installed properly by
pulling on the shaft lightly.
BOOT
19-27
REAR DRIVING MECHANISM
Coat a new O-ring with molybdenum disulfide
grease and install it into the groove in the output
shaft.
Apply molybdenum disulfide grease to the splines
of the both sides in the universal joint and install it
onto the output shaft until it is fully seated.
Coat a new O-ring with molybdenum disulfide
grease and install it into the propeller shaft groove.
Put the final drive assembly on a floor jack or other
adjustable support and place the assembly under
the main frame.
While adjusting the jack height, move the final drive
assembly forward and connect the propeller shaft
into the universal joint.
Be careful not to
disconnect the propeller shaft and universal joint.
Set the final drive assembly into the main frame and
seat the propeller shaft securely to align the bolt
holes, then insert the mounting bolts from the left
side.
Install new mounting nuts but do not tighten them
yet.
Route the breather hoses properly (page 1-20) and
connect them.
Insert the sub-frame joint bolt bolts from the inside.
Install new joint nuts.
Tighten the four mounting nuts and joint nuts alternately.
TORQUE:
Joint nut:
34 N m
Mounting
34 N m
Mounting
39 N m
(3.5 kgf-m, 25 Ibf-ft)
bolt (main frame):
(3.5 kgf-m, 25 Ibf-ft)
bolt (sub-frame):
(4.0 kgf-m, 29 Ibf-ft)
NUTS
19-28
REAR DRIVING MECHANISM
Install the brake hose clamp and tighten the brake
house clamp bolt securely.
BOLT
Install each lower arm of the suspension arm/shock
absorber assemblies into the frame and insert each
pivot bolt from the rear side.
Install new pivot nuts and tighten them.
TORQUE: 34 N m (3.5 kgf-m, 25 Ibfft)
Install the following:
-
drive shafts (page 19-11)
brake caliper (page 17-32)
engine guard (page 3-17)
Fill the gear case with the recommended oil (page 415).
19-29
20. BATTERY/CHARGING SYSTEM
COMPONENT LOCATION
20-2
BATTERY
••
20-6
SYSTEM DIAGRAM
20-2
CHARGING SYSTEM INSPECTION
20-7
SERVICE INFORMATION
20-3
ALTERNATOR CHARGING COIL
20-8
TROUBLESHOOTING
20-5
REGULATOR/RECTIFIER
20-9
20-1
BATTERY/CHARGING SYSTEM
COMPONENT LOCATION
FUSE (30 A)
ALTERNATOR
REGULATOR/
RECTIFIER
BATTERY
SYSTEM DIAGRAM
MAIN FUSE 30A
JZL
Y
Y
Y
R
G
e
e
BATTERY
REGULATOR/RECTIFIER
ALTERNATOR
G
R
Y
20-2
GREEN
RED
YELLOW
BATTERY/CHARGING SYSTEM
SERVICE INFORMATION
GENERAL
ikWARNING
• 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 the ignition switch to OFF before disconnecting any electrical component.
Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch is ON and current is present.
For extended storage, remove the battery, give it a full charge, and store it in a cool, dry space.
For a battery remaining in a stored vehicle, disconnect the negative battery cable from the battery.
The maintenance free 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 conditions contribute to shortening the "life span" of the battery. Even under normal use, the performance of the battery
deteriorates after 2-3 years.
Battery voltage may recover after battery charging, but under heavy load, the battery voltage will drop quickly and
eventually die out. For this reason, the charging system is often suspected as the problem. Battery overcharge 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 regulator/rectifier 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
vehicle.
The battery will self-discharge when the vehicle 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 (page 20-5).
For alternator removal/installation (page 11-9).
BATTERY CHARGING
• Turn power ON/OFF at the charger, not at the battery terminal.
• 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.
• Quick charging should only be done in an emergency; slow charging is preferred.
BATTERY TESTING
Refer to the instructions in the Operation Manual for the recommended battery tester for details about battery testing. The
recommended battery tester puts a "load" on the battery so that the actual battery condition can be measured.
Recommended Battery Tester: BM-210-AH (U.S.A. only), BM-210, BATTERY MATE (MTP08-0192, U.S.A. only) or equivalent
20-3
BATTERY/CHARGING SYSTEM
SPECIFICATIONS
Battery
(YTX20L-BS)
Alternator
ITEM
Capacity
Current leakage
Voltage
Fully charged
(20°C/68°F)
Needs charging
Charging curNormal
rent
Quick
Capacity
Charging coil resistance (20°C/68°F)
SPECIFICATIONS
12V- 18 Ah
1 mA maximum
13.0-13.2 V
Below 12.3 V
l.8A/5-10h
9.0 A/1 .Oh
360W/5,000rpm(min-1)
0.1-1.0 Q
TOOLS
Battery tester
BM-210-AH (U.S.A. only)
20-4
Christie battery charger
MC1012/2 (U.S.A. only)
Battery Mate tester/charger
MTP08-0192 (U.S.A only)
BATTERY/CHARGING SYSTEM
TROUBLESHOOTING
BATTERY IS DAMAGED OR WEAK
1. Battery Test
Remove the battery (page 20-6).
Check the battery condition using the recommended battery tester.
RECOMMENDED BATTERY TESTER: BM-210-AH (U.S.A. only), BM-210,
BATTERY MATE (MTP08-0192, U.S.A. only) or equivalent
Is the battery in good condition?
No
- Faulty battery
YES
- GO TO STEP 2.
2. Current Leakage Test
Install the battery (page 20-6).
Check the battery current leakage test (Leak test: page 20-7).
Is the current leakage below 1 mA?
YES
- G O TO STEP 4.
NO
- GO TO STEP 3.
3. Current Leakage Test With Regulator/Rectifier Connector Disconnected
Disconnect the regulator/rectifier connector and recheck the battery current leakage.
Is the current leakage below 1 mA?
YES
- Faulty regulator/rectifier
NO
- • Shorted wire harness
• Faulty ignition switch
4. Alternator Charging Coil Inspection
Check the alternator charging coil (page 20-8).
fe the alternator charging coil resistance within 0.1 - 1.0Q (20°C/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 20-6).
Start the engine.
Measure the charging voltage (page 20-8).
Compare the measurements to the results of the following calculation.
STANDARD: Measured BV < Measured CV < 15.5 V
• BV = Battery voltage
• CV = Charging voltage
Is the measured charging voltage within the standard voltage?
YES
- Faulty battery
NO
- GO TO STEP 6.
6. Regulator/Rectifier System Inspection
Check the voltage and resistance at the regulator/rectifier connector (page 20-9).
Are the measurements correct?
YES
- Faulty regulator/rectifier
NO
- • Open circuit in related wire
• Loose or poor contacts of related terminal
• Shorted wire harness
20-5
BATTERY/CHARGING SYSTEM
BATTERY
BATTERY REMOVAL/INSTALLATION
Remove the two bolts and the battery cover.
With the ignition switch OFF, disconnect the nega- j MFGATIVET-) CABLE
tive (-) cable first, then disconnect the positive (+)
cable by removing each terminal bolt.
Remove the battery holder band.
Remove the battery.
Connect the posi- Install the battery in the reverse order of removal
tive terminal first with the proper wiring as shown.
and then the negaAfter installing the battery, coat the terminals with
tive cable.
clean dielectric grease.
BATTERY CASE
REMOVAL/INSTALLATION
Remove the rear fender (page 3-14).
; BATTERY
BOLTS
Remove the starter relay switch from the battery
case.
I
Remove the four bolts and battery case.
Installation is the reverse order of removal.
STARTER RELAY SWITCH
VOLTAGE INSPECTION
Remove the battery cover (page 20-6).
Measure the battery voltage using a commercially
available digital multimeter.
VOLTAGE:
Fully charged: 13.0 -13.2V
Under charged: Below 12.3V
20-6
BATTERY/CHARGING SYSTEM
BATTERY TESTING
Remove the battery (page 20-6).
Refer to the instructions that are appropriate to the
battery testing equipment available to you.
TOOL:
Battery tester
BM-210-AH (U.S.A. only), BM-210,
BATTERY MATE (MTP08-0192,
U.S.A. only) or equivalent
BATTERY CHARGING (U.S.A. only)
Remove the battery (page 20-6).
Refer to the instructions that are appropriate to the
battery charging equipment available to you.
TOOL:
Battery charger
Christie battery charger (MC1012/
2, U.S.A. only), BATTERY MATE
(MTP08-0192, U.S.A. only) or
equivalent
CHARGING SYSTEM INSPECTION
CURRENT LEAKAGE INSPECTION
Remove the battery cover (page 20-6).
Turn the ignition switch OFF and disconnect the
negative (-) cable from the battery.
Connect the ammeter (+) probe to the negative (-)
cable and the ammeter (-) probe to the battery (-)
terminal.
With the ignition switch turned OFF, check for current leakage.
NEGATIVE (-) TERMINAL
• 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 ON. A sudden surge of current may blow
out the fuse in the tester.
SPECIFIED CURRENT LEAKAGE: 1 mA maximum
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.
20-7
BATTERY/CHARGING SYSTEM
CHARGING VOLTAGE INSPECTION
Remove the battery cover (page 20-6).
Be sure the battery is in good condition before performing this test.
Warm up the engine to normal operating temperature.
Connect the multimeter between the battery positive (+) and negative (-) terminals.
NOTICE
• To prevent a short, make absolutely certain
which are the positive (+) and negative (-) terminals or cables.
• Do not disconnect the battery or any cable in the
charging system without first switching off the
ignition switch. Failure to follow this precaution
can damage the tester or electrical components.
With the headlights on, measure the voltage on the
multimeter when the engine runs at 5,000 rpm
(min 1 ).
STANDARD: Measured BV < Measured CV < 15.5 V
BV = Battery voltage (page 20-6)
CV = Charging voltage
ALTERNATOR CHARGING COIL
INSPECTION
Remove the right side cover (page 3-5).
Disconnect the alternator 5P (Natural) connector.
Check the connector for loose contacts or corroded
terminals.
