Honda Foreman Rubicon Service Manual 2005 2012 [2005 2012] Honda_Rubicon_500_FA_FGA_FPA_Service_Manual 500 FA FGA FPA

User Manual: [2005-2012] Honda_Rubicon_500_FA_FGA_FPA_Service_Manual

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•
A Few Words About Safety
Service Information
The saNtee and repair information contained in thiS manual is intended for use by qualified, professional tectlmclans.
Attempllng service or repaIrs without the proper training, lools, and eqUipment could cause injury to you or others. It could also
damage the vehicle Of creale an unsafe condition.

This manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some procedures
require the use 01 specialty designed tools and dedicated eqUipment Any person who Imends to use a replacement part, service
procedure or a 1001 thai IS not recommended by Honda, must determIne the rISks to their personal salety and the sale operahon 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 01 interior quality

For Your Customer's Safety
Proper seNICe and maintenance are essential to the customer's safety and
the reliability of the vehICle. Any error or oversight while servicing a vehicle
can resuh in faulty operation, damage to the vehicle. or injury to others

For Your Safety
Because thiS manual IS Intended lor 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 sate servicing practice, we
recommended that you do not attempt to perform the procedures descnbed
In this manual
Some 01 the most Important general servICe salety precautions are given
below. However. we cannot warn you of f!N9ry 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
unsale condl\lon that can cause your customer
or others to be seriously hurt or killed
Follow the procedures and precautions in this
manual and other servICE! matenals carefully

AWARNING
Failure to properly IoIlow 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 praC\lces and that you are wearrng appropriate clothing and
using safety equipment. When performing any service task, be especially careful 01 the following·
• Read aU 01 the instructions before you begin and make sure you have the loc:Xs. the re~cemenl
required to perform the tasks salely and completely.

or repair parts.

and the skills

• Protect your eyes by USing proper salety 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. II there IS any doubt, put on eye protection.
• Use other protective wear wnen 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 )"Ourself and others whenever you have the vehicle up in the air. Any lime you bf1the Vehlde, either WIth a hoist or a jack.
make sure that It IS always securely supported Use}ack stands.
Make sure the engine is off before you begin arry serviclOg procedures, unless the rnstruction tells you to do otherwise.
This wdl help eliminate several potennal hazards:
• Carbon monoxide poisoning from engine exhaust Be sure there is adequate ventitallon whenever you run the engine.
• Burns from hot parts or coolant. lat Ihe engine and exhaust system cool before working in lhose areas
• InjUry from moving parts. JI the instruction tells you to run the engine. be sure your hands, fingers and dolhing are out of the way.
Gasoline vapors and hydrogen gases from battanes are explosive. To reduce the possibility of a fire or explosion, be careful when
wor1Cf1

CONTENTS

proe&durfl tor the

TRXSOOFAJFGAlFPA

GENERAL INFORMATION

Fellow IN Mall'llenanee Schedule (Secbon 3) reoommendabOnS 10
_ _ lllal thu vehoeIe IS on peak operating CXIOditJon and !he
IllTUS&IOr! IeveI5 are WIthin \he standards set by the U.S.
ErMfO(U'nel'ltal Prolectlon Agency (EPA) and CaltlogLS~"~rl~'~'~e'___ _ _ _ _ ___+~=~===--+_-----------I ends (lever side)
Multi purpose
Throttle cable adjuster threads (lever side)
grease (NlGI #2)
Throttle lever pivot and dust seal lips
Rear (parking) brake lever pivot
Parking lock arm pivot (screw)
Steering shah dust seal lips
Steering shaft end nut threads
Knuckle outer dust seal lips
Knuckle inner dust seal lips (inner and side lips)
Fill up 2.5 - 3 9 per each seal
Rear brake cam dust seal lips
Rear brake cam sliding surface
Apply 0.2 - 0.3 9
Rear brake anchor pin-to-brake shoe
contact area
Apply 0.2 - 0.3 9
Rear brake cam-to-brake shoe contact
Apply 0.2 - 0.3 9
area
Rear brake drum cover dust seal lips (inner and side lips)
Rear brake pedal pivot dust seal lips
Rear brake cable (pedal and lever) ends
Rear brake panel O-ring
Rear brake panel dust seal lips
Front differential case oil seal lips and O-rings
leh rear axle housing dust seal lips and O-ring (final gear
case)
Rear final gear case oil seal lips (ring gear and pinion joint)
and O-ring (pinion gear, filler cap and swingarm)
Front wheel hub dust seal lips
Rear wheel hub dust seal lips
Gearshift lever linkage arm pivot bolt groove
Gearshift lever linkage ball joints
Swingarm pivot bearing
('05, '06)
lithium based
grease (Shell
Swingarm pivot dust seal lips
('05, '06)
6459) or equiva(,05, '06)
Swingarm pivot bearing grease holder
lent
I

1-22

GENERAL INFORMATION
MATERIAL

LOCATION

Swingarm pivot bearing
(After '06)
Molybdenum disulfide grease
Swingarm pivot dust seal lips
(After '06)
Swingarm pivot bearing grease holder
(After '06)
Steering shaft spline
EPS unit output shaft spline
Front propeller shaft seal Quter surfaces (2 places)
Front propeller shaft splines (pinion joint and output shaft
joint)
Front differential pinion gear spline (pinion joint)
Output shaft splines and O-ring (output shaft joint)
Front drive shaft inboard joint inside
('05, '06)
(After '06)
('as, '06)
Front drive shaft outboard joint inside
(After '06)
Universal joint splines (output shaft and final drive shaft)
Rear axle splines
Upper arm dust seal lips
Upper arm pivot collar-to-pivot bushing contact area
Rear final drive shaft seal outer surface
Rear final driv~ shaft splines (pi nion joint )
Gearshift lever box sliding area
Gearshift lever knob push button sl iding surface
Gearshift lever lock pin rod sliding area
Engine oil
Rear brake cam felt seal
Master piston boot
Silicone grease
Front brake lever-to-master piston contacting area
Front brake lever pivot bolt-to-brake lever pivot contact
area
Front brake caliper pin boot inner surtace
Front brake caliper dust seal
EPS motor O-ring
Throttle cable outer inside
Cable lubricant
Choke cable outer inside
Rear brake cable (pedal and lever) outer insid,e_ _ _
Master cylinder piston, cups and oil seal
4 o OT4 b"ke flu;d
Front brake caliper piston seal
Front brake caliper Pis"t~o"n=~_ __ __ _ __ _
Honda bond A or
Handlebar grip rubber inside
Honda Hand Grip
Air cleaner case-to-connecting hose (carburetor and air
Cement (U.S.A.
intake duct) mating surtace
only) or equiva·
lent

REMARKS
Apply 3 g minimum
Apply 3 9 minimum
EPS model only

Fill up 5 - 8 g per each spline
Fill up 5 - 8 9 per spline
Fill
Fill
Fill
Fill

up 55 up 40 up 40 up 35 -

75
60
60
55

g
g
9
9

per
per
per
per

each
each
each
each

illups-a9

~------=~'

EPS model only

-I

t Rear final gear case cover mating siiu"rlc'O'"e'---______ ~+:'iS~e~a~la~n~t=;;;,:;==:;::=====--===Cooling fan motor shaft nut threads
Front brake switch screw threads
Differential ring gear boll threads
Differential case cover bolt threads
Final gear case cover bolt threads (10 mm bolt)
Gearshift lever l inkage arm pivot bolt threads
Sub-transmission piv~o~t~b~o~It,---_ _ _ _ _ _ _ __
Air cleaner element

EPS motor worm gear splines

joint
joint
joint
joint

Locking agent

---J

P, o-Honda lo,m
Apply 17 23 9
fi lter oil or equivalent
-1-iN 'H;'O"N;rcG"'RCi'E"AoS"E- - t -'EPS mode"l o;;;n"I"y- - - - - - 1
_ _L WR-S
Apply O.S g

1-23

GENERAL INFORMATION

CABLE & HARNESS ROUTING
'OS, '06:

THAOTIlE CABLE

GPS CONNECTOR IGPS model onlv)

•
ASSIST HEADLIG HT

CONNECTOR

/
FRONT BRAKE HOSE

(se) VALVE CABLE

After '06:
GP$ CONNECTOR (GPS model only)
THROITLE CABLE

ASSIST HEADLIGHT

CONNECTOR
HAND

CABLE

STARTING ENRICHMENT
(SE) VALVE CABLE

FRONT

HOSE

NOTE :
EPS model only: If the cables and harness around handlebar were replaced or removed/installed, perform the Torque Sensor Initialization (page 25- 13).

1-24

GENERAL INFORMATION
'OS, '06:
HAND BRAKE CABLE

THROTILE CABLE

REAR FINAL GEAR CASE
BREATHER HOSE

FRONT FINAL GEAR CASE
BREATHER HOSE
fRONT

HOSE

FAN MOTOR
BREATHER HOSE

REAR BRI'KE
BREATHER HOSE

After '06:

HAND BRI'KECABlE

THAOTIlE CABLE

REAR FINAL GEAR CASE

RRFA"r""R HOSE
\

~Pi?Ff~':~RONT FINAL GEAR CASE
1-I-F<.!1r n:¢~P BREATHER

FAN MOTOR

REAR BRIIKE

BREATHER HOSE

NOTE

EPS model only: If the cables and harness around handlebar were replaced or removed/installed, perform the Torque Sensor Initialization (page 25-13).

1-25

GENERAL INFORMATION
'05, '06:
THROTTLE CABLE

FRONT

HOSE

2"'DI4WD SELECT
SWITCH wIRe

RIGHT HANDLEBAR
SWITCH WIRE

STARTING ENRICHMENT
(SE) VALVE CABLE

After '06:
THl.oTTlE CABLE

FR()NTSRA,KE HOSE

RIGHT HANDLEBAR
SWITCHWIAE

2W[J/4V1iD SELECT
$WITCHWIRE

STARTING ENRICHMENT
(SE) VALVE CABLE
NOTE:

EPS model onlv: If the cables and harness around handlebar were replaced or removed/installed, perform the Torque Sensor Initialization (page 25- 13).

1-26

GENERAL INFORMATION
'05, ' 06:

HAND BRAKE CAB LE

HORN S""'ITCH!U type only)

MODE SELIECTSWITCH

MODE SELECT SWITCH WIRE

LEFT HANDLEBAR SWITCH WIRE

After '06:
HANO BRAKE CABLE

MODE SEI.ECTSWITCH

LEFT HANDLE

SWITCH WIRE

MODE

NOTE:
EPS model only: If the cables and harness around handlebar were replaced or removed/installed, perform the Torque Sensor Initial ization (page 25-13).

1-27

GENERAL INFORMATION
'05, '06:

ECM 5P (BLACK)

ECM 21
ASSIST

ECM 21P

",gAV'

HEADLIGHT 2P
(BLACK)
CONNECTOR

MAIN WIRE HARNESS

(GREEN) CDr""CTOR

MODE SELECT SWITCH

2P (GRAY)

CONNECTOR

FRONT
4P
(GREEN ) CONNECTOR

1-28

METER 14P

(GRAY) CONNECTOR

4P(BLACK) CONNECTOR
4WD

HANDLE SWITCH 10P

1
METER 4P
(YELLOW) CONNECTOR
HORN ';~'>Tru

CONNECTOR
(U type only)

GENERAL INFORMATION
After '06:

ECM 5P (BLACK)
CONNECTOR

ECM
ECM

MAIN WIRE HARNESS

HANDLE SWITCH 14P
(GREEN) CONNECTOR

COMBINATION METER 14P
(GRAY) CONNECTOR

MODE SELECT SWITCH

4P (BLACK) CQNNECTOR
4WD SWITCH 2P (GRAY)

CONNECTOR
IGNITION SWITCH 4P
(NATURAL) CONNECTOR

COMBINATION METER 4P (YELLOW)
CONNECTOR (Non EPS)
COMBINATION METER 6P (NATURAL)
CONNECTOR (EPS only)

1-29

GENERAL INFORMATION
'05, '06:
HORN SWITCH WIRE (U type only)

MAIN

REAR FINAL GEAR CASE
BREATHER HOSE

FAN MOTOR WIRE

BAND:
• Accessory socket wire
- Headlight wire
- Thermo switch wire
- Fan motor wire

REVERSE SWITCH WIRE

FRONT FINAL GEAR CASE
BREATHER HOSE

Aft er '06:

MAIN WIRE HARNESS

( fj[J
REAR FINAL GEAR CASE
HOSE
FAN MOTOR WIRE

BAND:

- Accessory socket wire
• Headlight wire
- Carburetor heater switch wire

. Fan motor wire

1-30

REVERSE

rCIR WIRE
ANGLE SENSOR WIRE
ANGLE SENSOR WIRE

AUTOMATIC TRANSMISSION
CONTROL MOTOR

1-37

GENERAL INFORMATION
Afte r '06 except EPS:
SPARK PLUG WIRE

CRANKCASE BREATHER PIPE

CARBURETOR
HEATER WIRE

THROTTLE
SENSOR

CONTROL
MOrOA 2P

(NATURAL)

CONNECTOR

CONTROL

1iR1o-- MOTOR WIRE
CONTROL
MOTOR WIRE
ANGLE SENSOR WIRE

AUTOMATIC TRI'NS,MI~;SI()N
CONTROL MOTOR

ANGLE SENSOR WIRE

After '09 EPS:

CARBURETOR
SPARK PLUG WIRE

CRANKCASE BREATHER PIPE

HEATER WIRE

THROTTLE
POSITION SENSOR

EPS MOTOR
2P (GREY)
CONNECTOR

CONTROL
MOTOR 2P
(NATURAL)
CONNECTOR

--':=;::;::1J2=~~

~~~J:~~~T

1>---,

CONTROL
J

CONTROL
MOTOR WIRE

ANGLE SENSOR WIRE
ANGLE SENSOR WIRE

AUTOMATIC TRANSMISSION

CONTROL MOTOR

1-38

~TORWIRE

GENERAL INFORMATION
'05 - '07:

START ING ENRICHMENT
(SE ) VALVE CABLE

THROTTLE CABLE

WI RE

SPARK

CA"BU'RElrOR HEATER WIRE

CRANKCASE BREATHER PIPE

After '07:
THROTTLE CABLE
STARTING ENRICHMENT
(SE ) VALVE CABLE

THROTTLE
POSITION SENSOR

0 - 3 mm
(0 - 0.1 in)

0 - 5mm
(0 - 0.2 in )

CARBURETOR HEATER WIRE

SPARK

WIRE

CRANKCASE BREATHER PIPE

FUEL HOSE

1-39

GENERAL INFORMATION
THROTILE POSITION SENSOR 3P

(BLACK) CONNECTOR

STARTING ENRICHMENT
(SEI VALVE CABLE
FUEL HOSE

CJ
Eer SENSOR WIRE

THROTTLE CABLE

CARBURETOR HEATER WIRE

Except EPS:
CLIP:

STARTING ENRICHMENT
(SE) VALVE CABLE

- Main wire harness

• Hand brake cable
- Rear brake breather hose
• Rear final gear case breather hose
- Radiator reserve tank siphon hose

FUEL HOSE
CRANKCASE
BREATHER HOSE

THROTTLE
CABLE

---.)J\:2~

STARTER MOTOR CABLE

1-40

WATER PUMP BYPASS HOSE

HAND BRAKE
CABLE

EOT SENSOR WIRE

GENERAL INFORMATION
EPS only:

CLIP:

STARTING ENRICHMENT
(SE) VALVE CABLE

• Main wire harness

- Hand brake cable
- Rear brake breather hose
- Rear final gear case breather hose
- Radiator reserve
siphon hose

CRANKCASE
BREATHER HOSE

THROTILE
CABLE

~-'l\:~:: HAND BRAKE

CABLE

EOT SENSOR WIRE

EPS ECU HAFINE!;S
STARTER Mr,m,RCABLE

WATER PUMP BYPASS HOSE

1-41

GENERAL INFORMATION

REAR BRAKE
BREATHER HOSE
ALTERNATOR 5P
CONNECTOR

HAND BRAKE CABLE
REAR FINAL GEAR
CASE BREATHER HOSE

MAIN wIRe HARNESS

TAIlUGHT3P
(NATURAL) CONNECTOR

GEAR POSITION SWITCH 4P
(NATURAL)

SIPHON HOSE

CARBURETOR HEATER 2P

(NATURAL) CO!'NECTC)R

GROUND CABLE
(Engine-te-frame )

(From HARNESS)

HAND BRAKE CABLE
PEDAL BRAKE CABLE
GROUND CABLE
(E ng ine-te-frame)

(From HARNESS)

REAR BRAKE LIGHT
SWITCH WIRE

CLIP:
- Rear brake breather hose
- Rear final gear case breather hose

- Radiator reserve tank siphon hose
- Gear position switch wire
- Alternator wire

1-42

GENERAL INFORMATION

GEAR POSITION SWITCH WIRE

GROUND CABLE
(Engine-la-frame)

CARBURETOR
DRAIN HOSE

CLIP:
- Alternator wire
- Gear position switch wire
- Carburetor drain hose

RADIATOR RESERVE
TANK SIPHON HOSE

HAND BRAKE CABLE

PEDAL BRAKE CABLE
REAR FINAL GEAR CASE

BREATHER HOSE
REAR BRAKE BREATHER HOSE

1-43

GENERAL INFORMATION
'OS - '07 (Except U type):

CLIPS:
- Front speed sensor wire

BRAKE HOSE

- Front final clutch wire
• Rear speed sensor wire
• Front final gear case breather hose

~~~---;fi

FRONT FINAL GEAR
CASE BREATHER HOSE

BAND:
- Front speed sensor wire
- Front final clutch wire
• Rear speed sensor wire

RIGHT FRONT BRAKE HOSE

lEFT FRONT BRAKE HOSE

'05 - '07 (U type):
CLIPS:
• Horn wire
• Front speed sensor wire
- Front final clutch wire
- Rear speed sensor wire
- Front final gear case breather hose

BRAKE HOSE

FRONT FINAL GEAR
CASE
HOSE

•
-

RIGHT FRONT BRAKE HOSE

1-44

Front speed sensor wire
Front final dut ch wi re
Rear speed sensor wire
Horn wire

lEFT FRONT BRAKE HOSE

GENERAL INFORMATION
After '07 (Except U type):

CLIPS:
- Front speed senso r wire
- Front final clutch wire
- Rear speed sensor wire

LEFT FRONT BRAKE HOSE

- Front final gear case b",,,he, hose

FRONT FINAL GEAR
CASE BREATHER HOSE

BANO:

- Front speed sensor wire
- Front final clutch wire
- Rear speed sensor wire

RIGHT <0''''0,

lEFT FRONT BRAKE HOSE

After '07 (U typel:
CLIPS:
- Horn wire
- Front speed sensor wire
- Front final clutch wire
- Rear speed sensor wire
- Front final gear case breather hose

LEFT FRONT BRAKE HOSE

FRONT FINAL GEAR
CASE BREATHER HOSE

Front speed sensor wire
Front final clutch wire
Rear speed sensor wire
Horn wire

HORN
LEFT FRClNT·BRAKE HOSE

1-45

GENERAL INFORMATION
Reverse side of the front fender:
HEAD LIGHT WIRE

ACCESSORY SOCKET WI RE

ACCESSORY SOCKET

'05, '06:
Reverse side of the rear fender:
TAIUBRAKE LIGHT WIRE

1-46

GENERAL INFORMATION
After '06:

TAIUBRAKE LIG HT
TAIUBRAKE LIGHT WIRE

Except EPS:

STARTER RELAY SWITCH

BATTERY 2P CONNECl-OR

BOX

2P CO"NEC:TOR

--~~=-~~~~~~~~====~============~~--~==~-----~

I\
I

STARTER MOTOR
CABLE

______

BATTERY GROUN D CABLE

-,~_1~~~~BATTERY

STARTER RE LAY SWITCH

1-47

GENERAL INFORMATION
EPS only:

BAnoRY2PCOINNI,CTOR

STARTER AELAYSW1TCH

BOX

EPS FU SE

BATIERY GROUND CABLE

1-48

STARTE R RElAY SWITCH

GENERAL INFORMATION

EMISSION CONTROL SYSTEMS
The U.S. Environmental Protection Agency (EPA), and the California Air Resources Board (CAR B) require that off-road ATV
comply with appl icable exhaust emissions standards during its usafullife, when operated and maintained according to the
instruction provided.

SOURCE OF EMISSIONS
The combustion process produces carbon monoxide, oxide of nitrogen and hydrocarbons. Control of hydro carbons and
oxides of nitrogen is very important because, under certain conditions, they react to form photochemical smog when subjected 10 sunlight. Carbon monoxide does not react in the same way, but it is toxic .
Honda Motor Co., ltd. uti l izes various systems to reduce carbon monoxide, oxides of nitrogen, and hydrocarbon.

EXHAUST EMISSION CONTROL SYSTEM
The exhaust emission control system is composed of 8 lean carburetor setting . and no adjustments should be made except
for high altitude setting and idle speed adjustment w ith the throttle stop screw. The exhaust emission control system is
separate from the crankcase emi ssion control system .

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 carburetor.
CARBURETOR
AIR CLEANER HOUSING

Fresh air

. . Blow-by gas

1-49

GENERAL INFORMATION
SERVICING THE HONDA
U.S.A. Only
Maintenance, replacem ent or repair of the emission control devices and systems may be performed by any 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 engine's 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.

NOISE EMISSION CONTROL SYSTEM (Except U type)
TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: State 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 aher such device or element of design has been removed or rendered inoperative by any person.

AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE TH E 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.

NOISE EMISSION CONTROL SYSTEM (U type only)
TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: law may prohibit: (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 aher such device or element of design has been removed or rendered inoperative by any person.

FUEL PERMEATION EMISSION CONTROL SYSTEM (After '07)
This AlV complies with the Fuel Permeation Emission Control regulations of the U.S. Environmental Protection Agency
(EPA), the California Air Resources Board (CAR B), and Environment Canada. The fuel tank, fuel hoses, and fuel vapor
charge hoses used on this AlV incorporate fuel permeation control technologies. Tampering with the fuel tank, fuel hoses,
or fuel vapor charge hoses to reduce or defeat the effectiveness of the fuel permeation technologies is prohibited by fed eral regulations.

REBUILT ENGINE
When you rebuild the 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 su re you are technically qualified to rebuild the engine and have the proper tools
Use only Genuine Honda parts or equivalents
Make sure to maintain all specifications as described in this Service Manual

1-50

2. FRAME/BODY PANELS/EXHAUST SYSTEM

SERVICE INFORMATION ························ ··· 2·2

INNER COVER ............................................ 2·7

TROUBLESHOOTING ................................. 2·2

FRONT MUD GUARD· ································ 2·8

BODY PANEL LOCATIONS ························ 2·3

INNER FENDER .......................................... 2·9

TRIM CLiP···················· ································ 2·4

FRONT CARRIER ........................................ 2·9

SEAT···························································· 2·4

FRONT CARRY PiPE ···························· .. ·.. 2· 10

RECOIL STARTER COVER····················· ····· 2·4

FRONT FENDER ... .................................... 2·11

ENGINE GUARD ............................ ........ ..... 2·5

REAR CARRIER ......................................... 2·11

GEARSHIFT LEVER KNOB ......................... 2·5

REAR FENDER ..................................... ..... 2·12

SIDE COVER· ········································ ······· 2·5

TOOL BOX ................................................ 2· 13

FUEL TANK COVER .... ·· ······························ 2·6

OUTER FENDER ............... ....................... . 2·13

CENTER MUD GUARD ............................... 2·7

EXHAUST SYSTEM ······························.. ·2·15

2-1

FRAME/BODY PANELS/EXHAUST SYSTEM

SERVICE INFORMATION
GENERAL
• This section covers removal and installation of the body panels and exhaust system.
• Serious burns may result if the exhaust system is not allowed to cool before components are removed or serviced.
• When installing the exhaust system, loosely insta ll all of the exhaust pipe fasteners. Always tighten the exhaust clamps
first, then tighten the mounting fasteners. If you tighten the mounting fasteners first, the exhaust pipe may not seat
properly.
• Always replace the gaskets after removing the exhaust system.
• Always inspect the exhaust system for leaks after installation.

TORQUE VALUES
Front carrier/carry pipe bolt
Gearshift lever knob screw
Rear ca rrier bolt
Muffler bend bolt
Front exhaust pipe cover band screw
Rear exhaust pipe cover end band screw
Rear exhaust pipe cover center band screw
Muffler cover screw

TROUBLESHOOTING
Excessive exhaust noise
• Broken exhaust system
• Exhaust gas leak
Poor perform ance
• Deformed exhaust system
• Exhaust gas leak
• Clogged muffler

2-2

37 N'm (3.8 kgf·m, 27 Ibf.ft)
2 N'm (0.2 kgf·m, 1.4 Ibf.ft)
37 N'm (3.8 kgf·m, 27 Ibf·h)
23 N'm (2.3 kgf·m, 17 Ibf.ft)
3.2 N'm (0.3 kgf·m, 2.4 Ibf.ft)
5.4 N·m (0.6 kgf·m, 4.0 Ibf·ft)
5.4 N·m (0.6 kgf·m, 4.0 Ibf.ft)
3.2 N·m (0.3 kgf·m , 2.4 Ibf·ft)

FRAME/BODY PANELS/EXHAUST SYSTEM

BODY PANEL LOCATIONS
'OS, '06 s hown:

(

(i)

)
(23)

(20)

(6)

(11)

(24)

(9)
(13)

(7)
(15)

(2)

(16)

( 12 )

(1) Seat (page 2-4)
(2) Recoil Starter COlier (page 2·4)
(3) Engine Guard (page 2-5)
(4) Gearshift lever Knob (page 2-5)
(5) Right Side Cover (page 2-5)
(6) left Side Cove r (page 2-6)
(7) Fuel Tank Cover (page 2-6)
(8) Right Center Mud Guard (page 2-7)
(91 left Center Mud Guard (page 2-7)
(10) Rig ht Inner Cover (page 2-7)
(11) left Inner Cover (page 2-8)
(12) Right Front Mud Gua rd (page 2-8)
(13) left Front Mud Guard (page 2-8)

(1 4) Inner Fender (page 2-9)
(15) Front Carr ier (page 2-9)
(16) Carry Pipe Gua rd (page 2-10)
(17) Front Skid Plate (page 2-10)
(18) Carry Pipe (page 2-10)
(19) Front Fender (page 2- 11 )
(20) Rear Ca rrier (page 2·' 1)
(21) Rear Fender (page 2· 12)
(22) Tool Box (page 2-13)
(23) Headlight Grille (page 2·13)
(24) Outer Fender (page 2-13)
(25) Ta illight Grille: '05, '06 only (page 2-14)
(25) Rear Corner Outer Fender: After '06 (page 2·14)

2-3

FRAME/BODY PANELS/EXHAUST SYSTEM

TRIM CLIP
Release by pul ling the center pin up using a snap , - - - - - - - - - - - - - - - - - ,
ring pliers or flat blade screwdriver and remove the
Remove and install
trim clip.
Vv'hen installmg the
tnm CliP, carefully
a/. If the gauge can be inserted into the gap, replace the
Do nor adjusflhe
spark plug gap. If plug with a new one.
tile gap IS out of

.r.2

speClf~tlon.

replace 1/ with 8

new one

I .d-

INSTALLATION
To prevent damage
/0 the cylinder

head, hand-lighten
the spark plug
be fore uSing 8

wrench to lighten
/0 the specified

Install the spark plug in the cylinder head and hand
tighten, then torque to specification.
TORQUE: 22 N'm (2.2 kgf·m , 16 Ibf.ft)
Install the removed parts in the reverse order of
removal.

torque

VALVE CLEARANCE
Inspect and ad/lJst
the valve clearance
whIle the engine 1$
cold (below 35~C/

Remove recoil starter cover (page 2-4).
Remove the fuel tank heat guard (page 8-6).

!f~"NG HOLE CAP

Remove the timing hole ca p.

9S"F),

Remove the bolts, intake and exhaust valve adjusting hole ca ps.

3-10

I~i~~~~~~~i~~i.

MAINTENANCE
Rotate the crankshaft u sing the recoil starter knob
and al ign the HI" mark on the flywheel with the
index mark on the alt ernator co v er.
Make sure the piston is at TDe (Top Dead Center) on
the compression stroke .
This position can be obtained by confi rming that
there is slack in the rocker ar m . If there is no slack, it
is because the piston is moving th rough the exhaust
stroke to TDe. Rotate the crankshaft one full turn
and match up the "T" mark again.

'T " MARK

INDEX MARK
When checking the
clearance, slide the
feeler gauge from

Check the clearance of each valve by inserting a
feeler gauge between the adjusting screw and valve

stem.

thlt center toward
the outside.

VALVE CLEARANCES:
IN : 0.15 mm (0.006 in)
EX: 0.23 mm (0.009 in )

Adjust by loosening the lock nut and turning the
adjusting screw unti l there is a slight drag on the
f eeler gauge.
Hold the adjusting screw and tighten the lock nut to
the specified torque.
TORQUE : 17 N ·m (1 .7 kgf·m , 13 Ibf.ft)
After t ighteni ng t he lock n ut, recheck t he valve
clearance.

Coat new O-ri ngs w it h engine oil and install them
into the grooves in the tappet adjusting hole caps.
install the tappet adjusting hole caps .

3-11

MAINTENANCE
Install and tighten the bolts to the specified torque.

Coat a new D-ring with engine oil and install it onto

the timing hole cap.
Install the timing hole cap and tighten it to the specified torque.

TORQU E: 10 N'm (1.0 kgf·m , 7 Ibf.ft)
Install the fuel tank heat guard (page 8-6),
Install the recoil starter cover (page 2-4).

ENGINE OIL
lEVEL CHECK
• 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.
• Before checking the oil level, remove the dipstick
and wipe it clean, insert the dipstick without
screwing it in, then remove the dipstick and
check the oil level at the tip mark.
Place the vehicle on a level ground.
Start the engine and let it idle for 5 minutes.
If the ai r temperature is below 10" C !50" F).
Let the engine idle for an additional 5 minutes (a
total of 10 minutes).
Stop the engine and wait 2·3 minutes.
Remove the dipstick and wipe it clean.
Check the oil level by inserting the dipstick into the
oil tank without screwing it in.

3-12

MAINTENANCE
The oil tank contains a sufficient amount of oil if the
oil level is between the upper and lower level ma rks

DIPSTICK

UPPER LE VE L

o n the di pstick.

LOWER LE VEL

TIP MARK

If the oil level is near or below the lower level mark,
remove the oil filler cap and add the recommended
engine oil up to the u pper level mark.

RECOMMENDED ENGINE Oil:
Pro Honda GN4 4-stroke 011 or equivalent motor
oil
API service class ification: SG or higher
JASO T 903 standard: MA
Viscosity: SAE 10W-30

Other viscosi ties shown in the chart may be used
when the average temperature in your riding area is

with in the indicated range.

OIL VISCOSITY

Reinstall the oil filler cap and dipstick.

Oil level che<:k when engine is runni ng
NOTE :
• The oil pump adjusts the oil level so that the oil
tank is always kept at the proper level. If this
check shows otherwise, some portion of the
lubrication system is not working property .
• 00 nOI check the oit level immediately aft er the
engine has been operated at high speeds. Make
sure that vehicle is on firm level ground while
idl ing. Allow the engine to idle for few minutes to
stabilize th e oille .... els.

The oille.... el i s correct if the oil is above the stepped
end line of the dipstick.

3-13

MAINTENANCE
OIL CHANGE
NOTE:
• Pour the engine oil after replacing the oil filt er
(page 3-15).
• Change the oil wi th the engine warm to assu re
complete and rapid draining.

Start the engine and let it idle for few m inutes.
SlOp the engine and remove the oil fi ller cap.

Remove the oil drain bolt and drain the engine oil.
After draining the oil completely, install the drain
bolt with a new sealing washer and tigh ten it.
TORQUE: 25 N 'm (2.5 kgf·m, 18 Ibf.ft)

DRA IN BOL T/SEALI NG WAS HE R

Pour the recommended engine oil (page 3-13) into
the oil tank up to the upper level mark on the dip-

stick.

ENGINE OIL CAPACITY:
4.4 liters 14.7 US qt. 3.9 Imp qt) after draining
4.6 liters (4.9 US qt, 4 .0 Imp qt) after draining / fil .

ter change
5.2 liters (5 .5 US qt, 4.6 Imp qt) after disassembly

Install the oil filler cap.
Check the oil level (page 3-12).
After oil change, be sure to reset the maintenance
indicator (See Owner's manual)
Make sure there are no oil leakage.

3-14

MAINTENANCE

ENGINE OIL FILTER
Drain the engine oil (page 3-14).
Remove the engine guard (page 2·5).

....

~ OIL FILTER

Remove the oil filter center bolt, cover, spring.
washer and oil filter.
Remove the O-rings from the oil filter cove r and

~' O-RING

center bolt.
Coat new O-rings w ith engine oil and install them
into the grooves in the oil filter cover and center
bolt.
Inslall a new oil filter.

Install the washer, spring . cover and center bolt.
Tighten the center bolt while holding the oil filter
cover by hand.
TORQUE: 18 N 'm (l.B kgf·m, 13 IbHt)
Fill the oil tank with the recommended engine oil
(page 3· 14).

SPRING

CENTER BOLT

ENGINE IDLE SPEED
• Inspect and adjust idle speed aher alt other
engine maintenance items have been performed
and are within specifications.
• The engine must be warm for accurate adjustment. Ten minutes of stop-and-go riding is sufficient.

Connect a tachometer.
Warm up the engine, shift the transmission into
neutral and place the vehicle on a level surface.
Check the idle speed.
IDLE SPEED: 1,400 ± 100 rpm (min·' )

If the adjustment is necessary, remove the recoil
starter cover (page 2-4).
Adjust the idle speed by turning the throttle stop
adjusting knob as required.
Remove the tachometer and install the removed
parts.

3-15

MAINTENANCE

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 Jines with the vehicle upright on a
level surface.
If the level is low, remove the reserve tank cap, and
fill the lank to the "UPPER" level line with a 1:1 mixture of distilled water and antifreeze (coolant preparation: page 6-5).

,------------r------,
UPPER lEVEL LINE

RECOMMENDED ANTIFREEZE:
Pro Honda HP coolant or an equivalent high quality ethylene glycol antifreeze containing silicatefre e corrosion inhibitors

I NOTICE I

LOWER LEVEL LINE
"

RESERVE TANK

Using coo/ant with silica te 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 reserve tank becomes completely empty, there is
a possibitity of air getting into the cooling system.
Be sure to remove aU air from the cooling system
(page 6-6J.

RESERVE TAN K CAP

COOLING SYSTEM
Remove the front fender (page 2-11).
Check for any coolant leakage from the water pump,
wate r hoses (radiato r and by-pass hoses) and hose
joints.
Check the water hoses for cracks or deterioration
and replace if necessary.
Check that aU hose clamps are tight.

3-16

MAINTENANCE
Remove the trim clips, radiator side plates and radi alor grille plate.