5P (NATURAL) CONNECTOR
Measure the resistance between the Yellow wire
terminals of the alternator side connector.
STANDARD: 0.1 - 1.0 U (at 20C/68 F)
Check for continuity between each Yellow wire terminal of the alternator side connector and ground.
There should be no continuity.
Replace the alternator stator if resistance is out of
specification, or if any wire has continuity to
ground.
Alternator stator replacement (page 11-9).
20-8
BATTERY/CHARGING SYSTEM
REGULATOR/RECTIFIER
WIRE HARNESS INSPECTION
Remove the two bolts and regulator/rectifier.
Disconnect the regulator/rectifier 3P (Gray) and 3P
(Black) connectors.
Check the connectors for loose contacts or corroded
terminals.
BATTERY LINE
Measure the voltage between the Red wire terminal
and ground.
There should be battery voltage at all times.
GROUND LINE
Check the continuity between the Green wire terminal and ground.
There should be continuity at all times.
REGULATOR/RECTIFIER
CHARGING COIL LINE
Measure the resistance between the Yellow wire terminals.
STANDARD: 0.1 - 1.0 Q (at 20°C/68°F)
Check for continuity between each Yellow wire terminal and ground.
There should be no continuity.
20-9
21. IGNITION SYSTEM
COMPONENT LOCATION
21-2
IGNITION SYSTEM INSPECTION
21-5
SYSTEM DIAGRAM
21-2
IGNITION COIL
21-7
SERVICE INFORMATION
21-3
IGNITION TIMING
21-8
TROUBLESHOOTING
21-4
21-1
IGNITION SYSTEM
COMPONENT LOCATION
ENGINE STOP SWITCH
IGNITION SWITCH
PCM
FUSE (10 A)
CKP SENSOR
BATTERY
SYSTEM DIAGRAM
PCM (ECM/TCM)
5PL
• Bl/Y •
5P L
IGNITION
COIL
CKP SENSOR
FUSE 10A
• Bl
o^o
R
IGNITION
SWITCH
MAIN
FUSE
30A
©
e
BATTERY
FUSE
10A
ENGINE STOP
RELAY
Bl : BLACK
Y : YELLOW
Bu:BLUE
G :GREEN
H :RED
W : WHITE
21-2
• Bl/Bu •
- Bl/W •
ENGINE STOP
SWITCH
To Bank Angle Sensor •
• R/W - Bl/Y •
— Bl/Bu- - BIW - - R/W — R/Y -
IGNITION SYSTEM
SERVICE INFORMATION
GENERAL
• Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch is ON and current is present.
When servicing the ignition system, always follow the steps in the troubleshooting table on page 21-4.
This ignition system is controlled by PCM.
The ignition timing cannot be adjusted since the PCM is factory preset.
The PCM may be damaged if dropped. Also, if the connector is disconnected when current is flowing, the excessive
voltage may damage the PCM. Always turn off the ignition switch 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.
This vehicle's spark plug is equipped with iridium type electrode. Do not use any spark plug other than specified.
For CKP sensor removal/installation (page 11-9).
For ignition switch servicing (page 23-6).
For engine stop switch inspection (page 23-7).
For gear position switch servicing (page 14-44).
SPECIFICATION
Spark plug
ITEM
Standard
For extended high speed
riding
Spark plug gap
Ignition coil peak voltage
CKP sensor peak voltage
Ignition timing ("F" mark)
SPECIFICATIONS
IFR5L11 (NGK)
VK16PRZ11 (DENSO)
IFR6L11 (NGK)
VK20PRZ11 (DENSO)
1.0 - 1.1 mm (0.039 - 0.043 in)
100 V minimum
0.7 V minimum
15°BTDCatidle
TORQUE
Spark plug
Timing hole cap
22 N m (2.2 kgf-m, 16 Ibf-ft)
10 N-m (1.0 kgf-m, 7 Ibf-ft)
TOOLS
IgnitionMate peak voltage tester
MTP07-0286 (U.S.A. only)
Peak voltage adaptor
07HGJ-0020100
Test probe
07ZAJ-RDJA110
(not available in U.S.A.) with commercially available digital
multimeter (impedance 10 Mii/DCV
minimum) or
Imrie diagnostic tester (model 625)
(not available in U.S.A.)
21-3
IGNITION SYSTEM
TROUBLESHOOTING
• Inspect the following before diagnosing the system:
- Faulty spark plug
- Loose spark plug cap or spark plug wire connection
- Water got into the spark plug cap (leaking the ignition coil secondary voltage)
No spark at spark plug
Ignition coil
primary
voltage
UNUSUAL CONDITION
Low peak voltage.
No peak voltage.
Peak voltage is normal, but no spark
jumps at the plug.
CKP sensor
Low peak voltage.
No peak voltage.
21-4
PROBABLE CAUSE! (Check in numerical order)
1. Incorrect peak voltage adapter connections. (System is
normal if measured voltage is over the specifications
with reverse connections.)
2. The multimeter impedance is too low.
3. Cranking speed is too slow (battery is under charged).
4. The sampling timing of the tester and measured pulse
were not synchronized. (System is normal if measured
voltage is over the standard voltage at least once.)
5. Poorly connected connectors or an open circuit in the
ignition system.
6. Faulty ignition coil.
7. Faulty Powertrain Control Module (PCM) (when above
No.1 through 6 are normal).
1. Incorrect peak voltage adaptor connections. (System is
normal if measured voltage is over the specifications
with reverse connections.)
2. Battery is undercharged. (Large voltage drop when the
engine is started.)
3. Faulty ignition switch or engine stop switch.
4. Loose or poorly connected PCM connectors.
5. No voltage at the Black/white (power source) wire of the
PCM.
6. Open circuit or poor connection in the Green (ground)
wire of the PCM.
7. Faulty peak voltage adaptor.
8. Faulty CKP sensor (Measure peak voltage)
9. Faulty PCM (when above No. 1 through 8 are normal).
1. Faulty spark plug or leaking ignition coil secondary current.
2. Faulty ignition coil.
1. The multimeter impedance is too low; below 10 Mfi/
DCV.
2. Cranking speed is too slow (battery is under charged).
3. The sampling timing of the tester and measured pulse
were not synchronized. (System is normal if measured
voltage is over the standard voltage at least once.)
4. Faulty CKP sensor (when above No. 1 through 3 are normal).
1. Faulty peak voltage adaptor.
2. Faulty CKP sensor
IGNITION SYSTEM
IGNITION SYSTEM INSPECTION
PEAK VOLTAGE CONNECTION
NOTE:
• If there is no spark at the plug, check all
connections for loose or poor contact before
measuring the peak voltage.
• Use the recommended digital multimeter or a
commercially available digital multimeter with
an impedance of 10 Mfi/DCV minimum.
• The display value differs depending upon the
internal impedance of the multimeter.
Use the peak voltage tester or connect the peak
voltage adaptor to the digital multimeter.
DIGITAL MULTIMETER
TOOLS:
U.S.A. and Canada type:
IgnitionMate peak voltage tester (U.S.A. only) or
Peak voltage adaptor
07HGJ-0020100
(not available in
U.S.A.)
with commercially available digital multimeter
(impedance 10 Mi2/DCV minimum)
Imrie diagnostic tester (model 625)
(not available in U.S.A.)
PEAK VOLTAGE ADAPTOR
IGNITION COIL PRIMARY PEAK
VOLTAGE
NOTE:
• Check all system connections before this
inspection. Poor connected connectors can cause
incorrect readings.
• Check the cylinder compression and check that
the spark plug is installed correctly in the
cylinder head.
Remove the fuel tank (page 6-39).
Disconnect the spark plug cap from the spark plug.
Connect a known-good spark plug to the spark plug
cap and ground the spark plug to the cylinder head
as done in a spark test.
KNOWN-GOOD SPARK PLUG
21-5
IGNITION SYSTEM
With the connector connected, connect the peak
voltage tester or adaptor probes to the ignition coil
primary terminal and body ground.
GREEN/RED WIRE TERMINAL
CONNECTION: Green/red (-) - Body ground (+)
Turn the ignition switch ON and the engine stop
switch to the "O.".
Shift the transmission into neutral.
Avoid touching Crank the engine with the starter motor and read
the spark plug the ignition coil primary peak voltage.
or tester probes
VOLTAGE: 100 V minimum
to prevent electric shock. |f t n e p ea k voltage is lower than the standard value,
follow the checks described in the troubleshooting
chart (page 21-4).
CKP SENSOR PEAK VOLTAGE
NOTE:
• Check that the cylinder compression is normal
and the spark plug is installed correctly in the
cylinder head.
Remove the steering cover (page 3-5).
Seal the PCM connector with tape to
prevent dirt and oil
from entering the
connector after disconnecting the 33P
connector.
Disconnect the 33P (Gray) connector
Powertrain Control Module (PCM).
from the
NOTE:
• When reconnecting the PCM 33P (Gray)
connector, check that there is no dirt and oil in
the connector.
PCM 33P (GRAY) CONNECTOR
Be careful not to Connect the peak voltage tester or adaptor probes
bend the connector to the Blue/yellow and Green/white terminals of the
terminals, wire harness side 33P (Gray) connector.
TOOL:
Test probe
V.
1j
I—'
1
07ZAJ-RDJA110
CONNECTION: B23 (+) - B12 (-)
Shift the transmission into neutral.
Turn the ignition switch ON.
Crank the engine with the starter motor and read
the CKP sensor peak voltage.
PEAK VOLTAGE: 0.7 V minimum
If the voltage measured at the PCM connector is
abnormal, measure the peak voltage at the
alternator connector.
21-6
PCM 33P (GRAY) CONNECTOR
(Wire side of female terminal)
1
-
1—'
—r
PEAK VOLTAGE ADAPTOR
4
i7
|
B23
B12
IGNITION SYSTEM
Remove the right side cover (page 3-5).
Disconnect the alternator 5P (Natural) connector
and connect the peak voltage tester or adaptor
probes to the Blue/yellow and Green/white wire
terminals of the alternator side connector.
5P NATURAL CONNECTOR
In the same manner as at the PCM connector,
measure the peak voltage and compare it to the
voltage measured at the PCM connector.
• If the peak voltage measured at the PCM
connector is abnormal and the one measured at
the alternator connector is normal, the Blue/
yellow or Green/white wire has an open or short
circuit, or loose connection.
• If both peak voltages are abnormal, follow the
checks described in the troubleshooting chart
(page 21-4).
5P (NATURAL) CONNECTOR
(Alternator side of female
terminal)
PEAK VOLTAGE
ADAPTOR
G/W
Bu/Y
If the CKP sensor is faulty, replace the stator/CKP
sensor assembly (page 11-11).
IGNITION COIL
REMOVAL/INSTALLATION
Remove the left side cover (page 3-6).
Disconnect the plug cap from the plug and free the
spark plug wire from the clamps.
Disconnect the ignition coil primary wire connector.
Remove the two mounting bolts, ground terminal
and the ignition coil.
Installation is in the reverse order of removal.
21-7
IGNITION SYSTEM
IGNITION TIMING
Remove the right side cover (page 3-6).
Start the engine and warm it up to operating
temperature.
Stop the engine and remove the timing hole cap
from the rear crankcase cover.
Connect the timing light and tachometer.
TIMING LIGHT I
Start the engine, let it idle and check the ignition
timing.
The ignition timing is correct if the "F" mark on the
flywheel aligns with the index mark on the rear
crankcase cover at idle.
INDEX VIARK

Increase the engine speed and make sure the "F"
mark begins to move.
"F" MARK
Coat a new O-ring with oil and install it onto the
timing hole cap.
Install the timing hole cap and tighten it to the
specified torque.
TORQUE: 10 N m (1.0 kgf-m, 7 Ibfft)
Install the right side cover (page 3-6).
21-8
22. ELECTRIC STARTER
COMPONENT LOCATION
22-2
STARTER MOTOR
22-6
SYSTEM DIAGRAM
22-2
STARTER RELAY SWITCH
22-12
SERVICE INFORMATION
22-3
DIODE
22-14
TROUBLESHOOTING
22-4
22-1
ELECTRIC STARTER
COMPONENT LOCATION
STARTER SWITCH
IGNITION SWITCH
GEAR POSITION
(NEUTRAL) SWITCH
STARTER MOTOR
FUSE(IOA)
STARTER RELAY SWITCH
BATTERY
SYSTEM DIAGRAM
Bl/Bu
•
To BATTERY
Bl:BLACK
Y : YELLOW
Bu:BLUE
G :GREEN
B :REO
W : WHITE
Lb : LIGHT BLUE
Lg : LIGHT GREEN
Gr : GRAY
22-2
r
ELECTRIC STARTER
SERVICE INFORMATION
GENERAL
• Always turn the ignition switch OFF before servicing the starter motor. The motor could suddenly start, causing serious
injury.
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 22-4).
A weak battery may be unable to turn the starter motor quickly enough, or supply adequate ignition current.
If the current is kept flowing through the starter motor to turn it while the engine is not cranking over, the starter motor
may be damaged.
For starter clutch servicing (page 11-9).
For ignition switch information (page 23-6).
For engine stop switch and starter switch inspection (page 23-7).
For front brake switch inspection (page 23-20).
For gear position switch information (page 14-44).
SPECIFICATIONS
ITEM
Starter motor brush length
STANDARD
12.0-13.0(0.47-0.51)
Unit: mm (in)
SERVICE LIMIT
6.5 (0.26)
22-3
ELECTRIC STARTER
TROUBLESHOOTING
NOTE:
• The starter motor should operate when the transmission is in heutral or when the transmission is in
drive and the front brake lever is squeezed.
• Make sure the engine stop switch is turned "O" before startirtg the engine. The starter motor does
not operate with the engine stop switch turned OFF.
Starter motor does not turn
1. Fuse Inspection
Check for blown main fuse (30 A) or IGN fuse (10 A).
Is the fuse blown?
YES
- Replace the fuse.
NO
- GO TO STEP 2.
2. Battery Inspection
Check that the battery is fully charged and in good condition.
Is the battery in good condition?
YES
- GO TO STEP 3.
NO
- Charge the battery (page 20-7).
3. Starter Relay Switch Operation Inspection
Check the operation of the starter relay switch (page 22-12).
Does the starter relay switch click?
YES
- GO TO STEP 4.
NO
- GO TO STEP 5.
4. Starter Motor Inspection
Turn the ignition switch OFF.
Apply battery voltage to the starter motor directly.
Does the starter motor turn?
YES
- • Poorly connected starter motor cable.
• Faulty starter relay switch (page 22-13).
NO
- Faulty starter motor (page 22-6).
5. Relay Coil Ground Line Inspection
Turn the ignition switch OFF.
Check the ground line of the starter relay switch (page 22-13).
Is the ground line normal?
NO
- •
•
•
•
Faulty
Faulty
Faulty
Loose
gear position switch (page 14-44).
diode (page 22-14).
front brake switch (page 23-20).
or poor contact of the related connector terminal.
• Open circuit in the wire harness.
YES
- GO TO STEP 6.
6. Relay Coil Power Input Line Inspection
Check the power input line of the starter relay switch (page 22-13).
Is the power input line normal?
YES
22-4
Faulty ignition switch (page 23-6).
Faulty engine stop switch (page 23-7).
Faulty starter switch (page 23-7).
Loose or poor contact of the related connector terminal.
Open circuit in the wire harness.
- GO TO STEP 7.
ELECTRIC STARTER
7. Starter Relay Switch Inspection
Check the function of the starter relay switch (page 22-13).
Does the starter relay switch function properly?
NO
- Faulty starter relay switch.
YES
- Loose or poor contact of the starter relay switch connector terminal.
Starter motor turns engine slowly
• Low battery voltage
• Poorly connected battery cable
• Poorly connected starter motor cable
• Faulty starter motor
• Poorly connected ground cable terminal
Starter motor turns, but engine does not turn
• Faulty starter clutch
• Damaged starter gear train
Starter relay switch clicks, but engine does not turn over
• Crankshaft does not turn due to engine problems
22-5
ELECTRIC STARTER
STARTER MOTOR
REMOVAL
Remove the following:
-
RIGHT ENGINE SIDE COVER
right side cover (page 3-5)
right center mud guard (page 3-7)
Disconnect the negative (-) cable from the battery
(page 20-6).
Remove the three bolts and the right engine side
cover.
Slide the rubber cap off the starter motor cable ter­
minal and remove the terminal nut and starter
motor cable.
Remove the two mounting bolts and hose guide.
Remove the bolt and ground cable from the engine.
Pull out the starter motor.
DISASSEMBLY/INSPECTION
Remove the O-ring from the starter motor.
22-6
O-RING
ELECTRIC STARTER
Remove the starter motor case bolts.
MOTOR CASE BOLTS
Record the location Remove the following:
and number of
- front cover
shims.
-
SHIMS
lock washer
insulated washer
shims
seal ring
FRONT COVER
INSULATED WASHER
LOCK WASHER
Record the location and number of shims. -
rear cover
shims
seal ring
armature
REAR COVER
SHIMS
SEAL RING
ARMATURE
Check the oil seal and needle bearing in the front
cover for deterioration, wear or damage.
DUST SEAL
BUSHING
Check the bushing in the rear cover for wear or
damage.
NEEDLE BEARING
22-7
ELECTRIC STARTER
Check the commutator bars of the armature for discoloration.
COMMUTATOR BARS
NOTE:
• Do not use emery or sand paper on the commu­
tator.
Check for continuity between pairs of commutator
bars.
There should be continuity.
Check for continuity between each commutator bar
and the armature shaft.
There should be no continuity.
Check for continuity between the insulated brush
and cable terminal.
There should be continuity.
22-8
prjNTINUITY­
NO CONTINUITY:
CONTINUITY:
INSULATED BRUSH
ELECTRIC STARTER
Check for continuity between the insulated brush
and motor case.
There should be no continuity.
NO CONTINUITY:
Measure the brush length.
SERVICE LIMIT: 6.5 mm (0.26 in)
Remove the following if necessary:
-
brush holder
-
nut
washer
insulator washers
O-ring
cable terminal
insulated brush
insulator
CABLE TERMINAL
INSULATED
BRUSH
INSULATOR
WASHERS
NUT
WASHER
INSULATOR
22-9
ELECTRIC STARTER
ASSEMBLY
SHIMS
ARMATURE
BOLTS
FRONT COVER
REAR COVER
WASHER
NUT
O-RING
»•#
INSULATOR
WASHERS
MOTOR CASE
Install the following:
-
insulator
insulated brush
cable terminal
O-ring
insulator washers
washer
nut
CABLE TERMINAL
O-RING
INSULATED
BRUSH
INSULATOR
WASHERS
WASHER
Install the brush holder, aligning the holder tab with
the case groove, and the holder grooves with the
insulated brush wires.
INSULATOR
BRUSH HOLDER
Align
22-10
ELECTRIC STARTER
Push and hold the brushes inside the brush holder,
and install the armature through the motor case and
brush holder.
When installing the armature into the motor case,
hold the armature tightly to keep the magnet of the
case from pulling the armature against it.
NOTICE
The coil may be damaged if the magnet pulls the
armature against the case.
Install the same number of shims in the same loca­
tion as noted during removal.
Install a new seal ring onto the motor case.
Apply a thin coat of grease to the armature shaft
end.
Install the rear cover, aligning its groove with the
brush holder tab.
REAR COVER
SHIMS
SEAL RING
ARMATURE
Install the shims
properly as noted
during removal.
Install the shims and insulated washer onto
armature shaft.
Install a new seal ring onto the motor case.
Apply grease to the oil seal lip and needle bearing in
the front cover.
Install the lock washer onto the front cover.
Install the front cover.
SHIMS
FRONT COVER
INSULATED WASHER
LOCK WASHER
INSTALLATION
Coat a new O-ring with oil and install it in the starter
motor groove.