Check the radiator air passage for clogging or damage.
Straighten bent fins with a small, flat blade screw·
driver and remove insects, mud or other obstruc·
tions with compressed air or low pressure water.
Replace the radiator if the air flow is restricted over
more than 20% of the radiating surface.
Installation is in the reverse order of removal.
Install the front fender (page 2·11).

DRIVE SHAFT BOOTS
Check the drive shaft boots for cuts or other dam·
age.
If the boot is damaged, replace it (page 17·7).

DRIVE SHAFT BOOTS

3-17

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 check bolt and sealing washer.
check that the oil flows out of the check bolt hole.
Check for leakage if there is no oil flow.

Oil CHECK BOLT
Remove the oil filler cap and pour the oil slowly
through the filler hole until the oil starts to flow out
of the check bolt hole.
RECOMMENDED OIL: HVpoid gea r oil SAE #80
Install the check bolt with a new sealing washer and
tighten it to the specified torque.
TORQUE: 12 N 'm (1 .2 kgf·m , 9 Ibf.ft)

Coat a new O·ring with grease and install it into the
oil filler cap groove.

Install the oil filler cap and tighten it to the specified
torque.
TORQUE: 12 N ·m (1 .2 kgf·m , 9 Ibf.ft)

3-18

MAINTENANCE
OIL CHANGE

Place the vehicle on a level surface.
Remove the oil filler cap and drain boll to drain the
oil.
When the oil is completely drained, install the drain
bolt with a new sealing washer.
Tighten the drain bolt to the specified torque.
TORQUE: 12 N'm (1.2 kgf·m . 9lbf·ftl
Fill the final gear case with the recommended oil
~page

3-18).

OIL CAPACITY:
75 em' (2.5 US OZ, 2.6 Imp oz) at draining
100 em' (3.4 US OZ, 3.5 Imp oz) at disassembly
InSlall the oil filler cap with a new O-ring (page 318).

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 oit through the fill er hole until it reaches
the lower edge of the hole.

RECOMMENDED OIL: Hypoid gear oil SAE #80
Coat a new O-ring w ith grease and install it into the
oil filler cap groove.
Install the oil filler cap and tighten it to the specified
torque .
TORQUE: 12 N·m (1.2 kgf.m. 9 IbUt)

3-19

MAINTENANCE
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 3-19).

Oil CAPACITY:
185 em' (6.3 US OZ, 6.5 Imp oz) at draining
230 em' (7.8 US

OZ,

8.1 Imp oz) at disassembly

Install the oil filler cap with a new O-ring (page 319).

BRAKE FLUID
• Do not mix different types of fluid, as they are
not compatible with each other.
• Do not allow foreign material to enter the system
when filling the reservoir.

I NOTICE I
Spilled fluid can damage painted, plastic or rubber
parts. Place 8 rag over fhese pans whenever the
system is s8lViced.

FRONT BRAKE
Turn the handlebar to the left side so that the reservoir is level and check the brake fluid level through
the sight glass.
If the level is near the -LOWER - level mark, check
the brake pads wear (page 3-21).
Check the brake system for leakage (page 3-22).

If they are OK and the fluid level is near the
~LOWEW level mark, remove the screws, reservoir
cap, set plate and diaphragm and fill the reservoir
with DOT 4 brake fluid from a sealed container to
the casting ledge.
Install the diaphragm, set plate and reservoir cap,
and tighten the cap screws.
TORQUE : 2 N·m (0.2 kgf·m, 1.4Ibf.ft)

3-20

MAINTENANCE

BRAKE SHOES WEAR
INSPECTION
Replace the brake shoes if the indicator plate aligns
with the brake panel reference mark when the rea r
brake lever or pedal is applied.

BRAKE PADS WEAR
INSPECTION
Check the brake pads for wear.
Replace the brake pads if the indicator aligns with
reference mark.
Refer to page 16-13 for brake pads replacement.

BRAKE LIGHT SWITCH
INSPECTION
• Adjust the rear brake light switch after adjusting
the brake pedal freeplay .
• The front brake light switch can not be adjusted.
Check that the brake light comes on just prior to the . - - - - - - - -brake actually being engaged.
If the light fails to come on, adjust the switch so that
the light comes on at the proper time.
Hold the switch body and turn the adjusting nut. Do

- -- - - - - - - - - ,

nol turn the switch body.

REAR BRAKE I

3-21

MAINTENANCE

BRAKE SYSTEM
FRONT BRAKE
Inspect the brake hoses, pipes and fittings for deterioration, cracks and signs of leakage. Tighten any
loose fittings.

Replace hoses and fittings as required.

REAR BRAKE
BRAKE LEVER
Check the cable, brake lever and brake pedal for
loose connections, excessive play or other damage.
Replace or repair if necessary.
For cable lubrication : Disconnect the brake cables at
the brake lever or pedal ends.
Thoroughly lubricate the cables and thei r pivot
points with commercially available cable lubricant.
Measure the rear (parking) brake lever freepley at
the end of the brake lever.

FREEPLAY: 15 - 20 mm 19/ 16 - 13/16 in)

Make sure the cutou r In the 8djusflllg
nut is sealed on the

brake arm JOlm

3-22

Adjustments should be made with the upper adjusting nut at the rear brake arm.

MAINTENANCE
BRAKE PEDAL
Measure the brake pedal freeplay at the end of the
brake pedal and adjust as required .
BRAKEPEDAL FREEPLAY;
15 - 20 mm (9/16 - 13 / 16 in)

"==-1&16_;7
15-20mm

-AO

t'
BRAKE PEDAL
Milke sure Ihe cu/-

Adjust the rear brake pedal freeplay by turning the

out m the ad;ustmg lower adjusting nut at the rear brake arm .
nul lS sealed on Ihe
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.

ENGINE GUARD

SUSPENSION
FRONT SUSPENSION INSPECTION
Check the action of the front and rear shock absor bers by compressing them several times.
suspenslOfl pans Check the entire shock absorber assembly for signs
Impair vahlCle of leaks, damage or loose fasteners.
stabtlity 8nd con/fol
Loose, worn Of

damaged

FRONT:

3-23

MAINTENANCE
REAR SUSPENSION INSPECTION
Replace damaged components which cannot be
repaired.

Tighten all nuts and boils.

SWINGARM BEARINGS INSPECTION
Raise the rear wheels off the ground by placing a
jack or block under the engine.
Check for worn swingarm pivot bearings by grabbing the rear axle housings and attempting to move
the swingarm side to side.
Replace the pivot bearings if any looseness is noted
(page 15-9).

SPARK ARRESTER
Remove the three bolts and the spark arrester with

the gasket.

BOLTS

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.
Install the spark arrester with a new gasket and
tighten the three bolts.

TORQUE: 12 N·m (1.2 kgf·m, 9 Ibf.ft)

3-24

SPARK ARRESTER

MAINTENANCE

NUTS, BOLTS, FASTENERS
Check that all chassis nuts and bolts are tightened to
their correct torque values (page 1-15).
Check that all cotter pins, safety cl i ps, hose clamps
and cable stays are in place and properly secured.

WHEELS/TIRES
Tire pressure

should be cheded
when rhe 1"65 are

Check the tire pressure with the tire pressure gauge.
RECOMMENDED TIRE PRESSURE ('05 - '01):

Front: Standard: 25 kPa (0.25 kgf/cm Z, 3.6 psi)
Minimum: 22 kPa (0.22 kgf/ crn Z, 3.2 psi)
Maximum: 28 kPa (0.28 kgf/ cm Z, 4.0 psi)

cold

With cargo: 25 kPa (0.25 kgf/cmZ, 3.6 psI)
Rear: Standard: 25 kPa (0.25 kgf/cml, 3.6 psi)
Minimum : 22 kPa (0.22 kgflcmZ, 3.2 psi)
Maximum : 28 kPa (0.28 kgflcm 2, 4.0 psi)

With cargo: 25 kPa (0.25 kgf/cmz, 3.6 psi)
RECOMMENDED TIRE PRESSURE
(After '07 except EPS):
Front: 25 kPa (0.25 kgflcm2, 3.6 psi)
Rear: 25 kPa (0.25 kgflcm 2 , 3.6 psi)

RECOMMENDED TIRE PRESSURE (EPS only) :
Front: 32 .5 kPa (0.33 kgf/ cm 2, 4.7 psi)
Rear: 25 kPa (0.25 kgf/cm 2, 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 li mit.
MINIMUM TREAD DEPTH (Front/ rear):
4 .0 mm (0.16 in)
Raise the wheel off the ground and check the hub or
knuckle bearings for excessive play or abnormal
noise.

TIE-ROD AND JOINT BOOTS (After '07)
Check the t ie-rod joint nuts f or looseness.
Check the ball joint boots of the tie-rod for tears or
other damage.
Check for looseness of the tie-rod ball joints or bearings by grabbing each front wheel side to side with
the wheels on the ground.

JOINT BOOTS

If any looseness is noted, inspect the following.
-

Tie-rod (page 14-42)
Hub or knuckle bearing (page 14-23)

3-25

MAINTENANCE

STEERING SHAFT HOLDER BEARING
Raise the front wheels off the ground and support
cables do nor the vehicle.
mterfere WIth the Check thaI the handlebar moves freely from side to
Make sure the

rotallon of the
handlebar.

side.
If the handlebar moves unevenly, binds, or has hori zontal movement, inspect the steering shaft holder
bushing and bearing (page 14-28).

EPS mode/only- Remove the floor jack or other safety support tool.
Compare the required steering force with the
engine running and with the engine stopped .
If the required steering force is the same, check the
EPS system (page 25-81.
If the handlebar moves unevenly, binds, or has horizontal or vertical movement, inspect the steering
shaft holder bushing and bearing (page 14-28).

STEERING SYSTEM
Place the vehicle on a 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.

~======---::==========~
FRONT _ _ ,

Measure the toe on the rear part of the tires at the
same points with no load on the vehicle.
Toe-out: 30 ± 15 mm (1 - 3/ 16 ± 9/ 16 in)
• 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.

3·26

REAR

MAINTENANCE
'05 - '06.

After adjusting each tie-rod, rotate both ball joints in
the same direction with the tie-rod axis until they
stop against the ball joint stud. Hold them i n that
position and tighten the tie-rod lock nuts.
TORQUE : 54 N 'm !5.5 kgf·m, 40 Ibf.ft)
After tightening the lock nuts, make sure the ball
joints operate properly by rotating the tie-rods, to
make sure both ball joints have equal play.
Raise the wheel off the ground and check the hub,
knuckle bearings, and tie-rod ball joints for excessive play or abnormal noise.

After '06.'

Using a 22 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.

TIE-ROD END

TORQUE: 54 N 'm (5.5 kgf·m, 40 Ibf·ft)
After tightening the lock nuts, rota te the tie-rods to
make sure the ball joints have operate property 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 abnor mal noise.

LOCK NUT
Left side shown:
STEERING
SIDE

Right side shown:
STEERING
SIDE

KNUCKLE
SIDE

i--I
16· 30'

Rear

KNUCKLE
SIDE

Rear

I-i

16· 30'

3-27

MEMO

4. LUBRICATION SYSTEM

LUBRICATION SYSTEM DIAGRAM ,,···,,··· 4·2

OIL COOLER " " " ." """""" .,, " """"""""" ,,. 4·7

SERVICE INFORMATION "".,,"""""""""" 4·3

OIL STRAINER """.""""""""""""""""",,. 4·8

TROUBLESHOOTING · ".".,," ".""." """. "." 4·5

OIL PUMP """"""""""."""""",,.,,"""",,. 4·12

OIL PRESSURE CHECK """"·" """"" " " ,,,,·4·6

4-1

LUBRICATION SYSTEM

LUBRICATION SYSTEM DIAGRAM

ROCKER ARMS

CAMSHAFT

CENTRIFUGAL

OIL PRESSURE
CHECK VALVE

CLUTCH

OIL COOLER

;

~tb~~~~~~~~~~I,h~-REUEF

Oil PRESSURE
VALVE

EDT SENSOR

OIL STFIA"'ERSCAEEN

Oil FILTER

OIL STFIA"'ER

4-2

LUBRICATION SYSTEM

SERVICE INFORMATION
GENERAL

ACAUTION
Used engine oil may cause skin cancer if repeatedly left in contact wi th 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 oi l.
•
•
•
•
•
•
•

This section covers service of the oil pump and oil caoler.
For oil level check, oil change and filter repla cement, refer t o page 3·12.
The service procedures in this section can be performed with the engine oil drained.
The service procedures in this section can be performed with the engine i nstalled in the frame.
When removing and installing the oll pump. use care not to allow dust or dirt to enter the engine.
If any portion of the oi l 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 that there are no oil leaks and that oil pressure is
correct.

SPECIFICATIONS
""_ _ __ _--.- .
Unit: mm (in)
- -" 'T"'E"'
M; -- - - - - - - - - - , - - - -- - .S"T"'A"'N""'DARD
SERVICE LIMIT
Engine oil capacity
I-Ax;;ft~'~
' ~d~'a~;~n;~n~g""o;;;c_-__.,,4.4 liters (4.7 US qt, 3.9 Imp qt)
After drainingtfilter
4.6 liters (4.9 US qt. 4.0 Imp qt)
change
After disassembly
5.2 liters (5.5 US qt, 4.6 Imp qt)
Pro Honda GN4 4-stroke oil or equivaRecommended engine oil
lent motor oil
API service classification: SG or Higher
JASO T 903 standard: MA
Viscosity: SAE lOW- 3~
At 1,400 rpm (min)
Above 150 kPa (1.5 kgflcm, 22 psi)
Oil pressure 80 0 C{176° F)
Above 800 kPa (8.2 kgf/cm , 116 psi)
At 5,000 rpm (min 1)
0.20 (0.008)
0.15 (0.006)
Oil pump rotor
Tip clearance
0.25 (0.010)
Body clearance
0.12 0.22 (0.005 0.009)
0.11 !O.O04)~
0.02 0.09 (0.001 0.004)
Side clearance

TORQUE VALUES
Oil gallery sealing bolt (front crankcase cover)
Engine oil temperature (EOT) sensor

34 N'm (3.5 kgf.m, 25 Ibf·ft)
18 N'm (1.8 kgf·m, 13 Ibl-h )

4-3

LUBRICATION SYSTEM
TOOLS
Oil pressure gauge

Oil pressure gauge

Pressure gauge hose

07YAJ-0010100

Q7YAJ-0010300

07FPJ·7520100

Not available in U.S.A.

Pressure gauge attachment
07KPJ·VD60100

Oil pressure gauge, 0 - 160 psi

or 07KPJ-VD601OA (U.S.A. only)

U.S.A. only

4-4

07ZMJ-HN2Al00

lUBRICATION SYSTEM

TROUBLESHOOTING
01118'0'81 too low - high oil consumption
• Oil consumption
• External oil leak
• Worn piston rings or incorrect piston ring i nstallation

• 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
• Oi l 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
O il 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
• Entry of water

4-5

LUBRICATION SYSTEM

OIL PRESSURE CHECK
PRESSURE INSPECTION
Check the oil level and add the recommended oil if 1~~~~~IT~1[;~~~I'I.''''''=3!
necessary (page 3-12). Also, check the engine and
oil line fo r external oil leak before checking the oil
pressu re.
Clean around Ihe Remove the oil gallery sealing bolt and washer on
sealmg boll With the leh side of the front crankcase cover.
compressed air
bef«e removmg
the boll and be
sure !hal no dm IS
allowed to eme! the
ollQ8l/ery

Connect an oil pressure gauge attachment and
gauge to the oil gallery hole.

TOOLS:
Oil pressure gauge
(for 1.400 rpm (min" ))
Oil pressure gauge
(for 5,000 rpm (min" ll
Pressure gauge hose

07YAJ·0010300
07FPJ·7520100

Pres sure gauge attachment

07KPJ·VD60100

01YAJ·0010100

U.S.A. only:
Oil pressure gauge, 0 - 160 psi
Adapter, 10 x 1.25 mm

07ZMJ·HN2A 100
07KPJ·VD6010A L
HOSE
-_ _ _ _ _ _ _ _ _ _ ATIACHMENT
Start the engine and check the oil pressure at each
engine rpm (min 1).

~~~

Oil PRESSURE ( S o<' C / 176~ FI :
Above 150 kPa (1 .5 kgf/cm 2, 22 p si)
at 1,400 rpm (mi n' l )
Above SOO kPa (S.2 kgf/ cm:, 116 psi)
at 5,000 rpm (min·1 )
Stop the engine.
If the pressure is abnormal, check the pressure
check valve in the front crankcase cover (page 4-7).
If it is OK, inspect the lubrication system.
Clean the sealing bolt threads and install it with a
new sealing washer.
TORQUE: 34 N'm (3.5 kgf·m , 25 Ibf.ft)

4-6

LUBRICATION SYSTEM
CHECK VALVE INSPECTION
Remove the oil gallery sealing bolt and washer on
the right side of the fron t crankcase cover.

SPRING

Remove the valve spring and check valve.
Check the valve for wear, sticking or other damage.
Check the spring for fatigue or damage.
Install the check valve and spring.
Clean the sealing bolt threads and install it with a
new sealing washer.
TORQUE: 34 N 'm (3.5 kgf·m. 25 Ibf·tt)

OIL COOLER
INSPECTION
Remove the radiator grille plate (page 3-16),

Check the oil cooler pipe joints and seams for leaks.
Check the oil cooler air passage for clogging 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.

REMOVAL
Remove the front fender (page 2- 11).
Remove the six clips and the radiat or grille.

Remove the oil cooler pipe joint bolts and joints
from the oil cooler.
Remove the O-rings.

4-7

LUBRICATION SYSTEM
Remove the four bolts and the oil cooler from the

radiator.

INSTALLATION
Install the oil cooler onto the radiator and tighten
the four bolts securely.

Coat new O-rings with engine oil and instal l them

onto the oil cooler pipe joints.
Install the pipe joints onto the oil cooler.
Install the removed parts in the reverse order of
removal.
• Check the oil level and add the recommended
engine oil if the level is low (page 3-12).

OIL STRAINER
CLEANING
FOR FEED PUMP:
Remove the front mud guard (page 2-8) and inner
fender (page 2-9).
Disconnect the engine oil temperature (EOT) sensor
connector and remove the EOT sensor.
Remove the bolts and oil pipes from the oil tank.

4-8

LUBRICATION SYSTEM
Remove the five bolts and oil tank.
Remove the a ·rings and collar.

OIL
Remove the five bolts from the front oil tank.

Remove the seven bolts and remove the rear oil
tank from the front oil tank.

Remove the oil strainer screen from the front oil
tank.
Clean the strainer screen thoroughly and reinstall it

FRONT Oil TANK

REAR

I TANK

OIL STFIA"'EASCAEEN

4-9

LUBRICATION SYSTEM
Apply sealant to the mating surface of the front oil
tank.
Coal a new O-ring with engine oil and install it onto
the plate on the rear oil tank.

111
,
Install the rear oil tank onto the front oil tank, and
tighten the seven bolts securely.

a ·RING

REAR OIL TANK

BOLTS

Install the five bolts and tighten them securely.

FRONT Oil TANK

BOLTS

Install the joint collar into the front crankcase cover.
Coat new O-rings with oil and install them onto the

collar and into the crankcase cover groove.

4-10

LUBRICATION SYSTEM
Install the oil tank onto the front crankcase cover
and tighten the five bolts securely.

OIL TANK

Coat new O-rings with oil and install them ont o the

oil pipes.
Install t he oil pipes into the oil tank and tighten the
bolts securely.

I all PIPE

BOLT

Install the engine oil temperature IEOT) sensor with
a new sealing washer and tighten it.

TORQUE: 18 N -m {l .B kgf-m , 13 Ibf.ftl
Connect the EDT sensor connector.
Install the inner fender (page 2-9) and front mud
guard (page 2-8),

FOR SCAVENGE PUMPS:
Remove the rear crankcase cover (page 12·6).

Remove the bolt and oil strainer for the sub-scavenge pump.

Oil STRAINER (SUB-SCAVENGE )

4-11

LUBRICATION SYSTEM
Remove the bolt and oil strainer screen for the main
scavenge pump.

Clean the oil strainer and screen thoroughly.

Install the oil strainer screen and tighten the bolt
securely _

Coat a new O-ring with oil and install it onto the oil
strainer.

Install the oil strainer and tighten the bolt securely.

:11 '1
OIL PUMP
REMOVAL
Separate the crankcases (page 13-8).

Remove the five bolts (goldl and oil pump from the
front crankcase.

4-12

QILPUMP

O-RING

LUBRICATION SYSTEM
Remove the O-rings.

DISASSEMBLY
Or/ pump body C Remove the three bolts and oil pump body C.
may pop our by the

spnng force.

BODYC
Remove the spring seat, spring and relief valve.

SPRING SEAT/SPRING

Check the valve for wear, sticking or other damage.
Check the spring for fatigue or damage.
Remove outer, inner rotors C and drive pin.
Remove the oil pump spacer.

~~~~ROTC)RSC
Remove outer, inner rotors B and drive pin.
Remove the dowel pins.

DRIVE PIN

DOWEl PIN

4-13

LUBRICATION SYSTEM
Separate oil pump bodies A and B.
Remove the outer, inner rotors A. drive pin and
pump shaft.
Clean the all disassembled parts thoroughly.

INSPECTION
Temporarily assemble each inner rotor, outer rotor
and drive pin onto 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 )

Measure the pump side clea rance.
SERVICE LIMIT: 0.'1 mm (0.004 in)

4-14

PUMP BODY A

LUBRICATION SYSTEM
ASSEMBLY
Dip all parts in clean engine oil.
OUTER ROTORS A

PUMP BODY A

PUMP BODY 8

RELIEF VALVE

PUMP SHAFT

SPRING
SPRING SEAT

Do\~ElPIN

PUMP BODye

INNER

INNER ROTORS B

OUTE A ROTORS B
INNER ROTORS C
OUTER ROTORS C

Install the pump shaft into pump body A with the
threaded hole end facing toward pump body A.
Install inner rotor A onto the shaft with the drive pin
grooves facing Qut.
Install outer rotor A.
Install the drive pin into the pump shaft hole and set
the drive pin in the inner rotor grooves.
Install pump body B.

PUMP BODYA
PUMP SHAFT

=;.;..;;;=_
Install the two dowel pins.
Install the drive pin and inner rotor B. aligning the
pin grooves with the drive pin .
Install outer rotor B.

DQWElPIN

DRIVER PIN

DOWEl PIN

-:,~[lRIV;ER PIN

INNER

4-15

LUBRICATION SYSTEM
Install the pump spacer.
Install the drive pin and inner rotor C, aligning the
pin grooves with the drive pin.

DRIVE PIN

INNEA ROTOR C

Install outer rotor C.
Install the relief valve, spring and spring seat.

Install the pump body C and tighten the three bolts.

INSTALLATION
Coat new O-rings with oil and install it into the
grooves in the front crankcase.

4-16

BOLTS

LUBRICATION SYSTEM
Install the oil pump onto the front crankcase and
tighten the five bolts securely.
Assemble the crankcases (page 13-16).

4-17

MEMO

5. FUEL SYSTEM

SYSTEM COMPONENTS ........................... 5-2

CARBURETOR ASSEMBLy ····················· 5-13

SERVICE INFORMATION ... .................. ...... 5-3

CARBURETOR INSTALLATION ··············· 5-18

TROUBLESHOOTING ................................. 5-4

PILOT SCREW ADJUSTMENT ................ 5-19

AIR CLEANER HOUSING ························ ··· 5-5

HIGH ALTITUDE ADJUSTMENT
(except U type) .. ············ ············ ··············· 5-20

CARBURETOR REMOVAL .. ························ 5-6
FUEL TANK ··············································· 5-21
CARBURETOR DISASSEMBLYI
INSPECTION ............ ................................... 5-8

5-1

FUEl SYSTEM

SYSTEM COMPONENTS

2.3 N'm (0.2 kgf·m, 1.7 Ibf.ft)

5-2

FUEL SYSTEM

SERVICE INFORMATION
GENERAL
• 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.
• Bending or twisting the control cable will impair smooth operation and cou ld cause the cable to stick or bind, resulting
in loss of vehicle control.
• Before removing the carburetor, place an approved fuel container under the drain hose, loosen the drain screw and
drain the carburetor.
• After removing the carbu reto r, cover the intake port of the cylinder head wi th shop towel to prevent any foreign material from dropping into the engine.
• When disassembling the fuel system parts, note the location of the O-rings. Replace them with new ones on reassembly.
• If the throttle cable was disconnected, perform the initial setti ng (page 24-6) after all carbureto r adjustments have been
completed.
• If the vehicle is to be slored for more than one month, drain the float chamber. Fuel left in the float chamber may cause
clogged jets, resulting i n hard starting or poor drive-ability.
• See page 22-1 1 for carburetor heater inspection.
• See page 24-40 for th rottle position senso r inspection and replacement.

SPECIFICATIONS
ITEM
Carburetor identification number

A. CM type
U type

Main jet
Slow jet
Pilot screw opening
Float level
Idle speed
Throttle lever freeplay

SPECIFICATIONS
VE6AE
VE6AF
# 162

#45
See page 5-19
15.9 mm (0.63 in)
1.400 ± 100 rpm (min' )
3 8 mm (1/8 - 5/ 16 in)

TORQUE VALUES
Carburetor insu lator band screw
Starter enrichment (Se) valve nut
Throttle drum cover screw

4 N'm (0.4 kgf·m, 2.9 Ibf·ft)
2.3 N'm (O.2 kgf·m, 1.7 Ibf.ft )
1.5 N'm (0.2 kgf·m, 1.1 Ibf·ft)

TOOL
Carburetor float level gauge
07401-0010000

Pilot screw wrench
07KMA·MN90101

or 07KMA-MN9A 100 (U.S.A. only)

5-3

FUELSVSTEM

TROUBLESHOOTING
Engine cranks but won't sta rt
• No fuel in lank
• No fuel to carburetor
- Clogged fuel strainer
- Clogged fuellins
- Clogged fuel tank breather hose
- Misadjusted fuel level
• Too much fuel getting to the engine
- Clogged ai r cleaner
- flooded ca rburet or
• Intake air leak
• Contaminated/deteriorated fuel

- Clogged jets
•
•
•
•

Clogged starting enrichment (SE) valve circuit
Improper choke operation
Improper throttle operation
No spark at plug (faulty ignition system - (page 20-4))

Lean mixture
• Clogged fuel jets
• Faulty float valve

• Float level too low
•
•
•
•
•
•

Restricted fuel line
Clogged carburetor air vent hose
Restricted fuel tank breather hose
Intake air leak
Faulty vacuum piston
Faulty throttle valve

Rich mixture
• SE valve open (ON)
• Clogged air jets
• Faulty float valve
• Float level too high
• Dirty air deaner
• Clogged slow circuit
• Clogged SE valve circuit
• Worn jet needle or needle jet
• Faulty vacuum piston
Engine stalls, hard to start, rough idling
• Restricted fuel line
• Fuel mixture too lean/rich
• Contaminated/deteriorated fuel
- Clogged jets
• Intake air leak
• Misadjusted idle speed
• Restricted fuel tank breather hose
• Dirty air deaner
• Misadjusted pilot screw
• Faulty ignition system (page 20-4)
Afterburn when engine braki ng is used
• Lean mixtu re in slow circui t
• Faulty ignition system (page 20-4)
Backfiring or misfiring during acceleration
• Lean mixtu re
• Faulty ignition system (page 20-4)
Poor performance (drive-ability) and poor fuel economy
• Clogged fuel system
• Faulty ignition system (page 20-4)

5-4

FUEL SYSTEM

AIR CLEANER HOUSING
REMOVAl/lNSTAlLA TION
Remove the following :

fuel tank cover (page 2-6)
two trim clips

TRIM CUPS

Release the breather pipe cl ip from the stay on the

muffler. Disconnect the crankcase breather pipe
from the air cleaner housing.

Disconnect the air cleaner hose from the carburetor
hose jOint.

Loosen the band screw and rem ove the air intake
duct from the air cleaner housing.
Be care ful not 10
damage rhe

Loosen the air cleaner connecti ng hose band

screws .

connectmg hose.

5-5

FUEL SYSTEM
Remove the bolts.
Remove the air cleaner housing from the frame.
InSlaUthe air cleaner housing and connecting hose,
and align the groove in the connecting hose with
the lug on the air cleaner housing.
Install the air intake duct, aligning guide on the duct
with the seat retainer.

Install the removed parts in the reverse order of
removal.

CARBURETOR REMOVAL
Remove the air cleaner housing (page 5-5),
Release the carburetor heater wire from the wire
clip and disconnect the heater 2P connector.
Remove the carburetor drain hose from the clamp.

Do nolloosen the
throttle POSItIOn

Disconnect the throttle position sensor 3P connec-

tor.

sensor attachmg
screws unless the
throttle posrll()(1
sensor rsqUires
rep/l1C6ment

Remove the throttle position sensor wi re from the
clamp.
Slide the rubber cap off the starting enrichment (SE)
valve nut.
Loosen the SE valve nut and remove the SE valve
from the carburetor.
Turn the fuel valve OFF and disconnect the fuel
hose from the carburetor.

5-6

FUEL SYSTEM
Remove the screw and thronle drum cover.

Slide the rubber cap off tha thronle cable adjuster.
Loosen the throttle cable lock nut and remove the
adjuster from the carburetor body, and disconnect
the cable from the throttle drum.

Loosen the carburetor insulator band screw and
remove the carburetor from the insulator.

5-7

FUEL SYSTEM

CARBURETOR DISASSEMBLY /
INSPECTION
STARTING ENRICHMENT (SEI VALVE
INSPECTION
Check the SE valve face for scores, scratches or

wear.
Check the SE valve seat at the tip of the valve for
stepped wear.
Check the seal ring for wear or damage.

HOSES
Remove the following :
-

air vent hoses
drain hose

DRAIN HOSE

CARBURETOR HEATER
Remove the ca rburetor heater and spacer.

5-8

FUEL SYSTEM
AIR CUT-OFF VALVE (U type only)
Remove the sc rew and the air cut-off valve from the
carburetor body _

~-----------------,

SLOW AIR

JET

Remove the slow air jet and three O -rings.
Check the air cut-off valve and jet for damage.

Clean the air jet with cleaning solvent and blow
open with compressed air.

O-RINGS

'1, \
~----:~

AIR CUT-OFF VALVE

SCREW

VACUUM CHAMBER
Remove the four screws and clamps while holding
the vacuum chamber cover.

WIRE CLA::t-SMALL HOSE CLAMP

o
Remove the vacuum chamber cover, compression
spring and diaphragmlvacuum piston from the carburetor body.

Be careful not 10

damage the
diaphragm.

Turn the needle holder counterclockwise by using a
screwdriver whi le pressing it in and release the

VACUUM CHAMBER COVER

NEEDLE HOLDER

holder flange from the vacuum piston.
Remove the needle holder, spring , jet needle and
washer.

5-9

FUELSVSTEM
Check the jet needle for stepped wear.
Check the vacuum piston for wear or damage.
Check the diaphragm for pin hole, deterioration or
damage.
Check the vacuum piston for smooth operation up
and down in the carburetor body.

Air will leak out of the vacuum chamber if the dia·
phragm is damaged in any way, even with just a pin
hole.

JET NEEDLE

WA~

SPRING

NEEDLE HOLDER

Remove the screw, set plate, air joint and O-ring.
O-RING

PRIMER KNOB
Remove the two screws while holding the primer
knob body.

Remove the primer knob assembly and spring.

PRIMER KNOB AS:SE"BLY

5-10

FUEL SYSTEM
Check the diaphragm for holes, deterioration or
damage.

DIAPHRAGM

FLOAT CHAMBER
Remove the four screws and the float chamber.

SCREWS

Remove the baffte plate.

BAFFLE PLATE

Drive out the float pin from the throttle stop screw
side using a pin driver.
Remove the float and float valve.
Check the float for damage or fuel in the float.

5-11

FUELSVSTEM
Check the float valve and valve seat for scoring,
scratches, clogging or damage.
Check the tip of the float valve. where it contacts the

valve seal, for stepped wear or contamination.
Check the operation of the float valve.

Remove the following:
Cilre. They can
- main jet
easily be scored or
- needle jet holder
scratched

Handle rile jelS with

needle jet
slow jet
starter jet
rubber plug

Turn the pilot screw in and carefully count the numscrew seat Will ber of turns until it seats lightly. Make a note of this
occur If the Pilot to use as a reference when reinstalling the pilot
screw IS ttghtened screw.
agamst the seat

Damage /0 the pilot

Remove the pilot screw, spring, washer and 0rings.

WASHER

~RING

Check each jet for wear or damage.
Check the pilot screw for wear or damage.
Clean the jets with cleaning solvent and blow open
with compressed air.

NEEDLE JET

CARBURETOR CLEANING
Remove the following:
Cleaning !he 8irsnd
fuel passages wr!h
s PIece of WIre WIll
damage !he
carburetor body

5-12

diaphragmlvacuum piston
all jets and pilot screw

Blow open alt air and fuel passages in the carburetor body with compressed air.

O-RINGS

FUEL SYSTEM

CARBURETOR ASSEMBLY

DIAPHRAGM!
VACUUM PISTON

VACUUM CH.AMBEF COVER

A IR VEN T HOSES

AlA CUT-OFF
VALVE

FLOAT VALVE
AIR BREAD

HOSE

PRIMER KNOB

1.5 N·m

10.2

FLOAT

U type only

FLOAT PIN

~~,ll

kgf·m,
1.1
Ibf.ft)

\o!"'-- NEEDLE HOLDER

/
{

/~O" '-""""

DRAIN SCREW

g
.0

FLOAT
CHAMBER

CARBURETOR

HEATER
AIR

SLOW JET

THROTTLE
POSITION SENSOR

SCREW CABLE

NEEDLE JET

PILOT SCREIN

HOLDER
ONE-WAY VALVE

MAIN JET

DRAIN HOSE

BAFFLE PLATE

FLOAT ANO JETS
Damage to the pilot

Install the pilot screw with the spring, washer and
screw seat Will new O-rings, and return it to its original position as
occur If the pilot noted during removal.
screw IS tightened Perform the pilOI screw adjustment if a new pilot
against the

sear.

PilOT SCREW

SLOW JET

MAIN JET

screw is installed .

Install the following :
care. They can
- needle jet
easIly be scored Of
- needle jet holder
scratched,
- main jet
- slow jet
- starter jet
- rubber plug

Handle the Jets With

5-13

FUEL SYSTEM
Hang the float valve onto the float arm lip.
Install the float valve and float, and insert the float
pin so thai the spline end rests in the short boss
(spline hole) side 85 shown.
Drive the float pin using the pin driver until its end is
flash with the boss.

FLOAT lEVEl INS PECTIO N
• Check the float level after checking the float
valve, valve seat and float.
Set the float level

gauge so tha t IllS
perpendicular 101M
f/oat chamber face
al the tllghes/ polm
of the float

With the float velve seated and the float arm just
touching the valve, measure the float level wi th the
float level gauge.

TOOL:
Carburetor fl oat lev el gauge 07401-0010000

FLOAT lEVEL: 15.9 mm (0.63 in )

The float cannot be adjusted.
Replace the float assembly if the float level is out of
specification .

BAFFLE PLATE

Install the baffle plate by aligning its groove with
the lug on the carburetor body as shown.