O-RING
22-11
ELECTRIC STARTER
Install the starter motor into the rear crankcase
cover and onto the crankcase.
Install the hose guide and mounting bolts, then
tighten the bolts securely.
Route the ground cable and tighten the bolt.
Install the starter motor cable and terminal nut, and
tighten the nut.
Install the rubber cap over the cable terminal.
Install the right engine side cover and tighten the
three bolts securely.
RIGHT ENGINE SIDE COVER
Connect the battery negative (-) cable (page 20-6).
Install the following:
-
right center mud guard lid (page 3-7)
right side cover (page 3-5)
STARTER RELAY SWITCH
OPERATION INSPECTION
Remove the battery cover (page 20-6).
Shift the transmission into neutral.
Make sure the engine stop switch is turned "O"
Turn the ignition switch ON and push the starter
switch.
The coil is normal if the starter relay switch clicks.
If you don't hear the switch click, and inspect the
relay switch circuits (page 22-13).
STARTER RELAY SWITCH
22-12
ELECTRIC STARTER
CIRCUIT INSPECTION
Remove the rear fender (page 3-14).
Disconnect the starter relay switch 2P (Natural) con­
nector.
GROUND LINE
Check for continuity between the Green/black wire
terminal of the wire harness side connector and
ground.
If there is continuity when the transmission is in
neutral or when the transmission is in drive and the
front brake lever is squeezed, the ground circuit is
normal.
POWER INPUT LINE
2P (NATURAL) CONNECTOR
Turn the engine stop switch "O" and the ignition
switch ON.
Measure the voltage between the Yellow/red wire
terminal (+) of the wire harness side connector and
ground.
If the battery voltage appears only when the starter
switch is pushed, the circuit is normal.
FUNCTION INSPECTION
Remove the following:
-
rear fender (page 3-14)
battery cover (page 20-6)
STARTER
RELAY
SWITCH
Disconnect the negative (-) cable from the battery
(page 20-6).
Disconnect the starter relay switch 2P (Natural) con­
nector.
Remove the battery (+) cable and starter motor
cable from the starter relay switch and ground (-).
Connect the fully charged 12 V battery positive ter­
minal to the Yellow/red wire terminal and negative
terminal to the Light green/red wire terminal of the
starter relay switch.
• BATTERY
There should be continuity between the cable termi­
nals while the battery is connected, and no continu­
ity when the battery is disconnected.
22-13
ELECTRIC STARTER
DIODE
INSPECTION
Remove the fuel tank (page 6-39).
DIODE
Remove the diode from the wire harness.
Z
Remove the seat (page 3-4).
DIODE
Remove the diode from the fuse box.
<fc
Check for continuity between the diode terminals.
I
When there is continuity, a small resistance value
will register.
If there is continuity in one direction, the diode is
normal.
22-14
23. LIGHTS/METERS/SWITCHES
COMPONENT LOCATION
23-2
FUEL GAUGE/FUEL LEVEL SENSOR
23-10
SERVICE INFORMATION
23-3
TEMPERATURE INDICATOR/
TEMPERATURE SENSOR
23-13
GPS RECEIVER (GPS model only)
23-16
BRAKE LIGHT SWITCH
23-19
FRONT BRAKE SWITCH
23-20
HEADLIGHT
TAILLIGHT
ACCESSORY SOCKET
IGNITION SWITCH
23-4
23-4
23-5
23-6
HORN SWITCH (AUSTRALIA type only) 23-20
HANDLEBAR SWITCH
23-7
HORN (AUSTRALIA type only)
COMBINATION METER/REAR VS
SENSOR
23-20
23-8
23-1
LIGHTS/METERS/SWITCHES
COMPONENT LOCATION
FRONT EitRAKE
(INHIBITOR) SWITCH
IGNITION SWITCH
FRONT BRAKE LIGHT
SWITCH
HANDLEBAR SWITCH
ACCESSORY
SOCKET
REAR VS SENSOR
EOT SENSOR
23-2
LIGHTS/METERS/SWITCHES
SERVICE INFORMATION
GENERAL
• A continuity test can be made with the switches installed on the vehicle.
• All plastic connectors have locking tabs that must be released before disconnecting, and must be aligned when reconnecting.
• To isolate an electrical failure, check the continuity of the electrical path through the part. A continuity check can usually
be made without removing the part from the vehicle. Simply disconnect the connectors and connect a continuity tester
to the terminals or connections.
• The following color codes are used throughout this section.
Bu: Blue
Bl: Black
Br: Brown
G: Green
Gr: Gray
Lb: Light Blue
Lg: Light Green
0: Orange
P: Pink
R:Red
W: White
Y: Yellow
SPECIFICATIONS
Bulb
Fuse
ITEM
Headlight
Brake/taillight
Neutral indicator
Reverse indicator
4WD indicator
Coolant/engine oil temperature
indicator
MIL (PGM-FI indicator)
Meter light
Main
Sub-fuse
SPECIFICATIONS
12V-40/40Wx2
12V-21/5Wx2
LED
LED
LED
LED
LED
LED x 10
30 A x 2
1 5 A x 1 , 10 A x 4
TORQUE VALUES
ECT sensor
EOT sensor
12N-m(1.2kgfm, 9 Ibf-ft)
12N-m(1.2kgf-m,9lbf-ft)
Apply sealant to the threads.
TOOLS
Inspection adaptor
07GMJ-ML80100
23-3
LIGHTS/METERS/SWITCHES
HEADLIGHT
BULB REPLACEMENT
Remove the screw and the headlight cover by
releasing the tab from the slit in the headlight case.
Remove the dust cover.
Remove the bulb socket by turning it counterclockwise.
Remove the bulb from the headlight.
HEADLIGHT COVER
ADJUSTING SCREW
SCREW
Align the socket Install a new bulb in the reverse order of removal.
tabs with the headlight grooves properly.
ACCESS PLUG
DUST COVER
SOCKET
BULB
REMOVAL/INSTALLATION
Remove the headlight bulb socket (page 23-4).
HEADLIGHT
Remove the two screws attaching the headlight
wire clamps.
Remove the two mounting bolts and the headlight.
Install the headlight in the reverse order of removal.
NOTE:
• The headlight beam can be adjusted vertically by
removing the access plug and turning the headlight beam adjusting screw.
SCREWS
BOLTS
TAILLIGHT
BULB REPLACEMENT
Remove the screw and taillight cover cap.
SCREW
Turn the bulb socket counterclockwise and remove
it.
Turn the taillight bulb counterclockwise while pushing it in and remove it.
Align the cover cap Install a new taillight bulb in the reverse order of
tabs with the removal.
grooves in the
cover properly.
SOCKET
BULB
23-4
LIGHTS/METERS/SWITCHES
REMOVAL/INSTALLATION
Remove the taillight bulb socket (page 23-4).
TAILLIGHT
Remove the trim clip, washer, three screws, protector and taillight cover.
Remove the taillight from the cover.
PROTECTOR
Align the bosses Install the taillight in the reverse order of removal.
and grommets
properly.
TRIM CLIP
WASHER
COVER
SCREWS
ACCESSORY SOCKET
INSPECTION
Remove the right inner fender (page 3-9).
Remove the accessory socket 2P (White) connector
from the frame and disconnect it.
Measure the voltage between the White/black (+)
and Green (-) wire terminals of the wire harness
side connector.
There should be battery voltage with the ignition
switch turned to ON.
If there is no voltage, check for brown fuse (10 A)
and an open circuit in the wire harness.
2P (WHITE) CONNECTOR
Remove the accessory socket cap.
BOTTOM CENTER White/black
Check for continuity between the White/black wire
terminal of the socket side 2P connector and bottom
center terminal of the socket, and between the
Green wire terminal and side wall terminal.
There should be continuity.
If there is no continuity, replace the accessory
socket.
23-5
LIGHTS/METERS/SWITCHES
REPLACEMENT
Remove the meter lower cover (page 3-18).
Disconnect the accessory socket 2P (White) connector (page 23-5).
Release the accessory socket wire from the wire clip
on the steering shaft holder.
Loosen the nut and remove the accessory socket
from the meter lower cover.
Install a new accessory socket by aligning the lug
with the groove in the meter lower cover.
Install the nut and tighten it securely.
Route the acces- Install the removed parts in the reverse order of
sory socket wire removal.
properly
(page 1-20).
SOCKET
COVER
IGNITION SWITCH
INSPECTION
Remove the right inner fender (page 3-9).
4P NATURAL CONNECTOR
Remove the ignition switch 4P (Natural) connector
from the frame and disconnect it.
Check for continuity between the switch side connector terminals in each switch position.
Continuity should exist between the color coded
wires as follows:
^Color
PositiorT
ON
OFF
Red/
black
Pink
o- -o
Red
Black
o- - o
REPLACEMENT
Remove the meter upper cover (page 3-18).
Disconnect the ignition switch 4P (Natural) connector (page 23-6).
IGNITION SWITCH
STOPPERS
Release the ignition switch wire from the wire clip
on the steering shaft holder.
Remove the ignition switch from the meter upper
cover by pushing in the two stoppers.
Install a new ignition switch by aligning the locating
tab with the cover groove.
Route the ignition Install the removed parts in the reverse order of
switch wire prop- removal.
erly (page 1-201.
23-6
COVER
LOCATING TAB
LIGHTS/METERS/SWITCHES
HANDLEBAR SWITCH
INSPECTION
Remove the right inner fender (page 3-9).
Remove the handlebar switch 10P (Light green) connector from the frame and disconnect it.
LIGHT GREEN) CONNECTOR
For gearshift Check for continuity between the switch side conswitch inspection nector terminals in each switch position.
(page 14-45). Continuity should exist between the color coded
wires as shown below:
DIMMER
SWITCH
LIGHTING
SWITCH
GEARSHIFT
SWITCH
ENGINE STOP
SWITCH
LIGHTING SWITCH
Color
Bl/Br
Position
ON
OFF
DIMMER SWITCH
Br
ENGINE STOP SWITCH
Color
Bl/G
Position
OFF
RUN
OFF
Color
Position
Low
(N)
High
w
Bu/BI
O
STARTER SWITCH
Bl/W
Bl/W
Y/R
FREE
PUSH
23-7
LIGHTS/METERS/SWITCHES
COMBINATION METER/REAR VS
SENSOR
POWER/GROUND LINE INSPECTION
Remove the left inner fender (page 3-9).
Remove the combination meter 14P (Gray) connector from the frame and disconnect it.
Check the following at the wire harness side connector.
POWER INPUT LINE
Measure the voltage between the Black/blue wire
terminal (+) and ground (-).
There should be battery voltage with the ignition
switch turned ON.
If there is no voltage, check for an open circuit in the
wire harness.
BACK-UP VOLTAGE LINE
14P (GRAY) CONNECTOR
Measure the voltage between the Red/black wire
terminal (+) and ground (-).
There should be battery voltage at all times.
If there is no voltage, check for an open circuit in the
wire harness.
GROUND LINE
Check for continuity between the Green wire terminal and ground.
There should be continuity at all times.
If there is no voltage, check for an open circuit in the
wire harness.
SPEEDOMETER/REAR VS SENSOR
Check there is no DTC before the speedometer rear
VS sensor inspection. If there is any DTC, refer to
the PGM-FI troubleshooting (page 6-13).
Check that the hour meter and odometer/trip meter
function properly.
• If they do not function, check the power/ground
line (page 23-8).
• If they function properly, check as follows:
Remove the left inner fender (page 3-9).
Remove the rear VS sensor 3P (Yellow) connector
from the frame and disconnect it.
Measure the voltage between the Black/pink (+) and
Green (-) wire terminals of the wire harness side
connector.
There should be 10 V or more with the ignition
switch turned ON.
If there is no voltage, check for an open circuit in the
wire harness.
23-8
' 3P (YELLOW) CONNECTOR
LIGHTS/METERS/SWITCHES
Connect the inspection adaptor to the rear VS sensor 3P (Yellow) connectors.
TOOL:
Inspection adaptor
WHITE CLIP i INSPECTION ADAPTOR
07GMJ-ML80100
Shift the transmission into neutral.
Raise the wheels off the ground and support the
vehicle securely with a hoist or equivalent.
Turn the ignition switch ON.
Measure the voltage between the Red clip (+) and
White clip (-) while slowly turning the rear wheels
by hand.
There should be 0 to 5 V pulse voltage.
• If the pulse voltage does not appear, replace the
VS sensor.
• If the pulse voltage appears, check as follows:
Remove the left inner fender (page 3-9).
Remove the combination meter 14P (Gray) connector from the frame and disconnect it.
Check for an open or short circuit in the Pink/green
wire between the rear VS sensor 3P (Yellow) connector and combination meter 14P (Gray) connector.
If the Pink/green wire is OK, replace the combination
meter.
14P (GRAY) CONNECTOR
COMBINATION METER REMOVAL/
INSTALLATION
Remove the left inner fender (page 3-9).
Remove the combination meter 14P (Gray) connector and 4P (Natural) connector from the frame and
disconnect it.
4P NATURAL CONNECTOR
Release the meter wire from the wire clip on the
steering shaft holder.
Remove the meter cover (page 3-18).
Route the acces- Installation is in the reverse order of removal.
sory socket wire
properly
(page 1-20).
14P (GRAY) CONNECTOR
REAR VS SENSOR REPLACEMENT
Remove both inner fenders (page 3-9).
Remove the rear VS sensor 3P (Yellow) connector
from the frame and disconnect it.
3P (YELLOW) CONNECTOR
23-9
LIGHTS/METERS/SWITCHES
Remove the two bolts and VS sensor cover.
Remove the rear VS sensor wire from the clamp.
Remove the three bolts, sensor cover stay and rear
VS sensor.
Coat a new O-ring with oil and install it onto a new
rear VS sensor.
Route the rear VS Install the rear VS sensor in the reverse order of
sensor wire prop- removal.
erly (page 1-20).
FUEL GAUGE/FUEL LEVEL SENSOR
SYSTEM INSPECTION
Check that the speedometer and indicators function
properly.
• If they do not function, check the power/ground
line (page 23-8).
• If they function, check as follows:
Remove the steering cover (page 3-5).
Turn the ignition switch OFF and disconnect the fuel
level sensor 2P (Natural) connector.
Release the sensor wire from the wire clamp.
2P NATURAL) CONNECTOR
23-10
LIGHTS/METERS/SWITCHES
Turn the ignition switch ON and check the fuel
gauge.
All segments should blink.
FA model:
Turn the ignition switch OFF.
Connect the meter side connector terminals with a
jumper wire.
Turn the ignition switch ON and check the fuel
gauge.
All segments should blink.
FGA model:
,..;„.
If the fuel gauge does not function properly, replace
the combination meter (page 23-9).
1
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Turn the ignition switch OFF.
FUEL GAUGE SEGMENTS
Remove the fuel tank cover (page 3-5).
Remove the three bolts, retaining plate and fuel
level sensor from the fuel tank.
With the fuel level sensor float at the top (FULL)
position, turn the ignition switch ON and check the
fuel gauge.
(FULL)
BOTTOM
(RESERVE)
All segments up to segment "F" should come on.
Turn the ignition switch OFF.
FA model:
FGA model:
SEGMENT "F"
23-11
LIGHTS/METERS/SWITCHES
Move the float to the bottom (RESERVE) position,
turn the ignition switch to ON and check the fuel
gauge.
FA model:
FGA model:
LOW FUEL INDICATOR
Segment "E" and low fuel indicator should blink.
If the fuel gauge does not function properly, check
the fuel level sensor (page 23-12).
If the fuel level sensor is OK, replace the combination meter.
If all segments blink during inspection, replace the
combination meter.
.irm
Turn the ignition switch OFF.
SEGMENT "E"
Install a new seal rubber onto the fuel level sensor.
Install the retainer plate onto the sensor by aligning
the tab with the groove.
Install the sensor into the fuel tank while aligning
the groove in the plate with the boss on the fuel
tank.
Install and tighten the bolts securely.
Install the removed parts in the reverse order of
removal.
FUEL LEVEL SENSOR INSPECTION
Remove the fuel level sensor (page 23-10).
Disconnect the fuel level sensor 2P (Natural) connector and connect the ohmmeter to the sensor side
connector terminals.
2P (NATURAL) CONNECTOR
23-12
LIGHTS/METERS/SWITCHES
Measure the fuel level sensor resistance with the
float at the top (FULL) and bottom (RESERVE) positions.
FLOAT POSITION
TOP (FULL)
BOTTOM (RESERVE)
FLOAT
RESISTANCE (20°C/68°)
5-7Q
204 - 210 n
TOP
(FULL)
BOTTOM
(RESERVE)
TEMPERATURE INDICATOR/
TEMPERATURE SENSOR
SYSTEM INSPECTION
NOTE:
• The coolant/engine oil temperature indicator
should come on for a few seconds when the ignition switch is turned ON, and should extinguish
shortly.
FGA model shown:
TEMPERATURE INDICATOR
Check the neutral indicator and reverse indicator
function properly.
• If they do not function, check the power/ground
line (page 23-8).
• If they function, check as follows:
Temperature indicator does not come on when the
ignition switch turned to ON
Seal the PCM con- Disconnect the Powertrain Control Module (PCM)
nectors with tape to 33P connectors.
prevent dirt and oil
from entering the
connector after disconnecting the 33P
connectors.
PCM 33P (BLACK) CONNECTOR
(Wire side of female terminal)
NOTE:
• When reconnecting the PCM 33P connectors,
check that there is no dirt and oil in the connector.
Be careful not to Short the Blue/red and Green wire terminals with a
bend the connec- jumper wire.
tor terminals. Turn the ignition switch ON and check the tempera-
ture indicator.
• If the indicator comes on, replace the PCM.
• If the indicator does not come on, check for an
open circuit in the Blue/red and Green wire. If the
wires are OK, replace the combination meter.
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PCM 33P (GRAY) CONNECTOR
(Wire side of female terminal)
23-13
LIGHTS/METERS/SWITCHES
Temperature indicator does not go off with the fan
motor stops
Remove the left engine side cover (page 3-17).
Disconnect the ECT sensor 2P (Black) connector.
(BLACK) CONNECTOR I
Turn the ignition switch ON and check the temperature indicator.
• If the indicator comes on, then goes off, check
the ECT sensor (page 23-14).
FGA model shown:
TEMPERATURE INDICATOR
If the indicator comes on and stays on, disconnect the connector from the EOT sensor and
check the temperature indicator.
- If the indicator goes off, check the EOT sensor
(page 23-15).
- If the indicator stays on, check for short circuit
in the White and Green/red wire on ECT sensor
wire or Yellow and Green/red wire on EOT
sensor.
2P BLACK) CONNECTOR
ECT SENSOR INSPECTION
Drain the coolant from the engine (page 7-7).
Remove the left engine side cover (page 3-17).
Replace the ECT Disconnect the ECT sensor 2P (Black) connector
sensor while the from the sensor.
engine is cold. Remove the ECT sensor and O-ring.
2P (BLACK) CONNECTOR
23-14
LIGHTS/METERS/SWITCHES
Suspend the ECT sensor in a pan of coolant (50 - 50
mixture) on an electric heating element and measure the resistance through the sensor as the coolant heats up.
THERMOMETER
NOTE:
• Soak the element in coolant up to its threads
with at least 40 mm (1.57 in) from the bottom of
the pan to the bottom of the sensor.
• Keep the temperature constant for 3 minutes
before testing. A sudden change of temperature
will result in incorrect readings. Do not let the
thermometer or ECT sensor touch the pan.
Resistance: 0.15 - 0.16 k£2 at 100C (212°F)
0.08 - 0.10 kti at 120°C (248F)
ECTSENSOR
Replace the ECT sensor if it is out of specifications
by more than 10% at any temperature listed.