_
Install a new a-ring into the float chamber groove
properly.
Install the float chamber and tighten the four
screws.

5-14

:11

a.RING

__. .,_lUG

FUEL SYSTEM
PRIMER KNOB
Install the spring primer knob assembly, and tighten
the two screws securely.

VACUUM CHAMBER
Install a new O-ring into the air joint groove.
Install the set plate into the air joint groove.
Install the air joint into the carburetor body, aligning
the set plate groove with the lug on the carburetor
body, and tighten the screw.

Install the needle clip onto the jet needle.
'05
After "OS'

DIAPHRAGM/PISTON

STANDARD CLIP POSITION: 2nd groove from top
Aher '05 model can not adjust the needle clip position.
Install the washer onto the jet needle and insert the
jet needle into the vacuum piston.
Install the spring into the needle holder and set t he
needle holder into the vacuum piston.

SPRING

Turn the needle holder 90 degrees clockwise while
pressing it until it locks.

NEEDLE HOLDER

NE'oDLEHOLDER

5-15

FUEL SYSTEM
Be careful no! 10

damage tlle/et
needle

Install the diaphragmlvacuum piston into the carbu retor body by aligning the tab of the diaphragm
with the air passage, then insert the jet needle into
the needle jet.
lift the bottom of the piston with your finger to set
the diaphragm rib into the groove in the carburetor
body.

Install the compression spring and vacuum chamber cover while lifting the piston in place. Align the
dl8phragm under tab of the cover with the air passage and secure the
rhechambercover, cover with at least two screws before releasing the
and /0 keep the vacuum piston.

DIAPHRAGMI
PISTON

Be careful not to

pinch the

VACUUM CHAMBER COVER

spong straight
WfIen compressing
the spring

Install the wire and hose clamps as shown, and
tighten the four screw securely.

WIRE CLA.MP

SMALL HOSE CLAMP

Turn the throttle stop screw to align the butterfly
throttle valve with the edge of the outside by-pass
hole in the carburetor body, if the throttle stop
screw was removed.

Align

THROTTl£ STOP SCREW

5-16

FUEL SYSTEM
AIR CUT· OFF VALVE (U type only)
Install a new O-rings onto the slow air jet and air

r-::::-:-:-c--c=-:-:--:--c----:c:---:--- ----,

cut-off valva.
Install the air 161

WIth Its small end
facmg the air cut-off
~I~

Install the slow air jet and air cut-off valve onto the
carburetor body

Install and tighten the screw.

AIR CUT-OFF VALVE

CARBURETOR HEATER
Install the collar and carburetor heater with the
stepped side of the collar facing the carburetor and

tighten carburetor heater.

HOSES
Connect the carburetor drain hose so that the " UP"
mark on the one-way valve is facing toward the carburetor.

Connect the air vent hoses.

,
HOSE

Route the air vent hoses into the hose damps as
shown.

LARGE HOSE CLAMP

SMALL HOSE CLAMP

5-17

FUEL SYSTEM

CARBURETOR INSTALLATION
Install the carburetor into the insulator, rest the carburetor rib against the insulator lug and tighten the
band screw.
TORQUE : 4 N'm (0.4 kgf·m, 2.9 IbUt)

Connect the throttle cable to the throttle drum,
install the cable adjuster into the carburetor body
and temporarily lighten the lock nut.

Install the throttle drum cover and tighten the

screw.

TORQUE: 1.5 N'm (0.2 kgf·m, 1.1Ibf.ft)

Install the starting enrichment (SE) valve and

tighten the SE valve nut.
TORQUE: 2.3 N·m (0.2 kgf·m. 1.7Ibf.ft )
Slide the rubber boot over the SE valve nut.
Connect the throttle position sensor connector to

the sensor.
Clamp the throttle position sensor wire onto the carburetor.
Connect the fuel hose to the carburetor.
Turn the fuel valve ON and check that there is no
fuel leak.

5-18

:::::::~~~~~~~~~=:~

I~~~~~~~~

FUEL SYSTEM
Route the carburetor heater wire and carburetor
drain hose properly (page 1·24).

Connect the ca rburetor heater connector.
Install the air cleaner housing (page 5-5).
Perform the following inspections and adjustments:
-

engine idle speed (page 3- 15)
throttle operation (page 3-5)
pitot screw if it was repla ced (page 5-19)

Periorm the initial setting (page 24-6) after all carburetor adjustments have been completed.

PILOT SCREW ADJUSTMENT
IDLE DROP PROCEDURE
• The pi lot screw is factory pre-set and no adjust-

ment is necessary unless the pilot screw is

replaced .
• Use a tachometer with graduations of 50 rpm
(min" ) or smaller that will accurately indicate a
50 rpm (min" ) cha nge.
Damage fO the pllor

screw seat will
occur If the pdot
screw IS lightened

agamstlhe seat

, . Remove the recoil starter cover (page 2-4).
Tu rn the pilot sc rew clockwise until it seats
lightly, then back it out to the specification given.
This is an initial sening prior to the final pilot
screw adjustment.
TOOL:
Pilot screw wrench

07KMA·MN90101 or
07KMA·MN9A100
(U.S.A. only)

INITIAL OPENING : A,eM type:
U type:

2 tums out
1-3 /4 tums out

2. Warm up the engine to operating temperature.
Stop and go riding for 10 minutes is sufficient.
3. Stop the engine and connect a tachometer
according to the tachometer manufacturer's
instructions.
4. Start the engine and adjust the idle speed with
the thronle stop screw.
IDLE SPEED: 1,400:t 100 rpm (min-' )
5. Turn the pilot screw in or out slowly to obtain the
highest engine speed.
6. Lightly open the throttle 2-3 times, then ad just
the idle speed wi th the thronle stop screw.
7. Turn the pilot screw in gradually until the engine
speed drops by 100 rpm (min 'I.
B. Turn the pilot screw out to the final opening .
FINAL OPENING: 3 /4 tum out from the position
obtained step #7
9. Readjust the idle speed with the thronle stop
screw.

5-19

FUEL SYSTEM

HIGH ALTITUDE ADJUSTMENT
(except U type)
At high altitude, the standard carburetor air-fuel
mixture will be too rich. Performance will decrease,
and fuel consumption will increase. A very rich mixture will also foul the spark plug and cause hard
starting. Operation at an altitude that differs from
that at which this engine was certi fied, for extended
periods of time, may increase emissions.

High altitude performance can be improved by specific modifications to the carburetor. If your customer always operates the A TV at altitudes above
6,500 feet (2.000 meters). you should perform this
carburetor modification .

Even with carbu retor modification, engine horsepower will decrease about 3.5% for each 1,ODD-foot
(300-meter) i ncrease in altitude. The effect of altitude on horsepower will be grea ter than this if no
carburetor modification is made.
This engine, when operated at high altitude with the
carburetor modifications for high altitude use, will
meet each emission standard throughout its useful
life.
The high altitude carburetor adjustment is performed as follows:
Remove the carburetor (page 5-6) and the floa t
chamber.
Replace the standard main jet with the high altitude
type.
HIGH ALTITUDE MAIN JET: 11 158
Check that the O-ring on the float chamber is in
good condition and replace it with a new one if
necessary.
Install the floal chamber and the carburetor.
Screw in the pilot screw the specified number of
turns from the factory preset position using the special tool.
TOOL:
Pilot screw w ren ch 07KMA·MN90101 or
07KMA·MN9Al00 (U .S.A .onlv)
HIGH ALTITUDE PILOT SCREW OPENING:
114 tum in from initial opening
Start the engine and warm it up.
Adjust the idle speed at high altitude w ith the throttle stop screw to ensure proper high altitude operation.
IDLE SPEED: 1,400:t 100 rpm (min" ,

NOTICE
when the carburetor has been modified for high altitude operation, the air-fuel mixture will be too lean
for low altitude use. Operation at altitudes below
5,000 feet (1,500 m} with a modified carburetor may
cause the engine overheat, resulting in serious
engine damage and increased exhaust emissions.

5-20

FUEL SYSTEM
For use at low attitudes, you should return the carburetor to original factory specifications.
Replace the main jet with the standard main jet, and
screw out the pilot screw the specified number of
turns from the high altitude setting.
STANDARD MAIN JET: 11162

TOOL:
Pilot screw wrench 07KMA-MN90101 or
07KMA-MN9Al00 (U.S.A.only)
LOW ALTITUDE PILOT SCREW OPENING:
114 tum out from the high a ltitud e setting

Warm up the engine and adjust the idle speed at
low altitude with the throttle stop screw.
IDLE SPEED: 1,400 ± 100 rpm (m in" )

FUEL TANK
REMOVALIINSTALLA TION
Remove the fuel tank cover (page 2·6).
TRIM CLIPS

Remove the trim clips and rubber seat.

Loosen the band screw and remove the air intake
duct from the air cleaner housing.

r.-::=::::

5-21

FUEl SYSTEM
Turn the fuel valve OFF and disconnect the fuel
hose from the carburetor.

Remove the two bolts and gearshift lever assembly.

Unhook the two holder bands from the fuel tank,
and remove the two bolts.
Slide the tank to the backward and disconnect the
fuel level sensor 2P (Red) connector.
Remove the fuel tank.
Install the fuel tank in the reverse order of removaL
• After connecting the fuel hose, turn the fuel valve
ON and check that there is no fuel leak.

FUEL STRAINER SCREEN CLEANING
Remove the fuel tank (page 5-21).

Drain the gasoline into an approved fuel container.
Turn fuel valve OFF and remove the two mounting
bolts, collars and the fuel valve.

5-22

FUEL SYSTEM
Remove the Coring.
Clean the fuel strainer screen with non-flammable
or high flash point solvent.
Dry the strainer screen thoroughly.

g
a-RING

Install a new Q'ring onto the fuel valve.
Install the fuel valve into the fuel tank with the two
collars and bolts, and tighten the bolts securely.
Install the fuel tank (page 5-21),

STRAINER SCREEN

5-23

MEMO

6. COOLING SYSTEM

SYSTEM FLOW PATTERN ......................... 6-2

RADIATOR RESERVE TANK ······················ 6-7

SERVICE INFORMATION ... ........................ 6-3

RADIATOR/ COOLING FAN ························ 6-7

TROUBLESHOOTING ................................. 6-3

THERMOSTAT ·········································· 6-10

SYSTEM TESTING ······································ 6-4

WATER PUMP ·············· ······ ················· .... ·6-12

COOLANT REPLACEMENT ······ ·················· 6-5

6-1

COOLING SYSTEM

SYSTEM FLOW PATTERN

RESERVE TANK

WH31.--j--'= = = ="'---I
Cylinder compression at 450 rpm (min-' )
psi)
Valve clearance
--l=~IN~:-~0.15 (0.006)
EX
0.23 (0.009)
Vel·vc e" "'
.,"'e=m" O"'.o' . - - - + - cI"'Nc - - - h5 .475 - 5.490 (0.2 156 0.2"1'"6'1'I ---+'5'.4"5"(0.215~
Valve,
valve guide
EX
5 455 - 5 470 (0 2148 - 0.2154)
5.43 (0. 214 ~
i
I
5.53 (0.218)
Valve guide 1.0.
IN/EX
5.500 - 5.512 (0.2165- 0.2170)
0.12 (0.005~
Stem-fo-guide clearance
IN
0.010 0.037 (0.0004 - 0.0015)
0.14 (0.006)
EX
0.030 0.057 (0.0012 0.0022)
Valve guide projection
IN
15.8 - 16.2 (0.62 0.64 1
above cylinder head
18.8-19.2 (0.74 0.76)
EX
1.4 (0.06)
Valve seat width
IN/EX
1.0 - 1.1 (0.039 0.043)
37.8 (1.49)
38.82 (1.528)
Valve spring
Free length
Inner
49.0 (1.93)
51.17 (2.015)
Outer
12.05 (0.474)
Arm I.D.
IN/EX
12.000 12.018 (0.472 4 - 0.4731)
Rocker arm
11.92 (0.469)
Shaft 0.0.
IN/EX
11.964 11.984 (0.4710 - 0.4718)
ITEM

Camshaft and
cam follower

rArm-to-Shaft:,~I~ee:,:e~n,:e:=hiS'~N~/E:X~riO!.O!'6;~O~.O~54~IO~.O~O~O~6~O~.~OO~2:'~I~~E~=O~.~08~(0.003.,1",-1
Cam lobe height

EX
Cam follower O, . <-D.' --_ _ ---;-c
IN/EX
Follower bore CO.
IN/EX
Follower-Io-bore clearIN/EX
l ance
Cylinder head warpage

33.9602 - 34.1202 (1.33701 -1.34331)
33.790 (1.3303)
34.1959 - 34.3559 (1.34629 - 1.35259)
. 33.946 (1.3365)
22.467 - 22.482 (0.8845 - 0.88-5..1f1_ _ ~
' -.;';;;'".4 6 (0.884)
7i(0.887) 1
22.510 - 22.526 (0.8862 - 0.8868)
22.54
0.028 - 0.059 (0.0011 - 0.0023)
0.07 (0.003)
0.10 (0.004)

TORQUE VALUES
53 N'm (5.4 kgf·m, 39 Ibf·h)

Cylinder head cover cap nut
Upper engine hanger bracket
nu1
Upper engine hanger bracket
bolt
Engine coolant temperature
(ECT) sensor
Spark plug

(frame side)

54 N·m (5.5 kgf·m, 40 Ibf·h)

(engi ne side)

32 N·m (3.3 kgf·m, 24 Ibf·h)
10 N·m (1.0 kgf·m, 7 Ibf·ft)
22 N'm (2.2 kgf·m, 16Ibf·h)

Apply oil to the threads and seating surface

Apply sealant to the threads

8-3

CYLINDER HEADIVALVE/CAMSHAFT
TOOLS
Valve spring compressor

Valve guide driver, 5.5 mm

Valve guide reamer, 5.5 mm

07757-0010000

07742·0010100

07984-2000001

or 07984-2000000 (U.S.A. only)
Cutter holder, 5.5 mm

Flat cutter, 33 mm (EX 32° )

Fla! cutte r, 36 mm (IN 32Q)
07780-0013500

07780-0012900

able in U.S.A.

or equivalent commercially available in U.S.A.

Seat cutter, 35 mm (IN 45° )

Seat cutter, 33 mm (EX 45° )

Interior cutter, 34 mm (IN 60° )

07780·0010400

07780·0010800

07780·0014700

or equivalent commercially available in U.S.A.

or equivalent commercially avail·
able in U.S.A.

or equivalent commercially available in U.S.A.

Interior cutter, 30 mm (EX 60° )
07780·0014000

Cam chain tensioner stopper
07NMG-MY90101

or equivalent commercially available in U.S.A.

or 07ZMG-MCAA400 (U.S.A. only)

07781 ·0010101

or equivalent commerciallv avail-

8-4

CYLINDER HEADIVALVE/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 sou nding rod or stethoscope.
• If the performance is poor at low speeds, check for a white smoke in the crank case breather hose. If th e hose is smoky.
check for seized piston ring (page 9·5).

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
- Wa rped or cracked cylinder head
• Cylinder/p iston problem (page 9-5)
Compression too high, overheat ing 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/pist on problem (page 9-5)
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 st em end
• Worn or damaged pu sh rod and/or cam followe r
• Worn cam chain
• Worn or damaged cam chain tensioner
• Worn cam sprocket teeth
• Cylinder/piston problem (page 9-5)
Rough idle
• Low cylinder compression

8-5

CYLINDER HEADIVALVEI CAMSHAFT

CYLINDER COMPRESSION
Warm up the engine to nor mal operating temperature.
Stop the engine, disconnect the spark plug cap and
remove the spark plug !page 3-9).
Install the compression gauge into the spark plug
hole.

COM PRESSION GAUGE

Shift the transmission in neutral.

Open the th rottle all the way and crank the engine
with the starter motor until the gauge reading stops
rising. The maximum reading is usua lly reached
within 4·7 seconds.
COMPRESSION PRESSURE:

608-902 kPa (6.2- 9.2 kgf/ cm 2 , 88 - 131 ps i) at 450
rpm (min" )
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 (page 5-21).
Release the radiator upper hose, SE valve cable and
throttle cable.
Remove the fuel tank heat guard.
Remove the wire clamp from the fuel tank heat
guard.

Remove the four bolts and valve adjusti ng hole
caps.

8-6

~ii:ij;!';;::;;;;;;;;iiii~

CYLINDER HEADIVALVEI CAMSHAFT
Remove the spark plug cap.
Remove the seven bolts, three sealing washers. four
cap nuts. washers and the cylinder head cover.

Marlc: rhe push rods
so that they can be
placed baclc: in their
OTlgmallOCBfJOns

Remove the push rods. gasket and dowel pi ns.

DISASSEMBLY
Remove the two setting bolts and sealing washers.
Push the rocker arm shah w ith the small screwdriver through the bolt hole until the O-ring on the
shah is removed from the cylinder head cover.

Remove the rocker arm shafts and rocker arms from
the cylinder head cover.

ROCKER

8-7

CYLINDER HEADIVALVE/CAMSHAFT
INSPECTION
ROCKER ARM / SHAFT

Check the rocker arms and shafts for wear or dam -

age.
If the rocker arm follower is worn or damaged,
check the push rod and oil passages.

Measure each rocker arm shaft 0.0.
SERVICE LIMITS: 11.92 mm (0.469 in )

Measure each rocker arm 1.0.
SERVICE LIMITS: 12.05 mm (0.474 i n)

Subtract each rocker arm shaft 0.0. from the corresponding rocker arm I.D. to obtain the rocker armlo-shaft clearance.
SERVICE LIMITS: 0.08 mm (0.003 i n)
PUSH ROD

Check the push rods for wear or damage .
If the push rod is worn or damaged, check the cam
follower and camshaft.

CYLINDER HEAD REMOVAL
Remove the following:
-

cam followers
thermostat (page 6-10)

bypass hoses from the cylinder head
water pump (page 6-12)
upper engine hanger bolts
hanger bracket and mounting rubbers

The cam followers can be removed
wnhou! removing
!he exhaust Pipe
and carbure !Of

exhaust pipe (page 2-15)
carburetor (page 5-6)
cylinder head cover (page 8-6)

Oisconnect the engine coolant temperature sensor
connector.

8-8

CYLINDER HEADIVALVE/CAMSHAFT
Remove the spark plug .
Loosen the band screw and remove the carburetor
insulator if necessary.
Remove the engine coolant temperature (ECl) sensor if necessary.

Do not strike the
cy/meier head 100
hard.

Remove the four bolts and the cylinder head .

BOLTS

Remove the gasket and dowel pins.

CYLINDER HEAD DISASSEMBLY
To prevenr loss of
tension. do not
compress rhe valve
springs more than
necessary to
remove the cotters

Remove the valve spring cotters using the valve
spring compressor.
TOOL:
Valve spri ng compresso r

SPRING COMPRESSOR

07757-0010000

8-9

CYLINDER HEADIV ALVE/CAMSHAFT
Mark all pans so
they can be placed

back In their angmal
locatIOnS

Remove the following :
-

spring retainer
inner and outer valve springs

SPRING SEAT

- valve
- stem seal
-

valve spring seat

OUTER

SPRING~

=\~~~"".
RETAINER

INSPECTION
CYLINDER HEAD

Remove the carbon deposits from the combustion
chamber, being careful not to damage the gasket
surface.
Check the spark plug hole and valve areas for
cracks.

Check the cylinder head for warpage with a straight
edge and feeler gauge.
SERVICE LIMIT: 0.10 mm (0.004 inl

CAM FOLLOWER
Check the ca m follower and follower bore in the cylinder head for scoring, scratches or damage.
Measure each follower 0 .0 .
SERVICE LIMIT: 22.46 mm (0.884 in)

8-10

INNER SPRING

CYLINDER HEADIVALVE/CAMSHAFT
Measure each follower bore I.D.

SERVICE LIMIT: 22.54 mm (0.887 in)
Subtract each follower 0 .0 . from the corresponding
bore I.D. t o obtain the rocker arm-ta-shaft clearance.

SERVICE LIMIT: 0.07 mm (0.003 in)

VALVE SPRING
Measure the valve spring free length.

SERVICE LIMITS: Inner: 37.8 mm (1.49 in)
Outer: 49.0 mm (1 .93 in)

II
VALVEIVAlVE GUIDE
Check that the valve moves smoothly in the guide.
Check the valve for bending, burning or abnormal
wear.
Measure each valve stem 0.0. and record it.

SERVICE LIMITS: IN: 5.45 mm (0.215 in)
EX : 5.43 mm (0.214 in)

Always rotate the
reamerc/ocKWlse.

Ream the valve guide to remove any carbon buildup before measuring the guide.
TOOL:
Valve guide reamer, 5.5 mm

REAMER

07984·2000001 or
07984·2000000
(U.S.A. only)

Measure each valve guide 1.0. and record it.

SERVICE LIMITS: IN/EX: 5.53 mm (0.218 in)

8-11

CYLINDER HEADIVALVE/CAMSHAFT
Subtract each valve stem 0.0. from the correspond·
ing guide 1.0. to obtain the stem-ta-guide clearance.
SERVICE LIMITS: IN: 0.12 mm (0.005 in )
EX: 0.14 mm (0.006 in)
Inspect and reface

If the stem-ta-guide clearance exceeds the sarvice

the valve seats limit, determine if a new guide with standard
wflenEMIf the valve dimensions would bring the clearance within tolerguides BfB replaced
(page 8-14)

anea.
If so, replace any guides as necessary and ream to

fit.
If the stem-ta-guide clearance exceeds the service

limit with a new guide. also replace the valve.

VALVE GUIDE REPLACEMENT
Chill new valve guides in the freezer section of a
refrigerator for about an hour.
8e sure to wear

heavy gloves to
aVOId burns when
handlmg the heated
cyllflder head.

USing a torch

heat the cylmder
head may cause

wo"",ge

DRIVER

Heat the cylinder head 10 130-140°C (275-290 G F)
with a hot plate or oven. Do not heat the cyl inder
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.
TOOL:

Valve g uid e d river, 5.5 mm

07742-0010100

While the cylinder head is still heated. drive new
valve guides in the cylinder head from the rocker
arm side using the same tool until the exposed
height is specified val ue.
VALVE GUIDE PROJECTION:
IN: 15.8 - 16.2 mm (0.62 - 0.64 in )
EX: 18.8 - 19.2 mm (0.74 - 0.76 in )
let the cylinder head cool to room temperatu re.

Take care not co tilt Ream the new valve guides.
or lean the reamer
In

tile guide while
r8amlflf}

Insert the reamer from the combustion chamber
side of the head and always rotate the reamer clockwise.
TOOL:

Va lve gu id e reame r, 5.5 mm

07984-2000001 or
07984-2000000
(U.S.A. only)

Use cutting oil on the reamer during this operation.
Clean the cylinder head thoroughly to remove any
metal particles after reaming and reface the valve
seat (page 8-14).

(

8-12

CYLINDER HEADIVALVE/CAMSHAFT

VALVE SEAT INSPECTION/REFACING
INSPECTION
Clean all intake and exhaust valves thoroughly to
remove ca rbon deposits.
Apply a light coating 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

Remove the valve and inspect the valve seat face.

ground. If the valve

The valve seat contact should be within the speci-

face is burned or

badly worn or If it

contacts the seat
unevenly, rep/ace

the valve

f ied 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,

retace the valve seat.

•t
SEAT WIDTH

Inspect the valve seat face for:
• Uneven seat w idth :
- Replace the valve and reface the valve seat.
• Damaged face:
- Replace the valve and reface the valve seat.

DAMAGED FACE

UNEVEN SEAT
W IDTH

• Contact area (too high or too low)
- Reface the valve seat.

TOO LOW

TOO HIGH

8-13

CYLINDER HEADIV ALVE/CAMSHAFT
REFACING
NOTE :
• Follow the refaeer manufacturer's operating , - - - - -- - - - - - - - -- - - ,
instructions .
• Be careful not to grind the seat more than necessary.

CZV\ 45"

[d~
If the contact area is too high on the valve, the seat
must be lowered using a 32° flat cutter.

If the contact area is too Iowan the valve, the seal

m," b, "',,d "'09 , 60" '01"'0' co"",

32"

\60"

~=================~
CONTACT TOO HIG H

32"

CONTACT TOO LOW

'T ..~
60"

Using a 45° seat cutter, remove any roughness or
irregularities from the seat.

~=================~
ROUGHNESS

TOOLS:

Valve seat cutter, 35 mm (IN) 07780·0010400
Valve seat cutter, 33 mm (EX ) 07780-0010800

Cutter holder, 5.5 mm

01781·0010101

or equivale nt commercially available in U.S.A.

Using a 32° flat cutter, remove 1/4 of the existing

valve seat material.
TOOLS:

Flat cutter, 36 mm (IN)
Flat cutter, 33 mm (EX)
Cutter holder, 5.5 mm

OLD SEAT WIDTH

07780·0013500
07780·0012900
07781·0010101

o r equivalent commercially available in U.S.A.

8-14

~==~~~~~~~~~~=====~

CYLINDER HEADIVALVE/CAMSHAFT
Using a 60 0 interior cutter, remove 114 of the existing valve seat material.
TOOLS :
Interior cutter. 34 mm (IN )
Interi or cutter, 30 mm (EX)
Cutter holder, 5.5 mm

~EATWIDTH

07780-0014700
07780-0014000
07781-0010101

or equivalent commercially available in U .S.A.

---6a

II ,

COnER PIN

~ (l

Install the washer and secure the slide shaft with a
new cotter pin.
Tighten all the tie-rod lock nuts.

TORQUE : 10 N'm (1.0 kgf·m , 7 Ibf.ft)
Install the following:
-

front fender (page 2-11)
left front mud guard (page 2-8)

TIE-ROD B

WASHER

12-19

MEMO

13. CRANKSHAFT/AUTOMATIC TRANSMISSION

SYSTEM COMPONENTS ························· 13-2

AUTOMATIC TRANSMISSION UNIT
AND CRANKSHAFT ............................... 13-10

SERVICE INFORMATION ························· 13-3
TROUBLESHOOTING ··········· ········ ····· ·······13-6

CRANKCASE BEARING
REPLACEMENT ······································ 13-13

CRANKCASE SEPARATION ····················· 13-8

CRANKCASE ASSEMBLY ···· ············ .. ·· .. 13-16

13-1

CRANKSHAFT I AUTOMATIC TRANSMISSION

SYSTEM COMPONENTS

, 12 Ibf·ft)

12 N'm (1.2 kgf·m , 9lbf.ftl

13-2

CRANKSHAFTI AUTOMATIC TRANSMISSION

SERVICE INFORMATION
GENERAL
• The crankcase halves must be separated to service the crankshaft and automatic transmission (mainshaft). To service
these parts, the engine must be removed from the frame (page 7-4).
• For elect rical system of the Hondamatic (page 24-2),
• The engine oil is used for automatic transmission oil. For lubrication system service(page 4-2).
• Be careful not to damage the crankcase mating surfaces when servicing.
• Cylinder head section lubricating oil is fed through the oil passage in the crankcase. Clean the oil passages before
assembling the crankcase halves
• Do not disassemble the automatic transmission unit. Replace the automatic transmission unit as an assembly when it is
faulty.

SPECIFICATIONS
Crankshaft

ITEM
Runout
Big end side clearance
Big end radial clearance

STANDARD

0.05 0.65 (0.D02 0.026)
0.006 0.018 (0.0002 0.0007)

Unit· mm (in )
SERVICE LIMIT

0.15 (0.006)
0.8 10.03)
0.05 (0.002)

TOROUE VALUES
Primary driven gear bolt

17 N'm (1.7 kgf·m, 12 Ibf·ft)

Oil pump driven sprocket bolt

12 N'm (l2 kgfm, 9 Ibf·ft)

Apply engine oil to the threads and seating
surface
Apply locking agent to the threads

13-3

CRANKSHAFTI AUTOMATIC TRANSMISSION
TOOLS
Bearing remover, 17 mm

Remover handle

Remover weight

07936-37 10300

07936-3710100

0774'-0010201

o r 07936·3710200
or 07936·371020A (U.S.A. only)

Bearing remover, 20 mm

Driver

07936-3710600

07749·0010000

Attachment, 42 x 47 mm
07746·0010300

07746-0010400

Attachment, 52 )( 55 mm

Attachment, 37 x 40 mm
07746-0010200

Attachment, 78 x 90 mm
07GAD·SD40101

Pilot, 17 mm

Pilot, 20 mm

Pilot, 25 mm

07746-0040400

07746-0040500

07746·0040600

13-4

CRANKSHAFTI AUTOMATIC TRANSMISSION
07746·0040700

Pilot, 32 mm
07MAD-PR90200

Pilot, 40 mm
07746-0040900

Assembly collar
07965-VM00100

Thread shaft
07965-VM00200

Thread adapter
07965-VM00300

Pilot, 30 mm

@~;
--

",-',

or Puller shaft (07931-ME40108J and
Special nut !07931-HB3020A)
(U.S.A. only)
Gear holder, 2.5

07724-0010100

or 07724-001Al00 (U.S.A. only)

or 07931-KF00200 (U.S.A. only)

Universal bearing puller
07631-0010000

or equivalent commercially avai lable in U.S.A.

13-5

CRANKSHAFTI AUTOMATIC TRANSMISSION

TROUBLESHOOTING
• Before starting this diagnostic troubleshooting, make sure that the gear position indicator is not
blinking "-" (Electrical system of the Hondamatic is normal) and all the engine maintenance items
have been performed and are within specifications.
Faulty drive performance of the vehicle

, . Oil level inspection
Check the oil level (page 3-12),
Is the oil level correct?

- Fill the crankcase with recommended oil (page 3-12)

YES

- GO TO STEP 2.

2. Oil pressure test
If poor performance occurs only at vehicle maximum speed with ESP selected, angle sensor malfunction is the likely cause. Periorm sensor inspection (page 24-41 J.
Check the engine oil pressure (page 4-6),

Is the oil pressure correct?
NO

- Faulty lubrication system (page 4-5)

YES

- GO TO STEP 3.

3. Centrifugal clutch inspection 1
Test-drive the vehicle to check the engine speed and vehicle speed condition.

Does vehicle engine speed rise, but vehicle speed does not rise ?
YES

- GO TO STEP 4.

- GO TO STEP 5.

4. Centrifugal clutch inspection 2
Check the cen trifugal clutch (page 10-9).

Is the centrifugal clutch normal condition?
NO

- Correct the faulty part

YES

- Faulty automatic transmission

5. Automatic transmission bearing inspection
Remove the front c rankcase cover (page 10-5), and check the automatic transmission bearing condition.

Is the bearing normal condition?
NO

- Faulty transmission bearing

YES

- GO TO STEP 6.

6. Sub-transmission inspection
Check the sub-transmission (page 12-12).

Is the sub-transmission normal condition?

13-6

- Faulty sub-transmission

YES

- Faulty automatic transm ission

CRANKSHAFT/AUTOMATIC TRANSMISSION
Vehicle does not move

1. Oil level inspection
Check the oil level (page 3-12),
Is the

oj(

- Fi1l the crankcase with r ecommended oil (page 3·12)

level correct?

YES

- GO TO STEP 2.

2. Oil pressure test
Check the engine oil pressure (page 4-6).

Is the oil pressure correct?
NO

- Faulty lubrication system (page 4-5)

YES

- GO TO STEP 3.

3. Sub-transmission inspection 1

Sla rt the engine.
Check the engine operation by ope rating the thronle with the sub-transmission in each D and R
range.

008S the flngine speed rise in Bny ranges?
NO

- GO TO STEP 5.

YES

- GO TO STEP 4.

4. Centrifugal clutch inspection

Check the centrifugal clutch (page 10·9).

Is the centrifugal clutch normal condition ?
NO

- Correct the faulty part

YES

- GO TO STEP 7.

5. Sub-transmission inspection 2
Check the operating condition in each sub-transmission range.
Does the engine speed rise and stop both ranges?
YES

- GO TO STEP 6.

- Faulty sub-transmission

6. Automatic transmission bearing inspection
Remove the front crankcase cover (page 10-5), and check the automatic transmission bearing condition.
Is the bearing normal condition?
NO

- Fau lty transmission bearing

YES

- GO TO STEP 7.

7. Sub-transmission inspection
Check the sub-transmission (page 12-12 ).
Is the sub-transmission normal condition?
NO

- Faulty sub-transmission

YES

- Faulty automatic transmission

Excessive engine noise
• Oil level too low
• 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

13-7

CRANKSHAFTI AUTOMATIC TRANSMISSION

CRANKCASE SEPARATION
Remove the following:
-

engine (page 7-4)
cylinder head and camshaft (page 8-8)
cylinder and piston (page 9-5)
centrifugal clu t ch (page 10-9)
flywheel and st arter clutch (page 1'-12)
sub-transmission and shift linkage (page 12-12)
angle sensor (page 24-4 1)
angle sensor joint

two bolts and oil separate plate

sprocket bolt

oil pump driven sprocket and drive chain
cam chain

pivot bolt and cam chain tensioner
washer and collar

Temporarily install the clutch drum onto the crankshaft and the gear holder as shown. Loosen the four
driven gear socket bolts and remove them.

TOOL:
Gear holde r, 2.5

07724· 0010100 or
07724-001A l00
(U.S.A. only)

Remove the clu tch drum and the primary driven
gear from the automatic transmission unit.
Remove the dowel pin.

13-8

CRANKSHAFTI AUTOMATIC TRANSMISSION
loosen the fille rear crankcase bolts in a crisscross
panern in several steps and remove them .

REAR CRANKCASE

loosen the twelve front crankcase bolts in a crisscross pattern in several steps and remove them.
Place the crankcase assembly with the rear crank-

case down.

Be careful not to The dowel pin hole in the automatic transmission
Interfere the front
crankcase With the

unit face to the left.
Remove the front crankcase from the rear crankcase

automatIC
transmlSSIOfI Unit

while tapping them at several locations with a soft

DOWEL PINS

hammer.

Do nO! pry the
Remove the following:
crankcase apart
With a scre'ollldriver. - front crankshaft bearing inner race

two dowel pins
two D-rings.

13-9

CRANKSHAFTI AUTOMATIC TRANSMISSION

AUTOMATIC TRANSMISSION UNIT
AND CRANKSHAFT
AUTOMATIC TRANSMISSION UNIT
REMOVAL
• Do not disassemble the automatic transmission

unit.
Separate the crankcase (page 13-8).
Remove the five mounti ng bolts and the automatic
transmission unit.
Remove the dowel pin.

CRANKSHAFT AND BALANCER
REMOVAL
Remove the crankshaft and balancer from the rear
crankcase using a hydraulic press. Be sure to hold
crankcase fI1811fl{J the crankshaft and balancer while pressing them
surface and Qut of the crankcase.
Becarefu/notto
damage rhe

crankshaft
assembly

If the rear crankshaft beari ng is lett on the crankshaft, remove it using the bea ring p u ller with a suitable protector.

TOOL:
Universal beari ng puller

07631·0010000 or
eq u iva le nt
comme rcially
ava ilab le in U.S.A.

• Always replace the rBar crankshaft bearing wilh a
new one when the crankshaft is removed .