Always replace the Install the new O-ring and ECT sensor.
O-ring with a new Tighten the ECT sensor to the specified torque.
°ne'
TORQUE: 12 N m (1.2 kgf-m, 9 Ibf-ft)
Connect the ECT sensor 2P (Black) connector.
Install the removed parts in the reverse order of
removal.
Fill and bleed the cooling system (page 7-7).
EOT SENSOR INSPECTION
Drain the engine oil (page 4-11).
Remove the left center mud guard (page 3-7).
2P BLACK CONNECTOR
Disconnect the EOT sensor 2P (Black) connector and
remove the EOT sensor.
Suspend the EOT sensor in a pan of engine oil on an
electric heating element and measure the resistance
through the sensor as the oil heats up.
THERMOMETER
NOTE:
• Soak the element in oil up to its threads with at
least 40 mm (1.57 in) from the bottom of the pan
to the bottom of the sensor.
• Keep the temperature constant for 3 minutes
before testing. A sudden change of temperature
will result in incorrect readings. Do not let the
thermometer or EOT sensor touch the pan.
Resistance: 1.23 - 1.32 kQ at 40°C (104°F)
Replace the EOT sensor if it is out of specifications
by more than 10% at any temperature listed.
EOT SENSOR
23-15
LIGHTS/METERS/SWITCHES
Install the EOT sensor with a new sealing washer
and tighten it.
2P BLACK CONNECTOR
TORQUE: 12 N m (1.2 kgf m, 9 Ibfft)
Connect the EOT sensor 2P (Black) connector.
Install the removed parts in the reverse order of
removal.
Fill the recommended engine oil (page 4-11).
GPS RECEIVER (GPS model only)
INSPECTION
If the GPS indicator is blinking and the antenna
mark and all segments do not indicate at all, check
the system by following the troubleshooting "GPS
INDICATOR BLINKS" (page 23-17).
If the GPS start-up time is too long every time the
ignition switch is turned to ON despite of the hot
start condition, check the system by following the
troubleshooting "GPS START-UP TIME IS TOO
LONG" (page 23-18).
NOTE:
The start-up time of the positioning varies as follows:
•
Hot start
When the ignition switch is turned ON within 2
hours after it was turned OFF, the position fix will
be completed in about 25 seconds.
• Warm start
When the ignition switch is turned ON more than
2 hours after it was turned OFF, the position fix
will be completed in about 2 minutes.
•
23-16
Cold start
The position fix will be completed within about 8
minutes in the following situations;
- When the ignition switch is turned ON more
than 1 month after it was turned OFF
- When the vehicle is transported for more than
100 km (62 miles) with the ignition switch
turned OFF
- When the battery is disconnected
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ANTENNA MARK
LIGHTS/METERS/SWITCHES
GPS INDICATOR BLINKS (COMMUNICATION
ERROR)
1. GPS Receiver Connector Check
Remove the meter covers (page 3-18).
Turn the ignition switch OFF.
Remove the GPS receiver 6P (Natural) connector
from the stay and disconnect it.
Check for loose connection or poor contact of
the GPS receiver connector.
Connect the GPS receiver 6P (Natural) connector.
Turn the ignition switch ON, wait for 8 minutes
and check the GPS indicator.
6P (NATURAL) CONNECTOR
Is the GPS indicator still blinking?
YES
- GO TO STEP 2.
NO
- No problem (Temporary failure).
2. GPS Receiver Input Voltage Line Inspection
Turn the ignition switch OFF.
Disconnect the GPS receiver 6P (Natural) connector.
Turn the ignition switch ON.
Measure the voltage between the meter side
connector terminal and ground.
Connection: Pink (+) - Ground (-)
Is there about 5 V?
YES
- GO TO STEP 3.
NO
- • Open or short circuit in the Pink wire.
• Inspect the power input line of the
combination meter (page 23-8).
METER SIDE 6P (NATURAL) CONNECTOR
(Viewed from the terminal side)
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3. GPS Receiver Ground Line Inspection
Turn the ignition switch OFF.
Check for continuity between the meter side connector terminal and ground.
Connection: White/green - Ground
METER SIDE 6P (NATURAL) CONNECTOR
(Viewed from the terminal side)
fe there continuity?
YES
- GO TO STEP 4.
NO
- • Open circuit in the White/green wire
• Inspect the ground line of the combination meter (page 23-8).
W/G
(Q)
23-17
LIGHTS/METERS/SWITCHES
4. GPS Receiver Replacement
Replace the GPS receiver with a known good
one.
Turn the ignition switch ON, wait for 5 minutes
and recheckthe GPS indicator.
Is the GPS indicator still blinking?
YES
- Faulty combination meter.
NO
- Faulty original GPS receiver.
INDICATOR
GPS START-UP TIME IS TOO LONG
1. Recheck With the GPS System Reset
Disconnect the battery negative (-) cable and
reconnect it.
Turn the ignition switch ON, wait until GPS system starts-up, and turn the ignition switch to OFF
and ON.
Does the GPS start-up within 30 seconds?
YES
- No problem (Temporary failure).
NO
- GO TO STEP 2.
2. GPS Receiver Back-up Voltage Inspection
Remove the meter covers (page 3-18).
Turn the ignition switch OFF.
Remove the GPS receiver 6P (Natural) connector
from the stay and disconnect it.
Measure the voltage between the meter side
connector terminal and ground.
METER SIDE 6P (NATURAL) CONNECTOR
(Viewed from the terminal side)
Connection: Black/blue {+) - Ground (-)
Is there about 5V?
YES - Faulty GPS receiver.
NO
- • Open or short circuit in the Black/
blue wire.
• Inspect the back-up voltage line of
the combination meter (page 23-8).
GPS receiver removal and installation (page 3-18).
23-18
Bl/Bu
LIGHTS/METERS/SWITCHES
BRAKE LIGHT SWITCH
FRONT BRAKE LEVER
NOTE:
• The lower switch is the front brake light switch.
Disconnect the front brake lever switch connectors
and check for continuity between the switch terminals.
There should be continuity with the front brake
lever squeezed and no continuity with the lever
released.
BRAKE LIGHT SWITCH CONNECTORS
REAR BRAKE LEVER
Disconnect the rear brake lever switch connectors
and check for continuity between the switch terminals.
There should be continuity with the rear brake lever
squeezed and no continuity with the lever released.
REAR BRAKE PEDAL
Remove the right side cover (page 3-5).
Disconnect the rear brake pedal switch 2P (Green)
connector and check for continuity between the
switch side connector terminals.
There should be continuity with the rear brake pedal
depressed and no continuity with the pedal
released.
2P (GREEN) CONNECTOR
23-19
LIGHTS/METERS/SWITCHES
FRONT BRAKE SWITCH
NOTE:
• The upper switch is the front brake (inhibitor)
switch.
Check the front brake lever free play and adjust it if
necessary (page 4-19).
Disconnect the front brake switch connectors and
check for continuity between the switch terminals.
There should be continuity with the front brake
lever squeezed and no continuity with the lever
released.
BRAKE SWITCH CONNECTORS
HORN SWITCH (AUSTRALIA type only)
Disconnect the horn switch wire connectors.
Check the continuity between the connector terminals.
There should be continuity when the horn switch is
pushed, and be no continuity when the switch is
released.
HORN (AUSTRALIA type only)
Disconnect the wire connectors from the horn.
Connect a 12 V battery to the horn terminals.
CONNECTORS
The horn is normal if it sounds when the 12V battery
is connected across the horn terminals.
HORN
23-20
24. WIRING DIAGRAM
TRX680FA/FGA:
24-3
24-1
WIRING DIAGRAM
TRX680FA/FGA:
0030Z-HN8-A600
24^3
25. TROUBLESHOOTING
ENGINE DOES NOT START OR IS
POOR PERFORMANCE AT LOW AND
HARD TO START
25-2
IDLE SPEED
ENGINE LACKS POWER
25-3
POOR PERFORMANCE AT HIGH SPEED •25-6
POOR HANDLING
25-5
25-6
25-1
TROUBLESHOOTING
ENGINE DOES NOT START OR IS HARD TO START
1. Spark Plug Inspection
Remove and inspect spark plug.
Is the spark plug in good condition?
NO
- • Incorrect spark plug heat range
• Incorrect spark plug gap
• Dirty air cleaner
YES
- GO TO STEP 2.
2. Spark Test
Perform spark test.
Is there weak or no spark?
YES - • Loose or disconnected ignition system wire
Faulty ignition coil
Broken or shorted spark plug wire
Loose or disconnected ignition system wires
Faulty CKP sensor
Faulty engine stop switch
Faulty ignition switch
Faulty PCM
NO
- GO TO STEP 3.
3. Fuel Pump Inspection
Check for operation of the fuel pump and inspect the fuel flow.
Is the fuel pump unit normal?
NO
- • Faulty fuel pump unit
YES
- G O TO STEP 4.
4. PGM-FI System Inspection
Check the PGM-FI system.
Is the PGM-FI system normal?
NO
- Faulty PGM-FI system
Yes
- GO TO STEP 5.
5. Cylinder Compression
Test cylinder compression.
Is the compression low?
YES
- •
•
•
•
•
Valve clearance too small
Valve stuck open
Worn cylinder and piston rings
Damaged cylinder head gasket
Seized valve
NO
- GO TO STEP 5.
• Improper valve timing
6. Engine Start Condition
Start by following normal procedure.
Did the engine start but stops?
YES
25-2
- •
•
•
•
Leaking intake manifold
Leaking intake pipe
Improper ignition timing (Faulty PCM or CKP sensor)
Contaminated fuel
TROUBLESHOOTING
ENGINE LACKS POWER
1. Drivetrain Inspection
Raise wheel off the ground and spin by hand.
Does the wheel spin freely?
NO
- • Brake dragging
• Worn or damaged wheel bearing
• Damaged differential or final drive bearing
• Faulty differential or final drive
YES
- GO TO STEP 2.
2. Tire Pressure Inspection
Check tire pressure.
Are the tire pressures correct?