PULLER

13-10

CRANKSHAFTI AUTOMATIC TRANSMISSION
INSPECTION
CRANKSHAFT

Set the crankshaft as shown and measure the
runout using a dial indicator.
SERVICE LIMIT: 0.15 mm (0.006 in )

HOLD

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)

BALANCER
Check the balancer gear for wear or damage.

13-11

CRANKSHAFTI AUTOMATIC TRANSMISSION
CRANKSHAFT AND BALANCER
INSTALLATION
ApplV engine oil to a new rear crankshaft bearing.
Drive the crankshaft bearing into the rear crankcase
with the marking side fa cing up.
TOOLS:

Driver

Attachment, 78 x 90 mm
Pilot, 32 mm

07749-0010000
07GAD-SD40101
07MAD-PR90200

For front crankshaft bearing replacement, see page

13-13.

Engage the balancer and crankshaft by al igning the
index lines on the side surfaces of the balancer
drive and driven gears and install the crankshaft and
balancer together int o the fear crankcase.

Assemble the special tools onto the crankshaft.

Be careful not to let Draw the cranksha ft into the bearing inner race.
the connectmg rod
press fIglImsl the

TOOLS:

cran/(case mating Assembly collar
surlace while
drawing

Threaded shaft

Threaded adaptor

07965-VM00100
07965-VM00200
not available in U.S.A . or
07931-ME4010B and
07931-HB3020A
(U.S.A . only)
07965-VM00300
not available in U .S.A . or
07931-KF00200
(U.S.A. only)

After i nstalling the crankshaft in, make sure that the
index lines on the crank weight and balancer driven
gear are aligned.

13-12

CRANKSHAFT/AUTOMATIC TRANSMISSION
AUTOMATIC TRANSMISSION UNIT
INSTALLATION
Before installing the automatic transmission unit, , - - - - - - - - - -- - - - - - - ,
check the following components for smooth oper a- PUMP SWASH
PUMP/MOTOA SHAFT
tion.
PLATE ASSEMBLY
-

rotation of the pump swash plate assembly
rotation of the pump/motor shaft
movement of the motor swash plate assembly
and ball nut

BALL NUT

MOTOR SWASH
PLATE ASSEMBLY

Install the dowel pin into the rear crankcase.

Install the automatic transmission unit and tighten
the five mounting bolts.

Assemble the crankcase halves (page 13-16).

CRANKCASE BEARING REPLACEMENT
REAR CRANKCASE
Drive the mainshaft bearing out of the rear crank-

case

Drive the balancer bearing out of the rear crankcase.

13-13

CRANKSHAFTI AUTOMATIC TRANSMISSION
Remove the sh ih drum and countershaft bearings
with the special tools.

TOOLS;
Shift d rum bearing:
Bearing rem over, 17 mm
Remover hand le
Remover weight

07936·3710300
07936·3710100
07741·0010201 o r
07936·371020 or
07936·371020A
(U.S.A . only)

Cou ntershaft bearing :
Bearing rem over, 20 mm
Remover ha nd le

Remover weig ht

07936·3710600
07936-3710100
07741·0010201 or
07936 -3710200 or
07936·37102OA
(U .S.A. only)

Apply engi ne oil to new bea rings.
Drive the followi ng bea ring s in with the m arking
side facing up using the special tools.
TOOLS:
M ainshaft bea rin g:

Driver
Attachment, 52 x 55 mm

Pilot, 30 mm
Countershaft bearing :
Driver

Attach ment , 42
Pilot, 20 m m

47 m m

07749-0010000
07746-0010400
07746-0040700

07749-0010000
07746-0010300
07746-0040500

Shift d rum bea ring:
Driver
Attach ment , 37
Pilot . 17 mm

40 mm

Balancer bea rin g:
Driver
Attachment , 37 x 40 mm
Pilot, 17 m m

07749-0010000
07746-0010200
07746-0040400

FRONT CRANKCASE
Remove the oil pu m p (page 4-12).
Drive output shaft and crankshaft bearings ou t of
the front crankcase.

13-14

COUNTERSHAFT
BEARING

CRANKSHAFT/AUTOMATIC TRANSMISSION
Remove the output shaft oil seal.

OUTPUT SHAFT

Remove the balancer bearing with the special too ls.
TOOLS:
Balancer bearing:
Bearing rem over, 17 mm
Remover handle

Remove r weig ht

07936·3710300
07936·3710100
07741 ·0010201 or
07936·371020A or
07936·3710200

Apply engine oil to new bearings.
~. .w:.~~~!i~
Drive the following bearings in with the marking
side facing up using the special tools.
TOOLS :
Crankshaft bearing :
Driver

Attachment, 78
Pilot, 40 mm

90 mm

07749·0010000
07GAD·S040101
07746·0040900

Balancer bearing:
Driver
Attachment, 37 )( 40 mm
Pilot, 17 mm

07749·0010000
07746·0010200
07746·0040400

Output shaft bearing:
Driver
Attachment, 42)1 47 mrn
Pilot. 25 rnm

07749-0010000
07746-0010300
07746-0040600

Apply engine oil to a new output shaft oil seal lips
and install it until it is flush with the crankcase.

OUTPUTSHAFT

Install the oil pump (page 4-12).

13-15

CRANKSHAFTI AUTOMATIC TRANSMISSION

CRANKCASE ASSEMBLY
Clean the front and rear crankcase mating surfaces
thoroughly. being careful not to damage them.
Blow through the oil passage in the rear crankcase
with compressed air.

..r~

Install the bearing inner race onto the crankshaft
with the flange side facing in.
Apply engine oil to new O' rings and install them
into the grooves in the rBar crankcase.
Apply liquid sealant to the mating surface of the
crankcase.
Install the two dowel pins.

Be careful nor to
In/erfere the front
crankcase with the

automstlc

Install the front crankcase over the fear crankcase.
Install the twelve front crankcase bolts and tighten
them in a crisscross panern in 2 or 3 steps.

transmlSSIOi1 unit

Install the five rear crankcase bolts and tighten them
in a crisscross pattern in 2 or 3 steps.

Install the dowel pi n and primary driven gear.
Apply engine oil to the driven gear bolt threads and
seating surface, and install them.
Temporarily install the clutch drum and the gear
holder.
TOOL:
Gear holder, 2.5

07724-0010100 or
07724-001A100
(U.S.A. only)

Tighten the four driven gear bolts in a crisscross
pattern in 2 or 3 steps.
TORQUE: 17 N·m " .7 kgf·m. 12 Ibf.ftl

13-16

BOLT

CRANKSHAFTI AUTOMATIC TRANSMISSION
Apply locking agent to the cam chain tensionsr
pivot bolt threads.
Install the following:
-

pivot collar (into the tensioner pivot)
cam chain tensioner with bolt and washer
(between the tensioner and crankcase)

cam chain
oil pump drive chain and driven sprocket (with
the rolled edge of the sprocket facing to the
crankcase, and by aligning the flats of the
sprocket and pump shaft)

driven sprocket bolt (apply locking agent to th e
threads)

TORQUE: 12 N 'm (1.2 kgf·m . 9Ibf.ft)

oil separate plale with two bolts

new oil seal (do not apply oil)

angle sensor joint

Install the removed parts:
-

angle sensor (page 24-41)

centrifugal clutch (page 10·12)
sub-transmission and shift linkage (page 12-12)
flywheel and starter clutch (page 11-12)
cylinder and piston (page 9-9)
cylinder head and camshah (page 8-17)
oil tank (page 4-8)
engine (page 7-8)

13-17

MEMO

14. FRONT WHEEL/SUSPENSION/STEERING

SYSTEM COMPONENTS ····· ···················· 14-2

FRONT WHEEL HUB ···· ·· ························ 14-18

SERVICE INFORMATION ························· 14-4

SUSPENSION ARM ································ 14-20

TROUBLESHOOTING ··················· ············14-6

STEERING SHAFT
(Except EPS model) ............................... 14-28

HANDLEBAR ·············································14-7
THROTILE HOUSING ······················· .... ·14-13
FRONT WHEEL ···································· .. · 14-14
TIRES ····· ····················· ····· ····· ·· ··· ··············14-15

STEERING SHAFT/EPS UNIT
(EPS model) ............................................ 14-34
TIE-ROD .................................................. 14-42
FRONT SHOCK ABSORBER .................. 14-44

14-1

FRONT WHEEL/SUSPENSION/STEERING

SYSTEM COMPONENTS
Except EPS model:
44 N·m (4.5 kgf·m. 33 IbUt)

39 N·m (4.0 kgf·m,
29 'bf·tt)

25 N'm (2.6 kgf·m,
19Ibf.ft)
44 N'm (4.5 kgf·m,
33Ibf·tt)

12N·m(1,2kgf.m,
9Ibf.ft)

32 N'm (3.3 kgf·m, 24 Ibf·h)

54 N'm (5.5 kgf·m, 40 Ibf·h)

108 N·m (11 .0 kgf·m. 80 Ibf.ft)

29 N-m (3.0 kgf·m, 21 Ibf.ft)

78 N'm (8.0 kgf·m, 58 Ibf.ft)

14-2

64 N·m (6.5 kgf·m, 47 Ibf.ft)

FRONT WHEEL/SUSPENSION/STEERING
EPS model:

44 N·m (4.5 kgf·m, 33 Ibf·h)

32 N' m (3.3

,24Ibf.ft)

39 N·m (4.0 kgf·m,
29Ibf·h)

54 N'm (5.5 kgf·m, 40 Ibf·h)

108 N'm (11.

kgf.=m~,8~O~'~b~f,ft~I,--~~~~"

29 N'm (3.0

78 N·m (8.0 kgf·m, 58 Ibf·h)

,21 Ibf·h)

64 N·m (6.5 kgf·m, 47 Ibf·h)

14-3

FRONT WHEEL/SUSPENSION/STEERING

SERVICE INFORMATION
GENERAL
•
•
•
•
•
•
•
•

A jack or other support is required t o support the vehicle.
Adjust toe whenever the tie-rod, knuckle or steering shaft are replaced or removed {page 3-26).
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.
Refer to 16-3 for brake system inf ormation.
Refer to 22-10 for handlebar switch inspection.
For electric power steering (EPS) service (page 25-8).
EPS model only: Perform the Torque Sensor Initialization when you service the following components (page 25- 13).

REPLACEMENT

MAINTENANCE lOCATION

Cables and I

;

INITIALIZE
INITIALIZE

;

'PS unit

II
~
INITIA
INITIA LIZE
I I

INITIALIZE

:~:~i

" ;rIA
NONE

SPECIFICATIONS

pressure

I .

TORQUE VALUES
Handlebar lower holder nut
Front wheel nut
Front wheel hub nut
Front brake disc plate bolt
Shock absor ber mounting nut
Upper arm pivot nut
Lower arm pivot nut
Upper and lower arm ball joint nut
Brake hose clamp bolt
Tie-rod ball joint nut
Assist headlight case mounting nut
Steering shaft end nut
Steering shaft holder bolt
Front master cylinder holder bolt
EPS unit output shaft nut (EPS model)
EPS unit mounting bolt (EPS model)
EPS unit mounting nut (EPS model)
EPS unit steering shaft flange bolt (E PS
model)
EPS motor flange bolt (EPS model )

14-4

39 N'm (4.0 kgf·m, 29 Ibf·tt)
64 N'm (6.5 kgf·m, 47 Ibf·tt)
78 N'm (8.0 kgf·m, 58 Ibf·ft)
42 N'm (4.3 kgf-m, 31 Ibf.ft)
44 N'm (4.5 kgf·m, 33 Ibf·tt)
34 N'm (3.5 kgf·m, 25 Ibf.ft)
44 N'm (4.5 kgf·m, 33 Ibf.ft)
29 N'm (3.0 kgf·m, 21 fbf.ft)
12 N·m (1.2 kgf·m, 9 fbf·ft)
54 N'm (5.5 kgf·m, 40 fbf·tt)
25 N'm (2.6 kgf·m, 19 fbf.ft)
108 N·m (11.0 kgf-m, 80 fbf·ft)
32 N·m (3.3 kgf·m, 24 fbf·ftl
12 N'm (1.2 kgf·m, 9 Ibf·tt)
108 N'm (11.0 kgf·m, 80 fbf.tt)
22 N'm (2.2 kgf·m, 16 fbf·tt)
22 N·m (2.2 kgf·m, 16 fbf-tt)
60 N'm (6.1 kgf·m,44 fbf·ft)
20 N·m (2.0 kg f·m, 15 fbf·tt)

Lock nut: replace with a new one
Castle nut
ALOC bolt: replace with
Lock nut: replace with a
Lock nut: replace with a
Lock nut: replace with a
Castle nut

a new one
new one
new one
new one

Lock nut: replace with a new one

Lock nut: replace with a new one.

ALOC bolt: replace with a new one.

FRONT WHEEL/SUSPENSION/STEERING
TOOLS
Ball jOint remover, 28 rnm

Ball joint remover/i nstaller

07MAC-SLOO201

07WMF-HNOOtOO

Oil seal driver
07JAD·PH801 01

~.(
07MAC-SlOA202(U.S.A.only) or

07MAC·Sl00200 and
07MAC·SlOA300 (U.SAonly)
Driver

07749-00 10000

Attachment, 28 x 30 mm
07946-1870100

Attachment, 42 x 47 mm
07746-0010300

C=j
07746-0010400

Attachment, 22 x 24 mm
07746-0010800

07746·0020200

Pilot, 30 mm
07746-0040700

Pilot, 22 mrn
07746-0041000

07746-0041300

Attachment, 52 x 55 mm

Attachment, 15 mm I.D.

Pilot, 16 mm

14-5

FRONT WHEEL/SUSPENSION/STEERING

ATV Bead Buster
KlS379024

TROUBLESHOOTING
Hard steering
• Steering shaft holder too tight
• Damaged steering shaft bearing/bushing
• Insufficient tire pressu re
• EPS does not assist the steering force (EPS model only)
Steers one side or does not track straig ht
• 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

14-6

FRONT WHEEL/SUSPENSION / STEERING

HANDLEBAR
REMOVAL
Remove the following;
-

- two screws

Keep the brake

WIRE BANDS

four wire bands
breather hose

throttle housing holder
throttle housing

brake light switch connectors
two bolts

master cylinder holder

front brake master cylinder

MASTER CYliNDER
BOLTS

THROTTLE HOUSING

master cylmder
upflght to prevent
air from entering
rhe h ydraulic

s ys tem
HOLDER
-

two screws
bracket holder
feaf (parking ) brake lever bracket

BRAKE LEVER BRACKET

- three screws
-

handlebar switch

14-7

FRONT WHEEL/SUSPENSION/STEERING

'05 - '07'

nut
choke knob

bolts
grip ends
handlebar grips

HANDLEBAR GRIP

BOLT

GRIP
After '07.

grip ends (turn the grip end to release the setting , - - - - - - - =
G-=
R"'P, - - - - - - - - ,

tabs from the holes in the handlebar and pry it
using a screwdriver)
handlebar grips

HOLES
-

14-8

screw
handlebar upper cover

TABS

GRIP END

HANDLEBAR UPPER COVER

FRONT WHEEL/SUSPENSION/STEERING
-

two nuts
handlebar front cover

two bolts
handlebar rear cover

four bolts
handlebar upper holders
handlebar

INSTALLATION
Place the handlebar onto the lower holders and
align the punch mark on the handlebar with the top
of the lower holder.
Install the upper holders with the bolt holes facing
forward.
Install the four bolts and tighten the front bolts first,
then tighten the rear bolts.

14-9

FRONT WHEEL/SUSPENSION/STEERING
Install the handleba r rear cover and tighten the two

bolts.

Install the handlebar front cover and tighten the two

nuts.

Install the handlebar upper cover and tighten the

screw.

14-10

~g~~~~~~~~

HANDLEBAR UPPEA COVER

FRONT WHEEl/SUSPENSION/STEERING
Apply Honda Bond A or Honda Hand Grip Cement
(U.S.A. only) to the inside surfaces of the handlebar
grips and to the clean surfaces of the handlebar.

'05 - '07 shown:

HANDLEBAR GRIP

Allowlheadhesive Wait 3- 5 minutes and install the grip. Rotate the
/0 dry for an hour grip for even application of the adhesive.
before using.
'05 - '07'

Install the grip ends and tighten the bolts.

After '07:

Install new grip ends by aligni ng their tabs with the

holes in the handlebar.

GRIP
After '07 shown :

GRIP

til

GRIP END

Install the choke knob and tighten the nut.

Install the handlebar switch and loosely tighten the

three screws.

14-11

FRONT WHEEL/SUSPENSION/STEERING
Install the brake lever bracket and holder with the
punch mark facing up by aligning the locating pin
on the lever bracket with the hole in the handlebar
switch housing.

loosely tighten the bracket holder screws.
Align the edge of the brake lever bracket with the
punch mark on the handlebar, and tighten the upper
bracket screw first, then lighten the lower screw.
Tighten the upper handlebar switch screw first, then

tighten the lower screws.

Install the front brake master cylinder and holder
with the ~ UP" mark facing up.
Align the edge of the master cylinder with the
punch mark on the handlebar, and tighten the upper
bolt first, then tighten the lower bolt.

TORQUE: 12 N-m 11,2 kgf·m, 9I bf.tt)
Connect the brake light switch connectors.

Install the throttle housing and holder against the
master cylinder.
Align the lug on the throttle housing with the mating surface of the master cylinder and holder, and
tighten the front screw first, then tighten the rear
screw.

Install the breather hose.
Install the four wire bands as shown.
EPS oo/y· Perform the Torque Sensor Initialization
(page 25-13).

14-12

MASTER CYLINDER

PUNCH MARK

FRONT WHEEL/SUSPENSION/STEERING

THROTTLE HOUSING
DISASSEMBLY
Remove the following:

- three screws
-

throttle housing cover
gasket

Slide the boot off the throttle cable adjuster.

loosen the lock nut and cable adjuster.
Bend down the lock washer tab and remove the
pivot nut, lock washer, throttle arm, return spring,
throttle lever and washer.
Disconnect the throttle cable from the throttle arm.
Remove the dust seal from the housing bottom.

ASSEMBLY
Coal 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.
Apply grease to the throttle cable end and connect

the cable to the throttle arm.
Install the washer onto the throttle lever and insert
the lever into the throttle housing.
Install the throttle arm with the return spring over
the throttle lever pivot by aligning the flat surfaces.
Install a new lock washer and the pivot nut.
Tighten the pivot nut and bend up the lock washer
tab against the nut.

Install the throttle housing cover with a new gasket.

14-13

FRONT WHEEL/SUSPENSION/STEERING
Install and tighten the three screws.
Adjust the throttle lever freaplay (page 3-5).
If the throttle cable was replaced, perform the initial
setting (page 24-6) after adjustment the freeplay.

FRONT WHEEL
REMOVAL
Loosen the wheel nuts.
Place the support block under the frame to raise the
front wheel off the ground.
Remove the nuts and wheel.

INSTALLATION
Do nor Interchange
the left and right
tlfes

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)

14-14

FRONT WHEEL/SUSPENSION/ STEERING

TIRES
REMOVAL (U.S.A. only)
NOTE :
• This service requires the AlV Bead Buster
(KLS379024).
• Remove and install the ti re 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
lubf/cam when
removmg or
mountmg [Ires

RIM SUPPORTS

l ube 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.

• " N' z:1)

Soap or some
mounting lubf/canlS
may leave a slippery
residue which can
cause the tlfe to
Shiff

the (1m and

lose /Ire pressure

durmg "ding
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 finge r tighten it so the wheel can rotate
fr eely during operation.

Install the breaker ar m 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 -----.......... :

NUT

BREAKER ARM ASSY.

14-15

FRONT WHEEL/SUSPENSION/STEERING
Pull the leverage bar down so the breaker shoe is
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
Failure to back our

thebreakershoe

which may cause
the we to leaf;.

lock.

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 fol lowing the above procedures.
Remove the tire from the rim using a tire changing
machine or tire irons and rim protectors.

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 provided hear.
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 (518 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 repai r 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 the rubber plug.
Push the inserting needle with the plug into the
injury until the plug is slightly above the tire.
8e careful nOf to
push !h8plugalltlle
way into the tIre to
prevent It from
falling inSIde

14-16

LEVERAGE BAR

Twist the needle and remove it from the tire; the
plug will stay i n the tire.

~_ _- - - LEVERAGE BAR

FRONT WHEEL/SUSPENSION/STEERING
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 t ire (page 14-15) and apply a cold patch
to the inside of the tire as described.
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.

14-17

FRONT WHEEL/SUSPENSION/STEERING
ASSEMBLY
Install the tire onto the rim where the rim shoulder
width is the narrowest, to simplify installation.

Clean the rim bead seal and flanges.
Use only waler as B Apply clean water to the rim flanges, bead seat and
lubncant when base.

removmgot
moun/my tlfes

Soaporsome
mountmg /ubflCClms

Install the valve core in the valve stem.
Install the tire with the arrow mark facing in the normal rotating direction.
Inftate the tire to seat the tire bead.

may leave a slippery
residue which can Deflate the tire. Wait 1 hour and inflate the tire to
cause the fire 10 the specified pressure.
shiff on rfle rim and
lose air pressure
dUring fldlng

RECOMMENDED TIRE PRESSURE
Front: Standard : 25 kPa (0.25
Minimum : 22 kPa (0.22
Muimum : 28 kPa (0.28
With cargo: 25 kPa (0.25
Rear: Standard: 25 kPa (0.25
Minimum : 22 kPa (0.22
Maximum: 28 kPa (0.28
With cargo: 25 kPa (0.25

('05 - '07):
kgf/cm2, 3.6
kgf/cm 2 , 3.2
kgf/cm 2, 4.0
kgflcm 2, 3.6
kgf/cm 2 , 3.6
kgf/cm 2, 3.2
kgf/ cm 2 , 4.0
kgf/ cm 2, 3.6

psi)
psi)
psi)
psi)
psi)
psi)
psi)
psi)

RECOMMENDED TIRE PRESSURE
(After '07 except EPS):
Front: 25 kPa (0.25 kgf/ cm 2, 3.6 psi)
Rear: 25 kPa (0.25 kgf/ cm 2, 3.6 psi)
RECOMMENDED TIRE PRESSURE (EPS only):
Front: 32.5 kPa (0.33 kgflcm 2, 4.7 psi)
Rear: 25 kPa (0.25 kgf/ cm 2, 3.6 psi)
Check for air leaks and install the valve cap.

FRONT WHEEL HUB
REMOVAL
Remove the front wheel (page 14-14).
Remove the front brake cal iper (page 16-1 4).
Remove the cotter pi n, nut and front wheel hub.

14-18

FRONT WHEEL/SUSPENSION/STEERING
DISASSEMBLY
Remove the bolts and brake disc.

BOLTS

BHJ\Kc DISC
Remove the dust seal.

ASSEMBLY
Apply grease to a new dust seal lip and install it to
the hub.

Install the brake disc and tighten the new disc plate
bolts to the specified torque.

.-A

S""

BOLTS

TORQUE: 42 N-m (4.3 kg f·m , 31 tbf.ft)

BRAKE DISC

14-19

FRONT WHEEL/SUSPENSION/STEERING
INSTALLATION
Install the wheel hub and hub nut onto the knuckle.
Tighten the hub nut to the specified torque and further tighten it until ils grooves align with the cotter
pin hole.

TOROUE: 78 N·m (8.0 kgf-m. 58 Ibf.ft l

Install a new cotter pin.
Install the front brake caliper (page 16-14).
Install the front wheel (page 14-14).

SUSPENSION ARM
REMOVAL
Remove the wheel hub (page 14-18).
Remove the brake disc guard bolts and brake disc

guard.

Remove the cotter pin.
Remove the tie-rod ball joint nut while holding the
joint stud flats with an open end wrench.
Remove the tie-rod from the knuckle.

Remove the cotter pins and loosen the ball joint castle nuts, but do not remove them yet.

14-20

FRONT WHEEL/SUSPENSION/STEERING
Release the ball joints, using the special tool according to the following instructions.
TOOL:
Ball joint remover, 28 mm

07MAC-SL00201
07MAC-SLOA202
(U .S.A . only) or
07MAC-SL00200 and
07MAC-SLOA300
!U .S.A . only)

BALL JOINT

REIMOVEF

Apply grease to the ball joint remover at the point '-----------P-R-E-S-S-U-R-E-B~O-L-T
shown.
Apply grease here
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
penetrating rype
lubricant to loosen
the oolljoml

Adjust the jaw spacing by turning the pressure bolt.

To prevent the tool from dropping, tie the strap on a
neighboring solid part such as the lower arm, tierod, etc. before operation.

~======::..o~=======~;;;;.;;=

• 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 bo lt and recheck the
jaws to make su re they are still parallel.

:=P
=R
=E
=S
=S
=U=R=E=B=O=L=T=============

Tighten the pressure bolt with a wrench until the
ball joint stud pops loose.

ADJUSTING BOLT

14-21

FRONT WHEEL/SUSPENSION/STEERING
Remove the two brake hose clamp bolts.

Remove the bolts and lower arm guard if necessary.

Remove the following:
-

front shock absorber lower mounting nut and
bolt
pivot nut bolt and upper arm
pivot nuts, bolts and lower arm

INSPECTION
UPPER/ LOWER ARM
Remove the dust seal caps and pivot collar from the
upper arm.
Check the pivot bushings of the upper arm for wear

or damage.

DUST SEAL CAPS

14-22

FRONT WHEEL/SUSPENSION/STEERING
Inspect the ball joint boot for tears or other damage
by moving the ball joint stud.
It should move freely and smoothly.

BAI.L JO"IT BOOT

Check the pivot bushings of the lower arm for wear

or damage.

PIVOT BUSHING
KNUCKLE

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 ouler race
fits tightly in the knuckle.

Inspect the knuckle for damage or cracks.
Inspect the ball joint boot for tears or other damage
by moving the ball joint stud.
It shou ld move freely and smoothly.
For ball joint replacement, see page 14-23.

BALL JOINT __~:..;..

BAll JOINT REPLACEMENT
UPPER ARM
Remove the snap ring from the ball joint.

SNAP RING

14-23

FRONT WHEEL/SUSPENSION/STEERING
Set the upper arm and special tools with "A" ma rk
side of the removerlinstaller facing to the ball joint

as shown.
Press the ball joint out of the upper arm.
TOOLS:

BaH joint removerlinstaller
Attachment, 28 x 30 mm

07WMF·HNOO100

0794&1870100

Set the upper arm and special tools with ~B" mark
side of the remover/i nstaller facing to the ball joint
as shown.
Press the ball joint into the upper arm until it is fully
seated.
TOOLS :

Ball joint removerlinstaller
Attachment, 15 mm 1.0.

07WMF·HNOO100

07746·0020200

• If you feel strong resistance when lowering the

press, stop. Reset the attachment of the tool so
that the ball joint head can go into the hollow of
the attachment and try 8gain.
Install the snap ring with the chamfered edge facing
in.

SNAP RING

KNUCKLE

Remove the snap ring and the inner du st seal.

INNER DUST SEAL

RING

14-24

FRONT WHEEL/SUSPENSION/STEERING
Set the knuckle and special tools with ~ A~ mark side
of the remover/inst aller facing t o the bal l joint. in a
vise as shown.
Press the ball joint out of the knuckle.
TOOLS:
Ball joint remover/installer

07WMF·HN00100

Attachment, 28 x 30 mm

07946·1870100

Set the knuckle and spedal tools with ~BH mark side
of the removerlinstal ler facing to the bal l joint in a
vise as shown.
Press the ball joint int o the knuckle until it is fu lly 1"'.......,~~...,.......- -....._ __.......:"'_"1

seated.
TOOLS :

Ball joint remover/ installer
Attachment, 15 mm 1.0 .

07WMF·HNOO100
07746·0020200

• If you feel strong resistance when lowering the
press, stop. Reset the attachment of the tool so
that the ball joint head can go into the hollow of
the anachment and try again.

Install the snap ring with the chamfered edge f aci ng
in.

:11 _u;;;..

INNER DUST SEAL

Install a new inner dust seal (page 14-25).

SNAP RING

KNUCKLE BEARING REPLACEMENT
Remove the dust seals from the knuckle.

DUST SEALS

14-25

FRONT WHEEL/SUSPENSION/STEERING
Remove the snap ring and drive the bea ri ng out of

the knuckle.

SNAP RIN G

Pack the cavities of a new bea ring wi th grease.
Drive in the bea ring squarely with th e m ark ed side
facing up until it is fu lly seated.
TOOLS:
Driver

Attachment. 52 x 55 mm
Pilot, 30 rnm

07749·0010000
07746·0010400
07746·0040700

Install the snap ri ng into the knuckle groove with the
chamfered edge faci ng

Apply grease to a new outer dust seal lip and install
it using the same tools until it is flush with the
knuckle end.

Apply 2.5 - 3 9 of grease to a new inner dust seal lip
and install it until it is fully seated, bei ng carefu l not
to damage the lips.

TOOLS:

14-26

Driver

07749·0010000

Oil seal drive r

07JAD· PH80101

DRIVER

FRONT WHEEL/SUSPENSION/STEERING
INSTALLATION
Apply molybdenum disulfide grease to the pivot
bushing contact area of the pivot collar and install it
i nto the upper arm.
Apply molybdenum disulfide grease to the new
dust seal cap lips and i nsta l l them onto the upper
arm.

:11

~
SEAL CAPS
Install the upper arm int o the frame with the pivot
bolt and a new nut, and tighten the nut.
TORQUE: 34 N 'm (3.5 kgf·m , 25 Ibf.ft)
Connect the shock absorber to the upper arm w ith
the lower mounting bolt and a new nut, and tighten

the nut.
TORQUE: 44 N·m 14.5 kgf·m . 33 Ibf.ft)
Install the lower arm into the frame with the two
pivot bolts and the new nuts, and loosely tighten
the nuts.

Install the brake hose clamps and tighten the brake
hose clamp bolts.
TORQUE: 12 N ·m ( 1.2 kgf·m , 9 Ibf·ft )

Tighten the ball joint castle nuts to the specified
torque and further tighten until their grooves align
with the cotter pin holes.
TORQUE: 29 N 'm (3.0 kgf·m , 21 Ibf.ft)

Install the new cotter pins.

14-27

FRONT WHEEL/SUSPENSION/STEERING
Install the tie-rod ball joint onto the knuckle with a
new nut, and tighten the nut while holding the joint
stud flats with an open end wrench
TORQUE : 54 N'm (5.5 kgf·m, 40 Ibf.ft)

Install a new cotter pin.

Install the brake disc guard and tighten the brake
disc guard bolts.
Install the wheel hub (page 14-'8).
Install the front wheel (page 14-14), then place the
vehicle on level ground.
Tighten the lower arm pivot nuts to the specified
torque.

TORQUE: 44 N 'm (4.5 kgf·m, 33 Ibf.ft )

STEERING SHAFT (Except EPS model)
REMOVAL
Remove the screw and handlebar upper cover.

14-28

inner fenders (page 2-9)
front fender (page 2-11)
screw and handlebar upper cover

nuts
handlebar front cover

HANDLEBAR UPPER COVER

FRONT WHEEl/SUSPENSION / STEERING
Keep the master
cylmder reservoir
upflgh/.

handlebar lower holder nuts and washers
handlebar assembly from the steering shah

Remove the cotte r pins.
Remove the tie-rod ball joi nt nut s while holding the
joint stud flats with an open end wrench .
Remove the tie-rods from the steering shaft arm.

Remove the cotter pin, steering shah end nut,
washer and steering shaft arm.

Remove the two bolts and steering shah holder A.

14-29

FRONT WHEEL/SUSPENSION/STEERING
Remove the steering shaft.
Remove the steering shaft bushing, holder 8 and

shaft.

INSPECTION
Check the steering shaft bushing for wear or dam-

age.

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 thaI the bearing outer race
fits tightly in the frame.

14-30

FRONT WHEEL/SUSPENSION/STEERING
BEARING REPLACEMENT
Remove the upper and lower dust seals.

Remove the snap ring.
Drive the steering shaft bearing out of the frame.

Drive in a new bearing squarely with the marked
side facing up until it is tully seated.

TOOLS :
Driver

Attachment, 42
Pilot, 22 mm

47 mm

07749· 0010000
07746·0010300
07746-0041000

Install the snap ring into the groove properly with
the chamfered edge facing up.

14-31

FRONT WHEEL/SUSPENSION/STEERING
Coat new dust seal lips with grease and install them
(the upper sea! is flush with the frame edge and the
lower seal is fully seated onto the bearing).

INSTALLATION
Apply 2 - 3 9 of grease to the shaft bushing inner ~~§~~ IS'HIING
surface.
.!
Install the shaft bushing onto the steering shaft with
the Harrow H mark facing up.
Install steering shaft holder B onto the frame.
Install the steering shaft into the shaft bearing.

Install steering shaft holder A.

Install and tighten the two bolts.
TORQUE: 32 N 'm (3.3 kg f·m, 24 Ibf.ft)

Apply molybdenum disulfide grease to the steering
shaft spline.

Install the shaft arm over the steering shaft by aligning the wide tooth with the wide groove.
Install the washer and steering shaft end nut, and
tighten the nut
TORQUE: 108 N'm (11 .0 kgf·m , 80 IbUt)
Install a new cotter pin.

14-32

FRONT WHEEl/SUSPENSION/STEERING
Install the tie-rods into the st eering shah arm.
Install the new nuts and tighten them by holdi ng the
ball joint stud flats w ith an open end w rench.

TORQUE: 54 N ·m (5.5 kgf·m , 40 IbUt)
Install new cot ter pins.

Install the handlebar assembly onto the steering
shaft with the washers and new lower holder nuts,
and tighten the nuts.

TORQUE: 39 N 'm (4.0 kgf·m , 29 Ibf·ft)

Install the meter/assist headlight assembly onto the
steering shaft and tighten the two nuts.

TORQUE : 25 N ·m (2.6 kgf·m , 19 Ibf·ft)

Install the handlebar upper cover and tighten the
screw.
Install the front fender (page 2-11).
Install the inner fenders (page 2-9).

HANDLEBAR UPPER COVER

14-33

FRONT WHEEL/SUSPENSION / STEERING

STEERING SHAFT/EPS UNIT
(EPS model)
REMOVAL
Remove the following:
-

front fender (page 2-11)
assist headlight (page 22-4)

Disconnect the torque sensor 3P connector.
Disconnect the EPS motor 2P connector and remove
the harness-side female connector from the frame.
Remove the control motor 2P connector from the
frame and position it to allow room for EPS unit
removal.

Remove the following:

Keep the master
cylinder reservoir
upright to prevent

bott and brake hose clamp.
cable and wire harnesses from the guide clip

handlebar lower holder nuts and washers
handlebar assembly from the steer ing shaft

cotter pins
ball joint nuts by holding the joint stud flat surfaces
tie-rods from the steering shaft arm

air from entering
the hydraulic

svstem.

14-34

FRONT WHEEL/SUSPENSION/STEERING
loosen mounting bolts and nuts.

Remove the following:
-

brake hose from the hose dip
two bolts
steering shaft holder A

steering shaft bolt

steering shaft
steering shaft bushing
steering shaft holder B

14-35

FRONT WHEEL/SUSPENSION/STEERING
- coner pin
-

nut

washer
steering shaft arm

mounting bolts and nuts

Remove the EPS unit from the frame to teh side.