NO
- • Faulty tire valve
• Punctured tire
YES
- GO TO STEP 3.
3. Engine Condition Inspection
Accelerate lightly.
Does the engine speed increase?
NO
- • Clogged air cleaner
• Restricted fuel flow
• Clogged muffler
• Restricted fuel fill cap breather
YES
- GO TO STEP 4.
4. Engine Condition Inspection
Accelerate or run at high speed.
Is there knocking?
YES
- • Worn piston and cylinder
• Use of poor quality fuel
• Excessive carbon build-up in combustion chamber
• Ignition timing too advance (Faulty PCM)
NO
- GO TO STEP 7.
5. Spark Plug Inspection
Remove and inspect spark plug.
Is the spark plug fouled or discolored?
YES
- • Plug not serviced frequently enough
• Incorrect spark plug used
NO
- GO TO STEP 6.
6. Engine Oil Inspection
Check oil level and condition.
Is there correct level and good condition?
NO
- • Oil level too high
• Oil level too low
YES
- GO TO STEP 7.
• Contaminated oil
7. Ignition Timing Inspection
Check the ignition timing.
Is the ignition timing correct?
NO
YES
- • Faulty PCM
• Faulty CKP sensor
- GO TO STEP 8.
25-3
TROUBLESHOOTING
8. Cylinder Compression Inspection
Test cylinder compression.
Is the compression low?
YES
- • Valve clearance too small
Valve stuck open
Worn cylinder and piston rings
Damaged cylinder head gasket
Seized valve
Improper valve timing
NO
- GO TO STEP 9.
9. Fuel pump Inspection
Inspect the fuel flow.
Is the fuel pump unit normal?
NO
- Faulty fuel pump unit (page 6-36)
YES
- G O TO STEP 10.
10. PGM-FI System Inspection
Check the PGM-FI system.
Is the PGM-FI System normal?
NO
- Faulty PGM-FI system (page 6-13)
YES
- G O TO STEP 11.
11. lubrication Inspection
Remove cylinder head cover and inspect lubrication.
Is the valve train lubricated properly?
25-4
NO
- • Clogged oil passage
• Clogged oil orifice
YES
- • Faulty A/T system
TROUBLESHOOTING
POOR PERFORMANCE AT LOW AND IDLE SPEED
1. Spark Test
Perform spark test.
Is there weak or intermittent spark?
YES
-
Faulty spark plug
Fouled spark plug
Loose or disconnected ignition system wires
Broken or shorted spark plug wire
Faulty ignition coil
Faulty CKP sensor
Faulty engine stop switch
Faulty ignition switch
Faulty PCM
NO
- GO TO STEP 2.
2. Fuel Pump Inspection
Inspect the fuel flow.
Is the fuel pump unit normal?
NO
- Faulty fuel pump unit (page 6-36)
YES
- GO TO STEP 3.
3. PGM-FI System Inspection
Check the PGM-FI system.
fe the PGM-FI system normal?
NO
- Faulty PGM-FI system (page 6-13)
YES
- G O TO STEP 4.
4. Intake Air Leak Inspection
Check for leaks at the intake manifold pipes.
Are there leaks?
YES
- • Loose insulator bands
• Damaged insulator
NO
- GO TO STEP 5.
5. Ignition Timing Inspection
Check the ignition timing.
fe the ignition timing correct?
NO
YES
- • Faulty PCM
• Faulty CKP sensor
- • Faulty A/T system
25-5
TROUBLESHOOTING
POOR PERFORMANCE AT HIGH SPEED
1. Fuel Pump Inspection
Inspect the fuel flow.
Is the fuel pump unit operation normal?
NO
- Faulty fuel pump unit (page 6-36)
YES
- GO TO STEP 2.
2. PGM-FI System Inspection
Check the PGM-FI system.
te the PGM-FI system normal?
NO
- Faulty PGM-FI system (page 6-13)
YES
- GO TO STEP 3.
3. Ignition Timing Inspection
Check ignition timing.
te the ignition timing correct?
NO
- • Faulty PCM
• Faulty CKP sensor
YES
- GO TO STEP 4.
4. Valve Timing Inspection
Check valve timing.
te the valve timing correct?
NO
- Camshaft not installed properly
YES
- GO TO STEP 5.
5. Valve Spring Inspection
Check valve springs.
Are the valve springs weak?
YES
- • Faulty valve spring
NO
- • Faulty A/T system
POOR HANDLING
Steering is heavy
• Steering shaft nut or holder too tight
• Damaged steering shaft bushing
• Damaged steering shaft bearing
Any wheel is wobbling
• Excessive wheel bearing play
• Bent rim
• Improperly installed wheel hub
• Loose suspension arm
• Bent frame
Vehicle pulls to one side
• Tire air pressure incorrect
• Faulty shock absorber
I • Bent tie-rod
• Incorrect tie-rod adjustment
• Bent frame
• Improper wheel alignment
25-6
26. INDEX
ACCESSORY SOCKET
23-5
AIR CLEANER
4-5
AIR CLEANER HOUSING
6-41
AIR CLEANER HOUSING DRAIN PLUG
4-7
ALTERNATOR CHARGING COIL
20-8
ALTERNATOR STATOR/STARTER REDUCTION
GEARS
11-9
ALTERNATOR/STARTER CLUTCH
SPECIFICATIONS
1-8
AUTOMATIC TRANSMISSION SYSTEM
2-7
:
BANK ANGLE SENSOR
6-51
BATTERY
-20-6
BATTERY/CHARGING SYSTEM SPECIFICATIONS
1-10
BODY PANEL LOCATIONS
3-3
BRAKE FLUID
4-17
BRAKE FLUID REPLACEMENT/AIR BLEEDING
17-7
BRAKE LIGHT SWITCH
LIGHTS/METERS/SWITCHES
23-19
MAINTENANCE
4-19
BRAKE PAD/DISC
17-10
BRAKE PADS WEAR
4-18
BRAKE SYSTEM
4-19
BRAKE SYSTEM SPECIFICATIONS
1-10
CABLE & HARNESS ROUTING
1-20
CAMSHAFT
9-16
CASE BEARING REPLACEMENT
18-22
CENTER MUD GUARD
3-7
CHARGING SYSTEM INSPECTION
20-7
COMBINATION METER
23-8
COMPONENT LOCATION
BATTERY/CHARGING SYSTEM
20-2
ELECTRIC STARTER
22-2
IGNITION SYSTEM
21-2
LIGHTS/METERS/SWITCHES
23-2
COOLANT REPLACEMENT
7-6
COOLING SYSTEM
4-13,7-5
COOLING SYSTEM SPECIFICATIONS•
1-7
CRANKCASE ASSEMBLY
13-12
CRANKCASE BEARING REPLACEMENT
13-10
CRANKCASE SEPARATION
13-6
CRANKCASE/CRANKSHAFT/BALANCER
SPECIFICATIONS
1-9
CRANKSHAFT
13-7
CYLINDER COMPRESSION
9-6
CYLINDER HEAD ASSEMBLY
9-19
CYLINDER HEAD COVER ASSEMBLY/
INSTALLATION
9-22
CYLINDER HEAD COVER REMOVAL/
DISASSEMBLY
9-6
CYLINDER HEAD DISASSEMBLY
9-10
CYLINDER HEAD INSPECTION
9-11
CYLINDER HEAD INSTALLATION
9-20
CYLINDER HEAD REMOVAL
9-9
CYLINDER HEAD/VALVE/CAMSHAFT
SPECIFICATIONS
1-8
CYLINDER/PISTON INSPECTION
10-5
CYLINDER/PISTON INSTALLATION
10-8
CYLINDER/PISTON REMOVAL
10-4
CYLINDER/PISTON SPECIFICATIONS
1-8
DIFFERENTIAL ASSEMBLY
18-25
DIFFERENTIAL DISASSEMBLY/INSPECTION
18-14
DIFFERENTIAL INSTALLATION
18-30
DIFFERENTIAL REMOVAL
18-12
DIODE
22-14
DRIVE MODE SELECT SWITCH
14-46
DRIVE SHAFT BOOTS
4-14
DRIVETRAIN CONNECTOR LOCATION
14-17
DRIVETRAIN DTC INDEX
14-24
DRIVETRAIN DTC TROUBLESHOOTING
14-26
DRIVETRAIN SPECIFICATIONS
DRIVETRAIN SYSTEM DIAGRAM
DRIVETRAIN SYSTEM LOCATION
DRIVETRAIN TROUBLESHOOTING
INFORMATION
DTC TROUBLESHOOTING
ECT SENSOR
ELECTRIC STARTER SPECIFICATIONS
EMISSION CONTROL SYSTEMS
ENGINE & FRAME TORQUE VALUES
ENGINE GUARD
ENGINE IDLE SPEED
ENGINE INSTALLATION
ENGINE OIL
ENGINE OIL FILTER
ENGINE REMOVAL
ENGINE SIDE COVER
ENGINE STOP RELAY
EXHAUST SYSTEM
FINAL DRIVE ASSEMBLY
FINAL DRIVE DISASSEMBLY/INSPECTION