INSPECTION
Check the steering shaft bushing for wear or
damage.

14-36

FRONT WHEEl/SUSPENSION/STEERING
Check the steering shaft for distortion or damage.

Check the EPS unit input shaft and output shaft for

wear or damage.

OUTPUT SHAFT

Turn the inner race of the output shaft bearing with
your finger.
The bearing should turn smoothly and quietly. Also
check that the bearing outer race fits tightly in the
frame.

EPS MOTOR
REMOVAL
Remove the bolts and EPS motor.

14-37

FRONT WHEEL/SUSPENSION/STEERING
Remove the D-ring from the EPS mot o r.

INSTALLATION
Pack the worm gear splines with 0.5 9 of specified
grease (page '·24).
Coat a new D-ring with silicone grease and insta ll it.
Install the EPS motor onto the EPS unit.

Install the bolts and tighten them.
TORQUE: 20 N 'm (2.0 kgf·m , 15 Ibf.ft)

BEARING REPLACEMENT
Remove the upper and lower dust seals.
Remove the snap ring.

14-38

FRONT WHEEL/SUSPENSION/STEERING
Remove the bearing from the frame using the special tools and a 10 mm washer as shown.

COMPRESSOR
___
BOLT

COMPRESSOR
ATIACHMENT

TOOLS:
Clutch compressor attachment 07LAE· PX40100

Compressor bolt assembly

07GAE· PG40200

Attachment, 32)r; 35 mm

07746-0010100

I ATIACHMENT --.'l:c":'\'~-_ WASHER
NUT

Draw a new bearing into the frame with the marked
side facing up until it is fully seated, using the special tools and a 10 mm washer as shown.

~==-----===========
COMPRESSOR
BOLT

WASHER

TOOLS:
Clutch compressor attachment 01LAE-PX40100
Compressor bolt assembly
07GAE-PG40200

Attachment, 42 x 41 mm

07746-0010300

~HMENT
Install the snap ring into the frame groove properly
with the cham fered edge facing down.
Apply grease to new dust seal lips.
Install the upper seal so that it is flush with the
frame edge.
Install the lower seal so that it is fuliV seated onto
the bearing.

INSTALLATION
Inspecr dust seal
lips for deformation
when you Ins/all
the EP$ umt

Apply grease to the tip of dust sea l lip and EPS unit
chamfer as shown.
Install the EPS unit onto the fram e from left side.

14-39

FRONT WHEEL/SUSPENSION/STEERING
Do not t'9hren the Loosely install the EPS unit mounting bolts and
mounting bollS and
nuts yel

nuts.

Apply molybdenum disulfide grease to the output
shaft spline.
Install the shaft arm over the outpu t shaft by aligning the wide tooth with the wide groove.
Install the washer and a new end nut. and tighten
the nut to the specified torque.
TORQUE: 108 N 'm (11.0 kgf·m , 80 Ibf.ft)
Install a new cotter pin.

Apply 2 - 3 9 of grease to the shaft bushing inner
surface.
Install the shaft bushing onto the steering shaft with
the arrow mark facing up.
Install steering shaft holder B onto the frame.
Make sure the

steenng shah IS
fully seated onto
the mput shaft of

Install the st eering shaft onto the input shaft of the
EPS unit by aligning the wide tooth with the wide

groove.

EP$umr

Install and tighten the new flange bolt to the speci- r-~-::~~
fied torque.
TORQUE : 60 N·m (6.1 kgf·m , 44lbf.ft)

14-40

FRONT WHEEL/SUSPENSION/STEERING
Install steering shaft holder A with the hose clip
toward the right side.
Tighten the holder bolts to the specified torque.
TORQUE: 32 N'm (3.3 kgf·m, 24 Ibf.ft)
Install the brake hose grommet into the hose clip.

Tighten the EPS unit mounting bolts and nuts
alternately to the specified torque.
TORQUE:
BOLTS: 22 N'm 12.2 kgf·m , 16 Ib'-ftl
NUTS: 22 N'm 12.2 kgf·m , 161bf.ftl

Install the tie-rods into the steering shaft arm.
Install new ball joint nuts and tighten them by holding the joint stud flat surfaces.
TORQUE: 54 N-m (5.5 kgf·m, 40 Ibf.ft)
Install new cotter pins into the ball joint studs.

Install the handlebar assembly onto the steering
shaft with the washers and new lower holder nuts.
Tighten the nuts to specified torque.
TORQUE: 39 N·m (4.0 kgf·m, 29 Ibf·ft)

14-41

FRONT WHEEL/SUSPENSION/STEERING
Install the cable and wire harnesses in the wire clip.
Install the brake hose clamp and tighten the bolt.

TORQUE: 12 N 'm (1.2 kgf -m , 9Ibf.ft)

Connect the torque sensor 3P connector.

Connect the EPS motor 2P connector and secure the
connector from the frame.
Secure the control motor 2P connector to the frame.
Connect the EPS motor 2P connector.
Install the following:
- front fender (page 2·1 1)
- assist headlight (page 22-4)
Refer/omfom18/10f)
for the torque
sensor InitJallzatlOl1
chan (page 2> 13)

Perform the Torque Sensor Initialization
(page 25· 13).

TIE-ROD
REMOVAL
Remove the inner fenders (page 2-9).
Remove the front wheel (page 14-14).
Remove the cotter pins.
Remove the tie-rod ball joi nt nuts while holding the
joint stud flats with an open end wrench.
Remove the tie-rod from the knuckle and steering
shaft.

INSPECTION
Inspect the tie-rod for distortion or damage.
Inspect the ball joint boots for tears or other damage by mOiling the ball joint studs.
They should move freely and smoothly.
Replace the ball joints if necessary.

14-42

BAll JOINT BOOTS

FRONT WHEEL/SUSPENSION/STEERING
BALL JOINT DISASSEMBLY/
ASSEMBLY
loosen the lock nuts and remove the ball joints and
lock nuts from the tie-rod.

LOCK NUT

FLAT
'05 - '06

Install the unmarked ball joint and gold colo red nul
on the flat side of the tie-rod, and the "L marked
ball joint and silver nut (left handed thread) on the

"L" MARK

opposite side.

After '06

Install the righI -hand threads nut and unmarked ball
joint on the flat (wrench holding area for toe adjustment) side of the tie-rod, and the left-hand threads

FLAT

LEFT HAN DED THREAD NUT

nut and "l " marked ball joint on the opposite side .

ll,

RIGH~ HANDED THREAD NUT
TheballJOm r Hand-tighten the lock nuts and measure the disposItions afe IBO°

tance between the lock nut and thread end.

('Os, '06)/16'30'

(Aftar '06/ 'rom
each other TJghlBl1
these nuts after

mstaillng The

TIE· ROO DISTANCE: 387 mm (15.2 in)

The difference between distances A and B should be

t,e- 3 mm (0.12 in) or less.

'00

Insta ll the tie-rod onto the knuckle and steering arm,
and adjust the toe (page 3·26) .

-B

1+-__ 387 mm (15.2 in) -~-j

14-43

FRONT WHEEl/SUSPENSION/STEERING
INSTALLATION
Install the tie-rods into the steering shaft arm and
knuckle.
Install new 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 Ibf.tt)
Install new cotter pins.
Install the front wheel (page 14-14)
Install the inner fenders (page 2-9)

FRONT SHOCK ABSORBER
REMOVAL
Support the vehicle with a support block to raise the
front wheels off the ground.
Support the suspension arm or front wheel, and
remove the upper and lower mounting nuts, bolts
and shock absorber.

INSPECTION
Check the upper pivot bushing for wear or damage.
Check the damper unit for leakage or other damage.
Replace the shock absorber assembly if necessary.

UPPER PIVOT BUSHING

Remove the lower pivot collar.

SEALS

Remove the dust seals.
'05, '06.

Check the lower pivot bearing for wear or damage.

Afler '06

Check the lower pivot bushing for wear or damage.

LOWER PIVOT COLLAR

14-44

BEARING/BUSHING

FRONT WHEEL/SUSPENSION/STEERING
BEARING REPLACEMENT (,05, '06)
Press the needle bearing out of the lower pivot
using the special tools.

DRIVER

ATTACHMENT

TOOLS :

Driver
Attachment, 22 x 24 mm
Pilot, 16 mm

Press In the bearmg
with the marking
side facing up

07749·0010000

07746·0010800
01746-0041300

Apply grease to the needle rollers of a new bearing.

Carefully press the needle bearing in the lower pivot
until the depth from the lower pivot outer surface is
5.4-5.5 mm (0.21-0.22 in), using the special tools.
TOOLS:
Driver

Attachme nt, 22 x 24 mm

07749·0010000
07746·0010800

Pilot, 16 rnm

07746-0041300

Apply grease to the new dust seal lips and install
t hem into the lower pivot.
Install the lower pivot collar.

LOWER PIVOT COLLAR

BUSHING REPLACEMENT IAfter '06)
Press the bushing out of the lower pivot using side , - - - - - - - - - - - -- - -- - - ,
"AUof the special tool.

TOOLS :
Bu shing driver. 16 mm

07AMO-HPOA100

DRIVER

"A"

14-45

FRONT WHEEL/SUSPENSION/STEERING
Carefully press the bushing into the lower pivot
until the tool bottoms, using side "8 " of the special
tool.

TOOLS :
Bushing driver, 16 mm

DRIVER
07AMD· HPOA100
"8 "

Apply grease to new dust seal lips and install the
dust seals into the lower pivot until they are flush
with the pivot surfaces.

Install the pivot collar.

COLLAR

INSTALLATION
Install the front shock absorber in the frame and
insert the upper and lower mounting bolts from the
front side.
Install and tighten the new mounting nuts.
TORQUE: 44 N 'm (4.5 kgf·m, 33 Ibf.ft)

¢Il!
........

14-46

LOWER MOUNTING
NUT/BOLT

15. REAR WHEEL/SUSPENSION

SYSTEM COMPONENTS ......................... 15·2

REAR WHEEL ............................................ 15·6

SERVICE INFORMATION ........................ · 15·3

REAR SHOCK ABSORBER .. ..................... 15·6

TROUBLESHOOTING ............................... 15·5

SWINGARM .............................................. 15·9

15-1

REAR WHEEL/SUSPENSION

SYSTEM COMPONENTS
f+-- -_ _ 34 N'm (3.5 kgf·m. 25 Ibf.ft)

64 N'm (6.5 kgf·m, 47 Ibf·ft)

44 N'm (4.5 kgf·m, 32 Ibf.ft)

112 N'm (11.4 kgf·m, 82Ibf.ft)

/
/

'05-'06: 10 N·m
7 Ibf·ft)
After '06: 3.9 N'm (0.4 kg f·m, 0.9 Ibf.ft)
"2 N'm (11.4 kgf·m, 82 Ibf.ft )

15-2

REAR WHEEL/SUSPENSION

SERVICE INFORMATION
GENERAL
•
•
•
•
•
•
•

This section covers service of the rear wheel and rear suspension.
For tire information, refer to 14-15.
For brake system service, refer to 16-3.
For rear driving mechanism service, refer to 18-3.
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.
When using the lock nut wrench, use a deflecting beam type torque wrench 20 i nches 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.

SPECIFICATIONS
TEM
IM'c,;mum, tice tee,d depth

'LiMIl

position

, 2

TORQUE VALUES
Rear wheel nut
Shock absorber upper mounting flange nut
Shock absorber lower mounting flange bolt
Swingarm pivot bolt

Swingarm right pivot lock nut

(left)
(Right)
(R ight)

'05 - '06
After '06

64 N'm (6.5 kgf·m, 47 Ibf·ft)
34 N'm (3.5 kgf·m, 25 Ibf·ft)
44 N'm (4.5 kgf.m, 33 Ibf·ft)
112 N·m (11.4 kgf·m, 82Ibf·ft)
10 N·m (1.0 kgf·m. 7 Ibf·ft)
3.9 N·m (0.4 kgf·m, 0.9 Ibf·ft)
112 N'm (11.4 kgf-m, 82 Ibf-tt)

15-3

REAR WHEEL/SUSPENSION
TOOLS
Driver
07749-0010000

Pilot, 16 mm
07746-0041300

Attachment, 37 x 40 mm

Attachment, 22 x 24 mm

07746·0010200

07746·0010800

Lock nut wrench

Adjustable bearing remover, 20 x 40 mm
07JAC-PH80100

07908-4690003

or 07736-A01000B
or 07736-A01000A(U.S.A. only) with
commercially available 3!8~ x 16
slide hammer
Adjustable bearing remover shaft
07JAC·PHB0200

15-4

Driver shaft

07949·3710001

Remover weight
07741-0010201

REAR WHEEL/SUSPENSION

TROUBLESHOOTING
Rear wheel wobbling
• Bent rim

• Faulty tire
• Wheel hub nut not tightened properly
• Faulty bearings

Steers to one side or does not track straight
• Unequal tire pressu re
• Bent swing arm or frame
• Weak shock absorber
Soft suspension
• Weak shock absorber spring
• Faulty shock absorber damper
Hard suspension
• Bent shock absorber damper rod
• Faulty suspension bushings or bearings
Rear suspension noise

• loose rear suspension fasteners
• Damaged suspension components

15-5

REAR WHEEL/SUSPENSION

REAR WHEEL
REMOVAL
Loosen the wheel nuts.
Support the vehicle with a support block to raise the
rear wheels off the ground.
Remove the nuts and wheel.

For tire removal/installation and repair, refer to

page 14-15.

INSTALLATION
00 not interchange Install the wheel with the arrow mark facing in the
the left and right normal rotating direction.
tires

Install the wheel nut s and tighten them.
TORQUE: 64 N 'm (6.5 kgf·m , 47 IbUtl

REAR SHOCK ABSORBER
REMOVAL
Support the vehicle with a support block to raise the
rear wheels off the ground.

Support the swingarm and remove the mounting
nut. washer, bolt and the shock absorber.

15-6

REAR WHEEL/SUSPENSION
INSPECTION
Check the upper pivot bushing for wear o r damage.
Check the damper unit for leakage or other damage.
Replace the shock absorber assembly if necessary.

UPPER I

BUSHING

Remove the lower pivot collar.

DUST >. 'IL>

'05, "06. Check the lower pivot bearing and lower pivot collar
for wear or damage.
After '06

Check the lower pivot bushing for wear or damage.

/ .,

PIVOT COLLAR

BEARING REPLACEMENT (,05, '06)
Remove the lower pivot collar.
DUST SEALS

Remove the dust seals.

/ .,

PIVOT COLlAR
Press the needle bearing out of the lower pivot
using the special tools.
TOOLS:
Driver shaft

Attachment, 22 )( 24 mm

07949·3710001
07746·0010800

Pilot, 16 mm

07746·0041300

15-7

REAR WHEEL/SUSPENSION
ApplV grease to the needle rollers of a new bearing.
Carefullv press the needle bearing in the lower pivot
until the depth from the lower pivot outer surface is
5.4-5.5 mm (0.21-0.22 in), using the special tools.

5.4-5.5 mm (0.2 1-0.22

TOOLS:
Driver shaft

Attachment, 22 x 24 mm
Pilot, 16 mm

07949-3710001
07746·0010800
07746-0041300

Apply grease to new dust seal lips and install them
into the lower pivot.
Install the lower pivot collar.

PIVOT COLLAR

BEARING

BUSHING REPLACEMENT (After '06)
Press the bushing out of the lower pivot using side
-A Mof the special tool.
TOOLS:

Bushing driver, 16 mm

07AMD-HPOA100

Carefully press the bushing into the lower pivot
until the tool bottoms, using side "8 " of the special

tool.
TOOLS:
Bu shing driver, 16 mm

07AMD·HPOA100

"6"

15-8

REAR WHEEL/SUSPENSION
Apply grease to new dust seal lips and install the
dust seals into the lower pivot until they are flush
with the pivot surfaces.

Install the pivot collar.

....

. - - . . DUST SEAILS

. . f'

"---

" ~

COLLAR

INSTALLATION
Install the rear shock absorber onto upper mounting ..,.,.",,.,,,,..,,"""":::"".,,.,,:,.,,.,.,,."",,.
stud of the frame.
Install the lower mounting bolt and tighten it.

TORQUE: 44 N'm (4.5 kgf·m . 33 Ibf·ft)
Install the washer and upper mounting nut and
tighten the nut.

TORQUE: 34 N'm (3.5 kgf·m , 25 Ibf·tt)

SWINGARM
REMOVAL
Remove the final drive assembly (page 18-9).

Remove the breather hoses from the clamps on the
swingarm.

Remove the band screw and universal joint boot
band.

15-9

REAR WHEEL/SUSPENSION
Remove the bott. brake light switch guard and brake
light switch.

Remove the left and right swingarm pivot caps.

Remove the right pivot lock nut using the special
tooL

TOOL:
lock nut wrench

07908-4690003

Remove the left and right pivot bolts.
Remove the universal joint boot from the 5wingarm,
then remove the swingarm from the frame.

15-10

REAR WHEEL/ SUSPENSION
Remove the universal joint.
Check the joint boot for tears or other damage and
replace it if necessary.

INSPECTION
'05 -'06

Both bearmgs,
ouler races and
grease holders
must be replaced
as 8 sellf any pan
IS

Remove the pivot bearings from the swingarm piv·
ots.
Check the bea ring rollers, dust seals and outer races
for wear or damage,

damaged 0,-

wom

BEARINGS
After '06

Afler '06

Remove the dust seal s from the swingarm.
Check the dust seals for wear or damage.

Turn the inner race of each pivot bearing with your
finger.
The bearing should turn smoothly and quietly.
Also check that the outer race of the bearing fits
tightly in the swingarm pivot.
Replace it if necessary.

/~1

~=====

DUST SEALS

----========--=

15-11

REAR WHEEL/SUSPENSION
Aher '06

Remove the swingarm pivot beari ng using the special tools.

TOOLS:
Remover handle
Bearing remover, 17mm
Remover weight

07936·3710100
07936·3710300
07741·0010201

~
~
~

-;0

I LEFT PIVOT BEARING
Drive the grease holder into the swingarm to

remove it.

~---===============~
SWINGARM

TOOLS;
Driver
Atta chment, 22 x 24 mm

07749-0010000
07746·0010800
GREASE HOLDER

Remove the outer race from the swingarm using the

special tools.
TOOLS:
Adju stable bearing remover,
20 x 40 mm
Adju st able bearing remover

shaft
Rem over weight

07JAC-PH80100

07JAC-PH80200
07741-0010201
OUTER RACE

U.S.A. only:
Adju stable bearing puller,
24 x 40mm
3/8" x 16 Slide hammer

07736·A01000B or
07736·A01000A
Commercially

available
Install a new grease holder into the swingarm pivot.
'OS, '06.

Drive a new outer race into the swingarm pivot until
it is fully seated, using the special tools.

Aher '06.

Drive a new bearing into the swingarm pivot until it
is fully seated, using the special tools,

rii5.':Qii,',m"n:

O""~J'
GREASE HOLDER

TOOLS:
Driver
Attachment, 37 )( 40 mm

15-12

07749-0010000
07746-0010200

REAR WHEEl/SUSPENSION
'OS - '06'

Apply lithium based grease (Shell 6459) to new
bearing roilers and dust seal lips and install the
bearings into the swingarm pivots,

BEARINGS
Aher '06'

Pack the grease holders and bearing cavities with 3 r - - - - - - - - - - - - - - - - - - - ,
9 of molybdenum disulfide grease,
~

After '06:

Apply molybdenum disulfide grease to the dust seal
lips, and install the dust seals in the swing arm using
the special tools.
TOOLS:
Driver
Attachment. 37 x 40 mm

07749·0010000
07746·0010200

DUST SEALS

INSTALLATION
Apply molybdenum disulfide grease to the output
shaft spline and install the universal joint onto the
output shaft,

15-13

REAR WHEEL/SUSPENSION
Set the swing arm into the frame and install the left

and right pivot bolts.
Install the universal joint boot onto the swingarm.

Tighten the left pivot bolt.
TORQUE: 112 N 'm 111.4 kgf-m, 82 Ibf.ft)

Tighten the right pivot bolt.
TORQUE: 'OS - '06: 10 N 'm (1 .0 kgf·m. 7 Ibf.ft)

After 'OS: 3.9 N'm (0.4 kgf-m , 0.9 IbUt)
Move the swingarm up and down several times to
seat the pivot bearings.
Retighten the pivot bolts to the same torques.

Tighten the right pivot lock nut using the special
tool, while holdi ng the pivot bolt.

TOOL:
lock nut wre nch
Refer to torque

wrendl reading
mformatlOn on page

07908·4690003

TORQUE: Actual: 112 N 'm 111.4 kgf·m, 82 Ibf.ft)
Indicated: 102 N'm (10.4 kgf·m, 75 Ibf.ft)

'5-3 'SerVlCe
/nform8tlOfl'

lnslall the left and right pivot caps securely.

Install the universal joint boot band and screw so
that the screw is positioned top and faci ng left side.
Tighten the band screw.

15-14

REAR WHEEL/SUSPENSION
Route the breather hoses properly (page 1-24) and
secure them w ith the clamps.
Install the final drive assembly (page 18-21).

15-15

MEMO

16. BRAKE SYSTEM

COMPONENT LOCATION ······················ .. 16-2

FRONT MASTER CyLINDER ···················· 16-8

SERVICE INFORMATION ·························16-3

BRAKE PAD/ DISC ............... ...... ..... ........ 16-13

TROUBLESHOOTING ··········· ···················· 16-5

FRONT BRAKE CALIPER ························ 16-14

BRAKE FLUID REPLACEMENT/
AIR BLEEDING ········································ .. 16-6

REAR BRAKE ·················· ················· ······· 16-19
BRAKE PEDAL ... ............................ ......... 16-27

16-1

BRAKE SYSTEM

COMPONENT LOCATION

20 N-m (2.0 kgf·m, 14 Ibf·h)

137 N'm (1 4.0 kgf·m, 101 IbUt)
34 N-m (3.5 kgf·m,

16-2

11 N'm (1 .1 kgf·m, 8Ibf.ft)

BRAKE SYSTEM

SERVICE INFORMATION
GENERAL

ACAUTION
Frequent inhalation of brake lining or pad dust, regardless of malerial composition could be hazardous to your health .

• Avoid breathing dust particles.
• Never use an air hose or brush to dean brake assemblies. Use an OSHA-approved vacuum cleaner.

NOTICE
Spilled brake fluid will severely damage the plastic pans and painted surfaces. It is also harmful to some rubber pans. Be
careful whenever you remove the reservoir cap: make sure the reservoir ;s horizontal first.
• A contaminated brake lining, drum, disc or pad reduces stopping power. Discard contaminated linings or pads, and
dean a contaminated drum or disc with a high quality brake digreasing agent.
• Check the brake system by applying the brake leve r after the air bleeding.
• 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 ridi ng the vehicle.

SPECIFICATIONS
Unit : mm (i n)

ST~A~N:D~A~RD~~~======~S~E~R~V~'C~E~L~'M~'T~

ITEM
Front brake

Recommended brake fluid
Master cylinder I.D.
Master cylinder 0.0.
Caliper cylinder I D
r--Caliper cy linder piston 0.0.
Brake disc thickness
Brake disc runout
Rear brak~Drum 1.0.
r Uning thi ckness
Rear (park ingl brake lever freeplay
- freeplay
Rear brake pedal

DOT 4 brake flui~
14.000 - 14.043 (0.55'2 0.55,'",9ii-1_ _~_';;4Ci'0i>5"5-ii10-

BRAKE SYSTEM

REAR BRAKE
BRAKE DRUM REMOVAL
Remove the rear wheel (page 15-6)'
Remove the cotter pin.
Remove the right rear hub nut and wheel hub.

Remove the bolts and brake drum cover.

Remove the brake drum cover D-ring.
Remove the brake drum.

INSPECTION
Measure the brake drum J.D.

SERVICE LIMIT: 181 mm (7.1 in )
Inspect the brake drum for scoring , cracks and Qut
of roundness.

16-19

BRAKE SYSTEM
Check the wheel hub dust seal for wear or damage.

DUST SEAL

Check the brake drum cover dust seal for wear or
damage.
Drive it Qut of the drum cover jf necessary.

DUST SEAL REPLACEMENT

Remove the dust seal from the wheel hub.
Apply grease to a new seal lips and install it into the

111 •--.

DUST SEAL

wheel hub with the flat side facing in until it is fully
seated .

Install a new dust seal into the drum cover using the
special tool as shown.
TOOL:
Driver
Attachment, 78)( 80 mm

DRIVER

07749-0010000
07NAO·PX40100
ATIACHMENT

Fill up with grease to the brake drum cover dust seal
lip.

16-20

BRAKE SYSTEM
BRAKE PANEL DISASSEMBLY
Mark the brake
shoes to indICate

Remove the cotter pins, setting plate, brake shoes
and shoe springs.

~";";: R PINS

their original

POSlflons before
removing them

Remove the adjusting nuts, brake cables, springs
and joint pins from the brake ar m.

Remove th e brake arm pinch bolt/nut and brake

arm.

Remove the indicator plate, return spring and felt

seal.

16-21

BRAKE SYSTEM
Remove the brake cam.

Disconnect the breather hose from the brake panel.

Remove the brake panel nuts and discard them.
Remove the brake panel.

Remove the a·ring from the brake panel groove.

BRAKE PANEL BEARING REPLACEMENT
Turn the inner race of the bearing with your finger.
The bearing should turn smoothly and quietly.
Also check that the outer race of the bearing fits
tightly in the brake panel.
Replace it if necessary.

Check the dust seal for wear or damage.

Remolle the axle dust seal and brake cam dust seal.

•

16-22

BRAKE SYSTEM
Remove the snap ring.
Drive the bearing out of the brake panel.

Drive a new bearing into the brake panel with its
sealed side facing out (facing the axle housing)
using the special tools as shown.
TOOLS :
Driver
Oil seal driver attachment
Pilot, 28 mm

07749·0010000
07JAD· PH80101
07746·0041100

Install the snap ring into the groove .

Pack a new dust seal lips with grease.
Install the dust seal into the brake panel until it flush
with the brake panel.
ApplV grease to the new brake cam dust seal lips.
Install the dust seal until it is seated.

16-23

BRAKE SYSTEM
BRAKE PANEL ASSEMBLY
20 N'm (2.0

, 14 Ibf.ft)

BRAKE ARM
IND'ICATOR PLATE

DRUM COliER

WHEEL HUB

--:,.<-

137 N'm (14.0 kgf·m,
101 Ibf-ft)

--""1

FELT SEAL

RETURN SPRING

• .a;;;.,
DUST SEAL

tI
COITeR PIN

BRAKE PANEL
BRAKE CAM

tI . .v;;;;;. O-RING
SHOES

BRAKE DRUM

conER

Coat a new O-ring with grease and install it in the
brake panel groove.
Install the brake panel onto the axle housing .

Donor reuse fila

nuts

16-24

Install and tighten the new nuts.
Connect the breather hose to the brake panel.

BRAKE SYSTEM
Apply 0.2 - 0.3 g of grease to the brake cam sliding
surface and anchor pi n contacting area of the brake
shoes.
Install the brake cam into the brake panel.

Apply engine oil to the felt seal and install it.
Install the return spri n g.
Install the indicator plate aligning the wide tooth on
the plate with the wide groove on the brake cam.

Install the brake arm, aligning the punch marks on
the brake arm and cam.
Hook the return spring end onto the brake arm.
Tighten the brake arm pinch bolt/nut to the specified
torque.
TORQUE: 20 N·m (2.0 kgf.m. 14Ibf·ft)

Apply 0.2 - 0.3 g of grease to the brake cam contacting area altha brake shoes.
Install the brake shoes in their original positions
with the spring as shown.
Install the anchor pin setting plate with its chamfered side (rolled edge side) facing in.

16-25

BRAKE SYSTEM
Install the new coner pins and secure the setting
plate as shown.

PINS

SETIING PLATE
Install the joint pins into the brake arm, then install
the brake cables and springs.
InSlalithe adjusting nuts.

Aii3UiiTl,iG NUTS
BRAKE DRUM INSTALLATION
Apply molybdenum disulfide grease to the axle
splines and install the brake drum.
Apply grease to a new O-ring and install it onto the
brake panel groove.

Install the brake drum cover and tighten the bolts.

16-26

BRAKE SYSTEM
Apply molybdenum disulfide grease to the axle
spli nes.
Install wheel hub onto the rear axle.

Install t he hub nut and tighten it to the specified ...."""....,""~
torque.
TORQUE: 137 N·m (14.0 kgf·m , 101 1bHt )
Further tighten the hub nut until its grooves align
with the cotter pin hole in the axle shaft.
Install a new cotter pin and secure the hub nut.
Install the rear wheel (page 15-6).
Adj ust the rear brake lever and pedal freeplay
(page 3+22).

BRAKE PEDAL
REMOVAL
Remove the brake ca bles from th e brake arm (page
16-2 1).
Remove the bolt and brake light switch guard.

Unhook the brake light switch spring and remove
the brake light switch.

16-27

BRAKE SYSTEM
Disconnect the brake cable.
Unhook the brake pedal return spring.

Remove the coner pin and washer from the pedal [iiiAiiHiER~
pivot shaft, then remove the brake pedal from the
shaft.
Remove the dust seals.

COTIERPIN

INSTALLATION
Apply grease to the brake pedal pivot shaft sliding
surface and dust seal lips.

Install the brake pedal onto the pivot shaft.

Install the washer and secure the brake pedal with a
new cotter pin.

16-28

BRAKE SYSTEM
Apply grease to the brake cable end .
Install and connect the brake cable.
Hook the return spring.

Install the brake light switch.
Hook the brake light switch spring.

Install the brake light switch guard and lighten the
bolt.
Adjust the rear brake (page 3-23).

16-29

MEMO

17. FRONT DRIVING MECHANISM

SYSTEM COMPONENTS ", .. "", .. " ........ , .. 17-2

DIFFERENTIAL DISASSEMBLY I
INSPECTION , .. , .. " .... , .. " .. ,.. ,.. " .... , .. " .. , .... 17-17

SERVICE INFORMATION .. , ..................... , 17-3
CASE BEARING REPLACEMENT .......... 17-24
TROUBLESHOOTING .............................. , 17-6
DIFFERENTIAL ASSEMBLy .................. , 17-27
FRONT DRIVE SHAFT ............... ,............. , 17-7
DIFFERENTIAL INSTALLATION ........... , 17-32
DIFFERENTIAL REMOVAL .................... , 17-14

17-1

FRONT DRIVING MECHANISM

SYSTEM COMPONENTS
44 N·m (4.5 kgf·m , 33 Ibf.ft)

44 N' m (4.5 kgf·m , 33 Ibf·h j

kgf·m, 21 Ibf.ftl
54 N·m (5.5 kgf·m ,

40Ibf.ft)

7 N·m (0.7 kgf·m ,
5.1 tbf·h )

~
,
10 N'm (1.0 kgf·m, 7Ibf.ft)

10 N 'm (1.0 kgf·m,
7 Ibf.ft)

22 N'm (2.2 kQf.m, !
16Ibf.ft)

22 N'm (2.2 kgf·m, 1Slbf.tt)

17-2

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 damp it IcO 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
Front differentiat

ITEM
OifCapacity

STANDARD

185 em' (6.3 US OZ, 6.5 Imp azl
230 cm J (7.8 US oz, 8.1 Imp oz)

After draining
After disassembly

Hypoid gear oil SAE #80
0.05 - 0.25 (0.002 0.010)

Recommended oil
Gear backlash
Backlash difference
I Slip torque
Face cam-to-housing distance
Differential ring gear depth
Cone spring height

Unit· mm (in)
,
SERVICE LIMIT

17 N·m 0.45 1.75 kgf·m,
10-13Ibf.ft)
3.3 3.7 (0. 13 0.15)
6.55 6.65)0.258 0.262)
2.8 (0.11)

0.4 (0.02)
0.2 (0.01 )
12 N'm (1.2
kgf·m, 9 lbf.ft)

3.310.13)
6.6 (0.26)
2.6 (0.10)

TORQUE VALUES
Upper and lower arm ball joint
nut
Front wheel hub nut
Differential ring gear bolt

29 N 'm (3.0 kgf·m , 21 Ibf.ft)
78 N'm (8.0 kg f·m , 58 Ibf.ft)
49 N 'm (5.0 kgf·m, 36 Ibfft)

Castle nut
Castle nut
Special bolt: replace with a new

on.
Apply locking agent to the threads
Differential case cover 10 mm
bolt
Differential case cover 8 mm
bolt
Differential case mounting
bolt
Differential case mounting
bracket bolt
Differential case mounting nut
Differential case mounti ng nut
Final drive clutch assembly
mounting bolt

('05 - '07)
(After '07 )

49 N'm (5.0 kgf·m, 36Ibf.ft)
46.5 N·m (4.7 kgf·m , 34 l bf·ft)

Apply locking agent to the threads
Apply locking agent to the threads

25 N 'm (2.6 kgf·m, 19 Ibf·ft)
( 10mm)

44 N'm (4.5 kgfm, 33 Ibf.ft)

(8 mm)
(10mm)
(8mm )

22 N'm (2.2 kgf.m, 16Ibf·ft)
44 N'm (4.5 kgf·m, 33 Ibf·ft)
22 N'm (2. 2 kgf·m, 16Ibf·ft)
25 N'm (2.6 kgf·m, 19 Ibf·ft)

Lock nut: replace with a new one

ALOC bolt: replace with a new

on.
Front vehicle speed sensor
cover bolt
Clutch cover stay bolt
Clutch cover bolt
Splash guard bolt

10 N'm (1.0 kgf·m, 7Ibf·ft)
10 N'm (1.0 kgf.m, 7 Ibf·ft)
7 N·m (0.7 kgf·m, 5.1 Ibf.ft)
11 N'm (1.1 kgf·m , 8Ibf.ft)

ALOC bolt: replace with a new

Tie-rod ball joint nut
Front wheel hub nut

54 N·m (5.5 kgf·m, 40 Ibf·ft)
78 N' m (8.0 kgf.m, 58 Ibf.ft)

Lock nut: replace with a new one
Castle nut

on.