FINAL DRIVE INSPECTION
FINAL DRIVE INSTALLATION
FINAL DRIVE REMOVAL
FINAL GEAR CASE BEARING REPLACEMENT
FLYWHEEL/STARTER CLUTCH
FRONT BRAKE CALIPER
FRONT BRAKE SWITCH
FRONT CARRIER
FRONT CARRY PIPE
FRONT CRANKCASE COVER
FRONT DRIVE SHAFT
FRONT DRIVING MECHANISM SPECIFICATIONS
FRONT FENDER
•
FRONT GRILLE
FRONT MASTER CYLINDER
FRONT MUD GUARD
FRONT SHOCK ABSORBER
FRONT WHEEL
FRONT WHEEL/SUSPENSION/STEERING
SPECIFICATIONS
FUEL GAUGE/FUEL LEVEL SENSOR
FUEL LINE
FUEL LINE INSPECTION
FUEL PUMP RELAY
FUEL SYSTEM (PGM-FI)
FUEL SYSTEM SPECIFICATIONS
FUEL TANK
FUEL TANK COVER
FUEL TANK SIDE COVER
GEAR POSITION SWITCH
GEAR SELECTOR LEVER LINKAGE
GEARSHIFT SWITCH
GENERAL SPECIFICATIONS
GPS RECEIVER (GPS model only)
HANDLEBAR
HANDLEBAR SWITCH
HEADLIGHT
HORN (AUSTRALIA type only)
HORN SWITCH (AUSTRALIA type only)
IACV
IACV (Idle Air Control Valve)
IGNITION COIL
IGNITION SWITCH
IGNITION SYSTEM INSPECTION
IGNITION SYSTEM SPECIFICATIONS
IGNITION TIMING
INJECTOR
INNER FENDER
1-9
14-16
14-15
14-20
6-18
6-50
1-11
1-39
1-12
3-17
6-55
8-8
4-10
4-12
8-4
3-17
6-52
3-19
19-23
19-16
19-14
19-27
19-12
19-21
11-14
17-17
23-20
3-11
3-10
14-54
18-7
1-10
3-11
3-10
17-13
3-8
15-22
15-11
1-9
23-10
4-4
6-32
6-38
6-2
1-7
6-39
3-5
3-6
14-44
12-14
14-45
1-5
23-16
15-6
23-7
23-4
23-20
23-20 I
6-56
2-4
21-7
23-6
21-5
1-11
21-8
6-48
3-9
26-1
INDEX
LIGHTS/METERS/SWITCHES SPECIFICATIONS
1-11
LUBRICATION & SEAL POINTS
1-17
LUBRICATION SYSTEM DIAGRAM
5-2
LUBRICATION SYSTEM SPECIFICATIONS
1-7
METER COVER
3-18
MIL CIRCUIT INSPECTION
6-31
MODEL IDENTIFICATION
1-3
MUFFLER PROTECTOR
3-12
NUTS, BOLTS, FASTENERS
4-22
OIL COOLER
5-12
OIL PRESSURE CHECK
AUTOMATIC TRANSMISSION
14-12
LUBRICATION SYSTEM
5-5
OIL PUMP
5-5
OUTER FENDER
3-16
PCM (POWERTRAIN CONTROL MODULE)
2-2,6-53
PGM-FI CONNECTOR LOCATION
6-8
PGM-FI DTC INDEX
6-17
PGM-FI SYSTEM
2-3
PGM-FI SYSTEM DIAGRAM
6-7
PGM-FI SYSTEM LOCATION
6-6
PGM-FI TROUBLESHOOTING INFORMATION
6-13
RADIATOR COOLANT
4-12
RADIATOR RESERVE TANK
7-9
RADIATOR/COOLING FAN
7-10
REAR BRAKE CALIPER
17-27
REAR BRAKE DISC
17-34
REAR BRAKE MASTER CYLINDER/BRAKE
PEDAL
17-21
REAR CARRIER/MUD GUARD
3-13
REAR CRANKCASE COVER
12-5
REAR DRIVE SHAFT
19-6
REAR DRIVING MECHANISM SPECIFICATIONS
1-10
REAR FENDER
3-14
REAR FINAL GEAR CASE OIL AND
DIFFERENTIAL OIL
4-15
REAR SHOCK ABSORBER/SUSPENSION ARM
16-10
REAR WHEEL
16-6
REAR WHEEL/SUSPENSION SPECIFICATIONS
1-9
RECOIL STARTER
11-5
REGULATOR/RECTIFIER
20-9
RIGHT SIDE COVER
3-5
SEAT
3-4
SELECTOR CABLE ADJUSTMENT
12-15
SERVICE INFORMATION
• 4-3
ALTERNATOR/STARTER CLUTCH
11-3
BATTERY/CHARGING SYSTEM
20-3
BRAKE SYSTEM
17-4
COOLING SYSTEM
7-3
CRANKCASE/CRANKSHAFT/BALANCER
13-3
CYLINDER HEAD/VALVE/CAMSHAFT
9-3
CYLINDER/PISTON
10-3
DRIVETRAIN SYSTEM
14-3
ELECTRIC STARTER
22-3
ENGINE REMOVAL/INSTALLATION
8-3
FRAME/BODY PANELS/EXHAUST SYSTEM
3-2
FRONT DRIVING MECHANISM
18-3
FRONT WHEEL/SUSPENSION/STEERING
15-3
FUEL SYSTEM (PGM-FI)
6-3
IGNITION SYSTEM
21-3
LIGHTS/METERS/SWITCHES
23-3
LUBRICATION SYSTEM
5-3
MAINTENANCE
4-2
REAR DRIVING MECHANISM
19-3
REAR WHEEL/SUSPENSION
16-3
SUB-TRANSMISSION/GEARSHIFT LINKAGE
12-3
SERVICE RULES
1-2
SHIFT CLUTCH/MAINSHAFT ASSEMBLY
14-67
SHIFT CLUTCH/MAINSHAFT DISASSEMBLY
14-62
26-2
SHIFT VALVE BODY
SKID PLATE, ENGINE GUARD
SPARK ARRESTERSPARKPLUG
STANDARD TORQUE VALUES
STARTER MOTOR
STARTER RELAY SWITCH
STEERING COVER
STEERING SHAFT
STEERING SHAFT HOLDER BEARING
STEERING SYSTEM
SUB FUEL TANK/FUEL PUMP
SUB-TRANSMISSION
SUB-TRANSMISSION/GEARSHIFT LINKAGE
SPECIFICATIONS
SUSPENSION
SUSPENSION ARM
SYMPTOM TROUBLESHOOTING
DRIVETRAIN SYSTEM
FUEL SYSTEM (PGM-FI)
SYSTEM COMPONENTS
ALTERNATOR/STARTER CLUTCH
BRAKE SYSTEM
CRANKCASE/CRANKSHAFT/BALANCER
CYLINDER HEADA/ALVE/CAMSHAFT
CYLINDER/PISTON
DRIVETRAIN SYSTEM
ENGINE REMOVAL/INSTALLATION
FRONT DRIVING MECHANISM
FRONT WHEEL/SUSPENSION/STEERING
FUEL SYSTEM (PGM-FI)
REAR DRIVING MECHANISM
REAR WHEEL/SUSPENSION
SUB-TRANSMISSION/GEARSHIFT LINKAGE
SYSTEM DIAGRAM
BATTERY/CHARGING SYSTEM
ELECTRIC STARTER
IGNITION SYSTEM
SYSTEM FLOW PATTERN
COOLING SYSTEM
SYSTEM TESTING
TAILUGHT
TEMPERATURE INDICATOR/TEMPERATURE
SENSOR
THERMOSTAT
THROTTLE BODY-THROTTLE HOUSING
THROTTLE OPERATION
TIE-ROD
TIRES
TORQUE CONVERTER INSPECTION
TORQUE CONVERTER INSTALLATION
TORQUE CONVERTER REMOVAL
TRIM CLIP
TROUBLESHOOTING
ALTERNATOR/STARTER CLUTCH
BATTERY/CHARGING SYSTEM
BRAKE SYSTEM
COOLING SYSTEM
CRANKCASE/CRANKSHAFT/BALANCER
CYLINDER HEADA/ALVE/CAMSHAFT
CYLINDER/PISTON
ELECTRIC STARTER
ENGINE DOES NOT START OR IS HARD TO
START
ENGINE LACKS POWER
FRAME/BODY PANELS/EXHAUST SYSTEM
FRONT DRIVING MECHANISM
FRONT WHEEL/SUSPENSION/STEERING
14-47
4-20
4-21
4-7
1-12
22-6
22-12
3-5
15-28
4-22
4-23
6-36
12-9
1-9
4-21
15-23
14-6
6-5
11-2
17-2
13-2
9-2
10-2
14-2
8-2
18-2
15-2
6-2
19-2
16-2
12-2
20-2
22-2
21-2
7-2
7-5
23-4
23-13
7-8
6-43
15-10
4-4
15-33
15-11
14-61
14-73
14-60
3-4
11-4
20-5
17-6
7-4
13-5
9-5
10-3
22-4
25-2
25-3
3-2
18-6
15-5
INDEX
TROUBLESHOOTING
IGNITION SYSTEM
LUBRICATION SYSTEM
POOR HANDLING
POOR PERFORMANCE AT HIGH SPEED
POOR PERFORMANCE AT LOW AND IDLE
SPEED
REAR DRIVING MECHANISM
REAR WHEEL/SUSPENSION
SUB-TRANSMISSION/GEARSHIFT LINKAGE
21-4
5-4
25-6
25-6
25-5
19-5
16-5
12-4
UNIVERSAL JOINT
VALVE CLEARANCE
VALVE GUIDE REPLACEMENT
VALVE SEAT INSPECTION/REFACING
WATER PUMP
WHEEL HUB AND KNUCKLE
WHEEL HUB/KNUCKLE(REAR)
WHEELS/TIRES
WIRING DIAGRAM
19-15
4-8
9-12
9-13
7-13
15-15
16-6
4-22
24-3
26-3

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Download Service manual of Honda TRX680FA Offroad Vehicle for Free or View it Online on All-Guides.com.

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Honda TRX680FA Offroad Vehicle PDF Service Manual (Updated: Wednesday 15th of March 2023 05:04:39 PM)

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Compatible devices: 1992 TRX300 FourTrax, FourTrax Rancher TRX420TM1 2020, FourTrax Foreman TRX520FM1 2020, FourTrax Foreman Rubicon 2005, FourTrax Rincon TRX680FA5 2018, TRX250TE Fourtrax, TRX500FE FourTrax Foreman 4×4 ES, 2001 TRX350FM.

Recommended Documentation:

Honda TRX680FA: Text of Service Manual

(Ocr-Read Version Summary of Contents, UPD: 15 March 2023)

Honda TRX680FA: Recommended Instructions

TD-8816B, SY86P, Santa Fe, DFI2309, 141844H

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