17-3

FRONT DRIVING MECHANISM
TOOLS
Attachment, 22 x 24 mm
07746-0010800

Attachment, 52 x 55 mm

07749-0010000

Attachment, 20 mm 1.0.
07746-0020400

Pilot, 15 mm

07746-0040300

Pilot, 28 mm
07746-0041100

Driver

Bearing remover head, 15 mm

Remover shah

07936·KC10200

07936-KC10100

07746·0010400

Remover weight
07741·0010201

or 07936-3710200
or 07936-371020A (U.S.A. only)

Ball joint remover, 28 mm
07MAC·SL00201

Bearing remover head, 30 mm

Remover handle

07936-8890300

07936-3710100

®
07MAC-SL0202(U.SAonly) or
07MAC-SLQ0200 and
07MAC·SLOA300 (U.S.Aonly)

17-4

FRONT DRIVING MECHANISM
Differential inspection tool
07KMK-HC50101

Driver, 40 mm I.D.
07746-0030100

Anachment, 30 mm I.D.
07746-0030300

Driver shaft
07949-3710001

07631-0010000

or 07KMK-HC501OA (U.S.A. only)
Differential beari ng clip compressor
07YME-HN4010A (U.S.A only)

Universal bearing p u ller

o
Press attachment
07LME-GE20100

17-5

FRONT DRIVING MECHANISM

TROUBLESHOOTING
Consistent noise during cruising
• Oille...el too low
• Foreign matter contaminati ng 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 gea r and pinion gear

Gear noise while coasting
• Chipped or damaged gears
Abnormal noises when turning
• Worn or damaged ring gea r bearing
• Worn or damaged face cams and cam followers
• Worn or damaged d ifferential housing grooves
• Worn cone spring or shim
Abnorm al noises at start or during acceleration
• Excessive backlash between ring gear and pinion gear
• Worn differential spl ines
• Loose fasteners
• Worn cone spring or shim

Oil leak
•
•
•
•

Oil level too high
Clogged breather
Damaged seals
Loose case cover bolt

Overheating
• Oi l level too low
• Insufficient backlash between ring gear and pinion gear

17-6

FRONT DRIVING MECHANISM

FRONT DRIVE SHAFT
REMOVAL
Remove the front wheel (page 14-14).

Remove the cotter pin and loosen the hub nut.

COTTER PIN

Remove the cotter pin.
Remove the tie-rod ball joint nut while holding the

joint stud flats with an open end wrench.
Remove the tie-rod from the knuckle.

Remove the two bolts and splash guard.

Remove the cotter pins and loosen the castle nuts of
the suspension arm ball joints, but do not remove
them yet.

17-7

FRONT DRIVING MECHANISM
Separate the ball joints, using the special tool
according to the instructions (page 14-21 J.
TOOL:
Ball joint rem over, 28 mm

07MAC-Sl00201
07MAC-SlOA202
(U.S.A. only) or

07MAC· Sl00200 and
07MAC·SLOA300
(U.S.A. only )

BALL
Do not gel grease

onto the shoe

limngs.

Remove the axle nut and the wheel hub/knuckle.
Remove the castle nuts, and separate the wheel
hub/knuckle assembly from the suspension arms
and drive shaft outboard joint.

Do not twist the Support the wheel hublknuckle assembly so that it
brake hose. does not hang from the brake hose.

To prevent damage
the differential oil
seal, hold the
inboard joint
oonzantal until the
drIVe shaft IS clear
of the differential.

Hold the inboard joint of the drive shaft and tug
firmly to force the stopper ring in the drive shaft end
past the groove while prying with a screwdriver.
Remove the stopper ring from the inboard joi nt.

DISASSEMBLYIINSPECTION
Check the boots for cuts or other damage.
Check the drive shaft joints fo r excessive play or
noise by moving the joi nts in a circu lar di rection.
If the outboard joint seems to be worn or damaged ,
t he drive shaft must be replaced .
• To replace t he outboard boot, fi rst remove the
inboard boot as described in t he following steps.
Then remove the bands and outboard boot from
the inboard end of the shaft .
• The outboard joint cannot be disassembled .

ITBIJAF.DJOINT

17-8

INBOARD JOINT

FRONT DRIVING MECHANISM
Replace the bands Bend up the lock tabs and raise the band ends to
With new ones loosen the boot bands on the inboard side.
whenever Remove the boot band B.
(emovlng them

Remove the boot from the inboard joint.

RemOve the following:

Replace the

components as an
assembly.

stopper ring
inboard joint

snap ring
bearing
inboard boot
boot band C

BEARING

Check the following for wear or damage:
-

bearing cage
race

steel balls

inboard joint

INBOAFH; JOINT

17-9

FRONT DRIVING MECHANISM
Bend up the lock tabs and raise the band ends to
loosen the boot bands on the outboard side.
Remove boot band A.
Remove the boot from the outboard joint.

BANDA

OUTBC)ARtDJOINT

OUlrBO"RD BOOT

ASSEMBLY
DRIVE SHAFT

INBOARD JOINT

:!!I

BAND C
OUTBOARD BOOT

RING

BEARING CAGE

INBOARD BOOT

BAND C

:!!I

BAN[) A

The outboard boots is larger than the inboard boots.

INBOARD BOOT

17-10

OUTBOARD BOOT

FRONT DRIVING MECHANISM
Note the installation direction of the boot bands.
Forward rotation direction

BAND
Pack the outboard joint with 40 - 60 9 1'05 - '06)135 559 (After '06) of molybdenum disulfide grease.

OU1-BO,'RO BOOT

INBF}?
Q

YES

- GO TO STEP 6.

- Faulty charging coil

6. Regulator/ Rectifier System Inspection
Check the voltage and resistance at the regulator/rectifier connector (page 19-8).

Are the measurements correct?
YES
NO

- Fau lty regulator/rectifier
• Open circuit in related wire
• Loose o r poor contacts of related terminal
• Shorted wi re harness

19-5

BATTERY/CHARGING SYSTEM

BATTERY
REMOVALIINSTALLATION
Remove the seat (page 2·4).
Remove the battery holder band.
With the ignition switch OFF, disconnect the negative H cable fi rst. then disconnect the positive (+)
cable by removing each terminal bolt.
Remove the battery.
Connect the Install the battery in the reverse order of removal
poSltfWIlermmal with the proper wiring as shown.
f,rst and then the

negative cable

After installing the battery, coat the terminals with
clean dielectric grease.
Inst all the terminal cover to the position terminal
securely.

VOLTAGE INSPECTION
Remove the seat (page 2-4).
Measure the battery voltage usi ng a commercially
available digital multimeter.
VOLTAGE:
Fully charg&d: 13.0 - 13.2V
Under charged: Below 12.3V

BATTERY TESTING
Remove the battery (page 19-6).
Refer to the instructions that are appropriate to the
battery testing equipment available to you.
TOOL:
Battery tester

Micro 404Xl (U .S.A . only).
BM·210 or equivalent

BATTERY CHARGING (U.S.A. only)
Remove the battery (page 19·6).
Refer to the i nstructions that are appropriat e to the
battery charging equipment available t o you.
TOOL:
Christie battery charger

19-6

MC1012/ 2T (U.S.A. on ly)

BATTERY/CHARGING SYSTEM

CHARGING SYSTEM INSPECTION
CURRENT LEAKAGE INSPECTION
Remove the seat (page 2-4),

Turn the ignition switch to OFF and disconnect the
negative (-) cable from the battery.
Connect the ammeter (+J probe to the negative H

NEGATIVE H TERMINAL
(+) PROBE

cable and the ammeter H probe to the battery H
termina l .
With the ignit ion switch turned to OFF, check for
current leakage.
• When measuring current using a tester, set it to a
high range, and then bring the range down to an
appropriate level. Current flow higher than the
range select ed may blowout 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.

H PROBE
NEGATIVE (-) CABLE

SPECIFIED CURRENT LEAKAGE: 1 rnA m ax imum
If curren t leakage exceeds the specified value, a
shorted circuit is likely.
Locate the short by disconnecting connections one
by one and measuri ng the current.

CHARGING VOLTAGE INSPECTION
Remove the seat (page 2-4).
Be sure the battery is in good condition before performi ng this test.
Warm up the engine to normal operating temperature.
Connect the multi meter between the battery positive (+) and negative H terminals.

NOTE :
• To prevent a short, make absolutely certain
which are the positive (+) and negative H terminals or cables.
• Do not disconnect the battery or any cable in the
charging system without first switching off the
ignitio n switch. Fai lure to follow this precaution
can damage the tester or electrical componen t s.
With the headlights on, and measure the voltage on
the multi meter when the engine runs at 5,000 rpm
(min" ).

STANDARD:
Measured BV < Measured CV < 15.5 V
• BV = Battery voltage (page 19-6)
• CV= Charging voltage

19-7

BATTERY/CHARGING SYSTEM

ALTERNATOR CHARGING COIL
INSPECTION
Remove the recoi l starter cover (page 2-4).
Disconnect the alternator 5P (Natural) connector.

Check the connector for loose contacts or corroded
terminals.

Measure the resistance between the Yellow wire
terminals of the alternator side connector.
STANDARD: 0.1 - 1.0 n (at 20° C/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 con tinuity to
ground.
Refer to page 11-8 for alternator stator replacement.

REGULATOR/RECTIFIER
WIRE HARNESS INSPECTION
Disconnect the regulator/rectifier 3P (Black) connector and 3P (Gray) connector.

Check the connectors for loose contacts or corroded
terminals.

19-8

BATTERY/CHARGING SYSTEM
BATIERY LINE
Measure the voltage between the Red wire terminal
of 3P !BlackJ connector and ground.
There should be battery voltage at all limes.

GROUND LINE
Check the continuity between the Green wire terminal of 3P (Black) connector and ground.
There should be continuity at all times.

CHARGING COil LINE
Measure the resistance between the Yellow wi re
terminals of 3P (GRAY) connector.

STANDARD: 0.1 - 1.0 n (at 20° C/68° F)
Check for continuity between each Yellow wire lerminal and ground.
There should be no continuity.

l~::~~

REMOVAlliNSTAlLATION
Disconnect the regulator/rectifier 3P (Black) connec-I~~~~~~
tor and 3P (Gray ) connector.
Remove the regulator/rectifier mounting boilS.

19-9

MEMO

20. IGNITION SYSTEM

COMPONENT LOCATION ............ ............ 20-2

IGNITION SYSTEM INSPECTION ············ 20-5

SYSTEM DIAGRAM .................................. 20-2

IGNITION COIL ......................................... 20-7

SERVICE INFORMATION ......................... 20-3

IGNITION TIMING .................................... 20-8

TROUBLESHOOTING ................ ............... 20-4

20-1

IGNITION SYSTEM

COMPONENT LOCATION
IGNITION SWITCH

ENGINE STOP .-

ocP,",PLUG

IGNITION PULSE GENERATOR

SYSTEM DIAGRAM

, - - - - R- - - ,

GlY llBl -

BI!R

ENGIMf WiTRIl.

(EeM)

TIfl(JTTLE
POSITlI*

BATTERY

""'"

BIIY

Bu/Y

BI/1

8I/G

,
I

Sf'"
It,.

[I"...,.---,"'_""---,-_,----JI: ~
EPS model only:

20-2

-l 3~>----,
m l

' - - - - - - ---,--

,----------1 --L...

1(111111*

roll

'"
I
BI /G ~

'------<:""-- BlI'
""II<

"",

SlITQI

BI: Blade
Bu: Blue
G: Green
P: Pink
R: Red
W: White
Y: Yellow

IGNITION SYSTEM

SERVICE INFORMATION
GENERAL
• Some electrical components may be damaged if terminals or connectors are connected or disconnected while the igni.
tion switch is ON and current is present.
• When servicing the ignition system, always follow the sleps in the troubleshooting table on page 20-4.
• This vehicle's Ignition Control Module oeM) is built in the engine control module (ECM).
• The ignition timing cannot be adjusted since the ECM is factory preset.
• The ECM may be damaged if dropped. Also, if the connector is disconnected when current is flowing, the excessive
voltage may damage the ECM. Always turn off the ignition switch before servicing.
• A faulty ignition system is often related to poor connections. Check Ihose 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.
• 11 -8 for ignition pulse generator removal/installation.
• See page 22-9 for ignition switch servicing.
• See page 22-10 for engine stop switch inspection.
• See page 22-22 for reverse switch servicing.
• See page 24-37 for gea r position switch servicing.

SPECIFICATION

r--~k

ITEM

S PECIFICATIONS

====j

~=-i=s~t~a~n~da~'~d~~~~~i:~;;;::E::::~_--==±'J~R~7~A~9i'~N~G~Kt''~V~X~2~2~B~ci'~D~EN~SgoI'

plug,~
For cold cli mate (below 5" C/4 1Q F)
Spark plug gap
Ignition coil primary peak voltage
Ignition pulse generator peak voltage
Ignition timing ("o F" mark)

IJR6A9 (NGK), VX20BC (DENSO)
0.8 - 0.9 mm (0.03 - 0.04 in)
100 V minimum
0.7 V minimum
15" BTDC at idle

TORQUE VALUES
Timing hole cap

10 N·m (1.0 kgf·m, 7 Ibf·h)

TOOLS
Peak voltage adapter
07 HGJ -0020100

Ignition Mate peak voltage tester
MTP07-0286

(not available in U.S.A.) with commercially available digital multimeter (impedance 10 MO'DCV
minimum)

(U.S.A. only)

20-3

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)
• If the engine speed will not rise above 2,200 rpm (min" ) with the gearshift lever in "R" position, inspect the following:
- Gearshift lever linkage adjustment (page 12-15)
- Reverse switch (page 22-22)
- Gear position switch (page 24-37)
• If the engine speed will not rise above 1,750 rpm (min·' ) wi th the front brake lever released and the gearshift lever in "0 "
or "L· position, inspect the brake switch (page 22-25) and its installation condition.

No spark at spark plug
~tioncoit

UNUSUAL CONDITION
low peak voltage.

PROBABLE CAUSE Check in numerical order)
1. Incorrect peak voltage adapter connections. ~System is

primary
voltage

2.
3.
4.

5.
6.
7.
- No peak voltage.

,.
2.
3.
4.
5.
6.
7.
8.
9.

Peak voltage is normal, but no spark
jumps at the plug.

1.
2.

Ignition
pulse
generator

low peak voltage.

1.
2.
3.
4.

No peak voltage.

20-4

normal if measured voltage is over the specifications
with reverse connections.)
The multimeter impedance is too low.
Cranking speed is too slow ~Battery is under charged).
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.)
Poorly connected connectors or an open circuit in the
ignition system.
Faulty ignition coil.
Faulty engine control module (EeM) (when above No.1
through 6 are normal).
Incorrect peak voltage adaptor connections. (System is
normal if measured voltage is over the specifications
with reverse connections.)
Banery IS undercharged. (large voltage drop when the
engine is started.)
Faulty ignition switch or engine stop switch.
Loose or poorly connected ECM connectors.
No voltage at the BlackJwhite (power source) wire of the
ECM.
Open circuit or poor connection in the Green (ground)
wire of the ECM.
Faulty peak voltage adaptor.
Faulty ignition pulse generator (Measure peak voltage)
Faulty ECM (when above No.1 through 8 are normal).
Faulty spark plug or leaking ignition coil secondary cur·
rent.
Faulty ignition coil.
The multi meter impedance is too low; below 10 M!)'
DCV.
Cranking speed is too slow (Banery is under charged).
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.)
Faulty ignition pulse generator (when above No.1
through 3 are normal).
Faulty peak voltage adaptor.
Faulty ignition pulse generator.

IGNITION SYSTEM

IGNITION SYSTEM INSPECTION
• If there is no spark at the plug, check all connections for loose or poor con tact before measu ring
the peak voltage.

• Use the recommended digital multi meter or a
commercially available digital multi meter with
an impedance of 10 MaDeV minimum.
• The display value differs depending upon the
internal impedance of the multi meter.
Use the peak vol t age tester or connect the peak voll- , -- - - - - - - - - -- - - - - - - - - ,
DIGITAL MULTIMETER

age adaptor to the digital multi meter.

TOOLS :
Ignition Mate peak voltage tester MTP07-0286
(U.S.A. only) or
Peak voltage adaptor
07HGJ-0020100
(not available in U.S.A .)

with commercially available digital multimeter
(impedance 10 M OIOCV minimum )

~
••

PEAK VOLTAGE ADAPTOR

IGNITION COIL PRIMARY PEAK
VOLTAGE
NOTE:
• Check all system connections before this inspection. Poor connected connectors can ca use incorrect readings.
• Check the cylinder compression and check that
the spark plug is installed correctly in the cylinder head.
Disconnect the spark plug cap from the spark plug
(page 3-9).
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.

Wi th the connector connected, connect the peak , - - - - -- - - -- - - - - - -- - -,
voltage tester or adaptor probes to the ignition coil
primary terminal and body ground .

CONNECTION: Black/ yellow H - Body ground (+)

••

Turn the ignition switch to ON and the engine stop
switch to the RUN.
Shift the transmission into neutral.
Avoid touching
the spark plug
or tester probes
to prevent elecmc shock

Crank the engi ne with the starter motor and read
the ignition coil primary peak voltage.
PEAK VOLTAGE: 100 V minimum
If the peak voltage is lower than the standard value,
follow the checks described in the troubleshooting

'---v~ u

/'-,""~rCIR BARS

• Do not use emery or sand paper on the commu-

tator.

21-7

ELECTRIC STARTER
Check for continuity between pairs of commutator
bars.
There should be continuity.

Continuity

Check for continuity between each commutator bar
and the armature shaft.
There should be no continuity.

No continuity

Check for continuity between the insulated brush

and cable terminal.

INO,UL".',U BRUSH

Continuity

There should be continuity.

Check for continuity between the cable terminal and

motor case.
There should be no continuity.

21-8

No continuity

ELECTRIC STARTER
Remove the following:
-

D -RING

nut

INSULATOR WASHERS

- washer
-

insulator washers
brush holder assembly
O-ring
insulator

NUT

I
?O

0
BRUSH HOLDER

WASHER
Remove the brushes from the brush holder.
Measure the brush length.

SERVICE LIMIT: 9.0 mm (0.35 in)

ASSEMBLY
./U/WASHER

~~ULATOR WAS HERS

~
, ..~
....
O-RING

REAR COVER
WASHER

BRUSH SPRING
SEAL RING
SEAL RING

MO"rORCASE

CASE BOLT
LOCK WASHER

FRONT COVER

21-9

ELECTRIC STARTER
Install the brushes into the brush holder.
Install the insulator onto the terminal bolt.

TERMINAL BOLT

Install the brush holder assembly into the rear cover
by aligning the tab of the holder with the groove in
the rear cover.

BRUSH HOLDE'"

INSULATOR WASHERS

Install the following:
-

new O-ring
insulator washers
washer
nut

WASHER

Install the armature into the motor case while holding the armature tightly to keep the magnet of the
magnel pulls the case from pulling the armature against it.
The COIl may be

damaged If the

:1!:1

REAR COVER

armature agamst
Install a new seal ring onto the motor case.
the case. Install the same number of shims in the same locations as noted during disassembly.
Install the rear cover while pushing the brushes int o
the brush holder and aligning the brush holder tab
with the motor case groove (aligning the index
lines).

Install a new seal ring ont o the motor case.
Install the shims and insulated washer onto the
armature shaft.

INSULATED

Apply grease to the dust seal lip and needle bearing
in the front cover.
Install the lock washer onto the front cover and the
front cover onto the motor case.

SHIMS

21-10

FRONT COVER

ELECTRIC STARTER
Al ign the index lines on the front cover and motor

case.
Install the set plates and new O-rings onto the
motor case bo lts.
Install the motor case bolts and tighten them.

INDEX LINES
BOLTS/SET PLATES

INSTALLATION
Coat a new C-ring with engine oil and install it into

the starter motor groove.
Apply molybdenum oil solution to the starter motor

shaft splines.

Set the water Install the starter motor into the rear crankcase
p ump bypass
hose properly
(page 1-24).

cover with the two mounting bolts and ground
cable, and tig hten the mounting bolts.
Install the starter motor cable and nut onto the
motor terminal and tighten the nut securely.
Install the rubber cap over the starter motor terminal properly.

Install the right eng ine side cover and tighten the

two bolts.
Connect the battery negative H cable.
Inst all the following:
- recoil starter cover (page 2-4)
- seat (page 2-4)

21-11

ELECTRIC STARTER

STARTER RELAY SWITCH
REMOVAL/INSTALLA TION
Remove the seat !page 2-4).
Slide the rubber caps off the starter relay switch ter-

minals.
Remove the nuts, battery positive (+) cable and
starter motor cable from the starter relay switch.
Remove the starter relay switch from the stay.
Installation is in the reverse order of removal.

INSPECTION
Remove the seat (page 2-4).
Shift the sub-transmission into neutral.
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", inspect the
relay switch using the procedure below.
Disconnect the starter relay 2P (white) connect or.

GROUND LINE

Check for continuity between the Light green/red
wire t erminal of the harness side connector and
ground.
If there is continuity w hen the sub-transmission is in
neutral or w hen the front brake lever is squeezed
and the sub-transmission is in any gear except neutral, the ground circuit is normal. (There is a slight
resistance due to the diode.)

21-12

ELECTRIC STARTER
STARTER RELAY VOLTAGE

Measure the voltage between the Yellow/red wire
terminal (+ ) of the harness side 2P connector and

ground H .
If the battery voltage appears only when the starter

switch is pushed with the ignition switch ON, the
circuit is normal.

OPERATION CHECK

Disconnect battery positive (+) cable and starter , - - - - - - - motor cable from the starter relay switch.

Connect the fully charged 12 V battery positive terminal to the Yellow/red wire terminal and negative

terminal to the light green/red wire terminal of the
relay switch side 2P connector.
There should be continuity between the cable terminals while the battery is connected, and no continuity when the battery is disconnected.

~~~~~S;TARTERRELAY
SWITCH

BATTERY

DIODE
INSPECTION
Remove the following:
-

seat (page 2~4)
fuel tank heat guard (page 8-6)

Remove the gear position (neutral) switch diode
and brake switch diode from the wire harness.

Check for continuity between the diode terminals.
When there is continuity, a small resistance value
will register.
If there is continuity in one direction. the diode is
normal.

GEAR POSITION
SWITCH DIODE

BRAKE S""'ITCH
DIODE

21-13

MEMO

22. LIGHTS/METERS/SWITCHES

COMPONENT LOCATION ........................ 22·2

FUEl GAUGE/
FUEl LEVEL SENSOR ········· ·· ················· 22· 15

SERVICE INFORMATION ·················· ······· 22·3
TEMPERATURE INDICATOR ................. 22· 17
ASSIST HEADLIGHT································· 22· 4
HEADLIGHT············································· ·· 22·5
TAIl/BRAKE LIGHT (' 05. ·06) ··················· 22·6
TAIl/BRAKE LIGHT (After ·06)················ 22·7
ACCESSORY SOCKET······························ 22·8
IGNITION SWiTCH ···································· 22·9
HANDLEBAR SWiTCH ···························· 22· 10
CARBURETOR HEATER ......................... 22· 11
CARBURETOR HEATER SWITCH ·········· 22· 12

ENGINE OIL TEMPERATURE (EOT)
SENSOR ................................ .................. 22·20
ENGINE COOLANT TEMPERATURE (ECT)
SENSOR ..................... ......... ...... .............. 22·21
REVERSE SWITCH ............... .......... ........ 22·22
GPS RECEIVER (GPS model only) ········ 22·23
BRAKE LIGHT SWITCH ................ .......... 22·25
FRONT BRAKE SWITCH ................ ........ 22·26
HORN SWITCH (U type only) ················ 22· 27
HORN (U type only)·· ····························· 22·27

COMBINATION METER/ REAR VEHICLE
SPEED SENSOR (VSS )··························· 22· 13

22-1

LIGHTS/METERS/SWITCHES

COMPONENT LOCATION

COMBINATION METER

HA"uc.e."H SWITCH
AUTO/ESP SWITCH

REVERSE SWITCH

FRONT BRAKE
(IN HI BITOR) SWITCH

EeT SENSOR

CARBURETOR HEA,TER

SPEED SENSOR

EOT SENSOR

22-2

REAR VEHICLE
SPEED SENSOR

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 recon necting.
• Check the banery condition before performing any inspection that requires proper battery vol tage.
• The following color codes are used throughout this section.

Bu : Blue
81 : Black
Sr: Brown

G: Green

Lg: Light Green

R:Aed

Gr; Gray
lb: Light Blue

0 : Orange

W: White
Y: Yellow

P: Pink

SPECIFICATIONS

--1
f~~======l=;;~~'T~E~M~~~ii~c=====~_I~~~~~~~~~~~~~~S~PE~c~'~F'gC~AT~lgO~N~S=====---------J
Bulb

12V • 30/3"O~WCifx,,2"---____
12V · 45 W

Headlight (high/tow beam)
Assist headlight

12V -2115 W2
t~B:"~k~.~h:a:;I:li9:h:t:}='~O~5i'~'O~6~_---==E========~
-+__________

After '06
Neutral in:~d~;~ca~t~o~'c-_ __ _ _ _
Reverse indicator
CoolanVoil temperature ind icator
4WO indicator
!--;;c:::::-_ _ _+ iEPS indicator (EPS model only,cl _ _
Fuse
Main fuse

LED

---iL~E~0c--_ _ __ _

_---===~

LED
LED
LED
-;L"'ECioc--_ _ _ _ _ _ __
30 A

t-_________

t:~~~a~n~'~m~;~"~;~o:n~c:o~n~"~o~l~m~o~t!o='======~================~~3~O~A~~~========~-

~ Sub-fuse

EPS fuse (EPS model only)

15Ax2~10Ax2

_ _--'-_ _ _ _ _ _ _ _ _40 A x ,

TORQUE VALUES
Engine oil temperature (EDT) sensor
Engine coolant temperature (ECT) sensor
Assist headlight case mounting nut

18 N-m (1.8 kgf-m , 131bf.fO
10 N-m (1.0 kgf-m, 7 Ibf.ft)
25 N-m (2.6 kgf·m, 19 Ibf.ft)

Apply sealant to the threads

TOOL
Inspection adapter
07GMJ-Ml80100

22-3

LIGHTS/METERS/SWITCHES

ASSIST HEADLIGHT
BULB REPLACEMENT
Remove the screw.
Release the four tabs of the assist headlight upper
cover from the slits in the front and lower covers.
Oisconnect the breather joint hose from the upper
cover and remove the cover.

HOSE

/~~

UPPER COVER

SUTS
Disconnect the assist headlight connector.
Remove the retaining ring by turning it counter·
clockwise and remove the bulb from the headlight.

BULB

Install a new bulb and removed parts in the reverse
order of removal.

RETAINING RING

REMOVALIINSTALLATION
Remove the assist headlight bulb (page 22-4).
Remove the two trim clips, 8 rnm nuts and the assist
headlight/meter bracket from the steering shaft.

SOCKET
BOLTS

FRONT COVER

Remove the two tapping screws, trim clips and the
headlight lower cover from the bracket.
Remove the two socket bolts and assist headlighU
front cover from the bracket.
Install the headlighVfront cover and removed parts
in the reverse order of removal.
TORQUE: 8 mm nut: 25 N ·m (2.6 kgf·m . 19 Ibf.tt)

LOWER COVER
TRIM CLIPS

22-4

LIGHTS/METERS/SWITCHES

HEADLIGHT
BULB REPLACEMENT
Remove the sc rew and headlight case cover cap.

Remove the dust cover.
Remove the bulb socket and bulb.

Install a new bulb in the case, aligning the bulb tab
with the case groove.
Install the bulb socket.

Install the dust cover with its tab facing left under

side.

22-5

LIGHTS/METERS/SWITCHES
Install the headlight cover cap while aligning its tab
with the headlight cover groove as shown.

InSl all and tighten the headlight case cover cap

screw.

1E~~mi~ci~liii

[

REMOVALIINSTALLATION
Remove the front side outer fender (page 2-13),

HEADLIGHT COVER

TRIM CLIP

Remove the screws, trim clip, bolt and headlight
cover/unit assembly.
Remove the headlight unit from the cover.
Installation is in the reverse order of removal.

SCREWS

BOLT
HEADLIGHT UNIT

TAIL/BRAKE LIGHT ('05, '06)
BULB REPLACEMENT
Remove the screw and taillight cover cap.

22-6

LIGHTS/METERS/SWITCHES
Turn the bulb sockel counterclockwise and remove
it.
Turn the taillight bulb counterclockwise wh ile pushing it in , then remove the bulb from the socket.
AI,gnthecovercap

tabs with the

Install a new taillight bulb in the reverse order of

removal.

grooves in the
cover proper/v_

REMOVALIINSTALLA TION
Remove the taillight bulb socket (page 22-6) ,

TAILLIGHT COVER

Remove the trim dips, screws and taillight cover.
Remove the taillight unit from the cover.
Align rhe bosses
and grommets
properly

Install the taillight in the reverse order of removal.

~0 ~

~T~A~IL=L~IG=H~T~U~N~IT

______

~S=C~R=EWS ~

TAIL/BRAKE LIGHT (After '06)
REMOVALIINSTALLATION
Open the storage box .
Push the tail/brake light assembly out of the storage
box lid.

GROMMETS

Disconnect the 3P black connector.
Replace the tail /brake light unit as an assembly.
AlIgn the bosses
8nd grommets
properly.

Install the tail /brake light in the reverse order of
removal.

BOSS
STORAGE BOX LID
TAIUBRAKE LIGHT

3P CONNECTOR

22-7

LIGHTS/METERS/SWITCHES

ACCESSORY SOCKET
INSPECTION
Remove the front fender (page 2-11).
Remove the accessory socket 2P (Black) connector
from the frame.
Measure the voltage between the Whitelblack (+)

and Green I- I wire terminals of the wire harness
side connector.
There should be battery voltage with the ignition
switch turned to ON.
tf there is no voltage, check for brown fuse (10 Al
and an open circuit in the wire harness.

Remove the accessory socket cap.

BOTTOM CENTER (White/black)

Check for continuity between the White/black wire
term inal of the socket side 2P (Natural) connector
and bottom canter 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.

SIDE WALL

REPLACEMENT
Remove the front fender (page 2- 1 1J.
Loosen the nut and remove the accessory socket
from the front fender.

NUT

COVER

Install the retainer by aligning the holes with the
cover tabs, then install a new accessory socket and
tighten the nut securely.
Roure the
accessory sad

83'1

CD
'-1
.j-I !j ®

-l:or

1lB.

'/'

23-9

SELECTABLE 4WD SYSTEM
2. Front Fin al Clutch Line Ope n Circuit Ins pection
Be careful not
to bend the

connector
terminals

Check the White/red and W h ite/black wires for
continuity between the ECM 21P (Black) and
front final clu t ch 2P (Green) connector terminals.

Is there continuity?
NO

_ . Open circuit in the White/red wi re .
• Open circuit in White/black wire.

YES

- GO TO STEP 3.

FINAL CLUTCH
CONNECTOR (Viewed
fr om the terminal side)

W/R

ECM CONNECTOR (Viewed
from the terminal side)

3. Fro nt Final Clutch line Short Circuit Insp ection
Check the White/red and White/black wi res for
continuity between the wire harness side clutch
2P (Green) connector terminals and g ro u nd.

Is there continuity?
YES

- . Short circu it in the White/red wire.
• Short circu it in White/black wire.

- GO TO STEP 4.

WIRE HARNESS SIDE FINAL
CLUTCH CONNECTOR (Viewed
from the terminal side)
-1'='1

4. Fro nt Final Clutch Inspection

Measure the resistance between the final clutch
side 2P (Green) connector terminals.

Is the resistance within 5. 1 - 5.8 Q (20 °CI 68°F)?
NO

- Faulty front final clutch.

YES

- Faulty ECM.

FINAL CLUTCH CONNECTOR
(Viewed from the termi nal side)

~---{ Q

23-10

W/BI

)-------'

SELECTABLE 4WD SYSTEM

REAR VEHICLE SPEED SENSOR (VSS)
REMOVAL
Disconnect the rear

vss 3P (Yellow) connector.

Remove the two bolts and front final clutch cover.

Remove the th ree front final clutch cover stay
mounting bolts and stay.
Release the rear VSS wire from the wire clamp.
Remove the front fina l clutch 2P (Green ) connector.

INSTALLATION
Install the front final clutch 2P (Green) connector.
Apply engine oil to a new O-ring and install it onto
the rear VSS.
Route the rear VSS wire into the front final clutch
cover slay and install the VSS.

23-11

SELECTABLE 4WD SYSTEM
Install the front final clutch cover stay onto the
clutch housing, then install and tighten the three
mounting bolts.

Clamp the rear VSS wire with the wire clamp.

Install the front final clutch cover onto the housing
while aligning its hole with the boss on the housing.
Install and tighten the two bolts.

Connect the rear VSS 3P !Yellow) connector.

23-12

24. HONDAMATIC

COMPONENT LOCATION ................. ....... 24-2

GEAR POStTIU'" ;:,on, I \,on ................. " .. 24·37

SERVICE INFORMATION ········ ················· 24-3

ESP SHIFT SWITCH ································ 24-38

CONNECTOR LOCATION···· ····················· 24-4

MODE SELECT SWITCH
('05· '08 only) .. ......................................... 24-39

CIRCUIT DIAGRAM ··································· 24-5
INITIAL SETTING PROCEDURE ............... 24-6
BEFORE STARTING
TROUBLESHOOTING ............................... 24-8

THROTTLE POSITION
(TP) SENSOR ...................... .................... 24-40
ANGLE SENSOR ·············· .. ··.. ···· .. ·········· 24-41
CONTROL MOTOR ····· .. ······ ··· .. ··············· 24-43

PROBLEM CODE INDEX ·························24-11
TROUBLESHOOTING ............................. 24-11

ENGINE CONTROL MODULE
(ECM) ...................................................... 24-44

24-1

HONDAMATIC

COMPONENT LOCATION

cm.e"'ATION METER

DRIVE MODE SElECT SWITCH

IGNITICINSWITCH

('05-'08 only)
AUTO/ESP SWITCH

(After '08 only)

ESP SHIFT SW'ITCH

GEARSHIFT

ENGINE CONTROL
M~UUIL.IECMI

THROTTLE posmC.N SENSOR
BATTERY

FRONT VSS
REAR VSS

AUTmMl"IIC TRANSMISSION
CONTROL MOTOA
GEAR POSITION SWITCH

ANI"LE SENSOR

IGNITION

24-2

HONDAMATIC

SERVICE INFORMATION
GENERAL
• This section covers service of the electrical system of the Hondamatic. The automatic transmission unit of the Hondamatic is mounted inside the crankcase. Removal/ installation of the aut omatic transmission is accomplished by separating the crankcase (page 13-8). Refer to page 13-6 if drive performance failure is caused by the mechanical system.
• Do not disassemble the automatic transmission unit. Replace the automatic transmission unit as an assembly when it is
faulty.
• Read "Before Starting Troubleshooting" carefully, and inspect and troubleshoot the Hondamatic system according to
the Troubleshooting. Observe each step of the procedures one by one. Note the problem code and related system
before starting diagnosis and troubleshooting .
• When the Engine Control Module (ECM) detects a problem with the Hondamatic system, it stops the automatic transmission function and the gear position indicator blinks ~--".
• After perlorming troubleshooting (including initial setting; 24-6). erase the problem code(s) and test-drive the vehicle to
be sure that the problem(s) has/have been removed .
• The ECM may be damaged if dropped. Also, if a connector is disconnected when current is flowing, the excessive voltage may damage the ECM. Always turn OFF the ignition switch before servicing .
• The following color codes used are indicated throughout this section .

Bu: Blue
Bl : Black
Br: Brown

G : Green
Gr: Gray
Lb: Light Blue

Lg: Light Green R: Red
0: Orange
W : White

P: Pink

Y: Yellow

TORQUE VALUES
Thronle position (TP) sensor
Angle sensor mounting bolt

3.4 N·m (0.3 kgf.m. 2.5 Ibf·ft)
6 N·m (0.6 kgf·m, 4.3 Ibf·ftl

TOOL
Peak voltage adapter
07HGJ-0020100

(not available in U.S.A.) with commercially available digital multi-tester Ompedance 10 Mil'DCV
minimum)

24-3

HONDAMATIC

CONNECTOR LOCATION
Refer to page 2·3 for the parts that must be removed for serviced.

For example :

_
_
vice

Front VSS 3P
- Inner fender

Electrical component
The parts that must be removed for sa,..

'OS, '06 shown :
ECM 5P (BLACK) - front
fender (page 2-11 )

ECM 21P (GRAY) - Front
fender
2-11 )

~~~~~f1I, ~;NI~:B"R SWITCH lOP or
DRIVE
SELECT
SWITCH 4P (BLACK) - Front
fender (page 2-11)
FRONT VSS 3P (BLACK)
-Inner fender (page 2-9)

REAR VSS 3P

METER 4P (YEllOW)Front fender (page 2- 11 )

f=bnrC~: THROTILE posmON SENSOR 3P (BLACK)

~~~~~~~~~i~~i~~

(YELlOW)~

- Inner fender (page 2-9 )

Front fender (page 2-11 )

14P (GREEN) (ESP SHIFT
SWITCH) - Front fender (page
2-11 )

Fuel tank cover (page 2-6)

CONTROL MOTOR 2P (NATURAL)
- Inner fender (page 2-9)

ANGLE SEI"S(lR 3P IBLACK)left engine side cover (page 10-5)

-;?-/~""~S'r:, ::';::::::t~;:::: GEAR POSITION SWITCH 4P -

~~~~~;~~~~~~~~~~

GROUND CABLE

24-4

(Engjne.to.F~"~m~')~~~~S~

Recoil starter cover (page 2-4)

~TEI""TOR5P INATURAL)Recoi l starter cover (page 2-4)

HONDAMATIC

CIRCUIT DIAGRAM

.,,'"

1M I fUll

'111111111
SlIT\II

••
•

Fft

(jill. $1(1' SlI1()1

(01·IfI'.IIIII;JIIJ

'"
••
"

....

••

.IjJ!(WUC_'lIi'lII
UJI'IIlIlI(.:
.~.

OL'

......

....

II.UTI.COIL

...
•

"Lilli

nmIllllA'I(IImr---,..-c~-----j,,.

vee,

Banery voltage

VB_M'- - - - + - Main b attery volt-

,, ,___I-,,,go

channell

Ratio voltage

Low sw itch
Neulra I switch
Revers e switch

SEl_UP

Selecto '"P
Selecto rdown

SEl~DOWN

FAN

FA_VWP

Vehicle speed sensor vol tage
Front V55 pulse

OIL TEMP -=

MODE
MAP
STOP

MO]

Motor power (..:)

""",,,",,-_~~v~o~ltage
RR_VWP
Rear V55 pulse
voltage

MO_M

COil

Ignition coil

STOP

Engine stop switch

=Final
=====:---'
clutch power

SWIT-:;C:;-H'---_ _

OND_P

1+1

L_SW
N5W
R_SW

Numbe r of engine
revolut ion
TPsen sor voltage

4WD switch

r- SGND 1

Drive switch

, VSP

IflliC/oJiI

~I------,

L~~~~iiii:'-T 4WD

RATIO

D_SW

-1------,

Jl'\U!l SlUOt?Jrr---O'"'""'~--

1-----+--'

24-5

HONDAMATIC

INITIAL SETIING PROCEDURE
• After removal/installation or replacement of any
of the following parts, perform the initial setting
below.

- ECM

- TP sensor
- Angle sensor

- Carburetor·
- Throttle cable
• Only if the TP sensor or throttle cable are disconnected from the carbu retor.
• The gear position indicator blinks in Indicator
mode 2 when the initial setting was not made
property. Repeat the procedure from the step 2.

INDICATOR MODE 2 BUNK DURATION :

.. ;

.. !

i ..

0.5 sec .
0.5 sec.

Patter n
repeated

INITIAL SETTING
Make sure 10 cfIedc
the OII/evel befOf6
executlflg the Ins/raj

Senmg procedure

1 . Start the engine and let it idle about 30 seconds

with the sub-transmission in the neutral.

2. Move the gearshift lever to the D position and
check that the gear position indicator shows ~ D ·.
3. Ride slowly forward for about 5 feet.
4. Move the gearshift lever back to the N position
and check that the gear position indicator shows

"N".

5. Turn the ignition switch OFF.

24-6

GNITION SWITCH

HONDAMATIC
6. On '05-'OS models only, move the drive mode
select switch to 01 or 02.

DRIVE MODE SELECT SWITCH

"'---""r-,I
\ OZ •
ES

7. Turn the ignition switch ON while pushing both
the UP and DOWN shih switches (ESP shih
switches) simultaneously (Do not release the
shift switches yet).
Wait a moment and check that the "NO, blinks at
the gear position indicator.
S. Immediately release both the UP and DOWN
shift switches, then push and release the shift
switches in the order of UP, DOWN and UP (Do
not hold onto the switch).
If rhe gear POSition
indicator shows rhe • A constant ~--- should be displayed on the gear
constam display of
position indicator.
'N' or the control • Usten for the control motor operation sound (t he
mo tor did nor cycle,
control motor should function at this time to
adjust the angle sensor).
tum the Ignmon
SWltdJ OFF and 9. Within 5 seconds of the display of ---" and while
repeat the
the control motor is operating , move the throttle
procedure from
lever from the fully closed position to the fully
step 7

L
UP

~N_

opened position, and then move it to the fully
closed position again.

-.-

THROTTLE LEVER

10.When the initial sening is complete, the indication on the gear position indicator changes from
the constant display of -._" to the constant display of "N."

GEAR POSITION INDICATOR

\
~@ I

oo® i'f"
@

•••
CI

83~

i/ - , I (Ii)

...'-I as,"
-!1
I ct_

24-7

HONDAMATIC

BEFORE STARTING
TROUBLESHOOTING
SELF-DIAGNOSTIC FUNCTION
OUTLINE
The engine control module (ECM) that controls the
Hondamatic system has a self-diagnostic function to
constantly monitor the system . The ECM checks the
condition of the Hondamatic system by detecting
the signals from each sensor, switch and control
motor when the ignition swit ch is ON and during

driving .
• When the ECM detects a problem, it indicates the , - - - - - - - - - - - - - - - - - ,
problem by blinking • __ at the gear position indiH

GEAR POSITION INDICATOR

cator.

•
•

Note how many times indicator blinki ng, determine the detection item (page 24- 11) and perform the troubleshooting (page 24-12).
,
Only one current prob lem code will be indicated
----~@
even if two or more problems occur.
Once the ECM detects a problem, it stores the
. .P
problem code in the erasable memory. It can be
@
indicated as freeze code by retrieval of problem
1< 1:1'
f) 83'1
Q/I,
code !page 24-9).
I ~
I
The shift function can be reset by turning the
ignition switch OFF and ON, but the shift control
stops when the ECM detects the problem again .
After performing troubleshooting (including ini- ' - - - - - - - - - - -- -- - - - ---'
tial setting; 24-6), erase the problem code(s) and
test·drive the vehicle to be sure that the problem(s) has/have been repaired.

@® I~ '

,-, !.1

J-I-

1 sec. ,

3 sec . . ' sec.
, ., "

-·-"ON
OFF ........... .

. .
.

_ _~.~

One Blink ,

•i

Current problem code
!Example: Blinking 3
times"" Problem code 3)

FAIL-SAFE FUNCTION
The ECM also has the fail·safe function to secure the
vehicle function.
When a problem occurs and the ECM detects the
problem in the Hondamatic system, the ECM stops
the automatic transmission shifti ng function and
control defaults to fail-safe mode so tha t the vehicle
can be still driven.

24-8

Pattern
repeated

CD
0

HONDAMATIC
RETRIEVAL/ERASURE OF PROBLEM
CODE
NOTE
• The ECM stores up to two problem codes and
displays the latest problem code first. and then
the earli er code alternately. When the two problem codes are displayed, perform troubleshooting starting with the latest code (i.e, the code
indicated first) ,

RETRIEVAL:
1. Put the gearshift leller in the neutral position (he , - - - - - - - - - - - - - - - - - - - ,
sure that the neutral indicator comes on) and
GEARSHIFT LEVER
turn the ignition switch OFF (vehicle at a stop).

2. Turn the ignition switch ON while pushing the
UP and DOWN shift switches (ESP shift switches)
simultaneously.

3. Release the UP and DOWN shift switches immediately, then push the UP and DOWN shift
switches simultaneously again for 2 seconds or

more.
4. The problem code is displayed by a number of
blinks -- " on the gear position indicator (page 24-

81.

\ J

If ~ N " stays on the gear position indicator, the
retrieval process was not correctly performed.
Repeat the procedures from step 1.

'GN'T'ON SWITCH

5. Note how many times indicator blinki ng , determine the detection item (page 24-11) and perform the troubleshooting (page 24-12).

I
If the gear position indicator blinks (in mode 1),
indicating a system failure before retrieving the
problem code, and the problem cannot be
retrieved by repeati ng the retrieval procedures,
perform the diagnostic troubleshooting of Problem code 3 or 7.

DOWN
INDICATOR MODE 1 BLINK DURATION

- : '- _
"--"ON

OFF

0.25 sec.

;-....;....- 0.25 sec.

.unU1-

Pattern
repeated

24-9

HONDAMATIC
PROBLEM CODe BLINK DURATION, (Indicating a problem code):

3 sec.

1 sec.

.. ..

"--"ON - - - - - ,

sec.

1 sec.

OFF

One Blink - -"- -••-

•

•
Earlier problem code
(Example: Problem code 4)

Latest problem code
(Example; Bli nki ng 3
ti m es = Problem code 3)

ERASURE:

1. Push the UP and DOWN shift switches simultaneously for 3 seconds or more while the problem
code is being displayed (i.e., "--" blinking on the
gear position indicator).

2. When the erasure is completed, the blinking pattern changes to the erasure confirmation blink .

3. Turn the ignition switch OFF.

DOWN
ERASURE CONFIRMATION BLINK DURATION (Indicating erasure of problem code) :

2 sec.

3 sec.

.. ..

3 sec .

•

"--"O N ------,

OFF

24-10

--------. ____

Pattern repea l ed

Panern
repeated

HONOAMATIC

PROBLEM CODE INDEX
Det ectio n item

TROUBLESHOOTING
• The connector location as shown on page 24-4.
• Perform inspection with the ignition switch
turned OFF, unless otherwise specified.
• Check the following befo re starting troubleshoot-

ing .
- Bansry voltage t12.3Vor m ore)

- Fuses
- Relevant connectors/components for water o r

loose contact
• After troubleshooting, erase the problem code
and test-d rive the vehicle t o be sure that the syst em Is norm al.
• When connecting the ECM connector, be careful

nol to enter the dust and dirt into the connector
inside.

PROBLEM CODE 1: IGNITION PULSE
GENERATOR SYSTEM
1. Ig nition Pulse Generator Connection Inspection
Check for loose or poor contact on the ECM 21P
(Black) connector.

24-11

HONDAMATIC
FAIFGA mod.l. only: Check for 10058 or poor
contact on the alternator 5P (Natural) connector.

Is there normal conditlonl
NO

- Loose or poor cont act on the ECM 21 P
(Black) connector and the alternator 5P
(Natural) connector

YES

- GO TO STEP 2.

FPA mod.' only: Check for loose or poor con·
tact on the EPS EeU 21P (Grav) A connector.

Is there normal condition?
NO

- Loose or poor contact on the ECM 21 P
(Black) connector and the EPS EeU 21P
(Gray) A connector

YES

- GO TO STEP 2.

2. Ground Cable Connection Inspection
Check for loose or poor camact on the ground

cable.
Is the connection no,,",,17
NO

- loose or poor con tact on the ground

YES

- GO TO STEP 3.

cable

3. Ignition Pulse Generator line Inspection/t EeM)
Short Circuit Inspection

FAIFGA model. only:
Turn the Ignit ion switch OFF.
Disconnect the ECM 21P !Black} connector and
the alternator 5P (Natural) connector.
Check for COnlinuity al the Bluelyellow wire
between the main harness side connectors.
I. th flre contInuIty'

24-12

- Open In wire between the ECM and
ignition pulse generator

YES

- GO TO STEP 4.

><
'----- BulV

----@-

BulV

HONDAMATIC
FPA model only:

Disconnect the ECM 21P (Black) and EPS ECU

EPS ECU 21P (GRAY) A CONNECTOR
(Viewed from terminal side)

21 P (Gray) A connectors.

Check for Violetlwhite wire continuity between
the wire harn ess side of the EPS ECU 21P (Gray)
A connector and the ECM 33P (Black) connector.

TOOL:

Pin probe (Male)

Oletlw~h:"~'~:+::;:;::=::::;~_---Qg

07ZAJ-ROJA 110

r-' .

Is there continuity'
NO

- Open in wire between the ECM and
ignition pulse generator

YES

- GO TO STEP 4.

4. Ignition

Pulse

Violet/white

"\:'
,: . ',+/ ' . . ,. , .

ECM 21 P BLACK CONNECTOR
(Viewed from t erminal side)

Generator

Peak

Voltage

Inspection/line (EeM) Short Circuit Inspection
FAIFGA models only:
Inspect the ignition pulse generator peak voltage
(page 20-5).

ECM 21P (BLACK) CONNECTOR
(Vi ewed from the terminal side)

<±l

Connection: Blue / yellow 1+) - Ground (-)

Standard:

0.7 V minimum

Is the voltage.s spBCifiBd7
NO

- Inspect the ignition pulse generator
(page 11-9)

YES

- GO TO STEP 5.

~ :~ D~

BuIV

PEAK VOLTAGE ADA:TOR

FPA model anI)':
Check for VioleUwhite wire continutiy between
the wire harness side of the EPS ECU 21P (Gray)
connector and body ground.
TOOL:
Pin probe (Male)

EPS ECU 21 P (GRAY) A CONNECTOR
(Viewed from terminal side)

07ZAJ-ROJA 110

- Short ci rcuit in the Violetlwhite wire

YES

- GO TO STEP 5.

Is there continuity?

A iXJ

V;OI'v:.:
5. System Failure Reproduction

Connect all connectors.
Test-ride the veh icle under the fo llowing condilions:
-

Gearshift lever in D range
FAIFGA model. only: Mode select switch at
ESP/1st
FPA model only: Auto/ESP switch at ESP
Driving for 2 seconds or more at over 3 mph
of vehicle speed

Is problem code 1 blink indicated?
NO

_. No problem (Temporary failure)
• Erase the problem code (page 24-9)

YES

- Faulty ECM . After replacement, perform
inilial setting procedure (page 24-6) _

GEAR POSITION INDICATOR

~® It ~'
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@

0-9

..
F

,-, 'II" 0
_'-1_:.1 :. ®
1<1

B3<

J;W

D.Il:r ".

8~
24-13

HONDAMATIC
PROBLEM CODE 2: VEHICLE SPEED
SENSOR (VSS) SYSTEM
1. Mechanica l System Inspection
Test-ride the vehicle with the gearshift lever in D , - - - - - - - - - - - -- - -- - ,
range.
GEARSHIFT LEVER
/

>--__-.(

Is it possible to ride?
NO

_ . Check the automatic transmISSion
mechanical system (page 13-6)
• Check the centrifugal clutch (page

10·9 )
YES

- GO TO STEP 2.

2. Speedometer Indication Inspection
Check the indication of the speedometer when , - - - - - - - driving at a low speed.

Is the indication accurate?

- Perform the troubleshooting of meter!
speed sensor (page 22- 13)

YES

- GO TO STEP 3.

3. VSS Connection Inspection
Check for loose or poor contact on the ECM 21 P
(Gray) connector.

Check f o r loose or poor contact on the rear VSS
3P (Yellow ) connector.

'Sthe connection normal?

24-14

- Loose or poor contact on the ECM 21P
(Gray) connector and the rear VSS 3P
(Yellow) connector

YES

- GO TO STEP 4.

HONDAMATIC
4. Rear VSS Input line Inspection
Turn the ignition switch ON.
Measure the voltage between the wire harness
side reaf VSS 3P (Yellow) connector terminal
and ground.

REAR VSS CONNECTOR
(Viewed from the terminal side)

=
,
II' I' ' I II

Connection : Black/orange (+J- Green/yellow H
Does the battery voltage exist?
NO

- Open or short circuit in the Black!
orange wire or Green/yellow wi re

YES

- GO TO STEP 5.

BIIO

GIY

~
CB 8

5. Rear VSS line Inspection
Be careful nor

10 bend the
connector
terminals.

Check the Pink/green wire for continuity
between the ECM 21 P (Gray) and rear VSS 3P
(Yel low) connecto r terminals.

Is there continuity?
NO

ECMCONNECTOR
(Viewed from the
terminal side)

- Open circuit in the Pink/green wire

between the ECM connector and rear
VSS connector
YES

- GO TO STEP 6.

REAR VSS
CONNECTOR
(Viewed from the
terminal side)

ffiEI
~

PIG

6. Rear VSS Line Short Circuit Inspection
Be careful nor

to bend the
connector
termmals

Check the Pink/green wire for continu ity
between the ECM 21P (Gray) connector terminal
and ground.
Check the Pink wi re for continuity between the
rear VSS side 3P (Yellow) connector terminal
and ground.
Is there continuity?

YES

_. Short circuit in the Pink/green wire
between the ECM connector and rear
VSS connector
• Short circuit in the Pink wire at the
rear VSS

- GO TO STEP 7.

•

PIG

1. Rear VSS Mechanical Inspection
Check the rear VSS for correct installation.
Remove the rear VSS (page 23-11), and check for
any object on the sensor tip or ring gear surface,
also check f or damage on the sen sor tip.
Is it installed certainly?

- Clean the rear VSS and ring gear, correctly install the rear VSS, or replace the
rear VSS

YES

- GO TO STEP 8.

24-15

HONDAMATIC
8. System Failure Reproduction
Connect all connectors.
Test-drive the vehicle under the following conditions:
-

Gearshift lever in 0 range

Mode select switch at ESP/1st
Driving for 2 seconds or more at over 7 mph
of vehicle speed
Is problem code 2 indicated?
NO

_ . No problem (Temporary failure)
• Erase the problem code (page 24-9)

YES

- Faulty ECM - After replacement, perform initial setting procedure (page 246)

PROBLEM CODE 3: GEAR POSITION
SWITCH SYSTEM
1. Gear Position Switch Connection Inspection
Check for loose or poor contact on the ECM 21 P
(Gray) connector.

Check for loose or poor contact on the junction
box.

Is the connection normal?

24-16

- Loose or poor contact on the ECM 21P
(G ray) connect or and the ju nction box

YES

- GO TO STEP 2.

GEAR POSITION INDICATOR

,--

~® ;

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--,

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08.

8--c

HONDAMATIC
2. Gear Position Switch line Inspection 1
Check for continui t y between each gear position
switch wire terminal of the ECM connector and
ground.

=..,..""'"""
;;:&:

•

DRIVE

NEUTAAl

,- "'"

REVERSE

Is there normal continuity?
NO

- GO TO STEP 3.

YES

- GO TO STEP 4.

G",

-•

3. Gear Position Switch line Inspection 2
Check for continuity between each terminal of
the switch side 4P connector and ground.

;;:&:

DRIVE

•

NEUTRAL

,- '''''

•

G",

REVERSE

Is there normal continuity?
NO

- . Faulty gear position switch
• Open or short circui t in engine subharness

YES

_ .

Open or short circuit in wire between
the ECM and junction box connector
• Open or short circuit in w i re between
the junction box and switch 4P con-

nector

4. Syste m Fa ilure Re production
Connect all connectors.

GEAR POSITION INDICATOR

Turn the ignition switch ON .

Check the gear position indicator.

Is problem code 3 indicated?

...,

_ . No problem (Temporary failure l
• Erase the problem code

~® ' r~\
®®
--

YES

- Faulty ECM - After replacement, perform initial setting procedure

9
0'-::::

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24-17

HONDAMATIC
PROBLEM CODE 4: THROTILE
POSITION (TP) SENSOR SYSTEM
1. TP Sensor Connection Inspection
Check for loose or poor contact on the ECM 21 P
(Gray) connector.

Check for loose or poor contact on the TP sensor
3P (Black) connector.

Is there normal condition?
NO

- Loose or poor contact on the ECM 21 P
(Gray) connector and the TP sensor 3P
(Black) connector

YES

- GO TO STEP 2.

2. TP Sensor Resistance Inspection 1
Measure the resistance at the TP sensor terminals of the sensor side.

Connection: Black/ red (+J - Green/vellow H

Is the resistance within 4.0 - 6.0 kfl(20"CI68 "F)7
NO

- Faulty TP sensor, perform initial setting
procedure after replacement (page 24-

YES

- GO TO STEP 3.

3. TP Sensor Resistance Inspection 2
Check that the resistance at the sensor terminals
varies with the throttle position while operating
the throttle lever.
Connection: Yellow / black (+) - Green / vellow
Standard : FullV close to FullV open
0.5 to 4.0 - 6.0 kO(20° C/ 60 F)

Y/SI

Is there normal condition and standard resistance?

24-18

- GO TO STEP 4.

YES

- GO TO STEP 5.

GfY

HONDAMATIC
4. TP Sensor Installation Condition
Check installation condition of the TP sensor

(page

24~40).

Is it installed certainly?
NO

- Install properly or replace the faulty part

YES

- Faulty TP sensor - After replacement,
perform initial setting procedure

5. TP Sensor Input Voltage In spection
Turn the ignition switch ON.
Measure the voltage between the wire harness
side connector terminal.
Connection: Black/red (+) - Green/yellow (-)

Is the voltage within 4.7 - 5.3 V7
NO

- GO TO STEP 6.

YES

- GO TO STEP 7.

6. TP Sensor Line Inspection 1

Turn the ignition switch OFF.

Disconnect the ECM 21 P (G ray) connector and
the TP sensor 3P (Black) connector.

GfY

Is there con tinuity?
NO

- Open in wire between the ECM and TP
sensor

YES

- Faulty ECM - After replacement, perform initial setting procedure (page 24-

BIIA

Check for continuity at the 81ackJred wire and
Green/yellow wire between the ECM connector
and sensor connector.

"'"

,I'

GiY,

,BIIR

7. TP Sensor line Inspection 2
Turn the ignition switch OFF.

;::::::;,

Disconnect the ECM 21 P (Gray) connector and
the TP sensor 3P (Black) connector.
Check for continuity on the Yellowlb lack wire
between the ECM connector and sensor connector.

Is there continuity?
NO

- Open in wi re between the ECM and TP
sensor

YES

- GO TO STEP 8.

VIBI

~
VIBI

db
24-19

HONDAMATIC
8. Syst em Failure Reproduction
Connect all connectors.

GEAR POSITION IN DICATOR

Turn the ignition switch ON .

Check the gear position i ndicator.

Is problem code 4 indicated?
NO
YES

_ . No problem (Temporary failure)
• Erase the problem code (page 24·9)
- Faulty ECM - After replacement, perform initial setting proced u re (page 24-

PROBLEM CODE 5: ANGLE SENSOR
SYSTEM (MOTOR LOCK)
1. Angle Sensor Co nnection Inspection
Check for loose or poor contact on the ECM 21 P
(Gray) and 5P (Black) connecto rs.

Check for loose o r poor contact on the angle sensor 3P connector.

Check for loose or poor con t act on the control
motor 2P (Natural) connector.

Is the connection normal?

24-20

- Loose or poor contact on the ECM connectors, the angle sensor 3P (Black)
connector and the control mot or 2P
(Natural) connector

YES

- GO TO STEP 2.

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12

"-,,,

- J'

0
0

8/,

HONDAMATIC
2 . Initial Setting Procedure
Perform initial setting procedure (page 24-6),
Is initial setting procedure completed?
NO

- GO TO STEP 4.

YES

- GO TO STEP 3.

3. ESP Shift Switch Operation Inspection
With the engine running , put the gearshift lever , - - - - - - - - - - - - - - - - - - - ,

in the 0 range and the mode select switch ESP,

and operate the shift switches to shift to each
speed range 1st through 5th.

Is it possible to operate?
NO

- GO TO STEP 4.

YES

_. No problem (Temporary failure)
• Erase the failure code (page 24-9)

DOWN
4. Control Motor Power Input Line Inspection

Turn the ignition switch OFF.
Disconnect the ECM 5P (Black ) connector.
Measure the voltage between the wire harness
side connector terminal.

Connection; Red /yellow (+1 - Ground (-)

Does the battery voltage exist?
NO

_ . Blown control motor fuse (30A).
• Open in wire between the ECM and
the battery

YES

- GO TO STEP 5.

5. Control Motor Ground Line Inspection
Turn the ignition switch OFF.
Disconnect the ECM 5P (Black) connector ,
Check for continuity between the wire harness
side connector terminal.
Connection: Green (+) - Ground H

Is there continuity?
NO

- Open in wire between the ECM and
ground

YES

- GO TO STEP 6.

24-21

HONDAMATIC
6. Control Motor line Inspection
Disconnect the ECM 5P (Black) connector and
the control motor 2P (Natural ) connector.
Check for continuity on the Green/red wire and
the Orange wi re between the ECM connector
and main harness side motor connector.

,--- G/R

-@---

G/R

Is there continuity?
NO

- Open in wire between t he ECM and the
control motor

YES

- GO TO STEP 7.
~

o--@--o

7. Control Motor Circuit Inspection
Disconnect the control motor 2P (Natural) con-

nector.
Check for continuity between the motor side
connector terminals.

Is there continuity?
NO

- Faulty control motor

YES

- GO TO STEP 8.

o
8. Control Motor Inspection
Be ex/remely
careful nor /0

Remove the control motor from the crankcase
(page 24-43).

diS/Off or apply
any force to the

grammetor

water may enter
the control
mowr.
Do nor usea
thin wire

because a large
amount of
current flows

24-22

Connect the battery directly to the control motor , - - - -- -- - - - - - - - - - - - - - - ,
side connector terminal and check whether the
control motor rotates.

Does the control motor rotate?
NO

- Faulty control motor

YES

- GO TO STE P 9.

-~-,o-EB

HONDAMATIC
9. Automa t ic Tra nsmission Operation Ins pection
Disconnect the angle sensor 3P (Black) connector.

Measure the resis t ance at the angle sensor connect or with the sensor installed in the crankcase.

Connection : Yellow/ blue (+) - Green/ yell ow H

Check angle sensor resistance and turn the
reduction gear in the direction as follows:
-

0.8 kO or below (locked at lower side): Turn
counterclockwise
1,2 kG or more (locked at high side) : Turn
clockwise

REDUCTION
Remove the control motor (page 24.43).
If the ball nut locks up, try to rotate the motor
shaft joint in the crankcase to move the ball nut .

• The ball nut of the automatic transmission
unit can strike the shaft end and lock up. This
is just a temporary symptom . In this case, be
sure that the motor shaft joint turns smoothly
after releasing it and recheck the indicator
blinking after erasing the problem code.
Is it possible to turn freely?
YES

- GO TO STEP 10.

- Fau lty aut omatic transmission unit

10. Angle Sen sor Resistance Inspect ion 1
Turn the ignition switch OFF.
Disconnect the ECM 21 P (Gray) connector.
Measure the angle sensor resistance at the ECM
21 P (Gray) connector (page 24-41) .
Connection : Blacklred (+J - Green/ yellow (-)

Is the r esist ance within 1.6 - 2.4 kil(2 0 °CI68 °F)?
NO

-GOTOSTEP11 .

YES

- GO TO STEP 12.

)

~
B'(R

24-23

HONDAMATIC
11 . Angle Sensor line Inspection 1
Disconnect the ECM 21 P (Gray) connector and
the angle sensor 3P (Black) connector.

~BlIA

Check for continuity on the Black/red wire and
the Greenlyellow wire between the ECM connector and main harness side angle sensor connector.

Is theTe continuity?
NO

angle sensor
YES

- Open in wire between the ECM and the

- Faulty angle sensor - After replacement, perform initial setting procedure
(page 24-6)

12. Angle Sen sor line Inspection 2

"""

BIIA

)

•I·

Disconnect the ECM 21 P (Gray) connector and
the angle sensor 3P (Black) connector.

Check for continuity on the Yellow/blue wire
between the ECM connector and main harness
side angle sensor connector.

Is there continuity?
NO

- Open in wire between the ECM and the
angle sensor

YES

- GO TO STEP 13.

13. Angle Sensor Input Voltage Inspection

Y/Bu

.Q
~

Y/Bu

1ft}

-------'

Turn the ignition switch ON.
Measure the voltage between the wire harness
side connector termi nal.
Connection: Blacklred (+) - Green/ yellow H

Is the lIoltage within 4.7 - 5.3 V7
NO

- Faulty ECM - After replacement, perform initial setting procedu re (page 24-

YES

- GO TO STEP 14.

14. Angle Sensor Resistance Inspection 2
Remove the angle sensor (page 24-42).
Check that the resistan ce at the angle sensor terminal va ries while turning the sensor joint.
Connection: Yellow/ blue (+) - Green/ yellow H
Standard: 0 to 1.6 - 2.4 kn(2 0~ C /60~ F)

Is there normal condition and standard resistance7

24-24

- Faulty angle sensor - After replacement, perform initial setting procedure.

YES

- Fau lty ECM - After replacement, perform initial setting procedure.

JOINT

HONDAMATIC
PROBLEM CODE 6: ANGLE SENSOR
SYSTEM IAUTOMATIC TRANSMISSION SWASH PLATE ANGLE)
1. An g le Sensor Connection Inspection

Check for loose or poor contact on the ECM 21P
(Gray) connector.

Check for loose or poor contact on the angle sensor 3P (Black) connector.

Is there normal condition?

- loose or poor contact on the ECM connector and the angle sensor connector

YES

- GO TO STEP 2.

2. Angle Sensor Resistance Inspection 1
Turn the ignition switch OFF.
Disconnect the ECM 21P (Gray) connector.
Measu re the angle sensor resistance at the ECM
21P (G ray ) connector.

Connection: Blacklred 1+1 - Green / yellowl- )
Is the r8sistance within 1.6 - 2.4 kfJ(20 a CI68 °F}?

- GO TO STEP 3.

YES

- GO TO STEP 4.

SI/A

24-25

HONDAMATIC
3. Angle Sensor line Inspection 1
Disconnect the ECM 21 P (Gray) connector and
the angle sensor 3P (Black) connector.
Check for continuity on the Black/Red wire and
the GreenIYeliow wire between the ECM connector and main harness side angle senSor connec-

tor.

Is there continuity?
NO

- Open circuit in wire between the ECM
and angle sensor

YES

- Faulty angle sensor - After replacement, perform initial setting procedure
(page 24-6)

~BI/R

~~
=

BI/R

I 1. 1. 11

IIIJ

4. Angle Sensor line Inspection 2
Disconnect the ECM 21 P (Gray) connector and
the angle sensor 3P (Black) connector.

Check for continuity on the Yellow/blue wire
between the ECM connector and main harness
side angle sensor connector.

Is there continuity?
NO

- Open in wire between the ECM and
angle sensor

YES

- GO TO STEP 5.

Y/Bu

~
Y/Bu

c:fb
5. Angle Sensor Input Voltage Inspection
Measure the voltage between the wire harness
side connector terminal.
Connection: Black/ red !+) - Green /yellow H

Is the voltage within 4.7 - 5.3 V7
NO

- Faulty ECM - After replacement, perform initial setting procedure (page 24·

6)
YES

- GO TO STEP 6.

6. Angle Sensor Installation Condition
Check installation condition of the angle sensor
(page 24-41).
Is it instaffed correctly?

24-26

- Install properly (page 24-42) or replace
the faulty part

YES

- GO TO STEP 7.

HONDAMATIC
7. Angle Sensor Resista nce Ins pection 2
Remove the angle sensor (page 24-41 ).
Check that the resistance at the angle sensor terminal varies while turning the sensor joint.
Connection: Yellow/blue (+1- Green/ yellow f-)

Standard:

0 to 1.6 - 2.4

kn(20° C/60~

JOINT

Is there normal condition and standard resistance?
No

- Faulty angle sensor - After replacement, perform initial setting procedure
(page 24-6)

YES

- GO TO STEP 8,

8. System Failure Reproduction

Install the angle sensor and connect all connec- , - - - - tors.
GEAR POSITION INDICATOR

Turn the ignition switch ON.

Check the gear position indicator.

Is the problem code blink indicated?
NO

_ . No problem (Temporary failure)
• Erase the failure code (page 24-9)

YES

- Faulty ECM - After replacement, perf orm initial setting procedure.

r@j)@

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PROBLEM CODE 7: ESP SHIFT SWITCH
SYSTEM
1. ESP Shift Switch Connection In spection
Check for loose or poor contact on the ECM 21P
(Black) connector.

24·27

HONDAMATIC
'05, '06.

Check for loose or poor contact on the handlebar

switch lOP !Green) connector.
Aller '06

Check for loose or poor contact on the handlebar
switch 14P (Green) connector.

Is the connection normal?

- Loose or poor contact on the ECM 21 P
(Black) connector and the handlebar
switch lOP (Green) connector

YES

- GO TO STEP 2.

2. ESP Shift Switch line Inspection (ECM s ide)
Check for continuity at the ECM 21P (Black) connector terminals in each shift switch position
(page 24·38).

Position

WhiteJ
blue

Black!

while!

yellow

Black!

U,
Free
Dow"
L

_________

Is there normal continuityl
No

- GO TO STEP 3.

YES

- GO TO STEP 5.

3. ESP Shift Switch Condition Inspection
Remove the handlebar switch (page 14-7).

Check for waler, mud and other foreign material
inside the switch.

Is the condition normal?
NO

- Clean inside the switch

YES

- GO TO STEP 4.

DOWN

24-28

HONDAMATIC
4. ESP Shift Switch Inspection (Handlebar switch
side )
'05,

'(16

After '06

Check for continuity
(Green) connector in
STEP 2 (page 24-28),
Check for continuity
(Green) connector in
STEP 2 (page 24-28).

at the switch side lOP
the same manner as the
at the switch side 14P
the same manner as the

Is there normal continuity?
No

- Faulty handlebar switch (shift switch)

YES

- Open or short circuit in wire between
the ECM and the shift switch

5. System Failure Reproduction
Connect all connectors.
Turn the ignition switch ON .

GEAR POSITION INDICATOR

Check the gear position indicator.

Is problem code 7 indicated?
NO

_ . No problem (Temporary failure)
• Erase the failure code

YES

- Faulty ECM - After replacement, perform initial setting procedure .

~®
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----

PROBLEM CODE 8: ECM EEPROM
(WRITING/READOUT CIRCUIT)
1. Initial Setting Procedure
Perform initial setting procedure (page 24-6).
Turn the ignition switch OFF and ON .

GEAR POSITION INDICATOR

Check the gear position indicator.
Is the problem code blink indicated?
NO
YES

_ . No problem (Temporary fai lure)
• Erase the failure code
- Faulty ECM - After replacement, perform initial setting procedure.

~®

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@
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IT'
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24-29

HONDAMATIC
PROBLEM CODE 9.10. 12: ECM VOLTAGE CONVERTER CIRCUIT. ECM FAILSAFE RELAY CIRCUIT. ECM CPU
1. System Failure Reproduction
Turn the ignition switch OFF and ON.
Check the gear position indicator.

GEAR POSITION INDICATOR

Is II problem code indicated?
NO

YES

_ . No problem (Temporary failure)
• Erase the failure code (page 24-9)

- GO TO STEP 2.

-!1

2. Retrieval of Problem Code
Retrieve the problem code again and check
(page 24·9) .

Is II problem code indicated?
NO

- Perform the necessary diagnostic trou bleshooting of the output problem code

YES

- Faulty ECM - After replacement, perform initial setting procedure (page 24-

PROBLEM CODE 11: ECM MOTOR
DRIVER CIRCUIT
1. ECM fControl Motor Connection Inspection
Check for loose or poor contact on the ECM 5P
(Black) connector.

Check for loose o r poor contact on the con trol
motor 2P (Natural) connector.

Is the connection normal?

24-30

- Loose or poor contact on the ECM connector and the control motor connector

YES

- GO TO STEP 2.

"""

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CD
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,8~
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HONDAMATIC
2. Control Motor Power Input line Inspection
Turn the ignition switch OFF.
Disconnect the EeM 5P (Black) connector.
Turn the ignition switch ON.
Measure the voltage between the wi re harness
side connector terminal and ground.

RN~

Connection: Red/ yellow (+1- Ground H

Is the voltage llV or above?
NO

- Open in wire between th e EeM and the
battery

YES

- GO TO STEP 3.

3. Control Motor Ground line Inspection

Disconnect the EeM 5P (Black) connector .
Check for continu ity between the wire harness
side connector terminal and ground.
Connection : Green (+) - Ground

1-1

Is there continuity?
NO

- Open in wire between the EeM and
ground

YES

- GO TO STEP 4.

4. Control Motor line Inspection
Disconnect the EeM 5P (Black) connector and
the control motor 2P (Natu ral) connector.
Check fo r conti nuity on the Green/red wire and
the Orange wire between the ECM connecto r
and main harness sid e motor connector .

G/ R

--@---

G/R

Is there continuity?

- Open ci rcu it in wi re between the ECM
and contro l m otor

YES

- GO TO STEP 5.

O---@-O

5. Control Motor Circuit Inspection
Disconnect the control motor 2P (Natural) connector.
Check fo r con tinuity between the motor side
connect or termina ls.

Is there continuity?
NO

- Faulty control motor

YES

- GO TO STE P 6.

24-31

HONOAMATIC
6. System Failure Reproduction
Connect all connectors.

GEAR POSITION INDICATOR

Turn the ignition switch ON .

Check the gear position indicator.

'S problem code 12 indica ted ?
NO
YES

_ . No problem (Temporary failure)
• Erase the failure code (page 24-9)
- Faulty ECM - After replacement, perform initial setting procedure (page 246)

PROBLEM CODE 13: MODE SELECT
SWITCH SYSTEM (01, 02 AND ESP)
, . Mode Select Switch Connection Inspection
Check for loose or poor contact on the ECM 21 P
(Black) connector.

Check for loose or poor contact on the mode
select switch 4P (Black) connect or.

Is the connection normal?
NO

- Loose or poor contact on the ECM connector and the mode select switch con-

nector
YES

24-32

- GO TO STEP 2.

r
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@

,,9

"'r, !1
.

•••

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rI
LI

':1'

a8.

--,

HONDAMATIC
2. Mode Select Switch line Inspection

Turn the ignition switch OFF.
'05·'08 model shown

Oisconnect the ECM 21 P (Black) connector
Check for continuity ECM 21P (Slack ) connector
terminals of the wire harness side with th e mod e
select switch in each mode position
Orange
~r
Position

Green

Bradd
green

Blue!
orange

01
02

ESP
Is there normal continuity?
NO

- GO TO STE P 3.

YES

- GO TO STEP 4.

3. Mode select Switch
switch side)

In spection

(Ha ndleba r

Disconnect the 4P (Black) connector.
Check for continuity at the mode select switch
side 4P (Black) connector in the same manner as
the STEP 2 (page 24-33)
Orange
~r
Position

Blue!

blact:

Siadt!
green

'05·'08 model shown

Green

01
02

-0

ESP
Is there normal continuity?
NO

- Faulty mode select switch

YES

- Open or short ci rcuit in wire between
the ECM and the mode select switch

4. System Failure Reproduction
Connect all connectors.
Turn the ignition switch ON.
Check the gear position indicator.

GEAR POSITION INDICATOR

Is problem code 13 indicated?
NO

_ . No problem (Temporary failure)
• Erase the failure code (page 24·9)

YES

- Faulty ECM - After replacement, perform
initial setting procedure (page 24-6)

24-33

HONDAMATIC
PROBLEM INDICATED (MODE 1), BUT
NO CODE IS RETRIEVABLE
Gear position indicator blinks indicating a problem,
but the problem code is not displayed by the
retrieval procedu re:
1. Automatic Transmission Inspection
Check the aut omatic transmission shift perfo rmance.

'05-'08 model shown

Note the position of the mode select switch at

the time the 8utomatic transmission does not
shift.

02 ..

"01 " or " D2"-Perform troubleshooting of prob-

lem code 3 (gear position switch sys-

t8m) (page 24-16).

" ESP" - GO TO STEP 2.

MODE SELECT SWITCH

2. System Failure Reproduction
Turn the ignition switch ON.
Check the gear position i ndicator.

GEAR POSITION INDICATOR

Is there the gear position (D, L. N, RJ indication?
NO

YES

- Perform troubleshooting of problem
code 3 (gear position switch system)
(page 24-16)

- Perform troubleshooting of problem
code 7 (ESP shift switch system) (page
24-27)

@®
@

08
'-

PROBLEM NOT DETECTED BY ECM
Gear position indicator does not blink to notify a
problem and the problem and the problem code is
not recorded: Faulty gear position indicator and/or
drive mode indicator (No indication/Stuck indication/Incorrect indication)
• See page 22-13 for the meter fu nction problems
(except for the gear position indicator and drive
mode indicator).
1. Meter Connection Inspection
Check for loose or poor contact on the ECM 21 P
(Gray) connector.

24-34

•••

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f> S3'f

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m",

:.J

:£1-

118. "

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CD

HONDAMATIC
Check for loose or poor con tact o n the combination meter 14P (G ray) connector, gear position
switch 4P (Natural) connector and mode select
switch 4P (Black) connector.

GEAR POSITION INDICATOR

Is the INDICA TOR MODE 1 blink indicated?

- Loose or poor contact on the ECM connector, combination meter connector,
the gear position switch connector and
the mode select switch connector

YES

@®
@

-08

- GO TO STEP 2.

'i® .- '- \
•••
0 83'1

,-, !.1
... 1../
;,1_
D.8lt il

0
0

2. Gear Position Switch line Inspection 1
Check for continuity between each gea r position
switch wire terminal of the ECM connecto r and
ground .

' u,

,- "'"

-,~

DRIVE

NEUTltAl

•

REVER SE

•
•

•

-. .. •

Is there normal continuity?
NO

- GO TO STEP 3.

YES

- GO TO STEP 4.

3. Gear Position Switch Line Inspection 2
Check for continuity between each terminal of
the switch side 4P connector and ground .

DRIVE

NEUTRAL

•

REVERSE

'.'

•
,

•

15 there normal continuity?
NO

_ . Faulty gear position switch
• Open o r short circuit in engine subharness

YES

- .

Open or short circuit in wire between
the ECM and junction box connector.
• Open or short circuit in wire between
the junction box and switch 4P connector.

24-35

HONDAMATIC
4. Mode Select Switch Line Inspection
Turn the ignition switch OFF.
Disconnect the ECM 21P (Black) con nector
Check for continuity ECM 21P (Black) connector
t erminals of the wire harness side with the mode

select switch in each mode position.

Orange

Bluel

blade:

Position

Black!
green

Green

01
02
(>

ESP
Is there normal continuity?
NO

- Replace the mode select switch

YES

- GO TO STEP 4.

5. Mode Select Switch line Inspection !Handlebar
switch side)
Check for continuity at the switch side 4P (Black)
connector in the same manner as the STEP 4

(page 24-36).

Is there continuity?
NO

- Faulty mode select switch

YES

- Open o r short circuit in wire between
the ECM and the mode select switch

6. M et er Line Inspection
Turn the ignition switch OFF.
Disconnect the ECM 21 P (Gray) connector, combination meter 4P (Yellow) con nect o r and the
combina tion met er 14P (G ray) connector.
Check for continuity on each wire between the
ECM connector and main harness side meter
connector in the same wire color terminals.

Is there continuity?

24-36

- Open in wire between the ECM and
combination meter

YES

- GO TO STEP 7.

'05-'08 model shown

HONDAMATIC
7. Meter Line Short Circuit Inspection

Connect the ECM 21 P (Gray) connector.
Put the gear shih lever in the D range and the

mode select switch al ESP.
Turn the ignition swit ch ON.
Check for continuity between each of the wire
terminals of main harness side combination
meter 4P (Yellow) and 14P (Gray) connector and
the frame ground.

Is there continuity at the Blue wire and Light
blue wire only?
NO

- Faulty combination meter

YES

- Faulty ECM - After replacement, perform initial setting procedure (page 24-

G
t

BulW
P/Bu

VIO

GEAR POSITION SWITCH
INSPECTION
Turn the ignition switch OFF.
Disconnect the ECM 21 P (Gray) connector.
Check for continuity between each gear position
switch wire terminal of the ECM connector and
ground.
There should be continuity only at the terminals that
correspond to the gear positions shown below, and
there should be no continuity at the other terminals.
You must test each of four wires in each gear position. Therefore, you need to make 16 tests, between
each gear position switch wire terminal and ground .

~.
~

cow
DRIVE
NEUTRAL

•

REVERSE

•

"'"

,
,

•

•
"

G,"

•

If the continuity is abnormal, disconnect the gear
position switch 4P (Natural) connector, and check
for continuity between each terminal of the switch
side 4P connector and ground in the same manner
as the prev ious step .
• If the continuity at the ECM is abnormal and continuity at the 4P connector is normal, check for
open or short circuit, or loose or poor connector
contact .
• If the both continuities are abnormal, replace the
gear position switch .

24-37

HONDAMATIC
REPLACEMENT
Shift the sub· transmission into neutral.
Remove the two bolts and gear position switch from
the crankcase cover.
Remove the D-ring.
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.

ESP SHIFT SWITCH
• The automatic transmission can shift and the
meter indicates the shift posit ion (1 through 5)
with the following conditions:

- Mode select switch at ESP (Electric Shift Program)
- Gearshift lever (Sub-transmission) in 0 range
- Engine is running

INSPECTION
Turn the ignition switch OFF.
Disconnect the ECM 21P (Black) connector.
Check for continuity between the ECM connector
terminals in each switch position.
Continuity should exist between the color coded
wires as follows:

Position

White1
blue

BlacIJ

white1
yellow

Black!

Free
Down

'05. '06.

If the continuity is abnormal, remove the handlebar
switch 10P (Green) connector from the frame and
disconnect it.

After '06.'

If the continuity is abnormal, remove the handlebar
switch 14P (Green) connector from the frame and
disconnect it.
Perform the inspection at the lOP (Green) connect or
in the same manner as the previous step.
• If the continuity at the EeM is abnormal and continuity at the lOP (Green) connector is normal,
check for an open or short circuit, or loose or
poor connector contact.
• If the both continuities are abnormal. replace the
handlebar switch (shift switch) (page 14-7).

24-38

HONDAMATIC

MODE SELECT SWITCH ('05-'08 only)
INSPECTION
Turn the ignition switch OFF.

Disconnect the ECM 21 P (Black) connector.

Check for continuity between the ECM connector
terminals in each switch position .
Continuity should exist between the color coded
wires as follows:

~r Orange

Position

Bluel
blado::

81ackJ

green

Green

01
01

ESP
If the continuity is abnormal, disconnect the mode
select switch 4P (Black) connector, and perform the
inspection at the 4P (Black) connector in the same
manner as the previous step .
• If the continuity at the ECM is abnormal and continuity at the 4P connector is normal. check for an
open or short circuit, or loose or poor connector

contact .
• If the both continuities are abnormal, replace the

mode select switch.

REPLACEMENT
Remove the handlebar cover (page 14-7).
Remove the screw.
Remove the mode select switch from the cover
while pushing in the stoppers.
Install the new switch by aligning the locating tab
with the groove in the cover.
Install and tighten the screw.

24-39

HONDAMATIC

THROTTLE POSITION (TP) SENSOR
REMOVAL/ INSTALLATION
NOTE:
• Do not loosen the throttle position sensor anach-

ing shear bolts unless the throttle position sensor requires replacement. It may cause the
sensor to move oul of position. For sensor
replacement, see page 24-40.

Remove the fuel tank cover (page 2-6),

Disconnect the throttle position sensor connector.
Remove the two sensor bracket screws, and TP sensor and bracket as an assembly.

Install a new O-ring onto the carburetor body,
Improper Install a new TP sensor assembly by aligning the
mstallanon can tabs of the sensor with the flat of the shaft as
cause damage to shown .
the TP sensor Install the screws and tighten them.
Connect the sensor 3P connector.

Install the removed parts in the reverse order of
removal.

REPLACEMENT
Remove the fuel tank cover (page 2·6).
Remove the two sensor shear bolts and TP sensor.

Install a new a-ring onto the sensor bracket groove.
Improper
insrallatlOn can
cause damage ro
the TP sensor

Install the TP sensor by aligning the tabs of the sen·
sor with the flat of the shaft as shown.

:It

O-RING _ _ _ _~Q

Loosely install the new shear bolts.

Align

24-40

HONDAMATIC
Check the engine idle speed and adjust it if necessary (page 3-15),
Adjust the TP sensor position so that the resistance
between terminals A and 8 IS 580 - 620 D, and
lighten the shear bolts until the bolt heads break off.
Connect the TP sensor connector.
Perform the initial setting procedure (page 24-6 ).
Install the removed parts in the reverse order of I~i.::~~~:::~
removal.
~

ANGLE SENSOR
INSPECTION
SENSOR RESISTANCE

Turn the ignit ion switch OFF.

Disconnecl lhe angle sensor 3P connector.
Measure the resistance at the angle sensor 3P con-

nector .
Connection : Black/ red (+) - Green l Veliow H
Standard:

1.6 - 2.4 kO (20° C/ 68" F)

Clean arou nd the sensor base with compressed air
before removing the angle sensor.
Remove the two socket bolts and angle sensorl
brackel assembly.

Check that the resistance at the angle sensor l ermi ·
nal varies whi le turning the sensor joi nt.

~~~~~~~~~~~~~~~~~~~~
JOINT

The resislance should change smoolhly as follows.
Connection: Yellow/ blue 1+1- Green / yellow H
Standa rd : 0 t o 1.6 - 2.4 k n (20~ C/ 60° F )

r
G/Y

Y/Bu

24-41

HONDAMATIC
REPLACEMENT
Remove the leh engine side cover (page 10-5),
Clean around the sensor base with compressed air
before remolling the angle sensor.
Disconnect the sensor 3P connector.
Remove the two bolts, washers and angle sensor
from the crankcase.

Install a new O-ring onto a new angle sensor.
Never allow foreign
rmJlenals (dust.
wa ler. oIl ercl to

Clean the sensor shaft, sensor joint and crankcase
base cavity, and be sure that no foreign material is
allowed.

gel mlo the Align the tabs of the sensor with the flat of the senclearance between
sor joint and set the angle sensor onto the crankthe sensor shaft
case in the position as shown.
and sensor JOmt

SENSOR PRELOAD
Turn the sensor clockwise to align the bolt holes in
the sensor bracket with the bolt holes in crankcase.

ANGlESENSOR ~~~==~~--------

Apply locking agent to the threads of the sensor
bolts.
Install the washers and bolts, then tighten them.
TORQUE: 6 N 'm (0.6 kgf·m. 4.3 Ibf.tt)
Connect the sensor 3P (Black) connector.
Perf orm the initial setting procedure if the angle
sensor is replaced (page 24.6 ).
Install the removed parts in the reverse order of
removal.

24-42

HONDAMATIC

CONTROL MOTOR
REMOVALfINSTALLATION
Remove the inner fender (page 2·9).
Disconnect the control motor 2P (Natural ) connec-

tor.

Remove the left engine side cover (page 10-5).
Remove the two mounting boils and control motor.

Coat a new O-r ing wi t h engine oil and install it into
the control motor groove.
Apply molybdenum oil solution to the motor shaft
splines and install the control motor into the front
crankcase cover by aligning the boll holes.

Install the mounting bolts and lighten them.

24-43

HONDAMATIC
Do not fort}6! to
securelhe w,r8S
WIth the clamp

Route the motor and angle sensor wires properly
(page '·24) and connect the mOlor 2P (Natural) cannector.
Install the removed parts in the reverse order of
removal.

ENGINE CONTROL MODULE (ECM)
REMOVALIINSTALLATION
Remove the front fender (page 2-11).
Disconnect the ECM 21P (Black), 21P (Gray) and 5P
(Black) connectors.
Remove the ECM/holder from the stay.

Installation is in the reverse order of removal.

24-44

25. ELECTRIC POWER STEERING (EPS)

COMPONENT LOCATION ........................ 25-2

TROUBLESHOOTING INDEX ......... ....... 25-15

SYSTEM DIAGRAM ...................... ............ 25 -3

SYMPTOM TROUBLESHOOTING
INDEX ················· ····································· 25-17

EPS CONNECTOR LOCATION ................. 25-4
DTC TROUBLESHOOTING .................... 25-18
SERVICE INFORMATION ......................... 25-7
SYMPTOM TROUBLESHOOTING ......... 25-34
GENERAL TROUBLESHOOTING
INFORMATION ········································· 25-8

EPS ECU REPLACEMENT ...................... 25-37

25-1

ELECTRIC POWER STEERING (EPS)

COMPONENT LOCATION

EPS INDICATOR
ElECTRIC POWER STEERING
ELECTRONIC CONTROL UNIT (EPS ECU)
ENGINE CONTROL
MODULE (ECM )

DATA LINK CONNECTOR (OLe)

,
,

TORQUE SENSOR

REAR
I
speED
SENSOR (REAR VS SENSOR)
CRANKSHAFT POSITION
SENSOR (CKP SENSOR )

25-2

EP$ MOTOR

ELECTRIC POWER STEERING (EPS)

SYSTEM DIAGRAM

40A

~_ _ _ R _ _

BATIEAY

MAIN

IGNITION

IGN

30A

SWITCH

l OA8(31) (32k:,

"7 IGI

EPS INDICATOR

COMBINATION

-------'J

..S Cl

;

,: t---~~- G""" , A5 WLP

METER

4WO INDICATOR e( 15

'-__

~_ "eN

,
,

All 4WOtNOO

J
M-

AI24'M)INOl

D==
I I

@(22)(23)TORQUE

SENSOR

AEAA

vs SENSOR

eKP
SENSOR

VIR

GK>

Al VSt
A3 VS2
A2 TIS GNO

EPS ECU
M_ B2

!1 (11)(24) PJG

A17 VSP

1-9=,',,'::'":.;:4, """

.4.19 NEP

L _ _-'.

•

8(13)(14)
(18) (21)

PG C2

NEGNO
ECM

EPS

MOTOR

rL9""',-",,,".::""'

,eN

A20 NEP2

61 (13)(16)
(17)(18)
(33) (35)

DLe~~

A14 K-LiNE

"9 SCS

...L
A14

EPS ECU

BI BlACK
Y YELLO'N

BI.I BlUE

G GREEN
W WHITE
Lg LIGHT GREEN

6r BflOWN
0 OflANGE
A REO
P PINK
Gr GRAY

V VIOlET

Bl A21

'15

25-3

ELECTRIC POWER STEERING (EPS)

EPS CONNECTOR LOCATION
FRONT CONNECTOR LOCATIONS
Note 1:
Note 2:
Note 3:

Remove the front fender.
Remove the right inner fender.
Remove the left inner fender.

ECM 21P GREY
CONNECTOR (NOle 1)
METER 4P GREEN

CONNECTOR (Note 1)

I .

'. j ,
",
, , •
·

METER 14P GRAY
¥

~:.-ri\'- CONNECTOR (Note 1)

· .

ECM 21P BLACK
CONNECTOR (Nole 1)

EPS ECU 2P BROWN
C CONNECTOR (Nota 2)

EPS ECU 2P GRAY
8 CONNECTOR (Note 2)

25-4

EPSECU21PGRAY
A CONNECTOR (Note 2)

(\ ' ,
"."<-.

ELECTRIC POWER STEERING (EPS)

EPS MOTOA 2P
CONNECTOR (Note 3)

TORQUE SENSOR 3P
CONNECTOR (Note 3)

REAR VS SENSOR 3P YEllOW
CONNECTOR (Note 3)

25-5

ELECTRIC POWER STEERING (EPS)
MIDDLE/REAR CONNECTOR
LOCATIONS
Note 1:

Behind the rear fender

ALTERNATOR 5P NATURAL
CONNECTOR (Note 1)

25-6

ELECTRIC POWER STEERING (EPS)

SERVICE INFORMATION
GENERAL
• This section covers the diagnosis and service for electric parts of Elect ric Power Steering (EPS) system. To service the
EPS unit refer to steering shaft service procedu re (page 13-34).
• Before disconnecting any connector of the EPS system, always turn the ignition switch OFF and disconnect the negative
cable from the battery.
• The following color codes are indicated throughout this section.
81: Black
Sr: Brown

Bu: Blue

G: Green
Gr: Gray
Lb: Light blue

Lg: Light green
0: Orange
P: Pink

Pu: Purple
A: Red

Y: Yellow
V: Violet

W: White

TOOLS
SCS connector
070PZ-ZY30100

Pin probe (Male)
07ZAJ-ROJA 110

25-7

ELECTRIC POWER STEERING (EPS)

GENERAL TROUBLESHOOTING INFORMATION
EPS INDICATOR
Under normal conditions, the EPS indicator comes on when the ignition switch is turned to ON position, then goes off after
the engine is started. This indicates that the LED and its circuit are operating correctly.
If there is any trouble in the system after the engine is started, the EPS indicator will stay on. (When OTe 22 (NO WRITING
THE TORGUE SENSOR NEUTRAL POSITION) is detected by the control unit the EPS indicator will blink. )
When the EPS indicator light comes on, the control unit memorizes the OTe. The control unit wil ' stop the EPS system after
the engine starts again, but it keeps the EPS indicator on.
When OTe 23 (TORQUE SENSOR PROBLEM) is stored in the control unit, the EPS indicator will stay on until the OTC is
erased.
When a problem is detected and the EPS indicator comes on, there are cases when the indicator stays on until the ignition
switch is turned OFF, and cases when the indicator goes off automatically when the system returns to normal.

DIAGNOSTIC TROUBLE CODE (DTC)
The OTCs are memorized in the EEPROM (nonvolatile memory) therefore the memorized OTCs cannot be erased by discon necting the battery. Perform the specified procedures to clear OTCs (page 25-11).

SELF DIAGNOSIS (DTC)
Self-diagnosis can be classified into three categories:
-

Initial diagnosis: performed right after the engine starts and until the EPS indicator goes off.
Regular diagnosis: performed right after the initial diagnosis until the ignition switch is turned OFF.
Revest: The EPS indicator turns on when the OTC is set. The EPS indicator will turn off after the vehicle has recovered
from the fail-safe condition, but the OTC will be stored in the EPS ECU. There was a temporary problem, but the system
is now fully operational.

The EPS ECU performs the following functions when a problem is detected by self-diagnosis:

1. Turns on the EPS indicator.
2. Memorizes the OTC.
3. Stops power assist and manual steering operation begins or reduce the steering assist power.

EPS INDICATOR BLINK PATTERN
• If the HOS pocket tester is not available, DTC can be read from the EPS ECU memory by the EPS indicator blink pattern.
• The number of EPS indicator blinks is the equivalent to the main code of the OTC (the sub code cannot be displayed by
the EPS indicator).
• When the EPS ECU stores more than one DTC, the EPS indicator will indicate them by blinking in the order from the
lower number to highest number.

1 3 sec

13 sec

0.3 sec
0.3 sec
0.5
0.5
so< /:sec! 13sec

0.3 sec
[

@OFF

----

..-_.. _.. _. f1

.L..

DTC code = 12
Problem code
Example: one long blink and
two short blinks DTC code = 12

25-8

..... . .. . . . L.. . . ..... ... . L..

26 sec

Pattern

DTe code", 21

Repeat ed

ELECTRIC POWER STEERING (EPS)
RESTRICTION ON POWER ASSIST OPERATION
Repeated extreme steering force, such as turning the handlebar continuously back-and-forth with the vehicle stopped,
causes an increase of power consumption in the EPS mOlor. The increase of electric current causes the motor to heat up.
Because this heat adversely affects the system, the control unit monitors th e electric current of the motor. When the control unit detects heat build-up in the motor, it reduces the electric current to the motor gradually to protect the system
(motor and EPS EeU), this restricts the power assist operation. The EPS indicator does not come on during this function.
When steering torque is not applied to the handlebar, or when the ignition is turned off. and the system cools, the control
unit will restore the power assist gradually until it's fully restored.

TORQUE SENSOR NEUTRAL POSITION (INITIALIZE THE TORQUE SENSOR)
The EPS ECU stores the torque sensor neutral position in the EEPROM. The torque sensor must be initialized whenever the
EPS unit, the motor, the EPS ECU , etc is serviced (page 25·'3) .
Perform the Torque Sensor Initialization when you service the following contents (page 25- 13).
MAINTENANCE LOCATION

REPLACEMENT

Cables and harness around,ch~aiin~d~l~eb~a~,====
Handlebar
Steering shaft and steering shaft bushing

IN ITIALIZE
INITIALIZE

Steering shaft arm and enc~
d =n~u~t===:-_ __ _
EPS unit
_
EPS ECU

INITIALIZE
INITIALIZE
INITIALIZE

REMOVAL!
INSTALLATION
INITIALIZE
INITIALIZE

INITIAlIZE:=====f~I~N~IT~IA~L~'ZE
INITIALIZE

INITIALIZE
NO NEED

NOTE
The torque sensor neutral position is not effected when erasing the DTCs.

HOW TO TROUBLESHOOT EPS DTC
1. Question the customer about the conditions when the problem occurred, and try to reproduce the same conditions for
troubleshooting. Find out when the EPS indicator came on, such as during EPS control, after EPS control, when the
vehicle was at a certain speed, etc.
2. When the EPS indicator does nol come on during the test-drive, but troubleshooting is done based on the DTC, check
for loose connectors, poor terminal contact, etc., i n the affected circuit before you start troubleshooting.
3. After troubleshooting, erase the OTC and test-drive the vehicle. Be sure the EPS indicator does not come on.

25-9

ELECTRIC POWER STEERING (EPS)
DTCREADOUT
NOTE;
Perform this procedure using fully charged battery.
The EPS indicator will stay lit and the ECU will abort
the process jf you use a low or dead battery.

Slart the engine and check the OTe .

• When the ignition switch is turned to ON, the
EPS indicator will stay on until engine start, then
go off.

I=-=:-==E~PS~

If the OTe stays on or blinks, connect the HOS

Pocket Tester to the Dle.

Read the Ole, freeze dat a and follow the troubleshooling index (page 25· 15).

~ '

To read the DTe with the EPS indicator blinking,
refer to the following procedure.

Reading the DTe with HOS
Turn the ignition switch to OFF.
Remove the seat (page 2-4).

DUMMY CONNECTOR

Remove the insulator rubber.
Remove the dummy connector.

Connect the HOS Pocket Tester to the OLe.
Make sure the engine stop switch is turned to "0",
turn the ignition switch to ON, check the OTC and
freeze data .
Refer to the troubleshooting index (page 25-15).

oLC
Reading OTC with the EPS indicator
Turn the ignition switch to OFF.

SCS CONNECTOR

Remove the seat (page 2-4).
Remove the insu lator rubber.
Remove the dummy connect or and short the OLC
terminals using the special tool.
TOOL:
SCS connector
070PZ-ZY30100
CONNECTION: Brown/ red - Green
Make sure the engine stop switch is turned to "0",
turn the ignition switch to ON, read and nOle the
EPS indicator blinks, and refer to the troubleshooting index (page 25-15),
NOTE
If the EPS ECU has any DTC in its memory, the EPS
indicalo r will start blinking.

25-10

oLC

ELECTRIC POWER STEERING IEPS)
ERASING DTC
NOTE :
Perform this procedu re using fully charged battery.
The EPS indicator will stay lit and the EeU will abort
the process if you use a low or dead battery.

How to erase the DTe with HDS
Connect the HDS Pocket Tester to the DLe.
Erase the DTe with the HDS while the engine is
stopped.
To erase the DTe without HDS, refer to the follow ing procedure.

How to erase the OTe with Ole
1. Remove the seat (page 2-4).

SCS CONNECTOR

2. Remove the insulator rubber .
3. Turn the ignition switch to OFF.

4. Remove the dummy connector and sholl the
Brown/red and Green wire term ina ls of the DLC
using the special tool.
TOOL:
SCS connector
070PZ-ZV30100
CONNECTION: Brown/ red - Green

DLC

5. Raise the f ront wheels off the ground and support the ATV with a jack or work stand.
6. Place a 6 mm screwdriver between the steering
shaft arm and the steering stopper plate as
shown.

~=================~

ARM
7. Fully turn the handlebar to the left and hold it.

EPS INDICATOR

8. Make sure the engine stop swit ch is turned to
"O"and turn the ignition switch to ON. The EPS
indicator lights and it goes off after 4 seconds.

25-11

ELECTRIC POWER STEERING IEPS)
9. Within 4 seconds after the EPS indicator goes off.
release the handlebar. The EPS indicator comes
on again 4 seconds after releasing the handlebar.

EPS

HANDLEBAR

10.Within 4 seconds after the EPS indicator comes
on, fully turn the handlebar to the left and hold it.
The EPS indicator goes off 4 seconds after holding the handlebar.

EPS I

•®
HANDLEBAR

11 .Within 4 seconds afterthe EPS indicator goes off,
release the handlebar. The EPS indicator blinks
twice 4 seconds after releasing the handlebar.
NOTE .
• If the EPS indicator does not blink twice, an error

was made in the procedure and the DTC was not
erased. Turn the ignition switch OFF, and repeat
the operation from step 3.
12.Turn the ignition switch OFF after the EPS indicator blinks twice.

13.Aemove the special tool from the OLe and connect the OLe to the dummy connector.
14.ln51all the following

25-12

insulator rubber
seat (page 2-4)

~==============:=.:=-=::=~
HANDLEBAR
EPS INDICATOR

ELECTRIC POWER STEERING (EPS)
INITIALIZING THE TORQUE SENSOR
NOTE
Perform this procedure using a fully charged battery. The EPS indicator will stay lit and the ECU will
abort the process if you use a low or dead battery.

How to Initialize the Torque Sensor with HOS
1. Raise the front wheels off the ground and support the ATV wilh a jack or work stand.

I D"MY CONNECTOR

2. Remove the dummy connector and connect the
HOS Pocket Tester to the OLe.
Turn the ignition switch to ON.
Turn the handlebar straight ahead.
Initialize the Torque Sensor with the HOS while

the engine is slopped.
-

Follow the instructions on the HDS display.

DLC

How to Initialize the Torque Sensor with Ole
NOTE '
The OTe will be erased when initializing the torque
sensor.

1. Remove the seat (page 2-4),

SCS CONNECTOR

2. Remove the insulator rubber.
3. Turn the ignition switch to OFF.
4. Remove the dummy connector and short the
Brown/red and Green wire terminals of the DLC
using the special tool.
TOOL:
070PZ-ZY30100
SCS connector
CONNECTION: Brown/ red - Green

OLC

5. Raise the front wheels off the ground and support the ATV with a jack or work stand.

;:::=============-=====:

6. Place a 6 mm screwdriver between the steering
shah arm and the steering stopper plate as
shown.

ARM

25-13

ELECTRIC POWER STEERING (EPS)
7. Fully turn the handlebar to the left and hold it.

EPS INDICATOR

8. Make sure the engine stop switch is turned to
MO "and turn the ignition switch to ON . The EPS
indicator lights and it goes off after 4 seconds.

9. Within 4 seconds after the EPS indicator goes off,
release the handlebar. The EPS indicator comes
on again 4 seconds after releasing the handlebar.

EPS INDICATOR

HANDLEBAR

lO.Within 4 seconds after the EPS indicator comes , - on, fully turn the handlebar to the left and hold it.
The EPS indicator goes off 4 seconds after holding the handlebar.

-~~.::~=:±~~~~g~:;;:==-l
EPS I

Leh

The rorque sensor
IS mltlallzed of thiS

rime

11.Within 4 seconds after the EPg indicat or goes off,
return the handlebar within 1 second to straight
ahead and release the handlebar. The EPS indicator blinks twice 4 seconds after releasing the
handlebar then EPS indicator blinks three times 5
seconds after blinking the EPS indicator.
NOTE
• If the EPS indicator does not blink twice, an error
was made in the procedure and the torque sen·
sor was not initialized. Turn the ignition switch
OFF, and repeat the operation from step 3.

12.Turn the ignition switch OFF after the EPS indicator blinks three times.
13.Aemove the special t ool from the OLC and connect the OLC to the dummy connector.
14.lnstall the following
-

25-14

insulator rubber
seat (page 2·4)

EPS INDICATOR

HANDLEBAR

Straight

ELECTRIC POWER STEERING (EPS)

TROUBLESHOOTING INDEX
DEFINITIONS
l at ch: The EPS indicator turns on and stays on whenever the ignition switch is in the ON position, or until the DTC is
erased.

Reset: The EPS indicator turns on when the DIG is set. The EPS indicator witl not turn on after the ignition switch is cycled
from ON to OFF, but the OTC will be stored in the EPS EeU.
Revest : The EPS indicator turns on when the OTe is set. The EPS indicator will turn off after vehicle has recovered from the
fail -safe condition, but the OTC will be stored in the EPS EeU . There was a temporary problem. but the system is now fully
operational.
Initial diagnosis: Performed right after the engine starts and until the EP$ indicator goes OFF.
Regular diagnosis: Performed right after the initial diagnosis until the ignition switch is turned OFF.

l11_0~TC
11 -02

13-01
13·02
13-03

13-04

13-05

14-01

Function Failure

Excessive change of the vehicle speed signal
j lndicato r ON/Substitution
(Regu lar diagnosis)
the engine RPM
Comparison between the vehicle speed and the Indicator ONlSubstitution
engine speed signal
the engine RPM
(Regular diagnosis)
EPS ECU internal circuit (Lower FET stuck ON)
Iindicator ONlHalt steering
immediately
I (Initial diagnosis)
EPS ECU internal circuit (Upper FET stuck ON)
Indicator ONlHalt steering
(Initial diagnosis)
immediately
EPS ECU internal circuit (FET stuck ON ))
(Regular diagnosis)
EPS ECU internal circuit (FET stuck ON (over cur- Indicator ONIHalt steering
immediately
rent
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